HITACHI EX16-2B EX17-2B EXCAVATOR SERVICE MANUAL pdf download

Technical Manual EX16-2B/EX17-2B

SPECIFICATION / General Information INTERCHANGEABILITY IMPORTANT: Part interchangeability is changed when the part is modified. Be sure to check update interchangeability referring to the current parts catalog.

Model Item

EX12-2

EX15-2

EX162B

EX172B

EX18-2

EX22-2

EX25-2

EX30-2

EX35-2

EX40-2

EX45-2

Upperstructure

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Engine

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Pump Device

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Swing Device

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Control Valve

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Pilot Valve

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Boom Swing Cylinder

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Travel Device

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Swing Bearing

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Center Joint

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Track Adjuster

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Front Idler

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Upper Roller

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Lower Roller

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Rubber Crawler

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Blade

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Blade Cylinder

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Boom

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Arm

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Bucket

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Boom Cylinder

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Arm Cylinder

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Bucket Cylinder

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Undercarriage

Front Attachment

T1-1B-1

SPECIFICATION / General Information (Blank)

T1-1B-2

(Blank)

T587

SYSTEM / Hydraulic System MAIN CIRCUIT EX16-2B, EX17-2B Main pumps (P1, P2) draw hydraulic oil from the hydraulic oil tank and discharge pressure oil to the control valve. (Refer to “Control Valve” group in “COMPONENT OPERATION” section.)

The pressure oil from main pump (P1) flows to the spools of blade (9), swing (8), arm (7) and right travel (6) in the control valve.

The pressure oil from main pump (P2) flows to the spools of left travel (1), bucket (2), boom swing (3), boom (4) and auxiliary (5) in the control valve.

The pressure oil in the control valve, depending on which spools are selected, flows to the cylinders or motors actuating them.

The return oil from cylinders or motors returns to control valve and flows through the valve. The return oil from the control valve flows through the oil cooler, then returns to the hydraulic oil tank.

When the temperature of the hydraulic oil is low (viscosity is high), hydraulic oil restriction increases in the oil cooler passages. Therefore, a bypass check valve opens to return the hydraulic oil directly to the hydraulic oil tank.

T2-1B-1

SYSTEM / Hydraulic System

Selector Valve Arm Cylinder

Travel Motor ЁRЂ

Blade Cylinder

Travel Motor ЁLЂ

Boom Cylinder

Boom Swing Cylinder

Bucket Cylinder

Swing Motor

T2

P1

P2

9

7

8

4

5

6

3

2

1

Control Valve Oil Cooler

Hydraulic Oil Tank

P2 Main Pump

P1 Engine

Bypass Check Valve T513-02-01-001

1 - Left Travel 2 - Bucket 3 - Boom Swing

4 - Boom 5 - Auxiliary

6 - Right Travel 7 - Arm

T2-1B-2

8 - Swing 9 - Blade

SYSTEM / Hydraulic System PILOT CIRCUIT EX16-2B, EX17-2B The pressure oil from the pilot pump is supplied to the following circuits: • Operation Circuit This circuit controls pressure oil from the pilot pump by pilot valve, and moves the spools in the control valve.

• Valve Control Circuit This circuit switches the flow combiner valve by opening or closing the pilot signal circuit.

• Swing Parking Brake Release Circuit (Refer to “Swing Device” group in “COMPONENT OPERATION” section) This circuit releases the swing parking brake when the pilot signal circuit in the control valve closes.

• Travel Speed Changeover Circuit (Refer to TRAVEL DEVICE group in COMPONENT OPERATION section) Travel speed changeover solenoid valve is switched ON-OFF by the travel speed changeover switch (fast speed travel pedal) to deliver travel speed changeover pressure to the travel motor.

• Swing Parking Brake Release Circuit (Refer to SWING DEVICE group in COMPONENT OPERATION section) This circuit releases the swing parking brake when the pilot signal circuit in the control valve closes.

T2-1B-3

SYSTEM / Hydraulic System

Pilot Valve (L)

Swing Motor

Pilot Valve (R)

Travel Motor

Control Valve

Pilot Signal Circuit

Flow Combiner Valve

Pilot Filter

Pilot Pump

Pilot Shut-Off Solenoid Valve

Pilot Relief Valve

Travel Speed Changeover Solenoid Valve

T513-02-01-002

T2-1B-4

COMPONENT OPERATION / Swing Device SWING MOTOR The swing motor is a orbit motor incorporating a parking brake.

The main components are; valve drive (1), valve plate (2), drive (3), pinion gear (8), gerotor (12) and valve (14).

Valve drive (1) is combined with valve (14) and the star inside of gerotor (12), and drive (3) is combined with the star inside of gerotor (12) and pinion gear (8).

14 1

13

2

12 3 4

11

5

6

10 9

7

T513-03-02-001

8 1234-

Valve Drive Valve Plate Drive Spring

5678-

Piston Bearing Housing Bearing Pinion Gear

9 - Friction Plate 10 - Plate 11 - Flange

T3-2B-1

12 - Gerotor 13 - Valve Housing 14 - Valve

COMPONENT OPERATION / Swing Device Operational Principle The pressure oil delivered from port BM (7) flows into the chambers in gerotor (5) through valve (2) and port (valve plate) (3). Star (9) is eccentrically installed to valve drive (4) and drive (10). Therefore, when the pressure oil flows into gerotor (5), star (9) in gerotor (5) revolves while rotating on its axis. The rotation force of star (9) drives pinion shaft (6).

In addition, the rotation force of star (9) drives valve (2) via valve drive (4). Valve (2) has 12 ports which offer oil passages for both the high and low pressure oil alternately. Valve plate (3) has seven ports connected to the seven chambers in gerotor (5). When valve (2) is driven, the relative position between valve plate (3) and valve (2) changes so that the pressure oil inlet port position is displaced in sequence, producing continuous rotation force.

1

2 7 3 8 4

5

9 10

11 12

6

T502-02-04-002

1 - Check Valve 2 - Valve 3 - Port (Valve Plate)

4 - Valve Drive 5 - Gerotor 6 - Pinion Shaft

7 - Port BM 8 - Port AM 9 - Star (Gerotor)

T3-2B-2

10 - Drive 11 - Inlet Pressure Oil 12 - Return Oil

COMPONENT OPERATION / Swing Device Make-Up Valve When the upperstructure is swing downward on a slope, the upperstructure is accelerated by its own weight and moves quicker than the swing motor drive speed developed by the pump oil flow rate. Therefore, cavitation can occur in the circuit.

To prevent cavitation, when the oil pressure in the circuit is lower than the pressure at port M (hydraulic oil tank pressure), the poppet opens drawing hydraulic oil into the circuit so that the pump oil flow rate is replenished.

Make-Up Valve

T513-03-02-001

T3-2B-3

COMPONENT OPERATION / Swing Device Relief Valve The relief valve functions to reduce shocks developed when starting or stopping swing movement (shockless) and to protect the circuit from overloading (relief).

Shockless Operation: When the circuit pressure increases, pressure oil is routed into the piston chamber via the oil passage inside the piston and moves the piston to the left. As long as the piston is moving, the spring set force is weak, allowing the poppet to open. Then, hydraulic oil is relieved to the hydraulic oil tank.

When the piston is moved to the stroke end, the spring set force maintains the poppet at the regular relief pressure.

Relief Operation: During swing operation, if the circuit pressure is increased due to an external load higher than the relief set pressure, the pressure higher than relief set pressure acts on the poppet so that the poppet opens allowing the hydraulic oil to be relieved.

Poppet

Oil Passage

Piston

Piston Chamber

Spring

T513-03-02-002

T3-2B-4

COMPONENT OPERATION / Control Valve OUTLINE • EX16-2B〠EX17-2B

The control valve controls oil pressure, flow rate and flow direction of the hydraulic circuit.

The main components are: main relief valve, overload relief valve, make-up valve, flow combiner valve and spool.

Spools in the sections for travel, blade, boom swing and auxiliary are operated mechanically. Spools in the sections for the boom, arm, bucket and swing are operated by pilot oil pressure system.

Travel (Left)

Bucket

Boom Swing

Boom

Auxiliary

Travel (Right)

Arm

Swing Blade

T513-03-02-003

Overload Relief Valve

Flow Combiner Overload Relief Valve Valve

Main Relief Valve

Main Relief Valve

Make-Up Valve

Overload Relief Valve

T3-3B-1

Overload Relief Valve

T513-03-02-004

COMPONENT OPERATION / Control Valve (Blank)

T3-3B-2

COMPONENT OPERATION / Travel Device OUTLINE The travel device consists of travel motor, travel reduction gear and travel brake valve.

The travel motor is a variable displacement axial plunger swash plate type. This motor is driven by pressure oil from the pump, and transmits the rotation to the travel reduction gear.

The travel reduction gear is a two-stage planetary-gear reduction type, reducing travel motor speed, increasing travel motor torque, and allowing the sprocket and track to rotate.

The travel brake valve functions to protect the travel circuit.

Travel Brake Valve

Travel Reduction Gear

T513-03-05-001

Travel Motor

T3-5B-1

COMPONENT OPERATION / Travel Device TRAVEL MOTOR The travel motor consists of valve plate, rotor, plungers, shoes, swash plate and shaft. The rotor is connected to the shaft by a spline joint, and the plungers are inserted in the rotor.

When the pressure oil is supplied from the pump, the plungers are pushed. The swash plate is installed at an angle toward the plungers, the shoe slides on the swash plate, so the rotor rotates. This rotation is transmitted to the travel reduction gear via the shaft.

Swash Plate

Shoe

Rotor

Plunger

T3-5B-2

Valve Plate

Shaft

T513-03-05-001

COMPONENT OPERATION / Travel Device TRAVEL BRAKE VALVE The travel brake valve consists of counterbalance valve and travel speed changeover valve.

The counterbalance valve has two functions; one is to start and stop the travel smoothly, and the other is to prevent the machine from running away while descending slopes.

The travel speed changeover valve is switched by pressure oil from the travel speed changeover solenoid valve. It switches the travel speed by the control piston.

Counterbalance Valve

Travel Speed Changeover Valve T513-03-05-002

T3-5B-3

COMPONENT OPERATION / Travel Device Counterbalance Valve • Descending Operation When the machine travels down a slope, the travel motors are forcibly driven by the machine weight so that the motor draws oil like a pump.

The pressure oil in port P1 is drawn into the travel motor, so the pressure on port P1 decreases.

Thereby, the spool returns to the left, and returning oil from port BM to port P2 is restricted, so the oil pressure brake is activated.

When the returning oil from port BM is restricted, the pressure on port P1 increases again, and moves spool to the right, so the motor rotates.

• Travel Operation When pressure oil from control valve is supplied to port P1, the pressure oil flows to motor port AM through the inside of the spool and opens the check valve. On the other hand, the return oil from motor port BM is blocked by the check valve and spool.

Thereby, the pressure on port P1 side increases gradually, so the pressure on port P1 enters into the spring chamber from the orifice, and moves the spool to the right by the pressure at the end surface of the spool.

As a result, spool notch opens so port BM and port P2 connect, so the travel motor rotates.

Control Valve Spool

Orifice

Orifice

P1

P2

AM

BM

Spring Chamber

Spring Chamber

Check Valve

Check Valve

T513-03-05-002

T3-5B-4

COMPONENT OPERATION / Travel Device Travel Speed Changeover Valve At Slow Speed: There are two surfaces on the swash plate; surface (a) and surface (b). Surface (a) makes contact with the housing at slow speed, and surface (b) makes contact with the housing at fast speed.

Two balls are located off the center line on the swash plate, so they can roll freely.

Surface (b)

• Slow Speed Operation When the travel is in slow speed, the pressure oil from the travel speed changeover solenoid valve is not supplied to the travel speed changeover valve. Thereby, surface (a) of the swash plate makes contact with the housing by the oil pressure acting on the plunger, and the spring force in the rotor.

As a result, the angle of the swash plate increases which makes the stoke of plunger longer. As a consequence, the motor capacity becomes larger, so the travel motor rotates in slow speed.

• Fast Speed Operation When the travel is in fast speed, the pressure oil from the travel speed changeover solenoid valve is supplied to the travel speed changeover valve.

Thereby, the travel speed changeover valve switches to supply the pressure oil to the control piston. The swash plate is pushed by the control piston, which makes surface (b) contact with the housing.

As a result, the angle of swash plate decreases which makes the stroke of the plunger shorter. As a consequence, the motor capacity becomes smaller, so the travel motor rotates in fast speed.

Swash Plate Rotor

Plunger

Surface (a) T571-03-05-004

At Fast Speed:

• When Engine Stops When engine stops, pressure oil applied to the control piston returns to the hydraulic oil tank through the travel speed changeover valve. As a consequence, surface (a) of the swash plate makes contact with the housing by the spring force in the rotor.

As a result, the travel motor always rotates in slow speed whenever the engine is started.

T3-5B-5

Swash Plate

Rotor

Plunger

Surface (b)

Surface (a) Control Piston

From Travel Speed Changeover Valve T571-03-05-005

COMPONENT OPERATION / Travel Device TRAVEL REDUCTION GEAR The travel motor rotates the shaft, and the rotation is transmitted to the first stage sun gear. The rotation of the first stage sun gear is reduced by the first stage planetary gear and the first stage carrier, and is transmitted to the second stage sun gear. The rotation of the second stage sun gear is reduced by the second stage planetary gear and the second stage carrier (united with the travel motor housing).

As second stage carrier and travel motor housing is united into one part, the rotation of the second stage planetary gear is transmitted to sprocket via the ring gear.

First Stage Planetary Gear

First Stage Sun Gear

First Stage Carrier

Ring Gear

Second Stage Planetary Gear

Second Stage Carrier

T3-5B-6

T513-03-05-001

COMPONENT OPERATION / Others (Upperstructure) SOLENOID VALVE There are two kinds of solenoid valves; one is the pilot shut-off valve solenoid valve, the other is the travel speed changeover solenoid valve.

Pilot Relief Valve Travel Speed Pilot Shut-Off Changeover Valve Solenoid Valve Solenoid Valve

Pilot Shut-Off Valve Solenoid Valve The solenoid valve is switched ON/OFF by the position of the pilot control shut-off lever to control the pilot pressure to the pilot valve.

When the pilot control shut-off lever is in the LOCK position, the pilot shut-off switch is OFF. By this action, solenoid valve is OFF, so that pilot pressure is blocked by the solenoid valve spool. As a consequence, the pressure oil is not delivered to the pilot valve.

When the pilot control shut-off lever is in the UNLOCK position, the pilot shut-off switch is ON. By this action, the solenoid valve is ON, so the pilot pressure is supplied to the pilot valve through the solenoid valve spool.

Travel Speed Changeover Solenoid Valve The travel speed is controlled by the fast speed travel pedal.

When the fast speed travel pedal is in the slow speed position (released position), the travel speed changeover switch is OFF. By this action, the solenoid valve is OFF, so that pilot pressure is blocked by the solenoid valve spool. As a consequence, the travel speed changeover pressure is not delivered to the travel motor.

When the fast speed travel pedal is in the fast speed position (step-on position), the travel speed changeover switch is ON. By this action, the solenoid valve is ON, so that pilot pressure is delivered to the travel motor as the travel speed changeover pressure through the solenoid valve spool.

To Pilot Valve

To Travel Motor

T574-03-06-001

Pilot Control Shut-Off Lever

Pilot Shut-Off Switch

T532-02-06-002

Fast Speed Travel Pedal

T532-02-06-005

T3-6B-1

COMPONENT OPERATION / Others (Upperstructure) (Blank)

T3-6B-2

Workshop Manual EX16-2B/EX17-2B

UPPERSTRUCTURE / Swing Device REMOVE AND INSTALL SWING DEVICE CAUTION: Escaping hydraulic fluid pressure can penetrate the skin or eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

Hydraulic oil and components may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for hydraulic oil and components to cool before starting repair work.

Preparation 1. Place the machine on a solid, level surface and lower bucket to the ground.

2. Stop the engine. Loosen the hydraulic oil tank cap to release the air in the hydraulic oil tank.

3. Remove the cap. Install a vacuum pump on the hydraulic oil tank. Operate the vacuum pump to create negative pressure in the tank. Keep the vacuum pump running continuously while working on the system.

T570-06-03-011

W2-5B-1

UPPERSTRUCTURE / Swing Device DISASSEMBLE SWING DEVICE Swing Motor

Shockless Valve 1 43 44

45 44 46

47 48 49 50 51 52 53

42 41

2

3

4

5

6

7

56 41 55 54

8 40

9

39

10 11

38

12 13

37 35 34 33

57

58 W513-02-01-002

12 14

36

15 16 17 18 19 20 21 22

32 31 30 29 28 27 26

23 24 25

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1- Bolt (4 Used) 2- Outer Face Seal 3- Balancing Ring 4- Inner Face Ring 5- Pin (2 Used) 6- Spring (2 Used) 7- Plug (2 Used) 8- O-Ring (2 Used) 9- Plug (2 Used) 10- Spring (2 Used) 11- Steel Ball (2 Used) 12- O-Ring (3 Used) 13- Valve Drive 14- Socket Bolt (8 Used) 15- Shaft Face Seal

W513-02-01-001

16- Rear Bearing 17- Retaining Ring 18- Ring 19- Piston 20- Plate (4 Used) 21- Friction Plate (4 Used) 22- Retaining Ring 23- Collar 24- Drive 25- Pinion Gear 26- Retaining Ring 27- Front Bearing 28- Bearing Housing 29- X-Ring 30- Plate

31- O-Ring 32- O-Ring (3 Used) 33- Spring (8 Used) 34- Flange Mounting 35- O-Ring (2 Used) 36- Gerotor 37- Valve Plate 38- O-Ring 39- Valve 40- Valve Housing 41- Filter Element (4 Used) 42- Orifice Plug (2 Used) 43- Valve Body 44- Backup Ring (4 Used)

W2-5B-2

45- O-Ring (2 Used) 46- Plunger (2 Used) 47- Spring (2 Used) 48- O-Ring (2 Used) 49- Shim 50- Piston (2 Used) 51- Cap Seal (2 Used) 52- O-Ring (2 Used) 53- Plug (2 Used) 54- Cartridge (2 Used) 55- Orifice Plug (2 Used) 56- Collar (2 Used) 57- O-Ring (2 Used) 58- Socket Bolt (6 Used)

UPPERSTRUCTURE / Swing Device Disassemble Swing Device • Thoroughly read Precautions for Disassembly and Assembly (W1-1B-1) before disassembling.

IMPORTANT: Don’t remove rear bearing (16) unless required.

IMPORTANT: Secure the flange in the vise with the pinion gear downward before beginning repair work.

8. Remove retaining ring (17) from flange mounting (34) to remove rear bearing (16) and shaft face seal (15).

1. Remove socket bolts (58) to shockless valve from the motor. : 6 mm

9. Remove piston (19), ring (18), plates (20), friction plates (21), and plate (30).

remove

the

IMPORTANT: Don’t disassemble the shockless valve unless required.

2. Secure the shockless valve in the vise. Remove the cartridge assembly. Remove O-rings (48) and backup rings (44) from the cartridge assembly.

3. Remove bolts (1). : 14 mm 4. Remove valve housing (40). Remove springs (6), pins (5), balancing ring (3), valve (39).

10. Secure bearing housing (28) in the vise with the pinion shaft upward. Remove retaining ring (26) from bearing housing (28).

11. Press out pinion gear (25) together with front bearing (27) from bearing housing (28).

IMPORTANT: Don’t remove front bearing (27) unless required.

12. After removing retaining ring (22) from pinion gear (25), press collar (23) and front bearing (27) out of pinion gear (25).

13. Remove X-ring (29) from bearing housing (28).

IMPORTANT: Take care not to lose springs (6) and pins (5).

5. Remove valve plate (37) and valve drive (13).

14. Remove plugs (7), springs (10), and steel balls (11) from valve housing (40). : 8 mm

6. Remove gerotor (36) and drive (24).

7. Remove socket bolts (14) to remove flange mounting (34) and springs (33). : 6 mm

W2-5B-3

UPPERSTRUCTURE / Swing Device ASSEMBLE SWING DEVICE Swing Motor

Shockless Valve 1 43 44

45 44 46

47 48 49 50 51 52 53

42 41

2

3

4

5

6

7

56 41 55 54

8 40

9

39

10 11

38

12 13

37 35 34 33

57

58 W513-02-01-002

12 14

36

15 16 17 18 19 20 21 22

32 31 30 29 28 27 26

23 24 25

9

1- Bolt (4 Used) 2- Outer Face Seal 3- Balancing Ring 4- Inner Face Ring 5- Pin (2 Used) 6- Spring (2 Used) 7- Plug (2 Used) 8- O-Ring (2 Used) 9- Plug (2 Used) 10- Spring (2 Used) 11- Steel Ball (2 Used) 12- O-Ring (3 Used) 13- Valve Drive 14- Socket Bolt (8 Used) 15- Shaft Face Seal

W513-02-01-001

16- Rear Bearing 17- Retaining Ring 18- Ring 19- Piston 20- Plate (4 Used) 21- Friction Plate (4 Used) 22- Retaining Ring 23- Collar 24- Drive 25- Pinion Gear 26- Retaining Ring 27- Front Bearing 28- Bearing Housing 29- X-Ring 30- Plate

31- O-Ring 32- O-Ring (3 Used) 33- Spring (8 Used) 34- Flange Mounting 35- O-Ring (2 Used) 36- Gerotor 37- Valve Plate 38- O-Ring 39- Valve 40- Valve Housing 41- Filter Element (4 Used) 42- Orifice Plug (2 Used) 43- Valve Body 44- Backup Ring (4 Used)

W2-5B-4

45- O-Ring (2 Used) 46- Plunger (2 Used) 47- Spring (2 Used) 48- O-Ring (2 Used) 49- Shim 50- Piston (2 Used) 51- Cap Seal (2 Used) 52- O-Ring (2 Used) 53- Plug (2 Used) 54- Cartridge (2 Used) 55- Orifice Plug (2 Used) 56- Collar (2 Used) 57- O-Ring (2 Used) 58- Socket Bolt (6 Used)

UPPERSTRUCTURE / Swing Device Assemble Swing Device • Thoroughly read Precautions for Disassembly and Assembly (W1-1-1) before assembling.

1. Press collar (23) and front bearing (27) onto pinion gear (25). Secure collar (23) and front bearing (27) with retaining ring (22).

IMPORTANT: Take care not to damage the ground collar face ( coming in contact with the X-ring) at this time.

2. Install X-ring (29) into bearing housing (28).

3. Install the pinion gear assembly into bearing housing (28) using a press.

4. Install retaining ring (26) into bearing housing (28) to secure front bearing (27).

5. Secure the flange in the vise with pinion gear (25) downward. Install plate (30) in bearing housing (28). Then, install friction plates (21) and plates (20) alternately into bearing housing (28).

IMPORTANT: Install friction plates (21) and plates (20) one by one in the correct order.

6. After installing O-rings (32 and 31) around ring (19), install ring (18) into bearing housing (28).

After installing O-ring (32) around piston (19), install piston (19) into bearing housing (28).

7. Install O-ring (32) around flange mounting (34).

8. Install shaft face seal (15) in flange mounting (34).

After installing rear bearing (16), secure rear bearing (16) with retaining ring (17).

9. Install springs (33) into flange mounting (34).

W2-5B-5

UPPERSTRUCTURE / Swing Device

Swing Motor

Shockless Valve

40 39

10 11

37 35 34

13 36

W513-02-01-002

12 14

28 24

W513-02-01-001

W2-5B-6

UPPERSTRUCTURE / Swing Device IMPORTANT: Install flange mounting (34) so that the drain port is located in the position as illustrated to the right.

Pilot Port Face

10. Install flange mounting (34) onto bearing housing (28). Apply LOCTITE #242 to socket bolts (14).

Secure flange mounting (34) to bearing housing (28) with socket bolts (14). : 6 mm : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)

11. Install O-rings (35 and 12) onto flange mounting (34). Install drive (24) and gerotor (36).

W513-02-01-003

Drain Port Location

IMPORTANT: Install gerotor (36) so that the drain hole on gerotor (36) aligns with the drain hole on flange mounting (34).

12. Install valve drive (13). Then, after installing Orings (35 and 12) onto valve plate (37), install valve plate (37).

IMPORTANT: Install valve plate (37) so that the drain hole on valve plate (37) aligns with the drain hole on gerotor (36).

13. Install valve (39).

IMPORTANT: Direction of the motor rotation is decided by the installation direction of valve (39). Install valve (39) carefully while referring to the illustration to the right. The motor will rotate in the reverse direction if the timing is not set correctly.

Incline the lateral hole by 15° from the external tooth tip.

Valve Valve Drive

14. Install steel balls (11), springs (10), and plugs (7) into valve housing (40). : 8 mm : 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft)

W2-5B-7

15°

Lateral Hole 15° External W513-02-01-004

UPPERSTRUCTURE / Swing Device

Swing Motor

Shockless Valve 1 43

2

3

4

5

45 44

48

6

40 39 38 12 W513-02-01-002

W513-02-01-001

W2-5B-8

UPPERSTRUCTURE / Swing Device NOTE: Take care not to damage the seal surfaces.

15. Install inner face seal (4) and outer face seal (2) onto balancing ring (3).

16. Install balancing springs (6) and pins (5) in valve housing (40).

17. While aligning the notch on balancing ring (3) with pin (5), install balancing ring (3) into valve housing (40).

40 2 3 4

18. Install O-rings (38 and 12) onto valve housing (40).

While holding balancing ring (3) with a small diameter bar like a screw driver inserted through the bolt hole not to allow balancing ring (3) to come off, install valve housing (3) on valve (39).

W513-02-01-005

IMPORTANT: Install valve housing (3) so that the drain hole on the valve housing aligns with the drain hole on the valve plate.

19. Apply LOCTITE #242 to bolts (1). Tighten bolts (1). : 14 mm : 53 N⋅m (5.4 kgf⋅m, 39 lbf⋅ft) 20. Install O-rings (48 and 45) and backup rings (44) onto the cartridge assembly. Install the cartridge assembly into valve body (43). : 113 to 118 N⋅m (11.5 to 12 kgf⋅m, 83 to 87 lbf⋅ft)

W2-5B-9

UPPERSTRUCTURE / Swing Device

Swing Motor

Shockless Valve 43

57

58 W513-02-01-002

W513-02-01-001

W2-5B-10

UPPERSTRUCTURE / Swing Device 21. Install O-rings (57) into valve body (43). Secure the shockless valve with socket bolts (58). : 6 mm : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft) 22. Check the rotation direction of the swing motor before installing the swing device onto the machine. If the rotation direction is incorrect, disassemble the device and reset the valve timing.

W2-5B-11

UPPERSTRUCTURE / Swing Device (Blank)

W2-5B-12

UNDERCARRIAGE / Travel Device REMOVE AND INSTALL TRAVEL DEVICE CAUTION: Escaping hydraulic fluid under pressure can penetrate the skin or eyes causing serious injury. Avoid this hazard by relieving pressure before disconnecting any hydraulic lines.

Hydraulic oil and components may be not just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for hydraulic oil and components to cool before starting repair work.

Preparation 1. Place the machine on a solid, level surface, and lower the bucket to the ground.

2. Stop the engine. Loosen the hydraulic oil tank cap to release the air in the hydraulic oil tank.

3. Remove the cap. Install a vacuum pump on the hydraulic oil tank. Operate the vacuum pump to create negative pressure in the tank.

Keep the vacuum pump running continuously while working on the system.

T570-06-03-011

W3-2B-1

UNDERCARRIAGE / Travel Device DISASSEMBLE TRAVEL DEVICE Reduction Gear

4

2

5

6

7

8

9

10

Motor

11 12 13 14 15 16 17 18 19

20 21

22

23

3 2 1

24 52

25 51 26 50

49 48 T513-03-05-001

47 46 45

44 43 42 41

29 40 39 38 37 36 35 34 33 32

31

28

27

30

1 - Retaining Ring(3 Used) 2 - Thrust Plate(6 Used) 3 - First Stage Planetary Gear(3 Used) 4 - Needle Bearing(3 Used) 5 - Housing 1 6 - Retaining Ring 7 - Oil Seal 8 - Retaining Ring 9 - Inner Ring 10 - Retainer with Balls 11 - Steel Ball(2 Used) 12 - O-Ring 13 - Seal Ring

16 - Retainer 17 - Plunger(7 Used) 18 - Housing 2

31 - Retainer 32 - Pin(3 Used) 33 - Holder

46 - Second Stage Sun Gear 47 - Carrier 48 - O-Ring

19 20 21 22 23 24 25 26 27 28 -

34 35 36 37 38 39 40 41 42 43 -

49 - Retaining Ring 50 - Plug 51 - Bearing 52 - Cover 53 - Plug 54 - O-Ring 55 - Spring(2 Used) 56 - Spool Assembly 57 - Spool 58 - Spring

14 - Swash Plate 15 - Shoe(7 Used)

29 - Retainer 30 - Spring

Cylinder Block Socket Bolt(7 Used) O-Ring Pin Shaft Housing 3 Bearing Valve Plate Retaining Ring O-Ring

O-Ring Seal Ring Inner Ring Retainer with Balls Bearing Piston Thrust Plate(4 Used) Ring(4 Used) Needle Bearing(4 Used) Second Stage Planetary Gear(4 Used) 44 - Thrust Plate 45 - Retaining Ring(4 Used)

W3-2B-2

59 - O-Ring 60 - Plug

UNDERCARRIAGE / Travel Device

53

54

55

60

56

59

58

W3-2B-3

57

T513-03-05-002

UNDERCARRIAGE / Travel Device

Reduction Gear

4

2

5

6

7

8

9

10

Motor

11 12 13 14 15 16 17 18 19

20 21

22

23

3 2 1

24 52

25 51 26 50

49 48 T513-03-05-001

47 46 45

44 43 42 41

29 40 39 38 37 36 35 34 33 32

W3-2B-4

31

30

28

27

UNDERCARRIAGE / Travel Device • Read PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING (W1-1-1) carefully before disassembling.

IMPORTANT: Valve plate (26) may stick to housing 2 (18). Take care not to drop valve plate (26) when removing housing 2 (18).

1. Remove plug (50) from cover (52).

14. Removes socket bolts (20) (7 used) to remove housing 3 (24) and valve plate (26).

: 8 mm 2. Remove retaining ring (49) from cover (52), then remove cover (52) from housing 1 (5).

: 8 mm 15. Remove O-rings (21, 28) and bearing (25) from housing 3 (24).

16. Remove cylinder block (19) assembly, swash plate (14), steel ball (11) (2 used) and piston (39) from housing 2 (18).

3. Remove bearing (51) from cover (52).

4. Remove O-ring (48) form housing 1 (5).

5. Remove carrier (47) assembly, retaining ring (6) and second stage sun gear (46) from housing 1 (5).

17. Remove plungers (17) (7 used), retainer (16), holder (33) and pin (32) from cylinder block (19).

CAUTION: Always hold retainer (29) and spring (30) with a press when removing retaining ring (27). If retaining ring (27) is removed without holding retainer (29) and spring (30), retainer (29) and spring (30) may fly out potentially causing serious injury.

6. Remove retaining rings (1) (3 used), thrust plates (2) (3 used), first stage planetary gears (3) (3 used) and needle bearing (4) (3 used) from carrier (47).

7. Remove retaining rings (45) (4 used), thrust plate (44), second stage planetary gears (43) (4 used), needle bearings (42) (4 used), rings (41) (4 used) and thrust plates (40) (4 used) from housing 1 (5).

18. Remove retaining ring (27) from cylinder block (19), then remove retainer (29), spring (30) and retainer (31).

8. Remove retaining ring (8) from housing 1 (5).

19. Remove oil seal (7) from housing 2 (18).

9. Remove housing 1 (5) from housing 2 (18).

10. Remove inner ring (9) and retainer with balls (10) from housing 1 (5).

11. Remove seal ring (13) and O-ring (12) from housing 1 (5).

12. Remove retainer with balls (37) and inner ring (36) from housing 2 (18).

13. Remove seal ring (35) and O-ring (34) from housing 2 (18).

NOTE: Seal ring (35) and O-ring (34) are the floating seals. Refer to W1-1-3 for precautions for handling the floating seal.

W3-2B-5

UNDERCARRIAGE / Travel Device

53

54

55

60

56

59

58

W3-2B-6

57

T513-03-05-002

UNDERCARRIAGE / Travel Device 20. Remove plug (53) from housing 3 (24), then remove spring (55), and spool assembly (56). : 27 mm IMPORTANT: Do not disassemble spool assembly (56).

21. Remove plug (60) from housing 3 (24), then remove spring (58) and spool (57). : 8 mm

W3-2B-7

UNDERCARRIAGE / Travel Device ASSEMBLE TRAVEL DEVICE Reduction Gear

4

2

5

6

7

8

9

10

Motor

11 12 13 14 15 16 17 18 19

20 21

22

23

3 2 1

24 52

25 51 26 50

49 48 T513-03-05-001

47 46 45

44 43 42 41

29 40 39 38 37 36 35 34 33 32

31

28

27

30

1 - Retaining Ring(3 Used) 2 - Thrust Plate(6 Used) 3 - First Stage Planetary Gear(3 Used) 4 - Needle Bearing(3 Used) 5 - Housing 1 6 - Retaining Ring 7 - Oil Seal 8 - Retaining Ring 9 - Inner Ring 10 - Retainer with Balls 11 - Steel Ball(2 Used) 12 - O-Ring 13 - Seal Ring

16 - Retainer 17 - Plunger(7 Used) 18 - Housing 2

31 - Retainer 32 - Pin(3 Used) 33 - Holder

46 - Second Stage Sun Gear 47 - Carrier 48 - O-Ring

19 20 21 22 23 24 25 26 27 28 -

34 35 36 37 38 39 40 41 42 43 -

49 - Retaining Ring 50 - Plug 51 - Bearing 52 - Cover 53 - Plug 54 - O-Ring 55 - Spring(2 Used) 56 - Spool Assembly 57 - Spool 58 - Spring

14 - Swash Plate 15 - Shoe(7 Used)

29 - Retainer 30 - Spring

Cylinder Block Socket Bolt(7 Used) O-Ring Pin Shaft Housing 3 Bearing Valve Plate Retaining Ring O-Ring

O-Ring Seal Ring Inner Ring Retainer with Balls Bearing Piston Thrust Plate(4 Used) Ring(4 Used) Needle Bearing(4 Used) Second Stage Planetary Gear(4 Used) 44 - Thrust Plate 45 - Retaining Ring(4 Used)

W3-2B-8

59 - O-Ring 60 - Plug

UNDERCARRIAGE / Travel Device

53

54

55

60

56

59

58

W3-2B-9

57

T513-03-05-002

UNDERCARRIAGE / Travel Device

Reduction Gear

4

2

5

6

7

8

9

10

Motor

11 12 13 14 15 16 17 18 19

20 21

22

23

3 2 1

24 52

25 51 26 50

49 48 T513-03-05-001

47 46 45

44 43 42 41

29 40 39 38 37 36 35 34 33 32

W3-2B-10

31

30

28

27

UNDERCARRIAGE / Travel Device • Read PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING (W1-1-1) carefully before assembling.

1. Install bearing (25) and pin (22) into housing 3 (24).

7

2. Install O-rings (21, and 28) onto housing 3 (24).

Motor Side

3. Install oil seal (7) into housing 2 (18).

Reduction Gear Side

4. Install the retaining pin onto housing 2 (18).

5. Install bearing (38) onto shaft (23) using a press.

6. Install piston (39) onto housing 2 (18).

7. Install shaft (23) into housing 2 (18).

NOTE: Do not damage oil seal (7) by shaft (23).

8. Install steel balls (11) (2 used) onto housing 2 (18).

Apply a film of hydraulic oil on the sliding surface of swash plate (14). Apply a film of grease on the back surface of swash plate (14) to prevent swash plate (14) from dropping. Install swash plate (14) onto housing 2 (18).

9. Install retainer (31), spring (30) and retainer (29) into cylinder block (19) in this order.

10. Depress retainer (29) and spring (30) downward with a press, and install retaining ring (27).

11. Install the assemblies of plungers (17) (7 used) and shoes (15) (7 used) into retainer (16).

12. Drive pins (32) (3 used) into cylinder block (19).

Install the assembly of plungers (17) and retainer (16) into cylinder block (19).

13. Install cylinder block (19) assembly into housing 2 (18). Add 0.1 litter (0.1 US qt) of hydraulic oil into housing 2 (18).

W3-2B-11

W513-03-03-001

UNDERCARRIAGE / Travel Device

Reduction Gear

4

2

5

6

7

8

9

10

Motor

11 12 13 14 15 16 17 18 19

20 21

22

23

3 2 1

24 52

25 51 26 50

49 48 T513-03-05-001

47 46 45

44 43 42 41

29 40 39 38 37 36 35 34 33 32

W3-2B-12

31

30

28

27

UNDERCARRIAGE / Travel Device 14. Apply a film of grease on the back surface of valve plate (26) to prevent valve plate (26) from dropping. Install valve plate (26) onto housing 2 (18). Apply a film of hydraulic oil on the sliding surface of valve plate (26).

NOTE: The bronze surface of valve plate (26) faces toward cylinder block (19).

15. Install housing 3 (24) onto housing 2 (18), and tighten socket bolts (20) (7 used). : 5 mm : 28 to 30 N⋅m (2.8 to 3.1 kgf⋅m, 20 to 22 lbf⋅ft) 16. Install O-ring (34) onto seal ring (35), then install them into housing 2 (18).

NOTE: Seal ring (35) and O-ring (34) are the floating seals. Refer to W1-1-3 for precautions for handling the floating seal.

17. Install inner ring (36) and retainer with balls (37) onto housing 2 (18).

NOTE: Keep the balls with retainers.

Refer to the section view drawing for the direction of inner ring (36).

18. Install O-ring (11) into seal ring (13). Apply a film of grease on seal ring (13). Install seal ring (13) onto housing 1 (5).

5

NOTE: The sliding surface of seal ring (13) faces toward the motor.

19. Install housing 2 (18) into housing 1 (5) using clamps. Tapping housing 1 (5).

Clamp

Clamp

20. Install retainer with balls (10) and inner ring (9) onto housing 1 (5).

NOTE: Keep the balls with retainers.

0Refer to the section view drawing for the direction of inner ring (9).

18 W571-03-02-006

21. Install retaining ring (8) onto housing 1 (5).

W3-2B-13

UNDERCARRIAGE / Travel Device

Reduction Gear

4

2

5

6

7

8

9

10

Motor

11 12 13 14 15 16 17 18 19

20 21

22

23

3 2 1

24 52

25 51 26 50

49 48 T513-03-05-001

47 46 45

44 43 42 41

29 40 39 38 37 36 35 34 33 32

W3-2B-14

31

30

28

27

UNDERCARRIAGE / Travel Device 22. Install rings (41) (4 used), thrust plates (40) (4 used), second stage planetary gears (43) (4 used), needle bearings (42) (4 used) and thrust plate (44) into housing 1 (5) in this order. Secure them with retaining rings (45) (4 used).

NOTE: The sharp edge surface of retaining ring (45) faces toward cover (52).

23. Install second stage sun gear (46) onto carrier (47), then secure them with retaining ring (6).

NOTE: The sharp edge surface of retaining ring (6) faces toward cover (52).

24. Install thrust plates (2) (3 used), first stage planetary gears (3) (3 used), needle bearings (4) (3 used) and thrust plates (2) (3 used) onto carrier (47) in this order, then secure them with retaining rings (1) (3 used).

NOTE: The sharp edge surface of retaining ring (1) faces toward cover (52).

25. Install carrier (47) assembly into housing 1 (5).

26. Install O-ring (48) onto housing 1 (5).

27. Install bearing (51) onto cover (52).

Add 0.33 litter (0.3 US gt) for lubrication oil into housing 1 (5).

Install cover (52) onto housing 1 (5), then secure them using retaining ring (49).

NOTE: Align the mark of DRAIN on cover (52) with the notch on housing 1 (5), before installing cover (52).

28. Install plug (50) onto cover (52).

Lock cover (52) with the flange of plug (50). : 8 mm : 46 to 51 N⋅m (4.7 to 5.2 kgf⋅m, 34 to 37 lbf⋅ft)

W3-2B-15

UNDERCARRIAGE / Travel Device

53

54

55

60

56

59

58

W3-2B-16

57

T513-03-05-002

UNDERCARRIAGE / Travel Device 29. Install spool assembly (56) and springs (55) (2 used) into housing 3 (24), then install O-ring (54) and plug (53). : 27 mm : 167 to 196 N⋅m (17 to 20 kgf⋅m, 123 to 145 lbf⋅ft) 30. Install spool (57), spring (58) and O-ring (59) into housing 3 (24), then install plug (60). : 8 mm : 46 to 51 N⋅m (4.7 to 5.3 kgf⋅m, 34 to 38 lbf⋅ft)

W3-2B-17

UNDERCARRIAGE / Travel Device (Blank)

W3-2B-18