Hitachi ex2500 excavator service repair manual

Page 1

EX2500 Workshop Manual


SECTION 1

GENERAL IMFORMATION —CONTENTS— Group 1 Precautions for Disassembly and Assembly Precautions for Disassembly and Assembly.............................................. W1-1-1

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

117W-1-1


(Blank)

117W-1-2


GENERAL INFORMATION / Precautions for Disassembly and Assembly PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY Precautions for Disassembly and Assembly

Preparations for Disassembly

• Clean the Machine

• Precautions for Disassembly • To prevent dirt from entering the hydraulic system, cap or plug the removed pipes. • Before disassembling, clean the exterior of the components and place them on a clean work bench. • Before disassembling, drain gear oil from the reduction gear. • Be sure to provide appropriate containers for fluids. • Use matching marks for easier reassembling. • Be sure to use the specified tools, when instructed. • If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove forcibly. Find the cause(s), then take the appropriate measures. • 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 Assembly

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. • 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 tools, so as to make sure that no tools are missing.


GENERAL INFORMATION / Precautions for Disassembly and Assembly 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. M104-07-021

W1-1-2


GENERAL INFORMATION / Precautions for Disassembly and Assembly Floating Seal Precautions

A

1. In general, always 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 seal ring face (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

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

(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 mating face (C) by measuring the distances (A) and (C) at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating.

W105-03-05-020

Correct

C

Incorrect

a

a

A B

b

a=b

b

aŇ?b W110-03-05-004

W1-1-3


GENERAL INFORMATION / Precautions for Disassembly and Assembly (Blank)

W1-1-4


GENERAL INFORMATION / Tightening Torque TIGHTENING TORQUE SPECIFICATIONS

No.

Descriptions

Bolt Dia mm

Q'ty

Torque

Wrench Size mm

N⋅m

(kgf⋅m)

(lbf⋅ft)

1 Engine cushion rubber mounting bolt:

36

6

55

3140

(320)

(2310)

2 Engine bracket mounting bolt:

30 22

12 4

46 32

1420 740

(145) (75)

(1050) (540)

3 Hydraulic oil tank mounting bolt:

30

10

46

1420

(145)

(1050)

4 Fuel tank mounting bolt:

30

12

46

1420

(145)

(1050)

5 Pump transmission mounting bolt:

12

16

19

108

(11)

(80)

6 Pump device mounting bolt:

24

12

36

690

(70)

(510)

7 Fan drive mounting bolt:

20

4

30

390

(40)

(290)

8 Gear pump moounting bolt:

12

4

19

88

(9)

(65)

9 Control valve mounting nut:

20

12

30

390

(40)

(290)

10 Swing device mounting bolt:

33

50

50

2550

(260)

(1880)

11 Swing motor mounting bolt:

20

16

30

390

(40)

(290)

12 Battery mounting bolt:

10

16

17

49

(5)

(36)

13 Cab mounting bolt:

18

8

27

295

(30)

(215)

14 Cab bed mounting bolt:

16

36

24

205

(21)

(152)

15 Swing vearing mounting bolt:

48

60

75

4900

(500)

(3620)

16 Counterweight mounting nut:

48

6

75

5150

(525)

(3800)

17 Engine bed mounting bolt:

30

26

46

1420

(145)

(1050)

18 Oil cooler mounting nut:

24

8

36

690

(70)

(510)

19 Radiator mounting nut:

27

16

41

1370

(140)

(1010)

20 Fan motor mounting bolt:

12

10

10

108

(11)

(80)

21 Fan motor bracket mounting bolt:

12

12

19

88

(9)

(65)

22 Travel device mounting bolt:

27 36 20 16

24 56 30 32

41 55 30 24

1370 3140 390 205

(140) (320) (40) (21)

(1010) (2310) (290) (152)

23 Travel motor mounting bolt:

22

8

32

740

(75)

(540)

24 Upper roller mounting bolt:

22

24

32

540

(55)

(400)

25 Lower roller mounting bolt:

36

64

55

3140

(320)

(2310)

26 Track pin-retaining bolt:

30

156

46

1910

(195)

(1410)

27 Side frame mounting bolt:

48

68

85

4900

(500)

(3620)

28 Front pin-retaining bolt:

24 20 16

28

36 30 24

690 390 265

(70) (40) (27)

(510) (290) (195)

16 6

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

W1-2-1


GENERAL INFORMATION / Tightening Torque 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 bolts, 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

SA-040

Socket Bolt

Hexagon M Bolt

Hexagon H Bolt

W162-01-01-001

Specified Tightening Torque Chart Hexagon T Bolt, Socket Bolt Bolt Wrench Wrench Dia. Size N⋅m (kgf⋅m) (lbf⋅ft) Size M 8 13 6 29.5 (3) (22) M 10 17 8 64 (6.5) (47) M 12 19 10 108 (11) (80) M 14 22 12 175 (18) (130) M 16 24 14 265 (27) (195) M 18 27 14 390 (40) (290) M 20 30 17 540 (55) (400) M 22 32 17 740 (75) (540) M 24 36 19 930 (95) (690) M 27 41 19 1370 (140) (1010) M 30 46 22 1910 (195) (1410) M 33 50 24 2550 (260) (1880) M 36 55 27 3140 (320) (2310)

H Bolt N⋅m 19.5 49 88 137 205 295 390 540 690 1030 1420 1910 2400

W1-2-2

(kgf⋅m) (lbf⋅ft) (2) (14.5) (5) (36) (9) (65) (14) (101) (21) (152) (30) (220) (40) (290) (55) (400) (70) (505) (105) (760) (145) (1050) (195) (1410) (245) (1770)

M Bolt N⋅m 9.8 19.5 34 54 78 118 167 215 275 390 540 740 930

(kgf⋅m) (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 / Tightening Torque 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 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 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

1,4

Tighten from center and diagonally

Tighten diagonally

1

12

9

4

1

6

7

14

13

8

5

2

3

10

11

3

6

5

4 2 2,3

W105-01-01-003

W1-2-3


GENERAL INFORMATION / Tightening Torque 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 removed, 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

WRONG

RIGHT

Nut and Bolt Lockings

Do not bend it round

Bend along edge sharply

• Lock Plate 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.

RIGHT

RIGHT

WRONG

Bend along edge sharply W105-01-01-009

• Lock Wire IMPORTANT: Apply wire to bolts in the bolttightening direction, not in the boltloosening direction.

RIGHT

RIGHT

RIGHT

WRONG

Loosen

WRONG

Tighten

W105-01-01-010

W1-2-4


GENERAL INFORMATION / Tightening Torque PIPING JOINT Pipe Thread Connection/Union Joint Tightening Torque Specifications

1

4

3

5

2

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°

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.

Male Union Joint

W105-01-01-017

Tightening Torque N⋅m (kgf⋅m) (Ibf⋅ft) 29 (3.0) (22) 39 (4.0) (29) 93 (9.5) (69) (14) (101) 137 175 (18) (130) 205 (21) (152) 255 (26) (188)

Wrench Size mm 19 22 27 32 36 41 50

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.

Female Union Joint

7

6

9

(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. (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.

W1-2-5

8

10 M104-07-033

Wrench Size mm 27 32 36 41, 46

Tightening Torque N⋅m (kgf⋅m) (Ibf⋅ft) 93 137 175 205

(9.5) (14) (18) (21)

(69) (101) (130) (152)


GENERAL INFORMATION / Tightening Torque Screwed-In Connection

PT

PF

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.

30°

Male Tapered Thread

Male Straight Thread

W105-01-01-018

NOTE: Cas Iron:For tightening screwed-in connection to cast-iron components. Steel :For tightening screwed-in connection to steel components.

Seal Tape Application

Tightening Torque Wrench Cast Iron Steel Size mm N⋅m (kgf⋅m) (Ibf⋅ft) N⋅m (kgf⋅m) 19 14.5 (1.5) (10) 34 (3.5) 22 29.5 (3.0) (22) 49 (5.0) 27 49 (5.0) (36) 93 (9.5) 36 69 (7.0) (51) 157 (16) 41 108 (11) (80) 205 (21) 50 157 (16) (116) 20 (33) 60 195 (20) (145) 410 (42) 70 255 (26) (190)

(Ibf⋅ft) (25) (36) (69) (116) (152) (240) (300)

Internal Thread

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.

External Thread

Clearance

W105-01-01-019

• Application Procedure

Leave one to two pitch threads uncovered

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.

Low-Pressure-Hose Clamp Tightening Torque

M114-07-041

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.

T-Bolt Type

Worm Gear Type

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 ) M114-07-042

W1-2-6

M114-07-043


GENERAL INFORMATION / Tightening Torque 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

W1-2-7


GENERAL INFORMATION / Tightening Torque (Blank)

W1-2-8


SECTION 2

UPPERSTRUCTURE —CONTENTS— Group 1 Cab

Group 4 Swing Device

Windowpane Dimensions ......................... W2-1-1

Remove and Install Swing Device............. W2-4-1 Disassemble Swing Device....................... W2-4-2

Group 2 Pump Device

Assemble Swing Device ........................... W2-4-6 Disassemble Swing Motor ...................... W2-4-12

Remove and Install Pump Device .......................................... W2-2-1

Assemble Swing Motor ........................... W2-4-14

Pump Device Line Connection.................. W2-2-3

Maintenance Standard............................ W2-4-16

Disassemble Main Pump .......................... W2-2-4

Disassemble and Assemble

Assemble Main Pump............................. W2-2-10

Relief Block .......................................... W2-4-17

Maintenance Standards.......................... W2-2-13 Disassemble Regulator .......................... W2-2-14 Assemble Regulator ............................... W2-2-20 Disassemble and Assemble

Group 5 Pilot Valve Remove and Install Front/Swing Pilot Valve............................................... W2-5-1

4-Unit Pump ......................................... W2-2-27

Remove and Install Travel and Bucket

Disassemble Fan Drive Pump ................ W2-2-28

Open/Close Pilot Valves ......................... W2-5-3

Assemble Fan Drive Pump ..................... W2-2-32

Pilot Valve Ports ....................................... W2-5-5

Maintenance Standards.......................... W2-2-34

Disassemble and Assemble

Disassemble Regulator .......................... W2-2-36

Pilot Valve............................................... W2-5-6

Assemble Regulator ............................... W2-2-40

Group 6 Pilot Shut-Off Valve

Disassemble and Assemble Compressor Drive Pump ⋅ Pilot Pump....................... W2-2-42 Disassemble and Assemble Transmission

Remove and Install Shut-Off Valve .......................................... W2-6-1

Oil Cooling Pump.................................. W2-2-44

Disassemble Pilot Shut-Off Valve ............. W2-6-2 Assemble Pilot Shut-Off Valve .................. W2-6-4

Group 3 Control Valve Remove and Install Control Valve .......................................... W2-3-1 Pilot Line Port Location ............................ W2-3-3 Main Hydraulic Line Port Location ............ W2-3-4 Disassemble and Assemble Control Valve .......................................... W2-3-5

117W-2-1


Group 7 Solenoid Valve Remove and Install Solenoid Valve........................................ W2-7-1 Disassemble and Assemble Fan Motor Solenoid Valve ....................... W2-7-2 Disassemble and Assemble Horsepower Reducing Solenoid Valve ........................ W2-7-3 Disassemble and Assemble EHC Valve .............................................. W2-7-4 Disassemble and Assemble Swing Stop Solenoid Valve ..................... W2-7-5 Disassemble and Assemble Travel Mode Shift Solenoid Valve........................................ W2-7-6

Group 8 Fan Drive Motor Remove and Install Fan Drive Motor...................................... W2-8-1 Disassemble Fan Drive Motor .................. W2-8-4 Assemble Fan Drive Motor ....................... W2-8-6 Maintenance Standards............................ W2-8-8

Group 9 Compressor Drive Motor Remove and Install Compressor Drive Motor......................... W2-9-1 Disassemble and Assemble Compressor Drive Motor......................... W2-9-4

Group 10 Air Conditioner Work After Component Replacement ........................................ W2-10-1 Add Compressor Oil ............................... W2-10-1 Charge Air Conditioner with Refrigerant ........................................... W2-10-2

117W-2-2


UPPERSTRUCTURE / Cab WINDOWPANE DIMENSIONS Material : JIS R 3211 or equivalent Unit:mm

NOTE: 1 mm=0.03937 in

1378±1.5

6 1

4-R91

7

1

1679+2.0 −0

2

3

Laminated glass Color : Transparent Thickness : 10 mm Chamfer all fringe Corners.

5

4

W117-02-01-001 W117-02-01-002

1369±1.5

4-R61

4-R61

2

917±1.0

3

Tempered glass Color : Bronze Thickness : 6 mm Chamfer all fringe Corners.

769±1.0

Tempered glass Color : Bronze Thickness : 5 mm Chamfer all fringe Corners.

433±1.0

1256±1.5

W117-02-01-004 W117-02-01-003

W2-1-1


UPPERSTRUCTURE / Cab NOTE: 1 mm=0.03937 in 422±1.0

4-R61

4-R61

4

5

Tempered glass Color : Bronze Thickness : 5 mm Chamfer all fringe Corners.

Tempered glass Color : Bronze Thickness : 5 mm Chamfer all fringe Corners.

777±1.0

934±1.0

514±1.0

W117-02-01-005

W117-02-01-006

1400±1.0

667±1.0

4-R61

7

6 848±1.0

4-R61

Tempered glass Color : Bronze Thickness : 5 mm Chamfer all fringe Corners.

Tempered glass Color : Bronze Thickness : 6 mm Chamfer all fringe Corners.

185

645±1.0

403±1.0

1296±1.0 W117-02-01-008 W117-02-01-007

W2-1-2


UPPERSTRUCTURE / Pump Device REMOVE AND INSTALL PUMP DEVICE CAUTION: Escaping fluid under pressure can penetrate the skin and eyes, causing serious injury. Avoid this 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. Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it. Preparation: 1. Stop the engine. Move all control levers to release the pressure remaining in the system. Slowly turn the cap on the hydraulic oil tank approximately 30 degrees counter-clockwise to release any remaining pressure. 2. Close all hydraulic line stop valves.

W2-2-1


UPPERSTRUCTURE / Pump Device Removal Mounting Bolt

1. Disconnect all wire harness ends and hydraulic line ends from the pump. CAUTION: Pump Device Weight: 298 kg (657 Ib) Approximate Quadruple Pump Weight: 100 kg (220 Ib) 2. Remove the pump mounting bolts to remove the pumps. : 36 mm : 690 N⋅m (70 kgf⋅m, 507 lbf⋅ft) : 30 mm : 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft) Installation

T117-02-01-001

NOTE: Refar to the Removal section for wrench size and tightening torque.

Air Bleed Position

Air Bleed Position

1. Install the pumps using the mounting bolts. 2. Connect all wire harness ends and hydraulic line ends to the pump. 3. Bleed the air from the pump. (Refer to W1-1-2) IMPORTANT: Prevent pump seizure from occurring. Be sure to perform running-in operation after installing the pumps. Pump Running-In Operation Procedure: 1. Run the engine at slow idle for 20 minutes. Check for oil leaks during the engine idling operation. 2. Increase the engine speed to the maximum speed. Slowly operate the boom from stroke end to stroke end repeatedly for 20 minutes.

W2-2-2

M117-07-118


UPPERSTRUCTURE / Pump Device PUMP DEVICE LINE CONNECTION

6

6

5 1 6

2

3 5 4 5 T117-02-01-001

1 - Main Main 2 - Main Main

Pump Pump Pump Pump

3 4 5 6

(Transmission Side) (Tip Side) (Transmission Side) (Tip Side)

3 - Main Pump 1 (Transmission Side) Main Pump 2 (Tip Side) 4 - Quadruple Pump

Pf

Pi

Pz

5 - Suction Line

Psv

6 - Delivery Line

Pz

Pi

Psv

T117-02-01-004

Psv - Pump Servo Assist Pressure (From the pilot pump) Pi -

Flow Rate Control Pressure (Switch Valves 1 and 2, Pressure Reducing Valve)

Pf - Horsepower Reducing Control Pressure (Horsepower Reducing Solenoid Valve) Pz -Horsepower Increasing Control Pressure (EHC Valve)

W2-2-3


UPPERSTRUCTURE / Pump Device DISASSEMBLE MAIN PUMP

20

21

19

18

11

12

14

13

16

15

22

17

23 25 A 26

10

27 29

9

8

24

28

7

6 5 4

31

3 1

32

2

30

36

35

34

37

C

38

33 39 40 42

81 48

47

46

45

44

41 51

43

52 53 54

50

49

61

A 71

70

69

68

67

66

65

64

63

60 58

55 57

56

62

59 73

80

72

76

C

75

74

77 78 79

W117-02-02-002

W2-2-4


UPPERSTRUCTURE / Pump Device 1 - Socket Bolt (2 Used)

22 - Stopper (2 Used)

2 - Cover 3 - O-Ring 4 - Cover

23 - Back-Up Ring (2 Used) 24 - O-Ring (2 Used) 25 - Servo Piston (2 Used)

5 - O-Ring 6 - Retaining Ring (2 Used) 7 - Spacer (2 Used) 8 - Bearing (2 Used) 9 - Spacer (2 Used)

26 - O-Ring (2 Used) 27 - Plug (2 Used)

42 - Cylinder Block (2 Used) 43 - Spring (18 Used) 44 - Spacer (2 Used) 45 - Spherical Bushing (2 Used) 46 - Retainer (2 Used) 47 - Plunger (18 Used)

28 - Taper Screw 29 - Plug 30 - O-Ring (4 Used)

48 - Shoe Plate (2 Used) 49 - Bushing (2 Used) 50 - Swash Plate (2 Used)

10 11 12 13

-

31 32 33 34

-

O-Ring Plug Socket Bolt (4 Used) Booster

51 52 53 54

-

Coupling Plug Spring Pin Pin

68 - Plug 69 - O-Ring 70 - Adjusting Screw (2 Used) 71 - Nut (2 Used) 72 - O-Ring (3 Used) 73 - O-Ring 74 - Pin

14 15 16 17 18 19

-

35 36 37 38 39 40

-

Eye Bolt Plug O-Ring Valve Cover O-Ring Needle Bearing

55 56 57 58 59 60

-

Socket Bolt (8 Used) Cover Oil Seal O-Ring Shaft Regulator

75 76 77 78 79 80

20 21 -

Shaft Cover Nut (2 Used) Adjusting Screw (2 Used) Spring Pin Stopper (2 Used) Back-Up Ring (2 Used) O-Ring (2 Used) Housing Displacement Angle Shift Pin (2 Used) Regulator Socket Bolt (4 Used)

41 - Valve Plate

61 - Socket Bolt (4 Used)

62 - Housing 63 - Socket Bolt (4 Used) 64 - O-Ring (12 Used) 65 - O-Ring 66 - Valve Plate 67 - Needle Bearing

- Spring Cover - Cover - O-Ring - Plug - O-Ring - Cover

81 - Socket Bolt (4 Used)

NOTE: The components of housing (62): parts (6) to (9), (15) to (17), (19), (22) to (25), and (42) to (50), are exactly the same as those of housing (18).

W2-2-5


UPPERSTRUCTURE / Pump Device 20

21

18

11

12

14

13

A 26

27

5 4

31

30

34

C

38

33 39 40 42

81 48

47

46

45

44

41 51

43

53 54 61

50

66

A 71

73

65

64

63

60

62

70

72

76

C

79

75

74

W117-02-02-002

W2-2-6


UPPERSTRUCTURE / Pump Device Disassemble Main Pump IMPORTANT: Do not attempt to remove nut (12), adjusting screw (13), nut (71), and adjusting screw (70). Leave them as installed. The set flow rate may be altered. 1. Remove plugs (27) (2 used) and O-rings (26) (2 used) to drain hydraulic oil from the pump. : 36 mm 2. Remove socket bolts (21) (4 used) and (61) (4 used) to remove regulators (20) and (60), respectively. : 6 mm 3. Turn the pump over (on the regulator mounting side). Remove socket bolts (33) (4 used) and (63) (4 used). : 17 mm 4. Separate housing (18), valve cover (38), cover (76), and housing (62) assemblies. Be sure to remove O-rings (39), (65), (64), (72), (73), and (79) and spring pins (53) and (75) when separating these assemblies. NOTE: Take care not to drop valve plates (41) and (66) while separating these assemblies. 5. Remove booster (34), coupling (51), valve plate (41) and pin (54) from valve cover (38). NOTE: Do not remove needle bearing (40) unless required. 6. Remove cylinder block (42), springs (43) (9 used), spacer (44), spherical bushing (45), retainer (46), and plungers (47) (9 used) from housing (18). 7. Remove socket bolts (81) (4 used) to remove cover (4) and O-ring (5). : 6 mm 8. Tap on cover (11) using a plastic hammer to remove it. Remove O-rings (30) (2 used) and (31), and spring pin (14) as well. 9. Remove swash plate (50) and shoe plate (48) from housing (18).

W2-2-7


UPPERSTRUCTURE / Pump Device

19

18

14

15

16

22

17

23 25

24

A

11

10 8 6

9

7

31

30

C

42

81 48

47

46

45

44

43

55 50

58

57

56

62

A

67

66

59 80

74 C

76

W117-02-02-002

W2-2-8


UPPERSTRUCTURE / Pump Device 10. Remove stopper (15), stopper (22), servo piston (25) and displacement angle shift pin (19) from housing (18). NOTE: As LOCTITE has been applied on the contacting part between servo piston (25) and displacement angle shift pin (19), do not separate them unless required. 11. Tap on the end of shaft (10) using a plastic hammer to remove it from cover (11). 12. Remove retaining ring (6), spacer (7), bearing (8) and spacer (9) from shaft (10). 13. Remove needle bearing (67), valve plate (66) and pin (74) from cover (76). NOTE: Do not remove needle bearing (67) unless required. 14. Remove cylinder block (42), springs (43) (9 used), spacer (44), spherical bushing (45), retainer (46), and plungers (47) (9 used) from housing (62). 15. Remove socket bolts (55) (8 used) to remove cover (56), oil seal (57) and O-ring (58). : 8 mm 16. Tap on cover (80) using a plastic hammer to remove it. Remove O-rings (30) (2 used) and (31), and spring pin (14) as well. 17. Remove swash plate (50) and shoe plate (48) from housing (62). 18. Tap on the end of shaft (59) using a plastic hammer to remove it from cover (80). 19. Remove retaining ring (6), spacer (7), bearing (8) and spacer (9) from shaft (59). 20. Remove stopper (15), stopper (22), servo piston (25) and displacement angle shift pin (19) from housing (62). NOTE: As LOCTITE has been applied on the contacting part between servo piston (25) and displacement angle shift pin (19), do not separate them unless required.

W2-2-9


UPPERSTRUCTURE / Pump Device ASSEMBLE MAIN PUMP

80

45 50 48 49 62 65 64 76 73

38 39 64

23, 24

22 19

25

15

16, 17 12

71

13

70

14 8 5

55

3

56

2

59

10 6 7

57

1

58

81

63

4 33 46

47

44 43 42 66 74

67 75 34 51 40 54

53

41

18

31

9

11 W117-02-02-003

1 - Socket Bolt (2 Used)

22 - Stopper (2 Used)

2 - Cover 3 - O-Ring 4 - Cover

23 - Back-Up Ring (2 Used) 24 - O-Ring (2 Used) 25 - Servo Piston (2 Used)

5 - O-Ring 6 - Retaining Ring (2 Used) 7 - Spacer (2 Used) 8 - Bearing (2 Used) 9 - Spacer (2 Used)

26 - O-Ring (2 Used) 27 - Plug (2 Used)

42 - Cylinder Block (2 Used) 43 - Spring (18 Used) 44 - Spacer (2 Used) 45 - Spherical Bushing (2 Used) 46 - Retainer (2 Used) 47 - Plunger (18 Used)

28 - Taper Screw 29 - Plug 30 - O-Ring (4 Used)

48 - Shoe Plate (2 Used) 49 - Bushing (2 Used) 50 - Swash Plate (2 Used)

10 11 12 13

-

31 32 33 34

-

O-Ring Plug Socket Bolt (4 Used) Booster

51 52 53 54

-

Coupling Plug Spring Pin Pin

68 - Plug 69 - O-Ring 70 - Adjusting Screw (2 Used) 71 - Nut (2 Used) 72 - O-Ring (3 Used) 73 - O-Ring 74 - Pin

14 15 16 17 18 19

-

35 36 37 38 39 40

-

Eye Bolt Plug O-Ring Valve Cover O-Ring Needle Bearing

55 56 57 58 59 60

-

Socket Bolt (8 Used) Cover Oil Seal O-Ring Shaft Regulator

75 76 77 78 79 80

20 21 -

Shaft Cover Nut (2 Used) Adjusting Screw (2 Used) Spring Pin Stopper (2 Used) Back-Up Ring (2 Used) O-Ring (2 Used) Housing Displacement Angle Shift Pin (2 Used) Regulator Socket Bolt (4 Used)

41 - Valve Plate

61 - Socket Bolt (4 Used)

62 - Housing 63 - Socket Bolt (4 Used) 64 - O-Ring (12 Used) 65 - O-Ring 66 - Valve Plate 67 - Needle Bearing

- Spring Cover - Cover - O-Ring - Plug - O-Ring - Cover

81 - Socket Bolt (4 Used)

NOTE: The components of housing (62): parts (6) to (9), (15) to (17), (19), (22) to (25), and (42) to (50), are exactly the same as those of housing (18).

W2-2-10


UPPERSTRUCTURE / Pump Device 1. Install displacement angle shift pin (19), servo piston (25), stopper (22) and stopper (15) into both housing (18) and housing (62). NOTE: If displacement angle shift pin (19) has been separated from servo piston (25), apply LOCTITE to the threaded part of servo piston (25). 2. Install cover (11) onto housing (18). Install cover (80) onto housing (62).

3. Place housings (18) and (62) on a workbench with their regulator mounting side on the bottom. Install swash plate (50) with shoe plate (48) onto displacement angle shift pin (19). NOTE: After installing swash plate (50), check if it moves smoothly. 4. Install spacer (9), bearing (8), spacer (7), and retaining ring (6) onto each shaft (11) and shaft (80).

5. Install O-ring (5) onto cover (4). Install cover (4) onto cover (11) using socket bolts (81). : 6 mm : 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 6. Install O-ring (58) and oil seal (57) onto cover (56). Install cover (56) onto cover (80) using socket bolts (55). : 8 mm : 57 N⋅m (5.8 kgf⋅m, 42 lbf⋅ft) 7. Install spring (43), spacer (44), spherical bushing (45), retainer (46), and plungers (47) into each cylinder block (42) (2 used). Aligning the splines, install the cylinder block assembly onto both shaft (10) and shaft (59). 8. Install pin (54), valve plate (41), O-ring (64), Oring (39), and pin (53) onto cover (38). Install cover (38) onto housing (18) using socket bolts (33). : 17 mm : 630 N⋅m (64 kgf⋅m, 463 lbf⋅ft)

W2-2-11


UPPERSTRUCTURE / Pump Device 9. Install pin (74), valve plate (66), O-ring (64), Oring (65) and pin (75) onto cover (76). Install cover (76) onto housing (80) using socket bolts (33). 10. Install booster (34) and coupling (51) onto shaft (10). NOTE: Be sure that booster (34) is facing the correct direction when installing. 11. Install O-rings (72), (73), and (79) onto cover (76). Connect housing (18) and (62) using socket bolts (63). : 17 mm : 630 N⋅m (64 kgf⋅m, 463 lbf⋅ft) 12. Install regulators (20) and (60) using socket bolts (21) and (61), respectively. : 6 mm : 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

W2-2-12


UPPERSTRUCTURE / Pump Device MAINTENANCE STANDARDS

NOTE: 1 mm= 0.03937 in

1. Clearance between plunger (47) diameter (d) and cylinder block (42) bore (D). D-d

d

Unit : mm Standard

Allowable Limit

0.047

0.094

D

W117-02-02-009

2. Spring (43) free length (L) Unit : mm Standard

Allowable Limit

49.5

48.0

L W117-02-02-010

3. Clearance between plunger and shoe: (e), and shoe thickness (t) e

Unit : mm Standard

Allowable Limit

0∼0.1

0.35

e t

t

Unit : mm Standard

Allowable Limit

6.5

6.3

W117-02-02-011

4. Distance between retainer (46) bottom and spherical bushing (45) top. H-h

Stand

Unit : mm Standard

Allowable Limit

16.5

15.5

h

H

W117-02-02-012

W2-2-13


UPPERSTRUCTURE / Pump Device DISASSEMBLE REGULATOR

13

12 10

11

9 8

3

5

4

7

6

22 23

2

24

26

21

1

20

14

15

16

30

63

29

27

19 17

32

31

25

62 61

18 28 58

59

60 74

57 56 55

33 34

53 36 49

52 68

69

70

71

72

73

77 79

43 42

50

51

76 78

54

35

75

67

45 41

44

40 39 38

80 37

64 65

47

46 97

98

48

81 82

66

83

84

89 96

95

85

91 92 93 94

W2-2-14

90

86

87

88 W117-02-02-005


UPPERSTRUCTURE / Pump Device 12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 -

Pin Sleeve O-Ring O-Ring Sleeve Compensating Piston Compensating Rod Spring Seat Spring Spring Piston Spring Seat O-Ring Retaining Ring Spring Seat Spring Spring Retaining Ring Sleeve Spool Pin Lever Feedback Lever Pin Pin

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

-

Lever Pin Pilot Piston Spring Seat Spring Spring Seat O-Ring Socket Bolt Cover Cover O-Ring Stopper Ball Seat O-Ring O-Ring Plug Plug Plug O-Ring Plug O-Ring Pin Cover Socket Bolt

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74

-

Washer Sleeve Piston Spool Spring Seat Spring Spring Spring Seat O-Ring Cover Socket Bolt Lock Nut Adjusting Screw Cover Socket Bolt Socket Bolt Socket Bolt O-Ring O-Ring Adjusting Screw Adjusting Screw Lock Nut O-Ring Plug

W2-2-15

75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98

-

Cover Lock Nut Adjusting Screw Lock Nut Socket Bolt Casing Pin Support Plug O-Ring Lock Ring Pin Support Plug O-Ring Lock Ring Pin O-Ring Stopper Ball Seat O-Ring O-Ring O-Ring O-Ring Plug


UPPERSTRUCTURE / Pump Device

12 10

13

11

9 8

5

6 31

2

32

30

1

63

29 62 61

17 58 57

75

56 55

33 34

53 36 49

50

51

76 78

54

35

59

60

52 70

71

72 77 79

67

45 44

40 39 38

80

64 65

47

37

48 97

66 96

95

W117-02-02-005

W2-2-16


UPPERSTRUCTURE / Pump Device 1. Remove socket bolts (50) and (67) to remove the regulators. : 6 mm 2. Remove socket bolts (33). Remove cover (34), O-ring (40), cover (35), O-ring (36), cover (49), Oring (47), and pin (48). : 5 mm 3. Remove stopper (37), ball (38), and seat (39) from cover (35). 4. Remove socket bolts (61) from cover (49). Remove cover (60), O-ring (59), spring seat (58), spring (57), spring (56), spring seat (55), spool (54), piston (53), sleeve (52), and washer (51). IMPORTANT: Never attempt to remove lock nut (62) and adjusting screw (63) from cover (60). Setting for the relief oil flow minimizing control may be altered. : 5 mm 5. Remove socket bolts (79) from casing (80). Remove cover (75), spring seat (12), piston (11), spring (10), spring (9), spring seat (8), spring seat (31), spring (30), and spring seat (29). IMPORTANT: Never attempt to remove adjusting screw (70), lock nut (76), adjusting screw (71) and lock nut (72) from cover (75). Setting for the horsepower reducing control and horsepower increasing controls may be altered. Also, never attempt to remove adjusting screw (77) and lock nut (78) from cover (75). Setting for the flow control may be altered. : 5 mm 6. Remove socket bolts (65) and (66) from casing (80). Remove cover (64), O-rings (95), (96), and (97), spring (17), pin (1), sleeve (2), sleeve (5) and compensating piston (6). : 5 mm

W2-2-17


UPPERSTRUCTURE / Pump Device

7 22 23

24 26

21 20

27

19

14

15

16

17 28

80

81 82 84

85

86 88 W117-02-02-005

W2-2-18


UPPERSTRUCTURE / Pump Device 7. Remove retaining ring (14) to remove spring seat (15), spring (16), spring (17), and sleeve (19).

IMPORTANT: Put identification mark on support plug (82) (86) for assembling. 8. Remove lock rings (84) and (88) from casing (80). Remove support plugs (82) and (86) and pin (85) utilizing a M6 bolt.

9. Remove lever (26) from casing (80) with a pair of tweezers. NOTE: Do not remove pin (27). 10. Remove pin (24) using a thin copper bar (less than φ 4). Remove feedback lever (23). NOTE: Take care not to hit pin (24) against lever (22) when pulling it out. 11. Remove lever (22) from casing (80). NOTE: Do not remove pins(81) and (21) when removing lever (22). 12. Remove pilot piston (28), spool (20), and compensating rod (7) from casing (80).

W2-2-19


UPPERSTRUCTURE / Pump Device ASSEMBLE REGULATOR

79

47

A

36

37 38 39

C

33

40

A'

A-B

15 14

97 17

16 18 19 20

24 81 22

8

9

C'

B

73 68

74 69

35 75

76

34 W117-02-02-004

10 11 70

3

72

1 2

71

4

6

5

7

23 21

90

89

12

13

W117-02-02-007

64

80

28

85

A-A’ 25

26 27

30

31

32

65 78

96

77 66

29 W117-02-02-006

C-C

49

60

82 83

84

46 61

45

62

44

63

86 87 51

53

52

54

49 55 56

57 58 59

W117-02-02-008

W2-2-20

88 W117-02-02-023


UPPERSTRUCTURE / Pump Device 12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 -

Pin Sleeve O-Ring O-Ring Sleeve Compensating Piston Compensating Rod Spring Seat Spring Spring Piston Spring Seat O-Ring Retaining Ring Spring Seat Spring Spring Retaining Ring Sleeve Spool Pin Lever Feedback Lever Pin Pin

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

-

Lever Pin Pilot Piston Spring Seat Spring Spring Seat O-Ring Socket Bolt Cover Cover O-Ring Stopper Ball Seat O-Ring O-Ring Plug Plug Plug O-Ring Plug O-Ring Pin Cover Socket Bolt

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74

-

Washer Sleeve Piston Spool Spring Seat Spring Spring Spring Seat O-Ring Cover Socket Bolt Lock Nut Adjusting Screw Cover Socket Bolt Socket Bolt Socket Bolt O-Ring O-Ring Adjusting Screw Adjusting Screw Lock Nut O-Ring Plug

W2-2-21

75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98

-

Cover Lock Nut Adjusting Screw Lock Nut Socket Bolt Casing Pin Support Plug O-Ring Lock Ring Pin Support Plug O-Ring Lock Ring Pin O-Ring Stopper Ball Seat O-Ring O-Ring O-Ring O-Ring Plug


UPPERSTRUCTURE / Pump Device

A

A'

A-B

15 14

97 17

16

19 20

24

C

C'

B

22

W117-02-02-004

3 1 2

4

6

5

7

23 21 W117-02-02-007

64

80

28

85

A-A’ 26 27

65 96

66

W117-02-02-006

C-C

82 83

86 87 W117-02-02-008

W2-2-22

84

88 W117-02-02-023


UPPERSTRUCTURE / Pump Device Assemble Regulator 1. Install compensating rod (7) into casing (80). 2. Attach pin (21) into the designated hole on lever (22). Install lever (22) by inserting pin (21) into the groove on compensating rod (7) and, at the same time, by inserting pin (81), which is already attached on lever (22), into the designated hole on casing (80). 3. Insert sleeve (19) and spool (20) into casing (80). NOTE: Before inserting, be sure that the correct end of spool (20) is facing the casing. Also, confirm that spool (20) moves smoothly in the casing. 4. Install feedback lever (23), aligning its pin hole with that on spool (20). Insert pin (24) into the pin hole. NOTE: Be sure that the correct end of feedback lever (23) is inserted into casing (80). 5. Insert pilot piston (28) into casing (80). NOTE: Confirm that pilot piston (28) moves smoothly in casing (80). 6. Install lever (26) so that the lever attached pin (27) fits in the groove on pilot piston (28). Install support plug (86) so that pin (85) on the support plug fits into the hole on lever (26). Install O-ring (87) and lock ring (88) onto support plug (86). 7. Install adjusting plug (82), O-ring (83), and lock ring (84) onto casing (80). 8. Install spring (17), spring (16), spring seat (15), and retaining ring (14) onto spool (20). 9. Install compensating piston (6), sleeve (5), O-ring (4), O-ring (3), sleeve (2), and pin (1) into casing (80). 10. Install O-rings (95), (96), and (97) onto casing (80). Install cover (64) using socket bolts (65) and (66). : 5 mm : 11.8 Nâ‹…m (1.2 kgfâ‹…m, 8.7 lbfâ‹…ft)

W2-2-23


UPPERSTRUCTURE / Pump Device 79

47

A

36

37 38 39

C

33

40

A'

A-B 8

C'

B

9

35 75

34 W117-02-02-004

10 11

12 W117-02-02-007

A-A’

80

30

31

29 W117-02-02-006

C-C

49

60

61

51

53

52

54

55 56

57 58 59

W117-02-02-008

W2-2-24

W117-02-02-023


UPPERSTRUCTURE / Pump Device 11. Install spring seat (29), spring (30), and spring seat (31) into casing (80). 12. Install spring seat (8), spring (9), and spring (10) into casing (80). 13. Install spring seat (12) and seat (11) into cover (75). Install cover (75) onto casing (80). : 5 mm : 11.8 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft) 14. Install washer (51), sleeve (52), piston (53), spool (54), spring seat (55), spring (56), spring (57), spring seat (58), and O-ring (59) into cover (49). Install cover (60) onto cover (49) using socket bolts (61). 15. Install O-ring (36), O-ring (47) and pin (48) onto cover (49). Install seat (39), ball (38), and stopper (37) into cover (35). Install O-ring (40) onto cover (35). 16. Assemble covers (49), (35), and (34). Install them onto casing (80) using socket bolts (33). : 5 mm : 11.8 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)

W2-2-25


UPPERSTRUCTURE / Pump Device (Blank)

W2-2-26


UPPERSTRUCTURE / Pump Device DISASSEMBLE AND ASSEMBLE 4-UNIT PUMP A

B

C

D

T117-02-01-017

A - Fan Drive Pump (Plunger Pump)

C - Compressor Drive Pump (Tumdem Gear Pump: Tip End) D - Transmission Lubricating Pump (Gear Pump)

B - Pilot Pump (Tumdem Gear Pump: Transmission Side)

NOTE: The 4-unit pump consists of plunger pump (A), tumdem gear pumps (B) and (C), and gear pump (D).

W2-2-27


UPPERSTRUCTURE / Pump Device DISASSEMBLE FAN DRIVE PUMP

21 20 25

19

10

6

7

11

12

13

14

15

16

17

24

22

23

18

26

8

27

9 50 49

5 28

4 3 1

46

47

48

45, 44, 43

2 29

38

32

34

35

36

39

40

41

51

42 53

52 54, 55, 56 57

37

58

60 59 61

31

62

30

33

W117-02-02-013

12345678910 11 12 13 14 15 16 -

Socket Bolt Cover O-Ring Oil Seal Shaft Spacer Bearing Spacer Retaining Ring Cover Nut Adjusting Screw Spring Spring Pin Stopper Back-Up Ring

17 - O-Ring 18 - Housing 19 - Displacement Angle Shift Pin 20 - Regulator 21 - Socket Bolt 22 - Stopper 23 - Back-Up Ring 24 - O-Ring 25 - Servo Piston 26 - O-Ring 27 - Plug 28 - Plug 29 - Socket Bolt 30 - Swash Plate 31 - Bushing

32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

- Shoe Plate - Shoe - Plunger - Retainer - Spherical Bushing - Spacer - Spring - Cylinder Block - Valve Plate - Needle Bearing - O-Ring - Stopper - Steel Ball - Seat - Valve Cover - Adjusting Screw

W2-2-28

48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

- Nut - Plate - Socket Bolt - O-Ring - Coupling - Retaining Ring - Stopper - Steel Ball - Seat - Casing - Socket Bolt - Plug - O-Ring - Spring Pin - Pin


UPPERSTRUCTURE / Pump Device IMPORTANT: Never attempt to remove adjusting screw (12), nut (11), adjusting screw (47) and nut (48). The set flow rate may be altered. 1. Remove plug (59) and O-ring (60) to drain hydraulic oil from the pump. : 36 mm 2. Remove socket bolts (21) to remove regulator (20). : 6 mm 3. Turn the pump over so that the regulator mounting side is on the bottom. Remove socket bolts (50) (4 used) to remove plate (49), O-ring (51) and coupling (52). NOTE: Do not remove retaining ring (53) unless it is required. : 10 mm 4. Remove socket bolts (29) to remove valve cover (46) from casing (18). NOTE: Valve plate (40) may drop when removing valve cover (46). Take care not to drop valve plate (40). 5. Remove O-ring (42), stopper (43), steel ball (44), seat (45a), valve plate (40), pin (62), spring pin (61), socket bolts (58), cover (57), stopper (54), steel ball (55), and seat (56) from valve cover (46). NOTE: Do not remove needle bearing (41) unless required. 6. Remove cylinder block (39), spring (38) (9 used), spacer (37), spherical bushing (36), retainer (35), plungers (34) (9 used), and shoes (33) from housing (18). 7. Remove socket bolts (1) to remove cover (2) and O-ring (3). : 6 mm 8. Tap on cover (10) using a plastic hammer to remove it. Remove O-ring (14) and spring (13) at the same time.

W2-2-29


UPPERSTRUCTURE / Pump Device 21 20 25

19

10

6

7

11

12

13

14

15

16

17

24

22

23

18

26

8

27

9 50 49

5 28

4 3 1

46

47

48

45, 44, 43

2 29

38

32

34

35

36

39

40

41

51

42 53

52 54, 55, 56 57

37

58

60 59 61

31

62

30

33

W117-02-02-013

12345678910 11 12 13 14 15 16 -

Socket Bolt Cover O-Ring Oil Seal Shaft Spacer Bearing Spacer Retaining Ring Cover Nut Adjusting Screw Spring Spring Pin Stopper Back-Up Ring

17 - O-Ring 18 - Housing 19 - Displacement Angle Shift Pin 20 - Regulator 21 - Socket Bolt 22 - Stopper 23 - Back-Up Ring 24 - O-Ring 25 - Servo Piston 26 - O-Ring 27 - Plug 28 - Plug 29 - Socket Bolt 30 - Swash Plate 31 - Bushing

32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

- Shoe Plate - Shoe - Plunger - Retainer - Spherical Bushing - Spacer - Spring - Cylinder Block - Valve Plate - Needle Bearing - O-Ring - Stopper - Steel Ball - Seat - Valve Cover - Adjusting Screw

W2-2-30

48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

- Nut - Plate - Socket Bolt - O-Ring - Coupling - Retaining Ring - Stopper - Steel Ball - Seat - Casing - Socket Bolt - Plug - O-Ring - Spring Pin - Pin


UPPERSTRUCTURE / Pump Device 9. Remove swash plate (30) and shoe plate (32) from housing (18). 10. Remove stopper (15), stopper (22), servo piston (25) and displacement angle shift pin (19) from housing (18). NOTE: As LOCTITE has been applied on the contacting part between servo piston (25) and displacement angle shift pin (19), do not separate them unless required. 11. Tap on the end of shaft (5) using a plastic hammer to remove it from cover (10). Remove oil seal (4) at the same time. 12. Remove retaining ring (9), spacer (8), bearing (7), and spacer (6) from shaft (5).

W2-2-31


UPPERSTRUCTURE / Pump Device ASSEMBLE FAN DRIVE PUMP 12

11 10

17 16

15 32

25 30 18 31 22

24 23

42 40

48

47

53

49

13 14 50 1 51

6

5 52 4 2 3 29 7

8

9

35 33 34 36 37

38

39

61

62

41

46

W117-02-02-014

12345678910 11 12 13 14 15 16 -

Socket Bolt Cover O-Ring Oil Seal Shaft Spacer Bearing Spacer Retaining Ring Cover Nut Adjusting Screw Spring Spring Pin Stopper Back-Up Ring

17 - O-Ring 18 - Housing 19 - Displacement Angle Shift Pin 20 - Regulator 21 - Socket Bolt 22 - Stopper 23 - Back-Up Ring 24 - O-Ring 25 - Servo Piston 26 - O-Ring 27 - Plug 28 - Plug 29 - Socket Bolt 30 - Swash Plate 31 - Bushing

32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

- Shoe Plate - Shoe - Plunger - Retainer - Spherical Bushing - Spacer - Spring - Cylinder Block - Valve Plate - Needle Bearing - O-Ring - Stopper - Steel Ball - Seat - Valve Cover - Adjusting Screw

W2-2-32

48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

- Nut - Plate - Socket Bolt - O-Ring - Coupling - Retaining Ring - Stopper - Steel Ball - Seat - Casing - Socket Bolt - Plug - O-Ring - Spring Pin - Pin


UPPERSTRUCTURE / Pump Device Assemble Fan Drive Pump 1. Install displacement angle shift pin (19), servo piston (25), stopper (22) and stopper (15) into housing (18). 2. If displacement angle shift pin (19) has been separated from servo piston (25), apply LOCTITE to the threaded part of servo piston (25).

3. Place housing (18) on a workbench with the regulator mounting side on the bottom. Attach the shoe plate (30) attached swash plate (30) to displacement angle shift pin (19). NOTE: Check if swash plate (30) moves smoothly after installing. 4. Install spacer (6), bearing (7), spacer (8), and retaining ring (9) onto shaft (5). Install shaft (5) into cover (11).

5. Install O-ring (3) onto cover (2). Install oil seal (4) and cover (2) onto cover (10) using socket bolts (1). : 6 mm : 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 6. Install spring (38), spacer (37), spherical bushing (36), retainer (35), plungers (34) and shoes (33) into cylinder block (39). Install cylinder block (39) onto shaft (5), aligning splines. 7. Install pin (62), valve plate (40), O-ring (42), pin (61), stopper (43), steel ball (44), seat (45), stopper (54), steel ball (55), and seat (56) onto valve cover (46). Install cover (57) onto valve cover (46) using socket bolts (58). 8. Install valve cover (46) onto housing (18) using socket bolts (29). : 17 mm : 430 N⋅m (44 kgf⋅m, 318 lbf⋅ft) 9. Install coupling (52) onto shaft (5). Install O-ring (51) and plate (49) onto valve cover (46). : 19 mm : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) 10. Install regulator (20) using socket bolts (21).

W2-2-33


UPPERSTRUCTURE / Pump Device MAINTENANCE STANDARDS

NOTE: 1 mm= 0.03937 in

1. Clearance between plunger (34) diameter (d) and cylinder block (39) bore (D). D−d

d

Unit : mm Standard

Allowable Limit

0.047

0.094

D

W117-02-02-009

2. Spring (38) free length (L) Unit : mm Standard

Allowable Limit

49.5

48.0

L

3. Clearance between plunger (34) and shoe (33):(e), and shoe thickness (t) e

W117-02-02-010

Unit : mm Standard

Allowable Limit

0∼0.1

0.35

t

Unit : mm Standard

Allowable Limit

6.5

6.3

e t

W117-02-02-011

4. Distance between retainer (35) bottom and spherical bushing (36) top. H−h

Unit : mm Standard

Allowable Limit

16.5

15.5

Stand

h

H

W117-02-02-012

W2-2-34


UPPERSTRUCTURE / Pump Device (Blank)

W2-2-35


UPPERSTRUCTURE / Pump Device DISASSEMBLE REGULATOR

13 10

12

9 8 7 6 4 1

5

22

23

3

2

20

24

25

21

32 31

26 30

29 19

14

15

16

17

27

18 28

46 45 42 38

37 34

43

47

44

48

41 40

33 49

68

50

35

51

36

67

52

65

53

54

59

64 63 66

62

55 61

60

56

57

58 W117-02-02-015

W2-2-36


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

Pin Sleeve O-Ring O-Ring Sleeve Compensating Piston Compensating Rod Spring Seat Spring Spring Spring Seat O-Ring Retaining Ring Spring Seat Spring Spring Retaining Ring

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

-

Sleeve Spool Pin Lever Feedback Lever Pin Pin Lever Pin Pilot Piston Spring Seat Spring Spring Seat O-Ring Socket Bolt Cover O-Ring

36 37 38 40 41 42 43 44 45 46 47 48 49 50 51 52

-

O-Ring Socket Bolt Socket Bolt O-Ring Adjusting Screw Adjusting Screw Lock Nut O-Ring Cover Lock Nut Adjusting Screw Lock Nut Socket Bolt Casing Pin Support Plug

W2-2-37

53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

- O-Ring - Lock Ring - Pin - Support Plug - O-Ring - Lock Ring - Pin - O-Ring - O-Ring - O-Ring - O-Ring - O-Ring - Plug - Socket Bolt - Socket Bolt - Cover


UPPERSTRUCTURE / Pump Device

13 10

12

9 8 7 6 4 1

5

22

23

3

2

20

24

25

21

32 31

26 30

29 19

14

15

16

17

27

18 28

46 45 42 38

37 34

43

47

44

48

41 40

33 49

68

50

35

51

36

67

52

65

53

54

59

64 63 66

62

55 61

60

56

57

58 W117-02-02-015

W2-2-38


UPPERSTRUCTURE / Pump Device Disassemble Regulator 1. Remove socket bolts (37) and (38) to remove the regulator.

7. Remove lever (26) from casing (50) with a pair of tweezers.

: 6 mm

NOTE: Do not remove pin (27).

2. Remove socket bolts (33) to remove cover (34) and O-rings (36) and (35).

8. Remove pin (24) using a thin copper bar (less than φ 4). Remove feedback lever (23).

: 5 mm 3. Remove socket bolts (49), cover (45), spring seat (12), spring (10), spring (9), spring seat (8), spring seat (31), spring (30), and spring seat (29) from casing (50). IMPORTANT: Never attempt to remove adjusting screw (41), lock nut (46), adjusting screw (42) and lock nut (43) from cover (45). Also, never attempt to remove adjusting screw (47) and lock nut (48) from cover (45). Setting for the flow control may be altered.

NOTE: Take care not to hit pin (24) against lever (22) when pulling it out. 9. Remove lever (22) from casing (50). NOTE: Do not remove pins (51) and (21) when removing lever (22). 10. Remove pilot piston (28), spool (20), and compensating rod (7) from casing (50).

: 5 mm 4. Remove socket bolts (66) and (67), cover (68), O-rings (62), (63), and (64), spring (17), pin (1), sleeve (2), sleeve (5), and compensating piston (6) from casing (50). : 5 mm 5. Remove retaining ring (14), spring seat (15), spring (16), spring (17) and sleeve (19).

IMPORTANT: Put identification mark on plug (52) (56) for assembling. 6. Remove lock rings (54) and (58) from casing (50). Utilizing a M6 bolt, remove support plug (52), support plug (56), and pin (55).

W2-2-39


UPPERSTRUCTURE / Pump Device ASSEMBLE REGULATOR

34 33

A

49

A'

A-B 64 16 18 19 20 17

24 51 22

8

9

44 40

45

B

46

W117-02-02-016

10

15 14

41

3

43

1 2

42

4

6

5

7

23 21

60

59

12

13

W117-02-02-017

68

50

28

55

A-A’ 25

26 27

30

31

32

67 48

63

47 66

29 W117-02-02-006

52 33

56 57

54

58 W117-02-02-023

W2-2-40


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