'SEBM020M0701 STI MAINUAIL KOMATSU PCO05-7 MACHINE MODEL SERIAL No. PCO5-7 8001 and up * This shop manual may contain attachments and optional equipment that are not available in your area, Please consult your local Komatsu distributor for those items you may required. Materials and specifications are subject to change without notice. + PCOS-7 mounts the 3D72N-2 engine; For details, see 72 Series Engine Shop Manual. ©1994 MOMATSU All Rights Reserved Printed in Japan 04-94(02)00402CONTENTS No. of page 10 STRUCTURE AND FUNCTION ....00.0.....o ccc 10-1 20 TESTING AND ADJUSTING ............. ee 204 30 DISASSEMBLY AND ASSEMBLY ................... ceeeeees BOT 40 MAINTENANCE STANDARD ............. 020M07020M07 ‘The affected pages are indicated by the use of the following marks. It is requested that necessary actions, be taken to these pages according to the table below. [Mar Indication ‘Action required O | Page to be newly added Add e Page to be replaced Replace Pages having no marks are those previously revised ‘or made additions, LIST OF REVISED PAGES Mark Pose Ramber [Merk Pane Remsen] Mark Peoe Revter] wan Page "evtO°l man page Revon e001 © | o 24 @ | 0 3022 © 40-10 © 02 ©} 0 25 ®/] 0 31023 Oo 40-11 © 021 © | o 26 © | o 3024 © 40-12 00-3 © 207 © | o 3025 o 40-13, 00-4 0 208 = | o 302 © 40-14 00-5 ° 209 © | o 3027 ® 40.15 00-6 © 2010 © | o 3028 @ 00-7 ° 2011 © | o 3029 © 00-8 © 2012 © | o 3030 © 00-9 > 2013 | 0 3031 @ 00-10 ° 2014 © | o 3092 © 00-11 © 2015 © | o 3033 o 00-12 0 2016 © | o 3034 © © 2017 © | o 3036 @ 10-1 © 2018 © | o 3037 © 102 © 2019 © | o 3038 ® 10:3 © 2020 © | o 3039 © 10-4 © 3040 © 105 © 301 © | o 308 © 10.6 0 302 © | o 304 © 10.7 303° ® | o 3043 @ 10.8 304 @ | o 3044 @ 109 35 O | o 304 @ e 1011 @ | o 306 ® | o 304 © 10-12 0 307 © | o 3087 o 10.13 © 308 © | o 3088 © 10.14 © 309 © | o 3049 © 10.15 © 3010 © | o 3050 © 10.16 2 3011 © | o 3051 © 10.17 2 3012 ® 10.18 0° 3013 © 40-1 10-19 o 90-14 @ 40.2 10.21 © 3015 © 40-3 10.22 ° 3016 ® 40-4 10-23 © 3017 ® 40-5 © 3018 ® 40-6 © 21 @} 0 3019 © 40-7 © 22 © | o 3020 © 40-8 o 203 © | o 302 © 40-9 00-2-1 oOA IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this ‘manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbols @& and "AX" are used to mark safety pre- cautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation A SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1, Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. ‘* Always wear safety glasses when hitting parts with a hammer. « Always wear safety glasses when grinding parts with a grinder, et 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work 4. When carrying out any operation with two or more workers, always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5.Keep all tools in good condition and learn the correct way to use them. 6.Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working, PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving 8.Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them, 9.When disassembling or assembling, sup- Port the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine, If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing 00-3PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before car- rying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (—) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires, 18.As a general rule, do not use gasoline to wash parts. In particular, use only the mini- mum of gasoline when washing electrical parts. 00-4 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts, © When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track.FOREWORD- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give ‘an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspécting disassembled parts. NOTICE shop manual are subject to change at any e. Contact your KOMATSU distributor for the The specifications contained in thi ime and without any advance no! latest information. 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carry- ing out repairs. They are divided as follows: Chassis volume: Issued for every machine model Issued for each engine series Each issued as, ‘one volume to cover all models Engine volume: Electrical volume Attachments volume These various volumes are designed to avoid duplicating the same information. Therefore to deal with all repairs for any model, it is neces- sary that chassis, engine, electrical and attach- ment volumes are ready. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU £ . > ‘Am conto ave | eee | 1 | Bucket contol valve e | Shing cont va a | | z L | | i aoe es | aoa | § | Soom wna contol vate 1 = & Blade contrat vate naa i i j LH. travel control vatve. 20F 73 | i FRM. travel conl ve | SSeS mer |e rere Tip of pad : ‘om contol iver eee eae rose 16216 od of Bucket contol ever Toa N= Ow, Oe 728 rost6 + Eosine oe al sebeed Swing cont ever N= LM, RM. swing 7057 roots i N~ UH nM | | oom swing contol pest bositeg 2623 2626 z mm |— | lee contol iver N= Fie, Lower e027 cou 8 WT Foard Raven Trae conto iver coe mar yet (aw | | + “uel control lever Low... High ry | + r tee tee, ~ Han 7027 ros | Boom ++ Bucket ‘Max. 30. ‘Max, 40 Amount of play in. | Peoria | | Am = Swing oe. 30 Max 40Machine mode! P0067 my er tem Maanurement conditions unit | standard vaue | permite vue Boom conto ever + Engin tinh ing 18204 Mon. 2.3 *Sifnse 8 sere { Roreonal lve, ft push ele to {paver of kno te rear : ‘Am control lever + For control pedal, fit push-pull scale to hadi fanaa pot padal tomeanes + Mute man valoe tnd of trv Bucket contro lover 18204 Mon. 2.9 8 |e oe on 23 3 | oom ming conto pds! ns | sac0s Max. 8.0 g 3 | ae conto! ver 1as08 Mox.28 Troe control iver 1se04 Mox.22 Low Hi rn | a Bi 30209 Max.46 ner wi ben ih 20508 Mana 00m + Oi temperature: 45 — 55°C 180 190 . nf pressure with engine at high idling 8 8 Cate ony ever toon mewnrad am = Avouier of bu 10} Bucket 100'§ 190% swing 110°, n10'§ 800m suing 1008 100°§ e io 190% 10% i 7 kalem! E [ew 190% 100° Lowered hydraulic pressure + Oil temperature: 45 — 55°C * Difference oil relief pressure between at ‘engine high iting ard at engine a halt Speed, (Measure pressure when ane pump real ols velieved 20-4 ® 020mo07020Mo7 Machine model 005-7 Tear ‘ice: Messurement conditions unit Standard value Permissible value Swing Swing brake angie + Engine at high ing zonrsi0¢ | (mm) HySrauite off temperature: 45 — 55°C * Stop after swinging one turn and measure distance tt sing cir + PP Distance of movement on outside circumference of swing ccle 20 (120) 30 (120) “Tire taken to start swing Work equipment Max. reach porture er eas + Engine at high idling {Hydraulte ot temperature: 180 | ae s5C | «Tite taken from starting position to'swing 80" and 180 OF When Bucket rated food Max. 3.5 43 “Tieme taken to swing Work equipment Max. reach] posture = 2oRF5108 | + Engine a high iting Hydraulic of temperature: 45 — 55°C | + Swing one turn, and measure time taker’ | to sming next turns 30215 a8 | Hvdrauticritt of swing (02,1 zourowr | + Engine stopped * rerulc temperaure: 48 — 55°C + Set machine on 15" slope, and set upper ‘Structure st 90" to the si + Make mateh marke on swing circle outer mn track frame re distance thet match marks move apart after 18 minutes (00) (90)ve model 05-7 Measurement conditions Unit Standard value Permissible value 2 | eskge tom swing = | wer + Engine at igh iting : ‘Hydraulic it temperature: 45 — 85°C “Reeve swing creut fi “Travel speed (1) ‘Measuring posture 208F5106 + Engine at high iting + Hiydroule oll temperature #- soc + Raise track on one side at atime, rotate one wrn, then mesure ‘ime token for next 5 tums 228 ‘Teavel speed (2) Travel ‘Measuring posture so) ., Sreh panieGalo te Engine at high idling | Hiydraule ot temperanu a-eoc + Fun up for atleast 10 m, and ‘messure time taken to travel ‘pext 20 mon flat ground, TN For nabber shoe 40524 40528 Teavel deviation ‘Wesruring porwure sos f= i Le + Engine a high idling * Hydraulic oil temperature: 45 — 55°C “Run up for at least 10 m, and measure ovition wien traveling next 20 m on {at ground, + Use t hard horizontal surface 20m 10m ‘Measure dimension X Max.600 020M07020Mo7 Machine made! P0057 Tat fies teem Measurement conditions Unit | Standard value | Permisibte value Woasarina posture | Hydrate ditt of travel mm | Max.200 240 £ zonesion | Engine stopped Hydraulic ol tempagature: 45 — 85°C + Stop machine om 30" slope with ‘rocket facing stralght up te slope. + Nasir the distance the machine ‘mows n'8 minutes Measuring porte Total work equipment ihyarauiednft stp 2 r Max. 178 350 of bucket teth) a Wy noe ener | Boom eylinde {grount.o} retraction | . pig in above posture and mesure eee of cylinder) fxteralon or retraction of cylinder | Sha downward movement stip oF bucket tet | + Bucket Rated losd (63 ko) oe 1 Horsontal, fs ground | Greets ecenian | 2 beer annus Moe. 24 « E | fever {Hygroulc of temperature: 45 — 55°C | § | ¢ |e 5 lz {Bimmer | £ | § | sucker eyinder & | 2] feounrot retraction mm Moto) 20 2 | 3 | ofeviineen 2 |3 2 + Engine stopped 2 Hydraulic o! temperature: 45 ~ 55°C = | oom {Buckets Rated oad (63 Sat ine + Stop te machine ne ove pote (enount of traction, | "ona 15 slope mith the upper scare . ‘corson of eyinde) oe = S80" tothe side, and means the the cylinder over 18 minute, Blade (nyaraulie dete at pot blade) + Engine stopped * Hydraulic ol! temperature: 45 — 55°C ‘Raise the Blade to the maximum height, then measure the amount the edge of the blade goes down over 15 minutes,Machine mode roan co tm Messirement conditions Unc | stanrvaiue | Permibi vue Tearing pore 001 : Boeke eth ig 28104 Max. 38 contact with ae ound é " \ Ce oo el s Cinder tty 2 24204 Max. 29 extended + Engine at high iting & "fart of temperate oes easing postre Gitnder futly = |é 40203 Max. sce oh iB ~“A- ‘e Ful extended 3 26208 Mox.92 + Engine thigh ing a "Hideto temperature ae Measuring posture | € ys s7s04 | mas ile aol we 3 Notxe te ola GED a 3 | S| runy oxtendea = 24204 Max.29 S + Engine at high idling a = + Hydraulic oil temperature: eee Teearng pore Blade in contact 2 toz01 snerourd é i | J, Blade fy g 10204 Max.1.2 ect = Engine at high idling § fit of tempeatore ers ‘200m swing 2 Gvlinaer fully bee 62:08 Mex.7.6 rete 7 5 | ( 3 uly etende ZF 73208 Mox.09 20-8 020Mo7020mo7 Machine mods 005.7 Car Machine mode! Unit Standard value Permissbie value Work equipment ‘Measuring posture ia BoRreI v6 + Lower bucket to ground and measure time taken for chasis to rise from round «+ Engine: Low ialing ‘Hydraulic ol temperature: 45 — 55°C ‘Measuring posture 2086117 + Amount of time when arm stops foramoment | + Engine: Low iting |" Hyarautc i! emperature: 45 — 55°C Time ing Bucket Mi (oe * | Nay \ Ay | + Amount of time when bucket stops | fora moment Engine: Low idling { Hyaraute ol temperature: 45 — 55°C Blade ‘Measuring posture 205119 + Engine seed: Low idling + Olttemperature: 45 ~ 58°C “Measure the time i takes forthe fear of the machine tobe ifted off the ground, sorting from the time the Blade contacts the grounds Internal leakage of each Slinger + Hydraulic ol temperature: 45 — 55°C 1 HRlleve circuit tbe measured eclmin Max. 1.2STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM nspecton Bee component | comecorna. [aoa Judgement abe Mesourement condioa ithe condtionis shown in Tole ad Table 2 the mentor paelis normal | 1) Insert T-adaperto C2. Tobie CHECK. CAUTION prion eaten ae Display | Sensor signal input on Mon WV oaanttamparnare | gy eto. on | 10-167 on | 10-10 cnecx, Stop engine koto ore Max V ae Charge level Assad ete stat engine fan OFF 10—16V. z Engine oil pressure. on pa H Start engine ed cy ‘OFF 10—16v. § reheating on | ote i Stop engine ae OFF Max. 1V Toble 2 (GAUGE portion 1) Turn staring switch OFF Sennaatore Gauge desley —] Dip oval oasance eco siee ath” | amomerssnctingr sentence) || ay Sacimnnel sense Onin near Sting ewich Ow [Stang ewith OFF ee ey =| | cauce 2) | Seton see apt : e so010 ee {female} (6) and (7}] F 1040.10 11 Txp staring switch of ota eee 2) Baonnet conecr temperature era) | eearee| [Normattenperure 6°) | Min Tmo & Above HOC Max 10 Ate conditonises shown inthetae below. | 1) Turn starting swteh the tater nota on Engine oil eve! Measure 2) Disconnect connector ‘sensor EB (Mate) resistance | | Engine oil level normal Max. 19. eB. Engine aioe! abnormal | Min MO Mine codons x shown nthe table below, | 1) Turn stating switch teeeor enon oF 2} lewonec connector Fueliovl sensor | QB Mole! | Mossure Fal acai | orenos 08 —09 Empty 202010 20-10 020M07020M07 ese] componem | connectorn, |'"apeeta Judgement ble Measurement condition ithe conditions a shown inthe table below, | 1) Start engine. the gener norma Engin ai aor erinas [Measure | | Engine ot pressure : pressure sensor | Sensor teminal | resistance | | 0.7 kg/em? and above Min. IMO : Eoin of posure ; : OB kg/em! end below pee i = {the condition is as shown inthe table below, | 1) Start engine the sensor nota 2 Disconnat connector e Alternator £3 (Mate), bel nenel vottge || 2 qaey()—<2) 135-145 + When engine is running (al trate o more) 20-117 ®TOOL FOR TESTING, ADJUSTING, AND TROUBLESHOOTING mens gm [Symbol] PartNo. Part Name Remarks Engine speed | 799-203-8000] muititachometer | Digita eispiay fi 62-2.000%em Water and oil eae | oialal nner aos Was ar 8 | 799-101-1600] Dist 50 —1,200%¢ Engine oil pressure | c | 799-401-2320] Hydraulic gauge | 10 ko/em* Valve clearance p | Commerciaty | Feeter gauge - O—70 kg/cm? 1 | 798-502-1590] compression gauge 70 Kae? Compression E Kit Part No. 795-502-1205, pressure 2| 795-101-1580] Adapter 799-201-9000] Handy smoke checker | Discoloration 0 — 70% (with standard color) Exhaust color F ‘Commercially (Discoloration % X 1/10 = smmercialy | Smoke meter Bosch index) 799-101-5001 | Hydrauictester | Bresture g2uge 25, 60, 400, 1 790-261-1201 | Digital hydraulic tester| Pressure gauge 500 ka/em? Hydraulic pressure G ee Both mate and female 720-261-1310 14 X 1.5 (female PT 1/8) 2 Adapter i Both male and female eae 18 X 1.6 (female PT 1/8) Operating force | Commercial | push-pull sate - Stroke, hydraulic dit Commercial | scate - Work equipment Commercially speed J available Stop watch fae Pump performance | K | 790-909-1003] Flowmeter kit - Troubleshoctingot | | 1 | 799-601-2600] T-adepter box + KitPart No. T-adapter kt wiring harnesses and L varing h 799-601-7100 2 | 799-601-7000] Adapter Ass’y Troubleshooting of voltage and M Commercially | Tester - resistance values available 20-12 oO 020M07ADJUSTING VALVE CLEARANCE 1. Remove the cylinder head cover. 2. Rotate the crankshaft in the normal direction so that, TDC {top dead center) line (1) on the outside circumference of the flywheel can be seen through the hole in the flywhee! housing when No. 3 cylinder is at compression top dead center. ‘* When rotating the crankshaft, the intake and exhaust valves of the cylinder near compression, top dead center do not move. If the intake and exhaust valves of No.3 cylinder move, rotate further to align at the compression top dead center. 2omro7101 3. Toadjust, insert feeler gauge D between rocker arm (2) and vaive stem (3), and turn adjustment screw (4) until the clearance is a sliding fit. 4. Tighten the locknut (5) 0 hold the adjustment screw in position ZZ Locknut: 2.6 + 0.1 kgm + After tightening the locknut, check the clearance again. 5. Turn the crankshaft 240° each time and check and adjust the valve clearnce of the next cylinder in the firing order in the same way, 4% Firing order: 3—1—2 020Mo7 SIT FT once 20-13 ®MEASURING COMPRESSION PRESSURE AA wren mecsuring we compression preset, bo carol not to touch the exhaust merits or tml ort got your eathes caught inthe fan fon bet or ether rotating pote 1. Adjust the valve clearance. For details, see ADJUSTING VALVE CLEARANCE. 2. Warm up the engine to make the oil temperature 40 — 60°C, 3. Remove the nozzle holder assembly (1) from the cylinder to be measured. + Be careful not to let any dirt or dust get in + If the nozzle holder assembly is removed, replace the seat gasket, 4. Install adapter £2 in the nozzle holder mount of the cylinder to be measured, and tighten to the specified torque. SD Adapter: §.2 + 0.2 kgm 5. Connect compression gauge E1 to adapter E2 6. Set mult-tachometer A in position. 7. Disconnect connector (2) of the engine stop motor, place the injection pump stop lever in the STOP position, then crank the engine with the starting motor and measure the compression pressure. * Measure the compression pressure at the point where the pressure gauge indicator remains steady. ‘* When measuring the compression pressure, mea- sure the engine speed also to confirm that itis within the specified range for the measurement conditions. After measuring the compression pressure, install the nozzle holder assmbly. * 20-14 ® 020Mo7020M07 TESTING AND ADJUSTING FUEL INJECTION TIMING 1. Disconnect fuel injection pipe (1). 2. Using crankshaft pulley mounting nut (2), turn the crankshaft in the direction of rotation of the engine, and stop the crankshaft at the point where the surface of the fuel at the tip of the delivery valve begins to rise. 3. In this condition, check that the 11° line (3) on the. outside circumference of the flywheel is aligned with the center of the inspection hole, 4. If the injection timing is not correct, change the thickness of shim (4) between the fuel injection pump and gear case to adjust the timing, ‘© INCREASE shim to RETARD injection timing © DECREASE shim to ADVANCE injection timing + Be careful of the following points when adjusting. 1) The standard for the injection timing adjust- ment shim is 0.6 mm. 2) The adjustment shim has a silicon coating, 80 use thinner to remove all the oil and grease from both faces of the shim and the pump ‘mounting surface. 3) A shim thickness of 0.1 mm changes approx. 1°. There are two types of shim thickness: 0.2 mm and 0.3 mm, 20MFO7107 F20Mog038A.x 20-15ADJUSTING FUEL CONTROL LEVER FS Disconnect cable(1) and adjust with adjustment nut {8) s0 that the operating force of fuel control lever (2)is 25 —3.5 kg. ‘* Measure the operating force at the center of the lever knob. Set fuel control lever (2) and engine governor lever {(4) at the low idling position, then connect cable 1). Start the engine and move fuel control lever (2) to the high idling position. |. Measure the engine speed and adjust the high idling position of fuel control lever (2) using stopper bolt ©). igh idling speed: 2,150 + 50 rpm Standard dimension # of stopper bolt: 23.0 mm. 20-16 @ 20MF07108 2omeo7110 020M07020Mo07 TESTING AND ADJUSTING HYDRAULIC PRESSURE OF WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS ‘& Oil temperature when measuring: 45 — 55°C “AK Lower the work equipment to the ground and ‘stop the engine, Then loosen the oil filler plug in the hydraulic tank slowly to release the pressure inside the hydraulic tank Set the safety lock lever to the LOCK position. 1. Measuring 1) Remove plug (PT 1/8) (1) or (2) of the circuit to be measured, and install oil pressure gauge G1 (400 kg/em) Table 1 Plug Pump Control actuator 1 | Front pump LH. travel motor D (8-spool control} Swing motor valve right side) | Arm cylinder Boom swing cylinder Grimace | Soot 6 2) Start the engine, run the engine at high idling, ‘and measure the main relief pressure ¥ Condition of actuator being measured: i) For the work equipment: Set all cylinders to the end of their stroke. ii) For swing: Lock with the swing lock pin ii) For travel: Put block @) under the track shoe grouser, or fit block @ between the sprocket and frame to lock the track, then measure each side separately + Measure all of the actuators at 1-pump relief + The set pressure of the safety valve of the swing control valve is lower than the set pressure of the main relief valve, so if the swing is relieved, it becomes the safety valve set pressure 201F01116. 2orF011172. Adjusting © (3): LH. travel, swing, arm, boom swing (8-spool control vaive right side) © (4): RAH. travel, bucket, boom, blade (8-spool control valve left side) Loosen locknut (6), then turn adjustment screw (6) to adjust, Turn the adjustment screw to adjust as follows. © To INCREASE pressure, turn CLOCKWISE © To DECREASE pressure, turn COUNTER- CLOCKWISE % Adjustment for one turn of adjustment screw: 179 kg/em? ZED Locknut: 35 + 0.5 kgm % After adjusting, repeat from Step 1 to check again. 20-18 20MFO7113 020M07020Mo7 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT + If there is any hydraulic drift in the work equipment (cylinders), check as follows to determine if the cause is in the eylinder packing or in the control valve, 1. CHECKING FOR DEFECTIVE CYLINDER PACKING 1) Checking boom and bucket cylinders i) Set in the same posture as when measuring hydraulic drift, and stop the engine. ii) Operate the boom control lever to RAISE or the bucket contral fever to CURL. ‘¢ If the lowering speed increases, the packing is defective, ‘+ If there is no change, the control valve is defective. 21 Checking arm cylinder ') Operate the arm cylinder to move the arm in fully, then stop the engine. ii) Operate the arm control lever to IN. ‘¢ If the lowering speed increases, the packing is defective ‘© If there is no change, the control valve is defective. * Set safety lock lever OF F position. + If it is difficult to judge the condition, fill the bucket with soil or apply the rated load when carrying out the test [Reference] If the cause of the hydraulic drift is in the packing, and the above operation is carried out, the downward move- ment becomes faster because of the following reasons. 1) If the work equipment is set to the above posture {holding pressure applied to the bottom end), the oil at the bottom end leaks to the head end. However, the volume at the head end is smaller than the volume at the bottom end by the volume of the rod, so the internal pressure at the head end increases because Of the oil flowing in from the bottom end. 2) When the internal pressure at the head end increase, the balance is maintained by a certain pressure (this differes according to the amount of leakage) in proportion to it. 3) When the pressure is balanced, the downward move- ment becomes slower. If the lever is then operated according to the procedure given above, the circuit of the head end is opened to the drain circuit (the bottom end is closed by the check valve), so the oil ‘at the head end flows to the drain circuit and the downward movement becomes faster. ‘Boom, bucket eylinder 207601195, ‘Aer cylinder 20-19 @BLEEDING AIR 1. BLEEDING AIR FROM CYLINDERS + When installing hydraulic cylinders or hydraulic piping after they have been removed, bleed the air from the hydraulic cylinder as follows. 1) Start the engine andrun it at low idling for approx. 5 min, 2) Run engine at low idling, and raise and lower boom 4 — 5 times in succession + Stop the piston rod approx. 100 mm before the end of the stroke. Do not relieve the circuit. 3) Run the engine at high idling and repeat Step 2), After this, run the engine at low idling and operate the piston rod to the end of its stroke to relieve the circuit, 4) Carry out the procedure in Steps 2) and 3) for both the arm and bucket cylinders. 2. BLEEDING AIR FROM TRAVEL MOTOR * When installing the travel motor or hydraulic piping after they have been removed, bleed the air as follows. 1) Disconnect drain tube (1) from the motor. 2) Run the engine at low idling and check that oil oozes out from the nipple. 3) When oil oozes out from the nipple, connect tube 0. 20-20 ® 2oMeo7118 020M0730 DISASSEMBLY AND ASSEMBLY o20Mo7 METHOD OF USING MANUAL ............. 30 3 PRECAUTIONS WHEN CARRYING OUT OPERATION .. 30-4 ‘SPECIAL TOOL LIST 30-6 STARTING MOTOR Removal ..... 30-7 Installation... 7 ALTERNATOR, Removal ..... 30-7 Installation 30-7 FUEL INJECTION PUMP Removal . 30-8 Installation 30- 8 NOZZLE HOLDER Removal 9 Installation 30-9 WATER PUMP Removal . 30-10 Installation = 30-10 ‘THERMOSTAT Removal . cece BOM Installation .. 2630-11 ENGINE FRONT SEAL Removal . = 30-12 Installation ...... = 30-12, ENGINE REAR SEAL Removal ++ 30-13 Installation... 30-13 CYLINDER HEAD Removal 30-14 Installation . 30-15 RADIATOR, OIL COOLER Removal : 30-16 Installation . = 30-16 ENGINE, HYDRAULIC PUMP Removal . 30-17 Installation 30-18 DAMPER, Removal = 30-19 Installation + 30-19) CENTER SWIVEL JOINT Removal Installation Disassembly . Assembly TRAVEL MOTOR Removal .....6scesse5 Installation .. ‘SPROCKET Removal Installation ..... ‘SWING MOTOR Removal ......- Installation REVOLVING FRAME Removal Installation ‘SWING CIRCLE Removal Installation IDLER AND RECOIL SPRING Removal A Installation ....... RECOIL SPRING Disassembly .......... Assembly TRACK ROLLER Removal ... Installation RUBBER SHOE Removal Installation HYDRAULIC PUMP Removal Installation 8-SPOOL CONTROL VA\ Removal Installation Disassembly . Assembly ........ = 30-20 30-20 30-21 = 30-21 30-22 30-22 ++ 30-23 = 30-23 + 30-24 230-24 = 30-25 30-26 22. 30-27 + 30-27 = 30-28 = 30-28 = 30-29 = 30-30 = 30-31 = 30-31 <5 30-32 = 30-32 30-33 + 30-33 30-34 30-34 : . 30-36 30-37 30-1 @BOOM CYLINDER Removal 3038, Installation 30-38 ARM CYLINDETR Removal 30-39 installetiog eee ee 30.39 BUCKET CYLINDER Reniovalsemee 30-40 instore 30-40 ‘SWING CYLINDER Removal . 30-41 instalation 30-41 BLADE CYLINDER o Inetalition -- HYDRAULIC CYLINDER Disassembly . . 30-43 Assembly sos. 30-45 WoaK EQUIPMENT Removal 30.47 installation 30-47 BuckeT Removal 30-48 installation ‘20-48 ARM Removal cea 80-49 installation “30-48 Boom Removal «+ 30-60 Installation “30.50 BLADE ee 30-51 Installation 30.81 30-2 020Mo7‘020M07 METHOD OF USING MANUAL 1. When removing or installing unit assemblies (1) When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. (2) Any special techniques applying only to the installation procedure are marked # 1), and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. (Example) REMOVAL OF 000 ASSEMBLY Tilte of operation A Precautions related to safety when carrying out the operation 1. XXXX (1) Step in operation ce Technique or important point to remember when removing XXXX (1) 2 A442) [#1 Indicates that a technique is listed for use during installation 3. COC Dassembly (3) Amount of Lubricant and Coolant INSTALLATION OF O OO ASSEMBLY .... Title of operation + Carry out installation in the reverse order to removal. #1 Technique used during installation * Technique or important point to remember when in- stalling A A A (2). + Adding water, oil Step in operation * Point to remember when adding water or oil w& Amount of Lubricant and Coolant 2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation, 3. Listing of special tools (1) For details of the description, part number, and quantity of any tools (A, etc.) that appear in the operation procedure, see the SPECIAL TOOLS LIST given in this manual 30-3 oOPRECAUTIONS WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.) 1. Precautions when carrying out removal work + Ifthe coolant contains antifreeze, dispose of it correctly. + After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. + When draining oil, prepare a container of adequate size to catch the + Confirm the match marks showing the installation position, and make match marks in the neces- sary places before removal to prevent any mistake when assembling + To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. + Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. + Check the number and thickness of the shims, and keep in a safe place. + When raising components, be sure to use lifting equipment of ample strength. + When using forcing screws to remove any components, tighten the forcing screws alternately. + Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal * Precautions when handling piping during disassembling Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Hoses and tubes using sleeve nuts Nominal ‘Sloove nut fetbow end number _| P20 lputerd | Use the two items below 0 8 set (02 | 07376-50210 | 07221-20210 WNutl, 07222-00210 Pg) (03 | 07376-50315 | 07221-20316 Nut), 07222-00312 Plug! 04 | 07376-50422 | 07221-20422 Wut), 07222-00414 Plug) (05 | 07876-50522 | 07221-20522 Wut), 07222-00815 Pug) 06 | 07376-80628 | 07221-20628 Wut), 07222-00616 (Plug) 10 | 07376-81034 | 07221-21034 Nut) 07222-01018 Plug) 12 [07376-51294 | 07221-21234 Nut, 07222-01219 (Plug! 2) Split flange type hoses and tubes Wominal i Sleeve head ; . lange hose ena) | Sleeve head Split flange (04 | 07878-00800 | 07378-10800 _| 07371-30800, (05 | 07378-00500 | 07378-10500 _| 07371-30800, 3) If the part is not under hydraulic pressure, the following corks can be used. Nominal Dimensions pura | Pertnumber | —rensns _ (05 _[o70ss-o0608| 6 | 5 | 8 (08 _[o7oas-ooari| 6 | 65 | 11 10 _|o7049-01012| 10 | a5 | 12 | Taper 1/8 sa 12 _[o7oas.01216) 12 | 10 | 15 14 _o7oas.orate) 14 [115 | 18 16 [07049-01620] 16 | 135 | 20 te joroas-ore22| 18 | 15 | 22 i: 20 [07080-02025 20 | 17 | 25 (cana 22_[o7089-02228) 22 | 185 | 28 202F2001 24 [07089-02430] 24 | 20 | 30 27 [07089-02734 27 [225 | 34 30-4 ® 020mo7020M07 2. Precautions for installation operations + Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. + Install the hoses without twisting or interference. + Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. + Bend the cotter pin or lock plate securely. + When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 — 3 drops of adhesive. + When coating with gasket sealant, clean the surfacé and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. + Clean all parts, and correct any damage, dents, burrs, or rust. + Coat rotating parts and sliding parts with engine oil. + When press fitting parts, coat the surface with antifriction compound (LM-P). + After fitting snap rings, check that the snap ring is fitted securely in the ring groove. + When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then con- nect securely. + When using eyebolts, check that there is no deformation or deterioration, screw them fully, and align the direction of the hook. + When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. 3. Precautions when completing the operations + If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. + If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. + If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been re- ‘moved for repair, always bleed the air from the system after reassembling the parts. For details, see TESTING AND ADJUSTING, Bleeding air. + Add the specified amount of grease (molybdenum disulphide grease) to the work equpment related parts. 30-5 qdSPECIAL TOOL LIST Nature of work Disassembly, assembly of recoil spring assembly ISymbol} Part No, A | 792-371-1400 Part Name Sleeve Remarks 795-502-1003 Cylinder repair stand 790-101-1102 or 1 | 790-102-1100 Pump Power wrench 790-442-2871 | Bracket 1 Disassembly, 790-445-3590 | Pin 1 assembly of 7 hydraulic cylinder 790-330-1100 assembly 2 or 1 | Removal of cylinder head 790-102-2301 3 | 790-720-1000 | Expander 1 | Expansion of piston ring 796-720-1620 | Ring 1 | Boom, arm, 4 [07281-00809 _| Clamp 1 | bucket ae 796-720-1630 | Ring 1 | Boom swing, | of Piston ring 07281-00709 | Clamp 1 | blade 30-6 020M07020M07 REMOVAL OF STARTING MOTOR ASSEMBLY By Disconnectihe cable rom the negative (-) terminal ofthe beter, Remove canopy (1) Remove operator's seat (2) Remove hood (3). Remove engine cover (4) Disconnect wiring (5) Remove starting motor assembly (6). Oe sens INSTALLATION OF STARTING MOTOR ASSEMBLY ‘© Carry out installation in the reverse order to removal, REMOVAL OF ALTERNATOR ASSEMBLY Ay disconnect the cable from the negative (-)terminal of the battery. Remove canopy (1) Remove operator's seat (2). Remove hood (3) Remove engine cover (4) Remove adjustment bolt (5). Remove fan belt (6). [31] Disconnect wiring (7). Remove alternator assembly (8). ePvogsen INSTALLATION OF ALTERNATOR ASSEMBLY Carry out installation in the reverse order to removal Adjust the fan belt tension. For details, see STANDARD VALUE TABLE FOR ENGINE,REMOVAL OF FUEL INJECTION PUMP ASSEMBLY 1, Disconnect fuel hoses (1), (2), (3), and (4). + To prevent fuel from leaking out, bend the end of fuel supply hose (1), and tie it to stop the fuel, (2. Remove fuel filter (5). 3. Disconnect fuel control cable (6). [1] 4. Remove engine stop motor assembly (7). + Remove the wiring connector, stop motor spring, and breather, then remove the stop motor assembly Disconnect fuel injection tube (8). (#2) Remove cover (9). Disconnect lever link (10). ‘* Remove snap ring (11), and disconnect lever link (10), 8. Remove fuel injection pump assembly (12). G3] % Check the number and thickness of injection timing adjustment shims (13), and keep in a safe place. + Cover the injection pump mount with tape to prevent dust or dirt from entering, Noe INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY © Carry out installation in the reverse order to removal. Ea ‘ Adjust the fuel contro! lever. For details, see TESTING AND ADJUSTING, adjusting fuel contro! lever. 2) GE Sleeve nut: 3.75 + 0.25 kam eS) 4 Adjust the fuel injection timing. For details, see TESTING AND ADJUSTING, adjusting fuel injection timing 30-8 20MF07205 20m07208 020M07020Mo07 REMOVAL OF NOZZLE HOLDER ASSEMBLY Remove air cleaner hoses (1) Remove air cleaner assembly (2). Disconnect fuel injection tube (3). [ET] Remove nozzle holder assembly (4). [7] INSTALLATION OF NOZZLE HOLDER ASSEMBLY ‘© Carry out installation in the reverse order to removal. GED Sleeve nut: 3.75 + 0.25 kgm ‘* When installing the nozzle holder assembly, check and clean the nozzle mount, then install S= Nonle holder: 6.2 + 0.2 kgm 30-9 ®REMOVAL OF WATER PUMP ASSEMBLY 1. Remove radiator assembly # For details, see REMOVAL OF RADIATOR ASSEMBLY, 2. Remove fan(1), 3. Remove fan bel (2). (87) + Loosen the adjustment bolts of the alternator, and move the alternator towards the cylinder block, then remove the fan belt 4. Remove pulley (3) 5. Remove water pump assembly (4) INSTALLATION OF WATER PUMP ASSEMBLY © Carry out installation in the reverse order to removal. , ao % Adjust the fan belt tension. For details, see STANDARD VALUE TABLE for engine 2) G32) Mounting bolt: 2.6 + 0.1 kgm © Refilling with water ‘Add water to the specified level and run the engine tocirculate the water through the system. Then check the water level again. 30-10 oO 020M07020mo7 REMOVAL OF THERMOSTAT ASSEMBLY Drain cooling water. Disconnect hose (1). Remove housing cover (2) Remove thermostat assembly (3). Pepe INSTALLATION OF THERMOSTAT ASSEMBLY ‘© Carry out installation in the reverse order to removal. © Refilling with water ‘Add water to the specified level, and run the engine tocirculate the water through the system. Then check the water level again. ° rir 20mFo7211 30-11 -REMOVAL OF ENGINE FRONT SEAL 1, Remove radiator assembly. For details, see REMOVAL OF RADIATOR ASSEMBLY. 2, Remove fan (1), 3. Remove fan belt (2) + Loosen the adjustment bolts of the alternator, and move the alternator towards the cylinder block, then remove the fan belt 4, Remove pulley (3) 5. Remove pulley (4), [RZ] + Remove bolt (5) and spacer (6), then screw in bolt (5) 2—3 turns, and using puller (), remove pulley (4). 6. Remove front seal (7). [#3] INSTALLATION OF ENGINE FRONT SEAL © Carry out installation in the reverse order to removal. ao Adjust the fan belt tension. For details, see STANDARD VALUE TABLE for engine. 2) =I Mounting bolt: 9.0 + 0.5 kgm AX. Lip of oil seal: Grease (G2-LI) 30-12 20°Fa5109| 020M07020Mo7 REMOVAL OF ENGINE REAR SEAL 1. Remove damper assembly % For details, see REMOVAL OF DAMPER ASSEMBLY. 2. Remove flywheel (1). GET] 3. Remove rear seal (2) [#7] INSTALLATION OF ENGINE REAR SEAL ASSEMBLY © Carry out installation in the reverse order to removal a S32 Mounting bolt: 8.5 + 0.5 kgm + Use dial gauge @ to measure the face runout and radial runout ofthe flywheel * Face runout: 0.2 mm # Radial runout: 0.2 mm ez) = Lip of oil seal: Grease (G2-LI) 20°FA5108 2007219 in 20PFA5165REMOVAL OF CYLINDER HEAD ASSEMBLY Drain cooling water. Remove canopy (1). Remove hood (2) Remove engine cover (3) Remove air cleaner assembly (4) Remove muffler assembly (5) Remove fuel filter (6) + Disconnect the fuel filter together with the bracket, and move it towards the counterweight 8. Disconnect fuel injection tube (7). [#1] 9. Disconnect fuel spill hose (). 10. Disconnect radiator hose (9). 11. Disconnect glow plug wiring (10) 12. Remove nozzle holder (11). (2) 13, Remove cylinder head cover (12). 14, Remove rocker arm assembly (13). + Loosen the locknuts, then loosen the adjustment screw 2 — 3 turns. 15, Remove push rod (14) 16. Remove cylinder head assembly (18). [a] 2omro721s 2omro7218 30-14 020Mo7020M07 INSTALLATION OF CYLINDER HEAD ASSEMBLY ‘Carry out installation in the reverse order to removal &o GED Sleeve nut: 3.75 + 0.25 kgm tE-¥a GE Nozzle holder: §.2 + 0.2 kam (ea) + Check that the ball ofthe adjustment screw is fitted securely in the socket of the push rod. + When tightening the mounting bolts, start from the middle and work in turn to the outside GB) Mounting bolt: 2.6 + 0:3 kgm + Adjust the valve clearance, For details, see TESTING AND ADJUSTING, adjusting valve clearance = Locknut: 26 + 0:3 kgm aa %* Coat the mounting bolt threads and seat face with engine oi ‘% Tighten the mounting bolts in the order shown in the diagram on the right. 32 Mounting bolt: kam 38 625 +025 © Refilling with water ‘Add water to the specified level and run the engine toccirculate the water through the system. Then check the water level again. Fivwheel side ovars02 30-15REMOVAL OF RADIATOR ASSEMBLY Drain cooling water. Remove canopy (1). Remove hood (2). Remove engine cover (3) Remove R.H. side protector, Remove air cleaner hose (4). Disconnect sub-tank hose (5). Disconnect radiator hoses (6) and (7). Remove shroud (8). + After disconnecting the shroud, move it towards the engine. 10. Remove radiator assembly (9). eanonsen Radiator assembly: INSTALLATION OF RADIATOR ASSEMBLY © Carry out installation in the reverse order to removal. © Refilling with water ‘Add water to the specified level and run the engine to circulate the water through the system. Then check the water level again, 30-16 020Mo7020M07 REMOVAL OF ENGINE, HYDRAULIC PUMP ASSEMBLY Ay Disconnect the cable from the negative (-)terminal of the battery AE Lower the work equipment to the ground and stop the engine. Then loosen the oil filler plug of the hydraulic tank slowly to release the pressure inside the hydraulic tank ‘Mark all the piping with tags to prevent mistakes in the mounting position when installing, Drain cooling water. Drain hydrauti ol wet Hydraulic tank: 22 2 Remove canopy (1). Remove hood (2). Remove engine cover (3). Remove LH. and R.H. side protectors (4). Disconnect alternator wiring (5) Disconnect starting motor wiring (6). Disconnect glow plug wiring (7) Disconnect engine stop motor wiring (8) Se 11. Disconnect engine oil pressure sensor wiring (9). 12. Disconnect engine oil level sensor wiring (10). 13. Disconnect coolant temperature sensor wiring (11). 14, Disconnect ground connection wiring (12). 18. Disconnect fuel control cable (13). 16. Disconnect fuel hoses (14) and (16). "20MFo7221,17. Disconnect pump inlet hose (16). 18. Disconnect pump outlet hoses (17). Disconnect 2 hoses. 19. Remove air cleaner hose (18). 20. Disconnect radiator hoses (19) and (20), 21. Remove shroud (21). + After disconnecting the shroud, move it towards the radiator. 22. Remove engine, hydraulic pump assembly (22). [RT] on [is] Engine, hydraulic pump assembly: 120 kg INSTALLATION OF ENGINE, HYDRAULIC PUMP ASSEMBLY © Carry out installation in the reverse order to removal. = 35) Mounting bolt: 10+ 2 kgm © Refilling with oit ‘Add oil to the specified level and run the engine to Circulate the oil through the system. Then check the oil level again, © Refilling with water ‘Add water to the specified level and run the engine tocirculate the water through the system. Then check the water level again. 30-18 {19} {21 ee ad Thebrora2s 020M07020M07 REMOVAL OF DAMPER ASSEMBLY 1. Remove hydraulic pump assembly. + For details, see REMOVAL OF HYDRAULIC PUMP. ASSEMBLY. Remove cover (1). Remove damper assembly (2). [1] INSTALLATION OF DAMPER ASSEMBLY © Carry out installation in the reverse order to removal. <= Coupling spline: Lubricant (LM-G) © Refilling with oi! ‘Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again. 20765168. ‘eau rena TEESE 20rrAsiooREMOVAL OF CENTER SWIVEL JOINT ASSEMBLY pA Lower the work equipment to the ground and stop ‘= the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1, Remove operator's seat (1). 2. Remove box (2). 3. Remove floor plate (3). 4. Disconnect hoses (4), % Disconnect 7 top hoses. + Mark the piping with tags to prevent mistakes in position when installing. 8. Remove undercover (6) 6. Disconnect hoses and tubes (6), + Disconnect 2 bottom hoses and 5 tubes. 7. Remove lock plate (7). 8. Remove center swivel joint assembly (8. ("ks") Center swivel joint assembly: 5 kg INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY * Carry out installation in the reverse order to removal Refilling with oil ‘Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again 20mr07227 20MF07230 5 = 8 8020Mo7 DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 1 2. 3. Remove flange (1) and O-ring (2). Remove snap ring (3), then remove washer (4), and pull out swivel shatt (6) from rotor (6) Remove O-ring (7) and backup ring (8) from rotor (6) ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY ‘* Coat the O-ring with engine oil before assembling. 1. Assemble O-ring (7) and backup ring (8) to rotor (6) 2. Install swivel shaft (5) to rotor (6), assemble washer (4), then secure with snap ring (3). 3. Assemble O-ring (2), and install flange (1). | 0 IRIED OQ eS 2omro7231 30-21 ®REMOVAL OF TRAVEL MOTOR ASSEMBLY 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Remove sprocket. For details, see REMOVAL OF SPROCKET. YAK Lower the work equipment to the ground and stop ® the engine. Then loosen the oil filler plug of the hydraulic tank slowly torelease the pressure inside the hydraulic tank 3. Remove cover (1). 4. Disconnect tubes (2). 5. Remove travel motor assembly (3). [ET] (xe) Travel motor assembly: 15 kg INSTALLATION OF TRAVEL MOTOR ASSEMBLY * Carry out installation in the reverse order to removal 0 “AX Mounting bolt: Thread tightener(LT-2) G32) Mounting bolt: 11.26 + 1.25 kam Refilling with oil ‘Add cil to the specified level and run the engine to circulate the oil through the system, Then check the oil level again. 2007233 020M07020Mo7 REMOVAL OF SPROCKET 1. Remove track shoe assembly % For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Remove sprocket (1). % Push the machine up withthe work equipment and set block () under the track roller 20PFA5170 INSTALLATION OF SPROCKET © Carry out installation in the reverse order to removal, 30-23REMOVAL OF SWING MOTOR ASSEMBLY SPE Lower the work equipment to the ground and stop ‘the engine. Then loosen the oil filler plug of the hydraulic tank slowly to release the pressure inside the hydraulic tank. Remove operator's seat (1) Remove box (2) Remove floor plate (3) Disconnect 2 hoses (4) * Mark all the piping with tags to prevent mistakes: in the mounting position when installing. Remove swing motor assembly (5). (ke Swing motor assembly: 13.5 kg peNe 2 INSTALLATION OF SWING MOTOR ASSEMBLY © Carry out installation in the reverse order to removal. © Refilling with oi! ‘Add cil to the specified level and run the engine to Circulate the oil through the system. Then check the oil level again. 20mF07227 020M07020M07 REMOVAL OF REVOLVING FRAME ASSEMBLY 1, Remove work equipment assembly. see REMOVAL OF WORK EQUIPMENT y. Remove boom cylinder assembly. For details, see REMOVAL OF BOOM CYLINDER. ASSEMBLY. Remove canopy (1). Remove hood (2). Remove engine cover (3) Remove LH. and R.H. side protectors (4), Remove operator's seat (5) Remove box (6). Remove floor plate (7) een 2our07298 10. Disconnect hoses (8) + Disconnect 19 hoses from 8-spool control valve. * Mark all the piping with the tags to prevent mistakes in the mounting position when installing. 11. Disconnect hoses (9) + Disconnect 7 upper hoses from swivel joint. Mark all the piping with tags to prevent mistakes in the mounting position when installing 12, Remove lack plate (10)13. Remove control assembly (11) ‘& Remove the control assembly together with the 8-spool control valve 14, Remove revolving frame assembly (12). [7] + Rotate the revolving frame assembly and remove the mounting bolts, leaving 2 bolts each at the front and rear 4 Using a lever block, adjust the balance of the revolving frame assembly to the front and rear, and left and right, then remove the remaining bolts, and liftoff + When removing the revolving frame assembly, be careful not to hit the center swivel joint assembly [Cig] Revolving frame assembly: 260 ko INSTALLATION OF REVOLVING FRAME ASSEMBLY © Carry out installation in the reverse order to removal. i) .ATXS Mounting bolt: Thread tightener (LT-2) 5 Mounting bolt: 6.7 + 0.7 kgm © Refilling with oi! ‘Add oil to the specified level and run the engine to circulate the oil through the system. Then check the oil level again, 2007238 2 20Meo7239 020M07REMOVAL OF SWING CIRCLE ASSEMBLY 1. Remove revolving frame assembly. For details, se REMOVAL OF REVOLVING FRAME ‘ASSEMBLY. 2. Remove swing circle assembly. [ET] ‘Swing circle assembly: 19 kg 20MO7245 INSTALLATION OF SWING CIRCLE ASSEMBLY ‘© Carry out installation in the reverse order to removal. ae + Set the soft zone in the correct position in relation to the track frame, then install. 3D Mounting bolt: 11.5 + 1.0 kgm Xx Face of circle teeth: Grease (G2-L)) 2or07246 020M07REMOVAL OF IDLER AND RECOIL SPRING ASSEMBLY 1. Remove track shoe assembly. % For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Remove idler and recoil spring assembly (1) % Sling the idler and recoil spring assembly, and pull out to the front to remove. (ke) Idler, recoil spring assembly: 22 kg INSTALLATION OF ILDER, RECOIL SPRING ASSEMBLY © Carry out installation in the reverse order to removal. 30-28 "20MF07287 ‘020M07020Mo7 DISASSEMBLY OF RECOIL SPRING ASSEMBLY 20mro7248 1. Disassembly of recoil spring assembly 1) Remove support (2) from recoil spring assembly (0. 2) Install tool A to recoil spring assembly (1), and set in press. QE Tho spring is under large installed load, so % be sure to set the press properly. Failure to do this is dangerous. ‘ Installed load of spring: 709 kg 3) Apply hydraulic pressure slowly to compress recoil spring (3), then remove cotter pin (4) and ut (5). ‘Compress the spring to a point where the nut, becomes loose. % Release the hydraulic pressure slowly and release the tension of the spring + Free length of spring: 200 mm 4) Remove plate (6), recoil spring (3), and spacer (7. + Spacer (7) is installed only on machines with rubber shoe specification, 2. Disassembly of cylinder assembly 1) Remove grease fitting (9) and valve (10) from rod (6). 2) Pull out rod (8) from cylinder (11). 3) Remove dust seal (12), backup ring (13), and O- ing (14) from eylinder (11). 20TFO12318-« 30-29 ®ASSEMBLY OF RECOIL SPRING ASSEMBLY 20MFO7248 1. Assembly of cylinder 1) Assemble O-ring (14), backup ring (13), and dust seal (12) in cylinder (11) 2) Insert rod (8). ‘ Be careful not to damage the dust seal lip. 3) Install valve (10) and grease fitting (9) to rod (8). 2. Assembly of recoil spring assembly 1) Assemble spacer (7), recoil spring (3), and plate (6) in cylinder (11), and set with too! A in press, *AK The spring is installed under a large load, ‘so be sure to set tool A to the press and plate properly. + Spacer (7) is installed only on machines with rubber shoe specification. 2) Apply hydraulic pressure slowly to compress spring, and tighten nut (5) so that installed length, of spring is dimension “a”, then install cotter pin (4. 4% Installed length of spring: 168 mm % After assembling, check that the out-of- parallel of plate surface A and rod surface B is less than 0.5 mm. 3) Install support (2) 30-30 @ 2oTror2a1a-« Surface A Surface 8 2oMro7249 020Mo7REMOVAL OF TRACK ROLLER ASSEMBLY 1. Loosen valve (1) GET) + Loosen the valve, and relieve the track shoe tension YAK The cushion cylinder is under extremely high 4 pressure. Never loosen the valve more than. one turn If the track tension is not relieved, move the ‘machine backwards and forwards. 2. Remove track roller assembly (2). [2] * Remove the mounting bolts of the track roller, then swing the work equipment 90°, jack up the oO machine, and remove the track roller assembly, i 20MFO7250 INSTALLATION OF TRACK ROLLER ASSEMBLY 020M07 © Carry out installation in the reverse order to removal. a ‘% When increasing the track tension, tighten valve (1) completely, and pump in grease through grease fitting (3) (w2) ‘% Set the track roller assembly in the mounting position, operate the work equipment levers 10 lower the machine slowly, then tighten the mounting bolts temporarily. Operate the work equipment levers to lower the machine completely to the ground, then tighten the mounting bolts fully. 30-31 ®REMOVAL OF RUBBER SHOE ASSEMBLY 1. Loosen valve (1). [7] + Loosen the valve, and relieve the track shoe tension. AK The cushion cylinder is under extremely high ‘pressure. Never loosen the valve more than one turn, If the track tension is not relieved, move the machine backwards and forwards. 2. Remove track shoe assembly (2). [#2] ‘ Swing the work equipment 90°, jack up the machine slightly, then fit steel pipes into the track ‘shoes. Rotate the sprocket in reverse, and when the rubber shoes are pushed up from the idler by the steel pipes, slide them off to the side to remove the rubber shoe assembly. INSTALLATION OF TRACK ROLLER ASSEMBLY © Carry out installation in the reverse order to removal. x) ‘* When increasing the track tension, tighten valve (1) completely, and pumpin grease through grease fitting (3) ez Adjust the tension of the rubber shoes assembly. For details, see the Operation and Maintenance Manual. 30-32 ® 20MFO7250 Rotating Steel pipe 20PFAS134 020Mo7020M07 REMOVAL OF HYDRAULIC PUMP ASSEMBLY AE Lower tne work equipment tothe ground and stop the engine. Then loosen the oil filler plug of the hydraulictankslowlytorelease the pressure inside the hydraulic tank 1. Drain hydraulic oi wale Hydraulic tank: 22 £ Remove LH. side protector. Disconnect pump inlet hose (1). Disconnect 2 pump outlet hoses (2) Remove hydraulic pump assembly (3). [GE] Hydrautic pump assembly: 5 kg oaON INSTALLATION OF HYDRAULIC PUMP ASSEMBLY ‘© Carry out installation in the reverse order to removal, © Refilling with oit Add oil to the specified level and run the engine to circulate the oil through the system. Then check the 30-33REMOVAL OF 8-SPOOL CONTROL VALVE ASSEMBLY AE Lowor the work equipment to the ground and stop % the engine, Then loosen the oil filler plug of the hydraulic tank slowly to release the pressure inside the hydraulic tank Remove operator's seat (1). Remove box (2) Remove floor plate (3). Remove 19 hoses (4). Disconnect 8 linkages (6). Remove 8-spool control valve assembly (6) [i278 -spoo! control valve assembly: 18.6 kg, eonens INSTALLATION OF 8-SPOOL CONTROL VALVE ASSEMBLY © Carry out installation in the reverse order to removal. © Refilling with oil ‘Add oil to the specified level and run the engine to circulate the oil through the system. Then check the oil level again. 30-34 @ 20MFr07256 020M07DISASSEMBLY OF 8-SPOOL CONTROL VALVE ASSEMBLY zowoz0 20MF07260 30-36020Mo7 Do not disassemble the safety valve assembly further as the set pressure cannot be adjusted after assembling it to the machine. If there is any abnormality in the spool or body, replace the spool and body as an assembly. Main relief valve assembly Remove main relief valve assembly (1) + Ilocknut 2)is loosened and adjustment screw (3) turned, the set pressure will change, so do not disassemble unless necessary. Safety-suction valve assembly Remove safety-suction valve assembly (4) Suction valve assembly Remove suction valve assembly (5). Control vaive spool assembly 1) Remove cover (6). 2) Loosen bolt (7). % Loosen the bolt with the spool still assembled in the body. 3) Pull out spool assembly (8), and remove bolt (7, collar (9), retainer (10), spring (11), and retainer (12) from spool (13). 4) Remove plate (14) and dust seal (15) 5) Remove plate (16) and dust seal (17) Check valve assembly Remove plug (18), then remove spring (19) and ball (20). ASSEMBLY OF 8-SPOOL CONTROL VALVE ASSEMBLY ‘% Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing % Alter assembling each spool assembly, check that the spool moves smoothly. 1. Check valve assembly Assemble ball (20) and spring (19), then fit O- ring and install plug (18). SZ] Plug: 3.5 +0.5 kgm 2. Control valve spool assembly 1) Install dust seal (15) and plate (14). 2) Set retainer (12), spring (11), retainer (10), and collar (9) to spool (13), and tighten bolt (7) temporarily. 3) Assemble spool assembly (8), then tighten bolt (7) fully. % Tighten the bolt fully with the spoo! still assembled in the body. SEI Bolt: 0.85 + 0.15 kgm 4) Install dust seal (17) and plate (16), 2) Mounting bolt: 1.35 + 0.15 kgm 5) Install cover (6). S32) Mounting bolt: 1.35 + 0.15 kgm 3. Suction valve assembly Fit O-ring and install suction valve assembly (5). S321 Suction valve assembly: 4.5 + 0.5 kgm 4. Safety-suction valve assembly Fit O-ring and install safety-suction valve assembly (4) = Safety-suction valve assembly. 4.5 + 0.5 kgm 5. Main relief valve assembly Fit O-ring and insall main relief valve assembly a, 3H Main relief valve assembly: 5.5 +05 kgmREMOVAL OF BOOM CYLINDER ASSEMBLY A. Extend the arm and bucket fully and lower the ‘work equipment tothe ground completely, 1. Remove pin (1 ez) % Sling the boom cylinder assembly, and remove the pin. AA sian the engine, and retract the cod of the boom eneder Then te the rod with wie to asa at a bk ea We the block “AX stop the engine and loosen the oil filler plug scales he greene aside hydraulic tank. 2. Disconnect hoses (2). 3. Remove pin (3). [3] 4% Sling the boom cylinder assembly, and remove the pin 4. Remove boom cylinder assembly (4). ox (7) Boom cylinder assembly: 10 kg INSTALLATION OF BOOM CYLINDER ASSEMBLY ‘© Carry out installation in the reverse order to removal. = By Wine atigning the position of the pin hoe, un the engine at low idling. Never insert your fingers inthe pin hole. ez) + Adjust with shims so that the clearance between the piston rod and boom boss, and the clearance between the cylinder bottom and revolving frame boss is less than 1 mm, © Refilling with oil ‘Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again. © Bleeding air Bleed the air from hydraulic cylinder. For details, see TESTING AND ADJUSTING, Bleeding air from cylinder. 30-38 ® 200FA517 200FA5178 020M07