The document provides instructions for disassembling and assembling various components of heavy machinery, including a main pump. It lists over 30 individual parts that make up the pump and their order of removal. General instructions are provided, such as working clean, avoiding damage to parts, ensuring proper alignment, and using presses instead of hammers. The priority valve disassembly is also described, which involves removing assembling bolts, washers, a plug, and spring and spool.
Hyundai hb90 backhoe loader service repair manualudjjfkkskemm
The document provides instructions for disassembling and assembling various components of heavy machinery, including a main pump. It lists over 30 individual parts that make up the pump and their order of removal. General instructions are provided, such as working clean, avoiding damage to parts, using proper tools for pressing/fitting components, and respecting rotation directions. The priority valve disassembly is also described, which involves removing assembling bolts, washers, a plug, and spring/spool.
Hyundai hbf18 t 5 forklift truck service repair manualfjjsekmmm
This document provides instructions for disassembling and assembling the steering unit of a machine. It includes the following sections:
1. Tools and torque specifications needed for the job.
2. Instructions for disassembling components like the end cover, gearwheel set, cardan shaft, distributor plate, seals and springs.
3. Instructions for assembling components like the spool, sleeve, seals, springs and end cover. Precise steps are provided to ensure correct assembly.
Hyundai 80 d 7e forklift truck service repair manualfjjsekmmm
The document provides instructions for disassembling and assembling a steering unit. It describes the individual parts of the steering unit and lists the necessary tools. The steps for disassembly include removing the end cover, gearwheel set, cardan shaft, distributor plate, check valve parts, thrust bearing and races from the sleeve and spool. Assembly involves reversing these steps, making sure to properly position springs, seals, and other small parts. Torque specifications are provided for mounting bolts.
Hyundai hlf1518(c) 5 forklift truck service repair manualfjjskekdmmse
The document outlines the contents and structure of a service manual for a machine. It includes 8 sections that cover general information, removal/installation procedures, power train, brake, steering, hydraulic, electrical, and mast systems. Each section contains groups that break down the systems and components. The document provides an overview of the contents, structure, and intended use of the service manual to aid technicians in performing repairs correctly.
Hyundai 20 l(g) 7a forklift truck service repair manualfjsekksmemm
This document provides instructions for disassembling and assembling hydraulic components, including:
1. Hydraulic gear pump disassembly instructions involving removing mounting bolts, draining oil, marking parts for reassembly, and removing individual parts like shafts, seals, and bearing blocks.
2. Hydraulic gear pump assembly instructions covering installing new seals, pressing in the shaft seal, installing bearing blocks and gears, and torquing mounting bolts.
3. Main control valve assembly instructions involving stacking sections with o-rings installed, inserting tie rods, and torquing nuts to attach sections.
Hyundai 16 b 9 forklift truck service repair manualfjsjekkmdmme
This document provides an overview of the service manual for a machine. It is divided into 8 sections that cover general information, removal/installation of components, power train, brake, steering, hydraulic, electrical, and mast systems. Each section contains groups that explain the structure, operation, troubleshooting, and disassembly/assembly of the various systems. Safety symbols and conventions for reading the manual are also outlined. The document aims to provide technicians an accurate understanding of the machine to perform repairs correctly.
Hyundai 20253032 bc 7 forklift truck service repair manualfjjsekmmm
This document provides instructions for disassembling and assembling the steering unit of a machine. It describes removing components like the end cover, gearwheel set, cardan shaft, distributor plate, check valve parts, thrust bearing and springs. It then explains how to reassemble these parts, including pressing in seals and springs correctly. Tools needed are also listed along with tightening torques for mounting bolts.
Hyundai 35 bh 9 forklift truck service repair manualfjjsekmsmmes
The document provides information on the disassembly and assembly of a steering unit. It includes diagrams of the major components of the steering unit and lists the necessary tools. It then provides step-by-step instructions for disassembling the steering unit, including removing components like the end cover, gearwheel set, distributor plate, check valve ball, and O-rings. Reassembly instructions are not provided. Tightening torques are specified for mounting bolts.
Hyundai hb90 backhoe loader service repair manualudjjfkkskemm
The document provides instructions for disassembling and assembling various components of heavy machinery, including a main pump. It lists over 30 individual parts that make up the pump and their order of removal. General instructions are provided, such as working clean, avoiding damage to parts, using proper tools for pressing/fitting components, and respecting rotation directions. The priority valve disassembly is also described, which involves removing assembling bolts, washers, a plug, and spring/spool.
Hyundai hbf18 t 5 forklift truck service repair manualfjjsekmmm
This document provides instructions for disassembling and assembling the steering unit of a machine. It includes the following sections:
1. Tools and torque specifications needed for the job.
2. Instructions for disassembling components like the end cover, gearwheel set, cardan shaft, distributor plate, seals and springs.
3. Instructions for assembling components like the spool, sleeve, seals, springs and end cover. Precise steps are provided to ensure correct assembly.
Hyundai 80 d 7e forklift truck service repair manualfjjsekmmm
The document provides instructions for disassembling and assembling a steering unit. It describes the individual parts of the steering unit and lists the necessary tools. The steps for disassembly include removing the end cover, gearwheel set, cardan shaft, distributor plate, check valve parts, thrust bearing and races from the sleeve and spool. Assembly involves reversing these steps, making sure to properly position springs, seals, and other small parts. Torque specifications are provided for mounting bolts.
Hyundai hlf1518(c) 5 forklift truck service repair manualfjjskekdmmse
The document outlines the contents and structure of a service manual for a machine. It includes 8 sections that cover general information, removal/installation procedures, power train, brake, steering, hydraulic, electrical, and mast systems. Each section contains groups that break down the systems and components. The document provides an overview of the contents, structure, and intended use of the service manual to aid technicians in performing repairs correctly.
Hyundai 20 l(g) 7a forklift truck service repair manualfjsekksmemm
This document provides instructions for disassembling and assembling hydraulic components, including:
1. Hydraulic gear pump disassembly instructions involving removing mounting bolts, draining oil, marking parts for reassembly, and removing individual parts like shafts, seals, and bearing blocks.
2. Hydraulic gear pump assembly instructions covering installing new seals, pressing in the shaft seal, installing bearing blocks and gears, and torquing mounting bolts.
3. Main control valve assembly instructions involving stacking sections with o-rings installed, inserting tie rods, and torquing nuts to attach sections.
Hyundai 16 b 9 forklift truck service repair manualfjsjekkmdmme
This document provides an overview of the service manual for a machine. It is divided into 8 sections that cover general information, removal/installation of components, power train, brake, steering, hydraulic, electrical, and mast systems. Each section contains groups that explain the structure, operation, troubleshooting, and disassembly/assembly of the various systems. Safety symbols and conventions for reading the manual are also outlined. The document aims to provide technicians an accurate understanding of the machine to perform repairs correctly.
Hyundai 20253032 bc 7 forklift truck service repair manualfjjsekmmm
This document provides instructions for disassembling and assembling the steering unit of a machine. It describes removing components like the end cover, gearwheel set, cardan shaft, distributor plate, check valve parts, thrust bearing and springs. It then explains how to reassemble these parts, including pressing in seals and springs correctly. Tools needed are also listed along with tightening torques for mounting bolts.
Hyundai 35 bh 9 forklift truck service repair manualfjjsekmsmmes
The document provides information on the disassembly and assembly of a steering unit. It includes diagrams of the major components of the steering unit and lists the necessary tools. It then provides step-by-step instructions for disassembling the steering unit, including removing components like the end cover, gearwheel set, distributor plate, check valve ball, and O-rings. Reassembly instructions are not provided. Tightening torques are specified for mounting bolts.
Hyundai hb100 backhoe loader service repair manualiekkdmmem
This document contains sections on safety, specifications, operational checks, engine systems, power train systems, brake systems, steering systems, work equipment, electrical systems, and troubleshooting guides for various components. It provides information on component locations, electrical circuits, monitoring systems, switch specifications, and testing and adjustment procedures. The sections cover the structure and function of components, operational checks and troubleshooting, tests and adjustments, and disassembly and reassembly instructions.
Hyundai 60 d 7e forklift truck service repair manualfusjejkdkmse
The document provides instructions for disassembling and assembling a steering unit. It describes the individual parts of the steering unit and lists the necessary tools. The steps for disassembly include removing the end cover, gearwheel set, cardan shaft, distributor plate, check valve parts, sleeve, spool and other components. Assembly instructions are then provided and describe cleaning, lubricating and inserting parts in the correct order and orientation. Tightening torques are also specified for reinstallation.
Hyundai 50 d 7e forklift truck service repair manualfusjejkdkmse
This document provides instructions for disassembling and assembling a steering system. It outlines the components and structure of the steering unit with labeled diagrams. The document lists the necessary tools required for disassembly and assembly. It provides the tightening torques for mounting bolts on different ports of the unit. Detailed step-by-step instructions are provided for disassembling the steering unit and removing components like the end cover, gearwheel set, and relief valve assembly.
Hyundai 70 d 7e forklift truck service repair manualfusjejkdkmse
This document provides instructions for disassembling and assembling a steering system. It outlines the components of the steering unit and their structure. It lists the necessary tools required for disassembly and assembly. It provides the tightening torque specifications for different ports of the steering unit. The disassembly process steps are described which include removing the end cover screws, lifting out the gearwheel set, and removing other internal components like the spool, springs, seals etc.
Hyundai 20253032 bc 7 forklift truck service repair manualidkkddkmd
The document provides instructions for disassembling and assembling the steering unit of a machine. It lists the necessary tools and torque specifications. The disassembly process is described in 18 steps and involves removing components like the end cover, gearwheel set, cardan shaft, distributor plate, check valve parts, sleeve, spool and seals. The assembly process is described in 16 steps and involves installing these components in reverse order, ensuring proper positioning of springs and seals using specialized tools. Tightening torques are provided for mounting bolts.
Hyundai 20253032 bc 7 forklift truck service repair manualfjjskekmdmme
The document provides instructions for disassembling and assembling the steering unit of a machine. It includes:
1. A list of tools needed for disassembly and assembly.
2. Steps for disassembling components like the end cover, gearwheel set, cardan shaft, distributor plate, check valve parts, sleeve, spool, springs, and pressure relief valve.
3. Steps for assembling the spool and sleeve, installing springs and pins, fitting bearing races and seals, and pressing components back into place. Tightening torques are also provided.
Hyundai 30 bh 9 forklift truck service repair manualfjjskdmnenemm
This document provides instructions for disassembling and assembling a steering unit. The major steps include:
1) Disassembling the steering unit by removing components like the end cover, gearwheel set, cardan shaft, distributor plate, check valve parts, sleeve, spool, and pressure relief valve parts.
2) Assembling the spool and sleeve with neutral position springs installed in slots. Bearing races and seals are also installed.
3) Lubricating O-rings and seals before installing them using assembly tools to properly position the components.
4) Reassembling the steering unit by installing the spool set, distributor plate, and other components removed during dis
Liebherr er 942 hydraulic excavator service repair manualudjjfkkskemm
The document is a service manual that provides technical data, maintenance guidelines, and information on systems for hydraulic excavators models ER 900-942. It covers general information, tools, the engine, coupling and splitterbox, hydraulic system, hydraulic components, electrical system, swing gear, swing ring, travel gear, track components, undercarriage and uppercarriage attachments, cab heater and air conditioning. The manual is intended to assist with maintenance and repairs for the excavator models.
Jcb js115 t2 excavator service repair manual sn 2397465 and upudjjfkkskemm
The document provides maintenance instructions for steel tracks on excavators. It includes procedures to check track components for wear, measure critical dimensions, and compare measurements to tolerance charts to determine replacement needs. Key components like links, pins, bushes and the sprocket are to be inspected, with links also checked for distortion. Measurements of dimensions like track tension, pin pitch and bush diameter indicate wear percentages and guide maintenance decisions.
Jcb 540 v140 telescopic handler service repair manual sn from 2460601 onwardsudjjfkkskemm
This service manual provides instructions for servicing the Loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear.
Jcb 540 200 telescopic handler service repair manual sn from 2902000 onwardsudjjfkkskemm
This service manual provides information on servicing the Loadall rough terrain variable reach truck. It contains instructions that were originally provided by the manufacturer and covers systems like the engine, brakes, hydraulics, and electrical systems. The manual instructs technicians to study it before operating or maintaining the machine to prevent injury or death. It also contains sections on safety, maintenance procedures, technical specifications, and the removal and installation of components.
Jcb 540 170 telescopic handler service repair manual sn from 2460601 onwardsudjjfkkskemm
This service manual provides instructions for servicing the Loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear.
Jcb 535 95 tier 4 telescopic handler service repair manual sn from 2460601 on...udjjfkkskemm
This service manual provides instructions for servicing the components of a Loadall rough terrain variable reach truck, including the fuel injection system. The document covers removal and installation procedures for fuel injectors, injector seals, the common fuel rail, and the high pressure fuel injection pump. Safety information is provided throughout regarding working on the fuel system and the need to relieve pressure before conducting repairs.
Jcb 536 60 tier 4 telescopic handler service repair manual sn from 2460601 on...udjjfkkskemm
This document provides service and repair instructions for fuel injectors on JCB Loadall vehicles. It begins with an introduction to the injector components and operation. The main sections provide procedures for checking injector operation with diagnostic tools, removing and installing individual injectors, and removing and installing injector seals in the cylinder head. The summary highlights that the document contains procedures for inspecting and replacing fuel injectors and their seals.
Jcb 526 56 telescopic handler service repair manual sn 2336575 and upudjjfkkskemm
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 250 skid steer loader service repair manual sn from 2675500 to 2675700udjjfkkskemm
This service manual provides instructions for servicing skid steer loaders and their engines. It details removing and installing the engine bedplate, which acts as the main strength component and maintains alignment of internal engine parts. The multi-step procedure requires cleaning parts, applying sealant, installing bearing shells and bolts, and torquing bolts to specified values. Special tools like templates and torque wrenches are needed to correctly complete the process.
Jcb 250 skid steer loader service repair manual sn from 2478301 to 2478700udjjfkkskemm
This service manual provides instructions for servicing JCB skid steer loaders and their components. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, driveline, hydraulics, and electrical system. The section summarized here provides instructions for removing and installing the crankshaft from the engine. It describes cleaning and inspecting the crankshaft, lists the required tools and consumables, and outlines the step-by-step removal and installation procedures.
Jcb 9 tst dumper service repair manual sn from grm0011 to grm9989udjjfkkskemm
This service manual provides instructions for servicing the braking system of dumpers. It contains information on health and safety when working on the brakes, technical specifications, component identification, troubleshooting, and bleeding the brakes. The braking system uses mineral oil and contains separate front and rear brake circuits for safety. Adjustment is generally not needed as the brakes are self-adjusting, but bleeding may be required if the brake lines leak fluid.
Jcb 9 tft dumper service repair manual sn from hrm1382 to hrm4003udjjfkkskemm
This service manual provides instructions for servicing the braking system of dumpers. It contains information on health and safety when working on the brakes, technical specifications, component identification, troubleshooting, and bleeding the brakes. The braking system uses mineral oil and contains separate front and rear brake circuits for safety. Adjustment is generally not needed as the brakes are self-adjusting, but bleeding may be required if the brake lines leak fluid.
Jcb 5 cx wastemaster eco backhoe loader service repair manual sn from 2442701...udjjfkkskemm
This service manual section provides information on servicing the crankshaft and related components on a backhoe loader. It includes identification of parts, technical specifications, operation descriptions, removal and installation instructions, and check/inspection procedures. Proper cleaning and installation of the crankshaft oil seal is critical to prevent oil leakage. Removal and installation of the crankshaft requires carefully following all steps while ensuring components remain clean and undamaged.
Jcb 5 cx backhoe loader service repair manual sn from 2509500 and upudjjfkkskemm
This service manual provides instructions for servicing the crankshaft on a backhoe loader. The crankshaft is a core component that connects the pistons to the flywheel. Key steps in servicing the crankshaft include cleaning it and inspecting the journals for wear. The crankshaft needs to be removed to service other engine components like the main bearings. Proper installation requires cleaning surfaces, installing new cooling jets, lubricating bearings, and fitting thrust washers in the correct orientation. Following the removal and installation procedures helps ensure the crankshaft operates properly.
Jcb 4 cx backhoe loader service repair manual sn from 2442701 to 2451000udjjfkkskemm
This service manual provides instructions for servicing the crankshaft on a backhoe loader. The crankshaft is a core component that connects the pistons to the flywheel. Key steps in servicing the crankshaft include cleaning the crankcase and bearings, checking crankshaft dimensions, installing new piston cooling jets, and properly positioning the thrust washers between the crankshaft and rear main bearing. Technicians must follow all removal and installation procedures carefully to ensure the crankshaft and related components are correctly serviced.
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This document provides instructions for disassembling and assembling a steering unit. The major steps include:
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Hyundai hb100 backhoe loader service repair manual
1. 0-9
CONTENTSCONTENTS
SECTION 1 GENERALSECTION 1 GENERAL
Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10
Group 3 Operational Checkout Record Sheet --------------------------------------------------------------- 1-17
SECTION 2 ENGINESECTION 2 ENGINE
Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1
Group 3 Engine Speed and Stall rpm ----------------------------------------------------------------------------- 2-8
SECTION 3 POWER TRAIN SYSTEMSECTION 3 POWER TRAIN SYSTEM
Group 1 Structure and Function -------------------------------------------------------------------------------------- 3-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 3-15
Group 3 Test and Adjustments ---------------------------------------------------------------------------------------- 3-23
Group 4 Disassembly and Assembly ------------------------------------------------------------------------------ 3-25
SECTION 4 BRAKE SYSTEMSECTION 4 BRAKE SYSTEM
Group 1 Structure and Function -------------------------------------------------------------------------------------- 4-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 4-7
Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 4-11
SECTION 5 STEERING SYSTEMSECTION 5 STEERING SYSTEM
Group 1 Structure and Function -------------------------------------------------------------------------------------- 5-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 5-8
Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 5-15
Group 4 Disassembly and Assembly ----------------------------------------------------------------------------- 5-22
SECTION 6 WORK EQUIPMENTSECTION 6 WORK EQUIPMENT
Group 1 Structure and Function -------------------------------------------------------------------------------------- 6-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 6-59
Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 6-72
Group 4 Disassembly and Assembly ----------------------------------------------------------------------------- 6-86
2. 0-10
SECTION 7 ELECTRICAL SYSTEMSECTION 7 ELECTRICAL SYSTEM
Group 1 Component Location ---------------------------------------------------------------------------------------- 7-1
Group 2 Electrical Circuit ------------------------------------------------------------------------------------------------ 7-3
Group 3 Monitoring System -------------------------------------------------------------------------------------------- 7-22
Group 4 Switches ------------------------------------------------------------------------------------------------------------ 7-27
Group 5 Electrical Component Specification ---------------------------------------------------------------- 7-35
3. 0-1
FOREWORDFOREWORD
1. STRUCTURE1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to
perform repairs and make judgements. Make sure you understand the contents of this manual and
use it to full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
Structure and functionStructure and function
This group explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
Operational checks and troubleshootingOperational checks and troubleshooting
This group explains the system operational checks and troubleshooting charts correlating problem to
remedy.
Tests and adjustmentsTests and adjustments
This group explains checks to be amide before and after performing repairs, as well as adjustments
to be made at completion of the checks and repairs.
Disassembly and assemblyDisassembly and assembly
This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your Hyundai distributor for the latest information.
4. 0-2
Revised edition markRevised edition mark ( )
When a manual is revised, an edition mark is
recorded on the bottom outside corner of the
pages.
RevisionsRevisions
Revised pages are shown at the list of revised
pages on the between the contents page and
section 1 page.
SymbolsSymbols
So that the shop manual can be of ample
practical use, important places for safety and
quality are marked with the following symbols.
2. HOW TO READ THE SERVICE MANUAL2. HOW TO READ THE SERVICE MANUAL
Distribution and updatingDistribution and updating
Any additions, amendments or other changes
will be sent to HYUNDAI distributors.
Get the most up-to-date information before you
start any work.
Filing methodFiling method
See the page number on the bottom of the
page.
File the pages in correct order.
Following examples shows how to read the
page number.
Example 1
3 - 3
Section number (3. Power train
system)
Consecutive page number for
each section.
Additional pages : Additional pages are
indicated by a hyphen(-) and number after the
page number. File as in the example.
1.
2.
3.
Symbol Item Remarks
Special safety precautions are
necessary when performing the
work.
Extra special safety precautions
are necessary when performing
the work because it is under
internal pressure.
Special technical precautions or
other precautions for preserving
standards are necessary when
performing the work.
Safety
Caution
10 - 4
10 - 4 - 1
10 - 4 - 2
10 - 5
Added pages
5. 0-3
3. CONVERSION TABLE3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
ExampleExample
Method of using the Conversion Table to convert from millimeters to inches
Convert 55 mm into inches.
Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal
line from .
Locate the number 5in the row across the top, take this as , then draw a perpendicular line
down from .
Take the point where the two lines cross as . This point gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
Convert 550 mm into inches.
The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
Carry out the same procedure as above to convert 55 mm to 2.165 inches.
The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value.
This gives 550 mm = 21.65 inches.
1.
2.
(1)
(2)
(3)
(1)
(2)
(3)
Millimeters to inchesMillimeters to inches
1mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
6. 6-86
1. MAIN PUMP1. MAIN PUMP
STRUCTURESTRUCTURE1)1)
GROUP 4 DISASSEMBLY AND ASSEMBLYGROUP 4 DISASSEMBLY AND ASSEMBLY
24
23 4
26
25
22
5
9
26 7
5
22
25
20
33
1
26
21
34
14
28
19
27
13
3
29
30
18
35
15
16
10
16
32
1125
22
5
5
22
25
20
6
8
2
17
12
31
26
1 Body
2 Body
3 Rear end cover
4 Front cover
5 Thrustplate
6 Driven gear
7 Driven gear
8 Drive shaft
9 Drive shaft
10 Screw
11 Screw
12 Screw
13 Screw
14 Screw
15 Screw
16 Washer
17 Washer
18 O-ring seal
19 O-ring seal
20 Ring
21 O-ring seal
22 Seal
23 Shaft seal
24 Ring
25 Ring
26 Sleeve bearing
27 Spool
28 Filter
29 Spring seat
30 Spring
31 Hub
32 Connection
33 Steel bushing
34 Plug
HB100WE21
7. 6-87
GENERAL INSTRUCTIONSGENERAL INSTRUCTIONS
Check immediately that any spare parts you receive have not been damaged in shipment.
Always work in a clean environment.
Wash all components in solvent and blow dry with compressed air before refitting.
Take care not to damage rubber seals.
Avoid damaging precision machined surfaces.
Components should fit into their housings without excessive force. If force is necessary, this
normally means that the component does not have the correct dimensional tolerances of is
aligned incorrectly.
When hand pressure is insufficient, only use presses or rubber hammer to fit components.
Never strike components with steel hammers.
Steel bushing must be fitted only with a suitable press.
Do not use hammers to fit bearings.
Always respect the direction of rotation when assembling components.
2)2)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
8. 6-88
HB100WE51
DISASSEMBLYDISASSEMBLY
LS priority valveLS priority valve
Loosen and remove the assembling bolts
and washers from the pump.
3)3)
(1)(1)
Loosen and remove plug and take out
spring & spool. (Only when it is needed
to replace components inside).
Pay attention not to give any damage on
the surface of the spool and contamina-
tion to the orifices prearranged at the
spool.
HB100WE52
①
②
※
HB100WE53
Mounting flangeMounting flange
Loosen and remove the assembling bolts
and washers from the pump.
(2)(2)
①
9. 6-89
HB100WE54
HB100WE55
HB100WE56
Remove mounting flange taking care to
keep it as straight as possible during
removal.
Tap around the edge with rubber mallet
in order to break away from the body.
Ensure that while removing it, the drive
shaft and other components remain
position.
②
※
Remove shaft seal with (-) screwdriver
and take out snap ring with proper tool
and shaft seal again.
Take out the shaft seals only needed.
Shaft seals disassembled from the
mounting flange is not reusable.
③
※
1st working section1st working section
Remove the pressure plate with
prearranged parts, O-ring & back up ring
from the working section and examine it
carefully.
(3)(3)
①
10. 6-90
HB100WE57
HB100WE58
Pull out driving gear & driven gear
keeping gears as straight as possible.
Remove other pressure plate on rear
side with same way for front side.
②
③
Remove square O-ring on the groove of
body.
Remove through shaft and front body.
Tap around marked points with rubber
mallet all around to break away first body
from second.
Do not wedge between the bodies, it
may give serious damage on the surface.
④
⑤
※
HB100WE59
2nd working section2nd working section
Remove all components inside of second
body with same way for 1st section.
Remove the square O-ring if necessary.
(4)(4)
①
②
11. 6-91
HB100WE60
ASSEMBLYASSEMBLY
PreassemblePreassemble
Pressure platesPressure plates
Locate O-ring into the groove on the
aluminum pressure plate.
Locate back-up ring upon the O-ring.
Smear clean grease on the O-ring &
back-up ring to fix their position while
moving.
4)4)
(1)(1)
Working bodyWorking body
Insert square rings into grooves.
Shape of square ring is different depend
on type of bodies.
HB100WE61
①
②
③
①
HB100WE62
Mounting flangeMounting flange
Locate shaft seal inside shaft hole to the
end.
Insert snap ring and locate it into the
groove prearranged on the mounting
flange.
Locate shaft seal again but different
direction.
①
②
③
12. 6-92
LS - priority valveLS - priority valve
Insert the spool prearranged all orifice
first, and spring, plugs.
·Torque value of both sides plugs :
10.2 kgf·m (73.8 lbf·ft)
·Torque value of LS plug :
1.53 kgf·m (11.1 lbf·ft)
HB100WE63
①
HB100WE64
AssemblingAssembling
Prepare cleaned 2nd body prearranged
guard pins and square O-ring.
Insert a pressure plate prearranged
O-ring & back-up ring inside of body.
Opened area of O-ring should face to
suction side. And O-ring side should face
to the body.
(2)(2)
①
②
※
HB100WE65
LS plug
13. 6-93
HB100WE66
Locate driving gear and driven gear
keeping as straight as possible during
assembling.
Locate one of pressure plates prepared.
③
④
HB100WE67
Locate 1st body on the 2nd body tapping
around the body with rubber mallet to fit it
completely.
Locate through shaft on the driving gear.
Locate pressure plate with same way for
2nd body.
⑤
⑥
⑦
HB100WE68
Locate driving gear and driven gear and
last pressure plate also.
⑧
14. 6-94
HB100WE69
Assemble mounting flange to the body,
taking care not to give any damage on
the shaft seals by sharp edge of shaft.
Smear clean grease on the lips of shaft
seals before assembling.
⑨
※
HB100WE70
Assemble the bolts and tighten the bolts
with in a crisscross pattern to a torque
value of 14.3 kgf·m (103 lbf·ft).
Check that the pump rotates freely when
the drive shaft is turned by hand, if not a
possible, plate seal may be pinched.
⑩
⑪
HB100WE71
Locate an O-ring into the groove on the
body.
Locate preassembled LS - priority valve
on the 1st working section and tighten
the bolts with in a crisscross pattern to a
torque value of 7.14 kgf·m (51.6 lbf·ft).
⑫
⑬
16. 6-96
INITIAL SETUP OF THE VALVE ONINITIAL SETUP OF THE VALVE ON
ASSEMBLY BENCHASSEMBLY BENCH
Clean the table.
Wear safety goggles.
Place the stacked valve with inlet to the
left side as shown in the picture.
Clean the valve using compressed air so
that valve is free from any dust or dirt.
2)2)
(1)
(2)
(3)
(4)
HB100WE91
HB100WE92
CHECK VALVE ASSEMBLYCHECK VALVE ASSEMBLY
Assemble the check valve into the check
valve cavity.
Make sure that O-ring is present in the
check valve.
3)3)
(1)
(2)
HB100WE93
Tighten in to 4.28 kgf·m (31 lbf·ft) torque
(wrench 08) using pneumatic torque gun.
(3)
HB100WE94
P PORT PLUG ASSEMBLYP PORT PLUG ASSEMBLY
Close the top inlet port with SAE 16 plug
and tighten it to 4.28 kgf·m (31 lbf·ft)
torque (wrench 12) using pneumatic
torque gun. (Make sure that O-ring is
present in the plug.)
4)4)
(1)
17. 6-97
HB100WE95
HB100WE96
MANOMETER PLUG ASSEMBLYMANOMETER PLUG ASSEMBLY
Insert the poppet in the manometer cavity.
Then insert the spring on to the poppet.
5)5)
(1)
(2)
HB100WE97
Insert the spacer on top of the spring.(3)
HB100WE98
Assemble the BSP 1/2" plug and tighten it
to 4.28 kgf·m (31 lbf·ft) torque (wrench
27) using pneumatic torque gun. (Make
sure that washer is present in the plug.)
(4)
Plug
18. 6-98
HB100WE99
HB100WE100
PRIORITY INLET SPOOL ASSEMBLYPRIORITY INLET SPOOL ASSEMBLY
Insert orifice of ( 0.75 mm) in the spool
as shown in picture.
Lubricate the spool cavity with hyspin
VG46.
6)6)
(1)
(2)
Insert the spring on to the spool seat.(4)
HB100WE101
HB100WE102
Assemble the adapter and tighten it to
4.28 kgf·m (31 lbf·ft) torque (wrench 32)
using pneumatic torque gun. (Make sure
that washer & O-rings are present in the
adapter.
(5)
Insert the spool into the spool cavity with
orifice face should go inside.
(3)
19. 6-99
HB100WE103
Plug the other side of the spool cavity with
M22×1.5 mm plug and tighten it to 4.28
kgf·m (31 lbf·ft) torque (wrench 12) using
pneumatic torque gun. (Make sure that
O-ring is present in the adapter.)
(6)
HB100WE104
HB100WE105
UNLOADING SOLENOID VALVEUNLOADING SOLENOID VALVE
ASSEMBLYASSEMBLY
Assemble the solenoid as shown in the
picture and tighten it to 5.10 kgf·m (36.9
lbf·ft) torque (wrench 24) using pneumatic
torque gun.
7)7)
(1)
HB100WE106
Insert the coil into the solenoid.
Assemble the insulator.
(2)
(3)
LS VALVE ASSEMBLYLS VALVE ASSEMBLY
Insert orifice of ( 1.25 mm) in the LS
cavity as shown in picture.
8)8)
(1)
20. 6-100
HB100WE107
Assemble the LS valve into LS cavity and
tighten it to 2.45 kgf·m (17.7 lbf·ft) torque
(wrench 19) using pneumatic torque gun.
(2)
HB100WE108
MAIN RELIEF VALVE ASSEMBLYMAIN RELIEF VALVE ASSEMBLY
Assemble main relief valve into the main
relief valve cavity as shown in picture and
tighten it to 4.28 kgf·m (31 lbf·ft) torque
(wrench 36) using pneumatic torque gun.
9)9)
(1)
HB100WE109
PORT RELIEF VALVE ASSEMBLYPORT RELIEF VALVE ASSEMBLY
Assemble the port relief valve into the port
relief valve cavity as describe below and
tighten it to 2.45 kgf·m (17.7 lbf·ft) torque
(wrench 19) using pneumatic torque gun.
1st section (from inlet) : ZTAL-00206
2nd section (bucket) : ZTAL-00196/00197
3rd section (boom) : ZTAL-00148
10)10)
(1)
HB100WE110
PORT RELIEF VALVE CAVITY PLUGPORT RELIEF VALVE CAVITY PLUG
ASSEMBLYASSEMBLY
Plug remaining port relief cavities with
P3T plugs (i.e. on B1 & B2 port) and
tighten it to 4.28 kgf·m (31 lbf·ft) torque
(wrench 12) using pneumatic torque gun.
11)11)
(1)
·
·
·
21. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
22. 6-101
HB100WE111
SPOOL ASSEMBLYSPOOL ASSEMBLY
Lubricate all the spool cavities with hyspin
VG46.
Insert spool as describe below with eye
end of the spool is on the lever side.
1st section (Aux) : ZTAL-00167
2nd section (bucket) : ZTAL-00167
3rd section (boom) : ZTAL-00168
Move the spools in and out two to three
times for free movement.
12)12)
(1)
(2)
(3)
HB100WE112
O-RING AND SPACER ASSEMBLY ONO-RING AND SPACER ASSEMBLY ON
CONTROL KIT SIDECONTROL KIT SIDE
Assemble the O-ring in the O-ring groove
as shown in the picture.
Assemble the spacer into the spacer
groove provided in spool cavity (chamfered
face should go inside the cavity).
13)13)
(1)
(2)
HB100WE113
CONTROL KIT ASSEMBLY ON BOTHCONTROL KIT ASSEMBLY ON BOTH
SIDE OF THE VALVESIDE OF THE VALVE
Apply a drop of loctite #270 thread locker
on control kit screw threads.
Place control kit spring in between two
bushes as shown, and then assemble
these into the spool with control kit screw.
(Bucket control kit : ZTAL-00192,
boom control kit : ZTAL-00234)
14)14)
(1)
(2)
·
·
·
HB100WE114
Tighten the control kit to 0.99 kgf·m (7.16
lbf·ft) torque (wrench 04) using pneumatic
torque gun.
Lubricate the proper quantity of grease to
all control kits.
(3)
(4)
23. 6-102
HB100WE115
Assemble the end cap with M6 screws
and tighten to 0.67 kgf·m (4.85 lbf·ft)
torque using pneumatic torque gun.
(5)
HB100WE116
LEVER KIT ASSEMBLYLEVER KIT ASSEMBLY
Assemble the O-ring in the O-ring groove
as shown in the picture.
Assemble the spacer into the spacer
groove provided in spool cavity (chamfered
face should go inside the cavity)
15)15)
(1)
(2)
HB100WE117
Assemble lever cap and tighten it with M6
screws to 0.99 kgf·m (7.16 lbf·ft) torque
using pneumatic torque gun.
(3)
HB100WE118
RE PLUG ASSEMBLYRE PLUG ASSEMBLY
Assemble the RE plug (M18×1.5 mm)
in tank port as shown in the picture and
tighten it with allen key.
16)16)
(1)