Yanmar B55W 2 Wheel Excavator Service Manual – PDF DOWNLOAD
YANMAR B55W-2 WHEEL EXCAVATOR SERVICE MANUAL:
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Yanmar B55W-2 Wheel Excavator Service ManualYanmar B55W-2 Wheel Excavator Service Manual
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Yanmar B55W 2 Wheel Excavator Service Manual – PDF DOWNLOAD
Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death.
Operator and maintenance personnel should read this manual thoroughly before beginning operation or maintenance.
Keep this manual in the storage compartment to the rear of the operator’s seat, and have all personnel involved in working on the machine read the manual periodically.
Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual.
The procedures and precautions given in this manual apply only to intended uses of the machine.
If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for any others.
In no event should you or others engage in prohibited uses or actions as described in this manual.
YANMAR delivers machines that comply with all applicable regulations and standards of the country to which it has been sent.
If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country.
If there is any question about whether your product complies with the applicable standards and regulations of your country, consult YANMAR or your YANMAR distributor before operating the machine.
TABLE OF CONTENTS:
Yanmar B55W 2 Wheel Excavator Service Manual – PDF DOWNLOAD
Table of Contents.............................................................................................. 7
Safety......................................................................................................... 9
Wheel Excavator Safety..................................................................................... 11
Safety Precautions..................................................................................... 15
Applicable Models...................................................................................... 15
To the Operator of a Excavator......................................................................... 16
Learn the Signal Words Used with the Safety Alert Symbol........................................... 18
General Safety Essentials.............................................................................. 20
Accessory Applications............................................................................. 20
Lifting Capacity Rating Configuration.............................................................. 20
Location of Safety Labels.............................................................................. 21
Summary of Safety Precautions for Lifting in Working Mode.............................................. 22
Unauthorized Modifications............................................................................. 23
General Hazard Information............................................................................. 23
Safety Rules....................................................................................... 23
Safety Features.................................................................................... 23
Inside Operator's Cabin............................................................................ 24
Clothing and Personal Protective Items............................................................. 24
Breathing Masks, Ear Protection May Be Required.................................................... 25
Vibration Level Information........................................................................ 25
Recommendations for Limiting Vibrations............................................................ 26
Mounting and Dismounting........................................................................... 27
Fuel, Oil and Hydraulic Fluid Fire Hazards......................................................... 27
Precautions When Handling Fluids at High Temperature............................................... 28
Asbestos Dust Hazard Prevention.................................................................... 28
Injury from Work Equipment......................................................................... 29
Fire Extinguisher and First Aid Kit................................................................ 29
Protection from Falling or Flying Objects.......................................................... 30
Attachment Precautions............................................................................. 30
Accumulator........................................................................................ 31
Indoor Ventilation................................................................................. 31
Emergency Glass Breaking Tool...................................................................... 32
Before Starting Engine................................................................................. 33
Work Site Precautions.............................................................................. 33
Checks Before Starting Engine...................................................................... 35
Engine Starting.................................................................................... 36
Before Operating Machine........................................................................... 37
Machine Operation...................................................................................... 38
When Swinging or Changing Direction of Travel...................................................... 38
Travel Precautions................................................................................. 38
Traveling on Slopes................................................................................ 39
Prohibited Operations.............................................................................. 40
Precautions for Operation.......................................................................... 41
Avoid Highvoltage Cables.......................................................................... 41
Operations on Slopes............................................................................... 42
Parking Machine.................................................................................... 42
Never Let Anyone Ride on Attachment................................................................ 42
Maintenance............................................................................................ 43
Warning Tag........................................................................................ 43
Clean Before Inspection or Maintenance............................................................. 43
Proper Tools....................................................................................... 44
Use of Lighting.................................................................................... 44
Fire Prevention and Explosion Prevention........................................................... 44
Burn Prevention.................................................................................... 45
Welding Repairs.................................................................................... 46
Treatment for Electrical Welding to the Body Structure......................................... 47
Warning for Counterweight and Front Attachment Removal............................................. 47
Precautions for Removal, Installation, and Storage of Attachments.................................. 48
Precautions When Working on Machine................................................................ 48
Prevention of Crushing and Cutting................................................................. 48
Supports and Blocking for Work Equipment........................................................... 49
Action When Abnormality Is Found During Inspection................................................. 49
Precautions with Highpressure Lines, Tubes and Hoses.............................................. 50
Waste Materials.................................................................................... 50
Battery................................................................................................ 51
Battery Hazard Prevention.......................................................................... 51
Boost Starting or Charging Engine Batteries........................................................ 52
Towing................................................................................................. 53
Precautions When Towing............................................................................ 53
Shipping and Transportation............................................................................ 54
Obey State and Local OvertheRoad Regulations..................................................... 54
Lifting With Sling..................................................................................... 54
Specifications................................................................................................. 55
Specification for DX55W.................................................................................... 57
Safety Precautions..................................................................................... 61
Applicable Models...................................................................................... 61
General Description.................................................................................... 63
Component Locations.................................................................................... 64
General Dimensions..................................................................................... 66
Working Range.......................................................................................... 67
Front Pin size......................................................................................... 70
Hydraulic Cylinders.................................................................................... 71
General Specifications................................................................................. 72
Hydraulic System Component Specifications.............................................................. 73
System Component Specifications........................................................................ 74
Engine Performance Curves (Per DIN6270 Standard)...................................................... 76
Approximate Weight of Workload Materials............................................................... 78
Performance Tests and Standards........................................................................ 80
Excavator Performance Standards........................................................................ 81
Test Conditions.................................................................................... 81
Travel Speed Tests................................................................................. 82
Swing Speed and Deceleration Force Test............................................................ 83
Swing Speed Test............................................................................... 83
Swing Deceleration Force Test.................................................................. 84
Cylinder Performance Tests......................................................................... 84
Boom Cylinders Test............................................................................ 84
Arm Cylinder Test.............................................................................. 84
Bucket Cylinder Test........................................................................... 85
Hydraulic Cylinder Natural Drop Test........................................................... 85
General Maintenance............................................................................................ 87
General Maintenance Procedures............................................................................. 89
Safety Precautions..................................................................................... 93
Applicable Models...................................................................................... 93
Welding Precautions and Guidelines..................................................................... 95
Hydraulic System - General Precautions................................................................. 96
Maintenance Service and Repair Procedure............................................................... 98
General Precautions................................................................................ 98
Hydraulic System Cleanliness and Oil Leaks............................................................. 99
Maintenance Precautions for Hydraulic System Service............................................... 99
Oil Leakage Precautions............................................................................100
Cleaning and Inspection................................................................................101
General Guidelines.................................................................................101
Bearing Inspection.................................................................................102
Normal Bearing.................................................................................103
Bent Cage......................................................................................103
Galling........................................................................................104
Abrasive Step Wear.............................................................................104
Etching........................................................................................105
Misalignment...................................................................................105
Indentations...................................................................................105
Fatigue Spalling...............................................................................106
Brinelling.....................................................................................106
Cage Wear......................................................................................106
Abrasive Roller Wear...........................................................................107
Cracked Inner Race.............................................................................107
Smears.........................................................................................107
Frettage.......................................................................................108
Heat Discoloration.............................................................................108
Stain Discoloration............................................................................108
Standard Torques...........................................................................................109
Safety Precautions.....................................................................................113
Applicable Models......................................................................................113
Torque Values for Standard Metric Fasteners............................................................115
Torque Values for Standard U.S. Fasteners..............................................................116
Type 8 Phosphate Coated Hardware.......................................................................118
Torque Values for Hose Clamps..........................................................................119
Torque Values for Split Flanges........................................................................120
Torque Wrench Extension Tools..........................................................................121
Torque Multiplication..............................................................................121
Other Uses for Torque Wrench Extension Tools.......................................................122
Tightening Torque Specifications (Metric)..........................................................123
I. "Loctite" Fastener Adhesives................................................................124
II. "Loctite" Pipe Thread Sealant..............................................................124
III. "Loctite" gasket/flange sealer............................................................124
IV. "Loctite" retaining compounds..............................................................125
V. "Loctite" Adhesives.........................................................................125
Upper Structure................................................................................................127
Cabin......................................................................................................129
Safety Precautions.....................................................................................133
Applicable Models......................................................................................133
Removal................................................................................................134
Installation...........................................................................................137
Counterweight..............................................................................................139
Safety Precautions.....................................................................................143
Applicable Models......................................................................................143
General................................................................................................144
Warning for Counterweight and Front Attachment Removal.............................................144
Removal................................................................................................146
Installation...........................................................................................147
Fuel Tank..................................................................................................149
Safety Precautions.....................................................................................153
Applicable Models......................................................................................153
General Description....................................................................................155
Parts List.........................................................................................156
Specifications.....................................................................................157
Removal................................................................................................158
Installation...........................................................................................162
Priming The Fuel System................................................................................164
Fuel Transfer Pump.........................................................................................165
Safety Precautions.....................................................................................169
Applicable Models......................................................................................169
General Description....................................................................................171
Theory of Operation................................................................................171
Troubleshooting........................................................................................172
Replacement of Rotor and Vane..........................................................................173
Replacement of Rear Cover..............................................................................173
Replacement of Armature................................................................................174
Swing Bearing..............................................................................................175
Safety Precautions.....................................................................................179
Applicable Models......................................................................................179
Swing Bearing Maintenance..............................................................................181
Operating Recommendation...........................................................................181
Measuring Swing Bearing Axial Play.................................................................181
Measuring Bearing Lateral Play.....................................................................181
Swing Bearing Basic Operation......................................................................182
Rebuilding Swing Bearing...........................................................................182
Lower Structure and Chassis....................................................................................185
Ram Lock Valve.............................................................................................187
Safety Precautions.....................................................................................191
Applicable Models......................................................................................191
Sectional Drawing and Part Names.......................................................................192
Hydraulic Circuit......................................................................................192
Operational Principle..................................................................................193
In Case of No Pilot Pressure at PI Port............................................................193
In Case of Pilot Pressure (Approx. 20 kg•cm2) at PI Port...........................................193
Disassembly And Assembly...............................................................................193
General Cautions...................................................................................193
Assembly and Disassembly of Chocking Valve.........................................................194
Performance Test.......................................................................................195
Oil Leakage Test...................................................................................195
Operational Test...................................................................................195
Axle.......................................................................................................197
Safety Precautions.....................................................................................201
Applicable Models......................................................................................201
Introduction...........................................................................................202
Introductory Statement.............................................................................202
Clark-Hurth Axle Identification........................................................................203
Maintenance Points.....................................................................................203
Maintenance Intervals..................................................................................204
Conversion Tables......................................................................................204
Tightening Torques.....................................................................................205
Brakes.................................................................................................206
Safety Brake...........................................................................................209
Adjustment.........................................................................................212
Wheel Hub..............................................................................................214
Wheel Hub onto Axle Housing............................................................................216
Epicycloidal Reduction 4.25............................................................................217
Steering Cylinder......................................................................................224
Disassembly - Assembly (T11 bis A, B, C)...........................................................226
Bevel Pinion Support...................................................................................227
Adjustments of Bevel Gear Set..........................................................................234
Taper Roller Bearings of Differential..................................................................236
Disassembling of Differential..........................................................................239
Assembling of the Differential.........................................................................241
Self Locking Differential..............................................................................242
NoSpin.................................................................................................244
Hydraulic Differential Lock............................................................................246
Special Tool...........................................................................................248
Trouble Shooting.......................................................................................257
Engine and Drive Train.........................................................................................259
Engine.....................................................................................................261
Safety Precautions.....................................................................................267
Applicable Models......................................................................................267
Safety.................................................................................................268
Safety Precautions.................................................................................268
General Service Information............................................................................291
Component Identification...........................................................................291
Location of Labels.................................................................................292
Function Of Major Engine Components................................................................293
Main Electronic Control Components and Features....................................................294
Function of Cooling System Components..............................................................296
Diesel Fuel........................................................................................297
Diesel Fuel Specifications.....................................................................297
Filling The Fuel Tank..........................................................................299
Priming the Fuel System........................................................................300
Engine Oil.........................................................................................301
Engine Oil Specifications......................................................................301
Engine Oil Viscosity...........................................................................302
Checking Engine Oil............................................................................302
Adding Engine Oil..............................................................................302
Engine Coolant.....................................................................................303
Engine Coolant Specifications..................................................................304
Filling Radiator with Engine Coolant...........................................................305
Principal Engine Specifications....................................................................306
4TNV98-E.......................................................................................306
Engine Service Standards...........................................................................307
Tightening Torques For Standard Bolts And Nuts.....................................................308
Periodic Maintenance...................................................................................310
Before You Begin Servicing.........................................................................310
Introduction.......................................................................................324
The Importance of Periodic Maintenance.........................................................324
Performing Periodic Maintenance................................................................324
Genuine Replacement Parts......................................................................324
Required EPA / ARB Maintenance - USA Only......................................................324
EPA / ARB Installation Requirements -USA Only..................................................325
Periodic Maintenance Schedule......................................................................325
Periodic Maintenance Procedures....................................................................327
After Initial 50 Hours of Operation............................................................327
Every 50 Hours of Operation....................................................................333
Every 250 Hours of Operation...................................................................338
Every 500 Hours of Operation...................................................................342
Every 1000 Hours of Operation..................................................................346
Every 1500 Hours of Operation..................................................................347
Every 2000 Hours of operation..................................................................349
Engine.................................................................................................352
Before You Begin Servicing.........................................................................352
Introduction.......................................................................................355
Cylinder Head Specifications.......................................................................355
Adjustment Specifications......................................................................355
Cylinder Head..................................................................................355
Intake / Exhaust Valve and Guide...............................................................355
Push Rod.......................................................................................356
Valve Spring...................................................................................356
Rocker Arm and Shaft...........................................................................356
Camshaft And Timing Gear Train Specifications......................................................357
Camshaft.......................................................................................357
Idler Gear Shaft and Bushing...................................................................357
Timing Gear Backlash...........................................................................357
Crankshaft and Piston Specifications...............................................................358
Crankshaft.....................................................................................358
Thrust Bearing.................................................................................358
Piston.........................................................................................358
Piston Ring....................................................................................359
Connecting Rod.................................................................................359
Tappet.........................................................................................360
Cylinder Block Specifications......................................................................360
Cylinder Block.................................................................................360
Special Torque Chart...............................................................................361
Torque for Bolts and Nuts......................................................................361
Special Service Tools..............................................................................362
Measuring Instruments..............................................................................364
4-valve Cylinder Head..............................................................................366
4-Valve Cylinder Head Components...............................................................366
Disassembly of 4-Valve Cylinder Head...........................................................368
Cleaning of Cylinder Head Components...........................................................372
Inspection of Cylinder Head Components.........................................................372
Inspection of Push Rods........................................................................372
Inspection of Rocker Arm Assembly..............................................................373
Inspection of Valve Guides.....................................................................373
Inspection of Cylinder Head....................................................................374
Inspection of Intake and Exhaust Valves........................................................374
Reassembly of Cylinder Head....................................................................377
Measuring And Adjusting Valve Clearance............................................................383
4-Valve Cylinder Heads.........................................................................384
Crankshaft And Camshaft Components.................................................................387
Disassembly of Engine..........................................................................389
Disassembly of Camshaft and Timing Components..................................................390
Disassembly of Crankshaft and Piston Components................................................395
Inspection of Crankshaft and Camshaft Components...............................................399
Honing and Boring..............................................................................405
Reassembly of Crankshaft and Piston Components.................................................406
Reassembly of Camshaft and Timing Components...................................................411
Final Reassembly of Engine.....................................................................416
EGR System.........................................................................................417
EGR System.....................................................................................417
Inspecting/cleaning EGR related components.....................................................420
Fuel System............................................................................................424
Before You Begin Servicing.........................................................................424
Introduction.......................................................................................427
Fuel Injection Pump............................................................................427
Stop Solenoid..................................................................................428
Cold Start Device..............................................................................428
Trochoid Fuel Pump.............................................................................429
Electronically controlled governor.............................................................429
Fuel System Specifications.........................................................................430
Special Torque Chart...........................................................................430
Test and Adjustment Specifications.............................................................430
Special Service Tools..............................................................................430
Measuring Instruments..............................................................................431
Fuel System Diagram................................................................................432
Fuel System Components.............................................................................434
4-Valve Cylinder Head..........................................................................434
Fuel Injection Pump................................................................................436
Removal of Fuel Injection Pump.................................................................436
Installation of Fuel Injection Pump............................................................440
Checking And Adjusting Fuel Injection Timing.......................................................445
Determining the Fuel Injection Timing Specification............................................445
Checking Fuel Injection Timing.................................................................446
Adjusting Fuel Injection Timing................................................................449
Fuel Injectors.....................................................................................450
Removal of Fuel Injectors......................................................................450
Testing of Fuel Injectors......................................................................450
Disassembly and Inspection of Fuel Injectors...................................................452
Adjusting Fuel Injector Pressure...............................................................453
Reassembly of Fuel Injectors...................................................................454
Installation of the Fuel Injectors.............................................................454
Cooling System.........................................................................................455
Before You Begin Servicing.........................................................................455
Introduction.......................................................................................458
Cooling System Diagram.............................................................................458
Engine Coolant Pump Components.....................................................................459
Engine Coolant System Check........................................................................460
Engine Coolant Pump................................................................................460
Disassembly of Engine Coolant Pump.............................................................462
Cleaning and Inspection........................................................................462
Reassembly of Engine Coolant Pump..............................................................463
Installation of Engine Coolant Pump............................................................463
Lubrication System.....................................................................................465
Before You Begin Servicing.........................................................................465
Introduction.......................................................................................467
Oil Pump Service Information.......................................................................467
Lubrication System Diagram.........................................................................468
Checking Engine Oil Pressure.......................................................................469
Trochoid Oil Pump..................................................................................469
Oil Pump Components............................................................................469
Disassembly of Oil Pump........................................................................469
Cleaning and Inspection........................................................................470
Reassembly of Oil Pump.........................................................................472
Starter Motor..........................................................................................473
Before You Begin Servicing.........................................................................473
Introduction.......................................................................................475
Starter Motor Specifications.......................................................................475
Starter Motor Troubleshooting......................................................................476
Starter Motor Components...........................................................................477
Starter Motor......................................................................................478
Removal of Starter Motor.......................................................................478
Disassembly of Starter Motor...................................................................478
Cleaning and Inspection........................................................................481
Reassembly of Starter Motor....................................................................486
Check Pinion Projection Length.................................................................488
No-Load Test...................................................................................489
Installation of Starter Motor..................................................................489
Alternator.............................................................................................490
Before You Begin Servicing.........................................................................490
Introduction.......................................................................................494
Alternator Specifications..........................................................................494
Dynamo Specifications..............................................................................494
Alternator Troubleshooting.........................................................................495
Alternator Components..............................................................................496
Alternator Wiring Diagram..........................................................................498
Alternator Standard Output.........................................................................499
Alternator.........................................................................................500
Removal of Alternator..........................................................................500
Disassembly of Alternator......................................................................501
Reassembly of Alternator.......................................................................503
Installation of Alternator.....................................................................505
Dynamo Component Location..........................................................................506
Dynamo Wiring Diagram..............................................................................507
Operation Of Dynamo................................................................................507
Dynamo Standard Output.............................................................................508
Testing of Dynamo..................................................................................509
Testing Stator Coil Continuity.................................................................509
Testing Stator Coil Short-to-Ground............................................................509
Testing Dynamo Regulated Output................................................................509
Dynamo.............................................................................................510
Removal of Dynamo..............................................................................510
Disassembly of Dynamo..........................................................................510
Reassembly of Dynamo...........................................................................511
Installation of Dynamo.........................................................................512
Electric Wiring........................................................................................513
Electric Wiring Precautions........................................................................513
Electrical Wire Resistance.........................................................................514
Battery Cable Resistance...........................................................................515
Electrical Wire Sizes - Voltage Drop...............................................................516
Conversion Of Awg To European Standards............................................................517
Troubleshooting........................................................................................518
Special Service Tools..............................................................................518
Troubleshooting By Measuring Compression Pressure..................................................519
Compression Pressure Measurement Method........................................................519
Standard Compression Pressure (Reference Value)................................................520
Engine Speed and Compression Pressure (Use for Reference)......................................520
Measured Value and Troubleshooting.............................................................521
Quick Reference Table For Troubleshooting..........................................................522
Failure Diagnosis Table............................................................................523
Electrical wiring.................................................................................. 0
Transmission...............................................................................................529
Safety Precautions.....................................................................................533
Applicable Models......................................................................................533
Data Plate.............................................................................................534
Maintenance Points.....................................................................................534
Screw-Locking, Sealing and Lubricating Materials.......................................................535
Maintenance Intervals and Oil Specification............................................................535
Conversion Tables......................................................................................536
Tightening Torques.....................................................................................537
Notes on safety precautions............................................................................538
Replacing Counter Revolution Sensor....................................................................539
Hydraulic Gear Control.................................................................................540
Disassembling......................................................................................540
Assembling.........................................................................................544
Integrated Reduction Gear 367..........................................................................549
Disassembling......................................................................................549
Assembl Clearance..................................................................................560
Drive Coupling (Main Pump).................................................................................575
Safety Precautions.....................................................................................579
Applicable Models......................................................................................579
Drive Coupling.........................................................................................580
Installation of Drive Coupling.........................................................................581
Installation Procedure.............................................................................581
Precaution.........................................................................................581
Hydraulics.....................................................................................................583
Hydraulic System Troubleshooting, Testing and Adjustment...................................................585
Safety Precautions.....................................................................................589
Applicable Models......................................................................................589
Hydraulic System - General Notes.......................................................................590
Hydraulic Schematic....................................................................................591
General Notes......................................................................................591
Operation of Working Components........................................................................593
Boom Operating Circuit.............................................................................593
Boom Up Circuit....................................................................................593
Boom Down Circuit..................................................................................593
Arm Operating Circuit..............................................................................594
Arm Crowd Circuit..................................................................................594
Arm Dump Circuit...................................................................................594
Bucket Operating Circuit...........................................................................595
Bucket Crowd Circuit...............................................................................595
Bucket Dump Circuit................................................................................595
Swing Operating Circuit............................................................................595
Right Swing Operating Circuit......................................................................596
Left Swing Operating Circuit.......................................................................596
Swing Relief Valve and Makeup Valve................................................................596
Drive Operating Circuit............................................................................597
Forward Circuit....................................................................................597
Reverse Circuit....................................................................................597
Dozer Operating Circuit............................................................................598
Dozer Down Circuit.................................................................................598
Dozer Up Circuit...................................................................................598
Boom Circle Operating Circuit......................................................................599
Right Boom Circle Circuit..........................................................................599
Left Boom Circle Circuit...........................................................................599
Procedural Troubleshooting Baseline Recommendations....................................................600
Initial Checks and Tests to Establish Operating Condition of the Excavator.........................600
Triage Summary.................................................................................600
Pilot Pressure.........................................................................................602
Adjustment and Testing.............................................................................602
Swing System Troubleshooting...........................................................................603
Precautions/Initial Checks.........................................................................603
Swing Relief Valve Checking and Adjustment.........................................................604
Troubleshooting – Swing Gearbox........................................................................606
Troubleshooting – Hydraulic Problems...................................................................607
Troubleshooting – Control Valve........................................................................609
Troubleshooting – Travel Control Valve.................................................................610
Troubleshooting – Joystick Control Valve...............................................................611
Accumulator................................................................................................613
Safety Precautions.....................................................................................617
Applicable Models......................................................................................617
General Description....................................................................................618
Specifications.....................................................................................620
Center Joint (Swivel)......................................................................................621
Safety Precautions.....................................................................................625
Applicable Models......................................................................................625
General Description....................................................................................626
Parts List.........................................................................................627
Troubleshooting, Testing and Adjustment................................................................628
Inspection.........................................................................................628
Testing............................................................................................628
Disassembly............................................................................................629
Reassembly.............................................................................................633
Cylinders..................................................................................................635
Safety Precautions.....................................................................................639
Applicable Models......................................................................................639
General Description....................................................................................640
Theory of Operation................................................................................640
Parts List.........................................................................................642
Boom Cylinder..................................................................................642
Arm Cylinder...................................................................................644
Bucket Cylinder................................................................................646
Dozer Cylinder.................................................................................648
Ram Cylinder...................................................................................649
Special Tools and Materials............................................................................650
Piston Nut.........................................................................................650
Piston Jig.........................................................................................651
Steel Bushing Jig..................................................................................652
Dust Wiper Jig.....................................................................................653
Slipper Seal Jig...................................................................................654
Slipper Seal Straightening Jig.....................................................................655
Disassembly............................................................................................656
Assembly...............................................................................................662
Main Control Valve.........................................................................................665
Safety Precautions.....................................................................................669
Applicable Models......................................................................................669
Composition, Function and Operation....................................................................670
Control valve consists of following sections:......................................................670
Function of Control Valve..........................................................................670
Operation of Main Section..........................................................................671
Arm2...........................................................................................671
Boom1..........................................................................................671
Travel.........................................................................................672
Boom2..........................................................................................672
Arm1...........................................................................................672
Flue plate(Figure 30)..........................................................................672
Disassembly............................................................................................673
Disassembly of Accessory...........................................................................673
Disassembly of Arm2, Bucket, Travel1, Travel2, Arm1, Boom2/preliminary, Dozer, Turning Section.....673
Disassembly of Boom1(Figure 36)....................................................................674
Disassembly of Inlet Section(Figure 38)............................................................674
Disassembly of Boom2 Section(Figure 40)............................................................674
Disassembly of Flue Plate Section(Figure 46).......................................................674
Take Off of Load Check Poppet Type.................................................................675
Disassembly of Valve Housing.......................................................................676
Cleaning...............................................................................................677
Inspection.............................................................................................677
Assembly...............................................................................................678
Assembly of Valve Housing..........................................................................678
Assembly of Arm2, Bucket, Travel1, Travel2, Arm1, Boom2/Preliminary, Dozer, Boom Swing, Turning....679
Assembly of Boom1 Section(Figure 36)...............................................................679
Assembly of Inlet Section(Figure 38)...............................................................679
Assembly of Flue Plate(Figure 46)..................................................................679
Inserting of Load Check............................................................................680
Accessory Adherence................................................................................681
Relief valve...........................................................................................682
Main Relief Valve(for P1, P2)......................................................................682
Opertation of main relief valve................................................................682
Hint for disassembly and assembly of main relief valve.........................................684
Main Relief Valve(P3)..............................................................................685
Operation......................................................................................685
Hint for disassembly and assembly of main relief valve.........................................686
Overload Relief Valve..............................................................................687
Overload relief valve..........................................................................687
Suction operation..............................................................................688
Hint for disassembly and assembly of overload relief valve.....................................688
Pressure Adjustment of Relief Valve................................................................689
Main relief valve(P1, P2 rise type)............................................................689
Main relief valve(P3)..........................................................................690
Overload relief valve..........................................................................690
Mounting...............................................................................................690
Operation..............................................................................................691
Specifications of control valve........................................................................691
Failure and Troubleshooting............................................................................692
Overall Control Valve..............................................................................692
Relief Valve.......................................................................................693
Overall Pneumatic System...........................................................................693
Control Valve (Standard)...........................................................................702
Control Valve (Option).............................................................................703
Arm2 Section.......................................................................................704
Bucket Section.....................................................................................705
Boom1 Section......................................................................................706
Travel1 Section....................................................................................707
Inlet Section......................................................................................708
Travel2 Section....................................................................................709
Rotary Section.....................................................................................710
Arm1 Section.......................................................................................711
Boom2/Preliminary Section..........................................................................712
Dozer Section......................................................................................713
Boom Swing Section.................................................................................714
Turning Section....................................................................................715
Straight Travel Section............................................................................716
Tilting Section (Optional).........................................................................717
Swing Motor................................................................................................719
Safety Precautions.....................................................................................723
Applicable Models......................................................................................723
Overview...............................................................................................724
Features...........................................................................................724
Specifications.....................................................................................724
Description of Functions and Operation.................................................................725
Swash Plate Motor..................................................................................725
Parking Brake (for the parking brake spec. only)...................................................727
Parking brake ON...............................................................................727
Parking brake OFF..............................................................................727
Hydraulic timer (for hydraulic timer spec. only)...............................................727
Principle of Operation of Relief Valve.............................................................731
Makeup Valve.......................................................................................733
Reduction Gear (Planetary twostage)...............................................................734
Precautions for Handling...............................................................................735
Inspection.........................................................................................735
Rotating Direction.................................................................................735
Hydraulic Fluid....................................................................................736
Optimum hydraulic fluid........................................................................736
Viscosity range................................................................................736
Filter.............................................................................................737
Installation and Piping............................................................................737
Installation...................................................................................737
Piping.........................................................................................737
Check Before and After Operation...................................................................738
Pressure Detection Port Location...................................................................738
Periodic Inspection and Replacement Intervals..........................................................739
Hydraulic Fluid....................................................................................739
Filter.............................................................................................739
Troubleshooting........................................................................................740
Motor Function.....................................................................................740
Motor Incorporated Valve Function................................................................742
Parking Brake and Hydraulic Timer Function.........................................................745
Service Manual.........................................................................................747
Disassembly Procedure..............................................................................747
Precautions before disassembly.................................................................747
Disassembly....................................................................................747
Assembly Procedure.................................................................................757
Precautions for assembly.......................................................................757
Assembly.......................................................................................757
Service Criteria...................................................................................767
Motor..........................................................................................767
Reduction gear.................................................................................767
Valve..........................................................................................768
Others.........................................................................................768
Travel Motor...............................................................................................769
Safety Precautions.....................................................................................773
Applicable Models......................................................................................773
General Repair Guidelines..............................................................................775
Seal Kits and Sub- assemblies..........................................................................776
Replace Seal Nut...................................................................................778
Disassembly............................................................................................779
Sealing the Drive Shaft............................................................................779
Seal of the Control Parts..........................................................................780
Seal of the Relief Valve / Counter-balance Valve...................................................782
Spare Parts List...................................................................................784
Counter-balance Valve..........................................................................784
Brake Release Valve (Pos.50)...................................................................785
Shuttle Valve (Pos.25).........................................................................785
Diassembly of the Port Plate.......................................................................786
Remove of the Positioning Piston...................................................................787
Remove Rotary Group................................................................................789
Exchanging of the Rotary Group.....................................................................790
Inspection Notes...................................................................................791
Assembly...............................................................................................794
Rotary Group Assembly..............................................................................794
Rotary Group Adjustment (See Service Information)..................................................796
Assembly of the Port Plate.........................................................................798
Tightening Torques.....................................................................................800
Shaft Bolts........................................................................................800
Locking Screws VSTI................................................................................800
Seal-Lock Nuts.....................................................................................801
Cross-slotted Lens Head Screws DIN 7985............................................................801
Steering Valve.............................................................................................803
Safety Precautions.....................................................................................807
Applicable Models......................................................................................807
General Description....................................................................................808
OSPC/OLSA..........................................................................................810
Theory of Operation................................................................................813
TOOLS..................................................................................................814
Disassembly............................................................................................816
Dismantling the Shock Valves for OSPC/ OSPC LS.....................................................820
Dismantling the Pressure Relief Valve for OSPC.....................................................821
Dismantling the Pressure Relief Valve (cartridge) for OSPC LS/OSPC LSR.............................822
Cleaning...........................................................................................823
Inspection and Replacement.........................................................................823
Lubrication........................................................................................823
Assembly...............................................................................................824
Assembly Pattern for Standard Bearing..............................................................826
Assembly Pattern for Double Bearing................................................................827
Installation Instructions for O-ring/Kin-ring /Roto Glyd...........................................827
Installation Instructions for Lip Seal.............................................................828
Assembly of the Pressure Relief Valve for OSPC.....................................................833
Assembly of the Shock Valves for OSPC/ OSPC LS/OSPC LSR............................................834
Hydraulic Connections..............................................................................836
Remote Control Valve (Work Lever / Joystick)...............................................................839
Safety Precautions.....................................................................................843
Applicable Models......................................................................................843
Structure Diagram......................................................................................844
Performance Specification..............................................................................845
Hydraulic Pressure Circuit Diagram.....................................................................845
Parts List.............................................................................................846
Disassembly and Assembly Tool..........................................................................847
Disassembly Method.....................................................................................847
Assembly Method........................................................................................850
Dozer Valve................................................................................................855
Safety Precautions.....................................................................................859
Applicable Models......................................................................................859
Structure Diagram......................................................................................860
Performance Specification..............................................................................861
Hydraulic Pressure Circuit Diagram.....................................................................861
Parts List.............................................................................................862
Disassembly and Assembly Tool..........................................................................863
Disassembly............................................................................................863
Assembly Method........................................................................................865
Accelerator Pedal Valve (Hydraulic)........................................................................869
Safety Precautions.....................................................................................873
Applicable Models......................................................................................873
Structure..............................................................................................874
Parts List.............................................................................................874
Performance Curve......................................................................................875
Hydraulics Symbol......................................................................................875
Disassembly & Assembly Tools...........................................................................875
Disassembly............................................................................................876
Assembly...............................................................................................877
Service Brake Pedal Valve..................................................................................879
Safety Precautions.....................................................................................883
Applicable Models......................................................................................883
Functions of Brake Pedal...............................................................................884
Internal Structure and Operation Principles............................................................885
Internal Structure.................................................................................885
Operation Principles...............................................................................887
Disassembly............................................................................................888
Reassembly.............................................................................................888
Reassembly of the Lower Part.......................................................................888
Reassembly of the Upper Part.......................................................................890
Assembly of Pedal Plate............................................................................893
Hydraulic Schematic (DX55W)................................................................................899
Safety Precautions.....................................................................................903
Applicable Models......................................................................................903
DX55W..................................................................................................905
Electrical System..............................................................................................906
Electrical System..........................................................................................908
Safety Precautions.....................................................................................912
Applicable Models......................................................................................912
Overview...............................................................................................914
Electrical Wire Color..............................................................................914
Electrical Supply System...............................................................................915
Engine Starting........................................................................................917
Start Operation....................................................................................917
After Start........................................................................................919
Engine Preheating System...............................................................................920
Engine Stop............................................................................................922
Charging System........................................................................................923
Instrument System......................................................................................924
Instrument Panel...................................................................................924
Function Check.....................................................................................925
Operation..............................................................................................925
Gauge..............................................................................................925
Warning Lights.....................................................................................926
Circuit Diagram of Instrument Panel................................................................929
Control Unit Circuit...............................................................................931
Performance Specification..........................................................................932
Performance Specification..........................................................................932
Engine Control System..............................................................................933
Engine Control Dial....................................................................................934
Acceleration Pedal.................................................................................935
Engine Control Circuit Diagram.....................................................................936
Automatic Deceleration Control (Auto Idle Control).................................................937
Engine Overheat Protection System..................................................................938
Engine Control Unit................................................................................939
Control Failure Detection..........................................................................940
Flashing Patterns of Engine Check Lamp.............................................................943
Fuel Injection Pump....................................................................................944
EGR Valve..............................................................................................945
Refrigerant Circulation................................................................................946
Air-conditioning System Circuit Diagram............................................................948
Air Flow Control...................................................................................949
Air Flow Control Motor.............................................................................950
Blower Motor.......................................................................................950
Coolant Flow Control Valve.........................................................................951
Temperature Level Control And Display..............................................................952
Refrigerant System Repairs.............................................................................953
Refrigerant Safe Handling Procedures...............................................................953
Repair and Replacement Procedure...................................................................954
Refrigerant Recovery...............................................................................956
Vacuuming Refrigerant System.......................................................................956
Leakage Check......................................................................................958
Refrigerant Charging...............................................................................958
Inspecting System for Leakage......................................................................960
Troubleshooting........................................................................................961
Refrigerant Pressure Check.........................................................................961
Electrical Schematic (DX55W)...............................................................................964
Safety Precautions.....................................................................................968
Applicable Models......................................................................................968
DX55W..................................................................................................970
Attachments....................................................................................................971
Boom and Arm...............................................................................................973
Safety Precautions.....................................................................................977
Applicable Models......................................................................................977
Front Attachment Pin Specifications....................................................................978
Front Attachment - Removal and Installation............................................................980
Arm Removal Procedure..............................................................................980
Boom Removal Procedure.............................................................................982
Installation...........................................................................................983
Arm Installation Procedure.........................................................................983
Boom Installation Procedure........................................................................983
Start-up Procedures....................................................................................983
Bucket.....................................................................................................985
Safety Precautions.....................................................................................989
Applicable Models......................................................................................989
Bucket Tooth Inspection and Replacement................................................................990
Bucket Oring Replacement..............................................................................992
Bucket Attachment, Removal and Reversal................................................................993
Detaching the Bucket...............................................................................993
Attaching the Bucket...............................................................................994
Reversing the Bucket...............................................................................994
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