Hitachi ZX35U-5A Hydraulic Excavator Workshop Manual

PART NO.

WADCJ0-EN-00

ZX35U-5A HYDRAULIC EXCAVATOR

Workshop Manual

WORKSHOP MANUAL

ZX35U-5A

Hydraulic Excavator

URL:http://www.hitachi-c-m.com

WADCJ0-EN-00

PRINTED IN JAPAN (K) 2013, 12

Service Manual consists of the following separate Part No. Technical Manual : Vol. No.TADCJ0-EN Workshop Manual : Vol. No.WADCJ0-EN Engine Manual : Vol. No.ETADB-EN, EWADB-EN

INTRODUCTION To The Reader This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.

The machine specification and description according to destination may be explained on this manual.

 If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.):  Technical Information Center Hitachi Construction Machinery Co. Ltd.  TEL: 81-29-832-7084  FAX: 81-29-831-1162  E-mail: HCM-TIC-GES@hitachi-kenki.com

 Be sure to thoroughly read this manual for correct product information and service procedures.

Additional References Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.

Manual Composition  Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.

This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.  Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

 Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.

Page Number Each page has a number, located on the center lower part of the page, and each number contains the following information: Example:  Technical Manual: T 1-3-5 T 1 3 5

 Workshop Manual: W 1-3-2-5 W 1 3 2 5

Technical Manual Section Number Group Number Consecutive Page Number for Each Group

IN-01

Workshop Manual Section Number Group Number Sub Group Number Consecutive Page Number for Each Group

INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage.

dCAUTION: Indicates potentially hazardous situation which could, if not avoided, result in personal injury or death.

d This is the safety alert symbol. When you see this

IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

symbol, be alert to the potential for personal injury.

Never fail to follow the safety instructions prescribed along with the safety alert symbol.

The safety alert symbol is also used to draw attention to component/part weights.

To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

fNOTE: Indicates supplementary technical information or knowhow.

Units Used SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parentheses just behind SI units.

Example: 24.5 MPa (250 kgf/cm2, 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposes.

Quantity

To Convert From

Into

Multiply By

Length

mm

in

0.03937

mm

ft

0.003281

L

US gal

0.2642

L

US qt

1.057

m3

yd3

1.308

Weight

kg

lb

2.205

Force

N

kgf

0.10197

N

lbf

0.2248

Torque

N·m

kgf·m

Pressure

MPa

kgf/cm

MPa

psi

145.0

kW

PS

1.360

kW

HP

1.341

Temperature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

min

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Volume

Power

Flow rate

-1

fNOTE:

The numerical value in this manual might be different from the above-mentioned table.

IN-02

0.10197 2

10.197

SYMBOL AND ABBREVIATION Symbol / Abbreviation TO TT T/M W, W/M

Name

Explanation

Technical manual (Operational principle) Technical manual (Troubleshooting) Technical manual Workshop manual

A/C OP, OPT MPDr.

Air Conditioner Option Maintenance Pro Dr.

A/I WU Li ATT

Auto-Idle Warming-Up Low (Slow) Idle Attachment

HI, Hi LO, Lo

High Low

Technical manual (Operational Principle).

Technical manual (Troubleshooting).

Technical manual.

Workshop manual (Removal and Installation, Disassembly and Assembly).

Air conditioner.

Optional component.

MPDr. is software that troubleshooting, monitoring, and adjustment.

Auto-idle.

Warming-up.

Slow idle engine speed.

Attachment. Attachment is optional parts such as breaker, crusher, and pulverizer in this manual.

Travel fast position.

Travel slow position.

SY-1

SYMBOL AND ABBREVIATION (Blank)

SY-2

SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS.  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.  Follow recommended precautions and safe operating practices.

SA-688

Understand Signal Words  On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.  DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.  WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.  CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.  DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.  Some safety signs do not use any of the designated signal words above after the safety alert symbol are occasionally used on this machine.  CAUTION also calls attention to safety message in this manual.  To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine. 

NOTE: indicates an additional explanation for an element of information.

SA-1

SA-1223

SAFETY Follow Safety Instructions  Carefully read and follow all safety signs on the machine and all safety messages in operator's manual.  Safety signs should be installed, maintained and replaced when necessary.  If a safety sign or operator's manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).  Learn how to operate the machine and its controls correctly and safely.  Allow only trained, qualified, authorized personnel to operate the machine.  Keep your machine in proper working condition.  Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.  Do not modify any machine parts without authorization.

Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Hitachi Warranty Policy.  Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void Hitachi Warranty Policy.  The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/ or your authorized dealer before operating or performing maintenance work on the machine.

SA-2

SA-003

SAFETY Prepare for Emergencies  Be prepared if a fire starts or if an accident occurs.  Keep a first aid kit and fire extinguisher on hand.  Thoroughly read and understand the label attached on the fire extinguisher to use it properly.  To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire extinguisher manual.  Establish emergency procedure guidelines to cope with fires and accidents.  Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.

SA-437

Wear Protective Clothing  Wear close fitting clothing and safety equipment appropriate to the job.

You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask Be sure to wear the correct equipment and clothing for the job. Do not take any chances.  Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.  Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.

SA-3

SA-438

SAFETY Protect Against Noise  Prolonged exposure to loud noise can cause impairment or loss of hearing.  Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

SA-434

Inspect Machine  Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.  In the walk-around inspection be sure to cover all points described in the "Inspect Machine Daily Before Starting" section in the operator’s manual.

SA-435

SA-4

SAFETY General Precautions for Cab  Before entering the cab, thoroughly remove all dirt and/or oil such as mud, grease, soil or stones that may mess up the cab from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident.  Do not mess up around the operator’s seat with parts, tools, soil, stones, obstacles that may fold up or turn over, cans or lunch box. The levers or pedals become inoperable if obstacle jams in operation stroke of the travel levers/pedals, pilot control shut-off lever or control levers, which may result in serious injury or death.  Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire.  Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine.  Keep all flammable objects and/or explosives away from the machine.  After using the ashtray, always cover it to extinguish the match and/or tobacco.  Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.  Use proper floor mat dedicated to the machine. If another floor mat is used, it may be displaced and contact with the travel pedals during operation, resulting in serious injury or death.

SA-5

SAFETY Use Handrails and Steps  Falling is one of the major causes of personal injury.  When you get on and off the machine, always use the crawler instead of the step for safety. Be sure you have adequate footing on the crawler when getting on or off the machine.  When you get on and off the machine, always face the machine.  Maintain a three-point contact with the steps and handrails.  Do not use any controls as handholds.  Never jump on or off the machine. Never mount or dismount a moving machine.  In case adhered slippery material such as oil, grease, or mud is present on steps, handrails, or platforms, thoroughly remove such material.

SA-439

Adjust the Operator's Seat  A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations.  The seat should be adjusted whenever changing the operator for the machine.  The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back.  If not, move the seat forward or backward, and check again.  Adjust the rear view mirror position so that the best rear visibility is obtained from the operator’s seat. If the mirror is broken, immediately replace it with a new one.

SA-6

SA-378

SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat  Before rising from the operator’s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death.  Before leaving the machine, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Turn the key switch OFF to stop the engine.  Before leaving the machine, close all windows, doors, and access covers and lock them up.

Fasten Your Seat Belt  If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.  Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine.  Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident.  We recommend that the seat belt be replaced every three years regardless of its apparent condition.

SA-7

SA-237

SAFETY Move and Operate Machine Safely  Bystanders can be run over.  Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine.  Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move.  Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine.  Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it.  Ensure the cab door, windows, doors and covers are securely locked.  Check the mirrors for problems.

If there is, replace the problem part(s) or clean the mirror.

SA-1291

Operate Only from Operator's Seat  Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.  Start the engine only when seated in the operator's seat.  NEVER start the engine while standing on the track or on ground.  Do not start engine by shorting across starter terminals.  Before starting the engine, confirm that all control levers are in neutral.  Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders.

SA-444

SA-8

SAFETY Jump Starting  Battery gas can explode, resulting in serious injury.  If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual.  The operator must be in the operator’s seat so that the machine will be under control when the engine starts.

Jump starting is a two-person operation.  Never use a frozen battery.  Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.

SA-032

Keep Riders off Machine  Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine.  Only the operator should be on the machine. Keep riders off.  Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.

SA-1292

SA-9

SAFETY Precautions for Operations  Investigate the work site before starting operations.  Be sure to wear close fitting clothing and required safety items, such as a hard hat, when operating the machine.  Keep all bystanders and unnecessary objects out of and away from the machine working areas. Always beware of the surroundings while operating the machine. Take care not to allow the rear part of the upperstructure to come in contact with objects when swinging the machine in a small area.  When loading a dump truck, bring the bucket from the rear side of the dump truck to avoid moving the bucket over the dump truck cab or over any co-workers.

M586-12-012

SA-10

SAFETY Investigate Job Site Beforehand  When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.  Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles or banks from collapsing.  Make a work plan. Use machines appropriate to the work and job site.  Reinforce ground, edges and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders.  When working on an incline or on a road shoulder, employ a signal person as required.  Confirm that your machine is equipped with a FOPS cab before working in areas where the possibility of falling stones or debris exist.  When the footing is weak, reinforce the ground before starting work.  When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery.  Beware the possibility of fire when operating the machine near flammable objects such as dry grass.

SA-11

SA-1293

SAFETY  Make sure the worksite has sufficient strength to firmly support the machine.

When working close to an excavation or at road shoulders, operate the machine with the tracks positioned perpendicular to the cliff face with travel motors at the rear, so that the machine can more easily evacuate if the cliff face collapses.  If working on the bottom of a cliff or a high bank is required, be sure to investigate the area first and confirm that no danger of the cliff or bank collapsing exists. If any possibility of cliff or bank collapsing exists, do not work on the area.  Soft ground may collapse when operating the machine on it, possibly causing the machine to tip over. When working on soft ground is required, be sure to reinforce the ground first using large pieces of steel plates strong and firm enough to easily support the machine.  Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes. Prevent machine tipping over from occurring. When operating on rough terrain or on slopes:  Reduce the engine speed.  Select slow travel speed mode.  Operate the machine slowly and be cautious with machine movements.

M586-05-021

Install OPG Guard In case the machine is operated in areas where the possibilities of falling stones or debris exist, equip Hitachi OPG guard.

Consult your authorized dealer for installing the OPG guard.

The guard can be compliant with ROPS standards depending on the machine specifications.

In order not to impair operator protective structure: Replace damaged ROPS or OPG guard. Never attempt to repair or modify the guard.

ROPS: Roll Over Protective Structure OPG: Operator Protective Guard

SA-490

SA-12

SAFETY Provide Signals for Jobs Involving Multiple Machines  For jobs involving multiple machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

SA-481

Confirm Direction of Machine to Be Driven  Incorrect travel pedal/lever operation may result in serious injury or death.  Before driving the machine, confirm the position of the undercarriage in relation to the operator’s position. If the travel motors are located in front of the cab, the machine will move in reverse when travel pedals/levers are operated to the front.

SA-1294

SA-13

SAFETY Drive Machine Safely  Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direction you wish to drive.  Be sure to detour around any obstructions.  Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Do not allow personnel to stay around the machine while traveling.  Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.  Never attempt to ascend or descend 35 degrees or steeper slopes.  Be sure to fasten the seat belt.  When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.2 to 0.3 m (A) above the ground.  If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.  Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.  Avoid swinging the upperstructure on slopes. Never attempt to swing the upperstructure downhill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed.  If the engine stalls on a slope, immediately lower the bucket to the ground. Return the control levers to neutral.

Then, restart the engine.

A

SA-1295

A

SA-1296

SA-441

MZX5-04-002

SA-14

SAFETY  When the machine descends a slope at high speed, machine weight accelerates descending speed. It may cause collision accident due to misjudging of braking distance or machine turnover due to running on an unexpected obstacle.

Always ensure that travel mode display (1) on the monitor is , and then reduce the engine speed before descending a slope.  Be sure to thoroughly warm up the machine before ascending steep slopes. If hydraulic oil has not warmed up sufficiently, sufficient performance may not be obtained.  Use a signal person when moving, swinging or operating the machine in congested areas. Coordinate hand signals before starting the machine.  Before moving machine, determine which way to move travel pedals/levers for the direction you want to go.

When the travel motors are in the rear, pushing down on the front of the travel pedals or pushing the levers forward moves the machine forward, towards the idlers.

An arrow-mark seal is stuck on the inside surface of the side frame to indicate the machine front direction.  Select a travel route that is as flat as possible. Steer the machine as straight as possible, making small gradual changes in direction.  Before traveling on them, check the strengths of bridges and road shoulders, and reinforce if necessary.  Use wood plates in order not to damage the road surface.

Be careful of steering when operating on asphalt roads in summer.  When crossing train tracks, use wood plates in order not to damage them.  Do not make contact with electric wires or bridges.  When crossing a river, measure the depth of the river using the bucket, and cross slowly. Do not cross the river when the depth of the river is deeper than the upper edge of the upper roller.  When traveling on rough terrain, reduce engine speed.

Select slow travel speed. Slower speed will reduce possible damage to the machine.  Avoid operations that may damage the track and undercarriage components.  During freezing weather, always clean snow and ice from track shoes before loading and unloading machine, to prevent the machine from slipping.

1

MADB-00-007

Travel Motor M104-05-008

SA-673

M586-05-002

SA-15

SAFETY Avoid Injury from Rollaway Accidents  Death or serious injury may result if you attempt to mount or stop a moving machine.

To avoid rollaways:  Select level ground when possible to park the machine.  Do not park the machine on a grade.  Lower the bucket and/or other work tools to the ground.  Turn the auto-idle switch OFF.  Run the engine at slow idle speed without load for 5 minutes to cool down the engine.  Stop the engine and remove the key from the key switch.  Pull the pilot control shut-off lever to LOCK position.  Block both tracks and lower the bucket to the ground.

Thrust the bucket teeth into the ground if you must park on a grade.  Position the machine to prevent rolling.  Park at a reasonable distance from other machines.

SA-1297

SA-16

SAFETY Avoid Injury from Back-Over and Swing Accidents  If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death.

To avoid back-over and swing accidents:  Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR.  Keep the travel alarm in working condition (if equipped).

ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE.  USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person.  No machine motions shall be made unless signals are clearly understood by both signalman and operator.  Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling.  Keep windows, mirrors, and lights clean and in good condition.  Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.  Read and understand all operating instructions in the operator’s manual.

SA-17

SA-383

SA-384

SAFETY Keep Person Clear from Working Area  A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death.  Keep all persons clear from the area of operation and machine movement.  Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area.

SA-667

Never Position Bucket Over Anyone  Never lift, move, or swing bucket above anyone or a truck cab.

Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.

SA-668

SA-18

SAFETY Avoid Undercutting  In order to retreat from the edge of an excavation if the footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear.  If the footing starts to collapse and if retreat is not possible, do not panic. Often, the machine can be secured by lowering the front attachment, in such cases.

SA-1300

Avoid Tipping DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE --- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT  The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.

To avoid tipping:  Be extra careful before operating on a grade.  Prepare machine operating area flat.  Keep the bucket low to the ground and close to the machine.  Reduce operating speeds to avoid tipping or slipping.  Avoid changing direction when traveling on grades.  NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable.  Reduce swing speed as necessary when swinging loads.  Be careful when working on frozen ground.  Temperature increases will cause the ground to become soft and make ground travel unstable.

SA-19

SA-1301

SAFETY Never Undercut a High Bank  The edges could collapse or a land slide could occur causing serious injury or death.

SA-1302

Dig with Caution  Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.  Before digging check the location of cables, gas lines, and water lines.  Keep the minimum distance required, by law, from cables, gas lines, and water lines.  If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.  Contact your local “diggers hot line” if available in your area , and/or the utility companies directly.

Have them mark all underground utilities.

SA-672

Operate with Caution  If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may result as well.  Take care to avoid hitting overhead obstacles with the boom or arm.

SA-673

SA-20

SAFETY Avoid Power Lines  Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines.  When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length.  Check and comply with any local regulations that may apply.  Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site.

SA-1305

Precautions for Lightning  The machine is vulnerable to lightning strikes.  In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine.  After the electrical storm has passed, check all of the machine safety devices for any failure. If any failed safety devices are found, operate the machine only after repairing them.

SA-1805

SA-21

SAFETY Object Handling  If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death.  When using the machine for craning operations, be sure to comply with all local regulations.  Do not use damaged chains or frayed cables, sables, slings, or ropes.  Before craning, position the upperstructure with the travel motors at the rear.  Move the load slowly and carefully. Never move it suddenly.  Keep all persons well away from the load.  Never move a load over a person’s head.  Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground.  Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall.

SA-014

Protect Against Flying Debris  If flying debris hit eyes or any other part of the body, serious injury may result.  Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.  Keep bystanders away from the working area before striking any object.

SA-432

SA-22

SAFETY Park Machine Safely To avoid accidents:  Park machine on a firm, level surface.  Lower bucket to the ground.  Turn auto-idle switch OFF.  Run engine at slow idle speed without load for 5 minutes.  Turn key switch to OFF to stop engine.  Remove the key from the key switch.  Pull the pilot control shut-off lever to the LOCK position.  Close windows, roof vent, and cab door.  Lock all access doors and compartments.

SA-1306

Handle Fluids Safely−Avoid Fires  Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.  Do not refuel the machine while smoking or when near open flame or sparks.  Always stop the engine before refueling the machine.  Fill the fuel tank outdoors.  All fuels, most lubricants, and some coolants are flammable.  Store flammable fluids well away from fire hazards.  Do not incinerate or puncture pressurized containers.  Do not store oily rags; they can ignite and burn spontaneously.  Securely tighten the fuel and oil filler cap.

SA-018

SA-019

SA-23

SAFETY Transport Safely  Take care the machine may turn over when loading or unloading the machine onto or off of a truck or trailer.  Observe the related regulations and rules for safe transportation.  Select an appropriate truck or trailer for the machine to be transported.  Be sure to use a signal person.  Always follow the following precautions for loading or unloading: 1. Select solid and level ground.

SA-1307

2. Always use a ramp or deck strong enough to support the machine weight.

3. Push auto-idle switch (1) to turn A/I display (2) OFF. (ZX68USR-5A)

3

4. Select the slow travel mode for loading or unloading the machine.

Always ensure that travel mode display (3) on the monitor is , before traveling the machine.

5. Never load or unload the machine onto or off a truck or trailer using the front attachment functions when driving up or down the ramp.

6. Never steer the machine while on the ramp. If the traveling direction must be changed while the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again.

7. The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it.

8. Place blocks in front of and behind the tires. Securely hold the machine to the truck or trailer deck with wire ropes.

Be sure to further follow the details described in the TRANSPORTING section.

SA-24

2

1

MADB-00-007

SAFETY Practice Safe Maintenance To avoid accidents:  Understand service procedures before starting work.  Keep the work area clean and dry.  Do not spray water or steam inside cab.  Never lubricate or service the machine while it is moving.  Keep hands, feet and clothing away from power-driven parts.

Before servicing the machine: 1. Park the machine on a level surface.

2. Lower the bucket to the ground.

3. Turn the auto-idle switch off.

4. Run the engine at slow idle speed without load for 5 minutes.

5. Turn the key switch to OFF to stop engine.

6. Relieve the pressure in the hydraulic system by moving the control levers several times.

SA-028

7. Remove the key from the key switch.

8. Attach a “Do Not Operate” tag on the control lever.

9. Pull the pilot control shut-off lever to the LOCK position.

10. Allow the engine to cool.  If a maintenance procedure must be performed with the engine running, do not leave the machine unattended.  If the machine must be raised, maintain a 90 to 110˚ angle between the boom and arm. Securely support any machine elements that must be raised for service work.  Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of operator's manual.  Keep all parts in good condition and properly installed.  Fix damage immediately. Replace worn or broken parts.

Remove any buildup of grease, oil, or debris.  When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces.  Disconnect battery ground cable (−) before making adjustments to electrical systems or before performing welding on the machine.

90 to 110°

M1M7-04-006

SA-527

SA-25

SAFETY  Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.  Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.  When the floor tilt mechanism check and/or maintenance is conducted, the operator’s station is tilted upward.

Before conducting maintenance work, refer to page 13-14 in operator's manual for the detailed operation procedures and correctly operate the machine.  When required to work under the floor, support the raised operator’s station with the fall prevention bars (red color) to ensure safety.  When the inspection/maintenance work is complete, tilt the operator’s station downward after housing the fall prevention bars. Be sure to slowly lower the operator’s station at the time.  Be careful not to allow the operator’s station to tilt down without first stowing the fall prevention bars. Damage to the tilt mechanism may result.

SA-037

M1MW-07-031

Warn Others of Service Work  Unexpected machine movement can cause serious injury.  Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever.

This tag is available from your authorized dealer.

SS3063861

SA-26

SAFETY Support Machine Properly  Never attempt to work on the machine without securing the machine first.  Always lower the attachment to the ground before you work on the machine.  If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

SA-527

Stay Clear of Moving Parts  Entanglement in moving parts can cause serious injury.  To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

SA-026

SA-2294

SA-27

SAFETY Prevent Parts from Flying  Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in serious injury, blindness, or death.  Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY.  As pieces may fly off, be sure to keep body and face away from valve.  Never attempt to disassemble the track adjuster.

Inadvertent disassembling of the track adjuster may cause the parts such as a spring to fly off, possibly resulting in severe personal injury or death.

SA-344

 Travel reduction gears are under pressure.  As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury.  GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure.

Store Attachments Safely  Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.  Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.

SA-034

SA-28

SAFETY Prevent Burns Hot spraying fluids:  After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and heater lines.

Skin contact with escaping hot water or steam can cause severe burns.  To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool.

When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.  The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.

SA-039

Hot fluids and surfaces:  Engine oil, gear oil and hydraulic oil also become hot during operation.

The engine, hoses, lines and other parts become hot as well.  Wait for the oil and components to cool before starting any maintenance or inspection work.

SA-225

SA-29

SAFETY Replace Rubber Hoses Periodically  Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.  Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.)  Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

SA-019

Avoid High-Pressure Fluids  Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.  Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.  Tighten all connections before applying pressure.  Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.  If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

SA-031

SA-292

SA-044

SA-30

SAFETY Prevent Fires Check for Oil Leaks:  Fuel, hydraulic oil and lubricant leaks can lead to fires.  Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.  Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.  Do not bend or strike high-pressure lines.  Never install bent or damaged lines, pipes, or hoses.  Replace fuel hoses and hydraulic hoses periodically even if there is no abnormality in their external appearance.

Check for Shorts:  Short circuits can cause fires.  Clean and tighten all electrical connections.  Check before each shift or after eight (8) to ten (10) hours operation for loose, kinked, hardened or frayed electrical cables and wires.  Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps.  DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.  Never attempt to modify electric wirings.

SA-31

SA-019

SAFETY Clean up Flammables:  Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.  Prevent fires by inspecting and cleaning the machine daily, and by removing adhered oil or accumulated flammables immediately. Check and clean high temperature parts such as the exhaust outlet and mufflers earlier than the normal interval.  Do not wrap high temperature parts such as a muffler or exhaust pipe with oil absorbents.  Do not store oily cloths as they are vulnerable to catching fire.  Keep flammables away from open flames.  Do not ignite or crush a pressurized or sealed container.  Wire screens may be provided on openings on the engine compartment covers to prevent flammables such as dead leaves from entering. However, flammables which have passed through the wire screen may cause fires.

Check and clean the machine every day and immediately remove accumulated flammables.

Check Key Switch:  If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting.

Always check key switch function before operating the machine every day: 1. Start the engine and run it at slow idle.

2. Turn the key switch to the OFF position to confirm that the engine stops.  If any abnormalities are found, be sure to repair them before operating the machine.

Check Heat Shields:  Damaged or missing heat shields may lead to fires.  Damaged or missing heat shields must be repaired or replaced before operating the machine.  If hydraulic hoses are broken while the engine cover is open, splattered oil on the high temperature parts such as mufflers may cause fire. Always close the engine cover while operating the machine.

SA-32

SAFETY Evacuating in Case of Fire  If a fire breaks out, evacuate the machine in the following way:  Stop the engine by turning the key switch to the OFF position if there is time.  Use a fire extinguisher if there is time.  Exit the machine.  In an emergency, if the cab door or front window can not be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer to the explanation pages on the Emergency Evacuation Method.

SA-393

SS-1510

Beware of Exhaust Fumes  Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.  If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

SA-016

SA-33

SAFETY Precautions for Welding and Grinding  Welding may generate gas and/or small fires.  Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding.  Only qualified personnel should perform welding.

Never allow an unqualified person to perform welding.  Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding.  After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

SA-34

SA-818

SAFETY Avoid Heating Near Pressurized Fluid Lines  Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders.  Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.  Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc..

SA-030

Avoid Applying Heat to Lines Containing Flammable Fluids  Do not weld or flame cut pipes or tubes that contain flammable fluids.  Clean them thoroughly with nonflammable solvent before welding or flame cutting them.

Precautions for Handling Accumulator and Gas Damper High-pressure nitrogen gas is sealed in the accumulator and the gas damper. Inappropriate handling may cause explosion, possibly resulting in serious injury or death.

Strictly comply with the following items:     

Do not disassemble the unit.

Keep the units away from open flames and fire.

Do not attempt to bore a hole or cut by torch.

Avoid giving shocks by hitting or rolling the unit.

Before disposing the unit, sealed gas must be released.

Consult your nearest Hitachi dealer.

SA-35

SAFETY Remove Paint Before Welding or Heating  Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.  Avoid potentially toxic fumes and dust.  Do all such work outside or in a well-ventilated area.

Dispose of paint and solvent properly.  Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

SA-029

Beware of Asbestos and Silicon Dust and Other Contamination  Take care not to inhale dust produced in the work site.

Inhalation of asbestos fibers may be the cause of lung cancer. Inhalation of silicon dust or other contamination may cause sickness.  Depending on the work site conditions, the risk of inhaling asbestos fiber, silicon dust or other contamination may exist. Spray water to prevent asbestos fibers, silicon dust or other contamination from becoming airborne. Do not use compressed air.  When operating the machine in a work site where asbestos fibers, silicon dust or other contamination might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos, silicon dust or other contamination.  Keep bystanders out of the work site during operation.  Asbestos fibers might be present in imitation parts. Use only genuine Hitachi Parts.

SA-36

SA-029

SAFETY Prevent Battery Explosions  Battery gas can explode.  Keep sparks, lighted matches, and flame away from the top of battery.  Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.  Do not charge a frozen battery; it may explode. Warm the battery to 16 ˚C ( 60 ˚F ) first.  Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result.  Loose terminals may produce sparks. Securely tighten all terminals.  Connect terminals to the correct electrical poles. Failure to do so may cause damage to the electrical parts or fire.

SA-032

 Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness.  Be sure to wear eye protection when checking electrolyte specific gravity.

Service Air Conditioning System Safely  If spilled onto skin, refrigerant may cause a cold contact burn.  Refer to the instructions described on the container for proper use when handling the refrigerant.  Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere.  Never touch the refrigerant.

SA-405

SA-37

SAFETY Handle Chemical Products Safely  Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives.  A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.  Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.  See your authorized dealer for MSDS’s (available only in English) on chemical products used with your machine.

SA-309

Dispose of Waste Properly  Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.  Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.  Do not pour waste onto the ground, down a drain, or into any water source.  Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.  Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

SA-38

SA-226

SAFETY Never Ride Attachment Never allow anyone to ride attachments or load. This is an extremely dangerous practice.

Precautions for Communication Terminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices.

Inquire the device manufacturer for electrical wave disturbance upon using an electronic device near the communication terminal.

Before Returning the Machine to the Customer ď‚— After maintenance or repair work is complete, confirm that: ď‚– The machine is functioning properly, especially the safety systems. ď‚– Worn or damaged parts have been repaired or replaced.

SA-435

SA-39

SAFETY (Blank)

SA-40

SECTION AND GROUP SECTION 1 GENERAL Group 1 Precautions for Disassembling and CONTENTS Assembling

WORKSHOP MANUAL

Group 2 Tightening Group 3 Painting Group 4 Bleeding Air Group 5 Pressure Release Procedure Group 6 Preparation

SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Group 2 Undercarrlage Group 3 Front Attachment

SECTION 3 UPPERSTRUCTURE Group 1 Cab Group 2 Counterweight Group 5 Pump Device Group 6 Control Valve Group 7 Swing Device Group 8 Pilot Valve Group 9 Solenoid Valve

SECTION 4 UNDERCARRIAGE

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

Group 1 Swing Bearing Group 2 Travel Device Group 3 Center Joint Group 4 Track Adjuster Group 5 Front Idler Group 6 Upper and Lower Roller Group 7 Track Group 8 Blade Cylinder

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder

COPYRIGHT(C)2013 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved

TECHNICAL MANUAL SECTION 1 GENERAL Group 1 Specification Group 2 Component Layout Group 3 Component Specifications SECTION 2 SYSTEM Group 1 Hydraulic System Group 2 Electrical System SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Pilot Valve Group 5 Travel Device Group 6 Others (Upperstructure) Group 7 Others (Undercarriage) SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Machine Performance Test Group 5 Component Test Group 6 Adjustment SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Monitor Group 3 Troubleshooting A Group 4 Troubleshooting B Group 5 Air Conditioner

SECTION 1

GENERAL CONTENTS Group 1 Precautions for Disassembling and Assembling

Precautions for Disassembling and Assembling..................................................................W1-1-1-1

Group 2 Tightening

Tightening Bolts and Nuts...........................................W1-2-1-1 Piping Joint.......................................................................W1-2-1-4

Group 3 Painting

Painting..............................................................................W1-3-1-1

Group 4 Bleeding Air

Bleeding Air from Hydraulic Oil Tank.......................W1-4-1-1 Bleeding Air from Hydraulic System........................W1-4-1-2 Bleeding Air from Fuel System...................................W1-4-1-3 Bleeding Air from Radiator..........................................W1-4-1-4

Group 5 Releasing Pressure

Releasing Pressure in Hydraulic Circuit...................W1-5-1-1

Group 6 Preparation

Preparation before Inspection and Maintenance...............................................................W1-6-1-1

ADCJ0W-1-1

(Blank)

ADCJ0W-1-2

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling Precautions for Disassembling  Clean the Machine 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 Disassembling and Assembling  Precautions for Disassembling  Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling.  Before disassembling, clean the exterior of the components and place on a workbench.  Drain hydraulic oil and gear oil from the hydraulic components and reduction gear.  Be sure to provide appropriate containers for draining fluids.  Use matching marks for easier reassembling if necessary.  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 if 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.  Precautions for Assembling  Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part.  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.  Apply appropriate lubricant oil onto parts in order to prevent them from seizing.  Be sure to replace O-rings, backup rings, oil seals, and floating seals with new ones once they have been disassembled. Apply 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.  Fit the matching marks made when disassembling and assemble them.  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 completed, count the number of tools so as to make sure that no forgotten tools remain in the assembled machine.

W1-1-1-1

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Using Floating Seal

1

1. In general, replace the floating seal with a new one after disassembling.

If the floating seal is required to be reused, follow these procedures:

 Keep seal rings together as a matched set with seal ring (1) surfaces together. Apply oil onto sliding surface (e) of seal ring (1).  Check sliding surface (e) of seal ring (1) for scuffing, scoring, corrosion, deformation, or uneven wear.

Check the step part of seal ring (1).  Check O-ring (2) for tears, breaks, deformation, or hardening.

W178-02-11-001

2

2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following to prevent trouble.  Clean the floating seal and seal mounting bores with cleaning solvent.

Use a wire brush to remove mud, rust, or dirt from seal mounting bores. After cleaning, thoroughly dry parts with compressed air.  Clean seal ring (1) and O-ring (2) mounting bores.

Check the bore surface for scuffing or scoring by touching the surface with finger.  After installing the floating seal, check that O-ring (2) is not twisted, and that it is installed correctly on seal ring (1).  After installing the floating seal, check that O-ring (2) and seal ring sliding surface (e) is parallel with seal mating surface (f ) by measuring the distances (e) and (f ) at point (A) and (B), as illustrated. If these distances differ, correct O-ring (2) seating.

a

c b d W178-02-11-002 a - Correct b - Incorrect

c - Twist of O-Ring d - Bend of O-Ring f a

b

A

A

e

2

B

A=B

B

A≠B W178-02-11-003

a - Correct b - Incorrect

W1-1-1-2

e - Sliding Surface f - Seal Mating Surface

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Using Nylon Sling a

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 being damaged 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 object.  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 that they won’t deteriorate with heat, sun light, or chemicals.

W102-04-02-016 a - Correct Eyehole Lifting Method b

W105-04-01-008 b - Incorrect Eyehole Lifting Method

c c - Bent of Sling

W1-1-1-3

W162-01-01-009

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling If a load is lifted with a damaged dCAUTION: nylon sling, serious personal injury may result.

Be sure to visually check the nylon sling for any damage before using.

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.

Damaged Appearance

a a

W162-01-01-002 a - Broken Sewing Thread

W162-01-01-006

e a - Broken Sewing Thread

e - Separation of Belt

f

b

W162-01-01-003 b - Scuffing

b b - Scuffing

f -

W162-01-01-007

Scoring

c c

g

d

W162-01-01-004 c - Fuzz

W162-01-01-008

d - Broken Sewing Thread c - Fuzz a

W162-01-01-005 a - Broken Sewing Thread

W1-1-1-4

g - Broken Warp

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Maintenance Standard Terminology “Standard” 1. Dimension for parts on a new machine.

2. Dimension of new components or assemblies adjusted to specification. Allowable errors will be indicated if necessary.

“Allowable Limit” 1. Normal machine performance cannot be accomplished after exceeding this limit.

2. Repair or adjustment is difficult after exceeding this limit.

3. Repair or adjustment is impossible after exceeding this limit.

Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching the “Allowable Limit”.

W1-1-1-5

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling (Blank)

W1-1-1-6

SECTION 1 GENERAL Group 2 Tightening Tightening Bolts and Nuts Use tools appropriate for the work dCAUTION: 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 injure.

IMPORTANT:  Apply lubricant to the bolts and nuts in order to reduce friction coefficient of them. (For example, spindle oil with white zinc B dissolved in it)  Clean the bolt and nut threads and remove dirt or corrosion before installing.

WDAA-01-02-001

Bolt Types Tighten the nuts or bolts correctly to the torque specifications.

As the different types and grades of bolt are used, use and tighten the correct bolts correctly when assembling the machine or components.

Specified Tightening Torque Chart 2013/09 Bolt Dia. mm

Hexagon Head Bolt Wrench Size mm WDAA-01-02-002

N·m 6 8 10 12 14 16 18 20 22 24 27 30 33 36

30 65 110 180 270 400 550 750 950 1400 1950 2600 3200

(lbf·ft) (22) (48) (81) (133) (200) (300) (410) (550) (700) (1030) (1440) (1920) (2360)

WDAA-01-02-003

N·m 20 50 90 140 210 300 400 550 700 1050 1450 1950 2450

(lbf·ft) (15) (37) (66) (103) (155) (220) (300) (410) (520) (770) (1070) (1440) (1810)

Socket Bolt Socket Bolt

Wrench Size mm

WDAA-01-02-004

N·m 3 to 4 10 20 35 55 80 120 170 220 280 400 550 750 950

(lbf·ft) (2.2 to 3) (7.4) (15) (26) (41) (59) (89) (125) (162) (205) (300) (410) (550) (700)

W1-2-1-1

N·m 10 13 17 19 22 24 27 30 32 36 41 46 50 55

20 50 90 140 210 300 400

(lbf·ft) (15) (37) (66) (103) (155) (220) (300)

5 6 8 10 12 14 14 17

SECTION 1 GENERAL Group 2 Tightening IMPORTANT: The following items are applied to both fine and coarse pitch threads.  Apply lubricant to the bolts and nuts in order to reduce friction coefficient of them. (For example, spindle oil with white zinc B dissolved in it)  Torque tolerance is ±10 %.  Use the bolts of correct length. The bolts that are too long cannot be tightened as the bolt tip comes into contact with the bottom of bolt hole.

Also the bolts that are too short cannot develop sufficient tightening force.  The torque given in the chart on the previous page are for general use only, however, a different torque is given for a specific application. Use the specified torque.  Clean the nut and bolt threads and remove dirt or corrosion before installing.

Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.

b

a

1.4

c

1

12

9

4

1

6

7

14

13

8

5

2

3

10

11

3

6

5

4 2 2.3

W105-01-01-003 a - Equally tighten upper and lower alternately

b - Tighten diagonally

W1-2-1-2

c - Tighten from center diagonally

SECTION 1 GENERAL Group 2 Tightening Precautions for Spilt Flange IMPORTANT:  Clean the sealing surfaces. Check if there are any scratches and roughness on the surface of the seal that cause oil leaks and damage to the O-ring.  Use only specified O-rings. Inspect O-rings for any damage. Do not file the O-ring surfaces.

When installing O-ring into a groove, use grease in order to hold O-ring in place.  While tightening the bolt by hand, check that flange is installed to the port correctly. Do not pinch the O-ring.  Tighten the bolts up and down, left and right alternately, in order to ensure even tightening to the specified torque.  Do not use air wrenches. Using an impact wrench often causes tightening of one bolt fully before tighten the others, resulting in damage to O-rings or uneven tightening of bolts.

WDAA-01-02-005

Incorrect

WDAA-01-02-006

Nut and Bolt Locking  Lock Plate IMPORTANT: Do not reuse the lock plates. Do not try to bend the same point twice.

W105-01-01-008

Incorrect

Correct

 Split Pin IMPORTANT: Do not turn in the loosening direction in order to align the grooves and holes on the nut.

Always turn in the tightening direction. Do not reuse the split pins.

a

b

Correct

Correct

Incorrect

 Wire IMPORTANT: Attach wire to bolts in the bolttightening direction. Do not reuse the wire. a a-

WDAA-01-02-007

Bend along edge sharply Correct

b-

Do not bend it round

Correct

Correct

Incorrect

d

Incorrect

c

WDAA-01-02-008 c-

W1-2-1-3

Tighten

d-

Loosen

SECTION 1 GENERAL Group 2 Tightening Piping Joint IMPORTANT:  The torque given in table below are for general use only, however, a different torque is given for a specific application. Use the specified torque.  Apply lubricant, such as the Grease Spray to the bolts and nuts in order to reduce friction coefficient of them.  Torque tolerance is ±10 %.  Slightly apply lubricant onto the threads first by using the Grease Spray.

W1-2-1-4

SECTION 1 GENERAL Group 2 Tightening Union Joint Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines.

IMPORTANT:  Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking the adapter. Tighten union nut (3) to the specifications.  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.

2013/09 Description Wrench Size mm Tightening Torque Union Nut N·m (lbf·ft) 30 ° male 17 25 (18.5) 19 30 (22) 22 40 (29.5) 27 80 (59) 32 140 (103) 36 180 (133) 41 210 (155) 50 350 (260) 55 380 (280) 60 380 (280) 37 ° female 17 25 (18.5) 19 30 (22) 22 40 (29.5) 27 80 (59) 32 140 (103) 36 180 (133) 41 210 (155) 50 350 (260)

1

4

3

5

a - Joint Body

2

a

WDAA-01-02-009

37 ° 30 °

b b - Male Union Joint

fNOTE:

Tightening torque of 37 ° male coupling without union is similar to tightening torque of 37° female.

W1-2-1-5

c c - Female Union Joint WDAA-01-02-010

SECTION 1 GENERAL Group 2 Tightening Pipe Joint Pipe connection (metal joint) (Union Nut Wrench Size: 17, 19, 22, 27) Metal (3) of adapter (1) and pipe (2) seals pressure oil.  Precautions for use Do not damage sealing surfaces (4) and (5) when disassembling and assembling.

1

4

5

3

2

Tightening Torque Use the specified tightening torque in the table below.

2013/09 Wrench Size (mm) 17 19 22 27 Tightening N·m 25 30 40 80 Torque (lbf·ft) (18.5) (22) (29.5) (59)

M1M7-07-005

O-ring Seal Joint O-ring (6) is installed against the end surface of adapter (7) and seals pressure oil.

IMPORTANT:  Replace O-ring (6) with a new one when reinstalling.  Before tightening union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening union nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage.  Do not damage O-ring groove (8) of adapter (7) or sealing surface (10) on the hose side. Damage to O-ring (6) may cause oil leakage.  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 O-ring groove (8).

7

6

8

9

10

a - Joint Body

2013/09 Wrench Size mm Tightening Torque Union Nut N·m (lbf·ft) 19 30 (22) 22 70 (52) 27 95 (70) 32 140 (103) 36 180 (133) 41 210 (155) 50 350 (260)

W1-2-1-6

a

WDAA-01-02-011

SECTION 1 GENERAL Group 2 Tightening Quick Coupling

3

1. Coupling procedure  Push socket ring (1) into plug (3) by rotating it fully counterclockwise and then pulling it toward you.  Release socket ring (1). Check that socket ring (1) is returned by the spring force and the coupling is locked completely by ball (2). At this time, check if socket ring (1) is returned to the original position (to the rightmost direction).

2. Separating procedure  Remove the hose by rotating socket ring (1) fully counterclockwise and then pulling it. Because no check function is attached inside, be careful that oil flows out.  Cap the removed hoses using special plug.

CAUTION:

d

 When disconnecting, do not damage joint surface.  When disconnecting, clean the joint part and thoroughly wipe off the cleaning solution to prevent any foreign material from entering.  Complete the joint disconnecting / connecting procedure. Check enough if oil leaks especially after installation.  After installation, check if socket ring (1) is returned to the original position (to the rightmost direction).

W1-2-1-7

1

2

M1M7-07-006

SECTION 1 GENERAL Group 2 Tightening Screw-In Connection

R

G 30 °

Depending on types of screw and sealing, different types of screw-in connection are used.

IMPORTANT: Check that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. (In general, the screw-in connection of male tapered thread (a) is used except for measurement purpose.)

a

Seal tape is used in order to seal clearances between male (d) and female (c) threads so that any leaks between threads may be prevented. Therefore, apply just enough seal tape to fill up thread clearances (e). Do not overwrap.  Application Procedure Check that the thread surface is clean and, free of dirt or damage. Apply the seal tape around threads in order to leave one to two pitch threads uncovered. Wrap the seal tape in the same direction as the threads.

b - Male Straight Thread W105-01-01-018

Wrench Size mm Joint Body

Seal Tape Application

b

a - Male Tapered Thread

19 22 27 36 41 50 60

fNOTE:

2013/09 Tightening Torque Cast iron Structural rolled steel 15 (11) 35 (26) 30 (22) 50 (37) 50 (37) 95 (70) 70 (52) 160 (118) 110 (81) 200 (148) 160 (118) 330 (245) 200 (148)

Unit: N·m (lbf·ft) c

e

d c - Internal Thread d - External Thread

Low-Pressure-Hose Clamp Tightening

W105-01-01-019

e - Clearance f

Low-pressure-hose clamp tightening torque differs depending on the type of clamp.

T-Bolt Type Band Clamp (g): 4.5 N·m (3.3 lbf·ft) Worm Gear Type Band Clamp (h): 6 to 7 N·m (4.4 to 5.2 lbf·ft) f -

Leave one to two pitch threads uncovered g

h

WDAA-01-02-012 g - T-Bolt Type Band Clamp

W1-2-1-8

M114-07-041

M114-07-043 h - Worm Gear Type Band Clamp

SECTION 1 GENERAL Group 2 Tightening Connecting Hose When replacing the hoses, use only dCAUTION: genuine Hitachi service parts. Using hoses other

Correct

Incorrect

than genuine Hitachi hoses may cause oil leaks, hose rupture or separation of fitting, possibly resulting in a fire on the machine. Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting. Utilize the print marks on hoses when installing in order to prevent hose from being kinked. Take necessary measures to protect hoses from rubbing against each other. If the hoses rub against each other, wear to the hoses may result and lead to hose rupture. Take care so that the hoses do not come into contact with the moving parts or sharp objects.

W105-01-01-011

Incorrect

a

Correct

W105-01-01-012 a - Rubbing Against Each Other

b

Incorrect

Correct

b

a

W105-01-01-013 a - Rubbing Against Each Other

b - Clamp

Correct

Incorrect

a b W105-01-01-014 a - Rubbing Against Each Other

W1-2-1-9

b - Clamp

SECTION 1 GENERAL Group 2 Tightening (Blank)

W1-2-1-10

SECTION 1 GENERAL Group 3 Painting PAINTING Surfaces to Be Painted

Painting Color

Main surface of upperstructure

PB5-01 [SP-424 Dark Gray]

(Except the resinated covers) Swing post, Boom swing cylinder Seat base, Floor plate (Except the resinated covers) Cylinder (Boom, Arm, Bucket) Track, Blade, Blade Cylinder Counterweight Cab Front attachment, Upperstructure cover part

YR1-01 [TAXI yellow]

Lever (Travel, Blade)

N-10 [Black]

W1-3-1-1

SECTION 1 GENERAL Group 3 Painting (Blank)

W1-3-1-2

SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Hydraulic Oil Tank Escaping fluid under pressure may dCAUTION: penetrate the skin and eyes, and cause serious

injury. Release the pressure before disconnecting the hydraulic pipings or removing other equipment. Hot hydraulic oil just after operation may spout out and cause severe burns. Wait until oil cools before starting any work. Do not turn cap (2) of hydraulic oil tank (3) quickly. Cap (2) may fly off by internal pressure. Release any remaining pressure before removing cap (2).

Preparation 1. Park the machine on a solid and level surface.

Set the front attachment in position for checking hydraulic oil level.

3

2. Stop the engine. Slowly loosen cap (2) of hydraulic oil tank (3) and bleed air from hydraulic oil tank (3).

2

3. Remove cap (2) of hydraulic oil tank (3).

W1M9-01-04-001

4. Install vacuum pump (a) to the position where cap (2) has been removed. Operate vacuum pump (a) and maintain negative pressure in hydraulic oil tank (3).

a

b

fNOTE:

Operate vacuum pump (a) continuously while working.

c

W1R7-01-04-002 a - Vacuum Pump b - Hose c - Adapter

W1-4-1-1

SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Hydraulic System Bleed air from the hydraulic system as follows when hydraulic oil has been drawn, the suction filter and suction pipe have been replaced, or the pump device, swing motor, travel motor, cylinders have been removed/ installed.

IMPORTANT: If air is accumulated inside of the pump and if the engine starts in lacking of hydraulic oil, the pump may be damaged.  Bleeding Air from Pump  Remove the air bleed plug on top of the pump. Add hydraulic oil to the pump.  After the pump is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run it at slow idle speed.  Slightly loosen the plug and bleed air from the pump until hydraulic oil comes out from the gap.  After bleeding all air, securely tighten the plug.

IMPORTANT: If air is accumulated inside of the motor and if the engine starts in lacking of hydraulic oil, the motor may be damaged.  Bleeding Air from Travel Motor, Swing Motor  Remove the air bleed plug (top) from the travel motor and swing motor. Fill the motor case with hydraulic oil.

IMPORTANT: If air is accumulated inside of the cylinder and if the cylinder is operated suddenly in lacking of hydraulic oil, the seal may be damaged or the cylinder may seize.  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 circuit has an air bleed device, air in the pilot circuit will be bled while performing the above operation for approx. 5 minutes.  Reset the front attachment in position for checking hydraulic oil level.  Stop the engine. Check hydraulic oil level. Replenish hydraulic oil if necessary.

W1-4-1-2

SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Fuel System Air in the fuel system may make the engine hard to start or make it run irregularly. After draining water and sediment from the fuel filter, replacing the fuel filter, or running the fuel tank dry, be sure to bleed the air from the fuel system.

Air Bleeding Procedures Automatic bleeding deveice is provided on this machine.

1. Confirm that the fuel level is more than one-half of the fuel tank capacity. If the fuel is lower, add fuel.

2. Set the key switch to the ON position and hold it for 10 to 15 seconds.

3. Start the engine and check the fuel system for fuel leaks.

W1-4-1-3

SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Radiator Do not loosen the radiator cap until dCAUTION: the system has cooled. Hot steam may spout out and cause severe burns. Wait until coolant cools and loosen the cap slowly. Release all pressure and remove the cap.

Preparation 1. Park the machine on a solid and level surface.

Set the front attachment in position for checking hydraulic oil level.

2. Stop the engine. Remove the radiator cap.

W1-4-1-4

SECTION 1 GENERAL Group 5 Releasing Pressure Releasing Pressure in Hydraulic Circuit

1

2

Release any remaining pressure in the following procedures when removing and installing the front attachment.

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

2. Tilt up the floor. (Refer to the operator’s manual.)

Each attachment may move rapidly in dCAUTION: case the overload relief valve is loosened rapidly.

Check that the machine has set in the position for inspection and maintenance and loosen it slowly.

Do not loosen it more than 3/4 turns as hydraulic oil may spout.

IMPORTANT: Do not turn lock nut (8) and adjusting screw (9). If turning, the setting changes.

3. Slowly loosen body (7) of the overload relief valve in which any remaining pressure will be released. j : 24 mm

6 1- Overload Relief Valve (Arm Roll-Out) 2- Overload Relief Valve (Bucket Roll-Out) 3- Overload Relief Valve (Bucket Roll-In)

m : 70 to 80 N·m (7 to 8 kgf·m, 52 to 59 lbf·ft)

5

4

3 TADB-04-05-001

4- Overload Relief Valve (Boom Lower) 5- Overload Relief Valve (Boom Raise) 6- Overload Relief Valve (Arm Roll-In)

7

8 9

TADB-04-05-004 7- Body 8- Lock Nut

W1-5-1-1

9 - Adjusting Screw

SECTION 1 GENERAL Group 5 Releasing Pressure (Blank)

W1-5-1-2

SECTION 1 GENERAL Group 6 Preparation Preparation before Inspection and Maintenance Components, hydraulic oil, lubricant, dCAUTION: and coolant just after operation are too hot. Wait

until they cool. Then, start the work.

Before performing the maintenance procedures given in the following chapters, park the machine as described below, unless otherwise specified.

1. Park the machine on a solid and level surface.

M1M7-05-024

2. Lower the bucket and the blade onto the ground.

3. Set the engine control lever to the slow idle position and run the engine for 5 minutes in order to cool the engine.

1

4. Set the key switch to the OFF position and stop the engine. Remove the key.

5. Set pilot shut-off lever (1) to the LOCK position.

6. Before performing any work on the machine, attach the tag on the door or control lever.

MADB-07-001

W1-6-1-1

SECTION 1 GENERAL Group 6 Preparation Never attempt to maintain the dCAUTION: machine when the engine is running in order to

prevent the accident. If maintenance work while engine running is unavoidable, strictly comply with the following items.

 One person should take the operator's seat to be ready to stop the engine any time while communicating with other workers.  When working around the moving parts is unavoidable, pay special attention to ensure that hands, feet, and clothing and do not become entangled.

SA-2294

 If parts or tools are dropped or inserted into the fan or the belt, they may fly off or be cut off.

Do not drop or insert parts and tools into the moving parts.  Set pilot control shut-off lever (1) to the LOCK position so that the front attachment will not move.  Never touch the control levers and pedals.

If operating the control levers or pedals is unavoidable, signal co-workers to evacuate to the safer place.

SA-026

W1-6-1-2

MEMO

MEMO

SECTION 2

MAINTENANCE STANDARD CONTENTS Group 1 Upperstructure

Pump Device....................................................................W2-1-1-1 Swing Motor.....................................................................W2-1-2-1

Group 2 Undercarriage

Travel Motor......................................................................W2-2-1-1 Sprocket.............................................................................W2-2-1-3 Front Idler..........................................................................W2-2-2-1 Upper Roller......................................................................W2-2-3-1 Lower Roller......................................................................W2-2-3-2 Track.....................................................................................W2-2-4-1

Group 3 Front Attachment

Pin and Bushing .............................................................W2-3-1-1 Side Cutter.........................................................................W2-3-1-3 Standard Dimensions for Arm and Bucket Connection...................................................W2-3-1-4 Cylinder..............................................................................W2-3-2-1

ADCJ0W-2-1

(Blank)

ADCJ0W-2-2

SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Pump Device

1

2

WADB-03-05-003

1-

Cylinder Block

2-

Plunger (10 Used)

W2-1-1-1

SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure 1. Clearance between outer diameter (d) of plunger (2) and inner diameter (D) of cylinder block (1) Unit: mm (in) Allowable Limit

0.05 (0.002)

D-d≤0.05 mm (0.002 in) 2. Clearance (ε) between plunger (2) and shoe (a) bottom

D

d

Unit: mm (in) Allowable Limit

W507-02-04-009

0.2 (0.008)

1

ε≤0.2 mm (0.008 in) 3. Wear amount of oil seal mounting surface

2

a

2

Check that there are no damage and/or abnormal wear.

Unit: mm (in) Standard Allowable Limit 0 0.025 (0.001) D0-D1≤0.025 mm (0.001 in)

a-

Shoe

W1V1-03-02-005

ε

D0 D1

W2-1-1-2

W507-02-04-010

SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Swing Motor

1

2

WADB-03-07-002

1-

Rotor

2-

Plunger (9 Used)

W2-1-2-1

SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure 1. Clearance between outer diameter (d) of plunger (2) and cylinder inner diameter (D) of rotor (1) Allowable Limit

0.04 (0.002)

Unit: mm (in)

D-d≤0.04 mm (0.002 in) 2. Clearance (ε) between plunger (2) and shoe (a) bottom Allowable Limit

0.4 (0.016)

D

d

Unit: mm (in)

W507-02-04-009

1

ε≤0.4 mm (0.016 in)

2

2

ε

a-

a

Shoe

W107-02-06-140

ε

W107-02-06-141

W2-1-2-2

SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Travel Motor

3 2

1

1- Valve Plate

2- Cylinder Block

WADB-04-02-006

3- Plunger (9 Used)

W2-2-1-1

SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage 1. Clearance between outer diameter (d) of plunger (3) and inner diameter (D) of cylinder block (2) Unit: mm (in) Allowable Limit 0.023 (0.001) D-d ≤ 0.023 mm (0.001 in) 2. Clearance (ε) between plunger (3) and shoe (a) bottom

D

Unit: mm (in) Allowable Limit ε ≤ 0.3 mm (0.012 in)

d

0.3 (0.012)

W507-02-04-009

2

3

3. Wear amount of sliding surface against valve plate of cylinder block (2)

Check that there are no damage, abnormal wear, and/or seizure.

Damage and/or wear: 0.02 mm (0.001 in) or less

a

4. Wear amount of sliding surface against cylinder block (2) of valve plate

ε

Check that there are no damage, abnormal wear, and/or seizure.

3 W1V1-03-02-005

Damage and/or wear: 0.02 mm (0.001 in) or less a-

W2-2-1-2

Shoe

SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Sprocket

D C B

E

A W503-03-02-004

Unit: mm (in) Standard

Allowable Limit

Remedy

A

28.5 (1.12)

22.5 (0.886)

Replace parts.

B

341.2 (13.4)

335 (13.2)

C

376.6 (14.8)

-

D

384 (15.1)

378 (14.9)

E

101.6 (4.0)

-

W2-2-1-3

SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage (Blank)

W2-2-1-4

SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Front Idler

C D F

E

A B W503-03-05-001

Unit: mm (in) Standard

Allowable Limit

Remedy

A

28 (1.10)

22 (0.866)

Replace

B

64 (2.52)

-

C

39 (1.54)

-

D

281 (11.1)

275 (10.8)

E

10 (0.394)

-

F

319 (12.6)

-

Axle and Bushing Unit: mm (in) Standard

Allowable Limit

Remedy Replace

Axle

Outer Diameter

35 (1.38)

34.2 (1.35)

Bushing

Inner Diameter

35 (1.38)

35.5 (1.40)

Flange Thickness

2 (0.079)

1.5 (0.059)

Lubrication Oil Engine Oil (API CD class, SAE #30) Amount of engine oil: 30 ml (30 cm3)

W2-2-2-1

SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage (Blank)

W2-2-2-2

SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Upper Roller

A

B

WADB-02-02-001

Unit: mm (in) Standard

Allowable Limit

Remedy

A

100 (3.94)

-

Replace

B

70 (2.76)

64 (2.52)

Lubrication Oil Engine Oil (API CD class, SAE #30) Amount of engine oil: 50 ml (50 cm3)

W2-2-3-1

SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Lower Roller B A

C

D

E

W1NG-03-06-001

Unit: mm (in) Standard

Allowable Limit

Remedy

A

31 (1.22)

23 (0.906)

Replace

B

110 (4.33)

-

C

34 (1.34)

-

D

85 (3.35)

77 (3.03)

E

107 (4.21)

-

Axle and Bushing Unit: mm (in) Standard

Allowable Limit

Remedy Replace

Axle

Outer Diameter

30 (1.18)

29.2 (1.15)

Bushing

Inner Diameter

30 (1.18)

30.5 (1.20)

Flange Thickness

2.0 (0.079)

1.5 (0.059)

fNOTE:

Values in [ ] are just for reference.

Lubrication Oil Engine Oil (API CD class, SAE #30) Amount of oil: 50 ml (50 cm3)

W2-2-3-2

SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Track Link Measure the length of four links.  Do not measure the part included the master pin.  Measure the length with tension on the track.

B

A

A B

Standard 406.4 (16.0) 60 (2.36)

W1N0-03-07-003

Unit: mm (in) Allowable Limit Remedy 423 (16.7) Replace 53 (2.09)

Grouser Shoe

W105-03-07-024

Unit: mm (in) Shoe Size A B C

300 mm Grouser Standard Allowable Limit Remedy 110 (4.33) Replace 6 (0.24) 16.5 (0.65) 7.5 (0.30)

W2-2-4-1

SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Master Pin

C

B

A

A B C

Standard 97.5 (3.84) 18.9 (0.74) 19.15 (0.75)

Unit: mm (in) Allowable Limit Remedy Replace 16.0 (0.63) -

W2-2-4-2

WADCJ0-02-02-001

SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Pin

B

A

A B

Standard 92.5 (3.64) 19.17 (0.76)

fNOTE:

WDAD-02-02-002

Unit: mm (in) Allowable Limit Remedy Replace [17.5 (0.69)]

Values in [ ] are just for reference.

Bushing

W105-03-07-023

A B C

Standard 52.0 (2.05) 19.5 (0.77) 32.2 (1.27)

fNOTE:

Unit: mm (in) Allowable Limit Remedy Replace [20.5 (0.81)] [30.2 (1.19)]

Values in [ ] are just for reference.

W2-2-4-3

SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage (Blank)

W2-2-4-4

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Pin and Bushing M N B

L A

W1M9-04-01-002

A F B

C

P

O

Q K

I E

D

H

J

G

TADB-01-02-008

Unit: mm (in) A B C D E F G

Part Name Pin Bushing (Boom) Pin Bushing (Boom Cylinder) Pin Bushing (Boom Cylinder) Pin Bushing (Arm) Pin Bushing (Arm Cylinder) Pin Bushing (Arm Cylinder) Pin Bushing (Bucket Cylinder)

Standard 45 (1.78) 45 (1.78) 45 (1.78) 45 (1.78) 45 (1.78) 45 (1.78) 45 (1.78) 45 (1.78) 40 (1.58) 40 (1.58) 40 (1.58) 40 (1.58) 40 (1.58) 40 (1.58)

W2-3-1-1

Allowable Limit 44 (1.73) 46.5 (1.83) 44 (1.73) 46.5 (1.83) 44 (1.73) 46.5 (1.83) 44 (1.73) 46.5 (1.83) 39 (1.54) 41.5 (1.63) 39 (1.54) 41.5 (1.63) 39 (1.54) 41.5 (1.63)

Remedy Replace

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment

Unit: mm (in) H

I

J K L

M

N

O P Q

Part Name

Standard

Allowable Limit

Remedy

Pin

40 (1.58)

39 (1.54)

Replace

Bushing (Bucket Cylinder)

40 (1.58)

41.5 (1.63)

Bushing (Link A)

40 (1.58)

41.5 (1.63)

Link B

40 (1.58)

41.5 (1.63)

Pin

40 (1.58)

39 (1.54)

Bushing (Arm)

40 (1.58)

41.5 (1.63)

Link B

40 (1.58)

41.5 (1.63)

Pin

40 (1.58)

39 (1.54)

Bushing (Link A)

40 (1.58)

41.5 (1.63)

Pin

40 (1.58)

39 (1.54)

Bushing (Arm)

40 (1.58)

41.5 (1.63)

Pin

80 (3.15)

79 (3.11)

Bushing (Main Frame)

80 (3.15)

81.5 (3.21)

Bushing (Swing Post)

80 (3.15)

81.5 (3.21)

Pin

45 (1.78)

44 (1.73)

Bushing (Boom Swing Cylinder)

45 (1.78)

46.5 (1.83)

Pin

45 (1.78)

44 (1.73)

Bushing (Boom Swing Cylinder)

45 (1.78)

46.5 (1.83)

Pin

35 (1.38)

34 (1.34)

Bushing (Blade)

35 (1.38)

36.5 (1.44)

Pin

45 (1.78)

44 (1.73)

Bushing (Blade Cylinder)

45 (1.78)

46.5 (1.83)

Pin

45 (1.78)

44 (1.73)

Bushing (Blade Cylinder)

45 (1.78)

46.5 (1.83)

IMPORTANT: When replacing HN bushing for the front attachment, install it by using a press.

W2-3-1-2

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Side Cutter

C D

A

B W505-04-01-001

Unit: mm (in) A

Standard

Allowable Limit

Remedy

104 (4.09)

70 (2.76)

Replace

B

138 (5.43)

-

C

153 (6.02)

-

D

90 (3.54)

-

Point C

B

A

D

W554-04-01-003

Unit: mm (in) Standard

Allowable Limit

Remedy

A

127.5 (5.02)

63 (2.48)

Replace

B

56 (2.21)

-

C

62 (2.44)

-

D

51 (2.01)

-

W2-3-1-3

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Standard Dimensions for Arm and Bucket Connection IMPORTANT: If the front attachment of a previous model machine is used, use the grease intervals for previous model machine.

Section A

Section B W1ND-04-01-001

Unit: mm a

152 (5.98)

b

13 (0.512)

c

251 (9.88)

d

230 (9.06)

e

185 (7.28)

f

720 (28.3)

g

234.5 (9.23)

h

140.5 (5.53)

i

40 (1.58)

j

185 (7.28)

k

0 (0)

l

234.5 (9.23)

m

140.5 (5.53)

n

40 (1.58)

o

90 °

p

90 °

fNOTE:

Dimensions o, p: 90 ° means the angle for the bolt hole.

W2-3-1-4

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Cylinder Rod

Rod Bend and Run Out b a A

W166-04-02-022 c W105-04-02-094

Cylinder Name Boom Arm Bucket Boom Swing Blade

Unit: mm (in) Recommended Size After Remanufacturing (A) 50-0.025-0.064 (1.97-0.001-0.003) 45-0.025-0.064 (1.78-0.001-0.003) 40-0.025-0.064 (1.58-0.001-0.003) 45-0.025-0.064 (1.78-0.001-0.003) 50-0.025-0.064 (1.97-0.001-0.003)

a- b-

Cylinder Rod Dial Gauge

Bend 0.5 (0.02) 1.0 (0.04)

W2-3-2-1

d c- d-

Run Out 1.0 (0.04) 2.0 (0.08)

V Block 1 m (39.4 in)

Unit: mm (in) Remedy Repair Replace

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment (Blank)

W2-3-2-2

MEMO

MEMO

SECTION 3

UPPERSTRUCTURE CONTENTS Group 1 Cab

Removal and Installation of Cab...............................W3-1-1-1 Dimensions of Cab Glass..............................................W3-1-2-1

Group 2 Counterweight

Removal and Installation of Counterweight.........W3-2-1-1

Group 5 Pump Device

Removal and Installation of Pump Device.............W3-5-1-1 Disassembly of Pump Device.....................................W3-5-2-1 Assembly of Pump Device...........................................W3-5-2-4

Group 6 Control Valve

Assembly of Pilot Valves for Boom Swing, Blade..............................................................................W3-8-8-4

Group 9 Solenoid Valve

Removal and Installation of 2-Spool Solenoid Valve...............................................................................W3-9-1-1 Disassembly of 2-Spool Solenoid Valve..................W3-9-2-1 Assembly of 2-Spool Solenoid Valve........................W3-9-2-3 Removal and Installation of Torque Control Solenoid Valve............................................................W3-9-3-1 Disassembly of Torque Control Solenoid Valve ..W3-9-4-1 Assembly of Torque Control Solenoid Valve ........W3-9-4-3

Removal and Installation of Control Valve.............W3-6-1-1 Disassembly and Assembly of Control Valve........W3-6-2-1 Disassembly of Body......................................................W3-6-3-1 Assembly of Body...........................................................W3-6-3-5 Disassembly of Boom Anti-Drift Valve.....................W3-6-4-1 Assembly of Boom Anti-Drift Valve..........................W3-6-4-3 Disassembly of Spool....................................................W3-6-5-1 Assembly of Spool..........................................................W3-6-5-3 Disassembly of Arm Regenerative Valve and Orifice............................................................................W3-6-6-1 Assembly of Arm Regenerative Valve and Orifice............................................................................W3-6-6-3

Group 7 Swing Device

Removal and Installation of Swing Device............W3-7-1-1 Disassembly of Swing Device.....................................W3-7-2-1 Assembly of Swing Device..........................................W3-7-2-3 Disassembly of Swing Motor......................................W3-7-3-1 Assembly of Swing Motor............................................W3-7-3-4

Group 8 Pilot Valve

Removal and Installation of Pilot Valve (Left).......W3-8-1-1 Removal and Installation of Pilot Valve (Right)....W3-8-2-1 Removal and Installation of Travel Pilot Valve......W3-8-3-1 Removal and Installation of Blade Pilot Valve......W3-8-4-1 Removal and Installation of Boom Swing Pilot Valve.....................................................................W3-8-5-1 Disassembly of Pilot Valves (Right and Left).........W3-8-6-1 Assembly of Pilot Valves (Right and Left)...............W3-8-6-4 Disassembly of Travel Pilot Valve...............................W3-8-7-1 Assembly of Travel Pilot Valve....................................W3-8-7-5 Disassembly of Pilot Valves for Boom Swing, Blade..............................................................................W3-8-8-1

ADCJ0W-3-1

(Blank)

ADCJ0W-3-2

SECTION 3 UPPERSTRUCTURE Group 1 Cab Removal and Installation of Cab

1

3

2

WAFA-03-01-005

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

2. Open door (1).

3. Remove floor mats (2, 3).

W3-1-1-1

SECTION 3 UPPERSTRUCTURE Group 1 Cab

a 1

8 4 2 3 5

6

10

2

3 4 7

3

9 WADB-03-01-031 a- Shackle Mounting Position

5. Disconnect connector (7).

dCAUTION: (455 lb)

The cab (1) assembly weight: 205 kg

7. Install shackles (3 used) to cab (1). Attach nylon slings onto shackles (3 used). Hoist and hold cab (1).

8. Remove caps (4) (2 used), bolts (2, 5, 10) (2 used for each), (6), (8) (4 used), washers (3) (5 used) and (9) (6 used) from cab (1). j : 19 mm 9. Hoist and remove the cab (1) assembly.

W3-1-1-2

SECTION 3 UPPERSTRUCTURE Group 1 Cab

a 1

8 4 2 3 5

6

10

2

3 4 7

3

9 WADB-03-01-031

a- Shackle Mounting Position

Installation

dCAUTION: (455 lb)

The cab (1) assembly weight: 205 kg

5. Connect connector (7).

1. Install shackles (3 used) to cab (1). Attach nylon slings onto shackles (3 used). Hoist and hold cab (1).

2. Hoist the cab (1) assembly. Fit it to the mounting holes on the floor.

3. Install cab (1) to the floor with washers (3) (5 used), (9) (6 used), bolts (2, 5, 10) (2 used for each), (6), (8) (4 used) and caps (4) (2 used). j : 19 mm m : 110 N·m (11 kgf·m, 81 lbf·ft)

W3-1-1-3

SECTION 3 UPPERSTRUCTURE Group 1 Cab

1

3

2

WAFA-03-01-005

7. Install floor mats (2, 3).

8. Close door (1).

W3-1-1-4

SECTION 3 UPPERSTRUCTURE Group 1 Cab Dimensions of Cab Glass Unit: mm

a - Mark Position

WADB-03-01-001

a - Mark Position

WADB-03-01-002

WADB-03-01-003 a - Mark Position

W3-1-2-1

WADB-03-01-004 b - Black Ceramic Coating Surface

SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm

WADB-03-01-005 a - Mark Position

a - Mark Position

W3-1-2-2

WADB-03-01-006 b - Black Ceramic Coating Surface

WADB-03-01-007

SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm

WADB-03-01-005

WADB-03-01-008 c - Silk-Screen Coating Surface

W3-1-2-3

SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm

WADB-03-01-009

a - Mark Position

WADB-03-01-010 b - Black Ceramic Coating Surface

a - Mark Position

WADB-03-01-011 b - Black Ceramic Coating Surface

W3-1-2-4

SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm

WADB-03-01-009

WADB-03-01-012 a - Mark Position

b - Black Ceramic Coating Surface

W3-1-2-5

WADB-03-01-013

SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm

WADB-03-01-009

WADB-03-01-014 a - Mark Position

W3-1-2-6

b - Black Ceramic Coating Surface

SECTION 3 UPPERSTRUCTURE Group 1 Cab Procedure to Remove Cab Glass and Overhead Window

1

Procedures to Remove Overhead Window (1), Lower Right-Hand Glass (6), Upper Right-Hand Glass (9), Rear Left-Hand Glass (3), Upper Door Glass (5), Lower Door Glass (4), and Rear Glass (2) CAUTION: When removing the broken or cracked glass, the glass shards may cause serious injury.

Before removing, use the duct tape or equivalent in order to paste the broken or cracked glass and reinforce them. Remove the glass pieces away.

1. Remove the resin panel, the garnish, and the spacer around the glass.

2

d

5

4

WADB-03-01-009

3 9

2. Prick a hole in adhesive (b) by using awl (a) (or a knife).

6

3. Pass piano wire (c) (or a metal wire) through the hole.

7

WADB-03-01-003

8 a

b 7 - Cab 8 - Glass

W1SE-02-01-033 a - Awl b - Adhesive

c

c - Piano Wire

W3-1-2-7

W1SE-02-01-034

SECTION 3 UPPERSTRUCTURE Group 1 Cab IMPORTANT: The piano wire is easily broken if a part of the piano wire turns hot. Change the position and cut the adhesive.

4. Wind the both ends of the piano wire onto the screwdriver. Draw the wire back and forth in order to cut adhesive (b) between cab (7) and glass (8).

Remove glass (8) from cab (7).

7

a

8

fNOTE:

Cut off the middle of adhesive between glass and cab.

b c a - Cab Outside b - Adhesive c - Cab Inside

W3-1-2-8

W1SE-02-01-035

SECTION 3 UPPERSTRUCTURE Group 1 Cab Procedure to Install Cab Glass Procedures to Install Lower Right-Hand Glass (6), Upper Right-Hand Glass (9), Rear Left-Hand Glass (3), Upper Door Glass (5), Lower Door Glass (4), and Rear Glass (2) 1. Cut off the residual adhesive from the cab (7) side by 1 to 2 mm deep all around by using knife (a) or similar.

fNOTE:

2

Do not damage the cab (7) paint.

5

WADB-03-01-009

3

4

9

2. Clean the cutting edge of adhesive at cab (7) side by using white spirit.

6

IMPORTANT: Primer should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer, apply Primer as quickly as possible and close the cap immediately after using. After opening Primer, all the contents should be used within 180 days (or 2 hours with the cap off).

3. Apply Primer for paint to the cutting edge of adhesive at cab (7) side by using a brush. Wait for about 15 minutes in order to let it dry by itself.

WADB-03-01-003

7

a

b W1SE-02-01-036 a - Knife

b - Cut off adhesive by 1 to 2 mm deep.

7 c d

W1SE-02-01-038 c - Apply Primer by using a brush.

W3-1-2-9

d - Cutting edge of adhesive at cab (7) side

SECTION 3 UPPERSTRUCTURE Group 1 Cab 4. Clean the mating edge of the new glass by using clean rag and white spirit.

IMPORTANT: Primer should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer, apply Primer as quickly as possible and close the cap immediately after using. After opening Primer, all the contents should be used within 180 days (or 2 hours with the cap off).

5. Apply Primer for glass to the cutting edge of adhesive at cab side by using a brush. Wait for about 15 minutes in order to let it dry by itself.

8 mm

12 mm

a

W1SE-02-01-027 a-

Cut nozzle end into V-shaped.

6. Put dam rubber (2) onto the cab (1) side.

7. Cut off the nozzle of adhesive cartridge (c) (Sikaflex 250-2) into V-shaped by using a knife.

8. Remove the seal of the cartridge end. Install the V-shaped nozzle.

9. Install the cartridge to the manual coking gun.

10. Evenly apply adhesive (d) to the cutting edge of the residual adhesive at the cab (1) side.

b

11. Raise the glass by using the suction lifter (rubber sucker 4355282), and adhere it to cab (1). c

fNOTE:

Remove all adhesive (d) except the mounting surface before solidifying by using white spirit.

12. Secure the glass by using the duct tape until adhesive (d) becomes solid in order to prevent them from being mispositioned or coming off.

W1SE-02-01-028 b-

Remove the seal.

c-

Adhesive Cartridge

fNOTE:

Time for adhesive (Sikaflex 250-2) to become solid: 12 hours in spring, 24 hours in winter (just for reference)

d

1

2 W1N0-02-01-020

d-

W3-1-2-10

Adhesive

SECTION 3 UPPERSTRUCTURE Group 1 Cab 13. Evenly apply adhesive (SUNSTAR Penguin Seal #2505) to part A of rear left-hand glass (1).

1

A

WADB-03-01-009

1

A

W3-1-2-11

WADB-03-01-020

SECTION 3 UPPERSTRUCTURE Group 1 Cab Procedure to Install Overhead Window 1

1. Cut off the residual adhesive from the cab (2) side by 1 to 2 mm deep by using knife (a) or similar.

fNOTE:

Do not damage the cab (2) paint.

2. Clean the cutting edge of adhesive at cab (2) side by using white spirit.

WADB-03-01-009

IMPORTANT: Primer should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer, apply Primer as quickly as possible and close the cap immediately after using. After opening Primer, all the contents should be used within 180 days (or 2 hours with the cap off).

3. Apply Primer for paint (SUNSTAR #580) to the cutting edge of adhesive at cab (2) side by using a brush. Wait from 5 minutes to 24 hours in order to let it dry by itself.

fNOTE:

The painting primer should be applied evenly in order to leave no blemishes.

4. Clean the mating edge of new overhead window (1) by using clean rag and white spirit.

IMPORTANT: Primer should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer, apply Primer as quickly as possible and close the cap immediately after using. After opening Primer, all the contents should be used within 180 days (or 2 hours with the cap off).

5. Apply Primer (SUNSTAR #435-41) for overhead window to the cutting edge of adhesive of overhead window (1) by using a brush. Wait from 5 minutes to 24 hours in order to let it dry by itself.

2

a

b W1SE-02-01-036 a - Knife

b - Cut off adhesive by 1 to 2 mm deep.

2 c d

W1SE-02-01-038 c - Apply Primer by using a brush.

W3-1-2-12

d - Cutting edge of adhesive at cab (2) side

SECTION 3 UPPERSTRUCTURE Group 1 Cab 6. Evenly apply adhesive (SUNSTAR Penguin Seal #560) to the cutting edge of the residual adhesive at the cab side.

7. Raise the overhead window by using the suction lifter (rubber sucker 4355282), and adhere it to the cab within 5 minutes. (As for the position to install the overhead window, refer to W3-1-3-14.)

fNOTE:

Remove all adhesive except the mounting surface before solidifying by using white spirit.

8. Secure the overhead window by using the duct tape until adhesive becomes solid in order to prevent them from being mispositioned or coming off.

W3-1-2-13

SECTION 3 UPPERSTRUCTURE Group 1 Cab Clearance between Cab and Overhead Window

D D B

B E

C

C

E WADB-03-01-015

Section B-B

Section C-C

39 mm

42 mm

WADB-03-01-016 Section D-D

WADB-03-01-017 Section E-E 21 mm

4 mm

WADB-03-01-018

W3-1-2-14

WADB-03-01-019

SECTION 3 UPPERSTRUCTURE Group 1 Cab Procedure to Install Front Window Glass 1. Stick seal (1) to port C, at lower side of the front Window glass by using adhesive. Stick and secure both right and left ends (the thicker part) of seal (1) to the glass by using adhesive. Stick part B at mating surface of seal (1) and front Window glass (a) by using adhesive so that no visible undulation or boss can be found.

A A

WADB-03-01-005

Section A-A

a B

C

1 W1MS-02-01-020 a-

W3-1-2-15

Front Door Glass

SECTION 3 UPPERSTRUCTURE Group 1 Cab (Blank)

W3-1-2-16

SECTION 3 UPPERSTRUCTURE Group 2 Counterweight Removal and Installation of Counterweight

1

2

3, 4

6

5

WADB-03-02-004

7

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

2. Tilt up the floor. (Refer to the operator’s manual.)

3. Remove bolts, washers (1) (3 used). Remove cover (6). j : 17 mm 4. Remove bolts (3)(5 used) and washers (4) (5 used).

Remove cover (5) from counterweight (2). j : 19 mm 5. Remove bolts, washers (7) (4 used). Remove cover (8). j : 17 mm

W3-2-1-1

8

WADB-03-05-005

SECTION 3 UPPERSTRUCTURE Group 2 Counterweight

1

3

WADB-03-02-002

2

6. Open cover (3).

CAUTION: d(1200 lb)

Counterweight (4) weight: 540 kg

7. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to eyebolt mounting holes (3). Hoist and hold counterweight (4).

8. Remove bolts (5) (3 used) and washers (6) (3 used) from counterweight (4). j : 32 mm 9. Raise counterweight (4) a little. Slide counterweight (4) to the rear side. Remove counterweight (4) from main frame (2).

W3-2-1-2

4

5, 6

WADB-03-02-003

SECTION 3 UPPERSTRUCTURE Group 2 Counterweight

3

1

4

5,6

WADB-03-02-003

WADB-03-02-002

2

Installation CAUTION: d(1200 lb)

Counterweight (4) weight: 540 kg

3. Close cover (1).

1. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to eyebolt mounting holes (3). Hoist counterweight (4). Place counterweight (4) onto main frame (2).

Slide counterweight (4) to the front side.

2. Install counterweight (4) to main frame (2) with bolts (5) (3 used) and washers (5) (3 used). j : 32 mm m : 750 N·m (75 kgf·m, 550lbf·ft)

W3-2-1-3

SECTION 3 UPPERSTRUCTURE Group 2 Counterweight

1

2

3, 4

6

WADB-03-05-005

7

8

4. Install cover (8) with bolts, washers (7) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 5. Install cover (5) with bolts (3) (5 used) and washers (4) (5 used). j : 19 mm m : 110 N·m (11 kgf·m, 81 lbf·ft) 6. Install cover (6) with bolts, washers (1) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 7. Tilt down the floor. (Refer to the operator’s manual.)

W3-2-1-4

5

WADB-03-02-004

SECTION 3 UPPERSTRUCTURE Group 5 Pump Device Removal and Installation of Pump Device IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

Bleed air from hydraulic oil tank (4). dCAUTION: (Refer to W1-4-1.)

Removal 1. Tilt up the floor. (Refer to the Operator's Manual.)

2. Remove bolts, washers (1) (4 used). Remove cover (2).

2

1

WADB-03-05-005

j : 17 mm 5

3. Disconnect hoses (4) (2 used) and hoses (7) (2 used) from pump device (3).

6

4

j : 22 mm, 27 mm

7

4. Remove socket bolts (9) (4 used). Remove suction pipe (8) from pump device (3).

8

l : 8 mm 3

5. Disconnect hose (10) from pump device (3).

9

j : 19 mm

W1M7-02-03-002

d

CAUTION: Pump device (3) weight: 21 kg (47 lb) 6. Attach the nylon slings onto the center of gravity in pump device (3). Hold pump device (3).

7. Remove socket bolts (6) (2 used). Hoist and remove pump device (3) from engine (5). l : 10 mm

10

W3-5-1-1

WADB-03-05-006

SECTION 3 UPPERSTRUCTURE Group 5 Pump Device Installation

dCAUTION:

Pump device (3) weight: 21 kg (47 lb) 1. Install pump device (3) to engine (5) with socket bolts (6) (2 used). l : 10 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

IMPORTANT: Apply grease onto O-ring (11).

2. Install O-ring (11) to the groove on the flange part in suction pipe (8). Install suction pipe (8) to pump device (3) with socket bolts (9) (4 used). l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3. Connect hoses (4) (2 used) and hoses (7) (2 used) to pump device (3).

10

j : 22 mm

5

WADB-03-05-006

6

m : 40 N·m (4 kgf·m, 30 lbf·ft) j : 27 mm

4

7

m : 80 N·m (8 kgf·m, 59 lbf·ft) 4. Connect hose (10) to pump device (3).

8

j : 19 mm

3

m : 30 N·m (3 kgf·m, 22 lbf·ft)

9

5. Tilt down the floor. (Refer to the Operator's Manual.)

W1M7-02-03-002

IMPORTANT: Bleed air from the pump device. (Refer to W1-4-1.) After completing the work, check the hydraulic oil level. Start the engine and check for any oil leaks.

6. Install cover (2) with bolts, washers (1) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

1

W3-5-1-2

2

WADB-03-05-005

SECTION 3 UPPERSTRUCTURE Group 5 Pump Device Disassembly of Pump Device

WADB-03-05-001 1- 2- 3- 4- 5- 8- 9- 10- 11- 12- 13- 14-

Retaining Ring Oil Seal Shaft Ball Bearing Retaining Ring Pin (2 Used) Body S Packing Spring (4 Used) Stopper pin A Rod Swash Plate

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

Stopper pin B Ball (2 Used) Plunger (10 Used) Retainer Holder Needle (3 Used) Cylinder Block Washer (2 Used) Spring Retaining Ring Valve Plate Spring Pin

28- 29- 30- 31- 32- 33- 34- 35- 36- 37- 38- 39-

W3-5-2-1

Needle Bearing Spring Holder Spring Spring Guide Pin O-Ring Body H Seal Washer Bolt Nut Socket Bolt (5 Used) O-Ring

40- 41- 42- 43- 44- 45- 46- 47- 50-

O-Ring O-Ring Collar Coupling Gear Pump Spring Washer (2 Used) Bolt (2 Used) Plug (5 Used) Rod

SECTION 3 UPPERSTRUCTURE Group 5 Pump Device Disassembly of Pump Device 1. Remove bolts (46) (2 used) and spring washers (45) (2 used). Remove gear pump (44) from body H (34). j : 13 mm

5. Remove other socket bolts (38) (3 used). l : 8 mm 6. Loosen and remove the temporary assembly bolts (M10, Length: 65 mm) (2 used) alternately from body H (34).

IMPORTANT: Do not turn bolt (36) and nut (37). If turning, the setting changes.

2. Remove O-rings (39, 40, and 41), collar (42), and coupling (43) from body H (34).

j : 17 mm

Remove body H (34) by using the dCAUTION: temporary assembly bolts (M10, Length:65 mm) in order not to fly out spring (30).

3. Remove socket bolts (38) (2 used) from mounting holes (a) (2 places) of socket bolt (38).

IMPORTANT: Do not drop valve plate (26) while removing body H (34).

IMPORTANT: Do not remove spring pin (27).

7. Remove body H (34) from body S (9).

8. Remove O-ring (33) from body H (34).

9. Remove needle bearing (28) from shaft (3).

l : 8 mm

10. Remove packin (10), pin (32), pins (8) (2 used), and valve plate (26) from body S (9). a

11. Remove spring guide (31), spring (30), spring holder (29), and the cylinder block (22) assembly from body S (9).

a

12. Remove plungers (18) (10 used), retainer (19), holder (20), and needles (21) (3 used) from cylinder block (22).

34

a-

Mounting hole of socket bolt (38)

WADB-03-05-002

4. Install the temporary assembly bolts (M10, Length: 65 mm) (2 used) to mounting holes (a) (2 places) of socket bolt (38) of body H (34). j : 17 mm

W3-5-2-2

SECTION 3 UPPERSTRUCTURE Group 5 Pump Device When removing retaining ring (25), dCAUTION: hold washers (23) (2 used) and spring (24) by

using the press in order not to fly out.

IMPORTANT: Do not disassemble the cylinder block (22) assembly (parts No.23 to 25) unless necessary.

13. Remove retaining ring (25), washers (23) (2 used), and spring (24) from cylinder block (22).

14. Remove swash plate (14) and balls (17) (2 used) from body S (9).

15. Remove stopper pin A (12), stopper pin B (16), springs (11) (4 used), and rods (13 , 50) from body S (9).

16. Remove retaining ring (1) from body S (9).

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

17. Tap the gear pump (44) mounting side and remove the shaft (3) assembly from body S (9) by using a hammer.

18. Remove oil seal (2) from shaft (3).

19. Remove retaining ring (5) from shaft (3).

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

20. Remove ball bearing (4) from shaft (3) by using a bar and a hammer.

W3-5-2-3

SECTION 3 UPPERSTRUCTURE Group 5 Pump Device Assembly of Pump Device 11

29

19 20 22 18 24 23

10 30 31 34

35 37 36

12

42

9

43

13

44

50 17

3 1 2 4 5 16 11 14 21 25 28 26 27 32

1- 2- 3- 4- 5- 8- 9- 10- 11- 12- 13- 14-

Retaining Ring Oil Seal Shaft Ball Bearing Retaining Ring Pin (2 Used) Body S Packing Spring (4 Used) Stopper Pin A Rod Swash Plate

fNOTE:

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

Stopper Pin B Ceramic Ball (2 Used) Plunger (10 Used) Retainer Holder Needle (3 Used) Cylinder Block Washer (2 Used) Spring Retaining Ring Valve Plate Spring Pin

33

41

28- 29- 30- 31- 32- 33- 34- 35- 36- 37- 38- 39-

As for the item with mark *, refer to W3-5-2-1.

W3-5-2-4

39

Needle Bearing Spring Holder Spring Spring Guide Pin O-Ring Body H Seal Washer Bolt Nut *Socket Bolt (5 Used) O-Ring

WADB-03-05-003

40- 41- 42- 43- 44- 45- 46- 47- 50-

*O-Ring O-Ring Collar Coupling Gear Pump *Spring Washer (2 Used) Bolt (2 Used) *Plug (5 Used) Rod

SECTION 3 UPPERSTRUCTURE Group 5 Pump Device Assembly of Pump Device IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

IMPORTANT: The length of stopper pin A (12) and stopper pin B (16) are different. Check the mounting positions.

6. Install springs (11) (2 used) to stopper pin A (12).

Install stopper pin A (12) to body S (9).

such as goggles, helmets, etc in order to prevent personal injury.

1. Evenly tap and install ball bearing (4) to shaft (3) by using a bar and a hammer.

12

11 9

2. Install retaining rings (5) to shaft (3).

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

16

such as goggles, helmets, etc in order to prevent personal injury.

3. Place body S (9) with the gear pump (44) mounting side down. Evenly tap ball bearing (4) with the shaft (3) assembly and install it to body S (9) by using a bar and a hummer.

11

WADB-03-05-004

4. Apply grease onto oil seal (2). Install oil seal (2) to body S (9) by using the special tool (ST 7712).

7. Install springs (11) (2 used) to stopper pin B (16).

Install stopper pin B (16) to body S (9).

5. Install retaining ring (1) to body S (9).

8. Install rods (13 , 50) to body S (9).

9. Apply grease onto balls (17) (2 used). Install balls (17) (2 used) to swash plate (14). Install swash plate (14) to body S (9).

When installing retaining ring (25) to dCAUTION: cylinder block (22), hold washers (23) (2 used) and spring (24) by using the press in order not to fly out.

10. Install washers (23) (2 used), spring (24), and retaining ring (25) to cylinder block (22) by using the press.

11. Install needles (21) (3 used) to cylinder block (22).

Install holder (20) on needle (21).

W3-5-2-5

SECTION 3 UPPERSTRUCTURE Group 5 Pump Device 12. Install retainer (19) and plungers (18) (10 used) to cylinder block (22).

20. Temporarily tighten body H (34) with socket bolts (38) (3 used).

13. While turning the cylinder block (22) assembly, insert the cylinder block (22) assembly into shaft (3).

14. Install spring holder (29), spring (30), and spring guide (31) to body S (9).

IMPORTANT: Check the direction to install valve plate (26).

15. Apply grease to body H (34) side of valve plate (26).

Fit spring pin (27) and install valve plate (26) to body H (34).

16. Install needle bearing (28) to shaft (3).

l : 8 mm 21. Remove the temporary assembly bolts (M10, Length: 65mm) (2 used) from mounting holes (2 places) of socket bolt (38). j : 17 mm 22. Temporarily tighten socket bolts (38) (2 used) to body H (34). l : 8 mm 23. Tighten socket bolts (38) (5 used).

17. Install pin (32), pins (8) (2 used), and packing (10) to body S (9).

l : 8 mm

18. Install O-ring (33) to body H (34).

m : 50 N·m (5 kgf·m, 37 lbf·ft)

19. Fit the mounting holes (a) of socket bolt (38) and install body H (34) to body S (9). Install the temporary assembly bolts (M10, Length:65 mm) (2 used) to the mounting holes (a) (2 places) of socket bolt (38).

24. Install collar (42), coupling (43), and O-rings (39, 40, and 41) to body H (34).

25. Install gear pump (44) to body H (34). Tighten bolts (46) (2 used) and spring washers (45) (2 used). l : 13 mm

j : 17 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft) a a 34

a-

Mounting hole of socket bolt (38)

WADB-03-05-002

W3-5-2-6

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Removal and Installation of Control Valve

2

3

4

4

W1ND-02-01-007

M1M7-07-067

IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

3. Remove bolts, washers (4) (4 used) from cover (3).

Remove cover (3) from frame (2).

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

Release any pressure in the hydraulic dCAUTION: circuit. (Refer to W1-5-1.)

2. Tilt up the floor. (Refer to the operator’s manual.)

W3-6-1-1

j : 17 mm

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve

5

2

2 1

3

4

W1M7-02-04-015

4. Disconnect connector (4) from pressure sensor (3).

5. Disconnect hoses (2) (40 used) from control valve (1). j : 17 mm, 19 mm, 22 mm, 27 mm, 36 mm

dCAUTION:

Control valve (1) weight: 33 kg (73 lb) 6. Attach nylon slings onto control valve (1). Hoist and hold control valve (1).

7. Remove bolts, washers (6) (4 used) and washers (7) (4 used) from plate (5). Remove control valve (1) from plate (5). j : 17 mm 8. Remove pressure sensor (3) from control valve (1). j : 24 mm 9. Remove the adapters with control valve (1) attached if necessary.

W3-6-1-2

6, 7

WADB-03-06-012

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve

5

2

2 1

3

4

6, 7

W1M7-02-04-015

WADB-03-06-012

Installation

4. Connect hoses (2) (40 used) to control valve (1).

1. Install all removed adapters to control valve (1).

j : 17 mm

2. Install pressure sensor (3) to control valve (1).

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

j : 24 mm

j : 19 mm

m : 16 N·m (1.6 kgf·m, 12 lbf·ft)

m : 30 N·m (3 kgf·m, 22 lbf·ft)

dCAUTION:

Control valve (1) weight: 33 kg (73 lb) 3. Attach nylon slings onto control valve (1). Hoist and hold control valve (1). Install control valve (1) to plate (5) with washers (7) (4 used) and bolts, washers (6) (4 used).

j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft) j : 27 mm

j : 17 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 5. Connect connector (4) to pressure sensor (3).

W3-6-1-3

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve

2

3

4

4

W1ND-02-01-007 M1M7-07-067

6. Install cover (3) to frame (2) with bolts, washers (4) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 7. Tilt down the floor. (Refer to the operator’s manual.)

IMPORTANT: Check the hydraulic oil level. Start the engine. Tilt up the floor and check for any oil leaks. After checking, tilt down the floor. (Refer to the operator’s manual.)

W3-6-1-4

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Disassembly and Assembly of Control Valve A

1

6

3 7 8

5

1a

2

15 16 3 17 18

9

14 19 20

3

21 10

1 11 12 13

B

1

4

1 15 16 17 3 18

3

14

1b 22

1

9

C

14 20

19

21

21 20

79

13

3

14

1c

23

1 21

15 16 17 18

9

13

19 21 3

3

14

20

24 25

20

26 1d

1 21

D

1

15 16 9 17 31

14

15 16 17 18 30 14 27

20

1

20

13

E

19

21

30 3

3

14 1

32

1f

21 13

20

W3-6-2-1

WADB-03-06-001

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve F

1

9

34

35

15 16 17 37

36

33 21 19 38 3 39 40 b 41 42 3 28

33

1

3

14

43 21 13 1

1g

3 46

14

20

50

47

9

3

3

1

19

28 44

13

45

9

3

1

1j

51

20

21

52

I

19 K

15 55 16 17 54 37

20 73

33 33 1

75 21 20 14

3

21

14

71

20

1

1k 15 16 17 37

L

20

15 16 33 21 17 76

9

14

13

53 72 3

J

70

74

21 13

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

14

3

1i

49

14

H

48

47 1

9 1

19

20

21

29

1h

G

1

45 44 21

13

14

9

20 14

20

a

19 14

3

33

3 11

1

78 21 13

20

77

5 WADB-03-06-002

W3-6-2-2

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve A- B- C- D-

Flow Combiner Valve Section Blade Section Swing Section Boom Swing Section

E- F- G- H-

Auxiliary Section Arm Section Travel (Right) Section Inlet Section

I- J- K- L-

Travel (Left) Section Boom Anti-Drift Valve Boom Section Bucket Section

a- Arm Check Valve b- Arm Regenerative Valve

1a- 1b- 1c- 1d- 1f- 1g- 1h- 1i- 1j- 1k- 1l- 1- 2- 3- 4- 5- 6- 7- 8- 9- 10- 11- 12-

Body (Flow Combiner Valve) Body (Blade) Body (Swing) Body (Boom Swing) Body (Auxiliary) Body (Arm) Body (Travel (Right)) Body (Inlet) Body (Travel (Left)) Body (Boom) Body (Bucket) Socket Bolt (42 Used) Spring O-Ring (22 Used) Main Relief Valve Nut (8 Used) Plug Filter Cover O-Ring (10 Used) Spool Spring Seat Spring Seat

13- 14- 15- 16- 17- 18- 19- 20- 21- 22- 23- 24- 25- 26- 27- 28- 29- 30- 31- 32- 33- 34- 35-

Cover (11 Used) Spring (18 Used) Plug (9 Used) O-Ring (9 Used) Spring (9 Used) Check Valve (4 Used) Cover (9 Used) Spring Seat (18 Used) Spring Seat (18 Used) Spool Spool Spring Check Valve Spool Plug (2 Used) Plug (2 Used) Plug Plug (2 Used) Check Valve Spool Overload Relief Valve (6 Used) O-Ring Orifice

36- 37- 38- 39- 40- 41- 42- 43- 44- 45- 46- 47- 48- 49- 50- 51- 52- 53- 54- 55- 56- 57- 58-

O-Ring Check Valve (3 Used) Plug Check Valve Spring O-Ring Plug Spool Spring Check Valve Spool Main Relief Valve (2 Used) Washer Spool Filter Spool Plug (2 Used) O-Ring Spacer O-Ring (2 Used) Plug Piston Spring

59- 60- 61- 62- 63- 64- 65- 66- 67- 68- 69- 70- 71- 72- 73- 74- 75- 76- 77- 78- 79-

W3-6-2-3

Plug O-Ring Spool Sleeve Backup Ring O-Ring O-Ring Backup Ring Check Valve Spring Seat Spring Socket Bolt (5 Used) Body Backup Ring Spring Check Valve Spool Check Valve Rod (4 Used) Spool Make-Up Valve

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve (Blank)

W3-6-2-4

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Disassembly of Body

6

A

5 9

4

B

15 16 17 18

1a

9 C

15 16 17 18

1b

9

79 D

15 16 17 18

1c

24 25

9

1d

15 16 17 18 30 27

15 16 17 31

E

30

1f

WADB-03-06-001

W3-6-3-1

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve

15 16 17 37

36 34 9

F

33

33 G

1g

28

9 45 44

47

H

29

1h 9 47

9

I

J

28 1i 44 45

9 1j

52

15 16 17 37

K

9 33

L

15 16 33 17 76

1k 15 16 17 37 33 1l

77

5 WADB-03-06-002

W3-6-3-2

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve A- Flow Combiner Valve Section B- Blade Section C- Swing Section

D- Boom Swing Section E- Auxiliary Section F- Arm Section

G- Travel (Right) Section H- Inlet Section I- Travel (Left) Section

J- Boom Anti-Drift Valve K- Boom Section L- Bucket Section

4- 5- 6- 9- 15- 16- 17-

18- 24- 25- 27- 28- 29- 30-

31- 33- 34- 36- 37- 44- 45-

47- 52- 76- 77- 79-

Main Relief Valve Nut (8 Used) Plug O-Ring (10 Used) Plug (9 Used) O-Ring (9 Used) Spring (9 Used)

Check Valve (4 Used) Spring Check Valve Plug (2 Used) Plug (2 Used) Plug Plug (2 Used)

Check Valve Overload Relief Valve (6 Used) O-Ring O-Ring Check Valve (3 Used) Spring (2 Used) Check Valve (2 Used)

W3-6-3-3

Main Relief Valve (2 Used) Plug (2 Used) Check Valve Rod (4 Used) Make-Up Valve

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Disassembly of Body

dCAUTION:

Control valve weight: 35 kg

IMPORTANT: Do not remove plugs (6, 27, 28, 29, 52).

1. Remove plugs (15) (9 used) from sections (B, C, D, E, F, K, L). Remove O-rings (16) (9 used) from plugs (15) (9 used).

IMPORTANT: Do not disassemble overload relief valve (33). If it has been disassembled, pressure should be adjusted. (Refer to T4-5 in the separated volume, T/M.) 6. Remove overload relief valves (33) (6 used) and make-up valve (79) from sections (D, E, K, L).

j : 14 mm

j : 24 mm

2. Remove springs (17) (9 used) from sections (B, C, D, E, F, K, L).

3. Remove check valves (18) (4 used) from sections (B, C, D, E).

4. Remove check valve (31), check valves (37) (3 used), and check valve (76) from sections (E, F, K, L).

IMPORTANT: Do not disassemble main relief valves (4, 47). If it has been disassembled, pressure should be adjusted. (Refer to T4-5 in the separated volume, T/M.) 5. Remove main relief valve (4) and main relief valves (47) (2 used) from sections (A, H). j : 24 mm

7. Remove plugs (30) (2 used) from section (E). j : 17 mm IMPORTANT: Do not drop O-rings (9, 34, 36), check valves (25, 45), and springs (24, 44) when removing rod (77).

8. Remove nuts (5) (8 used) and rods (77) (4 used) from the body. Divide the control valve into each section. j : 13 mm 9. Remove O-rings (9) (10 used) and O-rings (34, 36) from each section.

10. Remove spring (24), springs (44) (2 used), check valve (25), and check valves (45) (2 used) from sections (D, G, I).

W3-6-3-4

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Assembly of Body 79 A

B

C

D

30 E

33 F

47 G

H

33 I

J

K

L

77 a

5

J

WADB-03-06-011

4 a-

30

33

47

33

33

33

Machine Front Side

Section A (Flow Combiner Valve)

Section B (Blade)

16 15

6 1a

17 18

T1LA-03-03-015

W3-6-3-5

1b

T1LA-03-03-016

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Section C (Swing)

Section D (Boom Swing)

16 15

16 15

1c

1d

17 18

17 18

WADB-03-06-010

WADB-03-06-008

Section E (Auxiliary)

Section F (Arm)

27 31 16 17

16 15 1f

1g

17 37

15 16 18 27

T1ND-03-03-005

W3-6-3-6

WADB-03-06-009

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Section G (Travel (Right))

Section H (Inlet)

1h

28

29

WADB-03-06-004

Section I (Travel (Left))

28

1j

T1ND-03-03-004

W3-6-3-7

1i

WADB-03-06-007

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Section J-J (Boom)

52

Section K (Boom)

1k

16 15

1k

17 37

WADB-03-06-006

T1ND-03-03-002

Section L (Bucket)

76 17 16 15

1l

17 16 37

T1LA-03-03-024

W3-6-3-8

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve A- Flow Combiner Valve Section B- Blade Section C- Swing Section

D- Boom Swing Section E- Auxiliary Section F- Arm Section

G- Travel (Right) Section H- Inlet Section I- Travel (Left) Section

J- Boom Anti-Drift Valve K- Boom Section L- Bucket Section

1a- Body (Flow Combiner Valve) 1b- Body (Blade) 1c- Body (Swing)

1d- Body (Boom Swing) 1f- Body (Auxiliary) 1g- Body (Arm)

1h- Body (Travel (Right)) 1i- Body (Inlet) 1j- Body (Travel (Left))

1k- Body (Boom) 1l- Body (Bucket)

4- 5- 6- 9- 15- 16- 17-

18- 24- 25- 27- 28- 29- 30-

31- 33- 34- 36- 37- 44- 45-

47- 52- 76- 77- 79-

Main Relief Valve Nut (8 Used) Plug * O-Ring (10 Used) Plug (9 Used) O-Ring (9 Used) Spring (9 Used)

fNOTE:

Check Valve (4 Used) * Spring * Check Valve Plug (2 Used) Plug (2 Used) Plug Plug (2 Used)

Check Valve Overload Relief Valve (6 Used) * O-Ring * O-Ring Check Valve (3 Used) * Spring (2 Used) * Check Valve (2 Used)

As for the item with mark *, refer to W3-6-3-1 and W3-6-3-2.

W3-6-3-9

Main Relief Valve (2 Used) Plug (2 Used) Check Valve Rod (4 Used) Make-Up Valve

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Assembly of Body IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

1. Install check valve (25), check valves (45) (2 used), spring (24), and springs (44) (2 used) to sections (D, G, I).

2. Install O-rings (9) (10 used) and O-rings (34, 36) to each section.

3. Place bodies (1a to 1l) of each section in the same order as before disassembling. Tighten bodies (1a to 1l) with rods (77) (4 used) and nuts (5) (8 used). j : 13 mm m : 27 to 30 N·m (2.7 to 3 kgf·m, 20 to 22 lbf·ft) 4. Install plugs (30) (2 used) to section (E).

7. Install main relief valve (4) and main relief valves (47) (2 used) to sections (A, H). j : 24 mm m : 59 to 69 N·m (5.9 to 6.9 kgf·m, 44 to 51 lbf·ft) 8. Install check valve (31), check valves (37) (3 used), and check valve (76) to sections (E, F, K, L). Install check valves (18) (4 used) to sections (B, C, D, E).

9. Install springs (17) (9 used) to sections (B, C, D, E, F, K, L).

10. Install O-rings (16) (9 used) to plugs (15) (9 used).

Install plugs (15) (9 used) to sections (B, C, D, E, F, K, L).

j : 17 mm

j : 14 mm

m : 59 to 69 N·m (5.9 to 6.9 kgf·m, 44 to 51 lbf·ft)

m : 30 to 32 N·m (3 to 3.2 kgf·m, 22 to 24 lbf·ft)

5. Install overload relief valves (33) (6 used) to sections (F, K, L). j : 24 mm m : 59 to 69 N·m (5.9 to 6.9 kgf·m, 44 to 51 lbf·ft) 6. Install make-up valve (79) to section (D). j : 24 mm m : 59 to 69 N·m (5.9 to 6.9 kgf·m, 44 to 51 lbf·ft)

W3-6-3-10

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Disassembly of Boom Anti-Drift Valve 56 57 58 59 60 61 62 63 64 65 66 67 68 69 55 53

74

73

54 70

72

3

21

14

20

71

1k

WADB-03-06-003

1k- 3- 14- 20- 21- 53- 54-

Body (Boom) O-Ring (2 Used) Spring Spring Seat (2 Used) Spring Seat (2 Used) O-Ring Spacer

55- 56- 57- 58- 59- 60- 61-

O-Ring (2 Used) Plug Piston Spring Plug O-Ring Spool

62- 63- 64- 65- 66- 67- 68-

Sleeve Backup Ring O-Ring O-Ring Backup Ring Check Valve Spring Seat

W3-6-4-1

69- 70- 71- 72- 73- 74-

Spring Socket Bolt (5 Used) Body Backup Ring Spring Check Valve

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Disassembly of Boom Anti-Drift Valve IMPORTANT: Do not drop spring (14) and spring seats (20, 21) when removing body (71).

1. Secure the body (1k) assembly in a vise. Remove socket bolts (70) (5 used). Remove body (71) from body (1k).

5. Secure the body (71) assembly in a vise. Remove plug (56) from body (71). j : 24 mm 6. Remove piston (57) and spring (58) from plug (59) by using a screwdriver.

l : 5 mm

fNOTE:

As for disassembly of the boom spool, refer to W3-6-5-1.

2. Remove O-ring (3), O-rings (55) (2 used), spring (14), and spring seat (20) from body (71).

3. Remove spacer (54) from body (1k). Remove O-ring (53) and backup ring (72) from spacer (54).

4. Remove spring (73) and check valve (74) from body (1k).

7. Remove plug (59) from body (71). Remove O-ring (60) from plug (59). j : 24 mm 8. Remove spool (61) from sleeve (62).

9. Remove the sleeve (62) assembly from body (71).

10. Remove backup rings (63, 66) and O-rings (64, 65) from sleeve (62).

11. Remove check valve (67), spring seat (68), and spring (69) from body (71) by using a magnet.

W3-6-4-2

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Assembly of Boom Anti-Drift Valve J

K

a J

WADB-03-06-011 a-

Machine Front Side

Section J-J

Section K 56

1k

20 59

71

57

21

61

14 3

58 60 62 64

1k

63 55

66 65 68 69

74 73 72 53 54

67

71

WADB-03-06-006

T1ND-03-03-002

W3-6-4-3

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve 1k- 3- 14- 20- 21- 53- 54-

Body (Boom) O-Ring (2 Used) Spring Spring Seat (2 Used) Spring Seat (2 Used) O-Ring Spacer

fNOTE:

55- 56- 57- 58- 59- 60- 61-

O-Ring (2 Used) Plug Piston Spring Plug O-Ring Spool

62- 63- 64- 65- 66- 67- 68-

Sleeve Backup Ring O-Ring O-Ring Backup Ring Check Valve Spring Seat

As for the parts with mark *, refer to W3-6-4-1.

W3-6-4-4

69- 70- 71- 72- 73- 74-

Spring * Socket Bolt (5 Used) Body Backup Ring Spring Check Valve

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Assembly of Boom Anti-Drift Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

1. Install backup rings (63, 66) and O-rings (64, 65) to sleeve (62).

2. Install check valve (67) to sleeve (62).

3. Install spring seat (68) and spring (69) to the sleeve (62) assembly.

4. Place body (71) with the O-ring (55) mounting surface up. Install the sleeve (62) assembly to body (71).

fNOTE:

As for assembly of the boom spool, refer to W36-5-3.

8. Install check valve (74) and spring (73) to body (1k).

9. Install backup ring (72) and O-ring (53) to spacer (54). Install spacer (54) to body (1k).

10. Install spring seat (20), spring (14), O-ring (3), and O-rings (55) (2 used) to body (71).

11. Secure body (1k) in a vise. Install body (71) to body (1k) with socket bolts (70) (5 used).

5. Secure body (71) in a vise. Install O-ring (60) to plug (59). Install plug (59) to body (71). j : 24 mm m : 30 N·m (3 kgf·m, 22lbf·ft) 6. Install spool (61) and spring (58) to sleeve (62).

7. Install piston (57) and plug (56) to plug (59). j : 24 mm m : 30 N·m (3 kgf·m, 22lbf·ft)

W3-6-4-5

l : 10 mm m : 7 to 10 N·m (0.7 to 1 kgf·m, 5.2 to 7.4 lbf·ft)

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve (Blank)

W3-6-4-6

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Disassembly of Spool

fNOTE:

The illustration shows the arm.

1

20 21

14

19

3

a

14 1

3

1g

13 43 21 20

a- 1g- 1- 3-

Arm Regenerative Valve Body (Arm) Socket Bolt (4 Used) O-Ring (2 Used)

WADB-03-06-005

13- Cover 14- Spring (2 Used) 19- Cover

20- Spring Seat (2 Used) 21- Spring Seat (2 Used) 43- Spool

W3-6-5-1

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Disassembly of Spool

fNOTE:

The arm spool is explained here.

IMPORTANT: Do not drop spring (14) and spring seats (20, 21) when removing covers (13, 19).

1. Remove socket bolts (1) (4 used) from covers (13, 19). Remove covers (13, 19) and O-rings (3) (2 used) from body (1g). l : 5 mm 2. Remove springs (14) (2 used) and spring seats (20) (2 used) from covers (13, 19).

3. Remove spring seats (21) (2 used) from spool (43).

4. Remove spool (43) from body (1g) by rotating.

W3-6-5-2

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Assembly of Spool

fNOTE:

The illustration shows the arm.

20

19

3

21 14

13

T577-03-03-005

14

a- 1g- 1- 3-

Arm Regenerative Valve Body Socket Bolt (4 Used) O-Ring (2 Used)

1 21

a

13- Cover 14- Spring (2 Used) 19- Cover

1g

43

20- Spring Seat (2 Used) 21- Spring Seat (2 Used) 43- Spool

W3-6-5-3

3

20

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Assembly of Spool

fNOTE:

The arm spool is explained here.

IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

1. Install spool (43) to body (1g) by rotating.

2. Install spring seats (21) (2 used) to spool (43).

3. Install spring seats (20) (2 used), springs (14) (2 used), and O-rings (3) (2 used) to covers (13, 19).

4. Install cover (13) to body (1g) with socket bolts (1) (2 used). l : 5 mm m : 7 to 10 N·m (0.7 to 1 kgf·m, 5.2 to 7.4 lbf·ft) 5. Install cover (19) in the same way as step 4.

W3-6-5-4

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Disassembly of Arm Regenerative Valve and Orifice

35

39 40 41 42 1g

WADB-03-06-005 1g- Body 35- Orifice

39- Check Valve 40- Spring

41- O-Ring 42- Plug

W3-6-6-1

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Disassembly of Arm Regenerative Valve and Orifice 1. Remove plug (42) from body (1g). Remove O-ring (41) from plug (42). l : 6 mm 2. Remove spring (40) and check valve (39) from body (1g).

3. Remove orifice (35) from body (1g). l : 2.5 mm

W3-6-6-2

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Assembly of Arm Regenerative Valve and Orifice

1g

35

39 40

T577-03-03-006

42

1g- Body 35- Orifice

41

39- Check Valve 40- Spring

41- O-Ring 42- Plug

W3-6-6-3

SECTION 3 UPPERSTRUCTURE Group 6 Control Valve Assembly of Arm Regenerative Valve and Orifice IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

1. Install orifice (35) to body (1g). l : 2.5 mm m : 2 N·m (0.2 kgf·m, 1.5 lbf·ft) 2. Install check valve (39) and spring (40) to body (1g).

3. Install O-ring (41) to plug (42). Install plug (42) to body (1g). l : 6 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-6-6-4

SECTION 3 UPPERSTRUCTURE Group 7 Swing Device Removal and Installation of Swing Device IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

2. Tilt up the floor. (Refer to the Operator's Manual.)

3. Disconnect hoses (2) (5 used) from swing device (3). j : 17 mm, 19 mm, 22 mm

M1M7-07-067

d CAUTION:

Swing device (3) weight: 38 kg (84 lb) 4. Remove bolts (4) (6 used) and washers (5) (6 used).

Remove swing device (3) from main flame (6).

2

j : 22 mm

3

5. Remove the adapters with swing device (3) attached if necessary.

2

6

W3-7-1-1

4, 5

W1M9-02-05-001

SECTION 3 UPPERSTRUCTURE Group 7 Swing Device Installation 1. Install all removed adapters to swing device (3).

2

3

d CAUTION:

Swing device (3) weight: 38 kg (84 lb) 2. Install swing device (3) to main flame (6) with bolts (4) (6 used) and washers (5) (6 used). j : 22 mm

2

m : 140 N·m (14 kgf·m, 103 lbf·ft) 3. Connect hoses (2) (5 used) to swing device (3). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 6

j : 19 mm

4, 5

W1M9-02-05-001

m : 30 N·m (3 kgf·m, 22 lbf·ft) j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft) 4. Tilt down the floor. (Refer to the Operator's Manual.)

IMPORTANT: Check the hydraulic oil level. Start the engine. Tilt up the floor and check for any oil leaks. After checking, tilt down the floor. (Refer to Maintenance in the Operator's Manual.)

M1M7-07-067

W3-7-1-2

SECTION 3 UPPERSTRUCTURE Group 7 Swing Device Disassembly of Swing Device

WADB-03-07-001

1- 2- 3- 4- 5- 6- 7- 8-

Housing Shaft Plate Collar Roller Bearing Oil Seal Roller Bearing Plate (2 Used)

9- 10- 11- 12- 13- 14-

Collar Second Stage Carrier Thrust Plate (4 Used) Inner Race (4 Used) Needle Bearing (4 Used) Second Stage Planetary Gear (4 Used) 15- Thrust Plate

16- 17- 18- 19- 20- 21- 22-

Screw (4 Used) Second Stage Sun Gear First Stage Carrier Thrust Plate (4 Used) Inner Race (4 Used) Needle Bearing (4 Used) First Stage Planetary Gear (4 Used)

W3-7-2-1

23- 24- 35- 36- 37- 38- 39-

Thrust Plate First Stage Sun Gear Plug O-Ring O-Ring Socket Bolt (2 Used) Swing Motor

SECTION 3 UPPERSTRUCTURE Group 7 Swing Device Disassembly of Swing Device IMPORTANT: Shaft (2), collar (4), plate (3), roller bearings (5, 7), plates (8) (2 used), and collar (9) cannot be replaced individually. Replace them the housing (1) assembly.

dCAUTION:

Swing motor (39) weight: 21 kg 1. Remove socket bolts (38) (2 used). Remove swing motor (39) from housing (1).

8. Remove the second stage carrier (10) assembly from housing (1).

9. Remove screws (16) (4 used) and thrust plate (15) from second stage carrier (10). l : 3 mm 10. Remove second stage planetary gears (14) (4 used), needle bearings (13) (4 used), inner races (12) (4 used), and thrust plates (11) (4 used) from second stage carrier (10).

l : 10 mm 2. Remove O-ring (37) from housing (1).

3. Remove plug (35) from housing (1). Remove O-ring (36) from plug (35). l : 5 mm 4. Remove thrust plate (23) and first stage sun gear (24) from housing (1).

11. Remove collar (9) and plates (8) (2 used) from shaft (2).

IMPORTANT: Do not remove the inner race of roller bearing (5), plate (3), and collar (4) from shaft (2).

12. Remove the shaft (2) assembly from housing (1) by using a plastic hammer.

IMPORTANT: Do not remove the outer race of roller bearings (5, 7) from housing (1).

13. Remove oil seal (6) from housing (1).

5. Remove the first stage carrier (18) assembly from housing (1).

6. Remove first stage planetary gears (22) (4 used), needle bearings (21) (4 used), inner races (20) (4 used), and thrust plates (19) (4 used) from first stage carrier (18).

7. Remove second stage sun gear (17) from second stage carrier (10).

W3-7-2-2

SECTION 3 UPPERSTRUCTURE Group 7 Swing Device Assembly of Swing Device 16

39 22

23

37

38 21

24

20 19 18 14 13 12 11 10

15 17

8

9 7

35

6

36

5

1

3

4

2 WADB-03-07-002

1- 2- 3- 4- 5- 6- 7- 8-

Housing Shaft Plate Collar Roller Bearing Oil Seal Roller Bearing Plate (2 Used)

9- 10- 11- 12- 13- 14-

Collar Second Stage Carrier Thrust Plate (4 Used) Inner Race (4 Used) Needle Bearing (4 Used) Second Stage Planetary Gear (4 Used) 15- Thrust Plate

16- 17- 18- 19- 20- 21- 22-

Screw (4 Used) Second Stage Sun Gear First Stage Carrier Thrust Plate (4 Used) Inner Race (4 Used) Needle Bearing (4 Used) First Stage Planetary Gear (4 Used)

W3-7-2-3

23- 24- 35- 36- 37- 38- 39-

Thrust Plate First Stage Sun Gear Plug O-Ring O-Ring Socket Bolt (2 Used) Swing Motor

SECTION 3 UPPERSTRUCTURE Group 7 Swing Device Assembly of Swing Device

5. Install the inner race of roller bearing (7) to shaft (2).

IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

IMPORTANT: The shaft (2) is installed collar (4), plate (3), and the inner race of roller bearing (5).

1. Place shaft (2) with the roller bearing (5) mounting side up.

6. Install plates (8) (2 used) and collar (9) while applying a load 6870 N (700 kgf ) to roller bearing (7) by using special tool (ST 7711).

2. Apply grease (Shell Alvania Grease 2) onto the inner race of roller bearing (5).

24 63

9

IMPORTANT: Install oil seal (6) with the metal surface facing to the swing motor side.

4. Install oil seal (6) to casing (1) with the lip part side up.

90

IMPORTANT: The housing (1) is installed the outer races of roller bearings (5, 7).

3. Install housing (1) to the shaft (2) assembly.

φ40+0.20

50.2+0.20 ST 7711 W1ND-02-05-001

W3-7-2-4

SECTION 3 UPPERSTRUCTURE Group 7 Swing Device 7. Install thrust plates (11) (4 used), inner races (12) (4 used), needle bearings (13) (4 used), and second stage planetary gears (14) (4 used) to second stage carrier (10).

8. Apply LOCTITE #242 onto screws (16) (4 used).

IMPORTANT: Install thrust plate (15) with the chamfered surface facing to the swing motor side.

9. Install thrust plate (15) to the second stage carrier (10) with screws (16) (4 used).

IMPORTANT: Install thrust plate (23) with the chamfered surface facing to swing motor side.

14. Install first stage sun gear (24) and thrust plate (23) to first stage carrier (18).

15. Install O-ring (36) to plug (35). Install plug (35) to housing (1). l : 5 mm m : 16±1 N·m (1.6±0.1 kgf·m, 12±0.7 lbf·ft)

l : 3 mm

16. Install O-ring (37) to housing (5).

m : 4±0.5 N·m (0.4±0.05 kgf·m, 3±0.4 lbf·ft)

17. Install swing motor (39) to housing (5) with socket bolts (38) (2 used).

10. Install the second stage carrier (10) assembly to housing (1).

l : 10 mm

11. Install second stage sun gear (17) to second stage carrier (10).

12. Install thrust plates (19) (4 used), inner races (20) (4 used), needle bearings (21) (4 used), and first stage planetary gears (22) (4 used) to first stage carrier (18).

13. Install the first stage carrier (18) assembly to housing (1).

W3-7-2-5

m : 130±7 N·m (13±0.7 kgf·m, 96±5.2 lbf·ft)

SECTION 3 UPPERSTRUCTURE Group 7 Swing Device (Blank)

W3-7-2-6

SECTION 3 UPPERSTRUCTURE Group 7 Swing Device Disassembly of Swing Motor

WADB-03-07-003 1- 2- 3- 4- 5- 6- 7- 8- 9- 10-

Casing Ball Bearing Shaft Swash Plate Rotor Collar Spring Washer Retaining Ring Pin (3 Used)

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

Holder Retainer Plunger (9 Used) Disc Plate Brake Piston O-Ring O-Ring Spring Seat (2 Used) Disc Spring (2 Used) O-Ring

21- 22- 23- 24- 25- 26- 27- 28- 38- 39-

Cover Ball Bearing Pin Valve Plate Pin (2 Used) O-Ring (2 Used) Socket Bolt (5 Used) Orifice Relief Valve (2 Used) Check Valve (2 Used)

W3-7-3-1

40- 41- 42- 43- 44- 45- 46- 47-

Spring (2 Used) Plug (2 Used) O-Ring (2 Used) Plug O-Ring Plug O-Ring Retaining Ring

SECTION 3 UPPERSTRUCTURE Group 7 Swing Device Disassembly of Swing Motor IMPORTANT: As the setting changes, do not disassemble relief valve (38).

8. Put the matching marks on cover (21) and casing (1). Remove socket bolts (27) (5 used). l : 10 mm

1. Remove relief valves (38) (2 used) from casing (1).

IMPORTANT: Do not remove ball bearing (22) unless necessary.

IMPORTANT: Do not drop valve plate (24) while removing cover (21).

9. Remove cover (21) from casing (1). Remove O-ring (20).

j : 32 mm 2. Remove plug (41) from casing (1). Remove O-ring (42) from plug (41). l : 8 mm 3. Remove spring (40) and check valve (39) from casing (1).

4. Remove other check valve (39) in the same way as step 2 to step 3.

5. Remove orifice (28) from casing (1).

IMPORTANT: Do not damage the mating surfaces when separating valve plate (24) from casing (1) or rotor (5) by using a screwdriver.

10. Remove valve plate (24) from rotor (5).

IMPORTANT: Do not remove pin (23) and pins (25) (2 used) unless necessary.

11. Remove O-rings (26) (2 used) from cover (21).

l : 2.5 mm 6. Remove plug (45) from casing (1). Remove O-ring (46) from plug (45). l : 6 mm 7. Remove plugs (43) (2 used) from cover (21). Remove O-rings (44) (2 used) from plugs (43) (2 used). l : 5 mm

W3-7-3-2

SECTION 3 UPPERSTRUCTURE Group 7 Swing Device 12. Remove disc springs (19) (2 used) and spring seats (18) (2 used) from casing (1).

13. Put the matching marks on casing (1) and brake piston (15). Remove brake piston (15) from casing (1).

14. Remove O-rings (16, 17) from brake piston (15).

IMPORTANT: Do not damage the sliding surfaces of rotor (5) and plungers (13) (9 used).

15. Remove the rotor (5) assembly from shaft (3).

16. Remove plungers (13) (9 used), retainer (12), holder (11), and pins (10) (3 used) from rotor (5).

IMPORTANT: Do not disassemble the rotor (5) assembly (parts No.5 to 9) unless necessary.

When removing retaining ring (9), dCAUTION: push washer (8) and spring (7) by using the press

in order not to fly out.

17. Remove retaining ring (9), washer (8), spring (7), and collar (6) from rotor (5) by using a press.

IMPORTANT: Do not damage the sliding surface of swash plate (4).

18. Remove disc plate (14) and swash plate (4) from casing (1).

19. Place the casing (5) assembly horizontally with the orifice (28) mounting side down. Tap the ball bearing (2) mounting side and remove the shaft (3) assembly from casing (1) by using a plastic hammer.

20. Remove ball bearing (2) from shaft (3) by using a press.

21. Remove retaining ring (47) from ball bearing (2).

W3-7-3-3

SECTION 3 UPPERSTRUCTURE Group 7 Swing Device Assembly of Swing Motor 20

27 15 18 24

8

3 22 9 23 19 25

44 43 26 7

21 5 17 16 14 13

28 6 12

1 4 47

10 11

2

45 46

38 41 42 39 40 WADB-03-07-004 1- 2- 3- 4- 5- 6- 7- 8- 9- 10-

Casing Ball Bearing Shaft Swash Plate Rotor Collar Spring Washer Retaining Ring Pin (3 Used)

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

Holder Retainer Plunger (9 Used) Disc Plate Brake Piston O-Ring O-Ring Spring Seat (2 Used) Disc Spring (2 Used) O-Ring

21- 22- 23- 24- 25- 26- 27- 28- 38- 39-

Cover Ball Bearing Pin Valve Plate Pin (2 Used) O-Ring (2 Used) Socket Bolt (5 Used) Orifice Relief Valve (2 Used) Check Valve (2 Used)

W3-7-3-4

40- 41- 42- 43- 44- 45- 46- 47-

Spring (2 Used) Plug (2 Used) O-Ring (2 Used) Plug O-Ring Plug O-Ring Retaining Ring

SECTION 3 UPPERSTRUCTURE Group 7 Swing Device Assembly of Swing Motor IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

IMPORTANT: Install bearing (2) with its retaining ring (47) up as illustrated.

1. Install ball bearing (2) to shaft (3) by using a press.

3

47

IMPORTANT: Install collar (6) with the chamfered surface facing to casing (1) side.

5. Install collar (6), spring (7), and washer (8) to rotor (5).

When installing retaining ring (9) to dCAUTION: rotor (5), push washer (8) and spring (7) by using

the press in order not to fly out.

6. Push washer (8) and spring (7) by using a press.

Install retaining ring (9) to rotor (5). Turn over rotor (5).

7. Apply grease onto pins (10) (3 used). Install pins (10) (3 used) to rotor (5). Install holder (11) on pin (10).

8. Install retainer (12) and plungers (13) (9 used) to rotor (5).

2 W1M9-02-05-007

2. Install retaining ring (47) to ball bearing (2).

IMPORTANT: Install shaft (3) until the retaining ring (47) of ball bearing (2) comes in contact with casing (1). If pushing shaft (4) further, the retaining ring may be deformed.

3. Tap the cover (21) mounting side and install the shaft (3) assembly to casing (1) by using a plastic hammer.

9. Place the casing (1) assembly horizontally with the orifice (28) mounting surface side down. While turning the rotor (5) assembly, insert the rotor (5) assembly into the casing (1). Place casing (1) with the cover (21) mounting side up.

10. Install O-rings (16, 17) to brake piston (15). Fit the matching marks made when disassembling and install brake piston (15) to casing (1).

fNOTE:

IMPORTANT: Install swash plate (4) with the chamfered surface facing to casing (1) side.

4. Apply grease onto the chamfered surface of swash plate (4). Install swash plate (4) to casing (1).

W3-7-3-5

If it is not easy to install brake piston (15) into casing (1) due to the friction from O-rings (16, 17). Evenly tap brake piston (15) by using a plastic hammer.

SECTION 3 UPPERSTRUCTURE Group 7 Swing Device 11. Install spring seats (18) (2 used) and disc springs (19) (2 used) to brake piston (15) as illustrated.

19. Install cover (21) to casing (1) with socket bolts (27) (5 used). l : 10 mm

18

m : 130±7 N·m (13±0.7 kgf·m, 96±5.2 lbf·ft) 20. Install O-ring (44) to plug (43). Install plug (43) to cover (21).

19

l : 5 mm

18

m : 16±1 N·m (1.6±0.1 kgf·m, 12±0.7 lbf·ft) 21. Install O-ring (46) to plug (45). Install plug (45) to casing (1).

W565-02-05-004

IMPORTANT: Check the direction to install valve plate (24).

12. Install pin (23) and pins (25) (2 used) to cover (21).

13. Apply grease onto valve plate (24) in order not to drop valve plate (24) from cover (21).

l : 6 mm m : 23±1 N·m (2.3±0.1 kgf·m, 17±0.7 lbf·ft) 22. Install orifice (28) to casing (1). l : 2.5 mm m : 2.5±0.5 N·m (0.25±0.05 kgf·m, 1.8±0.4 lbf·ft)

14. Fit the pin (23) and install valve plate (24) to cover (21).

IMPORTANT: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury.

15. Evenly tap and install ball bearing (22) to cover (21) by using a bar and a hammer.

16. Install O-rings (26) (2 used) to cover (21).

23. Install check valve (39) and spring (40) to casing (1).

Install O-ring (42) to plug (41). Install plug (41) to casing (1). l : 8 mm m : 40±2 N·m (4±0.2 kgf·m, 29.5±1.5 lbf·ft) 24. Install other check valve (39) in the same way as step 23.

25. Install relief valves (38) (2 used) to casing (1).

17. Install O-ring (20) to casing (1).

j : 32 mm

18. Fit the matching marks made when disassembling and install cover (21) to casing (1).

m : 160±10 N·m (16±1 kgf·m, 118±7.4 lbf·ft)

W3-7-3-6

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Removal and Installation of Pilot Valve (Left)

3

6

7

4 8 5

2

14 9

13

10 11

1

12 15

WADB-03-08-011

WADB-03-08-010

IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

4. Raise boot (4). Loosen lock nut (13). Remove the lever (3) assembly and boot (4) from pilot valve (9). j : 19 mm 5. Disconnect hoses (12) (6 used) from pilot valve (9). j : 17 mm 6. Put the matching marks on frame (5) and pilot valve (9). Remove bolts, washers (2) (4 used) from frame (5). Remove pilot valve (9) from frame (5). j : 13 mm

d

CAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)

2. Remove bolts (7) (3 used), bolts (14), and washers (6) (4 used). Remove covers (8).

7. Remove clip band (10) and glass wool (11) from pilot valve (9).

8. Remove the adapter with pilot valve (9) attached if necessary.

j : 10 mm 3. Remove bolts, washers (15) (3 used). Remove cover (1). j : 19 mm

W3-8-1-1

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve

3

6

7

4 8 5

2

14 9

13

10 11

1

12 15

WADB-03-08-011

Installation

WADB-03-08-010

5. Install the lever (3) assembly and boot (4) to pilot valve (9). Secure the lever (3) assembly to pilot valve (9) with lock nut (13).

1. Install all removed adapters to pilot valve (9).

2. Secure glass wool (11) to pilot valve (9) with clip band (10).

j : 19 mm

3. Fit the matching marks on frame (5) and pilot valve (9). Install pilot valve (9) to frame (5) with bolts, washers (2) (4 used).

m : 90 N·m (9 kgf·m, 66 lbf·ft) 6. Install covers (1) with bolts, washers (15) (3 used). j : 10 mm

j : 13 mm

m : 5 N·m (0.5 kgf·m, 3.7 lbf·ft)

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

7. Install covers (8) with bolts (7) (3 used), bolts (14), and washers (6) (4 used).

4. Connect hoses (12) (6 used) to pilot valve (9). j : 17 mm

j : 10 mm

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

W3-8-1-2

m : 5 N·m (0.5 kgf·m, 3.7 lbf·ft)

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Removal and Installation of Pilot Valve (Right) 1 6 2

5 3 7

7

4 W1NG-02-06-001

WADB-03-08-019

IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

2. Raise boot (3). Loosen lock nut (5). Remove clip bands (6) from the shaft mounting part of pilot valve (4). Disconnect connector (2).

3. Remove the lever (1) assembly and boot (3) from pilot valve (4).

W3-8-2-1

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve

3

4

2 1

5 WADB-03-08-016

WADB-03-08-015

4. Remove bolt, washer (1), screws (3) (4 used), and washers (4) (4 used). j : 13 mm l : 5 mm 5. Raise cover (2). Disconnect all connectors (5).

Remove cover (2).

W3-8-2-2

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve

8

1

7

9

2 3

6

5

4 WADB-03-08-017

WADB-03-08-015

6. Disconnect hoses (9) (6 used) from pilot valve (2).

8. Remove clip band (3) and glass wool (4) from pilot valve (2).

j : 17 mm 7. Put the matching marks on bracket (5) and pilot valve (2). Remove spring pin (8), bolt (1), washer (7), and bolts, washers (6) (3 used) from bracket (5).

Remove pilot valve (2) from bracket (5).

9. Remove the adapters with pilot valve (2) attached if necessary.

j : 13 mm

W3-8-2-3

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve

8

1

7

9

2 3

6

5

4 WADB-03-08-017

WADB-03-08-015

Installation 1. Install all removed adapters to pilot valve (2).

4. Connect hoses (9) (6 used) to pilot valve (2).

2. Secure glass wool (4) to pilot valve (2) with clip band (3).

3. Fit the matching marks on bracket (5) and pilot valve (2). Install pilot valve (2) to bracket (5) with bolts, washers (6) (3 used), washer (7), bolt (1), and spring pin (8).

j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

W3-8-2-4

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve

3

4

2 1

5 WADB-03-08-016

WADB-03-08-015

5. Install cover (2).

6. Raise cover (2). Connect all connectors (5).

7. Install cover (2) with washers (4) (4 used), screws (3) (4 used), and bolt, washer (1). j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft) l : 5 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

W3-8-2-5

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve

1 6 2

5 3 7

7

4 W1NG-02-06-001

WADB-03-08-019

8. Secure harness to the shaft mounting part of pilot valve (4) with clip bands (6).

9. Install boot (3) and the lever (1) assembly to pilot valve (4). Connect connector (2). Secure the lever (1) assembly to pilot valve (4) with lock nut (5).

W3-8-2-6

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Removal and Installation of Travel Pilot Valve 1

IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

4

Removal 2. Remove floor mats (1, 2, 3, 4).

3

WAEBJ0-03-08-003

2

5

3. Remove bolts, washers (8) (4 used). Remove the pedal (6) assemblies (2 used) and the lever (5) assemblies (2 used) from pilot valve (7). j : 17 mm 4. Tilt up the floor. (Refer to the operator’s manual.)

6

8

7

WBAT-06-01-038

M1M0-07-032

W3-8-3-1

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve 5. Disconnect hoses (1) (8 used) from pilot valve (4). j : 17 mm, 19 mm 6. Tilt down the floor. (Refer to the operator’s manual.)

7. Remove socket bolts (2) (2 used) and washers (3) (2 used). Remove pilot valve (4) from floor (5). l : 8 mm

1

8. Remove the adapters with pilot valve (4) attached if necessary.

1

1 2, 3

5

W3-8-3-2

WADB-03-08-012

4

WAEBJ0-03-08-004

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Installation 2, 3

1. Install all removed adapters to pilot valve (4).

4

2. Install pilot valve (4) to floor (5) with socket bolts (2) (2 used) and washers (3) (2 used). l : 8 mm m : 50 N·m (5 kgf·m) 3. Tilt up the floor. (Refer to the operator’s manual.)

4. Connect hoses (1) (8 used) to pilot valve (4). j : 17 mm m : 25 N·m (2.5 kgf·m) j : 19 mm

WAEBJ0-03-08-004

5

m : 30 N·m (3 kgf·m)

1 1

1

W3-8-3-3

WADB-03-08-012

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve 5. Tilt down the floor. (Refer to the operator’s manual.)

IMPORTANT: Check the hydraulic oil level. Start the engine. Tilt up the floor and check for any oil leaks. After checking, tilt down the floor. (Refer to the operator’s manual.)

6. Install the lever (5) assemblies (2 used) and the pedal (6) assemblies (2 used) to pilot valve (7) with bolts, washers (8) (4 used). j : 17 mm m : 50 N·m (5 kgf·m) 7. Install floor mats (1, 2, 3, 4).

M1M0-07-032

5

6

8

7

WBAT-06-01-038

1

4

W3-8-3-4

3

2

WAEBJ0-03-08-003

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Removal and Installation of Blade Pilot Valve 4

1

5

6

7

3, 15

9 13 11

10

14

2

WADB-03-08-021

IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

IMPORTANT: The stopper has been installed to the screw (13) tip in order to prevent it from coming off. Do not loosen screw (13) excessively.

2. Loosen screw (13). Remove cover (14).

12

11

WADCJ0-03-08-001

4. Remove bolts, washers (6) (2 used). Remove the lever (7) assembly. j : 13 mm 5. Disconnect hoses (11) (6 used) from pilot valve (12). j : 17 mm, 19 mm 6. Remove bolts, washers (5) (2 used). Remove pilot valve (12) from bracket (4). j : 13 mm 7. Remove clip bands (9) (2 used) and glass wool (10) from pilot valve (12).

8. Remove the adapters with pilot valve (12) attached if necessary.

3. Remove screws (3) (7 used) and washers (15) (7 used). Remove covers (1, 2).

W3-8-4-1

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve

4

5

6

7 1

9

11

3, 15 13

10

14

12

11

WADCJ0-03-08-001

2

WADB-03-08-021

Installation 1. Install all removed adapters to pilot valve (12).

4. Connect hoses (11) (6 used) to pilot valve (12).

2. Secure glass wool (10) to pilot valve (12) with clip bands (9) (2 used).

j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

3. Install pilot valve (12) to bracket (4) with bolts, washers (5) (2 used).

j : 19 mm

j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

m : 30 N·m (3 kgf·m, 22 lbf·ft) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

5. Install the lever (7) assembly with bolts, washers (6) (2 used). j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 6. Install covers (1, 2) with screws (3) (7 used) and washers (15) (7 used).

7. Install cover (14) with screw (13).

W3-8-4-2

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Removal and Installation of Boom Swing Pilot Valve IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

1

W1M9-02-06-008

2

3

Removal

2 1

2. Remove bolts, washers (2) (2 used). Remove pedal (3) from bracket (6). j : 13 mm 3. Remove socket bolts (4) (2 used) and spring washers (5) (2 used). Remove bracket (6) from pilot valve (1). l : 6 mm

4, 5, 6

4. Tilt up the floor. (Refer to Operator's Manual.)

W1M9-02-06-009

M1M7-07-067

W3-8-5-1

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve 5. Disconnect hoses (1) (4 used) from pilot valve (2). j : 17 mm, 19 mm 6. Remove the adapters with pilot valve (2) attached if necessary.

7. Remove bolts, washers (4) (2 used). Remove pilot valve (3) and cover (5) from floor (6). j : 13 mm

1

2

WADB-03-08-018

3

6

W3-8-5-2

5

4

W1M9-02-06-009

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Installation 1. Install cover (6) and pilot valve (2) to floor (10) with bolts, washers (5) (2 used). j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 2. Install all removed adapters to pilot valve (2).

3. Connect hoses (1) (4 used) to pilot valve (2). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

1

2

WADB-03-08-018

j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 4. Tilt down the floor. (Refer to Operator's Manual.)

3

4

IMPORTANT: Check the hydraulic oil level. Start the engine. Tilt up the floor and check for any oil leaks. After checking, Tilt down the floor. (Refer to the operator’s manual.)

5. Install bracket (9) to pilot valve (2) with socket bolts (7) (2 used) and spring washers (8) (2 used).

4 2

l : 6 mm m : 20 N·m (2 kgf·m, 15 lbf·ft) 6. Install pedal (3) to pilot valve (2) with bolts, washers (4) (2 used).

10

7, 8, 9 6

5

W1M9-02-06-009

j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

M1M7-07-067

W3-8-5-3

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve (Blank)

W3-8-5-4

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Disassembly of Pilot Valves (Right and Left)

17 16 15

14

13 12 11 10

18

9 8 7 6

19

5

20

4

21 22

3 2 1

WADB-03-08-003

1- 2- 3- 4- 5- 6-

Spacer (4 Used) Shim (Several) Balance Spring (2 Used) Balance Spring (2 Used) Return Spring (2 Used) Return Spring (2 Used)

7- 8- 9- 10- 11- 12-

Spring Guide (4 Used) Retaining Ring (4 Used) Pusher (2 Used) Pusher (2 Used) Oil Seal (4 Used) Sleeve (4 Used)

13- 14- 15- 16- 17- 18-

O-Ring (4 Used) Plate Universal Joint Cam Screw Joint Casing

W3-8-6-1

19- 20- 21- 22-

Spool (4 Used) O-Ring Plug Retaining Ring

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Disassembly of Pilot Valves (Right and Left) IMPORTANT: Casing (18) is made of aluminium.

Strong force deforms it. Handle it with care.

IMPORTANT: Spool (19) has been selected to match the hole on casing (18). The dimensions of balance springs (3, 4) and return springs (5, 6) as well as those of pushers (9, 10) are different. Arrange the disassembled parts together with the port in order not to confuse. The port number is stamped on the outer surface of casing (18).

IMPORTANT: Do not remove screw joint (17) while securing casing (18) in a vise. The strong torque may act on screw joint (17).

1. Secure screw joint (17) in a vise. Turn cam (16) by using a spanner. Remove screw joint (17). j : 19 mm, 32 mm 2. Secure the flat surface of casing (18) in a vise.

Remove cam (16) from universal joint (15). j : 32 mm

3. Attach a spanner onto the upper part of universal joint (15). Remove universal joint (15). j : 17 mm

fNOTE:

Universal joint (15) has been secured on casing (18) by using LOCTITE #262 or equivalent.

4. Remove plate (14).

IMPORTANT: Do not damage sleeve (12). Insert a soft rubber between sleeve (12) and a tool. Oil seal (11) cannot be removed from sleeve (12). Sleeve (12) and oil seal (11) should be replaced as an assembly.

5. Remove sleeves (12) (4 used) upward by using a pair of pliers. Remove O-rings (13) (4 used) from sleeves (12) (4 used).

IMPORTANT: The dimensions of pushers (9, 10) for ports (1, 3) and for ports (2, 4) are different. Keep the disassembled parts together by the port number in order not to confuse.

6. Remove pushers (9, 10) (2 used for each) from casing (18).

W3-8-6-2

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve 7. When compressing the spring, do not lower spool (19). Install the special tool (ST 4145) to the port hole on casing (18) as illustrated. l : 6 mm

18

IMPORTANT: The quantity of shim (2) has been determined for each port during the performance testing. Do not lose shim (2). Keep shim (2) carefully in order to install shim (2) to the original port when assembling.

9. Remove the special tool (ST4146). Remove spring guides (7) (4 used), return springs (5, 6) (2 used for each), and balance springs (3, 4) (2 used for each) from spools (19) (4 used).

10. Remove shim (2) and spacers (1) (4 used) from spools (19) (4 used).

ST 4145

W178-02-07-048

8. Install the special tool (ST 4146) to the pusher hole on casing (18). Push the special tool (ST 4146) and compress the spring. Tighten the special tool (ST 4146) by using the socket bolt (M14, Pitch 2.0 mm).

Remove retaining rings (8) (4 used) from spools (19) (4 used) by using a screwdriver. l : 12 mm ST 4146

IMPORTANT: Spool (19) has been selected to match the hole on casing (18). Spool (19) and casing (18) should be replaced as an assembly.

11. Remove the special tool (ST 4145) from casing (18).

Slowly turn and remove spools (19) (4 used) from casing (18).

IMPORTANT: Retaining ring (22) may come off while disassembling. Do not drop retaining ring (22) inside casing (18). If retaining ring (22) falls inside casing (18), remove retaining ring (22) completely.

Retaining ring (22) cannot be reused.

12. Remove retaining ring (22) from casing (18) by using a screwdriver. Install the bolt (M8, Pitch 1.25 mm) to plug (21). Remove plug (21) from casing (18). Remove O-ring (20) from plug (21). j : 13 mm

18

W178-02-07-048

W3-8-6-3

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Assembly of Pilot Valves (Right and Left)

17 16

15 14

9, 10

11

12 8 7 3, 4

13

5, 6 2 1

20

21 19

22 18

W178-02-06-055

1- 2- 3- 4- 5- 6-

Spacer (4 Used) Shim (Several) Balance Spring (2 Used) Balance Spring (2 Used) Return Spring (2 Used) Return Spring (2 Used)

7- 8- 9- 10- 11- 12-

Spring Guide (4 Used) Retaining Ring (4 Used) Pusher (2 Used) Pusher (2 Used) Oil Seal (4 Used) Sleeve (4 Used)

13- 14- 15- 16- 17- 18-

O-Ring (4 Used) Plate Universal Joint Cam Screw Joint Casing

W3-8-6-4

19- 20- 21- 22-

Spool (4 Used) O-Ring Plug Retaining Ring

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Assembly of Pilot Valves (Right and Left) IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

IMPORTANT: The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling.

fNOTE:

The table below shows the relations between each port and the parts. Do not confuse them when assembling.

Port No. Spool (19) 1 Same to the former one 2 3 4

Port No. 1 2 3 4

6. Install the special tool (ST 4146) to the pusher (9, 10) holes on casing (18). Push the special tool (ST 4146) and compress the spring. Tighten the special tool (ST 4146) by using the bolt (M14, Pitch 2.0 mm). l : 12 mm ST 4146

ST 4144

Balance Springs (3, 4) Short Long Short Long

1. Check the port hole number and insert same spool (19) before disassembling. Install the thinner end of spool (19) into the port hole on casing (18) by turning slowly.

fNOTE:

4. Install spring guide (7) to return spring (5) with the protrusion up.

5. Install other spools (19) (3 used) in the same way as step 1 to step 4.

Shim Pushers (9, 10) (2) Same to the One outer groove former one Two outer grooves One outer groove Two outer grooves

Return Springs (5, 6) Short Long Short Long

IMPORTANT: Refer to the table in the left in order to assemble the parts correctly.

3. Install spacer (1), shim (2), and balance spring (3) to spool (19). Install return spring (5) to casing (18).

Spool (19) has been selected to match the port hole. Spool (19) and casing (18) should be replaced as an assembly.

2. Install the special tool (ST 4145) to the port hole on casing (18) in order not to lower spool (19) when the spring is compressed.

ST 4145

W178-02-07-049

7. Install retaining ring (8) to the ring holder (ST 4144).

l : 6 mm

W3-8-6-5

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve 8. Install retaining ring (8) to the groove on the head of spool (19) extending from the special tool (ST 4146).

IMPORTANT: Check the position to install pusher (9).

9. Install pusher (9).

After pushing pusher (9) several times by hand, remove it. Check if retaining ring (8) comes off or balance spring (3) is located correctly.

Install pusher (9) to casing (18) after checking.

10. Install other pushers (9, 10) in the same way as step 8 to step 9.

11. Apply grease onto the ball part at the ends of pushers (9, 10) (2 used for each).

IMPORTANT: Fit the bolt hole on plate (14) to the screw hole on casing (18).

16. Apply LOCTITE #262 or equivalent onto the screw part of universal joint (15). Place plate (14) on casing (18). Install universal joint (15). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) IMPORTANT: Check the tightness of cam (16).

17. Install cam (16) to universal joint (15). The clearance between cam (16) and pushers (9, 10) (2 used for each) should be 0 to 0.2 mm.

18. Secure cam (16) by using a spanner. Tighten screw joint (17) by using a spanner.

12. Apply grease onto the joint part of universal joint (15).

j : 19 mm, 30 mm

13. Apply grease onto the inner surface of oil seals (11) (4 used).

fNOTE:

Sleeve (12) and oil seal (11) should be replaced as an assembly.

14. Install oil seals (11) (4 used) and O-rings (13) (4 used) to sleeves (12) (4 used). Push the sleeve (12) assemblies (4 used) by hand until O-ring (13) is inserted into the hole on casing (18).

m : 70 N·m (7 kgf·m, 52 lbf·ft) 19. Install O-ring (20) to plug (21). Install the plug (21) assembly and retaining ring (22) to casing (18).

15. Secure casing (18) in a vise lightly.

W3-8-6-6

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Disassembly of Travel Pilot Valve 1

2

3 4 5 6

35

7 33 9

31

8

34

32

30 29

10 11 28 14 12

13

27 26

15

25

16

24

17 18

23

19 20 21

22 WADB-03-08-004

1- 2- 3- 4- 5- 6- 7- 8- 9-

Bolt, Washer (2 Used) Cover Spring Pin (2 Used) Spring Pin (2 Used) Cam (2 Used) Bushing (4 Used) Holder Spring Washer (4 Used) Socket Bolt (4 Used)

10- 11- 12- 13- 14- 15- 16- 17- 18-

Spring Pin (2 Used) Bracket (2 Used) Spring Pin (2 Used) Spring Pin (2 Used) O-Ring (4 Used) Bushing (4 Used) Pusher (4 Used) Spring Guide (4 Used) Balance Spring (4 Used)

19- 20- 21- 22- 23- 24- 25- 26- 27-

O-Ring (2 Used) Plug (2 Used) Plug (2 Used) O-Ring (2 Used) Casing Spool (4 Used) Spring (4 Used) Spacer (4 Used) Shim (12 Used)

W3-8-7-1

28- 29- 30- 31- 32- 33- 34- 35-

Oil Seal (4 Used) Spring Washer (2 Used) Socket Bolt (2 Used) Rubber Seat (2 Used) Damper (2 Used) O-Ring (2 Used) O-Ring (2 Used) Pin (2 Used)

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Disassembly of Travel Pilot Valve IMPORTANT: Casing (23) is made of aluminium.

Strong force deforms it. Handle it with care.

IMPORTANT: Spool (24) has been selected to match the hole on casing (23). Arrange the disassembled parts together with each port in order not to confuse. The port number is stamped on the outer surface of casing (23).

1. Remove bolts, washers (1) (2 used). Remove cover (2) from holder (7).

IMPORTANT: Spool (24) has been selected to match the hole of casing (23). Spool (24) and casing (23) should be replaced as an assembly.

IMPORTANT: Put the mark on spools (24) (4 used) when keeping in order to easily install spools (24) (4 used) to the original hole.

5. Remove the spool (24) assembly from casing (23) by rotating.

j : 10 mm 2. Remove socket bolts (30) (2 used) and spring washers (29) (2 used). Remove the holder (7) assembly from casing (23).

Spring guide (17), balance spring (18), shims (27) (3 used), and spacer (26) are removed with spool (24) together.

IMPORTANT: The quantity of shim (27) has been determined during the performance testing at the factory. When keeping, pair shim (27) with each spool.

6. Compress balance spring (18). Remove spring guide (17), balance spring (18), shims (27) (3 used), and spacer (26) from spool (24).

l : 8 mm 3. Remove the pusher (16) assemblies (4 used) from casing (23).

4. Remove pushers (16) (4 used) from bushings (15) (4 used). Remove oil seals (28) (4 used) and O-rings (14) (4 used) from bushings (15) (4 used) by using a bamboo spatula.

7. Remove spring (25) from casing (23).

8. Remove other spools (24) in the same way as step 5 to step 7.

W3-8-7-2

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve

d

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury.

IMPORTANT: Place a stand under bracket (11) and receive a reaction force. If holder (7) bears the reaction force, strong force acts on pin (35).

Therefore, pin (35) may be deformed.

9. Place stand (b) under bracket (11). The inner surfaces of the spring pins (12, 13) holes on bracket (11) are stepped-shape. The spring pin can only be removed in one direction. Tap and remove spring pins (12, 13) from bracket (11) at the same time by using the special tool (ST 1237). Remove bracket (11) from pin (35). Do not remove spring pin (10) with bracket (11) attached unless necessary. The hole end of spring pin (10) has been crimped.

11. Remove O-ring (33) from pin (35).

12. Remove other bracket (11) in the same way as step 9 to step 11.

13. Place holder (7) with the casing (23) mounting surface up.

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

14. The holes of spring pins (3, 4) (2 used for each) in cam (5) are stepped-shape. Tap the bottom of cam (5) and remove spring pins (3, 4) (2 used for each) from cams (5) (2 used) at the same time by using the special tool (ST 1237).

12, 13 35

11 10 a b

W176-02-07-019 a - Crimped Position b - Stand

10. Remove socket bolts (9) (2 used) and spring washers (8) (2 used). Remove damper (32) and rubber seat (31) from pin (35). O-ring (34) is removed together. l : 5 mm

W3-8-7-3

As the holes of spring pins (3, 4) (2 used for each) are crimped, spring pins (3, 4) may feel tight when removing.

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

15. Remove pins (35) (2 used) by using a bar and a hammer. At the same time, cams (5) (2 used) are removed.

Do not remove bushings (6) (4 used) with holder (7) attached unless necessary. If removing, remove bushings (6) (4 used) by tapping by using the special tool (ST 7256).

16. Remove plugs (20) (2 used) from casing (23).

Remove O-rings (19) (2 used) from plugs (20) (2 used). l : 5 mm 17. Remove plugs (21) (2 used) from casing (23).

Remove O-rings (22) (2 used) from plugs (21) (2 used). l : 6 mm

W3-8-7-4

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Assembly of Travel Pilot Valve

11

32

31

1

2

35 6

12 10

13

7

5

3, 4

30

29 34 9

15

33

8

17

28

18

14

19, 20

25 27

21, 22

16

26 24

23

WADB-03-08-005

1- 2- 3- 4- 5- 6- 7- 8- 9-

Bolt, Washer (2 Used) Cover Spring Pin (2 Used) Spring Pin (2 Used) Cam (2 Used) Bushing (4 Used) Holder Spring Washer (4 Used) Socket Bolt (4 Used)

10- 11- 12- 13- 14- 15- 16- 17- 18-

Spring Pin (2 Used) Bracket (2 Used) Spring Pin (2 Used) Spring Pin (2 Used) O-Ring (4 Used) Bushing (4 Used) Pusher (4 Used) Spring Guide (4 Used) Balance Spring (4 Used)

19- 20- 21- 22- 23- 24- 25- 26- 27-

O-Ring (2 Used) Plug (2 Used) Plug (2 Used) O-Ring (2 Used) Casing Spool (4 Used) Spring (4 Used) Spacer (4 Used) Shim (12 Used)

W3-8-7-5

28- 29- 30- 31- 32- 33- 34- 35-

Oil Seal (4 Used) Spring Washer (2 Used) Socket Bolt (2 Used) Rubber Seat (2 Used) Damper (2 Used) O-Ring (2 Used) O-Ring (2 Used) Pin (2 Used)

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Assembly of Travel Pilot Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

IMPORTANT: The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling.

1. Insert spacer (26), shims (27) (3 used), and balance spring (18) into spool (24) in sequence. Install shim (27) as the same condition before disassembling.

IMPORTANT: Check the direction to install spring guide (17).

2. Compress balance spring (18) by hand. Install spring guide (17) to spool (24) with the stepped part down.

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

fNOTE:

Bushings (6) (4 used) are identical. ď‚– Insert bushings (6) (4 used) into the special tool (ST 7256). Tap the special tool (ST 7256) by using a hammer and install bushing (6) to the end of hole on holder (7). Stop tapping when the bushing (6) end is flush with the hole end.

IMPORTANT: Before inserting the parts into holder (7) and casing (23), apply hydraulic oil.

3. Insert spring (25) into casing (23).

4. Insert the spool (24) assembly into the original port before disassembling. Insert the spool (24) assembly into casing (23) by rotating.

5. Install oil seal (28) to bushing (15).

6. Apply grease onto the inner surface of oil seal (28).

7. Install O-ring (14) and pusher (16) to bushing (15).

8. Apply grease onto the head of pusher (16).

9. Insert the pusher (16) assembly into casing (23).

10. Install other spools (24) in the same way as step 1 to step 9.

11. When bushing (6) has been removed from holder (7), install bushings (6) (4 used) to holder (7) by using the special tool (ST 7256) in the following procedures.

W3-8-7-6

7

ST 7256

6 W178-02-11-310

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve  Install bushing (6) in the same way.

12. Install O-rings (33) (2 used) to pins (35) (2 used).

Apply grease onto O-rings (33) (2 used). Install pins (35) (2 used) and cams (5) (2 used) to holder (7).

6 ST 7256

7

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

W178-02-11-311

 Install bushing (6) as illustrated. Stop tapping when the bushing (6) end is flush with the outside of holder (7).

6

7

such as goggles, helmets, etc in order to prevent personal injury.

IMPORTANT: Check the direction to install spring pins (3, 4).

13. Install spring pins (3, 4) to cam (5) by using the special tool (ST 1237). Secure cam (5) and pin (35).

At this time, slits (b) of spring pins (3, 4) should be positioned 90° away each other. Tap and install spring pins (3, 4) until spring pins (3, 4) come in contact with the stepped part in the hole.

3

ST 7256

a W178-02-11-312 a-

Outside of Holder

 Install bushing (6) as illustrated.

4

b

W178-02-07-050

b - Slit

14. Crimp the hole end of cam (5) where spring pins (3, 4) are inserted by using a punch.

15. Install other cam (5) in the same way as step 13 to step 14.

6 ST 7256

7

b

W178-02-11-313

W3-8-7-7

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve 16. Place holder (7) on the casing (23) assembly. Install holder (7) to casing (23) with socket bolts (30) (2 used) and spring washers (29) (2 used).

Check the mark direction and install holder (7). l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

17. Install rubber seats (31) (2 used) to pins (35) (2 used).

IMPORTANT: Check the direction of damper (32).

The inner surface of damper (32) is edged-shape.

If damper (32) is pried when installing, O-ring (33) may be damaged.

18. Install dampers (32) (2 used) to pins (35) (2 used) with the lever up.

21. As for the direction to install bracket (11), refer to the figure in Disassembly of Travel Pilot Valve on W3-8-7-1. Install bracket (11) to pin (35). Fit the holes to insert spring pins (12, 13).

IMPORTANT: Place stand (b) under bracket (11) and receive a reaction force. If holder (7) bears the reaction force, strong force acts on pin (35).

Therefore, pin (35) may be deformed.

22. Place stand (b) under bracket (11). Install spring pins (12, 13) to bracket (11) until they come in contact with the stepped part by using the special tool (ST 1237). The slits of spring pins (2 used) should be positioned 90° away each other. a

11

19. Secure dampers (32) (2 used) and rubber seats (31) (2 used) to holder (7) with socket bolts (9) (4 used) and spring washers (8) (4 used). l : 5 mm

b

a

35

12, 13

m : 7 N·m (0.7 kgf·m, 5 lbf·ft) 20. Apply grease onto O-rings (34) (2 used). Push O-rings (34) (2 used) to the end of pins (35) (2 used).

W176-02-07-011 a - Crimped Position b - Stand

W3-8-7-8

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve 23. Crimp the hole edge of bracket (11) where spring pins (12, 13) are inserted by using a punch.

24. Install other bracket (11) in the same way as step 22 to step 23.

25. Install cover (2) to holder (7) with bolts, washers (1) (2 used). j : 10 mm m : 5 N·m (0.5 kgf·m, 3.5 lbf·ft) 26. Apply grease onto the spring pin (10) contact part of dampers (32) (2 used).

27. Install O-rings (19) (2 used) to plugs (20) (2 used).

Install plugs (20) (2 used) to casing (23). j : 5 mm m : 10 N·m (1 kgf·m, 7.5 lbf·ft) 28. Install O-rings (22) (2 used) to plugs (21) (2 used).

Install plugs (21) (2 used) to casing (23). j : 6 mm m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-8-7-9

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve (Blank)

W3-8-7-10

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Disassembly of Pilot Valves for Boom Swing, Blade 11

09 05 10 10

07

06 08 07 B

B

A

A 04

04

C

C

D 03

D 03

02

02

01 00

01 00

16

16

A 15

B

B

00- Spacer (2 Used) 01- Shim (6 Used) 02- Balance Spring (2 Used) 03- Spring Guide (2 Used) 04A- Bushing (2 Used)

04B- Oil Seal (2 Used) 04C- O-Ring (2 Used) 04D- Pusher (2 Used) 05- Cam 06- Holder

07- 08- 09- 10- 11-

Bushing (2 Used) Pin Set Screw Socket Bolt (2 Used) Boot

W3-8-8-1

WADB-03-08-001

15A- Casing 15B- Spool (2 Used) 16- Return Spring (2 Used)

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Disassembly of Pilot Valve IMPORTANT: Casing (15A) is made of aluminium.

Strong force deforms it. Handle it with care.

IMPORTANT: Spool (15B) has been selected to match the hole on casing (15A). Arrange the disassembled parts together with each port in order not to confuse. The port number is stamped on the outer surface of casing (15A).

1. Secure the pilot valve in a vise. Remove boot (11) from holder (06).

2. Remove set screw (09) from cam (05). l : 2.5 mm

fNOTE:

LOCTITE #262 has been applied on set screw (09).

3. Remove pin (08). Remove cam (05) from holder (06).

IMPORTANT: When removing holder (06), the pusher (04D) assembly may fly out.

5. Put the matching marks on casing (15A) and holder (06). Loosen and remove socket bolts (10) (2 used) alternately. Remove holder (06) from casing (15A). l : 5 mm 6. Remove the pusher (04D) assemblies (2 used) from casing (15A).

IMPORTANT: Do not damage bushing (04A).

7. Remove pushers (04D) (2 used), O-rings (04C) (2 used), and oil seals (04B) (2 used) from bushings (04A) (2 used).

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

IMPORTANT: Do not remove bushing (07) unless necessary.

IMPORTANT: Bushing (07) cannot be reused.

4. Remove bushings (07) (2 used) from holder (06) by using a hammer and the special tool (ST7690).

W3-8-8-2

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve IMPORTANT: Casing (15A) has been selected to match the hole of spool (15B). Replace spool (15B) and casing (15A) as an assembly.

IMPORTANT: Put the mars on spools (15B) (2 used) when keeping in order to easily install spools (15B) (2 used) to the original hole.

8. Remove the spool (15B) assembly from casing (15A) by rotating.

IMPORTANT: The quantity of shims (01) has been determined during the performance testing at the factory. When keeping, pair shim (01) with each spool.

9. Compress balance spring (02). Remove spring guide (03), balance spring (02), shims (01) (3 used), and spacer (00) from spool (15B).

10. Remove return spring (16) from casing (15A).

11. Remove other spools (15B) in the same way as step 8 to step 11.

W3-8-8-3

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Assembly of Pilot Valves for Boom Swing, Blade

07

08

09

05 11 04D 10

04B 06

03 04C 16 04A

E 15B

02 01 00 15A Detail E

00- Spacer (2 Used) 01- Shim (6 Used) 02- Balance Spring (2 Used) 03- Spring Guide (2 Used) 04A- Bushing (2 Used)

04B- Oil Seal (2 Used) 04C- O-Ring (2 Used) 04D- Pusher (2 Used) 05- Cam 06- Holder

07- 08- 09- 10- 11-

Bushing (2 Used) Pin Set Screw Socket Bolt (2 Used) Boot

W3-8-8-4

WADB-03-08-006

15A- Casing 15B- Spool (2 Used) 16- Return Spring (2 Used)

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Assembly of Pilot Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

IMPORTANT: The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling.

IMPORTANT: Install shim (01) as the same quantity before disassembling.

1. Install spacer (00), shims (01) (3 used), and balance spring (02) to spool (15B) in sequnce.

IMPORTANT: Do not deform and damage the sliding surface when installing oil seal (04B).

IMPORTANT: Check the direction to install oil seal (04B).

5. Apply grease onto oil seal (04B). Install oil seal (04B) to bushing (04A).

04B

IMPORTANT: Install spring guide (03) with the stepped part down.

2. Compress balance spring (02) by hand. Install spring guide (03) to spool (15B).

IMPORTANT: When installing the parts to holder (06) and casing (15A), apply hydraulic oil.

3. Secure casing (15A) in a vise. Install return spring (16) to casing (15A).

IMPORTANT: Install the spool (15B) assembly to the original port before disassembling.

4. Install the spool (15B) assembly to casing (15A) by rotating.

04A WDAD-03-11-003

6. Apply grease onto the bushing (04A) sliding surface and O-ring (04C). Install O-ring (04C) and pusher (04D) to bushing (04A).

7. Install the pusher (04D) assembly to cashing (15A).

8. Install other spool (15B) and pusher (04D) in the same way as step 1 to step 7.

W3-8-8-5

SECTION 3 UPPERSTRUCTURE Group 8 Pilot Valve Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

9. Install bushings (07) (2 used) to holder (06) by using a hammer and the special tool (ST7690).

10. Fit the matching marks made when disassembling and install holder (06) to casing (15A) by tightening socket bolts (10) (2 used) alternately. l : 5 mm m : 7.0 N·m (0.7 kgf·m, 5.2 lbf·ft) 11. Apply grease onto A part of pushers (04D) (2 used).

Install cam (05) to holder (06) with pin (08).

A

04D

WDAD-03-11-004

12. Apply LOCTITE #262 onto set screw (09). Install set screw (09) to cam (05). l : 2.5 mm m : 7.0 N·m (0.7 kgf·m, 5.2 lbf·ft) 13. Install boot (11) to holder (06).

W3-8-8-6

SECTION 3 UPPERSTRUCTURE Group 9 Solenoid Valve Removal and Installation of 2-Spool Solenoid Valve IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

2. Tilt up the floor. (Refer to the Operator's Manual.)

3. Disconnect hoses (2) (6 used) and the connector from 2-spool solenoid valve (3).

M1M7-07-067

j : 17 mm, 19 mm, 22 mm 4. Remove socket bolts (5) (2 used). Remove 2-spool solenoid valve (3) from bracket (4).

2

l : 6 mm 5. Remove the adapters with 2-spool solenoid valve (3) attached if necessary.

3

2 5

W3-9-1-1

4

WADB-03-09-007

SECTION 3 UPPERSTRUCTURE Group 9 Solenoid Valve Installation 1. Install all removed adapters to 2-spool solenoid valve unit (3).

2

2. Install 2-spool solenoid valve (3) to bracket (4) with socket bolts (5) (2 used). l : 6 mm m : 20 N·m (2 kgf·m, 15 lbf·ft) 3. Connect hoses (2) (6 used) and the connector to 2-spool solenoid valve (3). j : 17 mm

3

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

2

j : 22 mm

5

m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

4

WADB-03-09-007

4. Tilt down the floor. (Refer to the Operator's Manual.)

IMPORTANT: Check the hydraulic oil level. Start the engine. Tilt up the floor and check for any oil leaks. After checking, tilt down the floor. (Refer to Maintenance in the Operator's Manual.)

M1M7-07-067

W3-9-1-2

SECTION 3 UPPERSTRUCTURE Group 9 Solenoid Valve Disassembly of 2-Spool Solenoid Valve

7

7 2

4

6 5 9

12 13

2

4

12

6 5 9

13

8

8 9 3

9 3

11

1

1

14 15 17 16 18

10

10

WADB-03-09-001

1- 2- 3- 4- 5-

Piston (2 Used) Pin (2 Used) Plate (2 Used) Casing (2 Used) Plate (2 Used)

6- 7- 8- 9- 10-

Wave Washer (2 Used) Lock Nut (2 Used) Solenoid (2 Used) O-Ring (4 Used) O-Ring (2 Used)

11- 12- 13- 14- 15-

Body Spool (2 Used) Spring (2 Used) Check Valve Spring

W3-9-2-1

16- Adjuster 17- O-Ring 18- Lock Nut

SECTION 3 UPPERSTRUCTURE Group 9 Solenoid Valve Disassembly of 2-Spool Solenoid Valve IMPORTANT: Arrange the disassembled parts together with each port in order not to confuse.

1. Remove lock nut (7) from the piston (1) assembly.

Remove casing (4) from body (11). j : 17 mm 2. Remove wave washer (6), plates (5, 3), O-rings (9) (2 used), and solenoid (8) from piston (1).

IMPORTANT: When removing piston (1), pin (2) may fall off. Do not lose pin (2).

3. Remove the piston (1) assembly from body (11).

Remove pin (2) and O-ring (10) from the piston (1) assembly.

4. Remove spool (12) and spring (13) from body (11) by using a magnet.

5. Remove the other piston (1) assembly in the same way as step 1 to step 4.

IMPORTANT: If turning lock nut (18) and adjuster (16), the setting changes. When they have been turned, adjust the pressure. should be adjusted.

(Refer to T4-5 in the separated volume, T/M.) 6. Loosen lock nut (18). j : 17 mm 7. Remove the adjuster (16) assembly from body (11).

Remove O-ring (17) from the adjuster (16) assembly. l : 6 mm 8. Remove spring (15) and check valve (14) from body (11) by using a magnet.

W3-9-2-2

SECTION 3 UPPERSTRUCTURE Group 9 Solenoid Valve Assembly of 2-Spool Solenoid Valve

4

7

6

5

9 1 8 2 9

3 10

11

14

12

15

13

TADB-03-06-001

11

1- 2- 3- 4- 5-

Piston (2 Used) Pin (2 Used) Plate (2 Used) Casing (2 Used) Plate (2 Used)

6- 7- 8- 9- 10-

Wave Washer (2 Used) Lock Nut (2 Used) Solenoid (2 Used) O-Ring (4 Used) O-Ring (2 Used)

11- 12- 13- 14- 15-

Body Spool (2 Used) Spring (2 Used) Check Valve Spring

W3-9-2-3

18

16

17

16- Adjuster 17- O-Ring 18- Lock Nut

WADB-03-09-002

SECTION 3 UPPERSTRUCTURE Group 9 Solenoid Valve Assembly of 2-Spool Solenoid Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

IMPORTANT: When adjuster (16) and lock nut (18) have been disassembled, adjust the pressure.

(Refer to T4-5 in the separated volume, T/M.) 1. Install check valve (14) and spring (15) to body (11).

2. Install O-ring (17) to the adjuster (16) assembly.

Install the adjuster (16) assembly to body (11). l : 6 mm 3. Tighten lock nut (18). j : 17 mm m : 15 to 20 N·m (1.5 to 2 kgf·m, 11 to 15 lbf·ft) 4. Install spring (13) and spool (12) to body (11).

5. Install pin (2) and O-ring (10) to piston (1). Install piston (1) to body (11).

6. Install plates (3, 5), solenoid (8), O-rings (9) (2 used), and wave washer (6) to piston (1).

7. Install casing (4) to the piston (1) assembly. Install the piston (1) assembly to body (11) with lock nut (7). j : 17 mm m : 15 to 20 N·m (1.5 to 2 kgf·m, 11 to 15 lbf·ft) 8. Install the other piston (1) assembly in the same way as step 4 to step 7.

W3-9-2-4

SECTION 3 UPPERSTRUCTURE Group 9 Solenoid Valve Removal and Installation of Torque Control Solenoid Valve

4

3 5 7

6 4

1

2

WADB-03-05-005

IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

WADB-03-09-006

4. Disconnect hoses (4) (3 used). j : 17 mm, 19 mm 5. Remove bolts, washers (5) (2 used). Remove torque control solenoid valve (6) from frame (3). j : 13 mm 6. Remove the adapters with torque control solenoid valve (6) attached if necessary.

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

2. Remove bolts, washers (1) (4 used). Remove cover (2). j : 17 mm 3. Disconnect connector (7).

W3-9-3-1

SECTION 3 UPPERSTRUCTURE Group 9 Solenoid Valve

4

3 5 7

6 4 WADB-03-09-006

1

2

WADB-03-05-005

Installation 1. Install all removed adapters to torque control solenoid valve (6).

2. Install torque control solenoid valve (6) with bolts, washers (5) (2 used).

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

5. Install cover (2) with bolts, washers (1) (4 used).

j : 13 mm

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 3. Connect hoses (4) (3 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 4. Connect connector (7).

W3-9-3-2

SECTION 3 UPPERSTRUCTURE Group 9 Solenoid Valve Disassembly of Torque Control Solenoid Valve

3

1

2

7

10

4

12

13 6 5

11

9

8

9

W1NG-02-07-003

1- 2- 3- 4-

Piston Pin Plate Casing

5- 6- 7- 8-

Plate Wave Washer Lock Nut Solenoid

9- 10- 11- 12-

O-Ring (2 Used) O-Ring Body Spool

W3-9-4-1

13- Spring

SECTION 3 UPPERSTRUCTURE Group 9 Solenoid Valve Disassembly of Torque Control Solenoid Valve 1. Remove lock nut (7) from the piston (1) assembly.

Remove casing (4) from body (11). j : 17 mm 2. Remove wave washer (6), plates (5, 3), O-rings (9) (2 used), and solenoid (8) from piston (1).

IMPORTANT: When removing piston (1), pin (2) may fall off. Do not lose pin (2).

3. Remove the piston (1) assembly from body (11).

Remove pin (2) and O-ring (10) from piston (1).

4. Remove spool (12) and spring (13) from body (11) by using a magnet.

W3-9-4-2

SECTION 3 UPPERSTRUCTURE Group 9 Solenoid Valve Assembly of Torque Control Solenoid Valve

Section B-B B

6

7

5 4 9

9

1 2

8

10

3

11 12 13 B

WADB-03-09-003 T1M9-03-07-003

1- 2- 3- 4-

Piston Pin Plate Casing

5- 6- 7- 8-

Plate Wave Washer Lock Nut Solenoid

9- 10- 11- 12-

O-Ring (2 Used) O-Ring Body Spool

W3-9-4-3

13- Spring

SECTION 3 UPPERSTRUCTURE Group 9 Solenoid Valve Assembly of Torque Control Solenoid Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

1. Install spring (13) and spool (12) to body (11).

2. Install pin (2) and O-ring (10) to piston (1). Install piston (1) to body (11).

3. Install plates (3, 5), O-rings (9) (2 used), solenoid (8), and wave washer (6) to piston (1).

4. Install casing (4) to the piston (1) assembly. Install the piston (1) assembly to body (11) with lock nut (7). j : 17 mm m : 15 to 20 N·m (1.5 to 2 kgf·m, 11 to 15 lbf·ft)

W3-9-4-4

MEMO

MEMO

SECTION 4

UNDERCARRIAGE CONTENTS Group 1 Swing Bearing

Removal and Installation of Swing Bearing..........W4-1-1-1

Group 2 Travel Device

Removal and Installation of Travel Device.............W4-2-1-1 Disassembly of Travel Reduction Gear....................W4-2-2-1 Assembly of Travel Reduction Gear..........................W4-2-2-4 Disassembly of Travel Motor.......................................W4-2-3-1 Assembly of Travel Motor............................................W4-2-3-4 Disassembly of Brake Valve.........................................W4-2-4-1 Assembly of Brake Valve...............................................W4-2-4-3 Precautions for Using Floating Seal.........................W4-2-5-1

Group 3 Center Joint

Removal and Installation of Center Joint...............W4-3-1-1 Disassembly of Center Joint........................................W4-3-2-1 Assembly of Center Joint.............................................W4-3-2-3

Group 4 Track Adjuster

Removal and Installation of Track Adjuster...........W4-4-1-1 Disassembly of Track Adjuster....................................W4-4-2-1 Assembly of Track Adjuster.........................................W4-4-2-6

Group 5 Front Idler

Removal and Installation of Front Idler...................W4-5-1-1 Disassembly of Front Idler...........................................W4-5-2-1 Assembly of Front Idler.................................................W4-5-2-4

Group 6 Upper and Lower Rollers

Removal and Installation of Upper Roller..............W4-6-1-1 Removal and Installation of Lower Roller..............W4-6-2-1

Group 7 Track

Removal and Installation of Rubber Crawler........W4-7-1-1 Removal and Installation of Steel Crawler.............W4-7-2-1

Group 8 Blade Cylinder

Removal and Installation of Blade Cylinder..........W4-8-1-1 Disassembly of Blade Cylinder...................................W4-8-2-1 Assembly of Blade Cylinder.........................................W4-8-2-4

ADCJ0W-4-1

(Blank)

ADCJ0W-4-2

SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Removal and Installation of Swing Bearing

1

3

4 5 5

ST 0052

3 a-

a

2

1

W1M9-03-01-002

W110-03-01-004

Matching Mark

Before removing and installing the swing bearing, the upperstructure must be removed first.

Therefore, the procedure starts on the premise that the upperstructure has already been removed here.

Removal 1. Put matching marks (a) on inner race (2) of swing bearing (1) and track frame (3).

dCAUTION: lb)

Swing bearing (1) weight: 47 kg (105

4. Install the special tools (ST 0052) (3 used) to swing bearing (1). Attach the nylon slings onto the special tools (ST 0052) (3 used). Hoist swing bearing (1).

Remove swing bearing (1).

2. Remove knock pins (5) (2 used).

3. Remove bolts (4) (20 used). j : 19 mm

W4-1-1-1

SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing

3

1

ST 0052

4 W110-03-01-004

1

5 5

d

3 a-

a

2

c

W1M9-03-01-002 b

Matching Mark

b

d b- c- d-

Installation 1. Clean the mounting surfaces of track frame (3) and swing bearing (1).

2. Apply THREEBOND #1102 onto the swing bearing (1) mounting surface of track frame (3).

dCAUTION: lb)

WADB-04-01-001

Soft Zone Marking Position Front Side Position for Knock Pin

IMPORTANT: If matching marks (a) do not fit, the soft zone position of the inner race will be dislocated.

4. Fit matching marks (a) on track frame (3) and inner race (2) of swing bearing (1).

5. Install swing bearing (1) with bolts (4) (20 used). j : 19 mm

Swing bearing (1) weight: 47 kg (105

3. Install the special tools (ST 0052) (3 used) to swing bearing (1). Attach the nylon slings onto the special tools (ST 0052) (3 used). Hoist swing bearing (1).

m : 110 N·m (11 kgf·m, 81 lbf·ft) IMPORTANT: Check the position to install knock pin (5).

6. Apply TGREEBOND #1102 onto knock pin (5). Install knock pins (5) (2 used) by using a plastic hammer.

W4-1-1-2

SECTION 4 UNDERCARRIAGE Group 2 Travel Device Removal and Installation of Travel Device

1

IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

The procedure starts on the premise that the tracks have been removed. (Refer to W4-7-1.)

2

Removal

3, 4

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

W1NG-03-02-001

8

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

2. Remove bolts (3) (3 used) and washers (4) (3 used).

Remove cover (2) from track frame (1). j : 17 mm 3. Disconnect hoses (8) (4 used) from travel device (7). j : 17 mm, 27 mm

dCAUTION:

Travel device (7) weight: 46 kg (105 lb) 4. Attach nylon slings onto travel device (7). Hoist and hold travel device (7). Remove bolts (5) (12 used) and washers (6) (12 used). Hoist and remove travel device (7). j : 19 mm

fNOTE:

LOCTITE #262 has been applied on bolt (5).

5. Remove the adapters with travel device (7) attached if necessary.

6. Remove other travel device in the same way as step 1 to step 5.

W4-2-1-1

7

5, 6

WADB-04-02-010

SECTION 4 UNDERCARRIAGE Group 2 Travel Device Installation

8

1. Install all removed adapters to travel device (7).

dCAUTION:

Travel device (7) weight: 46 kg (105 lb) 2. Apply LOCTITE #262 onto bolt (5). Attach nylon slings onto travel device (7). Hoist travel device (7).

Install travel device (7) with washers (6) (12 used) and bolts (5) (12 used). j : 19 mm m : 110 N·m (11 kgf·m, 81 lbf·ft) 3. Connect hoses (8) (4 used) to travel device (7). j : 17 mm

7

5, 6

WADB-04-02-010

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) j : 27 mm

1

m : 80 N·m (8 kgf·m, 59 lbf·ft) 4. Connect the track. (Refer to W4-7-1.)

5. Install other travel device in the same way as step 1 to step 4.

6. Bleed air from the hydraulic system. (Refer to W14-1.)

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. In order to prevent the travel motor from seizing, perform the break-in operation after installing.

Condition: 1. Engine speed: Slow idle speed

2. Travel mode switch: Slow speed

3. Operation duration: Over 2 minutes 7. Install cover (2) to track frame (1) with bolt (3) (3 used) and washers (4) (3 used). j : 17 mm m : 65 N·m (6.5 kgf·m, 48 lbf·ft) 8. Install other cover in the same way as step 7.

W4-2-1-2

2 3, 4

W1NG-03-02-001

SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Travel Reduction Gear

WADB-04-02-001

1- 2- 3- 4- 5- 6- 7- 8- 9- 10-

Sun Gear Thrust Washer Carrier Retaining Ring Drive Gear Slide Ring O-Ring Cover Stopper Ring O-Ring (2 Used)

11- 12- 13- 14- 15- 16- 17- 18-

Plug (2 Used) Plug O-Ring Retaining Ring (3 Used) Thrust Washer (6 Used) Pin (3 Used) Needle Bearing (3 Used) First Stage Planetary Gear (3 Used) 19- Spring Pin (3 Used)

20- 21- 22- 23- 24- 25- 26- 27- 28- 29-

Floating Seal Floating Seal Ball Bearing Retaining Ring Ball Bearing Ring Gear Retaining Ring Thrust Washer (4 Used) Inner Race (4 Used) Needle Bearing (4 Used)

W4-2-2-1

30- Second Stage Planetary Gear (4 Used) 31- Thrust Washer (4 Used) 32- Retaining Ring (4 Used) 33- Travel Motor 34- Sprocket 35- Bolt (12 Used) 36- Washer (12 Used)

SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Travel Reduction Gear ď‚–These are the procedures before Disassembly of Travel Motor (W4-2-3) and before Disassembly of Brake Valve (W4-2-4).

CAUTION: There may be pressure accumulated inside of the travel device. Loosen the air bleed plug slowly. Release any remaining pressure completely. Remove the drain plug and drain gear oil. If the air bleed plug is loosened suddenly, the plug may be fly out and gear oil may gush out.

Keep body and face away from plug.

1. Remove plugs (11) (2 used) and O-rings (10) (2 used) from cover (8). Drain gear oil from the travel device.

d

As the tightening torque of bolt (35) dCAUTION: of sprocket (34) is large, the travel device may move without securing. Receive a reaction force in order not to move the travel device when disassembling.

3. Remove bolts (35) (12 used) and washers (36) (12 used). Remove sprocket (34) from ring gear (25). j : 19 mm

fNOTE:

LOCTITE #262 has been applied onto bolts (35) (12 used).

4. Remove plug (12) and O-ring (13) from cover (8). l : 5 mm

l : 8 mm

fNOTE:

5. Remove stopper ring (9) from cover (8) by rotating ring gear (25). Remove the cover (8) assembly from ring gear (25).

Gear oil: 0.6 L (0.636 us qt)

dCAUTION:

Travel device weight: 46 kg (101 lb) 8

6. Remove slide ring (6) from cover (8).

7. Remove O-ring (7) from ring gear (25).

34

IMPORTANT: Replace carrier (3) as the carrier (3) assembly ((1 to 4), (14 to 19)).

8. Remove drive gear (5), the carrier (3) assembly, and collar (2) from ring gear (25).

WADB-04-02-002

2. Attach the nylon slings onto the travel device. Hoist the travel device. Place the travel device onto a workbench with the cover (8) side up.

W4-2-2-2

SECTION 4 UNDERCARRIAGE Group 2 Travel Device IMPORTANT: Spring pin (19) and pin (16) cannot be removed as they have been in carrier (3).

9. Remove retaining rings (14) (3 used), thrust washers (15) (6 used), first stage planetary gears (18) (3 used), and needle bearings (17) (3 used) from carrier (3).

12. Install a C-clamp to the flange parts in travel motor (33) and ring gear (25). Tighten the C-clamp.

Remove retaining ring (26) from travel motor (33).

25

10. Remove retaining ring (4) and sun gear (1) from carrier (3).

11. Remove retaining rings (32) (4 used), thrust washers (31) (4 used), second stage planetary gears (30) (4 used), needle bearings (29) (4 used), inner races (28) (4 used), and thrust washers (27) (4 used) from travel motor (33).

a a

33

a - C-Clamp

W571-03-02-006

IMPORTANT: Do not remove ball bearings (22, 24) unless necessary. When they have been removed, replace them with the new ones.

13. Remove the ring gear (25) assembly from travel motor (33).

IMPORTANT: Handle floating seals (20, 21) with care.

(Refer to W4-2-5.)

14. Remove floating seal (21) from ring gear (25).

15. Remove floating seal (20) from travel motor (33).

W4-2-2-3

SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Travel Reduction Gear

33

34

36 35

25

1

2 3 4 7

5 6 8 13 12 18 15 14

10 11 9

26 27 28 29 30 31 32 19 16 17

20 21 22 23 24

WADB-04-02-003

1- 2- 3- 4- 5- 6- 7- 8- 9- 10-

Sun Gear Thrust Washer Carrier Retaining Ring Drive Gear Slide Ring O-Ring Cover Stopper Ring O-Ring (2 Used)

11- 12- 13- 14- 15- 16- 17- 18-

Plug (2 Used) Plug O-Ring Retaining Ring (3 Used) Thrust Washer (6 Used) Pin (3 Used) Needle Bearing (3 Used) First Stage Planetary Gear (3 Used) 19- Spring Pin (3 Used)

20- 21- 22- 23- 24- 25- 26- 27- 28- 29-

Floating Seal Floating Seal Ball Bearing Retaining Ring Ball Bearing Ring Gear Retaining Ring Thrust Washer (4 Used) Inner Race (4 Used) Needle Bearing (4 Used)

W4-2-2-4

30- Second Stage Planetary Gear (4 Used) 31- Thrust Washer (4 Used) 32- Retaining Ring (4 Used) 33- Travel Motor 34- Sprocket 35- Bolt (12 Used) 36- Washer (12 Used)

SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Travel Reduction Gear ď‚–These are the procedures after Assembly of Brake Valve (W4-2-4) and after Assembly of Travel Motor (W4-2-3).

IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

1. Place ring gear (25) with the travel motor (33) side up.

IMPORTANT: Handle floating seals (20, 21) with care.

(Refer to W4-2-5.)

5. Apply grease onto O-rings of floating seals (20, 21).

Install floating seal (20) to travel motor (33). Install floating seal (21) to ring gear (25).

6. Fit ring gear (25) to travel motor (33). Evenly tap and install ring gear (25) to travel motor (33) by using a plastic hammer.

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

2. Evenly tap and install ball bearing (24) to ring gear (25) by using a bar and a hammer. At this time, install ball bearing (24) with the thinner inner race side facing to the retaining ring (23) side.

7. Install the flange parts in travel motor (33) and ring gear (25) by using a C-clamp. Tighten the C-clamp.

Install retaining ring (26) to travel motor (33).

fNOTE:

Check if ring gear (25) can turn. If not, disassemble ball bearings (22, 24) and floating seal (20) and assemble them again.

3. Install retaining ring (23) to ring gear (25).

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

4. Evenly tap and install ball bearing (22) to ring gear (25) by using a bar and a hammer. At this time, install ball bearing (22) with the thinner inner race side facing to the retaining ring (23) side.

25

a

a

33

a - C-Clamp

W4-2-2-5

W571-03-02-006

SECTION 4 UNDERCARRIAGE Group 2 Travel Device 8. Install inner races (28) (4 used), thrust washers (27) (4 used), second stage planetary gears (30) (4 used), needle bearings (29) (4 used), thrust washers (31) (4 used), and retaining rings (32) (4 used) to travel motor (33).

IMPORTANT: Replace carrier (3) as the carrier (3) assembly ((1 to 4), (14 to 19)).

9. Install sun gear (1) to carrier (3) with retaining ring (4).

10. Install thrust washers (15) (3 used), first stage planetary gears (18) (3 used), needle bearings (17) (3 used), thrust washers (15) (3 used), and retaining rings (14) (3 used) to pins (16) (3 used).

11. Place thrust washer (2) onto the stepped part of sun gear (1). Install the carrier (3) assembly and drive gear (5) to ring gear (25).

12. Apply grease onto O-ring (7).

14. Apply grease onto slide ring (6). Install slide ring (6) to cover (8).

15. Fit the plug (11) hole of cover (8) to the notch of ring gear (25). Install the cover (8) assembly and stopper ring (9) to ring gear (25).

fNOTE:

Attach a screwdriver onto the end of stopper ring (9). Tap the circumference of it by using a hammer and install cover (8).

17. Install O-rings (10) (2 used) to plugs (11) (2 used).

Install plugs (11) (2 used) to cover (8). l : 8 mm m : 47 to 52 N·m (4.7 to 5.2 kgf·m, 35 to 38 lbf·ft) 18. Install O-ring (13) to plug (12). Install plug (12) to cover (8). l : 5 mm

Install O-ring (7) to ring gear (25).

m : 12 to 23 N·m (1.2 to 2.3 kgf·m, 8.9 to17 lbf·ft)

13. Add gear oil (Apolo oil gear HE90 or SAE #30 CD) to ring gear (25).

fNOTE:

Oil amount: 0.6 L (0.636 us qt)

As the tightening torque of bolt (35) dCAUTION: of sprocket (34) is large, the travel device may

move without securing. Receive a reaction force in order not to move the travel device when disassembling.

IMPORTANT: Fit the chamfered side of sprocket (34) to the ring gear (25) side.

19. Degrease the bolt (36) holes and bolts (36) (12 used) of ring gear (25). Apply LOCTITE #262 onto bolts (36) (12 used). Install sprocket (34) to ring gear (25) with washers (36) (12 used) and bolts (35) (12 used). j : 19 mm m : 130 N·m (13 kgf·m, 96 lbf·ft)

W4-2-2-6

SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Travel Motor

WADB-04-02-004

01- 02- 03- 04- 05- 06- 08- 09-

Brake Valve Housing Shaft Cylinder Block Valve Plate Plunger (9 Used) Retainer Holder

10- 11- 12- 13- 14- 15- 16- 17-

Swash Plate Piston Pin (3 Used) Spring Washer (2 Used) Bearing Bearing O-Ring

18- 19- 20- 21- 22- 23- 24- 25-

O-Ring (2 Used) Oil Seal Steel Ball (2 Used) Retaining Ring Socket Bolt (7 Used) Spring Pin Pin Friction Plate

W4-2-3-1

26- 27- 28- 29- 30- 31- 32- 33-

Plate (2 Used) Brake Piston Spacer Spring (8 Used) O-Ring O-Ring Backup Ring Backup Ring

SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Travel Motor ď‚– These are the procedures after Disassembly of Travel Reduction Gear (W4-2-2).

IMPORTANT: Valve plate (05) and spring (29) may be removed with brake valve (01) together when removing brake valve (01) from housing (02). Do not drop valve plate (05) and spring (29).

IMPORTANT: The open end of brake valve (01) is the seat surface for pressure oil when releasing the parking brake. Take care not to damage the seat surface when placing it with the open end down.

1. Place the travel motor with the brake valve (01) side up. Remove socket bolts (22) (7 used). Remove the brake valve (01) assembly from housing (02).

3. Remove valve plate (05) and springs (29) (8 used) from housing (02).

When removing brake piston (27) by dCAUTION: using air, hold brake piston (27) with a cloth in

order not to fly out.

4. Apply air 1.8 MPa (18 kgf/cm2) or less to the parking brake releasing oil passage. Raise and remove brake piston (27).

5. Remove backup rings (32, 33) and O-rings (30, 31) from brake piston (27).

6. Remove plates (26) (2 used), friction plate (25), and spacer (28) from housing (02).

l : 8 mm 01

a- Seat Surface

a

WADB-04-02-005

IMPORTANT: Do not remove bearing (16) and spring pin (23). Replace bearing (16) and spring pin (23) as the brake valve (01) assembly.

IMPORTANT: Do not remove pin (24).

2. Remove O-ring (17) and O-rings (18) (2 used) from brake valve (01).

W4-2-3-2

SECTION 4 UNDERCARRIAGE Group 2 Travel Device 7. Place housing (02) horizontally with the parking brake releasing oil passage (a) side down. Remove the cylinder block (04) assembly from housing (02).

9. Remove swash plate (10) from housing (02).

10. Remove steel balls (20) (2 used) and piston (11) from housing (02) by using a magnet.

IMPORTANT: Do not remove bearing (15) from shaft (03). Replace bearing (15) as the shaft (03) assembly.

11. Remove shaft (03) with bearing (15) together from housing (02) by tapping the inner spline side of shaft (03) by using a bar and a plastic hammer.

02

04

12. Remove oil seal (19) from the shaft (03) mounting hole side of housing (02) by using a screwdriver.

fNOTE:

a

a- Parking Brake Releasing Oil Passage

Adhesive has been applied on the outer surface of oil seal (19). Oil seal (19) cannot be reused.

WADB-04-02-007

Do not disassemble retaining ring dCAUTION: (21), washer (14), and spring (13) from cylinder

block (04) unless necessary. When removing retaining ring (21) if necessary, push washer (14) and spring (13) by using a press in order not to fly out.

IMPORTANT: Replace cylinder block (04) as the assembly ((04 to 09), (12 to 14), 21).

8. Remove plungers (06) (9 used), retainer (08), holder (09), and pins (12) (3 used) from cylinder block (04).

W4-2-3-3

SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Travel Motor

19

15

11

20

08

10

09

12

04

14

28

13

26

02

25

06 31

33 32

30

24

17

27 23

05

16

03

21

01

29

22 WADB-04-02-006

01- 02- 03- 04- 05- 06- 08- 09-

Brake Valve Housing Shaft Cylinder Block Valve Plate Plunger (9 Used) Retainer Holder

fNOTE:

10- 11- 12- 13- 14- 15- 16- 17-

Swash Plate Piston Pin (3 Used) Spring Washer (2 Used) Bearing Bearing O-Ring

18- 19- 20- 21- 22- 23- 24- 25-

* O-Ring (2 Used) Oil Seal Steel Ball (2 Used) Retaining Ring Socket Bolt (7 Used) Spring Pin Pin Friction Plate

As for the item with mark *, refer to W4-2-3-1.

W4-2-3-4

26- 27- 28- 29- 30- 31- 32- 33-

Plate (2 Used) Brake Piston Spacer Spring (8 Used) O-Ring O-Ring Backup Ring Backup Ring

SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Travel Motor ď‚– These are the procedures before Assembly of Travel Reduction Gear (W4-2-4).

IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

1. Place housing (02) with the brake valve (01) mounting side up.

IMPORTANT: Replace oil seal (19) with the new one.

2. Clean the oil seal (19) mounting part of housing (02). Apply THREEBOND #1104 or #1215 onto the outer surface of oil seal (19). Install oil seal (19) to housing (02) by using the special tool (ST 7713) in order not to deform it. Apply OCEAN grease #7 onto the inner surface of oil seal (19) after installing.

5. Fit the hollow (2 places) on the back side of swash plate (10) to the steel ball (20) position. Install swash plate (10) to housing (02).

6. Place housing (02) horizontally with the parking brake releasing oil passage (a) side down. At this time, check if swash plate (10) is located correctly.

fNOTE:

If housing (02) is placed with parking brake releasing oil passage (a) topside, the thick part of swash plate (10) becomes topside and swash plate (10) may be located off the center.

IMPORTANT: Bearing (15) has been installed in shaft (03).

IMPORTANT: The lip contacting surface of oil seal (19) is located on the bearing (15) mounting side of shaft (03). Do not damage it.

3. Tap and install the shaft (03) assembly to housing (02) by using a plastic hammer.

02

IMPORTANT: Install piston (11) to the piston (11) hole with the stepped part down.

4. Apply grease onto steel balls (20) (2 used). Install piston (11) and steel balls (20) (2 used) to housing (02).

a

10

a- Parking Brake Releasing Oil Passage

W4-2-3-5

WADB-04-02-007

SECTION 4 UNDERCARRIAGE Group 2 Travel Device

d

CAUTION: When installing retaining ring (21) to cylinder block (04), hold washer (14) and spring (13) by using a press in order not to fly out.

7. Install washers (14) (2 used), spring (13), and retaining ring (21) to cylinder block (04) by using a press.

8. Apply grease onto pins (12) (3 used) in order to prevent them from falling off from cylinder block (04). Install pins (12) (3 used) to cylinder block (04).

Install holder (09) on pins (12) (3 used).

IMPORTANT: Install brake piston (27) so that notch (b) can face to the oil passage (a) side in piston (11).

IMPORTANT: Brake piston (27) keeps floating due to O-rings and backup rings in the outer surface.

Evenly push brake piston (27) by hands. Do not push brake piston (27) by using a hammer excessively.

13. Install O-rings (30, 31) and backup rings (32, 33) to brake piston (27). Install brake piston (27) to housing (02). a

9. Install retainer (08) and plungers (06) (9 used) to cylinder block (04).

27 b

c

10. Fit the splines of shaft (03) and cylinder block (04).

Install the cylinder block (04) assembly to shaft (03).

11. Place housing (02) with the brake valve (01) mounting side up.

11

IMPORTANT: Alternately install plates (26) (2 used) and friction plate (25).

12. Install spacer (28), plates (26) (2 used), and friction plate (25) to housing (02).

a- Oil Passage in Piston (6) b- Notch c- Parking Brake Releasing Oil Passage

14. Add hydraulic oil to housing (02).

fNOTE:

W4-2-3-6

Oil amount: 0.6 L (0.636 us qt)

W172-03-02-013

SECTION 4 UNDERCARRIAGE Group 2 Travel Device IMPORTANT: Bearing (16) and spring pin (23) have been installed in brake valve (01).

IMPORTANT: Install valve plate (05) with the brass thrust surface up.

IMPORTANT: Apply grease onto the back of valve plate (05) and spring (29) in order not to fall off.

14. Install valve plate (05) to brake valve (01) by fitting the position of spring pin (23).

15. Install springs (29) (8 used), O-ring (17), and O-rings (18) (2 used) to brake valve (01).

IMPORTANT: Do not drop valve plate (05). If valve plate (05) is damaged, oil leakage may occur.

16. Place housing (02) horizontally with the parking brake releasing oil passage (a) side down. Install brake valve (01) by fitting the socket bolt (22) hole position of housing (02). At this time, as brake piston (27) is not completely pushed in housing (02), the clearance between brake valve (01) and housing (02) is approx. 10 mm. Evenly tighten and install brake valve (01) to housing (02) with socket bolts (22) (7 used). l : 10 mm m : 52 to 56 N·m (5.2 to 5.6 kgf·m, 38 to 41 lbf·ft) )

02

a

a- Parking Brake Releasing Oil Passage

WADB-04-02-007

W4-2-3-7

SECTION 4 UNDERCARRIAGE Group 2 Travel Device (Blank)

W4-2-3-8

SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Brake Valve 6 5 4 3 1

2

7

9

8 11

10 9

11

10

8

15

2 18

17

1- 2- 3- 4-

Plug (2 Used) O-Ring (2 Used) Piston Spring

5- 6- 7- 8-

18

Spool Piston Counterbalance Valve Plate (2 Used)

1

17

19 W1LA-03-02-013

9- 10- 11- 15-

Spring (2 Used) O-Ring (2 Used) Plug (2 Used) Body

W4-2-4-1

17- Plug (2 Used) 18- O-Ring (2 Used) 19- Shuttle

SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Brake Valve IMPORTANT: Do not disassemble the brake valve unless necessary. Replace the brake valve as an assembly.

1. Remove plugs (11) (2 used) from body (15). Remove O-rings (10) (2 used) from plugs (11) (2 used). j : 36 mm IMPORTANT: Do not disassemble counterbalance valve (7).

2. Remove springs (9) (2 used), plates (8) (2 used), and counterbalance valve (7) from body (15).

3. Remove plugs (1) (2 used) from body (15). Remove O-rings (2) (2 used) from plugs (1) (2 used). l : 8 mm IMPORTANT: When removing spool (5), do not drop pistons (3, 6) and spring (4).

4. Remove pistons (3, 6), spring (4), and spool (5) from body (15).

5. Remove plugs (17) (2 used) from body (15). Remove O-rings (18) (2 used) from plugs (17) (2 used). l : 5 mm 6. Remove shuttle (19) from body (15).

W4-2-4-2

SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Brake Valve 7 15

10 11

9 8 1 2 6 3 5

17 19

4

18 TADB-03-05-003

1- 2- 3- 4-

Plug (2 Used) O-Ring (2 Used) Piston Spring

5- 6- 7- 8-

Spool Piston Counterbalance Valve Plate (2 Used)

9- 10- 11- 15-

Spring (2 Used) O-Ring (2 Used) Plug (2 Used) Body

W4-2-4-3

17- Plug (2 Used) 18- O-Ring (2 Used) 19- Shuttle

SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Brake Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

1. Install shuttle (19) to body (15).

2. Install O-ring (18) to plug (17). Install plugs (17) (2 used) to body (15). l : 5 mm m : 12 to 23 N·m (1.2 to 2.3 kgf·m, 8.9 to 17 lbf·ft) 3. Install spool (5), spring (4), and pistons (3, 6) to body (15).

4. Install O-rings (2) (2 used) to plugs (1) (2 used).

Install plugs (1) (2 used) to body (15). l : 8 mm m : 47 to 51 N·m (4.7 to 5.1 kgf·m, 35 to 38 lbf·ft) 5. Install counterbalance valve (7), plates (8) (2 used), and springs (9) (2 used) to body (15).

6. Install O-rings (10) (2 used) to plugs (11) (2 used).

Install plugs (11) (2 used) to body (15). l : 36 mm m : 200 to 245 N·m (20 to 24.5 kgf·m, 148 to 180 lbf·ft)

W4-2-4-4

SECTION 4 UNDERCARRIAGE Group 2 Travel Device Precautions for Using Floating Seal

1

1. In general, replace the floating seal with a new one after disassembling.

If the floating seal is required to be reused, follow these procedures:

 Keep seal rings together as a matched set with seal ring (1) surfaces together. Apply oil onto sliding surface (e) of seal ring (1).  Check sliding surface (e) of seal ring (1) for scuffing, scoring, corrosion, deformation, or uneven wear.

Check the step part of seal ring (1).  Check O-ring (2) for tears, breaks, deformation, or hardening.

W178-02-11-001

2

2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following to prevent trouble.  Clean the floating seal and seal mounting bores with cleaning solvent.

Use a wire brush to remove mud, rust, or dirt from seal mounting bores. After cleaning, thoroughly dry parts with compressed air.  Clean seal ring (1) and O-ring (2) mounting bores.

Check the bore surface for scuffing or scoring by touching the surface with finger.  After installing the floating seal, check that O-ring (2) is not twisted, and that it is installed correctly on seal ring (1).  After installing the floating seal, check that O-ring (2) and seal ring sliding surface (e) is parallel with seal mating surface (f ) by measuring the distances (e) and (f ) at point (A) and (B), as illustrated. If these distances differ, correct O-ring (2) seating.

a

c b d W178-02-11-002 a - Correct b - Incorrect

c - Twist of O-Ring d - Bend of O-Ring f a

b

A

A

e

2

B

A=B

B

A≠B W178-02-11-003

a - Correct b - Incorrect

W4-2-5-1

e - Sliding Surface f - Seal Mating Surface

SECTION 4 UNDERCARRIAGE Group 2 Travel Device (Blank)

W4-2-5-2

SECTION 4 UNDERCARRIAGE Group 3 Center Joint Removal and Installation of Center Joint

1

IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. Attach an identification tag onto the hoses and the pipe for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

5

4

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

2. Tilt up the floor. (Refer to the operator’s manual.)

3. Disconnect hoses (1) (8 used) from center joint (2).

3

2

1 WAFA-04-03-001

j : 17 mm, 19 mm, 22 mm 4. Remove bolts, washers (4) (2 used) from frame (5).

Remove stopper (3) from frame (5).

10

j : 19 mm

fNOTE:

LOCTITE #262 has been applied on bolt (4).

Remove cover (6) while holding it. Do dCAUTION: not drop cover (6).

7, 8, 9

5. Remove bolts (7) (4 used), collars (8) (4 used), and washers (9) (4 used) from track frame (10). Remove under cover (6) from track frame (10). j : 17 mm

6

W4-3-1-1

W1M9-03-03-003

SECTION 4 UNDERCARRIAGE Group 3 Center Joint 6. Disconnect hoses (1) (10 used) from center joint (4).

1

j : 17 mm, 22 mm, 27 mm

dCAUTION:

Center joint (4) weight: 22 kg (49 lb) 7. Install the special tool (ST 0261) to adapter (5) of center joint (4). Attach the nylon sling onto the special tool (ST 0261). Hoist and hold center joint (4).

8. Remove bolts (2) (4 used) and washers (3) (4 used).

Remove center joint (4). j : 22 mm

f

NOTE: LOCTITE #262 has been applied on bolt (2).

9. Remove the adapters with center joint (4) attached if necessary.

2, 3 4

1

WADB-04-03-009

5

4

W4-3-1-2

WAFA-04-03-002

SECTION 4 UNDERCARRIAGE Group 3 Center Joint Installation

9

1. Install all removed adapters to center joint (4).

dCAUTION:

Center joint (4) weight: 22 kg (49 lb) 2. Install the special tool (ST 0261) to adapter (9) of center joint (4). Attach the nylon sling onto the special tool (ST 0261). Hoist center joint (4).

3. Apply LOCTITE #262 onto bolt (2). Install center joint (4) to the track frame with bolts (2) (4 used) and washers (3) (4 used). j : 22 mm m : 140 N·m (14 kgf·m, 103 lbf·ft) 4. Connect hoses (1) (10 used) to center joint (4). j : 17 mm 4

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

WAFA-04-03-002

1

j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft) j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 5. Apply LOCTITE #262 onto bolt (8). Install stopper (7) to frame (5) with bolts, washers (8) (2 used).

2, 3

j : 19 mm 4

m : 90 N·m (9 kgf·m, 66 lbf·ft) 6. Connect hoses (6) (8 used) to center joint (4). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

WADB-04-03-009

1

j : 19 mm

6

m : 30 N·m (3 kgf·m, 22 lbf·ft) 5

j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

8

7

W4-3-1-3

4

6

WAFA-04-03-001

SECTION 4 UNDERCARRIAGE Group 3 Center Joint 7. Tilt down the floor. (Refer to the operator’s manual.)

IMPORTANT: Check the hydraulic oil level. Start the engine. Tilt up the floor and check for any oil leaks. After checking, tilt down the floor. (Refer to the Operator's Manual.)

8. Install under cover (4) to track frame (5) with washers (3) (4 used), collars (2) (4 used), and bolts (1) (4 used).

1, 2, 3

j : 17 mm m : 65 N·m (6.5 kgf·m, 48 lbf·ft) 5

W4-3-1-4

4

W1M9-03-03-003

SECTION 4 UNDERCARRIAGE Group 3 Center Joint Disassembly of Center Joint

5

1

2

4 12 13 11

8

9 10 7 3

17

15 6

14

WADB-04-03-001

1- 2- 3- 4-

Spindle Body Flange Ring

5- 6- 7- 8-

Pin Oil Seal (4 Used) O-Ring O-Ring

9- 10- 11- 12-

O-Ring Backup Ring Dust Seal Retaining Ring

W4-3-2-1

13- 14- 15- 17-

Plug (3 Used) Bolt (4 Used) Spring Washer (4 Used) Oil Seal (3 Used)

SECTION 4 UNDERCARRIAGE Group 3 Center Joint Disassembly of Center Joint

dCAUTION:

Center joint weight: 22 kg (49 lb) 1. Remove bolts (14) (2 used), spring washers (15) (2 used) diagonally. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to the bolts, spring washers (15) holes (2 places) of body (2). Attach the nylon slings onto the eyebolts (2 used). Hoist the center joint. Secure the center joint on a workbench.

IMPORTANT: For easy removal of oil seals (6, 17), use the pins (2 used). Do not damage the seal groove.

6. Remove oil seals (6) (4 used), oil seals (17) (3 used), O-rings (7, 9), backup ring (10), and dust seal (11) from body (2).

j : 17 mm 2. Put the matching marks on body (2) and spindle (1).

Remove bolts (14) (4 used) and spring washers (15) (4 used). Remove flange (3) from body (2). j : 17 mm 3. Remove O-ring (8), retaining ring (12), and ring (4) from body (2).

4. Install the special tools (ST 1033, ST 1020) to body (2) with bolts (14) (2 used) and spring washers (15) (2 used).

W178-02-11-240

j : 17 mm ST 1020

ST 1033

14, 15

2

WADB-04-03-003

IMPORTANT: Do not damage the seal sliding surface of spindle (1).

5. Remove spindle (1) from body (2).

W4-3-2-2

SECTION 4 UNDERCARRIAGE Group 3 Center Joint Assembly of Center Joint 1

5

11 9

7

10

17

2 6

4

15 1- 2- 3- 4-

Spindle Body Flange Ring

14 5- 6- 7- 8-

Pin Oil Seal (4 Used) O-Ring O-Ring

3

13 9- 10- 11- 12-

12 O-Ring Backup Ring Dust Seal Retaining Ring

W4-3-2-3

WADB-04-03-002

8 13- 14- 15- 17-

Plug (3 Used) Bolt (4 Used) Spring Washer (4 Used) Oil Seal (3 Used)

SECTION 4 UNDERCARRIAGE Group 3 Center Joint Assembly of Center Joint IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

IMPORTANT: When assembling the seals, apply grease (Apolloil Autorex C) and install the seals to each groove.

1. Place body (2) with the dust seal (11) mounting side up. Install oil seals (6) (4 used) and oil seals (17) (3 used) to body (2).

2. Install O-rings (7, 9) and backup ring (10) to body (2).

IMPORTANT: The clearance between body (2) and spindle (1) is approximately 0.1 mm. Insert body (2) along the axis straight and slowly. Do not damage the seal.

IMPORTANT: Do not make a step on ring (4) mounting part (b).

4. Place spindle (1) with the pin (5) mounting side down on a workbench. Fit the matching marks made when disassembling. Evenly tap and install body (2) to spindle (1) by using a plastic hammer.

3. Install dust seal (11) to spindle (1) with lip part (a) facing to the body (2) side. b

1

1 2

11 a

2

b - Ring (4) Mounting Part

a - Lip Part

WADB-04-03-007

W4-3-2-4

WADB-04-03-004

SECTION 4 UNDERCARRIAGE Group 3 Center Joint IMPORTANT: Install ring (4) with the chamfered surface facing to the flange (3) side.

6. Install ring (4) and retaining ring (12) to body (2). a

3

12

4

2 WADB-04-03-006 a - Chamfered Surface

7. Install O-ring (8) to body (2).

8. Install flange (3) to body (2) with bolts (14) (4 used) and spring washers (15) (4 used). j : 17 mm m : 55 N·m (5.5 kgf·m, 41 lbf·ft)

W4-3-2-5

SECTION 4 UNDERCARRIAGE Group 3 Center Joint (Blank)

W4-3-2-6

SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Removal and Installation of Track Adjuster 2 2

b

1

d

a

c W1M9-03-04-001

WADB-04-04-004

a- b-

Before removing and installing the track adjuster, the tracks and front idler must be removed first. (Refer to W45-1 and W4-7-1.) Therefore, the procedure starts on the premise that the tracks and front idler have already been removed here.

Removal Track adjuster (1) may fly out due dCAUTION: to the spring (b) force when removing track

adjuster (1). Do not stand in the same direction to remove track adjuster (1) or where it may fly out.

Particularly, the spring (b) load is always applied to thread part (c) of the rod. If the rod and/or thread part (c) are damaged, metal fragments may fly out due to the spring (b) force.

1. Pry and remove track adjuster (1) from track frame (2) by using a pry bar.

W4-4-1-1

Nut Spring

c- d-

Thread Part Rod

SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster 2

2

1 3

4

5 6 W1M9-03-04-001 WADB-04-04-004

Installation IMPORTANT: The left and right sides of track adjuster (1) are different according to the direction of grease nipple (4). Install track adjuster (1) with the lubrication port of grease nipple (4) facing to the hole (5) side of track frame (2).

1. Install track adjuster (1) to track frame (2). At this time, check that bracket (3) of track adjuster (1) comes in contact with the surface of plate (6).

2. Install the front idler. (Refer to W4-5-1.)

3. Connect the track. (Refer to W4-7-1.)

W4-4-1-2

SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Disassembly of Track Adjuster

WADB-04-04-001

00- Cylinder 01- Spring 03- Nut

04- Plug 05- Piston Rod 06- Seal

07- Dust Seal 08- Valve 09- Grease Fitting

W4-4-2-1

10- Washer

SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Disassembly of Track Adjuster

d The spring force is extremely large. dCAUTION: Carry out the disassembly and assembly work

CAUTION: Special tool (ST 4943) weight: 225 kg (500 lb)

carefully. In addition, inspect the special tool for any damage thoroughly in order to perform the work safely.

1. Place oil jack (c) (30 tons (66200 lb)) between holder (b) and base (d) of the special tool (ST 4943).

dCAUTION: (80 lb)

Special tool (ST 4140) weight: 36 kg

2. Remove nuts (a) (4 used) from the special tool (ST 4943). Attach the nylon slings onto the eyebolts (2 used) of the special tool (ST 4140). Hoist the special tool (ST 4140). Remove the special tool (ST 4140) from the special tool (ST 4943).

a

j : 46 mm

ST 4140

b ST 4943

c

WDCD-04-04-010 d a- b-

Nut Holder

W105-03-04-006 c- d-

Oil Jack Base

W4-4-2-2

SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster 3. Attach the nylon slings onto track adjuster (a). Hoist track adjuster (a). Install track adjuster (a) to holder (b) of the special tool (ST 4943).

4. Install the special tool (ST 4140) to the special tool (ST 4943) in order to cover track adjuster (a).

Operate the oil jack. Raise until nut (03) comes out from the center hole of the special tool (ST 4140).

ST 4140

a

03

b a- WDAD-04-04-002 a-

Track Adjuster

b-

Holder

W4-4-2-3

Track Adjuster

a

WDAD-04-04-003

SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster As spring (01) is compressed, a strong dCAUTION: force is applied. Check if track adjuster (a) is installed correctly when raised.

5. Install nuts (b) (4 used) of the special tool (ST 4943).

Secure track adjuster (a). Slowly operate the oil jack. Compress track adjuster (a) until the clearance between washer (10) and nut (03) becomes approx.

10 mm (0.4 in). j : 46 mm

fNOTE: Spring (01) compressed length: Rubber crawler: Spring free length (242.3 mm (9.5 in)) - Spring set length (176 mm (6.9 in)) = Spring compressed length (66.3 mm (2.61 in))

Steel crawler: Spring free length (242.3 mm (9.5 in)) - Spring set length (198 mm (7.8 in)) = Spring compressed length (44.3 mm (1.74 in))

There may be pressure accumulated dCAUTION: inside of cylinder (00). As valve (08) may fly out

and the high-pressure grease may spout out, do not loosen valve (08) quickly. Keep body parts and face away from valve (08) and loosen it carefully.

Do not loosen grease fitting (09).

6. Remove valve (08) from cylinder (00). j : 19 mm 7. Remove plug (04) from nut (03). l : 5 mm 8. Remove nut (03) from cylinder (00). j : 46 mm

Lower the oil jack before removing dCAUTION: nut (b) and the special tool (ST 4140). Prevent

washer (10) and spring (01) from flying out due to the spring (01) force.

9. Slowly lower the oil jack until spring (01) reaches the free length.

fNOTE:

b

W105-03-04-012 b-

Nut

W4-4-2-4

Spring (01) free length: 242.3 mm (9.5 in)

SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster

dCAUTION: (80 lb)

Special tool (ST 4140) weight: 36 kg

10. Attach the nylon slings onto the eyebolts (2 used) of the special tool (ST 4140). Hoist and hold the special tool (ST4140). Remove nuts (b) (4 used) from the special tool (ST 4943). Hoist and remove the special tool (ST 4140) from the special tool (ST 4943). j : 46 mm

ST 4140

WDAD-04-04-004

11. Remove washer (10) from spring (01).

12. Install eyebolt (M16, Pitch 1.5 mm) to the valve (08) hole of cylinder (00). Attach the nylon sling onto the eyebolt. Hoist the spring (01) assembly.

13. Remove the spring (01) assembly from the special tool (ST 4943). Place it horizontally.

14. Remove spring (01) from the cylinder (00) assembly.

15. Remove piston rod (05) from the cylinder (00) assembly.

IMPORTANT: Do not damage seal (06) and dust seal (07).

16. Remove dust seal (07) and seal (06) from cylinder (00).

W4-4-2-5

SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Assembly of Track Adjuster

05

07 06

00

01

10

04 03

08 09

WADB-04-04-002

00- Cylinder 01- Spring 03- Nut

04- Plug 05- Piston Rod 06- Seal

07- Dust Seal 08- Valve 09- Grease Fitting

W4-4-2-6

10- Washer

SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Assembly of Track Adjuster

4. Install spring (01) to cylinder (00).

IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

1. Apply grease onto the inner surfaces of seal (06) and dust seal (07). Install seal (06) and dust seal (07) to cylinder (00).

2. Apply grease onto the inner surface of cylinder (00).

Fill grease in portion A at the bottom of cylinder (00).

00

A

5. Install eyebolt (M16, Pitch 1.5 mm) to the valve (08) hole of cylinder (00). Attach the nylon sling onto the eyebolt. Hoist the spring (01) assembly. Place the spring (01) assembly on the special tool (ST 4943).

6. Remove the eyebolt from cylinder (00).

7. Install washer (10) to spring (01).

dCAUTION: (80 lb)

Special tool (ST 4140) weight: 36 kg

8. Attach the nylon slings onto the eyebolts (2 used) of the special tool (ST 4140). Hoist the special tool (ST 4140). Install the special tool (ST 4140) to the special tool (ST 4943).

WADB-04-04-003

3. Install piston rod (05) to the cylinder (00) assembly.

Bleed air from cylinder (00).

ST 4140

ST 4943

WDAD-04-04-004

W4-4-2-7

SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster 9. Install nuts (a) (4 used) of the special tool (ST 4943).

Secure the spring (01) assembly. j : 46 mm

14. Lower the oil jack.

dCAUTION: (80 lb)

Special tool (ST 4140) weight: 36 kg

15. Attach the nylon slings onto the eyebolts (2 used) of the special tool (ST 4140). Hoist and hold the special tool (ST4140). Remove nuts (a) (4 used) from the special tool (ST 4943). Hoist and remove the special tool (ST 4140) from the special tool (ST 4943). j : 46 mm

a

16. Attach the nylon slings onto track adjuster (b). Hoist track adjuster (b). Remove track adjuster (b) from the special tool (ST 4943).

W105-03-04-012 a-

Nut

10. Operate the oil jack. Compress spring (01) to the specified length.

fNOTE: Specified spring length: Rubber crawler: 176 mm (6.9 in) Steel crawler: 198 mm (7.8 in)

b

11. Install nut (03) to cylinder (00). j : 46 mm 12. Install plug (04) to nut (03). l : 5 mm ST 4943

m : 15 N·m (1.5 kgf·m, 11 lbf·ft) 13. Install valve (08) to cylinder (00).

WDAD-04-04-002

j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

b-

W4-4-2-8

Track Adjuster

SECTION 4 UNDERCARRIAGE Group 5 Front Idler Removal and Installation of Front Idler Before removing the front idler, the tracks should be removed first. (Refer to W4-7-1.)

Therefore, the procedure starts on the premise that the tracks have already been removed here.

Removal

dCAUTION: Front idler (1) weight: 25 kg (56 lb) Front idler (1) may fly out due to the dCAUTION: spring force of the track adjuster when removing

W1M3-03-05-001

front idler (1). Do not stand in the same direction to remove front idler (1) or where it may fly out.

1. Attach nylon slings (A) onto front idler (1). Hoist and hold front idler (1).

A

1

2. Insert a pry bar between front idler (1) and track frame (2). Hoist and remove front idler (1) with yoke (3) together by using a pry bar.

When keeping front idler (1), place it dCAUTION: on the wooden blocks.

2

Installation

3

W1LD-03-05-003

1. Install it in the reverse way of removal. Check the followings.

2

ď‚– Clean sliding surfaces (B) of track frame (2) and yoke (3). Apply grease.

B

WAEA-04-05-001

W4-5-1-1

SECTION 4 UNDERCARRIAGE Group 5 Front Idler (Blank)

W4-5-1-2

SECTION 4 UNDERCARRIAGE Group 5 Front Idler Disassembly of Front Idler 05

00A

00B

02

04

03

01 03

02

06

08

00B

07 05

08

06

04

00A- Idler 00B- Bushing (2 Used) 01- Axle

WADB-04-05-001

02- O-Ring (2 Used) 03- Floating Seal (2 Used) 04- Yoke (2 Used)

05- Bolt (2 Used) 06- Washer (2 Used) 07- Plate

W4-5-2-1

08- Bolt, Washer (4 Used)

SECTION 4 UNDERCARRIAGE Group 5 Front Idler Disassembly of Front Idler

dCAUTION: kg (55 lb)

The idler (00A) assembly weight: 25

1. Attach the nylon slings onto the idler (00A) assembly. Hoist the idler (00A) assembly. Place the idler (00A) assembly horizontally on wooden blocks.

4. Put the matching marks on yoke (04) and axle (01).

Remove the axle (01) assembly from idler (00A) by using a press.

04

01

fNOTE:

Wooden BlockL: 85 mm or more square 2. Remove bolts, washers (08) (4 used). Remove plate (07) from yokes (04) (2 used).

00A

j : 19 mm 3. Remove bolt (05) and washer (06) from yoke (04) at the upper side. j : 17 mm

fNOTE:

LOCTITE #262 or equivalent has been applied onto the thread part of bolt (05).

W105-03-05-008

IMPORTANT: Handle floating seal (03) with care.

(Refer to W4-5-3.)

5. Remove yoke (04) at the upper side from idler (00A).

Remove floating seals (03) (2 used) from idler (00A) and yokes (04) (2 used). Drain off engine oil from idler (00A).

fNOTE:

Engine Oil 0.03 L (0.032 us qt) 04 03

00A 03 02 01

04

W105-03-05-009

W4-5-2-2

SECTION 4 UNDERCARRIAGE Group 5 Front Idler IMPORTANT: Place wooden blocks (a) under bearing (00) in order not to damage yoke (04).

6. Place yoke (04) onto wooden blocks (a). Remove bolt (05) and washer (06) from yoke (04) at the other side. Put the matching marks on yoke (04) and axle (01). Remove axle (01) from yoke (04) by using a press.

7. Remove O-rings (02) (2 used) from axle (01).

IMPORTANT: Do not remove bushing (00B) unless necessary.

8. When replacing bushing (00B), remove bushings (00B) (2 used) from idler (00A) by the special tool (ST 1120) and a press.

j : 17 mm

05

00A

06 02

ST 1120

04 a

00B 01 02 W105-03-05-011

WADB-04-05-004 a - Wooden Block

W4-5-2-3

SECTION 4 UNDERCARRIAGE Group 5 Front Idler Assembly of Front Idler 00B

00A

04

02

07 08 01

03

00A- Idler 00B- Bushing (2 Used) 01- Axle

WADB-04-05-002

05 06

02- O-Ring (2 Used) 03- Floating Seal (2 Used) 04- Yoke (2 Used)

05- Bolt (2 Used) 06- Washer (2 Used) 07- Plate

W4-5-2-4

08- Bolt, Washer (4 Used)

SECTION 4 UNDERCARRIAGE Group 5 Front Idler Assembly of Front Idler IMPORTANT: Before assembling, apply engine oil onto parts in order to prevent them from seizing.

1. Install bushings (00B) (2 used) to idler (00A) by using a press.

2. Place idler (00A) horizontally on wooden blocks.

fNOTE:

Wooden Block: 85 mm or more square 3. Install O-ring (02) to axle (01).

IMPORTANT: Handle floating seal (03) with care.

(Refer to W4-5-3.)

5. Apply engine oil onto the sliding surface of floating seal (03) and the outer surface of O-ring. Install floating seal (03) to idler (00A) and yoke (04).

6. Install the axle (01) assembly to idler (00A) from the side where floating seal (03) has been installed by using a press.

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

4. Fit the matching marks made when disassembling and install yoke (04) to axle (01) by using a hammer.

Apply LOCTITE #262 or equivalent onto bolt (05).

Install yoke (04) to axle (01) with bolt (05) and washer (06). j : 17 mm m : 65 N·m (6.5 kgf·m, 48 lbf·ft)

05 06 01 04

02

WADB-04-05-003

W4-5-2-5

SECTION 4 UNDERCARRIAGE Group 5 Front Idler 7. Turn over the idler (00A) assembly. Place the idler (00A) assembly on wooden blocks.

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

8. Add engine oil (SAE #30, CD class) to the B part of idler (00A).

fNOTE:

such as goggles, helmets, etc in order to prevent personal injury.

10. Fit the matching marks made when disassembling and install yoke (04) to axle (01) by using a hammer.

Apply LOCTITE #262 or equivalent onto bolt (05).

Install yoke (04) to axle (01) with bolt (05) and washer (06).

Oil amount: 0.03 L (0.032 us qt) B

00A

j : 17 mm m : 65 N·m (6.5 kgf·m, 48 lbf·ft) WADB-04-05-007

IMPORTANT: Handle floating seal (03) with care.

(Refer to W4-5-3.)

9. Install other O-ring (02) to axle (01). Apply engine oil onto the sliding surface of floating seal (03) and the outer surface of O-ring. Install other floating seal (03) to idler (00A) and yoke (04).

11. Apply LOCTITE #262 or equivalent onto the thread part of bolts, washers (08) (4 used). Install plate (07) to yokes (04) (2 used) with bolts, washers (08) (4 used).

04 03 02 01

00A

04 WADB-04-05-005

W4-5-2-6

j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers Removal and Installation of Upper Roller 1

IMPORTANT: The upper roller cannot be disassembled. Replace it as an assembly.

Removal The pressure inside cylinder of the dCAUTION: track adjuster is high. As valve (1) may fly out and

the high-pressure grease may spout out from the grease outlet (a), do not loosen valve (1) quickly and/or excessively. Keep body parts and face away from valve (1) and loosen valve (1) carefully. Do not loosen grease fitting (2).

IMPORTANT: Loosening valve (1) by 1 to 1.5 turns is enough. Do not loosen it over those turns.

IMPORTANT: When gravel or mud is packed between sprockets and track links, remove them before loosening.

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

2. Loosen valve (1) in the track adjuster. Drain grease and loosen the track tension.

WAEBJ0-04-06-001

2

a-

1

a

W1NC-03-06-001

Grease Outlet

j : 19 mm d

IMPORTANT: Use nonskid cloths (c) between track frame (3) and oil jack (d) in order not to slip.

3. Raise track (6) by using oil jack (d) until enough clearance is observed between upper roller (5) and track (6). Place wooden blocks (b) between track (6) and track frame (3).

b

6

5

c

4. Remove bolt (7), nut (9), and spring washer (8).

Remove upper roller (5).

3

j : 24 mm

fNOTE:

LOCTITE #262 has been applied on bolt (7).

W105-03-06-003 b- c-

Wooden Block Nonskid Cloth

d-

Oil Jack

7, 8, 9

5 3

W4-6-1-1

M152-07-046

SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers Installation 1. Apply LOCTITE #262 onto bolt (7). Install upper roller (5) to track frame (3) with bolt (7), nut (9), and spring washer (8). j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 2. Remove wooden blocks (a).

7, 8, 9

3. Lower oil jack (c). Remove oil jack (c) and nonskid cloths (b) from track frame (3).

4. Tighten valve (1) in the track adjuster.

5

j : 19 mm

M152-07-046

3

m : 90 N·m (9 kgf·m, 66 lbf·ft) Securely support the raised machine dCAUTION: by using the blocks.

c

a

6

5

5. Raise track (6) to be adjusted. Rotate track (6) in the reverse direction a little. b

3 W105-03-06-003 a- b-

Wooden Block Nonskid Cloth

c-

Oil Jack

1

W1NC-03-06-001

W4-6-1-2

SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers 6. Apply grease through grease fitting (2) and adjust the track tension.

fNOTE:

At this time, turn the track in reverse direction so that the track sag should be located down.

2

Track Sag Specification (A): Steel Crawler (e): 120 to 140 mm 7. Lower the track.

W1NC-03-06-001

A e e-

W4-6-1-3

Steel Crawler

WAEBJ0-04-06-002

SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers (Blank)

W4-6-1-4

SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers Removal and Installation of Lower Roller IMPORTANT: The lower roller cannot be disassembled. Replace it as an assembly.

Removal Securely support the raised machine dCAUTION: by using the blocks.

b

1. Raise the machine off the ground by using the front attachment. Place the blocks under the track frame and support the machine.

The pressure inside cylinder of the dCAUTION: track adjuster is high. As valve (1) may fly out and

the high-pressure grease may spout out from the grease outlet (a), do not loosen valve (1) quickly and/or excessively. Keep body parts and face away from valve (1) and loosen it carefully. Do not loosen grease fitting (2).

IMPORTANT: Loosening valve (1) by 1 to 1.5 turns is enough. Do not loosen it over those turns.

IMPORTANT: When gravel or mud is packed between sprockets and track links, remove them before loosening.

2. Loosen valve (1) in the track adjuster carefully. Drain grease until the clearance in the track is enough to remove lower roller (4).

M195-07-003 b-

90 to 110°

2

a-

Grease Outlet

1

a

W1NC-03-06-001

j : 19 mm 3. Tighten valve (1) clockwise to the original condition. j : 19 mm m : 90 N·m (9 kgf·m) 4. Remove bolts (3) (2 used) and washers (6) (2 used).

Remove lower roller (4).

3, 6

j : 22 mm

fNOTE:

LOCTITE #262 has been applied on bolt (3).

4

W4-6-2-1

M588-07-052

SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers Installation

5

 The procedure starts on the premise that the track has been raised off the ground.

1. Set lower roller (4) below track frame (5). Fit lower roller (4) to the mounting holes of track frame (5).

2

2. Apply LOCTITE #262 onto bolts (3) (2 used). Install lower roller (4) with bolts (3) (2 used) and washers (6) (2 used). j : 22 mm m : 220 N·m (22 kgf·m)

3, 6

3. Apply grease through grease fitting (2) and adjust the track tension.

fNOTE:

At this time, turn the track in reverse direction so that the track sag should be located down.

4

M588-07-052

Track Sag Specification (A): Steel Crawler (e): 120 to 140 mm 4. Raise the machine off the ground by using the front attachment. Remove the blocks under track frame (5).

A

e WAEBJ0-04-06-002

e-

W4-6-2-2

Steel Crawler

SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers When adding engine oil, perform step 5 to step 7 after removing the lower roller from the track frame.

5. Add engine oil (API CD class, SAE #30) through the plug (2) hole of cover (1).

1

2

fNOTE:

Gear oil (API GL-4 or 5, SAE 140) was put in the lower roller at the time delivered from the factory.

fNOTE:

Amount of oil: 40 to 50 ml 6. Apply LOCTITE #503 onto plug (2).

7. Install plug (2). l : 4 mm m : 10 to 18 N·m (1 to 1.8 kgf·m)

WADB-04-06-003

W4-6-2-3

SECTION 4 UNDERCARRIAGE Group 6 Upper and Lower Rollers (Blank)

W4-6-2-4

SECTION 4 UNDERCARRIAGE Group 7 Track Removal and Installation of Rubber Crawler Removal Rubber crawler weight: 130 kg (290 dCAUTION: lb) Securely support the raised machine dCAUTION: by using the blocks.

b

1. Raise the machine off the ground by using the front attachment.

The pressure inside cylinder of the dCAUTION: track adjuster is high. As valve (1) may fly out and

the high-pressure grease may spout out from the grease outlet (c), do not loosen valve (1) quickly and/or excessively. Keep body parts and face away from valve (1) and loosen valve (1) carefully. Do not loosen grease fitting (2).

IMPORTANT: Loosening valve (1) 1 to 1.5 turns is enough. Do not loosen valve (1) over those turns.

IMPORTANT: When gravel or mud is packed between sprockets and track links, remove them before loosening.

2. Loosen valve (1) in the track adjuster slowly and drain grease.

M195-07-003 b-

90 to 110 °

2

c-

1

c

W1NC-03-06-001

Grease Outlet

j : 19 mm

fNOTE:

If rotating the track in forward and reverse direction with valve (1) loosened, the track can be removed and installed easily.

3. Insert steel pipe (3) into the track. Rotate the sprocket in reverse direction. After the track is floated from the front idler by steel pipe (3), slide and remove the track transversely.

a

3 a-

W4-7-1-1

Rotating Direction

M503-07-062

SECTION 4 UNDERCARRIAGE Group 7 Track Installation Rubber crawler weight: 130 kg (290 dCAUTION: lb) Securely support the raised machine dCAUTION: by using the blocks.

b

1. Raise the machine off the ground by using the front attachment.

2. Mesh the track with the sprocket. Attach the track onto the front idler. Rotate the sprocket in reverse direction and push the track.

3. Insert steel pipe (3) into the track. Rotate the sprocket in reverse direction. Attach the track onto the front idler. Check that the track is securely engaged with the sprocket and the front idler.

3 WAFA-04-07-001 b-

Rotating Direction

4. Tighten valve (1).

1 2

j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 5. Apply grease through grease fitting (2) and adjust the track tension.

fNOTE:

Joint part (c) of the track (rubber crawler (e)) should be in the center when measuring the track (rubber crawler (e)) tension. At this time, turn the track in reverse direction so that the track sag should be located down.

Track sag specification (A): 10 to 15 mm (0.39 to 0.59 in) (Rubber crawler (e))

M588-07-052

Side (a) d

A

e M503-05-050 d-

Lower Roller

e-

W567-03-07-007

Rubber Crawler

c

c c-

W4-7-1-2

Joint Part

e-

e

M102-07-075 Rubber Crawler

SECTION 4 UNDERCARRIAGE Group 7 Track Removal and Installation of Steel Crawler 1 2

5

3

6

b

4 W1NC-03-06-001 b-

a a-

W105-03-07-006

Wooden Block

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

2. Rotate the tracks so that master pin (3) is positioned over front idler (2). Place wooden blocks (a) under shoe (1) and support shoe (1).

The pressure inside cylinder of track dCAUTION: adjuster (4) is high. As valve (6) may fly out and

the high-pressure grease may spout out, do not loosen valve (6) quickly and/or excessively. Keep body parts and face away from valve (6) and loosen it carefully. Do not loosen grease fitting (5).

IMPORTANT: Loosening valve (6) by 1 to 1.5 turns is enough. Do not loosen valve (6) over those turns.

IMPORTANT: When gravel or mud is packed between sprockets and track links, remove them before loosening.

3. Loosen valve (6). Drain grease and loosen the tracks. j : 19 mm

W4-7-2-1

Grease Outlet

SECTION 4 UNDERCARRIAGE Group 7 Track

b ST 1653

a

1 a-

Direction to Install

WADCJ0-04-07-001 b-

W1V1-03-07-001

Direction to Remove

The front idler part may fly out due to dCAUTION: the spring force when removing the track. Do not stand in the same direction to remove the front idler or where it may fly out. Particularly, strong force is always applied to the thread part of the rod of the track adjuster. If the rod and/or the threads are damaged, metal fragments may fly out due to the spring force.

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

IMPORTANT: Master pin (1) can be removed to only one direction. Check direction (b) to remove master pin (1).

4. Remove master pin (1) by using the special tool (ST 1653) and a hammer.

W4-7-2-2

SECTION 4 UNDERCARRIAGE Group 7 Track

b

a a-

Stand

b-

90 to 100 ° M195-07-003

5. Set the angle between boom and arm to 90 ° to 110 °. Lower the boom with the round bottom of the bucket contacting with the ground. Raise the track frame and pull out the track. Place stand (a) under the track frame and support the machine at this time.

dCAUTION: (420 lb)

The track assembly weight: 190 kg

6. Slowly operate the travel control lever for the track to be removed to the reverse position and extend the track.

W4-7-2-3

W105-03-07-011

SECTION 4 UNDERCARRIAGE Group 7 Track

1 b

a

W105-03-07-014 WADCJ0-04-07-001 a- b-

2

Front Idler Side Sprocket (1) Side

W105-03-07-015

Installation 1. Raise the machine off the ground. Set the track under the machine so that sprocket (1) meshes with the track end. Check the direction of the track at this time.

dCAUTION: (420 lb)

3. Slowly operate the travel control lever on the side to install the track in the forward position with the machine raised off the ground. Wind the track while rotating travel device (2).

The track assembly weight: 190 kg

2. Hoist and mesh the track with the claws of sprocket (1).

W4-7-2-4

SECTION 4 UNDERCARRIAGE Group 7 Track

1 b

3

a

2 4

c W105-03-07-016 c-

a-

Wooden Block

4. Wind the track link (3) until the connection part of the track link (3) reaches front idler (1). Lower the machine. Place wooden blocks (c) under shoe (2) and support shoe (2).

Metal fragments may fly off when a dCAUTION: hammer is used. Wear necessary protection, such

as goggles and hard hats.

IMPORTANT: Master pin (4) can be installed to only one direction. Check direction (a) to install master pin (4).

5. Install master pin (4) to the track by a hammer.

W4-7-2-5

Direction to Install

WADCJ0-04-07-001 b-

Direction to Remove

SECTION 4 UNDERCARRIAGE Group 7 Track

2

3

a

1

WAEBJ0-04-06-002

W1NC-03-06-001 a-

6. Tighten valve (3) in the track adjuster (1). Apply grease through grease fitting (2) and adjust the track tension. j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

fNOTE:

Track Sag Specification (a): 120 to 140 mm (4.72 to 5.51 in)

W4-7-2-6

Track Sag Specification

SECTION 4 UNDERCARRIAGE Group 8 Blade Cylinder Removal and Installation of Blade Cylinder

1

2

3

IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

4

dCAUTION:

Blade cylinder (3) weight: 29 kg (64 lb) 2. Remove bolts, washers (1) (2 used). Remove cover (2) from blade cylinder (3). j : 17 mm 3. Attach nylon slings onto blade cylinder (3). Hoist and hold blade cylinder (2).

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

4. Remove bolts (7) (2 used) and washers (6) (2 used) from lock (5). Remove pin (8) from track frame (4) by using a bar and a hammer. j : 19 mm

fNOTE:

LOCTITE #262 has been applied on bolt (7).

5. Start the engine. Operate the blade control lever and retract the cylinder rod to the stroke end. In order not to extend the cylinder rod, pass wires through the boss of cylinder rod and secure it. Stop the engine.

W4-8-1-1

8

7

6

5 WADB-04-08-001

SECTION 4 UNDERCARRIAGE Group 8 Blade Cylinder Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

6. Remove bolt, washer (2) and clip (3) from blade cylinder (1).

1

j : 17 mm

2 3

9

7. Disconnect hoses (4) (2 used) from blade cylinder (1).

4

j : 22 mm

dCAUTION: Blade cylinder (1) weight: 29 kg (64 lb) Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

8

such as goggles, helmets, etc in order to prevent personal injury.

8. Remove bolts (7) (2 used) and washers (8) (2 used) from lock (6). Remove pin (5) from blade (9) by using a bar and a hammer. Hoist and remove blade cylinder (1). j : 19 mm

fNOTE:

LOCTITE #262 has been applied on bolt (7).

W4-8-1-2

7 6

5

WADB-04-08-001

SECTION 4 UNDERCARRIAGE Group 8 Blade Cylinder Installation

dCAUTION:

Blade cylinder (1) weight: 29 kg (64 lb) 1. Apply grease onto the bushing inside and the lip part of the dust seal for blade cylinder (1) (both bottom and rod sides).

1

2 3

9

2. Apply grease onto pin (5). Attach nylon slings onto blade cylinder (1). Hoist blade cylinder (1). Fit the pin (5) holes of blade cylinder (1) and blade (9).

4

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

3. Install blade cylinder (1) to blade (9) with pin (5) by using a hammer. Apply LOCTITE #262 onto bolt (7).

Secure pin (5) with lock (6), bolts (7) (2 used), and washers (8) (2 used).

8

7 6

j : 19 mm m : 110 N·m (11 kgf·m, 81 lbf·ft) 4. Connect hoses (4) (2 used) to blade cylinder (1). j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft) 5. Install clip (3) to blade cylinder (1) with bolt, washer (2). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-8-1-3

5

WADB-04-08-001

SECTION 4 UNDERCARRIAGE Group 8 Blade Cylinder 6. Remove the wires from the blade cylinder (3) rod side.

1

2

3

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

7. Start the engine. Operate the blade control lever and slowly extend the cylinder rod. Fit the pin (8) holes of blade cylinder (3) and track frame (4).

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

8. Apply grease onto pin (8). Install blade cylinder (3) to track frame (4) with pin (8) by using a hammer.

9. Apply LOTITE #262 onto bolt (7). Secure pin (8) to track frame (4) with lock (5), bolts (7) (2 used), and washers (6) (2 used).

4

8

7

6

5 WADB-04-08-001

j : 19 mm m : 110 N·m (11 kgf·m, 81 lbf·ft) 10. Install cover (2) to blade cylinder (3) with bolts, washers (1) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) IMPORTANT: After completing the work, operate the blade cylinder to the stroke end several times and bleed air from the circuit.

W4-8-1-4

SECTION 4 UNDERCARRIAGE Group 8 Blade Cylinder Disassembly of Blade Cylinder

1

10

15

13

12

11 10

6 5 9 8 7 4 3

14

WADC-04-08-001

1- 3- 4- 5-

Cylinder Rod Wiper Ring Cylinder Head Bushing

6- 7- 8- 9-

U-Ring O-Ring Backup Ring O-Ring

10- 11- 12- 13-

Piston Ring (2 Used) Piston Seal Ring Steel Ball

W4-8-2-1

14- Cylinder Tube 15- Set Screw

SECTION 4 UNDERCARRIAGE Group 8 Blade Cylinder Disassembly of Blade Cylinder ď‚– The procedures start on the premise that the piping has been removed.

CAUTION: Blade cylinder weight: 21 kg (46 lb) IMPORTANT: Slowly move cylinder rod (1) and drain off hydraulic oil from the cylinder.

1. Secure the pin mounting part (clevis part) of cylinder tube (14) in a vise horizontally. Drain off hydraulic oil from the cylinder.

3. Loosen cylinder head (4) by using a hook wrench.

Remove cylinder rod (1) from cylinder tube (14).

d

Diameter of cylinder head (4): 105 mm b

14

IMPORTANT: The lock washer in cylinder head (4) is provided on cylinder tube (14) and forms an integral part. Do not damage cylinder tube (14) and cylinder head (4) when bending and extending the lock washer.

2. Pull out cylinder rod (1) approximately 200 mm.

Install a protective cover to cylinder rod (1). Extend lock washer (a) in cylinder head (4).

1 b-

a

4

W506-04-02-004

Hook Wrench

4. Cut away the crimped part by using a hand drill.

Remove set screw (15). Remove steel ball (13).

fNOTE:

Set screw (15) has been crimped by using a punch (2 places) after installing. l : 4 mm

1

4 W506-04-02-003

a-

Lock Washer

W4-8-2-2

SECTION 4 UNDERCARRIAGE Group 8 Blade Cylinder 5. Remove piston (11) from cylinder rod (1) by using the special tool (ST 5908) and the special tool for nut. (ST 3451)

8. Insert a screwdriver between piston (11) and seal ring (12). Raise seal ring (12). Cut seal ring (12) by using a pair of pliers. Remove seal ring (12) from piston (11). When removing the seals, do not damage piston (11).

Special Tool for Nut: ST 3451: 55 mm

11 12 Special Tool: ST 5908

W158-04-02-022

6. Install a protection tape onto the thread part of cylinder rod (1) in order to protect the seal of cylinder head (4). Remove cylinder head (4) from cylinder rod (1).

7. Secure piston (11) in a vise. Remove piston rings (10) (2 used) from piston (11).

W506-04-02-007

9. Remove U-ring (6) and wiper ring (3) from cylinder head (4).

10. Remove O-rings (7, 9) and backup ring (8) from cylinder head (4).

IMPORTANT: When bushing (5) has been removed, replace it with the new one.

11. Remove bushing (5) from cylinder head (4).

W4-8-2-3

SECTION 4 UNDERCARRIAGE Group 8 Blade Cylinder Assembly of Blade Cylinder

13 15

10 12 10 11

14

1

9 8

7

6

4

3

5 WADC-04-08-002

1- 3- 4- 5-

Cylinder Rod Wiper Ring Cylinder Head Bushing

6- 7- 8- 9-

U-Ring O-Ring Backup Ring O-Ring

10- 11- 12- 13-

Piston Ring (2 Used) Piston Seal Ring Steel Ball

W4-8-2-4

14- Cylinder Tube 15- Set Screw

SECTION 4 UNDERCARRIAGE Group 8 Blade Cylinder Assembly of Blade Cylinder IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

IMPORTANT: Check that bushing (5) is not out from the mounting part for U-ring (6) in cylinder head (4) in order not to damage U-ring (6).

IMPORTANT: Check the direction to install U-ring (6).

2. Install U-ring (6) to the inside of cylinder head (4).

4

5 4

a

6

b

W1LD-04-02-004 WADC-04-08-003 a- b-

U-Ring (6) Mounting Part Check that bushing (5) is not out.

3. Install wiper ring (3) to cylinder head (4) by using the special tool (ST 8046).

1. Apply hydraulic oil onto the inside of cylinder head (4). Install bushing (5) to cylinder head (4) by using the special tool (ST 8039).

ST 8046 4

ST 8039 5 4

3 W506-04-02-012

4. Install O-rings (7, 9) and backup ring (8) to cylinder head (4).

W506-04-02-010

W4-8-2-5

SECTION 4 UNDERCARRIAGE Group 8 Blade Cylinder 5. Install piston rings (10) (2 used) to piston (11). Install seal ring (12) by using the special tools (ST 2595, 2591).

ST 2595 12 ST 2591 10

7. Rotate and install the cylinder head (4) assembly to cylinder rod (1).

Special Tool for Cylinder Head (Rod Outer Diameter):

ST 7982: 45 mm

8. Secure cylinder rod (1) to the special tool (ST 5908).

Install the piston (11) assembly to cylinder rod (1) by using the special tool (ST 5908) and the special tool for nut (ST 3451).

11

Special Tool for Nut: ST 3451: 55 mm m : 1250 N·m (125 kgf·m, 920 lbf·ft)

WADC-04-08-006

IMPORTANT: If not adjusted piston ring (10) and seal ring (12), piston (11) cannot be installed to cylinder tube (14).

6. Attach the special tool (ST 2599) onto piston (11).

Adjust piston rings (10) (2 used) and seal ring (12).

10

Special Tool: ST 5908

9. Insert steel ball (13) into piston (11). Install set screw (15). Crimp set screw (15) by using a punch (2 places).

12

l : 4 mm 11

W158-04-02-022

ST 2599

WADC-04-08-007

W4-8-2-6

m : 17 N·m (1.7 kgf·m, 13 lbf·ft)

SECTION 4 UNDERCARRIAGE Group 8 Blade Cylinder 10. Secure cylinder tube (14) on a workbench horizontally. Insert the cylinder rod (1) assembly into cylinder tube (14) straight by using the special tool (ST 7988) in order not to damage.

Special Tool for Cylinder Head (Tube Inner Diameter):

ST 7988: 85 mm

11. Tighten cylinder head (4) to cylinder tube (14) by using a hook wrench. Bend the lock washer in order not to loosen.

Diameter of cylinder head (4): 105 mm m : 490 N·m (49 kgf·m, 360 lbf·ft) a

14 a-

Hook Wrench

W506-04-02-019

W4-8-2-7

SECTION 4 UNDERCARRIAGE Group 8 Blade Cylinder (Blank)

W4-8-2-8

MEMO

MEMO

SECTION 5

FRONT ATTACHMENT CONTENTS Group 1 Front Attachment

Removal and Installation of Front Attachment....W5-1-1-1

Group 2 Cylinder

Removal and Installation of Boom Cylinder..........W5-2-1-1 Removal and Installation of Arm Cylinder.............W5-2-2-1 Removal and Installation of Bucket Cylinder........W5-2-3-1 Removal and Installation of Boom Swing Cylinder.........................................................................W5-2-4-1 Disassembly of Boom Cylinder..................................W5-2-5-1 Assembly of Boom Cylinder........................................W5-2-5-4 Disassembly of Arm, Bucket, and Boom Swing Cylinders.......................................................................W5-2-6-1 Assembly of Arm, Bucket, and Boom Swing Cylinders.......................................................................W5-2-6-6

ADCJ0W-5-1

(Blank)

ADCJ0W-5-2

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Removal and Installation of Front Attachment IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

Removal

1, 2, 3 4

5

7, 8, 9, 13

1. Park the machine on a solid and level surface. Fully retract the arm cylinders and the bucket cylinders and lower the boom. Place the arm end on the ground.

6

dCAUTION:

Boom cylinder (5) weight: 41 kg (91 lb) 2. Remove bolts (7) (2 used), spring washers (8) (2 used), and plane washers (9) (2 used). Remove cover (6) from boom cylinder (5). j : 17 mm

W1M7-04-01-001

12

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

3. Attach the nylon slings onto boom cylinder (5).

Hoist and hold boom cylinder (5). Remove bolt (1), spring washer (2), and bushing (3) from the boom.

Remove pin (4) from the boom by using a bar and a hammer. Remove shim (13) between the boom and boom cylinder (5). j : 22 mm

fNOTE:

LOCTITE # 262 has been applied on bolt (1).

4. Start the engine. Operate the boom control lever and retract cylinder rod (12). Pass the wires through the cylinder rod (12) hole and secure cylinder rod (12) in order not to extend.

5. Place the cylinder rod (12) side of boom cylinder (5) onto the stand.

W5-1-1-1

W554-02-03-007

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

Release any pressure in the hydraulic dCAUTION: circuit. (Refer to W1-5-1.)

11

6. Disconnect hoses (11) (2 used) from the boom. j : 22 mm 7. Disconnect connector (2) of the headlight. Loosen clips (1) (9 used) which secure the pipe of the boom back and the harness of the headlight. Remove the harness from clips (1) (9 used).

dCAUTION: lb)

W1M7-04-01-002

Front attachment weight: 416 kg (920 1

8. Attach the nylon slings onto the boom. Reduce slack of the nylon slings. Hoist and hold the boom at the center of gravity.

9. Disconnect hoses (7) (2 used) from the bracket (8). j : 22 mm 10. Disconnect hoses (3) (4 used).

2

j : 22 mm, 27 mm 11. Remove nuts (6) (2 used). Remove bolt (4) from the swing post.

W1M7-04-01-025

j : 19 mm

fNOTE:

LOCTITE #262 has been applied on bolt (4).

3

7

8

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

12. Remove boom foot pin (5) from the swing post by using a bar and a hammer.

fNOTE:

Put the matching marks on the swing post boss and boom foot pin (5) for assembling.

13. Hoist and remove the front attachment. Remove the thrust plates from left and right sides of the boom foot pin (5) part.

4 5 6

W1M7-04-01-004

W5-1-1-2

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Installation

dCAUTION: lb)

1

8

9

Front attachment weight: 416 kg (920

1. Hoist the front attachment. Fit the boom foot part to the mounting hole of the swing post. Insert the thrust plates to both right and left of the boom foot parts and adjust the right and left clearances within 1 mm.

2 3 4

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

2. Install boom foot pin (3) by using a hammer.

IMPORTANT: Install nut (4) so that the clearance between nut (4) and the swing post boss should be 3 to 5 mm.

3. Apply LOCTITE #262 onto bolt (2). Install bolt (2) and nuts (4) (2 used).

W1M7-04-01-004

5

6

j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 4. Connect hoses (1) (4 used). j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft) 7

j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 5. Connect hoses (8) (2 used) to bracket (9). j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

dCAUTION:

Boom cylinder (7) weight: 41 kg (91 lb) 6. Connect hoses (6) (2 used) to boom (5). Attach the nylon slings onto boom cylinder (7). Hoist and hold boom cylinder (7). j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

W5-1-1-3

W1M7-04-01-002

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 7. Remove the wires from the boom cylinder (5) rod side.

1, 2, 3 4

8. Start the engine with the cylinder rod of boom cylinder (5) retracted to the stroke end. Extend boom cylinder (5) slowly. Fit the pin (4) holes of the boom cylinder (5) cylinde rod side and the boom.

Install shim (13) between the boom and boom cylinder (5).

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

5

7, 8, 9, 13

such as goggles, helmets, etc in order to prevent personal injury.

9. Apply LOCTITE # 262 onto bolt (1). Install pin (4) by using a hammer. Secure pin (4) to the boom with bolt (1), spring washer (2), and bushing (3).

6

W1M7-04-01-001

j : 22 mm m : 140 N·m (14 kgf·m, 103 lbf·ft)

10

10. Install cover (6) to boom cylinder (5) with bolts (7) (2 used), spring washers (8) (2 used), and plane washers (9) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 11

11. Pass the light harness through clips (10) (9 used).

Connect connector (11). Secure the light harness and the boom pipes with clips (10) (9 used).

IMPORTANT: After completing the work, add hydraulic oil to the specified level. Operate each cylinder to the stroke end several times and bleed air in the circuit. Check for any oil leak of each hose connection.

W5-1-1-4

W1M7-04-01-025

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Removal and Installation of Boom Cylinder IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

Removal

1, 2, 3

4

5

7, 8, 9, 12

1. Park the machine on a solid and level surface.

Fully retract the arm cylinder and bucket cylinder and lower the boom. Place the arm end onto the ground.

6 W1MJ-04-02-007

dCAUTION:

Boom cylinder (5) weight: 41 kg (91 lb) 2. Remove bolts (7) (2 used), spring washers (8) (2 used), and plane washers (9) (2 used). Remove cover (6) from boom cylinder (5).

10

j : 17 mm Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

3. Attach the nylon slings onto boom cylinder (5).

Hoist and hold boom cylinder (5). Remove bolt (1), spring washer (2), and bushing (3). Remove pin (4) by using a bar and a hammer. j : 22 mm

W554-02-03-007

fNOTE:

LOCTITE #262 has been applied on bolt (1).

4. Remove the shims (12) from on both sides of the cylinder rod (10) boss. Start the engine. Retract cylinder rod (10) to the stroke end. Pass the wires through the cylinder rod (10) boss and secure cylinder rod (10) in order not to extend.

W5-2-1-1

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 5. Place boom cylinder (4) on the stands.

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

Release any pressure in the hydraulic dCAUTION: circuit. (Refer to W1-5-1.)

1

2

3

4

6

6. Disconnect hoses (6) (2 used) from boom cylinder (4). j : 22 mm

dCAUTION:

Boom cylinder (4) weight: 41 kg (91 lb) 7. Remove nuts (5) (2 used) and bolt (2) from pin (1). j : 19 mm

fNOTE:

LOCTITE #262 has been applied on bolt (2).

5

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

8. Remove pin (1) by using a bar and a hammer.

Remove the shims from both sides of the cylinder tube boss.

fNOTE:

Put the matching marks on swing post (3) and pin (1) for assembling.

9. Hoist and remove boom cylinder (4).

W5-2-1-2

W1MJ-04-02-008

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Installation

1

dCAUTION:

2

3

4

5

Boom cylinder (4) weight: 41 kg (91 lb) IMPORTANT: Insert at least one shim to both left and right sides of all pins respectively. When the shims should be used in order to adjust the clearance, the shims should be inserted at both sides respectively. (Clearance: 0.5 mm or less) 1. Apply grease onto the lip part of the dust seal for boom cylinder (4), the boss side, and the bushing inside (both bottom and rod sides).

2. Apply grease onto pin (1). Attach the nylon sling onto boom cylinder (4). Hoist boom cylinder (4).

Fit the pin (1) holes of boom cylinder (4) and swing post (3). Insert the shims to both sides of the cylinder tube boss.

d

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury.

3. Fit the bolt (2) holes of swing post (3) and pin (1).

Install pin (1) by using a hammer.

IMPORTANT: Install nut (6) so that the clearance between nut (6) and the swing post (3) boss should be 3 to 5 mm.

4. Apply LOCTITE #262 onto bolt (2). Install bolt (2) and nuts (6) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 5. Connect hoses (5) (2 used) to boom cylinder (4). j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

W5-2-1-3

6 W1MJ-04-02-008

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 6. Remove the wires from the boom cylinder (5) rod side.

1, 2, 3

4

5

7. Hoist boom cylinder (5). Start the engine with the cylinder rod retracted to the stroke end. Extend the cylinder rod slowly. Fit the pin (4) holes of boom cylinder (5) and the boom.

fNOTE:

When the work in step 7 is finished, air in the cylinder has been released.

7, 8, 9, 10

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

8. Insert the shims (10) to both sides of the cylinder rod boss. Install pin (4) by using a hammer. Apply LOCTITE #262 onto bolt (1). Secure pin (4) to the boom with bolt (1), spring washer (2), and bushing (3). j : 22 mm m : 140 N·m (14 kgf·m, 103 lbf·ft) 9. Install cover (6) to boom cylinder (5) with bolts (7) (2 used), spring washers (8) (2 used), and plane washers (9) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

IMPORTANT: After completing the work, operate the boom cylinder to the stroke end several times and bleed air from the circuit.

W5-2-1-4

6 W1MJ-04-02-007

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Removal and Installation of Arm Cylinder

1

IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

Removal

3

1. Park the machine on a solid, level surface. Fully retract the bucket and arm cylinders and lower the arm top onto the ground.

W571-04-02-018

dCAUTION:

Arm cylinder (1) weight: 30 kg (67 lb) 2. Set wooden blocks (3) between arm cylinder (1) and boom (2). Support arm cylinder (1).

d

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury.

3. Remove bolt (4), spring washer (5), and bushing (6). Remove pin (7) by using a bar and a hammer.

Remove the shims from both sides of the cylinder rod boss.

2

1

9

8 7

4, 5, 6

2

11

W1L7-04-02-007

j : 22 mm

fNOTE: fNOTE:

LOCTITE #262 has been applied on bolt (4).

If pin (7) can not be removed, raise the boom a little and remove pin (7).

4. In order not to extend cylinder rod (12), pass wires through the boss of cylinder rod (12) and secure it.

5. Remove bolt, washer (9). Remove clamp (11) from arm cylinder (1). j : 13 mm

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1- 4-1.)

Release any pressure in the hydraulic dCAUTION: circuit. (Refer to W1- 5-1.)

6. Disconnect hoses (8) (2 used). j : 27 mm

W5-2-2-1

12 W577-04-02-008

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 7. Attach the nylon slings onto arm cylinder (1). Hold arm cylinder (1).

1

2

3, 4, 5

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

8. Remove bolt (3), spring washer (4), and bushing (5).

Remove pin (2) from arm cylinder (1) by using a bar and a hammer. Remove the shims from both sides of the cylinder tube boss. j : 22 mm

fNOTE:

LOCTITE #262 has been applied on bolt (3).

9. Hoist and remove arm cylinder (1) from the boom.

W571-04-02-019

W5-2-2-2

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Installation

dCAUTION:

Arm cylinder (2) weight: 30 kg (67 lb) IMPORTANT: Insert at least one shim to both left and right sides of all pins respectively. When the shims should be used in order to adjust the clearance, the shims should be inserted at both sides respectively. (Clearance: 0.5 mm or less) 1. Apply grease onto the lip part of the dust seal for arm cylinder (2), the boss side, and the bushing inside (both bottom and rod sides).

5, 6, 7

2

3

4

1

2. Attach nylon slings onto arm cylinder (2). Hoist arm cylinder (2). Fit the pin (4) holes of arm cylinder (2) and boom (9). Insert the shims to both sides of the cylinder tube boss.

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

9

such as goggles, helmets, etc in order to prevent personal injury.

3. Apply LOCTITE #262 onto bolt (5). Install pin (4) by using a hammer. Secure pin (4) to boom (9) with bolt (5), spring washer (6), and bushing (7). j : 22 mm m : 140 N·m (14 kgf·m, 103 lbf·ft) 4. Connect hoses (1) (2 used) to arm cylinder (2). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 5. Secure rod side of hose (1) and clamp (8) to the arm cylinder (2) with bolt, washer (3). j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

W5-2-2-3

8

W1L7-04-02-007

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 6. Remove the wires from the arm cylinder (1) rod side.

7. Start the engine with the cylinder rod retracted to the stroke end. Slowly extend the cylinder rod. Fit the pin (3) holes of arm cylinder (1) and the arm (4).

fNOTE:

When the work in step 7 is finished, air in the cylinder has been released.

1

f

NOTE: If it is difficult to fit the pin (3) holes, raise the boom (5) a little and fit the pin (3) holes.

2, 9, 10

3

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

8. Insert the shims to both sides of the cylinder rod boss. Install pin (3) by using a hammer. Apply LOCTITE #262 onto bolt (2). Secure pin (3) to arm (4) with bolt (2), spring washer (9), and bushing (10). j : 22 mm m : 140 N·m (14 kgf·m, 103 lbf·ft)

IMPORTANT: After completing the work, operate the arm cylinder (1) to the stroke end several times and bleed air from the circuit.

W5-2-2-4

4

5

W1L7-04-02-007

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Removal and Installation of Bucket Cylinder IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

1

3 2

3

Removal

W554-04-02-006

1. Park the machine on a solid, level surface. Fully retract the arm cylinder and bucket cylinder (1).

Lower the arm (2) top onto the ground.

dCAUTION: lb)

4

Bucket cylinder (1) weight: 22 kg (49

2. Set wooden blocks (3) under the arm (2) top and between bucket cylinder (1) and arm (2).

Before removing pin (6), secure the dCAUTION: link by using wires in order not to fall off.

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

5

such as goggles, helmets, etc in order to prevent personal injury.

3. Remove nuts (5) (2 used) and stopper pin (4).

Remove pin (6) by using a bar and a hammer.

Remove the shim. j : 24 mm

6 W158-04-02-006

1

7

fNOTE:

LOCTITE #262 has been applied on stopper pin (4).

4. Start the engine. Operate the bucket control lever and retract bucket cylinder (1). In order not to extend rod (7), pass wires (8) through the rod hole and secure rod (7) to the bucket cylinder (1) tube.

8 W102-04-02-005

W5-2-3-1

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1- 4-1.)

Release any pressure in the hydraulic dCAUTION: circuit. (Refer to W1-5-1.)

5. Disconnect hoses (7) (2 used) from bucket cylinder (1). j : 22 mm

3, 4, 5 2 1

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

6. Attach nylon slings onto bucket cylinder (1). Hoist and hold bucket cylinder (1). Remove bolt (3), spring washer (4), and bushing (5) from arm (6). Remove pin (2) by using a bar and a hammer. Remove the shims from both sides of the cylinder tube boss. j : 19 mm

fNOTE:

LOCTITE #262 has been applied on bolt (3).

7. Hoist and remove bucket cylinder (1) from arm (6).

W5-2-3-2

W1L7-04-02-005

7

6

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Installation

3, 4, 5

d

CAUTION: Bucket cylinder (1) weight: : 22 kg (49 lb) IMPORTANT: Insert at least one shim to both left and right sides of all pins respectively. When the shims should be used in order to adjust the clearance, the shims should be inserted at both sides respectively. (Clearance: 0.5 mm or less) IMPORTANT: Apply grease onto the lip part of the dust seal for bucket cylinder (1), the boss side, and the bushing inside (both bottom and rod sides).

1. Attach the nylon Sling onto bucket cylinder (1).

Hoist bucket cylinder (1). Fit the pin (2) holes of bucket cylinder (1) and arm (6). Insert the shims to both sides of the cylinder tube boss.

2 1

6

7

W1L7-04-02-005

1

8

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury.

2. Apply LOCTITE #262 onto bolt (3). Install pin (2) by using a hammer. Secure pin (2) with bolt (3), spring washer (4), and bushing (5). j : 19 mm

9

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W102-04-02-005

3. Connect hoses (7) (2 used) to bucket cylinder (1). j : 22 mm

11

m : 40 N·m (4 kgf·m, 29.5 lbf·ft) 4. Remove wires (9) from rod (8) of bucket cylinder (1).

5. Start the engine with the cylinder rod retracted to the stroke end. Slowly extend the cylinder rod. Fit the pin (10) holes of bucket cylinder (1), link A (11) and link B (12) (2 used).

fNOTE:

When the work in step 5 is finished, air in the cylinder has been released.

10

12 W158-04-02-006

W5-2-3-3

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

1

such as goggles, helmets, etc in order to prevent personal injury.

6. Insert the shims to both sides of the cylinder rod boss. Remove the wires which secure link B. Install pin (3) by using a hammer.

2

7. Apply LOCTITE #262 onto stopper pin (1). Install stopper pin (1) to link B and pin (3) with nuts (2) (2 used). j : 24 mm

3

m : 270 N·m (27 kgf·m, 200 lbf·ft)

W158-04-02-006

IMPORTANT: After completing the work, operate the bucket cylinder to the stroke end several times and bleed air from the circuit.

W5-2-3-4

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Removal and Installation of Boom Swing Cylinder 1

IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.

2

3

Removal ď‚– The procedure starts on the premise that the front attachment has swung to the left.

1. Park the machine on a solid, level surface. Fully retract the bucket and arm cylinders and lower the arm top onto the ground.

dCAUTION: (71 lb)

Boom swing cylinder (4) weight: 32 kg

2. Set wooden blocks between boom swing cylinder (4) and main frame (5). Support boom swing cylinder (4). Remove nuts (3) (2 used). Remove bolt (1) from pin (2). Remove pin (2) from the swing post. j : 17 mm

fNOTE: fNOTE:

LOCTITE #262 has been applied on bolt (1).

When removing bolt (1), pin (2) may come off.

Put the matching marks on the boss of swing post and pin (2) for assembling.

3. Start the engine. Retract the cylinder rod to the stroke end. In order not to extend the cylinder rod, pass wires through the boss of cylinder rod and secure it.

W5-2-4-1

5

4 WADB-05-02-007

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Remove cover (2) while holding it. Do dCAUTION: not drop cover (2).

4. Remove bolts, washers (1) (4 used). Remove cover (2) from the frame. j : 17 mm Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

1

5. Disconnect hose (9) at the bottom side. j : 19 mm Remove cover (3) while holding it. Do dCAUTION: not drop cover (3).

4 3

6. Remove bolts, washers (4) (4 used). Remove cover (3) from the frame.

2

WADB-05-02-008

5

j : 17 mm 7. Disconnect hose (10) at the cylinder rod side. j : 19 mm 8. Remove bolt (6) and bushing (7). Remove pin (8) from the lower side of the main frame.

6, 7

j : 19 mm 9. Hoist and remove boom swing cylinder (5).

9

8

WADB-05-02-009

5

W5-2-4-2

10

WADB-05-02-010

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Installation

dCAUTION: (71 lb)

5

Boom swing cylinder (5) weight: 32 kg

1. Apply grease onto the dust seal lip part of boom swing cylinder (5).

2. Attach the nylon slings onto boom swing cylinder (5). Hoist boom swing cylinder (5). Place the boss of cylinder tube onto the main frame. Set wooden blocks between boom swing cylinder (5) and the main frame. Support boom swing cylinder (5).

3. Apply grease onto pin (8). Fit the pin (8) holes on the main frame and boom swing cylinder (5). Install pin (8) by using a plastic hammer. Secure pin (8) with bolt (6) and bushing (7).

6, 7

9

8

j : 19 mm m : 90 N·m (9 kgf·m, 66lbf·ft) WADB-05-02-009

4. Connect hose (9) to the bottom side of boom swing cylinder (5). Connect hose (10) to the cylinder rod side. j : 19 mm m : 30 N·m (3 kgf·m, 22lbf·ft)

5

W5-2-4-3

10

WADB-05-02-010

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 5. Remove the wires from the rod side of boom swing cylinder (4).

1

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

6. Start the engine with the cylinder rod retracted to the stroke end. Slowly extend the cylinder rod. Fit the pin (2) holes on boom swing cylinder (4) and the swing post.

2

fNOTE:

When the work in step 8 is finished, air in the cylinder has been released.

7. Apply grease onto pin (2). Fit the bolt (1) holes on the swing post and pin (2). Install pin (2).

3

IMPORTANT: Install nut (3) so that the clearance between the boss of swing post and nut (3) should be 2 to 3 mm.

8. Apply LOCTITE #262 onto bolt (1). Install bolt (1).

Install nuts (3) (2 used).

4

5

WADB-05-02-007

j : 17 mm m : 50 N·m (5 kgf·m, 37lbf·ft) 9. Install cover (8) with bolts, washers (9) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37lbf·ft) 10. Install cover (7) with bolts, washers (6) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37lbf·ft) IMPORTANT: After completing the work, operate boom swing cylinder (4) to the stroke end several times and bleed air from the circuit.

6

9 8

W5-2-4-4

7

WADB-05-02-008

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Boom Cylinder

1

13

14

12

8

4

6

5

9

10

11

7

3 2 20

15

16

17

18

21

22

19

23

WADB-05-02-006 1- 2- 3- 4- 5- 6-

Cylinder Rod Wiper Ring Cylinder Head O-Ring Backup Ring O-Ring

7- 8- 9- 10- 11- 12-

Bushing U-Ring Collar Cushion Seal Spacer Holder

13- 14- 15- 16- 17- 18-

Backup Ring O-Ring Cushion Bearing Slide Ring Piston Steel Ball

W5-2-5-1

19- 20- 21- 22- 23-

Set Screw O-Ring Seal Ring Slide Ring Cylinder Tube

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Boom Cylinder ď‚– The procedure starts on the premise that the pipes and the bands securing the pipes have been removed.

CAUTION: Boom cylinder weight: 41 kg (91 lb) IMPORTANT: The seals cannot be reused. Replace them with the new ones.

1. Secure the pin mounting part (clevis part) of cylinder tube (23) in a vise horizontally. Move cylinder rod (2) slowly and drain hydraulic oil from the cylinder.

3. Loosen cylinder head (3) by using hook wrench (b) with the protective cover on cylinder rod (1).

Remove the cylinder rod (1) assembly from cylinder tube (23).

d

Diameter of cylinder head (3): 105 mm b

IMPORTANT: Lock washer (a) in cylinder head (3) forms an integral part with cylinder tube (23). Do not damage cylinder tube (23) and cylinder head (3) when bending and extending lock washer (a).

2. Pull out cylinder rod (1) about 200 mm (7.87 in).

Install a protective cover to cylinder rod (1). Extend lock washer (a) in cylinder head (3)

23

1

3 W506-04-02-004

b-

a

1 a-

Lock Washer

3 W506-04-02-003

W5-2-5-2

Hook Wrench

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 4. Cut away the crimped part by using a hand drill.

Remove set screw (19). Remove steel ball (18).

8. Remove the holder (12) assembly from cylinder head (3).

fNOTE:

9. Remove backup ring (13) and O-ring (14) from holder (12).

Set screw (19) has been crimped by using a punch at two places after installing. l : 4 mm

5. Remove piston (17) and cushion bearing (15) by using the special tool (ST 5908) for cylinder and the special tool for piston.

10. Remove spacer (11), cushion seal (10), and collar (9) from holder (12).

11. Remove wiper ring (2) and U-ring (8) from cylinder head (3).

12. Remove O-rings (4, 6) and backup ring (5) from cylinder head (3).

Special Tool for Piston: ST 3239: 60 mm

IMPORTANT: Bushing (7) cannot be reused. When bushing (7) has been removed, replace it with the new one when assembling.

13. Remove bushing (7) from head cylinder head (3).

Special Tool for Cylinder: ST 5908 W158-04-02-022

6. Install the protective tape onto the thread part of cylinder rod (1) in order to protect the seal of cylinder head (3). Remove cylinder head (3) from cylinder rod (1).

IMPORTANT: When removing the seals, do not damage the parts.

7. Secure piston (17) in a vise. Remove slide rings (16, 22) from piston (17). Cut and remove seal ring (20) and O-ring (21) from piston (17) by using a screwdriver.

17 20, 21

W506-04-02-007

W5-2-5-3

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Boom Cylinder

12 9

a 2

3

4

7

13

14 10 11

Detail of Part A 8

5 6

1

23

15

17

16 21 20 22

19 18

A

WADB-05-02-001

a-

Hole (1 Place)

1- 2- 3- 4- 5- 6-

Cylinder Rod Wiper Ring Cylinder Head O-Ring Backup Ring O-Ring

7- 8- 9- 10- 11- 12-

Bushing U-Ring Collar Cushion Seal Spacer Holder

13- 14- 15- 16- 17- 18-

Backup Ring O-Ring Cushion Bearing Slide Ring Piston Steel Ball

W5-2-5-4

19- 20- 21- 22- 23-

Set Screw O-Ring Seal Ring Slide Ring Cylinder Tube

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Boom Cylinder IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

IMPORTANT: The seals cannot be reused. Replace them with the new ones.

IMPORTANT: Check that bushing (7) is not out from the U-ring (8) mounting part in cylinder head (3) in order not to damage U-ring (8).

IMPORTANT: Check the direction to install U-ring (8).

2. Install U-ring (8) to cylinder head (3).

3 8

7 3 a

W1LD-04-02-004 a-

Check that bushing (7) is not out.

W1M9-04-02-011

1. Install bushing (7) to cylinder head (3) by using the special tool (ST 8040).

3. Install wiper ring (2) to cylinder head (3) by using the special tool (ST 8047).

ST 8047

ST 8040

3

7 3

2 W506-04-02-012 W506-04-02-010

4. Install O-rings (4, 6) and backup ring (5) to cylinder head (3).

W5-2-5-5

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 5. Install collar (9), cushion seal (10), and spacer (11) to holder (12).

6. Install O-ring (14) and backup ring (13) to holder (12).

IMPORTANT: If not adjusting seal ring (21), piston (17) cannot be installed to cylinder tube (23).

9. Install the special tool (ST 2599) onto piston (17).

Adjust seal ring (21).

7. Install the holder (12) assembly to cylinder head (3).

IMPORTANT: Check that O-ring (20) is not twisted.

8. Install O-ring (20) to piston (17). Install seal ring (21) to piston (17) by using the special tools (ST 2591, ST 2595).

21

17

ST 2599

ST 2595

21 W566-04-02-011

ST 2591

20

10. Install slide rings (16, 22) to piston (17) in order not to fit their split positions.

17

11. Install the cylinder head (3) assembly to cylinder rod (1).

W566-04-02-010

Special Tool for Cylinder Head (Rod Outer Diameter):

ST 7983 : 50 mm

W5-2-5-6

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder IMPORTANT: Check the direction to install cushion bearing (15).

12. Install cushion bearing (15) and the piston (17) assembly to cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool (ST 3239)for piston.

IMPORTANT: When inserting the cylinder rod (1) assembly, do not drop slide rings (16, 22) from piston (17).

14. Secure cylinder tube (23) on a workbench horizontally. Insert the cylinder rod (1) assembly into cylinder tube (23) by using the special tool (ST 7988).

Special Tool for Piston: ST 3239: 60 mm m : 1620 N·m (162 kgf·m, 1190 lbf·ft)

Special Tool for Cylinder Rod (Tube Inner Diameter):

ST 7988: 85 mm

15. Tighten cylinder head (3) to cylinder tube (23) by using hook wrench (a). Bend the lock washer in order not to loosen.

Diameter of cylinder head (3): 105 mm m : 490 N·m (49 kgf·m, 360 lbf·ft) a

Special Tool for Cylinder: ST 5908 W158-04-02-022

13. Install steel ball (18) to piston (17). Install set screw (19). Crimp set screw (19) by using a punch (2 places). l : 4 mm m : 17 N·m (1.7 kgf·m, 12.5 lbf·ft)

23 a-

W5-2-5-7

Hook Wrench

W506-04-02-019

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder (Blank)

W5-2-5-8

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Arm, Bucket, and Boom Swing Cylinders Arm Cylinder

1

9 12 10

13

14

19

16

17

18

11

9 8

4

5

6

7

3 2

15

W1ND-04-02-001

W5-2-6-1

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Bucket Cylinder

1

9 13

14

12 10

11

9 8

3

4

5

6

7

20

2

15

WADB-05-02-002

W5-2-6-2

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Boom Swing Cylinder

1

9 14 13 12 10

11

9 8 7 6 5 4 3 2

15

WADB-05-02-003 1- 2- 3- 4- 5- 6- 7-

Cylinder Rod Wiper Ring Cylinder Head O-Ring Backup Ring O-Ring Bushing

8- 9- 10- 11- 12- 13- 14-

U-Ring Slide Ring (2 Used) Piston Steel Ball Set Screw O-Ring Seal Ring

15- Cylinder Tube 16- Cushion Bearing (only Arm Cylinder) 17- Cushion Seal (only Arm Cylinder) 18- Stopper (2 Used) (only Arm Cylinder)

W5-2-6-3

19- Retaining Ring (only Arm Cylinder) 20- Backup Ring (only Bucket Cylinder)

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Arm, Bucket, and Boom Swing Cylinders

3. Loosen cylinder head (3) by using hook wrench (b) with the protective cover on cylinder rod (1).

Remove the cylinder rod (1) assembly from cylinder tube (15).

ď‚–The procedure starts on the premise that the pipes and the bands securing the pipes have been removed.

CAUTION: Arm cylinder weight: 30 kg (67 lb)

d

Diameter of cylinder head (3):

Bucket cylinder weight: 22 kg (49 lb)

Arm Cylinder: 90 mm

Boom swing cylinder weight: 32 kg

Bucket Cylinder: 82 mm

Boom Swing Cylinder: 105 mm

(71 lb) IMPORTANT: The seals cannot be reused. Replace them with the new ones.

1. Secure the pin mounting part (clevis part) of cylinder tube (15) in a vise horizontally. Move cylinder rod (2) slowly and drain hydraulic oil from the cylinder.

b

15

IMPORTANT: Lock washer (a) in cylinder head (3) forms an integral part with cylinder tube (15). Do not damage cylinder tube (15) and cylinder head (3) when bending and extending lock washer (a).

2. Pull out cylinder rod (1) about 200 mm (7.87 in).

Install a protective cover to cylinder rod (1). Extend lock washer (a) in cylinder head (3)

1

W506-04-02-004 b-

a

1 a-

Lock Washer

3

3 W506-04-02-003

W5-2-6-4

Hook Wrench

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 4. Cut away the crimped part by using a hand drill.

Remove set screw (12). Remove steel ball (11).

8. Remove wiper ring (2), U-ring (8), and backup ring (20) from cylinder head (3). (only Bucket Cylinder: Remove backup ring (20).)

fNOTE:

Set screw (12) has been crimped by using a punch at two places after installing.

9. Remove O-rings (4, 6) and backup ring (5) from cylinder head (3).

l : 4 mm

IMPORTANT: Bushing (7) cannot be reused. When bushing (7) has been removed, replace it with the new one when assembling.

10. Remove bushing (7) from cylinder head (3).

5. Remove piston (10) by using the special tool (ST 5908) for cylinder and the special tool for piston.

Special Tool for Piston:

ST 3450: 50 mm (Bucket Cylinder)

11. (only Arm Cylinder)

ST 3451: 55 mm (Arm Cylinder, Boom Swing Cylinder)

Special Tool for Cylinder: ST 5908 W158-04-02-022

6. Install the protective tape onto the thread part of cylinder rod (1) in order to protect the seal of cylinder head (3). Remove cylinder head (3) from cylinder rod (1).

IMPORTANT: When removing the seals, do not damage the parts.

7. Secure piston (10) in a vise. Remove slide rings (9) (2 used) from piston (10). Cut and remove seal ring (14) and O-ring (13) from piston (10) by using a screwdriver.

10 13, 14

W506-04-02-007

W5-2-6-5

Remove retaining ring (19), stoppers (18) (2 used), cushion bearing (16), and cushion seal (17) from cylinder rod (1).

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Arm, Bucket, and Boom Swing Cylinders Arm Cylinder

3

2

4

7

5 6

15

10

1

9 14

8

9

13

12 19 16 18

11 17

WADB-05-02-004

Bucket Cylinder 2

3

4

20 8

5 6

15

1

10

9

7

14 9

12 11

13

WADB-05-02-005

Boom Swing Cylinder 2

3

4

7 1- 2- 3- 4- 5- 6- 7-

Cylinder Rod Wiper Ring Cylinder Head O-Ring Backup Ring O-Ring Bushing

5 6

15

1

8

10

9

14 9

13 8- 9- 10- 11- 12- 13- 14-

U-Ring Slide Ring (2 Used) Piston Steel Ball Set Screw O-Ring Seal Ring

15- Cylinder Tube 16- Cushion Bearing (only Arm Cylinder) 17- Cushion Seal (only Arm Cylinder) 18- Stopper (2 Used) (only Arm Cylinder)

W5-2-6-6

12

11

W1MJ-04-02-006

19- Retaining Ring (only Arm Cylinder) 20- Backup Ring (only Bucket Cylinder)

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Arm, Bucket, and Boom Swing Cylinders IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

IMPORTANT: The seals cannot be reused. Replace them with the new ones.

IMPORTANT: Check that bushing (7) is not out from the U-ring (8) mounting part in cylinder head (3) in order not to damage U-ring (8). (only Arm, Boom Swing Cylinders)

IMPORTANT: Check the direction to install U-ring (8).

2. Install U-ring (8) and backup ring (20) to cylinder head (3). (only Bucket Cylinder: Install backup ring (20).)

3 8

7

3 a

W1LD-04-02-004 a-

W1M9-04-02-011

Check that bushing (7) is not out.

3. Install wiper ring (2) to cylinder head (3) by using the special tool.

1. Install bushing (7) to cylinder head (3) by using the special tool.

Special Tool for Bushing (Rod Outer Diameter):

ST 8038: 40 mm (Bucket Cylinder)

ST 8039: 45 mm (Arm Cylinder, Boom Swing Cylinder)

Special Tool for Wiper Ring (Rod Outer Diameter):

ST 8045: 40 mm (Bucket Cylinder)

ST 8046: 45 mm (Arm Cylinder, Boom Swing Cylinder)

a

b 3

7 3

2 b-

a-

Special Tool for Bushing

W506-04-02-010

Special Tool for Wiper Ring

W506-04-02-012

4. Install O-rings (4, 6) and backup ring (5) to cylinder head (3).

W5-2-6-7

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder IMPORTANT: Check that O-ring (13) is not twisted.

5. Install O-ring (13) to piston (10). Install seal ring (14) to piston (10) by using the special tool.

Special Tool (a) for Seal Ring (Tube Inner Diameter):

ST 2592: 75 mm (Arm Cylinder)

ST 2481: 65 mm (Bucket Cylinder)

ST 2591: 85 mm (Boom Swing Cylinder)

Special Tool (b) for Seal Ring (Tube Inner Diameter):

ST 2596: 75 mm (Arm Cylinder)

ST 2482: 65 mm (Bucket Cylinder)

ST 2595: 85 mm (Boom Swing Cylinder)

IMPORTANT: If not adjusting seal ring (14), piston (10) cannot be installed to cylinder tube (15).

6. Install the special tool onto piston (10). Adjust seal ring (14).

Special Tool for Seal Ring (Tube Inner Diameter):

ST 2600: 75 mm (Arm Cylinder)

ST 2483: 65 mm (Bucket Cylinder)

ST 2599: 85 mm (Boom Swing Cylinder)

14 10 b

b 14 b-

Special Tool for Seal Ring

W566-04-02-011

13

a

7. Install slide rings (9) (2 used) to piston (10) in order not to fit their split positions.

10

8. Install the cylinder head (3) assembly to cylinder rod (1).

W566-04-02-010 a-

Special Tool for Seal Ring

b-

Special Tool for Seal Ring

Special Tool for Cylinder Head (Rod Outer Diameter):

ST 7982: 45 mm (Arm Cylinder)

ST 7979: 40 mm (Bucket Cylinder)

ST 7981: 45 mm (Boom Swing Cylinder)

W5-2-6-8

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 9. Install the piston (10) assembly to cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool for piston.

Special Tool for Piston:

ST 3451: 55 mm (Arm Cylinder) m : 1160 N·m (116 kgf·m, 860 lbf·ft)

IMPORTANT: When inserting the cylinder rod (1) assembly, do not drop slide ring (9) from piston (10).

11. Secure cylinder tube (15) on a workbench horizontally. Insert the cylinder rod (1) assembly into cylinder tube (15) by using the special tool.

Special Tool for Cylinder Rod (Tube Inner Diameter):

ST 3450: 50 mm (Bucket Cylinder)

ST 7986: 75 mm (Arm Cylinder)

m : 600 N·m (60 kgf·m, 440 lbf·ft)

ST 7984: 65 mm (Bucket Cylinder)

ST 3451: 55 mm (Boom Swing Cylinder)

ST 7988: 85 mm (Boom Swing Cylinder)

12. Tighten cylinder head (3) to cylinder tube (15) by using hook wrench (a). Bend the lock washer in order not to loosen.

m : 1250 N·m (125 kgf·m, 920 lbf·ft)

Diameter of cylinder head (3):

(Arm Cylinder): 90 mm m : 422 N·m (42 kgf·m, 310 lbf·ft)

Special Tool for Cylinder: ST 5908

(Bucket Cylinder): 82 mm m : 320 N·m (32 kgf·m, 235 lbf·ft)

W158-04-02-022

10. Install steel ball (11) to piston (10). Install set screw (12). Crimp set screw (12) by using a punch (2 places).

(Boom Swing Cylinder): 105mm m : 490 N·m (49 kgf·m, 360 lbf·ft) a

l : 4 mm m : 17 N·m (1.7 kgf·m, 12.5 lbf·ft)

15

a-

W5-2-6-9

Hook Wrench

W506-04-02-019

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder (Blank)

W5-2-6-10

MEMO

MEMO

Hitachi Construction Machinery Co. Ltd Attn: Technical Information Center Tel: 81-29-982-7084 Fax: 81-29-831-1162 E-mail: HCM-TIC-GES@hitachi-kenki.com

Hitachi Ref. No.

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