Link-Belt Crane 298HSL Crane Workshop Manual with Mitsubishi 6M70 6M70-TL Workshop Manual by engineparts2

MODEL LINK-BELT 298 HSL BOOK No. 1113 SERIAL No.

Mitsubishi 6M70 Workshop Manual begins on page 1057 Mitsubishi 6M70 Engine Parts Contact: Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 2696731638

CRANE SERIAL NUMBER The crane serial number is on the crane rating manual which is located inside the operator's cab. The serial number should always be furnished when ordering parts for the crane or when corresponding with the distributor or factory concerning the crane. Providing the serial number is the only way of ensuring the correct parts and/or information can be furnished. In the event the serial number plate is not readable, a number is stamped on the upper revolving frame which can be used to identify the crane. This number is located on the front face of the upper frame, between the boom foot mounting lugs.

Link-Belt Construction Equipment Company

F00056

Engine part numbers reference Link-Belt Crane Mitsubishi 6M70 engine 4648534 Hose, intercooler, air to air, 4411793 Hose, intercooler, air to air, 4648374 Hose, water, upper radiator hose 3107011 Hose, water, lower radiator hose ME352818 Hose, water cooling line to thermostat bypass 4641344-907 Water Pump 4665181 Belt Set ( three belts ) 4640773 Fan, engine cooling fan, ME355788 Injector tube with seal ME356331 Coolant pipe to air compressor ME356327 Coolant pipe to air compressor ME354629 Oil filter head assembly, oil filter base ME356765 > 4641344-907 Water Pump ME443076 Fan Drive Assembly, engine cooling ME443528 Belt tensioner assembly, water pump drive ME443421 Thermostat Case ME180616 Thermostat cover ME994310 Thermostat set, two thermostats with gasket ME053975 Boot, hose connector turbocharger to air intake pipe Email: EngineParts@HeavyEquipmentRestorationParts.com www.HeavyEquipmentRestorationParts.com

General Information and Manual Layout This manual is divided into 3 Sections separated Tabs. The front Section is the Workshop Instruction portion of the manual. It contains the removal/installation (R&I) and the assembly/disassembly (Recondition) instructions for major crane components. These pages are coded with a “W” in front of the Section/Group/Page numbers. Example, the pages coded/numbered W2-4-1 through W24-94, contain the instructions for R&I and Recondition of the main pump. (Code W2-4-1 identifies a page in the Workshop Instruction Manual, Section 2, Group 4, and Page 1.) There are “Contents” pages at the beginning of each sub-section, in front of pages W1-1-1, W2-1-1, and W3-1-1. The 2nd and 3rd Sections are the Principles of Operation/Specifications and Troubleshooting portions of the manual. These pages are coded with a “T” in front of the Section/Group/Page numbers. Example, the pages coded/numbered T1-3-1 through T1-3-10, contain the specifications for the engine and engine accessories.The Section behind Tab 1 contains the specifications and how main components operate to perform their intended functions. (Code T1-3-1 identifies a page in the Principles of Operation/Specifications/Troubleshooting Manual, Section 1, Group 3, and Page 1.) There are “Contents” pages at the beginning of each sub-section, in front of pages T1-2-1, T2-1-1, and T3-1-1. The Section behind Tab 2 contains Performance Tests/Standards and Troubleshooting for major components. There are “Contents” pages at the beginning of each sub-section, in front of pages T4-1-1 and T5-1-1.

BOOK1113 P3091410

Page 1 of 4

Terms/Terminology, Nomenclature, and Abbreviations The following terms/terminology, nomenclature, and abbreviations are given to help identify common terms/terminology, nomenclature, and abbreviations used in this manual that, due to language translations, may not be easily understood. Auxiliary Hoisting Mechanism Boom Pendant Rope Center Joint Crawler Shoe Derricking Derricking Drum Derricking Mechanism Derricking Motor Drive Tumbler Hoisting Drum Hoisting Drum Control Valve Hoisting Mechanism Hoisting Motor Pump Mechanism Screwed-In Connection Slewing Slewing Frame Slewing Mechanism Slewing Motor Slewing Pump Slewing Ring Stopper Take-Up Tumbler Travel Mechanism Upperstructure

= = = = = = = = = = = = = = = = = = = = = = = = =

Auxiliary Winch Assembly / Winch Drum Boom Pendants Rotating Joint Track Shoe Boom Hoist Boom Hoist Drum Boom Hoist System Boom Hoist Motor Travel Drive Sprocket Winch Drum Winch Drum Control Valve Winch Assembly / Winch Drum Winch Motor Pump Assembly Threaded Connection Swing Upper Revolving Frame Swing Reduction Unit Swing Motor Swing Pump Turntable Bearing Plug Track Take-Up Idler Travel Motor and Reduction Gears Crane Upper

Page 2 of 4

Conversion Tables Length Conversion Table millimeter, mm 1 10 1000 25.40 304.8

centimeter, cm 0.1 1 100 2.540 30.48

mile, mi 1 0.6214

kilometer, km 1.6093 1

meter, m 0.001 0.01 1 0.0254 0.3048

inch, in., " 0.03937 0.3937 39.37 1 12

foot, ft., ' 0.00328 0.03281 3.281 0.08333 1

square meter, m2

square inch, in2

square foot, ft2

0.000001 0.0001 1 0.000645 0.09290

0.00155 0.155 1550 1 144

0.001076 10.764 0.006944 1

Area Conversion Table square millimeter, mm2 1 100 1 000 000 645.2 92903.0

square centimeter, cm2 0.01 1 1 0000 6.452 929.03

Volume Conversion Table cubic centimeter, cm3, cc 1 1 000 000 16.39 28320

cubic meter, m3

cubic inch, in3

cubic foot, ft3

0.000001 1 0.0000164 0.02832

0.0610 61024 1 1728

0.0000353 35.31 0.000579 1

gallon, gal. 1 0.004329 0.2642

cubic inch, in3 231 1 61.02

liter, lit., l 3.785 0.01639 1

Page 3 of 4

Conversion Tables – (continued) Weight Conversion Table gram, g 1 1000 28.349 453.592 1 000 000 907185

kilogram, kg 0.001 1 0.02835 0.4536 1 000 907.2

ounce, oz 0.03527 35.27 1 16 35274 32 000

pound, lb. 0.0022 2.205 0.0625 1 2205 2000

metric ton, t

short ton, s.t.

0.001 0.00002835 0.0004536 1 0.9072

0.001102 0.00003125 0.0005 1.102 1

Pressure Conversion Table kg/cm3 1.0197 1 0.07031

bar 1 0.9807 0.06895

lb./in2, PSI 14.50 14.22 1

Work, Energy Conversion Table kg.cm 1 100 13.83 1.1525

kg.m 0.01 1 0.1383 0.01153

foot-pound, ft.-lb. 0.0723 7.233 1 0.08333

inch-pound,.in-lb. 0.8681 86.81 12 1

Centigrade-Fahrenheit Conversion Table °F -450 -400 -350 -300 -250

°C -267.78 -240.00 -212.22 -184.44 -156.67

°F -200 -150 -100 -50 0

°C -128.89 -101.11 -73.33 -45.56 -17.78

°F 5 10 15 20 25

°C -15.00 -12.22 -9.44 -6.67 -3.89

°F 30 35 40 45 50

°C -1.11 1.67 4.44 7.22 10.00

°F 55 60 65 70 75

°C 12.78 15.56 18.33 21.11 23.89

°F 80 85 90 95 100

°C 26.67 29.44 32.22 35.00 37.78

°F 150 200 250 300 350

°C 65.56 93.33 121.11 148.89 176.67

°F 400 450 500 550 600

°C 204.44 232.22 260.00 287.78 315.56

Page 4 of 4

INTRODUCTION TO THE READER x This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.

• If you have any questions or comments, or if you find any errors regarding the contents of this manual, please contact a Link-Belt Distributor.

• Be sure to thoroughly read this manual for correct product information and service procedures.

ADDITIONAL REFERENCES x Please refer to the materials listed below in addition to this manual.

• Operation Manual of the Engine • Parts Catalog of the Engine

• The Operator’s Manual • The Parts Catalog

PAGE NUMBER x Each page has a number, located on the center lower part of the page, and each number contains the following information: Example : T 1-3-5

Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual

W: Workshop Manual

IN-01

INTRODUCTION SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.

x IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

NOTE: Indicates supplementary technical information or know-how.

UNITS USED Example : 24.5 MPa (250 kgf/cm2, 3560 psi)

x SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units.

Quantity Length Volume

Weight Force Torque

To Convert From mm mm L L m3 kg N N N m N m

Into in ft US gal US qt yd3 lb kgf lbf kgf m lbf ft

A table for conversion from SI units to other system units is shown below for reference purposees.

Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375

Quantity Pressure Power Temperature Velocity Flow rate

IN-02

To Convert From MPa MPa kW kW qC km/h min-1 L/min mL/rev

Into

Multiply By 2

kgf/cm psi PS HP qF mph rpm US gpm cc/rev

10.197 145.0 1.360 1.341 qCu1.8+32 0.6214 1.0 0.2642 1.0

SAFETY RECOGNIZE SAFETY INFORMATION x This is the SAFETY ALERT SYMBOL. • When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

• Follow recommended precautions and safe operating practices.

001-E01A-0001-2

SA-001

UNDERSTAND SIGNAL WORDS x On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.

• DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

• WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

• CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

• DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.

x CAUTION also calls attention to safety messages in this manual.

x To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.

x NOTE indicates an additional explanation for an element of information. 002-E01A-0461-6

S-1

SA-1223

SAFETY FOLLOW SAFETY INSTRUCTIONS x Carefully read and follow all safety signs on the machine and all safety messages in this manual.

x Safety signs should be installed, maintained and replaced when necessary.

• If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).

SA-003

x Learn how to operate the machine and its controls correctly and safely.

x Allow only trained, qualified, authorized personnel to operate the machine.

x Keep your machine in proper working condition. • Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.

x The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine. 003-E01B-0003-5

PREPARE FOR EMERGENCIES x Be prepared if a fire starts or if an accident occurs. • Keep a first aid kit and fire extinguisher on hand. • Thoroughly read and understand the label attached on the fire extinguisher to use it properly.

• Establish emergency procedure guidelines to cope with fires and accidents.

• Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.

SA-437

004-E01A-0437-3

S-2

SAFETY WEAR PROTECTIVE CLOTHING x Wear close fitting clothing and safety equipment appropriate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

SA-438

• Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.

x Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine. 005-E01A-0438-4

PROTECT AGAINST NOISE x Prolonged exposure to loud noise can cause impairment or loss of hearing.

• Wear a suitable hearing protective mechanism such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

SA-434 006-E01A-0434-2

INSPECT MACHINE x Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.

• In the walk-around inspection, be sure to cover all points described in the “PRE-START INSPECTION” chapter.

SA-435

007-E01A-0435-2

S-3

SAFETY USE HANDHOLDS AND STEPS x Falling is one of the major causes of personal injury. • When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.

• Do not use any controls as handholds. • Never jump on or off the machine. Never mount or dismount a moving machine.

• Be careful of slippery conditions on platforms, steps,

SA-439

and handrails when leaving the machine.

008-E01A-0439-3

ADJUST THE OPERATOR’S SEAT x A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations.

• The seat should be adjusted whenever changing the operator for the machine.

• The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back.

• If not, move the seat forward or backward, and check again.

009-E01A-0464-3

S-4

SA-464

SAFETY FASTEN YOUR SEAT BELT (IF EQUIPPED) x If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.

• Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine.

• Be sure to remain seated with the seat belt securely

SA-237

fastened at all times when the machine is in operation to minimize the chance of injury from an accident.

• We recommend that the seat belt be replaced every three years regardless of its apparent condition.

010-E02B-0237-3

OPERATE ONLY FROM OPERATOR’S SEAT x Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.

• Start the engine only from the operator’s seat. • NEVER start the engine while standing on the crawler shoe or on ground.

• Do not start engine by shorting across starter terminals.

• Before starting the engine, confirm that all control levers are in neutral.

012-E01B-0444-3

S-5

SA-444

SAFETY JUMP STARTING x Battery gas can explode, resulting in serious injury.

• If the engine must be jump-started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter.

• The operator must be in the operator’s seat so that the machine will be under control when the engine starts. Jump-starting is a two-person operation.

• Never use a frozen battery. SA-032

• Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.

013-E01A-0032-3

S-6

SAFETY PROTECT AGAINST FLYING DEBRIS x If flying debris hit eyes or any other part of the body, serious injury may result.

• Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

• Keep bystanders away from the working area before striking any object.

SA-432

031-E01A-0432-2

S-7

SAFETY PARK MACHINE SAFELY

•Engage all brake and drum locks. Shutdown the engine.

To avoid accidents:

•Remove the key from the key switch. Lock the cab and all access doors.

• Park machine on a firm, level ground. • Lower the boom to the ground. • In a work site where the boom cannot be lowered to

033-E04A-0470-3

the ground, secure the boom using guy ropes so as to minimize the wind effect on the boom,

• Run the engine at slow idle for five (5) minutes to cool the engine down.

HANDLE FLUIDS SAFELY᧩AVOID FIRES x Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.

• Do not refuel the machine while smoking or when near open flame or sparks.

• Always shutdown the engine before refueling the machine.

• Fill the fuel tank outdoors. x All fuels, most lubricants, and some coolants are flam-

SA-018

mable.

• Store flammable fluids well away from fire hazards. • Do not incinerate or puncture pressurized containers. • Do not store oily rags; they can ignite and burn spontaneously.

SA-019

034-E01A-0496-4

S-8

SAFETY SAFE TRANSPORTATION x The danger of tipping is present when loading/unloading machine onto/from a truck or trailer bed.

• Be sure to observe local regulations when transporting the machine on public roads.

• Be sure to have a signal person when loading/unloading the machine.

• Provide an appropriate trailer for transporting the machine. Take the following precautions when loading/unloading the machine: 1) Select firm, level ground. 2)

Be sure to use a loading dock or ramp.

When using a loading ramp, use one which has antislip bands on the surface.

Drive the machine at very slow speed.

Avoid steering while driving up or down the ramp as it is extremely dangerous. If steering is unavoidable, first move back to the ground or flatbed, modify traveling direction, and begin to drive again.

Do not operate any levers besides the travel levers when driving up or down the ramp.

The top of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it.

Securely fasten chains or cables to the machine frame.

Less than 15q

SA-475A

035-E03A-0475-᧲

TOWING MACHINE x When towing the machine, be sure to attach tow wire ropes around the lower frames as illustrated. To prevent the wire ropes from being damaged, place protective material between the lower frames and the wire ropes. Pulling Rope

SA-605 061-E01A-0605-2

S-9

SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents:

• Understand service procedures before starting work. Keep the work area clean and dry. Do not spray water or steam inside cab.

• Never lubricate or service the machine while it is moving.

• Keep hands, feet and clothing away from power-driven parts.

• Before servicing the machine: 1)

Park machine on a solid, level surface.

Lower the boom to the ground. If the boom cannot be fully lowered, secure the boom with guy ropes to prevent the boom from being blown by wind.

Run the engine at slow idle speed without load for 5 minutes.

Apply all brakes and locks.

Turn the key switch to OFF to shutdown engine.

Remove the key from the switch.

Move the pilot shut-off lever to the LOCK position.

Attach a “Do Not Operate” tag on the cab door.

SA-028

• If a maintenance procedure must be performed with the engine running, do not leave machine unattended.

• Securely support any machine elements that must be raised for service work. If the machine must be raised, place supporting blocks under the frame.

• Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of this manual.

• Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil or debris.

• Disconnect battery ground cable (–) before making adjustments to electrical systems or before performing welding on the machine.

500-E07A-0497-8

S-10

SA-527

SAFETY WARN OTHERS OF SERVICE WORK x Unexpected machine movement can cause serious injury.

• Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever. This tag is available from your authorized dealer.

501-E01A-0287-2

SA-287

SUPPORT MACHINE PROPERLY x Never attempt to work on the machine without securing the machine first.

• Always lower the attachment to the ground before you work on the machine.

• If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

SA-527

519-E01A-0527-3

STAY CLEAR OF MOVING PARTS x Entanglement in moving parts can cause serious injury. • To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

SA-026

502-E01A-0026-2

S-11

SAFETY PREVENT BURNS Hot spraying fluids:

x After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns.

• To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be release before removing the cap.

SA-039

• The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap. Hot fluids and surfaces:

x Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well.

SA-225

• Wait for the oil and components to cool before starting any maintenance or inspection work.

505-E01B-0498-5

REPLACE RUBBER HOSES PERIODICALLY x Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.

• Periodically replace the rubber hoses. x Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death. 506-E01A-0019-3

S-12

SA-019

SAFETY AVOID HIGH-PRESSURE FLUIDS x Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.

• Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

• Relieve the pressure by moving the control levers several times. Tighten all connections before applying pressure.

• Search for leaks with a piece of cardboard; take care

SA-031

to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.

• If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

SA-292

SA-044

507-E01A-0499-5

NEVER ATTEMPT TO MODIFY SAFETY MECHANISM, HYDRAULIC COMPONENTS, OR ELECTRICAL WIRING x Incorrect modification or adjustment may cause accident.

• Do not modify or adjust the preadjusted parts of hydraulic components or safety mechanism. If readjustment or modification is required, consult your authorized dealer. SA-019

x Alternation on electrical wiring may cause fire. • If modification or alternation of electrical wiring is required, consult your authorized dealer.

520-E01A-0019-3

S-13

SAFETY PREVENT FIRES Check for Oil Leaks:

Check Heat Shields:

x Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.

• Tighten, repair or replace any missing, loose or dam-

x Damaged or missing heat shields may load to fires.

• Damaged or missing heat shields must be repaired or replaced before operating the machine. 508-E02B-0019-9

aged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.

• Do not bend or strike high-pressure lines. • Never install bent or damaged lines, pipes or hoses. Check for Shorts:

x Short circuits can cause fires. • Clean and tighten all electrical connections. • Check before each shift or after eight (8) to ten (10) hours operation for loose, kinked, hardened or frayed electrical cables and wires.

• Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps.

• DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc. Clean up Flammables:

x Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.

• Prevent fires by inspecting and cleaning the machine daily, and by removing spilled or accumulated flammables immediately. Check Key Switch:

x If a fire breaks out, failure to shutdown the engine will escalate the fire, hampering fire fighting.

• Always check key switch function before operating the machine every day: 1. Start the engine and run it at slow idle. 2. Turn the key switch to the OFF position to confirm that the engine stops.

• If any abnormalities are found, be sure to repair them before operating the machine. 508-E02B-0019-9

S-14

SA-019

SAFETY EVACUATING IN CASE OF FIRE x If a fire breaks out, evacuate the machine in the following way:

• Shutdown the engine with turning the key switch to the OFF position if there is time.

• Use a fire extinguisher if there is time. • Exit the machine. SA-393 518-E02A-0393-2

BEWARE OF EXHAUST FUMES x Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

• If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

• Be aware of California Proposition 65 Warning which reads “Diesel engine exhaust and some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer, birth defects, and other reproductive harm”. 509-E01A-0016-2

S-15

SA-016

SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES x Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to you and bystanders.

• Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

• Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.

SA-030

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids.

• Clean them thoroughly with nonflammable solvent before welding or flame cutting them.

510-E01B-0030-4

REMOVE PAINT BEFORE WELDING OR HEATING x Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.

• Avoid potentially toxic fumes and dust. • Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly.

SA-029

• Remove paint before welding or heating: 1)

If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.

If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

511-E01A-0029-4

S-16

SAFETY PREVENT BATTERY EXPLOSIONS x Battery gas can explode, resulting in serious injury. • Keep sparks, lighted matches, and flame away from the top of battery.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

• Do not charge a frozen battery; it may explode. Warm the battery to 16 qC (60 qF) first.

• Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result

• Loose terminals may produce sparks. Securely tighten all terminals.

x Battery electrolyte is poisonous. If the battery should explode battery electrolyte may be splashed into eyes, possibly resulting in blindness. If splashed in eyes, flush with water for 15 minutes. Get medical attention immediately.

• Be sure to wear eye protection when checking electrolyte specific gravity.

512-E01B-0032-4

S-17

SA-032

SAFETY HANDLE CHEMICAL PRODUCTS SAFELY x Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

• Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.

• See your authorized dealer for MSDS’s on chemical products used with your machine.

515-E01A-0309-4

DISPOSE OF WASTE PROPERLY x Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.

• Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

• Do not pour waste onto the ground, down a drain, or into any water source.

• Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

516-E01A-0226-4

S-18

SA-309

SECTION 1

GENERAL

CONTENTS Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling ............................................ W1-1-1

Group 2 Tightening Torque Tightening Torque Specifications ............. W1-2-1 Standard Torque Specifications ............... W1-2-2 Piping Joint.............................................. W1-2-5

2CNW-1-1

(Blank)

2CNW-1-2

GENERAL INFORMATION / Precautions for Disassembling and Assembling PRECAUTIONS FOR AND ASSEMBLING

DISASSEMBLING

• 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.

Precautions for Disassembling and Assembling

x Clean the Machine 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.

x Precautions for Assembling

x Inspect the Machine Be sure to thoroughly read and understand all disassembling/assembling procedures before starting any repair work. Understanding these procedures will help avoid incorrect disassembling of components as well as the purchasing of unnecessary service parts. • 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.

x Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work.

x 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.

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. • Before assembling, coat all inner parts with clean hydraulic oil or gear oil. Especially coat the sliding surfaces with clean hydraulic oil or gear oil. • Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing. • Be sure that liquid-gasket-applied surfaces are clean and dry. • If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent. • Utilize matching marks when assembling. • Be sure to use the designated tools to assemble bearings, bushings and oil seals. • Keep a record of the number of tools used for disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no tools are missing.

GENERAL INFORMATION / Precautions for Disassembling and Assembling Bleeding Air from Hydraulic System

When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and installation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures: IMPORTANT: If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result. If the hydraulic motor is operated with air trapped in the hydraulic motor housing, damage to the motor may result. If the cylinder is operated with air trapped in the cylinder tube, damage to the cylinder may result. Be sure to bleed air before starting the engine. x Bleeding Air from Hydraulic Pump • Remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil. • After the pump housing is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run at slow idle speed. • Slightly loosen the plug to bleed air from the pump housing until hydraulic oil oozes out. • After bleeding all the air, securely tighten the plug. x 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. x 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.

W328-01-01-001

W1-1-2

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.

(2) Check the seal ring face (A) for scuffing, scoring, corrosion, deformation or uneven wear. (3) Check O-ring (B) for deformation or hardening.

tears,

W105-03-05-019

breaks,

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. (2) Clean the floating seal and seal mounting bores, as dust on them tends to enter the floating seal when installing it. (3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring.

Correct

Incorrect

(4) After installing the floating seal, check that seal surface (C) is parallel with the seal mounting bore end face (D) and O-ring (B) as illustrated.

W105-03-05-020

C Incorrect

Correct a

a=b

aำ b

W110-03-05-004

W1-1-3

GENERAL INFORMATION / Precautions for Disassembling and Assembling Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings safely. • Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from damage and the lifted load from slipping. • Lower the temperature of the lifted load to lower than 100 qC (212 qF). If unavoidably lifting a load with a temperature of 100 qC (212 qF) or more, reduce the load weight. • Do not lift acid or alkali chemicals. • Take care not to allow the sling to become wet. The load may slip. • When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced. • When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force. • Avoid using twisted, bound, connected, or hitched slings. • Do not place any object on twisted or bent slings. (Refer to the right illustration.) • When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions. • Avoid dragging slings on the ground, throwing slings or pushing slings with a metal piece. • When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged. • Store the nylon slings indoors so they won’t deteriorate with heat, sun light, or chemicals.

Correct Eyehole Lifting Method

W102-04-02-016

Incorrect Eyehole Lifting Method

W105-04-01-008

Bent Sling

W1-1-4

W162-01-01-009

GENERAL INFORMATION / Precautions for Disassembling and Assembling CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using.

Damaged Appearance

Broken Sewing Thread

2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If any damage is found, cut and discard the sling. Even if no damage is found, do not use slings older than 7-years.

W162-01-01-002

Scuffing

W162-01-01-003

Fuzz

Broken Sewing Thread

W162-01-01-004

Broken Sewing Thread

W162-01-01-005

Broken Sewing Thread

Scoring

Separation of Belt

W162-01-01-006

Fuzz

Scuffing

W162-01-01-007

Broken Warp

W162-01-01-008

W1-1-5

GENERAL INFORMATION / Precautions for Disassembling and Assembling Maintenance Standard Terminology “Standard” 1. Dimension for parts on a new machine. 2. Dimension of components or assemblies adjusted to specification. Tolerances are indicated as necessary. “Allowable Limit” 1. Machine cannot operate normally with the parts exceeding this dimension installed. 2. Repair or adjustment is impossible if this dimension is exceeded. 3. To maintain high machine availability and to save the repair expense, the machine parts should be repaired or replaced before reaching the “Allowable Limit.”

W1-1-6

GENERAL INFORMATION / Tightening Torque TIGHTENING TORQUE SPECIFICATIONS

Bolts and Nuts of Machine: Standard Tightening Torque Chart

No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

Wrench Size mm 50

14 14 20 16 20 20 12 16 24

4 4 14 8 14 8 24 8 88

22 22 30 24 30 30 19 24 36

33 12

30 24

Hex.24 Hex.10

1640 to 1770 60 to 85 60 to 85 392 68 to 79 392 359 to 379 60 to 64 68 to 79 498 to 539 1640 to 1770 1950 106 to 120

104

540

60 to 64

6.1 to 6.6

539

550

34 to 37

3.5 to 3.8

16 20 16 10 20 16 10 10 20 16 12 10 -

4 36 8 8 4 4 4 2 4

Hex.14 30 24 17 Hex.17 Hex.14 Hex.12 Hex.8 30 24 19 17

750 350 to 379 235 41 to 45 400 240 33 41 to 45 400 148 to 160 60 to 64 41 to 45

76.5 35.7 to 38.7 24 4.2 to 4.6 41 24 3.4 4.2 to 4.6 41 15.0 to 16.3 6.1 to 6.6 4.2 to 4.6

Bolt Dia. mm 33

Descriptions Turntable Mounting Bolt Engine Mounting Bolt Front and Nut Rear R.H. Platform Mounting Bolt Cab Mounting Bolt L.H. Platform Mounting Bolt Live Mast Flip Cylinder Mounting Bolt Carrier Roller (Front/Rear) Mounting Bolt Carrier Roller (Center) Mounting Bolt Carrier Roller (To Machine No. 5) Mounting Bolt Carrier Roller (From Machine No. 6 and after) Mounting Bolt Travel Mechanism Mounting Bolt (Right/Left) Travel Motor Mounting Bolt (Right/Left) Hoisting Mechanism Mounting Bolt (Front/Rear Drum) Hoist Drum Cover Mounting Bolt (Front/Rear Drum) Hoist Motor Mounting Bolt (Front/Rear Drum) Boom Raising/Lowering Mechanism Mounting Bolt Boom Raising/Lowering Drum Cover Mounting Bolt Boom Raising/Lowering Motor Mounting Bolt Swing Mechanism Mounting Bolt Swing Motor Mounting Bolt Pump Mechanism Mounting Bolt Main Pump Mounting Bolt Swing Pump Mounting Bolt Reduction Gear Mounting Bolt Gear Pump Mounting Bolt Hydraulic Oil Tank Mounting Bolt Fuel Tank Mounting Bolt Radiator Mounting Bolt Radiator Stay Mounting Bolt Hydraulic Hose

NOTE: (1) Apply lubricant (i.e. white zinc B dissolved into spindle oil) to reduce their friction coefficients. (2) Remove rust, dirt, and dust before installing fasteners.

Q’ty

2 4 4

Torque N m

kgf m 167 to 181 6 to 9 6 to 9 40 7 to 8 40 35.7 to 38.7 6.1 to 6.6 7 to 8 50.8 to 55.0 167 to 181 200 10.8 to 13.2

(3) Apply LOCTITE onto the boom derricking mechanism mounting bolt, boom derricking motor mounting bolt, pump mechanism mounting bolt, main pump mounting bolt and gear pump mounting bolt.

W1-2-1

GENERAL INFORMATION / Tightening Torque STANDART TORQUE SPECIFICATIONS 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

Hexagon H Bolt

Hexagon M Bolt

Socket Bolt

W157-01-01-001

Specified Tightening Torque Chart T Bolt, Socket Bolt Bolt Wrench Hexagon Wrench Dia. Size N m kgf m lbf ft Size M 8 13 6 30 3.1 22 M 10 17 8 65 6.6 48 M 12 19 10 110 11.0 81 M 14 22 12 180 18.5 133 M 16 24 14 270 27.5 199 M 18 27 14 400 41.0 295 M 20 30 17 550 56.0 406 M 22 32 750 76.5 553 M 24 36 950 97.0 701 M 27 41 1400 143 1033 M 30 46 1950 200 1438 M 33 50 2600 265 1918 M 36 55 3200 325 2360

H Bolt N m 20 50 90 140 210 300 400 550 700 1050 1450 1950 2450

W1-2-2

kgf m 2.0 5.1 9.2 14.0 21.5 30.5 41.0 56.0 71.5 107 148 200 250

M Bolt lbf ft 15 37 66 103 155 221 295 406 516 774 1069 1438 1807

N m 10 20 35 55 80 120 170 220 280 400 550 750 950

kgf m 1.0 2.0 3.6 5.6 8.2 12.0 17.0 22.5 28.5 41.0 56.0 76.5 97.0

lbf ft 7.4 15 26 41 59 89 125 162 207 295 406 553 701

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 s10 %. (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 from center and diagonally

Tighten diagonally

1,4

6 4

5 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 O-rings. Inspect O-rings for any damage. Take care not to file O-ring 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. Hand-tighten 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

WRONG

RIGHT

Nut and Bolt Lockings

Do not bend it round

Bend along edge sharply

RIGHT

WRONG

x Lock Plate IMPORTANT: Do not reuse lock plates. Do not try to bend the same point twice.

Bend along edge sharply

W105-01-01-009

RIGHT

x Cotter Pin IMPORTANT: Do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening.

RIGHT

WRONG

Loosen

WRONG

Tighten

x Lock Wire IMPORTANT: Apply wire to bolts in the bolt-tightening direction, not in the bolt-loosening direction.

W1-2-4

W105-01-01-010

GENERAL INFORMATION / Tightening Torque 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

37q 30q

(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 30q Male Union Joint

37q Female Union Joint

Wrench Size Union Nut Joint Body 17 17 19 19 22 22 27 27 32 32 36 36 41 41 17 14 19 17 22 19 27 22 32 27 36 32 41 36

W1-2-5

Male Union Joint

Female Union Joint

W105-01-01-017

N m 24.5 29.5 39 93 137 175 205 24.5 29.5 39 93 137 175 205

Tightening Torque kgf m 2.5 3.0 4.0 9.5 14.0 18.0 21.0 2.5 3.0 4.0 9.5 14.0 18.0 21.0

Ibf ft 18 22 29 69 101 129 151 18 22 29 69 101 129 151

GENERAL INFORMATION / Tightening Torque 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 O-ring (6) displaced will damage O-ring (6), resulting in oil leakage.

Joint Body

10 M104-07-033

Wrench Size Union Nut Joint Body

(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.

W1-2-6

19 22 27 32 36 41 46

17 19 22 27 30, 32 36 41

Tightening Torque N m kgf m Ibf ft 29.5 69 93 137 175 205 205

3.0 7.0 9.5 14.0 18.0 21.0 21.0

22 51 69 101 129 151 151

GENERAL INFORMATION / Tightening Torque Screwed-In Connection

IMPORTANT: Many types of screwed-in connec-tions 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.

30q

Male Straight Thread

Male Tapered Thread

W105-01-01-018

Wrench Joint Body 17, 19 19, 22 27, 22 36, 32 41 50 60 70 Seal Tape Application

Male Tapered Thread Tightening Torque N m kgf m 59 6 98 10 118 12 235 24 295 30 490 50 670 68 980 100

Ibf ft 43 72 87 134 215 360 490 720

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

Leave one to two pitch threads uncovered

x Application Procedure 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.

M114-07-041

Low-Pressure-Hose Clamp Tightening Torque T-Bolt Type

Worm Gear Type

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 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

W1-2-7

M114-07-043

GENERAL INFORMATION / Tightening Torque Connecting Hose WRONG CAUTION: (1) When replacing hoses, be sure to use genuine manufacture parts. Using hoses other than genuine manufacture parts 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

GENERAL INFORMATION / Tightening Torque REFERENCE: Major Parts to Be Replaced at Regular Intervals. The parts listed below deteriorate as the machine ages and are worn out or fatigued by repeated loads, resulting in possible severe personal injury and/or machine trouble. The service life of these parts can not be detected through machine operation or visual inspection.

Part Location

Therefore, these parts should be replaced at regular intervals even if no abnormalities are noticed. In case any abnormalities are found on a part at any time regardless of its specified replacement interval, immediately replace the part.

Part to be Replaced

Q’ty

Pendant rope Front Attachment Winch Engine

Ball bearing (oil less bearing in the hook sheave) Ball bearing (boom hoist winch pedestal) Fuel hose (between the fuel tank and filter) Fuel hose (between the fuel tank and injection pump)

IMPORTANT: Each hose has an individual service life. If any abnormalities are found during the regular interval check and/or maintenance service, be sure to replace with a new one.

W1-2-9

1 -

Interval (Hours or Period) Crane: 400 hrs /2 years Bucket, Lifting Magnet (Heavy Duty Work) : 2000 hrs / 2 years 2000 hrs / 2 years 2000 hrs / 2 years 2000 hrs / 2 years 2000 hrs / 2 years

GENERAL INFORMATION / Tightening Torque (Blank)

W1-2-10

SECTION 2

SWING MACHINERY CONTENTS Group 1 Cab Remove and Install Cab .......................... W2-1-1

Remove and Install Gear Pump

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

(For Reeving Winch) .......................... W2-4-85 Disassemble Gear Pump

Group 2 Counterweight Remove and Install Counterweight............ W2-2-1

(For Reeving Winch) .......................... W2-4-88 Assemble Gear Pump (For Reeving Winch) .......................... W2-4-90

Group 3 Revolving Frame Remove and Install Revolving Frame ...... W2-3-1

Group 5 Control Valve Remove and Install 4-Unit Control Valve

Group 4 Pump Mechanism

for Front Drum, Rear Drum, Travel,

Remove and Install Main Pump ............... W2-4-1

Boom Raising/Lowering Drum and

Disassemble Main Pump ......................... W2-4-4 Assemble Main Pump............................ W2-4-10 Maintenance Standard........................... W2-4-16 Disassemble Front Regulator ................ W2-4-18 Assemble Front Regulator ..................... W2-4-24

Quick Draw .......................................... W2-5-1 Disassemble 4-Unit Control Valve............ W2-5-4 Assemble 4-Unit Control Valve .............. W2-5-10 Remove and Install 4-Uint Control Valve for Boom Foot and Lower

Disassemble Rear Regulator................. W2-4-28 Assemble Rear Regulator...................... W2-4-34 Remove and Install Swing Pump ........... W2-4-41 Disassemble Swing Pump ..................... W2-4-44 Assemble Swing Pump.......................... W2-4-48

Hydraulic Source................................ W2-5-16 Disassemble 4-Unit Control Valve.......... W2-5-18 Assemble 4-Unit Control Valve .............. W2-5-22 Remove and Install 3-Unit Control Valve for Counterweight Removal/Installation

Maintenance Standard ......................... W2-4-50 Disassemble Regulator ......................... W2-4-52 Assemble Regulator .............................. W2-4-58 Remove and Install Gear Pump (For Oil Cooler) .................................. W2-4-65 Disassemble Gear Pump (For Oil Cooler) .................................. W2-4-68 Assemble Gear Pump (For Oil Cooler) .. W2-4-70

and Live Mast Flip .............................. W2-5-26 Disassemble 3-Unit Control Valve.......... W2-5-28 Assemble 3-Unit Control Valve .............. W2-5-32 Remove and Install 2-Unit Control Valve for Swing ............................................ W2-5-36 Disassemble 2-Unit Control Valve.......... W2-5-38 Assemble 2-Unit Control Valve .............. W2-5-40

Remove and Install 2-Unit Gear Pump .. W2-4-75 Disassemble 2-Unit Gear Pump ............ W2-4-78 Assemble 2-Unit Gear Pump ................. W2-4-80

2CNW-2-1

Group 6 Swing Mechanism

(For Machine No.6 and after)

Remove and Install Swing Mechanism .... W2-6-1

Remove and Install Raising/Lowering

Disassemble Swing Mechanism .............. W2-6-4 Assemble Swing Mechanism ................... W2-6-8

Mechanism......................................... W2-8-31 Disassemble

Raising/Lowering

Disassemble Swing Motor ..................... W2-6-12

Mechanism......................................... W2-8-34

Assemble Slewing Motor ....................... W2-6-16

Assemble Raising/Lowering Mechanism W2-8-38

Maintenance Standard ......................... W2-6-20

Disassemble Raising/Lowering Motor .... W2-8-42 Assemble Raising/Lowering Motor ....... W2-8-46

Group 7 Hoisting Mechanism

Maintenance Standard ......................... W2-8-50

Remove and Install Hoisting Mechanism .......................................... W2-7-1 Disassemble Hoisting Mechanism ........... W2-7-6 Assemble Hoisting Mechanism.............. W2-7-10 Disassemble Hoisting Motor .................. W2-7-16 Assemble Hoisting Motor....................... W2-7-20 Maintenance Standard ......................... W2-7-24

Disassemble Regulator.......................... W2-8-52 Assemble Regulator............................... W2-8-54 Disassemble Counterbalance Valve....... W2-8-56 Assemble Counterbalance Valve ........... W2-8-58

Group 9 Remote Control Valve Remove

and

Install

Boom

Disassemble Regulator ......................... W2-7-26

Raising/Lowering Drums and Travel

Assemble Regulator .............................. W2-7-28

Remote Control Valves......................... W2-9-1

Disassemble Counterbalance Valve ...... W2-7-30

Remove and Install Swing Remote

Assemble Counterbalance Valve ........... W2-7-32

Control Valve........................................ W2-9-5

Disassemble Reeving Winch ...................W2-734

Disassemble Remote Control Valve ......... W2-9-8

Assemble Reeving Winch...................... W2-7-36

Assemble Remote Control Valve............ W2-9-14

Disassemble Reeving Winch Motor ....... W2-7-38 Assemble Reeving Winch Motor..............W2-740

Group 8 Raising/Lowering Mechanism (To Machine No.5)

Remove and Install Solenoid Valve Block .................................................. W2-10-1 Disassemble Solenoid Valve Block ........ W2-10-2 Assemble Solenoid Valve Block ............. W2-10-4

Remove and Install Raising/Lowering Mechanism .......................................... W2-8-1 Disassemble

Group 10 Solenoid Valve

Raising/Lowering

Group 11 Cylinder Remove and Install Flip Cylinder ........... W2-11-1

Mechanism .......................................... W2-8-4 Assemble Raising/Lowering Mechanism . W2-8-8 Disassemble Raising/Lowering Motor.... W2-8-12

Disassemble Flip Cylinder ..................... W2-11-4 Assemble Flip Cylinder .......................... W2-11-6 Remove and Install Counterweight

Assemble Raising/Lowering Motor ...... W2-8-16 Maintenance Standard ......................... W2-8-20 Disassemble Regulator ......................... W2-8-22 Assemble Regulator .............................. W2-8-24

Cylinder.............................................. W2-11-9 Disassemble Counterweight Cylinder .. W2-11-12 Assemble Counterweight Cylinder ....... W2-11-14 Remove and Install Boom Foot

Disassemble Counterbalance Valve ...... W2-8-26 Assemble Counterbalance Valve ........... W2-8-28

Cylinder............................................ W2-11-17 Disassemble Boom Foot Cylinder ........ W2-11-18 Assemble Boom Foot Cylinder............. W2-11-20

2CNW-2-2

SWING MACHINERY/ Cab REMOVE AND INSTALL CAB 2

Removal 1. Remove the seat bracket installing bolts (1) (4 used) and remove the seat (2). : 13 mm

W24X-02-01-001

8 8

2. Loosen the screws (8) (19 used) and bolts (9) (4 used) and remove the covers (3 to 7) behind the seat. : 17 mm

8 7

6 4 9

M2CN-02-01-001

3. Remove the screws (18) (4 used) and bolts (19) (4 used) and remove the covers (16) and (17) on the lower part of the front display. : 17 mm

16 14 18

4. Remove the screws (14) (14 used) and socket bolts (15) (2 used) and remove the covers (11) to (13) from the left stand (10). : 4 mm

13 14 19

5. Loosen the bolts (20) (4 used) of the left stand (10). (In order to move the left stand) : 13 mm

6. Move the left stand (10) approx. 20 mm to the inside.

14 15

W24X-02-01-003

W2-1-1

SWING MACHINERY/ Cab 7. Remove the screws (25) (14 used) and socket bolts (26) (2 used) and remove the covers (22) to (24) from the right stand (21). : 4 mm 8. Loosen the bolts (27) (4 used) of the right stand (21). (In order to move the right stand) : 13 mm

25 23 26 27

9. Move the right stand (21) approx. 20 mm to the inside.

21 27

22 W2CG-02-01-001

10. Loosen the bolts (33) (22 used) and remove the under covers (28) to (32) at front of the right bed. : 17 mm

32 29 31 30 33

11. Disconnect all connectors (34) of the electric wiring for each equipment installed on the cab.

M2CN-02-01-002

12. Loosen the hose clamp (36) and remove the air conditioner hoses (35) (2 used).

W24X-02-01-006

W2-1-2

SWING MACHINERY/ Cab

13. Remove the bolt (37) and nuts (38) (8 used). : 24 mm

M2CN-02-01-002

14. Attach a wire rope on the lifting position (M12) (4 places) on the top of cab (39) and support it with the crane. 39

CAUTION: Cab weight: 228 kg 15. Carefully lift the cab (39) in order not to touch the rear stand, left stand, right stand and other equipments on the floor plate.

M2CN-02-01-003

W2-1-3

SWING MACHINERY/ Cab Installation CAUTION: Cab weight: 228 kg 1. Attach a wire rope on the lifting position (12) (4 places) on the top of cab (39) and lift it with the crane.

2. Carefully lower the cab (39) in order not to touch the rear stand, left stand, right stand and other equipments on the floor plate.

3. Install the bolt (37) and nuts (38) (8 used). : 24 mm : 68.1 to 79.4 N m (6.9 to 8.1 kgf m)

M2CN-02-01-003

M2CN-02-01-002

4. Tighten and install the air conditioner hoses (35) (2 used) to the air conditioner with hose clamp (36).

5. Install all connectors (34) of the electric wiring for each equipment installed on the cab.

36 34

W24X-02-01-006

W2-1-4

SWING MACHINERY/ Cab 6. Install the under covers (28) to (32) at front of the right platform with the bolts (33) (25 used). : 17 mm : 50 N m (5.1 kgf m)

29 33

M2CN-02-01-002

7. Push the right stand (21) on the wall in the cab.

25 23

8. Tighten the bolts (27) (4 used) of the right stand (21). : 13 mm : 10 N m (1.0 kgf m)

26 27

26 25

9. Install the covers (22) to (24) on the right stand with the screws (25) (14 used) and socket bolts (26) (2 used). : 4 mm

21 27

W2CG-02-01-001

10. Push the left stand (10) on the wall in the cab.

11. Tighten the bolts (20) (4 used) of the left stand (10). : 13 mm : 10 N m (1.0 kgf m)

14 18

12. Install the covers (11) to (13) on the left stand (10) with the screws (14) (14 used) and socket bolts (15) (2 used). : 4 mm 13. Install the covers (16) and (17) on the bottom of the front display with the screws (18) (14 used) and socket bolts (19) (4 used). : 17 mm : 50 N m (5.1 kgf m)

14 19

20 10

14 15

W24X-02-01-003

W2-1-5

SWING MACHINERY/ Cab 14. Install the covers (3) to (7) on the rear stand with the screw (8) and bolt (9). : 17 mm : 50 N m (5.1 kgf m)

8 8 5

8 7

6 4 9

M2CN-02-01-001

15. Install the seat (2) with the bolt (1). : 13 mm : 10 N m (1.0 kgf m)

W24X-02-01-001

W2-1-6

SWING MACHINERY/ Cab DIMENSIONS OF THE CAB GLASS Unit: mm

NOTE: JIS R3211, 3212 or equivalent 565.2 25

R30 R55

810

Thickness : 6.8 mm

517.7

776 26 22.5

25 466

469.8

166

R53

276.5

(134.7)

R75.9

Thickness : 4 mm

42.5

Thickness : 4 mm

I11

64 32 88

897.5

122.5

Thickness: 5 mm

763 763 40

22.5

57.5

R75.9 I12.2

857.5

26 22

39.5 312.4

604.5

768 R5

376.6 Thickness: 5 mm R61 758

Thickness : 4 mm

558.5 R40

497.7 65.8

498

186.4

R61 R2519 Thickness : 4 mm

372.6

371.2

650.8 802.9 R61 233.5

123.2

735.9

406.8

Thickness : 4 mm 264.3

R61

251.6

Thickness : 4 mm

148.3

R61

648 623

667.7

Thickness : 4 mm 840

530 172.3

W2BC-02-01-001

W2-1-7

SWING MACHINERY/ Cab (Blank)

W2-1-8

SWING MACHINERY / Counterweight REMOVE AND INSTALL COUNTERWEIGHT

CAUTION: Never allow the workers enter under and/or between the base machine and counterweight. Removal 1. Lower the boom and remove the hook. After removing the wire rope of the front and rear drum, remove the pendant rope, extension and top section. (As for the removal of the pendant rope, extension and top section, refer to the Operator’s Manual.) A

2. Place the power switch on the control box in “ON” and slightly retract the right and left removal/installation cylinder (1) with operating the removal/installation cylinder switch.

M2CN-02-02-001

3. Draw the lever (3) installed on the base counterweight assembly (2). (Right and left: Each 2 places)

Detail A

IMPORTANT: Carefully operate the switch with adjusting so that the counterweight does not tilt to the right and left. 4. Extend the right and left removal/installation cylinder (1) with operating the removal/installation cylinder switch and lower the counterweight on the ground.

M2CN-02-02-002

M2CN-02-02-003

W2-2-1

SWING MACHINERY / Counterweight 5

5. Pull the lever (4) and draw the pin (5).

6. Retract the right and left removal/installation cylinder (1) with operating the removal/installation cylinder switch and lower the removal/installation frame (6).

Detail B

M2CN-02-02-004

D 2

IMPORTANT: Attach a cap so that the dust and foreign matter does not enter after disconnecting the quick couplers. If the quick couplers come in contact with other objects, it may be damaged. Handle with care.

M2CN-02-02-005

7 9

7. Remove the hose (7) for the removal/installation cylinder from the piping (9) installed on the revolving frame (8).

Detail C

8. Push the lever (4) and push the pin (5) into the removal/installation frame.

W2-2-2

M2CN-02-02-006

Detail B

M2CN-02-02-007

SWING MACHINERY / Counterweight 9. Push in the lever (3) of the base counterweight assembly (2). (Right and left: Each 2 places)

Detail D

M2CN-02-02-008

IMPORTANT: Take care not to damage the cable of the control box with riding or pinching it when moving the machine forward.

Counterweight Center

Approx. 6.1m to Rotation Center

10. Move the base machine forward and keep it from the counterweight.

NOTE: Move the base machine forward so that the distance between the center of the counterweight and the rotation center of the base machine is approx. 6m.

M2CN-02-02-009

W2-2-3

SWING MACHINERY / Counterweight Installation

IMPORTANT: Take care not to damage the cable of the control box with riding or pinching it when moving the machine backward. 1. Move the base machine backward to the direction of the counterweight at the status that the base section is supported with the quick draw.

NOTE: Move the base machine backward with aligning the removal/installation frame (6) and the revolving frame (8). Align the removal/installation (6) at the poison of 5m from the revolving frame (8) and stop moving the base machine.

M2CN-02-02-009

8 B

Center of Rotating Platform

M2CN-02-02-010

6 G

M2CN-02-02-005

W2-2-4

SWING MACHINERY / Counterweight 2. Move the lock lever (13) to “LOCK” side. UNLOCK LOCK

NOTE: When the lock lever (13) is moved to “UNLOCK” position, the counterweight can not be removed and installed.

3. Draw the lever (3) installed on the base counterweight assembly (2). (Right and left: Each 2 places)

W2CG-02-02-012

4. Pull the lever (4) and draw the pin (5).

Detail F

M2CN-02-02-002

Detail G

M2CN-02-02-007

7 9

IMPORTANT: Wipe off the dust and foreign from the quick couplers before connecting and clean it. If the quick couplers come in contact with other objects, it may be damaged. Handle with care. Securely connect the hydraulic hoses. 5. Connect the hose (7) for the removal/installation cylinder to the piping (9) installed on the revolving frame (8).

W2-2-5

Detail H M2CN-02-02-006

SWING MACHINERY / Counterweight 6. Place the power switch on the control box in “ON” and extend the right and left removal/installation cylinder (1) with operating the removal/installation cylinder switch.

J 1

NOTE: At this time, make sure that the hook (14) of the removal/installation frame (6) is set to the pin (15) of the revolving frame (8) side.

M2CN-02-02-003

7. Push the lever (4) and push the pin (5) into the removal/installation frame.

8 Detail I

M2CN-02-02-011

4 Detail J

W2-2-6

M2CN-02-02-004

SWING MACHINERY / Counterweight IMPORTANT: Carefully operate the switch with adjusting so that the counterweight does not tilt to the right and left.

8. Retract the right and left removal/installation cylinder (1) with operating the removal/installation cylinder switch on the control box and lift the counterweight.

9. Push in the lever (3) of the base counterweight assembly (2) and lock the counterweight. (Right and left: Each 2 places)

M2CN-02-02-001

NOTE: Slightly extend the removal/installation cylinder (1) so that the load is not applied to the removal/installation cylinder (1).

Detail K

M2CN-02-02-008

10. Install the extension, top section and pendant rope. (As for the installation of the extension, top section and pendant rope, refer to the Operator’s Manual.)

Detail L

M2CN-02-02-012

W2-2-7

SWING MACHINERY / Counterweight (Blank)

W2-2-8

SWING MACHINERY/ Revolving Frame REMOVE FRAME

AND

INSTALL

REVOLVING

CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.

Removal

1. Lower the boom and remove the hook. After removing the wire rope of the front/rear drum, remove the pendant rope, extension and boom top section. (As for the removal of the pendant rope, extension and boom top section, refer to the Operator’s Manual.)

2. Remove the counterweight. (As for the removal of the counterweight, refer to W2-2 in this section.)

3. Remove the boom base section, crawler and lower weight. (As for the removal of the boom base section, crawler and lower weight, refer to the Operator’s Manual.) 4. Remove the boom raising/lowering drum wire rope.

W2-3-1

SWING MACHINERY/ Revolving Frame 5. Remove the hose of the center joint of only the swing machinery side.

6. Attach the wire rope on the shackle (1). Install the shackle (1) on the live mast mounting portion of the revolving frame and counterweight mounting portion.

M2CN-02-03-001

M2CN-02-03-002

W2-3-2

SWING MACHINERY/ Revolving Frame CAUTION: Swing machinery weight: Approx. 20 t 7.

Balance the swing machinery with using the wire rope and chain block and support it with the crane.

Put the matching marks on the outer race side of the swing ring and revolving frame side.

M2CN-02-03-003

Loosen the bolt (2) 10 mm of the outer race of the swing ring in both side frames to the direction of the center in order. Carry out the same procedures for the rear side. (The illustration is viewed from the front.) : 50 mm

Center

10. Lift the swing machinery 10 mm with the crane and balance the whole.

11. Remove the bolt (2) from the outer race of the swing ring in both side frames to the direction of the center in order. : 50 mm

W324-02-03-006

12. Lift the swing machinery with the crane and remove it.

W2-3-3

SWING MACHINERY/ Revolving Frame Installation

CAUTION: Swing machinery weight: Approx. 20 t 1. Balance the swing machinery and lift it with the crane. 2. Align the matching marks on the outer race of the swing ring and revolving frame. Lower the swing machinery slowly and support it at the height of 10 mm with the crane.

M2CN-02-03-003

3. Insert the bolt (2) from the outer race side of the swing ring and tighten the bolt temporarily.

Center

4. Tighten all the bolts temporarily and lower the swing machinery completely. 5. Tighten the nuts diagonally and alternately. : 50 mm : 1640 to 1770 N m (167.0 to 181.0 kgf m) 6. Install all hoses on the center joint. (Refer to W3-3 in the following section.)

W324-02-03-006

W2-3-4

SWING MACHINERY/ Revolving Frame 7. Install the lower weight, crawler and boom base section. (As for the installation of the lower weight, crawler and boom base section, refer to the Operator’s Manual.)

8. Install the counterweight. (Refer to W2-2 in this section.)

9. Install the extension, boom top section and pendant rope. (As for the installation of the extension, boom top section and pendant rope, refer to the Operator’s Manual.) 10. Wind the wire rope on the front/rear drum and reeve the wire rope through the hook. (Refer to the Operator’s Manual.)

W2-3-5

SWING MACHINERY/ Revolving Frame (Blank)

W2-3-6

SWING MACHINERY / Pump Mechanism REMOVE AND INSTALL MAIN PUMP

Preparation

1. Shutdown the engine. Operate the control lever several times and release the remaining pressure in the circuit. 2. Remove the drain plug (1) and drain off the hydraulic oil with using a container (500 L). After draining, install the plug (1). : 19mm

W2CG-02-04-010

Removal

1. Remove all hoses, pipings and wire harness from the pump device. Cap the removed hoses. : 22 mm, 27 mm, 36 mm : 8 mm, 10 mm, 14 mm 2. Attach a wire rope on the main pump and support the main pump with the crane. CAUTION: Main pump weight: Approx. 304 kg 3. Remove the bolts (2) and (3). Lift the main pump with the crane and remove it. : 17mm : 30 mm

M2CN-02-04-001

W2-4-1

SWING MACHINERY / Pump Mechanism Installation

CAUTION: Main pump weight: Approx. 304 kg 2

1. Lift the main pump with the crane and install it to the coupling and bracket.

2. Apply LOCTITE on the bolts (2) and (3) and install them. : 17 mm : 400 N m (41.0 kgf m) : 30 mm : 350 to 379 N m (35.7 to 38.7 kgf m) 3. Install all hoses, pipings, and wire harness on the main pump. ᧶22 mm ᧶39 N m (4.0 kgf m) ᧶27 mm ᧶93 N m (9.5 kgf m) ᧶36 mm ᧶175 N m (18.0 kgf m) ᧶8 mm ᧶48 to 50 N m (4.9 to 5.1 kgf m) ᧶10 mm ᧶90 N m (9.2 kgf m) ᧶14 mm ᧶210 N m (21.5 kgf m)

M2CN-02-04-001

4. Remove the filler port cover of the hydraulic oil tank. Apply the hydraulic oil to the specified position of the level gauge. 5. Remove the air bleed plug (4) from the top of main pump and fill the hydraulic oil. Install the air bleed plug (4). Start the engine and run at low idling speed. : 36 mm : 170 N m (17.0 kgf m) 6. Loosen the air bleed plug (4) and release the air in the pump. : 36 mm 7. Tighten the air bleed plug (4) after releasing the air. Do the work at low idling speed. Check the hydraulic oil level and any oil leaks. : 36 mm : 170 N m (17.0 kgf m)

W2-4-2

SWING MACHINERY / Pump Mechanism (Blank)

W2-4-3

SWING MACHINERY / Pump Mechanism DISASSEMBLE MAIN PUMP

16 19 14, 15

23 24 25

7 4

67 27 44

2 29

57 10 58

1 41

62 66

40 39 38 37 35 30

46 10

33,34

47 48

59 60

53 52 56 50 42 49 40

W2CG-02-04-002

W2-4-4

SWING MACHINERY / Pump Mechanism 12345678910 11 12 13 14 15 16 17 -

Socket Bolt (4 Used) Plate O-Ring Retaining Ring (2 Used) Spacer (3 Used) Bearing (2 Used) Shaft Nut (2 Used) Screw (2 Used) Spring Pin (6 Used) Stopper (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Feedback Pin (2 Used) Tilt Pin (2 Used) Regulator Socket Bolt (4 Used)

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 -

Socket Bolt (4 Used) Stopper (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Servo Piston (2 Used) O-Ring (4 Used) Plug (4 Used) Pump Casing (2 Used) O-Ring (2 Used) Plug (26 Used) Support (2 Used) Socket Bolt (8 Used) Plate (2 Used) Bushing (2 Used) Plate (2 Used) Piston (18 Used) Shoe (18 Used)

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 -

W2-4-5

Spring (18 Used) Cylinder Block (2 Used) Spring (18 Used) Cylinder Block (2 Used) Valve Plate Bearing (2 Used) Gear O-Ring Block Screw (2 Used) Eyebolt (2 Used) Pin (2 Used) O-Ring (4 Used) Plug (2 Used) Valve Plate O-Ring (16 Used) Shaft

52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67

O-Ring Oil Seal Cover Socket Bolt (4 Used) Regulator Plug(᧮Used) O-Ring Reduction Gear Flange Socket (4 Used) O-Ring Cover Socket Bolt (2 Used) O-Ring Block Socket Bolt (4 Used) Block (4 Used)

SWING MACHINERY / Pump Mechanism 17

24 25

28 29

38 37 35

36 59

33,34

53 56

W2CG-02-04-002

W2-4-6

SWING MACHINERY / Pump Mechanism Disassemble Main Pump

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.

IMPORTANT: Place the rubber plate or cloth on the workbench not to damage the parts.

IMPORTANT: Place the rubber plate on the workbench not to damage the regulator mounting surface when placing it down.

1. Select the place to disassemble. NOTE: Select a clean place. 2. Remove the dust and rust on the surface of pump with using washing oil.

6. Place the pump on the workbench horizontally with the regulator mounting surface with placing downward. Separate the pump casing (25) from the block (43). NOTE: Remove the gear (41) at the same time when separating the pump casing (25) from the block (43).

3. Remove the plug (24) and drain the oil from the pump casing (25). : 36 mm NOTE: Drain the oil from the plug in front pump and rear pump respectively.

IMPORTANT: Do not damage the sliding surfaces of the cylinder block (38), bushing (36), shoe (34) and plate (30).

4. Remove the socket bolts (17), (18) and flange socket (60). Remove the regulators (16), (56) and reduction gear (59). : 6 mm, 12 mm

7. Remove the cylinder block (38) from the pump casing (25) straightly to the shaft. At the same time, remove the piston (33), plate (35), bushing (36), and spring (37).

NOTE: As for disassembly of the regulators (16) and (56), refer to the corresponding section.

IMPORTANT: Do not damage the oil seal (53) when removing the cover (54).

5. Remove the socket bolt (29) that tightens the support (28), pump casing (25) and block (43).

8. Remove the socket bolt (55) and remove the cover (54). : 6 mm

᧶ 17mm NOTE: In case the pump is installed behind the pump, carry out this working after removing the pump first.

W2-4-7

NOTE: If inserting the bolt in the hole (M6) on the cover (54), the cover (54) can be removed easily.

SWING MACHINERY / Pump Mechanism

19 15

11 8

67 28 2 43 1 40 39

32 30

W2CG-02-04-002

W2-4-8

SWING MACHINERY / Pump Mechanism 9. Remove the socket bolt (1) and block (67). Remove the plate (2). : 14 mm 10. Tap the mounting flange part of the support (28) from the pump casing (25) side and separate the support (28) from the pump casing (25). 11. Remove the plates (32) and (30) from the pump casing (25). 12. Tap the ends of the shafts (51) and (7) with using a plastic hammer and remove the shafts (51) and (7) from the support (28). 13. Remove the valve plates (39) and (49) from the block (43). NOTE: The valve plates (39) and (49) may be removed at step 6. IMPORTANT: When removing the tilt pin (15), use a special tool not to damage the head of tilt pin (15). As LOCTITE is applied on the fitting part between the tilt pin (15) and servo piston (22), do not damage the servo piston (22). Do not remove the bearing (40) except replacement. As the setting of flow rate changes, do not loosen the lock nut (8) of the block (43) and support (28). 14. If necessary, remove the stoppers (19), (11), servo piston (22) and tilt pin (15) from the pump casing (25). Remove the bearing (40) from the block (43).

W2-4-9

SWING MACHINERY / Pump Mechanism ASSEMBLE MAIN PUMP 56

22 31 14 15

19 50

23,24

10 26 54 55 4 51

53 5 52 6 30 28

32 35

10 29

40 49

47,48 43

41 65

64 59

66 62 63

68 67

61 58

66 65 69

W2CG-02-04-011

W2-4-10

SWING MACHINERY / Pump Mechanism

12345678910 11 12 13 14 15 16 17 18 -

Socket Bolt (4 Used) Plate O-Ring Retaining Ring (2 Used) Spacer (3 Used) Bearing (2 Used) Shaft Nut (2 Used) Screw ᧤2 Used᧥ Spring Pin (6 Used) Stopper (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Feedback Pin (2 Used) Tilt Pin (2 Used) Regulator Socket Bolt (4 Used) Socket Bolt (4 Used)

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 -

Stopper (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Servo Piston (2 Used) O-Ring (4 Used) Plug (4 Used) Pump Casing ᧤2 Used᧥ O-Ring (4 Used) Plug (26 Used) Support (2 Used) Socket Bolt (8 Used) Plate (2 Used) Bushing (2 Used) Plate (2 Used) Piston (18 Used) Shoe (18 Used) Plate (2 Used) Bushing (2 Used)

37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 -

Spring (18 Used) Cylinder Block (2 Used) Valve Plate Bearing (2 Used) Gear O-Ring (2 Used) Block Screw (2 Used) Eyebolt (2 Used) Pin (2 Used) O-Ring (4 Used) Plug (2 Used) Valve Plate O-Ring (16 Used) Shaft O-Ring (2 Used) Oil Seal Cover

W2-4-11

55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 -

Socket Bolt (4 Used) Regulator Plug (12 Used) O-Ring Reduction Gear Flange Socket (4 Used) O-Ring Cover Socket Bolt (2 Used) O-Ring Block Socket Bolt (4 Used) Block (4 Used) Seat (4 Used) Steel Ball (4 Used) Stopper (2 Used) Stopper (2 Used) Reducing Valve

SWING MACHINERY / Pump Mechanism

22 31 14 15

11 67 1

54 55 4 51

53 5 6 30 28

W2CG-02-04-011

W2-4-12

SWING MACHINERY / Pump Mechanism Assemble Main Pump IMPORTANT: When tightening the servo piston (22) and tilt pin (15), use a special tool not to damage the head of tilt pin (15) and feedback pin (14). Apply LOCTITE (medium intensity) on the thread part. 1. Install the support (28) on the pump casing (25) while tapping with using a hammer. NOTE: When the servo piston (22), the tilt pin (15), the stoppers (19) and (11) are removed, install them on the pump casing (25) first. 2. Place the pump casing (25) with directing the regulator mounting surface downward. Insert the bushing (31) of the plate (30) in the tilt pin (15). Install the plate (30) on the support (28) correctly. NOTE: Check if the plate (30) can move smoothly by fingers. If the grease is applied on the plate (30), support (28) and moving part, the shaft (7) and (51) can be installed easily. IMPORTANT: Do not tap the shaft (51) with using a hammer.

IMPORTANT: Do not damage the oil seal (53) when installing.

4. Secure the cover (54) on the pump casing (25) with the socket bolt (55). : 6 mm : 29 N m (3.0 kgf m) NOTE: Slightly apply grease on the oil seal (53) in the cover (54). 5. Secure the plate (2) on the pump casing (25) with the socket bolt (1) and block (67). : 14 mm : 430 N m (44.0 kgf m) 6. Assemble the piston cylinder sub assembly (cylinder block (38), piston (33), shoe (34), plate (35), bushing (36) and spring (37)). As aligning the spline of the bushing (36) and cylinder block (38), insert the piston cylinder sub assembly into the pump casing (25). IMPORTANT: Check the direction of the suction and delivery of the valve plate (49). 7. Align with pin (46) and install the valve plate (49) on the block (42).

3. Install the shaft with the bearing (6), spacer (5) and retaining ring (4) set on the support (28). NOTE: Install the outer ring of the bearing (6) while tapping with using a plastic hammer and install) the outer ring with using a steel bar completely.

W2-4-13

SWING MACHINERY / Pump Mechanism

14 15

W2CG-02-04-011

W2-4-14

SWING MACHINERY / Pump Mechanism IMPORTANT: Check the direction of the block (42). (Install the block (42) with the regulator (56) positioned upward and the suction flange positioned to the right.) 8. Install the block (43) on the pump casing (25) and tighten the socket bolt (29). : 17mm : 430 N m (44.0 kgf m) NOTE: If assembling the pump at rear side first, the assembling procedures are easy. Insert the gear (41) into the block (43) first and connect to the joint spline of shafts (7) and (51). IMPORTANT: Check the regulators (16) and (56) for the front and rear. 9. Insert the feedback pin (14) of the tilt pin (15) into the feedback lever of the regulators (16) and (56). Install the regulators (16), (56) and reduction gear (59). Tighten the socket bolts (17), (18) and flange socket (58). : 6 mm : 29 N m (3.0 kgf m) : 12 mm : 33 N m (3.4 kgf m) 10. Install the plug (24). : 36 mm : 170 N m (17.3 kgf m)

W2-4-15

SWING MACHINERY / Pump Mechanism MAINTENANCE STANDARD

1. Clearance between piston outer diameter and cylinder inner bore.

Standard

Allowable Limit

D-d

0.035 mm

0.062 mm

W25N-02-04-005

2. Clearance between piston and shoe calking portion

Standard

Allowable Limit

0 to 0.1 mm

0.3 mm

ˡ t

3. Shoe thickness

W25N-02-04-006

Standard

Allowable Limit

4.9 mm

4.7 mm

4. Free length of cylinder spring

Standard

Allowable Limit

39.5 mm

38.7 mm L

W25N-02-04-007

5. Combining height of plate and spherical bushing

H-h

Standard

Allowable Limit

23.0 mm

22.0 mm H h

W25N-02-04-008

W2-4-16

SWING MACHINERY / Pump Mechanism (Blank)

W2-4-17

SWING MACHINERY / Pump Mechanism DISASSEMBLE FRONT REGULATOR 3 11 10 9 8 21

6 5 1

23 16

24 25 26

29 30

27 28

44 41

43 42 40 36

37 38

31 32

47 47

35 34

56 54 55 58

52 51

W2CG-02-04-003

W2-4-18

SWING MACHINERY / Pump Mechanism 12345678910 11 12 13 14 15 -

Pin Sleeve O-Ring (2 Used) O-Ring Casing Piston Rod Spring Seat Spring Spring Adjusting Rod O-Ring Adjusting Rod Spring Spring Seat

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 -

Pin (2 Used) Lever Pin Pin Feedback Lever Lever Spool Sleeve Retaining Ring Set Spring Return Spring Spring Seat Retaining Ring Piston Socket Bolt (10 Used)

31 32 33 34 35 36 37 38 39 40 41 42 43 44

Cover O-Ring O-Ring (3 Used) O-Ring Plug (5 Used) Socket Bolt (2 Used) Socket Bolt (2 Used) O-Ring Adjusting Screw Adjusting Screw Nut (2 Used) O-Ring Cover Lock Nut

W2-4-19

45 46 47 48 49 50 51 52 53 54 55 56 57 58

Screw Casing Pin (2 Used) Plug O-Ring (2 Used) Retaining Ring (2 Used) Plug Pin O-Ring O-Ring (9 Used) O-Ring O-Ring Cover Socket Bolt (2 Used)

SWING MACHINERY / Pump Mechanism

11 10 9 8

13 14 15

23 24 25 26

27 28

44 41

43 45 40 36

48 30

54 51

54 58

W2CG-02-04-003

W2-4-20

SWING MACHINERY / Pump Mechanism Disassemble Front Regulator

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.

IMPORTANT: Put the rubber plate or cloth on the workbench not to damage the parts. As the parts are small, take care not to lose the parts.

1. Select the place to disassemble. NOTE: Select a clean place. 2. Remove the dust and rust on the surface of regulator with using washing oil. IMPORTANT: Take care not to lose the O-ring (54). 3. Remove the socket bolts (36) and (37). Remove the regulator from the pump. : 6 mm IMPORTANT: The adjusting screws (39), (40), adjusting rod (11), lock nut (44), nut (41) and screw (45) are installed on the cover (43). As the pressure-flow rate setting is changed, do not loosen these screws and nuts. 4. Remove the socket bolt (30) and remove the cover (43). : 5 mm

6. Remove the socket bolts (58) and (30). Remove the cover (57). After removing the cover (57), remove the set spring (25) from the pilot part. : 5 mm IMPORTANT: When removing the retaining ring (28), the return spring (26) flies out. Take care not to lose the return spring (26). 7. Remove the retaining ring (28) and remove the spring seat (27), return spring (26) and sleeve (23). NOTE: The retaining ring (24) is installed on the sleeve (23). 8. Remove the retaining ring (50) and remove the plugs (48) and (51). NOTE: The plugs (48) and (51) can be removed easily with using the bolt (M6).

W2-4-21

SWING MACHINERY / Pump Mechanism

22 16

W2CG-02-04-003

W2-4-22

SWING MACHINERY / Pump Mechanism IMPORTANT: Do not remove the pin (16). 9. Remove the lever (17). NOTE: The lever (17) can be removed easily with using a pair of tweezers.

10. Remove the pin (19) and remove the feedback lever (20). NOTE: Push out the pin (19) (pin dia. I4) from the top with using a thin steel bar not to touch with the lever (21). IMPORTANT: Do not remove the pin (16). 11. Remove the lever (21). 12. Pull out the piston (29) and spool (22). 13. Pull out the casing (5), piston (6) and rod (7). NOTE: When pushing out the rod (7) from the opposite side of the casing (5), the casing (5) can be removed.

W2-4-23

SWING MACHINERY / Pump Mechanism ASSEMBLE FRONT REGULATOR

32 36

45 33

25 37 21

47 19

50 48

57 28

29 53

27 26

44 39 41 40

W2CG-02-04-004

12345678910 11 12 13 14 15 -

Pin Sleeve O-Ring (2 Used) O-Ring Casing Piston Rod Spring Seat Spring Spring Adjusting Rod O-Ring Adjusting Rod Spring Spring Seat

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 -

Pin (2 Used) Lever Pin Pin Feedback Lever Lever Spool Sleeve Retaining Ring Set Spring Return Spring Spring Seat Retaining Ring Piston Socket Bolt (10 Used)

31 32 33 34 35 36 37 38 39 40 41 42 43 44

Cover O-Ring O-Ring (3 Used) O-Ring Plug (5 Used) Socket Bolt (2 Used) Socket Bolt (2 Used) O-Ring Adjusting Screw Adjusting Screw Nut (2 Used) O-Ring Cover Lock Nut

W2-4-24

45 46 47 48 49 50 51 52 53 54 55 56 57 58

Screw Casing Pin (2 Used) Plug O-Ring (2 Used) Retaining Ring (2 Used) Plug Pin O-Ring O-Ring (9 Used) O-Ring O-Ring Cover Socket Bolt (2 Used)

SWING MACHINERY / Pump Mechanism Assemble Front Regulator 1. Insert the rod (7) into the compensating hole of the casing (46).

5. Insert the piston (29) into the hole for the negative control on the casing (46).

2. Install the pin (16) on the lever (21). Insert the pin (16) into the groove of the rod (7). Install the pin (47) on the casing (46). Install the lever (21) into the pin (47).

NOTE: Check if the piston (29) moves smoothly.

IMPORTANT: Check if the spool (22) and sleeve (23) can move in the casing (46) smoothly. Check the direction of the spool (22).

6. Install the pin (16) on the lever (17). Insert the pin (16) into the groove of the piston (29). Install the lever (17). 7. Install the pin (47) to plug (48). Align the pin (47) with the pin hole on the lever (17) and install the plug (48). Install the retaining ring (50). IMPORTANT: Check the inserting holes for the plugs (48) and (51). 8. Insert the plug (51) and install the retaining ring (50).

20 W25N-02-04-011

3. Insert the spool (22) and sleeve (23) into the spool hole on the casing (46).

NOTE: Check if the feedback lever (20) has not too big play or moves smoothly. 9. Insert the return spring (26) and spring seat (27) into the spool hole and install retaining ring (28).

4. Install the feedback lever (20). Align the pin hole on the feedback lever (20) and insert the pin (19). NOTE: If the pin (19) is inserted into the feedback lever (20) first, the inserting procedure is easy. IMPORTANT: Check the direction of the feedback lever (20). Lever (21) Side

Lever (17) Side (Plugs (48, 51) Side)

W25N-02-04-012

W2-4-25

SWING MACHINERY / Pump Mechanism 14

45 41

44 39 41 40

W2CG-02-04-004

W2-4-26

SWING MACHINERY / Pump Mechanism 10. Insert the set spring (25) into the spool hole and insert the piston (6) and casing (5) into the compensating hole. Tighten the cover (57) with the socket bolts (58) and (30). : 5 mm : 12 Nᨿm (1.2kgfᨿm) IMPORTANT: Check the direction of the spring seat. 11. Insert the spring seat (15), spring (14) and adjusting rod (13) into the pilot hole. Insert the spring seat (8) and springs (10) and (9) into the compensating hole. 12. Install the adjusting screws (39), (40), adjusting rod (11), lock nut (44), nut (41) and screw (45) on the cover (43). Install the cover (43) and tighten socket bolt (30). : 5 mm : 12 Nᨿm (1.2kgfᨿm)

W2-4-27

SWING MACHINERY / Pump Mechanism DISASSEMBLE REAR REGULATOR

29 53

34 25 37

18 21

47 19

50 48

27 26

28 3

11 3

4 5

44 39 41 40

42 6

W2CG-02-04-005

W2-4-28

SWING MACHINERY / Pump Mechanism 12345678910 11 12 13 14 15 16 -

Pin Sleeve O-Ring (2 Used) O-Ring Casing Piston Rod Spring Seat Spring Spring Adjusting Rod O-Ring Adjusting Rod Spring Spring Seat Pin (2 Used)

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -

Lever Pin Pin Feedback Lever Lever Spool Sleeve Retaining Ring Set Spring Return Spring Spring Seat Retaining Ring Piston Socket Bolt (6 Used) Valve Casing O-Ring

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

O-Ring (2 Used) O-Ring Plug (7 Used) Socket Bolt (2 Used) Socket Bolt (2 Used) O-Ring Adjusting Screw Adjusting Screw Nut (2 Used) O-Ring Cover Lock Nut Screw Casing Pin (2 Used)

W2-4-29

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

Plug O-Ring (2 Used) Retaining Ring (2 Used) Plug Pin O-Ring O-Ring (9 Used) O-Ring O-Ring Cover Socket Bolt (2 Used) Socket Bolt (4 Used) O-Ring Reducing Valve

SWING MACHINERY / Pump Mechanism

45 13

15 54

25 37

50 48

27 26

44 39 41 40

W2CG-02-04-005

W2-4-30

SWING MACHINERY / Pump Mechanism Disassemble Rear Regulator

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.

2. Remove the dust and rust on the surface of regulator with using washing oil. IMPORTANT: Take care not to lose the O-ring (54). 3. Remove the socket bolts (36) and (37). Remove the regulator from the pump. : 6 mm IMPORTANT: The adjusting screws (39), (40), adjusting rod (11), lock nut (44), nut (41) and screw (45) are installed on the cover (43). As the pressure-flow rate setting is changed, do not loosen these screws and nuts. 4. Remove the socket bolt (30) and remove the cover (43). : 5 mm

5. After removing the cover (43) sub assembly, take out the springs (9), (10) and spring seat (8) from the compensating part. Pull out the adjusting rod (13), spring (14) and spring seat (15) from the pilot part. NOTE: The adjusting rod (13) can be removed easily with using the bolt (M4). 6. Remove the socket bolts (58) and (30). Remove the cover (57). After removing the cover (57), remove the set spring (25) from the pilot part. : 5 mm IMPORTANT: When removing the retaining ring (28), the return spring (26) flies out. Take care not to lose the return spring (26). 7. Remove the retaining ring (28) and remove the spring seat (27), return spring (26) and sleeve (23). NOTE: The retaining ring (24) is installed on the sleeve (23). 8. Remove the retaining ring (50) and remove the plugs (48) and (51). NOTE: The plugs (48) and (51) can be removed easily with using the bolt (M6).

W2-4-31

SWING MACHINERY / Pump Mechanism

22 19 21

17 16

20 5

W2CG-02-04-005

W2-4-32

SWING MACHINERY / Pump Mechanism IMPORTANT: Do not remove pin (16). 9. Remove lever (17). NOTE: The lever (17) can be removed easily with using a pair of tweezers. 10. Remove the pin (19) and remove the feedback lever (20). NOTE: Push out the pin (19) (pin dia. I 4) from the top with using a thin steel bar not to touch with the lever (21).

IMPORTANT: Do not remove pin (16). 11. Remove the lever (21). 12. Pull out the piston (29) and spool (22). 13. Pull out the casing (5), piston (6) and rod (7). NOTE: When pushing out the rod (7) from the opposite side of the casing (5), the casing (5) can be remove.

W2-4-33

SWING MACHINERY / Pump Mechanism ASSEMBLE REAR REGULATOR

29 53

34 25 37

18 21

47 19

50 48

27 26

28 3

11 3

4 5

44 39 41 40

42 6

W2CG-02-04-005

W2-4-34

SWING MACHINERY / Pump Mechanism 12345678910 11 12 13 14 15 16 -

Pin Sleeve O-Ring (2 Used) O-Ring Casing Piston Rod Spring Seat Spring Spring Adjusting Rod O-Ring Adjusting Rod Spring Spring Seat Pin (2 Used)

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -

Lever Pin Pin Feedback Lever Lever Spool Sleeve Retaining Ring Set Spring Return Spring Spring Seat Retaining Ring Piston Socket Bolt (6 Used) Valve Casing O-Ring

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

O-Ring (2 Used) O-Ring Plug (7 Used) Socket Bolt (2 Used) Socket Bolt (2 Used) O-Ring Adjusting Screw Adjusting Screw Nut (2 Used) O-Ring Cover Lock Nut Screw Casing Pin (2 Used)

W2-4-35

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

Plug O-Ring (2 Used) Retaining Ring (2 Used) Plug Pin O-Ring O-Ring (9 Used) O-Ring O-Ring Cover Socket Bolt (2 Used) Socket Bolt (4 Used) O-Ring Reducing Valve

SWING MACHINERY / Pump Mechanism

27 26 47 19 21

50 48

17 16

20 7

W2CG-02-04-005

W2-4-36

SWING MACHINERY / Pump Mechanism Assemble Rear Regulator 1. Insert the rod (7) into the compensating hole of the casing (46).

5. Inert the piston (29) into the hole for the negative control on the casing (46).

2. Install the pin (16) on the lever (21). Insert the pin (16) into the groove of the rod (7). Install the pin (47) on the casing (46). Install the lever (21) into the pin (47).

NOTE: Check if the piston (29) moves smoothly. 6. Install the pin (16) on the lever (17). Insert the pin (16) into the groove of the piston (29). Install the lever (17).

IMPORTANT: Check if the spool (22) and sleeve (23) can move in the casing (46) smoothly. Check the direction of the spool (22).

7. Install the pin (47) to plug (48). Align the pin (47) with the pin hole on the lever (17) and install the plug (48). Install the retaining ring (50). IMPORTANT: Check the inserting holes for the plugs (48) and (51). 8. Insert the plug (51) and nstall the retaining ring (50).

NOTE: Check if the feedback lever (20) has not too big play or moves smoothly. W25N-02-04-011

9. Insert the return spring (26) and spring seat (27) into the spool hole and install retaining ring (28).

3. Insert the spool (22) and sleeve (23) into the spool hole on the casing (46). 4. Install the feedback lever (20). Align the pin holes of the feedback lever (20) and insert the pin (19).

NOTE: If the pin (19) is inserted into the feedback lever (20) first, the inserting procedure is easy.

IMPORTANT: Check the direction of the feedback lever (20). Lever (21) Side

Lever (17) Side (Plugs (48, 51) Side)

W25N-02-04-012

W2-4-37

SWING MACHINERY / Pump Mechanism

45 13

15 58

44 39 41 40

W2CG-02-04-005

W2-4-38

IMPORTANT: Check the direction of the spring seat. 11. Insert the spring seat (15), spring (14) and adjusting rod (13) into the pilot hole. Insert the spring seat (8) and springs (10) and (9) into the compensating hole. 12. Install the adjusting screws (39), (40), adjusting rod (11), lock nut (44), nut (41) and screw (45) on the cover (43). Install the cover (43) and tighten socket bolt (30). : 5 mm : 12 Nᨿm(1.2kgfᨿm)

W2-4-39

SWING MACHINERY / Pump Mechanism (Blank)

W2-4-40

SWING MACHINERY / Pump Mechanism REMOVE AND INSTALL SWING PUMP

Preparation

1. Operate the control lever several times and release the remaining pressure in the circuit. 2. Remove the drain plug (1) and drain off the hydraulic oil with using a container (500 L). : 19mm

W2CG-02-04-010

Removal 1. Remove all hoses, pipings and wire harness from the swing pump. Cap the removed hoses. : 10 mm : 22 mm, 27 mm

2. Attach a wire rope on the swing pump and support the swing pump with the crane.

CAUTION: Swing pump weight: 45 kg 3. Remove the bolt (2). Lift the swing pump with the crane and remove it. : 14 mm M2CN-02-04-002

W2-4-41

SWING MACHINERY / Pump Mechanism Installation

CAUTION: Swing pump weight: 45 kg

1. Lift the swing pump with the crane and install it on the main pump.

2. Install the bolt (2). : 14 mm : 240 N m (24.0 kgf m) 2

3. Install all hoses, pipings and wire harness on the swing pump. Fill the hydraulic oil in the swing pump. : 10 mm : 90 N m (9.2 kgf m) : 22 mm : 39 N m (4.0 kgf m) : 27 mm : 93 N m (9.5 kgf m) 4. Remove the filler port cover of the hydraulic oil. Apply the hydraulic oil to a specified position of the level gauge. 5. Start the engine and run at low idling speed. Release the air in the swing pump. 6. Do the work at low idling speed after releasing the air. Check the hydraulic oil level and any oil leaks.

W2-4-42

M2CN-02-04-002

SWING MACHINERY / Pump Mechanism (Blank)

W2-4-43

SWING MACHINERY / Pump Mechanism DISASSEMBLE SWING PUMP 51

17 18 45 44 43

38 37

W2CG-02-04-007

1 - Stopper

15 - O-Ring

28 - O-Ring (2 Used)

41 - Bearing

2 - Backup Ring

16 - Screw

29 - Nut

42 - Spacer (2 Used)

3 - O-Ring

17 - Valve Plate

30 - Eye Bolt

43 - Shaft

4 - Cylinder Block

18 - Cover

31 - Pump Casing

44 - Oil Seal

5 - Servo Piston

19 - Socket Bolt (2 Used)

32 - Socket Bolt (4 Used)

45 - Socket Bolt (4 Used)

6 - Shoe (9 Used)

20 - Cover

33 - Bushing

46 - O-Ring

7 - Bushing

21 - O-Ring (2 Used)

34 - Plate

47 - Spring Pin (2 Used)

8 - Tilt Pin

22 - Bearing

35 - Plate

48 - Lock Nut (2 Used) 49 - Screw

23 - Plug

36 - Plug (7 Used)

10 - Piston (9 Used)

9 - Feedback Pin

24 - O-Ring

37 - Support

50 - Socket Bolt (4 Used)

11 - O-Ring

25 - Pin

38 - Plate

51 - Regulator

12 - Backup Ring

26 - Spring (9 Used)

39 - Cover

52 - Socket Bolt (2 Used)

13 - Stopper

27 - Plug (2 Used)

40 - Retaining Ring

53 - Socket Bolt (2 Used)

14 - O-Ring (9 Used)

W2-4-44

SWING MACHINERY / Pump Mechanism Disassemble Swing Pump

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” before disassembling.

IMPORTANT: Put the rubber plate and cloth on the workbench not to damage the parts.

IMPORTANT: Do not damage the sliding surfaces of the cylinder block (4), bushing (34), shoe (6) and plate (38).

1. Select the place to disassemble. NOTE: Select a clean place. 2. Remove the dust and rust on the surface of the pump with using washing oil. 3. Remove the plug (27) and drain the oil from the pump casing (31). : 27 mm 4. Remove the socket bolts (52) (2 used) and (53) (2 used). Remove the regulator (51). : 6 mm NOTE: As for disassembly of the regulator (51), refer to the corresponding section. 5. Loosen the socket bolts (32) (4 used) that connect the support (37), pump casing (31) and cover (18). : 14 mm IMPORTANT: Put the rubber plate or cloth on the workbench not to damage the mounting surface of the regulator when positioning the regulator mounting surface downward.

7. Pull out the cylinder block (4) from the pump casing (31) straightly to the shaft (43). At the same time, remove the piston (10) (9 used), plate (34), bushing (33) and spring (26) (9 used). IMPORTANT: As the oil seal (44) is installed on the cover (39), take care not to damage the oil seal (44) when removing. 8. Remove the socket bolt (45) (4 used) and remove the cover (39). : 5 mm 9. Tap the mounting flange part of the support (37) from the pump casing (31) side and separate the support (37) from the pump casing (31). 10. Remove the plates (35) and (38) from the pump casing (31). 11. As tapping the shaft end part of shaft (43) with using a plastic hammer, remove the shaft (43) from the support (37). 12. Remove the valve plate (17) from the cover (18). NOTE: The valve plate (17) may be removed at the step 6.

6. Place the pump onto the workbench horizontally with positioning the mounting surface downward. Separate the cover (18) from pump casing (31).

W2-4-45

SWING MACHINERY / Pump Mechanism

48 18

W2CG-02-04-007

W2-4-46

SWING MACHINERY / Pump Mechanism IMPORTANT: When removing the tilt pin (8), use a special tool not to damage the head of the tilt pin (8). As LOCTITE is applied on the fitting part between the tilt pin (8) and the servo piston (5), take care not to damage the servo piton (5). Do not remove the bearing (22) except replacement. As the setting of flow rate changes, do not loosen the lock nut (48) of the cover (18) and support (37). 13. If necessary, remove the stoppers (13), (1), servo piston (5) and tilt pin (8) from the pump casing (31) and remove the bearing (22) from the cover (18).

W2-4-47

SWING MACHINERY / Pump Mechanism ASSEMBLE SWING PUMP 51

8,9

17 18 45 44 42 43

41 40 39

38 37

W2CG-02-04-007

12345678910 11 12 13 14 -

Stopper Backup Ring O-Ring Cylinder Block Servo Piston Shoe (9 Used) Bushing Tilt Pin Feedback Pin Piston (9 Used) O-Ring Backup Ring Stopper O-Ring (9 Used)

15 16 17 18 19 20 21 22 23 24 25 26 27

O-Ring Screw Valve Plate Cover Socket Bolt (2 Used) Cover O-Ring (2 Used) Bearing Plug O-Ring Pin Spring (9 Used) Plug (2 Used)

28 29 30 31 32 33 34 35 36 37 38 39 40

O-Ring (2 Used) Nut Eye Bolt Pump Casing Socket Bolt (4 Used) Bushing Plate Plate Plug (7 Used) Support Plate Cover Retaining Ring

W2-4-48

41 42 43 44 45 46 47 48 49 50 51 52 53

Bearing Spacer (2 Used) Shaft Oil Seal Socket Bolt (4 Used) O-Ring Spring Pin (2 Used) Lock Nut (2 Used) Screw Socket Bolt (4 Used) Regulator Socket Bolt (2 Used) Socket Bolt (2 Used)

SWING MACHINERY / Pump Mechanism Assemble Swing Pump IMPORTANT: When tightening the servo piston (5) and tilt pin (8), use a special tool not to damage the head of the tilt pin (8) and feedback pin (9). Apply LOCTITE (medium intensity) on the thread part. 1. Install the support (37) on the pump casing (31) while tapping with using a hammer. NOTE: When the servo piston (5), tilt pin (8), stoppers (1) and (13) are removed, install them on the pump casing (31) first. 2. Place the pump casing (31) with positioning the mounting surface for regulator downward. Insert the bushing (7) of the plate (38) into the tilt pin (8). Install the plate (38) on the support (37) correctly. NOTE: Check if the plate (38) can move smoothly by fingers. If the grease is applied on the plate (38) and support (37) and moving portion, the shaft (43) can be installed easily. IMPORTANT: Do not hit the shaft (43) with using a hammer. 3. Install the shaft (43) with the bearing (41), spacer (42) (2 used) and retaining ring (40) set on the support (37). NOTE: Tap the outer ring of the bearing (41) with using a plastic hammer and insert the bearing (41) with using a steel bar completely.

IMPORTANT: Take care not to damage oil seal (44) when installing. 4. Install the cover (39) on the pump casing (31) and secure with the socket bolts (45) (4 used). : 5 mm : 93 N m (9.5 kgf m) NOTE: Slightly apply the grease on the oil seal (44) in the cover (39). 5. Assemble the piston cylinder sub assembly (cylinder block (4), pistons (10) (9 used), shoe (6) (9 used), plate (34), bushing (33) and springs (26) (9 used)). Align the splines of bushing (33) and cylinder block (4) and insert the piston cylinder sub assembly in the pump casing (31). IMPORTANT: Check the direction of suction and delivery of the valve plate (17). 6. As aligning with pin (25), install the valve plate (17) on the cover (18). 7. Install the cover (18) on the pump casing (31). Tighten the socket bolts (32) (4 used). : 14 mm : 240 N m (24.0 kgf m) 8. Insert the feedback pin (9) of the tilt pin (8) in the feedback lever of the regulator (51) and install the regulator (51). Tighten the socket bolts (52) (2 used) and (53) (2 used). : 6 mm : 29 N m (3.0 kgf m) 9. Install the plug (27). : 27 mm : 110 N m (11.0 kgf m)

W2-4-49

SWING MACHINERY / Pump Mechanism MAINTENANCE STANDARD

1. Clearance between piston outer diameter and cylinder inner bore.

D-d

Standard

Allowable Limit

0.028 mm

0.056 mm

W25N-02-04-005

2. Clearance between piston and shoe calking portion

Standard

Allowable Limit

0 to 0.1 mm

0.3 mm ˡ t

3. Shoe thickness

W25N-02-04-006

Standard

Allowable Limit

3.9 mm

3.7 mm

4. Free length of cylinder spring

Standard

Allowable Limit

31.3 mm

30.5 mm L

W25N-02-04-007

5. Combining height of plate and spherical bushing

H-h

Standard

Allowable Limit

19.0 mm

18.3 mm

H h

W25N-02-04-008

W2-4-50

SWING MACHINERY / Pump Mechanism (Blank)

W2-4-51

SWING MACHINERY / Pump Mechanism DISASSEMBLE REGULATOR

60 61

49 33

49,59

25 37

50 51

17 16 20

11 3

4 5

39 41 40

28 48

42 6

W2CG-02-04-008

W2-4-52

SWING MACHINERY / Pump Mechanism 12345678910 11 12 13 14 15 16 -

Pin Sleeve O-Ring (2 Used) O-Ring (2 Used) Casing Piston Rod Spring Seat Spring Spring Adjusting Rod O-Ring Adjusting Rod Spring Spring Seat Pin (2 Used)

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -

Lever Pin Pin Feedback Lever Lever Spool Sleeve Retaining Ring Set Spring Return Spring Spring Seat Retaining Ring Piston Socket Bolt (8 Used) Cover Socket Bolt (5 Used)

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 -

O-Ring (2 Used) O-Ring Plug (8 Used) Socket Bolt (2 Used) Socket Bolt (2 Used) O-Ring Adjusting Screw Adjusting Screw Nut (2 Used) O-Ring Cover Lock Nut Screw Casing Pin (2 Used) Plug

W2-4-53

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

O-Ring (5 Used) Retaining Ring (2 Used) Plug Pin O-Ring O-Ring (12 Used) O-Ring O-Ring Cover Reducing Valve Plug Seat (2 Used) Stopper (2 Used) Ball (2 Used)

SWING MACHINERY / Pump Mechanism

25 37

44 39 41 40

28 51 48

W2CG-02-04-008

W2-4-54

SWING MACHINERY / Pump Mechanism Disassemble Regulator

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.

IMPORTANT: Put the rubber plate or cloth on the workbench not to damage the parts. As the parts are small, take care not to lose the parts. 1. Select the place to disassemble. NOTE: Select a clean place. 2. Remove the dust and rust on the surface of regulator with using washing oil. IMPORTANT: Take care not to lose the O-ring (4). 3. Remove the socket bolts (36) and (37). Remove the regulator from the pump. : 6 mm IMPORTANT: The adjusting screws (39), (40), adjusting rod (11), lock nut (44), nut (41) and screw (45) are installed on the cover (43). As the pressure-flow rate setting is changed, do not loosen these screws and nuts. 4. Remove the socket bolt (30) and remove the cover (43). : 5 mm

5. After removing the cover (43) sub assembly, take out the springs (9), (10) and spring seat (8) from the compensating part. Pull out the adjusting rod (13), spring (14) and spring seat (15) from the pilot part. NOTE: The adjusting rod (13) can be removed easily with using the bolt (M4). 6. Remove the socket bolt (32) and remove the cover (57). After removing the cover (57), remove the set spring (25) from the pilot part. : 5 mm IMPORTANT: When removing the retaining ring (28), the return spring (26) flies out. Take care not to lose the return spring (26). 7. Remove the retaining ring (28) and remove the spring seat (27), return spring (26) and sleeve (23). NOTE: The retaining ring (24) is installed on the sleeve (23). 8. Remove the retaining ring (50) and remove the plugs (48) and (51). NOTE: The plugs (48) and (51) can be removed easily with using the bolt (M6).

W2-4-55

SWING MACHINERY / Pump Mechanism

22 21

17 16 20 5

W2CG-02-04-008

W2-4-56

W2-4-57

SWING MACHINERY / Pump Mechanism ASSEMBLE REGULATOR

60 61

49 33

49,59

25 37

50 51

17 16 20

11 3

4 5

39 41 40

28 48

42 6

W2CG-02-04-008

W2-4-58

SWING MACHINERY / Pump Mechanism 12345678910 11 12 13 14 15 16 -

Pin Sleeve O-Ring (2 Used) O-Ring (2 Used) Casing Piston Rod Spring Seat Spring Spring Adjusting Rod O-Ring Adjusting Rod Spring Spring Seat Pin (2 Used)

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -

Lever Pin Pin Feedback Lever Lever Spool Sleeve Retaining Ring Set Spring Return Spring Spring Seat Retaining Ring Piston Socket Bolt (8 Used) Cover Socket Bolt (5 Used)

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

O-Ring (2 Used) O-Ring Plug (8 Used) Socket Bolt (2 Used) Socket Bolt (2 Used) O-Ring Adjusting Screw Adjusting Screw Nut (2 Used) O-Ring Cover Lock Nut Screw Casing Pin (2 Used)

W2-4-59

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

Plug O-Ring (5 Used) Retaining Ring (2 Used) Plug Pin O-Ring O-Ring (12 Used) O-Ring O-Ring Cover Reducing Valve Plug Seat (2 Used) Stopper (2 Used) Ball (2 Used)

SWING MACHINERY / Pump Mechanism

27 21

50 28 51 48

17 16 20 7

W2CG-02-04-008

W2-4-60

SWING MACHINERY / Pump Mechanism Assemble Regulator 1. Insert the rod (7) into the compensating hole of the casing (46).

5. Inert the piston (29) into the hole for the negative control on the casing (46).

2. Install the pin (16) on the lever (21). Insert the pin (16) into the groove of the rod (7). Install the pin (47) on the casing (46). Install the lever (21) into the pin (47).

NOTE: Check if the piston (29) moves smoothly.

IMPORTANT: Check if the spool (22) and sleeve (23) can move in the casing (46) smoothly. Check the direction of the spool (22).

NOTE: Check if the feedback lever (20) has not too big play or moves smoothly. W25N-02-04-011

3. Insert the spool (22) and sleeve (23) into the spool hole on the casing (46).

9. Insert the return spring (26) and spring seat (27) into the spool hole and install retaining ring (28).

4. Install the feedback lever (20). Align the pin holes of the feedback lever (20) and insert the pin (19). NOTE: If the pin (19) is inserted into the feedback lever (20) first, the inserting procedure is easy. IMPORTANT: Check the direction of the feedback lever (20). Lever (21) Side

Lever (17) Side (Plugs (48, 51) Side)

W25N-02-04-012

W2-4-61

SWING MACHINERY / Pump Mechanism

45 41

44 39 40

W2CG-02-04-008

W2-4-62

SWING MACHINERY / Pump Mechanism 10. Insert the set spring (25) into the spool hole and insert the piston (6) and casing (5) into the compensating hole. Tighten the cover (57) with the socket bolts (58) and (30). : 5 mm : 12 Nᨿm (1.2 kgfᨿm) IMPORTANT: Check the direction of the spring seat. 11. Insert the spring seat (15), spring (14) and adjusting rod (13) into the pilot hole. Insert the spring seat (8) and springs (10) and (9) into the compensating hole. 12. Install the adjusting screws (39), (40), adjusting rod (11), lock nut (44), nut (41) and screw (45) on the cover (43). Install the cover (43) and tighten socket bolt (30). : 5 mm : 12 Nᨿm (1.2 kgfᨿm)

W2-4-63

SWING MACHINERY / Pump Mechanism (Blank)

W2-4-64

SWING MACHINERY / Pump Mechanism REMOVE AND INSTALL GEAR PUMP (FOR OIL COOLER) CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Before draining hydraulic oil, lower the boom and apply each brake and drum lock.

Preparation 1. Shutdown the engine. Operate the control lever several times and release the remaining pressure in the circuit. 2. Remove the drain plug (1) and drain off the hydraulic oil with using the container (500 L). : 19mm

W2CG-02-04-010

Removal 1. Remove all hoses and pipings from the gear pump (for oil cooler). Cap the removed hoses. : 32 mm

2. Support the gear pump (for oil cooler).

CAUTION: Gear pump (for oil cooler) weight: 4.2 kg 3. Remove the bolt (2) and remove the gear pump (for oil cooler). : 17 mm

M2CN-02-04-003

W2-4-65

SWING MACHINERY / Pump Mechanism Installation

CAUTION: Gear pump (for oil cooler) weight: 4.2 kg

1. Connect the gear pimp (for oil cooler) to the swing pump.

2. Apply LOCTITE on the bolt (2) and install. : 17 mm : 41 to 45 N m (4.2 to 4.6 kgf m)

3. Install all hoses and pipings on the gear pump (for oil cooler). Fill the hydraulic oil in the gear pump (for oil cooler). : 27 mm : 93 N m (9.5 kgf m) : 32 mm : 137 N m (14.0 kgf m)

4. Remove the filler port cover of the hydraulic oil tank. Fill the hydraulic oil to a specified position of the level gauge. 5. Start the engine and run at low idling speed. Release the air in the gear pump (for oil cooler). 6. After releasing the air, do the work at low idling speed. Check the hydraulic oil level and any oil leaks.

M2CN-02-04-003

W2-4-66

SWING MACHINERY / Pump Mechanism (Blank)

W2-4-67

SWING MACHINERY / Pump Mechanism DISASSEMBLE GEAR PUMP (FOR OIL COOLER)

M2CN-02-04-004

1234-

Drive Gear Front Cover Gasket (2 Used) Side Plate (2 Used)

5678-

Body Rear Cover Socket Bolt (4 Used) Washer (4 Used)

910 11 12 -

Bushing (4 Used) Driven Gear Oil Seal Retaining Ring

W2-4-68

13 - Gasket (2 Used) 14 - Backup Ring (2 Used)

SWING MACHINERY / Pump Mechanism Disassemble Gear Pump (For Oil Cooler)

•

Thoroughly read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-11-1) before disassembling.

10. Remove the gaskets (3), (13), side plate (4) and backup ring (14). 11. Remove the bushing (9) from the front cover (2).

NOTE: Although the gaskets (3,13), side plate (4) and backup ring (14) are the same type, the directions to install are different. Put a tag on part for reassembly when disassembling. The driven gear (10) is symmetrical with respect to the front/rear. Put an identification mark (front or rear) on the shaft when disassembling.

12. Remove the front cover (2) from the vise. 13. Remove the retaining ring (12). 14. Remove the oil seal (11).

1. Remove the dust and rust on the surface of the pump with using washing oil.

2. Turn the rear cover (6) side upward. Clamp the mounting part of front cover (2) in a vise. 3. Put the matching marks on the matching part in the drive side of front cover (2), body (5), and rear cover (6). 4. Remove the socket bolt (7). : 10 mm

M2CN-02-04-005

5. Remove the rear cover (6). 6. Remove the gaskets (3), (13), side plate (4) and Backup Ring (14). 7. Remove the bushing (9) from the rear cover (6). 8. Remove the drive gear (1) and driven gear (10). 9. Remove the body (5).

W2-4-69

SWING MACHINERY / Pump Mechanism ASSEMBLE GEAR PUMP (FOR OIL COOLER)

M2CN-02-04-004

1 - Drive Gear 2 - Front Cover 3 - Gasket (2 Used) 4 - Side Plate (2 Used)

5678-

Body Rear Cover Socket Bolt (4 Used) Washer (4 Used)

910 11 12 -

Bushing (4 Used) Driven Gear Oil Seal Retaining Ring

W2-4-70

13 - Gasket (2 Used) 14 - Backup Ring (2 Used)

SWING MACHINERY / Pump Mechanism Assemble Gear Pump (For Oil Cooler)

• Replace all oil seals and gaskets with the new ones. Before assembling, clean each part with using clean washing oil and dry. Apply the clean hydraulic oil on the inner parts. Specially, apply the hydraulic oil on the sliding to prevent it from seizing. IMPORTANT: Assemble the gaskets (3), (13), side plate (4) and backup ring (14) correctly with taking care about the used places and installing directions as referring to the tag marked when disassembling. Assemble the gears (1) and (10) so that they mesh each other. NOTE: Secure the gaskets (3), (13), side plate (4) and Backup Ring (14) on the groove with using grease and they are not bitten. Align the matching marks of each drive side when assembling the front cover (2), body (5) and rear cover (6). Check the direction of the matching mark on the shaft when installing the driven gears (10). 1. Secure the front cover (2) with turning the mounting surface for body (5) upward in a vise. 2. Install the bushing (9) on the front cover (2). 3. Install the gaskets (3), (13), side plate (4) and backup ring (14) on the front cover (2). 4. Install the body (5) on the front cover (2).

W2-4-71

SWING MACHINERY / Pump Mechanism

M2CN-02-04-004

1234-

Drive Gear Front Cover Gasket (2 Used) Side Plate (2 Used)

5678-

Body Rear Cover Socket Bolt (4 Used) Washer (4 Used)

910 11 12 -

Bushing (4 Used) Driven Gear Oil Seal Retaining Ring

W2-4-72

13 - Gasket (2 Used) 14 - Backup Ring (2 Used)

SWING MACHINERY / Pump Mechanism 5. Install the drive gear (1) and driven gear (10) on the body (5). 6. Install the bushing (9) on the front cover (2). 7. Install the gaskets (3), (13), side plate (4) and backup ring (14) on the rear cover (2). 8. Install the rear cover (6) on the body (5). 9. Install the socket bolt (7). : 10 mm

10. Turn over the pump with so that the oil seal (11) installing side faces upward. Clamp the pump in a vise. 11. Fill the grease between the main lip and the dust lip of the oil seal (11).

Dust Lip Fill grease. Main Lip

W25N-02-04-021

W2-4-73

SWING MACHINERY / Pump Mechanism IMPORTANT: Take care not to damage the oil seal (11). 14. Install the oil seal (11) on the front cover (2) with using a guide and pipe.

Pipe

Guide

11 2

M2CN-02-04-006

15. Install the retaining ring (12).

M2CN-02-04-007

W2-4-74

SWING MACHINERY / Pump Mechanism REMOVE AND INSTALL 2-UNIT GEAR PUMP CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Before draining hydraulic oil, lower the boom and apply each brake and drum lock.

W2CG-02-04-010

Removal 2

1. Remove all hoses and pipings from the 2-unit gear pump. Cap the removed hoses. : 8 mm : 27 mm 2. Support the 2-unit gear pump.

CAUTION: 2-unit gear pump weight: 7.6 kg 3. Remove the bolt (2) and remove the 2-unit gear pump. : 8 mm

M2CN-02-04-008

W2-4-75

SWING MACHINERY / Pump Mechanism Installation

CAUTION: 2-unit gear pump weight: 7.6 kg

1. Connect the gear pump to the reduction gear of the main pump.

2. Apply LOCTITE on the bolt (2) and install. : 8 mm : 25 to 25.6 N m (2.5 to 2.6 kgf m)

3. Install all hoses and pipings on the 2-unit gear pump. Fill the hydraulic oil in the gear pump. : 8 mm : 48 to 50 N m (4.9 to 5.1 kgf m) : 27 mm : 93 N m (9.5 kgf m)

4. Remove the filler port cover of the hydraulic oil tank. Fill the hydraulic oil to a specified position of the level gauge. 5. Start the engine and run at low idling speed. Release the air in the gear pump. 6. After releasing the air, do the work at low idling speed. Check the hydraulic oil level and any oil leaks.

M2CN-02-04-008

W2-4-76

SWING MACHINERY / Pump Mechanism (Blank)

W2-4-77

SWING MACHINERY / Pump Mechanism DISASSEMBLE 2-UNIT GEAR PUMP

8 6 5 13

4 3 2 1 7

12 6

5 4

4 5 6

5 6

W25N-02-04-017

1234-

Retaining Ring Oil Seal Front Cover Gasket (4 Used)

5678-

Gasket (4 Used) Side Plate (4 Used) Driven Gear Drive Gear

910 11 12 -

Body Adapter Plate Driven Gear Drive Gear

W2-4-78

13 14 15 16 -

Body Rear Cover Washer (4 Used) Socket Bolt (4 Used)

SWING MACHINERY / Pump Mechanism Disassemble 2-Unit Gear Pump

•

Thoroughly read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-11-1) before disassembling.

NOTE: Although the gaskets (4), (5) and side plate (6) are the same type, the directions to install are different. Put a tag on each block for reassembly when disassembling. The driven gears (7) and (11) are symmetrical with respect to the front/rear. Put an identification mark (front or rear) on the shaft when disassembling. 1. Remove the dust and rust on the surface of the pump with using washing oil. 2. Turn the rear cover (14) side upward. Clamp the mounting part of front cover (3) in a vise.

9. Remove the gaskets (4), (5) and side plate (6). 10. Remove the adapter plate (10). 11. Remove the gaskets (4), (5) and side plate (6). 12. Remove the body (9). 13. Remove the gaskets (4), (5) and side plate (6). 14. Remove the drive gear (8) and driven gear (7). 15. Remove the front cover (3) from the vise. 16. Remove the retaining ring (1). 17. Remove the oil seal (2).

3. Put the matching marks on the matching part in the drive side of front cover (3), body (9), adapter plate (10), body (13) and rear cover (14).

4. Remove the socket bolt (16). : 10 mm 5. Remove the rear cover (14). 3

6. Remove the gaskets (4), (5) and side plate (6). 7. Remove the drive gear (12) and driven gear (11).

W25N-02-04-018

8. Remove the body (13).

W2-4-79

SWING MACHINERY / Pump Mechanism ASSEMBLE 2-UNIT GEAR PUMP

W25N-02-04-024

12345-

Retaining Ring Oil Seal Front Cover Gasket (4 Used) Gasket (4 Used)

678910 -

Side Plate (4 Used) Driven Gear Drive Gear Body Adapter Plate

11 12 13 14 15 -

Driven Gear Drive Gear Body Rear Cover Washer (4 Used)

W2-4-80

16 17 18 19

Socket Bolt (4 Used) Bushing (8 Used) Plug O-Ring

SWING MACHINERY / Pump Mechanism Assemble 2-Unit Gear Pump

Delivery Side

Short Pulling-Out Hole

Suction Side Long Pulling-Out Hole

W25N-02-04-022

NOTE: Secure the gaskets (4), (5) and side plate (6) on the groove with using grease and they are not bitten. Align the matching marks of each drive side when assembling the front cover (3), body (9), adapter plate (10), body (13) and rear cover (14). Check the direction of the matching mark on each shaft when installing the driven gears (7) and (11).

Rotating Direction of Drive Gear Large Notch (No Bound Side)

1. Secure the front cover (3) with turning the mounting surface for body (9) upward in a vise.

Delivery Side

Small Notch (Bound Side)

Suction Side

Rotating Direction of Driven Gear W25N-02-04-023

2. Install the gaskets (4), (5) and side plate (6) on the front cover (3). 3. Install the body (9) on the front cover (3).

W2-4-81

SWING MACHINERY / Pump Mechanism

W25N-02-04-024

12345-

Retaining Ring Oil Seal Front Cover Gasket (4 Used) Gasket (4 Used)

678910 -

Side Plate (4 Used) Driven Gear Drive Gear Body Adapter Plate

11 12 13 14 15 -

Driven Gear Drive Gear Body Rear Cover Washer (4 Used)

W2-4-82

16 17 18 19

Socket Bolt (4 Used) Bushing (8 Used) Plug O-Ring

SWING MACHINERY / Pump Mechanism 4. Install the drive gear (8) and driven gear (7) on the body (9). 5. Install the gaskets (4), (5) and side plate (6) at the front and rear surfaces of the adapter plate (10). 6. Install the adapter plate (10) on the body (9). 7. Install the body (13) on the adapter plate (10). 8. Install the drive gear (12) and driven gear (11) on the body (13). 9. Install the gaskets (4), (5) and side plate (6) on the rear cover (14). 10. Install the rear cover (14) on the body (13). 11. Install the socket bolt (16). : 10 mm : 88.2 to 93.1 N m (9.0 to 9.5 kgf m) 12. Turn over the pump with so that the oil seal (2) installing side faces upward. Clamp the pump in a vise. 13. Fill the grease between the main lip and the dust lip of the oil seal (2).

2 Dust Lip Fill grease. Main Lip

W25N-02-04-021

W2-4-83

SWING MACHINERY / Pump Mechanism IMPORTANT: Take care not to damage the oil seal (2). 14. Install the oil seal (2) on the front cover (3) with using a guide and pipe.

Pipe

Guide

2 3

W25N-02-04-019

15. Install the retaining ring (1).

W25N-02-04-020

W2-4-84

SWING MACHINERY / Pump Mechanism REMOVE AND INSTALL GEAR PUMP (FOR REEVING WINCH) CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Before draining hydraulic oil, lower the boom and apply each brake and drum lock.

W2CG-02-04-010

Removal 1. Remove all hoses and pipings from the great pump (for reeving winch). Cap the removed hoses. : 27.36mm 2. Support the gear pump (for reeving winch).

CAUTION: Gear pump (for reeving winch) weight: 2.3 kg 3. Remove the bolt (2) and remove the gear pump (for reeving winch). : 8 mm M2CN-02-04-009

W2-4-85

SWING MACHINERY / Pump Mechanism Installation

CAUTION: Gear pump (for reeving winch) weight: 2.3 kg

1. Connect the gear pump (for reeving winch) to the reduction gear of the main pump.

2. Install the gear pump (for reeving winch) mounting bolt (2). : 8 mm : 50 N m (5.1 kgf m)

3. Install all hoses and pipings on the gear pump. Fill the hydraulic oil in the gear pump. : 27 mm : 93 N m (9.5 kgf m) : 36 mm : 175 N m (18.0 kgf m) 4. Remove the filler port cover of the hydraulic oil tank. Fill the hydraulic oil to a specified position of the level gauge. 5. Start the engine and run at low idling speed. Release the air in the gear pump (for reeving winch). 6. After releasing the air, do the work at low idling speed. Check the hydraulic oil level and any oil leaks.

M2CN-02-04-009

W2-4-86

SWING MACHINERY / Pump Mechanism (Blank)

W2-4-87

SWING MACHINERY / Pump Mechanism DISASSEMBLE GEAR PUMP (FOR REEVING WINCH)

7 6 5 4

3 2 1

13 12

11 10 6 7

W23F-02-04-012

1234-

Retaining Ring Oil Seal Front Cover Bush (2 Used)

5678-

Gasket Gasket (2 Used) Side Plate (4 Used) Driven Gear

9 - Drive Gear 10 - Bush (2 Used) 11 - Ball (2 Used)

W2-4-88

12 - Rear Cover 13 - Washer (4 Used) 14 - Socket Bolt (4 Used)

SWING MACHINERY / Pump Mechanism Disassemble Gear Pump (For Reeving Winch)

•

Thoroughly read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-11-1) before disassembling.

NOTE: Although the gaskets (5), (6) and side plate (7) are the same type, the directions to install are different. Put a tag on each block for reassembly when disassembling. The driven gears are symmetrical with respect to the front/rear. Put an identification mark (front or rear) on the shaft when disassembling.

10. Remove the front cover (3) from the vise. 11. Remove the retaining ring (1). 12. Remove the oil seal (2).

1. Remove the dust and rust on the surface of the pump with using washing oil. 2. Turn the rear cover (12) side upward. Clamp the mounting part of front cover (3) in a vise. 3. Put the matching marks on the matching part in the drive side of front cover (3) and rear cover (12). 4. Remove the socket bolt (14). : 10 mm 5. Remove the rear cover (12). 6. Remove the Bush (10), gaskets (6) and side plate (7). 7. Remove the drive gear (9) and driven gear (8). 8. Remove the gasket (5), (6) and side plate (7). 9. Remove the ball (11) and bushing (4).

W2-4-89

W23F-02-04-013

SWING MACHINERY / Pump Mechanism ASSEMBLE GEAR PUMP (FOR REEVING WINCH) 9

1 6 2

4 6

W23F-02-04-014

1234-

Retaining Ring Oil Seal Front Cover Bushing (2 Used)

5678-

Gasket Gasket (2 Used) Side Plate (2 Used) Driven Gear

9 - Drive Gear 10 - Bushing (2 Used) 11 - %DOO 8VHG

W2-4-90

12 - Rear Cover 13 - Washer (4 Used) 14 - Socket Bolt (4 Used)

SWING MACHINERY / Pump Mechanism Assemble Gear Pump (For Reeving Winch)

• Replace all oil seals and gaskets with the new ones. Before assembling, clean each part with using clean washing oil and dry. Apply the clean hydraulic oil on the inner parts. Specially, apply the hydraulic oil on the sliding to prevent it from seizing. IMPORTANT: Install the gasket (6) so that the flat surface is located at the front cover (3) and rear cover (12) side. Assemble the side plate (7) so that the opposite side against the gasket (6) mounting surface faces the gear side and the pulling-out hole faces the delivery side. The teeth of the gears (7) and (8) are asymmetrical. Mesh the gears with the small notch each other and assemble them. NOTE: Secure the gaskets (5), (6) and side plate (7) on the groove with using grease and they are not bitten. Align the matching marks of each drive side when assembling the front cover (3) and rear cover (12). Check the direction of the matching mark on each shaft when installing the driven gears (8).

Delivery Side

Suction Side

Short Pulling-Out Hole

W23F-02-04-015

Rotating Direction of Drive Gear Large Notch (No Bound Side)

1. Secure the front cover (3) with turning the mounting surface for rear cover (12) upward in a vise. 2. Install the bushing (4) on the front cover (3). 3. Install the gasket (5), (6) and side plate (7) on the front cover (3).

W2-4-91

Delivery Side

Small Notch (Bound Side)

Suction Side

Rotating Direction of Driven Gear W25N-02-04-023

SWING MACHINERY / Pump Mechanism 9

1 6 2

4 6

W23F-02-04-014

1234-

Retaining Ring Oil Seal Front Cover Bushing (2 Used)

5678-

Gasket Gasket (2 Used) Side Plate (2 Used) Driven Gear

9 - Drive Gear 10 - Bushing (2 Used) 11 - %DOO 8VHG

W2-4-92

12 - Rear Cover 13 - Washer (4 Used) 14 - Socket Bolt (4 Used)

SWING MACHINERY / Pump Mechanism 4. Install the drive gear (9) and driven gear (8) on the front cover (3). 5. Install the ball (11) on the front cover (3). 6. Install the bushing (10) on the rear cover (12). 7. Install the gaskets (6) and side plate (7) on the rear cover (12). 8. Install the rear cover (14) on the front cover (3). 9. Install the socket bolt (14) with washer (13). : 10 mm : 88.2 to 93.1 N m (9.0 to 9.5 kgf m) 10. Turn over the pump with so that the oil seal (2) installing side faces upward. Clamp the pump in a vise. 2

11. Fill the grease between the main lip and the dust lip of the oil seal (2).

Dust Lip Fill grease. Main Lip

W25N-02-04-021

IMPORTANT: Take care not to damage the oil seal (2).

Pipe

12. Install the oil seal (2) on the front cover (3) with using a guide and pipe. Guide

2 3

W23F-02-04-016

W2-4-93

SWING MACHINERY / Pump Mechanism 13. Install the retaining ring (1).

W23F-02-04-017

W2-4-94

SWING MACHINERY / Control Valve REMOVE AND INSTALL 4-UNIT CONTROL VALVE FOR FRONT DRUM, REAR DRUM, TRAVEL, BOOM RAISING/LOWERING DRUM AND QUICK DRAW

Removal 1. Shutdown the engine. Operate the control lever several times and release the remaining pressure in the circuit.

2. Remove all hoses and pipings from the control valves (1) and (2). : 22 mm : 8 mm, 10 mm NOTE: Attach a cap and an identification tag on the removed hoses and pipings for reassembling. 3. Remove the bolt (3). : 19 mm CAUTION: Control valve (1) weight: Approx. 80 kg Control valve (2) weight: Approx. 107 kg

4. Lift the control valves (1) and (2) and remove them.

2 3

W2-5-1

M2CN-02-05-001

SWING MACHINERY / Control Valve Installation

CAUTION: Control valve (1) weight: Approx. 80 kg Control valve (2) weight: Approx. 107 kg

1. Install the control valves (1) and (2) and tighten with the bolt (3). : 19 mm : 60 to 64 Nᨿm (6.1 to 6.6 kgfᨿm) 2. Install all hoses and pipings on the control valves (1) and (2). : 22 mm : 39 Nᨿm (4.0 kgfᨿm) : 8 mm : 50 Nᨿm (5.1 kgfᨿm) : 10 mm : 90 Nᨿm (9.2 kgfᨿm)

IMPORTANT: After completing the work, check the oil level. Check for any oil leaks.

W2-5-2

2 3

M2CN-02-05-001

SWING MACHINERY / Control Valve (Blank)

W2-5-3

SWING MACHINERY / Control Valve DISASSEMBLE 4-UNIT CONTROL VALVE 50

47 28

25 39

46 48

53 52 55

61 1

51 26 39

56 2

20 11

15 24

10 84

43 36

33 41

42 46 40 50 49

64 52 27

40 44

44 54

26 51 45

9 62 80

87 77 74 81

65 68 79

57 59

58 23

75 66

70 60

76 8 41

32 35

W2CG-02-05-006

W2-5-4

SWING MACHINERY / Control Valve 1 - Inlet Section

23 - O-Ring

45 - Spring (2 Used)

67 - Spool (2 Used)

2 - Outlet Section

24 - O-Ring (16 Used)

46 - Spring (2 Used)

68 - Spring (2 Used)

3 - Valve Section

25 - End Cover (2 Used)

47 - Spring (2 Used)

69 - Spring (2 Used)

4 - Valve Section

26 - End Cover (2 Used)

48 - Spring (2 Used)

70 - Spring (2 Used)

5 - Valve Section

27 - End Cover (2 Used)

49 - Spring (4 Used)

71 - Plug (4 Used)

6 - Valve Section

28 - End Cover

50 - Spring (4 Used)

72 - Plug (4 Used)

7 - Plug

29 - End Cover

51 - Spring Seat (2 Used)

73 - Plug (2 Used)

8 - Plug

30 - Plate (2 Used)

52 - Spring Seat (2 Used)

74 - Plug (2 Used)

31 - Valve Seat (6 Used)

53 - Spring Seat (4 Used)

75 - Orifice (2 Used)

32 - Plug (6 Used)

54 - Plug (2 Used)

76 - Steel Ball (2 Used)

9 - Plug 10 - Plug 11 - Plug

33 - Air Bleed Valve ᧤6 Used᧥ 55 - Plug (2 Used)

77 - O-Ring (4 Used)

12 - Plug (7 Used)

34 - Plug (16 Used)

78 - O-Ring (4 Used)

13 - O-Ring

35 - O-Ring (12 Used)

57 - Poppet

79 - O-Ring (2 Used)

14 - O-Ring

36 - O-Ring (10 Used)

58 - Spring

80 - Socket %ROW 8VHG

15 - O-Ring

37 - O-Ring (16 Used)

59 - Cap (4 Used)

81 - Socket Bolt (8 Used)

16 - O-Ring

38 - Socket Bolt (8 Used)

60 - O-ring (4 Used)

82 - Filter (2 Used)

56 - Valve

17 - O-Ring (7 Used)

39 - Socket Bolt (16 Used)

61 - Relief Valve

83 - Bolt (4 Used)

18 - O-Ring (14 Used)

40 - Socket Bolt (8 Used)

62 - Relief Valve

84 - Nut ᧤8 Used᧥

19 - O-Ring (7 Used)

41 - Solenoid Valve (4 Used)

63 - Casing

85 - Spring Washer (8 Used)

20 - O-Ring

42 - Spool

64 - Casing

86 - Cover

21 - O-Ring (4 Used)

43 - Spool

65 - Cover (2 Used)

87 - O-Ring

22 - O-Ring

44 - Spool (2 Used)

66 - Cover (2 Used)

88 - Socket Bolt (4 Used)

W2-5-5

SWING MACHINERY / Control Valve 50

47 28

46 51 26 39

25 39

53 52 55

61 1

48 53

E 37

30 43 36

44 54 25

4 50

40 44 47

52 27

46 40 50 49

26 51 45

36 80

69 65 68 37 30

W2CG-02-05-006

W2-5-6

SWING MACHINERY / Control Valve Disassemble 4-Unit Control Valve

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.

• The disassembling and assembling procedures of 4-unit control valve for travel (right), boom raising/lowering, rear drum (low speed) and front drum (high speed) are explained here. As the construction is similar, refer to this section when disassembling and assembling the 4-unit control valve for travel (left), quick draw, rear drum (high speed) and front drum (low speed).

CAUTION: Control valve weight for (travel (left), quick draw, rear drum (high speed) and front drum (low speed)): 80 kg Control valve weight for (travel (right), boom raising/lowering, rear drum (low speed) and front drum (high speed)): Approx. 107 kg 1. Place the control valve assembly on a clean workbench. IMPORTANT: Do not adjust the adjusting screw of the solenoid valve (41).

8. Remove the socket bolt (40) and remove the end cover (27) and plate (30) from the valve sections (4) and (6). : 5 mm 9. Remove the spring seats (52), (53), springs (47) to (50), O-rings (36) and (37) (2 used) from the end covers (27) (2 used). 10. Remove the O-rings (36) and (37) (2 used) from the plates (30) (2 used).

CAUTION: Do not damage the holes on the spool and valve section. 11. Remove the spools (42) to (44) from each valve section. NOTE: Do not remove the plugs (54) and (55) from the spools (43) and (44) unnecessarily.

12. Remove the socket bolt (80) and remove the cover (65), springs (68), (69) and O-ring (77) from the casings (63) (2 used). : 8 mm

2. Remove the solenoid valve (41) from the end covers (27) (2 used), (28) and (29). : 32 mm 3. Remove the socket bolts (38) and (39) and remove the end covers (25) (2 used), (26) (2 used), (28) and (29) from each valve section.

CAUTION: Do not damage the holes on the spool and casing. 13. Remove the spool (67) from the casing (63) (2 used).

᧶ 5 mm 4. Remove the spring seat (53), spring (49), (50) and O-ring (36) from the end covers (25) (2 used).

IMPORTANT: Do not disassemble the relief valve (61).

5. Remove the spring seat (51), springs (45), (46), O-rings (36) and (37) (2 used) from the end covers (26) (2 used).

14. Remove the relief valve (61) from the inlet section (1) and remove the O-rings (2 used).

6. Remove the spring seat (52), springs (48), (47), O-rings (36) and (37) (2 used) from the end cover (28). 7. Remove the spring seat (53), springs (49), (50), O-rings (36) and (37) (2 used) from the end cover (29).

W2-5-7

᧶ 30 mm

SWING MACHINERY / Control Valve

1 2

18 17 19

15 24

10 84

4 63

62 57 59 58 23

22 59 60 8

W2CG-02-05-006

W2-5-8

SWING MACHINERY / Control Valve IMPORTANT: Do not disassemble the relief valve (62). 15. Remove the relief valve (62) from the valve section (6) and remove the O-ring. : 30 mm 16. Remove the valve (56) from the valve section (4) and remove the O-ring. 17. Remove the plugs (8) and (10) from the valve sections (4) and (6). : 30 mm 18. Remove the O-rings (15), (16), (22) and (23) from the plugs (8) and (10). 19. Turn over the control valve and remove the caps (59) (4 used). : 41 mm 20. Remove the poppet (57) and spring (58) from the valve section (3). 21. Remove the O-ring (60) from the caps (59) (4 used). 22. Turn over the control valve. 23. Remove the nut (84) and remove the bolts (83) (4 used). : 24 mm 24. Divide each section into the inlet section (1), valve sections (3) to (6), casing (63), (64) and outlet section (2). 25. Remove the O-rings (17), (18) (2 used) and (19) from each section and casings (63) and (64). 26. Remove the O-rings (24) (4 used) from the casing (64), valve sections (3), (6) and outlet section (2).

W2-5-9

SWING MACHINERY / Control Valve ASSEMBLE 4-UNIT CONTROL VALVE

50 25 39 5

47 28

53 52 55

45 46 51 26 39

48 53

56 2

20 11

15 24

10 84

43 36

33 41

64 52 27

40 44

44 54

46 40 50 49

26 51 45

9 62 80

87 77 74 81

65 68 79

57 59

58 23

75 66

70 60

76 8 41

32 35

W2CG-02-05-006

W2-5-10

SWING MACHINERY / Control Valve 1 - Inlet Section

23 - O-Ring

45 - Spring (2 Used)

67 - Spool (2 Used)

2 - Outlet Section

24 - O-Ring (16 Used)

46 - Spring (2 Used)

68 - Spring (2 Used)

3 - Valve Section

25 - End Cover (2 Used)

47 - Spring (2 Used)

69 - Spring (2 Used)

4 - Valve Section

26 - End Cover (2 Used)

48 - Spring (2 Used)

70 - Spring (2 Used)

5 - Valve Section

27 - End Cover (2 Used)

49 - Spring (4 Used)

71 - Plug (4 Used)

6 - Valve Section

28 - End Cover

50 - Spring (4 Used)

72 - Plug (4 Used)

7 - Plug

29 - End Cover

51 - Spring Seat (2 Used)

73 - Plug (2 Used)

8 - Plug

30 - Plate (2 Used)

52 - Spring Seat (2 Used)

74 - Plug (2 Used)

31 - Valve Seat (6 Used)

53 - Spring Seat (4 Used)

75 - Orifice (2 Used)

32 - Plug (6 Used)

54 - Plug (2 Used)

76 - Steel Ball (2 Used)

9 - Plug 10 - Plug 11 - Plug

33 - Air Bleed Valve ᧤6 Used᧥ 55 - Plug (2 Used)

77 - O-Ring (4 Used)

12 - Plug (7 Used)

34 - Plug (16 Used)

78 - O-Ring (4 Used)

13 - O-Ring

35 - O-Ring (12 Used)

57 - Poppet

79 - O-Ring (2 Used)

14 - O-Ring

36 - O-Ring (10 Used)

58 - Spring

80 - Socket %ROW 8VHG

15 - O-Ring

37 - O-Ring (16 Used)

59 - Cap (4 Used)

81 - Socket Bolt (8 Used)

16 - O-Ring

38 - Socket Bolt (8 Used)

60 - O-ring (4 Used)

82 - Filter (2 Used)

56 - Valve

17 - O-Ring (7 Used)

39 - Socket Bolt (16 Used)

61 - Relief Valve

83 - Bolt (4 Used)

18 - O-Ring (14 Used)

40 - Socket Bolt (8 Used)

62 - Relief Valve

84 - Nut ᧤8 Used᧥

19 - O-Ring (7 Used)

41 - Solenoid Valve (4 Used)

63 - Casing

85 - Spring Washer (8 Used)

20 - O-Ring

42 - Spool

64 - Casing

86 - Cover

21 - O-Ring (4 Used)

43 - Spool

65 - Cover (2 Used)

87 - O-Ring

22 - O-Ring

44 - Spool (2 Used)

66 - Cover (2 Used)

88 - Socket Bolt (4 Used)

W2-5-11

SWING MACHINERY / Control Valve 25

5 53 36

1 2

18 17

15 24

10 84 43 36

44 4 25

64 44

36 80

65 68

22 59 60 8

W2CG-02-05-006

W2-5-12

SWING MACHINERY / Control Valve Assemble 4-Unit Control Valve 1. Install the O-rings (17), (18) (2 used) and (19) on each section and casings (63) and (64). 2. Install the O-rings (24) (4 used) on the casing (64), valve sections (3), (6) and outlet section (2). 3. As for each section and casings (63) and (64), arrange the inlet section (1), valve section (5), casing (63), valve section (4), casing (64), valve sections (6), (3) and outlet section (2) in order. 4. Install the bolts (83) (4 used) on each section and casings (63) and (64). Install the spring washer (85) and tighten with the nut (84). : 24 mm : 100 to 120 N m (10.0 to 12.0 kgf m) 5. Turn over the control valve. Install the poppet (57) and spring (58) on the valve section (3).

9. Install the plug (8) on the valve section (6). : 30 mm : 70 to 80 N m (7.1 to 8.2 kgf m) 10. Install the plug (10) on the valve section (4). : 30 mm : 100 to 120 N m (10.0 to 12.0 kgf m)

CAUTION: Do not damage the holes on the spool and valve section. IMPORTANT: Check the positions to insert the spool (42) to (44). 11. Insert the spool (44) into the valve sections (4) and (6). Insert the spool (43) into the valve section (5). Insert the spool (42) into the valve section (3).

6. Install the O-ring (60) on the caps (59) (4 used) and install the cap (59) on the valve sections (3) to (6). : 41 mm : 190 to 210 N m (19.0 to 21.0 kgf m)

CAUTION: Do not damage the holes on the spool (67) and casing (63). 12. Insert the spool (67) into the casings (63) (2 used) and install the springs (68) and (69) on the spool (67).

7. Turn over the control valve. 8. Install the O-rings (15), (16), (22) and (23) on the plugs (8) and (10).

13. Install the O-ring (77) on the casings (63) (2 used). Install the cover (65) on the casings (63) (2 used) and tighten with the socket bolt (80). : 8 mm : 51 to 63 N m (5.2 to 6.4 kgf m) 14. Install the O-ring (36), spring (49), (50) and spring seat (53) on the end covers (25) (2 used).

W2-5-13

SWING MACHINERY / Control Valve 25 39 5

47 28

45 46 51 26 39

E 37

4 25

40 52 47

46 40 50 49

26 52 45

37 30

W2CG-02-05-006

W2-5-14

SWING MACHINERY / Control Valve 15. Install the end cover (25) assemblies (2 used) on the valve section (5) and tighten with the socket bolt (39). : 5 mm : 11 to 13 N m (1.1 to 1.3 kgf m) 16. Install the O-rings (36), (37) (2 used), springs (48), (47) and spring seat (52) on the end cover (28). 17. Install the end cover (28) assembly on the valve section (4) and tighten with the socket bolt (38). : 5 mm : 15 to 17 N m (1.5 to 1.7 kgf m) 18. Install the O-rings (36), (37) (2 used) on the plate (30).

24. Install the O-rings (36), (37) (2 used), springs (49), (50) and spring seat (53) on the end cover (27). 25. Install the end cover (27) assembly and plate (30) on the valve section (6) and tighten with the socket bolt (40). : 5 mm : 11 to 13 N m (1.1 to 1.3 kgf m) 26. Install the O-rings (36), (37) (2 used), springs (45), (46) and spring seat (51) and (52) on the end covers (26) (2 used).

19. Install the O-rings (36), (37) (2 used), springs (47), (48) and spring seat (52) on the end cover (27).

27. Install the end cover (26) assemblies (2 used) on the valve section (3) and tighten with the socket bolt (39). : 5 mm : 11 to 13 N m(1.1 to 1.3 kgf m)

20. Install the end cover (27) assembly and plate (30) on the valve section (4) and tighten with the socket bolt (40). : 5 mm : 11 to 13 N m (1.1 to 1.3 kgf m)

28. Install the O-rings (2 used) on the relief valve (61) and install the relief valve (61) on the inlet section (1). : 30 mm : 69 to 79 N m (7.0 to 8.1 kgf m)

21. Install the O-rings (36), (37) (2 used), springs (49), (50) and spring seat (53) on the end cover (29).

29. Install the O-ring on the relief valve (62) and install the relief valve (62) on the valve section (6). : 30 mm : 69 to 79 N m (7.0 to 8.1 kgf m)

22. Install the end cover (29) assembly on the valve section (6) and tighten with the socket bolt (38). : 5 mm : 15 to 17 N m (1.5 to 1.7 kgf m) 23. Install the O-rings (36) and (37) (2 used) on the plates (30) (2 used).

30. Install the O-ring on the valve (56) and install the valve (56) on the valve section (4). : 30 mm : 100 to 120 N m (10.0 to 12.0 kgf m) 31. Install the solenoid valve (41) on the end covers (27) (2 used), (28) and (29). : 32 mm : 39 to 49 N m (4.0 to 5.0 kgf m)

W2-5-15

SWING MACHINERY / Control Valve REMOVE AND INSTALL 4-UNIT CONTROL VALVE FOR BOOM FOOT AND LOWER HYDRAULIC SOURCE

Removal

1. Shutdown the engine. Operate the control lever several times and release the remaining pressure in the circuit.

2. Remove all hoses and pipings from the control valve (1). : 22 mm, 27 mm NOTE: Attach a cap and an identification tag on the removed hoses and pipings for reassembling.

3. Remove the bolt (2). : 17 mm 2

CAUTION: Control valve (1) weight: Approx. 22 kg 4. Lift the control valves (1) with the crane and remove it.

M2CN-02-05-002

W2-5-16

SWING MACHINERY / Control Valve Installation

CAUTION: Control valve (1) weight: Approx. 22 kg

1. Install the control valve (1) and tighten with the bolt (2). : 17mm : 34 to 37 Nᨿm (3.5 to 3.8 kgfᨿm) 2. Install all hoses and pipings on the control valve (1). : 22 mm : 39 Nᨿm (4.0 kgfᨿm) : 27 mm : 93 Nᨿm (9.5 kgfᨿm) 2

IMPORTANT: After completing the work, check the oil level. Check for any oil leaks.

M2CN-02-05-002

W2-5-17

SWING MACHINERY / Control Valve DISASSEMBLE 4-UNIT CONTROL VALVE 13 13

21 22

16 5 31

40 39

4 24 25

1 11 2

29 3 20

20 36

26 34 28

35 32

9 28 30 8 10

M2CN-02-05-003

1 - Inlet Section

12 - O-Ring

23 - Plunger (4 Used)

34 - Plug (4 Used)

2 - Outlet Section

13 - End Cover (8 Used)

24 - Spring (4 Used)

35 - O-Ring (4 Used)

3 - Casing (4 Used)

14 - Plug (24 Used)

25 - Plug (4 Used)

36 - Solenoid Valve (8 Used)

4 - Plug (8 Used)

15 - Plug (8 Used)

26 - Plug (2 Used)

37 - Spool (8 Used)

5 - Plug (10 Used)

16 - O-Ring (8 Used)

27 - O-Ring (4 Used)

38 - Spring (8 Used)

6 - Plug

17 - O-Ring (16 Used)

28 - O-Ring (2 Used)

39 - Bolt (4 Used)

7 - Plug

18 - O-Ring (8 Used)

29 - Relief Valve

40 - Nut (4 Used)

8 - O-Ring (5 Used)

19 - Socket Bolt (32 Used)

30 - Spool

41 - Spring Washer (4 Used)

9 - O-Ring (15 Used) 10 - O-Ring (20 Used) 11 - O-Ring

20 - Spool (4 Used) 21 - Spring (8 Used) 22 - Spring Seat (8 Used)

31 - Spool 32 - Spring 33 - Spring

W2-5-18

SWING MACHINERY / Control Valve Disassemble 4-Unit Control Valve

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.

7. Remove the spring seat (22), spring (21), O-ring (17) (2 used) and (16) from the end cover (13) (8 used).

CAUTION: Control valve weight: Approx. 22 kg 1. Place the control valve assembly on a clean workbench.

IMPORTANT: Do not adjust the adjusting screw of the solenoid valve (36). 2. Remove the solenoid valve (36) from the end covers (13) (8 used) and remove the O-ring. : 32 mm

CAUTION: Take care not to damage the hole of the end cover (13). 3. Remove the spools (37) and spring (38) from the end covers (13) (8 used).

CAUTION: Take care not to damage the hole of the casing (3). 8. Pull out the spool (20) from the casing (3). 9. Remove the plug (25) from the casing (3) and removing the O-ring (27). : 24 mm 10. Remove the spring (24) and plunger (23) from the casing (3). 11. Remove the plug (26) from the casing (3) and remove the O-ring (28). : 10 mm 12. Remove the plugs (4) (2 used) from the casing (3). : 6 mm

4. Remove the plug (15) from the end covers (13) (8 used) and remove the O-ring (18). : 4 mm

13. Remove the plugs (34) (2 used) from the upper surface of the inlet section (1) and remove the O-rings (35) (2 used). : 8 mm

5. Remove the plug (14) (3 used) from the end covers (13) (8 used). : 5 mm

14. Remove the spring (32) and (33) from the inlet section (1).

6. Remove the socket bolt (19) and remove the end cover (13) from the casing (3). : 4 mm

15. Remove the plugs (34) (2 used) from the under surface of the inlet section (1) and remove the O-rings (35) (2 used). : 8 mm

W2-5-19

SWING MACHINERY / Control Valve

1 11 7

29 8 10

W2CG-02-05-007

W2-5-20

SWING MACHINERY / Control Valve CAUTION: Take care not to damage the hole of the inlet section (1). 16. Pull out the spools (30) and (31) from the inlet section (1)

IMPORTANT: Do not disassemble the relief valve (29). Do not adjust the adjusting screw of the relief valve (29). 17. Remove the relief valve (29) from the inlet section (1). : 22 mm 18. Remove the plug (6) from the inlet section (1) and remove the O-ring (11). : 6 mm 19. Remove the plug (5) (6 used) from the inlet section (1). : 4 mm 20. Remove the plug (26) (2 used) from the outlet section (2) and remove the O-ring (28) (2 used). : 10 mm 21. Remove the plug (7) from the outlet section (2) and remove the O-ring (12). :10 mm 22. Remove the plug (5) (4 used) from the outlet section (2). :4 mm 23. Remove the nuts (40) (4 used) and pull out the outlet section (2) and casing (3) from the bolt (39) in order. : 13 mm 24. Remove the O-rings (8), (9) and (10) from the inlet section (1) and casing (3).

W2-5-21

SWING MACHINERY / Control Valve ASSEMBLE 4-UNIT CONTROL VALVE 13 13

21 22

16 5 31

40 39

4 24 25

1 11 2

29 3 20

20 36

26 34 28

35 32

9 28 30 8 10

W2CG-02-05-007

1 - Inlet Section

12 - O-Ring

23 - Plunger (4 Used)

34 - Plug (4 Used)

2 - Outlet Section

13 - End Cover (8 Used)

24 - Spring (4 Used)

35 - O-Ring (4 Used)

3 - Casing (4 Used)

14 - Plug (24 Used)

25 - Plug (4 Used)

36 - Solenoid Valve (8 Used)

4 - Plug (8 Used)

15 - Plug (8 Used)

26 - Plug (2 Used)

37 - Spool (8 Used)

5 - Plug (10 Used)

16 - O-Ring (8 Used)

27 - O-Ring (4 Used)

38 - Spring (8 Used)

6 - Plug

17 - O-Ring (16 Used)

28 - O-Ring (2 Used)

39 - Bolt (4 Used)

7 - Plug

18 - O-Ring (8 Used)

29 - Relief Valve

40 - Nut (4 Used)

8 - O-Ring (5 Used)

19 - Socket Bolt (32 Used)

30 - Spool

41 - Spring Washer (4 Used)

9 - O-Ring (15 Used)

20 - Spool (4 Used)

31 - Spool

10 - O-Ring (20 Used)

21 - Spring (8 Used

32 - Spring

11 - O-Ring

22 - Spring Seat (8 Used)

33 - Spring

W2-5-22

SWING MACHINERY / Control Valve Assemble 4-Unit Control Valve 1. Install the O-rings (8), (9) and (10) on the inlet section (1) and casing (3).

IMPORTANT: Do not adjust the adjusting screw of the relief valve (29).

2. Install the casing (3) and outlet section (2) on the bolt (39) (4 used) attached on the inlet section (1) in order. Install the spring washer (41) on the bolt (39) (4 used) and tighten the bolt with the nut (40). : 13 mm : 20 to 25 N m (2.0 to 2.5 kgf m)

8. Install the relief valve (29) on the inlet section (1). : 22 mm : 41 to 47 N m (4.2 to 4.8 kgf m)

3. Install the plugs (5) (4 used) on the outlet section (2).

9. Install the O-rings (35) on the plugs (34) (2 used) and install the plug (34) on the under surface of the inlet section (1). : 8 mm : 69 to 78 N m (7.0 to 8.0 kgf m)

NOTE: Wrap the seal tape on the plug (5). : 4 mm : 7.8 to 9.8 N m (0.8 to 1.0 kgf m) 4. Install the O-ring (12) on the plug (7) and install the plug (7) on the outlet section (2). : 10 mm : 98 to 118 N m (10 to 12 kgf m) 5. Install the O-ring (28) on the plug (26) and install the plug (26) on the outlet section (2). : 10 mm : 98 to 118 N m (10 to 12 kgf m) 6. Install the plugs (5) (6 used) on the inlet section (1).

IMPORTANT: Check the position to insert the spools (30) and (31) and the direction of the upside and downside. 10. Install the spools (30), (31), springs (32) and (33) from the upper surface of the inlet section (1). 11. Install the O-ring (35) on the plugs (34) (2 used) and install the plug (34) on the upper surface of the inlet section (1). : 8 mm : 69 to 78 N m (7.0 to 8.0 kgf m) 12. Install the plugs (4) (2 used) on the casing (3). NOTE: Wrap the seal tape on the plug (4).

NOTE: Wrap the seal tape on the plug (5). : 4 mm : 7.8 to 9.8 N m (0.8 to 1.0 kgf m)

: 6 mm : 20 to 24 N m (2.0 to 2.4 kgf m)

7. Install the O-ring (11) on the plug (6) (6 used) and install the plug (6) on the inlet section (1). : 6 mm : 34 to 38 N m (3.5 to 3.9 kgf m)

13. Install the O-ring (28) on the plug (26) and install the plug (26) on the casing (3). : 10 mm : 98 to 118 N m (10.0 to 12.0 kgf m)

W2-5-23

SWING MACHINERY / Control Valve 12 20 21 15

12 20

24 16 18

W2CG-02-05-007

W2-5-24

SWING MACHINERY / Control Valve 14. Install the plunger (23) and spring (24) on the casing (3).

IMPORTANT: Do not adjust the adjusting screw of the solenoid valve (36).

15. Install the O-rings (27) on the plug (25) and install the plug (25) on the casing (3). : 24 mm : 49 to 59 N m (5.0 to 6.0 kgf m)

22. Install the O-ring on the solenoid valve (36) and install the solenoid valve (36) on the end covers (13) (8 used). : 32 mm : 39 to 49 N m (4.0 to 5.0 kgf m)

IMPORTANT: Check the direction to insert spool (20). 16. Install the spool (20) on the casing (3). 17. Install the spring (21), spring seat (22), O-rings (17) (2 used) and (16) on the end covers (13) (8 used). 18. Install the end cover (13) assembly on the casing (3) and tighten with the socket bolt (19). : 4 mm : 5.9 to 7.8 N m (0.6 to 0.8 kgf m) 19. Install the plugs (14) (3 used) on the end covers (13) (8 used). NOTE: Wrap the seal tape on the plug (14). : 5 mm : 8.3 to 11.0 N m (0.8 to 1.1 kgf m) 20. Install the O-ring (18) on the plug (15) and install the plug (15) on the end covers (13) (8 used). : 4 mm : 13 to 17 N m (1.3 to 1.7 kgf m) 21. Install the spool (37) and spring (38) on the end covers (13) (8 used).

W2-5-25

SWING MACHINERY / Control Valve REMOVE AND INSTALL 3-UNIT CONTROL VALVE FOR COUNTERWEIGHT REMOVAL/INSTALLTION AND LIVE MAST FLIP

Removal 1. Shutdown the engine. Operate the control lever several times and release the remaining pressure in the circuit.

2. Remove all hoses and pipings from the control valve (1) : 22 mm, 27 mm, 36 mm NOTE: Attach a cap and an identification tag on the removed hoses and pipings for reassembling. 2

3. Remove the bolt (2). : 17 mm

CAUTION: Control valve (1) weight: Approx. 24.4 kg 4. Lift the control valve (1) and remove it. 1

M2CN-02-05-004

W2-5-26

SWING MACHINERY / Control Valve Installation

CAUTION: Control valve (1) weight: Approx. 24.4 kg

1. Install the control valve (1) and tighten with the bolt (2). : 17 mm : 34 to 37 Nᨿm (3.5 to 3.8 kgfᨿm) 2. Install all hoses and pipings on the control valve (1). : 22 mm : 39 Nᨿm (4.0 kgfᨿm) : 27 mm : 93 Nᨿm (9.5 kgfᨿm) : 36 mm : 175 Nᨿm (18.0 kgfᨿm)

IMPORTANT: After completing the work, check the oil level. Check for any oil leaks. 1

M2CN-02-05-004

W2-5-27

SWING MACHINERY / Control Valve DISASSEMBLE 3-UNIT CONTROL VALVE 15 24 25

18 6

42 41

8 12 13 27 28 19

35 29 26 1 31

21 16

38 3

36 37 34 10

32 9 11

W2CG-02-05-008

1 - Inlet Section

12 - O-Ring (2 Used)

23 - Spool (2 Used)

2 - Outlet Section

13 - O-Ring (2 Used)

24 - Spring (6 Used)

34 - Spring 35 - Spring

3 - Casing

14 - O-Ring

25 - Spring (6 Used)

36 - Plug (4 Used)

4 - Casing (2 Used)

15 - End Cover (6 Used)

26 - Plunger (3 Used)

37 - O-Ring (4 Used)

5 - Plug (2 Used)

16 - Plug (18 Used)

27 - Spring (3 Used)

38 - Solenoid Valve (6 Used) 39 - Spool (6 Used)

6 - Plug (10 Used)

17 - Plug (6 Used)

28 - Plug (3 Used)

7 - Plug

18 - O-Ring (6 Used)

29 - O-Ring (3 Used)

40 - Spring (6 Used)

8 - Plug (2 Used)

19 - O-Ring (12 Used)

30 - Relief Valve

41 - Bolt (4 Used)

20 - O-Ring (6 Used)

31 - Relief Valve (2 Used)

42 - Nut (4 Used)

10 - O-Ring (12 Used)

9 - O-Ring (4 Used)

21 - Bolt (24 Used)

32 - Spool

43 - Spring Washer (4 Used)

11 - O-Ring (16 Used)

22 - Spool

33 - Spool

W2-5-28

SWING MACHINERY / Control Valve Disassemble 3-Unit Control Valve

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. CAUTION: Control valve weight: Approx. 20 kg

1. Place the control valve assembly on a clean workbench.

IMPORTANT: Do not adjust the adjusting screw of the solenoid valve (38). 2. Remove the solenoid valve (38) from the end covers (15) (6 used) and remove the O-ring. : 32 mm

CAUTION: Take care not to damage the hole of the end cover (15). 3. Remove the spools (39) and spring (40) from the end cover (15) (6 used).

9. Remove the spool (23) from the casing (4). 10. Remove the plug (28) from the casings (3) and (4) and remove the O-ring (21). : 24 mm 11. Remove the spring (27) and plunger (29) from the casings (3) and (4). 12. Remove the plugs (5) (2 used) from the casing (3). : 6 mm

IMPORTANT: Do not disassemble the relief valve (31). Do not adjust the adjusting screw of the relief valve (31). 13. Remove the relief valve (31) from the casing (4). : 24 mm 14. Remove the plug (8) from the casing (4) and remove the O-rings (12) and (13). : 24 mm

4. Remove the plug (17) from the end covers (15) (6 used) and remove the O-ring (20). : 4 mm

15. Remove the plugs (36) (2 used) from the upper surface of the inlet section (1) and remove the O-rings (37) (2 used). : 8 mm

5. Remove the plugs (16) (18 used) from the end covers (15) (6 used). : 5 mm

16. Remove the spring (34) and (35) from the inlet section (1).

6. Remove the socket bolt (21) and remove the end cover (15) from the casing (3) and (4). : 4 mm

17. Remove the plugs (36) (2 used) from the under surface of the inlet section (1) and remove the O-rings (37) (2 used). : 8 mm

7. Remove the spring seat (25), spring (24), O-rings (18) and (19) (2 used) from the end cover (15) (6 used).

CAUTION: Take care not to damage the hole of the casing (3) and (4). 8. Pull out the spool (22) from the casing (3).

W2-5-29

SWING MACHINERY / Control Valve

42 41

1 2

14 3

32 9 11

W2CG-02-05-008

W2-5-30

SWING MACHINERY / Control Valve CAUTION: Take care not to damage the hole of the inlet section (1). 18. Pull out the spools (32) and (33) from the inlet section (1)

IMPORTANT: Do not disassemble the relief valve (30). Do not adjust the adjusting screw of the relief valve (30). 19. Remove the relief valve (30) from the inlet section (1). : 22 mm 20. Remove the plug (7) from the inlet section (1) and remove the O-ring (14). : 6 mm 21. Remove the plugs (6) (6 used) from the inlet section (1). : 4 mm 22. Remove the plugs (6) (4 used) from the outlet section (2). : 4 mm 23. Remove the nuts (42) (4 used) and pull out the outlet section (2), casings (4) (2 used) and casing (3) from the bolt (41) in order. : 13 mm 24. Remove the O-rings (9), (10) and (11) from the inlet section (1), casings (3) and (4) (2 used).

W2-5-31

SWING MACHINERY / Control Valve ASSEMBLE 3-UNIT CONTROL VALVE 15 24 25

18 6

42 41

8 12 13 27 28 19

35 29 26 1 31

21 16

38 3

36 37 34 10

32 9 11

W2CG-02-05-008

1 - Inlet Section

12 - O-Ring (2 Used)

23 - Spool (2 Used)

34 - Spring

2 - Outlet Section

13 - O-Ring (2 Used)

24 - Spring (6 Used)

35 - Spring

3 - Casing

14 - O-Ring

25 - Spring (6 Used)

36 - Plug (4 Used)

4 - Casing (2 Used)

15 - End Cover (6 Used)

26 - Plunger (3 Used)

37 - O-Ring (4 Used)

5 - Plug (2 Used)

16 - Plug (18 Used)

27 - Spring (3 Used)

38 - Solenoid Valve (6 Used)

6 - Plug (10 Used)

17 - Plug (6 Used)

28 - Plug (3 Used)

39 - Spool (6 Used)

7 - Plug

18 - O-Ring (6 Used)

29 - O-Ring (3 Used)

40 - Spring (6 Used)

8 - Plug (2 Used)

19 - O-Ring (12 Used)

30 - Relief Valve

41 - Bolt (4 Used)

9 - O-Ring (4 Used)

20 - O-Ring (6 Used)

31 - Relief Valve (2 Used)

42 - Nut (4 Used)

10 - O-Ring (12 Used)

21 - Bolt (24 Used)

32 - Spool

43 - Spring Washer (4 Used)

11 - O-Ring (16 Used)

22 - Spool

33 - Spool

W2-5-32

SWING MACHINERY / Control Valve Assemble 3-Unit Control Valve 1. Install the O-rings (9), (10) and (11) on the inlet section (1), casings (3) and (4) (2 used). 2. Install the casing (3), casings (4) (2 used) and outlet section (2) on the bolts (41) (4 used) attached on the inlet section (1) in order. Tighten with the bolts (41) (4 used) and spring washer (42). : 13 mm : 20 to 25 N m (2.0 to 2.5 kgf m) 3. Install the plugs (6) (4 used) on the outlet section (2). NOTE: Wrap the seal tape on the plug (6). : 4 mm : 7.8 to 9.8 N m (0.8 to 1.0 kgf m) 4. Install the plugs (6) (6 used) on the inlet section (1). NOTE: Wrap the seal tape on the plug (6). : 4 mm : 7.8 to 9.8 N m (0.8 to 1.0 kgf m) 5. Install the O-ring (14) on the plug (7) and install the plug (7) on the inlet section (1). : 6 mm : 34 to 38 N m (3.5 to 3.9 kgf m)

IMPORTANT: Do not adjust the adjusting screw of the relief valve (30).

7. Install the O-rings (37) on the plugs (36) (2 used) and install the plug (36) on the under surface of the inlet section (1). : 8 mm : 69 to 78 N m (7.0 to 8.0 kgf m)

IMPORTANT: Check the position to insert the spools (32) and (33) and the direction of the upside and downside. 8. Install the spools (32), (33), springs (34) and (35) from the upper surface of the inlet section (1). 9. Install the O-ring (37) on the plugs (36) (2 used) and install the plug (36) on the upper surface of the inlet section (1). : 8 mm : 69 to 78 N m (7.0 to 8.0 kgf m) 10. Install the O-rings (12) and (13) on the plug (8) and install the plug (8) on the casing (4). : 24 mm : 39 to 49 N m (4.0 to 5.0 kgf m)

IMPORTANT: Do not adjust the adjusting screw of the relief valve (31). 11. Install the relief valve (31) on the casing (4). : 24 mm : 39 to 49 N m (4.0 to 5.0 kgf m) 12. Install the plugs (5) (2 used) on the casing (3). NOTE: Wrap the seal tape on the plug (5).

6. Install the relief valve (30) on the inlet section (1). : 22 mm : 41 to 47 N m (4.2 to 4.8 kgf m)

: 6 mm : 20 to 24 N m (2.0 to 2.4 kgf m) 13. Install the plunger (29) and spring (27) on the casings (3) and (4).

W2-5-33

SWING MACHINERY / Control Valve 15 24 25 18

28 19

21 16 38 3

W2CG-02-05-008

W2-5-34

SWING MACHINERY / Control Valve 14. Install the O-ring (29) on the plug (28) and install the plug (28) on the casings (3) and (4). : 24 mm : 49 to 59 N m (5.0 to 6.0 kgf m)

IMPORTANT: Check the direction to insert spool (22), (23).

IMPORTANT: Do not adjust the adjusting screw of the solenoid valve (38). 21. Install the O-ring on the solenoid valve (38) and install the solenoid valve (38) on the end covers (15) (6 used). : 32 mm : 39 to 49 N m (4.0 to 5.0 kgf m)

15. Install the spool (22) on the casing (3) and install the spool (23) on the casing (4). 16. Install the spring (25), spring seat (24), O-rings (18) and (19) (2 used) on the end covers (15) (6 used). 17. Install the end cover (15) assembly on the casings (3) and (4) and tighten with the socket bolt (21). : 4 mm : 5.9 to 7.8 N m (0.6 to 0.8 kgf m) 18. Install the plugs (16) (18 used) on the end covers (15) (6 used). NOTE: Wrap the seal tape on the plug (16). : 5 mm : 8.3 to 11.0 N m (0.8 to 1.1 kgf m) 19. Install the O-ring (20) on the plug (17) and install the plug (17) on the end covers (15) (6 used). : 4 mm : 13 to 17 N m (1.3 to 1.7 kgf m) 20. Install the spool (39) and spring (40) on the end covers (15) (6 used).

W2-5-35

SWING MACHINERY / Control Valve REMOVE AND INSTALL 2-UNIT CONTROL VALVE FOR SWING CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing the hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work.

Removal

1. Shutdown the engine. Operate the control lever several times and release the remaining pressure in the circuit.

2. Remove all hoses and pipings from the control valve (1). : 8 mm, 10 mm : 22 mm

NOTE: Attach a cap and an identification tag on the removed hoses and pipings for reassembling. 2

3. Remove the bolt (2). : 19 mm

CAUTION: Control valve (1) weight: Approx. 51 kg

4. Lift the control valve (1) and remove it.

M2CN-02-05-005

W2-5-36

SWING MACHINERY / Control Valve Installation

CAUTION: Control valve (1) weight: Approx. 51 kg

1. Install the control valve (1) and tighten with the bolt (2). : 19mm : 60 to 64 N m (6.1 to 6.6 kgf m)

2. Install all hoses and pipings on the control valve (1). : 8 mm : 50 N m (5.1 kgf m) : 10 mm : 90 N m (9.2 kgf m) : 22 mm : 39 N m (4.0 kgf m)

IMPORTANT: After completing the work, check the oil level. Check for any oil leaks.

M2CN-02-05-005

W2-5-37

SWING MACHINERY / Control Valve DISASSEMBLE 2-UNIT CONTROL VALVE 10

21 13

34 1 9 11

30 31 32

36 33

17 35

28 16 25

5 7 8 6

W2CG-02-05-009

1 - Inlet Section

11 - O-Ring (3 Used)

21 - Socket Bolt (8 Used)

2 - Outlet Section

12 - End Cover (2 Used)

22 - Solenoid Valve (2 Used)

31 - Spring 32 - Cap (2 Used)

3 - Valve Section

13 - End Cover (2 Used)

23 - Spool

33 - O-Ring (2 Used)

4 - Valve Section

14 - Air Bleed Valve (6 Used)

24 - Spool

34 - Relief Valve

5 - Plug

15 - Valve (6 Used)

25 - Spring (2 Used)

35 - Bolt (4 Used)

6 - Plug

16 - Plug (8 Used)

26 - Spring (2 Used)

36 - Nut (8 Used)

7 - O-Ring

17 - O-Ring (4 Used)

27 - Spring (2 Used)

37 - Spring Washer (8 Used)

8 - O-Ring

18 - O-Ring (4 Used)

28 - Spring Seat (2 Used)

9 - O-Ring (3 Used)

19 - O-Ring (4 Used)

29 - Spring Seat (2 Used)

20 - Socket Bolt (8 Used)

30 - Poppet

10 - O-Ring (6 Used)

W2-5-38

SWING MACHINERY / Control Valve Disassemble 2-Unit Control Valve

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. CAUTION: Control valve weight: Approx. 51 kg

1. Place the control valve assembly on a clean workbench.

8. Turn over the control valve and remove the caps (32) (2 used). : 41 mm 9. Remove the poppet (30) and spring (31) from the valve section (4). 10. Remove the O-ring (33) from the caps (32) (2 used). 11. Turn over the control valve.

IMPORTANT: Do not adjust the adjusting screw of the solenoid valve (22). 2. Remove the solenoid valve (22) from the end covers (13) (2 used). : 32 mm 3. Remove the socket bolts (20) and (21) and remove the end covers (12) (2 used) and (13) (2 used) from each valve section : 5 mm

12. Remove the nut (36) (2 used) and remove the bolts (35) (4 used). : 24 mm 13. Separate each section into the inlet section (1), valve sections (3), (4) and outlet section (2).

14. Remove the O-rings (9), (10) (2 used) and (11) from each section.

4. Remove the spring seat (28), spring (25), O-rings (18) and (19) (2 used) from the end covers (13) (2 used). 5. Remove the spring seat (29), springs (26), (27) and O-ring (18) from the end covers (12) (2 used).

CAUTION: Take care not to damage the holes of the spool and valve section. 6. Pull out the spools (23) and (24) from each valve section.

IMPORTANT: Do not disassemble the relief valve (34). 7. Remove the relief valve (34) from the inlet section (1) and remove the O-rings (2 used) : 30 mm

W2-5-39

SWING MACHINERY / Control Valve ASSEMBLE 2-UNIT CONTROL VALVE 10

21 13

34 1 9 11

30 31 32

36 33

17 35

28 16 25

5 7 8 6

W2CG-02-05-009

1 - Inlet Section

11 - O-Ring (3 Used)

21 - Socket Bolt (8 Used)

2 - Outlet Section

12 - End Cover (2 Used)

22 - Solenoid Valve (2 Used)

31 - Spring 32 - Cap (2 Used)

3 - Valve Section

13 - End Cover (2 Used)

23 - Spool

33 - O-Ring (2 Used)

4 - Valve Section

14 - Air Bleed Valve (6 Used)

24 - Spool

34 - Relief Valve

5 - Plug

15 - Valve (6 Used)

25 - Spring (2 Used)

35 - Bolt (4 Used)

6 - Plug

16 - Plug (8 Used)

26 - Spring (2 Used)

36 - Nut (8 Used)

7 - O-Ring

17 - O-Ring (4 Used)

27 - Spring (2 Used)

37 - Spring Washer (8 Used)

8 - O-Ring

18 - O-Ring (4 Used)

28 - Spring Seat (2 Used)

9 - O-Ring (3 Used)

19 - O-Ring (4 Used)

29 - Spring Seat (2 Used)

20 - Socket Bolt (8 Used)

30 - Poppet

10 - O-Ring (6 Used)

W2-5-40

SWING MACHINERY / Control Valve Assemble 2-Unit Control Valve 1. Install the O-rings (9), (10) (2 used) and (11) on each section. 2. Install each section with the inlet section (1), valve section (4), valve section (3) and outlet section (2) in order. 3. Install the bolts (35) (4 used) and spring washer (37) on each section and tighten with the nut (36). : 24 mm : 100 to 120 N m (10.0 to 12.0 kgf m) 4. Turn over the control valve and install the poppet (30) and spring (31) on the valve sections (3) and (4). 5. Install the O-ring (33) on the caps (32) (2 used) and install the caps (32) on the inlet section (1). : 41 mm : 190 to 210 N m (19.0 to 21.0 kgf m) 6. Turn over the control valve.

9. Install the end cover (13) assemblies (2 used) on the valve section (4) and tighten with the socket bolt (21). : 5 mm : 15 to 17 N m (1.5 to 1.7 kgf m) 10. Install the O-ring (18) springs (26), (27) and spring seat (29) on the end cover (12). 11. Install the end cover (12) assembly on the valve section (3) and tighten with the socket bolt (20). : 5 mm : 11 to 13 N m (1.1 to 1.3 kgf m) 12. Install the O-rings (2 used) on the relief valve (34) and install it on the inlet section (1). : 30 mm : 120 to 140 N m (12.0 to 14.0 kgf m) 13. Install the end covers (13) (2 used) on the solenoid valve (22). : 32 mm : 39 to 49 N m (4.0 to 5.0 kgf m)

CAUTION: Take care not to damage the holes of the spool and valve section. IMPORTANT: Check the inserting position of the spools (23) and (24). 7. Insert the spool (23) into the valve section (4) and insert the spool (24) into the valve section (3). 8. Install the O-rings (18), (19), spring (25) and spring seat (28) on the end covers (13) (2 used).

W2-5-41

SWING MACHINERY / Control Valve (Blank)

W2-5-42

SWING MACHINERY / Swing Mechanism REMOVE AND MECHANISM

INSTALL

SWING

Preparation

1. Shutdown the engine. Operate the control lever several times and release the remaining pressure in the circuit.

Removal

1. Remove all hoses (1 to 11) from the swing mechanism. Cap the removed hoses. : 22, 27, 36, 41 mm

2. Remove the bolts (12) (36 used). ᧶ 30 mm 6

CAUTION: Swing mechanism weight: 714 kg

assembly 8 11

3. Lift the swing mechanism with the crane and remove it.

M2CN-02-06-001

W2-6-1

SWING MACHINERY / Swing Mechanism Installation

CAUTION: Swing mechanism weight: 714 kg

assembly

1. Lift the swing mechanism with the crane and install it on the revolving frame.

IMPORTANT: When installing the swing mechanism, apply the liquid packing on the mounting surfaces of the reduction gear and revolving frame. 2. Install the bolts (12) (36 used). : 30 mm : 350 to 379 N m (35.7 to 38.7 kgf m)

3. Install all hoses (1 to 11) on the swing mechanism. : 22 mm : 39 N m (4.0 kgf m) : 27 mm : 93 N m (9.5 kgf m) : 36 mm : 175 N m (18.0 kgf m) : 41 mm : 205 N m (21.0 kgf m)

7 8 11

M2CN-02-06-001

W2-6-2

SWING MACHINERY / Swing Mechanism (Blank)

W2-6-3

SWING MACHINERY / Swing Mechanism DISASSEMBLE SWING MECHANISM

12 13 14

W2CD-02-06-002

1 - Ring Gear

11 - Motor

21 - Planetary Gear (3 Used)

2 - Shim

12 - O-Ring

22 - Thrust Washer (6 Used)

31 - Sun Gear 32 - Retaining Ring

3 - Bearing

13 - Retaining Ring

23 - Pin (8 Used)

33 - Plug (2 Used)

4 - Socket bolt

14 - Cover

24 - Bearing

34 - Plug

5 - Bearing (2 Used)

15 - Socket Bolt (3 Used)

25 - Casing

35 - Socket Bolt (10 Used)

6 - Casing

16 - Casing

26 - Cover

36 - Pipe

7 - Pinion

17 - Carrier

27 - Bolt (8 Used)

37 - Level Gauge

8 - Pin

18 - Bearing

28 - Shaft

38 - Plug

9 - O-Ring 10 - Bolt (4 Used)

19 - Spring Pin (3 Used)

29 - Thrust Button

39 - Bolt (6 Used)

20 - Knock Pin (2 Used)

30 - Oil Seal

40 - Socket Bolt (4 Used)

W2-6-4

SWING MACHINERY / Swing Mechanism Disassemble Swing Mechanism • Thoroughly read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. CAUTION: Swing mechanism weight: 714 kg

11. Remove the pinion (7) from the casing (6).

Amount of Gear Oil: Approx. 9.2 L : 8 mm

12. Remove the bearing (5) from the pinion (7).

NOTE: Drain the gear oil in the clean container and check the metal powder due to wearing. 2. Put the matching mark on the casing (6), (16), (25), ring gear (1) and motor (11). 3. Remove the bolts (10) (4 used) from the swing motor (11). : 24 mm

(11)

from

13. Remove the bearing (3) and shim (2) from the carrier (17). 14. Remove the socket bolt (4) and bolts (39) (6 used) from the casing (16) and remove the casing (16). : 17 mm : 30 mm 15. Remove the sun gear (31) from the planetary gear (21). 16. Remove the shaft (28) assembly from the casing (25).

CAUTION: Motor weight: 49 kg motor

NOTE: Install the eye bolt (M10) (2 places) on the carrier (17). Slowly lift and remove the carrier (17) by hands or with a crane.

assembly

1. Remove the plug (33) and drain off the gear oil.

4. Remove the mechanism.

10. Remove the carrier (17) assembly from the casing (16).

the

swing

NOTE: Lift the motor (11) slightly and tap the swing mechanism lightly with using a plastic hammer to remove the motor (11).

NOTE: Remove the shaft (28) assembly with using the screw (M12) (3 places) on the end of shaft (28). 17. Remove the ring gear (1) from the casing (25).

5. After removing the level gauge (37) from the pipe (36), remove the pipe (36) from the casing (16).

NOTE: Remove the ring gear (1) with using the pulling-out screw (M8) (2 places) of the ring gear (1).

6. Remove the O-ring (9) from the casing (16). 7. Remove the socket bolts (40) (4 used), (35) (10 used) and (15) (3 used) from the casing (16) and remove the casing (16). : 10 mm

18. Remove the bearing (18) and thrust button (29) from the shaft (28).

8. Remove the retaining ring (13), cover (14) and O-ring (12) from the casing (16). 9. Remove the pin (8) from the casing (16).

W2-6-5

SWING MACHINERY / Swing Mechanism

W2CD-02-06-002

W2-6-6

SWING MACHINERY / Swing Mechanism 19. Remove the pins (23) (3 used) from the planetary gears (21) (3 used) with using a special tool (A). Remove the spring pins (19) (3 used) from the shaft (28).

Special Tool (A)

˓35 mm

20. Remove the planetary gears (21) (3 used) and thrust washers (22) (6 used) from the shaft (28). 21. Remove the bearing (24) from the casing (25). 22. Remove the bolts (27) (8 used) from the cover (26) and remove the cover (26) from the casing (25). : 13 mm

˓238 mm

Press

23. Remove the oil seal (30) from the cover (26).

Pillar with semicircular section (3 Places)

284 mm Special Tool for Pin Pulling-Out

W2-6-7

W2CD-02-06-004

SWING MACHINERY / Swing Mechanism ASSEMBLE SWING MECHANISM

12 13 14

W2CD-02-06-002

1 - Ring Gear

11 - Motor

21 - Planetary Gear (3 Used)

2 - Shim

12 - O-Ring

22 - Thrust Washer (6 Used)

31 - Sun Gear 32 - Retaining Ring

3 - Bearing

13 - Retaining Ring

23 - Pin (8 Used)

33 - Plug (2 Used)

4 - Socket bolt

14 - Cover

24 - Bearing

34 - Plug

5 - Bearing (2 Used)

15 - Socket Bolt (3 Used)

25 - Casing

35 - Socket Bolt (10 Used)

6 - Casing

16 - Casing

26 - Cover

36 - Pipe

7 - Pinion

17 - Carrier

27 - Bolt (8 Used)

37 - Level Gauge

8 - Pin

18 - Bearing

28 - Shaft

38 - Plug

9 - O-Ring 10 - Bolt (4 Used)

19 - Spring Pin (3 Used)

29 - Thrust Button

39 - Bolt (6 Used)

20 - Knock Pin (2 Used)

30 - Oil Seal

40 - Socket Bolt (4 Used)

W2-6-8

SWING MACHINERY / Swing Mechanism Assemble Swing Mechanism 1. Install the bearing (24) on the shaft (28). 2. Install the thrust button (29) on the shaft (28). 3. Install the thrust washers (22) (6 used) and planetary gears (21) (3 used) on the shaft (28) with the pins (23) (3 used) and lock with the spring pins (19) (3 used). NOTE: Caulk the edge (2 places) with using a punch and lock with the spring pins (19) (3 used). Align the no-semicircular part of the thrust washer (22) with the periphery direction of the shaft (28) when installing. Lightly tap and insert the pin (23) with using a plastic hammer so that the holes of pin (23) and shaft (28) can be aligned. The spring pin (19) can be easily inserted with using a special tool (B).

2.5mm

ዘSpecial Tool (B)

5mm

15mm

4. Install the shaft (28) assembly on the casing (25). 5. Install the bearing (18) on the shaft (28). ˓5.5mm

6. Install the oil seal (30) inside of the cover (26).

Special Tool for Inserting Spring Pin

NOTE: Insert the oil seal (30) with using a special tool (C). 7. Install the cover (26) on the casing (25) with the bolts (27) (8 used). : 13 mm : 29 N m (3.0 kgf m)

W2CD-02-06-005

ዘSpecial Tool (C) ˓11mm

NOTE: Apply ThreeBond #1104 or #1215 on the mating surfaces of the cover (26) and casing (25).

˓154mm

˓170mm

Special Tool for Inserting Oil Seal

W2-6-9

W2CD-02-06-006

SWING MACHINERY / Swing Mechanism

12 13 14

W2CD-02-06-002

W2-6-10

SWING MACHINERY / Swing Mechanism IMPORTANT: Wrap a vinyl tape on the spline part of the shaft (28) assembly not to damage the lip of the oil seal (30). 8. Install the knock pins (20) (2 used) on the ring gear (1). Install it on the casing (25). NOTE: Align the matching marks on the casing (25) and ring gear (1) when installing. Apply ThreeBond #1104 or #1215 on the mating surfaces of the casing (25) and ring gear (1). 9. Install the casing (6) on the ring gear (1) with the socket bolt (4). : 17 mm : 430 N m (44.0 kgf m) : 30 mm : 430 N m (44.0 kgf m) NOTE: Align the matching marks on the ring gear (1) and casing (6) when installing. Apply ThreeBond #1104 or #1215 on the mating surfaces of the ring gear (1) and casing (6).

17. Install the casing (16) on the casing (6) with the socket bolts (40) (4 used), (35) (10 used) and (15) (3 used). : 10 mm : 98 N m (10.0 kgf m) NOTE: Align the matching marks on the casing (6) with (16) when installing. Apply ThreeBond #1104 or #1215 on the mating surfaces of the casing (6) and (16). 18. Install the O-ring on the casing (16). 19. Lift the swing motor (11) vertically. Install the swing motor (11) on the pinion (7) and tighten with the bolts (10) (4 used). : 24 mm : 235 N m (24.0 kgf m) 20. Install the plug (33) on the casing (25). : 8 mm : 44 N m (4.5 kgf m) NOTE: Wrap the seal tape on the plug (33).

10. Install the sun gear (31) on the shaft (28). 11. Install the shim (2) and bearing (3) on the carrier (17). 12. Install the bearings (5) (2 used) on the pinion (7). 13. Install the bearing (24) on the casing (16). 14. Install the carrier (17) and pinion (7) on the sun gear (31). 15. Install the pin (8) on the casing (6).

16. Install the O-ring (12), cover (14) and retaining ring (13) on the casing (16).

21. Add the gear oil through the oil filler. Amount of Gear Oil: Approx. 9.2 L NOTE: Temporarily install the pipe (36) and level gauge (37) and check the gear oil level. After installing the swing mechanism on the machine, install the pipe (36) and level gauge (37). At this time, completely remove the seal tape from the screwthread and wrap the new seal tape when installing after removing grease.

W2-6-11

SWING MECHANISM / Swing Mechanism DISASSEMBLE SWING MOTOR

27 26

31 32 23

15, 16

W2CD-02-06-003

123456789-

Shoe Retainer Piston (9 Used) Cylinder O-Ring Plug O-Ring Brake Piston O-Ring

10 11 12 13 14 15 16 17 -

Spring (24 Used) Valve Casing Valve Plate Plug Plug Plug (2 Used) O-Ring (2 Used) Bearing

18 19 20 21 22 23 24 25 -

Pin (2 Used) Separator Plate (4 Used) Friction Plate (3 Used) Spring Casing Shaft Oil Seal Bearing

W2-6-12

26 27 28 29 30 31 32 33 -

Shoe Plate Plunger (2 Used) Spring (2 Used) O-Ring (2 Used) Plug (2 Used) Socket Bolt (4 Used) O-Ring (2 Used) Relief Valve (2 Used)

SWING MECHANISM / Swing Mechanism Disassemble Swing Motor

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. CAUTION: Motor weight: 49 kg

1. Put the matching marks on the valve casing (11) and casing (22). 2. Remove the plug (13) from the valve casing (11). Drain the hydraulic oil. : 6 mm 3. Place the shaft end of the shaft (23) downward and secure the shaft (23) on the workbench to disassemble easily. NOTE: Place the rubber plate and cloth on the workbench not to damage the parts. 4. Remove the relief valves (33) (2 used) from the valve casing (11) and remove the O-rings (32) (2 used). : 41 mm

IMPORTANT: Do not fall off valve plate (12) from the valve casing (11). (The valve plate (12) may be attached at the cylinder (4) side.) Do not damage the mating surfaces when separating the valve casing (11) from the casing (22) with using a screwdriver. 6. Loosen the socket bolts (31) (4 used) and remove the valve casing (11) from the casing (22). : 17 mm NOTE: When loosening the socket bolt (31), the valve casing (11) is floated by the spring (10). 7. Remove the O-ring (9), valve plate (12) and pins (18) (2 used) from the valve casing (11). 8. Remove the spring (10) from the brake piston (8).

NOTE: When loosening the relief valve (33), the O-ring (32) is damaged. Be sure to replace the O-ring (32). IMPORTANT: Do not damage the seat part of plunger (27). 5. Remove the plug (30) from the valve casing (11) and remove the O-ring (29), spring (28) and plunger (27). : 14 mm

W2-6-13

SWING MECHANISM / Swing Mechanism

26 25 24

W2CD-02-06-003

W2-6-14

SWING MECHANISM / Swing Mechanism 9. Remove the brake piston (8) from the casing (22).

ዘSpecial Tool (A)

NOTE: Attach the claw of a special tool (A) to the brake piston (8) and pull the brake piston (8) upward straightly.

Special Tool

10. Re-place the motor horizontally. 8

IMPORTANT: Do not damage the sliding surfaces of the cylinder (4) and shoe (1).

11. Remove the cylinder (4), piston (3), retainer (2), shoe (1) and spring (21) from the shaft (23). 12. Remove the friction plate (20) and separator plate (19) from the casing (22). 13. Remove the shaft (23) assembly and shoe plate (26) from the casing (22). NOTE: When removing the shaft (23) assembly, the oil seal (24) is damaged by the spline. Wrap the vinyl tape on the spline of the shaft (23) assembly.

W25N-02-06-009

14 85 75 30 15

14. Remove the oil seal (24) from the casing (22). 35

• If necessary, do the following procedures. Do not use the removed bearings (17) and (25) again.

R12.5

30 14

100 8

NOTE: Evenly tap and remove the inner ring of bearing (25) with using a steel bar.

M16 Penetration

15. Remove the inner ring of bearing (25) from the shaft (23).

M16

16. Remove the outer ring of bearing (25) from the casing (22).

˳8

Special Tool for Brake Piston (8)

NOTE: Evenly tap and remove the outer ring of bearing (25) with using a steel bar. 17. Remove the O-rings (5) and (7) from the casing (22). 18. Remove the bearing (17) from the valve casing (11).

W2-6-15

W25N-02-06-010

SWING MECHANISM / Swing Mechanism ASSEMBLE SWING MOTOR

27 26

31 32 23

15, 16

W2CD-02-06-003

123456789-

Shoe Retainer Piston (9 Used) Cylinder O-Ring Plug O-Ring Brake Piston O-Ring

10 11 12 13 14 15 16 17 -

Spring (24 Used) Valve Casing Valve Plate Plug Plug Plug (2 Used) O-Ring (2 Used) Bearing

18 19 20 21 22 23 24 25 -

Pin (2 Used) Separator Plate (4 Used) Friction Plate (3 Used) Spring Casing Shaft Oil Seal Bearing

W2-6-16

26 27 28 29 30 31 32 33 -

Shoe Plate Plunger (2 Used) Spring (2 Used) O-Ring (2 Used) Plug (2 Used) Socket Bolt (4 Used) O-Ring (2 Used) Relief Valve (2 Used)

SWING MECHANISM / Swing Mechanism Assemble Swing Motor 1. Place the casing (22) on the workbench with placing the valve casing (11) side upward.

8. Install the piston (3) with the shoe (1) installed on the retainer (2) on the cylinder (4).

IMPORTANT: Check the direction of flange of the inner ring of the bearing (25).

9. Align the splines of the cylinder (4) and shaft (23). Install the cylinder (4) assembly on the shaft (23).

2. Install the bearing (25) on the shaft (23).

10. Re-place the casing (22) with placing the oil seal (24) side downward.

NOTE: Shrink the inner ring. IMPORTANT: Check the installing direction of the oil seal (24). When tapping the oil seal (24), do not damage the outer surface of the oil seal. 3. Insert the oil seal (24) into the casing (22).

11. Install the separator plate (19) and friction plate (20) on the casing (22) in order alternately. NOTE: Install the separator plates (19) (4 used) and friction plates (20) (3 used). 12. Install the O-rings (5) and (7) on the casing (22).

NOTE: Apply grease on the lip part of the oil seal (24) thinly. Use a special tool. IMPORTANT: Wrap a vinyl tape on the spline part of the shaft (23) assembly not to damage the lip of the oil seal (24). 4. Install the shaft (23) assembly on the casing (22). 5. Re-place the casing (22) horizontally. 6. Insert the shoe plate (26) into the casing (22). NOTE: Direct the larger-chamfered side of the shoe plate (26) inside of the casing (22). Apply grease on the mating surface to prevent from falling off.

NOTE: Apply grease on the O-rings (5) and (7) thinly. 13. Install the brake piston (8) on the casing (22). 14. Install the spring (10) on the brake piston (8). 15. With tapping the outer ring of the bearing (17) with using a steel bar lightly, insert the bearing (17) into the valve casing (11). NOTE: Evenly tap and insert the outer ring of the bearing (17) until the outer ring stops at the step part of the valve casing (11).

7. Install the retainer (2) and spring (21). Install the piston (3) with the shoe (1).

W2-6-17

SWING MECHANISM / Swing Mechanism

27 28 29 30

31 32 22

W2CD-02-06-003

W2-6-18

SWING MECHANISM / Swing Mechanism 16. Apply grease on the valve casing (11) mounting surfaces of the valve plate (12) and install the valve plate (12) on the valve casing (11). IMPORTANT: Check the installing direction of the valve casing (11). Do not fall off the valve plate (12). Do not fall the spring (10). 17. After installing the O-ring (9) on the valve casing (11), install the valve casing (11) on the casing (22) and tighten the socket bolt (31). : 17 mm : 430 N m (44.0 kgf m) 18. Insert the plunger (27) and spring (28) into the valve casing (11). NOTE: Check if the plunger (27) moves smoothly. 19. Install the O-ring (29) on the plug (30) and tighten the plug (30) to the casing (11). : 14 mm : 334 N m (34.0 kgf m) 20. Install the O-ring (32) on the relief valve (33) and install the relief valve (33) on the valve casing (11). : 41 mm : 177 N m (18.0 kgf m) 21. Add the hydraulic oil into the motor. Wrap the seal tape on the plug (13) and install the plug (13) to the valve casing (11). Amount of Hydraulic Oil: Approx. 0.8 L : 6 mm : 36 N m (3.7 kgf m)

W2-6-19

SWING MECHANISM / Swing Mechanism MAINTENANCE STANDARD Swing Mechanism

• Replacement Standard for Gear Replace the parts when the pitting (1 mm or more a pit, 5% or more on the rate of area) occurs on the tooth of the sun gear (31), planetary gears (21) and ring gear (1). When the damage on the appearance is found even if the pitting does not occur, replace the parts.

Swing Motor 1. Clearance between piston outer diameter and cylinder inner bore. Unit: mm

D-d

Standard

Allowable Limit

0.027

0.052 d

2. Clearance between piston and shoe shrinking portion

W25N-02-04-005

Unit: mm Standard

Allowable Limit

0.3

3. Shoe thickness Unit: mm

Standard

Allowable Limit

5.5

5.3

W25N-02-04-006

4. Friction plate thickness Unit: mm Standard

Allowable Limit

2.0

1.8

W2-6-20

SWING MACHINERY / Hoisting Mechanism REMOVE AND MECHANISM

INSTALL

HOISTING

Removal

1. Lower the boom and remove the hook. After removing the wire rope of the front and rear drum, remove the pendant rope, extension, top section and base section. (As for the removal of the pendant rope, extension, top section and base section, refer to the Operator’s Manual.)

2. Remove the counterweight. (As for the removal of the counterweight, refer to W2-2 in this section.) 3. Loosen the bolt (3) for the left houses (1) and (2) on the hoisting motors of the front and rear drums. Lift the left houses (1) and (2) with the crane and remove them. : 17mm

M2CN-02-07-001

4. Pull out the boom raising/lowering wire rope.

5. Remove the live mast. (As for the removal of the live mast, refer to W2-3 in this section.)

W2-7-1

SWING MACHINERY / Hoisting Mechanism 6. Remove the bolt (12) and remove the drum covers (4 to 7) and brackets (8 to 11). : 19 mm

6 10

7. Move the front and rear drum lock switches in the operator’s cab to the “UNLOCK” position (lock disengaged) and disengage the drum lock.

12 8

NOTE: In case the pawl is not disengaged, the pawl is disengaged when placing the hoisting lever in “hoisting” position slightly with the drum lock switch kept in the “UNLOCK” position (lock disengaged).

8 5 9 9

11 10

M2CN-02-07-002

8. Remove the wire harness and all hoses from the hoisting motor (13). Attach a plug on the removed hoses. : 22 mm : 36 mm : 10 mm

14 15

9. Remove the bolt (14) and remove the bracket (15) from the drum rotation sensor. : 19 mm

M2CN-02-07-003

W2-7-2

SWING MACHINERY / Hoisting Mechanism CAUTION: Hoisting mechanism weight: 1770 kg Hoisting mechanism weight: 1770 kg

(front)

(rear)

IMPORTANT: When lifting the hoisting mechanism with the crane, do not attach a wire rope on the motor.

10. Attach a wire rope on the drum of the hoisting mechanism and support it with the crane.

11. Remove the nut (16) and bolt (17). : 24 mm

12. Remove the bolt (18) and remove the lock plate (19). Pull out the pin (20) and remove the hoisting mechanism with the crane. : 19 mm

Installation CAUTION: Hoisting mechanism weight: 1770 kg Hoisting mechanism weight: 1770 kg

(front) (rear)

18 19

IMPORTANT: When lifting the hoisting mechanism with the crane, do not attach a wire rope on the motor.

17 16

1. Attach a wire rope on the hoisting mechanism. Lift it with the crane and align the hoisting mechanism with the rotating platform.

19 18

2. Install the hoisting mechanism on the rotating platform and lock it with the pin (20). Install the lock plate (19) with the bolt (18). : 19 mm : 60 to 64 N m (6.1 to 6.6 kgf m)

20 18

3. Adjust the right left position of the hoisting mechanism so that the drum flange meshes with the pawl of the drum lock. Tighten the nut (16). : 24 mm : 148 to 160 N m (15.0 to 16.3 kgf m)

19 16

17 M2CN-02-07-004

W2-7-3

SWING MACHINERY / Hoisting Mechanism

4. Install the bracket (15) of the drum rotation sensor. : 19 mm : 60 to 64 N m (6.1 to 6.6 kgf m)

M2CN-02-07-003

6 10

5. Install the wire harness and all hoses on the hoisting motor (13). ᧶22 mm ᧶ 39 N m (4.0 kgf m) ᧶36 mm ᧶ 175 N m (18.0 kgf m) ᧶10 mm ᧶ 90 N m (9.2 kgf m)

12 8

6. Install the drum covers (4 to 7) and brackets (8 to 11) on the revolving frame with the bolt (12). : 19 mm : 60 to 64 N m (6.1 to 6.6 kgf m)

8 5 9 9

11 10

M2CN-02-07-002

W2-7-4

SWING MACHINERY / Hoisting Mechanism 7. Install the live mast. (As for the installation of the live mast, refer to W2-3 in this section.)

8. Wind the wire rope on the boom raising/lowering mechanism. 9. Lift the left houses (1) and (2) with the crane and tighten the bolt (3). : 17mm : 34 to 37 N m (3.5 to 3.8 kgf m)

10. Install the counterweight. (Refer to W2-2 in this section.) 3

11. Wind the wire rope on the front and rear drum and reeve the wire rope through the hook. (Refer to the Operator’s Manual.) 3

M2CN-02-07-001

W2-7-5

SWING MACHINERY / Hoisting Mechanism DISASSEMBLE HOISTING MECHANISM 3,4

12 13 14 15 16

10 11

18 19

20 21

65 22

64 63 43 42 41 40 39 38 37

36 35 34 33

32 31 30

27 28 29

23 24 25

62 61 50

M2CN-02-07-005

12345678910 11 12 13 14 15 16 17 -

Drum Cover Bolt (16 Used) Washer (16 Used) Retainer Ring Gear Spacer Sun Gear Spacer Spacer Spline Shaft O-Ring Pedestal Plug Washer (24 Used) Bolt (24 Used) Casing

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 -

Bracket Washer (24 Used) Bolt (24 Used) Level Gauge Motor Bolt (4 Used) Washer (4 Used) O-Ring Plug Bolt (28 Used) Washer (28 Used) Plug Carrier Pin (5 Used) Spacer (5 Used) Thrust Plate (5 Used) Planetary Gear (5 Used)

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 -

W2-7-6

Needle Bearing (15 Used) Retaining Ring (5 Used) Thrust Plate (3 Used) Needle Bearing (6 Used) Retaining Ring (3 Used) Carrier Planetary Gear (3 Used) Bearing Shaft Bolt (8 Used) Washer (8 Used) Retainer Bearing Bearing Sleeve Oil Seal Retainer

52 53 54 55 56 57 58 59 60 61 62 63 64 65

Bolt (12 Used) Washer (12 Used) Sleeve Oil Seal Bearing Bracket Washer (6 Used) Bolt (6 Used) 1LSSOH Bolt (4 Used) Washer (4 Used) Retainer Plug Retainer

SWING MACHINERY / Hoisting Mechanism Disassemble Hoisting Mechanism CAUTION: Hoisting motor weight: Approx. 270 kg

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. CAUTION: Hoisting mechanism weight: 1770 kg

1. Lift the hoisting mechanism with the crane and remove put it on a workbench. After removing the plugs (26) and (29), drain off the gear oil. Gear oil : 12 L

10. Loosen the bolts (23) (4 used) of the hoisting motor (22). Lift the motor (22) assembly with the crane and remove it. ᧶ 30mm 11. Remove the O-ring (25) from the reduction gear. 12. Loosen the bolts (20) (24 used). Lift the bracket (18) with the crane and remove it. ᧶30mm

NOTE: Drain off the gear oil in the clean container and check the metal powder due to wearing. 2. Remove the bolts (61) (4 used) and remove the retainer (63). : 30 mm 3. Remove the bolts (59) (6 used) and remove the retainer (65). : 30 mm 4. Remove the oil seal (55) from the retainer (65). 5. Remove the sleeve (54) from the drum (1). 6. Lift the bracket (57) with the crane and remove it from the drum (1).

CAUTION: Reduction gear weight: Approx. 580 kg 13. Loosen the bolts (27) (28 used). Lift the reduction gear with the crane and remove it from the drum (1). ᧶30mm 14. Lift the reduction gear with the crane and place it on the workbench with positioning the hoisting motor (22) mounting side downward. At this time, place the wooden block (200 mm square) under the hoisting motor (22) mounting surface and stabilize the reduction gear. 15. Remove the bolts (3) (16 used) and remove the cover (2).

7. Remove the bearing (56) and oil seal (55) from the bracket (57).

᧶19 mm 16. Remove the retainer (5) from the cover (2).

8. Remove the sleeve (54) from the drum (1). 9. Lift the hoisting mechanism with the crane and place it on the workbench with positioning the bracket (57) side downward. At this time, place the wooden block (300 mm square) under the drum (1) and stabilize the hoisting mechanism.

17. Remove the bearing (42) from the cover (2). 18. Pull out the shaft (43). 19. Take out the carrier (40) assembly. 20. Remove the retaining ring (39) (3 used) from the carrier (40). 21. Remove the planetary gears (41) (3 used), thrust plates (37) (3 used) and needle bearings (38) (6 used) from the carrier (40).

W2-7-7

SWING MACHINERY / Hoisting Mechanism 6

10 11

12 13

17 16

36 35 34 33

32 31 30

M2CN-02-07-005

W2-7-8

SWING MACHINERY / Hoisting Mechanism 22. Remove the spacer (7) from the sun gear (8). 23. Remove the sun gear (8) and spacer (9). 24. Loosen the bolts (16) (24 used). Remove the ring gear (6) from the pedestal (13). : 36 mm 25. Take out the carrier (30) assembly. 26. Remove the retaining ring (36) (5 used) from the carrier (30). 27. Remove the pin (31) (5 used) from the carrier (30). 28. Remove the planetary gears (34) (5 used), thrust plates (33) (5 used) and needle bearings (35) (15 used) from the carrier (30). 29. Remove the spacer (10),(32) (5 used) from the carrier (30). 30. Remove the spline shaft (11) from the casing (17). 31. Remove the O-ring (12) from the pedestal (13). 32. Loosen the bolts (44) (8 used). Remove the retainer (46) from the casing (17). : 24 mm 33. Lift the pedestal (13), bearings (47) and (48), retainer (51) and oil seal (50) assembled with the crane and remove it from the casing (17). 34. Remove the bearing (47) from the pedestal (13). 35. Lift the pedestal (13) with the crane and place it on the workbench with positioning the drum (1) mounting side downward. At this time, place the wooden block (200 mm square) under the drum (1) mounting surface. 36. Loosen the bolts (52) (12 used). Remove the retainer (51) from the pedestal (13). : 17 mm 37. Remove the oil seal (50) from the retainer (51). 38. Remove the bearing (48) from the pedestal (13). 39. Remove the sleeve (49) from the casing (17).

W2-7-9

SWING MACHINERY / Hoisting Mechanism ASSEMBLE HOISTING MECHANISM 3,4

12 13 14 15 16

10 11

18 19

20 21

65 22

64 63 43 42 41 40 39 38 37

36 35 34 33

32 31 30

27 28 29

23 24 25

62 61 50

M2CN-02-07-005

12345678910 11 12 13 14 15 16 17 -

Drum Cover Bolt (16 Used) Washer (16 Used) Retainer Ring Gear Spacer Sun Gear Spacer Spacer Spline Shaft O-Ring Pedestal Plug Washer (24 Used) Bolt (24 Used) Casing

18 19 20 21 22 23 24 25 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 51 -

W2-7-10

52 53 54 55 56 57 58 59 60 61 62 63 64 65

Bolt (12 Used) Washer (12 Used) Sleeve Oil Seal Bearing Bracket Washer (6 Used) Bolt (6 Used) 1LSSOH Bolt (4 Used) Washer (4 Used) Retainer Plug Retainer

SWING MACHINERY / Hoisting Mechanism Assemble Hoisting Mechanism 1. Lift the pedestal (13) with the crane and place it on the workbench with positioning the drum (1) mounting side downward. At this time, place the wooden block (200 mm square) under the drum (1) mounting surface.

12. Install the spacer (10) and (32) (5 used) on the carrier (30). 13. Install the the planetary gears (34) (5 used), thrust plates (33) (5 used) and needle bearings (35) (15 used) on the carrier (30).

2. Install the bearing (48) on the pedestal (13). 14. Install the pins (31) (5 used) on the carrier (30) and install the retaining ring (36).

3. Install the oil seal (50) on the retainer (51). 4. Apply the liquid packing (ThreeBond #1215) on the mating surface with the retainer (51) of the pedestal (13). 5. Install the retainer (51) on the pedestal (13) and install the washer (53). Tighten it with the bolts (52) (12 used) with LOCTITE #242 applied. : 17mm : 41 to 45 N m (4.2 to 4.6 kgf m) 6. Lift the casing (17) with the crane and place it on the workbench with positioning the hoisting motor (22) mounting side downward. At this time, place the wooden block (200 mm square) under the hoisting motor (22) mounting surface. 7. Install the sleeve (49) on the casing (17).

15. Install the carrier (30) assembly on the casing (17). 16. Install the sun gear (8) and spacer (9) on the carrier (30) assembly. 17. Install the spacer (7) on the sun gear (8). 18. Install the ring gear (6) on the pedestal (13) and install the washer (15). Tighten it with the bolts (44) (8 used) with LOCTITE #242 applied. : 36mm : 605 to 655 N m (61.7 to 66.8 kgf m) 19. Install the planetary gears (41) (3 used), thrust plates (37) (3 used) and needle bearings (38) (6 used) on the carrier (40) . 20. Install the retaining ring (39) (3 used) on the carrier (40).

8. Install the pedestal (13) on the casing (17). 9. Install the bearing (47) on the casing (17). 10. Install the retainer (46) on the casing (17) and install the washer (45). Tighten it with the bolts (44) (8 used) with LOCTITE #242 applied. : 24mm : 179 to 194 N m (18.3 to 19.8 kgf m) 11. Install the spline shaft (11) on the casing (17).

21. Install the carrier (40) assembly on the ring gear (6) and sun gear (8). 22. Install the shaft (43) on the carrier (40) assembly. At this time, make sure that the shaft (43) rotates by hands. 23. Install the bearing (42) on the shaft (43).

W2-7-11

SWING MACHINERY / Hoisting Mechanism 3,4

18 19

65 22

64 63 43

23 24 27 28

62 61

M2CN-02-07-005

W2-7-12

SWING MACHINERY / Hoisting Mechanism 24. Apply the liquid packing (ThreeBond #1215) on the mating surface with the cover (2) of the ring gear (6).

CAUTION: Hoisting motor weight: Approx. 270 kg

25. Install the cover (2) on the ring gear (6) and tighten with the bolts (3) (16 used) with LOCTITE #242 applied and washer (4). : 19 mm : 72 to 78 N m (7.4 to 8.0 kgf m)

31. Lift the motor (22) assembly with the crane and install it on the casing (17). Tighten with the bolts (23) (4 used) and washer (24). : 30mm : 540 N m (55.0 kgf m)

26. Lift the drum (1) with the crane and place it on the workbench with positioning the bracket (57) mounting side downward. At this time, place the wooden block (300 mm square) under the drum (1) and stabilize the drum (1).

CAUTION: Hoisting mechanism weight: 1770 kg

CAUTION: Reduction gear weight: Approx. 580kg 27. Lift the reduction gear with the crane and install it on the drum (1). Tighten with the bolt (27) (28 used) and washer (28). : 30 mm : 540 N m (55.0 kgf m) 28. Hammer in the shaft (43) end surface several times with a plastic hammer. Make sure that the dimension “L” between the casing (17) end surface and the shaft (43) end is 50 mm. 29. Lift the bracket (18) with the crane and tighten with the bolts (20) (24 used) and washer (19) to the casing (17). : 30 mm : 750 N m (76.5 kgf m) 30. Apply the liquid packing (ThreeBond #1389) on the mating surface with the motor (22) of the casing (17).

32. Lift the hoisting mechanism with the crane and place it on the workbench horizontally. 33. Install the sleeve (54) on the drum (1). 34. Install the oil seal (55) and bearing (56) on the bracket (57). 35. Lift the bracket (57) with the crane and install it on the drum (1). 36. Install the sleeve (54) on the drum (1). 37. Install the oil seal (55) on the retainer (65). 38. Install the retainer (65) on the bracket (57) and tighten with the bolts (59) (6 used) and washer (58). : 30 mm : 88 N m (9.0 kgf m) 39. Tighten the retainer (63) on the sleeve (54) end surface with the bolts (61) (4 used) and washer (62). : 30 mm : 88 N m (9.0 kgf m) 40. Remove the plug (64) and grease through the nipple (60) until the grease (Shell Alvania EP2) comes out from the hole removed. : 7 mm

W2-7-13

SWING MACHINERY / Hoisting Mechanism 13 14 21

M2CN-02-07-005

W2-7-14

SWING MACHINERY / Hoisting Mechanism 41. Install the plug (64). : 7 mm 42. Add the gear oil to the center of the level gauge (21) through the filler port of the pedestal (13). Gear oil : 12 L 43. Install the plug (14) on the filler port of the pedestal (13). NOTE: Wrap the seal tape on the plug (14).

W2-7-15

SWING MACHINERY / Hoisting Mechanism DISASSEMBLE HOISTING MOTOR 14

38 27 40

15 8 50 16 51 19 55 18

1 54 4

46 46 57

5 3 2 17

33 31

M2CN-02-07-006

12345678910 11 12 13 14 15 -

Bolt (4 Used) Front Cover Oil Seal O-Ring Output Shaft Bearing Retaining Ring Socket Bolt (8 Used) Cover Stopper O-Ring Piston Piston O-Ring Stopper

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 -

Cover Bearing Spacer O-Ring O-Ring (4 Used) Pin Swash Plate Plunger (9 Used) Holder Spring (9 Used) Rotor Valve Plate Needle Bearing Plate Shoe Plate Retaining Ring

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 -

Socket Bolt (12 Used) Casing O-Ring (5 Used) Plug (5 Used) Front Casing Socket Bolt (14 Used) O-Ring Pin Valve Cover Socket bolt Shim (1 Unit) O-Ring Socket Bolt (9 Used) Coupling Plate (9 Used)

W2-7-16

46 47 48 49 50 51 52 53 54 55 56 57

Retaining Ring (2 Used) Casing Plug (3 Used) O-Ring (3 Used) O-Ring O-Ring Friction Plate (8 Used) Piston Spring (22 Used) O-Ring Cover Plug

SWING MACHINERY / Hoisting Mechanism Disassemble Hoisting Motor

• Thoroughly

IMPORTANT: When removing the valve cover (39), the valve plate (26) may be removed together. Do not fall off the valve plate (26). 10. Remove the socket bolts (40) and (43) (9 used) and remove the valve cover (39) from the casing (32). : 17 mm 11. Remove the O-rings (19) (2 used) from the casing (32). 12. Remove the valve plate (26) and O-ring (37) from the valve cover (39). NOTE: Do not remove the needle bearing (27) unnecessarily. 13. Remove the rotor (25), plungers (22) (9 used), springs (24) (9 used), holder (23) and plate (28) from the casing (32). 14. Remove the socket bolts (8) (8 used) and remove the covers (9) and (16) from the casing (32). : 14 mm 15. Pull out the stoppers (10), (15), pistons (12) and (13) from the casing (32).

6. Remove the casing (47) from the valve cover (39) and remove the O-rings (50) and (51) from the casing (47).

NOTE: Remove the stoppers (10) and (15) with using a screw (M6).

7. Remove the retaining ring (46), coupling (44) and retaining ring (46) from the output shaft (5).

16. Remove the O-rings (11) and (14) from the stoppers (10) and (15).

8. Remove the plates (45) (9 used), friction plates (52) (8 used), shim (41) and O-ring (42) from the valve cover (39).

17. Remove the bolts (1) (4 used) and remove the front cover (2) from the front casing (35). : 17 mm

9. Remove the retaining ring (30) from the output shaft (5).

18. Remove the oil seal (3) and O-ring (4) from the front cover (2). 19. Remove the socket bolts (36) (14 used) and remove the front casing (35) from the casing (32). : 12 mm

W2-7-17

SWING MACHINERY / Hoisting Mechanism 32

19 18

7 35

M2CN-02-07-006

W2-7-18

SWING MACHINERY / Hoisting Mechanism 20. Remove the O-rings (19) (2 used) from the casing (32) and O-ring (18) from the front casing (35) respectively. 21. Pull out the output shaft (5) from the front casing (35). 22. Remove the retaining ring (7) and bearing spacer (17) from the output shaft (5) and remove the bearing (5) with using a press. 23. Remove the swash plate (21) from the casing (32) and remove the shoe plate (29) from the swash plate (21).

W2-7-19

SWING MACHINERY / Hoisting Mechanism ASSEMBLE HOISTING MOTOR 14

38 27 40

15 8 50 16 51 19 55 18

1 54 4

46 46 57

5 3 2 17

33 31

M2CN-02-07-006

12345678910 11 12 13 14 15 -

Bolt (4 Used) Front Cover Oil Seal O-Ring Output Shaft Bearing Retaining Ring Socket Bolt (8 Used) Cover Stopper O-Ring Piston Piston O-Ring Stopper

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 -

Cover Bearing Spacer O-Ring O-Ring (4 Used) Pin Swash Plate Plunger (9 Used) Holder Spring (9 Used) Rotor Valve Plate Needle Bearing Plate Shoe Plate Retaining Ring

31 32 33 34 35 36 37 38 39 40 41 42 43 44 -

Socket Bolt (12 Used) Casing O-Ring (5 Used) Plug (5 Used) Front Casing Socket Bolt (14 Used) O-Ring Pin Valve Cover Socket bolt Shim (1 Unit) O-Ring Socket Bolt (9 Used) Coupling

W2-7-20

45 46 47 48 49 50 51 52 53 54 55 56 57

Plate (9 Used) Retaining Ring (2 Used) Casing Plug (3 Used) O-Ring (3 Used) O-Ring O-Ring Friction Plate (8 Used) Piston Spring (22 Used) O-Ring Cover Plug

SWING MACHINERY / Hoisting Mechanism Assemble Hoisting Motor 1. Install the shoe plate (29) on the swash plate (21) and install the swash plate (21) on the casing (32).

10. Install the O-ring (14) on the stopper (15) and the o-ring (11) on the stopper (10) respectively. Install the stoppers (10) and (15) on the end of the casing (32).

NOTE: Turn the larger chamfered side of the shoe plate (29) to the swash plate (21) side.

NOTE: Install the stoppers (15) and (10) to the end surface of the casing (32).

2. Install the bearing (6) on the output shaft (5) with using a press and install the bearing spacer (17) and retaining ring (7).

11. Install the cover (9) on the casing (32) with the socket bolts (8) (4 used). : 14 mm : 235 N m (24.0 kgf m)

3. Tap the outer race of the bearing (6) with using a copper bar and install the output shaft (5) ton the front casing (35). 4. Install the O-ring (18) on the front casing (35) and O-rings (19) (4 used) on the casing (32) respectively. 5. Install the front casing (35) and output shaft (5) on the casing (32). IMPORTANT: Check that swash plate (21) moves smoothly. 6. Tighten the socket bolts (36) (14 used). : 12 mm : 160 N m (16.3 kgf m) 7. Install the oil seal (3) on the front cover (2) with using a press and install the O-ring (4). 8. Install the front cover (2) on the front casing (35) and tighten the bolts (1) (4 used). : 17mm : 57 N m (5.8 kgf m) 9. Insert the piston (13) into the front casing (35) side of the casing (32) and the piston (12) into the valve cover (39) side.

12. Install the cover (16) on the casing (32) with the socket bolts (8) (4 used). : 14 mm : 235 N m (24.0 kgf m) 13. Install the springs (24) (9 used) on the rotor (25) and install the holder (23). 14. Install the plungers (22) (9 used) on the plate (28) and insert the plunger (22) into the rotor (25). 15. Align the spline of the output shaft (5), rotor (25) and holder (23). Install the rotor (25) assembly on the output shaft (5). 16. Apply the grease on the valve plate (26). Align with the pin (38) and install the valve plate (26) on the valve cover (39). Install the O-ring (37) on the valve cover (39). 17. Install the O-rings (19) (2 used) on the casing (32). 18. Place the casing (32) on the workbench vertically. 19. Install the valve cover (39) on the casing (32) with the socket bolts (40) and (43) (9 used). : 17 mm : 430 N m (43.8 kgf m)

W2-7-21

SWING MACHINERY / Hoisting Mechanism 27

50 51 55 56 54 30 46 46

33 31 53 47

M2CN-02-07-006

W2-7-22

SWING MACHINERY / Hoisting Mechanism 20. Install the retaining ring (30) on the output shaft (5) and fix the needle bearing (27). 21. Install the retaining ring (46) on the output shaft (5). 22. Install the coupling (44) on the output shaft (5) and install the retaining ring (46). IMPORTANT: Align the notches on the plate (45) and friction plate (52). Adjust with the shims (41) so that the dimension between the end of the valve cover (39) and the plate (45) is 3.1 mm. 23. Install the shim (41), plates (45) (9 used) and friction plates (52) (8 used) on the valve cover (39) and coupling (44). 24. Install the O-ring (42) on the valve cover (39). 25. Install the O-rings (50) and (51) on the casing (47) and install the piston (53). 26. Install the springs (54) (22 used) on the piston (53). 27. Install the O-ring (55) on the cover (56) and install the cover (56) on the casing (47) with the socket bolts (31) (12 used). : 10 mm : 98 N m (10.0 kgf m) 28. Install the O-ring (33) on the plug (34) and install the plug (34) on the casing (32). : 36 mm : 167 N m (17.0 kgf m)

W2-7-23

SWING MACHINERY / Hoisting Mechanism MAINTENANCE STANDARD Dial Gauge

1. Secure the plunger with the shoe attached in a vise. Install the dial gauge on the shoe. Move the shoe upward and downward and measure the clearance between the shoe and the spherical part of plunger. In case the measurement value is beyond the allowable limit, replace the plunger and shoe assembly.

Clearance

Guide

Unit: mm Standard

Allowable Limit

0 to 0.1

0.3

Vise

Soft Liner

W309-04-05-002

Remedy: Replace the shoe and the plunger as an assembly.

2. Measure the plunger diameter at upper, middle, lower positions (2 places for each) with using a micrometer. Measure the diameter at the second position 90 degrees away from the first position. Measure the rotor bore inner diameter at positions A and B (2 places for each) with using a cylinder gauge.

W309-04-05-003

Unit: mm Standard

Allowable Limit

0.039

0.078

Remedy: Replace the plunger or the rotor.

3. Measure the shoe thickness B with using a micrometer. Unit: mm Standard

Allowable Limit

8.8

8.6 W309-04-05-004

B W309-04-05-005

W2-7-24

SWING MACHINERY / Hoisting Mechanism 4. Measure the heights of H and h. Plate

C=H-h

Holder

Unit: mm Standard

Allowable Limit

32.2

31.6

H h

Remedy: Replace the holder and the plate as an assembly. W309-04-05-006

5. Measure the dimension A. Unit: mm Standard

Allowable Limit

3.1

3.6 A

Remedy: Adjust with the shims.

6. Measure the brake spring length. Unit: mm Standard

Allowable Limit

53.2

W309-04-05-007

Remedy: Replace the spring.

7. Measure the thickness of the plate and friction plate. (17 used) Unit: mm Standard

Allowable Limit

32.4

31.7

Remedy: Replace the plate.

W2-7-25

SWING MACHINERY / Hoisting Mechanism DISASSEMBLE REGULATOR 29

16 15 17

10 13

37 39

3 33 34

22 23 19 21

M2CN-02-07-007

12345678910 11 -

Plug (2 Used) O-ring (2 Used) Plug Casing Socket bolt (2 used) Spacer (2 Used) Solenoid Valve Spring O-ring Cover (2 Used) Socket bolt (4 Used)

12 13 14 15 16 17 18 19 20 21 22 -

Nut (2 Used) Adjusting Screw (2 Used) Pin 6SULQJ VHDW Spool Sleeve Lock pin Spring O-ring Plug Sleeve

23 24 25 26 27 28 29 30 31 32 33 -

W2-7-26

Spool Spring seat Spring seat O-ring Spring O-ring O-ring O-ring Orifice Plug O-ring

34 35 36 37 38 39 40 41 42 43 -

3LVWRQ Pin O-ring Socket bolt (6 Used) Cover O-ring Sleeve Piston Lever Pin

SWING MACHINERY / Hoisting Mechanism Disassemble Regulator

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.

10. Remove the plug (32) from the casing (4). : 8 mm 11. Remove the O-ring (33) from the plug (32).

1. Remove the solenoid valve (6) from the casing (4). : 32 mm 2. Remove the socket bolts (5) (4 used) and remove the casing from the hoisting motor (4). : 6 mm

12. Remove the lever (42) from the sleeve (17). 13. Remove the spring seat (9), spring (7), spring seat (15), spool (16) and sleeve (17) from the casing (4). 14. Remove the O-ring (8) from the spring seat (9).

3. Remove the O-rings (28) and (30) from the casing (4). 4. Remove the orifice (31) from the casing (4). : 4 mm

15. Remove the plug (21) from the casing (4) and remove the spring (19) and lock pin (18). : 13 mm 16. Remove the O-ring (20) from the plug (21).

5. Remove the socket bolts (37) (6 used) and remove the cover (38) from the casing (4). : 5 mm 6. Remove the O-rings (29), (36) and (39) from the casing.

17. Remove the spring seat (25), spring (27), spring seat (24), spool (23) and sleeve (22) from the casing (4). 18. Remove the O-ring (26) from the spring seat (25).

7. Remove the pin (35) and piston (34) from the cover (38). 8. Remove the piston (41) and sleeve (40) from the cover (38). 9. Remove the socket bolt (11) and remove the covers (10) (2 used) from the casing (4). : 5 mm IMPORTANT: Do not disassemble the adjusting nut (13) and nut (12).

W2-7-27

SWING MACHINERY / Hoisting Mechanism ASSEMBLE REGULATOR 29

16 15 17

10 13

37 39

3 33 34

22 23 19 21

M2CN-02-07-007

12345678910 11 -

Plug (2 Used) O-ring (2 Used) Plug Casing Socket bolt (2 used) Spacer (2 Used) Solenoid Valve Spring O-ring Cover (2 Used) Socket bolt (4 Used)

12 13 14 15 16 17 18 19 20 21 22 -

Nut (2 Used) Adjusting Screw (2 Used) Pin 6SULQJ VHDW Spool Sleeve Lock pin Spring O-ring Plug Sleeve

23 24 25 26 27 28 29 30 31 32 33 -

W2-7-28

Spool Spring seat Spring seat O-ring Spring O-ring O-ring O-ring Orifice Plug O-ring

34 35 36 37 38 39 40 41 42 43 -

3LVWRQ Pin O-ring Socket bolt (6 Used) Cover O-ring Sleeve Piston Lever Pin

SWING MACHINERY / Hoisting Mechanism Assemble Regulator 1. Install the sleeve (22), spool (23), spring seat (24) and spring (27) on the casing (4).

10. Install the O-ring (8) on the spring seat (9) and install it on the casing (4).

2. Install the O-ring (26) on the spring seat (25) and install it on the casing (4).

11. Install the cover (10) on the casing with the socket bolt (11). : 5 mm : 12 N m (1.2 kgf m)

3. Install the cover (10) on the casing (4) with the socket bolt (11). : 5 mm : 12 N m (1.2 kgf m) 4. Install the lock pin (18) and spring (19) on the casing (4).

12. Install the piston (34) on the casing (4). 13. Install the O-rings (29), (36) and (39) on the casing (4). 14. Install the pin (35) on the cover (38).

5. Install the O-ring (20) on the plug (21) and install it on the casing (4). : 13mm : 29 N m (3.0 kgf m)

15. Install the sleeve (40) and piston (41) on the cover (38).

6. Install the sleeve (17) and spool (16) on the casing (4).

16. Install the cover (38) on the casing with the bolts (37) (6 used). : 5 mm : 12 N m (1.2 kgf m)

7. Install the lever (42) on the sleeve (17). 8. Install the O-ring (33) on the plug (32) and install it on the casing (4). : 8 mm : 44 N m (4.5 kgf m) 9. Install the spring seat (15) and spring (7) on the casing (4).

17. Install the orifice (31) on the casing (4) and install the O-rings (28) and (30). : 4 mm : 9 N m (0.9 kgf m) 18. Install the casing (4) on the hoisting motor with the socket bolts (5) (4 used). : 6 mm : 29 N m (3.0kgf m) 19. Install the solenoid valve (6) on the casing (4). : 32mm : 44 N m (4.5 kgf m)

W2-7-29

SWING MACHINERY / Hoisting Mechanism DISASSEMBLE COUNTERBALANCE VALVE

19 21

15 20

7 6 35

5 17

13 14

22 23 25 26

12 13

27 28

10 11

29 30 31 32

33 33

M2CN-02-07-008

123456789-

Socket Bolt (4 Used) Spring Washer (4 Used) Cover O-Ring Plug Spool Steel Ball Spring Orifice

10 11 12 13 14 15 16 17 18 -

Plug O-Ring Plug (2 Used) O-Ring (2 Used) Casing Socket Bolt (6 Used) Spring Washer (6 Used) Plug O-Ring

19 20 21 22 23 24 25 26 27 -

Air Bleed Valve O-Ring Plug Socket Bolt (4 Used) Spring Washer (4 Used) Cover O-Ring Spring Seat

W2-7-30

28 29 30 31 32 33 34 35 -

Plunger Spring O-Ring Backup Ring Plug O-Ring (2 Used) Relief Valve Filter

SWING MACHINERY / Hoisting Mechanism Disassemble Counterbalance Valve

11. Remove the spring (29) and plunger (28) from the casing (14).

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.

1. Remove the O-rings (33) (2 used) from the casing (14). 2. Remove the socket bolts (1) and (22) (4 used for each) and remove the covers (3) and (24) from the casing (14). : 10 mm

NOTE: Do not remove the seat (27) except when replacing the seat. 12. Remove the relief valve (34) from the casing (14) and remove the O-ring and backup ring from the relief valve (34). : 50 mm

3. Remove the plug (21) from the cover (24) and remove the O-ring (20) from the plug (21). : 6 mm 4. Remove the plug (10) from the cover (3) and remove the O-ring (11) from the plug (11). : 6 mm 5. Remove the spring (26) and O-rings (4) and (25) from the casing (14). 6. Pull out the spool (6) assembly from the casing (14). 7. Remove the plug (5) from the spool (6) and remove the filter (35) from the plug (5). 8. Remove the orifice (9), spring (8) and steel ball (7) from the spool (6). 9. Remove the plug (32) from the casing (14). : 50 mm 10. Remove the O-ring (30) and backup ring (31) from the plug (32).

W2-7-31

SWING MACHINERY / Hoisting Mechanism ASSEMBLE COUNTERBALANCE VALVE 22

3 11

21 1 2

32 17

15 16

M2CN-02-07-009

123456789-

Socket Bolt (4 Used) Spring Washer (4 Used) Cover O-Ring Plug Spool Steel Ball Spring Orifice

10 11 12 13 14 15 16 17 18 -

Plug O-Ring Plug (2 Used) O-Ring (2 Used) Casing Socket Bolt (6 Used) Spring Washer (6 Used) Plug O-Ring

19 20 21 22 23 24 25 26 27 -

Air Bleed Valve O-Ring Plug Socket Bolt (4 Used) Spring Washer (4 Used) Cover O-Ring Spring Seat

W2-7-32

28 29 30 31 32 33 34 35 -

Plunger Spring O-Ring Backup Ring Plug O-Ring (2 Used) Relief Valve Filter

SWING MACHINERY / Hoisting Mechanism Assemble Counterbalance Valve 1. Install the O-ring and backup ring on the relief valve (34). 2. Install the relief valve (34) on the casing (14). : 50 mm : 166 to 186 N m (17.0 to 19.0 kgf m) 3. Install the O-ring (30) and backup ring (31) on the plug (32).

4. Insert the spring (29) into the plunger (28) and install the plunger (28) on the plug (32).

14. Install the O-ring (20) on the plug (21) and install the plug (21) on the cover (24). : 6 mm : 34 to 38 N m (3.5 to 3.9 kgf m)

5. Install the plug (32) on the casing (14). : 50 mm : 181 to 211 N m (18.5 to 21.5 kgf m)

15. Install the O-rings (33) (2 used) on the casing (14).

6. Insert the filter (35) into the plug (5) and install the plug (5) on the spool (6). 7. Install the steel ball (7), spring (8) and orifice (9) on the spool (6). 8. Insert the spool (6) into the casing (14). IMPORTANT: Check if the spool (6) moves smoothly with pushing the spool. 9. Install the spring (26) on the casing (14). 10. Install O-rings (4) and (25) on the casing (14). 11. Install the cover (3) on the casing (14) and tighten with the socket bolts (1) and spring washers (2) (4 used for each). : 10 mm : 88 to 108 N m (9.0 to 11.0 kgf m)

W2-7-33

SWING MACHINERY / Hoisting Mechanism DISASSEMBLE REEVING WINCH 1

13,14 15 16 17 18

W2CG-02-07-011

12345678-

Drum Spacer Spacer Ring Gear Carrier Assembly Spacer Pin (4 Used) Thrust Plate (8 Used)

910 11 12 13 14 15 16 -

Planetary Gear (4 Used) Needle Bearing (8 Used) Spring Pin (4 Used) Carrier Plug (2 Used) O-Ring (2 Used) Motor Retaining Ring

17 18 19 20 21 22 23

Oil Seal Sleeve Retaining Ring Bearing O-Ring Thrust Plate Sun Gear

W2-7-34

24 25 26 27 28 29 30

Coupling Spring Shaft O-Ring End Cover Plug (2 Used) Socket Bolt (12 Used)

SWING MACHINERY / Hoisting Mechanism Disassemble Reeving Winch 11. Take out the carrier (12) assembly.

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. CAUTION: Reeving winch weight: Approx. 93 kg

1. Remove the plug (13) and drain off the gear oil. Gear oil: 0.5 L NOTE: Drain the gear oil in the clean container and check the metal powder due to wearing. 2. Lift the reeving winch with the crane and place it on a workbench with placing the motor (15) downward. At this time, place the wooden block (200 mm square) under the motor (15) mounting surface to stabilize the reduction gear.

12. Remove the spacer (6) from the Carrier (12). 13. Remove the spring pin (11) and pull out the pins (7) (4 used) from the carrier (12). 14. Remove the planetary gears (9) (4 used), thrust plates (8) (8 used) and needle bearings (10) (8 used) from the carrier (12). 15. Remove the sun gear (23), coupling (24) and thrust plate (22) from the motor (15). 16. Remove the retaining ring (19) from the motor (15) and remove the bearing (20) and sleeve (18). 17. Remove the oil seal (17) from the motor (15).

3. Remove the bolts (30) (12 used). Lift the drum (1) with the crane and remove it. : 10 mm 4. Remove the retaining ring (16) from the drum (1). 5. Remove the spacers (2) and (3) from the ring gear (4). 6. Remove the end cover (28) and ring gear (4) from the reduction gear. 7. Remove the O-ring (27) from the end cover (28). 8. Remove the O-ring (21) from the ring gear (4). 9. Remove the carrier (5) assembly from the shaft. 10. Remove the shaft (26) and spring (25) from the coupling (24).

W2-7-35

SWING MACHINERY / Hoisting Mechanism ASSEMBLE REEVING WINCH 1

13,14 15 16 17 18

W2CG-02-07-011

12345678-

Drum Spacer Spacer Ring Gear Carrier Assembly Spacer Pin (4 Used) Thrust Plate (8 Used)

910 11 12 13 14 15 16 -

Planetary Gear (4 Used) Needle Bearing (8 Used) Spring Pin (4 Used) Carrier Plug (2 Used) O-Ring (2 Used) Motor Retaining Ring

17 18 19 20 21 22 23

Oil Seal Sleeve Retaining Ring Bearing O-Ring Thrust Plate Sun Gear

W2-7-36

24 25 26 27 28 29 30

Coupling Spring Shaft O-Ring End Cover Plug (2 Used) Socket Bolt (12 Used)

SWING MACHINERY / Hoisting Mechanism Assemble Reeving Winch 12. Install the O-ring on the end cover (28) and install the end cover (28) on the ring gear (4).

1. Lift the motor (15) with the crane and place it on the workbench. At this time, place the wooden block (200 mm square) under the motor (15).

13. Install the spacers (2) and (3) on the ring gear (4).

2. Install the oil seal (17) on the motor (15).

14. Install the retaining ring (16) on the drum (1).

3. Install the sleeve (18) and bearing (20) on the motor (15) and install the retaining ring (19).

15. Install the Install the drum (1) on the ring gear (4) with the bolts (30) (12 used). : 10 mm : 140 Nዘm (140. Kgfዘm)

4. Install the thrust plate (22), coupling (24) and sun gear (23) on the motor (15).

16. Add the gear oil through the plug (13) hole of the drum (1). Gear oil: 0.5 L

5. Install the planetary gears (9) (4 used), thrust plates (8) (8 used) and needle bearings (10) (8 used) on the carrier (12).

17. Install the O-ring (14) on the plug (13) and install it on the drum (1).

6. Install the pins (7) (4 used) on the carrier (12) and insert the spring pin (11). At this time, turn the slit portion of the spring pin (11) to the motor side. 7. Install the carrier (12) assembly on the sun gear (23) and motor (15). 8. Place the spacer (6) on the carrier (12). 9. Install the spring (25) and shaft (26) on the coupling (24). 10. Install the carrier (5) assembly on the shaft (26). 11. Install the O-ring (21) on the ring rear (4) and install the ring gear (4) on the carrier (12) assembly and carrier (5) assembly.

W2-7-37

SWING MACHINERY / Hoisting Mechanism DISASSEMBLE REEVING WINCH MOTOR

11,46

35 36

5 6 4 3 2 1

38 15

19 31 30

W2CG-02-07-012

12345678910 11 12 -

Cylinder Inner Ring Oil Seal Bearing Shoe Plate Collar Plate Auxiliary Spring Plunger (7 Used) Expander O-Ring Plug

13 14 15 16 17 18 19 20 21 22 23 24 -

Expander Plug (2 Used) Disk Spring (4 Used) Teflon Ring (4 Used) Bushing (4 Used) Bearing Retaining Ring Piston (2 Used) Teflon Ring (2 Used) Balance Plate O-Ring (2 Used) Teflon Ring

25 26 27 28 29 30 31 32 33 34 35 36 -

Spring (8 Used) Housing O-Ring Teflon Ring Piston Plate (3 Used) Friction Plate (3 Used) Socket Bolt (4 Used) Cover Plunger Spacer (2 Used) O-Ring (2 Used)

W2-7-38

37 38 39 40 41 42 43 44 45 46

Spring (2 Used) Piston (2 Used) Plug (2 Used) Spacer (2 Used) Plug (2 Used) Spring (2 Used) O-Ring (2 Used) Piston (2 Used) Pin (2 Used) Teflon Ring

SWING MACHINERY / Hoisting Mechanism Disassemble Reeving Winch Motor 12. Remove the oil seal (3) from the housing (26).

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.

1. Place the reeving winch motor on a workbench and remove the plug (14) from the casing (33). Drain off the hydraulic oil. : 6 mm 2. Loosen the socket bolts (32) (4 used) evenly and remove the cover (33) assembly from the housing (26). : 8 mm 3. Remove the springs (25) (8 used) from the piston (29). 4. Remove the piston (29) from the housing (26). 5. Remove the Teflon ring (24) and O-ring (23) from the piston (29).

13. Remove the O-ring (23), Teflon ring (46) and O-ring (11) from the cover (33). 14. Remove the retaining ring (19) from the shaft of the cover (33) and pull out the bearing (18) with using a press. 15. Remove the balance plate (22) from the shaft of the cover (33). 16. Remove the pistons (20) (2 used) and Teflon rings (21) (2 used) from the balance plate (22). 17. Remove the bushings (17) (4 used), Teflon rings (16) (4 used) and disk springs (15) (4 used) from the cover (33). 18. Remove the plugs (39) (2 used), pistons (38) (2 used), spacers (40) (2 used) and O-rings (36) (2 used) from the cover (33). : 41 mm

6. Remove the Teflon ring (28) and O-ring (27) from the housing (26).

19. Remove the springs (37) (2 used) and spacers (35) (2 used) from the cover (33).

7. Remove the Remove the cylinder (1) assembly from the housing.

20. Remove the O-rings (36) (2 used), spacers (40) (2 used) and pistons (38) (2 used) from the plug (39).

8. Remove the inner ring (2) from the cylinder (1) and pull out the bearing (4) with using a press.

21. Pull out the plunger (34) from the cover (33).

9. Remove the collar (6) from the cylinder (1). 10. Remove the shoe plate (5), plungers (9) (7 used), plate (7) and auxiliary spring (8) from the cylinder (1). 11. Remove the plates (30) (3 used) and friction plates (31) (3 used) from the housing (26).

22. Remove the plugs (41) (2 used) from the cover (33). : 12 mm 23. Remove the springs (42) (2 used) and pistons (44) (2 used) from cover (33). 24. Remove the O-rings (43) (2 used) from the plug (41).

W2-7-39

SWING MACHINERY / Hoisting Mechanism ASSEMBLE REEVING WINCH MOTOR

11,46

35 36

5 6 4 3 2 1

38 15

19 31 30

W2CG-02-07-012

12345678910 11 12 -

Cylinder Inner Ring Oil Seal Bearing Shoe Plate Collar Plate Auxiliary Spring Plunger (7 Used) Expander O-Ring Plug

13 14 15 16 17 18 19 20 21 22 23 24 -

Expander Plug (2 Used) Disk Spring (4 Used) Teflon Ring (4 Used) Bushing (4 Used) Bearing Retaining Ring Piston (2 Used) Teflon Ring (2 Used) Balance Plate O-Ring (2 Used) Teflon Ring

25 26 27 28 29 30 31 32 33 34 35 36 -

Spring (8 Used) Housing O-Ring Teflon Ring Piston Plate (3 Used) Friction Plate (3 Used) Socket Bolt (4 Used) Cover Plunger Spacer (2 Used) O-Ring (2 Used)

W2-7-40

37 38 39 40 41 42 43 44 45 46

Spring (2 Used) Piston (2 Used) Plug (2 Used) Spacer (2 Used) Plug (2 Used) Spring (2 Used) O-Ring (2 Used) Piston (2 Used) Pin (2 Used) Teflon Ring

SWING MACHINERY / Hoisting Mechanism Assemble Reeving Winch Motor 1. Install the O-rings (43) (2 used) on the plugs (41) (2 used). 2. Install the pistons (44) (2 used) and springs (42) (2 used) on the cover (33).

13. Install the plungers (9) (7 used) on the plate (7) and insert the auxiliary spring (8) and plunger (9) into the cylinder (1). 14. Insert the shoe plate (5) into the cylinder (1). 15. Insert the collar (6) into the cylinder (1).

3. Install the plugs (41) (2 used) on the cover (33). : 12 mm 4. Insert the plunger (34) into the cover (33).

16. Insert the bearing (4) into the output shaft of the cylinder (1) with using a press and install the inner ring (2).

5. Install the spacers (35) (2 used) and springs (37) (2 used) on the cover (33).

17. Insert the cylinder (1) assembly into the housing (26).

6. Install the pistons (38) (2 used), spacers (40) (2 used) and O-rings (36) (2 used) on the plugs (39) (2 used) and install the plugs (39) (2 used) on the cover (33). : 41mm

18. Install the O-ring (23) and Teflon ring (28) on the housing (26).

7. Install the disk springs (15) (4 used), Teflon rings (16) (4 used) and bushings (17) (4 used) on the cover (33).

20. Install the springs (25) (8 used) on the piston (29).

8. Install the Teflon rings (21) (2 used) and pistons (20) (2 used) on the balance plate (22) and insert the balance plate (22) into the shaft of the cover (33). 9. Insert the bearing (18) into the shaft of the cover (33) with using a press and install the retaining ring (19).

19. Install the O-ring (23) and Teflon ring (24) on the piston (29) and install the piston (29) on the housing (26).

21. Install the cover (33) assembly on the housing (26) with the socket bolts (32) (4 used). : 8 mm : 50 N m (5.1 kgf m) 22. Install the plug (14) on the cover (33). : 6 mm

10. Install the O-ring (11), Teflon ring (46) and O-ring (23) on the cover (33). 11. Insert the oil seal (3) into the housing (26) with using a press. 12. Install the friction plates (31) (3 used) and plates (30) (3 used) on the housing (26).

W2-7-41

SWING MACHINERY / Hoisting Mechanism (Blank)

W2-7-42

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) REMOVE AND MECHANISM

INSTALL RAISING/LOWERING

Removal 1. Lower the boom and remove the pendant rope, extension, top section and base section. (As for removal of the pendant rope, extension, top section and base section, refer to the Operator’s Manual.) 2. Remove the counterweight. (As for removal of the counterweight, refer to W2-2 in this section.) 2

3. Remove the boom raising/lowering wire rope. 4. Loosen the bolts (2) that installs the left house (1) on the raising/lowering motor and remove the house with lifting it with the crane. : 17 mm

M2CN-02-08-001

5. Remove the live mast. (As for removal of the live mast, refer to W2-3 in this section.)

11 11 7

6. Remove the bolts (8), (9), (10) and (11). Remove the drum covers (3), (4), (5), bracket (6) and plate (7). : 19 mm : 17 mm

9 8

8 9 8 10 10

3 6 10 6 10

M2CN-02-08-002

W2-8-1

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) 7. Remove all hoses from the raising/lowering motor (12). Attach a plug on the removed hoses. : 27 mm : 10 mm

12 13

8. Remove the bolt (13) and remove the bracket (14) of the drum speed sensor. : 19 mm CAUTION: Raising/lowering mechanism weight: 1670 kg 9. Attach a wire rope on the raising/lowering mechanism and support the raising/lowering mechanism with the crane.

W2CG-02-08-003

10. Remove the nut (15) and remove the bolt (16). : 24 mm 11. Remove the bolts (17) and remove the lock plate (18). After removing the pin (19), lift the raising/lowering mechanism with the crane and remove it. : 19 mm

Installation

CAUTION: Raising/lowering mechanism weight: 1670 kg 1. Attach a wire rope on the raising/lowering mechanism. Lift the raising/lowering mechanism with the crane and align the raising/lowering mechanism with the revolving frame. 2. Install the raising/lowering mechanism on the revolving frame. Install the lock plate (18) with the bolt (18). :19 mm :60 to 64 N m (6.1 to 6.6 kgf m)

19 19 17 18

M2CN-02-08-003

3. Adjust the raising/lowering mechanism with using the bolt (16) so that the flange of the drum can be aligned with the pawl of the drum lock and tighten it with the nut (15). : 24 mm : 148 to 160 N m (15.0 to 16.3 kgf m)

4. Install the bracket (14) of the drum speed sensor on the raising/lowering mechanism with the bolt (13). : 19 mm : 60 to 64 N m (6.1 to 6.6 kgf m) 5. Install all hoses on the raising/lowering motor (12). : 27 mm :93 N m (9.5 kgf m) : 10 mm :90 N m (9.2 kgf m)

W2-8-2

12 13

W2CG-02-08-003

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) 6. Install drum covers (3, 4, 5), bracket (6) and plate (7) to the revolving frame with bolts (8, 9, 10, 11). : 19 mm : 60 to 64 N m (6.1 to 6.6 kgf m) : 17 mm : 34 to 37 N m (3.5 to 3.8 kgf m)

11 11 7 9

8 9

3 6

M2CN-02-08-002

7. Install the live mast. (As for installation of the live mast, refer to W2-3 in this section.)

8. Wind the boom raising/lowering wire rope. 9. Lift the left house (1) with the crane. Install the right house with the bolt (2). : 17 mm : 34 to 37 N m (3.5 to 3.8 kgf m) 10. Install the counterweight. (Refer to W2-2 in this section.) 11. Install the base section. (As for installation of the base section, refer to the Operator’s Manual.) 12. Install the extension and top section on the base section and install the pendant rope. (Refer to the Operator’s Manual.) 13. Start the engine. After raising/lowering the boom, check raising/lowering mechanism for any oil leaks.

W2-8-3

M2CN-02-08-001

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) DISASSEMBLE RAISING/LOWERING MECHANISM 19 18

7 5,6 3 4

13 12 11 10

16,17 15

24 23

25 26

22 21

30 31

35 36

42 43 44 45 46 47 48 49 50

82 81 80 79

54 55 56

57 68

65 64

M2CN-02-08-004

12345678910 11 12 13 14 15 16 17 18 19 20 21 -

Motor Socket Bolt (4Used) O-Ring Sleeve Bolt (12 Used) Washer (12 Used) Bolt (32 Used) Washer (32 Used) Bracket Pedestal Bolt (30 Used) Washer (30 Used) Bolt (30 Used) Washer (30 Used) Lock Plate Bolt Washer Spacer O-Ring Carrier Spacer

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 -

Ring Gear Sun Gear Bearing Bolt (24 Used) Washer (24 Used) Bracket Washer (24 Used) Bolt (24 Used) Retaining Ring Carrier Ring Gear Spacer Sun Gear Carrier Spacer Washer (16 Used) Bolt (16 Used) Bearing Sleeve (2 Used) Bracket Bearing

43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 -

W2-8-4

Retainer Nipple Oil seal (2 Used) Bolt (4 Used) Washer(4 Used) Retainer Nipple Bolt (6 Used) Washer (6 Used) Drum Cover Retaining Ring (3 Used) Needle Bearing (6 Used) Retainer Planetary Gear (5 Used) Thrust Plate (3 Used) Retaining Ring (5 Used) Planetary Gear (5 Used) Needle Bearing (15 Used) Spacer (5 Used) Thrust Plate (5 Used)

64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 -

Spacer Pin (5 Used) Spacer Retaining Ring Retaining Ring (5 Used) Retaining Ring (5 Used) Planetary Gear (5 Used) Needle Bearing (10 Used) Retaining Ring (5 Used) Sleeve (5 Used) Plug Pin (5 Used) Nut Spline Shaft Case Bearing (2 Used) Retainer Oil seal Plug Shaft

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) Disassemble Raising/Lowering Mechanism CAUTION: Motor (1) weight: Approx. 103 kg

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. CAUTION: Raising/lowering mechanism weight: Approx. 2000 kg

1. Lift the raising/lowering mechanism with the crane and place it on a workbench. Remove the plug (74) and drain off the gear oil. Gear oil : 17 L NOTE: Drain the gear oil in the clean container and check the metal powder due to wearing. 2. Loosen the bolts (46) (4 used) and remove the retainer (48). : 19mm 3. Remove the bolts (50) (6 used) and remove the retainer (43). : 19mm 4. Remove the oil seal (45) from the retainer (43). 5. Remove the sleeve (40) from the drum (52). 6. Lift the bracket (41) with the crane and remove it from the drum (52). 7. Remove the bearing (42) and oil seal (45) from the bracket (41). 8. Remove the sleeve (40) from the drum (52). 9. Lift the raising/lowering mechanism with the crane and place it on a workbench with placing the bracket (41) mounting side downward. At this time, place the wooden block (200 mm square) under the drum (52) to stabilize the raising/lowering mechanism.

10. Remove the bolts (2) (4 used). Lift the motor (1) with the crane and remove it from the case (78). : 14 mm 11. Remove the bolts (58) (4 used). Lift the bracket (3) with the crane and remove it from the pedestal (9). : 14 mm 12. Remove the O-ring (3) from the case (78). 13. Put the mark on the head of the case (78) and bracket (9) and remove the bolts (7) (32 used). Lift the bracket (9) with the crane and remove it from the case (78). : 36 mm CAUTION: Reduction gear weight: Approx. 1060 kg 14. Remove the bolts (13) (30 used). Lift the reduction gear with the crane and remove it from the drum (52). : 32 mm 15. Lift the reduction gear with the crane and place it on a workbench with placing the raising/lowering motor (1) mounting side downward. At this time, place the wooden block (200 mm square) under the bracket (9) mounting surface of the case (78) to stabilize the reduction gear. 16. Remove the bolts (38) (20 used) and remove the cover (53). : 19 mm 17. Remove the retainer (56) from the cover (53). 18. Remove the bearing (39) from the cover (53). 19. Remove the shaft (83).

W2-8-5

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) 19 18

16,17 15

11 10

24 23

32 33

22 21

5,6 4

30 31

35 36

81 80 79

54 55

76 75

70 73

65 64

M2CN-02-08-004

W2-8-6

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) 20. Remove the carrier (35) assembly.

35. Remove the carrier (20) assembly.

21. Remove the retaining rings (54) (3 used) from the carrier (35).

36. Remove the retaining rings (69) (5 used) from the carrier (20).

22. Remove the planetary gears (57) (3 used), thrust plates (58) (3 used) and needle bearings (55) (6 used) from the carrier (35).

37. Remove the planetary gears (70) (5 used), sleeves (73) (5 used), pins (75) (5 used) and spacer (21) from the carrier (20).

23. Remove the spacer (36) from the carrier (35).

38. Remove the retaining rings (68) (5 used), and (72) (5used) from the planetary gears (70) (5 used). Remove the needle bearings (70) (10 used).

24. Remove the sun gear (34). 25. Remove the carrier (31) assembly.

39. Remove the spacer (18) and spline shaft (77) from the case (78).

26. Remove the retaining rings (59) (5 used) from the carrier (31). 27. Remove the planetary gears (60) (5 used) and thrust plates (63) (5 used), needle bearings (61) (15 used) and pins (65) (5 used) from the carrier (31). 28. Remove the spacer (33) and (62) from the carrier (31).

40. Remove the bolt (16) and remove the lock plate (15). : 13 mm 41. Remove the nut (76) from the case (78). 42. Remove the pedestal (10) and sleeve (4) from the case (78). 43. Remove the bearing (79) from the pedestal (10).

29. Remove the spacer (64) and (66) from the sun gear (23). 30. Remove the retaining rings (30) from the bracket (27).

44. Remove the bolts (5) (12 used) and remove the retainer (80). : 19 mm 45. Remove the oil seal (81) from the retainer (80).

31. Remove the sun gear (23) from the bracket (27). 46. Remove the bearing (79) from the pedestal (10). 32. Remove the retaining rings (67) from the sun gear (23). Remove the bearing (24) 33. Remove the bolts (29) (24 used) and remove the bracket (24). : 24 mm

47. Remove the bolts (11) (30 used) and remove the ring gear (22). : 36 mm 48. Remove the O-ring (19) from the pedestal (10).

34. Remove the bolts (25) (24 used) and remove the retaining ring (32). : 30 mm

W2-8-7

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) ASSEMBLE RAISING/LOWERING MECHANISM 19 18

7 5,6 3 4

13 12 11 10

16,17 15

24 23

25 26

22 21

30 31

35 36

42 43 44 45 46 47 48 49 50

82 81 80 79

54 55 56

57 68

65 64

M2CN-02-08-004

22 - Motor 23 - Socket Bolt (4Used) 24 - O-Ring 25 - Sleeve 26 - Bolt (12 Used) 27 - Washer (12 Used) 28 - Bolt (32 Used) 29 - Washer (32 Used) 30 - Bracket 31 - Pedestal 32 - Bolt (30 Used) 33 - Washer (30 Used) 34 - Bolt (30 Used) 35 - Washer (30 Used) 36 - Lock Plate 37 - Bolt 38 - Washer 39 - Spacer 40 - O-Ring 41 - Carrier 42 - Spacer

43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 -

64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 -

W2-8-8

84 - Spacer 85 - Pin (5 Used) 86 - Spacer 87 - Retaining Ring 88 - Retaining Ring (5 Used) 89 - Retaining Ring (5 Used) 90 - Planetary Gear (5 Used) 91 - Needle Bearing (10 Used) 92 - Retaining Ring (5 Used) 93 - Sleeve (5 Used) 94 - Plug 95 - Pin (5 Used) 96 - Nut 97 - Spline Shaft 98 - Case 99 - Bearing (2 Used) 100 Retainer 101 Oil seal 102 Plug 103 Shaft

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) Assemble Raising/Lowering Mechanism

17. Install the spline shaft (77) on the carrier (20) assembly.

1. Lift the case (78) with the crane and place it on a workbench. At this time, place the wooden block (200 mm square) under the bracket (9) mounting surface of the case (78). 2. Install the sleeve (4) on the case (78). 3. Install the O-ring (19) on the pedestal (10). 4. Install the ring gear (12) on the pedestal (10) with the bolts (11) (30 used) with LOCTITE #242 applied and the washer (12). : 36 mm : 1079 N m (105 kgf m) 5. Install the bearing (79) on the pedestal (10). 6. Install the oil seal (81) on the retainer (80). 7. Apply the liquid packing (ThreeBond #1398B) on the mating surface on the retainer (80) of the pedestal (10). 8. Install the retainer (80) on the pedestal (10) with the bolts (5) (12 used) with LOCTITE #242 applied and the washer (6). : 19 mm : 68 N m (6.9 kgf m) 9. Install the pedestal (10) on the case (78).

18. Apply the liquid packing (ThreeBond #1389B) on the mating surface on the ring gear (32) of the bracket (27). 19. Install the ring gear (32) on the bracket (27) with the bolts (25) (24 used) with LOCTITE #242 applied and the washer (26). : 30 mm : 628 N m (64 kgf m) 20. Apply the liquid packing (ThreeBond #1389B) on the mating surface on the bracket (27) of the ring gear (20). 21. Install the bracket (27) on the ring gear (20) with the bolts (29) (24 used) with LOCTITE #242 applied and the washer (28). : 24 mm : 230 N m (23.5 kgf m) 22. Install the sun gear (23) on the carrier (20) assembly. 23. Install the bearing (24) on the sun gear (23) and install the retaining rings (30) and (67). 24. Install the spacer (66) on the sun gear (23). 25. Install the spacer (33), (62) (5 used) and thrust plates (63) (5 used) on the carrier (31) and install the planetary gears (60) (5 used) and needle bearing (61) (15 used).

10. Install the bearing (79) on the case (78). 11. Install the nut (76) on the case (78). 12. Install the lock plate (15) on the nut (76) with the bolt (16) with LOCTITE #242 applied and the washer (17). : 13 mm : 20 N m (2.0 kgf m) 13. Install the spline shaft (77) and spacer (18) on the case (78).

26. Install the pins (65) (5 used) on the carrier (31) and install retaining rings (59) (5 used). 27. Install the carrier (31) assembly on the ring gear (32) and sun gear (23). 28. Install the spacer (64) and sun gear (34) on the carrier (31) assembly.

14. Install the needle bearings (71) (10 used), retaining rings (72) (5 used) and (68) (5 used) on the planetary gears (70) (5 used).

29. Install the spacer (36) on the carrier (35) and install the planetary gears (57) (3 used), thrust plates (58) (3 used) and needle bearings (55) (6 used).

15. Install the spacer (21), sleeves (73) (5 usd) and planetary gears (70) (5 used) on the carrier (20).

30. Install the retaining rings (54) (3 used) on the carrier (35).

16. Install the pins (75) (5 used) on the carrier (20) and insert the retaining rings (69) (5 used).

31. Install the carrier (35) assembly on the ring gear (32) and sun gear (34).

W2-8-9

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) 32

13 38 7 1

42 43 44 45 46 47 48 49 50

82 53

78 56

M2CN-02-08-004

W2-8-10

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) 32. Install the shaft (83) on the carrier (35) assembly. At this time, Make sure that the shaft (83) rotates with turning it by hands.

43. Lift the raising/lowering mechanism with the crane and place it on a workbench horizontally. 44. Install the sleeve (40) on the drum (52).

33. Install the bearing (39) on the cover (53). 45. Install the oil seal (45) and bearing (42) on the bracket (41).

34. Install the retainer (56) on the cover (53). 35. Apply the liquid packing (ThreeBond #1389B) on the mating surface on the cover (53) of the ring gear (32).

46. Lift the bracket (41) with the crane and Install it on the drum (52). 47. Install the sleeve (40) on the drum (52).

36. Install the cover (53) on the ring gear (32) with the bolts (38) (16 used) with LOCTITE #242 applied and the washer (37). : 19 mm : 90 N m (9.2 kgf m)

48. Install the oil seal (45) on the retainer (43). 49. Install the retainer (43) on the bracket (41) with the bolts (50) (6 used) and the washer (51). : 19mm : 88 N m (9.0 kgf m)

37. Lift the drum (52) with the crane and place it on a workbench with placing the bracket (41) mounting side downward. At this time, place the wooden block (200 mm square) under the drum (52) to stabilize the raising/lowering mechanism.

50. Install the retainer (48) on the end surface of the sleeve (40) with the bolts (46) (4 used) and the washer (47). : 19mm : 88 N m (9.0 kgf m)

CAUTION: Reduction gear weight: Approx. 1060 kg

51. Remove the nipple (44) and apply grease through the nipple (49) until the grease (Shell Alvania EP2) comes out

38. Lift the reduction gear with the crane and install it on the drum (52) with the bolts (13) (30 used) with LOCTITE #262 applied and the washer (14). : 32 mm : 735 N m (75.0 kgf m) 39. Install the bracket (9) on the case (78) with the bolts (7) (32 used) with LOCTITE #262 applied and the washer (8). At this time, align the marking of the case (78) and bracket (9). : 36 mm : 935 N m (95.0 kgf m)

52. Remove the plug (82) (level port) from pedstal and apply the gear oil to the level port. Oil amount : 17 L 53. Install the plug (82) (level port). NOTE: Wrap the seal tape on the plug (82).

40. Install the O-ring (3) on the case (78). 41. Apply the liquid packing (ThreeBond #1389B) on the mating surface on the motor (1) of the case (78). CAUTION: Motor (1) weight: Approx. 103 kg 42. Lift the motor (1) with the crane and install it on the case (78) with the socket bolts (2) (4 used). : 14 mm : 235 N m (24.0 kgf m)

W2-8-11

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) DISASSEMBLE RAISING/LOWERING MOTOR

25 26

37 27

3 33

41 53

19 21

33,34 9

49 16

43 M2CN-02-08-005

12345678910 11 12 13 14 -

Bolt (3 Used) Front Cover Oil Seal O-Ring Output Shaft Bearing Retaining Ring Socket Bolt (8 Used) Cover (2 Used) Stopper O-Ring Piston Piston O-Ring

15 16 17 18 19 20 21 22 23 24 25 26 27 28 -

Stopper Plug (6 Used) O-Ring (6 Used) O-Ring O-Ring (4 Used) Pin Swash Plate Plunger (9 Used) Holder Spring (9 Used) Rotor Valve Plate Needle Bearing Plate

29 30 31 32 33 34 35 36 37 38 39 40 41 -

Shoe Plate Retaining Ring Socket Bolt (5 Used) Casing O-Ring (5 Used) Plug (5 Used) Front Casing Socket Bolt (14 Used) O-Ring (2 Used) Pin Valve Cover Socket Bolt (7 Used) Cover

W2-8-12

42 43 44 45 46 47 48 49 50 51 52 53 54 -

Spring Washer (9 Used) Socket Bolt (9 Used) Coupling Plate (9 Used) Retaining Ring (2 Used) Seat (2 Used) Stopper (2 Used) Steel Ball (2 Used) O-Ring O-Ring Friction Plate (8 Used) Piston Spring (16 Used)

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) Disassemble Raising/Lowering Motor

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling. CAUTION: Raising/lowering motor weight: 103 kg

1. Place the raising/lowering motor on a workbench. Remove the plug (34) attached on the casing (32) and drain off the hydraulic oil. : 10 mm 2. Put the mating mark on the front casing (35), casing (32), valve cover (39) and cover (41). 3. Remove the socket bolts (31) (5 used) and socket bolt (40) (7 used). Remove the cover (41) from the valve cover (39). : 10mm

IMPORTANT: Since the valve plate (26) may be removed together, remove the valve cover (39) with care. Take care not to drop the valve plate (26). 10. Remove the socket bolts (43) (9 used) and spring washers (42) (9 used) and remove the valve cover (39) from the casing (32). : 10 mm 11. Remove the valve plate (26) and O-ring (37) from the valve cover (39). NOTE: Do not remove the needle bearing (27) unnecessarily. 12. Remove the rotor (25), plungers (22) (9 used), springs (24) (9 used), holder and plate (28) from the casing (32).

4. Remove the O-ring (6) from the cover (41).

13. Remove the socket bolts (8) (8 used) and remove the cover (9) (2 used) from the casing (32). : 10 mm

5. Remove the springs (54) (16 used) and piston (53) from the valve cover (39).

14. Pull out the stopper (10), (15), piston (12) and (13) from the casing (32).

6. Remove the O-ring (50) and (51) from the valve cover (39). 7. Remove the retaining ring (46), coupling (44) and retaining ring (46) from the output shaft (5). 8. Remove the plates (45) (9 used) and friction plates (52) (8 used) from the valve cover (39). 9. Remove the retaining ring (30) from the output shaft (5).

NOTE: Pull out the stopper (10) and (15) with using the screw (M6). 15. Remove the O-ring (11) and (14) from the stopper (10) and (15). 16. Remove the bolts (1) (3 used) and remove the front cover (2) from the front casing (35). : 17 mm 17. Remove the oil seal (3) and O-ring (4) from the front cover (2). 18. Remove the socket bolts (36) (14 used) and remove the front casing from the casing (32). : 10 mm

W2-8-13

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5)

6 5

19 21

M2CN-02-08-005

W2-8-14

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) 19. Remove the O-rings (19) (4 used) from the casing (32) and remove the O-ring (18) from the front casing (35). 20. Pull out the output shaft (5) from the front casing (35). 21. Remove the retaining ring (7) from the output shaft (5) and pull out the bearing (6) with using a press. 22. Remove the swash plate (21) from the casing (32) and remove the shoe plate (29) from the swash plate (21).

W2-8-15

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) ASSEMBLE RAISING/LOWERING MOTOR

25 26

37 27

3 33

41 53

19 21

33,34 9

49 16

M2CN-02-08-005

12345678910 11 12 13 14 -

Bolt (3 Used) Front Cover Oil Seal O-Ring Output Shaft Bearing Retaining Ring Socket Bolt (8 Used) Cover (2 Used) Stopper O-Ring Piston Piston O-Ring

15 16 17 18 19 20 21 22 23 24 25 26 27 28 -

Stopper Plug (6 Used) O-Ring (6 Used) O-Ring O-Ring (4 Used) Pin Swash Plate Plunger (9 Used) Holder Spring (9 Used) Rotor Valve Plate Needle Bearing Plate

29 30 31 32 33 34 35 36 37 38 39 40 41 -

Shoe Plate Retaining Ring Socket Bolt (5 Used) Casing O-Ring (5 Used) Plug (5 Used) Front Casing Socket Bolt (14 Used) O-Ring (2 Used) Pin Valve Cover Socket Bolt (7 Used) Cover

W2-8-16

42 43 44 45 46 47 48 49 50 51 52 53 54 -

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) Assemble Raising/Lowering Motor 1. Install the shoe plate (29) on the swash plate (21) and install the swash plate (21) on the casing (32). NOTE: Turn the larger chamfered side of the shoe plate (29) to the swash plate (21) side.

10. Install the O-ring (14) on the stopper (15) and the O-ring (11) on the stopper (10). Install the stopper (15) and (10) on the casing (32). NOTE: Install the stopper (15) and (10) to the end surface of the casing (32).

2. Install the bearing (6) on the output shaft (5) with using a press.

11. Install the cover (9) (2 used) on the casing (32) with the socket bolts (8) (8 used). : 10 mm : 98 N m (10.0 kgf m)

3. With lightly tapping the outer race of the bearing (6) with using the copper bar, install the output shaft (5) on the front casing (35).

12. Install the springs (24) (9 used) on the rotor (25) and install the holder (23).

4. Install the O-ring (18) on the front casing (35) and install the O-rings (19) (4 used) on the casing (32).

13. Install the plungers (22) (9 used) on the plate (28) and insert the plunger (22) in the rotor (25).

5. Install the front casing (35) with the output shaft (5) on the casing (32).

14. Install the rotor (25) assembly on the output shaft (5) with aligning the spline of the output shaft (5) with the spline of the rotor (25) and holder (23).

IMPORTANT: Make sure that the swash plate (21) moves smoothly.

15. Apply grease on the valve plate (26) install it on the valve cover (39) as mating with the pin (38). 16. Set up the casing (32) and place it on a workbench.

6. Tighten the socket bolts (36) (14 used). : 10 mm : 98 N m (10.0 kgf m) 7. Install the oil seal (3) on the front cover (2) with using a press and install the O-ring (4). 8. Install the front cover (2) on the front casing (35) with the bolts (1) (3 used). : 17 mm : 57 N m (5.8 kgf m) 9. Insert the piston (13) in the front casing (35) side of the casing (32) and insert the piston (12) in the valve cover (39) side.

17. Install the valve cover (39) on the casing (32) with the socket bolts (43) (9 used) and spring washers (42) (9 used). : 10 mm : 98 N m (10.0 kgf m) 18. Install the retaining ring (30) on the output shaft (5) and fix the needle bearing (27). 19. Install the retaining ring (46) on the output shaft (5).

W2-8-17

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5)

51 37 40 46 33

41 53 44 54

31 52

33,34

32 M2CN-02-08-005

W2-8-18

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) 20. Installing the coupling (44) on the output shaft (5) and install the retaining ring (46). IMPORTANT: Align the notch of the plate (45) and friction plate (52). 21. Install plate (45) (9 used) and friction plate (52) (8 used) in order on the valve cover (39) and coupling (44). 22. Install the O-ring (50) and (51) on the valve cover (39) and install the piston (53). 23. Install the springs (54) (16 used) on the piston (53). 24. Install the O-ring (37) on the cover (41) and install the cover (41) on the valve cover (39) with the socket bolts (31) (5 used) and (40) (7 used). : 10 mm : 98 N m (10.0 kgf m) 25. Install the O-ring (33) on the plug (34) and install it on the casing (32). : 10 mm : 108 N m (11.0 kgf m)

W2-8-19

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) MAINTENANCE STANDARD Dial Gauge

Clearance

Guide

Unit: mm Standard

Allowable Limit

0 to 0.1

0.3

Vise

Soft Liner

W309-04-05-002

Remedy: Replace the shoe and the plunger as an assembly.

2. Measure the plunger diameter at upper, middle, lower positions (2 places for each) with using a micrometer. Measure the diameter at the second position 90 raway from the first position. Measure the rotor bore inner diameter at positions A and B (2 places for each) with using a cylinder gauge.

W309-04-05-003

Unit: mm Standard

Allowable Limit

0.039

0.078

Remedy: Replace the plunger or the rotor.

3. Measure the shoe thickness B with using a micrometer. Unit: mm Standard

Allowable Limit

8.8

8.6 W309-04-05-004

B W309-04-05-005

W2-8-20

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) 4. Measure the heights of H and h. Plate

C=H-h

Holder

Unit: mm Standard

Allowable Limit

32.2

31.6

H h

Remedy: Replace the holder and the plate as an assembly. W309-04-05-006

5. Measure the dimension A. Unit: mm Standard

Allowable Limit

3.1

3.6 A

Remedy: Adjust with the shims.

6. Measure the brake spring length. Unit: mm Standard

Allowable Limit

53.2

W309-04-05-007

Remedy: Replace the spring.

7. Measure the thickness of the plate and friction plate. (15 used) Unit: mm Standard

Allowable Limit

32.4

31.7

Remedy: Replace the plate.

W2-8-21

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) DISASSEMBLE REGULATOR 29

16 15 17

42 10 13

37 39

11 25

35 3

36 22 23 19 21

M2CN-02-08-006

12345678910 11 -

Plug (2 Used) O-ring (2 Used) Plug Casing Socket bolt (2 used) Spacer (2 Used) Solenoid Valve Spring O-ring Cover (2 Used) Socket bolt (4 Used)

12 13 14 15 16 17 18 19 20 21 22 -

Nut (2 Used) Adjusting Screw (2 Used) Pin 6SULQJ VHDW Spool Sleeve Lock pin Spring O-ring Plug Sleeve

23 24 25 26 27 28 29 30 31 32 33 -

W2-8-22

Spool Spring seat Spring seat O-ring Spring O-ring O-ring O-ring Orifice Plug O-ring

34 35 36 37 38 39 40 41 42 43 -

3LVWRQ Pin O-ring Socket bolt (6 Used) Cover O-ring Sleeve Piston Lever Pin

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) Disassemble Regulator

• Thoroughly

read “PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING” (W1-1-1) before disassembling.

10. Remove the plug (32) from the casing (4). : 8 mm 11. Remove the O-ring (33) from the plug (32).

1. Remove the solenoid valve (6) from the casing (4). : 32 mm 2. Remove the socket bolts (5) (4 used) and remove the casing (4) from the raising/lowering motor. : 6 mm

3. Remove the O-rings (28) and (30) from the casing (4). 4. Remove the orifice (31) from the casing (4). : 4 mm

15. Remove the plug (21) from the casing (4) and remove the spring (19) and lock pin (18). : 13 mm 16. Remove the O-ring (20) from the plug (21).

5. Remove the socket bolts (37) (6 used) and remove the cover (38) from the casing (4). : 5 mm 6. Remove the O-rings (29), (36) and (39) from the casing.

17. Remove the spring seat (25), spring (27), spring seat (24), spool (23) and sleeve (22) from the casing (4). 18. Remove the O-ring (26) from the spring seat (25).

W2-8-23

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) ASSEMBLE REGULATOR 29

16 15 17

42 10 13

37 39

11 25

35 3

36 22 23 19 21

M2CN-02-08-006

12345678910 11 -

Plug (2 Used) O-ring (2 Used) Plug Casing Socket bolt (2 used) Spacer (2 Used) Solenoid Valve Spring O-ring Cover (2 Used) Socket bolt (4 Used)

12 13 14 15 16 17 18 19 20 21 22 -

Nut (2 Used) Adjusting Screw (2 Used) Pin 6SULQJ VHDW Spool Sleeve Lock pin Spring O-ring Plug Sleeve

23 24 25 26 27 28 29 30 31 32 33 -

W2-8-24

Spool Spring seat Spring seat O-ring Spring O-ring O-ring O-ring Orifice Plug O-ring

34 35 36 37 38 39 40 41 42 43 -

3LVWRQ Pin O-ring Socket bolt (6 Used) Cover O-ring Sleeve Piston Lever Pin

SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5) Assemble Regulator 1. Install the sleeve (22), spool (23), spring seat (24) and spring (27) on the casing (4).