Kobelco 80CS-2 ACERA Hydraulic Excavator Disassembling & Assembling Manual

31. DISASSEMBLING AND ASSEMBLING

31. DISASSEMBLING AND ASSEMBLING TABLE OF CONTENTS 31.1 DISASSEMBLY & ASSEMBLY OF THE WHOLE MACHINE ............................ 31-3 31.1.1 DISASSEMBLY & ASSEMBLY .................................................................. 31-3 31.1.2 INDICATION OF TIGHTENING TORQUE ................................................. 31-3

31

Book Code No. S5YN3129E01 31-1

31. DISASSEMBLING AND ASSEMBLING

Issue

Data of Issue

Applicable Machines

First Edition

December, 2008

SK200-8 : YN12-56001~ SK210LC-8 : YQ12-08001~

S5YN3129E01 (SE Asia & Oceania)

↑

February, 2009

SK330-8 : LC11-08501~

↑ SE Asia (HS Engine)

↑

↑

E265B : LQ13-07001~ E265BLC : LL13-06001~

↑ (NHK-TUR)

↑

↑

SK460-8 : LS11-02501~ SK480LC-8 : YS11-02001~

↑ (SE Asia & Oceania)

↑

March, 2009

E385B : LC11-08501~ E385BLC : YC11-04501~

↑ NHK-RUS (HS Engine)

↑

↑

E385B : LC11-08501~ E385BLC : YC11-04501~

↑ NHK-Mid.East & Afr. (HS Engine)

↑

↑

SK460-8 : LS11-02501~ SK480LC-8 : YS11-02001~

↑ SE Asia (HS Engine)

↑

April, 2009

E235BSR : YF06-02501~ E235BSR(N)LC : YU06-03001~

↑ (NHK-EUR)

↑

↑

SK235SRLC-2 : YU06-03001~

↑

May, 2009

SK235SR-2 : YF06-02501~ SK235SRLC-2 : YU06-03001~

↑

June, 2009

SK125SR : YV06-05501~ SK125SRL : LD06-01801~ SK135SR-2 : YY06-15001~ SK135SRLC-2 : YH06-08001~

↑ (SE Asia & Oceania)

↑

July, 2009

SK140LC-8 : YP09-05001~

↑ (SE Asia)

↑

↑

SK70SR-2 : YT06-18001~

↑ (SE Asia & Oceania)

↑

August, 2009

SK80MSR-2 : LF06-04501~

↑ (Oceania)

↑

September, 2009

SK225SR : YB06-03501~ SK225SRLC : LA06-02501~

↑

November, 2009 SK850LC : LY02-00151~

↑

February, 2010

↑

June, 2010

SK80CS-2 : LF06-04501~

↑

↑

E80BMSR : LF06-04501~

↑

↑

E70BSR : YT06-18001~

↑

↑

70SR-2 : YT06-18001~

SK140LC-8 : YP09-T0101~ SK130-8 : LP09-T0101~ SK130L-8 : LX07-T0101~

31-2

Remarks

↑ (NA) ↑ (OCE)

↑ (OCE) ↑ (SE Asia) ↑ (TKCM) ↑ (NA) ↑ (NHK) ↑ (NHK-EUR) ↑ (NA)

31. DISASSEMBLING AND ASSEMBLING

31.1

DISASSEMBLY & ASSEMBLY OF THE WHOLE MACHINE

31.1.1 DISASSEMBLY & ASSEMBLY The next three chapters explain disassembly and assembly of the complete machine: (1) ATTACHMENTS : Chapter 32 1) Removing and Installing 2) Disassembling and Assembling a. Cylinder (2) UPPER STRUCTURE : Chapter 33 1) Removing and Installing 2) Disassembling and Assembling a. Hydraulic Pump b. Control Valve c. Pilot Valve (ATT) d. Pilot Valve (Travel) e. Slewing Motor f. Swivel Joint (3) TRAVEL SYSTEM : Chapter 34 1) Removing and Installing 2) Disassembling and Assembling a. Travel Motor

31.1.2 INDICATION OF TIGHTENING TORQUE Tightening torque is indicated as follows, for example ; T = 98 N-m (72 lbf-ft) Tolerance is to 10% unless otherwise specified.

•

Refer to "Chapter 11 TOOLS" for standard tightening torque.

31

31-3

31. DISASSEMBLING AND ASSEMBLING

31-4

32. ATTACHMENTS

32. ATTACHMENTS TABLE OF CONTENTS 32.1 REMOVING AND INSTALLING .........................................................................32-3 32.1.1 ATTACHMENT ASSEMBLY .......................................................................32-3 32.1.2 BUCKET ....................................................................................................32-4 32.1.3 ARM ...........................................................................................................32-7 32.1.4 BOOM ........................................................................................................32-10 32.1.5 SWING .......................................................................................................32-15 32.1.6 DOZER ......................................................................................................32-17 32.2 DISASSEMBLING AND ASSEMBLING .............................................................32-19 32.2.1 CYLINDER .................................................................................................32-19

32

Book Code No. S5LF3212E01 32-1

32. ATTACHMENTS

Issue

Date of Issue

First Edition

June, 2010

Applicable Machines 80CS-2 : LF06-04501~

Remarks S5LF3212E01 (NA)

PREFACE (1) This Manual describes all the procedures from removing to attaching, arranging them by item.

(2) This Manual consists of 2 sections. "Removing and Installing", and "Disassembling and Assembling".

(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of actual repairing or time saving some process can be omitted.

(4) The removing and installing procedure does not completely cover all possible situations because of differences of field condition and defective section.

(5) Please be aware that the procedure to be followed must be determined according to the above conditions.

When disassembly and assembly are required, select the necessary section, itemize the work contents with good understanding, then start working.

32-2

32. ATTACHMENTS

32.1

REMOVING AND INSTALLING

32.1.1 ATTACHMENT ASSEMBLY SWING CYLINDER ROD PIN (M)

SWING CYLINDER HEAD PIN (N)

BOOM CYLINDER HEAD PIN (B) SWING CENTER PIN (UPPER) (L1)

BOOM CYLINDER ROD PIN (C)

BOOM INSTALL (FOOT) PIN (A)

ARM CYLINDER HEAD PIN (D) BOOM TOP PIN (F)

BUCKET DRIVE PIN (J)

BUCKET ATTACHING IDLER LINK PIN (K) PIN (I) BUCKET CYLINDER ROD PIN (H) ARM CYLINDER ROD PIN (E)

SWING CENTER PIN (LOWER) (L2)

BUCKET CYLINDER HEAD PIN (G) DOZER CYLINDER ROD PIN (Q) DOZER CYLINDER HEAD PIN (R)

DOZER PIN (P) Front attachment and position

32

32-3

32. ATTACHMENTS 32.1.2 BUCKET 32.1.2.1 REMOVING BUCKET (1) Put the machine in position to remove bucket.

Position to remove bucket (2) Removing pin (2) Expand slit of ring (1) with screwdriver, and remove it. Push out the pin (2) with flat-blade screwdriver .

BOSS SECTION DRIVER 2

1

SECTION OF BOSS Removing pin (2) (3) Removing bucket attaching pin (K) Lift up bucket, position it so that bucket attaching pin (K) is not loaded, adjust bucket link, and pull out bucket attaching pin (K).

K

Removing bucket attaching pin (4) Removing bucket drive pin (J) Put bucket on the ground, position it so that the bucket drive pin (J) is not loaded, adjust bucket link, and pull out pin (J).

Store the removed pin (J) in original position again.

J

Removing bucket drive pin

32-4

32. ATTACHMENTS 32.1.2.2 ATTACHING BUCKET (1) Attaching bucket drive pin (J) Attach bucket drive pin (J) first, then continue in the reverse procedure of removing.

J

Attaching bucket

-When aligning the pin holes, do not put your finger in the pin holes, but align them visually.

-Check the seals for damaged and replace as necessary.

-When inserting the pin, coat the shaft with grease.

32

32-5

32. ATTACHMENTS 32.1.2.3 PROCEDURE FOR ADJUSTING CLEARANCE Adjustment of clearance between bucket and arm (1) Shift O-ring (3) toward the bucket boss, using a spatula. (a-->b) (2) When adjusting clearance (B), bring the nonadjusting side of the bucket in contact with the arm.

(3) Measure clearance (B) and check that it is within 1.0 mm (0.04 in).

(4) Adjust clearance (B) where it is more than 1.0 mm (0.04 in).

(5) An average of 5 shims (8) of 1 mm (0.04in) thickness are set in the plate (6) fixed by the three capscrews (10). The clearance can be decreased by 1mm (0.04 in) if one shim is removed.

Tools: Socket: 19 mm, Tightening torque : 59 N-m (44 lbf-ft) (6) After adjustment, tighten the capscrews evenly.

-The gap exceeding the specified dimension causes early wear.

(7) Operate the bucket and confirm that the total sum of both clearance is within 1.0 mm (0.04 in).

(8) Replace O-ring (3) in its original position.

Adjusting clearance between bucket and arm

-When shifting O-ring (3) by means of a spatula, use care so as not to damage O-ring (3).

-Remove shims (8), push out bushing (7) rightward by means of three capscrews (10) and adjust clearance (B) so it settles within the standard value evenly all round.

-Check the clearance at 120 hours intervals in normal operation. Shorten these intervals in special hard operation.

Adjust the intervals as necessary.

32-6

32. ATTACHMENTS 32.1.3 ARM 32.1.3.1 REMOVING ARM (1) Put the machine in position to remove arm.

Extend the arm cylinder, retract the bucket cylinder and bring the arm down on the ground.

Position to remove arm (2) Disconnecting piping of bucket cylinder Release pressure of hydraulic tank, place oil pan to prepare for oil leaking, and disconnect pipes.

When the removal of bucket cylinder is not required, skip to procedure (6).

Disconnecting piping of bucket cylinder

Plug both end of disconnected pipes.

Plug: Tools section 11.5.2-(4) (3) Removing bucket cylinder rod pin (H) 1. Loosen nut (8), remove capscrew M12X100 (7), and push out pin (H).

Tools: Spanner: 19mm 2. Retract cylinder rod.

SHIM

Insert resin shim into bucket link side.

RESIN SHIM After adjustment of shim, the total gap should be within 0.6~1.0 mm (0.02~0.04 in).

SHIM

7 (H)=6

32

13 DUST SEAL

8

SECTION DD SHIM

RESIN SHIM Insert resin shim into bucket link side.

Detail of bucket cylinder rod pin (H)

32-7

32. ATTACHMENTS (4) Removing cylinder head pin (G) Loosen nut (3), remove capscrew M12X100 (2), and push out pin (G).

SHIM

Insert resin shim into bucket link side.

RESIN SHIM After adjustment of shim, the total gap should be within 0.6~2.0 mm (0.02~0.08 in).

SHIM

Tools: Spanner: 19 mm

2

3

(G)=1

SECTION AA

Detail of bucket cylinder head pin (G) (5) Removing bucket cylinder Sling tube of bucket cylinder with nylon sling, and remove it.

Bucket cylinder weight: 48 kg (106 lbs)

Slinging bucket cylinder (6) Removing arm cylinder rod pin (E) Loosen nut (3), remove capscrew (2), and push out arm cylinder rod pin (E).

Tools: Spanner: 22mm Retract arm cylinder rod, and return pin (E) to the original position (hole).

ARM CYLINDER

SHIM

A (E) B B

Insert resin shim into cylinder side.

RESIN SHIM After adjustment of shim, the total gap should be within 0.6~2.0 mm (0.02~0.08 in).

BOOM TOP PIN (F)

SHIM

A

2 BUCKET CYLINDER

(E)=1 SECTION BB 3 Detail of arm cylinder rod pin (E)

32-8

32. ATTACHMENTS (7) Removing boom top pin (F) Loosen remove capscrew (2), and pull out boom, top pin (F).

Put block between arm cylinder and boom.

Tools: Spanner: 19mm

Insert resin shim into cylinder side.

RESIN SHIM

SHIM

Apply Loctite #242

Insert pin (F) into the original hole.

After adjustment of shim, the total gap should be within 0.5 mm (0.02 in).

SHIM

1,2

(F)=1 SECTION AA Detail of boom top pin (F) (8) Slinging arm assembly Sling arm with nylon sling and remove it.

Arm weight: 255 kg (562 lbs) (with bucket cylinder) 205 kg (452 lbs) (without bucket cylinder)

Slinging arm assembly

32.1.3.2 ATTACHING ARM

4. Pin lock nut handling procedure Tools: Spanner: 24 mm 5. When installing the arm and the cylinder, inspect the clearance in the thrust direction of the pins and decide the thickness of shims by referring to the Maintenance Standard.

6. Tightening torque

Classfication Metric threads PF,PT threads

Size

Tightening torque N .m lbf.ft

M12

115

85

M14

144

106

1/8"

16.7

12.3

(0.02")

Instal the arm in the reverse order of removing, paying attention to the following: 1. When aligning the pin holes, do not put your finger in the pin holes, but align them visually.

2. Check the seals for damage and replace as necessary.

3. When inserting the pin, coat the shaft with grease.

CLEARANCE

32

32-9

32. ATTACHMENTS 32.1.4 BOOM 32.1.4.1 PREPARATION FOR REMOVING AND ATTACHING BOOM When removing and attaching boom in the position shown in below Fig. to remove and attach boom foot pin (A), removing and attaching of cab and guard are required.

32.1.4.2 REMOVING BOOM (1) Put the machine in position to remove boom.

Place top end of boom down on block, etc. giving attention for arm cylinder rod not to be extended.

A TIE

WOOD BLOCK Position to remove boom (2) Lifting up boom cylinder temporarily Lift up boom cylinder temporarily to prevent it from dropping.

Lifting up boom cylinder temporarily (3) Removing boom cylinder rod pin (C) Loosen nut (7), remove capscrew (3), and push out pin (C).

(4) Preparing for separating cylinder pipes Retract boom cylinder rod side, and place one side of cylinder on block (See Fig. "Lifting up boom cylinder temporarily")

Insert resin shim into bucket link side.

RESIN SHIM

IRON SHIM

After adjustment of shim, the total gap should be within 0.6~2.0 mm (0.02~0.08 in).

SHIM

3 1=(C)

7

SECTION AA Detail of boom cylinder rod pin (C)

32-10

32. ATTACHMENTS (5) Separating piping of arm cylinder and bucket cylinder Release pressure in hydraulic tank, and separate pipe at section E-E. Tools: Spanner: 36mm After separation of pipe, plug every pipe.

Plug : Tools section 11.5.2-(4)

BUCKET (R) ARM (R) ARM (H) BUCKET (H)

SECTION EE Boom piping disconnection (6) Lifting up boom assembly temporarily Lift up boom cylinder with nylon sling so that boom foot pin (A) is not loaded.

Weight of boom assembly : 480 kg (1060 lbs)

32

Boom assembly temporarily lift up procedure

32-11

32. ATTACHMENTS (7) Removing boom foot pin (A) Remove capscrew (2) for locking boom foot pin (1) and pull out pin (1).

Total clearance of both sides to be 0.1~0.5mm (0.00394~0.0197in) or less after adjusting by shims.

Apply grease.

1=(A) 2 3 Details of boom foot pin (A)section

Removing pin (A) using slide hammer (8) Slinging boom assembly Sling and remove boom assembly.

Weight of boom assembly : 480 kg (1060 lbs)

Boom assembly slinging procedure

32-12

32. ATTACHMENTS (9) Completion of removal of front attachments When the removing and attaching of cylinder are not required, the work is finished.

(10)Removing arm cylinder Disconnect hose at A section, and plug both ends.

Plug: TOOLS 11.5.2-(4) Plugs for ORS fitting Tools: Spanner: 36mm Tightening torque : 216 N-m (160 lbf-ft) Tools: Spanner: 27mm Tightening torque : 108 N-m (80 lbf-ft) (11)Removing arm cylinder head pin (D) Loosen nut (3), remove capscrew (2) and pull out pin (D).

Removing arm cylinder (2).

Weight of arm cylinder: 68 kg (150 lbs)

Opposing flats 27

A Opposing flats 27 Opposing flats 36 Insert resin shim into cylinder side.

RESIN SHIM

Opposing flats 36 IRON SHIM

(D)=1

3 2 SHIM After adjustment of shim, the total gap should be within 0.6~1.0 mm (0.02~0.04 in)

Removing arm cylinder (12)Removing boom cylinder Disconnect hose at B section. Plug both ends. plug : Tools section 11.5.2-(4) Tools: Spanner: 36mm Tightening torque : 216 N-m (160 lbf-ft)

B Opposing flats 36

Opposing flats 36

Removing boom cylinder (13)Removing boom cylinder head pin (B) Loosen capscrew (4) and pull out pin (B).

PLASTIC SHIM

IRON SHIM

PIN (B)

4

SHIM Total clearance of both sides to be 0.6~1.0mm (0.02~0.04in) or less after adjusting by shims.

Removing boom cylinder head pin (B)

32

32-13

32. ATTACHMENTS 32.1.4.3 ATTACHING BOOM (1) Attaching boom foot pin (A) Attach it in the reverse procedure of removing paying attention to the following points.

1. When aligning the pin holes, do not put your finger in the pin holes, but align them visually.

2. Check that the dust seals is not damaged and replace as necessary.

3. When inserting the pin, coat the shaft with grease.

4. M10 Tightening torque : 65.7 N-m (48.5 lbf-ft)

(A)

(B) Boom cylinder head pin (B) (0.02")

5. Pin lock nut handling procedure

CLEARANCE

6. To attach shim, fit resin shim on operating side and iron shim on the outside, and reduce the space.

PLASTIC SHIM

IRON SHIM

PIN (B)

CAPSCREW

SHIM Total clearance of both sides to be 0.6~1.0mm (0.02~0.04in) or less after adjusting by shims.

Attaching boom cylinder head pin (B)

32-14

32. ATTACHMENTS 32.1.5 SWING 32.1.5.1 REMOVAL OF SWING BRACKET AND CYLINDER (1) Preparation for removal 1. To make the removing work easy, swing by around 30° for leftward.

2. Remove cover (D1) then disconnect the hoses of bucket cylinder, arm cylinder and boom cylinder, and apply plugs to all the openings.

Tools : Spanner : 27 mm 32.1.5.2 REMOVAL OF SWING BRACKET (A9) (1) Removing the capscrew (C5) that is preventing the rod pin (C1) of swing cylinder (C) from coming out, remove the pin (C1).

Tools : Socket : 19 mm (2) Install the boom foot pin (D) to the original position on swing bracket (A1), then temporarily lift it up.

(3) Removing two capscrews (E3) those are preventing the pin (E1) (E2) from coming out, remove the pin (E1) (E2).

Tools : Socket : 24 mm (4) Remove the swing bracket (A1).

Weight of swing bracket : 245 kg (540 lb)

32.1.5.3 REMOVAL OF SWING CYLINDER (C) (1) Disconnect 2 connecting hoses for the swing cylinder.

Tools : Spanner : 22 mm (2) Removing the capscrew (C5) that is preventing the head side pin (C2) of swing cylinder from coming out, remove the pin (C2).

Tools : Socket : 19 mm (3) Take out the swing cylinder (C) from the machine front side.

Weight of swing cylinder : 70 kg (154 lb)

D1 E1

C5

A1

C1

E3

D

E2 C

C2 C5

Parts for swing

32-15

32

32. ATTACHMENTS 32.1.5.4 INSTALLATION OF SWING BRACKET AND CYLINDER Installation is performed in the reverse order of removal, including the following workings.

(1) Check the dust seal for damages, and replace the faulty dust seal to new one.

(2) Referring to the Chapter 3 "ATTACHMENT DIMENSIONS" replace the worn-out pin and bush to new ones.

(3) Before inserting the pin, apply grease to the shaft area.

(4) Referring to Fig. below, apply Loctite #242 and tighten the capscrew and nuts to prevent the pin from coming out.

(5) Refer to Fig. below for the shim adjustment at pin installing portion.

(6) For the adjustment for clearance, insert resin shim first, then adjust the clearance with iron shims.

To be face the groove of washer to the lower side.

B

D

D

D

D

A

A

C

C

Clearance to be 0.5mm (0.0197in) or less after SECTION C-C adjusting with shims.

SECTION A-A

SECTION B-B

Sectional view of installing pin

32-16

3.0 (0.02")

Total clearance of both sides to be 0.1~0.5mm (0.00394~0.0197in) or less after adjusting with shims.

1.0~1.5 (0.04"~0.06")

Total clearance of both sides to be 0.5~0.9mm (0.0197~0.0354in) or less after adjusting with shims.

SECTION D-D

32. ATTACHMENTS 32.1.6 DOZER 32.1.6.1 REMOVAL (1) Put a support of appropriate height under the mounting side of dozer body, and make the dozer at a stable condition not to exert any load to the pin (P).

(2) Disconnect the hydraulic hoses and apply a plug to the connecting portions.

Tools : Spanner : 22 mm (3) Apply a nylon sling to the dozer cylinder (C1), and lift it up slightly not to exert any load to the pin (Q) of rod side.

(4) Remove the capscrew (C2) and nuts (C3) those are preventing the pin (Q) from coming out. Remove the pin (Q), and support the cylinder (C1) with wood block, etc.

Tools : Spanner : 19mm (5) Remove the capscrew (B2) and nuts (B3) that are preventing the dozer body fixing pin (Q) from coming out, and remove the two pins (P).

Tools : Spanner : 19mm (6) Gradually move the machine to backward to remove the dozer.

Weight of dozer assembly : 450kg (992 lbs) (7) If necessary, remove the dozer cylinder by means of removing the pin (R) of head side.

Weight of dozer cylinder : 58 kg (128 lbs)

R

Q

C2, C3

C1

SUPPORT

P

B2, B3

Removing / Installing Dozer

32.1.6.2 INSTALLATION The installation is carried out with the reverse order of the removal paying attention for the following.

(1) Referring to the Section "ATTACHMENT DIMENSIONS" of Specifications, replace the wornout bushings and dust seals to new ones.

(2) Before installing pin (P), (Q) and (R), apply grease to their shaft area.

(3) Referring to right Fig., install the nuts for capscrew to prevent the pin from coming out.

Tools : Spanner : 19mm

NUT

0.5~1.0 (0.02"~0.04")

STOPPER CAPSCREW

Tightening Procedures for Nuts

32-17

32

32. ATTACHMENTS

This page is blank for editing convenience.

32-18

32. ATTACHMENTS

32.2

DISASSEMBLING AND ASSEMBLING

32.2.1 CYLINDER 32.2.1.1 PREPARATION BEFORE DISASSEMBLY Before disassembly, secure a dustfree workshop and necessary equipment and facilities.

32.2.1.1.1 WORK AREA The following working area is required for disassembly: (1) Ample space For the disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be drawn out. For this reason, the first condition is that the working area is long enough for the work. In terms of width, it is also necessary to keep sufficient space to disassembly, cleaning and measuring equipment are placed and the work can be performed.

(2) Suitable working environment The hydraulic cylinder is a precision-machined product that uses seals and packings made of rubber and plastic materials. For this reason full care should be exercised so the hydraulic cylinder is free from dust, dirt, and in particular, such hard particles as sand, metal chips, and weld slag (spatter). If the hydraulic cylinder is assembled with hard particles adhered on such components as the cylinder tube and the piston rod, the tube inner surface and the rod surface are scratched as the cylinder operates, consequently disabling it in worst cases. Damage to the piston seals and the rod seals will result in oil leaks. For this reason, grinding and welding operation should not be performed in the neighborhood of the working area to keep it clean.

32.2.1.1.2 APPARATUS The following equipment are required for disassembly: (1) Hoist or crane The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable of making level and liner movement under load for retracting and extending the piston rod and the tube.

(2) Work bench The work bench must have strength and rigi-dity capable of accommodating the total length of the cylinder in its most retracted condition and of withstanding the repulsive force of the tightening torques of the cylinder head and the piston nut. Since a vise is attached to the bench, the width of the work bench must be sufficiently large.

(3) Support stand If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the rod bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod to prevent damage of seals.

(4) Hydraulic source A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut and for oil leak tests after completion of assembly.

(5) Jet air source It is used for drying after oil draining and cleaning of the cylinder.

(6) Cleaning bath, cleaning oil and detergent (7) Oil pan and oil reservoir An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work.

(8) Others Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also necessary.

32-19

32

32. ATTACHMENTS 32.2.1.1.3 NECESSARY TOOLS List of Tools and Jigs Tool/Jig Hammer

Remarks

Tool/Jig

1. Steel hammer 2. Wooden or plastic hammer

Spatula

Metallic one with smooth corners.

Gimlet

A sharp-point tool may be used in place of a gimlet.

Screwdriver A few types of large and small sizes Chisel

Vise

Wrench

•

Flat chisel

Special jig

One having an operation wide enough to hold cylinder head O.D. and tube mounting pins (clevis) 1. Eye wrench 2. Allen wrench 3. Extension pipe for wrenches

Remarks

1. For fitting seal ring 2. For pushing seal ring 3. For inserting bushing 4. For press-fitting wiper ring

Rust remover Measuring 1. Slide caliper instruments 2. Micrometer 3. Cylinder gauge (Fig. "Cylinder gauge") 4. V-block

For the details of special tools and jigs, refer to the back pages of this manual.

32.2.1.1.4 EXTERNAL CLEANING The cylinder taken off the excavator has dust and foreign matter, and grease is usually adhered to the clevis part. For this reason, remove external soil and contamination from the cylinder with water and steam before bringing it into the workshop.

-The following describes the construction of arm cylinder (with cushions on both sides). When disassembling and servicing the cylinder, confirm the construction of cylinder referring to Parts Manual.

Cylinder gauge

32.2.1.1.5 DISCHARGING OIL Place a wooden-block on the work bench and place the cylinder on it to prevent it from rotating. Charge air into ports A and B alternately to actuate the piston rod till the hydraulic oil in the cylinder is drained out. At this time, connect a suitable hose to each port so that the hydraulic oil may not gush out.

WOODEN BLOCK PORT B V BLOCK PORT A

AIR

OIL PAN

Preparation

32-20

32. ATTACHMENTS 32.2.1.2 CONSTRUCTION OF CYLINDER (AN EXAMPLE OF ARM CYLINDER)

95 (3.74")

95 (3.74")

T=Torque : N.m (lbf.ft) (Thread)

25 26

26 25 2-PF1/2 O-Ring port

PT1/4 T=31.5(23.2)[M10 1.5] After tightening, fit it with punch caulking on two portions.

PS1/8

T=570(420)[M102 2] Apply three-bond #1901 on the thread T=3000 (2213)[M48

9 8 3 7 11 6 4 10

5

13 12 9 3, HEX75]

2 1 14 15 1618 17

20 19

24

21 22 23 DETAIL S

S

With one hole

Orientation of cut off part of cushion bearing

Location of the slit is shown in the drawing

Construction of cylinder (An example of arm cylinder) No.

NAME

Q'ty

No.

NAME

Q'ty

No.

NAME

Q'ty

1

CYLINDER TUBE ASSEMBLY

1

11

O-RING

1

21

CUSHION BEARING

1

2

PISTON ROD ASSEMBLY

1

12

HOLDER

1

22

CUSHION SEAL

1

3

ROD COVER

1

13

BACKUP RING

1

23

STOPPER

2

4

BUSHING

1

14

CUSHION BEARING

1

24

SNAP RING

1

5

SNAP RING

1

15

CUSHION SEAL

1

25

PIN BUSHING

4

6

BUFFER RING

1

16

PISTON

1

26

WIPER RING

4

7

U-RING

1

17

SEAL RING ASSEMBLY

1

8

WIPER RING

1

18

SLIDE RING

2

9

O-RING

2

19

SET SCREW

1

10

BACKUP RING

1

20

STEEL BALL

1

32-21

32

32. ATTACHMENTS 32.2.1.3 DISASSEMBLY • •

Before starting disassembling and servicing, confirm the construction and supply parts referring to Parts Manual in the separate volume, and also required tools and jig.

Figures noted just after the "Part name" correspond to the number stated in Fig. "Construction of cylinder (An example of arm cylinder)". Other cylinders may have some different parts.

32.2.1.3.1 REMOVING ROD COVER AND PISTON ROD (1) Fix the tube installing pin side using a vise. (Refer to 32.2.1.1.5 "Preparation".)

Take care not to damage the cylinder tube and machined surface.

Never use external pipe to stop turning.

(2) Pull piston rod (2) out about 200 mm (8 in).

Use air to push piston rod (2) out after draining the oil because of the weight of piston rod (2).

(3) Flatten the lock on slit section installed between rod cover (3) and cylinder tube (1) with chisel and hammer.

(4) Lift up cylinder rod section with nylon sling temporarily.

(5) Then, Hook a hook wrench to rod cover (3), turn it counterclockwise and remove it.

Special tool : Refer to 32.2.1.8(7).

(6) After putting threads out of mesh, remove the end of rod cover (3) using plastic hammer.

m

m 00 x, 2 o r App (8")

2 Removing piston rod CHISEL (Meet the width of chisel with the groove width, flatten the lock washer)

1 3

HAMMER

BENT-UP PORTION ON THE ROD COVER

Flatten the slit lock If pipe does not found, strike this portion with hammer.

1 Turn counter clockwise

Sling

Pull it straight out horizontally

Cover this portion with cloth.

3 3

Removing rod cover

OIL PAN

Pulling piston rod out

In this case, apply the hoisting force equivalent to the weight of piston rod, because the weight of piston rod weights upon the rod cover.

32-22

32. ATTACHMENTS (7) Place pulled out piston rod assembly (2) on the wooden V-block horizontally.

16 2

WOODEN V-BLOCK (cover with cloth.)

Placing piston rod assembly Remove slide ring (18).

Expand the slit portion in 45 degrees and remove.

18 Removing slide ring

32.2.1.3.2 REMOVING PISTON ASSEMBLY (1) Fix piston rod (2) grasping the installing pin portions with vise. Then fix it in strength so that it can withstand the tightening torque for piston rod (2) because the piston rod (2) is secured with large tightening torque.

2

WOODEN BLOCK

16

WOODEN V-BLOCK Cover with cloth.

Fixing piston rod assembly (2) Shave off the caulked section on set screw (20) with hand drill, loosen set screw and take out steel ball (21).

DRILL

STEEL BALL

Removing setscrew

32-23

32

32. ATTACHMENTS (3) Remove nut section of piston with a closed wrench.

Special tool : See 32.2.1.8 (8) -Since the piston section (16) is tightened by high torque, use the closed wrench closely fitted to the width across flat.

-Approx. 1.5 times or higher of torque is required to loosen piston nut. So prepare power wrench equipped with hydraulic jack or hydraulic cylinder, if possible.

EYE WRENCH 1.0 (3'3 ~1.5 "~4 m '11 ")

Turn counter clockwise

Removing piston nut

(4) Removing cushion bearing on the retraction side.

1.

Remove snap ring (24). Strike it lightly being careful not to damage cushion bearing and piston rod.

2.

Move cushion bearing (21) to threaded side, and remove stopper (23) (two pieces type).

3.

Pull out cushion bearing (21).

4.

Expand slit (1 place) of cushion seal (22) and remove it.

(5) Removing cushion bearing on extension side.

1.

Pull out cushion bearing (14).

2.

Expand slit (1 place) on cushion seal (15) and remove it.

16

THREADED PART

CUSHION BEARING (21)

STOPPER (23) (DIVIDE INTO 2 PORTIONS)

CUSHION SEAL (22) SNAP RING (24) PISTON ROD (2)

SLITTING (1 PLACE)

Disassembling cushioning bearing

CUSHION SEAL (15)

CUSHION BEARING (14)

SLITTING (1 PLACE)

Disassembling cushioning bearing

32.2.1.3.3 DISASSEMBLING PISTON ASSEMBLY Removing piston seal (1) Remove slide ring (18) by hand.

(2) Cut seal ring (17) with driver (-) and hammer as shown in the right figure.

(3) Pull out O-ring with spatula.

(4) Strictly prohibited to use pulled out seal parts.

SEAL RING (17) SLIDE RING (18) WOODEN PIECE VISE

O-RING

Disassembling piston assembly

32-24

32. ATTACHMENTS 32.2.1.3.4 REMOVING ROD COVER ASSEMBLY Remove rod cover assembly from piston rod (2). If it is too difficult to remove, strike flange section of rod cover (3) with plastic hammer.

Hang the rod cover assembly with crane and remove it straight horizontally.

Strike with a plastic mallet

Lift here

Pull straight

2

4

3

Removing rod cover assembly

Care should be taken not to damage the bushing (4) lip section of link and seal with screw of piston rod (2) when pulling out rod cover (3).

32.2.1.3.5 DISASSEMBLING ROD COVER ASSEMBLY (1) Removing buffer ring 1. Buffer ring (6) (Teflon made seal) is fitted on the inside of rod cover (3). Pierce with pointed tool on the seal, raise it, insert spatula and take it out.

-Strictly prohibited to use the removed seal.

BUFFER RING (6)

O-RING AND BACK-UP RING (9, 10) (9, 12)

WIPER RING (8)

BUSHING (4) SNAP RING (5) U RING (7)

Construction of rod cover assembly (2) Removing U-ring (7) and wiper ring (8) 1. Remove U-ring (7) with driver, etc.

2. The wiper ring (8) is press-fitted.

Pierce with driver, etc. on rubber and strike and remove it with driver.

-Strictly prohibited to use removed seal.

BUFFER RING ASSY (SQUARE RING + SLIDE RING) SQUARE RING (PROJECTION)

SLIDE RING (SLITTING)

32 SNAP RING

Direction of buffer ring

32-25

32. ATTACHMENTS (3) Removing bushing (4) Raise snap ring (5) with hooked bar and take it out from cylinder rod cover. And press out bushing (4) with jig. If it is too difficult to take it out with jig, use lathe to remove it.

Push with a press JIG

ROD COVER (3)

BUSHING (4)

JIG

Removing bushing (4) Removing pin bushing 1. Remove wiper ring (26).

2. The pin bushing (25) of piston rod (2) is pressfitted, so press it out with a press applying a plate to the section.

WIPER RING (26)

Push with a press PLATE

25

BASE

Drawing out pin bushing (rod & tube)

Where it is impossible to press it out, cut it with gas burner.

(5) Cleaning 1. After completion of cylinder disassembly, clean all the parts with detergent.

Apply hydraulic oil on them and cover them to store.

Leaving them in the as-disassembled condition causes rust, adherence of dust, etc., which may cause malfunction after assembling.

2. Replace all of U-ring, wiper ring, O-ring and backup ring as a general rule.

Do not use volatile agents (gasoline and thinner) as they deteriorate rubber.

32-26

32. ATTACHMENTS 32.2.1.4 INSTALL • • • •

Cylinder tube assembly Piston rod assembly Rod cover assembly Piston assembly

32.2.1.4.1 ASSEMBLING CYLINDER TUBE ASSEMBLY, PISTON ROD ASSEMBLY (1) Apply hydraulic oil on the head in which pin bushing is inserted and on the pin bushing hole of rod.

(2) Press pin bushing (26) into cylinder tube (1) and piston rod (2), using a press.

(3) Insert wiper ring (27) in both sides.

Push with a press

26

OIL HOLE LOCATION

PLATE PISTON ROD

WIPER RING

PIN BUSHING

Pressing in pin bushing (rod & tube)

32.2.1.4.2 ASSEMBLING ROD COVER ASSEMBLY (1) Press fit bushing (4) in rod cover (3) applying plate on the section. After press-fitting, check that the bushing is not projected from the end surface (A).

(See right Fig.)

Push with a press straight down

PLATE

A

3

4

32 Pressing in bushing

32-27

32. ATTACHMENTS (2) Fit snap ring (5).

(3) Apply hydraulic oil on U-ring (7) and fit it on the Uring groove.

PUSH BAR

5

7 6 9,10 3 10,12

Fitting U-ring

-The U-ring is harder than other seals, so fit it in the groove by hand first, then press in with pushing bar until it is fitted with a click.

-Fitting U-ring paying attention to the direction.

-After fitting U-ring (7), check that they are free from the permanent set.

(4) Installing buffer ring assembly Buffer ring assembly (6) is equipped with square ring and slide ring.

1. Fit square ring on the groove.

2. Depress slide ring in U shape by hand to house it in groove, and fit it pushing out to periphery.

SLIDE RING

SQUARE RING Depress slide ring in U shape to fit.

BUFFER RING ASSY (6) (SQUARE RING + SLIDE RING) SQUARE RING (PROJECTION)

SLIDE RING (SLITTING)

SNAP RING (5)

Installing buffer ring assembly (6)

-Depress it R 6 mm (0.24 in) or more, because if the depressed R is too small, it may remain wrinkled.

-After fitting, check that it is free from wrinkles.

-Fit it giving attention to the seal fitting direction. Reverse fitting produces high pressure between U-ring and seal and may cause the deformation of rod cover.

-Fit slide ring so that the groove matches to the root section of square ring.

32-28

32. ATTACHMENTS (5) Press fit wiper ring (8) by means of Jig 32.2.1.8(4).

Push with a press

8

METAL RING

JIG

RUBBER CLIP

Pressing in wiper ring Fit backup ring (10) and O-rings (9), (12). (Attention should be paid to the fitting order.)

O-RING AND BACK-UP RING (9, 10) (10, 12)

Fixing back-up ring and O-ring

32.2.1.4.3 ASSEMBLING PISTON ASSEMBLY (1) Installing seal ring assembly 1. Fit O-ring so as not to be distorted.

2. Press in seal ring (17) referring to Jig 32.2.1.8(1), (2).

SEAL RING PRESSING JIG

SEAL RING (17) PISTON (16)

PUSH

O-RING

Installing the seal ring (17)

32

32-29

32. ATTACHMENTS 3. Since the seal ring (17) is extended when fitting, press it referring to Correction jig 32.2.1.8(5).

CORRECTION JIG

PUSH

17 Correcting the seal ring (17) 4. Fitting slide ring (18) Fit it from rod side expanding slit by both hands.

-Expand slit in minimum.

If expansion is exceeded, the ring cannot be fitted.

-Slit is mutually shifted 90 degree.

Expand 45 deg. slit section in direction specified by arrow and fit the ring.

18 Installing the slide ring (18)

32.2.1.4.4 INSTALLING ROD COVER ASSEMBLY ON ROD (1) Fix piston rod assembly on work bench.

(2) Apply grease (or hydraulic oil) on outside of piston rod (2), inner surface of buffer ring (6), U-ring (7), wiper ring (8) and bushing (4), and slide rod cover assembly on piston rod (2) taking care not to damage the lip of wiper ring (8).

It may not slide smoothly due to frictional resistance of U-ring. In this case, sling rod cover assembly horizontally with crane, and push it striking flange of rod cover with mallet.

8

3

7

6

4 5

2

Installing rod cover assembly ROD COVER PRESSING JIG ROD COVER

PISTON ROD

PUSH

Pressing rod cover

While pushing, be careful that the rod cover assembly is not rotated to piston rod (2).

32-30

32. ATTACHMENTS 32.2.1.4.5 INSTALLING PISTON ASSEMBLY ON ROD (1) Fitting cushion bearing (14) on the extension side

Before attaching piston (nut ) (16), fit cushion bearing (14). If the piston nut is attached, the bearing can not be fitted.

1. Expand slit of cushion seal (15) and insert it into groove piston rod (2).

2. Fit cushion bearing (14).

CUSHIONING SEAL (15)

CUSHIONING BEARING (14)

CUT OUT FLAT SECTION SLITTING (1 PLACE)

Fitting cushion bearing (14) on the extension side

-Insert cushion seal (15) directing the cut out toward the thread side of rod as shown in Figure.

-Fit cushion bearing (14) directing the flat section toward as shown in Figure.

(2) Fitting cushion bearing (21) on retraction side 1. Fit cushion seal (22) in groove directing the cutout toward the thread side.

2. Assemble cushion bearing (21) directing the flat section toward as shown in Figure.

3. Fit stopper (23) in groove.

4. Push cushion bearing (21) to stopper (23) fully, and strike and fit snap ring (24).

THREADED PART

PISTON ROD (2)

CUSHION BEARING (21) STOPPER (23) (DIVIDE INTO 2 PORTIONS) FLAT SECTION CUSHION SEAL (22)

SNAP RING (24)

CUT OUT

SLITTING (1 PLACE)

Fitting cushion bearing (21) on retraction side

Strike snap ring with plastic hammer being careful not to damage rod (2) and cushion bearing (21).

32

32-31

32. ATTACHMENTS (3) Tightening piston nut 1. Insert piston (nut) (16) into rod, and tighten piston (nut) (16) to the specified torque.

Special tool : See Table 32.2.1.8(8).

Tightening torque : Refer to 32.2.1.7(1).

EYE WRENCH

Tightening piston nut (16) 2. Put steel ball (20) in and tighten setscrew (19).

Tools: Allen wrench, Tightening torque : Refer to 32.2.1.7(2).

3. Caulk 2 places on outer surface with punch.

CAULK

PUNCH

SETSCREW (19)

STEEL BALL (20)

Caulking set screw of piston nut

32-32

32. ATTACHMENTS 32.2.1.4.6 OVERALL INSTALL (1) Place a V-block on a rigid work bench (A wooden V block is preferable.) Mount the cylinder tube assembly (1) on it and fix the assembly by barring a bar through the attaching pin hole to lock the assembly. (See right Fig.) (2) Insert piston rod (2) into cylinder tube (1) while hanging and moving it with crane. Then, apply hydraulic oil on tube lip inner side and piston outer surface and insert horizontally aligning the center of piston rod and center of cylinder tube.

-Also, the use of fork lift makes inserting easier.

-Insert piston into tube being careful that seal ring and slide ring are not caught in the stepped section of tube.

(3) Apply Three Bond #1901 on thread section of rod cover and hydraulic oil on O-ring (12), rotate rod cover assembly (3) by hand. Screw in 2 or 3 threads first, then tighten it to the specified torque with hook spanner wrench.

(4) Bend slit of cylinder tube toward cutout of rod cover (3) to lock.

Bar used to prevent rotation (Wood is preferable) or fix with vise

Lift it lever

PISTON Apply Three-Bond #1901

Installing piston rod SLIT

ROD COVER (3)

CHISEL

Bending lock of slit

32

32-33

32. ATTACHMENTS 32.2.1.5 MAINTENANCE STANDARDS (1) Inspection after disassembly 1. Inspection Parts Name

Piston rod

Cylinder tube

Rod cover

Inspecting Portion

Inspection Item

Remedy

1. Neck of rod pin

Presence of crack

Replace

2. Stepped part to which piston is attached

Presence of crack

Replace

3. Threads

Presence of seizure

Recondition or replace

4. Bend

Measure degree of bend

Refer to rod bend

5. Plated surface

Check that: 1) Plating is not worn off to base 1) Replace or replate metal 2) Replace or replate 2) Rust is not present on plating.

3) Recondition or replace 3) Scratches are not present

6. Rod

Wear of O. D.

Recondition or replace

7. Bushing at mounting part

Wear of I. D.

Replace

1. Weld on bottom

Presence of crack

Replace

2. Tube at mounting part

Presence of crack

Replace

3. Tube interior

Scratches are not present

Replace if oil leak is seen

4. Bushing at mounting part

Wear of I.D.

Replace

1.Bushing

1) Wear on inner surface 2) Flaw on inner surface

Replace

(2) Maintenance standards Replace sliding parts and seal parts according to the following.

1. Bushing: Where 1/4 of circumference is worn in red copper color.

2. Seals and slide ring: Replace them when cylinder is disassembled.

3. Pin bushing: Where severe scuffing is produced.

4. Piston rod: Where the bent 0.5 mm/m (0.02 in / 3.37 in) or more is produced.

(3) Inspection after assembling No-load performance inspection

When operating 5 time or more in full stroke at no-load, it operates smoothly with no abnormality.

Dimensional inspection Check the fully retracted length and stroke specified in drawing.

Pressure inspection

After applying test pressure specified in drawing to each stroke end for 3 minutes or more, it is free from loosening, permanent set and oil leaking.

No-load performance inspection

Check rod section for oil leaking.

(Refer to Criterion of oil leak quantity on rod section in proceeding page.)

Oil leak quantity unit mL (cc) / 10min

Internal leakage inspection

I. D. mm (in)

Oil leak quantity

32 (1.26) 40 (1.57) 50 (1.97) 63 (2.48) 80 (3.15)

0.4 0.6 1.0 1.6 2.3

I. D. mm (in)

Oil leak quantity

100 (3.94) 125 (4.92) 140 (5.51)

4.0 5.6 6.0

32-34

I. D. mm (in)

Oil leak quantity

160 (6.30) 180 (7.09) 200 (7.87) 220 (8.66) 250 (9.84)

10.0 12.6 15.6 20.0 22.0

32. ATTACHMENTS (4) Criterion of oil leak quantity on rod section Determine according to the oil ring condition produced on rod after 20 strokes in oil temperature 20 degC (68 degF) to 40 degC (104 degF). When oil ring is changed to A condition, it is in abnormality. Refer to 32.2.1.9 "Troubleshooting", and take a measure.

OIL RING 2mm 1mm

A Reject

B

C

D

E

F

G

Accept

Oil ring condition on rod section

32.2.1.6 GENERAL TOOL

No.

Tools name

Q'TY 1

1

Flat-bladed screw driver

2

Allen key wrench

3

Vise

4

Spanner (see 32.2.1.8.(8)) (for piston nut)

5

Punch

6

Torque wrench

7

Hammer (Plastic mallet)

1

8

Adjustable wrench

1

9

Spatula

1 set

1

1 set

1 1 set

1 pair

32

32-35

32. ATTACHMENTS 32.2.1.7 TIGHTENING TORQUE (1) Piston nut

Cylinder name Opposing flat A

Tightening torque

Boom

80 mm

3000 N·m (2210 lbf·ft)

Arm

75 mm

3000 N·m (2210 lbf·ft)

Bucket

60 mm

1420 N·m (1050 lbf·ft)

Dozer

80 mm

5100 N·m (3360 lbf·ft)

Swing

75 mm

2510 N·m (1850 lbf·ft)

A

(2) Setscrew

Cylinder name Opposing flat

CAULK

Tightening torque

Boom

6 mm

56.9 N·m (42 lbf·ft)

Arm

5 mm

31.5 N·m (23 lbf·ft)

Bucket

4 mm

16.2 N·m (12 lbf·ft)

Dozer

-

-

Swing

5 mm

31.5 N·m (23 lbf·ft)

PUNCH

SETSCREW

STEEL BALL

(3) Rod cover

Cylinder name

Tightening torque

Boom

834 N·m (615 lbf·ft)

Arm

570 N·m (420 lbf·ft)

Bucket

450 N·m (330 lbf·ft)

Dozer

1360 N·m (1003 lbf·ft)

Swing

736 N·m (540 lbf·ft)

HOOK WRENCH

PIPE

(4) For piping

Piping band Pipe holder Cylinder name Opposing flat Tightening Opposing flat Tightening torque torque Boom

-

-

Arm

31.5 N·m (23 lbf·ft)

19 mm

Bucket

17 mm

Dozer

-

-

Swing

-

-

56.9 N·m (42 lbf·ft) PIPE HOLDER

32-36

PIPING BAND BOLT

32. ATTACHMENTS 32.2.1.8 TOOL AND JIGS LIST (1) Seal ring fitting jig ( I ) Material : Mild steel

Unit: mm(in) Applicable cylinder

(D2)

D3

L0

(L1)

L2

111 (4.3701) 110 (4.3307)

86 (3.39)

96 (3.78)

100 (3.94)

72 (2.83)

24 (0.9449)

Arm

96 (3.7795)

95 (3.7401)

71 (2.80)

81 (3.19)

100 (3.94)

72 (2.83)

23 (0.9055)

Bucket

81 (3.1890)

80 (3.1496)

56 (2.20)

66 (2.60)

100 (3.94)

72 (2.83)

20 (0.7874)

Dozer

131 (5.1575) 130 (4.1181)

111 (4.37)

116 (4.57)

99 (3.90)

66 (2.60)

28 (1.1024)

Swing

106 (4.1732) 105 (4.1339)

81 (3.19)

91 (3.58)

100 (3.94)

72 (2.83)

23 (0.9055)

Boom

D0

D1

32

32-37

32. ATTACHMENTS (2) Seal ring fitting jig ( II ) Material : Nylon or acrylic resin

Unit: mm(in) Applicable cylinder

D0

D1

L

Boom

112 (4.41)

104 (4.09)

100 (3.9370)

Arm

97 (3.82)

89 (3.51)

100 (3.9370)

Bucket

82 (3.23)

74 (2.91)

100 (3.9370)

Dozer

132 (5.20)

124 (4.88)

100 (3.9370)

Swing

107 (4.21)

99 (3.9)

100 (3.9370)

32-38

32. ATTACHMENTS (3) Bushing press-fit jig Material : Mild steel

Unit: mm(in) Applicable cylinder

D0

D1

(D2)

D3

L0

(L1)

Boom

85 (3.3465)

79.5 (3.13)

78 (3.07)

105 (4.13)

65.5 (2.58)

59.5 (2.3425)

Arm

75 (2.9528)

69.5 (2.74)

68 (2.68)

95 (3.74)

65.3 (2.57)

53.3 (2.0984)

Bucket

60 (2.3622)

54.5 (2.15)

53 (2.09)

80 (3.15)

20.5 (0.807)

8.5 (0.3346)

Dozer

85 (3.3465)

79.5 (3.13)

78 (3.07)

105 (4.13)

25.5 (1.00)

13.5 (0.5315)

Swing

70 (2.7559)

64.5 (2.54)

63 (2.48)

90 (3.54)

65.5 (2.58)

53.5 (2.1063)

(4) Wiper ring (rod cover) press-fit jig Material : Mild steel

finishing unless otherwise specified.

32 Unit: mm(in) Applicable cylinder

D0

D1

D3

Boom, Dozer

70 (2.7559)

78.5 (3.0905)

95 (3.74)

Bucket

55 (2.1654)

63.5 (2.5000)

80 (3.15)

Arm, Swing

65 (2.5591)

73.5 (2.8937)

90 (3.54)

32-39

32. ATTACHMENTS (5) Seal ring straightening jig Material : Mild steel

finishing unless otherwise specified.

Unit: mm(in) Applicable cylinder

D0

(D1)

L0

(L1)

Boom

110 (4.3307)

130 (5.12)

120 (4.72)

40 (1.57)

Arm

95 (3.7401)

115 (4.53)

120 (4.72)

40 (1.57)

Bucket

80 (3.1496)

100 (3.94)

120 (4.72)

40 (1.57)

Dozer

130 (5.1181)

150 (5.91)

120 (4.72)

40 (1.57)

Swing

105 (4.1339)

125 (4.92)

120 (4.72)

40 (1.57)

32-40

32. ATTACHMENTS (6) Piston insert jig Material : Mild steel

Split into 2 portions with 2 to 3 mm (0.08~0.12ý) cutter.

finishing unless otherwise specified.

Unit: mm(in) Applicable cylinder

øA

øB

øC

D

E

Boom

122 (4.80)

110 (4.3307)

113 (4.4488)

67 (2.64)

42 (1.65)

Arm

107 (4.21)

95 (3.7401)

98 (3.8583)

67 (2.64)

42 (1.65)

Bucket

92 (3.62)

80 (3.1496)

83 (3.2677)

62 (2.44)

37 (1.46)

Dozer

142 (5.59)

130 (5.1181)

133 (5.2362)

72 (2.83)

47 (1.85)

Swing

117 (4.61)

105 (4.1399)

108 (4.2520)

67 (2.64)

42 (1.65)

32

32-41

32. ATTACHMENTS (7) Hook wrench

Material : Chromium-vanadium steel, hardness HRc 36 ± 4

Unit: mm (in) Applicable cylinder

A

B

C

t

D

r

f

L

Boom

138 (5.433)

12 (0.4724)

5 (0.1969)

15 (0.591)

2 (0.0787)

86 (3.39)

12 (0.472)

380 (15.0)

Arm

120 (4.7244)

12 (0.4724)

4.5 (0.1772)

15 (0.591)

2 (0.0787)

80 (3.15)

12 (0.472)

380 (15.0)

Bucket

104 (4.094)

10 (0.3937)

4.5 (0.1772)

15 (0.591)

2 (0.0787)

68 (2.68)

9 (0.354)

320 (12.6)

Dozer

150 (5.9055)

12 (0.4724)

5 (0.1969)

15 (0.591)

2 (0.0787)

96 (3.78)

12 (0.472)

460 (18.1)

Swing

130 (5.1181)

12 (0.4724)

5 (0.1969)

15 (0.591)

2 (0.0787)

93 (3.66)

12 (0.472)

380 (15.0)

32-42

32. ATTACHMENTS (8) Eye wrench

Tolerance of A : 0.3 mm~0.8 mm (0.0118"~0.0315")

Straight in this area

Material : Mild steel FInish by grinding after gas cutting

Unit: mm (in) Applicable cylinder

Size A

L=300 (11.8) B2

t

B1

B2

B3

t

80 (3.1496) 110 (4.33)

78 (3.07)

28 (1.10)

122 (4.80)

107 (4.21)

87 (3.43)

28 (1.10)

Arm

75 (2.9528)

95 (3.74)

67 (2.64)

25 (0.984)

104 (4.09)

90 (3.54)

78 (3.07)

25 (0.984)

Bucket

60 (2.3622)

95 (3.74)

67 (2.64)

16 (0.630)

104 (4.09)

90 (3.54)

78 (3.07)

16 (0.630)

Dozer

80 (3.1496) 110 (4.33)

78 (3.07)

28 (1.10)

122 (4.80)

107 (4.21)

87 (3.43)

28 (1.10)

Swing

75 (2.9528) 110 (4.33)

78 (3.07)

28 (1.10)

122 (4.80)

107 (4.21)

87 (3.43)

28 (1.10)

Boom

B1

L=500 (19.7)

32

32-43

32. ATTACHMENTS 32.2.1.9 TROUBLESHOOTING Failure on hydraulic cylinder and corrective action It is very difficult to find defective section. The following table explains general phenomenon, estimated causes and corrective actions.

For repair, refer to the estimated causes and corrective actions.

However, Most machine problems are not caused by the failure of only one part, but involve relations with other parts.

Therefore corrective action other than those described in Table is often required. Please contact us to pursue the problems and causes further and to take appropriate corrective action.

Items

Items

Phenomenon

1

Oil leakage from piston rod sliding section (For criterion, refer to 32.2.1.5(3).)

2

Oil leakage from rod cover set section

3

Oil leakage from pipe and cylinder tube weld zone

4

Malfunction

Phenomenon

Related parts

Abnormalities

Flaw and rust on sliding surface.

Piston rod

Measures and corrective actions 1) Remove flaws with oil stone to make the surface smooth. If oil is leaking after making rod surface smooth (1.5S or less), disassemble it and check seals of U ring, etc. that it is free from flaw.

2) In case the flaw is too wide to repair with oilstone, replace seals of U ring and wiper ring, etc. and bearing parts of piston rod.

1) Plate it again, or replace piston rod.

Plating is peeled.

Foreign matter is caught in inner bore and outer surface.

1

Flaw on inner bore and outer surface.

Oil leakage from piston rod sliding section

2) At the same time, check seals and bearing parts of piston rod for possible damage, if damaged, replace it.

1) Remove foreign matter.

2) Replace defective packing.

1) Replace it.

1) May be a burning caused by adiabatic compression due to the remained air.

A part of lip and groove is carbonized 2) After replacement of packing, release air (burned). completely through operation in low pressure and low speed and start cylinder operating.

Rod packing (Buffer ring, U ring)

1) Replace it.

Rubber packing is deteriorated. Or lip section is damaged.

2) May be service life expired, deterioration of hydraulic oil and high temperature. a) Change hydraulic oil with new one. b) Check hydraulic oil temperature. (Temperature 80°C or less is preferable.) c) Be certain that temperature is not locally raised.

1) Replace it.

2) Extraordinary high pressure may be applied to The protrusion of packing. packing heel section is a) Check pressure at operating. too large. b) Where buffer ring is fitted, it may be damaged.

Check buffer ring for possible damage.

32-44

32. ATTACHMENTS Items

Phenomenon

Related parts

Backup ring

Wiper ring

1

Oil leakage from piston rod sliding section

Bearing (Bushing)

Abnormalities

Large deformation

1) Replace rod packing at the same time as a rule.

(Where buffer ring is fitted, it is preferable to replace it at the same time.)

2) It may be caused by extraordinary high pressure.

In this case, check it using the same procedure as the above packing heel.

Foreign matter is caught on lip section

1) Remove foreign matter.

Lip is damaged.

Or there is another abnormal damage.

1) Replace it.

Worn, and the space between bearing and piston rod exceeds the maximum clearance. 1) Replace it.

(Refer Item 32.2.1.5 (2) "Maintenance Standard".)

Large flaw on sliding surface

Rod cover

Measures and corrective actions

1) Replace it.

2) Check piston rod for possible damage at the same time.

Flaw and rust on seal 1) Remove flaw and rust with oilstone. fitting surface 2) In case it is too large to repair, replace rod cover.

1) Remove foreign matter.

2) Replace damaged O-ring.

O-ring

Foreign matter is caught in inner bore and outer surface.

3) Inspect inner surface of tube.

If flaw and rust are detected, make it smooth with oil stone.

4) Inspect groove of rod cover.

- do 5) Inspect backup ring.

Replace deformed or incompletely fit Oring.Check O-ring for above failure. If failed, replace it.

2

Oil leakage from rod cover set section

Backup ring

Deformed and incomplete fitting

1) Replace it with O-ring 1) Disassemble rod cover, check O-ring and backup ring for possible damage.

If damaged, replace it.

Rod cover

2) Check thread ridges of tube and rod cover for possible damage.

Loosen

3) After inspection, tighten it to the specified torque.

(See Item 32.2.1.4 "Install".)

Bolt

Cylinder tube

Loosen, elongation and damage

1) Replace all bolts, and tighten them to the specified torque.

Abnormal expansion

1) Replace it with new one.

The oil leakage from set section may be caused by the production of extraordinary high pressure.

Check tube for expansion and deformation, and also circuit pressure for possible error.

32-45

32

32. ATTACHMENTS Items

Phenomenon

Related parts

Abnormalities

Measures and corrective actions 1) Replace it.

3

Oil leakage from Cylinder tube, pipe and pipe (hollow Crack on weld zone cylinder tube piston rod) weld zone

Piston rod Cylinder tube

Internal leakage Piston rod is extended and retracted of itself or abnormally drops in operation.

And the speed does not rise to the specified speed.

Dent

Piston rod Cylinder tube sliding parts

Wear or damage on sliding parts Foreign matter is caught in piston and cylinder head sliding section.

Piston seal

Flaw, wear, etc.

Cylinder tube

•

The rupture is very dangerous. So when crack has been detected, stop operating immediately and replace the parts with new one.

•

The weld on crack for repair is ineffective.

1) Replace it with new one.

Check seal and sliding parts for possible damage same as the above.

Cylinder tube

4

Crack is progressed and ruptured mechanically.

Bending exceed the 1) Replace it with new one. specified deformation.

Seal and sliding parts may be damaged.

(See Item 32.2.1.5 (2) Check for possible damage. If damaged, replace "Maintenance it.

Standard".)

Malfunction Unsmooth operation

•

1) Replace it with new one.

Check seal and sliding parts for possible damage same as the above.

2) Remove foreign matter.

Check seal and sliding parts for possible damage same as the above.

1) Replace it with new one.

Check inner surface of cylinder tube for possible damage.

1) Remove flaw and rust with horning and oilstone to make it flat.

Flaw and rust on inner If it is too large to repair, replace cylinder tube surface with new one.

2) Replace piston seal with new one.

Piston nut

1) Tighten it to the specified torque.

Insufficient tightening (See Item 32.2.1.4.5 "Installing piston assy on rod".)

Valves

Leakage from valve

1) Inspect the leaking quantity and repair it.

Hydraulic oil is expanded and contracted with change of temperature and pressure.

Consequently the cylinder is also extended and retracted, so care must be taken in order not to mistake this for internal leakage. Check it for internal oil leakage in the constant temperature and pressure conditions.

32-46

32. ATTACHMENTS Items

Phenomenon

Related parts

Abnormalities

Measures and corrective actions 1) Remove air. a) If cylinder is not equipped with air bleed port ; Release air by extending and retracting it at low speed several times.

4

b) If cylinder is equipped with air bleed port ; Unload so that the internal pressure is not raised, loosen air breather and release air completely.

The operation is Air unstable.

Air is remained in cylinder.

Great shock when changed Pin bushing from / to Pin extension to / from retraction.

The space between 1) Measure dimension of pin and pin bushing, if it fitting section and pin exceeds the specified dimension, replace it with bushing is too large. new one.

Lubrication Noise when cylinder is Pin bushing worked.

Pin

(Reference) When cylinder has stopped in an emergency, cylinder may be extended and contracted slightly. This phenomenon is caused by the pressure of hydraulic oil, and easily occurs on the cylinder of which the stroke is longer.

Insufficient lubrication

1) Lubricate.

Scuffing on engaged section

1) Replace it with new one, and lubricate.

Hydraulic oil is expanded and contracted with change of temperature and pressure.

Consequently the cylinder is also extended and retracted, so care must be taken in order not to mistake this for internal leakage. Check it for internal oil leakage in the constant temperature and pressure conditions.

32

32-47

32. ATTACHMENTS

32-48

33. UPPER SLEWING STRUCTURE

33

33. UPPER SLEWING STRUCTURE TABLE OF CONTENTS 33.1 REMOVING AND INSTALLING .........................................................................33-3 33.1.1 OPERATOR SEAT .....................................................................................33-3 33.1.2 CAB ............................................................................................................33-5 33.1.3 BATTERY ...................................................................................................33-8 33.1.4 GUARD ......................................................................................................33-10 33.1.5 UNDER COVER ........................................................................................33-14 33.1.6 FUEL TANK ...............................................................................................33-15 33.1.7 HYDRAULIC TANK ....................................................................................33-17 33.1.8 HYDRAULIC PUMP ...................................................................................33-21 33.1.9 AIR CLEANER ...........................................................................................33-24 33.1.10 MUFFLER ..................................................................................................33-26 33.1.11 COUNTERWEIGHT ...................................................................................33-28 33.1.12 RADIATOR & OIL COOLER ......................................................................33-29 33.1.13 ENGINE .....................................................................................................33-34 33.1.14 CONSOLE COVER ....................................................................................33-37 33.1.15 CONTROL VALVE .....................................................................................33-39 33.1.16 PILOT VALVE (FOR ATT) ..........................................................................33-41 33.1.17 PILOT VALVE (FOR TRAVEL) ...................................................................33-43 33.1.18 SWING MOTOR UNIT ...............................................................................33-44 33.1.19 SWIVEL JOINT ..........................................................................................33-46 33.1.20 UPPER FRAME .........................................................................................33-49 33.2 DISASSEMBLING AND ASSEMBLING .............................................................33-52 33.2.1 HYDRAULIC PUMP - REGULATOR ..........................................................33-52 33.2.2 CONTROL VALVE .....................................................................................33-73 33.2.3 PILOT VALVE (FOR ATT) ..........................................................................33-88 33.2.4 PILOT VALVE (FOR TRAVEL) ...................................................................33-100 33.2.5 SWING MOTOR UNIT ...............................................................................33-105 33.2.6 SWIVEL JOINT ..........................................................................................33-121

Book Code No. S5LF3312E01 33-1

33. UPPER SLEWING STRUCTURE

Issue

Date of Issue

First Edition

June, 2010

Applicable Machines 80CS-2 : LF06-04501~

Remarks S5LF3312E01 (NA)

PREFACE (1) This Manual describes all the procedures from removing to installing, arranging them by item.

(2) This Manual consists [Removing and installing], and [Disassembling and assembling].

(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of actual repairing or time saving some process can be omitted.

(4) The removing and installing procedure does not completely cover all possible situations because of differences of field condition and defective section.

(5) Recognize well that the service man must decide a work procedure before proceeding to repair. When deciding the work procedure, choose an item that is needed, familiarize yourself with the contents of the work and itemize the work procedure, before starting work.

(6) Disconnect the negative terminal of battery first, when the removing and the installing of the electric component and wiring are performed.

(7) The explanatory note and figure of this manual may differ from the actual machine by the difference in specification.

33-2

33. UPPER SLEWING STRUCTURE

33.1

REMOVING AND INSTALLING

33

33.1.1 OPERATOR SEAT 33.1.1.1 REMOVAL (1) Preparation for removal 1. Remove the head rest (A1-1) of the operator's seat (A1) to ease handling.

2. Move the whole control stand to its foremost position.

3. Move the operator's seat to its forward end.

4. Incline the reclining seat as forward as possible.

(2) Remove operator's seat. (Include upper rail.)

1. With the above-mentioned condition, remove two cap screws (B2) M8X20 from the upper rail. Then move the control stand to its rearmost end and remove two capscrews (B2) M8X20.

Tools: Allen wrench: 6 mm 2. Remove the operator's seat. [about 28 kg (62 lbs).]

Carry out the following operations as required.

3. Remove seat belt (C1), bracket (C2).

4. Remove armrest (A3)(A4).

5. Remove bracket assembly (1), rail (7).

A1-1 A1 C1 7/16

C4

C4

7/16

B2 C1

C2 C3

7

1

Disassembling and Assembling seat

33-3

33. UPPER SLEWING STRUCTURE 33.1.1.2 INSTALLATION Install it in reverse procedure of removing according to the tightening torque table.

Tightening position Capscrew (B2) Sems bolt (C3) Sems bolt (A6) Capserew (A5)

Allen wrench HEX

Tightening torque N·m (lbf·ft)

6 17 13 13

23 (17) 46.5 (34.3) 23 (17) 23 (17)

A4 A5 A3 A2

A5

A1

A6

A6

Disassembling and Assembling armrest Reference : Movement on rail Upper rail.....Fixed on lower surface of seat [Forward 80mm (0.26in), backward 80mm (0.26in)] Lower rail.....Fixed on seat stand.

[Forward 60mm (0.19in), backward 60mm (0.19in)] Amount of adjustment of seat height [Up; 23mm (0.07in), down; 37mm (0.16in)] Suspension stroke [Up; 37.5mm (1.48in), down; 37.5mm (1.48in)]

33-4

33. UPPER SLEWING STRUCTURE 33.1.2 CAB

33

33.1.2.1 REMOVAL (1) Remove floor mat.

(2) Remove cover assembly (A8).

1. Remove 3 caps (A15) and loosen 4 sems bolts (A38) M6X20.

Tools: Phillips screwdrive 2. Disconnect harness connector of power socket and remove cover assembly (A8).

(3) Removal of cover assembly (A10).

1. Loosen 2 sems bolts (A38) M6X20.

Tools: Phillips screwdriver 2. Remove cover assembly (A10).

(4) Removal of harness connector.

(See Chapter 23 "Electric System") 1. Disconnect connectors of cab harness at rear right of cab.

2. Disconnect antenna cable for tuner located at rear left of cab.

3. Disconnect harness for cab light located at rear left of cab.

(5) Removal of cover assembly (A1).

1. Loosen 2 sems bolts (A38) M6X20.

Tools: Phillips screwdriver 2. Disconnect harness connector of hour-meter and remove cover assembly (A1).

(6) Remove plastic tube for window washer located at right front of cab.

A15 A38

A8

A38 A38

A38

A38

A10 A38

A1 A38

Disassembly and assembly of right panels (A1), (A8) and (A10)

(7) Removal of mechatro-controller 1. Loosen 4 sems bolts (B9) M6X25.

2. With harnesses are connected condition, remove mechatro-controller, and place it in front of it temporally.

4 PLACES

B9

MECHATRONICS CONTROLLER RELAY BOX ASSY

FORWARD

Removal of mechatro-controller

33-5

A15

33. UPPER SLEWING STRUCTURE (8) Removal of cab attaching bolts 1. Loosen 4 capscrews (C1) M12X35.

2. Loosen 2 nut (D4) M16.

3. Loosen 2 nut (D9) M20.

C1

C1

C1

C1 Removing and installing cab mounting bolts

D4

D9 Removing and installing cab mounting bolts

33-6

33. UPPER SLEWING STRUCTURE (9) Slinging cab 1. Remove 2 plastic plugs at the front of the ceiling of the cab, and attach 2 eyebolts. Then hook slinging wires to eyebolts as shown in figure.

2. Then lift up cab slowly avoiding interference with surroundings.

Wire with hook; Length 1.5m (4 ft 11 in) X Dia. 10 mm (0.4 in) X 3 pcs.

Weight of cab; Approximately. 400kg (880lbs)

33

EYE BOLT M16 EYE BOLT M12

Slinging cab

33.1.2.2 Installation Install it in reverse order of removing according to the Tightening Torque Table.

Tightening position Capscrew (C1)

Allen wrench HEX(mm)

Tightening torque N·m (lbf·ft)

19

80 (66)

Sems bolt M6 (A38)(B9) Plus driver

5.0 (3.7)

Nut (D4)

24

191 (141)

Nut (D9)

30

191 (141)

33-7

33. UPPER SLEWING STRUCTURE 33.1.3 BATTERY 33.1.3.1 REMOVING (1) Open left hand cover (1).

1. Open it with starter key.

2. Open left hand cover (1).

3. Fix it with stay.

(2) Remove battery cover (A1) Loosen 3 sems bolts (A6) M10 and remove battery cover (A1).

Tools: Spanner: 17mm (3) Remove battery cable 1.

Remove cable (4) [between the earth and battery ()].

(Always remove (-) terminal first and install it at last.)

2.

Remove cable (5) [between battery (+) and (-)] 3.

Remove cable (3) [between battery (+) and battery relay] Tools: Spanner: 13mm

1 3

5 4

Grounding cable for main body

Follow the battery removal order.

Start removing battery from grounding side, and finish attaching to grounding side. If this order is missed, shortcircuits may occur.

(4) Remove battery (B1) 1.

Loosen 2 capscrews (A3) M10X225.

Tools: Socket: 17mm 2.

Remove plate (A2).

3.

Remove battery (B1).

A6 A5 A1

A2

A3, A4

B1 Removing and installing battery cable

33-8

33. UPPER SLEWING STRUCTURE 33.1.3.2 INSTALL (1) Install the battery in the reverse order of removing.

Hold down plate (A2) against battery (B1), and tighten capscrew (A3).

Tools: Socket: 17mm Tightening torque : 10.8N-m (8.0 lbf-ft) (2) Installing grounding cable Install grounding cable (4) last. Especially care must be taken that the grounding face is free from painting, rust, etc.

Tools: Spanner: 13mm

33-9

33

33. UPPER SLEWING STRUCTURE 33.1.4 GUARD 33.1.4.1 PREPARATION FOR REMOVAL (1) Remove guard in the following procedure.

Remove these equipments according to the order of items (2), (4), (3), (5), and (1).

(2) All the locked equipment, open them using starter key.

4

2 3

1

5 Guard assembly

33.1.4.2 REMOVE GUARD (1) Remove panel assembly (2-1) 1. Unlock panel assembly (2-1) and open it.

2. Remove 2 sems-bolts M12X25.

3. Remove panel assembly (2-1).

Tools: Socket: 19mm Weight : 13kg (29 lbs)

2-1

2-2

2-2 Removing cover assembly (2-1) (2) Removing cover assembly (2-5) 1. Remove 2 sems-bolts (2-2) M12X25 and 2 sems-bolts (2-13) M12 X 30.

2. Removing cover assembly (2-5).

Tools: Socket: 19mm Weight : 7kg (15 lbs)

2-5

2-13

2-2 2-2

Removing cover assembly (2-5)

33-10

33. UPPER SLEWING STRUCTURE (3) Remove panel assembly (2-4) 1. Remove 3 sems-bolts (2-2) M12 X 25.

2. Remove panel assembly (2-4).

Tools: Socket: 19mm Weight : 8kg (18 lbs)

2-4

33

2-2

2-2

2-2

Removing panel assembly (2-4) (4) Remove panel assembly (2-3) 1. Remove a sems-bolts (2-8) M12X40.

2. Remove a sems-bolt (2-17) M12X45.

3. Remove 2 sems-bolts (2-2) M12X25.

4. Remove panel assembly (2-3).

Tools: Socket: 19mm Weight : 14 kg (31 lbs)

2-2

2-2

2-3

2-8

2-17 Removing panel assembly (2-3) (5) Remove cover assembly (4-3) 1. Remove 5 sems-bolts (4-5) M12X25.

2. Remove cover assembly (4-3).

Tools: Socket: 19mm (6) Remove cover assembly (4-1) 1. Remove 3 sems-bolts (4-5) M12X25.

2. Remove cover assembly (4-1).

Tools: Socket: 19mm Weight : 16 kg (35 lbs)

4-5 4-3 4-5

4-5

4-5

4-5

4-1

4-5 Removing cover assembly (4-3), (4-1)

33-11

33. UPPER SLEWING STRUCTURE (7) Remove bonnet assembly (3-2) 1. Unlock bonnet assembly (3-2) and open it.

2. Remove 4 sems-bolts (3-12) M12X20.

3. Remove bonnet assembly (3-2).

Tools: Socket: 19mm Weight : 17 kg (37 lbs)

3-2

3-12

3-12 Removing bonnet assembly (3-2) (8) Remove bonnet assembly (3-1) 1. Remove 4 sems-bolts (3-13) M12X25.

2. Remove bonnet assembly (3-1).

Tools: Socket: 19mm Weight : 15 kg (33 lbs) (9) Remove covers (3-3), (3-4) 1. Remove a sems-bolt (3-13) M12X25.

2. Remove cover assembly (3-3).

3. Remove a sems-bolt (3-13) M12X25.

4. Remove cover (4).

Tools: Socket: 19mm Weight : 10 kg, 4 kg (22 lbs, 9 lbs)

3-1

3-13

3-13

3-3 3-13

3-13

3-4 Removing bonnet assembly (3-1) and covers (3-3), (3-4)

(10)Remove left hand cover (5-1) 1.

Remove 2 sems-bolts (5-4) M12X25 and remove left hand cover (5-1).

Tools: Socket: 19mm (11)Remove right hand cover (5-2) 1.

Remove 2 sems-bolts (5-4) M12X25 and remove right hand cover (5-2).

Tools: Socket: 19mm

5-1 5-4

MACHINE FRONT

5-2 5-4

Removing left/right hand covers (5-1), (5-2)

33-12

33. UPPER SLEWING STRUCTURE (12)Remove bracket (1-5) Remove 2 sems-bolts (1-8) M12X25 and remove bracket (1-5).

Tools: Socket: 19mm

33

1-5 1-8

1-8

Removing bracket (1-5) (13)Remove guard assembly (1-2) 1. Remove 2 sems-bolts (1-9) M12X30.

2.

Remove the sems-bolt (1-8) M12X25 attaching support (1-3).

3. Remove guard assembly (1-2).

Tools: Socket: 19mm Weight : 7 kg (15 lbs) (14)Remove pillar (1-4) 1. Remove 2 sems-bolts (1-8) M12X25.

2. Remove pillar (1-4).

Tools: Socket: 19mm Weight : 7 kg (15 lbs)

1-4

1-13

1-8

1-2 1-8 1-8 1-9

1-9

Removing guard assembly (1-2) and pillar (1-4) (15)Remove guard assembly (1-1) 1. Remove 4 sems-bolts (1-8) M12X25.

2. Remove guard assembly (1-1).

Tools: Socket: 19mm Weight : 20 kg (44 lbs)

1-8 1-1

1-8

Removing guard assembly (1-1) 33.1.4.3 INSTALLATION (1) Installing is done in the reverse order of removing.

(2) Tightening torque Tools: Socket: 19mm, M12 79.4 N-m (58.6 lbf-ft)

33-13

33. UPPER SLEWING STRUCTURE 33.1.5 UNDER COVER 33.1.5.1 REMOVAL (1) Remove under cover (1,2,3,4,5,6,8,9) 1. Remove sems bolts (7) M12X30.

2. Remove covers.

Tools: Socket: 19mm

6-PLACES

3, 7 5-PLACES

2

4, 7 4-PLACES

8, 7 4-PLACES

1 8-PLACES

5, 7 3-PLACES

9, 7 4-PLACES

6, 7

FOWARD

4-PLACES

Removing under cover assembly

33.1.5.2 INSTALLATION (1) Install under cover (1,2,3,4,5,6,8,9) Tools: Socket: 19mm Tightening torque : 80 N-m (59 lbf-ft)

33-14

33. UPPER SLEWING STRUCTURE 33.1.6 FUEL TANK

33

33.1.6.1 PREPARATION FOR REMOVAL (1) Draining fuel (See Fig. "Removing fuel tank") 1. Unlock cap (B1) with a starter key and open it.

2. Loosen valve (A10) under the tank.

3. Draining fuel Capacity of tank : 367L (97gal) (2) Remove panel assembly (2-3),(2-4).

(See 33.1.4 GUARD) (3) Remove the connector for fuel level sensor (A4).

(See Fig. "Removing fuel tank") (4) Remove fuel hose 1.

Loosen clip (17),(18) and draw out hoses (8) and (9).

2. Put in plugs that match the hose bore.

9,18 8,17

Removing fuel hose (8),(9) 33.1.6.2 REMOVAL (1) Remove 4 capscrews (A1) M16X50.

Tools: Socket: 24mm (2) Hook the wire to the lifting eye on the fuel tank assembly (B6) and remove the fuel tank.

Weight : 63kg (139 lbs) (3) Remove shim (A3).

B1

A1 A4

A1

A9 B6

A5

A9 A3

A3

A7 A10

Removing fuel tank

Record the shim locations.

33-15

33. UPPER SLEWING STRUCTURE 33.1.6.3 INSTALLATION (1) Installing is done in the reverse order of removing.

Tank attaching bolt (A1) M16X50 Tools: Socket: 24 mm, Apply Loctite #262 Tightening torque: 191N-m (140 lbf-ft)

If the gap (looseness) between tank mount and frame exceeds 1 mm (0.04 inch), adjust the gap with shim (A3) and tighten capscrew (A1) to install the tank.

(2) Tightening torque

No.

Name

Q'ty

Tightening torque N.m (lbf.ft)

A1

Capscrew

4

191 (140)

A5

Machine screw

5

1.96 (1.4)

A7

Cock

1

34 (25)

33-16

33. UPPER SLEWING STRUCTURE 33.1.7 HYDRAULIC TANK

33

33.1.7.1 PREPARATION FOR REMOVAL (1) Swinging upper structure 45 degrees.

Swing upper structure to make the removal of suction hose for pump installed under tank easier.

(2) Necessary to remove the hydraulic oil tank.

Swinging upper structure 45 degrees (3) Bleeding internal air of tank Press cap by finger to bleed internal air.

Push (ELEMENT NO. YN57V00004S002)

Bleeding internal air of tank

Keep pressing until the hissing sound stops.

(4) Remove cover (B1) 1. Remove 6 sems bolts (B10) M10X25.

Tools: Socket: 17mm 2. Remove cover (B1).

3. Remove suction strainer (B4).

(5) Remove cover (B2) 1. Remove 6 sems bolts (B10) M10X25.

Tools: Socket: 17mm 2. Remove cover (B2).

3. Remove filter element (B7).

(6) Turn the handle of element assembly (B7), and disassemble the removed filter element (B7).

(7) Draining hydraulic oil Place pump in tank and draw up hydraulic oil.

Capacity of tank : 72 L (19gal)

B5

B10 B2

B10

B11 B12 B1

B7-4 B7-3 B7

B7-1 B4

B7-2 B7-1 B13 B15

B14

Remove cover (B1),(B2)

33-17

33. UPPER SLEWING STRUCTURE 33.1.7.2 REMOVAL (1) Draw out the suction hose (1) Remove 2 clips (9) of the tank side and pull out hose (1).

Tools: Flat-blade screwdriver

1

9

9 At installing suction hose, apply PERMATEX to the inner end of both hoses.

Removing the suction hose (2) Disconnecting the main pipe return hose (7) Tools: Spanner: 41mm (3) Remove drain hose (6) of pump Tools: Spanner: 27mm (4) Remove drain hose (4) of swing motor Tools: Spanner: 36mm

Removing main piping return hose (5) Disconnecting pilot return hose 1. Remove pilot hose (A1),(A22).

Tools: Spanner: 22mm 2. Remove pilot hose (A4).

Tools: Spanner: 22mm 3. Remove pilot hose (A6).

Tools: Spanner: 22mm

A22

S/V TTANK

A4 C/V Dr2TANK

A19

A2

A6 PT T TANK

A22

C/V T2TANK

Remove pilot return hose (6) Remove drain hose (6) of pilot pump Tools: Spanner: 27mm

$

Removing pump drain hose

33-18

33. UPPER SLEWING STRUCTURE (7) Remove hydraulic tank attaching bolt Remove 4 capscrews (A1) M16X50.

Tools: Socket: 24mm (8) Slinging hydraulic oil tank Place a wire sling, using the lifting plate on top of the tank.

Tank weight: Approximately : 62kg (137 lbs) (9) Remove shim (A3).

) )

33

)! ) ) )!

Removing hydraulic tank

Record the shim locations.

33-19

33. UPPER SLEWING STRUCTURE 33.1.7.3 INSTALLATION (1) Cleaning hydraulic oil tank (2) Cleaning suction hose (3) Cleaning mount of tank.

Installing is done in the reverse order of removing.

(4) Install 4 mounting capscrews (A1) M16X50 with Loctite #262. (See Fig. "Removing hydraulic tank".)

Tools: Socket: 24mm, Apply Loctite # 262 Tightening torque: 191N-m (40 lbf-ft)

If the gap (looseness) between tank mount and frame exceeds 1mm (0.04 inch), adjust the gap with shim (A3) and tighten capscrew (A1) to install the tank.

(5) Connection of suction hose (See 33.1.8.2) 1.

Apply PERMATEX on pipe side of hose connection and insert it.

2.

Put the hose with clip (A19).

Tightening torque: 5.39N-m (4.0 lbf-ft) (6) Assembling return element Assemble filter element by the use of element kit.

(See right Fig.) (7) Install return element. (See Fig. "Remove cover (B1), (B2)") (8) Installing suction strainer (B4) (9) Tighten sems bolts (B10) M10X25 that attach tank covers (B1), (B2).

M10 Tightening torque : 46.1 N-m (34 lbf-ft)

B4 B7-1 B7

B7-2 B7-1

ELEMENT KIT(K) YR52V01004R200

Two elements (B7-1) are used as one set.

Replace O-ring fitted on the back side of tank cover with new one.

33-20

O-RING SUCTION STRAINER YT50V00003F1

Return element & suction strainer

33. UPPER SLEWING STRUCTURE 33.1.8 HYDRAULIC PUMP

33

33.1.8.1 PREPARATION FOR REMOVAL (1) Remove bonnet assembly (3-1),(3-2).

(See 33.1.4 GUARD (7),(8)) (2) Remove cover assembly (3-3),(3-4).

(See 33.1.4 GUARD (9)) (3) Remove counterweight.

(4) Release pressure in hydraulic oil tank.

(See 33.1.7 HYDRAULIC TANK) (5) Remove 6 capscrews (B10) M10.

(6) Remove cover (B1).

Tools: Socket: 17mm (7) Take out suction strainer.

(8) Install suction stopper.

For suction stopper, see Chapter "Tools".

B11 B12

B5 B10

B1 SUCTION STRAINER

B4

B15

B14 Hydraulic oil tank

Pump can be removed even when counterweight is not removed. But removal of counterweight facilitates working, and the working time is also reduced.

(9) Disconnect drain down pipe installed under engine muffler.

33.1.8.2 REMOVAL (1) Loosen sems bolts (13) M12X40 and remove half clamp (7). And disconnect 2 hoses (17), (A5) from the delivery side. (See right Fig., and Fig. "Pump port") Tools: Spanner: 36mm (2) Remove suction flange 1. Remove 4 socket bolts (14) M12.

2. Remove flange (3) of suction hose (1) from pump (S1).

Tools: Allen wrench: 10mm

PUMP DrTANK

6

2

13 15

12

7

7

8

18 5

13 15

12

17 PUMP D1

S1

1

10 3 14 16

9

33-21

9

33. UPPER SLEWING STRUCTURE (3) Removing other hoses 1. Disconnect hoses of the following ports.

2. Attach tags to hoses to identify.

Port Size

Tool Connected to

2

Remarks

D2 PF1/2

27

Tank

Drain

Pb PF1/4

19

Tank

Pi1 PF1/4

19

C/V

Back pressure compensation port Negative flow control port

PUMP pi1C/V Pn

14

S/V PPUMP D2

A5

1

C/V PrPUMP Pb

Pump port (3) Removing main pump 1. Attach eye bolt (M10) on upper surface of pump.

2. Lift it with wire lightly.

3. Remove 2 socket bolts (4) M12.

4. Pull pump horizontally and remove it.

Tools: Allen wrench: 10mm Weight of pump : Approximately. 45 kg (99 lbs)

Tightening torque : 67 N·m (49 lbf·ft) Apply Loctite #262 4 4 PLACES

Removing pump

33-22

EYE BOLT

33. UPPER SLEWING STRUCTURE 33.1.8.3 INSTALLATION Installing pump in the reverse procedure of removal following the specification for tightening torque and sealant.

(1) Apply grease on spline of input shaft.

Grease ; Shell Retinax AM (General-purpose extreme-pressure molybdenum disulfide grease) (2) Hook wire to eye bolts (M10) on upper surface of pump and lift it.

(3) Insert pump spline section.

4

APPLY GREASE

Installing pump (4) Remove suction stopper (5) Mounting suction strainer (6) To bleed air by loosen the air vent port.

Tools: Spanner: 19mm (7) Check hydraulic oil level.

(8) Start engine and check it for oil leakage and noise.

(9) Install guards See 33.1.4.2 (7),(8),(9).

AIR VENT PORT

Release air in pump

After replacing pump, be sure to fill hydraulic oil of 1L (0.26 gal) or more.

33-23

33

33. UPPER SLEWING STRUCTURE 33.1.9 AIR CLEANER 33.1.9.1 PREPARATION FOR REMOVAL (1) Opening bonnet assembly (2) 1. Unlock it with starter key.

2. Open bonnet (2) and support it with stay (5).

(2) Unplug terminals on indicator lines (5-5) (See Fig. "Pulling out hose (3)")

5

2 Preparation for removal

33.1.9.2 REMOVAL (1) Pulling out hose (5).

1. Loosen clips (11) on air cleaner side.

2. Pulling out hose (5) Tools: Flat-blade screw driver

7 2

11

8 1

3

5

I

10

6 10

11

9

4

Pulling out hose (5) (2) Pulling out hose (3) 1. Loosen clip (11) on air cleaner side.

2. Pulling out hose (3).

Tools: Flat-blade screw driver (3) Remove air cleaner assembly (1) 1. Remove 2 sems-bolts (7) M8X16.

2. Remove air cleaner assembly (1) together with bracket (2).

Tools: Socket: 13mm

INSERTION ALLOWANCE OF HOSE 40

INDICATOR AIR CLEANER ACCESSORIES 5-5 TIGHTENING TORQUE 3.9N.m (2.9 lbf.ft)

3 TIGHTENING TORQUE 11 5.9N.m (4.4 lbf.ft) Place the clip as shown in the drawing.

5

11

TIGHTENING TORQUE 2.5N.m (1.8 lbf.ft)

VIEW I

Pulling out hose (3)

33-24

33. UPPER SLEWING STRUCTURE 33.1.9.3 INSTALLATION (1) Installing is done in the reverse order of removing.

(2) Spare parts for deteriorated elements

FILTER ELEMENT YT11P00009S002

33-25

33

33. UPPER SLEWING STRUCTURE 33.1.10 MUFFLER 33.1.10.1 PREPARATION FOR REMOVAL (1) Remove 4 sems-bolts (9).

(2) Remove exhaust tube (3),(4).

(3) Remove guard (3).

(4) Remove right hand cover (2).

3

2

Preparation for removal

33.1.10.2 REMOVAL (1) Remove U bolt (6).

1. Remove 4 nuts (14) M8.

Tools: Socket: 13mm 2. Remove 2 U bolts (6).

(2) Remove cover (18).

1. Remove 3 sems-bolts (21),(22).

2. Remove 2 capscrews (23).

3. Remove cover (18).

(3) Remove clamp assembly (5) 1. Remove 2 capscrews (9) M10X35 Tools: Socket: 17mm 2. Separate clamp assembly (5) from muffler (1).

(4) Removing other parts Remove brackets (2) as necessary.

Tools: Socket: 19mm

'

!

Removing exhaust tube (3)

6

1 6

14 9 14

12 14

10 5 20 23 24

2 17

4

19

11 13 18 22 21

Removing and installing the muffler

33-26

33. UPPER SLEWING STRUCTURE 33.1.10.3 INSTALLATION Installing is the reverse order of removing with attention paid to the following items:

33 GAP

B

A

C

(1) Procedure of fastening U bolt (6) (See right Fig.) 1.

Tighten 4 nuts (A) till there is no space and make sure that the dimension C is even all around.

2.

Tighten nuts (A) to specified torque and confirm the C dimensions on the right and left once again.

3.

Tighten nuts (B) to specified torque and make sure that U bolts are not inclined.

4. Tightening torque Nut A : 8.8 N-m (6.5 lbf-ft) Nut B : 10.8 N-m (8.0 lbf-ft) (2) Installing clamp assembly (5) 1.

Place the end of clamp (5) 10mm (0.40in) away from the tip of the muffler slit so the joint of clamp does not extend over the slit in the muffler. (See right Fig.) 2.

Install the clamp assembly (5) in the illustrated direction.

(3) Install cover (18).

1. Tightening torque : Sems-bolt (21) : 9.8 N-m (7.2 lbf-ft) Sems-bolt (22) : 29.4 N-m (21.7 lbf-ft) Capscrew (23) : 9.8 N-m (7.2 lbf-ft)

TIGHTENING PROCEDURES FOR U-BOLT 10,11,13 5

4

FROM THE END OF SLIT 10

INSTALLING THE CLAMP (5)

2 PLACES

23

18

21 THE COVER IS INSTALLED Installing the muffler (4) Replacing parts

Name Muffler (1)

Part No. YT12P00013P1

33-27

22

2 0

33. UPPER SLEWING STRUCTURE 33.1.11 COUNTERWEIGHT 33.1.11.1 PREPARATION FOR REMOVAL (1) Removing bonnet assembly (3-2).

Remove bonnet on engine. (See 33.1.4.2(7)) (2) Removing bonnet assembly (3-1). (33.1.4.2(8)) (3) Preparing slinging jig Remove plug (A6), and attach weight slinging jig (See Chapter Tools.) to counterweight.

Tools: Spanner: 36mm

Lifting up counterweight 33.1.11.2 REMOVAL (1) Lifting up counterweight temporarily Hook wire rope to slinging jig, and lift it and stretch wire rope to the degree where it is providing no slack temporarily.

Weight of counterweight : Approximately. 840 kg (1850 lbs) Wire more than ø10 (0.394") : 1.5 m (4 ft 11 in) X 2 pcs.

(2) Removing counterweight 1. Remove 3 capscrews (A1) M20X130.

Tools: Socket: 30mm 2. Remove shim.

C1

A1

A2 A1 A2 A6

SHIM

SHIM SHIM A2

A1

Removing counterweight 33.1.11.3 INSTALLATION (1) Install counterweight in the reverse procedure of removing.

(2) Install shim as it was (3) Slinging counterweight Check that 3 attaching bolts can be screwed in by hand.

(4) Apply Loctite #262 on capscrews (A1), and tighten them with washers (A2).

Tools: Socket: 30mm Tightening torque : 490 N-m (361 lbf-ft) (5) Remove slinging tools, and attach plugs (A6).

Attaching bolts counterweight

33-28

33. UPPER SLEWING STRUCTURE 33.1.12 RADIATOR & OIL COOLER

33

33.1.12.1 PREPARATION FOR REMOVAL (1) Remove counterweight.

(2) Bleed air from the hydraulic tank and install the suction stopper. (See 33.1.12 RADIATOR & OIL COOLER) (3) Remove cover of suction strainer, and adjust oil quantity so that oil level becomes lower than the return tube level.

(4) Remove air cleaner hose Refer to 33.1.9 AIR CLEANER 1. Loosen 2 clips (11).

2. Pulling out hose (5).

Tools: Flat-blade screwdriver

#

Removing hose (5)

(5) Removing under cover installed on lower side of radiator.

1. Remove 6 sems-bolts (7) M12X25.

2. Remove cover (3).

Tools: Socket: 19mm

6-PLACES

3, 7

Removing under cover (3) (6) Drain down of radiator Put container 18L (4.8gal) under drain valve hose for draining water.

[Water capacity of radiator : 4.6L (1.2gal)] (7) Remove hose from radiator sub tank (6).

1.

Remove clip of radiator cap side and disconnect hose (17).

2. Remove 2 sems-bolts (29) M8X20.

3. Remove radiator sub tank (6) and guard (5).

Tools: Socket: 13mm

5 10 6

29

17 Removing hose of sub tank (1)

Do not loosen the joints of the hoses related to the air-conditioner. Otherwise the refrigerant leaks.

33-29

33. UPPER SLEWING STRUCTURE (8) Move air-conditioner condenser and receiver tank 1.

Loosen 4 sems-bolts (60) M8X16 and Loosen 2 sems bolts (8) M8X20.

Tools: Socket: 13mm 2.

Move a set of air-conditioner condenser and receiver tank.

&

$ Moving condensers and receiver tank

33.1.12.2 REMOVAL (1) Remove radiator stay (B1).

1. Remove 2 sems-bolts (B2) M12X30.

Tools: Spanner: 19mm 2. Remove 2 stays (B1).

(2) Remove water hose (11), (12).

1.

Loosen the hose bands (22), (24) for water hose (11).

Tools: Flat-blade screwdriver 2. Remove hose (2).

3.

Loosen hose bands (22), (24) on water hose (12) and remove a sems-bolt (25) M10X25.

Tools: Flat-blade screwdriver Tools: Spanner: 17mm 4. Remove hose (12).

11

24

15

22

24 25

B2

24

22

25 21

B1 12

24 24 B2

16 23

A2 14 Removing radiator assembly

33-30

33. UPPER SLEWING STRUCTURE (3) Remove hoses (14), (15) for inter-cooler.

1. Loosen hose band (24) and remove hose (15).

Tools: Flat-blade screwdriver 2. Loosen hose bands (23), (24) and remove hose (14).

Tools: Flat-blade screwdriver 3. Remove two fixing U-bolts (19) from tube (16).

Tools: Spanner: 13mm 4. Loosen sems-bolt (28) M8X20.

Tools: Spanner: 13mm 5. Loosen hose bands (22) and remove hose (13) and tube (16).

Tools: Flat-blade screwdriver

3 29

33

1

28

Removing and installing bracket assembly (3) and guard (1) (4) Remove bracket assembly (3) 1. Remove 2 sems-bolts M8X16.

2. Remove bracket assembly (3).

Tools: Spanner: 13mm (5) Remove guard (1) 1. Remove 6 sems-bolts M8X20.

2. Remove guard (1).

Tools: Spanner: 13mm (6) Disconnecting hydraulic oil hose (2), (3) 1.

Loosen 2 capscrews (28) M10X50 for attaching clamp (24), (25).

2.

Place an oil pan under the hose joint.

3.

Remove connector (15) and disconnect "OUT" side tube (2) and hose (8).

4.

Remove elbow (20 and disconnect "IN" side hose (3).

(7) Remove radiator assembly. (See Fig. "Removing radiator assembly") 1. Remove 4 sems bolts (A2) M12X30.

Tools: Spanner: 41mm Tools: Socket: 19mm 2.

When lifting the engine fan, shift the radiator so it does not interfere with the engine fan.

3. Plug up pipe ends with clean cloth, etc.

4. Removing radiator Place a wire sling in the lifting eyes of the radiator assembly and remove the assembly by crane.

Weight : 55kg (121 lbs)

33-31

Removing hydraulic oil hose (2), (3)

33. UPPER SLEWING STRUCTURE 33.1.12.3 INSTALLATION (1) Installing is done in the reverse order of removing.

And removed clips of hose should be clamped at original position.

(2) Install radiator assembly Place a wire sling in the lifting eyes of the radiator and move it to original position temporally. And install hydraulic hose, radiator hose and hose of inter-cooler. Regarding Inserting width of hose.

(See right Fig.) (3) Radiator attaching bolt Apply Loctite #262 on 4 semsbolts (A2) M12X30.

Tools: Socket: 19mm Tightening torque : 121 N-m (89 lbf-ft) (4) Adjust the clearance between the fan and the radiator shroud all around the circumference, as below : Full circumference: 20±5mm (0.8in±0.2in) (5) Clean the plastering area of the insulation thoroughly before plastering it.

(6) Making up hydraulic oil and LLC (Long Life Coolant) After completion of other installation, make up hydraulic oil and water.

Coolant volume of engine body : 2.8 L (0.7gal) Coolant capacity of radiator : 4.0 L (1.1gal) Hydraulic oil capacity of oil cooler : 4.1 L (1.1gal)

INSERTION ALLOWANCE OF HOSE 40mm (1.6in)

FORWARD

INSERTION ALLOWANCE OF HOSE 30mm (1.2in)

INSERTION ALLOWANCE OF HOSE 35mm (1.3in) INSERTION ALLOWANCE OF HOSE 20mm (0.8in)

INSERTION ALLOWANCE OF HOSE 40mm (1.6in) INSERTION ALLOWANCE OF HOSE 40mm (1.6in)

INSERTION ALLOWANCE OF HOSE 40mm (1.6in)

Inserting width of hose FAN TO BE ADJUSTED SO AS TO BE OUTSIDE BY 24 5mm FROM RADIATOR SHROUD.

24

5

Back-and-forth adjusting position of radiator

33-32

33. UPPER SLEWING STRUCTURE 33.1.12.4 PROCEDURE OF DISASSEMBLING AND ASSEMBLING THE RADIATOR/INTER COOLER CORE (1) Preparation for disassembly and assembly 1. Remove one under cover at the bottom of the radiator.

2. Wait till the engine coolant cools down so you do not get burned. Then remove the cap of the radiator, discharge the coolant by opening the drain valve located at the back bottom and receive it in a container. * In case of removing inter cooler only, the above mentioned work is not necessary.

33

)# )!

)

) ) " ) ) % )

)

) ' ) $ ) $

Removing radiator and inter-cooler (2) Disassembly 1. Loosen 8 sems bolts (A21) M8X16 attaching shroud assembly (A5), remove shroud assembly (A5).

2. Loosen 2 bolts (A17) attaching radiator core.

3. After confirming that the coolant has been drained out completely, loosen and remove only the radiator side of hose bands (24) at the top and bottom of the radiator. (See 33.1.12.2 Fig. "Removing radiator assembly") 4. Lift and remove radiator core using lifting eyes and hoist on the radiator core.

Weight : approximately. 4.8 kg (11 lbs) Confirm the missing of rubber bushing (A16) under the radiator core.

5. Loosen a bolt (A17) attaching the top of the inter-cooler core.

6. Loosen and remove only the inter-cooler side of hose bands (24) at the top and bottom of the inter-cooler. (See 33.1.12.2 Fig. "Removing radiator assembly") 7. Lift and remove inter-cooler using lifting eyes and hoist on the inter-cooler.

Confirm the missing of rubber bushing (A16) under the inter-cooler.

8. Disconnection of oil cooler hose Disconnect hose (2), (3) from upper and lower of cooler, and drain hydraulic oil. (See 33.1.12.2 Fig. "Removing hydraulic oil hose (2), (3)") 9. Lift cooler temporally using cooler head flange for slinging.

10.Loosen 4 sems-bolts (A22) M10X25 attaching oil cooler.

11. Lift the oil cooler.

There is no predetermined sequential order in removing radiator core, inter-cooler core and oil cooler. Removing these components can be done as necessary.

(3) Installing Installing is done in the reverse order of removing.

33-33

33. UPPER SLEWING STRUCTURE 33.1.13 ENGINE 33.1.13.1 PREPARATION FOR REMOVING (1) Remove battery ground (See 33.1.3 BATTERY) (2) Remove bonnet and guard (See 33.1.4 GUARD ) Remove under cover (See 33.1.5 UNDER COVER) (3) Remove air cleaner hose (See 33.1.9 AIR CLEANER) (4) Remove counterweight (See 33.1.11 COUNTERWEIGHT) (5) Remove radiator hose and inter-cooler hose (See 33.1.12 RADIATOR & OIL COOLER) (6) Remove fuel hose and heater hose, and if necessary disconnect air-con hose.

(7) If necessary, remove pump, muffler and radiator.

(8) Remove harness connector (Refer to ELECTRIC SYSTEM) 1. Remove E/G ground cable 2. Starter cable-Starter B terminal 3. Upper harness

CN-359,CN-358-Stepping (governor) motor P8-Alternator B terminal CN-136-E/G speed sensor CN-141-EGR cut solenoid CN-303-Engine stop solenoid P5-Glow CN212-Starter motor S terminal

Prepare a stand, which withstands the weight of the engine assembly and can place the removed engine firmly.

(Refer to Tools)

Outside view of engine

33-34

33. UPPER SLEWING STRUCTURE 33.1.13.2 REMOVAL

6 7 5

A

33

6 7 5

3 3 21

B

21

4

4 7 8

7 8 A

6 7 5

6 7 17 19

5

20

3 9

22

3 9

16

22

22 12 15

15

15

14

21 11

15 22 18 19

4

14

11

2 21

11 13

4

B

Dismantling and mounting engine (1) Remove hose of engine oil filter Place oil pan under the connection of filter (1), and disconnect 2 hoses (11).

Tools: Spanner: 17mm (2) Plug connector of filter side and hose (3) Loosen engine mounting bolt of frame 1. Loosen 2 nuts (20) M12.

Tools: Socket: 19mm 2. Loosen 4 capscrews (6) M12X120.

3. Remove 4 plates (5).

4. Remove upper rubber mounts (3) 2 each.

(4) Slinging engine body

Prepare a stand, which withstands the weight of the engine assembly and can place the removed engine firmly.

(Refer to "Tool".)

1. Sling engine hooking wire to lifting lugs on the front and rear sides.

Weight: Approximately. 200kg (441lbs) Wire: 6 dia. (0.236 in) X 1 m (3 ft 3 in) - 2 pcs.

(5) Position engine on the stand stably.

33-35

33. UPPER SLEWING STRUCTURE 33.1.13.3 INSTALLATION Installing is done in the reverse order of removing.

(1) Tightening torque

No.

Name

Tightening torque N.m (lbf.ft)

Remarks Apply Loctite #271 Apply Loctite #271

6

Capscrew

80 (59)

9

Sems bolt

80 (59)

Tightening torque of Separated engine oil filter piping ORS joint Thread size Torque N.m (lbf.ft) PF1/2 PF3/4

162 (119)

Hose Torque N.m (lbf.ft) 78.5 (58) -

33-36

33. UPPER SLEWING STRUCTURE 33.1.14 CONSOLE COVER

33

33.1.14.1 REMOVAL (1) Removing right-hand console cover 1. Press into the "A" part of rubber boot which is tucked into console, and remove right rubber boot (3-4) from console.

2. Loosen 2 sems bolts (7-9) M6X16.

Tools: Plus screw driver 3. During lifting right upper console cover (7-1A) up; disconnect connector of tuner and antenna. Move boot (3-4) upwards and remove console cover (71A).

-Removing of boot and lever is unnecessary.

4. Loosen 3 sems bolts (1-16) M6X16 and remove lower console (1-3A).

Tools: Plus screw driver (2) Removing left-hand console cover 1. Remove left boot (3-4) same way as right console cover. (See above Fig.) Tools: Flat-blade screwdriver 2. Loosen 2 sems bolts (1-16) M6X16.

Tools: Plus screw driver 3. Remove the left upper console cover (1-4A) in the same way as right-hand console cover.

4. Loosen 2 sems bolts (1-16) M6X16 while lifting left under console cover (1-5A) up, and remove left lower console cover.

A 3-4

Removing boot (4)

1-3A 1-4A

1-16

7-9

1-16

1-16

I 1-5A 1-16

1-16

VIEW I Removing console covers

33-37

7-1A

33. UPPER SLEWING STRUCTURE 33.1.14.2 INSTALLATION Install it in reverse order of removing according to the tightening torque table.

Item

Bolts

Tightening torque N.m (lbf.ft)

1-16

Sems bolt M6

5.0 (3.7)

A6

Sems bolt M8

23.0 (17.0)

7-9

Sems bolt M6

5.0 (3.7)

A6

Removing left armrest

33-38

33. UPPER SLEWING STRUCTURE 33.1.15 CONTROL VALVE

33

33.1.15.1 PREPARATION FOR REMOVING (1) Remove panel assembly (2-1) (See 33.1.4.2 Fig. "Removing cover assembly (2-1)") (2) Remove cover assembly (2-5) (See 33.1.4.2 Fig. "Removing panel assembly (2-4)") (3) Release air in hydraulic oil tank, open cover of suction element of hydraulic oil, and lower the level.

(See 33.1.8.1 Fig. "Hydraulic oil tank")

Mark each hose with a port name before removing it.

33.1.15.2 REMOVAL (1) Removing hoses for each piping Attach tag on hose, and write port name on it, then remove hoses.

Functions

Ports A8

Option (Head)

A7

Arm out

Ports on right sides (on machine)

Ports

Functions

B8

Option (Rod)

B7

Arm in

Dr3 Drain

B6

Bucket digging

A6

Bucket dump

Dr2 Drain

A5

Boom down

UPPER SIDE

REAR

B5

Boom up

FRONT

A4

Dozer down

B4

Dozer up

A3

Travel left (Forward)

B3

Travel left (Reverse)

A2

Travel right(Forward)

B2

Travel right (Reverse)

A1

Swing (Right)

B1

Swing (Left)

Ports

Functions

BOTTOM SIDE

Ports on rear sides (on machine) LEFT SIDE

P3

Pr

P

UPPER SIDE

Pump

Functions

a8

Option (Head)

a7

Arm out

Pi2

Back press.

CompensatonPump

Pump

RIGHT SIDE

Ports

BOTTOM SIDE

33-39

a6

Bucket dump

a5

Boom down

a4

Dozer down

a3

Travel left

a2

Travel right

a1

Swing (Right)

Ps

LS press. detection

33. UPPER SLEWING STRUCTURE

Functions

Ports

Ports on front sides (on machine) RIGHT SIDE

T1

UPPER SIDE

Ports

LEFT SIDE

Functions

b8

Option (Rod)

b7

Arm digging

b6

Bucket digging

b5

Boom up

b4

Dozer up

b3

Travel left (Reverse)

b2

Travel right (Reverse)

b1

Swing (Left)

Tank

Pi1 Boom lock valve release

dr1 Drain BOTTOM SIDE

(2) Remove control valve 1. Remove 2 sems bolts (6) M12x30 and remove 2 sems bolts (7) M12x35 attaching bracket (1), remove bracket (1).

2. Remove 4 sems bolts (7) M12X35 from upper frame.

3. Install the eye bolt to the tap (a) M12 X depth 25.

4. Remove bracket (1) together with control valve.

5. Remove 3 sems bolts (7) M12X35 from bracket.

Tools: Spanner: 19mm Weight : 42 kg (93 lbs)

a

2

0 3

1 6 7

7 4

7 7 Removing main control valve 33.1.15.3 INSTALLATION (1) Installing is done in the reverse order of remove.

Tools: Socket: 19mm Weight of seat stand : 121 N-m (89 lbf-ft) (Bracket to upper frame) 100 N-m (74 lbf-ft) (Bracket to control valve) (2) Make certain that attachment moves normally in operation.

(3) Check oil level and that it is free from oil leakage.

33-40

33. UPPER SLEWING STRUCTURE 33.1.16 PILOT VALVE (FOR ATT)

33

33.1.16.1 PREPARATION FOR REMOVING The removing procedure for right and left is the same, so the preparation for left side is described here.

(1) Put attachment on ground, stop engine and release pressure in tank.

(2) Remove left console cover (1-4A), (1-5A) assembly referring to Section 33.1.14CONSOLE COVER. (3) Disconnect harness connector for horn at * position.

(4) Attach a tag to the hose to make assembly work easier.

3-1B

3-3

3-4

Installing and removing boot and lever part 33.1.16.2 REMOVAL (1) Remove hoses from your side to far side in order.

Tools: Spanner: 19mm, 22mm (2) Move the boot (3-4) up and loosen nut (3-3).

(See above Fig.) Tools: Spanner: 22mm (3) Turn and loosen lever (3-1B) tightened in pilot valve, and remove lever assembly in a set. (See above Fig.) (4) Remove 4 capscrews (A14) M6X25. (See right Fig.) Tools: Allen wrench: 5mm (5) Remove pilot valve.

(6) Plug hose ends.

Plug PF1/4, PF3/8

A14

PILOT VALVE Tightening torque 49N.m (36 lbf.ft) PF3/8 Valve side Opposing flats 22

Tightening torque 29.4N.m (22 lbfft) PF1/4 Opposing flats 19 Mark "F"

PF3/8

1

Hose side 4,5 6,T port connector

PF1/4

P port connector (With filter)

Pilot valve connector Front of machine T

Arm (R) (Green)

T

Boom (R) (Gray)

Swing (R) (Red)

Bucket (R) (Blue)

Swing (L) (Gray)

Arm (H) (Blue)

LEFT SIDE

Bucket (H) (Red) P Boom (H) (Green) RIGHT SIDE

P

Pilot valve port position (from upper side)

33-41

33. UPPER SLEWING STRUCTURE 33.1.16.3 INSTALLATION Install it in the reverse order of removal and tighten it.

Tools: Allen wrench: 5mm T = 11.8N-m (11 lbf-ft) capscrew (A14) See Fig. "Pilot valve connector".

Make sure the tightening torque for capscrews, because pilot valve is made of aluminum.

33-42

33. UPPER SLEWING STRUCTURE 33.1.17 PILOT VALVE (FOR TRAVEL)

33

33.1.17.1 PREPARATION FOR REMOVING (1) Release pressure in hydraulic oil tank (2) Remove under cover (See 33.1.5 UNDER COVER) (3) Remove floor mat 33.1.17.2 REMOVAL (1) Disconnect pre pressure sensors connectors at two places from under floor harness.

(2) Remove two pressure sensors.

Tools: Spanner: 19mm (3) Disconnect lead cable CA103 for travel 1,2 speed at two places from under floor harness.

(4) Attach tag, and disconnect connectors and hoses.

Tools: Spanner: 19mm (P port) Tools: Spanner: 19mm (T port, 1~4 port) (5) Plug hose ends Plug PF1/4 (6) Remove four capscrews (7) M10 (7) Remove right and left levers.

(8) Remove four socket bolts (10) M10.

Tools: Allen wrench: 8mm (9) Remove pilot valve lifting it upward.

(10)Stop up holes with blank plugs PF1/4, 3/8.

7

Lead cable for travel 1,2 speed

10 PF1/4 PRESSURE SENSOR

Connect to under floor harness with CA103 plug PRESSURE SENSOR

T

CONNECTORS

P 4 3

2 1

33.1.17.3 INSTALLATION Install it in the reverse order of removal and tighten it to the below tightening torque.

Tools: Spanner: 19 mm, 22 mm T=29 N-m (22 lbf-ft) Tools: Allen wrench: 8 mm T=46 N-m (34 lbf-ft) Pressure sensor Tools: Spanner: 19 mm T=29 N-m (22 lbf-ft)

Opposing PF3/8 flats 22 PF1/4

HOSE SIDE

VALVE SIDE VALVE SIDE

T port connector PF3/8 Opposing flats 22

Opposing flats 22 MARK “ F ” PF1/4

PF1/4

PF1/4 HOSE SIDE 1-4 port connector

P port connector

Installing and Removing pilot V

33-43

33. UPPER SLEWING STRUCTURE 33.1.18 SWING MOTOR UNIT 33.1.18.1 PREPARATION FOR REMOVING (1) Park machine on flat and solid ground and put attachment and dozer on ground.

(2) Operate the switch on gauge cluster and select the pressure release mode, and then release the inner pressure in circuit by operating control lever. (See HYDRAULIC SYSTEM) (3) Release internal pressure through bleeder of hydraulic oil tank.

(4) Remove boom as necessary to make work easier.

(Refer to chapter of Attachment.)

(5) Remove cab if necessary to make work easier.

(Refer to Chapter of Upper structure.)

(6) Remove cover under engine.

(7) Attach tag to hose.

C/V R2S/M MU

5

S/M DrTANK

4

S/M DrS/J E

9

SWIVEL JOINT

SWING MOTOR

7

A3

C/V B1S/M B

7

S/V A3S/M PG

C/V A1S/M A

Swing unit piping 33.1.18.2 REMOVAL (1) Remove hose.

1.

Remove hose (5) from the connector in the makeup port MU. Tools: Spanner: 36 mm 2.

Remove 2 hoses (4), (9) from the Tee in the drain port Dr. Tools: Spanner: 22 mm 3.

Remove hose (3) from the elbow of the PG port.

(For swing parking brake) Tools: Spanner: 19 mm 4.

Remove 2 hoses (7) from the connectors of the A, B port.

Tools: Spanner: 32 mm Put in plugs PF3/8, PF3/4, PF1/2, and PF1/4 into the removed ports.

(2) Removing the swing unit 1.

Remove a sems bolt (8) M10X20 and remove connector (4).

2. Remove 8 capscrews (9) M16X50.

Tools: Socket: 24mm 3.

Remove tee of MU port and install eye bolts.

33-44

APPLY LOCTITE #515 APPLY TO ALL ROUND OF MOUNTING FACE FOR MOTOER, SWING

4

SETTING POSITION OF SWING MOTOR ASSY

9

APPLY LOCTITE #262 TIGHTENING TORQUE 279 N.m (206 lbf.ft)

8 Installing swing motor unit

33. UPPER SLEWING STRUCTURE 4.

Put a wire sling in the eye bolts and remove the swing motor unit.

Weight of swing motor unit ; Approximately. 70kg (154 lbs) (Include reduction assembly) 33.1.18.3 PREPARATION FOR INSTALL (1) Clean mating surfaces of swing motor unit and upper frame.

Tools : spatula, wash oil (2) Apply Loctite #515 on entire mounting surface of swing motor unit.

33.1.18.4 INSTALLATION Install the swing motor unit in the reverse order of disassembly, confirming the orientation of the swing motor unit.

(1) Tighten 8 capscrews (9) M16X50.

Tools: Socket: 24mm Tightening torque: 279N-m (206 lbf-ft) Apply Loctite #262 (2) Fill inside from motor drain port to casing with hydraulic oil before piping for drain

33.1.18.5 PREPARATION FOR DRIVE (1) Before starting operation, check that gear oil #90 (API grade GL-4) level of swing reduction is sufficient.

Amount of oil : 3L (0.8gal) (2) When starting operation, operate motor in low idling and at low speed for several minutes, and check it for possible oil leak and noise.

33-45

33

33. UPPER SLEWING STRUCTURE 33.1.19 SWIVEL JOINT 33.1.19.1 PREPARATION FOR REMOVING (1) Remove attachment assembly (Refer to 3. ATTACHMENT DIMENSIONS) (2) Remove cab (See 33.1.2 CAB) (3) Remove guard (See 33.1.4 GUARD) (4) Removing hoses on undercarriage (See Chapter : Undercarriage) (5) Remove swing reduction unit if necessary. (See 33.2.5 SWING MOTOR UNIT)

33.1.19.2 REMOVAL (1) Remove travel motor hose and tube 1. Remove a hose (A1). (C port : PF1/2) Tools: Spanner: 32mm, Tightening torque : 147N-m (108 lbf-ft) 2. Remove 3 hoses (A2). (A, B, D port : PF1/2) Tools: Spanner: 32mm, Tightening torque : 147N-m (108 lbf-ft) 3. Remove hoses (A4),(A6). (E port : PF3/8) Tools: Spanner: 22mm, Tightening torque : 73.5N-m (54 lbf-ft) 4. Remove hoses (A3),(A5). (H port : PF1/4) Tools: Spanner: 19mm, Tightening torque : 36.3N-m (27 lbf-ft) 5. Remove tubes (A9),(A10). (F, G port : PF3/8) Tools: Spanner: 15mm, Tightening torque : 118N-m (87 lbf-ft)

CONNECTOR T : TIGHTENING TORQUE N.m (lbf.ft)

A10 T=108 (80) B1

B

C

B3

A1

B2

T=108 (80)

D A

B3

B1

A2

A9

B3

B2

E

A3

B5

B3

A2

A6

A2 Removing piping (lower side)

33-46

A5

H

G T=108 (80)

T=108 (80)

B4

F

A4

33. UPPER SLEWING STRUCTURE (2) Disconnecting the hoses on the top part of swivel joint 1. Remove a drain hose (9). (E port : PF3/8) Tools: Spanner: 22mm Tightening torque: 73.5N-m (54 lbf-ft) 2. Remove hoses (7).

(B, C, D port) Tools: Spanner: 32mm Tightening torque: 137N-m (101 lbf-ft) 3. Remove a hose (6).

(A port) Tools: Spanner: 32mm Tightening torque: 137N-m (101 lbf-ft) 4. Remove hoses (1).

(F, G port) Tools: Spanner: 12mm Tightening torque: 59N-m (44 lbf-ft)

C/V B2S/J A

33

6

S/M DrS/J E

9

7

C/V A3S/J D

7

C/V A2S/J C

7

C/V B3S/J B C/V B4S/J F

1

1

C/V A4S/J G

Disconnecting the hoses on the top part of swivel joint (3) Remove whirl-stop of swivel joint.

1. Loosen the nut (3) M20.

2. Remove a capscrew (4) M20X85.

Tools: Spanner: 30mm

3

4 TIGHTENING TORQUE 157N.m (116 lbf.ft)

mm 11 At assembling, this distance should be 11mm (0.433in).

Removing whirl-stop nut & the capscrew

33-47

33. UPPER SLEWING STRUCTURE (4) Remove sems-bolt for installation Attach eye bolt, lift it up temporarily, and remove 3 sems-bolts (C2) M12X30.

Tools: Socket: 19mm (See 11.7 SPECIAL TOOLS No.9 Plug) EYE BOLT

LOWER FRAME

C2 SEMS-BOLT M12 30 Loctite #262 T=108N.m (80 lbf.ft)

C1 SWIVEL JOINT

Removing sems bolts for installation (5) Slinging the swivel joint Weight: Approximately. 28kg (62 lbs)

33.1.19.3 INSTALLATION (1) Installing is done in the reverse order of removing.

Piping tightening torque (2) Check for oil leak and the hydraulic oil level.

(3) Check for operating.

33-48

Tightening torque N.m (lbf.ft) O-ring type Hydraulic hose Connector 29 (22) 36 (27)

Size PF

Tool.

HEX

1/4

19

3/8

22

1/2

27

108 (80)

78 (58)

3/4

36

162 (120)

118 (87)

1

41

255 (180)

137 (101)

1-14UN

32

-

137 (101)

74 (54)

49 (36)

33. UPPER SLEWING STRUCTURE 33.1.20 UPPER FRAME

33

33.1.20.1 PREPARATION FOR REMOVING (1) Remove attachment (See chapter 32) (2) Remove cab (See 33.1.2 CAB) (3) Remove guard (See 33.1.4 GUARD) (4) Remove counterweight (See 33.1.11 COUNTERWEIGHT) (5) Remove swivel joint (See 33.1.19 SWIVEL JOINT) 33.1.20.2 REMOVAL (1) Lifting up upper frame temporarily Attach an upper-frame hoisting jig to attaching holes of counterweight. Attach 2 chain blocks to holes of boom foot pin and use these four points and hoist upper-frame.

Wire ropes ; 16 dia. X 2.5m, 1 pc.

16 dia. X 1.5m, 2 pcs.

Chain blocks ; For 1 ton, 2 pcs.

WIRE ROPE 16X2.5m CHAIN BLOCK

LIFTING JIG

Lifting up upper frame temporarily (2) Marking match marks on swing bearing Put match marks on upper frame and swing bearing.

MATCH MARK

Matching mark on swing bearing and upper frame (3) Removing upper frame attaching bolts Remove 23 capscrews (B31) M16X85 and a reamer bolt (B30) used to install swing bearing and upper frame.

Tools: Socket: 24 mm (4) Slinging upper frame Sling according to Fig "Lifting up upper frame temporarily", and remove upper frame and put it on a stand.

Weight: Approximately. 5 tons (11,000 lbs)

Removing upper frame attaching bolts

33-49

33. UPPER SLEWING STRUCTURE 33.1.20.3 INSTALLATION (1) Installing is done in the reverse order of removing.

(2) Cleaning mating surfaces of upper frame and swing bearing.

(3) Apply Loctite #515 to the inside of the capscrews on the contact surface.

(4) Slinging upper frame Match marks and install it with a reamer bolt (30) temporarily.

Tools: Socket: 24 mm Apply Loctite #262 Tightening torque : 157N-m (116 lbf-ft) (5) Install swing bearing Install 23 capscrews (B31) M16X85.

Tools: Socket: 24 mm Apply Loctite #262 Tightening torque : 157N-m (116 lbf-ft) Install a reamer bolt (B30).

Tools: Socket: 24 mm, Tightening torque : 157N-m (116 lbf-ft) SWING BEARING OUTER (S) ZONE POSITION

Apply Loctite #515.

Only circumference hatched portion Apply race face of inside capscrew.

*

B30,B31 Apply Loctite #262 TIGHTENING TORQUE: 157N.m (116 lbf.ft)

Bearing mount

Reamer bolt position (*) Apply Loctite to shaded area

Confirm the reamer bolt positions referring to above Fig.

33-50

33. UPPER SLEWING STRUCTURE

33

This page is blank for editing convenience.

33-51

33. UPPER SLEWING STRUCTURE

33.2

DISASSEMBLING AND ASSEMBLING

33.2.1 HYDRAULIC PUMP - REGULATOR 33.2.1.1 CONSTRUCTION 1

2

3 4 5 6 7

8

9 10 11

16

17

12 1314 15

18

19

20

21

A

86 36 38 39 40 42 43 44 45 46 47 48 49 22 23 24 25 26 27 28 29 30 31 32 33 34 35 37 41

44 50 51 52

85

A

56

53 54 55 26

57

58 59 86 73 747576

19

60

61

62 63 19

64 65 66 67 68

69 70

80

7778 79 24 86

81 82

83

84 75

VIEW AA Construction of hydraulic pump & regulator

33-52

71 72

33. UPPER SLEWING STRUCTURE

No.

NAME

Q'TY

No.

NAME

Q'TY

No.

NAME

Q'TY

1

SHAFT

1

31

SPRING

1

61

ROD RE

1

2

OIL SEAL

1

32

SPRING GUIDE

1

62

SPRING

6

3

SHIM

REC

33

CAP: PF1/16

6

63

PISTON RE

1

4

HOUSING

1

34

O-RING: A90

6

64

COVER

1

5

TAPERED ROLLER BRG.

1

35

ROD PW

1

65

SPRING

1

6

SCREW: M5X10

2

36

SLEEVE

1

66

BUSHING

2

7

CRADLE H

1

37

PIN

1

67

SPRING

2

8

CAM

1

38

SERVO CASE

1

68

PLUG

2

9

RETURN PLATE

1

39

ROD

1

69

O-RING: 1B P22.4

1

10

PISTON ASSEMBLY

9

40

PISTON B

1

70

CAP RE: PF3/4

1

11

CYLINDER

1

41

POWER PISTON LAS

1

71

COUPLING

1

12

PORT PLATE CW

1

42

PISTON

1

72

GEAR PUMP

1

13

RING

1

43

SPRING

1

73

SOCKET BOLT: M10X30

1

14

BUSHING

1

44

O-RING

1

74

SNAP RING

1

15

SPRING

1

45

SERVO COVER H

1

75

PLUG

1

16

CRADLE L

1

46

PISTON H

1

76

O-RING: P11 A90

3

17

RETAINER SPH

1

47

SERVO COVER

1

77

LINK

1

18

O-RING

1

48

PISTON U

1

78

PIN

1

19

PARALLEL PIN

6

49

SOCKET BOLT: M6X70

4

79

O-RING: G50 A90

1

20

NEEDLE BRG.

1

50

O-RING: 1B P10

1

80

SOCKET BOLT: M16X90

3

21

O-RING: 1B G55

1

51

BUCK UP RING

1

81

CAPSCREW: M8X25

2

22

NUT: M10

1

52

STOPPER

1

82

WASHER

2

23

NUT: M20

1

53

SET SCREW: M12X30

1

83

SOCKET BOLT: M16X110

1

24

O-RING: P9 A90

4

54

NUT: M12

1

84

CAP: PF1/4

2

25

CAP SP: PF1

1

55

CAP: PF1

1

85

CAP ASSEMBLY

1

26

O-RING: 1B P29

2

56

SPRING

1

86

SERVO CASE ASSY

1

27

SLEEVE

1

57

SEAL RETAINER

1

28

O-RING: 1B P20

1

58

SOCKET BOLT; M10X20

6

29

STOPPER

1

59

O-RING: 1B G75

1

30

SPRING

1

60

GUIDE

1

33-53

33

33. UPPER SLEWING STRUCTURE 33.2.1.2 DISASSEMBLY AND ASSEMBLY (1) Disassembly of components (Body, Regulator, Gear Pump) 1. Gear pump removing Loosen bolts (81) (Opposing flats 13), and remove plain ground washers (82) and gear pump (72).

Remove collar, coupling (71), and O-ring (21).

81

2 PLACES

82

2 PLACES

72 COLLAR

21 71

Gear pump removing 2. Removing regulator Loosen bolts (73) (Opposing flats 8), and remove regulator. Remove pin (19) from cover (64).

73 2 PLACES

38 37 19

64

Removing regulator

The regulator might be hard to remove due to the interference of parallel pin (19).

33-54

33. UPPER SLEWING STRUCTURE (2) Piston pump disassembly 1. Disassembly of regulator Turn the piston pump upside down and face shaft input axis downwards, fix housing (4) to work bench with bolts (M12 X 30). Loosen cap PW (55) (Opposing flats 41) and remove spring (56).

The cap PW (55) has stopper (52), set screw (53), and nut (54). Loosen cap RE (70) (Opposing flats 36) and remove spring (65). Using magnet, remove piston RE (63) and rod RE (61). Loosen socket bolts (80) (83) (Opposing flats 14).

54

70

55

65

56 81,82 64

63 61

4 WORK BENCH HOLE( 128 to

130)

FIXING BOLT

(M12 X 30 OR MORE)

Disassembly of regulator

-Above mentioned cap is used to determine the maximum flow rate and the minimum flow rate. Make sure to mark the original position with matchmark for reassembly before disassembly.

-Do not loosen nut (54) when not required.

-Since piston pump is turned upside down in the following procedure, loosen socket bolt but do not remove it completely.

2. Removing seal retainer Turn the piston pump upside down and face the input shaft axis upwards.

Loosen socket bolt (58) (Opposing flats 8) and remove seal retainer (57), shim (3), and O-ring (59).

58

6 PLACES

57 3

59

4

Removing seal retainer (57)

Use the tapped hole (M10) provided on seal retainer (57).

33-55

33

33. UPPER SLEWING STRUCTURE 3. Removing oil seal Put seal retainer (57) on wood blocks (30 mm in height), and tap the oil seal (2) with screw driver and remove it.

4. Removing bolts Remove 3 socket bolts (80) and 1 socket bolt (83) (Opposing flats 14) from cover (64).

2 30

57

64

83 80 3 PLACES

Removing oil seal (2) and bolts (80),(81)

Do not reuse oil seal (2).

5. Removing housing Lift housing (4) by hand and remove it.

(About 10 kg)

FLANGE PART

4

19 64 Removing housing (4)

-During removing inner parts, do not damage them.

-The housing might be hard to remove due to the interference of parallel pin (19). At that time, tap the housing flange using soft head hammer to make the removal easier.

33-56

33. UPPER SLEWING STRUCTURE 6. Removing rotary assembly Remove parts installed on cover (64) in order of shaft (1) on which taper roller bearing inner race (5) is installed, cam (8), return plate (9) on which piston assembly is installed, retainer SPI (17), spring (62), cylinder (11), port plate CW (12), and bushing (66).

And then, remove rod PW (35) and power piston assembly (41).

5 (INNER RACE)

1

8 9 10 17

35

62 6 PLACES

11 12

41

2 PLACES

66

64 Removing rotary assembly

Put matchmark on the sides of return plate (9) and cylinder (11) to make the installation position into piston hole easy to find.

7. Removing bushing Remove O-ring (18), ring (13), bushing (14), and spring (15) from cover (64).

18 13 14 15 67 2 PLACES

64

Removing bushing (14)

33-57

33

33. UPPER SLEWING STRUCTURE 8. Removing taper roller bearing Apply gear puller to inner race of taper roller bearing (5) and spline of shaft (1) as shown in right Fig., and remove the inner race of taper roller bearing (5) from the shaft.

5 (INNER RACE)

1

Removing taper roller bearing (5) 9. Removing cradles Loosen socket head screws (6) (Opposing flats 3) and remove cradles (7) (16). And remove the outer race of taper roller bearing (5).

6

2 PLACES

12 7

4

5 Removing cradles (7), (16)

Cradles (7) and (16) differ from each other in groove form. Install them to the original positions by putting the matchmark when assembling the cradles again.

33-58

33. UPPER SLEWING STRUCTURE (3) Disassembling regulator 1. Loosen and remove cap SP (25) (Opposing flats 41) and remove springs (30) (31) and spring retainer (32). Using a magnet, remove rod (39) and piston B (40) together.

Loosen 4 socket head bolts (49), remove regulator cover (47), piston U (48), and O-ring (44). And then remove regulator cover H (45), piston H (46), and O-ring (44).

And remove piston (42) and spring (43).

22 23 25

30 31 32

39 38 48

40

44

43

47 42 44 45

49

46 Disassembly of regulator (1/2)

Do not loosen nut (23) when not required.

(It might change the power setting.)

2. Remove O-rings (24) (79) from regulator casing (38).

Using a pliers, remove snap ring (74), and using tapped hole (M5), remove plug (75).

Remove link (77) and then remove sleeve (36).

36

74 75 79

38 24

3 PLACES

77 Disassembly of regulator (2/2)

33-59

33

33. UPPER SLEWING STRUCTURE (4) Preparation for assembly Complete the following items in advance before reassembly.

1. Check every part for possible damage caused by operation or disassembly, and when flaw found, remove the flaw with oil stone in grain size or sand paper as required, clean it with the wash oil and dry it with air blow.

2. Replace all sealing parts with new ones.

(Oil seal and gasket included) 3. Lap the sliding surfaces of piston assembly (10), cylinder (11), port plate (12) and cam (8) with #2000 sand paper on surface plate.

4. In installing sealing parts, apply grease slightly prior to assemble.

5. When assembling sliding section, apply thin film of clean hydraulic oil before assembling.

10

Lapping of piston assembly

(5) Assembling of piston pump body 1. Installing of bushing Install spring (15), bushing (14), and ring (13) into cover (64) in order. And install O-ring (18) into Oring groove of cover (64).

18 13 14 15 2 PLACES

67 64

Installing of bushing O-RING GROOVE

Installing of O-ring (18)

33-60

33. UPPER SLEWING STRUCTURE 2. Installing of port plate Apply grease to bushing (66) to prevent from fall.

And install the bushing into the hole of port plate (12). Then align the port plate with positioning pin, and install it into cover (64).

12

33

SECTION

66

2 PLACES

64

Installing of port plate (12)

INSTALLING DIRECTION

Positioning of cover (64) 3. Installing of piston assembly Install return plate (9), which is installed spring (57), retainer SPH (17), and piston assembly (10), into cylinder (11).

9 10 17 57

6 PLACES

11

Installing of piston assembly (10)

Refer to matchmark, which is put on the side faces of return plate (9) and cylinder (11) prior to disassemble it, install piston assembly (10) to the original hole.

4. Installing of cradles Install cradles (7) (16) into housing (4), and tighten them to the specified torque 5.9 Nom (4.4 lbfoft) with socket head screw (6) (Opposing flats 3).

6

2 PLACES

16

7

4

Installing of cradles (7), (16)

33-61

33. UPPER SLEWING STRUCTURE

Tighten socket head screw (6) temporarily to position cradles (7) and (16) in parallel. And apply hydraulic oil to cradles (7) and (16), place cam (8) on them, and get the smooth movement of cradles by tilting several times. Then remove cam (8) once and tighten socket head screw (6) to specified torque.

5. Installing shaft Apply hydraulic oil to port plate (12) (sliding surface with cylinder (11)) which is installed by the procedure shown in Item 2). And place the port plate on cylinder (11) which is installed by the procedure shown in Item 3). Apply hydraulic oil to the shoe sliding surface of piston assembly (10) and place cam (8) on the shoe sliding surface.

Install shaft (1) so as to connect to the spline of cylinder (11).

Install power piston assembly (41) on cover (64) and install rod PW (35) on power piston assembly (41).

1

8 35 9 11 41

64

Installing shaft (1) 6. Installing rod PW In order to make the assembly easier, install spring (Jig) to the lower part of power piston (41) and cover the spring with cap (Jig) to float power piston (41).

Connect power piston assembly (41) and cam (8) to rod PW (35) in this condition.

35 41 ASSEMBLY JIG (SPRING) (SEE (9) ASSEMBLY JIG) ASSEMBLY JIG (CAP) (SEE (9) ASSEMBLY JIG)

Installing rod PW (35)

-Apply grease on the spherical surface of rod PW (35).

(To prevent fall) -Pay attention to rod PW (35) direction. The side the diameter of sphere is larger is in contact with the cam.

33-62

33. UPPER SLEWING STRUCTURE 7. Installing housing Lower the housing assembly slowly which is assembled by the procedure of Item 5) from upper side of the cover assembly which is assembled by the procedure of Item 4). And tighten it temporarily with socket bolts (80) (83) (Opposing flats 14).

4

64 83 80 3 PLACES

Installing housing (4)

-In this case, cam (8) and cradles (7) (16) might be hard to fit each other. At that time, rock the housing side assembly and it becomes easier to insert into cover assembly.

-Do not pinch your fingers between housing (4) and cover (64).

8. Installing taper roller bearing (Inner race) Using press-fitting jig, and tap it with hammer, and press-fit the taper roller bearing (Inner race).

PRESS FITTING JIG (SEE (9) ASSEMBLY JIG)

5

(INNER RACE)

Installing taper roller bearing (Inner race) (5) 9. Installing taper roller bearing (Outer race) Install taper roller bearing (5) (Outer race).

5

(OUTER RACE)

Installing taper roller bearing (Outer race) (5)

33-63

33

33. UPPER SLEWING STRUCTURE 10.Installing oil seal Clean and degrease the groove of seal retainer (52) for oil seal (2). And clean the periphery of oil seal (2) and apply liquid sealant (ThreeBond #1211 or equivalent). Then using assembly jig, install the oil seal into seal retainer (52).

PRESS FITTING JIG (SEE (9) ASSEMBLY JIG)

2

52 Installing oil seal (2) TAPERED ROLLER BEARING SIDE

SHAFT INPUT AXIS SIDE

Installing direction of oil seal (2)

Pay attention to oil seal (2) installing direction.

11.Installing seal retainer Install shim of the number of sheets which was originally installed. Install seal retainer (52) which is installed oil seal (2) and O-ring (59) into housing (4). Remove seal protector and tighten 6 socket bolts (58) (Opposing flats 8) to the specified torque 64.7 N-m (47.7 lbf-ft).

58

6 PLACES

57 59 SEAL PROTECTOR (SEE (9) ASSEMBLY JIG)

3

4

Installing seal retainer (52)

-Apply grease to lip surface of oil seal (2) slightly.

-When adjustment of thickness with shim (3) is required after replacement of parts, refer to 33.2.1.2(8) "Shim adjusting method".

12.Installing cap/rod RE/piston RE Remove assembly jig (For cap and spring) and install spring (56). And install cap (55) (Opposing flats 41), which includes stopper (52)/set screw (53)/nut (54).

Install rod RE (61) into piston RE (63) and install them into cover together.

ASSEMBLY JIG (SPRING) ASSEMBLY JIG (CAP)

64

55

56

63 61 Installing of rod RE (61), piston RE (63)

33-64

33. UPPER SLEWING STRUCTURE

33

-Remove the assembly jig using care that power piston assembly (41) is not moved toward cap (55) side.

(Rod PW (35) may fall.)

-If rod PW (33) should fall, try the installation again from the procedure of Item 6.

13.Installing cap RE Install assembly jig to cover (64) and push piston RE (63) in. Remove assembly jig and install cap RE (70) with spring (65) and O-ring (69).

64

ASSEMBLY JIG (SPRING) (SEE (9) ASSEMBLY JIG)

65

63 6mm or LESS

69

70

ASSEMBLY JIG (SOCKET BOLT) (SEE (9) ASSEMBLY JIG)

Installing cap RE (70) 14.Installing cap PW/cap RE/Tightening socket bolt Turn the piston pump upside down and face the input shaft axis downwards. Install the pump to work bench with socket bolts.

Tighten cap PW (55) (Opposing flats 41) to the specified torque 350 N-m (258 lbf-ft).

Tighten cap RE (70) (Opposing flats 36) to the specified torque 240 N-m (177 lbf-ft).

Tighten 3 socket bolts (80) and a socket bolt (83) (Opposing flats 14) to the specified torque 290 N-m (214 lbf-ft).

55

81,82

70

WORK BENCH

HOLE( 128 to

130)

FIXING BOLT

(M12 X 30 OR MORE)

Installing cap PW (55), cap RE (70) 15.Check the assembling After assembling the main pump, turn shaft (1) with pipe wrench while protecting spline shaft (1) with cloth, and make sure that it rotates smoothly.

1

Check the assembling

33-65

33. UPPER SLEWING STRUCTURE (6) Assembling regulator 1. Install sleeve (36) to regulator (38) from cap SP (25) side.

36 SLOTTED HOLE

38

Installing of sleeve (36)

Install sleeve (36) placing the slotted hole in the depths.

2. Install link (77) on which pin (78) is installed on the matching surface side to cover (38), insert pin (78) into the slotted hole of sleeve (36) and match the position of link fulcrum hole of the regulator to that of fulcrum hole of the link.

Install plug (75) with O-ring (76) is installed through the link fulcrum hole from the side. Install snap ring with snap ring pliers and install O-rings (24) (79).

FULCRUM HOLE

38

VIEW I

SLOTTED HOLE

77

Installing of link (77)

74 75

76

FULCRUM HOLE

77 78 3 PLACES

24 79 Installing of plug (75) and O-rings (24),(79)

33-66

33. UPPER SLEWING STRUCTURE 3. Install piston B (40) on rod (39) and insert it in sleeve (36) installed by the procedure shown in Item 2).

Install spring retainer (32), spring (31) and spring (30) in order and tighten cap SP (25) (Opposing flats 41) to the specified torque 50 N-m (37 lbf-ft).

4. Install spring (43) and piston (42) on regulator (38) in this order. Pass socket bolt (49) through servo cover (47) on which piston U (48) and O-ring (44) are installed and servo cover H (45) on which piston H (46) and O-ring (44) are installed, bring the end face of servo cover H (45) in contact with servo case (38), and tighten socket bolt (49) to the specified torque 12 N-m (9 lbf-ft).

22 25 30

31 32

39 48 44

43 40

42

47

44

49

45 46 Assembling of regulator

-Be careful not to drop and miss piston B. -Make sure that link moves smoothly.

-Pay attention to the directions of rod (39), piston B (40), piston (42), and piston H (46).

-Pay attention to the phases of servo covers (45) (47).

(7) Assembly of components 1. Assembly of control part a. Using the hole of cover (64), install pin (37) to power piston assembly (41).

73

2 PLACES

38 37 19

64

Assembling of regulator

When the groove phase of power piston assembly (41) is displaced, turn it in circumferential direction with scriber and adjust the groove phase of power piston assembly (41) to cover (64) pin hole.

33-67

33

33. UPPER SLEWING STRUCTURE b. Match the pin phase of power piston assembly (41) to the notch of link (77), install it on the main body so that the pin falls in the range of helical groove, and tighten socket bolt (73) (Opposing flats 8) to the specified torque 66 N-m (49 lbf-ft).

77

NG

77

OK

Position of pin phase

Checking on the link connection A space about 3mm is left between servo case (38) and cover (64) due to the parallel pin (19) with servo case (38) lightly placed on cover (64). Push link (77) with thin plate through this space and check that it is not moved.

When it is wrong assembly, link (77) is moved.

3. Installing gear pump Install O-ring (21) and collar to cover (64), and assemble coupling (71) and shaft (1). Then check the phase on gear pump (72), and install it by tightening bolts (81) (Opposing flats 13) with plain ground washers (82) to the specified torque 32.4 Nm (23.9 lbf-ft).

If this pump does not have gear pump, tighten bolts (81) (Opposing flats 13) with hole caps to the specified torque 30 N-m (22 lbf-ft).

81

2 PLACES 2

82 72

COLLAR

21 71

Installing gear pump (72) 4. Check the assembling After assembling the main pump, turn shaft (1) with pipe wrench while protecting spline shaft (1) with cloth, and make sure that it rotates smoothly. And check the rotation of gears in gear pump (72).

1

Check the assembling

33-68

33. UPPER SLEWING STRUCTURE (8) Shim adjusting method After disassembly and adjustment, if the shim thickness adjustment is required by replacement of parts, carry out the adjustment by the following procedure. Prepare shim adjusting collar 1, collar 2 for assembly jig in advance, and install collar 2 on the outer ring of taper roller bearing (5) and collar 1 on housing (4) in the condition where the procedure in Item 9) "Assembling piston pump main body" is completed.

Place seal retainer (52) on it and tighten 3 socket bolts M10X35 to the specified torque 1.5 N-m (1.1 lbf-ft).

Measure the space between collar 1 and seal retainer (52) with thickness gauge, and determine "Shim thickness = 1.9 - measured space value (mm)".

Remove collars for adjustment and install shim (3) equivalent to the determined thickness on the outer ring of taper roller bearing (5).

(9) Assembly jig 1. Rod PW assembly jig Spring Spring rate : 0.3 Wire diameter : 1.4 Free length of spring : 60 Total number of coils : 5.25 Outer diameter : 17 Above mentioned specification spring or equivalent is required.

2. Taper roller bearing press-fitting jig

3. Oil seal press-fitting jig

33-69

SHIM ADJUSTING COLLAR 1 (SEE (9) ASSEMBLY JIG) SHIM ADJUSTING COLLAR 2 (SEE (9) ASSEMBLY JIG) SOCKET BOLTS 3 PCS. (M10 X 35)

57 5 4

Shim adjusting method

CAP

OPPOSING FLATS 17, DEPTH 7.5

33

33. UPPER SLEWING STRUCTURE 4. Assembly jig for seal retainer (Seal protector)

5. Shim adjusting collar

COLLAR 1 THROUGH

COLLAR 2

6. Piston RE inserting jig

CAP

SOCKET BOLT COMPLETE THREAD

33-70

33. UPPER SLEWING STRUCTURE 33.2.1.3 MAINTENANCE STANDARD After disassembly of pump, if any remarkable damage was found on any part or the wear of each sliding part is more than the standard value, replace the parts with new ones.

Inspection and Measurement location

Parts

Piston assembly (10)

Standard (Service limit)

Measuring Instrument

Corrective action

Surface roughness meter

Correct by paper lapping

0.4mm (0.016") or less

Micrometer

Replace with a new one

0.4mm (0.016") or less

Dial gauge

Replace with a new one

Roughness of shoe sliding surface

0.8 S

Flaw depth of shoe sliding surface Looseness of connection part between caulked piston and shoe

Outer diameter of piston

Hardly worn out. In case of flaw or seize, replace it with new one.

Cam (8)

Roughness of surface

0.8 S

Surface roughness meter

Lapping

Cylinder (11)

Roughness of end surface

0.4 S

Surface roughness meter

Lapping

Piston bore

Hardly worn out. In case of flaw or seize, replace it with new one.

Port plate (12)

Roughness of surface

0.8 S

Gap between piston Piston assembly (10) outer diameter and Cylinder (11) piston bore

Parts

0.04mm (0.0016") or less

Surface roughness meter

Lapping

Micrometer Pneumatic Micrometer

Replace with a new one

Inspection and Maintenance Standard

Taper roller bearing (5) Needle bearing (20)

If flaking on inner and outer race is found, replace the bearing with a new one.

After disassembling replace the bearing with a new one, and reassemble it.

Oil seal (2)

If flaw on lip is found, replace the oil seal with a new one.

After disassembling replace the oil seal with a new one, and reassemble it.

O-ring If flaw on O-ring is found, replace the O-ring with a new one.

(18),(21),(26),(41),(43),(54),(64),(73) After disassembling replace the O-ring with a new one, and reassemble it.

33-71

33

33. UPPER SLEWING STRUCTURE 33.2.1.4 TROUBLESHOOTING

Trouble Pump does not deliver.

Delivery rate is extremely small.

Pressure does not rise.

Engine stalls.

(Over load)

Oil leak

Noise Abnormal vibration

Cause

Remedy

Pump does not run.

Check connection of coupling.

Suction pipe and filter are clogged.

Check pipe and clean suction filter.

Suction pipe is not immersed in hydraulic oil.

Check hydraulic oil level.

Wrong connection of regulator piping.

Check piping for regulator.

Breakage of pump itself.

Replace the damaged part.

Swash plate is not out of control. Link and power piston were assembled incorrectly.

Correct failure.

Set pressure of regulator is too high.

Readjust set of regulator.

Pump is seized or broken itself.

Replace the damaged part.

Breakage of regulator itself.

Replace the damaged part.

Oil leaks from oil seal.

Replace the oil seal with a new one.

Oil leaks from mating surfaces.

If seal was damaged, replace it.

Check the tightening torque of mounting bolts.

Check foreign matter between mating surfaces.

Air bubble is mixed in hydraulic oil.

(Cavitation, Aeration)

Check hydraulic oil level.

Check for the clogging of suction pipe and filter.

Check suction pipe at air inlet.

Check viscosity of hydraulic oil.

Was the air bleed from casing done?

Pump is installed incorrectly.

Align and readjust pump again.

Scuffing and seizure between piston and cylinder.

Replace broken parts and check cleanliness of hydraulic oil.

Seizure between cylinder and port plate.

Replace broken parts.

Wrong assembly of port plate.

Check the assembling of suction and delivery.

Abnormal wear of sliding parts.

Replace worn parts.

Check cleanliness, moisture, viscosity, and temperature of hydraulic oil.

33-72

33. UPPER SLEWING STRUCTURE 33.2.2 CONTROL VALVE

33

33.2.2.1 PREPARATION FOR DISASSEMBLY (1) General cautions 1. Since hydraulic components are finished to precision with small clearance, it is necessary to disassemble and reassemble them in clean, less dusty place.

Use clean tools and cleaning oil and handle components with sufficient care.

2. If the control valve is removed from the machine, clean ports thoroughly and put a plug in each port so as to prevent entry of dust and water.

When installing the control valve back to the machine, do not remove plugs until the valve is properly piped.

3. Study the structural drawing before beginning work and prepare necessary parts according to the purpose and the scope of the work. Some parts are not available loosely but in assemblies. Therefore, prepare parts beforehand according to the Parts Manual.

(2) Cautions to be exercised in disassembly 1. Since components are finished to high precision, handle them with sufficient care. Use care so as not to bump components against each other or drop them.

2. Do not strike or twist components by force even if they are tight, or the components develop burrs or are broken.

This makes the components impossible to be assembled and results in oil leakage and deterioration in performances. Therefore, handle components with full care.

3. Attach a tag to each component so it is reassembled in a correct position.

4. Once disassembled, do not reuse O-rings and backup rings.

(Remove them with the tip of a steel wire shaped in a spatula. Take care so the groove is not scored.)

5. If parts are left, as they are halfway during disassembly or after disassembly, they may rust due to moisture and dust. When interrupting the work for unavoidable reason, use care so as to prevent parts from rusting or being exposed to dust.

Replacing the main plungers Since the main plunger is selectively fitted to the housing, it is designated as "not service part". Therefore, note that in principle the main plunger cannot be replaced in the field. In case the plunger must be replaced for some reason, inform us with the model and the manufacturing number that are stamped on the nameplate.

33-73

33. UPPER SLEWING STRUCTURE

70

1

40

D

(3) Tools and jigs Holder Matenrial: brass

19

Devided by 2

Tools and jigs

NAME PLATE

Name plate

33.2.2.2 DISASSEMBLY The disassembly procedure is explained as below. Assembly is the reverse order of disassembly.

Before disassembly, attach tags to parts so they are reassembled properly.

(1) Disassembling the main plunger 1. Remove socket bolt (1) and cover (2) in that order.

Tools: Allen wrench: 5 mm Tightening torque : 13N-m (9.6 lbf-ft)

3

2

1

Removing cover (2)

Before reassembling the cover, make certain that an O-ring is placed on the mouth of the housing.

2. Draw out the plunger sub-assembly.

Draw out the plunger sub-assembly

33-74

33. UPPER SLEWING STRUCTURE

-Do not draw out the plunger in a breath, but rotate it slowly while drawing it out and confirming the contact with the housing.

-When reassembling BM-1, match the keyway at the tip of the plunger to the plug in whirl-stop cover.

3. Hold the plunger by the tool (holder), hold it in a vise and loosen plunger cap (3).

Tools: Allen wrench: 6 mm Tightening torque : 30 N-m (22 lbf-ft)

HOLDER

3

Removing plunger cap (3)

Degrease the plunger and the holder thoroughly.

4. Remove plunger cap (3). Then remove spacers (4) (5), spring (6), and spring guide (7).

3

4

5

6

7

7 6 5 4 3 Removing plunger and spring

Note that the spring differs in each plunger.

(2) Removing main relief valve 1. Lock adjusting screw (1) and loosen nut (2).

2. Lock cap (4) and loosen cap (3).

1

2

3

4

Removing main relief valve

33-75

33

33. UPPER SLEWING STRUCTURE 3. Loosen cap (4) and remove the cartridge assembly.

A

4. Remove main poppet sub-assembly (A). Then remove orifice (5), spring (6), and main poppet (7) from sleeve (8).

1 2 3 4

5

NAME OPPOSING FLATS 4 ADJUSTING SCREW 13 NUT 27 CAP 30 CAP

6

7

8

7 6 5 Removing sleeve (8) 5. Remove adjusting part sub-assembly (B). Then remove spring (9) and pilot poppet (10) from cap (4).

B

4

9

10

10 9

Do not disassemble pilot seat (C) because it is press fitted to the sleeve.

33-76

PILOT SEAT C

33. UPPER SLEWING STRUCTURE (3) Disassembling selector valve 1. Remove socket bolt (1) and remove selector valve.

Tools: Allen wrench: 6 mm Tightening torqu : 30 N-m (22 lbf-ft)

2

3

4

A

33

N SECTION A-A

B

A

Disassembling selector valve

Before reassembling the cover, make sure that an O-ring is placed in the mouth of the cover.

2. Remove snap ring (2), and remove spacer (3) and rotor spool (4).

1

2

4

3

(4) Disassembling of load check valve Remove cap (1), and remove spring (2) and check valve (3).

Tools: Allen wrench: 27 mm Tightening torqu : 80 N-m (59 lbf-ft)

1 2

3

2 3 Disassembling of load check valve

33-77

33. UPPER SLEWING STRUCTURE (5) Disassembling the load holding valve (Boom, Arm, Boom swing) 1. Disassembling the main poppet a. Remove socket bolt (1) and cover assembly (2) in that order.

Tools: Allen wrench: 6mm Tightening torque : 30 N-m (22 lbf-ft)

2

1

3

4

Load holding valve (Boom, Arm, Boom swing)

Before reassembling the cover, make sure that an O-ring is placed in the matching surface of the cover. b. Remove spring (3) and poppet (4).

3 4 Removing spring (3) and poppet (4)

2. Disassembling the cover (2) a. Remove cap (5) and take out piston (6), spring (7) and piston (8).

Tools: Spanner: 41mm Tightening torque : 100 N-m (74 lbf-ft) b. Remove cap (11), spring (10) and poppet (8) in that order.

Tools: Allen wrench: 8mm Tightening torque : 50 N-m (37 lbf-ft)

6 7

8 10 13 14 15 Disassembling the cover (2)

33-78

33. UPPER SLEWING STRUCTURE

After a long period of operation, the poppet does not come off in some cases because of the edge on the seat surface of sleeve. Do not disassemble it by force. c. Remove cap (12) and remove spacer (13), spring (14), and check valve (15). d. Knock sleeve (9) out by lightly tapping it to the left, using a pipe of ø4mm (0.157in) bore diameter and ø10mm (0.394in) OD.

11

10

9

8

7

15

6

14

5

13

12

Removing sleeve (9)

(6) Disassembling of recirculation valve (Boom, Bucket) 1. Remove cap (1), and remove spring (2) and check valve (3).

Tools: Allen wrench: 27mm Tightening torqu : 80 N-m (59 lbf-ft)

1

2

3

Disassembling of recirculation valve (Boom, Bucket)

3 2

(7) Disassembling of pressure compensation valve (Dozer, Boom, Bucket) 1. Remove cap (1), and remove spool assembly (2) 1 2 3 4 and spring (3).

Tools: Allen wrench: 27mm Tightening torqu : 80 N-m (59 lbf-ft) 2. Hold spool assembly in the holder, hold it further in a vise, and remove cap, spring (6), and check valve (7).

Tools: Allen wrench: 5mm TAPPED HOLE: M5 Tightening torqu : 20 N-m (14.8 lbf-ft) (DOZER, BOOM)

BKT

Disassembling of pressure compensation valve (Dozer, Boom, Bucket)

33-79

33

33. UPPER SLEWING STRUCTURE

Degrease the plunger and the holder thoroughly.

3. Remove orifice cap (4) which was left in the HG. Tools: Allen wrench: 10mm Tightening torqu : 15 N-m (11 lbf-ft)

3 2 HOLDER

7 6 5 4

Approx. 70

(BKT)

(8) Disassembling of flow control valve 1. Loosen cap (2) and remove it as an assembly.

Tools: Allen wrench: 36mm Tightening torque : 100 N-m (74 lbf-ft) 2. Remove cap (1), and remove spring retainer (3), spring (4), spring retainer (5) and spool (6).

Tools: Allen wrench: 12mm Tightening torque : 60 N-m (44 lbf-ft)

1

2

3

4

5

6

7

8

Disassembling of flow control valve

5 4

3

6

-When the cap (1) is removed, spring reacts with the force of 90 N (20.2 lbs) to 100 N (22.5 lbs). Hold down the cap to prevent the parts jumping out, and remove every part.

-Do not disassemble the cap (8) because it was caulked.

33-80

33. UPPER SLEWING STRUCTURE (9) Disassembling of slow return check valve 1. Loosen cap (1) and remove filter retainer (4) and filter (5).

Tools: Allen wrench: 19mm Tightening torque : 30 N-m (22 lbf-ft)

1

33

2 3 4 5 Disassembling of slow return check valve

Direct the large rounded corner of the filter to the cap.

2. Remove orifice (2), and remove check valve (3).

Tools: Allen wrench: 4mm Tightening torque : 8 N-m (5.9 lbf-ft)

4

3

5 (10)Disassembling of arm recirculation valve 1. Loosen sleeve (1) and remove it as an assembly.

Tools: Allen wrench: 24mm Tightening torque : 60 N-m (44 lbf-ft)

1

2 3

4

5

6

7

Disassembling of arm recirculation valve

Do not disassemble sleeve (1) (8) because they are press fitted to seat (5).

33-81

8

33. UPPER SLEWING STRUCTURE (11) Disassembling of LS check valve 1. Loosen cap (1) and remove it as an assembly.

Tools: Allen wrench: 24mm Tightening torque : 60 N-m (44 lbf-ft) 2) 2. Remove cap (2), and remove spring (3), and check valve (4).

Tools: Allen wrench: 6mm Tightening torque : 30 N-m (22 lbf-ft)

1

3

2

4

Disassembling of LS check valve

4

3 (12)Disassembling of LS passage orifice 1. Loosen cap (1) and remove orifice assembly (2).

And then remove inner orifice (3) from orifice assembly.

• Cap Tools: Allen wrench: 6mm Tightening torque : 60 N-m (22 lbf-ft) • Orifice Tools: Allen wrench: 2mm Tightening torque : 1.5 N-m (1.1 lbf-ft)

3

2

1

Disassembling of LS passage orifice

3 2

-Do not disassemble filter because it was press fitted.

-Make sure of the orifice diameter because it differs according to the installed position.

33-82

33. UPPER SLEWING STRUCTURE (13)Disassembling of pressure compensation valve (Slewing, Travel, Arm) 1. Loosen cap (1) and remove spring (4) and spool 4 3 2 assembly (2). And then remove inner orifice (3) from spool assembly.

• Cap Tools: Allen wrench: 27mm Tightening torque : 80 N-m (59 lbf-ft) • Orifice Tools: Allen wrench: 4mm Tightening torque : 8 N-m (5.9 lbf-ft)

1

33

5 Disassembling of pressure compensation valve (Slewing, Travel, Arm)

2

4

3

Make sure of the spring because it differs according to the installed position.

(14)Disassembling of over load relief valve

Do not disassemble the pressure adjusting part because it is difficult to adjust the pressure with the real machine.

1. Loosen sleeve (1) and remove the over load relief valve as a cartridge.

Tools: Allen wrench: 24mm • At body installing Tightening torque : 60 N-m (44 lbf-ft)

PRESSURE ADJUSTING PART

1

Disassembling of over load relief valve

Install the over load relief valve to its original position because its setting pressure differs according to the installed position.

33-83

33. UPPER SLEWING STRUCTURE 2. Remove cap (2) as a sub-assembly and remove spring (3) and pilot poppet (4).

Tools: Allen wrench: 17mm Tightening torque : 50 N-m (37 lbf-ft)

2 3 4 Removing of cap (2) 3. Remove pilot seat (5), spring (6) (7), piston (8), and main poppet (9).

9

8

7,6 5

5

6 7 8 9 (15)Addition of option valve 1. Loosen socket bolt and remove it.

Tools: Allen wrench: 8mm

C

B

A

D

N

Loosen socket bolts in order of D, C, B, and A.

33-84

B

33. UPPER SLEWING STRUCTURE

83

END COVER

53

2. Install optional addition valve and tighten socket bolts.

Tightening torque : 50 N-m (37 lbf-ft)

(OPTIONAL ADDITION VALVE) (OPTIONAL ADDITION VALVE)

-In this case, the total length of socket bolts is different depending on the kind and the number of optional valve.

-Tighten socket bolts in order of A, B, C, and D. -Be careful of over tightening of socket bolt, because the over tightening causes stick of main plunger.

33-85

33

33. UPPER SLEWING STRUCTURE 33.2.2.3 ASSEMBLY (1) Cautions to be exercised in assembly 1. Exercise care the same way as in disassembly.

2. Before proceeding to assembly, clean parts free from metallic particles and foreign matter and make sure that the parts are free from burrs and dents. Eliminate burrs and dents with an oilstone or the like.

3. Replace O-rings and backup rings with new ones.

4. Handle O-rings and backup rings with care so as not to score them.

(Apply a small amount of grease to make the surface smooth.)

5. Tighten bolts and caps to specified torque.

(2) Disassembly procedure Assembly is the reverse order of disassembly.

33.2.2.4 PRESSURE SETTING OF MAIN RELIEF VALVE (1) Assembly 1. Locate and confirm the set pressure "0" position.

Direct the pressure adjusting sub-assembly (B) downwards. And place spring (9) and pilot poppet (10) on the sub-assembly (B). Then cover the subassembly (B) with cap (4) and assemble them.

And tighten the cap (4) temporarily until the pilot poppet (10) comes in contact with the seat of pilot seat (C) and the pressure adjusting spring (9) begins to work.

2. Install main poppet sub-assembly (A) and assemble it as a cartridge.

3. Assemble the temporarily assembled cartridge to the valve body and tighten cap (4).

Tightening torque : 100 N-m (73.8 lbf-ft) 4. Tighten the cap of pressure adjusting subassembly (B).

Tightening torque : 60 N-m (44 lbf-ft)

C

4

10 9

B

This distance is adjusted to approx.3.5mm (0.138").

4

B

A

Assembling of relief valve

If the pressure of the relief valve is not set properly, the hydraulic device may be destroyed in some cases. This is dangerous. Therefore, do not raise the pressure above a level that is specified for each machine model.

33-86

33. UPPER SLEWING STRUCTURE (2) Pressure setting 1. While monitoring the pressure gauge, turn the adjusting screw (1) clockwise, and adjust the pressure.

1

2

33

Pressure setting of relief valve

The pressure is changed about 8.5 MPa (1230 psi) per 1/4 turn.

Do not tighten the relief valve jerkily because this valve is extremely sensitive.

2. After the setting of pressure, lock the adjusting screw (1) and tighten nut (2).

Tightening torque : 20 N-m (14.8 lbf-ft)

Check the setting pressure by operating the plunger.

33-87

33. UPPER SLEWING STRUCTURE 33.2.3 PILOT VALVE (FOR ATT) 33.2.3.1 CROSS-SECTIONAL VIEW

"

"

&"

&

# $

# %!

$!

# %! $!

!

!

" !

" !

'

(

"

)

*

+ ," -" "$ .

Pilot valve (For ATT)

Apply loctite #277 to areas marked ** Tightening torque N-m (lbf-ft)

No.

Parts

Q'ty

101 151 201-1 201-2 211

Casing Plate Spool Spool Plug

1 1 2 2 4

212 213 214 216-1 216-2

Push rod Seal O-ring; 1B P20 Spring seat Spring seat

4 4 4 2 2

Washer 2 (Shim)

4

217

Tightening torque N-m (lbf-ft)

*218-1 *218-2 221 241-1 241-2 47.1 (35) 68.6 (51)**

Note) The parts marked * might not be equipped depending on valve type.

33-88

No.

*246 301 302 312 501

Parts

Q'ty

Seat Seat Spring Spring Spring

2 2 4 2 2

Spring Joint: M14 Circular plate Adjust nut: M14 Boots

4 1 1 1 1

33. UPPER SLEWING STRUCTURE 33.2.3.2 DISASSEMBLY (1) Plug each port of pilot valve, and clean it with kerosine.

P port: PF1/4 1 to 4 and T port: PF3/8 (2) Fix pilot valve with vise via a protective plate (Alminum plate etc.), and remove boots (501).

33

501

Removing boot (501) (3) Remove adjusting nut (312) applying spanners to adjusting nut (312) and circular plate (302).

Tools: Spanner: 22mm, 32mm

312

302

Removing adjusting nut (312) (4) Remove circular plate (302) Tools: Spanner: 32mm

302

Removing circular plate (302)

Circular plate is removed Installing Jig A

33-89

33. UPPER SLEWING STRUCTURE (5) Turn joint (301) in counterclockwise with Jig A to remove.

Jig A: See page 33.2.3.7(1).

Tools: Spanner: 24mm

301

Removing joint (301)

When the force of return springs (221) is strong, never loosen joint (301). If loosened, it might result in jumping out of plate (151), plug (211) and push rod (212).

Remove joint (301) pressing plate (151) downward with two fingers.

(6) Remove plate (151) -When the force of return springs (221) are strong, press plate to let it come up slowly.

151

Removing plate (151) -When the force of return springs (221) are weak, plug is left in casing (101) due to sliding resistance of O-ring (214).

Tools: Pull plug (211) out with a flat-blade screw driver.

211 Removing plug (211)

To prevent personal injury, plug (211) must be removed slowly and evenly until the return spring (221) force is completely released.

33-90

33. UPPER SLEWING STRUCTURE (7) Remove push rod (212), plug (211), pressure reducing valve assembly (spool), return springs (221) from casing (101).

33

212 211 221

101 Removing push rod, plug, pressure reducing valve and spring

Record combination of port holes on casing and the pulled out parts. The stroke differs according to direction.

(8) Push springs (241-1), (241-2) in the range of 7mm (0.276in) that the movement of spring seats (2161), (216-2) and shift the seats (216) in a side direction, and remove spools (201-1), (201-2) through the larger hole of seat.

216-1 216-2

201-1 201-2 Removing spool (201)

Never push down spring seat (216-1) in 7 mm (0.276 in) or more. (For port 1,3) Never push down spring seat (216-2) in 9.4 mm (0.370 in) or more. (For port 2,4) (9) Remove spool (201-1), (201-2), spring seats (2161), (216-2), spring (241-1), (241-2) and washer (217).

241-1 241-2

216-1 216-2

217

201-1 201-2 Disassembling pressure reducing valve

33-91

33. UPPER SLEWING STRUCTURE (10)Remove spring (*246), spring seat (*218-1), (*2182) from push rod (212).

*218-1 *218-2

*246

214

212 211 Disassembling push rod

The parts marked * might not be equipped depending on valve type.

(11)Pull out push rod (212) from plug (211).

(12)Remove O-ring (214) from plug (211).

212 Removing push rod (212) Remove inside seal (213) from plug (211) with small driver.

213 Removing seal (213)

33.2.3.3 CLEANING PARTS (1) Clean parts with wash oil roughly.

(2) Clean parts with wash oil completely.

(3) Dry parts by swabbing clean rag.

(4) Apply rust preventives on parts.

33-92

33. UPPER SLEWING STRUCTURE 33.2.3.4 ASSEMBLING (1) Fit washer 2 (217), springs (241-1), (241-2), spring seats (216-1), (216-2) to spool (201-1), (201-2).

201-1

241-1

201-2

241-2

216-1 216-2

217 Assembling pressure reducing valve (2) Push spring (241-1), (241-2) in the range of that the movement of spring seats (216-1), (216-2) in a side direction, and install spools (201-1) through the larger hole of spring seat.

216-1 216-2

201-1 201-2 Installing spools (201-1), (201-2)

Never push down spring seat (216-1) in 7mm (0.276in) or more. (For port 1,3) Never push down spring seat (216-2) in 9.4mm (0.370in) or more. (For port 2,4) (3) Place spring (221) into ports 1,3 of casing (101), and then install pressure reducing valve assembly in it.

Place springs (221) into ports 2,4 and install it.

PRESSURE REDUCING VALVE ASSY

221

101

Installing pressure reducing valve assembly

Install the removed respective assembly into respective holes.

33-93

33

33. UPPER SLEWING STRUCTURE (4) Fit O-ring (214) and seal (213) into plug (211).

-Apply hydraulic oil on surface of push rod.

PLUG (211)

211

SEAL (213)

213

214 -RING (214) PUSH ROD (212)

Apply hydraulic oil

For the assembling direction of seal (213).

Installing O-ring (214) and seal (213) (5) Insert push rod (212) in plug (211) and install spring (*246) and spring seat (*218-1) to push rod (212) on port 1,3 side.

And install spring seat (*218-2) to push rod on port 2,4 side.

212

211

246

218-1

Assembling push rod, spring (246) and seat (218)

The parts marked * might not be equipped depending on valve type.

(6) Fit plug (211) assembly to casing (101).

1. When the force of spring (211) is weak, it stops at the position where it is pushed in by the sliding resistance of O-ring (214).

101

211 Installing plug assembly

33-94

33. UPPER SLEWING STRUCTURE 2. When the force of spring (221) is strong, attach plate (151) and press 4 push rods by hand at the same time, and tighten joint (301) temporarily.

-Install spool (201) straight and evenly into the hole of casing (101).

-Take care so that plug (211) and plate (151) do not jump out of casing (101).

301

33

151 Installing plug assembly and plate (151) (7) Install joint (301) on casing (101) with jig A securely.

Jig A : See 33.2.3.7 JIG. Tightening torque : 47.1N-m (32.8 to 37.2 lbf-ft)

101 A

Installing joint (301) (8) Install circular plate (302) to joint (301) (9) Screw adjusting nut (312) in until it touches circular plate (302), and tighten it applying spanner to stop circular plate returning.

Tools: Spanner: 32mm Tools: Socket: 22mm -Apply Loctite #277 to threads of joint.

Tightening torque: 68.6N-m (51 lbf-ft)

312

302

Installing circular plate (302)

-Screw it in until it comes in contact with 4 push rods (212) equally.

-The exceeding of screw in may cause malfunction of machine.

33-95

33. UPPER SLEWING STRUCTURE (10)Apply heat-resisting grease to joint (301) rotating section and the top of push rod (212).

(11)Cover it with boots.

(12)Spray rust preventives through each port and attach plug respectively.

GREASE

301 212 Applying grease to joint section and push rod

33-96

33. UPPER SLEWING STRUCTURE 33.2.3.5 MAINTENANCE STANDARDS

Check item

Standard

Leakage

When leakage quantity reaches to 1000 cc/ min. or more where handle is set in neutral position, or to 2000 cc/min. or more in operation, replace spool with new one.

If leaked, even if the spool is replaced, replace pilot valve assembly with new one.

Conditions Primary pressure 2.94 MPa (426 psi) Hydraulic oil viscosity 23 cSt

Spool

When the wear of sliding section is 10 μm more than the that of non sliding section, replace it with new one.

This condition may be the same as the above.

Push rod Looseness of control section

Remarks

When the wear of top is 1 mm (0.04 in) or more, replace it with new one.

When looseness of 2 mm (0.08 in) or more on circular plate (302) on control section and joint section (301) due to wear is pro- duced, replace them with new ones.

In case of the looseness due to the loosening on tightening section, adjust it.

When trouble such as noise, hunting, drop of primary pressure, etc. has occurred in operation, and it does not restore after taking Stability of operation corrective action according to below 33.2.3.6 (TROUBLESHOOTING), replace pilot valve assembly with new one.

-O-ring, etc. should be replaced with new one at every disassembling.

-If socket bolt (125) was loosened, seal washer (121) should be replaced.

33-97

33

33. UPPER SLEWING STRUCTURE 33.2.3.6 TROUBLESHOOTING It is very difficult to find defective section. The following table explains the several estimated causes. For repair, refer to the estimated causes and corrective actions.

The following table explains general phenomenon, estimated causes and corrective actions. However, most machine problems are not caused by the failure of only one part, but involve relations with other parts. Therefore corrective action other than those described in this table is often required. The following table does not cover causes and corrective actions for all the troubles. So it may be necessary to perform further investigation of troubles and causes.

Phenomenon

Possible Cause

Corrective action

1. Primary pressure is insufficient.

2. Secondary pressure springs (241) are broken or fatigued.

3. Clearance between spool (201) and casing (101) is abnormally large.

4. Handle has a looseness.

1. Secure primary pressure.

2. Replace with new ones.

Secondary pressure is unstable.

1. Sliding parts are caught.

2. Tank line pressure varies.

3. Air has mixed into pipeline.

1. Repair the unsmoothed section.

2. Bring pressure directly to oil tank.

3. Bleed air by operating it several times.

Secondary pressure is high.

1. Tank line pressure is high.

2. Sliding parts are caught.

1. Bring pressure directly to oil tank.

2. Correct.

Secondary pressure does not rise.

33-98

3. Replace spool (201).

4. Disassembly and reassembly or replace handle section.

33. UPPER SLEWING STRUCTURE 33.2.3.7 JIG (1) Jig for removing and installing joint (301)

33

" # $ !!

!

!

*

+ + + ,+

% & + - +& ,

' ' ( )

. +& *

33-99

33. UPPER SLEWING STRUCTURE 33.2.4 PILOT VALVE (FOR TRAVEL) 33.2.4.1 CONSTRUCTION

Pilot valve (Travel) Torque N-m (lbf-ft)

No.

NAME

Q'TY

Torque N-m (lbf-ft)

No.

NAME

Q'TY

101 102 191 192 193

CASING CASING (DAMPER) SEAT 1 SEAT 2 BUSHING 2

1 1 2 2 2

29.4 (22) 6.9 (5.1)

251 252 253 261 263

RO PLUG PLUG RO PLUG O-RING O-RING

3 6 2 3 2

194 201 202 203 210

STEEL BALL COVER PLUG GREASE CUP PACKING

2 2 4 4 4

8.8 (6.5)

271 301 311 313 324

SOCKET BOLT SPOOL SPRING SEAT WASHER SPRING

4 4 4 4 4

211 212 213 214 217

O-RING O-RING O-RING PUSH ROD SHIM

4 4 2 4 4

335 336 413 414 420

SPRING SPRING CAM SHAFT BUSHING CAM

4 4 2 4 2

218 224 225

SPRING SEAT PISTON STEEL BALL

4 4 12

471 472 501

STEEL BALL SET SCREW BELLOWS (BOOTS)

4 2 2

6.9 (5.1)

33-100

33. UPPER SLEWING STRUCTURE 33.2.4.2 DISASSEMBLY AND ASSEMBLY (1) Special jig for disassembly and assembly Special jig 1(for removal of bushing)

33

(2) Precautions for disassembly and assembly 1. Disassemble and assemble the pilot valve paying attention to the rust protection for dust, dirt, etc. in order not to allow them to enter in.

2. Handle parts carefully not to damage.

3. Write down the installing positions of respective part during disassembly, and assemble respective part to the position as they were before.

30˚

(0.787") 20

2 (0.008")

30 (1.181") Special jig 1

33-101

(Ø0.315" -0.008" -0.0118")

CENTERING HOLE IS ALLOWABLE (SMALLER THAN Ø2 mm)

Ø8 -0.2 -0.3

(Ø0.3937" -0.0118" -0.0157") Ø10 -0.3 -0.4

(3) Disassembly 1. Stop respective port (P, T, 1, 2, 3, 4, 5 and 6) of the valve with plugs and clean the outer surface.

2. Fix the cleaned valve with vise.

3. Remove bellows (501) from cover (201).

4. Remove set screw (472).

Tools: Allen wrench: 6 mm 5. Contact pry bar (ø7 or less) to one end of cam shaft (413), and strike it lightly with a hammer.

6. Remove cam (420).

7. Remove socket bolt (271).

Tools: Allen wrench: 6 mm 8. Remove cover (201).

9. Remove the casing upper assembly and fix the assembly with vise, again.

10.Draw push rod (214) out of plug (202).

11. Remove plug (202) with grease cup (203), packing (210) and O-ring (212).

12.Remove piston (224).

13.Remove damping spring (336) from the casing.

14.Take out spring seat (218) from casing (102) with tweezers.

15.Take out steel ball (225) using magnet.

16.Fix the lower casing assembly with vise, and take out O-rings (211,213) from casing (101).

17.Remove reduction unit valve assembly and return spring (335) from casing (101).

18.Place cover (201) on the flat bench transverse, apply bushing (414) to special jig 1, strike it lightly with hammer, and pull the bushing out.

33. UPPER SLEWING STRUCTURE 19.For disassembly of the reduction unit valve assembly first push spring seat (311) in and shift the spring seat crosswise making secondary pressure spring (324), remove it from spool (301) passing through the large hole.

•

Handle the assembled unit as an assembly.

20.Separate spool (301), spring (324) for secondary pressure setting, shim (217) and washer.

•

Handle the assembled unit as a assembly. And there may be unit on which washer is not installed.

21.Remove grease cup (203) from plug (202).

22.Remove O-ring (212) from plug (202).

(4) Assembly 1. Clean all parts before assembly, and dry them by means of compressed air. Do not use rag.

• •

Repair the parts damaged when being disassembled, clean them, apply oil to the moving section, and install the same parts on the positions where they are before.

Replace every O-ring and packing with new ones.

2. Install washer (313), shim (217), spring (324) for resetting the secondary pressure, and spring seat on spool (301) in order.

3. Pass spool (301) through the larger hole of spring seat (311), push the spring seat in , and install it making the spring for the secondary pressure flex and shifting the spring seat crosswise.

4. Fix casing (101) with vise, and place spring (335) for return in casing (101).

5. Place the reduction unit subassembly described in Articles 2. and 3. in casing (101).

• •

Install them on the positions as they were before.

When placing the reduction unit subassembly in, pay attention to the spool lower end so as not to bring into contact with the corner of the casing.

33-102

33. UPPER SLEWING STRUCTURE

33

6. Place O-rings (211,213) in casing (101).

7. Fix upper casing (102) with vise and place the steel ball in it.

8. Place spring seat (218) in casing (102) with tweezers.

9. Place damping spring (336) in casing (102).

10.Install piston (224).

11. Place O-ring (212) in plug (202).

12.Place packing (210) in plug (202).

• •

Pay attention to the direction when placing the packing in.

Apply grease slightly before placing packing in.

13.Place grease cup (203) in plug (202).

14.Install push rod (214) on plug (202).

15.Place the push rod subassembly which is sub-assembled by the procedures in Articles 11) to 14) in casing (102).

16.Put cover (201) on the flat work bench, press bushing (414) with special jig 1, and press fit the bushing striking lightly.

17.Fix the lower cover assembly which is assembled by the procedures in Articles 2) to 6) with vise, and install the upper cover assembly which is assembled by the procedures in Articles 7 to 15) on it.

18.Install cover (201) on casing (102).

19.Tighten socket bolt (271) to the specified torque.

20.Install cam (420) on cover (201).

21.Insert cam shaft (413) from the outside pressing cam (420).

22.Apply Loctite #241 or equivalent to the thread of socket bolt.

23.Tighten socket set bolt (472) to the specified torque.

24.Incline cam (420), apply grease to the top end of push rod (214), and fill grease cup (203) of plug (202) with grease.

25.After fitting the top end of bellows (501) in cam (402), fit the lower side in the groove of cover (201).

33-103

33. UPPER SLEWING STRUCTURE 33.2.4.4 TROUBLESHOOTING

Phenomenon

Cause

Corrective action

Secondary pressure does not rise.

1. Insufficient primary pressure 2. Permanent set in fatigue of spring (324) for setting of secondary pressure.

3. The gap between spool and casing is too large.

4. The control section is loosened.

1. Secure primary pressure.

2. Replace it with new one.

Secondary pressure is unstable.

1. Sliding part is not smooth.

2. Variation of pressure of tank line 3. Air contamination in piping

1. Repair unsmooth section.

2. Return oil to oil tank directly.

3. Bleed air by operating several times.

Secondary pressure is high.

1. Pressure of tank line is high.

2. Sliding part is not smooth.

1.

Return oil to oil tank directly.

2.

Repair unsmooth section.

Damping does not work.

1. Air is accumulated in piston chamber.

2. Sliding part is not smooth.

3. Permanent set in fatigue of damping spring (336) 4. Gap between damping piston (224) and casing (damper) (102) is too large.

5. Malfunction of check valve

1. Bleed air by operating several times.

2. Repair unsmooth section.

3. Replace it with new one.

6. Orifice of damping piston (224) is too large.

Damping torque is heavy.

3. Replace it with complete remote control valve.

4. Replace parts of control section.

4. Replace it with complete remote control valve.

5. Disassemble and check on check valve section.

6. Replace damping piston.

1. Sliding part is not smooth.

1. Repair unsmooth section.

2. Orifice of damping piston (224) is clogged. 2. Repair or replace damping piston.

33-104

33. UPPER SLEWING STRUCTURE 33.2.5 SWING MOTOR UNIT

33

33.2.5.1 CONSTRUCTION (1) Swing motor Composition

Slewing motor assy

Two-stage planetary gear reduction unit

Swash plate type axial piston motor

M-33 M-34

M-36 M-35 M-37 M-38

M-32 Mechanical brake Relief valve Makeup valve Bypass valve M-31 M-30 M-39 M-29

M-13 M-14 M-15 M-16 M-17

M-11 M-12 M-10

M-18 M-19

M-9 M-8

M-20

M-7 M-6 M-5 M-4

M-21 M-22

M-3

M-23

M-2

M-24 M-25 M-40 M-1

M-28 Swing motor

33-105

M-27

M-26

33. UPPER SLEWING STRUCTURE Torque N-m (lbf-ft)

No.

Q'ty

No.

Parts

Q'ty

1 2 2

PISTON ASSEMBLY RETURN PLATE CAM PLATE LEVEL GAUGE O-RING

7 1 1 1 1

NEEDLE BEARING O-RING O-RING O-RING BALANCE PLATE

1 1 1 1 1

M-26 M-27 M-28 M-30 M-31

HOUSING COLLAR OIL SEAL BACK UP RING O-RING : 1B P21

1 1 1 2 2

M-11 M-12 M-13 M-14 M-15

PISTON TEFLON RING PLUG ; PT 1/4 BUSHING SCROLL WAVE

2 2 2 4 4

M-33 M-34 M-35 M-36 M-37

BACK UP RING O-RING : 1B P26 PARALLEL PIN PLUG : PF3/8 O-RING : 1B P14

2 2 2 1 1

M-16 M-17 M-18 M-19 M-20

TEFLON RING SPRING PISTON CYLINDER RETAINING SPRING

4 13 1 1 1

M-38 M-39 M-40 70 100

SOCKET BOLT : M12X30 COVER PLUG RELIEF VALVE ASSEMBLY BY-BASS VALVE ASSEMBLY

4 1 1 2 2

1

M-3 M-4 M-5 M-6 M-7 M-8 M-9 M-10

Relief and check valve assembly (70) 71

90

72

89 88

76

87

85

77

78

79

86

80 81 82

84

Parts

No.

Q'ty No.

70 RELIEF & CHECK VALVE ASSY 71 LOCK NUT 72 CAP 76 BACK UP RING 77 O-RING ; 1B P26 78 SPRING 79 BUSHING 80 CHECK SEAT 81 SLEEVE

83

Detail view of relief & check valve assy 2.

Torque N-m (lbf-ft)

M-21 M-22 M-23 M-24 M-25

TAPERED ROLLER BEARING FRICTION PLATE SEPARATOR PALATE SNAP SING

M-1

1.

Parts

2 2 2 2 2 2 2 2 2

82 83 84 85 86 87 88 89 90

Parts

Q'ty

SEAT POPPET SPRING O-RING SHIM PISTON SLEEVE O-RING CAP

2 2 2 2 2 2 2 2 2

By-pass valve assembly (100) 101

102

103

104

105

106 107

No. 100 101 102 103 104 105 111

110

109

Parts

Q'ty BY-PASS VALVE ASSY 2 2 SEAT 2 SLEEVE 2 POPPET 2 BACK UP RING 2 O-RING : 1B P14

No. 106 107 108 109 110 111

108

Detail view of by-pass valve assy (swing shockless valve)

33-106

Parts O-RING : 1B P21 BACK UP RING CAP SPRING POPPET SPRING

Q'ty 2 2 2 2 2 2

33. UPPER SLEWING STRUCTURE (2) Swing reduction unit

R-3 R-4 R-5

R-6 R-7 R-8

R-9 R-10

33

R-11 R-12

R-2 R-1

R-13

R-23

R-22

R-21 R-20 R-19 R-18 R-17 R-19

R-14

R-15 Swing reduction unit Torque N-m (lbf-ft)

No.

Parts

Q'ty

Torque N-m (lbf-ft)

No.

Parts

Q'ty

R-1 R-2 R-3 R-4 R-5

PINION SHAFT COLLAR PLATE TAPER ROLLER BEARING GEAR CASE

1 1 1 1 1

R-15 R-16 R-17 R-18 R-19

HOLDER 2 ASSEMBLY NEEDLE BEARING SHAFT 2 SPUR GEAR 5 THRUST PLATE 2

1 6 3 3 6

R-6 R-7 R-8 R-9 R-10

GREASE NIPPLE OIL SEAL TAPER ROLLER BEARING PIN RING GEAR

1 1 1 2 1

R-20 R-21 R-22 R-23

SPRING PIN : 8X5 HOLDER 2 COLLAR RELIEF NIPPLE

3 1 2 1

R-11 R-12 R-13 R-14

SPUR GEAR 4 SUN GEAR HOLDER 1 ASSEMBLY SOCKET BOLT : M12X95

1 1 1 6

33-107

33. UPPER SLEWING STRUCTURE 33.2.5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR (1) Disassembly 1. Remove the relief assembly (70).

Tools: Socket: 27 mm 2. Remove the by-pass valve (100).

Tools: Allen wrench: 8 mm

70

100

Removing relief valve assembly and by-pass valve

Install it in the original position.

3. Apply match mark on cover (39) and housing (26).

39

26 MATCHING MARK

Maching marks on cover and housing 4. Remove socket bolt (38).

Tools: Allen wrench: 10 mm

39

38

Removing cover mounting bolts

33-108

26

33. UPPER SLEWING STRUCTURE 5. Lift up and remove cover (39).

33 39

Removing cover 6. Remove snap ring (5) with plier.

7. Remove inner race of needle bearing (6).

6

Removing bearing (6) inner race 8. Remove the O-ring (9).

9

Removing O-ring (9) 9. Remove the balance plate (10).

10

Removing balance plate

33-109

33. UPPER SLEWING STRUCTURE 10.Remove the bushing (14) with a teflon ring (16) on it, and the scroll wave (15).

14

Removing bushing (14) and scrollwave (15) 11.Remove spring (17) from brake piston (18).

17

18

Removing spring (17)

Fit spring in the original position.

12.Remove brake piston (18).

18

Removing brake piston (18)

The O-ring (7) (8) make it difficult to slide the piston (18) easily from the housing (26). For this reason, use tapped hole (M6) provided in the piston (18) to remove it, as shown in the above Fig.

33-110

33. UPPER SLEWING STRUCTURE 13.Remove the separator plate (4) and friction plate (3).

33 4

3

Removing separator plate (4) and friction plate (3) 14.Remove cylinder assembly (19) from housing (26).

19

26

Removing cylinder assembly (19)

-Oil seal (28) and outer race of taper roller bearing (1) are left in housing.

-Take care not to damage the sliding surface on upper section of cylinder housing.

-Assemble piston bore of cylinder (19) and piston assembly (21) in the same original combination.

15.Remove the outer race of tapered roller bearing (1) from the housing.

1

Removing outer race of tapered roller bearing (1)

33-111

33. UPPER SLEWING STRUCTURE 16.Remove oil seal (28) from housing (26) with driver and hammer.

-The reuse of the removed oil seal is not allowed.

28

26

Removing oil seal (28) 17.Removing the cylinder assembly. a. Attach an gear puller to two positions of the inner race of the tapered roller bearing (1) and to the splined end of the cylinder (19), and pull out the inner race along with the collar (27).

27

1

Pulling inner race of tapered roller bearing (1) b. Remove the cam plate (23), piston assembly (21) and return plate (22) together from the cylinder (19).

23

22 21

Removing cam plate (23), piston assembly (21) and return plate (22) c. Remove cam plate (23) from the piston assembly (21) as is by sliding it on sliding surface of piston assembly (21).

21

Removing cam plate (23)

33-112

23

33. UPPER SLEWING STRUCTURE

33

Handle cam plate with care so as not to damage its sliding surface. d. Remove retaining spring (20) from cylinder (19).

19

20

Removing retaining spring (20)

33-113

33. UPPER SLEWING STRUCTURE (2) Installation Install swing motor unit in the reverse procedure of disassembling.

1. Jigs Jig used for installing is not provided with part number.

(0.08") 2

60 (2.36")

(0.5315" +0.0039 ) -0 13.5 +0.1 -0

+0.15" -0

(+0.0059" ) -0

(0.8720") 22.15

17.5 (0.689")

Press-fitting jig for collar (27)

27 (1.06")

75 (2.95")

Seal protector 7 (0.276")

(2.4350" -0.00591")

+0

10.5 (0.413") 155 (6.10")

) R3 18" .1 (0

(0.9921"+0.0039" ) -0 +0.1 25.2-0

3 (0.008")

29±0.2

Press-fitting jig for oil seal (28)

C1 (0.04")

61.85 +0 -0.15"

Dimensions

(1.9488"±0.0039") 49.5±0.1 (1.1417"±0.0039")

Jigs

30.3 (1.19")

Press-fitting jig for inner race of tapered roller bearing (1)

Dimensions 35 (1.38") (1.1909"±0.0039") 30.25±0.1 (1.0039±0.0039) 25.5±0.1

Jigs

25 (0.984")

50 (1.97")

45 (1.77")

60 (2.36")

2. Assembling relief assembly Fit relief assembly (70) to cover (39).

Tools: Socket: 27 mm Tightening torque : 39 N-m (29 lbf-ft)

70 39

Assembling relief assembly (70) 3. Confirming correct assembly Open the brake release port, apply a pilot pressure of 1.96 MPa (280 psi) to the P port and confirm that the output shaft rotates more than 1 turn smoothly by 19.6~29.4 N-m (14~22 lbf-ft) torque. In case the output shaft does not rotate, disassemble it again and readjust.

Rotate spline by 19.6 to 29.4 N·m (14 to 22 lbf·ft) with torque wrench.

A,B release (inlet / outlet ports)

Apply pressure 1.96 MPa (280 psi) to brake release port (PF 1/4)

Confirming correct assembly

33-114

33. UPPER SLEWING STRUCTURE 33.2.5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT (1) Removal 1. Remove the sun gear (12) and then remove the holder 1 assembly (13).

33 15

-Because the shafts in the holder 1 assembly (13) are press-fit in the holder (1), and caulked at the end, further removal of the assembly is impossible.

20

Removing spring pin (20) 2. Remove spur gear 4 (11) and then remove the holder 2 assembly (15).

3. Removing the holder 2 assembly (15). a.

Drive the spring pin (20) through the holder 2 assembly (15).

-The spring pin (20) cannot be reused. b.

Holding spur gear 5 (18) with your hand, remove the shaft 2 (17) from holder 2 (15).

18 17

Removing shaft (17) 4. Remove the ring gear (10).

-The mating surface between the ring gear (10) and the gear case (5) is coated with liquid packing (Three Bond #1215, gray) to prevent oil leakage.

Use the notch in the gear case (5) to remove the ring gear (10).

5. Removing the collar (16).

Remove the collar (16) from the shaft (1) by tapping the collar with a screwdriver and hammer.

10

5

Removing ring gear (10) 6. Removing the shaft (1) assembly.

Place blocks about 300 mm high under the flange of the gear case (5) to allow removal of the shaft (1) and push the end of the shaft with a hydraulic press to remove the shaft (1), collar (2), plate (3) and taper roller bearing (4) as an assembly.

7. Remove the oil seals (7) from the gear case (5).

PRESS

5

Removing shaft (1) assembly

33-115

33. UPPER SLEWING STRUCTURE

-Do not remove any further, unless the bearings etc. are abnormal.

-Do not reuse the oil seals.

(2) Installation The jigs to be used for installation are shown below.

Unit : mm (in) Oil seal (7) press-fitting jig

Seal protector

• Heat vinyl chloride tube in hot

15 6.9 15 30 (0.591") (0.272") (0.591") (1.18") ±0.1 (0.00394")

85 (3.34")

(0.118") 3

C2 (0.08")

water and inset it onto the pinion shaft to from a seal protector.49

150 (5.91")

Ø50 (1.97")

0" (2.5512" -0.0079" ) 0 15˚ Ø64.8-0.2

Remarks

15˚

-0.0079" Ø89 -0.2 -0.5 (3.5039" -0.0197" )

Ø119 (4.69")

Ø65 (2.56")

1. Apply grease to the rollers of the taper roller bearing (4).

-Grade : SHELL ALVANA EP2 or equivalent (grease for extreme pressure duty) -Quantity : About 150cc (9.15 cu-in)

GREASE

Applying grease to taper roller bearing (4) 2. Press-fitting the oil seal (7) Degrease the oil seal position on the gear case (5) and the oil seal (7). Apply liquid packing (Three Bond #1211, white) to the outside of the oil seal.

Using the seal press-fitting jig and a hand press, install the oil seal (7) on the gear case (5).

5 SEAL PRESSFITTINGH JIG

7

-After press-fitting, apply grease to the oil seal lips.

Press-fitting oil seal (7)

33-116

33. UPPER SLEWING STRUCTURE 3. Place the gear case (5) with the output shaft side facing upward, and install the pinion shaft (1) assembly into the gear case (5).

1

33 4

-Use the seal protector to prevent the spline of the pinion shaft (1) from damaging the lips of the oil seal (7).

SEAL PROTECTOR 5

7

Installing pinion shaft (1) assembly 4. Installing the taper roller bearing (8) Place gear case (5) directing pinion shaft downward, warm collar (22) of taper roller bearing to temperature adding +50 degC (122 degF) to the room temperature and fit it.

22

5

Installing taper roller bearing (8) 5. Installing the collar (22) The nominal thickness of the collar (22) is 7.0 mm (0.2756 in). Adjust this thickness so that the clearance between the collar (22) and the groove in the shaft (1) is 0.06 mm (0.0024 in).

Adjust the clearance 0.06 mm (0.0024 in)

COLLAR (22) TAPER ROLLER BEARING (8) SHAFT (1)

Adjusting clearance between collar (22) and shaft (1)

33-117

33. UPPER SLEWING STRUCTURE 6. Installing the ring gear (10).

• Degrease the mating surface between the gear case (5) and the ring gear (10) and the pin (9).

• Apply liquid packing (Three Bond #1215, gray) to the area of the gear case (5) inside the bolt circle, and install the ring gear (10) on the gear case (5).

• Apply sealant equally so that the thickness projecting from nozzle is about 1.5 mm (0.06 in) in diameter.

Applying liquid packing to gear case (5) 10

Installing ring gear (10) 7. Installing the holder 2 assembly (15) a. Install the needle bearing (16) in spur gear 5 (18).

Install this assembly together with the thrust plate 2 (19) into holder 2 (21), and insert the shaft 2 (17) into the spur gear.

-Apply hydraulic oil to the inside diameter of spur gear 5 (18), needle bearing (16) and the outside diameter of the shaft 2 (17).

15

17

Installing holder assembly 2 (15)

33-118

33. UPPER SLEWING STRUCTURE b. Drive the spring pin (20)

33 Drive spring pin facing the split to gear side.

Beware of the direction of spring pin.

GEAR SIDE

Caulk two point with a punch.

20

15

Driving spring pin (20) 8. Carefully mesh the holder 2 assembly (15) in the internal teeth of the ring gear (10), and the spline of the pinion shaft (1) with its mating part. In this condition, insert the holder 2 assembly (15) while turning it.

9. Carefully mesh spur gear 4 (11) in the spur gear 5 (18).

15

11

Inserting holder 2 assembly (15) 10.Installing the holder 1 assembly (13) a.

Carefully mesh the holder 1 assembly (13) in the internal teeth of the ring gear (10), and holder 1 (13) in the teeth of sun gear (12). In this condition, insert the holder 1 assembly (13) while turning it slowly. b.

Place sun gear (12) in while engaging with planet gear of holder 1 assembly (13) slowly.

11. Turn the holder 1 assembly (13) with your hand to confirm that the pinion shaft rotates smoothly.

13

Inserting holder 1 assembly (13)

33-119

33. UPPER SLEWING STRUCTURE 33.2.5.4 MAINTENANCE STANDARDS

Parts Gear, Pinion

Maintenance Replace if harmful wear, pitting, peeling, scratch, etc. are found on the tooth face.

Holder 1, 2 assembly

Replace if harmful wear, indentation, etc. are found on the spline portion, there is a backlash on the pin portion (For holder 1 assembly, loosening of caulking, for holder 2 assembly, wear of pin bore), or the needle bearing is worn making a backlash.

Taper roller bearing, Needle bearing

Even if the bearing works normally, when the "Hour meter" arrives to the time in 3000 hours, replace them with new ones.

Even through the "Hour meter" is within 3000 hours, when the rolling contact surface of needle bearing is flawed while removing, replace them with new ones.

And if possible we will recommend that you replace bearings with new ones because they will often be damaged during removing.

Oil seal Other parts

When the lip is damaged, replace it with a new one.

And even if there is no leak, replace seal every 3000 hours.

Also, replace it with new ones without fail while installation.

Replace parts worn or damaged with new ones.

33-120

33. UPPER SLEWING STRUCTURE 33.2.6 SWIVEL JOINT

33

33.2.6.1 CONSTRUCTION VIEW TIGHTNING TORQUE 30.4 N.m (22.4 lbf.fb) APPLY LOCTITE #242

7

1

5

11

6

11

10

8

2

13 3

4 11 SECTION AA

9

TIGHTNING TORQUE 30.4 N.m (22.4 lbf.fb) APPLY LOCTITE #242

12,16

SECTION BB Construction of swivel joint No.

NAME

Q'TY

No.

NAME

Q'TY

1

BODY

1

8

O-RING

2

2

STEM

1

9

SOCKET BOLT (M8X20)

3

3

THRUST PLATE

1

10

SOCKET BOLT (M8X30)

1

4

COVER

1

11

PLUG : PT1/8

3

5

SEAL

7

12

PLUG : PF1/4

2

6

SEAL

1

13

PLUG : PT3/8

1

7

O-RING (G95 1A)

1

16

O-RING

2

33-121

33. UPPER SLEWING STRUCTURE 33.2.6.2 DISASSEMBLY AND ASSEMBLY 33.2.6.2.1 Tools

No.

Tool Name

a

Hammer

b

Rubber mat

c

Wrench

d

Torque wrench

Used for

Remarks 1. Steel hammer 2. Wooden or plastic mallet

Disassembly Assembly

500 mm (20in) square or more 1. Allen wrench 2. Double-ended and single-ended wrench 3. Extension pipe

Pin

e

Assembly

98 N•m (72 lbf•ft) Grind the tip of "a nail" to shape as a screwdriver.

Disassembly

Make from a hack-saw blade

f

Spatula

Disassembly Assembly

Approx. 120mm (4.72in)

Vinyl tape

g

V block or vise

h

Loctite

i

Lubricating oil

j

Cleaning oil

Disassembly Assembly

Remove the edge completely and make corner round smooth.

Vise movable over 150mm (6in)

Thrust plate, Cover # 290 Hydraulic oil or vaseline

33.2.6.2.2 Apparatus (1) Hoist or crane The lifting device should be capable of lifting the swivel joint assembly.

(2) Work bench The work bench should have an area of 1.2mX1.5m (4ftX5ft).

(3) Others Also prepare cloth, wooden block and oil pan.

33.2.6.2.3 Cleaning outside Clean the swivel joint to be free from dirt and dust, using steam and cleaning oil.

• Keep all ports plugged up while cleaning.

33-122

33. UPPER SLEWING STRUCTURE 33.2.6.2.4 Disassembly The part numbers used in this disassembly procedure correspond to those of a construction drawing in Fig."Construction of swivel joint".

(1) Removing cover 1. Mark cover (4) and body (1) with matching marks for convenient reassembly.

2. Place a V-block on a work bench, place a swivel joint set on the side, fix it and loosen socket bolt (10) by means of a pipe and wrench. Alternately, the swivel joint may be fixed by holding stem (2) in a vise.

Tools: Allen wrench: 6mm

1 MATCHING MARK 10 4

ALLEN WRENCH

V-BLOCK

PIPE

Removing cover (4) 3. Remove cover (4) from body (1) and draw out Oring (7) from cover (4).

7 O-RING

4 COVER

Removing O-ring (7) (2) Removing thrust plate Loosen socket bolt (9) fastening thrust plate (3), in the same manner as the removing of the above-mentioned cover.

Tools: Allen wrench: 6mm

1 BODY 3 THRUST PLATE 9 SOCKET BOLT

PIPE

2 STEM

Removing thrust plate (3)

When removing thrust plate (3) by fixing body (1), support stem (2) so it may not fall down.

33-123

33

33. UPPER SLEWING STRUCTURE (3) Removing stem Place body (1) on a V-block. Put a wooden block against stem (2) via the body so about half of the stem is covered by the wooden block and knock it out using a mallet.

By hitting out the stem over about 1/2 from the body, it can be easily pulled out by hand.

Stem weight: 13kg (29 lbs)

1 BODY

WOODEN BLOCK

V-BLOCK

2 STEM

Work bench Drawing out stem (2) (4) Removing sealing parts 1. Remove rings (8) of seal assemblies (6) and (5) with spatula (f).

SPATULA (f)

8

Removing O-ring (8)

Pay attention to the body (1) not to be damaged by the top edge of spatula (f).

2. Pierce slipper ring of seal assemblies (6) and (5) with pin (e) and remove them from the seal groove.

Right Fig. shows only one pin, but use two pins to remove it securely.

Removing out seal assembly (5)(6)

33-124

33. UPPER SLEWING STRUCTURE 33.2.6.2.5 Assembly Prior to assembly, clean each parts (excluding the O-ring and seal), and arrange in the sequence of assembly.

Apply grease on the groove of seal to be installed on seal assembly (6) and O-ring (8).

(1) Assembling seals to body 1. Apply hydraulic oil to O-ring (8) thinly and insert it in O-ring groove.

Check the twist of O-ring 2. Slipper ring is assembled, after first inserting the backup ring, by slightly-distorting the shape as shown in Right Fig. Also after inserting all of the seals, be certain that these are installed in the seal groove by use of the spatula.

3. Assemble seal (5) by the same procedure above mentioned.

Inserting slipper ring (6)

Remove grease, hydraulic oil and vaseline from the groove of seal.

And insert seal (5).

Seals (5) have no back-up ring.

(2) Assembling stem Lightly coat the outer circumference of stem (2) and the inner surface of body (1) with grease or vaseline and slowly insert stem (2) into body (1).

Press in by applying your weight by your hands.

2 STEM

O-RING 8 1 BODY SEAL ASSY 6 SEAL 5 WORK BENCH

Inserting stem (2)

-If stem (2) is pressed in too fast, the seal may be damaged. Do it slowly.

-The clearance between body (1) and stem (2) is about 0.1mm (0.004in). Push stem straight along the shaft center.

33-125

33

33. UPPER SLEWING STRUCTURE (3) Assembling thrust plate 1. While holding stem (2) and body (1), match the hole of thrust plate (3) and the stem (2) hole.

2. Next, after removing any oil from the thread of socket bolt (9), coat it with Loctite #242 and tighten to stem (2).

Tools: Allen wrench: 6mm, Tightening torque: 30.4N-m (22lbf-ft)

9

3

2

Tightening socket bolt (9) (4) Assembling cover After installing O-ring (7) to cover (4) and aligning the matching marks of the cover (4) and body (1), coat socket bolt (10) with Loctite #242 and tighten it which will then complete assembly.

Tools: Allen wrench: 6mm, Tightening torque : 30.4N-m (22lbf-ft)

1 MATCHING MARK 10 4

V-BLOCK

ALLEN WRENCH PIPE

Tightening socket bolt (10)

33-126

33. UPPER SLEWING STRUCTURE 33.2.6.3 MAINTENANCE STANDARDS

33

33.2.6.3.1 USABLE LIMIT OF PARTS

Parts

Maintenance Standards

Sliding surface with sealing Plating worn or peeled due to seizure or sections contamination.

Remedy Replace

1) Worn abnormality or damaged more than 0.1 mm Replace Sliding surface between (0.004 in) in depth due to seizure or contamination. body and stem other than Smooth with oil 2) Damaged more than 0.1 mm (0.004 in) in depth.

Body, Stem sealing sections stone.

1) Worn more than 0.5 mm (0.02 in) or abnormality.

Sliding surface with thrust 2) Worn less than 0.5 mm (0.02 in). plate 3) Damage due to seizure or contamination remediable within wear limit 0.5 mm (0.02 in).

1) Worn more than 0.5 mm (0.02 in) or abnormality.

Cover

Sliding surface with thrust 2) Worn less than 0.5 mm (0.02 in). plate 3) Damage due to seizure or contamination remediable within wear limit 0.5 mm (0.02 in).

Replace Smooth Smooth Replace Smooth Smooth

1) Extruded excessively from seal groove square ring.

Replace (With back-up ring)

2) Slipper ring 1.5 mm (0.06 in) narrower than seal groove, or narrower than back-up ring.

Slipper ring Seal ring 1.5mm (0.02in) (max.)

Replace (With back-up ring)

BACKUP RING

3) Worn more than 0.5 mm (0.02 in).

Replace (With back-up ring)

33-127

33. UPPER SLEWING STRUCTURE 33.2.6.3.2 INSPECTION AFTER ASSEMBLY After completion of assembly, inspection for oil leakage, pressure resistance, etc., using a device as shown in Right Fig. (1) High pressure port

Install a directional valve and pressure gauge to the stem side port and body side port respectively, and while watching the pressure gauge (for high

pressure) installed on the body side and also by

regulating high pressure relief valve (7), gradually increase the pressure and when the pressure has

reached 1.5 times the maximum working pressure,

close stop valve (3) and lock in the hydraulic oil in

the swivel. Keep stop valve (6) on the low pressure

relief valve side closed at this time.

Check that it is free from looseness, deformation,

breakage, etc. under three minutes pressurizing.

And, the oil leakage must be checked for the first 1 minute, and if there be a pressure drop for any

reason, the pressure drop should be in 10% of the trapped pressure.

This checking must be carried out for every circuit.

Hydraulic circuit for inspection equipment (2) Low pressure port (Drain port, return port, etc.)

Similar to the high pressure port, install a directional valve and pressure gauge on each port of the stem side and body side.

Open stop valve (6) on the side of low pressure relief valve (5) and while watching the pressure gauge (for low pressure) connected to the body side and also by regulating low pressure relief valve (5), gradually increase the pressure and check for outside leakage with a color check at a pressure of 0.49 MPa (71 psi).

•

Item

Description

1

Pressure Gauge

2 3 6

Swivel Joint Stop Valve Relief Valve for low pressure Stop Valve

7

Relief Valve for high pressure

8 9

Directional Valve Piping, etc.

5

Remarks High and Low Pressures are required.

Setting Pressure : 0.49 MPa (71 psi) Setting Pressure : [Max. operating pressure 25.5 MPa (3700 psi) X 1.5 times]

The maximum working pressure stands for pressure of hydraulic excavator equipped with swivel joint.

33-128

33. UPPER SLEWING STRUCTURE 33.2.6.3.3 TROUBLESHOOTING

Trouble 1.

External leakage of hydraulic oil

Cause

Remedy

Defective O-ring & seal

Replace all seals.

2.

Internal leakage of hydraulic oil

1) Defective slipper seal 2) Sliding face worn excessively

1) Replace all seals.

2) Replace assembly.

3.

Swivel stem seized

1) Stem and body seized

1) Grind and hone.

Replace assembly, if stem and body are too loose and causing oil leakage.

2) Reinstall Secure 2 to 3 mm (0.08 to 0.12 in) allowance for bolt stopper.

2) Inappropriate swivel stopper bracket 4.

Loose swivel stem and cover

Socket bolt tightened insufficiently.

33-129

Retighten to specified torque.

33

33. UPPER SLEWING STRUCTURE

33-130

34. TRAVEL SYSTEM

34

34. TRAVEL SYSTEM TABLE OF CONTENTS

34.1 REMOVING AND INSTALLING .........................................................................34-3 34.1.1 TRAVEL SYSTEM .....................................................................................34-3 34.1.2 CRAWLER .................................................................................................34-3 34.1.3 UPPER ROLLER .......................................................................................34-8 34.1.4 LOWER ROLLER (TRACK ROLLER) .......................................................34-14 34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) ..............................................34-21 34.1.6 SPROCKET ...............................................................................................34-31 34.1.7 TRAVEL MOTOR ......................................................................................34-33 34.1.8 SWING BEARING ......................................................................................34-36 34.2 DISASSEMBLING AND ASSEMBLING .............................................................34-41 34.2.1 TRAVEL MOTOR .......................................................................................34-41

Book Code No. S5LF3412E01 34-1

34. TRAVEL SYSTEM

Issue

Date of Issue

First Edition

June, 2010

Applicable Machines 80CS-2 : LF06-04501~

Remarks S5LF3412E01 (NA)

PREFACE (1) This Manual describes all the procedures from removing to attaching, arranging them by item.

(2) This Manual consists of first part. Removing and attaching, and sequel. Disassembling and assembling.

(3) The removing and attaching can be performed in the procedure specified in Table of Contents, but in view of actual repairing or time saving some process can be omitted.

(4) The removing and attaching procedure does not completely cover all possible situations because of differences of field condition and defective section.

(5) Please be aware that the procedure to be followed must be determined according to the above conditions.

When disassembly and assembly are required, select the necessary section, itemize the work contents with good understanding, then starts working.

34-2

34. TRAVEL SYSTEM

34.1

REMOVING AND INSTALLING

34.1.1 TRAVEL SYSTEM

34

8. SWING BEARING

2. CRAWLER

7. TRAVEL MOTOR

5. FRONT IDLER GUARD

6. SPROCKET

GREASE NIPPLE OF THE TRACK SPRING ADJUSTER

4. LOWER ROLLER LOWER FRAME

3. UPPER ROLLER

Designation and location of undercarriage

34.1.2 CRAWLER 34.1.2.1 REMOVING CRAWLER (1) Position the machine to remove crawler.

(2) Pushing out master pin.

1.

Find the master pin and place it in its removing/fixing position in right Fig..

2.

Loosen the grease nipple and slacken crawler.

Tools: Socket: 19 mm

Crawler removing position

-When loosening the grease nipple of the adjuster, do not loosen it more than one turn.

-Where grease does not come out well, move the machine back and forth. The over loosening of grease nipple may cause it to jump out incurring danger of injury. So be careful not to over loosen the grease nipple.

34-3

34. TRAVEL SYSTEM 3.

Pushing out master pin Apply jig on master pin and strike it out with a mallet.

(Refer to 34.1.2.2(4) Fig. "Press fitting of master pin")

Removing/fixing position of master pin

When using a big hammer, wear protective goggles and a long-sleeved uniform so you do not injure yourself by flying objects.

(3) Removing crawler Put attachment on ground so that weight is not loaded to the lower frame, and remove track link assy rotating sprocket.

Removing crawler

Crawler end section may fall on the ground just before extending it on the ground incurring danger of injury.

Please keep well away from the equipment.

34-4

34. TRAVEL SYSTEM 34.1.2.2 INSTALLING Installing is done in the reverse order of removing.

(1) Checking crawler installation direction.

Place the track links on the ground so they converge, facing the front idler, as shown in the figure on the right.

Front idler side

34

Installing direction of crawler (2) Installing crawler 1. Preparation for installation Treat paint flaking protection with care not to damage lower flame.

2. Winding crawler Insert bar into master pin hole, lift lower frame up 1 or 2 cm (0.4 in~0.8 in) using attachment and hold it, then turn sprocket in rearward positioning the machine so that the weight is not loaded to shoe.

(3) Preparation for press fitting master pin 1. Preparing for installation Put square wood under the shoe plate.

2. Aligning master pin holes Aligning master pin holes through fine adjustment turning sprocket.

Winding crawler

Connecting position of master pin

Preparation for press fitting master pin

-When using a big hammer, exercise care so you are not injured by flying objects the same way as when pushing out the master pin.

-Coat the master pin with molybdenum disulfide grease, before pressing it in.

34-5

34. TRAVEL SYSTEM (4) Press fitting of master pin Apply press fitting jig on master pin, and strike it with a mallet to press fit.

Press fitting jig on master pin

Press fitting of master pin (5) Adjusting crawler tension (See right Fig.) After installing, adjust tension of crawler.

Tools: Socket: 19 mm

Proper tensioning of the iron crawler Proper tensioning of the rubber crewler

MODEL

A DIMENSION

SK80CS-2

200~230 mm (8 in~9 in) 140~150 mm (5 in~6 in)

SK80CS-2

A

Adjusting crawler tension 34.1.2.3 CONSTRUCTION

PART No. No.

1 2 3 4 5 6 7 8 9 10 11

YT60D00012F1 [Width of shoe 450 mm(17.7 in)] YT60D00012F2 [Width of shoe 600 mm(23.6 in)] Name SHOE ASSY • TRACK LINK ASSY • • TRACK LINK (R.H) • • TRACK LINK (L.H) • • BUSHING • • PIN • • MASTER BUSHING • • MASTER PIN • • SEAL • • MASTER COLLAR • SHOE • SHOE BOLT • SHOE NUT

7 4

Q'ty

3

2 1X2 39 X 2 39 X 2 38 X 2 38 X 2 1X2 1X2 76 X 2 2X2 39 X 2 156 X 2 156 X 2

7

8

5 8 6

11

1

2

9

10

Shoe assy

34-6

34. TRAVEL SYSTEM 34.1.2.4 MAINTENANCE STANDARDS Track link assy (YT62D00007F1)

F

E

D

B

89 (3.50")

73 (2.87")

G

57 (2.24") A

34

C

H I

Unit : mm (in) No.

ITEM

STANDARD VALUE

REPAIRA SERVICE BLE LIMIT LEVEL

A

Link pitch

155.6–0.1(6.126–0.0039)

160 (6.30) 164 (6.46)

B

O.D. of bushing

C

Height of link

41 Basic dimension

D

(1.6142

)

75–0.15 (2.9528–0.0059)

Interference between bushing and link

41 (1.6142)

Replace the link 37 (1.46) 36 (1.42) assy if the service 69 (2.72) 67 (2.64) limit is exceeded.

Tolerance

Shaft

REMEDY

Fit

Fit

+0.214 Interferenc (+0.0084 ) Interferenc e 0.05 +0.174 e0 (0.0020) (+0.0069)

Replace

Shaft

+0.15 (+0.008) 0 (0)

Shaft

-0.05 Interferenc (-0.0020) Interferenc e 0.05 -0.08 e0 (0.0020) (-0.0032)

Replace Link

Clearance between links (both sides)

1.6 (0.06)

8 (0.32)

10 (0.39)

Replace

H

STD shoe plate

26 (1.02)

15 (0.59)

13 (0.51)

Replace

I No.

Tightening torque of shoe JIGS bolt

E

Interference between track pin and link

24 (0.9449)

F

Interference between master pin and link

24 (0.9449)

G

Interferenc Interferenc e 0.05 e0 (0.0020)

294 N m 2( 20 lbt t)f SHAPE

34.1.2.5 TOOLS AND JIGS a Master pin fixing jig (1)Tightening tools (2) Jig

34-7

Retighten

34. TRAVEL SYSTEM 34.1.3 UPPER ROLLER 34.1.3.1 UPPER ROLLER ASSY

ASSY PART No. No. 1 2 3 4

Parts ROLLER ASSY CAPSCREW NUT WASHER

YT64D00002F1 Q'ty 2 2 2 4

4

Remarks

4

IDLER SIDE

YT64D01001F1 M16 X 90 M16

3

2

1

Upper roller assy 34.1.3.2 REMOVING (1) Preparation for removal Remove crawler (Above mentioned).

(2) Removing upper roller (1) 1.

Remove nuts on support tightening section, and also remove capscrew (2) M16X90.

Tools: Socket: 24 mm

(2) M16 X 80

Removing upper roller (1) 34.1.3.3 INSTALLING Installing is done in the reverse order of removing.

(1) Inspection Before reassembling, check it that it rotates smooth manually and for leak.

(2) Installing upper roller (1) 1. Fit it directing nut toward idler side.

2. Insert it until collar comes in contact with support.

3. Fit it directing the countersinking mark of shaft end upward.

4. Apply Loctite #262 on capscrew M16X90, and tighten it to the specified torque.

Tools: Socket: 24 mm Tightening torque: 279 N-m (210 lbf-ft)

IDLER SIDE 1

Countersinking 3

Up

COLLAR

SUPPORT

2 Apply Loctite #262 T=279 N·m (210lbf·ft)

Installing upper roller (1)

Installing upper roller (1)

34-8

34. TRAVEL SYSTEM 34.1.3.4 CONSTRUCTION ASSY PART No.

YT64D01001F1

No.

Parts

Q'ty No.

1 2 3 4 5 6

ROLLER SHAFT PLATE COVER BUSHING FLOATING SEAL

1 1 1 1 1 1

Parts

7 8

O-RING ; G45 1A SOCKET BOLT ; M8 X 22 9 SNAP RING 10 PLUG 11 COLLAR

10

7

8

1

5

6

11 2

Q'ty 1 2 1 1 1

34

9

4

3

Construction of upper roller 34.1.3.5 DISASSEMBLY AND ASSEMBLY (1) Disassembly 1. Draining out oil Remove plug (10) and drain out oil.

Tools: Allen wrench: 5 mm 2. Removing snap ring (9) Mount the end face inside upper roller (1) on stand jig (f) and separate snap ring (9), using snap ring pliers.

3. Removing cover (4) Take off cover (4) upwards, utilizing the screwed hole for the plug.

8

9

3

10 7 4 1

f

Removing snap ring (9), cover (4), O-ring (7), plate (3) 4. Removing O-ring (7) Separate O-ring (7) from cover (4).

5. Removing plate (3) Loosen 2 socket bolts (8) and draw out plate (3) from roller (1).

Tools: Allen wrench: 6mm 6. Removing shaft (2) Put the extrusion jig (g) against the end face of shaft (2) and push shaft (2) with collar (11) for floating seal (6), using a press or hammer.

Push with press

g

2

6 11 f

Extruding shaft (2)

34-9

34. TRAVEL SYSTEM 7. Removing floating seal (6).

Take out floating seal (6) from roller (1).

6

1

Taking out floating seal (6) 8. Removing floating seal (6).

Remove from collar (11), floating seal (6) that is located on the side from which shaft (2) was disassembled.

2

6 11

Removing floating seal (6)

Collar (11) is press fitted into shaft (2). Therefore do not disassemble it.

9. Removing bushing (5) Since the bushing is thin, machine it on a lathe or scrape it off, take care so as not to damage the bore of roller (1).

If the bushing is not worn much, mount upper roller (1) on jig (f), insert jig (g) into the end face of bushing (5) and push it out with a press.

Push-out bar

5 1

f

Pushing in bushing (5) (2) Assembly Assembly of the upper roller is done in the reverse order of disassembly.

1. Pressing the bushing (5).

Align inner hole of roller (1) and bushing (5) and press fit it vertically with press so that jig (h) for bushing push-in jig (h) is inserted into bushing (5).

Push with press h 5 1 f

Pushing in bushing (5)

34-10

34. TRAVEL SYSTEM

If you fail in this operation by pressing the bushing unevenly, the bushing is distorted and gets unserviceable. In that case, do not re-use the bushing as it may develop malfunctioning after assembly.

2. Installing floating seals (6).

Two floating seals (6) make a pair. Attach one floating seal to retainer fixed in shaft (2), and another to the inside of upper roller (1).

-Prior to placing floating seal (6) in, apply engine oil lightly to seal surface.

6 2 6

1

COLLAR

Installing floating seal (6) 3. Inserting shaft (2).

Coat shaft (2) with a thin film of oil and insert it into upper roller (1).

4. Installing plate (3).

Mount upper roller (1) on the stand jig (f) and attach plate (3) to the end face of the shaft with socket bolt (8). In that case, coat the screwed part of socket bolt (8) with Loctite #242 beforehand.

Tools: Allen wrench: 6 mm Tightening torque : 33 N-m (25 lbf-ft)

2

1

Pressing the shaft (2) 5. Installing O-ring (7).

Fit O-ring (7) to the groove of cover (4).

-Apply grease to O-ring.

6. Installing cover (4).

Attach cover (4) to upper roller (1). Use a press in this operation as a press fit is used.

7. Installing snap ring (9).

Fix snap ring (9) into upper roller (1), using snap ring pliers.

8

9 7 4 3 1

f

Installing plate (3), O-ring (7), cover (4), snap ring (9)

34-11

34

34. TRAVEL SYSTEM 8. Filling oil Fill in 20 cc (1.22 cuoin) of engine oil API grade CD #30 through the plug hole in cover (4).

9. Installing plug (10).

Place seal tape around plug (10) and screw it into the plug hole of cover (4).

Tools: Allen wrench: 5 mm Tightening torque : 23 N-m (17 lbf-ft) -After assembling the upper roller, confirm that oil is not leaking from it and that it rotates smoothly by hand.

10 4 1

f

Filling oil

34-12

34. TRAVEL SYSTEM 34.1.3.6 MAINTENANCE STANDARD

A

D

34 (1.34")

B

C

34

E

Unit : mm (in) No.

ITEM

STANDARD VALUE

REPAIRA SERVICE BLE LIMIT LEVEL

A

Tread dia.

Ø82 (3.23)

Ø73 (2.87) Ø70 (2.76)

B

Tread width

102 (4.02) Basic dimension

Clearance between shaft and bushing

C

Ø32 (1.2598) Ø36 (1.4173)

95 (3.74)

92 (3.62)

Fit

Fit

Tolerance

Shaft

-0.025 (-0.00098 ) Clearance Clearance -0.050 0.7 (0.028) 1.0 (0.04) (-0.00197)

REMEDY

Replace

Replace bushing

0 Clearance Interferenc -0.03 0.01 e0 (-0.0012) (0.0004)

D

Interference between roller and bushing

E

Tightening torque of socket bolt

33 N•m (25 lbt•ft)

Apply Loctite #242

Oil

Engine oil API grade CD #30, 20 cc (1.22 cu•in)

Replenish.

Roller rotation

Roller rotates smoothly by hand.

Reassembly.

Hole

34.1.3.7 TOOLS AND JIGS

Unit : mm (in) No.

f

JIGS

SHAPE

No.

JIGS

g

For extruding shaft

h

Bushing fixing jig

Stand jig

34-13

SHAPE

34. TRAVEL SYSTEM 34.1.4 LOWER ROLLER (TRACK ROLLER) 34.1.4.1 LOWER ROLLER ASSY

ASSY PART No.

YT64D00005F1

No.

Parts

Q'ty

1 2

LOWER ROLLER CAPSCREW

10 40

Remarks YT64D00004F1 M14 X 55 1

2 Apply Loctite #262 T=181 N·m (130 lbf·ft)

Lower roller assy 34.1.4.2 REMOVAL (1) Preparation for removal 1. Preparation for removal Loosen grease nipple to slacken the link. Put wood blocks on the front and rear sides of under section of lower frame, and stabilize the machine.

2. Removing lower roller Remove capscrew (2) M14X55.

Tools: Socket: 22mm Weight of lower roller : Approx.15 kg (33 lbs) Holding up the lower frame (2) Where crawler is installed 1. Preparation for removal Slacken crawler, and stop engine keeping lower frame lifted up with front attachment.

2. Put safe blocks under the front and rear sides of lower frame.

3. Remove lower roller Remove capscrews (2) in the same procedure as that shown in Fig. "Lower roller assy".

Removing lower roller 34.1.4.3 INSTALLATION (1) Securing lower roller temporarily Apply Loctite #262 on 4 capscrews (2) and tighten them temporarily.

Tools: Socket: 22 mm (2) Securing lower roller regularly.

Tighten capscrews (2) to the specified torque.

(3) Adjusting tension of crawler.

Tighten grease nipple and fill it with grease.

GREASE NIPPLE

Adjusting tension of crawler

34-14

34. TRAVEL SYSTEM 34.1.4.4 CONSTRUCTION T=23 N·m (17 lbf·ft)

ASSY PART No. YT64D00004F1 No.

Parts

Q'ty

1 2 3 4 5 6 7 8

ROLLER SHAFT BUSHING PIN SEAL O-RING COLLAR PLUG

1 1 2 2 2 2 2 2

8

34 1

2

3

5

6 4 7

Construction of lower roller 34.1.4.5 DISASSEMBLY AND ASSEMBLY (1) Disassembly 1. Drain oil Remove plug (8) and drain out oil.

Tools: Allen wrench: 6mm 2. Removing pin (4) Put both ends of lower roller assy on the V-shaped blocks (K), apply push-out bar (j) on upper end face of pin (4), and push pin out striking with mallet.

J

Ø14 (0.551")

4

K

Drawing out collar fixing pin (4) 3. Removing collar (7), O-ring (6) Put lower roller on jig (m) for repair stand so that the shaft is perpendicularly located, apply pushout jig (P) on shaft end on upper side, and push shaft (2) until the O-ring separate from collar (7) with press or mallet, and take out collar (7) and O-ring (6).

4. Removing shaft (2) In addition, push out and remove shaft (2) together with the lower collar (7) and O-ring (6).

Push with press

Push with press P

P

7

7

6

6

2

2

m

m

Removing shaft (2), collar (7), O-ring (6)

The shaft (2) extrusion operation may cause the remaining lube oil to flow out. Prepare an oil container beforehand.

34-15

34. TRAVEL SYSTEM 5. Removing collar (7), O-ring (6) Insert shaft (2) with collar (7) and O-ring (6) removed in the said procedure into roller (1) directing the collar (7) side upward, and take out collar (7) and O-ring (6) from shaft (2) in the same procedure as that described in Item 3).

6. Removing floating seal (5) Take out floating seal (5) from collar (7).

5

7

Removing floating seal (5)

7. Removing floating seal (5) Take out floating seal (5) from roller (1).

5

1

5

Removing floating seal (5)

a n Ø16 (0.63")

200 (8")

8. Removing bushing (3) Since thickness of bushing (3) is thin, remove it through lathe or strip it with care not damage inner hole of roller. When the wear of bushing is not large, place upper roller (1) on jig (m) for repair stand and apply the end of push-out jig on the end face of bushing (3) end, and push it out striking it with mallet.

3

m

Extruding bushing (3)

Hammer the inside surface of roller lightly so as not to damage the surface. Put the extrusion jig (n) uniformly over the circumference of bushing (3) and extrude it little by little.

(2) Installing 1. Attach O-ring (6) to one side Install O-ring (6) to shaft groove.

-Apply grease to O-ring.

-Replace O-ring with new one.

6

2

Attach O-ring (6) to one side

34-16

34. TRAVEL SYSTEM 2. Press fitting bushing (3) Align inner hole of roller (1) and bushing (3) and press fit it vertically in capacity of press fit load, 3600kg (7940 lbs), in the condition that bushing push-in jig (g) is inserted into bushing (3).

-Apply molybdenum disulfide grease on press-fit section of bushing, and press-fit it in ordinary temperature.

-Bushing which fails to press-fit because of the oneside pressing should not be fitted.

Push with press

q

3

1

34 Press fitting bushing (3)

3. Press fitting collar (7) Fit O-ring to the one side of shaft (2) mating pin hole of collar (7) on which floating seal (5) is fit with pin hole of shaft (2) in advance.

-Care should be taken not to damage O-ring (6) while press-fitting collar (7) to shaft.

4. Inserting pin (4) Press-fit pin (4) to pin hole on aligning pin holes of shaft (2) and collar (7).

5 4

2

6

7

Inserting pin (4) 5. Attach floating seal (5) to roller side Fit floating seal (5) to inner holes on both ends of roller (1).

-Check that the seal surface is free from flaws, rusts, etc. before reusing the floating seal.

6. Inserting roller (1) Insert roller (1) from the side where collar (7), Oring (6) is not press-fitted to the shaft (2).

1

2

Inserting roller (1)

34-17

34. TRAVEL SYSTEM 7. Installing O-ring (6) Install O-ring (6) to shaft groove.

-Apply grease to O-ring.

-Replace O-ring with new one.

8. Press fitting collar (7) Press-fit collar (7) to shaft (2).

-Press-fit collar (7) on aligning pin (4) hole.

9. Inserting pin (4) Press-fit pin (4) described in to the pin hole mating pin hole of collar (7) with pin hole on the end side of shaft (2).

Press

Pin 7

6

2

Installing O-ring (6), collar (7) 10.Filling oil Remove plug (8) and fill in 90 cc (5.49 cuoin) of engine oil API grade CD #30.

11.Check it for leakage Before tightening plug (8), check it for leakage in the condition of air pressure 0.2 MPa (28 psi).

12.Installing plug (8) Apply oil resistant sealant on plug (8), and tighten it in the plug hole on the collar (7) end face.

Tools: Allen wrench: 6mm Tightening torque : 23 Nom (17 lbfoft)

8 Tightening torque : 23 N·m (17 lbf·ft)

7

Installing filling oil plug (8)

After assembling the lower roller, confirm that oil is not leaking and that the roller rotates smoothly by hand.

34-18

34. TRAVEL SYSTEM 34.1.4.6 MAINTENANCE STANDARD C

95 (3.74)

24 (0.945")

ØA ØB ØD

G

E

199 (7.83") Before tightening plug, apply oil resistant sealant on it.

Tightening torque 23 N·m (17 lbf·ft)

Lower roller (Track roller)

Unit : mm (in) No.

ITEM

STANDARD VALUE

REPAIRABLE LEVEL

SERVICE LIMIT

REMEDY Reinforcement weld repair or replace

A

O.D. of flange

Ø147 (5.79)

—

—

B

Tread dia.

Ø120 (4.72)

Ø110 (4.33)

Ø106 (4.17)

C

Flange width

17.5 (0.689)

12 (0.472)

10 (0.394)

Fit

Fit

-0.060 (-0.00236) Ø40 Shaft -0.090 (1.57480) (-0.00354)

Clearance 0.7 (0.028)

Clearance 1.0 (0.39)

+0.025 Interference between Ø44 (+0.00098) Hole roller and bushing (1.73228) -0.020 (-0.00079)

Interference 0

Clearance 0.01 (0.0004)

D

E

Clearance between shaft and bushing (Coiled bushing)

Oil Roller rotation G

Clearance between roller and collar

Basic dimension

Tolerance

Replace bushing

Engine oil API grade CD #30, 90 cc (5.49 cu•in)

Replenish

Rotates smoothly by hand.

Reassembly

Keep 2.5±0.5 (0.09843±0.01969) space.

34-19

34

34. TRAVEL SYSTEM 34.1.4.7 TOOLS AND JIGS

Unit : mm (in) No.

JIGS

k

V-block

l

Pin (4) extrusion rod

n

Bushing extrusion rod

m

Stand jig

p

Shaft extrusion jig

q

Bushing fixing jig

SHAPE

34-20

34. TRAVEL SYSTEM 34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) 34.1.5.1 FRONT IDLER ASSY

ASSY PART No.

YT52D00006F1

No.

Parts

Q'ty

1 2 3 4

IDLER ASSY IDLER ADJUSTER GREASE NIPPLE CAPSCREW

2 2 2 4

700 IRON SHOE (27.6")

Remarks

205 (8.07")

YT52D00002F1 YT54D00002F1 2444P803 M12 X 35

1

495 IRON SHOE (19.5") 116 270+STROKE 31.8 (1.25") (4.57") (10.6")

34

") 7.6 (1

4 Apply Loctite #262 or equivalent T=115 N·m (85 lbf·ft)

2 3 Grease nipple is positioned on the outside T=58.8 N·m (43 lbf·ft)

Front idler assy 34.1.5.2 REMOVING (1) Preparation for removal Remove crawler. (Above mentioned) (2) Removing idler assy Sling idler assy, and push it forward with bar.

Weight of front idler assy (one side): 73 kg (160 lbs) (3) Installing Installing is done in the reverse order of removing.

BAR

Removing and installation the front idler

Keep away from the front side of front idler.

(4) Where idling assy (1) has to be separated Loosen capscrew (4), and separate idler assy (1) from idler adjuster assy (2).

Tools: Socket: 19mm Weight of idler assy : 45 kg (99 lbs) Weight of idler adjuster assy : 49 kg (110 lbs)

1

2

-The separated idler assy (1) should be placed on square timbers.

4

34-21

3

Separating idler assy (1) from idler adjuster

34. TRAVEL SYSTEM 34.1.5.3 IDLER ASSY 34.1.5.3.1 CONSTRUCTION

IDLER ASSY PART No. No. 1 2 3 4 5 6 7 8

Parts IDLER SHAFT COLLAR BUSHING PIN SEAL O-RING PLUG

YT52D00002F1

Q'ty

Remarks

1 1 2 2 2 2 2 2

YT52D00003P1

8

1 4 3

YT52D01002P1 2

16 X 78

5 7

1A G45 PT1/8

6

Storage procedure

Idler assy

34.1.5.3.2 REMOVING AND INSTALLING (1) Removing 1. Drain oil Remove plug (8) on the side of collar (3) to drain.

Tools: Allen wrench: 5 mm 2. Removing pin (5) Apply pin push bar (jig R) to the top of pin, and push out striking bar (jig R) lightly by hammer.

5

R

Removing pin (5) 3. Removing collar (3) Put idler (1) on stand (U), apply push-out jig (S) on shaft (2), push out shaft (2) with collar (3), then remove collar (3).

Push with press S

2

3 1

U

3

Removing collar (3) 4. Removing collar (3) from shaft (2) If removal of collar (3) on the opposite side is required, turn over front idler and proceed with the procedure described in Par. 3.

Push with press

2

S 3

U

Removing collar (3)

34-22

34. TRAVEL SYSTEM 5. Removing bushing (4) With idler (1) mounted on the stand, tap bushing (4) lightly by hammer, while placing the bushing drawing rod (T) against the end face of bushing (4) evenly all round, till it comes out.

6. Removing floating seals (6) Take out floating seals (6) from idler (1), collar (3). If you intend to re-use floating seals (6), confirm that there is no scoring and rusting on the contact surface and store the floating seals in pairs by placing card board between the sealing faces.

7. Removing O-ring (7) Separate O-ring (7) from shaft (2).

(2) Assembly 1. Pressing in bushing (4) Align inner hole of idler (1) and bushing (4) and press fit it vertically with press so that jig (V) for bushing press-fitting is inserted into bushing (4).

2. Installing O-ring (7) Fit O-ring (7) to O-ring groove on shaft (2).

1

4

T

U

Removing bushing (4)

4

Push with press V

1

-Apply grease to O-ring Pressing in bushing (4) 3. Installing collar (3) (See right Fig.) Press fit the O-ring (7) installed side of shaft (2) into collar (3), and drive pin (5).

4. Installing floating seal (6) Fit the half of floating seal (6) on each side of collar (3) and idler (1).

Pressing 2

3 5

Installing collar (3), shaft (2) 5. Inserting idler (1) Insert floating seal (6) fitted side of idler (1) into shaft (2).

6. Installing floating seal (6) Fit floating seal (6) on the other side of idler (1).

2

6 1

Inserting idler (1) and installing floating seal (6)

34-23

34

34. TRAVEL SYSTEM 7. Installing collar (3) Fit the half of floating seal (6) on the other collar (3), press fit it in shaft (2), and drive pin (5) in with hummer.

8. Filling oil and Inspection Fill in 150~160 cc (9.15~9.76 cu-in) of engine oil API grade CD #30 through the plug hole of collar (3), wind seal tape and tighten plug (8).

Tools: Allen wrench: 5 mm

8

2

3 5 1

Installing collar (3) and filling oil

-After installing the idler assy to the idler adjuster assy, make certain that no oil leaks from floating seal and plug (8) and that idler (1) rotates smoothly.

34.1.5.3.3 MAINTENANCE STANDARD 104 (4.09") C

F

C

E

A B

D

A B

DETAIL TREAD PORTION

Front idler

Unit : mm (in) No.

ITEM

STANDARD VALUE

REPAIRABLE LEVEL

SERVICE LIMIT

A

Dia. of idler projection

Ø446 (17.6)

Ø440 (17.3)

Ø438 (17.2)

B

Tread dia.

Ø400 (15.8)

Ø394 (15.5)

Ø392 (15.4)

C

Flange width

43 (1.69)

38 (1.50)

36 (1.42)

Fit

Fit

Basic dimension D

E

Clearance between shaft and bushing

Interference between roller and bushing Oil Roller rotation

Tolerance

Ø50 Shaft (1.96850)

-0.050 (-0.00197) -0.075 (-0.00295)

Clearance 1.5 (0.059)

Clearance 2.0 (0.079)

Ø57 (2.2441)

-0.03 (-0.0012) -0.02 (-0.0008)

Interference 0

Clearance 0.01 (0.0004)

Hole

REMEDY Replace

Replace bushing

Engine oil API grade CD #30, 150~160 cc (9.15~9.76 cu•in)

Replenish

Rotates smoothly by hand.

Reassemble

34-24

34. TRAVEL SYSTEM 34.1.5.3.4 TOOLS AND JIGS

Unit : mm (in) No.

JIGS

R

Pin striking jig

S

Shaft push out jig

T

Bushing drawing rod

SHAPE

34

About 400 (15.7")

U

Repair stand About 250 (9.84")

V

About 80 (3.15")

2 pcs

Bushing Press fitting jig

34-25

34. TRAVEL SYSTEM 34.1.5.4 IDLER ADJUSTER ASSY 34.1.5.4.1 CONSTRUCTION

No. 1 2 3 4 5 6 7 8 9 10

Parts GREASE CYLINDER BRACKET NUT SPRING PIN SPRING PISTON O-RING OIL SEAL PIN COVER

4

YT54D00002F1

ASSY PART No. Q'ty 1 1 1 1 1 1 1 1 2 1

3

Remarks

2 10

SPECIAL M36 X P3 5

1B G50 1 8

9 7 6

9

Idler adjuster assy

34.1.5.4.2 DISASSEMBLY AND ASSEMBLY (1) Disassembly 1. Spring set special jig Before disassembling and assembling the idler adjuster assy, prepare spring setting jig (V).

Capacity of hydraulic jack : more than 10 tons (22000 lbs) Tools: Spanner: 46 mm 2. Preparation for working Place a hydraulic jack between the jig base and the stand.

Loosen the holding-down nuts of the jig and draw out the retainer plate upward.

Tools: Spanner: 46 mm

M30

HOLDING-DOWN NUT RETAINER PLATE

V HYDRAULIC JACK

BASE

Spring set special jig (V)

Large power is needed to set the spring. Prepare a special jig before disassembly and assembly.

34-26

34. TRAVEL SYSTEM 3. Draw out grease cylinder (See Fig. "Idler adjuster assy".)

Draw out piston (6) from grease cylinder (1) of the idler adjuster assy.

4. Removing oil seal (8), O-ring (7) (See Fig. "Idler adjuster assy".)

Remove oil seal (8) and O-ring (7) from grease cylinder (1).

5. Slinging work idler adjuster Set the idler adjuster assy on the stand of the jig, with its bracket (2) side facing up.

2

5

34

V

Slinging work idler adjuster 6. Fixing idler adjuster assy Fit retainer plate to bracket (2), tighten holdingdown nuts alternately, and secure idler adjuster assy.

Tools: Spanner: 46 mm

3

HOLDING-DOWN NUT

RETAINER PLATE

4

Fixing idler adjuster assy 7. Compression of spring (5) Remove spring pin (4), press spring (5) lifting it with jack so that nut (3) can be turned freely, and remove nut (3).

Tools: Socket: 46 mm

5

Compression of spring (5) 8. Removing bracket (2) Allow the hydraulic jack to retract slowly till the spring is extended to its free length. Remove the retainer plate and take off bracket (2), cover (10).

The free length of the spring: 320 mm (12.6 in) Tools: Socket: 46 mm

RETAINER PLATE

2 10

Removing retainer plate, bracket (2)

34-27

34. TRAVEL SYSTEM 9. Removing spring (5), grease cylinder (1) Hook lifting eye nut (W) to screw M36 X P3 on grease cylinder (1) top end and hoist it. Then, remove the set of grease cylinder (1) and spring (5) using crane from the jig.

Remove spring (5) and grease cylinder (1), in that order.

W

1

5

Removing spring (5), grease cylinder (1)

34-28

34. TRAVEL SYSTEM (2) Assembly Assembly is done in the reverse order of disassembly.

1. Installing spring (5), grease cylinder (1) Insert grease cylinder (1) into spring (5) and attach lifting eye nut (W) to screw M36 X P3 at the tip of the grease cylinder. Lift the grease cylinder by crane and erect it in the center of the jig stand upright.

2. Fixing idler adjuster assy Install bracket (2), cover (10) on top of spring (5).

Center the rod of grease cylinder (1) and the holes in bracket (2). Attach the retainer plate and four holding-down nuts. Fasten the nuts evenly all round and fix the idler adjuster assy to the jig body.

Tools: Spanner: 46 mm

W 1

5

34 Attach spring (5) and grease cylinder (1) to the jig

3. Compressing spring (5) and tightening nut (3) Extend the hydraulic jack, compress spring (5) to a set length and screw in nut (3) to the screwed part at the tip of grease cylinder (1).

Set length of the spring: 270 mm (10.63 in) 4. Installing spring pin (4) Tighten nut (3) till the holes for locking spring pins (4) are aligned. Then fit spring pin (4).

Tools: Spanner: 46 mm Tools: Socket: 55 mm

Holding-down nut Retainer plate

2 4 3 10

5 1

Compression of spring (5), and attaching nut (3) and spring pin (4) 5. Removing idler adjuster assy Remove idler adjuster assy from jig.

Removing idler adjuster assy

34-29

34. TRAVEL SYSTEM 6. Installing oil seal (8), O-ring (7) Fit oil seal (8) and O-ring (7) to grease cylinder (1).

-Grease oil seal (8) and O-ring (7).

7. Filling grease cylinder(1) with grease.

Fill up grease in cylinder (1), remove the grease nipple from piston (6) to discharge the inside air, and press in the piston by hand.

-Direct grease nipple hole downward to make air discharge easier.

8. Installing grease nipple Tighten grease nipple to piston (6).

Tools: Socket: 19 mm, Tightening torque: 59 N-m (43 lbf-ft)

1 8 7 6

GREASE NIPPLE

Grease cylinder (1)

34.1.5.4.3 MAINTENANCE STANDARD

No.

ITEM

A

Installed length of spring Free length of spring Stroke Set length Outer circumference of piston Tightening torque of grease nipple

B C D E F

STANDARD VALUE

H

E

mm 270 (10.63 in) mm About 320 (12.6 in) mm 31.8 (1.25 in) mm 495 (19.49 in)

Close contact length of spring

No scoring and rusting

G A, B, (C)

58.8 N.m (43 lbt.ft)

D

H

235 (9.25 in)

DETAIL G

34-30

F

34. TRAVEL SYSTEM 34.1.6 SPROCKET 34.1.6.1 REMOVING (1) Preparation for removal Remove crawler referring to "34.1.2 CRAWLER", lift up crawler frame with attachment, and put it on square timbers to float and stabilize.

34

Preparation for removal (2) Removing sprocket Loosen 12 capscrews (3) M14, for the attaching of the sprocket by means of a socket and remove the sprocket (2).

Weight of sprocket: 29 kg (64 lbs) Tools: Socket: 22 mm

3 2

Removing sprocket

34.1.6.2 INSTALLING (1) Check before installing Check the mating portion of the travel reduction unit and the sprocket, eliminate burrs and contamination thoroughly and install the sprocket.

(2) Installing sprocket temporarily Coat the sprocket attaching capscrews with Loctite #262 and fasten the sprocket temporarily.

(3) Installing sprocket completely Remove the wooden blocks under the truck frame, bring the machine down on the ground and tighten the sprocket.

Tools: Socket: 22 mm Tightening torque: 181 N-m (134 lbf-ft)

34-31

Installing sprocket completely

34. TRAVEL SYSTEM 34.1.6.3 MAINTENANCE STANDARD (2404N267)

SPECIFICATION

PITCH

78.7mm (3.10in)

NUMBER OF TEETH

21

ROLLER DIA.

Dia. 41mm (1.61in)

PITCH DIA.

527.9 (20.78in)

Unit : mm (in)

4

A C

64 20.813") (0.

P.C.D 52 7.9 (20.783 4")

(0.157") 4 (0.157")

20.64 (0.813")

10 ") 94 .3 (0

10 (0.3 94"

)

B

Sprocket Unit : mm (in) No.

ITEM

A

O.D. of sprocket

B

Width of sprocket teeth

C

I.D. of sprocket

STANDARD VALUE Ø540 38

(21.260 (1.4961

) )

Ø487 (19.2)

REPAIRABLE LEVEL

SERVICE LIMIT

REMEDY

534 (21.0)

532 (20.9)

Reinforcement weld, repair or replace

32 (1.26)

30 (1.18)

Replace.

481 (18.93)

479 (18.85)

Reinforcement weld, repair or replace

34.1.6.4 SPROCKET TOOTH PROFILE GAUGE

Unit : mm (in)

Tooth profile gauge

34-32

34. TRAVEL SYSTEM 34.1.7 TRAVEL MOTOR 34.1.7.1 TRAVEL MOTOR

TRAVEL MOTOR INSTALL

YT53D00001F1

No.

Parts

Q'ty

1

TRAVEL MOTOR ASSY

2

2

CAPSCREW

24 M16 X 40

1

Remarks YT53D00002F1

34 2 Apply Loctite #262 or equivalent T=279 N·m (210 lbf·ft)

Installing travel motor 34.1.7.2 REMOVING (1) Preparation for removal Remove crawler, lift up crawler frame using attachment, and put it on square timbers to float and stabilize.

(2) Removing cover (1) Remove capscrew (2) and also remove covers (1).

Tools: Socket: 19 mm (3) Preparation of oil pan

1

2

Removing and installing cover (1) (4) Removing hydraulic pipe Release pressure from travel circuit, and bleed air in hydraulic oil tank, then remove all pipes connecting to travel motor. Then plug up all pipes and joint section to protect them from entry of dust.

Tools: Spanner: 19 mm, 22 mm, 24 mm, 27 mm, 32 mm Refer to "Hydraulic pipe plug" 4.1 (See Chapter 11. TOOLS)

Removing and installing hydraulic pipe

34-33

34. TRAVEL SYSTEM (5) Removing sprocket Removing 24 (one side) capscrews (3) M14 X 35.

Tools: Socket: 22 mm

3

Removing and installing sprocket (6) Loosening travel motor attaching bolts (2) Apply match marks on travel motor and crawler frame, and remove 24 (one side) capscrews (2) M16 X 40.

Tools: Socket: 24 mm

REMOVE PIPES (DISCONNECT)

2

Removing and installing travel motor attaching bolts (7) Slinging travel motor assy Sling travel motor with nylon sling applied on the side close to sprocket installing section and remove the motor.

Weight of motor: About. 90 kg (198 lbs)

Slinging travel motor

34-34

34. TRAVEL SYSTEM 34.1.7.3 INSTALLING Installing of the travel motor piping is performed in the reverse order of removal.

1. Cleaning Check that contact surface of travel motor and crawler frame is free from burr and stain.

2. Tightening torque Tighten capscrew and hydraulic pipes to the torque specified in "Tightening Torque".

3. Fill inside from motor drain port to casing with hydraulic oil before piping for drain. When starting operation, operate motor in low idling and at low speed for several minutes, and check it for possible oil leakage and noise.

34 Parts

Size

Tools

No.

Tightening Torque N-m(lbf-ft)

Remarks

Capscrew

M14 M16

22 24

3 2

181 (134) 279 (210)

Apply loctite #262 Apply loctite #262

Flareless nut for pipes, sleeve

ø10 X 1.5 ø15 X 2.0 ø18 X 2.5

19 27 32

-

49 (36) 118 (87) 147 (110)

Connector

PF1/4 PF3/8 PF1/2

19 22 27

PP T1,T2 P1,P2

36.3 (27) 73.6 (54) 108 (80)

34-35

34. TRAVEL SYSTEM 34.1.8 SWING BEARING 34.1.8.1 SWING BEARING ASSY

SWING BEARING ASSY No. 1 2

YT40F00005F1

NAME

Q'TY REMARKS 1 YT40F00004F1 SWING BEARING 30 M16 X 85 CAPSCREW FRONT

A

2

A

Inner S mark position of swing bearing

1

SECTION A-A Swing bearing assy

34.1.8.2 REMOVING (1) Matchmarks Remove upper structure, apply matchmarks on inner race of swing bearing and lower frame.

(2) Remove 30 capscrews (2) M16 X 85 for installation inner race.

Tools: Socket: 24 mm

SWING BEARING OUTER RACE INNER RACE MATCHMARKS

Matchmarks (3) Removing grease Remove grease in grease bath.

(4) Removing swing bearing Attach eyebolt on swing bearing (1) and sling it.

SWING BEARING EYE BOLT

Weight of swing bearing: 100 kg (221 lbs) GREASE BATH

Removing and installing swing bearing

34-36

34. TRAVEL SYSTEM 34.1.8.3 INSTALLING (1) Cleaning Clean it completely so that installing surfaces of swing bearing and lower frame are free from dust and dirt.

(2) Installing Install swing bearing on lower frame meeting the matchmarks and positioning the S mark on inner race as shown in the right Fig..

(3) Temporary fastening of inner race Coat the threads of the capscrews (2) with Loctite #262 and tighten all the capscrews (2) temporarily.

Tools: Socket: 24 mm

FRONT

A

A

34

Inner S mark position of swing bearing

Location of S mark on swing bearing (4) Regular tightening of inner race Tighten the capscrews (2) at 180 degrees intervals alternately to a specified torque.

Tools: Socket: 24 mm, Tightening torque: 279 N-m (210 lbf-ft) (5) Filling grease Fill grease bath with 4.9 kg (11 lbs) of grease NLGI2 (molybdenum disulfide grease) or equivalent.

2 Apply Lpctite #262 or equivalent to be applied T=279 N·m (210 lbf·ft) 1

SECTION A-A Removing and installing capscrew (2)

34.1.8.4 CONSTRUCTION

SWING BEARING No. 1 2 3 4 5

NAME

3, 4, 5 8 1

YT40F00004F1 Q'TY No.

INNER RACE 1 OUTER RACE 1 BALL 84 RETAINER 69 REGULATION 1 RETAINER

NAME

Q'TY 1 6 PLUG 1 7 TAPER PIN 1 8 SEAL 1 9 SEAL 10 GREASE NIPPLE 1 (PT1/8)

34-37

2 6 10 7 9

Sectional view of swing bearing

34. TRAVEL SYSTEM 34.1.8.5 DISASSEMBLY AND ASSEMBLY (1) Disassembly 1. Remove seal (9) fitted in the groove in the outer circumference under inner race (1) and seal (8) fitted in the groove in the inner circumference on top of outer race (2) and place them level on a square wooden block or something.

2. Remove taper pin (7), using a hammer and an extrusion rod.

3. Remove plug (6), utilizing an pull bolt inserted in the screwed hole in the center of the plug and using a puller.

EYE BOLT

1

8

7 2

WOOD BLOCKS

6 9

Disassembling swing bearing 4. While rotating outer race (2) little by little, take out ball (3) and retainer (4) through plug hole, in that order.

2

4

1

3

Removing balls (3) and retainers (4) (2) Installing 1. Thoroughly remove the grease from the groove of the seal (8) located on the inner surface of the outer race (2) and from the groove of the seal (9) located on the surface of the inner race (1).

Coat the grooves with adhesive Cyano Bond P0-1 equivalent. fit seal (9) and place it on a surface plate.

2 PUSH ROD

8 1

SQUARE WOODEN BLOCK

9

3

Fitting balls (3) 2. Lower outer race (2) to the position where upper surface of inner race (1) and lower portion of seal groove is mated, put adjusting washer under outer race (2) so that outer raceway surface of ball (3) aligns with inner raceway, and support it.

3. Insert ball (3) and retainer (4), on which grease is applied, through plug (6) hole on outer race (2), alternately.

EYE BOLT

HOOKED ROD

4 SQUARE WOODEN BLOCK

Fitting retainer (4)

34-38

34. TRAVEL SYSTEM

To insert ball (3) and retainer (4), use a push rod, etc., to protect persons from injury from inserting fingers into plug hole.

4. Fit plug (6) to outer race (2) while checking it for direction and position of taper pin hole.

5. Coat seal (8) with adhesive Cyano Bond P0-1 equivalent and fit it in the groove of outer race (2).

6. Check that grease nipple (10) is properly fitted, and fill it with grease. Then, check bearing for smooth rotation and flaws on seal lip portion.

34.1.8.5 MAINTENANCE STANDARD Maintenance standard concerning wear of swing bearing is described in the section 13.6 MEASURING SWING PERFORMANCES of "Maintenance Standard and Test Procedure" in this manual.

34-39

34

34. TRAVEL SYSTEM

This page is blank for editing convenience.

34-40

34. TRAVEL SYSTEM

34.2

DISASSEMBLING AND ASSEMBLING

34.2.1 TRAVEL MOTOR 34.2.1.1 CONSTRUCTION (1) General view

34 P2

PF3/8 FILLING PORT OIL LEVEL

P1

T2

T1 PP FP3/8 DRAIN PORT VIEW A (M2)

Z

A

(M1)

12-M16X2

HYDRAULIC CIRCUIT

PORT NAME AND SIZE

PP T2

T1

(M2)

(M1)

No. P1 P2 T1 T2 PP (M1) (M2)

Ports HYDAULIC OIL FILLING / DRAIN PORT HYDAULIC OIL FILLING / DRAIN PORT DRAIN PORT DRAIN PORT 1st / 2nd SPEED SELECT PORT GAUGE PORT GAUGE PORT

SIZE PF 1/2 PF 3/8 PF 1/4 PF 1/4 PF 1/4

ROTATIONAL DIRECTION (VIEWED FROM Z SIDE) INLET P1 PORT, OUTLET P2 PORT, CW INLET P2 PORT, OUTLET P1 PORT, CCW

P1 P2

34-41

34. TRAVEL SYSTEM (2) Structure of Travel unit

1-7 1-9

1-8

1-25 1-18 1-16 1-15 1-21 1-24

1-6 1-10 1-23 1-22 1-5 13 15 63 10-1 10-2

1-12 1-13 1-11 1-17 1-19 1-20 11 16 2 4 7-2 7-1

1-4 6 5

21 22 24 59 X Y

X

65 34 56 65 19 63

Y

9 12 43 51 73 75 74 18 14 63 8 23

1-3 1-2 1-1 3 17 20 32,33 59 30,31 65 50

A 67 63 68

26 27 28 25 41 44-2

47 46 48 45 44-1 SECTION XX 81 80

42 63 VIEW A

60-16 60-12 60-15 60-4 60-11 60-8 60-1 60-2 60-3 60-13

62 61 59 58 57 SECTION ZZ

60-5 60-7

SECTION YY

34-42

34. TRAVEL SYSTEM (3) Parts list No.

Q'ty

No.

• TRAVEL GEAR ASSY

1

11

• BALL BEARING

1

1-1

• • CASING B•DY

1

12

• BALL BEARING

1

1-2

• • FLOATING SEAL

1

13

• OIL SEAL

1

1-3

• • BALL BEARING

2

14

• SPRING

1

1-4

• • RING NUT

1

15

• SPRING

1

1-5

• • CASING GEAR

1

16

• STEEL BALL

2

1-6

• • SUN GEAR A

1

17

• PIN

3

1-7

• • PLANETARY GEAR A

3

18

• SNAP RING

1

1-8

• • NEEDLE BEARING A

3

19

• SPRING PIN

1

1-9

• • CARRIER

1

20

• BRAKE PISTON

1

1-10

• • SUN GEAR B

1

21

• FRICTION PLATE

2

1-11

• • PLANETARY GEAR B

4

22

• STEEL PLATE

2

1-12

• • BUSHING

4

23

• SPRING

1

1-13

• • NEEDLE BEARING B

4

24

• PLATE

1

1-15

• • THRUST PLATE 2

1

25

• PLUG

2

1-16

• • THRUST PLATE 3

1

26

• POPPET

2

1-17

• • THRUST PLATE 4

4

27

• SPRING

2

1-18

• • SCREW

8

28

• O-RING

2

1-19

• • WASHER

1

30

• O-RING

1

1-20

• • PARALLEL PIN

1

31

• BACK UP RING

1

1-21

• • COVER

1

32

• O-RING

1

1-22

• • SPRING WASHER

12

33

• BACK UP RING

1

1-23

• • BOLT

12

34

• O-RING

1

1-24

• • PLUG

2

41

• PIN

2

1-25

• • O-RING

2

42

• BOLT

8

2

• SHAFT

1

43

• MOTOR COVER

1

3

• CYLINDER BARREL

1

44

• SPOOL ASSY

1

4

• BALL RETAINER

1

44-1

• • SPOOL (LL)

1

5

• RETAINER

1

44-2

• • ORIFICE

2

6

• CAM

1

45

• PUSHER

2

7

• PISTON ASSY

9

46

• SPRING

2

7-1

• • PISTON

9

47

• COVER

2

7-2

• • SLIPPER

9

48

• O-RING

2

8

• VALVE PLATE

1

50

• ORIFICE

1

9

• PLATE

1

51

• SPOOL

1

10

• PISTON ASSY

1

56

• ORIFICE

1

10-1

• • PISTON

1

57

• STEEL BALL

2

10-2

• • PUSHER

1

58

• PLUG

2

1

Parts

34-43

Parts

Q'ty

34

34. TRAVEL SYSTEM

No.

Parts

Q'ty

No.

Parts

60-16 • • BACK UP RING

Q'ty

59

• O-RING

4

60

• RELIEF VALVE ASSY

2

61

• PLUG

2

60-1

• • BODY

2

62

• O-RING

2

60-2

• • POPPET

2

63

• PLUG

7

60-3

• • ROD

2

65

• PLUG

3

60-4

• • SEAT

2

67

• NAME PLATE

1

60-5

• • PISTON

2

68

• RIVET

2

60-7

• • NUT CAP

2

73

• SPRING

1

60-8

• • SPRING

2

74

• PLUG

2

60-11 • • O-RING

2

75

• O-RING

1

60-12 • • O-RING

2

80

• PLUG

1

60-13 • • O-RING

2

81

• O-RING

1

60-15 • • BACK UP RING

2

34-44

4

34. TRAVEL SYSTEM 34.2.1.2 JIGS

1~2

(0.039"~0.079")

CUTTING SLIT ON THE CIRCUMSTANS (1 PLACE)

(1) Jig for floating seal fitting

34

239 (9.41") 219 (8.62")

45

")

39

(0.0 R 39" 1 )

(0.3 R8 15" )

0 0.

(

R1

R5 (0

.197

")

140 (5.51")

20 (0.787")

255 (10.04")

A

10 (0.394") 225 (8.86")

.5 R0 7") 9 01 (0.

2.6 (0.102") (0.

16 7") R4 .25

1 (0. ") R R1 039") 9 3 0 (0. ( R 9") 0.03 1 3 0 9" (0. 1 ) R (0.065") 1.64

(0.225") (0.198") 5.71 5.02

3 (0.118")

DETAIL A

R1 (

0.

3.36 (0.132")

03

9"

) Part Name: Jig For Floating Seal Fitting Material: MC Nylon Unit: mm (inch)

34-45

34. TRAVEL SYSTEM 34.2.1.3 DISASSEMBLING (1) Disassembling 1. Clean the outside surface of travel unit prior to disassembly. Be sure to attach the parts to the original positions.

For this purpose, we strongly recommend to record the original positions of parts before and during disassembling.

2. Remove the drain plug and drain lubricating oil.

The travel unit oil capacity is 1.35L. Place the travel unit on flat and clean ground.

3

2

1

3. Remove the relief valves (1) on both sides.

1

Remove the relief valve (1) first, and the removal of 8 bolts (2) and the motor cover (3) becomes easier.

4. Loosen 8 bolts (2) and remove cover (3).

4

Be careful not to drop the valve plate.

Be careful not to damage the valve plate. Valve plate is located at the internal surface side of the motor cover.

34-46

34. TRAVEL SYSTEM

Raise the motor cover and insert 2 flat-blade screwdrivers in the space between the casing and the body, and pry them slowly and the motor cover can be removed with relative ease.

(Do not damage the O-ring on the mating surface.)

5. Place the motor cover (3) on the wood blocks (5).

5

34

3

6. Remove the backup rings (6) and O-rings (7) from the relief valve (1).

6

7. Remove the cover (8) from the motor cover (3) as shown by the right figure.

7

8

The strong spring force is applied to the cover (8). Loosen bolts gradually with care to ensure safe and prevent the cover from damaging when removing.

34-47

34. TRAVEL SYSTEM 8. Remove the spring (9), pusher (10), and spool (11) from the motor cover. These parts are located under the cover (8).

9

10

11

9. Remove the plug (12) from top of the motor cover.

12

10.Remove the spring (13) and spool (14) from the motor cover. These parts are located under the plug (12).

13

14

12

11.Remove 2 plugs (15).

15

34-48

34. TRAVEL SYSTEM 12.Remove the O-rings (16) from respective plugs.

And remove the steel balls (17) from the motor cover.

16

17

34

13.Remove the plug (18) from the motor cover.

14.Remove the spring (19) and poppet (20) from under the plug (18). Remove the O-ring (21) from the plug (18).

19 18

20

15.Turn the motor cover over. And remove the valve plate (22) from the motor cover.

34-49

21

22

34. TRAVEL SYSTEM 16.Remove the bearing (23) if required.

23

17.Next, remove the 3 O-rings (24) (25) from the casing body.

24

25 24

18.Remove the brake piston from the casing body. The brake piston rises from the casing body by the air blow from "A" port.

A 26

Be sure to cover the brake piston to prevent being injured by springing out of the brake piston in blowing air in.

34-50

34. TRAVEL SYSTEM 19.Remove the O-rings (27) (28) and the backup rings (29) (30) from the brake piston.

34

29 27

28

30

20.Using the steel wire or magnet, remove the friction 2 plates (31) and 2 steel plates from the body casing.

Do not remove the cylinder barrel yet.

31 32

31

34-51

32

34. TRAVEL SYSTEM 21.Place the travel unit on the wood blocks as shown by the photo. And block the unit to prevent from rolling.

Remove the cylinder barrel assembly (33) from the body casing.

33

22.Make sure that reassemble the retainer (34), piston assembly (35), and cylinder barrel to the original position.

To avoid misassembling, record the original positions of parts before disassembling.

23.Remove the retainer (34) and piston assembly (35) from the cylinder barrel (36). And remove the piston assembly from the retainer.

34

35 36

24.Remove the retainer ball (37) from the cylinder barrel.

37

34-52

34. TRAVEL SYSTEM 25.Remove 3 pins (38) from the cylinder barrel.

34

38

26.Using the suitable jig in diameter, compress the plate (39) slightly with the press machine. And remove the snap ring (40). Then, remove the plate (39) and plate (42) from the cylinder barrel.

39

39

42

41

39

40

36

The strong spring force is applied to the plate (39).

During disassembling the cylinder barrel, use a press machine and hold the spring in compressed state to ensure the safety and to prevent the parts damage.

34-53

34. TRAVEL SYSTEM 27.Remove the cam (43) from the body casing.

43

43

28.Remove the 2 steel balls (44) and piston (45) from the body casing. And remove the spring (46) which is located under the piston.

45

44

46

46

34-54

45

44

34. TRAVEL SYSTEM 29.Place the travel motor unit on the wood blocks.

To avoid the damage of X shaft, do not place the travel motor unit on a flat board directly, and place the unit on the wood blocks surely. Remove 12 bolts (47) and 12 washers (48).

47 48

34

SHAFT

30.Using a soft head hammer, tap and loosen the sealant between the cover (49) and gear casing (50).

And remove the cover (49).

49

50

49

DRAIN PLUG

34-55

34. TRAVEL SYSTEM 31.Remove 3 bolts (51) and the thrust plate (52).

#

#

32.Remove the sun gear (53), 3 planetary gears (54), and 3 bearings (55).

53

55

54

53

33.Remove the carrier (56).

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34-56

34. TRAVEL SYSTEM 34.Remove the 3 inner races from the shaft of carrier, if required.

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34 #%

35.Remove the sun gear (58).

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36.Remove 4 bolts (59) and the thrust plate (60).

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34-57

34. TRAVEL SYSTEM 37.Remove each of 4 planetary gears (61), bearings (62), bushings (63), and plates (64).

61

62

63

64

61

62

63

64

38.Remove the bolt (65) and the washer (66).

$# $$

39.Using a magnet, remove the pin (67). If it is difficult to remove, follow the next procedures. a.

Apply an adhesive tape or a magnet plate to cover the thread hole as shown by the photo. b.

Drill a hole in the pin (67). c.

Do the tapping work in the drilled hole of the pin (67). d.

Screw a suitable bolt in the thread hole, and lift up the pin.

40.Remove the ring nut (68) from the body casing.

34-58

68

67

COVER PLATE

34. TRAVEL SYSTEM 41.Using a crane, remove the gear casing (50) from the body casing.

#

34

42.Remove one of the angular bearings (69) from the gear casing.

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43.Turn the gear casing over. Remove the floating seal (72) and the other angular bearings (69) from the gear casing.

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44.Remove another floating seal (72) from the body casing (73).

To remove them from the body casing, strike the shaft (74) and the bearing (75) with plastic hammer and suitable jig in direction shown in the figure.

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34-59

34. TRAVEL SYSTEM 45.Remove the bearing (75) from the body casing, if required.

And remove the oil seal (76) from the body casing.

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46.Remove the bearing (75) from the shaft (74), if required.

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This completes disassembly.

34-60

%"

34. TRAVEL SYSTEM (2) Assembling 1. Be sure to check that all parts are clean and free from earth and dirt.

Check all O-ring, backup ring and oil seal fitted on travel unit for poor condition. When any defect was found, replace it with new one.

Install the new floating seal.

Place the body casing on clean sheet spread on flat ground.

2. Install the oil seal in the body casing.

And install the bearing (75) on the shaft (74).

Then, install the shaft (74) in the body casing.

75

34

74

75

3. Place body casing on wooden block or suitable jig directing the shaft side downward.

Do not place the body casing directly on flat surface to prevent shaft from damaging.

SHAFT

4. Using the "Jig for floating seal fitting", install the floating seal (72) in the body casing.

34-61

34. TRAVEL SYSTEM

Clean and dry O-ring (rubber) and seal ring (metal) before attaching the floating seal.

Apply SAE30 engine oil or gear oil 80W-90 to the contact surface of the seal ring.

5. Apply SAE30 engine oil or gear oil 80W-90 to the contact surface (flat surface) of the seal ring (metal).

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6. Install the angular bearing (69) in the gear casing.

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7. Turn the gear casing over as shown by the photo.

Install the other angular bearings (71) in the gear casing.

34-62

%

34. TRAVEL SYSTEM 8. Using the "Jig for floating seal fitting", install the other floating seal (70) in the body casing. Apply SAE30 engine oil or gear oil 80W-90 to the contact surface (flat surface) of the seal ring (metal).

%

34

-Clean and dry O-ring (rubber) and seal ring (metal) before attaching the floating seal.

Apply SAE30 engine oil or gear oil 80W-90 to the contact surface of the seal ring.

-When joining 2 parts, use caution to prevent damage like scratch and so on to the floating seal.

9. Lift the gear casing (50) on the body casing (73) by means of a crane as shown in the figure. Install the gear casing to the body casing (73).

50

73

With the ring gear placed on the body casing, there is a space left between them. This space is not a problem because it is caused by the action of a floating seal. This space is eliminated by attaching ring nut (68).

34-63

34. TRAVEL SYSTEM 10.According to the following procedure, adjust the precompression between the bearings (69) and (71). a.

To avoid narrow gap among the body casing, 2 bearings, the gear casing, and the ring nut, tighten the ring nut (68) tightly. b.

Rotate the gear casing (50) several turn. c.

Pull the ring nut in tangential direction with the weight scale as shown by the photo, and adjust the position of the ring nut (68). During tightening or loosening of the ring nut, the scale reading should be adjusted within the range from 100N to 135N (22.5 lb~30.4 lb).

SPRING WEIGHT SCALE

11.Apply an adhesive tape or a magnet plate to cover the thread hole. Drill the new hole at middle position between the body casing and the ring nut as shown by the photo.

Specification of the hole: Hole diameter: 6.00 to 6.15 mm (ø0.236"~ø0.242") in diameter Hole depth: 7.0 to 7.5 mm (0.276"~0.295") in depth

DRILLING POSITION

COVER PLATE

When attaching the pin (67) to the ring nut (68), new hole must be drilled on the opposite side of the original hole.

Because the ring nut position is not always the same after adjustment performed by the procedure 10).

12.Remove the all drilling chips.

Install the pin (67) into the new hole which is drilled at middle position between the body casing (73) and the ring nut (68).

67 68

73

34-64

34. TRAVEL SYSTEM 13.Apply the sealant "Three Bond #2403" to the bolt (65). Install the bolt (65) and the washer (66) in the casing. Tighten the bolt to the specified torque 35.3±2.0 N-m (26±1.5 lbf-ft).

65 66

34

14.Place the travel unit as shown by the photo. Install the 2 steel balls (44), spring (46), and piston (60) in the body casing.

44

45 46

15.Install the cam (43) into the body of the travel unit.

Push the cam several times, and check that the motion is smooth.

43

16.Install the plate (42), the spring (41), and the plate (39) in the cylinder barrel.

42

36

34-65

41

39

40

34. TRAVEL SYSTEM 17.Using the press machine, push the plate (39) to compress the spring (41). And install the snap ring (40).

" !' " "

18.Install 3 pins (38) in the cylinder barrel.

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19.Install the retainer ball (37) in the cylinder barrel.

Apply clean hydraulic oil to the retainer ball (37).

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20.Install the piston assembly (35) in the respective original holes of the retainer (34).

Apply clean hydraulic oil to the hole of cylinder barrel and the piston assembly (35).

Install the assembly of retainers and pistons into the original positions in the original combinations.

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34-66

!#

34. TRAVEL SYSTEM 21.Apply clean hydraulic oil to the cam, the sliding surface of 9 piston shoes, and the spline of motor shaft.

Then, lay the travel unit down, and install the integrated cylinder barrel assembly (33) into the shaft.

!!

34

22.Apply the clean hydraulic oil to 2 friction plates and 2 steel plates (32).

GEAR SIDE

BRAKE VALVE SIDE

31

32

23.Install these plates in the body of travel unit alternately. The innermost plate is the friction plate, and the nearest plate is steel plate.

! !

24.Check that brake piston (26) is clean and is free from earth and dirt. Check the backup rings (29) (30) and O-rings (27) (28) for possible damage.

When any irregularity or damage was detected, replace it with new one.

Fit the backup rings (29) (30) and O-rings (27) (28) as shown in the figure.

Apply a small amount of grease to the backup rings and O-rings.

Be careful about the fitting positions of the O-rings and the backup rings. (See figures)

34-67

! & %

$

'

34. TRAVEL SYSTEM 25.Apply clean hydraulic oil to the sliding surface of brake piston (26) of the body casing. Using a soft head hammer, install the brake piston (26) in to the travel unit body.

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26.Install 3 O-rings (24) (25) into the casing body.

"

#

"

27.Install the bearing (23) into the motor cover.

!

28.Turn the motor cover over, and place it on the wood blocks.

34-68

34. TRAVEL SYSTEM 29.Install the spring (19) and the poppet (20) into the motor cover. Install the O-ring (21) in the plug (18).

'

&

30.Tighten the plug (18) to the specified torque 65.7 Nm (48.5 lbf-ft).

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31.Install the O-rings (16) in 2 plugs (15). Put the steel ball (17) in the motor cover.

#

$

32.Tighten the plug (15) to the specified torque 19.6±1.0 N-m (14.5±0.7 lbf-ft).

#

34-69

%

34

34. TRAVEL SYSTEM 33.Install the spring (13) and spool (14) in the motor cover.

!

"

34.Tighten the plug (12) to the specified torque 78.5 Nm (57.9 lbf-ft).

35.Apply the appropriate amount of hydraulic oil to the spool (11), and install it in the motor cover.

36.Tighten the cover (8) to the specified torque 176.4 N-m (130 lbf-ft).

34-70

'

&

34. TRAVEL SYSTEM 37.Turn the motor cover over. Install the valve plate (22) in the original position.

Apply the appropriate amount of hydraulic oil to the surface of the valve.

34

38.Apply grease to the 10 holes of the motor cover.

Install the springs (76) into the holes.

To prevent the springs (76) from falling from holes, the grease was applied.

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39.Place the motor cover (3) on the body casing.

Check if the springs (76) are not fallen.

Tighten 8 bolts (2) to install the motor cover.

Tighten the bolts (2) to the specified torque 129.4 N-m (95.4 lbf-ft).

!

40.Install the backup ring (6) and O-ring (7) into the relief valve (1).

34-71

$

%

34. TRAVEL SYSTEM 41.Tighten the relief valve (1) to the specified torque 142.1 N-m (104.8 lbf-ft).

42.Place the travel unit with directing the brake side downwards as shown by the photo. Apply the torque load to the shaft (74), and check the value of the parking brake torque. At the start of the rotation, the torque should be 239 N-m (176.3 lbf-ft) or more.

43.Install each four of plates (649, bushings (63), bearings (62), and planetary gears (61).

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44.Install the thrust plate (60) as shown by the photo.

Apply the sealant "Three Bond #2403" to the bolt (59), and tighten 4 bolts (59). Tighten the bolts to the specified torque 35.3±2.0 N-m (26±1.5 lbf-ft).

Next, install the sun gear (58).

59

60 58

34-72

34. TRAVEL SYSTEM 45.Install 3 inner races (57) in the shaft of the carrier (56).

55

56

54

34 57

46.Install the carrier (56) as shown by the photo.

56

47.Install 3 bearings (55) and 3 planetary gears (54) into the carrier (Inner race was installed already).

Next, install the sun gear (53).

53

55

48.Install the thrust plate (52) in the carrier.

Apply the sealant "Three Bond #2403" to the bolt (51), and tighten 3 bolts (51), and install the plate (52) in the carrier. Tighten the bolts to the specified torque 35.3±2.0 N-m (26±1.5 lbf-ft).

51

52

34-73

54

34. TRAVEL SYSTEM 49.Check that the machined surfaces of the gear casing (59) and the cover (49) are clean, are free from earth and dirt and are dried. Apply "Three Bond #1389" to the machined surface of gear casing as shown in the figure.

50.Attach the cover (49) to the original position with 12 bolts (47) and 12 washers (48). Tighten bolts to the specified torque 13.7±1.0 N-m (10.1±0.7 lbf-ft).

Fill lube oil from drain port. The optimum oil quantity for the reduction gear is 1.35L. Attach 2 drain plugs (77).

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"% "&

Fill the case of motor with hydraulic oil to prevent damage of the motor before starting operation.

34-74