Page 1

EX1800-3 Workshop Manual


SECTION 1

GENERAL INFORMATION —CONTENTS— Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling........................................... W1-1-1

Group 2 Tightening Tightening Torque Specification.............. W1-2-1 Torque Chart .......................................... W1-2-2 Piping Joint ............................................ W1-2-5

144W-1-1


(Blank)

144W-1-2


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

DISASSEMBLING

Precautions for Disassembling and Assembling

• Clean the Machine

• Precautions for Disassembling • To prevent dirt from entering, cap or plug the removed pipes. • Before disassembling, clean the exterior of the components and place it on a work bench. • Before disassembling, drain gear oil from the reduction gear. • Be sure to provide appropriate containers for draining fluids. • Use matching marks for easier reassembling. • Be sure to use the specified special tools, when instructed. • If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause(s), then take the appropriate measures to remove it. • Orderly arrange disassembled parts. Mark and tag them as necessary. • Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. • Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. • Measure and record the degree of wear and clearances.

Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work.

• Inspect the Machine Be sure to thoroughly understand all disassembling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future. • The machine model, machine serial number, and hour meter reading. • Reason for disassembly (symptoms, failed parts, and causes). • Clogging of filters and oil, water or air leaks, if any. • Capacities and condition of lubricants. • Loose or damaged parts.

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

• Precautions for Assembling

W1-1-1

• Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace it. • Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces. • Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing. • Be sure that liquid-gasket-applied surfaces are clean and dry. • If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent. • Utilize matching marks when assembling. • Be sure to use the designated tools to assemble bearings, bushings and oil seals. • Keep a record of the number of tools used for disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no tools are missing.


GENERAL INFORMATION / Precautions for Disassembling and Assembling Bleeding Air from Hydraulic System When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and installation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures:

• Bleeding Air from Hydraulic Pump IMPORTANT: If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result. Be sure to bleed air before starting the engine. • Remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil. • After the pump housing is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run at slow idle speed. • Slightly loosen the plug to bleed air from the pump housing until hydraulic oil oozes out. • After bleeding all the air, securely tighten the plug.

• Bleeding Air from Travel Motor/Swing Motor • With the drain plug/hose on travel motor/swing motor removed, fill the motor case with hydraulic oil.

• Bleeding Air from Hydraulic Circuit • After refilling hydraulic oil, start the engine. While operating each cylinder, swing motor and travel motor evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes. • Reposition the front attachment to check hydraulic oil level. • Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary.

W1-1-2

M104-07-021


GENERAL INFORMATION / Precautions for Disassembling and Assembling Floating Seal Precautions

A

1. In general, replace the floating seal with a new one. If the floating is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. W105-03-05-019

(2) Check seal ring face (C) for scuffing, scoring, corrosion, deformation or uneven wear.

B

(3) Check O-ring (B) for tears, breaks, deformation or hardening. 2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble. (1) Clean floating seal (A) and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air.

Correctly

Incorrectly

(2) Clean the floating seal and seal mounting bores, as dust on them tends to enter the floating seal when installing it. (3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring. (4) After installing the floating seal, check that seal face (C) is parallel with seal mounting bores ring face (D) by measuring the distances (C) and (D) at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating.

W105-03-05-020

Incorrectly

Correctly

D a

a

C B

b

a=b

b

aŇ?b W110-03-05-004

W1-1-3


GENERAL INFORMATION / Precautions for Disassembling and Assembling MAINTENANCE STANDARD TERMINOLOGY “Standard” 1. Dimension for parts on a new machine. 2. Dimension of components or assemblies adjusted to specification. Both dimensions are shown with tolerances as necessary. “Allowable Limit” 1. Normal machine performance cannot be accomplished after exceeding this limit. 2. Repair or replacement is required before reaching this limit. Machine performance will decrease, and maintenance and down time expense will increase as machine operating hours accumulate. It is recommended that parts are repaired or replaced before reaching the “Allowable Limit”.

W1-1-4


GENERAL INFORMATION / Tightening TIGHTENING TORQUE SPECIFICATIONS

1 2

N⋅m

kgf⋅m

lbf⋅ft

4 4

50 32

2550 740

260 75

1880 540

24 4

41 27

1030 390

105 40

760 290

Q'ty

Engine cushion rubber mounting bolt

33 22

Engine bracket mounting bolt

27 18

No.

Descriptions

3

Hydraulic oil tank mounting bolt

4

Fuel tank mounting bolt

5

Pump transmision mouting bolt

6 7

Torque

Wrench Size (mm)

Bolt Dia mm

30

8

46

1420

145

1050

30 1/2-13UNC

12

46

1420

145

1050

28

118

12

87

Pump device mounting bolt

20

24

390

40

290

Gear pump mounting bolt

14

4

19 Hexagonbar wrench 17 Hexagonbar wrench 12

137

14

101

Air-con. Compressor drive pump mounting bolt

14

4

Hexagonbar wrench 12

137

14

101

9

Control valve mounting nut

10

Swing device mounting bolt

20 33 24

8 48 48

30 50 36

390 2550 690

40 260 70

290 1880 510

11

Swing motor mounting bolt

20

8

30

390

40

290

8

12

Battery mounting bolt

10

16

17

13

Cab mounting bolt

18

8

27

295

30

215

14

Cab bed mounting bolt Swing bearing mounting bolt to upperstructure Swing bearing mounting bolt to undercarriage

16 45 45

36 58 60

24 70 70

205 4710 4710

21 480 480

152 3470 3470

16

Counterweight mounting nut

45

7

70

3920

400

2890

17

Radiator mounting nut Travel device mounting bolt

27 22 33 30

8 32 64 60

41 32 50 46

1030 740 2550 1910

105 75 260 195

760 540 1880 1410

15

18

(A) (B) (C)

19.5

2

14.5

19

Travel motor mounting bolt

20

8

30

390

40

290

20

Upper roller mounting bolt

20

25

30

390

40

290

21

Lower roller mounting bolt

30

64

46

1910

195

1410

22

Track guard mounting bolt

30

12

46

1910

195

1410

23

Track shoe bolt

33

392

50

3190

325

2350

24

Side frame mounting bolt Loader front pin-retaining bolt (A) Loader front pin-retaining bolt (B) Loader front pin-retaining bolt (C) Backhoe front pin-retaining bolt (A) Backhoe front pin-retaining bolt (B)

45 20 16 24 20 16

68 32 4 4 24 12

70 30 24 36 30 24

4710 390 205 690 390 205

480 40 21 70 40 21

3470 290 152 510 290 152

25 26

NOTE: (1) Apply lubricant (e.g. white Zinc B dissolved into spindle oil) to bolts and nuts to stabilize friction coefficient of them. (2) Make sure bolt and nut threads are clean before installing.

W1-2-1


GENERAL INFORMATION / 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 the correct tools. Avoid bodily injury caused by slipping wrenches. Bolt Types Tighten nuts or bolts correctly to torque specifications. Four kinds of bolts, hexagon bolts T, H, M and socket bolt, each made of different material, are used. Make sure to employ the correct bolts and tighten them to specification when assembling the machine or components.

Hexagon T Bolt

Hexagon H Bolt

SA-040

Hexagon M Bolt

Socket Bolt

W105-01-01-007

Specified Tightening Torque Chart Hexagon T Bolt, Socket bolt Bolt Wrench Wrench Dia. Size N⋅m kgf⋅m lbf⋅ft Size M 8 13 6 29.5 3 22 M 10 17 8 64 6.5 47 M 12 19 10 108 11 80 M 14 22 12 175 18 130 M 16 24 14 265 27 195 M 18 27 14 390 40 290 M 20 30 17 540 55 400 M 22 32 17 740 75 540 M 24 36 19 930 95 690 M 27 41 19 1370 140 1010 M 30 46 22 1910 195 1410 M 33 50 24 2550 260 1880 M 36 55 27 3140 320 2310

H Bolt N⋅m 19.5 49 88 137 205 295 390 540 690 1030 1420 1910 2400

W1-2-2

kgf⋅m 2 5 9 14 21 30 40 55 70 105 145 195 245

M Bolt lbf⋅ft 14.5 36 65 101 152 220 290 400 505 760 1050 1410 1770

N⋅m 9.8 19.5 34 54 78 118 167 215 275 390 540 740 930

kgf⋅m 1 2 3.5 5.5 8 12 17 22 28 40 55 75 95

lbf⋅ft 7.2 14.5 25.5 40 58 87 123 159 205 290 400 540 690


GENERAL INFORMATION / Tightening IMPORTANT: (1) Apply lubricant (i. e. white zinc B dissolved into spindle oil) to nuts and bolts to stabilize their friction coefficients. (2) Torque tolerance is Âą10 %. (3) Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force. (4) The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application. (5) Make sure that the nut and bolt threads are clean before installing. Remove dirt or corrosion, if any. Bolt Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.

Equally tighten upper and lower alternately

1,4

Tighten from center and diagonally

Tighten diagonally

1 6

3

4

5 2

12

9

4

1

6

7

14

13

8

5

2

3

10

11

2,3

W105-01-01-003

W1-2-3


GENERAL INFORMATION / 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 Orings. Inspect O-rings for any damage. Take care not to file Oring surfaces. When installing an O-ring into a groove, use grease to hold it in place. (3) Loosely assemble split flange halves. Make sure that the split is centrally located and perpendicular to the port. Hand-tighten the bolts to hold the parts in place. Take care not to pinch the O-ring. (4) Tighten bolts alternately and diagonally, as shown, to ensure even tightening. (5) Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before tighten the others, resulting in damage to O-rings or uneven tightening of bolts.

W105-01-01-015

WRONG

W105-01-01-016

W105-01-01-008

WRONG

RIGHT

Nut and Bolt Lockings

Do not bend it round

Bend along edge sharply

• Lock Plate IMPORTANT: Do not reuse lock plates. Do not try to bend the same point twice. • Cotter Pin IMPORTANT: Do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening.

RIGHT

RIGHT

WRONG

Bend along edge sharply W105-01-01-009

• Lock Wire IMPORTANT: Apply wire to bolts in the bolttightening direction, not in the boltloosening direction.

RIGHT

RIGHT

RIGHT

WRONG

Loosen

WRONG

Tighten

W105-01-01-010

W1-2-4


GENERAL INFORMATION / Tightening PIPING JOINT

1

4

3

5

2

Pipe Thread Connection/Union Joint Tightening Torque Specifications Union Joint Joint Body

Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines.

M202-07-051

30 ° or 37 °

IMPORTANT: (1) Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adaptor (1). Be sure to tighten union nut (3) to specifications.

30 ° or 37 °

Male Union Joint

W105-01-01-017

(2) Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting/disconnecting.

Type 30 ° Male Union Joint

37 ° Female Union Joint

Wrench Size Union Nut Joint Body 19 19 22 22 27 27 36 36 41 41 50 50 60 60 70 70 17 19 19 22 22 27 30, 32 36 36 41 46 50

NOTE: Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint.

W1-2-5

Female Union Joint

Tightening Torque N⋅m kgf⋅m Ibf⋅ft 43 6 59 72 10 98 87 12 118 134 24 235 215 30 295 360 50 490 490 68 670 720 100 980 32.5 4.5 44 43 6 59 87 12 118 134 24 235 215 30 295 360 50 490


GENERAL INFORMATION / Tightening O-ring Seal Joint

7

6

9

O-ring (6) seats against the end face of adaptor (7) to seal pressure oil. IMPORTANT: (1) Be sure to replace O-ring (6) with a new one when reconnecting. (2) Before tightening union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening union nut (9) with Oring (6) displaced will damage Oring (6), resulting in oil leakage. (3) Take care not to damage O-ring groove (8) or sealing face (10). Damage to O-ring (6) will cause oil leakage. (4) If union nut (9) is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-ring (6) with a new one, then tighten union nut (9) after confirming that O-ring (6) is securely seated in place.

W1-2-6

8

Joint Body

10

M104-07-033

Wrench Size Union Nut Joint Body 19 22 27 36 41 50

17 19 22 30, 32 36 46

Tightening Torque N⋅m kgf⋅m Ibf⋅ft 59 98 118 235 295 490

6 10 12 24 30 50

43 72 87 134 215 360


GENERAL INFORMATION / Tightening Screwed-In Connection

PT

PF

IMPORTANT: Many types of screwed-in connections are used for hose connections. Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection.

30°

Male Tapered Thread

Male Straight Thread

W105-01-01-018

Male Tapered Thread Wrench Tightening Torque Joint Body N⋅m kgf⋅m Ibf⋅ft 43 6 59 17, 19 72 10 98 19, 22 87 12 118 27, 22 134 24 235 36, 32 215 30 295 41 360 50 490 50 490 68 670 60 720 100 980 70

Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leakage between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap.

Internal Thread

• Application Procedure External Thread

Confirm that the thread surface is clean, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads.

Clearance

W105-01-01-019

Leave one to two pitch threads uncovered

Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp. See below for correct tightening torque of each type of low-pressure-hose clamp.

M114-07-041

T-Bolt Type

Worm Gear Type

T-Bolt Type Band Clamp: 4.4 N⋅m (0.45 kgf⋅m, 3.25 lbf⋅ft) Worm Gear Type Band Clamp: 5.9 to 6.9 N⋅m (0.6 to 0.7 kgf⋅m, 4.3 to 5.1 lbf⋅ft)

M114-07-042

W1-2-7

M114-07-043


GENERAL INFORMATION / Tightening Connecting Hose WRONG CAUTION: (1) When replacing hoses, be sure to use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leakage, hose rupture or separation of fitting, possibly resulting in a fire on the machine. (2) Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leakage, hose rupture or separation of fitting. Utilize print marks on hoses when installing hoses to prevent hose from being installed kinked. (3) If hoses rub against each other, wear to the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing against each other. Take care that hoses do not come into contact with moving parts or sharp objects.

RIGHT

W105-01-01-011

WRONG

RIGHT Rubbing Against Each Other

W105-01-01-012

WRONG Clamp

RIGHT Clamp

Rubbing

W105-01-01-013

WRONG

RIGHT

Rubbing Clamp

W105-01-01-014

W1-2-8


SECTION 2

UPPERSTRUCTURE

—CONTENTS— Group 1 Cab Main Hydraulic Line Locatinos (Backhoe) ....................... W2-3-6 Disassemble and Assemble Control Valve .................................. W2-3-7

Windowpane Dimensions ................. W2-1-1

Group 2 Pump Device Remove and Install Pump Device .................................. Disassemble Pump Transmission ........................ Assemble Pump Transmission ........................ Disassemble Main Pump .................. Assemble Main Pump....................... Maintenance Standards.................... Disassemble Main Pump Regulator ..................... Assemble Main Pump Regulator ..................... Disassemble Swing Pump Regulator ................... Assemble Swing Pump Regulator ................... Disassemble and Assemble Triple Gear Pump ........................... Disassemble and Assemble Center Gear Pump .........................

W2-2-1

Group 4 Swing Device

W2-2-8

Remove and Install Swing Device..... Disassemble Swing Device............... Assemble Swing Device ................... Disassemble Swing Motor ................ Assemble Swing Motor ..................... Maintenance Standards .................... Disassemble and Assemble Relief Block ....................................

W2-2-12 W2-2-16 W2-2-20 W2-2-24 W2-2-26 W2-2-32

Remove and Install Front and Swing Pilot Valves........... Remove and Install Travel and Bucket Pilot Valves ..................................... Pilot Line Connections (Loading Shovel) ............................ Pilot Line Connections (Backhoe) ....................................... Disassemble and Assemble Pilot Valves .....................................

W2-2-38 W2-2-44 W2-2-50 W2-2-52

W2-3-1

W2-4-28

Group 5 Pilot Valve

Group 3 Control Valve Remove and Install Control Valve .................................. Pilot Line Locations (Loading Shovel) ............ Main Hydraulic Line Locations (Loading Shovel) ............ Pilot Line Locations (Backhoe) .........

W2-4-1 W2-4-3 W2-4-11 W2-4-21 W2-4-23 W2-4-27

W2-5-1 W2-5-3 W2-5-5 W2-5-6 W2-5-8

Group 6 Pilot Shut-Off Valve

W2-3-3 W2-3-4 W2-3-5

144W-02-01

Remove and Install Pilot Shut-Off Valve ................................ W2-6-1 Disassemble Pilot Shut-Off Valve ..... W2-6-3 Assemble Pilot Shut-Off Valve .......... W2-6-5


Group 7 Solenoid Valve Remove and Install Solenoid Valves .............................. W2-7-1 Disassemble and Assemble Travel Speed Change Solenoid Valve and Swing Pi Control Solenoid Valve ............... W2-7-3 Disassemble and Assemble Swing Inter Lock Solenoid Valve ............... W2-7-4

Group 8 Fuel Cooler Fan Motor Remove and Install Fuel Cooler Fan Motor .................... W2-8-1 Disassemble and Assemble Fuel Cooler Fan Motor .................... W2-8-3

Group 9 Compressor Drive Motor Remove and Install Compressor Drive Motor................. W2-9-1 Disassemble and Assemble Compressor Drive Motor................. W2-9-3

Group 10 Air Conditioner Work After Component Replacement .................................. W2-10-1 Add Compressor Oil ......................... W2-10-1 Charge Air Conditioner with Refrigerant ..................................... W2-10-2

Group 11 Shuttle Valve Remove and Install Multi Shuttle Valve .......................... W2-11-1

144W-02-02


UPPERSTRUCTURE / Cab WINDOWPANE DIMENSIONS Material :

JIS R 3211, ANSI AS2, ECE ANNEX5 or equivalent

NOTE: 1 mm=0.03937 in

1378±1.5

4−R61

6 1

1

7 1679+2.0 -0

Laminated glass Color : Transparent Thickness : 10 mm Chamfer all fringe Corners.

2

3 4

5

W117-02-01-001

W117-02-01-002

1369±1.5

4−R61 2

917±1.0

4−R61

3

Tempered glass Color : Bronze Thickness : 6 mm (Serial No. from 000501 to 000516) 5 mm (Serial No. from 000517 and later) Chamfer all fringe Corners.

769±1.0

Tempered glass Color : Bronze Thickness : 5 mm Chamfer all fringe Corners.

433±1.0

1256±1.5 W117-02-01-003

W2-1-1

W117-02-01-004


UPPERSTRUCTURE / Cab NOTE: 1 mm=0.03937 in 422±1.0

4−R61 4−R61 4

934±1.0

5 777±1.0

Tempered glass Color : Bronze Thickness : 5 mm Chamfer all fringe Corners.

Tempered glass Color : Bronze Thickness : 5 mm Chamfer all fringe Corners.

514±1.0

W117-02-01-006 W117-02-01-005

667±1.0

1400±1.0

7 4−R61

Tempered glass Color : Bronze Thickness : 5 mm Chamfer all fringe Corners.

6 848±1.0

4−R61

Tempered glass Color : Bronze Thickness : 6 mm Chamfer all fringe Corners.

185

1296±1.0

645±1.0

403±1.0

W117-02-01-008

W117-02-01-007

W2-1-2


UPPERSTRUCTURE / Pump Device REMOVE AND INSTALL PUMP DEVICE CAUTION: Escaping fluid under pressure can penetrate the skin or eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. The hydraulic oil tank cap may fly off by remaining pressure if removed quickly. Slowly loosen the cap to completely release any remaining pressure. Preparation 1. Stop the engine. Move all control levers to release pressure remaining in the system. Rotate the hydraulic oil tank cap approx. 30 ° counterclockwise to release any pressure remaining in the hydraulic oil tank.

W2-2-1


UPPERSTRUCTURE / Pump Device

Main Pumps

Triple Gear Pump

Swing Pump

Engine Main Frame W144-02-02-010

Pump Transmission Mounting Bolts

Lifting Bracket

Manifold Center Gear Pump Check Valve

T144-03-01-001

W144-02-02-009

Pump Transmission Engine Bracket Mounting Bolts Engine Bracket

M144-07-013

W2-2-2


UPPERSTRUCTURE / Pump Device Remove Pump Device 1. Disconnect all hydraulic lines and electric wires from the hydraulic pumps and transmission.

CAUTION: The approximate weight of the pump device is 1100 kg (2430 lb).

Tightening Torque Specifications Wrench Size

Tightening Torque Nxm kgfxm lbfxft

Remarks

: 17 mm

49

5

36

Hydraulic Lines

: 19 mm

59

6

43

Hydraulic Lines

: 19 mm

88

9

65

Bolts

: 22 mm

98

10

72

Bolts

: 24 mm

205

21

152

Bolts

: 27 mm

118

12

87

Hydraulic Lines

: 36 mm

235

24

175

Hydraulic Lines

: 8 mm

64

6.5

47

Socket Bolts

: 10 mm

108

11

80

Socket Bolts

4. Remove the pump transmission mounting bolts and engine bracket mounting bolts. Remove the pump device using a crane. ȀȚ ȀȚ ȀȚ ȀȚ

CAUTION: The approximate weight of each component pump is as follows: Main Pump: 159 kg (350 lb) Swing Pump: 155 kg (340 lb) Triple Gear Pump: 9 kg (20 lb) Center Gear Pump: 5 kg (11 lb)

2. Remove check valves from the main pumps. Remove manifold from swing pump. Tightening Torque Specifications Wrench Size : 19 mm

Tightening Torque Nxm kgfxm lbfxft 88

9

65

41 mm 1030 Nxm (105 kgfxm, 760 lbfxft) 19 mm 118 Nxm (12 kgfxm, 87 lbfxft)

5. Remove each component pump from the pump transmission using a crane.

Remarks Bolts

IMPORTANT: The engine brackets are installed onto the pump transmission. Be sure to insert a steel plate (100 mm (3.9 in) length x 65 mm (2.6 in) width x 25 mm (1 in) thickness) between the engine and main frame to prevent the engine from falling off when removing the pump transmission. 3. Connect the pump device to a crane using chain slings attached to the lifting brackets and straps attached to the main pump. The chain sling attached to the swing pump side lifting bracket is approximately 22 mm (0.8 in) shorter in length.

W2-2-3

ȀȚ ȀȚ ȀȚ ȀȚ

12 mm 137 Nxm (14 kgfxm, 101 lbfxft) 17 mm 390 Nxm (40 kgfxm, 290 lbfxft)


UPPERSTRUCTURE / Pump Device

Main Pumps

Triple Gear Pump

Check Valve

Swing Pump Engine Main Frame W144-02-02-010

Pump Transmission Mounting Bolts

Manifold Lifting Bracket

Center Gear Pump Check Valve

T144-03-01-001

Pump Transmission Oil Seal Hub

W144-02-02-009

Pump Transmission Engine Bracket Mounting Bolts Engine Bracket

M144-07-013

W2-2-4

W144-02-02-011


UPPERSTRUCTURE / Pump Device Install Pump Device CAUTION: The approximate weight of each component pump is as follows: Main Pump: 159 kg (350 lb) Swing Pump: 155 kg (340 lb) Triple Gear Pump: 9 kg (20 lb) Center Gear Pump: 5 kg (11 lb) 1. Install each component pump onto the pump transmission, aligning the splines of the pumps and transmission. ȀȚ ȀȚ ȀȚ ȀȚ

IMPORTANT: After installing the pumps, always perform break-in operation to prevent seizure. 7. Start the engine and run at slow idle for 20 minutes. Check all connections for oil leaks while running at slow idle. 8. Then, run the engine at full speed and slowly raise and lower the boom for 20 minutes. Slowly operate the control lever to full stroke while avoiding abrupt lever operation.

12 mm 137 Nxm (14 kgfxm, 101 lbfxft) 17 mm 390 Nxm (40 kgfxm, 290 lbfxft)

CAUTION: The approximate weight of the pump device is 1100 kg (2430 lb). IMPORTANT: Be careful not to damage the pump transmission oil seal with the engine side hub when installing the pump device onto the pump transmission. 2. Install the pump transmission onto the engine shaft, aligning the splines and tighten the pump transmission mounting bolts. Install the engine brackets on the pump transmission and tighten the engine bracket mounting bolts. ȀȚ ȀȚ ȀȚ ȀȚ

41 mm 1030 Nxm (105 kgfxm, 760 lbfxft) 19 mm 118 Nxm (12 kgfxm, 87 lbfxft)

3. Remove the steel plate inserted between the engine and main frame. 4. Install the check valve on the main pump delivery end. Install the manifold on the swing pump delivery end. 5. Connect all hydraulic lines and electric wires to the pumps and transmission. 6. Purge air from the main pumps and swing pump (Refer to the next page).

W2-2-5


UPPERSTRUCTURE / Pump Device Main Pump Air Bleeding Procedure 1. Disconnect connector (2) of contamination sensor (1). IMPORTANT: Never loosen contamination sensor (1) completely as hydraulic oil will spout.

1

2. Loosen contamination sensor (1) plug 2 to 3 turns. 2

ȀȚ 36 mm 3. Start the engine and run at slow idle. Purge air from the main pump until oil flows out from sensor (1) plug. 4. Stop the engine and tighten contamination sensor (1) plug.

M144-07-089

ȀȚ 36 mm ȀȚ 118 Nxm (12 kgfxm, 87 lbfxft) 5. Connect connector (2) of contamination sensor (1).

3

Swing Pump Air Bleeding Procedure IMPORTANT: Never loosen drain hose plug (3) completely as hydraulic oil will spout. 1. Loosen drain hose plug (3) 2 to 3 turns. ȀȚ 36 mm M144-07-113

2. Start the engine and run at slow idle. Purge air until oil flows out from drain hose plug (3). 3. Stop the engine and tighten drain hose plug (3). ȀȚ 36 mm ȀȚ 175 Nxm (18 kgfxm, 130 lbfxft)

W2-2-6


UPPERSTRUCTURE / Pump Device (Blank)

W2-2-7


UPPERSTRUCTURE / Pump Device DISASSEMBLE PUMP TRANSMISSION 38 37 35

25 26

30

27

31

32

33

36

34

29

39

28 5 4

3 2 1

10

40

9 8

7 6

11

12

24

13

20

21

22

23

5 7

4

19

3

18

2

17

1

16

6

15

W144-02-02-008

14

12345678910 -

Cartridge (2 Used) O-Ring (2 Used) Bearing (2 Used) Gear (2 Used) Bearing (2 Used) Socket Bolt (8 Used) Plug (2 Used) Spacer Cover O-Ring

11 12 13 14 15 16 17 18 19 20 -

Bolt (3 Used) Spring Washer (3 Used) Plug Socket Bolt (4 Used) Cartridge O-Ring Bearing Gear Bearing Spacer

21 22 23 24 25 26 27 28 29 30 -

Retaining Ring Bearing Spacer Bearing Bolt (8 Used) Bracket (2 Used) Case Disc Spring Spacer Bearing

W2-2-8

31 32 33 34 35 36 37 38 39 40 -

Retaining Ring Coupling Retaining Ring Gear Bearing O-Ring Cartridge Bolt (10 Used) Oil Seal Gear


UPPERSTRUCTURE / Pump Device Disassemble Pump Transmission • Before starting any disassembly or assembly work, carefully read “Precautions for Disassembling and Assembling” shown on page W1-1-1 of this manual. CAUTION: The approximate weight of cartridge (1) is 24 kg (53 lb). 1. Remove socket bolts (6) and remove cartridge (1) and O-ring (2) from the pump transmission. (2 places) ȀȚ 17 mm CAUTION: The approximate weight of cartridge (15) is 34 kg (75 lb). 2. Remove socket bolts (14) and remove cartridge (15) and O-ring (16) from the pump transmission. ȀȚ 17 mm 3. Remove bolts (11), spring washers (12) and remove cover (9), O-ring (10) from the pump transmission. ȀȚ 22 mm CAUTION: The approximate weight of the gear assemblies is as follows: Gear (4) Assembly : 25 kg (55 lb) Gear (18) Assembly: 32 kg (71 lb) 4. Remove gear (4) assembly and gear (18) assembly from case (27). 5. Remove bearings (3, 5) from gear (4) using a press or puller. 6. Remove bearings (17, 19) from gear (18) using a press or puller. 7. Remove bolts (25) and bracket (26).(2 places) ȀȚ 19 mm CAUTION: The approximate weight of case (27) assembly is 360 kg (790 lb). 8. Turn over case (27) assembly. CAUTION: The approximate weight of cartridge (37) is 21 kg (46 lb). 9. Remove bolts (38) and remove cartridge (37) and O-ring (36). ȀȚ 19 mm

W2-2-9


UPPERSTRUCTURE / Pump Device

35

27

30

31

32

33

34

29

28

40

24

20

21

22

23

W144-02-02-008

W2-2-10


UPPERSTRUCTURE / Pump Device CAUTION: The approximate weight of gear (34) assembly is 40 kg (88 lb). 10. Remove gear (34) assembly from case (27). 11. Remove retaining rings (31, 33) from gear (34). Remove coupling (32) using a press or puller. 12. Remove bearings (30, 35) from gear (34) using a press or puller. 13. Remove spacer (29) and disc spring (28) from case (27). CAUTION: The approximate weight of case (27) assembly is 300 kg (660 lb). 14. Turn over case (27) assembly. 15. Remove retaining ring (21) and remove gear (40) using a press. 16. Remove spacers (20, 23) and bearings (22, 24) from case (27) using a puller.

W2-2-11


UPPERSTRUCTURE / Pump Device ASSEMBLE PUMP TRANSMISSION 13

6

7

11, 12

6

7

27 A

1

2

4

33

5

36

37 39

26 25 3

30 29 9 8 32 A

31 10 14

28

B

34 35

Section B

17 15

20

21

16

18

19

38

Section A-A

W144-02-02-007

22 12345678910 -

Cartridge (2 Used) O-Ring (2 Used) Bearing (2 Used) Gear (2 Used) Bearing (2 Used) Socket Bolt (8 Used) Plug (2 Used) Spacer Cover O-Ring

23

24 11 12 13 14 15 16 17 18 19 20 -

40

Bolt (3 Used) Spring Washer (3 Used) Plug Socket Bolt (4 Used) Cartridge O-Ring Bearing Gear Bearing Spacer

21 22 23 24 25 26 27 28 29 30 -

Retaining Ring Bearing Spacer Bearing Bolt (8 Used) Bracket (2 Used) Case Disc Spring Spacer Bearing

W2-2-12

31 32 33 34 35 36 37 38 39 40 -

Retaining Ring Coupling Retaining Ring Gear Bearing O-Ring Cartridge Bolt (10 Used) Oil Seal Gear


UPPERSTRUCTURE / Pump Device Assemble Pump Transmission 1. Install gear (40) in case (27) and place a support under gear (40). NOTE: If gear (40) is not supported, gear (40) will fall off when installing bearing (24), spacer (23) and bearing (22) in case (27). 2. Press bearing (24), spacer (23) and bearing (22) in case (27). Install retaining ring (21) on gear (40). Remove the support under gear (40). 3. Install spacer (20) in case (27). CAUTION: The approximate weight of case (27) assembly is 300 kg (660 lb). 4. Turn over case (27) assembly. 5. Install retaining ring (33), coupling (32) and retaining ring (31) in gear (34). 6. Heat bearings (30, 35) to approximately 90 °C (194 °F) and press them on gear (34). CAUTION: The approximate weight of gear (34) assembly is 40 kg (88 lb). 7. Install disc spring (28) and spacer (29) in case (27). Press gear (34) assembly in case (27). CAUTION: The approximate weight of cartridge (37) is 21 kg (46 lb). 8. Install O-ring (36) on cartridge (37). Apply LOCTITE #262 to bolts (38). Install cartridge (37) on case (27) and tighten bolts (38). ȀȚ 19 mm ȀȚ ȑȑȘ Nxm (12 kgfxm, 87 lbfxft) 9. Apply grease to oil seal (39) lip. Install oil seal (39) in cartridge (37) with the lip towards cartridge (37). CAUTION: The approximate weight of case (27) assembly is 360 kg (790 lb). 10. Turn over case (27) assembly.

W2-2-13


UPPERSTRUCTURE / Pump Device

11, 12

6

6

27

1

2

4

5

A

3

9 8 A

10 14

B

34 Section B

17 15

16

18

19 Section A-A

W144-02-02-007

W2-2-14


UPPERSTRUCTURE / Pump Device 11. Heat bearings (17, 19) to approximately 90 °C (194 °F) and press them on gear (18). 12. Heat bearings (3, 5) to approximately 90 °C (194 °F) and press them on gear (4). CAUTION: The approximate weight of the gear assemblies is as follows: Gear (4) Assembly : 25 kg (55 lb) Gear (18) Assembly: 32 kg (71 lb) 13. Press gear (18) and gear (4) in case (27) keeping the teeth of gear (34) meshed. NOTE: Pressing in case (27) after gear (18) and gear (4) have cooled is recommended. 14. Install spacer (8) in cover (9). Install O-ring (10) on cover (9). Install cover (9) in case (27). Install spring washers (12) and tighten bolts (11). ȀȚ 22 mm ȀȚ 137 Nxm (14 kgfxm, 101 lbfxft)

CAUTION: The approximate weight of cartridge (15) is 34 kg (75 lb). 15. Install O-ring (16) on cartridge (15). Apply LOCTITE #262 to socket bolts (14). Install cartridge (15) on case (27) and tighten socket bolts (14). ȀȚ 17 mm ȀȚ 540 Nxm (55 kgfxm, 400 lbfxft)

CAUTION: The approximate weight of cartridge (1) is 24 kg (53 lb). 16. Install O-ring (2) on cartridge (1). Apply LOCTITE #262 to socket bolts (6). Install cartridge (1) on case (27) and tighten socket bolts (6). ȀȚ 17 mm ȀȚ 540 Nxm (55 kgfxm, 400 lbfxft)

W2-2-15


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