Yanmar B55W 2 Wheel Excavator Service Manual – PDF DOWNLOAD
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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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