IHI 9VX3, Service Manual

Page 1: ...Service Guide 9VX3 I H I SERIAL NUMBERS WB004001 up PUB No 1 1205...

Page 2: ...9VX3 HYDRAULIC MINI EXCAVATOR TABLE OF CONTENTS SECTION 1 SPECIFICATIONS SECTION 2 STRUCTURE AND FUNCTION SECTION 3 OPERATION SECTION 4 MAINTENANCE SECTION 6 PERFORMANCE STANDARDS...

Page 3: ...ENTS Subject page General Specifications 1 1 1 Overall Dim ensions 1 2 1 Working Ranges 1 3 1 Weight Breakdown 1 4 1 Painting Diagram 1 5 1 Engine Main Date and Specifications 1 6 1 Lifting Capacities...

Page 4: ...gine special eddy current type No of cyl bore x stroke mm 2 70 x 74 Total piston displacement L 0 569 Rated output kW min 1 7 3 2400 DIN6271 7 2 2400 Max torque N m min 1 34 8 1800 WEIGHT Machine mass...

Page 5: ...et capacity Side cutter width mm Number of teeth Weight kg Combinations Remarks Use ISO m3 Std arm Long arm Heaped Struck 0 0 2 2 0 013 370 4 18 3 X Standard General digging 0 017 0 0 1 1 320 3 16 8 O...

Page 6: ...verall width of crawler 700 950 D Width 720 E Height 1405 F Rear end swing radius 485 G Rear end ground clearance 405 H Mini ground clearance 160 I Overall length of undercarriage 1500 J Blade height...

Page 7: ...SPECIFICATIONS 9VX3 WORKING RANGES OFFSET DIGGING WORKING RANGE g R950 Front end min radius at right boom swing 1 3 1...

Page 8: ...1770 D Radius of max digging depth 1330 1340 E Max digging height 2755 2950 F Radius of max digging height 1740 1820 G Max dumping height 1970 2150 H Radius of max digging height 1590 1700 I Min dumpi...

Page 9: ...achment Shoe Cabin Spec Weight kg Rubber shoe 890 Shoe Cabin Spec Weight kg Rubber shoe 785 This weight is not the mass of the machine body It includes the weight of water fuel blade and others Specif...

Page 10: ...1 Do not coat rubber sponges catch metal fixtures hydraulic hoses cylinder rods rod packing air cleaners mufflers with paint 2 Do not coat operating lever side box gauges pedal handrail seat or under...

Page 11: ...and cross Momentary 30 degrees longitudinal and cross Engine rotating direction Counterclockwise when viewed from the flywheel side Engine weight Dry 84 5 0 kg Fuel system Applicable fuel JIS K2204 N...

Page 12: ...lic capacity or 75 stability m 9 9 6 6 3 3 ft s 0 a u o 3 3 6 6 13 2 352 ______ _ l_ lifting 1 Maxim tieight um lifting radius T v f 374 352 374 3 I 374 374 352 352 52 i 396 Iflla f I 1 374 396 4 396...

Page 13: ...f hydraulic capacity or 75 stability ft 9 9 6 6 3 3 ft 0 o 3 3 6 6 13 2 242 X 286 Unit lbs Position of lifting height normal lifting Maximum lifting radius 352 198 220 220 176 352 I 4 4 330 396 198 22...

Page 14: ...LABELS There are several specific safety signs i k on your machine Make sure that you can read all safety signs Clean or replace these if you cannot read the words Q 10 9 View D 1 Put into the pocket...

Page 15: ...t not avoidable put s u ita b le block on the crawer shoes and down the blade to penetrate ground_ 40590300 j 2 Read m anual D405 359 00 Read manual before operation maintenance disassembly assembly...

Page 16: ...or or hydraulic tank is uncapped while hot Allow radiator or hydraulic tank to cool before removing cap 11 Warming for track adjuster D405 505 00 Sign indicates an electrical hazard from handing the c...

Page 17: ...Bearing 2 11 1 Swing Motor Ass y 2 12 1 Rotary Joint and Lower Piping Ass y 2 13 1 Travel Motor and Reduction Gear Ass y 2 14 1 Crawler Shoe Adjusting D evice 2 15 1 Front Idler Ass y 2 16 1 Lower Ro...

Page 18: ...cylinder 27 Battery 4 Bucket Cylinder 16 Slide pad 28 Hydraulic Pump 5 Arm 17 Shoe adjusting device 29 Fuel Tank 6 Boom 18 Front Idler 30 Boom Swing Cylinder 7 Arm Cylinder 19 Blade Cylinder 31 Retur...

Page 19: ...alve sheet 24 mm wide 9VX Engine Engine YANMAR 2TNV70 9VX Pump 2PF 4 64cc x 2 With involete spline shaft 9VX Control valve Circuit arrangement Same as 10Z2 10VZ 9VX 4 C D E Swing motor With shock lees...

Page 20: ...y 8 2 L Total system volume 16 L Relief valve set pressure Suction strainer Main pump Code Item Pressure MPa MR1 Main relief valve P1 Pump 16 2 MR2 Main relief valve P2 Pump 16 2 OR1 Overload relief v...

Page 21: ...Swing motor...

Page 22: ...de a A4 yTravel R H F i 1 B3 A3 B2 A2 B1 A1 Boom swing Bucket Boom TO T aMwot Gauge port Blade lower Forward Swing left Dump Hoist P1 S u i i i i High speed travel shift i valvfi Relief valve set pres...

Page 23: ...NTS Engine component names layout supply port Fuel return pipe Fuel suetion pipe Thermo sensor Engine stop solenoid A Fan Contro1lever level gauge pressure switch Water drain plug V Oil supply port G...

Page 24: ...level gauge Disassembly drawing Maintenance AAIa aIo Intervals Every Hlours f Drnl A rl f Suction strainer w0 ni6 nis Cleaning Initial a Tier 1 0 0 0 DlaKS WOlKS 500 Return filter Replace 50 500 1 0...

Page 25: ...g is empty and free from oil due to pump exchange etc be sure to supply clean hydraulic oil from the oil supply port before start up 2 Tighten hexagonal socket headed bolt 3 with the specified tighten...

Page 26: ...ar 1 5 Side plate 4 6 Bushing 2 7 Bushing 2 2 0 Body 1 2 1 Drive Gear 1 2 2 Driven Gear 1 23 Bushing 2 24 Bushing 2 50 Gasket 4 51 Gasket 2 52 Socket head bolt 4 53 Treatment washer 4 55 Steel Ball 4...

Page 27: ...O ring 1 1 2 O ring 1 13 O ring 2 14 Backup ring 2 15 O ring 1 Symbol Overload relief valve setting pressure MPa OR1 Boom up 18 6 49 at 5 L min OR2 Boom down 18 6 49 at 5 L min OR3 Arm pull off 18 6 4...

Page 28: ...9VX3 CONTROL VALVE 1 Weight 10 5 kg MR2 Main relief valve OR1 Boom up Overload relief valve MR1 Main relief valve Upon assembling the valve block Observe the tightening torque 3 positions 13 7 14 7N m...

Page 29: ...identification Pressure adjusting part assembly Attach seal tape 4 Hexagonal socket headed pipe plug 1 12 7 14 7N m 3 O ring 1 2 Plug 1 24 5 29 4N m 1 Pressure adjusting member 1 No Part name Q ty Tig...

Page 30: ...1 24 5 29 4N m 9 O ring 1 P11 1 8 Check valve spring 1 7 Check valve 1 6 Cross socket headed small pan screw M5x10 1 96 2 94N m 5 O ring retainer 1 4 Backup ring 10A 1 3 O ring 1A P10A 1 g Valve rod...

Page 31: ...2 d O ring retainer 1 Backup ring 1 b O ring 1A POA 1 a Valve rod bucket 1 I Valve rod assembly bucket 1 1 Switching part body ZF 1 No Part name Q ty Tightening torque 13 PF 1 4 plug 2 24 5 29 4N m 12...

Page 32: ...ck Tite 242 14 PF 3 8 Plug 1 39 2 49 0N m 13 ring 1B P14 1 12 Hexagonal socket headed bolt M5x45 5 88 6 86N m 11 Return spring lid 1 10 Check valve support 1 24 5 29 4N m 9 O ring 1 P11 1 8 Check valv...

Page 33: ...is designated in place Swinq frame Inner ring soft zone Creasing Port I Outer rinq soft zone Note Assemble the swing bearing soft zone and greasing port as shown above Treatment B o lt M10 x 30 Tighte...

Page 34: ...A 1 34 6 7 14 15 17 18 10 19 20 25 23 13 35 SECTION...

Page 35: ...ar 1 22 Plug 1 23 Bolt Socket Head 24 Key 1 25 Brake Housing 1 26 Bushing 1 27 Gear Wheel 1 28 Bearing Needle 1 29 Spring Coil 30 Plate Push 1 31 Plate Friction 1 32 Piston 1 33 Bolt Socket Head 34 Pl...

Page 36: ...Pin ring Sipper seal Structure cross section Flange Hexagonal socket headed bolt Spring washer I Hexagonal socket Snap ring headed bolt Spring Steel ball ring Detent cover Note 1 Upon assembling the r...

Page 37: ...STRUCTURE AND FUNCTION 9VX3 Rotary joint assembly ROTARY JOINT AND LOWER PIPING ASS Y weight 14 kg Left travel motor piping Right travel motor piping 2 1 3 1...

Page 38: ...3 1 0 Disassembly drawing For part names and numbers refer to the parts catalog...

Page 39: ...PI type class CD SAE30 Volume 0 33L PP Weight 17 kg External view Oil supply level Lubricant supply drain port Swing motor mounting bolt Tightening torque 55N m Coat Screw Lock 262 j Sprocket mounting...

Page 40: ...e with install the desrice 2 Loosen the check valve one turn maximum and escap the internal grease when loosening the shoe Never loosen the grease fitting Do not watch the check valve to see if grease...

Page 41: ...Install the plug after fill gear oil SAE 90 API GL4 20CC 2 Inspect oil leak Apply air press 98 kPa to oil gill hole after assembly Key Description Q t2y 1 Oil Seal 2 2 Snap Ring 2 3 Ball Bearing 2 4 F...

Page 42: ...l gear oil SAE 90 API GL4 70CC 2 Inspect oil leak Apply air press 98 kPa to oil gill hole after assembly Lubricant type Q ty API GL4 SAE 90 70 cc Key Description Q ty 1 Treatment Bolt 2 2 Lock Washer...

Page 43: ...STRUCTURE AND FUNCTION 9VX3 RUBBER CRAWLER SHOE ASEMBLY Weight 31 kg Sec A A 37 Link Sec 2 1 9 1...

Page 44: ...FT VALVE ASS Y Key Description Q ty 1 Bolt 1 2 Spring 1 3 Spring Cover 1 4 Seal Retainer 2 5 Spring Holder 2 6 Pan Head Screw W L W 4 7 Spool 1 8 Body 1 9 0 Ring 1 1 0 Spool Head 1 11 Back up Ring 2 1...

Page 45: ...Boom Cylinder head details...

Page 46: ...g 1 7 Back up Ring 8 0 Ring 1 9 0 Ring 1 1 0 Back up Ring 1 11 U Ring 1 1 2 Back up Ring 13 Set Screw 1 14 Steel Ball 1 15 Cylinder Head 1 16 Bushing 1 17 Cushion Bearing 1 18 Spacer 1 19 Stopper 1 2...

Page 47: ...Arm Tightening torque 9 8 N m M6 x 1 0 Locking 2 points with punch Tightening torque 147 N m M16 x 1 5 14 15 11 12 13 1 18 8 7 6 16 5 t DETAIL P DETAIL H...

Page 48: ...g 1 4 Seal Kit 1 5 Wear Ring 1 6 0 Ring 1 7 Back up Ring 1 8 0 Ring 1 9 U Ring 1 1 0 Piston Ass y 1 11 Slide Ring 1 2 Seal Ring ass y 1 13 Piston 1 14 Steel Ball 1 15 Set Screw 1 16 Cylinder Head 1 17...

Page 49: ...Bucket Tightening torque 6 8 N m Tightening torque 167 N m Calk at 2 positions M6 Tightening torque 255 N m M18 x 1 5 M55 x 2 0 13 14 10 11 10 12 17 7 6 5 15 1 Cylinder head details...

Page 50: ...od Ass y 1 2 Bushing 1 3 seal kit 1 4 Dust Seat 1 5 0 Ring 1 6 Back up Ring 1 7 0 Ring 1 8 U Ring 1 9 Piston Ass y 1 1 0 Slide Ring 11 Seal Ring Ass y 1 1 2 Piston 1 13 Steel Ball 1 14 Set Screw 1 15...

Page 51: ...Boom Swing Tightening torque 176 N m M16 x 1 5 19 8 7 6 13 5 DETAIL P DETAIL H...

Page 52: ...y 1 2 Grease Nipple 1 3 Bushing 1 4 Seal Kit 1 5 Dust Seal 1 6 0 Ring 1 7 Back up Ring 1 8 0 Ring 1 9 Back up Ring 1 1 0 U Ring 1 11 U Ring 1 2 Back up Ring 13 0 Ring 1 14 Cylinder Head 1 15 Bushing 1...

Page 53: ...Blade Tightening torque 9 8 N m M6 x 1 0 Tightening torque 397 N m Locking 2 points with punch M24 x 1 5 DETAIL P DETAIL H...

Page 54: ...2 Grease Nipple 1 3 Bushing 1 4 Cylinder Head 1 5 Bushing 1 6 Piston Ass y 1 7 Slide Ring 8 Seal Ring Ass y 1 9 Piston 1 1 0 Set Screw 1 11 Steel Ball 1 1 2 Seal Kit 1 13 Wiper Ring 1 14 0 Ring 1 15...

Page 55: ...Tightening torque 7 8N m Tightening torque 98 N m Tightening torque 226 N m M5 Calk at 2 positions M14 x 1 5 14 15 12 11 10 13 M45 x 2 0 18 6 5 4 16 3 1 Piston details Cylinder head details...

Page 56: ...Kit 1 3 Dust Seal 1 4 0 Ring 1 5 Back up Ring 1 6 0 Ring 1 7 Back up Ring 1 8 U Ring 1 9 Piston Ass y 1 1 0 Wear Ring 1 11 Back up Ring 1 2 Seal 1 13 Piston 1 14 Steel Ball 1 15 Set Screw 1 16 Cylind...

Page 57: ...2 0 Ring 0 2 19 Fitting 6 8 Bushing 2 7 Bushing 2 16 Bushing 8 15 Pin Wing 1 14 Pin Wing 1 13 Pin Wing 1 1 2 Pin Wing 1 11 Pin Wing 2 1 0 Pin Wing 2 9 Pin Wing 2 8 Cover 1 7 Link Arm L 1 6 Link Arm R...

Page 58: ...STRUCTURE AND FUNCTION 9VX3 BUCKET ASS Y Dimension of the ear plates Detail of ear plates 2 25 1...

Page 59: ...J C M N 0 p Q Dimensions mm 95 95 151 25 25 0 7 25 36 5 Key R S T u V W X Z Dimensions mm 157 150 700 177 5 95 2 0 95 30 HYDRAULIC SYSTEM when details are request see for SERVICE GUIDE 1 Type of pump...

Page 60: ...CTURE AND FUNCTION 9VX3 ELECTRICAL WIRING LOCATIONS B a t t e r y T e r m i n a H a r n e s s g r o u n d B a t t e r y T e r m i n a Names and layout of electrical wiring and components are shown 2 2...

Page 61: ...r cannot operate during engine operation under power generation D b p NC E o COM E a N O N X J O O C N A C h a r g e l a m p H o u r m e t e r r e l a y During an operation under power generation it i...

Page 62: ...Starting the Engine 3 5 1 Break in Operation 3 5 1 Backhoe Operation 3 6 1 Operating the Special Attachments and Actuators 3 7 1 Traveling the Machine 3 8 1 Crawler extension retraction 3 9 1 Towing...

Page 63: ...arning lamp 11 Engine throttle lever 3 Engine oil pressure warning lamp 12 Travel lever 4 Service hour meter 13 High speed select pedal 5 Light switch 14 Blade crawler operation lever 6 Engine start s...

Page 64: ...idling state lower temperature and check a cooling system 3 Engine Oil Pressure Warning Lamp This warning lamp indicates that engine oil pressure has fallen If it lights during operation stop the engi...

Page 65: ...rical system The key will return to the ON position when released from the START position START Turn the key to the START position to crank the engine Release the key as soon as the engine starts HEAT...

Page 66: ...machine Set the operation lock lever to the UNLOCK position when starting work Operation lock lever LOCK UNLOCK The machine may move in an unexpected way and a serious accident may result if you touch...

Page 67: ...ver The lever returns to the neutral position autom atically and operation stops Sim ultaneous operation Turn the lever diagonally to operate the arm and swing simultaneously WB C210110 10 Right opera...

Page 68: ...vement with the blade in the front position If the blade is at the rear position the traveling directions are contrary to the lever operations Check if the blade is in the front or rear position befor...

Page 69: ...e lower Crawler extend 15 Blade brawler select lever Change blade operation and crawler operation with this lever Blade operation Push down the lever Crawler operation Pull up the lever 1 0 I I Blade...

Page 70: ...nts and the hydraulic components Inspect the operator s compartment for cleanliness Keep it clean Inspect any cracks in boom and arm pivot area and cylinder mounting brackets Repair if damaged Refer t...

Page 71: ...set at the neutral position 4 Insert the key into the engine key switch 2 Turn it to the ON run position and make sure of the following The engine oil pressure warning lamp 3 and battery charge warni...

Page 72: ...or for 15 seconds or more If the engine fails to start return the key to the OFF position wait for 30 seconds and try to start the engine again HEAT OFF Starting in Cold Seasons Preheat the engine wit...

Page 73: ...nd Move all controls to HOLD Stop the engine on boost machine 4 Connect POSITIVE jumper cable red POSITIVE cable terminal of discharged battery Do not allow positive cable clamp to touch any metal oth...

Page 74: ...position Operate the bucket control lever for 10 to 15 seconds and then return the control lever HOLD position to ten seconds 3 Move the engine throttle lever to maximum engine speed Run the engine fo...

Page 75: ...ation direction Operation mode Pattern A Pattern Pattern F 1 Boom raise Boom raise Arm in 2 Boom lower Boom lower Arm out 3 Bucket dig Bucket dig Bucket dig 4 Bucket dump Bucket dump Bucket dump 5 Arm...

Page 76: ...ration system of the m achine is stuck at the top of the lever stand on the operator s seat side Operation mode Operation mode plate Pattern AB AB select type f 03 _ _ D4077330 A 4 i r o f X A O A U 6...

Page 77: ...he cover on the front of the lever stand and re assemble the reach rods 2 The operation system changing plate is stuck on the inside of the lever stand front cover 3 Lower the attachm ent onto the gro...

Page 78: ...lever forward BOOM SWING OPERATION O pen the pedal cover to the unlock position before starting operation Step on the right or left position of the boom swing pedal to operate the boom Right boom swi...

Page 79: ...ever to the right Swing left Turn the lever to the left Return the lever to the neutral position to stop swinging Left operation lever Right swing Left swing4 gall r WB C210350 WARNING Do not let any...

Page 80: ...USED FOR BREAKER AND OTHERS 1 Install the hydraulic hoses supply hose to A port and return hose to B port 2 Open the pedal into unlocked position Hose connection for the single action 3 Push down the...

Page 81: ...INGLE ACTION OPERATION USED FOR POWER PORT WORKS B port t o d y A port 8 4 HU Hose connection for double action Pedal A port actuated port actuated Locked f Unlocked Pedal Pedal stopper 1 Install the...

Page 82: ...lever to unlock it 3 Raise the bucket and blade to certain height that allow smooth traveling without hitting them 4 Operate the right and left travel levers as shown below Forward Push both travel le...

Page 83: ...ever 1 to turn the machine forward Pull it back to turn the machine backward Forward turning to left turning to right Pivot turn to left WB C210410 2 Pivot turn to the right Use the left travel lever...

Page 84: ...ill Work up and down slopes rather then sideways whenever possible Do not travel across a grade by all means Avoid changing the direction of travel on a slope which could result in tipping or side sli...

Page 85: ...backward Extend NOTICE Be sure to extend or retract the crawlers on a flat place with no obstacles The crawlers may be extended or retracted without jacking up the machine body However if there are ob...

Page 86: ...nt could overload the tow line or bar and cause it to break Gradual and smooth machine movement will work better Keep the tow line angle to a minimum Do not exceed a 30 angle from the straight ahead p...

Page 87: ...Lifting Procedures 1 Start the engine and swing the machine to position the blade to front 2 Position the machine on the level ground with the boom arm and bucket cylinders fully extended 3 Position...

Page 88: ...ine so that it can be run 1 Align the upper structure with the truck straight on the loading ramps Never operate 2 Move the control shut off lever to the LOCKED 4 MACHINE LOADING ONTO A TRUCK SECURING...

Page 89: ...t the sprocket and iron core extremely Excessive tension increases travel resistance which prevents proper travel force and speed It also causes damages and extreme wear at undercarriage as well as ov...

Page 90: ...freezing temperature are expected each crawler frame should be cleaned of mud and dirt and the machine parked on wood planks Engine Stopping 1 Operate the engine at LOW IDLE for five minutes This give...

Page 91: ...n Required Maintenance and Checks 4 4 1 Daily Maintenance and Checks 4 5 1 50 hours Maintenance and Checks 4 6 1 250 hours Maintenance and Checks 4 7 1 500 hours Maintenance and Checks 4 8 1 1000 hour...

Page 92: ...il and Filter 4 7 1 Hydraulic System Change Return Filter 4 8 2 Every 250 Service Hours First perform previous service hour items Engine Oil Change Oil and Filter 4 7 1 Air Cleaner Clean or Change Fil...

Page 93: ...cate G 2 Fuel Tank Water sediment drain Hydraulic oil H 3 Hydraulic oil Tank Water sediment drain Suction strainer cleaning 4 Return filter Cartridge Engine oil E REngine Fuel filter v J Oil filter Ra...

Page 94: ...draulic Fluid ISO VG46 Ambient Temperature Below 5 C Wear Proof Hydraulic Fluid ISO VG32 Track Rollers 0 05 liter Each Upon occasion API GL 4 ISO VG320 SAE90 Gear Oil Front Idlers 0 02 liter Each Upon...

Page 95: ...proximately 1 0 to 2 0 mm slack with rubber shoes Suported the machine Track Tightening 1 Add grease through check valve fitting until the correct track tension is reached 2 Move the tracks forward an...

Page 96: ...rubber or damage replace it with brand new one Repair is necessary when a crack is over 30 mm length or over 8 mm depth Replacement is Lug recommended when lug is 5 mm or less high Covering rubber Br...

Page 97: ...off the fuse cover 3 Replace the blown fuse with a new fuse of the same capacity Fuse capacity Circuit name 1 5 A Warning lamps three hour meter 2 5 A Fuel pump 3 10 A Boom light horn 4 20 A Engine s...

Page 98: ...e recharged as soon as possible If battery is out of use for a long time it must not be allowed to run down completely The battery should be given a small recharge sufficient to bring it back to fully...

Page 99: ...to the bucket boss 3 Remove the pins of section A and B then remove the arm and the bucket Install the Bucket 1 Clean the removed pins and pin holes and apply coat the grease to them surface 2 Place a...

Page 100: ...level gauge Add oil if necessary 4 Remove the oil fill plug and add oil Clean and install the oil fill plug 5 Close the access door Check the Coolant Level AWARNING Steam generated by hot fluid under...

Page 101: ...owly loosen the fill plug to relieve pressure and remove it to add oil if necessary 4 Clean and install the fill plug To pressurize the hydraulic tank refer to Change Hydraulic Oil section Bucket posi...

Page 102: ...of drained fluids as established by local regulations 5 Clean the inside surfaces of the body and bowl 6 Clean the filter 7 Inspect the ring on bowl replace them if they are worn or damaged 8 Install...

Page 103: ...amage or excessive wear Repair if damaged Inspect and remove any trash build up in the engine compartment Inspect the cooling system for leaks faulty hose and trashbuiltup Correct any leaks and remove...

Page 104: ...egulations 4 Close the drain valve Lubrication Perform the 50 hours lubrication as required by the Lubrication Chart Be sure to lubricate all cylinder mounting bushings and pins The following maintena...

Page 105: ...y the filter wrench Use a filter wrench with the type shown at right Clean the filter housing base 5 Apply a light coat of engine oil to the gasket of the new filter 6 Install the new filter by hand W...

Page 106: ...ve grasses Housing 1 Stop the engine 2 Release the two latches and remove the service cover 3 Remove the element from the air cleaner housing NOTE Remove the seal unit of element gently The element is...

Page 107: ...ause leak If the striped dust is seen on the seal surface it is a symptom of dust leak If such dust seen inspect if there are foreign substances on the inside and outside of the housing seal tube 7 In...

Page 108: ...e container NOTE Always dispose of drained fluids as established by local regulations 6 Clean the inside surface of the cup and theelement 7 Install the clean element 8 Install cup Tighten ring nut 9...

Page 109: ...n cause personal injury Stop the engine and remove the start switch key Inspect Stop the engine Inspect the belt for wear and cracking To check the belt tension push the belt inward by hand apply 98N...

Page 110: ...ch Size metrie Thread Size Tightening Torque N m Travel drive Bar 8 M10 54 Sprocket Bar 8 M10 54 Lower roller 19 M12 97 Swing bearing 17 M10 59 Swing motor Bar 10 M12 97 Swing gear case 17 M10 P1 25 5...

Page 111: ...e filter base Fill plug Return filter Fillter base JSGasket J Cartridge NOTE This is a cartridge type element It cannot be reused 5 Coat the gasket of new finer with clean hydraulic oil 6 Install the...

Page 112: ...ring nut 4 Remove the cup and the element 5 Drain water and sediment into a suitable container NOTE Always dispose of drained fluids as established by local regulations 6 Clean the inside surface of...

Page 113: ...lder 6 Install a new filter element Install and secure the dust pan with arrow point upward 7 Reset the dust indicator by pushing in the reset button f l CAUTION Service the air cleaner only with the...

Page 114: ...4 Install drain plug 5 Fill the travel drive to bottom of level plug opening Recommended oil Refill capacities Engine oil API CD SAE30 0 33 Liter 6 Install oil level fill plug 7 Perform procedure on...

Page 115: ...d as shown Stop j the engine I Fill plug 2 Relieve the internal pressure from the hydraulic tank by loosening the fill plug 3 Clean area thoroughly to keep dirt out of strainer cover unit and fill plu...

Page 116: ...between FULL and ADD marks on the level gauge 15 Pressurize the hydraulic tank Raise the boom with the arm boom and bucket cylinder fully extended 16 Remove the fill plug and then install fill plug a...

Page 117: ...ssure and remove the cap 3 Open the radiator drain plug and allow the coolant to drain into a container 4 Remove the radiator drain plug allow the coolant to drain into a container Drain plug is locat...

Page 118: ...maintain the machine free from coolant exchange for 2 years through summer and winter seasons The Long Life Coolant is therefore recommended for use with this machine when exchanging its coolant Mixi...

Page 119: ...the fuel supply drain the tank and refill it with uncontaminated fuel 3 Lubricate the machine with the lubricants recommended for cold weather operation in the Lubrication Section If necessary change...

Page 120: ...olant will most often be corrected by SLOWLY adding coolant while the engine is running at FAST IDLE Should this fail to correct the problem drain and flush the system and refill with fresh coolant 50...

Page 121: ...eteriorating effects of salt moisture or both To protect exposed metallic surfaces wiring paint and other items keep them dry and well lubricated where salt or high humidity are encountered Follow the...

Page 122: ...he battery after move the negative terminal and covering it or dismounting the battery from the machine Lock the control levers and pedals with the lock lever and pedal lock Bucket position at the tim...

Page 123: ...ng Service P1 MR1 C O C l 1 CM CO Rated Engine RPM Arm Swing Travel LH Service P2 MR2 0 3 16 2 0 2 Rated Engine RPM Overload Boom Hoist Install Gauge Adapter in Att Line OR1 00 CD Refer to Pressure Me...

Page 124: ...ove the cover and install the pressure gauge to measure port on the control valve Install the fill plug 2 Measure the MR1 Main relief valve Operation for Boom Bucket Travel R H and Service 1 Start the...

Page 125: ...ng screw with a hexagon bar spanner while measuring the pressure Adjusting screw turn to clockwise to raise the pressure Adjusting screw 1 turn approx 9 8 MPa change pressure 4 Install and tighten the...

Page 126: ...IN line 1 Start the engine move the bucket contact to the hard wall Fig 4 2 Move the engine throttle lever to low idle Pull the travel levers fully stroke to hold it and measure the pressure while tra...

Page 127: ...nge pressure 4 Install and tighten the lock nut 5 After locking measure the pressure again 6 Lower the bucket to the ground Stop the engine Remove the fill plug on the hydraulic tank 7 Remove the pres...

Page 128: ...move the fill plug on the hydraulic tank 5 Remove the pressure gauge Apply pipe sealant to the plug Install the fill plug on the hydraulic tank This swing relief valve not equipped pressure adjusting...

Page 129: ...ssure 6 2 1 Lever Operating Force 6 2 1 Spool Stroke Control Valve 6 2 1 Swing Operating Speed Natural Drift 6 2 2 Travel Travel Speed Travel Alignment Drift Time for Crawler Belt 6 2 3 Boom Cylinder...

Page 130: ...m straight 4 Safety measures such as Keep Off should be in place for the measurement using ropes to mark Keep O ff The meeting regarding work procedures and signs should be held in advance with other...

Page 131: ...pressure oil temperature ground for measurement bucket load 2 Performance has been greatly degraded In that case the performance will have been degraded because of the maintenance conditions work type...

Page 132: ...At hydraulic temperature 50 5 C Arm t t Bucket t t Swing 6 9 Travel I C M CD Boom Swing t t Blade t t LEVER FORCE Boom kg 1 3 0 5 At engine stopped Arm 1 3 0 5 Bucket 1 3 0 5 Swing 1 3 0 5 Travel 2 0...

Page 133: ...oad Measure floating angle after stop the machine Swing Operating Speed Engine Rated r p m Oil temp 50 5 C Fully retracted bucket cylinder and arm cylinder Arm point pin positioned to be horizontal wi...

Page 134: ...Low Speed below 23 2 sec Travel Alignment Engine Rated r p m Oil temp 50 5 C Measure turning distance x after 10 m travel Below 700 mm Below 1000 mm Natural Drift Engine Low idling Oil temp 50 5 C Me...

Page 135: ...py Hoist 2 7 sec 0 5 sec Lower 2 3 sec 0 5 sec Below 3 5 sec Below 3 1 sec ARM CYLINDER SPEED Engine Rated r p i Oil temp 50 5 C Divided Measure time for fi retraction of cylinde cusion stroke 71 r 1E...

Page 136: ...tention or retraction of cylinder Without measure cusion stroke Left 4 6 sec 0 5 sec Right 4 7 sec 0 5 sec Below 6 0 sec Below 6 0 sec CYLINDER DRIFT Engine Stopped Oil temp 50 5 C Bucket load Non loa...