Hitachi ex5500 excavator service repair manual
- 2. 118W-1-1 SECTION 1 GENERAL INFORMATION —CONTENTS— Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling........................................... W1-1-1 Group 2 Tightening Torque Specification............................... W1-2-1 Torque Chart .......................................... W1-2-2 Piping joint ............................................. W1-2-5
- 4. GENERAL INFORMATION / Precautions for Disassembling and Assembling W1-1-1 PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING Preparations 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 disassem- bling/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 • To prevent dirt from entering, cap or plug the removed pipes. • Before disassembling, clean the exterior of the components and place it on a work bench. • Before disassembling, drain gear oil from the reduction gear. • Be sure to provide appropriate containers for draining fluids. • Use matching marks for easier reassembling. • Be sure to use the specified special tools, when instructed. • If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause(s), then take the appropriate measures to remove it. • Orderly arrange disassembled parts. Mark and tag them as necessary. • Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. • Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. • Measure and record the degree of wear and clearances. • Precautions for Assembling • Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace it. • Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces. • Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing. • Be sure that liquid-gasket-applied surfaces are clean and dry. • If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent. • Utilize matching marks when assembling. • Be sure to use the designated tools to assemble bearings, bushings and oil seals. • Keep a record of the number of tools used for disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no tools are missing.
- 5. GENERAL INFORMATION / Precautions for Disassembling and Assembling W1-1-2 Bleeding Air from Hydraulic System When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and installation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures: • Bleeding Air from Hydraulic Pump IMPORTANT: If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result. Be sure to bleed air before starting the engine. • Remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil. • After the pump housing is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run at slow idle speed. • Slightly loosen the plug to bleed air from the pump housing until hydraulic oil oozes out. • After bleeding all the air, securely tighten the plug. • Bleeding Air from Travel Motor / Swing Motor • With the drain plug / hose on travel motor / swing motor removed, fill the motor case with hydraulic oil. • Bleeding Air from Hydraulic Circuit • After refilling hydraulic oil, start the engine. While operating each cylinder, swing motor and travel motor evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes. • Reposition the front attachment to check hydraulic oil level. • Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary. M104-07-021
- 6. GENERAL INFORMATION / Precautions for Disassembling and Assembling W1-1-3 Floating Seal Precautions 1. In general, replace the floating seal with a new one. If the floating is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. (2) Check the seal ring face (A) for scuffing, scoring, corrosion, deformation or uneven wear. (3) Check O-ring (B) for tears, breaks, deformation or hardening. 2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble. (1) Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air. (2) Clean the floating seal and seal mounting bores, as dust on them tends to enter the floating seal when installing it. (3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring. (4) After installing the floating seal, check that seal ring surface (A) is parallel with idler face (C) by measuring the distances seal ring surface (A) and idler face (C) at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating. W105-03-05-019 W105-03-05-020 W110-03-05-004 A B Incorrect Correct a b b b aa a=b A B Correct Incorrect C
- 7. GENERAL INFORMATION / Precautions for Disassembling and Assembling W1-1-4 Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely. • Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from damage and the lifted load from slip- ping. • Lower the temperature of the lifted load to lower than 100 °C (212 °F). If unavoidably lifting a load with a temperature of 100 °C (212 °F) or more, reduce the load weight. • Do not lift acid or alkali chemicals. • Take care not to allow the sling to become wet. The load may slip. • When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced. • When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force. • Avoid using twisted, bound, connected, or hitched slings. • Do not place any object on twisted or bent slings. (Refer to the right illustration.) • When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions. • Avoid dragging slings on the ground, throwing slings or pushing slings with a metal piece. • When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged. • Store the nylon slings indoors so they won’t dete- riorate with heat, sun light, or chemicals. W102-04-02-016 W105-04-01-008 W162-01-01-009 Correct Eyehole Lifting Method Incorrect Eyehole Lifting Method Bent Sling
- 8. GENERAL INFORMATION / Precautions for Disassembling and Assembling W1-1-5 CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may re- sult. Be sure to visually check the nylon sling for any damage before using. 2. Before using a nylon sling, visually check the ny- lon sling for any damage corresponding to exam- ples 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 W162-01-01-002 W162-01-01-003 W162-01-01-004 W162-01-01-005 W162-01-01-006 W162-01-01-007 W162-01-01-008 Broken Sewing Thread Scuffing Broken Sewing Thread Fuzz Broken Sewing Thread Separation of Belt Broken Sewing Thread Scuffing Scoring Broken Warp Fuzz
- 9. GENERAL INFORMATION / Precautions for Disassembling and Assembling W1-1-6 Maintenance Standard Terminology “Standard” 1. Dimension for parts on a new machine. 2. Dimension of components or assemblies adjusted to specification. Tolerances are indicated as nec- essary. “Allowable Limit” 1. Machine cannot operate normally with the parts exceeding this dimension installed. 2. Repair or adjustment is impossible if this dimen- sion is exceeded. 3. To maintain high machine availability and to save the repair expense, the machine parts should be repaired or replaced before reaching the “Allowable Limit.”
- 10. GENERAL INFORMATION / Tightening Torque W1-2-1 TIGHTENING TORQUE SPECIFICATIONS Torque Descriptions Bolt Dia (mm) Qty Wrench Size (mm) N⋅m kgf⋅m lbf⋅ft 1 Engine cushion rubber mounting bolt 36 12 55 3140 320 2310 2 Engine bracket mounting bolt 30 22 UNC 3/4 24 8 32 46 36 28.6 1420 740 440 145 75 45 1050 540 330 3 Hydraulic oil tank mounting bolt 36 10 55 2400 245 1770 4 Fuel tank mounting bolt 36 22 55 2400 245 1770 5 Pump transmission mounting bolt UNC 1/2 32 19 118 12 87 6 Pump device mounting bolt 24 24 36 690 70 510 7 Fan drive pump mounting bolt 20 8 30 390 40 290 8 Gear pump mounting bolt 12 8 19 88 9 65 9 Control valve mounting nut 20 24 30 390 40 290 10 Swing device mounting bolt 36 56 55 3140 320 2310 11 Swing motor mounting bolt 20 16 30 390 40 290 12 Battery mounting bolt 10 24 17 49 5 36 13 Cab mounting bolt 18 8 27 295 30 215 14 Cab bed mounting bolt 12 50 19 88 9 65 15 Swing bearing mounting bolt 56 142 85 9800 1000 7230 16 Counterweight mounting nut 56 14 85 6860 700 5060 17 Engine bed mounting bolt 36 84 55 3140 320 2310 18 Oil cooler mounting bolt 27 8 41 1370 140 1010 19 Radiator mounting nut 27 8 41 1370 140 1010 20 Fan motor housing mounting bolt 16 8 24 205 21 152 21 Fan motor bracket mounting bolt 12 12 19 88 9 65 22 Travel device mounting bolt 36 56 24 20 24 56 40 46 55 85 36 30 3140 9800 690 390 320 1000 70 40 2310 7230 510 290 23 Travel motor mounting bolt 22 16 32 740 75 540 24 Upper roller mounting bolt 30 24 46 1910 195 1410 25 Lower roller mounting bolt 56 56 85 9800 1000 7230 26 Track pin-retaining bolt 30 156 46 1910 195 1410 27 Side frame mounting bolt 64 80 95 14700 1500 10850 28 Track guard mounting bolt 45 24 22 48 70 36 4710 690 480 70 3470 510 29 Travel motor cover mounting bolt (backhoe) 36 30 55 3140 320 2310 30 Front pin lock bolt (loading shovel) 24 20 27 36 8 10 36 30 19 (Hexagon bar wrench) 930 390 1030 95 40 105 690 290 760 31 Front pin lock bolt (backhoe) 24 20 20 22 36 30 930 390 95 40 690 290 NOTE: 1. Apply lubricant (e.g.white zinc B dis- solved into spindle oil)to bolts and nuts to stabilize friction coefficient of them. 2. Make sure bolt and nut threads are clean before installing. 3. Apply loctite to threads of engine cush- ion rubber mounting bolts, and lower roller mounting bolts before installing.
- 11. GENERAL INFORMATION / Tightening Torque W1-2-2 TORQUE CHART CAUTION: Use tools appropriate for the work to be done. Makeshift tools and proce- dures can create safety hazards. For loosen- ing and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injury. Bolt Types Tighten nuts or bolts correctly to torque specifications. Four different types and grades of bolt are employed. Make sure to employ correct bolts and tighten them correctly when assembling the machine or compo- nents. SA-040 W162-01-01-001 Specified Tightening Torque Chart T Bolt, Socket Bolt H Bolt M BoltBolt Dia. Wrench Size Hexagon Wrench Size N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft M 8 13 6 29.5 3 22 19.5 2 14.5 9.8 1 7.2 M 10 17 8 64 6.5 47 49 5 36 19.5 2 14.5 M 12 19 10 108 11 80 88 9 65 34 3.5 25.5 M 14 22 12 175 18 130 137 14 101 54 5.5 40 M 16 24 14 265 27 195 205 21 152 78 8 58 M 18 27 14 390 40 290 295 30 220 118 12 87 M 20 30 17 540 55 400 390 40 290 167 17 123 M 22 32 17 740 75 540 540 55 400 215 22 159 M 24 36 19 930 95 690 690 70 505 275 28 205 M 27 41 19 1370 140 1010 1030 105 760 390 40 290 M 30 46 22 1910 195 1410 1420 145 1050 540 55 400 M 33 50 24 2550 260 1880 1910 195 1410 740 75 540 M 36 55 27 3140 320 2310 2400 245 1770 930 95 690 Socket BoltHexagon M BoltHexagon H BoltHexagon T Bolt
- 12. GENERAL INFORMATION / Tightening Torque W1-2-3 IMPORTANT: The following items are applied to both fine and coarse pitch threads. 1. Apply lubricant (i. e. white zinc B dissolved Into Spindle oil) to nuts and bolts to reduce their friction coefficients. The plated bolts require no lubri- cant. 2. Torque tolerance is 10 %. 3. Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop suf- ficient tightening force. 4. The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific ap- plication. 5. Make sure that nut and bolt threads are clean before install- ing. Remove dirt or corrosion, if any. Bolt Tightening Order When tightening two or more bolts, tighten them alter- nately, as shown, to ensure even tightening. W105-01-01-003 1 6 4 2 3 Equally tighten upper and lower alternately Tighten diagonally Tighten from center and diagonally 1st to 4th 2nd to 3rd 13 1110 1412 7614 3258 9 5
- 13. GENERAL INFORMATION / Tightening W1-2-4 Service Recommendations for Split Flange IMPORTANT: (1) Be sure to clean and inspect sealing surfaces. Scratches / roughness cause leaks and seal wear. Unevenness causes seal extrusion. If defects cannot be polished out, replace the component. (2) Be sure to use only specified O- rings. Inspect O-rings for any damage. Take care not to file O- ring surfaces. When installing an O-ring into a groove, use grease to hold it in place. (3) Loosely assemble split flange halves. Make sure that the split is centrally located and perpendicular to the port. Hand- tighten the bolts to hold the parts in place. Take care not to pinch the O-ring. (4) Tighten bolts alternately and diagonally, as shown, to ensure even tightening. (5) Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before tighten the others, resulting in damage to O-rings or uneven tightening of bolts. Nut and Bolt Lockings • Lock Plate IMPORTANT: Do not reuse lock plates. Do not try to bend the same point twice. • Cotter Pin IMPORTANT: Do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening. • Lock Wire IMPORTANT: Apply wire to bolts in the bolt- tightening direction, not in the bolt- loosening direction. W105-01-01-015 W105-01-01-016 W105-01-01-008 W105-01-01-009 W105-01-01-010 WRONG WRONG WRONGRIGHTRIGHT Bend along edge sharply Do not bend it roundBend along edge sharply RIGHT Tighten Loosen WRONG WRONGRIGHT RIGHT RIGHT
- 14. GENERAL INFORMATION / Tightening W1-2-5 PIPING JOINT IMPORTANT: The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application. Pipe Thread Connection / Union Joint Tightening Torque Specifications Union Joint Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. IMPORTANT: (1) Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adaptor (1). Be sure to tighten union nut (3) to specifications. (2) Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting /disconnecting. M202-07-051 W105-01-01-017 Wrench Size Tightening Torque Type Union Nut Joint Body N⋅m (kgf⋅m) Ibf⋅ft 30° Male Union Joint 19 22 27 36 41 50 60 70 19 22 27 36 41 50 60 70 59 (6) 98 (10) 118 (12) 235 (24) 295 (30) 490 (50) 670 (68) 980 (100) 43 72 87 134 215 360 490 720 37° Female Union Joint 19 22 27 36 41 50 17 19 22 30, 32 36 46 44 (4.5) 59 (6) 118 (12) 235 (24) 295 (30) 490 (50) 32.5 43 87 134 215 360 NOTE: Tightening torque for the non-union type 37 ° male joint is the same as the 37 ° female union joint. Female Union JointMale Union Joint 30° or 37° 30° or 37° Joint Body 1 4 3 5 2
- 15. GENERAL INFORMATION / Tightening W1-2-6 O-Ring Seal Joint O-ring (6) seats against the end face of adaptor (7) to seal pressure oil. IMPORTANT: (1) Be sure to replace O-ring (6) with a new one when reconnecting. (2) Before tightening union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening union nut (9) with O- ring (6) displaced will damage O- ring (6), resulting in oil leakage. (3) Take care not to damage O-ring groove (8) or sealing face (10). Damage to O-ring (6) will cause oil leakage. (4) If union nut (9) is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-ring (6) with a new one, then tighten union nut (9) after confirming that O-ring (6) is securely seated in place. M104-07-033 Wrench Size Tightening Torque Union Nut Joint Body N⋅m (kgf⋅m) Ibf⋅ft 19 22 27 36 41 50 17 19 22 30, 32 36 46 59 (6) 98 (10) 118 (12) 235 (24) 295 (30) 490 (50) 43 72 87 134 215 360 7 6 9 8 10 Joint Body
- 16. GENERAL INFORMATION / Tightening W1-2-7 Screwed-In Connection IMPORTANT: Many types of screwed-in connec- tions are used for hose connections. Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leakage between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap. • Application Procedure Confirm that the thread surface is clean, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads. Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp. See below for correct tightening torque of each type of low-pressure-hose clamp. W105-01-01-018 Male Tapered Thread Wrench Tightening Torque Joint Body N⋅m (kgf⋅m) Ibf⋅ft 17, 19 19, 22 27, 22 36, 32 41 50 60 70 59 (6) 98 (10) 118 (12) 235 (24) 295 (30) 490 (50) 670 (68) 980 (100) 43 72 87 134 215 360 490 720 W105-01-01-019 M114-07-041 T-Bolt Type Band Clamp: 4.4 N⋅m (0.45 kgf⋅m, 3.25 lbf⋅ft ) Worm Gear Type Band Clamp: 5.9 to 6.9 N⋅m (0.6 to 0.7 kgf⋅m, 4.3 to 5.1 lbf⋅ft ) M114-07-042 M114-07-043 Male Straight ThreadMale Tapered Thread ClearanceExternal Thread Internal Thread Leave one to two pitch threads uncovered PT 30° PF T-Bolt Type Worm Gear Type
- 17. GENERAL INFORMATION / Tightening W1-2-8 Connecting Hose CAUTION: (1) When replacing hoses, be sure to use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leakage, hose rupture or separation of fitting, possibly resulting in a fire on the machine. (2) Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leakage, hose rupture or separation of fitting. Utilize print marks on hoses when installing hoses to prevent hose from being installed kinked. (3) If hoses rub against each other, wear to the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing against each other. Take care that hoses do not come into contact with moving parts or sharp objects. W105-01-01-011 W105-01-01-012 W105-01-01-013 W105-01-01-014 RIGHTWRONG Rubbing Against Each Other RIGHTWRONG RIGHTWRONG Rubbing Clamp Clamp WRONG Rubbing Clamp RIGHT
- 18. GENERAL INFORMATION / Tightening W1-2-9 * REFEREVCE: Major Parts to Be Replaced at Regular Intervals. The parts listed below deteriorate as the machine ages and are worn out or fatigued by repeated loads, resulting in possible severe personal injury and/or machine trouble. The service life of these parts can not be detected through machine operation or visual inspection. Therefore, these parts should be replaced at regular intervals even if no abnormalities are noticed. In case any abnormalities are found on a part at any time re- gardless of its specified replacement interval, imme- diately replace the part. Periodic Replacement Parts Replacement Intervals Fuel hose (Fuel tank to filter) Every 2 years Fuel hose (Fuel tank to injection pump) Every 2 yearsEngine Heater hose (Heater to engine) Every 2 years Pump suction hose Every 2 years Basic Machine Pump delivery hose Every 2 years Motor line hose Every 2 years Cylinder line hose Every 2 years Hydraulic System Front-End Attachment Pilot hose Every 2 years IMPORTANT: Be sure to replace seals, such as O- rings and hose clamp along with re- placing hoses. Each hose has an in- dividual service life. If any abnor- malities are found during the regular interval check and/or maintenance service, be sure to replace with a new one.
- 19. GENERAL INFORMATION / Tightening W1-2-10 (Blank)
- 20. 118W-2-1 SECTION 2 UPPERSTRUCTURE —CONTENTS— Group 1 Cab Windowpane Dimension......................... W2-1-1 Group 2 Pump Device Remove and Install Pump Device........... W2-2-1 Disassemble Pump Transmission........... W2-2-8 Assemble Pump Transmission ............. W2-2-10 Disassemble Main Pump...................... W2-2-12 Assemble Main Pump........................... W2-2-18 Maintenance Standard ......................... W2-2-20 Disassemble Main Pump Regulator...... W2-2-22 Assemble Main Pump Regulator........... W2-2-28 Disassemble Oil Cooler Fan Drive Pump ........................................ W2-2-36 Assemble Oil Cooler Fan Drive Pump ........................................ W2-2-38 Maintenace Standard ........................... W2-2-40 Disassemble Oil Cooler Fan Drive Pump Regulator ........................ W2-2-42 Assemble Oil Cooler Fan Drive Pump Regulator ........................ W2-2-46 Group 3 Control Valve Remove and Install Control Valve........... W2-3-1 Disassemble Control Valve..................... W2-3-4 Assemble Control Valve ....................... W2-3-12 Group 4 Swing Device Remove and Install Swing Device........... W2-4-1 Disassemble Swing Device..................... W2-4-4 Assemble Swing Device ......................... W2-4-8 Disassemble Swing Motor .................... W2-4-12 Assemble Swing Motor ......................... W2-4-14 Maintenance Standard.......................... W2-4-18 Valve Unit Construction ........................ W2-4-20 Group 5 Pilot Valve Remove and Install Front/Swing Pilot Valve ......................... W2-5-1 Remove and Install Travel and Bucket Open/Close Pilot Valve.............. W2-5-3 Pilot Port Connections ............................ W2-5-5 Front/Swing Pilot Valve Construction ...... W2-5-6 Travel and Bucket Open/Close Pilot Valve Construction ........................ W2-5-8 Group 6 DQR Valve Remove and Install DQR Valve............... W2-6-1 DQR Valve Construction......................... W2-6-4 Group 7 Pilot Shut-Off Valve Remove and Install Pilot Shut-off Valve ............................... W2-7-1 Disassemble Pilot Shut-off Valve ............ W2-7-4 Assemble Pilot Shut-off Valve................. W2-7-6
- 21. 118W-2-2 Group 8 Solenoid Valve Remove and Install Solenoid Valve......... W2-8-1 Solenoid Valve Construction................... W2-8-4 Group 9 Oil Cooler Fan Motor Remove and Install Oil Cooler Fan Motor ............................ W2-9-1 Disassemble Oil Cooler Fan Motor ............................ W2-9-4 Assemble Oil Cooler Fan Motor.............. W2-9-6 Maintenance Standard ........................... W2-9-8 Group 10 Compressor Drive Motor Remove and Install Compressor Drive Motor......................................... W2-10-1 Disassemble Compressor Drive Motor......................................... W2-10-4 Assemble Compressor Drive Motor......................................... W2-10-6 Group 11 Air Conditioner Work after Component Replacement .......................................W2-11-1 Add Compressor Oil ..............................W2-11-1 Charge Air Conditioner with Refrigerant ..........................................W2-11-2
- 22. UPPERSTRUCTURE / Cab W2-1-1 WINDOWPANE DIMENSION Material: JIS R 3211, ANSI AS2, ECE ANNEX5 or equivalent NOTE: 1 mm = 0.03937 in W117-02-01-001 W117-02-01-003 Unit: mm W117-02-01-002 W117-02-01-004 4 7 6 5 3 2 1 1 Laminated glass Color : Transparent Thickness : 10 mm Chamfer all fringe Corners 1679+2.0 -0 1378±1.5 4-R91 2 917±1.0 1256±1.5 1369±1.5 4-R61 3 433±1.0 769±1.0 4-R61 Tempered glass Color : Bronze Thickness : 6 mm Chamfer all fringe Corners Tempered glass Color : Bronze Thickness : 5 mm Chamfer all fringe Corners
- 23. UPPERSTRUCTURE / Cab W2-1-2 NOTE: 1 mm = 0.03937 in W117-02-01-005 W117-02-01-006 W117-02-01-007 W117-02-01-008 4 934±1.0 422±1.0 4-R61 5 777±1.0 514±1.0 4-R61 6 4-R61 1296±1.0 1400±1.0 848±1.0 7 4-R61 645±1.0 403±1.0185 667±1.0 Tempered glass Color : Bronze Thickness : 5 mm Chamfer all fringe Corners Tempered glass Color : Bronze Thickness : 5 mm Chamfer all fringe Corners Tempered glass Color : Bronze Thickness : 6 mm Chamfer all fringe Corners Tempered glass Color : Bronze Thickness : 5 mm Chamfer all fringe Corners
- 24. UPPERSTRUCTURE / Pump Device W2-2-1 REMOVE AND INSTALL PUMP DEVICE CAUTION: 1. Escaping fluid under pressure can penetrate the skin and eyes,causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. 2. Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting work. 3. Do not quickly loosen the air breather cap on the hydraulic oil tank. The air breather cap may fly off due to internal pressure. Always turn the air breather cap slowly to release any remaining pressure before removing it. Preparation: 1. Park the machine on a level solid surface. Lower the front attachment to the ground. 2. Stop the engine. Turn the air breather cap on the hydraulic oil tank approximately 30° counter- clockwise to release any remaining pressure. 3. Close all hydraulic line stop valves. 4. Remove socket bolt (2) from one hydraulic tank air breather cap to remove air breather cap (1). Remove filter (3). Wind an adhesive tape around bayonet assembly (4) approx. one and half turns so that the port is plugged. Reinstall filter (3) and air breather cap (1) to the original position. 4. Remove another side air breather cap (1). Con- nect a vacuum pump. Operate the vacuum pump continuously to create negative pressure in the hydraulic oil tank. NOTE: Keep the vacuum pump running continu- ously while working on the hydraulic sys- tem. IMPORTANT: After completing the work, be sure to remove the adhesive tape from bayonet assembly (4). W118-02-03-018 W118-02-05-001 T142-05-03-007 T142-05-03-008 1 1 2 3 4 Port
- 25. UPPERSTRUCTURE / Pump Device W2-2-22 DISASSEMBLE MAIN PUMP REGULATOR W118-02-02-009 1 2 3 4 5 6 7 8 9 10 11 12 13 33 34 43 4142 40 39 38 37 35 36 14 15 16 17 18 20 19 21 22 23 24 25 26 27 29 30 31 32 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 98 97 66 67 68 69 70 71 72 73 74 75 76 78 77 79 80 81 82 83 84 89 85 86 87 88 96 95 91 92 93 94 61 60 59 58 57 56 55 54 49 48 47 53 50 45 46 99 44 62 Serial Number 000105 and later Serial Number from 000101 to 000104 28 90
- 26. UPPERSTRUCTURE / Pump Device W2-2-23 1 - Pin 26 - Lever 51 - O-Ring 76 - Lock Nut 2 - Sleeve 27 - Pin 52 - Pin 77 - Adjusting Screw 3 - O-Ring 28 - Pilot Piston 53 - Cover 78 - Lock Nut 4 - O-Ring 29 - Spring Seat 54 - Spring Seat 79 - Socket Bolt (4 Used) 5 - Sleeve 30 - Spring 55 - Spring 80 - Casing 6 - Compensating Piston 31 - Spring Seat 56 - Spring 81 - Pin 7 - Compensating Rod 32 - O-Ring 57 - Spring Seat 82 - Support Plug 8 - Spring Seat 33 - Socket Bolt (4 Used) 58 - O-Ring 83 - O-Ring 9 - Spring 34 - Cover 59 - Cover 84 - Lock Ring 10 - Spring 35 - Cover 60 - Socket Bolt (2 Used) 85 - Pin 11 - Piston 36 - O-Ring 61 - Lock Nut 86 - Support Plug 12 - Spring Seat 37 - Stopper 62 - Adjusting Screw 87 - O-Ring 13 - O-Ring 38 - Ball 63 - Cover 88 - Lock Ring 14 - Retaining Ring 39 - Seat 64 - Socket Bolt (2 Used) 89 - Pin 15 - Spring Seat 40 - O-Ring 65 - Socket Bolt (2 Used) 90 - O-Ring 16 - Spring 41 - O-Ring 66 - Socket Bolt (2 Used) 91 - Stopper 17 - Spring 42 - Plug 67 - Socket Bolt (2 Used) 92 - Ball 18 - Retaining Ring 43 - Plug 68 - O-Ring 93 - Seat 19 - Sleeve 44 - Nut 69 - O-Ring 94 - O-Ring 20 - Spool 45 - Screw 70 - Adjusting Screw 95 - O-Ring 21 - Pin 46 - O-Ring 71 - Adjusting Screw 96 - O-Ring 22 - Lever 47 - Sleeve 72 - Lock Nut 97 - O-Ring 23 - Feedback Lever 48 - Piston 73 - O-Ring 98 - Plug 24 - Pin 49 - Spool 74 - Plug 99 - Washer 25 - Pin 50 - Plug (2 Used) 75 - Cover
- 27. UPPERSTRUCTURE / Pump Device W2-2-24 W118-02-02-009 1 2 5 6 8 9 10 11 12 13 33 34 40 39 38 37 35 36 17 29 30 31 32 44 45 46 47 48 49 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 97 66 67 70 71 72 75 76 78 77 79 80 96 95 61 60 59 58 57 56 55 54 49 48 47 53 45 46 44 62 Serial Number 000105 and later Serial Number from 000101 to 000104
- 28. UPPERSTRUCTURE / Pump Device W2-2-25 Disassemble Main Pump Regulator 1. Remove socket bolts (66) and (67) to remove the regulators. : 6 mm 2. Remove socket bolts (33). Remove cover (34), O-ring (40), cover (35), O-ring (36), cover (53), O- ring (51), and pin (52). : 5 mm 3. Remove stopper (37), ball (38), and seat (39) from cover (35). 4. Serial/No. Up to 000104: Remove socket bolts (60) from cover (53). Remove cover (59), O-ring (58), spring seat (57), spring (56), spring (55), spring seat (54), spool (49), piston (48) and sleeve (47). Serial/No. 000105 and later: Remove socket bolts (60) from cover (53). Remove cover 59), O-ring (58), spring seat (57), spring (56), spring (55) and spring seat (54). Remove nut (44), screw (45), O-ring (46), piston (48), spool (49) and sleeve (47) from cover (53). IMPORTANT: Never attempt to remove lock nut (61) and adjusting screw (62) from cover (59). Setting for the relief oil flow minimizing control may be changed. : 5 mm 5. Remove socket bolts (79) from casing (80). Remove cover (75), spring seat (12), piston (11), spring (10), spring (9), spring seat (8), spring seat (31), spring (30), and spring seat (29). IMPORTANT: Never attempt to remove adjusting screw (70), lock nut (76), adjusting screw (71) and lock nut (72) from cover (75). Setting for the power reduce control and power increase controls may be changed. Also, never attempt to remove adjusting screw (77) and lock nut (78) from cover (75). Setting for the flow control may be altered. : 5 mm 6. Remove socket bolts (64) and (65) from casing (80). Remove cover (63), O-rings (95), (96), and (97), spring (17), pin (1), sleeve (2), sleeve (5) and compensating piston (6). : 5 mm
- 29. UPPERSTRUCTURE / Pump Device W2-2-26 W118-02-02-009 7 14 15 16 17 20 19 21 22 23 24 26 27 80 81 82 84 85 86 88 Serial Number 000105 and later Serial Number from 000101 to 000104 28
- 30. UPPERSTRUCTURE / Pump Device W2-2-27 7. Remove retaining ring (14) to remove spring seat (15), spring (16), spring (17), and sleeve (19). 8. Remove lock rings (84) and (88) from casing (80). Remove support plugs (82) and (86) and pin (85) using a M6 bolt. 9. Remove lever (26) from casing (80) with a pair of tweezers. IMPORTANT: Do not remove pin (27). 10. Remove pin (24) using a thin copper bar (less than dia. 4). Remove feedback lever (23). IMPORTANT: Take care not to hit pin (24) against lever (22) when pulling it out. 11. Remove lever (22) from casing (80). IMPORTANT: Do not remove pins(81) and (21) when removing lever (22). 12. Remove pilot piston (28), spool (20), and compensating rod (7) from casing (80).
- 31. UPPERSTRUCTURE / Pump Device W2-2-28 ASSEMBLE MAIN PUMP REGULATOR W117-02-02-004 Section A−B W117-02-02-007 W117-02-02-023 Section A−A’ W117-02-02-006 Section C-C (Serial Number from 000101 to 000104) W118-02-02-011 Section C-C (Serial Number 000105 and later) W118-02-02-010 19 79 BA’ C’ C A 51 36 37 38 39 3435 18 20 24 81 22 8 9 10 11 68 74 69 40 33 70 72 71 16 97 17 15 1 2 4 6 5 7 23 21 90 89 12 13 64 96 65 63 28 85 25 323130272680 78 77 29 76 75 73 53 82 83 84 86 87 88 14 3 45 44 46 53 59 60 61 62 99 48 47 49 54 55 56 57 58 45 44 50 53 59 60 62 48 47 49 54 55 56 57 58 46 61
- 32. UPPERSTRUCTURE / Pump Device W2-2-29 1 - Pin 26 - Lever 51 - O-Ring 76 - Lock Nut 2 - Sleeve 27 - Pin 52 - Pin 77 - Adjusting Screw 3 - O-Ring 28 - Pilot Piston 53 - Cover 78 - Lock Nut 4 - O-Ring 29 - Spring Seat 54 - Spring Seat 79 - Socket Bolt (4 Used) 5 - Sleeve 30 - Spring 55 - Spring 80 - Casing 6 - Compensating Piston 31 - Spring Seat 56 - Spring 81 - Pin 7 - Compensating Rod 32 - O-Ring 57 - Spring Seat 82 - Support Plug 8 - Spring Seat 33 - Socket Bolt (4 Used) 58 - O-Ring 83 - O-Ring 9 - Spring 34 - Cover 59 - Cover 84 - Lock Ring 10 - Spring 35 - Cover 60 - Socket Bolt (2 Used) 85 - ∗ Pin 11 - Piston 36 - O-Ring 61 - Lock Nut 86 - Support Plug 12 - Spring Seat 37 - Stopper 62 - Adjusting Screw 87 - O-Ring 13 - O-Ring 38 - Ball 63 - Cover 88 - Lock Ring 14 - Retaining Ring 39 - Seat 64 - Socket Bolt (2 Used) 89 - Pin 15 - Spring Seat 40 - O-Ring 65 - Socket Bolt (2 Used) 90 - O-Ring 16 - Spring 41 - ∗ O-Ring 66 - Socket Bolt (2 Used) 91 - ∗ Stopper 17 - Spring 42 - ∗ Plug 67 - ∗ Socket Bolt (2 Used) 92 - ∗ Ball 18 - Retaining Ring 43 - ∗ Plug 68 - O-Ring 93 - ∗ Seat 19 - Sleeve 44 - Nut 69 - O-Ring 94 - ∗ O-Ring 20 - Spool 45 - Screw 70 - Adjusting Screw 95 - ∗ O-Ring 21 - Pin 46 - O-Ring 71 - Adjusting Screw 96 - O-Ring 22 - Lever 47 - Sleeve 72 - Lock Nut 97 - O-Ring 23 - Feedback Lever 48 - Piston 73 - O-Ring 98 - ∗ Plug 24 - Pin 49 - Spool 74 - Plug 99 - Washer 25 - Pin 50 - Plug (2 Used) 75 - Cover NOTE: For the part names with mark ∗, see page W2-2-22.
- 33. UPPERSTRUCTURE / Pump Device W2-2-30 W117-02-02-004 Section A−B W117-02-02-007 W117-02-02-023 Section A−A’ W117-02-02-006 Section C-C (Serial Number from 000101 to 000104) W118-02-02-011 Section C-C (Serial Number 000105 and later) W118-02-02-010 19 BA’ C’ C A 20 24 2216 97 17 15 1 2 4 6 5 7 23 21 64 96 65 63 28 85 272680 82 83 84 86 87 88 14 3
- 34. UPPERSTRUCTURE / Pump Device W2-2-31 Assemble Regulator 1. Install compensating rod (7) into casing (80). 2. Attach pin (21) into the designated hole on lever (22). Install lever (22) by inserting pin (21) into the groove on compensating rod (7) and, at the same time, by inserting pin (81), which is already attached on lever (22), into the designated hole on casing (80). 3. Insert sleeve (19) and spool (20) into casing (80). IMPORTANT: Be sure to install spool (20) in the correct direction. Also, confirm that spool (20) moves smoothly in the casing. 4. Install feedback lever (23), aligning its pin hole with that on spool (20). Insert pin (24) into the pin hole. IMPORTANT: Be sure to install feedback lever (23) in the correct direction. 5. Insert pilot piston (28) into casing (80). IMPORTANT: Confirm that pilot piston (28) moves smoothly in casing (80). 6. Install lever (26) so that the lever attached pin (27) fits in the groove on pilot piston (28). Install support plug (86) so that pin (85) on the support plug fits into the hole on lever (26). Install O-ring (87) and lock ring (88) onto support plug (86). 7. Install adjusting plug (82), O-ring (83), and lock ring (84) onto casing (80). 8. Install spring (17), spring (16), spring seat (15), and retaining ring (14) onto spool (20). 9. Install compensating piston (6), sleeve (5), O-ring (4), O-ring (3), sleeve (2), and pin (85) into casing (80). 10. Install O-rings (95), (96), and (97) onto casing (80). Install cover (63) using socket bolts (64) and (65). : 5 mm : 11.5 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
- 35. UPPERSTRUCTURE / Pump Device W2-2-32 W117-02-02-004 Section A−B W117-02-02-007 W117-02-02-023 Section A−A’ W117-02-02-006 Section C-C (Serial Number from 000101 to 000104) W118-02-02-011 Section C-C (Serial Number 000105 and later) W118-02-02-010 79 BA’ C’ C A 51 36 37 38 39 3435 8 9 10 11 40 33 12 313080 29 75 53 45 44 46 53 59 60 48 47 49 54 55 56 57 58 53 59 60 48 47 49 54 55 56 57 5899
- 36. UPPERSTRUCTURE / Pump Device W2-2-33 11. Install spring seat (29), spring (30), and spring seat (31) into casing (80). 12. Install spring seat (8), spring (9), and spring (10) into casing (80). 13. Install spring seat (12) and seat (11) into cover (75). Install cover (75) onto casing (80). : 5 mm : 11.5 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft) 14. Serial/Number Up to 000104: Install sleeve (47), piston (48), spool (49), spring seat (54), spring (55), spring (56), spring seat (57), and O-ring (58) into cover (53). Install cover (59) onto cover (53) using socket bolts (60). Serial/Number 000105 or after: Install spring seat (54), spring (55), spring (56), spring seat (57), and O-ring (58) into cover (53). Install cover (59) onto cover (53) using socket bolts (60). Install sleeve (47), spool (49), piston (48), O-ring (46), screw (45), washer (99), and nut (44) int cover (53). 15. Install O-ring (36), O-ring (51) and pin (52) onto cover (53). Install seat (39), ball (38), and stopper (37) into cover (35). Install O-ring (40) onto cover (35). 16. Assemble covers (53), (35), and (34). Install them onto casing (80) using socket bolts (33). : 5 mm : 11.5 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
- 37. UPPERSTRUCTURE / Pump Device W2-2-34 (Blank)
- 38. UPPERSTRUCTURE / Pump Device W2-2-35 DISASSEMBLE AND ASSEMBLE 4-UNIT PUMP T117-02-01-017 Left Engine A - Oil Cooler Fan Drive Pump (Plunger Pump) C - Air Con. Compressor Drive Pump (Tumdem Gar Pump: Tip End) B - Pilot Pump (Tumdem Gear Pump: Transmission Side) D - Transmission Lubricating Pump (Gear Pump) Right Engine A - Oil Cooler Fan Drive Pump (Plunger Pump) C - Hydraulic Generator Drive Pump B - Pilot Pump (Tumdem Gear Pump: Transmission Side) D - Transmission Lubricating Pump (Gear Pump) DCBA
- 39. UPPERSTRUCTURE / Pump Device W2-2-36 DISASSEMBLE OIL COOLER FAN DRIVE PUMP W118-02-02-007 1 - Socket Bolt (4 Used) 19 - Displacement Angle Shift Pin 37 - Plunger (9 Used) 55 - O-Ring 2 - Cover 20 - Regulator 38 - Retainer 56 - Coupling 3 - O-Ring 21 - Socket Bolt (4 Used) 39 - Spherical Bushing 57 - Stopper 4 - Oil Seal 22 - Stopper 40 - Spacer 58 - Steel Ball 5 - Shaft 23 - Backup Ring 41 - Spring (9 Used) 59 - Seat 6 - Spacer 24 - O-Ring 42 - Cylinder Block 60 - Plug 7 - Bearing 25 - Servo Piston 43 - Valve Plate 61 - O-Ring (4 Used) 8 - Spacer 26 - O-Ring 44 - Needle Bearing 62 - Casing 9 - Retaining Ring 27 - O-Ring 45 - O-Ring 63 - Plug 10 - Cover 28 - Plug 46 - Stopper 64 - Socket Bolt 11 - Nut 29 - Lock Nut 47 - Steel Ball 65 - O-Ring 12 - Adjusting Screw 30 - Eye Bolt 48 - Seat 66 - Plug 13 - Spring 31 - Plug 49 - Valve Cover 67 - O-Ring 14 - O-Ring 32 - Socket Bolt (4 Used) 50 - Plug (3 Used) 68 - Plug 15 - Stopper 33 - Swash Plate 51 - Adjusting Screw 69 - Spring Pin (4 Used) 16 - Backup Ring 34 - Bushing 52 - Nut 70 - Pin 17 - O-Ring 35 - Shoe Plate 53 - Plate 71 - O-Ring (2 Used) 18 - Housing 36 - Shoe (9 Used) 54 - Socket Bolt (4 Used) 16 20 11 14 65 32 60 12 13 21 22 24 25 23 19 18 17 15 9 8 7 6 5 4 3 2 1 10 31 71 28 29 30 27 26 61 62 63 64 59 58 57 54 53 33 5150 55 56 6667 6869 70 52 34 39 40 45 48 47 46 49 44 43 42 41 38 37 36 35
- 40. UPPERSTRUCTURE / Pump Device W2-2-37 Disassemble Oil Cooler Fan Drive Pump IMPORTANT: Never attempt to remove adjusting screw (12), nut (11), adjusting screw (51) and nut (52). The set flow rate may be changed. 1. Remove plug (68) and O-ring (67) to drain hydraulic oil from the pump. : 36 mm 2. Remove socket bolts (21) to remove regulator (20). : 6 mm 3. Turn the housing (18) over so that the regulator mounting side is on the bottom. Remove socket bolts (54) (4 used) to remove plate (53), O-ring (55) and coupling (56). : 10 mm 4. Remove socket bolts (32) to remove valve cover (49) from housing (18). IMPORTANT: Valve plate (43) may drop when removing valve cover (49). Take care not to drop valve plate (43). 5. Remove O-ring (45), stopper (46), steel ball (47), seat (48), valve plate (43), pin (70), spring pin (69), socket bolts (64), casing (62), stopper (57), steel ball (58), and seat (59) from valve cover (49). IMPORTANT: Do not remove needle bearing (44) unless required. 6. Remove cylinder block (42), spring (41) (9 used), spacer (40), spherical bushing (39), retainer (38), plungers (37) (9 used), and shoes (36) from housing (18). 7. Remove socket bolts (1) to remove cover (2) and O-ring (3). : 6 mm 8. Tap on cover (10) using a plastic hammer to remove it. Remove O-ring (14) and spring (13) at the same time. 9. Remove swash plate (33) and shoe plate (35) from housing (18). 10. Remove stopper (15), stopper (22) and servo piston (25) from housing (18). NOTE: As LOCTITE has been applied on the contacting part between servo piston (25) and displacement angle shift pin (19), do not separate them unless required. 11. Tap on the end of shaft (5) using a plastic hammer to remove it from cover (10). Remove oil seal (4) at the same time. 12. Remove retaining ring (9), spacer (8), bearing (7), and spacer (6) from shaft (5).
- 41. UPPERSTRUCTURE / Pump Device W2-2-38 ASSEMBLE OIL COOLER FAN DRIVE PUMP W117-02-02-014 1 - Socket Bolt (4 Used) 19 - Displacement Angle Shift Pin 37 - Plunger (9 Used) 55 - O-Ring 2 - Cover 20 - ∗ Regulator 38 - Retainer 56 - Coupling 3 - O-Ring 21 - ∗ Socket Bolt (4 Used) 39 - Spherical Bushing 57 - Stopper 4 - Oil Seal 22 - Stopper 40 - Spacer 58 - Steel Ball 5 - Shaft 23 - Backup Ring 41 - Spring (9 Used) 59 - Seat 6 - Spacer 24 - O-Ring 42 - Cylinder Block 60 - Plug 7 - Bearing 25 - Servo Piston 43 - Valve Plate 61 - O-Ring (4 Used) 8 - Spacer 26 - O-Ring 44 - Needle Bearing 62 - Casing 9 - Retaining Ring 27 - O-Ring 45 - O-Ring 63 - Plug 10 - Cover 28 - Plug 46 - Stopper 64 - Socket Bolt 11 - Nut 29 - Lock Nut 47 - Steel Ball 65 - O-Ring 12 - Adjusting Screw 30 - Eye Bolt 48 - Seat 66 - Plug 13 - Spring 31 - Plug 49 - Valve Cover 67 - O-Ring 14 - O-Ring 32 - Socket Bolt (4 Used) 50 - Plug (3 Used) 68 - Plug 15 - Stopper 33 - Swash Plate 51 - Adjusting Screw 69 - Spring Pin (4 Used) 16 - Backup Ring 34 - Bushing 52 - Nut 70 - Pin 17 - O-Ring 35 - Shoe Plate 53 - Plate 71 - O-Ring (2 Used) 18 - Housing 36 - Shoe (9 Used) 54 - Socket Bolt (4 Used) NOTE: For the part names with mark ∗, see page W2-2-36. 25 53432215 35 33 341819 4944706942414039373638987 54 55 56 13 14 1 6 5 4 2 3 32 24 23 17 16 45 51 12 11 10 52
- 42. UPPERSTRUCTURE / Pump Device W2-2-39 Assemble Fan Drive Pump 1. Install displacement angle shift pin (19), servo piston (25), stopper (22) and stopper (15) into housing (18). 2. If displacement angle shift pin (19) has been separated from servo piston (25), apply LOCTITE to the threaded part of servo piston (25). 3. Place housing (18) on a workbench with the regulator mounting side on the bottom. Attach the shoe plate (35) attached swash plate (33) to displacement angle shift pin (19). IMPORTANT: Check if swash plate (33) moves smoothly after installing. 4. Install spacer (6), bearing (7), spacer (8), and retaining ring (9) onto shaft (5). Install shaft (5) into cover (10). 5. Install O-ring (3) onto cover (2). Install oil seal (4) and cover (2) onto cover (10) using socket bolts (1). : 6 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) 6. Install spring (41), spacer (40), spherical bushing (39), retainer (38), plungers (37) and shoes (33) into cylinder block (42). Install cylinder block (42) onto shaft (5), aligning splines. 7. Install pin (70), valve plate (43), O-ring (45), spring pin (69), stopper (46), steel ball (47), seat (48), stopper (57), steel ball (58), seat (59), casing (62), and socket bolt (64) onto valve cover (49). 8. Install valve cover (49) onto housing (18) using socket bolts (32). : 17 mm : 430 N⋅m (44 kgf⋅m, 320 lbf⋅ft) 9. Install coupling (56) onto shaft (5). Install O-ring (55) and plate (53) onto valve cover (49) using socket bolts (54). : 10 mm : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) 10. Install regulator (20) using socket bolts (21).
- 43. UPPERSTRUCTURE / Pump Device W2-2-2 W118-02-02-005 1 - Bolt 4 - Lifting Bracket 7 - Step 9 - Engine 2 - Engine Bracket 5 - Bolt 8 - Pump Transmission 10 - Frame 3 - Engine Bracket Mounting Bolt 6 - Pump Transmission Mounting Bolt Right Engine T117-02-01-001 (Left Engine) T117-02-01-001 12 11 Main Pump 9 (Transmission Side) Main Pump 10 (Outer Side) Main Pump 3 (Transmission Side) Main Pump 4 (Outer Side) Main Pump 11 (Transmission Side) Main Pump 12 (Outer Side) Main Pump 5 (Transmission Side) Main Pump 6 (Outer Side) Main Pump 7 (Transmission Side) Main Pump 8 (Outer Side) Main Pump 1 (Transmission Side) Main Pump 2 (Outer Side) 4-Unit Pump 4-Unit Pump 7 6 5 4 3 2 1 10 9 8
- 44. UPPERSTRUCTURE / Pump Device W2-2-3 Removal 1. Disconnect all hydraulic lines and electric wires from the hydraulic pumps and transmission. 2. Remove bolts (5) to remove step (7). : 19 mm IMPORTANT: Engine bracket (2) is installed on pump transmission (8). Install sup- porters (Width: 55 mm, Length: 130 mm, Height: 650 mm) between en- gine (9) and frame (10) when remov- ing the pump transmission so that engine (9) does not fall. 3. Attach chains to lifting brackets (4) (2 used) and straps around the main pumps to hold the pump device with a crane. CAUTION: Pump device weight: 2200 kg (4850 lb) 4. Remove pump transmission mounting bolts (6) and bolts (1), and engine bracket mounting bolts (3). Lift to remove the pump device using a crane. CAUTION: Main pump weight: 300 kg (660 lb) 4-Unit pump weight: 100 kg (220 lb) 5. Remove each component pump from the pump transmission using a crane. : 17 mm : 36 mm Wrench Size Remarks 17 mm Hydraulic Lines (Joint) 19 mm Hydraulic Lines 19 mm Bolts 22 mm Hydraulic Lines (Joint) 27 mm Hydraulic Lines 30 mm Hydraulic Lines (Joint) 36 mm Hydraulic Lines 14 mm Socket Bolts Wrench Size Remarks 3/4 inch Bolt (6) 28 mm Bolt (1) 55 mm Bolt (3)
- 45. UPPERSTRUCTURE / Pump Device W2-2-4 W118-02-02-005 1 - Bolt 4 - Lifting Bracket 7 - Step 9 - Engine 2 - Engine Bracket 5 - Bolt 8 - Pump Transmission 10 - Frame 3 - Engine Bracket Mounting Bolt 6 - Pump Transmission Mounting Bolt Right Engine T117-02-01-001 (Left Engine) T117-02-01-001 12 11 Main Pump 9 (Transmission Side) Main Pump 10 (Outer Side) Main Pump 3 (Transmission Side) Main Pump 4 (Outer Side) Main Pump 11 (Transmission Side) Main Pump 12 (Outer Side) Main Pump 5 (Transmission Side) Main Pump 6 (Outer Side) Main Pump 7 (Transmission Side) Main Pump 8 (Outer Side) Main Pump 1 (Transmission Side) Main Pump 2 (Outer Side) 4-Unit Pump 4-Unit Pump 7 6 5 4 3 2 1 10 9 8
- 46. UPPERSTRUCTURE / Pump Device W2-2-5 Installation CAUTION: Main pump weight: 300 kg (660 lb) 4-Unit pump weight: 100 kg (220 lb) 1. Install each component pump onto the pump transmission (8), aligning the splines of the pumps and transmission. : 17 mm : 540 N m (55 kgf m, 400 lbf⋅ft) : 36 mm : 690 N m (70 kgf m, 510 lbf⋅ft) CAUTION: Pump device weight: 2200 kg (4850 lb) 2. Install pump transmission (8) onto the engine shaft, aligning the splines and tighten the pump transmission mounting bolts (6). Install engine brackets (2) on the pump transmission (8) and tighten the engine bracket mounting bolts (1 and 3). 3. Remove the supports installed between the en- gine and the mainframe to prevent the engine from falling. 4. Secure step (7) with bolts (5). : 19 mm : 88 N m (9 kgf m, 65 lbf⋅ft) 5. Connect all hydraulic lines and electric wires to the pumps and transmission. 6. Bleed air from the pumps. (Refer to the next page.) IMPORTANT: Prevent pump seizure from occurring. Be sure to perform break- in operation after installing the pumps. 7. Run the engine at slow idle for 20 minutes. Check for oil leaks during the engine idling operation. 8. Increase the engine speed to the maximum speed. Slowly operate the boom from stroke end to stroke end repeatedly for 20 minutes. Tightening Toque Remarks Wrench Size N⋅m kgf⋅m lbf⋅ft 3/4 inch 118 12 87 Bolt (6) 28 mm 440 45 330 Bolt (1) 55 mm 3140 320 2310 Bolt (3) Tightening Toque Remarks Wrench Size N⋅m kgf⋅m lbf⋅ft 17 mm - - - Hydraulic lines (Joint) 19 mm 44 4.5 32.5 Hydraulic lines 19 mm 88 9 65 Bolts 22 mm - - - Hydraulic lines (Joint) 27 mm 118 12 87 Hydraulic lines 30 mm - - - Hydraulic lines (Joint) 36 mm 235 24 175 Hydraulic lines 14 mm 265 27 195 Socket Bolts
- 47. UPPERSTRUCTURE / Pump Device W2-2-6 • Main Pump Air Bleeding Procedure IMPORTANT: Never loosen the pipe completely. Hydraulic oil will spout. 1. Loosen pipe connector (1) 2 to 3 turns. : 17 mm 2. Start the engine and run at slow idle. Purge air from the main pump until oil flows out from pipe connector (1). 3. Stop the engine. Tighten pipe connector (1). : 17 mm : 34 N m (3.5 kgf m, 25.5 lbf⋅ft) • Oil Cooler Fan Drive Pump Air Bleeding Proce- dure IMPORTANT: Never loosen drain hose plug (2) completely. Hydraulic oil will sport. 1. Loosen drain hose connector (2) 2 to 3 turns. : 27 mm 2. Start the engine and run at slow idle. Purge air from the main pump until only hydraulic oil flows out from drain hose connector (2) threads. 3. Stop the engine and tighten drain hose plug (2). : 27 mm : 118 N m (12 kgf m, 87 lbf⋅ft) M117-07-118 M117-07-163 T117-02-01-017 1 1 2 Oil Cooler Fan Drive Pump
- 48. UPPERSTRUCTURE / Pump Device W2-2-7 (Blank)
- 49. UPPERSTRUCTURE / Pump Device W2-2-8 DISASSEMBLE PUMP TRANSMISSION W118-02-02-006 1 - Bolt (6 Used) 10 - Roller Bearing 19 - Gear 28 - Spacer (3 Used) 2 - Cover 11 - Case 20 - Spacer 29 - Ball Bearing (3 Used) 3 - Spacer 12 - Cover 21 - Retaining Ring 30 - Gear (3 Used) 4 - Disc Spring 13 - Bolt (6 Used) 22 - Ball Bearing 31 - Spacer (3 Used) 5 - Spacer 14 - Bolt (31 Used) 23 - Elbow 32 - Retaining Ring (3 Used) 6 - Roller Bearing 15 - Washer Spring (31 Used) 24 - Adapter 33 - Ball Bearing (3 Used) 7 - Retaining Ring 16 - Knock Pin (2 Used) 25 - Reducer 8 - Stopper 17 - Spacer 26 - Air Breather 9 - Gear 18 - Ball Bearing 27 - Case 1 2 3 4 5 6 7 8 9 10 11 26 25 24 23 16 17 18 19 20 21 22 33 32 31 30 29 2827 16 14 15 Pump Side Engine Side 12 13
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