EX400-5, EX400LC-5, EX450LC-5
Workshop Manual
SECTION 1
GENERAL INFORMATION —CONTENTS— Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling........................................... W1-1-1 Maintenance Standard Terminology........ W1-1-6
Group 2 Tightening Tightening Torque Specification.............. W1-2-1 Torque Chart .......................................... W1-2-3 Piping joint ............................................. W1-2-6 Periodic Replacement of Parts ............. W1-2-10
166W-1-1
(Blank)
166W-1-2
GENERAL INFORMATION / Precautions for Disassembling and Assembling PRECAUTIONS FOR AND ASSEMBLING
DISASSEMBLING
Precautions for Disassembling and Assembling
• Clean the Machine
• Precautions for Disassembling • To prevent dirt from entering, cap or plug the removed pipes. • Before disassembling, clean the exterior of the components and place it on a work bench. • Before disassembling, drain gear oil from the reduction gear. • Be sure to provide appropriate containers for draining fluids. • Use matching marks for easier reassembling. • Be sure to use the specified special tools, when instructed. • If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause(s), then take the appropriate measures to remove it. • Orderly arrange disassembled parts. Mark and tag them as necessary. • Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. • Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. • Measure and record the degree of wear and clearances.
Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work.
• Inspect the Machine Be sure to thoroughly understand all disassembling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future. • The machine model, machine serial number, and hour meter reading. • Reason for disassembly (symptoms, failed parts, and causes). • Clogging of filters and oil, water or air leaks, if any. • Capacities and condition of lubricants. • Loose or damaged parts.
• Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work.
• Precautions for Assembling
W1-1-1
• Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace it. • Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces. • Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing. • Be sure that liquid-gasket-applied surfaces are clean and dry. • If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent. • Utilize matching marks when assembling. • Be sure to use the designated tools to assemble bearings, bushings and oil seals. • Keep a record of the number of tools used for disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no tools are missing.
GENERAL INFORMATION / Precautions for Disassembling and Assembling Bleeding Air from Hydraulic System When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and installation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures: IMPORTANT: If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result. If the hydraulic motor is operated with air trapped in the hydraulic motor housing, damage to the motor may result. If the cylinder is operated with air trapped in the cylinder tube, damage to the cylinder may result. Be sure to bleed air before starting the engine.
• Bleeding Air from Hydraulic Pump • Remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil. • After the pump housing is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run at slow idle speed. • Slightly loosen the plug to bleed air from the pump housing until hydraulic oil oozes out. • After bleeding all the air, securely tighten the plug.
• Bleeding Air from Travel Motor / Swing Motor • With the drain plug / hose on travel motor / swing motor removed, fill the motor case with hydraulic oil.
• Bleeding Air from Hydraulic Circuit • After refilling hydraulic oil, start the engine. While operating each cylinder, swing motor and travel motor evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes. • Reposition the front attachment to check hydraulic oil level. • Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary.
W1-1-2
M104-07-021
GENERAL INFORMATION / Precautions for Disassembling and Assembling Floating Seal Precautions A
1. In general, replace the floating seal with a new one. If the floating seal is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. (2) Check the slide surface on seal ring surface (A) for scuffing, scoring, corrosion, deformation or uneven wear.
B
W105-03-05-019
(3) Check O-ring (B) for tears, breaks, deformation or hardening. 2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble. (1) Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air.
Correct
Incorrect
(2) Clean the floating seal and seal mounting bores. Check the bore surface for scuffing or scoring by touching the surface with finger. (3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring. (4) After installing the floating seal, check that seal ring surface (A) is parallel with seal mating face (C) by measuring the distances seal ring surface (A) and seal mating face (C) at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating.
Correct
C
W105-03-05-020
Incorrect
a
a
A B
b
a=b
b
aŇ?b W110-03-05-004
W1-1-3
GENERAL INFORMATION / Precautions for Disassembling and Assembling Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely. • Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from damage and the lifted load from slipping. • Lower the temperature of the lifted load to lower than 100 °C (212 °F). If unavoidably lifting a load with a temperature of 100 °C (212 °F) or more, reduce the load weight. • Do not lift acid or alkali chemicals. • Take care not to allow the sling to become wet. The load may slip. • When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced. • When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force. • Avoid using twisted, bound, connected, or hitched slings. • Do not place any object on twisted or bent slings. (Refer to the right illustration.) • When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions. • Avoid dragging slings on the ground, throwing slings or pushing slings with a metal piece. • When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged. • Store the nylon slings indoors so they won’t deteriorate with heat, sun light, or chemicals.
W1-1-4
Correct Eyehole Lifting Method
W102-04-02-016
Incorrect Eyehole Lifting Method W105-04-01-008
Bent Sling
W162-01-01-009
GENERAL INFORMATION / Precautions for Disassembling and Assembling
CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using.
Damaged Appearance
Broken Sewing Thread
W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If any damage is found, cut and discard the sling. Even if no damage is found, do not use slings older than 7-years.
W162-01-01-003
Fuzz Broken Sewing Thread
W162-01-01-004
Broken Sewing Thread
W162-01-01-005
Broken Sewing Thread
Scoring
Fuzz
Separation of Belt
Scuffing
W162-01-01-006
W162-01-01-007
Broken Warp
W162-01-01-008
W1-1-5
GENERAL INFORMATION / Precautions for Disassembling and Assembling MAINTENANCE STANDARD TERMINOLOGY “Standard” 1. Dimension for parts on a new machine. 2. Dimension of components or assemblies adjusted to specification. Both dimensions are shown with tolerances as necessary. “Allowable Limit” 1. Normal machine performance cannot be accomplished after exceeding this limit. 2. Repair or replacement is required before reaching this limit. Machine performance will decrease, and maintenance and down time expense will increase as machine operating hours accumulate. It is recommended that parts are repaired or replaced before reaching the “Allowable Limit”.
W1-1-6
GENERAL INFORMATION / Tightening TIGHTENING TORQUE SPECIFICATIONS Bolt and Nut on Base Machine Standard Torques
No.
Bolt Dia
Location
Q’ty
mm 1
Engine-cushion rubber mounting bolt
Nxm
(kgfxm)
(lbfxft)
Torque
22
2
32
740
(75)
(540)
Engine-cushion rubber
22
2
32
740
(75)
(540)
Cushion rubber-machine
16
4
24
265
(27)
(195)
Front Rear
Wrench Size (mm)
2
Engine bracket mounting bolt
14
8
22
175
(18)
(130)
3
Radiator mounting bolt
16
4
24
205
(21)
(152)
4
Hydraulic oil tank mounting bolt
16
8
24
205
(21)
(152)
5
Fuel tank mounting bolt
16
8
24
205
(21)
(152)
6
ORS fittings for Hydraulic hoses and piping
36
175
(18)
(130)
41
205
(21)
(152)
Fittings
3 -12UNF 1– — 16 7 -12UNF 1– 16 —
7
Pump transmission mounting bolt
12
12
19
88
(9)
(65)
8
Pump mounting bolt
20
4
30
390
(40)
(290)
9
Control valve mounting bolt (hexagon wrench)
20
4
17
390
(40)
(290)
10
Swing device mounting bolt
22
26
32
740
(75)
(540)
11
Swing motor mounting bolt (hexagon wrench)
18
24
14
295
(30)
(220)
12
Battery mounting nut
8
3
13
19.5
(2)
(14.5)
13
Cab mounting nut
16
6
24
205
(21)
(152)
14
Swing bearing mounting bolt to upperstructure
27
36
41
1370
(140)
(1010)
Swing bearing mounting bolt to undercarriage
27
36
41
1370
(140)
(1010)
Travel device mounting bolt
22
40
32
740
(75)
(540)
Travel motor mounting bolt
18
8
27
390
(40)
(290)
STD, H
22 18
48 16
32 27
740 390
(75) (40)
(540) (290)
LC, LCH
18
24
27
390
(40)
(290)
STD, H
22
64
32
740
(75)
(540)
LC, LCH
22
72
32
740
(75)
(540)
15
Sprocket mounting bolt 16 17 18
Upper roller mounting Lower roller mounting bolt Track Shoe bolt
STD, H
24
392
32
1370
(140)
(1010)
LC, LCH
24
424
32
1370
(140)
(1010)
Continued on next page
W1-2-1
GENERAL INFORMATION / Tightening
No.
Location
19
Track guard mounting bolt
20 21
22 23 24
Track mounting bolt Coupling and clamp of low preddure piping
Bolt Dia mm
Q’ty
STD
22
28
32
LC
22
36
H
22
LCH Coupling Clamp
Wrench Size (mm) Nxm
Torque (kgfxm)
lbfxft
740
(75)
(540)
32
740
(75)
(540)
40
32
740
(75)
(540)
22
40
32
740
(75)
(540)
33 8
36
50 13
1720
(175)
(1260)
10.5 to 12.5
(1.05 to 1.26)
(7.6 to 9.1)
11
9.8
(1.0)
(7.2)
1 — 4 -28 UNF
Counterweight mounting bolt
45
2
65
2350
(240)
(1740)
Counterweight
24
4
36
440
(45)
(330)
Front pin lock bolt
20
15
30
390
(40)
(290)
Front pin lock nut
20
7
30
390
(40)
(290)
Front pin retain bolt (Loading shovel)
12
4
19
88
(9)
(65)
16
6
24
205
(21)
(152)
20
36
24
265
(57)
(195)
12
30
540
(55)
(398)
lock bolt
NOTE: 1. When tightening bolts and nuts, apply a lubricant to threads to reduce friction. (i.e.: White zinc B dissolved into spindle oil) 2. Remove rust, soil, and dust before tightening. 3. Use LOCTITE to the engine cushion rubber mounting nuts and the lower roller mounting bolts.
W1-2-2
GENERAL INFORMATION / Tightening TORQUE CHART CAUTION: Use tools appropriate for the work to be done. Makeshift tools and parts create safety hazards. If an incorrect tool is used, the tool may slip or come off or break, resulting in personal injury. Bolt Types When tightening bolts and nuts, use the specified torque. Bolts are classified according to materals and applications. Be sure to use the correct bolts and nuts, and tighten them to specification.
Hexagon 10.9 Bolt
SA-040
Hexagon 8.8 Bolt
Hexagon 4.8 Bolt
Socket Bolt
W162-01-01-001
Specified Tightening Torque Chart Bolt Dia. M 8 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 M 33 M 36
Wrench Hexagon Size Wrench Size 13 17 19 22 24 27 30 32 36 41 46 50 55
6 8 10 12 14 14 17 17 19 19 22 24 27
10.9 Bolt Nxm 29.5 64 108 175 265 390 540 740 930 1370 1910 2550 3140
kgfxm 3 6.5 11 18 27 40 55 75 95 140 195 260 320
8.8 Bolt, Socket bolt lbfxft 22 47 80 130 195 290 400 540 690 1010 1410 1880 2310
Nxm 19.5 49 88 137 205 295 390 540 690 1030 1420 1910 2400
W1-2-3
kgfxm 2 5 9 14 21 30 40 55 70 105 145 195 245
lbfxft 14.5 36 65 101 152 220 290 400 505 760 1050 1410 1770
4.8 Bolt Nxm 9.8 19.5 34 54 78 118 167 215 275 390 540 740 930
kgfxm 1 2 3.5 5.5 8 12 17 22 28 40 55 75 95
lbfxft 7.2 14.5 25.5 40 58 87 123 159 205 290 400 540 690
GENERAL INFORMATION / Tightening IMPORTANT: The following items are applied to both fine and coarse pitch threads. 1. Apply lubricant (i. e. white zinc B dissolved Into Spindle oil) to nuts and bolts to reduce their friction coefficients. The plated bolts require no lubricant. 2. Torque tolerance is Âą10 %. 3. Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force. 4. The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application. 5. Make sure that nut and bolt threads are clean before installing. Remove dirt or corrosion, if any. Bolt Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening. Equally tighten upper and lower alter-
Tighten diagonally 1
1st to 4th
Tighten from center and diago12
9
4
1
6
7
14
13
8
5
2
3
10
11
3
6 4
5 2
2nd to 3rd W105-01-01-003
W1-2-4
GENERAL INFORMATION / Tightening Service Recommendations for Spilt Flange IMPORTANT: 1. Be sure to clean and Inspect sealing surfaces. Scratches / roughness cause leaks and seal wear. Unevenness causes seal extrusion. If defects cannot be polished out, replace the component. 2. Be sure to use only specified Orings. Inspect O-rings for any damage. Take care not to file Oring surfaces. When installing an O-ring into a groove, use grease to hold it in place. 3. While lightly tightening split flange halves, check that split is centered and perpendicular to the port. Hand-tighten bolts to hold parts in place. Take care not to pinch the O-ring. 4. Tighten bolts alternately and diagonally, as shown, to ensure even tightening. 5. Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before tightening of the others, resulting in damage to O-rings or uneven tightening of bolts.
W105-01-01-015
WRONG
W105-01-01-016
W105-01-01-008
WRONG
RIGHT
Do not bend it round
Bend along edge sharply
Nut and Bolt Locking RIGHT
• Lock Plate
WRONG
RIGHT
IMPORTANT: Do not reuse lock plates. Do not try to bend the same point twice.
• Cotter Pin IMPORTANT: Do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening. • Lock Wire IMPORTANT: Apply wire to bolts in the bolttightening direction, not in the boltloosening direction.
Bend along edge sharply
RIGHT
RIGHT
RIGHT
WRONG
Loosen
W105-01-01-009
WRONG
Tighten
W105-01-01-010
W1-2-5
GENERAL INFORMATION / Tightening PIPING JOINT
1
4
3
2
5
IMPORTANT: The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application.
M202-07-051
Joint Body
Union Joint Metal sealing surfaces (4) and (5) of adaptor (l) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines.
37ѯ 30ѯ
IMPORTANT: 1. Do not over-tighten nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adaptor (1). Be sure to tighten nut (3) to specifications. 2. Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting/disconnecting.
Description 30ѯmale
37ѯfemale
Male Union Joint
Female Union Joint W105-01-01-017
Wrench Size mm Union Nut 19 22 27 36 41 50 60 70 19 22 27 36 41 50
Wrench Size mm Hose Fittings 19 22 27 36 41 50 60 70 17 19 22 30,32 36 46
Tightening Torque N⋅m (kgf⋅m, lbf⋅ft) 59 (6,44) 98 (10,72) 118 (12,87) 235 (24,173) 295 (30,218) 490 (50,361) 670 (68,494) 980 (100,723) 44 (4.5,32) 59 (6,44) 118 (12,87) 235 (24,173) 295 (30,218) 490 (50,361)
NOTE: Tightening torque of 37ѯmale coupling without union is similar to tightening torque of 37ѯfemale.
W1-2-6
GENERAL INFORMATION / Tightening O-ring Seal Joint
7
6
9
O-ring (6) seats against the end face of adaptor (7) to seal pressure oil. IMPORTANT: 1. Be sue to replace O-ring (6) with a new one when reconnecting. 2. Before tightening nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (e). Tightening nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage. 3. Take care not to damage O-ring groove (e) or sealing surface (10). Damage to O-ring (6) will cause oil leakage. 4. If nut (9) is loose and oil is leaking, do not re-tighten nut (9). Replace O-ring (6) with a new one and check that O-ring (6) is correctly seated in place, tighten nut (9).
W1-2-7
8
Wrench Size mm Union Nut 19 22 27 36 41 50
Wrench Size mm Hose Fittings 17 19 22 30,32 36 46
10
Hose Fittings M104-07-033
Tightening Torque N⋅m (kgf⋅m, lbf⋅ft) 59 (6,44) 98 (10,72) 118 (12,87) 235 (24,173) 295 (30,218) 490 (50,361)
GENERAL INFORMATION / Tightening Screw-In Connection PT
Depending on types of screw and sealing, different types of screw fittings are used. IMPORTANT: Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. (This machine is equipped with male-type taper thread screwed joints except at the inspection joints.)
30ѯ
Male Tapered Thread
PF
Male Straight Thread W105-01-01-018
Male Tapered Thread Wrench Size Tightening mm Torque Hose Fittings N⋅m (kgf⋅m, lbf⋅ft) 17,19 59 (6,44) 19,22 98 (10,72) 27,22 118 (12,87) 36,32 235 (24,173) 41 295 (30,218) 50 490 (50,301) 60 670 (68,494) 70 980 (100,723)
Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leaks between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap.
Internal Thread
External Thread
Clearance
• Application Procedure
W105-01-01-019
Confirm that the thread surface is clean and, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads.
Leave one to two pitch threads uncovered
Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp. T-Bolt Type Band Clamp: 4.4 N⋅m (0.45 kgf⋅m, 3.25 lbf⋅ft ) Worm Gear Type Band Clamp: 5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)
W1-2-8
M114-07-041
T-Bolt Type
Worm Gear Type
M114-07-043
M114-07-042
GENERAL INFORMATION / Tightening Connecting Hose RIGHT
WRONG CAUTION: When replacing hoses, be sure to use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leaks, hose rupture or Separation of fitting, possibly resulting in a fire on the machine. Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting. Utilize Print marks on hoses when installing to prevent hose from being kinked.
W105-01-01-011
RIGHT
WRONG Rubbing Against Each Other
If hoses rub against each other, wear to the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing against each other. Take care so that hoses do not come into contact with moving parts or sharp objects.
W105-01-01-012
WRONG Clamp
RIGHT Clamp
Rubbing Against Each Other W105-01-01-013
WRONG
Rubbing Against Each Other
RIGHT
Clamp W105-01-01-014
W1-2-9
GENERAL INFORMATION / Tightening PERIODIC REPLACEMENT OF PARTS To ensure safe operation, be sure to conduct periodic inspection of the machine. In addition, the parts listed below, if defective, may pose serious safety/fire hazards. It is very difficult to gauge the extent of deterioration, fatigue, or weakening of the parts listed below simply by visual inspection alone. For this reason, replace these parts at the intervals shown in the table below. However, if any of these parts are found to be defective, replace before starting operation, regardless of the interval. Also, when replacing hoses, check the clamps for deformation, cracks, or other deterioration, and replace as necessary. Be sure to perform periodic inspection of all hoses, as shown below, and replace or retighten any defective parts found, as necessary. Consult your authorized dealer for correct replacement. Periodic Replacement Parts Engine Base Machine Hydraulic System Front Attachment
Fuel hose (Fuel tank to filter) Fuel hose (Fuel tank to injection pump) Heater hose (Heater to engine) Pump suction hose Pump delivery hose Swing hose Boom cylinder line hose Arm cylinder line hose Bucket cylinder line hose Pilot hose
NOTE: Be sure to replace seals, such as O-rings and gaskets, when replacing hoses.
W1-2-10
Replacement Intervals Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years
SECTION 2
UPPERSTRUCTURE ; CONTENTS; ; Group 1 Cab
Disassemble Control Valve 5 ............. W2-5-34 Assemble Control Valve 5.................. W2-5-36
Remove and Install Cab ...................... W2-1-1 Dimensions of the Cab Glass .............. W2-1-7
Group 6 Swing Device Group 2 Counterweight
Remove and Install Swing Device........ W2-6-1
Remove and Install Counterweight ...... W2-2-1
Disassemble Swing Device.................. W2-6-4
Remove and Install Counterweight (With
Assemble Swing Device .................... W2-6-10 Disassemble Swing Motor ................. W2-6-14
Counterweight Removal Device) ........ W2-2-3
Assemble Swing Motor ...................... W2-6-18 Maintenance Standard....................... W2-6-22
Group 3 Main Frame Remove and Install Main Frame .......... W2-3-1
Group 7 Pilot Valve Remove and Install Right
Group 4 Pump Device
Pilot Valve (Front Attachment) ........... W2-7-1
Remove and Install Pump Device ........ W2-4-1
Remove and Install Left
Disassemble Pump Transmission........ W2-4-4
Pilot Valve (Front Attachment) ........... W2-7-5
Assemble Pump Transmission ............ W2-4-8
Remove and Install
Remove and Install Main Pump ......... W2-4-11
Travel Pilot Valve ............................... W2-7-9
Disassemble Main Pump ................... W2-4-14
Disassemble Front Attachment
Assemble Main Pump........................ W2-4-20
Pilot Valve........................................ W2-7-12
Maintenance Standard ...................... W2-4-24
Assemble Front Attachment
Disassemble Regulator ..................... W2-4-26
Pilot Valve........................................ W2-7-14
Assemble Regulatoer ........................ W2-4-28
Disassemble Travel Pilot Valve.......... W2-7-18
Disassemble and Assemble
Assemble Travel Pilot Valve .............. W2-7-20
Pilot Pump ....................................... W2-4-30
Bucket Open / Close and Breaker Pilot Valve .......................... W2-7-24
Group 5 Control Valve
Assemble Bucket Open / Close and
Remove and Install Control Valve ........ W2-5-1
Breaker Pilot Valve .......................... W2-7-26
Disassemble Control Valve 1 ............... W2-5-4 Assemble Control Valve 1.................... W2-5-8 Disassemble Control Valve 2 ............ W2-5-14
Group 8 Pilot Shut-Off Valve
Assemble Control Valve 2.................. W2-5-16
Remove and Install
Disassemble Control Valve 3 ............. W2-5-18
Pilot Shut-off Valve ............................ W2-8-1
Assemble Control Valve 3.................. W2-5-24
Disassemble Pilot Shut-off Valve ......... W2-8-4
Disassemble Control Valve 4 ............. W2-5-30
Assemble Pilot Shut-off Valve.............. W2-8-6
Assemble Control Valve 4.................. W2-5-32
166W-2-1
Group 9 Shockless Valve Remove and Install Front Attachment Shockeless Valve .............................. W2-9-1 Disassemble and Assemble Front Attachment Shockless Valve.............. W2-9-3 Remove and Install Travel Shockless Valve ................................ W2-9-7 Disassemble and Assemble Travel Shockless Valve...................... W2-9-9
Group 10 Solenoid Valve Remove and Install Three-Spool Solenoid Valve................................. W2-10-1 Disassemble and Assemble Three Spool Solenoid Valve ............. W2-10-3
166W-2-2
UPPERSTRUCTURE / Cab REMOVE AND INSTALL CAB Remove Cab 1. Remove seat mounting nuts (2) and (1). : 13 mm
1 2 W157-02-01-005
2. Remove bolt (5) in the cab rear section, bolt (6) in rear boxes (3 and 4) and rear boxes (3 and 4). : 13 mm
3. Remove bolts (8) and lower cover (7) of the rear box.
3 6
5
: 13 mm 6 5
8
4 7
W157-02-01-017
4. Remove filter (24), screw (9) and duct (10) from the cab.
9
24 10
W2-1-1
W158-02-01-001
UPPERSTRUCTURE / Cab 5. Disconnect harness connectors (11) located at the rear inside the cab. NOTE: Number of connectors differs depending on the machine serial No.
11
6. Disconnect connectors for wiper limit switch (12), cab light (13), speaker (14), antenna (15) and ground (17) located in the cab. Remove washer vinyl hose(16) located behind the cab.
W166-02-01-001
13
12
14
15
17 16
7. Remove caps (20) from duct cover (18). Remove screws (19) and duct cover (18).
W162-02-01-002
18 20
19
W158-02-01-002
Duct Mating Face
8. While pushing the mating face of duct (21) backward, remove duct (21).
21
W157-02-01-011
W2-1-2
UPPERSTRUCTURE / Cab 9. Attach the sling belts to the top of the cab. CAUTION: Cab weight: Standard cab : 260 kg (573 lb) Headguard-Integrated cab : 470 kg (1036 lb)
W157-02-01-009
10. Remove cab mounting bolts (22) and nuts (23). : 17 mm
22
: 24 mm : 8 mm
23
23 W157-02-01-010
11. Slowly lift the cab with a crane to remove the cab from the machine.
W157-02-01-001
W2-1-3
UPPERSTRUCTURE / Cab Install Cab 1. Attach cab to crane with sling belts and install cab onto the machine. CAUTION: Cab weight: Standard cab: Headguard-Integrated cab:
260 kg (573 lb) 470 kg (1036 lb)
W157-02-01-001
22
2. Tighten cab mounting bolts (22) and nuts (23). : 17 mm : 49 Nxm (5 kgfxm, 36 lbfxft) : 24 mm
23
: 205 Nxm (21 kgfxm, 152 lbfxft) : 8 mm
23
64 Nxm (6.5 kgfxm, 47 lbfxft)
W157-02-01-010
3. Install duct (10) into the cab and tighten screw (9). Install filter (24).
: 4.9 Nxm (0.5 kgfxm, 3.6 lbfxft) 24
9 10
W158-02-01-001
4. Connect harness connectors (11) at the rear, inside the cab. NOTE: Number of connectors differs depending on the machine serial No.
11
W2-1-4
W166-02-01-001
UPPERSTRUCTURE / Cab 5. Connect wiper limit switch (12), cab light (13), speaker (14), antenna (15) and ground (17) in the cab. Connect washer vinyl hose (16) behind the cab.
13
12
14
: 19.5 Nxm (2 kgfxm, 14.5 lbfxft) 15
17 16
W162-02-01-002
6. Install rear box lower cover (7) and tighten bolts (8). : 13 mm : 19.5 Nxm (2 kgfxm, 14.5 lbfxft)
3
7. Install rear boxes (3 and 4) and tighten bolts (5 and 6).
6
5 6
: 13 mm
5
: 19.5 Nxm (2 kgfxm, 14.5 lbfxft)
8
4 7
W157-02-01-017
8. Push duct (21) to the cab front until the duct mating face comes in contact. Duct Mating Face
21
W157-02-01-011
W2-1-5
UPPERSTRUCTURE / Cab 9. Install duct cover (18). Tighten screws (19) and put caps (20) on. 18 20
19
10. Install seat (1) and tighten nuts (2).
W158-02-01-002
: 13 mm : 19.5 Nxm (2 kgfxm, 14.5 lbfxft)
1 2 W157-02-01-005
W2-1-6
UPPERSTRUCTURE / Cab DIMENSIONS OF THE CAB GLASS R2
Standard Cab Unit: mm
A 25.106
R11516
NOTE: 1 mm=0.03937 in
3.015
221.399R70 4-∅13
+10 −1
(64.74)
R78142.25
Section A Chamfer both fringes
580
R9487 30 360.78
(87.81)
(5 mm) R3018
391.8
R118
Chamfer fringe corners.
4°
51.03
154.81
188.5 R15 66.84
164.12
43.59
558.78
230.50 222.65
B
All Around c1
15
216. 73
All Around c1 2-R59
R11509
R2309 900. 7 R4009
(4 mm)
Section B
905
R1009
R9509
R509
R209 R4009
R84 63.97
NOTE:Material:
JIS-R3211, R3212 ANSI-AS2 ECE-ANNEX5 or equivalent
66.41 87.84 947.152
35.73
756
4-R62 612
(5 mm)
W157-02-01-013
W2-1-7
UPPERSTRUCTURE / Cab Unit: mm
Chamfer fringe corners.
NOTE: 1 mm=0.03937 in 208
(38.5)
333.5±1.0 Chamfer fringe corners.
113.9
337.5±1.0 22.5 9.2
R3
10.6 R72.5
R30 R105 R2285.4 39.5
7735.4 (4 mm)
R3985.4 Chamfer both fringes
61.8
D
Chamfer both fringes
Section C and D
39.5 3.1
728.5±1.0
40
C
488.5
2–Ø 12.2 +0.5 –0
40 728.5±1.0
R120885.4 2–Ø12.2 +0.5 –0
475.8 60.1
290 2–R4 (4 mm)
R1985.1
398.5±1.0
3–R4
Chamfer fringe corners.
503±1.0 (38.5)
541.5 Chamfer fringe corners.
468.17 90.672 45.67 R2590
2–R5
R2477
R5175 904.13 R3877 980
R8075 753.99 740.51
19.70
8
890.03
74.95
(5 mm)
213.97
R120 4–R5
227.39
R12095
R1995
370±1.0
R895
R595
R345
R295
(5 mm)
11.22 18
276.58
R1145
833±1.0 910
165
R12.5 19.29 33.60
516.26 549.86
39.63 50.71 59
W157-02-01-014
W2-1-8
UPPERSTRUCTURE / Cab Headguard-Integrated Cab
416+0.5 -1.5
Unit: mm NOTE: 1 mm=0.03937 in
4-R61 484 (4 mm)
811+0.5 -1.5
327
442.5+0.5 -1.5 220.9
753+0.5 -1
3-R61
857.5+0.5 -1
(5 mm)
915.8+0.5 -1 R191
NOTE:Material:
58.3
JIS-R3211, R3212 ANSI-AS2 ECE-ANNEX5 or equivalent
973.9+0.5 -1 826+0.5 -1.5
4-R73
2-R153 1154
+0.5
-1.5
R82
(6 mm)
431 120
826+0.5 -1.5
304+0.5 -1.5
(6 mm)
4-R73
W166-02-01-005
W2-1-9
UPPERSTRUCTURE / Cab Unit: mm
NOTE:Material:
NOTE: 1 mm=0.03937 in 415±1
176
JIS-R3211, R3212 ANSI-AS2 ECE-ANNEX5 or equivalent
262
R5
R5
2-R75.4
(376)
383
2-φ11.2+0 -1
2-R75.4 (4 mm) 2-φ11.2+0.5 -0
40
727±1
727±1
4 mm
(344)
39+0 -1
292.5
292.5
R5
R5
453
40 39+0 -1
351
398±1
138
591
423±1.0
4-R61
(5 mm)
549
873.5±1.0 769
140 305
324.5
6-R73 (5 mm)
5.14+0.5 -1.5
374 209
243
513
453.5±1.0
W166-02-01-006
8.46+0.5 -1.5
W2-1-10
UPPERSTRUCTURE / Cab Unit: mm NOTE: 1 mm=0.03937 in
Serial Number 7495 and up (EX450H-5) Serial Number 7670 and up (EX450LCH-5) 150
2-φ12
30
(4 mm)
435+0.5 -2
4-R41
720+0.5 -2
Serial Number 7495 and up (EX450H-5) Serial Number 7670 and up (EX450LCH-5) 150
NOTE:Material:
JIS-R3211, R3212 ANSI-AS2 ECE-ANNEX5 or equivalent
2-φ12
30
(4 mm)
535+0.5 -2
4-R41
720+0.5 -2
W2-1-11
W166-02-01-007
UPPERSTRUCTURE / Cab Cab Glass Installation Method
Mounting Rubber Section
Standard Cab Procedure of installing left-hand cab glass 1. Install the mounting rubber on cab glass. Put and fasten mounting rubber onto the mounting face of cab.
Mounting Rubber
IMPORTANT: Be sure to install the cab glass and mounting rubber using the special bonding agent. The cab glass may fall if the special bonding agent is not used. The cab glass assembly can’t be replaced individually. Be sure to change the cab glass as a unit.
Cab Glass
Cab Seal Rubber
W216-02-01-004
Procedure of installing right-hand cab glass 1. Insert mounting rubber into the surrounding of cab glass. Stick the connectors of mounting rubber with the bonding agent (Cemedine 366 Standard or equivalent). NOTE: Rubber aging will cause the contraction of rubber, be sure to leave a little bit long, and stick by pressing. 2. Put and fasten the mounting rubber on the mounting face of cab, after installing rubber.
W216-02-01-002
Mounting Rubber Section Cab Glass
Mounting Rubber
Cab
W216-02-01-005
W216-02-01-006
W2-1-12
UPPERSTRUCTURE / Cab Procedure of installing rear cab glass 1. Insert mounting rubber around the cab glass. Install the connectors of mounting rubber with the bonding agent (Cemedine 366 Standard or equivalent). Ȁ
Mounting Rubber Section Mounting Rubber
NOTE: Rubber aging will cause the rubber to contract rubber, be sure to leave a little extra, install by pressing with hands.
Cab Glass
Stopper
Č€ 2. After installing glass assembly on the cab, insert the stopper into rubber.
Cab W216-02-01-003
W216-02-01-007
W2-1-13
UPPERSTRUCTURE / Cab Headguard-Integrated Cab Procedure of installing front and both side cab glass 1. Insert mounting rubber into the surrounding of cab glass. Stick the connectors of mounting rubber with the bonding agent (Cemedine 366 Standard or equivalent).
Mounting Rubber Section Mounting Rubber
NOTE: Rubber aging will cause the contraction of rubber, be sure to leave a little bit long, and stick by pressing. 2. Put and fasten the mounting rubber on the mounting face of cab, after installing rubber.
Cab Glass
Cab
W166-02-01-008
W166-02-01-009
W166-02-01-010
W166-02-01-011
W2-1-14
UPPERSTRUCTURE / Counterweight REMOVE AND INSTALL COUNTERWEIGHT Removal CAUTION: Counterweight weight: 9300 kg (20500 lb) 1. Install lifting accessories and wire ropes to sling brackets on the top of the counterweight. Set the wire rope taut using a crane. CAUTION: Watch out the power-wrench reaction bar movement. Take care not to be hit the reaction bar.
W166-02-02-002
2. Using a power wrench, remove bolts (10), nuts (8), shims (7), and washers (9). 1 2
NOTE: Shims (7) are used only when any gap between nuts (8) and the lock brackets exist. When no gap exists, shims are not required. 1
: 65 mm
3
4
7 5
6
8 9
2 7
3. Remove bolts (1), lock washers (2), washers (3), and spacers (4). If shims (5 and 6) are provided, remove shims (5 and 6).
3 4
5
6
8
9
9 10
: 36 mm
W166-02-02-003
4. Remove the counterweight using a crane. 9 7
10
8 3
9
1, 2
6, 5, 4
W2-2-1
W166-02-02-001
UPPERSTRUCTURE / Counterweight Installation CAUTION: Counterweight weight: 9300 kg (20500 lb) 1. Install lifting accessories and wire ropes to sling brackets on the top of the counterweight. Then, lift the counterweight by crane.
CAUTION: Do not allow anyone under the lifted counterweight. 2. Insert protrusions on the counterweight into holes on the frame to install the counterweight. W166-02-02-002
CAUTION: Watch out the power-wrench reaction bar movement. Take care not to be hit the reaction bar.
1 2
IMPORTANT: Apply lubricant to bolts (10) before installing. Install shims (7) between nuts (8) and the lock brackets with the flange positioned in the upper side.
1
3
4
7 5
6
8 9
2 7
3. Install bolts (10), nuts (8), shims (7), and washers (9). Using a power wrench, tighten bolts (10). 3
: 65 mm
4
: 2350 Nxm (240 kgfxm, 1740 lbfxft)
5
6
8
9
9 10 W166-02-02-003
4. Install shims (5 and 6), spacers (4), washers (3) lock washers (2), and bolts (1). Remove wire ropes and lifting accessories. 9
: 36 mm
7
: 440 Nxm (45 kgfxm, 330 lbfxft)
10
8 3
9
1, 2
6, 5, 4
W2-2-2
W166-02-02-001
UPPERSTRUCTURE / Counterweight REMOVE AND INSTALL COUNTERWEIGHT (WITH COUNTERWEIGHT REMOVAL DEVICE) Removal NOTE: Counterweight removal procedure must be performed with machine located on a level surface. 1. Park the machine on a level surface with the upperstructure rotated 90°.
M116-06-019
2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down. 4. Run the engine at slow idle speed without load for three minutes. 5. Stop the engine. 6. Pull the pilot control shut-off lever to the LOCK position.
2
CAUTION: Avoid personal injury from unexpected counterweight movement. DO NOT go directly under machine counterweight. To remove or install counterweight hardware, go under machine entering from the area on either SIDE of the counterweight. The counterweight weighs approximately 8200 kg (18100 lb). Clear everyone from the area before removing or installing the counterweight.
1
M111-06-023
7. Remove bolts (1) to remove counterweight top cover plate (2). 8. Open the engine hood. 9. Remove bottom covers (3) and (5). 3
10. Remove cylinder guard (4).
4
5 M116-06-020
W2-2-3
UPPERSTRUCTURE / Counterweight 11. Set variable orifice (1) by turning in the direction of the arrow until closed. Then open orifice 2 turns. IMPORTANT: Linkage pivot areas may bind if not properly lubricated resulting in failure of cylinder (3) to raise counterweight to full height. 12. Grease all pivot areas of counterweight lift linkage (three fittings at the bottom and one fitting at the top of the counterweight cylinder), the FIRST TIME and every time the counterweight device is operated.
1 M116-06-021
2
3
13. Open shut off valve (2) by turning the handle counterclockwise to supply hydraulic pressure to cylinder (3).
14. Make sure length (A) is correct and lock nuts (4) are not loose. Length A: 110Âą2 mm (4.33Âą0.08 in)
M116-06-022
4 A
M116-06-023
W2-2-4
UPPERSTRUCTURE / Counterweight 15. Remove both lock pins (3) from nut (2) on bolts (1). 1
3
2
M116-06-024
16. Open the left rear access door and pull off lever cover (4) of counterweight pilot control valve (5).
4
5
M111-06-024
17. Start the engine. Run machine in “precision� work mode (6) with the engine control dial set to the fully counterclockwise position (slow idle).
6
M166-01-016
W2-2-5
UPPERSTRUCTURE / Counterweight CAUTION: To insure good footing and visibility, always stand on the machine catwalk when operating counterweight pilot control valve. IMPORTANT: To prevent possible damage to hydraulic cylinder lines and adjustable orifice canister, cylinder guard (See step 10) must be removed before lowering the counterweight.
M116-06-025
18. Slowly move the counterweight pilot control valve lever UP and DOWN several times to check the response of cylinder control. CAUTION: Keep hands (fingers) out of slots (1) and out of movable parts of linkage during cylinder movement.
1
19. Slide the lifting yokes forward to the upward position of slot (1) away from the rear of counterweight and slowly raise cylinder (counterweight pilot control valve lever “UP�) to hold both lifting yokes in the forward position. 20. Alternately loosen each bolt (2) 2 or 3 turns.
M116-06-026
2
21. Using a screwdriver, pry the corner of lock plate (4) away from the head of each of bolts (3).
3
22. Loosen each bolts (3) 5 mm (0.20 in). 4
M116-06-036
W2-2-6
UPPERSTRUCTURE / Counterweight NOTE: Lifting yokes must be in the forward position or highest point of the slot.
A
1
23. Slowly move the counterweight pilot valve lever UP until counterweight bottom bosses (2) move away from machine mainframe (1) approximately 5 mm (0.20 in.) (A). This will ensure that the weight of the counterweight is on the lift cylinder. 2
CAUTION: When the threads of tie bolt (7) disengage from nut (6), nut (6) and nut spacer may drop to the ground. Stay clear from under the machine when removing bolts (7). 24. To avoid binding, loosen bolts (7) by alternately turning each bolt one turn at-a-time. NOTE: It is not necessary to remove bolts (7) from the counterweight/frame holes. It is enough nuts (6) are dropped down. The bolts (7) will be removed from frame holes when the counterweight is lowered by the lift cylinder. 25. Remove bolts (4), lock plates (5), spacers and shims (3) from each counterweight boss. To avoid binding, alternately loosen left hand and right hand bolts (4) 2 or 3 turns at-a-time.
M116-06-028
3
7
6
4
5
M116-06-036
W2-2-7
UPPERSTRUCTURE / Counterweight 26. Slowly lower counterweight to the ground until all weight is removed from the linkage and the yokes move freely in their slots. IMPORTANT: Do not operate the pilot control valve with full stroke of lever. Move the cylinder as slowly as possible.
1
27. Remove yoke-to-link pins (1). 28. Tighten adjusting cap screw jam nut. 29. Raise lift cylinder to end of its stroke. 30. Store yoke-to-link pins (1) by attaching pins to the counterweight lift brackets. 31. Close hydraulic shut off valve by turning valve handle clockwise. 32. Install top cover to the counterweight and two bottom covers to the machine mainframe. 33. Install lift cylinder lower guard. 34. Install the lever cover over the counterweight pilot valve. 35. Close left rear access door and engine hood.
W2-2-8
M116-06-023
UPPERSTRUCTURE / Counterweight Installation NOTE: Counterweight installation procedure must be performed with machine located on a level surface. 1. Park the machine on a level surface. 2. Rotate upperstructure 90° with front attachment on the ground. 3. Turn the auto-idle switch off.
M116-06-029
IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.
1 3 3
4. Run the engine at slow idle speed without load for three minutes.
3
5. Stop the engine. 6. Pull the pilot control shut-off lever to the LOCK position. M111-06-025
7. Open the engine hood.
3
3
8. Remove two pump drive covers (1) and (2) and bolts (3). 9. Remove both machine mainframe bottom access covers and counterweight top cover.
2 3
3
10. Remove the lift cylinder guard. 11. Turn the handle of shut off valve (4) (located through opening under the engine) counterclockwise to open hydraulic pressure to cylinder (5). M111-06-026
12. Start the engine. Run machine in “precision” work mode with the engine dial set to the fully counterclockwise position (slow idle).
4 5
M116-06-022
W2-2-9
UPPERSTRUCTURE / Counterweight CAUTION: To insure good footing and visibility, always stand on the machine catwalk when operating counterweight pilot control valve.
1 2 A
3
13. Lower the lift cylinder. 14. Install counterweight lifting yoke-link-pins (4) to the counterweight pin brackets (5). Slide yoke (3) forward to the top position of the slot in the counterweight pin bracket.
4 5
15. When installing the counterweight for the first time, check removal device adjustment as follows. (When installing counterweight next times [not the first time] see item 16.) M116-06-023
(1) Adjust bolts (1) on each yoke (3) to length (A) A: 110±2 mm (4.3±0.08 in) (2) Slowly raise the counterweight until the counterweight bosses are set into the mainframe holes. If alignment of the counterweight bosses to the mainframe holes is incorrect (Bosses can’t be set into holes), lower the counterweight to the ground and adjust length (A) as required. After adjusting correct length (A), tighten lock nut (2). Tightening torque 390 Nxm (40 kgfxm, 290 lbfxft)
CAUTION: • Length (A) can not be made for more than 120 mm (4.7 in). Damage to bolts may occur. • Stop cylinder when bosses are set to the main frame holes. Do not raise the cylinder when bosses are engaged with the main frame holes. 16. Make sure length (A) is correct and lock nut (2) are not loose. 17. Put bolts (6) into the counterweight holes.
W2-2-10
6
M116-06-030
UPPERSTRUCTURE / Counterweight 18. Slowly raise the counterweight until the counterweight bosses are set into the main frame holes.
1
2
3
NOTE: When raising counterweight, bolts (1) are set into frame holes. 19. Install spacers (2) and nut (3) at the pump side. Turn nut (3) into bolts (1) until the end of the bolt face with end of nut. 20. Install spacer (2) and nut (3) at the radiator side. Turn nut (3) into bolts (1) until the end of the bolt face with end of nut. 21. Lower the lift cylinder slightly until yoke (4) slide backward in slots (5) to the “REST� position.
M116-06-031
4
22. Install shims (6), spacer (7), new lock plate (9) and bolts (8) to each of the lower counterweight bosses.
5
23. Tighten bolts (1). Tightening torque: 2400 Nxm (245 kgfxm, 1770 lbfxft) NOTE: Tighten or loosen bolts (1) (from torque) to align lock pins. M116-06-032
24. Tighten bolts (8). Tightening torque: 690 Nxm (70 kgfxm, 510 lbfxft)
6
7
1 8
9
M116-06-036
W2-2-11
UPPERSTRUCTURE / Counterweight 25. Make sure the counterweight lift arms are below the top surface of the counterweight and are not touching the counterweight plate from inside. Make sure yoke connected to the counterweight pin brackets are not tight. (If necessary, lower or raise cylinder slightly to meet above requirements and check again torques.)
1
26. Install lock pins (1) into the nuts from the top side of the machine. 27. Bend one top and bottom corner of lock plate (2) against the head of each bolt. 28. Close shut off valve (3). 29. Install two pump drive covers. 30. Install the both machine mainframe bottom access covers and counterweight top cover.
M116-06-024
31. Install the cylinder guard.
2
M116-06-036
3
M116-06-022
W2-2-12
UPPERSTRUCTURE / Main Frame REMOVE AND INSTALL MAIN FRAME CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting work. The hydraulic oil tank cap may pop off if removed without releasing internal pressure first. Push the air release valve on top of the hydraulic oil tank to release any remaining pressure. Preparation 1. Park the machine on a firm, level surface. 2. Stop the engine. Push the air release valve on top of the hydraulic oil tank to release any remaining pressure.
M104-07-021
3. Remove hydraulic oil tank cap. Connect a vacuum pump to maintain negative pressure in the hydraulic oil tank. NOTE: Be sure to run the vacuum continuously while working.
pump
W166-02-03-011
W2-3-1
UPPERSTRUCTURE / Main Frame Removal CAUTION: Approximate weight of cab: Standard cab: 260 kg (573 lb) Headguard-Integrated: 470 kg (1040 lb) 1. Remove cab assembly. (See Remove Cab in this section.) : 24 mm, 17 mm : 8 mm CAUTION: Approximate weight of counterweight: 9300 kg (20500 lb)
W157-02-01-001
2. Remove the counterweight. (See Remove Counterweight in this section.) Wrench size : 36 mm : 65 mm
W155-02-02-001
W2-3-2
UPPERSTRUCTURE / Main Frame CAUTION: Approximate weight of front attachment assembly; Backhoe 7530 kg (16600 lb) Loading shovel 9550 kg (21100 Ib) (EX400-5) 9880 kg (21800 Ib) (EX450H-5) 3. Remove front attachment assembly from the upperstructure. (See Remove Front Attachment in this section.)
W105-02-03-002
: 19 mm, 30 mm, 36 mm, 41 mm
M162-07-071
4. Drain hydraulic oil from the hydraulic oil tank, and disconnect hydraulic lines from the control valve to the center joint on top of the center joint. Disconnect drain hose, and remove the fitting and stopper from the center joint.
ST 0915
Shackle
ST 0915
12
13
12
: 22 mm, 27 mm, 41 mm Rear
W166-02-03-009
W166-02-03-010
CAUTION: Approximate weight frame; 9380 kg (20700 lb) (EX400-5) 9500 kg (21000 Ib) (EX450H-5)
of
main
5. Install special tool (ST 0915), bolts (12) (M45 Pitch3, 2 used) and nuts (13) to main frame. Install shackles (4.8 ton) to special tool (ST 0915). Front
6. Attach wire ropes to the front and shackle of main frame. See wire ropes taut using a crane. Use chain blocks (1) for easy adjustment of wire rope lengths and to level the frame.
W105-02-03-005
1
: 70 mm IMPORTANT: Make sure rear slings and special tool (ST0915) do not touch engine.
W157-02-03-002
W2-3-3
UPPERSTRUCTURE / Main Frame 7. Put matching marks on swing bearing and main frame. Remove bolts (2) and the knock pins from the swing bearing. : 41 mm 8. Lift main frame slightly from undercarriage. Level main frame by adjusting chain blocks (1). Remove main frame. 2 W105-02-03-007
1
W157-02-03-002
W2-3-4
UPPERSTRUCTURE / Main Frame Installation CAUTION: Approximate weight of main frame: 9380 kg (20700 lb) (EX400-5) 9500 kg (21000 Ib) (EX450H-5)
1
1. Fasten hoist to front and shackle of main frame. Level main frame by adjusting chain blocks (1) and lower main frame onto undercarriage. Align the matching mark on the swing bearing with that on the main frame.
W157-02-03-002
2. Install bolts (2) and the knock pins on the swing bearing and tighten temporary. Remove wire ropes and the special tool (ST 0915). Install main frame and tighten bolts to specification. : 41 mm Upperstructure side : 1370 N⋅m (140 kgf⋅m, 1010 lbf⋅ft)
2 W105-02-03-007
3. Connect drain hose (7) to the center joint. Connect lines (3 to 6). : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 27 mm : 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
3
4 5
6
7
M162-07-071
W2-3-5
UPPERSTRUCTURE / Main Frame CAUTION: Approximate weight of cab; Standard cab: 260 kg (573 lb) Headguard-Integrated cab: 470 kg (1040 lb) 9
4. Install cab (9). (See Cab in this section.) : 24 mm : 205 N⋅m (21 kgf⋅m, 159 lbf⋅ft) : 17 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) : 8 mm : 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
W157-02-01-001
CAUTION: Approximate weight of counterweight: 9300 kg (20500 lb) 5. Install counterweight (10). (See Counterweight in this section.) Wrench size: 65 mm : 2350 N⋅m (240 kgf⋅m, 1740 lbf⋅ft) CAUTION: Approximate weight attachment assembly: Backhoe 7530 kg (16600 lb) Loading Shovel 9550 kg (21100 Ib) (EX400-5) 9880 kg (21800 Ib) (EX450H-5)
of
10
front
W155-02-02-001
6. Install front attachment assembly (3). (See Front Attachment in this section.) : 19 mm : 29 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) : 30 mm : 540 N⋅m (55 kgf⋅m, 400 lbf⋅ft) : 36 mm : 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
11
W105-02-03-002
7. Fill the hydraulic oil tank with hydraulic oil to the specified level. Run the engine at slow idle. Check hose connections for any oil leakage. M104-07-021
W2-3-6
UPPERSTRUCTURE / Pump Device REMOVE AND INSTALL PUMP DEVICE CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. The hydraulic oil tank cap may pop off by remaining pressure if removed quickly. Slowly loosen the cap to completely release any remaining pressure. Preparation 1. Park the machine on a level solid surface. Lower the front attachment to the ground. 2. After stopping the engine, move the control levers several times to release any pressure remaining in the system. 2. Rotate the hydraulic oil tank cap approx. 30° counterclockwise to release trapped air in the hydraulic oil tank.
W2-4-1
UPPERSTRUCTURE / Pump Device Remove Pump Device 1. Disconnect all hydraulic lines and electrical cables from the pump.
Pump Device Mounting Bolt
: 19 mm, 27 mm, 32 mm, 36 mm, 41 mm : 10 mm, 14 mm CAUTION: Pump device weight: 275 kg (610 lb) 2. Sling the pump device with a crane or hoist. 3. Remove the pump device mounting bolts (12 used) and the pump device. : 19 mm : 88 Nxm (9 kgfxm, 65 lbfxft)
Install Pump Device 1. Hoist the pump device. 2. Install the pump with the mounting bolts. 3. Connect all hydraulic lines and electrical cables to the pump. 4. Bleed air trapped inside the pump. (Refer to page W1-1-2.)
W166-02-03-001
Wrench Sizes
Tightening Torque N⋅m (kgf⋅m) (lbf⋅ft)
IMPORTANT: After installing the pump, be sure to perform break-in operation to prevent seizure.
: 19 mm
29.5
(3)
(21.5)
: 27 mm
93
(9.5)
(69)
Break-In Operation Process: 1. Start the engine and run at slow idle speed for 20 minutes. Check for oil leaks while running at slow idle. 2. Increase the engine speed to the fast idle speed. Raise and lower the boom for 20 minutes repeatedly. (Do not operate the control levers quickly. Slowly move the levers to full stroke.)
: 32 mm
68.6
(7)
(51)
: 36 mm
175
(18)
(130)
: 41 mm
205
(21)
(152)
: 10 mm
108
(11)
(80)
: 14 mm
265
(27)
(195)
W2-4-2
Remarks Hydraulic lines Hydraulic lines Hydraulic lines Hydraulic lines Hydraulic lines Socket Bolts Socket Bolts
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