PART NO. ZX870-5G • 870LC-5G • 870H-5G • 870LCH-5G • 870LCR-5G HYDRAULIC EXCAVATOR WORKSHOP MANUAL
URL:http://www.hitachi-c-m.com
WJBE-EN-00
Workshop Manual
ZX
870-5G 870LC-5G 870H-5G 870LCH-5G 870LCR-5G
Hydraulic Excavator WJBE-EN-00
PRINTED IN JAPAN (K) 2012, 07
Service Manual consists of the following separate Part No. Technical Manual (Operational Principle) : Vol. No.TOJBE-EN Technical Manual (Troubleshooting) : Vol. No.TTJBE-EN Workshop Manual : Vol. No.WJBE-EN
INTRODUCTION To The Reader 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, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-29-832-7084 FAX: 81-29-831-1162 E-mail: dc@hitachi-kenki.com
Be sure to thoroughly read this manual for correct product information and service procedures.
Additional References Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.
Manual Composition Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.
This manual consists the Technical Manual, the Workshop Manual and the Engine Manual. Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.
Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.
Page Number Each page has a number, located on the center lower part of the page, and each number contains the following information: Example: Technical Manual: T 1-3-5 T 1 3 5
Workshop Manual: W 1-3-2-5 W 1 3 2 5
Technical Manual Section Number Group Number Consecutive Page Number for Each Group
IN-01
Workshop Manual Section Number Group Number Sub Group Number Consecutive Page Number for Each Group
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.
d CAUTION:
Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.
d This is the safety alert symbol. When you see this
IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.
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.
f NOTE:
Indicates supplementary technical information or knowhow.
Units Used Example: 24.5 MPa (250 kgf/cm2, 3560 psi)
SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parentheses just behind SI units.
A table for conversion from SI units to other system units is shown below for reference purposes.
Quantity
To Convert From
Into
Multiply By
Length
mm
in
0.03937
mm
ft
0.003281
L
US gal
0.2642
L
US qt
1.057
m3
yd3
1.308
Weight
kg
lb
2.205
Force
N
kgf
0.10197
N
lbf
0.2248
Torque
N·m
kgf·m
Pressure
MPa
kgf/cm
MPa
psi
145.0
kW
PS
1.360
kW
HP
1.341
Temperature
°C
°F
°C×1.8+32
Velocity
km/h
mph
0.6214
min
rpm
1.0
L/min
US gpm
0.2642
mL/rev
cc/rev
1.0
Volume
Power
Flow rate
-1
fNOTE:
The numerical value in this manual might be different from the above-mentioned table.
IN-02
0.10197 2
10.197
SYMBOL AND ABBREVIATION Symbol / Abbreviation TO TT T/M W, W/M MC ECM VGS
GSM
GPS CAN
A/C OP, OPT MPDr. A/I WU Li ATT HI, Hi LO, Lo
Name
Explanation
Technical manual (Operational principle) Technical manual (Troubleshooting) Technical manual Workshop manual
Technical manual (Operational Principle). Technical manual (Troubleshooting). Technical manual. Workshop manual (Removal and Installation, Disassembly and Assembly). Main Controller Main controller. MC controls the engine, pump, and valve according to the machine operating condition. Engine Control Module Engine controller. ECM controls fuel injection amount according to the machine operating condition. Variable Geometry System controller Variable turbo controller. VGS is an exhaust turbo charged system to supercharge the exhaust energy while running the engine at slow idle speed. VGS optimizes the turbine rotation, improves the performance at slow-speed torque and the acceleration, reduces fuel consumption, and reduces particulate matter (PM) by adjusting the nozzle opening of turbine housing. Global System for Mobile communications Communication controller. GSM is a type of wireless controller communication system, is used in more than on 100 countries around Europe and Asia, and becomes the factual global standards of the mobile telephone. Global Positioning System Global positioning system. Controller Area Network CAN communication. CAN is a serial communications protocol internationally-standardized by ISO (International Organization for Standardization). Air Conditioner Air conditioner. Option Optional component. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and adjustment. Auto-Idle Auto-idle. Warming-Up Warming-up. Low (Slow) Idle Slow idle engine speed. Attachment Attachment. Attachment is optional parts such as breaker, crusher, and pulverizer in this manual. High Travel fast position. Low Travel slow position.
SY-1
SYMBOL AND ABBREVIATION Symbol / Name Abbreviation DPF Diesel Particulate Filter
DPD
Diesel Particulate Diffuser
DOC
Diesel Oxidation Catalyst
CSF
Catalyzed Soot Filter
PM EGR
Particulate Matter Exhaust Gas Recirculation
Explanation DPF is a filter which removes particulate matter (PM) including the toxic substance of exhaust gas of the diesel engine. Exhaust particulate removal equipment. DPD is an exhaust emission control system, a type of DPF, which cleans up particulate matter (PM) of diesel engine exhaust gas. DPD is a ceramic filter which traps and filters PM of exhaust gas. DPD burns up accumulated PM when PM increases and regenerates the filter. Oxidation catalyst for the diesel engine. Diesel oxidation catalyst oxidizes unburnt fuel and raises exhaust temperature. Filter. The filter traps, burns, and remove particulate matter (PM) by using high-temperature-exhaust gas with diesel oxidation catalyst. Catalyst is applied onto the filter. This advances PM burning. Particulate matter. The EGR control re-circulates a part of exhaust gas in the intake manifold and combines it with intake-air. Therefore, combustion temperature is lowered and generation of oxide of nitrogen (NOx) is controlled.
SY-2
SAFETY Recognize Safety Information These are the SAFETY ALERT SYMBOLS. When you see these symbols on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices.
SA-688
Understand Signal Words 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. Some safety signs do not use any of the designated signal words above after the safety alert symbol are occasionally used on this machine. CAUTION also calls attention to safety message in this manual. 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.
NOTE: indicates an additional explanation for an element of information.
SA-1
SA-1223
SAFETY Follow Safety Instructions Carefully read and follow all safety signs on the machine and all safety messages in the operator's manual. Safety signs should be installed, maintained and replaced when necessary. If a safety sign or the operator's 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). Learn how to operate the machine and its controls correctly and safely. Allow only trained, qualified, authorized personnel to operate the machine. Keep your machine in proper working condition. Unauthorized modifications of the machine may impair its function and/or safety and affect machine life. Do not modify any machine parts without authorization. Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Hitachi Warranty Policy. Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void Hitachi Warranty Policy. 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.
SA-2
SA-003
SAFETY Prepare for Emergencies 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. To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire extinguisher manual. 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
Wear Protective Clothing 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. Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.
SA-3
SA-438
SAFETY Protect Against Noise Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.
SA-434
Inspect Machine 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 "Inspect Machine Daily Before Starting" section in the operator’s manual.
SA-435
SA-4
SAFETY General Precautions for Cab Before entering the cab, thoroughly remove all dirt and/or oil such as mud, grease, soil or stones that may mess up the cab from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident. Do not mess up around the operator's seat with parts, tools, soil, stones, obstacles that may fold up or turn over, cans or lunch box. The levers or pedals become inoperable if obstacle jams in operation stroke of the travel levers/pedals, pilot control shut-off lever or control levers, which may result in serious injury or death. Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire. Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine. Keep all flammable objects and/or explosives away from the machine. After using the ashtray, always cover it to extinguish the match and/or tobacco. Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode. Use proper floor mat dedicated to the machine. If another floor mat is used, it may be displaced and contact with the travel pedals during operation, resulting in serious injury or death.
SA-5
SAFETY Use Handholds and Steps 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 hand-holds. Never jump on or off the machine. Never mount or dismount a moving machine. Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine. Never get on and off the machine with tools in your hands.
SA-439
Adjust the Operator's Seat 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. Adjust the rear view mirror position so that the best rear visibility is obtained from the operator’s seat. If the mirror is broken, immediately replace it with a new one.
SA-6
SA-378
SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat Before rising from the operator’s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever and/or pedal, possibly resulting in serious personal injury or death. Before leaving the machine, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Turn the key switch OFF to stop the engine. Before leaving the machine, close all windows, doors, and access covers and lock them up.
Fasten Your Seat Belt 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 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.
SA-7
SA-237
SAFETY Move and Operate Machine Safely Bystanders can be run over. Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine. Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move. Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine. Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it. Ensure the cab door, windows, doors and covers are securely locked. Check the mirrors and the monitor in the CAB for problems. If there is, replace the problem part(s) or clean the mirror, camera and the monitor. Refer to Rear View Monitor section on the cleaning of the camera and the monitor in the operator's manual.
SA-426
Operate Only from Operator's Seat Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. Start the engine only when seated in the operator's seat. NEVER start the engine while standing on the track or on ground. Do not start engine by shorting across starter terminals. Before starting the engine, confirm that all control levers are in neutral. Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders.
SA-8
SA-444
SAFETY Jump Starting 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 in the operator’s manual. 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. Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine. SA-032
Keep Riders off Machine Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. Only the operator should be on the machine. Keep riders off. Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.
SA-379
SA-9
SAFETY Precautions for Operations Investigate the work site before starting operations. Be sure to wear close fitting clothing and safety equipment appropriate for the job, such as a hard hat, etc. when operating the machine. Clear all persons and obstacles from area of operation and machine movement. Always beware of the surroundings while operating. When working in a small area surrounded by obstacles, take care not to hit the upperstructure against obstacles. When loading onto trucks, bring the bucket over the truck beds from the rear side. Take care not to swing the bucket over the cab or over any person.
M178-05-007
SA-10
SAFETY Investigate Job Site Beforehand When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death. Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles or banks from collapsing. Make a work plan. Use machines appropriate to the work and job site. Reinforce ground, edges and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders. When working on an incline or on a road shoulder, employ a signal person as required. Confirm that your machine is equipped with a FOPS cab before working in areas where the possibility of falling stones or debris exist. When the footing is weak, reinforce the ground before starting work. When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery. Beware the possibility of fire when operating the machine near flammable objects such as dry grass.
SA-11
SA-380
SAFETY Make sure the worksite has sufficient strength to firmly support the machine. When working close to an excavation or at road shoulders, operate the machine with the tracks positioned perpendicular to the cliff face with travel motors at the rear, so that the machine can more easily evacuate if the cliff face collapses. If working on the bottom of a cliff or a high bank is required, be sure to investigate the area first and confirm that no danger of the cliff or bank collapsing exists. If any possibility of cliff or bank collapsing exists, do not work on the area. Soft ground may collapse when operating the machine on it, possibly causing the machine to tip over. When working on soft ground is required, be sure to reinforce the ground first using large pieces of steel plates strong and firm enough to easily support the machine. Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes. Prevent machine tipping over from occurring. When operating on rough terrain or on slopes: Reduce the engine speed. Select slow travel speed mode. Operate the machine slowly and be cautious with machine movements.
M104-05-016
Install OPG Guard In case the machine is operated in areas where the possibilities of falling stones or debris exist, equip Hitachi OPG guard. Consult your authorized dealer for installing the OPG guard. The guard can be compliant with ROPS standards depending on the machine specifications. In order not to impair operator protective structure: Replace damaged ROPS or OPG guard. Never attempt to repair or modify the guard. ROPS: Roll Over Protective Structure OPG: Operator Protective Guard
SA-490
SA-12
SAFETY Provide Signals for Jobs Involving Multiple Machines For jobs involving multiple machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.
SA-481
Confirm Direction of Machine to Be Driven Incorrect travel pedal/lever operation may result in serious injury or death. Before driving the machine, confirm the position of the undercarriage in relation to the operator’s position. If the travel motors are located in front of the cab, the machine will move in reverse when travel pedals/levers are operated to the front.
SA-491
SA-13
SAFETY Drive Machine Safely Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direction you wish to drive. Be sure to detour around any obstructions. Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Do not allow personnel to stay around the machine while traveling.
A
SA-657
Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death. Never attempt to ascend or descend 35 degrees or steeper slopes. Be sure to fasten the seat belt. When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.2 to 0.3 m (A) above the ground. If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop. Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.
A
SA-658
SA-441
WRONG
SA-590
SA-14
SAFETY Avoid swinging the upperstructure on slopes. Never attempt to swing the upperstructure downhill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed. If the engine stalls on a slope, immediately lower the bucket to the ground. Return the control levers to neutral. Then, restart the engine. Be sure to thoroughly warm up the machine before ascending steep slopes. If hydraulic oil has not warmed up sufficiently, sufficient performance may not be obtained. Use a signal person when moving, swinging or operating the machine in congested areas. Coordinate hand signals before starting the machine. Before moving machine, determine which way to move travel pedals/levers for the direction you want to go. When the travel motors are in the rear, pushing down on the front of the travel pedals or pushing the levers forward moves the machine forward, towards the idlers. An arrow-mark seal is stuck on the inside surface of the side frame to indicate the machine front direction. Select a travel route that is as flat as possible. Steer the machine as straight as possible, making small gradual changes in direction. Before traveling on them, check the strengths of bridges and road shoulders, and reinforce if necessary. Use wood plates in order not to damage the road surface. Be careful of steering when operating on asphalt roads in summer. When crossing train tracks, use wood plates in order not to damage them. Do not make contact with electric wires or bridges. When crossing a river, measure the depth of the river using the bucket, and cross slowly. Do not cross the river when the depth of the river is deeper than the upper edge of the upper roller. When traveling on rough terrain, reduce engine speed. Select slow travel speed. Slower speed will reduce possible damage to the machine. Avoid operations that may damage the track and undercarriage components. During freezing weather, always clean snow and ice from track shoes before loading and unloading machine, to prevent the machine from slipping.
SA-15
Travel Motor M104-05-008
Arrow -mark M178-03-001
SA-011
SAFETY Avoid Injury from Rollaway Accidents Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: Select level ground when possible to park the machine. Do not park the machine on a grade. Lower the bucket and/or other work tools to the ground. Turn the auto-idle switch OFF and the power mode switch ECO. Run the engine at slow idle speed without load for 5 minutes to cool down the engine. Stop the engine and remove the key from the key switch. Pull the pilot control shut-off lever to LOCK position. Block both tracks and lower the bucket to the ground. Thrust the bucket teeth into the ground if you must park on a grade. Position the machine to prevent rolling. Park at a reasonable distance from other machines.
SA-391
SA-2273
SA-16
SAFETY Avoid Injury from Back-Over and Swing Accidents If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR. Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE. USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person. No machine motions shall be made unless signals are clearly understood by both signalman and operator. Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling. Keep windows, mirrors, and lights clean and in good condition. Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting. Read and understand all operating instructions in the operator’s manual.
SA-17
SA-383
SA-384
SAFETY Keep Person Clear from Working Area A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death. Keep all persons clear from the area of operation and machine movement. Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area.
SA-386
Never Position Bucket Over Anyone Never lift, move, or swing bucket above anyone or a truck cab. Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.
SA-487
SA-18
SAFETY Avoid Undercutting In order to retreat from the edge of an excavation if the footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear. If the footing starts to collapse and if retreat is not possible, do not panic. Often, the machine can be secured by lowering the front attachment, in such cases.
SA-488
Avoid Tipping DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE --- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death. To avoid tipping: Be extra careful before operating on a grade. Prepare machine operating area flat. Keep the bucket low to the ground and close to the machine. Reduce operating speeds to avoid tipping or slipping. Avoid changing direction when traveling on grades. NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable. Reduce swing speed as necessary when swinging loads.
SA-012
Be careful when working on frozen ground. Temperature increases will cause the ground to become soft and make ground travel unstable.
SA-440
SA-19
SAFETY Never Undercut a High Bank The edges could collapse or a land slide could occur causing serious injury or death.
SA-489
Dig with Caution Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death. Before digging check the location of cables, gas lines, and water lines. Keep the minimum distance required, by law, from cables, gas lines, and water lines. If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury. Contact your local “diggers hot line” if available in your area , and/or the utility companies directly. Have them mark all underground utilities.
SA-382
Operate with Caution If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may result as well. Take care to avoid hitting overhead obstacles with the boom or arm.
SA-389
SA-20
SAFETY Avoid Power Lines Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length. Check and comply with any local regulations that may apply. Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site. SA-381
Precautions for Lightning The machine is vulnerable to lightning strikes. In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine. After the electrical storm has passed, check all of the machine safety devices for any failure. If any failed safety devices are found, operate the machine only after repairing them.
SA-1088
SA-21
SAFETY Object Handling If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death. When using the machine for craning operations, be sure to comply with all local regulations. Do not use damaged chains or frayed cables, sables, slings, or ropes. Before craning, position the upperstructure with the travel motors at the rear. Move the load slowly and carefully. Never move it suddenly. Keep all persons well away from the load. Never move a load over a person’s head. Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground. Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall.
SA-014
Protect Against Flying Debris 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. Always close the front windows, doors, door windows and the overhead window when operating the machine.
SA-432
SA-22
SAFETY Park Machine Safely To avoid accidents: Park machine on a firm, level surface. Lower bucket to the ground. Turn auto-idle switch OFF and power mode switch ECO. Run engine at slow idle speed without load for 5 minutes. Turn key switch to OFF to stop engine. Remove the key from the key switch. Pull the pilot control shut-off lever to the LOCK position. Close windows, roof vent, and cab door. Lock all access doors and compartments. SA-390
Handle Fluids Safely−Avoid Fires 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 stop the engine before refueling the machine. Fill the fuel tank outdoors. All fuels, most lubricants, and some coolants are flammable. 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. Securely tighten the fuel and oil filler cap.
SA-018
SA-019
SA-23
SAFETY Transport Safely Take care the machine may turn over when loading or unloading the machine onto or off of a truck or trailer. Observe the related regulations and rules for safe transportation. Select an appropriate truck or trailer for the machine to be transported. Be sure to use a signal person. Always follow the following precautions for loading or unloading: 1. Select solid and level ground. 2. Always use a ramp or deck strong enough to support the machine weight. 3. Turn auto-idle switch OFF and turn mode switch to ECO position. 4. Always select the slow speed mode with the travel mode switch. 5. Never load or unload the machine onto or off a truck or trailer using the front attachment functions when driving up or down the ramp. 6. Never steer the machine while on the ramp. If the traveling direction must be changed while the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again. 7. The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it. 8. Place blocks in front of and behind the tires. Securely hold the machine to the truck or trailer deck with wire ropes. Be sure to further follow the details described in the TRANSPORTING section in the operator's manual.
SA-24
SA-395
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 the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Run the engine at slow idle speed without load for 5 minutes. 5. Turn the key switch to OFF to stop engine. 6. Relieve the pressure in the hydraulic system by moving the control levers several times.
SA-028
7. Remove the key from the key switch. 8. Attach a “Do Not Operate” tag on the control lever. 9. Pull the pilot control shut-off lever to the LOCK position. 10. Allow the engine to cool. If a maintenance procedure must be performed with the engine running, do not leave the machine unattended. If the machine must be raised, maintain a 90 to 110˚ angle between the boom and arm. Securely support any machine elements that must be raised for service work. Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter in the operator's 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. When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces. Disconnect battery ground cable (−) before making adjustments to electrical systems or before performing welding on the machine.
SA-25
SA-527
SAFETY Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine. Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.
SA-037
Warn Others of Service Work 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.
SS3076175
SS2045102
Support Machine Properly 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-26
SA-527
SAFETY Stay Clear of Moving Parts 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
SA-2294
Prevent Parts from Flying Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY. Do not attempt to remove grease fitting securing cover. As pieces may fly off, be sure to keep body and face away from valve. Never attempt to disassemble the track adjuster. Inadvertent disassembling of the track adjuster may cause the parts such as a spring to fly off, possibly resulting in severe personal injury or death. Travel reduction gears are under pressure. As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury. GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure.
SA-27
SA-344
SAFETY Store Attachments Safely Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death. Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.
SA-034
Prevent Burns Hot spraying fluids: 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 released before removing the cap. The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.
SA-039
Hot fluids and surfaces: Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well. Wait for the oil and components to cool before starting any maintenance or inspection work.
SA-225
SA-28
SAFETY Replace Rubber Hoses Periodically 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. (See the page of “Periodic replacement of parts” in the operator’s manual.) 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.
SA-019
Avoid High-Pressure Fluids 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. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard; take care 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-031
SA-292
SA-044
SA-29
SAFETY Prevent Fires Check for Oil Leaks: 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 damaged 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. Replace fuel hoses and hydraulic hoses periodically even if there is no abnormality in their external appearance. Check for Shorts: 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. Never attempt to modify electric wirings.
SA-30
SA-019
SAFETY Clean up Flammables: 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 adhered oil or accumulated flammables immediately. Check and clean high temperature parts such as the exhaust outlet and mufflers earlier than the normal interval. Do not wrap high temperature parts such as a muffler or exhaust pipe with oil absorbents. Do not store oily cloths as they are vulnerable to catching fire. Keep flammables away from open flames. Do not ignite or crush a pressurized or sealed container. Wire screens may be provided on openings on the engine compartment covers to prevent flammables such as dead leaves from entering. However, flammables which have passed through the wire screen may cause fires. Check and clean the machine every day and immediately remove accumulated flammables. Check Key Switch: If a fire breaks out, failure to stop 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. Check Heat Shields: Damaged or missing heat shields may lead to fires. Damaged or missing heat shields must be repaired or replaced before operating the machine. If hydraulic hoses are broken while the engine cover is open, splattered oil on the high temperature parts such as mufflers may cause fire. Always close the engine cover while operating the machine.
SA-31
SAFETY Evacuating in Case of Fire If a fire breaks out, evacuate the machine in the following way: Stop the engine by turning the key switch to the OFF position if there is time. Use a fire extinguisher if there is time. Exit the machine. In an emergency, if the cab door or front window can not be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer to the explanation pages on the Emergency Evacuation Method in the operator's manual.
SA-393
SS-1510
Beware of Exhaust Fumes 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.
SA-016
SA-32
SAFETY Precautions for Welding and Grinding Welding may generate gas and/or small fires. Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding. Only qualified personnel should perform welding. Never allow an unqualified person to perform welding. Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding. After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.
SA-33
SA-818
SAFETY Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself 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.
Precautions for Handling Accumulator and Gas Damper High-pressure nitrogen gas is sealed in the accumulator and the gas damper. Inappropriate handling may cause explosion, possibly resulting in serious injury or death. Strictly comply with the following items: Do not disassemble the unit. Keep the units away from open flames and fire. Do not bore a hole, do not cut by torch. Avoid giving shocks by hitting or rolling the unit. Before disposing the unit, sealed gas must be released. Consult your nearest Hitachi dealer.
SA-34
SAFETY Remove Paint Before Welding or Heating 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. Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. 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.
SA-029
Beware of Asbestos and Silicon Dust and Other Contamination Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer. Inhalation of silicon dust or other contamination may cause sickness. Depending on the work site conditions, the risk of inhaling asbestos fiber, silicon dust or other contamination may exist. Spray water to prevent asbestos fibers, silicon dust or other contamination from becoming airborne. Do not use compressed air. When operating the machine in a work site where asbestos fibers, silicon dust or other contamination might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos, silicon dust or other contamination. Keep bystanders out of the work site during operation. Asbestos fibers might be present in imitation parts. Use only genuine Hitachi Parts.
SA-35
SA-029
SAFETY Prevent Battery Explosions Battery gas can explode. 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 ˚C ( 60 ˚F ) 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. Connect terminals to the correct electrical poles. Failure to do so may cause damage to the electrical parts or fire.
SA-032
Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness. Be sure to wear eye protection when checking electrolyte specific gravity.
Service Air Conditioning System Safely If spilled onto skin, refrigerant may cause a cold contact burn. Refer to the instructions described on the container for proper use when handling the refrigerant. Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere. Never touch the refrigerant.
SA-405
SA-36
SAFETY Handle Chemical Products Safely 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 (available only in English) on chemical products used with your machine.
SA-309
Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI 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. Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.
SA-37
SA-226
SAFETY Never Ride Attachment Never allow anyone to ride attachments or load. This is an extremely dangerous practice.
Precautions for Communication Terminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices. Inquire the device manufacturer for electrical wave disturbance upon using an electronic device near the communication terminal.
SA-38
SAFETY Precaution for Communication Terminal Equipment This machine has a communication terminal equipment emitting electrical waves installed inside a rear tray which is situated at the back of the driver's seat. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, would be affected and would malfunction by the electrical waves emitted from the communication terminal equipment. Any person affixed with a medical device such as the above should not use this machine, unless the medical device and the rear tray are at least 22 centimeters (8.662 inches) apart at all times. If such condition cannot be met, please contact our company's nearest dealer and have the person in charge stop the communication terminal equipment from functioning completely and confirm that it is not emitting electrical waves. Specific Absorption Rate ("SAR") (measured by 10 g per unit) of communication terminal equipments: E-GSM900 0.573 W/Kg (914.80 MHz) DCS-1800 0.130 W/Kg (1710.20 MHz) WCDMA Band I 0.271 W/Kg (1950.00 MHz) *This data was measured by having each type of communication terminal equipment, such as the communication terminal equipment used with this machine, and a human body set apart by 3 cm (1.18 inches). * SAR is a measure of the amount of radio frequency energy absorbed by the body when using a wireless application such as a mobile phone. In Japan: *Under the Japanese Radio Act and other relevant Japanese regulations, the maximum SAR value is 2 W/kg (as of March 2010). In EU Member nation: *Under the "Council Recommendation 1999/519/EC 12 July 1999'; the maximum SAR value is 2 W/kg (as of March 2010).
SA-39
SA-2302
SAFETY ď‚— Never attempt to disassemble, repair, modify or displace the communication terminal, antennas or cables. Failure to do so may result in damage and/or fire to the base machine or to the communication terminal. (When required to remove or install the communication terminal, consult your nearest Hitachi dealer.) ď‚— Do not pinch or forcibly pull cables, cords or connectors. Failure to do so may cause short circuit or broke circuit that may result in damage and/or fire to the base machine or to the communication terminal.
SA-40
SAFETY Before Returning The Machine To The Customer After maintenance or repair work is complete, confirm that: The machine is functioning properly, especially the safety systems. Worn or damaged parts have been repaired or replaced
SA-435
SA-41
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SA-42
SECTION AND GROUP SECTION 1 GENERAL INFORMATION Group 1 Precautions for Disassembling and Assembling CONTENTS Group 2 Tightening Torque Group 3 Painting Group 4 Bleeding Air Group 5 Pressure Release Procedure Group 6 Preparation
WORKSHOP MANUAL
SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Group 2 Undercarriage Group 3 Front Attachment
SECTION 3 UPPERSTRUCTURE
All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.
COPYRIGHT(C)2012 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved
Group 1 Cab Group 2 Counterweight Group 3 Main Frame Group 4 Engine Group 5 Radiator Assembly Group 6 Hydraulic Oil Tank Group 7 Fuel Tank Group 8 Pump Device Group 9 Control Valve Group 10 Swing Device Group 11 Pilot Valve Group 12 Solenoid Valve Group 13 Signal Control Valve Group 14 Shockless Valve Group 15 Fan Valve Group 16 Fan Motor
SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Center Joint Group 4 Track Adjuster Group 5 Front Idler Group 6 Upper and Lower Roller Group 7 Track
SECTION 5 ATTACHMENT Group 1 Front Attachment Group 2 Cylinder
SECTION 6 ENGINE
TECHNICAL MANUAL (Operational Principle)
TECHNICAL MANUAL (Troubleshooting)
SECTION 1 GENERAL Group 1 Specification Group 2 Component Layout Group 3 Component Specifications SECTION 2 SYSTEM Group 1 Controller Group 2 Control System Group 3 Hydraulic System Group 4 Electrical System SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Pilot Valve Group 5 Travel Device Group 6 Signal Control Valve Group 7 Others (Upperstructure) Group 8 Others (Undercarriage)
SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test Group 6 Adjustment SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Monitor Group 3 e-Service Group 4 Component Layout Group 5 Troubleshooting A Group 6 Troubleshooting B Group 7 Air Conditioner
SECTION 1
GENERAL CONTENTS Group 1 Precautions for Disassembling and Assembling
Precautions for Disassembling and Assembling.........................................................W1-1-1-1
Group 2 Tightening
Tightening Bolts and Nuts...........................................W1-2-1-1 Piping Joint.......................................................................W1-2-1-4
Group 3 Painting
Painting specification....................................................W1-3-1-1 Final painted color..........................................................W1-3-1-1
Group 4 Bleeding Air
Bleeding Air from Hydraulic Oil Tank.......................W1-4-1-1 Bleeding Air from Hydraulic System........................W1-4-1-2 Bleeding Air from Fuel System...................................W1-4-1-3 Bleeding Air from Radiator..........................................W1-4-1-4
Group 5 Pressure Release Procedure
Hydraulic Circuit Pressure Release Procedure......W1-5-1-1
Group 6 Preparation
Preparation before Inspection and Maintenance.......................................................W1-6-1-1
JBEW-1-1
(Blank)
JBEW-1-2
SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling Precautions for Disassembling 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. Inspect the Machine Be sure to thoroughly understand all disassembling / assembling procedures beforehand to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future. The machine model, machine serial number, and hour meter reading. Reason for disassembly (symptoms, failed parts, and causes). Clogging of filters and oil, water or air leaks, if any. Capacities and condition of lubricants. Loose or damaged parts. Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work. Precautions for Disassembling and Assembling Precautions for Disassembling Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Before disassembling, clean the exterior of the components and place on a workbench. Drain hydraulic oil and gear oil from the hydraulic components and reduction gear. Be sure to provide appropriate containers for draining fluids. Use matching marks for easier reassembling if necessary. 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 if necessary. Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. Measure and record the degree of wear and clearances. Precautions for Assembling Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part. 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. Apply appropriate lubricant oil onto parts in order to prevent them from seizing. Be sure to replace O-rings, backup rings, oil seals, and floating seals with new ones once they have been disassembled. Apply 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. Fit the matching marks made when disassembling and assemble them. 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 completed, count the number of tools so as to make sure that no forgotten tools remain in the assembled machine.
W1-1-1-1
SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Using Floating Seal
1
1. In general, replace the floating seal with a new one after disassembling.
If the floating seal is required to be reused, follow these procedures:
Keep seal rings together as a matched set with seal ring (1) surfaces together. Apply oil onto sliding surface (e) of seal ring (1). Check sliding surface (e) of seal ring (1) for scuffing, scoring, corrosion, deformation, or uneven wear. Check the step part of seal ring (1). Check O-ring (2) for tears, breaks, deformation, or hardening.
W178-02-11-001
2
2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following to prevent trouble. Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust, or dirt from seal mounting bores. After cleaning, thoroughly dry parts with compressed air. Clean seal ring (1) and O-ring (2) mounting bores. Check the bore surface for scuffing or scoring by touching the surface with finger. After installing the floating seal, check that O-ring (2) is not twisted, and that it is installed correctly on seal ring (1). After installing the floating seal, check that O-ring (2) and seal ring sliding surface (e) is parallel with seal mating surface (f ) by measuring the distances (e) and (f ) at point (A) and (B), as illustrated. If these distances differ, correct O-ring (2) seating.
a
c b d W178-02-11-002 a - Correct b - Incorrect
c - Twist of O-Ring d - Bend of O-Ring f a
b
A
A
e
2
B
A=B
B
A≠B W178-02-11-003
a - Correct b - Incorrect
W1-1-1-2
e - Sliding Surface f - Seal Mating Surface
SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Using Nylon Sling a
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 being damaged and the lifted load from slipping. Lower the temperature of the lifted load to lower than 100 °C (212 °F). If unavoidably lifting a load with a temperature of 100 °C (212 °F) or more, reduce the load weight. Do not lift acid or alkali chemicals. Take care not to allow the sling to become wet. The load may slip. When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced. When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force. Avoid using twisted, bound, connected, or hitched slings. Do not place any object on twisted or bent slings. (Refer to the right illustration.) When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions. Avoid dragging slings on the ground, throwing slings, or pushing slings with a metal object. 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 that they won’t deteriorate with heat, sun light, or chemicals.
W102-04-02-016 a - Correct Eyehole Lifting Method b
W105-04-01-008 b - Incorrect Eyehole Lifting Method
c c - Bent of Sling
W1-1-1-3
W162-01-01-009
SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling If a load is lifted with a damaged dCAUTION: nylon sling, serious personal injury may result.
Be sure to visually check the nylon sling for any damage before using.
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.
Damaged Appearance
a a
W162-01-01-002 a - Broken Sewing Thread
W162-01-01-006
e a - Broken Sewing Thread
e - Separation of Belt
f
b
W162-01-01-003 b - Scuffing
b b - Scuffing
f -
W162-01-01-007
Scoring
c c
g
d
W162-01-01-004 c - Fuzz
W162-01-01-008
d - Broken Sewing Thread c - Fuzz a
W162-01-01-005 a - Broken Sewing Thread
W1-1-1-4
g - Broken Warp
SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Maintenance Standard Terminology “Standard” 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies adjusted to specification. Allowable errors will be indicated if necessary.
“Allowable Limit” 1. Normal machine performance cannot be accomplished after exceeding this limit. 2. Repair or adjustment is difficult after exceeding this limit. 3. Repair or adjustment is impossible after exceeding this limit. Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching the “Allowable Limit”.
W1-1-1-5
SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling (Blank)
W1-1-1-6
SECTION 1 GENERAL Group 2 Tightening Tightening Bolts and Nuts Use tools appropriate for the work dCAUTION: to be done. Makeshift tools and procedures
can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injure.
fNOTE: Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to reduce friction coefficient of them. Make sure bolt and nut threads are clean before installing.
WDAA-01-02-001
Bolt Types Tighten the nuts or bolts correctly to the torque specifications. As the different types and grades of bolt are used, use and tighten the correct bolts correctly when assembling the machine or components. Specified Tightening Torque Chart
Bolt Dia.
M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36
Hexagon Wrench Wrench Size Size 10 13 17 19 22 24 27 30 32 36 41 46 50 55
5 6 8 10 12 14 14 17
WDAA-01-02-002
WDAA-01-02-003
N·m
(kgf·m)
(lbf·ft)
N·m
30 65 110 180 270 400 550 750 950 1400 1950 2600 3200
(3) (6.5) (11) (18) (27) (40) (55) (75) (95) (140) (195) (260) (320)
(22) (48) (81) (133) (200) (300) (410) (550) (700) (1030) (1440) (1920) (2360)
20 50 90 140 210 300 400 550 700 1050 1450 1950 2450
W1-2-1-1
Socket Bolt (kgf·m) (lbf·ft) (2) (5) (9) (14) (21) (30) (40) (55) (70) (105) (145) (195) (245)
(15) (37) (66) (103) (155) (220) (300) (410) (520) (770) (1070) (1440) (1810)
WDAA-01-02-004
N·m 3 to 4 10 20 35 55 80 120 170 220 280 400 550 750 950
(kgf·m) (lbf·ft) (0.3 to 0.4) (2.2 to 3) (1) (7.4) (2) (15) (3.5) (26) (5.5) (41) (8) (59) (12) (89) (17) (125) (22) (162) (28) (205) (40) (300) (55) (410) (75) (550) (95) (700)
SECTION 1 GENERAL Group 2 Tightening IMPORTANT: The following items are applied to both fine and coarse pitch threads. Apply lubricant to the bolts and nuts in order to reduce friction coefficient of them. (For example, spindle oil with white zinc B dissolved in it) Torque tolerance is ±10 %. Use the bolts of correct length. The bolts that are too long cannot be tightened as the bolt tip comes into contact with the bottom of bolt hole. Also the bolts that are too short cannot develop sufficient tightening force. The torque given in the chart on the previous page are for general use only, however, a different torque is given for a specific application. Use the specified torque. Clean the nut and bolt threads and remove dirt or corrosion before installing.
Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.
b
a
1.4
c
1
12
9
4
1
6
7
14
13
8
5
2
3
10
11
3
6
5
4 2 2.3
W105-01-01-003 a - Equally tighten upper and lower alternately
b - Tighten diagonally
W1-2-1-2
c - Tighten from center diagonally
SECTION 1 GENERAL Group 2 Tightening Precautions for Spilt Flange IMPORTANT: Clean the sealing surfaces. Check if there are any scratches and roughness on the surface of the seal that cause oil leaks and damage to the O-ring. Use only specified O-rings. Inspect O-rings for any damage. Do not file the O-ring surfaces. When installing O-ring into a groove, use grease in order to hold O-ring in place. While tightening the bolt by hand, check that flange is installed to the port correctly. Do not pinch the O-ring. Tighten the bolts up and down, left and right alternately, in order to ensure even tightening to the specified torque. Do not use air wrenches. Using an impact wrench often causes tightening of one bolt fully before tighten the others, resulting in damage to O-rings or uneven tightening of bolts.
WDAA-01-02-005
Incorrect
WDAA-01-02-006
Nut and Bolt Locking Lock Plate IMPORTANT: Do not reuse the lock plates. Do not try to bend the same point twice.
W105-01-01-008
Incorrect
Correct
Split Pin IMPORTANT: Do not turn in the loosening direction in order to align the grooves and holes on the nut. Always turn in the tightening direction. Do not reuse the split pins.
a
b
Correct
Correct
Incorrect
Wire IMPORTANT: Attach wire to bolts in the bolttightening direction. Do not reuse the wire. a a-
WDAA-01-02-007
Bend along edge sharply Correct
b-
Do not bend it round
Correct
Correct
Incorrect
d
Incorrect
c
WDAA-01-02-008 c-
W1-2-1-3
Tighten
d-
Loosen
SECTION 1 GENERAL Group 2 Tightening Piping Joint IMPORTANT: The torque given in table below are for general use only, however, a different torque is given for a specific application. Use the specified torque.
1
4
3
5
2
Union Joint Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. IMPORTANT: Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking the adapter. Tighten union nut (3) to the specifications. 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.
a - Joint Body
a
WDAA-01-02-009
37° 30°
b b - Male Union Joint
c c - Female Union Joint WDAA-01-02-010
Description 30° male
37° female
Wrench Size mm Union Nut 17 19 22 27 32 36 41 50 55 60 17 19 22 27 32 36 41
N·m 25 30 40 80 140 180 200 270 380 380 25 30 40 80 140 180 200
Tightening Torque (kgf·m) (2.5) (3) (4) (8) (14) (18) (20) (27) (38) (38) (2.5) (3) (4) (8) (14) (18) (20)
fNOTE:
Tightening torque of 37° male coupling without union is similar to tightening torque of 37° female.
W1-2-1-4
(lbf·ft) (18) (22) (30) (59) (103) (133) (148) (200) (280) (280) (18) (22) (30) (59) (103) (133) (148)
SECTION 1 GENERAL Group 2 Tightening Pipe Joint Pipe connection (metal joint) (Union Nut Wrench Size: 17, 19, 22, 27) Metal (3) of adapter (1) and pipe (2) seals pressure oil. Precautions for use Do not damage sealing surfaces (4) and (5) when disassembling and assembling.
1
4
5
3
2
Tightening Torque Use the specified tightening torque in the table below. Wrench Size (mm) N·m Tightening (kgf·m) Torque (lbf·ft)
17 25 (2.5) (18)
19 30 (3) (22)
22 40 (4) (30)
27 80 (8) (59)
M1M7-07-005
O-ring Seal Joint O-ring (6) is installed against the end surface of adapter (7) and seals pressure oil. IMPORTANT: Replace O-ring (6) with a new one when reinstalling. 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. Do not damage O-ring groove (8) of adapter (7) or sealing surface (10) on the hose side. Damage to O-ring (6) may cause oil leakage. 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 O-ring groove (8).
7
6
8
9
10
a
WDAA-01-02-011
a - Joint Body
Wrench Size mm Union Nut 19 22 27 32 36 41 50
W1-2-1-5
Tightening Torque N·m (kgf·m) (lbf·ft) 30 (3) (22) 70 (7) (52) 95 (9.5) (70) 140 (14) (103) 180 (18) (133) 200 (20) (148) 350 (35) (260)
SECTION 1 GENERAL Group 2 Tightening Quick Coupling
3
1. Coupling procedure Push socket ring (1) into plug (3) by rotating it fully counterclockwise and then pulling it toward you. Release socket ring (1). Check that socket ring (1) is returned by the spring force and the coupling is locked completely by ball (2). At this time, check if socket ring (1) is returned to the original position (to the rightmost direction). 2. Separating procedure Remove the hose by rotating socket ring (1) fully counterclockwise and then pulling it. Because no check function is attached inside, be careful that oil flows out. Cap the removed hoses using special plug.
dCAUTION: When disconnecting, do not damage joint surface. When disconnecting, clean the joint part and thoroughly wipe off the cleaning solution to prevent any foreign material from entering. Complete the joint disconnecting / connecting procedure. Check enough if oil leaks especially after installation. After installation, check if socket ring (1) is returned to the original position (to the rightmost direction).
W1-2-1-6
1
2
M1M7-07-006
SECTION 1 GENERAL Group 2 Tightening Screw-In Connection
R
G 30°
Depending on types of screw and sealing, different types of screw-in connection are used. IMPORTANT: Check that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. (In general, the screw-in connection of male tapered thread is used except for measurement purpose.)
a
Seal tape is used in order to seal clearances between male and female threads so that any leaks between threads may be prevented. Therefore, apply just enough seal tape to fill up thread clearances. Do not overwrap.
b - Male Straight Thread W105-01-01-018
Wrench Size mm Joint Body 19 22 27 36 41 50 60
Seal Tape Application
b
a - Male Tapered Thread
fNOTE:
Tightening Torque FC material SS material 15 (1.5, 11) 35 (3.5, 26) 30 (3, 22) 50 (5, 37) 50 (5, 37) 95 (9.5, 70) 70 (7, 52) 160 (16, 118) 110 (11, 81) 200 (20, 148) 160 (16, 118) 330 (33, 245) 200 (20, 148)
Unit: N·m (kgf·m, lbf·ft)
Application Procedure Check that the thread surface is clean and, free of dirt or damage. Apply the seal tape around threads in order to leave one to two pitch threads uncovered. Wrap the seal tape in the same direction as the threads.
c
e
d c - Internal Thread d - External Thread
Low-Pressure-Hose Clamp Tightening
W105-01-01-019
e - Clearance f
Low-pressure-hose clamp tightening torque differs depending on the type of clamp. T-Bolt Type Band Clamp: 4.5 N·m (0.45 kgf·m, 3.3 lbf·ft) Worm Gear Type Band Clamp: 6 to 7 N·m (0.6 to 0.7 kgf·m, 4.4 to 5.2 lbf·ft) f -
Leave one to two pitch threads uncovered g
h
WDAA-01-02-012 g - T-Bolt Type Band Clamp
W1-2-1-7
M114-07-041
M114-07-043 h - Worm Gear Type Band Clamp
SECTION 1 GENERAL Group 2 Tightening Connecting Hose When replacing the hoses, use only dCAUTION: genuine Hitachi service parts. Using hoses other
Correct
Incorrect
than genuine Hitachi hoses may cause oil leaks, hose rupture or separation of fitting, possibly resulting in a fire on the machine. Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting. Utilize the print marks on hoses when installing in order to prevent hose from being kinked. Take necessary measures to protect hoses from rubbing against each other. If the hoses rub against each other, wear to the hoses may result and lead to hose rupture. Take care so that the hoses do not come into contact with the moving parts or sharp objects.
W105-01-01-011
Incorrect
a
Correct
W105-01-01-012 a - Rubbing Against Each Other
b
Incorrect
Correct
b
a
W105-01-01-013 a - Rubbing Against Each Other
b - Clamp
Correct
Incorrect
a b W105-01-01-014 a - Rubbing Against Each Other
W1-2-1-8
b - Clamp
SECTION 1 GENERAL Group 3 Painting Painting specification Surfaces to Be Painted
Painting Colour
Main surface of upperstructure (except cab)
YR-01 [TAXI yellow]
Main frame
High Grade Black
Inner
HK1 Coat Primer gray
Counterweight
YR-01 [TAXI yellow]
Front attachment
YR-01 [TAXI yellow]
Track including Swing Bearing
N-10 [Black]
Floor plate
M/F Cation (allowed)
Final painted color Inside and outside surface of cab
High Grade Black
Shaded area on cab (Only the left side) (5)
Shining Silver
Right window beam, U-bolt
[KANSAI PAINT LF-113-230B (Charcoal series black, half glossy)]
Suspension lifter
N2.0 [Black]
Lever (Travel, pilot shut-off, foot rest)
High Grade Black
Lubricator box (4)
High Grade Black
Step (2)
High Grade Black
Step (3)
TAXI Yellow
Eruption plate (7)
KANSAI PAINT AMYLAC. 1400 (Deep Black)
Mirror stay, Handrail (1)
High Grade Black
Camera cover (6)
HG Beige Deep
W1-3-1-1
SECTION 1 GENERAL Group 3 Painting
1
1
6
1
WJBE-01-03-001
7
4
WJBE-01-03-004
2
4 3 7 2
5 A
WJBE-01-03-003
a
WJBA-01-03-004
Section A
10 mm
W1J1-01-03-005
a - Paint all circumference in the lower hinge swing position shining silver. 1- 2-
Handrail Step
3- 4-
Step Lubricator Box
5- 6-
Shaded Area on Cab Camera Cover
W1-3-1-2
7-
Eruption Plate
SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Hydraulic Oil Tank Escaping fluid under pressure may dCAUTION: penetrate the skin and eyes, and cause serious
injury. Release the pressure before disconnecting the hydraulic pipings or removing other equipment. Hot hydraulic oil just after operation may spout out and cause severe burns. Wait until oil cools before starting any work. Do not turn cap (2) of hydraulic oil tank (3) quickly. Cap (2) may fly off by internal pressure. Release any remaining pressure before removing cap (2).
Preparation 1. Park the machine on a solid and level surface. Set the front attachment in position for checking hydraulic oil level.
1
2
3
2. Stop the engine. Push air bleed button (1) of hydraulic oil tank (3) and bleed air from hydraulic oil tank (3). 3. Remove cap (2) of hydraulic oil tank (3).
W1R7-01-04-001
4. Install vacuum pump (a) to the position where cap (2) has been removed. Operate vacuum pump (a) and maintain negative pressure in hydraulic oil tank (3).
a
b
fNOTE:
Operate vacuum pump (a) continuously while working.
c
W1R7-01-04-002 a - Vacuum Pump b - Hose c - Adapter
W1-4-1-1
SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Hydraulic System Bleed air from the hydraulic system as follows when hydraulic oil has been drawn, the suction filter and suction pipe have been replaced, or the pump device, swing motor, travel motor, cylinders have been removed/ installed. IMPORTANT: If air is accumulated inside of the pump and if the engine starts in lacking of hydraulic oil, the pump may be damaged. Bleeding Air from Pump Remove the air bleed plug on top of the pump. Add hydraulic oil to the pump. After the pump is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run it at slow idle speed. Slightly loosen the plug and bleed air from the pump until hydraulic oil comes out from the gap. After bleeding all air, securely tighten the plug. IMPORTANT: If air is accumulated inside of the motor and if the engine starts in lacking of hydraulic oil, the motor may be damaged. Bleeding Air from Travel Motor, Swing Motor Remove the air bleed plug (top) from the travel motor and swing motor. Fill the motor case with hydraulic oil.
IMPORTANT: If air is accumulated inside of the cylinder and if the cylinder is operated suddenly in lacking of hydraulic oil, the seal may be damaged or the cylinder may seize. 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 circuit has an air bleed device, air in the pilot circuit will be bled while performing the above operation for approx. 5 minutes. Reset the front attachment in position for checking hydraulic oil level. Stop the engine. Check hydraulic oil level. Replenish hydraulic oil if necessary.
W1-4-1-2
SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Fuel System Air in the fuel system may make the engine hard to start or make it run irregularly. After draining water and sediment from the fuel filter, replacing the fuel filter, cleaning the fuel solenoid pump strainer or running the fuel tank dry, be sure to bleed the air from the fuel system. Air Bleeding Procedures
dCAUTION:
Fuel leaks may lead to fires.
1. Check that fuel cock (1) on bottom of the fuel tank is opened.
1
2. Loosen priming pump (3). 3. Loosen joint bolt (2) on the fuel main filter. j : 12 mm 4. Supply fuel by reciprocating priming pump (3). After no air bubbles are spouted through joint bolt (2), tighten joint bolt (2).
M1U1-07-015
2
j : 12 mm 5. After tightening joint bolt (2), reciprocate priming pump (3) until its movement becomes slow. 6. Tighten priming pump (3). 7. Wipe off any spilled fuel. 8. Start the engine. Check that no fuel leaks are present. If the engine does not start, repeat the above procedures from step 1. 3
M111-07-046
W1-4-1-3
SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Radiator Do not loosen the radiator cap until dCAUTION: the system has cooled. Hot steam may spout out and cause severe burns. Wait until coolant cools and loosen the cap slowly. Release all pressure and remove the cap.
Preparation 1. Park the machine on a solid and level surface. Set the front attachment in position for checking hydraulic oil level. 2. Stop the engine. Remove the radiator cap.
W1-4-1-4
SECTION 1 GENERAL Group 5 Pressure Release Procedure Hydraulic Circuit Pressure Release Procedure Release any remaining pressure as follows before removing/installing the front attachment. 1. Set pilot shut-off lever (1) to the UNLOCK position. 2. Turn engine stop switch (2) ON.
fNOTE:
Perform step 1 and step 2, and set the key switch to the START position. Although the starter rotates, the engine does not start. IMPORTANT: Battery will deplete. Operate the key switch for short period. 3. With the key switch set in the START position, operate the control lever in order to release any pressure in the hydraulic circuit 4 to 5 times. 4. Return pilot shut-off lever (1) to the LOCK position. 5. Turn engine stop switch (2) OFF.
W1-5-1-1
1 2 M1U1-01-029
SECTION 1 GENERAL Group 5 Pressure Release Procedure (Blank)
W1-5-1-2
SECTION 1 GENERAL Group 6 Preparation Preparation before Inspection and Maintenance Before performing the maintenance procedures given in the following chapters, park the machine as described below, unless otherwise specified. 1. Park the machine on a level surface. M104-07-021
2. Lower the bucket to the ground. 3. Turn the auto-idle switch OFF. 4. Set the engine control dial to the slow idle position. Run the engine at slow idle speed without load for five minutes.
1
5. Set the key switch to the OFF position. Stop the engine. Remove the key from the key switch. If maintenance should be performed with the engine running, do not leave the machine unattended. 6. Set pilot shut-off lever (1) to the LOCK position. 7. Before performing any work on the machine, attach tag (2) on the door or control lever. 2
WDAA-01-06-001
W1-6-1-1
SECTION 1 GENERAL Group 6 Preparation (Blank)
W1-6-1-2
MEMO
MEMO
SECTION 2
MAINTENANCE STANDARD CONTENTS Group 1 Upperstructure
Main Pump........................................................................W2-1-1-1 Fan Pump...........................................................................W2-1-1-2 Swing Motor.....................................................................W2-1-2-1
Group 2 Undercarriage
Travel Device....................................................................W2-2-1-1 Sprocket.............................................................................W2-2-1-2 Center Joint.......................................................................W2-2-2-1 Front Idler..........................................................................W2-2-3-1 Upper Roller......................................................................W2-2-4-1 Lower Roller......................................................................W2-2-4-2 Track.....................................................................................W2-2-5-1
Group 3 Front Attachment
Pin and Bushing...............................................................W2-3-1-1 Side Cutter.........................................................................W2-3-1-3 Point.....................................................................................W2-3-1-3 Standard Dimensions for Arm and Bucket Connection..................................................................W2-3-1-4 Standard Dimensions for Arm and Boom Connection..................................................................W2-3-1-6 Cylinder..............................................................................W2-3-2-1
JBEW-2-1
(Blank)
JBEW-2-2
SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Main Pump 1. Clearance between plunger (36) outer diameter (A) and cylinder block (29A) bore diameter (B). A
B-A
B
Unit: mm (in) Standard
Allowable Limit
0.032 (0.001)
0.056 (0.002) W117-02-02-009
2. Outer diameter (C) of shaft. C
C
Unit: mm (in) Standard
Allowable Limit
65 (2.56)
64.8 (2.55) W176-02-04-019
3. Clearance (D) between plunger (36) and shoe bottom and shoe thickness (E) D
Unit: mm (in) Standard
Allowable Limit
0 to 0.1 (0 to 0.004)
0.3 (0.012)
E
Unit: mm (in) Standard
Allowable Limit
3.9 (0.154)
3.7 (0.146)
E
D
W117-02-02-011
4. Clearance between small chamber inner diameter and servo piston F-G
Unit: mm (in) Standard
Allowable Limit
0.065 (0.0026)
0.085 (0.0033)
5. Clearance between large chamber inner diameter and servo piston F-G
G
G F
b
a
F
Unit: mm (in) Standard
Allowable Limit
0.07 (0.0028)
0.09 (0.0035)
WDCD-02-01-001 a- b-
W2-1-1-1
Small Chamber Diameter Large Chamber Diameter
SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Fan Pump 1. Clearance between plunger (011) outer diameter (A) and cylinder block (014A) bore diameter (B). A
B-A
B
Unit: mm (in) Standard
Allowable Limit
0.032 (0.001)
0.056 (0.002) W117-02-02-009
2. Free length (C) of spring (157) C
Unit: mm (in) Standard
Allowable Limit
41.1 (1.62)
40.3 (15.9)
3. Clearance (D) between plunger (011) and shoe bottom and shoe thickness (E)
C W117-02-02-010
D
Unit: mm (in) Standard
Allowable Limit
0 to 0.1 (0 to 0.004)
0.3 (0.012)
E
Unit: mm (in) Standard
Allowable Limit
3.9 (0.154)
3.7 (0.146)
E
D
W117-02-02-011
4. The difference between the surface of plate (153) to the top of bushing (156) F-G
a
Unit: mm (in) Standard
Allowable Limit
17.0 (0.67)
15.8 (0.62)
G
F
W117-02-02-012 a-
W2-1-1-2
Base
SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Swing Motor 1. Clearance between plunger (8) outer diameter (A) and rotor (11) inner bore (B) A
B-A
Unit: mm (in) Standard
Allowable Limit
0.028 (0.0011)
0.058 (0.0023)
W107-02-06-138
B
B
2. Clearance (C) between plunger (8) and shoe bottom C
Unit: mm (in) Standard
Allowable Limit
0 (0)
0.3 (0.0118)
W107-02-06-139
C
W107-02-06-140
C
W107-02-06-141
W2-1-2-1
SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure 3. Shoe thickness (D) D
Unit: mm (in) Standard
Allowable Limit
5.5 (0.22)
5.3 (0.21) D
W107-02-06-142
4. Friction plate (12) thickness (E) E
E
Unit: mm (in) Standard
Allowable Limit
2.0 (0.08)
1.6 (0.06)
W107-02-06-143
W2-1-2-2
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Travel Device 1. Clearance between inner diameter (A) of rotor (14) and outer diameter (B) of plunger (10): A-B: 0.06 mm (0.002 in) or less A
B
W507-02-04-009
2. Clearance (C) between plunger (10) and shoe C: 0.4 mm (0.02 in) or less
C
3. Clearance between inner diameter (D) and outer diameter (E) at the mounting position (4) of housing (1) and piston (4):
W107-02-06-140
D-E: 0.03 mm (0.001 in) or less
E
4. Wear amount on the sliding surfaces of rotor (14) and valve plate (15):
D
Check if there is no abnormal scratch, wear, score or seizure.
Wear amount within 0.02 mm (0.0008 in) or less.
W162-03-02-005
W2-2-1-1
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Sprocket
C
B
D
E
A
W105-03-07-042
Unit: mm (in)
fNOTE:
Standard
Allowable Limit
A
114 (4.5)
[104 (4.1)]
B
152.5 (6.0)
147.5 (5.81)
C
198.5 (7.81)
-
D
210 (8.27)
205 (8.07)
E
260.35 (10.2)
-
Value in [ ] is just for reference.
W2-2-1-2
Remedy
Build up and finishing
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Center Joint Item
Allowable Limit (basis of judgment)
Remedy
1. Wear more than 0.2 mm (0.008 in)
Replace
2. Seizure and abnormal wear
Replace
3. Uneven wear within 180 Ëš Bushing
Wear Area Within Half Range
Replace
T157-01-01-040
Sliding surface with seals
Body, Spindle
Sliding surface 1 Excessively worn one by seizure or foreign matter, or one between body having the score of 0.1 mm (0.004 in) or more and spindle other than sliding 2 One having the score of less than 0.1 mm (0.004 in) surfaces with seals
Replace Replace Repair the surface smooth by using an oil stone
1 One that has worn 0.5 mm (0.02 in) or more, or excessively Replace worn Sliding surface with ring
Cover
Heavily damaged one by seizure or foreign matter
Sliding surface with ring
2 One that has worn 0.5 mm (0.02 in) or less
Repair the surface smooth
3 One that has scores due to seizure or foreign matter but the damage is less than the allowable wear limit 0.5 mm (0.02 in) and is repairable
Repair the surface smooth
1 One that has worn 0.5 mm (0.02 in) or more
Replace
2 One that has worn less than 0.5 mm (0.02 in)
Repair the surface smooth
3 One that has scores due to seizure or foreign matter but the damage is less than the allowable wear limit 0.5 mm (0.02 in) and is repairable
Repair the surface smooth
W2-2-2-1
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage (Blank)
W2-2-2-2
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Front Idler Idler
C D
E A B
W166-03-05-001
Unit: mm (in) Standard
Allowable Limit
A
126 (5.0)
-
B
260 (10.2)
-
C
800 (31.5)
780 (30.7)
D
845 (33.3)
-
E
22.5 (0.9)
32.5 (1.3)
Remedy
Cladding by welding and finish or replace
Axle and Bushing Unit: mm (in) Axle Bushing
fNOTE:
Standard
Allowable Limit
Outside Dia.
120 (4.7)
[119.2 (4.7)]
Inside Dia.
120 (4.7)
[121 (4.8)]
Flange Thickness
6 (0.2)
[5.2 (0.2)]
Values in [ ] are just for reference.
W2-2-3-1
Remedy Replace
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage (Blank)
W2-2-3-2
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Upper Roller Roller
C
A B W157-03-06-003
Unit: mm (in) Standard
Allowable Limit
A
116 (4.6)
-
B
260 (10.2)
-
C
210 (8.3)
202 (8.0)
Remedy Replace
Axle and Bushing Unit: mm (in) Standard Axle Bushing
Outside Dia.
85 (3.3)
Inside Dia.
85 (3.3)
Flange Thickness
4.5 (0.2)
W2-2-4-1
Remedy Replace
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Lower Roller Roller
W157-03-06-003
Unit: mm (in) Standard
Allowable Limit
A
274 (10.8)
-
B
356 (14.0)
-
C
41 (1.6)
-
D
240 (9.4)
220 (8.7)
Cladding by welding and finish or replace
Axle and Bushing Standard Axle Bushing
Outside Dia.
110 (4.3)
Inside Dia.
110 (4.3)
Flange Thickness
6 (0.2)
W2-2-4-2
Remedy
Remedy Replace
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Track Link Measure the length of four links. 1. Do not measure the part included the master pin. 2. Measure the length with tension on the track.
B
A W155-03-07-001
Unit: mm (in) Standard
Allowable Limit
Remedy
A
1041.4 (41.0)
1062.2 (41.8)
B
155 (6.1)
[147.2 (5.8)]
Cladding by welding and finish or replace
Master Pin C
B
C
A
W800-03-07-028
Unit: mm (in)
fNOTE:
Standard
Allowable Limit
A
319.5 (12.6)
-
B
56.8 (2.2)
[53.8 (2.1)]
C
57.2 (2.3)
-
Values in [ ] are just for reference.
W2-2-5-1
Remedy Replace
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Master Bushing
W105-03-07-023
Unit: mm (in) Standard
Allowable Limit
A
204.15 (8.0)
-
B
57.65 (2.27)
[60.7 (2.4)]
C
85.35 (3.36)
[80.4 (3.2)]
Remedy Replace
Grouser Shoe
W105-03-07-024
Unit: mm (in) Shoe Size A
fNOTE:
Grouser Shoe Standard
Allowable Limit
302 (11.89)
-
B
19 (0.75)
-
C
50 (1.97)
24 (0.95)
Values in [ ] are just for reference.
W2-2-5-2
Remedy Replace
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Bushing
W105-03-07-023
Unit: mm (in) Standard
Allowable Limit
A
223.6 (8.80)
-
B
58.15 (2.29)
[60.7 (2.4)]
C
85.35 (3.36)
[78.55 (3.09)]
Remedy Replace
Pin B A
W142-03-07-004
Unit: mm (in)
fNOTE:
Standard
Allowable Limit
A
319.5 (21.6)
-
B
57.1 (2.25)
[54.1 (2.1)]
Values in [ ] are just for reference.
W2-2-5-3
Remedy Replace
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage (Blank)
W2-2-5-4
SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Pin and Bushing
D C
F G
B
H I
E
A
K J W1JB-04-02-015
Unit: mm (in) Position A: Boom Cylinder and Main Frame
B: Boom and Main Frame
C: Boom Cylinder and Boom
Item
Standard
Allowable Limit
Pin Outer Dia. Pin Hole Inner Dia. (Main Frame Side)
130 (5.12) 130 (5.12)
129 (5.08) -
Bushing Inner Dia. (Cylinder Side)
130 (5.12)
131.5 (5.18)
Pin Outer Dia. Bushing Inner Dia. (Frame Side) Bushing Outer Dia.
170 (6.69) 170 (6.69) 190 (7.48)
169 (6.65) 171.5 (6.75) -
Bushing Inner Dia. (Boom Side) Bushing Outer Dia.
170 (6.69) 200 (7.87)
171.5 (6.75) -
Pin Outer Dia. Pin Hole Inner Dia. (Boom Side)
130 (5.12) 130 (5.12)
129 (5.08) -
Bushing Inner Dia. (Cylinder Side)
130 (5.12)
131.5 (5.18)
W2-3-1-1
SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Unit: mm (in) Position D: Boom and Arm Cylinder
E: Boom and Arm
F: Arm Cylinder and Arm
G: Arm and Bucket Cylinder
H: Bucket Cylinder and Links A, B
I: Link A and Bucket
J: Arm and Bucket
K: Arm and Link B
Item
Standard
Allowable Limit
Pin Outer Dia. Pin Hole Inner Dia. (Boom Side)
140 (5.51) 140 (5.51)
139 (5.47) -
Bushing Inner Dia. (Cylinder Side)
140 (5.51)
141.5 (5.57)
Pin Outer Dia. Bushing Inner Dia. (Boom Side) Bushing Outer Dia.
150 (5.91) 150 (5.91) 180 (7.09)
149 (5.87) 151.5 (5.97) -
Bushing Inner Dia. (Arm Side) Bushing Outer Dia.
150 (5.91) 180 (7.09)
151.5 (5.97) -
Pin Outer Dia. Pin Hole Inner Dia. (Arm Side)
140 (5.51) 140 (5.51)
139 (5.47) -
Bushing Inner Dia. (Cylinder Side)
140 (5.51)
141.5 (5.57)
Pin Outer Dia. Pin Hole Inner Dia. (Arm Side)
130 (5.12) 130 (5.12)
129 (5.08) -
Bushing Inner Dia. (Cylinder Side)
130 (5.12)
131.5 (5.18)
Pin Outer Dia. Bushing Inner Dia. (Link A Side) Bushing Outer Dia.
150 (5.91) 150 (5.91) 180 (7.09)
149 (5.87) 151.5 (5.97) -
Bushing Inner Dia. (Cylinder Side)
150 (5.91)
151.5 (5.97)
Pin Outer Dia. Bushing Inner Dia. (Link A Side) Bushing Outer Dia.
130 (5.12) 130 (5.12) 160 (6.30)
129 (5.08) 131.5 (5.18) -
Bushing Inner Dia. (Bucket Side) Bushing Outer Dia.
130 (5.12) 160 (6.30)
129 (5.08) -
Pin Outer Dia. Bushing Inner Dia. (Arm Side) Bushing Outer Dia.
140 (5.51) 140 (5.51) 170 (6.69)
139 (5.47) 141.5 (5.57) -
Bushing Inner Dia. (Bucket Side) Bushing Outer Dia.
140 (5.51) 170 (6.69)
141.5 (5.57) -
Pin Outer Dia. Bushing Inner Dia. (Arm Side) Bushing Outer Dia.
110 (4.33) 110 (4.33) 140 (5.51)
109 (4.29) 111.5 (4.39) -
IMPORTANT: When replacing HN bushing for the front attachment, install it by using a press.
W2-3-1-2
SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Side Cutter
B
A
W166-04-01-011
Unit: mm (in) Standard
Allowable Limit
Remedy
A
351(13.8)
228(8.97)
Replace
B
25(0.98)
-
Point
C
B
A D
W142-04-01-021
Unit: mm (in) Standard
Allowable Limit
Remedy Replace
A
306(12.05)
153(6.02)
B
153(6.02)
-
C
164(6.46)
-
D
158(6.22)
-
W2-3-1-3
SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Standard Dimensions for Arm and Bucket Connection IMPORTANT: If the front attachment of a previous model machine is used, use the grease intervals for previous model machine.
W1JB-04-01-001
I P J
N
WJBC-02-03-001
(Without bushing)
(Without bushing)
Section A’
Section B’
W2-3-1-4
W1JB-04-01-008
SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment ZX870-5 class
Unit: mm (in)
Front
STD., H
BE
A
600 (23.6)
B
20 (0.79)
0
C
890 (35.0)
D
820 (32.3)
E
676 (26.6)
697 (27.4)
F
2190 (86.2)
2257 (88.9)
G
555 (21.85)
H
170 (6.69)
I
674 (26.5)
690 (27.2)
J
56 (2.20)
100 (3.94)
K
627 (24.7)
L
555 (21.85)
M
160 (6.30)
N
10 ˚
20 ˚
O
627 (24.7)
P
5˚
10 ˚
fNOTE:
1. Dimension B is different according to the arm type.
2. Dimension G and L includes the clearance for shims in order to adjust the bucket clearance.
3. Dimension N and P indicate the angle of stopper.
4. Dimension E, F, I, J, N, and P are different according to the bucket type.
5. Front attachments STD and H indicate the dimension when installing the bucket 3.5.
6. Front attachment BE indicates the dimension when installing the rock bucket 4.3 BE.
W2-3-1-5
SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Standard Dimensions for Arm and Boom Connection IMPORTANT: If the front attachment of a previous model machine is used, use the grease intervals for previous model machine.
(Without Q bushing)
R S Section C’
ZX870-5 class
Unit: mm (in)
Front
STD., H
BE
Q
180 (7.09)
R
538 (21.2)
S
708 (27.9)
W2-3-1-6
WJBA-02-03-001
SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Cylinder
Rod Bend and Run Out
Rod
b a
A
1m
W105-04-02-094
W166-04-02-022
c a- b-
Cylinder Rod Dial Gauge
c-
V Block
Unit: mm (in)
Unit: mm (in) Cylinder Name
Recommended Size After Re-manufacturing (A)
Bend
Run Out
Remedy
0.5 (0.02)
1.0 (0.04)
Repair
Boom
150 +0.031-0.061
1.0 (0.04)
2.0 (0.08)
Replace
Arm
160 +0.031-0.061
Bucket
140 +0.031-0.061
fNOTE:
1mm=0.039 in
W2-3-2-1
SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment (Blank)
W2-3-2-2
MEMO
MEMO
SECTION 3
UPPERSTRUCTURE CONTENTS Group 1 Cab
Removal and Installation of Cab...............................W3-1-1-1 Dimensions of Cab Glass (Standard Cab)...............W3-1-2-1 Dimensions of Cab Glass (H Cab)........................... W3-1-2-20
Group 2 Swing Counterweight
Removal and Installation of Counterweight.........W3-2-1-1
Group 3 Main Frame
Removal and Installation of Main Frame................W3-3-1-1
Group 4 Engine
Removal and Installation of Engine.........................W3-4-1-1
Group 5 Radiator Assembly
Replacement of Radiator.............................................W3-5-1-1 Replacement of Intercooler........................................W3-5-2-1 Replacement of Oil Cooler...........................................W3-5-3-1
Group 6 Hydraulic Oil Tank
Removal and Installation of Hydraulic Oil Tank......................................................W3-6-1-1
Group 7 Fuel Tank
Removal and Installation of Fuel Tank.....................W3-7-1-1
Group 8 Pump Device
Removal and Installation of Pump Device.............W3-8-1-1 Disassembly of Pump Transmission.........................W3-8-2-1 Assembly of Pump Transmission...............................W3-8-2-6 Disassembly of Main Pump.........................................W3-8-3-1 Assembly of Main Pump...............................................W3-8-3-6 Disassembly of Regulator for Main Pump..............W3-8-4-1 Assembly of Regulator for Main Pump...................W3-8-4-4 Disassembly of Fan Pump............................................W3-8-5-1 Assembly of Fan Pump.................................................W3-8-5-5 Disassembly of Regulator for Fan Pump................W3-8-6-1 Assembly of Regulator for Fan Pump......................W3-8-6-3 Structure of Pilot Pump................................................W3-8-7-1
Group 9 Control Valve
Removal and Installation of Control Valve.............W3-9-1-1 Disassembly and Assembly of Valve Unit...............W3-9-2-1 Disassembly of Control Valve (4-Spool Side)........W3-9-3-1 Assembly of Control Valve (4-Spool Side)..............W3-9-3-9 Disassembly of Control Valve (5-Spool Side)........W3-9-4-1 Assembly of Control Valve (5-Spool Side)..............W3-9-4-8
Group 10 Swing Device
Removal and Installation of Swing Device......... W3-10-1-1 Disassembly of Swing Device.................................. W3-10-2-1 Assembly of Swing Device....................................... W3-10-2-7 Disassembly of Swing Motor................................... W3-10-3-1 Assembly of Swing Motor......................................... W3-10-3-4 Structure of Swing Parking Brake Valve............... W3-10-4-1
Group 11 Pilot Valve
Removal and Installation of Pilot Valve (Left)....................................................... W3-11-1-1 Removal and Installation of Pilot Valve (Right)................................................... W3-11-2-1 Removal and Installation of Travel Pilot Valve..................................................... W3-11-3-1 Disassembly of Pilot Valves (Right and Left)...... W3-11-4-1 Assembly of Pilot Valves (Right and Left)............ W3-11-4-4 Disassembly of Travel Pilot Valve............................ W3-11-5-1 Assembly of Travel Pilot Valve................................. W3-11-5-5
Group 12 Solenoid Valve
Removal and Installation of Pilot Shut-Off Solenoid Valve....................................... W3-12-1-1 Removal and Installation of 4-Spool Solenoid Valve Unit............................................... W3-12-2-1 Removal and Installation of 2-Spool Solenoid Valve Unit................................................ W3-12-3-1 Disassembly of Pilot Shut-Off Solenoid Valve......................................................... W3-12-4-1 Assembly of Pilot Shut-Off Solenoid Valve ........................................................ W3-12-4-3 Structure of 4-Spool Solenoid Valve Unit............ W3-12-5-1 Structure of 2-Spool Solenoid Valve Unit............ W3-12-6-1
Group 13 Signal Control Valve
Removal and Installation of Signal Control Valve............................................... W3-13-1-1 Structure of Signal Control Valve........................... W3-13-2-1
Group 14 Shockless Valve
Removal and Installation of Shockless Valve....................................................... W3-14-1-1 Structure of Shockless Valve.................................... W3-14-2-1
Group 15 Fan Valve
Removal and Installation of Oil Cooler Fan Valve............................................... W3-15-1-1
JBEW-3-1
Removal and Installation of Radiator Fan Valve.................................................. W3-15-2-1 Structure of Oil Cooler Fan Valve and Radiator Fan Valve............................. W3-15-3-1
Group 16 Fan Motor
Removal and Installation of Oil Cooler Fan Motor............................................ W3-16-1-1 Removal and Installation of Radiator Fan Motor............................................... W3-16-2-1 Structure of Oil Cooler Fan Motor and Radiator Fan Motor.......................... W3-16-3-1
JBEW-3-2
SECTION 3 UPPERSTRUCTURE Group 1 Cab Removal and Installation of Cab 1
5
6
5
4
3
2
WDAA-03-01-023
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal
WJAA-03-01-013
dCAUTION:
Seat (6) weight: 41 kg (91 lb) 3. Remove bolts, washers (5) (4 used). Remove seat (6). j : 13 mm 4. Remove floor mat (3). 5. Remove bolts, washers (4) (4 used). Remove travel control levers (1) (2 used).
1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)
j : 17 mm
2. Open door (2).
W3-1-1-1
SECTION 3 UPPERSTRUCTURE Group 1 Cab
1
A Detail A
4
5
6
3
2
WDAA-03-01-050
6. Remove cover (1). 7. Disconnect connector (5) and connectors (4) (2 used). 8. Remove bolt, washer (2) and screw (6). Remove cover (3). j : 13 mm
W3-1-1-2
4
WDAA-03-01-051
SECTION 3 UPPERSTRUCTURE Group 1 Cab 1
2
3, 4
11
12
13
14
B
A
5
6, 7
6, 7
8, 9, 10 WDAA-03-01-052
19
16
22
Detail A
Detail B
20, 21, 22
WDAA-03-01-053
15 17
18
WDAA-03-01-065
WDAA-03-01-062
9. Open cover (1). 10. Remove caps (20) (2 used). Remove seals (21) (2 used) and screws (22) (3 used). Remove cover (19). 11. Remove bolts, washers (6) (2 used) and washers (7) (2 used). j : 13 mm 12. Remove caps (8) (3 used). Remove rubbers (9) (3 used) and screws (10) (3 used). Remove cover (5).
13. Remove caps (3) (2 used). Remove screws (4) (2 used). Remove cover (2) and duct (13). 14. Remove bolts, washers (15) (2 used). j : 17 mm 15. Remove bolt, washer (14). Remove cover (16). j : 13 mm 16. Remove screws (11) (2 used). Remove duct (12). 17. Remove bolt, washer (18). Remove duct (17). j : 13 mm
W3-1-1-3
SECTION 3 UPPERSTRUCTURE Group 1 Cab
1
Detail A
A
1
B
WJBE-03-01-006
1 Detail B
1
1
WJBE-03-01-005
WJBE-03-01-007
18. Disconnect connectors (1) (5 used).
W3-1-1-4
SECTION 3 UPPERSTRUCTURE Group 1 Cab
A
B
WDAA-03-01-063
WDAA-03-01-064
1 Detail A
Detail B
1
2
1
WDAA-03-01-054
19. Remove clip (2). 20. Disconnect connectors (1) (6 used). 21. Remove clip (4). 22. Disconnect connectors (3) (3 used).
W3-1-1-5
3
4
WDAA-03-01-055
SECTION 3 UPPERSTRUCTURE Group 1 Cab 1
2 A
9
6
7
8
WJBE-03-01-004
Detail A
10 5
4
3
11
WJBA-03-01-001
WJBE-03-01-002
23. Close door (1).
30. Remove bolt (11). Disconnect connector (10).
24. Open cover (5).
j : 13 mm
25. Remove filter (3).
31. Open door (1).
26. Remove screws (4) (6 used). Remove filter case (2). 27. Open cover (9). 28. Disconnect hose (8). 29. Remove bolts, washers (6) (4 used). Remove cover (7). j : 17 mm
W3-1-1-6
SECTION 3 UPPERSTRUCTURE Group 1 Cab 2, 3
a
4
2, 3
5, 6
1
WJAA-03-01-014
4
5, 6
4
2, 3
7, 8
a - Lifting Bracket
d Standard machine : 475 kg (1050 lb) H spec. machine : 570 kg (1260 lb)
CAUTION: The cab (1) assembly weight:
32. Attach nylon slings onto lifting brackets (a) (4 places) of cab (1). Hoist and hold the cab (1) assembly.
2, 3 WJAA-03-01-018
33. Remove socket bolts (7) (2 used) and washers (8) (2 used). l : 8 mm 34. Remove socket bolts (5) (5 used) and washers (6) (5 used). l : 8 mm 35. Remove bolts, washers (4) (5 used). j : 17 mm 36. Remove nuts (2) (4 used) and washers (3) (4 used). Remove the cab (1) assembly. j : 24 mm
W3-1-1-7
SECTION 3 UPPERSTRUCTURE Group 1 Cab 1
Detail A
2, 13
1 A
B
WJBE-03-01-009
Detail B 3
4
5
6
7
7
8
WJBE-03-01-008
11, 12
37. Disconnect connectors (1) (6 used). 38. Remove bolt, washer (2). Disconnect ground (13). j : 13 mm 39. Remove screws (3) (4 used). Disconnect connector (4). 40. Remove screws (5) (2 used). Remove controller (6). 41. Disconnect connectors (7) (2 used). 42. Remove bolt, washer (11) and clip (12). j : 17 mm 43. Remove bolt, washer (8). Remove horn (9). j : 13 mm 44. Disconnect cable (10).
W3-1-1-8
10
9
WJBE-03-01-010
SECTION 3 UPPERSTRUCTURE Group 1 Cab
1
A
2
1
3
Detail A
WJBE-03-01-008
45. Remove bolts, washers (1) (4 used). Remove MC (2). j : 13 mm 46. Disconnect connectors (3) (2 used). 47. Remove bolt, washer (4) and clip (5). j : 17 mm
W3-1-1-9
4, 5
WJBE-03-01-011
SECTION 3 UPPERSTRUCTURE Group 1 Cab
2
2
WDAA-03-01-061
1 WDAA-03-01-067
dCAUTION: kg (64 lb)
The bracket (1) assembly weight: 29
48. Remove bolts, washers (2) (6 used). Remove the bracket (1) assembly. j : 17 mm
W3-1-1-10
SECTION 3 UPPERSTRUCTURE Group 1 Cab
2
2
WDAA-03-01-061
1 WDAA-03-01-067
Installation
dCAUTION: kg (64 lb)
The bracket (1) assembly weight: 29
1. Install the bracket (1) assembly with bolts, washers (2) (6 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-1-1-11
SECTION 3 UPPERSTRUCTURE Group 1 Cab
1
A
2
1
3
Detail A
WJBE-03-01-008
2. Install clip (5) and bolt, washer (4). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3. Connect connectors (3) (2 used). 4. Install MC (2) with bolts, washers (1) (4 used). j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-1-1-12
4, 5
WJBE-03-01-011
SECTION 3 UPPERSTRUCTURE Group 1 Cab 1
Detail A
2, 13
1 A
B
WJBE-03-01-009
Detail B 3
4
5
6
7
7
8
WJBE-03-01-008
11, 12
5. Connect cable (10). 6. Install horn (9) with bolt, washer (8). j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 7. Install clip (12) and bolt, washer (11). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 8. Connect connectors (7) (2 used). 9. Install controller (6) with screws (5) (2 used). 10. Install connector (4) with screws (3) (4 used). 11. Install ground (13) with bolt, washer (2). j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 12. Connect connectors (1) (6 used).
W3-1-1-13
10
9
WJBE-03-01-010
SECTION 3 UPPERSTRUCTURE Group 1 Cab 2, 3
a
4
2, 3
5, 6
1
WJAA-03-01-014
4
5, 6
4
2, 3
a - Lifting Bracket
7, 8
2, 3 WJAA-03-01-018
16. Install washers (6) (5 used) and socket bolts (5) (5 used).
d Standard machine : 475 kg (1050 lb) H spec. machine : 570 kg (1260 lb)
CAUTION: The cab (1) assembly weight:
l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 17. Install washers (8) (2 used) and socket bolts (7) (2 used).
13. Attach nylon slings onto lifting brackets (a) (4 places) of cab (1). Hoist the cab (1) assembly. 14. Install the cab (1) assembly with washers (3) (4 used) and nuts (2) (4 used). j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 15. Install bolts, washers (4) (5 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-1-1-14
l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
SECTION 3 UPPERSTRUCTURE Group 1 Cab 1
2 A
9
6
7
8
WJBE-03-01-004
Detail A
10 5
4
3
11
WJBA-03-01-001
WJBE-03-01-002
18. Open cover (9).
23. Open cover (5).
IMPORTANT: Do not use an impact wrench when tightening bolt (11). The cover may be damaged. 19. Connect connector (10) with bolt (11). j : 13 mm
24. Install filter case (2) with screws (4) (6 used). 25. Install filter (3). 26. Close cover (5). 27. Open door (1).
m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 20. Install cover (7) with bolts, washers (6) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 21. Connect hose (8). 22. Close cover (9).
W3-1-1-15
SECTION 3 UPPERSTRUCTURE Group 1 Cab
A
B
WDAA-03-01-063
WDAA-03-01-064
1 Detail A
Detail B
1
2
1
WDAA-03-01-054
28. Connect connectors (3) (3 used). 29. Install clip (4). 30. Connect connectors (1) (6 used). 31. Install clip (2).
W3-1-1-16
3
4
WDAA-03-01-055
SECTION 3 UPPERSTRUCTURE Group 1 Cab
1
Detail A
A
1
B
WJBE-03-01-006
1 Detail B
1
1
WJBE-03-01-005
WJBE-03-01-007
32. Connect connectors (1) (5 used).
W3-1-1-17
SECTION 3 UPPERSTRUCTURE Group 1 Cab 1
2
3, 4
11
12
13
14
B
A
5
6, 7
6, 7
8, 9, 10 WDAA-03-01-052
19
16
22
Detail A
Detail B
20, 21, 22
WDAA-03-01-053
15 17
18
WDAA-03-01-065
WDAA-03-01-062
33. Install duct (17) with bolt, washer (18). j : 13 mm m : 8 N·m (0.8 kgf·m, 5.9 lbf·ft)
38. Install cover (5) with screws (10) (3 used). Install rubbers (9) (3 used) and caps (8) (3 used). 39. Install washers (7) (2 used) and bolts, washers (6) (2 used).
34. Install duct (12) with screws (11) (2 used).
j : 13 mm
m : 3 N·m (0.3 kgf·m, 2.2 lbf·ft) 35. Install cover (16) with bolt, washer (14). j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 40. Open cover (1). 41. Install cover (19) with screws (22) (3 used). Install seals (21) (2 used) and caps (20) (2 used).
36. Install bolts, washers (15) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 37. Install duct (13) and cover (2) with screws (4) (2 used). Install caps (3) (2 used).
W3-1-1-18
SECTION 3 UPPERSTRUCTURE Group 1 Cab
1
A Detail A
4
5
6
3
2
WDAA-03-01-050
42. Install cover (3) with screw (6) and bolt, washer (2). j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 43. Connect connectors (4) (2 used) and connector (5). 44. Install cover (1).
W3-1-1-19
4
WDAA-03-01-051
SECTION 3 UPPERSTRUCTURE Group 1 Cab 1
5
6
5
4
3
2
WDAA-03-01-023
45. Install travel control levers (1) (2 used) with bolts, washers (4) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 46. Install floor mat (3).
dCAUTION:
Seat (6) weight: 41 kg (91 lb) 47. Install seat (6) with bolts, washers (5) (4 used). j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 48. Close door (2).
W3-1-1-20
WJAA-03-01-013
SECTION 3 UPPERSTRUCTURE Group 1 Cab Dimensions of Cab Glass (Standard Cab) Unit: mm
Section A
WDAA-03-01-036
WDAA-03-01-030
a - Black Ceramic Painted Surface
b - Black Ceramic Painted Range
Detail C
Section B
a - Black Ceramic Painted Surface
WDAA-03-01-001
WDAA-03-01-035
W3-1-2-1
WDAA-03-01-002
SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm
WDAA-03-01-030
a - Black Ceramic Painted Surface
WDAA-03-01-034
Section A
a - Black Ceramic Painted Surface
WDAA-03-01-037
W3-1-2-2
SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm
Section A
WDAA-03-01-004
WDAA-03-01-031
a - Chamfer along the Periphery
WDAA-03-01-003
W3-1-2-3
SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm
Section A
WDAA-03-01-006
WDAA-03-01-031
a - Chamfer along the Periphery
WDAA-03-01-005
W3-1-2-4
SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm
Section A
WDAA-03-01-038 WDAA-03-01-031
a - Black Ceramic Painted Surface b - Black Ceramic Painted Range
a - Black Ceramic Painted Surface
c - Chamfer here.
d - Shaded Paint along the Periphery Here
WDAA-03-01-007
Section B
Section C
WDAA-03-01-008
W3-1-2-5
WDAA-03-01-009
SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm
WDAA-03-01-031
a - Black Ceramic Painted Surface
b - Black Ceramic Painted Range
Section A
WDAA-03-01-010
Detail B
WDAA-03-01-038 a - Black Ceramic Painted Surface
d - Shaded Paint along the Periphery Here
W3-1-2-6
WDAA-03-01-011
SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm
WDAA-03-01-031
a - Black Ceramic Painted Surface b - Black Ceramic Painted Range c - Chamfer here.
Section A
a - Black Ceramic Painted Surface d - Dotted edge along the Periphery Here
WDAA-03-01-012
Section B
WDAA-03-01-038
W3-1-2-7
WDAA-03-01-008
SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm
Section A
a - Black Ceramic Painted Surface d - Shaded Paint along the Periphery Here
WDAA-03-01-030
a - Black Ceramic Painted Surface
b - Black Ceramic Painted Range
W3-1-2-8
WDAA-03-01-038
WDAA-03-01-013
SECTION 3 UPPERSTRUCTURE Group 1 Cab Procedure to Remove Cab Glass 1
Procedures to Remove Right-Hand Glass (1), Rear LeftHand Glass (2), Lower Door Glass (3), and Rear Glass (4) When removing the broken or cracked dCAUTION: glass, the glass shards may cause serious injury. Before removing, use the duct tape or equivalent in order to paste the broken or cracked glass and reinforce them. Remove the glass pieces away. 1. Remove resin panel (5), garnish (6), and the spacer around the glass.
WDAA-03-01-030
4 6
2
6
2. Prick a hole in adhesive (b) by using awl (a) (or a knife).
3 5 7
WDAA-03-01-031
8 a
3. Pass piano wire (c) (or a metal wire) through the hole.
b 7 - Cab 8 - Glass
W1SE-02-01-033 a - Awl b - Adhesive
c
c - Piano Wire
W3-1-2-9
W1SE-02-01-034
SECTION 3 UPPERSTRUCTURE Group 1 Cab IMPORTANT: The piano wire is easily broken if a part of the piano wire turns hot. Change the position and cut the adhesive. 4. Wind the both ends of the piano wire onto the screwdriver. Draw the wire back and forth in order to cut adhesive (b) between cab (7) and glass (8). Remove glass (8) from cab (7).
7
a
8
fNOTE:
Cut off the middle of adhesive between glass and cab.
b c a - Cab Outside b - Adhesive c - Cab Inside
W3-1-2-10
W1SE-02-01-035
SECTION 3 UPPERSTRUCTURE Group 1 Cab Procedure to Install Cab Glass 1
Procedures to Install Right-Hand Glass (1), Rear Left-Hand Glass (2), Lower Door Glass (3), and Rear Glass (4) 1. Cut off the residual adhesive from the cab (7) side by 1 to 2 mm deep all around by using a knife or similar.
fNOTE:
Do not damage the cab (7) paint. WDAA-03-01-030
4
3 2
2. Clean the cutting edge of adhesive at cab (7) side by using white spirit.
WDAA-03-01-031
7
a
b
IMPORTANT: Primer should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer, apply Primer as quickly as possible and close the cap immediately after using. After opening Primer, all the contents should be used within 180 days (or 2 hours with the cap off). 3. Apply Primer for paint (Sika Aktivator DM-1) to the cutting edge of adhesive at cab (7) side by using a brush. Wait for about 15 minutes in order to let it dry by itself.
W1SE-02-01-036 a - Knife
b - Cut off adhesive by 1 to 2 mm deep.
7 c d
W1SE-02-01-038 c - Apply Primer by using a brush.
W3-1-2-11
d - Cutting edge of adhesive at cab (7) side
SECTION 3 UPPERSTRUCTURE Group 1 Cab 4. Clean the mating edge of the new glass by using clean rag and ethyl alcohol. IMPORTANT: Primer (Sika Primer 206G+P) should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer, apply Primer as quickly as possible and close the cap immediately after using. After opening Primer, all the contents should be used within 180 days (or 2 hours with the cap off). 5. Apply Primer for glass (Sika Primer 206G+P) to the cutting edge of adhesive at cab side by using a brush. Wait for about 15 minutes in order to let it dry by itself. 6. Install the spacer with facing to the glass surface by using the instant adhesive. (As for the positions to install spacers A, B, and C dam rubber, refer to W3-12-14 to W3-1-2-16.) 7. Cut off the nozzle of adhesive cartridge (Sika Tack Go!) into V-shaped by using a knife. (As for the cutting procedure of nozzle, refer to W3-1-2-17.) 8. Remove the seal of the cartridge end. Install the V-shaped nozzle. 9. Install the cartridge to the manual manual caulking gun. 10. Apply adhesive to the adhesive position at cab side so that the bead triangle may be even. (As for the position to apply adhesive, refer to W3-1-2-17.) 11. Raise the glass by using the suction lifter (rubber sucker 4355282), and adhere it to the cab within 5 minutes.
fNOTE:
Install the glass while fitting the spacer position on the glass. Remove all adhesive except the mounting surface, before solidifying by using white spirit. 12. Secure the glass by using the duct tape until the adhesive becomes solid in order to prevent them from being mispositioned or coming off. (Refer to W3-1-2-13.)
fNOTE:
Time for adhesive (Sika Tack Go!) to become solid: 8 hours (just for reference)
W3-1-2-12
SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm Rear Glass
Right-Hand Glass
WDAA-03-01-039
Rear Left-Hand Glass WDAA-03-01-040
Lower Door Glass
WDAA-03-01-042
WDAA-03-01-041
Spacer A
Spacer B
Spacer C
WDAA-03-01-043 a - Two-Side Adhesive Tape
WDAA-03-01-044 a - Two-Side Adhesive Tape
Dam Rubber
WDAA-03-01-046
W3-1-2-13
WDAA-03-01-045
SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm Left-Hand Glass
1 - Spacer A 2 - Dam Rubber 3 - Stopper
a - From Radius Curve End b - Glass External Form Line c - Adhesive Range
Section A
WDAA-03-01-014
Section B
Section C
WDAA-03-01-017 d - Clearance between glass and panel: 6 mm e - Glass
Section D
WDAA-03-01-018 e - Glass
e - Glass
Detail E
WDAA-03-01-020 e - Glass
WDAA-03-01-024 f -
WDAA-03-01-019
Apply Super X.
W3-1-2-14
SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm Right-Hand Glass
1 - Spacer A 2 - Spacer C 3 - Dam Rubber
Section A
Section B
WDAA-03-01-022 e - Glass
WDAA-03-01-016
a - From Radius Curve End b - Glass External Form Line c - Adhesive Range
Section C
WDAA-03-01-027 d - Glass and panel: Clearance OR-02: 8 mm e - Glass
W3-1-2-15
WDAA-03-01-028 a - From Radius Curve End e - Glass
SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm Rear Glass
Section A
WDAA-03-01-021 a - From Radius Curve End e - Glass WDAA-03-01-015 1 - Spacer B a - From Radius Curve End
b - Glass External Form Line c - Adhesive Range
Section B
Section C
WDAA-03-01-026
WDAA-03-01-025 d - Glass and panel: Clearance OR-02: 8 mm e - Glass
e - Glass
W3-1-2-16
SECTION 3 UPPERSTRUCTURE Group 1 Cab
8 to 9 mm
a 13 to 15 mm b e 9 W1SE-02-01-027
12 W1JB-02-01-031 a - Apply adhesive (bead) here.
b - Cut nozzle end into V-shaped.
f
W1SE-02-01-043
e - Apply bead so that bead triangle may be even. f - Panel
c
d
W1SE-02-01-028 c - Remove the seal. d - Adhesive Cartridge
13. The required amount (just for reference) of adhesive and primer Painted Surface or Adhesive Surface Primer Sika Aktivator DM-1
Adhesive Sika Tack Go!
Lower Door Glass Rear Left-Hand Glass Rear Right-Hand Glass Rear Glass
310 ml Cartridge 170 ml 220 ml 105 ml 205 ml
W3-1-2-17
250 ml Can 0.6 ml 0.55 ml 1 ml 0.5 ml
Glass Surface Primer Sika Primer 206G+P
30 ml Bottle 0.5 ml 0.5 ml 0.9 ml 0.45 ml
SECTION 3 UPPERSTRUCTURE Group 1 Cab Procedures to Install Upper Door Glass 1. Before installing the glass, remove garnish (2) around sash assembly (1) from the cab inside for easy removal. Push sash assembly (1) by hands and remove the sash outside.
1
2
2. Install glass A (3) and glass B (4) into the sash grooves. 3
4 WDAA-03-01-031
3. Install sash assembly (1) onto the door from the outside of cab. Secure sash assembly (1) at the inside of cab by using garnish (2).
W3-1-2-18
SECTION 3 UPPERSTRUCTURE Group 1 Cab Procedures to Install Upper Front Glass 1. Stick the seal to the lower side of the front upper glass by using Cemedine Super X.
Stick and secure both right and left ends (the thicker part) of the seal to the glass by using adhesive.
Stick the mating surface of seal (1) and the glass by using Cemedine Super X so that no visible undulation or boss can be found.
fNOTE: Cemedine Super X No. 8008 Glue-state adhesive, tubed Cemedine 366 Deluxe IMPORTANT: The front glass is arched-fringed. When replacing the glass, contact with the nearest HITACHI Office and replace it as an assembly.
WDAA-03-01-029
Detail A (Inside)
Detail A (Outside)
WDAA-03-01-032 a - b - c - d -
Cemedine Super X No. 8008 Cemedine 366 Deluxe Fill seal for the inside of installation point here. Do not apply seal to this groove.
WDAA-03-01-033 a - Cemedine Super X No. 8008 b - Cemedine 366 Deluxe e - No gap between drainage and wedge
W3-1-2-19
SECTION 3 UPPERSTRUCTURE Group 1 Cab Dimensions of Cab Glass (H Cab)
fNOTE:
The glasses are same to those of the standard cab except for the front glass.
Unit: mm
WJAA-03-01-001
WJAA-03-01-002
W3-1-2-20
SECTION 3 UPPERSTRUCTURE Group 1 Cab Procedures to Install Front Glass (H Cab) Lower Front Glass
Upper Front Glass
4 a
a
4
b
b
WJAA-03-01-005
1 2 3 WJAA-03-01-004
1. Install Z rubber (2) around glass (1).
WJAA-03-01-007
2. Install only A part (4) of wedge (3) into the groove on Z rubber (2).
1- Glass 2- Z Rubber a - Connecting Position
W3-1-2-21
3- Wedge 4- A Part b - Drainage Hole Position
SECTION 3 UPPERSTRUCTURE Group 1 Cab
2 5
6
WJAA-03-01-006 c
1
WJAA-03-01-012
2
1 2 5
5 6 WJAA-03-01-010
WJAA-03-01-009
1 2
3. Install cord (5) around the inside of Z rubber (2). Apply soapy water onto the cord (5) part.
3
4. Install Z rubber (2) to cab (6) from the lower side of glass (1) while pulling cord (5). IMPORTANT: Use a tool, which the edge of screwdriver is rounded, in order not to damage Z rubber (2). 5. Install wedge (3) into the groove on Z rubber (2).
6
WJAA-03-01-011 1 - 2 - 3 - a - b -
W3-1-2-22
Glass Z Rubber Wedge Connecting Position Drainage Hole Position
5 - Cord 6 - Cab c - Get cord (5) long enough to remove.
SECTION 3 UPPERSTRUCTURE Group 2 Counterweight Removal and Installation of Counterweight
5
1
WJBC-03-02-001
Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Open door (1). 3. Disconnect connector (5).
W3-2-1-1
SECTION 3 UPPERSTRUCTURE Group 2 Counterweight 13 18 14 15 16 17
10 9 11 6 11 7
a
9
12 8 7
a - Bracket
WJBC-03-02-002
dCAUTION: (29600 lb)
8
14 13, 18
Counterweight (6) weight: 13400 kg
4. Attach a wire rope onto lifting bracket (a) (2 places) of counterweight (6). Hoist and hold counterweight (6). 5. Remove bolts (7) (2 used), washers (8) (2 used), nuts (9) (2 used), shims (10) (several), and washers (11) (2 used). j : 65 mm
fNOTE:
Shim (10) is installed to the clearance between nut (9) and main frame (12). 6. Remove bolts (13) (4 used), washers (18) (4 used), stoppers (14) (2 used), spacers (15) (2 used), and shims (16, 17) (several). Remove counterweight (6). j : 36 mm
W3-2-1-2
12
15, 16, 17
WJBC-03-02-003
SECTION 3 UPPERSTRUCTURE Group 2 Counterweight 13
18 14 15 16 17
10 9 11 6 11 7
a
9
12 8 7
a - Bracket
WJBC-03-02-002
Installation
dCAUTION: (29600 lb)
8
14 13, 18
Counterweight (6) weight: 13400 kg
1. Attach a wire rope onto lifting bracket (a) (2 places) of counterweight (6). Hoist counterweight (6). 2. Install counterweight (6) with bolts (7) (2 used), washers (8) (2 used), washers (11) (2 used), nuts (9) (2 used), and shims (10) (several). j : 65 mm m : 2800 N·m (280 kgf·m, 2070 lbf·ft) 3. Install shims (16, 17) (several), spacers (15) (2 used), stoppers (14) (2 used), washers (18) (4 used), and bolts (13) (4 used). j : 36 mm m : 700 N·m (70 kgf·m, 520 lbf·ft)
fNOTE:
Adjust shims (16, 17) so that there is no clearance between main frame (12) and spacers (15).
W3-2-1-3
12
15, 16, 17
WJBC-03-02-003
SECTION 3 UPPERSTRUCTURE Group 2 Counterweight
5
1
WJBC-03-02-001
4. Connect connector (5). 5. Shut door(1).
W3-2-1-4
SECTION 3 UPPERSTRUCTURE Group 3 Main Frame Removal and Installation of Main Frame
3 4
1
2
17
16 WJBE-03-03-003
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the machine for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Remove cab (1). (Refer to W3-1-1.) 3. Remove counterweight (2). (Refer to W3-2-1.) 4. Remove bucket (16). (Refer to W5-1-1.) 5. Remove arm (17). (Refer to W5-1-2.) 6. Remove boom (3). (Refer to W5-1-3.) 7. Remove boom cylinder (4). (Refer to W5-2-1.)
W3-3-1-1
SECTION 3 UPPERSTRUCTURE Group 3 Main Frame
6
8
11 9, 10
6
5 7 WJBA-03-03-002
8. Place a container under center joint (5). Disconnect hoses (6) (4 used). j : 41 mm 9. Disconnect hose (7). j : 27 mm 10. Disconnect hose (8). j : 17 mm 11. Remove bolts (9) (2 used) and washers (10) (4 used). Remove stopper (11). j : 22 mm
W3-3-1-2
SECTION 3 UPPERSTRUCTURE Group 3 Main Frame
d 12 ST0232
ST0233
b, c
b, c
W1J1-02-03-002
ST0232, ST0233
a a - Counterweight Mounting Part b - Bolt
WJBE-03-03-002
c
b
c - Nut d - Boom Mounting Bracket Hole W166-02-03-010
Main frame (12) weight: 19200 kg dCAUTION: (42400 lb) tools (ST0232, ST0233) weight: 130 kg Special (290 lb) each 12. Install special tools (ST0232, ST0233) to counterweight mounting part (a) (2 places) of the main frame (12) rear side with bolts (b) (M39) (2 used) and nuts (c) (2 used). j : 60 mm 13. Attach wire ropes onto special tools (ST0232, ST0233) and boom mounting bracket hole (d) (2 places).
W3-3-1-3
SECTION 3 UPPERSTRUCTURE Group 3 Main Frame
12 14
15
e
15 13
14, 15
WJBC-03-03-002
WJAA-03-03-004 e - Front Attachment Side
14. Reduce slack of the wire rope by using a chain block. Put the matching marks onto main frame (12) and outer race (13) of the swing bearing. 15. Remove bolts (14) (37 used) and bolts (15) (4 used). j : 50 mm 16. Adjust the chain block in order to level main frame (12). Hoist and remove main frame (12).
W3-3-1-4
SECTION 3 UPPERSTRUCTURE Group 3 Main Frame
ST0232
ST0233
b, c
d
b, c
12
W1J1-02-03-002
ST0232, ST0233
c
a a - Counterweight Mounting Part b - Bolt
WJBE-03-03-002
c - Nut d - Boom Mounting Bracket Hole
Installation Main frame (12) weight: 19200 kg dCAUTION: (42400 lb) tools (ST0232, ST0233) weight: 130 kg Special (290 lb) each 1. Install special tools (ST0232, ST0233) to counterweight mounting part (a) (2 places) of the main frame (12) rear side with bolts (b) (M39) (2 used) and nuts (c) (2 used). j : 60 mm 2. Attach wire ropes onto special tools (ST0232, ST0233) and boom mounting bracket hole (d) (2 places). 3. Adjust the chain block in order to level main frame (12).
W3-3-1-5
b
W166-02-03-010
SECTION 3 UPPERSTRUCTURE Group 3 Main Frame
12 14
15
e
15 13
WJBC-03-03-002
WJAA-03-03-004 e - Front Attachment Side
4. Fit the matching marks made when disassembling and install main frame (12) to outer race (13) of the swing bearing. Install bolts (15) (4 used) and bolts (14) (37 used). j : 50 mm m : 2200 N·m (220 kgf·m, 1620 lbf·ft)
W3-3-1-6
SECTION 3 UPPERSTRUCTURE Group 3 Main Frame
6
8
11 9, 10
6
7 WJBA-03-03-002
5. Install stopper (11) with washers (10) (4 used) and bolts (9) (2 used). j : 22 mm m : 140 N·m (14 kgf·m, 103 lbf·ft) 6. Connect hose (8). j : 17 mm m : 25 N·m (2.5 kgf·m, 18 lbf·ft) 7. Connect hose (7). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 8. Connect hoses (6) (4 used). j : 41 mm m : 200 N·m (20 kgf·m, 148 lbf·ft)
W3-3-1-7
SECTION 3 UPPERSTRUCTURE Group 3 Main Frame
3 4
1
2
17
16 WJBE-03-03-003
9. Install boom cylinder (4). (Refer to W5-2-1.) 10. Install boom (3). (Refer to W5-1-3.) 11. Install arm (17). (Refer to W5-1-2.) 12. Install bucket (16). (Refer to W5-1-1.) 13. Install counterweight (2). (Refer to W3-2-1.) 14. Install cab (1). (Refer to W3-1-1.) 15. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.
W3-3-1-8
SECTION 3 UPPERSTRUCTURE Group 4 Engine 2
Removal and Installation of Engine
3
2
4
1
WJBE-03-16-034
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the machine position for inspection and maintenance. Close the fuel cock. (Refer to W1-6-1.) 2. Open door (1). 3. Remove bolts, washers (2) (4 used). Remove cover (3). j : 17 mm 4. Disconnect ground (4).
W3-4-1-1
WJBE-03-04-001
SECTION 3 UPPERSTRUCTURE Group 4 Engine 1
2
WJBE-03-08-001
Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 5. Remove bolts, washers (2) (6 used). Remove cover (1). j : 17 mm 6. Drain off hydraulic oil by using an oil feed pump.
fNOTE:
Total oil amount: 1042 L (275 US gal)
W3-4-1-2
SECTION 3 UPPERSTRUCTURE Group 4 Engine
1, 2
3
4
5, 6
14, 15 13 11, 12 10 8, 9 7 WJBE-03-15-005
Remove cover (13) while holding it. dCAUTION: Do not drop cover (13).
Remove cover (3) while holding it. Do dCAUTION: not drop cover (3).
7. Remove bolts, washers (14) (7 used) and washers (15) (7 used). Remove cover (13).
10. Remove bolts, washers (1) (7 used) and washers (2) (7 used). Remove cover (3).
j : 19 mm
j : 19 mm
Remove cover (10) while holding it. dCAUTION: Do not drop cover (10).
Remove cover (4) while holding it. Do dCAUTION: not drop cover (4).
8. Remove bolts, washers (11) (5 used) and washers (12) (5 used). Remove cover (10).
11. Remove bolts, washers (5) (7 used) and washers (6) (7 used). Remove cover (4).
j : 19 mm
j : 19 mm
Remove cover (7) while holding it. Do dCAUTION: not drop cover (7). 9. Remove bolts, washers (8) (7 used) and washers (9) (7 used). Remove cover (7). j : 19 mm
W3-4-1-3
SECTION 3 UPPERSTRUCTURE Group 4 Engine
1 2, 3
4
5, 6
7
8, 9
WJBE-03-08-003
Remove cover (1) while holding it. Do dCAUTION: not drop cover (1). 12. Remove bolts, washers (2) (6 used) and washers (3) (6 used). Remove cover (1). j : 19 mm Remove cover (4) while holding it. Do dCAUTION: not drop cover (4). 13. Remove bolts, washers (5) (6 used) and washers (6) (6 used). Remove cover (4). j : 19 mm Remove cover (7) while holding it. Do dCAUTION: not drop cover (7). 14. Remove bolts, washers (8) (7 used) and washers (9) (7 used). Remove cover (7). j : 19 mm
W3-4-1-4
SECTION 3 UPPERSTRUCTURE Group 4 Engine
1
3, 4
2
M1J7-07-018
15. Remove bolts, washers (1) (2 used). Remove plate (2).
M1J7-07-022
5
j : 19 mm 16. Place a containers under coolant outlets (4, 6). Open cocks (3, 5). Drain off coolant.
fNOTE:
Coolant amount: 112 L (29.6 US gal) 17. Close cocks (3, 5)
6
18. Install plate (2) with bolts, washers (1) (2 used). M1J1-07-044
j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-4-1-5
SECTION 3 UPPERSTRUCTURE Group 4 Engine Detail A 9
10
11 12
13 1
2
8
A
8
7
6
WJBE-03-16-034
3
4 5
dCAUTION:
Cover (10) weight: 42 kg (93 lb) 19. Open cover (10).
WJBE-03-16-031
20. Remove pin (12) and washer (11). Remove the cover (10) side of cylinder (13). 21. Remove pin (9) and washers (8) (2 used). Remove the cover (10) side of stay (7). 22. Remove bolts, washers (6) (6 used). Remove cover (10). j : 17 mm
dCAUTION:
Cover (5) weight: 22 kg (49 lb) 23. Remove bolts, washers (3, 4) (4 used for each). Remove cover (5). j : 19 mm 24. Remove bolts, washers (1) (3 used). Remove cover (2). j : 19 mm
W3-4-1-6
SECTION 3 UPPERSTRUCTURE Group 4 Engine Detail A 1
A
2
3 4
WJBE-03-16-034
5
25. Remove bolts, washers (2) (4 used). Remove cover (1). j : 19 mm 26. Remove bolts, washers (3) (4 used). Remove cover (4). j : 19 mm 27. Open doors (6, 8). 28. Remove bolts, washers (5) (4 used). Remove door (6). j : 17 mm 29. Remove bolts, washers (7) (4 used). Remove door (8). j : 17 mm
W3-4-1-7
8
7
6
WJBE-03-16-031
SECTION 3 UPPERSTRUCTURE Group 4 Engine 3
1
4
1
1
2
1
1 1
WJBE-03-08-009
30. Remove the muffler (3) assembly and the pump device (4) assembly. (Refer to W3-8-1.)
dCAUTION: (190 lb)
The beam (2) assembly weight: 85 kg
31. Attach nylon slings onto the beam (2) assembly. Hoist and hold the beam (2) assembly. 32. Remove bolts, washers (1) (13 used). Remove the beam (2) assembly. j : 19 mm
W3-4-1-8
WJBE-03-16-036
SECTION 3 UPPERSTRUCTURE Group 4 Engine
3 2
1
5
4
6
WJBE-03-05-011
33. Remove clamps (1, 3) (2 used for each). Disconnect pipe (2). 34. Remove clamps (4) (2 used) and clamp (6). Disconnect the pipe (5) assembly.
W3-4-1-9
SECTION 3 UPPERSTRUCTURE Group 4 Engine
1
2
5
4
9
8
7
6 WJBE-03-16-035
3 WJBE-03-16-004
35. Remove clamps (1, 3). Disconnect hose (2). 36. Remove clamps (5, 9) (2 used for each). Disconnect hose (4). 37. Remove clamps (6, 8) (2 used for each). Disconnect hose (7).
W3-4-1-10
SECTION 3 UPPERSTRUCTURE Group 4 Engine
4
1, 2, 3
WJBE-03-04-002
38. Remove nuts (1) (6 used) and washers (2) (6 used). Remove pipe (4). j : 14 mm 39. Remove gasket (3).
W3-4-1-11
SECTION 3 UPPERSTRUCTURE Group 4 Engine 1
17 18
2
3
4
5
6, 7, 8
16
15
13, 14 12
11
40. Remove clamp (18). Disconnect hose (17). 41. Remove clamp (16). Disconnect hose (15). 42. Remove clamp (1). Disconnect hose (2). 43. Loosen nut (3). j : 12 mm 44. Disconnect engine stop cable (4). 45. Loosen nut (9). j : 22 mm 46. Remove nut (13) and washer (14). Disconnect engine control cable (10). j : 10 mm 47. Disconnect terminals (11, 12) 48. Disconnect connectors (5) (2 used). 49. Remove bolts (6) (2 used), washers (7) (2 used), and clips (8) (2 used). j : 17 mm
W3-4-1-12
10
9
WJBE-03-04-003
SECTION 3 UPPERSTRUCTURE Group 4 Engine
1
2
10, 11,12
3
13
4, 5 ,6, 7
14
15, 16, 17
18
19, 20
8, 9 WJBE-03-04-004
50. Disconnect terminals (1, 2, 13, 14 and 18). 51. Disconnect connector (3). 52. Remove bolt (4), washer (5), spring washer (6), and clip (7). j : 17 mm 53. Remove bolts, washers (8, 19) and clips (9, 20). j : 17 mm 54. Remove bolt (15), washer (16), and clip (17). j : 17 mm 55. Remove bolt (10), washer (11), and clip (12). j : 13 mm
W3-4-1-13
WJBE-03-04-005
SECTION 3 UPPERSTRUCTURE Group 4 Engine
1, 2, 3 6
4, 5
WJBE-03-04-008
56. Disconnect connector (6). 57. Remove nut (1) and washer (2). Disconnect the main frame side of ground (3). j : 19 mm 58. Remove bolts, washers (4) (2 used) and clips (5) (2 used). j : 17 mm
W3-4-1-14
SECTION 3 UPPERSTRUCTURE Group 4 Engine 1
2, 3
1
5, 6
4
59. Disconnect hoses (1) (2 used). j : 41 mm 60. Remove clips (2) (2 used). Disconnect hoses (3) (2 used). 61. Disconnect connector (4). 62. Remove clamp (5). Disconnect tube (6).
W3-4-1-15
WJBE-03-04-011
SECTION 3 UPPERSTRUCTURE Group 4 Engine
1
2
7 4, 5, 6
3
WJBE-03-04-007
11
10 9 8
63. Disconnect connector (3). 64. Release the belt tension by moving pulley (1) back and forth by using adjusting bolt (2). IMPORTANT: Do not disconnect hoses (2 used) of compressor (7). 65. Remove socket bolts (4) (4 used), spring washers (5) (4 used), and washers (6) (4 used). Place the compressor (7) assembly horizontally. l : 6 mm 66. Install bracket (10) with bolts, washers (11) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 67. Install washers (9) (4 used) and bolts (8) (4 used). j : 22 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)
W3-4-1-16
WJBE-03-08-013
SECTION 3 UPPERSTRUCTURE Group 4 Engine a
a
1
Detail A 2 3 4 5
6
3 A a-
7
WJBE-03-04-009
WJBE-03-04-010
Lifting Bracket
The engine (1) assembly weight: 1220 dCAUTION: kg (2690 lb) 68. Install shackles to lifting brackets (a) (3 places) of engine (1). Attach nylon slings onto the shackles (3 used). Hoist and hold the engine (1) assembly.
73. Place engine (1) on wooden blocks. 74. Remove cushions (6) at the counterweight and front attachment sides.
69. Remove bolt (2), nut (7), washers (3) (2 used), plate (4), and cushion (5) at the counterweight side. j : 41 mm 70. Remove bolt (2) at the front attachment side in the same way as step 68. 71. Hoist engine (1) by 15 mm (0.59 in). 72. Move engine (1) to the pump device side by 50 mm (1.97 in). Remove engine (1).
W3-4-1-17
SECTION 3 UPPERSTRUCTURE Group 4 Engine 5
3
4 WJBE-03-04-009
3
2
1
WJBE-03-08-013
75. Remove bolts (1) (4 used) and washers (2) (4 used). 6
j : 22 mm
7
76. Remove bolts, washers (4) (4 used). Remove bracket (3). 8
j : 19 mm 77. Remove bolts (7) (4 used) and washers (6) (4 used) at the counterweight side. Remove bracket (8).
fNOTE: used).
LOCTITE #262 has been applied onto bolts (7) (4
j : 22 mm 78. Remove bracket (8) at the front attachment side in the same way as step 76. 79. Remove the adapter with engine (5) attached if necessary.
W3-4-1-18
WJBE-03-04-010
SECTION 3 UPPERSTRUCTURE Group 4 Engine
5
4
4 3 WJBE-03-04-009
2
1
WJBE-03-08-013
Installation 1. Install all removed adapters to engine (5). 2. Apply LOCTITE #262 onto bolts (7) (4 used). Install bracket (8) with washers (6) (4 used) and bolts (7) (4 used). j : 22 mm
6
7
8
m : 210 N·m (21 kgf·m, 155 lbf·ft) 3. Install bracket (8) at the front attachment side in the same way as step 2. 4. Install bracket (3) with bolts, washers (4) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
WJBE-03-04-010
5. Install washers (2) (4 used) and bolts (1) (4 used). j : 22 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)
W3-4-1-19
SECTION 3 UPPERSTRUCTURE Group 4 Engine a
a
1
Detail A 2 3 4 5
6
3 7 A a-
WJBE-03-04-010
WJBE-03-04-009
Lifting Bracket
1
6. Install cushions (6) at the counterweight and front attachment sides. The engine (1) assembly weight: 1220 dCAUTION: kg (2690 lb) 7. Install shackles to lifting brackets (a) (3 places) of engine (1). Attach nylon slings onto the shackles (3 used). Hoist the engine (1) assembly. 8. Set wooden blocks (b) between engine (1) and main frame (8). Place engine (1). 9. Install engine (1) with cushion (5), plate (4), washers (3) (2 used), nut (7), and bolt (2). j : 41 mm m : 1050 N·m (105 kgf·m, 770 lbf·ft) 10. Install bolt (2) at the front attachment side in the same way as step 9.
8 b-
W3-4-1-20
Wooden Block
b
W1JB-02-04-007
SECTION 3 UPPERSTRUCTURE Group 4 Engine
1
11
10
2
7 4, 5, 6 9 8
WJBE-03-08-013
11. Remove bolts (8) (4 used) and washers (9) (4 used). j : 22 mm 12. Remove bolts, washers (11) (4 used). Remove bracket (10). j : 19 mm 13. Install the compressor (7) assembly with washers (6) (4 used), spring washers (5) (4 used), and socket bolts (4) (4 used). j : 6 mm m : 25 to 30 N·m (2.5 to 3 kgf·m, 18.5 to 22 lbf·ft) IMPORTANT: The belt does not fit when replacing with a new one. Therefore, adjust the belt tension again after running the engine at slow idle for 3 to 5 minutes. 14. Adjust the belt tension by moving pulley (1) back and forth by using adjusting bolt (2). 15. Connect connector (3).
W3-4-1-21
3
WJBE-03-04-007
SECTION 3 UPPERSTRUCTURE Group 4 Engine 1
2, 3
1
5, 6
4
16. Connect tube (6) with clamp (5). 17. Connect connector (4). 18. Connect hoses (3) (2 used) with clips (2) (2 used). 19. Connect hoses (1) (2 used). j : 41 mm m : 200 N·m (20 kgf·m, 148 lbf·ft)
W3-4-1-22
WJBE-03-04-011
SECTION 3 UPPERSTRUCTURE Group 4 Engine
1, 2, 3 6
4, 5
WJBE-03-04-008
20. Install clips (5) (2 used) and bolts, washers (4) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 21. Connect ground (3) with washer (2) and bolt (1). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 22. Connect connector (6).
W3-4-1-23
SECTION 3 UPPERSTRUCTURE Group 4 Engine
1
2
10, 11,12
3
13
4, 5 ,6, 7
14
15, 16, 17
18
19, 20
8, 9 WJBE-03-04-004
23. Connect connector (3). 24. Connect terminals (1, 2, 13, 14 and 18). 25. Install clip (12), washer (11), and bolt (10). j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 26. Install clips (9, 20) and bolts, washers (8, 19). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 27. Install clip (7), spring washer (6), washer (5), and bolt (4). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 28. Install clip (17), washer (16), and bolt (15). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-4-1-24
WJBE-03-04-005
SECTION 3 UPPERSTRUCTURE Group 4 Engine 1
17 18
2
3
4
5
6, 7, 8
16
15
13, 14 12
11
29. Connect connectors (5) (2 used). 30. Install clips (8) (2 used), washers (7) (2 used), and bolts (6) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 31. Connect terminals (11, 12). 32. Connect engine control cable (10) with washer (14) and nut (13). j : 10 mm m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft) 33. Tighten nut (9). j : 19 mm m : 55 N·m (5 kgf·m, 37 lbf·ft) 34. Connect engine stop cable (4). 35. Tighten nut (3). j : 12 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 36. Connect hose (2) with clamp (1). 37. Connect hose (15) with clamp (16). 38. Connect hose (17) with clamp (18).
W3-4-1-25
10
9
WJBE-03-04-003
SECTION 3 UPPERSTRUCTURE Group 4 Engine
4
1, 2, 3
WJBE-03-04-002
IMPORTANT: Replace gasket (3) with the new one. 39. Install gasket (3). 40. Install pipe (4) with washers (2) (6 used) and nuts (1) (6 used). j : 14 mm m : 21 to 35 N·m (2.1 to 3.5 kgf·m, 15.5 to 26 lbf·ft)
W3-4-1-26
SECTION 3 UPPERSTRUCTURE Group 4 Engine
1
5
4
9
8
7
2
6 WJBE-03-16-035
3 WJBE-03-16-004
41. Install hose (7) with clamps (6, 8) (2 used for each). m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 42. Install hose (4) with clamps (5, 9) (2 used for each). m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 43. Install hose (2) with clamps (1, 3). m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-4-1-27
SECTION 3 UPPERSTRUCTURE Group 4 Engine 3 2
1
5
4
6
WJBE-03-05-011
44. Connect pipe (2) with clamps (1, 3) (2 used for each). m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 45. Connect the pipe (5) assembly with clamps (4) (2 used) and clamp (6). m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-4-1-28
SECTION 3 UPPERSTRUCTURE Group 4 Engine 3 1
1
1
2
1
4
1 1 WJBE-03-16-036
dCAUTION: (190 lb)
The beam (2) assembly weight: 85 kg
46. Attach nylon slings onto the beam (2) assembly. Hoist the beam (2) assembly. 47. Install the beam (2) assembly with bolts, washers (1) (13 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 48. Install the pump device (4) assembly and the muffler (3) assembly. (Refer to W3-8-1.)
W3-4-1-29
WJBE-03-08-009
SECTION 3 UPPERSTRUCTURE Group 4 Engine
1
2
WJBE-03-08-001
49. Add coolant to the radiator.
fNOTE:
Coolant amount: 112 L (29.6 US gal) 50. Fill hydraulic oil to the hydraulic oil tank.
fNOTE:
Total oil amount: 1042 L (275 US gal) 51. Install cover (1) with bolts, washers (2) (6 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 52. Bleed air from the hydraulic system. (Refer to W14-1.) 53. Bleed air from the fuel system. (Refer to W1-4-1.)
W3-4-1-30
SECTION 3 UPPERSTRUCTURE Group 4 Engine 2
3
2
4
1 WJBE-03-16-034
WJBE-03-04-001
54. Connect ground (4). IMPORTANT: Check the hydraulic oil level and the coolant level. Start the engine and check for any oil and coolant leaks. 55. Install cover (3) with bolts, washers (2) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 56. Close door (1).
W3-4-1-31
SECTION 3 UPPERSTRUCTURE Group 4 Engine Detail A
A
1
2
3 4
WJBE-03-16-034
5
8
57. Install door (8) with bolts, washers (7) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 58. Install door (6) with bolts, washers (5) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 59. Close doors (6, 8). 60. Install cover (4) with bolts, washers (3) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 61. Install cover (1) with bolts, washers (2) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-4-1-32
7
6
WJBE-03-16-031
SECTION 3 UPPERSTRUCTURE Group 4 Engine Detail A 9
10
11 12
13 1
2
8
A
8
7
3
6
WJBE-03-16-034
4 5
WJBE-03-16-031
62. Install cover (2) with bolts, washers (1) (3 used).
dCAUTION:
Cover (10) weight: 42 kg (93 lb) 64. Install cover (10) with bolts, washers (6) (6 used).
j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
j : 17 mm
dCAUTION:
Cover (5) weight: 22 kg (49 lb) 63. Install cover (5) with bolts, washers (3, 4) (4 used for each). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft) 65. Install the cover (10) side of stay (7) with washers (8) (2 used) and pin (9). 66. Install the cover (10) side of cylinder (13) with washer (11) and pin (12). 67. Close cover (10).
W3-4-1-33
SECTION 3 UPPERSTRUCTURE Group 4 Engine
1 2, 3
4
5, 6
7
8, 9
WJBE-03-08-003
68. Install cover (7) with washers (9) (7 used) and bolts, washers (8) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 69. Install cover (4) with washers (6) (6 used) and bolts, washers (5) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 70. Install cover (1) with washers (3) (6 used) and bolts, washers (2) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-4-1-34
SECTION 3 UPPERSTRUCTURE Group 4 Engine
1, 2
3
4
5, 6
14, 15 13 11, 12 10 8, 9 7 WJBE-03-15-005
71. Install cover (7) with washers (9) (7 used) and bolts, washers (8) (7 used).
74. Install cover (3) with washers (2) (7 used) and bolts, washers (1) (7 used).
j : 19 mm
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
72. Install cover (10) with washers (12) (5 used) and bolts, washers (11) (5 used).
75. Install cover (4) with washers (6) (7 used) and bolts, washers (5) (7 used).
j : 19 mm
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
73. Install cover (13) with washers (15) (7 used) and bolts, washers (14) (7 used). j : 19 mm
76. Perform engine speed adjustment and engine learning. (Refer to T4-6 in the separated volume, T/M.)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-4-1-35
SECTION 3 UPPERSTRUCTURE Group 4 Engine (Blank)
W3-4-1-36
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly Replacement of Radiator
2, 3 1
5, 6 4
8, 9 7 WJBE-03-15-005
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.
Remove cover (7) while holding it. Do dCAUTION: not drop cover (7). 4. Remove bolts, washers (8) (7 used) and washers (9) (7 used). Remove cover (7).
Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) Remove cover (1) while holding it. Do dCAUTION: not drop cover (1). 2. Remove bolts, washers (2) (7 used) and washers (3) (7 used). Remove cover (1). j : 19 mm Remove cover (4) while holding it. Do dCAUTION: not drop cover (4). 3. Remove bolts, washers (5) (5 used) and washers (6) (5 used). Remove cover (4). j : 19 mm
W3-5-1-1
j : 19 mm
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly
10
11
12,13
M1J7-07-018
5. Remove bolts, washers (10) (2 used). Remove plate (11). j : 19 mm 6. Place a container under coolant outlet (12). Loosen cock (13). Drain off coolant.
fNOTE:
Coolant amount: 112 L (29.6 US gal) 7. Close cock (13). 8. Install plate (11) with bolts, washers (10) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-1-2
M1J7-07-022
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly Detail A 16
A
14 15
89 88 92
97
100
98
95
96 WJBE-03-16-034
94 93
99
17 18 21
19
20
WJBE-03-16-032
dCAUTION:
dCAUTION: (165 lb)
Cover (16) weight: 25 kg (56 lb) 9. Remove bolts, washers (14) (4 used) and washers (15) (4 used). Remove cover (16).
The duct (92) assembly weight: 73 kg
15. Remove bolts (97) (2 used) and washers (98) (2 used). Remove the duct (92) assembly.
j : 19 mm
j : 22 mm
10. Remove bolts, washers (17) (4 used) and washers (18) (4 used). Remove cover (19). j : 19 mm 11. Remove bolts, washers (20) (2 used). Remove bracket (21). j : 19 mm 12. Remove bolts, washers (99) (2 used). Remove bracket (100). j : 19 mm 13. Remove bolts (88) (4 used) and washers (89) (4 used). Open the duct (92) assembly. j : 22 mm 14. Remove pin (93) and washer (94). Remove the cover (96) side of stay (95).
W3-5-1-3
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly Detail B 22
B
33 34 36 35
37 38
32 WJBE-03-16-034
31 30
86
dCAUTION:
Cover (30) weight: 22 kg (49 lb) 16. Remove bolts, washers (31, 32) (4 used for each). Remove cover (30). j : 19 mm 17. Open covers (22, 86, and 87). 18. Remove bolts, washers (33) (3 used). Remove cover (34). j : 19 mm 19. Remove bolts, washers (35) (4 used). Remove cover (36). j : 19 mm 20. Remove bolts, washers (37) (4 used). Remove cover (38). j : 19 mm
W3-5-1-4
87
WJBE-03-16-031
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 149 148 46
47
43, 44
45
52
50 53
51
48, 49
55
54 WJBE-03-16-033
21. Remove bolts, washers (43) (4 used). Remove clamps (44) (2 used). j : 17 mm 22. Remove clamps (45, 46) (2 used for each). Disconnect the pipe (47) assembly. 23. Remove bolts, washers (48) (2 used). Remove clamp (49). j : 17 mm 24. Remove bolts, washers (50) (2 used). j : 19 mm 25. Remove clamps (51, 52) (2 used for each). Disconnect pipe (53). 26. Remove bolts, washers (54) (2 used). Remove bracket (55). j : 19 mm 27. Remove bolts, washers (148) (6 used). Remove cover (149). j : 19 mm
W3-5-1-5
WJBE-03-16-032
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly
56
58
63 62 59 65 64
66
67
61
60
101
103 102 WJBE-03-16-035
57 WJBE-03-16-004
28. Remove clamps (56, 57). Disconnect hose (58). 29. Remove clamps (59, 60) (2 used for each). Disconnect hose (61). 30. Remove clamps (101, 102) (2 used for each). Disconnect hose (103). 31. Remove split pins (62) (2 used) and pins (63) (2 used). 32. Remove bolts, washers (64) (4 used). Remove the stay (65) assembly. j : 19 mm 33. Remove bolts, washers (66) (4 used). Remove the stay (67) assembly. j : 19 mm
W3-5-1-6
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly
68
69
69 WJBE-03-15-009
34. Disconnect hose (68). j : 27 mm 35. Disconnect hoses (69) (2 used). j : 36 mm
W3-5-1-7
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly
107
104, 105
106
a
108
a
114 113 112 111 110 109
WJBE-03-05-001 a-
36. Remove bolts, washers (104) (3 used) and clips (105) (3 used). j : 17 mm 37. Remove clamp (106). Disconnect hose (107). The radiator (108) assembly weight: dCAUTION: 425 kg (940 lb) 38. Install shackles (2 used) to lifting holes (a) (2 places) of the radiator (108) assembly. Attach nylon slings onto the shackles. Hoist and hold the radiator (108) assembly. 39. Remove bolts (109) (4 used), washers (110) (4 used), retainers (111) (2 used), rubbers (112) (2 used), and spacers (113) (4 used). Remove the radiator (108) assembly. j : 41 mm 40. Remove rubbers (114) (2 used).
W3-5-1-8
Lifting Hole
WJBE-03-05-002
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly b b
115 116 115 118 119 120 117 121 122
124 123 125 126
b-
144
Lifting Hole
WJBE-03-05-003
41. Remove intercooler (144). (Refer to W3-5-2.)
46. Disconnect packing (124) from radiator core (123).
42. Remove clips (115) (3 used). Disconnect pipe (116).
47. Remove cushion (125) and O-rings (126) (2 used).
43. Remove bolts, washers (117) (4 used). j : 19 mm 44. Remove bolts (118) (4 used), washers (119) (4 used), and cushions (120) (4 used). Remove brackets (121) (2 used) and collars (122) (4 used). j : 17 mm
dCAUTION: lb)
Radiator core (123) weight: 22 kg (49
45. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to lifting holes (b) (2 places) of radiator core (123). Attach nylon slings onto the eyebolts. Hoist radiator core (123). Remove radiator core (123).
W3-5-1-9
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 135 132 131
128
146
134
133
130 129 127 WJBE-03-05-003
dCAUTION: lb)
Radiator core (127) weight: 22 kg (49
48. Remove radiator core (127) in the same way as step 42 to step 45. 49. Remove packings (128) (2 used) from radiator core (127). 50. Remove cushion (129) and O-rings (130) (2 used).
dCAUTION: lb)
Radiator core (131) weight: 22 kg (49
51. Remove radiator core (131) in the same way as step 42 to step 45. 52. Remove packing (132) from radiator core (131). 53. Remove cushion (133) and O-rings (134) (2 used). 54. Remove packings (135, 146).
W3-5-1-10
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly
137
140
147
136 138 139
142 141
dCAUTION:
Tank (137) weight: 33 kg (73 lb) 55. Remove bolts, washers (136) (6 used). Remove tank (137). j : 19 mm 56. Remove clamps (140) (4 used). 57. Remove bolts, washers (138) (2 used). Disconnect pipe (139). j : 19 mm 58. Disconnect hose (141).
dCAUTION:
Tank (143) weight: 54 kg (120 lb) 59. Remove bolts, washers (142) (7 used). Remove tank (143). j : 19 mm 60. Remove cock (145). 61. Remove fan (147). (Refer to W3-16-2.)
W3-5-1-11
145
143
142
WJBE-03-05-003
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly
137
140
147
136 138 139
142 141
Installation
145
143
142
WJBE-03-05-003
dCAUTION:
Tank (137) weight: 33 kg (73 lb) 7. Install (137) with bolts, washers (136) (6 used).
1. Install fan (147). (Refer to W3-16-2.) 2. Install cock (145).
d
CAUTION: Tank (143) weight: 54 kg (120 lb) 3. Install tank (143) with bolts, washers (142) (7 used). j : 19 mm m : 55 to 123 N·m (5.5 to 12.5 kgf·m, 41 to 91 lbf·ft) 4. Connect hose (141). 5. Connect clamps (140) (4 used). 6. Connect pipe (139) with bolts, washers (138) (2 used). j : 19 mm m : 55 to 123 N·m (5.5 to 12.5 kgf·m, 41 to 91 lbf·ft)
W3-5-1-12
j : 19 mm m : 55 to 123 N·m (5.5 to 12.5 kgf·m, 41 to 91 lbf·ft)
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly b b
115 116 115
135
118 119 120 117 121 122 146
124 123 125 126
b-
Lifting Hole
WJBE-03-05-003
8. Install packings (135, 146).
12. Install bracket (121) and collars (122) (2 used) with cushions (120) (2 used), washers (119) (2 used), and bolts (118) (2 used).
9. Install cushion (125) and O-rings (126) (2 used). 10. Install packing (124) to radiator core (123).
j : 17 mm
d
CAUTION: Radiator core (123) weight: 22 kg (49 lb) 11. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to lifting holes (b) (2 places) of radiator core (123). Attach nylon slings onto the eyebolts. Hoist radiator core (123). Install radiator core (123).
m : 30 to 45 N·m (3 to 4.5 kgf·m, 22 to 33 lbf·ft) 13. Install bolts, washers (117) (2 used). j : 19 mm m : 55 to 123 N·m (5.5 to 12.5 kgf·m, 41 to 91 lbf·ft) 14. Install pipe (116) with clips (115) (3 used).
W3-5-1-13
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 132 131
144
128
134
133
130 129 127 WJBE-03-05-003
15. Install cushion (129) and O-rings (130) (2 used). 16. Install packings (128) (2 used) to radiator core (127).
dCAUTION: lb)
Radiator core (127) weight: 22 kg (49
17. Install radiator core (127) in the same way as step 11 to step 14. 18. Install cushion (133) and O-rings (134) (2 used). 19. Install packing (132) to radiator core (131).
dCAUTION: lb)
Radiator core (131) weight: 22 kg (49
20. Install radiator core (131) in the same way as step 11 to step 14. 21. Install intercooler (144). (Refer to W3-5-2.)
W3-5-1-14
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly
107
104, 105
106
a
108
a
114 113 112 111 110 109
WJBE-03-05-001 a-
22. Install rubbers (114) (2 used). The radiator (108) assembly weight: dCAUTION: 425 kg (940 lb) 23. Install shackles (2 used) to lifting holes (a) (2 places) of the radiator (108) assembly. Attach nylon slings onto the shackles. Hoist the radiator (108) assembly. 24. Install the radiator (108) assembly with spacers (113) (4 used), rubbers (112) (2 used), retainers (111) (2 used), washers (110) (4 used), and bolts (109) (4 used). j : 41 mm m : 1050 N·m (105 kgf·m, 770 lbf·ft) 25. Connect hose (107) with clamp (106). 26. Install clips (105) (3 used) with bolts, washers (104) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-5-1-15
Lifting Hole
WJBE-03-05-002
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly
68
69
69
WJBE-03-15-009
27. Connect hose (68). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 28. Connect hoses (69) (2 used). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)
W3-5-1-16
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly
56
58
63 62 59 65 64
66
67
61
60
101
103 102 WJBE-03-16-035
57 WJBE-03-16-004
29. Install the stay (67) assembly with bolts, washers (66) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 30. Install the stay (65) assembly with bolts, washers (64) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 31. Install pins (63) (2 used) and split pins (62) (2 used). 32. Install hose (103) with clamps (101, 102) (2 used for each). m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 33. Install hose (61) with clamps (59, 60) (2 used for each). m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 34. Install hose (58) with clamps (56, 57). m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-5-1-17
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 149 148 46
47
43, 44
45
52
50 53
51
48, 49
55
54 WJBE-03-16-033
35. Install cover (149) with bolts, washers (148) (6 used). j : 19 mm
WJBE-03-16-032
40. Connect the pipe (47) assembly with clamps (45, 46) (2 used for each). m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft) 36. Install bracket (55) with bolts, washers (54) (2 used).
41. Install clamps (44) (2 used) with bolts, washers (43) (4 used).
j : 19 mm
j : 17 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
37. Connect pipe (53) with clamps (51, 52) (2 used for each). m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 38. Install bolts, washers (50) (2 used).
42. Add coolant to the radiator.
fNOTE:
Coolant amount: 112 L (29.6 US gal)
43. Bleed air from the hydraulic system. (Refer to W1-41.)
j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 39. Install clamp (49) with bolts, washers (48) (2 used).
IMPORTANT: Check the hydraulic oil level and the coolant level. Start the engine and check for any oil and coolant leaks.
j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-5-1-18
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly Detail B 22
B
33 34 36 35
37 38
32 WJBE-03-16-034
31 30
86
87 WJBE-03-16-031
44. Install cover (38) with bolts, washers (37) (4 used).
48. Close covers (22, 86, and 87).
j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 45. Install cover (36) with bolts, washers (35) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 46. Install cover (34) with bolts, washers (33) (3 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION:
Cover (30) weight: 22 kg (49 lb) 47. Install cover (30) with bolts, washers (31, 32) (4 used for each). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-1-19
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly Detail A 16
A
14 15
89 88 92
97
100
98
95
96 WJBE-03-16-034
94 93
99
17 18 21
19
20
WJBE-03-16-032
d
CAUTION: The duct (92) assembly weight: 73 kg (165 lb) 49. Install the duct (92) assembly with washers (98) (2 used) and bolts (97) (2 used). j : 22 mm
54. Install cover (19) with washers (18) (4 used) and bolts, washers (17) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION:
m : 140 N·m (14 kgf·m, 103 lbf·ft) 50. Install the cover (96) side of stay (95) with washer (94) and pin (93).
Cover (16) weight: 25 kg (56 lb) 55. Install cover (16) with washers (15) (4 used) and bolts, washers (14) (4 used).
51. Close the duct (92) assembly. Install washers (89) (4 used) and bolts (88) (4 used). j : 22 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 52. Install bracket (100) with bolts, washers (99) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 53. Install bracket (21) with bolts, washers (20) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-1-20
j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly
2, 3
1
5, 6 4
8, 9
7 WJBE-03-15-005
56. Install cover (7) with washers (9) (7 used) and bolts, washers (8) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 57. Install cover (4) with washers (6) (5 used) and bolts, washers (5) (5 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 58. Install cover (1) with washers (3) (7 used) and bolts, washers (2) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-1-21
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly (Blank)
W3-5-1-22
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly Replacement of Intercooler
Detail A 1
A
2
3
4
5
6
7 8
9
10 WJBE-03-16-034
11 12
WJBE-03-16-032
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal
dCAUTION: (165 lb)
The duct (6) assembly weight:73 kg
5. Remove bolts (7) (2 used) and washers (8) (2 used). Remove the duct (6) assembly.
1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)
dCAUTION:
Cover (1) weight: 25 kg (56 lb) 2. Remove bolts, washers (2) (4 used) and washers (3) (4 used). Remove cover (1). j : 19 mm 3. Remove bolts (5) (4 used) and washers (4) (4 used). Open the duct (6) assembly. j : 22 mm 4. Remove pin (12) and washer (11). Remove the cover (10) side of stay (9).
W3-5-2-1
j : 22 mm
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
1
3 4 3
WJBE-03-05-011
6. Remove clamps (1) (4 used). Disconnect hose (2). 7. Remove clamps (3) (4 used). Disconnect hose (4).
W3-5-2-2
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly
1
a-
Lifting Hole
2
3
4
7
2
dCAUTION:
Intercooler (6) weight: 40 kg (89 lb) 8. Install shackles (2 used) to lifting holes (a) (2 places) of intercooler (6). Attach nylon slings onto shackles. Hoist and hold intercooler (6). 9. Remove bolts, washers (4) (2 used), pipes (3) (2 used), plates (2) (2 used), and rubbers (1) (2 used). j : 17 mm
10. Remove bolts, washers (5) (2 used) and plates (2) (2 used). j : 19 mm 11. Hoist and remove intercooler (6) while avoiding touch with radiator (7).
W3-5-2-3
6
5
a
WJBE-03-05-003
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly
1
a-
Lifting Hole
2
3
4
7
2
Installation
dCAUTION:
Intercooler (6) weight: 40 kg (89 lb) 1. Install shackles (2 used) to lifting holes (a) (2 places) of Intercooler(6). Attach nylon slings onto shackles. Hoist intercooler (6). Hoist and install intercooler (6) while avoiding touch with radiator (7). 2. Install plates (2) (2 used) and bolts, washers (5) (2 used). j : 19 mm m : 55 to 123 N·m (5.5 to 12.5 kgf·m, 41 to 91 lbf·ft) 3. Install rubbers (1) (2 used), plates (2) (2 used), pipes (3) (2 used), and bolts, washers (4) (2 used). j : 17 mm m : 34 to 74 N·m (3.4 to 7.4 kgf·m, 25 to 55 lbf·ft)
W3-5-2-4
6
5
a
WJBE-03-05-003
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
1
3 4 3
WJBE-03-05-011
4. Connect pipe (4) with clamps (3) (4 used). m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 5. Connect pipe (2) with clamps (1) (4 used). m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-5-2-5
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly Detail A 1
A
2
3
4
5
6
7 8
9
10 WJBE-03-16-034
11 12
WJBE-03-16-032
dCAUTION: (165 lb)
The duct (6) assembly weight:73 kg
6. Install the duct (6) assembly with washers (8) (2 used) and bolts (7) (2 used). j : 22 mm m : 140 N·m (14 kgf·m, 103 lbf·ft) 7. Install the cover (10) side of stay (9) with washer (11) and pin (12). 8. Close the duct (6) assembly. Install washers (4) (4 used) and bolts (5) (4 used). j : 22 mm m : 140 N·m (14 kgf·m, 103 lbf·ft)
dCAUTION:
Cover (1) weight: 25 kg (56 lb) 9. Install cover (1) with washers (3) (4 used) and bolts, washers (2) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-2-6
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly Replacement of Oil Cooler 1
2
3, 4
5
WJBE-03-08-001
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Remove bolts, washers (2) (6 used). Remove cover (1). j : 17 mm 3. Drain off hydraulic oil by using an oil feed pump.
fNOTE:
6, 7 8 9, 10 11
WJBE-03-15-001
Remove cover (5) while holding it. Do dCAUTION: not drop cover (5). 4. Remove bolts, washers (3) (5 used) and washers (4) (5 used). Remove cover (5). j : 19 mm Remove cover (8) while holding it. Do dCAUTION: not drop cover (8). 5. Remove bolts, washers (6) (6 used) and washers (7) (6 used). Remove cover (8). j : 19 mm Remove cover (11) while holding it. dCAUTION: Do not drop cover (11). 6. Remove bolts, washers (9) (7 used) and washers (10) (7 used). Remove cover (11). j : 19 mm
Total oil amount: 1042 L (275 US gal)
W3-5-3-1
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
WJBE-03-05-040
dCAUTION: kg (53 lb)
The handrail (1) assembly weight: 24
7. Attach nylon slings onto the handrail (1) assembly. Hoist and hold the handrail (1) assembly. 8. Remove bolts, washers (2) (10 used). Remove the handrail (1) assembly. j : 19 mm
W3-5-3-2
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
9
2
3
4
5
8
6
7
WJBE-03-05-032
9. Remove bolts (5) (4 used) and washers (4) (4 used). Open the duct (3) assembly. j : 22 mm 10. Remove pin (7) and washer (8). Remove the cover (9) side of stay (6).
dCAUTION: (145 lb)
The duct (3) assembly weight: 64 kg
11. Remove bolts (2) (2 used) and washers (1) (2 used). Remove the duct (3) assembly. j : 22 mm
W3-5-3-3
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1 2
3
4
5
6
7
8 9
10 11
14 13
11
12
WJBE-03-16-001
12. Remove bolts, washers (4) (4 used). Remove door (3).
17. Remove bolts, washers (1) (3 used). Remove cover (2).
j : 19 mm
j : 19 mm
13. Remove bolts, washers (10) (4 used). Remove the cap (7) assembly.
18. Remove bolts, washers (11) (3 used). Remove support (12).
j : 17 mm
j : 19 mm
14. Remove bolts, washers (5) (9 used). Remove cover (6). j : 19 mm 15. Remove bolts, washers (9) (3 used). Remove cover (8). j : 19 mm 16. Remove bolts, washers (14) (5 used). Remove cover (13). j : 19 mm
W3-5-3-4
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1, 2
8
7
3
4, 5
6
WJBE-03-16-001
19. Remove bolts, washers (1) (9 used) and washers (2) (9 used). Remove cover (3). j : 19 mm 20. Remove bolts, washers (7) (4 used). Remove cover (8). j : 19 mm
dCAUTION:
Cover (6) weight: 25 kg (56 lb) 21. Remove bolts, washers (4) (4 used) and washers (5) (4 used). Remove cover (6). j : 19 mm
W3-5-3-5
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
3
4
5
6
5
WJBE-03-16-003
dCAUTION:
Cover (3) weight: 25 kg (56 lb) 22. Remove bolts, washers (2) (7 used) and washers (1) (7 used). Remove cover (3). j : 19 mm 23. Remove bolts, washers (5) (6 used) and washers (6) (4 used). Remove cover (4). j : 19 mm
W3-5-3-6
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
3
4
5
WJBE-03-16-034
7
6
WJBE-03-16-004
24. Open cover (1). 25. Disconnect Connectors (3) (2 used). 26 Remove clamps (4, 6). Disconnect hose (5).
dCAUTION:
Air cleaner (2) weight: 28 kg (62 lb) 27. Attach nylon slings onto the body of air cleaner (2). Hoist and hold air cleaner (2). 28. Remove bolts, washers (7) (4 used). Remove air cleaner (2). j : 17 mm
W3-5-3-7
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
3
4
8
7
5, 6
3
WJBE-03-16-006
dCAUTION:
Bracket (2) weight: 23 kg (51 lb) 29. Remove bolts, washers (1) (13 used). Remove bracket (2). j : 19 mm 30. Place a container under the pipe (7) assembly. Disconnect hoses (3) (2 used). j : 36 mm
dCAUTION: (47 lb)
The pipe (7) assembly weight: 21 kg
31. Attach nylon slings onto the pipe (7) assembly. Hoist and hold the pipe (7) assembly. Remove bolts, washers (5) (4 used) and clamps (6) (2 used). j : 19 mm 32. Remove couplings (4, 8). Disconnect the pipe (7) assembly.
W3-5-3-8
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1, 2
3 4
5
6
7
8
9, 10
9, 10 8
1, 2
4
13 11, 12
WJBE-03-16-007
33. Remove bolts, washers (11) (2 used). Remove clamp (12). j : 17 mm 34. Place a container under pipe (13). Remove coupling (5). Disconnect the oil cooler side of pipe (13). 35. Remove bolts, washers (9) (6 used). Remove clamps (10) (3 used). j : 17 mm 36. Place a container under the oil cooler (7) assembly. Remove couplings (8) (2 used). Disconnect pipe (6). 37. Remove bolts, washers (1) (6 used). Remove clamps (2) (3 used). j : 17 mm 38. Remove couplings (4) (2 used). Disconnect pipe (3).
W3-5-3-9
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
7, 8
3
3
4, 5
3
6
4, 5
WJBE-03-05-033
39. Remove bolts, washers (4) (4 used) and clips (5) (4 used). j : 17 mm 40. Disconnect connectors (6) (2 used). IMPORTANT: Take care not to disconnect hoses (2) (2 used). 41. Remove bolts (3) (6 used). Place the air conditioner (1) assembly outside of the work area. j : 19 mm 42. Disconnect connector (11). 43. Remove bolt, washer (7) and clip (8). j : 17 mm 44. Remove bolt, washer (9) and clip (10). j : 17 mm
W3-5-3-10
11
9, 10
WJBE-03-16-009
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
a
2
3, 4
5 a-
Lifting Hole
WJBE-03-16-010
45. Disconnect hoses (5) (2 used). j : 36 mm 46. Disconnect hose (2). j : 27 mm 47. Remove bolts, washers (3) (2 used) and clips (4) (2 used). j : 17 mm The oil cooler (1) assembly weight: dCAUTION: 545 kg (1210 lb) 48. Install shackles (2 used) to lifting holes (a) (2 places) of the oil cooler (1) assembly. Attach nylon slings onto shackles. Hoist and hold the oil cooler (1) assembly.
W3-5-3-11
5
WJBE-03-16-008
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
4
3 2
WJBE-03-05-034
49. Remove bolts (2) (4 used) and spacers (3) (4 used). j : 36 mm 50. Remove bolts, washers (4) (2 used). Remove the oil cooler (1) assembly. j : 17 mm
W3-5-3-12
WJBE-03-05-032
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 2
3
1
4
6
5
WJBE-03-05-032
51. Remove bolts (6) (4 used) and washers (5) (4 used). Remove cover (4). j : 22 mm 52. Remove bolts (3) (4 used) and washers (2) (4 used). Remove cover (1). j : 22 mm
W3-5-3-13
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
1
1
2
2
2
WJBE-03-05-036
dCAUTION: kg (98 lb)
The support (3) assembly weight: 44
53. Attach nylon slings onto the support (3) assembly. Hoist and hold the support (3) assembly. 54. Remove bolts, washers (2) (7 used) and bolts, washers (1) (4 used). Remove the support (3) assembly. j : 19 mm
W3-5-3-14
3
1
WJBE-03-05-037
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
3
4
5
6
WJBE-03-05-032
55. Remove bolts, washers (3) (4 used). Remove cover (4). j : 19 mm 56. Remove bolts, washers (2) (2 used). Remove cover (1). j : 19 mm 57. Remove bolts, washers (6) (2 used). Remove cover (5). j : 19 mm
W3-5-3-15
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1 5
7
6
4 3
2 1
1
1
WJBE-03-05-038
58. Remove bolts, washers (2) (8 used). Remove covers (3) (4 used) and rubbers (4) (4 used). j : 17 mm 59. Remove bolts (5) (8 used) and spring washers (6) (8 used). Disconnect pipes (1) (4 used). Remove O-rings (7) (4 used). j : 19 mm
W3-5-3-16
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
3
3
b b
2 1
4
5 b-
Lifting Hole
WJBE-03-05-039
dCAUTION:
Oil cooler (5) weight: 110 kg (245 lb) 60. Install shackles to lifting holes (b) (2 places) of oil cooler (5). Attach nylon slings onto shackles. Hoist and hold oil cooler (5). 61. Remove bolts (3) (4 used) and washers (2) (4 used). j : 19 mm 62. Remove bolts, washers (1) (4 used). Remove oil cooler (5). j : 19 mm 63. Remove fan (4). (Refer to W3-16-1.)
W3-5-3-17
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
3
3
b b
2 1
4
5 b-
Lifting Hole
WJBE-03-05-039
Installation 1. Install fan (4). (Refer to W3-16-1.)
dCAUTION:
Oil cooler (5) weight: 110 kg (245 lb) 2. Install shackles to lifting holes (b) (2 places) of oil cooler (5). Attach nylon slings onto shackles. Hoist oil cooler (5). 3. Install oil cooler (5) with bolts, washers (1) (4 used). j : 19 mm m : 55 to 123 N·m (5.5 to 12.5 kgf·m, 41 to 91 lbf·ft) 4. Install bolts (3) (4 used) and washers (2) (4 used). j : 19 mm m : 55 to 123 N·m (5.5 to 12.5 kgf·m, 41 to 91 lbf·ft)
W3-5-3-18
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1 5
7
6
4 3
2 1
1
1
WJBE-03-05-038
5. Install O-rings (7) (4 used). Install pipes (1) (4 used) with spring washers (6) (8 used) and bolts (5) (8 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 6. Install covers (3) (4 used) and rubbers (4) (4 used) with bolts, washers (2) (8 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-5-3-19
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
3
4
5
6
WJBE-03-05-032
7. Install cover (5) with bolts, washers (6) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 8. Install cover (1) with bolts, washers (2) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 9. Install cover (4) with bolts, washers (3) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-3-20
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
1
1
2
2
2
WJBE-03-05-036
dCAUTION: kg (98 lb)
The support (3) assembly weight: 44
10. Attach nylon slings onto the support (3) assembly. Hoist the support (3) assembly. 11. Install the support (3) assembly with bolts, washers (2) (7 used) and bolts, washers (1) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-3-21
3
1
WJBE-03-05-037
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 2
3
1
4
6
5
WJBE-03-05-032
12. Install cover (4) with washers (5) (4 used) and bolts (6) (4 used). j : 22 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 13. Install cover (1) with washers (2) (4 used) and bolts (3) (4 used). j : 22 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)
W3-5-3-22
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
a-
Lifting Hole
a
WJBE-03-16-010
The oil cooler (1) assembly weight: dCAUTION: 545 kg (1210 lb) 14. Install shackles (2 used) to lifting holes (a) (2 places) of the oil cooler (1) assembly. Attach nylon slings onto the shackles. Hoist the oil cooler (1) assembly.
W3-5-3-23
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
4
3 2
WJBE-03-05-034
15. Install the oil cooler (1) assembly with spacers (3) (4 used) and bolts (2) (4 used). j : 36 mm m : 950 N·m (95 kgf·m, 700 lbf·ft) 16. Install bolts, washers (4) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-5-3-24
WJBE-03-05-032
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly
1
2, 3
4
4
WJBE-03-16-008
17. Connect hose (1). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 18. Install clips (3) (2 used) and bolts, washers (2) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 19. Connect hoses (4) (2 used).
W3-5-3-25
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 7, 8
1
2
3
3
4, 5
3
11
9, 10
WJBE-03-16-009
20. Install clip (10) and bolt, washer (9). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 21. Install clip (8) and bolt, washer (7). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 22. Connect connector (11). 23. Connect connectors (6) (2 used). IMPORTANT: Take care not to disconnect hoses (2) (2 used). 24. Install the air conditioner condenser (1) assembly with bolts (3) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 25. Install clips (5) (4 used) and bolts, washers (4) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-5-3-26
6
4, 5
WJBE-03-05-033
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1, 2
3 4
5
6
8
9, 10
9, 10 8
1, 2
4
13 11, 12
WJBE-03-16-007
26. Connect pipe (3) with couplings (4) (2 used). 27. Install clamps (2) (3 used) with bolts, washers (1) (6 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 28. Connect pipe (6) with couplings (8) (2 used). 29. Install clamps (10) (3 used) with bolts, washers (9) (6 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 30. Connect pipe (13) with coupling (5). 31. Install clamp (12) with bolts, washers (11) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-5-3-27
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
3
4
8
dCAUTION: (47 lb)
7
5, 6
3
WJBE-03-16-006
The pipe (7) assembly weight: 21 kg
32. Attach nylon slings onto the pipe (7) assembly. Hoist and hold the pipe (7) assembly. Connect the pipe (7) assembly with couplings (4, 8). 33. Install clamps (6) (2 used) with bolts, washers (5) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 34. Connect hoses (3) (2 used). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)
dCAUTION:
Bracket (2) weight: 23 kg (51 lb) 35. Install bracket (2) with bolts, washers (1) (13 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-3-28
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 2
3
4
1
5
WJBE-03-16-034
7
6
WJBE-03-16-004
dCAUTION:
Air cleaner (2) weight: 28 kg (62 lb) 36. Attach nylon slings onto the body of air cleaner (2). Hoist and hold air cleaner (2). 37. Install air cleaner (2) with bolts, washers (7) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 38. Connect hose (5) with clamps (4, 6). m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 39. Connect Connectors (3) (2 used). 40. Close cover (1).
W3-5-3-29
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
WJBE-03-08-001
41. Fill the hydraulic oil tank with hydraulic oil.
fNOTE:
Total oil amount: 1042 L (275 US gal) 42. Install cover (2) with bolts, washers (1) (6 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 43. Bleed air from the hydraulic system. (Refer to W14-1.)
IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.
W3-5-3-30
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
3
4
5
6
5
WJBE-03-16-003
44. Install cover (4) with washers (6) (4 used) and bolts, washers (5) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION:
Cover (3) weight: 25 kg (56 lb) 45. Install cover (3) with washers (1) (7 used) and bolts, washers (2) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-3-31
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1, 2
8
3
4, 5
7
6
WJBE-03-16-001
dCAUTION:
Cover (6) weight: 25 kg (56 lb) 46. Install cover (6) with washers (5) (4 used) and bolts, washers (4) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 47. Install cover (8) with bolts, washers (7) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 48. Install cover (3) with washers (2) (9 used) and bolts, washers (1) (9 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-3-32
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1 2 3
4
5 6
7
8 9
10
11
14 13 11
12
WJBE-03-16-001
49. Install support (12) with bolts, washers (11) (3 used). j : 19 mm
54. Install the cap (7) assembly with bolts, washers (10) (4 used). j : 17 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
50. Install cover (2) with bolts, washers (1) (3 used).
55. Install door (3) with bolts, washers (4) (4 used).
j : 19 mm
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft) 51. Install cover (13) with bolts, washers (14) (5 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 52. Install cover (8) with bolts, washers (9) (3 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 53. Install cover (6) with bolts, washers (5) (9 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-3-33
m : 90 N·m (9 kgf·m, 66 lbf·ft)
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
3
4
9
8 5 7
6
WJBE-03-05-032
dCAUTION: (145 lb)
The duct (3) assembly weight: 64 kg
56. Install the duct (3) assembly with washers (1) (2 used) and bolts (2) (2 used). j : 22 mm m : 140 N·m (14 kgf·m, 103 lbf·ft) 57. Install the cover (9) side of stay (6) with washer (8) and pin (7). 58. Close the duct (3) assembly. Install washers (4) (4 used) and bolts (5) (4 used). j : 22 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)
W3-5-3-34
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 1
2
WJBE-03-05-040
dCAUTION: kg (53 lb)
The handrail (1) assembly weight: 24
59. Attach nylon slings onto the handrail (1) assembly. Hoist the handrail (1) assembly. 60. Install the handrail (1) assembly with bolts, washers (2) (10 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-3-35
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly
1, 2
3
4, 5 6
7, 8
9
WJBE-03-15-001
61. Install cover (9) with washers (8) (7 used) and bolts, washers (7) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 62. Install cover (6) with washers (5) (6 used) and bolts, washers (4) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 63. Install cover (3) with washers (2) (5 used) and bolts, washers (1) (5 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-3-36
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank Removal and Installation of Hydraulic Oil Tank
2
1
3
WJBE-03-08-001
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)
d
CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to W1-4-1.) 2. Bleed air from the hydraulic system. (Refer to W1-41.)
6
7, 8
WJBE-03-06-001
CAUTION: Remove cover (6) while holding it. Do dnot drop cover (6). 5. Remove bolts, washers (7) (8 used) and washers (8) (8 used). Remove cover (6). j : 19 mm CAUTION: Remove cover (3) while holding it. Do dnot drop cover (3). 6. Remove bolts, washers (4) (5 used) and washers (5) (5 used). Remove cover (3).
3. Remove bolts, washers (2) (6 used). Remove cover (1). j : 17 mm 4. Drain off hydraulic oil by using an oil feed pump.
fNOTE:
4, 5
Total oil amount: 1042 L (275 US gal)
W3-6-1-1
j : 19 mm
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank
1 2
3
M1J1-07-037
7. Place a container under hydraulic oil tank (3). 8. Remove plug (2). 9. Slowly open drain cock (1) and drain off remaining hydraulic oil. 10. Close drain cock (1). 11. Install plug (2) to the original position. 12. Install cover (4) with bolts, washers (5) (6 used). j : 17 mm
W3-6-1-2
4
5
WJBE-03-08-001
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank
1
2
3
4
5
6
5
WJBE-03-16-003
dCAUTION:
Cover (3) weight: 25 kg (56 lb) 13. Remove bolts, washers (2) (7 used) and washers (1) (7 used). Remove cover (3). j : 19 mm 14. Remove bolts, washers (5) (6 used) and washers (6) (4 used). Remove cover (4). j : 19 mm
W3-6-1-3
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank
1
WJBE-03-16-034
15. Open door (1). 16. Remove bolts, washers (2) (6 used). Remove door (1). j : 17 mm
W3-6-1-4
1
2
WJBE-03-06-003
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank 8, 14
1
1
2
3
13
12
8, 11 8, 10 8, 9
1
6, 7
17. Place a container under the hydraulic oil tank. 18. Remove coupling (2). Disconnect pipe (3). 19. Remove bolts, washers (6) (2 used). Remove clamp (7). j : 17 mm 20. Remove coupling (4). Disconnect pipe (5). 21. Disconnect hoses (13) (2 used). j : 36 mm 22. Disconnect hose (12). j : 19 mm 23. Disconnect hoses (1) (4 used). j : 27 mm 24. Remove bolts, washers (8) (4 used). Remove clips (9, 10, 11, and 14). j : 17 mm
W3-6-1-5
5
4
WJBE-03-06-004
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank 2, 3
5
1
2, 3
4
1
25. Disconnect hoses (1) (3 used). j : 19 mm 26. Disconnect hoses (4) (3 used). j : 17 mm 27. Disconnect hose (5). j : 27 mm 28. Remove bolts, washers (2) (3 used). Remove clips (3) (3 used). j : 17 mm
W3-6-1-6
4
WJBE-03-06-006
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank
1
2, 3, 4
29. Remove bolt, washer (2). Remove clips (3, 4). j : 17 mm 30. Disconnect hoses (1) (3 used). j : 19 mm
W3-6-1-7
WJBE-03-06-005
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank 1
2
3
4
7
8
a
9
a
6 5
WJBE-03-06-002
a-
31. Remove bolts, washers (3) (7 used). Remove cover (4). j : 19 mm 32. Remove bolts, washers (1) (5 used). Remove cover (2). j : 19 mm
d CAUTION:
Cover (5) weight: 31 kg (69 lb) 33. Remove bolts, washers (6) (8 used). Remove cover (5). j : 19 mm 34. Remove bolts, washers (8) (4 used). Remove handrail (7). j : 19 mm
CAUTION: d(995 lb)
Hydraulic oil tank (9) weight: 450 kg
35. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to screw holes (a) (2 places) of hydraulic oil tank (9). Attach wire ropes onto the eyebolts. Hoist and hold hydraulic oil tank (9).
W3-6-1-8
Screw Hole
WJBE-03-06-007
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank 6
4, 5
WJBE-03-06-002
1 2
1
3
36. Disconnect connector (3). 37. Remove bolts, washers (4) (2 used). Remove clips (5) (2 used). j : 17 mm 38. Place a container under hose (2). Remove hose clamps (1) (4 used). Disconnect hose (2). 39. Remove bolts (7) (8 used) and spacers (8) (8 used).
fNOTE: used).
LOCTITE #262 has been applied onto bolts (7) (8
j : 30 mm 40. Remove hydraulic oil tank (6).
W3-6-1-9
8
7
WJBE-03-06-007
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank a
a-
Screw Hole
1
a
WJBE-03-06-007
Installation CAUTION: d(995 lb)
Hydraulic oil tank (1) weight: 450 kg
1. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to screw holes (a) (2 places) of hydraulic oil tank (1). Attach wire ropes onto the eyebolts. Hoist hydraulic oil tank (1).
W3-6-1-10
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank 6
4, 5 3 8 7
WJBE-03-06-002
WJBE-03-06-007
2. Apply LOCTITE #262 onto bolts (7) (8 used). Install hydraulic oil tank (6) with spacers (8) (8 used) and bolts (7) (8 used).
1 2
1
4. Connect connector (3). 5. Install clips (5) (2 used) with bolts, washers (4) (2 used).
j : 30 mm
j : 17 mm
m : 400 N·m (40 kgf·m, 300 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
3. Connect hose (2) with hose clamps (1) (4 used). m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-6-1-11
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank 7
8
1
2
3
4
6 5
WJBE-03-06-007
6. Install handrail (7) with bolts, washers (8) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
d CAUTION:
Cover (5) weight : 31 kg (69 lb) 7. Install cover (5) with bolts, washers (6) (8 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 8. Install cover (2) with bolts, washers (1) (5 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 9. Install cover (4) with bolts, washers (3) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-6-1-12
WJBE-03-06-002
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank
1
2, 3, 4
10. Connect hoses (1) (3 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 11. Install clips (3, 4) with bolt, washer (2). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-6-1-13
WJBE-03-06-005
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank 2, 3
5
1
2, 3
4
1
12. Connect hose (5). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 13. Connect hoses (4) (3 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 14. Connect hoses (1) (3 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 15. Install clips (3) (3 used) with bolts, washers (2) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-6-1-14
4
WJBE-03-06-006
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank 8, 14
1
1
2
3
13
12
8, 11 8, 10 8, 9
1
6, 7
16. Connect hoses (1) (4 used). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 17. Connect hose (12). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 18. Connect hoses (13) (2 used). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 19. Install clips (9, 10, 11, and 14) with bolts, washers (8) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 20. Connect pipe (5) with coupling (4). 21. Connect pipe (3) with coupling (2). 22. Install clamp (7) with bolts, washers (6) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-6-1-15
5
4
WJBE-03-06-004
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank
1
2
WJBE-03-08-001
23. Remove bolts, washers (2) (6 used). Remove cover (1). j : 17 mm 24. Fill the hydraulic oil tank with hydraulic oil.
fNOTE:
Total oil amount: 1042 L (275 US gal) 25. Install cover (1) with bolts, washers (2) (6 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 26. Bleed air from the hydraulic system. (Refer to W1-41.)
IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.
W3-6-1-16
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank
1
WJBE-03-16-034
27. Install door (1) with bolts, washers (2) (6 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 28. Close door (1).
W3-6-1-17
1
2
WJBE-03-06-003
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank 1
2
3
4
5
6
5
WJBE-03-16-003
29. Install cover (4) with washers (6) (4 used) and bolts, washers (5) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION:
Cover (3) weight: 25 kg (56 lb) 30. Install cover (3) with washers (1) (7 used) and bolts, washers (2) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-6-1-18
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank
3
4, 5
6
7, 8
WJBE-03-06-001
31. Install cover (3) with washers (5) (5 used) and bolts, washers (4) (5 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 32. Install cover (6) with washers (8) (8 used) and bolts, washers (7) (8 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-6-1-19
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank (Blank)
W3-6-1-20
SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank Removal and Installation of Fuel Tank 1
2
3
WJBE-03-05-040
Fuel is highly flammable. Never bring daCAUTION: fire close to fuel. IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal
dCAUTION: kg (53 lb)
4. Attach nylon slings onto the handrail (1) assembly. Hoist and hold the handrail (1) assembly. 5. Remove bolts, washers (2) (10 used). Remove the handrail (1) assembly.
1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Remove cap (3). 3. Place a container. Drain off fuel by using an oil feed pump.
fNOTE:
The handrail (1) assembly weight: 24
Oil amount: 1110 L (293 US gal)
W3-7-1-1
j : 19 mm
SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank 1
2
3
4
5
6
5
WJBE-03-16-003
dCAUTION:
Cover (3) weight: 25 kg (56 lb) 6. Remove bolts, washers (2) (7 used) and washers (1) (7 used). Remove cover (3). j : 19 mm 7. Remove bolts, washers (5) (6 used) and washers (6) (4 used). Remove cover (4). j : 19 mm
W3-7-1-2
SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank 1, 2
3
4, 5 6
7, 8 9
WJBE-03-06-001
CAUTION: Remove cover (3) while holding it. Do dnot drop cover (3). 8. Remove bolts, washers (1) (5 used) and washers (2) (5 used). Remove cover (3). j : 19 mm CAUTION: Remove cover (6) while holding it. Do dnot drop cover (6). 9. Remove bolts, washers (4) (4 used) and washers (5) (4 used). Remove cover (6). j : 19 mm CAUTION: Remove cover (9) while holding it. Do dnot drop cover (9). 10. Remove bolts, washers (7) (4 used) and washers (8) (4 used). Remove cover (9). j : 19 mm
W3-7-1-3
SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank 7, 10 1, 2
3, 4
5, 6
7, 8
7, 8, 9
7, 9
WJBE-03-07-001
11. Remove bolt, washer (1). j : 17 mm 12. Disconnect connector (2). 13. Remove bolts, washers (7) (4 used), clips (8, 9) (2 used for each), and clip (10). j : 17 mm 14. Remove clamps (3, 5). Disconnect hoses (4, 6).
W3-7-1-4
SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank 1
2
5, 7
3
4
5, 6
WJBE-03-07-002
15. Remove bolts, washers (1) (3 used). Remove cover (2). j : 17 mm 16. Remove cap (3). 17. Remove bolts, washers (5) (2 used), and clips (6, 7). j : 17 mm 18. Disconnect connectors (4) (2 used).
W3-7-1-5
SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank a
a
1
2
3 4 5 WJBE-03-07-002
a - Screw Hole
d CAUTION:
Fuel tank (1) weight: 480 kg (1060 lb) 19. Install eyebolts (M12, Pitch 1.75 mm) to screw holes (a) (2 places) of fuel tank (1). Attach nylon slings onto the eyebolts. Hoist and hold fuel tank (1). 20. Place a container under hoses (2, 4). Remove clamps (3) (2 used). Disconnect hoses (2, 4). Drain fuel completely. 21. Remove bolts (5) (8 used) and spacers (6) (8 used). Remove fuel tank (1).
fNOTE: used).
LOCTITE #262 has been applied onto bolts (5) (8
j : 27 mm
W3-7-1-6
6
WJBE-03-07-003
SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank a
a
1
2
3 4 5 WJBE-03-07-002
a - Screw Hole
Installation
d CAUTION:
Fuel tank (1) weight: 480 kg (1060 lb) 1. Install eyebolts (M12, Pitch 1.75 mm) to screw holes (a) (2 places) of fuel tank (1). Attach nylon slings onto the eyebolts. Hoist fuel tank (1). 2. Apply LOCTITE #262 onto bolts (5) (8 used). Install fuel tank (1) with spacers (6) (8 used) and bolts (5) (8 used). j : 27 mm m : 300 N·m (30 kgf·m, 220 lbf·ft) 3. Connect hoses (2, 4) with clamps (3) (2 used).
W3-7-1-7
6
WJBE-03-07-003
SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank 1
2
5, 7
3
4
5, 6
WJBE-03-07-002
4. Connect connectors (4) (2 used). 5. Install clips (6, 7), and bolts, washers (5) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 6. Install cap (3). 7. Install cover (2) with bolts, washers (1) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-7-1-8
SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank 7, 10 1, 2
3, 4
5, 6
7, 8
7, 8, 9
7, 9
WJBE-03-07-001
8. Connect hoses (4, 6) with clamps (3, 5). 9. Install clip (10), clips (8, 9) (2 used for each), and bolts, washers (7) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 10. Connect connector (2). 11. Install bolt, washer (1). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-7-1-9
SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank 1, 2
3
4, 5
6
7, 8 9
WJBE-03-06-001
12. Install cover (9) with washers (8) (4 used) and bolts, washers (7) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 13. Install cover (6) with washers (5) (4 used) and bolts, washers (4) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 14. Install cover (3) with washers (2) (5 used) and bolts, washers (1) (5 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-7-1-10
SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank 1
2
3
4
5
6
5
WJBE-03-16-003
15. Install cover (4) with washers (6) (4 used) and bolts, washers (5) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION:
Cover (3) weight: 25 kg (56 lb) 16. Install cover (3) with washers (1) (7 used) and bolts, washers (2) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-7-1-11
SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank 1
2
3
WJBE-03-05-040
dCAUTION: kg (53 lb)
The handrail (1) assembly weight: 24
17. Attach nylon slings onto the handrail (1) assembly. Hoist and hold the handrail (1) assembly. 18. Install the handrail (1) assembly with bolts, washers (2) (10 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) IMPORTANT: Take care not to contaminate fuel tank (3) with dust, water, or sand when filling the fuel. 19. Fill fuel tank (3) with fuel.
fNOTE:
Oil amount: 1110 L (293 US gal) 20. Bleed air from the fuel system. (Refer to W1-4-1.)
W3-7-1-12
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Removal and Installation of Pump Device
Detail A 6 5
2
1
5
A
7
5
5
8
7
140
WJBE-03-08-020
4
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)
2. Remove bolts, washers (1) (6 used). Remove cover (2).
WJBE-03-08-002
4. Drain oil from the pump transmission. (Refer to MAINTENANCE in the separated volume, the operator’s manual.)
fNOTE:
Oil amount: 6.2 L (1.64 US gal)
dCAUTION:
Cover (4) weight: 29 kg (64 lb) 5. Remove nuts (138) (6 used), spring washers (139) (6 used), and washers (140) (6 used). Remove cover (4).
6. Remove bolts, washers (5) (6 used). Remove cover (6). j : 19 mm 7. Remove bolts, washers (7) (4 used). Remove cover (8). j : 19 mm
3. Drain off hydraulic oil by using an oil feed pump.
fNOTE:
138
j : 19 mm
Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)
j : 17 mm
139
Total oil amount: 1042 L (275 US gal)
W3-8-1-1
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 60 9, 10 61 11, 12
62 13, 14
63
WJBE-03-08-008
WJBE-03-08-003
Remove cover (60) while holding it. dCAUTION: Do not drop cover (60).
dCAUTION:
8. Remove bolts, washers (9) (6 used) and washers (10) (6 used). Remove cover (60).
64 65 66
Cover (65) weight: 24 kg (53 lb) 12. Remove bolts, washers (66) (11 used). Remove cover (65).
j : 19 mm Remove cover (61) while holding it. dCAUTION: Do not drop cover (61). 9. Remove bolts, washers (11) (6 used) and washers (12) (6 used). Remove cover (61). j : 19 mm Remove cover (62) while holding it. dCAUTION: Do not drop cover (62). 10. Remove bolts, washers (13) (7 used) and washers (14) (7 used). Remove cover (62). j : 19 mm
dCAUTION:
Cover (63) weight: 23 kg (51 lb) 11. Remove bolts, washers (64) (9 used). Remove cover (63). j : 19 mm
W3-8-1-2
j : 19 mm
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device
71
67, 68
71
67, 68
WJBE-03-08-010
13. Remove bolts (67) (4 used) and washers (68) (4 used). Remove support (69). j : 22 mm
dCAUTION: (58 lb)
The cover (70) assembly weight: 26 kg
14. Remove bolts, washers (71) (4 used). j : 19 mm 15. Remove bolts, washers (72) (8 used). Remove the cover (70) assembly. j : 19 mm
W3-8-1-3
69
70
72
72
WJBE-03-08-009
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device
WJBE-03-08-004
WJBE-03-08-021
16. Place a container under the pump (107) assembly. Remove clamps (20) (2 used). Disconnect hose (142).
25. Disconnect hose (25).
17. Disconnect the both ends of hose (21).
26. Remove bolts (26) (5 used), washers (27) (5 used), clips (28) (3 used), and clips (29) (2 used).
j : 41 mm
d
CAUTION: The pipe (15) assembly weight: 22 kg (49 lb) 18. Attach nylon slings onto the pipe (15) assembly. Hoist and hold the pipe (15) assembly.
j : 36 mm
j : 17 mm 27. Disconnect connectors (30) (2 used).
19. Remove socket bolts (19) (8 used). l : 10 mm 20. Remove clamps (22) (2 used). Disconnect the pipe (15) assembly. 21. Remove bolts, washers (16) (4 used). Remove clamps (17) (2 used). j : 17 mm 22. Disconnect the pipe (15) assembly. Remove O-rings (23) (2 used). 23. Remove clamps (141) (2 used). Disconnect hose (142). 24. Disconnect hose (24). j : 27 mm
W3-8-1-4
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device
WJBE-03-08-005
28. Remove bolts, washers (31) (2 used). Remove bracket (32).
WJBE-03-08-006
36. Disconnect connector (47). 37. Remove socket bolts (48) (8 used) and flanges (49) (4 used). Disconnect hoses (50) (2 used). Remove O-rings (51) (2 used).
j : 19 mm 29. Remove bolts, washers (33) (2 used). Remove bracket (34).
l : 10 mm
j : 19 mm 30. Remove socket bolts (35) (8 used) and flanges (36) (4 used). Disconnect hoses (37) (2 used). Remove O-rings (38) (2 used). l : 10 mm 31. Disconnect the both ends of hose (39). j : 27 mm 32. Disconnect hoses (40) (2 used). j : 36 mm 33. Disconnect hose (41). j : 17 mm 34. Remove bolt (42), washer (43), and clip (44). j : 17 mm 35. Remove bolt, washer (45) and clip (46). j : 19 mm
W3-8-1-5
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device
WJBE-03-08-007
38. Disconnect the both ends of hose (52). j : 19 mm 39. Disconnect hose (53). j : 19 mm 40. Disconnect hose (54). j : 36 mm 41. Remove bolts (55) (8 used), washers (56) (8 used), clips (57) (3 used), and clips (58) (5 used). j : 17 mm 42. Disconnect connectors (59) (4 used).
W3-8-1-6
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 74 75
78 80
73, 131
81
WJBE-03-08-011
79
82
77 76
WJBE-03-08-013
43. Remove bolt, washer (73) and clip (131). j : 17 mm
dCAUTION: kg (91 lb)
The muffler (74) assembly weight: 41
44. Attach nylon slings onto the muffler (74) assembly. Hoist and hold the muffler (74) assembly. 45. Remove bolts (78) (2 used) and nuts (79) (4 used). Remove gasket (80). j : 19 mm 46. Remove U-bolts (75) (2 used), nuts (76) (8 used), and washers (77) (4 used). j : 19 mm 47. Remove the muffler (74) assembly. 48. Remove clamp (81). Disconnect tube (82).
W3-8-1-7
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 101
102
92 93 86, 87 89
88 95 94
Detail A
98
84 85 83 143
90 91
100 99
A
96, 97 WJBE-03-08-014
49. Loosen nut (143).
WJBE-03-08-015
55. Remove bolts, washers (94) (2 used). Remove cover (95).
j : 19 mm 50. Remove nut (84) and washer (85). Disconnect cable (83). j : 10 mm 51. Remove bolts, washers (86) (2 used) and clips (87) (2 used). j : 17 mm 52. Remove bolts, washers (88) (3 used). Remove plate (89). j : 19 mm
j : 19 mm 56. Remove bolts, washers (96) (4 used) and spacers (97) (4 used). Remove rubber (98). j : 19 mm 57. Remove bolts, washers (99) (2 used). Remove cover (100). j : 19 mm 58. Remove bolts, washers (101) (4 used). Remove cover (102).
53. Remove bolts, washers (90) (4 used). Remove cover (91). j : 19 mm 54. Remove bolts, washers (92) (4 used). Remove cover (93). j : 19 mm
W3-8-1-8
j : 19 mm
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device
106
105
103, 104
WJBE-03-08-012
59. Remove bolts (103) (4 used) and washers (104) (4 used). j : 22 mm 60. Remove bolts, washers (105) (4 used). Remove bracket (106). j : 19 mm
W3-8-1-9
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device a
108
107
110
109
a
Detail A
111
111 113
A 118
115
a-
Lifting Bracket
114 113 112
WJBE-03-08-016
WJBE-03-08-018
The pump device (107) assembly dCAUTION: weight: 755 kg (1670 lb) 61. Install shackles and nylon slings onto lifting brackets (a) (2 places) of the pump device (107) assembly. Attach nylon slings onto main pumps (108, 109). Install chain blocks. Hoist and hold the pump device (107) assembly.
116
62. Remove bolt (111), nut (112), washers (113) (2 used), plate (114), and cushion (115). j : 50 mm 117
63. Remove bolt (111) at the front attachment side in the same way as step 62. 64. Slightly hoist the pump device (107) assembly. Set wooden blocks (b) between engine (116) and main frame (117). Place engine (116).
b-
65. Remove bolts (110) (14 used).
fNOTE:
LOCTITE #262 has been applied onto bolts (110) (14 used). j : 19 mm
66. Adjust the chain blocks in order to level the pump device (107) assembly. Remove the pump device (107) assembly. 67. Place the pump (107) assembly on the wooden blocks. 68. Remove cushions (118) at the counterweight and front attachment sides.
W3-8-1-10
Wooden Block
b
W1JB-02-04-007
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device C 119, 120 108, 132 C 124, 135 130 125, 126 109, 133
127, 128 129
123, 134 c-
121, 122
Eyebolt Mounting Hole WJBE-03-08-017
dCAUTION: lb)
Main pump (108) weight: 180 kg (400
69. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to eyebolt mounting holes (c) (2 places) of main pump (108). Attach nylon slings onto the eyebolts. Hoist and hold main pump (108). 70. Remove socket bolts (119) (4 used) and spring washers (120) (4 used). Remove main pump (108). Remove O-ring (132).
75. Remove bolts (127) (6 used) and washers (128) (6 used). Remove bracket (129).
fNOTE:
LOCTITE #262 has been applied onto bolts (127) (6 used). j : 30 mm
76. Remove bracket (129) at the front attachment side in the same way as step 75.
j : 17 mm 71. Remove main pump (109) and O-ring (133) at the counterweight side in the same way as step 69 and step 70. 72. Remove socket bolts (121) (2 used) and washers (122) (2 used). Remove pilot pump (123). Remove O-ring (134). j : 8 mm
dCAUTION:
Fan pump (124) weight: 50 kg (115 lb) 73. Attach nylon slings onto the body of fan pump (124). Hoist and hold fan pump (124). 74. Remove socket bolts (125) (2 used) and spring washers (126) (2 used). Remove fan pump (124). Remove O-ring (135). j : 14 mm
W3-8-1-11
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 108
136
124
130
109
137
123 WJBE-03-08-019
77. Remove the adapters with main pumps (108, 109), pilot pump (123), fan pump (124), and pump transmission (130) attached if necessary. 78. Remove socket bolts (136) (8 used). Remove coupling (137).
fNOTE:
LOCTITE #262 has been applied onto socket bolts (136) (8 used). j : 17 mm
W3-8-1-12
WJBE-03-08-017
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 108
136
124
130
109
137
123
WJBE-03-08-019
Installation 1. Apply LOCTITE #262 onto socket bolts (136) (8 used). Install coupling (137) with socket bolts (136) (8 used). j : 17 mm m : 540 N·m (54 kgf·m, 400 lbf·ft) 2. Install all removed adapters to main pumps (108, 109), pilot pump (123), fan pump (124), and pump transmission (130).
W3-8-1-13
WJBE-03-08-017
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device C 119, 120 108, 132 C
124, 135 130 125, 126 109, 133
127, 128 129
123, 134 c-
121, 122
Eyebolt Mounting Hole WJBE-03-08-017
3. Apply LOCTITE #262 onto bolts (127) (6 used). Install bracket (129) with washers (128) (6 used) and bolts (127) (6 used).
8. Install O-ring (134) to pilot pump (123). Install pilot pump (123) with washers (122) (2 used) and socket bolts (121) (2 used).
j : 30 mm
j : 8 mm
m : 400 N·m (40 kgf·m, 300 lbf·ft)
m : 45 to 55 N·m (4.5 to 5.5 kgf·m, 33.0 to 40.5 lbf·ft)
4. Install bracket (129) at the front attachment side in the same way as step 3.
dCAUTION:
Fan pump (124) weight: 50 kg (115 lb) 5. Apply THREEBOND #1215 onto the pump transmission (130) mounting surface of fan pump (124). Attach nylon slings onto the body of fan pump (124). Hoist fan pump (124). 6. Install O-ring (135) to fan pump (124). Install fan pump (124) with spring washers (126) (2 used) and socket bolts (125) (2 used). j : 14 mm
dCAUTION: lb)
9. Apply THREEBOND #1215 onto the pump transmission (130) mounting surface of main pump (108). Install eyebolts (M12, Pitch 1.75 mm) (2 used) to eyebolt mounting holes (c) (2 places) of main pump (108). Attach nylon slings onto the eyebolts. Hoist main pump (108). 10. Install O-ring (132) to main pump (108). Install main pump (108) with spring washers (120) (4 used) and socket bolts (119) (4 used). j : 17 mm
m : 189 to 231 N·m (19 to 23 kgf·m, 139 to 170 lbf·ft) 7. Apply THREEBOND #1215 onto the fan pump (124) mounting surface of pilot pump (123).
Main pump (108) weight: 180 kg (400
m : 360 to 440 N·m (36 to 44 kgf·m, 265 to 320 lbf·ft) 11. Install main pump (109) and O-ring (133) at the counterweight side in the same way as step 9 and step 10.
W3-8-1-14
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device a
108
107
110
109
a
111
Detail A 111 113
118 A
a-
Lifting Bracket
115 114 113 112
WJBE-03-08-016
WJBE-03-08-018
12. Install cushions (118) at the counterweight and front attachment sides.
116
The pump device (107) assembly dCAUTION: weight: 755 kg (1670 lb) 13. Install shackles and nylon slings onto lifting brackets (a) (2 places) of the pump device (107) assembly. Attach nylon slings onto main pumps (108, 109). Install chain blocks. Adjust the chain blocks in order to level the pump device (107) assembly. Hoist the pump device (107) assembly.
117
14. Apply LOCTITE #262 onto bolts (110) (14 used). Install the pump device (107) assembly with bolts (110) (14 used). j : 19 mm
b-
m : 110 N·m (11 kgf·m, 81 lbf·ft) 15. Hoist the pump device (107) assembly. Remove wooden blocks (b) between engine (116) and main frame (117). Place engine (116). 16. Install cushion (115), plate (114), washers (113) (2 used), nut (112), and bolt (111). j : 50 mm m : 1950 N·m (195 kgf·m, 1440 lbf·ft) 17. Install bolt (111) at the front attachment side in the same way as step 16.
W3-8-1-15
Wooden Block
b W1JB-02-04-007
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 101
106
102
98
100 99 105
103, 104
WJBE-03-08-012
18. Install bracket (106) with bolts, washers (105) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 19. Install washers (104) (4 used) and bolts (103) (4 used). j : 22 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 20. Install cover (102) with bolts, washers (101) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 21. Install cover (100) with bolts, washers (99) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 22. Install rubber (98) with spacers (97) (4 used) and bolts, washers (96) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-8-1-16
96, 97 WJBE-03-08-014
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Detail A 92 93 86, 87 89
88
95 94
84 85 83 143
04
90 91
A WJBE-03-08-014
23. Install cover (95) with bolts, washers (94) (2 used).
WJBE-03-08-015
28. Install cable (83) with washer (85) and nut (84).
j : 19 mm
j : 10 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3.0 lbf·ft)
24. Install cover (93) with bolts, washers (92) (4 used).
29. Tighten nut (143).
j : 19 mm
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 55 N·m (5.5 kgf·m, 41 lbf·ft)
25. Install cover (91) with bolts, washers (90) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 26. Install plate (89) with bolts, washers (88) (3 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 27. Install clips (87) (2 used) and bolts, washers (86) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-8-1-17
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 74 75
78 80
81 79 73, 131
WJBE-03-08-011
82
77 76
WJBE-03-08-013
dCAUTION: kg (91 lb)
The muffler (74) assembly weight: 41
30. Attach nylon slings onto the muffler (74) assembly. Hoist the muffler (74) assembly. 31. Connect tube (82) with clamp (81). 32. Install gasket (80). Install nuts (79) (4 used) and bolts (78) (2 used). j : 19 mm m : 69 to 98 N·m (6.9 to 9.8 kgf·m, 51 to 72 lbf·ft) 33. Install washers (77) (4 used), nuts (76) (8 used), and U-bolts (75) (2 used). j : 19 mm m : 35 N·m (3.5 kgf·m, 26 lbf·ft) 34. Install clip (131) and bolt, washer (73). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-8-1-18
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device
WJBE-03-08-007
35. Connect connectors (59) (4 used). 36. Install clips (57) (3 used), clips (58) (5 used), washers (56) (8 used), and bolts (55) (8 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 37. Connect hose (54). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 38. Connect hose (53). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 39. Connect the both ends of hose (52). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-8-1-19
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device
WJBE-03-08-005
40. Install O-rings (51) (2 used) to hoses (50) (2 used). Connect hoses (50) (2 used) with flanges (49) (4 used) and socket bolts (48) (8 used).
WJBE-03-08-006
46. Connect the both ends of hose (39). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)
l : 10 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 41. Connect connector (47).
47. Install O-rings (38) (2 used) to hoses (37) (2 used). Connect hoses (37) (2 used) with flanges (36) (4 used) and socket bolts (35) (8 used).
42. Install clip (46) and bolt, washer (45).
l : 10 mm
j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft) 48. Install bracket (34) with bolts, washers (33) (2 used).
43. Install clip (44), washer (43), and bolt (42).
j : 19 mm
j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft) 49. Install bracket (32) with bolts, washers (31) (2 used).
44. Connect hose (41).
j : 19 mm
j : 17 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 45. Connect hoses (40) (2 used). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)
W3-8-1-20
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device
WJBE-03-08-004
50. Connect connectors (30) (2 used).
WJBE-03-08-021
57. Install socket bolts (19) (8 used).
51. Install clips (28) (3 used), clips (29) (2 used), washers (27) (5 used), and bolts (26) (5 used). j : 17 mm
l : 10 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 58. Install clamps (22) (2 used).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
52. Connect hose (25).
59. Connect hose (142) with clamps (20) (2 used).
j : 36 mm
60. Connect the both ends of hose (21).
m : 180 N·m (18 kgf·m, 133 lbf·ft)
j : 41 mm
53. Connect hose (24).
m : 200 N·m (20 kgf·m, 148 lbf·ft)
j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 54. Connect hose (142) with clamps (141) (2 used).
dCAUTION: (49 lb)
The pipe (15) assembly weight: 22 kg
55. Attach nylon slings onto the pipe (15) assembly. Hoist the pipe (15) assembly. 56. Install O-rings (23) (2 used) to the pipe (15) assembly. Install the pipe (15) assembly with clamps (17) (2 used) and bolts, washers (16) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-8-1-21
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device
2
1
WJBE-03-08-020
61. Fill the pump transmission with oil. (Refer to MAINTENANCE in the separated volume, the operator’s manual.)
fNOTE:
Oil amount: 6.2 L (1.64 US gal) 62. Fill the hydraulic oil tank with hydraulic oil.
fNOTE:
Total oil amount: 1042 L (275 US gal) 63. Install cover (2) with bolts, washers (1) (6 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 64. Bleed air from the hydraulic system. (Refer to W1-41.)
IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.
W3-8-1-22
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device
71
67, 68
71
67, 68
WJBE-03-08-010
dCAUTION: (58 lb)
The cover (70) assembly weight: 26 kg
65. Install the cover (70) assembly with bolts, washers (72) (8 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 66. Install bolts, washers (71) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 67. Install support (69) with washers (68) (4 used) and bolts (67) (4 used). j : 22 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)
W3-8-1-23
69
70
72
72
WJBE-03-08-009
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Detail A 6 5
5
A
7
5
5
8
7
140
WJBE-03-08-020
68. Install cover (6) with bolts, washers (5) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 69. Install cover (8) with bolts, washers (7) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION:
Cover (4) weight: 29 kg (64 lb) 70. Install cover (4) with washers (140) (6 used), spring washers (139) (6 used), and nuts (138) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-8-1-24
4
139
138
WJBE-03-08-002
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 63
64 65 66
60 9, 10 61
11, 12 62 13, 14
WJBE-03-08-008
dCAUTION:
Cover (65) weight: 24 kg (53 lb) 71. Install cover (65) with bolts, washers (66) (11 used).
WJBE-03-08-003
74. Install cover (61) with washers (12) (6 used) and bolts, washers (11) (6 used). j : 19 mm
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION:
Cover (63) weight: 23 kg (51 lb) 72. Install cover (63) with bolts, washers (64) (9 used).
75. Install cover (60) with washers (10) (6 used) and bolts, washers (9) (6 used). j : 19 mm
j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 73. Install cover (62) with washers (14) (7 used) and bolts, washers (13) (7 used).
m : 90 N·m (9 kgf·m, 66 lbf·ft) 76. Perform engine speed adjustment and engine learning. (Refer to T4-6 in the separated volume, T/M.)
j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-8-1-25
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device (Blank)
W3-8-1-26
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Disassembly of Pump Transmission
WJBC-03-09-001
W3-8-2-1
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 00- 02- 04- 06- 07- 09-
Casing Gear Ball Bearing (3 Used) Coupling Retaining Ring (2 Used) Cartridge
10- 11- 12- 14- 15- 18-
O-Ring Bolt, Washer (10 Used) Socket Bolt (8 Used) Oil Seal Gear (2 Used) Cartridge (2 Used)
19- 20- 24- 26- 27- 31-
O-Ring (2 Used) O-Ring Level Gauge Pipe Socket Bolt (4 Used) Plug (3 Used)
W3-8-2-2
37- 38- 42- 43- 47- 48-
O-Ring Elbow Ball Bearing (2 Used) Ball Bearing Air Breather Pipe
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Disassembly of Pump Transmission
6. Remove O-ring (19) from cartridge (18).
1. Remove plugs (31) (3 used) from casing (00). Drain off oil from casing (00).
dCAUTION: (64 lb)
7. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to lifting holes (2 places) of gear (15). Attach a nylon sling onto the eyebolts. Hoist the gear (15) assembly. Remove the gear (15) assembly from casing (00).
j : 36 mm
fNOTE:
Amount of oil: 6.2 L (1.6 US gal)
dCAUTION: (695 lb)
The gear (15) assembly weight: 29 kg
Pump transmission weight: 314 kg
b
2. Remove socket bolts (27) (4 used). Remove level gauge (24), pipe (26), and O-ring (20) from casing (00).
15
l : 8 mm 3. Remove pipe (48) and O-ring (37) from elbow (38). b-
j : 46 mm
Lifting Hole
WJBC-03-09-003
4. Remove elbow (38) from casing (00). j : 32 mm
dCAUTION:
Cartridge (18) weight: 31 kg (69 lb) 5. Remove socket bolts (12) (4 used). Install eyebolts (M12, Pitch 1.75 mm) (2 used) to lifting holes (a) (2 places) of cartridge (18). Attach a nylon sling onto the eyebolts. Hoist cartridge (18). Remove cartridge (18) from casing (00).
8. Remove ball bearings (04, 42) from gear (15) by using a puller. 9. Remove other gear (15) in the same way as step 5 to step 8.
l : 17 mm
a 18
a-
Lifting Hole
WJBC-03-09-002
W3-8-2-3
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device
dCAUTION: kg (425 lb)
The casing (00) assembly weight: 191
10. Place the casing (00) assembly with the cartridge (09) side up. 11. Remove bolts, washers (11) (10 used). Evenly install bolts (M12, Pitch 1.75 mm) (2 used) to screw holes (c) (2 places) of cartridge (09). Float cartridge (09).
dCAUTION: (75 lb)
The gear (02) assembly weight: 34 kg
14. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to lifting holes (d) (2 places) of gear (02). Attach a nylon sling onto the eyebolts. Hoist the gear (02) assembly. Remove the gear (02) assembly from casing (00). d
j : 19 mm
02
c d-
09
c-
Screw Hole
WJBC-03-09-004
dCAUTION:
Cartridge (09) weight: 21 kg (47 lb) 12. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to screw holes (c) (2 places) of cartridge (09). Attach a nylon sling onto the eyebolts. Hoist cartridge (09). Remove cartridge (09) from casing (00). 13. Remove O-ring (10) and oil seal (14) from cartridge (09).
W3-8-2-4
Lifting Hole
WJBC-03-09-005
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 15. Remove retaining ring (07) from gear (02). Remove coupling (06) from gear (02) by using a bar and a hammer. Remove retaining ring (07) from gear (02). 16. Remove ball bearings (04, 43) from gear (02) by using a puller.
W3-8-2-5
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Assembly of Pump Transmission 15 19 00 42
04 12
31 31
18
10
07
43 09
06 02 14
04
27 11 42
04 12
18
19 38
37, 48
47
15 26
24
20 WJBC-03-09-006
W3-8-2-6
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 00- 02- 04- 06- 07- 09-
Casing Gear Ball Bearing (3 Used) Coupling Retaining Ring (2 Used) Cartridge
10- 11- 12- 14- 15- 18-
O-Ring Bolt, Washer (10 Used) Socket Bolt (8 Used) Oil Seal Gear (2 Used) Cartridge (2 Used)
19- 20- 24- 26- 27- 31-
O-Ring (2 Used) O-Ring Level Gauge Pipe Socket Bolt (4 Used) Plug (3 Used)
W3-8-2-7
37- 38- 42- 43- 47- 48-
O-Ring Elbow Ball Bearing (2 Used) Ball Bearing Air Breather Pipe
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Assembly of Pump Transmission IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.
dCAUTION: (75 lb)
4. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to lifting holes (d) (2 places) of gear (02). Attach a nylon sling onto the eyebolts. Hoist the gear (02) assembly. Install the gear (02) assembly to casing (00). d
d
CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION: too hot.
The gear (02) assembly weight: 34 kg
Be careful as ball bearings (04, 43) are
02
1. Warm up ball bearings (04, 43) to 50 to 70 °C (122 to 158 °F) by using a heater. Install ball bearings (04, 43) to gear (02) by using a bar and a hammer. Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
d-
such as goggles, helmets, etc in order to prevent personal injury. 2. Install retaining ring (07) to gear (02). Install coupling (06) to gear (02) by using a bar and a hammer. Install retaining ring (07) to gear (02).
dCAUTION:
Casing (00) weight: 136 kg (300 lb) 3. Place casing (00) with the cartridge (09) side up.
W3-8-2-8
Lifting Hole
WJBC-03-09-005
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device
dCAUTION:
Cartridge (09) weight: 21 kg (47 lb) 5. Install oil seal (14) and O-ring (10) to cartridge (09). Apply grease onto the lip part in oil seal (14). 6. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to screw holes (c) (2 places) of cartridge (09). Attach a nylon sling onto the eyebolts. Hoist cartridge (09). Install cartridge (09) to casing (00) with bolts, washers (11) (10 used) with stamped mark (e) of cartridge (09) facing to the air breather (47) side.
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION: too hot.
8. Warm up ball bearings (04, 42) to 50 to 70 °C (122 to 158 °F) by using a heater. Install ball bearings (04, 42) to gear (15) by using a bar and a hammer.
dCAUTION: (64 lb)
j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
Be careful as ball bearings (04, 42) are
The gear (15) assembly weight: 29 kg
9. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to lifting holes (2 places) of gear (15). Attach a nylon sling onto the eyebolts. Hoist the gear (15) assembly. Install the gear (15) assembly to casing (00).
e c
b 15
09
c-
Screw Hole
e-
b-
Stamped Mark WJBC-03-09-004
dCAUTION: kg (425 lb)
The casing (00) assembly weight: 191
7. Place the casing (00) assembly with the cartridge (09) side down.
W3-8-2-9
Lifting Hole
WJBC-03-09-003
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 10. Install O-ring (19) to cartridge (18).
dCAUTION:
Cartridge (18) weight: 31 kg (69 lb) 11. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to lifting holes (a) (2 places) of cartridge (18). Attach a nylon sling onto the eyebolts. Hoist cartridge (18). Install cartridge (18) to casing (00) with socket bolts (12) (4 used) with oil groove (f ) of cartridge (18) facing to the air breather side.
13. Install a seal tape onto elbow (38). Install elbow (38) to casing (00). j : 32 mm m : 140 N·m (14 kgf·m, 103 lbf·ft) 14. Install O-ring (37) and pipe (48) to elbow (38). j : 46 mm m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
l : 17 mm
15. Install O-ring (20), pipe (26), and level gauge (24) to casing (00) with socket bolts (27) (4 used).
m : 400 N·m (40 kgf·m, 300 lbf·ft)
l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 16. Fill casing (00) with oil.
a
fNOTE: 18
Amount of oil: 6.2 L (1.6 US gal) 17. Install a seal tape onto plugs (31) (3 used). Install plugs (31) (3 used) to casing (00). j : 36 mm m : 140 N·m (14 kgf·m, 103 lbf·ft)
a-
WJBC-03-09-002
Lifting Hole
f
18
f-
Oil Groove
WJBC-03-09-007
12. Install other gear (15) in the same way as step 8 to step 11.
W3-8-2-10
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Disassembly of Main Pump
WJBA-03-09-004
W3-8-3-1
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 01- 03- 04- 05- 06- 08- 10- 11- 12- 13- 14- 16- 18- 19- 20- 22- 24-
Casing Shaft Retaining Ring (2 Used) Spacer Roller Bearing Retaining Ring Plate O-Ring (2 Used) Knock Pin Plug (2 Used) Socket Bolt (4 Used) Servo Piston Swash Plate Pin Plate Guide Cover
25- Oil Seal 26- O-Ring 27- Socket Bolt (4 Used) 29A- Rotor 29B- Valve Plate 31- Disc Spring 32- Bushing 34- Retainer 36- Piston (9 Used) 39- Port Block 41- Ring 42- Knock Pin 43- Needle Bearing 45- Knock Pin 46- Pin 47- Backup Ring (2 Used) 48- O-Ring (2 Used)
50- 51- 52- 54- 55- 56- 57- 58- 59- 61- 62- 63- 64- 66- 67- 68- 69-
O-Ring Socket Bolt (6 Used) Washer (6 Used) Stopper O-Ring Stopper O-Ring Plug (2 Used) Socket Bolt (12 Used) Impeller Cover O-Ring Socket Bolt (6 Used) Link Lever Spring Pin Pin
W3-8-3-2
70- Retaining Ring (2 Used) 71- Pin 75- Spring Pin (2 Used) 76- O-Ring 77- O-Ring (3 Used) 80- Pressure Sensor 80A- O-Ring 81- Plug (3 Used) 82- O-Ring (3 Used) 84- Plug 85- O-Ring 87- Plug (4 Used) 88- O-Ring (4 Used) 90- Plug 91- O-Ring
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Disassembly of Main Pump 1. Remove pressure sensor (80) from port block (39). 2. Remove O-ring (80A) from pressure sensor (80).
dCAUTION:
Main pump weight: 177 kg (395 lb) 3. Remove plug (87) from casing (01). Drain off oil from the main pump. Remove O-ring (88) from plug (87).
dCAUTION:
Port block (39) weight: 52 kg (115 lb) 10. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to screw holes (a) (2 places) of port block (39). Attach a nylon sling onto the eyebolts. Hoist and hold port block (39). a
l : 12 mm 4. Remove the main pump regulator from casing (01). (Refer to W3-8-4.)
39
5. Remove O-ring (76) and O-rings (77) (3 used) from casing (01). IMPORTANT: Do not disassemble the link (66) assembly unless necessary. 6. Remove the link (66) assembly from casing (01). 7. Remove socket bolts (64) (6 used). Remove cover (62) from port block (39). l : 8 mm 8. Remove O-ring (63) from cover (62). 9. Remove impeller (61) from shaft (03).
WJBA-03-09-001 a-
Screw Hole
IMPORTANT: Do not drop valve plate (29B). 11. Remove socket bolts (51) (6 used) and washers (52) (6 used). Remove port block (39) from casing (01). l : 17 mm 12. Remove valve plate (29B), ring (41), and the pin (46) assembly from port block (39). 13. Remove O-rings (48) (2 used) and backup rings (47) (2 used) from pin (46).
W3-8-3-3
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 14. Remove O-ring (50) from casing (01). 15. Remove the rotor (29A) assembly from shaft (03). 16. Remove retainer (34), pistons (36) (9 used), bushing (32), and disc spring (31) from rotor (29A). 17. Remove socket bolts (27) (4 used). Evenly install the bolts (M8, Pitch 1.25 mm) to screw holes (b) (2 places) on cover (24). Float cover (24).
IMPORTANT: Do not damage the lip part of oil seal (25). 18. Remove the cover (24) assembly from casing (01). 19. Remove O-ring (26) from casing (01). IMPORTANT: Do not remove oil seal (25) unless necessary. Oil seal (25) cannot be reused. 20. Remove oil seal (25) from cover (24). 21. Tap and remove the shaft (03) assembly from casing (01) by using a plastic hammer.
l : 6 mm
IMPORTANT: Do not remove needle bearing (43) unless necessary. Needle bearing (43) cannot be reused. 22. Remove retaining ring (08) and needle bearing (43) from shaft (03).
b
23. Remove retaining ring (04), roller bearing (06), spacer (05), and retaining ring (04) from shaft (03).
24
24. Remove the swash plate (18) assembly and guide (22) from casing (01). 25. Remove plate (20) from swash plate (18).
WJBA-03-09-002 b-
Screw Hole
W3-8-3-4
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 26. Remove socket bolts (14) (4 used). Evenly install the bolts (M8, Pitch 1.25 mm) (2 used) to screw holes (c) (2 places) on plate (10). Float plate (10). 27. Remove plate (10) from casing (01).
30. Remove socket bolts (59) (6 used). Remove stopper (56) from casing (01). l : 6 mm 31. Remove O-ring (57) from stopper (56).
l : 8 mm
32. Remove servo piston (16) from casing (01).
10
c
WJBA-03-09-009 c-
Screw Hole
28. Remove socket bolts (59) (6 used). Remove stopper (54) from casing (01). l : 6 mm 29. Remove O-ring (55) from stopper (54).
W3-8-3-5
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Assembly of Main Pump 32 31 34
42
20
14 26
64
24
63 62
25
61 03 27 29B 39
45
36
29A
90, 91
19 10 13
51, 52 01 87, 88
12 06
08 80, 80A
84, 85
43 59
59 56, 57 58
04
41
11
54, 55 46
08 05
81, 82
66
48, 47
47, 48
50
22 16
67 68 71
69, 70
76 77
75 WJBA-03-09-003
W3-8-3-6
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 01- 03- 04- 05- 06- 08- 10- 11- 12- 13- 14- 16- 18- 19- 20- 22- 24-
Casing Shaft Retaining Ring (2 Used) Spacer Roller Bearing Retaining Ring Plate O-Ring (2 Used) Knock Pin Plug (2 Used) Socket Bolt (4 Used) Servo Piston Swash Plate Pin Plate Guide Cover
25- Oil Seal 26- O-Ring 27- Socket Bolt (4 Used) 29A- Rotor 29B- Valve Plate 31- Disc Spring 32- Bushing 34- Retainer 36- Piston (9 Used) 39- Port Block 41- Ring 42- Knock Pin 43- Needle Bearing 45- Knock Pin 46- Pin 47- Backup Ring (2 Used) 48- O-Ring (2 Used)
50- 51- 52- 54- 55- 56- 57- 58- 59- 61- 62- 63- 64- 66- 67- 68- 69-
O-Ring Socket Bolt (6 Used) Washer (6 Used) Stopper O-Ring Stopper O-Ring Plug (2 Used) Socket Bolt (12 Used) Impeller Cover O-Ring Socket Bolt (6 Used) Link Lever Spring Pin Pin
W3-8-3-7
70- Retaining Ring (2 Used) 71- Pin 75- Spring Pin (2 Used) 76- O-Ring 77- O-Ring (3 Used) 80- Pressure Sensor 80A- O-Ring 81- Plug (3 Used) 82- O-Ring (3 Used) 84- Plug 85- O-Ring 87- Plug (4 Used) 88- O-Ring (4 Used) 90- Plug 91- O-Ring
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Assembly of Main Pump IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install servo piston (16) to casing (01). 2. Install O-ring (57) to stopper (56). 3. Install stopper (56) to casing (01) with socket bolts (59) (6 used).
10. Install retaining ring (04), spacer (05), roller bearing (06), and retaining ring (04) to shaft (03). 11. Install needle bearing (43) and retaining ring (08) to shaft (03). 12. Install the shaft (03) assembly to casing (01) by using a plastic hammer. 13. Install oil seal (25) to cover (24). 14. Install O-ring (26) to casing (01).
l : 6 mm
15. Install the cover (24) assembly to casing (01) with socket bolts (27) (4 used).
m : 30 N·m (3 kgf·m, 22 lbf·ft) 4. Install O-ring (55) to stopper (54).
l : 6 mm
5. Install stopper (54) to casing (01) with socket bolts (59) (6 used).
m : 30 N·m (3 kgf·m, 22 lbf·ft)
l : 6 mm
16. Install disc spring (31), bushing (32), retainer (34), and pistons (36) (9 used) to rotor (29A).
m : 30 N·m (3 kgf·m, 22 lbf·ft)
17. Install the rotor (29A) assembly to shaft (03).
6. Fit the knock pin (12) positions and install plate (10) to casing (01). Install socket bolts (14) (4 used). l : 8 mm m : 65 N·m (6.5 kgf·m, 48 lbf·ft) 7. Fit the pin (19) positions and install plate (20) to swash plate (18). 8. Install guide (22) to swash plate (18). 9. Fit the guide (22) positions and install the swash plate (18) assembly to casing (01).
18. Install O-ring (50) to casing (01). 19. Install backup rings (47) (2 used) and O-rings (48) (2 used) to pin (46). 20. Install the pin (46) assembly and ring (41) to port block (39). 21. Apply grease onto the port block (39) mating surface of valve plate (29B). 22. Fit the knock pin (42) positions and install valve plate (29B) to port block (39).
W3-8-3-8
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device
d
CAUTION: Port block (39) weight: 52 kg (115 lb) 23. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to screw holes (a) (2 places) of port block (39). Attach a nylon sling onto the eyebolts. Hoist port block (39). a
28. Fit the lever (67) position and install the link (66) assembly to casing (01). 29. Install O-ring (76) and O-rings (77) (3 used) to casing (01). 30. Install the main pump regulator to casing (01). At this time, install the feedback lever of the regulator to pin (69). (Refer to W3-8-3.) 31. Install O-ring (88) to plug (87). 32. Install plug (87) to casing (01).
39
l : 12 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 33. Install O-ring (80A) to pressure sensor (80). Install pressure sensor (80) to port block (39). j : 27 mm WJBA-03-09-001
a-
Screw Hole
24. Fit the knock pin (45) positions and install port block (39) to casing (01). Install washers (52) (6 used) and socket bolts (51) (6 used). l : 17 mm m : 550 N·m (55 kgf·m, 410 lbf·ft) 25. Install impeller (61) to shaft (03). 26. Install O-ring (63) to cover (62). 27. Install cover (62) to port block (39) with socket bolts (64) (6 used). l : 8 mm m : 65 N·m (6.5 kgf·m, 48 lbf·ft)
W3-8-3-9
m : 100 N·m (10 kgf·m, 74 lbf·ft)
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device (Blank)
W3-8-3-10
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Disassembly of Regulator for Main Pump
WJBC-03-09-013
WJBC-03-09-014
W3-8-4-1
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 00- 02- 03- 05- 06- 07- 09- 10-
Casing Sleeve Spool Piston Cylinder O-Ring (2 Used) Front Cover Adjusting Screw
11- 13- 14- 15- 16- 17- 18- 20-
Nut Stopper Inner Stopper O-Ring Rear Cover Nut Nut Spring
22- 24- 26- 27- 39- 40- 41- 42-
Socket Bolt (8 Used) Plug (2 Used) Plug (4 Used) O-Ring (4 Used) Solenoid Valve Block O-Ring O-Ring (2 Used) O-Ring
W3-8-4-2
43- 46- 47- 50- 52-
Socket Bolt (4 Used) Plug O-Ring Socket Bolt (4 Used) Pressure Sensor
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Disassembly of Regulator for Main Pump
10. Remove inner stopper (14) and O-ring (07) from stopper (13).
1. Remove socket bolts (50) (4 used). Remove the regulator from the main pump.
11. Remove O-ring (15) from inner stopper (14). 12. Remove spring (20) from casing (00).
l : 8 mm
IMPORTANT: As the setting changes, do not turn nut (11) and adjusting screw (10). 13. Remove socket bolts (22) (4 used). Remove front cover (09) from casing (00).
2. Remove pressure sensor (52) from casing (00). j : 27 mm 3. Remove plug (46) from casing (00).
l : 6 mm
j : 27 mm 4. Remove O-ring (47) from plug (46). 5. Remove socket bolts (43) (4 used). Remove solenoid valve block (39) from casing (00). l : 6 mm
14. Remove cylinder (06), spool (03), and sleeve (02) from casing (00). 15. Remove piston (05) and O-ring (07) from cylinder (06).
6. Remove O-ring (40), O-ring (42), and O-rings (41) (2 used) from solenoid valve block (39). 7. Remove plugs (26) (4 used) from casing (00). l : 5 mm 8. Remove O-rings (27) (4 used) from plugs (26) (4 used). IMPORTANT: As the setting changes, do not turn nut (17), nut (18), and stopper (13). 9. Remove socket bolts (22) (4 used). Remove rear cover (16) from casing (00). l : 6 mm
W3-8-4-3
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Assembly of Regulator for Main Pump 26, 27
24
07 20
22
00
17 18
09 11
14
10
13
22
16
15
02
03 05 06
50
07 26, 27
WJBC-03-09-015
52
46, 47
WJBC-03-09-013
W3-8-4-4
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 00- 02- 03- 05- 06- 07- 09- 10-
Casing Sleeve Spool Piston Cylinder O-Ring (2 Used) Front Cover Adjusting Screw
11- 13- 14- 15- 16- 17- 18- 20-
Nut Stopper Inner Stopper O-Ring Rear Cover Nut Nut Spring
22- 24- 26- 27- 39- 40- 41- 42-
Socket Bolt (8 Used) Plug (2 Used) Plug (4 Used) O-Ring (4 Used) Solenoid Valve Block O-Ring O-Ring (2 Used) O-Ring
W3-8-4-5
43- 46- 47- 50- 52-
Socket Bolt (4 Used) Plug O-Ring Socket Bolt (4 Used) Pressure Sensor
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Assembly of Regulator for Main Pump IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install O-ring (07) and piston (05) to cylinder (06).
10. Install O-ring (40), O-ring (42), and O-rings (41) (2 used) to solenoid valve block (39). 11. Install solenoid valve block (39) to casing (00) with socket bolts (43) (4 used). l : 6 mm
2. Install sleeve (02), spool (03), and cylinder (06) to casing (00).
m : 30 N·m (3 kgf·m, 22 lbf·ft)
3. Install front cover (09) to casing (00) with socket bolts (22) (4 used).
12. Install O-ring (47) to plug (46). 13. Install plug (46) to casing (00).
l : 6 mm
j : 27 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
4. Install spring (20) to casing (00).
14. Install pressure sensor (52) to casing (00).
5. Install O-ring (15) to inner stopper (14).
j : 27 mm
6. Install O-ring (07) and inner stopper (14) to stopper (13). 7. Install rear cover (16) to casing (00) with socket bolts (22) (4 used).
m : 40 N·m (4 kgf·m, 30 lbf·ft) 15. Install the regulator to the main pump with socket bolts (50) (4 used).
l : 6 mm
l : 8 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)
8. Install O-rings (27) (4 used) to plugs (26) (4 used). 9. Install plugs (26) (4 used) to casing (00). l : 5 mm m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
W3-8-4-6
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Disassembly of Fan Pump
WJBC-03-09-008
W3-8-5-1
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 01- Regulator 011- Plunger (9 Used) 014A- Cylinder Block 014B- Valve Plate 030A- Swash Plate 030B- Bushing 111- Shaft 116- Coupling 123- Roller Bearing 124- Needle Bearing 127- Spacer 153- Plate 156- Bushing 157- Spring (6 Used)
211- Plate 251- Support 257A- Lock Pin 257B- O-Ring 261- Cover 271- Casing 312- Cover 401- Socket Bolt (2 Used) 402- Socket Bolt (2 Used) 406- Socket Bolt (4 Used) 465- Plug 466- Plug (2 Used) 467- Plug 468- Plug (2 Used)
490- Plug (2 Used) 530A- Tilt Pin 530B- Pin 532- Servo Piston 534- Stopper 550A- Plug 550B- Stopper 550C- O-Ring 550D- O-Ring 550E- Backup Ring 550F- Nut 550G- Adjusting Screw 702- O-Ring 710- O-Ring
W3-8-5-2
717- O-Ring 723- O-Ring (4 Used) 724- O-Ring (7 Used) 727- O-Ring (2 Used) 732- O-Ring 774- Oil Seal 792- Backup Ring 808- Nut 824- Retaining Ring 827- Ring 886- Pin (2 Used) 901- Eyebolt 954- Adjusting Screw
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Disassembly of Fan Pump
9. Remove O-ring (717), O-rings (723) (2 used), and O-rings (724) (6 used) from casing (271).
1. Remove coupling (116) from shaft (111). 2. Remove ring (827) from coupling (116). 3. Remove plugs (468) (2 used) from casing (271). Drain off hydraulic oil from the fan pump. Remove O-rings (727) (2 used) from plugs (468) (2 used). l : 10 mm
11. Remove plungers (011) (9 used) and plate (153), bushing (156), and springs (157) (6 used) from cylinder block (014A). 12. Remove socket bolts (406) (4 used).
4. Remove regulator (01) from casing (271). (Refer to W3-8-6.)
dCAUTION: kg (95 lb)
10. Remove the cylinder block (014A) assembly from casing (271).
The casing (271) assembly weight: 43
5. Attach a nylon sling onto the body of casing (271). Place the casing (271) assembly with the regulator (01) side down. IMPORTANT: Do not drop valve plate (014B). As the setting changes, do not remove nut (808) and adjusting screw (954). 6. Remove socket bolts (401, 402) (2 used for each). Remove cover (312) from casing (271). l : 14 mm
l : 5 mm IMPORTANT: Do not damage the lip part of oil seal (774). 13. Remove the cover (261) assembly from casing (271). IMPORTANT: Do not remove oil seal (774) unless necessary. Oil seal (774) cannot be reused. 14. Remove O-ring (710) and oil seal (774) from cover (261). 15. Tap and remove the shaft (111) assembly from casing (271) by using a plastic hammer. 16. Remove retaining ring (824), spacer (127), and roller bearing (123) from shaft (111).
7. Remove valve plate (014B) from cover (312). IMPORTANT: Do not remove needle bearing (124) unless necessary. Needle bearing (124) cannot be reused. 8. Remove needle bearing (124) from cover (312).
W3-8-5-3
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device IMPORTANT: Do not remove bushing (030B) unless necessary. 17. Remove plate (211) and swash plate (030A) from casing (271). 18. Insert the wire into hole (a) of lock pin (257A). Remove lock pin (257A) from casing (271).
23. Remove O-ring (550C) and backup ring (550E) from stopper (550B). 24. Remove stopper (534) from casing (271). 25. Remove O-ring (702) and backup ring (792) from stopper (534). IMPORTANT: Do not remove servo piston (532) and tilt pin (530A) unless necessary. Do not damage servo piston (532). 26. Warm up tilt pin (530A) by using a drier. Remove tilt pin (530A) from servo piston (532). Remove servo piston (532) and tilt pin (530A) from casing (271).
251 a 271
#1305N has been applied fNOTE: THREEBOND between servo piston (532) and tilt pin (530A). a-
Hole of Lock Pin (257A)
WJBC-03-09-009
19. Remove O-ring (257B) from lock pin (257A). 20. Remove support (251) from casing (271). IMPORTANT: As the setting changes, do not remove nut (550F) and adjusting screw (550G). 21. Remove plug (550A) from casing (271). j : 41 mm 22. Remove O-ring (550D) and stopper (550B) from plug (550A).
W3-8-5-4
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Assembly of Fan Pump 550D 550G 550F 550B 550A 550E 550C 532 030B 530B 530A 011 702 792 534 808 954 490
724 717 723 312
257A 257B 261 123 824
827 116
124
111
014B 886
774 127 406
710 251 030A 271 211 153 468, 727
155
467, 732 157 014A 402
465, 724
466, 723 901
401
466, 723
WJBC-03-09-010
W3-8-5-5
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 01- Regulator 011- Plunger (9 Used) 014A- Cylinder Block 014B- Valve Plate 030A- Swash Plate 030B- Bushing 111- Shaft 116- Coupling 123- Roller Bearing 124- Needle Bearing 127- Spacer 153- Plate 156- Bushing 157- Spring (6 Used)
211- Plate 251- Support 257A- Lock Pin 257B- O-Ring 261- Cover 271- Casing 312- Cover 401- Socket Bolt (2 Used) 402- Socket Bolt (2 Used) 406- Socket Bolt (4 Used) 465- Plug 466- Plug (2 Used) 467- Plug 468- Plug (2 Used)
490- Plug (2 Used) 530A- Tilt Pin 530B- Pin 532- Servo Piston 534- Stopper 550A- Plug 550B- Stopper 550C- O-Ring 550D- O-Ring 550E- Backup Ring 550F- Nut 550G- Adjusting Screw 702- O-Ring 710- O-Ring
W3-8-5-6
717- O-Ring 723- O-Ring (4 Used) 724- O-Ring (7 Used) 727- O-Ring (2 Used) 732- O-Ring 774- Oil Seal 792- Backup Ring 808- Nut 824- Retaining Ring 827- Ring 886- Pin (2 Used) 901- Eyebolt 954- Adjusting Screw
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Assembly of Fan Pump
9. Install O-ring (257B) to lock pin (257A).
IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Apply THREEBOND #1305N onto servo piston (532) and tilt pin (530A). 2. Install servo piston (532) and tilt pin (530A) to casing (271). 3. Install backup ring (792) and O-ring (702) to stopper (534). 4. Install stopper (534) to casing (271). 5. Install backup ring (550E) and O-ring (550C) to stopper (550B).
10. Install lock pin (257A) to casing (271). 11. Install swash plate (030A) and plate (211) to casing (271). 12. Install roller bearing (123), spacer (127), and retaining ring (824) to shaft (111). 13. Install the shaft (111) assembly to casing (271) by using a plastic hammer. 14. Install oil seal (774) and O-ring (710) to cover (261). 15. Install the cover (261) assembly to casing (271) with socket bolts (406) (4 used). l : 5 mm
6. Install stopper (550B) and O-ring (550D) to plug (550A). 7. Install plug (550A) to casing (271). j : 41 mm m : 220 N·m (22 kgf·m, 162 lbf·ft) 8. Install support (251) to casing (271).
m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft) 16. Install springs (157) (6 used), bushing (156), plate (153), and plungers (011) (9 used) to cylinder block (014A). 17. Install the cylinder block (014A) assembly to casing (271). 18. Install O-ring (717), O-rings (723) (2 used), and O-rings (724) (6 used) to casing (271).
W3-8-5-7
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 19. Install needle bearing (124) to cover (312). 20. Install valve plate (014B) to cover (312). 21. Install cover (312) to casing (271) with socket bolts (401, 402) (2 used for each). l : 14 mm m : 240 N·m (24 kgf·m, 177 lbf·ft)
dCAUTION: kg (95 lb)
The casing (271) assembly weight: 43
22. Attach a nylon sling onto the body of casing (271). Place the casing (271) assembly with the regulator (01) side up. 23. Install regulator (01) to casing (271). (Refer to W38-6.) 24. Install O-rings (727) (2 used) to plugs (468) (2 used). 25. Fill hydraulic oil in the fan pump. 26. Install plugs (468) (2 used) to casing (271). l : 10 mm m : 110 N·m (11 kgf·m, 81 lbf·ft) 27. Install ring (827) to coupling (116). 28. Install coupling (116) to shaft (111).
W3-8-5-8
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Disassembly of Regulator for Fan Pump
WJBC-03-09-011
041A- Seat (2 Used) 041B- Stopper (2 Used) 041C- Steel Ball (2 Used) 079- Pump Control Solenoid Valve 325- Casing 402- Socket Bolt (4 Used) 407- Socket Bolt (4 Used) 415- Socket Bolt (4 Used) 418- Socket Bolt (2 Used)
466- Plug 496- Plug (9 Used) 601- Casing 611- Feedback Lever 614- Support Plug 616- Plug 624- Spring Seat 627- Rod 631- Sleeve
643- Piston 646- Spring 651- Sleeve 652- Spool 656- Cover 658- Plug 708- O-Ring 724- O-Ring (5 Used) 726- O-Ring
W3-8-6-1
731- O-Ring 733- O-Ring 754- O-Ring (2 Used) 755- O-Ring (3 Used) 801- Nut 875- Pin 887- Pin 897- Pin 924- Adjusting Screw
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Disassembly of Regulator for Fan Pump
10. Remove O-ring (731), sleeve (631), and piston (643) from casing (325).
IMPORTANT: Do not remove pin (887) unless necessary. 1. Remove socket bolts (415) (4 used). Remove the regulator from the fan pump.
IMPORTANT: As the setting changes, do not turn nut (801) and adjusting screw (924). 11. Remove socket bolts (402) (4 used). Remove cover (656) from casing (601).
l : 6 mm 2. Remove O-ring (724), O-ring (755), and O-rings (754) (2 used) from casing (601). 3. Remove seat (041A), steel ball (041C), and stopper (041B) from casing (601). 4. Remove socket bolts (418) (2 used). Remove pump control solenoid valve (079) from casing (325). l : 4 mm
l : 5 mm 12. Remove rod (627), spring (646), and spring seat (624) from casing (601). 13. Remove O-ring (733) from rod (627). 14. Remove O-rings (724) (2 used) from casing (601). 15. Remove plug (616) from support plug (614).
5. Remove plug (466) from casing (325).
Remove support plug (614) from casing (601). l : 6 mm
l : 6 mm
16. Remove O-ring (726) from support plug (614).
6. Remove O-ring (755) from plug (466). 7. Remove socket bolts (407) (4 used). Remove casing (325) from casing (601).
IMPORTANT: Do not remove pin (897) unless necessary. 17. Remove feedback lever (611) from casing (601). 18. Remove spool (652) and sleeve (651) from casing (601).
l : 5 mm 8. Remove O-ring (755) and O-rings (724) (2 used) from casing (601). 9. Remove seat (041A), steel ball (041C), and stopper (041B) from casing (601).
W3-8-6-2
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Assembly of Regulator for Fan Pump Section A
897 755 466
041A
041B
496 601 496
415
041B 041C
614 616 726
755 041C
755
708
724 611 875
WJAA-03-09-003
041A WJAA-03-09-002
496
418 079
651
652
624 646
627 733 656
325 402
731 631 643
801 924
A
407 724
754
658
887
754 WJAA-03-09-001
W3-8-6-3
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 041A- Seat (2 Used) 041B- Stopper (2 Used) 041C- Steel Ball (2 Used) 079- Pump Control Solenoid Valve 325- Casing 402- Socket Bolt (4 Used) 407- Socket Bolt (4 Used) 415- Socket Bolt (4 Used) 418- Socket Bolt (2 Used)
466- Plug 496- Plug (9 Used) 601- Casing 611- Feedback Lever 614- Support Plug 616- Plug 624- Spring Seat 627- Rod 631- Sleeve
643- Piston 646- Spring 651- Sleeve 652- Spool 656- Cover 658- Plug 708- O-Ring 724- O-Ring (5 Used) 726- O-Ring
W3-8-6-4
731- O-Ring 733- O-Ring 754- O-Ring (2 Used) 755- O-Ring (3 Used) 801- Nut 875- Pin 887- Pin 897- Pin 924- Adjusting Screw
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Assembly of Regulator for Fan Pump IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install sleeve (651) and spool (652) to casing (601).
11. Install stopper (041B), steel ball (041C), and seat (041A) to casing (601). 12. Install O-ring (755) and O-rings (724) (2 used) to casing (601). 13. Install casing (325) to casing (601) with socket bolts (407) (4 used).
2. Fit and install pin (897) of feedback lever (611) to the pin (897) hole on sleeve (651). 3. Install O-ring (726) to support plug (614).
l : 5 mm
4. Move feedback lever (611) so that the support plug (614) hole on feedback lever (611) can be seen from the mounting hole on support plug (614). Install support plug (614) to casing (601) while fitting support plug (614) to the support plug (614) hole on feedback lever (611).
m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft) 14. Install O-ring (755) to plug (466). 15. Install plug (466) to casing (325). l : 6 mm m : 35 N·m (3.5 kgf·m, 26 lbf·ft)
l : 6 mm
16. Install pump control solenoid valve (079) to casing (325) with socket bolts (418) (2 used).
m : 36 N·m (3.6 kgf·m, 27 lbf·ft) 5. Install plug (616) to support plug (614).
l : 4 mm
6. Install O-rings (724) (2 used) to casing (601).
m : 7 N·m (0.7 kgf·m, 5.2 lbf·ft)
7. Install O-ring (733) to rod (627). 8. Install spring seat (624), spring (646), and rod (627) to casing (601).
17. Install stopper (041B), steel ball (041C), and seat (041A) to casing (601).
9. Install cover (656) to casing (601) with socket bolts (402) (4 used).
18. Install O-ring (724), O-ring (755), and O-rings (754) (2 used) to casing (601). 19. Install the regulator to the fan pump with socket bolts (415) (4 used).
l : 5 mm m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft)
l : 6 mm
10. Install piston (643), sleeve (631), and O-ring (731) to casing (325).
W3-8-6-5
m : 29 N·m (2.9 kgf·m, 21 lbf·ft)
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device (Blank)
W3-8-6-6
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Structure of Pilot Pump
WJBC-03-09-012
W3-8-7-1
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Tightening Torque No.
Part Name
Q’ty
01
Front Cover
1
02
Rear Cover
1
03
Body
1
04
Drive Gear
1
05
Gear
1
06
Plate
2
50
Gasket
2
51
Gasket
2
52
Socket Bolt
4
53
Washer
4
54
Oil Seal
1
55
Retaining Ring
1
Wrench Size (mm)
l : 10
W3-8-7-2
N·m
(kgf·m, lbf·ft)
90
(9, 66)
Remark
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Removal and Installation of Control Valve 3
2
1
6
4
5
4
WJBE-03-16-003
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) CAUTION: Bleed air from the hydraulic oil tank. d(Refer to W1-4-1.) d CAUTION: Cover (1) weight: 25 kg (56 lb) 2. Remove bolts, washers (2) (7 used) and washers (3) (7 used). Remove cover (1). j : 19 mm 3. Remove bolts, washers (4) (6 used) and washers (5) (4 used). Remove cover (6). j : 19 mm
W3-9-1-1
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
WJBE-03-09-017
4. Remove bolts, washers (12) (2 used). Remove bracket (13).
9. Disconnect the both ends of hoses (16) (2 used). j : 19 mm
j : 17 mm
10. Disconnect hoses (17) (4 used).
5. Remove bolts, washers (14) (2 used). Remove bracket (15).
j : 19 mm 11. Disconnect hose (18).
j : 17 mm
j : 17 mm
6. Place a container under control valve (64). 7. Remove signal control valve (20). (Refer to W3-13-1.) 8. Remove 2-spool solenoid valve unit (19). (Refer to W3-12-3.)
W3-9-1-2
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
26
82
25
23
87 24
22
21
86
WJBE-03-09-001
12. Remove coupling (86). 13. Remove socket bolts (21) (4 used). Disconnect pipe (22). Remove O-ring (23). l : 10 mm 14. Remove coupling (82). 15. Remove bolts (24) (4 used) and washers (87) (4 used). Disconnect pipe (25). Remove O-ring (26). j : 19 mm
W3-9-1-3
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 63 65 66
67
68
67
WJBE-03-09-002
16. Remove bolt (63), washer (65), and clamps (66, 68). j : 19 mm 17. Disconnect the control valve side of hoses (67) (4 used). j : 36 mm
W3-9-1-4
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
WJBE-03-09-003
18. Remove bolt, washer (27). Remove clip (28).
117, 118 41
117, 118
89, 90
40
89, 90
38, 39
WJAA-03-10-026
26. Remove bolts, washers (89) (2 used) and clips (90) (2 used).
j : 17 mm
j : 17 mm
19. Remove bolt, washer (29). Remove clip (30).
27. Remove bolt, washer (38). Remove clip (39).
j : 17 mm
j : 17 mm
20. Remove bolt, washer (79). Remove clip (80).
28. Remove bolts, washers (40) (2 used). Remove the bracket (41) assembly.
j : 17 mm 21. Disconnect connectors (31) (3 used).
j : 19 mm
22. Disconnect hoses (36) (2 used). j : 41 mm 23. Remove socket bolts (32) (4 used) and flanges (33) (2 used). Disconnect hose (34). Remove O-ring (35). l : 12 mm 24. Disconnect hoses (37) (2 used). j : 17 mm 25. Remove bolts, washers (117) (2 used) and clips (118) (2 used). j : 17 mm
W3-9-1-5
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
94, 95
WJBE-03-09-004
29. Remove socket bolts (42) (20 used) and flanges (43) (10 used). Disconnect hoses (44) (5 used). Remove O-rings (45) (5 used). l : 12 mm 30. Remove socket bolts (52) (8 used). Disconnect the pipe (50) assembly. Remove O-rings (51) (2 used). l : 12 mm 31. Remove socket bolts (46) (4 used). Disconnect the pipe (47) assembly. Remove O-ring (48).
53
55
83, 84
94, 95
54
WJBE-03-09-005
32. Remove bolts, washers (94) (2 used) and clips (95) (2 used). j : 17 mm 33. Remove bolts, washers (83) (2 used) and clip (84). j : 19 mm 34. Remove bolts, washers (53, 54) (2 used for each). Remove bracket (55).
l : 12 mm
W3-9-1-6
j : 19 mm
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
WJBE-03-09-006
35. Remove socket bolts (72) (4 used). l : 12 mm 36. Remove socket bolts (75) (4 used) and flanges (76) (2 used). Disconnect pipe (73). Remove O-rings (74, 77). l : 12 mm 37. Remove socket bolts (69) (4 used). Disconnect the pipe (70) assembly. Remove O-ring (71). l : 12 mm 38. Remove socket bolts (58) (20 used) and flanges (59) (10 used). Disconnect hoses (60) (5 used). Remove O-rings (61) (5 used). l : 12 mm 39. Remove bolts, washers (56) (2 used). Remove bracket (57). j : 19 mm 40. Disconnect hoses (62) (6 used). j : 17 mm
W3-9-1-7
WJBE-03-09-007
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
WJBE-03-09-008
41. Disconnect hose (49). j : 19 mm 42. Remove bolt, washer (120) and clip (121). j : 17 mm 43. Disconnect hose (88). j : 17 mm 44. Remove bolt, washer (122) and clips (123, 124). j : 17 mm 45. Remove bolts, washers (103) (2 used) and clips (104) (2 used). j : 17 mm 46. Disconnect hose (102). j : 27 mm
W3-9-1-8
49
WJBE-03-09-018
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 96
97,98
99
WJBE-03-09-009
CAUTION: Remove cover (96) while holding it. dDo not drop cover (96). 47. Remove bolts, washers (97) (8 used) and washers (98) (8 used). Remove cover (96). j : 19 mm 48. Disconnect connector (99).
W3-9-1-9
WJBE-03-09-010
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve a
64
a - Lifting Hole
100, 101
WJBE-03-09-011
49. Remove bolt, washer (100) and clip (101). j : 17 mm CAUTION: The control valve (64) assembly dweight: 515 kg (1140 lb) 50. Install eyebolts (M12, Pitch 1.75 mm) (3 used) to lifting holes (a) (3 places) of control valve (64). Attach nylon slings onto the eyebolts (3 used). Hoist and hold the control valve (64) assembly.
W3-9-1-10
a
WJAA-03-10-032
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 64 91
93
92 93
115 WJBE-03-09-019
51. Remove bolts (91) (4 used) and spacers (93) (4 used).
fNOTE: used).
LOCTITE #262 has been applied onto bolts (91) (4
j : 30 mm 52. Remove bolts (92) (4 used) and spacers (93) (4 used). Place wooden blocks under bracket (115) so that the control valve (64) assembly is horizontal. Place the control valve (64) assembly on a workbench.
fNOTE: used).
LOCTITE #262 has been applied onto bolts (92) (2
j : 30 mm
W3-9-1-11
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
WJBE-03-09-012
53. Disconnect hoses (105) (3 used). j : 17 mm 54. Disconnect hoses (107) (6 used). j : 19 mm 55. Disconnect the both ends of hose (106). j : 17 mm
W3-9-1-12
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
WJBE-03-09-013
56. Disconnect hoses (125) (5 used). j : 17 mm
W3-9-1-13
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
WJBE-03-09-014
57. Disconnect the both ends of hoses (126) (2 used). j : 17 mm 58. Disconnect the both ends of hose (127). j : 19 mm
W3-9-1-14
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
WJBE-03-09-015
59. Disconnect the both ends of hose (108). j : 17 mm 60. Disconnect the both ends of hoses (109) (2 used). j : 19 mm 61. Disconnect hoses (110) (6 used). j : 19 mm 62. Disconnect hoses (111) (2 used). j : 17 mm
W3-9-1-15
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
a
64
a WJBE-03-09-016
a-
63. Disconnect connectors (116) (3 used).
dCAUTION: lb)
Control valve (64) weight: 430 kg (950
64. Install eyebolts (M12, Pitch 1.75 mm) (3 used) to lifting holes (a) (3 places) of control valve (64). Attach nylon slings onto the eyebolts (3 used). Hoist and hold control valve (64). 65. Remove bolts (112) (4 used) and spacers (113) (4 used). Remove control valve (64) from brackets (114, 115).
fNOTE:
LOCTITE #262 has been applied on bolt (112).
j : 30 mm 66. Remove the adapter with control valve (64) attached if necessary.
W3-9-1-16
Lifting Hole
WJAA-03-10-032
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
a
64
a a- WJBE-03-09-016
Installation 1. Install all removed adapters to control valve (64).
dCAUTION: lb)
Control valve (64) weight: 430 kg (950
2. Install eyebolts (M12, Pitch 1.75 mm) (3 used) to lifting holes (a) (3 places) of control valve (64). Attach nylon slings onto the eyebolts (3 used). Hoist and hold control valve (64). 3. Apply LOCTITE #262 onto bolts (112) (4 used). Install control valve (64) to brackets (114, 115) with spacers (113) (4 used) and bolts (112) (4 used). j : 30 mm m : 400 N·m (40 kgf·m, 300 lbf·ft) 4. Connect connectors (116) (3 used).
W3-9-1-17
Lifting Hole
WJAA-03-10-032
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
WJBE-03-09-015
5. Connect hoses (111) (2 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 6. Connect hoses (110) (6 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 7. Connect the both ends of hoses (109) (2 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 8. Connect the both ends of hose (108). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
W3-9-1-18
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
WJBE-03-09-014
9. Connect the both ends of hose (127). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 10. Connect the both ends of hoses (126) (2 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
W3-9-1-19
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
WJBE-03-09-013
11. Connect hoses (125) (5 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
W3-9-1-20
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
WJBE-03-09-012
12. Connect the both ends of hose (106). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 13. Connect hoses (107) (6 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 14. Connect hoses (105) (3 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
W3-9-1-21
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 64 91
a
93
92 64 93
a a- WJBE-03-09-019
CAUTION: The control valve (64) assembly dweight: 515 kg (1140 lb) 15. Install eyebolts (M12, Pitch 1.75 mm) (3 used) to lifting holes (a) (3 places) of control valve (64). Attach nylon slings onto the eyebolts (3 used). Hoist the control valve (64) assembly. 16. Apply LOCTITE #262 onto bolts (92) (4 used). Install the control valve (64) assembly with spacers (93) (4 used) and bolts (92) (4 used). j : 30 mm m : 400 N·m (40 kgf·m, 300 lbf·ft) 17. Apply LOCTITE #262 onto bolts (91) (4 used). Install spacers (93) (4 used) and bolts (91) (4 used). j : 30 mm m : 400 N·m (40 kgf·m, 300 lbf·ft)
W3-9-1-22
Lifting Hole
WJAA-03-10-032
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 99
100, 101
WJBE-03-09-011
18. Install bolt, washer (100) and clip (101). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 19. Connect connector (99).
W3-9-1-23
WJBE-03-09-010
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
WJBE-03-09-008
20. Connect hose (102). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 21. Install clips (104) (2 used) and bolts, washers (103) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 22. Install clips (123, 124) and bolt, washer (122). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 23. Connect hose (88). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 24. Install clip (121) and bolt, washer (120). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 25. Connect hose (49). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-9-1-24
49
WJBE-03-09-018
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
WJBE-03-09-006
26. Connect hoses (62) (6 used).
WJBE-03-09-007
30. Install O-rings (74, 77) to pipe (73). Connect pipe (73) with flanges (76) (2 used) and socket bolts (75) (4 used).
j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
l : 12 mm
27. Install bracket (57) with bolts, washers (56) (2 used). j : 19 mm
m : 140 N·m (14 kgf·m, 103 lbf·ft) 31. Connect pipe (73) with socket bolts (72) (4 used).
m : 90 N·m (9 kgf·m, 66 lbf·ft)
l : 12 mm
28. Install O-rings (61) (5 used) to hoses (60) (5 used). Connect hoses (60) (5 used) with flanges (59) (10 used) and socket bolts (58) (20 used). l : 12 mm m : 140 N·m (14 kgf·m, 103 lbf·ft) 29. Install O-ring (71) to the pipe (70) assembly. Connect the pipe (70) assembly with socket bolts (69) (4 used). l : 12 mm m : 140 N·m (14 kgf·m, 103 lbf·ft)
W3-9-1-25
m : 140 N·m (14 kgf·m, 103 lbf·ft)
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 94, 95
WJBE-03-09-004
32. Install bracket (55) with bolts, washers (53, 54) (2 used for each).
53
55
94, 95
83, 84
54
WJBE-03-09-005
37. Install O-rings (45) (5 used) to hoses (44) (5 used). Connect hoses (44) (5 used) with flanges (43) (10 used) and socket bolts (42) (20 used).
j : 19 mm
l : 12 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft) 33. Install clamp (84) with bolts, washers (83) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 34. Install clips (95) (2 used) with bolts, washers (94) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 35. Install O-ring (48) to the pipe (47) assembly. Connect the pipe (47) assembly with socket bolts (46) (4 used). l : 12 mm m : 140 N·m (14 kgf·m, 103 lbf·ft) 36. Install O-rings (51) (2 used) to the pipe (50) assembly. Connect the pipe (50) assembly with socket bolts (52) (8 used). l : 12 mm m : 140 N·m (14 kgf·m, 103 lbf·ft)
W3-9-1-26
m : 140 N·m (14 kgf·m, 103 lbf·ft)
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
117, 118 41
117, 118
89, 90
40
89, 90
38, 39
WJAA-03-10-026
38. Install the bracket (41) assembly with bolts, washers (40) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 39. Install clip (39) with bolt, washer (38). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 40. Install clips (90) (2 used) and bolts, washers (89) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 41. Install clips (118) (2 used) and bolts, washers (117) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-9-1-27
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
WJBE-03-09-003
42. Connect hoses (37) (2 used).
47. Install clip (30) with bolt, washer (29).
j : 17 mm
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
43 Install O-ring (35) to hose (34). Connect hose (34) with flanges (33) (2 used) and socket bolts (32) (4 used).
48. Install clip (28) with bolt, washer (27). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
l : 12 mm m : 140 N·m (14 kgf·m, 103 lbf·ft) 44. Connect hoses (36) (2 used). j : 41 mm m : 200 N·m (20 kgf·m, 148 lbf·ft) 45. Connect connectors (31) (3 used). 46. Install clip (80) with bolt, washer (79). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-9-1-28
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 63 65 66
67
68
67
WJBE-03-09-002
49. Connect hoses (67) (4 used). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 50 Install clamps (66, 68), washer (65), and bolt (63). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-9-1-29
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
26
82
25
23
87 24
22
21
86
WJBE-03-09-001
51. Install O-ring (26) to pipe (25). Connect pipe (25) with washers (87) (4 used) and bolts (24) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 52. Install coupling (82). 53. Install O-ring (23) to pipe (22). Connect pipe (22) with socket bolts (21) (4 used). l : 10 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 54. Install coupling (86).
W3-9-1-30
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
WJBE-03-09-017
55. Connect hose (18). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 56. Connect hoses (17) (4 used).
58. Install 2-spool solenoid valve unit (19). (Refer to W312-3.) 59. Install signal control valve (20). (Refer to W3-13-1.) 60. Install bracket (15) with bolts, washers (14) (2 used). j : 17 mm
j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 57. Connect the both ends of hoses (16) (2 used).
m : 50 N·m (5 kgf·m, 37 lbf·ft) 61. Install bracket (13) with bolts, washers (12) (2 used). j : 17 mm
j : 19 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-9-1-31
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 96 3
2
1
6
4
97,98
5
4
WJBE-03-16-003
62. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 63. Install cover (6) with washers (5) (4 used) and bolts, washers (4) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
d CAUTION:
Cover (1) weight: 25 kg (56 lb) 64. Install cover (1) with washers (3) (7 used) and bolts, washers (2) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 65. Install cover (96) with washers (98) (8 used) and bolts, washers (97) (8 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-9-1-32
WJBE-03-09-009
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly and Assembly of Valve Unit 1
A
WJAA-03-10-020
W3-9-2-1
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
13
WJAA-03-10-021
W3-9-2-2
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve View A
54
55 55
56 56 53
56
55
55
54
41
W3-9-2-3
WJAA-03-10-019
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 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- 31- 32- 33- 34-
Housing Spool Spool Spool Spool Spool (2 Used) Cap (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Spacer (2 Used) Spring (2 Used) Check Valve (2 Used) Housing Spool Spool Spool Cap Spring O-Ring (13 Used) Spacer Spool Main Relief Valve Cover O-Ring (18 Used) Spring Guide (18 Used) Spring (9 Used) Cap (9 Used) Cover Cover Cap (8 Used) O-Ring (11 Used) Socket Bolt (26 Used) Plug (4 Used) Cover (2 Used)
35- 36- 37- 38- 39- 40- 41- 42- 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-
Socket Bolt (4 Used) Flange (4 Used) O-Ring (4 Used) Socket Bolt (16 Used) Check Valve Overload Relief Valve (6 Used) O-Ring (14 Used) Backup Ring (10 Used) O-Ring (10 Used) Cap (2 Used) O-Ring (4 Used) Cap (2 Used) Backup Ring (7 Used) Spring (10 Used) Check Valve (7 Used) Socket Bolt (8 Used) Washer (14 Used) Socket Bolt (6 Used) O-Ring O-Ring (2 Used) O-Ring (5 Used) O-Ring (6 Used) Boom Overload Relief Valve Cap (2 Used) Cap (2 Used) O-Ring (12 Used) O-Ring (4 Used) Backup Ring (5 Used) Cap Piston (2 Used) Cap (2 Used) Cap (2 Used) O-Ring (5 Used) Spring (2 Used)
69- 70- 71- 72- 73- 74- 75- 76- 77- 78- 79- 80- 81- 82- 83- 84- 85- 86- 87- 88- 89- 90- 91- 92- 93- 94- 95- 96-
Spool (2 Used) Cap Cap Check Valve (2 Used) Cap (2 Used) Check Valve (2 Used) Cap Sleeve Piston O-Ring (2 Used) Backup Ring (2 Used) Spool (2 Used) Spring O-Ring (3 Used) Spring Guide (2 Used) Sleeve O-Ring (2 Used) Cap (2 Used) Boom 2 Anti-Drift Valve Socket Bolt (5 Used) Spring (3 Used) Poppet (3 Used) O-Ring (2 Used) Spring Sleeve O-Ring (3 Used) Flow Rate Control Valve Flow Rate Control Valve (2 Used) 97- Socket Bolt (12 Used) 98- Spring (3 Used) 99- Piston (3 Used) 100- Check Valve (3 Used) 101- Poppet
102- Poppet 103- Check Valve 104- Piston 105- Cap 106- Backup Ring 107- O-Ring 108- Check Valve 109- Spring 110- Check Valve 111- Arm Rod Anti-Drift Valve 112- Flow Rate Control Valve Assembly 113- Socket Bolt (6 Used) 114- Piston 115- Cap 116- Backup Ring 117- O-Ring (2 Used) 118- Spring (2 Used) 119- Check Valve 120- Poppet 121- Spring 122- Cap 123- Cap 124- Spool 125- Auxiliary Flow Combiner Valve 127- Cap 128- Backup Ring 129- Spacer 130- Check Valve 131- Sleeve 132- Piston
a- b- c- d- e-
Load Check Valve Arm Regeneration Cut Valve Bucket Regeneration Cut Valve Check Valve Flow Combiner Valve
f- g- h- i- j-
Check Valve Bypass Shut-Out Valve Load Check Valve Load Check Valve Boost Check Valve
k- l- m- n- o-
p- q-
Load Check Valve Check Valve Check Valve Check Valve Load Check Valve
W3-9-2-4
Load Check Valve Bypass Shut-Out Valve
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Housing
Disassembly of Housing 1. Remove socket bolt (50) and washer (51) from housing (1). l : 14 mm 2. Remove socket bolts (50) (7 used), socket bolts (52) (6 used), and washers (51) (13 used) from housing (13). l : 14 mm
IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install O-rings (41) (2 used), O-ring (53), O-rings (54) (2 used), O-rings (55) (5 used), and O-rings (56) (6 used) to housing (1). 2. Install housing (13) to housing (1) with socket bolts (50) (7 used), socket bolts (52) (6 used), and washers (51) (13 used).
3. Remove housing (13) from housing (1).
l : 14 mm
4. Remove O-rings (41) (2 used), O-ring (53), O-rings (54) (2 used), O-rings (55) (5 used), and O-rings (56) (6 used) from housing (1).
m : 250 N·m (25 kgf·m, 185 lbf·ft) 3. Install washer (51) and socket bolt (50) to housing (1). l : 14 mm m : 250 N·m (25 kgf·m, 185 lbf·ft)
W3-9-2-5
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve (Blank)
W3-9-2-6
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly of Control Valve (4-Spool Side) a b
f
e
d
c
WJBC-03-10-001
W3-9-3-1
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
13
g
h
WJBC-03-10-002
W3-9-3-2
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 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- 31- 32- 33- 34-
Housing Spool Spool Spool Spool Spool (2 Used) Cap (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Spacer (2 Used) Spring (2 Used) Check Valve (2 Used) Housing Spool Spool Spool Cap Spring O-Ring (13 Used) Spacer Spool Main Relief Valve Cover O-Ring (18 Used) Spring Guide (18 Used) Spring (9 Used) Cap (9 Used) Cover Cover Cap (8 Used) O-Ring (11 Used) Socket Bolt (26 Used) Plug (4 Used) Cover (2 Used)
35- 36- 37- 38- 39- 40- 41- 42- 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-
Socket Bolt (4 Used) Flange (4 Used) O-Ring (4 Used) Socket Bolt (16 Used) Check Valve Overload Relief Valve (6 Used) O-Ring (14 Used) Backup Ring (10 Used) O-Ring (10 Used) Cap (2 Used) O-Ring (4 Used) Cap (2 Used) Backup Ring (7 Used) Spring (10 Used) Check Valve (7 Used) Socket Bolt (8 Used) Washer (14 Used) Socket Bolt (6 Used) O-Ring O-Ring (2 Used) O-Ring (5 Used) O-Ring (6 Used) Boom Overload Relief Valve Cap (2 Used) Cap (2 Used) O-Ring (12 Used) O-Ring (4 Used) Backup Ring (5 Used) Cap Piston (2 Used) Cap (2 Used) Cap (2 Used) O-Ring (5 Used) Spring (2 Used)
69- 70- 71- 72- 73- 74- 75- 76- 77- 78- 79- 80- 81- 82- 83- 84- 85- 86- 87- 88- 89- 90- 91- 92- 93- 94- 95- 96-
Spool (2 Used) Cap Cap Check Valve (2 Used) Cap (2 Used) Check Valve (2 Used) Cap Sleeve Piston O-Ring (2 Used) Backup Ring (2 Used) Spool (2 Used) Spring O-Ring (3 Used) Spring Guide (2 Used) Sleeve O-Ring (2 Used) Cap (2 Used) Boom 2 Anti-Drift Valve Socket Bolt (5 Used) Spring (3 Used) Poppet (3 Used) O-Ring (2 Used) Spring Sleeve O-Ring (3 Used) Flow Rate Control Valve Flow Rate Control Valve (2 Used) 97- Socket Bolt (12 Used) 98- Spring (3 Used) 99- Piston (3 Used) 100- Check Valve (3 Used) 101- Poppet
102- Poppet 103- Check Valve 104- Piston 105- Cap 106- Backup Ring 107- O-Ring 108- Check Valve 109- Spring 110- Check Valve 111- Arm Rod Anti-Drift Valve 112- Flow Rate Control Valve Assembly 113- Socket Bolt (6 Used) 114- Piston 115- Cap 116- Backup Ring 117- O-Ring (2 Used) 118- Spring (2 Used) 119- Check Valve 120- Poppet 121- Spring 122- Cap 123- Cap 124- Spool 125- Auxiliary Flow Combiner Valve 127- Cap 128- Backup Ring 129- Spacer 130- Check Valve 131- Sleeve 132- Piston
a- b- c- d- e-
Load Check Valve Arm Regeneration Cut Valve Bucket Regeneration Cut Valve Check Valve Flow Combiner Valve
f- g- h- i- j-
Check Valve Bypass Shut-Out Valve Load Check Valve Load Check Valve Boost Check Valve
k- l- m- n- o-
p- q-
Load Check Valve Check Valve Check Valve Check Valve Load Check Valve
W3-9-3-3
Load Check Valve Bypass Shut-Out Valve
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly of Check Valve (39)
Disassembly of Control Valve (4-Spool Side)
IMPORTANT: Do not disassemble check valve (39) unless necessary. 8. Remove check valve (39) from housing (13).
Disassembly of Spools (6, 14, 15, and 16) 1. Remove socket bolts (32) (6 used). Remove cover (28) and O-rings (24) (4 used) from housing (13).
j : 41 mm
l : 10 mm 2. Remove socket bolts (32) (3 used) and socket bolts (35) (2 used). Remove cover (34) and O-rings (24) (3 used) from housing (13). l : 10 mm 3. Remove socket bolts (32) (2 used). Remove cover (23) and O-ring (24) from housing (13). l : 10 mm 4. Put the matching marks on housing (13) and spools (6, 14, 15, and 16). IMPORTANT: Do not disassemble spools (6, 14, 15, and 16) unless necessary. 5. Remove spools (6, 14, 15, and 16) from housing (13).
Remove O-rings (41, 43) and backup ring (42) from check valve (39). Disassembly of Main Relief Valve (22) IMPORTANT: As the setting changes, do not disassemble the relief valve. If the relief valve is disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 10. Remove main relief valve (22) from housing (13). j : 41 mm 11. Remove O-ring (19) from main relief valve (22).
Disassembly of Boom Overload Relief Valve (57) IMPORTANT: As the setting changes, do not disassemble the relief valve. If the relief valve is disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 6. Remove boom overload relief valve (57) from housing (13). j : 41 mm 7. Remove O-rings (41, 43), and backup ring (42) from boom overload relief valve (57).
W3-9-3-4
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly of Overload Relief Valve (40)
Disassembly of Bucket Regeneration Cut Valve (c)
IMPORTANT: As the setting changes, do not disassemble the relief valve. If the relief valve is disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 12. Remove overload relief valves (40) (3 used) from housing (13). j : 41 mm
22. Remove sleeve (84) from housing (13). j : 36 mm 23. Remove sleeve (131), spool (80), spring (81), and spring guide (83) from housing (13). 24. Remove piston (132), backup ring (79), and O-ring (78) from sleeve (131). 25. Remove O-ring (82) and cap (86) from sleeve (84).
13. Remove O-rings (41, 43) (3 used for each) and backup rings (42) (3 used) from overload relief valves (40) (3 used).
l : 12 mm 26. Remove O-ring (85) from cap (86).
Disassembly of Load Check Valve (a) 14. Remove cap (123) from housing (13). l : 14 mm 15. Remove spring (48) and check valve (49) from housing (13). 16. Remove O-rings (61, 19) and backup ring (62) from cap (123). Disassembly of Arm Regeneration Cut Valve (b) 17. Remove sleeve (93) from housing (13). j : 36 mm 18. Remove sleeve (76), spool (80), spring (92), and spring guide (83) from housing (13). 19. Remove piston (77), backup ring (79), and O-ring (78) from sleeve (76). 20. Remove O-ring (82) and cap (86) from sleeve (93). l : 12 mm 21. Remove O-ring (85) from cap (86).
W3-9-3-5
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly of Check Valve (d) 27. Remove cap (63) from housing (13). j : 14 mm 28. Remove check valve (49) and spring (48) from housing (13). 29. Remove O-rings (61, 19) and backup ring (62) from cap (63). Disassembly of Flow Combiner Valve (e) 30. Remove cap (17) from housing (13). j : 46 mm 31. Remove spring (18) spacer (20), and spool (21) from housing (13). 32. Remove O-ring (19) from cap (17). Disassembly of Check Valve (f) 33. Remove cap (46) from housing (13). l : 14 mm 34. Remove spring (48) and check valve (49) from housing (13). 35. Remove O-ring (19) and backup ring (47) from cap (46). 36. Remove cap (58) from housing (13). l : 17 mm 37. Remove O-ring (45) from cap (58).
W3-9-3-6
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly of Flow Rate Control Valve (95)
Disassembly of Bypass Shut-Out Valve (g)
IMPORTANT: Do not disassemble flow rate control valve (95) unless necessary. 38. Remove socket bolts (97) (4 used). Remove flow rate control valve (95) from housing (13). l : 12 mm 39. Remove piston (99), spring (98), check valve (100), and poppet (101) from housing (13). 40. Remove O-rings (60, 94) from flow rate control valve (95). Disassembly of Flow Rate Control Valve Assembly (112)
45. Remove cap (65) from housing (13). j : 46 mm 46. Remove spool (69) and spring (68) from housing (13). 47. Remove piston (64), cap (66), and O-ring (67) from cap (65). j : 46 mm 48. Remove O-ring (67) from cap (66). Disassembly of Load Check Valve (h)
IMPORTANT: Do not disassemble flow rate control valve assembly (112) unless necessary. 41. Remove socket bolts (113) (6 used). Remove flow rate control valve assembly (112) from housing (13). l : 12 mm 42. Remove spring (89) and poppet (90) from housing (13).
49. Remove cap (73) from housing (13). l : 14 mm 50. Remove spring (48) and check valve (74) from housing (13). 51. Remove O-ring (19) and backup ring (47) from cap (73).
43. Remove piston (99), spring (98), check valve (100), and piston (114) from housing (13). 44. Remove O-rings (60) (4 used) and O-rings (91, 94) from flow rate control valve assembly (112).
W3-9-3-7
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 52. Remove cap (70) from housing (13). l : 14 mm 53. Remove O-ring (19) and backup ring (47) from cap (70). 54. Remove socket bolts (38) (4 used). l : 12 mm 55. Remove flange (36) from housing (13). 56. Remove O-ring (37) from flange (36). 57. Remove cap (44) from housing (13). j : 46 mm 58. Remove O-ring (45) from cap (44).
W3-9-3-8
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Control Valve (4-Spool Side) 13
A
97
113
35
32
B C D E F G 32
32 TJBA-03-03-005
Section A
13
Section C
24 28
40
14
b
94
15 34 24
H
41 42, 43
101
95
16
49 61, 62
6 23 24
48
98
19
100
TJAA-03-03-009
Section B
99
a
23
WJBC-03-10-006
Section D 39
60 89 90 41 42, 43
36 38
91
37 112 94
g
66 67
99 98 65 67
64 68 69
WJAA-03-10-005
100
114 42, 43 41 57 WJAA-03-10-007
W3-9-3-9
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Section H (Arm Regeneration Cut Valve (b))
Section E 40
I
41 42, 43
86 85 c
74 48 73
83 92 82
93
80
h
47, 19
78, 79
132 131
42, 43 41
WJAA-03-10-009
40
WJAA-03-10-008
Section I (Bucket Regeneration Cut Valve (c))
Section F
86 85
84
70
83 81 82 80
77 76
47, 19 WJAA-03-10-010
58 45 Section G
19 63 d
22 19
48 62, 61 49 44
21
45 49 48 47, 19
20 19 18 46
f 17 e
WJAA-03-10-011
W3-9-3-10
78, 79
WJAA-03-10-009
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 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- 31- 32- 33- 34-
Housing Spool Spool Spool Spool Spool (2 Used) Cap (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Spacer (2 Used) Spring (2 Used) Check Valve (2 Used) Housing Spool Spool Spool Cap Spring O-Ring (13 Used) Spacer Spool Main Relief Valve Cover O-Ring (18 Used) Spring Guide (18 Used) Spring (9 Used) Cap (9 Used) Cover Cover Cap (8 Used) O-Ring (11 Used) Socket Bolt (26 Used) Plug (4 Used) Cover (2 Used)
35- 36- 37- 38- 39- 40- 41- 42- 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-
Socket Bolt (4 Used) Flange (4 Used) O-Ring (4 Used) Socket Bolt (16 Used) Check Valve Overload Relief Valve (6 Used) O-Ring (14 Used) Backup Ring (10 Used) O-Ring (10 Used) Cap (2 Used) O-Ring (4 Used) Cap (2 Used) Backup Ring (7 Used) Spring (10 Used) Check Valve (7 Used) Socket Bolt (8 Used) Washer (14 Used) Socket Bolt (6 Used) O-Ring O-Ring (2 Used) O-Ring (5 Used) O-Ring (6 Used) Boom Overload Relief Valve Cap (2 Used) Cap (2 Used) O-Ring (12 Used) O-Ring (4 Used) Backup Ring (5 Used) Cap Piston (2 Used) Cap (2 Used) Cap (2 Used) O-Ring (5 Used) Spring (2 Used)
69- 70- 71- 72- 73- 74- 75- 76- 77- 78- 79- 80- 81- 82- 83- 84- 85- 86- 87- 88- 89- 90- 91- 92- 93- 94- 95- 96-
Spool (2 Used) Cap Cap Check Valve (2 Used) Cap (2 Used) Check Valve (2 Used) Cap Sleeve Piston O-Ring (2 Used) Backup Ring (2 Used) Spool (2 Used) Spring O-Ring (3 Used) Spring Guide (2 Used) Sleeve O-Ring (2 Used) Cap (2 Used) Boom 2 Anti-Drift Valve Socket Bolt (5 Used) Spring (3 Used) Poppet (3 Used) O-Ring (2 Used) Spring Sleeve O-Ring (3 Used) Flow Rate Control Valve Flow Rate Control Valve (2 Used) 97- Socket Bolt (12 Used) 98- Spring (3 Used) 99- Piston (3 Used) 100- Check Valve (3 Used) 101- Poppet
102- Poppet 103- Check Valve 104- Piston 105- Cap 106- Backup Ring 107- O-Ring 108- Check Valve 109- Spring 110- Check Valve 111- Arm Rod Anti-Drift Valve 112- Flow Rate Control Valve Assembly 113- Socket Bolt (6 Used) 114- Piston 115- Cap 116- Backup Ring 117- O-Ring (2 Used) 118- Spring (2 Used) 119- Check Valve 120- Poppet 121- Spring 122- Cap 123- Cap 124- Spool 125- Cap 126- Auxiliary Flow Combiner Valve 127- Cap 128- Backup Ring 129- Spacer 130- Check Valve 131- Sleeve 132- Piston
a- b- c- d- e-
Load Check Valve Arm Regeneration Cut Valve Bucket Regeneration Cut Valve Check Valve Flow Combiner Valve
f- g- h- i- j-
Check Valve Bypass Shut-Out Valve Load Check Valve Load Check Valve Boost Check Valve
k- l- m- n- o-
p- q-
Load Check Valve Check Valve Check Valve Check Valve Load Check Valve
W3-9-3-11
Load Check Valve Bypass Shut-Out Valve
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Control Valve (4-Spool Side)
Assembly of Bypass Shut-Out Valve (g)
IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install O-ring (45) to cap (44).
9. Install O-ring (67) to cap (66). 10. Install O-ring (67), cap (66), and piston (64) to cap (65).
Install cap (44) to housing (13).
j : 46 mm
j : 46 mm
m : 250 N·m (25 kgf·m, 185 lbf·ft)
m : 250 N·m (25 kgf·m, 185 lbf·ft)
11. Install spring (68) and spool (69) to housing (13).
2. Install O-ring (37) to flange (36).
12. Install cap (65) to housing (13).
3. Install flange (36) to housing (13) with socket bolts (38) (4 used).
j : 46 mm m : 250 N·m (25 kgf·m, 185 lbf·ft)
l : 12 mm m : 140 N·m (14 kgf·m, 103 lbf·ft) 4. Install backup ring (47) and O-ring (19) to cap (70).
Assembly of Flow Rate Control Valve Assembly (112) 13. Install O-rings (91, 94) and O-rings (60) (4 used) to flow rate control valve assembly (112).
5. Install cap (70) to housing (13). l : 14 mm
14. Install piston (114), check valve (100), spring (98), and piston (99) to housing (13).
m : 350 N·m (35 kgf·m, 260 lbf·ft)
15. Install poppet (90) and spring (89) to housing (13). Assembly of Load Check Valve (h) 6. Install backup ring (47) and O-ring (19) to cap (73).
16. Install flow rate control valve assembly (112) to housing (13) with socket bolts (113) (6 used).
7. Install check valve (74) and spring (48) to housing (13). 8. Install cap (73) to housing (13). l : 14 mm m : 350 N·m (35 kgf·m, 260 lbf·ft)
W3-9-3-12
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Flow Rate Control Valve (95)
Assembly of Check Valve (d)
17. Install O-rings (60, 94) to flow rate control valve (95). 18. Install poppet (101), check valve (100), spring (98), and piston (99) to housing (13). 19. Install flow rate control valve (95) to housing (13) with socket bolts (97) (4 used).
28. Install backup ring (62) and O-rings (61, 19) to cap (63). 29. Install spring (48) and check valve (49) to housing (13). 30. Install cap (63) to housing (13).
l : 12 mm
l : 14 mm
m : 140 N·m (14 kgf·m, 103 lbf·ft)
m : 350 N·m (35 kgf·m, 260 lbf·ft)
20. Install O-ring (45) to cap (58).
Assembly of Bucket Regeneration Cut Valve (c)
21. Install cap (58) to housing (13).
31. Install O-ring (85) to cap (86).
l : 17 mm
32. Install cap (86) and O-ring (82) to sleeve (84).
m : 400 N·m (40 kgf·m, 300 lbf·ft)
l : 12 mm
Assembly of Check Valve (f)
m : 180 N·m (18 kgf·m, 133 lbf·ft)
22. Install backup ring (47) and O-ring (19) to cap (46). 23. Install check valve (49) and spring (48) to housing (13). 24. Install cap (46) to housing (13). l : 14 mm
33. Install O-ring (78), backup ring (79), and piston (132) to sleeve (131). 34. Install spring guide (83), spring (81), spool (80), and sleeve (131) to sleeve (84). 35. Install sleeve (84) to housing (13). j : 36 mm
m : 350 N·m (35 kgf·m, 260 lbf·ft)
m : 180 N·m (18 kgf·m, 133 lbf·ft)
Assembly of Flow Combiner Valve (e) 25. Install O-ring (19) to cap (17). 26. Install spool (21), spacer (20), and spring (18) to housing (13). 27. Install cap (17) to housing (13). j : 46 mm m : 250 N·m (25 kgf·m, 185 lbf·ft)
W3-9-3-13
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Arm Regeneration Cut Valve (b)
Assembly of Overload Relief Valve (40)
38. Install O-ring (78), backup ring (79), and piston (77) to sleeve (76).
IMPORTANT: As the setting changes, do not disassemble the relief valve. If the relief valve is disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 44. Install backup rings (42) (3 used) and O-rings (41, 43) (3 used for each) to overload relief valves (40) (3 used).
39. Install spring guide (83), spring (92), spool (80), and sleeve (76) to sleeve (93).
45. Install overload relief valves (40) (3 used) to housing (13).
36. Install O-ring (85) to cap (86). 37. Install cap (86) and O-ring (82) to sleeve (93). l : 12 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)
40. Install sleeve (93) to housing (13).
j : 41 mm
j : 36 mm
m : 100 N·m (10 kgf·m, 74 lbf·ft)
m : 180 N·m (18 kgf·m, 133 lbf·ft)
Assembly of Main Relief Valve (22)
Assembly of Load Check Valve (a) 41. Install backup ring (62) and O-rings (61, 19) to cap (123). 42. Install check valve (49) and spring (48) to housing (13). 43. Install cap (123) to housing (13).
IMPORTANT: As the setting changes, do not disassemble the relief valve. If the relief valve is disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 46. Install O-ring (19) to main relief valve (22). 47. Install main relief valve (22) to housing (13).
l : 14 mm
j : 41 mm
m : 350 N·m (35 kgf·m, 260 lbf·ft)
m : 100 N·m (10 kgf·m, 74 lbf·ft)
W3-9-3-14
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Check Valve (39)
Assembly of Spools (6, 14, 15, and 16)
48. Install backup ring (42) and O-rings (41, 43) to check valve (39).
52. Fit the matching marks made when disassembling and install spools (6, 14, 15, and 16) to housing (13).
49. Install check valve (39) to housing (13).
53. Install O-ring (24) and cover (23) to housing (13) with socket bolts (32) (2 used).
j : 41 mm
l : 10 mm
m : 100 N·m (10 kgf·m, 74 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
Assembly of Boom Overload Relief Valve (57) IMPORTANT: As the setting changes, do not disassemble the relief valve. If the relief valve is disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 50. Install backup ring (42) and O-rings (41, 43) to boom overload relief valve (57). 51. Install boom overload relief valve (57) to housing (13).
54. Install O-rings (24) (3 used) and cover (34) to housing (13) with socket bolts (32) (3 used) and socket bolts (35) (2 used). l : 10 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 55. Install O-rings (24) (4 used) and cover (28) to housing (13) with socket bolts (32) (6 used).
j : 41 mm
l : 10 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 100 N·m (10 kgf·m, 74 lbf·ft)
W3-9-3-15
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve (Blank)
W3-9-3-16
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly of Control Valve (5-Spool Side)
k
i
j
l m
WJBC-03-10-003
W3-9-4-1
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve
1
n
o
p
q
WJAA-03-10-002
W3-9-4-2
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 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- 31- 32- 33- 34-
Housing Spool Spool Spool Spool Spool (2 Used) Cap (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Spacer (2 Used) Spring (2 Used) Check Valve (2 Used) Housing Spool Spool Spool Cap Spring O-Ring (13 Used) Spacer Spool Main Relief Valve Cover O-Ring (18 Used) Spring Guide (18 Used) Spring (9 Used) Cap (9 Used) Cover Cover Cap (8 Used) O-Ring (11 Used) Socket Bolt (26 Used) Plug (4 Used) Cover (2 Used)
35- 36- 37- 38- 39- 40- 41- 42- 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-
Socket Bolt (4 Used) Flange (4 Used) O-Ring (4 Used) Socket Bolt (16 Used) Check Valve Overload Relief Valve (6 Used) O-Ring (14 Used) Backup Ring (10 Used) O-Ring (10 Used) Cap (2 Used) O-Ring (4 Used) Cap (2 Used) Backup Ring (7 Used) Spring (10 Used) Check Valve (7 Used) Socket Bolt (8 Used) Washer (14 Used) Socket Bolt (6 Used) O-Ring O-Ring (2 Used) O-Ring (5 Used) O-Ring (6 Used) Boom Overload Relief Valve Cap (2 Used) Cap (2 Used) O-Ring (12 Used) O-Ring (4 Used) Backup Ring (5 Used) Cap Piston (2 Used) Cap (2 Used) Cap (2 Used) O-Ring (5 Used) Spring (2 Used)
69- 70- 71- 72- 73- 74- 75- 76- 77- 78- 79- 80- 81- 82- 83- 84- 85- 86- 87- 88- 89- 90- 91- 92- 93- 94- 95- 96-
Spool (2 Used) Cap Cap Check Valve (2 Used) Cap (2 Used) Check Valve (2 Used) Cap Sleeve Piston O-Ring (2 Used) Backup Ring (2 Used) Spool (2 Used) Spring O-Ring (3 Used) Spring Guide (2 Used) Sleeve O-Ring (2 Used) Cap (2 Used) Boom 2 Anti-Drift Valve Socket Bolt (5 Used) Spring (3 Used) Poppet (3 Used) O-Ring (2 Used) Spring Sleeve O-Ring (3 Used) Flow Rate Control Valve Flow Rate Control Valve (2 Used) 97- Socket Bolt (12 Used) 98- Spring (3 Used) 99- Piston (3 Used) 100- Check Valve (3 Used) 101- Poppet
102- Poppet 103- Check Valve 104- Piston 105- Cap 106- Backup Ring 107- O-Ring 108- Check Valve 109- Spring 110- Check Valve 111- Arm Rod Anti-Drift Valve 112- Flow Rate Control Valve Assembly 113- Socket Bolt (6 Used) 114- Piston 115- Cap 116- Backup Ring 117- O-Ring (2 Used) 118- Spring (2 Used) 119- Check Valve 120- Poppet 121- Spring 122- Cap 123- Cap 124- Spool 125- Auxiliary Flow Combiner Valve 127- Cap 128- Backup Ring 129- Spacer 130- Check Valve 131- Sleeve 132- Piston
a- b- c- d- e-
Load Check Valve Arm Regeneration Cut Valve Bucket Regeneration Cut Valve Check Valve Flow Combiner Valve
f- g- h- i- j-
Check Valve Bypass Shut-Out Valve Load Check Valve Load Check Valve Boost Check Valve
k- l- m- n- o-
p- q-
Load Check Valve Check Valve Check Valve Check Valve Load Check Valve
W3-9-4-3
Load Check Valve Bypass Shut-Out Valve
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly of Control Valve (5-Spool Side)
Disassembly of Auxiliary Flow Combiner Valve (125)
Disassembly of Spools (2, 3, 4, 5, and 6)
8. Remove auxiliary flow combiner valve (125) from housing (1).
1. Remove socket bolts (32) (6 used). Remove cover (29) and O-rings (24) (5 used) from housing (1).
j : 32 mm
l : 10 mm 2. Remove socket bolts (32) (3 used) and socket bolts (35) (2 used). Remove cover (34) and O-rings (24) (3 used) from housing (1). l : 10 mm 3. Remove socket bolts (32) (4 used). Remove covers (23) (2 used) and O-rings (24) (2 used) from housing (1).
9. Remove O-ring (19) from auxiliary flow combiner valve (125). Disassembly of Boom 2 Anti-Drift Valve (87) IMPORTANT: Do not disassemble boom 2 anti-drift valve (87) unless necessary. 10. Remove socket bolts (88) (4 used). Remove boom 2 anti-drift valve (87) from housing (1). l : 12 mm
l : 10 mm 4. Put the matching marks on housing (1) and spools (2, 3, 4, 5, and 6). IMPORTANT: Do not disassemble spools (2, 3, 4, 5, and 6) unless necessary. 5. Remove spools (2, 3, 4, 5, and 6) from housing (1).
11. Remove spring (89) and poppet (90) from housing (1). 12. Remove O-ring (91) and O-rings (60) (2 used) from boom 2 anti-drift valve (87).
Disassembly of Overload Relief Valve (40) IMPORTANT: As the setting changes, do not disassemble the relief valve. If the relief valve is disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 6. Remove overload relief valves (40) (5 used) from housing (1). j : 41 mm 7. Remove O-rings (41, 43) (5 used for each) and backup rings (42) (5 used) from overload relief valves (40) (5 used).
W3-9-4-4
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly of Load Check Valve (i)
Disassembly of Check Valve (l)
13. Remove cap (105) from housing (1).
22. Remove cap (115) from housing (1).
l : 14 mm
l : 10 mm
14. Remove check valve (108), spring (109), and check valve (110) from housing (1).
23. Remove spring (118) and check valve (119) from housing (1).
15. Remove backup ring (62), O-ring (61), backup ring (62), O-ring (107), backup ring (106), and O-ring (82) from cap (105).
24. Remove O-ring (117) and backup ring (116) from cap (115). Disassembly of Check Valve (m)
Disassembly of Boost Check Valve (j)
25. Remove cap (46) from housing (1).
16. Remove cap (122) from housing (1).
l : 14 mm
j : 36 mm
26. Remove spring (48) and check valve (49) from housing (1).
17. Remove spring (121) and poppet (120) from housing (1).
27. Remove O-ring (19) and backup ring (47) from cap (46).
18. Remove O-ring (67) from cap (122).
28. Remove cap (58) from housing (1).
Disassembly of Load Check Valve (k)
l : 17 mm
19. Remove cap (124) from housing (1).
29. Remove O-ring (45) from cap (58).
l : 14 mm 20. Remove spring (48) and check valve (49) from housing (1). 21. Remove O-rings (61, 19) and backup ring (62) from cap (124).
W3-9-4-5
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly of Arm Rod Anti-Drift Valve (111)
Disassembly of Flow Rate Control Valve (96b)
IMPORTANT: Do not disassemble arm rod anti-drift valve (111) unless necessary. 30. Remove socket bolts (88) (4 used). Remove arm rod anti-drift valve (111) from housing (1).
IMPORTANT: Do not disassemble flow rate control valve (96b) unless necessary. 36. Remove socket bolts (97) (4 used). Remove another flow rate control valve (96b) from housing (1).
l : 12 mm
l : 12 mm
31. Remove spring (89) and poppet (90) from housing (1).
37. Remove piston (99), spring (98), check valve (100), and poppet (102) from housing (1).
32. Remove O-ring (91) and O-rings (60) (3 used) from arm rod anti-drift valve (111).
38. Remove O-rings (60, 94) from flow rate control valve (96b).
Disassembly of Flow Rate Control Valve (96a)
Disassembly of Check Valve (n)
IMPORTANT: Do not disassemble flow rate control valve (96a) unless necessary. 33. Remove socket bolts (97) (4 used). Remove flow rate control valve (96a) from housing (1). l : 12 mm
39. Remove cap (73) from housing (1). l : 14 mm 40. Remove spring (48) and check valve (74) from housing (1). 41. Remove O-ring (19) and backup ring (47) from cap (73).
34. Remove piston (104), spring (48), and check valve (103) from housing (1). 35. Remove O-rings (60, 94) from flow rate control valve (96a).
Disassembly of Load Check Valve (o) 42. Remove cap (75) from housing (1). l : 14 mm 43. Remove check valve (72), spring (48), and check valve (49) from housing (1). 44. Remove O-ring (19) and backup ring (47) from cap (75).
W3-9-4-6
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly of Load Check Valve (p) 45. Remove cap (71) from housing (1). l : 14 mm 46. Remove check valve (72), spring (48), and check valve (49) from housing (1). 47. Remove O-ring (19) and backup ring (47) from cap (71). Disassembly of Bypass Shut-Out Valve (q) 48. Remove cap (65) from housing (1). j : 46 mm 49. Remove spool (69) and spring (68) from housing (1). 50. Remove piston (64), cap (66), and O-ring (67) from cap (65). j : 46 mm 51. Remove O-ring (67) from cap (66). 52. Remove cap (44) from housing (1). j : 46 mm 53. Remove O-ring (45) from cap (44). 54. Remove socket bolts (38) (12 used). l : 12 mm 55. Remove flanges (36) (3 used) from housing (1). Remove O-rings (37) (3 used) from flanges (36) (3 used).
W3-9-4-7
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Control Valve (5-Spool Side) 32
J
1
88
44, 45
97
45, 58
K L M N O P 88 Section J
29 24
TJAA-03-03-007
Section L
1
89 24 23 24
2
60 111 91 94 60 96b
3 34
90
4
102
5 24 23
6
100 99
19 125 98
40
42, 43 41 WJBC-03-10-004
TJBA-03-03-006
Section K
Section M
j 122
60 87
40
k
67 121 120 n 74
41 42,43
19 124 61, 62
91 89 90 73 19, 47
94 96a
48 49
l 119 118 116, 117
60
38 37 36 42, 43 41
103 48
104
WJAA-03-10-012
W3-9-4-8
115
48
40
WJBC-03-10-005
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Section N 40 41 42, 43 37 36 38 19, 47 75
48 o
Q
38 37 36 42, 43 41
49
72
40
TJAA-03-03-017
WJAA-03-10-015
Section O
Section Q i
19 107, 106
82 105
m
62, 61, 62 46
108 19, 47 71
109 110
47
p
49 48
72
WJAA-03-10-016
Section P
67 66
q
64
69
68 67 65
WJAA-03-10-017
W3-9-4-9
48
49
T450-03-03-008
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 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- 31- 32- 33- 34-
Housing Spool Spool Spool Spool Spool (2 Used) Cap (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Spacer (2 Used) Spring (2 Used) Check Valve (2 Used) Housing Spool Spool Spool Cap Spring O-Ring (13 Used) Spacer Spool Main Relief Valve Cover O-Ring (18 Used) Spring Guide (18 Used) Spring (9 Used) Cap (9 Used) Cover Cover Cap (8 Used) O-Ring (11 Used) Socket Bolt (26 Used) Plug (4 Used) Cover (2 Used)
35- 36- 37- 38- 39- 40- 41- 42- 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-
Socket Bolt (4 Used) Flange (4 Used) O-Ring (4 Used) Socket Bolt (16 Used) Check Valve Overload Relief Valve (6 Used) O-Ring (14 Used) Backup Ring (10 Used) O-Ring (10 Used) Cap (2 Used) O-Ring (4 Used) Cap (2 Used) Backup Ring (7 Used) Spring (10 Used) Check Valve (7 Used) Socket Bolt (8 Used) Washer (14 Used) Socket Bolt (6 Used) O-Ring O-Ring (2 Used) O-Ring (5 Used) O-Ring (6 Used) Boom Overload Relief Valve Cap (2 Used) Cap (2 Used) O-Ring (12 Used) O-Ring (4 Used) Backup Ring (5 Used) Cap Piston (2 Used) Cap (2 Used) Cap (2 Used) O-Ring (5 Used) Spring (2 Used)
69- 70- 71- 72- 73- 74- 75- 76- 77- 78- 79- 80- 81- 82- 83- 84- 85- 86- 87- 88- 89- 90- 91- 92- 93- 94- 95- 96-
Spool (2 Used) Cap Cap Check Valve (2 Used) Cap (2 Used) Check Valve (2 Used) Cap Sleeve Piston O-Ring (2 Used) Backup Ring (2 Used) Spool (2 Used) Spring O-Ring (3 Used) Spring Guide (2 Used) Sleeve O-Ring (2 Used) Cap (2 Used) Boom 2 Anti-Drift Valve Socket Bolt (5 Used) Spring (3 Used) Poppet (3 Used) O-Ring (2 Used) Spring Sleeve O-Ring (3 Used) Flow Rate Control Valve Flow Rate Control Valve (2 Used) 97- Socket Bolt (12 Used) 98- Spring (3 Used) 99- Piston (3 Used) 100- Check Valve (3 Used) 101- Poppet
102- Poppet 103- Check Valve 104- Piston 105- Cap 106- Backup Ring 107- O-Ring 108- Check Valve 109- Spring 110- Check Valve 111- Arm Rod Anti-Drift Valve 112- Flow Rate Control Valve Assembly 113- Socket Bolt (6 Used) 114- Piston 115- Cap 116- Backup Ring 117- O-Ring (2 Used) 118- Spring (2 Used) 119- Check Valve 120- Poppet 121- Spring 122- Cap 123- Cap 124- Spool 125- Cap 126- Auxiliary Flow Combiner Valve 127- Cap 128- Backup Ring 129- Spacer 130- Check Valve 131- Sleeve 132- Piston
a- b- c- d- e-
Load Check Valve Arm Regeneration Cut Valve Bucket Regeneration Cut Valve Check Valve Flow Combiner Valve
f- g- h- i- j-
Check Valve Bypass Shut-Out Valve Load Check Valve Load Check Valve Boost Check Valve
k- l- m- n- o-
p- q-
Load Check Valve Check Valve Check Valve Check Valve Load Check Valve
W3-9-4-10
Load Check Valve Bypass Shut-Out Valve
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Control Valve (5-Spool Side)
Assembly of Load Check Valve (o)
IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install O-rings (37) (3 used) to flanges (36) (3 used). 2. Install flanges (36) (3 used) to housing (1) with socket bolts (38) (12 used).
12. Install backup ring (47) and O-ring (19) to cap (75). 13. Install check valve (49), spring (48), and check valve (72) to housing (1). 14. Install cap (75) to housing (1). l : 14 mm
l : 12 mm
m : 350 N·m (35 kgf·m, 260 lbf·ft)
m : 140 N·m (14 kgf·m, 103 lbf·ft) 3. Install O-ring (45) to cap (44).
Assembly of Check Valve (n)
4. Install cap (44) to housing (1).
15. Install backup ring (47) and O-ring (19) to cap (73). 16. Install check valve (74) and spring (48) to housing (1).
j : 46 mm m : 250 N·m (25 kgf·m, 185 lbf·ft)
17. Install cap (73) to housing (1).
Assembly of Bypass Shut-Out Valve (q)
l : 14 mm
5. Install O-ring (67) to cap (66).
m : 350 N·m (35 kgf·m, 260 lbf·ft)
6. Install O-ring (67), cap (66), and piston (64) to cap (65). 7. Install spring (68) and spool (69) to housing (1). 8. Install cap (65) to housing (1). j : 46 mm m : 250 N·m (25 kgf·m, 185 lbf·ft) Assembly of Load Check Valve (p) 9. Install backup ring (47) and O-ring (19) to cap (71). 10. Install check valve (49), spring (48), and check valve (72) to housing (1). 11. Install cap (71) to housing (1). l : 14 mm m : 350 N·m (35 kgf·m, 260 lbf·ft)
W3-9-4-11
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Flow Rate Control Valve (96b)
27. Install O-ring (45) to cap (58).
18. Install O-rings (60, 94) to flow rate control valve (96b).
28. Install cap (58) to housing (1). l : 17 mm
19. Install poppet (102), check valve (100), spring (98), and piston (99) to housing (1). 20. Install flow rate control valve (96b) to housing (1) with socket bolts (97) (4 used).
m : 400 N·m (40 kgf·m, 300 lbf·ft) Assembly of Check Valve (m)
l : 12 mm
29. Install backup ring (47) and O-ring (19) to cap (46).
m : 140 N·m (14 kgf·m, 103 lbf·ft)
30. Install check valve (49) and spring (48) to housing (1). 31. Install cap (46) to housing (1).
Assembly of Flow Rate Control Valve (96a)
l : 14 mm
21. Install O-rings (60, 94) to another flow rate control valve (96a). 22. Install check valve (103), spring (48), and piston (104) to housing (1).
m : 350 N·m (35 kgf·m, 260 lbf·ft) Assembly of Check Valve (l)
23. Install flow rate control valve (96a) to housing (1) with socket bolts (97) (4 used).
32. Install backup ring (116) and O-ring (117) to cap (115).
l : 12 mm
33. Install check valve (119) and spring (118) to housing (1).
m : 140 N·m (14 kgf·m, 103 lbf·ft)
34. Install cap (115) to housing (1).
Assembly of Arm Rod Anti-Drift Valve (111)
l : 10 mm
24. Install O-ring (91) and O-rings (60) (3 used) to arm rod anti-drift valve (111). 25. Install poppet (90) and spring (89) to housing (1). 26. Install arm rod anti-drift valve (111) to housing (1) with socket bolts (88) (4 used). l : 12 mm m : 140 N·m (14 kgf·m, 103 lbf·ft)
W3-9-4-12
m : 80 N·m (8 kgf·m, 59 lbf·ft)
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Load Check Valve (k)
Assembly of Boom 2 Anti-Drift Valve (87)
35. Install backup ring (62) and O-rings (61, 19) to cap (124).
44. Install O-ring (91) and O-rings (60) (2 used) to boom 2 anti-drift valve (87).
36. Install check valve (49) and spring (48) to housing (1).
45. Install poppet (90) and spring (89) to housing (1).
37. Install cap (124) to housing (1).
46. Install boom 2 anti-drift valve (87) to housing (1) with socket bolts (88) (4 used).
l : 14 mm
l : 12 mm
m : 350 N·m (35 kgf·m, 260 lbf·ft)
m : 140 N·m (14 kgf·m, 103 lbf·ft)
Assembly of Boost Check Valve (j)
Assembly of Auxiliary Flow Combiner Valve (125)
38. Install O-ring (67) to cap (122). 39. Install poppet (120) and spring (121) to housing (1). 40. Install cap (122) to housing (1).
47. Install O-ring (19) to auxiliary flow combiner valve (125). 48. Install auxiliary f low combiner valve (125) to housing (1).
j : 36 mm
j : 32 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)
m : 83 N·m (8.3 kgf·m, 61 lbf·ft)
Assembly of Load Check Valve (i) 41. Install O-ring (82), backup ring (106), O-ring (107), backup ring (62), O-ring (61), and backup ring (62) to cap (105). 42. Install check valve (110), spring (109), and check valve (108) to housing (1). 43. Install cap (105) to housing (1). l : 14 mm m : 350 N·m (35 kgf·m, 260 lbf·ft)
W3-9-4-13
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Overload Relief Valve (40) IMPORTANT: As the setting changes, do not disassemble the relief valve. If the relief valve is disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 49. Install backup rings (42) (5 used) and O-rings (41, 43) (5 used for each) to overload relief valves (40) (5 used). 50. Install overload relief valves (40) (5 used) to housing (1). j : 41 mm m : 100 N·m (10 kgf·m, 74 lbf·ft) Assembly of Spools (2, 3, 4, 5, and 6) 51. Fit the matching marks made when disassembling and install spools (2, 3, 4, 5, and 6) to housing (1). 52. Install O-rings (24) (2 used) and covers (23) (2 used) to housing (1) with socket bolts (32) (4 used). l : 10 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 53. Install O-rings (24) (3 used) and cover (34) to housing (1) with socket bolts (32) (3 used) and socket bolts (35) (2 used). l : 10 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 54. Install O-rings (24) (5 used) and cover (29) to housing (1) with socket bolts (32) (6 used). l : 10 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-9-4-14
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Removal and Installation of Swing Device 3
2
1
WJBE-03-16-003
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) dCAUTION: Cover (1) weight: 25 kg (56 lb) 2. Remove bolts, washers (2) (7 used) and washers (3) (7 used). Remove cover (1). j : 19 mm
W3-10-1-1
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device
WJBE-03-10-001
3. Remove bolts, washers (5) (2 used), plates (6) (2 used), spacers (7) (2 used), and clamps (8) (2 used). j : 19 mm 4. Place a container under hose (4). Disconnect hoses (4) (4 used). j : 41 mm
11. Disconnect hose (17). j : 19 mm Swing devices (18, 19) weight: 405 kg dCAUTION: (895 lb) for each 12. Attach nylon slings onto the body of swing motor. Hoist and hold swing device (18). 13. Remove bolts (20) (14 used) and washers (21) (14 used). Remove swing device (18).
5. Place containers under swing devices (18, 19). Disconnect hose (22).
j : 36 mm
j : 41 mm 6. Remove socket bolts (9) (16 used) and flanges (10) (8 used). Disconnect hoses (11) (4 used). Remove O-rings (12) (4 used). l : 8 mm
14. Remove swing device (19) in the same way as step 12 to step 13. 15. Remove the adapter with swing devices (18, 19) attached if necessary.
7. Disconnect hose (13). j : 41 mm 8. Disconnect the both ends of hose (14). j : 27 mm 9. Disconnect hoses (15) (3 used). j : 27 mm 10. Disconnect the both ends of hose (16). j : 19 mm
W3-10-1-2
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device
WJBE-03-10-002
Installation
5. Connect hose (17).
1. Install all removed adapters to swing devices (18, 19).
d
CAUTION: Swing devices (18, 19) weight: 405 kg (895 lb) for each 2. Apply THREEBOND #1102 onto the main frame mounting surface of swing device (18). Attach nylon slings onto the body of swing motor. Hoist swing device (18).
j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 6. Connect the both ends of hose (16). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 7. Connect hoses (15) (3 used).
3. Install swing device (18) with washers (21) (14 used) and bolts (20) (14 used).
j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)
j : 36 mm
8. Connect the both ends of hose (14).
m : 950 N·m (95 kgf·m, 700 lbf·ft)
j : 27 mm
4. Install swing device (19) in the same way as step 2 to step 3.
m : 80 N·m (8 kgf·m, 59 lbf·ft) 9. Connect hose (13). j : 41 mm m : 200 N·m (20 kgf·m, 148 lbf·ft)
W3-10-1-3
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device
3
2
1
WJBE-03-16-003 WJBE-03-10-003
10. Install O-rings (12) (4 used). Connect hoses (11) (4 used) with flanges (10) (8 used) and socket bolts (9) (16 used). l : 8 mm
14. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.
dCAUTION:
Cover (1) weight: 25 kg (56 lb) 15. Install cover (1) with washers (3) (7 used) and bolts, washers (2) (7 used).
m : 50 N·m (5 kgf·m, 37 lbf·ft) 11. Connect hose (22). j : 41 mm
j : 19 mm
m : 200 N·m (20 kgf·m, 148 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
12. Connect hoses (4) (4 used). j : 41 mm m : 200 N·m (20 kgf·m, 148 lbf·ft) 13. Install clamps (8) (2 used), spacers (7) (2 used), plates (6) (2 used), and bolts, washers (5) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-10-1-4
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Disassembly of Swing Device 1
2
3
24 25 28
27
26 4 23
5
22
21
6
20 19
7 18
29
8
17
16
9
15
30
16
31 32
10
14
11
33
12
34
13 35
WJAA-03-11-008 1- 2- 3- 4- 5- 6- 7- 8- 9-
Motor Socket Bolt (12 Used) Ring Gear First Stage Sun Gear Thrust Plate First Stage Carrier Second Stage Sun Gear Thrust Plate Second Stage Carrier
10- 11- 12- 13- 14- 15- 16- 17- 18-
Bolt (2 Used) Lock Plate Bearing Nut Roller Bearing Thrust Plate (3 Used) Planetary Gear (3 Used) Needle Bearing (6 Used) Spring Pin (3 Used) Pin (3 Used)
19- 20- 21- 22- 23- 24- 25- 26- 27-
Thrust Plate (3 Used) Planetary Gear (3 Used) Needle Bearing (3 Used) Spring Pin (3 Used) Pin (3 Used) Socket Bolt (12 Used) Drain Plug Cock Housing
W3-10-2-1
28- 29- 30- 31- 32- 33- 34- 35-
Cork (2 Used) Oil Seal Roller Bearing Screw (4 Used) Magnet (4 Used) Sleeve O-Ring Shaft
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Disassembly of Swing Device
dCAUTION: lb)
Swing device (b) weight: 405 kg (895
3. Remove drain plug (25). Turn cock (26). Drain oil from swing device (b). Remove cock (26) from housing (27). j : 26 mm
1. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to swing device (b). Hoist the swing device.
fNOTE:
a
Drain Plug: R1/2
dCAUTION:
Motor (1) weight: 69 kg (155 lb) 4. Put the matching marks on the jointed part of motor (1) and ring gear (3), and ring gear (3) and housing (27). Remove socket bolts (2) (8 used). Hoist and remove motor (1).
b
l : 10 mm
fNOTE:
a - Eyebolt Mounting Position
WJBC-03-11-002 b - Swing Device
Insert a screwdriver into the clearance between motor (1) and ring gear (3), and float up motor (1) in order to remove easily. 5. Remove first stage sun gear (4). Remove the first stage carrier (6) assembly from ring gear (3).
2. Place swing device (b) on bracket (ST 5106). Secure swing device (b) on a bracket with bolts (M24, Pitch 3.0 mm) (2 used). Secure the bracket on a workbench in order to receive the reaction force. j : 36 mm
b
ST 5106
b - Swing Device
W1V7-02-06-001
W3-10-2-2
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device
dCAUTION:
Ring gear (3) weight: 34 kg (75 lb) 6. Remove socket bolts (24) (12 used). Install eyebolts (M12, Pitch 1.75 mm) to the motor mounting screw part of ring gear (3). Hoist ring gear (3). Remove ring gear (3) from housing (27). l : 17 mm
The housing (27) assembly weight: dCAUTION: 230 kg (510 lb) 10. Install eyebolts (M20, Pitch 2.5 mm) (2 used) to the bolt (24) hole of housing (27). Remove bolts (M24, Pitch 3.0 mm) (2 used) which secure housing (27) and bracket (ST 5106). Hoist the housing (27) assembly and remove the bracket.
fNOTE:
TREEBOND has been applied onto the mating surface of housing (27) and ring gear (3). Insert a screwdriver into the notch between jointed parts and separate the surface in order to remove easily.
j : 36 mm 11. Place block (a) on a press. Place the housing (27) assembly on block (a).
The second stage carrier (9) assembly dCAUTION: weight: 43 kg (95 lb)
27
7. Remove second stage sun gear (7) and the second stage carrier (9) assembly from housing (27). 8. Remove bolts (10) (2 used). Remove lock plate (11) from bearing nut (12). j : 17 mm 9. Remove bearing nut (12) from shaft (35) by using the special tool (ST 2926). 35
a a - Block
ST 2926 W178-02-06-008
W3-10-2-3
W1HH-02-06-012
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device If pushing shaft (35) by using a press dCAUTION: (c), provide a protection cover (b) (outer diameter:
380 mm (15.0 in), inner diameter: 100 mm (3.9 in), thickness: 25 to 30 mm (1.0 to 1.2 in) ). Housing (27) and roller bearing (13) are broken and flown off. The metal fragments may result in personal injury. Press at 30 ton or less. Degrease the housing inside before heating roller bearing (13). Failure to degrease may cause a fire. 12. Cover housing (27) with protection cover (b) and remove shaft (35) by using press (c). At this time, the inner race and sleeve (33) of roller bearing (30) are removed with shaft (35) together.
35
14
27
b
W157-02-06-010 b - Protection Cover
c
b
W1V7-02-06-002 b - Protection Cover c - Press
W3-10-2-4
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device 13. Remove outer race of roller bearing (13) from housing (27).
dCAUTION: (200 lb)
The shaft (35) assembly weight: 90 kg
14. Set a special tool to the shaft (35) assembly.
fNOTE:
Use the following parts as a special tool when removing roller bearing (30). Shaft (b) or bolt: lengh: 270 mm (10.6 in), diameter: 19 mm (0.7 in) (8 used) (All shoud be identical in lengh with no wear and deformation on both ends.) Material: S35C Hose clamp (c): standard diameter: 8-1/2inch (applicable diameter: 720 to 760 mm (28.3 to 29.9 in) (2 used) Guide (d): height: 230 mm (9.1 in), outer diameter: 270 mm (10.6 in), inner diameter: 250 mm (9.8 in)
Push shaft (35) inside the guide by dCAUTION: using a press. 15. Install shaft (35) with a special tool attached to a press (e). Remove the inner race of roller bearing (30). 16. Remove sleeve (33) from shaft (35). Remove the O-ring (34), screws (31) (4 used) and magnets (32) (4 used) from sleeve (33). e
35 30 33
a b
c
d
W157-02-06-014 d - Guide e - Press
W157-02-06-012
35 30 33 c
b d W157-02-06-013 a - Special tool when removing roller bearing (30) b - Shaft
c - Hose Clamp d - Guide
W3-10-2-5
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device 17. Insert a round bar into housing (27). Tap and remove the outer race of roller bearing (30).
dCAUTION:
Housing (27) weight: 135 kg (300 lb) 18. Attach a nylon sling onto the body of housing (27). Hoist and turn over the housing (27). Insert a screwdriver into the notch on housing (27) where oil seal (29) is mounted. Remove oil seal (29).
fNOTE:
THREEBOND has been applied onto the outer surface of oil seal (29). Therefore, the oil seal cannot be reused.
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 19. Tap the outer race of roller bearing (13) by using a bar and a hammer. Remove the outer race from housing (27).
21. Remove pins (23) (3 used), first stage planetary gears (20) (3 used), thrust plates (19) (3 used), and needle bearings (21) (3 used) from first stage carrier (6). 22. Remove thrust plate (5) from first stage carrier (6). Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 23. Remove spring pins (17) (3 used) from second stage carrier (9) by using a round bar and hammer. 24. Remove pins (18) (3 used), second stage planetary gears (15) (3 used), thrust plates (14) (3 used), and needle bearings (16) (6 used) from second stage carrier (9). 25. Remove thrust plate (8) from second stage carrier (9).
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 20. Remove spring pins (22) (3 used) from first stage carrier (6) by using a round bar and hammer.
W3-10-2-6
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Assembly of Swing Device 20 1
23 22 2 21 19
4 6 5
17 15 16
7 9 8
24
3 10 27
14 18
11 12
26 25
13
30 29 33 34
32 31
35
WJBC-03-11-001
1- 2- 3- 4- 5- 6- 7- 8- 9-
Motor Socket Bolt (12 Used) Ring Gear First Stage Sun Gear Thrust Plate First Stage Carrier Second Stage Sun Gear Thrust Plate Second Stage Carrier
10- 11- 12- 13- 14- 15- 16- 17- 18-
Bolt (2 Used) Lock Plate Bearing Nut Roller Bearing Thrust Plate (3 Used) Planetary Gear (3 Used) Needle Bearing (6 Used) Spring Pin (3 Used) Pin (3 Used)
19- 20- 21- 22- 23- 24- 25- 26- 27-
Thrust Plate (3 Used) Planetary Gear (3 Used) Needle Bearing (3 Used) Spring Pin (3 Used) Pin (3 Used) Socket Bolt (12 Used) Drain Plug Cock Housing
W3-10-2-7
28- 29- 30- 31- 32- 33- 34- 35-
Cork (2 Used) Oil Seal Roller Bearing Screw (4 Used) Magnet (4 Used) Sleeve O-Ring Shaft
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Assembly of Swing Device IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install needle bearings (21) (3 used) to first stage planetary gears (20) (3 used). 2. Install thrust plate (5) to first stage carrier (6) with the oil groove up. 3. Install first stage planetary gears (20) (3 used) and thrust plates (5) (3 used) to first stage carrier (6). 4. Fit pin (23) to the spring pin holes on first stage carrier (6). Install pins (23) (3 used) by using a plastic hammer. Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
6. Assemble second stage carrier (9) in the same way as steps 1 to 5. Assemble thrust plate (8), second planetary gears (15) (3 used), needle bearings (16) (6 used), thrust plates (14) (3 used), pins (18) (3 used), and spring pins (17) (3 used). 7. Install O-ring (34), magnets (32) (4 used) and screws (31) (4 used) to sleeve (33).
dCAUTION:
Shaft (35) weight: 69 kg (155 lb) 8. Install sleeve (33) and the inner race of roller bearing (30) to shaft (35). Install the inner race of roller bearing (30) to sleeve (33) by using special tool (ST 7289) and press (b).
fNOTE:
The press-in distance of the inner race of roller bearing (30) can be assured by using the special tool when installing.
such as goggles, helmets, etc in order to prevent personal injury. IMPORTANT: Check the direction of spring pin (22). 5. Install spring pin (22) to first stage carrier (6) with the slit (a) of spring pin (22) facing to the end of pin (23) by using hammer.
b
ST 7289
30 33
22
35
23 a
W1V7-02-06-004
W1V7-02-06-003
b - Press
a - Slit
W3-10-2-8
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device
d
CAUTION: Housing (27) weight: 128 kg (285 lb) 9. Attach a nylon sling onto the body of housing (27). Hoist and place housing (27) with the sleeve (33) mounting side up.
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 10. Evenly tap and install the outer race of roller bearing (30) to housing (27) evenly by using a bar and a hammer. Tap and listen to ring in order to check if the installation is completed.
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 11. Apply THREEBOND #1215 onto the outer surface of oil seal (29). Place oil seal (29) flat on housing (27) and push by hands in gently. Place plate (a) on oil seal (29). Tap it in by using a hammer straight.
a
29
12. Apply grease onto the inner surface of oil seal (29). Therefore, apply grease onto the outer surface of sleeve (33) with shaft (35) attached. 13. Turn over a housing (27). Install eyebolts (M20, Pitch 2.5 mm) (2 used) to the bolt (24) holes of housing (27). Hoist housing (27). Slowly place and install housing (27) to shaft (35). At this time, Check and fit carefully in order not to curl the lip of oil seal (29). Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 14. Evenly tap and install the outer race of roller bearing (13) to housing (27) evenly by using a bar and a hammer. Tap and listen to ring in order to check if the installation is completed.
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 15. Install the inner race of roller bearing (13) to shaft (35) by using a bar and a hammer. Tap the inner race until the upper end on the inner race of roller bearing (14) reaches two threads for bearing nut (12) in shaft.
27
WIHH-02-06-010 a - Plate
W3-10-2-9
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device 16. Install bearing nut (12) to shaft (35) and tighten by hand.
fNOTE:
Prevent shaft (35) from falling off when hoisting housing (27).
The housing (27) assembly weight: dCAUTION: 230 kg (510 lb)
20. Hoist and place the housing (27) assembly on bracket (ST 5106). Install the housing (27) assembly with bolts (M24, Pitch 3.0 mm) (2 used). Secure bracket on a workbench in order to receive the reaction force.
17. Install eyebolts (M20, Pitch 2.5 mm) (2 used) to the bolt (24) hole of housing (27). Hoist and place housing (27) on a press.
j : 36 mm
27 ST 5106
18. Remove bearing nut (12) from shaft (35). 19. Place inner race special tool (ST 7290) onto the roller bearing (13) inner race. Install the inner race by using a press.
fNOTE:
The specified press-in distance of the inner race can be assured by using the special tool when installing.
13
ST 7290
WIHH-02-06-009
W3-10-2-10
W1V7-02-06-001
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device IMPORTANT: Check the direction to install bearing nut (12). 21. Apply grease onto the thread part of bearing nut (12). Install the thread part of bearing nut (12) to shaft (35). At this time, face the step side of bearing nut (12) to the roller bearing (13) side. Tighten bearing nut (13) by using special tool (ST 2926) to the specified torque.
dCAUTION:
Second stage carrier (9) weight: 43 kg IMPORTANT: Check the direction to install second stage carrier (95 lb). 23. Install the second stage carrier (9) assembly to the spline in shaft (35). 9 35
m : 490 N·m (49 kgf·m, 360 lbf·ft)
fNOTE:
torque.
Apply grease for keeping correct tightening 12 W1V7-02-06-005
24. Install second stage sun gear (7) to the second stage carrier (9) assembly. ST 2926 W178-02-06-008
25. Apply THREEBOND #1215 onto the ring gear (3) mounting surface of housing (27). Clean off old adhesive in advance.
22. Install lock plate (11) to bearing nut (12) with bolts (10) (2 used). In case the spline of lock plate (11) and that of shaft (35) are not aligned, tighten bearing nut (12) in tightening direction until both splines are aligned. j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-10-2-11
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device
dCAUTION:
Ring gear (3) weight: 34 kg (75 lb) 26. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the motor mounting screw part of ring gear (3) before hoisting. Fit the matching marks made when disassembling and install ring gear (3) to housing (27). Tighten socket bolts (24) (12 used). l: 17 mm m : 400 N·m (40 kgf·m, 300 lbf·ft) 27. Fit the spline and install the first stage carrier (6) assembly to second stage sun gear (7).
IMPORTANT: Check the direction to install first stage sun gear (4). 28. Install first stage sun gear (4) to the first stage carrier (6) assembly with the step part down. 29. Install cock (26) to housing (27). Install a seal tape onto drain plug (25). Install drain plug (25) to cock (26). j : 26 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
fNOTE:
Drain Plug: R1/2 30. Add gear oil (15.7 L, 4.1 US gal) to housing (27). 31. Apply liquid packing (THREEBOND #1215) onto the motor (1) mounting surface of ring gear (3).
dCAUTION:
Motor (1) weight: 69 kg (155 lb) 32. Hoist motor (1). Fit the matching marks made when diassembling. Install motor (1) to ring gear (3) with socket bolts (2) (12 used). l : 10 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-10-2-12
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Disassembly of Swing Motor 13
11 10 9
8
12
1 7
2 6 3 4
5
14
15
16
19 17
20
18
22
17
30
29
1- 2- 3- 4- 5- 6- 7-
Socket Bolt (3 Used) Swing Parking Brake Selection Valve Casing Oil Seal Bearing Shaft Shoe Plate
8- 9- 10- 11- 12- 13- 14- 15-
Plunger (9 Used) Plate Retainer Rotor Friction Plate (3 Used) Plate (4 Used) Plug (2 Used) O-Ring (2 Used)
28
27
26
25
24
21
16 15
14
23
WJBC-03-11-003
16- 17- 18- 19- 20- 21- 22- 23-
Spring (2 Used) Poppet (2 Used) Valve Casing Socket Bolt (4 Used) O-Ring (2 Used) Plug (2 Used) O-Ring Relief Valve (2 Used)
W3-10-3-1
24- 25- 26- 27- 28- 29- 30-
Bearing Valve Plate Spring (20 Used) Brake Piston O-Ring O-Ring Pin (2 Used)
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Disassembly of Swing Motor
d
CAUTION: The swing motor assembly weight: 71 kg (160 lb) 1. Remove socket bolts (1) (3 used) from swing parking brake selection valve (2). Remove swing parking brake selection valve (2) from casing (3). l : 5 mm
IMPORTANT: Do not disassemble relief valve (23). 2. Remove relief valves (23) (2 used) from valve casing (18).
IMPORTANT: Do not damage the mating surfaces when separating valve plate (25) from valve casing (18) or rotor (11) by using a screwdriver. 8. If valve plate (25) is still attached on rotor (11) in step 7, remove valve plate (25) from the rotor (11) side. Remove springs (26) (20 used). 9. Put the matching marks on casing (3) and brake piston (27). Attach a claw of the special tool (ST 1468) onto the brake piston (27) groove by using the special tool (ST 1468). Raise and remove brake piston (27) from casing (3) straight.
j : 41 mm 3. Remove plug (14) from valve casing (18). Remove O-ring (15) from plug (14).
ST 1468
l : 17 mm
27
4. Remove spring (16) and poppet (17) from valve casing (18). 5. Remove another poppet (17) in the same way as step 3 to step 4. 6. Put the matching marks at the jointed surface between valve casing (18) and casing (3). Remove socket bolts (19) (4 used). Record the clearance between valve casing (18) and casing (3).
W1HH-02-06-006
10. Remove O-rings (28, 29) from casing (3).
l : 17 mm IMPORTANT: Do not remove pin (30) and bearing (24) unless necessary. 7. Remove valve casing (18) from casing (3). As valve plate (25) may be removed with valve casing (18) together, do not drop valve plate (25). Remove O-ring (22).
W3-10-3-2
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device IMPORTANT: Do not damage the sliding surfaces of rotor (11) and plunger (8). 11. Place casing (3) horizontally. Remove rotor (11), retainer (10), plate (9), and plungers (8) (9 used) from shaft (6). 12. Remove plates (13) (4 used) and friction plates (12) (3 used) from casing (3). IMPORTANT: Do not damage the sliding surface of shoe plate (7). 13. Remove shoe plate (7) from casing (3). 14. Tap and remove shaft (6) from casing (3) by using a plastic hammer. 15. Remove oil seal (4) from casing (3). Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 16. Remove the outer race of bearing (5) from casing (3) by using a bar and a hammer. 17. Remove the inner race of bearing (5) from shaft (6) by using a press.
W3-10-3-3
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Assembly of Swing Motor 17
16
15
14
19
23 21
WDAA-03-11-101
24
18
30
20
23 25 26
22
27 28
1 2
29 12
11
13
9
8
3
10 7
6
4
5 WJBC-03-11-004
1- 2- 3- 4- 5- 6- 7-
Socket Bolt (3 Used) Swing Parking Brake Selection Valve Casing Oil Seal Bearing Shaft Shoe Plate
8- 9- 10- 11- 12- 13- 14- 15-
Plunger (9 Used) Plate Retainer Rotor Friction Plate (3 Used) Plate (4 Used) Plug (2 Used) O-Ring (2 Used)
16- 17- 18- 19- 20- 21- 22- 23-
Spring (2 Used) Poppet (2 Used) Valve Casing Socket Bolt (4 Used) O-Ring (2 Used) Plug (2 Used) O-Ring Relief Valve (2 Used)
W3-10-3-4
24- 25- 26- 27- 28- 29- 30-
Bearing Valve Plate Spring (20 Used) Brake Piston O-Ring O-Ring Pin (2 Used)
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Assembly of Swing Motor IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install the inner race of bearings (5, 24) to shaft (6) by using a press. Install the inner race of bearing (5) with the flange part facing to the stepped part of shaft (6). 2. Install oil seal (4) to casing (3) by using a plate with the lip part up. 3. Install the outer race of bearing (5) to casing (3) by using a bar. 4. Install a tape onto the spline at the end of shaft (6) in order not to damage oil seal (4). Place casing (3) horizontally. Install shaft (6) to casing (3). 5. Place casing (3) vertically with the valve casing (18) mounting side up. Install shoe plate (7) to casing (3) with the chamfered surface facing inside.
8. Place casing (3) horizontally. Install the rotor (11) assembly to shaft (6). IMPORTANT: There are four notches on the outer side of plate (13). There are four notches on the spline teeth side of friction plate (12). 9. Place casing (3) vertically. Alternately install plates (13) (4 used) and friction plates (12) (3 used) in order to align each notch at the same place. 10. Install O-rings (28, 29) to casing (3). 11. Fit the matching marks and install brake piston (27) to casing (3).
fNOTE:
If it is not easy to install brake piston (27) due to the resistant force from O-rings (28, 29), evenly tap brake piston (27) by using a plastic hammer. 12. Install springs (26) (20 used) to brake piston (27).
6. Fit the notches on plate (9) and retainer (10). Install plungers (8) (9 used). Install retainer (10) to plunger (8) with the notch facing to the shoe plate (7) side. 7. Apply hydraulic oil onto the plunger hole on rotor (11). Insert the plunger (8) assembly into rotor (11).
W3-10-3-5
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device 13. Tap and install the outer race, the bearing type indicated surface of bearing (24) to valve casing (18) by using a plastic hammer. IMPORTANT: Check the surfaces of valve plate (25). 14. Install O-ring (22) and pins (30) (2 used) to valve casing (18). Install valve plate (25) to valve casing (18) with the notch in the port facing to rotor (11). Apply grease onto valve plate (25) in order to prevent from falling off from valve casing (18).
17. Install valve casing (18) to casing (3) with socket bolts (19) (4 used). l : 17 mm ml : 440 N·m (44 kgf·m, 320 lbf·ft) 18. Install poppet (17) and spring (16) to valve casing (18). Install O-ring (15) to plug (14). Install plug (14) to valve casing (18). l : 17 mm
15. Apply grease onto the needle part of bearing (24) in order to install shaft (6) to bearing (24) easily. 16. Fit the matching marks on valve casing (18) and casing (3). Place valve casing (18) onto casing (3). Check that a clearance between valve casing (18) and casing (3) is equal to that before disassembling. If the clearance is larger than that before disassembling, repeat the procedures from step 5.
m : 540 N·m (54 kgf·m, 400 lbf·ft) 19. Install another poppet (17) in the same way as step 18. 20. Install relief valves (23) (2 used) to valve casing (18). j : 41 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 21. Install swing parking brake selection valve (2) to casing (3) with socket bolts (1) (3 used). l : 5 mm m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)
W3-10-3-6
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Structure of Swing Parking Brake Valve
1
2
3 4
5 6
W800-02-06-007
1- 2-
Plug O-Ring
3- 4-
Casing Spool
5- 6-
W3-10-4-1
Spring Steel Ball
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device (Blank)
W3-10-4-2
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Removal and Installation of Pilot Valve (Left) 1
3
2
3
WDAA-03-01-023
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal
WJAA-03-01-013
dCAUTION:
Seat (2) weight: 41 kg (91 lb) 3. Remove bolts, washers (3) (4 used). Remove seat (2).
1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Open door (1).
W3-11-1-1
j : 13 mm
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve
14
13
Detail B
14 21
23
22
15 B
17 35 10 9 16 WDAA-03-12-002
12 36
7
8 37 20
18 19
11
WJBE-03-11-001
4. Remove screws (35) (3 used). Remove covers (36, 37). 5. Remove socket bolts (7) (2 used) and washers (8) (2 used). Remove lever (9). l : 6 mm 6. Remove socket bolts (10) (2 used) and washers (11) (2 used). Remove armrest (12). l : 6 mm 7. Raise boot (13) and remove screws (14) (3 used). 8. Raise cover (15). Disconnect connector (16). Remove cover (15). 9. Remove screw (17), bolt, washer (18), and washer (19). Remove cover (20). j : 10 mm 10. Remove screws (21, 22) (2 used for each). Remove cover (23).
W3-11-1-2
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve 13 25
29
27
28
26
24 32
30, 31
WDAA-03-12-023
11. Remove clip bands (24, 25). 12. Loosen lock nut (26). Remove the lever (27) assembly and boot (13). j : 19 mm 13. Place a container under pilot valve (29). Disconnect hoses (28) (6 used). j : 19 mm 14. Remove socket bolts (30) (4 used) and washers (31) (4 used). Remove pilot valve (29) and boot (32). l : 6 mm 15. Remove the adapter with pilot valve (29) attached if necessary.
W3-11-1-3
WJBE-03-11-001
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve 13 25
29
27
28
26
30, 31
24 32
WDAA-03-12-023
Installation 1. Install all removed adapters to pilot valve (29). 2. Install pilot valve (29) and boot (32) with washers (31) (4 used) and socket bolts (30) (4 used). l : 6 mm m : 20 N·m (2 kgf·m, 15 lbf·ft) 3. Connect hoses (28) (6 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 4. Install boot (13). 5. Tighten lock nut (26) and install the lever (27) assembly. j : 19 mm m : 35 to 45 N·m (3.5 to 4.5 kgf·m, 26 to 33 lbf·ft) 6. Install clip bands (25, 24).
W3-11-1-4
WJBE-03-11-001
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve
14
13
Detail B
14 21
23
22
15 B
17 35 10 9 16 WDAA-03-12-002
12 36
7
8 37 20
18 19
11
WJBE-03-11-001
7. Install cover (23) with screws (22, 21) (2 used for each).
14. Install lever (9) with washers (8) (2 used) and socket bolts (7) (2 used).
m : 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
l : 6 mm
8. Install cover (20) with washer (19), bolt, washer (18), and screw (17). j : 10 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft) 15. Install covers (36, 37) with screws (35) (3 used).
m : 3 N·m (0.3 kgf·m, 2.2 lbf·ft) 9. Install cover (15). 10. Raise cover (15). Connect connector (16). 11. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 12. Install screws (14) (3 used). Lower boot (13). 13. Install armrest (12) with washers (11) (2 used) and socket bolts (10) (2 used). l : 6 mm m : 20 N·m (2 kgf·m, 15 lbf·ft)
W3-11-1-5
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve
1
3
2
3
WDAA-03-01-023
dCAUTION:
Seat (2) weight: 41 kg (91 lb) 16. Install seat (2) with bolts, washers (3) (4 used). j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 17. Shut door (1).
W3-11-1-6
WJAA-03-01-013
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Removal and Installation of Pilot Valve (Right) 1
3
2
3
WDAA-03-01-023
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal
WJAA-03-01-013
dCAUTION:
Seat (2) weight: 41 kg (91 lb) 3. Remove bolts, washers (3) (4 used). Remove seat (2).
1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Open door (1).
W3-11-2-1
j : 13 mm
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve
Detail A
14 11
15
13 10
A
12
16
WDAA-03-12-006
7
8
9
11 WDAA-03-12-005
4. Remove socket bolts (7) (2 used) and washers (8) (2 used). Remove armrest (9). l : 6 mm 5. Remove tray (10). Remove screws (11) (3 used). 6. Raise cover (12). Disconnect connectors (13) (2 used). Remove cover (12). 7. Raise boot (14). Remove screws (15) (2 used). Remove cover (16).
W3-11-2-2
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve 19
20
17
18
20
14
24
23
21
WDAA-03-12-007
22
24
25 24 WDAA-03-12-005
8. Remove clip bands (17, 18). 9. Loosen lock nut (19). Remove the lever (20) assembly and boot (14). j : 19 mm 10. Remove bolts, washers (21) (3 used). Tilt the bracket (22) assembly with the cover (23) side up. j : 17 mm 11. Remove screws (24) (3 used) and washer (25). Remove cover (23).
W3-11-2-3
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve
A
Detail A
28, 29
30
26
WDAA-03-12-008
27
12. Place a container under pilot valve (27). Disconnect hoses (26) (6 used). j : 19 mm 13. Remove socket bolts (28) (4 used) and washers (29) (4 used). Remove pilot valve (27) and boot (30). l : 6 mm 14. Remove the adapter with pilot valve (27) attached if necessary.
W3-11-2-4
26
WDAA-03-12-020
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve
A
Detail A
28, 29
30
26
WDAA-03-12-008
27
Installation 1. Install all removed adapters to pilot valve (27). 2. Install pilot valve (27) and boot (30) with washers (29) (4 used) and socket bolts (28) (4 used). l : 6 mm m : 20 N·m (2 kgf·m, 15 lbf·ft) 3. Connect hoses (26) (6 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-11-2-5
26
WDAA-03-12-020
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve 19
20
17
20
18
14
24
23
21
WDAA-03-12-007
22
24
25 24 WDAA-03-12-005
4. Install cover (23) with washer (25) and screws (24) (3 used). m : 3 N·m (0.3 kgf·m, 2.2 lbf ·ft) 5. Install bracket (22) with bolts, washers (21) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 6. Install boot (14). 7. Tighten lock nut (19) and install the lever (20) assembly. j : 19 mm m : 35 to 45 N·m (3.5 to 4.5 kgf·m, 26 to 33 lbf·ft) 8. Install clip bands (18, 17).
W3-11-2-6
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve
Detail A
11
15
10
A
13
12
16
WDAA-03-12-006
7
8
9
11 WDAA-03-12-005
9. Install cover (16) with screws (15) (2 used). m : 3 N·m (0.3 kgf·m, 2.2 lbf·ft) 10. Install cover (12). 11. Raise cover (12). Connect connectors (13) (2 used). 12. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 13. Install screws (11) (3 used). Install tray (10). m : 3 N·m (0.3 kgf·m, 2.2 lbf·ft) 14. Install armrest (9) with washers (8) (2 used) and socket bolts (7) (2 used). l : 6 mm m : 20 N·m (2 kgf·m, 15 lbf·ft)
W3-11-2-7
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve
1
3
2
3
WDAA-03-01-023
dCAUTION:
Seat (2) weight: 41 kg (91 lb) 15. Install seat (2) with bolts, washers (3) (4 used). j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 16. Shut door (1).
W3-11-2-8
WJAA-03-01-013
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Removal and Installation of Travel Pilot Valve 1
2, 3
4 5
6
5
WJAA-03-12-001
WJBE-03-12-001
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal
5. Place a container under pilot valve (6). Disconnect hoses (5) (6 used).
1. Swing the upperstructure by 90 degrees and set the machine for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Open door (1). 3. Remove the floor mat. Remove cover (4) while holding it. Do dCAUTION: not drop cover (4). 4. Remove bolts, washers (2) (8 used), and washers (3) (8 used). Remove cover (4). j : 19 mm
W3-11-3-1
j : 19 mm
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve
6
WDAA-03-12-017
6. Remove bolts, washers (7) (4 used). Remove levers (8) (2 used) and pedals (9) (2 used). j : 17 mm 7. Remove socket bolts (10) (2 used) and washers (11) (2 used). Remove pilot valve (6). l : 8 mm 8. Remove the adapter with pilot valve (6) attached if necessary.
W3-11-3-2
WDAA-03-12-018
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve
6
WDAA-03-12-017
Installation 1. Install all removed adapters to pilot valve (6). 2. Install pilot valve (6) with washers (11) (2 used) and socket bolts (10) (2 used). l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3. Install pedals (9) (2 used) and levers (8) (2 used) with bolts, washers (7) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-11-3-3
WDAA-03-12-018
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve
1
2, 3
4 5
5 WJBE-03-12-001
4. Connect hoses (5) (6 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 5. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 6. Install cover (4) with washers (3) (8 used), and bolts, washers (2) (8 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 7. Install the floor mat. 8. Shut door (1).
W3-11-3-4
WJAA-03-12-001
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Disassembly of Pilot Valves (Right and Left)
17 16 15
14
13 12 11 10
18
9 8 7 6
19
23
5
20 21 22
4 3 2 1
WDAA-03-12-021
1- 2- 3- 4- 5- 6-
Spacer (4 Used) Shim (Several) Balance Spring (2 Used) Balance Spring (2 Used) Return Spring (2 Used) Return Spring (2 Used)
7- 8- 9- 10- 11- 12-
Spring Guide (4 Used) Retaining Ring (4 Used) Pusher (2 Used) Pusher (2 Used) Oil Seal (4 Used) Sleeve (4 Used)
13- 14- 15- 16- 17- 18-
O-Ring (4 Used) Plate Universal Joint Cam Screw Joint Casing
W3-11-4-1
19- 20- 21- 22- 23-
Spool (4 Used) O-Ring Plug Retaining Ring Filter
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Disassembly of Pilot Valves (Right and Left) IMPORTANT: Casing (18) is made of aluminium. Strong force deforms it. Handle it with care. IMPORTANT: Spool (19) has been selected to match the hole on casing (18). The dimensions of balance springs (3, 4) and return springs (5, 6) as well as those of pushers (9, 10) are different. Arrange the disassembled parts together with the port in order not to confuse. The port number is stamped on the outer surface of casing (18). IMPORTANT: Do not remove screw joint (17) while securing casing (18) in a vise. The strong torque may act on screw joint (17). 1. Secure screw joint (17) in a vise. Turn cam (16) by using a spanner. Remove screw joint (17). j : 19 mm, 32 mm 2. Secure the flat surface of casing (18) in a vise. Remove cam (16) from universal joint (15). j : 32 mm
3. Attach a spanner onto the upper part of universal joint (15). Remove universal joint (15). j : 17 mm
fNOTE:
Universal joint (15) has been secured on casing (18) by using LOCTITE #262. 4. Remove plate (14).
IMPORTANT: Do not damage sleeve (12). Insert a soft rubber between sleeve (12) and a tool. Oil seal (11) cannot be removed from sleeve (12). Sleeve (12) and oil seal (11) should be replaced as an assembly. 5. Remove sleeves (12) (4 used) upward by using a pair of pliers. Remove O-rings (19) (4 used) from sleeves (12) (4 used). IMPORTANT: The dimensions of pushers (9, 10) for ports (1, 3) and for ports (2, 4) are different. Keep the disassembled parts together by the port number in order not to confuse. 6. Remove pushers (9, 10) (2 used for each) from casing (18).
W3-11-4-2
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve 7. When compressing the spring, do not lower spool (19). Install the special tool (ST 4145) to the port hole on casing (18) as illustrated. l : 6 mm
10. Remove shim (2) and spacers (1) (4 used) from spools (19) (4 used).
18
ST 4145
IMPORTANT: The quantity of shims (2) has been determined for each port during the performance testing. Do not lose shim (2). Keep shim (2) carefully in order to install shim (2) to the original port when assembling. 9. Remove the special tool (ST4146). Remove spring guides (7) (4 used), return springs (5, 6) (2 used for each), and balance springs (3, 4) (2 used for each) from spools (19) (4 used).
W178-02-07-048
8. Install the special tool (ST 4146) to the pusher hole on casing (18). Push the special tool (ST 4146) and compress the spring. Tighten the special tool (ST 4146) by using the socket bolt (M14, Pitch 2.0 mm). Remove retaining rings (8) (4 used) from spools (19) (4 used) by using a screwdriver. l : 12 mm
IMPORTANT: Spool (19) has been selected to match the hole on casing (18). Spool (19) and casing (18) should be replaced as an assembly. 11. Remove the special tool (ST 4145) from casing (18). Slowly turn and remove spool (19) from casing (18). IMPORTANT: Retaining ring (22) may come off while disassembling. Do not drop retaining ring (22) inside casing (18). If retaining ring (22) falls inside casing (18), remove retaining ring (22) completely. Retaining ring (22) cannot be reused. 12. Remove retaining ring (22) from casing (18) by using a screwdriver. Install a bolt (M8, Pitch 1.25 mm) to plug (21). Remove plug (21) from casing (18). Remove O-ring (20) from plug (21). j : 13 mm 13. Remove filter (23) from casing (18).
ST 4146
j : 10 mm 18
W178-02-07-048
W3-11-4-3
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Assembly of Pilot Valves (Right and Left)
17 15
16
14
11
9, 10
13
12 8 7 3, 4 5, 6 2
1
21
20 23
19
18
22 WDAA-03-12-022 1- 2- 3- 4- 5- 6-
Spacer (4 Used) Shim (Several) Balance Spring (2 Used) Balance Spring (2 Used) Return Spring (2 Used) Return Spring (2 Used)
7- 8- 9- 10- 11- 12-
Spring Guide (4 Used) Retaining Ring (4 Used) Pusher (2 Used) Pusher (2 Used) Oil Seal (4 Used) Sleeve (4 Used)
13- 14- 15- 16- 17- 18-
O-Ring (4 Used) Plate Universal Joint Cam Screw Joint Casing
W3-11-4-4
19- 20- 21- 22- 23-
Spool (4 Used) O-Ring Plug Retaining Ring Filter
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Assembly of Pilot Valves (Right and Left) IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling.
IMPORTANT: Refer to the table in the left in order to assemble the parts correctly. 3. Install spacer (1), shim (2), and balance spring (3) to spool (19). Install return spring (5) to casing (18). 4. Install spring guide (7) to return spring (5) with the protrusion up.
fNOTE:
5. Install other spools (19) (3 used) in the same way as step 1 to step 4.
Port No.
6. Install the special tool (ST 4146) to the pusher (9, 10) holes on casing (18). Push the special tool (ST 4146) and compress the spring. Tighten the special tool (ST 4146) by using a bolt (M14, Pitch 2.0 mm).
The table below shows the relations between each port and the parts. Do not confuse them when assembling.
1
Spool (19)
Shim (2)
Pushers (9, 10)
One outer groove Two outer grooves Same to the Same to the former one former one One outer groove Two outer grooves
2 3 4
l : 12 mm ST 4146
ST 4144
Port No. 1 2 3 4
Return Springs (5, 6) Short Long Short Long
Balance Springs (3, 4) Short Long Short Long
1. Check the port hole number and insert same spool (19) before disassembling. Install the thinner end of spool (19) into the port hole on casing (18) by turning slowly.
fNOTE:
Spool (19) has been selected to match the port hole. Spool (19) and casing (18) should be replaced as an assembly. 2. Install the special tool (ST 4145) to the port hole on casing (18) in order not to lower spool (19) when the spring is compressed.
ST 4145
W178-02-07-049
7. Install retaining ring (8) to the ring holder (ST 4144).
j : 6 mm
W3-11-4-5
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve 8. Install retaining ring (8) to the groove on the head of spool (21) extending from the special tool (ST 4146). IMPORTANT: Check the position to install pusher (9). 9. Install pusher (9). After pushing pusher (9) several times by hand, remove it. Check if retaining ring (8) comes off or balance spring (3) is located correctly. Install pusher (9) to casing (18) after checking. 10. Install other pushers (9, 10) in the same way as step 8 to step 9. 11. Apply grease onto the ball part at the ends of pushers (9, 10) (2 used for each). 12. Apply grease onto the joint part of universal joint (15).
IMPORTANT: Fit the bolt hole on plate (14) to the screw hole on casing (18). 16. Apply LOCTITE #262 onto the screw part of universal joint (15). Place plate (14) on casing (18). Install universal joint (15). j : 17 mm m : 25 N·m (2.5 kgf·m, 19 lbf·ft) IMPORTANT: Check the tightness of cam (16). 17. Install cam (16) to universal joint (15). The clearance between cam (16) and pushers (9, 10) (2 used for each) should be 0 to 0.2 mm. 18. Secure cam (16) by using a spanner. Tighten screw joint (17) by using a spanner. j : 19 mm, 32 mm
13. Apply grease onto the inner surface of oil seals (11) (4 used).
fNOTE:
Sleeve (12) and oil seal (11) should be replaced as an assembly. 14. Install oil seals (11) (4 used) to sleeves (12) (4 used). Push the sleeve (12) assemblies (4 used) by hand until O-ring (13) is inserted into the hole on sleeves (12) (4 used).
m : 70 N·m (7 kgf·m, 51 lbf·ft) 19. Install plug (23) to casing (18).
15. Secure casing (18) in a vise lightly.
W3-11-4-6
l : 10 mm m : 20 N·m (2 kgf·m, 15 lbf·ft)
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Disassembly of Travel Pilot Valve 1
2
3 4 5 6
35
7 33 9
31
8
34
32
30 29
10 11 28 14 12
13
27 26
15
25
16
24
17 18
23 36
19 20 21
22 WDAA-03-12-024
1- 2- 3- 4- 5- 6- 7- 8- 9-
Bolt, Washer (2 Used) Cover Spring Pin (2 Used) Spring Pin (2 Used) Cam (2 Used) Bushing (4 Used) Holder Spring Washer (4 Used) Socket Bolt (4 Used)
10- 11- 12- 13- 14- 15- 16- 17- 18-
Spring Pin Bracket (2 Used) Spring Pin (2 Used) Spring Pin (2 Used) O-Ring (4 Used) Bushing (4 Used) Pusher (4 Used) Spring Guide (16 Used) Balance Spring (4 Used)
19- 20- 21- 22- 23- 24- 25- 26- 27-
O-Ring (2 Used) Plug (2 Used) Plug (2 Used) O-Ring (2 Used) Casing Spool Spring (4 Used) Spacer (4 Used) Shim (12 Used)
W3-11-5-1
28- 29- 30- 31- 32- 33- 34- 35- 36-
Oil Seal (4 Used) Spring Washer (2 Used) Socket Bolt (2 Used) Rubber Seat (2 Used) Damper (2 Used) O-Ring (2 Used) O-Ring (2 Used) Pin Plug
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Disassembly of Travel Pilot Valve IMPORTANT: Casing (23) is made of aluminium. Strong force deforms it. Handle it with care. IMPORTANT: Spool (24) has been selected to match the hole on casing (23). Arrange the disassembled parts together with each port in order not to confuse. The port number is stamped on the outer surface of casing (23). 1. Secure casing (23) in a vise. Remove bolts, washers (1) (2 used). Remove cover (2) from holder (7). j : 10 mm 2. Remove socket bolts (30) (2 used) and spring washers (29) (2 used). Remove the holder (7) assembly from casing (23). l : 8 mm 3. Remove the pusher (16) assemblies (4 used) from casing (23). 4. Remove pushers (16) (4 used) from bushings (15) (4 used). Remove oil seals (28) (4 used) and O-rings (14) (4 used) from bushings (15) (4 used) by using a bamboo spatula.
IMPORTANT: Spool (24) has been selected to match the hole of casing (23). Spool (24) and casing (23) should be replaced as an assembly. IMPORTANT: Put the mark on spools (24) (4 used) when keeping in order to easily install spools (24) (4 used) to the original hole. 5. Remove the spool (24) assembly from casing (23) by rotating. Spring guide (17), balance spring (18), shims (27) (3 used), and spacer (26) are removed with spool (24) together. IMPORTANT: The quantity of shims (27) have been determined during the performance testing at the factory. When keeping, pair shim (27) with each spool. 6. Compress balance spring (18). Remove spring guide (17), balance spring (18), shims (27) (3 used), and spacer (26) from spool (24). 7. Remove spring (25) from casing (23). 8. Remove other spools (24) in the same way as step 5 to step 7.
W3-11-5-2
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve
d
CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury. IMPORTANT: Place a stand under bracket (11) and receive a reaction force. If holder (7) bears the reaction force, strong force acts on pin (35). Therefore, pin (35) may be deformed. 9. Place a stand under bracket (11). The inner surfaces of the spring pins (12, 13) holes on bracket (11) are stepped-shape. The spring pin can only be removed in one direction. Tap and remove spring pins (12, 13) from bracket (11) at the same time by using the special tool (ST 1237). Remove bracket (11) from pin (35). Do not remove spring pin (10) with bracket (11) attached unless necessary. The hole end of spring pin (10) has been crimped.
11. Remove O-ring (33) from pin (35). 12. Remove other bracket (11) in the same way as step 9 to step 11. 13. Place holder (7) with the casing (23) mounting surface up. Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 14. The holes of spring pins (3, 4) (2 used for each) in cam (5) are stepped-shape. Tap the bottom of cam (5) and remove spring pins (3, 4) (2 used for each) from cams (5) (2 used) at the same time by using the special tool (ST 1237). As the holes of spring pins (3, 4) (2 used for each) are crimped, spring pins (3, 4) may feel tight when removing.
12, 13 35
11 10 a b
W176-02-07-019 a - Crimped Position b - Stand
10. Remove socket bolts (9) (2 used) and spring washers (8) (2 used). Remove damper (32) and rubber seat (31) from pin (35). O-ring (34) is removed together. l : 5 mm
W3-11-5-3
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 15. Remove pin (35) by using a bar and a hammer. At the same time, cams (5) (2 used) are removed. Do not remove bushings (6) (4 used) with holder (7) attached unless necessary. If removing, remove bushings (6) (4 used) by tapping by using the special tool (ST 7256). 16. Remove plugs (20) (2 used) from casing (23). Remove O-rings (19) (2 used) from plugs (20) (2 used). l : 5 mm 17. Remove plugs (21) (2 used) from casing (23). Remove O-rings (22) (2 used) from plugs (21) (2 used). l : 6 mm
W3-11-5-4
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Assembly of Travel Pilot Valve
32
11
31
1
2
35 6
12 10
13
7
5
3, 4
30
29 34
9
15
33
8
17
28
18
14
25 27
16
26 24
23
36
WDAA-03-12-025 1- 2- 3- 4- 5- 6- 7- 8- 9-
Bolt, Washer (2 Used) Cover Spring Pin (2 Used) Spring Pin (2 Used) Cam (2 Used) Bushing (4 Used) Holder Spring Washer (4 Used) Socket Bolt (4 Used)
fNOTE:
10- 11- 12- 13- 14- 15- 16- 17- 18-
Spring Pin Bracket (2 Used) Spring Pin (2 Used) Spring Pin (2 Used) O-Ring Bushing (4 Used) Pusher (4 Used) Spring Guide (16 Used) Balance Spring (4 Used)
19- 20- 21- 22- 23- 24- 25- 26- 27-
*O-Ring (2 Used) *Plug (2 Used) *Plug (2 Used) *O-Ring (2 Used) Casing Spool (4 Used) Spring (4 Used) Spacer (4 Used) Shim (12 Used)
As for the parts with mark *, refer to W3-11-5-1.
W3-11-5-5
28- 29- 30- 31- 32- 33- 34- 35- 36-
Oil Seal (4 Used) Spring Washer (2 Used) Socket Bolt (2 Used) Rubber Seat (2 Used) Damper (2 Used) O-Ring (2 Used) O-Ring (2 Used) Pin Plug
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Assembly of Travel Pilot Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling. 1. Insert spacer (26), shims (27) (3 used), and balance spring (18) into spool (24) in sequence. Install shim (27) as the same condition before disassembling. IMPORTANT: Check the direction to install spring guide (17). 2. Compress balance spring (18) by hand. Install spring guide (17) to spool (24) with the stepped part down.
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury.
fNOTE:
Bushings (6) (4 used) are identical. ď‚– Insert bushings (6) (4 used) into the special tool (ST 7256). Tap the special tool (ST 7256) by using a hammer and install bushing (6) to the end of hole on holder (7). Stop tapping when the bushing (6) end is flush with the hole end.
IMPORTANT: Before inserting the parts into holder (7) and casing (23), apply hydraulic oil. 3. Insert spring (25) into casing (23). 4. Insert the spool (24) assembly into the original port before disassembling. Insert the spool (24) assembly into casing (23) by rotating. 5. Install oil seal (28) to bushing (15). 6. Apply grease onto the inner surface of oil seal (28). 7. Install O-ring (14) and pusher (16) to bushing (15). 8. Apply grease onto the head of pusher (16). 9. Insert the pusher (16) assembly into casing (23). 10. Install other spools (24) in the same way as step 1 to step 9. 11. When bushing (6) has been removed from holder (7), install bushings (6) (4 used) to holder (7) by using the special tool (ST 7256) in the following procedures.
W3-11-5-6
7
ST 7256
6 W178-02-11-310
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Install bushing (6) on the opposite side in the same way. 6 ST 7256
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
7
W178-02-11-311
Install bushing (6) in the near side as illustrated. Stop tapping when the bushing (6) end is flush with the outside of holder (7). 6 7
12. Install O-rings (33) (2 used) to pin (35). Apply grease onto O-rings (33) (2 used). Install pin (35) and cams (5) (2 used) to holder (7).
such as goggles, helmets, etc in order to prevent personal injury. IMPORTANT: Check the direction to install spring pins (3, 4). 13. Install spring pins (3, 4) to cam (5) by using the special tool (ST 1237). Secure cam (5) and pin (35). At this time, the slits of spring pins (3, 4) should be positioned 90SDgr away each other. Tap and install spring pins (3, 4) until spring pins (3, 4) come in contact with the stepped part in the hole.
ST 7256
3
a
b
a W178-02-11-312
4
a - Outside of Holder
Install bushing (6) in the near and opposite side as illustrated. 6 ST 7256
W178-02-07-050
a - Slit b - Slit
14. Crimp the hole end of cam (5) where spring pins (3, 4) are inserted by using a punch. 15. Install other cam (5) in the same way as step 13 to step 14.
7
W178-02-11-313
W3-11-5-7
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve 16. Place holder (7) on the casing (23) assembly. Install holder (7) to casing (23) with socket bolts (30) (2 used) and spring washers (29) (2 used). Check the mark direction and install holder (7). l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 17. Install rubber seats (31) (2 used) to pin (35). IMPORTANT: Check the direction of damper (32). The inner surface of damper (32) is edged-shape. If damper (32) is pried when installing, O-ring (33) may be damaged. 18. Install dampers (32) (2 used) to pin (35) with the lever up.
21. As for the direction to install bracket (11), refer to the figure in Disassembly of Travel Pilot Valve on W3-11-5-1. Install bracket (11) to pin (35). Fit the holes to insert spring pins (12, 13). IMPORTANT: Place a stand under bracket (11) and receive a reaction force. If holder (7) bears the reaction force, strong force acts on pin (35). Therefore, pin (35) may be deformed. 22. Place a stand under bracket (11). Install spring pins (12, 13) to bracket (11) until they come in contact with the stepped part by using the special tool (ST 1237). The slits of spring pins (2 used) should be positioned 90° away each other.
19. Secure damper (32) and rubber seat (31) to holder (7) with socket bolts (9) (4 used) and spring washers (8) (4 used).
b
11
c
35
l : 5 mm m : 7 N·m (0.7 kgf·m, 5 lbf·ft) 20. Apply grease onto O-ring (34). Push O-rings (34) (2 used) to the end of pin (35).
a
12, 13
W176-02-07-011 a - Stand b - Crimped Position c - Crimped Position
W3-11-5-8
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve 23. Crimp the hole edge of bracket (11) where spring pins (12, 13) are inserted by using a punch. 24. Install other bracket (11) in the same way as step 22 to step 23. 25. Install cover (2) to holder (7) with bolts, washers (1) (2 used). j : 10 mm m : 5 N·m (0.5 kgf·m, 3.5 lbf·ft) 26. Apply grease onto the spring pin (10) contact part of dampers (32) (2 used). 27. Install O-rings (19) (2 used) to plugs (20) (2 used). Install plugs (20) (2 used) to casing (23). j : 5 mm m : 10 N·m (1 kgf·m, 7.5 lbf·ft) 28. Install O-rings (22) (2 used) to plugs (21) (2 used). Install plugs (21) (2 used) to casing (23). j : 6 mm m : 20 N·m (2 kgf·m, 15 lbf·ft)
W3-11-5-9
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve (Blank)
W3-11-5-10
Section 3 UPPERSTRUCTURE Group 12 Solenoid Valve Removal and Installation of Pilot Shut-Off Solenoid Valve 1
2, 3
4
WJBE-03-12-001
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Swing the upperstructure by 90 degrees and set the machine for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Open door (1). 3. Remove a floor mat. Remove cover (4) while holding it. Do dCAUTION: not drop cover (4). 4. Remove bolts, washers (2) (8 used) and washers (3) (8 used). Remove cover (4). j : 19 mm
W3-12-1-1
Section 3 UPPERSTRUCTURE Group 12 Solenoid Valve
7
7 5
6
7
WJAA-03-13-007
5. Disconnect connector (5). 6. Place a container under pilot shut-off solenoid valve (6). Disconnect hoses (7) (10 used). j : 19 mm 7. Remove bolts, washers (8) (2 used). Remove pilot shut-off solenoid valve (6). j : 17 mm 8. Remove the adapter with pilot shut-off solenoid valve (6) attached if necessary.
W3-12-1-2
8 WDAA-03-13-007
Section 3 UPPERSTRUCTURE Group 12 Solenoid Valve
7
7 5
6
7
WJAA-03-13-007
Installation 1. Install all removed adapters to pilot shut-off solenoid valve (6). 2. Install pilot shut-off solenoid valve (6) with bolts, washers (8) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3. Connect hoses (7) (10 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 4. Connect connector (5).
W3-12-1-3
8 WDAA-03-13-007
Section 3 UPPERSTRUCTURE Group 12 Solenoid Valve 1
2, 3
4
WJBE-03-12-001
5. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 6. Install cover (4) with washers (3) (8 used) and bolts, washers (2) (8 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 7. Install a floor mat. 8. Shut door (1).
W3-12-1-4
SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve Removal and Installation of 4-Spool Solenoid Valve Unit 3
2
1
6
4
5
4
WJBE-03-16-003
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) CAUTION: Bleed air from the hydraulic oil tank. d(Refer to W1-4-1.) d CAUTION: Cover (1) weight : 25 kg (56 lb) 2. Remove bolts, washers (2) (7 used), and washers (3) (7 used). Remove cover (1). j : 19 mm 3. Remove bolts, washers (4) (6 used), and washers (5) (4 used). Remove cover (6). j : 19 mm
W3-12-2-1
SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve
WJBE-03-12-002
4. Disconnect connectors (7) (4 used). 5. Place a container under 4-spool solenoid valve unit (12). Disconnect hoses (9) (8 used). j : 17 mm 6. Disconnect hoses (10) (2 used).
7. Remove bolts, washers (11) (2 used). Remove 4-spool solenoid valve unit (12). j : 17 mm 8. Remove the adapter with 4-spool solenoid valve unit (12) attached if necessary.
j : 19 mm
W3-12-2-2
SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve
WJBE-03-12-002
Installation 1. Install all removed adapters to 4-spool solenoid valve unit (12). 2. Install 4-spool solenoid valve unit (12) with bolts, washers (11) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3. Connect hoses (10) (2 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 4. Connect hoses (9) (8 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 18 lbf·ft) 5. Connect connectors (7) (4 used).
W3-12-2-3
SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve
3
2
1
6
4
5
4
WJBE-03-16-003
6. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 7. Install cover (6) with washers (5) (4 used), and bolts, washers (4) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
d CAUTION:
Cover (1) weight : 25 kg (56 lb) 8. Install cover (1) with washers (3) (7 used), and bolts, washers (2) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-12-2-4
SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve Removal and Installation of 2-Spool Solenoid Valve Unit 3
2
1
6
4
5
4
WJBE-03-16-003
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) dCAUTION: Cover (1) weight : 25 kg (56 lb) 2. Remove bolts, washers (2) (7 used) and washers (3) (7 used). Remove cover (1). j : 19 mm 3. Remove bolts, washers (4) (6 used), and washers (5) (4 used). Remove cover (6). j : 19 mm
W3-12-3-1
SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve
WJAC-03-12-001
4. Disconnect connectors (10) (2 used). 5. Place a container under 2-spool solenoid valve unit (11). Disconnect hoses (14) (2 used). j : 19 mm 6. Disconnect hoses (12) (7 used). j : 17 mm 7. Remove bolts, washers (13) (2 used). Remove 2-spool solenoid valve unit (11). j : 17 mm 8. Remove the adapter with 2-spool solenoid valve unit (11) attached if necessary.
W3-12-3-2
SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve
WJAC-03-12-001
Installation 1. Install all removed adapters to 2-spool solenoid valve unit (11). 2. Install 2-spool solenoid valve unit (11) with bolts, washers (13) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3. Connect hoses (12) (7 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 18 lbf·ft) 4. Connect hoses (14) (2 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 5. Connect connectors (10) (2 used).
W3-12-3-3
SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve 3
2
1
6
4
5
4
WJBE-03-16-003
6. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 7. Install cover (6) with washers (5) (4 used), and bolts, washers (4) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION:
Cover (1) weight : 25 kg (56 lb) 8. Install cover (1) with washers (3) (7 used), and bolts, washers (2) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-12-3-4
SECTION 3 UPPER STRUCTURE Group 12 Solenoid Valve Disassembly of Pilot Shut-Off Solenoid Valve
1
2
3
4
9
5
6 7 8
WDAA-03-13-014 1- 2- 3-
Socket Bolt (2 Used) Solenoid O-Ring
4- 5- 6-
Body Spool Spring
7- 8- 9-
O-Ring Plug Filter
W3-12-4-1
SECTION 3 UPPER STRUCTURE Group 12 Solenoid Valve Disassembly of Pilot Shut-Off Solenoid Valve IMPORTANT: Filter (9) cannot be removed. 1. Put the matching marks on body (4) and solenoid (2). Secure body (4) in a vise. Remove socket bolts (1) (2 used) from body (4). Remove solenoid (2) and O-ring (3) from body (4). l : 4 mm 2. Remove plug (8) from body (4). Remove O-ring (7) from plug (8). l : 6 mm 3. Remove spring (6) and spool (5) from body (4).
W3-12-4-2
SECTION 3 UPPER STRUCTURE Group 12 Solenoid Valve Assembly of Pilot Shut-Off Solenoid Valve
2 1 3
4 9 5 6 7 8
T1V1-03-07-012 1- 2- 3-
Socket Bolt (2 Used) Solenoid O-Ring
4- 5- 6-
Body Spool Spring
7- 8- 9-
O-Ring Plug Filter
W3-12-4-3
SECTION 3 UPPER STRUCTURE Group 12 Solenoid Valve Assembly of Pilot Shut-Off Solenoid Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Secure body (4) in a vise. Insert spool (5) and spring (6) into body (4). 2. Install O-ring (7) to plug (8). Install plug (8) to body (4). l : 6 mm m : 27 N·m (2.7 kgf·m, 20 lbf·ft) IMPORTANT: When solenoid (2) is installed after installing O-ring (3) to body (4), O-ring (3) may be damaged. 3. Install O-ring (3) to solenoid (2). Fit the matching marks and install solenoid (2) to body (4). 4. Install solenoid (2) to body (4) with socket bolts (1) (2 used). l : 4 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft)
W3-12-4-4
SECTION 3 UPPER STRUCTURE Group 12 Solenoid Valve Structure of 4-Spool Solenoid Valve Unit 1
5
2
3
2
4
WJAA-03-13-001
4 3
6
7
8
9
10
11
15
14
13
12
WJAA-03-13-002
W3-12-5-1
SECTION 3 UPPER STRUCTURE Group 12 Solenoid Valve No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Part Name Body Socket Bolt Solenoid Plug (Filter) Plug (Filter) Washer Spring Spool Sleeve Plate Wave Spring O-Ring O-Ring O-Ring O-Ring
Q’ty 1 8 4 4 1 4 4 4 4 4 4 4 4 4 4
Wrench Size (mm)
Tightening Torque N·m (kgf·m, lbf·ft)
l:4
5
(0.5, 3.7)
l:6 l : 10
10 20
(1, 7.4) (2, 15)
W3-12-5-2
Remark
SECTION 3 UPPER STRUCTURE Group 12 Solenoid Valve Structure of 2-Spool Solenoid Valve Unit 1 5
2
2 3
4
WJAA-03-13-003
4 3
6
7
8
9
10
11
15
14
13
12
WJAA-03-13-004
W3-12-6-1
SECTION 3 UPPER STRUCTURE Group 12 Solenoid Valve No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Part Name Body Socket Bolt Solenoid Plug (Filter) Plug (Filter) Washer Spring Spool Sleeve Plate Wave Spring O-Ring O-Ring O-Ring O-Ring
Q’ty 1 4 2 2 1 2 2 2 2 2 2 2 2 2 2
Wrench Size (mm)
Tightening Torque N·m (kgf·m, lbf·ft)
l:4
5
(0.5, 3.7)
l:6 l : 10
10 20
(1, 7.4) (2, 15)
W3-12-6-2
Remark
SECTION 3 UPPERSTRUCTURE Group 13 Signal Control Valve Removal and Installation of Signal Control Valve 3
2
1
6
4
5
4
WJBE-03-16-003
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) dCAUTION: Cover (1) weight : 25 kg (56 lb) 2. Remove bolts, washers (2) (7 used), and washers (3) (7 used). Remove cover (1). j : 19 mm 3. Remove bolts, washers (4) (6 used), and washers (5) (4 used). Remove cover (6). j : 19 mm
W3-13-1-1
SECTION 3 UPPERSTRUCTURE Group 13 Signal Control Valve Pilot Valve Side 14
15
b
15
15
a
WJBE-03-13-001 a-
Pilot Valve Side
b-
Control Valve Side
15
4. Place a container under signal control valve (14). Disconnect hoses (15) (18 used). j : 19 mm
W3-13-1-2
WJAA-03-14-002
SECTION 3 UPPERSTRUCTURE Group 13 Signal Control Valve Control Valve Side 14
10
b
11
9
9 10 9 10
a
12, 13
WJBE-03-13-001 a-
Pilot Valve Side
b-
10
Control Valve Side
5. Disconnect hoses (9) (12 used). j : 19 mm 6. Disconnect hoses (10) (4 used). j : 17 mm 7. Disconnect connectors (11) (2 used). 8. Remove socket bolts (12) (4 used) and washers (13) (4 used). Remove signal control valve (14). l : 8 mm 9. Remove the adapter with signal control valve (14) attached if necessary.
W3-13-1-3
11
9
WJAA-03-14-003
SECTION 3 UPPERSTRUCTURE Group 13 Signal Control Valve Control Valve Side
14
10
11
9
b
9 10 9 10 a
12, 13
WJBE-03-13-001 a-
Pilot Valve Side
b-
Control Valve Side
10
Installation 1. Install all removed adapters to signal control valve (14). 2. Install signal control valve (14) with washers (13) (4 used) and socket bolts (12) (4 used). l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3. Connect connectors (11) (2 used). 4. Connect hoses (10) (4 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 18 lbf·ft) 5. Connect hoses (9) (12 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-13-1-4
11
9
WJAA-03-14-003
SECTION 3 UPPERSTRUCTURE Group 13 Signal Control Valve Pilot Valve Side
14
15
b
15
15
a
WJBE-03-13-001 a-
Pilot Valve Side
b-
Control Valve Side
15
6. Connect hoses (15) (18 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-13-1-5
WJAA-03-14-002
SECTION 3 UPPERSTRUCTURE Group 13 Signal Control Valve
3
2
1
6
4
5
4
WJBE-03-16-003
7. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 8. Install cover (6) with washers (5) (4 used), and bolts, washers (4) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION:
Cover (1) weight : 25 kg (56 lb) 9. Install cover (1) with washers (3) (7 used), and bolts, washers (2) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-13-1-6
SECTION 3 UPPERSTRUCTURE Group 13 Signal Control Valve Structure of Signal Control Valve
13
12
4
7 11 7
10
4
9 7
7
8 7 6
5 4
4
3
2 4
1
W1JB-02-10-002
W3-13-2-1
SECTION 3 UPPERSTRUCTURE Group 13 Signal Control Valve
15
16 16
14
17
18
17
16
19 20
21
17
19 20
18
19
20 14 22 23 24 25
26 27
19
28
17
16 29
20 5 20
19
19
18
21
18
17
17
17
20 19
14 16
16
16
W1JB-02-10-003
1- 2- 3- 4- 5- 6- 7- 8-
Bolt (3 Used) Body 1 Gasket Filter (17 Used) Body 2 Gasket Shuttle Valve (2 Used) Spring (4 Used)
9- 10- 11- 12- 13- 14- 15- 16-
Body 3 Gasket Body 4 Gasket Body 5 Socket Bolt (11 Used) Plate Plug (7 Used)
17- 18- 19- 20- 21- 22- 23- 24-
O-Ring (7 Used) Spring (4 Used) Spring Guide (7 Used) Spool (6 Used) Spring (2 Used) Plate O-Ring Shuttle Valve
W3-13-2-2
25- 26- 27- 28- 29-
O-Ring Spring Spool Spring Plate
SECTION 3 UPPERSTRUCTURE Group 14 Shockless Valve Removal and Installation of Shockless Valve
Detail A
3
1
2
WJAA-03-15-001
A WJAA-03-02-001
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal
2. Disconnect hoses (1) (2 used). j : 19 mm 3. Remove bolts, washers (2) (2 used). Remove shockless valve (3). j : 13 mm 4. Remove the adapter with shockless valve (3) attached if necessary.
1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)
W3-14-1-1
SECTION 3 UPPERSTRUCTURE Group 14 Shockless Valve
Detail A
3
1
2
WJAA-03-15-001
A WJAA-03-02-001
Installation 1. Install all removed adapters to shockless valve (3). 2. Install shockless valve (3) with bolts, washers (2) (2 used).
4. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.
j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 3. Connect hoses (1) (2 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-14-1-2
SECTION 3 UPPERSTRUCTURE Group 14 Shockless Valve Structure of Shockless Valve 4
5
6
7
1
2
T183-03-07-008
No. 1 2 3 4 5 6 7
Part Name Plug O-Ring Body Spring Plunger Ring Orifice
Q’ty 2 2 1 2 1 1 1
Wrench Size (mm) l:8
W3-14-2-1
Tightening Torque N·m (kgf·m, lbf·ft) 40 (4, 30)
Remark
SECTION 3 UPPERSTRUCTURE Group 14 Shockless Valve (Blank)
W3-14-2-2
SECTION 3 UPPERSTRUCTURE Group 15 Fan Valve Removal and Installation of Oil Cooler Fan Valve
2, 3
1
5, 6 4 8, 9
7
WJBE-03-15-001
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal
Remove cover (7) while holding it. Do dCAUTION: not drop cover (7). 4. Remove bolts, washers (8) (7 used) and washers (9) (7 used). Remove cover (7).
1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) Remove cover (1) while holding it. Do dCAUTION: not drop cover (1). 2. Remove bolts, washers (2) (5 used) and washers (3) (5 used). Remove cover (1). j : 19 mm Remove cover (4) while holding it. Do dCAUTION: not drop cover (4). 3. Remove bolts, washers (5) (6 used) and washers (6) (6 used). Remove cover (4). j : 19 mm
W3-15-1-1
j : 19 mm
SECTION 3 UPPERSTRUCTURE Group 15 Fan Valve 11, 12
13, 14
13, 14
17
13
15, 16
13
10 10 WJBE-03-15-002
5. Place a container under oil cooler fan valve (17). Disconnect hoses (10) (2 used). j : 36 mm 6. Remove socket bolts (11) (8used) and flanges (12) (4 used). Disconnect hoses (13) (2 used). Remove O-rings (14) (2 used). j : 8 mm 7. Remove bolts (15) (2 used) and washers (16) (2 used). Remove oil cooler fan valve (17). j : 17 mm 8. Disconnect hoses (13) (2 used). j : 36 mm
W3-15-1-2
WJBE-03-15-003
SECTION 3 UPPERSTRUCTURE Group 15 Fan Valve 11, 12
13, 14
13, 14
17
13
15, 16
13
10 10 WJBE-03-15-002
Installation 1. Connect hoses (13) (2 used). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 2. Install oil cooler fan valve (17) with washers (16) (2 used) and bolts (15) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3. Install O-rings (14) (2 used) to hoses (13) (2 used). Connect hoses (13) (2 used) with flanges (12) (4 used) and socket bolts (11) (8 used). l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 4. Connect hoses (10) (2 used). l : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 5. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.
W3-15-1-3
WJBE-03-15-003
SECTION 3 UPPERSTRUCTURE Group 15 Fan Valve
2, 3
1
5, 6 4
8, 9 7
WJBE-03-15-001
6. Install cover (7) with washers (9) (7 used) and bolts, washers (8) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 7. Install cover (4) with washers (6) (6 used) and bolts, washers (5) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 8. Install cover (1) with washers (3) (5 used) and bolts, washers (2) (5 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-15-1-4
SECTION 3 UPPERSTRUCTURE Group 15 Fan Valve Removal and Installation of Radiator Fan Valve 1
3
2
WJBE-03-15-004
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Remove bolts, washers (1) (4 used). Remove cover (2). j : 19 mm 3. Remove bolts, washers (3) (2 used). j : 19 mm
W3-15-2-1
WJBE-03-15-007
SECTION 3 UPPERSTRUCTURE Group 15 Fan Valve 13
8, 9 7 11, 12 10
WJBE-03-15-005
Remove cover (7) while holding it. Do dCAUTION: not drop cover (7). 4. Remove bolts, washers (8) (5 used) and washers (9) (5 used). Remove cover (7). j : 19 mm Remove cover (10) while holding it. dCAUTION: Do not drop cover (10). 5. Remove bolts, washers (11) (7 used) and washers (12) (7 used). Remove cover (10). j : 19 mm 6. Remove bolts, washers (13) (3 used). Remove cover (14). j : 19 mm
W3-15-2-2
14
WJBE-03-15-008
SECTION 3 UPPERSTRUCTURE Group 15 Fan Valve Detail A A
18
15
15
WJBE-03-15-008
7. Place a container under radiator fan valve (18). Disconnect hoses (15) (4 used). j : 36 mm 8. Remove bolts (16) (2 used) and washers (17) (2 used). Remove radiator fan valve (18). j : 17 mm
W3-15-2-3
16 17
15 15
WJBE-03-15-009
SECTION 3 UPPERSTRUCTURE Group 15 Fan Valve Detail A
A
18
15
15
WJBE-03-15-008
Installation 1. Install radiator fan valve (18) with washers (17) (2 used) and bolts (16) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 2. Connect hoses (15) (4 used). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)
W3-15-2-4
16 17
15 15
WJBE-03-15-009
SECTION 3 UPPERSTRUCTURE Group 15 Fan Valve 13
8, 9 7 11, 12 10
WJBE-03-15-005
3. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 4. Install cover (14) with bolts, washers (13) (3 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 5. Install cover (10) with washers (12) (7 used) and bolts, washers (11) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 6. Install cover (7) with washers (9) (5 used) and bolts, washers (8) (5 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-15-2-5
14
WJBE-03-15-008
SECTION 3 UPPERSTRUCTURE Group 15 Fan Valve 1
2
3
WJBE-03-15-004
7. Install bolts, washers (3) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 8. Install cover (2) with bolts, washers (1) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-15-2-6
WJBE-03-15-007
SECTION 3 UPPERSTRUCTURE Group 15 Fan Valve Structure of Oil Cooler Fan Valve and Radiator Fan Valve View A
B
A
Section B
W1JB-02-13-003
W1JB-02-13-002
1 2 3
4 5 6 7
8
9
10
11
12
13
14
18
17
16
15
W1JB-02-13-001
W3-15-3-1
SECTION 3 UPPERSTRUCTURE Group 15 Fan Valve No.
Part Name
Q’ty
Wrench Size (mm)
No.
Part Name
Q’ty
1
Pin
2
10
O-Ring
1
2
Poppet
2
11
Spring
1
3
Poppet
1
12
O-Ring
1
4
Backup Ring
2
13
Lock Nut
1
5
O-Ring
1
14
Screw
1
6
O-Ring
1
15
Body
1
7
Spring
1
16
Poppet
1
8
O-Ring
1
17
Adaptor
1
9
Spring
1
18
Backup Ring
2
W3-15-3-2
Wrench Size (mm)
j : 19 j : 32 j : 32
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor Removal and Installation of Oil Cooler Fan Motor 11
10
2, 3
1
WJBE-03-08-001
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Remove bolts, washers (10) (6 used). Remove cover (11). j : 17 mm 3. Drain off hydraulic oil by using an oil feed pump.
fNOTE:
5, 6 4 8, 9
7
WJBE-03-15-001
Remove cover (1) while holding it. Do dCAUTION: not drop cover (1). 4. Remove bolts, washers (2) (5 used) and washers (3) (5 used). Remove cover (1). j : 19 mm Remove cover (4) while holding it. Do dCAUTION: not drop cover (4). 5. Remove bolts, washers (5) (6 used) and washers (6) (6 used). Remove cover (4). j : 19 mm Remove cover (7) while holding it. Do dCAUTION: not drop cover (7). 6. Remove bolts, washers (8) (7 used) and washers (9) (7 used). Remove cover (7). j : 19 mm
Total oil amount: 1042 L (275 US gal)
W3-16-1-1
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor 22 23 13 12
16 17
15
19 18
14 24
20 21
24
25
WJBE-03-16-001
7. Remove bolts, washers (12) (4 used). Remove door (13).
12. Remove bolts, washers (22) (3 used). Remove cover (23).
j : 19 mm
j : 19 mm
8. Remove bolts, washers (14) (4 used). Remove the cap (15) assembly.
13. Remove bolts, washers (24) (3 used). Remove support (25).
j : 17 mm
j : 19 mm
9. Remove bolts, washers (16) (9 used). Remove cover (17). j : 19 mm 10. Remove bolts, washers (18) (3 used). Remove cover (19). j : 19 mm 11. Remove bolts, washers (20) (5 used). Remove cover (21). j : 19 mm
W3-16-1-2
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
27 26
28
31
29
91 92
30
97
90 93
94 95 96
29
WJBE-03-16-003
dCAUTION:
Cover (28) weight: 25 kg (56 lb) 14. Remove bolts, washers (26) (7 used) and washers (27) (7 used). Remove cover (28). j : 19 mm 15. Remove bolts, washers (29) (6 used) and washers (30) (4 used). Remove cover (31). j : 19 mm 16. Remove bolts (90) (4 used), spring washers (91) (4 used), and washers (92) (4 used). Remove cover (93). j : 19 mm 17. Remove bolts (94) (6 used), spring washers (95) (6 used), and washers (96) (6 used). Remove cover (97). j : 19 mm
W3-16-1-3
WJBE-03-05-031
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor 73 61
70
98
71
WJBE-03-16-034
72
99
WJBE-03-16-004
18. Open cover (98). 19. Disconnect plugs (61) (2 used). 20. Remove clamps (70, 99). Disconnect hose (71).
dCAUTION:
Air cleaner (73) weight: 28 kg (62 lb) 21. Attach nylon slings onto the body of air cleaner (73). Hoist and hold air cleaner (73). 22. Remove bolts, washers (72) (4 used). Remove air cleaner (73). j : 17 mm
W3-16-1-4
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor 74
75
69
81
80
76
78, 79 88
89 69
WJBE-03-16-051
dCAUTION:
Bracket (75) weight: 23 kg (51 lb) 23. Remove bolts, washers (74) (13 used). Remove bracket (75). j : 19 mm 24. Place a container under the pipe (76) assembly. Disconnect hoses (69) (2 used). j : 36 mm
dCAUTION: (47 lb)
The pipe (76) assembly weight: 21 kg
25. Attach nylon slings onto the pipe (76) assembly. Hoist and hold the pipe (76) assembly. Remove bolts, washers (78) (4 used) and clamps (79) (2 used). j : 19 mm 26. Remove couplings (80, 81). Disconnect the pipe (76) assembly. 27. Remove bolts, washers (88) (4 used). Remove bracket (89). j : 19 mm
W3-16-1-5
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor 38, 39 41 40 83
35 37
36
33, 34 33, 34 33, 34 36
38, 39 40
83 84, 85 82 84, 85
WJBE-03-16-007
28. Remove bolts, washers (84) (4 used). Remove clamps (85) (2 used). j : 17 mm 29. Place a container under pipe (82). Remove couplings (83) (2 used). Disconnect pipe (82). 30. Remove bolts, washers (33) (6 used). Remove clamps (34) (3 used). j : 17 mm 31. Place a container under the oil cooler (37) assembly. Remove couplings (36) (2 used). Disconnect pipe (35). 32. Remove bolts, washers (38) (6 used). Remove clamps (39) (3 used). j : 17 mm 33. Remove couplings (40) (2 used). Disconnect pipe (41). 34. Remove bolt, washer (42) and clip (43). j : 17 mm
W3-16-1-6
42, 43
WJBE-03-16-009
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor 49
63
45 56 55
59 58
50
60
48 56 57 54 46, 47
52 51 53 53
62
44
44
50
WJBE-03-16-008
WJBE-03-16-010
35. Disconnect hoses (44) (2 used).
41. Remove socket bolts (51) (8 used) and flanges (52) (4 used). Disconnect hoses (53) (2 used). Remove O-rings (54) (2 used).
j : 36 mm 36. Remove bolts, washers (46) (2 used) and clips (47) (2 used). j : 17 mm
l : 8 mm 42. Remove bolts, washers (62) (4 used). Remove fan guards (63) (2 used).
37. Disconnect hose (45).
j : 19 mm
j : 27 mm The oil cooler fan motor (48) assembly dCAUTION: weight: 110 kg (245 lb) 38. Attach a nylon sling onto the oil cooler fan motor (48) assembly. Hoist and hold the oil cooler fan motor (48) assembly. 39. Remove bolts, washers (49) (8 used).
43. Remove nut (58) and washer (59). Remove the fan (60) assembly.
fNOTE:
LOCTITE #262 has been applied on nut (58).
j : 24 mm 44. Remove bolts (55) (2 used), washers (56) (4 used), and nuts (57) (2 used). Remove oil cooler fan motor (48).
j : 19 mm 40. Remove bolts, washers (50) (9 used). Remove the oil cooler fan motor (48) assembly. j : 19 mm
W3-16-1-7
j : 19 mm
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor 56 55
50
59 58
60
49
63
48 56 57 54 52 51 53 53
50 64
WJBE-03-16-008
62 WJBE-03-16-010
Installation 1. Install oil cooler fan motor (48) with nuts (57) (2 used), washers (56) (4 used), and bolts (55) (2 used). j : 19 mm m : 110 N·m (11 kgf·m, 81lbf·ft)
The oil cooler fan motor (48) assembly dCAUTION: weight: 110 kg (245 lb) 5. Attach a nylon sling onto the oil cooler fan motor (48) assembly. Hoist the oil cooler fan motor (48) assembly. 6. Install the oil cooler fan motor (48) assembly with bolts, washers (50) (9 used).
2. Apply LOCTITE #262 onto nut (58). Install the fan (60) assembly with washer (59) and nut (58).
j : 19 mm
j : 24 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 100 N·m (10 kgf·m, 74 lbf·ft) 3. Insert fan guards (63) (2 used) between fan (60) and bracket (64). Install them with bolts, washers (62) (4 used).
7. Install bolts, washers (49) (8 used).
j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 4. Install O-rings (54) (2 used) to hoses (53) (2 used). Connect hoses (53) (2 used) with flanges (52) (4 used) and socket bolts (51) (8 used). l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-16-1-8
j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
45
46, 47
42, 43
WJBE-03-16-009
44
8. Install clip (43) and bolt, washer (42). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 9. Connect hose (45). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 10. Install clips (47) (2 used) and bolts, washers (46) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 11. Connect hoses (44) (2 used). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)
W3-16-1-9
44
WJBE-03-16-008
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
38, 39 41 40 83
35 37
36
33, 34 33, 34 33, 34 36
38, 39 40
83 84, 85 82 84, 85
WJBE-03-16-007
12. Connect pipe (41) with couplings (40) (2 used). 13. Install clamps (39) (3 used) with bolts, washers (38) (6 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 14. Connect pipe (35) with couplings (36) (2 used). 15. Install clamps (34) (3 used) with bolts, washers (33) (6 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 16. Connect pipe (82) with couplings (83) (2 used). 17. Install clamps (85) (2 used) with bolts, washers (84) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-16-1-10
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
74
75
69
81
80
76
78, 79 88
89 69
WJBE-03-16-051
18. Install bracket (89) with bolts, washers (88) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION: (47 lb)
The pipe (76) assembly weight: 21 kg
19. Attach nylon slings onto the pipe (76) assembly. Hoist and hold the pipe (76) assembly. Connect the pipe (76) assembly with couplings (80, 81). 20. Install clamps (79) (2 used) with bolts, washers (78) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 21. Connect hoses (69) (2 used). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)
dCAUTION:
Bracket (75) weight: 23 kg (51 lb) 22. Install bracket (75) with bolts, washers (74) (13 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-16-1-11
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor 73 61
70
98
71
WJBE-03-16-034
72
99
WJBE-03-16-004
dCAUTION:
Air cleaner (73) weight: 28 kg (62 lb) 23. Attach nylon slings onto the body of air cleaner (73). Hoist and hold air cleaner (73). 24. Install air cleaner (73) with bolts, washers (72) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 25. Connect hose (71) with clamps (70, 99). m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 26. Connect plugs (61) (2 used). 27. Close cover (98).
W3-16-1-12
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
27 26
28
31
29
91 92
30
97
90 93
94 95 96
29
WJBE-03-16-003
28. Install cover (31) with washers (30) (4 used) and bolts, washers (29) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION:
Cover (28) weight: 25 kg (56 lb) 29. Install cover (28) with washers (27) (7 used) and bolts, washers (26) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 30. Install cover (93) with washers (92) (4 used), spring washers (91) (4 used), and bolts (90) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 31. Install cover (97) with washers (96) (6 used), spring washers (95) (6 used), and bolts (94) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-16-1-13
WJBE-03-05-031
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor 22 23 13 12
16 17
15
19 18
14 24
20 21
24
25
WJBE-03-16-001
32. Install support (25) with bolts, washers (24) (3 used). j : 19 mm
37. Install the cap (15) assembly with bolts, washers (14) (4 used). j : 17 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft) 33. Install cover (23) with bolts, washers (22) (3 used). j : 19 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft) 38. Install door (13) with bolts, washers (12) (4 used). j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft) 34. Install cover (21) with bolts, washers (20) (5 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 35. Install cover (19) with bolts, washers (18) (3 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 36. Install cover (17) with bolts, washers (16) (9 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-16-1-14
m : 90 N·m (9 kgf·m, 66 lbf·ft)
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor 11
2, 3
1
5, 6 4 8, 9
7
WJBE-03-15-001
39. Install cover (7) with washers (9) (7 used) and bolts, washers (8) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 40. Install cover (4) with washers (6) (6 used) and bolts, washers (5) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 41. Install cover (1) with washers (3) (5 used) and bolts, washers (2) (5 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 42. Fill the hydraulic oil tank with hydraulic oil.
fNOTE:
Total oil amount: 1042 L (275 US gal) 43. Install cover (11) with bolts, washers (10) (6 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 44. Bleed air from the hydraulic system. (Refer to W14-1.)
IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.
W3-16-1-15
10
WJBE-03-08-001
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor (Blank)
W3-16-1-16
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor Removal and Installation of Radiator Fan Motor
5, 6 4
8, 9 7 WJBE-03-15-005
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) Remove cover (4) while holding it. Do dCAUTION: not drop cover (4). 2. Remove bolts, washers (5) (5 used) and washers (6) (5 used). Remove cover (4). j : 19 mm Remove cover (7) while holding it. Do dCAUTION: not drop cover (7). 3. Remove bolts, washers (8) (7 used) and washers (9) (7 used). Remove cover (7). j : 19 mm
W3-16-2-1
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
10
11
12,13
M1J7-07-018
4. Remove bolts, washers (10) (2 used). Remove plate (11). j : 19 mm 5. Place a container under coolant outlet (12). Open cock (13). Drain off coolant.
fNOTE:
Coolant amount: 112 L (29.6 US gal) 6. Close cock (13). 7. Install plate (11) with bolts, washers (10) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-16-2-2
M1J7-07-022
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor Detail A 16
A
14 15
89 88 92 97
98 95 96 94 93
WJBE-03-16-034
17 18
21
19
20
WJBE-03-16-032
dCAUTION:
dCAUTION: (165 lb)
Cover (16) weight: 25 kg (56 lb) 8. Remove bolts, washers (14) (4 used) and washers (15) (4 used). Remove cover (16).
The duct (92) assembly weight: 73 kg
13. Remove bolts (97) (2 used) and washers (98) (2 used). Remove the duct (92) assembly.
j : 19 mm
j : 22 mm
9. Remove bolts, washers (17) (4 used) and washers (18) (4 used). Remove cover (19). j : 19 mm 10. Remove bolts, washers (20) (2 used). Remove bracket (21). j : 19 mm 11. Remove bolts (88) (4 used) and washers (89) (4 used). Open the duct (92) assembly. j : 22 mm 12. Remove pin (93) and washer (94). Remove the cover (96) side of stay (95).
W3-16-2-3
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor Detail B 26
B
22
24 23
25 33 34 36 35
27 27 37
28
38
32 WJBE-03-16-034
29
31 30
86
87
WJBE-03-16-031
20. Remove bolts, washers (35) (4 used). Remove cover (36).
dCAUTION:
Cover (22) weight: 42 kg (93 lb) 14. Open cover (22). 15. Remove pin (23) and washer (24). Remove the cover (22) side of cylinder (25). 16. Remove pin (26) and washers (27) (2 used). Remove the cover (22) side of stay (28). 17. Remove bolts, washers (29) (6 used). Remove cover (22).
j : 19 mm 21. Remove bolts, washers (37) (4 used). Remove cover (38). j : 19 mm 22. Open covers (86, 87).
j : 17 mm
dCAUTION:
Cover (30) weight: 22 kg (49 lb) 18. Remove bolts, washers (31, 32) (4 used for each). Remove cover (30). j : 19 mm 19. Remove bolts, washers (33) (3 used). Remove cover (34). j : 19 mm
W3-16-2-4
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
42
41 39 42
40 WJBE-03-16-036
dCAUTION:
Beam (40) weight: 22 kg (49 lb) 23. Attach nylon slings onto beam (40). Hoist and hold beam (40). 24. Remove bolts, washers (39) (6 used). Remove beam (40). j : 19 mm
dCAUTION:
Support (41) weight: 33 kg (73 lb) 25. Attach nylon slings onto support (41). Hoist and hold support (41). 26. Remove bolts, washers (42) (5 used). Remove support (41). j : 19 mm
W3-16-2-5
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
46
47
43, 44
45
52
50 53
51
48, 49
55
54 WJBE-03-16-033
27. Remove bolts, washers (43) (4 used). Remove clamps (44) (2 used). j : 17 mm 28. Remove clamps (45, 46) (2 used for each). Disconnect the pipe (47) assembly. 29. Remove bolts, washers (48) (2 used). Remove clamp (49). j : 17 mm 30. Remove bolts, washers (50) (2 used). j : 19 mm 31. Remove clamps (51, 52) (2 used for each). Disconnect pipe (53). 32. Remove bolts, washers (54) (2 used). Remove bracket (55). j : 19 mm
W3-16-2-6
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
56
58
63 62 59 65 64
66
67
60
61 WJBE-03-16-035
57 WJBE-03-16-004
33. Remove clamps (56, 57). Disconnect hose (58). 34. Remove clamps (59, 60) (2 used for each). Disconnect hose (61). 35. Remove split pins (62) (2 used) and pins (63) (2 used). 36. Remove bolts, washers (64) (4 used). Remove the stay (65) assembly. j : 19 mm 37. Remove bolts, washers (66) (4 used). Remove the stay (67) assembly. j : 19 mm
W3-16-2-7
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
68
71
70 72 WJBE-03-16-035
69
69 WJBE-03-15-009
38. Disconnect hose (68). j : 27 mm 39. Disconnect hoses (69) (2 used). j : 36 mm The radiator fan motor (70) assembly dCAUTION: weight: 113 kg (250 lb) 40. Attach nylon slings onto the radiator fan motor (70) assembly. Hoist and hold the radiator fan motor (70) assembly. 41. Remove bolts, washers (71) (6 used). j : 19 mm 42. Remove bolts, washers (72) (8 used). Remove the radiator fan motor (70) assembly. j : 19 mm
W3-16-2-8
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
74 73
85 83
81 80
82
79
70
77
75 76
78
84
85
91
90 WJBE-03-16-037
WJBE-03-15-009
43. Remove bolts, washers (73) (5 used). Remove cover (74).
fNOTE:
j : 19 mm 44. Remove socket bolts (75) (8used) and flanges (76) (4 used). Disconnect hoses (77) (2 used). Remove O-rings (78) (2 used). j : 8 mm
47. Remove nut (80) and washer (81). Remove the fan (82) assembly. LOCTITE #262 has been applied on nut (80).
j : 24 mm 48. Remove bolts (83) (2 used), washers (85) (4 used), and nuts (84) (2 used). Remove radiator fan motor (70).
45. Disconnect hose (79).
j : 19 mm
j : 27 mm 46. Remove bolts, washers (90) (4 used). Remove fan guards (91) (2 used). j : 19 mm
W3-16-2-9
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
99
74 73
85 83
81 80
82
79
70
77
75 76
78
84
85
91
90 WJBE-03-16-037
WJBE-03-15-009
Installation 1. Install radiator fan motor (70) with nuts (84) (2 used), washers (85) (4 used), and bolts (83) (2 used).
5. Install O-rings (78) (2 used) to hoses (77) (2 used). Connect hoses (77) (2 used) with flanges (76) (4 used) and socket bolts (75) (8 used). l : 8 mm
j : 19 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 110 N·m (11 kgf·m, 81 lbf·ft) 2. Apply LOCTITE #262 onto nut (80). Install the fan (82) assembly with washer (81) and nut (80).
6. Install cover (74) with bolts, washers (73) (5 used).
j : 24 mm
j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 100 N·m (10 kgf·m, 74 lbf·ft) 3. Insert fan guards (91) (2 used) between fan (82) and bracket (99). Install them with bolts, washers (90) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 4. Connect hose (79). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)
W3-16-2-10
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
68
71
70 72 69
69
WJBE-03-15-009
The radiator fan motor (70) assembly dCAUTION: weight: 113 kg (250 lb) 7. Attach nylon slings onto the radiator fan motor (70) assembly. Hoist the radiator fan motor (70) assembly. 8. Install the radiator fan motor (70) assembly with bolts, washers (71) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 9. Install bolts, washers (72) (8 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 10. Connect hose (68). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 11. Connect hoses (69) (2 used). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)
W3-16-2-11
WJBE-03-16-035
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
56
58
63 62 59 65 64
66
67
60
61 WJBE-03-16-035
57 WJBE-03-16-004
12. Install the stay (67) assembly with bolts, washers (66) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 13. Install the stay (65) assembly with bolts, washers (64) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 14. Install pins (63) (2 used) and split pins (62) (2 used). 15. Install hose (61) with clamps (59, 60) (2 used for each). m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 16. Install hose (58) with clamps (56, 57). m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-16-2-12
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
46
47
43, 44
45
52
50 53
51
48, 49
55
54 WJBE-03-16-033
17. Install bracket (55) with bolts, washers (54) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 18. Connect pipe (53) with clamps (51, 52) (2 used for each). m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 19. Install bolts, washers (50) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 20. Install clamp (49) with bolts, washers (48) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 21. Connect the pipe (47) assembly with clamps (45, 46) (2 used for each). m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 22. Install clamps (44) (2 used) with bolts, washers (43) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-16-2-13
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
42
41 39 42
40 WJBE-03-16-036
dCAUTION:
Support (41) weight: 33 kg (73 lb) 23. Attach nylon slings onto support (41). Hoist support (41). 24. Install support (41) with bolts, washers (42) (5 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION:
Beam (40) weight: 22 kg (49 lb) 25. Attach nylon slings onto beam (40). Hoist beam (40). 26. Install beam (40) with bolts, washers (39) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 27. Add coolant to the radiator.
fNOTE:
Coolant amount: 112 L (29.6 US gal)
28. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level and the coolant level. Start the engine and check for any oil and coolant leaks.
W3-16-2-14
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor Detail B 26
B
22
24 23
25 33 34 36 35
27 27 37
28
38
32 WJBE-03-16-034
29
31 30
86
87 WJBE-03-16-031
29. Install cover (38) with bolts, washers (37) (4 used). j : 19 mm
dCAUTION:
Cover (22) weight: 42 kg (93 lb) 33. Install cover (22) with bolts, washers (29) (6 used).
m : 90 N·m (9 kgf·m, 66 lbf·ft)
j : 17 mm
30. Install cover (36) with bolts, washers (35) (4 used). j : 19 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft) 34. Install the cover (22) side of stay (28) with washers (27) (2 used) and pin (26).
m : 90 N·m (9 kgf·m, 66 lbf·ft) 31. Install cover (34) with bolts, washers (33) (3 used). j : 19 mm
35. Install the cover (22) side of cylinder (25) with washer (24) and pin (23). 36. Close covers (22, 86, and 87).
m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION:
Cover (30) weight: 22 kg (49 lb) 32. Install cover (30) with bolts, washers (31, 32) (4 used for each). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-16-2-15
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor Detail A 16
A
14 15
89 88 92 97
98 95 96 94 93
WJBE-03-16-034
17 18
21
19
20
WJBE-03-16-032
dCAUTION: (165 lb)
The duct (92) assembly weight: 73 kg
41. Install cover (19) with washers (18) (4 used) and bolts, washers (17) (4 used). j : 19 mm
37. Install the duct (92) assembly with washers (98) (2 used) and bolts (97) (2 used). j : 22 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION:
m : 140 N·m (14 kgf·m, 103 lbf·ft) 38. Install the cover (96) side of stay (95) with washer (94) and pin (93).
Cover (16) weight: 25 kg (56 lb) 42. Install cover (16) with washers (15) (4 used) and bolts, washers (14) (4 used).
39. Close the duct (92) assembly. Install washers (89) (4 used) and bolts (88) (4 used). j : 22 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 40. Install bracket (21) with bolts, washers (20) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-16-2-16
j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor
5, 6 4
8, 9
7 WJBE-03-15-005
43. Install cover (7) with washers (9) (7 used) and bolts, washers (8) (7 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 44. Install cover (4) with washers (6) (5 used) and bolts, washers (5) (5 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-16-2-17
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor (Blank)
W3-16-2-18
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor Structure of Oil Cooler Fan Motor and Radiator Fan Motor 7
21 22
23 W1JB-02-12-002
1
20
2 3 4
19
5 6
18
7
17
8
9
16
W3-16-3-1
10
15 14
11
13
12
W1JB-02-12-001
SECTION 3 UPPERSTRUCTURE Group 16 Fan Motor No.
Part Name
Q’ty
1
End Cap
1
2
Rotor Insert Assembly
3
Tightening Torque N·m
(kgf·m, lbf·ft)
No.
Part Name
Q’ty
13
Retaining Ring
1
1
14
Retaining Ring
1
Vane Spring
24
15
Seal
1
4
Mount
12
16
Seal
1
5
Vane
12
17
Pin
2
6
Cam Ring
1
18
Seal
1
7
Port Plate Pressure
1
19
Needle Bearing
1
8
O-Ring
1
20
Socket Bolt
4
9
Housing
1
21
Bolt
1
10
Ball Bearing
1
22
Valve
1
11
Key
1
23
Screw
1
12
Shaft
1
W3-16-3-2
Tightening Torque N·m
(kgf·m, lbf·ft)
100
(10, 74)
12
(1.2, 8.9)
MEMO
MEMO
SECTION 4
UNDERCARRIAGE CONTENTS Group 1 Swing Bearing
Removal and Installation of Swing Bearing..........W4-1-1-1 Disassembly of Swing Bearing...................................W4-1-2-1 Assembly of Swing Bearing.........................................W4-1-2-4
Group 2 Travel Device
Removal and Installation of Travel Device.............W4-2-1-1 Disassembly of Travel Device......................................W4-2-2-1 Assembly of Travel Device...........................................W4-2-2-9 Disassembly of Travel Motor.......................................W4-2-3-1 Assembly of Travel Motor............................................W4-2-3-6 Disassembly of Brake Valve.........................................W4-2-4-1 Assembly of Brake Valve...............................................W4-2-4-4 Precautions for Using Floating Seal.........................W4-2-5-1
Group 3 Center Joint
Removal and Installation of Center Joint...............W4-3-1-1 Disassembly of Center Joint........................................W4-3-2-1 Assembly of Center Joint.............................................W4-3-2-3 Replacement of Body and Spindle...........................W4-3-2-6
Group 4 Track Adjuster
Removal and Installation of Track Adjuster...........W4-4-1-1 Disassembly of Track Adjuster....................................W4-4-2-1 Assembly of Track Adjuster.........................................W4-4-2-6
Group 5 Front Idler
Removal and Installation of Front Idler...................W4-5-1-1 Disassembly of Front Idler...........................................W4-5-2-1 Assembly of Front Idler.................................................W4-5-2-4 Precautions for Using Floating Seal.........................W4-5-3-1
Group 6 Upper and Lower Rollers
Removal and Installation of Upper Roller..............W4-6-1-1 Removal and Installation of Lower Roller..............W4-6-2-1 Disassembly of Upper Roller.......................................W4-6-3-1 Assembly of Upper Roller............................................W4-6-3-3 Disassembly of Lower Roller.......................................W4-6-4-1 Assembly of Lower Roller.............................................W4-6-4-3 Precautions for Using Floating Seal.........................W4-6-5-1
Group 7 Track
Removal and Installation of Track.............................W4-7-1-1
JBEW-4-1
(Blank)
JBEW-4-2
SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Removal and Installation of Swing Bearing
a
1
4
1
W105-03-01-002
2
a-
3
3
Matching Mark W142-03-01-001
ST 0051
1 W110-03-01-004
Before removing and installing the swing bearing, the upperstructure must be removed first. (Refer to W3-3-1.) Therefore, the procedure starts on the premise that the upperstructure has already been removed here. Removal 1. Put matching mark (a) on inner race (2) of swing bearing (1) and track frame (3).
dCAUTION: (2740 lb)
Swing bearing (1) weight: 1240 kg
3. Install special tools (ST 0051) (3 used) to swing bearing (1). Attach wire ropes onto special tools (ST 0051) (3 used). Hoist swing bearing (1). Remove swing bearing (1).
fNOTE:
THREEBOND #1102 has been applied between swing bearing (1) and track frame (3).
2. Remove bolts (4) (48 used). j : 46 mm
W4-1-1-1
SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing
3
a
1
ST 0051
W110-03-01-004
1 e b
2
a-
3
f
Matching Mark W142-03-01-001
c
c 123°
123°
d
d
b
b f
WJBE-04-01-001 b- c- d- e- f-
Installation 1. Clean the mounting surfaces of track frame (3) and swing bearing (1). 2. Apply THREEBOND #1102 onto the swing bearing (1) mounting surface of track frame (3).
dCAUTION: (2740 lb)
Position for Grease Fitting Soft Zone Marking Position Position for Plug Front Side Position for Knock Pin (2 Used)
IMPORTANT: If matching marks (a) do not fit, the soft zone position of inner race will be dislocated. 4. Fit matching marks (a) on track frame (3) and inner race (2) of swing bearing (1).
Swing bearing (1) weight: 1240 kg
3. Install special tools (ST 0051) (3 used) to swing bearing (1). Attach wire ropes onto special tools (ST 0051) (3 used). Hoist swing bearing (1).
W4-1-1-2
SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing
1
4
W105-03-01-002
5. Install swing bearing (1) with bolts (4) (48 used). j : 46 mm m : 1750 N·m (175 kgf·m, 1290 lbf·ft) 6. After installing swing bearing (1), add grease (Alvania EP2 or equivalent) to grease bath.
fNOTE:
Grease amount: 22 L (5.8 US gal)
W4-1-1-3
SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing (Blank)
W4-1-1-4
SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Disassembly of Swing Bearing 2
1
3
4
7
8
6
5 W1J1-03-01-001
9
1
2
6 8 7 5
WJAA-04-01-001 1- 2- 3- 4-
Outer Race Seal Pin Plug
5- 6- 7- 8-
Seal Ball (85 Used) Inner Race Support (85 Used)
9-
Grease Fitting
W4-1-2-1
SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Disassembly of Swing Bearing
3. Install bolt (10) to the screw hole (M10, Pitch 1.5 mm) of plug (4). Tap from within or pull bolt (10) and remove plug (4) from outer race (1).
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 1. Grind off the crimped part of pin (3) by using a grinder. Tap the bottom side of pin (3) of plug (4) by using a bar and a hammer. Remove pin (3) of plug (4).
1
3
4 4
10
W178-02-11-195
2. Thread hole (a) of plug (4) by using a tap (M10, Pitch 1.5 mm).
dCAUTION: lb)
Swing Bearing weight: 1240 kg (2740
4. Place inner race (7) of swing bearing on a wooden block by using the special tool (ST 0051). Hoist outer race (1) horizontally. Hold outer race (1).
4 a
WJAA-04-01-002 a-
W178-02-11-196
Hole
W4-1-2-2
SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing 5. Remove balls (6) (85 used) and supports (8) (85 used) from the plug (4) hole while rotating outer race (1).
1
2
7
11
6
5
W178-02-11-197
12
8
W178-02-11-198
fNOTE:
Remove ball (6) by using magnet (11). Use wire (12) and remove support (8). 6. Remove seals (2, 5) from outer race (1) and inner race (7) by using a scrapper.
W4-1-2-3
SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Assembly of Swing Bearing 2
1
3
4
8
7
6
5 W178-02-11-193
9
1
2
6 8 7 5
WJAA-04-01-001 1- 2- 3- 4-
Outer Race Seal Pin Plug
5- 6- 7- 8-
Seal Ball (85 Used) Inner Race Support (85 Used)
9-
Grease Fitting
W4-1-2-4
SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Assembly of Swing Bearing
dCAUTION: lb)
Swing Bearing weight: 1240 kg (2740
1. Install special tools (ST 0051) (3 used) to outer race (1). Attach a wire rope onto special tools (ST 0051) (3 used). Hoist the swing bearing horizontally. Align outer race (1) and inner race (7) coaxially. Apply grease onto balls (6) (85 used) and supports (8) (85 used). Install balls (6) (85 used) and supports (8) (85 used) alternately from the plug (4) hole by using a round bar while turning outer race (1).
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 2. Install plug (4) to outer race (1) by using a hammer. Secure plug (4) to outer race (1) with pin (3). Crimp the pin (3) hole of outer race (1) by using a punch (2 places).
3 1
4 2 W178-02-11-201
6 5 W178-02-11-199
8
W178-02-11-200
W4-1-2-5
SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing 3. Degrease the groove part for seals (2, 5) completely. Apply THREEBOND #1530D onto seals (2,5). Install seals (2, 5) to outer race (1) and inner race (7). 4. Add grease (Alvania EP2 or equivalent) to the swing bearing through grease fitting (9). At this time, add grease while turning outer race (1).
fNOTE:
Grease amount: 2.9 L (3.1 US qt)
W4-1-2-6
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Removal and Installation of Travel Device
2, 3
1 4
11, 12 W800-03-02-001
Removal IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.
d CAUTION:
Cover (4) weight: 46 kg (105 lb) 4. Install eyebolts (M16, Pitch 2 mm) to the bolt (2) hole. Attach nylon slings onto the eyebolts. Hoist and hold cover (4). 5. Remove bolts (11) (7 used) and spring washers (12) (7 used). Remove cover (4). j : 24 mm
Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Disconnect track (1). (Refer to W4-7-1.) 3. Remove bolt (2) and washers (3) (2 used). j : 24 mm
W4-2-1-1
SECTION 4 UNDERCARRIAGE Group 2 Travel Device
7
8
9, 10
5 6
13
14
W800-03-02-002
6. Place a container under travel device (5). Remove socket bolts (13) (8 used) and split flanges (14) (4 used). Disconnect hoses (6) (2 used). l : 10 mm 7. Disconnect hose (7). j : 27 mm 8. Disconnect hose (8). j : 19 mm
CAUTION: d(2410 lb)
Travel device (5) weight: 1090 kg
9. Attach nylon slings onto travel device (5). Hoist and hold travel device (5). Remove bolts (9) (24 used) and washers (10) (24 used). Hoist and remove travel device (5). j : 41 mm 10. Remove the adapter with travel device (5) attached if necessary. 11. Remove another travel device in the same way as step 1 to step 10.
W4-2-1-2
SECTION 4 UNDERCARRIAGE Group 2 Travel Device
7
8
9, 10
5 6
13
14
W800-03-02-002
Installation
4. Connect hose (7).
1. Install all removed adapters to travel device (5). CAUTION: d(2410 lb)
j : 27 mm
Travel device (5) weight: 1090 kg
2. Attach nylon slings onto travel device (5). Hoist travel device (5). Install travel device (5) with washers (10) (24 used) and bolts (9) (24 used).
m : 80 N·m (8 kgf·m, 59 lbf·ft) 5. Connect hoses (6) (2 used) with split flanges (14) (4 used) and socket bolts (13) (8 used). l : 10 mm
j : 41 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 1400 N·m (140 kgf·m, 1030 lbf·ft) 3. Connect hose (8). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)
W4-2-1-3
SECTION 4 UNDERCARRIAGE Group 2 Travel Device
2, 3
1 4
11, 12 W800-03-02-001
6. Connect track (1). (Refer to W4-7-1.) 7. Install another travel device in the same way as step 1 to step 6. 8. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. In order to prevent the travel motor from seizing, perform the break-in operation after installing. Condition: 1. Engine speed: Slow idle speed 2. Travel mode switch: Slow speed 3. Operation duration: Over 2 minutes
d CAUTION:
Cover (4) weight: 46 kg (105 lb) 9. Install eyebolts (M16, Pitch 2 mm) to the bolt (2) hole. Attach nylon slings onto the eyebolts. Hoist cover (4).
10. Install cover (4) with spring washers (12) (7 used) and bolts (11) (7 used). j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 11. Install washers (3) (2 used) and bolt (2). j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 12. Install another cover (4) in the same way as step 9 to step 11.
W4-2-1-4
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Travel Device
12 11 10
8
9
7 6 5 4
26 25
3
23
2 1
17
18
19
20
21
13
15
25 29 30
24 31
22
35
37 14
28 27
41
40
39
38
37
36 32
34
33
32
50
16
49 48 47 44 42
W4-2-2-1
43
45
46
W17V-03-02-001
SECTION 4 UNDERCARRIAGE Group 2 Travel Device 1- 2- 3- 4- 5- 6- 7- 8- 9- 10- 11- 12- 13- 14-
Bolt (4 Used) Spring Washer (4 Used) Motor O-Ring Housing Floating Seal Roller Bearing Bolt (12 Used) Support Drum Roller Bearing O-Ring Bearing Nut Lock Plate
15- 16- 17- 18- 19- 20- 21- 22- 23- 24- 25- 26- 27-
Bolt (2 Used) Sprocket Spring Washer (24 Used) Bolt (24 Used) Third Stage Carrier Spacer Third Stage Sun Gear Second Stage Carrier Spacer Second Stage Sun Gear Thrust Plate (6 Used) Needle Bearing (3 Used) Pin (3 Used)
28- First Stage Planetary Gear (3 Used) 29- Spring Pin (3 Used) 30- Spacer 31- First Stage Carrier 32- Thrust Plate (8 Used) 33- Second Stage Planetary Gear (4 Used) 34- Spring Pin (4 Used) 35- Pin (4 Used) 36- Needle Bearing (4 Used) 37- Thrust Plate (8 Used) 38- Third Stage Planetary Gear (4 Used)
W4-2-2-2
39- 40- 41- 42- 43- 44- 45- 46- 47- 48- 49- 50-
Spring Pin (4 Used) Pin (4 Used) Needle Bearing (8 Used) Shaft Ring Gear Socket Bolt (30 Used) Stopper Pin Bearing Cover Spring Washer (18 Used) Bolt (18 Used) Plug (3 Used)
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Travel Device There may be pressure accumulated dCAUTION: inside of the travel device. Loosen the air bleed
plug slowly. Release any remaining pressure completely. Remove the drain plug and drain gear oil. If the air bleed plug is loosened suddenly, the plug may be fly out and gear oil may gush out. Keep body and face away from plug.
dCAUTION: lb)
Travel device weight: 1090 kg (2410
1. Attach a nylon sling onto the body of travel device. Hoist and hold the travel device. Place a container under the travel device. Loosen plug (50a) by 2 to 3 turns. Remove plug (50b). Drain gear oil from the travel device. Place the travel device on a workbench with the travel motor (3) side up.
fNOTE:
dCAUTION: lb)
Travel motor (3) weight: 134 kg (300
2. Put the matching marks on travel motor (3) and housing (5). Install eyebolts (M12, Pitch 1.75 mm) (2 used) to lifting holes (c) ( 2 places) of travel motor (3). Attach a nylon sling onto the eyebolts. Hoist and hold travel motor (3). Remove bolts (1) (4 used) and spring washers (2) (4 used) from travel motor (3). Remove travel motor (3) from housing (5). Remove O-ring (4) from travel motor (3). j : 27 mm 1, 2 5
Amount of oil: 19.0 L (5.0 US gal) 3
j : 17 mm
c
50a c - Lifting Hole
50b WJAA-04-02-004
W4-2-2-3
W16J-03-02-002
SECTION 4 UNDERCARRIAGE Group 2 Travel Device
dCAUTION: (2100 lb)
Travel reduction gear weight: 950 kg
3. Attach a nylon sling onto the body of drum (10) and ring gear (43). Hoist the travel reduction gear. Place the travel reduction gear on a workbench with the cover (47) side up.
dCAUTION:
Cover (47) weight: 40 kg (90 lb) 4. Put the matching marks on cover (47) and ring gear (43). Remove bolts (49) (18 used) and spring washers (48) (18 used) from cover (47). Evenly install bolts (M12, Pitch 1.75 mm) (2 used) to bolt holes (d) (2 places) on cover (47). Float cover (47). Install eyebolts (M12, Pitch 1.75 mm) (2 used) to lifting holes (d) (2 places) on cover (47). Attach a nylon sling onto the eyebolts. Hoist and hold cover (47). Remove cover (47) from ring gear (43). j : 22 mm
Ring gear (43) weight: 130 kg (290 lb) 5. Put the matching marks on ring gear (43) and drum (10). Install eyebolts (M14, Pitch 2.0 mm) (2 used) to the bolt (49) holes (2 places) of ring gear (43). Attach a nylon sling onto the eyebolts. Hoist and hold ring gear (43). 6. Remove socket bolts (44) (30 used) from ring gear (43). Remove ring gear (43) from drum (10). Remove O-ring (12) from drum (10). l : 17 mm
The first stage carrier (31) assembly dCAUTION: weight: 30 kg (67 lb) 7. Remove shaft (42) from first stage carrier (31). Remove the first stage carrier (31) assembly and second stage sun gear (24) from second stage carrier (22). The second stage carrier (22) dCAUTION: assembly weight: 50 kg (115 lb)
47
8. Attach nylon slings (2 used) onto second stage carrier (22). Hoist second stage carrier (22). Remove the second stage carrier (22) assembly and third stage sun gear (21) from third stage carrier (19).
d
d - Lifting Hole
dCAUTION:
WJBC-04-02-001
W4-2-2-4
SECTION 4 UNDERCARRIAGE Group 2 Travel Device The third stage carrier (19) assembly dCAUTION: weight: 130 kg (290 lb) 9. Attach nylon slings (2 used) onto third stage carrier (19). Hoist third stage carrier (19). Remove the third stage carrier (19) assembly from drum (10). 10. Remove bolts (15) (2 used) from lock plate (14). Remove lock plate (14) from bearing nut (13). j : 19 mm 11. Install the special tool (ST 3140) to bearing nut (13). Remove bearing nut (13) from housing (5).
ST 3140
W1JB-03-02-003
W4-2-2-5
SECTION 4 UNDERCARRIAGE Group 2 Travel Device
d
CAUTION: Drum (10) + sprocket (16) + others weight: 350 kg (775 lb) IMPORTANT: The housing (5) side of drum (10) is the seal sliding surface for housing (5). Place it on a wooden block after removing. 12. Put the matching marks on support (9) and housing (5). Install eyebolts (M22, Pitch 2.5 mm) (2 used) to the bolt (44) holes (2 places) of drum (10). Attach a nylon sling onto the eyebolts. Hoist and hold drum (10). 13. Remove the drum (10) assembly from housing (5). Remove the inner race of roller bearing (11) from drum (10).
15. Put the matching marks on sprocket (16) and drum (10).
dCAUTION:
Sprocket (16) weight: 150 kg (335 lb) 16. Remove bolts (18) (24 used) and spring washers (17) (24 used) from sprocket (16). Install eyebolts (M27, Pitch 3.0 mm) (2 used) to lifting holes (e) (2 places) of sprocket (16). Attach a nylon sling onto the eyebolts. Hoist the sprocket. Remove sprocket (16) from drum (10). j : 41 mm
fNOTE:
LOCTITE #262 has been applied on bolt (18).
IMPORTANT: Handle floating seal (6) with care. (Refer to W4-2-5.) 14. Remove one side of floating seal (6) from housing (5).
16
e e - Lifting Hole
W4-2-2-6
WJBC-04-02-002
SECTION 4 UNDERCARRIAGE Group 2 Travel Device
dCAUTION: (445 lb)
dCAUTION: kg (400 lb)
Drum (10) + others weight: 200 kg
17. Install eyebolts (M27, Pitch 3.0 mm) (2 used) to the bolts (18) hole (2 places) of drum (10) through the motor (3) side. Attach a nylon sling onto the eyebolts. Hoist and turn over drum (10). IMPORTANT: Handle floating seal (6) with care. (Refer to W4-2-5.) 18. Remove one side of floating seal (6) from support (9). 19. Put the matching marks on support (9) and drum (10). Remove bolts (8) (12 used). Remove support (9) from drum (10). Remove the inner race of roller bearing (7) from drum (10). j : 19 mm
fNOTE:
THREEBOND #1215 has been applied between support (9) and drum (10).
The drum (10) assembly weight: 180
21. Hoist and turn over drum (10). Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. IMPORTANT: Do not remove the outer race of roller bearing (7) unless necessary. When it has been removed, replace it with the new one. 22. Remove the outer race of roller bearing (7) from drum (10) by using a bar and a hammer. 23. Remove spring pin (39) from third stage carrier (19) by using a round bar (diameter: 8 mm, 0.32 in). Remove pin (40), third stage planetary gear (38), and thrust plates (37) (2 used) from third stage carrier (19). Remove needle bearings (41) (2 used) from third stage planetary gear (38).
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. IMPORTANT: Do not remove the outer race of roller bearing (11) unless necessary. When it has been removed, replace it with the new one. 20. Remove the outer race of roller bearing (11) from drum (10) by using a bar and a hammer.
W4-2-2-7
SECTION 4 UNDERCARRIAGE Group 2 Travel Device 24. Remove spring pins (39) (3 used), pins (40) (3 used), third stage planetary gears (38) (3 used), thrust plates (37) (6 used), and needle bearings (41) (6 used) from third stage carrier (19) in the same way as step 23. 25. Disassemble the first stage carrier (31) assembly and the second stage carrier (22) assembly in the same way as step 23 and step 24.
Spring pin (29)
Diameter of round bar: 4 mm (0.16 in)
Spring pin (34)
Diameter of round bar: 5 mm (0.20 in)
26. Remove spacer (30) from first stage carrier (31). Remove spacer (23) from second stage carrier (22). Remove spacer (20) from third stage carrier (19).
W4-2-2-8
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Travel Device
4
5
6
8 9
7
11 13
16
10 12 44 20 19 43 22 23 31
50
30 42 24 47 46 45
3
28 26 27 29
35 25 1 2
49 48
21
14 15 17 18
37
41
38 40 37 39 32 33 36 32 34 T17V-03-05-001
W4-2-2-9
SECTION 4 UNDERCARRIAGE Group 2 Travel Device 1- 2- 3- 4- 5- 6- 7- 8- 9- 10- 11- 12- 13- 14-
Bolt (4 Used) Spring Washer (4 Used) Motor O-Ring Housing Floating Seal Roller Bearing Bolt (12 Used) Support Drum Roller Bearing O-Ring Bearing Nut Lock Plate
15- 16- 17- 18- 19- 20- 21- 22- 23- 24- 25- 26- 27-
Bolt (2 Used) Sprocket Spring Washer (24 Used) Bolt (24 Used) Third Stage Carrier Spacer Third Stage Sun Gear Second Stage Carrier Spacer Second Stage Sun Gear Thrust Plate (6 Used) Needle Bearing (3 Used) Pin (3 Used)
28- First Stage Planetary Gear (3 Used) 29- Spring Pin (3 Used) 30- Spacer 31- First Stage Carrier 32- Thrust Plate (8 Used) 33- Second Stage Planetary Gear (4 Used) 34- Spring Pin (4 Used) 35- Pin (4 Used) 36- Needle Bearing (4 Used) 37- Thrust Plate (8 Used) 38- Third Stage Planetary Gear (4 Used)
W4-2-2-10
39- 40- 41- 42- 43- 44- 45- 46- 47- 48- 49- 50-
Spring Pin (4 Used) Pin (4 Used) Needle Bearing (8 Used) Shaft Ring Gear Socket Bolt (30 Used) Stopper Pin Bearing Cover Spring Washer (18 Used) Bolt (18 Used) Plug (3 Used)
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Travel Device IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.
4. Install the inner race of roller bearing (7) to drum (10).
dCAUTION:
5. Apply THREEBOND #1215 onto the support (9) mounting surface of drum (10). Fit the matching marks made when disassembling and install support (9) to drum (10) with bolts (8) (12 used).
Housing (5) weight: 140 kg (310 lb) 1. Attach a nylon sling onto the body of housing (5). Hoist housing (5). Place housing (5) with the motor (1) side down.
IMPORTANT: Handle floating seal (6) with care. (Refer to W4-2-5.) 2. Apply grease onto O-ring of one side of floating seal (6). Install one side of floating seal (6) to housing (5). Apply gear oil onto the whole sliding surface on floating seal (6).
fNOTE:
If it is difficult to install O-ring of floating seal (6), push O-ring to the periphery direction by using a bamboo spatula.
dCAUTION: Drum (10) weight: 170 kg (375 lb) Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. IMPORTANT: Do not tap except for the outer race of roller bearing (7). 3. Install eyebolts (M27, Pitch 3.0 mm) (2 used) to the bolt (18) holes (2 places) of drum (10) through the motor (3) side. Attach a nylon sling onto the eyebolts. Hoist drum (10). Place drum (10) with the ring gear (43) side down. Evenly tap and install the outer race of roller bearing (7) to drum (10) by using a bar and a hammer.
fNOTE:
Check that the outer race of roller bearing (7) is installed completely.
W4-2-2-11
j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
SECTION 4 UNDERCARRIAGE Group 2 Travel Device IMPORTANT: Handle floating seal (6) with care. (Refer to W4-2-5.) 6. Apply grease onto O-ring of other side of floating seal (6). Install one side of floating seal (6) to support (9).
fNOTE:
If it is difficult to install O-ring of floating seal (6), push O-ring to the periphery direction by using a bamboo spatula. 7. Install eyebolts (M27, Pitch 3.0 mm) (2 used) to the bolt (18) holes (2 places) of drum (10) through the ring gear (43) side. Attach a nylon sling onto the eyebolts. Hoist drum (10). Place drum (10) with the ring gear (43) side up.
dCAUTION: Sprocket (16) weight: 150 kg (335 lb) When installing sprocket (16), dCAUTION: gather up the nylon sling and hoist sprocket (16)
horizontally. Do not drop sprocket (16). IMPORTANT: Fit the chamfered side of sprocket (16) to the drum (10) side. 9. Install eyebolts (M27, Pitch 3.0 mm) (2 used) to lifting holes (e) (2 places) of sprocket (16). Attach a nylon sling onto the eyebolts. Hoist the sprocket. Place sprocket (16) onto drum (10).
16
d
CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury. IMPORTANT: Do not tap except for the outer race of roller bearing (11). 8. Evenly tap and install the outer race of roller bearing (11) to drum (10) by using a bar and a hammer.
e e - Lifting Hole
fNOTE:
Check that the outer race of roller bearing (11) is installed completely.
WJBC-04-02-002
10. Degrease the bolt (18) holes on drum (10) and bolts (18) (24 used). Apply LOCTITE #262 onto bolts (18) (24 used). Install sprocket (16) to drum (10) with bolts (18) (24 used) and spring washers (17) (24 used). j : 41 mm m : 1400 N·m (140 kgf·m, 1030 lbf·ft)
W4-2-2-12
SECTION 4 UNDERCARRIAGE Group 2 Travel Device
d
CAUTION: Drum (10) + sprocket (16) + others weight: 350 kg (775 lb) 11. Hoist the drum (10) assembly. Fit the matching marks made when disassembling and place the drum (10) assembly straight on housing (5). At this time, check that the clearance between housing (5) and support (9) is even all around.
15. Install bearing nut (13) by using the special tool (ST 3140) and a torque wrench. m : 790 N·m (79 kgf·m, 580 lbf·ft) ST 3140
12. While applying the weight and shaking drum (10), push drum (10) into housing (5) straight. Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION: hot.
Be careful as roller bearing (11) is too
13. Warm up the inner race of roller bearing (11) to 50 to 70 °C (122 to 158 °F) by using a heater. Install the inner race of roller bearing (11) to housing (5) by using a bar and a hammer.
fNOTE:
Check that the inner race of roller bearing (11) is installed completely. IMPORTANT: Check the direction to install bearing nut (13). 14. Apply grease onto the thread part of bearing nut (13). Install bearing nut (13) to housing (5) with the turned surface facing to the roller bearing (11) side. Tighten bearing nut (13) by hand.
W1JB-03-02-003
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 16. After installing bearing nut (13), tap the sprocket (16) end by using a hammer and reduce play. Rotate sprocket (16) both clockwise and counterclockwise by 4 to 5 turns. 17. Repeat step 15 and step 16. 18. Tighten bearing nut (13) in the same way as step 15 again.
W4-2-2-13
m : 790 N·m (79 kgf·m, 580 lbf·ft)
SECTION 4 UNDERCARRIAGE Group 2 Travel Device IMPORTANT: In case the spline of lock plate (14) and that of housing (5) do not fit, tighten bearing nut (13) in tightening direction until both splines fit. 19. Degrease the bolt (15) holes on bearing nut (13) and bolts (15) (2 used). Apply LOCTITE #262 onto bolts (15) (2 used). Install lock plate (14) to bearing nut (13) with bolts (15) (2 used). j : 19 mm
24. Install spring pin (39) to third stage carrier (19) with the slit (a) side facing to the second stage carrier (22) side. 40
a - Slit
m : 90 N¡m (9 kgf¡m, 66 lbf¡ft) 20. Install spacer (20) to third stage carrier (19). IMPORTANT: There is an identification groove on one side of third stage planetary gear (38). Install third stage planetary gear (37) with the identification groove side facing to the cover (47) side. 21. Install needle bearings (41) (2 used) to third stage planetary gear (38). 22. Secure third stage planetary gear (38) between thrust plates (37) (2 used). Install them to third stage carrier (19). 23. Install pin (40) to third stage carrier (19). At this time, fit the spring pin (39) holes of third stage carrier (19) and pin (40).
39 a
W178-02-11-210
25. Install other third stage planetary gears (38) (3 used) to third stage carrier (19) in the same way as step 21 to step 24. The third stage carrier (19) assembly dCAUTION: weight: 130 kg (290 lb) 26. Attach two nylon slings onto the third stage carrier (19) assembly. Hoist the third stage carrier (19) assembly. Install the third stage carrier (19) assembly to housing (5). 27. Install third stage sun gear (21) to third stage carrier (19) with the small outer diameter side up. 28. Install spacer (23) to second stage carrier (22). 29. Install needle bearing (36) to second stage planetary gear (33). 30. Secure second stage planetary gear (33) between thrust plates (32) (2 used). Install them to second stage carrier (22). 31. Install pin (35) to second stage carrier (22). At this time, fit the spring pin (34) holes of second stage carrier (22) and pin (35).
W4-2-2-14
SECTION 4 UNDERCARRIAGE Group 2 Travel Device 32. Install spring pin (34) into second stage carrier (22) with the slit (a) side facing to cover (47). 35
a - Slit
34
38. Secure first stage planetary gear (28) between thrust plates (25) (2 used). Install them to first stage carrier (31). 39. Install pin (27) to first stage carrier (31). At this time, fit the spring pin (29) holes of first stage carrier (31) and pin (27).
a
W178-02-11-210
40. Install spring pin (29) into first stage carrier (31) with the slit (b) side facing to cover (47). 27
33. Install other second stage planetary gears (33) (3 used) to second stage carrier (22) in the same way as step 29 to step 32. The second stage carrier (22) dCAUTION: assembly weight: 50 kg (115 lb)
b - Slit
34. Attach nylon slings (2 used) onto the second stage carrier (22) assembly. Hoist the second stage carrier (22) assembly. Install the second stage carrier (22) assembly to third stage sun gear (21). 35. Install second stage sun gear (24) to second stage carrier (22) with the small outer diameter side up. 36. Install spacer (30) to first stage carrier (31).
29
b
W178-02-11-210
41. Install other first stage planetary gears (28) (2 used) to first stage carrier (31) in the same way as step 37 to step 40. The first stage carrier (31) assembly dCAUTION: weight: 30 kg (67 lb) 42. Install the first stage carrier (31) assembly to second stage carrier (22).
37. Install needle bearing (26) to first stage planetary gear (28).
W4-2-2-15
SECTION 4 UNDERCARRIAGE Group 2 Travel Device 43. Insert the spline side of shaft (42) into the center of second stage sun gear (24). Rotate sprocket (16) slowly by hand. Engage travel motor (3) and first stage planetary gears (28) (3 used) with shaft (42), and install them. 44. Install O-ring (12) to drum (10).
dCAUTION:
Ring gear (43) weight: 130 kg (290 lb) 45. Install eyebolts (M14, Pitch 2.0 mm) (2 used) to the bolt (49) holes (2 places) of ring gear (43). Attach a nylon sling onto eyebolts. Hoist ring gear (43). Fit the matching marks made when disassembling and place ring gear (43) onto drum (10).
dCAUTION:
Cover (47) weight: 40 kg (90 lb) 49. Clean the mating surfaces of ring gear (43) and cover (47). Apply THREEBOND #1215. 50. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to lifting holes (d) (2 places) on cover (47). Attach a nylon sling onto the eyebolts. Hoist cover (47). Place cover (47) onto ring gear (43). 47 d
46. Degrease the socket bolt (44) holes on drum (10) and socket bolts (44) (30 used). Apply LOCTITE #262 onto socket bolts (44) (30 used). Install ring gear (43) to drum (10) with socket bolts (44) (30 used). l : 17 mm d - Lifting Hole
m : 750 N·m (75 kgf·m, 550 lbf·ft) Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 47. Attach a tube bar onto ball bearing (46). Tap a tube bar by using a hammer and install ball bearing (46) to cover (47).
fNOTE:
Ball bearing (46) inner diameter: 35 mm (1.4 in), outer diameter: 80 mm (3.2 in)
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 48. Attach a tube bar onto stopper pin (45). Tap a tube bar by using a hammer and install stopper pin (45) to ball bearing (46).
fNOTE:
Stopper pin (45) diameter: 26 mm (1.0 in)
W4-2-2-16
WJBC-04-02-001
SECTION 4 UNDERCARRIAGE Group 2 Travel Device 51. Degrease the bolt (49) holes on ring gear (43) and bolts (49) (18 used). Apply LOCTITE #262 onto bolts (49) (18 used). Install cover (47) to ring gear (43) with spring washers (48) (18 used) and bolts (49) (18 used). j : 22 mm
dCAUTION:
Motor (3) weight: 134 kg (300 lb) 56. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to lifting holes (c) (2 places) of motor (3). Attach a nylon sling onto the eyebolts. Hoist motor (3). Fit the splines of shaft (42) and motor (3). Install motor (3) to housing (5) and driven shaft (45).
m : 210 N·m (21 kgf·m, 155 lbf·ft) 52. Install a seal tape onto plugs (50) (3 used). Install plugs (50) (3 used) to cover (47).
1, 2
5
l : 17 mm 3
m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION:
Travel reduction gear weight: 950 kg 53. Install eyebolts (M27, Pitch 3.0 mm) (2 used) to the bolt holes (2 places) of the flange part in housing (5). Attach a nylon sling onto the eyebolts. Hoist and turn over the travel reduction gear. 54. Fill gear oil to the travel reduction gear.
fNOTE:
Amount of oil: 19.0 L (5.0 US gal) 55. Install O-ring (4) to motor (3).
c
c - Lifting Hole
W16J-03-02-002
57. Install motor (3) to housing (5) with spring washers (2) (4 used) and bolts (1) (4 used). j : 27 mm m : 300 N·m (31 kgf·m, 220 lbf·ft)
W4-2-2-17
SECTION 4 UNDERCARRIAGE Group 2 Travel Device (Blank)
W4-2-2-18
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Travel Motor
3
2
4
1
7
16
17
15
6 5 14
2 13 12 11 10 9
32
8
18
31 27
30
19 29 26
28
25 24 23 22 21 20
WJAA-04-02-001
W4-2-3-1
SECTION 4 UNDERCARRIAGE Group 2 Travel Device 1- 2- 3- 4- 5- 6- 7- 8-
Housing O-Ring (4 Used) Spring (2 Used) Piston (2 Used) Oil Seal Roller Bearing Shaft Steel Ball (2 Used)
9- 10- 11- 12- 13- 14- 15- 16-
Swash Plate Plunger (9 Used) Retainer Bushing Spring (9 Used) Rotor Valve Plate Collar
17- 18- 19- 20- 21- 22- 23- 24-
Roller Bearing Plate (4 Used) Friction Plate (5 Used) Backup Ring O-Ring O-Ring Backup Ring Brake Piston
W4-2-3-2
25- 26- 27- 28- 29- 30- 31- 32-
O-Ring Spring (10 Used) Pin Pin (4 Used) Brake Valve Socket Bolt (9 Used) Plate Plate
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Travel Motor
dCAUTION:
Travel motor weight: 134 kg (300 lb) 1. Attach a nylon sling onto the travel motor. Hoist the travel motor. Place the travel motor with the brake valve (29) side up.
dCAUTION:
Brake valve (29) weight: 39 kg (86 lb) IMPORTANT: Evenly loosen socket bolts (30) (9 used). When loosening socket bolt (30), valve housing (29) is floated from case (1) by the reaction force of springs (13, 26). At this time, record the clearance between case (1) and valve housing (29). IMPORTANT: When removing the brake valve (29) assembly, do not drop valve plate (15). 2. Remove socket bolts (30) (9 used). Install an eyebolt (M12, Pitch 1.75 mm) to the lifting hole (a) of brake valve (29). Attach a nylon sling onto the eyebolt. Hoist brake valve (29). Remove brake valve (29) from housing (1).
IMPORTANT: Do not remove roller bearing (17) unless necessary. Remove roller bearing (17) by using a small puller if necessary. As the outer race is deformed, roller bearing (17) cannot be reused. IMPORTANT: Do not damage valve plate (15). 3. Remove valve plate (15), pin (27), and pins (28) (4 used) from brake valve (29). 4. Wrap the tape on the thrust surface of shaft (7) for roller bearing (17) in order to protect. 5. Remove springs (26) (10 used) from housing (1). 6. Remove O-ring (25) and O-rings (2) (4 used) from housing (1). When removing brake piston (24), dCAUTION: cover with a cloth in order not to fly out brake
piston (24). 7. Apply air 100 to 300 kPa (1.0 to 3.0 kgf/cm2, 15 to 44 psi) to the brake releasing oil passage in housing (1). Float and remove brake piston (24).
l : 14 mm
1
29
30
a
W16J-03-02-002 a - Lifting Hole
W4-2-3-3
SECTION 4 UNDERCARRIAGE Group 2 Travel Device 8. Remove O-rings (21, 22), and backup rings (20, 23) from brake piston (24). 9. Remove plate (32), friction plates (19) (5 used), plates (18) (4 used), and plate (31) from housing (1). 10. Remove rotor (14), springs (13) (9 used), bushing (12), retainer (11), and plungers (10) (9 used) from housing (1).
dCAUTION: kg (145 lb)
The housing (1) assembly weight: 65
11. Attach a nylon sling onto housing (1). Hoist the housing (1) assembly. Place the housing (1) assembly horizontally with the brake releasing oil passage (a) down.
fNOTE:
When facing the brake releasing oil passage (a) upward, the thicker part of swash plate (9) faces upward. When placing the housing (1) assembly horizontally, swash plate (9) suddenly may come out.
When removing swash plate (9), cover dCAUTION: with a cloth in order not to fly out piston (4). IMPORTANT: When swash plate (9) cannot be removed, apply air 100 to 300 kPa (1.0 to 3.0 kgf/ cm2, 15 to 44 psi) through the piston oil passage hole. Swash plate (9) and piston (4) are removed. 12. Remove swash plate (9) from housing (1). 13. Remove balls (8) (2 used), pistons (4) (2 used), and springs (3) (2 used) from housing (1) by using a magnet. 14. Attach a bar onto the bottom of the spline hole of shaft (1). Tap and remove shaft (1) and roller bearing (6) from housing (1) by using a bar and a plastic hammer. Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 15. Remove the outer race of roller bearing (6) from housing (1) by using a bar and a hammer.
1
a - Brake Releasing Oil Passage
a
WJBA-04-02-002
W4-2-3-4
SECTION 4 UNDERCARRIAGE Group 2 Travel Device IMPORTANT: Oil seal (5) cannot be reused. 16. Remove oil seal (5) from housing (1) by using a screwdriver.
fNOTE:
THREEBOND #1104 or #1215 has been applied onto the outer surface of the oil seal. IMPORTANT: When removing shaft (7) from roller bearing (6), do not drop shaft (7). 17. Secure the inner race of roller bearing (6) remained on shaft (7) in a vise. Remove shaft (7) from roller bearing (6) by using a bar and a plastic hammer.
6 7
WJAA-04-02-007
W4-2-3-5
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Travel Motor 3
4
7
31
32 20,21
24
22,23 26
30
32 16 8
29 17
1 5 15 28 6
9
12 11 13 18
19
25 2
10 14
W17V-03-02-002
1- 2- 3- 4- 5- 6- 7- 8-
Housing O-Ring (4 Used) Spring (2 Used) Piston (2 Used) Oil Seal Roller Bearing Shaft Steel Ball (2 Used)
9- 10- 11- 12- 13- 14- 15- 16-
Swash Plate Plunger (9 Used) Retainer Bushing Spring (9 Used) Rotor Valve Plate Collar
17- 18- 19- 20- 21- 22- 23- 24-
Roller Bearing Plate (4 Used) Friction Plate (5 Used) Backup Ring O-Ring O-Ring Backup Ring Brake Piston
W4-2-3-6
25- 26- 27- 28- 29- 30- 31- 32-
O-Ring Spring (10 Used) Pin Pin (4 Used) Brake Valve Socket Bolt (9 Used) Plate Plate
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Travel Motor IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
Housing (1) weight: 60 kg (135 lb) 1. Attach a nylon sling onto housing (1). Hoist housing (1). Place housing (1) with the brake valve (29) side up.
such as goggles, helmets, etc in order to prevent personal injury. 6. Install the inner race to shaft (7) with the flange part facing to the stepped part of shaft (7) by using a bar and a hammer.
2. Apply OCEAN grease #7 onto the inner surface of oil seal (5).
7. Install springs (3) (2 used) and pistons (4) (2 used) to housing.
dCAUTION:
3. Apply THREEBOND #1104 or #1215 onto the outer surface of oil seal (5). 4. Clean the oil seal (5) mating part of housing (1). Install oil seal (5) to housing (1) by using a plate, a bar, and a plastic hammer. Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 5. Install the outer race of roller bearing (6) to housing (1) by using a bar and a hammer.
IMPORTANT: The small diameter side of shaft (7) is matched with the inner race on roller bearing (17). Do not damage the inner race of roller bearing (17). 8. Install shaft (7) to housing (1) by using a plastic hammer.
fNOTE:
W4-2-3-7
Shaft (7) can be inserted without tapping when aligning them correctly.
SECTION 4 UNDERCARRIAGE Group 2 Travel Device 9. Install balls (8) (2 used) to housing (1). 10. Apply grease onto the ball (8) hole on swash plate (9). Align the position of balls (8) (2 used) and install swash plate (9) to housing (1).
dCAUTION: kg (145 lb)
IMPORTANT: Install retainer (11) with the chamfered surface (b) facing to the bushing (12) side. 12. Install springs (13) (9 used), bushing (12), retainer (11), and plungers (10) (9 used) to rotor (14). 11
The housing (1) assembly weight: 65
11. Attach a nylon sling onto housing (1). Hoist the housing (1) assembly. Place the housing (1) assembly horizontally with the brake releasing oil passage (a) down.
12
b
fNOTE:
When facing the brake releasing oil passage (a) upward, the thicker part of swash plate (9) faces upward. When placing the housing (1) assembly horizontally, swash plate (9) suddenly may come out.
b - Chamfered Surface Side
W178-02-11-225
13. Install the rotor (14) assembly to housing (1).
dCAUTION: kg (190 lb)
The housing (1) assembly weight: 85
14. Attach a nylon sling onto housing (1). Hoist the housing (1) assembly. Place the housing (1) assembly with the brake valve (29) mounting surface side up.
1
IMPORTANT: Check the order to install friction plate (19) and plates (18, 31, and 32). 15. Install plate (31), friction plates (19) (5 used), plates (18) (4 used), and plate (32) to housing (1). 16. Apply grease onto O-rings (21, 22) and backup rings (20, 23). Install O-rings (21, 22) and backup rings (20, 23) to brake piston (24). a
WJBA-04-02-002
a - Brake Releasing Oil Passage
W4-2-3-8
SECTION 4 UNDERCARRIAGE Group 2 Travel Device IMPORTANT: Check the direction to install brake piston (24). Install brake piston (24) with the notch vertical corresponding to the pin (28) mounting hole on housing (1). 17. Install brake piston (24) to housing (1) by using a plastic hammer.
IMPORTANT: The spring (26) mounting holes (12 places) on brake piston (24) are located corresponding to springs (26) (10 used). Check the position to install springs (26). 18. Install springs (26) (10 used) to brake piston (24). 24
f
NOTE: As O-ring (22) is positioned around brake piston (24), brake piston (24) cannot be fully inserted. When installing brake valve (29), tighten brake piston (24) with socket bolt (30).
b 26
1
26 b
24
W16J-03-02-003 b - Not Used
19. Install O-rings (2) (4 used) and O-ring (25) to housing (1).
a
20. Add hydraulic oil into housing (1) until plate (18) is submerged. 28
W16J-03-02-003
a - Notch
W4-2-3-9
SECTION 4 UNDERCARRIAGE Group 2 Travel Device 21. Install pin (27) to brake valve (29).
25. Install collar (16) to shaft (7).
IMPORTANT: Check the direction to install pin (28). 22. Install pins (28) (4 used) to brake valve (29) with the large diameter side facing to the brake valve (29) side. Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. IMPORTANT: Check the direction to install the outer race of roller bearing (17). 23. Install the outer race of roller bearing (17) to brake valve (29) with the stamped mark facing outside by using a bar and a hammer.
dCAUTION:
Brake valve (29) weight: 39 kg (86 lb) IMPORTANT: When installing valve housing (29) to housing (1), check that a clearance between housing (1) and valve housing (29) is equal to that before disassembling. If the dimension differs, disassemble and assemble again. IMPORTANT: Do not drop valve plate (15). If valve plate (15) is damaged, oil leakage will occur. 26. Install brake valve (29) to housing (1) with socket bolts (30) (9 used).
24. Apply grease onto the flat surface of valve plate (15).Fit the valve plate (15) with the pin (27) position and install valve plate (15) to brake valve (29).
fNOTE:
Valve plate (15) is secured to brake valve (29) tightly in order not to drop brake valve (15) when turning over.
W4-2-3-10
l : 14 mm m : 300 N·m (30 kgf·m, 220 lbf·ft)
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Brake Valve
1
2
3
6
5
4
7
9 10 11
8
12 35 36 37
38
39
40
41
42
43
44
48 47
49 10 9 16
13 17
18 19
14 20
51 4
21
3 2
23
1
45 44 50
43 42
46
22
24
26
27
15
28
25
30 31
33 34
29 41 40
32
5
36 39
38
35 37 WJAA-04-02-012
1- 2- 3- 4- 5- 6- 7- 8- 9- 10- 11- 12- 13-
Plug (2 Used) O-Ring (2 Used) Spring (2 Used) Check Valve (2 Used) Relief Valve Plug O-Ring Spring Plug (6 Used) O-Ring (6 Used) Orifice (2 Used) Socket Bolt (9 Used) Valve Assembly
14- 15- 16- 17- 18- 19- 20- 21- 22- 23- 24- 25- 26-
O-Ring Plug Poppet Seat (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Backup Ring (2 Used) Poppet (2 Used) Relief Housing (2 Used) Piston (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Backup Ring (2 Used) Spring Seat (2 Used)
27- 28- 29- 30- 31- 32- 33- 34- 35- 36- 37- 38- 39-
Spring (2 Used) Spring Guide (2 Used) O-Ring (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Plug (2 Used) Nut (2 Used) Set Screw (2 Used) Socket Bolt (8 Used) Cap (2 Used) O-Ring (2 Used) Spring Seat (2 Used) Spring (2 Used)
W4-2-4-1
40- 41- 42- 43- 44- 45- 46- 47- 48- 49- 50- 51-
Spring Seat (2 Used) Plug (2 Used) O-Ring (2 Used) Spring (2 Used) Check Valve (2 Used) Spool Valve Housing Pin (4 Used) Pin Orifice Spool Assembly Orifice (2 Used)
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Brake Valve IMPORTANT: Spool assembly (50), valve assembly (13), orifices (11, 49, and 51), and the plug should be replaced as the valve housing (46) assembly.
dCAUTION:
The brake valve weight: 39 kg (86 lb) 1. Secure the brake valve on a workbench. 2. Remove plug (6) from valve housing (46). Remove O-ring (7) from plug (6). Remove spring (8) from valve housing (46) by using a magnet. l : 10 mm
IMPORTANT: As the setting changes, do not disassemble relief valves (5) (2 used). As the setting changes, do not turn set screws (34) (2 used). Attach an identification tag onto relief valves (5) (2 used) for assembling. IMPORTANT: Do not move piston (22) attached on the outer surface of relief valve (5). O-ring (24) may be damaged. 6. Remove relief valves (5) (2 used) from valve housing (46). j : 36 mm
3. Remove plug (15) from valve housing (46). Remove O-ring (14) from plug (15).
22
24
5
l : 10 mm IMPORTANT: Remove valve housing assembly (13) by rotating. If they stick even a little, try again instead of pulling them roughly. Do not disassemble valve assembly (13). 4. Remove valve assembly (13) from valve housing (46).
34
WJAA-04-02-010
5. Remove plugs (1) (2 used) from valve housing (46). Remove O-rings (2) (2 used) from plugs (1) (2 used). Remove springs (3) (2 used) and check valves (4) (2 used) from valve housing (46) by using a magnet. l : 14 mm
7. Hold one cap (36). Evenly loosen and remove socket bolts (35) (4 used) from cap (36). Remove cap (36) from valve housing (46). l : 10 mm
fNOTE:
If cap (36) cannot be removed, tap by using a plastic hammer. Tap cap (36) with socket bolt (35) attached (loosened).
W4-2-4-2
SECTION 4 UNDERCARRIAGE Group 2 Travel Device 8. Remove socket bolts (35) (4 used) from another cap (36). Remove cap (36) from valve housing (46). l : 10 mm 9. Remove spring seats (38) (2 used), springs (39) (2 used), and spring seats (40) (2 used) from valve housing (46). IMPORTANT: Remove spool assembly (50) by rotating. If they stick even a little, try again instead of pulling them roughly. 10. Remove spool assembly (50) from valve housing (46). 11. Secure spool assembly (50) by using wooden pieces in a vise. 12. Remove plugs (41) (2 used) from spool (45). Remove O-rings (42) (2 used) from plugs (41) (2 used). Remove springs (43) (2 used) and check valves (44) (2 used) from spool (45).
W4-2-4-3
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Brake Valve Relief Valve (5) 18
17,19
26 24 27 31
20
10 11 6 7
22 23,25
29
28
32
33
30
36 38
41 37 39 51 42 40 43 44 45
35 A
A
A 9
49
8
50
13 48
47
14 12 15
46
5
2 1
3
4 WJAA-04-02-011
W4-2-4-4
SECTION 4 UNDERCARRIAGE Group 2 Travel Device 1- 2- 3- 4- 5- 6- 7- 8- 9- 10- 11- 12- 13-
Plug (2 Used) O-Ring (2 Used) Spring (2 Used) Check Valve (2 Used) Relief Valve Plug O-Ring Spring Plug (6 Used) O-Ring (6 Used) Orifice (2 Used) Socket Bolt (9 Used) Valve Assembly
14- 15- 16- 17- 18- 19- 20- 21- 22- 23- 24- 25- 26-
O-Ring Plug Poppet Seat (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Backup Ring (2 Used) Poppet (2 Used) Relief Housing (2 Used) Piston (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Backup Ring (2 Used) Spring Seat (2 Used)
27- 28- 29- 30- 31- 32- 33- 34- 35- 36- 37- 38- 39-
Spring (2 Used) Spring Guide (2 Used) O-Ring (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Plug (2 Used) Nut (2 Used) Set Screw (2 Used) Socket Bolt (8 Used) Cap (2 Used) O-Ring (2 Used) Spring Seat (2 Used) Spring (2 Used)
W4-2-4-5
40- 41- 42- 43- 44- 45- 46- 47- 48- 49- 50- 51-
Spring Seat (2 Used) Plug (2 Used) O-Ring (2 Used) Spring (2 Used) Check Valve (2 Used) Spool Valve Housing Pin (4 Used) Pin Orifice Spool Assembly Orifice (2 Used)
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Brake Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: Check the direction to install valve assembly (13). 1. Install O-rings (7, 14) to plugs (6, 15). Install valve assembly (13), spring (8), and plugs (6, 15) to valve housing (46).
6. Install the spool (45) assembly approximately half way into valve housing (46). 7. Install O-rings (37) (2 used) to caps (36) (2 used). 8. Install spring seat (40), spring (39), and spring seat (38) to valve housing (46). Install cap (36) with socket bolts (35) (4 used). l : 10 mm m : 110 N·m (11 kgf·m, 81 lbf·ft)
l : 10 mm
9. Install another cap (36) in the same way as step 8.
m : 65 N·m (6.5 kgf·m, 48lbf·ft) 2. Install O-rings (2) (2 used) to plugs (1) (2 used). Install check valves (4) (2 used), springs (3) (2 used), and plugs (1) (2 used) to valve housing (46). l : 14 mm m : 420 N·m (42 kgf·m, 310 lbf·ft) IMPORTANT: Install relief valve (5) to the original position before disassembly. 3. Install relief valves (5) (2 used) to valve housing (46). j : 36 mm m : 420 N·m (42 kgf·m, 310 lbf·ft) 4. Install O-rings (42) (2 used) to plugs (41) (2 used). 5. Install check valves (44) (2 used), springs (43) (2 used), and plugs (41) (2 used) to spool (45).
W4-2-4-6
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Precautions for Using Floating Seal
1
1. In general, replace the floating seal with a new one after disassembling.
If the floating seal is required to be reused, follow these procedures:
Keep seal rings together as a matched set with seal ring (1) surfaces together. Apply oil onto sliding surface (e) of seal ring (1). Check sliding surface (e) of seal ring (1) for scuffing, scoring, corrosion, deformation, or uneven wear. Check the step part of seal ring (1). Check O-ring (2) for tears, breaks, deformation, or hardening.
W178-02-11-001
2
2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following to prevent trouble. Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust, or dirt from seal mounting bores. After cleaning, thoroughly dry parts with compressed air. Clean seal ring (1) and O-ring (2) mounting bores. Check the bore surface for scuffing or scoring by touching the surface with finger. After installing the floating seal, check that O-ring (2) is not twisted, and that it is installed correctly on seal ring (1). After installing the floating seal, check that O-ring (2) and seal ring sliding surface (e) is parallel with seal mating surface (f ) by measuring the distances (e) and (f ) at point (A) and (B), as illustrated. If these distances differ, correct O-ring (2) seating.
a
c b d W178-02-11-002 a - Correct b - Incorrect
c - Twist of O-Ring d - Bend of O-Ring f a
b
A
A
e
2
B
A=B
B
A≠B W178-02-11-003
a - Correct b - Incorrect
W4-2-5-1
e - Sliding Surface f - Seal Mating Surface
SECTION 4 UNDERCARRIAGE Group 2 Travel Device (Blank)
W4-2-5-2
SECTION 4 UNDERCARRIAGE Group 3 Center Joint Removal and Installation of Center Joint
WJAA-04-03-001
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.
4. Disconnect hose (4). j : 17 mm 5. Remove bolts (8) (2 used) and washers (9) (2 used). Remove stopper (10). Remove washers (14) (2 used) between stopper (10) and center joint (1) at this time.
Removal
j : 22 mm
1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Place a container under center joint (1). Disconnect hoses (2) (4 used). j : 41 mm 3. Disconnect hose (3). j : 27 mm
W4-3-1-1
SECTION 4 UNDERCARRIAGE Group 3 Center Joint
WJAA-04-03-002
6. Remove adapters (15) (4 used).
10. Disconnect hoses (7) (2 used).
j : 41 mm
dCAUTION:
j : 19 mm
Center joint (1) weight: 52 kg (115 lb) 7. Install eyebolts (G1) to the plug (15) hole (2 places in diagonal position) of center joint (1). Attach nylon slings onto the eyebolts. Hoist and hold center joint (1). 8. Disconnect hoses (5) (2 used).
11. Remove bolts (12) (4 used) and washers (13) (4 used). Remove center joint (1). j : 24 mm 12. Remove the adapter with center joint (1) attached if necessary.
j : 27 mm 9. Disconnect hoses (6) (4 used). j : 41 mm
W4-3-1-2
SECTION 4 UNDERCARRIAGE Group 3 Center Joint
WJAA-04-03-002
Installation
5. Connect hoses (6) (4 used).
1. Install all removed adapters to center joint (1).
j : 41 mm
dCAUTION:
Center joint (1) weight: 52 kg (115 lb) 2. Install eyebolts (G1) to the plug (15) hole (2 places in diagonal position) of center joint (1). Attach nylon slings onto the eyebolts. Hoist center joint (1). 3. Install center joint (1) with washers (13) (4 used) and bolts (12) (4 used). j : 24 mm
m : 200 N·m (20 kgf·m, 148 lbf·ft) 6. Connect hoses (5) (2 used). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 7. Install adapters (15) (4 used). j : 41 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)
m : 210 N·m (21 kgf·m, 155 lbf·ft)
4. Connect hoses (7) (2 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)
W4-3-1-3
SECTION 4 UNDERCARRIAGE Group 3 Center Joint
WJAA-04-03-001
8. Install washers (14) (2 used) between stopper (10) and center joint (1). Install stopper (10) with washers (9) (2 used) and bolts (8) (2 used).
10. Connect hose (3). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)
j : 22 mm m : 140 N·m (14 kgf·m, 103 lbf·ft)
11. Connect hoses (2) (4 used). j : 41 mm
9. Connect hose (4).
m : 200 N·m (20 kgf·m, 148 lbf·ft)
j : 17 mm m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
12. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.
W4-3-1-4
SECTION 4 UNDERCARRIAGE Group 3 Center Joint Disassembly of Center Joint 00B
00A
01 02 03 05 06 07 08 04 09 10
W16J-03-03-001
00A- Spindle 00B- Plug (With Ball) 01- Body
02- Dust Seal 03- O-Ring 04- Oil Seal (6 Used)
05- Bushing 06- Ring 07- Retaining Ring
W4-3-2-1
08- O-Ring 09- Cover 10- Bolt, Washer (4 Used)
SECTION 4 UNDERCARRIAGE Group 3 Center Joint Disassembly of Center Joint
dCAUTION:
Center joint weight: 52 kg (115 lb) 1. Remove bolts, washers (10) (2 used) diagonally. Install an eyebolt (M12, Pitch 1.75 mm) to the bolt (10) hole (2 places) of body (01). Attach a nylon sling onto the eyebolt. Hoist the center joint. Secure the center joint on a workbench.
IMPORTANT: For easy removal of oil seal (04), use the pins (2 used). Do not damage the seal groove. 6. Remove oil seals (04) (6 used), O-ring (03), and dust seal (02) from body (01).
j : 19 mm 2. Put the matching marks on body (01) and spindle (00A). Remove other bolts, washers (10) (2 used). Remove cover (09) from body (01). j : 19 mm 3. Remove O-ring (08), retaining ring (07), and ring (06) from body (01). 4. Install the special tools (ST 1033, ST 1020) to body (01) with bolts, washers (10) (2 used). j : 19 mm, 32 mm
W178-02-11-240
IMPORTANT: Do not damage the seal surface. 7. When replacing bushing (05), build-up weld at 4 places in its inner diameter by using a welding rod. Shrink and remove bushing (05).
ST 1020 ST 1033
10
01
W183-03-03-004
IMPORTANT: Do not damage the the seal sliding surface of spindle (00A). 5. Remove spindle (00A) from body (01).
W4-3-2-2
SECTION 4 UNDERCARRIAGE Group 3 Center Joint Assembly of Center Joint
00A
02 03 05
04
01
06 08
10
07 09
00A- Spindle 00B- *Plug (With Ball) 01- Body
fNOTE:
W183-03-08-001
02- Dust Seal 03- O-Ring 04- Oil Seal (6 Used)
05- Bushing 06- Ring 07- Retaining Ring
As for the parts with mark *, refer to W4-3-2-1.
W4-3-2-3
08- O-Ring 09- Cover 10- Bolt, Washer (4 Used)
SECTION 4 UNDERCARRIAGE Group 3 Center Joint Assembly of Center Joint IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: When assembling the seals, apply grease (Apolloil Autorex C) and install seals to each groove. IMPORTANT: If bushing (05) has been removed, install bushing (05) first. (Refer to W4-3-2-6.) 1. Apply grease onto the mounting part for dust seal (02) on body (01). Install dust seal (02) to body (01) with the metal part (a) facing to the body (01) side.
a
IMPORTANT: Do not damage bushing (05). IMPORTANT: The clearance between body (01) and spindle (00A) should be 0.1 mm (0.004 in). Insert body (01) along axis straight and slowly. Do not damage the seal. IMPORTANT: Install body (01) so that the ring (06) mounting part (b) is flat. 3. Apply grease onto the oil seal (04) inside, the bushing (05) inside, and the dust seal (02) sliding surface of spindle (00A). Place spindle (00A) on a workbench. Fit the matching marks made when disassembling and install body (01) to spindle (00A).
02
b
00A 01
W800-03-03-001
01 a - Metal Part
2. Install O-ring (03) and oil seals (04) (6 used) to body (01).
W800-03-03-002 b - Ring (06) Mounting Part
W4-3-2-4
SECTION 4 UNDERCARRIAGE Group 3 Center Joint IMPORTANT: Install ring (06) with the chamfered surface facing to the spindle (00A) side. 4. Install ring (06) and O-ring (08) to body (01). 5. Install retaining ring (07) to spindle (00A). 6. Install cover (09) to body (01) with bolts, washers (10) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W4-3-2-5
SECTION 4 UNDERCARRIAGE Group 3 Center Joint Replacement of Body and Spindle ST 2670
IMPORTANT: When replacing body (01) or spindle (00A) with the new one, the following procedures are required.
01
In case of Body (01) 1. Clean body (01) and bushing (05).
05
2. Apply grease onto the bushing (05) mounting part on body (01). 3. Install bushing (05) to body (01) by using the special tool (ST 2670).
fNOTE:
Pushing force: 0.5 to 1.5 t (1100 to 3310 lb)
W178-02-11-242
In case of spindle (00A)
00B
C
1. Clean spindle (00A).
00A
2. Install plug (00B) to spindle (00A) by using the special tool (ST 2560). 3. Install ball (a) of plug (00B) so that the top of each ball is 0.4 mm (0.02 in) or more lower than the respective sleeve (c) edge as illustrated in detail C.
WDAA-04-03-005 ST 2560
Detail C
b
c
a
WDAA-04-03-006 a - Ball
W4-3-2-6
WDAA-04-03-007 b - 0.4 mm or more c - Sleeve
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Removal and Installation of Track Adjuster
1
W142-03-04-002
Before removing and installing the track adjuster, the tracks and front idler must be removed first. (Refer to W47-1 and W4-5-1.) Therefore, the procedure starts on the premise that the tracks and front idler have already been removed here. Removal
d CAUTION:
Track adjuster (1) weight
ď‚— ZX870-5G, 870H-5G: 492 kg (1090 lb) ď‚— ZX870LC-5G, 870LCH-5G, 870LCR-5G: 505 kg (1120 lb) CAUTION: Track adjuster (1) may fly out due to dthe spring force when removing track adjuster
(1). Do not stand in the same direction to remove track adjuster (1) or where it may fly out. 1. Attach nylon slings onto track adjuster (1). Hoist and hold track adjuster (1). Remove track adjuster (1).
fNOTE:
pry bar.
If it is difficult to remove it, pry it out by using a
W4-4-1-1
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster
1
W142-03-04-002
2
Installation
d CAUTION:
Track adjuster (1) weight
ZX870-5G, 870H-5G: 492 kg (1090 lb) ZX870LC-5G, 870LCH-5G, 870LCR-5G: 505 kg (1120 lb) 1. Attach nylon slings onto track adjuster (1). Hoist track adjuster (1). 2. Install track adjuster (1) with the grease outlet (2) side down.
W4-4-1-2
W16J-03-04-002
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Disassembly of Track Adjuster
8 9
15
4 7 18 16 14
6
17
5
3
13
1 2
12 10
11
WJBC-04-04-001
1- 2- 3- 4- 5-
Socket Bolt (6 Used) O-Ring Guide Piston Rod Wear Ring
6- 7- 8- 9- 10-
U-Ring Retaining Ring Cylinder O-Ring Spacer
11- 12- 13- 14- 15-
Spring Bracket Nut Bolt Rod
W4-4-2-1
16- Valve 17- Backup Ring 18- Plate
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Disassembly of Track Adjuster Use a pump unit which has the maximum pressure of 69 MPa (700 kgf/cm2, 10010 psi) and the oil capacity of 8 to 10 liters (2.1 to 2.6 US gal). Set the main relief pressure to 49 MPa (500 kgf/cm2, 7110 psi), the thrust to 80 t (176000 lb) or lower. CAUTION: The spring (11) force is extremely large. Carry out the disassembly and assembly work carefully. Inspect the special tool for any damage thoroughly in order to perform the work safely.
2. Check that valve (16) is loose. Compress spring (11) of the track adjuster by using the special tool (ST 4932) so that clearance (h) between bracket (12) and nut (13) is 10 mm (0.4 in).
d
dCAUTION:
h
Track adjuster weight
12 13
ZX870-5G, 870H-5G: 492 kg (1090 lb) ZX870LC-5G, 870LCH-5G,
14
870LCR-5G: 505 kg (1120 lb) 1. Attach a nylon sling onto the track adjuster. Hoist the track adjuster. Install the track adjuster to holder (e) of the special tool (ST 4932). ST 4932
15
16 W142-03-04-020 h - Clearance
e
W142-03-04-019 e - Holder
W4-4-2-2
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster 3. Put the matching marks on rod (15) and nut (13).
9. Install an eyebolt (M16, Pitch 2.0 mm) to piston rod (4). Attach a nylon sling onto spring (11). Pass a nylon sling through the eyebolt on piston rod (4). Hoist and place the spring (11) assembly on holder (e).
4. Remove valve (16) from rod (15). j : 24 mm 5. Remove bolt (14) from nut (13). j : 19 mm
4
6. Remove nut (13) from rod (15). j : 140 mm 7. Retract the cylinder of the special tool (ST 4932) slowly and extend spring (11) to the free length.
fNOTE:
11
Spring (11) free length: 1005 mm (40.0 in)
dCAUTION:
The spring (11) assembly weight
ď‚— ZX870-5G, 870H-5G: 483 kg (1070 lb) ď‚— ZX870LC-5G, 870LCH-5G,
e
870LCR-5G: 496 kg (1100 lb) 8. Secure bracket (12) and spring (11) by using wire (g). Attach a nylon sling onto spring (11). Hoist the spring (11) assembly. Remove the spring (11) assembly from the special tool (ST 4932).
11
W142-03-04-006 e - Holder
ST 4932
12
g
W142-03-04-005 g - Wire
W4-4-2-3
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster 13. Remove socket bolts (1) (6 used) from guide (3). Remove guide (3) from piston rod (4).
d
CAUTION: The cylinder (8) assembly weight
ZX870-5G, 870H-5G: 217 kg (480 lb)
l : 12 mm
ZX870LC-5G, 870LCH-5G,
2
870LCR-5G: 230 kg (510 lb) 10. Remove the cylinder (8) assembly from spring (11).
3 1
8
8
15
W142-03-04-010
11
14. Remove piston rod (4) from cylinder (8). 15. Remove O-ring (2) from guide (3). e
W142-03-04-007
dCAUTION:
Spring (11) weight: 266 kg (590 lb) 11. Remove wire (g) which secure spring (11) and bracket (12). Attach a nylon sling onto spring (11). Hoist spring (11). Remove spring (11) from holder (e).
dCAUTION: dCAUTION:
Spacer (10) weight: 32 kg (71 lb)
Bracket (12) weight: 34 kg (75 lb) 12. Remove spacer (10) and bracket (12) from holder (e).
W4-4-2-4
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster
dCAUTION: Cylinder (8) weight: 65 kg (145 lb) Rod (15) weight: 47 kg (105 lb) 16. Install an eyebolt (M16, Pitch 2.0 mm) to rod (15). Attach a nylon sling onto the eyebolts. Hoist cylinder (8). Remove rod (15) from cylinder (8). 17. Remove O-ring (9) from cylinder (8). 18. Remove retaining ring (7), plate (18), U-ring (6), backup ring (17), and wear ring (5) from piston rod (4).
W4-4-2-5
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Assembly of Track Adjuster
16
13
11
12
10
9
7, 18
5
4
3
8
c
f
14
15
a
6, 17
b 1
2
WJBC-04-04-002
a - Grease Chamber
b - Grease Groove
c - Lifting Hole
f -
1- 2- 3- 4- 5-
6- 7- 8- 9- 10-
11- 12- 13- 14- 15-
16- Valve 17- Backup Ring 18- Plate
Socket Bolt (6 Used) O-Ring Guide Piston Rod Wear Ring
U-Ring Retaining Ring Cylinder O-Ring Spacer
Spring Bracket Nut Bolt Rod
W4-4-2-6
Grease Outlet
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Assembly of Track Adjuster
6. Fill grease chamber (a) with grease.
IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Apply grease onto wear ring (5), backup ring (17), and U-ring (6).
7. Apply hydraulic oil onto piston rod (4).
2. Install wear ring (5) and backup ring (17) to piston rod (4). 3. Install U-ring (6) to piston rod (4) with the lip part facing to the rod (15) side. 4. Install plate (18) and retaining ring (7) to piston rod (4).
dCAUTION:
Cylinder (8) weight: 65 kg (145 lb)
Rod (15) weight: 47 kg (105 lb) 5. Apply grease onto O-ring (9). Install O-ring (9) to cylinder (8). Install an eyebolt (M16, Pitch 2.0 mm) to the rod (15) lifting hole (d). Attach a nylon sling onto the eyebolt. Hoist the rod. Install rod (15) to cylinder (8). d 9
15 8
WJAA-04-04-001 d - Lifting Hole
W4-4-2-7
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster 8. Install an eyebolt (M16, Pitch 2.0 mm) to piston rod (4). Attach a nylon sling onto the eyebolt. Hoist the piston rod. Insert piston rod (4) to cylinder (8) and completely bleed air from grease chamber (a) and rod (15). 9. Fill grease groove (b) with grease. 10. Apply grease onto O-ring (2). Apply LOCTITE #262 onto socket bolts (1) (6 used). 11. Install O-ring (2) to guide (3). Install guide (3) to cylinder (8) with socket bolts (1) (6 used).
dCAUTION: Spacer (10) weight: 32 kg (71 lb) Bracket (12) weight: 34 kg (75 lb) Spring (11) weight: 266 kg (590 lb) 12. Attach a nylon sling onto bracket (12). Hoist bracket (12). Place bracket (12) and spacer (10) onto holder (e). Attach a nylon sling onto spring (11). Hoist the spring (11) assembly. Place spring (11) onto bracket (12). Secure bracket (12) and spring (11) by using a wire.
l : 12 mm m : 140 N·m (14 kgf·m, 103 lbf·ft) 8 2 3
1
4
10 11
12
e
W142-03-04-018 W142-03-04-007 e - Holder
dCAUTION:
The cylinder (8) assembly weight
ZX870-5G, 870H-5G: 217 kg (480 lb) ZX870LC-5G, 870LCH-5G, 870LCR-5G: 230 kg (510 lb) 13. Fit the cylinder (8) assembly with spacer (10) and bracket (12), and install the cylinder (8) assembly to the bracket (12) assembly.
W4-4-2-8
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster IMPORTANT: Slowly compress spring (11) while fitting the center of rod (15) with that of bracket (12) by using a pry bar. Do not damage the threads on rod (15). 16. Operate the cylinder of the special tool (ST 4932) and remove wire (g). Compress spring (11) to the specified spring (11) length.
d
CAUTION: The spring (11) assembly weight
ď‚— ZX870-5G, 870H-5G: 483 kg (1070 lb) ď‚— ZX870LC-5G, 870LCH-5G, 870LCR-5G: 496 kg (1100 lb) 14. Attach a nylon sling onto spring (11). Pass a nylon sling through the eyebolt on piston rod (4). Hoist and place the spring (11) assembly slowly and horizontally.
fNOTE:
Specified spring length: 805 mm (31.7 in)
4
11
ST 4932
11 12
g
W142-03-04-006
W142-03-04-015
15. Install the spring (11) assembly to the special tool (ST 4932) with grease outlet (f ) on rod (15) facing down. Remove the eyebolt from piston rod (4).
g - Wire
ST 4932
W142-03-04-005
W4-4-2-9
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster IMPORTANT: Check that the grease outlet of rod (15) is fitting with that of nut (13). 17. Fit the matching marks made when disassembling and install nut (13) to rod (15). Secure nut (13) to rod (15) with bolt (14). j : 140 mm j : 19 mm m : 60 N·m (6 kgf·m, 44 lbf·ft) 13 15
14 16 W142-03-04-020
18. Install valve (16) to rod (15). j : 24 mm m : 150 N·m (15 kgf·m, 111 lbf·ft) 19. Retract the cylinder of special tool (ST 4932).
dCAUTION:
Track adjuster weight
ZX870-5G, 870H-5G: 492 kg (1090 lb) ZX870LC-5G, 870LCH-5G, 870LCR-5G: 505 kg (1120 lb) 20. Attach a nylon sling onto the track adjuster. Hoist the track adjuster. Remove the track adjuster from special tool (ST4932). If only the spring assembly is dCAUTION: transported, use a firm steel box and take any other precautions in order to carry the track adjuster safely.
W4-4-2-10
SECTION 4 UNDERCARRIAGE Group 5 Front Idler Removal and Installation of Front Idler 1
3
2
1
a
W17P-03-05-001
a-
Before removing and installing the front idler, the tracks must be removed first. (Refer to W4-7-1.) Therefore, the procedure starts on the premise that the tracks have already been removed here.
Wooden Block
2. Attach nylon slings onto yoke (2) and bearing (3). Hoist and hold front idler (1). Remove front idler (1). 3. Place front idler (1) on wooden blocks (a) (2 used).
Removal
dCAUTION: Front idler (1) weight: 574 kg (1270 lb) Front idler (1) may fly out due to the dCAUTION: spring force when removing front idler (1). Do not stand in the same direction to remove front idler (1) or where front idler (1) may fly out. 1. Pull out front idler (1) to the position where nylon slings can be attached onto yoke (2).
fNOTE:
W105-03-05-003
If it is difficult to remove it, use a pry bar.
W4-5-1-1
SECTION 4 UNDERCARRIAGE Group 5 Front Idler
1
3
2
W17P-03-05-001
Installation
dCAUTION:
Front idler (1) weight: 574 kg (1270 lb) 1. Attach nylon slings onto yoke (2) and bearing (3). Hoist front idler (1). 2. Install front idler (1) to the track frame, the position where nylon slings can be removed. 3. Remove the nylon slings. 4. Install front idler (1).
W4-5-1-2
SECTION 4 UNDERCARRIAGE Group 5 Front Idler Disassembly of Front Idler 2 1
7
6
3
8
5
9
6 4 1
5
10
3
11
2
14 13 8
1- 2- 3- 4-
Bearing (2 Used) Pin (2 Used) O-Ring (2 Used) Axle
5- 6- 7- 8-
Floating Seal (2 Used) Bushing (2 Used) Idler Plug (2 Used)
9- 10- 11- 12-
Guard Bolt (4 Used) Spring Washer (4 Used) Yoke
W4-5-2-1
12
W800-03-05-001
13- Bolt (4 Used) 14- Spring Washer (4 Used)
SECTION 4 UNDERCARRIAGE Group 5 Front Idler Disassembly of Front Idler 1. Remove bolts (10) (4 used) and spring washers (11) (4 used) from guard (9). Remove guard (9) from yoke (12). j : 19 mm
dCAUTION:
Yoke (12) weight: 71 kg (160 lb) 2. Attach a nylon sling onto yoke (12). Hoist and hold yoke (12). Remove bolts (13) (4 used) and spring washers (14) (4 used). Remove yoke (12) from bearings (1) (2 used).
The idler (7) assembly weight: 425 kg dCAUTION: (940 lb) The axle (4) assembly weight: 97 kg (215 lb) 5. Put the matching marks on bearing (1) and axle (4). Remove the axle (4) assembly from idler (7) by using a press. 1
4 7
j : 36 mm 3. Remove plug (8) from bearing (1). Drain off oil. l : 6 mm Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 4. Remove pin (2) from bearing (1) by using a bar and a hammer.
W105-03-05-008
dCAUTION:
Bearing (1) weight: 52 kg (115 lb) IMPORTANT: Handle the floating seal with care. (Refer to W4-5-3.) 6. Remove bearing (1) from the upper side of idler (7). Remove floating seals (5) (2 used) from idler (7) and bearings (1) (2 used). 1 5
7 5 3 4
1
W105-03-05-009
W4-5-2-2
SECTION 4 UNDERCARRIAGE Group 5 Front Idler
d
CAUTION: The axle (4) assembly weight: 97 kg (215 lb) IMPORTANT: Place wooden block (a) under bearing (1) in order not to damage bearing (1). 7. Attach a nylon sling onto the axle (4) assembly. Hoist the axle (4) assembly. Place bearing (1) onto wooden block (a).
IMPORTANT: Do not remove bushing (6) unless necessary. 10. When replacing bushing (6), remove bushings (6) (2 used) from idler (7) by using the special tool (ST1977) and a press.
ST1977
2
3 1
a 6
4 3
W105-03-05-011
W105-03-05-010 a - Wooden Block
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
Bearing (1) weight: 52 kg (115 lb) 8. Remove pin (2) from bearing (1) at the other side by using a bar and a hammer. Put the matching marks on bearing (1) and axle (4). Remove axle (4) from bearing (1) by using a press. 9. Remove O-rings (3) (2 used) from axle (4).
W4-5-2-3
SECTION 4 UNDERCARRIAGE Group 5 Front Idler Assembly of Front Idler 1
5
6
7
3 2
10, 11
9
14
2
4
12
13
W800-03-05-002
1- 2- 3- 4-
Bearing (2 Used) Pin (2 Used) O-Ring (2 Used) Axle
5- 6- 7- 8-
Floating Seal (2 Used) Bushing (2 Used) Idler Plug (2 Used)
8 W800-03-05-003
9- 10- 11- 12-
Guard Bolt (4 Used) Spring Washer (4 Used) Yoke
W4-5-2-4
13- Bolt (4 Used) 14- Spring Washer (4 Used)
SECTION 4 UNDERCARRIAGE Group 5 Front Idler Assembly of Front Idler IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.
dCAUTION:
Idler (7) weight: 344 kg (760 lb) 1. Install bushings (6) (2 used) to idler (7) by using a press.
IMPORTANT: Handle the floating seal with care. (Refer to W4-5-3.) 4. Apply engine oil onto O-ring of floating seal (5). Install floating seal (5) to idler (7) and bearing (1).
dCAUTION: (215 lb)
5. Attach a nylon sling onto bearing (1) of the axle (4) assembly. Hoist the axle (4) assembly. Install the axle (4) assembly to idler (7) from the side where floating seal (5) has already been installed.
dCAUTION: Axle (4) weight: 45 kg (100 lb) Bearing (1) weight: 52 kg (115 lb) 2. Attach a nylon sling onto axle (4). Hoist axle (4). Place axle (4) vertically. Install O-ring (3) to the upper side of axle (4). Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 3. Fit the matching marks made when disassembling and install bearing (1) to axle (4) by using a plastic hammer. Install pin (2) to bearing (1) by using a bar and a hammer. 2 4 1
3
The axle (4) assembly weight: 97 kg
W105-03-05-014
W4-5-2-5
SECTION 4 UNDERCARRIAGE Group 5 Front Idler 6. Apply LOCTITE #503 onto plug (8). Install plug (8) to bearing (1).
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury.
l : 6 mm m : 20 N·m (2 kgf·m, 15 lbf·ft)
d
CAUTION: The idler (7) assembly weight: 442 kg (975 lb) 7. Attach a nylon sling onto the idler (7) assembly. Hoist the idler (7) assembly. Turn over the idler (7) assembly.
IMPORTANT: Handle the floating seal with care. (Refer to W4-5-3.) 8. Install other O-ring (3) to axle (4). Apply engine oil onto O-ring of floating seal (5). Install other floating seal (5) to idler (7) and bearing (1).
dCAUTION:
Bearing (1) weight: 52 kg (115 lb) 9. Fit the matching marks made when disassembling and install bearing (1) to axle (4) by using a plastic hammer. Install pin (2) to bearing (1) by using a bar and a hammer.
10. Add engine oil (API CD class, SAE #30) through the plug (8) hole of bearing (1).
fNOTE:
Oil amount: 0.5 L (0.53 US qt) 11. Apply LOCTITE #503 onto plug (8). Install plug (8) to bearing (1). l : 6 mm m : 20 N·m (2 kgf·m, 15 lbf·ft)
1
5
3
dCAUTION:
Yoke (12) weight: 71 kg (160 lb) 12. Attach a nylon sling onto yoke (12). Hoist yoke (12). Fit the bolt (13) holes of bearing (1) and yoke (12).
7
1
13. Install yoke (12) to bearings (1) (2 used) with bolts (13) (4 used) and spring washers (14) (4 used). j : 36 mm m : 700 N·m (70 kgf·m, 520 lbf·ft)
4 W157-03-05-005
14. Install guard (9) to yoke (12) with bolts (10) (4 used) and spring washers (11) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
W4-5-2-6
SECTION 4 UNDERCARRIAGE Group 5 Front Idler Precautions for Using Floating Seal
1
1. In general, replace the floating seal with a new one after disassembling.
If the floating seal is required to be reused, follow these procedures:
Keep seal rings together as a matched set with seal ring (1) surfaces together. Apply oil onto sliding surface (e) of seal ring (1). Check sliding surface (e) of seal ring (1) for scuffing, scoring, corrosion, deformation, or uneven wear. Check the step part of seal ring (1). Check O-ring (2) for tears, breaks, deformation, or hardening.
W178-02-11-001
2
2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following to prevent trouble. Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust, or dirt from seal mounting bores. After cleaning, thoroughly dry parts with compressed air. Clean seal ring (1) and O-ring (2) mounting bores. Check the bore surface for scuffing or scoring by touching the surface with finger. After installing the floating seal, check that O-ring (2) is not twisted, and that it is installed correctly on seal ring (1). After installing the floating seal, check that O-ring (2) and seal ring sliding surface (e) is parallel with seal mating surface (f ) by measuring the distances (e) and (f ) at point (A) and (B), as illustrated. If these distances differ, correct O-ring (2) seating.
a
c b d W178-02-11-002 a - Correct b - Incorrect
c - Twist of O-Ring d - Bend of O-Ring f a
b
A
A
e
2
B
A=B
B
A≠B W178-02-11-003
a - Correct b - Incorrect
W4-5-3-1
e - Sliding Surface f - Seal Mating Surface
SECTION 4 UNDERCARRIAGE Group 5 Front Idler (Blank)
W4-5-3-2
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers Removal and Installation of Upper Roller 2
W105-03-06-001
The pressure inside cylinder of the dCAUTION: track adjuster is high. As valve (1) may fly out
and the high-pressure grease may spout out, do not loosen valve (1) quickly and/or excessively. Keep body parts and face away from valve (1) and loosen valve (1) carefully. Do not loosen grease fitting (2). IMPORTANT: When gravel or mud is packed between sprockets and track links, remove them before loosening. IMPORTANT: Loosening valve (1) 1 to 1.5 turns is enough. Do not loosen valve (1) over those turns. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Loosen valve (1) of the track adjuster. Drain grease from the cylinder. j : 24 mm
W4-6-1-1
1
W800-03-07-002
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers
4
3
a
6, 7 a- b-
5
b
W116-03-06-002
Oil Jack Wooden Block
3. Raise track (4) until enough clearance is observed between upper roller (3) and track (4) by using the oil jack. 4. Insert wooden blocks (b) between upper roller (3) and track frame (5). 5. Remove bolts (6) (4 used) and washers (7) (4 used) from upper roller (3). j : 32 mm
dCAUTION:
Upper roller (3) weight: 82 kg (185 lb) 6. Attach nylon slings onto the body of upper roller (3). Hoist upper roller (3). Remove upper roller (3).
W4-6-1-2
3
W116-03-06-003
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers 4
3
a
6, 7 a- b-
5
b
W116-03-06-002
W116-03-06-003
3
Oil Jack Wooden Block
2
1
c
Wxxx-03-07-001 c - Track Sag Specification W800-03-07-002
Installation
dCAUTION:
Upper roller (3) weight: 82 kg (185 lb) 1. Attach nylon slings onto the body of upper roller (3). Hoist upper roller (3). 2. Apply LOCTITE #262 onto bolts (6) (4 used) 3. Install upper roller (3) with washers (7) (4 used) and bolts (6) (4 used). j : 32 mm
6. Raise the track to be adjusted. Rotate the track in the reverse direction a little. 7. Apply grease through grease fitting (2) and adjust the track (4) tension.
fNOTE:
Track sag specification (c): ZX870-5G, 870H-5G : 450 to 500 mm (17.7 to 19.7 in) ZX870LC-5G, 870LCH-5G, 870LCR-5G : 470 to 530 mm (18.5 to 20.9 in) 8. Lower the track.
m : 750 N·m (75 kgf·m, 550 lbf·ft) 4. Remove wooden blocks (b) and oil jack (a) between track (4) and track frame (5). 5. Tighten valve (1) of the track adjuster. j : 24 mm m : 150 N·m (15 kgf·m, 111 lbf·ft) Securely support the raised machine dCAUTION: by using the blocks.
W4-6-1-3
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers (Blank)
W4-6-1-4
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers Removal and Installation of Lower Roller 3, 4
6
90˚~110˚
2
1
a
b
WJAA-04-06-001
a - Wooden Block
b - Stand
Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Put the matching marks on track guard (1) and track frame (2). If removing bolt (3) without holding dCAUTION: track guard (1), track guard (1) falls off. 3. Insert wooden blocks (a) under track guard (1). 4. Remove bolts (3) (4 used) and spacers (4) (4 used). j : 41 mm 5. Remove bolts (6) (4 used). j : 36 mm 6. Swing the upperstructure by 90 degrees so that the angle between boom and arm should be 90 ° to 110°. Lower the boom with the round bottom contacting with the ground. Raise the track frame. Place stand (b) under the track frame and support the machine at this time.
W4-6-2-1
M104-07-067
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers 7
8
W800-03-07-002
1
9
W105-03-06-001
WJAA-04-06-002
The pressure inside cylinder of the dCAUTION: track adjuster is high. As valve (7) may fly out
and the high-pressure grease may spout out, do not loosen valve (7) quickly and/or excessively. Keep body parts and face away from valve (7) and loosen valve (7) carefully. Do not loosen grease fitting (8). IMPORTANT: Loosening valve (7) 1 to 1.5 turns is enough. Do not loosen valve (7) over those turns. IMPORTANT: When gravel or mud is packed between sprockets and track links, remove them before loosening. 7. Loosen valve (7). Drain grease. Loosen the track until the clearance enough to remove track guard (1) and lower roller (9) is obtained. j : 24 mm
dCAUTION: Track guard (1) weight: 86 kg (190 lb) Lower roller (9) weight: 142 kg (315 lb) 8. Remove track guard (1) and lower roller (9) by using a forklift.
W4-6-2-2
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers 1
3, 4
9
2 WJAA-04-06-002
10
Installation
dCAUTION: Track guard (1) weight: 86 kg (190 lb) Lower roller (9) weight: 142 kg (315 lb) 1. Set track guard (1) and lower roller (9) on track link (10) by using a forklift while fitting the matching marks made when removing. 2. Lower the machine so that the position to install lower roller (9) can be adjusted. 3. Fit the bolt (6) holes of track frame (2) and lower roller (9). Apply LOCTITE #262 onto bolts (6) (4 used). Install lower roller (9) with bolts (6) (4 used). j : 36 mm m : 950 N·m (95 kgf·m, 700 lbf·ft) 4. Apply LOCTITE #262 onto bolts (3) (4 used). Install track guard (1) with spacers (4) (4 used) and bolts (3) (4 used) by using a pry bar. j : 41 mm m : 1400 N·m (140 kgf·m, 1030 lbf·ft)
W4-6-2-3
1
a
6
WJAA-04-06-001
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers
7
8 a
Wxxx-03-07-001
W800-03-07-002 a - Track Sag Specification
5. Tighten valve (7). j : 24 mm m : 150 N·m (15 kgf·m, 111 lbf·ft) Securely support the raised machine dCAUTION: by using the blocks. 6. Raise the track to be adjusted. Rotate the track in the reverse direction a little. 7. Apply grease through grease fitting (8) and adjust the track tension.
fNOTE:
Track sag specification (a) ZX870-5G, 870H-5G : 450 to 500 mm (17.7 to 19.7 in) ZX870LC-5G, 870LCH-5G, 870LCR-5G : 470 to 530 mm (18.5 to 20.9 in)
W4-6-2-4
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers Disassembly of Upper Roller
10 8
4 2
5
6
9
11
7
3
1
W800-03-06-003
1- 2- 3-
Socket Bolt (3 Used) Plug Cover
4- 5- 6-
O-Ring Socket Bolt (3 Used) Thrust Plate
7- 8- 9-
Bushing Roller Bushing
W4-6-3-1
10- Axle 11- Floating Seal
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers Disassembly of Upper Roller
IMPORTANT: Do not remove bushings (7, 9) unless necessary. 6. Remove bushings (7, 9) by using the special tool (ST 1653) and a press.
1. Remove plug (2). Drain oil. l : 6 mm 2. Put the matching marks on roller (8) and cover (3). Remove socket bolts (1) (3 used). Remove cover (3) from roller (8).
ST 1653
7
l : 8 mm
fNOTE:
Insert a screwdriver into the clearance between cover (3) and roller (8). Pry and remove cover (3) by using a screwdriver. 3. Remove socket bolts (5) (3 used). Remove thrust plates (6) from roller (8).
9
W17V-03-06-002
l : 8 mm The axle (10) assembly weight: 34 kg dCAUTION: (75 lb) Roller (8) weight: 40 kg (89 lb)
fNOTE:
If no special tool is available, build up weld at the inner surface of bushing at 4 places in equal distance of 90° apart. Shrink and remove the bushing.
4. Remove roller (8) from the axle (10) assembly. 90 °
IMPORTANT: Handle floating seal (11) with care. (Refer to W4-6-5.) 5. Remove floating seal (11) from the axle (10) assembly and roller (8).
90 °
W105-03-05-012
W4-6-3-2
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers Assembly of Upper Roller 10
11
6
1 5
2
3
8
9
7
4 W800-03-06-002
1- 2- 3-
Socket Bolt (3 Used) Plug Cover
4- 5- 6-
O-Ring Socket Bolt (3 Used) Thrust Plate
7- 8- 9-
Bushing Roller Bushing
W4-6-3-3
10- Axle 11- Floating Seal
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers Assembly of Upper Roller IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: Do not damage bushings (7, 9). 1. Install bushings (7, 9) to roller (8) by using a press. IMPORTANT: Handle floating seal (11) with care. (Refer to W4-6-5.)
l : 8 mm m : 65 N·m (6.5 kgf·m, 48 lbf·ft) 7. Add engine oil (API CD class, SAE #30) through plug (2) of cover (3).
fNOTE:
Amount of oil: 0.28 L (0.29 US qt) 8. Apply LOCTITE #503 onto plug (2). Install plug (2) to cover (3).
dCAUTION:
Roller (8) weight: 40 kg (89 lb) 2. Install floating seal (11) to the axle (10) assembly and roller (8).
dCAUTION: (75 lb)
6. Fit the matching marks and install cover (3) to roller (8). Install socket bolts (1) (3 used).
The axle (10) assembly weight: 34 kg
l : 6 mm m : 20 N·m (2 kgf·m, 15 lbf·ft)
3. Install roller (8) to the axle (10) assembly. 4. Install thrust plate (6) to the axle (10) assembly with socket bolts (5) (3 used). l : 8 mm m : 65 N·m (6.5 kgf·m, 48 lbf·ft) 5. Apply grease onto O-ring (4). Install O-ring (4) to cover (3).
W4-6-3-4
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers Disassembly of Lower Roller 5 6
4 3
2
1
7
5 8 7 6 3
1
4
W166-03-06-006
1- 2-
Floating Seal (2 Used) Axle
3- 4-
O-Ring (2 Used) Collar (2 Used)
5- 6-
Pin (2 Used) Plug (2 Used)
W4-6-4-1
7- 8-
Bushing (2 Used) Roller
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers Disassembly of Lower Roller
dCAUTION:
Lower roller weight: 142 kg (315 lb) 1. Remove plug (6) from the end of collar (4). Drain oil from roller (8).
4. Remove pin (5) from the axle (2) assembly. Remove axle (2) from collar (4) by using a press. 3
4
l : 6 mm Axle (2) + collar (4) weight: 48 kg (110 dCAUTION: lb) Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury. 2. Put the matching marks on collar (4) and axle (2). Remove pin (5) from collar (4) at one side by using a round bar and a hammer. Remove axle (2) from roller (8), from the side where pin (5) was removed by using a press. At this time, pin (5) and collar (4) on the opposite side are removed with axle (2) together.
fNOTE:
Diameter of round bar: 25 mm (1.0 in) 4
1
8
1
2
W178-02-11-268
5. Remove O-rings (3) (2 used) from axle (2).
dCAUTION:
Roller (8) weight: 81 kg (180 lb) IMPORTANT: Do not remove bushing (7) unless necessary. 6. Remove bushing (7) by using the special tool (ST 1973) and a press.
ST 1973
1 4
7 2 W105-03-06-026
IMPORTANT: Handle floating seal (1) with care. (Refer to W4-6-5.) 3. Remove floating seals (1) (2 used) from both sides of roller (8) and collars (4) (2 used).
W4-6-4-2
8
W178-02-11-269
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers Assembly of Lower Roller 4
8
1- 2-
Floating Seal (2 Used) Axle
3- 4-
2
O-Ring (2 Used) Collar (2 Used)
7
5- 6-
1
Pin (2 Used) Plug (2 Used)
W4-6-4-3
5
6
3
W162-03-06-002
7- 8-
Bushing (2 Used) Roller
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers Assembly of Lower Roller IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.
dCAUTION:
Roller (8) weight: 81 kg (180 lb) IMPORTANT: Do not damage bushing (7). 1. Install bushings (7) (2 used) to roller (8) by using a press.
dCAUTION:
Axle (2) weight: 38 kg (85 lb) 2. Apply grease onto O-ring (3) at one side. Install O-ring (3) to axle (2).
IMPORTANT: Do not damage O-ring (3). 3. Fit the pin (5) hole and install collar (4) to one side of axle (2) with pin (5). 2
5
4 W105-03-06-031
IMPORTANT: Handle floating seal (1) with care. (Refer to W4-6-5.) 4. Install floating seal (1) to roller (8) and collar (4). 8
1
1
4
W157-03-06-008
W4-6-4-4
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers The roller (8) assembly weight: 84 kg dCAUTION: (190 lb) The axle (2) assembly weight: 48 kg (110 lb) 5. Install the axle (2) assembly to the roller (8) assembly. 6. Apply grease onto O-ring (3) at the other side. Install O-ring (3) to the roller (8) assembly. IMPORTANT: Handle floating seal (1) with care. (Refer to W4-6-5.) 7. Install floating seal (1) to roller (8) and collar (4) at the other side. IMPORTANT: Do not damage O-ring (3). 8. Fit the pin (5) hole and install collar (4) to axle (2) with pin (5). 9. Install a seal tape onto plug (6). 10. Add engine oil (API CD class, SAE #30) through the plug (6) hole of collar (4). Tighten plug (6). l : 6 mm m : 20 N·m (2 kgf·m, 15 lbf·ft)
fNOTE:
Oil amount: 1.0 L (1.1 US qt)
W4-6-4-5
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers (Blank)
W4-6-4-6
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Roller Precautions for Using Floating Seal
1
1. In general, replace the floating seal with a new one after disassembling.
If the floating seal is required to be reused, follow these procedures:
Keep seal rings together as a matched set with seal ring (1) surfaces together. Apply oil onto sliding surface (e) of seal ring (1). Check sliding surface (e) of seal ring (1) for scuffing, scoring, corrosion, deformation, or uneven wear. Check the step part of seal ring (1). Check O-ring (2) for tears, breaks, deformation, or hardening.
W178-02-11-001
2
2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following to prevent trouble. Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust, or dirt from seal mounting bores. After cleaning, thoroughly dry parts with compressed air. Clean seal ring (1) and O-ring (2) mounting bores. Check the bore surface for scuffing or scoring by touching the surface with finger. After installing the floating seal, check that O-ring (2) is not twisted, and that it is installed correctly on seal ring (1). After installing the floating seal, check that O-ring (2) and seal ring sliding surface (e) is parallel with seal mating surface (f ) by measuring the distances (e) and (f ) at point (A) and (B), as illustrated. If these distances differ, correct O-ring (2) seating.
a
c b d W178-02-11-002 a - Correct b - Incorrect
c - Twist of O-Ring d - Bend of O-Ring f a
b
A
A
e
2
B
A=B
B
A≠B W178-02-11-003
a - Correct b - Incorrect
W4-6-5-1
e - Sliding Surface f - Seal Mating Surface
SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Roller (Blank)
W4-6-5-2
SECTION 4 UNDERCARRIAGE Group 7 Track Removal and Installation of Track 3 5
4
2
b W800-03-07-027
1 b - Grease Outlet
a
W105-03-07-006
a - Wooden Block
Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Rotate the tracks so that master pin (1) is positioned over the front idler (2) side of the track adjuster. Insert wooden blocks (a) under shoe (3) and support it. The pressure inside cylinder of the dCAUTION: track adjuster is high. As valve (4) may fly out
and the high-pressure grease may spout out, do not loosen valve (4) quickly and/or excessively. Keep body parts and face away from valve (4) and loosen valve (4) carefully. Do not loosen grease fitting (5). IMPORTANT: Loosening valve (4) 1 to 1.5 turns is enough. Do not loosen valve (4) over those turns. IMPORTANT: When gravel or mud is packed between sprockets and track links, remove them before loosening. 3. Loosen valve (4). Drain grease and loosen the tracks. j : 24 mm
W4-7-1-1
SECTION 4 UNDERCARRIAGE Group 7 Track
3 6, 7
3
1 3 6, 7
3 c W105-03-07-006 W1J7-03-07-002 c - Chain Block
dCAUTION: Shoe (3) weight: 650 mm: 43 kg (95 lb) 750 mm: 50 kg (115 lb) 900 mm: 59 kg (135 lb) 4. Remove bolts (6) (8 used) and nuts (7) (8 used) from shoes (3) (2 used) at the front and rear of master pin (1). Remove shoes (3) (2 used). j : 41 mm 5. Secure shoes (3) (2 used) at the front and rear of master pin (1) by using chain blocks (c).
W4-7-1-2
SECTION 4 UNDERCARRIAGE Group 7 Track Assembly of Special Tool (ST 1532) for Removal / Installation of Master Pin 14
13 12 11 10 9
1 8
10
15
19
10
15
16
17
11 12
9
1 9 8 - 9 - 10 - 11 -
Hydraulic Cylinder (ST 1512) Screw (2 Used) (ST 1516) Nut (2 Used) (ST 1515) Frame (ST 1513)
12 - 13 - 14 -
Pusher (ST 1521) Handling Screw (ST 1530) Adapter (ST 1518)
10
16
15 - 16 - 17 -
Extension (3 Kinds) (ST 1514) Nut (2 Used) (ST 1515) Pilot (ST 1517)
W4-7-1-3
WJBE-04-07-001
19 - Guide Pin (ST 1529)
SECTION 4 UNDERCARRIAGE Group 7 Track Assembly of Special Tool (ST 1532) for Removal / Installation of Master Pin
12. Install hoses (d) (2 used) of electric pump (ST 1531) to hydraulic cylinder (8).
The procedures for assembly of special tool (ST 1532) for removal / installation of master pin are explained. Theses are not unnecessary in case the special tool (ST 1532) for removal / installation of master pin has already been assembled.
10 9
8
IMPORTANT: Screws (9) (2 used) should be installed to the hole of hydraulic cylinder (8) surely. In case screws (9) (2 used) are not installed surely, they may come off from hydraulic cylinder (8) when removing and installing master pin (1). 6. Install screws (9) (2 used) to hydraulic cylinder (8).
A
IMPORTANT: In case dimensions (A) of nuts (10) (2 used) are different, screw (9) may be deformed when removing and installing master pin (1). Install nuts (10) (2 used) so that dimensions (A) from hydraulic cylinder (8) should be same. 7. Install nuts (10) (2 used) to screws (9) (2 used) so that dimensions (A) from hydraulic cylinder (8) should be same.
d W1J7-03-07-005
d
CAUTION: Frame (11) weight: 74 kg (165 lb) 8. Install frame (11) to the nut (10) position of screws (9) (2 used). Install nut (16).
d - Hose
9. Install extension (15) to hydraulic cylinder (8).
fNOTE:
There are three kinds of extension (15). Their dimensions are different. In case the stroke of hydraulic cylinder (8) is insufficient when removing and installing master pin (1), add other extensions (15). 10. Install pilot (17) and pusher (12) to extension (15). 11. Install adapter (14) to frame (11) with handling screw (13).
W4-7-1-4
SECTION 4 UNDERCARRIAGE Group 7 Track
14 12 e
1
ST 1532
W1J7-03-07-004
ST 1532
9 W1J7-03-07-003
e - Nylon Sling
Special tool (ST 1532) for removal / dCAUTION: installation of master pin weight: 150 kg (335 lb) 13. Attach nylon slings (e) onto screw (9) (2 places) of special tool (ST 1532) for removal / installation of master pin. Hoist special tool (ST 1532) for removal / installation of master pin. Move special tool (ST 1532) for removal / installation of master pin to the master pin (1) mounting position. Adjust nylon slings (e) so that the height of adapter (14) and pusher (12) in special tool (ST 1532) for removal / installation of master pin should be aligned with that of master pin (1).
W4-7-1-5
SECTION 4 UNDERCARRIAGE Group 7 Track 10 14
16
9
12 8
17
1 15 ST 1532
W1J7-03-07-004 W1J7-03-07-005
IMPORTANT: Align the center of adapter (14) and pusher (12) with that of master pin (1). When removing master pin (1) with the centers misaligned, special tool (ST 1532) for removal / installation of master pin may be deformed and damaged. 14. Fit the end of master pin (1) to the adapter (14) hole of special tool (ST 1532) for removal / installation of master pin. Adjust hydraulic cylinder (8) and push pusher (12) to the end of master pin (1). Check the mounting condition of master pin (1) and special tool (ST 1532) for removal / installation of master pin.
15. Extend hydraulic cylinder (8) and push out master pin (1).
fNOTE:
W4-7-1-6
In case the stroke of hydraulic cylinder (8) is insufficient, retract it once and add shorter extensions (15) between extension (15) and pilot (17). In case the stroke of hydraulic cylinder (8) is insufficient in spite of using extensions (15) (3 used), move the mounting position of nuts (10, 16) (2 used for each) to the hydraulic cylinder (8) side.
SECTION 4 UNDERCARRIAGE Group 7 Track
c
90˚ to 110˚
f f - ST 1532
9
W1J7-03-07-003
Stand M104-07-067
c - Chain Block
16. Remove special tool (ST 1532) for removal / installation of master pin and chain blocks (c). 17. Set the angle between boom and arm to 90˚ to 110˚. Lower the boom with the round bottom contacting with the ground. Raise the track frame. Place stand (f ) under the track frame and support the machine at this time. W105-03-07-011
dCAUTION: The track assembly weight: ZX870-5G, 870H-5G 650 mm: 4080 kg (9000 lb) 750 mm: 4410 kg (9730 lb) 900 mm: 4840 kg (10700 lb) ZX870LC-5G, 870LCH-5G, 870LCR-5G 650 mm: 4430 kg (9770 lb) 750 mm: 4780 kg (10600 lb) 900 mm: 5250 kg (11600 lb) 18. Slowly operate the travel control lever for the track to be removed to the reverse position and extend the track.
W4-7-1-7
SECTION 4 UNDERCARRIAGE Group 7 Track
20
b
a
W105-03-07-014
21 W105-03-07-013 a - Front Idler Side b - Sprocket (20) Side
W105-03-07-015
Installation 1. Raise the machine. Set the track under the machine so that sprocket (20) should mesh with the track end. Check the direction of the track at this time.
dCAUTION: The track assembly weight: ZX870-5G, 870H-5G 650 mm: 4080 kg (9000 lb) 750 mm: 4410 kg (9730 lb) 900 mm: 4840 kg (10700 lb) ZX870LC-5G, 870LCH-5G, 870LCR-5G 650 mm: 4430 kg (9770 lb) 750 mm: 4780 kg (10600 lb) 900 mm: 5250 kg (11600 lb) 2. Hoist and mesh the track with the claws of sprocket (20) 3. With the machine raised, slowly operate the travel control lever for the track to be installed in the forward direction. Wind the track while rotating travel device (21).
W4-7-1-8
SECTION 4 UNDERCARRIAGE Group 7 Track
2 3
3 c W1J7-03-07-007 W1J7-03-07-002 c - Chain Block
4. Wind track link (22) until the connection part of track link (22) reaches the front idler (2) side. IMPORTANT: The taper part of guide pin (19) should be inserted first. 5. Secure shoes (3) (2 used) by using chain blocks (c). Fit the master pin (1) mounting hole of track link (22) by using chain blocks (c). Install guide pin (19) to the master pin (1) mounting hole.
19 17
12 22
15
1 ST 1532 WJBE-04-07-002
6. Install extension (15), pilot (17), pusher (12), and master pin (1) to special tool (ST 1532) for removal / installation of master pin.
fNOTE:
Master pin (1) is symmetrical. The installing direction is not specified.
W4-7-1-9
SECTION 4 UNDERCARRIAGE Group 7 Track
19
e
14
22 1 ST 1532
WJBE-04-07-002
9 W1J7-03-07-003
e - Nylon Sling
Special tool (ST 1532) for removal / dCAUTION: installation of master pin weight: 150 kg (335 lb) 7. Attach nylon slings (e) onto screw (9) (2 places) of special tool (ST 1532) for removal / installation of master pin. Hoist special tool (ST 1532) for removal / installation of master pin. Move special tool (ST 1532) for removal / installation of master pin to the master pin (1) mounting position of track link (22). Adjust nylon slings (e) so that the hole height of adapter (14) in special tool (ST 1532) for removal / installation of master pin should be aligned with the master pin (1) mounting hole of track link (22).
W4-7-1-10
SECTION 4 UNDERCARRIAGE Group 7 Track 10 19
16
9
14 8
17
22 15 1 WJBE-04-07-002
W1J7-03-07-005
IMPORTANT: Align the center of adapter (14) and master pin (1) with that of the master pin (1) mounting hole. When installing master pin (1) with the centers misaligned, special tool (ST 1532) for removal / installation of master pin may be deformed and damaged. 8. Fit the end of guide pin (19) to the adapter (14) hole of special tool (ST 1532) for removal / installation of master pin. Adjust hydraulic cylinder (8) and push master pin (1) until it comes in contact with guide pin (19). Check the mounting condition of guide pin (19) and special tool (ST 1532) for removal / installation of master pin.
9. Extend hydraulic cylinder (8) and insert master pin (1) until guide pin (19) is pushed out.
fNOTE:
W4-7-1-11
In case the stroke of hydraulic cylinder (8) is insufficient, retract it once and add shorter extensions (15) between extension (15) and pilot (17). In case the stroke of hydraulic cylinder (8) is insufficient in spite of using extensions (15) (3 used), move the mounting position of nuts (10, 16) (2 used for each) to the hydraulic cylinder (8) side.
SECTION 4 UNDERCARRIAGE Group 7 Track
3 6, 7 c
ST 1532
22
6, 7 3
W1J7-03-07-003
c - Chain Block
10. Remove special tool (ST 1532) for removal / installation of master pin and chain blocks (c) from track link (22).
dCAUTION: Shoe (3) weight: 650 mm: 43 kg (95 lb) 750 mm: 50 kg (115 lb) 900 mm: 59 kg (135 lb) 11. Install shoes (3) (2 used) with nuts (7) (8 used) and bolts (6) (8 used). j : 41 mm m : 2000 N·m (200 kgf·m, 1480 lbf·ft)
W4-7-1-12
W105-03-07-006
SECTION 4 UNDERCARRIAGE Group 7 Track
5
4
a
W800-03-07-027 WXXX-03-07-001 a - Track Sag Specification
12. Tighten valve (4). Apply grease through grease fitting (5) and adjust the track tension. j : 24 mm m : 150 N·m (15 kgf·m, 111 lbf·ft)
fNOTE:
Track sag specification (A) ZX870-5G, 870H-5G: 450 to 500 mm (17.7 to 19.7 in) ZX870LC-5G, 870LCH-5G, 870LCR-5G: 470 to 530 mm (18.5 to 20.9 in)
W4-7-1-13
SECTION 4 UNDERCARRIAGE Group 7 Track 9
19 17
10
12 8
15
10 9 WJBE-04-07-002
13. Remove extension (15), pilot (17), and pusher (12) from special tool (ST 1532) for removal / installation of master pin.
d d - Hose
14. Remove hoses (d) (2 used) of electric pump (ST 1531) from hydraulic cylinder (8). Disassemble special tool (ST 1532) for removal / installation of master pin in the reverse way as assembly procedures on W4-7-1-4 when disassembling and keeping it.
fNOTE:
Put the matching marks on screw (9) and nut (10) for assembly before removing nuts (10) (2 used) from screws (9) (2 used).
W4-7-1-14
W1J7-03-07-005
MEMO
MEMO
SECTION 5
FRONT ATTACHMENT CONTENTS Group 1 Front Attachment
Removal and Installation of Bucket..........................W5-1-1-1 Removal and Installation of Arm...............................W5-1-2-1 Removal and Installation of Boom...........................W5-1-3-1 Remove and Install Bushing.......................................W5-1-4-1
Group 2 Cylinder
Removal and Installation of Boom Cylinder..........W5-2-1-1 Removal and Installation of Arm Cylinder.............W5-2-2-1 Removal and Installation of Bucket Cylinder........W5-2-3-1 Disassembly of Boom Cylinder..................................W5-2-4-1 Assembly of Boom Cylinder........................................W5-2-4-4 Disassembly of Arm Cylinder......................................W5-2-5-1 Assembly of Arm Cylinder...........................................W5-2-5-4 Disassembly of Bucket Cylinder................................W5-2-6-1 Assembly of Bucket Cylinder......................................W5-2-6-4
JBEW-5-1
(Blank)
JBEW-5-2
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Removal and Installation of Bucket IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Lower the bucket bottom onto the ground and set the arm in vertical against the ground contacting surface.
W1J7-04-01-020
2. Remove nuts (4) (8 used) and washers (3) (4 used) from split type O-rings (1) (2 used). Remove split type O-rings (1) (2 used) from bucket (a).
3, 4
a
j : 8 mm 3. Remove nuts (4) (8 used) and washers (3) (4 used) from split type O-rings (2) (2 used). Remove split type O-rings (2) (2 used) from bucket (a).
3, 4
1
j : 8 mm
3, 4
fNOTE:
Split type O-rings (1, 2) cannot be reused. Replace split type O-rings (1, 2) with new ones when assembling. 4. Remove bolts (8) (3 used) and washers (7) (3 used) from stopper (6). Remove stopper (6) from pin (5).
a-
2
Bucket
M1J1-07-074
c
j : 30 mm Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
7, 8
Pin (5) weight: 82 kg (185 lb)
6
5. Slowly move pin (5) to the position where link A (d) can be removed from bucket (a). Attach nylon slings onto the body of pin (5). Hoist pin (5). Remove pin (5) from bucket (a).
a W1J7-04-01-022
a-
Bucket
IMPORTANT: Put a soft waste under link A (d) and bucket cylinder (c) in order not to damage arm (b). 6. Start the engine. Slowly retract bucket cylinder (c). Secure link A (d) and the bucket cylinder (c) rod side to arm (b) by using wires. Stop the engine.
c-
Bucket Cylinder
c
b
d 5 a W1J7-04-01-021 a- b-
W5-1-1-1
Bucket Arm
c- d-
Bucket Cylinder Link A
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 7. Remove bolts (12) (3 used) and washers (11) (3 used) from stopper (10). Remove stopper (10) from pin (9).
b
j : 30 mm
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
10
a
11, 12
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
W1J7-04-01-022
Pin (9) weight: 94 kg (210 lb) a-
Bucket
b-
Arm
8. Slowly move pin (9) to the position where bucket (a) can be removed from arm (b). Attach nylon slings onto the body of pin (9). Hoist pin (9). Remove pin (9) from bucket (a). b
dCAUTION: Bucket weight: 3.5 m Bucket: 2980 kg (6570 lb) 4.5 m Bucket: 3980 kg (8780 lb) 3
9
3
9. Remove bucket (a) from arm (b).
a W1J7-04-01-021 a-
W5-1-1-2
Bucket
b-
Arm
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Installation
dCAUTION: Bucket weight: 3.5 m Bucket: 2980 kg (6570 lb) 4.5 m Bucket: 3980 kg (8780 lb)
b
c
j
k
3 3
1. Hoist the bucket and lower the bucket bottom onto the ground. 2. Start the engine. Move the machine forward. Operate arm (b) and fit the pin (9) hole of bucket (a) and pin hole (j) of arm (b). Stop the engine. 3. Insert shim (e) between the arm (b) end and bucket (a). Adjust clearance (f ) between the arm (b) end and bucket (a) to 0.5 to 1.0 mm (0.02 to 0.04 in).
W1J7-04-01-009 b- c-
Arm Bucket Cylinder
a
j- k-
Pin Hole Pin Hole
f
9
Shim thickness: 1.0 mm or 2.0 mm (0.04 in or 0.08 in)
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
e a- b- e-
Pin (9) weight: 94 kg (210 lb)
b
Bucket Arm Shim
M1JB-07-057 f-
Clearance between the arm and the bucket
4. Attach nylon slings onto the body of pin (9). Hoist pin (9). Install pin (9). Install stopper (10) to pin (9) with washers (11) (3 used) and bolts (12) (3 used).
b
j : 30 mm m : 400 N·m (40 kgf·m, 300 lbf·ft) 10
a
5. Remove the wires from link A (d) and the bucket cylinder (c) rod side. Extend bucket cylinder (c). Fit the pin (5) hole of bucket (a) and the pin (k) hole of link A (d).
11, 12 W1J7-04-01-022 a-
Bucket
b-
Arm
c
b
d
9
5 a W1J7-04-01-021
a- b-
W5-1-1-3
Bucket Arm
c- d-
Bucket Cylinder Link A
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
b
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
Pin (5) weight: 82 kg (185 lb)
6. Attach nylon slings onto body of pin (5). Hoist pin (5). Install pin (5). Install stopper (6) to pin (5) with washers (7) (3 used) and bolts (8) (3 used).
7, 8 a
6
j : 30 mm m : 400 N·m (40 kgf·m, 300 lbf·ft)
W1J7-04-01-022 a-
Bucket
IMPORTANT: Install split type O-rings (1, 2) so that split part (h) does not contact sand in order to prevent the damage of split type O-rings (1, 2).
b-
Arm
3, 4
a
7. Install split type O-rings (1) (2 used) with washers (3) (4 used) and nuts (4) (8 used). j : 8 mm 8. Install split type O-rings (2) (2 used) with washers (3) (4 used) and nuts (4) (8 used).
3, 4
1
j : 8 mm
h
3, 4
g
fNOTE:
After installing split type O-rings (1, 2), cut the bolt at bolt cutting position (g) where dimension between bolt and nut (4) is 10 to 20 mm (0.4 to 0.8 in) in order not to damage split type O-rings (1, 2).
2 a- g-
Bucket Bolt Cutting Position
h-
M1J1-07-074
Split Part
9. Apply grease onto grease fitting (i) at the bucket connecting side in arm (b) and link A (d). b
d
i
5
W1J7-04-01-021 b- d-
W5-1-1-4
Arm Link A
i-
Grease Fitting
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Removal and Installation of Arm IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.
1
2
Removal 3
a
1. Remove the bucket. (Refer to W5-1-1.) 2. Fully retract arm cylinder (1) and lower boom (2). Place the end of arm (3) onto wooden block (a).
a-
Wooden Block
Release any pressure in the hydraulic dCAUTION: circuit. (Refer to W1-5-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)
W1J7-04-01-010
6, 7, 8 5
3. Remove socket bolts (6) (8 used) and flanges (7) (4 used). Disconnect hoses (5) (2 used). Remove O-rings (8) (2 used). l : 12 mm 4. Disconnect lubrication hose (9). 6, 7, 8
j : 19 mm
3
f
W1J7-04-01-011
NOTE: Step (5) is for the machine equipped with the auto lubrication device (optional). 5. Disconnect lubrication hose (10).
9
j : 22 mm
1
3
W1JB-04-02-010
10 1
3 W1J7-04-01-012
W5-1-2-1
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment
dCAUTION:
The arm (3) assembly weight:
3.7 m Arm: 4.4 m Arm: H3.7 m Arm: BE2.9 m Arm:
4260 kg (9400 lb) 4590 kg (10200 lb) 4440 kg (9790 lb) 4620 kg (10200 lb)
b 1
6. Install the shackles (2 used) to the arm (3) assembly. Attach the wire ropes onto the shackles (2 used). Hold the arm (3) assembly.
dCAUTION: (2650 lb)
Arm cylinder (1) weight: 1200 kg
7. Place wooden block (b) between boom (2) and arm cylinder (1). Hold arm cylinder (1).
2 b-
8. Remove bolts (13) (2 used) and washers (14) (2 used) from plate (12). Remove plate (12) from pin (11).
W1JB-04-02-012
Wooden Block
11
j : 30 mm Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
1
3
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
Pin (11) weight: 44 kg (98 lb)
9. Move pin (11) to the position where the arm cylinder (1) rod can be removed from arm (3). Attach the nylon slings onto pin (11). Hoist and remove pin (11).
12
13, 14
2
10. Start the engine and retract arm cylinder (1). In order not to extend the rod, pass the wires through the rod hole and secure the rod to the tube.
W1J7-04-01-015
11. Secure arm cylinder (1) to boom (2). 2
12. Remove washers (18) (3 used) and bolts (16) (3 used) from stopper (15). Remove stopper (15) from pin (19). j : 30 mm
2
15
19
16, 18
3 W1JB-04-01-012
W5-1-2-2
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
Pin (19) weight: 110 kg (245 lb)
13. Move pin (19) to the position where the arm (3) assembly can be removed from boom (2). Remove plate (17) from arm (3).
19
14. Attach the nylon slings onto pin (19). Hoist and remove pin (19).
dCAUTION:
3 W1J7-04-01-012
2
The arm (3) assembly weight:
3.7 m Arm: 4.4 m Arm: H3.7 m Arm: BE2.9 m Arm:
4260 kg (9400 lb) 4590 kg (10200 lb) 4440 kg (9790 lb) 4620 kg (10200 lb)
2
2
19
15. Hoist and hold the arm (3) assembly. Move the machine back. Remove the arm (3) assembly.
17
3
17
W1JB-04-01-012
2
3
W5-1-2-3
M1J7-06-018
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Installation
d CAUTION:
The arm (3) assembly weight:
3.7 m Arm: 4.4 m Arm: H3.7 m Arm: BE2.9 m Arm:
4260 kg (9400 lb) 4590 kg (10200 lb) 4440 kg (9790 lb) 4620 kg (10200 lb)
2
1. Hoist arm (3) and fit pin hole (g) of arm (3) to pin hole (f ) of boom (2). 2. Install plates (17) between boom (2) and arm (3) at the right and left sides.
f
g
Plate (17) thickness: 8.0 mm (0.3 in)
3. Insert the shim between arm (3) and plate (17). Adjust clearance c to arm (3) within 1.5 mm (0.06 in).
Shim thickness: 1.0 mm or 2.0 mm (0.04 in or 0.08 in)
3 f- g-
M1J7-06-018
Pin Hole Pin Hole
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
2
2 17
such as goggles, helmets, etc in order to prevent personal injury.
d
15
19
CAUTION: Pin (19) weight: 110 kg (245 lb)
16, 18
4. Attach the nylon slings onto pin (19). Hoist pin (19). Install pin (19) into boom (2). Install stopper (15) to pin (19) with washers (18) (3 used) and bolts (16) (3 used). j : 30 mm 17
m : 400 N·m (40 kgf·m, 300 lbf·ft)
3
c W1JB-04-01-012
c-
W5-1-2-4
Clearance
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment
dCAUTION: (2650 lb)
Arm cylinder (1) weight: 1200 kg
5. Remove the wires from the tube. Attach the wire ropes onto arm cylinder (1). Hoist the arm cylinder (1) rod side. Start the engine and extend the arm cylinder (1) rod. Fit the rod pin holes of arm cylinder (1) to pin (11) of arm (3). Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
11
1
3
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
Pin (11) weight: 44 kg (98 lb)
2 M1J1-06-022
6. Stop the engine. Attach the nylon slings onto pin (11). Hoist pin (11). Install pin (11). Install plate (12) to arm (3) with bolts (13) (2 used) and washers (14) (2 used). 11
j : 30 mm 3
m : 400 N·m (40 kgf·m, 300 lbf·ft) 7. Install O-rings (8) (2 used) to hoses (5) (2 used). Connect hoses (5) (2 used) with flanges (7) (4 used) and socket bolts (6) (8 used). l : 12 mm
12
13, 14
m : 140 N·m (14 kgf·m, 103 lbf·ft)
W1J7-04-01-015
6, 7, 8 5
6, 7, 8 3
W5-1-2-5
W1J7-04-01-011
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 8. Connect lubrication hose (9). 9
j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)
1
3
fNOTE:
Step (9) is for the machine equipped with the auto lubrication device (optional).
9. Connect lubrication hose (10). j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft)
W1JB-04-02-010
10. After installing the arm, apply grease onto joint pins (e) of boom and arm and arm cylinder rod side (d) by using a grease gun. As for the machine equipped with the auto lubrication device (optional), turn the auto lubrication switch ON.
10 1
11. After completing the work, add hydraulic oil to the specified level. 12. Operate every cylinder fully to the stroke end several times and bleed air from the circuit. Check for any oil leaks at the hose connection.
3
13. Install the bucket. (Refer to W5-1-1.)
W1J7-04-01-012
e d
e
W1J7-04-01-018 d- e-
W5-1-2-6
Arm Cylinder Rod Side Joint Pin of Boom and Arm
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Removal and Installation of Boom IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Remove the bucket.
(Refer to W5-1-1.)
2. Remove the arm.
(Refer to W5-1-2.)
3. Start the engine. Retract boom cylinder (2) and place the boom end onto the wooden blocks. Stop the engine.
1
4. Disconnect lubrication hose (1) from the boom cylinder (2) rod side. (2 places on both right and left sides). Disconnect the connector of boom light between the front attachment and the main frame. (2 places on both right and left sides). j : 17 mm Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
2
WJBE-05-01-002
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION: (1830 lb)
Boom cylinder (2) weight: 830 kg
3
5. Attach the wire ropes onto boom cylinder (2). Hold boom cylinder (2). Remove bolts (6) (2 used). Remove plate (7) and washers (5) (2 used) from pin (4). j : 30 mm
dCAUTION:
7
8
6 5 4
Pin (4) weight: 37 kg (82 lb)
6. Move pin (4) to the position where the boom cylinder (2) rod side can be removed from boom (3). Attach the nylon slings onto pin (4). Hoist and remove pin (4). Remove the boom cylinder (2) rod side from boom (3). Remove plate (7).
W5-1-3-1
2
W1JB-04-02-008
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 2
7. Lower the tube end of boom cylinder (2) onto stand (a). Start the engine and retract boom cylinder (2). In order not to extend the rod, pass the wires through the rod hole and secure the rod to the cylinder tube. Stop the engine.
a
8. Remove other boom cylinder (2) in the same way as step 5 to step 7.
fNOTE:
Step 9 and step 10 are for the machine equipped with the auto lubrication device (optional). a-
9. Disconnect lubrication hoses (9) (2 used).
Stand
W1J7-04-01-019
j : 22 mm 10. Remove bolt, washer (10) and remove clip (11). j : 19 mm Release any pressure in the hydraulic dCAUTION: circuit. (Refer to W1-5-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 11. Remove socket bolts (12) (12 used) and flanges (13) (6 used). Disconnect hoses (19) (3 used). Remove O-rings (14) (3 used).
9 11
15, 16, 17
10 12, 13, 14
15, 16, 17
l : 14 mm 12. Remove socket bolts (15) (8 used) and flanges (16) (4 used). Disconnect hoses (18) (2 used). Remove O-rings (17) (2 used).
18 12, 13, 14
19
18
l : 12 mm
WJBE-05-01-003
19
13. Remove bolts (20) (2 used) and spring washers (21) (2 used) from plate (22) for boom foot pin (23). j : 30 mm
fNOTE:
20, 21
Put mark (b) for boom foot position on inside of main frame (c) in order to fit the boom foot pin (23) holes easily when installing.
22
23
W105-04-01-007
c b
b-
Mark
c-
Main Frame W1JB-04-01-010
W5-1-3-2
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment
dCAUTION:
Boom assembly (24) weight: 8.4 m Boom: 7860 kg (17400 lb) H 8.4 m Boom: 7860 kg (17400 lb) BE 7.1 m Boom: 7350 kg (16300 lb)
24
14. Attach the wire ropes onto boom assembly (24). Hoist and hold boom assembly (24).
W1J7-04-01-017
24
dCAUTION: (555 lb)
Boom foot pin (23) weight: 250 kg 23
15. Insert a pry bar between the flange of boom foot pin (23) and the boss of main frame. Pull out boom foot pin (23) a little. Rotate boom foot pin (23) by hand with the flange up. Slightly rotate boom foot pin (23) left and right and move boom foot pin (23). Attach the nylon slings onto boom foot pin (23). Hoist and remove boom foot pin (23). 16. Hoist and remove boom assembly (24).
WJBE-05-01-007
W5-1-3-3
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Installation
dCAUTION:
Boom assembly (24) weight: 8.4 m Boom: 7860 kg (17400 lb) H 8.4 m Boom: 7860 kg (17400 lb) BE 7.1 m Boom: 7350 kg (16300 lb)
24
1. Hoist boom assembly (24) and fit the boom foot part to the mounting hole of main frame (c). Insert the shims into the left and right sides of boom foot. Adjust the clearance between the boom and main frame (c) within 1.5 mm (0.06 in).
Shim thickness: 2.3 mm or 1.0 mm (0.1 in or 0.04 in)
W1J7-04-01-017
f
NOTE: Fit the matching marks made when removing.
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION: (555 lb)
Boom foot pin (23) weight: 250 kg
2. Insert boom foot pin (23) which grease has been applied. Install plate (22) to main frame (c) with bolts (20) (2 used) and spring washers (21) (2 used). j : 30 mm
20, 21
c
22
23
W105-04-01-007 c-
Main Frame
m : 400 N·m (40 kgf·m, 300 lbf·ft) 3. Install O-rings (14) (3 used) to hoses (19) (3 used). Connect hoses (19) (3 used) with flanges (13) (6 used) and socket bolts (12) (12 used). l : 14 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 4. Install O-rings (17) (2 used) to hoses (18) (2 used). Connect hoses (18) (2 used) with flanges (16) (4 used) and socket bolts (15) (8 used). l : 12 mm m : 140 N·m (14 kgf·m, 103 lbf·ft)
15, 16, 17 12, 13, 14
15, 16, 17
18 12, 13, 14
19
18 19
W5-1-3-4
WJBE-05-01-003
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment
fNOTE:
Step 5 and step 6 are for the machine equipped with the auto lubrication device (optional). 5. Connect lubrication hoses (9) (2 used). j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft) 6. Install clip (11) to lubrication hoses (9) (2 used) and secure them with bolt, washer (10).
9
j : 19 mm
11
m : 90 N·m (9 kgf·m, 66 lbf·ft)
10
IMPORTANT: Add hydraulic oil to the specified level. Start the engine and check the hose connections for any oil leaks.
dCAUTION: (1830 lb)
Boom cylinder (2) weight: 830 kg WJBE-05-01-003
7. Remove the wires which secure the boom cylinder (2) rod hole and tube. (2 places on both right and left sides). 4
8. Hoist the boom cylinder (2) rod side. Start the engine. Extend boom cylinder (2) and fit the pin (4) holes on boom cylinder (2).
2
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
Pin (4) weight: 37 kg (82 lb)
9. Attach the nylon slings onto pin (4). Hoist pin (4). Insert plate (8) between boom (3) and boom cylinder (2). Install pin (4). Install boom cylinder (2) to boom (3). 10. Install pin (4) to boom (3) with plate (7), washers (5) (2 used), and bolts (6) (2 used).
W1J7-04-01-016
3 7
8
6
j : 30 mm
5
m : 400 N·m (40 kgf·m, 300 lbf·ft) 11. Install other boom cylinder (2) in the same way as step 8 to step 10.
4 2
W5-1-3-5
W1JB-04-02-008
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 1
12. Connect lubrication hose (1) to the boom cylinder (2) rod side. (2 places on both right and left sides). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 13. Connect the connector of boom light. (2 places on both right and left sides). 14. Apply grease onto boom foot side (e) and boom cylinder rod side (d) by using a grease gun.
2
WJBE-05-01-002
As for the machine equipped with the auto lubrication device (optional), turn the auto lubrication switch ON.
15. Install the arm.
d
(Refer to W5-1-2.)
e
16. Install the bucket.
(Refer to W5-1-1.)
17. After completing the work, add hydraulic oil to the specified level. Operate each cylinder to the stroke end several times and bleed air from the circuit. Check for any oil leaks of the hose connections.
WJBE-05-01-004 d-
W5-1-3-6
Boom Cylinder Rod Side
e-
Boom Foot Side
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment IMPORTANT: As for handling of HN bushing for the front attachment, check the followings. Precautions when installing the bushing When installing the bushing by using a hammer, the bushing may be damaged. Install the bushing by using a press. Precautions when welding The heat when welding may cause oil leakage and decrease lubrication performance. When welding heat causes oil leakage of the bushing, replace it.
W5-1-3-7
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment (Blank)
W5-1-3-8
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Remove and Install Bushing
D
C
B A
E F W1JB-04-02-015
2 2
1
2
1
1 2
1
2 A: Bucket and Link A
B: Link A and Link B W17V-04-01-001
1
2
C: Boom and Arm W1JB-04-01-015
1
2
WJBE-02-03-003
2
1
2
2
D: Boom and Main Frame WJBE-02-03-001
1-
Dust Seal
F: Arm and Bucket
E: Arm and Link B
2-
WJBE-02-03-002
Bushing
W5-1-4-1
W1JB-04-01-014
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Removal 1. Remove dust seal (1) and bushing (2).
fNOTE:
If bushing (2) cannot be removed, burn off bushing (2).
Installation 1. Cool bushing (2) by using dry ice. 2. Install bushing (2) and dust seal (1).
fNOTE:
Install bushing (2) by using the following plate.
Plate when installing bushing A: Bucket side .............................................................. ST 2081 Link A side ............................................................... ST 2081 B: Link A ........................................................................ ST 2179 C: Arm ............................................................................ ST 2179 Boom side ................................................................ ST 2080 D: Boom side ................................................................ ST 2038 Main frame side ..................................................... ST 2038 E: Arm ............................................................................ ST 2007 F: Bucket side .............................................................. ST 2081 Arm side ................................................................... ST 2134
W5-1-4-2
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Removal and Installation of Boom Cylinder
1
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.
4 3
Removal
WJBE-05-01-002
2
1. Disconnect lubrication hoses (1) (2 used) from the boom cylinder (2) rod side. (2 places on both right and left sides). j : 17 mm 2. Disconnect lubrication hoses (5) (2 used) from the boom cylinder (2) bottom side. (2 places on both right and left sides).
5
5
j : 19 mm
dCAUTION: (1830 lb)
Boom cylinder (2) weight: 830 kg W1JB-04-01-017
3. Attach the nylon slings onto boom cylinder (2). Hoist and hold boom cylinder (2). Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
8
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
4
3
7
Pin (3) weight: 37 kg (82 lb) 6
4. Remove bolts (7) (2 used), washers (8) (2 used), and plate (6) from the boom cylinder (2) rod side. Pry and remove pin (3) from boom (4) by using a Pry bar. Remove the boom cylinder (2) rod side from boom (4). j : 30 mm
W5-2-1-1
2 W1JB-04-02-008
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 5. Lower the tube end of boom cylinder (2) onto stand (a). Start the engine and retract boom cylinder (2). In order not to extend the rod, pass the wires through the rod hole and secure the rod to the tube.
2
6. Stop the engine. 7. Remove other boom cylinder (2) rod side in the same way as step 3 to step 6.
a
Release any pressure in the hydraulic dCAUTION: circuit. (Refer to W1-5-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 8. Remove socket bolts (11) (8 used) and flanges (9) (4 used). Disconnect hydraulic hoses (12) (2 used) from boom cylinder (2). Remove O-rings (10) (2 used).
a-
W1J7-04-01-019
Stand
l : 12 mm
9, 10
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
11
2
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION: dCAUTION: (1830 lb)
12
Pin (13) weight: 41 kg (91 lb)
13
Boom cylinder (2) weight: 830 kg
W162-04-01-019
9. Remove bolts (15) (2 used) from the boom cylinder (2) bottom side. Remove spring washers (16) (2 used) and plate (14). Pry and remove pin (13) from main flame (19) by using a Pry bar. Remove boom cylinder (2) and shims (17, 18) from main frame (19).
2 13
j : 30 mm
14
10. Remove other boom cylinder (2) bottom side in the same way as step 8 to step 9.
15
19
W5-2-1-2
17, 18
16
W1JB-04-02-009
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Installation
2
IMPORTANT: If a hammer is used to install the bushing, the bushing may be damaged. Install the bushing by using a press.
13
14
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
15
such as goggles, helmets, etc in order to prevent personal injury.
Boom cylinder (2) weight: 850 kg dCAUTION: (1880 lb) Pin (13) weight: 41 kg (91 lb)
19
17, 18
16
W1JB-04-02-009
2
1. Hoist boom cylinder (2). Fit the pin hole at boom cylinder (2) bottom side to the pin hole of main frame (19).
a
2. Install shims (17, 18) between main frame (19) and boom cylinder (2). Install pin (13). Secure pin (13) to main frame (19) with plate (14), spring washers (16) (2 used), and bolts (15) (2 used). Support the boom cylinder (2) rod side by using stand (a). j : 30 mm
W1J7-04-01-019
m : 400 N·m (40 kgf·m, 300 lbf·ft)
a-
3. Install O-rings (10) (2 used) to hydraulic hoses (12) (2 used). Connect hydraulic hoses (12) (2 used) to boom cylinder (2) with flanges (9) (4 used) and socket bolts (11) (8 used).
Stand
9, 10
11
2
l : 12 mm 12
m : 140 N·m (14 kgf·m, 103 lbf·ft) 13
4. Install other boom cylinder (2) bottom side in the same way as step 1 to step 3.
W162-04-01-019
W5-2-1-3
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.
1 4
5. Remove the wires from the boom cylinder (2) rod side. Hoist the boom cylinder (2) rod side. Start the engine. Operate the boom control lever and fit the hole at cylinder rod side to the pin hole of boom (4).
3
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
2
WJBE-05-01-002
Pin (3) weight: 37 kg (82 lb) 8
6. Install pin (3) to boom (4). 7. Install bolts (7) (2 used), washers (8) (2 used), and plate (6) to pin (3).
3
7
j : 30 mm
6
m : 400 N·m (40 kgf·m, 300 lbf·ft)
2
8. Connect lubrication hose (1) of the boom cylinder (2) rod side.
W1JB-04-02-008
j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 9. Install other boom cylinder (2) rod side in the same way as step 5 to step 8. 10. Connect lubrication hose (5) of the boom cylinder (2) bottom side. (2 places on both right and left sides).
5
5
j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 11. After completing the work, operate boom cylinder (2) to the stroke end several times and bleed air from the circuit.
W5-2-1-4
W1JB-04-01-017
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Removal and Installation of Arm Cylinder
2
1
IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.
7 6
3
Removal 1. Disconnect hose (1) from the rod side of arm cylinder (2).
4, 5
j : 19 mm
W1JB-04-02-010
a
2. Place wooden block (a) between arm cylinder (2) and boom (8).
2
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
Pin (7) weight: 44 kg (98 lb)
3. Remove bolts (4) (2 used), washers (5) (2 used), and plate (3) from the arm cylinder (2) rod side. Attach the nylon slings onto the body of pin (7). Hoist pin (7). Remove pin (7) from arm (6). j : 30 mm
8 a-
Wooden Block W1JB-04-02-012
2
4. Start the engine. Operate the arm control lever and retract arm cylinder (2). In order not to extend the rod, pass the wires through the rod hole and secure the rod to the cylinder tube.
6
7
3 4, 5
W1JB-04-02-011
W5-2-2-1
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 5. Stop the engine.
2
d Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)
CAUTION: Release any pressure in the hydraulic circuit. (Refer to W1-5-1.)
9
10
11, 12
13
6. Remove socket bolts (11) (4 used) and flanges (10) (2 used). Disconnect hose (13). Remove O-ring (12).
14
l : 14 mm 7. Remove socket bolts (19) (4 used) and flanges (9) (2 used). Disconnect hose (14). Remove O-ring (20). 8
l : 17 mm
19, 20
18
16, 17
8. Disconnect hose (15) from the bottom side of arm cylinder (2).
dCAUTION: (2650 lb)
W1JB-04-02-012
2
j : 17 mm
15
8
Arm cylinder (2) weight: 1200 kg
9. Attach the nylon slings onto arm cylinder (2). Hoist and hold arm cylinder (2).
18
21
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
16, 17
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
Pin (18) weight: 44 kg (98 lb) W1JB-04-02-011
10. Remove bolts (16) (2 used), washers (17) (2 used), and plate (21) from the arm cylinder (2) bottom side. Attach the nylon slings onto the body of pin (18). Hoist pin (18). Remove pin (18) from boom (8). j : 30 mm 11. Remove arm cylinder (2) from boom (8).
W5-2-2-2
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Installation
dCAUTION: (2650 lb)
10
11, 12
Arm cylinder (2) weight: 1200 kg 13
1. Hoist arm cylinder (2). Fit the pin hole at the arm cylinder (2) bottom side to the pin hole of boom (8). Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
14 a
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
9
2
IMPORTANT: If a hammer is used to install the bushing, the bushing may be damaged. Install the bushing by using a press.
Pin (18) weight: 44 kg (98 lb)
8 a-
2. Hoist pin (18). Insert pin (18) into the pin hole of arm cylinder (2) bottom side. Install bolts (16) (2 used), washers (17) (2 used), and plate (21).
19, 20
18
16, 17
Wooden Block
W1JB-04-02-012
2
j : 30 mm
15
8
18
m : 400 N·m (40 kgf·m, 300 lbf·ft) 21
3. Connect hose (15) of the arm cylinder (2) bottom side.
16, 17
j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 4. Install O-ring (12) to hose (13). Connect hose (13) to arm cylinder (2) with flanges (10) (2 used) and socket bolts (11) (4 used).
W1JB-04-02-011
l : 14 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 5. Install O-ring (20) to hose (14). Connect hose (14) to arm cylinder (2) with flanges (9) (2 used) and socket bolts (19) (4 used). l : 17 mm m : 400 N·m (40 kgf·m, 300 lbf·ft)
W5-2-2-3
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder
dCAUTION: (2650 lb)
2
Arm cylinder (2) weight: 1200 kg
6
7
IMPORTANT: Add hydraulic oil to the specified level. Start the engine and check for any oil leaks. 6. Hoist arm cylinder (2). Remove the wires which secure the rod. Start the engine and extend the cylinder rod. Fit the pin hole at the arm cylinder (2) rod side to the pin hole of arm (6).
3 4, 5
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
W1JB-04-02-011
Pin (7) weight: 44 kg (98 lb)
1
7. Hoist pin (7). Insert pin (7) into pin hole of the cylinder rod side. Install pin (7) to arm (6) with bolts (4) (2 used), washers (5) (2 used), and plate (3).
2
7 6
j : 30 mm m : 400 N·m (40 kgf·m, 300 lbf·ft)
3
8. Connect hose (1) of the arm cylinder (2) rod side. j : 19 mm 4, 5
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W1JB-04-02-010
9. After completing the work, operate arm cylinder (2) to the stroke end several times and bleed air from the circuit.
W5-2-2-4
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Removal and Installation of Bucket Cylinder IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.
1
a
Removal 1. Insert wooden blocks (a) (2 used) under the arm (2) top and between arm (2) and bucket cylinder (1). a-
d Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
CAUTION: Before removing pin (5), secure the link by using the wires in order not to fall off.
Wooden Block W178-02-11-287
3
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
2
a
Pin (5) weight: 94 kg (210 lb) 1
2. Remove bolts (8) (3 used), washers (7) (3 used), and stopper (6) from the bucket cylinder (1) rod side. Attach the nylon slings onto the body of pin (5). Hoist pin (5). Remove pin (5) from link B (4) and link A (3).
8
j : 30 mm
7
6
5
4
W1JB-04-02-013
3 7
3. Start the engine. Operate the bucket control lever and retract bucket cylinder (1). In order not to extend the rod, pass the wires through the rod hole and secure the rod to the cylinder tube.
5
8 6 1 4
W1JB-04-02-014
1
W102-04-02-005
W5-2-3-1
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 4. Stop the engine. Release any pressure in the hydraulic dCAUTION: circuit. (Refer to W1-5-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 5. Remove socket bolts (11) (8 used) and flanges (12) (4 used). Disconnect hoses (9) (2 used) from bucket cylinder (1). Remove O-rings (10) (2 used) from hoses (9) (2 used). l : 12 mm
9,10
11 12
13
2 1
14
6. Disconnect hose (13) from bucket cylinder (1).
W166-04-01-009
j: 17 mm Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
1
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION: Bucket cylinder (1) weight: 630 kg (1390 lb) BE Bucket cylinder (1) weight: 832 kg (1840 lb)
2 14
15 16, 17
7. Attach the nylon slings onto bucket cylinder (1). Hoist bucket cylinder (1).
dCAUTION:
Pin (14) weight: 38 kg (84 lb)
W1JB-04-02-011
8. Remove bolts (16) (2 used), washers (17) (2 used), and plate (15) from the bucket cylinder (1) bottom side. Attach the nylon slings onto the body of pin (14). Hoist pin (14). Remove pin (14) from arm (2). j: 30 mm 9. Remove bucket cylinder (1) from arm (2).
W5-2-3-2
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Installation IMPORTANT: If a hammer is used to install the bushing, the bushing may be damaged. Install the bushing by using a press.
9, 10
11 12
13
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION: Bucket cylinder (1) weight: 630 kg (1390 lb) BE Bucket cylinder (1) weight: 832 kg (1840 lb) dCAUTION: Pin (14) weight: 38 kg (84 lb)
2 1
14 W166-04-01-009
1. Hoist bucket cylinder (1). Fit the pin hole of bucket cylinder (1) bottom side to the pin hole on arm (2). 2. Hoist pin (14). Insert pin (14) into the pin hole of bucket cylinder (1) bottom side. Install pin (14) to arm (2) with plate (15), washers (17) (2 used), and bolts (16) (2 used).
1
2 14
15
j : 30 mm m : 400 N·m (40 kgf·m, 300 lbf·ft)
16, 17
3. Connect hose (13) to bucket cylinder (1). j : 17 mm W1JB-04-02-011
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 4. Install O-rings (10) (2 used) to hoses (9) (2 used). Connect hoses (9) (2 used) to bucket cylinder (1) with flanges (12) (4 used) and socket bolts (11) (8 used). l : 12 mm m : 140 N·m (14 kgf·m, 103 lbf·ft)
W5-2-3-3
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 5. Remove the wires from the bucket cylinder (1) rod. Remove the wires to secure the link. IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 6. Start the engine. Operate the bucket control lever and fit the pin hole of bucket cylinder (1) rod side to the pin holes of link A (3) and link B (4).
1
a
Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury.
dCAUTION:
a-
Pin (5) weight: 94 kg (210 lb)
2
a Wooden Block
W178-02-11-287
7. Hoist pin (5). Insert pin (5) into the pin hole of bucket cylinder (1) rod side. Install stopper (6), washers (7) (3 used), and bolts (8) (3 used) to pin (5).
3
j : 30 mm m : 400 N·m (40 kgf·m, 300 lbf·ft)
1
8. After completing the work, operate bucket cylinder (1) to the stroke end several times and bleed air from the circuit. 8
7
6
5
4
W1JB-04-02-013
3 7 5
8 6 1 4
W5-2-3-4
W1JB-04-02-014
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Boom Cylinder
13 14 15 16 22 15 14
1
17 18
19
20
21
2 3
4 5 6 7 8 9 10 11
WJBC-05-02-001
1- 2- 3- 4- 5- 6-
Cylinder Rod Wiper Ring Socket Bolt (8 Used) Cylinder Head Backup Ring O-Ring
7- 8- 9- 10- 11- 13-
Backup Ring U-Ring Ring Bushing Retaining Ring Cushion Bearing
14- 15- 16- 17- 18- 19-
Slide Ring (2 Used) Slide Ring (2 Used) Seal Ring Piston Nut Steel Ball
W5-2-4-1
20- Set Screw 21- Cylinder Tube 22- O-Ring
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Boom Cylinder ď‚– The procedure starts on the premise that the piping and the bands securing the piping have been removed. CAUTION: Boom cylinder weight: 830 kg (1830 lb) 1. Hoist the cylinder. Secure the cylinder horizontally on a workbench. Drain hydraulic oil from the cylinder.
4. Install cylinder rod (1) to the special tool (ST 5908). Put the matching marks on cylinder rod (1) and nut (18).
d
ST 5908
W158-04-02-022
5. Cut away the crimped part (2 places) of set screw (20) by using a hand drill. Remove set screw (20) and steel ball (19). W102-04-02-027
2. Fully extend cylinder rod (1). Remove socket bolts (3) (8 used) from cylinder head (4). l : 24 mm
d dCAUTION: lb)
CAUTION: The cylinder rod (1) assembly weight: 437 kg (965 lb) Cylinder tube (21) weight: 359 kg (795
l : 14 mm 6. Remove nut (18) from cylinder rod (1) by using special tools (ST 3285, ST 5908). Remove piston (17) from cylinder rod (1). j : 155 mm IMPORTANT: Slide rings (14, 15) cannot be reused. Replace them with new ones when assembling. 7. Remove slide rings (14, 15) (2 used for each), seal ring (16), and O-ring (22) from piston (17).
IMPORTANT: Do not damage the sliding surface of cylinder rod (1). 3. Tap and remove cylinder head (4) with cylinder rod (1) together from cylinder tube (21) by using a plastic hammer.
W5-2-4-2
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder
dCAUTION: lb) dCAUTION: lb)
Cylinder rod (1) weight: 380 kg (840 Cylinder head (4) weight: 57 kg (130
8. Remove cushion bearing (13) and cylinder head (4) from cylinder rod (1). 9. Remove O-ring (6), backup ring (5), wiper ring (2), retaining ring (11), ring (9), U-ring (8), and backup ring (7) from cylinder head (4). 10. Remove bushing (10) from cylinder head (4) by using the special tool (ST 1194).
fNOTE:
Cylinder rod (1) outer diameter: 150 mm (5.9 in)
W5-2-4-3
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Boom Cylinder 2
8
9
3
6
4
21
1
13
14 15 16 15 14 18
17 7
10
11
22
20
19
5 W1J7-04-02-007
1- 2- 3- 4- 5- 6-
Cylinder Rod Wiper Ring Socket Bolt (8 Used) Cylinder Head Backup Ring O-Ring
7- 8- 9- 10- 11- 13-
Backup Ring U-Ring Ring Bushing Retaining Ring Cushion Bearing
14- 15- 16- 17- 18- 19-
Slide Ring (2 Used) Slide Ring (2 Used) Seal Ring Piston Nut Steel Ball
W5-2-4-4
20- Set Screw 21- Cylinder Tube 22- O-Ring
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Boom Cylinder IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 1. Install bushing (10) to cylinder head (4) by using the special tool (ST 2508), a bar, and a hammer.
fNOTE:
Cylinder rod (1) outer diameter: 150 mm (5.9 in) 2. Install retaining ring (11) to cylinder head (4).
5. Install U-ring (8) to cylinder head (4) with the lip part facing to the bushing (10) side. 6. Install wiper ring (2) to cylinder head (4) by using a plate and a plastic hammer. 7. Install O-ring (6) and backup ring (5) to cylinder head (4). 8. Install O-ring (22) and seal ring (16) to piston (17) by using special tools (ST 2052, ST 2053). After installing seal ring (16), adjust seal ring (16) by using special tools (ST 7360, ST 7361).
fNOTE:
3. Install ring (9) to cylinder head (4) with the lip part facing to the bushing (10) side. 4. Install backup ring (7) to cylinder head (4).
W5-2-4-5
Cylinder tube (21) inner bore: 215 mm (8.5 in)
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 9. Install slide rings (14, 15) (2 used for each) with their slits positioned 180 ° away facing to the opposite each other.
d dCAUTION: lb)
CAUTION: Cylinder rod (1) weight: 380 kg (840 lb) Cylinder head (4) weight: 57 kg (130
10. Install the cylinder head (4) assembly to cylinder rod (1). 11. Install cushion bearing (13) to cylinder rod (1) with the chamfered surface facing of cushion bearing (13) to the cylinder head (4) side.
dCAUTION: lb)
Cylinder tube (21) weight: 359 kg (795
15. Secure cylinder tube (21) on a workbench horizontally. The cylinder rod (1) assembly weight: dCAUTION: 437 kg (965 lb) IMPORTANT: Do not damage the rings. 16. Fit to the center of cylinder tube (21) and insert the cylinder rod (1) assembly straight. 17. Install cylinder head (4) to cylinder tube (21) with socket bolts (3) (8 used).
12. Install the piston (17) assembly to cylinder rod (1).
l : 24 mm
13. Fit the matching marks made when disassembling and install nut (18) to cylinder rod (1) by using special tools (ST 5908, ST 3285).
m : 1910 N·m (191 kgf·m, 1410 lbf·ft)
j : 155 mm m : 30200 N·m (3020 kgf·m, 22280 lbf·ft) 14. Install ball (19) and set screw (20) to nut (18). Crimp set screw (20) by using a punch (2 places). l : 14 mm m : 100 N·m (10 kgf·m, 74 lbf·ft)
ST 5908
W158-04-02-022
W5-2-4-6
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Arm Cylinder 13 17 14 15 16 22 15 14
1
18
19 20
21
2 4 3 7 8 9 10 11 5 6
WJBC-05-02-002
1- 2- 3- 4- 5- 6-
Cylinder Rod Wiper Ring Socket Bolt (8 Used) Cylinder Head Backup Ring O-Ring
7- 8- 9- 10- 11- 13-
Backup Ring U-Ring Ring Bushing Retaining Ring Cushion Bearing
14- 15- 16- 17- 18- 19-
Slide Ring (2 Used) Slide Ring (2 Used) Seal Ring Piston Nut Steel Ball
W5-2-5-1
20- Set Screw 21- Cylinder Tube 22- O-Ring
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Arm Cylinder ď‚– The procedure starts on the premise that the piping and the bands securing the piping have been removed. CAUTION: Arm cylinder weight: 1200 kg (2650 lb) 1. Hoist the cylinder. Secure the cylinder horizontally on a workbench. Drain hydraulic oil from the cylinder.
4. Install cylinder rod (1) to the special tool (ST 5908). Put the matching marks on cylinder rod (1) and nut (18). ST 5908
d
W158-04-02-022
5. Cut away the crimped part (2 places) of set screw (20) by using a hand drill. Remove set screw (20) and steel ball (19). l : 17 mm W102-04-02-027
2. Fully extend cylinder rod (1). Remove socket bolts (3) (8 used) from cylinder head (4). l : 24 mm The cylinder rod (1) assembly weight: dCAUTION: 571 kg (1260 lb) Cylinder tube (21) weight: 561 kg dCAUTION: (1240 lb)
6. Remove nut (18) from cylinder rod (1) by using special tools (ST 3278, ST 5908). Remove piston (17) from cylinder rod (1). j : 180 mm IMPORTANT: Slide rings (14, 15) cannot be reused. Replace them with new ones when assembling. 7. Remove slide rings (14, 15) (2 used for each), seal ring (16), and O-ring (22) from piston (17).
IMPORTANT: Do not damage the sliding surface of cylinder rod (1). 3. Tap and remove cylinder head (4) with cylinder rod (1) together from cylinder tube (21) by using a plastic hammer.
W5-2-5-2
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder
dCAUTION: lb) dCAUTION: lb)
Cylinder rod (1) weight: 508 kg (1120 Cylinder head (4) weight: 63 kg (140
8. Remove cushion bearing (13) and cylinder head (4) from cylinder rod (1). 9. Remove O-ring (6), backup ring (5), wiper ring (2), retaining ring (11), ring (9), U-ring (8), and backup ring (7) from cylinder head (4). 10. Remove bushing (10) from cylinder head (4) by using the special tool (ST 1195).
fNOTE:
Cylinder rod (1) outer diameter: 160 mm (6.3 in)
W5-2-5-3
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Arm Cylinder 2
8
9
3
6
4
21
1
13
14 15 16 15 14 18
17 7
10
11
22
20
19
5 W1J7-04-02-007
1- 2- 3- 4- 5- 6-
Cylinder Rod Wiper Ring Socket Bolt (8 Used) Cylinder Head Backup Ring O-Ring
7- 8- 9- 10- 11- 13-
Backup Ring U-Ring Ring Bushing Retaining Ring Cushion Bearing
14- 15- 16- 17- 18- 19-
Slide Ring (2 Used) Slide Ring (2 Used) Seal Ring Piston Nut Steel Ball
W5-2-5-4
20- Set Screw 21- Cylinder Tube 22- O-Ring
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Arm Cylinder IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 1. Install bushing (10) to cylinder head (4) by using the special tool (ST 1195), a bar, and a hammer.
fNOTE:
Cylinder rod (1) outer diameter: 160 mm (6.3 in) 2. Install retaining ring (11) to cylinder head (4).
5. Install U-ring (8) to cylinder head (4) with the lip part facing to the bushing (10) side. 6. Install wiper ring (2) to cylinder head (4) by using a plate and a plastic hammer. 7. Install O-ring (6) and backup ring (5) to cylinder head (4). 8. Install O-ring (22) and seal ring (16) to piston (17) by using special tools (ST 2054, ST 2055). After installing seal ring (16), adjust seal ring (16) by using special tools (ST 7362, ST 7363).
fNOTE:
3. Install ring (9) to cylinder head (4) with the lip part facing to the bushing (10) side. 4. Install backup ring (7) to cylinder head (4).
W5-2-5-5
in)
Cylinder tube (21) inner diameter: 225 mm (8.9
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 9. Install slide rings (14, 15) (2 used for each) with their slits positioned 180° away facing to the opposite each other.
d dCAUTION: lb)
CAUTION: Cylinder rod (1) weight: 508 kg (1120 lb) Cylinder head (4) weight: 63 kg (140
10. Install the cylinder head (4) assembly to cylinder rod (1). 11. Install cushion bearing (13) to cylinder rod (1) with the chamfered surface of cushion bearing (13) facing to the cylinder head (4) side.
dCAUTION: (1240 lb)
Cylinder tube (21) weight: 561 kg
15. Secure cylinder tube (21) on a workbench horizontally. The cylinder rod (1) assembly weight: dCAUTION: 571 kg (1260 lb) IMPORTANT: Do not damage the rings. 16. Fit to the center of cylinder tube (21) and insert the cylinder rod (1) assembly straight. 17. Install cylinder head (4) to cylinder tube (21) with socket bolts (3) (8 used).
12. Install the piston (17) assembly to cylinder rod (1).
l : 24 mm
13. Fit the matching marks made when disassembling and install nut (18) to cylinder rod (1) by using special tools (ST 5908, ST 3278).
m : 1910 N·m (191 kgf·m, 1410 lbf·ft)
j : 180 mm m : 51800 N·m (5180 kgf·m, 38210 lbf·ft) 14. Install ball (19) and set screw (20) to nut (18). Crimp set screw (20) by using a punch (2 places). l : 17 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) ST 5908
W158-04-02-022
W5-2-5-6
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Bucket Cylinder
13 17 14 15 16 22 15 14
1
19
18
20
21
2 3 4 7 8 9 10 11 5 6
WJBC-05-02-003
1- 2- 3- 4- 5- 6-
Cylinder Rod Wiper Ring Socket Bolt (8 Used) Cylinder Head Backup Ring O-Ring
7- 8- 9- 10- 11- 13-
Backup Ring U-Ring Ring Bushing Retaining Ring Cushion Bearing
14- 15- 16- 17- 18- 19-
Slide Ring (2 Used) Slide Ring (2 Used) Seal Ring Piston Nut Steel Ball
W5-2-6-1
20- Set Screw 21- Cylinder Tube 22- O-Ring
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Bucket Cylinder ď‚– The procedure starts on the premise that the piping and the bands securing the piping have been removed. CAUTION: Bucket cylinder weight: 630 kg (1390 lb) 1. Hoist the cylinder. Secure the cylinder horizontally on a workbench. Drain hydraulic oil from the cylinder.
4. Install cylinder rod (1) to the special tool (ST 5908). Put the matching marks on cylinder rod (1) and nut (18). ST 5908
d
W158-04-02-022
5. Cut away the crimped part (2 places) of set screw (20) by using a hand drill. Remove set screw (20) and steel ball (19). l : 14 mm W102-04-02-027
2. Fully extend cylinder rod (1). Remove socket bolts (3) (8 used) from cylinder head (4). l : 22 mm The cylinder rod (1) assembly weight: dCAUTION: 331 kg (730 lb) Cylinder tube (21) weight: 280 kg (620 dCAUTION: lb)
6. Remove nut (18) from cylinder rod (1) by using special tools (ST 3284, ST 5908). Remove piston (17) from cylinder rod (1). j : 150 mm IMPORTANT: Slide rings (14, 15) cannot be reused. Replace them with new ones when assembling. 7. Remove slide rings (14, 15) (2 used for each), seal ring (16), and O-ring (22) from piston (17).
IMPORTANT: Do not damage the sliding surface of cylinder rod (1). 3. Tap and remove cylinder head (4) with cylinder rod (1) together from cylinder tube (21) by using a plastic hammer.
W5-2-6-2
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder
dCAUTION: lb) dCAUTION: lb)
Cylinder rod (1) weight: 286 kg (635 Cylinder head (4) weight: 45 kg (100
8. Remove cushion bearing (13) and cylinder head (4) from cylinder rod (1). 9. Remove O-ring (6), backup ring (5), wiper ring (2), retaining ring (11), ring (9), U-ring (8), and backup ring (7) from cylinder head (4). 10. Remove bushing (10) from cylinder head (4) by using the special tool (ST 1193).
fNOTE:
Cylinder rod (1) outer diameter: 140 mm (5.5 in)
W5-2-6-3
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Bucket Cylinder 2
8
9
3
6
4
21
1
13
14 15 16 15 14 18
17 7
10
11
22
20
19
5 W1J7-04-02-007
1- 2- 3- 4- 5- 6-
Cylinder Rod Wiper Ring Socket Bolt (8 Used) Cylinder Head Backup Ring O-Ring
7- 8- 9- 10- 11- 13-
Backup Ring U-Ring Ring Bushing Retaining Ring Cushion Bearing
14- 15- 16- 17- 18- 19-
Slide Ring (2 Used) Slide Ring (2 Used) Seal Ring Piston Nut Steel Ball
W5-2-6-4
20- Set Screw 21- Cylinder Tube 22- O-Ring
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Bucket Cylinder IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent personal injury. 1. Install bushing (10) to cylinder head (4) by using the special tool (ST 1193), a bar, and a hammer.
fNOTE:
Cylinder rod (1) outer diameter: 140 mm (5.5 in) 2. Install retaining ring (11) to cylinder head (4).
5. Install U-ring (8) to cylinder head (4) with the lip part facing to the bushing (10) side. 6. Install wiper ring (2) to cylinder head (4) by using a plate and a plastic hammer. 7. Install O-ring (6) and backup ring (5) to cylinder head (4). 8. Install O-ring (22) and seal ring (16) to piston (17) by using special tools (ST 2059, ST 2060). After installing seal ring (16), adjust seal ring (16) by using special tools (ST 7364, ST 7365).
fNOTE:
3. Install ring (9) to cylinder head (4) with the lip part facing to the bushing (10) side. 4. Install backup ring (7) to cylinder head (4).
W5-2-6-5
in)
Cylinder tube (21) inner diameter: 200 mm (7.9
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 9. Install slide rings (14, 15) (2 used for each) with their slits positioned 180° away facing to the opposite each other.
d dCAUTION: lb)
CAUTION: Cylinder rod (1) weight: 286 kg (635 lb) Cylinder head (4) weight: 45 kg (100
10. Install the cylinder head (4) assembly to cylinder rod (1). 11. Install cushion bearing (13) to cylinder rod (1) with the chamfered surface of cushion bearing (13) facing to the cylinder head (4) side.
dCAUTION: lb)
Cylinder tube (21) weight: 280 kg (620
15. Secure cylinder tube (21) on a workbench horizontally. The cylinder rod (1) assembly weight: dCAUTION: 331 kg (730 lb) IMPORTANT: Do not damage the rings. 16. Fit to the center of cylinder tube (21) and insert the cylinder rod (1) assembly straight. 17. Install cylinder head (4) to cylinder tube (21) with socket bolts (3) (8 used).
12. Install the piston (17) assembly to cylinder rod (1).
l : 22 mm
13. Fit the matching marks made when disassembling and install nut (18) to cylinder rod (1) by using special tools (ST 5908, ST 3284).
m : 1590 N·m (159 kgf·m, 1170 lbf·ft)
j : 150 mm m : 34600 N·m (3460 kgf·m, 25520 lbf·ft) 14. Install ball (19) and set screw (20) to nut (18). Crimp set screw (20) by using a punch (2 places). l : 14 mm m : 100 N·m (10 kgf·m, 74 lbf·ft) ST 5908
W158-04-02-022
W5-2-6-6
MEMO
MEMO
SECTION 6
ENGINE AND ACCESSORY CONTENTS General Information
General Repair Instruction....................................................0A-1 Illustration Arrows...................................................................0A-2 Abbreviations Charts..............................................................0A-3 Nut and Bolt Angular Tightening Method......................0A-4 Standard Bolt Torque Specifications.................................0A-6 Recommended Thread Locking Agents..........................0A-8 Main Data and Specification................................................0A-9 Performance Curve.............................................................. 0A-11 Engine External Drawing................................................... 0A-12 Service Standard................................................................... 0A-13 Torque Specifications.......................................................... 0A-19 Special Tools........................................................................... 0A-27 Troubleshooting.................................................................... 0A-29 Lubricant Application.......................................................... 0A-39 Sealant Application.............................................................. 0A-39
Service Information
Identification.............................................................................0B-1 Lubrication System..................................................................0B-2 Fuel System................................................................................0B-2 Cooling System.........................................................................0B-6 Valve Clearance Adjustment................................................0B-7 Compression Pressure Measurement...............................0B-9 Recommended Lubricants................................................ 0B-10 Engine Oil Viscosity Chart.................................................. 0B-10
Engine Mechanical
Service Precautions.................................................................6A-2 General Description................................................................6A-2 Fan Center..................................................................................6A-4 Turbocharger.............................................................................6A-7 Exhaust Manifold.....................................................................6A-9 Inlet Manifold......................................................................... 6A-10 Water Pump............................................................................ 6A-13 Alternator................................................................................. 6A-15 Oil Cooler................................................................................. 6A-18 Injection Pump...................................................................... 6A-20 Coupling Assembly.............................................................. 6A-24 Cylinder Head......................................................................... 6A-27 Rocker Arm and Shaft Assembly..................................... 6A-47 Camshaft.................................................................................. 6A-52 Timing Gears........................................................................... 6A-57 Flywheel Housing................................................................. 6A-66 Oil Pan....................................................................................... 6A-69 Piston......................................................................................... 6A-73 Crankshaft............................................................................... 6A-88 Crank Pulley............................................................................ 6A-99 Flywheel.................................................................................6A-102 Cylinder Block......................................................................6A-104
Engine Cooling
Service Precautions.................................................................6B-1 General Description................................................................6B-2 Water Pump...............................................................................6B-3 Thermostat.................................................................................6B-8
JBEW-6-1
Engine Fuel
Service Precautions.................................................................6C-1 General Description................................................................6C-2 Fuel Filter.....................................................................................6C-5 Injection Nozzle Holder.........................................................6C-7 Injection Pump...................................................................... 6C-13 Injection Nozzle Holder-Tow-Stage Injection Type................................................................... 6C-17
Starting and Charging
Service Precautions..............................................................6D3-1 Alternator.................................................................................6D3-2 Starter Motor....................................................................... 6D3-11
Engine Lubrication
Service Precaution.................................................................. 6G-1 General Description............................................................... 6G-2 Oil Pump.................................................................................... 6G-4 Oil Cooler.................................................................................6G-12
Engine Induction
Service Precaution....................................................................6J-1 Turbocharger..............................................................................6J-2
JBEW-6-2
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 1
GENERAL INFORMATION
0A–1
GENERAL INFORMATION CONTENTS General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B
GENERAL INFORMATION CONTENTS General Repair Instruction . . . . . . . . . . . . . . . . . . . . 0A-1 Illustration Arrows . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Abbreviations Charts . . . . . . . . . . . . . . . . . . . . . . . . 0A-3 Nut and Bolt Angular Tightening Method. . . . . . . . . 0A-4 Standard Bolts Torque Specification . . . . . . . . . . . . 0A-6 Recommended Thread Locking Agents . . . . . . . . . 0A-8 Main Data and Specification. . . . . . . . . . . . . . . . . . . 0A-9 Performance Curve. . . . . . . . . . . . . . . . . . . . . . . . . 0A-11
Engine External Drawing . . . . . . . . . . . . . . . . . . . . 0A-12 Service Standard . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-13 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 0A-19 Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-27 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-29 Lubricants Application . . . . . . . . . . . . . . . . . . . . . . 0A-39 Sealant Application . . . . . . . . . . . . . . . . . . . . . . . . . 0A-39
General Repair Instruction
12. When a service operation is completed, make a final check to be sure the service has been done properly and the problem has been corrected. 13. Allow the engine to cool before beginning any service procedure. This will eliminate the danger of fire and possible injury. 14. Hot steam under pressure may escape from the radiator if the coolant is drained while the engine is hot. This can result in serious burns. Allow the engine to cool before draining the coolant. 15. Hot engine oil can cause severe skin burns. Allow the engine to cool before draining the engine oil. 16. While working around a running engine, avoid contact with moving parts and hot surfaces to prevent possible bodily injury. 17. Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 18. Always wear safety goggles when working with fuel in order to protect the eye from fuel splash. 19. Test fluid from the injection nozzle tester will spray out of the injection nozzle under great pressure. It can easily puncture a person’s skin. Keep your hands away from the injection nozzle at all time. 20. Do not use your fingers to feel for fuel leaks at fittings. Fuel pressure is high enough to penetrate the skin. 21. Be careful when changing fuel system components: Diesel fuel is flammable. Be sure that the ignition key of OFF. Do not smoke or allow sources of open flame in the area while changing fuel system components.
1. Before performing service operations, disconnect ground cable from the battery to reduce the chance of cable damage and burning due to short circuiting. 2. Use a cover on body, seats and floor to protect them against damage and contamination. 3. Brake fluid and anti-freeze solution must be handled with reasonable care, as they can cause paint damage. 4. The use of proper tools and recommended essential and available tools, where specified, is important for efficient and reliable performance of service repairs. 5. Use genuine Isuzu parts. 6. Used cotter pins, plastic clips, gaskets, O-rings oil seals, lock washers and self-locking nuts should be discarded and new ones should be installed, as normal function of the parts cannot be maintained if these parts are reused. 7. To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nuts separate is very important, as they vary in hardness and design depending on position of installation. 8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air, and make certain they are free from restrictions. 9. Lubricate rotating and sliding faces of the parts with oil or grease before installation. 10. When necessary, use a sealer on gaskets to prevent leakage. 11. Carefully observe all specifications for bolt and nut torques.
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 2
0A–2
GENERAL INFORMATION
Illustration Arrows Arrows are designed for specific purposed to aid your understanding of technical illustration. Arrow Type
A
Application
Arrow Type
Application
Front of Engine
• Ambient/Clean air flow • Cool air flow
Up Side
• Gas other than ambient air • Hot air flow
Task Related
• Ambient air mixed with another gas • Can indicate temperature change
View Detail
Motion of direction
View Angle
Lubrication point oil or fluid
Dimension (1:2)
Lubrication point grease
Sectioning (1:3)
Lubrication point jelly
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 3
GENERAL INFORMATION
Abbreviations Charts List of industrial abbreviations which may be used in this manual A – Ampere(s) AC – Alternating Current ACL – Air Cleaner Adj – Adjust AMP – Ampere(s) ASM –Assembly ATDC – After Top Dead Center Auto – Automatic Bat – Battery B+ – Battery Positive Voltage BHP – Brake Horsepower BTDC – Before Top Dead Center °C – Degrees Celsius cc – Cubic Centimeter CID – Cubic Inch Displacement CO – Carbon Monoxide Conn – Connector Crank – Crankshaft Cu. In. – Cubic Inch Cyl – Cylinder(s) DOHC – Double Overhead Camshaft DTC – Diagnostic Trouble Code DTM – Diagnostic Test Mode DTT – Diagnostic Test Terminal ECM – Engine Control Module ECT – Engine Coolant Temperature EGR – Exhaust Gas Recirculation Exh – Exhaust °F – Degrees Fahrenheit FL – Fusible Link FLW – Fusible Link Wire FP – Fuel Pump FRT – Front ft – Foot Gal – Gallon GND – Ground Gov – Governor g – Gram Harn – Harness HC – Hydrocarbons HD – Heavy Duty Hg – Hydrargyrum (Mercury) IC – Integrated Circuit / Ignition Control ID – Identification / Inside Diameter IGN – Ignition INJ – Injection Int – Intake kg – Kilograms km – Kilometers km/h – Kilometer per Hour kPa – Kilopascals kV – Kilovolts (thousands of volts) kW – Kilowatts L – Liter lb ft – Foot Pounds
lb in – Inch Pounds LF – Left Front LH – Left Hand LR – Left Rear LS – Left Side L-4 – In-Line Four Cylinder Engine Max – Maximum Min – Minimum mm – Millimeter N – Newtons NA – Naturally Aspirated NC – Normally Closed N·m – Newton Meters NO – Normally Open NOX – Nitrogen, Oxides of OD – Outside Diameter OHC – Overhead Camshaft PCV – Positive Crankcase Ventilation PRESS – Pressure PROM – Programmable Read Only Memory PSI – Pounds per Square Inch PSP – Power Steering Pressure Pt. – Pint PWM – Pulse Width Modulate Qt. – Quart REF – Reference RF – Right Front RH – Right Hand RPM – Revolutions Per Minute RPM Sensor – Engine Speed Sensor RR – Right Rear RS – Right Side RTV –Room Temperature Vulcanizing SAE – Society of Automotive Engineers Sec – Secondary SI – System International SOHC – Single Overhead Camshaft Sol – Solenoid SPEC – Specification Speedo – Speedometer ST – Start / Scan Tool Sw – Switch SYN – Synchronize Tach – Tachometer TDC – Top Dead Center Term – Terminal TEMP – Temperature TURBO – Turbocharger V – Volt(s) VAC – Vacuum V-ref – ECM Reference Voltage VSS – Vehicle Speed Sensor VSV – Vacuum Switch Valve V-6 – Six Cylinder “Vee” Engine V-8 – Eight Cylinder “Vee” Engine W – Watt(s) w/ – With w/o – Without WOT – Wide Open Throttle
0A–3
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 4
0A–4
GENERAL INFORMATION
Nut and Bolt Angular Tightening Method The angular tightening method uses the plastic region of high tensile steel nuts and bolts to precision tighten important engine fasteners. Because of the method's nature, there is a limit to the number of times a particular fastener may be reused. This limit is specified in this Manual where applicable. 1. Carefully wash the nuts and bolts to remove all oil and grease. 2. Apply a coat of molybdenum disulfide grease to the threads and setting faces of the nuts and bolts. 3. Tighten the nuts and bolts to the specified torque (snug torque) with a torque wrench. 4. Draw a line A–B across the center of each nut or bolt after tighten the snug torque.
Line
C
D
F00EY00002
6. Draw another line F – G on the face of each of the parts to be clamped. This line will be in the direction of the specified angle Q across the center E of the nut or bolt.
Center line
A
B
E
Specified angle Q F F00EY00001
5. Draw another line C – D on the face of each of the parts to be clamped. This line should be an extension of the line A – B.
G Coincide line F00EY00003
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 5
GENERAL INFORMATION 7. Use a socket wrench to tighten each nut or bolt to the point where the line A – B is aligned with the line F – G.
Tighten A
C
D
B F
G
F00EY00005
Example: Specified Angle and Tightening Rotation A B C D E
30° 60° 90° 180° 360°
1 / 12 of a turn 1 / 6 of a turn 1 / 4 of a turn 1 / 2 of a turn One full turn
A B C D E
F00EY00004
0A–5
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0A–6
GENERAL INFORMATION
Standard Bolts Torque Specification The tightening torque values given in the table below are applicable to the bolts unless otherwise specified.
STANDARD BOLT
N·m (kgf·m/lb.ft)
Bolt Identification
Bolt Diameter × pitch (mm)
*
*
*
*
*
*
*
*
M6 × 1.0
4 – 8 (0.4 – 0.8/3 – 6)
5 – 10 (0.5 – 1.0/4 – 7)
M8 × 1.25
8 – 18 (0.8 – 1.8/6– 13)
12 – 23 (1.2 – 2.3/9 – 17)
17 – 30 (1.7 – 3.1/12 – 22)
M10 × 1.25
21 – 34 (2.1 – 3.5/5 – 25)
28 – 46 (2.8 – 4.7/20 – 33)
37 – 62 (3.8 – 6.4/28 – 46)
M10 × 1.5
20 – 33 (2.0 – 3.4/15 – 25)
28 – 45 (2.8 – 4.6/20 – 33)
36 – 60 (3.7 – 6.1/27– 44)
M12 × 1.25
49 – 74 (5.0 – 7.5/36 – 54)
61 – 91 (6.2 – 9.3/45 – 67)
76 – 114 (7.7 – 11.6/56 – 84)
M12 × 1.75
45 – 69 (4.6 – 7.0/33 – 51)
57 – 84 (5.8 – 8.6/42 – 62)
72 – 107 (7.3 – 10.9/53 – 79)
M14 × 1.5
77 – 115 (7.8 – 11.7/56 – 85)
93 – 139 (9.5 – 14.2/69 – 103)
114 – 171 (11.6 – 17.4/84 – 126)
M14 × 2.0
72 – 107 (7.3 – 10.9/53 – 79)
88 – 131 (9.0 – 13.4/65 – 97)
107 – 160 (10.9 – 16.3/79 – 118)
M16 × 1.5
104 – 157 (10.6 – 16.0/77 – 116)
135 – 204 (13.8 – 20.8/100 – 150)
160 – 240 (16.3 – 24.5/118 – 177)
M16 × 2.0
100 – 149 (10.2 – 15.2/74 – 110)
129 – 194 (13.2 – 19.8/96 – 143)
153 – 230 (15.6 – 23.4/113 – 169)
M18 × 1.5
151 – 226 (15.4 – 23.0/110 – 166)
195 – 293 (19.9 – 29.9/144 – 216)
230 – 345 (23.4 – 35.2/169 – 255)
M18 × 2.5
151 – 226 (15.4 – 23.0/110 – 166)
196 – 294 (20.0 – 30.0/145 – 217)
231 – 346 (23.6 – 35.5/171 – 255)
M20× 1.5
206 – 310 (21.0 – 31.6/152 – 229)
270 – 405 (27.5 – 41.3/199 – 299)
317 – 476 (32.3 – 48.5/234 – 351)
M20× 2.5
190 – 286 (19.4 – 29.2/140 – 211)
249 – 375 (25.4 – 38.2/184 – 276)
293 – 440 (29.9 – 44.9/216 – 325)
M22× 1.5
251 – 414 (25.6 – 42.2/185 – 305)
363 – 544 (37.0 – 55.5/268 – 401)
425 – 637 (43.3 – 64.9/313 – 469)
M22× 2.5
218 – 328 (22.2 – 23.4/161 – 242)
338 – 507 (34.5 – 51.7/250 – 374)
394 – 592 (40.2 – 60.4/291 – 437)
M24× 2.0
359 – 540 (36.6 – 55.0/265 – 398)
431 – 711 (43.9 – 72.5/318 – 524)
554 – 831 (56.5 – 84.7/409 – 613)
M24× 3.0
338 – 507 (34.5 – 51.7/250 – 374)
406 – 608 (41.4 – 62.0/299 – 448)
521 – 782 (53.1 – 79.7/384 – 576)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials such as casting.
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 7
GENERAL INFORMATION
0A–7
The tightening torque values given in the table below are applicable to the bolts unless otherwise specified.
FLANGED HEAD BOLT
N·m (kgf·m/lb.ft)
Bolt Identification
Bolt Diameter × pitch (mm)
*
*
*
*
M6 × 1.0
5 – 9 (0.5 – 0.9/4 – 7)
6 – 12 (0.6 – 1.2/4 – 9)
M8 × 1.25
11 – 20 (1.1 – 2.0/8 – 15)
15 – 28 (1.6 – 2.9/12 – 21)
18 – 34 (2.1 – 3.4/15 – 25)
M10 × 1.25
23 – 39 (2.4 – 3.9/17 – 28)
35 – 59 (3.6 – 6.1/26 – 44)
42 – 71 (4.3 – 7.2/31 – 52)
M10 × 1.5
22 – 37 (2.3 – 3.8/17 – 28)
35 – 58 (3.5 – 5.8/25 – 42)
40 – 67 (4.1 – 6.8/30 – 49)
M12 × 1.25
55 – 82 (5.6 – 8.4/40 – 61)
77 – 117 (7.9 – 11.9/57 – 86)
85 – 128 (8.7 – 13.0/63 – 94)
M12 × 1.75
51 – 77 (5.2 – 7.8/38 – 56)
71 – 107 (7.3 – 10.9/53 – 79)
80 – 119 (8.1 – 12.2/59 – 88)
M14 × 1.5
83 – 125 (8.5 – 12.7/62 – 92)
115 – 172 (11.7 –17.6/85 – 127)
123 – 185 (12.6 – 18.9/91 – 137)
M14 × 2.0
77 – 116 (7.9 – 11.8/57 – 85)
108 – 162 (11.1 – 16.6/80 – 120)
116 – 173 (11.8 – 17.7/85 – 128)
M16 × 1.5
116 – 173 (11.8 – 17.7/85 – 128)
171 – 257 (17.4 – 26.2/126 – 190)
177 – 265 (18.0 – 17.1/130 – 196)
M16 × 2.0
109 – 164 (11.2 – 16.7/81 – 121)
163 – 244 (16.6 – 24.9/120 – 180)
169 – 253 (17.2 – 25.8/124 – 187)
A bolt with an asterisk (*) is used for female screws of soft material such as cast iron.
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 8
0A–8
GENERAL INFORMATION
Recommended Thread Locking Agents LOCTITE Type
LOCTITE Color
LOCTITE 242
Blue
LOCTITE 262
Red
LOCTITE 271
Red
Application Steps 1. Completely remove all lubricant and moisture from the bolts and the female-threaded surfaces of the parts to be joined. The surfaces must be perfectly dry. 2. Apply LOCTITE to the bolts.
Apply LOCTITE to at least 1/3 of the bolt's threaded area
F00RW014
3. Tighten the bolts to the specified torque. After tightening, be sure to keep the bolts free from vibration and torque for at least an hour until LOCTITE hardens. NOTE: When the application procedures are specified in this manual, follow them.
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 9
GENERAL INFORMATION
Main Data and Specifications ITEMS
6WG1TQA
Engine type
Four cycle, water cooled, in-line, overhead camshaft direct injection
Combustion chamber
Open type in piston crown
Cylinder liner
Dry type
Timing drive system
Gear drive
No. of cylinders – bore × stroke
mm (in)
6 – 147 × 154 (5.79 × 6.06)
Rated output
kW/min–1
235.4/1800
Max. torque
kW/min–1
1274.9/1500
No. of piston rings
Four rings (Compression rings: 3, Oil ring: 1)
Total piston displacement
L (cid)
Compression ratio (to 1)
16.4
Compression pressure at 200 min–1 MPa (kg/cm2/psi) Engine dimensions
mm (in)
Engine weight (Dry)
kg (lb)
Fuel injection order deg
Specified fuel type
1,642 × 1007 × 1,287 (64.6 × 39.6 × 50.7) 1,252 (2,764) 11 SAE No.2 diesel fuel
min–1
Idling speed Valve clearances
Exhaust valves
2.75 (28/400) or more
1–5–3–6–2–4
Fuel injection timing (TDC)
Intake valves
15.681 (956.9)
900
Intake
mm (in)
0.40 (0.016)
Exhaust
mm (in)
0.40 (0.016)
Open at (BTDC)
deg
21
Close at (ABDC)
deg
27
Open at (BBDC)
deg
52
Close at (ATDC)
deg
17
Injection pump
Bosch, in-line P-Type
Governor type
Mechanical
Injection nozzle
Multi-hole type
Injection nozzle opening pressure MPa (kg/cm2/psi) Main fuel filter type Lubrication system Lubrication method Specified engine oil (API grade) Oil pressure (at oil gallery) kPa (kg/cm2/psi)/min–1
20.1 (205/2,920) Paper element Full flow pressure circulation CD 300 (3.1/44.1)/1,200 390 (4.0/56.9)/2,000 Condition: SAE 30 API CD grade engine oil at an oil temperature of 80°C (176°F)
Oil pump type
Gear (Timing gear drive)
0A–9
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 10
0A–10
GENERAL INFORMATION ITEMS
6WG1TQA
Relief valve opening pressure kPa (kg/cm2/psi) 1st stage 2nd stage
440 (4.5/64.0) 690 (7.0/99.5)
Oil pressure switch operating pressure kPa (kg/cm2/psi)
10 (0.1/0.7)
Main oil filter type
Paper element
Bypass valve opening pressure kPa (kg/cm2/psi)
200 (2.0/28.4)
Oil volume
L (qts)
Oil cooler
52 (55) with combined main and partial oil filter Plate type – Water cooled in water jacket
Oil thermostat opening temperature °C (°F) Cooling system
98.0 (208) Pressured compulsory circulation water
Coolant volume
L (qts)
Water pump type
36 (38) Centrifugal impeller, Gear drive
Delivery volume Lit/min. (Imp. gal/US gal) Thermostat type Valve initial opening temperature Valve lift
420 (92.4/111.0) Pump speed at 2,840 rpm Wax pellet
°C (°F)
82 (180)
mm (in)
11.0 (0.433)
Air cleaner Alternator capacity
V–A
Regulator type
24 – 50 Mitsubishi IC (Built-in)
Brush length
mm (in)
Brush less
Starter motor output
V – kW
24 – 7 Mitsubishi
Number of poles Turbocharger model Manufacturer
4 RHC 92 Ishikawajima Harima Heavy Industry (IHI)
Note: Some values are different due to the difference of the models and the specifications.
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 11
GENERAL INFORMATION
0A–11
Performance Curve 1. MODEL AA-6WG1TQA Fully φ 850 No load
Air cleaner Exhaust silencer Ambient condition
Non Non Standard
240
1400
220
1200
200
1000
Torque (Nm)
Condition Break in period Cooling fan Alternator
Power Output (kW)
180
160
140
120
100
230 220 210
SFC (g/kW/h)
240
200
1000
1200
1400
1600
1800
2000
Engine Speed (min-1) F06EY00020
Note: Some values are different due to the difference of the models and the specifications.
Water drain plug
Inlet duct
Alternator
Cooling fan
Water pump
Fan guide
Water inlet pipe Thermostat housing Oil port cover
Turbocharger
Fan pulley
Crank pulley
Water outlet pipe
Coupling cover Oil drain plug
Injection pump
Fuel pump
Breather hose
Starter motor
Fuel filter
Oil dipstick
PCV
Oil filler cap
0A–12
Exhaust manifold
ENGINE EXTERNAL DRAWING MODEL AA-6WG1 TQA
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 12
GENERAL INFORMATION
Note: Some components and shapes are different due to the difference of the models and the specifications.
015EY00001
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 13
GENERAL INFORMATION
0A–13
Service Standard ITEMS
SERVICE STANDARD
SERVICE LIMIT
27.5 (28 / 400 ) / 200 or more, after warm up the engine.
21.6 ( 22 / 312 )
0.085 – 0.170 (0.0033-0.0067)
0.25 ( 0.0098 )
0.065 – 0.125 (0.0026-0.0049)
0.15 ( 0.0059 )
ENGINE Compression Pressure MPa(kg/cm2/psi)/min–1 CYLINDER HEAD and VALVE Camshaft End Play
mm(in)
Clearance between Camshaft and Bracket
mm(in)
Idle Gear “C” End Play
mm(in)
0.05 – 0.14 (0.0020-0.0055)
0.25 ( 0.0098 )
Clearance between Shaft and Idle “C” Gear mm(in)
0.04 – 0.105 (0.0016-0.0041)
0.2 ( 0.0079 )
Valve Spring Free Height
Outer
mm(in)
Inlet
79.3 (3.1220)
75.3 ( 2.965 )
Exhaust
102.7 (4.0433)
97.6 ( 3.843 )
–
–
96.5 (3.7992)
91.7 ( 3.6102 )
3.5 (0.1378)
4.8 ( 0.1890 )
Outer
4.5 (0.1772)
6.2 ( 0.2441 )
Inner
4.2 (0.1654)
5.9 ( 0.2323 )
Inlet
392 (40.0/88.2)/64
372 ( 37.9/83.6)/64
Exhaust
610 (62.2/137)/69
579 ( 59.0/130)/69
–
–
224 (22.8/50.3)/66
213 ( 21.7/47.8 )/66
Inlet
0.040 – 0.077 (0.0016 – 0.0030)
0.15 ( 0.0059 )
Exhaust
0.065 – 0.102 (0.0026 – 0.0040)
0.25 ( 0.0098 )
Inner Inlet Exhaust Valve Spring Squareness
mm(in)
Inlet Exhaust
Valve Spring tension
N(kg/lb)/mm
Outer
Inner Inlet Exhaust Valve Stem and Guide Clearance mm(in)
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 14
0A–14
GENERAL INFORMATION ITEMS
Valve Stem Outside Diameter
SERVICE STANDARD mm(in)
Bridge Guide and Bridge Clearance mm(in) Valve Thickness Valve Depression Valve Contact Width
mm(in) mm(in) mm(in)
Valve Contact Surface Angle
deg
Valve Seat Angle
deg
Inlet
10.0 (0.3937)
9.92 ( 0.3906 )
Exhaust
10.0 (0.3937)
9.90 ( 0.3898 )
0.020 – 0.057 (0.0080-0.0022)
0.10 ( 0.0039 )
Inlet
2.14 (0.0843)
1.64 ( 0.0646 )
Exhaust
2.3 (0.0906)
1.8 ( 0.0709 )
Inlet
1.9 (0.0748)
2.9 ( 0.1142 )
Exhaust
1.8 (0.0709)
2.8 ( 0.1102 )
Inlet
3.3 (0.1299)
3.7 ( 0.1457 )
Exhaust
2.6 (0.1024)
3.0 ( 0.1181 )
Inlet
30
–
Exhaust
45
–
Inlet
30
–
Exhaust
45
–
Valve Bridge Guide Upper End Height mm(in) Valve Guide Upper End Height
mm(in)
SERVICE LIMIT
49.0 (1.9291)
–
Inlet
27.0 (1.0630)
–
Exhaust
29.0 (1.1417)
–
ROCKER ARM AND CAMSHAFT Rocker Arm Shaft Run Out
mm(in)
–
0.3 ( 0.012 )
mm(in)
27.979 – 28.000 (1.1015-1.1024)
27.85 (1.0965)
mm(in)
28.020 – 28.053 (1.1031 – 1.1044)
–
mm(in)
0.020 – 0.074 (0.0008 – 0.0029)
0.2 (0.0079)
mm(in)
0.036 – 0.069 (0.0014 – 0.0027)
0.15 (0.0059)
39.915 – 39.940 (1.5715 – 1.5724)
39.89 (1.57047)
Rocker Arm Shaft Outside Diameter Rocker Arm Bushing Inside Diameter Rocker Arm and Rocker Arm Shaft Clearance Rocker Arm Roller and Pin Clearance Camshaft Journal Diameter
mm(in)
Cam Height (Nose Height)
mm(in)
Inlet
9.4 (0.3700)
8.85 ( 0.3484 )
Exhaust
10.4 (0.4094)
9.75 ( 0.3839 )
mm(in)
0.080 (0.0031)
0.100 ( 0.0039 )
mm(in)
40.015 – 40.040 (1.5754 – 1.5764)
–
Clearance Camshaft and Cam Bearing mm(in)
0.065 – 0.125 (0.0026 – 0.0049)
0.15 ( 0.0059 )
Camshaft Run Out Camshaft Bearing Inside Diameter
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 15
GENERAL INFORMATION ITEMS
SERVICE STANDARD
SERVICE LIMIT
0.095 – 0.135 ( 0.0037 – 0.0053 )
0.25 ( 0.0098 )
TIMING GEAR TRAIN Idle Gear Backlash
mm(in)
Idle Gear End Play
mm(in)
Idle Gear Spindle Outside Diameter
“A”
0.155 – 0.220 (0.0061 – 0.0089)
0.35 ( 0.0138 )
“B”
0.050 – 0.140 (0.0020 – 0.0055)
0.25 ( 0.0098 )
“C”
0.050 – 0.140 (0.0020 – 0.0055)
0.25 ( 0.0098 )
“A”
56.93 – 56.96 (2.2413 – 2.2425)
56.85 ( 2.2382 )
“B”
141.93 – 141.96 (5.5878 – 5.5890)
141.85 ( 5.5846 )
“C”
48.93 – 48.96 (1.9264 – 1.9286)
48.85 ( 1.9232 )
0.040 – 0.105 (0.0015 – 0.0041)
0.20 ( 0.0079 )
mm(in)
Clearance Between Idle Gear and Spindle
“A” mm(in)
“B” “C”
CRANKSHAFT Crankshaft End Play
mm(in)
Crankshaft Journal Diameter
mm(in)
0.10 – 0.28 (0.0039-0.0110)
0.35 ( 0.0138 )
No.4
104.850 – 104.875 (4.1279 – 4.1289)
–
Others
104.880 – 104.905 (4.1291 – 4.1309)
–
Crankpin Diameter
mm(in)
91.895 – 91.925 (3.6179 – 3.6191)
–
Crankshaft Run Out
mm(in)
0.120 (0.0005)
0.15 ( 0.0059 )
Crankshaft End Play
mm(in)
0.10 – 0.28 (0.0039 – 0.0110)
0.30 (0.0121)
–
111.5 ( 4.3898 )
Crank Bearing Spread Clearance Crankshaft journal and Bearing
mm(in) mm(in)
No.4 Journal
0.075 – 0.150 (0.0030 – 0.0059)
Others
0.045 – 0.120 (0.0018 – 0.0047)
0.16 (0.0063)
0A–15
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 16
0A–16
GENERAL INFORMATION ITEMS
SERVICE STANDARD
SERVICE LIMIT
PISTON AND CONNECTING ROD Piston Ring Gap
mm(in)
Clearance Piston Ring and Groove
1st, 3rd
0.35 – 0.50 (0.0138 – 0.0197)
2nd
0.80 – 0.95 (0.0315 – 0.0374)
Oil
0.30 – 0.50 (0.0118 – 0.0197)
1st
0.115 – 0.160 (0.0045 – 0.0063)
0.24 (0.0094)
2nd 3rd
0.10 – 0.135 (0.0039 – 0.0053)
0.20 (0.0079)
Oil
0.025 – 0.065 (0.0010 – 0.0026)
0.15 (0.0059)
mm(in)
1.00 (0.0394)
Piston Pin Diameter
mm(in)
55.995 – 56.000 (2.2015 – 2.2047)
55.970 (2.2035)
Clearance Piston Pin and Hole
mm(in)
0.008 – 0.021 (0.0003 – 0.0008)
0.05 (0.0020)
Clearance Connecting Rod Small End Bushing and Piston Pin mm(in)
0.020 – 0.037 (0.0008 – 0.0015)
0.10 (0.0039)
0.05 (0.002 or less)
0.10 (0.0039)
Clearance Crankpin and Connecting Rod Bearing mm(in)
0.033 – 0.103 (0.0013 – 0.0041)
0.16 (0.0063)
Clearance Connecting Rod and Crankshaft
mm(in)
0.175 – 0.290 (0.0069 – 0.0114)
0.35 (0.0138)
mm(in)
0.166 – 0.200 (0.0065 – 0.0079)
–
Connecting Rod Alignment
mm(in)
Clearance Piston and Cylinder Liner PISTON AND CYLINDER LINER GRADE Cylinder Measuring point
mm(in)
130 (5.1181)
Cylinder Liner Inside Diameter
mm(in)
147.011 – 147.030 (5.7878 – 5.7886)
–
Piston Measuring Point from Piston Top
mm(in)
113 (4.4488)
–
Piston Outside Diameter
mm(in)
146.830 – 146.845 (5.7807 – 5.7813)
–
Clearance Cylinder Liner and Cylinder Block mm(in)
0.001 – 0.030 (0.00004 – 0.00118)
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 17
GENERAL INFORMATION ITEMS
SERVICE STANDARD
SERVICE LIMIT
CYLINDER BLOCK AND CYLINDER LINER GRADE Cylinder Block Bore Diameter
Cylinder Liner Outside Diameter
mm(in)
mm(in)
Grade “1”
151.600 – 151.610 (5.9685 – 5.9689)
–
“2” “3”
151.611 – 151.630 (5.9689 – 5.9697)
–
“1X”
151.590 – 151.599 (5.9681 – 5.9685)
–
“3X”
151.600 – 151.610 (5.9685 – 5.9689)
–
Grade
CYLINDER BODY Nominal Measurement 147.0 (5.7874)
147.3 (5.7992)
0.0075 (0.0030) or less
0.2 (0.008)
0.05 – 0.09 (0.0020 – 0.0035)
–
0.02 (0.0008) or less
–
Clearance Oil Pump Body and Driven Gear mm(in)
0.050 – 0.098 (0.0020 – 0.0039)
0.15 (0.0059)
Side Clearance Oil Pump Cover and Gear mm(in)
0.040 – 0.094 (0.0016 – 0.0037)
–
20.0 (0.7874)
19.9(0.7835)
Clearance Oil Pump Gear Shaft and Body mm(in)
0.040 – 0.074 (0.0015 – 0.0029)
–
An Interference Oil Pump Drive Gear and Driven Gear mm(in)
0.019 – 0.047 (0.0007 – 0.0019)
–
98.0 (208.4)
–
1.7 – 2.7 (0.0669 – 0.1063)
3.2 (0.1260)
Cylinder Liner Bore
mm(in)
Cylinder Block Upper Face Warpage mm(in) Cylinder Liner Projection
mm(in)
Projection Height Between Adjacent Cylinder mm(in) LUBRICATING SYSTEM
Oil Pump Gear Shaft Diameter
mm(in)
Oil Thermostat Opening Temperature °C (°F) ENGINE COOLING SYSTEM Clearance Water Pump Impeller and Pump Body mm(in) Thermostat Opening Temperature Thermostat Full Valve Lift
Initial Opening °C (°F) Full Opening mm(in)
82 (180.0)
–
95 (203.0)
–
11 (0.433)
–
0A–17
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0A–18
GENERAL INFORMATION ITEMS
SERVICE STANDARD
SERVICE LIMIT
11.7
–
ENGINE ELECTRICAL Alternator Rotor Coil Resistance
ohm
Starter Motor Commutator Undercut
mm(in)
0.5 (0.197)
0.2 (0.0079)
Commutator Outside Diameter
mm(in)
32 (1.26)
31.4 (1.24)
Brush Length
mm(in)
18 (0.709)
11 (0.43)
mm(in)
0.075 – 0.110 (0.0030 – 0.0043)
0.12 (0.0047)
0.130 – 0.235 (0.0051 – 0.0093)
0.275 (0.0108)
TURBOCHARGER Turbine Shaft End Play Clearance Turbine Shaft and Bearing mm(in)
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 19
GENERAL INFORMATION
0A–19
Torque Specifications Auxiliary Parts 118(12/87)
52(5.3/38)
N·m (kgf·m/lb ft)
118(12/87)
103(10.5/76)
52(5.3/38)
F06EY00021
Note: Some components and shapes are different due to the difference of the models and the specifications.
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 20
0A–20
GENERAL INFORMATION
Engine External Parts
N·m (kgf·m/lb ft) 43(4.4/32) 52(5.3/38)
39(4.0/29)
88(9.0/65) 108(11/80)
43(4.4/32)
20(2.0/14)
50(5.1/37)
39(4.0/29) 43(4.4/32)
F06EY00022
Note: Some components and shapes are different due to the difference of the models and the specifications.
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 21
GENERAL INFORMATION
Cylinder Head
0A–21
N·m (kgf·m/lb ft)
20(2.05/14.8)
15(1.5/11)
90(9.2/67) Apply engine oil
49(5.0/36)
137(14/101)
M18: 177 (18/130) 245 (25/181) 60° 90° M12: 76 (7.7/57) M10: 38 (3.9/28) M18: Apply molybdenum disulfide grease M12,M10: Apply engine oil Apply engine oil
39(4.0/29)
Apply Loctite FMD-127
F06EY00166
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0A–22
GENERAL INFORMATION
Oil Pan
N·m (kgf·m/lb ft)
69(7.0/51)
55(5.6/41)
38(3.9/28)
38(3.9/28) 25(2.5/18) 19(1.9/14) PAW0Z0LF001301
PAW0Z0LF001301
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GENERAL INFORMATION
Timing Gears
0A–23
N·m (kgf·m/lb ft)
135(13.8/100)
49(5.0/36)
39(4.0/29)
Apply Loctite FMD-127
39(4.0/29)
108(11.0/80)
52(5.3/38)
46(4.7/34)
22(2.2/16)
96(9.8/71) 267(27.2/197) Apply engine oil
014EY00127
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 24
0A–24
GENERAL INFORMATION N·m (kgf·m/lb ft)
(Without Cooling Fan)
135 {13.8 / 100}
49 {5.0 / 36}
39 {4.0 / 29}
39 {4.0 / 29}
108 {11.0 / 80}
39 {4.0 / 29}
M8
23 {2.3 / 17}
M10
43 {4.4 / 32}
96 {9.8 / 71} 267 {27.2 / 197}
PAW0Z0LF001401
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GENERAL INFORMATION
Flywheel
0A–25
N·m (kgf·m/lb ft)
136(13.8/100)
136(13.8/100)
Apply Loctite FMD-127
136(13.8/100)
M14: 123 (12.5/90) M 8 : 22 (2.2/16) 78(8.0/58)
60°
30°
Apply molybdenum disulfide grease
136(13.8/100)
015EY00080
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0A–26
GENERAL INFORMATION
Piston, Connecting Rod, Crankshaft
N·m (kgf·m/lb ft)
98(10/72)
30°
30°
Apply molybdenum disulfide grease
M12: 96(9.8/71) Apply engine oil
M18: 49(5/36) 88(9/65) 105° Apply molybdenum disulfide grease
51743A 00/06/27
0 一般輸出 015EY00081
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GENERAL INFORMATION
0A–27
Special Tools TOOL NO. TOOL NAME
ILLUSTRATION
ILLUSTRATION
TOOL NO. TOOL NAME
1-8523-0013-0 Remover; Nozzle holder
1-8522-1187-0 Installer; Valve stem seal for intake
1-8531-7019-0 Adapter; Compression gauge
1-85221-184-0 Installer; Valve stem seal for exhaust
5-8840-0266-0 Angle gauge
1-8522-1025-0 Setting tool; Piston ring
1-8523-5013-0 Compressor; Valve spring
1-8522-0052-0 Remover; Slinger
9-8523-1202-0 Remover; Valve guide/Installer
1-8522-0059-0 Setting tool; Piston
9-8522-1324-0 Installer; Valve bridge guide
1-8522-0043-0 Installer; Oil seal
901LX030
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0A–28
GENERAL INFORMATION
ILLUSTRATION
TOOL NO. TOOL NAME
1-8521-0064-0 Remover; Crankshaft gear
1-8522-0045-0 Installer; Crankshaft gear
11.3 ± 0.1
1-8521-0062-0 Remover; Impeller
1-8522-0047-0 Installer; Seal Unit
1-8521-0067-0 Puller; Seal ring
1-8522-1034-0 Installer; Seal ring
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GENERAL INFORMATION
0A–29
Troubleshooting 1. Hard starting Condition
Possible Cause
Starter motor does not turn over Loose battery cable terminals Poor battery connections due to rusting
Starter motor operates but engine does not turn over
Engine turns over but does not start
Battery discharged or weak Fusible link shorted Defective starter switch or starter relay Defective magnetic switch of starter motor or starter relay Defective starter motor Loose battery cable terminals Poor battery connections due to rusting Battery discharged or weak Loose fan belts Defective starter motor pinion gear Defective magnetic switch of the starter motor Worn starter motor Weak brush spring Piston,crank bearing seizure,or other damage Air in the fuel system Defective engine stop mechanism Control wire improperly adjusted” Fuel tank is empty Clogged or damaged fuel lines Loose fuel line connections Clogged fuel filter element Fuel feed pump strainer is clogged Defective feed pump Poor return of the engine stop button Use of the wrong fuel Water particles in the fuel Air in the injection pump Injection nozzle sticking Injection nozzle starting pressure too low Improper spray condition Improper injection pump control rack operation Injection pump plunger worn or stuck Injection pump camshaft seizure or other damage
Correction Clean and/or retighten the battery cable terminals Recharge or replace the battery Replace the fusible link Replace the starter switch or starter relay Repair or replace the magnetic switch or starter relay Repair or replace the starter motor Clean and/or retighten the battery cable terminals Recharge or replace the battery Adjust the fan belt tension Replace pinion gear Repair or replace the magnetic switch Replace the brush and /or brush spring Repair or replace the related parts Bleed air from the fuel system Replace the engine stop mechanism Adjust the control wire Fill the fuel tank Repair or replace the fuel lines Retighten the fuel line connections Replace the fuel filter element or cartridge Clean the fuel pump strainer Repair or replace the feed pump Completely return the engine stop button Use the recommended fuel Change fuel Bleed air from the fuel system Replace the injection nozzle Adjust or replace the injection nozzle
Repair or replace the injection pump control rack Replace the injection pump plunger assembly Replace the injection pump camshaft
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0A–30
GENERAL INFORMATION
2. Unstable Idling Condition
Possible Cause
Trouble in the engine stop Poor return of the engine stop button mechanism Trouble in the fuel system
Correction Completely return the engine stop button
Fuel system leakage or blockage
Repair or replace the fuel system
Air in the fuel system
Bleed the air from the fuel system
Water particles in the fuel
Replace fuel
Clogged fuel filter element
Replace the fuel filter element or cartridge
Injection nozzle sticking
Replace the injection nozzle
Injection nozzle starting pressure too low
Adjust or replace the injection nozzle
Improper spray condition
Trouble in the valve gear train Low compression pressure
Defective delivery valve resulting in fuel drippage after fuel injection
Replace the delivery valve
Injection timing improperly adjusted
Adjust the injection timing
Insufficient injection volume
Adjust the injection volume
Broken plunger spring of the injection pump
Replace the plunger spring
Worn plunger of the injection pump
Replace the plunger assembly
Worn camshaft of the injection pump
Replace the camshaft
Worn roller tappet of the injection pump
Replace the roller tappet
Valve clearance improperly adjusted
Adjust the valve clearance
Worn camshaft
Replace the camshaft
Blown out cylinder head gasket
Replace the related parts
Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and valve seat
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GENERAL INFORMATION
0A–31
3. Insufficient Power Condition
Possible Cause
Correction
Trouble in the air intake system
Clogged air cleaner element
Clean or replace the air cleaner element
Trouble in the fuel system
Water particles in fuel system
Replace fuel
Clogged fuel filter element
Replace the fuel filter element or cartridge
Clogged strainer or defective fuel feed pump
Repair or replace the feed pump
Injection nozzle sticking
Replace the injection nozzle
Injection nozzle starting pressure too low
Adjust or replace the injection nozzle
Improper spray condition
Adjust or replace the injection nozzle
Fuel injection pipes damaged or obstructed
Replace the injection pipes
Defective delivery valve
Replace the delivery valve
Injection timing improperly adjusted
Adjust the injection timing Repair or replace the timing advancer
Worn plunger of the injection pump
Replace the plunger assembly
Worn camshaft of the injection pump
Replace the camshaft
Trouble in the turbocharged Exhaust gas leakage from the exhaust system system Air leakage from the intake system Low compression pressure
Repair or replace the related parts Repair or replace the related parts
Defective turbocharger assembly
Replace the turbocharger assembly
Blown out cylinder head gasket
Replace the related parts
Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and valve seat Trouble in the valve gear train
Valve clearance improperly adjusted
Adjust the valve clearance
Worn camshaft lobe
Replace the camshaft
Valve spring weak or broken
Replace the valve spring
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0A–32
GENERAL INFORMATION
4. Excessive Fuel Consumption Condition
Possible Cause
Correction
Fuel leakage
Repair or replace the fuel system related parts
Injection nozzle starting pressure too low
Adjust or replace the injection nozzle
Improper spray condition
Adjust or replace the injection nozzle
Injection timing improperly adjusted
Adjust the injection timing
Trouble in the air intake system
Clogged air cleaner element
Clean or replace air cleaner element
Improper idle speed
Poorly adjusted idling speed
Adjust idling speed
Trouble in the cooling system
Defective thermostat
Replace
Trouble in the fuel system
Trouble in the lubricating system Improper engine oil viscosity Trouble in turbocharged system
Low compression pressure
Replace engine oil
Air leakage from the turbocharger intake Repair the turbocharger intake side side Defective turbocharger assembly
Replace the turbocharger assembly
Blown out cylinder head gasket
Replace the related parts
Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and valve seat. Trouble in the valve gear train
Valve clearance improperly adjusted
Adjust the camshaft
Worn camshaft lobe
Replace the camshaft
Valve spring weak or broken
Replace the valve spring
5. Excessive Oil Consumption Condition
Possible Cause
Trouble in the lubricating system Engine oil unsuitable
Correction Replace engine oil
Too much engine oil volume
Correct engine oil volume
Leakage
Oil leakage from the oil seal and/or gasket
Replace the oil seal and/or gasket
Oil leaking into the combustion chamber due to poor seal in the valve system
Worn valve stems and valve guides
Replace the intake and exhaust valves and valve guides
Worn valve stem oil seal
Replace the oil seal
Improper sealing
Worn or broken seal ring in the turbocharger
Replace the seal ring
Low compression pressure
Blown out cylinder head gasket
Replace the related parts
Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and valve seat. Trouble in the ventilation
Clogged air breather
Clean the air breather
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GENERAL INFORMATION
0A–33
6. Engine Cooling Trouble Condition Overheating
Possible Cause
Correction
Insufficient cooling water
Replenish coolant
Defective pressure cap or clogged radiator core
Replace the radiator pressure cap or clean radiator core
Defective water pump
Repair or replace the water pump
Defective sealing cap resulting in the cooling water leakage
Replace the sealing cap
Defective thermostat
Replace the thermostat
Cooling system clogged by foreign material
Take out the foreign material from the cooling system
Fuel injection timing improperly adjusted
Adjust the fuel injection timing
7. White Exhaust Smoke Condition Trouble in the fuel system Low compression pressure
Possible Cause
Correction
Water particles in fuel
Replace the fuel
Retarded fuel injection timing
Adjust the fuel injection timing
Blown out cylinder head gasket
Replace the related parts
Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and valve seat. Trouble in the cooling system
Defective thermostat
Replace the thermostat
Trouble in the turbocharger system
Defective turbocharger
Repair or replace
8. Black Exhaust Smoke Condition
Possible Cause
Correction
Trouble in the fuel system
Clogged air cleaner element
Clean or replace the air cleaner element
Trouble in the fuel system
Injection nozzle starting pressure tool low
Adjust or replace the injection nozzle
Improper spray condition
Trouble in the valve train
Advanced fuel injection timing
Adjust the fuel injection timing
Excessive injection volume
Adjust the injection volume
Worn camshaft lobe
Replace the camshaft
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0A–34
GENERAL INFORMATION
9. Lubrication Problems Condition Oil pressure does not rise
Possible Cause
Correction
Improper engine oil viscosity
Replace the engine oil
Insufficient engine oil
Correct the engine oil volume
Defective oil pressure gauge or unit
Repair or replace the oil pressure gauge or unit
Clogged oil filter element
Replace the oil filter element or cartridge
Relief valve sticking and/or weak bypass valve spring
Replace the relief valve and/or by-pass valve spring
Clogged oil pump strainer
Clean the oil pump strainer
Worn oil pump related parts
Replace the oil pump related parts
Worn rocker arm bushing
Replace the rocker arm bushing
Worn camshaft and camshaft bearing
Replace the camshaft and camshaft bearing
Worn crankshaft and bearings
Replace the crankshaft and/or bearing
Oiling jet valve does not close
Replace the oiling jet
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GENERAL INFORMATION
0A–35
10. Abnormal Engine Noise Start the engine and allow it to warm up before beginning the troubleshooting procedure. Condition Engine knocking
Possible Cause
Correction
Use of wrong fuel
Use correct fuel
Fuel injection timing improperly adjusted
Adjust the injection timing
Improper injection nozzle starting pressure
Adjust or replace the injection nozzle
Improper spray condition
Gaseous leakage noise
Broken piston ring resulting in low compression pressure
Replace the piston ring
Defective fuel injection nozzle resulting in fuel drippage after fuel injection
Replace the fuel injection nozzle
Loosely connected exhaust pipes
Tighten the exhaust pipe connection
Broken exhaust pipes
Replace the exhaust pipes
Loose injection nozzles and/or glow plug
Tighten the injection nozzles and/or glow plug Replace the washer
Continuous noise
Slapping noise
Loosely connected exhaust manifold
Tighten the exhaust manifold connections
Damaged cylinder head gasket
Replace the cylinder head gasket
Loose fan belt
Readjust the belt tension
Loose cooling fan
Retighten cooling fan
Worn or damaged water pump bearing
Replace the water pump bearing
Worn or damaged alternator bearing
Replace the alternator bearing
Valve clearance improperly adjusted
Adjust the valve clearance
Valve clearance improperly adjusted
Adjust the valve clearance
Damaged rocker arm
Replace the rocker arm
Worn or damaged crankshaft and/or thrust bearings
Replace the crankshaft and/or thrust bearing
Worn or damaged crankshaft and/or connecting rod bearings
Replace the crankshaft and/or connecting rod bearings
Worn or damaged connecting rod bushing and piston pin
Replace the connecting rod bushing and/or piston pin
Worn or damaged piston and cylinder liner
Replace the piston and cylinder liner
Foreign material in the cylinder
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0A–36
GENERAL INFORMATION
11. Alternator Condition Battery dead
Battery overcharged
Flashing charge light or fluctuating ammeter indication
Charge light on but gim while operating
Alternator noise
Charge circuit fuse blown
Possible Cause
Correction
Loose alternator drive belt
Adjust
Low battery fluid
Replenish
Defective battery terminals
Replace
Blown fuse
Replace
Poor contact between the fuse holder and fuse
Repair
Low battery fluid specific gravity
Adjust
Broken or poorly connected starter switch and regulator terminal wire
Repair
Broken or poorly connected regulator terminal and alternator terminal wire
Repair
Defective alternator ground circuit
Repair
Defective voltage regulator
Replace
Defective diode
Replace
Grounded or broken alternator stator coil
Repair or replace
Broken rotor coil
Replace
Excessive electrical load
Check the alternator output at normal operating speed
Poor connections or open circuit
Correct
Poor ground connection of voltage regulator
Correct
Voltage set of regulator too high
Replace
Defective voltage regulator
Replace
Loose belt
Adjust
Defective starter switch contacts
Replace
Broken or poorly connected wiring
Replace or reconnect
Loose starter switch terminal wiring
Retighten
Excessive resistance of alternator and fuse holder terminal wire
Replace the wire with a large one
Defective starter switch contacts
Replace
Defective alternator bearing
Replace or regrease
Exposed stator coil wires
Replace
Short circuit of the stator coil
Replace
Grounded terminal wiring
Repair
Defective alternator end flame diode
Replace the end flame assembly
Out of voltage regulator adjustment
Replace
Reversed battery connections
Correct
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GENERAL INFORMATION
0A–37
12. Starter Motor Condition Starter and magnetic switch does not operate
Magnetic switch operates but the starter does not turn
Starter runs slowly
Starter operates but the engine does not start
Abnormal operating noise
Possible Cause
Correction
Low battery fluid level
Replenish
Low battery specific gravity
Recharge or replace
Poor battery switch contacts
Replace
Defective starter switch
Replace
Defective magnetic switch pull-in coil and plunger
Replace
Broken armature coil
Replace
Broken field coil
Replace
Broken magnetic switch
Replace
Broken holding coil
Replace
Low battery fluid level
Replenish
Low battery specific gravity
Recharge or replace
Poor starting circuit contacts
Repair
Poor contacts of magnetic switch terminal
Replace
Worn brushes
Replace
Shorted armature
Repair or replace
Bad contact of magnetic terminal circuit switches
Repair
Excessive brush wear
Replace
Shorted starter motor armature
Repair or replace
No engaging of pinion and ring gear
Repair or replace the running clutch and driving lever
Slippage of overrunning clutch
Replace
Excessive brush wear
Replace
Excessive bushing wear
Replace
Excessive pinion gear wear
Replace overrunning clutch and pinion gear
Rough sliding action pinion gear
Lubricate or replace the overrunning clutch
Excessive ring gear wear
Replace overrunning clutch and ring gear
Excessive brush wear
Replace
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0A–38
GENERAL INFORMATION
13. Turbocharger Condition Engine has less than normal power
Blue or black smoke
Excessive oil consumption
Excessive turbocharger noise
Excessive rotating part wear
Possible Cause Restricted air cleaner Restricted intake pipe and hose Loose connection of the turbocharger inlet and outlet Restricted exhaust and silencers Restricted air breather Impact damage of the compressor wheel Impact damage of the turbine wheel Carbon build-up on the turbine wheel Dragging or seized rotating assembly Restricted air cleaner Leakage from turbocharger oil seal Restricted turbocharger oil drain pipe Restricted air breather Impact damage of compressor wheel Impact damage of turbine wheel Restricted center housing oil drain passage Restricted air breather Leakage from turbocharger oil seal Impact damage of compressor wheel Impact damage of turbine wheel Excessive oil pressure Restricted center housing oil drain passage Restricted intake and exhaust system joints Damaged intake and exhaust system gasket Rough rotation of turbocharger rotating parts Rubbing compressor wheel against housing Damaged compressor wheel Rubbing turbine wheel against housing Damaged turbine wheel Carbon built-up on the turbine wheel Too low engine oil level Contaminated oil level Restricted turbocharger oil feed pipe Carbon built-up on the turbine housing Dirty compressor housing Worn turbine shaft bearings Contaminated engine oil Wrong grade or type of engine oil Restricted turbocharger oil feed pipe Defective turbocharger oil seal Restricted center housing oil drain passage Oil sludgy and coking turbine shaft In adequate oil supply
Correction Clean or replace Clean or replace Repair Repair Clean or replace Replace Replace Replace Replace Clean or replace Replace Repair or replace Clean Replace Replace Clean or replace Clean Replace Replace Replace Repair Clean or replace Repair Repair Replace Replace Replace Replace Replace Clean or replace Correct Replace oil Repair or replace Clean Clean Replace Change Change Clean or replace Replace Clean or replace Replace Correct
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 39
GENERAL INFORMATION
0A–39
Lubricants Application Name of Sealant or Lubricant Engine Oil
Location for Application Turbocharger bearing Inside of camshaft bracket Idle gear shaft & fixing bolt Bridge Rocker arm Camshaft cam nose Crank pulley fixing bolt threads and seating face Inside and outside of cylinder liner Connrod bearing sliding face Crankshaft bearing sliding face Thrust bearing Piston and piston rings Piston pin
Molybdenum disulfied grease
Crankcase fixing bolt threads and seating face Cylinder head fixing bolt thread and seating face Connrod bearing fixing bolt thread and seating face
Sealant Application Location Name of part
Name of mating part
Name of sealant
1
Crankcase
Cylinder block
Loctite FMD-127
2
Gearcase
Cylinder block
Loctite FMD-127
3
Flywheel housing
Cylinder block
Loctite FMD-127
4
Gearcase
Cylinder head
Loctite FMD-127
5
Gearcase
Upper cylinder block
Loctite FMD-127
6
Upper and lower gearcase
Cylinder head
Loctite FMD-127
7
Crankcase
Gearcase
Cemedyn LG-020L
8
Crankcase
Flywheel housing
Cemedyn LG-020L
9
Oil cooler
Cylinder block
Three Bond 1207C
10
Nozzle sleeve
Cylinder head
Loctite TL290
11
Thermometer unit threads
Cylinder head
Loctite No.271 or Three Bond No. 1241
12
Oil pressure switch threads
Cylinder block
Loctite No.271 or Three Bond No. 1241
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MEMO
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 1
SERVICE INFORMATION
0B–1
GENERAL INFORMATION SERVICE INFORMATION CONTENTS Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-1 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-2 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-2 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-6
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . 0B-7 Compression Pressure Measurement . . . . . . . . . . . 0B-9 Recommended Lubricants . . . . . . . . . . . . . . . . . . . 0B-10 Engine Oil Viscosity Chart . . . . . . . . . . . . . . . . . . . 0B-10
Identification Engine Serial Number The engine serial number is stamped on the front, upper area of the cylinder block.
Engine model
Serial number
6WG1
000000
015EY00002
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 2
0B–2
SERVICE INFORMATION
Lubrication System Oil filter replacement The oil filter is remotely mounted on the equipment side. 1. Set a filter wrench at the cartridge and remove the oil filter. Discard the used cartridge. 2. Before installing the new oil filter, apply engine oil to the gasket of the cartridge. 3. Turn the oil filter until the filter gasket comes in contact with its sealed face. 4. Use the filter wrench to turn in the oil filter by additional one full turn.
2. Before installing a new fuel filter, apply fuel to the gasket of the cartridge. 3. Turn the fuel filter until the filter gasket comes in contact with its sealed face. 4. Use the filter wrench to turn in the fuel filter by additional 2/3 of a turn.
NOTE: Be careful not to spill out the fuel retaining in the fuel filter when the filter is removed. After changing the fuel filter element, conduct fuel air bleeding and check for fuel leaks.
Injection Timing Adjustment 050EY00002
Fuel System Fuel filter replacement procedure 1. Use a filter wrench to remove the cartridge. Discard the used cartridge.
Injection Timing Inspection 1. Disconnect the negative battery cable. 2. Rotate the crankshaft in the normal direction of engine rotation to align the injection timing mark on the flywheel with the timing pointer. • Injection Timing (Static-TDC): 11 degree
T C 5 10 15
015EY00003
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 3
SERVICE INFORMATION
0B–3
3. Check that the timing advancer notched line is aligned with the injection pump notched line. If the notched lines are out of alignment, the injection timing must be adjusted.
Injection Timing Adjustment 1. Rotate the crankshaft in normal direction of rotation until the timing mark on the timing advancer can be seen. 2. Align the injection timing mark on the flywheel with the pointer.
T C 5 10 15
015EY00003
3. Loosen the two coupling bolts.
4. Move the timing advancer to the correct timing. 5. Tighten the two coupling bolts. 6. Rotate the crankshaft two turns in normal direction of crankshaft rotation. 7. Verify the new setting is correct injection timing. 8. Connect the negative battery cable.
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 4
0B–4
SERVICE INFORMATION
Injection Nozzle Opening Pressure and Spray Condition Check 1. Use an injection nozzle tester to check the nozzle opening pressure. If the opening pressure is above or below the specified value, the injection nozzle must be replaced or adjusted. Refer to “Adjustment of Injection Nozzle Opening Pressure”. Injection Nozzle Opening Pressure: 20.1 MPa (205 kg/cm2 / 2,915 psi)
1
2
3
040EY00030
Injection Nozzle Adjustment 1. Attach the injection nozzle holder to the injection nozzle tester. 2. Apply pressure to the nozzle tester. Note the pressure at which the injection nozzle opens. Injection Nozzle Opening Pressure: 20.1 MPa (205 kg/cm2 / 2,915 psi)
040EY00023
WARNING: Test fluid from the injection nozzle tester will spray out of the injection nozzle under great pressure. It can easily puncture a person’s skin. Keep your hands away from the injection nozzle at all times. 2. Check the spray condition. If the spray condition is bad, the injection nozzle must be replaced or reconditioned. (1) Correct (2) Incorrect (Restrictions in orifice) (3) Incorrect (Dripping) If lapping is required, refer to “Nozzle Lapping Procedure of FUEL SYSTEM”.
An adjusting shim of 0.007 mm (0.0003 in) allows the press to change by about 98 kPa (1.0 kg/cm2 / 14.2 psi). The adjusting shim thickness calculation method as follows. The adjusting shim thickness calculation method. P × π/4 × (A2 – B2) = Shim thickness (mm) C P (kPa)
A (cm) B (cm) C (N/mm)
= (Target injection nozzle opening pressure – Indicated value (pressure) of nozzle tester) = Needle diameter 0.6 cm = Sheet diameter 0.3 cm = Spring constant 264.0 N/mm
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 5
SERVICE INFORMATION After calculating shim thickness, select shims from below list. Adjusting Shim Availability mm Thickness
Part number
0.50
5-15339-007-0
0.52
5-15339-018-0
0.54
5-15339-019-0
0.56
5-15339-020-0
0.58
5-15339-021-0
0.60
5-15339-008-0
0.70
5-15339-009-0
0.80
5-15339-010-0
0.90
5-15339-011-0
1.00
5-15339-012-0
0.10
8-94128-982-0
0.20
8-94128-983-0
0.30
8-94128-984-0
0.40
8-94128-985-0
0B–5
2. With a wrench, loosen the air plug (1) of the fuel filter and pump the fuel until all the air bubbles in it disappear by being pumped out through the air plug. 3. There are no bubbles and the fuel comes out in a solid stream. Now securely tighten the air plug and priming pump cap.
Feed pump strainer Remove the joint bolt on the intake side of the feed pump, then screw out the strainer counterclockwise and clean it. Then, operate the priming pump on the injection pump to bleed the fuel system.
Air Bleeding When servicing the fuel filters or if the fuel tank is emptied, air might be allowed to go into the fuel system. With air in the fuel system, smooth flow of fuel into the engine is interrupted and to prevent this, bleeding of the fuel system should be performed. 1. Loosen the priming pump cap and pump the fuel into the injection pump by manually operating the priming pump (2).
Strainer
040EY00008
Fuel tank Remove the drain plug and drain the water and sediment completely. 1
2
040EY00006
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 6
0B–6
SERVICE INFORMATION
Drive Belt Inspection (Scrum belt)
Cooling System Drive Belt Inspection (Single belt) Check the drive belt tension. Depress the drive belt mid-portion with a 100 N (10kg/22 lb) force. Drive Belt Deflection: 8 – 12 mm (0.31 – 0.47 in)
1. Tighten the idle pulley lock nut and generator section lock nut. 2. Adjust the belt tension so it becomes equal to the standard value by adjusting the idle pulley adjusting bolt and generator section adjusting bolt. 3. The deflection when 98 N {10 kg/22 lb} is applied to the center between the idle pulley and generator pulley Drive Belt Deflection: 6 – 8 mm (0.24 – 0.31 in) 1
2
4 3
033EY00001
5
Check the drive belts for cracking and other damage. 6
PAW5Z0MH000801
Name 1. Lock Nut (Generator) 2. Adjusting Bolt (Generator) 3. Lock Nut 4. Adjusting Bolt (Idle Pulley) 5. Belt Tension Measurement Position 6. Mounting Bolt 033EY00009
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 7
SERVICE INFORMATION Check the drive belt for cracking and other damage.
PAW5Z0SH006001
0B–7
Valve Clearance Adjustment The following instructions assume that valve clearance is adjusted beginning with the No. 1 piston at top dead center (TDC) on the compression stroke. Check alignment timing mark between timing advancer and mark line on injection pump body. In this position indicate T.D.C. of No. 1 piston. Valve clearance must be adjusted when the engine is cold. When remove the head cover, wipe off spilled oil with a rag. 1. Bring the piston in the No. 1 or No. 6 cylinder to the top dead center on the compression stroke by turning the crankshaft until the T.D.C. line on the flywheel is aligned with the timing pointer. Check the rocker arm shaft bracket nuts for looseness and retighten as necessary before adjusting the valve clearance.
015EY00070
2. Check that the No. 1 intake and exhaust rocker arms have play. If they have play, it indicates that the No. 1 piston is at TDC (Top Dead Center) on the compression stroke. If the No. 1 exhaust valves are depressed, the No. 6 piston is at TDC on the compression stroke. 3. Adjust valve clearances for the No. 1 or No. 6 cylinder which its piston is at TDC on compression stroke. 1. Loosen each adjusting screw (1) on the bridge (2) and rocker arm (3).
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 8
0B–8
SERVICE INFORMATION 4. In this condition, the opposite end of the bridge is raised. Readjust by loosening the adjusting screw on the bridge until there is a slight drag on the feeler gauge and tighten the lock nut securely.
1 3
No.1 cylinder T. D. C. (comp. stroke)
1
2
E
I
3
E
I
4
E
I
5
E
I
6
E
I
E
I
2 Front 014EY00129
Valve Clearance: 0.4 mm (0.0016 in) 2. Insert a feeler gauge between the rocker arm (1) and the cam (2) and adjust by turning the adjusting screw on the rocker arm until there is a sight drag on the feeler gauge. Tighten the lock nut securely.
1
014EY00125
4. Rotate the crankshaft 360° and realign the T.C. mark on the flywheel with the pointer and adjust clearance for remaining valves. The “●” mark in the illustration indicates the cylinders and valves to be adjusted.
No.6 cylinder T. D. C. (comp. stroke)
1 E
2 I
E
3 I
E
4 I
E
5 I
E
6 I
E
I
2 014EY00130
3. With a feeler gauge inserted, screw in the adjusting screw on the bridge gradually until it touches to the end of the valve stem, and make sure that the movement of the feeler gauge becomes hard.
Front
014EY00126
NOTE: Be sure to move the No. 1 cylinder to TDC on the compression stroke after completing the valve clearance adjustment procedure. Torque: 79 N·m (8.0 kg·m/58 lb·ft) Rocker Arm Adjusting Screw Nut Torque: 54 N·m (5.5 kg·m/40 lb·ft) Bridge Adjusting Screw Nut
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 9
SERVICE INFORMATION
0B–9
Intake and Exhaust Valve Arrangement Cylinder No.
1
2
Valve Names
E
I
No. 1 cyl. at TDC on compression
●
●
No. 6 cyl. at TDC on compression I : Intake valve.
E ●
3 I
E
●
●
4 I ●
E ●
5 I
E
●
●
6 I
E
I
●
●
●
E: Exhaust valve
Compression Pressure Measure To measure the compression pressure, the engine must be cold. Engine coolant temperature should be at 20°C. Battery and starter motor condition must be normal. 1. Remove the injection nozzle assembly and the injection fuel pipe from the each cylinder, using nozzle holder remover: 1-8523-0013-0.
011EY00025
011EY00026
2. Install the compression gauge adapter 5-8531-70190 to the No. 1 cylinder injection nozzle installation hole. 3. Install the compression gauge to the compression gauge adapter.
4. Crank the engine with starter motor (about 200 min–1) and take the compression gauge reading. 5. Repeat the procedure (Step 2 to 4) for the remaining cylinder. Compression Pressure Standard : 2.75 MPa (28.0 kg/cm2 / 400 psi) Limit : 2.26 MPa (23.0 kg/cm2 / 327 psi) Compression pressure should be approximately the same for each cylinder. A variation exceeding 200 kPa (2.0 kg/cm2 / 28 psi) is unacceptable.
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 10
0B–10
SERVICE INFORMATION
Recommended Lubricants ENGINE TYPE
TYPES OF LUBRICANTS (API)
Without turbocharger & With turbocharger
Diesel engine oil CD grade
Engine Oil Viscosity Chart
ENGINE OIL VISCOSITY GRADE-AMBIENT TEMPERATURE [Single grade]
SAE 20,20W SAE 30
SAE 10W Ambient temperature [Multi grade]
-30ºC (-22ºF)
-15ºC (0ºF)
SAE 40,50
-0ºC (32ºF)
15ºC (60ºF)
25ºC 30ºC (80ºF) (90ºF)
SAE 10W-30 SAE 15W-40,20W-40,20W-50
F00EY00006
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 1
ENGINE MECHANICAL
6A–1
ENGINE CONTENTS Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . 6A Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C
Starting and Charging . . . . . . . . . . . . . . . . . . . . . . . 6D3 Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F Engine Induction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J
ENGINE MECHANICAL CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 General Description. . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Engine Cleanliness and Care . . . . . . . . . . . . . . . 6A-2 General Information on Engine Service . . . . . . . 6A-2 Fan Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Inlet Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15 Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18 Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20 Coupling Assembly . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-30 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-38 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-42 Rocker Arm and Shaft Assembly. . . . . . . . . . . . . 6A-47 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-47 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-48
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-50 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-52 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-52 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-53 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55 Timing Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-57 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-60 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-61 Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . 6A-66 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-66 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-67 Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-69 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-69 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-70 Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-73 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-73 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-74 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-77 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-78 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-84 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-88 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-88 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-89 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-92 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-93 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-97 Crank Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-99 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-99 Inspection and Repair. . . . . . . . . . . . . . . . . . . 6A-100 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-100 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-102 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-102 Inspection and Repair. . . . . . . . . . . . . . . . . . . 6A-103 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-103 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-104 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-104 Inspection and Repair. . . . . . . . . . . . . . . . . . . 6A-105 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-109
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 2
6A–2
ENGINE MECHANICAL
Service precaution CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
General Description Engine Cleanliness and Care
clearance between the oil pan and the oil pump strainer, jacking against the oil pan may cause damage to the oil pick-up unit. • The 12-volt electrical system is capable of damaging circuits. When performing any work where electrical terminals could possibly be grounded, the ground cable of the battery should be disconnected at the battery. • Any time the intake air duct or air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material into the cylinder which could cause extensive damage when the engine is started.
General The 6WG1 engine is a four-cycle, six-cylinder, in-line, direct fuel injection type diesel engine with the piston displacement of 15.681 L (957 cid). It features a geardriven OHC (overhead camshaft) timing train and unique mechanisms and systems designed for outstanding quietness, economy and durability.
An industrial engine is a combination of many machines, honed, polished and lapped surfaces with tolerances that are measured in the thousandths of a millimeter (ten thousandths of an inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. • A liberal coating of engine oil should be applied to all friction areas during assembly to protect and lubricate the surfaces on initial operation. • Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal bearings are removed for service, they should be retained in oder. • At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. • Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts. • The in-line cylinders of this engine are identified by numbers; Cylinders 1, 2, 3. …, as counted from crankshaft pulley side to flywheel side.
Cylinder Head
General Information on Engine Service
The crankshaft is made of forge steel with seven bearings and twelve counter weights to reduce revolution load to the bearing. The crankshaft is treated by soft nitriding to enhance the crankshaft strength.
The following information on engine service should be noted carefully, as it is important in preventing damage and contributing to reliable engine performance: • When raising or supporting the engine for any reason, do not use a jack under the oil pan. Due to the small
The cylinder head is made of cast iron and has a crossflow layout with the intake system in the left side and the exhaust system in the right side, designed to reduce resistance in the intake and exhaust system. The cylinder head gasket is of the laminated of least fatigue in combination with the angular cylinder head bolt tightening method, equally designed to increase reliability against gaseous and water leakage.
Cylinder Block The cylinder block is made of cast iron having dry cylinder liner and seven bearings. The bearing cap has a ladder frame construction integrating the crankcase to increase rigidity. The cylinder liner is made of thin special iron alloys and is combined with the chrome-plate piston ring to ensure good resistance against wear.
Piston The piston is made of aluminum alloy. A ring trigger is cast into the first and second ring groove and chrome plating is applied to four sides of the first and third ring to ensure sufficient strength and wear resistance of the ring and the ring groove.
Crankshaft
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 3
ENGINE MECHANICAL
Gear Train The gear train is located at the front of cylinder block to minimize influence of the torsional vibration of the crankshaft and the radiant sound. Noise is further reduced, to the same level as a timing belt driven system, by integrating the crankshaft gear with the crankshaft by shrink fit careful tuning of the gear precision, contact gear ratio, backlash, bearing rigidity neutral frequency, etc.
Combustion System The combustion chamber has a clean and simple design for maximum operating economy also easy starting. A direct fuel injection system is adopted. The injection nozzles are placed at the center of each cylinder. Intake ports generate optimum swirl effect while exhaust ports minimize exhaust resistance. Isuzu’s unique combustion chamber design provides maximum power output and fuel economy.
Value Arrangement Each cylinder has two intake valves and two exhaust valves. To ensure high efficiency and complete combustion, the intake system has a Isuzu’s unique designed inlet ports. The two exhaust valves are connected to a single port.
Lubrication All engine parts are lubricated by a gear pump pressure circulation system. Oil flows from the oil pump though oil cooler to main oil filter for oil cooling and oil cleaning. From the main oil filter it moves to the cylinder block oil gallery and the oil circulates to lubricates the engine parts. Oil jets are installed to the cylinder block main oil gallery. The jet spray oil to the inside portions of the pistons for lubrication and cooling.
Oil Pump and Oil Filter The oil pump is a gear type with a relief valve. The pump is driven by the timing gear. A full flow main oil filter with a highly efficient paper element used. Should the element become clogged with sludge or other foreign material, a by-pass valve open to route the oil directly to the oil gallery.
Oil Cooler The temperature of the engine oil circulating through the lubricating system tends to rise with an accompanying decrease in lubricating efficiency. The oil cooler maintains the oil temperature at the optimum level for effective engine lubrication. The oil cooler consists of the body and the cooling element.
6A–3
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 4
6A–4
ENGINE MECHANICAL
Fan Center Removal 1. Remove the fan guide.
4
1
3 2
033EY00002
4. Remove the fan center (1) from the timing gearcase (2). 2. Remove the cooling fan (2) from the fan center (1).
2 1 1
2
033EY00011
033EY00010
3. Remove the fan belt • Loosen the alternator mounting bolt (2). • Loosen the sliding piece nut (4). • Adjust the adjusting bolt (3) to remove the fan belt.
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 5
ENGINE MECHANICAL
Installation 1. Install the fan center (1) to the timing gearcase (2) and tighten the fixing nuts to the specified torque. Torque: 52 N·m (5.3 kgm)
6A–5
4. Install the cooling fan to the fan center and tighten the fixing nuts to the specified torque. Torque: 52 N·m (5.3 kgm) NOTE: Install the fan to the installation direction properly.
2
1
1
2
033EY00011
2. Install the fan belt. 3. Adjust the fan belt tension by adjusting the adjusting bolt. • Depress the fan belt at the midway between the alternator pulley and fan center pulley with 100 N (10 kg). Belt deflection : 8 – 12 mm • Tighten the alternator fixing nut to the specified torque. Torque: 147 N·m (15.0 kgm)
033EY00001
033EY00010
5. Install the fan guide to the water outlet pipe and bracket on the gearcase with the mounting rubbers. • Tighten the fixing bolt to the specified torque. Torque: 52 N·m (5.3 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 6
6A–6
ENGINE MECHANICAL
• Adjust the clearance between the fan and fan guide. Clearance: 7 – 13 mm
033EY00013
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 7
ENGINE MECHANICAL
6A–7
Turbocharger Removal 1. Remove the inlet pipe from the air cleaner to the turbocharger. 2. Remove the inlet duct from the inlet pipe to the turbocharger. 3. Remove the oil feed pipe. • Discard the gaskets. 4. Remove the oil drain pipe. • Discard the gaskets. 5. Remove the turbocharger. NOTE: Plug the turbocharger body oil ports and openings to prevent the entry of foreign material or dust.
033EY00003
2. Install the oil drain pipe for the turbocharger and tighten the bolt to the specified torque. Torque: 50 N·m (5.1 kgm) 3. Install the oil feed pipe for the turbocharger and tighten the bolt to the specified torque. Torque: Turbocharger side: 50 N·m (5.1 kgm) Oil port cover side: 34 N·m (3.5 kgm)
Installation 1. Install the turbocharger assembly with the gasket to the exhaust manifold and tighten the nuts to the specified torque. Torque: 40 N·m (4.1 kgm) NOTE: Lubricate the turbine shaft dripping the engine oil from the oil feed hole and turning the turbine wheel by hand.
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 8
6A–8
ENGINE MECHANICAL
4. Install the inlet duct from the inlet pipe to the turbocharger and tighten the fixing bolts to the specified torque. • Connect the rubber hose between the inlet duct and turbocharger. • Install the heat protector to the rubber hose. Torque: 43 N·m (4.4 kgm) 5. Install the inlet pipe from the air cleaner to the turbocharger. Tighten the inlet pipe fixing bolts to the specified torque. Inlet pipe at turbocharger side Torque: 5.4 N·m (0.55 kgm) Inlet pipe at bracket side Torque: 52 N·m (5.3 kgm) Inlet pipe bracket Torque: 118 N·m (12 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 9
ENGINE MECHANICAL
6A–9
Exhaust Manifold Removal 1. Remove the inlet pipe from air cleaner to turbocharger. 2. Remove inlet duct from the inlet pipe to the turbocharger. 3. Remove the turbocharger oil feed pipe. 4. Remove the turbocharger oil drain pipe. 5. Remove the turbocharger. Refer to “Turbocharger” in this section. 6. Remove the exhaust manifold. Clean the sealing surfaces of the exhaust manifold.
2
1
3
5 3 1
4
2
6
Indicator
027EY00016
2. Install the turbocharger assembly with the gasket to the exhaust manifold. Refer to “Turbocharger” in this section.
027EY00011
Installation 1. Install the exhaust manifold assembly with the new gasket to the cylinder head. Tighten the nuts to the specified torque in the order shown. Torque: 37 N·m (3.8 kgm) 036EY00003
3. Install the oil drain pipe for the turbocharger. 4. Install the oil feed pipe for the turbocharger. 5. Install the inlet duct from the inlet pipe to the turbocharger. 6. Install the inlet pipe from the air cleaner to the turbocharger.
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 10
6A–10
ENGINE MECHANICAL
Inlet Manifold Removal 1. Remove the breather hose. 2. Remove the oil dipstick and guide tube. 3. Remove the fuel pipes. 4. Remove the air pipe for the boost. 5. Remove the injection pipes. 6. Remove the fuel filter and bracket. 7. Remove the inlet pipe. NOTE: Plug the outlet of the turbocharger compressor. 8. Remove the inlet cover. 9. Remove the inlet manifold. 10. Clean the sealing surfaces of the inlet manifold.
Installation 1. Install the inlet manifold with new gaskets. • Install the rubber boot and spring. • Tighten the nut to the specified torque. Torque: 20 N·m (2.0 kgm)
3. Install the inlet pipe with new gasket. Tighten the fixing bolt to the specified torque. Torque: 43 N·m (4.4 kgm)
Rubber boot
Indicator
10 6
12
9
5
7
3
2 1
4
11
8
025EY00006
2. Install the inlet cover with new gasket. Tighten the fixing bolt to the specified torque. Torque: 43 N·m (4.4 kgm)
4. Install the fuel filter and bracket to the inlet manifold. Tighten the fixing bolt to the specified torque. Torque: Fuel Filter: 52 N·m (5.3 kgm) Bracket : 50 N·m (5.1 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 11
ENGINE MECHANICAL
5. Install the injection pipes, tightening to the specified. Torque: Cylinder head side: 29 N·m (3.0 kgm) Injection pump side: 39 N·m (4.0 kgm)
7. Install the guide tube to the cylinder block in the order shown. Torque: Bolt (1) 88 N·m (9.0 kgm) Bolt (2) 49 N·m (5.0 kgm)
2 1
6. Install the fuel pipe to tighten to the specified torque as follows. M8 eye bolt Torque: 15 N·m (1.5 kgm) M10 eye bolt Torque: 27 N·m (2.8 kgm) M12 eye bolt Torque: 34 N·m (3.5 kgm) M14 eye bolt Torque: 41 N·m (4.2 kgm)
6A–11
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 12
6A–12
ENGINE MECHANICAL
8. Connect the breather hose to the breather and clamp the hose.
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 13
ENGINE MECHANICAL
6A–13
Water Pump 2. Install the thermostat housing. • Install the thermostat to the oil cooler. Refer to “Thermostat installation” in this manual. • Tighten the bolts to the specified torque. Torque: 39 N·m (4.0 kgm)
Removal 1. Remove the water inlet pipe. 2. Remove the thermostat housing. 3. Remove the water pump (1).
1
2 030EY00006 031EY00007
Installation 1. Install the water pump (1) with new gasket, tighten to the specified torque. • First tighten the bolts (2) to the oil cooler side then tighten Torque: 39 N·m (4.0 kgm)
1
031EY00008
3. Install the water inlet pipe (1) to the oil cooler. Tighten the bolts to the specified torque. Torque: 43 N·m (4.4 kgm) 2 030EY00006
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 14
6A–14
ENGINE MECHANICAL
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 15
ENGINE MECHANICAL
6A–15
Alternator Removal 1. Remove the sliding piece nut (4). 2. Remove the adjust plate fixing bolt (1). 3. Remove the alternator fixing bolt (2). 4. Remove the fan belt. 5. Remove the alternator.
4
1
3 4
2
1
033EY00002
3 2
033EY00002
Installation Single belt 1. Install the alternator. 2. Install the adjusting plate. 3. Install the fan belt. 4. Adjust the belt tension by adjusting the bolt (3). • Depress the fan belt at the midway between the alternator. Belt Deflection: 8 – 12 mm (0.3150 – 0.4724 in) 5. Tighten the alternator fixing bolt to the specified torque. Torque: 147 N·m (15.0 kgm)
033EY00001
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 16
6A–16
ENGINE MECHANICAL
Scrum belt
1 2
1. Install the generator to the bracket and adjusting plate.
2
3
3
1
5
4
PAW5Z0SH006101
Name 1. Belt 2. Adjusting Nut 3. Adjusting Bolt (Generator) 4. Bolt (Generator) 5. Adjusting Bolt (Idle Pulley)
2. Install the belt (for the generator) and adjust the tension of the belt. • Secure the reliable standard position by setting a standard string (1) or a weighted at both ends string (2) on the back of the belt.
1
2
PAW5Z0SH006301
• Arrange the push gauge so that the edge of the push gauge presses uniformly on the overall width of the belt, or set an iron plate with a thickness of about 2 mm {0.08 in} on the belt.
PAW5Z0SH006201
Name 1. Push Gauge 2. Iron Plate 3. Deflection
• Loosen the generator mounting bolt and lock nut, then loosen the idle pulley lock nut. • In order to set the deflection to within the stan-dard value range when approximately 98 N {10 kg/22 lb} of force is applied to the central sec-tion of the belt, correctly adjust the balance using the generator adjusting bolt and idle pul-ley adjusting bolt. • After adjusting the tension of the belt, tighten the lock nuts (1) and (3), and the mounting bolt (6). Torque: Idle pulley: 147 N·m {15.0 kg m}
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 17
ENGINE MECHANICAL 1
2
4 3 5
6
PAW5Z0MH000801
Name 1. Lock Nut (Generator) 2. Adjusting Bolt (Generator) 3. Lock Nut (Idle Pulley) 4. Adjusting Bolt (Idle Pulley) 5. Belt Tension Measurement Position 6. Bolt
Belt Deflection: 6 – 8 mm (0.2362 – 0.3150 in)
6A–17
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 18
6A–18
ENGINE MECHANICAL
Oil Cooler Removal 1. Remove the turbocharger oil feed pipe. 2. Remove the turbocharger oil drain pipe. 3. Remove the oil port cover. 4. Remove the water inlet pipe. 5. Remove the water pump. Refer to “Water Pump” in this section. 6. Remove the oil cooler assembly. • Remove the water drain pipe (1). • Install the two removed fixing bolts to the holes (2) for replacement and screw the bolts, then remove the oil cooler.
050EY00010
• Install the water drain pipe (1) and tighten the connector (2). Torque: 79 N·m (8.0 kgm) • Tighten the bracket (3) to the specified torque. Torque: 69 N·m (7.0 kgm)
1
2 1
050EY00009
2
Installation 1. Install the oil cooler with gaskets. • Install the gasket shown in the illustration. • Install the oil cooler assembly to the cylinder block and tighten the bolts to the specified torque in the order shown. Torque: 50 N·m (5.1 kgm)
4
3 1
050EY00011
2. Install the thermostat housing. • Install the thermostat to the oil cooler. Refer to “Thermostat Installation” in this manual. • Tighten the bolts to the specified torque. Torque: 39 N·m (4.0 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 19
ENGINE MECHANICAL
031EY00007
5. Install the turbocharger oil feed pipe. 6. Install the turbocharger oil drain pipe. Refer to “Turbocharger” in this section.
031EY00008
3. Install the water inlet pipe to the oil cooler. 4. Install the oil port cover with new gasket. Tighten the fixing bolts to the specified torque. Torque: 43 N·m (4.4 kgm)
6A–19
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 20
6A–20
ENGINE MECHANICAL
Injection Pump Removal
the foreign material or dust.
1. Remove the oil level gauge and guide tube. 2. Remove the coupling cover. 3. Remove the fuel pipes and fuel leak off pipe.
9. Remove the injection pump bracket.
Installation 4. Remove the injection pipe with clips.
5. Remove the air pipe for the boost. 6. Remove oil feed pipe and oil return pipe for the injection pump. 7. Loosen the two coupling fixing bolts and the four injection pump fixing bolts. 8. Remove the injection pump. NOTE: Plug the injection pump delivery holder ports with the shipping caps or equivalent to prevent the entry of
1. Install the injection pump bracket to the cylinder block. • Install the bracket into place over the bracket locating dowel pin on the cylinder block. • Install the gaskets on the bracket. • Tighten the bracket fixing bolts to the specified torque. Torque: 108 N·m (11 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 21
ENGINE MECHANICAL
6A–21
2. Install the injection pump • Align the flywheel injection timing mark with the flywheel housing pointer by rotating crankshaft counterclockwise. Injection timing (BTDC): 11 deg.
4
2
1
3
T C 5 10 15
015EY00003
• Align the injection timing mark on the timing advancer with the injection pump body pointer.
• Install the injection pump assembly to the injection pump bracket. • Tighten the bolts to the specified torque in the order shown. Torque: 39 N·m (4.0 kgm)
• Make sure the injection pump alignment on the injection pump, and tighten the coupling bolts to the specified torque. Torque: Timing advancer side: 62 N·m (6.3 kgm) Coupling ASM side: 88 N·m (9.0 kgm)
3. Install the injection pump coupling cover. Tighten the fixing bolts to the specified torque. Torque: Bolt (1) : 50 N·m (5.1 kgm) Bolt (2) : 52 N·m (5.3 kgm) Bolt (3) : 50 N·m (5.1 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 22
6A–22
ENGINE MECHANICAL
1 3
2
4. Install the oil pipe to the injection pump. Torque: M10 27 N·m (2.8 kgm) M14 41 N·m (4.2 kgm) M18 58 N·m (5.9 kgm)
5. Install the injection pipes. Tighten the injection pipe sleeve nuts to the specified torque. Torque: Cylinder head side: 29 N·m (3.0 kgm) Injection pump side: 39 N·m (4.0 kgm)
6. Install the fuel pipe to tighten to the specified torque as follows. M8 eye bolt Torque: 15 N·m (1.5 kgm) M10 eye bolt Torque: 28 N·m (2.8 kgm) M12 eye bolt Torque: 34 N·m (3.5 kgm) M14 eye bolt Torque: 41 N·m (4.2 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 23
ENGINE MECHANICAL 7. Install the air pipe for the boost. 8. Install the guide tube to the cylinder block in the order shown. Torque: Bolt (1) 88 N·m (9.0 kgm) Bolt (2) 49 N·m (5.0 kgm)
2 1
6A–23
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 24
6A–24
ENGINE MECHANICAL
Coupling Assembly Removal
Installation
1. Remove the coupling cover. 2. Remove the oil feed pipe from the cylinder block to coupling assembly. 3. Loosen the coupling fixing bolt (1) and remove the coupling disc fixing bolt (2), (3).
1. Install the coupling assembly to the gearcase. • Install the gear to the coupling assembly. • Apply molybdenum disulfide grease to the thread portion and flange surface of bolts and the washer, tightening the bolts to the specified torque in the order shown. Torque: 39 N·m (4.0 kgm) → 105 deg.
2
3 1
040EY00024
4. Remove the coupling. 5. Remove the coupling assembly fixing bolts and nut. 6. Remove the coupling assembly.
• Align the flywheel “T/C” mark with the flywheel housing pointer by rotating the crankshaft counterclockwise.
038EY00001
015EY00070
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 25
ENGINE MECHANICAL
2. Install the coupling oil pipe from the cylinder block to the coupling assembly. Torque: M10 27 N·m (2.8 kgm)
A
S
• Install the new gasket to the coupling assembly. • Install the injection pump coupling to the coupling assembly shaft. • Align the mark “A” on the coupling with the coupling assembly body pointer.
6A–25
Mark A
1 039EY00003
039EY00001
• Install the coupling assembly to the gearcase. • Check alignment mark “S” with the coupling assembly body pointer after installing the coupling assembly to the timing gearcase. • Tighten the coupling assembly fixing bolts and nut to the specified torque. Torque: 133 N·m (13.6 kgm)
3. Install the coupling. • Tighten the coupling fixing bolt (1) to the specified torque. Torque: 88 N·m (9.0 kgm) • Tighten the fixing bolt (3) to the specified torque. Torque: 62 N·m (6.3 kgm)
A
S
2
Mark S 3 1
040EY00024
039EY00001
• Align the injection timing mark on the flywheel with the flywheel housing pointer by rotating crankshaft counterclockwise. Injection timing (BTDC): 11 deg.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 26
6A–26
ENGINE MECHANICAL
T C 5 10 15
015EY00003
• Align the injection timing mark on the timing advancer with the injection pump body pointer.
• Tighten the coupling bolt to the specified torque. Torque: 88 N·m (9.0 kgm) • Rotate the crankshaft two turns in normal direction of crankshaft rotation. Verify that the injection timing is correct. 4. Install the coupling cover.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 27
ENGINE MECHANICAL
Cylinder Head Removal
1
2
3 6
7 8
5 4
10
9
11
6A–27
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 28
6A–28
ENGINE MECHANICAL
Legend (1) Cylinder head cover (2) Gasket (3) Rocker arm assembly (4) Bridge (5) Camshaft assembly (6) Leak off pipe
1. Remove the cylinder head cover (and Insulator). 2. Remove the gasket of the cylinder head cover.
3. Remove the rocker arm assembly. • Loosen the rocker arm shaft bracket bolts from both outside bolt.
(7) (8) (9) (10) (11)
Nozzle clamp Nozzle holder assembly Idle gear C and shaft Cylinder head assembly Cylinder head gasket
4. Remove the bridge. NOTE: Sort or organize the bridge for assembly to original location.
5. Remove the camshaft. • Use a feeler gauge to measure the camshaft end play before removing. Standard: 0.008 – 0.170 mm (0.0033 – 0.0067 in.) Limit: 0.25 mm (0.0098 in)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 29
ENGINE MECHANICAL
6A–29
• Loosen the camshaft bracket fixing nuts from both outside nut. 6. Remove the leak off pipe. 7. Remove the nozzle clamp. 8. Remove the nozzle holder assembly. • Use the nozzle holder remover 1-8523-0013-0 to remove the nozzle holder. NOTE: Take care not to damage the injection nozzle tips during injection nozzle holder removal.
10. Remove the cylinder head assembly. • First loosen the bolts B – D. • Loosen the cylinder head bolts a little at a time in the numerical order shown in the illustration. NOTE: Failure to loosen the cylinder bolts in numerical order a little at a time will adversely affect the cylinder head lower surface. 11. Remove the cylinder head gasket. Discard the cylinder head gasket.
011EY00026
9. Remove the idle gear “C” and shaft. • Use a feeler gauge to measure the idle gear “C” end play. Standard: 0.05 – 0.14 mm (0.0020 – 0.0055 in.) Limit: 0.25 mm (0.098 in.)
D
B
2
H
;
8
F
N
G
9
1
M
O D
L C
3
I
A 4
B
7
E
6
P J
K
C
5
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 30
6A–30
ENGINE MECHANICAL
Installation 1. Install the new cylinder head gasket. • Clean the cylinder block surface. • Apply Loctite FMD127 or equivalent to the cylinder block and the timing gearcase fitting faces. The sealant must be 1.0 – 2.0 mm (0.04 – 0.08 in) thick and 5.0 mm (0.20 in.) wide. The sealant must not obstruct the cylinder oil port.
012EY00016
• Install the new cylinder head gasket to the cylinder block. 2. Install the cylinder head assembly. • Align the cylinder block dowel pins and the cylinder head dowel holes. Carefully place the cylinder head on the cylinder head gasket.
• Apply molybdeum disulfide grease to the cylinder head bolts (M18) threads and setting faces. • Apply engine oil to the cylinder head bolts (M10 and M12) threads and setting faces. • Tighten the M18 cylinder head bolts in three steps using the angular tightening method. Follow the tightening order shown in the illustration. • Tighten the M10 and M12 cylinder head bolts to the specified torque. NOTE: Cylinder head bolts may be installed as many as four (4) times, and then must be replaced. Replace if any doubt exists. M18 bolt Torque: 1st step 177 N·m (18 kgm) 2nd step 245 N·m (25 kgm) 3rd step 60 – 90 deg. M12 bolt Torque: 75 N·m (7.7 kgm) M10 bolt Torque: 38 N·m (3.9 kgm) NOTE: Cover the timing gear hole by cloth for preventing into foreign materials.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 31
ENGINE MECHANICAL
6A–31
M12 M10
3. Install the idle gear “C” and shaft. • Apply engine oil to the idle gear “C” shaft bolts. • Tighten the idle gear “C” shaft bolt to the specified torque. Torque: 39 N·m (4.0 kgm)
011EY00026
6. Install the leak off pipe. Tighten to specified torque. Torque: 15 N·m (1.5 kgm)
4. Install the nozzle holder assembly. 5. Install the nozzle clamp. Tighten the nozzle clamp bolt to the specified torque. Torque: 49 N·m (5.0 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 32
6A–32
ENGINE MECHANICAL
1
014EY00068
7. Install the camshaft assembly. • Align the flywheel TDC mark with the pointer by rotating the crankshaft normal direction. Same time check alignment timing mark on injection pump for No. 1 piston TDC.
• Apply engine oil to the camshaft bearing sliding surfaces. • Install the camshaft bearing caps to use same stamped mark (1). • Apply engine oil to the threads and tighten to the specified torque. Torque: 76 N·m (7.7 kgm)
1 015EY00070
• Apply engine oil to the camshaft bearing sliding surfaces before installing the camshaft assembly. • Install the camshaft assembly to the cylinder head. • Carefully align the camshaft gear hole mark and pointer (1) on the cylinder head shown in the illustration.
014EY00069
8. Install the bridge. • Loosen adjusting screw. • Apply engine oil on the bridge guide. • Install the bridge, the adjusting screw (1) facing to the intake manifold side. NOTE: Bridges must be reinstalled into their original location and position.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 33
ENGINE MECHANICAL
6A–33
1
6
4
2
1
3
5
7
014EY00070
9. Install the rocker arm assembly. • Tighten the bolts in numerical order to the specified torque shown in the illustration. Torque: 90 N·m (9.2 kgm)
10. Install the gasket of the head cover. 11. Install the cylinder head cover. • Apply Loctite FMD127 or equivalent to the upper surface of cylinder head and timing gear case fitting area shown as illustration. The sealant must be 1.0 – 2.0 mm (0.04 – 0.08 in.) thick and 5.0 mm (0.20 in.) wide.
LOCTITE FMD127
011EY00027
• Tighten cylinder head cover bolt, follow the numerical order shown in the illustration. Torque: 20 N·m (2.1 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 34
6A–34
ENGINE MECHANICAL
10 9
11 12
13
1
8 7
14
15
16 17
6
5
4
3
2
20 19 18
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 35
ENGINE MECHANICAL
Disassembly 10 11
9
12 9
15 19
16
20
13 1
21
17
8 3
2
6
18 14
5 4
6
14 7
Legend (1) Thermometer unit (2) Gearcase (3) Gasket (4) Idle gear shaft (“C”) (5) Idle gear “C” (6) Gasket (7) Inlet manifold (8) Exhaust manifold (9) Seal rings (10) Split collar
(11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21)
Spring upper seat Valve spring Spring lower seat Valve Valve stem seal Valve guide Bridge guide Valve seat insert Injection nozzle sleeve Gasket Cylinder head
6A–35
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 36
6A–36
ENGINE MECHANICAL
1. Remove the thermometer unit. 2. Remove the gearcase. 3. Remove the shaft of the idle gear “C”. Measure end play between the cylinder head and idle gear “C”. Standard: 0.05 – 0.014 mm (0.0020 – 0.0055 in.) Limit: 0.25 mm (0.0098 in.)
5. Remove the gasket of the inlet manifold. 6. Remove the inlet manifold assembly. 7. Remove the exhaust manifold assembly. 8. Remove the seal rings. 9. Remove the split collar. • Place the cylinder head on a flat wooden surface. • Use the valve spring compressor 1-8523-5013-0 to remove the split collar. NOTE: Do not allow the valve to fall from the cylinder head.
1
4. Remove the idle gear “C”. • Disassemble the shaft of idle gear “C”. • Disassemble the idle gear “C”.
014EY00061
10. Remove the spring upper seat. 11. Remove the valve spring. 12. Remove the spring lower seat. 13. Remove the valve. If the intake and exhaust valves are to be reinstalled, mark their installation position by tagging each valve with the cylinder number from which it was removed. If the intake and exhaust valves are to be replaced, the valve guides must also be replaced. 14. Remove the valve stem seal. Discard the valve stem seal. 15. Remove the valve guide. Use valve guide remover 9-8523-1202-0 to remove the valve guide.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 37
ENGINE MECHANICAL
16. Remove the bridge guide. • Electric welding (1) the bolt to bridge guide, use sliding hammer to remove the bridge guide.
1
011EY00028
17. Remove the valve seat insert. • Heat up (about 600 – 700°C) two point on the valve seat insert by gas torch, allow the valve seat insert to cool for few minutes. • This will invite contraction and make removal of the valve seat insert easier. • Use screwdriver to pry the valve seat insert free. Take care not to damage the cylinder head. • Carefully remove carbon and other foreign materials from the cylinder head insert bore.
6A–37
18. Remove the injection nozzle sleeve. • Use suitable size brass bar to hit nozzle sleeve from lower side cylinder head.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 38
6A–38
ENGINE MECHANICAL
Inspection and Repair Make the necessary adjustments, repair and part replacements if excessive wear or damage is discovered during inspection.
Bridge Inspect any cracking, damage on bridge and inspect any separation wear out and damage on the surface of bridge.
Clearance between Camshaft and Bracket Measure the clearance between the camshaft and camshaft bracket. Standard: 0.065 – 0.125 mm (0.0026 – 0.0049 in.) Limit: 0.15 mm (0.0059 in.)
Shaft Idle Gear “C” and Idle Gear “C” 1. Measure the outside diameter of shaft idle gear “C”. Standard: 48.93 – 48.96 mm (1.9264 – 1.9286 in.) Limit: 48.85 mm (1.9232 in.) 2. Measure the clearance between the shaft and idle gear “C”. Standard: 0.04 – 0.105 mm (0.0016 – 0.0041 in.) Limit: 0.2 mm (0.0079 in.)
Valve Spring 1. Use a vernier caliper to measure the valve spring free height. If the measured value is less than the specified limit, the valve spring must be replaced. Valve spring free height Inlet spring: Standard: 79.3 mm (3.122 in.) Limit: 75.3 mm (2.965 in.) Exhaust spring: outer Standard: 102.7 mm (4.0433 in.) Limit: 97.6 mm (3.0843 in.) Exhaust spring: inner Standard: 96.4 mm (3.0795 in.) Limit: 91.7 mm (3.0610 in.)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 39
ENGINE MECHANICAL
6A–39
3. Use a spring tester to measure the valve spring tension. If the measured value is less than the specified limit, the valve spring must be replaced. Valve spring tension Inlet spring: Standard: 392 N (40.0 kg)/64 mm Limit: 294 N (38.0 kg)/64 mm Exhaust spring: outer Standard: 610N (62.2 kg)/69 mm Limit: 579 N (59.0 kg)/69 mm Exhaust spring: inner Standard: 224 N (22.8 kg)/66 mm Limit: 213 N (21.7 kg)/66 mm
2, Use a surface plate and a square to measure the valve spring squareness. If the measured value exceeds the specified limit, the valve spring must be replaced. Valve spring squareness Inlet spring: Standard: 3.5 mm (0.138 in.) Limit: 4.8 mm (0.189 in.) Exhaust spring: outer Standard: 4.5 mm (0.177 in.) Limit: 6.2 mm (0.244 in.) Exhaust spring: inner Standard: 4.2 mm (0.165 in.) Limit: 5.9 mm (0.232 in.)
Valve Stem 1. Set the dial indicator to the valve stem measuring point. 2. Move the valve stem end from side to side. Read the dial indicator. Note the total indicator reading. If the measured value exceed the specified limit, the valve and the valve guide must be replaced as a set. Valve stem and Valve guide clearance Inlet: Standard: 0.040 – 0.077 mm (0.0016 – 0.0030 in.) Limit: 0.15 mm (0.0059 in.) Exhaust: Standard: 0.065 – 0.102 mm (0.0026 – 0.0040 in.) Limit: 0.25 mm (0.0098 in.)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 40
6A–40
ENGINE MECHANICAL
Bridge Guide and Bridge Clearance
10mm(0.4in)
014EY00062
1. Use a caliper calibrator or a telescoping gauge to measure the valve bridge (2) inside diameter. 2. Calculate the difference between the valve bridge inside diameter and the valve bridge guide (1) outside diameter. If the clearance exceeds the specified limit, the valve bridge must be replaced. Bridge guide and bridge clearance Standard: 0.020 – 0.057 mm (0.0080 – 0.0022 in.) Limit: 0.10 mm (0.0039 in.)
1
3. Measure the valve stem diameter at three points. If the measured value is less than the specified limit, the valve and the valve guide must be replaced as a set. Valve stem outside diameter Inlet: Standard: 10.0 mm (0.3937 in.) Limit: 9.92 mm (0.3906 in.) Exhaust: Standard: 10.0 mm (0.3937 in.) Limit: 9.90 mm (0.3898 in.)
2
014EY00063
Valve Thickness and Depression 1. Measure the valve thickness. If the measured value is less than the specified limit, the valve and the valve seat insert must be replaced as a set. Valve thickness Inlet: Standard: 2.14 mm (0.0843 in.) Limit: 1.64 mm (0.0646 in.) Exhaust: Standard: 2.3 mm (0.0906 in.) Limit: 1.8 mm (0.0709 in.)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 41
ENGINE MECHANICAL
6A–41
Valve Contact Width 1. Check the valve contact faces for roughness and unevenness. Make smooth the valve contact surfaces. 2. Measure the valve contact width. If the measured value exceeds the specified limit, the valve seat insert must be corrected or replaced. Valve contact width Inlet: Standard: 3.0 mm (0.1181 in.) Limit: 3.4 mm (0.1339 in.) Exhaust: Standard 2.5 mm (0.0984 in.) Limit: 2.9 mm (0.1141 in.)
2. Install the new valve (1) to the cylinder head (2). 3. Use a depth gauge or a straight edge with steel rule to measure the valve depression from the cylinder head lower surface. If the measured value exceeds the specified limit, the valve seat insert and/or the valve must be replaced. Valve depression Inlet: Standard: 1.9 mm (0.0748 in.) Limit: 2.9 mm (0.1142 in.) Exhaust: Standard: 1.8 mm (0.0709 in.) Limit: 2.8 mm (0.1102 in.) 014EY00065
Contact Surface Angle on Valve 1. Measure contact surface angle on valve seat. 2. If the measured value exceeds the limit, replace valve, valve guide and valve seat as a set. Valve contact surface angle Standard: Inlet: 30 degree Exhaust: 45 degree
2
1
014EY00064
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 42
6A–42
ENGINE MECHANICAL 3. Apply abrasive compound to the valve seat insert surface. 4. Insert the valve into the valve guide. 5. Turn the valve while tapping it to fit the valve seat insert. 6. check to see if the valve contact width is correct. 7. Check to see if the valve seat insert surface is in contact with the entire circumference of the valve.
014EY00071
Valve Seat Insert Correction 1. Remove the carbon from the valve seat insert surface. 2. Use a valve cutter (15°, 45°, and 75° blades) to minimize scratches and other rough areas. This will bring the contact width back to the standard value.
Reassembly 150° 90° 30°
011EY00032
Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away unblemished areas of the valve seat surface. Valve seat angle Inlet: 30 degree Exhaust: 45 degree NOTE: Use an adjustable valve cutter pilot. Do not allow the valve cutter pilot to wobble inside the valve guide.
1. Install the injection nozzle sleeve with new gasket to the cylinder head. • Clean the nozzle sleeve circumference and the nozzle sleeve fitting faces of cylinder head. • Apply the recommended sealant (LOCTITE TL290 or equivalent) to the nozzle sleeve outer circumference (1). • Apply engine oil to the nozzle sleeve gaskets. • Install the new gaskets to the nozzle sleeve gasket groove. • Use a bench press to install the nozzle sleeve. Apply pressure to the nozzle sleeve gradually. CAUTION: Do not apply an excessive amount of pressure with the bench press. Damage to the injection nozzle sleeve and cylinder head will result.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 43
ENGINE MECHANICAL
6A–43
3. Install the bridge guide. • Apply engine oil to the valve bridge guide outer circumference. • Attach the valve bridge guide installer 9-85221324-0 to the bridge guide. • Use a brass hammer to tap the guide into position from the cylinder head upper face. • Measure the height of the valve bridge guide upper end from the cylinder head upper face (cylinder head cover fitting surface). Valve bridge guide upper end height Standard: 49.0 mm (1.929 in.)
1
011EY00029
2. Install the valve seat insert into the cylinder head. • Carefully place the attachment (1) (having a smaller outside diameter than the valve seat insert) on the valve seat insert (2). NOTE: The smooth side of the attachment must contact the valve seat insert. • Use a bench press (3) to gradually apply pressure to the attachment and press the valve seat insert into place. CAUTION: Do not apply excessive amount of pressure with the bench press. Damage to the valve seat insert will result.
49.0mm
4. Install the valve guide into the cylinder head. • Apply engine oil to the valve guide outer circumference. • Attach the valve guide replacer 9-8523-1202-0 to the valve guide. • Use a hammer to drive the valve guide into position from the cylinder head upper face. • Measure the height of the valve guide upper end from the upper face of the cylinder head. Valve guide upper end height Intake side: 27.0 mm (1.0630 in.) Exhaust side: 29.0 mm (1.1417 in.) NOTE: If the valve guide has been removed, both the valve and the valve guide must be replaced as a set.
• The valve should be lapped before final assembly to ensure a good valve seal. Refer to “Valve Seat Insert Correction” in this section.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 44
6A–44
ENGINE MECHANICAL
014EY00066
5. Install the spring lower seat to the cylinder head. 6. Install the valve stem seal on the valve guide. • Apply engine oil to the oil seal inner face. • Use the oil seal installer 1-8522-1187-0 for inlet and 1-8522-1184-0 for exhaust to install the oil seal to the valve guide.
• Install the intake valve springs with their fine pitched end facing down. (Painted yellow) • There are not assembly direction on both inner and outer exhaust valve spring.
014EY00067
7. Install the valve spring and valve. • Apply engine oil to each valve stem before installation. • Install the inlet and exhaust valves. • Turn the cylinder head up to install the valve springs. Take care not to allow the installed valves to fall free.
8. Install the spring upper seat and split collar. • Use the spring compressor 1-8523-5013-0 to compress the valve spring. • Install the split collars (1) to the valve stem. Do not allow the valve to fall from the cylinder head. • Set the split collars by tapping around the head of each collar with a rubber hammer.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 45
ENGINE MECHANICAL
6A–45
1 2
3 1
014EY00061
9. Install the exhaust manifold assembly to the cylinder head. • Check that the seal ring (1) gaps are positioned 120 degrees apart form each other. There is installation direction on seal ring as illustration. • Install the exhaust manifold gasket. The direction indicator must be faced lower side.
027EY00014
• The bracket tightening manner as follows. Tighten the bracket (1) and (3) with out washer. Put the bracket (2) on the washer, and tighten together with exhaust manifold.
2
1
3
5
1
3 1
4
2
6
Indicator Rear
Front
027EY00016
027EY00013
• Install distance tube (1), washer (3) and disk spring (2). The convex side of disk spring must be faced to exhaust manifold nut. • Tighten the exhaust manifold nut to specified torque. Follow the tightening order shown in the illustration. Torque: 37 N·m (3.8 kgm)
10. Install the intake manifold assembly. • Tighten the nut to numerical order shown in the illustration. • Install the rubber boot and spring with tightening specified torque. Torque: 20 N·m (2.0 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 46
6A–46
ENGINE MECHANICAL
Rubber boot
Indicator 2 10 6
12
9
5
7
3
2 1
4
11
8
1
025EY00006
011EY00031
11. Install the idle gear “C” and the shaft of the idle gear “C”. • Apply engine oil to the shaft of the idle gear “C”. • Install the shaft with idle gear “C” to cylinder head. • Tighten the bolts to the specified torque. Torque: 39 N·m (4.0 kgm)
13. Install the thermometer unit. • Apply Loctite FMD127 or equivalent to thread on thermometer unit. • Tighten the thermometer unit to the specified torque. Torque: 20 N·m (2.0 kgm)
Cylinder head side
011EY00030
12. Install the gearcase with new gasket (1). • Apply Loctite FMD127 or equivalent to the gearcase fitting area (2) or the cylinder head shown in the illustration. The sealant must be 0.3 mm (0.012 in.) thick and 5 mm (0.20 in.) wide. The sealant (2) must not obstruct the bolt holes the of cylinder head. • Tighten the bolts to the specified torque. Torque: 38 N·m (3.9 kgm)
69697_ESS-172A_SEC6A-2 11.8.5 10:45 AM ページ 47
ENGINE MECHANICAL
6A–47
Rocker Arm and Shaft Assembly Disassembly
3 2
4
1
Front Mark
5
014EY00072
Legend (1) Bracket (2) Rocker Arm (3) Spring
(4) Bracket (5) Rocker Arm Shaft
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 48
6A–48
ENGINE MECHANICAL
1. Remove the rocker arm and shaft assembly. • Loosen the bolt of the rocker arm shaft bracket from out side bolt a little at time and remove rocker arm and shaft assembly. • Disassembly the bracket, rocker arm, spring, bracket and rocker arm shaft.
014EY00073
Rocker Arm Shaft Outside Diameter
Inspection and Repair Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.
Use a micrometer to measure the rocker arm fitting portion outside diameter. If the measured value is less than the specified limit, the rocker arm shaft must be replaced. Rocker arm shaft outside diameter Standard: 27.979 – 28.000 mm (1.1015 – 1.1024 in.) Limit: 27.85 mm (1.0965 in.)
Rocker Arm Shaft Run-Out 1. Place the rocker arm shaft on V-blocks. 2. Use a dial indicator to measure the rocker arm shaft central portion run-out. If the run-out is very slight, correct the rocker arm shaft run-out with a bench press. The rocker arm must be at cold condition. If the measured rocker arm shaft run-out exceeds the specified limit, the rocker arm shaft must be replaced. Rocker arm shaft run-out Limit: 0.3 mm (0.012 in.)
014EY00074
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 49
ENGINE MECHANICAL
Rocker Arm Bushing Inside Diameter
6A–49
Rocker Arm Roller and Rocker Arm Pin
Use either a vernier caliper or a dial indicator to measure the rocker arm bushing inside diameter. Rocker arm bushing inside diameter Standard: 28.020 – 28.053 mm (1.1031 – 1.1044 in.) Rocker arm and rocker arm shaft clearance Standard: 0.020 – 0.074 mm (0.0008 – 0.0029 in.) Limit: 0.2 mm (0.0079 in.)
1. Pass a string through the rocker arm-roller (1) clearance and measure the roller protrusion while pulling both ends of the string in the arrow indicated directions to push out the roller. 2. Mark the measuring point and draw out the string. Measure the roller protrusion again while the roller is pushed in. 3. Note the difference in the above measurements is the standard roller rocker arm and pin clearance. If the clearance exceeds the limit, the rocker arm must be replaced. Rocker arm roller and pin clearance Standard: 0.036 – 0.069 mm (0.0014 – 0.0027 in.) Limit: 0.15 mm (0.0059 in.)
1
014EY00075
Check to see if the rocker arm and rocker arm shaft oil port is free of obstructions. If necessary, use compressed air to clean the rocker arm and rocker arm shaft oil port.
014EY00076
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 50
6A–50
ENGINE MECHANICAL
Reassembly
3 2
4
1
Front Mark
5
014EY00072
Legend (1) Bracket (2) Rocker Arm (3) Spring
(4) Bracket (5) Rocker Arm Shaft
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 51
ENGINE MECHANICAL 1. Install the bracket, spring, rocker arm and bracket to the rocker arm shaft. 2. Apply engine oil to the roller portion of the rocker arm and threads of the adjusting screw. 3. Put the rocker arm and shaft assembly on the cylinder head. 4. Temporally tighten the bolts of the rocker arm and shaft assembly to the cylinder head, sufficiently loosen the adjusting screw. 5. Tighten the bolts of the rocker arm and shaft assembly to the specified torque by numerical order shown in the illustration. Torque: 90 N·m (9.2 kgm)
6
4
2
1
3
5
7
6A–51
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 52
6A–52
ENGINE MECHANICAL
Camshaft Disassembly
5 3
2
1 4
Legend (1) Camshaft gear (2) Key (3) Camshaft bearing cap
(4) Camshaft bearing lower (5) Camshaft
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 53
ENGINE MECHANICAL 1. Remove the camshaft gear. • Check visually gear for excessive wear or damage. • Use an universal puller to pull out the camshaft gear with wooden plate (1) for prevent make damage gear. 2. Loosen nuts to remove the camshaft bearing cap. 3. Remove the camshaft.
6A–53
2 1
1
014EY00078
1
014EY00077
Inspection and Repair Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. 1. Use a micrometer to measure each camshaft journal diameter in two directions ((1) and (2)). If the measured value is less than the specified limit, the camshaft must be replaced. Camshaft journal diameter Standard: 39.915 – 39.940 mm (1.5715 – 1.5724 in.) Limit: 39.890 mm (1.5705 in.)
2. Measure the cam height A and B with a micrometer. If the measured value is less than the specified limit, the camshaft must be replaced. Cam height (A – B) Inlet Standard: 9.4 mm (0.370 in.) Limit: 8.85 mm (0.3484 in.) Exhaust Standard: 10.4 mm (0.4094 in.) Limit: 9.75 mm (0.3839 in.)
B
A
014EY00079
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 54
6A–54
ENGINE MECHANICAL
3. Mount the camshaft on V-blocks. Measure the run-out with a dial indicator on the No. 4 camshaft journal. If the measured value exceeds the specified limit, the camshaft must be replaced. Camshaft run-out Standard: 0.080 mm (0.0031 in.) Limit: 0.100 mm (0.0039 in.)
4. Use an inside dial indicator to measure the camshaft bearing inside diameter. Camshaft bearing inside diameter Standard: 40.015 – 40.040 mm (1.5754 – 1.5764 in.) If the clearance between the camshaft bearing inside diameter and the journal exceeds the specified limit, the camshaft bearing must be replaced. Camshaft bearing clearance Standard: 0.065 – 0.125 mm (0.0026 – 0.0049 in.) Limit: 0.15 mm (0.0059 in.)
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 55
ENGINE MECHANICAL
Reassembly
5 3
2
1 4
Legend (1) Camshaft gear (2) Key (3) Camshaft bearing cap
(4) Camshaft (5) Camshaft bearing lower
6A–55
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 56
6A–56
ENGINE MECHANICAL
1. Install the camshaft bearing lower. • Install the camshaft bearing lower to the cylinder head. • Apply engine oil to the bearing portion. 2. Install the camshaft. • Put camshaft onto the lower camshaft bearing. • Apply engine oil to the journal of camshaft. 3. Install the camshaft bearing cap. • Install the camshaft bearing cap on the stud bolts to use same stamped mark of lower bearing. • Apply engine oil to the threads of the stud bolt and nut seat. • Tighten the camshaft bearing cap nut to the specified torque. Torque: 76 N·m (7.7 kgm)
014EY00080
4. Insert the key to the camshaft. 5. Install the camshaft gear and tighten the bolt to the specified torque. • Apply engine oil to the threads of the bolt. Torque: 137 N·m (14.0 kgm)
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 57
ENGINE MECHANICAL
Timing Gear Timing Gear and Associated Parts
11
7 6
10
8 9
1
4 3 5
2
6A–57
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 58
6A–58
ENGINE MECHANICAL
Legend (1) Fan center assembly (2) Crank pulley (3) Gearcase cover (4) Gasket (5) Oil seat (front) (6) Oil pump
(7) (8) (9) (10) (11)
Gasket Distance bolt Idle gear “A” Idle gear “B” Timing gearcase
(Without Cooling Fan)
11 6
7
10
8
5 9 4 1
3
2
PAW0Z0LF001001
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 59
ENGINE MECHANICAL Legend (1) Fan center assembly (2) Crank pulley (3) Gearcase cover (4) Gasket (5) Oil seat (front) (6) Oil pump
(7) (8) (9) (10) (11)
6A–59
Gasket Distance bolt Idle gear “A” Idle gear “B” Timing gearcase
Removal 1. Remove the fan center. 2. Remove the crank pulley. 3. Remove the front oil seal to use the oil seal remover 1-8522-0052-0. CAUTION: Take care not to damage or deform the sealing flange surface of the gearcase.
020E100035
5. Remove the oil pump with the gasket. Discard the gasket. 6. Remove the idle gear “A”. • Before loosening the idle gear fixing bolts, measure the backlash of the idle gear “A” and “B”. Idle gear backlash Standard: 0.095 – 0.135 mm (0.0037 – 0.0053 in.) Limit: 0.23 mm (0.0091 in.)
4. Remove the gearcase cover. Remove the gearcase cover gasket and discard it.
020E100030
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 60
6A–60
ENGINE MECHANICAL
• Measure the end play of the idle gear “A” (1) and “B” (2). Idle gear “A” end play Standard: 0.155 – 0.220 mm (0.0061 – 0.0089 in.) Limit: 0.35 mm (0.0138 in.) Idle gear “B” end play Standard: 0.050 – 0.140 mm (0.0020 – 0.0055 in.) Limit: 0.25 mm (0.0098 in.)
2
1
020E100031
7. Remove the idle gear “B”. • Scribe a front mark on the thrust plate to aid in assembly.
Inspection and Repair 1. Visually inspect the idle gear and idle gear spindle for damage or wear. 2. Use a micrometer to measure the idle gear spindle out side diameter. Spindle outside diameter for idle gear “A” Standard: 56.93 – 56.96 mm (2.2413 – 2.2425 in.) Limit: 56.85 mm (2.2382 in.) Spindle outside diameter for idle gear “B” Standard: 141. 93 – 141.96 mm (5.5878 – 5.5890 in.) Limit: 141.85 mm (5.5846 in.) Spindle outside diameter for idle gear “C” Standard: 48.93 – 48.96 mm (1.9264 – 1.9286 in.) Limit: 48.85 mm (1.9232 in.) 3. Use a cylinder bore dial indicator to measure the idle gear inside diameter. 4. Calculate the clearance between the idle gear and idle gear spindle. Clearance for idle gear “A”, “B”, and “C” Standard: 0.040 – 0.105 mm (0.0016 – 0.0041 in.) Limit: 0.02 mm (0.0079 in.) If the measured value exceeds from the specified limit, the idle gear spindle or idle gear must be replaced.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 61
ENGINE MECHANICAL
6A–61
Installation
1
2
6
3
Y
5
Y
Y Y
4
020E100033
Legend (1) Camshaft gear (2) Idle gear “C” (3) Injection pump gear
(4) Idle gear “A” (5) Crankshaft gear (6) Idle gear “B”
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 62
6A–62
ENGINE MECHANICAL
1. Install the timing gearcase. • Clean the sealing surface block and remove sealant residue. • Apply a 4 mm bead of Loctite FMD127 or equivalent to the cylinder block. The sealant must not obstruct the cylinder block bolt holes. • Install the timing gearcase to the cylinder block. • Tighten the bolts to the specified torque. M14 Bolt Torque: 135 N·m (13.8 kgm) M10 Bolt Torque: 43 N·m (4.4 kgm)
1
014EY00084
3. Install the idle gear “A” to the timing gearcase. • Align the flywheel TDC mark with the pointer by rotating the crankshaft normal direction. Same time check alignment of the timing mark on the injection pump for No. 1 piston TDC.
2. Install the idle gear “B”. • Apply engine oil to the bushing area of the idle gear and both thrust plate (1) surface. • Face front the scribed mark on the thrust plate. • Tighten the bolts to the specified torque. Torque: 39 N·m (4.0 kgm)
015EY00070
• Apply engine oil to the bushing of the idle gear “A”. • Install the idle gear “A” with the idle gear shaft to the timing gearcase. The timing marks (“O”, “I”, “Y”) must be aligned as shown in the illustration. • Tighten the idle gear “A” shaft bolts to the specified torque. Torque: 108 N·m (11.0 kgm)
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 63
ENGINE MECHANICAL
6A–63
Y Y
Y Y
020E100024
4. Install the distance bolt to the gearcase. Tighten the distance bolts to the specified torque. Torque: 39 N·m (4.0 kgm)
020HV001
5. Install the oil pump assembly. • Install the new gasket to the oil pump assembly. • Install the oil pump assembly to the cylinder pump. • Tighten the oil pump bolts to the specified torque. Torque: 49 N·m (5.0 kgm) CAUTION: Do not tighten arrow mark bolt shown in the illustration.
051HT002
6. Install the timing gearcase cover. • Apply Loctite FMD127 or equivalent to the timing gearcase fitting face. • Install the timing gearcase cover with new gasket. • Tighten the bolts to the specified torque. With cooling fan M10 bolts Torque: 39 N·m (4.0 kgm) M8 bolts Torque: 26 N·m (2.6 kgm)
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 64
6A–64
ENGINE MECHANICAL
HCW31BSH019301
Without cooling fan M10 bolts Torque: 43 N·m (4.4 kgm) M8 bolts Torque: 23 N·m (2.3 kgm)
7. Install the oil seal with the slinger.
020EY00028
A
1
HCW31BSH019201
4
5
After press
Before press
3
2 015EX00001
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 65
ENGINE MECHANICAL
6A–65
8. Install the crankshaft pulley assembly. • Install the crankshaft pulley. • Apply engine oil to the bolt threads. • Tighten the crankshaft pulley bolts to the specified torque. Torque: 267 N·m (27.2 kgm)
Legend (1) Crankshaft (2) Slinger (3) Oil seal (4) Adapter (5) Sleeve • Apply engine oil to the entire circumference of the oil seal. • Use the oil seal installer 1-8522-0043-0 to install the oil seal. • Tighten the center bolt until the sleeve comes into contact with the adapter stopper. • After pressing the oil seal, make sure that the distance between the crankshaft end surface and the oil seal is A as specified. Distance (A): 6.7 – 7.3 mm (0.264 – 0.287 in) • There is identification color on the oil seal. For front oil seal: Dark violet color For rear oil seal: Gray color • If there is small scratch on the crankshaft, apply Threebond 127C or equivalent to the oil slinger shown in the illustration.
015EY00096
1mm
;À @;À @
À @;;À @;À @
; @ À ;À @
9. Install the fan center (1) to the gearcase cover (2). Tighten the fixing nuts to the specified torque. Torque: 52 N·m (5.3 kgm)
1
3mm
2 020MT001
033EY00011
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 66
6A–66
ENGINE MECHANICAL
Flywheel Housing Removal 4 1
6 7
2
5
4
3
Legend (1) N-TDC sensor (2) Washer (3) Flywheel (4) Stiffener
(5) Flywheel housing (6) Oil seal (7) Slinger
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 67
ENGINE MECHANICAL 1. Loosen the flywheel fixing bolts. Remove the flywheel. 2. Use the oil seal remover 1-8522-0052-0 to remove the oil seal from the crankshaft. • Take care not to damage on the inserting surface of the housing.
6A–67
Installation 1. Install the flywheel housing to the cylinder block. • Apply a 4 mm bead of Loctite FMD127 or equivalent to the cylinder block as shown in the illustration. The sealant must not obstruct the cylinder bolt holes. • Install the flywheel housing. Tighten the fixing bolts to the specified torque. M14 bolt Torque: 123 N·m (12.5 kgm) M8 bolt Torque: 22 N·m (2.2 kgm)
020E100036
3. Remove the stiffeners. 4. Remove the flywheel housing.
2. Install the stiffeners (1) to the flywheel housing. Tighten the fixing bolts to the specified torque. Torque: 136 N·m (13.9 kgm)
020E100037
1
013EY00015
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 68
6A–68
ENGINE MECHANICAL
3. Install the oil seal with the slinger. • Apply engine oil to the entire circumference of the oil seal. • Use the oil seal installer 1-8522-0043-0 to install the oil seal. • Tighten the center bolt until the sleeve comes into contact with the adapter stopper. • After pressing the oil seal, make sure that the distance between the crankshaft end surface and the oil seal is A as specified. Distance (A): 6.7 – 7.3 mm (0.264 – 0.287 in) • There is identification color on the oil seal. For front oil seal: Dark violet color For rear oil seal: Gray color • Do not make separation between the oil seal and slinger. 1
A 4
5
After press
Before press
2
3 015EY00203
Legend (1) Crankshaft (2) Slinger (3) Oil seal (4) Adapter (5) Sleeve
4. Install the flywheel to the crankshaft. • Apply molybdenum disulfied grease to the bolt and setting face. • Tighten the flywheel bolts in three steps using the angular tightening method. Torque: 1st step: 79 N·m (8.0 kgm) 2nd step: 60 deg. 3rd step: 30 deg. • Follow the numerical order as shown in the illustration.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 69
ENGINE MECHANICAL
6A–69
Oil Pan Removal
7
6
8
5
4 4
3 2 1
3 2
1 PAW0Z0LF000701
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 70
6A–70
ENGINE MECHANICAL
Legend (1) Oil pan (2) Oil pan gasket (or bracket) (3) Oil pan spacer (4) Oil pan spacer gasket
1. Remove the oil pan. Remove the oil pan gasket. Discard the oil pan gasket. 2. Remove the oil pan spacer. Remove the oil pan spacer gasket. Discard the oil pan spacer gasket. 3. Remove the oil strainer. 4. Remove the oil strainer bracket. 5. Remove the oil jet assembly. CAUTION: Take care not to bend the oil jet tubing. Do not attempt to repair a damaged oil jet. If damaged, replace the oil jet with a new one.
(5) (6) (7) (8)
Oil strainer Oil strainer bracket Gasket Oil jet assembly
4 6 5 2
3 1
Installation 1. Install the oil jet assembly to the cylinder block. Tighten the joint bolt to the specified torque. Torque: 69 N·m (7.0 kgm) 3. Install the oil pan spacer with new gasket. • Apply Cemedain LG-020L or equivalent to the cylinder block, flywheel housing and gearcase fitting face. The sealant must be 3 – 4 mm of bead.
Sealant
2. Install the oil strainer with new gasket and the oil strainer bracket. Tighten the bolts in numerical order as shown in the illustration. Torque: 55 N·m (5.6 kgm)
012EY00017
Tighten the bolts in numerical order as shown in the illustration. Torque: 38 N·m (3.9 kgm)
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ENGINE MECHANICAL
then re-apply the gasket and pro-ceed to reassemble the parts. • When installing the oil pan, erect about four guide studs for positioning in the oil pan spacer bolt holes. • After tightening the oil pan, do not remove any of the protruding gasket from the inner or outer circumference of the oil pan. • Do not fill the engine with oil or start the engine until at least 30 minutes has passed since the parts were installed.
20 1
21
Front
36 3
6A–71
2
013EY00016
1
4. Install the oil pan to the oil pan spacer. Without liquid gasket • Install the oil pan with new gasket. Tighten the bolts to the specified torque in numerical order as shown in the illustration. Torque: 25 N·m (2.5 kgm)
V
1
Front
3 2 3
PAW5Z0MH000501
2
013EY00017
With liquid gasket • Degrease the installation surface of the oil pan flange side, flange R, and oil pan spacer. • Apply liquid gasket along the line on the dia-gram below. Liquid gasket: TB1207B • Aim for a liquid gasket diameter of ø 4 mm {0.16 in} (ø 3.5 — 4.5 mm {0.14 — 0.18 in}). • Apply liquid gasket, then assemble the oil pan within 7 minutes. If more than 7 minutes passes, use a gasket remover to remove the liquid gasket,
Name 1. Line connected to the bolt hole perimeter line (inner side) 2. Oil pan R finish line 3. Apply to the constant clearance along the oil pan angle R
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6A–72
ENGINE MECHANICAL
1
2 PAW5Z0SH002801
Name 1. Aim to apply so that the edge of the gasket is on the R finish line 2. Aim to apply so that the edge of the liquid gasket includes the bolt hole outer circumference
PAW5ZHSH000401
• Tighten to the specified torque. Torque: 19 N·m (1.9 kgm)
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ENGINE MECHANICAL
6A–73
Piston Removal
1
2
3
2 4
015EY00097
Legend (1) Piston with connecting rod (2) Connecting rod bearing
(3) Crankshaft (4) Connecting rod bearing cap
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 74
6A–74
ENGINE MECHANICAL
1. Remove the cylinder head assembly. Refer to “Cylinder Head” in this section. 2. Remove the oil pan. Refer to “Oil Pan” in this section. 3. Remove the piston with connecting rod. • Remove the carbon deposits from the upper potion of the cylinder wall by the scraper. • Loosen the connecting rod cap nuts. • Move the piston to the top of the cylinder and tap it with a hammer grip or similar object from the connecting rod lower side to drive it out. CAUTION: Take care not to damage the oil jets.
4. Remove the connecting rod bearing. • Mark, sort or organize the connecting rod bearing for assembly to the original location.
Installation 1. Install the piston with the connecting rod. • Clean the piston in solvent. Remove all sludge. • Carefully wipe any foreign materials inside cylinder bore and piston with connecting rod. Clean the bearing cap and bearing • Install the connecting rod upper bearing to the connecting rod.
012EY00018
• Install the connecting rod lower bearing to the connecting rod. • Apply engine oil to the cylinder wall, upper/lower bearing surface and crank pin of crankshaft.
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ENGINE MECHANICAL
6A–75
1
012EY00028
015EY00134
• Position the piston ring gaps as shown in the illustration. Gap position (1) 1st compression ring (2) 2nd compression ring (3) 3rd compression ring (4) Oil ring (5) Coil expander
• Use the piston setting tool 1-8522-0059-1 to install the piston with the connecting rod to the cylinder block. At this time rotate the crankshaft until the crankpin is at bottom dead center.
Front mark 1
2,5
4
3
CAUTION: Do not bend or damage the oil jet. • Apply molybdenum disulfied grease to the threads and setting faces of each connecting rod bolts. 012HW002
• Position the piston head front mark (1) so that it is facing front of the engine.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 76
6A–76
ENGINE MECHANICAL
• Tighten the connecting rod cap nuts in three steps using the angular tightening method. Torque: 1st step: 98 N·m (10.0 kgm) 2nd step: 30 deg. 3rd step: 30 deg. • Check the crankshaft rotation smoothly. 2. Install the oil pan to the cylinder block. Refer to “Oil Pan” to this section. 3. Install the cylinder head to the cylinder block. Refer to “Cylinder Head” in this section.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 77
ENGINE MECHANICAL
Disassembly 1
2 3
4
2
5
7
6
Legend (1) Piston rings (2) Snap ring (3) Piston pin (4) Piston
(5) Connecting rod (6) Connecting rod cap (7) Bearing
6A–77
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 78
6A–78
ENGINE MECHANICAL
CAUTION: Do not bend or damage the oil jet. NOTE: When removing the piston and connection rod assembly, pull the connecting rod in parallel with the cylinder bore. 1. Remove the connecting rod cap. 2. Remove the bearings. • Take out the connecting rod bearing cap nuts and disassemble the bearing cap with the lower bearing. • Mark, sort or organize the connecting rod bearing for assembly to the original location. 3. Remove the piston rings. • Clamp the connecting rod in a vise. Take care not to damage the connecting rod. • Use piston ring replacer to reassemble the piston rings. Do not attempt to use some other tool to disassemble the piston rings. Piston ring stretching will result in reduced piston ring tension.
1
015EY00098
5. Remove the piston pin. 6. Remove the piston. 7. Remove the connecting rod. Tap the piston pin out with a hammer and a brass bar. Mark, sort or organize the piston and piston rings for assembly to the original location.
Inspection and Repair Make the necessary adjustments, repairs and part replacements if excessive wear or damage is discovered during inspection.
Piston Ring Gap
4. Remove the snap ring. Use a pair of snap ring pliers to remove the snap rings.
1. Insert the piston ring horizontally (in the position it would assume if it were installed to the position) into the cylinder liner bore. 2. Push the piston ring into the cylinder liner bore until it reaches the point where the cylinder liner bore is the smallest. Do not allow the piston ring to slant to one side or the other. It must be perfectly horizontal.
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ENGINE MECHANICAL
6A–79
Piston Ring and Piston Ring Groove Clearance 1. Visually inspect the piston ring grooves. If a piston ring groove is damaged or distorted, the piston must be replaced. 2. Use a feeler gauge to measure the clearance between the piston ring and the piston ring groove at several points around the piston. 3. When measuring the clearance for 1st piston ring, press the 1st piston ring by straight gauge show in the illustration.
1
015EY00099
3. Use a feeler gage to measure the piston ring gap. If the measured value exceeds the specified limit, the piston ring must be replaced. Piston ring gap 1st, 3rd ring: Standard: 0.35 – 0.50 mm (0.0138 – 0.0197 in.) Limit: 1.0 mm (0.0394 in.) 2nd ring: Standard: 0.80 – 0.95 mm (0.0315 – 0.0374 in.) Limit: 1.0 mm (0.0394 in.) Oil ring: Standard: 0.30 – 0.50 mm (0.0118 – 0.0197 in.) Limit: 1.0 mm (0.0394 in.)
1
015EY00100
2
015EY00101
Piston ring and piston ring groove clearance 1st ring: Standard: 0.115 – 0.160 mm (0.0045 – 0.0063 in.) Limit: 0.24 mm (0.0094 in.) 2nd, 3rd ring: Standard: 0.10 – 0.135 mm (0.0039 – 0.0053 in.) Limit: 0.20 mm (0.787 in.) Oil ring: Standard: 0.025 – 0.065 mm (0.0010 – 0.0026 in.) Limit: 0.15 mm (0.0059 in.)
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 80
6A–80
ENGINE MECHANICAL
Piston Pin Diameter Use a micrometer to measure the piston pin outside diameter at several points If the measured value is less than the specified limit, the piston pin must be replaced. Piston pin diameter Standard: 55.995 – 56.000 mm (2.2015 – 2.2047 in.) Limit: 55.970 mm (2.2035 in.)
Piston Ring Expansion Force Use an expansion force gauge to measure the piston ring expansion force. Piston ring expansion force 1st ring: Standard: 38.5 – 49.2 N (3.92 – 8.64 kg/8.64 – 11.07 lb) Limit: 29 N (3.0 kg/6.6 lb) 2nd ring: Standard: 29.9 – 38.7 N (3.05 – 3.95 kg/6.73 – 8.71 lb) Limit: 20 N (2.0 kg/4.4 lb) 3rd ring: Standard: 28.1 – 36.6 N (2.87 – 3.73 kg/6.33 – 8.22 lb) Limit: 20 N (2.0 kg/4.4 lb) Oil ring: Standard: 85.3 – 104.9 N (8.7 – 10.7 kg/19.2 – 23.6 lb) Limit: 64 N (6.5 kg/14.3 lb)
Piston Pin Hole and Piston Pin Clearance Use a inside dial indicator to measure the piston pin hole (in the piston). Piston pin hole and piston pin clearance Standard: 0.008 – 0.021 mm (0.0003 – 0.0008 in.) Limit: 0.05 mm (0.0020 in.)
Piston Pin and Connecting Rod Small End Bushing Clearance Use a caliper calibrator and dial indicator to measure the clearance between the piston pin and connecting rod small end bushing If the clearance between the piston pin and the connecting rod small end bushing exceeds the specified limit, replace the piston pin and/or the connecting rod assembly. Small end bushing clearance Standard: 0.020 – 0.037 mm (0.0079 – 0.0016 in.) Limit: 0.10 mm (0.0039 in.)
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ENGINE MECHANICAL
6A–81
Crankshaft and Connecting Rod Bearing Clearance
015EY00102
Connecting Rod Alignment Use a connecting rod aligner to measure the distortion and the parallelism between the connecting rod big end hole and the connecting rod small end hole. If either the measured distortion or parallelism exceeds the specified limit, the connecting rod must be replaced. Connecting rod alignment Per length of 100 mm (3.94 in.) Standard: 0.05 mm (0.002 in.) or less Limit: 0.20 mm (0.008 in.)
1. Clean the crankshaft, connecting rod, bearing cap, and bearings. 2. Install the bearing to the connecting rod and bearing cap. 3. Apply a coat of molybdenum disulfide grease to the bearing cap bolt threads and setting faces. 4. Prevent the connecting rod from moving. 5. Tighten the bearing cap to the specified torque. Connecting rod bearing cap nut torque 1st step: 98.1 N·m (10.0 kgm/72.3 lb·ft) 2nd step: 30 deg. 3rd step: 30 deg. 6. Use a dial indicator to measure the connecting rod bearing inside diameter. Crankpin and connecting rod bearing clearance Standard: 0.033 – 0.103 mm (0.0013 – 0.0041 in.) Limit: 0.16 mm (0.0063 in.)
1
2
B
A
A 1
2
B
7. If the clearance between the measured bearing inside diameter and the crankpin exceeds the specified limit, the bearing and/or crankshaft must be replace.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 82
6A–82
ENGINE MECHANICAL
Piston and Liner Bore Clearance
1 2
A B
B A
Connecting Rod and Crankshaft Clearance 1. Fix the connecting rod assembly to the crankshaft by the specified torque. The fixing manner is follow as mentioned above. 2. Use a feeler gauge to measure the clearance between the connecting rod and crankshaft. If the measured value exceeds the specified limit, the connecting rod must be replaced. Connecting rod and crankshaft clearance Standard: 0.175 – 0.290 mm (0.0069 – 0.0114 in.) Limit: 0.35 mm (0.0138 in.)
Measure the cylinder liner bore after installing the cylinder liner. Then select the appropriate piston for the installed cylinder liner. 1. Measure the cylinder liner bore. Refer to the “Cylinder Liner Bore Measurement”. Measuring Point 130 mm (5.118 in.) Cylinder liner bore Standard: 147.011 – 147.030 mm (5.7878 – 5.7886 in.)
130mm
012EY00022
2. Measure the piston outside diameter (Reference). Piston Measuring Point 113 mm (4.449 in.)
113mm
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ENGINE MECHANICAL The grade mark is stamped on the top of the piston installed at the factory, but the piston for service part does not have any grade. Piston outside Standard: 146.830 – 146.845 mm (5.7805 – 5.7813 in.) Piston and Liner bore clearance Standard: 0.166 – 0.200 mm (0.0065 – 0.0079 in.) If the piston and liner clearance exceeds the standard value, the piston and/or liner must be replaced. CAUTION: Cylinder liner kit clearances are preset. However, the cylinder liner installation procedure may result in slight decreases in cylinder liner clearances. Always measure the cylinder liner clearance after installation to be sure that its is correct.
6A–83
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6A–84
ENGINE MECHANICAL
Reassembly 1
2 3
4
2
5
7
6
Legend (1) Piston rings (2) Snap ring (3) Piston pin (4) Piston
(5) Connecting rod (6) Connecting rod cap (7) Bearing
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 85
ENGINE MECHANICAL 1. Install the snap ring. Use a pair of sanp ring pliers to reassemble the snap ring to the piston. 2. Install the connecting rod and piston pin. • Clamp the connecting rod in the vise. Take care not to damage the connecting rod. • Install the piston so that the piston head front mark and the connecting rod front mark are set in the same direction.
1
1N
Red
2
2N
Blue
6A–85
3
3N
Green
015EY00103
1 1 2
3 015EY00098
• Apply engine oil to the piston pin. • Insert the piston pin to the connecting rod through piston pin hole on the piston. • Install the snap ring. 3. Install the piston ring. • Apply engine oil to the piston rings. • Confirm the discrimination mark on the piston ring. Discrimination mark 1st ring: Red color 2nd ring: Blue color 3rd ring: Green color Oil ring: Not available
4
015EY00104
• Use the piston ring setting tool 1-8522-1025-0 to reassemble the four piston rings according to top mark on the piston ring. The oil ring does not have top mark. NOTE: Insert the expander coil into the oil ring groove so that there is no gap on either side of the expander coil before installing the oil ring.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 86
6A–86
ENGINE MECHANICAL Gap position (1) 1st compression ring (2) 2nd compression ring (3) 3rd compression ring (4) Oil ring (5) Coil expander
Front mark 1
2,5
4
3
012HW002
• Apply molybdenum disulfide grease to the two piston skirts. This will facilitate smooth break-in when the engine is first started after reassembly. • Apply engine oil to the upper connecting rod bearing. • Apply engine oil to the cylinder wall. • Position the front mark on the piston head so that it is facing the front of the engine.
1
015EY00098
• Check to see if the piston rings rotate smoothly in the piston ring grooves. 4. Install the connecting rod bearing. Carefully wipe any oil or other foreign material from the connecting rod bearing back face and the bearing fitting surface. 5. Install the connecting rod cap. • Fit the lower connecting rod bearing to the connecting rod cap. • Apply engine oil to the circumference of the each piston ring, piston and crankpin. • Position the piston ring gaps as shown in the illustration.
Front mark
Engine front
Front mark
015HV014
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 87
ENGINE MECHANICAL • Use the piston ring setting tool 1-8522-0059-0 to compress the piston rings.
• Use a hummer grip to push the piston in until the connecting rod marks contact with the crankpin. As the same time, rotate the crankshaft until the crankpin is at bottom dead center. CAUTION: Do not bend or damage the oil jet. • Align the connection rod cap cylinder number marks and the connecting rod cylinder number marks. • Install the connection rod caps. • Apply molybdenum disulfide grease to the threads and setting faces of each connecting rod bolts and nuts. • Tighten the connecting rod nut to the specified torque. Torque: 1st step: 98 N·m (10.0 kgm) 2nd step: 30° 3rd step: 30°
6A–87
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 88
6A–88
ENGINE MECHANICAL
Crankshaft Removal
1
2 5
6
6
4
2
6 6
5
3
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 89
ENGINE MECHANICAL Legend (1) Piston with connecting rod (2) Connecting rod bearing (3) Lower crankcase
6A–89
(4) Crankshaft (5) Crankshaft bearing (6) Crankshaft thrust bearing
1. Remove the cylinder head assembly. Refer to “Cylinder Head” in this section. 2. Remove the oil pan. Refer to “Oil Pan” in this section. 3. Remove the timing gear. Refer to “Timing Gear” in this section. 4. Remove the flywheel. Refer to “Flywheel” in this section. 5. Remove the piston with connecting rod. Refer to “Piston” in this section. 6. Remove the lower crankcase. • Measure the crankshaft end play at the No. 1 crankshaft journal before removing the crankshaft thrust bearing. If the measured value exceeds the specified limit, the crankshaft thrust bearing must be replaced. Crankshaft end play Standard: 0.04 – 0.18 mm (0.0016 – 0.0070 in.) Limit: 0.35 mm (0.0138 in.)
1
1
5
9
C
B
8
4
2
6
0
D
A
7
3
1
012EY00024
7. Remove the crankshaft from the cylinder block. 8. Remove the crankshaft bearing. • Mark, sort or organize the connecting bearing for assembly to the original location. 9. Remove the crankshaft thrust bearing.
Installation 1. Install the crankshaft bearing to the cylinder block. • Carefully wipe any foreign materials from the fitting area of the cylinder block and upper crankshaft bearing. All upper bearing have oil grooves. • Install the upper bearings to the original location, if to be reused. CAUTION: Do not apply engine oil to the bearing back faces and cylinder block bearing fitting surfaces. 012EY00023
• Loosen the crankcase lower bolt. A little at a time in the numerical order shown in the illustration. • Use M10 bolts into the holes (1) for replacement to remove the crankcase lower.
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6A–90
ENGINE MECHANICAL
Dowel pin hole Cylinder body side Crankcase side
Oil groove
012EY00025
015EY00108
2. Install the crankshaft to the cylinder block. • Clean the crankshaft in solvent. Remove all sludge or restrictions from the oil passages. • Apply engine oil to the crankshaft journal and crankshaft bearing surfaces before installing the crankshaft.
4. Install the lower crankcase to the cylinder block. • Carefully wipe any foreign materials from the fitting area of the crankcase. • Apply Loctite FMD127 or equivalent to cylinder block lower surfaces. The sealant must be 0.3 mm thick and 4 mm wide. • Install the crankshaft bearings and thrust bearing. CAUTION: Do not apply engine oil to the bearing back. NOTE: The thrust bearing oil grooves must be facing the sliding face.
Apply FMD-127 FMD-127 {
}
Ft FMD-127 015EY00107
3. Install the crankshaft thrust bearing. • Apply engine oil to the thrust bearing oil grooves side. • Install the upper thrust bearing to both side of the No. 1 journal by hand. NOTE: The thrust bearing oil groove must be faced the sliding side.
FMD-127
Rr
{
}
FMD-127
FMD-127 Cylinder body lower surface
012EY00026
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 91
ENGINE MECHANICAL
5. Install the piston with the connecting rod. Refer to “Piston” in this section. 6. Install the flywheel to the crankshaft. Refer to “Flywheel Housing” in this section. 7. Install the timing gears to the cylinder block. Refer to “Timing Gear” in this section. 8. Install the oil pan to the cylinder block. Refer to “Oil Pan” in this section. 9. Install the cylinder head to the cylinder block. Refer to “Cylinder Head” in this section.
Oil groove
015EY00109
• Install the lower crankcase to the cylinder block. • Apply molybdenum disulfide grease to the crankcase bolts (M18) threads and setting faces. • Apply engine oil to the crankcase bolts (M12) threads and setting faces. Order 1 to 14 in the three steps using the angular tightening method. M18 bolt Torque: 1st step: 49 N·m (5.0 kgm) 2nd step: 88 N·m (9.0 kgm) 3rd step: 90 – 120 deg. M12 bolt Torque: 96 N·m (9.8 kgm)
0
6
2
3
7
D
A
C
B 9
5
6A–91
1
4
8
012Ey00027
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 92
6A–92
ENGINE MECHANICAL
Disassembly
1
3 2
Legend (1) Crankshaft (2) Bearings (3) Crankshaft gear
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 93
ENGINE MECHANICAL 1. Remove the crankshaft assembly (1) from the cylinder block. 2. Remove the crankshaft bearing and thrust bearing (2). 3. Use the crankshaft gear remover 1-8521-0064-0 to remove the crankshaft gear (3). If the slinger on the crankshaft remain, remove slinger by the slinger remover 1-8521-0027-0. CAUTION: The crankshaft must not be ground as it has been treated by soft nitriding to enhance the crankshaft strength.
12
A B
6A–93
B A
Crankshaft Run-Out • Set a dial indicator to the center of the crankshaft No. 4 journal. • Gently turn the crankshaft in the normal direction of rotation. Read the dial indicator as you turn the crankshaft. If the measured value exceeds the specified limit, the crankshaft must be replaced. Crankshaft run-out Standard: 0.120 mm (0.0005 in.) Limit: 0.15 mm (0.0059 in.)
Inspection and Repair Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.
Crankshaft Journal and Crankpin Diameter • Use a micrometer to measure the crankshaft journal diameter across points shown in the illustration. • Use a micrometer to measure the crankshaft journal diameter at the two points as shown in the illustration (1) and (2). • Repeat steps 1) and 2) to measure the crankpin diameter. If the measured values are less than the standard value, the crankshaft must be replaced. Crankshaft journal and Crankpin diameter Standard No. 4 journal: 104.850 – 104.875 mm (4.1279 – 4.1289 in.) Others: 104.880 – 104.905 mm (4.1291 – 4.1309 in.) Crankpin: 91.895 – 91.925 mm (3.6179 – 3.6191 in.)
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 94
6A–94
ENGINE MECHANICAL
Bearing Spread Use a vernier caliper to measure the bearing spread. If the measured value is less than the specified limit, the bearing must be replaced. Bearing spread: Limit: 111.5 mm (4.3898 in.)
0
6
2
3
7
D
A
C
B 9
5
1
4
8
012EY00027
015EY00110
Crankshaft Journal and Bearing Clearance • Clean the cylinder block and lower crankcase, the journal bearing fitting surface, and the journal bearings. • Install the bearings to the cylinder block and lower crankcase. • Reassembly the lower crankcase to cylinder block. • Apply molybdenum disulfide grease to the M18 bolts and apply engine oil to the M12 bolts thread and it seat. • Tighten the lower crankcase to the specified torque in the numerical order shown in the illustration. Crankcase bolt torque M18 bolt 1st step: 49 N·m (5.0 kgm) 2nd step: 88 N·m (9.0 kgm) 3rd step: 90 – 120° M12 bolt Torque: 96 N·m (9.8 kgm)
• Measure the crankshaft bearing inside diameter by a dial indicator. • If the clearance between the crankshaft journal and bearing exceeds the specified limit, the crankshaft must be replaced. No. 4 journal Standard: 0.081 – 0.144 mm (0.0032 – 0.0057 in.) Limit: 0.16 mm (0.0063 in.) Others Standard: 0.051 – 0.114 mm (0.0020 – 0.0045 in.) Limit: 0.16 mm (0.0063 in.)
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 95
ENGINE MECHANICAL
B
• Tighten the lower crankcase to the specified torque in the numerical order shown in the illustration. Crankcase bolt torque M18 bolt 1st step: 49 N·m (5.0 kgm) 2nd step: 88 N·m (9.0 kgm) 3rd step: 90 – 120° M12 bolt Torque: 96 N·m (9.8 kgm)
12
A
6A–95
B A
0
Crankshaft Journal and Bearing Clearance (with plastigage) • Clean the cylinder block and lower crankcase, the journal bearing fitting surface, and the journal bearings. • Install the bearings to the cylinder block and lower crankcase. • Reassembly the lower crankcase to the cylinder block. • Cut the plastigage same wide of crankshaft journal and put it on the crankshaft journal. • Apply molybdenum disulfide grease to the M18 bolts and apply engine oil to the M12 bolts thread and it seat.
015EY00111
6
2
3
7
D
A
C
B 9
5
1
4
8
012EY00027
• Carefully disassembly the lower crankcase from the cylinder block. • Measure the width of plastigage by the scale which printed on the plastigage envelop. • If the clearance between the crankshaft journal and bearing exceeds the specified limit, the crankshaft must be replaced. Crankshaft journal and bearing clearance No. 4 journal Standard: 0.081 – 0.144 mm (0.0032 – 0.0057 in.) Limit: 0.16 mm (0.0063 in.) Others Standard: 0.051 – 0.114 mm (0.0020 – 0.0045 in.) Limit: 0.16 mm (0.0063 in.)
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 96
6A–96
ENGINE MECHANICAL
Crankshaft Tufftriding Judgment • Wait for thirty to forty seconds. If there is no discoloration after thirty or forty seconds, the crankshaft is usable. If discoloration appears (the surface being tested will become the color of copper), the crankshaft must be replaced. • Steam clean the crankshaft surface immediately after completing the test. NOTE: the ammonium cuprous chloride solution is highly corrosive. Be cause of this, it is imperative that the surfaces being tested by cleaned immediately after completing the test.
015EY00112
Crankshaft Tufftriding Inspection • Use an organic cleaner to thoroughly clean the crankshaft. There must be not traces of oil on the surface to be inspected. • Prepare a 5 – 10% solution of ammonium cuprous chloride (dissolved in distilled water). • Use a syringe to apply the solution to the surface to be inspected. Hold the surface to be inspected perfectly horizontal to prevent the solution from running. NOTE: Do not allow the solution to come in contact with the oil ports and their surrounding area.
The portion to be tested must be held horizontally so as not to let the test solution flow. The sliding surface of the pin or journal.
Test liquid should not be applied to the area around the oil port.
Approximatery 10mm (0.4in)
015EY00113
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 97
ENGINE MECHANICAL
Reassembly
1
3 2
Legend (1) Crankshaft (2) Bearings (3) Crankshaft gear
6A–97
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 98
6A–98
ENGINE MECHANICAL
1. Install the crankshaft gear to the crankshaft. • Use the oil heater to heat the crankshaft gear to 170 – 180°C (338 – 350°F). • With the timing alignment mark “O” on the side of crankshaft gear turned outward, align the key groove on the crankshaft gear with the crankshaft dowel pin position. • Hammer it in with a crankshaft gear installer 18522-0045-0 until it hits the bottom. CAUTION: When hammered in with the gear slanted, the crankshaft gear may be caught in the middle and cannot be hammered in fully. Hammer it in quickly enough not to allow a shaft line along the gear and the crankshaft to slant.
2. Install the bearings. Install the crankshaft bearings and thrust bearings. Refer to “Crankshaft” in this section. 3. Install the crankshaft to the cylinder block. Refer to “Crankshaft” in this section.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 99
ENGINE MECHANICAL
6A–99
Crank Pulley Disassembly
2 1
015EY00114
Legend (1) Crank pulley (2) Crankshaft damper
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 100
6A–100
ENGINE MECHANICAL
1. Loose the crankshaft pulley disassemble the crank pulley.
fixing
bolts
to
Inspection Visually inspect the crankshaft damper for cracking or separation.
015EY00096
2. Loose the fixing bolts to disassemble the crankshaft damper.
Reassembly 1. Install the crankshaft damper. • Install the crankshaft damper to the crankshaft, and two grooves face to the front side. • Tighten the bolts in numerical order to the specified torque shown in the illustration. Torque: 96 N·m (9.8 kgm)
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 101
ENGINE MECHANICAL 2. Install the crank pulley. • Apply engine oil to the threads of fixing bolts. • Set the crank pulley to the crankshaft damper. • Tighten the bolts in numerical order to the specified torque shown in the illustration. Torque: 267 N·m (27.2 kgm)
015EY00096
6A–101
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 102
6A–102
ENGINE MECHANICAL
Flywheel Disassembly
3
2
1 015EY00115
Legend (1) Ring gear (2) Flywheel (3) Washer
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 103
ENGINE MECHANICAL 1. Loose the fixing bolts to remove flywheel from the crankshaft. 2. Put the flywheel with ring gear on the wood piece, and strike around the edges of the ring gear with a hammer and brass bar to remove it.
Inspection and Repair 1. Visually inspect the flywheel for cracking, scratching or worn out. 2. Visually inspect the ring gear for damage.
6A–103
Reassembly 1. Heat the ring gear evenly with a burner to invite thermal expansion. Do not allow the temperature of the gas burner to exceed 200°C (390°F). 2. Install the ring gear to the flywheel when it is sufficiently heated. The ring gear must be installed with the chamfer facing the flywheel. WARNING: Take care not to burn yourself on the heated ring gear.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 104
6A–104
ENGINE MECHANICAL
Cylinder Block Disassembly
3 2
4
1
5
6
012EY00029
Legend (1) Oil relief valve (2) Cylinder liner (3) Cylinder block
(4) Oil pressure switch (5) Oil jet (6) Lower crankcase
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 105
ENGINE MECHANICAL 1. Remove the lower crankcase. • Loosen the fixing bolts to disassemble the lower crankcase. • Put it on the wood plate or piece. 2. Remove the oil jet. Loosen the bolt to disassemble the oil jet. NOTE: Take care do not bend or damage the oil jet. 3. Remove the cylinder liner. • Use a scraper to remove carbon deposit. • Use a cylinder bore dial indicator to measure the cylinder bore at measuring point in the thrust and axial direction of the crankshaft. Measuring point: 20 – 25 mm (0.79 – 1.0 in.) If the measured value exceeds the specified limit, the cylinder liner must be replaced. Cylinder liner bore Limit: 147.3 mm (5.7992 in.) NOTE: If the inside of the cylinder liner is scored or scratched, the cylinder liner must be replaced.
6A–105
Inspection and Repair Make the necessary adjustment, repairs, and part replacement if excessive wear or damage is discovered during inspection.
Cylinder Block Flatness • Remove the cylinder liners. • Visually inspect the cylinder block any cracking or damage and the oil and/or water holes for choking. If possible it is required to specially inspect by dye penetrant flaw detector.
20∼ 25mm
4. Visually inspect the cylinder block for damage.
• Use a straight edge (1) and a feeler gauge (2) to measure upper face warpage of the cylinder block on the four sides and two diagonals of upper face shown in the illustration. Upper face warpage Standard: 0.075 N·m (0.0030 in.) or less Limit: 0.2 mm (0.008 in.) If the measured value exceeds the specified limit, the cylinder block must be replaced.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 106
6A–106
ENGINE MECHANICAL
1
20∼ 25mm
2
012EY00030
• Inspect water leakage to apply water pressure in the cylinder body water jacket. Water Pressure: 490 kPa (5 kg/cm2) If water leakage is fund, the cylinder block must be replaced.
Cylinder Liner Bore • Use a scraper to remove carbon deposit. • Use a cylinder bore dial indicator to measure the cylinder bore at measuring point in the thrust and axial direction of the crankshaft. Measuring point: 20 – 25 mm (0.79 – 1.0 in.) Cylinder liner bore Limit: 147.3 mm (5.7992 in.) If the measured value exceeds the specified limit, the cylinder liner must be replaced. NOTE: If the inside of the cylinder liner is scored or scratched, the cylinder liner must be replaced.
Cylinder Liner Grade Selection and Standard Fitting Interference Accurately measured fitting interference and proper cylinder liner grade selection are extremely important. If the cylinder liner fitting interference is too small, engine cooling efficiency will be adversely affected. If the cylinder liner fitting interference is too large, it will be difficult to insert the cylinder liner into the cylinder block. A mark was stamped on the right side of the cylinder block during production to indicate the correct liner. The liner grade (1, 2, 3) is indicated in metal stamp. Cylinder liner grade Line Cylinder Bore Service Liner Outside Grade Diameter mm (in.) Grade Diameter mm (in.) 1
151.600 – 151.610 (5.9685 – 5.9689)
1X
151.590 – 151.599 (5.9681 – 5.9685)
2·3
151.611 – 151.630 (5.9689 – 5.9697)
3X
151.600 – 151.610 (5.9685 – 5.9689)
The cylinder liner grade is stamped on the outside of the cylinder liner.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 107
ENGINE MECHANICAL
6A–107
Lower Crankcase Visually inspect the lower crankcase for cracking or damage. If possible it is required to specially inspect by dye penetrant flaw detector.
Liner outside Grade No.
012EY00020
1
Oil Jet Check the oil port on the oil jet for choking.
Grade No.
012EY00021
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 108
6A–108
ENGINE MECHANICAL
Relief Valve Inspect the relief valve for choking.
012EY00031
Cylinder Liner Projection • Use a dial indicator or a straight edge and feeler gauge to measure the cylinder liner projection. Cylinder liner projection Standard: 0.05 – 0.09 mm (0.0020 – 0.0035 in.) The difference in the cylinder liner projection height between any adjacent cylinders must not exceed limit. Projection height between adjacent cylinder: 0.02 mm (0.0008 in.) or less
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 109
ENGINE MECHANICAL
6A–109
Reassembly
3 2
4
1
5
6
012EY00029
Legend (1) Oil relief valve (2) Cylinder liner (3) Cylinder block .
(4) Oil pressure switch (5) Oil jet (6) Lower crankcase
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 110
6A–110
ENGINE MECHANICAL
1. Install the cylinder liner into the cylinder block. • Use new kerosene or diesel fuel to thoroughly clean the cylinder liner and bore. • Use compressed air to brow-dry cylinder liner and bore surface. WARNING: Pressure air can cause personal injury when using pressure air for cleaning. Wear safety glasses and protection clothing. NOTE: All foreign materials must be carefully removed from the cylinder liner and the cylinder bore before installation. • Apply engine oil to outside surface cylinder liner. • Install the cylinder liner into the cylinder block from the top of the cylinder block by your hand. • Check cylinder liner projection. NOTE: 1) Do not apply unreasonableness stress or hit the cylinder liner during installing. 2) Take care to not remove the cylinder liner when cylinder block turns over.
2. Install the oil jet to the cylinder block. Tighten to the specified torque. Torque: 69 N·m (7.0 kgm) Be sure direction of the oil jet tip to cooling hole of piston. Do not bend or damage the oil jet.
3. Install the crankshaft to the cylinder block. Refer to “Crankshaft” in this section. 4. Install the lower crankcase. Refer to “Crankshaft” in this section.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 111
ENGINE MECHANICAL 5. Install the oil relief valve. • Apply engine oil to the relief valve assembly with new gasket. • Install the relief valve to the cylinder block to the specified torque. Torque: 20 N·m (2.0 kgm)
012EY00032
6. Install the oil pressure unit. • Install the adapter with new gasket to the cylinder block to the specified torque. Torque: 41 N·m (4.2 kgm)
012EY00033
6A–111
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 112
6A–112
MEMO
ENGINE MECHANICAL
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 1
ENGINE COOLING
6B–1
ENGINE COOLING CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6B-5 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-5
Service precaution CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-8 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6B-9 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 2
6B–2
ENGINE COOLING
General Description Coolant Flow Chart
Radiator
Cylinder Head
Thermostat
Water Pump
Oil Cooler
Cylinder Body
Air Compressor (If equiped)
030EY00017
Cooling Flow
Thermostat
The cooling system main parts consist of the radiator, the water pump, the water outlet pipe and the thermostat. This top-bypass type cooling system controls the cooling water temperature though the thermostat installed at the water pump inlet. The system maintains optimum cooling water volume and minimizes cooling water temperature fluctuation and hunting.
A wax pellet type thermostat is used.
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 3
ENGINE COOLING
6B–3
Water Pump Water Pump Exploded View
12 11
10
8 7 6 5 9 3 1
4
2
030EY00008
Legend (1) Rear cover (2) Bearing (3) Gear (4) Bearing (5) Oil seal (6) Pump body
(7) (8) (9) (10) (11) (12)
Gasket Shaft Seal unit Impeller Joint pipe Front cover
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 4
6B–4
ENGINE COOLING • Use the bench press the rear cover side to disassemble the bearings (1) and gear (2).
Disassembly 1. Loosen the rear cover fixing bolts to remove the front cover. 2. Use the impeller remover (1) 1-8521-0062-0 to remove the impeller from the shaft.
2 1
030EY00010
030EY00009
3. Remove the rear cover. 4. Remove the small bearing. 5. Remove the gear. 6. Remove the large bearing. 7. Remove the shaft. • Use bench press from the impeller side to disassembly the shaft with the bearings and the gear.
8. Remove the oil seal (1). 9. Remove the seal unit (2). NOTE: Do not make scratch or damage seating surface of the oil seal and the seal unit on the pump body when disassemble them from the pump body.
2
1
030EY00011
10. Remove the pump body.
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 5
ENGINE COOLING
Inspection and Repair
6B–5
3. Inspect the shaft for damage or worn out.
Make the necessary adjustments, repair and part replacement if excessive or damage wear is discovered during inspection. 1. Inspect the impeller for corrosion and the seal unit for worn out touching surface or some damage.
030EY00012
Reassembly
2. Inspect the bearings. • Wash bearing in the clean kerosene. • Visually check scratches or damages on the ball and bearing race. • Rotate the bearing on your hand for hearing abnormal noise. • Check abnormal clearance between the ball and bearing race.
1. Install the oil seal to the pump body. • Apply engine oil to inside and outside of the oil seal. • Seal lip face to upper and carefully press fit the oil seal to the pump body.
2. Install the large bearing to the shaft. • Apply engine oil to the shaft. • Use a bench press to press the large bearing onto the shaft. • Use a bench press to press the shaft with large bearing into the pump body.
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 6
6B–6
ENGINE COOLING
030EY00013
4. Use the bench press to gradually press the bearing small (1) into the rear cover.
1
3. Install the gear on the shaft. • Place the gear long boss side facing to bearing large on the shaft. • Use a bench press to press the gear onto the shaft as shown in the illustration.
030EY00014
5. Install the rear cover. • Use a bench press to install the rear cover assembly into the shaft shown in the illustration. • Same time align bolt holes between rear cover and pump body.
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 7
ENGINE COOLING
6B–7
1
2
030EY00016
6. Use seal unit installer (1) 1-8522-0047-0 to install the seal unit (2).
1 2
030EY00015
7. Use the bench press to gradually press the impeller (1) until make specified clearance between the impeller and pump body (2). Clearance between impeller and pump body Standard: 1.7 – 2.7 mm (0.0669 – 0.1063 in.)
8. Set the gasket to the pump body. 9. Install the front cover. • Align bolt hole together with rear cover assembly. • Tighten the bolt from rear cover side to the specified torque. Torque: 28 N·m (2.8 kgm)
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 8
6B–8
ENGINE COOLING
Thermostat Disassembly
1 2 3
4 5
6
031EY00012
Legend (1) Seal ring (2) Thermostat (3) Gasket
(4) Thermostat housing (5) Gasket (6) Temperature switch
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 9
ENGINE COOLING
6B–9
1. Loosen the fixing bolts to remove the thermostat housing. Discard the gaskets. 2. Remove the thermostat housing. • Carefully remove the thermostat from the oil cooler case. 3. Remove the seal ring. • Loosen the seal ring puller 1-8521-0067-0 to take out the seal rings.
1
Inspection and Repair Make the necessary adjustments, repair and part replacements if excessive or damage wear is discovered during inspection. 1. Visually inspect leakage of wax pellet, some damage of the spring or caulking position on the thermostat. 2. Perform the operating test. Completely submerge the thermostat in water. Heat the water. Stir the water constantly to avoid direct heat being applied to the thermostat. Measure the thermostat initial opening temperature. Thermostat initial opening temperature 79°C (174°F) Measure the thermostat full opening temperature. Thermostat full opening temperature 95°C (203°F) Measure the valve lift at the thermostat full open position. Valve lift at full open position: 11 mm (0.433 in.)
2
031EY00013
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 10
6B–10
ENGINE COOLING
Reassembly 1. Use the seal ring installer 1-8522-1034-0 to install the seal ring to the oil cooler case, as the direction of seal ring shown in the illustration.
4. Install the temperature switch on the portion “A” of the thermostat housing.
031EY00016
2. Carefully install the thermostat to oil cooler case shown in the illustration.
A
031EY00015
3. Install the thermostat housing with new gaskets. • Set the gasket to the thermostat housing to install the thermostat housing with the new gasket. • Pushing the thermostat housing to oil cooler case, initially tighten the water pump side bolts then tighten the oil cooler side bolts to the specified torque. Bolt Torque: 39 N·m (4.0 kgm)
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 1
ENGINE FUEL
6C–1
ENGINE FUEL CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . . 6C-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . 6C-2 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-5 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-5 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6C-6 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-6 Injection Nozzle Holder . . . . . . . . . . . . . . . . . . . . . 6C-7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-7 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6C-8 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-10
Service precaution CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-13 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-13 Calibration Data. . . . . . . . . . . . . . . . . . . . . . . . . 6C-14 Injection Nozzle Holder – Two-Stage Injection Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-17 Nozzle and Holder Specification . . . . . . . . . . . . 6C-17 Reassembly and Opening Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-18
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 2
6C–2
ENGINE FUEL
General Description Fuel System Operation The engine crankshaft drives the fuel injection pump which in turn, drives the fuel feed pump. The fuel feed pump draws fuel from the fuel tank, through the fuel/water separator and transfers it, by way of the secondary fuel filter, into the injection pump. The governor regulates the flow of fuel to the delivery valves. At the correct timing intervals a plunger in the injection pump sends fuel, at high pressure, through a delivery valve to one of the fuel injection nozzles. Fuel pressure causes a needle valve in the fuel injection nozzle to open. Fuel is then injected through injection nozzle holes into the cylinder in a fine spray. Excess fuel is directed back to the fuel tank by means of the fuel return lines.
When working on the fuel system, there are several things to keep in mind: • Any time the fuel system is being worked on, disconnect the negative battery cable except for those tests where the battery voltage is required. • Always keep a dry chemical (Class B) fire extinguisher near the work area. • Always relieve the line pressure before servicing any fuel system components. • Do not attempt repair on the fuel system until you have read the instructions and checked the pictures relating to the repair.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 3
ENGINE FUEL
6C–3
Fuel Flow Diagram
040EY00031
The fuel system consists of the fuel tank, the water sedimentor, the fuel filter, the injection pump, and the injection nozzle. The fuel from the fuel tank passes through the water sedimentor and the fuel filter where water particles and other foreign material are removed from the fuel. Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the metered volume at the optimum timing for efficient engine operation.
Water Sedimentor When the condensed water in the water sedimentor comes to the warning level indicated on its plastic body, drain the water immediately from the drain plug located bottom of water sedimentor.
Fuel Filter The purpose of the fuel filter is to clean the fuel in any dirt particles that can cause wear on the fuel injection nozzle’s sliding surface. The water separator is located between the fuel tank and the fuel feed pump.
Fuel Feed Pump The fuel feed pump draws fuel from the fuel tank to the fuel filter. It delivers the fuel, under pressure, to the injection pump through fuel filter. An independent priming pump permits manual fuel feed while the engine is not running.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 4
6C–4
ENGINE FUEL
Injection Pump Major components of the injection pump are the pump body and plunger unit, the governor, the timing advancer and the feed pump. An aneroid compensator is available as an option. The injection pump is the nucleus of the diesel engine fuel system. It pressurizes and delivers a metered volume of fuel to the engine cylinders at the optimum time for the current engine load and speed. The injection pump plungers are pushed up by cam lobes. They are returned to their original position by the plunger springs. This action creates a reciprocal motion. The plunger barrel receives fuel from the feed pump and filter through its inlet port when the injection pump plunger is on the down stroke. Surplus fuel is delivered to the injection pump fuel chamber through the plunger outlet port when the plunger is on its up stroke. The injection pump has an identification plate attached to the pump body.
Governor The injection pump is equipped with a RSV type, variable speed governor. Diesel engine operating speed and load will very widely during the course of normal driving. If the engine speed falls too low, the engine may run sluggishly or stall. If the engine speed becomes too high, the engine overrun will result. The governor acts to maintain engine speed within acceptable limits, thus protection against engine stall and/or overrun.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 5
ENGINE FUEL
Fuel Filter Disassembly
2
3
1
Legend (1) Fuel filter (2) Overflow valve (3) Fuel filter body
6C–5
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 6
6C–6
ENGINE FUEL
1. Remove the fuel filter with using the filter wrench. CAUTION: Be careful not to spill out the fuel remaining in the fuel filter when the filter is removed.
040EY00007
2. Remove the overflow valve. 3. Remove the fuel filter body.
Inspection and Repair Inspection the overflow valve for restriction or leak. Overflow valve opening pressure 280 – 310 kPa (40 – 46 psi).
Reassembly 1. Install the overflow valve to the fuel filter body. 2. Install the fuel filter. • Before installating a new fuel filter, apply fuel to the gasket. • Turn the new fuel filter until the filter gasket comes in contact with its sealed face. • Use a filter wrench to turn in the fuel filter by additional 1/2 – 3/4 of a turn.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 7
ENGINE FUEL
6C–7
Injection Nozzle Holder Disassembly
5
4 6
3 2
7 8 9 10
1
040EY00032
Legend (1) Retainer nut (2) Nozzle (3) Nozzle holder pin (4) Spring seat (5) Gasket
(6) (7) (8) (9) (10)
Nozzle holder body Adjusting shim Spring Pin Spacer
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 8
6C–8
ENGINE FUEL
1. Remove the retaining nut. • Clamp the injection nozzle holder in a vice. • Use a wrench to remove the injection nozzle retainer nut.
CAUTION: 1. Wash all the part removed and arrange them on a cylinder basis, care should be taken not to miss any parts. 2. Soak the nozzle assembly in a parts receptacle filled clean diesel fuel. 3. Care should be taken not to miss shim, if used.
Inspection and Repair Make the necessary adjustments, repair and part replacements if excessive wear or damage is discovered during inspection.
Retaining Nut Inspect the retaining nut for any wear or corrosion.
2. Remove the nozzle from the nozzle holder. • Keep the nozzle along with the needle valve separately to maintain the original nozzle to needle valve combination. • Clean the nozzle in the clean diesel fuel.
Injection Nozzle Needle Valve 1. Remove the needle valve from the nozzle body. 2. Carefully wash the nozzle needle and the nozzle body in the clean diesel fuel. 3. Check that the nozzle needle moves smoothly inside the nozzle body. If the nozzle does not move smoothly, it must be repaired (See “Nozzle Lapping Procedure”) or replaced nozzle assembly.
3. Remove the nozzle holder pin, spacer,spring seat, spring and adjusting shim from the nozzle holder. Keep the adjusting shims in the original groups to hold the initial shim to the nozzle spring combination. 4. Remove the nozzle holder body.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 9
ENGINE FUEL
6C–9
Spring
Nozzle Lapping Procedure
Inspect the spring for any wear, fell and corrosion.
1. Lap the nozzle needle (1), and the nozzle body (2) by applying a compound of oxidized chrome with animal oil. NOTE: Do not apply an excessive amount of the oxidized chrome with animal oil compound to the injection needle valve seat area. 2. Carefully wash the needle valve and the nozzle body in clean diesel fuel after lapping.
3
040EY00033
Nozzle Body and Needle Valve Check the nozzle body and the needle valve for damage and deformation. The nozzle and body assembly must be replaced if either of these two conditions are discovered during inspection. NOTE: New nozzles must be cleaned in a solvent to remove protective coating. The nozzle body and needle must always be replaced as an assembly.
2
1
040EY00034
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 10
6C–10
ENGINE FUEL
Reassembly
5
4 6
3 2
7 8 9 10
1
040EY00032
Legend (1) Retainer nut (2) Nozzle (3) Nozzle holder pin (4) Spring seat (5) Gasket
(6) (7) (8) (9) (10)
Nozzle holder body Adjusting shim Spring Pin Spacer
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 11
ENGINE FUEL 1. Install the locating pin to the nozzle holder body. 2. Install the adjusting shim, spring and spring seat into the nozzle holder body. 3. Install the spacer to the nozzle holder body over the locating pin. 4. Install the locating pin to the nozzle. 5. Install the nozzle to the nozzle holder.
6C–11
Adjustment of Injection Nozzle Opening Pressure After reassembling the injection nozzle, recheck the opening pressure and spray condition. With the nozzle holder set to the nozzle tester, adjust the pressure with an adjusting shim so that the pressure becomes equal to the specified injection nozzle opening pressure. Injection nozzle opening pressure: 20.1 MPa (2920 psi) An adjusting shim of 0.007 mm (0.0003 in.) allows the press to change by about 100 kPa (14.2 psi). The adjusting shim thickness calculation method as follows. WARNING: The test fluid from the injection nozzle tester will spraying out of the injection nozzle under great pressure. It can easily puncture a person’s skin. Keep your hands away from the injection nozzle at all times. The adjusting shim thickness calculation method. P × π/4 × (A2 – B2) = Additional shim thickness (mm) C × 100
6. Install the retaining nut • Clamp the injection nozzle holder in a vice. • Tighten the retaining nut to the specified torque. Torque: 93 N·m (9.5 kgm)
7. Install the new gasket to the nozzle holder.
P (kPa)
= (Target injection nozzle opening pressure – Indicated value (pressure) of nozzle tester)
A (cm)
= Needle diameter.
0.6 cm
B (cm)
= Sheet diameter.
0.3 cm
C (N/mm) = Spring constant.
264.0 N/mm
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 12
6C–12
ENGINE FUEL
Adjusting Shims After calculates shim thickness to select shims from below list. mm Thickness
Part number
0.50
5-15339-007-0
0.52
5-15339-018-0
0.54
5-15339-019-0
0.56
5-15339-020-0
0.58
5-15339-021-0
0.60
5-15339-008-0
0.70
5-15339-009-0
0.80
5-15339-010-0
0.90
5-15339-011-0
1.00
5-15339-012-0
0.10
8-94128-982-0
0.20
8-94128-983-0
0.30
8-94128-984-0
0.40
8-94128-985-0
Spray Pattern Check the spray condition to shown in the illustration. If the spray conditions is not suitable pattern, the injection nozzle must be replaced or readjusted.
1
2
3
040EY00030
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 13
ENGINE FUEL
Injection Pump Identification 1. It is important that you refer to the injection pump assembly number on the identification plate to determine the applicable calibration data in this section for the injection pump being serviced. 2. In the event this section does not contain calibration data applicable to the injection pump being serviced, contact the nearest manufacturer’s authorized service facility (Bosch Automotive System Corp. or Robert Bosch GMBH). 3. Refer to the Isuzu Injection Pump Assembly Number stamped on the injection pump assembly Identification Plate to order a replacement injection pump.
MADE IN JAPAN
ISUZU part number ZEXEL pump assembly number
F06HV015
6C–13
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 14
6C–14
ENGINE FUEL
Injection Pump Calibration Data Test Conditions Injection nozzle
ZEXEL No. 105780-0000
Injection nozzle holder
ZEXEL NO. 105780-2080
Injection starting pressure
17.2 MPa
Injection line dimensions
Inside diameter = 3 mm Outside diameter = 8 mm Length = 600 mm
Transfer pump pressure
255 kPa
Test diesel fuel
ISO4113 or SAE standard test oil (SAEJ967d)
Fuel temperature
39 – 41°C (109.2 – 114.8°F)
Pump rotation
Clockwise viewed from the drive side
Overflow valve opening pressure
255 kPa (2.6 kg/cm2 / 37.0 psi)
CAUTION: Strictly observe the above test conditions during injection pump fuel injection volume adjustment. Failure to observe the test conditions will result in misadjustment of the injection pump fuel injection volume. Misadjustment of the fuel injection volume will result in serious engine damage.
Injection Timing Pre-stroke
5.6 ± 0.05 mm (0.220 ± 0.01 in.)
Injection order and interval
1–5–3–6–2–4 Plungers are numbered from the drive side.
Tappet clearance
Manually rotate the camshaft several times to make sure that it rotates smoothly.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 15
ENGINE FUEL
6C–15
Injection Volume and Governor Performance Diagram 6WG1TQA Injection Pump Assembly Number ISUZU No.
ZEXEL No.
1-15603-341-0
106671-6440
Remarks
ISUZU No.
ZEXEL No.
Remarks
Injection Volume Control rack position (mm)
Pump speed (min–1)
Injection volume (mm3/1,000 strokes)
Variance (%)
Boost pressure (kPa)
Remarks
11.9
900
221 ± 2
±3
more than 128
Basic
6.6
450
9 ± 3.2
± 13
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 16
6C–16
ENGINE FUEL
Governor Performance
NOTCH ; 5 RACK LIMIT
14.0 RACK POSITION (mm)
IDLING SUB SPRING SET BOOST COMPENSATION STROKE : 0.8±0.1mm B A
E 12.7±0.1 11.9 10.2
D 350
7.2 6.7 6.6 0
GOVERNOR SPRING SET C
250
450 (420)
+25 900 +15 1000±15
PUMP SPEED (min-1)
040EY00039
Speed Control Lever and Stop Lever
※ SPEED LEVER
IDLE~STOP 18 °± 5°
STOP LEVER
°
°± 5
19
°±
13°
22
± 3°
5°
70°±
STOP
°
±5
53°
FULL SPEED
STOP
5°
NORMAL
IDLING
040EY00036
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 17
ENGINE FUEL
Injection Nozzle Holder – Two-Stage Injection Type Nozzle and Holder Specification ITEMS
6WG1
Injection nozzle & holder assembly type
KBL2.4/S, two-spring
Injection nozzle type
Hole
Number of injection nozzle orifices
Eight holes
Orifices diameter Opening pressure
mm (in) MPa
(kg/cm2
/ psi)
0.24 (0.0094) 1st stage 17.7 (180/2,560) 2nd stage 22.1 (225/3,200)
Nozzle needle valve full-lift
mm (in)
0.32 (0.0126)
Nozzle needle valve pre-lift
mm (in)
0.06 (0.0024)
6C–17
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 18
6C–18
ENGINE FUEL
Reassembly and Opening Pressure Adjustment
5 15
7
14 6 8 9
1
10 11
12
2 3 4
13
040H100004
Legend (1) Nozzle holder body (2) shim (First opening pressure adjustment) (3) First spring (4) Spring seat (5) Collar (6) Second spring (7) Push rod
(8) (9) (10) (11) (12) (13) (14) (15)
Shim (Second opening pressure adjustment) Spring seat Lift piece Spacer & pin Nozzle & pin Retaining nut Gasket Eye bolt
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 19
ENGINE FUEL
6C–19
Adjustment Procedure As adjustment of the two-stage injection type nozzle holder is made in hundredths of a millimeter, clean the parts thoroughly in light oil to completely remove any dirt or foreign matter.
1
First nozzle opening pressure adjustment
2
Full needle valve lift confirmation
3
Pre-lift confirmation
Adjust the first nozzle opening pressure using the shim.
Confirm the full needle valve lift in accordance with the closed method.
Confirm pre-lift in accordance with the closed method. CAUTION: If not as specified, replace the nozzle assembly, lift piece, pins and spacer using the nozzle service kit.
4
Second nozzle opening pressure confirmation
Confirm the second nozzle opening pressure in accordance with the closed method.
5
Second nozzle opening pressure adjustment
Adjust the second nozzle opening pressure using the shim.
6
Final inspection
Confirm the condition of the fuel spray with the nozzle and nozzle holder assembled.
Adjustment Service Data Nozzle needle valve full-lift
0.32 mm (0.0126 in)
Nozzle needle valve pre-lift
0.06 mm (0.0024 in) at 18.7 MPa (190 kg/cm2, 2,700 psi)
Nozzle pressure
1st stage
17.7 MPa (180 kg/cm2, 2,560 psi)
2nd stage
23.0 – 24.0 MPa (235 – 245 kg/cm2, 3,340 – 3,480 psi) at lift 0.11 mm (0.0043 in) = (pre lift + 0.05 mm (0.0020 in))
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 20
6C–20
ENGINE FUEL
First Nozzle Opening Pressure Adjustment 1. Clamp the nozzle holder in a vise.
3. Install the collar, second spring, shim, spring seat and pushrod in the nozzle holder.
Second nozzle opening pressure adjusting shim
Nozzle holder body
Push rod
Second spring Collar Spring seat
040MV017 040MV015
2. Install the shim, first spring and spring seat in the nozzle holder.
4. Install the pins, lift piece and spacer in the nozzle holder.
Spacer
Spring seat
Lift piece
First spring
Pin
First nozzle opening pressure adjusting shim
040MV018 040MV016
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 21
ENGINE FUEL
6C–21
8. Tighten the adjustment retaining nut to the specified torque. Torque: 34 N·m (3.5 kg·m / 25 lb·ft)
5. Install the pins in the spacer. 6. Install the nozzle on the spacer.
Nozzle Torque wrench Pin
Retaining nut (special tool)
040MV019
7. Hand-tighten the adjustment retaining nut together with the gasket to the nozzle holder. Retaining nut: 157892-4000 (★Bosch AS) 5-86777-145-0 (ISUZU) Gasket: 157892-1500 (★Bosch AS) 5-86777-146-0 (ISUZU) (★Bosch Automotive Systems Corporation)
040MV014-1
9. Set the nozzle holder to the nozzle tester. 10. Operate the nozzle tester and measure the first nozzle opening pressure. 11. If the first nozzle opening pressure is not as specified, disassemble the nozzle holder and replace the shim until the pressure is as specified.
Nozzle holder Retaining nut (Special tool)
Nozzle tester
Nozzle
Gasket
040MV030 040MV010
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 22
6C–22
ENGINE FUEL
CAUTION: • Use a micrometer to measure shim thickness. • Use some combination of 3 adjusting shims to adjust the pressure. • First nozzle opening pressure adjusting shims mm (in) Part No.
Thickness
115349-1120
0.40 (0.0157)
115349-1130
0.50 (0.0197)
115349-1140
0.52 (0.0205)
115349-1150
0.54 (0.0213)
115349-1160
0.56 (0.0220)
115349-1170
0.58 (0.0228)
115349-1180
0.60 (0.0236)
115349-1190
0.70 (0.0276)
Full needle valve lift confirmation 1. Install the gasket and plug on the adjustment retaining nut. Gasket: 026508-1140 (Bosch AS) 894227-6020 (ISUZU) Plug: 157892-1600 (Bosch AS) 5-86777-141-0 (ISUZU)
Plug
Thickness
Gasket
040MV013
2. Position the nozzle holder with the nozzle facing down and install the dial gauge holder on the nozzle holder. Dial gauge holder: 157892-5000 (Bosch AS) 586777-1420 (ISUZU)
φ3.8mm φ8.9mm
040MY00023
Holder (special tool)
040MV012
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 23
ENGINE FUEL 3. Install the nut on the dial gauge holder. Nut: 157892-1000 (Bosch AS) 586777-143-0 (ISUZU)
6C–23
5. Secure the dial gauge to the nozzle holder using the nut so that the pin contacts the tip of the first spring seat. CAUTION: • Secure the dial gauge so that a stroke of 2 mm (0.0787 in) can be measured. • Do not over-tighten the nut as the dial gauge shaft may jam. (Confirm from the dial gauge that the shaft moves smoothly.)
Nut (special tool) Holder (special tool)
Dial gauge
Nut Holder Pin
040MV011
4. Install the pin to the dial gauge. Note: The lengths of the pins do not include the threaded portions. Pin (l = 86 mm): 157892-6400 (Bosch AS) Dial gauge: 157892-3800 (Bosch AS) (General type)
Dial gauge
Nozzle holder
First spring seat
Pin
040MV009
040MV029
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 24
6C–24
ENGINE FUEL
6. Set the nozzle holder to the nozzle tester and put needle to zero on the dial gauge. 7. Operate the nozzle tester to bleed any air from inside the retaining nut and to confirm that no fuel leaks.
Nozzle holder
Pre-lift confirmation 1. With the needle valve at full lift, release the nozzle tester handle. Note: The in-line pressure will decrease and needle valve lift (as indicated on the dial gauge) will also decrease a little.
Nozzle tester
200
300
100
0
400
kgf／cm2
500
Pressure gauge
040MV030
Needle Valve lift
040MV007
(mm) L Needle Valve lift
8. Operate the nozzle tester and increase the in-line pressure to 34.3 – 44.1 MPa ( 350 – 450 kg/cm2 / 4977 – 6399 psi) so that the nozzle’s needle valve moves through its full lift. Record full lift ‘L’. (Rear dial gauge) Nozzle Holder Assy: 115300-3722 (ISUZU) Nozzle full lift: 0.32 ± 0.02 mm (0.0126 ± 0.0008 in) Note: The above operation is used to determine whether the nozzle seat is worn and whether the nozzle assembly is in good condition.
17.7 22.1 In line pressure
L
(MPa)
040H100006
0
First nozzle 34.3∼44.1MPa opening pressure {350∼450kgf/cm 2 } In line pressure
040MV008
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 25
ENGINE FUEL 2. Read the needle valve lift ‘l’ from the dial gauge indication (once the needle valve has descended when the second spring has stopped operating). Refer to the pre-lift measuring point for ‘l’. Pre-lift measuring point: Read the dial gauge at first nozzle opening pressure +approx 1 MPa (10 kg/cm2). Pre-lift: 0.06 m (0.0024 in.) at pressure 18.6 MPa (190 kg/cm2/2700 psi) Note: This point can be found while the pressure is decreasing.
6C–25
4. If pre-lift is not as specified, replace the pins, lift piece, spacer and nozzle assembly as a set with the service kit. Service kit; Bosch AS: 105019-2310 Service kit; ISUZU: 115319-007-1
Lift piece
Pin Spacer
Capsule L Needle valve lift
Measuring point of prelift
Nozzle assembly
0
040HV031
First nozzle opening pressure
Second nozzle opening pressure confirmation 040H100007
Pushrod
Second spring
Spring seat
Adjusting shim
1. After pre-lift confirmation, operate the nozzle tester to increase in-line pressure to 34.3 – 44.1 MPa (350 – 450 kg/cm2 / 4977 – 6399 psi) so that the nozzle’s needle valve moves through its full lift.
Nozzle holder
Nozzle tester
Spacer Lift piece Needle valve
040MV005
3. Confirm that pre-lift ‘l’ is as specified.
040MV030
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 26
6C–26
ENGINE FUEL
2. Release the nozzle tester handle so that in-line pressure decreases. Note: The in-line pressure will decrease and needle valve lift (as indicated on the dial gauge) will also decrease a little.
If the second nozzle opening pressure is not as specified, disassemble the nozzle from the nozzle holder and replace the shim until the pressure is as specified. CAUTION: • Because the second opening pressure changes when the first opening pressure changes, the second opening pressure must be adjusted when the first opening pressure changes. • Use some combination of 3 adjusting shims to adjust the pressure. • Use a micrometer to measure shim thickness.
L Needle valve lift(mm)
Second nozzle opening pressure adjustment
+0.05
0 Second nozzle opening pressure
34.3-44.1MPa (350-450kg/cm2) Second nozzle opening pressure adjusting shim
Push rod
Second spring 040H100008
Collar
3. Then, read the pressure gauge indication (second nozzle opening pressure) the instant that the dial gauge indicates the specified needle valve lift (usually pre-lift l + 0.05 mm (0.002 in)). Second nozzle opening pressure: 23.0 - 24.0 MPa (235 - 240 kg/cm2/3340 - 3480 psi) at lift 0.11 mm (0.0043 in)
Spring seat
040MV017
• Second nozzle opening pressure adjusting shims mm (in)
When needle valve lift is + 0.05mm
90
10
80 20 70 30 60 50
40 Full needle valve lift
Dial gauge
040H100005
Part No.
Thickness
115349-1200
0.40 (0.0157)
115349-1210
0.50 (0.0197)
115349-1220
0.52 (0.0205)
115349-1230
0.54 (0.0213)
115349-1240
0.56 (0.0220)
115349-1250
0.58 (0.0228)
115349-1260
0.60 (0.0236)
115349-1270
0.70 (0.0276)
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 27
ENGINE FUEL
6C–27
Thickness
2. Remove the adjustment retaining nut and gasket. 3. Install the original retaining nut, confirm that the pins are inserted fully into the nozzle, and then handtighten the retaining nut. Then, tighten the original retaining nut to the specified torque. Torque: 69 N·m (7.0 kg·m / 51 lb·ft)
φ4.8mm Torque wrench φ9.9mm
Retaining nut (special tool)
040MY00024
Final inspection 1. Remove the dial gauge, nut and dial gauge holder.
040MV014-1
4. Set the nozzle holder to the nozzle tester and check first nozzle opening pressure, spray condition, seat oil tightness and each part for oil leaks. 5. When replacing the nozzle, replace the nozzle, lift piece, pins and spacer as a set with the nozzle service kit.
Dial gauge
Nut
CAUTION: Pre-lift will not be as specified if only the nozzle is replaced.
Dial gauge holder
040MV028
Nozzle holder
Nozzle tester
040MV030
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 28
MEMO
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 1
STARTING AND CHARGING
6D3–1
STARTING AND CHARGING CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . 6D3-1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-2 General Description. . . . . . . . . . . . . . . . . . . . . . 6D3-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-5 Inspection and Repair . . . . . . . . . . . . . . . . . . . . 6D3-7 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-8
Service precaution CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-11 General Description. . . . . . . . . . . . . . . . . . . . . 6D3-11 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-14 Inspection and Repair . . . . . . . . . . . . . . . . . . . 6D3-16 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-18
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 2
6D3–2
STARTING AND CHARGING
Alternator General Description
5
6
4
7 8
3
2
1
9 10
060EY00002
Legend (1) Rear bracket (2) IC regulator (3) Bearing (4) Rectifier (5) Stator
This alternator is a brushless unit. The main components are the rotor, stator, rectifier assembly, front bracket, rear bracket, IC regulator, bearings and pulley. The movable parts in the assembly are the rotor and pulley. The field coil is fixed to the rear bracket. To rectify 3-phase alternator in the stator coil to direct current, 6 main diodes and 2 additional diodes are used: 3 main diodes are called “positive diode”, while the others are called “negative” diode. Also, 3 small diodes called “diode trio” are used and the field current is supplied from these diodes.
(6) (7) (8) (9) (10)
Rotor Bearing Pulley Front bracket Field coil assembly
This alternator has three terminals; a terminal-B (DC power output terminal), terminal-L and terminal-R. Since terminal-L is connected to the field coil, it is an input terminal of initial exciting current together with terminal-R until the alternator begins to generate. Also, it has another function of a voltage output terminal (current output capacity is only one ampere). When terminal-L voltage reaches to battery voltage it turns the indicator lamp off. The bearings are sealed so that no periodic lubrication is required. The IC regulator is a solid state unit so that it can be serviced as an assembly.
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 3
STARTING AND CHARGING
6D3–3
MITSUBISHI IDENTIFICATION PLATE
Identification The alternator identification plate is attached to the alternator rear bracket. The ISUZU part number, the manufacturer’s code number, and other important information are stamped on the plate. Refer to the identification plate together with the “Main Data and Specifications” Tables and accompanying charts in this Manual when requesting service assistance from a qualified electrical repair shop. If you are unable to locate the data applicable to your engine, please contact ISUZU MOTORS LIMITED through your machine supplier.
A B C
D
E
A: B: C: D: E:
Isuzu part number Manufacturer’s short type name System voltage output Manufacturer’s lot no. Bar code
Charging Circuit
B
ADDITIONAL DIODES
INDICATOR LAMP
DIODE TRIO STATOR COIL
L L R
R
KEY SWITCH
F
BATTERY (24V) E FIELD COIL IC REGULATOR ALTERNATOR
E
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 4
6D3–4
STARTING AND CHARGING
Main Data and Specifications Isuzu Part No.
1-81200-5901
Manufacturer’s code No. (MITSUBISHI)
A004T05485
Rated voltage
(V)
24
Rated output
(A)
50
Rated speed
(min–1)
Rated output at r.p.m No-load output at 0 Amp.
(Amp./Volt/min–1) (Volt/min–1)
Direction of rotation as viewed from pulley side
50/27/5000 24/900 Clockwise
Polarity grounded Pulley diameter
5000
(–) mm (in.)
80 (3.15)
(Ω)
4.5 – 5.2
Coil resistance at 20°C Field coil Regulator’s applicable Isuzu part No.
1-81260-0170
Manufacturer’s code No.
A866X38282
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 5
STARTING AND CHARGING
6D3–5
Disassembly
2 3
1 4
7 5 6
9
8
060EY00004
Legend (1) IC regulator (2) Terminal stud (3) Side entry terminal (Terminal B) (4) Rectifier assembly (5) Cap
(6) (7) (8) (9)
Nut Side entry terminal Terminal stud Tube
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 6
6D3–6
STARTING AND CHARGING
NOTE: Before disassembling alternator, be sure to put match marks at two locations (front bracket and rear bracket) so that any possible mistake can be avoided. 1. Remove four through bolts. Pry between stator and front bracket with the blade of a screwdriver. Carefully separate the front bracket, pulley and rotor assembly away from the stator and rear bracket assembly. NOTE: Do not insert screwdriver too deep, or the stator coil will be damaged. 2. Cramp the rotor in a vice, being careful not to distort the rotor poles (1), and remove the pulley securing nut, pulley, fan, spacer and front bracket. NOTE: When a vice or tool is used to secure the rotor, be sure to hold the location “A”. Do not hold the location “B” as it does not have enough structural strength.
1
2
3
060EY00003
Ｂ
Ａ
Ａ 1
060EY00030
3. If necessary to remove the front bracket bearing, remove four retainer screws and press the bearing out of bracket with a suitable socket. NOTE: Do not remove bearing for normal service. If the bearing is removed, the bearing must be replaced. 4. If necessary to remove the rotor bearing, remove the bearing with a normal bearing puller. NOTE: Do not remove bearing for normal service. If bearing is removed, the bearing must be replaced. 5. To move the coil assembly from the rear bracket; first, remove two screws (2) that hold the terminal plate of coil to the IC regulator. If the screws (2) are removed before removing screws (3) that hold the coil assembly to the rear bracket, the terminal plate may be broken. While being careful not to damage the terminal plate, hold the coil assembly by hand. Then, remove the coil assembly by removing the screw (3). 6. Disconnect the connector (1).
7. Remove the cap and nut from the terminal stud on the rectifier. Pry between the rear bracket and side entry terminal, and remove the side entry terminal. The tube will remain in the bracket. NOTE: Do not loss the tube. 8. Remove the rectifier retaining screw and two IC regulator retaining screws. Separate the stator and rectifier assemblies, as a unit, from the rear bracket. Then remove IC regulator. 9. Unsolder four stator coil leads and remove the stator from the rectifier. NOTE: High temperature solder (Melting point of 230°C) is used to secure stator coil leads to rectifier terminals. Disconnect quickly, use a 180 – 280 watts soldering iron more than about 5 seconds because the diode may be damaged if it is overheated.
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 7
STARTING AND CHARGING
6D3–7
Rotor
Inspections and Repair Stator Visually inspect the stator for damage, a loose connection, or discolored windings. 1. Check for continuity between each pair of the stator coil leads (1) using a circuit tester. Replace the stator if there is no continuity.
1. Check the bearing for any scraping noise, roughness, or grease leakage (If the amount of grease leakage is very small, wipe it away.), and replace it as necessary. It is more effective to check with the bearing fitted into the rotor shaft than to check the bearing itself (with no parts mounted).
Coil Assembly 1. Measure the coil resistance between both terminals (1) on the terminal plate (2) using an ohmmeter. If it is not within the specification, replace the coil assembly. 1 2
1
060EY00007
2. Check for continuity between the stator coil leads and core using a circuit tester. Replace the stator if there is no continuity.
060EY00005
Rectifier Assembly 1
2
060EY00008
1. Check positive diodes and positive side additional diode for continuity between the positive heat sink (2) and each of four diodes terminals (1) with a circuit tester. If there is continuity in both directions, the diode is shorted. Replace the rectifier assembly. If there is no continuity in both directions, the diode is open-circuit. Replace the rectifier assembly. 2. Check negative diodes and negative side additional diode for continuity between the negative heat sink (3) and each of four diodes terminals (1) with a circuit tester. If there is continuity in both directions, the diode is shorted. Replace the rectifier assembly. If there is no continuity in both directions, the diode is open-circuit. Replace the rectifier assembly.
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 8
6D3–8
STARTING AND CHARGING
3. Using a circuit tester, check the diode trio for continuity in both directions. If there is either continuity or open circuit in both directions, the diode trio is defective. Replace the rectifier assembly.
1
2
3. Tightening torque. • Pulley securing nut. : 147 N·m • Through bolts. : 5.1 N·m • Bearing retainer screws. : 3.6 N·m • Coil assembly retaining screws. : 3.6 N·m • Rectifier retaining screw. : 3.6 N·m • Regulator retaining screws. : 3.4 N·m • Nut for stud bolt. : 8.8 N·m 4. To assemble the rear bracket / stator assembly and front bracket / rotor assembly. • Since the rotor bearing and rear bracket fitting is tight, before installing the rotor into the rear bracket assembly, heat the area around the bearing box of the rear bracket to 50 to 60°C. • After the alternator has been completely assembled, rotate the pulley slowly by hand to be sure that the rotor turns smoothly.
Bench Test
3
To check the alternator on a test bench, proceed as follows: 060EY00006
Front bracket bearing Check the bearing for any scraping noise, roughness, or grease leakage (If the amount of leakage is very small, wipe it away.) and replace it as necessary. It is more effective to check with the bearing fitted into the front bracket than to check the bearing itself (with no parts mounted).
Regulator The regulator cannot be checked with a circuit tester. After the alternator has been completely assembly, the unit should be tested to make certain it will control the alternator voltage properly.
Reassembly To reassemble the alternator, follow the reverse of disassembling procedure, and observe the following precautions: 1. Lubrication is not required. Both bearing are prelubricated. NOTE: For the rotor bearing with resin bands, grease should not be applied. Remove oils completely to prevent creep of the bearing if found on the bearing box. 2. High temperature solder (Melting point of 230°C) should be used. Solder quickly, use a 180 – 270 watts soldering iron no more than about 5 seconds because the rectifier may be damaged if it is overheated.
Regulated Voltage Test 1. Make connections as shown in the illustration. Use a 0 – 100 ampere scale ammeter and a 0 – 30 volt scale voltmeter. Use a variable load resistor of capacity 0 – 50 ampere minimum. 2. Close switch 1. Open switch 2. Lamp should light. If the lamp does not light, check voltage at terminal-L. When the voltage is nearly to battery voltage, check the alternator. When the voltage is low, the lamp or relational wiring is open circuit. 3. Slowly increase the alternator speed. Be sure the lamp goes out until the alternator speed reaches to approx. 1300 min–1. Observe the voltage. If the voltage is uncontrolled with speed and increases above 30V, a defective IC regulator is suspected. If the voltage does not increase higher than battery voltage, this means alternator does not generate. Recheck the alternator. 4. Increase the alternator speed to approx. 500 min–1 and take the ammeter reading. If the ammeter reading is 5A or less, take the voltmeter reading without changing the alternator speed (approx. 500 min–1). The reading is the regulated voltage. If the ammeter reading is more than 5A, continue to charge battery until the reading falls to less than 5A
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 9
STARTING AND CHARGING or replace the battery with a fully charged one. If the regulated voltage does not meet the specified limits, it will have to be replaced.
AMMETER
SWITCH 1
A
LAMP (24V) B V
(3W MAX.)
L
ALTERNATOR
SWITCH 2
R
VOLTMETER
BATTERY (24V) LOAD RESISTOR
Current Output Test The current output test determines whether or not alternator is capable of supplying its rated current output. 1. After the regulated voltage test is completed, reduce the alternator revolution. 2. Close the switch 1. Be sure the lamp lights. 3. Set the load resistor in maximum resistance value position (Minimum current draw) and close the switch 2. 4. Increase and hold the alternator speed to 5000 min–1 and adjust the load resistor to obtain maximum current output. Run the alternator for 15 minutes at this speed and output to rise in the alternator temperature. After 15 minutes rotate the alternator to specified speed (2500 and 5000 min–1) and adjust the load resistor to obtain maximum current output. The output should be within the specified limits. If the output is less than the specified limits, recheck the alternator.
6D3–9
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 10
6D3–10
STARTING AND CHARGING
Troubleshooting Condition No output
Low output
Overcharging Unstable current
Abnormal noise
Possible Cause
Correction
Disconnected terminal connection
Repair terminal connection
Open or short system circuit
Repair the system circuit
Open field coil
Replace the filed coil
Defective diode
Replace the diode
Defective IC regulator
Replace the regulator
Loosened terminal connection
Retighten the terminal connection
Loosened cooling fan belt
Adjust the belt tension
Defective diode
Replace the diode
Short field coil
Replace the field coil
Short stator coil
Replace the stator coil
Defective regulator
Replace the regulator
Defective battery
Replace the battery
Poor terminal contact
Repair the terminal contact
Defective regulator
Replace the regulator
Defective battery
Replace the battery
Poor terminal contact
Repair the terminal contact
Loosened cooling fan belt
Adjust the belt tension
Short field coil
Replace the field coil
Short stator coil
Replace the stator coil
Intermittent contact in wiring
Repair the wiring
Poor terminal contact
Repair the terminal contact
Defective regulator
Replace the regulator
Improper alternator installation
Correct the installation
Defective bearing
Replace the bearing
Contact between the rotor core and stator core
Replace the rotor core or stator core
Defective diode
Replace the diode
Short stator coil
Replace the stator coil
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 11
STARTING AND CHARGING
6D3–11
Starter Motor General Description
060EY00009
The starter motor adapts the planetary gears in reduction gear mechanism.
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 12
6D3–12
STARTING AND CHARGING
Main Data and Specifiction Isuzu Part No.
1-81100-3411
Mitsubishi code No.
M009T80971
Rated voltage
V
24
Rated output
kW
7.0
Rating
Sec
30
Direction of rotation (Viewed from the pinion side) Terminal voltage (No. Load) Minimum current (No. Load) Starter motor minimum operating speed (No. Load)
Clockwise V
23
A
85
min–1
3300
Pinion gear Modules
3.5
Number of teeth
11
Outside diameter
mm (in.)
48.9 (1.93)
mm (in.)
105 (4.13)
Standard
mm (in.)
18 (0.71)
Limit
mm (in.)
11 (0.43)
Yoke outside diameter Brush length
Brush spring standard fitting load
N
29 – 39
Commutator Outside diameter Standard
mm (in.)
32 (1.26)
Limit
mm (in.)
31.4 (1.23)
Standard
mm (in.)
0.5 (0.02)
Limit
mm (in.)
0.2 (0.008)
mm (in.)
0.5 – 2.0 (0.0197 – 0.079)
Depth of undercut mica
Pinion projection Standard
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 13
STARTING AND CHARGING
Identification MITSUBISHI starter motor is identified by the name plate attached to the yoke. (Illustration) (1) Manufacturer’s type (2) Isuzu part number (3) Bar code NOTE: Always check the identification number before beginning a service operation. Applicable service data will vary according to the identification number. Use of the wrong service data will result in starter damage.
MITSUBISHI ELECTRIC CORP, JAPAN
TYPE NO.
24V
1 2 3
060EY00012
6D3–13
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 14
6D3–14
STARTING AND CHARGING
Disassembly 8
6
5
20 7 19
4 3 1
2 27
9 18
13 17 16 15 14
12
26
11 25 21 10
24
22
23 060EY00029
Legend (1) Snap ring (2) Stop ring (3) Pinion (4) Pinion spring (5) Screw (6) Pinion case (7) Bearing (8) Magnetic switch (9) Lever (10) Clutch (11) Internal gear (12) Washer (13) E-type stop ring
(14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27)
Gear shaft Planetary gear Ball Gasekt Plate Armature Bearing Gasket Yoke Brush Gasket Brush holder Rear cover Through bolt
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 15
STARTING AND CHARGING NOTE: • When disassembling the starter motor, to make reassembling easier, mark to match the magnetic switch and yoke. • First remove the pinion, or the pinion can not be disassembled when proceeding disassembly without disassembling the pinion.
6D3–15
5 4 3
6
2 1
1. Remove the pinion. • Remove the pinion at the location travelling to cranking position.
SW 1 SW 2
060EY00015
Legend (1) Pinion (2) Clutch shaft (3) Snap ring (4) Stop ring (5) Pipe (6) Pinion spring
24 V
060EY00014
• Connect the starter motor to the battery. When closing the switch SW1 and SW2, the pinion travels to cranking position and the armature rotates. Then opening the switch SW2, the armature stops to rotate. NOTE: Remove the pinion in 10 seconds as the armature generates heat with being energized. • Hold the suitable pipe on the stop ring. Hit the pipe with a hammer, and remove and expose the stop ring, then remove the snap ring, stop ring, pinion, and pinion spring. Discard the snap ring.
2. Remove the magnetic switch. 3. Loosen the brush holder fixing screw and the through bolt. Remove the rear bracket and gasket. Discard the gasket. 4. Hold the socket (major diameter 32 mm) on the armature commutator and remove the yoke assembly, sliding the brush onto the socket. • Removing this way makes reassembling easier. 5. Pull up the brush spring and remove the brush. 6. Remove the brush holder after removing the brush. 7. Pull out the armature from the planetary gear and remove the bearing with a puller. Be careful not to lose the ball. 8. Remove the plate and gasket. 9. Remove the planetary gears. 10. Put the internal gear, gear shaft overrunning clutch, and lever together, then remove them from the front bracket. 11. Remove the lever. • Remember the lever installation direction. 12. Remove the E-type stop ring. Then remove the overrunning clutch from the gear shaft assembly. Discard the E-type stop ring. 13. Remove the internal gear and washer for adjusting the gear shaft end play together.
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 16
6D3–16
STARTING AND CHARGING
Inspection and Repair Armature 1. Use a circuit tester to measure the armature for continuity. Step 1. Hold the circuit tester probes against two commutator segments. Step 2. Repeat step 1 at different segment of the commutator. There should be continuity between all segment of the commutator.
3. Measure the commutator outside diameter. If the measurement is less than limit, replace the commutator assembly. Standard: 32 mm Limit: 31.4 mm
2. Use a circuit tester to measure the armature for grounding. Step 1. Hold one probe of the circuit tester against the commutator segment. Step 2. Hold the other probe of the circuit tester against the armature shaft. If the circuit tester indicates continuity, the armature is grounded, replace the armature assembly.
4. Inspect the commutator mica segment for excessive wear. If the mica segment depth is less than the limit, replace the commutator. Measure the mica segment depth. Standard: 0.5 mm Limit: 0.2 mm
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 17
STARTING AND CHARGING
060EY00016
5. Inspect the gear for damage or wear. Replace the armature if any damage is discovered. 6. Inspect the bearing for abnormal noise, rattling or grease leakage. Replace the bearing if any malfunction is discovered.
Field Coil 1. Use a circuit tester to check for any broken winding. A broken wire is indicated if no continuity is found between the field coil and lead wire. Replace the field coil.
060EY00018
2. Check for continuity between the field coil and the yoke. Repair or replace the yoke assembly if continuity is found.
6D3–17
060EY00017
Brush and Brush Holder 1. Measure the brush length. If the measured value exceeds the limit, replace the brush and/or yoke. Standard: 18 mm Limit: 11 mm 2. Visually check the brush spring for weakness and rusting. Replace the brush spring if it is weak or rusted. Use a spring balancer to measure the spring tension. If the measured value exceeds the limit, replace the brush spring. Standard: 29 – 39 N Limit: 13.7 N 3. Use a circuit tester to check the brush holder insulation. • Touch one probe the field winding lead wire. • Touch the other probe to the brush. There should be no continuity. If continuity is found, repair or replace the brush holder.
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 18
6D3–18
STARTING AND CHARGING
Front Bracket Check the bearing and oil seal for damage. Replace the front bracket assembly if the malfunction is found.
Internal Gear and Planetary Gear Check for the gear for abnormal wear or damage. Replace the gear if the malfunction is found.
Magnetic Switch Check for continuity across the magnetic terminal-M (1) and body. If no continuity is replace the magnetic switch. Check for continuity across the magnetic terminal-M and terminal-B (3). If continuity is replace the magnetic switch.
switch found, switch found,
060EY00019
Overrunning Clutch and Pinion
2
Check the pinion teeth for excessive wear and damage. Rotate the pinion in the drive direction of starter motor. The pinion should rotate smoothly. Rotate the pinion in the opposite direction. The pinion should lock. Replace the overrunning clutch, if any malfunction is discovered. NOTE: The inside of the overrunning clutch is filled with grease. Do not soak in any liquid cleaner or solvent because grease leakages may result. Wipe the dirt of the overrunning clutch with a clean rag.
1
3
060EY00021
Reassembly
060EY00020
To reassemble the starter motor, follow the reverse of disassembling procedure, and observe the following precautions: 1. Lubricate the following portion: • Surrounding armature bearing (1) : a little • Plunger (2) : a little • Gear shaft spline and sliding part (3) • Clutch shaft (4) • Oil seal (5) • Pinion of overrunning clutch (6) • Sliding part of lever with overrunning clutch (7) • Sleeve bearing and ball (8) • Armature shaft gear, internal gear and planetary gears (9)
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 19
STARTING AND CHARGING
6D3–19
Recommended lubricant type: Portion (1) to (6) : MUL TEMP OA–171 or equivalent Portion (7) to (9) : Molycoat R AG650 or equivalent (Dow Corning)
2 3 4 5 6 1
9
8
7
060EY00010
2. Tightening torque Nut (1) : 20 – 26 N·m Bolt (2) : 4.9 – 8.8 N·m Bolt (3) : 7.8 – 13 N·m Bolt (4) : 2.4 – 4.4 N·m
1
2
4 3
060EY00031
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 20
6D3–20
STARTING AND CHARGING
3. Armature shaft axial play Any adjustment is not required. Install the ball to the top of the armature shaft. 4. Gear shaft axial play Any adjustment is not required. Install the washer between the internal gear and gear shaft.
4 3
5
2 1
5 3
060EY00023
6. Inspect the projection position of the pinion. • After reassembling the starter motor, inspect the projection position of the pinion. Projection position: 0.5 to 2 mm
4 2 1
060EY00022
Legend (1) Overrunning clutch (2) Internal gear (3) Washer (4) E-type stop ring (5) Gear shaft Install the washer, internal gear and overrunning clutch to the gear shaft. Then install the E-type stop ring. 5. Install the pinion to the clutch shaft. • Install the pinion spring (5), pinion (1), and stop ring (4) in sequence to the clutch shaft (2). • Install the snap ring (3) finally. • Then put the stop ring on the snap ring in place.
SW 1
B SW 2
S M 24 V
060EY00024
• Connect the starter motor to the battery. When the switch (1) and (2) are turned on, the pinion will travel forward to the cranking position. At this time, the armature will rotate. Next, stop to rotate the armature with the switch (2) turned off. • Lightly push the head of overrunning clutch shaft by hand and measure the movement (return) of the clutch shaft. If the value is within 0.5 – 2.0 mm, it is the normal position. If it is outside the limit, adjust the packing (0.5 mm ) between the front bracket and magnetic switch, or replace the lever.
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 21
STARTING AND CHARGING
060EY00025
7. Conduct the performance test. • Connect the starter motor as shown in the illustration.
2 A
SW
B S
1 3
M
V
060EY00026
Legend (1) Battery (2) Amperemeter (3) Voltmeter • Measure the speed, current and voltage with the switch turned on. If the value is outside the limit, disassemble and inspect.
6D3–21
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 22
MEMO
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 1
ENGINE LUBRICATION
6G–1
ENGINE LUBRICATION CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . . 6G-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . 6G-2 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-5 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6G-6 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-9
Service precaution CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-12 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-12 Inspection and Repair . . . . . . . . . . . . . . . . . . . . 6G-13 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-14
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 2
6G–2
ENGINE LUBRICATION
General Description Lubricating Oil Flow Lubrication system is of pressure feed circulation system with a gear type oil pump driven by crankshaft. Oil flows from the oil pump though oil cooler to main oil filter for oil cooling and oil cleaning. From the main oil filter it moves to the cylinder block oil gallery and the oil circulates to lubricates the engine parts. Oil jets are installed to the cylinder block main oil gallery in the inside portion of the cylinder block. The jet sprays oil to the inside portions of the pistons for lubrication and cooling.
Oil Pump and Oil Filter The oil pump is of a gear type with a relief valve. The pump is driven by the timing gear. A full flow main oil filter with a highly efficient paper element used. Should the element become clogged with sludge or other foreign material, a by-pass valve open to route the oil directly to the oil gallery. A warning lamp will light at this time to warn the operator of the equipment the oil directly to the oil gallery. The oil is cleaned and delivered to the oil pan.
Oil Cooler The temperature of the engine oil circulating through the lubricating system tends to rise with an accompanying decrease in lubricating efficiency. The oil cooler maintains the oil temperature at the optimum level for effective engine lubrication. The oil cooler consists of the body and the cooling element.
OIL PORT COVER
STRAINER
OIL PUMP
1 690 (7.0/99.5) 2 200 (2.0/28.4) 3 440 (4.5/64.0)
3
OILING JET
IDLE GEAR "C"
INJECTION PUMP
COUPLING or AIR COMPRESSOR
4 Oil thermostat opening temperature °C (°F) 98 (208)
CONNECTING ROD BUSHING
CRANKPIN
IDLE GEAR "B"
TIMING GEAR OILING JET
CYLINDER BODY LEFT HAND OIL GALLERY
CRANKSHAFT JOURNAL
IDLE GEAR "A"
OIL PRESS. UNIT & SWITCH
OIL PAN
RELIEF VALVE
(kg/cm2/psi)
ROCKER ARM & VALVE
ROCKER ARM SHAFT
CAMSHAFT JOURNAL (No2 & 5)
CAMSHAFT JOURNAL (No1,3,4,6)
TURBO CHARGER
CYLINDER HEAD
Relief valve opening pressure kPa
RELIEF VALVE
1
OIL COOLER
OIL THERMOVALVE
4
OIL FILTER RELIEF VALVE
2
REMOTE TYPE OIL FILTER
CYLINDER BODY RIGHT HAND OIL GALLERY
LUBRICANT FLOW CHART
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 3
ENGINE LUBRICATION 6G–3
F06EY00033
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 4
6G–4
ENGINE LUBRICATION
Oil Pump Oil Pump Construction
8
9
3
2 11
10
4
5
6
7 1
051EY00026
Legend (1) Oil pump body (2) Oil pump driven gear (3) Ball (4) Driven gear (5) Drive gear (6) Driven gear
(7) (8) (9) (10) (11)
Oil pump cover Relief valve Split pin Spring seat Spring
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 5
ENGINE LUBRICATION
Disassembly
1 2
8
6 5
9
3
4
11
7
Legend (1) Cover (2) Ball (3) Split pin (4) Spring seat (5) Spring (6) Oil relief valve
10
(7) (8) (9) (10) (11)
Oil pump drive gear Oil pump cover Oil pump driven gear Drive gear shaft Oil pump body
6G–5
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 6
6G–6
ENGINE LUBRICATION
1. Loosen bolts to remove the cover 2. Take out the ball from the oil pump assembly. 3. Remove the split pin, spring seat, spring and oil relief valve.
5. Loosen the fixing bolts to remove the oil pump cover.
6. Take out the oil pump driven gears and drive gear shaft from oil pump body. 4. Use a gear puller to pull out the oil pump drive gear.
Inspection and Repair Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.
Ball Carefully inspect the ball scratches or damage.
Oil Relief Valve Inspect the oil relief valve seat portion damage and spring damage. NOTE: If there is some scratch or damage, the ball and relief valve must be replaced.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 7
ENGINE LUBRICATION
Clearance Between Oil Pump Body and Driven Gear Use a feeler gauge to measure the clearance between the oil pump body and driven gear. Standard: 0.050 – 0.098 mm (0.0020 – 0.0039 in.) Limit: 0.15 mm (0.0059 in.)
Side Clearance Between Oil Pump Cover and Gears Use a feeler gauge to measure the side clearance between the oil pump cover and gears. Standard: 0.040 – 0.094 mm (0.0016 – 0.0037 in.)
6G–7
Oil Pump Gear Shaft Outside Diameter and Clearance between Oil Pump Gear Shaft and Oil Pump Body Use an inside and outside micrometer to measure the oil pump gear shaft outside diameter and oil pump body holes. Oil pump gear shaft diameter Nominal measurement: 20.0 mm (0.7874 in.) Limit: 19.9 mm (0.7835 in.) Clearance between oil pump gear shaft and oil pump body Standard: 0.040 – 0.074 mm (0.0016 – 0.0029 in.) NOTE: If measuring value exceeds, the parts must be replaced.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 8
6G–8
ENGINE LUBRICATION
Interference between Oil Pump Drive Gear and Drive Gear Shaft Measure the inside diameter of oil pump drive gear and outside diameter of drive gear shaft. An interference Standard: 0.019 – 0.047 mm (0.0007 – 0.0019 in.) NOTE: The measuring value exceeds from limit or standard, the parts must be replaced.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 9
ENGINE LUBRICATION
Reassembly
1 2
8
6 5
9
3
4
11
7
Legend (1) Cover (2) Ball (3) Split pin (4) Spring seat (5) Spring (6) Oil relief valve
10
(7) (8) (9) (10) (11)
Oil pump drive gear Oil pump cover Oil pump driven gear Drive gear shaft Oil pump body
6G–9
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 10
6G–10
ENGINE LUBRICATION
1. Apply engine oil to the drive gear (1) and install the drive gear to the oil pump body. 2. Install the oil pump drive gear (2). • Put the oil pump drive gear (2) on the bed of bench press, place the oil pump body with the drive gear shaft. • Use bench press to press the drive gear shaft into the oil pump drive gear as shown in the illustration.
4. Install the oil pump cover. Tighten the bolts to the specified torque. Torque: M8: 17 N·m (1.8 kgm) M10: 39 N·m (4.0 kgm)
1
2
051EY00027
3. Install the oil pump driven gear. • Apply engine oil and install the oil pump driven gear to the oil pump body.
5. Install the oil relief valve, spring and spring seat to the oil pump body. 6. Install the split pin into the oil pump body and lock it. 7. Install the ball 8. Install the cover
051EY00028
NOTE: Make sure the oil pump assembly to move smoothly.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 11
ENGINE LUBRICATION
6G–11
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 12
6G–12
ENGINE LUBRICATION
Oil Cooler Disassembly
1
2 11
10 9 8 4
3
7 6
5
Legend (1) Water guide (2) Oil cooler element (3) Gasket (4) Gasket (5) Oil pipe (6) Gasket
(7) (8) (9) (10) (11)
Oil thermostat Spacer Supporter Seal ring Oil cooler body
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 13
ENGINE LUBRICATION 1. Loosen the bolts to remove the water guide. 2. Loose the nuts to remove the oil cooler element with the gaskets. 3. Loosen the bolts to remove the oil pipe with the gasket.
6G–13
Inspection and Repair Make the necessary adjustments, repairs and part replacements if excessive wear or damage is discovered during inspection.
Oil Cooler Element Inspect the oil cooler element for cracking or damage.
4. Carefully remove the oil thermostat.
Oil Thermostat 1. Inspect for wear or damage on the piston and valve seat. 2. Check for damage or decrease of the spring force. 3. Inspect opening temperature with oil heater. Opening temperature: 98.0°C (208.4°F)
5. Remove the spacer, supporter and seal ring from the oil cooler body.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 14
6G–14
ENGINE LUBRICATION
Reassembly
1
2 11
10 9 8 4
3
7 6
5
Legend (1) Water guide (2) Oil cooler element (3) Gasket (4) Gasket (5) Oil pipe (6) Gasket
(7) (8) (9) (10) (11)
Oil thermostat Spacer Supporter Seal ring Oil cooler body
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ENGINE LUBRICATION
6G–15
1. Be sure seal ring direction shown in the illustration.
1
2 3
050EY00020
Legend (1) Seal ring (2) Rotation stopper (3) Supporter 2. Install the supporter into the oil cooler body. • Align the rotation stopper (2) on the supporter to the oil cooler body as shown in the illustration.
5. Install the oil cooler element with new gaskets. • Apply Three Bond 1208 to grooves to install the gaskets. • Install the gaskets to the oil cooler element. • Reassemble the oil cooler element to the oil cooler body. • Tighten the fixing nuts for oil cooler element to the specified torque. Torque: 25 N·m (2.5 kgm)
2
050EY00021 050EY00022
3. Install the spacer and oil thermostat into the oil cooler body. 4. Install the oil pipe to the oil cooler body. • Install the oil pipe with new gasket to the oil cooler body. • Tighten the oil pipe to the specified torque. Torque: 39 N·m (4.0 kgm)
6. Install the water guide.
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ENGINE INDUCTION
6J–1
ENGINE INDUCTION CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . . 6J-1 Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J-2 General Description . . . . . . . . . . . . . . . . . . . . . . . 6J-2
Service precaution CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J-4 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6J-5 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J-7
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6J–2
ENGINE INDUCTION
Turbocharger General Description
037EY00003
Major turbocharger components consist of the Center Housing and Rotating Assembly (CHRA), the compressor housing, and the turbine housing. Rotating parts include the turbine shaft, the compressor wheel, the shaft bearings, the thrust bearings and the oil seal ring. There parts are supported by the center housing.
The turbocharger increases air intake efficiency, the results in increased engine power, reduced fuel consumption and minimal engine noise. Turbocharger rotating parts operate at very high speeds and temperatures. The parts materials have been carefully selected and machined to extremely high precision.
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ENGINE INDUCTION
Identification
6J–3
Turbocharger Servicing
The turbocharger name plate gives the date of manufacturer and other important information required to identify the unit when service inquiries are made. The turbocharger name plate has the following information stamped on it. Refer to the illustration. (1) Turbocharger specification, production year and production month. Example: VIBU (2) Production date, serial number and production line name. Example: RHC92 (3) Part number assigned is ISUZU MOTORS LIMITED. Example: 1144003281 Part numbers (3) indicate specific designs or configurations.
1. Refer to TROUBLESHOOTING in this Manual to determine whether or not turbocharger repair or overhaul is required. 2. The following procedures should also be performed (either with the turbocharger on the equipment or removed form the equipment but not disassembled) to determine whether or not turbocharger repair or overhaul is required. * Visual checks * Clearance measurements * End play measurements Refer to INSPECTION AND REPAIR. 3. The turbocharger compressor and turbine housing may be removed from the center housing and rotating assembly (CHRA) for further visual inspection. Refer to DISASSEMBLY and REASSEMBLY.
Precaution Turbocharger servicing requires great care and expertise. Faulty turbocharger servicing procedures can result in serious damage to pistons, valves, cylinder liners, and other important engine parts. ISUZU does not recommended the performance of any servicing procedure not specified described in this Manual. Contact your nearest IHI service facility to have the turbocharger assembly repaired or overhauled. The identification plate and assembly number will be required by the service facility. A list of IHI Turbocharger Service Network locations is given at the end of this Section.
Name plate example Turbo Spec.
1
Serial No.RHC9
2
Parts No.
3
037EY00010
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6J–4
ENGINE INDUCTION
Disassembly
2
5
3 4
1
036HT001
Legend (1) Lock plate and bolt (2) Turbine housing (3) Lock plate and bolt
(4) Compressor housing (5) Center housing and rotating assembly
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ENGINE INDUCTION 1. Remove the lock plate and bolt. Apply a setting mark across the center housing and rotating assembly (1), the turbine housing (2), and the compressor housing (3).
6J–5
Take care not to allow foreign material to enter the center housing. NOTE: Disassembly and servicing of the center housing and rotating assembly is not recommended.
Inspection and Repair Make the necessary adjustment, repairs, and part replacements if excessive wear or damage is discovered during inspection. Minor servicing operations are described in this Section. Contact the nearest IHI SERVICE FACILITY for major repairs and maintenance. Refer to IHI SERVICE NETWORK at the end of this Section for the location of your area’s IHI SERVICE FACILITY.
3
1
Turbine shaft End Play
2
037EY00005
1. Set a dial indictor to the turbine shaft end. 2. Apply a force of 11.7 N (1.2 kg/2.6 lb) alternately to the compressor wheel end and the the turbine wheel end. 3. Read the dial indicator. Turbine shaft end play Standard: 0.075 – 0.110 mm (0.0030 – 0.0043 in.) Limit: 0.12 mm (0.0047 in.)
1
3
037EY00006
2. Remove the turbine housing. 3. Remove the lock plate and bolt. 4. Remove the compressor housing. 5. Remove the center housing and rotating assembly. • Loosen the lock plate bolts. • Disassembly the parts. Handle the parts with extreme care. Be particularly careful not to damage the turbine wheel blades and the compressor wheel blades.
Turbine Shaft Bearing Clearance Due to the unique location of the center housing casting internal opening, access to the shaft wheel is difficult. To check the turbine shaft and bearing clearance, a special gauge arm assembly must be fabricated for use with a dial gauge. The assembly can be constructed from any conveniently available material. However, it must conform to the dimensions shown in the illustration.
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6J–6
ENGINE INDUCTION
1. Pass the gauge arm assembly through the oil outlet port and the casting internal opening. The curved end of the gauge arm assembly must make contact with the wheel shaft.
037EY00007
2. Set the dial gauge to “0”. 3. Grasp both ends of the shaft at the wheel hubs. Move the shaft gently back and forth in a motion that is parallel to the plane of the oil drain flange face. Note the dial gauge reading. If the dial gauge reading is above or below the standard range, the center housing and rotating assembly must be replaced. Standard: 0.130 – 0.235 mm (0.0051 – 0.0093 in.) Limit: 0.275 mm (0.0108 in.)
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ENGINE INDUCTION
6J–7
Reassembly
2
5
3 4
1
036HT001
Legend (1) Lock plate and bolt (2) Turbine housing (3) Lock plate and bolt
(4) Compressor housing (5) Center housing and rotating assembly
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6J–8
ENGINE INDUCTION
1. Install the center housing and rotating assembly to the compressor housing. • Apply Threebond 1215 or equivalent to the flange surface of compressor houisng shown in the illustration.
1
3
037EY00006
037EY00008
• Align the setting marks (applied at disassembly) on the center housing and rotating assembly and the compressor housing. Handle the parts with extreme care to avoid damaging the compressor wheel blades. • Apply an anti-seizing agent (LOCTITE ANTISEIZE LUBRICANT or equivalent) to the new bolt threads or the V-band threads. • Install the new lock plate and bolts to the compressor housing. • Tighten the bolts to the specified torque. Torque: 23 N·m (2.3 kgm)
2. Install the turbine housing. • Align the setting marks (applied at disassembly) on the center housing and rotating assembly and the turbine housing. Handle the parts with extreme care to avoid damaging the turbine shaft wheel blades. • Apply an anti-seizing agent (LOCTITE ANTISEIZE LUBRICANT or equivalent) to the bolt. • Tighten the bolt to the specified torque. Torque: 28 N·m (2.85 kgm) • Check that the rotating assembly turns smoothly.
3
1
2
037EY00005
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ENGINE INDUCTION
6J–9
IHI SERVICE NETWORK For inquiries relating to turbochargers, please contact you ISUZU distributor or the nearest IHI Turbocharger Service Facility. HEADQUARTERS ISHIKAWAJIMA HARIMA HEAVY INDUSTRIES CO., LTD. (IHI) General Machinery Division Tokyo Chuo Building 1-6-2 Marunouchi Chiyoda-ku Tokyo 100-0005 JAPAN TEL: 81-(3)-3286-2405 to 2407 (3 lines) FAX: 81-(3)-3286-2430 CHINA IHI BEIJING OFFICE Room 705, China World Trade Center, No. 1 Jian Guo Men Wai Avenue Beijing, People’s Republic of CHINA TEL: 86-(1)-505-4997, 0408 FAX: 86-(1)-505-4350 TLX: 210343 IHIPK CN TAIWAN IHI TAIPEI OFFICE Room 1202, Chia Hsin Building, No. 96 Chung Shan North Road, Section 2, Taipei, TAIWAN TEL: 886-(3)-542-5520, 5521, 5523 FAX: 886-(2)-542-4362 TLX: 11320 IHICO THAILAND IHI BANGKOK OFFICE 8th Floor, Thaniya Building, 62 Silom Road, Bangkok, THAILAND TEL: 66-(2)-236-2390, 7356, 9099 FAX: 66-(2)-236-7340 TLX: 82375 IHICO TH MALAYSIA IHI KUALA LUMPUR OFFICE Letter Box No. 52, 22nd Floor, UBN Tower, 10 Jin. P. Ramlee 50250 Kuala Lumpur, MALYASIA TEL: 60-(3)-232-1255, 1271 FAX: 60-(3)-232-1418 TLX: IHI KLMA 20257 INDONESIA IHI JAKARTA OFFICE 9th Floor, Skyline Building JI, M.H. Thamrin, No. 9, Jakarta, INDONESIA TEL: 62-(21)-32-2147, 390-2211 FAX: 62-(21)-32-3273 TLX: 44175 IHIJKT
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