Shop Manual Sumitomo SH330-3B PDF
Shop Manual Sumitomo SH330-3B PDF
Shop Manual Sumitomo SH330-3B PDF
Specifications
Major Equipment Specifications
Equipment Configuration .................................................. 300-2-01-00-05 26
Lower Mechanism............................................................. 330-2-01-01-49 28
Upper Mechanism............................................................. 330-2-01-02-43 32
Engine and Related Areas ............................................... .330-2-01-03-48 33
Hydraulic System .............................................................. 330-2-01-04-49 36
Controls............................................................................. 330-2-01-05-50 39
Backhoe Attachments ....................................................... 330-2-01-06-51 41
Fuel / Lubricants and Filters .................................................. 330-2-02-00-39 43
Performances
Lifting Capacity ...................................................................... 330-3-03-00-44 52
Lifting Position ....................................................................... 330-3-03-01-03 61
Hydraulic Pump Control Curve .............................................. 330-3-01-04-03 62
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Lifting Capacity Page No. 1/ 9
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Lifting Capacity SH330
Lifting Capacity
[4] Do not allow anyone to be under [5] Do not lift a load exceeding the [6] The wire ropes and the chains for
the suspended load or at other rated capacity. (The machine can rigging must be sturdy enough
dangerous areas. overturn and jeopardize the safe- and be free of disfigurement and
ty of workers.) corrosion.
Caution
[1] The operators must be trained specifically.
[2] The weight of the loads and the rigging equipment combined must not exceed the maximum load value.
[3] During the crane operations, lower the engine speed (mode L) and keep working at low engine speed.
[4] Be extra careful while carrying out the swing operations. Move the machine slowly.
[5] Do not leave the cab while you are suspending a load.
[6] Do not travel any distance while you are suspending a load.
[7] Sling the load in such a manner that the wire rope and the ring do not get detached from the hook.
[8] If the bucket hook, or the rigging equipment gets damaged during operation, stop the procedure and make nec-
essary repairs.
[9] Please contact our authorized service shops when you wish to have hooks attached to your bucket.
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Lifting Position SH330
Lifting Position
Lifting Position
BKSU4036-B00
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SH330
Hydraulic Pump Control Curve
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Maintenance Instructions SH330SH700SH800SH450
Maintenance Instructions
TAKE-UP
ROLLER
*1 *4
REMOVE
LOOSEN TRACK GREASE
RECOIL SPRING DISASSEMBLE
SHOE CYLINDER
ASSEMBLY
DISASSEMBLE
RECOIL SPRING
WITH JIGS
SPRING, YOKE,
ETC.
*2, *6
LIFT UP TRACK REMOVE UPPER
UPPER ROLLER
SHOE ROLLER
*2
JACK UP REMOVE LOWER
LOWER ROLLER
LOWER FRAME ROLLER
*3
RELEASE REMOVE
ROTATING
HYDRAULIC ROTATING
JOINT
PRESSURE JOINT
Items marked with an asterisk (*) in this drawing require the following preparation:
*1 Refer to Track shoe tension adjustment (Instruction Manual).
*2 Prepare protection blocks.
*3 Refer to the procedures for bleeding the hydraulic pressure.
*4 Prepare jigs for recoil spring disassembly and reassembly. Be sure you know how to use them.
*5 Prepare a press for pulling out and press fitting track pins of track shoe.
*6 Prepare a hydraulic jack.
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Maintenance Instructions SH330
Maintenance Instructions
• For bolts on important areas, apply engine oil to the threaded portion so that tightening force is
applied evenly without unnecessary engagement on the thread.
• For bolts and nuts in the areas that it is difficult to check from outside or bolts and nuts in impor-
tant areas, secure them using wires, cotter pins or folding washers.
• Clean bolts to which Loctite was applied (identified as bolts with white substances when re-
moved) with cleaning solution and dry them. After that, apply Loctite two or three drops to the
threaded portion of the bolts and fasten them.
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Lower Mechanism Page No. 1/ 4
Third Edition : 03/2005
Lower Mechanism SH330SH700SH450
Lower Mechanism
Track Shoe
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1. Disassembly
1 Position the master pin of the track shoe as shown in the draw-
ing on the left.
Place track shoe support blocks as shown in the drawing.
MASTER
PIN
BLOCK
LOCKING PIN
5 Lift one side of the lower frame about 20 cm and hold it there.
CAUTION: Place protection blocks under the lower
frame and secure them.
Move the travel unit as shown in the drawing to the left to
remove the track shoe.
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2. Assembly
2 Feed the track shoe toward the take-up roller by moving the
FEED
travel unit slowly as shown in the drawing to the left.
UP TO
HERE
NOTE: Be careful. Sudden and quick movements may
cause the track shoe to jump and run off.
(During work, lift the roller shoe using the steel bar when
crossing over the upper roller.)
Remove protection blocks and lower the lower frame.
3 Wind the end of the track shoe onto the take-up roller of the
track shoe.
Connect the track shoe.
• Place the track shoe support blocks.
• Insert the master pin using a jig.
• Insert a locking pin.
MASTER PIN
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Lower Mechanism SH330
Lower Mechanism
Travel Unit
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2. Disassembly
[1] Remove track shoe.
(See 2. Track Shoe, Disassembly.)
[2] Lift one side of lower frame about 20 cm and hold it
there.
(Lift it high enough for the drive sprocket to be removed
from the track shoe.)
[3] Place protection blocks under lower frame and secure
them.
[4] Stop engine and release pressure in hydraulic circuits.
(See the procedures for bleeding the hydraulic pres-
sure in Precautions for Use in Chapter 0.)
[5] Remove motor cover.
[6] Remove drive sprocket mounting bolts (2).
[7] Separate drive sprocket from mounting flange on travel
unit using a steel bar.
[8] Attach a lifting tool onto the drive sprocket.
[9] Using the lifting tool, lift the drive sprocket and remove
it from the travel unit.
[10] Attach marking tags to the travel motor hoses to tell
them apart when they are reconnected.
[11] Remove the hoses and put bull plugs or caps on them
to keep out dust.
[12] Attach the lifting tool onto the travel unit.
Note: Lift the travel unit until the wire on the lifting tool
is tense.
[13] Remove travel unit mounting bolts (5).
[14] Remove travel unit using a steel bar.
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3. Assembling
[1] Lift travel unit and align it so that it fits on the frame. (Be
careful of the fitting angles.)
[2] Apply Loctite No. 262 to threads of travel unit mounting
bolts (5) and finger tighten all mounting bolts.
[3] Tighten travel unit mounting bolts (5) to the specified
torque alternatively, up/down and left/right, so that the
tightening force acts on them equally. (Refer to Tight-
ening torque in the Maintenance Instructions.)
[4] Lift drive sprocket and confirm that it is oriented correct-
ly.
[5] Align drive sprocket to mounting flange on the travel
unit using a steel bar.
[6] Apply Loctite No. 262 to threads of drive sprocket
mounting bolts (2), and finger tighten all mounting
bolts.
[7] Tighten drive sprocket mounting bolts (2) to the speci-
fied torque alternatively, up/down and left/right, so that
the tightening force acts on them equally. (Refer to
Tightening torque in the Maintenance Instructions.)
[8] Connect hoses to travel motor.
[9] Check reduction gear oil level. Fill if necessary.
[10] Bleed air from travel motor. (Fill motor with hydraulic
oil)
[11] Remove protection blocks.
[12] Lower the lower frame on the track shoe.
[13] Install track shoe. (See Track Shoe, Assembly)
[14] Check to ensure that there is no oil leakage. If leakage
is found, take appropriate measures.
[15] Install motor cover.
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Lower Mechanism SH330
Lower Mechanism
2
4
5
17
7 15
13
8 16
9
11 14 7
12
10
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1. Disassembly
[1] Remove the track shoe. (See Track Shoe, Disassem-
bly.)
[2] Pull out the recoil spring assembly from the side frame
using a steel bar.
[3] Attach a lifting tool to the recoil spring assembly.
[4] Lift the recoil spring assembly out from the side frame
using the lifting tool.
[5] Place the recoil spring assembly on blocks.
[6] Remove the take-up roller mounting bolts (2) to sepa-
rate the take-up roller and coil spring.
[7] Prepare hydraulic jack and jigs for recoil spring disas-
sembling and reassembling.
[8] Set recoil spring in jig as shown in the drawing to the
left.
[9] Raise the hydraulic jack to compress the spring.
[10] Pull out the spring pin (5) and remove the castle nut (4).
[11] Lower the hydraulic jack to restore the spring to its orig-
inal position.
[12] Take the recoil spring components out from the jig in
the following order: yoke (1), spring (6) .
[13] Remove the grease cylinder mounting bolts (17) them,
remove the grease cylinder from the side frame.
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2. Assembly
[1] Apply Loctite No.262 to the grease cylinder mounting
bolts (17).
[2] Tighten the grease cylinder mounting bolts (17) ac-
cording as the specified torque on the side frame.
Note: Set it so that the grease cylinder check valve fac-
es outward.
[3] Set the recoil spring components in the recoil spring jig
in the following order: spring (6) and yoke (1).
[4] Raise the hydraulic jack to compress the spring.
Mounting length of spring: 779 mm
[5] Attach the castle nut (4) and lock it with spring pin (5).
[6] Lower the hydraulic jack to restore the spring to the
original position.
[7] Remove the recoil spring from the jig.
[8] Apply Loctite No. 262 to the take-up roller mounting
bolts (2).
[9] Tighten the take-up roller mounting bolts (2) to the
specified torque to reassemble the take-up roller and
recoil spring.
[10] Attach lifting tool to recoil spring assembly.
[11] Place recoil spring assembly on side frame using a lift-
ing tool.
[12] Set the recoil spring assembly in the side frame using
a steel bar.
[13] Install the track shoe. (See Track Shoe, Assembly.)
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Lower Mechanism SH330
Lower Mechanism
Upper Roller
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1. Disassembly
[1] Loosen the track shoe. (See Track shoe, Disassembly)
[2] Place the hydraulic jack as shown in the drawing to the
left.
[3] Using the hydraulic jack, lift the track shoe high enough
that the upper roller can be removed.
[4] Place blocks between the track shoe and side frame
and secure them.
[5] Loosen the upper roller mounting bolt (2) slightly (so
that the bolt head comes off 2 to 4 mm).
[6] Hit the upper roller gently with a copper hammer and
detach it from the side frame.
[7] Attach lifting tools on the upper roller.
[8] Remove the upper roller by removing mounting bolts
(2) completely while lifting the upper roller using the lift-
ing tools.
Note: Be careful to keep fingers and hands clear.
2. Assembly
[1] Apply Loctite No. 262 to the upper roller mounting bolts
(2).
[2] Finger tighten all upper roller mounting bolts (2) while
lifting the upper roller.
Note: Adjust the position of the upper roller if neces-
sary, using shims (4) so that the track links are
evenly supported.
[3] Tighten the upper roller mounting bolts (2) to the spec-
ified torque.
[4] Remove the blocks and jack.
[5] Fill grease into the grease cylinder and give the track
shoe the specified tension.
(See Track shoe, Assembly)
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Lower Mechanism SH330SH700
Lower Mechanism
Lower Roller
SYMBOL PART NAME
1 LOWER ROLLER
2 SEMS BOLT
3 LOCTITE 262
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1. Disassembly
[1] Loosen the track shoe. (See Track Shoe, Disassembly)
[2] Remove the lower roller mounting bolts (2).
[3] Lift one side of the lower frame about 20 cm and hold it
there. (Lift it high enough that the lower roller can be re-
moved from the track shoe.)
[4] Place protection blocks under the lower frame and se-
cure them.
[5] Remove the lower roller from the track shoe.
2. Assembly
[1] Place the lower roller on the track links with its fitting
surface up.
[2] Remove the protection blocks.
[3] Lower the frame slowly and gradually to where the
bolts can be installed.
Note: Be careful to keep fingers and hands clear. (Keep
the frame raised about 5 to 10 mm, instead of
lowering it completely.)
[4] Align the lower roller to the frame fitting position.
[5] Apply Loctite No. 262 to the lower roller mounting bolts
(2).
[6] Tighten the lower roller mounting bolts (2) to the spec-
ified torque.
[7] Fill the grease cylinder with grease to give the track
motor cover shoe the specified tension.
(See Track shoe, Assembly)
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Lower Mechanism SH330SH450
Lower Mechanism
Rotating Joint
1
SYMBOL PART NAME
2 1 SEMS BOLT
2 LOCK BAR
3 SEMS BOLT
4 ROTATING JOINT ASSY
3
5 HIGH STRENGTH BOLT
6 SEAL WASHER
7 SEAL CAP
8 RUBBER PACKING
9 SEAL RING
4
7 6
SWING FRAME
LOWER FRAME
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1. Disassembly
[1] Jack up the body.
[2] Stop the engine and release pressure in the hydraulic
circuits. (Refer to the procedures for bleeding the hy-
draulic pressure in 05 Precautions for Use in Choter 0.)
[3] Place protection blocks under the track shoe and se-
cure them.
[4] Remove the under cover.
[5] Attach marking tags to the rotating joint hoses to tell
them apart when they are reconnected.
[6] Remove the hoses and put blank plugs or caps on BLOCK
them to keep out dust.
[7] Remone the lock bar mounting bolts (1).
[8] Remove the lock bar (2).
[9] Remove the rotating joint mounting bolts (3).
[10] Lift out the rotating joint.
2. Assembly
[1] Align it so that it fits on the lower frame.
[2] Apply Loctite No. 262 to the rotating joint mounting
bolts (3).
[3] Tighten the rotating joint mounting bolts (3) to the spec-
ified torque. UNDER
COVER
[4] Apply Loctite No. 262 to the lock bar mounting bolts (1).
[5] Tighten the lock bar mounting bolts (1) to the specified
torque to install the lock bar (2). (See illustration.)
[6] Connect the hoses. ATTACH MARKING
TAGS
[7] Check to ensure that there is no oil leakage. If leakage
is found, take appropriate measures.
[8] Install the under cover.
[9] Remove the blocks.
[10] Lower the body.
2 3
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Upper Mechanism SH330SH300
Upper Mechanism
300-5-02-01-19
Swing Unit
Upper Mechanism Page No. 1/ 2
First Edition : 01/2002
PART NAME SYMBOL QTY.
HOSE ASSY 1 1
HEADED PIN 2 1
SEMS BOLT M12x25 3 3
COVER PLATE 4 1
CORK PACKING 5 1
GREASE NIPPLE (A-R1/8) 6 3
HIGH STRENGTH BOLT M24x140 7 41
HIGH STRENGTH WASHER 24 8 41
SEMS BOLT M24x90 9 46
PINION GEAR 10 1
END PLATE 11 1
KEEPER WASHER 125 12 1
HIGH STRENGTH BOLT M16x40 13 2
LOCTITE 262 14 AS NEEDED
LIQUID PACKING 1104 15 AS NEEDED
TURNTABLE BEARING ASSY 16 1
PLUG PF3/8 17 1
SEMS BOLT M24x90 18 12
REDUCTION GEAR 19 1
BOLT M8x25 20 1
CLAMP 21 1
NOTES:
1. THE MOUNTING BOLTS (7), (9), (13) AND (18) SHOULD BE FASTENED TO REQUIRED
SPECIFIED TORQUE. PRIOR TO ASSEMBLY, APPLY LOCTITE NO. 262 OR EQUIVALENT TO
THE THREADED PORTION OF THE BOLTS (13) AND (18) AFTER DEGREASING THE SURFACE.
2. LIQUID GASKET (THREEBOND 1104) SHOULD BE APPLIED BETWEEN THE TURNTABLE
BEARING AND BOTH SWING AND LOWER FRAMES.
3. AFTER ASSEMBLING THE MACHINE OR LONG TERM STORAGE OF THE MACHINE, OPERATE
IT AT A LOW SPEED FIRST TO CHECK IF THERE ARE ANY ABNORMAL NOISES OR VIBRATIONS.
4. REMOVE PLUG OF DRAIN PORT AND FILL THE SWING MOTOR CASING WITH HYDRAULIC OIL
BEFORE OPERATION. AND THE AIR IN THE SWING MOTOR SHOULD BE BLED OFF FROM AIR
BLEEDING PORT.
KSC0229Z-D02
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SYM-
PART NAME QTY.
BOL
SWING MOTOR 1 1
LIQUID PACKING 2 AS NEEDED
REDUCTION GEAR ASSY 3 1
NOTES:
1. FASTEN MOUNTING BOLTS (HEX. SOCKET HEAD BOLTS) TO MOTOR
WITH REQUIRED TORQUE OF 568.4 +810 N m. BEFORE FASTENING, APPLY
LOCTITE NO. 262 (KRC5007) OR LIQUID GASKET
(THREEBOND 1360K; KSC0188) TO THE THREADED PORTION OF THE BOLTS.
2. LIQUID GASKET (THREEBOND 1215; KTF0086) SHOULD BE APPLIED
BETWEEN THE MOTOR AND THE REDUCTION GEARS.
3. LUBRICATE WITH GEAR OIL API GL-5 (3.7 L).
KSC0231Z-C04
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Upper Mechanism
330-5-02-02-24
Engine
Upper Mechanism Page No. 1/ 1
Second Edition:04/2006
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Upper Mechanism
330-5-02-03-21
Hydraulic Pump
Upper Mechanism Page No. 1/ 1
First Edition : 11/2005
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Upper Mechanism SH330
Upper Mechanism
Control Valve
CONTROL VALVE PORTS
DESCRIPTION SYMBOL QTY. LINE NAME MAIN PORT LINE NAME MAIN PORT
BRACKET 1 1 BUCKET OPEN LINE B7 OPTION CONFLUENCE LINE P3, P4
SEMS BOLT M16x40 2 8 BUCKET CLOSED LINE A7 RETURN LINE T1, T2
LOCTITE 262 3 AS NEEDED BOOM DOWN LINE B8 NEGATIVE CONTROL ps1, ps2
CONTROL VALVE 4 1 BOOM UP LINE A8 TRUCTION PRESSURE NEASUREMENT PT
CONTROL VALVE HBCV 5 1 TRAVEL LEFT FORWARD LINE A6 RAISED PRESSURE PH
TRAVEL LEFT BACKWORD LINE B6 ATTACHMENT PRESSURE MEASUREMENT PP, PA
ARM OUT LINE A5 DRAIN DR
ARM IN LINE B5 LOAD HOLDING AT ARM pc1
SWING RIGHT LINE B3 LOAD HOLDING AT BOOM pc2
SWING LEFT LINE A3 BYPASS FILTER T4
OPTION LINE A2 HEAT LINE T5
OPTION LINE B2 SWING MOTOR MAKE-UP T3
TRAVEL RIGHT FORWARD LINE A1 SWING PRIORITY (ARM) pc3, pc3'
TRAVEL RIGHT BACKWARD LINE B1 SWING PRIORITY RELEASE pbu
PRESSURE LINE P1, P2
NOTE:
1. LOCTITE #262 OR EQUAL SHOULD BE APPLIED
ON THE THREAD OF THE BOLTS AFTER REMOVING
THE OIL FILM.
KSJ2777Z-C01
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Upper Mechanism
000-5-02-05-09
Remote Control Valve
Upper Mechanism Page No. 1/ 1
Second Edition:04/2006
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Upper Mechanism
000-5-02-06-06
Operator’s Cab
Upper Mechanism Page No. 1/ 1
Third Edition : 11/2005
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Attachments SH700SH330SH450
Attachments
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2. Installation
2 Install the pin and fasten it with a bolt and spacer. When
putting in a pin, it unites with the circle boss of a arm.
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2. Installation
2 Install the pin and fasten it with a bolt and spacer. When
putting in a pin, it unites with the circle boss of a arm.
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6 Install the pin and fasten it with a bolt and spacer. When
putting in a pin, it unites with the circle boss of a arm.
Note: Cycle the cylinder to bleed air from the cylinder.
After bleeding air, check for oil leakage.
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2. Installation
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Second Edition:04/2006
Take-up Roller SH330
Take-up Roller
6
SYMBOL PART NAME
9 1 TAKE-UP ROLLER
2 BUSHING
3 3 FLOATING SEAL
2 4 O-RING
5 SHAFT
6 HUB PIN
7 HUB (WITH PLUG)
8 PLUG
1 9 HUB (WITHOUT PLUG)
2 6
3
4
5
8
4
(2) Jigs
1.5
15
5R
JIG HAMMER
ROLLER 150
BUSHING
PULLING JIG
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3. Disassembling Instructions
(1) Preparation
Prior to disassembly, take full preparatory measures.
[1] Workbench with vises
Prepare a suitable workbench large enough to arrange and keep parts and perform the work.
[2] Tools and Jigs
For tools and jigs, refer to the previous section.
(2) General cautions
[1] Handle precision parts carefully during the operation; do not drop or hit them on other parts
during the operation.
[2] Do not attempt to finish the operation quickly; do not forcedly pry or hit the parts.
Perform the operation carefully and patiently in order to prevent parts deformation, oil leakage
and lower efficiency.
[3] As disassembled parts tend to get rusted or collect dust and dirt, dust proof and rust preven-
tion treatment should be applied immediately after disassembling the parts.
(3) Disassembling procedure
2 1. Remove the hub pin (6) from the shaft (5) (or hub (7)).
The removal is to be performed on one side only.
2. Remove the hub (7) from the shaft (5).
The removal is to be performed on one side only.
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4 1. Remove the hub pin (6) from the shaft (5) (or hub (9)).
2. Remove the hub (9) from the shaft (5).
3. Remove the O-ring (4) from the shaft (5).
6 Remove the floating seals (3) from the take-up roller (1).
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7 Remove the bushings (2) from the take-up roller (1) us-
ing pulling jigs, press and other instruments.
Do not attempt to disassemble bushings (2) un-
less they are unusable due to wear.
8 Cleaning Parts
1. Preparatory cleaning 2. Finish cleaning
1) Place parts in the preparatory cleaning 1) Put the parts in the finish cleaning container con-
container containing cleaning oil. taining cleaning oil and wash them by slowly mov-
ing them.
2) Wipe off remaining cleaning oil with clean cloth.
Wash off deposited substances which Place the parts somewhere free of dust and
may cause scratches. moisture, and dry them using compressed air.
Leave the parts submerged in the kero- After drying, apply engine oil to the parts.
sene until the dirt and grease come off
and float up.
4. Assembling instructions
(1) Prior to assembly:
• Clean all the parts.
• Polish scratches, flashes or burrs using oil stones.
• Change sealing parts such as O-rings with new ones.
(2) Assembling procedure
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Forth Edition : 04/2006
Take-up Roller SH330
Take-up Roller
Assembly Drawings
KSA1307Z-C01
112
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Upper Roller Page No. 1/ 7
Second Edition:04/2006
Upper Roller SH330
Upper Roller
4, 5
1 SYMBOL PART NAME
1 COVER
2 4, 5 2 O-RING
3 6 3 PLUG
8 4 HIGH STRENGTH BOLT
5 LOCTITE 262
6 THRUST PLATE
7 BUSHING
8 SHAFT
9 BUSHING
10 ROLLER
7 11 FLOATING SEAL
12 BRACKET
10
9
11
12
(2) Jigs
1.5
15
5R
JIG HAMMER
ROLLER 150
BUSHING
PULLING JIG
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Second Edition:04/2006
3. Disassembling Instructions
(1) Preparation
Prior to disassembly, take full preparatory measures.
[1] Workbench with vises
Prepare a suitable workbench large enough to arrange and keep parts and perform the work.
[2] Tools and Jigs
For the tools and jigs, refer to the previous section.
(2) General cautions
[1] Handle precision parts carefully during the operation; do not drop or hit them on other parts
during the operation.
[2] Do not attempt to finish the operation quickly; do not forcedly pry or hit the parts. Perform the
operation carefully and patiently in order to prevent parts deformation, oil leakage and lower
efficiency.
[3] As disassembled parts tend to get rusted or collect dust and dirt, dust proof and rust preven-
tion treatment should be applied immediately after disassembling the parts.
(3) Disassembling procedure
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7 Remove the floating seal (11) from the bracket (12) using
pulling jig.
8 Cleaning Parts
1. Preparatory cleaning 2. Finish cleaning
1) Place parts in the preparatory cleaning 1) Put the parts in the finish cleaning container con-
container containing cleaning oil. taining cleaning oil and wash them by slowly mov-
ing them.
2) Wipe off the remaining cleaning oil with clean
cloth.
Wash off deposited substances which Place the parts somewhere free of dust and
may cause scratches. moisture, and dry them using compressed air.
Leave the parts submerged in the After drying, apply engine oil to the parts.
cleaning oil until the dirt and grease
come off and float up.
116
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4. Assembling instructions
(1) Prior to assembly:
• Clean all the parts.
• Polish scratches, flashes or burrs by using an oil stone.
• Replace sealing parts such as O-rings with new ones.
(2) Assembling procedure
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6 Install the thrust plate (6) to the shaft (8) with High
strength bolts (4).
Apply grease to inner side of the thrust plate
(6).
Apply Loctite No.262 to High strength bolts
(4).
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Third Edition : 04/2006
Upper Roller SH330
Upper Roller
Assembly Drawings
KBA1141Z-C02
120
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Second Edition:04/2006
Lower Roller SH330
Lower Roller
1 6
7
5
3
8
4
(2) Jigs
1.5
15
5R
JIG HAMMER
ROLLER 150
BUSHING
PULLING JIG
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Second Edition:04/2006
3. Disassembling Instructions
(1) Preparation
Prior to disassembly, take full preparatory measures.
[1] Workbench with vises
Prepare a suitable workbench large enough to arrange and keep parts and perform the work.
[2] Tools and Jigs
For the tools and jigs, refer to the previous section.
(2) General cautions
[1] Handle precision parts carefully during the operation; do not drop or hit them on other parts
during the operation.
[2] Do not attempt to finish the operation quickly; do not forcedly pry or hit the parts.
Perform the operation carefully and patiently in order to prevent parts deformation, oil leakage
and lower efficiency.
[3] As disassembled parts tend to get rusted or collect dust and dirt, dust proof and rust preven-
tion treatment should be applied immediately after disassembling the parts.
(3) Disassembling procedure
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7 Cleaning Parts
1. Preparatory cleaning 2. Finish cleaning
1) Place parts in the preparatory 1) Put the parts in the finish cleaning container
cleaning container containing kero- containing kerosene and clean them by
sene. slowly moving them.
2) Wipe off kerosene with clean cloth.
123
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4. Assembling instructions
(1) Prior to assembly:
• Clean all the parts.
• Polish scratches, flashes or burrs by using an oil stone.
• Change sealing parts such as O-rings with new ones.
(2) Assembling procedure
1 Install the bushings (3) to the roller (1) using jig and
hammer.
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6 Press fit the collars (6),(9) to the shaft (2) and install
9 the wire clips (7). (Temporary fastening)
1
7
7
Do not reuse wire clips (7).
WATER TANK
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HAMMER
126
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Lower Roller SH330
Lower Roller
Assembly Drawings
KSA1068Z-C02
127
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Second Edition:01/2002
Safety SH330SH700SH225SH800SH450
Safety
Sections marked with this symbol address extremely important safety issues.
Make sure to read and fully understand the sections before starting operations.
[1] Before starting maintenance work, read carefully and fully understand materials (instruction manual
and maintenance manual).
[2] Before disassembling and assembling, take sufficient safety measures to prevent accidents such as
falling loads, being caught in or under the machine and burns.
When working under the machine, use safety blocks to support the machine to avoid workers getting
caught.
[3] Cranes and other hoist equipment must be operated by licensed operators.
1) Crane operators and slinging workers must be licensed.
2) Make sure to inspect rigging.
[4] Wear proper clothing and protective gear as necessary during inspection or maintenance
(safety shoes, helmets, protective goggles, gloves, earplugs, dust mask and other protective devic-
es).
[5] Always keep the work area clean to avoid accidents such as skidding during travel and falling objects.
[6] Make sure to ventilate properly when inspecting or servicing a machine indoors.
[7] Be prepared for any emergencies and take necessary fire preventative measures.
1
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Grease Cylinder Page No. 1/ 4
Second Edition:04/2006
Grease Cylinder SH330
Grease Cylinder
HAMMER SPANNER
(2) Jigs
1.5
HAMMER
JIG 15
5R
150
PULLING JIG
128
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Second Edition:04/2006
3. Disassembling Instructions
(1) Preparation
Prior to disassembly, take full preparatory measures.
[1] Workbench with vises
Prepare a suitable workbench large enough to arrange and keep parts and perform the
work.
[2] Tools and jigs
For the tools and jigs, refer to the previous section.
(2) General cautions
[1] Handle precision parts carefully during the operation; do not drop or hit them on other parts
during the operation.
[2] Do not attempt to finish the operation quickly; do not forcedly pry or hit the parts.
Perform the operation carefully and patiently in order to prevent parts deformation, oil leakage
and lower efficiency.
[3] As disassembled parts tend to get rusted or collect dust and dirt, dust proof and rust preven-
tion treatment should be applied immediately after disassembling the parts.
(3) Disassembling procedure
129
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4. Assembling instructions
(1) Prior to assembly:
• Clean all parts.
• Polish scratches, flashes or burrs using an oil stone.
• Change sealing parts such as O-rings with new ones.
(2) Assembling procedure
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131
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Grease Cylinder SH330
Grease Cylinder
Assembly Drawings
KSA0832Z-B01
132
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Rotating Joint SH330SH450
Rotating Joint
133
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First Edition : 03/2006
(2) Jigs
Jig for pushing out axle
134
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First Edition : 03/2006
3. Disassembling instructions
(1) Prior to disassembly
[1] As this is a hydraulic device, follow the cautions below.
• Rough handling should be avoided (e.g. forcedly prying and hitting).
• Be careful when handling parts; do not drop or hit against other parts.
• Do not allow foreign substances such as dirt or moisture to enter into the parts.
[2] Always use jigs when disassembling axles and rotors.
[3] Use a strongly-built, stable workbench which has enough space. The workspace should be
clean and free of dirt and moisture. Remove all dirt and moisture before starting work.
[4] Inspect the tools and jigs before starting work. Remove dirt and moisture to make them clean.
[5] Use suitable tools and jigs which meet requirements for the job.
Follow the procedure below to disassemble rotating joints.
(2) Disassembling procedure
3 Remove the thrust plate (10) together with the bolt (9).
10
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4 Push out the axle (1) from the rotor (5) using a jig.
Do not hit the parts with a hammer while carrying
out this operation.
5
6 Remove the O-ring (3) and packing rings (4) from the ro-
tor (5).
3
5
4
136
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4. Assembling instructions
(1) Prior to assembly:
• Clean all the parts.
• Polish scratches, flashes or burrs using an oil stone.
• Change sealing parts such as O-rings and packing ring with new ones.
Prior to the disassembly described in the Section 3-(1), perform the same cautions and mea-
sures mentioned in this section.
(2) Assembling procedure
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139
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First Edition : 04/2006
Rotating Joint SH330SH450
Rotating Joint
Assembly Drawings
140
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Air Conditioner Page No. 1/ 7
First Edition : 03/2005
Air Conditioner SH330SH450SH800
Air Conditioner
Table 2
Nominal diameter Pitch Tightening torque
Category Type
(mm) (mm) N・m
Bolt 7T M6 1.0 8 to 12
M8 1.25 20 to 30
M10 (air conditioning unit
― 17 to 19
mounting section)
M10 1.25 40 to 54
M10 1.5 37 to 51
9T M8 1.25 24 to 36
M10 1.25 56 to 76
M10 1.5 53 to 72
Nut Pipe 8 mm 1.5 12 to 15
diameter
1/2 inch 1.5 20 to 25
5/8 inch 1.5 30 to 35
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Table 3
Replacement part Oil level adjustment
Compressor 1. Measure the oil volume in compressor that is re-
moved.
2. Remove all the oil except that remaining in the com-
pressor that was removed from the brand new com-
pressor.
Example:
If 30 cc of oil remains in the removed compressor
(for a SD7H13WM7359 compressor),remove 105 cc
from the brand new compressor.
(135 cc - 30 cc = 105 cc)
Evaporator Refill 40 cc.
Condenser Refill 40 cc.
Receiver dryer Refill 20 cc.
Note: The oil type is different according to compressors. Refer to the nameplate attached to the
compressor, which has indications for the oil type.
[3] Before starting the operation, stop the engine and turn off the power for air conditioner related
devices.
[4] Avoid water or dust from entering the refrigerating circuits. In addition, do not leave the piping
unattached from the machine.
Avoid conducting piping removal or fitting work under rainy conditions.
[5] When the work is completed, check that the faulty parts have been fully repaired by running the
air conditioner.
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[5] Removing the upper and lower cases of the air conditioning unit:
1) Remove the rod D from the rod holder mounted on the lever of
the mode motor actuator.
2) Remove the motor actuator mounted on the lower unit case
and the upper unit case by removing 3 screws.
3) Remove the 11 mounting screws (+N5 x 16) from the lower unit
case and the upper unit case.
4) Pull upward the upper unit case, paying attention not to have
evaporation sensor cords caught by the case.
145
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146
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147
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Maintenance Standards Page No. 1 / 12
First Edition : 03/2006
Maintenance Standards SH330SH450
Maintenance Standards
Check Sheets
1. Drive Sprocket
a p
e
d
b
Note:For measuring gauges, refer to the reference data for inspection gauge.
Use the Maintenance Standard Value Table for determination.
Measured
Part Name Symbol Determination Measures
dimensions (mm)
Drive sprocket a Good / No good Buildup welding or
replacement
b Diameter: Good / No good
c Diameter: Good / No good
d Diameter: Good / No good
e Good / No good
p Good / No good
148
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2. Take-up Roller
c
b
a
e f
d
Note:For measuring gauges, refer to the reference data for inspection gauge.
Use the Maintenance Standard Value Table for determination.
Measured
Part Name Symbol Determination Measures
dimensions (mm)
Take-up roller a Diameter: Good / No good Buildup welding or
b Good / No good replacement
c Good / No good
Shaft d Diameter: Good / No good Replacement
Bushing d Diameter: Good / No good Replacement
e Good / No good
Hub f Good / No good Replacement
149
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3. Upper Roller
c
b
d
a
g e
Note: For measuring gauges, refer to the reference data for inspection gauge.
Use the Maintenance Standard Value Table for determination.
Measured
Part Name Symbol Determination Measures
dimensions (mm)
Upper roller a Diameter: Good / No good Buildup welding or
b Good / No good replacement
c Good / No good
Shaft d Diameter: Good / No good Replacement
Bushing d Diameter: Good / No good Replacement
Bushing e Good / No good Replacement
Thrust plate f Good / No good Replacement
Cover g Good / No good Replacement
150
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First Edition : 03/2006
4. Lower Roller
f g
a
e
b
Note:For measuring gauges, refer to the reference data for inspection gauge.
Use the Maintenance Standard Value Table for determination.
Measured
Part Name Symbol Determination Measures
dimensions (mm)
Lower roller a Diameter: Good / No good Buildup welding or
b Good / No good replacement
d Good / No good
Shaft e Diameter: Good / No good Replacement
Bushing e Diameter: Good / No good Replacement
f Good / No good
Collar g Good / No good Replacement
151
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First Edition : 03/2006
c' c
d
d'
e' e
f f
f' (4 pieces)
b
a
152
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First Edition : 03/2006
4
3
5
6
9
2
11
8
10 7
1 Boom and swing frame mounting section
a
b c
d
153
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Maintenance Standards Page No. 7 / 12
First Edition : 03/2006
4
3
5
6
9
2
11
8
10 7
3 Boom and boom cylinder mounting section 4 Boom and arm cylinder mounting section
a
b a
c b c
e
d
d
154
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Maintenance Standards Page No. 8 / 12
First Edition : 03/2006
4
3
5
6
9
2
11
8
10 7
g a g
b c
e
155
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Maintenance Standards Page No. 9 / 12
First Edition : 03/2006
4
3
5
6
9
2
11
8
10 7
6 Arm and arm cylinder mounting section 7 Arm and bucket cylinder mounting section
a
a
b
b c c
d
e
d
e
156
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Maintenance Standards Page No. 10 / 12
First Edition : 03/2006
4
3
5
6
9
2
11
8
10 7
8 Arm and arm link mounting section 9 Bucket and bucket link mounting section
c c
a
b
b
a
e e
a
d
d
157
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Maintenance Standards Page No. 11 / 12
First Edition : 03/2006
4
3
5
6
9
2
11
8
10 7
f
b
i
d
e
h
a
158
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4
3
5
6
9
2
11
8
10 7
c
g
d
f
a
b
159
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Maintenance Standards SH330
Maintenance Standards
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(Units : mm)
No. Symbol Part Name Reference value Use limit
a Arm 146 152
b Bucket cylinder (foot section) 145 143
7 c Clearance 1.0~2.5 Shim adjustment
d Pin φ 95 φ 94
e Bushing (bucket cylinder) φ 95 φ 96.5
a Arm link 50 47
b Arm 375 371
8 c Clearance 1.0~1.5 Shim adjustment
d Pin φ 85 φ 84
e Bushing (arm) φ 85 φ 86.5
a Bucket 401 406
b Bucket link 400 397
9 c Clearance 1.0~3.5 Shim adjustment
d Pin φ 90 φ 89
e Bushing (bucket link) φ 90 φ 91.5
a Arm link 50 48
b Bucket link 375 371
c Clearance 1.0~1.5 Shim adjustment
d Bucket link 121 123
10 e Bucket cylinder (top section) 120 118
f Clearance 1.0~2.0 Shim adjustment
g Pin φ 105 φ 104
h Bushing (bucket link) φ 105 φ 106.5
i Bushing (bucket cylinder) φ 105 φ 106.5
a Bucket 401 406
b Arm 400 397
c Clearance 0.8~3.7 Shim adjustment
11 d Bushing (bucket) 16 10
e Pin φ 90 φ 89
f Bushing (arm) φ 90 φ 91.5
g Bushing (bucket) φ 90 φ 91.5
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Maintenance Standards SH330SH800SH700
Maintenance Standards
(Units: mm)
Part No. I.D. O.D. Shim Thickness Material
KMV0650 30.2 50 0.4 SPCC
KMV0651 30.2 50 0.8 SPCC
KMV0652 30.2 50 1.6 SPHC
KMV0653 30.2 50 3.2 SPHC
KMV0654 30.2 50 4.5 SS00
KMV0655 30.2 50 6.0 SS00
KMV0912 32 45 0.4 SPCC
KMV0913 32 45 0.8 SPCC
KMV0914 32 45 1.2 SPCC
KHV0327 36 65 1.2 SPHC
KHV0316 36 70 1.2 SPHC
KHV0315 41 75 1.2 SPHC
KHV0324 41 80 1.2 SPHC
KHV0317 41 90 1.2 SPHC
KAV0058 43 90 1.6 SPHC
KHV0347 46 80 1.2 SPHC
KAV0180 46 80 1.6 SPHC
KAV0682 46 90 1.2 SPHC
KHV0299 46 100 1.2 SPHC
KHV0328 51 85 1.2 SPHC
KAV0160 51 85 1.6 SPHC
BHV1030 51 90 1.2 SPHC
BHV1031 51 90 2.6 SPHC
KHV0330 51 95 1.2 SPHC
KAV0813 51 100 1.2 SPHC
KAV1951 51 100 2.6 SPHC
KAV0061 51 101.6 1.6 SPHC
KHV0348 51 105 1.2 SPHC
KAV0805 51 120 1.2 SPHC
KAV0812 56 90 1.2 SPHC
KAV0558 56 100 1.2 SPHC
BHV1033 56 100 2.6 SPHC
KHV0298 56 105 1.2 SPHC
KAV0395 56 110 0.8 SPHC
KAV0060 56 110 1.6 SPHC
KAV0396 56 115 1.2 SPHC
KAV0427 56 120 1.2 SPHC
KMV0771 60.5 76 1.2 SPHC
KAV0161 61 90 1.6 SPHC
163
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Fourth Edition: 03/2006
(Units: mm)
Part No. I.D. O.D. Shim Thickness Material
KAV0811 61 110 1.2 SPHC
KNV0230 61 110 1.2 SPHC
KAV0059 61 110 1.6 SPHC
KHV0286 61 120 1.2 SPHC
KAV0801 61 130 1.2 SPHC
KMV0942 61 140 3.2 SPHC
KMV1246 61 160 1.2 SPHC
KMV0693 65.5 90 1.2 SPHC
KNV0538 66 100 1.2 SPHC
KLV0034 66 110 1.2 SPHC
KNV0535 66 120 1.2 SPHC
KMV0122 66 130 1.2 SPHC
KHV0273 66 150 1.2 SPHC
KHV0458 66 170 1.2 SPHC
KNV0696 71 110 1.2 SPHC
KNV0539 71 130 1.2 SPHC
KRV0823 71 130 1.2 SPHC
KMV0144 71 135 1.2 SPHC
KMV0145 71 135 2.6 SPHC
KMV0774 71 150 1.2 SPHC
KMV0775 71 150 2.6 SPHC
KMV0941 71 150 3.2 SPHC
KNV0189 71 150 1.2 SPHC
KRV1176 76 130 1.2 SPHC
KRV1177 76 140 1.2 SPHC
KRV1584 76 140 1.2 SPHC
KHV0169 76 140 1.2 SPHC
KNV0534 76 160 1.2 SPHC
KRV2264 76 180 1.2 SPHC
KAV0776 77 120 1.2 SPHC
KSV0141 78 170 1.2 SPHC
KSV0142 78 170 2.6 SPHC
KSV0143 78 170 3.2 SS00
KAV0095 81 105 1.6 SPHC
KLV0170 81 110 1.2 SPHC
KRV1197 81 140 1.2 SPHC
KRV0822 81 150 1.2 SPHC
KRP1350 81 150 2.6 SPHC
KLV0035 81 170 1.2 SPHC
164
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(Units: mm)
Part No. I.D. O.D. Shim Thickness Material
KSP0408 81 200 1.2 SPHC
KSP0409 81 200 2.6 SPHC
KBV0122 82 120 3.2 SS00
KBV0123 82 120 4.5 SS00
KBV0124 82 120 6.0 SS400
KBV0373 82 180 1.0 SPCC
KRV1178 86 130 1.2 SPHC
KRV1585 86 150 1.2 SPHC
KHV0170 86 150 1.2 SPHC
KBV0389 87 210 1.0 SPCC
KBV0390 87 210 1.6 SPCC
BHV1030 90 51 1.2 SPHC
KBV0837 91 135 1.2 SPHC
KSV0477 91 145 1.2 SPHC
KSP0411 91 145 2.6 SPHC
KMV0121 91 159 1.2 SPHC
KBV0769 91 160 1.2 SPHC
KSP0269 91 160 2.6 SPHC
KBV0764 91 165 1.2 SPHC
KRV0559 91 180 1.2 SPHC
KRV1180 91 190 1.2 SPHC
KSP0412 91 200 1.2 SPHC
KSP0413 91 200 2.6 SPHC
KBV0381 92 180 1.0 SPCC
KBV0382 92 180 1.6 SPCC
KBV0383 92 180 2.0 SPCC
KBV0384 92 180 3.2 SS00
KBV0377 92 220 1.0 SPCC
KBV1749 96 140 1.2 SPHC
KNV0468 96 150 1.2 SPHC
KSP0828 96 150 1.2 SPHC
KBV1629 96 170 1.2 SPHC
KBV0361 97 250 1.0 SPCC
KBV0362 97 250 1.6 SPCC
BHV1032 100 56 1.2 SPHC
KSV0478 101 160 1.2 SPHC
KSP0415 101 160 2.6 SPHC
KSP0416 101 180 1.2 SPHC
KSP0417 101 180 2.6 SPHC
KBV0474 101 219 1.2 SPHC
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(Units: mm)
Part No. I.D. O.D. Shim Thickness Material
KBV0369 102 210 1.0 SPCC
KSV0138 103 190 1.2 SPHC
KSV0139 103 190 2.6 SPHC
KSV0140 103 190 3.2 SS00
KSV0135 103 213 1.2 SPHC
KSV0136 103 213 2.6 SPHC
KSV0137 103 213 3.2 SS00
KSP0827 106 170 1.2 SPHC
KHV0190 111 150 1.2 SPHC
KSP0418 111 180 1.2 SPHC
KSP0419 111 180 2.6 SPHC
KTV0533 111 190 1.2 SPHC
KSV0476 111 230 1.2 SPHC
KBV0214 112 150 6.0 SS400
KBV0215 112 150 9.0 SS400
KBV0357 112 270 1.0 SPCC
KHV0193 121 155 1.2 SPHC
KMV1517 121 220 0.4 SPHC
KMV1518 121 220 0.6 SPHC
KMV1519 121 220 0.8 SPHC
KHV0296 121 230 1.2 SPHC
KTV0534 121 250 1.2 SPHC
KWV0101 131 170 1.2 SPHC
KSV0839 131 200 1.2 SPHC
KHV0287 131 240 1.2 SPHC
KTV0850 141 225 1.2 SPHC
KHV0297 141 240 1.2 SPHC
KHV0288 151 300 1.2 SPHC
KUV0080 171 280 1.2 SPHC
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Shim
Part No. I.D. O.D. R H Material
Thickness
KNV1132 76 160 100 30 1.2 SPHC
KRV2390 91 190 115 30 1.2 SPHC
KBV1441 101 220 130 30 1.2 SPHC
KBV1748 101 230 135 30 1.2 SPHC
KSV1805 111 240 140 30 1.2 SPHC
Shim
Part No. I.D. O.D. R H Material
Thickness
KSV1930 111 240 140 30 1.0 Urethone
KSV11380 111 240 140 30 2.0 Urethone
KSV1931 116 240 140 30 1.0 Urethone
KSV11390 116 240 140 30 2.0 Urethone
KWV0097 141 280 160 50 1.0 Urethone
KWV10510 141 280 160 50 2.0 Urethone
KWV0096 141 300 180 50 1.0 Urethone
KWV10500 141 300 180 50 2.0 Urethone
KUV10150 141 300 170 30 1.0 Urethone
KUV10160 141 300 170 30 2.0 Urethone
KUV10130 151 300 170 30 1.0 Urethone
KUV10140 151 300 170 30 2.0 Urethone
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Maintenance Standards SH330
Maintenance Standards
Inspection Gauges
1. For Drive Sprocket Use
(Units: mm)
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Hydraulic Pump SH330
Hydraulic Pump
55 - - VP-11/2 -
Adjustable
- 1 Medium size
wrench
Screwdriver - Åõ Åõ Åõ Åõ 2 Minus type screwdrivers, medium size
Hammer - Åõ Åõ Åõ Åõ 1 Plastic hammer
Pliers - Åõ Åõ Åõ Åõ TSR - 160 for stop ring
Steel bar - Åõ Åõ Åõ Åõ Steel bar for key aproxmately 10 x 8 x 200
Torque wrench - Åõ Åõ Åõ Åõ Wrenches capable of tightening to the torque spec.
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5 Loosen the hexagon socket head bolts (401), If a gear pump and others are at-
which lock the swash plate support (251), pump tached to the back side of the pump,
casing (271), and valve block (312). this procedure should be done after
disconnecting the gear pump and
others.
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7 Pull out the cylinder block (141) from the pump Handle with care to prevent scratch- All types
casing (271) along the direction of the drive shaft es on the frictional surfaces of the
(111) and remove the piston (151), retainer (153), cylinders, spherical bush, and swash
spherical bush (156), and cylinder spring (157) at plate, etc.
the same time.
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13 If necessary, remove the stopper (L) (534), stop- 1. When removing the leaning pin, All types
per (S) (535), servo piston (532), tilting pin (531) use appropriate tools to prevent
from the pump casing (271) and needle bearing damage to the top of the leaning
(124) and the gear 1st (116) from the valve lock pin.
(312). 2. Be careful not to damage the ser-
vo piston because Loctite is ap-
plied to the connecting part of the
leaning pin and the servo piston.
3. The needle bearing should not be
removed except when it wears
out.
4. Do not loosen the hexagonal nut
for the valve block and swash
plate support. Loosening the nut
causes the flow rate to change.
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2 Place the pump casing with the regulator installa- 1. Make sure the swash plate moves All types
tion side facing down, push down the tilting pin smoothly by pushing it with finger
(531) of the swash plate, and install the swash tips of both hands.
plate (212) on the swash plate support (251) prop- 2. Apply grease on the swash plate,
erly. swash plate support or other mov-
ing part for the easy installation of
the drive shaft.
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4 Assemble the seal cover (F) (261) with the pump 1. Apply grease lightly on the oil seal All types
casing (271), and secure them with hexagon sock- inside the seal cover (F).
et head bolts (406). 2. Make sure not to damage the oil
seal when handling it.
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6 Install the valve plate (313) on the valve block Be careful not to mix up the inlet and
(312) with the pins aligned. outlet direction on the valve plate.
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8 Clamp the feedback pin of the tilting pin on the Be careful not to mix up the regulator All types
feedback lever of the regulator, install and fasten for the front use and the rear use.
the hexagon socket head bolts (412, 413).
9 Install the drain port plug (467) to complete the All types
procedure.
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(2) Repair standards for cylinder, valve plate and swash plate (shoe plate)
Tightening
Part Name Size Tool name (mm)
torque (N ・ m)
Hexagon socket head cap screw M5 6.9 B=4
(Material SCM435)
M6 11.8 5
M8 29.4 6
M10 56.9 8
M12 98.1 10
M14 156.9 12
M16 235.4 14
M18 333.4 14
M20 431.5 17
Rc plug R 1/16 6.9 4
(Material SCM45C)
R 1/8 10.3 5
Note: Wrap seal tape with 1.5 to 2
R 1/4 17.2 6
rotations. Hexagon bar
R 3/8 34.3 8 wrench
R 1/2 49.0 10
PF Plug G 1/4 29.4 6
(Material S45C)
G 1/2 98.1 10
G 3/4 147.1 14
G1 186.3 17
G 1 1/4 264.8 17
G 1 1/2 274.6 17
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3. Troubleshooting
(1) General precautions
Following are countermeasures if you find abnormality during the operation of Kawasaki swash
plate type axial piston pump and motor.
General precautions are:
[1] Considerations before starting repair.
Determine the characteristics of the abnormality before starting repair. Consider if the cause
is originated from the wrong circuit, failure of regulator, or attached valve. Double check that
the problem involves the pump motor.
[2] Before disassembling a system, make sure to read through the service manual. Conduct the
disassembly in a correct manner.
[3] When disassembling a system, be careful not to allow dust to enter.
[4] Parts are finished precisely. Be careful not to damage them when handling.
(2) Troubleshooting for the pump main body
Pumps are often attached to a regulator, attached valves and attached pumps. It can be difficult
to find the cause of the problem. Checking the following points is useful to identify the problem
area.
[1] Filter check and drain oil check
Check the filter element. Check if a considerable amount of contamination is found.
It is normal that a little amount of metal dust originated from abrasion of the shoe or cylinders
is seen. However, if the amount of metal dust is extremely high in the filter, the shoe might
be damaged. Check drain oil of inside the pump casing, as well.
[2] Abnormal noise / abnormal vibration
Check for abnormal noise or abnormal vibration in the main pump. Examine if the sound re-
peats with regular frequency such as, a hunching sound in the regulator or hunching sound
of the valve relief.
If there is an abnormal vibration or sound, cavitation or damage inside the pump should be
considered.
[3] When using two pumps.
If piping uses two single pumps or two motors, change the pipe of each pump.
By changing the pipe, the problem can be identified whether it is caused by a pump failure
or a piping failure after the pump.
[4] Perform pressure measurement.
If the problem is related to the controlling function, examine the problem areas using pres-
sure measurement tools instead of performing overhaul inspection.
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(4) When pump flow rate declines significantly or discharging pressure does not increase.
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Cross Sectional View of Pump
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Hydraulic Pump SH330
Hydraulic Pump
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2. Assembly drawing
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Hydraulic Pump SH330
Hydraulic Pump Rev.1 04/2007
Regulator Handling
1. Description
The regulator KR 3*-9N** for KAWASAKI incline type axial piston pump K3V Series use is composed
of the following control mechanism.
[1] Power control
As the discharge pressure P1 at the self pump and discharge pressure P2 at the counterpart
pump rise, restrain the input torque to a constant value or less by reducing the pump incline ro-
tation angle (discharge flow) automatically (when the number of revolutions is constant, the input
power is kept constant).
It is operated by the load pressures(1.33 x Self pump load pressure + 0.67 x Counterpart pump
load pressure) at the two pumps of the tandem type double pumps.
The overload of the self pump is prevented by adopting the mechanism that raises the sensitivity
of the self pump load pressure for the counterpart pump load pressure.
Moreover, the overload of the motor is automatically prevented with this mechanism irrespective
of the load of two pumps.
[2] Power shift control
Set power values can be shifted by changing command current values for the electromagnetic
proportional pressure-reducing valve that is attached to the regulator.
There is only one electromagnetic proportional pressure-reducing valve but the secondary pres-
sure Pf (power shift pressure) is introduced into the power control section in the regulator of each
pump through the passage inside the pump. Each pressure is shifted into the same set power
value. As the pump's output power can be changed to an arbitrary value through this mecha-
nism, it is possible to obtain optimal power according to the work condition.
[3] Flow control
By changing pilot pressure Pi, the pump incline rotation angle (discharge flow) can be arbitrarily
controlled.
This regulator adopts a negative flow control (negative control) method where the discharge flow
Q decreases as the pilot pressure Pi increases. Through this mechanism, a pilot pressure
matching the flow required for the work is instructed, the pump discharges only the required flow,
thus no useless power is consumed.
This regulator has those three control mechanisms above described, but each control works in a
combined way. The priority is given to the low incline rotation (low flow) command by mechanical
computing which is to be described later.
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2. Description of Operation
(1) Flow control
As shown in the figure on the right, the pump discharge flow is con-
trolled arbitrarily by pilot pressure Pi.
1) Flow decrease operation
When pilot pressure Pi rises, pilot piston (643) moves to the right
and stops at a position where the force of pilot spring (646) and
the oil pressure force are balanced. As Pin (876) fixed on lever 2
(613) is fitted in the grooved section [Section A] made on the pilot
piston, when the pilot piston moves, lever 2 turns around the fix-
ation point as a fulcrum due to the function of fulcrum plug (614)
and pin (875). As pin (897) fixed on feedback lever (611) is pro-
jected into the larger hole section on lever 2 [Section C], pin (897)
moves to the right as lever 2 rotates. The part formed with two surfaces [Section D] on the
feedback lever has the pin (548) fixed onto incline rotation pin (531) which oscillates the
swash plate, the feedback lever rotates with Section D as its fulcrum when pin (897) moves.
As the feedback lever has spool (652) jointed to it via pin (874), the spool moves to the right.
When the spool moves, discharge pressure P1 is communicated with Port Cl through the
spool and is introduced into the servo piston's large diameter part. The discharge pressure
P1 is always introduced into the servo piston's small diameter part but the servo piston moves
to the right because of the differential area, and the incline rotation angle is reduced.
When the servo piston moves to the right, Point D also moves to the right. As the spool has
a return spring (654) fitted and the spring force to pull to the left always acts on the spool, pin
(897) is pushed against the larger hole section [Section C] on the lever 2. Therefore, the
feedback lever turns around Point C as its fulcrum as Point D moves, and the spool moves
to the left.
In junction with this movement, the opening between the sleeve (651) and spool (652) starts
closing gradually and the servo piston stops at the position where the opening has complete-
ly closed.
2) Flow increase operation
When pilot pressure Pi decreases, pilot piston (643) moves to the left by the force of pilot
spring (646) and lever 2 (613) turns around Point B as its fulcrum. As pin (897) is pushed
against the larger hole section [Section C] on lever 2 by return spring (654) via spool (652),
pin (874) and feedback lever (611), the feedback lever turns around Point D as its fulcrum
as the lever 2 rotates and the spool moves to the left.
As Port Cl is opened to the tank port when the spool moves, the pressure in the large diam-
eter part is released and the servo piston moves to the left by action of discharge pressure
P1 in the small diameter section. As a result, the flow increases.
As the servo piston moves, Point D moves to the left, the feedback lever turns around Point
C as its fulcrum, and the spool moves to the right. The spool continues to move until the spool
sleeve opening is closed. It stops at the position where the opening has been closed.
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Rev.1 04/2007
(2)Power control
As shown in the figure on the right , the overload of the motor and the
overload of the self pump are prevented by reducing the pump incline
rotation angle when the load pressure rises.
As this regulator adopts the method to assume the oil pressure power
of the sum of the 1.33 times the self pump pressure power and 0.67
times the counterpart pump pressure to be a signal and to control the
horsepower.
The area of Compensation piston
Self pump pressure part : Counterpart pump pressure part = 2 : 1
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4. Troubleshooting
If malfunctions possibly caused by regulator occurs, disassemble and reassemble it referring to the
maintenance instructions.
(1) Motor Overloading
Apply a load onto each pump separately and find out which pump (front or rear) is abnormal? If
both are abnormal, first check the following (1) and (2):
If only one side is available, start from (3).
[1] Check that the power shift command current value is normal.
[2] Lower power shift pressure.
• Check for dither on the amplifier
• Replace electromagnetic proportional pressure-reducing valves
[3] Compensation piston/compensation rod sticking
• Disassemble and clean
[4] Pin (898) sticking
• Disassemble and clean
(2) Maximum flow is not available
[1] Ensure that pilot pressure Pi is normal.
[2] Pilot piston sticking
• Disassemble and clean
[3] Spool sticking
• Disassemble and clean
Note: If the parts have deep scratches, replace the parts.
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5. Attachements
(1) List of adjustments for regulator
KR3S-
Regulator type:
9N0A
Revolution (min-1) 2,030
Adjusting screw (954) Fastening (turns) +1/4
Adjusting Maximum Flow
Changes in flow (L/min.) 6.3
Adjusting screw (953) Fastening (turns) +1/4
Adjusting Minimum Flow
Changes in flow (L/min.) 5.1
Adjusting screw (628) Fastening (turns) +1/4
Changes in compensation control start pressure
Adjusting out- (MPa) 1.75
er spring
Changes in input torque (N ・ m) 71.6
Adjusting Input A 1.9
Power
Adjusting ring (627) Fastening (turns) +1/4
Adjusting Flow Controlling Changes in flow control start pressure (MPa) 0.15
Characteristics Changes in flow (L/min.) 16.4
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Hydraulic Pump SH330SH450
Hydraulic Pump
Regulator Maintenance
1. Disassembling Precautions
[1] This regulator is composed of small precision components. Disassembling and reassembling it
involves complicated procedures. We therefore recommend that you replace the entire regulator
assembly. However, if you must proceed and disassemble the regulator, thoroughly read the in-
structions before you do so.
[2] Numbers in parentheses following the part names indicate symbols in the structural drawings.
2. Tools
3. Disassembling Instructions
Procedures Precautions
1 Pick a work area for disassembling the regulator. 1. Choose a clean area.
2. Place a rubber sheet or cloth on the workbench
so parts do not become scratched.
2 Remove debris or rust from the surface of regula-
tor with a solvent.
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Procedures Precautions
3 Remove hexagon socket head bolts (412 and Do not lose the O-rings.
413), and remove the regulator body from the
pump body.
4 Remove hexagon socket head bolts (438) to re- Adjusting screw (C) (628), adjustings ring (C)
move cover (C) (629). (627), lock nut (630), hexagon nuts (801, 802),
and adjusting screw (924) are fitted on the cover
(C). Do not loosen those screws and nuts.
If loosened, the pressure and flow settings will be
altered.
5 After removing cover (C) (629) subassembly, re- Adjusting ring (Q) (645) comes out easily when
move outer spring (625), inner spring (626) and you use an M4 bolt to pull it out.
spring seat (C) (624) from the compensating sec-
tion. Also, pull out adjusting ring (Q) (645), pilot
spring (646) and spring seat (644) from the pilot
section.
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Procedures Precautions
6 Remove hexagon socket head bolts (436 and
438) and remove pilot cover (641).
After you remove the pilot cover, remove set
spring (655) from the pilot section.
7 Remove stop ring (814) to remove spring seat 1. A snap ring (836) is fitted onto the sleeve (651).
(653), return spring (654), and sleeve (651). 2. Return spring (654) will pop out while removing
stop ring (814); do not lose it.
8 Remove locking ring (858), and remove support Support plug (614) and adjusting plug (615) can
plug (614) and adjusting plug (615). be easily pulled out if you use an M6 bolt.
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Procedures Precautions
9 Remove lever 2 (613). Leave pin (875) in. Tweezers will facilitate the process.
10 Pull out pin (874) and remove feedback lever Push out pin (874) (pin dia. 4) from top with a fine
(611). steel rod. Avoid hitting lever (1) (612) during this
process.
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Procedures Precautions
1 Install compensating rod (623) into the compen-
sating hole on the casing (601).
2 The pin that is press-fitted onto the lever 1 (612) is
to be inserted in the compensating groove. After
you insert the pin, install lever 1 onto the pin that
is press-fitted onto the casing.
3 Install spool (652) and sleeve (651) into the spool 1. Ensure that the spool and sleeve slides
hole on the casing. smoothly in casing without engagement.
2. The spool must be oriented properly.
4 Install feedback lever (611), align the pinholes on 1. You can facilitate the process by slightly insert-
the feedback lever, and insert pin (874). ing the pin into the feedback lever beforehand.
2. The feedback lever must be facing the right di-
rection.
5 Install pilot piston (643) into the negative control Ensure that the pilot piston slides smoothly with-
hole on casing. out engagement.
6 The pin that is press-fitted onto lever 2 (613) is to
be inserted in the groove on pilot piston. Insert the
pin and install lever 2.
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Procedures Precautions
7 The pin that is press-fitted into support plug (614)
goes into the pin hole on lever 2. Install the sup-
port plug (614) in this manner, and install locking
ring (858).
8 Insert adjusting plug (615) and install the locking 1. Ensure that you placed the support plug and
ring. the adjusting plug in the respective holes.
2. At this point, move the feedback lever to see it
is not loose and there is no engagement.
9 Install return spring (654) and spring seat (653)
into the spool hole, and install stop ring (814).
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Procedures Precautions
11 Install spring seat (644), pilot ring (646), adjusting The spring seat must face the right direction.
ring (Q) (645) into the pilot hole, then fit spring seat
(624), inner spring (626), outer spring (625) into
compensating hole.
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5. Cross-sectional view of regulator
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Travel Unit SH330
Travel Unit
Motor
1. Structural Drawing
(1) STRUCTURE
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(2) DISASSEMBLY
1) GENERAL PRECAUTIONS
Combustibles such as white kerosene are used for washing parts. These combustibles are
easily ignited, and could result in fire or injury.
Be very careful when using.
Internal parts are coated with hydraulic fluid during disassembling and are slippery. If a part
slips out of your hand and falls, it could result in bodily injury or could damage the part.
Be very careful when handling.
[1] Generally, hydraulic equipment is precisely manufactured and clearances between each
parts are very narrow.
Therefore, disassembling and assembling works should be performed on the clean
place where dusts hardly gather.
Tools and kerosene to wash parts should also be clean and handled with great care.
[2] When motor is removed from the host machine, wash around the ports sufficiently, and
put the plugs so that no dust and/or water may invade.
Take off these plugs just before the piping works when re-attach it to the host machine.
[3] Before disassembling, review the sectional drawing and prepare the required parts, de-
pending on the purpose and the range of disassembling.
Seals, O-rings, etc., if once disassembled, are not reusable.
There are some parts that should be replaced as a sub-assembly.
Consult with the parts book in advance.
[4] The piston can be inserted to whichever cylinder block for the initial assembling.
However, their combination should not be changed if they are once used. To reuse them,
put the mating mark on both pistons and cylinder block before disassembling.
[5] Take great care not to pinch your hand between parts while disassembling nor let fall
parts on your foot while lifting them.
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2) DISASSEMBLING INSTRUCTIONS
Numeral in ( ) after the part name corresponds to the number on structure drawing Fig.1 on
page 1.
a) Removing accessory valves
Before disassembling motor, remove accessory valves.
According to disassembling purpose, select the valves to be removed.
However, you cannot disassemble the motor without removing overload relief valve (57).
There is dread of the burn, disassemble motor after cooling it to ambient temperature.
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FOR REFERENCE
Above disassembling is mentioned as a motor only and naturally can be applied to
the motor with reduction gears.
The situation is rather easier for with reduction gears because the shaft is rather re-
stricted by a gear to move.
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(3) ASSEMBLY
1) GENERAL PRECAUTIONS
[1] Wash each parts sufficiently with ker-
osene, and blow them by plant air.
[2] Assemble sliding parts after coating
clean hydraulic oil on them.
[3] Take great care not to pinch your
hand between parts or tools while as-
sembling nor let fall parts on your foot
while lifting them.
2) ASSEMBLING INSTRUCTIONS
[1] Coat outer surface of oil seal (3) and
inner face of casing (1) with grease.
Using jig, rightly and evenly press in
the oil seal (3) into casing (1).
[2] Fix oil seal (3) by retaining ring (4).
[3] Put the outer race of bearing (10) on
casing (1) (this fit is loose), and press
the inner race on shaft (9) (this fit is
tight).
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When changing bearings (10), (51), shaft (9), casing (1) or rear cover (24), it affects the
clearance of the bearings. Therefore, shim (52) should be adjusted.
Refer to "Deciding shim (52) thickness for tapered roller bearings" (PAGE 8/20) and de-
cide shim (52) thickness.
[12] Install two guide pins diagonally on
casing (1).
(Purpose: Guide for installing rear
cover)
[13] Lay down rear cover (24) to mount
valve plate (54) coinciding mating
mark made prior to disassembling
and also place brake springs (55) with
ample grease to be attached to rear
cover (24) while assembling.
Also set shim (52), outer race of rear
bearing (51) and O-rings (50), (47),
(49) on rear cover (24).
[14] Insert rear cover (24) to casing (1)
along the guide pin, and install two
Hex. socket head bolts M18 x 50 (56)
diagonally upper and lower position
and tight them to assemble rear cover
(24) parallely.
Figure 16. Assembling brake piston
Then, install the rest of Hex. socket
head bolts M18 x 50 (56) and remove
guide pin and install two the remain-
der.
Take great care not to pinch your
hand between parts or tools while as-
sembling nor let fall parts on your foot
while lifting them.
When removing outer race of rear
bearing (51), install shim (52) without
fail.
Confirm that O-rings (47), (49), (50)
are installed to rear cover (24).
Tightening torque of Hex. socket
head bolt M18 x 50 (56) is 324 ±32.4
N-m without removing rust preventive
Figure 17. Assembling accessory valves
agent on the threads.
[15] Assemble coupling (58).
[16] Assemble spring (34), spring holder (33), pilot valve spool (31) and pin (32) to rear cover
(24), and then install pilot valve plug (35) with O-ring (36).
Tightening torque of pilot valve plug (35) is 49.0 - 58.8 N-m.
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3. Maintenance Standard
(1) MAINTENANCE STANDARD OF PARTS
The followings are the general maintenance standards. However, it is the most important to de-
termine which parts should be replaced, depending on the characteristics before disassembling,
damages and discoloration of exterior view, the purpose of disassembling, the expected remain-
ing service life, etc..
ITEM AND MEASURING METHOD
1) Sliding surface of: cylinder block, valve plate and swash plate
JUDGING CRITERIA AND DISPOSITOIN
Measure the surface roughness by roughness tester.
Allowable
Check Items Criteria Disposition
Roughness
Surface roughness;
-cylinder block below below
Replace or Repair
-valve plate 0.4 zμ 3.0 zμ
-swashnlate
Table2
Note: Lap together the surfaces of both cylinder block and valve plate to remedy their rough-
ness. (Lap with #1200 powder)
Measure the surface hardness of swash plate by hardness tester.
Allowable
Check Items Criteria Disposition
Handness
Swash plate
Over HS78 HS74 Replace
-hardness of sliding surface
Table3
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7) Splines
Replace if the wear of splines exceeds the allowable value.
JUDGING CRITERIA AND DISPOSITOIN
If the wear of splines is less than 0.3 mm, the spline is reusable.
8) Overload relief valve
Do not try to adjust the valve, since special hydraulic test bench is required for inspecting
and adjusting the pressure.
JUDGING CRITERIA AND DISPOSITOIN
Replace relief valve part as an assembly each time the host machine works for 10,000 hours.
(2) TIGHTENING TORQUE
Use torque wrench when tightening the following Hex. socket head bolt, plugs and valves.
Lubricating with rust preventive oil.
TIGHTENING TORQUE
ITEM DESCRIPTION SIZE
(N ・ m)
(29) Plug M42 441 - 461
(35) Plug (Pilot valve) G3/8 49.0 - 58.8
(38) Plug G1/4 29.4
(42) Plug G1/8 14.7
(56) Hex. socket head bolt M18 324 ± 32.4
(57) Overload relief valve M27 98.1 - 118
(60) Plug G1/2 98.1
Table 7
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5) Oil leakage
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Travel Unit SH330
Travel Unit
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Work stand
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(2)DISASSEMBLY
1) GENERAL INSTRUCTIONS
Combustibles such as white kerosene are used for washing parts. These combustibles are
easily ignited, and could result in fire or injury.
Be very careful when using.
Internal parts are coated with gear oil during disassembly and are slippery. If a part slips out
of your hand and falls, it could result in bodily injury or could damage the part.
Be very careful when handling.
[1] Therefore, disassembling and assembling works should be performed on the clean
place where dusts hardly gather.
Tools and kerosene to wash parts should also be clean and handled with great care.
[2] Before disassembling, review the sectional drawing and prepare the required parts, de-
pending on the purpose and the range of disassembling.
Seals, O-rings, etc., if once disassembled, are not reusable.
There are some parts that should be replaced as a sub-assembly.
Consult with the parts book in advance.
[3] Take great care not to pinch your hand between parts while disassembling nor let
fall parts on your foot while lifting them.
2) DISASSEMBLING PROCEDURES
Numeral in ( ) after the part name corresponds to the number on structure drawing Fig.1 on
page 1/17.
a) Preparation for disassembling
[1] The reduction units removed from excavator are usually covered with mud.
Wash outside of propelling unit sufficiently and dry it.
There is dread of the burn, disassemble reduction unit after cooling it to ambient tem-
perature.
[2] Loosen taper screw plug G3/4 (26) of drain and fill port and drain oil from reduction
gears.
While oil is still hot, inside of the unit may be pressurized. Take care of the hot oil
gushing out of the unit when loosening the plug.
[3] Mark for mating
Put marks on each mating parts when disassembling so as to reassemble correctly
as before.
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c) Removing cover
[1] Remove the rest of Hex. socket
head bolts M10 x 30 (25) that se-
cure cover (24).
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i) Disassembling carrier 1
ASSY
When carrier pins 1 (20) are to
be re-used, mark each pin with
its mated hole of carrier 1 (16)
to assure the same combina-
tion as before.
[1] Knock spring pins 6 x 36
(21) fully into carrier pins 1
(20).
[2] Tap carrier pins 1 (20) out
from carrier 1 (16).
[3] Remove thrust washers 1
(18), planetary gears 1
(17) and needle bearings
(19).
Take great care not to
pinch your hand between
gears and carrier 1 (16)
while disassembling.
[4] Knock out spring pins 6 x
36 (21) from carrier pins 1
(20) for re-assembling.
When carrier pin 1 (20) or
planetary gear 1 (17) is
needed to be exchanged,
three pins or three gears
should be all exchanged.
j) Disassembling carrier 2
ASSY
When carrier pins 2 (13) are to
be re-used, mark each pin with
its mated hole of carrier 2 (9)
to assure the same combina-
tion as before.
[1] Knock spring pins 10 x 50
(14) fully into carrier pins 2
(13).
[2] Tap carrier pins 2 (13) out
from carrier 2 (9).
[3] Remove thrust washers 2
(11), planetary gears 2 (10)
and needle bearings (12).
Take great care not to
pinch your hand between
gears and carrier 2 (9)
while disassembling.
[4] Knock out spring pins 10 x
50 (14) from carrier pins 2
(13) for re-assembling.
When carrier pin 2 (13) or
planetary gear 2 (10) is
needed to be exchanged,
three pins or three gears
should be all exchanged.
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(3)ASSEMBLY
1) GENERAL INSTRUCTIONS
[1] Clean every part by kerosene and dry them by air blow. Surfaces to be applied by Loctite
must be degreased by solvent.
[2] Check every parts for any abnormals.
[3] Each Hex. socket head bolt should be used with Loctite #242 applied on its threads.
[4] Apply gear oil slightly on each part before assembling.
[5] Remove the refuse of Loctite #242 in thread holes by tap and degrease by solvent.
[6] Take great care not to pinch your hand between parts while assembling nor let fall parts
on your foot while lifting them.
2) ASSEMBLING PROCEDURES
a) Assembling carrier 2 ASSY
[1] Install planetary gears 2
(10), needle bearings (12)
and thrust washer 2 (11)
into carrier 2 (9).
Take great care not to
pinch your hand between
gears and carrier 2 (9)
while assembling.
Install carrier pins 2 (13)
into carrier 2 (9) where the
holes for spring pins 10 x
50 (14) are to be in line
with those of carrier 2 (9).
Install spring pins 10 x 50
(14) into carrier 2 (9) and at
the same time into carrier
pins 2 (13).
(Sink spring pins of 1 - 2
mm from surface)
Calk carrier 2 (9) on diago-
nally position to prevent spring pin 10 x 50 (14) from coming out.
Refer to Fig.15 "Detail of
calking".
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i) Installing cover
Gear oil can be filled before installing cover (24) if you can measure prescribed volume
of oil.
[1] Apply Loctite #515 on mating surfaces of
cover (24) and ring gear (3) and install
cover (24) on ring gear (3).
Take great care not to pinch your hand
between parts while assembling nor let
fall parts on your foot while lifting them.
[2] After applying Loctite #242 on the
threads of 18 pieces of Hex. socket head
bolts M10 x 30 (25), tighten them with
torque wrench.
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3. Maintenance
(1) PREPARATION PRIOR TO ASSEMBLING
a) Thrust washer
[1] Check if there are seizure, abnormal wear or uneven wear.
[2] Check if the wear is over the allowable limit.
b) Gears
[1] Check if there are pitting or seizure on the tooth surface.
[2] Check if there are clacks on the root of tooth by die check.
c) Bearings
Rotate by hand to see if there are something unusual such as noise or uneven rotation.
d) Floating seal
Check flaw or score on sliding surfaces or on O-rings.
(2) PARTS MAINTENANCE
The followings are the general maintenance standards. However, it is most important to deter-
mine which parts should be replaced, depending on the characteristics shown before disassem-
bling, damages or discoloration of exterior view, the purpose of disassembling, the expected
remaining service life etc..
The parts applying maintenance standards
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TIGHTNING TORQUE
ITEM DESCRIPTION SIZE
(N-m)
402 ± 39.2
(4) Hex. socket head bolt M18x110
(with applying Loctite #242)
68.6 ± 6.8
(25) Hex. socket head bolt M10x30
(with applying Loctite #242)
(26) Taper plug G3/4 147 ± 14.7
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Introduction Page No. 1/ 1
Second Edition:01/2002
Introduction SH330SH700SH225SH800SH450
Introduction
Introduction
Appropriate operations, maintenance, inspections, troubleshooting, and repair of the machine are vital to
keep it performing at its best and for the longest possible period of time, and to prevent it from breaking
down.
This document includes a General Outline, Specifications (Performance), Troubleshooting and Disas-
sembly/maintenance instructions, which are necessary for inspection, troubleshooting and repair of the
machine.
(Note: This Shop Manual is to be filed with the additional information to be added later.)
For details of the engine, refer to the maintenance manual published by the engine manufacturer.
For daily inspections and maintenance, see the Operator's Manual to take advantage of the machine's full
performance.
Numerical values or others may be changed without notice due to design alterations or other reasons.
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Swing Unit SH330
Swing Unit
Motor Maintenance
1. Troubleshooting
Described below are measures to be taken when any abnormalities or malfunctions are found while
the hydraulic motor is used.
Details on disassembling/inspection and reassembling are also described later but careful handling
is absolutely needed to avoid any damage to the sliding parts of the motor while conducting these
procedures.
Table 1
Symptom Cause Exterior inspection Remedy Repairs
Motor's internal Measure drain output. If motor supply input is equal See Table 2.
breakage to the drain output, there is
high possibility of breakage
in sliding section. Disassem-
bling/inspection is required.
Motor's internal Open the inlet and outlet If the output shaft does not Replace damaged
breakage ports on the motor and apply rotate smoothly with the parts or motor as-
Does not
pilot pressure of 2.9 to 4.9 torque stated to the left, there sembly.
rotate
MPa to the brake relief port. is high possibility of internal
Then attempt to rotate the breakage. Disassembling/in-
output shaft with torque of 30 spection is required.
to 40 N ・ m.
Incorrect settings Measure load pressure with Reset to specified set pres-
at relief valve in pressure gauge. sure.
the circuit
Wear or damage Measure drain output. If the drain output is more See Table 2.
in the sliding part than 2.5 L / min., the leakage
of the motor and in is too high. Disassembling/in-
the high pressure spection is required.
Excessive seal section
slippage Oil temperature is Measure oil temperature. Lower the oil temperature.
too high and there
is excessive inter-
nal leakage inside
the motor
Wear or seizure of Open the inlet and outlet If the output shaft does not Inspect parts (a) to
the motor sliding ports on the motor and apply rotate smoothly with the (e) listed in Table
section pilot pressure of 2.9 to 4.9 torque stated to the left, there 2, and also the
Lack of MPa to the brake relief port. is high possibility of internal bearings. Change
torque Then attempt to rotate the breakage. Disassembling/in- them if any abnor-
Abnormal output shaft with a torque of spection is required. mality is found.
noises approx. 30 to 40 N ・ m.
Incorrect settings Measure load pressure with Reset to specified set pres-
at relief valve in pressure gauge. sure.
the circuit
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Table 2
Letter Parts to be inspected Repairs
a Wear in the sliding part of balance plate (24) Repair or replace parts.
b Damage in the sliding section of the cam plate (7) Repair parts or replace the motor.
c Damage in the sliding section of the piston assembly (9) Repair parts or replace the motor.
d Wear in piston outer diameter of the piston assembly (9) Repair parts or replace the motor.
e Wear in piston hole of the cylinder (27) Replace motor.
f Damage in Teflon ring (17) Replace parts.
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Piston diameter Almost no wear. If scratches or seizure are found, replace with new
ones.
Table 2
Part name Inspection and Maintenance Reference
Replace bearings with new ones every 3,000 hours even if they function normally.
Taper roller bearing (4)
Additionally, always replace bearings when reassembling, even if it's within 3,000
Needle bearing (25)
hours.
If damage is found on the lip, replace it with a new one.
Additionally, replace seals with new ones every 3,000 hours even if they function
Oil seal (3) normally with no leaking.
Additionally, always replace seals when reassembling, even if it's within 3,000
hours.
If damage is found on O-ring, replace it with a new one.
Additionally, replace rings with new ones every 3,000 hours even if they function
O-rings (12), (14), (20), (31),
normally with no leaking.
(32), (33) and (38)
Additionally, always replace rings when reassembling, even if it's within 3,000
hours.
Backup rings (30) and (34) Always replace rings when reassembling.
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3. Disassembling Instructions
(1) Removing relief assembly and others
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Loosen the socket head bolts (40) (WAF 17) and re-
move the cover (19) by lifting it while placing it with
the motor output shaft facing downward.
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(5)Removing O-rings
(6)Removing bushings
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(7)Removing springs
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Grasp the end part of the cylinder (27) and draw out
the cylinder assembly from the housing (28).
Special attention should be taken not to drop
the cylinder (27). It will be slippery with oil.
At this stage, only the outer ring of the taper
roller bearing (4) and the oil seal (3) remain in
the housing (28).
Protect the end section (A) of the cylinder
(27) with a soft cloth or equivalent to avoid
scratches on its sliding surface.
Place counter marks or numbers on the pis-
ton hole and piston assemblies (9) of the cyl-
inder (27) so that the piston assemblies can
be reassembled into the same original hole.
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2)
3)
Take out the cam plate (7) by sliding it on the
sliding surface of the piston assemblies (9).
Careful handling is required to prevent dam-
age to the sliding surfaces on the cam plate (7)
and piston assemblies (9).
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4)
Withdraw the backing spring (6) from the cylinder
(27).
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4. Assembling Instructions
(1) Preparations
1)
2)
3)
4)
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2)
3)
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4)
5)
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6)
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Press fit the inner ring for the needle bearing (25)
onto the cover (19) and install the snap ring (26).
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(12)Installing O-rings
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(14)Installing covers
(15)Tightening bolts
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29
44 42
(17)Verifying installation
Open the entry and exit ports and apply pilot pres-
sure of 2.9 to 4.9 MPa to the brake relief port.
Then make sure that the output shaft can be
smoothly rotated, one turn or more, with torque of
30 to 40 N ・ m. If it does not rotate properly, it is
suspected that assembly is not completed cor-
rectly. Disassemble once again and readjust it.
Make sure that drain port is released.
Now the assembling procedure has been com-
pleted.
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Press fitting jig for inner ring (2) and taper roller bearing (4)
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Seal protector
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Swing Unit SH330
Swing Unit
[5] Crimp by opening the end of planetary pin (No. 1) (27) with crimping jig (Photo 4) (Photo
5).
Crimping may produce string-like chips. Eliminate all if this happens.
[6] Rotate planetary gear No. 1 (26) manually to check again that there is no engagement
or rotational irregularity. If found, reassemble using new parts (Photo 6).
PHOTO 4 PHOTO 5 PHOTO 6
Repeat steps (1) through (6) above on other 3 locations to finish the procedure.
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[3] Ensure that the spring pin insertion holes on planetary carrier No. 2 (29) and planetary
pin No. 2 (31) are aligned. Drive the spring pin (10x40) (33) with the jig (see Photo 9),
monitoring the orientation (marked surface upward) and the depth (1 mm). After the pin
is driven in, crimp by deforming the spring pin hole: hammer approx. 1 mm from the
spring pin hole using a punch (See Photo 10).
[4] Rotate planetary gear No. 2 (30) manually to check there is no engagement or rotational
irregularity (See Photo 11). If found, refer to 2. Disassembling Carrier No. 2 Subassem-
bly (Page 8/10) to first disassemble, then reassemble according to the instructions in 1-
2 on this page.
A new spring pin (33) must be used in reassembly. (Reusing the spring pin that has gone
through disassembly may reduce the holding force which could lead to breakage.)
PHOTO 9 PHOTO 10 PHOTO 11
Repeat steps (1) through (4) above on other 4 locations to finish the procedure.
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[5] Once the temperature of the roller bearing (16) reaches the outside air temperature
range, apply grease (KHP1406) to the inside of roller bearing (16) (Photo 15).
[6] Watch the upward/downward orientation and insert the bearing cover (17) (Photo 16).
[7] Remove pipe spacer (19) from the bearing heater and insert observing the upward/
downward orientation (Photo 16).
[8] Once the temperature of the pipe spacer (19) reaches the outside air temperature range,
turn over and apply grease to the inside of the roller bearing (16) (Photo 15). Add an ad-
ditional mound of grease as well (Photo 17).
PHOTO 15 PHOTO 16 PHOTO 17
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[4] Turn over the case subassembly and place on the jig. Use caution to prevent the shaft
end from hitting the ground. (It may cause the shaft to fall out.)
[5] Apply liquid packing (KSC0189: ThreeBond 1208B) (13) (Photo 20) to the outer circum-
ference of the oil seal (12). Then, press fit using the jig. Apply a thin coat of lithium grease
to lubricate the lip seal and press fit carefully to avoid damage to the lips (Photo 21).
PHOTO 20 PHOTO 21
[6] Watch the upward/downward orientation and insert the pipe spacer (10) (Photo 22).
PHOTO 22
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[7] Press fit roller bearing (9) onto gear case (8) using a jig (Photo 23).
[8] Punch the knock pins (7) on 4 locations (Photo 24).
[9] Degrease the end surface of gear case (8) and apply a uniform coat of liquid packing
(KTH0086: ThreeBond 1215) (22) (Photo 24).
PHOTO 23 PHOTO 24
[10] Watch the upward/downward orientation, as well as the knock pins (7) positions, and in-
stall the ring gear (6). Fasten with 3 jig bolts (M20x200, hexagon socket head bolts) and
3 spacers (outer dia. = 27.2, inner dia. = 21.6, height = 20) (Photo 25).
[11] Screw the plugs with nylon seals (11), (14) onto the drain port on the gear case (8) side
(Photo 26).
PHOTO 25 PHOTO 26
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[4] Insert the thrust plate (2) into the sun gear No.2 (5) on the end surface (Photo 29).
[5] Insert the carrier No. 1 subassembly (1-1) (Photo 30).
PHOTO 29 PHOTO 30
[6] Watch the upward/downward orientation and insert the sun gear No. 1 (1) carefully (Photo
31).
PHOTO 31
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[7] Make sure that the distance between the end surface of the sun gear No.1 (1) and the ring
gear (6) is 1.04 to 3.70 mm [i.e. (1) is lower than (6)] (Photo 32). If the distance falls short of
reaching 1.04 mm:
• Gear shaft (20) and the roller bearing (16) are dislocated.
• The roller bearing (9) is not inserted completely.
• Foreign substances are engaged.
If the distance is larger than 3.70 mm:
• The wire (18) is not installed properly.
• The ring gear (6) is not completely tightened into the gear case (8).
• Foreign substances are engaged.
Consider the above and conduct disassembly/assembly again (Photo 32).
[8] Remove the jig bolts and spacers used during the assembly of the case subassembly (1-4).
Degrease the end surface of the ring gear (6) and apply a uniform coat of liquid packing
(KTF0086 ThreeBond 1215) (22) (Photo 33).
PHOTO 32 PHOTO 33
[9] Install the swing motor. Then degrease the thread of the hexagon socket head bolts
M20x200 (23) first, and apply liquid packing (KSC0188:ThreeBond 1360K) (24). Tighten 12
locations by applying the torque of 568.4 to 649.7 N.m (Photo 34 and Photo 35).
PHOTO 34 PHOTO 35
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Disassembling Instructions
1. Disassembling the swing reduction gears
The procedures in this section are basically the reverse of those described in 2. Assembling the
Swing Reduction Gears. Refer to 2. Assembling the Swing Reduction Gears (Page 6/10) for the dis-
assembly of swing reduction gear.
[1] Remove the plug with nylon seal (11) and drain the gear oil.
[2] Remove all hexagon socket head bolts (M20 x200) (23) (Photo 35).
[3] Use a crane to gradually lift and remove the swing motor.
[4] Remove the sun gear No. 1 (1) and the carrier No. 1 subassembly (1-1) (Photo 31 and Photo 30).
[5] Use the lifting taps (M10, 2 locations) on planetary carrier No. 2 (29) to slowly lift and remove the
carrier No. 2 subassembly (1-2) (Photo 27).
[6] Remove the sun gear No. 2 (5), which is remaining on the shaft.
2. Disassembling the carrier No. 1 subassembly
The disassembly of this component is not possible due to the fact that it is crimped.
3. Disassembling the carrier No. 2 subassembly
[1] Use the jig and press the spring pin (33) (10x40) securely into the planetary carrier No. 2 (29).
Use caution and avoid applying excessive force to prevent the planetary carrier No. 2 (29) pin
hole bore from getting damaged.
[2] Gently tap through the casting hole at the bottom of planetary carrier No. 2 (29) and remove the
planetary pin No. 2 (31). Use caution to prevent the planetary gear No. 2 (30) and the side plate
No. 2 (32) from falling off.
[3] Draw out the spring pin (33) through the spring pin hole of planetary pin No. 2 (31). If it is neces-
sary to use a vise on the planetary pin No. 2 (31), use cloth, etc. to avoid damage to the pin.
[4] Repeat Steps (1) through (3) on the four locations.
4. Disassembling the case subassembly
[1] Turn over the case subassembly.
[2] Remove the wire (18).
[3] Use the lifting tap holes (M16, 2 locations) on the gear shaft (20) end and draw out the shaft sub-
assembly (1-3).
5. Disassembling the shaft subassembly
The component is not intended for disassembly.
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KSC0252Z-C00
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KSC0245X-B00
KSC0246X-B00
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Control Valve SH330
Control Valve
Maintenance Instructions
1. Disassembly
(1) Disassembly Precautions
[1] Stop the engine after the pressure in the actuator has been released. Otherwise, it is very
dangerous because highly pressurized oil may erupt or parts may abruptly pop out. When
the valves are partially disassembled while they are still attached to the main body, the fol-
lowing special precaution should be taken:
If disassembly of the short cap assembly is attempted with insufficient pressure release or
the bucket not firmly placed on the ground, the poppet will pop out and the bucket will drop
at the same time, which causes a very dangerous situation. Therefore, place the bucket firm-
ly on the ground and release pressure completely before disassembling.
[2] Release air pressure in the tank.
[3] Clean well areas neighboring the location to be disassembled and take caution to prevent
foreign substances from entering into the valves while disassembling.
[4] Put tags on the disassembled parts to easily identify the assembly locations.
[5] Replace all disassembled seals (O-rings, backup rings) with new ones.
[6] Do not change spools because they are selectively matched with their valve housings.
(2) Disassembly Procedure (See the Service Parts List for reference numbers.)
1) Disassembling the main spool section
[1] Loosen and remove the socket head bolts (74: 2 locations for each section, width across
flats, 8) on the caps (8: 8 locations) and caps (9: 2 locations).
[2] As necessary, loosen and remove the plug assembly (73: width across flats, 6) and plug
(91: width across flats, 19).
[3] Remove O-ring (7: one location for each section) from the valve housings (1), (13).
[4] Pull out each spool from the valve housing as a subassembly.
1. Be careful not to cause any dents or scratches while pulling out the spool.
2. Place tags on each spool to easily identify the locations when assembling.
[5] Loosen and remove the socket head bolts (74: 2 locations for each section, width across
flats, 8) on the caps (10: 3 locations) and caps (12: 7 locations).
[6] As necessary, loosen and remove the plug assembly (73: width across flats, 6).
[7] Remove O-rings (7: one location for each section) from the valve housings (1), (13).
[8] Disassemble the spool assembly
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1) Loosen the spool ends (width across flats, 8) in the spool assemblies (2 to 6), (14 to
17) to disassemble the spring seats and springs.
2) Poppets, springs and plugs are integrated into the spool within the assemblies (3),
(14). Do not disassemble them unless it is necessary.
If it is necessary to disassemble them, heat the spool peripheral and break down the
adhesive around the threaded section to remove the plug.
When assembling, always replace O-rings and backup rings with new ones.
2) Disassembling the arm 1 parallel tandem spool section
[1] Loosen and remove the socket head bolts (78: width across flats, 5) on the cap (18).
[2] Remove O-ring (23) from the cap (18).
[3] Pull out the spool (19) from the valve housing as a subassembly.
[4] Disassemble the spool assembly
1. Use blocks (see the drawing on the previous page) to fasten the spool between them with a vise
in order to avoid damage to the periphery of the spool.
2. Use an industrial dryer and heat spool peripheral to break down the adhesive, which is applied
around the threaded part of the spool end.
3. The heating temperature should be 200 to 250×C. Heat until the spool end becomes loose
enough to remove immediately after heating.
4. If overheated, replace the spring with a new one.
1) Loosen the spool end (22: width across flats, 5) in the spool (19) and disassemble
the spring seats (20) and spring (21).
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3) Disassembling the arm regenerative relief valve (for a subassembly contained in the as-
sembly, it is expressed as assembly No. - subassembly No.)
1. Danger! Parts can pop out due to unreleased internal pressure when removing plugs.
2. Loosen plugs slowly and make sure that there is no resistance due to unreleased pressure.
Then, start disassembling.
[1] Loosen and remove the plug (24: width across flats, 32), and then, remove O-ring (25).
[2] Pull out spring (26) and spool (27-1) from the sleeve (27-2).
[3] Pull out the sleeve (27-2) from the valve housing.
[4] Remove the piston (27-3), O-ring (30) and backup ring (31) from the sleeve (27-2).
1. Danger! Parts can pop out due to unreleased internal pressure when removing plugs.
2. Loosen plugs slowly and make sure that there is no resistance due to unreleased pressure.
Then, start disassembling.
[1] Loosen and remove the socket head bolts (75: 4 locations for each section, width across
flats, 8) on the flanges (37: 8 locations).
[2] Remove the spring (35), poppet (34) [poppet (51)] and O-ring (36) from the valve hous-
ing.
Note: Please note that there is no poppet or spring in the straight travel valve section
(Section H-H).
[3] Loosen and remove the socket head bolts (75: width across flats, 8) on the flanges (52:
2 locations).
[4] Remove the spacer (53) from the valve housing and remove the O-ring (54) and backup
ring (55) from the spacer (53).
[5] Remove the spring (35) and poppet (34) from the valve housing.
[6] Loosen and remove the plug (72: width across flats, 8). (Section C-C)
[7] Remove the spring (33) and poppet (32) from the valve housing.
[8] Loosen and remove the plug (72: width across flats, 8). (Section L-L)
[9] Remove the spacer (57), spring (33) and poppet (32) from the valve housing.
[10] Loosen and remove the plug (92: width across flats, 36). (Section G-G)
[11] Loosen and remove the socket head bolts (96: 4 locations, width across flats, 8) on the
flange (43).
[12] Remove the spring (45), poppet (44) and O-ring (36) from the valve housing.
[13] Loosen and remove the plug (46: width across flats, 27) and O-ring (47).
[14] Remove the spring (48) and poppet (49) from the valve housing.
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5) Disassembling the anti-drift valve section (for a subassembly contained in the assembly,
it is expressed as assembly No. - subassembly No.)
1. Danger! Parts such as seals can pop out due to unreleased internal pressure when removing
anti-drift valve assemblies.
2. Loosen socket head bolts slowly and make sure that there is no resistance due to unreleased
pressure. Then, start disassembling.
[1] Loosen and remove the socket head bolts (76: 4 locations for each section, width across
flats, 8) on the anti-drift valve assembly (67: 2 locations).
[2] Remove the O-rings (41), (42) from the valve housing, and remove the O-ring (40-4)
from the spacer assembly.
[3] Screw the socket head bolt (78: M6 x 1) into the spacer and remove the space assembly
(40) from the valve housing.
[4] Remove the O-ring (40-2) and backup ring (40-3).
[5] Remove the spring (39) and poppet (38) from the valve housing.
[6] Disassemble the anti-drift assembly
1. Danger! Parts can pop out due to unreleased internal pressure when internal parts of the anti-
drift valve are disassembled while the valve is attached to the valve housing.
2. Loosen the plug assembly (67-14) and plug (67-3) slowly and make sure that there is no resis-
tance due to unreleased pressure. Then, start disassembling.
1) Loosen and remove the plug assembly (67-14: width across flats, 38) and remove
the O-ring.
2) Remove the piston (67-4), spool (67-5) and spring (67-7).
3) Loosen and remove the plug (67-3: width across flats, 38) and remove the O-ring
(67-13).
4) Remove the sleeve (67-6) and poppet (67-2) from the body, and remove the O-rings
(67-9 and 10) and backup rings (67-11 and 12) on the sleeve peripheral.
5) Take out the spring seat (67-16) and spring (67-8) from the bottom of the hole.
6) As necessary, loosen and remove the plug assembly (67-15: width across flats, 5).
Note: Do not disassemble the steel balls (67-17) because they are press-fitted into
the body.
6) Disassembling the relief valve
1. Loosen and remove the plug on the main body mounting section when removing the relief valve.
2. Do not loosen the plug or lock nut for adjusting the set pressure.
3. Danger! If the plug for adjusting the set pressure rotates, the set pressure changes.
[1] Loosen and remove the overload relief valves (69: 6 locations, width across flats, 32).
[2] Loosen and remove the main relief valve (68: width across flats, 32).
[3] Loosen and remove the relief valve assembly (70: 2 locations, width across flats, 32) and
remove the O-rings (70-5 and 6).
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2. Cleaning
Clean all disassembled parts completely with clean mineral oil.
Dry them with compressed air and place each part on a clean paper or vinyl sheet for inspection.
3. Inspection
Inspect all surfaces of each part for burrs, scratches, dents or other damage.
[1] Check for scratches or cuts on the surface of the load check sheet in the valve housing and make
sure there are no dents, dirt or rust. If scratches are small, remove them with an oilstone.
[2] Ensure that there are no scratches, dents or other damage on spool peripheral. If scratches are
small, remove them with an oilstone.
[3] All sliding parts should move smoothly.
Additionally, there should be no foreign substances in any grooves or passages.
[4] Any broken, extremely deformed or worn springs should be replaced with new ones.
[5] If the relief valve malfunctions, inspect it following the maintenance instructions in Relief Valve.
[6] All O-rings and backup rings attached to the disassembled parts should be replaced with new
ones.
[7] Make sure that there are no remaining paint pieces around holes on the body and plug seats.
(Paint pieces inside the valve can cause engagement and blockage and lead to malfunctions and
oil leakage.)
4. Assembly
1. Assembly Precautions
(1) Precautions for handling O-rings
[1] Do not use O-rings that have been deformed/defective or damaged while handling.
[2] For sufficient lubrication, apply grease or hydraulic oil to O-rings and O-ring fitting sur-
faces to facilitate smooth attachment.
[3] Do not expand O-rings to the extent that they deform permanently.
[4] When inserting O-rings, do not place them by rolling. (Distorted O-rings cannot be re-
covered by themselves after insertion, and this could cause oil leakage.)
(2) Precautions for handling spools
[1] Always observe specified torque. Applying excessive torque to threaded parts can
cause spool malfunctions.
[2] Be careful that each spool, spring and spool end are installed exactly the same way as
before disassembly.
(3) How to apply adhesive (male and female sections of the part where adhesion is nec-
essary)
[1] Cleaning (degreasing)
Clean by vapor degreasing using acetate or ether or clean with alkali washing agent.
[2] Drying
Dry the adhesion surfaces by blowing clean air or natural drying.
Insufficient drying lowers adhesive effects.
[3] Primer application
Lightly spray a hardening accelerator, "Loctite Primer T" onto the adhesive surfaces
and leave for at least 3 to 5 minutes to dry.
[4] Applying adhesive
Apply a small portion of adhesive (Loctite No. 271 or equivalent) to 2 or 3 threads of the
entry part in the spool female screw.
At this time, be careful to mount it so that the applied part does not touch the spring
sheet.
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1. Do not apply too much adhesive. Be careful not to allow the adhesive to enter the inside of the
parts.
2. Do not apply torque exceeding specified value. Doing so may cause poor spool operation.
3. Pay special attention. Two types of springs are used.
(2) Assembling the arm 1 parallel tandem spool assembly
[1] Apply adhesive to the threaded part of the spool (19) and install the spring sheet (20),
spring (21) and spool end (22).
[2] Hold the spool between the blocks (used in the disassembly procedure) and fasten
them with a vise and tighten the spool end with specified torque. Torque value: 19 to
22 N ・ m.
1. Do not apply too much adhesive. Be careful not to allow the adhesive to enter the inside of the
parts.
2. Do not apply torque exceeding specified value. Doing so may cause poor spool operation.
(3) Assembling the anti-drift valve assembly
[1] Install the O-rings (67-9 and10) and backup rings (67-11 and 12) onto the peripheral
grooves of the sleeve (67-6).
1. Pay attention to the installing positions of the O-ring and backup ring.
2. Reversed positions can cause O-ring breakage and lead to a larger natural drop of the actuator.
[2] Insert the poppet (67-2) and spool (67-5) into the sleeve hole.
[3] Install the spring sheet (67-16) in the smaller diameter part of the poppet end, and
place the spring (67-8) on them. Insert them all together with a sleeve into the body
(67-1).
Apply grease to the seat before installing so that the spring and spring sheet can be firmly placed
on the seat.
[4] Install the spring (67-7) and piston (67-4) onto the plug (67-3).
[5] Fasten the plug assembly (67-14) attached with O-ring onto the plug (67-3).
Torque value: 147 to 157 N ・ m.
[6] Fasten the plug (67-3) attached with O-ring (67-13) onto the body (67-1).
Torque value: 147 to 157 N ・ m.
[7] Fasten the plug assembly (67-15) attached with O-ring onto the body (67-1).
Torque value: 14 to 18 N ・ m.
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1. Always fasten the plug on the main body mounting section when installing relief valves.
2. Do not fasten the plug and lock nut for adjusting the set pressure.
3. Danger! If the plug for adjusting the set pressure rotates, the set pressure changes.
[1] Screw and fasten the main relief valve (68).
Torque value: 78 to 88 N ・ m.
[2] Screw and fasten the overload relief valves (69: 6 locations) into each section.
Torque value: 78 to 88 N ・ m.
[3] Screw and fasten the relief valve assembly (70: 2 locations) attached with O-rings.
Torque value: 103 to 113 N ・ m.
(2) Assembling the load check valve
[1] Attach O-rings (36) to Arm 1 and 2 (Section D - D), Boom 1 and 2 (Section E - E), Swing
and Bucket (Section F - F) sections, and install the poppet (34) and spring (35) onto
them.
Place the flange (37) and fasten with socket head bolts (75).
Torque value: 58 to 64 N ・ m.
[2] Attach O-ring (36) to Travel section (Section H - H), and install the poppet (51) and
spring (35) onto it.
Place the flange (37) and fasten with socket head bolts (75).
Torque value: 58 to 64 N ・ m.
[3] Attach O-ring (36) to Straight Travel section (Section H - H), and fasten the flange (37)
with socket head bolts (75).
Torque value: 58 to 64 N ・ m.
[4] Install the poppet (34) and spring (35) to Common section (Section I - I), and insert the
spacer (53) attached with O-ring (54) and backup ring (55).
Fasten the flange (52) with socket head bolts (75).
Torque value: 39 to 44 N ・ m.
1. Pay attention to the installing positions of the O-ring and backup ring.
2. Reversed positions can cause O-ring breakage and lead to an external oil leakage.
[5] Attach O-ring to the backup section (Section G - G) and install the poppet (44) and
spring (45).
Place the flange (43) and fasten them with socket head bolts (96).
Torque value: 58 to 64 N ・ m.
Screw and fasten the plug assembly (92) attached with O-ring.
Torque value: 205 to 227 N ・ m.
[6] Install the poppet (49) and spring (48) onto Travel section (Section G - G).
Screw and fasten the plug (46) attached with O-ring (47).
Torque value: 107 to 117 N ・ m.
[7] Install the poppet (32) and spring (33) onto Arm 1 parallel tandem section (Section C -
C).
Screw and fasten the plug assembly (72) attached with O-ring.
Torque value: 73 to 79 N ・ m.
[8] Install the poppet (32), spring (33) and spacer (57) onto Arm 2 parallel tandem section
(Section L - L).
Screw and fasten the plug assembly (72) attached with O-ring.
Torque value: 73 to 79 N ・ m.
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1. Pay attention to the installing positions of the O-ring and backup ring.
2. Reversed positions can cause O-ring breakage and lead to an external oil leakage.
3. Make sure that O-ring (40-4) is attached onto the spacer assembly and it is installed in the cor-
rect direction.
[3] Install the anti-drift valve assemblies (67: 2 locations) and fasten them with socket
head bolts (76).
Torque value: 39 to 44 N ・ m.
(4) Assembling the auxiliary section
[1] Install the caps (88: 2 locations) attached with O-ring (89) and fasten them with socket
head bolts (75).
Torque value: 58 to 64 N ・ m.
[2] Screw and fasten the plug assemblies (87: 2 locations) attached with O-ring and back-
up ring.
Torque value: 78 to 88 N ・ m.
(5) Assembling the arm regenerative relief valve
[1] Install the O-rings (30) and backup rings (31: 2 locations) onto the sleeve (28).
[2] Install the piston (29) and spool (27) onto the sleeve and insert them into the valve
housing.
[3] Place the spring (26) inside the plug (24) attached with O-ring (25) and screw and fas-
ten them into the valve housing.
Torque value: 103 to 113 N ・ m.
(6) Assembling the arm 1 parallel tandem spool
[1] Install the spool (19) as a subassembly into the valve housing.
After inserting the spool, make sure that there is no roughness or sticking by sliding the spool.
[2] Place the cap (18) attached with O-ring (23) and fasten them with socket head bolts
(78).
Torque value: 8.8 to 10.8 N ・ m.
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1. Install the spool slowly with its direction aligned straight to the hole.
2. After inserting spool, make sure that there is no roughness or sticking by sliding the spool.
3. If the spool is inserted when there is roughness or sticking, the spool can malfunction.
[3] Install the caps (10: 3 locations) and caps (12: 7 locations) and fasten them with socket
head bolts (74).
Torque value: 39 to 44 N ・ m.
[4] Install the caps (8: 8 locations) and caps (9: 2 locations) and fasten them with socket
head bolts (74).
Torque value: 39 to 44 N ・ m.
[5] Screw and fasten the plug assembly (73) attached with O-ring onto the long caps of
Boom 2 (Section E - E) and Straight Travel (Section H - H) sections.
Torque value: 19 to 22 N ・ m.
[6] Screw and fasten the plug assembly (73) attached with O-ring onto the short caps of
Backup (Section G - G) and Straight Travel (Section H - H) sections.
Torque value: 19 to 22 N ・ m.
[7] Screw and fasten the plug (91) attached with O-ring onto the long cap of Backup (Sec-
tion G - G) section.
Torque value: 19 to 22 N ・ m.
1. Be careful and do not apply excessive torque when fastening the cap onto the plug.
2. Excessive torque may destroy the threaded part of the cap.
(8) Assembling other plugs
[1] Screw and fasten the plug assembly (60) attached with O-ring.
Torque value: 103 - 113 N ・ m.
[2] Screw and fasten the plug (61) attached with O-ring (62).
Torque value: 39 to 44 N ・ m.
[3] Screw and fasten the orifice plug (63).
Torque value: 14 to 18 N ・ m.
[4] Screw and fasten the plug assembly (92) attached with O-ring.
Torque value: 205 to 227 N ・ m.
[5] Screw and fasten the plug assembly (72) attached with O-ring.
Torque value: 73 to 79 N ・ m.
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Relief Valve
1. Instructions for Disassembling and Assembling the Relief Valve
(1) Disassembly
This product has to be replaced as an assembly.
When replacing, loosen the plug (1: width across flats, 32) with spanners, and remove O-ring (2).
If oil leakage from the nut (4) is found, loosen the nut (4) and plug (1) and replace O-ring (3).
If oil leakage from the nut (7) is found, loosen the nut (7) and plug (8) and replace O-ring (5).
(2) Assembly
Make sure that there are no dirt and paint pieces around the threaded part of the plugs (1, 6 and
8) and nuts (4 and 7) before installing new O-rings.
Also clean the relief valve fitting section sufficiently. Then, install the relief valve and fasten the
plug (1: width across flats: 32).
Torque value: 78 to 88 N ・ cm.
If the adjuster kit was disassembled, adjust the pressure following the instructions in section 4.
Adjusting the relief valve.
The specified tightening torque values are all for under wet conditions (with hydraulic oil applied).
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(1) Disassembly
This product has to be replaced as an assembly.
When replacing, loosen the cap (1: width across flats, 31.75) with spanners and remove O-ring
(2).
If oil leakage from the adjuster kit section (3) is found, loosen the adjuster kit to replace O-ring (4).
When disassembling the adjuster kit, pay attention to parts popping out caused by the spring and/
or the poppet being misplaced.
(2) Assembly
Make sure that there are no dirt and paint pieces around the threaded part of the cap (1) before
installing new O-rings (2).
Also clean sufficiently the relief valve attaching section on the valve housing. Then, install the
relief valve and fasten the cap (1: width across flats: 31.75).
Torque value: 78 to 88 N ・ m.
If the adjuster kit was disassembled, adjust the pressure following the instructions in section 4
Adjusting relief valve after cleaning sufficiently around the threaded section.
The specified tightening torque values are all for under wet conditions (with hydraulic oil applied).
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3. Instructions for Disassembling and Assembling the Low Pressure Relief Valve
(1) Disassembly
This product should be replaced as an assembly because it is press-fit at Section D. Do not try
to disassemble.
(2) Assembly
Make sure that there are no dirt and paint pieces around the threaded part of the plug (1) before
installing new O-ring (3).
Install new O-ring (4) onto the sleeve (2).
Clean sufficiently the relief-valve-attaching-section on the valve housing. Then, fasten the plug
(1) (width across flats: 32) of the relief valve assembly.
Torque value: 103 to 113 N ・ m.
The specified tightening torque values are all for under wet conditions (with hydraulic oil applied).
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[4] High pressure setting (one-step) (See the drawing on Page 11/32.)
1) Tighten the plug (8) until the piston hits the end face of the plug (6) (marked with *). Dur-
ing this procedure, tightening torque for plug (8) should be no greater than 19.6 N ・ m.
Ensure that the plug (6) will not be rotated when tightening the plug (8) (A dimension: 4
mm or greater).
2) Tighten the plug (6) under the conditions of step (a) and adjust the pressure. (Tighten
the plug (11) slowly observing the pressure gauge: 28.4 MPa of pressure increase per a
turn of the plug.)
After setting the pressure, lock the plug with hexagonal nut (4).
[5] Low pressure setting (two-step)
Loosen the plug (8) under the conditions described in 4. High pressure setting and adjust
the pressure.
(When the plug (8) is loosened, the piston moves to the right in the drawing, the spring load
decreases: 21.3 MPa of pressure decrease per a turn of the plug.)
After setting the pressure, lock the plug with hexagon nut (7).
[6] Once again, by increasing the pressure, make sure that the specified pressure is gained.
If the set pressure on the overload relief valve is higher than one on the main relief valve, do not
adjust the overload relief valve. Replace it with a preset relief valve as an assembly.
[1] Switch over the spool in the control valve. Read the value on the pressure gauge when the
cylinder is at the end of the stroke.
[2] Turn the adjuster clockwise until the required pressure is obtained.
Reference no. 69, 6 locations in total: 21.2 MPa of pressure increase per a turn of the adjust-
er.
[3] When the specified pressure is reached, press the adjuster to prevent its turning and tighten
the lock nut.
Torque value: 27.5 to 31.4 N ・ m.
[4] Once again, by increasing the pressure, make sure that the specified pressure is gained.
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Installation
[1] Ensure that piping does not give any extra external load on the valve.
[2] Tighten all the mounting bolts uniformly.
[3] Welding should not be carried out too close to the valve. Otherwise, the seals can be damaged by
excessive heat or spatter.
[4] To prevent dirt from entering, keep the curing materials on until the piping is conducted.
Operation
[1] Before operating the machine, ensure that the hydraulic circuit and hydraulic oil are clean.
[2] For oil, use hydraulic fluid designed for oil pressure whose aniline point is between 82 and 113×C.
[3] Do not increase the relief valve pressure more than the specified set pressure.
[4] The set pressure difference between main relief valve and overload relief valve should be 2.0 MPa
or more.
[5] Idle the machine sufficiently before starting the work.
In particular, in order to prevent sticking caused by spool's heat shocks, it is necessary to take the
following precautions to start operating the machine when the temperatures of the hydraulic oil and
valve are low:
• Avoid a sudden continuous operation on the main relief valve and overload relief valve. Attempt
to increase the temperatures in each section uniformly by operating the machine to allow the hy-
draulic oil to circulate in each actuator.
• Fine operation or combined operation may cause partial heat in each orifice section. Do not per-
form these operations suddenly when it is cold.
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Troubleshooting
Control valve in general
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Relief valve
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Parts List
Item No. Part Name Qty. Item No. Part Name Qty.
1 Valve housing 1 35 Spring 9
2 Spool assembly (Arm 2) 1 36 O-ring 9
3 Spool assembly (Boom 1) 1 37 Flange 8
4 Spool assembly (Bucket) 1 38 Poppet 2
5 Spool assembly (Travel) 2 39 Spring 2
6 Spool assembly (Straight travel) 1 40 Spacer assembly 2
7 O-ring 20 41 O-ring 2
8 Cap 8 42 O-ring 2
9 Cap 2 43 Flange 1
10 Cap 3 44 Poppet 1
11 Number not used - 45 Spring 1
12 Cap 7 46 Plug 1
13 Valve housing 1 47 O-ring 1
14 Spool assembly (Arm 1) 1 48 Spring 1
15 Spool assembly (Boom 2) 1 49 Poppet 1
16 Spool assembly (Swing) 1 50 Number not used ―
17 Spool assembly (Backup) 1 51 Poppet 1
18 Cap 1 52 Flange 2
19 Spool 1 53 Spacer 2
20 Spring seat 2 54 O-ring 2
21 Spring 1 55 Backup ring 2
22 Spool end 1 56 Number not used ―
23 O-ring 1 57 Spacer 1
24 Plug 1 58 Number not used ―
25 O-ring 1 59 Number not used ―
26 Spring 1 60 Plug assembly 1
27 Spool assembly 1 61 Plug 1
28 Number not used ― 62 O-ring 1
29 Number not used ― 63 Orifice plug 1
30 O-ring 1 64 O-ring 1
31 Backup ring 2 65 O-ring 14
32 Poppet 2 66 O-ring 7
33 Spring 2 67 Anti-drift valve assembly 2
34 Poppet 8 68 Relief valve kit 1
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Service Parts
1. Reference No. 2: Spool Assembly
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Cylinder SH330
Cylinder
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Structural Drawings
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1. Boom Cylinder
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2. Arm Cylinder
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3. Bucket Cylinder
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Cylinder SH330
Cylinder
Maintenance Instructions
1. Description of Functions
(1) Basic functions
The hydraulic piston system is a kind of hydraulic actuator which converts hydraulic energy sup-
plied from the hydraulic pump into a larger force for linear movement via a piston. In addition, it
switches its operational direction between extension and retraction by way of lever operation on
the hydraulic oil direction switch-over valve.
This larger force, linear movement, and operational direction switching over are the basic func-
tions.
(2) Function by section
[1] Cylinder head assembly
The piston assembly has a bearing function for the piston rod (16) provided by means of
bushing (05) press fitted into the inside surface of cylinder head (17). It prevents external oil
leakage by means of a buffer ring (03), Rod packing (04) inserted into the inside surface of
cylinder head. It also prevents dust from the outside by means of a dust seal (02) press fitted
into the inside surface of the cylinder head.
Engaging with the plunger (12) at the cylinder's most extended position, it generates high
pressure in the cushion chamber and this softens the cylinder's impact at the most extended
position.
In addition, it also supplies and drains high-pressure oil from the inside of cylinder tube to the
ports.
Bushing (05)
The bushing is press fitted into the inner face of the cylinder head and is in contact with the
piston rod. It reduces eccentricity, which adversely affects the seal performance, by sharing
lateral load applied on the cylinder together with the slide ring located on the outer circumfer-
ence of the piston, performing high-bearing linear motion against the piston rod, as well as
supporting one end of the piston rod.
Buffer ring (03)
The buffer ring is located between the rod packing and bushing. It prolongs the life of the rod
packing, which is the main seal, by relieving high pressure with the auxiliary seal which is di-
rectly in contact with the high pressure oil in the cylinder, and reducing the load acting on the
rod packing.
Rod packing (04)
The rod packing is located between the dust seal and the buffer ring. The rod packing seals
the annular space formed between the piston rod and cylinder head against the pressure oil
between the rod packing and the backup ring. It also forms suitable oil films on the piston rod
to prevent rust.
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Screw (11)
Screw prevents the piston from turning.
Plunger (13)
It generates high pressure in the cushion chamber and this softens the cylinder's impact at
the most shorten position.
Ball (14)
Ball is an omission stop of plunger. Moreover, eccentric of plunger is prevented.
Cap (15)
Cap prevents the ball from coming off.
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4. Error Diagnosis
(1) Hydraulic cylinder errors and their remedy measures
It is not easy to locate faulty parts. General symptoms, possible reasons and remedy measures
are shown in the table below. For repairs, refer to the possible causes and remedy measures in
the table.
However, it is often the case that machine troubles occur because not only one part but many
other relating parts have problems.
Measures other than ones shown in the table may be required.
Item Symptom
1 Oil leakage on the sliding section of piston rod.
2 Oil leakage from cylinder head fitting section
3 Oil leakage from welded section between pipe and cylinder tube
4 Bad operation
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CAUTION
Hydraulic oil tends to expand and shrink according to changes in temperature and pressure. This also caus-
es cylinders to extend and retract; therefore, we sometimes see this as internal oil leakage. Check internal
oil leakage under given temperature and pressure conditions.
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5. Storage Standards
We take all possible measures at the time of shipping hydraulic cylinders. However, in order to avoid
trouble when storing them, please handle them following the precautions below.
(1) Storing one unit only (as a general rule, store indoors)
Avoid a place with high temperature and high humidity or a place where corrosive gas or liquid
is stored. Store the unit off the floor. To prevent condensation due to temperature difference, we
conduct inspections by using test oil with a given volume of volatile corrosion inhibitor, retract the
piston rod using super dry air (dew point 35×C), put caps when shipping.
Therefore, do not leave a cylinder with the cap removed or drain the remaining oil from the cyl-
inder without clear intention.
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4
7/32" (5.556) 3 5/16 DIA.
(7.938)
2
D3
/4
"(
19
.0
5)
1
3/32"
(2.381) MIN.2" - MAX.6"
(50.8 - 152.4)
ELEMENT
No Item Name Qty Remarks
1 Arm 1 square drive 3/4"
2 Arm 1
3 Center pin 1
4 Pin 2 diameter 1/4", diameter 5/16"
5 Set Screw 2
Torque wrench
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U2
U3 U4
ELEMENT
Tool Item Name Item Number Qty Remarks
U2 Expander KRV10570 1
KRV10600 1 Outside diameter of piston for φ120 ~ φ135
U3 Clamp
KRV10610 1 Outside diameter of piston for φ100 ~ φ115
KRV10580 1 Outside diameter of piston for φ120 ~ φ135
U4 Ring (Rubber band)
KRV10590 1 Outside diameter of piston for φ100 ~ φ115
The teflon ring used for the oil pressure cylinder is not possible to install it by as is shape.
Turns a handle of piston ring expander, the teflon ring can be swollen easily without dam-
age.
Also the ring can surely install the teflon ring in the piston.
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Stand
3
Tap
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2-φ10 Hole
13
12
11
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16
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21
15 20
19
17
18
16
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12
11
Stand
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2-φ10 Hole
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Tap drill
Cylinder Tap drill Tap Tapping
name hole diameter hole size depth
depth 2
Boom 10.3 24 12x1.75 20
Bucket
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9) Install piping.
7. Trial run
[1] After fitting the cylinder on the machine, move slowly more than 8 times at the full stroke by op-
erating the switch-over valve. The inside of the cylinder will be filled with oil.
Quick and sudden movement at the initial stage can cause aeration by the hydraulic oil.
[2] If air bleeder is attached (boom cylinder), apply pressure to bleed by making its air bleeding side
the pressured side (return oil side).
[3] Lubricate pins on both ends.
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Remote Control Valve SH330SH700SH800SH450
Remote Control Valve
1. Before starting this device, ensure that nobody and no objects are near the machine or within
the working range.
2. If the machine indicates any dangerous behavior, immediately stop the device which sup-
plies the machine with hydraulic pressure.
3. When abnormality (noises or oil leakage) occurs, immediately stop operation and take nec-
essary measures. It may cause breakage and injury.
1. When operating the device for the first time, ensure that the hydraulic circuits and electric ca-
bles are correctly set and there are no loose connections before starting the operation.
2. Do not use the devices in other than specified manners described in dimensional outline
drawings.
3. While operating, be careful and keep your hands and body away from the devices as they
often get hot due to the increased oil temperature. It may cause burns.
4. Use specified hydraulic oils, and control their contamination level using estimated values. It
may cause malfunction and breakage.
5. Always install filters at the entry side of the device described in the dimensional outline draw-
ing.
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1. Prior to the operation, always turn off the power on the device and ensure that the motor and
engine have stopped completely. In addition, check that the pressure in the hydraulic piping
is zero. Release the remaining pressure in the accumulator by operating device lever more
than 10 times.
2. Installation, removal, piping and wiring should be carried out by qualified technicians only.
(Qualified technician: one who has acquired a Hydraulics Adjustment 2nd Grade Certificate
or equivalent, or has had service training held by our company's business department.)
3. Clean the fitting holes and surfaces. It may cause breakage and oil leakage due to poorly
tightened bolts and defective sealing.
4. When installing, always use specified bolts and apply specified torque to tighten the product.
Do not install products in other than a specified manner. If this is neglected, it may cause mal-
function, breakage and oil leakage.
As this product is one of the essential safety devices, performances and functions are only guar-
anteed on products that have passed our performance and operation tests conducted by us. Do
not disassemble and assemble this product unless you fully understand the precaution de-
scribed above.
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2. Description
The pilot valve is a pressure reducing valve type remote control valve, integrating 4 pressure reduc-
ing valves to control secondary pressure in one valve casing. Adjusting the inclination of the operat-
ing section controls output pressures.
3. Specifications
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4. Structure
The structure of a pilot valve is as shown in the assembly sectional drawing (Page 21/22). The casing
has openings along the vertical axis, in which pressure reducing valves are integrated.
The pressure reducing valve section consists of spools (201), springs (241) for setting secondary
pressure, return springs (221), spring seats 1 (216) and washers 2 (217). The spring (241) for setting
secondary pressure is configured to obtain reduced secondary pressures of 0.49 to 0.98MPa (de-
pending on models). The spool (201) is pushed against the push rod (212) by the return spring (221).
As the push rod (212) is pressed down when the operating part of the handle is inclined, the spring
seat 1 (216) is also lowered at the same time, as a result, the settings of the spring for setting sec-
ondary pressure (241) change.
The casing (101) and port plate (111) have oil entry ports P (Primary pressure) and exit ports T
(Tank), and the secondary pressure is delivered from the ports 1, 2, 3 and 4.
5. Functions
(1) Basic functions
The pilot valve is a valve designed for controlling the strokes and directions of the control valve
spool. This is achieved by acting output pressures from the pilot valve on the end of the control
valve spool.
To meet requirements for this function, the pilot valve is composed of the following segments:
[1] Entry port (P) through which the hydraulic pump supplies oil
[2] Multiple output ports (1, 2, 3 and 4) which are designed to apply pressure supplied from the
entry port on the end of spool in the control valve.
[3] Tank port (T) which is required to control the output pressures described above.
[4] Spool which connects an output port to the entry port or tank port.
[5] Mechanical measures including springs which act on the spool described above in order to
control output pressure.
(2) Major component functions
The function of the spool (201) is to receive pressure oil supplied from the hydraulic pump at the
port P, and by switching the oil paths, to introduce the pressure oil at port P to output ports (1, 2,
3 and 4) or introduce to port P. It is the role of the spring for setting secondary pressure (241) to
determine output pressure by acting on this spool (201).
The push rod (212) is inserted in the plug (211) so that it can slide and change the deflection of
the spring for setting secondary pressures (241).
The return spring (221), regardless of the output pressure, acts on the casing (101) and spring
seat (216) to return the push rod (212) in the direction of zero displacement, ensuring that the
spool (201) can return to its neutral position. This return spring also functions as reaction spring,
to give good operational responsiveness.
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6. Operation
This section describes the operation of pilot valves based on the Hydraulic Oil Circuit Drawing (Figure
1) and Operation Description Diagrams (Figures 2 through 4). Figure 1 shows a typical usage of the
pilot valve.
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7. Maintenance Procedures
(1) Required tools and tightening torque
Other:
• Volatile corrosion inhibitor • Sandpaper (#1000, #2000)
• White kerosene • Oil stone
• High-temperature grease • Vise
Servicing/Inspec-
Standards Notes
tion Items
Handle in neutral: 1000 cc/min. or more Conditions:
Leak amount In operation: 2000 cc/min. or more Primary pressure: 2.94 MPa
Replace pilot valve assembly in either case above. Oil viscosity: 23 cst
The situation shown in the left is re-
Replace the pilot valve assembly if its sliding part is garded in terms of leak amount as
Spool
worn more than 10 mm more than the non-sliding part. almost the same conditions de-
scribed above.
Push rod Replace if the tip is worn 1 mm or more.
Replace if looseness of 2 mm or more caused by wears Adjust and rectify any looseness
Looseness in the
is found in the circular plate (302) and joint (301) in the caused by poor tightening in the
operating section
operating section. connection.
If abnormal noises, hunting, primary pressure decrease
Stability of opera- or any other problems occur while in operation and are
tion not rectified by the measures described in 8. Trouble-
shooting, change the complete pilot valve assembly.
Note:1 It is recommended that sealing parts such as O-rings should be replaced every time they are
disassembled. However, they can be reused after confirming no damage.
Note:2 Always replace seal washer (121) when a hexagon socket head bolt (125) is loosened.
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[4] Remove the adjusting nut (312) and circular plate (302) by applying spanners with their width
across flats on the adjusting nut and the circular plate.
[5] Turn counter-clockwise and loosen the joint (301) using a jig.
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When the return springs (221) is strong. When the return springs (221) is weak.
[7] When the return springs (221) is weak, it is necessary to pull up using a minus driver because
the plugs (211) remains inserted in the casing (101) by the action of the O-rings sliding resis-
tance.
• Pull up the plug using the outer side of the plug, avoiding damage to the plugs (211) due to
the unbalanced load.
Be careful when drawing it out, the plugs (211) sometimes may pop out by the action of the
return springs (221).
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[8] Draw out the push rods (212), plugs (211), pressure reducing valve assembly and return
springs (221) from the casing (101).
• Record the positional relationship between the components and casing holes.
[9] Secure the pilot valve on the vise by facing port plate (111) upward.
[10] Loosen and remove the hexagon socket head bolts (125) using a hexagon bar spanner.
[11] Remove also the port plate (111) and O-ring (122) from the casing (101). Draw out the bush-
ing (131) from the casing (101).
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[12] Disassemble the pressure reducing valve in the following order: Move the spring seat verti-
cally while pushing in the spring seats (216) and bending the secondary pressure springs
(241). Then, remove the spools (201) through the larger opening. Then, separate spools
(201), spring seats (216), secondary pressure springs (241) and washers 2 (217).
• Do not press the spring seats (216) downward more than 6 mm.
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[14] Remove the O-rings (214) and seals (213) from the plugs (211).
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2) Fit the port plate (111) to the casing (101) using the hexagon socket head bolts (125) and
seal washers (121).
• Check the assembling positions so that the spring pin (126) are inserted into the cas-
ing holes.
• Replace the seal washers (121).
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5) Install the return springs (221) to the casing (101). Fit the pressure reducing valve assem-
bly into the casing (101).
• Install the seals (213) with its lip as shown in the figure below.
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SEAL PLUG
PUSH ROD
APPLY HYDRAULIC OIL
• Do not pry the spools (201). This will damage the holes of the casing (101).
• If the return springs (221) are strong, install the four springs at the same time into the
joint (301) using a plate (151).
• Be careful that the plug assembly and plate (151) do not pop out.
10) Install plate (151).
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11) With jig, tighten the joint (301) to the casing (101) by applying specified torque.
• Screw the circular plate up to the position where the circular plate contacts the four
push rods (212) equally.
Ensure that the circular plate (302) screwing position is correctly adjusted as its over
screwing position leads to increases in secondary pressures when the lever is in neu-
tral and causes operational errors.
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13) Install the adjusting nut (312), fix the circular plate (302) by applying spanner with its width
across flats on the circular plate, and tighten the adjusting nut by specified torque.
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8. Troubleshooting
It is not easy to find the faulty part. The following table lists some possible problems. As repairs are
not easy, refer to the possible causes and countermeasures in the table.
The table below shows general symptoms/possible causes and countermeasures. However, as a
machine's trouble is generally caused not by a single faulty component but by other related compo-
nents as well, it may be necessary to apply measures other than those listed in the Table.
The table shown below does not necessarily include all possible causes and remedies. Therefore,
the technician in charge of repairs must further investigate problems and their causes as necessary.
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Remote Control Valve SH330SH450
Remote Control Valve
CAUTION:
Disassembly/reassembly must be conducted at the manufacturer's factory as a general
rule.
When the circumstances do not allow this, the work should be done at a well-equipped
service shop by staff with full knowledge of hydraulic equipment.
Handle hydraulic devices carefully because they consist of precision components and
have a structure that forms small spaces.
Conduct disassembly/reassembly in a clean place that is free of dust following the instruc-
tions below.
Never attempt to forcedly hit a device when it does not move smoothly.
1. Tools Needed
[1] Vise; for securing valve main body
[2] Small-sized vise (with copper plates at the mouth); for disassembling pressure reducing valves
[3] Hexagon bar wrench (3, 4, 5, 6, 8 mm)
[4] Scriber (or tapered bar of the same shape); for disassembling packing
[5] Hexagon bar for wrench (3, 4, 5, 6, 8 mm)
[6] Torque wrench (compatible for torque range 4.9 to 58.8 Nom)
[7] Bar magnet (for removing steel ball (35) and holder (20))
2. Disassembling Instructions
Disassembling damper selection and pressure reducing valve selection
[1] Cover all ports for valves (P, T, 1, 2, 3, and 4) with blank plugs and clean the outside.
[2] After the valve is cleaned, secure with vise.
[3] Remove the boots (15) (2 locations).
[4] Using a hexagon bar wrench (4 mm), loosen hexagon socket head bolts (2 locations) and re-
move them from the cams (14)
[5] Pull out pins (16) from covers (17) (2 locations). If a hexagon bar wrench (4 mm) is used to push
the pins out from the inside, they will come out easily.
[6] Remove cams (14) (2 locations).
[7] Loosen hexagon socket head bolts (25) using a hexagon bar wrench (8 mm) and remove it along
with plain washers (29) (2 locations).
[8] Remove damper section (A) from pressure reducing valve section (B) (2 locations).
Keep an eye on spring (9) since it is not secured.
Disassembling damper selection
[9] Pull out guide (18) and piston assembly (42) from cover (17). (They can be pulled out easily if
pressure is applied from the steel ball (35) side.)
[10] Take out steel ball (35), holder (20), orifices (1), (2) and spring (9) from piston assembly (42) (4
locations). Verify the number of orifices (1), (2) in each piston assembly, and group together pis-
ton assembly (42) and guide (18) for each hole on cover (17), to keep them separate from the
other sets for installation at the original locations later. As orifices (1), (2) serve to prevent back-
lash in the lever, not having the correct number of orifices will result in backlash. Each part is
matched and adjusted independently. If parts removed from one location are taken and installed
into a different location when reassembling, the machine will malfunction. As ring (21), orifice (4),
spring (22) and steel ball (33) are press-fit with ring (21) into piston assembly (42), they cannot
be disassembled.
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Remote Control Valve Page No. 2/ 4
First Edition : 04/2005
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Cross-sectional View of the Assembly
Remote Control Valve Page No. 4/ 4
First Edition : 04/2005
TIGHTENING TORQUE LIST NO PART MANE QTY
TIGHTENING 1 ORIFICE 4
NO. SIZE
TORQUE 2 ORIFICE 4
24 G 1/8 9.8±0.98 N ・ m 3 SPOOL 4
4 ORIFICE 4
25 M10 58.8±4.9 N ・ m
5 BODY 1
26 M4 4.9±0.98 N ・ m 6 SPRING 4
27 M8 14.7±1.4 N ・ m 7 SPRING 4
- M10 SCREW 42.1±3.9 N ・ m 8 PISTON 4
9 SPRING 4
- M10 BOLT 42.1±3.9 N ・ m
10 STOPPER 4
PORT G 1/4 36.3±2.0 N ・ m
11 NAME PLATE 1
12 SHIM 4
13 SHIM 4
14 CAM 2
15 BOOT 2
16 PIN 2
17 COVER 2
18 GUIDE 4
19 SLEEVE 4
20 HOLDER 4
21 RING 12
22 SPRING 4
23 -
24 PLUG 2
25 HEX SOCKET HEAD BOLT 2
26 FLANGE BOLT 4
27 SET SCREW 4
28 PLAIN WASHER 4
29 PLAIN WASHER 2
30 RIVET 2
31 PARALLEL 4
32 STEEL BALL 2
33 STEEL BALL 4
34 STEEL BALL 4
35 STEEL BALL 4
36 U-PACKING 4
37 O-RING 4
38 O-RING 4
39 O-RING 4
40 O-RING 2
41 -
42 PISTON ASSY 4
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First Edition : 08/2006
Solenoid Valve (6-Way) SH330SH450
Solenoid Valve (6-Way)
Assembly Drawing
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Solenoid Valve (6-Way) Page No. 2/ 7
First Edition : 08/2006
Theory of operation
The hydraulic fluid supplied from the port P is fed to the solenoid
operated directional valves S1 to S5 when the valve SP is ener-
gized. The hydraulic fluid is then fed to the ports C1 to C5 de-
pending on whether or not the valves S1 to S5 are energized.
Electromagnetic selector valves S1, S3, S4 and S5:
Oil passes through when energized
Electromagnetic selector valve S2:
Oil passes through when not energized
Maintenance
1. Assembling and Disassembling Precautions
[1] Disassemble the valve with due attention not to damage the
O-ring and other parts, and store the parts in a safe place.
[2] If there is any flaw on the O-ring, replace it with a new one.
[3] Be careful to assemble the parts in the correct orientation
and without forgetting any of the parts.
[4] When assembling, reverse the order of disassembling and pay attention not to allow any foreign
matters such as dirt to get into the valve.
2. Assembling and disassembling a Solenoid Operated Directional Valve
[1] Remove the mounting bolts from the solenoid (C) and remove the coil part.
(Tool: 3 mm Hexagon wrench)
[2] Remove the tube, while paying attention not to damage the edges of the flat portion of the core.
However, if the core is removed, replace the O-ring (A) with a new one.
(Tool: 23 mm spanner)
[3] Take out the spools (2) and (3) and the springs (4) and (5).
[4] Pry the snap ring (7) off by inserting a flat head screwdriver or the like in the notch, and remove
the adapter (6).
[5] Assemble the valve by reversing the order of disassembling. When tightening the core, pay at-
tention not to damage the edges of the flat portion of the core.
When mounting the adaptor, apply grease or other appropriate lubricant to the O-ring (B) and
pay attention not to damage the O-ring.
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3. Maintenance standards
4. Troubleshooting
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First Edition : 08/2006
Safety Precautions
In this instruction manual, safety precautions are classified into three ranks: DANGER, WARNING, and
CAUTION. These words are defined as follows:
Indicates an imminent danger that is very likely to cause death or severe in-
DANGER
jury unless the situation is avoided.
Indicates a potential danger that may cause death or severe injury unless
WARNING
the situation is avoided.
Note that even precautions labeled "CAUTION" may cause serious harm. Since all precautions are im-
portant regardless of their rank, be sure to follow all of them.
YUKEN KOGYO assumes no liability for any accident causing death, injury, or property damage caused
by the unauthorized use or handling of the product or information contained herein.
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First Edition : 08/2006
The following are specific important safety precautions that you must observe:
DANGER
Do not use the product in an EXPLOSIVE Foreign matters (debris) in the hydraulic fluid can cause
ATMOSPHERE, such as where flammable gas or the hydraulic system to malfunction.
powder is handled. Otherwise, combustion or ignition Always keep the hydraulic fluid clean (pollution level
may result in a fire or explosion, possibly causing death within class NAS 1638-8) and use 10-micrometer or less
or severe injury. line type filters.
WARNING
Do not perform wiring, assembly, or maintenance Do not modify the product. Doing so could create a
inspection with the power on. hazardous situation, resulting in a malfunction or
Doing so may result in electric shock, burns or death. reduced performance.
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First Edition : 08/2006
The following are specific important safety precautions that you must observe:
CAUTION
Do not step or stand on the product or put any heavy Valve characteristics may vary with the load pressure or
object on it. Doing so may damage the product or fluid temperature. Adjust the product so that it can accel-
hydraulic system and may result in an injury from falling. erate, decelerate, and stop the flow of hydraulic fluid
safely throughout the actual operating ranges of pres-
sure and fluid temperature.
368
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Cushion Valve Page No. 1/ 4
First Edition : 08/2006
Cushion Valve SH330
Cushion Valve
Operational Description
1. Assembly Drawing
369
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Cushion Valve Page No. 2/ 4
First Edition : 08/2006
2. System Drawing
HYDRAULIC
OIL TANK
REMOTE
CONTRAL VALVE
ARM REMOTE
CONTRAL VALVE
BOOM
OUT UP
IN DOWN
370
000-7-08-01-08
Cushion Valve Page No. 3/ 4
First Edition : 08/2006
3. Operational Description
(1) Lever in neutral
[1] The heat oil separated from the oil cooler line enters the cushion valve Port R.
[2] Then, the oil passes the reverse notch spool and goes through passages e and f. After pass-
ing the outer circumference of each cushion spool, the oil returns to the hydraulic oil tank via
the cushion valve Port T.
FROM TO
REMOTE CONTROL REMOTE CONTROL
VALVE VALVE
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Cushion Valve Page No. 4/ 4
First Edition : 08/2006
TO
REMOTE CONTROL
VALVE
THROTTLE
CUSHION SPOOL
[1] As the pilot pressure from the remote control valve stops, the reverse notch spool returns to
the neutral position.
[2] The cushion spool also returns to the neutral position and the pilot return oil from the control
valve passes the throttle.
[3] Due to this restricting effect, the spool of the main control valve returns gradually to the neu-
tral position.
372
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Attachment Reinforcement Procedures Page No. 1/ 5
First Edition :11/2005
Attachment Reinforcement Procedures SH330
Attachment Reinforcement Procedures
t8 × 420 × 800
5 KSV1595 2
Standard 24.6
Arm
(3.2 m)
t8 × 300 × 650
6 KSV1596 1
7.5
t8 × 300 × 650
7 KSV1597 1
7.4
t8 × 320 × 1650
8 KSV1598 1
26.2
t8 × 320 × 3000
9 KSV1599 1
54.7
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First Edition :11/2005
t8 × 320 × 1650
11 KSV1598 1
26.2
t8 × 300 × 650
14 KSV1596 1
7.5
t8 × 300 × 650
15 KSV1597 1
7.4
t8 × 320 × 2380
16 KSV1602 1
43.3
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First Edition :11/2005
Note 1
4 points on both sides,
total of 8 points
KSV1592X-B00
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First Edition :11/2005
8
4
6 5
7 3
Note 1
Note 1
Note 1
Note 1 Note 1
KSV1593X-D00
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First Edition :11/2005
10
11
12
14
13
15
16
Note 1
Note 1
Note 1
Note 1
KSV1594X-D00
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Using Technical Information Page No. 1/ 1
Second Edition:01/2002
Using Technical Information SH330SH700SH225SH800SH450
Using Technical Information
Symbols
The following symbols are used in this Shop Manual to bring your attention to the particularly important
information for safety, quality, etc.
Warning Weight
Indicates precautions for safe opera- Indicates the weight of parts to advise
tions. caution for the operation.
Internal pressure
Adjustment
Indicates that caution is needed be-
Indicates items that require adjustment.
cause internal pressure exists.
Measurement
Caution
Indicates items to be measured for in-
Indicates precautions to avoid damage
spections. (Dimensions and other infor-
to devices.
mation)
Measurement
Tightening torque Indicates items to be measured for in-
Indicates specified tightening torques. spections. (Current, Voltage and other
information)
Cleaning
Grease
Indicates items to be cleaned during dis-
Indicates greasing points.
assembling and assembling.
Adhesive
Indicates application of adhesive or liq-
uid packing.
Adding grease
Indicates additional greasing.
Oiling
Indicates adding of oil or other lubri-
cants.
3
330-8-07-01-03
Platform Plate for Repair Page No. 1/ 1
First Edition : 11/2005
Platform Plate for Repair SH330
Platform Plate forRepair
Platform
35
6
2340
200
110
378
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Precautions for Use Page No. 1 / 18
Second Edition:01/2002
Precautions for Use SH330SH700SH225SH800SH450
Precautions for Use
MAINTENANCE/
INSPECTION
SECTION
N
ECTIO
INSP R WAY
UN D E
4
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Precautions for Use Page No. 2 / 18
Second Edition:01/2002
5
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Precautions for Use Page No. 3 / 18
Second Edition:01/2002
Fire prevention
• Use incombustible oils for cleaning parts.
• Extinguish flames which may cause fire hazards.
• Prepare fire extinguishing appliances such as extin-
guishers.
• Do not smoke while inspecting and maintaining the FUEL
machine.
6
000-0-05-00-10
Precautions for Use Page No. 4 / 18
Second Edition:01/2002
Holding attachments
• It is very dangerous to replace or repair joints/hoses
while holding an attachment in the air. Always lower
it to the ground or place it on blocks.
7
000-0-05-00-10
Precautions for Use Page No. 5 / 18
Second Edition:01/2002
Battery
• Batteries emit flammable gases. Always keep flames
away.
• The battery electrolyte contains dilute sulfuric acid. If
the fluid touches the skin, immediately wash it off
with water and then wash fully with soap. If it gets in
the eyes, after flushing them with plenty of water, get
medical help.
• Before checking and handling the battery, turn off
the power supply (by placing the starter switch to
OFF).
• If you use or recharge the battery while the battery
electrolyte is lower than the lower level indicated on
the side of the battery, it may cause breakage (ex-
plosion).
• Check the level of the battery electrolyte and battery
mounting conditions, and check the voltage using a
tester on a regular basis.
8
000-0-05-00-10
Precautions for Use Page No. 6 / 18
Second Edition:01/2002
Ventilation
• When conducting maintenance work in poorly venti-
lated locations indoors, keep doors and windows
open and ventilate air to avoid gas poisoning.
9
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Precautions for Use Page No. 7 / 18
Second Edition:01/2002
Washing vehicles
[1] When washing the machine, be careful not to splash the electrical equipment.
• Monitors and electrical equipment in the operator's cab.
• Do not apply steam directly to battery, connectors and other electrical equipment.
[2] Do not apply high pressure washing steam directly to the radiators.
Wash the radiator carefully and gently.
dirt
10
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Precautions for Use Page No. 8 / 18
Second Edition:01/2002
11
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Precautions for Use Page No. 9 / 18
Second Edition:01/2002
Installing O-rings
• When removing sealing parts containing O-rings, clean the fitting faces.
• Be careful not to damage O-rings and assemble them by applying oil when attaching them.
12
000-0-05-00-10
Precautions for Use Page No. 10 / 18
Second Edition:01/2002
Inspection and maintenance when the machine is used under special situa-
tions
When used under extremely hot conditions
[1] Check/maintain cooling water and radiators.
[2] Check and adjust the fan belt tension.
When used in a rocky place
Pay special attention to breakage of the suspension, loose bolts and nuts, cracks, and wear. Loosen
the tension of the shoes by a small amount.
When used by the ocean
Wash salt off especially carefully. Take special care of electronic equipment, hydraulic cylinders and
suspension to prevent corrosion.
When used at sites full of dust and sand
[1] Check the elements of air cleaners more often, and clean or change the elements and dust cups
regardless of replacement intervals.
[2] Tighten caps fully to prevent dust and sand from entering the hydraulic oil tank.
When used in marshes or on soft ground
Lubricate and grease the parts earlier than usual. Daily grease any pins which have been submerged
in muddy water. In addition, check and clean the suspension.
13
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Precautions for Use Page No. 11 / 18
Second Edition:01/2002
CAUTION
14
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Precautions for Use Page No. 12 / 18
Second Edition:01/2002
15
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Precautions for Use Page No. 13 / 18
Second Edition:01/2002
16
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Precautions for Use Page No. 14 / 18
Second Edition:01/2002
3. After Disassembly
(1) Cleaning
• Clean the disassembled parts and arrange them by each component. Be especially careful to
remove sludge or dust completely from the oil holes for each part and inside the pipes.
• Divide the solvent into two containers, one for removing dirt and one for finishing for efficient
cleaning. When cleaning critical parts, divide the tubs further to avoid using dirty solvent.
• When cleaning bearings or other high precision parts, use kerosene or neutral absolute light oil.
• When cleaning large castings such as the cylinder head or block in a container, clean them in
solvent of pH 10 to 12 at 50 to 70 ℃ for 5 to 10 minutes and rinse thoroughly afterwards.
• When using special chemicals as cleansing agents, understand the proper usage thoroughly
and be careful not to get it in your eyes or on your skin. Properly dispose of the used solvents.
(2) Dust or rust prevention
• Cover the cleaned parts to prevent dust from entering. Use caps for ends of hoses and tubes.
• If it is assumed to take a long time before reassembling, use corrosion inhibitor.
CORRECT WRONG
CORRECT WRONG
17
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Precautions for Use Page No. 15 / 18
Second Edition:01/2002
18
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Precautions for Use Page No. 16 / 18
Second Edition:01/2002
19
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Precautions for Use Page No. 17 / 18
Second Edition:01/2002
20
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Precautions for Use Page No. 18 / 18
Second Edition:01/2002
21
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Tightening Torque Page No. 1/ 1
First Edition : 03/2005
Tightening Torque SH330SH700SH225SH800SH450
Tightening Torque
• For bolts on important areas, apply engine oil on the threaded portion so that tightening force is ap-
plied evenly without unnecessary engagement on the thread.
• For bolts and nuts in the areas that it is difficult to check from outside or bolts and nuts in important
areas, secure them using wires, cotter pins or folding washers.
CORRECT WRONG
CORRECT WRONG
• Clean bolts to which Loctite was applied (identified as bolts with white substances when removed)
with light oil and trichlene, and dry them. After that, apply two or three drops of Loctite to the threaded
portion of the bolts and fasten them.
22
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Numerical Conversion Table Page No. 1/ 3
Second Edition:01/2002
Numerical Conversion Table SH330SH700SH225SH800SH450
Numerical Conversion Table
23
000-0-07-00-06
Numerical Conversion Table Page No. 2/ 3
Second Edition:01/2002
Torque kgf ・ m → N ・ m
kgf ・ m 0 1 2 3 4 5 6 7 8 9 kgf ・ m
N・m N・m N・m N・m N・m N・m N・m N・m N・m N・m
― ― 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 ―
10 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33 10
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 30
40 392.27 402.07 411.88 421.69 431.49 441.30 451.11 460.91 470.72 480.53 40
50 490.33 500.14 509.95 519.75 529.56 539.37 549.17 558.98 568.79 578.59 50
60 588.40 598.21 608.01 617.82 627.63 637.43 647.24 657.05 666.85 676.66 60
70 686.47 696.27 706.08 715.89 725.69 735.50 745.31 755.11 764.92 774.73 70
80 784.53 794.34 804.15 813.95 823.76 833.57 843.37 853.18 862.99 872.79 80
90 882.60 892.41 902.21 912.02 921.83 931.63 941.44 951.25 961.05 970.86 90
100 980.67 990.47 1000.28 1010.08 1019.89 1029.70 1039.50 1049.31 1059.12 1068.92 100
Torque N ・ m → kgf ・ m
N・m 0 10 20 30 40 50 60 70 80 90 N・m
kgf ・ m kgf ・ m kgf ・ m kgf ・ m kgf ・ m kgf ・ m kgf ・ m kgf ・ m kgf ・ m kgf ・ m
― ― 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 ―
100 10.197 11.217 12.237 13.256 14.276 15.296 16.315 17.335 18.355 19.375 100
200 20.394 21.414 22.434 23.453 24.473 25.493 26.513 27.532 28.552 29.572 200
300 30.591 31.611 32.631 33.651 34.670 35.690 36.710 37.729 38.749 39.769 300
400 40.789 41.808 42.828 43.848 44.868 45.887 46.907 47.927 48.946 49.966 400
500 50.986 52.006 53.025 54.045 55.065 56.084 57.104 58.124 59.144 60.163 500
600 61.183 62.203 63.222 64.242 65.262 66.282 67.301 68.321 69.341 70.360 600
700 71.380 72.400 73.420 74.439 75.459 76.479 77.498 78.518 79.538 80.558 700
800 81.577 82.597 83.617 84.636 85.656 86.676 87.696 88.715 89.735 90.755 800
900 91.774 92.794 93.814 94.834 95.853 96.873 97.893 98.912 99.932 100.952 900
1000 101.972 102.991 104.011 105.031 106.050 107.070 108.090 109.110 110.129 111.149 1000
Pressure kgf/cm2 → kPa (1 kPa = 1/1000 MPa)
kgf/cm2 0 1 2 3 4 5 6 7 8 9 kgf/cm2
kPa kPa kPa kPa kPa kPa kPa kPa kPa kPa
― ― 98.1 196.1 294.2 392.3 490.3 588.4 686.5 784.5 882.6 ―
10 980.7 1078.7 1176.8 1274.9 1372.9 1471.0 1569.1 1667.1 1765.2 1863.3 10
20 1961.3 2059.4 2157.5 2255.5 2353.6 2451.7 2549.7 2647.8 2745.9 2843.9 20
30 2942.0 3040.1 3138.1 3236.2 3334.3 3432.3 3530.4 3628.5 3726.5 3824.6 30
40 3922.7 4020.7 4118.8 4216.9 4314.9 4413.0 4511.1 4609.1 4707.2 4805.3 40
50 4903.3 5001.4 5099.5 5197.5 5295.6 5393.7 5491.7 5589.8 5687.9 5785.9 50
60 5884.0 5982.1 6080.1 6178.2 6276.3 6374.3 6472.4 6570.5 6668.5 6766.6 60
70 6864.7 6962.7 7060.8 7158.9 7256.9 7355.0 7453.1 7551.1 7649.2 7747.3 70
80 7845.3 7943.4 8041.5 8139.5 8237.6 8335.7 8433.7 8531.8 8629.9 8727.9 80
90 8826.0 8924.1 9022.1 9120.2 9218.3 9316.3 9414.4 9512.5 9610.5 9708.6 90
100 9806.7 9904.7 10002.8 10100.8 10198.9 10297.0 10395.0 10493.1 10591.2 10689.2 100
24
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Numerical Conversion Table Page No. 3/ 3
Second Edition:01/2002
kPa 0 100 200 300 400 500 600 700 800 900 kPa
kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2
― ― 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 ―
1000 10.197 11.217 12.237 13.256 14.276 15.296 16.315 17.335 18.355 19.375 1000
2000 20.394 21.414 22.434 23.453 24.473 25.493 26.513 27.532 28.552 29.572 2000
3000 30.591 31.611 32.631 33.651 34.670 35.690 36.710 37.729 38.749 39.769 3000
4000 40.789 41.808 42.828 43.848 44.868 45.887 46.907 47.927 48.946 49.966 4000
5000 50.986 52.006 53.025 54.045 55.065 56.084 57.104 58.124 59.144 60.163 5000
6000 61.183 62.203 63.222 64.242 65.262 66.282 67.301 68.321 69.341 70.360 6000
7000 71.380 72.400 73.420 74.439 75.459 76.479 77.498 78.518 79.538 80.558 7000
8000 81.577 82.597 83.617 84.636 85.656 86.676 87.696 88.715 89.735 90.755 8000
9000 91.774 92.794 93.814 94.834 95.853 96.873 97.893 98.912 99.932 100.952 9000
10000 101.972 102.991 104.011 105.031 106.050 107.070 108.090 109.110 110.129 111.149 10000
25
300-2-01-00-05
Main Body Page No. 1/ 2
MAJOR EQUIPMENT SPECIFICATIONS First Edition :07/2001
Main Body SH300SH330SH350SH450
MAJOR EQUIPMENT SPECIFICATIONS
Equipment Configuration
Overall
Solenoid valves
Hydraulic pump
Hydraulic oil tank Engine
Radiator
Fuel tank
Air cleaner
Control valve
Swing motor
26
300-2-01-00-05
Main Body Page No. 2/ 2
MAJOR EQUIPMENT SPECIFICATIONS First Edition :07/2001
Operator’s Cab
Interior light
Air conditioner switch Radio
Tilt lever
Seat
Monitor / Switch panel
Tilt open rear
Control lever right
window
(With idle switch)
(Emergency exit)
Travel lever
Defroster
Console box
27
Main Body SH330SH350
MAJOR EQUIPMENT SPECIFICATIONS
Lower Mechanism
Main Body Page No. 1/ 4
Assembly Drawing SH330-3B / SH350HD-3B
MAJOR EQUIPMENT SPECIFICATIONS Second Edition:05/2006
KSA10510-D01
28
330-2-01-01-49
Assembly Drawing SH330LC-3B
Main Body Page No. 2/ 4
MAJOR EQUIPMENT SPECIFICATIONS Second Edition:05/2006
KSA10520-D01
29
330-2-01-01-49
Main Body Page No. 3/ 4
MAJOR EQUIPMENT SPECIFICATIONS Second Edition:05/2006
Travel Unit
Sumitomo Part No. KSA10220
Traction motor
Manufacturer Nabtesco Corporation
Variable displacement piston motor
Motor type
automatic 2-speed switch-over with parking brake
Displacement 290.7 / 170.1 cm3/rev
Operating pressure 34.3 MPa
Operating flow 284.2 L/min
Brake torque 4738 N・m or over (with reduction gear)
Relief set pressure 35.8 to 37.8 MPa (at 5 L/min)
2-speed control pressure 26.5 MPa
Traction reduction gears
Reduction gear type Planetary gear 2-stage reduction system
Reduction ratio 40.467
Dry weight 399 kg
Take-up Roller
Sumitomo Part No. KSA1307
Weight 165 kg
Upper-Roller
Sumitomo Part No. KBA1141
Weight 43 kg
Lower-Roller
Sumitomo Part No. KSA1068
Weight 60 kg
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MAJOR EQUIPMENT SPECIFICATIONS Second Edition:05/2006
Recoil Spring
Part Name Sumitomo Part No.
Yoke KSA1065 39.8 kg
Sems bolt M16 x 50 105R016Y050R 0.5 kg
Threaded rod KSA1066 50.3 kg
Castle nut M64 165R064HSN 1.9 kg
Spring pin 10 x 100 338W100Z100B 0.1 kg
Recoil spring KSA1310 119.4 kg
Grease cylinder assembly KSA0832 41.3 kg
Sems bolt M16 x 65 105R016Y065R 0.3 kg
Assembly Total weight 254.0 kg
Mounting length of spring: 779 mm
Shoes
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MAJOR EQUIPMENT SPECIFICATIONS First Edition :11/2005
Main Body SH330SH350
MAJOR EQUIPMENT SPECIFICATIONS
Upper Mechanism
Swing Unit
Swing moter
Sumitomo Part No. KSC0247
Manufacturer TOSHIBA MACHINE CO., LTD
Motor type Fixed displacement piston motor with parking brake
and reversal prevention valve
Displacement 186.7 cm3/rev
Operating pressure 29.4 MPa
Operating flow 284 L/min
Brake torque 961.6 N・m or over
Brake off pressure 2.9 MPa less than
Relief set pressure 29.3 MPa (at 100 L/min)
Swing reduction gears
Sumitomo Part No. KSC0252
Reduction gear type Planetary gear 2-stage reduction system
Reduction ratio 27.143
Dry weight 435 kg
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MAJOR EQUIPMENT SPECIFICATIONS Second Edition:05/2006
Main Body SH330SH350
MAJOR EQUIPMENT SPECIFICATIONS
Muffler
Sumitomo Part No. KSH0948
Manufacturer SANKEI GIKEN KOGYO CO., LTD
External dimensions dia. 283.2 x 780 mm
Weight 20.0 kg
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MAJOR EQUIPMENT SPECIFICATIONS Second Edition:05/2006
Air Cleaner
Sumitomo Part No. KSH0895
Manufacturer Nippon Donaldson, Ltd
Element (outer) KSH0933
Element (inner) KSH0932
Weight 13.6 kg
Radiator
Sumitomo Part No. KSH1028
Manufacturer T. RAD Co., Ltd
Oil cooler Weight 34.0 kg
Oil capacity 16.0 L
Radiator Weight 21.1 kg
Water capacity 9.4 L
Air cooler Weight 19.9 kg
Capacity ―
Fuel cooler Weight 1.2 kg
Capacity 0.44 L
Total weight 137 kg
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Fuel Tank
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KSH0904Z-D03
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MAJOR EQUIPMENT SPECIFICATIONS Second Edition:05/2006
Main Body SH330SH350
MAJOR EQUIPMENT SPECIFICATIONS
Hydraulic System
Hydraulic Pump
Sumitomo Parts No. KSJ2851
Manufacturer Kawasaki Precision Machinery Ltd.
Main pump
Pump type Double variable displacement piston pump
Displacement 140 x 2 cm3/rev
Rated operating pressure 34.3 MPa
Meximum operating pressure 37.3 MPa
Input revolution speed 2030 min-1
Maximum flow 284 x 2 L/min (at 2030 min-1)
Input horsepower 171.7 kW
Shaft input horsepower 174.7 kW (at 2030 min-1)
Shaft input torque 821.8 N・m (at 2030 min-1)
Pilot pump
Pump type Gear pump
Displacement 15 cm3/rev
Operating pressure 3.9 MPa
Maximum flow 30.5 L/min (at 2030 min-1)
Input horsepower 3.0 kW
Control characteristics Simultaneous output control of overall
Negative control
Electric horse power control
Dry weight 130 kg
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Sump Tank
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MAJOR EQUIPMENT SPECIFICATIONS Second Edition:05/2006
KSJ11140-D00
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MAJOR EQUIPMENT SPECIFICATIONS Second Edition:05/2006
Rotating Joint
Sumitomo Part No. KSA1305
Operating pressure High pressure passage (ABCD) 34.3 MPa
Drain port (T) 1.0 MPa
Pilot port (P) 3.9 MPa
Hydrostatic test pressure High pressure passage (ABCD) 51.5 MPa
Drain port (T) 2.0 MPa
Pilot port (P) 5.9 MPa
Flow High pressure passage (ABCD) 360 L/min
Drain port (T) 40 L/min
Pilot port (P) 31 L/min
Number of revolutions 15 min-1
Torque When pressurizing 2 ports 196 N・m
Port A Forward right G1
Port B Forward left G1
Port C Backward right G1
Port D Backward left G1
Port E Drain port G1/2
Port F Pilot port G1/4
Weight 56 kg
Solenoid Valve
Sumitomo Part No. KHJ15460
Manufacturer YUKEN KOGYO CO., LTD.
Valve specifications
Maximum flow P → B : 20 L/min Other : 5 L/min
Rated pressure 4.5 MPa
Solenoid specifications
Operating voltage DC 20 to 32 V
Current 17.0 W or less
Weight 7.0 kg
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Main Body SH330SH350
MAJOR EQUIPMENT SPECIFICATIONS
Controls
Control Valve
Sumitomo Part No. KSJ3106
Manufacturer KYB Corporation
Maximum flow 284 L/min
Pressure setting for overload 27.4 MPa (at 20 L/min) when boom down
39.2 MPa (at 20 L/min) other
Pressure setting for main relief 34.3 MPa (at 190 L/min)
37.3 MPa (at 165 L/min) at boosting
Pressure setting for foot relief 2.89 MPa (at 53 L/min)
Functions Straight travel circuit
Boom up / 2-speed internal confluence for arm
Boom/Arm load holding circuit
Boom down regenerative circuit
Arm in forced regenerative circuit
Variable throttle valve in the parallel circuit arm
Swing priority variable throttle valve
Backup 2-speed confluence
Weight 192 kg
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Main Body SH330SH350
MAJOR EQUIPMENT SPECIFICATIONS
Backhoe Attachments
Cylinder
Boom cylinder (R.H / L.H)
Sumitomo Part No. KSV1925 / KSV1926
Manufacturer ZENOAH
Cylinder bore dia. 145 mm
Rod diameter dia. 100 mm
Max. retracted length 2090 mm
Stroke 1495 mm
Dry weight 279 kg
Arm cylinder
Sumitomo Part No. KSV1927
Manufacturer ZENOAH
Cylinder bore dia. 170 mm
Rod diameter dia. 120 mm
Max. retracted length 2445 mm
Stroke 1748 mm
Dry weight 462 kg
Bucket cylinder
Sumitomo Part No. KSV1928
Manufacturer ZENOAH
Cylinder bore dia. 150 mm
Rod diameter dia. 105 mm
Max. retracted length 1870 mm
Stroke 1210 mm
Dry weight 276 kg
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MAJOR EQUIPMENT SPECIFICATIONS Second Edition:05/2006
Attachments
SH330-3B / SH330LC-3B Bucket Types
● : Standard bucket
◎ : For general digging (Specific gravity: 2.0 ton/m3 or less)
○ : For light digging (Specific gravity: 1.6 ton/m3 or less)
△ : For loading only (Specific gravity: 1.2 ton/m3 or less)
× : Do not use
Bucket capacity (m3) 1.15 STD 1.4 STD 1.4 HD 1.6 STD 1.8 STD
Number of teeth 4 5 5 5 5
1233 1435 1424 1575 1733
Width (mm)
(1100) (1302) (1310) (1442) (1600)
Long arm
● ○ ○ × ×
(4.04 m)
Type of arm Standard arm
◎ ● ◎ ○ ×
specified (3.25 m)
Short arm
◎ ◎ ◎ ● ○
(2.63 m)
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Second Edition:04/2006
Fuel / Lubricants and Filters SH330
Fuel / Lubricants and Filters
Fuel / Oil
Recommended type by temperature
Refer to the table for proper fuel / oil ac- Where to refill Type of oil
cording to the temperature range. Refer to
Grease / Oil and Elements for proper oil
levels.
Engine oil pan Engine oil
Antifreeze
Add antifreeze when the temperatures
falls below 32×F (0×C). As for the ratio, re-
fer to the section for cold weather condi- Swing reduction gear
Gear oil
tions. Travel reduction gear
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Sulfur content reacts to moisture to change into sulfuric acid after combustion.
Use of a fuel containing much sulfur content allows it to accelerate internal corrosion and wear.
In addition, much sulfur content quickens deterioration of engine oil allowing its cleaning disper-
sive property to be worse which results in acceleration of wear of sliding portions.
HFRR is an index that indicates lubricating property of a fuel.
Large value of the index means poor lubrication so that seizure of the machine components may
result if such a fuel is used.
Since a fuel with high HFRR value also has lower viscosity, it can easily be leaked out.
If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property re-
sulting in acceleration of wear.
Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the fuel
filter.
This may also cause wear and seizure of the machine components.
If atmospheric temperature goes below the freezing point, moisture content in the fuel forms fine
particle of ice allowing the fuel line to be clogged.
Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it meets
the criteria described above.
Important
If a fuel which does not meet the specifications and the requirements for the diesel engine, func-
tion and performance of the engine will not be delivered.
In addition, never use such a fuel because a breakdown of the engine or an accident may be
invited.
Guarantee will not be given to a breakdown caused by the use of a improper fuel.
Some fuels are used with engine oil or additives mixed together with diesel engine fuel.
In this case, do not use these fuels because damage to the engine may result as the fuel has
been contaminated.
It is natural that the emission control regulation of 3rd-stage will not be cleared in case where a
fuel that does not meet the specifications and the requirements is used.
Use the specified fuel for compliance of the exhaust gas control.
Important
It you use diesel fuel which contains much sulfur content more than 2500 ppm, be sure to follow
the items below for the engine oil selection and maintenance of engine parts.
Guarantee will not be given to breakdowns caused by not to follow these items.
[1] Selection of engine oil
Use API grade CF-4 or JASO grade DH-1.
[2] Exchange the engine oil and engine oil filter element by periodical interval below.
Engine oil Every 250 hour of use
Engine oil filter element Every 250 hour of use
[3] Inspect and exchange the EGR parts and fuel injector parts of engine by periodical interval
below.
EGR (*) parts Every 3000 hour of use
Fuel injector parts Every 3000 hour of use
* EGR : Exhaust Gas Recircultion
For the detail of inspection and replacement for the above engine parts, please contact
your nearest SUMITOMO outlet.
[4] In addition above if the value of HFRR or water content in the fuel you use is more then lim-
itation in above table of this manual, please also contact your nearest SUMITIMO outlet.
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Important
If a fuel filter other than the genuine filter is used, guaranty will not be applied to a fault caused
by the use of a wrong filter.
(2) Two kinds of fuel filter, the pre-filter and the main filter, are mounted on the machine.
Be sure to use the genuine fuel filters and replace them at a periodic intervals.
Replacement criteria
Every 250 hour of use Every 500 hour of use
Pre-filter ○
Main filter ○
Since the pre-filter also has a function of water separation, discharge water and sediment when
the float reaches lower part of the filter elements.
(3) Time to replace filters may be advanced according to properties of the fuel being sup-
plied.
Running the engine with the fuel filter blocked may cause the engine to be stopped due to estab-
lishment of engine error code.
If much foreign objects are found in the fuel, carry out earlier inspection and regular replacement
of the filters.
(4) If dust or water get mixed with the fuel, It may cause the engine trouble and an accident.
Therefore, take measures to prevent dust and/or water from being entered in the fuel tank when
supplying fuel.
When supplying fuel directly from a fuel drum can, leave the drum as it stands for a long period
of time to supply clean fuel standing above a precipitate.
If it is hard to leave the drum for a long period of time, install a fuel strainer and a water separator
before the fuel tank of the machine to supply clean fuel.
(5) Water drain cock is provided on the bottom side of the fuel tank.
Drain water before starting the engine every morning.
In addition, remove the cover under the tank once a year to clean up inside of the tank.
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Com Turbocharger
Engine
Injector
EGR cooler
Muffler
Inter cooler
Fuel cooler
Radiator
Common rail
Supply pump
Main filter
In
Electromagnetic
pump
Pre-filter
Thermo valve
Fuel tank
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Disposable Items
Replace disposable items, such as filter elements and bucket teeth, either when the service intervals rec-
ommend or before they reach maximum life span.
We recommend that you use our genuine parts / elements guaranteed for premium quality.
Monitor those disposable items and replace when necessary. This will save your money in the long run.
The few items in parentheses ( ) in the list need to be replaced with the matching item to be replaced.
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Replacement Intervals for Hydraulic Oil and Filters When Using Breaker
• When using the hydraulic breaker, the deterioration and/or contamination of hydraulic oil progresses
faster compared to ordinary digging work. Be sure to carry out the maintenance more often. In addition,
when replacing the hydraulic filters, also measure the cleanliness and deterioration of the oil.
• Replace the hydraulic oil and filter element, using the graph as a guideline, depending on the operation
frequency of the breaker.
• If the breaker work continues during a short period of time and the hour meter exceeds 100 hours during
the period, replace the element every 100 hours.
• Replace the return filter for the breaker at the same interval as the element. Additionally, if using a filter
with indicator, change the filter according to the indicator's indication.
AVERAGE OPERATION RATE OF
HYDRAULIC BREAKER (%)
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Inspection and Maintenance of Hydraulic Oil and Filters Based on Frequency of Breaker Use
Recommended Hydraulic Oil Servicing Use frequency Use frequency Use frequency Use frequency
Intervals 100% 40% 20% 10%
Inspection/Maintenance Location Time 10 100 600 10 300 1500 10 600 3000 10 800 4000
Hydraulic Oil ○ ◎ ○ ◎ ○ ◎ ○ ◎
Return Filter ◎ ◎ ◎ ◎
Suction Filter ◇ ◎ ◇ ◎ ◇ ◎ ◇ ◎
Drain Filter ◎ ◎ ◎ ◎
Pilot Filter ◎ ◎ ◎ ◎
Nephron Filter ◎ ◎ ◎ ◎
Line Filter ◎ ◎ ◎ ◎
Measure hydraulic oil contamination Every 200 Hrs Every 300 Hrs Every 600 Hrs Every 800 Hrs
When the hour meter exceeds 100 hours and breaker operations are done continuously for short periods,
change the element each time.
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