PART NO. ZAXIS450-3 • 450LC-3 • 470H-3 • 470LCH-3 • 500LC-3 • 520LCH-3 class HYDRAULIC EXCAVATOR WORKSHOP MANUAL URL:http://www.hitachi-c-m.com W1J1-E-00 Workshop Manual 450-3 450LC-3 470H-3 470LCH-3 500LC-3 520LCH-3 Hydraulic Excavator PRINTED IN JAPAN (E) 2006, 02 W1J1-E-00 Page 1 Service Manual consists of the following separate Part No; Technical Manual (Operational Principle) : Vol. No.TO1J1-E Technical Manual (Troubleshooting) : Vol. No.TT1J1-E Workshop Manual : Vol. No.W1J1-E 2006.2.
INTRODUCTION TO THE READER • This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine. • Be sure to thoroughly read this manual for correct product information and service procedures. • If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.
INTRODUCTION SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. • This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights.
SAFETY RECOGNIZE SAFETY INFORMATION • These are the SAFETY ALERT SYMBOLS. • When you see these symbols on your machine or in this manual, be alert to the potential for personal injury. • Follow recommended precautions and safe operating practices. 001-E01A-0001 SA-688 UNDERSTAND SIGNAL WORDS • On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.
SAFETY FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the machine and all safety messages in this manual. • Safety signs should be installed, maintained and replaced when necessary. • If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering). • Learn how to operate the machine and its controls correctly and safely.
SAFETY PREPARE FOR EMERGENCIES • Be prepared if a fire starts or if an accident occurs. • Keep a first aid kit and fire extinguisher on hand. • Thoroughly read and understand the label attached on the fire extinguisher to use it properly. • To ensure that a fire-extinguisher can be always used when necessary, check and service the fire-extinguisher at the recommended intervals as specified in the fire-extinguisher manual. • Establish emergency procedure guidelines to cope with fires and accidents.
SAFETY PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing. • Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. 006-E01A-0434 SA-434 INSPECT MACHINE • Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.
SAFETY GENERAL PRECAUTIONS FOR CAB • Before entering the cab, thoroughly remove all dirt • • • • • • and/or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator's work boots the operator's foot may slip off the pedal, possibly resulting in a personal accident. Do not leave parts and/or tools lying around the operator's seat. Store them in their specified locations. Avoid storing transparent bottles in the cab.
SAFETY USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury. • When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. • Do not use any controls as hand-holds. • Never jump on or off the machine. Never mount or dismount a moving machine. • Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.
SAFETY ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR'S SEAT • Before rising from the operator's seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death.
SAFETY MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over. • Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine. • Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move. • Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine. • Use appropriate illumination.
SAFETY OPERATE SEAT ONLY FROM OPERATOR'S • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. • Start the engine only when seated in the operator's seat. • NEVER start the engine while standing on the track or on ground. • Do not start engine by shorting across starter terminals. • Before starting the engine, confirm that all control levers are in neutral.
SAFETY KEEP RIDERS OFF MACHINE • Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. • Only the operator should be on the machine. Keep riders off. • Riders also obstruct the operator's view, resulting in the machine being operated in an unsafe manner. 014-E01B-0427 SA-379 PRECAUTIONS FOR OPERATIONS • Investigate the work site before starting operations.
SAFETY INVESTIGATE JOB SITE BEFOREHAND • When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death. • Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing. • Make a work plan. Use machines appropriate to the work and job site. • Reinforce ground, edges, and road shoulders as necessary.
SAFETY EQUIPMENT OF HEAD GUARD, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.
SAFETY DRIVE MACHINE SAFELY • Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direction you wish to drive. • Be sure to detour around any obstructions. • Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Don't allow personnel to stay around the machine while traveling. • Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.
SAFETY DRIVE MACHINE SAFELY • Driving across the face of a slope or steering on a • • • • • • • slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation. Avoid swinging the upperstructure on slopes. Never attempt to swing the upperstructure downhill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed.
SAFETY • Use wood plates in order not to damage the road • • • • • • surface. Be careful of steering when operating on asphalt roads in summer. When crossing train tracks, use wood plates in order not to damage them. Do not make contact with electric wires or bridges. When crossing a river, measure the depth of the river using the bucket, and cross slowly. Do not cross the river when the depth of the river is deeper than the upper edge of the upper roller.
SAFETY AVOID INJURY FROM ROLLAWAY ACCIDENTS • Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: • Select level ground when possible to park machine. • Do not park the machine on a grade. • Lower the bucket and/or other work tools to the ground. • Turn the auto-idle switch and the H/P mode switch off. • Run the engine at slow idle speed without load for 5 minutes to cool down the engine. • Stop the engine and remove the key from the key switch.
SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: • Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR. • Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA.
SAFETY KEEP PERSON CLEAR FROM WORKING AREA • A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death. • Keep all persons clear from the area of operation and machine movement. • Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area.
SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT • The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death. To avoid tipping: • Be extra careful before operating on a grade. SA-012 • Prepare machine operating area flat. • Keep the bucket low to the ground and close to the machine.
SAFETY DIG WITH CAUTION • Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death. • Before digging check the location of cables, gas lines, and water lines. • Keep the minimum distance required, by law, from cables, gas lines, and water lines. • If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.
SAFETY AVOID POWER LINES • Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. • When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length. • Check and comply with any local regulations that may apply. • Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site.
SAFETY PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result. • Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. • Keep bystanders away from the working area before striking any object. 031-E01A-0432 SA-432 PARK MACHINE SAFELY To avoid accidents: • Park machine on a firm, level surface. • Lower bucket to the ground. • Turn auto-idle switch and H/P mode switch OFF.
SAFETY TRANSPORT SAFELY • Take care the machine may turn over when loading or unloading the machine onto or off of a truck or trailer. • Observe the related regulations and rules for safe transportation. • Select an appropriate truck or trailer for the machine to be transported. • Be sure to use a signal person. • Always follow the following precautions for loading or unloading: 1. Select solid and level ground. 2. Always use a ramp or deck strong enough to support the machine weight. 3.
SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before starting work. • Keep the work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving. • Keep hands, feet and clothing away from power-driven parts. Before servicing the machine: 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Run the engine at slow idle speed without load for 5 minutes.
SAFETY • If a maintenance procedure must be performed • • • • • • • • with the engine running, do not leave machine unattended. If the machine must be raised, maintain a 90 to 100° angle between the boom and arm. Securely support any machine elements that must be raised for service work. Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the "MAINTENANCE" chapter of this manual. Keep all parts in good condition and properly installed.
SAFETY SUPPORT MACHINE PROPERLY • Never attempt to work on the machine without securing the machine first. • Always lower the attachment to the ground before you work on the machine. • If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.
SAFETY PREVENT PARTS FROM FLYING • Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. • Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY. • As pieces may fly off, be sure to keep body and face away from valve. • Never attempt to disassemble the track adjuster.
SAFETY PREVENT BURNS Hot spraying fluids: • After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. • To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap. • The hydraulic oil tank is pressurized.
SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. • Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. • Tighten all connections before applying pressure. • Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.
SAFETY PREVENT FIRES Check for Oil Leaks: • Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts. • Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts. • Do not bend or strike high-pressure lines. • Never install bent or damaged lines, pipes, or hoses.
SAFETY EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way: • Stop the engine by turning the key switch to the OFF position if there is time. • Use a fire extinguisher if there is time. • Exit the machine. • In an emergency, if the cab door or front window cannot be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer the explanation pages on the Emergency Evacuation Method in the operator's manual.
SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. • Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. • Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc..
SAFETY BEWARE OF ASBESTOS DUST • Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer. • Depending on the wok site conditions, the risk of inhaling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Don't use compressed air. • When operating the machine in a work site where asbestos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos.
SAFETY SERVICE AIR CONDITIONING SYSTEM SAFELY • If spilled onto skin, refrigerant may cause a cold contact burn. • Refer to the instructions described on the container for proper use when handling the refrigerant. • Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere. • Never touch the refrigerant. 513-E01A-0405 SA-405 HANDLE CHEMICAL PRODUCTS SAFELY • Direct exposure to hazardous chemicals can cause serious injury.
SAFETY DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. • Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. • Do not pour waste onto the ground, down a drain, or into any water source.
SAFETY (Blank) SA-36
SECTION AND GROUP CONTENTS SECTION 1 GENERAL INFORMATION Group 1 Precautions for disassembling and Assembling Group 2 Tightening Torque Group 3 Painting Group 4 Bleeding Air from Hydraulic Oil Tank WORKSHOP MANUAL SECTION 2 UPPERSTRUCTURE Group 1 Cab Group 2 Counterweight Group 3 Main Frame Group 4 Pump Device Group 5 Control Valve Group 6 Swing Device Group 7 Pilot Valve Group 8 Pilot Shut-Off Solenoid Valve Group 9 Solenoid Valve Group 10 Signal Control Valve Group 11 Shockless Valve Group 12 Fan Valve
TECHNICAL MANUAL (Operational Principle) SECTION 1 GENERAL Group 1 Specification Group 2 Component Layout Group 3 Component Specifications SECTION 2 SYSTEM Group 1 Controller Group 2 Control System Group 3 ECM System Group 4 Hydraulic System Group 5 Electrical System SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Pilot Valve Group 5 Travel Device Group 6 Signal Control Valve Group 7 Others (Upperstructure) Group 8 Others (Undercarriage) TECHNICAL MANUA
SECTION 1 GENERAL CONTENTS Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling.............................................T1-1-1 Group 2 Tightening Torque Tightening Torque Specification .............. W1-2-1 Torque Chart .......................................... W1-2-3 Piping Joint ............................................ W1-2-6 Periodic Replacement of Parts ............. W1-2-10 Group 3 Painting Painting ...........................................
(Blank) 1J1W-1-2
GENERAL / Precautions for Disassembling and Assembling PRECAUTIONS FOR AND ASSEMBLING DISASSEMBLING Precautions for Disassembling and Assembling • Clean the Machine • Precautions for Disassembling 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.
GENERAL / Precautions for Disassembling and Assembling • Precautions for Assembling Bleeding Air from Hydraulic System • Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part. • Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces. • Before assenbling, coat all inner parts with clean hydraulic oil or gear oil.
GENERAL / Precautions for Disassembling and Assembling • 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).
GENERAL / Precautions for Disassembling and Assembling Floating Seal Precautions A 1. In general, replace the floating seal with a new one after disassembling. If the floating seal is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. (2) Check the slide surface on seal ring (A) for scuffing, scoring, corrosion, deformation or uneven wear. (3) Check O-ring (B) for deformation or hardening.
GENERAL / Precautions for Disassembling and Assembling Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely. • Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from being damaged and the lifted load from slipping. • Lower the temperature of the lifted load to lower than 100 °C (212 °F).
GENERAL / Precautions for Disassembling and Assembling CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using. Damaged Appearance Broken Sewing Thread W162-01-01-002 Scuffing 2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If any damage is found, cut and discard the sling.
GENERAL / Precautions for Disassembling and Assembling MAINTENANCE STANDARD TERMINOLOGY “Standard” 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies adjusted to specification. “Allowable Limit” 1. Normal machine performance cannot be accomplished after exceeding this limit. 2. Repair or adjustment is impossible after exceeding this limit. 3.
GENERAL / Precautions for Disassembling and Assembling (Blank) W1-1-8
GENERAL / Tightening TIGHTENING TORQUE SPECIFICATION No.
GENERAL / Tightening No. Descriptions 25 Counterweight mounting bolt 26 Signal control valve mounting bolt Front pin-retaining bolt Front pin-retaining nut 27 Bolt Dia mm 45 24 10 20 20 NOTE: 1. Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to reduce friction coefficient of them. 2. Make sure bolt and nut threads are clean before installing. W1-2-2 Q’ty 2 4 4 15 7 Wrench Size (mm) 65 36 8 holes 30 30 Torque Nxm 2400 450 50 400 400 (kgfxm) (240) (45.0) (5.
GENERAL / Tightening 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 correct size tools. Otherwise, tightening tools may slip, potentially causing personal injury. Bolt Types Tighten nuts or bolts correctly to torque specifications. Make sure to employ correct bolts and tighten them correctly when assembling the machine or components.
GENERAL / Tightening 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 lubricant. 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.
GENERAL / Tightening 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.
GENERAL / Tightening 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. 1 4 3 2 5 Union Joint M202-07-051 Joint Body Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. IMPORTANT: 1. Do not over-tighten union nut (3).
GENERAL / Tightening O-ring Seal Joint 7 9 6 O-ring (6) seats against the end surface of adapter (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 surface (10).
GENERAL / Tightening Screw-In Connection PT Depending on types of screw and sealing, different types of screw fittings are used. IMPORTANT: Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. 30° Male Tapered Thread PF Male Straight Thread W105-01-01-018 Wrench Size mm Joint Body 19 22 27 36 41 50 60 Male Tapered Thread Tightening Torque N⋅m (kgf⋅m, lbf⋅ft) FC material SS material 14.5 (1.5,10.5) 34 (3.5, 25) 29.
GENERAL / Tightening Connecting Hose RIGHT WRONG CAUTION: When replacing hoses, be sure to use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leaks, hose rupture or Separation of fitting, possibly resulting in a fire on the machine. Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting.
GENERAL / Tightening PERIODIC REPLACEMENT OF PARTS 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 cannot be detected through machine operation or visual inspection. Therefore, these parts should be replaced at regular intervals even if no abnormalities are noticed.
GENERAL / Painting PAINTING Painting specification Surfaces to Be Painted • Main surface of upperstructure Painting Colour YR-01 [TAXI yellow] Bed cover YR-01[TAXI yellow] Inner surface Grey • Front attachment YR-01 [TAXI yellow] • Track (undercarriage) N1.
GENERAL / Painting Shaded Part: Shining Silver Align with the panel. Panel W1J1-01-03-003 Left Side of Cab W1J1-01-03-004 (Rear Panel of Door) (Door) 10 W1J1-01-03-005 Painted Range of Door Track (Undercarriage) N1.
GENERAL / Bleeding Air from Hydraulic Oil Tank BLEED AIR FROM HYDRAULIC OIL TANK CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Do not turn the cap on hydraulic oil tank quickly. The cap may fly off by internal pressure.
GENERAL / Bleeding Air from Hydraulic Oil Tank (Blank) W1-4-2
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SECTION 2 UPPERSTRUCTURE — CONTENTS — Group 1 Cab Group 5 Control Valve Remove and Install Cab ......................... W2-1-1 Remove and Install Control Valve...........W2-5-1 Dimensions of Cab Glass....................... W2-1-9 Disassemble Control Valve (4-Spool Housing Side) .........................W2-5-4 Group 2 Counterweight Remove and Install Counterweight ........ W2-2-1 Assemble Control Valve (4-Spool Housing Side) .......................
Group 6 Swing Device Group 12 Fan Valve Remove and Install Swing Device.......... W2-6-1 Remove and Install Fan Valve ..............W2-12-1 Disassemble Swing Device.................... W2-6-4 Structure of Fan Valve ..........................W2-12-4 Assemble Swing Device....................... W2-6-14 Disassemble Swing Motor .................. W2-6-24 Group 13 Fan Motor Remove and Install Fan Motor..............W2-13-1 Assemble Swing Motor ........................ W2-6-28 Structure of Fan Motor ....
UPPERSTRUCTURE / Cab REMOVE AND INSTALL CAB Removal CAUTION: Seat (1) weight: 40 kg (88 lb) 1. Remove bolts (2) (2 used). Remove the seat belt from bracket (4). : 16 mm 1 3 2 W1JB-02-01-008 2. Remove socket bolts (3) (4 used) from seat (1). Remove seat (1) from bracket (4). : 6 mm 1 3 4 W1JB-02-07-007 3. Remove mat (6) from the cab inside.
UPPERSTRUCTURE / Cab 7 4. Remove bolts (8) (3 used) and washers (9) (3 used) from bracket (7). Remove bracket (7) from bracket (10) and cab (5). : 19 mm 8, 9 10 5. Remove bolts (12) (2 used) from cover (11). : 13 mm 5 W1JB-02-01-003 11 12 W1JB-02-01-004 6. Remove caps (13) (6 used) from cover (11). Remove screws (14) (6 used) from cover (11). 5 7. Remove cover (11) from cab (5). 13, 14 11 W1JB-02-01-005 13, 14 8. Remove bolts (15) (2 used) from bracket (16) and cover (17). : 13 mm 15 9.
UPPERSTRUCTURE / Cab 10. Remove screws (21) (2 used) from cover (20). Remove cap (22) and screw (23) from cover (20). Remove cover (20) from cab (5). 20 21 22, 23 11. Remove bolt (24) from duct (25). Remove duct (25) from bracket (26). : 13 mm W1JB-02-01-001 5 24 16 25 26 W1JB-02-01-041 12. Remove bolts (27, 29) (6 used for each). Remove under covers (28, 30) from the main frame.
UPPERSTRUCTURE / Cab 13. Remove bolts (33) (2 used), washers (32) (2 used) and spacers (31) (2 used) from the cab. : 32 mm Cab W1J1-02-01-003 31, 32, 33 Bracket CAUTION: Cab (5) weight: 550 kg (1210 lb) 36 5 Bracket 14. Attach a nylon sling onto the bracket and hold cab (5). 15. Remove nuts (34) (6 used) and washers (35) (6 used) from cab (5). : 24 mm 34, 35 34, 35 16. Remove socket bolts (36) (6 used) from cab (5). : 8 mm 36 17.
UPPERSTRUCTURE / Cab Installation CAUTION: Cab (5) weight: 550 kg (1210 lb) 1. Attach a nylon sling onto cab (5) and hoist cab (5). Align cab (5) with the mounting hole on main frame (39). 5 W1J1-02-01-001 39 2. Install cab (5) to main frame (39) with bolts (34) (6 used) and washers (35) (6 used). : 24 mm : 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft) 3. Install cab (5) to main frame (39) with socket bolts (36) (6 used). : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 36 Bracket 5 34, 35 Bracket 34, 35 4.
UPPERSTRUCTURE / Cab 6. Install covers (28, 30) to the lower side of main frame (39) with bolts (27, 29) (6 used for each). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 27 28 29 30 W1J1-02-01-002 7. Install duct (25) to brackets (16, 26) with bolt (24). : 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 8. Install the connector, plug and vinyl hose to cab (5).
UPPERSTRUCTURE / Cab 20 9. Install cover (20) to cab (5) with screws (21) (2 used). Install cover (20) to cab (5) with screw (23). Install cap (22) to screw (23). 21 10. Install bracket (16) to bracket (18) with bolts (15) (2 used). Install cover (17) to bracket (18) with bolts (19) (2 used). : 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 22, 23 5 W1JB-02-01-001 15 16 17 18 15 19 W1JB-02-01-040 11. Install cover (11) to cab (5) with bolts (14) (5 used).
UPPERSTRUCTURE / Cab 13. Install bracket (7) to bracket (10) and cab (5) with bolts (8) (3 used) and washers (9) (3 used). : 19 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft) 7 8, 9 10 CAUTION: Seat (1) weight: 40 kg (88 lb) 1 5 W1JB-02-01-003 3 Seat Belt 14. Install seat (1) to bracket (4) with socket bolts (3) (4 used). : 6 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 4 W1JB-02-07-007 15. Install the seat belt to bracket (4) with bolts (2) (2 used).
UPPERSTRUCTURE / Cab DIMENSIONS OF THE CAB GLASS NOTE: Unit: mm (1 mm=0.039 in) Black Ceramic Coating Range 115 70 21 60 C0.5 2-R20 2-R10 2-R127 Black Ceramic Coating Surface 107 2-R50 2-R250 2-R50 70 C0.5 A 106.6 W1JB-02-01-013 1081 R50 Section A (4 mm) R2975 R800 φ28 B R75 Black Ceramic Coating Surface R120 R40 2R-5 271 50 268 20 70 16.5 W1JB-02-01-011 21 214 847 21 Black Ceramic Coating Range R1075 372.9 C (4 mm) 22 W1JB-02-01-009 50 54.
UPPERSTRUCTURE / Cab NOTE: Unit: mm (1 mm=0.039 in) 375 214 R155 (4 mm) (4 mm) 796.5 2-φ12.2 +0.5 -0 796.5 40 R2852 34.2 267.5 3-R4 50 50 234.5 50 W1JB-02-01-015 W1JB-02-01-016 50 390 13.9 434.5 C0.5 C0.5 Black Ceramic Coating Surface W1JB-02-01-013 Section A W1JB-02-01-010 860.8 833 Black Ceramic Coating Range 506 63.5 581 438.5 353.5 50 2-φ21 64.5 R50 448 R964 R75 R58 185 R250 R103 R42 R329 R10 17 2-R4 R150 R2854 498.5 26.5 327.5 173 109.5 (4 mm) R60 R25 1 102.
UPPERSTRUCTURE / Cab NOTE: Unit: mm (1 mm=0.039 in) Black Ceramic Coating Range 30 R30 39 29 652 87.5 (4 mm) R200 87.5 R200 R500 A R500 R50 185 185 45 70 R50 205 848 4-R10 W1JB-02-01-021 W1JB-02-01-010 Black Ceramic Coating Range 567.5 496 C0.5 123.5 80 3-R4 Black Ceramic Coating Surface 75.5 C0.5 R25 100 W1JB-02-01-013 R25 R20 R25 87.7° R75 Section A 887 1008 R4044.5 mm) (4 19.5 B R25 R4139.5 1127.3 59.5 85 1099 1145.5 C0.5 R40 R35 C0.
UPPERSTRUCTURE / Cab NOTE: Unit: mm (1 mm=0.039 in) C1 C1 Black Ceramic Coating Surface W1JB-02-01-013 Section A W1JB-02-01-009 1646.47 1599.44 Black Ceramic Coating Range 187 80 50 106 2-R25 50 R75 R20 R30 90 R30 R50 158 R2875 R575 R125 R1040 R10 R50 R30 R50 28° R1525 R30 R55 393 400 807.65 963.7 W2-1-12 1636.3 R3025 1496.7 40 A 1205 R2940 (5 mm) R25 873.14 50 1230 R30 150 145 696.73 R300 R2145 900 R20 313.
UPPERSTRUCTURE / Cab Procedure to Remove Cab Glass Right-Hand Glass Procedures to Remove Right-Hand Glass, Rear Left Glass, Lower Door Glass and Rear Glass CAUTION: When removing the broken or cracked glass, the glass shards may cause serious injury. Before removing, use the gummed tape or something like in order to paste the broken or cracked glass and reinforce them. Remove the glass pieces away. W1JB-02-01-009 1. Remove the resin panel, garnish, spacer or etc. around the glass.
UPPERSTRUCTURE / Cab 4. Wind the both ends of piano wire onto the screwdriver. Draw the wire back and forth in order to cut the adhesive between cab and glass. Remove the glass from the cab. Glass (Cab Outside) Cab NOTE: Cut off the middle of adhesive between glass and cab. Piano wire is easily broken if a part of piano wire turns hot. Change the position and cut the adhesive.
UPPERSTRUCTURE / Cab Procedure to Install Cab Glass Right-Hand Glass Procedures to Install Right-Hand Glass, Rear Left-Hand Glass, Lower Door Glass and Rear Glass 1. Cut off the residual adhesive from cab side by 1 to 2 mm deep all around by using a cutter knife or similar. NOTE: Do not damage the cab paint. W1JB-02-01-009 Rear Glass 2. Clean the cutting edge of adhesive at cab side by using white spirit.
UPPERSTRUCTURE / Cab 4. Clean the mating edge of new glass by using clean rag and ethylalcohol. IMPORTANT: Primer （ Sika Primer Z06G+P ） should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer, apply Primer as quickly as possible and replace the cap immediately after using. After opening Primer, all the contents should be used within 180 days (or 2 hours with the cap off). 5.
UPPERSTRUCTURE / Cab NOTE: Unit: mm (1 mm=0.
UPPERSTRUCTURE / Cab NOTE: Unit: mm (1 mm=0.039 in) Spacer C Spacer B Spacer A 20 20 6 6 4 4 6 Apply Adhesive to Both Sides 20 6 R0.5 R5 84° 2 6 R0.5 4 R8 R0.5 3 75° 8 R10 78° 12 Apply Adhesive to Both Sides 3 10.5 10.5 W1JB-02-01-024 W1JB-02-01-023 W1JB-02-01-022 Dam Rubber 30 6.
UPPERSTRUCTURE / Cab 13. The required amount (just for reference) of adhesive and primer Adhesive Sika Tack-Drive 310 ml Cratridge Upper Front Glass Lower Glass of Door Rear Left-Hand Glass Rear Right-Hand Glass Rear Glass Painted Surface or Adhesive Surface Primer Sika Aktivator DM-1 250 ml Can Glass Surface Primer Sika Primer 206G+P 30 ml Bottle 310 ml 0.75 ml 0.67 ml 150 ml 0.5 ml 0.45 ml 250 ml 0.65 ml 0.6 ml 100 ml 1 ml 0.9 ml 210 ml 0.5 ml 0.
UPPERSTRUCTURE / Cab Procedures to Install Upper Door Glass 1. Before installing the glass, remove the garnish around sash assembly from the cab inside for easy removal. Push the sash assembly by hands and remove the sash outside. Sash Assembly Garnish 2. Install glass A and glass B into the sash grooves. 3. Install the sash assembly, which the glass is installed on, onto the door from the outside of cab. Secure the sash assembly at the inside of cab by using the garnish.
UPPERSTRUCTURE / Cab Procedures to Install Upper Front Glass Adhere the glass in the same method as right-hand glass. 1. Stick seal (1) to the lower side of front upper glass by using Cemedine Super X. Stick and secure both right and left ends (the thicker part) of seal (1) to the glass by using Cemedine Super X. Stick the mating surface of seal (1) and the glass by using Cemedine Super X so that no visible undulation or boss can be found. NOTE: Cemedine Super X Black No.
UPPERSTRUCTURE / Cab (Blank) W2-1-22
UPPERSTRUCTURE / Counterweight REMOVE AND INSTALL COUNTERWEIGHT Removal CAUTION: Counterweight weight: 9150 kg (20200 lb) 1. Attach a lifting tool, wire rope and chain block to the lifting hole on counterweight in order to hold. Adjust the wire rope length by using the chain block and make the counterweight horizontal. CAUTION: Do not stay under the lifted counterweight. W1J1-02-02-001 2. Remove bolts (13), spring washers (14) and washers (11) (11 used for each). Remove covers (11, 12) from the main frame.
UPPERSTRUCTURE / Counterweight Installation CAUTION: Counterweight weight: 9150 kg (20200 lb) 1. Attach a lifting tool, wire rope and chain block to the lifting hole on counterweight in order to hoist. Adjust the wire rope length by using the chain block and make the counterweight horizontal. CAUTION: Do not stay under the lifted counterweight. 2. Install the projection of counterweight to the hole on bracket. W1J1-02-02-001 CAUTION: When using a power wrench, do not injure hands by the reaction bar. 3.
UPPERSTRUCTURE / Main Frame REMOVE AND INSTALL MAIN FRAME Removal CAUTION: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) W1J1-02-01-001 CAUTION: Cab weight: 560 kg (1235 lb) 1. Remove the cab from the main frame. (Refer to the Remove and Install Cab section on W2-1.) CAUTION: Counterweight weight: 9150 kg (20200 lb) 2. Hoist and remove the counterweight from the main frame.
UPPERSTRUCTURE / Main Frame 4. Remove all hoses from center joint (2). Remove lock plate (1). (Refer to the Remove and Install Center Joint section on W3-3.) 1 CAUTION: Upperstructure weight: 10800 kg (23800 lb) Upperstructure weight with removal / installation device: 11200 kg (24700 lb) 5. Install special tools (ST 0234, ST 0235) to the bracket at the mounting position for counterweight with the bolts (M45, Pitch 3.0 mm) and the nuts (2 used). Install the shackle (for 4.
UPPERSTRUCTURE / Main Frame 6. Remove bolts (3) (29 used) and (4) (7 used) from the outer race of swing bearing. 7. Adjust the wire rope length by using a chain block (6) in order to make the counterweight horizontal. Hoist and remove the main frame from the track frame.
UPPERSTRUCTURE / Main Frame Installation CAUTION: Upperstructure weight: 10800 kg (23800 lb) Upperstructure weight with removal / installation device: 11200 kg (24700 lb) 6 1. Attach a wire rope onto special tools (ST 0234, ST 0235) and the boom bracket. Adjust the wire rope length by using a chain block (6) and make the counterweight horizontal. Hoist and install the main frame to the track frame. Main Frame Track Frame W157-02-03-002 2. Hoist the main frame.
UPPERSTRUCTURE / Main Frame CAUTION: Cab weight: 560 kg (1235 lb) 6. Install the cab to the center frame. (Refer to the Remove and Install Cab section on W2-1.) W1J1-02-01-001 CAUTION: Counterweight weight: 9150 kg (20200 lb) 7. Install the counterweight to the main frame. (Refer to the Remove and Install Counterweight section on W2-2.) CAUTION: Front attachment weight: 7920 kg (17470 lb) assembly 8. Install the front attachment assembly to the main frame.
UPPERSTRUCTURE / Main Frame (Blank) W2-3-6
UPPERSTRUCTURE / Pump Device REMOVE AND INSTALL PUMP DEVICE CAUTION: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 2 1 1. Open engine cover (2). Remove lock pins (5) (2 used) and washers (4) (2 used). Remove stays (3) (2 used) from the bracket. Lay down engine cover (2) to the muffler cover (1) side. W1J1-02-13-001 CAUTION: Engine cover (2) weight: 32kg (70 lb) 8 3 2.
UPPERSTRUCTURE / Pump Device CAUTION: Cover (15) weight: 32 kg (70 lb) 15 4. Remove catches (2). Open cover (11). Remove bolts (16) (11 used). Remove cover (15). : 19 mm Rain Cover 16 NOTE: Remove cover (15) with cover (11) and the rain cover attached. 11 Catch 17 W1J1-02-04-038 18 19 5. Remove bolts (21) (4 used). Remove bracket (8) from bracket (22). : 19 mm 8 21 6. Remove bolts (18) (3 used). Remove bracket (22). : 19 mm 22 7. Remove bolts (19) (4 used). Remove bracket (17).
UPPERSTRUCTURE / Pump Device 9. Loosen nut (29) and move band (28) to the center of hose (31). Remove the terminals (2 used) of contamination sensor (27). Remove hose (31) from air cleaner (30). : 11 mm 27 28 Terminal 29 30 31 W1J1-02-04-042 10. Remove bolts (34) (2 used). Remove clamps (35) (2 used) from bracket (32).
UPPERSTRUCTURE / Pump Device 11. Open and lock the pump cover. 36 37 38 37 37 12. Remove bolts (40) (2 used). Remove the harness from cover (39). : 17 mm 13. Remove bolts (37) (18 used) and (42). Remove covers (36, 38, 39, 41). : 19 mm 39 40 41 37 42 CAUTION: Air cleaner (38) weight: 35 kg (77 lb) Harness W1J1-02-04-041 14. Remove bolts (45) (4 used) from the bolt mounting hole at pump space side. Attach a nylon sling onto air cleaner (43). Hoist and remove air cleaner (43) from bracket (32).
UPPERSTRUCTURE / Pump Device 15. Remove bolts (45) (5 used). Remove bracket (32). : 19 mm 32 45 W1J1-02-04-045 Main Frame 46 16. Remove socket bolts (52, 57) (4 used for each). Remove pipes (53, 58) from the pump device. : 14 mm 47, 48 17. Remove socket bolts (47, 49, 60) (4 used for each). Remove hoses (48, 50, 61) from the pump device. : 10 mm 52, 53 5 18. Remove hoses (46, 51, 54, 55, 56, 59). Cap the hose and pump. Attach identification tags to the removed hoses for reassembling.
UPPERSTRUCTURE / Pump Device CAUTION: Pump device weight: 290 kg (640 lb) 20. Attach a wire rope onto eyebolts (2 used) in the pump device and hold the pump device. IMPORTANT: The engine is connected to the pump device through the coupling. When removing the pump device from the engine, slide the pump device to 50 mm (2.0 in) in parallel to the shaft. 21. Put the matching marks on the mating surfaces on engine and pump device.
UPPERSTRUCTURE / Pump Device Installation IMPORTANT: When removing the pump device from the engine, replace the coupling of engine and pump device. Do not reuse the coupling. 1. Apply LOCTITE #262 to socket bolts (69) (10 used). Install coupling (68) to the engine with socket bolts (69) (10 used). : 8 mm : 49 N⋅m (5.0 kgf⋅m, 36 lbf⋅ft) 2. Insert coupling (66) until spline end surface (A) in the pump device comes in contact with hub end surface (B) in coupling (66).
UPPERSTRUCTURE / Pump Device CAUTION: Pump device weight: 290 kg (640 lb) 62, 63, 64 3. Attach a wire rope onto eyebolts (2 used) in the upper surface on pump. Hoist the pump device and insert coupling (66) in the pump device into coupling (68) in the engine. Align the matching marks made when disassembling on engine and pump device. 4. Apply LOCTITE #262 to socket bolts (62) (8 used) and (65) (2 used).
UPPERSTRUCTURE / Pump Device 7. Install bracket (44) to the main frame with bolts (45) (5 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 32 45 W1J1-02-04-045 Main Frame CAUTION: Air cleaner (38) weight: 35 kg (77 lb) 43 8. Apply LOCTITE #262 to bolts (45) (4 used). Attach a nylon sling onto air cleaner (38). Hoist and move air cleaner (38) to the mounting position for bracket (44). Install air cleaner (43) to bracket (32) with bolts (45) (4 used). : 17 mm : 50 N⋅m (5.
UPPERSTRUCTURE / Pump Device 9. Install covers (36, 38, 39, 41) with bolts (37) (18 used) and (42). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 10. Install harness (33) and the clamps (2 used) with bolts (40) (2 used). Pass harness (33) through the hole on cover (39). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 36 37 38 37 穴 37 39 40 41 33 42 37 11. Install harness (33) with clamp (35) and bolts (34) (2 used). : 19 mm : 90 N⋅m (9.
UPPERSTRUCTURE / Pump Device 12. Install hose (31) to air cleaner (27). Tighten band (29) with nut (30). : 11 mm 13. Install the terminals (2 used) of contamination sensor (28). 27 28 Terminal 29 30 31 W1J1-02-04-042 17 18 19 8 14. Install bracket (17) with bolts (19) (4 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 21 22 15. Install bracket (22) with bolts (18) (3 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 16. Install bracket (8) to bracket (22) with bolts (21) (4 used).
UPPERSTRUCTURE / Pump Device 18. Install muffler cover (1) with bolts (10) (8 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 10 1 CAUTION: Engine cover (2) weight: 32 kg (70 lb) W1J1-02-13-003 19. Place engine cover (2) onto muffler cover (1). Install hinges (6) (4 used) to bracket (8) with bolts (7) (8 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 1 2 20. Install stays (3) (2 used) to bracket (8) with washers (4) (2 used) and lock pins (5) (2 used).
UPPERSTRUCTURE / Pump Device 21. Install under covers (24, 26) to the main frame with bolts (23, 25) (5 used for each). : 19 mm : 90 N⋅m (9.
UPPERSTRUCTURE / Pump Device DISASSEMBLE PUMP DEVICE 56 64 63 57 63 D 58 59 15 64 69 57 67 68 55 65 80 79 78 75 74 56 57 73 57 64 62 16 63 83 71 72 70 110 71 18 70 62 29 C 33 36 81 45 47 41 36 34 41 E 30 41 40 33 54 46 47 43 42 102 112 104 20 B 108 21 109 27 25 50 48 52 49 51 39 40 A 112 28 29 34 44 106 31, 32 C 38 H 28 37 39 46 G 30 31, 32 D 42 26 27 16 38 37 F 111 61 19 77 42 60 19 84 66 76 A E B C 2 22 3 4 53 7 5 1
UPPERSTRUCTURE / Pump Device 1- Valve Cover 31 - Shoe (18 Used) 2345678- Nut (2 Used) Set Screw (2 Used) Socket bolt Booster O-Ring Booster Cover Socket Bolt (5 Used) 32 33 34 36 37 38 39 - O-Ring Cover Socket Bolt (2 Used) Socket Bolt (2 Used) Socket Bolt (9 Used) Plug (2 Used) O-Ring (2 Used) Plug (12 Used) Valve Plate Pin (2 Used) Seat Packing (2 Used) Pin (4 Used) Stopper 1 (2 Used) Steel Ball (2 Used) Seat (2 Used) Plug (2 Used) Needle Bearing (2 Used) Valve Plate R Valve Plate L Cylinder Block (
UPPERSTRUCTURE / Pump Device D A E B 55 63 G C F D H C E C 4 7 A B 8 1 11 F 10 12 13 G H W1J1-02-04-004 W2-4-16
UPPERSTRUCTURE / Pump Device Disassemble Pump Device CAUTION: The pump assembly weight: 290 kg (640 lb) 1. Remove plug (63). Drain oil from pump casing (55). 2. Remove the regulators (2 used) in pumps 1, 2 from pump casing (55). NOTE: As for removal and disassembly of the regulator, refer to the regulator section on W2-4-39. The structures of pumps 1, 2 are identical. Put the marks on the regulator in pumps 1,2 in order not to confuse. 3. Remove the gear pump (pilot pump) from booster cover (7).
UPPERSTRUCTURE / Pump Device D 69 68 A E B 67 55 76 26 27 80 29 79 C 37 F 31, 32 D G 30 33 H 28 81 C 37 45 32, 31 E 34 30 29 28 27 33 25 50 34 51 52 C 2 3 44 A B 1 F 24 G H 85 24 86 W1J1-02-04-004 W2-4-18
UPPERSTRUCTURE / Pump Device IMPORTANT: Do not remove needle bearing (24) unless replacing needle bearing (4). 8. Remove stop ring (86), inner spacer (85) and valve plate (25) from drive shaft (44). Remove valve plate (26) from driven shaft (45). 9. Remove plungers (32, 31), retainer (30), spherical bushing (29) and the cylinder block (27) assembly attached with cylinder spring (28) from drive shaft (44) and driven shaft (45) in pump casing (55). 10.
UPPERSTRUCTURE / Pump Device D 55 65 A E B 19 84 76 75 74 73 83 70 71 72 71 70 G C F D H 81 39 C E 45 47 46 41 42 111 42 41 41 46 39 43 42 C 44 A B 47 F G H W1J1-02-04-004 W2-4-20
UPPERSTRUCTURE / Pump Device CAUTION: Front casing (76) weight: 32 kg (70 lb) 14. Attach a lifting tool onto the bolt hole mounting the engine and hold front casing (76). Remove socket bolts (81) (12 used). Hoist and remove front casing (76) from pump casing (55). : 10 mm 20. Remove socket bolts (65) (8 used). Remove swash plate stands (39) (2 used) from pump casing (55). : 6 mm NOTE: Pins (19) (2 used), (83, 84) are located between front casing (76) and pump casing (55).
UPPERSTRUCTURE / Pump Device D A E B 76 G 110 C F D H C E C A 102 112 104 106 112 B 107 108 109 F 92 93 101 96 100 94 95 98 99 95 G H W1J1-02-04-004 W2-4-22
UPPERSTRUCTURE / Pump Device CAUTION: Fan pump Transmission weight: 28 kg (62 lb) Fan pump weight: 51 kg (112 lb) 21. Hoist and hold eyebolt in the fan pump. Remove the socket bolts (4 used) mounting the fan pump. Remove the fan pump from transmission housing (98). (Refer to “Disassemble Fan Pump” on W2-4-49.) 22. Hoist and hold eyebolt (101). 23. Remove socket bolts (100) (8 used). Remove transmission housing (98) from front casing (76). : 10 mm 24.
UPPERSTRUCTURE / Pump Device ASSEMBLE PUMP DEVICE 53, 54 52 51 38 37 56 55 2 3 17 4 1 66 68 69 20 21 15 22 67 81 58 65 59 Section X-X 10 34 9 36 76 16 11 39 57 29 33 28 31 30 15 14 27 32 18 13 23 16 58 40 62 26 41 73 47 46 42 111 42 41 45 5 6 8 7 74 75 47 71 71 19 77 44 86 80 70 24 79 25 80 12 78 72 18 46 43 42 41 85 88 89 91 90 Section A-A W1J1-02-04-005 W2-4-24
UPPERSTRUCTURE / Pump Device 102 104 110 100 42 107 108 109 106 112 98 95 95 96 94 W1J1-02-04-013 93 Fan Pump 92 Transmission Section for Fan Pump 1- Valve Cover 31 - Shoe (18 Used) 2345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 - Nut (2 Used) Set Screw (2 Used) Socket bolt Booster O-Ring Booster Cover Socket Bolt (5 Used) O-Ring Cover Socket Bolt (2 Used) Socket Bolt (2 Used) Socket Bolt (9 Used) Plug (2 Used) O-Ring (2 Used) Plug (12 Used) Valve Plate (2 Used) Seat Pac
UPPERSTRUCTURE / Pump Device 65 Apply adhesive (THREEBOND #1305N). 55 Section X-X 39 41 73 47 18 42 111 42 41 45 74 75 47 71 71 Apply adhesive (SEALAND L101) to outer surface of oil seal.
UPPERSTRUCTURE / Pump Device Assemble Pump Device 1. Apply adhesive (THREEBOND #1305N) onto the thread part of socket bolts (65) (8 used). 2. Install swash plate stand (39) to pump casing (55) with socket bolts (65) (8 used). : 6 mm : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft) 3. Install roller bearing (43), bearing spacer (42) and retaining ring (41) to drive shaft (44). CAUTION: Front casing weight: 32 kg (70 lb) 10. Install pins (19) (2 used), (83, 84) to pump casing (55). 11.
UPPERSTRUCTURE / Pump Device 52 51 Apply adhesive (THREEBOND #1305N).
UPPERSTRUCTURE / Pump Device 12. Install front casing (76) to pump casing (55) with socket bolts (81) (8 used). : 10 mm : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) NOTE: When it is difficult to install front casing (76), tap and install front casing (76) by using a plastic hammer. 13. Apply grease to the lip part in oil seal (78). Install oil seal (78) to front cover (79). 18. Install servo cover (67) onto pump casing (55) with socket bolt (66). : 10 mm : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) 19.
UPPERSTRUCTURE / Pump Device 55 17 1 20 21 15 22 58 59 Section X-X 29 28 31 30 27 32 45 26 44 24 25 18 Section A-A W1J1-02-04-005 W2-4-30
UPPERSTRUCTURE / Pump Device 20. Install the plunger assemblies (31, 32), retainer (30), spherical bushing (29) and cylinder spring (28) to cylinder block (27) in drive shaft (44) and driven shaft (45). 21. Align the splines and install spherical bushings (29) (2 used) and the cylinder block (27) assembly to pump casing (55). IMPORTANT: The directions to install valve plates (25, 26) at the drive shaft (44) side and driven shaft (45) side are different.
UPPERSTRUCTURE / Pump Device 38 37 55 4 1 Section X-X 10 11 13 45 5 8 19 7 Gear Pump 44 12 Section A-A W1J1-02-04-005 W2-4-32
UPPERSTRUCTURE / Pump Device CAUTION: Valve cover (1) weight: 60 kg (130 lb) 26. Install special tool to the end of drive shaft (44) and driven shaft (45). 148 mm 29. Install booster (5) to valve cover (1). Install O-ring (6) to booster cover (7). Install booster cover (7) to valve cover (1) with socket bolts (8) (4 used). Install O-ring (9) to cover (10). Install cover (10) to valve cover (1) with socket bolts (11) (2 used). : 8 mm : 57 N⋅m (5.8 kgf⋅m, 42 lbf⋅ft) 0 -0.075 +0.15 φ34.5 +0.05 φ387 30.
UPPERSTRUCTURE / Pump Device Transmission Housing Side 102 104 110 100 42 107 108 109 106 112 98 95 95 96 94 W1J1-02-04-013 93 Fan Pump 92 W2-4-34
UPPERSTRUCTURE / Pump Device CAUTION: Fan pump transmission weight: 28 kg (62 lb) 31. Install needle bearing (95) to transmission housing (98). 32. Install drive gear (96) to needle bearing (95) at the transmission housing (98) side. CAUTION: Fan pump weight: 51 kg (112 lb) 40. Hoist eyebolt in the fan pump and install the fan pump to transmission housing (98). Install the socket bolts (4 used). : 14 mm : 235 N⋅m (24 kgf⋅m, 175 lbf⋅ft) 33.
UPPERSTRUCTURE / Pump Device (Blank) W2-4-36
UPPERSTRUCTURE / Pump Device MAINTENANCE STANDARD Allowable Limits for vulnerable Parts 1. Clearance between plunger (32) outer diameter (d) and cylinder block (27) bore diameter (D). D-d d Unit: mm (in) Standard Allowable Limit 0.038 (0.001) 0.078 (0.003) D W117-02-02-009 2. Free length (L) of cylinder spring (28) L Unit: mm (in) Standard Allowable Limit 40.9 (1.61) 40.1 (1.58) 3.
UPPERSTRUCTURE / Pump Device ALLOWABLE LIMITS FOR CYLINDER BLOCK The Repair Limits for Cylinder, Valve Plate and Swash Plate (Shoe Plate) Valve plate (sliding portion) Swash plate (shoe plate portion) Cylinder (sliding portion) Roughness when repair is necessary Standard roughness (values after being repaired) W2-4-38 3-Z Less than 0.
UPPERSTRUCTURE / Pump Device DISASSEMBLE REGULATOR 6 7 5 4 3 2 8 1 26 34 28 30 31 9 33 32 11 26 13 14 15 29 27 5 18 25 22 24 35 21 20 10 16 19 17 23 W16J-02-04-002 123456789- Regulator Casing Spring Seat Pilot Spring Adjusting Disc Q O-Ring (2 Used) Cover Socket Bolt (4 Used) Nut Adjusting Screw 10 - Support Plug 11 - O-Ring (2 Used) 13 - Pin 14 - O-Ring (5 Used) 15 - O-Ring 16 - Pin 17 - Feedback Lever 18 - Spool 19 - Sleeve 20 21 22 23 24 25 26 27 28 - Pilot Piston Pf S
UPPERSTRUCTURE / Pump Device 6 3 7 4 2 1 34 28 31 32 33 10 27 18 25 21 20 19 17 24 W16J-02-04-002 W2-4-40
UPPERSTRUCTURE / Pump Device Disassemble Regulator IMPORTANT: The same type regulator is installed to pumps 1 and 2. As these characteristics are different each other, do not confuse them. These procedures are for the pump 1 regulator. 1. Remove socket bolts (34) (6 used). Remove the regulator from the pump casing. : 5 mm 2. Remove socket bolts (24, 25). Remove valve casing (27) attached with proportional pressure reducing valve (28) from casing (1). : 6 mm 3. Remove socket bolts (7) (4 used).
UPPERSTRUCTURE / Pump Device ASSEMBLE REGULATOR Section A-A 29 16 34 10 26 1 35 30 15 17 A 27 26 31 32 33 28 2 4 3 9 25 11, 23 8 24 7 21 6 20 5 22 14 5 19 13 18 A W16J-02-04-010 W2-4-42
UPPERSTRUCTURE / Pump Device 123456789- Regulator Casing Spring Seat Pilot Spring Adjusting Disc Q O-Ring (2 Used) Cover Socket Bolt (4 Used) Nut Adjusting Screw 10 - Support Plug 11 - O-Ring (2 Used) 13 - Pin 14 - O-Ring (5 Used) 15 - O-Ring 16 - Pin 17 - Feedback Lever 18 - Spool 19 - Sleeve 20 21 22 23 24 25 26 27 28 - Pilot Piston Pf Sleeve O-Ring Plug Socket Bolt (4 Used) Socket Bolt Plug (9 Used) Valve Casing Proportional Pressure Reducing Valve W2-4-43 29 30 31 32 33 34 35 - Socket Bolt (2 Us
UPPERSTRUCTURE / Pump Device Section A-A 16 Pin Hole 10 1 30 17 A 27 31 32 33 16 2 4 3 25 24 21 6 20 22 19 Support Hole 18 A W16J-02-04-010 W2-4-44
UPPERSTRUCTURE / Pump Device Assemble Regulator IMPORTANT: Spread the rubber sheet or cloth or etc. on the workbench in order not to damage the parts. 1. Install spool (18) and sleeve (19) to casing (1). Check if spool (18) and sleeve (19) move inside casing (1) smoothly. 2. Insert pin (16) in feedback lever (17) into the pin hole on sleeve (19). Slide feedback lever (17) so that the support hole on feedback lever (17) can be seen through the mounting hole on support plug (10). Install support plug (10).
UPPERSTRUCTURE / Pump Device DISASSEMBLE FAN PUMP 51 9 10 11 12 50 49 45 48 B 14 13 16 22 A 5 3 4 8 7 6 26 7 27 54 20 19 54 23 24 15 55 28 43 2 21 44 59 58 1 39 40 46 38 55 37 47 3 36 35 B 42 34 57 32, 33 56 30 29 A 31 W1J1-02-04-006 W2-4-46
UPPERSTRUCTURE / Pump Device 12345678910 11 12 13 14 - Socket Bolt (4 Used) Cover O-Ring (2 Used) Oil Seal Shaft Bearing Spacer (2 Used) Retaining Ring Nut (2 Used) Adjusting Screw Spring Pin (2 Used) Stopper Backup Ring O-Ring 15 16 19 20 21 22 23 24 26 27 28 29 30 31 - Housing Tilt Pin Stopper L Backup Ring O-Ring Servo Piston O-Ring (2 Used) Plug (2 Used) O-Ring Swash Plate Stand Socket Bolt (4 Used) Swash Plate Bushing Shoe Plate 32 33 34 35 36 37 38 39 40 42 43 44 45 46 - W2-4-47 Shoe (9 Used) Pl
UPPERSTRUCTURE / Pump Device 9 A 10 24 15 4 28 43 44 46 39 47 38 37 36 35 B 42 34 32, 33 A W1J1-02-04-006 W2-4-48
UPPERSTRUCTURE / Pump Device Disassemble Fan Pump CAUTION: Fan pump weight: 51 kg (110 lb) IMPORTANT: Do not remove adjusting screws (10, 43) and nuts (9, 44). If removing adjusting screws (10, 43) and nuts (9, 44), the characteristics are changed. 1. Remove plug (24) from housing (15). Drain hydraulic oil from the pump. : 13 mm IMPORTANT: Do not remove oil seal (4) unless replacing oil seal (4). 8. Remove spherical bushing (35) and springs (36) (9 used) from cylinder block (37). 2.
UPPERSTRUCTURE / Pump Device 45 16 19 22 12 A 5 8 7 6 15 7 27 2 1 B 31 29 A W1J1-02-04-006 W2-4-50
UPPERSTRUCTURE / Pump Device 9. Remove socket bolts (1) (4 used). Remove cover (2) from swash plate stand (27). : 6 mm 10. Remove swash plate stand (27) from housing (15). When swash plate stand (27) cannot be removed, tap and remove swash plate stand (27) by using a plastic hammer. 11. Remove swash plate (29) and shoe plate (31) from housing (15). 12. Remove shaft (5) from swash plate stand (27). When shaft (5) cannot be removed, tap and remove shaft (5) by using a plastic hammer.
UPPERSTRUCTURE / Pump Device (Blank) W2-4-52
UPPERSTRUCTURE / Pump Device ASSEMBLE FAN PUMP 27 12 13, 14 22 32 16 15 30 20, 21 19 41 44 43 9 10 40 11 26 23, 24 3 5 2 4 47 8 7 46 7 1 3 28 6 29 31 34 35 32, 33 36 37 48, 49, 50, 51 38 56 39 42 57 58, 59 W1J1-02-04-007 12345678910 11 12 13 14 - Socket Bolt (4 Used) Cover O-Ring (2 Used) Oil Seal Shaft Bearing Spacer (2 Used) Retaining Ring Nut (2 Used) Adjusting Screw Spring Pin (2 Used) Stopper Backup Ring O-Ring 15 16 19 20 21 22 23 24 26 27 28 29 30 31 - Housing Tilt Pin Sto
UPPERSTRUCTURE / Pump Device 27 12 13, 14 22 32 16 15 20, 21 19 11 26 3 5 2 4 8 7 7 1 6 29 31 34 35 32, 33 36 37 38 W1J1-02-04-007 W2-4-54
UPPERSTRUCTURE / Pump Device Assemble Fan Pump 1. Apply LOCTITE onto the contacting part between servo piston (22) and tilt pin (16). 2. Install tilt pin (16) and servo piston (22) to housing (15). 11. Install plungers (33) (9 used) and shoes (32) (9 used) to retainer plate (34). Install retainer plate (34) to cylinder block (37). 12. Install cylinder block (37) to shaft (5). 3. Install O-ring (21) and backup ring (20) to stopper (19). Install stopper (19) to housing (15). 4.
UPPERSTRUCTURE / Pump Device 16 15 41 40 23, 24 47 46 3 28 38 42 W1J1-02-04-007 W2-4-56
UPPERSTRUCTURE / Pump Device 13. Install pins (56, 57) and O-ring (40) to cover (42). NOTE: Align the pin hole on valve plate (38) with pin (54) and install valve plate (38). 14. Install cover (42) to housing (15) with socket bolts (28) (4 used). : 17 mm : 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft) 15. Install O-ring (3) to cover (46). Install cover (46) to cover (42) with socket bolts (47) (2 used). : 8 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 16. Align the feedback lever in regulator with tilt pin (16).
UPPERSTRUCTURE / Pump Device (Blank) W2-4-58
UPPERSTRUCTURE / Pump Device MAINTENANCE STANDARD 1. Clearance between plunger (33) outer diameter (d) and cylinder block (37) bore diameter (D). D-d d Unit: mm (in) Standard Allowable Limit 0.028 (0.001) 0.056 (0.002) D W117-02-02-009 2. Free length (L) of spring (36) L Unit: mm (in) Standard Allowable Limit 31.3 (1.23) 30.2 (1.19) 3. Clearance (e) between plunger (33) and shoe (32) bottom and shoe (31) thickness (t) e L W117-02-02-010 Unit: mm (in) Standard Allowable Limit 0 to 0.1 0.
UPPERSTRUCTURE / Pump Device DISASSEMBLE REGULATOR (FAN PUMP) 3 11 10 9 8 7 6 B F 5 2 3 1 19 17 13 22 23 4 20 14 D 15 21 A 24 25 30 G 18 20 CE 31 29 16 28 44 32 27 43 40 41 42 39 38 46 41 37 32 33 34 36 66 65 D E 48 49 35 F 64 57 58 64 61 63 A B C 60 67 51 52 53 54 59 52 67 62 49 G 52 69 53 W1J1-02-04-008 W2-4-60
UPPERSTRUCTURE / Pump Device 12345678910 11 13 14 15 16 17 - Pin Sleeve O-Ring (2 Used) O-Ring Sleeve Compensating Piston Compensating Rod Spring Seat Spring Spring Adjusting Disc Retaining Ring Spring Seat Spring Spring Retaining Ring 18 19 20 21 22 23 24 25 27 28 29 30 31 32 33 34 - Sleeve Spool Pin (2 Used) Lever Feedback Lever Pin Pin Lever Pilot Piston Spring Seat Spring Adjusting Disc O-Ring Socket Bolt (8 Used) Cover O-Ring 35 36 37 38 39 40 41 42 43 44 46 48 49 51 52 53 - W2-4-61 O-Ring (3 Use
UPPERSTRUCTURE / Pump Device 11 10 9 8 7 6 B F 5 D 22 23 25 2 20 1 19 21 A 13 14 15 30 G 18 20 CE 16 29 28 44 32 27 43 40 41 39 46 41 37 32 33 36 66 65 D E 48 49 49 F A 63 B C G 51 53 54 52 62 53 W1J1-02-04-008 W2-4-62
UPPERSTRUCTURE / Pump Device Disassemble Regulator (Fan Pump) 1. Remove socket bolts (36) (2 used) and (37) (2 used). Remove housing (48) from the pump. : 6 mm IMPORTANT: Do not remove adjusting screws (39, 40, 46) and nuts (41) (2 used), (44). If adjusting screws (39, 40, 46) and nuts (41) (2 used), (44) are removed, the pump characteristics are changed. 2. Remove socket bolts (32) (4 used). Remove cover (33) from housing (48). : 5 mm 3. Remove socket bolts (63) (4 used).
UPPERSTRUCTURE / Pump Device ASSEMBLE REGULATOR (FAN PUMP) 51 62 48 49 23 52 B 48 37 53 A 25 49 36 32 24 21 34 B 33 35 56 A 55 52, 69 20 64 67 63 59 64 54 26 22 66 65 29 30 32 Section A-A 31 45 46 43 60 68, 69 58 27 20 16 15 17 18 22 28 37 19 9 10 42 13 11 43 44 Section B-B 39 3 41 1 40 2 3 38 4 6 5 7 22 20 8 W1J1-02-04-009 W2-4-64
UPPERSTRUCTURE / Pump Device 12345678910 11 13 14 15 16 17 - Pin Sleeve O-Ring (2 Used) O-Ring Sleeve Compensating Piston Compensating Rod Spring Seat Spring Spring Adjusting Disc Retaining Ring Spring Seat Spring Spring Retaining Ring 18 19 20 21 22 23 24 25 27 28 29 30 31 32 33 34 - Sleeve Spool Pin (2 Used) Lever Feedback Lever Pin Pin Lever Pilot Piston Spring Seat Spring Adjusting Disc O-Ring Socket Bolt (8 Used) Cover O-Ring 35 36 37 38 39 40 41 42 43 44 46 48 49 51 52 53 - W2-4-65 O-Ring (3 Use
UPPERSTRUCTURE / Pump Device 48 49 23 51 52 53 25 48 49 21 20 26 54 55 56 29 30 32 Section A-A 31 27 28 17 18 19 9 10 42 11 43 Section B-B 3 7 22 8 W1J1-02-04-009 W2-4-66
UPPERSTRUCTURE / Pump Device Assemble Regulator (Fan Pump) 9. Install O-ring (55) to adjusting plug (54). Install adjusting plug (54) to housing (48). Install retaining ring (56) to housing (48). 1. Insert compensating rod (7) and lever (21) into housing (48). 2. Align the pin (49) hole on lever (21) with the pin hole on housing (48). Align pin (20) in lever (21) with the stepped part on compensating rod (7). Install lever (21) to housing (48). 3. Install retaining ring (17) to sleeve (18).
UPPERSTRUCTURE / Pump Device 62 48 48 37 36 32 34 33 35 63 66 65 Section A-A 16 15 17 14 Section B-B 18 19 13 3 1 2 4 6 5 W1J1-02-04-009 W2-4-68
UPPERSTRUCTURE / Pump Device 14. Install spring (15), spring seat (14) and retaining ring (13) to spool (19). 15. Install O-ring (4) to sleeve (5). Install sleeve (5), compensating piston (6), O-ring (3), sleeve (2) and pin (1) to housing (48). 16. Install spring (16) and O-rings (59, 60, 61) to housing (48). Install cover (62) with socket bolts (63) (4 used). : 5 mm : 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft) 17. Install O-rings (34) and (35) (3 used) to cover (33). 18.
UPPERSTRUCTURE / Pump Device STRUCTURE OF PILOT PUMP 27 13 26 10 10 12 1 9 6 26 14 27 6 9 2 3 5 16 15 7 12 W137-02-04-034 W2-4-70
UPPERSTRUCTURE / Pump Device Item Part Name Q’ty 1 Housing 1 2 Flange 1 3 Oil Seal 1 Wrench Size (mm) Tightening Torque N⋅m (kgf⋅m) Remarks (Ibf⋅ft) Apply grease to the 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 2 16 Bolt 2 26 Bushing 4 : 17
UPPERSTRUCTURE / Pump Device (Blank) W2-4-72
UPPERSTRUCTURE / Control Valve REMOVE AND INSTALL CONTROL VALVE 1 Removal 2 CAUTION: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) 1. Remove bolts (2) (4 used) from covers (1) (2 used). Remove covers (1) (2 used) from the main frame. : 19 mm W1J1-02-05-061 3 2. Remove solenoid valve (3) and signal control valve (4) from control valve (5).
UPPERSTRUCTURE / Control Valve 5. Remove bolts (6) (4 used) and spacers (7) (4 used) from control valve (5). : 30 mm CAUTION: Control valve (5) weight: 400 kg (880 lb) 6. Hoist and remove control valve (5) from the main frame. Installation 1. Install eyebolts (M12, Pitch 1.75 mm) (4 used) to control valve (5). 6, 7 6, 7 CAUTION: Control valve (5) weight: 400 kg (880 lb) 2. Hoist and align control valve (5) with the mounting position. 3. Apply LOCTITE #262 to bolts (6) (4 used).
UPPERSTRUCTURE / Control Valve 6. Install solenoid valve (3) and signal control valve (4). (Refer to “Remove and Install Solenoid Valve” on W2-9 and “Remove and Install Signal Control Valve” on W2-10.) 3 5 4 7. Install covers (1) (2 used) to the main frame with bolts (2) (4 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) W1J1-02-10-001 1 2 IMPORTANT: After completing the work, check the oil level. Start the engine and check for any oil leaks.
UPPERSTRUCTURE / Control Valve DISASSEMBLE CONTROL VALVE (4-SPOOL HOUSING SIDE) Boom Anti-Drift Valve 10 1 3 2 4 5 7 6 8 11 13 12 14 9 16 15 17 8 18 19 8 20 21 22 Load Check Valve 23 24 25 Bypass Shut-Out Valve 26 31 30 28 29 35 27 32 24 25 33 36 34 Boom Flow Rate Control Valve 10 40 19 8 41 44 42 37 38 43 10 39 17 45 15 47 48 49 50 14 46 8 14 45 44 43 51 41 15 52 17 39 8 19 35 8 46 55 47 48 49 54 53 37 Arm Flow Rate Control Valve W1Ｊ1-02-05-051
UPPERSTRUCTURE / Control Valve 12345678910 11 12 13 14 - Cap O-Ring Spring Poppet O-Ring Backup Ring Sleeve O-Ring (10 Used) Backup Ring Socket Bolt (12 Used) Piston O-Ring Cap O-Ring (3 Used) 15 16 17 18 19 20 21 22 23 24 25 26 27 28 - Cap (2 Used) Cover Check Valve (3 Used) Spring Cap (3 Used) O-Ring Spring Poppet Cap Backup Ring (2 used) O-Ring (2 Used) Spring Check Valve Cap 29 30 31 32 33 34 35 36 37 38 39 40 41 42 - W2-5-5 O-Ring Cap Cap O-Ring Spool Spring Socket Bolt (8 Used) Flange O-Ring (2
UPPERSTRUCTURE / Control Valve Boom Anti-Drift Valve 10 1 3 2 4 5 7 6 8 11 13 12 14 9 16 15 17 18 8 19 8 20 21 22 Bypass Shut-Out Valve 31 32 33 34 Boom Flow Rate Control Valve 10 40 19 8 41 44 42 38 43 10 39 17 45 15 47 48 49 50 14 46 8 14 45 44 43 51 41 15 52 17 39 8 19 8 46 47 48 49 53 54 Arm Flow Rate Control Valve W2-5-6 W1Ｊ1-02-05-051
UPPERSTRUCTURE / Control Valve Disassemble Control Valve (4-Spool Housing Side) • Disassemble Bypass Shut-Out Valve 1. Remove cap (31) from housing (38). : 46 mm 2. Remove spool (33) and spring (34) from housing (38). • Disassemble Boom Anti-Drift Valve 11. Remove socket bolts (10) (4 used). Remove cover (16) and O-rings (8) (4 used), (20) from housing (38). : 12 mm 12. Remove spring (21) and poppet (22) from housing (38). • Disassemble Arm Flow Rate Control Valve 3. Remove socket bolts (10) (4 used).
UPPERSTRUCTURE / Control Valve Load Check Valve 23 24 25 26 28 30 29 24 25 35 27 36 37 38 35 55 54 37 W1Ｊ1-02-05-051 W2-5-8
UPPERSTRUCTURE / Control Valve • Disassemble Load Check Valve 17. Remove cap (23), spring (26) and check valve (27) from housing (38). : 14 mm 18. When replacing O-ring (25), remove cap (30) from housing (38). 19. When replacing O-ring (29), remove cap (28) from housing (38). 20. When replacing O-rings (37, 54), remove flanges (36, 55) from housing (38).
UPPERSTRUCTURE / Control Valve ASSEMBLE CONTROL VALVE (4-SPOOL HOUSING SIDE) Boom Flow Rate 38 10 Control Valve 10 33 34 32 31 Bypass Shut-Out Valve 38 Bypass Shut-Out Valve Load Check Valve 10 Boom Anti-Drift Valve Arm Flow Rate Control Figure of Control Valve (Right) Valve Arm Flow Rate Control Valve (Refer to Close-Up.) Section of Bypass Shut-Out Valve Boom Flow Rate Control Valve (Refer to Close-Up.) Boom Anti-Drift Valve (Refer to Close-Up.
UPPERSTRUCTURE / Control Valve 12345678910 11 12 13 14 - Cap O-Ring Spring Poppet O-Ring Backup Ring Sleeve O-Ring (10 Used) Backup Ring Socket Bolt (12 Used) Piston O-Ring Cap O-Ring (3 Used) 15 16 17 18 19 20 21 22 23 24 25 26 27 28 - Cap (2 Used) Cover Check Valve (3 Used) Spring Cap (3 Used) O-Ring Spring Poppet Cap Backup Ring (2 used) O-Ring (2 Used) Spring Check Valve Cap 29 30 31 32 33 34 35 36 37 38 39 40 41 42 - W2-5-11 O-Ring Cap Cap O-Ring Spool Spring Socket Bolt (8 Used) Flange O-Ring (2
UPPERSTRUCTURE / Control Valve Boom Flow Rate 38 10 Control Valve 10 33 34 32 31 38 Bypass Shut-Out Valve Arm Flow Rate Control Figure of Control Valve (Right) Valve Arm Flow Rate Control Valve (Refer to Close-Up.) Section of Bypass Shut-Out Valve 38 Section of Boom Flow Rate Control Valve, Boom Anti-Drift Valve Section of Arm Flow Rate Control Valve 42 (51) 43 40 (52) 45 45 44 41 19 48 8 47 ( 49 50 (53) 39 17 46 8 ): No.
UPPERSTRUCTURE / Control Valve Assemble Control Valve (4-Spoo Housing Side) • Assemble Bypass Shut-Out Valve • Assemble Boom Flow Rate Control Valve 1. Install spool (33) and spring (34) to housing (38). 2. Install O-ring (32) to cap (31). Install cap (31) to housing (38). : 46 mm : 250 N⋅m (25.5 kgf⋅m, 185 lbf⋅ft) • Assemble Arm Flow Rate Control Valve 3. Install poppet (53), check valve (49), spring (48) and piston (47) to housing (38). 4. Install O-ring (43) to cap (44).
UPPERSTRUCTURE / Control Valve Load Check Valve Boom Anti-Drift Valve 10 Section of Bypass Shut-Out Valve Figure of Control Valve (Right) Boom Anti-Drift Valve (Refer to Close-Up.
UPPERSTRUCTURE / Control Valve • Assemble Boom Anti-Drift Valve 11. Install poppet (22) and spring (21) to housing (38). 12. Install O-rings (8, 5) and backup rings (9, 6) to sleeve (7). Install sleeve (7) to cover (16). 13. Install O-ring (2) to cap (1). Install poppet (4), spring (3) and cap (1) to cover (16). : 8 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 14. Install O-ring (12) to cap (13). Install piston (11) and cap (13) to cover (16). : 30 mm : 60 N⋅m (6.1 kgf⋅m, 44 lbf⋅ft) 15.
UPPERSTRUCTURE / Control Valve DISASSEMBLE CONTROL (5-SPOOL HOUSING SIDE) VALVE Arm Anti-Drift Valve 11 10 2 1 3 4 5 6 7 8 12 13 9 15 16 17 18 14 17 19 20 21 Bypass Shut-Out Valve 22 Load Check Valve-1 Load Check Valve-2 26 23 27 28 24 29 30 25 31 32 Load Check Valve-3 27 28 29 30 31 33 Load Check Valve-4 27 28 34 29 27 28 30 31 35 29 30 38 Load Check Valve-5 31 27 28 30 31 36 37 39 40 41 W1Ｊ1-02-05-052 W2-5-16
UPPERSTRUCTURE / Control Valve 12345678910 11 - Cap O-Ring Spring Poppet O-Ring Backup Ring Sleeve O-Ring Backup Ring Socket Bolt (4 Used) Piston 12 13 14 15 16 17 18 19 20 21 22 - O-Ring Cap Cover Check Valve Spring O-Ring (5 Used) Cap O-Ring Spring Poppet Cap 23 24 25 26 27 28 29 30 31 32 33 - W2-5-17 O-Ring Spool Spring Cap Backup Ring (5 Used) O-Ring (5 Used) Check Valve (4 Used) Spring (5 Used) Check Valve (5 Used) Cap Cap 34 35 36 37 38 39 40 41 - Cap Cap Cap O-Ring Socket Bolt (16 Used) Flang
UPPERSTRUCTURE / Control Valve Arm Anti-Drift Valve 11 10 2 1 3 4 5 6 7 8 12 13 9 15 16 17 18 14 17 19 20 21 Bypass Shut-Out Valve 22 Load Check Valve-1 Load Check Valve-2 26 23 27 28 24 29 30 25 31 32 Load Check Valve-3 27 28 29 30 31 33 Load Check Valve-4 27 28 34 29 27 28 30 31 35 29 30 38 Load Check Valve-5 31 27 28 30 31 36 37 39 40 41 W1Ｊ1-02-05-052 W2-5-18
UPPERSTRUCTURE / Control Valve Disassemble Control Valve (5-Spool Housing Side) • Disassemble Arm Anti-Drift Valve • Disassemble Bypass Shut-Out Valve 1. Remove cap (22) from housing (41). : 46 mm 2. Remove spool (24) and spring (25) from housing (41). • Disassemble Load Check Valve-1 3. Remove cap (26), check valve (29), spring (30) and check valve (31) from housing (41). : 14 mm • Disassemble Load Check Valve-2 4. Remove cap (32), check valve (29), spring (30) and check valve (31) from housing (41).
UPPERSTRUCTURE / Control Valve ASSEMBLE CONTROL VALVE (5-SPOOL HOUSING SIDE) Load Check Load Check Valve-3 Valve-2 Arm Anti-Drift Valve 10 3 4 5 1 6 41 Load Check Valve-4 Load Check Valve-1 Load Check Valve-5 Bypass Shut-Out Valve Section of Bypass Shut-Out Valve Figure of Control Valve (Right) 31 30 29 26 27, 28 31 41 30 29 33 41 29 32 41 27, 28 Section of Load Check Valve-2 Section of Load Check Valve-1 31 30 Arm Anti-Drift Valve (Refer to Close-Up.
UPPERSTRUCTURE / Control Valve 12345678910 11 - Cap O-Ring Spring Poppet O-Ring Backup Ring Sleeve O-Ring Backup Ring Socket Bolt (4 Used) Piston 12 13 14 15 16 17 18 19 20 21 22 - O-Ring Cap Cover Check Valve Spring O-Ring (5 Used) Cap O-Ring Spring Poppet Cap 23 24 25 26 27 28 29 30 31 32 33 - W2-5-21 O-Ring Spool Spring Cap Backup Ring (5 Used) O-Ring (5 Used) Check Valve (4 Used) Spring (5 Used) Check Valve (5 Used) Cap Cap 34 35 36 37 38 39 40 41 - Cap Cap Cap O-Ring Socket Bolt (16 Used) Flang
UPPERSTRUCTURE / Control Valve Load Check Valve-2 Load Check Valve-3 Arm Anti-Drift Valve 10 24 25 23 41 22 41 Load Check Valve-4 Load Check Valve-1 Load Check Valve-5 Bypass Shut-Out Valve Section of Bypass Shut-Out Valve Figure of Control Valve (Right) 31 30 29 26 27, 28 41 30 29 33 41 30 32 29 27, 28 41 Section of Load Check Valve-2 Section of Load Check Valve-1 31 31 Arm Anti-Drift Valve (Refer to Close-Up.
UPPERSTRUCTURE / Control Valve Assemble Control Valve (5-Spool Housing Side) • Assemble Bypass Shut-Out Valve • Assemble Load Check Valve-5 1. Install spool (24) and spring (25) to housing (41). 2. Install O-ring (23) to cap (22). Install cap (22) to housing (41). : 46 mm : 250 N⋅m (25.5 kgf⋅m, 185 lbf⋅ft) 7. Install O-ring (28) and backup ring (27) to cap (35). Install check valve (31), spring (30) and cap (35) to housing (41). : 14 mm : 350 N⋅m (35.
UPPERSTRUCTURE / Control Valve Arm Anti-Drift Valve 10 41 Section of Bypass Shut-Out Valve Figure of Control Valve (Right) Section of Load Check Valve-1 Section of Load Check Valve-2 Arm Anti-Drift Valve (Refer to Close-Up.
UPPERSTRUCTURE / Control Valve • Assemble Arm Anti-Drift Valve 8. Install poppet (21) and spring (20) to housing (41). 9. Install O-rings (8, 5) and backup rings (9, 6) to sleeve (7). Install sleeve (7) to cover (14). 10. Install O-ring (2) to cap (1). Install poppet (4), spring (3) and cap (1) to cover (14). : 8 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 11. Install O-ring (12) to cap (13). Install piston (11) and cap (13) to cover (14). : 30 mm : 60 N⋅m (6.1 kgf⋅m, 44 lbf⋅ft) 12. Install O-ring (17) to cap (18).
UPPERSTRUCTURE / Control Valve DISASSEMBLE CONTROL VALVE (4-SPOOL HOUSING UPPER AND LOWER SURFACES) Bucket Regenerative Valve 19 20 38 21 39 40 30 Overload Relief Valve Arm Regenerative Valve 31 19 20 2 3 4 5 6 7 9 24 21 25 22 26 27 28 23 10 11 8 12 13 14 33 34 35 24 Main Relief Valve 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 Check Valve-1 56 57 35 34 36 37 36 37 25 26 27 28 29 15 16 17 18 37 36 57 59 61 60 1 62 18 17 16 65 66 15 14 13 12 8 11 10 9 67 68 Overload Relief Val
UPPERSTRUCTURE / Control Valve 12345678910 11 12 13 14 15 16 17 - Housing (4-Spool Side) Lock Nut (4 Used) Adjusting Screw (4 Used) O-Ring (4 Used) Spring (4 Used) Pilot Poppet (4 Used) Seat (4 Used) Spring (4 Used) O-Ring (4 Used) Backup Ring (8 Used) O-Ring (4 Used) Spring (4 Used) Piston (4 Used) Main Poppet (4 Used) Sleeve (4 Used) O-Ring (4 Used) Backup Ring (4 Used) 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 - O-Ring (4 Used) Cap (2 Used) O-Ring (2 Used) Spring Seat (2 Used) Spring Sleeve O
UPPERSTRUCTURE / Control Valve Bucket Regenerative Valve 19 20 38 21 39 40 30 Overload Relief Valve Arm Regenerative Valve 31 19 20 2 3 4 5 6 7 9 24 21 25 22 26 27 28 23 10 11 8 12 13 14 33 34 35 24 Main Relief Valve 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 Check Valve-1 56 57 35 34 36 37 36 37 25 26 27 28 29 15 16 17 18 1 Check Valve-2 65 66 67 68 Overload Relief Valve W2-5-28 W1Ｊ1-02-05-053
UPPERSTRUCTURE / Control Valve Disassemble Control Valve (4-Spool Housing Upper and Lower Surfaces) • Disassemble Overload Relief Valve IMPORTANT: Do not disassemble the overload relief valve. When the overload relief valve is disassembled, pressure must be adjusted. 1. Remove the sleeve (15) assembly (2 to 18) from housing (1). : 41mm 2. Clamp sleeve (15) into a vise. Remove the seat assembly (2 to 7, 9, 10) from sleeve (15). Remove springs (8, 12), piston (13) and poppet (14) from sleeve (15).
UPPERSTRUCTURE / Control Valve Main Relief Valve 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 37 36 57 59 61 60 1 62 Check Valve-2 63 57 64 Flow Combiner Valve W1Ｊ1-02-05-053 W2-5-30
UPPERSTRUCTURE / Control Valve • Disassemble Check Valve-2 14. Remove cap (60), check valve (37) and spring (36) from housing (1). : 14 mm • Disassemble Main Relief Valve IMPORTANT: Do not disassemble the main relief valve. When the main relief valve is disassembled, pressure must be adjusted. 15. Remove the cap (46) assembly (38 to 55) from housing (1). : 41mm IMPORTANT: As pilot seat (50) is installed to cap (46), do not disassemble pilot seat (50). 16. Remove sleeve (55) from cap (46) .
UPPERSTRUCTURE / Control Valve ASSEMBLE CONTROL VALVE (4-SPOOL HOUSING UPPER AND LOWER SURFACES) Check Valve-1 1 Overload Relief Valve Arm Regenerative Valve 1 Overload Relief Valve Flow Combiner Valve Check Valve-2 2 3 4 7 Main Relief Valve 9 5 15 6 8 Bucket Regenerative Valve 11, 10 16 12 13 Figure of Control Valve (Upper) Arm Regenerative Valve (Refer to Close-Up.
UPPERSTRUCTURE / Control Valve 12345678910 11 12 13 14 15 16 17 - Housing (4-Spool Side) Lock Nut (4 Used) Adjusting Screw (4 Used) O-Ring (4 Used) Spring (4 Used) Pilot Poppet (4 Used) Seat (4 Used) Spring (4 Used) O-Ring (4 Used) Backup Ring (8 Used) O-Ring (4 Used) Spring (4 Used) Piston (4 Used) Main Poppet (4 Used) Sleeve (4 Used) O-Ring (4 Used) Backup Ring (4 Used) 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 - O-Ring (4 Used) Cap (2 Used) O-Ring (2 Used) Spring Seat (2 Used) Spring Sleeve O
UPPERSTRUCTURE / Control Valve Overload Relief Valve Overload Relief Valve 2 3 4 7 9 5 15 6 8 11, 10 16 12 13 Figure of Control Valve (Upper) Figure of Control Valve (Lower) 14 18, 17 Close-Up of Overload Relief Valve Arm Regenerative Valve (Refer to Close-Up.) Overload Relief Valve 1 (Refer to Close-Up.) 1 Overload Relief Valve (Refer to Close-Up.
UPPERSTRUCTURE / Control Valve Assemble Control Valve (4-Spool Housing Upper and Lower Surfaces) • Assemble Overload Relief Valve IMPORTANT: Align the matching marks and tighten adjusting screw (3) to the same turns when disassembling. 1. Install pilot poppet (6), spring (5), adjusting screw (3) and lock nut (2) to seat (7). 2. Install O-ring (16), backup ring (17) and O-ring (18) to sleeve (15). 3. Install piston (13) to main poppet (14). Install main poppet (14) to sleeve (15). 4.
UPPERSTRUCTURE / Control Valve 1 Main Relief Valve Bucket Regenerative Valve Figure of Control Valve (Upper) Figure of Control Valve (Lower) Close-Up of Overload Relief Valve Bucket Regenerative Valve (Refer to Close-Up.) Section of Arm Regenerative Valve Section of Overload Relief Valve Main Relief Valve (Refer to Close-Up.
UPPERSTRUCTURE / Control Valve • Assemble Bucket Regenerative Valve 10. Install piston (26), spring (36) and check valve (37) to sleeve (33). 16. Install poppet (49), spring (48) and piston (41) to cap (46). 11. Install O-rings (28, 35) and backup rings (27, 34) to sleeve (33). Install sleeve (33) to sleeve (31). IMPORTANT: Align the matching marks and tighten adjusting screw (38) to the same turns when disassembling. 17. Install lock nut (40) and O-ring (39) to adjusting screw (38).
UPPERSTRUCTURE / Control Valve Check Valve-1 1 Check Valve-2 Figure of Control Valve (Upper) Figure of Control Valve (Lower) Close-Up of Overload Relief Valve Section of Arm Regenerative Valve Section of Overload Relief Valve Section of Bucket Regenerative Valve, Overload Relief Valve Check Valve-1 56 57 36 34, 35 37 37 61 36 62 57, 59 60 Check Valve-2 57 63 64 Flow Combiner Valve Section of Check Valve-1, Check Valve-2, Flow Combiner Valve Close-Up of Arm Regenerative Valve W2-5-38 Close-
UPPERSTRUCTURE / Control Valve • Assemble Flow Combiner Valve 23. Install O-ring (57) to cap (64). Install spool (61), spacer (62), spring (63) and cap (64) to housing (1). : 46 mm : 250 N⋅m (26 kgf⋅m, 184 lbf⋅ft) • Assemble Check Valve-1 24. Install O-rings (57, 34) and backup ring (35) to cap (56). Install spring (36), check valve (37) and cap (56) to housing (1). : 14 mm : 350 N⋅m (35.7 kgf⋅m, 258 lbf⋅ft) • Assemble Check Valve-2 25. Install O-ring (57) and backup ring (59) to cap (60).
UPPERSTRUCTURE / Control Valve DISASSEMBLE CONTROL VALVE (5-SPOOL HOUSING UPPER AND LOWER SURFACES) Overload Relief Valve-1 46 47 48 49 Overload Relief Valve-2 1 2 3 50 53 51 4 5 6 7 8 9 10 11 12 13 14 15 16 6 5 19 20 21 22 23 24 26 Check Valve-2 Check Valve-3 38 36 52 44 45 24 39 23 54 55 56 40 Check Valve-1 32 31 33 32 37 34 33 35 41 42 57 43 28 29 30 37 34 35 64 27 30 29 28 29 30 28 57 58 59 60 61 62 56 55 54 23 24 52 51 53 63 50 49 48 47 46 Overload Relief Valve-1 W1Ｊ1-0
UPPERSTRUCTURE / Control Valve 12345678910 11 12 13 14 15 16 - Cap O-Ring Piston Sleeve Backup Ring (2 Used) O-Ring (2 Used) Poppet Spring Spring Seat Spring Pilot Poppet Lock Nut Backup Ring O-Ring Sleeve O-Ring 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 - Pilot Seat Spring Spring Piston O-Ring (4 Used) Backup Ring (10 Used) Main Poppet Sleeve O-Ring (5 Used) Backup Ring (5 Used) O-Ring (5 Used) Cap O-Ring (2 Used) Backup Ring (2 Used) Spring (2 Used) Check Valve (2 Used) 36 37 38 39 40 41 42 43 4
UPPERSTRUCTURE / Control Valve Overload Relief Valve-1 46 47 48 49 Overload Relief Valve-2 1 2 3 50 53 51 4 5 6 7 8 9 10 11 12 13 14 15 16 6 5 19 20 21 22 23 24 26 Check Valve-2 Check Valve-3 38 36 52 44 45 24 39 23 54 55 56 40 Check Valve-1 32 31 33 32 37 34 33 35 41 42 57 43 28 29 30 37 34 35 64 27 30 29 28 29 30 28 58 59 57 56 55 54 23 24 52 51 53 50 49 48 47 46 Overload Relief Valve-1 W1Ｊ1-02-05-054 W2-5-42
UPPERSTRUCTURE / Control Valve Disassemble Control Valve (5-Spool Housing Upper and Lower Surfaces) • Disassemble Overload Relief Valve-1 IMPORTANT: Do not disassemble the overload relief valve. When the overload relief valve is disassembled, pressure must be adjusted.(Refer to the Operational Performance Test section / TROUBLESHOOTING in the separated volume, T/M.) Attach the identification tag onto the overload relief valves (4 used) in order to install to the original position. 6.
UPPERSTRUCTURE / Control Valve Overload Relief Valve-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 6 5 19 20 21 22 23 24 26 64 27 28 29 30 W1Ｊ1-02-05-054 W2-5-44
UPPERSTRUCTURE / Control Valve • Disassemble Overload Relief Valve-2 IMPORTANT: Do not disassemble the overload relief valve. When the overload relief valve is disassembled, pressure must be adjusted. Refer to the Operational Performance Test section / TROUBLESHOOTING in the separated volume, T/M.) 8. Rotate sleeve (27) and remove the overload relief valve assembly (1 to 30) from housing (64). : 41 mm IMPORTANT: Put the matching marks on sleeves (27, 15). Record the rotation number of adjusting sleeve (15).
UPPERSTRUCTURE / Control Valve ASSEMBLE CONTROL VALVE (5-SPOOL HOUSING UPPER AND LOWER SURFACES) Overload Relief Valve-2 Check Valve-2 Check Valve-3 Check Valve-1 64 Figure of Control Valve (Upper) Check Valve-3 (Refer to Close-Up.) 64 Overload Relief Valve-1 Figure of Control Valve (Lower) Overload Relief Valve-1 Overload Relief Valve-2 (Refer to Close-Up.) Overload Relief Valve-1 (Refer to Close-Up.) Check Valve-2 (Refer to Close-Up.) Overload Relief Valve-1 (Refer to Close-Up.
UPPERSTRUCTURE / Control Valve 12345678910 11 12 13 14 15 16 - Cap O-Ring Piston Sleeve Backup Ring (2 Used) O-Ring (2 Used) Poppet Spring Spring Seat Spring Pilot Poppet Lock Nut Backup Ring O-Ring Sleeve O-Ring 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 - Pilot Seat Spring Spring Piston O-Ring (4 Used) Backup Ring (10 Used) Main Poppet Sleeve O-Ring (5 Used) Backup Ring (5 Used) O-Ring (5 Used) Cap O-Ring (2 Used) Backup Ring (2 Used) Spring (2 Used) Check Valve (2 Used) 36 37 38 39 40 41 42 43 4
UPPERSTRUCTURE / Control Valve Overload Relief Valve-2 Check Valve-2 Check Valve-3 Check Valve-1 64 Overload Relief Figure of Control Valve (Upper) Valve-1 Overload Relief Valve-1 64 Figure of Control Valve (Lower) Check Valve-3 (Refer to Close-Up.) Overload Relief Valve-1 (Refer to Close-Up.) Check Valve-2 (Refer to Close-Up.) Overload Relief Valve-1 (Refer to Close-Up.) Overload Relief Valve-1 (Refer to Close-Up.
UPPERSTRUCTURE / Control Valve Assemble Control Valve (5-Spool Housing Upper and Lower Surfaces) • Assemble Overload Relief Valve-1 • Assemble Check Valve-1, Check Valve-2 1. Install O-ring (52), backup rings (24) (2 used) and O-ring (23) to seat (53). Install O-ring (48) to adjusting screw (47). IMPORTANT: Align the matching marks and tighten adjusting screw (47) to the same turns when disassembling. 2. Install pilot poppet (50), spring (49), adjusting screw (47) and lock nut (46) to seat (53). 3.
UPPERSTRUCTURE / Control Valve 64 Overload Relief Valve-2 64 Figure of Control Valve (Upper) Section of Check Valve-3, Overload Relief Valve-1 Section of Check Valve-2, Overload Relief Valve-2 Figure of Control Valve (Lower) Section of Overload Relief Valve-1 1 4 12 15 16 Close-Up of Check Valve-3 27 5, 6 21, 20 Close-Up of Overload Relief Valve-1 22 ( Section of Check Valve-1, Overload Relief Valve-1 )：For Check Valve-2 Close-Up of Check Valve-1, Check Valve-2 W2-5-50 2 3 13 14 7 8 5, 6 9 10
UPPERSTRUCTURE / Control Valve • Assemble Overload Relief Valve-2 9. Install O-ring (2) to cap (1). Install piston (3) and cap (1) to sleeve (4). : 27 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 10. Install lock nut (12), backup ring (13) and O-ring (14) to sleeve (4). Install backup ring (5), O-ring (6) and poppet (7) to sleeve (4). IMPORTANT: Align the matching marks and tighten sleeve (4) to the same turns when disassembling. 11. Install the sleeve (4) assembly to sleeve (15). Tighten lock nut (12).
UPPERSTRUCTURE / Control Valve DISASSEMBLE CONTROL (4-SPOOL CONTROL VALVE) VALVE 4 1 5 4 2 6 5 3 7 6 5 7 20 4 5 4 5 6 5 6 7 12 5 13 14 15 16 17 18 10 7 5 8 21 19 11 9 22 3 3 23 24 1 1 W1J1-02-05-055 W2-5-52
UPPERSTRUCTURE / Control Valve 123456- Socket Bolt (13 Used) Cover O-Ring (8 Used) Cap (4 Used) Spring Guide (8 Used) Sleeve (4 Used) 78910 11 12 - Spring (4 Used) Spool Spool (Arm 2) Spool Spool (Boom 2) Spool 13 14 15 16 17 18 - W2-5-53 Check Valve Spring Spacer O-Ring Backup Ring Cap 19 20 21 22 23 24 - Spool (Bucket) Spool Spool (Travel) Housing (4-Spool Side) Cover Cover
UPPERSTRUCTURE / Control Valve 4 1 5 4 2 6 5 3 7 6 5 7 20 4 5 4 5 6 5 6 7 12 5 13 14 15 16 17 18 10 7 5 8 21 19 11 9 22 3 3 23 24 1 1 W1J1-02-05-055 W2-5-54
UPPERSTRUCTURE / Control Valve Disassemble Control Valve (4-Spool Control Valve) • Disassemble Spool 1. Remove socket bolts (1) (6 used) from cover (2). Remove cover (2) and O-rings (3) (4 used) from housing (22). : 10 mm 2. Remove socket bolts (1) (7 used) from covers (23, 24). Remove covers (23, 24) and O-rings (3) (4 used) from housing (22). : 10 mm IMPORTANT: Rotate and remove spool (9, 11, 19, 21) assemblies. Do not disassemble spool (9, 11, 19, 21) assemblies unless necessary. 3.
UPPERSTRUCTURE / Control Valve ASSEMBLE CONTROL VALVE (4-SPOOL CONTROL VALVE) 22 1 2 23 Figure of Control Valve (Upper) 8 10 1 1 24 Figure of Control Valve (Lower) 12 5 7 2 22 4 6 1 3 5 20 13 14 18 15 16, 17 3 23 9 11 19 3 21 24 W1J1-02-05-048 1 Section of 4-Spool 123456- Socket Bolt (13 Used) Cover O-Ring (8 Used) Bolt (4 Used) Spring Guide (8 Used) Sleeve (4 Used) 78910 11 12 - Spring (4 Used) Spool Spool (Arm 2) Spool Spool (Boom 2) Spool 13 14 15 16 17 18 - W2-5-5
UPPERSTRUCTURE / Control Valve Assemble Control Valve (4-Spool Control Valve) 1. Install O-rings (3) (8 used) to housing (22). Install cover (24) to housing (22) with socket bolts (1) (2 used). Install cover (23) to housing (22) with socket bolts (1) (5 used). : 10 mm : 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft) 2. Apply LOCTITE #262 to the thread part of bolts (4) (4 used). Install spring guide (5), sleeve (6), spring (7) and spring guide (5) to spools (20, 12, 10, 8) with bolt (4) respectively.
UPPERSTRUCTURE / Control Valve DISASSEMBLE CONTROL (5-SPOOL CONTROL VALVE) VALVE 4 1 5 4 2 5 4 3 12 5 5 7 6 7 7 5 21 22 13 5 14 10 15 5 23 24 25 16 17 18 8 20 5 6 7 28 5 4 5 7 6 6 4 6 29 26 27 19 30 11 9 3 31 1 3 3 31 32 1 1 W1J1-02-05-056 W2-5-58
UPPERSTRUCTURE / Control Valve 12345678- Socket Bolt (15 Used) Cover O-Ring (10 Used) Bolt (5 Used) Spring Guide (10 Used) Sleeve (5 Used) Spring (5 Used) Spool 910 11 12 13 14 15 16 - Spool (Travel) Spool Spool (Auxiliary) Spool Check Valve Spring Spacer O-Ring 17 18 19 20 21 22 23 24 - W2-5-59 Backup Ring Cap Spool (Boom 2) Spool Check Valve Spring Spacer O-Ring 25 26 27 28 29 30 31 32 - Backup Ring Cap Spool (Arm 2) Spool Spool (Swing) Housing (5-Spool Side) Cover (2 Used) Cover
UPPERSTRUCTURE / Control Valve 4 1 5 4 2 5 4 3 12 5 5 7 14 6 7 5 21 22 13 5 14 10 15 7 23 24 25 16 17 18 8 20 5 6 7 28 5 4 5 7 6 6 4 6 29 26 27 19 30 11 9 3 31 1 3 3 31 32 1 1 W1J1-02-05-056 W2-5-60
UPPERSTRUCTURE / Control Valve Disassemble Control Valve (5-Spool Control Valve) Disassemble Spools (6 to 10) 1. Remove socket bolts (1) (6 used) from cover (2). Remove cover (2) and O-rings (3) (5 used) from housing (30). : 10 mm 2. Remove socket bolts (1) (9 used) from covers (31) (2 used) and (32). Remove covers (31) (2 used) and (32) from housing (30). : 10 mm IMPORTANT: Slowly rotate and straightly remove spool (9, 11, 19, 27, 29) assemblies.
UPPERSTRUCTURE / Control Valve ASSEMBLE CONTROL VALVE (5-SPOOL CONTROL VALVE) 30 1 1 1 2 31 31 32 Figure of Control Valve (Upper) 3 9 2 11 19 27 29 1 Figure of Control Valve (Lower) 5 4 6 7 1 5 30 8 28 10 20 12 13 21 14 22 15 23 18 24, 25 26 3 31 3 16, 17 32 3 W1J1-02-05-049 31 Section of 5-Spool 12345678- Socket Bolt (15 Used) Cover O-Ring (10 Used) Cap (5 Used) Spring Guide (10 Used) Sleeve (5 Used) Spring (5 Used) Spool 910 11 12 13 14 15 16 - Spool (Travel) Sp
UPPERSTRUCTURE / Control Valve Assemble Control Valve (5-Spool Control Valve) 1. Install O-rings (3) (5 used) to housing (30). Install covers (31) (2 used) and (32) to housing (30) with socket bolts (1) (9 used). : 10 mm : 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft) 6. Install O-rings (3) (5 used) to housing (30). Install cover (2) to housing (30) with bolts (1) (6 used). : 10 mm : 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft) IMPORTANT: Apply LOCTITE #262 to the thread part of bolt (4). 2.
UPPERSTRUCTURE / Control Valve DISASSEMBLE CONTROL (HOUSING FRONT AND SURFACES) VALVE REAR 2 1 3 4 5 6 W1Ｊ1-02-05-062 12- Housing (4-Spool Side) Housing (5-Spool Side) 34- Check Valve Spring 5- W2-5-64 O-Ring, Backup Ring 6- Cap
UPPERSTRUCTURE / Control Valve Disassemble Control Valve (Housing Front and Rear Surfaces) 1. Remove cap (6), spring (4) and check valve (3) from housing (2).
UPPERSTRUCTURE / Control Valve ASSEMBLE CONTROL VALVE (HOUSING FRONT AND REAR SURFACES) 2 1 2 1 Check Valve Figure of Control Valve (Rear) Figure of Control Valve (Front) 6 5 4 3 Section of Check Valve W1J1-02-05-050 12- Housing (4-Spool Side) Housing (5-Spool Side) 34- Check Valve Spring 5- W2-5-66 O-Ring, Backup Ring 6- Cap
UPPERSTRUCTURE / Control Valve Assemble Control Valve (Housing Front and Rear Surfaces) 1. Install O-ring and backup ring (5) to cap (6). Install check valve (3), spring (4) and cap (6) to housing (2).
UPPERSTRUCTURE / Control Valve 3 DISASSEMBLE HOUSING 4 2 3 5 1 6 4 3 3 8 10 5 4 3 8 8 10 9 8 9 W1Ｊ1-02-05-057 123- Housing (4-Spool Side) Housing (5-Spool Side) O-Ring (6 Used) 456- O-Ring (3 Used) O-Ring (3 Used) O-Ring (6 Used) 8 - Washer (14 Used) 9 - Socket Bolt (8 Used) 10 - Socket Bolt (6 Used) W2-5-68
UPPERSTRUCTURE / Control Valve Disassemble Housing 1. Remove all valves from the upper and lower surfaces at 5-spool side and 4-spool side. CAUTION: Control valve weight: 400 kg (880 lb) IMPORTANT: When placing housing (2) at 5-spool side or housing (1) at 4-spool side on the workbench, use the cloth in order not to damage. 2. Install eyebolts (M12, Pitch 1.75 mm) (2 used) into the hole on control valve. Hoist and place the control valve onto the workbench with housing (1) facing downward. 3.
UPPERSTRUCTURE / Control Valve ASSEMBLE HOUSING 10, 8 1 2 9, 8 9, 8 9, 8 3 10, 8 2 4 5 6 6 4 3 3 4 W1J1-02-05-060 5 123- Housing (4-Spool Side) Housing (5-Spool Side) O-Ring (6 Used) 456- O-Ring (3 Used) O-Ring (3 Used) O-Ring (6 Used) 8 - Washer (14 Used) 9 - Socket Bolt (8 Used) 10 - Socket Bolt (6 Used) W2-5-70
UPPERSTRUCTURE / Control Valve Assemble Housing IMPORTANT: When placing housing (2) or housing (1) on the workbench, use the cloth in order not to damage. CAUTION: Housing (2) weight: 200 kg (440 lb) 1. Install eyebolts (M12, Pitch 1.75 mm) (2 used) into the hole (2 places) on housing (2). Hoist and place housing (2) onto the workbench with the side facing downward. 2. Apply grease to O-rings (6) (6 used), (7) (6 used), (8) (3 used) and (9) (3 used).
UPPERSTRUCTURE / Control Valve (Blank) W2-5-72
UPPERSTRUCTURE / Swing Device REMOVE AND INSTALL SWING DEVICE There are swing devices (9, 10). These procedures are for swing device (9). Swing device (10) can be removed and installed in the same procedures. CAUTION: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) 2 Removal 1 2 1. Remove bolts (2) (4 used). Remove covers (1) (2 used) from the main frame. : 19 mm 2. Remove socket bolts (4) (8 used) from swing device (9).
UPPERSTRUCTURE / Swing Device CAUTION: Swing device (9) weight: 230 kg (510 lb) Nylon Sling 1. Install the bolts (M20, Pitch 2.5 mm) (2 used) to the hole (2 places) for cork (14). Attach a nylon sling onto the motor outer surface in swing device (9). 2. Rotate the bolt and raise off swing device (9) from the main frame. Hoist and remove swing device (9) from the main frame. : 30 mm Motor Installation 1. Apply liquid packing (THREEBOND #1215) to the mounting surface for main frame in swing device (9).
UPPERSTRUCTURE / Swing Device 4. Install hoses (5, 6) to swing device (9) with socket bolts (4) (8 used). : 8 mm : 57 N⋅m (5.8 kgf⋅m, 42 lbf⋅ft) 5. Install hoses (3, 7, 8) to swing device (9). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 27 mm : 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft) 7 6 3 5 4 6 3 5 4 8 6. Release any pressure in the pump device. (Refer to W1-1.) Check the hydraulic oil level.
UPPERSTRUCTURE / Swing Device DISASSEMBLE SWING DEVICE 1 2 3 24 25 26 27 4 23 28 5 22 21 6 20 19 7 18 29 8 17 16 9 30 15 31 10 14 32 11 33 12 34 13 35 W16J-02-06-001 123456789- Motor Socket Bolt (8 Used) Ring Gear First Stage Sun Gear Thrust Plate First Stage Carrier Second Stage Sun Gear Thrust Plate Second Stage Carrier 10 11 12 13 14 15 16 17 18 - Bolt (2 Used) Lock Plate Bearing Nut Roller Bearing Thrust Plate (3 used) Planetary Gear (3 Used) Thrust Plate (3 used) Spring Pi
UPPERSTRUCTURE / Swing Device Disassemble Swing Device CAUTION: Swing device weight: 230 kg (510 lb) 1. Install bracket (ST 5101) onto the workbench. 2. Attach a nylon sling onto the swing device and hoist the swing device. CAUTION: Swing motor (1) weight: 50 kg (110 lb) 6. Remove socket bolts (2) (8 used). Remove motor (1) from ring gear (3). : 10 mm NOTE: THREEBOND is applied to the mating surfaces on ring gear (3) and motor (1). Insert a screwdriver into the notch in mating part and raise off motor (1).
UPPERSTRUCTURE / Swing Device 24 27 23 22 5 21 6 20 19 7 18 8 17 16 9 15 14 10 11 12 35 W16J-02-06-001 W2-6-6
UPPERSTRUCTURE / Swing Device 11. Remove second stage sun gear (7) from second stage carrier (9). 18. Remove bearing nut (12) from shaft (35) by using special tool (ST 2926). ST 2926 CAUTION: The second stage carrier (9) assembly weight: 23 kg (51 lb) 12 12. Remove the second stage carrier (9) assembly from shaft (35). 13. Remove spring pins (22) (3 used) from first stage carrier (6) by using special tool (ST 1462). 14.
UPPERSTRUCTURE / Swing Device 27 13 35 W16J-02-06-001 W2-6-8
UPPERSTRUCTURE / Swing Device 20. Install the housing (27) assembly to bracket (ST 7298). Set the housing (27) assembly to the press. CAUTION: The shaft (35) assembly weight: 50 kg (110 lb) 21. Remove the shaft (35) assembly from housing (27) by using a press. Press Press 27 Cover 27 ST 7298 W178-02-06-006 CAUTION: When pressing shaft (35), cover housing (27) with the cover (outer dia.: 290 mm (11.4 in), inner dia.: 90 mm (3.5 in), thickness: 25 to 30 mm (1.0 to 1.2 in)).
UPPERSTRUCTURE / Swing Device 27 30 13 35 W16J-02-06-001 W2-6-10
UPPERSTRUCTURE / Swing Device 22. Install the shaft (35) assembly to the guide. 23. Set shaft (35) to the press. Special Tool when Removing Bearing Hose Clamp Shaft Press 35 30 33 W157-02-06-012 Guide 35 30 W157-02-06-014 33 NOTE: Remove roller bearing (30) by using special tools (ST 7297, ST 7299). Place special tool (ST 7299) onto the stepped part of special tool (ST 7297). Insert the pinion gear of shaft (35) into the tooth-hole of special tool (ST 7299).
UPPERSTRUCTURE / Swing Device 27 Body 29 30 33 34 13 35 W16J-02-06-001 W2-6-12
UPPERSTRUCTURE / Swing Device 24. Remove the inner race of roller bearing (30) and sleeve (33) from shaft (35). 25. Remove O-ring (34), screws (30) (4 used) and magnets (31) (4 used) from sleeve (33). IMPORTANT: Do not remove roller bearings (13, 30) and the outer race from housing (27) unless replacing the parts. 26. Remove the inner race of roller bearing (13) from housing (27). Insert a round bar into the oil passage in housing (27). Tap by using a hammer and remove the outer race of roller bearing (30).
UPPERSTRUCTURE / Swing Device ASSEMBLE SWING DEVICE 1 2 4 22 21 23 20 19 17 5 6 3 7 16 9 18 24 15 8 14 10 13 11 26 12 25 27 32 30 31 29 33 35 34 W16J-02-06-002 123456789- Motor Socket Bolt (8 Used) Ring Gear First Stage Sun Gear Thrust Plate First Stage Carrier Second Stage Sun Gear Thrust Plate Second Stage Carrier 10 11 12 13 14 15 16 17 18 - Bolt (2 Used) Lock Plate Bearing Nut Roller Bearing Thrust Plate (3 used) Planetary Gear (3 Used) Thrust Plate (3 used) Spring Pin (3 Used
UPPERSTRUCTURE / Swing Device Assemble Swing Device 1. Apply LOCTITE to screws (30) (4 used). Install magnets (31) (4 used) to sleeve (33) with screws (30) (4 used). Install O-ring (34) to sleeve (33). CAUTION: Shaft (35) weight: 36 kg (80 lb) IMPORTANT: Apply THREEBOND #1215 to the outer surface of oil seal (29) and grease to the lip part respectively. Install oil seal (29) with the lip part facing to the motor side. 5. Install oil seal (29) to housing (27) by using special tool (ST 7300). 2.
UPPERSTRUCTURE / Swing Device 3 24 13 12 27 29 33 35 W16J-02-06-002 W2-6-16
UPPERSTRUCTURE / Swing Device CAUTION: The housing weight: 90 kg (200 lb) (27) assembly CAUTION: The housing weight: 130 kg (290 lb) (27) assembly 7. Attach a nylon sling onto the body of housing (27). Hoist and place housing (27) with the ring gear (3) side facing upward. 12. Install eyebolt (M16, Pitch 2.0 mm) into the socket bolt (24) hole (2 places) on housing (27). Hoist and place housing (27) on a press. 8.
UPPERSTRUCTURE / Swing Device 17 16 9 18 15 8 14 10 13 11 12 27 35 W16J-02-06-002 W2-6-18
UPPERSTRUCTURE / Swing Device 15. Secure bracket (ST 5101) on a workbench. Place the housing (27) assembly on bracket (ST 5101) so that the stopper in bracket (ST 5101) is inserted between the teeth of pinion gear. Install the housing (27) assembly to bracket (ST 5101) with bolts (M20) (2 used). ： 30 mm 18. Install thrust plate (8) to second stage carrier (9) with the oil groove side facing to the outside. 27 ST 5101 Stopper 17. Apply LOCTITE to the thread part of bolts (10) (2 used).
UPPERSTRUCTURE / Swing Device 5 22 6 23 20 19 17 3 7 9 16 18 15 14 8 13 11 27 35 W16J-02-06-002 W2-6-20
UPPERSTRUCTURE / Swing Device 21. Install spring pin (17) into the hole on second stage carrier (9) by using special tool (ST 1463). Concave NOTE: Install spring pin (17) with the slit facing to the motor side. 11 35 17 18 9 Motor Side Slit W178-02-06-002 W178-02-06-014 22. Install planetary gears (15) (2 used), thrust plates (14) (2 used), (16) (2 used), pins (18) (2 used) and spring pins (17) (2 used) to other hole (2 places) on second stage carrier (9) in the same procedures as steps 19, 20.
UPPERSTRUCTURE / Swing Device 1 2 4 5 6 3 7 24 26 25 27 W16J-02-06-002 W2-6-22
UPPERSTRUCTURE / Swing Device CAUTION: Ring gear (3) weight: 22.5 kg (50 lb) Eyebolt Mounting Positions 28. Install eyebolt (M12, Pitch 1.75 mm) into the socket bolt (2) hole (2 places) on ring gear (3). Align the matching marks made when disassembling and install ring gear (3). Install ring gear (3) to housing (27) with socket bolts (24) (12 used). : 14 mm : 205 N⋅m (21 kgf⋅m, 150 lbf⋅ft) 29. Align with the spline of second stage sun gear (7) and install the first stage carrier (6) assembly.
UPPERSTRUCTURE / Swing Device DISASSEMBLE SWING MOTOR 11 9 8 7 6 5 4 10 3 2 24 25 1 26 29 27 15 14 27 17 Casing Oil Seal Bearing Shaft Shoe Plate Plunger (9 Used) Plate Retainer 910 11 12 13 14 15 16 - 26 25 24 12 16 12345678- 31 28 23 13 30 Rotor Plate (4 Used) Friction Plate (3 Used) O-Ring Piston Spring Ball Plug (2 Used) 17 18 19 20 21 22 23 24 - 18 19 O-Ring O-Ring Brake Piston Spring (24 Used) Valve Plate Bearing O-Ring Plug (2 Used) W2-6-24 20 21 22 32 W178-02-06-01
UPPERSTRUCTURE / Swing Device Disassemble Swing Motor 28 CAUTION: Swing motor weight: 50 kg (110 lb) 19 Notch A 1 IMPORTANT: Do not disassemble relief valve (32). 1. Remove relief valves (32) (2 used) from valve casing (28). : 41 mm 2. Remove plugs (24) (2 used) from valve casing (28). : 14 mm Port B 3. Remove springs (26) (2 used) and poppets (27) (2 used) from valve casing (28). IMPORTANT: Record the clearance dimension between valve casing (28) and casing (1). 4.
UPPERSTRUCTURE / Swing Device 11 9 8 7 6 5 4 10 3 2 24 25 1 26 29 27 15 14 31 28 27 23 13 30 26 25 24 12 16 17 W2-6-26 18 19 20 21 22 32 W178-02-06-015
UPPERSTRUCTURE / Swing Device 9. Hoist and set casing (1) horizontally. Remove rotor (9), retainer (8), plate (7) and plungers (6) (9 used) from shaft (4). 10. Remove plates (10) (4 used) and friction plates (11) (3 used) from casing (1). 11. Remove shoe plate (5) from casing (1). 12. Remove shaft (4) from casing (1) by using a plastic hammer. 13. Remove oil seal (2) from casing (1) by using a bar and hammer. 14. Remove the outer race of bearing (3) from casing (1) by using a bar and hammer. 15.
UPPERSTRUCTURE / Swing Device ASSEMBLE SWING MOTOR 27 26 25 24 12 13 14 15 16 29 T178-03-02-004 T178-03-02-003 31 30 28 32 21 20 22 23 19 18 10 17 6 11 9 7 5 8 3 1 2 4 12345678- Casing Oil Seal Bearing Shaft Shoe Plate Plunger (9 Used) Plate Retainer T178-03-02-002 910 11 12 13 14 15 16 - Rotor Plate (4 Used) Friction Plate (3 Used) O-Ring Piston Spring Ball Plug (2 Used) 17 18 19 20 21 22 23 24 - O-Ring O-Ring Brake Piston Spring (24 Used) Valve Plate Bearing O-Ring Plug (2 Used) W
UPPERSTRUCTURE / Swing Device Assemble Swing Motor IMPORTANT: Install the inner race of bearing (3) with the flange facing to the stepped side of shaft (4). 1. Install the inner races of bearings (3, 22) to shaft (4) by using a press. IMPORTANT: Install oil seal (2) with the lip part facing upward (the rotor (9) side). 2. Install oil seal (2) to casing (1) by using a plate. 3. Install the outer race of bearing (3) to casing (1) by using a bar and hammer.
UPPERSTRUCTURE / Swing Device 27 26 25 24 12 13 14 15 16 29 T178-03-02-004 T178-03-02-003 31 30 28 32 21 20 22 23 19 18 10 17 6 11 9 7 5 8 3 1 2 4 T178-03-02-002 W2-6-30
UPPERSTRUCTURE / Swing Device IMPORTANT: When replacing the inner parts in piston (13), replace them as an assembly. Install so that the ends of piston (13) and casing (1) may be in the same position. 13. Install ball (15), spring (14) and piston (13) to casing (1). IMPORTANT: Tap the type indicated surface on bearing (22) by using a plastic hammer. 14. Install the outer race of bearing (22) to valve casing (28) by using a plastic hammer. 19.
UPPERSTRUCTURE / Swing Device MAINTENANCE STANDARD Swing Motor 1. Clearance between plunger outer diameter and rotor inner bore D-d d Unit: mm (in) Standard Allowable Limit 0.027 (0.0011) 0.052 (0.0020) W107-02-06-138 D D W107-02-06-139 2. Clearance (δ) between plunger and shoe bottom Unit: mm (in) Standard Allowable Limit 0 (0) 0.3 (0.
UPPERSTRUCTURE / Swing Device 3. Shoe thickness Unit: mm (in) Standard Allowable Limit 5.5 (0.22) 5.3 (0.21) ｔ W107-02-06-142 4. Friction plate thickness Unit: mm (in) Standard Allowable Limit 2.0 (0.08) 1.8 (0.
UPPERSTRUCTURE / Swing Device (Blank) W2-6-34
UPPERSTRUCTURE / Pilot Valve REMOVE AND INSTALL PILOT VALVE CAUTION: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Remove Left Pilot Valve 1 CAUTION: Seat (1) weight: 40 kg (88 lb) 1. Remove bolts (2) (2 used). : 16 mm 3 2 W1JB-02-01-008 2. Remove socket bolts (3) (4 used). Remove seat (1) from bracket (4).
UPPERSTRUCTURE / Pilot Valve 3. Remove cap (7) from lever (5). Remove screw (8). Remove cover (6) from lever (5). 5 6 W1JB-02-07-013 7, 8 4. Remove bolts (10) (2 used). Remove lever (5) from bracket (9). : 13 mm 5 9 10 W1JB-02-07-012 11 5. Remove screws (12) (4 used). Move boot (11) up from bracket (9). 9 12 W1JB-02-07-002 6. Remove screw (13).
UPPERSTRUCTURE / Pilot Valve 7. Remove bolts (14) (2 used) and screw (17). Remove covers (15, 16) from bracket (9). : 10 mm 14 15 16 17 9 8. Remove clip bands (20) (2 used). Disconnect the connector of wire (21). 18 W1JB-02-07-011 19 20 9. Loosen lock nut (19). Remove the lever (18) assembly from pilot valve (22). : 19 mm, 22 mm 21 W1JB-02-07-005 22 10. Remove hoses (23) (6 used) from pilot valve (22). Attach an identification tag onto the removed hoses for assembling. Cap the open ends.
UPPERSTRUCTURE / Pilot Valve 11. Remove bolt (24). Remove pilot valve (22) from bracket (9).
UPPERSTRUCTURE / Pilot Valve Install Left Pilot Valve 24 9 1. Install pilot valve (22) to bracket (9) with bolts (24) (4 used). : 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 22 W1JB-02-07-005 24 22 2. Install hoses (23) (6 used) onto pilot valve (22). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) W1JB-02-07-006 23 3. Install the lever (18) assembly to pilot valve (22). Secure the lever (18) assembly to pilot valve (22) with lock nut (19). : 22 mm : 55 N⋅m (5.5 kgf⋅m, 41 lbf⋅ft) 18 19 20 21 4.
UPPERSTRUCTURE / Pilot Valve 6. Install covers (15, 16) to bracket (9) with bolts (14) (2 used) and screw (17). : 10 mm : 3.3 to 4.2 N⋅m (0.3 to 0.4kgf⋅m, 2.4 to 3.1 lbf⋅ft) 14 15 16 17 9 7. Install covers (15, 16) to bracket (9) with screw (13). W1JB-02-07-011 13 9 16 15 W1JB-02-07-014 11 9 8. Install boot (11) to bracket (9) with screws (12) (4 used). 12 W1JB-02-07-002 9. Install lever (5) to bracket (9) with bolts (10) (2 used).
UPPERSTRUCTURE / Pilot Valve 10. Install cover (6) to lever (5) with screw (8). Attach cap (7) to cover (6). 5 6 W1JB-02-07-013 CAUTION: Seat (1) weight: 40 kg (88 lb) 7, 8 11. Install seat (1) to bracket (4) with socket bolts (3) (4 used). : 6 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)) 1 12. Install the seat belt to bracket (4) with bolts (2) (2 used).
UPPERSTRUCTURE / Pilot Valve Remove Right Pilot Valve 1. Remove the seat. (Refer to W2-7-1.) 2. Remove caps (1) (2 used). Remove screws (2, 4) (2 used for each). Remove cover (3) from bracket (5). 1, 2 3 5 4 W1JB-02-07-009 3. Remove screw (6). 1, 2 3 4 7 6 5 W1JB-02-07-008 8 4. Remove screws (9) (4 used). Move boot (8) up from bracket (5). Remove screw (10). 5 5. Remove cover (7) from bracket (5).
UPPERSTRUCTURE / Pilot Valve 6. Remove clip bands (13) (2 used). Disconnect the connector of wire (14). 11 12 13 7. Loosen lock nut (12). Remove the lever (11) assembly from pilot valve (15). : 19 mm, 22 mm 14 8. Remove bolts (17) (3 used). Remove the bracket (5) assembly from stand (16). Lay down the bracket (5) assembly with the bracket (5) assembly facing downward. : 17 mm W1JB-02-07-005 15 9. Remove bolt (19). Remove cover (18) from bracket (5). : 10 mm 5 17 16 W1JB-02-07-008 10.
UPPERSTRUCTURE / Pilot Valve 11. Remove bolts (21) (4 used). Remove pilot valve (15) from bracket (5).
UPPERSTRUCTURE / Pilot Valve Install Right Pilot Valve 21 5 1. Install pilot valve (15) to bracket (5) with bolts (21) (4 used). : 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 15 W1JB-02-07-005 21 2. Install hoses (20) (6 used) to pilot valve (15). : 19 mm : 29.
UPPERSTRUCTURE / Pilot Valve 3. Install the lever (11) assembly to pilot valve (15). Secure the lever (11) assembly to pilot valve (15) with lock nut (12). : 22 mm : 55 N⋅m (5.5 kgf⋅m, 41 lbf⋅ft) 11 12 13 14 4. Connect the connector of wire (14). 5. Install wire (14) to pilot valve (15) and bracket (5) with clip bands (13) (2 used). 15 W1JB-02-07-005 18 6. Install cover (18) to bracket (5) with bolt (19). : 10 mm : 3.3 to 4.2 N⋅m (0.3 to 0.4 kgf⋅m, 2.4 to 3.1 lbf⋅ft) 19 5 W1JB-02-07-010 7.
UPPERSTRUCTURE / Pilot Valve 8 10. Install boot (8) to bracket (5) with screws (9) (4 used). 5 9 W1JB-02-07-002 11. Install cover (3) to bracket (5) with screws (2, 4) (2 used for each). Attach caps (1) (2 used) to cover (3). 1, 2 3 5 CAUTION: Seat (1) weight: 40 kg (88 lb) 1 4 W1JB-02-07-009 3 12. Install seat (1) to bracket (4) with socket bolts (3) (4 used). : 6 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 4 W1JB-02-07-007 13. Install the seat belt to bracket (4) with bolts (2) (2 used).
UPPERSTRUCTURE / Pilot Valve Remove Travel Pilot Valve 1 1. Remove bolts (3) (7 used). Remove cover (2) from main frame (1). : 19 mm 2 3 W1J1-02-08-001 2. Remove hoses (5) (6 used) from pilot valve (6). Attach identification tags to the removed hoses for reassembling. Attach a cap onto pilot valve (6) and hoses (5) (6 used). : 17 mm, 19 mm 5 5 6 W1JB-02-07-001 3. Remove floor mat (7) from the cab.
UPPERSTRUCTURE / Pilot Valve 4. Remove bolts (10) (4 used). Remove levers (9) (2 used) and pedals (8) (2 used) from pilot valve (6). : 17 mm 9 8 10 5. Remove socket bolts (11) (2 used). Remove pilot valve (6) from main frame (1).
UPPERSTRUCTURE / Pilot Valve Install Travel Pilot Valve 1 1. Install pilot valve (6) to main frame (1) with socket bolts (11) (2 used). : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 6 11 W1JB-02-07-004 2. Install levers (9) (2 used) and pedals (8) (2 used) to pilot valve (6) with bolts (10) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 9 8 3. Install hoses (5) (6 used) to pilot valve (6). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.
UPPERSTRUCTURE / Pilot Valve 4. Install cover (2) onto main frame (1) with bolts (3) (7 used). : 19 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft) 1 2 3 W1J1-02-08-001 5. Install floor mat (7) to the cab.
UPPERSTRUCTURE / Pilot Valve DISASSEMBLE RIGHT AND LEFT PILOT VALVES 17 16 15 14 13 12 11 10 18 9 8 7 6 19 5 4 20 21 3 22 2 1 W178-02-07-064 123456- Spacer (4 Used) Shim (Several) Balance Spring A (2 Used) Balance Spring B (2 Used) Return Spring A (2 Used) Return Spring B (2 Used) 78910 11 12 - Spring Guide (4 Used) Retaining Ring (4 Used) Pusher A (2 Used) Pusher B (2 Used) Oil Seal (4 Used) Sleeve (4 Used) 13 14 15 16 17 - W2-7-18 O-Ring (4 Used) Plate Universal Joint Cam Screw Joint 18
UPPERSTRUCTURE / Pilot Valve Disassemble Right and Left Pilot Valves IMPORTANT: Casing (18) is made of aluminium. Too strong a force can deform or damage them. Be careful while handling them. IMPORTANT: Spool (19) has been selected to match the hole of casing (18). The dimensions of balance springs A (3), B (4) and return springs A (5), B (6) as well as those of pushers A (9), B (10) are different. Indicate the port number from which it is removed.
UPPERSTRUCTURE / Pilot Valve 18 8 7 6 19 5 4 21 3 22 2 1 W178-02-07-064 W2-7-20
UPPERSTRUCTURE / Pilot Valve 7. When compressing the spring, do not lower the spool. Install special tool (ST 4145) to the port hole on casing (18) as illustrated. : 6 mm 8. Install special tool (ST 4146) to the pusher hole on casing (18). Push special tool and compress the spring. Tighten special tool (ST 4146) by using the socket bolt (M14, Pitch 2.0 mm). Remove retaining rings (8)(4 used) from spools (19) (4 used) by using a screwdriver.
UPPERSTRUCTURE / Pilot Valve ASSEMBLE RIGHT AND LEFT PILOT VALVES 17 15 16 14 11 9, 10 12 13 8 7 3, 4 5, 6 2 21 20 1 18 19 22 W1V1-02-07-001 123456- Spacer (4 Used) Shim (Several) Balance Spring A (2 Used) Balance Spring B (2 Used) Return Spring A (2 Used) Return Spring B (2 Used) 78910 11 12 - Spring Guide (4 Used) Retaining Ring (4 Used) Pusher A (2 Used) Pusher B (2 Used) Oil Seal (4 Used) Sleeve (4 Used) 13 14 15 16 17 - W2-7-22 O-Ring (4 Used) Plate Universal Joint Cam Screw Joint 1
UPPERSTRUCTURE / Pilot Valve Assemble Right and Left Pilot Valves IMPORTANT: The pilot valve is susceptible to contamination. Keep the parts clean when assembling. NOTE: Table below shows the relations between each port and the components. Do not confuse them when assembling. Port No. 1 2 Spool (19) Shim (2) Same to the Same to the former one former one 3 4 Port No.
UPPERSTRUCTURE / Pilot Valve 17 15 16 14 11 13 9, 10 12 8 3, 4 18 W1V1-02-07-001 W2-7-24
UPPERSTRUCTURE / Pilot Valve 7. Install retaining rings (8) (4 used) to ring holder (ST 4144). Install retaining rings (8) (4 used) to the groove on the head of spool (21) out of special tool (ST 4146). IMPORTANT: Check the mounting positions of pushers (9, 10) (2 used for each). 8. Install pushers (9, 10) (2 used for each). After pushing pushers (9, 10) (2 used for each) by hand, remove them. Check if retaining ring (8) falls off or balance springs (3, 4) (2 used for each) are located correctly.
UPPERSTRUCTURE / Pilot Valve DISASSEMBLE TRAVEL PILOT VALVE 1 2 3 4 5 6 35 34 7 33 32 8 31 30 9 10 29 11 28 27 14 12 26 15 13 25 16 24 17 18 23 19 20 21 22 W178-02-07-063 123456789- Bolt (2 Used) Cover Spring Pin (2 Used) Spring Pin (2 Used) Cam (2 Used) Bushing (4 Used) Holder Spring Washer (4 Used) Socket Bolt (4 Used) 10 11 12 13 14 15 16 17 18 - Spring Pin Bracket (2 Used) Spring Pin (2 Used) Spring Pin (2 Used) O-Ring (4 Used) Bushing (4 Used) Pusher (4 Used) Spring Guide (16 Used) B
UPPERSTRUCTURE / Pilot Valve Disassemble Travel Pilot Valve IMPORTANT: Casing (23) is made of aluminium. Too strong a force can deform or damage them. Be careful while handling them. IMPORTANT: Spool (24) has been selected to match the hole of casing (23). Indicate the port number from which it is removed. Port numbers are stamped on the outer surface of casing (23). 1. Clamp casing (23) in a vise. Remove bolts (1) (2 used). Remove cover (2) from holder (7).
UPPERSTRUCTURE / Pilot Valve 3 4 6 3 4 10 5 11 5 6 12 6 13 35 34 7 33 32 31 9 10 31 11 32 33 34 35 12 13 23 19 20 21 22 W178-02-07-063 W2-7-28
UPPERSTRUCTURE / Pilot Valve IMPORTANT: Place the stand under bracket (11) and form the reaction force. If holder (7) bears the reaction force, a strong force acts on pin (35) and pin (35) may be deformed. 8. Place a stand under bracket (11). The hole insides of spring pins (12, 13) (2 used for each) in bracket (11) are in stepped-shape. The spring pin can only be removed in one direction. Remove both spring pins (12, 13) (2 used for each) from bracket (11) at the same time by using special tool (ST 1237).
UPPERSTRUCTURE / Pilot Valve ASSEMBLE TRAVEL PILOT VALVE 11 32 31 1 2 35 6 12 10 13 5 3, 4 30 7 29 34 9 15 33 28 8 17 18 14 25 27 16 26 24 23 W178-02-11-316 123456789- Bolt (2 Used) Cover Spring Pin (2 Used) Spring Pin (2 Used) Cam (2 Used) Bushing (4 Used) Holder Spring Washer (4 Used) Socket Bolt (4 Used) 10 11 12 13 14 15 16 17 18 - Spring Pin Bracket (2 Used) Spring Pin (2 Used) Spring Pin (2 Used) O-Ring Bushing (4 Used) Pusher (4 Used) Spring Guide (16 Used) Balance Spring (
UPPERSTRUCTURE / Pilot Valve Assemble Travel Pilot Valve IMPORTANT: Check the direction to install spring guide (17). 1. Assemble spools (24) (4 used) into the assembly. • Insert spacers (26) (2 used), shims (27) (12 used) and balance springs (18) (4 used) into spools (24) (4 used) in this order. Install the shim as the same condition before disassembling. • Push balance springs (18) (4 used) by hand. Install spring guides (17) (4 used) to spools (24) (4 used) with the stepped-end facing downward.
UPPERSTRUCTURE / Pilot Valve 32 31 35 31 5 32 3, 4 30 7 29 34 9 33 8 23 W178-02-11-316 W2-7-32
UPPERSTRUCTURE / Pilot Valve 7. Install O-rings (33) (2 used) to pin (35). Apply grease to O-rings (33) (2 used). Assemble pin (35) and cams (5) (2 used) to holder (7). IMPORTANT: Check the direction to install spring pins (3, 4) (2 used for each). 8. Install spring pins (3, 4) (2 used for each) to cams (5) (2 used) by using special tool (ST 1237). Secure cams (5) (2 used) and pin (35). At this time, spring pins (3, 4) (2 used for each) should be displaced with their slits at 90°.
UPPERSTRUCTURE / Pilot Valve 11 32 1 2 35 12 10 13 1 1 7 19, 20 21, 22 W178-02-11-316 W2-7-34
UPPERSTRUCTURE / Pilot Valve 15. As for the direction to install bracket (11), refer to the figure in the disassemble section. Install bracket (11) to pin (35). Align the inserting holes of spring pins (12, 13) (2 used for each). 21. Install O-rings (19) (2 used) to plugs (20) (2 used). Install plugs (20) (2 used) to casing (23). : 5 mm : 10 N⋅m (1 kgf⋅m, 7.4 lbf⋅ft) IMPORTANT: Place a stand under bracket (11) and form a reaction force.
UPPERSTRUCTURE / Pilot Valve (Blank) W2-7-36
UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve REMOVE AND INSTALL PILOT SHUT-OFF SOLENOID VALVE 2 1 CAUTION: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Remove bolts (3) (7 used) from cover (2). Remove cover (2) from main frame (1). : 19 mm 3 W1J1-02-08-001 Bottom of Main Frame 2. Remove bolt (6). Remove wiring connector (7). : 17 mm 5 6 3. Remove hoses (5) (9 used) from pilot shut-off solenoid valve (8).
UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve Installation 1. Install pilot shut-off solenoid valve (8) to plate (9) with bolts (10) (2 used) and washers (11) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft) Footrest Travel Pilot Valve 6 W1JB-02-08-004 10, 11 2. Install hoses (5) (9 used) to pilot shut-off solenoid valve (8). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 5 6 3. Install wiring connector (7). 4. Install bolt (6).
UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve STRUCTURE OF PILOT SHUT-OFF SOLENOID VALVE A W1JB-02-08-001 3 4 5 6 7 8 2 1 9 Section A Item Part Name Q’ty 1 Plug 1 2 O-Ring 1 3 Spring 1 4 Spool 1 5 Filter 1 6 Body 1 7 O-Ring 1 8 Solenoid 1 9 Socket bolt 2 Wrench Size (mm) : 6 W1JB-02-08-002 Tightening Torque Remark N⋅m (kgf⋅m) (lbf⋅ft) 26.5 (2.7) (19.5) （1B P11） （1A P16） : 4 3.92 W2-8-3 (0.4) （2.
UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve (Blank) W2-8-4
UPPERSTRUCTURE / Solenoid Valve REMOVE AND INSTALL SOLENOID VALVE CAUTION: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) 2 1 2 Removal 1. Remove bolts (2) (4 used). Remove covers (1) (2 used) from the main frame. : 19 mm W1J1-02-05-061 2. Remove all hoses, pipes and connectors (5) (4 used) from solenoid valve (3). Attach an identification tag onto the removed hoses for assembling. Cap the hose and solenoid valve (3).
UPPERSTRUCTURE / Solenoid Valve Installation 4 1. Install solenoid valve (3) to control valve (4) with bolts (6) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 3 5 6 3 W1JB-02-09-005 Signal Control Valve 2. Install all hoses, pipes and connectors (5) (4 used) to solenoid valve (3). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 4 W1J1-02-10-001 2 1 2 3. Install covers (1) (2 used) onto the main frame with bolts (2) (4 used).
UPPERSTRUCTURE / Solenoid Valve STRUCTURE OF SOLENOID VALVE Housing W800-02-09-001 Proportional Solenoid Valve B A Proportional Solenoid Valve W800-02-09-002 Filter Plug Plug Filter W800-02-09-004 View A W800-02-09-003 W2-9-3 Section B
UPPERSTRUCTURE / Solenoid Valve DISASSEMBLE AND ASSEMBLE PROPOTIONAL SOLENOID VALVE 1 2 3 4 5 6 7 8 9 12 14 13 10 15 11 16 17 18 19 W18G-02-08-012 4 2 3, 5 6 1 8 12 13 17 10 18 19 W18G-02-08-013 7 12345- Socket Bolt (2 Used) Lock Nut O-Ring Adjusting Bolt Spring 678910 - Solenoid Spring O-Ring Diaphragm Spool 9 14 11 12 13 14 15 - W2-9-4 Orifice Washer Spring O-Ring O-Ring 15 16 16 17 18 19 - 11 O-Ring Sleeve Plate Wave Spring
UPPERSTRUCTURE / Solenoid Valve Assemble Proportional Solenoid Valve Disassemble Proportional Solenoid Valve IMPORTANT: Do not disassemble lock nut (2) and adjusting bolt (4) for pressure adjustment. 1. Remove socket bolts (1) (2 used). Remove solenoid (6) and O-ring (8) from the housing. : 4 mm 2. Remove spool (10), diaphragm (9), washer (12) and spring (13) from sleeve (17). 3. Remove sleeve (17), plate (18) and wave spring (19) from the housing. IMPORTANT: Do not remove orifice (11) from sleeve (17). 4.
UPPERSTRUCTURE / Solenoid Valve (Blank) W2-9-6
UPPERSTRUCTURE / Signal Control Valve REMOVE AND CONTROL VALVE INSTALL SIGNAL CAUTION: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) 2 1 2 Removal 1. Remove bolts (2) (4 used). Remove covers (1) (2 used) from the main frame. : 19 mm W1J1-02-05-061 2. Remove all hoses and from signal control identification tag onto assembling. Cap signal hose. : 17 mm, 19 mm the connectors (2 used) valve (3).
UPPERSTRUCTURE / Signal Control Valve Installation 3 1. Install signal control valve (3) to bracket (5) with socket bolts (6) (4 used). : 8 mm : 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 5 W1JB-02-10-001 6 2. Install all hoses and the connector to signal control valve (3). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 4-Spool Solenoid Valve 3 W1JB-02-09-004 2 1 2 3. Install covers (1) (2 used) onto the main frame with bolts (2) (4 used).
UPPERSTRUCTURE / Signal Control Valve STRUCTURE OF SIGNAL CONTROL VALVE 13 4 12 7 11 7 4 10 9 7 7 8 7 6 5 4 4 3 2 4 1 W1JB-02-10-002 W2-10-3
UPPERSTRUCTURE / Signal Control Valve 15 16 14 16 16 17 17 17 18 19 21 19 18 19 20 20 20 14 22 23 24 25 26 27 19 20 5 19 21 18 17 17 20 19 17 16 29 18 20 19 28 17 14 16 16 16 W1JB-02-10-003 Detail of Body 2 12345678- Bolt (3 Used) Body 1 Gasket Filter (17 Used) Body 2 Gasket Shuttle Valve (2 Used) Spring (4 Used) 910 11 12 13 14 15 16 - Body 3 Gasket Body 4 Gasket Body 5 Socket Bolt (11 Used) Plate Plug (7 Used) 17 18 19 20 21 22 23 24 - W2-10-4 O-Ring (7 Used) Spri
UPPERSTRUCTURE / Shockless Valve REMOVE VALVE AND INSTALL SHOCKLESS CAUTION: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) 1 Removal 1. Remove bolts (3) (6 used). Remove cover (2) from main frame (1). : 19 mm 3 2 W1J1-02-08-001 5 2. Remove hoses (8) (2 used) from shockless valve (7). Cap hose (8) and shockless valve (7). : 19 mm 6 3. Remove bolts (5) (2 used). Remove shockless valve (7) from bracket (6).
UPPERSTRUCTURE / Shockless Valve Installation 5 1. Install shockless valve (7) to bracket (6) with bolts (5) (2 used). : 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 6 2. Install hoses (8) (2 used) to shockless valve (7). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 7 8 3. Install cover (2) onto main frame (1) with bolts (3) (6 used).
UPPERSTRUCTURE / Shockless Valve STRUCTURE OF SHOCKLESS VALVE 4 5 6 7 1 2 3 T183-03-07-008 Item Part Name Q’ty 1 Plug 2 2 O-Ring 2 3 Body 1 4 Spring 2 5 Plunger 1 6 Ring 1 7 Orifice 1 Wrench Size (mm) : 8 Tightening Torque N⋅m (kgf⋅m) (lbf⋅ft) 39 (4) (29) W2-11-3 Remark
UPPERSTRUCTURE / Shockless Valve (Blank) W2-11-4
UPPERSTRUCTURE / Fan Valve REMOVE AND INSTALL FAN VALVE 2 2 1 CAUTION: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Remove bolts (2) (4 used). Remove covers (1) (2 used) from the main frame. : 19 mm Engine Cover W1J1-02-05-061 2. Open and lock the engine cover. Remove bolts (3) (4 used) from cover (4). Remove cover (4) from the bracket. : 19 mm 3 Fan Motor 4 W1J1-02-12-001 3.
UPPERSTRUCTURE / Fan Valve 4. Remove bolts (9) (2 used) from fan valve (7). Remove fan valve (7) from bracket (8).
UPPERSTRUCTURE / Fan Valve Installation 5 1. Install fan valve (7) to bracket (8) with bolts (9) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 8 6 2. Install hoses (5) (2 used) and (6) (2 used) to fan valve (7). : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft) 7 W1J1-02-12-002 9 Fan Motor 3 3. Install cover (4) to the bracket with bolts (3) (4 used). : 19 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft) 4 W1J1-02-12-001 4. Install covers (1) (2 used) to the main frame with bolts (2) (4 used).
UPPERSTRUCTURE / Fan Valve STRUCTURE OF FAN VALVE B View A A W1JB-02-13-003 W1JB-02-13-002 1 2 3 4 5 6 7 8 9 10 11 12 13 14 18 17 16 15 Section B Item Part Name Q’ty W1JB-02-13-001 Wrench Size (mm) Item Part Name Q’ty 1 Pin 2 10 O-Ring 2 Poppet 2 11 Spring 1 3 Poppet 1 12 O-Ring 1 4 Backup Ring 2 13 Lock Nut 1 5 O-Ring 1 14 Screw 1 6 O-Ring 1 15 Body 1 7 Spring 1 16 Poppet 1 1 8 O-Ring 1 17 Adapter 1 9 Spring 1 18 Backup Rin
UPPERSTRUCTURE / Fan Motor REMOVE AND INSTALL FAN MOTOR CAUTION: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) 2 1 3 Counterweight Removal Machine Front 1. Drain half of hydraulic oil through the oil filler on hydraulic oil tank by using a pump. Remove plug (4). Drain hydraulic oil in the hydraulic oil cooler (16 L, 4.2 US gal.) and drain pipe. After draining hydraulic oil, install plug (4).
UPPERSTRUCTURE / Fan Motor 6. Remove refrigerant in the air conditioner. Remove hoses (14) (2 used) from condenser (10). Cap the adapter in condenser and hose (14). As for the procedures to remove refrigerant, refer to the operator’s manual. : 19 mm Radiator Assembly 7. Remove the bands (2 used) from hoses (12) (2 used). Remove hoses (12) (2 used) from fuel cooler (11). Drain fuel in the hoses between engine and fuel cooler (11) and between fuel cooler (11) and fuel tank.
UPPERSTRUCTURE / Fan Motor IMPORTANT: Insert the protective material between engine cover (18) and muffler cover (17) in order not to damage the cover. 9. Open and hold engine cover (18). Remove lock pins (21) (2 used) and washers (20) (2 used) from stays (19) (2 used). Lay down engine cover (18) to the muffler cover (17) side. 17 18 W1J1-02-13-001 19 20 CAUTION: Engine cover (18) weight: 32 kg (70 lb) 10. Remove bolts (22) (8 used) from hinges (23) (4 used).
UPPERSTRUCTURE / Fan Motor 11. Remove bolts (28) (18 used). Remove radiator covers 1, 2 (24, 29) from the main frame. 24 ： 19 mm 25 17 Ａ 12. Remove bolts (25) (8 used). Remove muffler cover (17) from the main frame. : 19 mm 13. Remove bolts (26) (4 used). Remove covers (27) (2 used) from the main frame. : 19 mm 28 29 W1J1-02-13-003 28 26 27 View A 24 28 17 25 W1J1-02-13-002 Radiator Assembly 14. Remove bolts (32, 33) (6 used for each). Remove covers (31, 34) from the main frame.
UPPERSTRUCTURE / Fan Motor 15. Loosen nuts (42, 44, 46) (2 used for each). Move bands (43, 45, 48) (2 used for each) to the center of hoses (41, 47). : 11 mm 35 16. Remove bolts (49, 53). Remove clamps (50, 52) from pipe (51). : 17 mm 17. Remove pipe (51) from hoses (41, 47). 36, 37 B A Machine Front 44, 45 42, 43 W1J1-02-13-005 41 46 47 48 49, 50 51 18. Loosen nuts (36, 54) (2 used for each). Move bands (37, 56) (2 used for each) to the center of hoses (35, 55). : 11 mm 52 53 19.
UPPERSTRUCTURE / Fan Motor 21. Loosen nuts (65) (2 used). Move bands (66) (2 used) to the center of hose (67). Remove hose (67) from the radiator. : 11 mm 22. Loosen nuts (62) (2 used). Move bands (63) (2 used) to the center of hose (64). Remove hose (64) from the radiator.
UPPERSTRUCTURE / Fan Motor 23. Remove bolts (68) (4 used). Remove bracket (69) from the main frame. : 19 mm 68, 69 24. Remove hose (70) from the coolant reservoir. 70 Coolant Reservoir Machine Front W1J1-02-13-004 25. Remove bolt (72). Remove coupler holder (71) from the coupler. : 11 mm 71 72 Coupler W1J1-02-13-018 26. Remove bolts (74) (4 used) from flange (73).
UPPERSTRUCTURE / Fan Motor 27. Remove hoses (76 to 78) from fan valve (75). : 27 mm, 36 mm Machine Front W1J1-02-13-004 78 75 77 76 W1J1-02-13-021 Machine Front 28. Remove bolts (80) (4 used), washers (81) (4 used) and nuts (82) (4 used).
UPPERSTRUCTURE / Fan Motor 29. Close dust cover (2). Temporarily tighten dust cover (2) with bolts (3) (2 used) and the washers (2 used). : 19 mm Lifting Hole Machine Front NOTE: While hoisting radiator, do not open dust cover (2). 3 CAUTION: The radiator assembly weight: 570 kg (1260 lb) 2 30. Attach a wire rope onto the lifting hole on radiator assembly and hold the radiator assembly. 31. Hoist the radiator assembly and check if the hydraulic hose is removed.
UPPERSTRUCTURE / Fan Motor 35. Remove socket bolts (92) (4 used). Remove fan (94) from coupling (93). : 8 mm 99 95 Shaft 96 92 94 36. Remove lock pin (95) and nut (96) from the shaft in fan motor (98). : 24 mm IMPORTANT: Key (97) is attached with the shaft in fan motor (98). Do not lose key (97). 37. Remove coupling (93) and fan guard (87) from the shaft in fan motor (98). 93 97 98 88 NOTE: When it is difficult to remove coupling (93), use special tool when removing the bearing.
UPPERSTRUCTURE / Fan Motor 40. Remove bolts (107) (2 used), washers (108) (2 used) and nuts (109) (2 used). Remove fan motor (98) from bracket (88). : 19 mm 98 NOTE: Replace fan motor (98) with the assembly.
UPPERSTRUCTURE / Fan Motor Installation CAUTION: Bracket (88) weight: 41 kg (90 lb) 1. Attach a nylon sling onto the hole on bracket (88). Hoist and place bracket (88) with the mounting surface for fan motor (98) facing downward. 98 2. Install fan motor (98) to bracket (88) with bolts (107) (2 used), washers (108) (2 used) and nuts (109) (2 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 107, 108, 109 3. Install hoses (105, 106) to fan motor (98) with socket bolts (101, 104) (4 used for each).
UPPERSTRUCTURE / Fan Motor CAUTION: The bracket weight: 70 kg (155 lb) (88) assembly 4. Hoist and place the bracket (88) assembly with the shaft in fan motor (98) facing upward. 98 107, 108, 109 5. Apply LOCTITE #262 to nut (96). Install key (97), coupling (93), washer (99), nut (96) and lock pin (95) to the shaft in fan motor (98). : 24 mm : 100 N⋅m (10 kgf⋅m, 75 lbf⋅ft) 6. Apply LOCTITE #262 to socket bolt (92). Install fan guard (87) between bracket (88) and coupling (93).
UPPERSTRUCTURE / Fan Motor CAUTION: The bracket weight: 90 kg (200 lb) (88) assembly 94 87 7. Hoist and install bracket (88) to the radiator with bolts (91) (6 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 88 93 92 W1JB-02-12-010 8. Install cover (89) onto bracket (88) with bolts (90) (6 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 88 98 91 W1J1-02-13-009 9. Install fan guard (87) to the radiator with bolts (86) (8 used). : 19 mm : 90 N⋅m (9.
UPPERSTRUCTURE / Fan Motor CAUTION: The radiator assembly weight: 570 kg (1260 lb) Lifting Hole IMPORTANT: Before installing the radiator assembly to the main frame, check the connections in hydraulic oil cooler and hoses. 10. Temporarily tighten dust cover (2) with bolts (3) (2 used). Attach a wire rope to the lifting hole on the radiator assembly. Hoist and move the radiator assembly to the mounting position for radiator in the main frame. Machine Front 3 2 W1J1-02-13-005 11.
UPPERSTRUCTURE / Fan Motor 13. Install hoses (76 to 78) to fan valve (75). : 27 mm : 137 N⋅m (14 kgf⋅m, 100 lbf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft) 14. Install hose (70) to the coolant reservoir.
UPPERSTRUCTURE / Fan Motor 15. Install coupler holder (71) with bolt (72). : 11 mm Machine Front W1J1-02-13-004 71 72 Coupler 16. Install flange (73) with bolts (74) (4 used). : 19 mm : 90 N⋅m (9.
UPPERSTRUCTURE / Fan Motor 17. Install hose (67) to the radiator. Tighten bands (66) (2 used) with nuts (65) (2 used). : 11 mm 18. Install hose (64) to the radiator. Tighten bands (63) (2 used) with nuts (62) (2 used).
UPPERSTRUCTURE / Fan Motor 19. Install pipe (51) to hose (47). Install hose (41) to pipe (56). Tighten bands (43, 45, 48) (2 used for each) with nuts (42, 44, 46) (2 used for each). : 11 mm 35 20. Install clamps (50, 52) to pipe (51) with bolts (49, 53). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 36, 37 B A Machine Front 44, 45 42, 43 W1J1-02-13-005 41 46 47 48 49, 50 51 52 Machine Front 53 Detail for Part A 21. Install pipe (59) to hose (35). Install hose (55) to pipe (59).
UPPERSTRUCTURE / Fan Motor 23. Remove bolts (3) (2 used). Open and secure dust cover (2) to the counterweight side. : 19 mm 2 3 W1J1-02-13-012 Radiator Assembly Machine Front 24. Install hoses (12) (2 used) to fuel cooler (11). Secure hoses (12) (2 used) with the bands (2 used). 25. Install hoses (14) (2 used) to condenser (13). : 19 mm : 29.
UPPERSTRUCTURE / Fan Motor 26. Install cover (8) to the radiator with bolts (7) (2 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) Radiator Assembly 8 7 W1J1-02-13-008 27. Install connector (15) to fresh air temperature sensor (16).
UPPERSTRUCTURE / Fan Motor 28. Install covers (27) (2 used) to the main frame with the bolts (26) (4 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 29. Install radiator covers (24, 29) to the main frame with the bolts (28) (18 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 30. Install muffler cover (17) to the main frame with bolts (25) (8 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 24 17 25 Ａ 28 29 W1J1-02-13-003 31.
UPPERSTRUCTURE / Fan Motor 33. Place engine cover (18) onto muffler cover (17). Install engine cover (18) to the main frame with hinges (23) (4 used) and bolts (22) (8 used). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 17 18 34. Insert the end of stays (19) (2 used) in engine cover (18) into the bracket and install with washers (20) (2 used) and lock pin (21).
UPPERSTRUCTURE / Fan Motor 35. Add coolant into the radiator. 36. Add refrigerant in the air conditioner. NOTE: As for type and amount of refrigerant, refer to the operator’s manual. 37. Add hydraulic oil into the hydraulic oil tank. Release any pressure in the main pump and fan pump. 38. Start the engine. Keep the engine idling for several minutes in order to circulate the coolant and hydraulic oil. 39. Stop the engine. Check coolant in coolant reservoir. Add coolant to the specification. 40.
UPPERSTRUCTURE / Fan Motor STRUCTURE OF FAN MOTOR 7 21 22 23 W1JB-02-12-002 1 2 3 4 5 6 7 8 9 10 11 W1JB-02-12-001 20 123456- 19 End Cap Rotor Insert Assembly Vane Spring (24 Used) Mount (12 Used) Vane (12 Used) Cam Ring 18 17 78910 11 12 - 16 Pressure Port Plate O-Ring Housing Ball Bearing Key Shaft 13 14 15 16 17 18 - 15 14 Retaining Ring Retaining Ring Seal Seal Pin (2 Used) Seal NOTE: Tightening Torque 20- Socket bolt 100 N⋅m (10 kgf⋅m, 75 lbf⋅ft) 23- Screw 11.5 to 12.
UPPERSTRUCTURE / Fan Motor (Blank) W2-13-26
UPPERSTRUCTURE / Engine REMOVE AND INSTALL ENGINE CAUTION: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4.)Remove the grounding wire from the battery. 2 1 Removal 1. Drain off coolant (max. 55 L (14.5 US gal)) from the radiator. : 19 mm W1J1-02-13-001 2. Open engine cover (2). Remove lock pins (5) (2 used) and washers (4) (2 used) from the stay and cylinder (3). Lay down engine cover (2) to the muffler cover (1) side.
UPPERSTRUCTURE / Engine CAUTION: Air cleaner cover (10) weight: 32 kg (71 lb) 10 Rain Cover 5. Unlock the catch. Open air cleaner cover (12). Remove bolts (11) (11 used). Attach a nylon sling to air cleaner cover (10). Hoist and remove air cleaner cover (10). : 19 mm 11 12 NOTE: Remove air cleaner cover (10) with cover (12) and the rain cover attached. Catch W1J1-02-04-038 13 6. Remove bolts (14) (18 used). Remove radiator Ａ covers (13, 15). : 19 mm 14 15 14 W1J1-02-13-003 7.
UPPERSTRUCTURE / Engine CAUTION: Bracket (24) weight: 21 kg (46 lb) 8. Remove bolts (23) (4 used) from both ends of bracket (24). Attach a nylon sling to bracket (24). Hoist and remove bracket (24). : 19 mm 22 23 9. Remove bolts (27) (2 used). Remove bracket (22). : 19 mm 10. Remove bolts (26) (3 used). Remove bracket (25). : 19 mm 24 25 27 CAUTION: Muffler (28) weight: 31 kg (68 lb) 26 11. Remove bolts (32) (4 used) and washers (33) (4 used) from exhaust pipe (31).
UPPERSTRUCTURE / Engine 37 14. Loosen nuts (38) (2 used) in bands (39) (2 used). Remove bolts (41) (4 used) from clamps (40) (2 used). Remove pipe (42) from hose (37). : 11 mm, 17 mm 38, 39 40, 41 42 Pipe 15. Loosen nuts (43) (2 used) in bands (44) (2 used). Remove hose (45) from the pipe in radiator. : 11 mm 43 44 40 41 45 16. Loosen nuts (47) (2 used) in bands (46) (2 used). Remove bolts (49) (4 used) from clamps (50) (2 used). Remove pipe (51) from hose (48).
UPPERSTRUCTURE / Engine 19. Remove terminals (67) (2 used) from air cleaner restriction switch (61). Remove clip (66). Loosen nut (63) in band (62). : 11 mm 61 62 67 63 64 65 66 W1J1-02-04-042 20. Disconnect connector (70) temperature sensor (68). from intake-air 70 68 W1J1-02-14-021 71 72 65 64 21. Remove bolts (71) (2 used). Remove clamp (72) from bracket (73). : 17 mm 21. Loosen nut (75) in band (74). Remove the hose/pipe assembly (76, 69, 65) from the pipe in engine.
UPPERSTRUCTURE / Engine 77 W1J1-02-04-045 Main Frame 23. Remove bolts (79) (2 used). : 17 mm 78 79 80 77 W1J1-02-04-046 81 24. Open and lock the pump cover. Remove bolts (85) (2 used). Pull out harness (78) to the pump space from cover (84). : 17 mm 25. Remove bolts (82) (18 used) and (89). Remove covers (81, 83, 84, 87).
UPPERSTRUCTURE / Engine 64 CAUTION: Air cleaner (64) weight: 30 kg (66 lb) 77 26. Remove bolts (90) (4 used). Attach a nylon sling onto air cleaner (64). Hoist and remove air cleaner (64). : 17 mm W1J1-02-04-044 NOTE: Remove bolts (90) (4 used) from the mounting hole on pump space. 90 77 27. Remove bolts (91) (4 used). Remove bracket (77).
UPPERSTRUCTURE / Engine Radiator Pipe 28. Remove nut (93). Remove harness (92) from overheat switch (94). : 6.6 mm 29. Disconnect connector (97). Attach a nylon sling to air compressor (99) and hold air compressor (99). Loosen bolt (96) fully. Remove bolts (100) (4 used). Remove air compressor (99) from the engine. : 12 mm, 13 mm 94 93 95 92 W1J1-02-14-022 Engine 96 NOTE: Remove and install the engine with air compressor (99) hoisted inside the machine. Do not remove hose (98). 97 30.
UPPERSTRUCTURE / Engine IMPORTANT: Before removing nut (111) from the terminal in starter motor (112), remove the grounding wire in battery. If the work is continued with the grounding wire connected, the circuit may be shorted. 32. Remove nuts (111) (2 used). Remove harness (114) from the terminal in starter motor (112). Remove nut (113). Remove the grounding wire from the bracket. : 17 mm, 22 mm 111 112 Bracket 113 114 33. Remove bolts (115) (3 used). Remove clips (116) (3 used) from harness (118).
UPPERSTRUCTURE / Engine Pipe 35. Loosen nuts (130) (2 used) in bands (131) (2 used). Remove hose (132) from the pipe in engine. : 11 mm 130 131 132 36. Remove hoses (133) (2 used) from the engine. Cap the open ends of hose and pump. Attach an identification tag to the hose. : 41 mm W1J1-02-14-002 Engine 133 37. Remove socket bolts (140, 144) (4 used for each). Remove pipes (141, 145) from the pump device. Cap the open ends of hose and pump. Attach an identification tag to the hose. : 14 mm 38.
UPPERSTRUCTURE / Engine 40. Remove bolts (150) (2 used), washers (151) (4 used), plates (149) (2 used), cushions (152) (2 used) and nuts (155) (2 used) from brackets (153) (2 used). : 41 mm NOTE: After removing the engine from the main frame, remove cushions (154) (2 used). 150, 151 149 W1J1-02-14-013 Air Compressor 150 151 149 152 153 154 152 155 Details when installing W1J1-02-14-020 41. Remove bolts (157) (2 used) and washer (158) or the spacer from brackets (156) (2 used).
UPPERSTRUCTURE / Engine CAUTION: Engine/pump weight: 1630 kg (3590 lb) 42. Attach a wire rope to the lifting hole (3 places) on engine. Hoist and remove the engine. Lifting Hole 153 IMPORTANT: Secure the wooden block in order to attach on the engine. Place the engine horizontally. Hold the engine in order not to fall down. 43. After placing the wooden blocks (300 mm×600 mm, 11.8 in×23.6 in) (2 used) under brackets (153) (2 used) at the engine radiator side and the wooden block (300 mm×300 mm, 11.8 in×11.
UPPERSTRUCTURE / Engine Installation 1. Install cushion (154) to the place for brackets (153) (2 used) in the main frame. CAUTION: Engine/pump weight: 1630 kg (3590 lb) 2. Attach a wire rope to the lifting hole (3 places) on engine. Hoist and move the engine to the mounting position for engine in the main frame. 152 153 154 W1J1-02-14-016 3.
UPPERSTRUCTURE / Engine 4. Install brackets (156) (2 used) with bolts (157) (2 used), washer (158) or the spacer. Install the spacer instead of washer (158) to bracket (156) at the muffler side. : 32 mm : 750N⋅m (77 kgf⋅m, 553 lbf⋅ft) 156 Starter Motor 157, 158 W1J1-02-14-014 5. Install hoses (133) (2 used) to the engine. : 41 mm : 300 N⋅m (31 kgf⋅m, 221 lbf⋅ft) 133 6. Tighten nuts (130) (2 used). Tighten hose (132) to the pipe in engine with bands (131) (2 used).
UPPERSTRUCTURE / Engine 7. Install bracket (77) with bolts (91) (4 used). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 77 91 W1J1-02-04-045 Main Frame CAUTION: Air cleaner (64) weight: 30 kg (66 lb) 8. Attach a nylon sling onto air cleaner (64). Hoist and move air cleaner (64) to the mounting position on bracket (77). Apply LOCTITE #262 to bolts (90) (4 used). Install air cleaner (64) with bolts (90) (4 used). : 17 mm : 50 N⋅m (5.
UPPERSTRUCTURE / Engine 9. Install hose (76) to the pipe in engine. Tighten nut (75). Tighten hose (76) with band (74). Install pipe (69) to bracket (73) with clamp (72) and bolts (71) (2 used). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) : 11 mm 71 72 65 64 69 76 75 74 73 W1J1-02-14-006 10. Install connector (70) to intake-air temperature sensor (68). 70 68 W1J1-02-14-021 11. Pull in harness (78) through the pump space.
UPPERSTRUCTURE / Engine 12. Install hose (65) to the pipe in air cleaner (64). Tighten nut (63). Tighten hose (65) with band (62). Install clip (66). : 11 mm 61 62 13. Connect terminals (67) (2 used) in air cleaner restriction switch (61). 67 63 64 65 66 W1J1-02-04-042 14. Install covers (81, 83, 84, 87) with bolts (82) (18 used) and (89). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 15. Install clips (86) (2 used) in harness (78) with bolts (85) (2 used).
UPPERSTRUCTURE / Engine 134 17. Install pipes (141, 145) to the pump device with socket bolts (140, 144) (4 used for each). Install hoses (137, 139, 147) to the pump device with socket bolts (136, 138, 146) (4 used for each). : 10 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) : 14 mm : 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft) 18. Install hoses (134, 135, 142, 143, 148) to the pump device. : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 27 mm : 93 N⋅m (9.
UPPERSTRUCTURE / Engine 21. Install hoses (110) (2 used) to the fuel pipes (2 used) in engine. Tighten hoses (110) (2 used) with bands (109) (2 used) by using a screwdriver. 22. Install air compressor (99) to the engine with bolts (100) (4 used). Adjust a slack in belt (95) by using bolt (96). : 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 109, 110 109, 110 95 96 W1J1-02-14-011 Engine 97 98 100 99 Push Here Approx. 98 Ｎ (10 kgf） Idle Pulley W1J1-02-14-003 Slack 6 to 10 mm (0.2 to 0.
UPPERSTRUCTURE / Engine 23. Install harness (106) to the terminals (2 used) in alternator with nut (102) and screw (108). Install terminal covers (101, 107). Install connector (103). Install clips (104) (2 used) in harness (106) with bolts (105) (2 used). : 12 mm : 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) Alternator 107, 108 IMPORTANT: Before installing harness (114) to the terminal in starter motor (112), remove the grounding wire in battery.
UPPERSTRUCTURE / Engine 26. Install hose (55) to the pipe in engine. Tighten nuts (56) (2 used). Tighten hose (55) with bands (57) (2 used). : 11mm 52 53, 54 27. Install hose (52) to the pipe in engine. Tighten nuts (53) (2 used). Tighten hose (52) with bands (54) (2 used). : 11mm 55 56, 57 28. Install pipe (42) to hose (37). Tighten nuts (38) (2 used). Tighten hose (37) with bands (39) (2 used). : 11mm W1J1-02-13-004 37 29. Secure pipe (42) with clamps (40) (2 used) and bolts (41) (4 used).
UPPERSTRUCTURE / Engine 33. Install exhaust pipe (31) to the engine with nuts (29) (8 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) CAUTION: Bracket (27A) weight: 30 kg (66 lb) 34. Hoist and hold bracket (27A). Install bracket (27A) to the main frame with bolts (36) (4 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 32, 33 CAUTION: Muffler (28) weight: 30 kg (66 lb) 35. Hoist and place muffler (28) onto bracket (27).
UPPERSTRUCTURE / Engine 37. Install bracket (22) with bolts (27) (2 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 22 38. Install bracket (25) with bolts (26) (3 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 23 24 CAUTION: Bracket (24) weight: 21 kg (46 lb) 39. Hoist and hold bracket (24). Install bracket (24) to brackets (22, 25) with bolts (23) (4 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 25 27 26 40. Install covers (16, 18, 21) with bolts (17, 19) (5 used for each) and (20) (4 used).
UPPERSTRUCTURE / Engine CAUTION: Air cleaner cover (10) weight: 32 kg (71 lb) 10 Rain Cover 41. Hoist and move air cleaner cover (10) to the mounting position. Install air cleaner cover (10) with bolts (11) (11 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 11 12 Catch W1J1-02-04-038 13 42. Install radiator covers (13, 15) with bolts (14) (18 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 14 15 14 W1J1-02-13-003 1 9 43. Install muffler cover (1) with bolts (9) (8 used). : 19 mm : 90 N⋅m (9.
UPPERSTRUCTURE / Engine 44. Hoist and place engine cover (2) onto muffler cover (1). Install hinges (6) (4 used) in engine cover (2) with bolts (7) (8 used). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 1 2 45. Insert the end of stay and cylinder (3) into the bracket and install with washers (4) (2 used) and lock pins (5) (2 used). W1J1-02-13-001 3 4 5 Bracket 7 6 W1J1-02-14-023 46. Connect the grounding wire to the negative terminal in battery. 47. Add coolant (max. 55 L, 14.5 US gal.) into the radiator.
UPPERSTRUCTURE / Engine (Blank) W2-14-26
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SECTION 3 UNDERCARRIAGE — CONTENTNS — Group 1 Swing Bearing Group 4 Track Adjuster Remove and Install Remove and Install Track Adjuster .........W3-4-1 Swing Bearing ........................................ W3-1-1 Disassemble Track Adjuster ...................W3-4-2 Disassemble Swing Bearing .................. W3-1-4 Assemble Track Adjuster ......................W3-4-10 Assemble Swing Bearing ....................... W3-1-6 Group 5 Front Idler Group 2 Travel Device Remove and Install Front Idler..
(Blank) 1J1W-3-2
UNDERCARRIAGE / Swing Bearing REMOVE AND INSTALL SWING BEARING Before removing and installing the swing bearing, the upperstructure must be removed first. For removal and installation of the upperstructure, refer to “Remove and Install Frame”, “Remove and Install Front Attachment” and “Remove and Install Counterweight” sections. In this section, the procedure starts on the premise that the upperstructure has already been removed. 1 Matching Mark 3 2 Removal 1.
UNDERCARRIAGE / Swing Bearing Installation Clean the mounting surfaces of track frame (2) and swing bearing (1). 1. Apply THREEBOND #1102 to the mounting surface for swing bearing (1) on track frame (2). 1 3 2 W105-03-01-003 CAUTION: Swing bearing (1) weight: 642 kg (1420 Ib) IMPORTANT: Check sure to align the matching marks. Otherwise, the inner race soft zone will be in wrong position. 2. Hoist swing bearing (1).
UNDERCARRIAGE / Swing Bearing 3. Apply LOCTITE #262 to bolts (4) (40 used). Tighten swing bearing (1) to track frame (2) with bolts (4) (40 used). : 41 mm : 1375 N⋅m (140 kgf⋅m, 1015 Ibf⋅ft) 4 4. Install all grease pipes to swing bearing (1). : 17 mm : 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft) 1 W105-03-01-002 2 5. After installing the swing bearing, fill the grease bath with grease until the pinion of swing bearing is covered clearance A or B in grease. Swing Bearing Grease Level Pinion Grease amount: 18 L (4.
UNDERCARRIAGE / Swing Bearing DISASSEMBLE SWING BEARING 1 2 3 4 W1J1-03-01-001 7 6 5 9 1 9 2 8 7 6 5 W157-03-01-002 1 - Outer Race 2 - Seal 3 - Pin 4 - Plug 5 - Seal 67- Ball (86 Used) Inner Race W3-1-4 89- Support (86 Used) Grease Fitting (3 Used)
UNDERCARRIAGE / Swing Bearing Disassemble Swing Bearing CAUTION: Swing bearing weight: 642 kg (1420 Ib) 1. Remove pin (3) from the bottom side of plug (4). NOTE: As pin (3) head was crimped after installation, grind off the crimped part. 3. Hoist outer race (1) of the swing bearing horizontally and slightly. Remove seals (2 and 5) from outer race (1) and inner race (7). 4. Place inner race (7) of the swing bearing on the wooden blocks. Hoist outer race (1). 3 5.
UNDERCARRIAGE / Swing Bearing ASSEMBLE SWING BEARING 1 2 3 4 W1J1-03-01-001 7 6 5 9 1 9 2 8 7 6 5 W157-03-01-002 1 - Outer Race 2 - Seal 3 - Pin 4 - Plug 5 - Seal 67- Ball (86 Used) Inner Race W3-1-6 89- Support (86 Used) Grease Fitting (3 Used)
UNDERCARRIAGE / Swing Bearing Assemble Swing Bearing 3. Clean the groove part for seals (2, 5) completely. Apply THREE BOND #1530D and install seal (2) to outer race (1). Install seal (5) to the groove part on inner race (7). CAUTION: Swing bearing weight: 642 kg (1420 lb) Outer race (1) weight: 289 kg (640 lb) 1. Align inner race (7) of the swing bearing with the ball groove on outer race (1). IMPORTANT: Apply grease to balls (6) and support (8). 2.
UNDERCARRIAGE / Swing Bearing (Blank) W3-1-8
UNDERCARRIAGE / Travel Device REMOVE AND INSTALL TRAVEL DEVICE IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to “BLEED AIR FROM HYDRAULIC OIL TANK” on W1-4-1.) 5. Put the matching marks on travel device (10) and track frame (1). Remove bolts (8) and washers (9). Hoist and remove travel device (10) from track frame (1). : 32 mm Removal Before removing the travel device, the tracks must be removed first.
UNDERCARRIAGE / Travel Device Installation CAUTION: Travel device (10) weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 671 kg (1480 lb) ZAXIS500LC-3, 520LCH-3: 855 kg (1885 lb) 5 1 6 IMPORTANT: Align the matching marks made when disassembling. If the matching marks are not aligned, it is difficult to install hoses (6, 7). 1. Install travel device (10) to track frame (1) with bolts (8) and washers (9). : 32 mm : 750 N⋅m (76.
UNDERCARRIAGE / Travel Device (Blank) W3-2-3
UNDERCARRIAGE / Travel Device DISASSEMBLE TRAVEL DEVICE 10 (ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3) 9 8 7 6 5 4 3 2 23 24 26 25 22 1 19 18 17 15 20 27 21 16 28 29 30 14 11 12 31 13 39 42 41 38 36 35 37 34 33 32 40 51 50 49 46 47 48 45 43 44 123456- Motor Bolt (4 Used) Spring Washer (4 Used) O-Ring Housing Floating Seal 14 15 16 17 18 19 - Sprocket Washer (24 Used) Bolt (24 Used) Third Stage Carrier Third Stage Sun Gear Second Stage Carrier 27 28 29 30 31 32 - 78910 11 -
UNDERCARRIAGE / Travel Device (ZAXIS500LC-3, 520LCH-3) 53 8 12 7 13 11 6 5 15 16 9 51 4 14 1 50 22 23 24 27 25 26 47 48 49 52 29 3 2 21 44 43 20 19 28 18 30 35 34 33 31 32 36 17 42 41 40 38 39 37 W17P-03-02-001 12345- Motor Bolt (4 Used) Spring Washer (4 Used) O-Ring Housing 15 16 17 18 19 - Washer (24 Used) Bolt (24 Used) Third Stage Carrier Third Stage Sun Gear Second Stage Carrier 28 29 30 31 32 - 678911 - Floating Seal Roller Bearing Drum Roller Bearing Be
UNDERCARRIAGE / Travel Device (ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3) 10 9 8 7 6 5 4 3 2 23 24 26 25 22 1 19 18 17 15 20 27 21 16 28 29 30 14 11 12 31 13 39 42 41 38 36 35 37 34 33 32 40 51 50 49 46 47 48 45 43 44 W3-2-6 W1J1-03-02-006
UNDERCARRIAGE / Travel Device Disassemble Travel Device The disassembling procedures of travel device for ZAXIS450-3, 450LC-3, 470H-3 and 470LCH-3 are same to ZAXIS500LC-3 and 520LCH-3 except ring gear (44). This is explained according to the illustration of ZAXIS450-3, 450LC-3, 470H-3 and 470LCH-3. CAUTION: There may be pressure accumulated inside of the travel device. Slowly loosen the air bleed plug and completely release the residual pressure. Remove the drain plug and drain gear oil.
UNDERCARRIAGE / Travel Device (ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3) 10 8 51 50 49 45 44 W3-2-8 W1J1-03-02-006
UNDERCARRIAGE / Travel Device Procedure to Remove Ring Gear (44) ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 CAUTION: Cover (49) weight: 22 kg (50 lb) 4. Put the matching marks on the mating positions of cover (49) and ring gear (44). Install eyebolt (PT 3/4) into the plug (51) hole (2 places). Remove bolts (50) (16 used) from cover (49). Hoist and remove cover (49) from ring gear (44). : 22 mm NOTE: THREEBOND has been applied to the mating surfaces of ring gear (44) and cover (49).
UNDERCARRIAGE / Travel Device (ZAXIS500LC-3, 520LCH-3) 53 8 51 50 49 52 44 W17P-03-02-001 W3-2-10
UNDERCARRIAGE / Travel Device Procedure to Remove Ring Gear (44) ZAXIS500-3LC-3, 520LCH-3 CAUTION: Cover (49) weight: 40 kg (88 lb) 7. Put the matching marks on the mating positions of cover (49) and drum (8). Install eyebolt (M10, Pitch 1.5 mm) into the plug (51) hole (2 places). Remove bolts (50) and spring washers (52) (2 used for each from cover (49). Hoist and remove cover (49) from drum (8). : 22 mm NOTE: THREEBOND has been applied to the mating surfaces of drum (8) and cover (49).
UNDERCARRIAGE / Travel Device (ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3) 8 5 23 24 26 25 22 19 20 27 21 18 17 28 29 30 31 11 12 13 39 41 42 38 36 35 37 34 33 32 40 43 W1J1-03-02-006 W3-2-12
UNDERCARRIAGE / Travel Device 9. Remove shaft (43) from first stage carrier (29). Remove first stage carrier assemblies (22 to 29) and second stage sun gear (21) from second stage carrier (19). CAUTION: The second stage carrier (19) assembly weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 25 kg (55 lb) ZAXIS500LC-3, 520LCH-3: 30 kg (66 lb) 10. Wind the nylon slings (2 used) onto second stage carrier (19). Hoist and remove second stage carrier assemblies (19, 20, 30 to 35) and third stage sun gear (18).
UNDERCARRIAGE / Travel Device (ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3) 8 9 7 6 5 15 16 14 45 W1J1-03-02-006 W3-2-14
UNDERCARRIAGE / Travel Device CAUTION: Drum (8), sprocket (14) and other parts weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 180 kg (400 lb) ZAXIS500LC-3, 520LCH-3: 855 kg (1885 lb) IMPORTANT: The mating parts of drum (8) and housing (5) are sliding surface. Place the drum (8) assembly on the wooden blocks in order not to damage the sliding surface. 14. Put the matching marks on the mating positions of drum (8) and housing (5). Install eyebolt (A) into the bolt (45) hole (2 places) on drum (8).
UNDERCARRIAGE / Travel Device (ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3) 9 8 1 27 19 20 17 16 28 29 31 39 42 41 38 36 37 40 W1J1-03-02-006 W3-2-16
UNDERCARRIAGE / Travel Device CAUTION: Drum (8) and other parts weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 100 kg (221 lb) ZAXIS500LC-3, 520LCH-3: 185 kg (408 lb) 21. Install eyebolt (M22, Pitch 2.5 mm) into the bolt (16) hole (2 places) on drum (8) from the motor (1) side. Attach a nylon sling to eyebolt. Hoist and turn over drum (8). Remove the outer race of roller bearing (9) from drum (8) by using a bar and hammer. 22. Remove spring pin (38) from third stage carrier (17) by using a round bar.
UNDERCARRIAGE / Travel Device ASSEMBLE TRAVEL DEVICE (ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3) 15 16 14 5 2 3 6 9 7 8 11 10 45 44 17 18 20 4 19 21 28 1 29 51 49 46 48 47 43 25 26 27 24 23 22 50 35 32 34 33 36 12 13 42 37 40 Spring Pin (3 Used) Spacer First Stage Carrier Thrust Plate (3 used) Spring Pin (3 Used) Second Stage Planetary Gear (3 used) Pin (3 Used) Needle Bearing (3 Used) Thrust Plate (3 used) Thrust Plate (4 used) Third Stage Planetary Gear (4 Used) Spring Pin (4 Used) M
UNDERCARRIAGE / Travel Device (ZAXIS500LC-3, 520LCH-3) 18 8 17 44 52 14 50 5 51 19 29 21 20 28 49 43 1 47 48 25 23 24 26 2 22 3 4 30 6 7 9 11 12 13 42 37 40 39 38 Motor Bolt (4 Used) Spring Washer (4 Used) O-Ring Housing 15 16 17 18 19 - Washer (24 Used) Bolt (24 Used) Third Stage Carrier Third Stage Sun Gear Second Stage Carrier 28 29 30 31 32 - 678911 - Floating Seal Roller Bearing Drum Roller Bearing Bearing Nut 20 21 22 23 24 - Spacer Second Stage Sun Gear Thrust Plate (3 used
UNDERCARRIAGE / Travel Device (ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3) 14 5 6 8 7 9 15 16 45 44 1 T16J-03-05-001 W3-2-20
UNDERCARRIAGE / Travel Device Assemble Travel Device The disassembling procedures of travel device for ZAXIS450-3, 450LC-3, 470H-3 and 470LCH-3 are same to ZAXIS500LC-3 and 520LCH-3 except ring gear (44). This is explained according to the illustration of ZAXIS450-3, 450LC-3, 470H-3 and 470LCH-3. 5. Install eyebolt (A) into the bolt (45) hole (2 places) on drum (8). Hoist and place drum (8) with the ring gear (44) side facing upward.
UNDERCARRIAGE / Travel Device (ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3) 14 5 8 9 11 T16J-03-05-001 W3-2-22
UNDERCARRIAGE / Travel Device CAUTION: Drum (8), sprocket (14) and other part weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 180 kg (397 lb) ZAXIS500LC-3, 520LCH-3: 300 kg (661 lb) IMPORTANT: Align the matching marks made when disassembling. Check the clearance all around drum (8) in housing (5) shall be equal. 8. Hoist and place the drum (8) assembly to housing (5). 9. Tap and install the inner race of roller bearing (9) to housing (5) by using a bar and hammer evenly.
UNDERCARRIAGE / Travel Device (ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3) 14 5 9 8 11 10 17 49 36 12 13 42 37 41 40 W3-2-24 39 38 T16J-03-05-001
UNDERCARRIAGE / Travel Device 11. Install special tool (ST 3136) to bearing nut (11). Tighten bearing nut (11) by using a torque wrench. ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: : 500 N⋅m (51 kgf⋅m, 369 lbf⋅ft) ZAXIS500LC-3, 520LCH-3 : 780 N⋅m (80 kgf⋅m, 575 lbf⋅ft) ST 3136 IMPORTANT: There is an identification groove on one half of third stage planetary gear (37). Install third stage planetary gear (37) with the identification groove facing to cover (49). 15.
UNDERCARRIAGE / Travel Device (ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3) 5 8 45 44 17 18 19 21 28 29 49 43 25 26 27 24 23 22 50 35 32 34 33 36 42 37 41 40 W3-2-26 39 30 31 38 T16J-03-05-001
UNDERCARRIAGE / Travel Device 18. Install spacer (28) to first stage carrier (29). 19. Install needle bearings (23) (3 used) to first stage planetary gears (25) (3 used). Clamp first stage planetary gear (25) with thrust plates (26, 22) (3 used for each). Install first stage planetary gear (25) to first stage carrier (29). IMPORTANT: Install spring pin (27) with the slit of spring pin (27) facing to the end of pin (24). 20.
UNDERCARRIAGE / Travel Device ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 51 46 47 48 49 50 44 45 10 8 W1J1-03-02-007 ZAXIS500LC-3, 520LCH-3 W1J1-03-02-008 W3-2-28
UNDERCARRIAGE / Travel Device Procedure to Install Ring Gear (44) ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 28. Install O-ring (10) to drum (8). CAUTION: Cover (49) weight: 22 kg (50 lb) CAUTION: Ring gear (44) weight: 70 kg (150 lb) IMPORTANT: Align the matching marks made when disassembling. 29. Install eyebolts (M14, Pitch 2.0 mm) into the bolt (50) hole on ring gear (44). Hoist and lower ring gear (44) onto drum (8). 30. Apply LOCTITE #262 to bolt (45).
UNDERCARRIAGE / Travel Device ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 W1J1-03-02-007 ZAXIS500LC-3, 520LCH-3 51 47 48 50 49 52 53 8 44 W1J1-03-02-008 W3-2-30
UNDERCARRIAGE / Travel Device Procedure to Install Ring Gear (44) ZAXIS500LC-3, 520LCH-3 CAUTION: Ring gear (44) weight: 75 kg (165 lb) IMPORTANT: Align the matching marks made when disassembling. 37. Install eyebolt (M10, Pitch 1.5 mm) into the bolt (50) hole on ring gear (44). Hoist and lower ring gear (44) onto drum (8). 38. Install knock pin (53) between drum (8) and ring gear (44). 39. Attach a tube bar onto ball bearing (48).
UNDERCARRIAGE / Travel Device 5 2 3 44 4 1 T16J-03-05-001 W3-2-32
UNDERCARRIAGE / Travel Device CAUTION: Travel device weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 540 kg (1191 lb) ZAXIS500LC-3, 520LCH-3: 720 kg (1587 lb) 44. Install eyebolt (B) into the bolt hole (2 places) on the housing (5) flange part. Hoist and turn over the travel device. Eyebolt (B) ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: M18, Pitch 2.5 mm ZAXIS500LC-3, 520LCH-3: M22, Pitch 2.5 mm 45. Fill gear oil (C) into the travel device. Gear oil (C) ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 11.5 L (3.0 US gal.
UNDERCARRIAGE / Travel Device DISASSEMBLE TRAVEL MOTOR 4 1 2 3 7 2 6 5 15 16 17 14 11 12 13 10 25 9 24 8 22 23 21 20 18 30 29 19 28 27 26 W1J1-03-02-002 12345678- Case O-Ring (4 Used) Spring (2 Used) Piston (2 Used) Oil Seal Roller Bearing Shaft Steel Ball (2 Used) 910 11 12 13 14 15 16 - Swash Plate Piston (9 Used) Retainer Holder Spring (9 Used) Cylinder Block Valve Plate Collar 17 18 19 20 21 22 23 24 - NOTE: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 18-*Disc Plate (5 Used) 19
UNDERCARRIAGE / Travel Device Disassemble Travel Motor CAUTION: Valve housing (29) weight: 39 kg (90 lb) IMPORTANT: Loosen socket bolts (30) (9 used) evenly. When socket bolts (30) are loosened, valve housing (29) will raise from case (1) under the reaction force from springs (13, 26). Take down the clearance between case (1) and valve housing (29). When removing valve housing (29) from case (1), valve plate (15) may be removed with valve housing (29) together. Do not drop valve plate (15). 1.
UNDERCARRIAGE / Travel Device 4 1 3 7 5 6 9 8 W1J1-03-02-002 W3-2-36
UNDERCARRIAGE / Travel Device CAUTION: The cylinder block (14) assembly weight: 20 kg (40 lb) IMPORTANT: If cylinder block (14) needs to be replaced, cylinder block assemblies (10 to 15) with valve plate (15) should be replaced. 7. Remove cylinder block (14) assemblies (10 to 15) from case (1). NOTE: Hold and rotate cylinder block (14) left and right lightly by both hands in order to remove slowly. 8.
UNDERCARRIAGE / Travel Device ASSEMBLE TRAVEL MOTOR 27 30 26 22, 23 24 20, 21 7 4 3 16 8 29 17 15 1 28 25 W1J1-03-02-003 2 Brake Release Circuit 12345678- Case O-Ring (4 Used) Spring (2 Used) Piston (2 Used) Oil Seal Roller Bearing Shaft Steel Ball (2 Used) 910 11 12 13 14 15 16 - 14 10 18 Swash Plate Piston (9 Used) Retainer Holder Spring (9 Used) Cylinder Block Valve Plate Collar 19 17 18 19 20 21 22 23 24 - NOTE: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 18-*Disc Plate (5 Used) 19-
UNDERCARRIAGE / Travel Device Assemble Travel Motor IMPORTANT: Apply grease to the inner periphery of oil seal (5) for case (1) at the pressed-in part and the outer periphery of oil seal (5). In addition, oil seal (5) should be pressed in straight in order not to deform. 1. Install oil seal (5) to case (1). IMPORTANT: Install the outer race of roller bearing (6) with the stamped mark facing to the swash plate (9) side. 2.
UNDERCARRIAGE / Travel Device 27 26 22, 23 24 20, 21 16 29 17 15 1 28 W1J1-03-02-003 14 18 19 W3-2-40
UNDERCARRIAGE / Travel Device 9. Install eyebolt (M18, Pitch 2.5 mm) into the socket bolt (30) hole (2 places) on case (1). Attach a nylon sling to eyebolt. Hoist and place case (1) vertically. 10. Install disc plates (18) and friction plates (19) alternately case (1). 12. Lightly tap and install brake piston (24) to case (1) by using a plastic hammer. IMPORTANT: As for springs (26) (10 used), there are twelve spring (25) mounting holes on brake piston (24). Check the correct hole to install spring (26).
UNDERCARRIAGE / Travel Device 30 24 29 1 28 25 W1J1-03-02-003 2 W3-2-42
UNDERCARRIAGE / Travel Device IMPORTANT: Install the outer race of roller bearing (17) with the stamped mark facing to the valve plate (15) side. 14. Tap the outer race of roller bearing (17) evenly by using a bar and hammer and install the outer race to valve housing (29). NOTE: Tap and listen to ring in order to check if the outer race is installed to valve housing (29) completely. IMPORTANT: Apply grease to the contact surfaces of valve plate (15) and valve housing (29). 15.
UNDERCARRIAGE / Travel Device DISASSEMBLE BRAKE VALVE 2 1 5 3 4 9 Plug 10 11 7 6 8 9 10 12 35 36 37 38 51 39 40 41 42 43 44 48 47 49 10 9 16 13 17 18 14 19 20 21 51 3 2 45 44 23 1 15 22 24 4 50 46 26 27 28 30 25 31 32 33 29 43 42 41 40 36 39 5 35 38 34 37 W1J1-03-02-004 12345678910 11 12 13 - Plug (2 Used) O-Ring (2 Used) Spring (2 Used) Check Valve (2 Used) Relief Valve (2 Used) Plug O-Ring Spring Plug (6 Used) O-Ring (6 Used) Orifice (2 Used) Socket B
UNDERCARRIAGE / Travel Device Disassemble Brake Valve CAUTION: The valve housing (46) assembly weight: 39 kg (90 lb) 1. Secure the valve housing (46) assembly on a firm workbench. 2. Remove plugs (6, 15), O-rings (7, 14) and spring (8) from valve housing (46). : 10 mm IMPORTANT: Remove valve assembly (13) while rotating. If a little resistance is felt while removing, do not try to remove it by force, return to original position and retry. In addition, do not disassemble valve assembly (13).
UNDERCARRIAGE / Travel Device ASSEMBLE BRAKE VALVE Relief Valve (5) 16 18 21 26 24 27 31 29 32 33 34 17、19 10 11 6 20 22 23、25 30 28 7 36 38 41 37 39 35 A A 51 42 A 9 40 8 43 44 48 13 45 14 50 47 12 15 46 5 12345678910 11 12 13 - Plug (2 Used) O-Ring (2 Used) Spring (2 Used) Check Valve (2 Used) Relief Valve (2 Used) Plug O-Ring Spring *Plug (6 Used) *O-Ring (6 Used) *Orifice (2 Used) Socket Bolt (9 Used) Valve Assembly 14 15 16 17 18 19 20 21 22 23 24 25 26 - O-Ring Plu
UNDERCARRIAGE / Travel Device Assemble Brake Valve 1. Install O-rings (7, 14) to plugs (6, 15) respectively. Install valve assembly (13), spring (8) and plugs (6, 15) to valve housing (46). : 10 mm : 67.3±4.9 N⋅m (6.9±0.5 kgf⋅m, 50±3.6 lbf⋅ft) 2. Install O-rings (2) (2 used) to plugs (1) (2 used) Install check valves (4) (2 used), springs (3) (2 used) and plugs (1) (2used) to valve housing (46).
UNDERCARRIAGE / Travel Device MAINTENANCE STANDARD 1. Clearance between inner diameter of cylinder block and outer diameter of piston: Cylinder Block (D-d): 0.06 mm (0.002 in) or less D d W507-02-04-009 Piston 2. Clearance between piston and shoe engaging: Piston δ: 0.4 mm (0.016 in) or less Shoe δ W107-02-06-140 3. Clearance between inner diameter and outer diameter at the mounting position of case and piston: (D-d): 0.03 mm (0.001 in) or less Piston D Case D 4.
UNDERCARRIAGE / Travel Device Sprocket B C D E A W105-03-07-042 ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 Standard Allowable Limit A 92 (3.6) [82 (3.2)] B 131.6 (5.2) 126.6 (4.9) C 167.6 (6.6) D 177.5 (7.0) 172.5 (6.8) E 215.9 (8.5) ZAXIS500LC-3, 520LCH-3 Standard A 102 (4.0) B 91.4 (3.6) C 132.3 (5.2) D 143.9 (5.6) E 228.6 (9) NOTE: Value in [ Allowable Limit 86.4 (3.4) 138.9 (5.5) - ] is just for reference.
UNDERCARRIAGE / Travel Device (Blank) W3-2-50
UNDERCARRIAGE / Center Joint REMOVE AND INSTALL CENTER JOINT IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to “Bleed Air from Hydraulic Oil Tank” on page W1-4-1.) Machine Front Removal 7 IMPORTANT: Attach an identification tag to all the hoses of center joint for reassembling. IMPORTANT: Remove all the hoses and adapters from center joint. Attach a cap to the removed hoses. 1.
UNDERCARRIAGE / Center Joint Installation CAUTION: Center joint weight: 52 kg (110 lb) IMPORTANT: Align the matching marks made when disassembling. 1. Install the center joint to the track frame with bolts (17) (4 used) and spring washers (4 used). : 24 mm : 210 N⋅m (21.5 kgf⋅m, 154 Ibf⋅ft) 2. Install hoses (9 to 16) to the lower side of center joint.
UNDERCARRIAGE / Center Joint (Blank) W3-3-3
UNDERCARRIAGE / Center Joint DISASSEMBLE CENTER JOINT 1 2 7 3 4 5 8 9 6 10 11 12 W16J-03-03-001 1 - Plug 2 - Spindle 3 - Dust Seal 4 - O-Ring 5 - Bushing 6 - Oil Seal (6 Used) 7 - Body 8 - Ring 9 - Retaining Ring W3-3-4 10 - O-Ring 11 - Cover 12 - Bolt (4 Used)
UNDERCARRIAGE / Center Joint Disassemble Center Joint CAUTION: Spindle (2) weight: 22 Kg (50 lb) Body (7) weight: 29 kg (60 lb) CAUTION: Center joint weight: 52 kg (110 lb) 1. Remove bolts (12) (2 used) in diagonal position from cover (11). Install eyebolts (M12, Pitch 1.75 mm) into the bolt holes. Attach a nylon sling onto eyebolt. Place the center joint on the workbench. : 19 mm 2. Remove bolts (12) (2 used) and eyebolts (2 used) from body (7). Remove cover (11) from body (7). : 19 mm 3.
UNDERCARRIAGE / Center Joint ASSEMBLE CENTER JOINT 2 3 4 5 6 7 8 10 12 9 11 W183-03-08-001 1 - *Plug 2 - Spindle 3 - Dust Seal 4 - O-Ring 5 - Bushing 6 - Oil Seal (6 Used) 7 - Body 8 - Ring 9 - Retaining Ring NOTE: As for the item with mark*, refer to W3-3-4.
UNDERCARRIAGE / Center Joint Assemble Center Joint IMPORTANT: Apply grease to the bushing (5) mounting part on body (7). 1. When bushing (5) is removed, first install bushing (5) to body (7). (Refer to page W3-3-10.) IMPORTANT: Apply grease to the dust seal (3) mounting part on body (7). Face the metal part of dust seal (3) to the body (7) side. 2. Install O-ring (4) and dust seal (3) to body (7). Metal Part IMPORTANT: The clearance between body (7) and spindle (2) is not much.
UNDERCARRIAGE / Center Joint 2 5 6 7 8 10 12 9 11 W183-03-08-001 W3-3-8
UNDERCARRIAGE / Center Joint CAUTION: Spindle (2) weight: 22 kg (50 lb) Body (7) weight: 29 kg (60 lb) IMPORTANT: Apply grease to the sliding surface of dust seal (3) on spindle (2) and inner surfaces of oil seal (6) and bushing (5). 4. Place spindle (2) on a workbench with its upside down. Install eyebolt (M12, Pitch 1.75 mm) into the bolt (12) holes (2 places) on body (7). Hoist and place body (7) while aligning the matching mark with that of spindle (2). 5.
UNDERCARRIAGE / Center Joint When replacing body (7) with a new one, the following procedures are required. ST 2670 IMPORTANT: When installing bushing (5) to body (7), grease and molybdenum disulphide should be applied to the fitting surface. 7 5 Push and install bushing (5) to body (7). 1. Clean body (7) and bushing (5). 2. Push bushing (5) to body (7) by using a press. Pushing force: 0.5 to 1.
UNDERCARRIAGE / Center Joint MAINTENANCE STANDARD Item Allowable Limit (basis of judgment) 1. Wear more than 0.2 mm (0.008 in) Remedy Replace 2. Seizure and abnormal wear Replace 3. Uneven wear within 180° Replace Wear Area Within Half Range Bushing T157-01-01-040 Sliding surface with Heavily damaged one by seizure or foreign matter seals 1) Excessively worn one by seizure or foreign matter, or one having the score of 0.1 mm Sliding surface be(0.
UNDERCARRIAGE / Center Joint (Blank) W3-3-12
UNDERCARRIAGE / Track Adjuster REMOVE JUSTER AND INSTALL TRACK AD- Before removing and installing the track adjuster, the tracks and the front idler must be removed first. For removal and installation of the tracks and the front idler, refer to “Remove and Install Track” and “Remove and Install Front Idler” sections. In this section, the procedure starts on the premise that the tracks and the front idler have already been removed.
UNDERCARRIAGE / Track Adjuster DISASSEMBLE TRACK ADJUSTER (ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3) 2 3 4 5 1 6 7 8 9 10 11 12 13 14 15 W1J1-03-04-002 16 1234- Socket Bolt (4 Used) O-Ring Guide Piston Rod 5678- Wear Ring U-Ring Retaining Ring Cylinder 910 11 12 - W3-4-2 O-Ring Spacer Spring Bracket 13 14 15 16 - Nut Bolt Rod Valve
UNDERCARRIAGE / Track Adjuster (ZAXIS500LC-3, 520LCH-3) 2 3 4 5 1 17 6 18 7 15 8 10 9 11 12 13 16 14 12345- Socket Bolt (4 Used) O-Ring Guide Piston Rod Wear Ring (2 Used) 678910 - U-Ring Retaining Ring Cylinder O-Ring Spacer 11 12 13 14 - W3-4-3 Spring Bracket Nut Bolt W1J1-03-04-004 15 16 17 18 - Rod Valve Backup Ring Plate
UNDERCARRIAGE / Track Adjuster 2 3 4 5 1 6 7 8 9 10 11 12 13 14 15 W1J1-03-04-002 16 W3-4-4
UNDERCARRIAGE / Track Adjuster Disassemble Track Adjuster • Use a pump unit which has the maximum pres2 sure of 69 MPa (700 kgf/cm , 9950 psi) and the flow rate of 8 to 10 liters (2.1 to 2.6 US gal). Set the main relief pressure to 49 MPa (500 2 kgf/cm , 7110 psi) (80 tons) or lower. IMPORTANT: Use special tool (ST4932) when assembling and disassembling the track adjuster. IMPORTANT: Compress the spring until the clearance between bracket (12) and nut (13) is approximately 10 mm (0.4 in). 2.
UNDERCARRIAGE / Track Adjuster (ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3) 4 8 10 11 12 W1J1-03-04-002 (ZAXIS500LC-3, 520LCH-3) 4 8 10 11 12 W1J1-03-04-004 W3-4-6
UNDERCARRIAGE / Track Adjuster 5. Slowly return the piston of special tool (ST 4932) until spring (11) extends to its free length. NOTE: Spring (11) free length: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 782 mm (31 in) ZAXIS500LC-3, 520LCH-3: 733 mm (29 in) 7. Install eyebolt (M16, Pitch 2.0 mm) to piston rod (4). Attach a nylon sling to spring (11). Pass a nylon sling through eyebolt. Hoist and place the assembly on the rest.
UNDERCARRIAGE / Track Adjuster (ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3) 2 3 4 5 1 6 7 8 9 10 11 12 (ZAXIS500LC-3, 520LCH-3) 2 15 W1J1-03-04-002 3 4 5 1 17 6 18 7 15 8 10 9 11 12 W1J1-03-04-004 W3-4-8
UNDERCARRIAGE / Track Adjuster CAUTION: Spring (11) weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 122 kg (269 lb) ZAXIS500LC-3, 520LCH-3: 150 kg (331 lb) 9. Remove wire fastening spring (11) and bracket (12). Hoist and remove spring (11) from the rest. CAUTION: Bracket (12) weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 22 kg (48.5 lb) ZAXIS500LC-3, 520LCH-3: 21.5 kg (47.4 lb) 10. Remove spacer (10) and bracket (12) from the rest.
UNDERCARRIAGE / Track Adjuster ASSEMBLE TRACK ADJUSTER 16 13 12 11 9 6 5 8 3 4 Grease Outlet W1J1-03-04-001 14 12345- Socket Bolt (4 Used) O-Ring Guide Piston Rod *Wear Ring 15 678910 - 10 U-Ring Retaining Ring Cylinder O-Ring Spacer Chamber B 11 12 13 14 - 7 Spring Bracket Nut Bolt NOTE: *: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 1 used ZAXIS500LC-3, 520LCH-3: 2 used **: The parts are used for ZAXIS500LC-3, 520LCH-3.
UNDERCARRIAGE / Track Adjuster Assemble Track Adjuster IMPORTANT: Apply grease to wear ring (5) and U-ring (6). Install U-ring (6) with the lip facing to rod (15). 1. After cleaning all parts, install the following parts below to piston rod (4). ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: Wear ring (5), retaining ring (7) and U-ring (6) ZAXIS500LC-3, 520LCH-3: Wear ring (5) (2 used), backup ring (17), U-ring (6), plate (18) and retaining ring (7) 4 5 6 7 IMPORTANT: Fill chamber (B) in cylinder (8) with grease.
UNDERCARRIAGE / Track Adjuster 12 11 8 4 Grease Outlet W1J1-03-04-001 15 10 W3-4-12
UNDERCARRIAGE / Track Adjuster CAUTION: Bracket (12) weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 22 kg (48.5 lb) ZAXIS500LC-3, 520LCH-3: 21.5 kg (47.4 lb) Spring (11) weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 122 kg (270 lb) ZAXIS500LC-3, 520LCH-3: 150 kg (331 lb) CAUTION: Track adjuster weight: ZAXIS450-3, 470H-3: 235 kg (518 lb) ZAXIS450LC-3, 470LCH-3: 239 kg (527 lb) ZAXIS500LC-3, 520LCH-3: 365 kg (805 lb) 7. Attach a nylon sling to spring (11) and pass it through eyebolt on piston rod (4).
UNDERCARRIAGE / Track Adjuster 16 13 12 11 15 Grease Outlet A mm (Free Length B mm) 14 C mm NOTE: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: A=620 mm (24.4 in), B=782 mm (30.8 in), C=830 mm (32.7 in) ZAXIS500LC-3, 520LCH-3: A=590 mm (23.2 in), B=733 mm (28.9 in), C=885 mm (34.
UNDERCARRIAGE / Track Adjuster IMPORTANT: Slowly compress spring (11) while aligning the center of rod (15) with that of bracket (12) by using a pry bar. Do not damage the threads on rod (15). 9. Operate the cylinder of special tool (ST 4932) and remove a wire. Compress spring (11) until specified spring (11) length (A) is obtained. IMPORTANT: Align the matching marks made when disassembling. Check that the grease outlet in rod (15) is aligned with that in nut (13). 10. Install nut (13) to rod (15).
UNDERCARRIAGE / Track Adjuster (Blank) W3-4-16
UNDERCARRIAGE / Front Idler REMOVE AND INSTALL FRONT IDLER Before removing and installing the front idler, the tracks must be removed first. For removal and installation of the tracks, refer to “Remove and Install Track” section (W3-7-1). In this section, the procedure starts on the premise that the tracks have already been removed.
UNDERCARRIAGE / Front Idler Installation Direction to Install CAUTION: Front idler weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 281 kg (619 lb) ZAXIS500LC-3, 520LCH-3: 353 kg (778 lb) 1 1. Install the front idler in reverse procedures when removing. • Clean and apply grease to the bearing (5) sliding surface on track frame (1).
UNDERCARRIAGE / Front Idler (Blank) W3-5-3
UNDERCARRIAGE / Front Idler DISASSEMBLE FRONT IDLER ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 2 1 8 3 6 7 5 10 11 6 9 5 4 2 12 3 1 14 13 8 1234- Bearing (2 Used) Pin (2 Used) O-Ring (2 Used) Axle W1J1-03-05-001 5678- Floating Seal (2 Used) Bushing (2 Used) Idler Plug (2 Used) 9 - Guard 10 - Bolt (3 Used) 11 - Spring Washer (3 Used) W3-5-4 12 - Yoke 13 - Bolt (4 Used) 14 - Spring Washer (4 Used)
UNDERCARRIAGE / Front Idler ZAXIS500LC-3, 520LCH-3 2 1 5 7 8 6 3 6 4 3 9 2 10 11 5 8 1 12 14 W1J1-03-05-003 13 1234- Bearing (2 Used) Pin (2 Used) O-Ring (2 Used) Axle 5678- Floating Seal (2 Used) Bushing (2 Used) Idler Plug (2 Used) 9 - Guard 10 - Bolt (3 Used) 11 - Spring Washer (3 Used) W3-5-5 12 - Yoke 13 - Bolt (4 Used) 14 - Spring Washer (4 Used)
UNDERCARRIAGE / Front Idler ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 2 1 8 3 6 7 5 10 11 6 9 5 4 2 12 3 1 14 13 8 W1J1-03-05-001 ZAXIS500LC-3, 520LCH-3 2 1 5 7 8 6 3 6 4 3 9 2 10 11 5 8 1 12 14 13 W3-5-6 W1J1-03-05-003
UNDERCARRIAGE / Front Idler Disassemble Front Idler 1. Loosen bolts (10) (3 used), and spring washers (11) (3 used) from guard (9). Remove guard (9) from yoke (12). : 19 mm 6. Remove bearing (1) from the upper side of idler (7). Remove floating seals (5) (2 used) from both sides of idler (7) and bearing (1). 1 CAUTION: Yoke (12) weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 44 kg (97 lb) ZAXIS500LC-3, 520LCH-3: 70 kg (154 lb) 5 7 2. Attach a nylon sling to yoke (12) and hold yoke (12).
UNDERCARRIAGE / Front Idler ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 2 1 3 6 6 5 9 5 4 2 3 1 W1J1-03-05-001 ZAXIS500LC-3, 520LCH-3 2 1 5 7 6 3 6 4 3 9 2 5 1 W1J1-03-05-003 W3-5-8
UNDERCARRIAGE / Front Idler CAUTION: The axle (4) assembly weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 54 kg (119 Ib) ZAXIS500LC-3, 520LCH-3: 50 kg (110 lb) IMPORTANT: Do not remove bushing (6) unless necessary. 9. When replacing bushing (6), remove bushing (6) by using special tool (ST 1973) and a press. IMPORTANT: Place wooden blocks or etc. under the lower part of bearing (1) in order not to damage bearing (1). 7. Wind a nylon sling to the axle (4) assembly.
UNDERCARRIAGE / Front Idler ASSEMBLE FRONT IDLER 1 2 5 7 4 6 3 7 8 9 10 14 13 11 12 W1J1-03-05-002 1234- Bearing (2 Used) Pin (2 Used) O-Ring (2 Used) Axle 5678- Floating Seal (2 Used) Bushing (2 Used) Idler Plug (2 Used) 9 - Guard 10 - Bolt (3 Used) 11 - Spring Washer (3 Used) W3-5-10 12 - Yoke 13 - Bolt (4 Used) 14 - Spring Washer (4 Used)
UNDERCARRIAGE / Front Idler Assemble Front Idler CAUTION: Idler (7) weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 150 kg (331 lb) ZAXIS500LC-3, 520LCH-3: 208 kg (459 lb) CAUTION: The axle (4) assembly weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 54 kg (119 lb) ZAXIS500LC-3, 520LCH-3: 50 kg (110 lb) 1. Install bushing (6) to idler (7). 5. Wind a nylon sling to bearing (1) of the axle (4) assembly.
UNDERCARRIAGE / Front Idler 1 2 4 8 9 10 14 13 11 12 W1J1-03-05-002 W3-5-12
UNDERCARRIAGE / Front Idler 8. Apply grease to O-ring (3) of floating seal (5). Install the other floating seal (5) to idler (7) and bearing (1). 1 5 3 7 1 4 W157-03-05-005 IMPORTANT: Align the matching marks made when disassembling. 9. Evenly tap and install bearing (1) into axle (4) by using a plastic hammer. Insert pin (2) into bearing (1) by using a bar and hammer. 10. Add engine oil (API CD grade SAE30) 450 mL (0.12 US gal.) via the plug (8) hole on bearing (1). 11. Apply LOCTITE #503 to plug (8).
UNDERCARRIAGE / Front Idler MAINTENANCE STANDARD ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 C D E A W166-03-05-001 B A B C D E Standard 116 (4.6) 234 (9.2) 716 (28.2) 761 (30) (22.5 (0.9) Unit: mm (in) Allowable Limit Remedy [88.4 (3.5)] Cladding by welding [689 (27.1)] and finish or replace 32.5 (1.3) Axle and Bushing Axle Bushing NOTE: Values in [ Standard Allowable Limit Outside Dia. 110 (4.33) [109.2 (4.30)] Inside Dia. 111 (4.37) [112 (4.41)] Flange Thickness 6 (0.24) [5.2 (0.
UNDERCARRIAGE / Front Idler ZAXIS500LC-3, 500LCH-3 C D E A W166-03-05-001 B A B C D E Standard 116 (4.6) 234 (9.2) 716 (28.2) 761 (30) (22.5 (0.9) Unit: mm (in) Allowable Limit Remedy [88.4 (3.5)] Cladding by welding [689 (27.1)] and finish or replace 32.5 (1.3) Axle and Bushing Axle Bushing NOTE: Values in [ Allowable Limit Outside Dia. Standard 110 (4.33) Inside Dia. 111 (4.37) [112 (4.41)] Flange Thickness 6 (0.24) [5.2 (0.21)] ] are just for reference.
UNDERCARRIAGE / Front Idler (Blank) W3-5-16
UNDERCARRIAGE / Upper and Lower Roller REMOVE AND INSTALL UPPER ROLLER Removal CAUTION: Grease pressure in the adjuster cylinder is high. Do not loosen valve (1) quickly or too much as valve (1) may fly off or high-pressure grease in the adjuster cylinder may gush out. Keep body parts and face away from valve (1) and loosen valve (1) carefully. Do not loosen grease fitting (2). IMPORTANT: Remove any mud or gravel between sprockets and tracks before loosening valve (1).
UNDERCARRIAGE / Upper and Lower Roller 4. Remove bolts (6) (4 used) from upper roller (3). : 27 mm 3 6 W116-03-06-002 CAUTION: Upper roller (3) weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 39 kg (86 lb) ZAXIS500LC-3, 520LCH-3: 46.5 kg (102.5 lb) 5. Attach a nylon sling to the roller part of upper roller (3). Hoist and remove upper roller (3) from track frame (5).
UNDERCARRIAGE / Upper and Lower Roller 3. Tighten valve (1) on the track adjuster. : 24 mm : 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft) 2 1 CAUTION: If track sag should be measured with the machine raised, support the jacked up machine firmly by using the wooden blocks. 4. Jack up the track to be measured. Apply grease via grease fitting (2) and adjust track tension. Track sag specifications (A): ZAXIS450-3, 470H-3: 380 to 430 mm (15 to 17 in) ZAXIS450LC-3, 470LCH-3: 390 to 440 mm (15.4 to 17.
UNDERCARRIAGE / Upper and Lower Roller REMOVE AND INSTALL LOWER ROLLER Removal CAUTION: Track guard weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 40 kg (88 lb) ZAXIS500LC-3, 520LCH-3: 56 kg (123 lb) 1 1. Remove the track guard. ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: : 32 mm ZAXIS500LC-3, 520LCH-3: : 36 mm W105-03-06-008 2. Remove bolts (1) (4 used) from the lower roller. ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: : 32 mm ZAXIS500LC-3, 520LCH-3: : 36 mm 90° to 110° 2 W800-03-07-003 3.
UNDERCARRIAGE / Upper and Lower Roller CAUTION: Lower roller (5) weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 80 kg (176 lb) ZAXIS500LC-3, 520LCH-3: 108 kg (238 lb) 5. Remove lower roller (5) by using a fork lift. 5 W105-03-06-010 Installation CAUTION: Lower roller (5) weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 80 kg (176 lb) ZAXIS500LC-3, 520LCH-3: 108 kg (238 lb) 2 1. Set lower roller (5) under track frame (2) by using a fork lift. 5 W105-03-06-011 2 2.
UNDERCARRIAGE / Upper and Lower Roller CAUTION: Track guard weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 80 kg (176 lb) ZAXIS500LC-3, 520LCH-3: 108 kg (238 lb) 2 3. Install the track guard to track frame (2). ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: : 32 mm : 750 N⋅m (77 kgf⋅m, 553 lbf⋅ft) ZAXIS500LC-3, 520LCH-3: : 36 mm : 950 N⋅m (97 kgf⋅m, 700 lbf⋅ft) 5 4. Tighten valve (3) on the track adjuster.
UNDERCARRIAGE / Upper and Lower Roller (Blank) W3-6-7
UNDERCARRIAGE / Upper and Lower Roller DISASSEMBLE LOWER ROLLER 5 4 6 3 2 1 7 5 8 6 7 1 3 4 W166-03-06-006 1 - Floating Seal (2 Used) 2 - Axle 3 - O-Ring (2 Used) 4 - Collar (2 Used) 5 - Pin (2 Used) 6 - Plug (2 Used) W3-6-8 7 - Bushing (2 Used) 8 - Roller
UNDERCARRIAGE / Upper and Lower Roller Disassemble Lower Roller IMPORTANT: Put the matching marks on collar (4) and axle (2). 1. Remove plug (6) from the end of collar (4). Drain oil. (2 places). Remove pin (5) from collar (4) (2 places) by using a bar (Dia. 25 mm (1.0 in)) and hammer. : 6 mm 5. Remove floating seal (1) from roller (8) and collar (4). 4 1 8 1 1 4 CAUTION: Lower roller (8) weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 80 kg (176 lb) ZAXIS500LC-3, 520LCH-3: 108 kg (238 lb) 2.
UNDERCARRIAGE / Upper and Lower Roller ASSEMBLE LOWER ROLLER 4 8 2 7 1 5 6 3 W162-03-06-002 1 - Floating Seal (2 Used) 2 - Axle 3 - O-Ring (2 Used) 4 - Collar (2 Used) 5 - Pin (2 Used) 6 - Plug (2 Used) W3-6-10 7 - Bushing (2 Used) 8 - Roller
UNDERCARRIAGE / Upper and Lower Roller Assemble Lower Roller CAUTION: Lower roller (8) weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 47 kg (104 lb) ZAXIS500LC-3, 520LCH-3: 61 kg (134 lb) Axle (2) weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 20 kg (44 lb) ZAXIS500LC-3, 520LCH-3: 29 kg (62 lb) CAUTION: The axle (2) assembly weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 25 kg (55 lb) ZAXIS500LC-3, 520LCH-3: 38 kg (84 lb) 4. Insert axle (2) into roller (8).
UNDERCARRIAGE / Upper and Lower Roller MAINTENANCE STANDARD Upper Roller • Roller C A B W166-03-06-007 ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 Standard A 103 (4.1) B 210 (8.3) C 170 (6.7) Allowable Limit 160 (6.3) Unit: mm (in) Remedy Replace ZAXIS500LC-3, 520LCH-3 Standard 114 (4.5) 220 (8.7) 180 (7.1) A B C Allowable Limit [170 (6.7)] Remedy Replace • Axle and Bushing ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 Axle Bushing Outside Dia. Inside Dia. Flange Thickness Standard 60 (2.4) 61 (2.4) 4.5 (0.
UNDERCARRIAGE / Upper and Lower Roller Lower Roller • Roller W157-03-06-003 ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 Standard A 214 (8.4) B 284 (11.2) C 35 (1.4) D 200 (7.9) Allowable Limit [249 (9.8)] [17.5 (0.7)] 180 (7.1) ZAXIS500LC-3, 520LCH-3 A B C D Standard 246 (9.7) 320 (12.6) 37 (1.5) 220 (8.7) Allowable Limit [283 (11.1)] [18.5 (0.7)] [202 (8.
UNDERCARRIAGE / Upper and Lower Roller (Blank) W3-6-14
UNDERCARRIAGE / Track REMOVE AND INSTALL TRACK Removal CAUTION: Grease pressure in the adjuster cylinder is high. Do not loosen valve (2) quickly or too much as valve (2) may fly off or high-pressure grease in the cylinder may gush out. Keep body parts and face away from valve (2) and loosen valve (2) carefully. Do not loosen grease fitting (1). 1 Adjuster Cylinder 2 1. Loosen valve (2) in the track adjuster and drain grease. 2.
UNDERCARRIAGE / Track CAUTION: Shoe (5) weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 600 mm: 28 kg (62 lb) 750 mm: 36 kg (79 lb) 900 mm: 42 kg (93 lb) ZAXIS500LC-3, 520LCH-3: 600 mm: 32 kg (71 lb) 600 mm (WG): 31 kg (68 lb) 750 mm: 40 kg (88 lb) 900 mm: 48 kg (106 lb) 6 5 7 3 5 7 3. Remove bolts (7) (8 used) from shoes (5) (2 used) at front and rear of master pin (3). Remove shoes (5) (2 used) from track link (6). : 41 mm W105-03-07-006 4.
UNDERCARRIAGE / Track (Blank) W3-7-3
UNDERCARRIAGE / Track ASSEMBLE SPECIAL TOOL WHEN REMOVING AND INSTALLING MASTER PIN 13 14 12 11 10 9 Master Pin When Removing 8 10 15 19 *Hose *: Electric Pump (ST 1531) Accessory 10 15 16 17 11 12 18 9 Master Pin When Installing 16 W1J7-03-07-001 10 9 8- Hydraulic Cylinder (ST 1512) 9 - Screw (2 Used) (ST 1516) 11 - Frame (ST 1513) 14 - Adapter (ST 1518) 17 - Pilot (ST 1517) 12 - Pusher (ST 1521) 18 - Guide (ST 1525) 10 - Nut (2 Used) (ST 1515) 13 - Handling Screw (ST 1530) 15 -
UNDERCARRIAGE / Track Assemble Special Tool (ST 1532) Removing and Installing Master Pin When The procedures (steps 5 to 11) are for assembly of special tool (ST 1532) when removing and installing master pin. If special tool (ST 1532) when removing and installing master pin has already been assembled, these procedures are unnecessary. 11. Install the hoses (2 used) of electric pump (ST 1531) to hydraulic cylinder (8).
UNDERCARRIAGE / Track CAUTION: Special tool (ST 1532) when removing and installing master pin weight: 150kg (330 lb) 12. Attach a nylon sling to screws (9) (2 used) in special tool (ST 1532) when removing and installing master pin and hoist special tool. Move special tool (ST 1532) when removing and installing master pin to the mounting position for master pin (3).
UNDERCARRIAGE / Track 15. Remove special tool (ST 1532) when removing and installing master pin and a chain block from track link (6). IMPORTANT: After raise the machine, support the machine by using a block securely. 16. Turn the upperstructure 90° to the direction to remove the track. Set the angle between boom and arm in 90° to 110° and lower the bucket onto the ground. Raise the machine and support the machine by using a block.
UNDERCARRIAGE / Track Installation CAUTION: The track assembly weight: ZAXIS450-3, 470H-3: 600 mm: 2450 kg (5401 lb) 750 mm: 2810 kg (6195 lb) ZAXIS450LC-3, 470LCH-3: 600 mm: 2470 kg (5445 lb) 750 mm: 3040 kg (6702 lb) 900 mm: 3380 kg (7452 lb) ZAXIS500LC-3, 520LCH-3: 600 mm: 2975 kg (6559 lb) 600 mm (WG): 2915 kg (6426 lb) 750 mm: 3380 kg (7452 lb) 900 mm: 3745 kg (8256 lb) W800-03-07-003 Block 5 IMPORTANT: Check the direction of track. 1. Raise the machine and support the machine by using a block.
UNDERCARRIAGE / Track 5. After the track is attached to front idler (4), raise the machine. Remove the block. Lower the machine. 4 W1J7-03-07-007 IMPORTANT: Insert the tapered side of guide pin (19) first. 6. Secure shoe (5) of both ends of the track by using a chain block. Adjust the chain length by using the chain block and align with the master pin (3) mounting hole on track link (6). Insert guide pin (19) into the master pin (3) mounting hole. 5 5 W1J7-03-07-002 Chain Block 19 7.
UNDERCARRIAGE / Track CAUTION: Special tool (ST 1532) when removing and installing master pin weight: 150 kg (330 lb) Nylon Sling 9. Attach a nylon sling to screws (9) (2 used) in special tool (ST 1532) when removing and installing master pin and hoist special tool. Move special tool (ST 1532) when removing and installing master pin to the mounting position for master pin (3).
UNDERCARRIAGE / Track 12. Remove special tool (ST 1532) when removing and installing master pin and a chain block from track link (6). Nylon Sling Chain Block ST 1532 6 W1J7-03-07-003 13. Install shoes (5) (2 used) with bolts (7) (8 used). : 32 mm : 750 N⋅m (77 kgf⋅m, 553 lbf⋅ft) 5 7 7 5 W105-03-07-006 14. Tighten valve (2). Apply grease through grease fitting (1) and adjust the track tension.
UNDERCARRIAGE / Track 15. Remove extension (15), pilot (17), pusher (12) and guide (18) from special tool (ST 1532) when removing and installing master pin. 19 17 12 18 15 W1J7-03-07-006 16. Remove the hoses (2 used) of electric pump (ST 1531) from hydraulic cylinder (8). If special tool (ST 1532) when removing and installing master pin is disassembled and stored, disassemble according to the assembling procedures on W3-7-5 in reverse.
UNDERCARRIAGE / Track MAINTENANCE STANDARD Link Measure the length of four links. 1. Do not measure the part included the master pin. 2. Measure the length with tension on the track. B A W155-03-07-001 ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 Standard A 863.6 (34) B 129 (5.1) ZAXIS500LC-3, 520LCH-3 Standard A 915.5 (36) B 134.6 (5.3) Unit: mm (in) Remedy Cladding by welding and finish or replace Allowable Limit [905.3 (35.6)] [122 (4.8)] Allowable Limit [944.3 (37.2)] [127.6 (5.
UNDERCARRIAGE / Track Master Bushing W105-03-07-023 ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 Standard A 160.8 (6.3) B 47.9 (1.89) C 71.35 (2.81) ZAXIS500LC-3, 520LCH-3 Standard A 181.4 (7.1) B 49.2 (1.94) C 79.0 (3.11) Allowable Limit [59.9 (2.36)] [66.4 (2.61)] Allowable Limit [52.2 (2.06)] [74.0 (2.91)] Unit: mm (in) Remedy Replace Remedy Replace [ ]：Reference Grouser Shoe W105-03-07-024 ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 Standard A 247 (9.7) B 15 (0.6) C 36 (1.
UNDERCARRIAGE / Track Bushing W105-03-07-023 ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 Standard A 169 (6.7) B 48.4 (1.91) C 71.35 (2.81) ZAXIS500LC-3, 520LCH-3 Standard A 192.4 (7.6) B 49.6 (1.95) C 79.0 (3.11) Unit: mm (in) Remedy Allowable Limit [49.4 (1.95)] [66.4 (2.61)] Replace Allowable Limit [50.6 (1.99)] [74.0 (2.91)] Remedy Replace [ ]：Reference Pin B W142-03-07-004 A ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 Standard A 254 (10) B 47.6 (1.87) ZAXIS500LC-3, 520LCH-3 Standard A 290 (11.4) B 48.
UNDERCARRIAGE / Track (Blank) W3-7-16
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SECTION 4 FRONT ATTACHMENT CONTENTS Group 1 Front Attachment Hydraulic Circuit Pressure Release Procedure............................................. W4-1-1 Remove and Install Front Attachment ........ W4-1-2 Remove and Install Bushing .................... W4-1-10 Maintenance Standard............................... W4-1-12 Standard Dimensions for Arm and Bucket Connection .................... W4-1-15 Standard Dimensions for Arm and Boom Connection ..................
(Blank) 1J1W-4-2
FRONT ATTACHMENT / Front Attachment HYDRAULIC CIRCUIT RELEASE PROCEDURE PRESSURE NOTE: Operate the pilot pump by using the power from battery without starting the engine and deliver the pilot pressure to the spool of control valve. 3 1. Turn pilot shut-off lever (1) to the UNLOCK position. 2. Turn engine stop switch (2) ON. NOTE: Perform steps 1, 2 and turn the key switch to the START position. Although the starter rotates, the engine does not start. IMPORTANT: Battery will deplete.
FRONT ATTACHMENT / Front Attachment REMOVE AND ATTACHMENT INSTALL FRONT Removal 1. Park the machine on a solid, level surface. Fully retract the bucket and arm cylinders and lower the front attachment onto the ground. W1J1-04-01-001 2 2. Remove the connector in boom light between cab and main frame. 3. Remove lubrication hose (2) from the rod side of boom cylinder (1). (2 places on both right and left) : 19 mm 1 4. Remove bolts (5) (4 used). Remove washer (3) and stopper (4).
FRONT ATTACHMENT / Front Attachment 8. Start the engine. Operate the boom lever and retract the rod of boom cylinder (1). In order not to extend the rod, pass a wire through the rod hole and secure the rod to the cylinder tube. Stop the engine. 9. Operate the control lever several times with the pilot shut-off lever in the UNLOCK position and release any pressure in the circuit. NOTE: The accumulator is equipped for the pilot circuit.
FRONT ATTACHMENT / Front Attachment CAUTION: Standard front weight: 8000 kg (17650 lb) attachment 16. Attach a wire rope to the boom. Hoist the boom and take up slack of wire ropes. W105-04-01-008 17. Install a bar of special tool (ST 1975) into the hole on boom foot pin (15). Install the nut. Remove boom foot pin (15). : 36 mm 15 ST 1975 Bar Nut W105-04-01-022 18. Hoist the front attachment and operate the machine in reverse.
FRONT ATTACHMENT / Front Attachment Installation CAUTION: Standard front weight: 8000 kg (17650 lb) attachment 1. Hoist the front attachment. Align the boom foot with the mounting hole of main frame. Insert the shim into the left and right sides of boom foot and adjust the clearance between the boom foot and main frame within 1.5 mm. Shim thickness: 3.2 mm, 2.3 mm or 1.0 mm Boom Foot Position CAUTION: Metal fragments may fly off when a hammer is used.
FRONT ATTACHMENT / Front Attachment CAUTION: Boom cylinder weight: 430 kg (950 lb) IMPORTANT: Fill hydraulic oil to specified level. Start the engine. Check for any oil leaks of each hose. 7. Hoist boom cylinder (1). Start the engine. Extend the boom cylinder and align with the pin hole. 1 CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. 8. Install pin (6) and install boom cylinder (1) to both sides.
FRONT ATTACHMENT / Front Attachment 12. Apply grease into the boom foot position and the rod side of boom cylinder by using a grease gun. As for the machine attached with the auto lubrication device (Optional), turn the auto lubrication switch ON. Boom Cylinder Rod Side Boom Foot Side 13. After completing the work, add hydraulic oil to the specified level. 14. Operate every cylinder fully to the stroke end several times and release the pressure in the circuit. Check for any oil leaks of each hose.
FRONT ATTACHMENT / Front Attachment IMPORTANT: When the arm has been removed from the boom, perform the followings when installing the arm. 15. Install shim (14) to the left and right sides of arm. Shim (14) thickness: 8.0 mm Arm 14 Boom 16. Insert the shim between the arm and shim (14) so that the clearance between shim and arm is within 1.5 mm. Shim thickness: 1.0 mm or 2.0 mm 17. After installing the arm, apply grease into the boom/arm joint pin and the rod side of arm cylinder by using a grease gun.
FRONT ATTACHMENT / Front Attachment (Blank) W4-1-9
FRONT ATTACHMENT / Front Attachment REMOVE AND INSTALL BUSHING d c b a e W166-04-02-005 Bucket Link A 1 2 2 1 2 f Arm 3 Link A 1 2 1 2 a: Bucket and Link A W166-04-02-012 1 2 Boom 3 Link B c: Boom and Arm b: Link A W166-04-02-014 W166-04-02-013 1 2 2 3 2 1 2 Arm 3 Bucket Main Frame Boom Link B d: Boom and Main Frame W166-04-02-010 f: Arm and Bucket e: Arm and Link B W166-04-02-016 W166-04-02-015 1- Dust Seal 2 - Bushing 3 - Spacer W4-1-10
FRONT ATTACHMENT / Front Attachment Removal 1. Remove dust seal (1) and bushing (2). NOTE: If bushing (2) cannot be removed, burn off bushing (2). Installation 1. Cool bushing (2) by using dry ice. 2. Install bushing (2) and dust seal (1). When installing bushing (2), use the following plate. Plate when installing bushing a: Bucket side .....................................ST 2881 Link A side.......................................ST 2873 b: Link A ..............................................
FRONT ATTACHMENT / Front Attachment MAINTENANCE STANDARD Pin and Bushing f d c g h b i a e k j W105-04-01-018 Position a: Boom Cylinder and Main Frame b: Boom and Main Frame c: Boom Cylinder and Boom Item Pin Outer Dia. Bushing Inner Dia. (Frame Side) Bushing Outer Dia. Bearing Inner Dia. (Cylinder Side) Pin Outer Dia. Bushing Inner Dia. (Frame Side) Bushing Outer Dia. Bushing Inner Dia. (Boom Side) Bushing Outer Dia. Pin Outer Dia. Pin Hole Inner Dia. (Boom Side) Bearing Inner Dia.
FRONT ATTACHMENT / Front Attachment Position d: Boom and Arm Cylinder e: Boom and Arm f: Arm Cylinder and Arm g: Arm and Bucket Cylinder h: Bucket Cylinder and Link i: Link and Bucket j: Arm and Bucket k: Arm and Link Item Pin Outer Dia. Pin Hole Inner Dia. (Boom Side) Bearing Inner Dia. (Cylinder Side) Pin Outer Dia. Bushing Inner Dia. (Boom Side) Bushing Outer Dia. Bushing Inner Dia. (Arm Side) Bushing Outer Dia. Pin Outer Dia. Pin Hole Inner Dia. (Arm Side) Bearing Inner Dia.
FRONT ATTACHMENT / Front Attachment Side Cutter B A W166-04-01-011 Unit: mm (in) Standard 305 (12.0) 40 (1.6) A B Allowable Limit 200 (7.9) - Remedy Replace Point B C D A W1J1-04-01-002 Unit: mm (in) A B C D Standard 254 (10.0) 140 (5.5) 137 (5.4) 129 (5.1) Allowable Limit 127 (5.
FRONT ATTACHMENT / Front Attachment STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION IMPORTANT: If the front attachment of a previous model machine is used, use the grease intervals for previous model machine. Section B Section A Unit: mm (in) Model ZX450-3/500LC-3 ZX450 EX400-5 a 520 (20.47) ← ← b 10 (0.39) ← ← c 750 (29.53) ← ← d 710 (27.95) ← ← e f 1911 (75.24) 1896 (74.65) ← g 643 (25.32) ← 470.5 to 471.0 h ← ← (18.52 to 18.54) i 110 (4.33) ← ← j 558 (21.97) ← ← k 106 (4.17) ← ← l 648 (25.
FRONT ATTACHMENT / Front Attachment STANDARD DIMENSIONS FOR ARM AND BOOM CONNECTION IMPORTANT: If the front attachment of a previous model machine is used, use the grease intervals for previous model machine. Section C W187-04-01-002 Model ZX450-3/500LC-3 s 140 (5.51) t 471 (18.54) u 632 (24.
FRONT ATTACHMENT / Cylinder REMOVE AND INSTALL CYLINDER Preparation 1. Park the machine on a solid, level surface. Fully retract the bucket and arm cylinders and lower the front attachment onto the ground. 2. Stop the engine. Operate the control lever several time with the pilot shut-off lever in the UNLOCK position and release any pressure in the circuit. NOTE: The accumulator is equipped for the pilot circuit.
FRONT ATTACHMENT / Cylinder Remove and Install Boom Cylinder A B W1J1-04-01-003 A: Rod Side Lubrication Hose B: Bottom Side 6 1 3 4 5 Hydraulic Hose 2 7 W166-04-01-002 W166-04-01-003 6 7 2 3 8 5, 4 6 9 1 10 12 W166-04-01-005 123- Pin Washer (2 Used) Stopper (2 Used) 4 - Spring Washer (8 Used) 5 - Bolt (8 Used) 6 - Boom Cylinder (2 Used) 7 - Pin (2 Used) 8 - Washer (2 Used) 9 - Bolt (2 Used) W4-2-2 W162-04-01-025 11 10 - Spring Washer (2 Used) 11 - Spacer 12 - Shim
FRONT ATTACHMENT / Cylinder Removal 1. Remove the lubrication hoses (4 used) from the rod side and bottom side in boom cylinder (6) on both sides. : 19 mm CAUTION: Boom cylinder weight: 430 kg (950 lb) Pin (1) weight: 90 kg (200 lb) CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. CAUTION: Pin (7) weight: 24 kg (53 lb) 6. Remove bolt (9) from the bottom side of boom cylinder (6).
FRONT ATTACHMENT / Cylinder A B W1J1-04-01-003 A: Rod Side Lubrication Hose B: Bottom Side 6 1 3 4 5 Hydraulic Hose 2 7 W166-04-01-002 W166-04-01-003 6 7 2 3 8 5, 4 6 9 1 10 12 W166-04-01-005 123- Pin Washer (2 Used) Stopper (2 Used) 4 - Spring Washer (8 Used) 5 - Bolt (8 Used) 6 - Boom Cylinder (2 Used) 7 - Pin (2 Used) 8 - Washer (2 Used) 9 - Bolt (2 Used) W4-2-4 W162-04-01-025 11 10 - Spring Washer (2 Used) 11 - Spacer 12 - Shim
FRONT ATTACHMENT / Cylinder Installation CAUTION: Boom cylinder weight: 430 kg (950 lb) Pin (7) weight: 24 kg (53 lb) CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. 1. Hoist boom cylinder (6) and align with the pin hole on cylinder bottom side. Install spacer (11) to inside and install shim (12) to outside. Install pin (7). Install washer (8), spring washer (10) and bolt (9).
FRONT ATTACHMENT / Cylinder Remove and Install Arm Cylinder W1J1-04-01-003 Lubrication Hose Hydraulic Hose 2 1 3 5 4 Lubrication Hose 2 Wooden Block Boom W166-04-01-004 1 W162-04-01-008 3 4 1 5 2 W166-04-01-006 12- Pin (2 Used) Arm Cylinder 3- Bolt (2 Used) 4 - Stopper (2 Used) W4-2-6 5 - Lock Nut (4 Used)
FRONT ATTACHMENT / Cylinder Removal 1. Remove the lubrication hose from the rod side of arm cylinder (2). : 19 mm CAUTION: Arm cylinder weight: 660 kg (1455 lb) Pin weight: 25 kg (55 lb) CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. CAUTION: Pin weight: 25 kg (55 lb) CAUTION: Metal fragments may fly off when a hammer is used.
FRONT ATTACHMENT / Cylinder W1J1-04-01-003 Lubrication Hose Hydraulic Hose 2 1 3 5 4 Lubrication Hose 2 1 Wooden Block Boom W166-04-01-004 W162-04-01-008 3 4 1 5 2 W166-04-01-006 12- Pin (2 Used) Arm Cylinder 3- Bolt (2 Used) 4- W4-2-8 Stopper (2 Used) 5- Lock Nut (4 Used)
FRONT ATTACHMENT / Cylinder Installation CAUTION: Arm cylinder weight: 660 kg (1455 lb) CAUTION: Pin weight: 25 kg (55 lb) CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. 1. Hoist arm cylinder (2). Align the pin hole on the mounting part for cylinder bottom side. CAUTION: Pin weight: 25 kg (55 lb) CAUTION: Metal fragments may fly off when a hammer is used.
FRONT ATTACHMENT / Cylinder Remove and Install Bucket Cylinder W1J1-04-01-003 1 2 3 Hydraulic Hose 4 Lubrication Hose 4 8 Arm 5 Wooden Block 6 W16J-04-02-001 W166-04-01-009 1 4 2 3 8 5 9 3 2 W166-04-01-007 6 123- 7 W166-04-01-006 4 Link A Lock Nut (4 Used) Bolt (2 Used) 4 - Bucket Cylinder 5 - Pin 67- W4-2-10 Link B (2 Used) Shim (2 Used) 89- Pin Stopper
FRONT ATTACHMENT / Cylinder Removal 1. Insert a wooden block between the arm and bucket cylinder (4). Remove the lubrication hose from the bottom side of bucket cylinder (4). : 19 mm 1. Remove the hydraulic hoses (2 used) from the cylinder bottom side. : 10 mm CAUTION: Pin (8) weight: 20 kg (44 lb) 2. Place the wooden block under link A (1). Secure link A and link B by using a wire in order not to drop links B (6) (2 used) when removing pin (5).
FRONT ATTACHMENT / Cylinder W1J1-04-01-003 1 2 3 Hydraulic Hose 4 Lubrication Hose 4 8 5 Wooden Block 6 Arm W16J-04-02-001 W166-04-01-009 1 4 2 3 8 5 9 3 2 W166-04-01-007 6 7 4 W166-04-01-006 123- Link A Lock Nut (4 Used) Bolt (2 Used) 4 - Bucket Cylinder 5 - Pin 67- W4-2-12 Link B (2 Used) Shim (2 Used) 89- Pin Stopper
FRONT ATTACHMENT / Cylinder Installation CAUTION: Bucket cylinder weight: 410 kg (905 lb) CAUTION: Pin (5) weight: 46 kg (101 lb) CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. 1. Hoist bucket cylinder (4). Align the pin hole on mounting part for cylinder bottom side with that on arm side. CAUTION: Pin (8) weight: 20 kg (44 lb) CAUTION: Metal fragments may fly off when a hammer is used.
FRONT ATTACHMENT / Cylinder DISASSEMBLE CYLINDERS Boom Cylinder １ 2 8 9 10 11 3 4 5 6 7 12 13 14 15 13 12 16 17 18 W158-04-02-001 1 2 3 4 5 - Cylinder Rod Retaining Ring Dust Seal Seal Ring 678910 - Bushing Retaining Ring Socket Bolt (8 Used) Cylinder Head O-Ring 11 12 13 14 - Cushion Ring Teflon Ring (2 Used) Wear Ring (2 Used) Piston W4-2-14 15 16 17 18 - Seal Ring Set Screw Nut Cylinder Tube
FRONT ATTACHMENT / Cylinder Disassemble Boom Cylinder • The disassembling procedure starts on the premise that the hydraulic lines and the bands securing lines have been removed. 5. Remove set screw (16). : 6 mm NOTE: As set screw (16) was mushroomed by using a punch and hammer at two places after set screw (16) had been screwed in, cut away its mushroomed part by using a drill first. CAUTION: Boom cylinder weight: 430 kg (950 lb) 1. Hoist the cylinder. Secure the cylinder on a workbench horizontally.
FRONT ATTACHMENT / Cylinder Arm Cylinder 15 16 17 18 19 20 19 18 14 21 22 1 13 23 2 3 4 5 6 7 8 9 10 11 12 W166-04-02-002 123456- Cylinder Rod Wiper Ring Cylinder Head Socket Bolt (8 Used) Slide Ring Backup Ring 78910 11 12 - U-Ring Buffer Ring Bushing Retaining Ring Backup Ring O-Ring 13 14 15 16 17 18 - Set Screw Steel Ball Cushion Seal Cushion Bearing Piston Slide Ring (2 Used) W4-2-16 19 20 21 22 23 - Slide Ring (2 Used) Seal Ring Shim Nut Cylinder Tube
FRONT ATTACHMENT / Cylinder Bucket Cylinder 16 17 18 19 1 20 19 18 22 14 23 13 2 3 4 5 6 7 8 9 10 11 12 W166-04-02-003 123456- Cylinder Rod Wiper Ring Cylinder Head Socket Bolt (8 Used) Slide Ring Backup Ring 78910 11 - U-Ring Buffer Ring Bushing Retaining Ring Backup Ring 12 13 14 16 17 - O-Ring Set Screw Steel Ball Cushion Bearing Piston W4-2-17 18 19 20 22 23 - Slide Ring (2 Used) Slide Ring (2 Used) Seal Ring Nut Cylinder Tube
FRONT ATTACHMENT / Cylinder NOTE: The illustration shows arm cylinder.
FRONT ATTACHMENT / Cylinder Disassemble Arm Cylinder, Bucket Cylinder • As the other hydraulic oil cylinders are very similar in construction, the procedures of arm cylinder are shown as an example. • The disassembling procedure starts on the premise that the hydraulic lines and the bands securing lines have been removed. IMPORTANT: Pull out cylinder rod (1) straightly in order not to damage the sliding surface. 3.
FRONT ATTACHMENT / Cylinder 15 16 17 18 19 20 19 18 1 21 22 2 3 5 6 7 8 9 10 11 12 W166-04-02-002 W4-2-20
FRONT ATTACHMENT / Cylinder 6. Loosen nut (21) and remove piston (17) by using special tool (ST 5908). Remove the nut. Remove shim (21) from cylinder rod (1). Special Tool when turning nut: Arm cylinder ST 3283: 135 mm (5.3 in) Bucket cylinder ST 7213: 130 mm (5.1 in) 10. Remove retaining ring (10) and bushing (9) from cylinder head (3). 11. Remove O-ring (12) and backup ring (11) from cylinder head (3). ST 5908 W158-04-02-022 NOTE: Shim (21) is not equipped for the bucket cylinder.
FRONT ATTACHMENT / Cylinder ASSEMBLE CYLINDERS Boom Cylinder 2 8 3 4 5 6 10 9 12 13 7 1 18 15 13 11 17 12 14 16 W158-04-02-002 1 2 3 4 5 - Cylinder Rod Retaining Ring Dust Seal Seal Ring 678910 - Bushing Retaining Ring Socket Bolt (8 Used) Cylinder Head O-Ring 11 12 13 14 - Cushion Ring Teflon Ring (2 Used) Wear Ring (2 Used) Piston W4-2-22 15 16 17 18 - Seal Ring Set Screw Nut Cylinder Tube
FRONT ATTACHMENT / Cylinder Assemble Boom Cylinder 1. Install bushing (6) to cylinder head (9). Special tool when installing bushing: ST 2671: 115 mm (4.5 in) 2. Install ring (5), seal (4) and retaining ring (7) to cylinder head (9). 8. Align the matching marks before disassembling and tighten nut (17) by using special tool (ST 5908). Special Tool when turning nut: ST 3268: 125 mm (4.9 in) : 14220±1420 N⋅m (1450±145 kgf⋅m, 10490±1049 lbf⋅ft) 3.
FRONT ATTACHMENT / Cylinder Arm Cylinder Bucket Cylinder 1 8 9 2 1 2 5 5 8 6 9 7 10 10 6 7 4 4 11, 12 11, 12 3 3 23 23 16 16 Slit 18 15 18 19 17 20 19 17 19 20 18 19 21 14 22 18 13 22 14 13 W162-04-02-004 123456- Cylinder Rod Wiper Ring Cylinder Head Socket Bolt (8 Used) Slide Ring Backup Ring 78910 11 12 - U-Ring Buffer Ring Bushing Retaining Ring Backup Ring O-Ring W162-04-02-005 13 14 15 16 17 18 - Set Screw Steel Ball Cushion Seal Cushion Bearing Piston Slid
FRONT ATTACHMENT / Cylinder Assemble Arm Cylinder, Bucket Cylinder 1. Install bushing (9) to cylinder head (3). Install retaining ring (10). Special tool when installing bushing: Arm cylinder ST 8023: 135 mm (5.3 in) Bucket cylinder ST 8036: 120 mm (4.7 in) 6. Install O-ring (12) and backup ring (11) to cylinder head (3). IMPORTANT: Install buffer ring (8) with the lip facing to the cylinder bottom side. 2. Install buffer ring (8) to cylinder head (3).
FRONT ATTACHMENT / Cylinder Arm Cylinder Bucket Cylinder 1 1 4 4 3 3 23 23 16 16 Slit 15 17 17 14 21 14 22 22 13 13 W162-04-02-004 W4-2-26 W162-04-02-005
FRONT ATTACHMENT / Cylinder 11. Install cylinder head (3) to cylinder rod (1). Special tool when installing cylinder head: Arm cylinder: ST 8023 Bucket cylinder: ST 8022 17. Install steel ball (14) to nut (22). Install set screw (13). : 8 mm : 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft) IMPORTANT: Install cushion seal (15) with the slit facing to the piston side. 12. Install cushion seal (15) to cylinder rod (1). 18. Crimp set screw (13) at two places on the outer surface by using a punch in order not to loosen.
FRONT ATTACHMENT / Cylinder MAINTENANCE STANDARD Cylinder Tube 1. Tube Section (1) • Check the inside and outside for any damage. 1 2. Pin, Bushing Section (2) • Check whether the wear on surface of inner diameter is 0.5 mm (0.02 in) more than specified dimension (B). • Check the inside for any damage. IMPORTANT: Check the completely. inner bore in 2 A B tube W145-04-01-015 Cylinder Rod 1. Rod Section (3) • Place two V-blocks 1 m apart on level ground. Lay the cylinder rod across the V-blocks.
FRONT ATTACHMENT / Cylinder Pipe 5 1. Pipe (5) • Check for any damage in depth more than 0.1 mm (0.004 in). • Check for any deformation and damage 2. Socket bolt (6) • Check for any heavy rust. • Check the thread for any damage. 6 5 6 7 7 3. Ring (7) • Replace O-ring when disassembling. T182-05-02-004 Piston, Cylinder Head • Check the inside and outside for any damage. • Check the groove for any damage. • When the internal leakage is found, check the seals for damage.
FRONT ATTACHMENT / Cylinder (Blank) W4-2-30
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Hitachi Construction Machinery Co. Ltd Attn: Publications, Marketing & Product Support Fax: 81-29-831-1162 Hitachi Ref. No. SERVICE MANUAL REVISION REQUEST FORM NAME OF COMPANY: MODEL: PUBLICATION NO.: YOUR NAME: DATE: FAX: (Located at the right top corner in the cover page) PAGE NO.: (Located at the bottom center in the page. If two or more revisions are requested, use the comment column) YOUR COMMENTS / SUGGESTIONS: Attach photo or sketch if required.
