Page 1

EX550-5, EX600H-5 Workshop Manual


SECTION 1

GENERAL INFORMATION —CONTENTS— Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling........................................... W1-1-1 Maintenance Standard Terminology .......................................... W1-1-4

Group 2 Tightening Tightening Torque Specification.............. W1-2-1 Torque Chart .......................................... W1-2-3 Piping Joint ............................................ W1-2-6

167W-1-1


(Blank)

167W-1-2


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

DISASSEMBLING

Precautions for Disassembling and Assembling

• Clean the Machine

• Precautions for Disassembling • To prevent dirt contamination, cap or plug all removed pipes. • Before disassembling, clean the exterior of the components and place 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 purchasing unnecessary parts. 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). • Contamination or clogging of filters and oil, water or air leaks, if any. • Capacities and condition of lubricants. • Loose or damaged parts.

• Precautions for Assembling

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

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 (upper side) / hose on travel motor / swing motor removed, fill the motor case with hydraulic oil.

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

W1-1-2

M104-07-021


GENERAL INFORMATION / Precautions for Disassembling and Assembling Precautions for Handling Floating Seal 1. In general, replace the floating seal with a new one after disassembling. If the floating is to be reused, follow these procedures:

A

(1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of card-board to protect surfaces. (2) Check slide surface (C) on seal ring (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 leaks 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. Check the bore surface for scuffing or scoring by touching the surface with finger.

Correctly

Incorrectly

(3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring. (4) After installing the floating seal, check that seal surface (C) is parallel with idler face (D) by measuring the distances (a) and (b) as illustrated. If these distances differ, correct the O-ring seating.

W105-03-05-020

D

Correct a

Incorrect a

C B

b a=b

b a≠b W110-03-05-004

W1-1-3


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

W1-1-4


GENERAL INFORMATION / Tightening TIGHTENING TORQUE SPECIFICATIONS Bolt and Nut on Base Machine Standard Torques Torque Specifications Torque

Bolt Dia mm

Q’ty

Wrench Size mm

N⋅m

kgf⋅m

lbf⋅ft

16

2

24

205

21

152

16

2

24

205

21

152

22

2

32

540

55

400

16

4

24

205

21

152

Radiator mounting bolt

16

4

24

205

21

152

3

Hydraulic oil tank mounting bolt

16

8

24

205

21

152

4

Fuel tank mounting bolt

16

8

24

205

21

152

5

ORS fittings for hydraulic hoses and piping

1-3/16-12UNF

36

175

18

130

1-7/16-12UNF

41

205

21

152

No.

Descriptions

1

Engine cushion Engine cushion rubber rubber mounting Front Cushion rubber-machine bolt Engine cushion rubber Rear Cushion rubber-machine

2

6

Pump transmission mounting bolt

7/16-14UNF

14

16

69

7

51

7

Pump device mounting bolt

20

8

30

390

40

290

8

Control valve mounting bolt

20

4

30

390

40

290

9

Swing device mounting bolt

22

26

32

740

75

540

Ring gear housing mounting bolt

18

24

14

295

30

215

10 Swing motor mounting bolt (hexagonal wrench)

12

16

10

88

9

65

11 Battery mounting nut

12

2

19

34

3.5

25.5

STD, LC

16

4

24

205

21

152

H, LCH

16

6

24

205

21

152

13 Swing bearing mounting bolt to upperstructure

30

36

46

1910

195

1410

Swing bearing mounting bolt to undercarriage

30

36

46

(hexagonal wrench)

12 Cab mounting bolt

W1-2-1

1720 175 1270 Continued on next page


GENERAL INFORMATION / Tightening Torque Specifications (continued) Torque

Bolt Dia mm

Q’ty

Wrench Size mm

N⋅m

kgf⋅m

lbf⋅ft

22

40

32

740

75

540

Travel motor mounting bolt

18

8

27

295

30

215

Sprocket mounting bolt

22

48

32

32

75

540

20

24

30

540

55

400

STD, H

24

64

36

930

95

690

LC, LCH

24

72

36

930

95

690

STD, H

24

392

32

1370

140

1010

LC, LCH

24

416

32

1370

140

1010

STD, H

24

16

36

930

95

690

LC, LCH

24

24

36

930

95

690

19 Track frame mounting bolt

33

36

50

2160

225

1590

20 Coupling and clamp of low pres- Coupling sure piping

8

13

1/4-28UNF

11

5.9

0.6

4.3

No.

Descriptions

14 Travel device mounting bolt

15 Upper roller mounting 16 Lower roller mounting bolt 17 Track shoe bolt 18 Track guard mounting bolt

Clamp 21 Counterweight mounting bolt Counterweight retaining bolt

10.5 to 10.5 to 7.6 to 12.5 1.26 9.1

45

2

65

2750

280

2030

24

4

36

440

45

330

22 Front pin-retaining bolt

20

30

390

40

290

Front pin-retaining nut

20

30

390

40

290

NOTE: 1.

2. 3.

When tightening bolts and nuts, apply a lubricant to threads to reduce friction. (i.e.: white zinc B dissolved into spindle oil) Remove rust, soil, and dust before tightening. Use LOCTITE to the engine cushion rubber mounting nuts and the lower roller mounting bolts.

W1-2-2


GENERAL INFORMATION / Tightening TORQUE CHART CAUTION: Use tools appropriate for the work to be done. Makeshift tools and parts create safety hazards. If an incorrect tool is used, the tool may slip or come off or break, resulting in personal injury. Bolt Types When tightening bolts and nuts, use the specified torque. Bolts are classified according to materials and applications. Be sure to use the correct bolts and nuts, and tighten them to specification. SA-040

Hexagon T Bolt

Hexagon H Bolt

Hexagon M Bolt

Socket Bolt

W105-01-01-007

Specified Tightening Torque Chart Bolt Dia.

Wrench Size

M 8 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 M 33 M 36

13 17 19 22 24 27 30 32 36 41 46 50 55

Hexagon Wrench Size 6 8 10 12 14 14 17 17 19 19 22 24 27

T Bolt, Socket bolt N⋅m

kgf⋅m

lbf⋅ft

29.5 64 108 175 265 390 540 740 930 1370 1910 2550 3140

3 6.5 11 18 27 40 55 75 95 140 195 260 320

22 47 80 130 195 290 400 540 690 1010 1410 1880 2310

H Bolt

M Bolt

N⋅m

kgf⋅m

lbf⋅ft

N⋅m

19.5 49 88 137 205 295 390 540 690 1030 1420 1910 2400

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

14.5 36 65 101 152 220 290 400 505 760 1050 1410 1770

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

W1-2-3

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

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


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

Equally tighten upper and lower alternately

Tighten diagonally

1 1, 4

6

Tighten from center and diagonally 12

9

4

1

6

7

14

13

8

5

2

3

10

11

3

4

5 2

2, 3 W105-01-01-003

W1-2-4


GENERAL INFORMATION / Tightening Service Recommendations for Split Flange IMPORTANT: (1) Be sure to clean and inspect sealing surfaces. Scratches / roughness cruse 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 contact 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

Nut and Bolt Lockings

WRONG

Do not bend it round

Bend along edge sharply

• Lock Plate

RIGHT

RIGHT

WRONG

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

• Cotter Pin IMPORTANT: Do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening.

Bend along edge sharply

RIGHT

RIGHT

W105-01-01-009

WRONG

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

WRONG Loosen

Tighten

W105-01-01-010

W1-2-5


GENERAL INFORMATION / Tightening PIPING JOINT 1

Pipe Thread Connection / Union Joint Tightening Torque Specifications

4

3

5

Union Joint Metal sealing faces (4) of adapter (1) and (5) of hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. IMPORTANT: (1) Do not over-tighten nut (3). If excessive force is applied to metal sealing faces (4) and (5), adaptor (1) will be cracked. Always tighten nut (3) to specifications.

Joint Body

30° Male

37° Female

M202-07-051

30° or 37°

30° or 37°

(2) Scratches or other damage to sealing faces (4) or (5) will cause oil to leak at the joint. Take care not to damage the sealing faces when connecting or disconnecting the union joint. Union Joint

2

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

NOTE: 37° male union joint tightening torque values are equal to those for 37° female union joint.

W1-2-6

Male Joint

Female Joint W105-01-01-017

Tightening Torque N⋅m (kgf⋅m) lbf⋅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) 125 295 (30) 360 490 (50)


GENERAL INFORMATION / Tightening O-ring Seal Joint O-ring (6) is located on the end face of adapter (7) to seal pressure oil at the joint.

7

6

9

IMPORTANT: (1) Be sure to replace O-ring (6) with new one when reconnecting. (2) Check that O-ring (6) is Correctly seated in O-ring groove (8) before tightening union nut (9). If union nut (6) is tightened with O-ring (6) displaced from the groove, O-ring (6) will be damaged, causing oil leaks. (3) Take care not to damage O-ring groove (8) on adapter (7) and sealing face (10) of the hose end. Damaged O-ring (6) will cause oil leaks. (4) If oil leaks due to looseness of union nut (9), always replace Oring (6) with new one and check that the O-ring is correctly seated in O-ring groove (8) before re-tightening union nut (9).

8

10

Union Body M104-07-033

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

W1-2-7

Tightening Torque N⋅m (kgf⋅m) lbf⋅ft 43 59 (6) 72 98 (10) 87 118 (12) 134 235 (24) 215 295 (30) 360 490 (50)


GENERAL INFORMATION / Tightening Screwed-In Connector

PT

IMPORTANT: Many types of screwed-in connectors are used for hose or pipe connections. Be sure to confirm that the thread pitch and thread type (tapered or straight) correctly match before connection.

PF

30°

Male Tapered Thread

Male Straight Thread W105-01-01-018

Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leaks between threads. Be sure to apply just enough seal tape to fill up the thread clearances. Wrapping too much tape has no effect.

Male Tapered Thread Wrench Tightening Torque Joint Body N⋅m (kgf⋅m) lbf⋅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) 50 190 670 (68) 61 720 980 (100) 70 Female Thread

Male Thread

Clearance

• Application Procedure

W105-01-01-019

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

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

Leave one to two pitch threads uncovered

M114-07-041

T-Bolt Type

Worm Gear Type

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

M114-07-042

W1-2-8

M114-07-043


GENERAL INFORMATION / Tightening Connecting Hose

WRONG

CAUTION: (1) When replacing hoses, be sure to use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leaks, 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 check if hoses are installed properly. (3) If hoses contact each other, wear on the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from contacting each other. Take care that hoses do not come into contact with moving parts or sharp objects.

RIGHT

W105-01-01-011

WRONG

RIGHT Rubbing Each Other

W105-01-01-012

WRONG Clamp

RIGHT Clamp

Rubbing W105-01-01-013

WRONG

RIGHT

Rubbing Clamp W105-01-01-014

W1-2-9


GENERAL INFORMATION / Tightening (Blank)

W1-2-10


SECTION 2

UPPERSTRUCTURE —CONTENTS— Group 1 Cab Disassemble

Remove and Install Cab ...................... W2-1-1

Control Valve 2 ................................ W2-4-14

Dimensions of the Cab Glass .............. W2-1-7

Assemble Control Valve 2 ................................ W2-4-16

Group 2 Counterweight

Disassemble

Remove and Install

Control Valve 3 ................................ W2-4-18

Counterweight ................................... W2-2-1

Assemble Control Valve 3 ................................ W2-4-24

Group 3 Pump Device

Disassemble

Remove and Install

Control Valve 4 ................................ W2-4-30

Pump Device ..................................... W2-3-1

Assemble

Disassemble Pump Transmission........ W2-3-4

Control Valve 4 ................................ W2-4-32

Assemble Pump Transmission ............ W2-3-6

Disassemble

Remove and Install

Control Valve 5 ................................ W2-4-34

Main Pump ........................................ W2-3-8

Assemble

Disassemble Main Pump ................... W2-3-10

Control Valve 5 ................................ W2-4-36

Assemble Main Pump........................ W2-3-16 Disassemble and Assemble Pilot Pump ....................................... W2-3-24

Group 5 Swing Device Remove and Install Swing Device ..................................... W2-5-1

Group 4 Control Valve

Disassemble Swing Device.................. W2-5-4

Remove and Install Control Valve ..................................... W2-4-1

Assemble Swing Device ...................... W2-5-8 Disassemble Swing Motor ................. W2-5-12

Disassemble Control Valve 1 .................................. W2-4-4

Assemble Swing Motor ...................... W2-5-16 Maintenance Standard....................... W2-5-20

Assemble Control Valve 1 .................................. W2-4-8

167W-2-1


Group 6 Pilot Valve Remove and Install Right Pilot Valve ......................................... W2-6-1 Remove and Install Left Pilot Valve ......................................... W2-6-4 Remove and Install Travel Pilot Valve ............................... W2-6-7 Disassemble Front Attachment Pilot Valve ......................................... W2-6-8 Assemble Front Attachment Pilot Valve ....................................... W2-6-10 Disassemble Travel Pilot Valve ....................................... W2-6-14 Assemble Travel Pilot Valve ....................................... W2-6-16

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

Group 8 Shockless Valve Remove and Install Front Attachment Shockless Valve.............. W2-8-1 Disassemble and Assemble Front Attachment Shockless Valve.............. W2-8-4 Remove and Install Travel Shockless Valve...................... W2-8-7 Disassemble and Assemble Travel Shockless Valve...................... W2-8-8

Group 9 Solenoid Valve Remove and Install Three-Spool Solenoid Valve............... W2-9-1 Disassemble and Assemble Three-Spool Solenoid Valve............... W2-9-3

167W-2-2


UPPERSTRUCTURE / Cab REMOVE AND INSTALL CAB Remove Cab 1. Remove seat mounting nut (2) to remove seat (1). : 13 mm

1 2 W157-02-01-005

2. Loosen bolt (5) in the cab rear section and bolt (6) in rear boxes (3 and 4) to remove rear boxes (3 and 4). : 13 mm

3. Loosen bolt (8) to remove lower cover (7) of the rear box.

3 5

: 13 mm

6

6 5 8

4 7

W157-02-01-017

4. Remove filter (24) and loosen screw (9) to remove duct (10) from the cab.

24 10

9 W158-02-01-001

W2-1-1


UPPERSTRUCTURE / Cab 5. Disconnect harness connectors (11) located at the rear inside the cab.

11

6. Disconnect connectors for wiper limit switch (12), cab light (13), speaker (14), antenna (15) and ground (17) located in the cab. Remove washer vinyl hose (16) located behind the cab.

W167-02-01-001

13

12

14

15

17

7. Remove cap (20) from duct cover (18). Loosen screws (19) to remove duct cover (18).

16

W162-02-01-002

18 20

19

W158-02-01-002

8. While pushing the mating face of duct (21) backward, remove duct (21).

Duct Mating Face

21

W157-02-01-011

W2-1-2


UPPERSTRUCTURE / Cab 9. Attach a sling belt to the top of the cab. CAUTION: Cab weight: 260 kg (573 lb)

W157-02-01-009

10. Remove cab mounting bolt (22) and nuts (23). : 17 mm : 24 mm : 8 mm

22

23

23

11. Slowly lift the cab with a crane to remove the cab from the machine.

W157-02-01-010

W157-02-01-001

W2-1-3


UPPERSTRUCTURE / Cab Install Cab 1. Attach cab to crane with sling belts and install cab onto the machine. CAUTION: Cab weight: 260 kg (573 lb)

W157-02-01-001

2. Tighten cab mounting bolts (22) and nuts (23). 22

: : : : : :

17 mm 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 24 mm 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) 8 mm 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

23

23 W157-02-01-010

3. Install duct (10) into the cab and tighten screw (9). Install filter (24). : 4.9 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)

24

9 10 W158-02-01-001

4. Connect harness connectors (11) at the rear, inside the cab.

11 W167-02-01-001

W2-1-4


UPPERSTRUCTURE / Cab 5. Connect wiper limit switch (12), cab light (13), speaker (14), antenna (15) and ground (17) in the cab. Connect washer vinyl hose (16) behind the cab.

13

12

14

: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

15

17

16

W162-02-01-002

6. Install rear box lower cover (7) and tighten bolts (8). : 13 mm : 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

3

7. Install rear boxes (3 and 4) and tighten bolts (5 and 6).

5

: 13 mm : 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

6

6 5 8

4 7

W157-02-01-017

8. Push duct (21) to the cab front until the duct mating face comes in contact.

Duct Mating Face

21

W157-02-01-011

W2-1-5


UPPERSTRUCTURE / Cab 9. Install duct cover (18). Tighten screw (19) and put cap (20) on. 18 20

19

W158-02-01-002

10. Install seat (1) and tighten nut (2). : 13 mm : 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

1 2 W157-02-01-005

W2-1-6


UPPERSTRUCTURE / Cab DIMENSIONS OF THE CAB GLASS R2

Unit : mm NOTE : 1 mm=0.03937 in

A 25.106 R11516

3.015

221.399 R70 4-φ13 +0 -1

R78

(64.74)

142.25

Section A Chamfer both fringes

580

R9487 30 360.78

(87.81)

(5 mm)

R3018 R118

391.8

Chamfer fringe comers.

51.03 154.81

188.5 R15

66.84

164.12

43.59

558.78

230.50 222.65

B All Around

15

216.73

All Around

c1

c1

2-R59

R11509

R2309

R4009

R9509

900.7 905

(4 mm) R1009

Section B R209

R509 R4009

NOTE: Material: JIS- R3211,R3212 ANSI - AS2 ECE - ANNEX5 or equivalent

R84

63.97 66.41 87.84

947.152

35.73

756

4-R62

612

(5 mm)

W157-02-01-013

W2-1-7


UPPERSTRUCTURE / Cab Chamfer fringe corners. Unit : mm NOTE : 1 mm=0.03937 in 208

333.5±1.0

(38.5)

Chamfer fringe comers.

113.9

337.5±1.0 22.5

R3

9.2

10.6 R30

7735.4

R105 R2285.4 39.5

61.8

R3985.4

728.5±1.0

Chamfer both fringes

(4 mm)

Chamfer both fringes

C

Section C and D

728.5±1.0 488.5

2-φ12.2 +0.5 -0 R120885.4

2-φ12.2 +0.5 -0

2-R4

R1985.1

60.1

39.5 3.1

40

40 475.8

D

R72.5

290

(4 mm)

3-R4

398.5±1.0

Chamfer fringe comers.

503±1.0 (38.5)

541.5

Chamfer fringe comers.

468.17 90.672 45.67

R2590

2-R5

R2477

R5175 904.13 R3877

980

R8075 753.99 740.51

19.70

8

890.03

74.95

(5 mm)

213.97

R120 227.39 370±1.0

R12.5

276.58

R1995

R1145

R895

R595

19.29

R345

R295

33.60

(5 mm)

11.22 18

165

R12095

4-R5

833±1.0 910

516.26 549.86

39.63 50.71 59

W157-02-01-014

W2-1-8


UPPERSTRUCTURE / Counterweight REMOVE WEIGHT

AND

INSTALL

COUNTER-

Removal CAUTION: Approximate counterweight weight: 10500 kg (23200 lb) 1. Install lifting accessories and wire ropes to sling brackets on the top of the counterweight. Set the wire rope taut using a crane. CAUTION: Watch out the power-wrench reaction bar movement. Take care not to be hit the reaction bar. 2. Loosen bolts (10) using a power wrench to remove bolts (10), nuts (8), shims (7), and washers (9).

W166-02-02-002

NOTE: Shims (7) are used only when any gap between nuts (8) and the lock brackets exist. When no gap exists, shims are not required. : 65 mm

7 8 9 3 4

2 1

5

1

6

2 7

3. Loosen bolts (1) to remove lock washers (2), washers (3), and spacers (4). If shims (5 and 6) are provided, remove shims (5 and 6).

3

4 5

: 36 mm

6

8

9 9

10 W166-02-02-003

4. Remove the counterweight using a crane. 9 7

10

8 9 3 2,1 6,5,4

W2-2-1

W166-02-02-001


UPPERSTRUCTURE / Counterweight Installation CAUTION: Approximate counterweight weight: 10500 kg (23200 lb) 1. Install lifting accessories and wire ropes to sling brackets on the top of the counterweight. Then, lift the counterweight by crane. CAUTION: Do not allow anyone under the lifted counterweight. 2. Insert protrusions on the counterweight into holes on the frame to install the counterweight.

W166-02-02-002

CAUTION: Watch out the power-wrench reaction bar movement. Take care not to be hit the reaction bar. IMPORTANT: Apply lubricant to bolts (10) before installing. Install shims (7) between nuts (4) and the lock brackets with the flange positioned in the upper side. 3. Install bolts (10), nuts (4), shims (7), and washers (9). Using a power wrench, tighten bolts (10). : 65 mm : 2750 N⋅m (280 kgf⋅m, 2030 lbf⋅ft)

7 8 9 3 4

2 1

5

1

6

2 7

3

4 5

6

8

9 9

10 W166-02-02-003

4. Install shims (5 and 6), spacers (4), washers (3) lock washers (2), and bolts (1). Remove wire ropes and lifting accessories. 9

: 36 mm : 440 N⋅m (45 kgf⋅m, 330 lbf⋅ft)

7

10

8 9 3 2,1 6,5,4

W2-2-2

W166-02-02-001


UPPERSTRUCTURE / Pump Device REMOVE AND INSTALL PUMP DEVICE CAUTION: 1. Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. 2. Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off by remaining pressure if removed quickly. Slowly loosen the cap to completely release any remaining pressure. Preparation 1. Stop the engine. Move all control levers to release pressure remaining in the system. Turn the hydraulic oil tank cap approx. 30° counterclockwise to release any pressure remaining in the hydraulic tank.

W2-3-1


UPPERSTRUCTURE / Pump Device Removal 1. Disconnect all hoses and electrical cables from the pump. Wrench size (mm)

Tightening Torque

Remark

N⋅m

kgf⋅m

lbf⋅ft

: 19

29.5

3

22

Piping

: 22

59

6

44

Piping

: 27

93

: 36

175

9.5

: 10

108

11

80

Piping

: 12

175

18

130

Piping

: 14

265

27

195

Piping

: 30

390

40

290

Bolt

: 16

69

7

50

Bolt

: 32

540

55

400

Bolt

18

Engine Rear Mounting Bolt

69

Piping

130

Piping

Wooden Block

W167-02-03-005

2. Lay a wooden block (300 mm long, 200 mm wide, and 20 mm thick) under the engine oil pan.

Pump Transmission Mounting Bolt Main Pump Mounting Bolt

CAUTION: Main pump weight: 125 kg (276 lb) 3. Remove the main pump mounting bolts to remove the main pump. CAUTION: Pump transmission weight: 150 kg (330 lb)

W167-02-03-003

4. Remove the pump transmission mounting bolts and the engine rear mounting bolts to remove the pump transmission. Installation NOTE: Refer to the “removal” section above for wrench sizes and tightening torque. 1. Secure the pump device with the mounting bolts. 2. Re-connect all hoses and electrical cables to the pump device. 3. Bleed any trapped air from the pump (refer to page W1-1-2). IMPORTANT: After installing the pump, be sure to perform break-in operation to prevent seizure. Break-In Operation Process: 1. Start the engine and run at slow idle speed for 20 minutes. Check for oil leaks while running at slow idle. 2. Increase the engine speed to the fast idle speed. Raise and lower the boom for 20 minutes repeatedly. (Do not operate the control levers quickly. Slowly move the levers to full stroke.)

W2-3-2


UPPERSTRUCTURE / Pump Device (Blank)

W2-3-3


UPPERSTRUCTURE / Pump Device DISASSEMBLE PUMP TRANSMISSION

10 9 8

11

7 6 5 4 3 2 1

W167-02-03-001

1 - Casing 2 - Bearing 3 - Retaining Ring

4 - Coupling 5 - Retaining Ring 6 - Gear

7 - Bearing 8 - O-Ring 9 - Cartridge

W2-3-4

10 - Bolt (10 Used) 11 - Oil Seal 12 - Drain Plug


UPPERSTRUCTURE / Pump Device Disassemble Pump Transmission

• Be sure to thoroughly read all precautions for disassembly/assembly work on page W1-1-1 before starting any repair work. 1. Loosen drain plug (12) to drain gear oil from the pump transmission. Remove the pilot pump from casing (1). : 27 mm : 8mm CAUTION: Pump transmission weight: 150 kg (330 lb) 2. Place casing (1) on a work bench with the main pump mounting side facing downward. 3. Remove bolts (10). : 19 mm CAUTION: Pump transmission weight: 150 kg (330 lb) 4. Turn casing (1) over and place it on a work bench. NOTE: At this time, set a wooden block (100 mm high) so that it does not come in contact with cartridge (9). 5. Attach a protection plate (Dia. 50 mm) to coupling (4). While tapping the protection plate, remove cartridge (9), bearing (2 and 7) and gear (6) from casing (1).

6. Remove bearing (7), O-ring (8) and oil seal (11) from cartridge (9).

7. Remove retaining ring (3), coupling (4) and retaining ring (5) from gear (6).

8. Using a press or a puller, remove bearings (2 and 7) from gear (6).

W2-3-5


UPPERSTRUCTURE / Pump Device ASSEMBLE PUMP TRANSMISSION

10

Pilot Pump A

A

1

6

2

3

4

8

11

5

12

Section A-A

9

7 W167-02-03-002

1 - Casing 2 - Bearing 3 - Retaining Ring

4 - Coupling 5 - Retaining Ring 6 - Gear

7 - Bearing 8 - O-Ring 9 - Cartridge

W2-3-6

10 - Bolt (10 Used) 11 - Oil Seal 12 - Drain Plug


UPPERSTRUCTURE / Pump Device Assemble Pump Transmission 1. Press bearings (2 and 7) into gear (6). 2. Install retaining ring (5), coupling (4), and retaining ring (3) to gear (6).

CAUTION: Casing (1) weight: 95 kg (210 lb) 3. With the main pump mounting face .downward, place casing (1) on a work bench. 4. Press bearing (2) along with gear (6) into casing (1).

5. Using a protection plate, press oil seal (11)into cartridge (9). 6. Coat the inner diameter of oil seal (11) with grease. 7. Install O-ring (8) to cartridge (9). IMPORTANT: Position the casting imprint on cartridge (9) upward (the oil filler side) and install the cartridge on casing (1).

Upward

Casting Imprint

8. Install cartridge (9) on casing (1).

9. Tighten bolts (10) (10 used). : 19 mm : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

W167-02-03-006

10. Install the pilot pump on casing (1). : 8 mm : 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

W2-3-7


UPPERSTRUCTURE / Pump Device REMOVE AND INSTALL MAIN PUMP CAUTION: 1. Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. 2. Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off by remaining pressure if removed quickly. Slowly loosen the cap to completely release any remaining pressure. Preparation 1. Stop the engine. Move all control levers to release pressure remaining in the system. Turn the hydraulic oil tank cap approx. 30° counterclockwise to release any pressure remaining in the hydraulic tank.

W2-3-8


UPPERSTRUCTURE / Pump Device Removal 1. Disconnect all hoses and electrical cables from the pump. : : : : : : : : : : : : : :

Main Pump Mounting Bolt

19 mm 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 22 mm 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft) 27 mm 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft) 36 mm 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft) 10 mm 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft) 12 mm 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft) 14 mm 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)

CAUTION: Main pump weight: Approx. 125 kg (276 lb)

T167-01-02-003

2. Remove the main pump mounting bolts to remove the main pump. : 30 mm : 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft) Installation NOTE: Refer to the “Removal” section above for wrench sizes and tightening torque. 1. Secure the pump device with the mounting bolts. 2. Re-connect all hoses and electrical cables to the pump device. 3. Bleed any trapped air from the pump (refer to page W1-1-2). IMPORTANT: After completing installation of the pump device, be sure to perform break-in operation to prevent pump seizure during initial machine operation. Procedure: 1. Start the engine. Run at slow idle speed for 20 minutes. Check for oil leaks during this operation. 2. Increase the engine speed to the first idle speed and raise or lower the boom for 20 minutes. (Do not operate the control lever quickly. Slowly operate the lever full stroke.)

W2-3-9


UPPERSTRUCTURE / Pump Device DISASSEMBLE MAIN PUMP 5

6 4

7

8

3 2 1 9

10 9

A 11 12

W116-02-04-048

Pump displacement Angle Sensor (6)

13

23 22 21 14 20 19 18 17 16 15 24 25 26 27

28 W116-02-04-049

123456-

Retaining Ring Seal Case Oil Seal O-Ring Housing Pump Displacement Angle Sensor (A-Sensor) 7 - Socket Bolt (3 Used)

8910 11 12 13 -

Socket Bolt Socket Bolt (4 Used) Regulator Control Plate Rotary Group Socket Bolt (3 Used)

14 - Case

15 16 17 18 19 20 -

Shaft Spring Oil Seal Retainer Retaining Ring O-Ring

21 - Potentiometer

W2-3-10

22 23 24 25 26 27 -

Washer Socket Bolt (2 Used) Spring Spring Seat Arm Set Screw (2 Used)

28 - O-Ring


UPPERSTRUCTURE / Pump Device Regulator (10)

Regulator Cover (29) Section

47 30

48

31

29

49

32

50 33

A

51 52

34

53 54

46 45

59

55

58

42

44

57

30 56

43

63 56

57

58 59

36 41

37 38

29

39

62

40

60

61

W116-02-04-051

W116-02-04-050

29 30 31 32 33 34 -

Regulator Cover Socket Bolt (4 Used) Spring Seat Spring Spring Pump Control Solenoid Valve 35 - Body 36 - Set Screw 37 - O-Ring

38 39 40 41 42 43 -

Plate Socket Bolt (4 Used) Piston Ring (2 Used) Piston Packing Rod

44 - Knock Pin (2 Used) 45 - Bushing 46 - Pin

47 48 49 50 51 52 -

Lock Nut Guide O-Ring Adjusting Screw O-Ring Spring

53 - Distant Piece 54 - Spool 55 - Barrel

W2-3-11

56 57 58 59 60 61 -

Guide (2 Used) Steel Ball (2 Used) Plug (2 Used) Plug (2 Used) O-Ring (6 Used) Retainer

62 - O-Ring 63 - Filter


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