Hitachi ex750 5 excavator service repair manual
- 2. 162W-1-1 SECTION 1 GENERAL IMFORMATION CONTENTS Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling........................................... W1-1-1 Maintenance Standard Terminology.......................................... W1-1-4 Group 2 Tightening Tightening Torque Specification.............. W1-2-1 Torque Chart .......................................... W1-2-2 Piping Joint ............................................ W1-2-5
- 3. GENERAL INFORMATION / Precautions for Disassembling and Assembling W1-1-1 PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING Precautions for Disassembling and Assembling • 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 • 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.
- 4. 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 install ation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures: • Bleeding Air from Hydraulic Pump IMPORTANT: If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result. Be sure to bleed air before starting the engine. • Remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil. • After the pump housing is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run at slow idle speed. • Slightly loosen the plug to bleed air from the pump housing until hydraulic oil oozes out. • After bleeding all the air, securely tighten the plug. • Bleeding Air from Travel Motor/Swing Motor • With the drain plug/hose on travel motor/swing motor removed, fill the motor case with hydraulic oil. • Bleeding Air from Hydraulic Circuit • After refilling hydraulic oil, start the engine. While operating each cylinder, swing motor and travel motor evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes. • Reposition the front attachment to check hydraulic oil level. • Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary. M104-07-021
- 5. 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 seal ring face (C) 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 floating seal (A) and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air. (2) Clean the floating seal and seal mounting bores, as dust on them tends to enter the floating seal when installing it. (3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring. (4) After installing the floating seal, check that seal face (C) is parallel with seal mounting bores ring face (D) by measuring the distances (C) and (D) at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating. W105-03-05-019 W105-03-05-020 W110-03-05-004 Correctly Incorrectly A B a b a=b a≠b a b Correctly IncorrectlyD C B
- 6. GENERAL INFORMATION / Precautions for Disassembling and Assembling W1-1-4 MAINTENANCE STANDARD TERMINOLOGY “Standard” 1. Dimension for parts on a new machine. 2. Dimension of components or assemblies adjusted to specification. Both dimensions are shown with tolerances as necessary. “Allowable Limit” 1. Normal machine performance cannot be accomplished after exceeding this limit. 2. Repair or replacement is required before reaching this limit. Machine performance will decrease, and maintenance and down time expense will increase as machine operating hours accumulate. It is recommended that parts are repaired or replaced before reaching the “Allowable Limit”.
- 7. GENERAL INFORMATION / Tightening W1-2-1 TIGHTENING TORQUE SPECIFICATIONS Bolt Dia Wrench Size Torque No. Descriptions mm Q’ty (mm) N⋅m kgf⋅m lbf⋅ft Engine cushion rubber 16 2 24 265 27 195 Front Cushion rubber-machine 16 2 24 265 27 195 Engine cushion rubber 24 2 36 690 70 510 1 Engine cushion rubber mount- ing bolt Rear Cushion rubber-machine 18 4 27 390 40 290 2 Muffler bracket mounting bolt UNC 1/2 UNC 3/8 4 6 19 14 88 49 9 5 65 36 3 Radiator mounting bolt 24 4 36 690 70 510 4 Hydraulic oil tank mounting bolt 18 8 27 295 30 215 5 Fuel tank mounting bolt 18 4 27 295 30 215 6 ORS fittings for hydraulic hoses and piping 1- -12UNF 41 205 21 152 7 Pump transmission mounting bolt UNC 14 16 69 7 51 8 Pump device mounting bolt 24 4 36 690 70 510 9 Control valve mounting bolt 20 4 30 390 40 290 10 Swing device mounting bolt 24 28 36 930 95 690 11 Swing motor mounting bolt (hexagonal wrench) 20 24 30 390 40 290 12 Battery mounting bolt 12 2 19 34 3.5 25.5 STD 16 4 24 205 21 152 13 Cab mounting bolt H 16 6 24 205 21 152 14 Swing bearing mounting bolt to upperstructure Swing bearing mounting bolt to undercarriage 33 33 30 36 4 40 50 50 46 2160 2160 1720 220 220 175 1590 1590 1270 15 Travel device mounting bolt Travel motor mounting bolt Sprocket mounting bolt 27 18 27 40 8 48 41 27 41 1370 295 1370 140 30 140 1010 215 1010 16 Upper roller mounting 20 24 30 540 55 400 17 Lower roller mounting bolt STD, H 24 72 36 930 95 690 18 Track shoe bolt STD, H 27 408 41 1960 200 1450 19 Track guard mounting bolt STD, H 27 16 41 1370 140 1010 20 Track frame mounting bolt 36 44 55 2750 280 2030 Coupling 8 13 10.5 to 12.5 1.05 to 1.26 7.6 to 9.121 Coupling and clamp of low pressure piping Clamp -28UNF 11 5.9 0.6 4.3 22 Counterweight mounting bolt Counterweight retaining bolt 45 24 2 4 65 36 2750 690 280 70 2030 510 23 Front pin-retaining bolt 20 30 30 390 40 290 NOTE: (1) Apply lubricant (e.g. white Zinc B dissolved into spindle oil) to bolts and nuts to stabilize friction coefficient of them. (2) Make sure bolt and nut threads are clean before installing. (3) Apply LOCTITE to threads before installing and tightening swing bearing mounting bolts. 7 16 7 16 1 4
- 8. GENERAL INFORMATION / Tightening W1-2-2 TORQUE CHART CAUTION: Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use the correct tools. Avoid bodily injury caused by slipping wrenches. Bolt Types Tighten nuts or bolts correctly to torque specifications. Four kinds of bolts, hexagon bolts T, H, M and socket bolt, each made of different material, are used. Make sure to employ the correct bolts and tighten them to specification when assembling the machine or components. SA-040 W105-01-01-007 Specified Tightening Torque Chart T Bolt, Socket bolt H Bolt M Bolt Bolt 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 T Bolt Hexagon H Bolt Hexagon M Bolt
- 9. GENERAL INFORMATION / Tightening W1-2-3 IMPORTANT: (1) Apply lubricant (i. e. white zinc B dissolved into spindle oil) to nuts and bolts to stabilize their friction coefficients. (2) Torque tolerance is ±±±±10 %. (3) Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force. (4) The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application. (5) Make sure that the nut and bolt threads are clean before installing. Remove dirt or corrosion, if any. Bolt Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening. W105-01-01-003 Equally tighten upper and lower alternately 1,4 2,3 Tighten diagonally 1 132 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 14 Tighten from center and diagonally
- 10. 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 WRONG W105-01-01-016 W105-01-01-008 W105-01-01-009 W105-01-01-010 Bend along edge sharply Do not bend it round Bend along edge sharply RIGHT WRONG RIGHT RIGHT WRONG Tighten Loosen RIGHT RIGHT WRONG RIGHT WRONG
- 11. GENERAL INFORMATION / Tightening W1-2-5 PIPING JOINT Pipe Thread Connection/Union Joint Tightening Torque Specifications Union Joint Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. IMPORTANT: (1) Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adaptor (1). Be sure to tighten union nut (3) to specifications. (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 Type Wrench Size Tightening Torque Union Nut Joint Body N⋅m kgf⋅m Ibf⋅ft 30° Male Union 19 19 59 6 43 Joint 22 22 98 10 72 27 27 118 12 87 36 36 235 24 134 41 41 295 30 215 50 50 490 50 360 60 60 670 68 490 70 70 980 100 720 37° Female Union 19 17 44 4.5 32.5 Joint 22 19 59 6 43 27 22 118 12 87 36 30 32 235 24 134 41 36 295 30 215 50 46 490 50 360 NOTE: Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint. 1 4 3 5 2 Male Union Joint Female Union Joint 30° or 37° 30° or 37° Joint Body
- 12. 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 17 59 6 43 22 19 98 10 72 27 22 118 12 87 36 30, 32 235 24 134 41 36 295 30 215 50 46 490 50 360 Joint Body 7 6 9 8 10
- 13. GENERAL INFORMATION / Tightening W1-2-7 Screwed-In Connection IMPORTANT: Many types of screwed-in con- nections 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. 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) W105-01-01-018 Male Tapered Thread Wrench Size Tightening Torque Joint Body N⋅m kgf⋅m lbf⋅ft 17, 19 59 6 43 19, 22 98 10 72 27, 22 118 12 87 36, 32 235 24 134 41 295 30 215 50 490 50 360 60 670 68 490 70 980 100 720 W105-01-01-019 M114-07-041 M114-07-042 M114-07-043 PT Male Straight Thread PF ° Male Tapered Thread Leave one to two pitch threads uncovered Internal Thread External Thread Clearance Worm Gear TypeT-Bolt Type
- 14. 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. WRONG RIGHT W105-01-01-011 WRONG RIGHT W105-01-01-012 WRONG RIGHT W105-01-01-013 WRONG RIGHT W105-01-01-014 Rubbing Against Each Other Clamp Clamp Rubbing Rubbing Clamp
- 15. 162W-2-1 SECTION 2 UPPERSTRUCTURE CONTENTS Group 1 Cab Remove and Install Cab ...................... W2-1-1 Dimensions of the Cab Glass .............. W2-1-7 Group 2 Counterweight Remove and Install Counterweight ................................... W2-2-1 Group 3 Pump Device Remove and Install Pump Device ..................................... W2-3-1 Disassemble Pump Transmission........ W2-3-2 Assemble Pump Transmission ............ W2-3-6 Remove and Install Main Pump ........................................ W2-3-9 Disassemble Main Pump................... W2-3-10 Assemble Main Pump........................ W2-3-16 Maintenance Standard ...................... W2-3-20 Disassemble Regulator ..................... W2-3-22 Assemble Regulator .......................... W2-3-24 Disassemble and Assemble Pilot Pump....................................... W2-3-26 Group 4 Control Valve Remove and Install Control Valve ..................................... W2-4-1 Disassemble Control Valve 1 .................................. W2-4-4 Assemble Control Valve 1 .................................. W2-4-8 Disassemble Control Valve 2 ................................ W2-4-14 Assemble Control Valve 2 ................................ W2-4-16 Disassemble Control Valve 3 ................................ W2-4-18 Assemble Control Valve 3 ................................ W2-4-24 Disassemble Control Valve 4 ................................ W2-4-30 Assemble Control Valve 4 ................................ W2-4-32 Disassemble Control Valve 5 ................................ W2-4-34 Assemble Control Valve 5 ................................ W2-4-36 Group 5 Swing Device Remove and Install Swing Device..................................... W2-5-1 Disassemble Swing Reduction Gears ................................................ W2-5-4 Assemble Swing Reduction Gears ................................................ W2-5-8 Disassemble Swing Motor ................. W2-5-12 Assemble Swing Motor ...................... W2-5-16 Disassemble and Assemble Swing Parking Brake Release Valve.................................. W2-5-20 Maintenance Standard....................... W2-5-22
- 16. 162W-2-2 Group 6 Pilot Valve Remove and Install Right Pilot Valve ......................................... W2-6-1 Remove and Install Left Pilot Valve ......................................... W2-6-4 Remove and Install Travel Pilot Valve............................... W2-6-7 Disassemble Right and Left Pilot Valve ......................................... W2-6-8 Assemble Right and Left Pilot Valve ....................................... W2-6-10 Disassemble Travel Pilot Valve ....................................... W2-6-14 Assemble Travel Pilot Valve ....................................... W2-6-16 Group 7 Pilot Shut-Off Valve Remove and Install Pilot Shut-off Valve ............................ W2-7-1 Disassemble Pilot Shut-off Valve ......... W2-7-4 Assemble Pilot Shut-off Valve.............. W2-7-6 Group 8 Shockless Valve Remove and Install Front Attachment Shockless Valve.............. W2-8-1 Disassemble and Assemble Shockless Valve (Front Attachment) ............................ W2-8-4 Remove and Install Travel Shockless Valve...................... W2-8-7 Disassemble and Assemble Travel Shockless Valve.................... W2-8-10 Group 9 Solenoid Valve Remove and Install Two-Spool Solenoid Valve ................. W2-9-1 Disassemble and Assemble Two-Spool Solenoid Valve ................. W2-9-3
- 17. UPPERSTRUCTURE / Cab W2-1-1 REMOVE AND INSTALL CAB Removal 1. Remove nuts (2) and seat (1). : 13 mm 2. Loosen bolts (5) behind the cab and bolts (6) in rear boxes (3 and 4). Remove rear boxes (3 and 4). : 13 mm 3. Loosen bolts (8) to remove rear box lower cover (7). : 13 mm 4. Remove filter (25). Loosen screws (9) to remove duct (10) from the cab. W157-02-01-005 W157-02-01-017 W158-02-01-001 1 2 5 4 6 65 7 8 3 25 10 9
- 18. UPPERSTRUCTURE / Cab W2-1-2 5. Remove cable connectors (11) located inside cab at the rear. 6. Disconnect wiper limit switch (12), cab light (13), speaker (14), antenna (15) and ground (17) lo- cated inside the cab. Remove washer vinyl hose(16) outside the cab. 7. Disconnect work light plug connector (18) outside the cab. 8. Remove cap (21) from duct cover (19). Loosen screws (20) to remove duct cover (19). W162-02-01-001 W162-02-01-002 W162-02-01-003 W158-02-01-002 11 12 13 14 15 16 16 18 21 20 19
- 19. UPPERSTRUCTURE / Cab W2-1-3 9. While pushing the mating face of duct (22) toward the rear side of the cab, remove duct (22). 10. Attach lifting straps to the top of the cab. CAUTION: cab weight : 260 kg (573 lb) 11. Remove cab mounting bolts (23) and nuts (24). : 17 mm : 24 mm : 8 mm 12. Carefully remove the cab. W157-02-01-011 W157-02-01-009 W157-02-01-010 W157-02-01-001 Duct Mating Face 22 24 23
- 20. UPPERSTRUCTURE / Cab W2-1-4 Installation CAUTION: cab weight : 260 kg (573 lb) 1. Attach the lifting straps to the cab. Install the cab onto the frame. 2. Tighten bolts (23) and nut (24). : 17 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) : 24 mm : 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) : 8 mm : 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft) 3. Install duct (10) to the cab with screws (9). Install filter (25) into the duct. : 4.9 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft) 4. Connect cable connectors (11) at the rear inside the cab. W157-02-01-001 W157-02-01-010 W158-02-01-001 W162-02-01-001 11 24 23 25 10 9
- 21. UPPERSTRUCTURE / Cab W2-1-5 5. Reconnect wiper limit switch (12), cab light (13), speaker (14) antenna (15) and ground (17) lo- cated in the cab. Reinstall washer vinyl hose (16) outside the cab. : 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 6. Reconnect work light plug connector (18) outside the cab. 7. Install rear box lower cover (7) with bolts (8). : 13 mm : 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 8. Install rear boxes (3 and 4) with bolts (5 and 6). : 13 mm : 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) W162-02-01-002 W162-02-01-003 W157-02-01-017 5 4 6 12 6 13 5 14 7 15 8 16 16 3 18
- 22. UPPERSTRUCTURE / Cab W2-1-6 9. While pushing duct (22) to the front of the cab, in- sert duct (22) into the front duct until the mating faces come in contact with each other. 10. Install duct cover (19) with screws (20). Install caps (21). 11. Secure seat (1) with nuts (2). : 13 mm : 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) W157-02-01-011 W158-02-01-002 W157-02-01-005 1 2 Duct Mating Face 22 21 20 19
- 23. UPPERSTRUCTURE / Cab W2-1-7 DIMENSIONS OF THE CAB GLASS 391.8 R2 Unit : mm NOTE: 1 mm=0.03937 in Section A 25.106 164.12 66.84 43.59 558.78 580 188.5 A Along the periphery C1 154.81 4° (87.81) R9487 (64.74) 3.015 51.03 360.7 R15 R118 R3018 30 142.25 221.399 R70 R78 2-R59 R11509 R2309 R4009 R1009 R509 R84 R4009 R209 R9509 4-R62 4-φ13 +0 B 230.50 222.65 216.73 905 900.7 66.41 87.84 947.152 35.73 63.97 756 612 No polish chamfering is required in this range. 15 R11516 Along the periphery C1 Section B (4 mm) (5 mm) (5 mm) NOTE: Material: JIS-R3211,R3212 ANSI-AS2 ECE-ANNEX5 or equivalent Chamfer Both Sides W157-02-01-013
- 24. UPPERSTRUCTURE / Cab W2-1-8 Unit : mm NOTE: 1 mm=0.03937 in Section C,D 208 113.9 333.5±1.0 10.6 R105 R2285.4 39.5 61.8 475.8 728.5±1.0 60.1 R3985.4 40 2-φ12.2 +0.5 0 R1985.1 3-R4 503±1. 541.5 (38.5) (38.5) R3 337.5±1.0 22.5 9.2 R30 R72.5 7735.4 39.5 3.1 40 728.5±1.0 488.5 290 R120885.4 2-R4 398.5±1.0 19.70 8 890.03 74.95 213.97 276.58 227.39 370±1.0 833±1.0 11.22 39.63 50.71 18 468.17 90.672 45.67 R2477 R3877 753.99 980 904.13 740.51 165 R2590 2-R5 R5175 R8075 R120 R12.5 19.29 516.26 33.60 549.86 910 4-R5 R1995 R895 R345 R1209 R1145 R595 R295 C 2-φ12.2 +0.5 0 59 D No polish chamfering are required in this range. No polish chamfering are required in this range. Chamfer Both Sides Chamfer Both Sides No polish chamfering are required in this range. No polish chamfering are required in this range. (4 mm) (4 mm) (5 mm) (5 mm) W157-02-01-014
- 25. UPPERSTRUCTURE / Counterweight W2-2-1 REMOVE AND INSTALL COUNTERWEIGHT Removal CAUTION: Counterweight weight: 12500 kg (27560 lb) 1. Attach wire ropes with shackles to the lifting lugs on the top of the counterweight. Take out any slack on the wire ropes by applying tension slowly with a crane. CAUTION: Use care to prevent hand injury from the power wrench reaction bar. 2. Use a power wrench to remove bolts (7), nuts (10), stoppers (8) and washers (6 and 9). : 65 mm 3. Loosen bolts (1) to remove spring washers (2), stoppers (3) and spacers (4). Remove shims (5) if equipped. : 36 mm 4. Remove the counterweight. W162-02-02-001 W162-02-02-002 W162-02-02-003 1 2 3 4 5 10 9 8 6 7 6 7 1 2 3 10 5 4 9 8
- 26. UPPERSTRUCTURE / Counterweight W2-2-2 Installation CAUTION: Counterweight weight: 12500 kg (27560 lb) 1. Attach wire ropes with shackles to the lifting lugs on the top of the counterweight. CAUTION: Never allow anyone under the lifted counterweight. 2. Lift the counterweight. With the bosses on the back face of the counterweight aligned with holes on the frame, install the counterweight. CAUTION: Use care to prevent hand injury from the power wrench reaction bar. IMPORTANT: Apply a lubricant to bolts (7) before installing. Install stoppers (8) with flanges positioned downward. 3. Install bolts (7), nuts (10), stoppers (8) and washers (6 and 9). Tighten bolts (7) using a power wrench. : 65 mm : 2750 N⋅m (280 kgf⋅m, 2025 lbf⋅ft) 4. Install shims (5), spacers (4), stoppers (3), and spring washers (2) and bolts (1). Detach the wire ropes and shackles. : 36 mm : 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft) W162-02-02-001 W162-02-02-002 W162-02-02-003 1 2 3 4 5 10 9 8 6 7 6 7 1 2 3 10 5 4 9 8
- 27. UPPERSTRUCTURE / Pump Device W2-3-1 REMOVE AND INSTALL PUMP DEVICE CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. The hydraulic oil tank cap may fly off by remaining pressure if removed quickly. Slowly loosen the cap to completely release any remaining pressure. Preparation 1. After stopping the engine, move the control levers several times to release any pressure remaining in the system. 2. Rotate the hydraulic oil tank cap approx. 30° counterclockwise to release trapped air in the hydraulic oil tank. Removal 1. Disconnect all hydraulic lines and electrical cables from the pump. : 22 mm, 27 mm : 8 mm, 14 mm 2. Place a block (100 mm square, approx. 30 mm thick) underneath the engine flywheel housing. CAUTION: Pump device weight: 445 kg (980 lb) 3. Remove the pump device mounting bolts and rear side engine mounting bolts to remove the pump device. : 36 mm, 16 mm Installation 1. Install the pump with the mounting bolts. 2. Connect all hydraulic lines and electrical cables to the pump. 3. Bleed air trapped inside the pump. (Refer to page W1-1-2.) IMPORTANT: After installing the pump, be sure to perform break-in operation to prevent seizure. W162-02-03-003 W162-02-03-004 Tightening Torque Wrench Size (mm) N⋅m kgf⋅m lbf⋅ft Remark : 22 49 5 36 Hose : 27 93 9.5 69 Hose : 8 108 11 80 Hose : 14 265 27 195 Hose : 36 690 70 506 Bolt : 16 69 7 51 Bolt Break-In Operation Process: 1. Start the engine and run at slow idle speed for 20 minutes. Check for oil leaks while running at slow idle. 2. Increase the engine speed to the fast idle speed. Raise and lower the boom for 20 minutes repeatedly. (Do not operate the control levers quickly. Slowly move the levers to full stroke.) Block Engine Rear Side Mounting Bolt Pump Device Mounting Bolt
- 28. UPPERSTRUCTURE / Pump Device W2-3-2 DISASSEMBLE PUMP TRANSMISSION W162-02-03-002 1 - Casing 6 - Retaining Ring 10 - Bolt (5 Used) 14 - O-Ring 2 - Bearing 7 - Bearing 11 - Bolt (8 Used) 15 - Bearing 3 - Sleeve 8 - O-Ring 12 - Oil Seal 16 - Gear 4 - Retaining Ring 9 - Cartridge 13 - Cartridge 17 - Bearing 5 - Gear 1 2 3 4 5 6 7 8 9 10 17 16 15 14 13 12
- 29. UPPERSTRUCTURE / Pump Device W2-3-3 Disassemble Pump Transmission • Before starting any repair work, thoroughly read all “Precautions for Disassembling and Assembling” (W1-1-1). CAUTION: Pump device weight: 145 kg (320 lb) 1. Place casing (1) on a work bench with the main pump mounting side facing downward. 2. Remove bolts (10). : 8 mm CAUTION: Pump device weight: 145 kg (320 lb) 3. Re-position casing (1) on the work bench so that the engine mounting side faces downward. NOTE: At this time, lay two wooden blocks (100 mm high) under the casing so that the blocks are not under cartridges (9 and 13). 4. Attach metal protector (dia 30 mm) to top of sleeve (3) and tap the protector over top of sleeve (3) with a plastic hammer until gear (5) comes in contact with casing (1). Then, cartridge (9) and bearing (7) are pushed out of casing (1). CAUTION: Pump device weight: 145 kg (320 lb) 5. Lay two wooden blocks (150 mm high) on the work bench. Place casing (1) on the wooden blocks with the main pump mounting side facing downward. 6. Remove cartridge (9) from casing (1). Remove O- ring (8) from cartridge (9). 7. Attach metal protector (dia 25 mm) to top of sleeve (3) and tap the protector over top of sleeve (3) with a plastic hammer until gear (5) comes in contact with casing (1). Remove sleeve (3) from the outer race of bearing (7). 8. Using a puller, remove the outer race of bearing (7). 9. Remove retaining ring (6) from sleeve (3). 10. Attach metal protector (dia. 30 mm) to top of sleeve (3) and tap the protector over top of sleeve (3) with a plastic hammer to remove sleeve (3) and bearing (2) from casing (1). 11. Using a press, remove bearing (2) from sleeve (3). 12. Remove retaining ring (4) from sleeve (3). 13. Remove bolts (11) and cartridge (13). : 17 mm 14. Remove oil seal (12) and o-ring (14) from cartridge (13). CAUTION: Pump transmission weight: 140 kg (310 lb) 15. Lay two wooden blocks (150 mm high) on the work bench. Place casing (1) on the wooden blocks with the engine mounting side facing downward. 16. Attach metal protector (dia 90 mm) to top of gear (16). Using a press, push gear (16) out of casing (1). 17. Take gear (5) out of casing (1). 18. Using a press or puller, remove bearings (15 and 17) from gear (16).
- 30. UPPERSTRUCTURE / Pump Device W2-3-4 ASSEMBLE PUMP TRANSMISSION W162-02-03-001 1 - Casing 6 - Retaining Ring 10 - Bolt (5 Used) 14 - O-Ring 2 - Bearing 7 - Bearing 11 - Bolt (8 Used) 15 - Bearing 3 - Sleeve 8 - O-Ring 12 - Oil Seal 16 - Gear 4 - Retaining Ring 9 - Cartridge 13 - Cartridge 17 - Bearing 5 - Gear 1 5 10 8 9 7 14 12 13 11 1516172346
- 31. UPPERSTRUCTURE / Pump Device W2-3-5 Assemble Pump Transmission 1. Press bearings (15 and 17) onto gear (16). 2. Install retaining ring (4) to sleeve (3). 3. Press bearing (2) onto sleeve (3). 4. Install gear (5) into casing (1). IMPORTANT: Press bearing (2) into casing (1) until the end face of bearing (2) is flush with the stepped face in the casing bore. 5. With splines on sleeve (3) and gear (5) aligned, press sleeve (3) with bearing (2) into casing (1). CAUTION: Assembly weight of casing (1), gear (5), etc.: 125 kg (276 lb) 6. Turn casing (1) over. 7. Install retaining ring (6) to sleeve (3). 8. After centering the outer and inner races of bearing (7), press the outer race of bearing (7) into casing (1). 9. Install O-ring (8) around cartridge (9). 10. Install cartridge (9) in casing (1) with bolts (10). : 13 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 11. Press gear (16) into casing (1) so that gear (16) meshes with gear (5). 12. Attaching a protector on oil seal (12), press oil seal (12) into cartridge (13). 13. Apply grease on the inner lip of oil seal (12). 14. Install O-ring (14) in cartridge (13). 15. Install cartridge (13) in casing (1) with bolts (11). : 17 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) CAUTION: Pump transmission weight: 145 kg (320 lb) 16. Check that bearing (2) and sleeve (3) are correctly installed in casing (1) by softly tapping bearing (2) with a plastic hammer.
- 32. UPPERSTRUCTURE / Pump Device W2-3-6 (Blank)
- 33. UPPERSTRUCTURE / Pump Device W2-3-7 REMOVE AND INSTALL MAIN PUMP CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. The hydraulic oil tank cap may fly off by remaining pressure if removed quickly. Slowly loosen the cap to completely release any remaining pressure. Preparation 1. After stopping the engine, move the control levers several times to release any pressure remaining in the system. 2. Rotate the hydraulic oil tank cap approx. 30° counterclockwise to release trapped air in the hydraulic oil tank. Removal 1. Disconnect all hydraulic lines and electrical cables from the pump. : 22 mm, 27 mm : 8 mm, 14 mm CAUTION: Main pump weight: 300 kg (661 lb) 2. Remove the pump mounting bolts to remove the pump. : 36 mm Installation 1. Install the pump with the mounting bolts. 2. Connect all hydraulic lines and electrical cables to the pump. 3. Bleed air trapped inside the pump. (Refer to page W1-1-2.) IMPORTANT: After installing the pump, be sure to perform break-in operation to prevent seizure. T162-03-01-001 Tightening Torque Wrench Size (mm) N⋅m kgf⋅m lbf⋅ft Remark : 22 49 5 36 Hose : 27 93 9.5 69 Hose : 8 108 11 80 Hose : 14 265 27 195 Hose : 36 690 70 506 Bolt Break-In Operation Process: 1. Start the engine and run at slow idle speed for 20 minutes. Check for oil leaks while running at slow idle. 2. Increase the engine speed to the fast idle speed. Raise and lower the boom for 20 minutes repeatedly. (Do not operate the control levers quickly. Slowly move the levers to full stroke.) Mounting Bolt
- 34. UPPERSTRUCTURE / Pump Device W2-3-8 Disassemble Main Pump W162-02-04-001 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 47 46 45 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 737475 72 76 49 48 22
- 35. UPPERSTRUCTURE / Pump Device W2-3-9 1 - Socket Bolt 20 - Tilt Pin 39 - Spacer 58 - Valve Plate 2 - Cover 21 - Regulator 40 - Spring 59 - O-Ring 3 - O-Ring 22 - Socket Bolt 41 - Cylinder Block 60 - O-Ring 4 - Oil Seal 23 - Servo Piston 42 - Valve Plate 61 - Housing 5 - Shaft 24 - O-Ring 43 - Bearing 62 - O-Ring 6 - Spacer 25 - Backup Ring 44 - O-Ring 63 - Cover 7 - Bearing 26 - Stopper 45 - Cover 64 - Socket Bolt 8 - Spacer 27 - O-Ring 46 - Plug 65 - Cover 9 - Retaining Ring 28 - Taper Pin 47 - O-Ring 66 - Socket Bolt 10 - Socket Bolt 29 - Plug 48 - Screw 67 - Shaft 11 - Cover 30 - A Sensor 49 - Nut 68 - Pin 12 - Nut 31 - O-Ring 50 - Booster 69 - Filter 13 - Screw 32 - Plug 51 - Coupling 70 - Spring Pin 14 - Pin 33 - Swash Plate 52 - Spring Pin 71 - Cover 15 - O-Ring 34 - Bushing 53 - Filter 72 - O-Ring 16 - Stopper 35 - Shoe 54 - Pin 73 - Plug 17 - Backup Ring 36 - Plunger 55 - Shoe Plate 74 - O-Ring 18 - O-Ring 37 - Retainer 56 - Feed Back Link 75 - O-Ring 19 - Housing 38 - Spherical Bushing 57 - Bearing 76 - O-Ring NOTE: Parts (6 to 9, 12 to 18, 20 to 41, 55, and 56) in housing (61) are the same as those used in housing (19).
- 36. UPPERSTRUCTURE / Pump Device W2-3-10 W162-02-04-001 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 47 46 45 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 737475 72 76 49 48 22
- 37. UPPERSTRUCTURE / Pump Device W2-3-11 Disassemble Main Pump • Before starting any repair work, thoroughly read all “Precautions for Disassembling and Assembling” (W1-1-1). IMPORTANT: Do not remove screws (13 and 48) and nuts (12 and 49). If removed, the pump set flow rate may be changed. 1. Remove two plugs (32) and O-rings (31) to drain hydraulic oil from the pump. : 36 mm 2. Remove socket bolt (22) and regulator (21). Remove A sensors (30) (two places). : 6 mm IMPORTANT: Take care not to allow valve plates (42 and 58) to drop when separating housing (19) assembly, cover (45) assembly, cover (71) assembly, and housing (61) assembly. 3. Insert a steel bar or pipe into the pump mounting bolt holes in covers (11 and 65). While holding the bar or pipe to prevent the pump assembly from rotating, loosen socket bolts (10 and 66) to separate housing (19) assembly, cover (45) assembly, cover (71) assembly and housing (61) assembly. At this time, remove O-rings (44, 59, 60, and 74 to 76), spring pins (52 and 70), and filters (53 and 69). : 17 mm 4. Remove booster (50), coupling (51), valve plate (42) and pin (54) from cover (45). Remove valve plate (58) and pin (68) from cover (71). NOTE: Do not remove bearing (43, 57) unless required. 5. Remove cylinder blocks (41), springs(40), spacers (39), spherical bushings (38), retainers (37) plungers (36), and shoes (35) from housings (19 and 61). 6. Loosen socket bolts (1 and 64) to remove covers (2 and 63) and O-rings (3 and 62). Remove oil seal (4) from cover (2). : 6 mm 7. Tap covers (11 and 65) with a plastic hammer to remove from housings (19 and 61). Remove O- rings (27) and spring pins (14). 8. Remove swash plates (33) and shoe plates (55) from housings (19 and 61). NOTE: Do not remove feedback links (56) unless required. 9. Tap with a plastic hammer to remove shafts (5 and 67) from covers (11 and 65). 10. Remove retaining rings (9), spacers (8), bearings (7) and spacers (6) from shafts (5 and 67) IMPORTANT: LOCTITE is applied to the joint between servo piston (23) and tilt pin (20). Take care not to damage servo piston (23) when disassembling. 11. Remove stoppers (16), stoppers (26), servo pistons (23) and tilt pins (20) from housings (19 and 61).
- 38. UPPERSTRUCTURE / Pump Device W2-3-12 Assemble Main Pump W162-02-04-003 1 - Socket Bolt 20 - Tilt Pin 39 - Spacer 58 - Valve Plate 2 - Cover 21 - Regulator 40 - Spring 59 - O-Ring 3 - O-Ring 22 - Socket Bolt 41 - Cylinder Block 60 - O-Ring 4 - Oil Seal 23 - Servo Piston 42 - Valve Plate 61 - Housing 5 - Shaft 24 - O-Ring 43 - Bearing 62 - O-Ring 6 - Spacer 25 - Backup Ring 44 - O-Ring 63 - Cover 7 - Bearing 26 - Stopper 45 - Cover 64 - Socket Bolt 8 - Spacer 27 - O-Ring 46 - Plug 65 - Cover 9 - Retaining Ring 28 - Taper Pin 47 - O-Ring 66 - Socket Bolt 10 - Socket Bolt 29 - Plug 48 - Screw 67 - Shaft 11 - Cover 30 - A Sensor 49 - Nut 68 - Pin 12 - Nut 31 - O-Ring 50 - Booster 69 - Filter 13 - Screw 32 - Plug 51 - Coupling 70 - Spring Pin 14 - Pin 33 - Swash Plate 52 - Spring Pin 71 - Cover 15 - O-Ring 34 - Bushing 53 - Filter 72 - O-Ring 16 - Stopper 35 - Shoe 54 - Pin 73 - Plug 17 - Backup Ring 36 - Plunger 55 - Shoe Plate 74 - O-Ring 18 - O-Ring 37 - Retainer 56 - Feed Back Link 75 - O-Ring 19 - Housing 38 - Spherical Bushing 57 - Bearing 76 - O-Ring NOTE: Parts (6 to 9, 12 to 18, 20 to 41, 55, and 56) in housing (61) are the same as those used in housing (19). 12 13 11 1 2 5 27 15 10 3 4 14 33 55 35 19 34 44 60 46,47 49 26 60577548 74 76 24,25 23 59 20 61 16 17,18 65 64 67 62 9 63 8 66 56 669,70 728,2931,32 71 72,73505145435452,5342 68 58404136 3937 3830
- 39. UPPERSTRUCTURE / Pump Device W2-3-13 Assemble Main Pump IMPORTANT: Apply LOCTITE (medium adhesive) to the joint between servo piston (23) and tilt pin (20). 1. Install A sensors (30), tilt pins (20), servo pistons (23), O-rings (18 and 24), backup rings (17 and 25) and stoppers (16 and 26) into housings (19 and 61). : 6 mm : 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 2. Heat bearing (7). Install spacers (6), bearings (7), spacers (8) and retaining rings (9) onto shafts (5 and 67). 3. Install pins (14), O-rings (15 and 27) to covers (11 and 65). Install covers (11 and 65) to housings (19 and 61). IMPORTANT: Install feedback link (56) to swash plate (33) with the link hole connected to tilt pin (20). 4. Install shoe plate (55) to swash plate (33). Install swash plates (33) into housings (19 and 61) so that the swash plate joins with tilt pin (20). NOTE: After installing swash plate (33), make sure that the swash plate can be moved smoothly by hand. 5. Press shafts (5 and 67) in covers (11 and 65). Install oil seals (4), O-rings (3 and 62) to covers (2 and 63). Install covers (2 and 63) to covers (11 and 65) with socket bolts (1 and 64). : 6 mm : 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 6. Install springs (40), spacer (39), spherical bushing (38), plungers (36), retainer (37) and shoes (35) to cylinder block (41). Install the cylinder blocks onto shafts (5 and 67) while aligning splines. IMPORTANT: Apply greae to the valve plate (42). 7. Install spring pins (52), filter (53), pin (54), valve plate (42) and O-rings (44) to cover (45). NOTE: When installing valve plate (42), align the pin hole position with pin (54). 8. Install housing (19) assembly to cover (45) with socket bolts (10). : 17 mm : 630 N⋅m (64 kgf⋅m, 463 lbf⋅ft) 9. Install coupling (51) and booster (50) to cover (45). IMPORTANT: Apply a film of grease to valve plate (58). 10. Install spring pins (70), filter (69), pin (68), valve plate (58) and O-rings (60, 59, 74, 75, and 76) to cover (71). NOTE: When installing valve plate (58), align the pin hole position with pin (68). 11. Install housing (61) to cover (71). Then, install them to housing (19) assembly with socket bolts (66). : 17 mm : 630 N⋅m (64 kgf⋅m, 463 lbf⋅ft) 12. Install regulator (21) onto housing (19) with socket bolts (22) so that the regulator feedback lever joints with tilt pin (20). : 6 mm : 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 13. Install O-rings (31) and plugs (32). : 36 mm : 165 N⋅m (17 kgf⋅m, 123 lbf⋅ft)
- 40. UPPERSTRUCTURE / Pump Device W2-3-14 MAINTENANCE STANDARDS 1. Clearance between Plunger (36) Outer Diameter (d) and Cylinder Block (41) Bore Diameter (D). D−d Unit : mm (in) Standard Allowable Limit 0.047 (0.002) 0.094 (0.004) 2. Free Length (L) of Spring (40) Unit : mm (in) Standard Allowable Limit 49.5 (1.95) 48.0 (1.89) 3. Clearance (e) between Plunger (36) and Shoe (35) and Thickness (t) of Shoe (35). e Unit : mm (in) Standard Allowable Limit 0 to 0.1 (0 to 0.004) 0.35 (0.014) t Unit : mm (in) Standard Allowable Limit 6.5 (0.26) 6.3 (0.25) 4. Height difference from the reverse face of retainer (37) to the top of spherical bushing (38) H−h Unit : mm (in) Standard Allowable Limit 16.5 (0.65) 15.5 (0.61) W117-02-02-009 W117-02-02-010 W117-02-02-011 W117-02-02-012 d D L e t H Base h
- 41. UPPERSTRUCTURE / Pump Device W2-3-15 (Blank)
- 42. UPPERSTRUCTURE / Pump Device W2-3-16 DISASSEMBLE REGULATOR W162-02-04-002 1 - Casing 11 - Plug 21 - Sleeve 30 - Valve Seat 2 - Spring Seat 12 - Pin 22 - O-Ring 31 - Steel Ball 3 - Spring 13 - O-Ring 23 - Pump Control Solenoid Valve 32 - Stopper 4 - Stopper 14 - O-Ring 24 - Valve Cover 33 - Socket Bolt 5 - O-Ring 15 - O-Ring 25 - Socket Bolt 34 - Plug 6 - Cover 16 - Spool 26 - Plug 35 - Stopper 7 - Socket Bolt 17 - Pin 27 - O-Ring 36 - Steel Ball 8 - Screw 18 - Feedback Lever 28 - Plug 37 - Valve Seat 9 - Nut 19 - Sleeve 29 - O-Ring 38 - O-Ring 10 - O-Ring 20 - Pilot Piston 1 2 3 4 5 6 7 8 9 10 11 12 13 18 14 15 16 19 20 21 22 23 17 24 25 35 36 37 38 27 28 29 30 31 32 33 34
- 43. UPPERSTRUCTURE / Pump Device W2-3-17 Disassemble Regulator • Before starting any repair work, thoroughly read all “Precautions for Disassembling and Assembling” (W1-1-1). 1. Remove pump control solenoid valve (23). : 32 mm 2. Loosen socket bolts (25) to remove valve cover (24). : 5 mm 3. Remove O-ring (29), valve seat (30), steel ball (31), and stopper (32) from casing (1). 4. Remove O-ring (22), sleeve (21), and pilot piston (20) from casing (1). 5. Remove plug (11) to remove feedback lever (18), pin (17), sleeve (19), and spool (16). : 6 mm NOTE: Feedback lever (18) and pin (17) will come off at the same time . 6. Loosen socket bolts (7) to remove cover (6). : 5 mm IMPORTANT: Do not remove screw (8) and nut (9). If removed, the pump flow rate setting may be changed. 7. Using forcing bolt (M4), remove stopper (4). Then, remove spring (3) and spring seat (2). 8. Remove O-ring (38), valve seat (37), steel ball (36), and stopper (35) from casing (1).
- 44. UPPERSTRUCTURE / Pump Device W2-3-18 ASSEMBLE REGULATOR T111-02-03-005 1 - Casing 11 - Plug 21 - Sleeve 30 - Valve Seat 2 - Spring Seat 12 - Pin 22 - O-Ring 31 - Steel Ball 3 - Spring 13 - O-Ring 23 - Pump Control Solenoid Valve 32 - Stopper 4 - Stopper 14 - O-Ring 24 - Valve Cover 33 - Socket Bolt 5 - O-Ring 15 - O-Ring 25 - Socket Bolt 34 - Plug 6 - Cover 16 - Spool 26 - Plug 35 - Stopper 7 - Socket Bolt 17 - Pin 27 - O-Ring 36 - Steel Ball 8 - Screw 18 - Feedback Lever 28 - Plug 37 - Valve Seat 9 - Nut 19 - Sleeve 29 - O-Ring 38 - O-Ring 10 - O-Ring 20 - Pilot Piston 1 2 3 4 5 6 7 8 9 25 10 11 12 13171814191516 21 20 22 32 31 30292827 35 36 37 38 3433 23 24
- 45. UPPERSTRUCTURE / Pump Device W2-3-19 Assemble Regulator 1. Install stopper (35), steel ball (36), valve seat (37) and O-ring (38) into casing (1). 2. Install sleeve (19) and spool (16) into casing (1). Then, install feedback lever (18) to sleeve (19) with pin (17). NOTE: Take care not to mistake the installing direction of sleeve (19) and spool (16). 3. Install O-ring (10) around plug (11). Align the pin holes of feed back lever (18) and casing (1). Then, install plug (11) with O-ring (10) into casing (1). : 6 mm : 19 N⋅m (2 kgf⋅m, 15 lbf⋅ft) NOTE: After installing plug (11), check that the feedback lever (18) moves smoothly. 4. Install spring seat (2), spring (3), stopper (4) and O-ring (5) into casing (1). Install cover (6) with socket bolts (7). : 4 mm : 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft) 5. Install pilot piston (20), sleeve (21), and O-ring (22) into casing (1). 6. Install stopper (32), steel ball (31), valve seat (30) and O-ring (29) into casing (1). 7. Install pump control solenoid valve (23) to valve cover (24). Install valve cover (24) to casing (1) with socket bolts (25). : 32 mm : 44 N⋅m (4.5 kgf⋅m, 33 lbf⋅ft) : 4 mm : 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
- 46. UPPERSTRUCTURE / Pump Device W2-3-20 DISASSEMBLE AND ASSEMBLE PILOT PUMP W137-02-04-034 1 9 6 26 10 27 6 9 2 3 5 10 12 26 13 27 12 7 15 16 14
- 47. UPPERSTRUCTURE / Pump Device W2-3-21 Tightening Torque Item Part Name Q’ty Wrench Size (mm) N⋅m kgf⋅m lbf⋅ft Remarks 1 Housing 1 2 Flange 1 3 Oil Seal 1 Apply grease to oil seal lip when installing. 5 Retaining Ring 1 6 Seal 2 Apply grease to seal when installing. 7 Cover 1 9 Backup Ring 2 Apply grease to backup ring when installing. 10 Key 2 12 O-Ring 2 Apply grease to O-ring when installing. 13 Gear 1 14 Gear 1 15 Washer 4 16 Bolt 4 : 17 39 to 44 4 to 4.5 29 to 33 26 Bushing 2 Apply a film of hydraulic oil to bushing when installing. 27 Bushing 2 Apply a film of hydraulic oil to bushing when installing.
- 48. UPPERSTRUCTURE / Pump Device W2-3-22 (Blank)
- 49. UPPERSTRUCTURE / Control Valve W2-4-1 REMOVE AND INSTALL CONTROL VALVE CAUTION: 1. Escaping pressure hydraulic oil can penetrate the skin or eyes, causing serious injury. Avoid this hazard by relieving pressure before discon- necting hydraulic lines. 2. Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting work. 3. The hydraulic oil tank cap may fly off due to internal pressure if turned quickly. Slowly turn the cap to release internal pressure before completely removing the cap. Preparation 1. Park the machine on firm and level surface. Lower the front attachment to the ground. 2. Stop the engine. Move all control levers to release any pressure remaining in the system.Slowly turn the hydraulic oil tank cap approx. 30 degrees counterclockwise to release any remaining pressure from the hydraulic oil tank. Refer to “Bleed Pressure from Hydraulic Circuit” on page W1-1-2. 3. Remove the cap and connect a vacuum pump. Operate the vacuum pump constantly to maintain the negative pressure in the hydraulic oil tank. NOTE: Keep the vacuum pump running continuously while working.
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