Hitachi ex3500 3 excavatora service repair manual by 1631278

EX3500-3 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 Torque Specification ............................... W1-2-1 Torque Chart .......................................... W1-2-2 Piping joint ............................................. W1-2-6

145W-1-1

(Blank)

145W-1-2

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

DISASSEMBLING Precautions for Disassembling and Assembling

Preparations for Disassembling

• 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

• Precautions for Assembling

Prepare the necessary tools to be used and the area for disassembling work.

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 cylinders 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 staring the engine. 1. Disconnect the contamination sensor plug cable connector from the pump. 2. Open the all stop valves in suction pipings. Loosen the contamination sensor plug: plug hole appears. NOTE: Once the contamination sensor plug is completely removed, hydraulic oil may spout. Take care. : 36 mm 3. Bleed air until only hydraulic oil oozes around the contamination sensor plug thread. 4. Tighten the contamination sensor plug. : 118 N⋅m (12 kgf⋅m) 5. Connect the contamination sensor plug cable connector to the pump. • 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 upper travel motor, swing motor drain plug 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

Contamination Sensor Air Bleed Plug

W115-02-03-157

GENERAL INFORMATION / Precautions for Disassembling and Assembling Floating Seal Precautions

1. In general, replace the floating seal with a new one. If the floating is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. (2) Check the seal ring face (A) for scuffing, scoring, corrosion, deformation or uneven wear.

B W105-03-05-019

(3) Check O-ring (B) for tears, breaks, deformation or hardening. 2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble. (1) Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air. (2) Clean the floating seal and seal mounting bores, as dust on them tends to enter the floating seal when installing it. (3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring.

Correctly

Incorrect

Correctly

(4) After installing the floating seal, check that seal ring surface (C) is parallel with idler 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

D a

C B

a=b

aŇ?b W110-03-05-004

W1-1-3

GENERAL INFORMATION / Precautions for Disassembling and Assembling (Blank)

W1-1-4

GENERAL INFORMATION / Tightening Torque TIGHTENING TORQUE SPECIFICATIONS Descriptions 1 2

Engine cushion rubber mounting bolt Engine bracket mounting bolt

3 4 5 6

Hydraulic oil tank mounting bolt Fuel tank mounting bolt Pump transmission mounting bolt Pump mounting bolt/nut

7 8

Control valve mounting bolt Swing device mounting bolt (Main frame) (Truck frame) Swing motor mounting bolt Battery mounting bolt Cab mounting bolt Cab bed mounting bolt Swing bearing mounting bolt Counterweight mounting bolt Engine unit mounting bolt Engine cover support mounting bolt Radiator mounting bolt Travel device cover mounting bolt (A) (B) (C) Travel motor mounting bolt Upper roller mounting bolt Lower roller mounting bolt Truck pin Side frame mounting bolt Front attachment pin

9 10 11 12 13 14 15 16 17 18

19 20 21 22 23 24

Bolt Dia (mm)

Qty

33 27 u 003/4 30 30 16 20 16 20 33 24 20 6 18 12 56 56 33 16 27 30 39 20 20 24 45 30 56 24 20

4 24 4 12 18 24 40 64 12 56 96 16 24 8 43 60 11 60 32 16 24 56 36 16 48 32 152 68 28 72

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

W1-2-1

Wrench Size (mm) 50 41 28.6 46 46 24 46 24 30 50 36 30 10 27 19 85 85 50 24 41 46 60 30 30 36 70 46 85 36 30

Torque N⋅m

kgf⋅m

lbf⋅ft

2550 1030 441 1420 1420 206 392 206 392 2250 686 392 21 294 108 9800 6860 2550 265 1370 1910 4410 392 392 686 4700 1911 9800 686 392

260 105 45 145 145 21 40 21 40 260 70 40 2 30 11 1000 700 260 27 140 195 450 40 40 70 480 195 1000 70 40

1880 760 325 1050 1050 150 290 150 290 1880 510 290 15 220 80 7230 5060 1880 195 1010 1410 3255 290 290 510 3470 1410 7230 510 290

GENERAL INFORMATION / Tightening Torque 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. Four different types and grades of bolt are employed. Make sure to employ correct bolts and tighten them correctly when assembling the machine or components. Hexagon T Bolt

SA-040

Hexagon H Bolt

Hexagon M Bolt

Socket Bolt

W162-01-01-001

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 Torque 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 Ń° 10 %. 3. Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force. 4. The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application. 5. Make sure that 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

Tighten diagonally 1

1st to 4th

Tighten from center and diagonally 12

6 4

5 2

2nd to 3rd 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. Handtighten 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

Do not bend it round

Bend along edge sharply

Nut and Bolt Lockings

• Lock Plate IMPORTANT: Do not reuse lock plates. Do not try to bend the same point twice.

RIGHT

WRONG

Bend along edge sharply W105-01-01-009

• Cotter Pin IMPORTANT: Do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening. • Lock Wire IMPORTANT: Apply wire to bolts in the bolttightening direction, not in the boltloosening direction.

RIGHT

WRONG

Loosen

WRONG

Tighten

W105-01-01-010

W1-2-4

GENERAL INFORMATION / 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.

Joint Body

Pipe Thread Connection / Union Joint Tightening Torque Specifications

M202-07-051

30° or 37°

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

30° or 37°

Male Union Joint

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.

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

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

GENERAL INFORMATION / Tightening O-Ring Seal Joint O-ring (6) seats against the end face of adaptor (7) to seal pressure oil.

IMPORTANT: (1) Be sure to replace O-ring (6) with a new one when reconnecting. (2) Before tightening union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening union nut (9) with 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

Joint Body

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 (6) 98 (10) 118 (12) 235 (24) 295 (30) 490 (50)

43 72 87 134 215 360

GENERAL INFORMATION / Tightening Screwed-In Connection 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.

PF 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 59 (6) 17, 19 72 98 (10) 19, 22 87 118 (12) 27, 22 134 235 (24) 36, 32 215 295 (30) 41 360 490 (50) 50 490 670 (68) 60 720 980 (100) 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 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.

External Thread

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 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 )

T-Bolt Type

Worm Gear Type

M114-07-042

W1-2-7

M114-07-043

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

WRONG

RIGHT

W105-01-01-011

WRONG

RIGHT 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

GENERAL INFORMATION / Tightening * REFEREVCE: Major Parts to Be Replaced at Regular Intervals. The parts listed below deteriorate as the machine ages and are worn out or fatigued by repeated loads, resulting in possible severe personal injury and/or machine trouble. The service life of these parts can not be detected through machine operation or visual inspection.

Therefore, these parts should be replaced at regular intervals even if no abnormalities are noticed. In case any abnormalities are found on a part at any time regardless of its specified replacement interval, immediately replace the part.

Periodic Replacement Parts

Engine

Basic Machine Hydraulic System

Front-End Attachment

Replacement Intervals

Fuel hose (Fuel tank to filter)

Every 2 years

Fuel hose (Fuel tank to injection pump)

Every 2 years

Heater hose (Heater to engine)

Every 2 years

Pump suction hose

Every 2 years

Pump delivery hose

Every 2 years

Motor line hose

Every 2 years

Cylinder line hose

Every 2 years

Pilot hose

Every 2 years

IMPORTANT: Be sure to replace seals, such as Orings and hose clamp along with replacing hoses. Each hose has an individual service life. If any abnormalities are found during the regular interval check and/or maintenance service, be sure to replace with a new one.

W1-2-9

GENERAL INFORMATION / Tightening (Blank)

W1-2-10

SECTION 2

UPPERSTRUCTURE â&#x20AC;&#x201D;CONTENTSâ&#x20AC;&#x201D; Group 1 Cab

Group 5 Control Valve

Windowpane Dimension ......................... W2-1-1

Remove and Install Control Valve ........... W2-5-1 Disassemble and Assemble

Group 2 Tank

Control Valve ........................................ W2-5-2

Remove and Install Fuel Tank ............................................. W2-2-1 Remove and install

Group 6 Pilot Valve Remove and Install Pilot Valve ............... W2-6-1

Hydraulic Oil Tank ................................ W2-2-1

Disassemble and Assemble Pilot Valve............................................. W2-6-2

Group 3 Pump Device Remove and Install Pump Device ........... W2-3-1

Group 7 Air Drier

Disassemble Main Pump ........................ W2-3-2

Remove and Install Air Drier ................... W2-7-1

Assemble Main Pump............................. W2-3-4

Disassemble Air Drier............................. W2-7-2

Disassemble R1424 Regulator ............... W2-3-8

Assemble Air Drier ................................. W2-7-4

Assemble R1424 Regulator .................. W2-3-10 Disassemble R1129 Regulator ............. W2-3-12 Assemble R1129 Regulator .................. W2-3-14 Maintenace Standard ........................... W2-3-17 Disassemble and Assemble

Group 8 Oil Mist Separator Remove and Install Oil Mist Separator ................................. W2-8-1 Disassemble Oil Mist Separator.............. W2-8-2

Pilot Pump .......................................... W2-3-18

Assemble Oil Mist Separator .................. W2-8-4 Inspection After Assembling ................... W2-8-6

Group 4 Swing Device

Maintenance........................................... W2-8-6

Remove and Install Swing Device........... W2-4-1 Disassemble Swing Device .................... W2-4-2 Assemble Swing Device ......................... W2-4-8 Disassemble Swing Motor .................... W2-4-16 Assemble Swing Motor ......................... W2-4-20 Maintenance Standard ......................... W2-4-24

Group 9 Grease Pump Remove and Install Grease Pump Air Motor ........................ W2-9-1 Disassemblie and Assemble Grease Pump Air Motor ........................ W2-9-2

Group 10 Air Conditioner Charge Air Conditioner With Refrigerant ................................. W2-10-1 Tightening Torque Specification .......... W2-10-10

145W-2-1

(Blank)

145W-2-2

UPPERSTRUCTURE / Cab WINDOWPANE DIMENSIONS Unit: mm

502± 0 2 571±1

(1)

832± 0 2

(3) t=5 Bronze

(4) t=5 Bronze

(2)

832± 1 2

(4) (3) R61

R61

2-R54

2-φ11+0.7 -0

889±1

737±1

2-R5 (2) t=5 Bronze

(1) t=5 Bronze 40

981±1

2-φ11+0.7 -0

38.5

981±1

384 383

729

(160) W145-02-01-001

NOTE: 1 in=0.03937 mm

W2-1-1

UPPERSTRUCTURE / Cab

4-R91

(7) t=8 Sun Blue (5) (7) 1691±1 (6)

1381±1

1611±1

(5) t=6 Bronze 1015±1

Mark Position 50

4-R61

50 1445.5±1

793±1

R (6) t=5 Bronze

Mark Position 50

4-R61

532±1

50 706.5±1 W145-02-01-002

W2-1-2

UPPERSTRUCTURE / Tank REMOVE AND INSTALL FUEL TANK Removal 1. Remove the plug located underneath the fuel tank. Then, open the cock to drain fuel. NOTE: Fuel tank capacity: 1320 US gal (5000 L) 2. Disconnect electrical harness and all piping from the fuel tank. 3. Remove the lubrication device from the fuel tank. CAUTION: Fuel tank weight: 1810 kg (3990 lb) 4. Remove fuel tank mounting bolts, then remove the fuel tank.

Fuel Tank Cock Mounting Bolt

Plug

Fuel Tank Mounting Bolt W145-02-02-001

: 46 mm : 1400 N⋅m (145 kgf⋅m, 1050 lbf⋅ft) Installation 1. Install the fuel tank using mounting bolts. 2. Install the lubrication device to the fuel tank. 3. Connect electrical harness and all piping to the fuel tank.

REMOVE AND INSTALL HYDRAULIC OIL TANK Removal 1. Remove the plug located underneath the hydraulic oil tank. Then, open the cock to drain hydraulic oil. NOTE: Hydraulic tank capacity: 422 US gal (1600 L) 2. Disconnect electrical harness and all piping from the hydraulic oil tank. CAUTION: Hydraulic oil tank weight: 2840 kg (6260 lb) 3. Remove hydraulic oil tank mounting bolts, then remove the hydraulic oil tank.

Hydraulic Oil Tank Plug Mounting Bolt

Cock

Hydraulic Oil Tank Mounting Bolt W145-02-02-002

: 46 mm : 1400 N⋅m (145 kgf⋅m, 1050 lbf⋅ft) Installation 1. Install the hydraulic oil tank using mounting bolts. 2. Connect electrical harness and all piping to the hydraulic oil tank.

W2-2-1

UPPERSTRUCTURE / Tank (Blank)

W2-2-2

UPPERSTRUCTURE / Pump Device REMOVE AND INSTALL PUMP DEVICE CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting work. Preparation 1. Park the machine on a firm, level surface. 2. Stop the engine. Move all control levers to release pressure remaining in the system. Rotate the air release cock on top of the hydraulic oil tank to release any remaining pressure. 3. Close the all stop valves for hydraulic pipings

W2-3-1

UPPERSTRUCTURE / Pump Device Remove Pump Device 1. Disconnect electrical harness and all piping from the pump device. 2. Attach crane to the pump device using a sling. Then, lift and hold the pump device. CAUTION: Pump device weight: 194 kg (428 lb) 3. Remove pump mounting bolts. Then, remove the pump using removing bolts (M12, length 45 mm).

Mounting Bolt

: 24 mm : 206 N⋅m (21 kgf⋅m, 152 lbf⋅ft) Install Pump Device 1. Install the pump using mounting bolts. 2. Connect electrical harness and all piping to the pump. IMPORTANT: Be sure to perform a break-in operation after installing the pump to prevent premature pump seizure. Refer to W2-3-16. W145-02-03-001

W2-3-2

UPPERSTRUCTURE / Pump Device (Blank)

W2-3-3

UPPERSTRUCTURE / Pump Device DISASSEMBLE MAIN PUMP 55

17 16 5

32 43

3,7

8 34 26

48,54

13 4,9

35 37 36 31

14 15 18 23 50

51 2

40 20,24,17

25,11 42

29 28

1,6,10

39 61 44 45

22 57

53,15,14

58 30

31ϡ ϡ 46

48ϡ ϡ 55

Detail B C

Cross Section A-A

Cross Section C-C 12345678910 11 12 13 14 15 16 -

Plug Plug Plug Plug Backup Ring O-Ring O-Ring O-Ring O-Ring Screw Screw Oil Seal Pin Servo Piston Pin Stopper

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 -

Cover Screw Socket Bolt Socket Bolt Screw Nut Screw Socket Bolt Cover Housing Packing O-Ring Socket Bolt Drive Shaft Assembly Drive Shaft

32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 -

W2-3-4

Plunger Assembly Cone Rod Plunger Bearing Retaining Ring Shim Spacer Shim Spacer Bearing Disc Spring Spacer Retainer Screw Center Rod

60 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 -

W115-02-03-024

Cylinder Assembly Plug Cylinder Block Spring Seat Inner Spring Outer Spring Bushing Valve Plate Cover Center Pin Washer Stop Ring Orifice Plug Drive Disc

UPPERSTRUCTURE / Pump Device â&#x20AC;˘ Be sure to thoroughly read â&#x20AC;&#x153;Precautions for Disassembly and Assemblyâ&#x20AC;? on page W1-1-1 before disassembling and assembling. 1. Loosen plug (1) to drain hydraulic oil from the pump. 2. Remove regulator mounting bolts, then remove the regulator. 3. Remove socket bolts (20), then remove cover (55) and valve plate (54) using a crane. 4. Remove cylinder block (49) and center rod (46) from housing (26). 5. Remove socket bolts (19) from cover (55), then remove cover (17). IMPORTANT: Never attempt to remove screw (21) and nut (22). Otherwise, pump flow rate will change. 6. Remove two stoppers (16) from cover (55) using removing bolt (M8, pitch 1.25). 7. Remove screw (18) from servo piston (14), then remove pin (15).

Turn the Nut

ST 1969

8. Remove servo piston (14) from cover (55). 9. Remove socket bolts (29), then remove cover (25) using a plastic hammer. 10. Remove oil seal (12) from cover (25). 11. Remove drive shaft assembly (30) from housing (26) using special tool (ST 1969). 12. Remove screws (45), then remove retainer (44), cone rod (33) and plungers (34) from drive shaft (31). 13. Remove retaining ring (36) and spacer (40) from drive shaft (31). 14. Remove bearing (35), disc spring (42), spacer (38) and bearing (41) from drive shaft (31) using a press.

W2-3-5

W145-02-03-002

UPPERSTRUCTURE / Pump Device ASSEMBLE MAIN PUMP 55

17 16 5

32 43

3,7

8 34 26

48,54

13 4,9

35 37 36 31

14 15 18 23 50

51 2

40 20,24,17

25,11 42

29 28

1,6,10

39 61 44 45

22 57

53,15,14

58 30

31ϡ ϡ 46

48ϡ ϡ 55

Detail B C

Cross Section A-A

Cross Section C-C 12345678910 11 12 13 14 15 16 -

Plug Plug Plug Plug Backup Ring O-Ring O-Ring O-Ring O-Ring Screw Screw Oil Seal Pin Servo Piston Pin Stopper

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 -

Cover Screw Socket Bolt Socket Bolt Screw Nut Screw Socket Bolt Cover Housing Packing O-Ring Socket Bolt Drive Shaft Assembly Drive Shaft

32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 -

W2-3-6

Plunger Assembly Cone Rod Plunger Bearing Retaining Ring Shim Spacer Shim Spacer Bearing Disc Spring Spacer Retainer Screw Center Rod

60 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 -

W115-02-03-024

Cylinder Assembly Plug Cylinder Block Spring Seat Inner Spring Outer Spring Bushing Valve Plate Cover Center Pin Washer Stop Ring Orifice Plug Drive Disc

UPPERSTRUCTURE / Pump Device 1. Measure height (h) of bearing (41). Calculate the required shim thickness using the following formula:

11. Install O-ring (8) and backup ring (5) in the groove on stopper (16), then install stopper (16) into cover (55). 12. Install cover (17) to cover (55) using socket bolts (19).

Required shim thickness = 59.8 mm−(h) mm

: 430 N⋅m (44 kgf⋅m, 318 lbf⋅ft)

13. Install drive shaft assembly (30) into housing (26). W145-02-03-013

2. Heat bearing (41) inner race to 120 °C (248 °F). Install shim (39) and bearing (41) inner race and outer race onto drive shaft (31).

14. Install oil seal (12) and O-ring (28) into cover (25), then install it on housing (26) using socket bolts (29).

3. Install spacer (38), disc spring (42) and spacer (43) onto drive shaft (31). 4. Install bearing (35) outer race onto spacer (43). Place special tool (ST 5066) on bearing (35) outer race. Depress disc spring (42) with special tool (ST 5066) using socket bolts (29). 5. Heat bearing (35) inner race to 120 °C (248 °F). Install bearing (35) inner race onto drive shaft (31) by tapping the inner race with a plastic hammer. 6. Adjust the clearance between bearing (35) inner race and spacer (40) to 0 to 0.1 mm by removing or adding shims (37). NOTE: 1 mm=0.03937 in 7. Install plunger assembly (32) to drive shaft (31) with retainer (44). 8. Align the center of cone rod (33) with drive disc (61) and tighten screw (45). If cone rod (33) does not move smoothly, move retainer (44) slightly to adjust. : 26 N⋅m (2.7 kgf⋅m, 19.5 lbf⋅ft) 9. Apply a film of hydraulic oil to the surface of servo piston (14). Install servo piston (14) into bore of cover (55), then install pin (15) into servo piston (14). 10. Apply LOCKTITE to screw (18) threads, then install it in servo piston (14). : 53 N⋅m (5.4 kgf⋅m, 39.1 lbf⋅ft)

W2-3-7

: 330 N⋅m (34 kgf⋅m, 245 lbf⋅ft)

UPPERSTRUCTURE / Pump Device 55

17 16 5

32 43

3,7

8 34 26

48,54

13 4,9

35 37 36 31

14 15 18 23 50

51 2

40 20,24,17

25,11 42

29 28

1,6,10

39 61 44 45

22 57

53,15,14

58 30

ϡ 46 31ϡ

ϡ 55 48ϡ

Detail B C

Cross Section A-A

Cross Section C-C

W2-3-8

W115-02-03-024

UPPERSTRUCTURE / Pump Device 15. Pull drive shaft assembly (30) using special tool (ST 1969) until spacer (38) comes into contact with cover (25). 16. Attach special tool (ST 6607) to housing (26), and measure housing (26) and center rod (46) distance (a).

ST 1969

Turn the Nut

17. Install center pin (56) on valve plate (54). Install valve plate (54) and cylinder block (49) on cover (55) with the centers of the valve plate and the cylinder block aligned. Hold cylinder block (49) using social tool (ST 6608). 18. Measure distance (b) and (c) and calculate the required thickness (w) of spring seat (50) using the following formula: W145-02-03-003

(a)+(b)−(c)−0.5 mm ≥ (W) ≥ (a)+(b)−(c)−1.0 mm

19. Install outer spring (52), inner spring (51), spring seat (50) and center rod (46) into the center bore of cylinder block (49), then install it into housing (46).

ST 6607

NOTE: When installing plunger assembly (32) into cylinder block (49), tilt the cylinder assembly to the maximum displacement position. Then, start inserting the lower side piston for easy installation. 20. Apply a layer of grease to the sliding surface of cover (55). Install valve plate (54) on cover (55) with pin (15) and bushing (53) centers aligned. 21. Install pin (13) and packing (27) on housing (26). Raise and support cover (55) using a crane. With the center of cylinder block (49) and valve plate (54) aligned, install them using a round bar.

W145-02-03-004

w c

Round Bar: Φ7 mm × Length 200 mm W115-02-03-068

22. Install cover (55) on housing (26) using socket bolts (20). : 430 N⋅m (44 kgf⋅m, 318 lbf⋅ft) 23. Install O-ring on cover (55), then the install regulator to cover (55) using socket bolts. Be sure that the feedback lever engages with pin (15).

W2-3-9

UPPERSTRUCTURE / Pump Device DISASSEMBLE R1424 REGULATOR 67

31 32 33 34

29 28 66 65 27 64 63

62 61

60 59

58 57 56

68 69

55 54

70 35 36 37 38

30 71 Cross Section A

W145-02-03-006

46 43

51 52

W145-02-03-014

42 47

43 45 44 Cross Section B

Cross Section C

W145-02-03-008

W145-02-03-007

Screw Nut Socket Bolt O-Ring Spring Seat Spring Spring Cover O-Ring Sleeve Piston Pin Sleeve Housing Sleeve Spool Spring Seat Spring Spring

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

9 10 11 12 13 14 15

16 17 18 19 20 21 22 23 24 25 W145-02-03-005

12345678910 11 12 13 14 15 16 17 18 -

O-Ring O-Ring Screw Cover Socket Bolt Nut Screw Nut Housing Nut Push Rod Socket Bolt O-Ring Spacer O-Ring Feedback Lever Spring Pin Pin

37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

Spindle Plug O-Ring O-Ring Stopper Seat Poppet Spring Seat Spring Seat O-Ring O-Ring O-Ring Plug O-Ring Plug Housing Screw

W2-3-10

55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71

Nut Socket Bolt O-Ring Bar Piston Spring Seat Spring Housing Spring Seat O-Ring Spool Sleeve Plug Piston O-Ring Plug Plug

UPPERSTRUCTURE / Pump Device • Be sure to thoroughly read “Precautions for Disassembly and Assembly” on page W1-1-1 before disassembling and assembling. 1. Remove socket bolts (30), then remove housing (27). 2. Remove socket bolts (3) and spring cover (7), then remove spring (6) and sleeve (9). IMPORTANT: Never attempt to remove screw (1) and nut (2). Otherwise, pump flow rate will change.

11. Remove piston (59) and bar (58) from housing (53). IMPORTANT: Never attempt to remove screw (54) and nut (55). Otherwise, the relief-oil minimizing control setting will change. 12. Remove spool (65) and sleeve (66) from housing (27). 13. Remove plug (70) and piston (68) from housing (27).

3. Remove socket bolts (23) and cover (22), then remove screw (21), spring (17), spring (18) and spring seat (16). IMPORTANT: Never attempt to remove screw (25) and nut (24). Otherwise, pump flow rate will change. 4. Remove O-ring (47), spring seat (42), poppet (43), spring (44) and seat (46) shown in cross section C. 5. Remove stopper (41), spring seat (42), spring (44), poppet (43) and seat (45) shown in cross section B. 6. Remove spacer (32) and plug (38) shown in cross section A. 7. Remove spindle (37) and pin (36) by softly tapping spring pin (35). Then, remove feedback lever (34). 8. Remove sleeve (9), piston (10), pin (11) and sleeve (12) from housing (13). 9. Remove sleeve (14) and spool (15) from housing (13). 10. Remove socket bolts (56) and housing (53). Then, remove spring seat (60) spring (61) spring seat (63) and housing (62).

W2-3-11

UPPERSTRUCTURE / Pump Device ASSEMBLE R1424 REGULATOR 31 32 33 34

29 28 66 65 27 64 63

62 61

60 59

58 57 56

68 69

55 54

70 35 36 37 38

30 71 Cross Section A

W145-02-03-006

46 43

51 52

W145-02-03-014

42 47

43 45 44 Cross Section B

Cross Section C

W145-02-03-008

W145-02-03-007

Screw Nut Socket Bolt O-Ring Spring Seat Spring Spring Cover O-Ring Sleeve Piston Pin Sleeve Housing Sleeve Spool Spring Seat Spring Spring

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

9 10 11 12 13 14 15

16 17 18 19 20 21 22 23 24 25 W145-02-03-005

12345678910 11 12 13 14 15 16 17 18 -

O-Ring O-Ring Screw Cover Socket Bolt Nut Screw Nut Housing Nut Push Rod Socket Bolt O-Ring Spacer O-Ring Feedback Lever Spring Pin Pin

37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

Spindle Plug O-Ring O-Ring Stopper Seat Poppet Spring Seat Spring Seat O-Ring O-Ring O-Ring Plug O-Ring Plug Housing Screw

W2-3-12

55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71

Nut Socket Bolt O-Ring Bar Piston Spring Seat Spring Housing Spring Seat O-Ring Spool Sleeve Plug Piston O-Ring Plug Plug

UPPERSTRUCTURE / Pump Device 1. Install sleeve (14) and spool (15) into housing (13).

15. Install housing (27) to housing (13) using socket bolts (30).

2. Install spring pin (35) and pin (36) to spindle (37). 3. Install feedback lever (34) to sleeve (14). Then, install spindle to housing (13). Insert spring pin (35) in the bore on feedback lever (34). 4. Install plug (38) and spacer (32) into housing (13). : 170 N⋅m (17 kgf⋅m, 130 lbf⋅ft) 5. Install seat (45), poppet (43), spring (44), spring seat (46) and stopper (41) into housing (13).

: 29 N⋅m (3 kgf⋅m, 29 lbf⋅ft) 16. Tighten push rod (29) until spacer (32) comes into contact with feedback lever (34). Turn push rod (29) back 90 degrees, then tighten nut (28) to secure push rod (29) in position. Check that feedback lever (34) moves smoothly. IMPORTANT: Be sure to purge air from the regulator after installing it on the main pump.

6. Install spring seat (46), spring (44), poppet (43), seat (42) and O-ring (47) into housing (13). 7. Install screw (21), spring seat (16), spring (17) and spring (18) to cover (22), then install cover (22) assembly to housing (13) using socket bolts (23). : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) 8. Install piston (10) and pin (11) into sleeve (9). Apply LOCKTITE to sleeve (12) threads, then install it in sleeve (9). : 33 N⋅m (3.4 kgf⋅m, 24 lbf⋅ft) 9. With pin (11) aligned with spool (15) hole, install sleeve (9) assembly in housing (13). 10. Install spring seat (5) and spring (6) into spring cover (7), then install spring cover (7) assembly to housing (13) using socket bolts (3). : 12 N⋅m (1.2 kgf⋅m, 9 lbf⋅ft) 11. Install piston (68) and plug (70) into housing (27). 12. Install sleeve (66) and spool (65) into housing (27). 13. Install spring seat (63), spring (61) and spring seat (60) into housing (62). 14. Install bar (58) and piston (59) into housing (53). Install housing (53) and housing (62) to housing (27) using socket bolts (56).

W2-3-13

UPPERSTRUCTURE / Pump Device 63

DISASSEMBLE R1129 REGULATOR 30 31 32 33

61 60 59

57 55

64 54 53

65 34 35 36

37 Cross Section A

52 W145-02-03-010

47 48 49

41 43

51 W115-02-03-156

45 46

41 42 44

W145-02-03-012

27 26

Cross Section C

Cross Section B

W145-02-03-011

29 28

24 23 22

11 12 13

14 15 16 17 18 19 20 21 W145-02-03-009

12345678910 11 12 13 14 15 16 17 -

Screw Nut Socket Bolt O-Ring Spring Seat Spring Spring Cover O-Ring Sleeve Pin Housing Sleeve Spool Spring Seat Spring Spring O-Ring

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 -

O-Ring Screw Cover Socket Bolt Nut Screw Nut Socket Bolt Push Rod Nut Plug Plate O-Ring Spacer O-Ring Feedback Lever Spring Pin

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 -

Pin Spindle Stopper O-Ring O-Ring Stopper Spring Seat Spring Poppet Seat Seat O-Ring Piston Spool Nozzle Housing

W2-3-14

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 -

O-Ring Socket Bolt Screw Nut Cover Spring Guide O-Ring Spring Spring Guide Ball Plug O-Ring Socket Bolt O-Ring Cover Socket Bolt

UPPERSTRUCTURE / Pump Device • Be sure to thoroughly read “Precautions for Disassembly and Assembly” on page W1-1-1 before disassembling and assembling.

11. Remove socket bolts (52) and cover (55), then remove spring guide (56), spring (58), spring guide (59) and ball (60). IMPORTANT: Never attempt to remove screw (53) and nut (54). Otherwise, the reducing valve set pressure will change.

1. Remove socket bolts (63) and housing (50). 2. Remove socket bolts (25) and plate (29). 3. Remove socket bolts (3) and spring cover (7), then remove spring (6) and sleeve (9). IMPORTANT: Never attempt to remove screw (1) and nut (2). Otherwise, the pump flow rate will change.

12. Remove socket bolts (66) and cover (65), then remove piston (47) and spool (48) from housing (50).

4. Remove socket bolts (21) and cover (20), then remove screw (19), spring (16), spring (15) and spring seat (14). IMPORTANT: Never attempt to remove screw (23) and nut (24). Otherwise, the driving pump constant-torque-control setting will change. 5. Remove O-ring (46), seat (45), poppet (43), spring (42) and spring seat (41) shown in cross section C. 6. Remove stopper (40), spring seat (41), spring (42), poppet (43) and seat (44) shown in cross section B. 7. Remove spacer (31) and plug (37) shown in cross section A. 8. Remove spindle (36) together with pin (35) by softly tapping spring pin (34). Then, remove feedback lever (33). 9. Remove pin (10) and sleeve (9) from housing (11). 10. Remove sleeve (12) and spool (13) from housing (11).

W2-3-15

UPPERSTRUCTURE / Pump Device 63

ASSEMBLE R1129 REGULATOR 30 31 32 33

61 60 59

57 55

64 54 53

65 34 35 36

37 Cross Section A

52 W145-02-03-010

47 48 49

41 43

51 W115-02-03-156

45 46

41 42 44

W145-02-03-012

27 26

Cross Section C

Cross Section B

W145-02-03-011

29 28

24 23 22

11 12 13

14 15 16 17 18 19 20 21 W145-02-03-009

12345678910 11 12 13 14 15 16 17 -

Screw Nut Socket Bolt O-Ring Spring Seat Spring Spring Cover O-Ring Sleeve Pin Housing Sleeve Spool Spring Seat Spring Spring O-Ring

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 -

O-Ring Screw Cover Socket Bolt Nut Screw Nut Socket Bolt Push Rod Nut Plug Plate O-Ring Spacer O-Ring Feedback Lever Spring Pin

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 -

Pin Spindle Stopper O-Ring O-Ring Stopper Spring Seat Spring Poppet Seat Seat O-Ring Piston Spool Nozzle Housing

W2-3-16

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 -

O-Ring Socket Bolt Screw Nut Cover Spring Guide O-Ring Spring Spring Guide Ball Plug O-Ring Socket Bolt O-Ring Cover Socket Bolt

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