New Holland E20.2SR E22.2SR E27.2SR Crawler Excavator Service Repair Manual 604.13.401 – PDF DOWNLOAD

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New Holland E20.2SR E22.2SR E27.2SR Crawler Excavator Service Repair Manual

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New Holland E20.2SR E22.2SR E27.2SR Crawler Excavator Service Repair Manual 

Language : English
Pages : 768
Downloadable : YES
Format : PDF
Size : 35.8 MB
Print No. 604.13.401

DESCRIPTION:

New Holland E20.2SR E22.2SR E27.2SR Crawler Excavator Service Repair Manual 

SAFETY PRECAUTIONS:

The serviceman or mechanic 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 serviceman or mechanic 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 .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 firm level 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. Do not operate this machine unless you have read and understand the instructions in the OPERATOR’S MANUAL. Improper machine operation is dangerous and could result in injury or death.
(6) Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.
(7) Lower the bucket, dozer, or other attachments to the ground before performing any work on the machine. If this cannot be done, make sure the bucket, dozer, ripper or other attachment is blocked correctly to prevent it from dropping unexpectedly.
(8) Use steps and grab handles when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face to the machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.
(9) To avoid back injury, use a hoist when lifting components which weigh 20kg (45lbs) or more. Make sure all chains, hooks, slings, etc., are in good condition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.
(10)To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments.

TABLE OF CONTENTS:

New Holland E20.2SR E22.2SR E27.2SR Crawler Excavator Service Repair Manual 

SAFETY PRECAUTIONS......................................................................................................................................................................................................................................................  5
	GENERAL SAFETY INFORMATION..........................................................................................................................................................................................................................................  6
		SWARNING........................................................................................................................................................................................................................................................  6
		Do not operate or perform any maintenance on this machine until all instructions found in the OPERATION & MAINTENANCE MANUAL hav................................................................................................................................  6
	SAFETY PRECAUTIONS..................................................................................................................................................................................................................................................  7
		SWARNING........................................................................................................................................................................................................................................................  7
		The proper and safe lubrication and maintenance for this machine, recommended by Manufacturer, are outlined in the OPERATOR’S MA................................................................................................................................  7
		The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution wh................................................................................................................................  7
		Do not operate this machine unless you have read and understand the instructions in the OPERATOR’S MANUAL. Improper machine operation is dangerous and could result in injury or death..........................................................................  7
			1.1 GENERAL PRECAUTIONS FOR REPAIRS 1-3..................................................................................................................................................................................................................... 11
				1.1.1 PREPARATION BEFORE DISASSEMBLING 1-3.............................................................................................................................................................................................................. 11
				1.1.2 SAFETY IN DISASSEMBLING AND ASSEMBLING 1-3........................................................................................................................................................................................................ 11
				1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT 1-3.............................................................................................................................................................................................. 11
				1.1.4 ELECTRICAL EQUIPMENT 1-4.......................................................................................................................................................................................................................... 11
				1.1.5 HYDRAULIC PARTS 1-5............................................................................................................................................................................................................................... 11
				1.1.6 WELDING REPAIR 1-5................................................................................................................................................................................................................................ 11
				1.1.7 ENVIRONMENTAL MEASURE 1-5......................................................................................................................................................................................................................... 11
			1.2 INTERNATIONAL UNIT CONVERSION SYSTEM 1-6................................................................................................................................................................................................................ 11
1. OUTLINE.............................................................................................................................................................................................................................................................. 13
	1.1 GENERAL PRECAUTIONS FOR REPAIRS................................................................................................................................................................................................................................. 15
		1.1.1 PREPARATION BEFORE DISASSEMBLING.......................................................................................................................................................................................................................... 15
		1.1.2 SAFETY IN DISASSEMBLING AND ASSEMBLING.................................................................................................................................................................................................................... 15
		1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT.......................................................................................................................................................................................................... 15
		SWARNING........................................................................................................................................................................................................................................................ 16
		Operation of the hydraulic equipment without filling hydraulic oil or lubricant or without performing air bleeding will result in damage to the equipment....................................................................................................... 16
		SWARNING........................................................................................................................................................................................................................................................ 16
		Do not allow the hydraulic cylinder to bottom on the stroke end just after the maintenance...................................................................................................................................................................... 16
			1.1.4 ELECTRICAL EQUIPMENT.................................................................................................................................................................................................................................. 16
		SWARNING........................................................................................................................................................................................................................................................ 17
		Battery electrolyte is hazardous. Battery electrolyte is dilute sulfuric acid. Exposure of skin or eyes to this liquid will caus................................................................................................................................ 17
		. When skin exposed: Wash with water and soap sufficiently...................................................................................................................................................................................................... 17
		. When eyes exposed: Immediately wash away with city water continuously for more than 10 minutes................................................................................................................................................................ 17
		. When a large amount of the liquid flows out: Neutralize with sodium bicarbonate or wash away with city water.................................................................................................................................................. 17
		. When swallowed: Drink a large amount of milk or water......................................................................................................................................................................................................... 17
		. When clothes exposed: Immediately undress and wash............................................................................................................................................................................................................ 17
			1.1.5 HYDRAULIC PARTS....................................................................................................................................................................................................................................... 17
			1.1.6 WELDING REPAIR........................................................................................................................................................................................................................................ 17
			1.1.7 ENVIRONMENTAL MEASURE................................................................................................................................................................................................................................. 17
	1.2 INTERNATIONAL UNIT CONVERSION SYSTEM (Based on MARKS’ STANDARD HANDBOOK FOR MECHANICAL ENGINEERS)............................................................................................................................................................... 18
	Table 1-1........................................................................................................................................................................................................................................................... 18
	Table 1-2........................................................................................................................................................................................................................................................... 18
	Table 1-3........................................................................................................................................................................................................................................................... 18
	Table 1-4........................................................................................................................................................................................................................................................... 18
	Table 1-5........................................................................................................................................................................................................................................................... 19
	Table 1-6........................................................................................................................................................................................................................................................... 19
		2.1 COMPONENTS NAME 2-3......................................................................................................................................................................................................................................... 21
		2.2 MACHINE DIMENSIONS 2-4...................................................................................................................................................................................................................................... 21
		2.3 SPECIFICATIONS AND PERFORMANCE 2-6.......................................................................................................................................................................................................................... 21
		2.4 MACHINE & COMPONENTS WEIGHT (DRY) 2-7....................................................................................................................................................................................................................... 21
		2.5 TRANSPORTATION 2-9.......................................................................................................................................................................................................................................... 21
		2.6 TYPE OF CRAWLER SHOES 2-11.................................................................................................................................................................................................................................. 21
		2.7 TYPE OF BUCKET 2-11......................................................................................................................................................................................................................................... 21
		2.8 ENGINE SPECIFICATIONS 2-13.................................................................................................................................................................................................................................. 21
			2.8.1 SPECIFICATIONS 2-13................................................................................................................................................................................................................................... 21
			2.8.2 ENGINE PERFORMANCE CURVE 2-14......................................................................................................................................................................................................................... 21
2. SPECIFICATIONS....................................................................................................................................................................................................................................................... 23
	2.1 COMPONENTS NAME................................................................................................................................................................................................................................................. 25
	2.2 MACHINE DIMENSIONS.............................................................................................................................................................................................................................................. 26
	2.3 SPECIFICATIONS AND PERFORMANCE.................................................................................................................................................................................................................................. 28
		SPEED AND GRADEABILITY.......................................................................................................................................................................................................................................... 28
		ENGINE.......................................................................................................................................................................................................................................................... 28
		HYDRAULIC COMPONENTS............................................................................................................................................................................................................................................ 28
		SIDE DIGGING & DOZER............................................................................................................................................................................................................................................ 28
		WEIGHT.......................................................................................................................................................................................................................................................... 28
	2.4 MACHINE & COMPONENTS WEIGHT (DRY)............................................................................................................................................................................................................................... 29
	2.5 TRANSPORTATION.................................................................................................................................................................................................................................................. 31
		SWARNING........................................................................................................................................................................................................................................................ 31
		Do not put chains over or against hydraulic lines or hoses...................................................................................................................................................................................................... 31
	2.6 TYPE OF CRAWLER SHOES........................................................................................................................................................................................................................................... 33
	2.7 TYPE OF BUCKET.................................................................................................................................................................................................................................................. 33
	2.8 ENGINE SPECIFICATIONS........................................................................................................................................................................................................................................... 35
		2.8.1 SPECIFICATIONS............................................................................................................................................................................................................................................ 35
		2.8.2 ENGINE PERFORMANCE CURVE.................................................................................................................................................................................................................................. 36
		E20.2SR / E22.2SR / E27.2SR..................................................................................................................................................................................................................................... 36
			3.1 BOOM 3-3................................................................................................................................................................................................................................................ 37
				3.1.1 BOOM DIMENSIONAL DRAWINGS 3-3..................................................................................................................................................................................................................... 37
				3.1.2 BOOM MAINTENANCE STANDARDS 3-4.................................................................................................................................................................................................................... 37
			3.2 ARM 3-10................................................................................................................................................................................................................................................ 37
				3.2.1 ARM DIMENSIONAL DRAWINGS 3-10..................................................................................................................................................................................................................... 37
				3.2.2 ARM MAINTENANCE STANDARDS 3-12.................................................................................................................................................................................................................... 37
			3.3 BUCKET 3-17............................................................................................................................................................................................................................................. 37
				3.3.1 BUCKET DIMENSIONAL DRAWINGS 3-17.................................................................................................................................................................................................................. 37
				3.3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION 3-18................................................................................................................................................................................................... 37
			3.4 DOZER 3-19.............................................................................................................................................................................................................................................. 37
				3.4.1 DOZER DIMENSIONAL DRAWINGS 3-19................................................................................................................................................................................................................... 37
				3.4.2 DOZER MAINTENANCE STANDARDS 3-20.................................................................................................................................................................................................................. 37
			3.5 SWING 3-23.............................................................................................................................................................................................................................................. 37
				3.5.1 SWING BRACKET DIMENSIONAL DRAWINGS 3-23........................................................................................................................................................................................................... 37
				3.5.2 SWING PORTION MAINTENANCE STANDARDS 3-24.......................................................................................................................................................................................................... 37
3. ATTACHMENT DIMENSIONS................................................................................................................................................................................................................................................ 39
	3.1 BOOM............................................................................................................................................................................................................................................................ 41
		3.1.1 BOOM DIMENSIONAL DRAWINGS................................................................................................................................................................................................................................. 41
	Fig. 3-1 Boom Dimensional Drawings.................................................................................................................................................................................................................................. 41
	Table 3-1........................................................................................................................................................................................................................................................... 41
		3.1.2 BOOM MAINTENANCE STANDARDS................................................................................................................................................................................................................................ 42
	Fig. 3-2 Clearance of pin and bushing on boom section............................................................................................................................................................................................................... 42
	Table 3-2........................................................................................................................................................................................................................................................... 42
	Table 3-3........................................................................................................................................................................................................................................................... 43
	Fig. 3-3 Clearance in thrust direction on boom section.............................................................................................................................................................................................................. 44
	Table 3-4........................................................................................................................................................................................................................................................... 45
	Table 3-5........................................................................................................................................................................................................................................................... 46
		3.2 ARM......................................................................................................................................................................................................................................................... 48
			3.2.1 ARM DIMENSIONAL DRAWINGS.............................................................................................................................................................................................................................. 48
	Fig. 3-4 Dipper dimensional drawings................................................................................................................................................................................................................................ 48
	Table 3-6........................................................................................................................................................................................................................................................... 48
		3.2.2 ARM MAINTENANCE STANDARDS................................................................................................................................................................................................................................. 50
	Fig. 3-5 Clearance of pin and bushing on dipper section............................................................................................................................................................................................................. 50
	Table 3-7........................................................................................................................................................................................................................................................... 50
	Table 3-8........................................................................................................................................................................................................................................................... 51
	Fig. 3-6 Clearance in thrust direction on dipper section............................................................................................................................................................................................................ 52
	Table 3-9........................................................................................................................................................................................................................................................... 53
	Table 3-10.......................................................................................................................................................................................................................................................... 54
		3.3 BUCKET...................................................................................................................................................................................................................................................... 55
			3.3.1 BUCKET DIMENSIONAL DRAWINGS........................................................................................................................................................................................................................... 55
	Fig. 3-7 Bucket dimensional drawings................................................................................................................................................................................................................................ 55
	Table 3-11.......................................................................................................................................................................................................................................................... 55
		3.3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION................................................................................................................................................................................................................ 56
	Fig. 3-8 Dimension of lug section................................................................................................................................................................................................................................... 56
	Table 3-12.......................................................................................................................................................................................................................................................... 56
		3.4 DOZER....................................................................................................................................................................................................................................................... 57
			3.4.1 DOZER DIMENSIONAL DRAWINGS............................................................................................................................................................................................................................ 57
	Fig. 3-10 Dozer dimensional drawings................................................................................................................................................................................................................................ 57
	Table 3-14.......................................................................................................................................................................................................................................................... 57
		3.4.2 DOZER MAINTENANCE STANDARDS............................................................................................................................................................................................................................... 58
	Fig. 3-15 Dozer maintenance standards............................................................................................................................................................................................................................... 58
	Table 3-15.......................................................................................................................................................................................................................................................... 58
	Table 3-17.......................................................................................................................................................................................................................................................... 60
	Table 3-18.......................................................................................................................................................................................................................................................... 60
		3.5 SWING....................................................................................................................................................................................................................................................... 61
			3.5.1 SWING BRACKET DIMENSIONAL DRAWINGS.................................................................................................................................................................................................................... 61
	Fig. 3-12 Swing bracket dimensional drawings........................................................................................................................................................................................................................ 61
	Table 3-19.......................................................................................................................................................................................................................................................... 61
		3.5.2 SWING PORTION MAINTENANCE STANDARDS....................................................................................................................................................................................................................... 62
	Fig. 3-13 Clearance of pin and bushing on swing portion............................................................................................................................................................................................................. 62
	Table 3-20.......................................................................................................................................................................................................................................................... 62
	Fig. 3-14 Clearance in thrust direction on swing portion............................................................................................................................................................................................................ 63
		1. Washer - To be install the groove to the lower side [t= 2.3 (0.091)]......................................................................................................................................................................................... 63
		2. Washer [t= 2.3 (0.091)]...................................................................................................................................................................................................................................... 63
	Table 3-21.......................................................................................................................................................................................................................................................... 64
		11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS 11-3............................................................................................................................................................................................................ 65
			11.1.1 METRIC COARSE THREAD STANDARD TIGHTENING TORQUE VALUES. MAKE CERTAIN TO TIGHTEN ALL CAPSCREWS & NUTS TO PROPER TORQUE VALUES 11-3.................................................................................................................... 65
			11.1.2 METRIC FINE THREAD STANDARD TIGHTENING TORQUE VALUES. MAKE CERTAIN TO TIGHTEN ALL CAPSCREWS & NUTS TO PROPER TORQUE VALUES 11-4...................................................................................................................... 65
		11.2 SCREW AND TOOL SIZES 11-5.................................................................................................................................................................................................................................. 65
			11.2.1 Capscrew 11-5........................................................................................................................................................................................................................................ 65
			11.2.2 Capscrew (Socket bolt) 11-5.......................................................................................................................................................................................................................... 65
		11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES 11-5............................................................................................................................................................................................................ 65
			11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE) 11-5......................................................................................................................................................................................................... 65
			11.3.2 HYDRAULIC HOSE (30 FLARE TYPE) 11-5................................................................................................................................................................................................................. 65
		11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS 11-6................................................................................................................................................................................................... 65
			11.4.1 SLEEVE TYPE TUBE FITTINGS 11-6....................................................................................................................................................................................................................... 65
		11.5 SPECIAL SPANNERS FOR TUBES 11-7............................................................................................................................................................................................................................ 65
		11.6 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS 11-7.................................................................................................................................................................................................... 65
		11.7 COUNTERWEIGHT LIFTING JIG 11-8............................................................................................................................................................................................................................. 65
11. TOOLS............................................................................................................................................................................................................................................................... 67
	11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS..................................................................................................................................................................................................................... 69
		1. Classification............................................................................................................................................................................................................................................... 69
		11.1.1 Metric Coarse Thread Standard Tightening Torque Values. Make Certain to tighten all Capscrews & Nuts to proper torque values............................................................................................................................. 69
		11.1.2 Metric Fine Thread Standard Tightening Torque values. Make certain to tighten all Capscrews & Nuts to proper torque values............................................................................................................................... 70
	11.2 SCREW AND TOOL SIZES........................................................................................................................................................................................................................................... 71
		11.2.1 Capscrew................................................................................................................................................................................................................................................. 71
		11.2.2 Capscrew (Socket bolt)................................................................................................................................................................................................................................... 71
	11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES..................................................................................................................................................................................................................... 71
		11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE).................................................................................................................................................................................................................. 71
		11.3.2 HYDRAULIC HOSE (30 FLARE TYPE).......................................................................................................................................................................................................................... 71
	11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS............................................................................................................................................................................................................ 72
		11.4.1 SLEEVE TYPE TUBE FITTINGS................................................................................................................................................................................................................................ 72
	11.5 SPECIAL SPANNERS FOR TUBES..................................................................................................................................................................................................................................... 73
	11.6 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS............................................................................................................................................................................................................. 73
	11.7 COUNTERWEIGHT LIFTING JIG...................................................................................................................................................................................................................................... 74
	Fig. 11-1 Counterweight lifting jig................................................................................................................................................................................................................................. 74
		12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR 12-4.......................................................................................................................................................................................... 75
12. STANDARD MAINTENANCE TIME TABLE..................................................................................................................................................................................................................................... 77
	PREFACE............................................................................................................................................................................................................................................................. 79
	12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR................................................................................................................................................................................................... 80
		13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS 13-3...................................................................................................................................................................................................... 87
		13.2 PERFORMANCE INSPECTION STANDARD TABLE 13-5................................................................................................................................................................................................................. 87
			13.2.1 STANDARD VALUE TABLE 13-5............................................................................................................................................................................................................................ 87
		13.3 MEASURING ENGINE SPEED 13-7................................................................................................................................................................................................................................ 87
			13.3.1 ENGINE SPEED MEASUREMENT 13-7........................................................................................................................................................................................................................ 87
		13.4 MEASURING HYDRAULIC OIL PRESSURE 13-9...................................................................................................................................................................................................................... 87
			13.4.1 STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT 13-9................................................................................................................................................................................................. 87
			13.4.2 PRESSURE MEASUREMENT AND ADJUSTMENT 13-9............................................................................................................................................................................................................. 87
		13.5 MEASURING TRAVEL PERFORMANCES 13-13........................................................................................................................................................................................................................ 87
			13.5.1 Travel 13-13......................................................................................................................................................................................................................................... 87
			13.5.2 Travel Deviation 13-13............................................................................................................................................................................................................................... 87
			13.5.3 Movement drift due to gravity 13-14.................................................................................................................................................................................................................. 87
			13.5.4 DRAIN RATE ON TRAVEL MOTOR 13-14..................................................................................................................................................................................................................... 87
		13.6 MEASURING SLEW PERFORMANCES 13-15.......................................................................................................................................................................................................................... 87
			13.6.1 Slew Time 13-15...................................................................................................................................................................................................................................... 87
			13.6.2 Overrun When Slewing Stops 13-15..................................................................................................................................................................................................................... 87
			13.6.3 Slew Drift due to Gravity 13-15...................................................................................................................................................................................................................... 87
			13.6.4 Drain Rate of Travel Motor 13-16..................................................................................................................................................................................................................... 87
		13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES 13-17.......................................................................................................................................................................................................... 87
			13.7.1 Cylinder Speed 13-17................................................................................................................................................................................................................................. 87
			13.7.2 Gravity drift of Cylinders 13-18..................................................................................................................................................................................................................... 87
		13.8 MEASURING SLEW BEARING PERFORMANCES 13-19.................................................................................................................................................................................................................. 87
			13.8.1 Slew Bearing-Bucket Tip Play 13-19................................................................................................................................................................................................................... 87
			13.8.2 Slew Bearing Play 13-19.............................................................................................................................................................................................................................. 87
		13.9 MEASURING CRAWLER TENSION 13-20............................................................................................................................................................................................................................ 87
			13.9.1 Crawler Tension 13-20................................................................................................................................................................................................................................ 87
13. MAINTENANCE STANDARDS AND TEST PROCEDURES........................................................................................................................................................................................................................... 89
	13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS............................................................................................................................................................................................................... 91
	13.2 PERFORMANCE INSPECTION STANDARD TABLE.......................................................................................................................................................................................................................... 93
		13.2.1 STANDARD VALUE TABLE..................................................................................................................................................................................................................................... 93
	13.3 MEASURING ENGINE SPEED......................................................................................................................................................................................................................................... 95
		13.3.1 ENGINE SPEED MEASUREMENT................................................................................................................................................................................................................................. 95
	Fig. 13-1 Engine Speed measurement (The above figure shows concept)................................................................................................................................................................................................. 95
	WATER TEMP.......................................................................................................................................................................................................................................................... 95
		CAUTION However, if the proper high idling speed is not obtainable, consult it with the engine manufacturer..................................................................................................................................................... 96
	Fig. 13-2 Accelerator wire adjustment............................................................................................................................................................................................................................... 96
		13.4 MEASURING HYDRAULIC OIL PRESSURE........................................................................................................................................................................................................................... 97
			13.4.1 STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT...................................................................................................................................................................................................... 97
			CAUTION After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and measure with the............................................................................................................................ 97
				13.4.2 PRESSURE MEASUREMENT AND ADJUSTMENT.............................................................................................................................................................................................................. 97
					13.4.2.1 Main Circuit Pressure...................................................................................................................................................................................................................... 97
	Fig. 13-3 Main hydraulic oil pressure measurement................................................................................................................................................................................................................... 98
	Fig. 13-4 Main hydraulic oil pressure measurement................................................................................................................................................................................................................... 98
	Fig. 13-5 Relief valve.............................................................................................................................................................................................................................................. 99
		Main relief valve Overload relief valve......................................................................................................................................................................................................................... 99
	Fig. 13-6 Relief valve (Slewing motor).............................................................................................................................................................................................................................. 99
		13.4.2.2 Pilot Circuit Pressure................................................................................................................................................................................................................................. 99
	Fig. 13-7 Pilot oil pressure measurement............................................................................................................................................................................................................................ 99
	Fig. 13-8 Relief valve..............................................................................................................................................................................................................................................100
		13.5 MEASURING TRAVEL PERFORMANCES..............................................................................................................................................................................................................................101
			13.5.1 Travel...............................................................................................................................................................................................................................................101
			13.5.2 Travel Deviation.....................................................................................................................................................................................................................................101
			13.5.3 Movement drift due to gravity........................................................................................................................................................................................................................102
			13.5.4 DRAIN RATE ON TRAVEL MOTOR...........................................................................................................................................................................................................................102
			WARNING Make sure of the rotating direction of travel motor referring to the right sketch. Otherwise, the rib (A) may be broken by the stopper pin (1)......................................................................................................102
		13.6 MEASURING SLEW PERFORMANCES................................................................................................................................................................................................................................103
			13.6.1 Slew Time............................................................................................................................................................................................................................................103
			13.6.2 Overrun When Slewing Stops...........................................................................................................................................................................................................................103
			13.6.3 Slew Drift due to Gravity............................................................................................................................................................................................................................103
			13.6.4 Drain Rate of Travel Motor...........................................................................................................................................................................................................................104
		13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES................................................................................................................................................................................................................105
			13.7.1 Cylinder Speed.......................................................................................................................................................................................................................................105
			13.7.2 Gravity drift of Cylinders...........................................................................................................................................................................................................................106
		13.8 MEASURING SLEW BEARING PERFORMANCES........................................................................................................................................................................................................................107
			13.8.1 Slew Bearing-Bucket Tip Play.........................................................................................................................................................................................................................107
			13.8.2 Slew Bearing Play....................................................................................................................................................................................................................................107
		13.9 MEASURING CRAWLER TENSION..................................................................................................................................................................................................................................108
			13.9.1 Crawler Tension......................................................................................................................................................................................................................................108
			CAUTION In the case of rubber crawlers, measurements should be taken with setting the joint ("M" or "" mark) in the top center position.....................................................................................................................108
				22.1 SUMMARY 22-3.......................................................................................................................................................................................................................................109
					22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT 22-3..............................................................................................................................................................................................109
				22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS 22-4.......................................................................................................................................................................................................109
				22.3 HYDRAULIC CIRCUIT OPERATION 22-6...................................................................................................................................................................................................................109
					22.3.1 COLOR CODING STANDARD FOR HYDRAULIC 22-6.....................................................................................................................................................................................................109
					22.3.2 NEUTRAL CIRCUIT 22-6.........................................................................................................................................................................................................................109
					22.3.3 TRAVEL OPERATING CIRCUIT 22-7................................................................................................................................................................................................................109
					22.3.4 SLEW OPERATING CIRCUIT 22-8..................................................................................................................................................................................................................109
					22.3.5 BUCKET OPERATING CIRCUIT 22-8................................................................................................................................................................................................................109
					22.3.6 BOOM OPERATING CIRCUIT 22-9..................................................................................................................................................................................................................109
					22.3.7 ARM OPERATING CIRCUIT 22-9...................................................................................................................................................................................................................109
					22.3.8 SWING OPERATING CIRCUIT 22-10................................................................................................................................................................................................................109
					22.3.9 DOZER OPERATING CIRCUIT 22-10................................................................................................................................................................................................................109
					22.3.10 TRAVEL / DOZER COMBINED OPERATING CIRCUIT 22-11.............................................................................................................................................................................................109
					22.3.11 TRAVEL / BOOM COMBINED OPERATING CIRCUIT 22-11..............................................................................................................................................................................................109
					22.3.12 NIBBLER & BREAKER OPERATING CIRCUIT 22-12...................................................................................................................................................................................................109
				22.4 SCHEMATIC PIPING FOR HYDRAULIC SYSTEM 22-13........................................................................................................................................................................................................109
22. HYDRAULIC SYSTEM....................................................................................................................................................................................................................................................111
	22.1 SUMMARY........................................................................................................................................................................................................................................................113
		22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT...............................................................................................................................................................................................................113
	22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS........................................................................................................................................................................................................................  0
		NOTE: This is for reference only, because the model number might be changed due to improvement..................................................................................................................................................................  0
		NOTE: This is for reference only, because the model number might be changed due to improvement..................................................................................................................................................................115
	22.3 HYDRAULIC CIRCUIT OPERATION....................................................................................................................................................................................................................................116
		22.3.1 COLOR CODING STANDARD FOR HYDRAULIC......................................................................................................................................................................................................................116
		NOTE: For the hydraulic circuit operation, refer to Fig. 71-2 to 12 of Supporting Data that is provided at the end of this Shop Manual..........................................................................................................................116
			22.3.2 NEUTRAL CIRCUIT......................................................................................................................................................................................................................................116
			22.3.3 TRAVEL OPERATING CIRCUIT.............................................................................................................................................................................................................................117
				22.3.3.1 2nd Speed Operating Circuit (Independent-forward travel).......................................................................................................................................................................................117
			22.3.4 SLEW OPERATING CIRCUIT...............................................................................................................................................................................................................................118
				22.3.4.1 Slew (left) Operating Circuit..................................................................................................................................................................................................................118
			22.3.5 BUCKET OPERATING CIRCUIT.............................................................................................................................................................................................................................118
				22.3.5.1 Bucket Digging Operation Circuit...............................................................................................................................................................................................................118
				22.3.5.2 Bucket Dumping Operating Circuit...............................................................................................................................................................................................................118
			22.3.6 BOOM OPERATING CIRCUIT...............................................................................................................................................................................................................................119
				22.3.6.1 Boom UP Operating Circuit......................................................................................................................................................................................................................119
				22.3.6.2 Boom Down Operating Circuit....................................................................................................................................................................................................................119
			22.3.7 ARM OPERATING CIRCUIT................................................................................................................................................................................................................................119
				22.3.7.1 Arm In Operating Circuit.......................................................................................................................................................................................................................119
				22.3.7.2 Operating Circuit for Arm Out..................................................................................................................................................................................................................119
			22.3.8 SWING OPERATING CIRCUIT..............................................................................................................................................................................................................................120
				22.3.8.1 Swing (left) Operating Circuit.................................................................................................................................................................................................................120
			22.3.9 DOZER OPERATING CIRCUIT..............................................................................................................................................................................................................................120
				22.3.9.1 Dozer Down Operating Circuit...................................................................................................................................................................................................................120
			22.3.10 TRAVEL / DOZER COMBINED OPERATING CIRCUIT...........................................................................................................................................................................................................121
				22.3.10.1 Travel (1st speed forwarding) /Dozer Down Operating Circuit...................................................................................................................................................................................121
			22.3.11 TRAVEL / BOOM COMBINED OPERATING CIRCUIT............................................................................................................................................................................................................121
				22.3.11.1 Travel (1st speed forward) / Boom Up Operating Circuit........................................................................................................................................................................................121
			22.3.12 NIBBLER & BREAKER OPERATING CIRCUIT.................................................................................................................................................................................................................122
				22.3.12.1 Nibbler Close Operating Circuit...............................................................................................................................................................................................................122
				22.3.12.2 Nibbler Open Operating Circuit................................................................................................................................................................................................................122
				22.3.12.3 Breaker Blow Operating Circuit................................................................................................................................................................................................................122
	22.4 SCHEMATIC PIPING FOR HYDRAULIC SYSTEM..........................................................................................................................................................................................................................123
		23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION 23-3....................................................................................................................................................................................................125
			23.1.1 ELECTRIC CIRCUIT DIAGRAM 23-3........................................................................................................................................................................................................................125
			23.1.2 HARNESS CONNECTION 23-3..............................................................................................................................................................................................................................125
		23.2 ELECTRICAL EQUIPMENT & HARNESS 23-4........................................................................................................................................................................................................................125
			23.2.1 ELECTRICAL EQUIPMENT LIST 23-4.......................................................................................................................................................................................................................125
			23.2.2 HARNESS & CABLE LIST 23-6............................................................................................................................................................................................................................125
			23.2.3 ARRANGEMENT DRAWING FOR COMPONENTS & HARNESS 23-7....................................................................................................................................................................................................125
23. ELECTRICAL SYSTEM...................................................................................................................................................................................................................................................127
	23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION.............................................................................................................................................................................................................129
		23.1.1 ELECTRIC CIRCUIT DIAGRAM.................................................................................................................................................................................................................................129
		NOTE: For the electric circuit diagram, refer to Fig. 71-13 of Supporting Data that is provided at the end of this shop manual..................................................................................................................................129
			1. Wire color red...........................................................................................................................................................................................................................................129
			2. Wire size 2 sq (mm2).....................................................................................................................................................................................................................................129
			3. Wire N. 6................................................................................................................................................................................................................................................129
			23.1.2 HARNESS CONNECTION...................................................................................................................................................................................................................................129
	23.2 ELECTRICAL EQUIPMENT & HARNESS.................................................................................................................................................................................................................................130
		23.2.1 ELECTRICAL EQUIPMENT LIST................................................................................................................................................................................................................................130
		23.2.2 HARNESS & CABLE LIST.....................................................................................................................................................................................................................................132
		23.2.3 ARRANGEMENT DRAWING FOR COMPONENTS & HARNESS.............................................................................................................................................................................................................133
			23.2.3.1 Upper Frame Portion................................................................................................................................................................................................................................133
	Fig. 23-1 Upper Frame Portion (1/6).................................................................................................................................................................................................................................133
		NOTE: Tightening torgue of battery terminal to be 4,4 N.m (3.25 lbf.ft) In case of not specified, tighten ground portion to 46.1 (34.0 lbf.ft)..................................................................................................................133
			1. TO CANOPY LIGHT..........................................................................................................................................................................................................................................133
			2. TO BOOM..................................................................................................................................................................................................................................................133
			3. FIX WHITE TAPING PART....................................................................................................................................................................................................................................133
			4. B (BLACK (-))............................................................................................................................................................................................................................................133
			5. PB (PINK . BLACK (+))....................................................................................................................................................................................................................................133
			6. CAPSCREW (GND. TIGHTEN AFTER CHECKING NO PAINT - TIGHTENING TORQUE: 46.1 N.m (34 lbf.ft))................................................................................................................................................................133
			7. CAPSCREW TIGHTENING TORQUE 23.5 N.m (17.1 lbf.ft)).......................................................................................................................................................................................................133
			8. FIX WHITE TAPING PART....................................................................................................................................................................................................................................133
			9. GROUND CONNECTOR.........................................................................................................................................................................................................................................133
	Fig. 23-2 Upper Frame Portion (2/6).................................................................................................................................................................................................................................134
		1. Clip. Boom light harness is fixed to boom hose...............................................................................................................................................................................................................135
		2. Connect with boom light harness..............................................................................................................................................................................................................................135
		3. Clip. A 30 mm place below a whit taping part is fixed from boom hose mouthpiece parts in a 180 mm place......................................................................................................................................................135
		4. Clip. White taping part is fixed to the hose for boom cylinders..............................................................................................................................................................................................135
		5. Clip. White taping part is fixed to the hose for boom cylinders..............................................................................................................................................................................................135
		6. Connect with boom light harness..............................................................................................................................................................................................................................135
		7. Inst main harness (vender connection)........................................................................................................................................................................................................................135
		8. White tapingpart is fixed on a hose clamp....................................................................................................................................................................................................................135
		9. Clip. Fix in 100 mm pitch....................................................................................................................................................................................................................................135
		10. Connect with fuel sensor....................................................................................................................................................................................................................................135
		11. Clip. Fix white taping part.................................................................................................................................................................................................................................135
		12. Clip. Fix white taping part Tightening torque: 46.1 N.m (34 lbf.ft).........................................................................................................................................................................................135
		13. To boom.....................................................................................................................................................................................................................................................135
		14. Connect with two-speed select sw............................................................................................................................................................................................................................135
		15. Grommet.....................................................................................................................................................................................................................................................135
		16. Fix with ring terminal gnd. connector.......................................................................................................................................................................................................................135
		17. Nut. Tightening after checkin no paint Tightening torque: 10.7 N.m (7.9 lbf.ft).............................................................................................................................................................................135
	Fig. 23-3 Upper Frame Portion (3/6).................................................................................................................................................................................................................................136
		1. To boom......................................................................................................................................................................................................................................................136
		2. Fix white taping part. A clip is attached downward...........................................................................................................................................................................................................136
		3. Fix white taping art.........................................................................................................................................................................................................................................136
		4. Tighten after checking. No paint.............................................................................................................................................................................................................................136
		5. Clip. Fix white taping part. Capscrew. Tightening torque: 46.1 N.m (34 lbf.ft)...............................................................................................................................................................................136
	Fig. 23-4 Upper Frame Portion (4/6).................................................................................................................................................................................................................................137
	Fig. 23-5 Upper Frame Portion (5/6).................................................................................................................................................................................................................................138
		1. Main harness and eng. harness are connected by the machine center side so that a tube may not hit a bared part...............................................................................................................................................138
		2. Clip.........................................................................................................................................................................................................................................................138
		3. Grommet......................................................................................................................................................................................................................................................138
		4. Relay assy...................................................................................................................................................................................................................................................138
		5. Clip. Fix option connector...................................................................................................................................................................................................................................138
		6. Clip. Fix to clip of seatstand...............................................................................................................................................................................................................................138
		7. Connect with main harness....................................................................................................................................................................................................................................138
		8. Eng. harness.................................................................................................................................................................................................................................................138
		9. Fix white taping part........................................................................................................................................................................................................................................138
		10. Connection with a heater relay harness......................................................................................................................................................................................................................138
		11. Main harness come is front..................................................................................................................................................................................................................................138
		12. Capscrew tightening torque 23.5 N.m (17 lbf.ft).............................................................................................................................................................................................................138
		13. Clip. It fixes so that harness may not swell to a breather tank side.It fixes so that harness may not swell to a breather tank side.........................................................................................................................138
		14. Harness is fixed so that a plate may not be straddled.......................................................................................................................................................................................................138
		15. Breather tank...............................................................................................................................................................................................................................................138
		16. Connect main harness to cab harness.........................................................................................................................................................................................................................138
		17. Through the slit............................................................................................................................................................................................................................................138
		18. Connect with lever lock sw..................................................................................................................................................................................................................................138
		19. Clip. Fix white taping part.................................................................................................................................................................................................................................138
	Fig. 23-6 Upper Frame Portion (6/6).................................................................................................................................................................................................................................139
		1. Nut tightening torque: 46.1 N.m (34 lbf.ft) Tighten after checking no paint..................................................................................................................................................................................139
		2. Instal a cable at 45 degree angle to down....................................................................................................................................................................................................................139
		3. Capscrew. Tightening torque 23.5 N.m (17 lbf.ft).............................................................................................................................................................................................................139
		4. To canopy light..............................................................................................................................................................................................................................................139
		5. Fix white taping part........................................................................................................................................................................................................................................139
		6. WG (White . Green) (+).......................................................................................................................................................................................................................................139
		7. P (Pink) (-).................................................................................................................................................................................................................................................139
		8. Fix white taping part to upp. frame..........................................................................................................................................................................................................................139
		9. Clip.........................................................................................................................................................................................................................................................139
		23.2.3.2 Engine Portion.........................................................................................................................................................................................................................................140
	Fig. 23-7 Engine Portion (1/3)......................................................................................................................................................................................................................................140
		1. Clip.........................................................................................................................................................................................................................................................140
		2. Clip. Capscrew...............................................................................................................................................................................................................................................140
		3. Fix connector................................................................................................................................................................................................................................................140
	Fig. 23-8 Engine Portion (2/3)......................................................................................................................................................................................................................................141
		1. Clip. Move white taping part of harness nearer to generator side with a clip.................................................................................................................................................................................141
		2. Connect with main harness....................................................................................................................................................................................................................................141
		3. Nut. Tightening torque 7.4~9.8 N·m (5.5~7.4 lbf·ft)..........................................................................................................................................................................................................141
		4. To battery...................................................................................................................................................................................................................................................141
		5. Capscrew.....................................................................................................................................................................................................................................................141
		6. Clip. Fix white taping part..................................................................................................................................................................................................................................141
		7. Connect with engine harness plug direction separated fan.....................................................................................................................................................................................................141
		8. To install eng thermo sensor with packin tightening torque: 39.2 N·m (29 lbf·ft).............................................................................................................................................................................141
		9. Clip.........................................................................................................................................................................................................................................................141
	Fig. 23-9 Engine Portion (3/3)......................................................................................................................................................................................................................................142
		1. Clip. Fix clip upper.........................................................................................................................................................................................................................................142
		2. Clip. Fix white taping part fasten with a bracket............................................................................................................................................................................................................142
		3. It is the thing of fixation by 85 direction so that a cable may not interfere in a sheet stand...............................................................................................................................................................142
		4. Nut. Tightening torque 7.4~9.8 N·m (5.5~7.4 lbf·.............................................................................................................................................................................................................142
		5. Clip. Fasten with a lug fix white taping part................................................................................................................................................................................................................142
		6. Clip. Fix white taping part..................................................................................................................................................................................................................................142
		7. Clip.........................................................................................................................................................................................................................................................142
		23.2.3.3 Relay Unit Portion.....................................................................................................................................................................................................................................143
			1. To decel to air heater...................................................................................................................................................................................................................................143
			2. To horn sw. lever lock sw................................................................................................................................................................................................................................143
			3. Clip.....................................................................................................................................................................................................................................................143
			4. To cab harness...........................................................................................................................................................................................................................................143
			5. Clip. It attaches so that the cut portion of clip may not be from the plate side.........................................................................................................................................................................143
			6. Relay assy...............................................................................................................................................................................................................................................143
	Fig. 23-11 Relay Unit Portion (2/2).................................................................................................................................................................................................................................144
		23.2.3.4 Fuel Tank Portion......................................................................................................................................................................................................................................145
	Fig. 23-12 Fuel Tank Portion (1/2)..................................................................................................................................................................................................................................145
		1. Capscrew. Tightening torque 11 N·m (8.1 lbf·ft)..............................................................................................................................................................................................................145
		2. Fuel tank....................................................................................................................................................................................................................................................145
		3. Tightening torque 2.94 N·m (2.2 lbf·ft)......................................................................................................................................................................................................................145
	Fig. 23-13 Fuel Tank Portion (2/2)..................................................................................................................................................................................................................................146
		1. Fasten hoses on clip of cover 2 hoses except from pump fuel to filter........................................................................................................................................................................................146
		2. Fasten hoses on clip of cover 3 hoses........................................................................................................................................................................................................................146
		3. Water separator..............................................................................................................................................................................................................................................146
		4. Suction (separator assy, water pump, fuel)...................................................................................................................................................................................................................146
		5. Fasten hoses on clip of bracket..............................................................................................................................................................................................................................146
		6. Fuel tank....................................................................................................................................................................................................................................................146
		7. Return.......................................................................................................................................................................................................................................................146
		8. Inlet........................................................................................................................................................................................................................................................146
		9. Fuel filter..................................................................................................................................................................................................................................................146
		10. Return......................................................................................................................................................................................................................................................146
		11. Suction (Tank fuel ->separator assy water)..................................................................................................................................................................................................................146
		12. Water separator.............................................................................................................................................................................................................................................146
		13. Fasten hoses on clip of frame...............................................................................................................................................................................................................................146
	Fig. 23-13 Socket and Hour meter Assembly...........................................................................................................................................................................................................................146
		23.2.3.5 Work Light Portion.....................................................................................................................................................................................................................................147
			1. Clip. Fix white taping part Capscrew tightening torque 46.1 N·m (34 lbf·ft)..............................................................................................................................................................................147
			2. Lets harness pass so that a white taping part may come to a hose stop clamp..............................................................................................................................................................................147
			3. Connect with main harness................................................................................................................................................................................................................................147
			4. Clip.....................................................................................................................................................................................................................................................147
			5. Clip. Harness is fixed to a plate using a hole...........................................................................................................................................................................................................147
			6. Clip. Harness is bundled and it clips in the hole of a bracket...........................................................................................................................................................................................147
			7. Eyelet terminal to be binded to bolt.....................................................................................................................................................................................................................147
			8. Through to the hole......................................................................................................................................................................................................................................147
			9. Clip. A terminal is fixed to the hole of a bracket after clipping to the main line as this figure........................................................................................................................................................147
			10. The electric wire by the side of work light is slacked so that water may not enter......................................................................................................................................................................147
			11. To working light........................................................................................................................................................................................................................................147
			1. It is the inside of the pillar of a canopy...............................................................................................................................................................................................................148
			2. Tightening torque 16.7~21.6 N·m (12~16 lbf·ft............................................................................................................................................................................................................148
			3. Tightening torque 7.0~8.0 N·m (5.16~5.91 lbf·ft) Install light 40 lower from ground level...............................................................................................................................................................148
			4. Canopy. Working light harness Tightening torque 16.7~21.6 N·m (12.3~15.9 lbf·ft).........................................................................................................................................................................148
			5. Fix to the welding clip..................................................................................................................................................................................................................................148
			6. To connect harness of upp frame side.....................................................................................................................................................................................................................148
			7. Connects with cable terminal of the harness of harness assy, cab.........................................................................................................................................................................................148
			8. Tube. A tube is rolled focusin on a connection part after cable terminals connections....................................................................................................................................................................148
			9. Clip. Fix to the bracket of a light......................................................................................................................................................................................................................148
		23.2.3.6 Cab Portion (OPT)......................................................................................................................................................................................................................................149
	Fig. 23-14 Cab Portion (OPT) (1/2)..................................................................................................................................................................................................................................149
		1. Connects white cab harness...................................................................................................................................................................................................................................149
		2. Fix with plate...............................................................................................................................................................................................................................................149
		3. Capscrew. Fix a terminal for ground..........................................................................................................................................................................................................................149
		4. Connects white light harness.................................................................................................................................................................................................................................149
		5. Washer tank..................................................................................................................................................................................................................................................149
		6. Switch. Connect to connector of inst-main harness with “wiper” tag...........................................................................................................................................................................................149
		NOTE: Tightening torque. Threads size Tightening torque M8 23 N·m (17 lbf·ft)...................................................................................................................................................................................149
			23.2.3.7 Heather Portion (OPT)..............................................................................................................................................................................................................................150
				1. Hose.................................................................................................................................................................................................................................................150
				2. Clip.................................................................................................................................................................................................................................................150
				3. Rubber...............................................................................................................................................................................................................................................150
				4. Heather front cover..................................................................................................................................................................................................................................150
				5. Sems-bolt. Tightening torque: 23.5 N·m (17 lbf·ft)...................................................................................................................................................................................................150
				6. Packing..............................................................................................................................................................................................................................................150
		NOTE: 2 A parts of taper pipe thread apply three bond #1110B. Tightening torque to be 25 N·m (19 lbf·ft) 3 Overlapped length of hose to be longer than 25mm, and put a clamp lenin middle part of the length....................................................150
			24.1 HYDRAULIC COMPONENTS 24-3..............................................................................................................................................................................................................................151
				24.1.1 HYDRAULIC PUMP 24-3..............................................................................................................................................................................................................................151
				24.1.2 PILOT VALVE (ATT) 24-14..........................................................................................................................................................................................................................151
				24.1.3 PILOT VALVE (TRAVEL) 24-18.......................................................................................................................................................................................................................151
				24.1.4 CONTROL VALVE 24-24..............................................................................................................................................................................................................................151
				24.1.5 SLEWING MOTOR 24-40..............................................................................................................................................................................................................................151
				24.1.6 TRAVEL MOTOR 24-52...............................................................................................................................................................................................................................151
				24.1.7 SWIVEL JOINT 24-69...............................................................................................................................................................................................................................151
				24.1.8 CYLINDER 24-71...................................................................................................................................................................................................................................151
			24.2 ELECTRICAL EQUIPMENT 24-79.............................................................................................................................................................................................................................151
				24.2.1 ELECTRICAL EQUIPMENT LIST 24-79..................................................................................................................................................................................................................151
				24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT 24-81........................................................................................................................................................................................................151
24. COMPONENTS SYSTEM...................................................................................................................................................................................................................................................153
24.1 HYDRAULIC COMPONENTS...............................................................................................................................................................................................................................................155
	24.1.1 HYDRAULIC PUMP...............................................................................................................................................................................................................................................155
		24.1.1.1 SUMMARY................................................................................................................................................................................................................................................155
			1. GENERAL VIEW.............................................................................................................................................................................................................................................155
		Fig. 24-1 General view of hydraulic pump........................................................................................................................................................................................................................155
	2. SPECIFICATIONS...................................................................................................................................................................................................................................................156
		24.1.1.2 CONSTRUCTION . FUNCTION................................................................................................................................................................................................................................157
		Fig. 24-2.......................................................................................................................................................................................................................................................157
			1. Piston pump..............................................................................................................................................................................................................................................157
	2. Operation........................................................................................................................................................................................................................................................158
		1. Piston.......................................................................................................................................................................................................................................................158
		2. Bottom dead point............................................................................................................................................................................................................................................158
		3. Cylinder block...............................................................................................................................................................................................................................................158
		4. Control plate................................................................................................................................................................................................................................................158
		5. Suction port.................................................................................................................................................................................................................................................158
		6. In side P2...................................................................................................................................................................................................................................................158
		7. Out side P1..................................................................................................................................................................................................................................................158
		8. Delivery port................................................................................................................................................................................................................................................158
		9. Suction stroke...............................................................................................................................................................................................................................................158
		10. Delivery stroke.............................................................................................................................................................................................................................................158
		11. Top dead point..............................................................................................................................................................................................................................................158
		12. Hanger (Sliding surface)....................................................................................................................................................................................................................................158
			a. The cylinder block is fitted on the spline and rotates with the drive shaft..............................................................................................................................................................................158
			b. The piston fitted on the cylinder block follows the sliding surface of the hanger and moves to and from it...............................................................................................................................................158
			c. The piston moves to increase the capacity from the bottom dead point to the top dead point, the pressure oil flows from the inlet port into cylinder block through the control plate. (Suction stroke 9).................................................158
			d. But as the piston moves to decrease the capacity from the top dead point to the bottom dead point, the pressure oil is sent out to the delivery port. (Delivery stroke 10)...............................................................................158
			e. By changing the tilting angle of the hanger (sliding surface), the displacement varies...................................................................................................................................................................158
			f. The oil sucked from the inside port of the cylinder block is delivered from the delivery port inside of the control valve................................................................................................................................158
			g. The oil sucked from the outside port of the cylinder block is delivered from the delivery port outside of the control plate..............................................................................................................................158
			a. The piston sliding on the surface of the hanger acts on the hanger through the hydraulic pressure due to the delivery oil pressure P1 and P2.............................................................................................................159
			b. The spring is located in the position which is in opposition to the delivery oil pressure................................................................................................................................................................159
			c. When the hydraulic pressure acting on the hanger through the piston goes below the setting load of the spring, the hanger is fixed at the maximum tilt angle.............................................................................................159
			d. When the hydraulic pressure acting on the hanger through the position exceeds the setting load of the spring, the hanger is tilted and held tilting at the position where the hydraulic pressure balances the spring pressure. (Control line, Area A)....159
			e. The control line is shifted after the hydraulic pressure P3 acts on the shift piston.....................................................................................................................................................................159
			a. Adjusting procedure......................................................................................................................................................................................................................................160
				1. Loosen the hexagon nut...............................................................................................................................................................................................................................160
				2. Set the power line by tightening or loosening the adjusting screw....................................................................................................................................................................................160
		24.1.1.3 INNER CONSTRUCTION.....................................................................................................................................................................................................................................161
			1. Drive shaft..............................................................................................................................................................................................................................................161
	2. Swash plate (Hanger).............................................................................................................................................................................................................................................161
	3. Rotary group.....................................................................................................................................................................................................................................................162
	4. Control spring...................................................................................................................................................................................................................................................162
	5. Cover............................................................................................................................................................................................................................................................163
	6. Gear pump........................................................................................................................................................................................................................................................164
	7. Housing..........................................................................................................................................................................................................................................................165
	8. Trochoid pump....................................................................................................................................................................................................................................................165
		24.1.2 PILOT VALVE (ATT)........................................................................................................................................................................................................................................166
			24.1.2.1 SUMMARY............................................................................................................................................................................................................................................166
				1. General view.........................................................................................................................................................................................................................................166
			24.1.2.2 CONSTRUCTION.......................................................................................................................................................................................................................................168
			Fig. 24-3 Pilot valve-Sectional view........................................................................................................................................................................................................................168
				1. Apply Loctite #277 (part of slant line)..............................................................................................................................................................................................................168
					2. Apply grease on top..............................................................................................................................................................................................................................168
					3. Secondary pressure adjusting shims...............................................................................................................................................................................................................168
				24.1.2.3 OPERATION......................................................................................................................................................................................................................................169
			Fig. 24-4 Lever in neutral position.........................................................................................................................................................................................................................169
			Fig. 24-5 When Lever is tilted..............................................................................................................................................................................................................................169
			Fig. 24-6 Lever being held..................................................................................................................................................................................................................................169
		24.1.3 PILOT VALVE (TRAVEL).....................................................................................................................................................................................................................................170
			24.1.3.1 SUMMARY............................................................................................................................................................................................................................................170
				1. General view.........................................................................................................................................................................................................................................170
				1. 4-M8 X P1.25 T= 16.7±1.5 N×m.........................................................................................................................................................................................................................170
					2. 2-PF1/4 T= 29.4±2.0 N×m..........................................................................................................................................................................................................................170
					3. 4-PF1/4 T= 29.4±2.0 N×m..........................................................................................................................................................................................................................170
	2. Specifications...................................................................................................................................................................................................................................................170
	3. Performance Characteristics......................................................................................................................................................................................................................................171
		24.1.3.2 CONSTRUCTION...........................................................................................................................................................................................................................................172
		Fig. 24-7 Pilot valve-Sectional view............................................................................................................................................................................................................................172
			24.1.3.3 OPERATION..........................................................................................................................................................................................................................................173
				1. Reducing valve.......................................................................................................................................................................................................................................173
		Fig. 24-8.......................................................................................................................................................................................................................................................173
		Fig. 24-9.......................................................................................................................................................................................................................................................173
	2. Dumping mechanism................................................................................................................................................................................................................................................174
		Fig. 24-10 Operation when the lever is stroked from the neutral position........................................................................................................................................................................................174
			1. Cam......................................................................................................................................................................................................................................................174
				2. Orifice..............................................................................................................................................................................................................................................174
				3. Push rod.............................................................................................................................................................................................................................................174
				4. Piston...............................................................................................................................................................................................................................................174
				5. Steel ball...........................................................................................................................................................................................................................................174
		Fig. 24-11 Operation when the lever is stroked or operated in reverse...........................................................................................................................................................................................175
			1. Cam......................................................................................................................................................................................................................................................175
				3. Push rod.............................................................................................................................................................................................................................................175
				4. Piston...............................................................................................................................................................................................................................................175
				6. Damping spring.......................................................................................................................................................................................................................................175
				7. Neutral position.....................................................................................................................................................................................................................................175
				8. Full stroke..........................................................................................................................................................................................................................................175
				9. Return spring........................................................................................................................................................................................................................................175
		24.1.4 CONTROL VALVE............................................................................................................................................................................................................................................176
			24.1.4.1 GENERAL VIEW AND HYDRAULIC PORTS NO................................................................................................................................................................................................................176
				1. Dozer................................................................................................................................................................................................................................................176
					2. Slewing..........................................................................................................................................................................................................................................176
					3. Supply and independent travel....................................................................................................................................................................................................................176
					4. Arm..............................................................................................................................................................................................................................................176
					5. Service..........................................................................................................................................................................................................................................176
					6. Swing............................................................................................................................................................................................................................................176
					7. Travel right.....................................................................................................................................................................................................................................176
					8. Supply...........................................................................................................................................................................................................................................176
					9. Travel left......................................................................................................................................................................................................................................176
					10. Boom............................................................................................................................................................................................................................................176
					11. Boom lock.......................................................................................................................................................................................................................................176
					12. Bucket..........................................................................................................................................................................................................................................176
					13. Manual operate..................................................................................................................................................................................................................................176
			24.1.4.2 SPECIFICATIONS.....................................................................................................................................................................................................................................176
			24.1.4.3 CONSTRUCTION.......................................................................................................................................................................................................................................177
				1. Control Valve: Overall composition...................................................................................................................................................................................................................177
	2. Component Parts The control valve is roughly classified into the following four sections.........................................................................................................................................................................177
		24.1.4.4 HYDRAULIC CIRCUIT......................................................................................................................................................................................................................................180
			1. Dozer spool..............................................................................................................................................................................................................................................181
				2. Swing spool..........................................................................................................................................................................................................................................181
				3. Travel independent and conflux spool.................................................................................................................................................................................................................181
				4. Arm spool............................................................................................................................................................................................................................................181
				5. Service spool........................................................................................................................................................................................................................................181
				6. Boom swing spool.....................................................................................................................................................................................................................................181
				7. Travel right spool...................................................................................................................................................................................................................................181
				8. Travel left spool....................................................................................................................................................................................................................................181
				9. Boom spool...........................................................................................................................................................................................................................................181
				10. Bucket spool........................................................................................................................................................................................................................................181
				11. P1 (RV1) relief valve...............................................................................................................................................................................................................................181
				12. P2 (RV2) relief valve...............................................................................................................................................................................................................................181
				13. P3 (RV3) relief valve...............................................................................................................................................................................................................................181
				14. B1 Over load relief valve...........................................................................................................................................................................................................................181
				15. A3 Over load relief valve...........................................................................................................................................................................................................................181
				16. B3 Over load relief valve...........................................................................................................................................................................................................................181
				17. B8 Over load relief valve...........................................................................................................................................................................................................................181
				18. B9 Over load relief valve...........................................................................................................................................................................................................................181
				19. B10 Over load relief valve..........................................................................................................................................................................................................................181
				20. Boom lock valve.....................................................................................................................................................................................................................................181
				21. Anticavitation valve................................................................................................................................................................................................................................181
				22. Over load relief plug...............................................................................................................................................................................................................................181
				23. P1 by-pass passage..................................................................................................................................................................................................................................181
				24. P2 by-pass passage..................................................................................................................................................................................................................................181
				25. P3 by-pass passage..................................................................................................................................................................................................................................181
				26. P1 parallel passage.................................................................................................................................................................................................................................181
				27. P2 parallel passage.................................................................................................................................................................................................................................181
				28. P3 parallel passage.................................................................................................................................................................................................................................181
				29. Pp1 Pilot passage...................................................................................................................................................................................................................................181
				30. Tank passage........................................................................................................................................................................................................................................181
				31. Supply..............................................................................................................................................................................................................................................181
		24.1.4.5 EXPLANATION OF OPERATION...............................................................................................................................................................................................................................182
			1. Neutral position.........................................................................................................................................................................................................................................182
			WARNING As the flow from the pump is fed into each line (P1, P2, P3), the switching sections of respective line shown below are ............................................................................................................................182
			WARNING When the engine is stopped (when each hydraulic pump is stopped), the actuator does not function even when being loaded ............................................................................................................................182
		Fig. 24-12 Operation at neutral position........................................................................................................................................................................................................................183
			1. Dozer....................................................................................................................................................................................................................................................183
				2. Slewing..............................................................................................................................................................................................................................................183
				3. Supply and independent travel........................................................................................................................................................................................................................183
				4. Arm..................................................................................................................................................................................................................................................183
				5. Service..............................................................................................................................................................................................................................................183
				6. Swing................................................................................................................................................................................................................................................183
				7. Travel (right).......................................................................................................................................................................................................................................183
				8. Supply...............................................................................................................................................................................................................................................183
				9. Travel (left)........................................................................................................................................................................................................................................183
				10. Boom................................................................................................................................................................................................................................................183
				11. Boom lock...........................................................................................................................................................................................................................................183
				12. Bucket..............................................................................................................................................................................................................................................183
	2. Pilot operating section..........................................................................................................................................................................................................................................184
		Fig. 24-13 Operation at boom raising............................................................................................................................................................................................................................184
			13. Boom cylinder...........................................................................................................................................................................................................................................184
	3. Manual operation section.........................................................................................................................................................................................................................................185
		Fig. 24-14 Operation of swing...................................................................................................................................................................................................................................185
	4. Flow conflux function............................................................................................................................................................................................................................................186
		Fig. 24-15 Actuation of flow conflux circuit in service operation...............................................................................................................................................................................................186
			`...........................................................................................................................................................................................................................................................186
	5. Independent travel function......................................................................................................................................................................................................................................187
		Fig. 24-16 Independent travel actuation.........................................................................................................................................................................................................................187
			1. Dozer....................................................................................................................................................................................................................................................187
				2. Slewing..............................................................................................................................................................................................................................................187
				3. Supply and independent travel........................................................................................................................................................................................................................187
				4. Arm..................................................................................................................................................................................................................................................187
	6. Function of Lock Valve...........................................................................................................................................................................................................................................188
		Fig. 24-17 Function of Lock Valve (piston holding)..............................................................................................................................................................................................................188
		Fig. 24-18 Function of Lock Valve (release).....................................................................................................................................................................................................................189
	7. Operation of relief valve........................................................................................................................................................................................................................................190
		Fig. 24-19......................................................................................................................................................................................................................................................190
		24.1.5 SLEWING MOTOR............................................................................................................................................................................................................................................192
			24.1.5.1 GENERAL VIEW.......................................................................................................................................................................................................................................192
			24.1.5.2 HYDRAULIC CIRCUIT..................................................................................................................................................................................................................................192
			24.1.5.3 SPECIFICATIONS.....................................................................................................................................................................................................................................192
			24.1.5.4 CONSTRUCTION.......................................................................................................................................................................................................................................193
			24.1.5.5 FUNCTION AND OPERATION.............................................................................................................................................................................................................................194
				1. Swash plate motor....................................................................................................................................................................................................................................194
			Fig. 24-21..................................................................................................................................................................................................................................................195
	2. Parking brake....................................................................................................................................................................................................................................................196
	3. The hydraulic timer is provided to protect the parking brake from dragging and plays to secure delay time so that the parking....................................................................................................................................196
		Fig. 24-22 PG (Brake releasing pressure) ON.....................................................................................................................................................................................................................197
		Fig. 24-23 PG (Brake releasing pressure) OFF....................................................................................................................................................................................................................197
		Fig. 24-24......................................................................................................................................................................................................................................................198
			76. In this interval, main control valve is switched........................................................................................................................................................................................................199
			77. Time zone the flow is controlled by orifice.............................................................................................................................................................................................................199
			78. In this interval, (PG) supply pressure is acting on.....................................................................................................................................................................................................199
			79. Releasing parking brake.................................................................................................................................................................................................................................199
			80. Timer set time..........................................................................................................................................................................................................................................199
			81. In this interval, parking brake does not act on and does not draggs.....................................................................................................................................................................................199
			82. Set slewing speed.......................................................................................................................................................................................................................................199
			83. Acceleration............................................................................................................................................................................................................................................199
			84. Uniform speed area......................................................................................................................................................................................................................................199
			85. Time (t)................................................................................................................................................................................................................................................199
			86. Deceleration area hydraulic pressure dynamic brake......................................................................................................................................................................................................199
	4. Operating principle of relief valve..............................................................................................................................................................................................................................200
		Fig. 24-25 Construction of relief valve.........................................................................................................................................................................................................................200
			1st step:...................................................................................................................................................................................................................................................201
		Fig. 24-26 1st step: Operation of relief valve..................................................................................................................................................................................................................201
			2nd step:...................................................................................................................................................................................................................................................201
		Fig. 24-27 2nd step: Operation of relief valve..................................................................................................................................................................................................................201
		Fig. 24-28 Comparison of pressure wave forms....................................................................................................................................................................................................................201
	5. Make-up valve (check valve, No.54)...............................................................................................................................................................................................................................202
	6. Reduction Unit (2-stage planetary)...............................................................................................................................................................................................................................203
		24.1.6 TRAVEL MOTOR.............................................................................................................................................................................................................................................204
			24.1.6.1 SPECIFICATIONS.....................................................................................................................................................................................................................................204
				1. General View.........................................................................................................................................................................................................................................204
	2. Hydraulic circuit................................................................................................................................................................................................................................................204
		24.1.6.2 CONSTRUCTION...........................................................................................................................................................................................................................................206
			1. Sectional view...........................................................................................................................................................................................................................................206
		24.1.6.3 FUNCTION...............................................................................................................................................................................................................................................208
		Fig. 24-29 Structure of traveling motor.........................................................................................................................................................................................................................208
			24.1.6.3.1 Working principle of swash plate type axial piston motor.........................................................................................................................................................................................209
		Fig. 24-30 Structure of swash plate type axial piston motor.....................................................................................................................................................................................................209
			24.1.6.3.2 Working principle of counter balance valve.......................................................................................................................................................................................................210
		Fig. 24-31 Structure of counter balance valve...................................................................................................................................................................................................................210
		Fig. 24-32 Structure of counter balance valve (counter balance valve work)......................................................................................................................................................................................211
		Fig. 24-33 Structure of counter balance valve (Brake work)......................................................................................................................................................................................................212
			24.1.6.3.3 Working principle of two speed change mechanism..................................................................................................................................................................................................213
		Fig. 24-34 At 1st speed (low speed).............................................................................................................................................................................................................................213
		Fig. 24-35 At 2nd speed (high speed)............................................................................................................................................................................................................................214
			24.1.6.3.4 Working principle of auto two speed change mechanism.............................................................................................................................................................................................215
		Fig. 24-36 Auto two speed control (Motor pressure is low).......................................................................................................................................................................................................215
		Fig. 24-37 Auto two speed (Motor pressure is high)..............................................................................................................................................................................................................216
			24.1.6.3.5 Working principle of anti cavitation valve.......................................................................................................................................................................................................217
		Fig. 24-38 Anti cavitation valve (From stopping to starting)....................................................................................................................................................................................................217
		Fig. 24-39 Anti cavitaion valve (From continuous rotating to decleration).......................................................................................................................................................................................218
		Fig. 24-40 Hydraulic circuit of anti cavitation valve...........................................................................................................................................................................................................218
			24.1.6.3.6 Working principle of parking brake...............................................................................................................................................................................................................219
		Fig. 24-41 Structure of parking brake...........................................................................................................................................................................................................................219
			24.1.6.3.7 Working principle of reduction unit..............................................................................................................................................................................................................220
		Fig. 24-42 Structure of reduction unit..........................................................................................................................................................................................................................220
		24.1.7 SWIVEL JOINT.............................................................................................................................................................................................................................................221
			24.1.7.1 GENERAL VIEW.......................................................................................................................................................................................................................................221
			Fig. 24-43 General view.....................................................................................................................................................................................................................................221
				24.1.7.2 SPECIFICATIONS.................................................................................................................................................................................................................................221
				24.1.7.3 CONSTRUCTION...................................................................................................................................................................................................................................222
			Fig. 24-44 Construction.....................................................................................................................................................................................................................................222
				24.1.7.4 FUNCTION.......................................................................................................................................................................................................................................222
		24.1.8 CYLINDER.................................................................................................................................................................................................................................................223
			24.1.8.1 SPECIFICATIONS.....................................................................................................................................................................................................................................223
				1. General View.........................................................................................................................................................................................................................................223
			Fig. 24-45 General view of cylinder.........................................................................................................................................................................................................................223
			Table 24-1 E20.2SR / E22.2SR................................................................................................................................................................................................................................223
			Table 24-2 E27.2SR..........................................................................................................................................................................................................................................223
				24.1.8.2 CONSTRUCTION AND FUNCTION......................................................................................................................................................................................................................224
					24.1.8.2.1 Construction.............................................................................................................................................................................................................................224
						1. Boom cylinder................................................................................................................................................................................................................................224
			Fig. 24-46 Construction of boom cylinder....................................................................................................................................................................................................................224
	2. Arm cylinder.....................................................................................................................................................................................................................................................225
		Fig. 24-47 Construction of Arm cylinder.........................................................................................................................................................................................................................225
	3. Bucket cylinder..................................................................................................................................................................................................................................................226
		Fig. 24-48 Construction of bucket cylinder......................................................................................................................................................................................................................226
	4. Swing cylinder...................................................................................................................................................................................................................................................227
		Fig. 24-49 Construction of swing cylinder.......................................................................................................................................................................................................................227
	5. Dozer cylinder...................................................................................................................................................................................................................................................228
		Fig. 24-50 Construction of dozer cylinder.......................................................................................................................................................................................................................228
			24.1.8.2.2 Function (Example for boom cylinder).............................................................................................................................................................................................................229
				1. Fundamental Function.................................................................................................................................................................................................................................229
	2. Function of each Parts...........................................................................................................................................................................................................................................229
		Fig. 24-51 Cylinder head assy...................................................................................................................................................................................................................................229
		Fig. 24-52 Piston assy..........................................................................................................................................................................................................................................230
24.2 ELECTRICAL EQUIPMENT...............................................................................................................................................................................................................................................231
	24.2.1 ELECTRICAL EQUIPMENT LIST....................................................................................................................................................................................................................................231
	24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT..........................................................................................................................................................................................................................233
		31.1 GENERAL DISASSEMBLY AND ASSEMBLY 31-3......................................................................................................................................................................................................................255
			31.1.1 CONTENTS OF GENERAL DISASSEMBLY AND ASSEMBLY 31-3....................................................................................................................................................................................................255
			31.1.2 SPECIFICATION OF TIGHTENING TORQUE 31-3..............................................................................................................................................................................................................255
		31. GENERAL DISASSEMBLY AND ASSEMBLY............................................................................................................................................................................................................................257
			31.1 GENERAL DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................................................................................259
				31.1.1 CONTENTS OF GENERAL DISASSEMBLY AND ASSEMBLY.....................................................................................................................................................................................................259
				31.1.2 SPECIFICATION OF TIGHTENING TORQUE...............................................................................................................................................................................................................259
					32.1 REMOVING AND INSTALLING 32-3...................................................................................................................................................................................................................261
						32.1.1 ATTACHMENT ASSEMBLY AND NAME 32-3........................................................................................................................................................................................................261
						32.1.2 BUCKET 32-4..............................................................................................................................................................................................................................261
						32.1.3 ARM 32-6.................................................................................................................................................................................................................................261
						32.1.4 BOOM 32-9................................................................................................................................................................................................................................261
						32.1.5 SWING 32-12..............................................................................................................................................................................................................................261
						32.1.6 DOZER 32-14..............................................................................................................................................................................................................................261
					32.2 DISASSEMBLING AND ASSEMBLING 32-15.............................................................................................................................................................................................................261
						32.2.1 CYLINDER 32-15...........................................................................................................................................................................................................................261
		32. ATTACHMENTS.................................................................................................................................................................................................................................................263
			32.1 REMOVING AND INSTALLING................................................................................................................................................................................................................................265
				32.1.1 ATTACHMENT ASSEMBLY AND NAME.....................................................................................................................................................................................................................265
			Fig. 32-1 Attachment name and position......................................................................................................................................................................................................................265
				32.1.2 BUCKET...........................................................................................................................................................................................................................................266
					32.1.2.1 REMOVAL OF BUCKET..........................................................................................................................................................................................................................266
			Fig. 32-2 To place Bucket on ground.........................................................................................................................................................................................................................266
			Fig. 32-3 Assembly of pin (A-A).............................................................................................................................................................................................................................266
				32.1.2.2 INSTALLATION OF BUCKET.........................................................................................................................................................................................................................267
				CAUTION When aligning the pin position, do not put your finger in the pin holes in any circumstances, but align them visually...........................................................................................................................267
			Fig. 32-4 Installation of bucket............................................................................................................................................................................................................................267
				32.1.3 ARM..............................................................................................................................................................................................................................................268
					32.1.3.1 REMOVAL OF ARM.............................................................................................................................................................................................................................268
			Fig. 32-5 Arm removing posture..............................................................................................................................................................................................................................268
			Fig. 32-6 Sectional view of Installing Pin..................................................................................................................................................................................................................268
			Fig. 32-7 Removal of Arm assembly...........................................................................................................................................................................................................................268
			Fig. 32-8 Sectional view of Installing Pin..................................................................................................................................................................................................................269
				32.1.3.2 INSTALLATION OF ARM............................................................................................................................................................................................................................269
				CAUTION At the alignment of pin positions, never insert your finger into the pin holes. Make sure to align them with visual confirmation................................................................................................................269
			Fig. 32-9 Dust seal installation............................................................................................................................................................................................................................269
			Fig. 32-10 Sectional view of Installing Pin.................................................................................................................................................................................................................270
				32.1.4 BOOM.............................................................................................................................................................................................................................................271
					32.1.4.1 REMOVAL OF BOOM............................................................................................................................................................................................................................271
			Fig. 32-11 Removal of Boom Cylinder.........................................................................................................................................................................................................................271
			Fig. 32-12 Sectional view of Installing Pin.................................................................................................................................................................................................................271
			Fig. 32-13 Removal of Boom assembly.........................................................................................................................................................................................................................271
			Fig. 32-14 Sectional view of Installing Pin.................................................................................................................................................................................................................272
				32.1.4.2 INSTALLATION OF BOOM...........................................................................................................................................................................................................................272
				CAUTION At the alignment of pin positions, never insert your finger into the bores. Make sure to align them with visual confirmation....................................................................................................................272
			Fig. 32-15 Dust seal installation...........................................................................................................................................................................................................................272
			Fig. 32-16 Sectional view of Installing Pin.................................................................................................................................................................................................................273
				32.1.5 SWING............................................................................................................................................................................................................................................274
					32.1.5.1 PREPARATION FOR REMOVAL....................................................................................................................................................................................................................274
					32.1.5.2 REMOVAL OF SWING BRACKET AND CYLINDER......................................................................................................................................................................................................274
			Fig. 32-17 Swing portion....................................................................................................................................................................................................................................274
				32.1.5.3 INSTALLATION OF SWING BRACKET AND CYLINDER.....................................................................................................................................................................................................275
			Fig. 32-18 Sectional view of Pin Installing.................................................................................................................................................................................................................275
				32.1.6 DOZER............................................................................................................................................................................................................................................276
					32.1.6.1 REMOVAL....................................................................................................................................................................................................................................276
			Fig. 32-19 Removing/Installing Dozer........................................................................................................................................................................................................................276
				32.1.6.2 INSTALLATION...................................................................................................................................................................................................................................276
			Fig. 32-20 Tightening Procedures for Nuts...................................................................................................................................................................................................................276
				32.2 DISASSEMBLING AND ASSEMBLING.......................................................................................................................................................................................................................277
					32.2.1 CYLINDER.....................................................................................................................................................................................................................................277
						32.2.1.1 NECESSARY TOOLS........................................................................................................................................................................................................................277
						32.2.1.2 GENERAL PRECAUTIONS....................................................................................................................................................................................................................277
						32.2.1.3 CYLINDER CONSTRUCTION (EXAMPLE OF BOOM CYLINDER).......................................................................................................................................................................................278
			Fig. 32-21 Construction of boom cylinder....................................................................................................................................................................................................................278
				32.2.1.4 DISASSEMBLY....................................................................................................................................................................................................................................278
			Fig. 32-22 Disassembling cylinder assembly..................................................................................................................................................................................................................278
			Fig. 32-23 Disassembling cylinder assembly..................................................................................................................................................................................................................279
			Fig. 32-24 Disassembling cylinder head......................................................................................................................................................................................................................279
			Fig. 32-25 Disassembling piston rod.........................................................................................................................................................................................................................279
			Fig. 32-26 Removing piston assembly.........................................................................................................................................................................................................................279
			Fig. 32-27 Removing cylinder head and holder................................................................................................................................................................................................................280
			Fig. 32-28 Disassembling piston assembly....................................................................................................................................................................................................................280
			Fig. 32-29 Disassembling cylinder head assembly.............................................................................................................................................................................................................280
			Fig. 32-30 Disassembling holder.............................................................................................................................................................................................................................280
			Fig. 32-31 Disassembling cylinder head......................................................................................................................................................................................................................281
			Fig. 32-32 Removing wiper ring..............................................................................................................................................................................................................................281
			Fig. 32-33 Removing bushing.................................................................................................................................................................................................................................281
			Fig. 32-34 Removing dust seal...............................................................................................................................................................................................................................281
			Fig. 32-35 Removing pin bushing.............................................................................................................................................................................................................................282
				32.2.1.5 ASSEMBLY.......................................................................................................................................................................................................................................282
			Fig. 32-36 Installing pin bushing (2).......................................................................................................................................................................................................................282
			Fig. 32-37 Installing dust seal.............................................................................................................................................................................................................................282
			Fig. 32-38 Assembling cylinder head.........................................................................................................................................................................................................................282
			Fig. 32-39 Installing U-ring................................................................................................................................................................................................................................283
			Fig. 32-40 Installing holder................................................................................................................................................................................................................................283
			Fig. 32-41 Installing wiper ring............................................................................................................................................................................................................................283
			Fig. 32-42 Installing back-up ring and O-ring...............................................................................................................................................................................................................283
			Fig. 32-43 Assembling piston assembly.......................................................................................................................................................................................................................284
			Fig. 32-44 Assembling piston assembly.......................................................................................................................................................................................................................284
			Fig. 32-45 Reforming seal ring..............................................................................................................................................................................................................................284
			Fig. 32-46 Installing slide ring............................................................................................................................................................................................................................284
			Fig. 32-47 Installing head and holder.......................................................................................................................................................................................................................285
			Fig. 32-48 Installing piston assembly.......................................................................................................................................................................................................................285
			Fig. 32-49 Inserting piston rod assembly....................................................................................................................................................................................................................285
			Fig. 32-50 Installing cylinder head.........................................................................................................................................................................................................................286
			Fig. 32-51 Assembling cylinder assembly.....................................................................................................................................................................................................................286
				32.2.1.6 MAINTENANCE STANDARDS..........................................................................................................................................................................................................................286
			Fig. 32-52 Measuring method.................................................................................................................................................................................................................................287
			Fig. 32-53 Unloaded test....................................................................................................................................................................................................................................288
				32.2.1.7 JIG LIST.......................................................................................................................................................................................................................................290
				32.2.1.8 POSSIBLE CAUSES FOR TROUBLE AND REMEDY.........................................................................................................................................................................................................294
					33.1 REMOVING AND INSTALLING 33-3...................................................................................................................................................................................................................295
						33.1.1 CANOPY / CAB 33-3........................................................................................................................................................................................................................295
						33.1.2 GUARD (COVER) 33-5.......................................................................................................................................................................................................................295
						33.1.3 FLOOR PLATE ASSEMBLY 33-7................................................................................................................................................................................................................295
						33.1.4 BATTERY 33-9.............................................................................................................................................................................................................................295
						33.1.5 COUNTERWEIGHT 33-10......................................................................................................................................................................................................................295
						33.1.6 PUMP 33-11...............................................................................................................................................................................................................................295
						33.1.7 CONTROL VALVE 33-13......................................................................................................................................................................................................................295
						33.1.8 SOLENOID VALVE 33-17.....................................................................................................................................................................................................................295
						33.1.9 FUEL TANK 33-18..........................................................................................................................................................................................................................295
						33.1.10 HYDRAULIC OIL TANK 33-20................................................................................................................................................................................................................295
						33.1.11 AIR CLEANER 33-23.......................................................................................................................................................................................................................295
						33.1.12 GENERATOR 33-24.........................................................................................................................................................................................................................295
						33.1.13 MUFFLER 33-25...........................................................................................................................................................................................................................295
						33.1.14 CONTROL STAND 33-26.....................................................................................................................................................................................................................295
						33.1.15 STARTER 33-31...........................................................................................................................................................................................................................295
						33.1.16 RADIATOR 33-32..........................................................................................................................................................................................................................295
						33.1.17 ENGINE 33-34............................................................................................................................................................................................................................295
						33.1.18 PILOT VALVE 33-36.......................................................................................................................................................................................................................295
						33.1.19 SLEWING MOTOR 33-38.....................................................................................................................................................................................................................295
						33.1.20 SWIVEL JOINT 33-40......................................................................................................................................................................................................................295
						33.1.21 UPPER FRAME 33-43.......................................................................................................................................................................................................................295
					33.2 DISASSEMBLING AND ASSEMBLING 33-45.............................................................................................................................................................................................................295
						33.2.1 HYDRAULIC PUMP 33-45.....................................................................................................................................................................................................................295
						33.2.2 CONTROL VALVE 33-66......................................................................................................................................................................................................................295
						33.2.3 PILOT VALVE (Attachment) 33-85...........................................................................................................................................................................................................295
						33.2.4 PILOT VALVE (TRAVEL) 33-94...............................................................................................................................................................................................................295
						33.2.5 SLEWING MOTOR 33-99......................................................................................................................................................................................................................295
						33.2.6 SWIVEL JOINT 33-118......................................................................................................................................................................................................................295
		33. UPPER SLEWING STRUCTURE.....................................................................................................................................................................................................................................297
			33.1 REMOVING AND INSTALLING................................................................................................................................................................................................................................299
				33.1.1 CANOPY / CAB.....................................................................................................................................................................................................................................299
					33.1.1.1 CANOPY REMOVAL.............................................................................................................................................................................................................................299
			Fig. 33-1 Floor mat removal.................................................................................................................................................................................................................................299
			Fig. 33-2 Removal of canopy assembly and handrail...........................................................................................................................................................................................................299
				C. Harness Outlet.......................................................................................................................................................................................................................................299
					33.1.1.2 CAB REMOVAL (Option).......................................................................................................................................................................................................................299
						33.1.1.2.1 Cab removal preparation..............................................................................................................................................................................................................299
			Fig. 33-3 Floor mat removal.................................................................................................................................................................................................................................299
				33.1.1.2.2 Cab removal..................................................................................................................................................................................................................................300
			B...........................................................................................................................................................................................................................................................300
			Fig. 33-4 Outside of cab....................................................................................................................................................................................................................................300
			Fig. 33-5 Cab assembly fastening positions..................................................................................................................................................................................................................300
				D. Adjust the clearance between guard and cab rear bracket with shims (t1.2,2.0,3.2)....................................................................................................................................................................300
			Fig. 33-6 Seat belt assembly removal........................................................................................................................................................................................................................301
				33.1.2 GUARD (COVER)....................................................................................................................................................................................................................................301
					33.1.2.1 REMOVAL....................................................................................................................................................................................................................................301
			Fig. 33-7 Cover removal.....................................................................................................................................................................................................................................301
			Fig. 33-8 Bonnet assembly (3) removal.......................................................................................................................................................................................................................301
			Fig. 33-9 Cover assembly (8) removal........................................................................................................................................................................................................................302
			Fig. 33-10 Cover assemblies (4) and (5) removal.............................................................................................................................................................................................................302
			Fig. 33-11 Cover assembly (1) removal.......................................................................................................................................................................................................................302
			Fig. 33-12 Cover assembly (1) removal.......................................................................................................................................................................................................................302
				33.1.2.2 Installation...................................................................................................................................................................................................................................303
				33.1.3 FLOOR PLATE ASSEMBLY.............................................................................................................................................................................................................................303
					33.1.3.1 FLOOR PLATE REMOVAL PREPARATION............................................................................................................................................................................................................303
			Fig. 33-13 Cover assembly (2) removal.......................................................................................................................................................................................................................303
				NOTE: Take care of the tightening torque as the pilot valve is made of aluminum.........................................................................................................................................................................303
			Fig. 33-14 Pilot piping disconnection.......................................................................................................................................................................................................................303
			Fig. 33-15 Swing cable disconnection........................................................................................................................................................................................................................304
				NOTE: Take care of the tightening torque as the pilot valve is made of aluminum.........................................................................................................................................................................304
			Fig. 33-16 Pilot piping removal.............................................................................................................................................................................................................................304
				33.1.3.2 FLOOR PLATE REMOVAL............................................................................................................................................................................................................................304
			Fig. 33-17 Floor plate (1) removal The figure is for the standard...........................................................................................................................................................................................304
				33.1.3.3 ASSEMBLING FLOOR PLATE.........................................................................................................................................................................................................................305
				33.1.4 BATTERY..........................................................................................................................................................................................................................................305
					33.1.4.1 REMOVAL PREPARATION........................................................................................................................................................................................................................305
			Fig. 33-18 Floor section removal preparation................................................................................................................................................................................................................305
				33.1.4.2 REMOVAL........................................................................................................................................................................................................................................305
			Fig. 33-19 Battery removal..................................................................................................................................................................................................................................305
				33.1.4.3 INSTALLATION...................................................................................................................................................................................................................................305
				33.1.5 COUNTERWEIGHT....................................................................................................................................................................................................................................306
					33.1.5.1 REMOVAL PREPARATION........................................................................................................................................................................................................................306
					33.1.5.2 REMOVAL....................................................................................................................................................................................................................................306
			Fig. 33-20 Counterweight removal............................................................................................................................................................................................................................306
				33.1.5.3 INSTALLATION...................................................................................................................................................................................................................................306
			Fig. 33-21 Counterweight installation.......................................................................................................................................................................................................................306
				33.1.6 PUMP.............................................................................................................................................................................................................................................307
					33.1.6.1 REMOVAL PREPARATION........................................................................................................................................................................................................................307
			Fig. 33-22 Filler neck removal..............................................................................................................................................................................................................................307
				A1. Fuel tank...........................................................................................................................................................................................................................................307
					33.1.6.2 REMOVAL....................................................................................................................................................................................................................................307
			Fig. 33-23 Pump removal.....................................................................................................................................................................................................................................307
				33.1.6.3 INSTALLATION...................................................................................................................................................................................................................................308
			Fig. 33-24 Pump installation................................................................................................................................................................................................................................308
				C4. T= 85.3 N.m.........................................................................................................................................................................................................................................308
				C5. T= 85 ~ 94 N.m (63 to 69 lbf.ft) Apply no Loctite as microcapsule coating has been applied..........................................................................................................................................................308
				C8. Apply grease........................................................................................................................................................................................................................................308
				C9. Air bleed valve.....................................................................................................................................................................................................................................308
				C10. T= 64.7 N.m (48 lbf.ft) Apply Loctite #262.........................................................................................................................................................................................................308
					33.1.7 CONTROL VALVE................................................................................................................................................................................................................................309
						33.1.7.1 REMOVAL PREPARATION....................................................................................................................................................................................................................309
						33.1.7.2 REMOVAL................................................................................................................................................................................................................................309
			Fig. 33-25 Main hydraulic hose disconnection and Nibbler & Breaker..........................................................................................................................................................................................309
				C/O. Pump...............................................................................................................................................................................................................................................309
				S/C. Swing..............................................................................................................................................................................................................................................309
				A. Arm..................................................................................................................................................................................................................................................309
				O/C. Oil cooler.........................................................................................................................................................................................................................................309
				S/J. Swivel joint.......................................................................................................................................................................................................................................309
				B. Boom.................................................................................................................................................................................................................................................309
				H/T. Hydraulic Tank.....................................................................................................................................................................................................................................309
				S/M. Slewing motor......................................................................................................................................................................................................................................309
				U. Bucket...............................................................................................................................................................................................................................................309
				C/V.Control valve.......................................................................................................................................................................................................................................309
			Fig. 33-26 Pilot hydraulic hose disconnection and Nibbler & Breaker.........................................................................................................................................................................................310
				C/B. Control block......................................................................................................................................................................................................................................310
				P/V. Pilot valve........................................................................................................................................................................................................................................310
				S/V. Shuttle valve......................................................................................................................................................................................................................................310
			Fig. 33-27 Cable disconnection..............................................................................................................................................................................................................................311
			Fig. 33-28 Control valve removal............................................................................................................................................................................................................................311
				33.1.7.3 INSTALLATION...................................................................................................................................................................................................................................312
			Fig. 33-29 Control valve removal............................................................................................................................................................................................................................312
				A. Arm section..........................................................................................................................................................................................................................................312
				B. Boom section.........................................................................................................................................................................................................................................312
				B/L. Boom lock section..................................................................................................................................................................................................................................312
				D. Dozer section........................................................................................................................................................................................................................................312
				S. Supply...............................................................................................................................................................................................................................................312
				S/C. Slewing section....................................................................................................................................................................................................................................312
				S/T. Supply and travel straight.........................................................................................................................................................................................................................312
				S/E. Service section....................................................................................................................................................................................................................................312
				S/O. Swing section......................................................................................................................................................................................................................................312
				T/R. Travel (right) section.............................................................................................................................................................................................................................312
				T/L. Travel (left) section..............................................................................................................................................................................................................................312
				U. Bucket section.......................................................................................................................................................................................................................................312
					33.1.8 SOLENOID VALVE...............................................................................................................................................................................................................................313
						33.1.8.1 REMOVAL PREPARATION....................................................................................................................................................................................................................313
						33.1.8.2 REMOVAL................................................................................................................................................................................................................................313
			Fig. 33-30 Solenoid valve removal...........................................................................................................................................................................................................................313
				B14. Plug...............................................................................................................................................................................................................................................313
					33.1.8.3 INSTALLATION...............................................................................................................................................................................................................................313
					33.1.9 FUEL TANK....................................................................................................................................................................................................................................314
						33.1.9.1 DISASSEMBLY PREPARATION................................................................................................................................................................................................................314
			Fig. 33-31 Fuel drain.......................................................................................................................................................................................................................................314
				A1. Fuel tank...........................................................................................................................................................................................................................................314
					33.1.9.2 DISASSEMBLY................................................................................................................................................................................................................................315
			Fig. 33-32 Fuel tank removal................................................................................................................................................................................................................................315
				33.1.9.3 INSTALLATION...................................................................................................................................................................................................................................315
				33.1.10 HYDRAULIC OIL TANK..............................................................................................................................................................................................................................316
					33.1.10.1 DISASSEMBLY PREPARATION...................................................................................................................................................................................................................316
			Fig. 33-33 Cover removal....................................................................................................................................................................................................................................316
			Fig. 33-34 Draining hydraulic oil...........................................................................................................................................................................................................................316
				A1. Hydraulic oil tank..................................................................................................................................................................................................................................316
				B1. Solenoid valve......................................................................................................................................................................................................................................316
				B8. Plug................................................................................................................................................................................................................................................316
					33.1.10.2 DISASSEMBLY...............................................................................................................................................................................................................................317
			Fig. 33-35 Suction hose removal.............................................................................................................................................................................................................................317
				A15. Cap boot...........................................................................................................................................................................................................................................317
			Fig. 33-36 Return oil hose removal..........................................................................................................................................................................................................................317
			Fig. 33-37 Hydraulic oil tank removal.......................................................................................................................................................................................................................317
				33.1.10.3 ASSEMBLY......................................................................................................................................................................................................................................318
			Fig. 33-38 Posture for stopping engine......................................................................................................................................................................................................................318
				33.1.11 AIR CLEANER.....................................................................................................................................................................................................................................319
					33.1.11.1 DISASSEMBLY PREPARATION...................................................................................................................................................................................................................319
					33.1.11.2 DISASSEMBLY...............................................................................................................................................................................................................................319
			Fig. 33-39 Air cleaner removal..............................................................................................................................................................................................................................319
				33.1.11.3 ASSEMBLY......................................................................................................................................................................................................................................319
				33.1.12 GENERATOR.......................................................................................................................................................................................................................................320
					33.1.12.1 DISASSEMBLY PREPARATION...................................................................................................................................................................................................................320
					33.1.12.2 DISASSEMBLY...............................................................................................................................................................................................................................320
			Fig. 33-40 Generator removal................................................................................................................................................................................................................................320
				33.1.12.3 ASSEMBLY......................................................................................................................................................................................................................................320
			Fig. 33-41 Generator terminal...............................................................................................................................................................................................................................320
				B. Nut for terminal B tightening torque 5.9~9.8 N.m (4.4~7.2 lbf.ft)....................................................................................................................................................................................320
				C. Clip.................................................................................................................................................................................................................................................320
				E-4. To fusible link....................................................................................................................................................................................................................................320
					33.1.13 MUFFLER.....................................................................................................................................................................................................................................321
						33.1.13.1 DISASSEMBLY PREPARATION...............................................................................................................................................................................................................321
						33.1.13.2 DISASSEMBLY...........................................................................................................................................................................................................................321
			Fig. 33-42 Muffler removal..................................................................................................................................................................................................................................321
				33.1.13.3 ASSEMBLY......................................................................................................................................................................................................................................321
				33.1.14 CONTROL STAND...................................................................................................................................................................................................................................322
					33.1.14.1 DISASSEMBLY PREPARATION...................................................................................................................................................................................................................322
					33.1.14.2 DISASSEMBLY...............................................................................................................................................................................................................................322
			Fig. 33-43 Control cable removal............................................................................................................................................................................................................................322
			Fig. 33-44 Filler neck removal..............................................................................................................................................................................................................................322
			Fig. 33-45 Air bleed hose disconnection.....................................................................................................................................................................................................................322
			Fig. 33-46 Pilot valve removal for dozer....................................................................................................................................................................................................................323
			Fig. 33-47 Seat and cover removal...........................................................................................................................................................................................................................323
			Fig. 33-48 Cover removal....................................................................................................................................................................................................................................323
			Fig. 33-49 Pilot hose disconnection.........................................................................................................................................................................................................................324
			Fig. 33-50 Heater hose disconnection........................................................................................................................................................................................................................324
			Fig. 33-51 Control stand removal............................................................................................................................................................................................................................325
			Fig. 33-52 Support (7) removal..............................................................................................................................................................................................................................326
				33.1.14.3 INSTALLATION..................................................................................................................................................................................................................................326
				33.1.15 STARTER.........................................................................................................................................................................................................................................327
					33.1.15.1 REMOVAL PREPARATION.......................................................................................................................................................................................................................327
			Fig. 33-53 Seat and cover removal...........................................................................................................................................................................................................................327
				33.1.15.2 REMOVAL.......................................................................................................................................................................................................................................327
			Fig. 33-54 Starter removal..................................................................................................................................................................................................................................327
				B. M8 nut for terminal B tightening torque 7.4~9.8 N.m (lbf.ft).........................................................................................................................................................................................327
				E4. To fusibile link....................................................................................................................................................................................................................................327
				H4. Starter cable.......................................................................................................................................................................................................................................327
				M1. Starter motor.......................................................................................................................................................................................................................................327
					33.1.15.3 INSTALLATION..............................................................................................................................................................................................................................327
					33.1.16 RADIATOR....................................................................................................................................................................................................................................328
						33.1.16.1 DISASSEMBLY PREPARATION...............................................................................................................................................................................................................328
			Fig. 33-55 Duct removal.....................................................................................................................................................................................................................................328
				33.1.16.2 DISASSEMBLY...................................................................................................................................................................................................................................328
			Fig. 33-56 Radiator disassembly.............................................................................................................................................................................................................................328
			Fig. 33-57 Draining hydraulic oil in oil cooler.............................................................................................................................................................................................................328
				33.1.16.3 ASSEMBLY......................................................................................................................................................................................................................................329
				Tightening torque for related parts.....................................................................................................................................................................................................................329
			Fig. 33-58 Radiator installation............................................................................................................................................................................................................................329
				26. Position the fan at a distance of 27.5 mm (1’.1”) from radaitor shroud..............................................................................................................................................................................329
				27. Shroud..............................................................................................................................................................................................................................................329
				28. Adjust the clearance between the fan and radiator shroud so that it is set to 15mm (0.59”) around the circumference.................................................................................................................................329
				29. Fan.................................................................................................................................................................................................................................................329
					33.1.17 ENGINE......................................................................................................................................................................................................................................330
						33.1.17.1 REMOVAL PREPARATION...................................................................................................................................................................................................................330
						33.1.17.2 REMOVAL...............................................................................................................................................................................................................................330
			Fig. 33-59 Fuel hose removal................................................................................................................................................................................................................................330
				30. Fuel filter.........................................................................................................................................................................................................................................330
				31. Fuel feed pump......................................................................................................................................................................................................................................330
					33.1.17.3 INSTALLATION..............................................................................................................................................................................................................................331
			Fig. 33-60 Engine removal...................................................................................................................................................................................................................................331
				33.1.18 PILOT VALVE.....................................................................................................................................................................................................................................332
					33.1.18.1 PREPARATION FOR REMOVAL...................................................................................................................................................................................................................332
			Fig. 33-61 Cover removal (Right control box)................................................................................................................................................................................................................332
				33.1.18.2 REMOVAL.......................................................................................................................................................................................................................................332
			TK..........................................................................................................................................................................................................................................................332
			Fig. 33-62 Hose removal.....................................................................................................................................................................................................................................332
				TK. Tank................................................................................................................................................................................................................................................332
					33.1.18.3 INSTALLATION..............................................................................................................................................................................................................................333
				NOTE: Take care of the tightening torque as the pilot valve is made of aluminum.........................................................................................................................................................................333
			Fig. 33-63 Pilot valve port location........................................................................................................................................................................................................................333
				1. Bucket (H)...........................................................................................................................................................................................................................................333
				5. Slewing (L)..........................................................................................................................................................................................................................................333
				2. Bucket (R)...........................................................................................................................................................................................................................................333
				6. Slewing (R)..........................................................................................................................................................................................................................................333
				3. Boom (H).............................................................................................................................................................................................................................................333
				7. Arm (H)..............................................................................................................................................................................................................................................333
				4. Boom (R).............................................................................................................................................................................................................................................333
				8. Arm (R)..............................................................................................................................................................................................................................................333
				R. Right side...........................................................................................................................................................................................................................................333
				L. Left side............................................................................................................................................................................................................................................333
					33.1.19 SLEWING MOTOR...............................................................................................................................................................................................................................334
						33.1.19.1 REMOVAL PREPARATION...................................................................................................................................................................................................................334
						33.1.19.2 REMOVAL...............................................................................................................................................................................................................................334
			Fig. 33-64 Main hose disconnection..........................................................................................................................................................................................................................334
			Fig. 33-65 Main hose disconnection..........................................................................................................................................................................................................................334
			Fig. 33-66 Pilot hose removal...............................................................................................................................................................................................................................334
			Fig. 33-67 Slewing motor removal............................................................................................................................................................................................................................335
				33.1.19.3 INSTALLATION..................................................................................................................................................................................................................................335
				33.1.20 SWIVEL JOINT....................................................................................................................................................................................................................................336
					33.1.20.1 REMOVAL PREPARATION.......................................................................................................................................................................................................................336
			Fig. 33-68 Lifting machine..................................................................................................................................................................................................................................336
			Fig. 33-69 Undercover removal...............................................................................................................................................................................................................................336
				33.1.20.2 REMOVAL.......................................................................................................................................................................................................................................337
			Fig. 33-70 Drain hose disconnection.........................................................................................................................................................................................................................337
				12. To hydraulic oil tank...............................................................................................................................................................................................................................337
			Fig. 33-71 Upper side hose disconnection....................................................................................................................................................................................................................337
			Fig. 33-72 Lower side hose disconnection....................................................................................................................................................................................................................337
			Fig. 33-73 Stopper removal..................................................................................................................................................................................................................................337
			Fig. 33-74 Swivel joint removal.............................................................................................................................................................................................................................338
				33.1.20.3 INSTALLATION..................................................................................................................................................................................................................................338
			Fig. 33-75 Connecting port relation.........................................................................................................................................................................................................................338
				AL. (Upper) forward.....................................................................................................................................................................................................................................338
				AR. (Lower) reverse.....................................................................................................................................................................................................................................338
				BL. (Upper) forward.....................................................................................................................................................................................................................................338
				BR. (Lower) reverse.....................................................................................................................................................................................................................................338
				L. Dozer (H)............................................................................................................................................................................................................................................338
				R. Dozer (R)............................................................................................................................................................................................................................................338
				TL. Travel motor (left).................................................................................................................................................................................................................................338
				TR. Travel motor (right)................................................................................................................................................................................................................................338
					33.1.21 UPPER FRAME.................................................................................................................................................................................................................................339
						33.1.21.1 REMOVAL PREPARATION...................................................................................................................................................................................................................339
						33.1.21.2 REMOVAL...............................................................................................................................................................................................................................339
			Fig. 33-76 Slewing bearing and upper frame..................................................................................................................................................................................................................339
			Fig. 33-77 Lifting rear side................................................................................................................................................................................................................................339
				33.1.21.3 INSTALLATION..................................................................................................................................................................................................................................340
			Fig. 33-78 Slewing bearing installation.....................................................................................................................................................................................................................340
			Fig. 33-79 Reamer bolt position.............................................................................................................................................................................................................................340
				33.2 DISASSEMBLING AND ASSEMBLING.......................................................................................................................................................................................................................341
					33.2.1 HYDRAULIC PUMP...............................................................................................................................................................................................................................341
						33.2.1.1 CONSTRUCTION...........................................................................................................................................................................................................................341
					NOTE: Refer to section 33.2.1 HYDRAULIC PUMP in COMPONENTS SYSTEM PW24 for detail...................................................................................................................................................................341
						33.2.1.2 DISASSEMBLY AND ASSEMBLY...............................................................................................................................................................................................................342
							33.2.1.2.1 Tools and Jig....................................................................................................................................................................................................................342
							33.2.1.2.2 Cautions during Assembling and Dissembling.......................................................................................................................................................................................342
							33.2.1.2.3 Disassembly......................................................................................................................................................................................................................343
						2. C-Snap ring..................................................................................................................................................................................................................................346
						3. Shim.........................................................................................................................................................................................................................................346
						4. Shaft........................................................................................................................................................................................................................................346
						5. Cylinder Block...............................................................................................................................................................................................................................346
							33.2.1.2.4 Assembly.........................................................................................................................................................................................................................351
						6. Marking......................................................................................................................................................................................................................................352
						2. C-Snap ring..................................................................................................................................................................................................................................354
						3. Shim.........................................................................................................................................................................................................................................354
						4. Shaft........................................................................................................................................................................................................................................354
						5. Cylinder block...............................................................................................................................................................................................................................354
						T. Trochoid pump side...........................................................................................................................................................................................................................356
						R. Round side...................................................................................................................................................................................................................................356
						C. Cover side...................................................................................................................................................................................................................................356
						I. Inner rotor..................................................................................................................................................................................................................................356
						M. Matchmark....................................................................................................................................................................................................................................356
						O. Outer rotor..................................................................................................................................................................................................................................356
						D. Delivery side................................................................................................................................................................................................................................358
						S. Suction side.................................................................................................................................................................................................................................358
						L. Large chamfered side.........................................................................................................................................................................................................................359
						D. Delivery side................................................................................................................................................................................................................................359
						S. Suction side.................................................................................................................................................................................................................................359
							33.2.1.3 MAINTENANCE STANDARD...............................................................................................................................................................................................................361
						5. Oil seal installing range....................................................................................................................................................................................................................361
							33.2.2 CONTROL VALVE........................................................................................................................................................................................................................362
								33.2.2.1 ASSEMBLY DRAWING...............................................................................................................................................................................................................362
					1. Outside view.....................................................................................................................................................................................................................................362
			Fig. 33-80..................................................................................................................................................................................................................................................362
				2. Cross section........................................................................................................................................................................................................................................363
			Fig. 33-81..................................................................................................................................................................................................................................................363
			Fig. 33-82..................................................................................................................................................................................................................................................363
				A .Only for Overload relief valve & P3 main relief valve................................................................................................................................................................................................364
			Fig. 33-83..................................................................................................................................................................................................................................................364
			Fig. 33-84..................................................................................................................................................................................................................................................364
				33.2.2.2 PRECAUTIONS FOR DISASSEMBLY....................................................................................................................................................................................................................365
				33.2.2.3 REQUIRED TOOLS AND OTHERS......................................................................................................................................................................................................................365
				33.2.2.4 DISASSEMBLING..................................................................................................................................................................................................................................366
			Fig. 33-85 Hydraulic pilot switching type...................................................................................................................................................................................................................366
			Fig. 33-86 Manual switching type............................................................................................................................................................................................................................366
			Fig. 33-87 P3 supply and travel straight sections...........................................................................................................................................................................................................367
				A. Load check valve (Dozer, Slewing, Arm, Swing, Boom, Bucket)..........................................................................................................................................................................................368
				B. Load check valve (Travel right and left switching, P3 supply and boom lock valve section)............................................................................................................................................................368
				C. Load check valve (Service switching section).........................................................................................................................................................................................................368
			Fig. 33-88 Load check valve.................................................................................................................................................................................................................................368
			Fig. 33-89..................................................................................................................................................................................................................................................368
			Fig. 33-91 Service section..................................................................................................................................................................................................................................370
			Fig. 33-92 Plug in the bottom of boom lock valve section....................................................................................................................................................................................................370
				33.2.2.5 PRECAUTIONS WHEN ASSEMBLING....................................................................................................................................................................................................................372
				33.2.2.6 PRECAUTIONS WHEN FITTING SEALS.................................................................................................................................................................................................................372
				33.2.2.7 ASSEMBLY WORK..................................................................................................................................................................................................................................373
				NOTE: The symbols are engraved on the upper surface of the main frame of the switching section (Actuator port face).....................................................................................................................................373
					33.2.2.8 Maintenance standard.......................................................................................................................................................................................................................378
					33.2.2.9 Cause of failure and corrective action.....................................................................................................................................................................................................378
					33.2.3 PILOT VALVE (Attachment).....................................................................................................................................................................................................................381
						33.2.3.1 CONSTRUCTION...........................................................................................................................................................................................................................381
			Fig. 33-93 Pilot valve (Attachment).........................................................................................................................................................................................................................381
				A. Apply grease.........................................................................................................................................................................................................................................381
				S. Shim for adjusting secondary pressure................................................................................................................................................................................................................381
					33.2.3.2 DISASSEMBLY & ASSEMBLY.....................................................................................................................................................................................................................382
			Fig. 33-94 Special jig......................................................................................................................................................................................................................................382
				33.2.3.3 Disassembling procedure........................................................................................................................................................................................................................382
					33.2.3.3.1 General cautions for disassembly.........................................................................................................................................................................................................382
					33.2.3.3.2 Disassembly..............................................................................................................................................................................................................................383
			Fig. 33-95 Handle lever disassembly.........................................................................................................................................................................................................................383
			Fig. 33-96 Adjusting nut (312) removal......................................................................................................................................................................................................................383
			Fig. 33-97 Joint (301) removal..............................................................................................................................................................................................................................383
			Fig. 33-98 Plate (151) removal..............................................................................................................................................................................................................................383
			Fig. 33-99 Spring (221) removal.............................................................................................................................................................................................................................384
			Fig. 33-100 Push rod (212) removal..........................................................................................................................................................................................................................384
			Fig. 33-101 Pressure reducing valve disassembly.............................................................................................................................................................................................................384
			Fig. 33-102 Pressure reducing valve disassembly.............................................................................................................................................................................................................384
			Fig. 33-103 Pulling out plug (211)..........................................................................................................................................................................................................................385
			Fig. 33-104 Seal (213) removal..............................................................................................................................................................................................................................385
				33.2.3.4 Assembling procedures..........................................................................................................................................................................................................................386
					33.2.3.4.1 General cautions for assembling work.....................................................................................................................................................................................................386
					33.2.3.4.2 Assembly.................................................................................................................................................................................................................................386
			Fig. 33-105 Assembling spool (201)..........................................................................................................................................................................................................................386
			Fig. 33-106 Assembling spool (201)..........................................................................................................................................................................................................................386
			Fig. 33-107 Installing spool (221)..........................................................................................................................................................................................................................386
			Fig. 33-108 Installing seal (213)...........................................................................................................................................................................................................................387
			Fig. 33-109 Installing push rod (212).......................................................................................................................................................................................................................387
			Fig. 33-110 Installing plug assembly........................................................................................................................................................................................................................387
			Fig. 33-111 Installing plug assembly........................................................................................................................................................................................................................387
			Fig. 33-112 Installing joint (301)..........................................................................................................................................................................................................................388
			Fig. 33-113 Installing joint (301)..........................................................................................................................................................................................................................388
			Fig. 33-114 Applying grease.................................................................................................................................................................................................................................388
				33.2.3.5 Maintenance standard...........................................................................................................................................................................................................................389
				NOTE: Replace seal such as O-ring with new ones after every disassembly.................................................................................................................................................................................389
					33.2.3.6 TROUBLESHOOTING............................................................................................................................................................................................................................389
					1) Primary pressure is insufficient.................................................................................................................................................................................................................389
					1) Secure primary pressure..........................................................................................................................................................................................................................389
					2) Springs (241-1, 241-2) are broken or fatigued....................................................................................................................................................................................................389
					2) Replace with new ones............................................................................................................................................................................................................................389
					3) Clearance between spool (201-1, 201-2) and valve body (101) is abnormally large..................................................................................................................................................................389
					3) Replace assembly.................................................................................................................................................................................................................................389
					4) Play of handle portion is too much...............................................................................................................................................................................................................389
					4) Disassembly and reassembly or replace handle portion.............................................................................................................................................................................................389
					1) Sliding parts are caught.........................................................................................................................................................................................................................389
					1) Correct..........................................................................................................................................................................................................................................389
					2) Tank line pressure varies........................................................................................................................................................................................................................389
					2) Return directly to oil tank......................................................................................................................................................................................................................389
					3) Air has contained into pipeline..................................................................................................................................................................................................................389
					3) Release air......................................................................................................................................................................................................................................389
					1) Tank line pressure is high.......................................................................................................................................................................................................................389
					1) Return directly to oil tank......................................................................................................................................................................................................................389
					2) Sliding parts are caught.........................................................................................................................................................................................................................389
					2) Correct..........................................................................................................................................................................................................................................389
						33.2.4 PILOT VALVE (TRAVEL).....................................................................................................................................................................................................................390
							33.2.4.1 CONSTRUCTION.......................................................................................................................................................................................................................390
					A. Apply grease.....................................................................................................................................................................................................................................390
			Fig. 33-115 Pilot valve (Travel)............................................................................................................................................................................................................................390
				33.2.4.2 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................................................................................391
			Fig. 33-116 Special jig 1...................................................................................................................................................................................................................................391
			Fig. 33-117.................................................................................................................................................................................................................................................392
				33.2.4.3 ASSEMBLY.......................................................................................................................................................................................................................................392
			Fig. 33-118.................................................................................................................................................................................................................................................392
			Fig. 33-119.................................................................................................................................................................................................................................................393
				33.2.4.4 TROUBLESHOOTING................................................................................................................................................................................................................................394
				33.2.5 SLEWING MOTOR....................................................................................................................................................................................................................................395
					33.2.5.1 CONSTRUCTION...............................................................................................................................................................................................................................395
					33.2.5.2 DISASSEMBLING PROCEDURE....................................................................................................................................................................................................................396
					33.2.5.3 DISASSEMBLY................................................................................................................................................................................................................................396
				NOTE: Be careful not to drop valve plate (43) when removing cover (40)..................................................................................................................................................................................396
				NOTE: Valve plate (43) may be left on the motor side....................................................................................................................................................................................................396
				NOTE: Don’t turn set bolt (53-7) to maintain the set pressure. Don’t disassemble relief valve assembly because it has an important function.............................................................................................................397
				NOTE: Valve plate (43) may be left on the cover side....................................................................................................................................................................................................398
				NOTE: The piston may pop out due to the air pressure, so be careful not to be injured. So, set the air pressure to low position,........................................................................................................................398
				NOTE: Don’t reuse the removed ball bearing..............................................................................................................................................................................................................400
				NOTE: For taper roller bearings (5 and 7) and collar (3), replace the body assembly.....................................................................................................................................................................402
				NOTE: Be careful not to drop the shaft when removing. When it is difficult to pull it out, tap it by a hammer...........................................................................................................................................402
				NOTE: Don’t reuse the removed oil seal. When removing, be careful not to damage the outer race of taper roller bearing (5) (7)..........................................................................................................................403
					33.2.5.4 ASSEMBLING PROCEDURE.......................................................................................................................................................................................................................403
					33.2.5.5 ASSEMBLY...................................................................................................................................................................................................................................403
				NOTE: Fit O-ring (51) carefully without damaging........................................................................................................................................................................................................405
				NOTE: Do not mistake the direction of installation......................................................................................................................................................................................................405
					T. Taper surface....................................................................................................................................................................................................................................405
				NOTE: Apply enough hydraulic oil on the sliding section before installation.............................................................................................................................................................................406
				NOTE: Install ball bearing (21) directing the snap ring (74) as shown in the figure.....................................................................................................................................................................406
				NOTE: Do not mistake the direction of the thrust plate..................................................................................................................................................................................................407
					D. Direct the taper side toward the motor case side.................................................................................................................................................................................................407
				NOTE: Be careful not to drop pin (29) when installing. Install disk (33)................................................................................................................................................................................407
				NOTE: Be careful not to drop pin (44) and valve plate (43)..............................................................................................................................................................................................408
				NOTE: Apply grease to the oil seal fitting section of housing (1) and around the oil seal before press fitting..........................................................................................................................................409
					D. Dimension after oil seal is press fitting........................................................................................................................................................................................................409
				NOTE: Apply grease to the lip section of oil seal (6) before installing pinion shaft (2)................................................................................................................................................................409
				NOTE: Install thrust plate (15) payng attention to the direction. For the direction (DR) refer to the figure shown below................................................................................................................................410
					A. Align the protruded section with port............................................................................................................................................................................................................411
						33.2.5.6 MAINTENANCE STANDARD...................................................................................................................................................................................................................412
						33.2.6 SWIVEL JOINT.............................................................................................................................................................................................................................414
							33.2.6.1 CONSTRUCTION.......................................................................................................................................................................................................................414
					14. Tightening torque 52~57 N.m (38~42 lbf.ft)......................................................................................................................................................................................................414
			Fig. 33-120.................................................................................................................................................................................................................................................414
				33.2.6.2 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................................................................................415
					33.2.6.2.1 General precautions......................................................................................................................................................................................................................415
					33.2.6.2.2 Disassembly..............................................................................................................................................................................................................................415
					33.2.6.2.3 Assembling...............................................................................................................................................................................................................................416
				33.2.6.3 MAINTENANCE STANDARDS..........................................................................................................................................................................................................................418
					33.2.6.3.1 Check Procedures and Remedy..............................................................................................................................................................................................................418
					33.2.6.3.2 Parts Service Limit......................................................................................................................................................................................................................418
					33.2.6.3.3 Inspection After Assembly................................................................................................................................................................................................................420
				33.2.6.4 TROUBLESHOOTING................................................................................................................................................................................................................................420
E20_22_27.2SR_2.pdf.....................................................................................................................................................................................................................................................  0
	2. Crawler..........................................................................................................................................................................................................................................................425
	3. Upper roller (E27.2SR ONLY)......................................................................................................................................................................................................................................425
	4. Lower roller.....................................................................................................................................................................................................................................................425
	5. Front idler......................................................................................................................................................................................................................................................425
	6. Idler adjuster...................................................................................................................................................................................................................................................425
	7. Sprocket.........................................................................................................................................................................................................................................................425
	8. Travel motor.....................................................................................................................................................................................................................................................425
	9. Slewing bearing..................................................................................................................................................................................................................................................425
		A. Link pitch...................................................................................................................................................................................................................................................433
	B. Link height......................................................................................................................................................................................................................................................433
	C. Height of shoe lug...............................................................................................................................................................................................................................................433
	D. Bushing O.D......................................................................................................................................................................................................................................................433
	E. Interference of bushing and link.................................................................................................................................................................................................................................433
	F. Interference of track pin and link...............................................................................................................................................................................................................................433
	G. Fitting of master pin and link...................................................................................................................................................................................................................................433
	H. Clearence gap of link............................................................................................................................................................................................................................................433
	I. Master pin.......................................................................................................................................................................................................................................................433
	Slewing speed is slow...............................................................................................................................................................................................................................................494
	Replace seal for pump shaft.........................................................................................................................................................................................................................................502
	NO..................................................................................................................................................................................................................................................................523
	Medium speed........................................................................................................................................................................................................................................................524
	OK..................................................................................................................................................................................................................................................................524
	Not reach max. speed................................................................................................................................................................................................................................................524
	Adjust engine speed.................................................................................................................................................................................................................................................524
	OK..................................................................................................................................................................................................................................................................525
	1. Diaphragm cover..................................................................................................................................................................................................................................................527
	2. Spring...........................................................................................................................................................................................................................................................527
	3. Center plate.....................................................................................................................................................................................................................................................527
	4 Diaphragm.........................................................................................................................................................................................................................................................527
	5. Remove this side.................................................................................................................................................................................................................................................527
	6. Bonnet...........................................................................................................................................................................................................................................................527
	7. Breather baffle..................................................................................................................................................................................................................................................527
	8. Breather pipe....................................................................................................................................................................................................................................................527
	9. Baffle plate.....................................................................................................................................................................................................................................................527
	10. Plug............................................................................................................................................................................................................................................................527
	11. Suction manifold................................................................................................................................................................................................................................................527

NEW HOLLAND E20.2SR E22.2SR E27.2SR CRAWLER EXCAVATOR SERVICE REPAIR MANUAL 604.13.401 – PDF DOWNLOAD:

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]