HITACHI EX800H-5 EXCAVATOR Service Repair Manual by 163633

EX750-5, EX800H-5 Workshop Manual

SECTION 1

GENERAL IMFORMATION ; CONTENTS; ; Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling........................................... W1-1-1 Maintenance Standard Terminology .......................................... W1-1-4

Group 2 Tightening Tightening Torque Specification.............. W1-2-1 Torque Chart .......................................... W1-2-2 Piping Joint ............................................ W1-2-5

162W-1-1

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

• Precautions for Assembling

Prepare the necessary tools to be used and the area for disassembling work.

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 install ation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures:

• Bleeding Air from Hydraulic Pump IMPORTANT: If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result. Be sure to bleed air before starting the engine. • 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 1. In general, replace the floating seal with a new one. If the floating 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. B

(2) Check seal ring face (C) for scuffing, scoring, corrosion, deformation or uneven wear.

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 floating seal (A) 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. (2) Clean the floating seal and seal mounting bores, as dust on them tends to enter the floating seal when installing it.

Correctly

Incorrectly

(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 face (C) is parallel with seal mounting bores ring face (D) by measuring the distances (C) and (D) at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating.

Correctly

Incorrectly

C B

b a=b

W1-1-3

W105-03-05-020

b aâ&#x2030; b

W110-03-05-004

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 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”.

W1-1-4

GENERAL INFORMATION Ȁ / Ȁ Tightening TIGHTENING TORQUE SPECIFICATIONS No.

Bolt Dia

Descriptions

Engine cushion rubber Engine cushion Front Cushion rubber-machine 1 rubber mountEngine cushion rubber ing bolt Rear Cushion rubber-machine

Q’ty

Wrench Size

Torque

(mm)

N⋅m

kgf⋅m

lbf⋅ft

265

195

265

195

690

510

390

290

UNC 1/2 UNC 3/8

4 6

19 14

88 49

9 5

65 36

3 Radiator mounting bolt

690

510

4 Hydraulic oil tank mounting bolt

295

215

5 Fuel tank mounting bolt

295

215

205

152

2 Muffler bracket mounting bolt

6 ORS fittings for hydraulic hoses and piping 7 Pump transmission mounting bolt

7 1-Ӹ 16 -12UNF 7 UNC 16 14

8 Pump device mounting bolt

690

510

9 Control valve mounting bolt

390

290

10 Swing device mounting bolt

930

690

11 Swing motor mounting bolt (hexagonal wrench)

390

290

12 Battery mounting bolt

3.5

25.5

STD

205

152

205

152

33 33 30

36 4 40

50 50 46

2160 2160 1720

220 220 175

1590 1590 1270

Travel device mounting bolt 15 Travel motor mounting bolt Sprocket mounting bolt

27 18 27

40 8 48

41 27 41

1370 295 1370

140 30 140

1010 215 1010

16 Upper roller mounting

540

400

13 Cab mounting bolt

Swing bearing mounting bolt to upperstructure 14 Swing bearing mounting bolt to undercarriage

17 Lower roller mounting bolt

STD, H

930

690

18 Track shoe bolt

STD, H

408

1960

200

1450

19 Track guard mounting bolt

STD, H

1370

140

1010

2750

280

2030

10.5 to 12.5

1.05 to 1.26

7.6 to 9.1

5.9

0.6

4.3

20 Track frame mounting bolt Coupling and clamp of low 21 pressure piping 22

Coupling

8 1 4

Clamp

Counterweight mounting bolt Counterweight retaining bolt

23 Front pin-retaining bolt

-28UNF

45 24

2 4

65 36

2750 690

280 70

2030 510

390

290

NOTE: (1) Apply lubricant (e.g. white Zinc B dissolved into spindle oil) to bolts and nuts to stabilize friction coefficient of them. (2) Make sure bolt and nut threads are clean before installing.

W1-2-1

(3) Apply LOCTITE to threads before installing and tightening swing bearing mounting bolts.

GENERAL INFORMATION Ȁ / Ȁ Tightening TORQUE CHART CAUTION: Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use the correct tools. Avoid bodily injury caused by slipping wrenches. Bolt Types Tighten nuts or bolts correctly to torque specifications. Four kinds of bolts, hexagon bolts T, H, M and socket bolt, each made of different material, are used. Make sure to employ the correct bolts and tighten them to specification when assembling the machine or components.

Hexagon T Bolt

Hexagon H Bolt

SA-040

Hexagon M Bolt

Socket Bolt

W105-01-01-007

Specified Tightening Torque Chart Bolt Dia. M M M M M M M M M M M M M

8 10 12 14 16 18 20 22 24 27 30 33 36

Wrench Size 13 17 19 22 24 27 30 32 36 41 46 50 55

Hexagon Wrench Size 6 8 10 12 14 14 17 17 19 19 22 24 27

T Bolt, Socket bolt

H Bolt

N⋅m

kgf⋅m

lbf⋅ft

N⋅m

29.5 64 108 175 265 390 540 740 930 1370 1910 2550 3140

3 6.5 11 18 27 40 55 75 95 140 195 260 320

22 47 80 130 195 290 400 540 690 1010 1410 1880 2310

19.5 49 88 137 205 295 390 540 690 1030 1420 1910 2400

W1-2-2

kgf⋅m 2 5 9 14 21 30 40 55 70 105 145 195 245

M Bolt lbf⋅ft

N⋅m

kgf⋅m

14.5 36 65 101 152 220 290 400 505 760 1050 1410 1770

9.8 19.5 34 54 78 118 167 215 275 390 540 740 930

1 2 3.5 5.5 8 12 17 22 28 40 55 75 95

lbf⋅ft 7.2 14.5 25.5 40 58 87 123 159 205 290 400 540 690

GENERAL INFORMATION Ȁ / Ȁ Tightening IMPORTANT: (1) Apply lubricant (i. e. white zinc B dissolved into spindle oil) to nuts and bolts to stabilize their friction coefficients. (2) Torque tolerance is ±10 %. (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 the 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 alternately

Tighten diagonally

1,4

Tighten from center and diagonally 12

6 4

5 2

2,3 W105-01-01-003

W1-2-3

GENERAL INFORMATION Ȁ / Ȁ Tightening Service Recommendations for Split 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) Loosely assemble split flange halves. Make sure that the split is centrally located and perpendicular to the port. Handtighten the bolts to hold the 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 tighten 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

RIGHT

Nut and Bolt Lockings • Lock Plate IMPORTANT: Do not reuse lock plates. Do not try to bend the same point twice.

WRONG

RIGHT

• Cotter Pin

Do not bend it round

Bend along edge sharply

RIGHT

WRONG

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

W105-01-01-009

WRONG

Loosen

WRONG

Tighten

W105-01-01-010

W1-2-4

GENERAL INFORMATION Ȁ / Ȁ Tightening PIPING JOINT

Pipe Thread Connection/Union Joint Tightening Torque Specifications Union Joint Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. IMPORTANT: (1) Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adaptor (1). Be sure to tighten union nut (3) to specifications.

Joint Body M202-07-051

30° or 37°

(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.

Type 30° Male Union Joint

37° Female Union Joint

Wrench Size Union Nut Joint Body 19 19 22 22 27 27 36 36 41 41 50 50 60 60 70 70 19 17 22 19 27 22 36 30ȌȀ32 41 36 50 46

NOTE: Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint.

W1-2-5

Male Union Joint

Female Union Joint W105-01-01-017

Tightening Torque N⋅m kgf⋅m Ibf⋅ft 59 6 43 98 10 72 118 12 87 235 24 134 295 30 215 490 50 360 670 68 490 980 100 720 44 4.5 32.5 59 6 43 118 12 87 235 24 134 295 30 215 490 50 360

GENERAL INFORMATION Ȁ / Ȁ Tightening 7

O-ring Seal Joint O-ring (6) seats against the end face of adaptor (7) to seal pressure oil.

IMPORTANT: (1) Be sure to replace O-ring (6) with a new one when reconnecting. (2) Before tightening union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening union nut (9) with Oring (6) displaced will damage Oring (6), resulting in oil leakage. (3) Take care not to damage O-ring groove (8) or sealing face (10). Damage to O-ring (6) will cause oil leakage.

8 10

Joint Body M104-07-033

Wrench Size Union Nut Joint Body 19 17 22 19 27 22 36 30, 32 41 36 50 46

(4) If union nut (9) is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-ring (6) with a new one, then tighten union nut (9) after confirming that O-ring (6) is securely seated in place.

W1-2-6

Tightening Torque N⋅m kgf⋅m Ibf⋅ft 59 6 43 98 10 72 118 12 87 235 24 134 295 30 215 490 50 360

GENERAL INFORMATION Ȁ / Ȁ Tightening Screwed-In Connection IMPORTANT: Many types of screwed-in connections are used for hose connections. Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection.

PF ȓȐ°

Male Tapered Thread

Male Straight Thread W105-01-01-018

Male Tapered Thread Wrench Size Tightening Torque Joint Body N⋅m kgf⋅m lbf⋅ft 17, 19 59 6 43 19, 22 98 10 72 27, 22 118 12 87 36, 32 235 24 134 41 295 30 215 50 490 50 360 60 670 68 490 70 980 100 720

Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leakage between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap.

Internal Thread

• Application Procedure External Thread

Confirm that the thread surface is clean, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads.

Clearance

W105-01-01-019

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. See below for correct tightening torque of each type of low-pressure-hose clamp. M114-07-041

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 kgf⋅m, 4.3 to 5.1 lbf⋅ft)

T-Bolt Type

Worm Gear Type

M114-07-042

W1-2-7

M114-07-043

GENERAL INFORMATION Č&#x20AC; / Č&#x20AC; Tightening Connecting Hose WRONG

CAUTION: (1) When replacing hoses, be sure to use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leakage, hose rupture or separation of fitting, possibly resulting in a fire on the machine. (2) Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leakage, hose rupture or separation of fitting. Utilize print marks on hoses when installing hoses to prevent hose from being installed kinked. (3) 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 that hoses do not come into contact with moving parts or sharp objects.

RIGHT

W105-01-01-011

WRONG

RIGHT Rubbing Against Each Other

W105-01-01-012

WRONG Clamp

RIGHT Clamp

Rubbing W105-01-01-013

WRONG

RIGHT

Rubbing Clamp W105-01-01-014

W1-2-8

SECTION 2

UPPERSTRUCTURE ; CONTENTS; ; Group 1 Cab Disassemble

Remove and Install Cab ...................... W2-1-1

Control Valve 2 ................................ W2-4-14

Dimensions of the Cab Glass .............. W2-1-7

Assemble Control Valve 2 ................................ W2-4-16

Group 2 Counterweight

Disassemble

Remove and Install

Control Valve 3 ................................ W2-4-18

Counterweight ................................... W2-2-1

Assemble Control Valve 3 ................................ W2-4-24

Group 3 Pump Device

Disassemble

Remove and Install

Control Valve 4 ................................ W2-4-30

Pump Device ..................................... W2-3-1

Assemble

Disassemble Pump Transmission........ W2-3-2

Control Valve 4 ................................ W2-4-32

Assemble Pump Transmission ............ W2-3-6

Disassemble

Remove and Install

Control Valve 5 ................................ W2-4-34

Main Pump ........................................ W2-3-9

Assemble

Disassemble Main Pump ................... W2-3-10

Control Valve 5 ................................ W2-4-36

Assemble Main Pump........................ W2-3-16 Maintenance Standard ...................... W2-3-20 Disassemble Regulator ..................... W2-3-22

Group 5 Swing Device

Assemble Regulator .......................... W2-3-24

Remove and Install Swing Device ..................................... W2-5-1

Disassemble and Assemble Pilot Pump ....................................... W2-3-26

Disassemble Swing Reduction Gears ................................................ W2-5-4 Assemble Swing Reduction

Group 4 Control Valve

Gears ................................................ W2-5-8

Remove and Install Control Valve ..................................... W2-4-1

Disassemble Swing Motor ................. W2-5-12 Assemble Swing Motor ...................... W2-5-16

Disassemble Control Valve 1 .................................. W2-4-4

Disassemble and Assemble Swing Parking Brake

Assemble Control Valve 1 .................................. W2-4-8

Release Valve.................................. W2-5-20 Maintenance Standard....................... W2-5-22

162W-2-1

Group 6 Pilot Valve Remove and Install Right Pilot Valve ......................................... W2-6-1 Remove and Install Left Pilot Valve ......................................... W2-6-4 Remove and Install Travel Pilot Valve ............................... W2-6-7 Disassemble Right and Left Pilot Valve ......................................... W2-6-8 Assemble Right and Left Pilot Valve ....................................... W2-6-10 Disassemble Travel Pilot Valve ....................................... W2-6-14 Assemble Travel Pilot Valve ....................................... W2-6-16

Group 7 Pilot Shut-Off Valve Remove and Install Pilot Shut-off Valve ............................ W2-7-1 Disassemble Pilot Shut-off Valve ......... W2-7-4 Assemble Pilot Shut-off Valve.............. W2-7-6

Group 8 Shockless Valve Remove and Install Front Attachment Shockless Valve.............. W2-8-1 Disassemble and Assemble Shockless Valve (Front Attachment) ............................ W2-8-4 Remove and Install Travel Shockless Valve...................... W2-8-7 Disassemble and Assemble Travel Shockless Valve.................... W2-8-10

Group 9 Solenoid Valve Remove and Install Two-Spool Solenoid Valve ................. W2-9-1 Disassemble and Assemble Two-Spool Solenoid Valve ................. W2-9-3

162W-2-2

UPPERSTRUCTURE / Cab REMOVE AND INSTALL CAB Removal 1. Remove nuts (2) and seat (1). : 13 mm

1 2 W157-02-01-005

2. Loosen bolts (5) behind the cab and bolts (6) in rear boxes (3 and 4). Remove rear boxes (3 and 4). : 13 mm

3. Loosen bolts (8) to remove rear box lower cover (7).

3 5

: 13 mm

6 5

4 7 W157-02-01-017

4. Remove filter (25). Loosen screws (9) to remove duct (10) from the cab.

25 9 10 W158-02-01-001

W2-1-1

UPPERSTRUCTURE / Cab 5. Remove cable connectors (11) located inside cab at the rear.

6. Disconnect wiper limit switch (12), cab light (13), speaker (14), antenna (15) and ground (17) located inside the cab. Remove washer vinyl hose(16) outside the cab.

11 W162-02-01-001

15 16

7. Disconnect work light plug connector (18) outside the cab.

16 W162-02-01-002

W162-02-01-003

8. Remove cap (21) from duct cover (19). Loosen screws (20) to remove duct cover (19). 21 20

W158-02-01-002

W2-1-2

UPPERSTRUCTURE / Cab 9. While pushing the mating face of duct (22) toward the rear side of the cab, remove duct (22). Duct Mating Face

W157-02-01-011

10. Attach lifting straps to the top of the cab. CAUTION: cab weight : 260 kg (573 lb)

11. Remove cab mounting bolts (23) and nuts (24). W157-02-01-009

: 17 mm 23

: 24 mm : 8 mm

24 W157-02-01-010

12. Carefully remove the cab.

W157-02-01-001

W2-1-3

UPPERSTRUCTURE / Cab Installation CAUTION: cab weight : 260 kg (573 lb) 1. Attach the lifting straps to the cab. Install the cab onto the frame.

W157-02-01-001

2. Tighten bolts (23) and nut (24). : 17 mm

: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) : 24 mm : 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) : 8 mm 24

: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

W157-02-01-010

3. Install duct (10) to the cab with screws (9). Install filter (25) into the duct.

: 4.9 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft) 25

9 10 W158-02-01-001

4. Connect cable connectors (11) at the rear inside the cab.

11 W162-02-01-001

W2-1-4

UPPERSTRUCTURE / Cab 5. Reconnect wiper limit switch (12), cab light (13), speaker (14) antenna (15) and ground (17) located in the cab. Reinstall washer vinyl hose (16) outside the cab.

: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

15 16

16 W162-02-01-002

6. Reconnect work light plug connector (18) outside the cab.

W162-02-01-003

7. Install rear box lower cover (7) with bolts (8). : 13 mm : 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

8. Install rear boxes (3 and 4) with bolts (5 and 6).

: 13 mm

: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 6 5

4 7 W157-02-01-017

W2-1-5

UPPERSTRUCTURE / Cab 9. While pushing duct (22) to the front of the cab, insert duct (22) into the front duct until the mating faces come in contact with each other.

Duct Mating Face

W157-02-01-011

10. Install duct cover (19) with screws (20). Install caps (21). 21 20

W158-02-01-002

11. Secure seat (1) with nuts (2). : 13 mm : 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

1 2 W157-02-01-005

W2-1-6

UPPERSTRUCTURE / Cab DIMENSIONS OF THE CAB GLASS Unit : mm A

NOTE: 1 mm=0.03937 in R2

25.106

R11516

3.015

221.399 +0 4-φ13 ҥȑ

R70

R78 (64.74)

142.25

Section A Chamfer Both Sides

580

R9487 30 360.7

(87.81)

R3018

(5 mm) R118 51.03

391.8

No polish chamfering is required in this range.

4° 154.81

188.5 R15 66.84

164.12

43.59

558.78

230.50 222.65

216.73

Along the periphery C1

2-R59

R11509

R2309

R4009

900.7 905

R9509 (4 mm) R1009

Section B

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

No polish chamfering are required in this range.

NOTE: 1 mm=0.03937 in 208

No polish chamfering are required in this range.

333.5±1.0

113.9 10.6

337.5±1.0

(38.5)

22.5 9.2

R3 R30

R72.5

R105 R2285.4 39.5

61.8 R3985.4

728.5±1.0

7735.4

Chamfer Both Sides

(4 mm)

Chamfer Both Sides

728.5±1.0

Section C,D

39.5 3.1

40 +0.5 2-φ12.2 ҥ0

488.5 R120885.4

475.8

+0.5 2-φ12.2 ҥ0 60.1

2-R4

290 (4 mm)

R1985.1 398.5±1.0

3-R4

No polish chamfering are required in this range.

503±1. (38.5)

541.5

No polish chamfering are required in this range.

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

213.97

(5 mm) R120

4-R5

227.39

R895

R595

19.29

R345

R295

33.60

(5 mm)

11.22 18

R12.5

276.58

R1145

R1995

370±1.0

165

R1209

833±1.0 910

516.26 549.86

39.63 50.71 59

W157-02-01-014

W2-1-8

UPPERSTRUCTURE / Counterweight REMOVE AND INSTALL COUNTERWEIGHT Removal CAUTION: Counterweight weight: 12500 kg (27560 lb) 1. Attach wire ropes with shackles to the lifting lugs on the top of the counterweight. Take out any slack on the wire ropes by applying tension slowly with a crane.

W162-02-02-001

CAUTION: Use care to prevent hand injury from the power wrench reaction bar. 2. Use a power wrench to remove bolts (7), nuts (10), stoppers (8) and washers (6 and 9).

: 65 mm

4 5

3. Loosen bolts (1) to remove spring washers (2), stoppers (3) and spacers (4). Remove shims (5) if equipped.

9 8

6 7

: 36 mm

W162-02-02-002

4. Remove the counterweight. 8 9 10 5 4

6 7

3 1 2

W162-02-02-003

W2-2-1

UPPERSTRUCTURE / Counterweight Installation CAUTION: Counterweight weight: 12500 kg (27560 lb) 1. Attach wire ropes with shackles to the lifting lugs on the top of the counterweight. CAUTION: Never allow anyone under the lifted counterweight. 2. Lift the counterweight. With the bosses on the back face of the counterweight aligned with holes on the frame, install the counterweight.

W162-02-02-001

CAUTION: Use care to prevent hand injury from the power wrench reaction bar. IMPORTANT: Apply a lubricant to bolts (7) before installing. Install stoppers (8) with flanges positioned downward.

3. Install bolts (7), nuts (10), stoppers (8) and washers (6 and 9). Tighten bolts (7) using a power wrench. : 65 mm : 2750 N⋅m (280 kgf⋅m, 2025 lbf⋅ft)

4 5

10 9 8

6 7

W162-02-02-002

4. Install shims (5), spacers (4), stoppers (3), and spring washers (2) and bolts (1). Detach the wire ropes and shackles.

8 9

: 36 mm : 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)

10 5 4

6 7

3 1 2

W162-02-02-003

W2-2-2

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.

Block

The hydraulic oil tank cap may fly off by remaining pressure if removed quickly. Slowly loosen the cap to completely release any remaining pressure. Preparation 1. After stopping the engine, move the control levers several times to release any pressure remaining in the system.

W162-02-03-003

Pump Device Mounting Bolt Engine Rear Side Mounting Bolt

2. Rotate the hydraulic oil tank cap approx. 30° counterclockwise to release trapped air in the hydraulic oil tank. Removal 1. Disconnect all hydraulic lines and electrical cables from the pump. : 22 mm, 27 mm : 8 mm, 14 mm 2. Place a block (100 mm square, approx. 30 mm thick) underneath the engine flywheel housing.

W162-02-03-004

Wrench Size (mm)

CAUTION: Pump device weight: 445 kg (980 lb) 3. Remove the pump device mounting bolts and rear side engine mounting bolts to remove the pump device. : 36 mm, 16 mm Installation 1. Install the pump with the mounting bolts. 2. Connect all hydraulic lines and electrical cables to the pump. 3. Bleed air trapped inside the pump. (Refer to page W1-1-2.) IMPORTANT: After installing the pump, be sure to perform break-in operation to prevent seizure.

Tightening Torque N⋅m

kgf⋅m lbf⋅ft

Remark

: 22

Hose

: 27

9.5

Hose

: 8

108

Hose

: 14

265

195

Hose

: 36

690

506

Bolt

: 16

Bolt

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.)

W2-3-1

UPPERSTRUCTURE / Pump Device DISASSEMBLE PUMP TRANSMISSION

12 13 14

15 16 17

W162-02-03-002

12345-

Casing Bearing Sleeve Retaining Ring Gear

6789-

Retaining Ring Bearing O-Ring Cartridge

10 11 12 13 -

W2-3-2

Bolt (5 Used) Bolt (8 Used) Oil Seal Cartridge

14 15 16 17 -

O-Ring Bearing Gear Bearing

UPPERSTRUCTURE / Pump Device Disassemble Pump Transmission • Before starting any repair work, thoroughly read all “Precautions for Disassembling and Assembling” (W1-1-1).

8. Using a puller, remove the outer race of bearing (7). 9. Remove retaining ring (6) from sleeve (3).

CAUTION: Pump device weight: 145 kg (320 lb) 1. Place casing (1) on a work bench with the main pump mounting side facing downward. 2. Remove bolts (10). : 8 mm

10. Attach metal protector (dia. 30 mm) to top of sleeve (3) and tap the protector over top of sleeve (3) with a plastic hammer to remove sleeve (3) and bearing (2) from casing (1). 11. Using a press, remove bearing (2) from sleeve (3).

CAUTION: Pump device weight: 145 kg (320 lb)

12. Remove retaining ring (4) from sleeve (3).

3. Re-position casing (1) on the work bench so that the engine mounting side faces downward. NOTE: At this time, lay two wooden blocks (100 mm high) under the casing so that the blocks are not under cartridges (9 and 13).

13. Remove bolts (11) and cartridge (13). : 17 mm 14. Remove oil seal (12) and o-ring (14) from cartridge (13).

4. Attach metal protector (diaȎȀ30 mm) to top of sleeve (3) and tap the protector over top of sleeve (3) with a plastic hammer until gear (5) comes in contact with casing (1). Then, cartridge (9) and bearing (7) are pushed out of casing (1).

CAUTION: Pump transmission weight: 140 kg (310 lb) 15. Lay two wooden blocks (150 mm high) on the work bench. Place casing (1) on the wooden blocks with the engine mounting side facing downward.

CAUTION: Pump device weight: 145 kg (320 lb) 5. Lay two wooden blocks (150 mm high) on the work bench. Place casing (1) on the wooden blocks with the main pump mounting side facing downward. 6. Remove cartridge (9) from casing (1). Remove Oring (8) from cartridge (9). 7. Attach metal protector (diaȎȀ25 mm) to top of sleeve (3) and tap the protector over top of sleeve (3) with a plastic hammer until gear (5) comes in contact with casing (1). Remove sleeve (3) from the outer race of bearing (7).

16. Attach metal protector (diaȎȀ90 mm) to top of gear (16). Using a press, push gear (16) out of casing (1). 17. Take gear (5) out of casing (1). 18. Using a press or puller, remove bearings (15 and 17) from gear (16).

W2-3-3

UPPERSTRUCTURE / Pump Device ASSEMBLE PUMP TRANSMISSION

2 17

13 11

W162-02-03-001

12345-

Casing Bearing Sleeve Retaining Ring Gear

6789-

Retaining Ring Bearing O-Ring Cartridge

10 11 12 13 -

W2-3-4

Bolt (5 Used) Bolt (8 Used) Oil Seal Cartridge

14 15 16 17 -

O-Ring Bearing Gear Bearing

UPPERSTRUCTURE / Pump Device Assemble Pump Transmission 1. Press bearings (15 and 17) onto gear (16).

11. Press gear (16) into casing (1) so that gear (16) meshes with gear (5).

2. Install retaining ring (4) to sleeve (3). 12. Attaching a protector on oil seal (12), press oil seal (12) into cartridge (13). 3. Press bearing (2) onto sleeve (3). 13. Apply grease on the inner lip of oil seal (12). 4. Install gear (5) into casing (1). 14. Install O-ring (14) in cartridge (13). IMPORTANT: Press bearing (2) into casing (1) until the end face of bearing (2) is flush with the stepped face in the casing bore.

15. Install cartridge (13) in casing (1) with bolts (11). : 17 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

5. With splines on sleeve (3) and gear (5) aligned, press sleeve (3) with bearing (2) into casing (1).

CAUTION: Assembly weight of casing (1), gear (5), etc.: 125 kg (276 lb)

CAUTION: Pump transmission weight: 145 kg (320 lb) 16. Check that bearing (2) and sleeve (3) are correctly installed in casing (1) by softly tapping bearing (2) with a plastic hammer.

6. Turn casing (1) over. 7. Install retaining ring (6) to sleeve (3). 8. After centering the outer and inner races of bearing (7), press the outer race of bearing (7) into casing (1). 9. Install O-ring (8) around cartridge (9). 10. Install cartridge (9) in casing (1) with bolts (10). : 13 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

W2-3-5

UPPERSTRUCTURE / Pump Device (Blank)

W2-3-6

UPPERSTRUCTURE / Pump Device REMOVE AND INSTALL MAIN PUMP CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines.

Mounting Bolt

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 fly off by remaining pressure if removed quickly. Slowly loosen the cap to completely release any remaining pressure. Preparation 1. 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. Removal 1. Disconnect all hydraulic lines and electrical cables from the pump. : 22 mm, 27 mm : 8 mm, 14 mm

T162-03-01-001

Wrench Size (mm)

CAUTION: Main pump weight: 300 kg (661 lb) 2. Remove the pump mounting bolts to remove the pump. : 36 mm Installation 1. Install the pump with the mounting bolts. 2. Connect all hydraulic lines and electrical cables to the pump. 3. Bleed air trapped inside the pump. (Refer to page W1-1-2.) IMPORTANT: After installing the pump, be sure to perform break-in operation to prevent seizure.

Tightening Torque N⋅m

kgf⋅m lbf⋅ft

Remark

: 22

Hose

: 27

9.5

Hose

: 8

108

Hose

: 14

265

195

Hose

: 36

690

506

Bolt

W2-3-7

UPPERSTRUCTURE / Pump Device Disassemble Main Pump

30 28

46 48

44 41 39

52 62

53 54

59 57

49 76

66 67 68 69 70

71 W162-02-04-001

W2-3-8

UPPERSTRUCTURE / Pump Device 12345678910 11 12 13 14 15 16 17 18 19 -

Socket Bolt Cover O-Ring Oil Seal Shaft Spacer Bearing Spacer Retaining Ring Socket Bolt Cover Nut Screw Pin O-Ring Stopper Backup Ring O-Ring Housing

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

Tilt Pin Regulator Socket Bolt Servo Piston O-Ring Backup Ring Stopper O-Ring Taper Pin Plug A Sensor O-Ring Plug Swash Plate Bushing Shoe Plunger Retainer Spherical Bushing

39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

NOTE: Parts (6 to 9, 12 to 18, 20 to 41, 55, and 56) in housing (61) are the same as those used in housing (19).

W2-3-9

Spacer Spring Cylinder Block Valve Plate Bearing O-Ring Cover Plug O-Ring Screw Nut Booster Coupling Spring Pin Filter Pin Shoe Plate Feed Back Link Bearing

58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76

Valve Plate O-Ring O-Ring Housing O-Ring Cover Socket Bolt Cover Socket Bolt Shaft Pin Filter Spring Pin Cover O-Ring Plug O-Ring O-Ring O-Ring

UPPERSTRUCTURE / Pump Device

30 28

46 48

44 41 39

52 62

53 54

59 57

49 76

66 67 68 69 70

71 W162-02-04-001

W2-3-10

UPPERSTRUCTURE / Pump Device Disassemble Main Pump â&#x20AC;˘ Before starting any repair work, thoroughly read all â&#x20AC;&#x153;Precautions for Disassembling and Assemblingâ&#x20AC;? (W1-1-1). IMPORTANT: Do not remove screws (13 and 48) and nuts (12 and 49). If removed, the pump set flow rate may be changed.

5. Remove cylinder blocks (41), springs(40), spacers (39), spherical bushings (38), retainers (37) plungers (36), and shoes (35) from housings (19 and 61). 6. Loosen socket bolts (1 and 64) to remove covers (2 and 63) and O-rings (3 and 62). Remove oil seal (4) from cover (2).

1. Remove two plugs (32) and O-rings (31) to drain hydraulic oil from the pump.

: 6 mm 7. Tap covers (11 and 65) with a plastic hammer to remove from housings (19 and 61). Remove Orings (27) and spring pins (14).

: 36 mm 2. Remove socket bolt (22) and regulator (21). Remove A sensors (30) (two places).

8. Remove swash plates (33) and shoe plates (55) from housings (19 and 61).

: 6 mm IMPORTANT: Take care not to allow valve plates (42 and 58) to drop when separating housing (19) assembly, cover (45) assembly, cover (71) assembly, and housing (61) assembly. 3. Insert a steel bar or pipe into the pump mounting bolt holes in covers (11 and 65). While holding the bar or pipe to prevent the pump assembly from rotating, loosen socket bolts (10 and 66) to separate housing (19) assembly, cover (45) assembly, cover (71) assembly and housing (61) assembly. At this time, remove O-rings (44, 59, 60, and 74 to 76), spring pins (52 and 70), and filters (53 and 69). : 17 mm

NOTE: Do not remove feedback links (56) unless required. 9. Tap with a plastic hammer to remove shafts (5 and 67) from covers (11 and 65). 10. Remove retaining rings (9), spacers (8), bearings (7) and spacers (6) from shafts (5 and 67) IMPORTANT: LOCTITE is applied to the joint between servo piston (23) and tilt pin (20). Take care not to damage servo piston (23) when disassembling. 11. Remove stoppers (16), stoppers (26), servo pistons (23) and tilt pins (20) from housings (19 and 61).

4. Remove booster (50), coupling (51), valve plate (42) and pin (54) from cover (45). Remove valve plate (58) and pin (68) from cover (71). NOTE: Do not remove bearing (43, 57) unless required.

W2-3-11

UPPERSTRUCTURE / Pump Device Assemble Main Pump

14 33 55 35 19 34 44 60

46,47 49

48 74

75 57 24,25 26 60

23 59 20 61

16 17,18 65

12 13 11 5

62 67 63

15 27

36 39 41 40 31,32 42 52,53

54 43 45 51 50 71 72,73 68

69,70

58 28,29 56 6

W162-02-04-003

12345678910 11 12 13 14 15 16 17 18 19 -

Socket Bolt Cover O-Ring Oil Seal Shaft Spacer Bearing Spacer Retaining Ring Socket Bolt Cover Nut Screw Pin O-Ring Stopper Backup Ring O-Ring Housing

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 -

Tilt Pin Regulator Socket Bolt Servo Piston O-Ring Backup Ring Stopper O-Ring Taper Pin Plug A Sensor O-Ring Plug Swash Plate Bushing Shoe Plunger Retainer Spherical Bushing

39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 -

Spacer Spring Cylinder Block Valve Plate Bearing O-Ring Cover Plug O-Ring Screw Nut Booster Coupling Spring Pin Filter Pin Shoe Plate Feed Back Link Bearing

NOTE: Parts (6 to 9, 12 to 18, 20 to 41, 55, and 56) in housing (61) are the same as those used in housing (19).

W2-3-12

58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 -

Valve Plate O-Ring O-Ring Housing O-Ring Cover Socket Bolt Cover Socket Bolt Shaft Pin Filter Spring Pin Cover O-Ring Plug O-Ring O-Ring O-Ring

UPPERSTRUCTURE / Pump Device Assemble Main Pump IMPORTANT: Apply LOCTITE (medium adhesive) to the joint between servo piston (23) and tilt pin (20).

IMPORTANT: Apply greae to the valve plate (42). 7. Install spring pins (52), filter (53), pin (54), valve plate (42) and O-rings (44) to cover (45).

1. Install A sensors (30), tilt pins (20), servo pistons (23), O-rings (18 and 24), backup rings (17 and 25) and stoppers (16 and 26) into housings (19 and 61).

NOTE: When installing valve plate (42), align the pin hole position with pin (54). 8. Install housing (19) assembly to cover (45) with socket bolts (10).

: 6 mm : 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 2. Heat bearing (7). Install spacers (6), bearings (7), spacers (8) and retaining rings (9) onto shafts (5 and 67). 3. Install pins (14), O-rings (15 and 27) to covers (11 and 65). Install covers (11 and 65) to housings (19 and 61). IMPORTANT: Install feedback link (56) to swash plate (33) with the link hole connected to tilt pin (20). 4. Install shoe plate (55) to swash plate (33). Install swash plates (33) into housings (19 and 61) so that the swash plate joins with tilt pin (20). NOTE: After installing swash plate (33), make sure that the swash plate can be moved smoothly by hand. 5. Press shafts (5 and 67) in covers (11 and 65). Install oil seals (4), O-rings (3 and 62) to covers (2 and 63). Install covers (2 and 63) to covers (11 and 65) with socket bolts (1 and 64).

: 17 mm : 630 N⋅m (64 kgf⋅m, 463 lbf⋅ft) 9. Install coupling (51) and booster (50) to cover (45). IMPORTANT: Apply a film of grease to valve plate (58). 10. Install spring pins (70), filter (69), pin (68), valve plate (58) and O-rings (60, 59, 74, 75, and 76) to cover (71). NOTE: When installing valve plate (58), align the pin hole position with pin (68). 11. Install housing (61) to cover (71). Then, install them to housing (19) assembly with socket bolts (66). : 17 mm : 630 N⋅m (64 kgf⋅m, 463 lbf⋅ft) 12. Install regulator (21) onto housing (19) with socket bolts (22) so that the regulator feedback lever joints with tilt pin (20).

: 6 mm : 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

6. Install springs (40), spacer (39), spherical bushing (38), plungers (36), retainer (37) and shoes (35) to cylinder block (41). Install the cylinder blocks onto shafts (5 and 67) while aligning splines.

13. Install O-rings (31) and plugs (32).

W2-3-13

: 36 mm : 165 N⋅m (17 kgf⋅m, 123 lbf⋅ft)

UPPERSTRUCTURE / Pump Device MAINTENANCE STANDARDS 1. Clearance between Plunger (36) Outer Diameter (d) and Cylinder Block (41) Bore Diameter (D). D−d

Unit : mm (in) Standard

Allowable Limit

0.047 (0.002)

0.094 (0.004)

W117-02-02-009

2. Free Length (L) of Spring (40) Unit : mm (in) Standard

Allowable Limit

49.5 (1.95)

48.0 (1.89)

L W117-02-02-010

3. Clearance (e) between Plunger (36) and Shoe (35) and Thickness (t) of Shoe (35). e Unit : mm (in) Standard

Allowable Limit

0 to 0.1 (0 to 0.004)

0.35 (0.014)

Unit : mm (in) Standard

Allowable Limit

6.5 (0.26)

6.3 (0.25)

e t

W117-02-02-011

4. Height difference from the reverse face of retainer (37) to the top of spherical bushing (38) H−h

Unit : mm (in) Standard

Allowable Limit

16.5 (0.65)

15.5 (0.61)

Base

W117-02-02-012

W2-3-14

UPPERSTRUCTURE / Pump Device (Blank)

W2-3-15

UPPERSTRUCTURE / Pump Device DISASSEMBLE REGULATOR

6 5 4 34

2 1

28 16 15

27 19 20 21

37 38

22 24 25 23

W162-02-04-002

1 - Casing 2 - Spring Seat 3 - Spring

11 - Plug 12 - Pin 13 - O-Ring

45678910 -

14 15 16 17 18 19 20 -

Stopper O-Ring Cover Socket Bolt Screw Nut O-Ring

O-Ring O-Ring Spool Pin Feedback Lever Sleeve Pilot Piston

21 - Sleeve 22 - O-Ring 23 - Pump Control Solenoid Valve 24 - Valve Cover 25 - Socket Bolt 26 - Plug 27 - O-Ring 28 - Plug 29 - O-Ring

W2-3-16

30 - Valve Seat 31 - Steel Ball 32 - Stopper 33 34 35 36 37 38 -

Socket Bolt Plug Stopper Steel Ball Valve Seat O-Ring

UPPERSTRUCTURE / Pump Device Disassemble Regulator • Before starting any repair work, thoroughly read all “Precautions for Disassembling and Assembling” (W1-1-1). 1. Remove pump control solenoid valve (23). : 32 mm 2. Loosen socket bolts (25) to remove valve cover (24). : 5 mm 3. Remove O-ring (29), valve seat (30), steel ball (31), and stopper (32) from casing (1). 4. Remove O-ring (22), sleeve (21), and pilot piston (20) from casing (1). 5. Remove plug (11) to remove feedback lever (18), pin (17), sleeve (19), and spool (16). : 6 mm NOTE: Feedback lever (18) and pin (17) will come off at the same time . 6. Loosen socket bolts (7) to remove cover (6). : 5 mm IMPORTANT: Do not remove screw (8) and nut (9). If removed, the pump flow rate setting may be changed. 7. Using forcing bolt (M4), remove stopper (4). Then, remove spring (3) and spring seat (2). 8. Remove O-ring (38), valve seat (37), steel ball (36), and stopper (35) from casing (1).

W2-3-17

UPPERSTRUCTURE / Pump Device ASSEMBLE REGULATOR 23

31 27 33

28 29

34 10 11 9

35 36 37

20 22

12 13

T111-02-03-005

1 - Casing 2 - Spring Seat 3 - Spring

11 - Plug 12 - Pin 13 - O-Ring

45678910 -

14 15 16 17 18 19 20 -

Stopper O-Ring Cover Socket Bolt Screw Nut O-Ring

O-Ring O-Ring Spool Pin Feedback Lever Sleeve Pilot Piston

21 - Sleeve 22 - O-Ring 23 - Pump Control Solenoid Valve 24 - Valve Cover 25 - Socket Bolt 26 - Plug 27 - O-Ring 28 - Plug 29 - O-Ring

W2-3-18

30 - Valve Seat 31 - Steel Ball 32 - Stopper 33 34 35 36 37 38 -

Socket Bolt Plug Stopper Steel Ball Valve Seat O-Ring

UPPERSTRUCTURE / Pump Device Assemble Regulator 1. Install stopper (35), steel ball (36), valve seat (37) and O-ring (38) into casing (1). 2. Install sleeve (19) and spool (16) into casing (1). Then, install feedback lever (18) to sleeve (19) with pin (17). NOTE: Take care not to mistake the installing direction of sleeve (19) and spool (16). 3. Install O-ring (10) around plug (11). Align the pin holes of feed back lever (18) and casing (1). Then, install plug (11) with O-ring (10) into casing (1). : 6 mm : 19 N⋅m (2 kgf⋅m, 15 lbf⋅ft) NOTE: After installing plug (11), check that the feedback lever (18) moves smoothly. 4. Install spring seat (2), spring (3), stopper (4) and O-ring (5) into casing (1). Install cover (6) with socket bolts (7). : 4 mm : 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft) 5. Install pilot piston (20), sleeve (21), and O-ring (22) into casing (1). 6. Install stopper (32), steel ball (31), valve seat (30) and O-ring (29) into casing (1). 7. Install pump control solenoid valve (23) to valve cover (24). Install valve cover (24) to casing (1) with socket bolts (25). : 32 mm : 44 N⋅m (4.5 kgf⋅m, 33 lbf⋅ft) : 4 mm : 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)

W2-3-19

UPPERSTRUCTURE / Pump Device DISASSEMBLE AND ASSEMBLE PILOT PUMP

27 13 26

12 9 6

26 14 27 6 9

3 5

16 15 7 W137-02-04-034

W2-3-20

UPPERSTRUCTURE / Pump Device

Item

Part Name

Q’ty

Wrench Size (mm)

Tightening Torque N⋅m

kgf⋅m

lbf⋅ft

Remarks

Housing

Flange

Oil Seal

Retaining Ring

Seal

Cover

Backup Ring

Key

O-Ring

Gear

Washer

Bolt

Bushing

Apply a film of hydraulic oil to bushing when installing.

Bushing

Apply a film of hydraulic oil to bushing when installing.

Apply grease to oil seal lip when installing. Apply grease to seal when installing. Apply grease to backup ring when installing. Apply grease to when installing.

: 17

39 to 44

W2-3-21

4 to 4.5

O-ring

29 to 33

UPPERSTRUCTURE / Pump Device (Blank)

W2-3-22

UPPERSTRUCTURE / Control Valve REMOVE AND INSTALL CONTROL VALVE CAUTION: 1. Escaping pressure hydraulic oil can penetrate the skin or eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. 2. 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 work. 3. The hydraulic oil tank cap may fly off due to internal pressure if turned quickly. Slowly turn the cap to release internal pressure before completely removing the cap. Preparation 1. Park the machine on firm and level surface. Lower the front attachment to the ground. 2. Stop the engine. Move all control levers to release any pressure remaining in the system.Slowly turn the hydraulic oil tank cap approx. 30 degrees counterclockwise to release any remaining pressure from the hydraulic oil tank. Refer to â&#x20AC;&#x153;Bleed Pressure from Hydraulic Circuitâ&#x20AC;? on page W1-1-2. 3. Remove the cap and connect a vacuum pump. Operate the vacuum pump constantly to maintain the negative pressure in the hydraulic oil tank. NOTE: Keep the vacuum pump continuously while working.

running

W2-4-1

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