Page 1

EX5500 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 ............................................. W1-2-5

118W-1-1


(Blank)

118W-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 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.

M104-07-021

W1-1-2


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. (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.

Correct

Incorrect

Incorrect

Correct

(4) After installing the floating seal, check that seal ring surface (A) is parallel with idler face (C) by measuring the distances seal ring surface (A) and idler face (C) at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating.

W105-03-05-020

C a

a

A B

b

b

a=b

aŇ?b W110-03-05-004

W1-1-3


GENERAL INFORMATION / 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 damage and the lifted load from slipping. • Lower the temperature of the lifted load to lower than 100 °C (212 °F). If unavoidably lifting a load with a temperature of 100 °C (212 °F) or more, reduce the load weight. • Do not lift acid or alkali chemicals. • Take care not to allow the sling to become wet. The load may slip. • When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced. • When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force. • Avoid using twisted, bound, connected, or hitched slings. • Do not place any object on twisted or bent slings. (Refer to the right illustration.) • When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions. • Avoid dragging slings on the ground, throwing slings or pushing slings with a metal piece. • When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged. • Store the nylon slings indoors so they won’t deteriorate with heat, sun light, or chemicals.

W1-1-4

Correct Eyehole Lifting Method

W102-04-02-016

Incorrect Eyehole Lifting Method W105-04-01-008

Bent Sling

W162-01-01-009


GENERAL INFORMATION / 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. Even if no damage is found, do not use slings older than 7-years.

W162-01-01-003

Fuzz Broken Sewing Thread

W162-01-01-004

Broken Sewing Thread

W162-01-01-005

Broken Sewing Thread

Scoring

Fuzz

Separation of Belt

Scuffing

W162-01-01-006

W162-01-01-007

Broken Warp

W162-01-01-008

W1-1-5


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. Tolerances are indicated as necessary. “Allowable Limit” 1. Machine cannot operate normally with the parts exceeding this dimension installed. 2. Repair or adjustment is impossible if this dimension is exceeded. 3. To maintain high machine availability and to save the repair expense, the machine parts should be repaired or replaced before reaching the “Allowable Limit.” Ȁ

W1-1-6


GENERAL INFORMATION / Tightening Torque TIGHTENING TORQUE SPECIFICATIONS Descriptions 1 2

Engine cushion rubber mounting bolt Engine bracket mounting bolt

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Hydraulic oil tank mounting bolt Fuel tank mounting bolt Pump transmission mounting bolt Pump device mounting bolt Fan drive pump mounting bolt Gear pump mounting bolt Control valve mounting nut Swing device mounting bolt Swing motor mounting bolt Battery mounting bolt Cab mounting bolt Cab bed mounting bolt Swing bearing mounting bolt Counterweight mounting nut Engine bed mounting bolt Oil cooler mounting bolt Radiator mounting nut Fan motor housing mounting bolt Fan motor bracket mounting bolt Travel device mounting bolt

23 24 25 26 27 28

Travel motor mounting bolt Upper roller mounting bolt Lower roller mounting bolt Track pin-retaining bolt Side frame mounting bolt Track guard mounting bolt

29

Travel motor cover mounting bolt (backhoe) Front pin lock bolt (loading shovel)

30

31

N⋅m

kgf⋅m

lbf⋅ft

12 24 8 32 10 22 32 24 8 8 24 56 16 24 8 50 142 14 84 8 8 8 12 24 56 40 46 16 24 56 156 80 22 48 30

3140 1420 740 440 2400 2400 118 690 390 88 390 3140 390 49 295 88 9800 6860 3140 1370 1370 205 88 3140 9800 690 390 740 1910 9800 1910 14700 4710 690 3140

320 145 75 45 245 245 12 70 40 9 40 320 40 5 30 9 1000 700 320 140 140 21 9 320 1000 70 40 75 195 1000 195 1500 480 70 320

2310 1050 540 330 1770 1770 87 510 290 65 290 2310 290 36 215 65 7230 5060 2310 1010 1010 152 65 2310 7230 510 290 540 1410 7230 1410 10850 3470 510 2310

24 20 27

36 8 10

36 30 19

930 390 1030

95 40 105

690 290 760

24 20

20 22

930 390

95 40

690 290

Qty

36 30 22 UNC 3/4 36 36 UNC 1/2 24 20 12 20 36 20 10 18 12 56 56 36 27 27 16 12 36 56 24 20 22 30 56 30 64 45 24 36

Front pin lock bolt (backhoe)

Torque

Wrench Size (mm) 55 46 36 28.6 55 55 19 36 30 19 30 55 30 17 27 19 85 85 55 41 41 24 19 55 85 36 30 32 46 85 46 95 70 36 55

Bolt Dia (mm)

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

(Hexagon bar wrench)

36 30

3. Apply loctite to threads of engine cushion rubber mounting bolts, and lower roller mounting bolts before installing.


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

9

4

1

6

7

14

13

8

5

2

3

10

11

3

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

RIGHT

WRONG

Do not bend it round

Bend along edge sharply

Nut and Bolt Lockings RIGHT

• Lock Plate

RIGHT

WRONG

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

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.

RIGHT

• Lock Wire

RIGHT

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

1

4

3

5

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.

2

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.

7

6

9

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 (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.

PT

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 —CONTENTS— Group 1 Cab

Group 4 Swing Device

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

Remove and Install Swing Device........... W2-4-1 Disassemble Swing Device..................... W2-4-4

Group 2 Pump Device

Assemble Swing Device ......................... W2-4-8

Remove and Install Pump Device ........... W2-2-1

Disassemble Swing Motor .................... W2-4-12

Disassemble Pump Transmission........... W2-2-8

Assemble Swing Motor ......................... W2-4-14

Assemble Pump Transmission ............. W2-2-10

Maintenance Standard.......................... W2-4-18

Disassemble Main Pump ...................... W2-2-12

Valve Unit Construction ........................ W2-4-20

Assemble Main Pump........................... W2-2-18 Maintenance Standard ......................... W2-2-20 Disassemble Main Pump Regulator ...... W2-2-22 Assemble Main Pump Regulator........... W2-2-28 Disassemble Oil Cooler Fan

Group 5 Pilot Valve Remove and Install Front/Swing Pilot Valve ......................... W2-5-1 Remove and Install Travel and

Drive Pump ........................................ W2-2-36 Assemble Oil Cooler Fan

Bucket Open/Close Pilot Valve.............. W2-5-3 Pilot Port Connections ............................ W2-5-5

Drive Pump ........................................ W2-2-38 Maintenace Standard ........................... W2-2-40 Disassemble Oil Cooler Fan

Front/Swing Pilot Valve Construction ...... W2-5-6 Travel and Bucket Open/Close Pilot Valve Construction ........................ W2-5-8

Drive Pump Regulator ........................ W2-2-42

Group 6 DQR Valve

Assemble Oil Cooler Fan Drive Pump Regulator ........................ W2-2-46

Remove and Install DQR Valve............... W2-6-1 DQR Valve Construction ......................... W2-6-4

Group 3 Control Valve Remove and Install Control Valve ........... W2-3-1 Disassemble Control Valve ..................... W2-3-4 Assemble Control Valve ....................... W2-3-12

Group 7 Pilot Shut-Off Valve Remove and Install Pilot Shut-off Valve ............................... W2-7-1 Disassemble Pilot Shut-off Valve ............ W2-7-4 Assemble Pilot Shut-off Valve................. W2-7-6

118W-2-1


Group 8 Solenoid Valve Remove and Install Solenoid Valve......... W2-8-1 Solenoid Valve Construction ................... W2-8-4

Group 9 Oil Cooler Fan Motor Remove and Install Oil Cooler Fan Motor ............................ W2-9-1 Disassemble Oil Cooler Fan Motor ............................ W2-9-4 Assemble Oil Cooler Fan Motor .............. W2-9-6 Maintenance Standard ........................... W2-9-8

Group 10 Compressor Drive Motor Remove and Install Compressor Drive Motor......................................... W2-10-1 Disassemble Compressor Drive Motor......................................... W2-10-4 Assemble Compressor Drive Motor......................................... W2-10-6

Group 11 Air Conditioner Work after Component Replacement .......................................W2-11-1 Add Compressor Oil ..............................W2-11-1 Charge Air Conditioner with Refrigerant ..........................................W2-11-2

118W-2-2


UPPERSTRUCTURE / Cab WINDOWPANE DIMENSION Unit: mm Material: JIS R 3211, ANSI AS2, ECE ANNEX5 or equivalent NOTE: 1 mm = 0.03937 in 1378±1.5

1

6

4-R91

7

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

1679+2.0 -0

2

5 3 4 W117-02-01-001 W117-02-01-002

1369±1.5

4-R61 4-R61

2

3

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

769±1.0

917±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

934±1.0

4

5

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

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

777±1.0

W117-02-01-006

514±1.0 W117-02-01-005

1400±1.0

667±1.0

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

6 848±1.0

4-R61

7

4-R61 Tempered glass Color : Bronze Thickness : 6 mm Chamfer all fringe Corners

185

645±1.0

403±1.0 W117-02-01-008

1296±1.0 W117-02-01-007

W2-1-2


UPPERSTRUCTURE / Pump Device REMOVE AND INSTALL PUMP DEVICE CAUTION: 1. Escaping fluid under pressure can penetrate the skin and eyes,causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. 2. Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting work. 3. Do not quickly loosen the air breather cap on the hydraulic oil tank. The air breather cap may fly off due to internal pressure. Always turn the air breather cap slowly to release any remaining pressure before removing it.

Preparation: 1. Park the machine on a level solid surface. Lower the front attachment to the ground.

1

2 3

W118-02-03-018

1 Port

4

2. Stop the engine. Turn the air breather cap on the hydraulic oil tank approximately 30° counterclockwise to release any remaining pressure. 3. Close all hydraulic line stop valves. 4. Remove socket bolt (2) from one hydraulic tank air breather cap to remove air breather cap (1). Remove filter (3). Wind an adhesive tape around bayonet assembly (4) approx. one and half turns so that the port is plugged. Reinstall filter (3) and air breather cap (1) to the original position.

W118-02-05-001

4. Remove another side air breather cap (1). Connect a vacuum pump. Operate the vacuum pump continuously to create negative pressure in the hydraulic oil tank. NOTE: Keep the vacuum pump running continuously while working on the hydraulic system.

T142-05-03-007

IMPORTANT: After completing the work, be sure to remove the adhesive tape from bayonet assembly (4). T142-05-03-008

W2-2-1


UPPERSTRUCTURE / Pump Device DISASSEMBLE MAIN PUMP REGULATOR 10

9

11

12

13

8

1

33

2

14

4

3

15

16

5

17

7

6

22

19

18

20

24

21

25 29 26 27

28

34

35

36 54

55

57

56

58

59

30

32

62

61

60

31

53

43 42

23

40

41

44

45

39

74 38

46

37

48

51

47

52 67

49 50

68

69

70

71

72

75

73

78 77

66

Serial Number 000105 and later

79 80

63

81

98

82

97

64

76

65

83

84

85 89 86 90 87 93 88 94

96 95 91 92

56

57

58

59

60

61

62

55 54 47

48

49

53

Serial Number from 000101 to 000104

44

99

46

45

50

W118-02-02-009

W2-2-22


UPPERSTRUCTURE / Pump Device

12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 -

Pin Sleeve O-Ring O-Ring Sleeve Compensating Piston Compensating Rod Spring Seat Spring Spring Piston Spring Seat O-Ring Retaining Ring Spring Seat Spring Spring Retaining Ring Sleeve Spool Pin Lever Feedback Lever Pin Pin

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 -

Lever Pin Pilot Piston Spring Seat Spring Spring Seat O-Ring Socket Bolt (4 Used) Cover Cover O-Ring Stopper Ball Seat O-Ring O-Ring Plug Plug Nut Screw O-Ring Sleeve Piston Spool Plug (2 Used)

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 -

O-Ring Pin Cover Spring Seat Spring Spring Spring Seat O-Ring Cover Socket Bolt (2 Used) Lock Nut Adjusting Screw Cover Socket Bolt (2 Used) Socket Bolt (2 Used) Socket Bolt (2 Used) Socket Bolt (2 Used) O-Ring O-Ring Adjusting Screw Adjusting Screw Lock Nut O-Ring Plug Cover

W2-2-23

76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 -

Lock Nut Adjusting Screw Lock Nut Socket Bolt (4 Used) Casing Pin Support Plug O-Ring Lock Ring Pin Support Plug O-Ring Lock Ring Pin O-Ring Stopper Ball Seat O-Ring O-Ring O-Ring O-Ring Plug Washer


UPPERSTRUCTURE / Pump Device

10

9

11

12

13

8 5 1

6

2

29

30

31

32

17 33 34

35

36 54

55

57

56

58

59

62

61

60

53 40

44

45

39

75 38

46

37

48

51

47

70

52

71

72

78

67

49

77

66

Serial Number 000105 and later

76

79 80

63 97

64 65

96 95

56

57

58

59

60

61

62

55 54 47

48

49

53

Serial Number from 000101 to 000104

46

45

44

W118-02-02-009

W2-2-24


UPPERSTRUCTURE / Pump Device Disassemble Main Pump Regulator 1. Remove socket bolts (66) and (67) to remove the regulators. : 6 mm 2. Remove socket bolts (33). Remove cover (34), O-ring (40), cover (35), O-ring (36), cover (53), Oring (51), and pin (52). : 5 mm 3. Remove stopper (37), ball (38), and seat (39) from cover (35). 4. Serial/No. Up to 000104: Remove socket bolts (60) from cover (53). Remove cover (59), O-ring (58), spring seat (57), spring (56), spring (55), spring seat (54), spool (49), piston (48) and sleeve (47). Serial/No. 000105 and later: Remove socket bolts (60) from cover (53). Remove cover 59), O-ring (58), spring seat (57), spring (56), spring (55) and spring seat (54). Remove nut (44), screw (45), O-ring (46), piston (48), spool (49) and sleeve (47) from cover (53).

5. Remove socket bolts (79) from casing (80). Remove cover (75), spring seat (12), piston (11), spring (10), spring (9), spring seat (8), spring seat (31), spring (30), and spring seat (29). IMPORTANT: Never attempt to remove adjusting screw (70), lock nut (76), adjusting screw (71) and lock nut (72) from cover (75). Setting for the power reduce control and power increase controls may be changed. Also, never attempt to remove adjusting screw (77) and lock nut (78) from cover (75). Setting for the flow control may be altered. : 5 mm 6. Remove socket bolts (64) and (65) from casing (80). Remove cover (63), O-rings (95), (96), and (97), spring (17), pin (1), sleeve (2), sleeve (5) and compensating piston (6).

IMPORTANT: Never attempt to remove lock nut (61) and adjusting screw (62) from cover (59). Setting for the relief oil flow minimizing control may be changed. : 5 mm

W2-2-25

: 5 mm


UPPERSTRUCTURE / Pump Device

7 22

19

14

15

16

20

23

24 26 27

21

17 28

Serial Number 000105 and later

80

81

82 84

85 86 88

Serial Number from 000101 to 000104

W118-02-02-009

W2-2-26


UPPERSTRUCTURE / Pump Device 7. Remove retaining ring (14) to remove spring seat (15), spring (16), spring (17), and sleeve (19).

8. Remove lock rings (84) and (88) from casing (80). Remove support plugs (82) and (86) and pin (85) using a M6 bolt.

9. Remove lever (26) from casing (80) with a pair of tweezers. IMPORTANT: Do not remove pin (27). 10. Remove pin (24) using a thin copper bar (less than dia. 4). Remove feedback lever (23). IMPORTANT: Take care not to hit pin (24) against lever (22) when pulling it out. 11. Remove lever (22) from casing (80). IMPORTANT: Do not remove pins(81) and (21) when removing lever (22). 12. Remove pilot piston (28), spool (20), and compensating rod (7) from casing (80).

W2-2-27


UPPERSTRUCTURE / Pump Device ASSEMBLE MAIN PUMP REGULATOR

79

36

51

A

37

38 39

C

33

40

A’

B

C’

53

Section A−B 97

16 18 19 20 24 81 22

8

11

9

73 68 74

34 82 83

69

10

17 15

W117-02-02-004

35

84

75 76

14 3 1

70 72

2

71 86 87 4

6

5

7

23

21

90

89

12 13

88 W117-02-02-023

W117-02-02-007

63

Section A−A’

80

28 85

25

26

27

30

31

32

64

78

96

65

77

29 W117-02-02-006

Section C-C (Serial Number from 000101 to 000104)

Section C-C (Serial Number 000105 and later)

53

59 60

46 44 61

45

46

53

59

50 44

60

45

61

62

99

48 47

49

54 55 56 57

62

48 47

58 W118-02-02-011

W2-2-28

49

54 55 56 57

58 W118-02-02-010


UPPERSTRUCTURE / Pump Device

12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 -

Pin Sleeve O-Ring O-Ring Sleeve Compensating Piston Compensating Rod Spring Seat Spring Spring Piston Spring Seat O-Ring Retaining Ring Spring Seat Spring Spring Retaining Ring Sleeve Spool Pin Lever Feedback Lever Pin Pin

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 -

Lever Pin Pilot Piston Spring Seat Spring Spring Seat O-Ring Socket Bolt (4 Used) Cover Cover O-Ring Stopper Ball Seat O-Ring ∗ O-Ring ∗ Plug ∗ Plug Nut Screw O-Ring Sleeve Piston Spool Plug (2 Used)

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 -

O-Ring Pin Cover Spring Seat Spring Spring Spring Seat O-Ring Cover Socket Bolt (2 Used) Lock Nut Adjusting Screw Cover Socket Bolt (2 Used) Socket Bolt (2 Used) Socket Bolt (2 Used) ∗ Socket Bolt (2 Used) O-Ring O-Ring Adjusting Screw Adjusting Screw Lock Nut O-Ring Plug Cover

NOTE: For the part names with mark ∗, see page W2-2-22.

W2-2-29

76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 -

Lock Nut Adjusting Screw Lock Nut Socket Bolt (4 Used) Casing Pin Support Plug O-Ring Lock Ring ∗ Pin Support Plug O-Ring Lock Ring Pin O-Ring ∗ Stopper ∗ Ball ∗ Seat ∗ O-Ring ∗ O-Ring O-Ring O-Ring ∗ Plug Washer


UPPERSTRUCTURE / Pump Device A

A’

C

B

C’

W117-02-02-004

Section A−B 97

19 20 24

16

82 83

22

84

17 15 14 3 1 2 86 87 4

6

5

7

23

21

88 W117-02-02-023

W117-02-02-007

63

Section A−A’

80

28 85

26

27

64 96

65

W117-02-02-006

Section C-C (Serial Number from 000101 to 000104)

Section C-C (Serial Number 000105 and later)

W118-02-02-011

W2-2-30

W118-02-02-010


UPPERSTRUCTURE / Pump Device Assemble Regulator 8. Install spring (17), spring (16), spring seat (15), and retaining ring (14) onto spool (20).

1. Install compensating rod (7) into casing (80). 2. Attach pin (21) into the designated hole on lever (22). Install lever (22) by inserting pin (21) into the groove on compensating rod (7) and, at the same time, by inserting pin (81), which is already attached on lever (22), into the designated hole on casing (80). 3. Insert sleeve (19) and spool (20) into casing (80).

9. Install compensating piston (6), sleeve (5), O-ring (4), O-ring (3), sleeve (2), and pin (85) into casing (80). 10. Install O-rings (95), (96), and (97) onto casing (80). Install cover (63) using socket bolts (64) and (65).

IMPORTANT: Be sure to install spool (20) in the correct direction. Also, confirm that spool (20) moves smoothly in the casing. 4. Install feedback lever (23), aligning its pin hole with that on spool (20). Insert pin (24) into the pin hole. IMPORTANT: Be sure to install feedback lever (23) in the correct direction. 5. Insert pilot piston (28) into casing (80). IMPORTANT: Confirm that pilot piston (28) moves smoothly in casing (80). 6. Install lever (26) so that the lever attached pin (27) fits in the groove on pilot piston (28). Install support plug (86) so that pin (85) on the support plug fits into the hole on lever (26). Install O-ring (87) and lock ring (88) onto support plug (86). 7. Install adjusting plug (82), O-ring (83), and lock ring (84) onto casing (80).

W2-2-31

: 5 mm : 11.5 Nâ‹…m (1.2 kgfâ‹…m, 8.7 lbfâ‹…ft)


UPPERSTRUCTURE / Pump Device 79

36

51

A

37

38 39

C

33

40

A’

B

C’

53

Section A−B 8

9

10

W117-02-02-004

35

34

11 75

12

W117-02-02-023

W117-02-02-007

80

Section A−A’

30

31

29 W117-02-02-006

Section C-C (Serial Number from 000101 to 000104)

Section C-C (Serial Number 000105 and later)

53

59 60

53

46

59

44

60

45

99

48 47

49

54 55 56 57

48 47

58 W118-02-02-011

W2-2-32

49

54 55 56 57

58 W118-02-02-010


UPPERSTRUCTURE / Pump Device 11. Install spring seat (29), spring (30), and spring seat (31) into casing (80). 12. Install spring seat (8), spring (9), and spring (10) into casing (80). 13. Install spring seat (12) and seat (11) into cover (75). Install cover (75) onto casing (80). : 5 mm : 11.5 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft) 14. Serial/Number Up to 000104: Install sleeve (47), piston (48), spool (49), spring seat (54), spring (55), spring (56), spring seat (57), and O-ring (58) into cover (53). Install cover (59) onto cover (53) using socket bolts (60). Serial/Number 000105 or after: Install spring seat (54), spring (55), spring (56), spring seat (57), and O-ring (58) into cover (53). Install cover (59) onto cover (53) using socket bolts (60). Install sleeve (47), spool (49), piston (48), O-ring (46), screw (45), washer (99), and nut (44) int cover (53). 15. Install O-ring (36), O-ring (51) and pin (52) onto cover (53). Install seat (39), ball (38), and stopper (37) into cover (35). Install O-ring (40) onto cover (35). 16. Assemble covers (53), (35), and (34). Install them onto casing (80) using socket bolts (33). : 5 mm : 11.5 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)

W2-2-33


UPPERSTRUCTURE / Pump Device (Blank)

W2-2-34


UPPERSTRUCTURE / Pump Device DISASSEMBLE AND ASSEMBLE 4-UNIT PUMP A

B

C

D

T117-02-01-017

Left Engine A-

Oil Cooler Fan Drive Pump (Plunger Pump)

C-

B-

Pilot Pump (Tumdem Gear Pump: Transmission Side)

D-

Air Con. Compressor Drive Pump (Tumdem Gar Pump: Tip End) Transmission Lubricating Pump (Gear Pump)

CD-

Hydraulic Generator Drive Pump Transmission Lubricating Pump (Gear Pump)

Right Engine AB-

Oil Cooler Fan Drive Pump (Plunger Pump) Pilot Pump (Tumdem Gear Pump: Transmission Side)

W2-2-35


UPPERSTRUCTURE / Pump Device DISASSEMBLE OIL COOLER FAN DRIVE PUMP

21 22

20 24

19

11

12

13

14

15

16

17

23

25

18

26

27

10

6

7

8

1

3

29 30

9

54 53

71

5 2

28

31

4

32 47

48

49

50 51

52

46 45

34

35

37 36

39 38

40

41

42

43

56

44 67 70

69

55

66

68 60 61 62

33 65

63 64

57

58

59

W118-02-02-007

12345678910 11 12 13 14 15 16 17 18 -

Socket Bolt (4 Used) Cover O-Ring Oil Seal Shaft Spacer Bearing Spacer Retaining Ring Cover Nut Adjusting Screw Spring O-Ring Stopper Backup Ring O-Ring Housing

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

Displacement Angle Shift Pin Regulator Socket Bolt (4 Used) Stopper Backup Ring O-Ring Servo Piston O-Ring O-Ring Plug Lock Nut Eye Bolt Plug Socket Bolt (4 Used) Swash Plate Bushing Shoe Plate Shoe (9 Used)

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

Plunger (9 Used) Retainer Spherical Bushing Spacer Spring (9 Used) Cylinder Block Valve Plate Needle Bearing O-Ring Stopper Steel Ball Seat Valve Cover Plug (3 Used) Adjusting Screw Nut Plate Socket Bolt (4 Used)

W2-2-36

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

O-Ring Coupling Stopper Steel Ball Seat Plug O-Ring (4 Used) Casing Plug Socket Bolt O-Ring Plug O-Ring Plug Spring Pin (4 Used) Pin O-Ring (2 Used)


UPPERSTRUCTURE / Pump Device Disassemble Oil Cooler Fan Drive Pump IMPORTANT: Never attempt to remove adjusting screw (12), nut (11), adjusting screw (51) and nut (52). The set flow rate may be changed. 1. Remove plug (68) and O-ring (67) to drain hydraulic oil from the pump.

8. Tap on cover (10) using a plastic hammer to remove it. Remove O-ring (14) and spring (13) at the same time. 9. Remove swash plate (33) and shoe plate (35) from housing (18). 10. Remove stopper (15), stopper (22) and servo piston (25) from housing (18).

: 36 mm 2. Remove socket bolts (21) to remove regulator (20).

NOTE: As LOCTITE has been applied on the contacting part between servo piston (25) and displacement angle shift pin (19), do not separate them unless required.

: 6 mm 3. Turn the housing (18) over so that the regulator mounting side is on the bottom. Remove socket bolts (54) (4 used) to remove plate (53), O-ring (55) and coupling (56).

11. Tap on the end of shaft (5) using a plastic hammer to remove it from cover (10). Remove oil seal (4) at the same time. 12. Remove retaining ring (9), spacer (8), bearing (7), and spacer (6) from shaft (5).

: 10 mm 4. Remove socket bolts (32) to remove valve cover (49) from housing (18). IMPORTANT: Valve plate (43) may drop when removing valve cover (49). Take care not to drop valve plate (43). 5. Remove O-ring (45), stopper (46), steel ball (47), seat (48), valve plate (43), pin (70), spring pin (69), socket bolts (64), casing (62), stopper (57), steel ball (58), and seat (59) from valve cover (49). IMPORTANT: Do not remove needle bearing (44) unless required. 6. Remove cylinder block (42), spring (41) (9 used), spacer (40), spherical bushing (39), retainer (38), plungers (37) (9 used), and shoes (36) from housing (18). 7. Remove socket bolts (1) to remove cover (2) and O-ring (3). : 6 mm

W2-2-37


UPPERSTRUCTURE / Pump Device ASSEMBLE OIL COOLER FAN DRIVE PUMP

17 16

15 35 25 33 19

18

34

24 22 23

45 43 52 51

53

10 11 12 13 54

14 1 6

55

5 56 4 2 3 32 W117-02-02-014

7

1 - Socket Bolt (4 Used) 2345678910 11 12 13 14 15 16 17 18 -

Cover O-Ring Oil Seal Shaft Spacer Bearing Spacer Retaining Ring Cover Nut Adjusting Screw Spring O-Ring Stopper Backup Ring O-Ring Housing

8

9

38

36

19 - Displacement Angle Shift Pin 20 - ∗ Regulator 21 - ∗ Socket Bolt (4 Used) 22 - Stopper 23 - Backup Ring 24 - O-Ring 25 - Servo Piston 26 - O-Ring 27 - O-Ring 28 - Plug 29 - Lock Nut 30 - Eye Bolt 31 - Plug 32 - Socket Bolt (4 Used) 33 - Swash Plate 34 - Bushing 35 - Shoe Plate 36 - Shoe (9 Used)

37

39 40

41

42

69 70

44

49

37 - Plunger (9 Used)

55 - O-Ring

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

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

Retainer Spherical Bushing Spacer Spring (9 Used) Cylinder Block Valve Plate Needle Bearing O-Ring Stopper Steel Ball Seat Valve Cover Plug (3 Used) Adjusting Screw Nut Plate Socket Bolt (4 Used)

NOTE: For the part names with mark ∗, see page W2-2-36.

W2-2-38

Coupling Stopper Steel Ball Seat Plug O-Ring (4 Used) Casing Plug Socket Bolt O-Ring Plug O-Ring Plug Spring Pin (4 Used) Pin O-Ring (2 Used)


UPPERSTRUCTURE / Pump Device Assemble Fan Drive Pump 1. Install displacement angle shift pin (19), servo piston (25), stopper (22) and stopper (15) into housing (18). 2. If displacement angle shift pin (19) has been separated from servo piston (25), apply LOCTITE to the threaded part of servo piston (25).

3. Place housing (18) on a workbench with the regulator mounting side on the bottom. Attach the shoe plate (35) attached swash plate (33) to displacement angle shift pin (19).

8. Install valve cover (49) onto housing (18) using socket bolts (32). : 17 mm : 430 N⋅m (44 kgf⋅m, 320 lbf⋅ft) 9. Install coupling (56) onto shaft (5). Install O-ring (55) and plate (53) onto valve cover (49) using socket bolts (54). : 10 mm : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) 10. Install regulator (20) using socket bolts (21).

IMPORTANT: Check if swash plate (33) moves smoothly after installing. 4. Install spacer (6), bearing (7), spacer (8), and retaining ring (9) onto shaft (5). Install shaft (5) into cover (10).

5. Install O-ring (3) onto cover (2). Install oil seal (4) and cover (2) onto cover (10) using socket bolts (1). : 6 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) 6. Install spring (41), spacer (40), spherical bushing (39), retainer (38), plungers (37) and shoes (33) into cylinder block (42). Install cylinder block (42) onto shaft (5), aligning splines. 7. Install pin (70), valve plate (43), O-ring (45), spring pin (69), stopper (46), steel ball (47), seat (48), stopper (57), steel ball (58), seat (59), casing (62), and socket bolt (64) onto valve cover (49).

W2-2-39


UPPERSTRUCTURE / Pump Device

7 6 8 5

4 3 9 2

1

10 W118-02-02-005

1 - Bolt 2 - Engine Bracket 3 - Engine Bracket Mounting Bolt

4 - Lifting Bracket 5 - Bolt 6 - Pump Transmission Mounting Bolt

7 - Step 8 - Pump Transmission

9 - Engine 10 - Frame

(Left Engine)

ČˆRight Engineȉ

Main Pump 3 (Transmission Side) Main Pump 4 (Outer Side)

12

Main Pump 9 (Transmission Side) Main Pump 10 (Outer Side)

11

4-Unit Pump

Main Pump 7 (Transmission Side) Main Pump 8 (Outer Side)

Main Pump 11 (Transmission Side) Main Pump 12 (Outer Side) 4-Unit Pump T117-02-01-001

W2-2-2

Main Pump 1 (Transmission Side) Main Pump 2 (Outer Side)

Main Pump 5 (Transmission Side) Main Pump 6 (Outer Side) T117-02-01-001


UPPERSTRUCTURE / Pump Device Removal 1. Disconnect all hydraulic lines and electric wires from the hydraulic pumps and transmission. 2. Remove bolts (5) to remove step (7). : 19 mm IMPORTANT: Engine bracket (2) is installed on pump transmission (8). Install supporters (Width: 55 mm, Length: 130 mm, Height: 650 mm) between engine (9) and frame (10) when removing the pump transmission so that engine (9) does not fall.

Wrench Size ϖ17 mm ϖ19 mm ϖ19 mm ϖ22 mm ϖ27 mm ϖ30 mm ϖ36 mm ϖ14 mm

Remarks Hydraulic Lines (Joint) Hydraulic Lines Bolts Hydraulic Lines (Joint) Hydraulic Lines Hydraulic Lines (Joint) Hydraulic Lines Socket Bolts

3. Attach chains to lifting brackets (4) (2 used) and straps around the main pumps to hold the pump device with a crane. CAUTION: Pump device weight: 2200 kg (4850 lb) 4. Remove pump transmission mounting bolts (6) and bolts (1), and engine bracket mounting bolts (3). Lift to remove the pump device using a crane. CAUTION: Main pump weight: 300 kg (660 lb) 4-Unit pump weight: 100 kg (220 lb) 5. Remove each component pump from the pump transmission using a crane. : 17 mm : 36 mm

W2-2-3

Wrench Size

Remarks

ϖ3/4 inch Bolt (6) ϖ28 mm Bolt (1) ϖ55 mm Bolt (3)


UPPERSTRUCTURE / Pump Device

7 6 8 5

4 3 9 2

1

10 W118-02-02-005

1 - Bolt 2 - Engine Bracket 3 - Engine Bracket Mounting Bolt

4 - Lifting Bracket 5 - Bolt 6 - Pump Transmission Mounting Bolt

7 - Step 8 - Pump Transmission

9 - Engine 10 - Frame

(Left Engine)

ČˆRight Engineȉ

Main Pump 3 (Transmission Side) Main Pump 4 (Outer Side)

12

Main Pump 9 (Transmission Side) Main Pump 10 (Outer Side)

11

4-Unit Pump

Main Pump 7 (Transmission Side) Main Pump 8 (Outer Side)

Main Pump 11 (Transmission Side) Main Pump 12 (Outer Side) 4-Unit Pump T117-02-01-001

W2-2-4

Main Pump 1 (Transmission Side) Main Pump 2 (Outer Side)

Main Pump 5 (Transmission Side) Main Pump 6 (Outer Side) T117-02-01-001


UPPERSTRUCTURE / Pump Device Installation CAUTION: Main pump weight: 300 kg (660 lb) 4-Unit pump weight: 100 kg (220 lb) 1. Install each component pump onto the pump transmission (8), aligning the splines of the pumps and transmission. : 17 mm : 540 Nxm (55 kgfxm, 400 lbf⋅ft) : 36 mm : 690 Nxm (70 kgfxm, 510 lbf⋅ft) CAUTION: Pump device weight: 2200 kg (4850 lb) 2. Install pump transmission (8) onto the engine shaft, aligning the splines and tighten the pump transmission mounting bolts (6). Install engine brackets (2) on the pump transmission (8) and tighten the engine bracket mounting bolts (1 and 3). 3. Remove the supports installed between the engine and the mainframe to prevent the engine from falling. 4. Secure step (7) with bolts (5). : 19 mm : 88 Nxm (9 kgfxm, 65 lbf⋅ft) 5. Connect all hydraulic lines and electric wires to the pumps and transmission. 6. Bleed air from the pumps. (Refer to the next page.) IMPORTANT: Prevent pump seizure from occurring. Be sure to perform breakin operation after installing the pumps. 7. Run the engine at slow idle for 20 minutes. Check for oil leaks during the engine idling operation. 8. Increase the engine speed to the maximum speed. Slowly operate the boom from stroke end to stroke end repeatedly for 20 minutes.

W2-2-5

Wrench Size

Tightening Toque N⋅m

kgf⋅m

Remarks

lbf⋅ft

ϖ3/4 inch 118 12 87 Bolt (6) ϖ28 mm 440 45 330 Bolt (1) ϖ55 mm 3140 320 2310 Bolt (3)

Wrench Size

Tightening Toque N⋅m

kgf⋅m

lbf⋅ft

ϖ17 mm

-

-

-

ϖ19 mm ϖ19 mm

44 88

4.5 9

32.5 65

ϖ22 mm

-

-

-

ϖ27 mm

118

12

87

ϖ30 mm

-

-

-

ϖ36 mm ϖ14 mm

235 265

24 27

175 195

Remarks Hydraulic lines (Joint) Hydraulic lines Bolts Hydraulic lines (Joint) Hydraulic lines Hydraulic lines (Joint) Hydraulic lines Socket Bolts


UPPERSTRUCTURE / Pump Device • Main Pump Air Bleeding Procedure IMPORTANT: Never loosen the pipe completely. Hydraulic oil will spout. 1

1. Loosen pipe connector (1) 2 to 3 turns. : 17 mm 2. Start the engine and run at slow idle. Purge air from the main pump until oil flows out from pipe connector (1).

1

3. Stop the engine. Tighten pipe connector (1). : 17 mm : 34 Nxm (3.5 kgfxm, 25.5 lbf⋅ft) M117-07-118

• Oil Cooler Fan Drive Pump Air Bleeding Procedure IMPORTANT: Never loosen drain hose plug (2) completely. Hydraulic oil will sport.

2

1. Loosen drain hose connector (2) 2 to 3 turns. : 27 mm 2. Start the engine and run at slow idle. Purge air from the main pump until only hydraulic oil flows out from drain hose connector (2) threads. M117-07-163

3. Stop the engine and tighten drain hose plug (2). : 27 mm : 118 Nxm (12 kgfxm, 87 lbf⋅ft)

Oil Cooler Fan Drive Pump

T117-02-01-017

W2-2-6


UPPERSTRUCTURE / Pump Device (Blank)

W2-2-7


UPPERSTRUCTURE / Pump Device DISASSEMBLE PUMP TRANSMISSION 1

2

3 4 5 6 7 8 9 Pump Side

10 14 15 16 26 17

25

18 19

23 20

21

16

27

11

24

Engine Side

22

28 29 12

30 31 32

33

13

W118-02-02-006

1 2 3 4 5 6 7 8 9

-

Bolt (6 Used) Cover Spacer Disc Spring Spacer Roller Bearing Retaining Ring Stopper Gear

10 11 12 13 14 15 16 17 18

-

Roller Bearing Case Cover Bolt (6 Used) Bolt (31 Used) Washer Spring (31 Used) Knock Pin (2 Used) Spacer Ball Bearing

19 20 21 22 23 24 25 26 27

- Gear - Spacer - Retaining Ring - Ball Bearing - Elbow - Adapter - Reducer - Air Breather - Case

W2-2-8

28 29 30 31 32 33

-

Spacer (3 Used) Ball Bearing (3 Used) Gear (3 Used) Spacer (3 Used) Retaining Ring (3 Used) Ball Bearing (3 Used)


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Hitachi ex5500 excavator service repair manual  
Hitachi ex5500 excavator service repair manual  
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