INTRODUCTION TO THE READER ‘© This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine. Be sure to thoroughly read this manual for correct product information and service procedures. if you have any questions or comments regarding the contents of this manual. please contact: Technical Document Center Hitachi Construction Machinery Co. Lid. TEL: 81-298-32-7173 FAX: 81-298-31-1162 ADDITIONAL REFERENCES Please refer to the materials listed below in addition to this manual. “The Operator's Manual ‘The Parts Catalog + Operation Manual of the Engine Parts Catalog of the Engine + Hitachi Training Material MANUAL COMPOSITION © This manual consists of two portions: the T/M (Technical Manual) portion and the W/M (Workshop Manual) portion. At the beginning of each section, a tab fixed separator is inserted to help in opening sections needed. Green tabs are used for the sections in the T/M portion and yellow tabs for those in the WIM portion. Information included in the T/M portion: technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and ‘troubleshooting procedures. Information included in the W/M portion: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removai/installation and assemble/disassemble procedures. PAGE NUMBER © Each page has a number, located on the center lower part of the page, and each number contains the following information: Example: T 01-03-05 '—> Group Number ‘———* Section Number T: Technical Manual ‘Consecutive Page Number for Each Group W: Workshop Manual IN-O1INTRODUCTION SAFETY ALERT SYMBOL AND HEAD- LINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the poten- tial for personal injury or machine damage. AA Tris is the safety alert symbol. When you see this symbol, be alert to the potential for personal in- jury. Never fail to follow the safety instructions prescribed along with the safety alert symbol The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropri- ate lifting techniques and equipment when lifting heavy parts. « & cauTion: incicates a potentially hazardous situation which could, if not avoided, result in personal injury or death. © IMPORTANT: indicates a situation which, if not avoided, could result in damage to the machine. © NOTE: indicates supplementary technical informa- tion or know-how. UNITS USED ‘¢ SI Units (International System of Units) are used in this manual MKSA system units and English units are also indi- cated in parentheses just behind SI units. Example: 24.5 MPa (250 kgf/cm’, 3 560 psi) A table for conversion from Si units to other system units is shown below for reference purposes. To Convert Multiply To Convert Multiply Quantity | From Into By Quantity | From Into By mim in. 0039 37, a MPa Kate” [70.197 ae mm ft 0,003 267 Pressure MPa psi [745.0 L US gal_| 0.2642 Tower kW. PS) 1.360, Volume cE US gt 7.057 kW. HP. 1.341 ria iF 7,308 [[Temperature [°C SF [0x1 Bae Weight iq ib 2.205 Velocity Tn moh 1621 4 Force N kf 0.101 97, min tpm. 1.0 N To (0.2248 || Flow rate Lin | “US qom | 0.2642 Torque Nem kgf 4.0197 mUjrev_| — ccjrev 1.0. Nem Toff 0.7375 IN-02SAFETY FOLLOW SAFE PROCEDURES © Safety First This safety-alert symbol AM warns you of the potential for personal injury. Be sure to take all recommended precautions seriously and follow safe operating procedures and practices, Be sure to thoroughly read, understand and comply with the safety precautions of this manual and of the ‘operator's manual. sx003 PRECAUTIONS FOR SERVICE WORK © Prepare for Emergencies + Be prepared if a fire starts or if an accident occurs. © Wear Protective Clothing Wear close fitting clothing and safe equipment appropriate for the job. Do not wear a necktie, scart, loose clothing, or eckiace when you work near machine tools or moving parts. If these items get caught in the machine, severe injury could result. “Remove rings and other jewelry, to help avoid electrical shocks and entanglement in moving parts, © Protect Against Noise Prolonged exposure to loud noise can cause impairment or loss of hearing, Wear a suitable hearing protective device, such as earmuffs or earplugs, to protect against constant or uncomfortably loud noise. Protect Against Flying Debris Flying pieces of metal or debris are very dangerous, and can cause serious personal injury. + Be sure to wear goggles or safety glasses before performing any service work in which flying pleces of metal or debris are anticipated, especially before removing/installing pins. SA-01SAFETY PREPARATIONS FOR SERVICE WORK Before working on the machine: Park the machine on a firm, level surface. + Lower the bucket to the ground Run the engine at slow idle without load for 3 minutes. Tum the key switch to the OFF position to stop the a engine. Remove the key ffom the switch. Pull the pilot control shut-off lever to the LOCK position. Allow the engine to cool down. ¢ Warn Others of Service Work Unexpected machine movement can result in serious injury. Before performing any work on the excavator, attach a clearly visible “Do Not Operate” tag on the control levers andjor on the cab door. snows ‘© Support the Machine Properly “Always lower the attachment or implement to the ground before you work on the machine. I you must work on a lifted machine or a raised attachment, be sure to securely support the machine or the attachment, using the provided cylinder supports or solid wooden blocks. If the machine must be jack-up, Keep a 90 to 110° angle between the boom and arm. If you must park the machine on a slope, take the following measures in addition to the ordinary parking procedure: Before servicing the travel system Block both tracks and lower the bucket to the ground, thrusting the bucket teeth into the ground, as shown. Before servicing the swing system s Position the front attachment down the slope’ and lower the blade and bucket to the ground, thrusting the bucket teeth and blade into the ground, as shown, so as to prevent the upperstructure from swinging downhill unexpectedly. SA-02SAFETY PRACTICE SAFE MAINTENANCE © Fully understand the procedures of the service to be e done before starting work. Also, make sure that your co-workers understand the service procedures as welt ¢ Prepare and Clean the Work Area Select a firm, level surface, protected trom wind and provided. shoes Before starting any service work, clean the work area. Remove any objects that may be a safety hazard to the service personal or bystanders. Remove any buildup of grease, oil, paints, or debris. ‘ Park the Machine Safely Refer to the PREPARATION FOR SERVICE WORK section on the previous page. © Beware of Exhaust Fumes Engine exhaust fumes can cause sickness or death + If you must operate inside a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes, or open doors and windows to bring enough outside air into the area. ¢@ Iluminate Work Area Safely illuminate your work area adequately but safely. Use a portable safety light for working inside or Under the machine. Make sure that the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can gy ignite spilled fuel or cr '® Allow the engine and the hydraulic oil-to cool before starting any service work. © Disconnect the battery ground cable (—) before servicing the electrical system or welding on the machine. SA-03SAFETY USE HANDHOLDS AND STEPS «Falling is one of the major causes of personal injury When getting on and off the machine, always maintain a three-point contact with the steps and handrails, and face the machine. Do not use any controls as handholds + Never jump on or off the machine. Never mount or dismount a moving machine. S | Be careful of slippery conditions on platforms, steps, and handrails when getting on or off the machine, PRECAUTIONS FOR MACHINE OPERATION @ Never lubricate or service the machine while it is moving. if a maintenance procedure must be performed with the engine running, do not leave the machine unattended, © Take precautions when operating the machine - Be sure to start the engine only while seated in the operator's seat. —_= - Always be alert for bystanders moving into the work area. Use the horn or other signal to warn bystanders before starting the engine and before moving the machine. Machines experiencing trouble may move in unexpected ways. Be sure to operate the machine slowly while observing machine movements closely. Use a signal person when backing up, if your view is obstructed. Always keep the signal person in view. sxoor + Learn the meaning of all flags, signs, and markings used on the job, and confirm who has the responsibilty fr signaling Be sure to remain seated in the operator's seat while operating the machine. ‘© Keep riders off the machine. Only allow the operator on the machine, SA-04SAFETY USE TOOLS PROPERLY 4 Use tools appropriate for the work to be done. a, Makeshift tools, parts, and procedures can create safety hazards. For loosening and tightening hardware, use the correct size tools to avoid injury caused by slipping wrenches. Use only recommended replacement part. (See the parts catalog.) sao STAY CLEAR OF MOVING PARTS. d © Entanglement in moving parts can cause serious lo injury. Never attempt to touch any moving parts with your hands. To prevent accidents, use extra care and take a necessary safety measures when working around moving parts. AVOID HIGH-PRESSURE FLUIDS @ If escaping fluid under pressure penetrates the skin, or if it is splashed into the eyes, serious personal a injury may result. “Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. Be sure to retighten all connections before reapplying pressure. + Search for leaks with a piece of cardboard, not your hands. Protect all body parts from high pressure a fluids, Be sure to wear a face shield or goggles to protect your eyes from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed whe within a few hours or gangrene may result. SA-05SAFETY HANDLE FLUIDS SAFELY - AVOID FIRES ‘© Handle fuel with care; it is highly flammable. Also, be sure to handle fiammable lubricants safely. Do not smoke while refueling the machine. Do not refuel near open flame or sparks. Always stop the engine before refueling the ‘machine, Fill the fuel tank outdoors. + Store flammable fluids well away from fire hazards. Make sure the machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously. sacte HANDLE BATTERIES SAFELY © Prevent battery explosions. Keep sparks, lighted matches, and flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. Do not attempt to charge a frozen battery; it may explode. Warm the battery to 16 °C (60 F°) first. Sulfuric acid in battery electrolyte is poisonous. Fil batteries in a well-ventilated area. Wear eye protection and rubber gloves. ‘Avoid breathing fumes when adding electrolyte. Avoid spilling or dripping electrolyte, ‘© Follow proper jump start procedures. Refer to the jump start section of the Operator's Manual. SA-06SAFETY SERVICE COOLING SYSTEM SAFELY ‘© Explosive release of fluids from the pressurized cooling system can cause serious burns. ~ Always run the engine at slow idle for a few minutes before shutting off the engine. Only remove the radiator cap when it is cool enough to touch with the bare hands. + Be sure to loosen the radiator cap to release system pressure before removing it. REMOVE PAINT BEFORE WELDING OR HEATING ‘# Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all welding or heating work outside or in a well ventilated area. Dispose of paint and solvent property. Avoid potentially toxic fumes and dust. ‘@ Remove paint before welding or heating + If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. aaa Hf you use solvent or paint stripper, remove stripper with soap and water before welding, Remove solvent or paint stripper container and other flammable material from area. Allow fumes to disperse for at least 15 minutes before welding or heating AVOID HEATING NEAR PRESSURIZED FLUID LINES © Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. © Do not heat by welding, soldering, or using a torch near pressurized fiuid lines or other flammable materials. © Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials. SA-07SAFETY USE PROPER LIFTING EQUIPMENT © Lifting heavy components incorrectly can result in severe injury or machine damage. Refer to the component weights listed in this manual before lifting heavy components. When using a crane, confirm that the lifting capacity of the crane and hoisting accessories to be used ate appropriate for the work to be done, and that the crane is maintained in good condition. DISPOSE OF FLUIDS PROPERLY «Improper disposal of fluids can harm the environment and the ecology. Use proper containers when draining fluids. DO NOT pour oil into the ground, down a drain, or into a stream, pond, or lake, © Observe all relevant environmental protection regulations when disposing of oil, fuel, coolant, brake fluid, fiters, batteries, and other harmful waste. REPLACE SAFETY SIGNS © Maintain all safety signs, so that they are intact and legible. Replace any missing safety signs. + If safety signs are damaged, replace them with new ones. See the machine Operator's Manual for correct safety sign placement. A009 BEFORE RETURNING THE MACHINE TO THE CUSTOMER Alter maintenance or repair work is complete, confirm that: The machine is functioning properly, especially the safety systems. Worn or damaged parts have been repaired or replaced SA-08x2003 SECTION 01 GENERAL IMFORMATION CONTENTS Group 01- Precautions for Disassembling and Assembling Precautions for Disassembling and ‘Assembling WO1-01-01 Group 02- Tightening Torque Tightening Torque Specification . WO1-02-01 Torque Chart .. seers W01-02-02 137W-01-01Ex200-3, 137W-01-02GENERAL INFORMATION / Precautions for Disassembling and Assembling PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING Preparations for Disassembling * Clean the Machine Remove soil, mud and debris from the machine and thoroughly wash the machine before bringing It into the shap. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work. + Inspect the Machine Be sure to thoroughly understand disassembling procedures beforehand, to help avoid incorrect disassembling of components as well as the perchase of unnecessary service parts, Record the items listed below to help prevent problems from occurring in the future. The machine model, machine serial number, and hour meter reading, + Observed phenomenon, failed parts, and causes, Dirty, clogged fiters and oll or air leakages, if any, + Levels and degrees of deterioration of lubricants, Loose or damaged parts. + Prepare and Clean Tools and Disasembly Area Prepare tools to be used and areas for disassembling as well as for disassembled parts, Clean the tools and areas. Precautions for Disassembling and Assembling + Precautions for Disassembling Be sure to provide appropriate containers for draining fulid. Use aligning marks for easier reassembling. Be sure to use specified special tools, when so instructed, It @ part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly, Find the cause(s), then take appropriate measures to remove it. + Orderly arraenge disassembled parts. Mark and/or put tags on them as necessary. Orderly arrange common parts, such as nuts and bolts, by placing them in designated places. Keep common parts used on different parts or ‘components separate, and record the number of common parts used, so as to help prevent common parts from becoming lost. Inspect contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. “Measure and record degrees of wear and clearances. Precautions for Assembling Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace with new ones. Dirt or debris on contact or sliding surfaces may shorten the service life of the machine, Take care riot to contaminate any contact or sliding surfaces of the parts to be assembied. Be sure that liquid-gasket-applied surfaces are clean and dry. Thoroughly wash new parts to be used to remove anti-corrosive agent from the surfaces. Utilize aligning marks when assembling. Be sure to use designated tools to assemble bearings, bushings and oil seals. Keep a record of the number of tools used for disassembling/assembling. After assembling is complete, count the number of tools, so as to make sure that no tolls are left in the assembled components, Wo1-01-01GENERAL INFORMATION ; Precautions for Disassembling and Assembling Wo1-01-02ay) GENERAL INFORMATION/ Tightening Torque TIGHTENING TORQUE SPECIFICATIONS Bolt Dia Wrench Size Torque Descriptions mm |C%] mm Nm kgtm | let 1% [2 2 390 | 40 =: 200 1. | Engine cushion rubber mounting bolt aomealad ea ose Seo eriae 2_| Engine cushion rubber mounting nut ae) 22 137,14 =: ~*100 | Engine bracket mounting Bolt 70 |e 7 49 5) 36 4_| Hydraulic oil tank mounting bolt 1% [4 24 205 ai (180 3 _| Fuel tank mounting bolt 1 [4 24 205 2: 160 19 25: 3 2 22 39 420 5 | ORS fitings for hydraulic hoses and a 8 25: 68 piping 32 137; 14 =| +100 RE TCRE 36 175 | 18: 130 *TTNE-AZ a 205 at: +150 7_| Pump mounting bolt 70 7 49 3% @_| Control valve mounting bok 14 4 22 137; 14 | +100 @_| Swing device mounting bot 20 | i2| 30 540; 55 | 400 40 _| Swing motor mounting bolt 2 [se 10 co 6 1_| Battery mounting nut 10 7 195: 14 72_| Gab mounting bolt 16 24 205 | at; 180 ‘Swing bearing mounting Balt to 20 |2| 20 B10: 82: 878 13 T Swing bearing mounting bolt to 20 36 30 540 55; 400 74_| Travel device mounting bolt 20 || 20 620) 63,455 15_| Sprocket mounting bolt 20 | se[__30 a0; 55: 400 76_| Track guard mounting bolt 73 | 8 a7 450. 46: 930 77_| Upper roller mounting Bok 7 [| 2 25 | 7 | 195 1@_| Lower roller mounting bolt 7 [sl 7 40 46: «830 a_| Track shoe mounting boi 78 _|see| 27 360 7 NO 70 7 9 5 86 20 | Cover mounting bolt fa 7) aa on ance 21_| Counterweight mounting bolt 36 4 55 [i910 | 195 11410 22_| Front pin holding nut 20 1 30 540, 85-400 UNF thread NOTE: (1) Apply lubricant (e.g. white zinc B solved into spindle oil) to bolts and nuts to stabilize friction coetti- cient of them. (2) Make sure bolt and nut threads are clean before installing (3) Apply Loctite to threads before installing and tightening swing bearing mounting bolts. WO01-02-01GENERAL INFORMATION/ Tightening Torque ans | A cauTION: Use tools appropriate for the work to be done. Makeshift tools and proce- dures can create safety hazards. For loosen- ing and tightening nuts and bolts, use correct size tools. Avoid bodily injury caused by slip- ping of wrenches. Bolt Types Tighten nuts or bolts correctly to torque specifications. Four kinds of bolts, hexagon boits T, H, M and socket bolt, each made of different material, are used. Make sure to employ correct bolts and tighten them correctly when assembling the machine or components Hexagon T Bolt Hexagon H Bolt Hexagon MBolt Socket Bolt Specified Tightening Torque Chart Hexagon nl Bott | Wrench | 1ex#60"] T Bott, Socket-Head bolt H Bolt M Bott Dia_| Size | size | Nem! kgtm {ib | Nem | kgtm | itt | Nm | kgtm I on 98. d MOP ef ee ear ng zl ies eT Maat 78 08 80 88 Sia eee 5 a ee oe eer ere 76048 po es Mote] 4 14 365, ere i MI | Ba 300 a6 i W 20] "30 17 540.2 55 ie 470) 740 8 2a] Bega | 886 warp ar ta 118707 F440 LOt0 ae ee: Se (4g 3360 Ba] 8860" 2360 BBO TF 910 E198 TAO 36 [55 373440" 380 E2310] 2.400 Bas T4770 NOTE: (1) Apply lubricant (Le. white zinc B als- solved into spinale oil) to nuts and bolts 10 stabilize their friction coefficients. (2) Torque tolerance is + 10%. WO01-02-02A 9503GENERAL INFORMATION/ Tightening Torque IMPORTANT: (1) Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop tightening force due to shortness of thread lengths. (2) The torques given in the chart are standard figures. All torque figures specified in this manual take priority. (3) Make sure that nut and boit threads are clean before install- ing. Remove dirt or corrosion, if any. Bolt Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening, Equally tighten upper Tighten diagonally Tighten trom center and lower alternately ‘and diagonally O O”~ 8 OG @ 23 ieso1-01-008 Wo1-02-03GENERAL INFORMATION/ Tightening Torque Service Recommendations for Split Flange IMPORTANT: (1) Clean sealing surfaces. Inspect. Scratches cause leaks. Rough- ess causes seal wear. Out-of- flat causes seal extrusion. If de- fects cannot be polished out, re- place the component. (2) Be sure to use specified O-ring. Inspect O-rings for any damage. Take care not to file O-ring sur- faces. When installing an O-ring into a groove, use grease to hold itin place. (8) Loosely assemble split flange halves. Make sure that split is centrally located and perpendicu- lar to the port. Hand tighten bolts to hold parts in place. Do not pinch the O-ring. (4 Tighten one bolt, then tighten the diagonally opposite bolt. Tighten two remaining bolts. Tighten all bolts to specification. (5) Do not use air wrenches. Using an air wrench often causes tight- ening of one bolt fully before tightening of the others, resulting in damage to O-rings or uneven tightening of bolts. Nut and Bolt Lockings # Lock Plate IMPORTANT: Do not reuse lock plates bend the same point twice. Do not try to Split Pin IMPORTANT: Do not reuse lock plates. Do not try to bend the same point twice, Wire IMPORTANT: Apply wire to bolts in the bolt tighten- ing direction, not in the bolt loosening direction. t Bend along edge sharply DO not bend it round ° Bend along edge sharply was 01.008 ° ° Tighten 4 cb ‘OX Loosen a & WO01-02-04a GENERAL INFORMATION Tightening Torque Pipe Thread Connection / Union Joint Tightening Torque Specifications Union Joint Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. IMPORTANT: (1) Do not over-tighten nut (3). Ex: cessive force will be applied to metal sealing surfaces (4) and (8), possibly cracking adaptor (1). Be sure to tighten nut (3) to specifications. (2) Scratches or other damage to sealing surtaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting /disconnecting. O-ring Seal Joint O-ring (6) fits to the end face of adaptor (7) to seal pressure oll. IMPORTANT: (1) Be sure to replace O-ring (6) with anew one when reconnecting. (2) Before tightening nut (9), confirm that O-ring (6) is seated correctly O-ring groove (8). Tightening nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage. (8) Take care not to damage O-ring groove (8) or sealing face (10). Damage to O-ring (6) will result, causing oil leakage. (4) If loose nut (9) is found, causing il leakage, do not tighten it to stop leakage. Instead, replace O- ring (6) with a new one, then tighten nut (9) after confirming that O-ring (6) is securely seated in place. 20" Male Union Joint Female Union Joint ‘Wrench Size Tightening Torque mm Nem (kgtm, Ibf) 19 42 (5.0, 36) 22 69 (7.0,51) 27 93 (9.5,69) 32 187 (14,101) 36 175 (18, 130) 4 205 (21, 152) 50 345 (35, 255) 60 540 (55, 400) 70 600 (60, 430) ‘Wrench Size Tightening Torque mm N:m (kgfm, tot) 27 93 (9.5, 69) 32 187 (14,101) 36 175 (18, 130) 41,46 205 (21, 152) W01-02-05GENERAL INFORMATION Tightening Torque ‘Screwed-In Connection IMPORTANT: Many types of screwed-in connections are used for hose connections. Check thread pitch and thread type {taper or straight), to contirm use of the correct one before installing it. Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leakage between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not apply too much, otherwise loosening of the sorew may occur. * Application Procedure Confirm that the thread surface is clean, free of dirt or damage. Wrap seal tape along threads, with each pitch thread ‘covered by one or two winds of tape. Leave one to two pitch threads uncovered at the screw end. Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs de- pending on type of clamp. ‘See below for correct tightening torque of each type of fow-pressure-hose clamp, T-Bolt Type Band Clamp : 4.4 Nem (0.45 kgfm, 3.25 Ibft) Worm Gears Type Band Clamp: 5.90 6.9 Nm (0.6 t0 0.7 kgfm, 4.30 5.1 Ibft) PF = JL Male Taper Thread Male Straight Thread Wrench Size Tightening Torque i Nem (kgf-m, Ibf-ft) 19 19.5 (20,145) 22 295 (30,22) 27 49 (5.0,35) 32 69 (7.0,51) 36 69 (70,51) 41 108 (11,80) 80 187 (16, 116) 60 4195 (20,145) 70 255 (26,190) Internal Thread < Extemal Thread Clearance Leave one to two pitch threads uncovered T-Bolt Type + cates | Worm Gears Type 'W01-02-06GENERAL INFORMATION/ Tightening Torque Connecting Hose CAUTION: When replacing hoses, be sure to ise only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oll leakage, hose rupture or separation of fitting, possibly resulting in a fire on the ma- chine. Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leakage, hose rupture or separation of fitting. Utilize print marks on hoses when installing hoses to pre- vent hose from being installed kinked.if hoses rub against each other, wear to the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing against each other. Also, take care that hoses do not come into contact with moving parts or sharp objects. a } x Rubbed Against Each Other wrasororor2 x ° Clamp Clamp ee Rubbed W01-02-07GENERAL INFORMATION/ Tightening Torque 'W01-02-08£X2003 SECTION 02 UPPERSTRUCTURE CONTENTS Group 01- Cab Remove and Install Cab ~ — W02-01-01 Adjustment DP Sensor .... WO02-05-38 Dimensions of the Cab Glass ... W02-01-05 Group 06- Swing Device Group 02- Counterweight Remove and Install Remove and Install ‘Swing Device... ‘Wo2-08-01 Counterweight .........5 wo2-02-01 Disassemble Swing Reduction Gears . 'W02-06-02 Group 03- Main Frame Assemble SwingReduction Remove and Install Gears 'W02-06-09 Main Frame wees W02-03-01 Remove and install Swing Motor .. penne WO02-06-17 Group 04- Pump Device Disassemble Swing Motor ..... W02-06-18 Remove and install Assemble Swing Motor... WO2-08-26 Pump Device ae . W02-04-01 Maintenance Standard wees _WO02-06-35, Disassemble Pump Device .... W02-0402 ‘Assemble Pump Device . Wo2.04-07 Group 07- Pilot Valve Disassemble Main Pump W02-04-12 Remove and Install Left ‘Assemble Main Pump ........ W02-04-18 Pilot Valve . ceceeee Wo2-07-01 Disassemble and Assemble Remove and Install Right Pilot Pump .... . WO02-04-28 Pilot Valve . wee W02-07-02 Disassemble Right and Left Group 05- Control Valve Pilot Valve .. ps wo2.07-03, Remove and Install Assemble Right and Left Control Valve . ane W02-05-01 Pilot Valve .... - . W02-07-07 Disassemble Four Section Remove and Install Control VaNe ....esseee+ WO2-05-02 Travel Pilot Valve ........... WO207-13 Assemble Four Section Disassemble Travel Pilot Valve .. W02-07-14 Control Valve oes eeeeeeee WO205-11 Assemble Travel Pilot Valve... WO02-07-19 Disassemble Three Section Control Valve ....... WO02-05-22 Assemble Three Section Control Valve wo2-05-30 137W-02-01x2003, Group 08- Pilot Shut-Off Valve Remove and Install Pilot Shut-off Vaive : Disassemble Pilot Shut-off Valve Assemble Pilot Shut-off Valve Group 09- Shockless Valve Remove and install Shockless Valve «6... 2... Disassemble and Assemble Shockiess Valve ........- Group 10- Accumulator Remove and Install Accumulator . Group 11- Solenoid Valve Remove and install ‘Solenoid Valve Unit Disassemble Swing Parking Brake Solenoid Valve Assemble Swing Parking Brake Solenoid Valve Disassemble Propotional Solenoid Valve Assemble Propotional Solenoid Valve Disassemble Relite Valve Assemble Relife Valve ....... Disassemble and Assemble Reducing Valve .......... Group 12- Shuttle Valve wo2-08-01 ‘wo2-08-02 wo2-08-04 Remove and Install ‘Swing / Bucket shuttle valve wo2-12-01 Disassemble and Assemble ‘Swing / Bucket shuttle valve wo2-12.02 Group 13- Swing Dampener valve W02-09-01 ‘wo2-09.02 W02-10-01 wo2-11-01 wo2-11-03 wo2-11-05 Wo2-11-08 wo2-11-11 wo2-t1-14 wo2-11-17 wo2-11-20 Remove and Install ‘Swing Dampener Valve ...... W02-13-01 Disassemble ‘Swing Dampener Valve ...... W02-13-02 Assemble ‘Swing Dampener Valve ...... W02-13-08 Disassemble Valve Wo2-13-11 Assemble Valve... se W0213-13 137W-02-023 UPPERSTRUCTURE / Cab REMOVE AND INSTALL CAB Remove Cab 1. Remove nuts (10) and seat (1). at: 13 mm 2, Remove covers (2), (3), (4) and (5). ame :13 mm — 3, Remove cover (6). —- 4. Disconnect wire harness junction box and con- nectors, and ground. (Wiper motor, radio anten- nna, cab ground and dome light.) ‘Wo2-01-01UPPERSTRUCTURE / Cab 5. Attach cab to hoist using liting straps. Ad CAUTION: The approximate weight of cab : 230 kg (507 Ib) 6. Remove bolts (9). G17 mm me: 24 mm fF :8 mm 7. Carefully remove cab. Wo2-01-02A 9503UPPERSTRUCTURE / Cab Install cab 1. Attach cab to hoist using straps. Install cab onto frame. A CAUTION: The approximate weight of cab: 230 kg (507 Ib). 2, Tighten botts (9). mee 17 mm ae 49 Nim (5 kgf, 36 bff) Ame: 24 mm at: 205 Nim (21 kgfm, 152 Ibfft) [— :amm amt 64 Nm (6.5 kgtm, 47 Itt) 3. Install cover (6). — =": 4.9 Nim (05 kgim, 36 loft) 4, Install covers (6), (4), (8) and (2) in order. amet 13 mm Fae 19.5 Nm (2 kghim, 14.5 IbFtt) —= W02-01-03A 9503UPPERSTRUCTURE / Cab 5. Install seat (1) and tighten nuts (10). ae 13 mm =H 19.5 Nim (2 kghm, 14.5 Ibfft) 6. Connect wire hamess junction box, connectors and ground, wo2-01-04UPPERSTRUCTURE / Cab DIMENSIONS OF THE CAB GLASS it: mm NOTE: 1 mm=0.03997 in W02-01-05UPPERSTRUCTURE / Cab ‘W02-01-06UPPERSTRUCTURE / Counterweight REMOVE AND INSTALL COUNTER- WEIGHT Remove Counterweight 1. Remove caps from counterweight. Install lifting tools (1) to the counterweight. Lifting tool: STOO11 (M36, Pitch4.0) A CavTION: The approximate weight of counterweight is 3900 kg (8598 tb) 2. Fasten slings and hoist to counter weight. 3, Remove four bolts (3) and washers (4). Ce W02-02-01A 9503UPPERSTRUCTURE / Counterweight Install counterweight 1, Attach ling tools (1) to the counterweight. Fasten hoist to counterweight. Install four bolts (1) and washers (3) to counter- weight and tighten temporarily amet 41 mm 2. Lower counterweight. Tighten four bolts. © 241 mm =: 1.970 Nem (140 kgm, 1 010 Iofft) 3, Remove lifting tools. Install caps to counterweight. 'W02-02-02A 9503at] UPPERSTRUCTURE / Main Frame REMOVE AND INSTALL MAIN FRAME Ay caution: Escaping ttuid under pressure can penetrate the skin, causing serious in- jury. ‘Avoid the hazard by relieving pressure be- fore disconnecting hydraulic or other line: Hydraulic oll may be hot just after opera- tion. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for il to cool before starting work. Stop the engine. Move all control levers to release pressure remaining in the system. Push the air re- lease valve on top of the hydraulic oil tank to release any remaining pressure. Remove Main Frame 1, Remove cab assembly. (See Remove Cab in this section.) A CAUTION: Approximate weight of cab: 230 kg (507 Ib). mee = 24 mm, 17 mm — :3 mm 2, Remove the counterweight (See Remove Counterweight in this section ) CAUTION: Approximate weight of counter- weight: 3900 kg (8600 Ib). 3, Remove front attachment assembly from the Upperstructure. (See Remove Front Attachment in this section.) BA CAUTION: Approximate weight of front at- tachment assembly: 2 780 kg (6 130 Ib ). SS WO02-03-01A 9503UPPERSTRUCTURE / Main Frame 4, Drain hydraulic oil from the hydraulic oil tank, and disconnect hydraulic lines running from the control valve to the center joint on top of the center joint. Disconnect drain hose, and remove the nipple and stopper from the center joint. Fm: 19 mm, 22 mm, 27 mm, 36 mm CAUTION: Approximate weight of main frame: 3.440 kg (7580 Ib). IMPORTANT: Make sure rear slings do not touch engine. 5. Attach wire ropes to the front and rear of main frame and take out slack use chain-blocks for easy adjustment of wire rope lengths, to level the frame. Rear Front WO02-03-02A 9503ort UPPERSTRUCTURE / Main Frame 6. Put matching marks on swing bearing and main frame. Remove bolts (14) from swing bearing. ae 30 mm 7. Lift main frame up slightly from undercarriage. Level main frame by adjusting with chain-blocks. Remove main frame. Install Main Frame 4. Attach the main frame to a crane or hoist using wire ropes. 2. Level main frame by adjusting with chain-biocks and lower main frame onto undercarriage. (See Remove Main Frame in this section.) Align swing bearing with matching mark on main frame. 3. Install bolts (14) on the swing bearing and tighten temporarily 4. Install main frame and tighten bolts to specification. a=: 30 mm at 540 Nem (55 kom, 400 IbFt) W02-03-03A 9503UPPERSTRUCTURE / Main Frame 6. Install nipple (10) and stopper (9) and connect hose (8) to the center joint. 19 mm at 29.5 Nim (3 kgtm, 22 loft) 6. Connect hidraulic lines (4 to 7) 22 mm Se 33: Nim (4 kghm, 29 bff) ame: 27 mm = 93. Nim (9.5 kgfm, 69 loft) 7. Install cab (2). (See Install Cab in this section.) By CAUTION: approx weght ofthe cab: 290 kg (507 Ib). mee 24 mm ar 205 Nem (21 kgtim, 152 Itt) ame 17 mm at 49 Nem (5 kgfim, 36 Ihr) [ wese20r07 Pt 64 Nm (6.5 kgf, 47 IbFft) 8. Install the counterweight. (See Install Counterweight in this section.) AQ cauTION: Approx. weight of the counter- welght: 3.900 kg (8.600 Ib). me 4 mm at: 1.370 Nem (140 kgtim, 1010 Ibtft) 9. Install the front attachment assembly, (See Install Front Attachment in this section.) AX CAUTION: Approx. weight of the front assem. bly: 2780 kg (6130 Ib). 36 mm 2175 Nem (18 kgm, 130 Ibtf) 41 mm 205 Nem (21 kgtm, 182 IbFft) Wo02-03-04A 9503UPPERSTRUCTURE / Pump Device REMOVE AND INSTALL PUMP DEVICE CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns, Be sure to wait for oil to cool before starting work. Removal 1. Stop the engine. Move all control levers to release pressure remaining in the system. Push the ait re- lease vaive on top of the hydraulic oil tank to re- lease any remaining pressure. 2, Remove hydraulic oil tank cap. Connect a vacuum pump to maintain negative pressure in the hydrau- lic oil tank, NOTE: Be sure to keep the vacuum pump activated while working 3. Disconnect connectors. A CAUTION: Pump device weight: 140 kg (308 Ib) 4, Disconnect all hoses and pipes from the pump de- vice. eee 27 mm, 96. mm [7 110 mm 5. Attach eyebolts (M12x1.75%22) to the pump de- vice, then fasten a hoist 6. Remove pump device mounting bolts to remove pump device. ee 17 mm Installation 1. Install the pump device with pump device mount- ing bos. reco. ao1 2. Connect all hoses and pipes. 3, Connect connectors. Wrenchsize [_ Tightening Torque (am) nem_[katm | bee Remark IMPORTAN : Be sure to check hydraulic oil level and oil leakage, after assembling, gat | [os | Hose aes oe [7 | C28] 8 [on [0 Bok atl so [s | e W02-04-01UPPERSTRUCTURE / Pump Device DISASSEMBLE PUMP DEVICE 21— Bolt (6 Used) 53— Adapter 22— Spring Washer (6 Used) 55— Fitting (2 Used) 23— O-ring 56— Pipe 25— Oil Seal 57— Clamp 26— Retaining Ring 42— Plug 58 Bolt T= Retaining Ring 28— Pilot Pump 45— Engin ped Sensor 68—Spring Washer 10— Main Pump 30— Socket Bott (2 Used) 48— O-ring 64— Driving Dise 14 Gear ‘31— Spring Washer (2 Used) 65~ Driving Dise 15— Gear 32— Washer (2 Used) 66~ Cover 16— Retaining Ring (2 Used) 34 Adapter (2 Used) Wo2-04-0240) 3) View A ©) © OOS OO 'W02-04-03 abeUPPERSTRUCTURE / Pump Device Before disassembling the pump device, clean its exterior. 1, Remove plug (42) to drain gear oil Approx. 1.0 L( 1.0 US at) (77 : plug (42): 8 mm 2, Place the pump device as illustrated ? M12%1,75%22 pont CAUTION: Pump device weight: 140 kg ) 4 (308 Ib ) a 2 B|° lo © > 3, Remove clamp (57) and pipe (56) from the pump device. AO : bolt (58): 13 mm Ame : pipe(s6): 17 mm 4, Remove socket bolts (30) to remove pilot pump (28) T— :8 mm W02-04-04ob UPPERSTRUCTURE / Pump Device 5. Attach eyebolts to main pump (10). Attach a sling to eyebolts and fasten the sling toa hoist -wion.rs0 BA CAUTION: Main pump weight: 95 kg (210 kg) Eyebolt Mounting Position Eyebolt Mounting Peston 6. Remove bolts (21) to remove main pump (10) and O-ring (23) ae 24 mm. 7. Put three aligning marks on each mashed parts: between gear (14) and driving disc (64) spline, gear (18) and driving disc (65) spline, and gear (14) and (18), as illustrated IMPORTANT: If aligning marks are not made, it is very hard to align pump timing when reassembling 8, Remove retaining ring (16) and gears (14 and 18). IMPORTANT: Never remove gears (14 and 15), when not disassembling main pump (10). W02-04-05UPPERSTRUCTURE / Pump Device 9, Remove retaining rings (6 and 7). at 10. Remove upper ball bearing (5) and gear shatt (4), using a special tool (ST 1993), then take out gear (3) and lower ball bearing (5). Press out ball bearing(S) from gear shaft (4), using a press. 11, Remove retaining ring (26) from gear casing (1), then remove oil seal (25). ate Wo02-04-06UPPERSTRUCTURE / Pump Device ASSEMBLE PUMP DEVICE 1 Gear Casing 21— Bolt (6 Used) 3~ Gear 22— Spring Washer (6 Used) 4— Gear Shatt 23— O-ring 5— Ball Bearing (2 Used) 25— OllSeal 8— Retaining Ring 26— Retaining ing 7— Retaining Ring 28— Pilot Pump 10— Main Pump 30 Socket Bolt (2 Used) 14— Gear 31— Spring Washer (2 Used) 15~ Gear 32— Washer (2 Used) 16— Retaining Ring (Used) 94 Adapter (2 Used) 36— Plug 30 Pipe 40~ Packing 41— Socket Bolt (2 Used) 42— Plug 45— Engine Speed Sensor (i 8ensor) 46— O-ring 47— Washer 48— Socket Bolt 5a— Adapter ‘55— Fitting (2 Used) 56~ Pipe 57 Clamp 58— Bolt 59— Spring Washer 64— Driving Dise 65— Driving Disc 66— Cover W02-04-07UPPERSTRUCTURE / Pump Device BEFORE ASSEMBLING (1) Thoroughly clean disassembled parts and dry them with compressed air. (2) Lubricate inner parts with clean hydraulic oil (3) As a general rule, replace O-rings and oil seals with new ones. 1. Apply a film of hydraulic oil to ball bearing (5). Assemble ball bearing (5) and gear (3) into gear casing(1), then press in gear shaft (4) and ball bearing (5). Install retaining ring (7) to gear casing (1) and retaining ring (6) to gear shaft (4). 2. Apply THREEBOND #1215 to gear casing (1) THREEBOND Application Surface surface. Install pilot pump (28) to gear casing (1), then tighten it with socket bolts (30). [7 :e mm = 49 Nim (5 kgf, 36 Ibfft ) W02-04-08UPPERSTRUCTURE / Pump Device 3, Match aligning marks for driving disc (64) and gear ‘Aligning Mace ‘igning Mark (14) (14), as well as aligning marks for criving disc (65) and gear (15). Install retaining rings (16) to driving discs (64 and 65). at IMPORTANT: Refer to W04-04-23 when making aligning marks. 4. Apply a film of grease to O-ring (23), then install it to gear casing (1) Install main pump (10) to gear casing (1), then tighten it with bolts (21), Amt : bolts (21): 22 mm ae: 147 Nem (15 kgm, 108 Ibttt) A CAUTION: Main pump weight: 95 kg (210 Ib) Wo2-04-09UPPERSTRUCTURE / Pump Device 5. Connect pipe (56), then clamp it using bolt (68) and ‘clamp (57). Apa : Pipe (56): 17 mm Pat 34 Nim (3.5. kgtim, 25 bE) Ame | Bolt (58): 13 mm a 2.9 Nim (0.3 kgtm, 75 Ibftt) NOTE: Apply LOCTITE LI 829 to adapter (53) and fitting (65) to tighten them, if they were removed. amet : Adapter (53): 27 mm a 93. Nm (9.5 kgtm, 125 IbFft) wis7.92.04001 Armee : Fitting (55): 13 mm. Pat 84 Nim (3.5 kgtm, 25 IbFtt) 8. Apply a film of grease to oil seal (25) li, then press oil seal (25) to gear casing (1) and install retaining ring (26). ot Wo2-04-10oy UPPERSTRUCTURE / Pump Device © : Adapter (34): 36 mm Pt 69 Nim (7 kgm, 49 ott) pm : Plug (96): 17 mm = 69 Nm (7 kgtim, 49 Ibftt) 7. Tighten plug (42) to gear casing (1). Add gear oil via adapter (34) Gear oll: 1.0 L( 1.0 USat) Apply seal tape to plug (36), and tighten it to gear casing (1) [7 : Plug (42): 8 mm =n 69: Nm (7 kgf, 49 IbFft ) W02-04-11UPPERSTRUCTURE / Pump Device DISASSEMBLE MAIN PUMP 1 a ra & - 10- ne a a 1“ 6 16 Pump Casing Driving Disc Driving Disc Roller Bearing @Used) Bear 19 Nut (2 Used) Roller Bearing (2 Used) Ring (2 Used) (il Seal (2 Used) Retaining Ring 2Used) ‘Thrust Plate Plug (2 Used) ‘O-ring (2 Uses) Plunger (14 Used) a oOo ¢ | O ET pe Io 28 ©) | ‘° ° o a (61) Sioa aunt) 3 Gove ie rene Sune ee «7 ereup tee ee ss seo etna ed = ce oneeung aes oon ne Washer (4 Used) Pressure Sensor (P Sensor) Lever Assembly Bushing Washer Retaining Ring 11 Seat Spacer ‘Spring Plate o-ring ‘Socket Bolt (2 Used) Spring Washer (2 Used) Wo2-04-12CHT, G69) CA @ 89) @ 2br QL OS NOOMOEGA 6762) co ° | of tI G3) G4 66) GE) EQE) ES) & 65746) 66) DHA Oe (8) (5) Gi) W02-04-13UPPERSTRUCTURE / Pump Device Before disassembling, thoroughly clean the outside of the main pump. 1. Remove pressure sensor (73), pump displacement solenoid valves (69), and O-rings (68). Remove pump displacement angle sensor (27) and spacer (90). Ap : Pressure sensor (73) : 30 mm 1: Socket bolts (71 and 98) : 5 mm 2, Remove stopper (47), cover (51), and O-ring(54) from head (38). I: Socket botts (65) : 6 mm 3, Remove head (39), O-ring (62), and backup ring (67) from pump casing (1). 1: Socket bolts (60 and 61) : 10mm NOTE: Head (39) is secured to pump casing (1) with spring pin (58). Do not remove spring pin (58). 4. Remove set screw (44) to take out pin (43) from servo piston (41). Take out servo piston (41) from head (39). Take out piston ring (42) from servo piston (41). [7 : Set screw (44) :5 mm NOTE: Set screw (44) is applied with LOCTITE. W02-04-14ok UPPERSTRUCTURE / Pump Device 5, Remove valve (87) and rotor (24). @ Remove spring (23), center shaft (21), and By plungers (18) from driving discs (3 and 4), in that order. @3 (9) ays @ 6. Hit lever assembly (85) end with plastic hammer to press out oil seal (89). Remove retaining ring (88) and washer (87), then Push lever assembly (85) to the inside. Remove spring plate (91) from lever assembly (85). Take out bushing (86) from pump casing (1). 7. Remove plug (15) from pump casing (1). Remove driving discs (3 and 4) assembly and thrust ring (14) from pump casing (1) 7 NOTE: Use driving disc tap hole when removing driving discs (3 and 4). aXe B AmmG : plug (15) : 19 mm LS Mant 25 i aa) Ve, W02-04-15UPPERSTRUCTURE / Pump Device 8. Remove retaining ring (13) and take out oll seal (12), te 9, Remove bearing nut (9) trom driving dises (3 and 4), using special tool (ST 3058). Remove roller bearing (10), ring (11), and roller bearing (5) from driving discs (8 and 4), using a puller and press. W02-04-166) UPPERSTRUCTURE / Pump Device W02-04-17UPPERSTRUCTURE / Pump Device ASSEMBLE MAIN PUMP Wo2-04-18Detail 1— Pump casing a 3 Driving Dise 23 4— Driving Dise 2 5— Roller Bearing 2 (2Usea) — Bearing Nut (2 Used) 37— 10— Roller Bearing Used) a 11— Ring (2 Used) a 12— Oil Seat (2 Used) a 13— Retaining Ring a QUsed}. 14— Thrust Plate a 15— Plug (2 Used) a8- 16— Owing (2 Used) ar Plunger (14 Used) 50— Center Shatt (2 Used) Spring (2 Used) Rotor 2 Used) Pump Displacement Angle Sensor (Sensor) Valve Head Servo Piston Piston Ring Pin Set Screw O-ring ‘Stopper o-ring st 54 se Cover xing Socket Bolt (8 Used) Spring Washer (8 Used) Backup Ring Spring Pin (2 Used) Socket Bolt (10 Used) Socket Bolt (2 Used) O-ting O-ring (4 Usea) Pump Displacement Solenoid Vale (2 Used) Socket Bolt (2 Used) 72— Washer (4 Used) 7A Pressure Sensor (P Sensor) Lever Assembly Bushing 87— Washer 88— Retaining Ring 29— Oilseal ‘90 Spacer ‘81— Spring Plate 92— O-ring 9%3— Socket Bolt (2 Used) 94— Spring Washer (2 Used) ot Wo2-04-19UPPERSTRUCTURE / Pump Device Before Assembling (1) Thoroughly wash disassembled parts with a cleaning oll and dry them with compressed air. (2) Apply a fim of hydraulic oil to inner parts. Be sure to apply a film of hydraulic oll to frictional sliding surfaces to prevent them from seizure. (8) Be sure to replace O-rings and oll seals with new ones. 1. Heat inner race of roller bearings (5 and 10) to 50 to 80 °C (122 to 176 °F), then install roller bearings (6) onto driving discs (4 and 3) using a press. Install rings (11) and roller bearings (10) onto driving discs (4 and 3) using a press. 'W02-04-20UPPERSTRUCTURE / Pump Device 2, Preset preload of roller bearings (5 and 10) using the following procedure. 2.1. Apply a film of hydraulic oil to bearing nut (9) thread. Tighten bearing nut (9) until it comes in contact with roller bearing (10), using special tool (ST 3058) 2.2. Rotate roller bearing (10) 2 to 3 turns for break-in, using special tool (ST 3070). 2.3. Measure starting torque. wisraz 04005 2.4, Follow the above three steps (2.1 to 2.3) to agjust starting torque to specifications. Starting torque specifications: 1.962049 Nem ( 0.20 + 0.05 kfm, 1.55 + 0.36 oft) st 2070 IMPORTANT: If starting torque is increased over the specifications, loosen bearing nut (9) then tap driving discs (3 and 4) shaft end to release load. Retry steps 2.1. to 2.3. to adjust the starting torque. 3. Heat pump casing (1) to 50 to 80 °C (122 to 176 °F). Apply a film of hydraulic oil to the outer 7 circumference of roller bearings (5 and 10). Instail thrust ring (14) and the driving disc (3 and 4) assembly into pump casing (1). WG Apply a film of grease to O-ring (16) then install it NG ‘onto plug (15). Tighten plug (15) to pump casing (1), e wost.2s t © : Plug (15): 19 mm ® a ae 34 Nim (35 kat, 25 ttt) VA W02-04-21 oyUPPERSTRUCTURE / Pump Device 4. Apply a film of grease to oil seal (12) lp, then install it and retaining ring (13) into pump casing (1). at rar 02.94.028 W02-04-22UPPERSTRUCTURE / Pump Device @ When replacing the driving disc and/or transmission gi NOTE: Key Nos used in figures on this page are equal to those used on page W02-04-07. 5, Be sure to follow procedure below when the criving disc andjor transmission gear was replaced new one. 5.1. Install special tool (ST 7933) to driving discs (64 and 65), IMPORTANT: Install special tool with the D mark ena facing toward long driving dise (64) side. 5.2. Rotate driving disc (64) counterclockwise, as viewed from the shaft end side to remove circumferential play between the special tool and driving disc bore. 5.3. Install gear (14) and retaining ring (16) onto driving disc (64). 5.4. Install gear (15) so that both splines on driving disc (65) and gear (14) teeth, can correctly ‘engage with those of gear (15). 5.5. Install retaining ring (16) onto driving disc (65). ate 5.6. Put three aligning marks on each meshed parts: between gear (14) and driving disc (64) spline, gear (15) and driving disc (65) spline, and gear (14 and 15), as illustrated W02-04-23UPPERSTRUCTURE / Pump Device 6. Press bushing (86) into pump casing (1). Apply a film of grease to the entire surface of spring plate (91), then install it into lever assembly (85). Install lever assembly (85) into bushing (86). Install wash- er (87) and retaining ring (88). Apply a film of THREEBOND #1215 to the outer circumference of «il seal (88). Apply a film of grease to the lip, then press it to pump casing (1). Install spacer (90) into pump casing (1). ate 7. Apply a film of grease to O-ring (92), then install it to pump displacement angle sensor (A-sensor) (27). Install A sensor (27) so that the punched mark on the A sensor shaft is positioned on 180 ° oppo- site of the harness. t 5mm = 8.8 Nem (1 kgtm, 7.2 IbFtt) IMPORTANT: If the A-sensor is positioned incorrect- ly, the A-sensor will not able to detect pump swash angle. Adjust A-sensor (27) position when mounting the pump on the machine. W02-04-24on UPPERSTRUCTURE / Pump Device 8. Install plungers (19), center shaft (21), and spring @) @ (23) onto driving discs (3 and 4), in that order. In- @@) stall rotor (24) to center shaft (21) and plungers @ (19). With valve (87) side pin installed into lever 4) @8) assembly (85), install valve (37) onto rotor (24).. 4 : TAIN a © @ Y UZ 9. Install piston ring (42) onto servo piston (41), then (44) (43) 41) 42) insert it into head (39). Install pin (43) into servo piston (41). Apply LOCTITE LI 829 to set screw (44) thread, then tighten it to servo piston (41). T : 5mm 24.5 Nm (25 kgfm, 18 Ihr) Ve Wo02-04-25UPPERSTRUCTURE / Pump Device 10. Apply a film of grease to O-ring (62), then install O- ring (62) and backup ring (57) to pump casing (1). Install head (39) to pump casing (1) with socket bolts (60 and 61). [— :5 mm FS" 108 Nem (11 kgm, 80 Ibfft) 11. Apply a film of grease to O-ring (46) then install it to stopper (47). Apply a film of grease to O-ring (60) then install it to cover (51). Install stopper (47), O-ring (54), and cover (51) to head (39). T— :6 mm St: 29.5 Nim (3 kgtm, 22 Ibtt) 12. Apply a film of grease to O-ring (68), then install O- ring (68) and pump displacement solenoid valves (69) to head (39). [— :8 mm FSH: 9.8 Nem (1 kgf, 7.2 bff) 13, install pressure sensor (73) to pump casing (1). ame: 20 mm =F: 98 Nem (10 kgf, 22 bt) W02-04-26ae UPPERSTRUCTURE / Pump Device W02-04-27UPPERSTRUCTURE / Pump Device DISASSEMBLE AND ASSEMBLE PILOT PUMP 'W02-04-28oF ize Tightening Torque tem Part Name ay Wrench St —— (em) tem [_totm [orn + | Housing 7 2 |_Fianee rl 3 | O1sea 7 ‘Apply grease o ol seal lip when installing 3 [_ Retaining Ang 7 Seal 2 “Roply grease to seal when instaling 7_|_ cover f © | Backup Ring 2 “Apply grease to backup ng when installing 10 | Key z 12 | Ong 2 “Apply grease to Oring when instaling 13 | Gee 7 4 | Gear 1 15 |_Washer 4 @ oss | 0m 2 ‘Apply a film ot hydraulicollto bushing when installing ‘Apply a fm of hydraulicolto bushing when installing Before Assembling (1) Thoroughly wash disassembled parts with a cleaning oil and dry them with compressed air. (2) Apply a film of hydraulic oil to inner parts. Be sure to apply a film of hydraulic oil to frictional sliding surfaces to prevent secure of them. (8) Be sure to replace O-rings and oil seals with new ones. 'W02-04-29UPPERSTRUCTURE / Pump Device W02-04-30UPPERSTRUCTURE / Control Valve REMOVE AND INSTALL CONTROL VALVE CAUTION: Escaping fluid under pressure can penetrate the skin, causing seriou: Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot just after operation. Hot hydraulic oll may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting work. Removal 1. Stop the engine. Move all control levers to release pressure remaining in the system. Push the air re- lease valve on top of the hydraulic oll tank to re- lease any remaining pressure. 2, Remove the cap and install vacuum pump (ST 6908) to be negative-pressurize the hydraulic oil tank, NOTE: Be sure to run the vacuum pump continuously while working. 3. Disconnect all hoses and pipes from the control valve. mt : 36 mm t 26 mm, 8 mm, 10 mm NOTE: Attach caps to hoses and pipes. Attach labels or tags to hoses and pipes, to ald in assembly, 4, Remove control valve mounting bolts. A caution: contro! vaive assembly weight: 180 kg (395 Ib) me 22 mm Installation 1. Install control valve to frame and tighten the bolts. eer 1 ‘ Wrenehsize [_TehtenigTorque [oS 2. Connect all hoses and pipes to the control valve, aa auligeiliece IMPORTANT: Be sure to check hydraulic oil level Bae [ es [ie | 30 [tose and oil leakage, after assembling. Fe Bolt tT «| [as [as sles [x 0 6 [on | o 2 W02-05-01UPPERSTRUCTURE / Control Valve DISASSEMBLE FOUR-SPOOL CONTROL VALVE 5 32) (15) D@OOQHODOE® OO Nil? 2 3 BQ Oo & BO @® @O@ 4920) q = G1) 63) 8) (3) 8) 26) G78) wo2-05-02ye - A pS re 5 Pa ~ ‘Ss SS 10- n ne B- 4 16 Plug O-ing Overload Relit Valve Backup Ring o-ring Spring Poppet Sleeve Oring Backup Ring Poppet Sering Plug o-ring Backup Ring Spacer Coller — O-ring Backup Ring o-ting ‘Spool Spring cap ‘Spool Assembly ‘Spool Assembly Spacer Collar Plug Shuttle Spoo! at +e a a 35 36 a2 a 46 a 49 ee 51 cap Plug Plug Bolt Flange Housing ‘Spool Assembly ‘Spool Assembly Bott Plate Bolt cap O-ring Spring Spoo! 52~ Plug 53— Surge Reliet Valve 54— Poppet 55— Spring 65— Oring 72— Spring Seat W02-05-03UPPERSTRUCTURE / Control Valve 1. Thoroughly clean the outside of the control valve. Then place the control valve assembly on a clean work bench. Remove the differential pressure sen sor (DP sensor) and the arm bottom pressure sen- sor (ABP sensor). SO: 27,30 mm ‘ABP Sensor 2. Remove the joint bolts connecting the four spool side and three spool side. [7 :12 mm * Disassembling Variable Pressure Compensated Valves in 4-spool Side 3, Remove bolts (34), flange (35), and O-rings (18) T— :emm Wo2-05-04UPPERSTRUCTURE / Control Valve ‘@ Load Check Valve 4, Remove backup ring (15) and O-ring (14) from plugs (18, 32) Remove spring (12) from poppet (11) NOTE: Plug (13): for boom and bucket lug (32): or arm and auxiliary NOTE: If removal of plugs is dificult, use a forcing bolt (6 mm), 5. Remove the variable pressure compensated valve assembly from the control valve. Remove spacer (16), collar (17), O-ring (20), and backup ring (19) Remove spacer (16), collar (27), O-ring (20), and backup ring (19) Remove spring (22) from spools (21, 30). NOTE: Collar (17): for bucket, arm and auxiliary Collar (27): for boom Spool (21): tor boom Spoo! (30): for bucket, arm and auxiliary NOTE: Be sure to put identification marks on each valve assembly. 2b W02-05-05UPPERSTRUCTURE / Control Valve © Shuttle Valve 6. Remove plug (28) and O-ring. Remove shuttle (29). [7 25 mm © Overload Relief Valve 7. Remove overload relief valves (3) NOTE: Be sure to put identification marks on each valve. + Holding Valve 8. Remove bolts (42) and plate (43) me: 27 mm 9. Remove plug (1), O-ring (6), backup ring (4), and O-ring (5). Wo2-05-06UPPERSTRUCTURE / Control Valve 10. Remove spring (6) and sleeve (8). Remove poppet (7), backup ring (10), and O-ring (8) from sleeve (8) 11. Remove bolts (62). T— :8 mm 412, Remove cap (31) and O-rings (63). NOTE: Do not disassemble parts (67 to 71) unless they are to be replaced. 70~ O-ring 71— Adjuster Wo2-05-07UPPERSTRUCTURE / Control Valve © Atm Regenerative Valve 18, Remove spring (61), spring seat (60), spool (58), piston (56), sieeve (57), spring (55), and poppet (84). © Spool Assembly "4 sa _ : ‘honor soa asentes 2425.92.55 me @——- A Hl ) control valve, NOTE: Spoo! assembly (24): ‘Spool assembly (25): for boom ‘Spool assembly (37): for bucket ‘Spool assembly (38): for auxiliary 15. Remove spool end (A), seats (B), and springs (C, ) from spool (€). 17 mm W02-05-08278 UPPERSTRUCTURE / Control Valve 16. Remove bolts (64), cap (23) and O-rings (65). [— :8 mm NOTE: Do not disassemble parts (67 to 71) unless they are to be replaced. 67 Nut 70— O-ring 68— Plug 71— Adjuster 69— Oning © Surge Relief Valve 17. Remove surge relief valve (53). mt 27 mm WO02-05-09UPPERSTRUCTURE / Control Valve ‘© System Pressure Regulator (Unloading Valve) 18. Remove bolts (46). cap (47), O-ring (49), spring (60), and spool (51) from the control valve. Remove spring seat (72) from spring (51). T— :3 mm Wo02-05-10ay UPPERSTRUCTURE / Control Valve ‘ASSEMBLE FOUR-SPOOL CONTROL VALVE Suceava Pte tm Ome = Bact Ring 12 Oem 0 Ore 3 CotarUPPERSTRUCTURE / Control Valve Wo02-05-12UPPERSTRUCTURE / Control Valve Thoroughly clean all inner parts, and before assembling, arrange them in order by section group. © Spool Assembly 1. Apply LOCTITE onto spool end (J) threads. Install seat (K), springs (L, M), seat (K), and spool end (J) to spool (N), then tighten spool end (J) ab :8mm at 14.5 Nem (1.5 kgtm, 11 Ibe) 2. Apply a film of hydraulic oil to spool assemblies (13 to 16), then install them into housing (78). NOTE: Spool assembly (19): for arm Spool assembly (14): for boom Spool assembly (18): for bucket Spool assembly (16): for auxiliary 20 W02-05-13UPPERSTRUCTURE / Control Valve ‘© Arm Regenerative Valve 3, Install spring (30) into poppet (31). Apply a film of hydraulic oi! to spool (34), then in- stall it with piston (35) into sleeve (36). Install poppet (31), sleeve (86) and spring seat (33) into housing (78).. % 4. Apply a film of grease to O-rings (17, 18, 28), then install them and spring (32) to cap (26). 5. Install cap (26), and tighten bolts (19). [— :8mm an 61 Nm (6.2 kgtm, 45 IbFft) Wo02-05-142! UPPERSTRUCTURE / Control Valve 6. Install spacer (12) to respective spool assemblies (13 to16), Apply a film of grease to O-rings (11), then install (O-rings (11) to cap (10). Install spool assemblies (13 to 16) and cap (10), then tighten bolts (2 [— :emm P=": 61 Nim (6.2 kghm, 45 Ibitt) . ible Pressure Compensated Valve in 4-Spool Side 7. Install O-ring (85) and backup ring (84) into collars (63, 83). Install spring (87), collar (63) and spacer (62) to spool (64) Install_ spring (87), collar (83) and spacer (62) to spool (88). 8. Apply a film of hydraulic oil to spools (64, 86), then install it into housing (78). W02-05-15UPPERSTRUCTURE / Control Valve © Load Check Valve 9. Install O-ring (89) and backup ring (88) onto plugs (90, 93). Install spring (81) into poppet (92). NOTE: Plug (90): for arm and auxiliary lug (99): for boom and bucket 10. Apply a film of hydraulic oll to plugs (90, 93). Install poppet (92) and plugs (90, 93) into housing 78). 11. Apply a film of grease to O-rings (82) then install it to flange (40). Install flange (40) onto housing (78), then tighten bolts (39). 18mm co 61 Nm (6.2 kgfm, 45 Ibtft) W02-05-162P2, UPPERSTRUCTURE / Control Valve ‘© Holding Valve 12, Apply a film of grease to O-ring (69), then install O- ring (68) and backup ring (68) to sleeve (70). Install sieeve (70) into housing (78). 18. Apply a film of hydraulic oil to O-rings (74, 76) and backup ring (75), then install them onto plug (73). Apply a film of hydraulic oil to poppet (71), spring (72) and plug (73), then install them into housing (8) W02-05-17UPPERSTRUCTURE / Control Valve 14, Install plate (67), then tighten bolts (66). [— :10 mm a: 61 Nm (6.2 kgm, 45 ltt) ‘© Overload Relief Valve 15, Tighten overload relief valves (64) to housing (78) amt 32 mm = 83, Nm (8.5. kgfim, 61 bt) © Surge Relief Valve 16. Tighten surge relief valve (1) to housing (78) me 92 mm =: 79 t0 88 Nim (8109 kgtm, 58 to 65 lott) W02-05-18UPPERSTRUCTURE / Control Valve © System Pressure Regulator (Unloading Valve) ® 17. eprig seat (49) and spring (St) onto sooo oa 8) @QTI1a Apply a film of grease to O-ring (50), then install it % toeep 62) 18. Apply a film of hydraulic oll to spool (48), then in- stall it into housing (78). Tighten cap (52) with botts (53) [se mm Pt 61 Nim (6.2 kghm, 45 Ibe) © Shuttle Valve 19. Install O-ring to plug (93), then install it into housing (78). Apply a film of hydraulic oil to shuttle (94), then in- stall it into housing (78). [7 :5 mm 14.5 Nim (1.5 kgf, 11 Ibfft) aaa Wo2-05-19UPPERSTRUCTURE / Control Valve 20. Install O-ring to plug (95), then install it to housing (78). [— 8mm at 51 Nem (5.2 kghm, 38 Ibttt ) Wo02-05-20UPPERSTRUCTURE / Control Valve W02-05-21UPPERSTRUCTURE / Control Valve DISASSEMBLE THREE-SPOOL CONTROL VALVE @ Qe) @8) @ GGG Gd) @ (45) FT IY a ® 62) Fi G8) a 2 tb G mM @ WOE G9) WADED A 1— O-ring 13~ Spool Spacer 2 O-ring 14 Filter Spacer 3 Onring 15— Fier Plug 4 Oring Shultle 5~ O-ring o-ring 6— Bok Cap 7 O-ring Housing 8 Spacer 20— O-ring 32- Spring ‘Spool Assembly 9 Oning 21— Adjuster 38— Spool Assembly 45— Spring 10 Bor 22- Plug uM Cap Poppet 41— cap 23— O-ring 36— Plug Unloading Relet Valve 12 Collar 24— Backup Ring 36— O-ring W02-05-22@5) (8) @é) G7) G8) (29169) 4f23) ———) G2) @ @ LE or Wo02-05-23UPPERSTRUCTURE / Control Valve 1. Thoroughly clean the outside of the control valve. Then place the control valve assembly on a clean work bench. @ Variable Pressure Compensated Valve in 3-Spool Side 2, Remove bolts (25), flange (26), and O-rings (28). [— :8 mm Wo02-05-24UPPERSTRUCTURE / Control Valve ‘© Load Check Valve 3. Remove backup ring (24) and O-ring (28) from plug 22). Remove spring (45) from poppet (46). NOTE: Spring (45) and poppet (46) are used in the ‘swing valve only. NOTE: f removal of plugs is dificult, use a forcing bolt (6 mm). 4, Remove the variable pressure compensated valve assembly from the control valve. Remove spacer (8), collar (12), O-ring (30), and backup ring (29). Remove spacer (8), collar (27), O-ring (30), and backup ring (29) Remove spring (32) from spools (13, 31). NOTE: Collar (12): for swing Collar (27): for travel ‘Spoo! (13): for swing Spo! (31): for travel NOTE: Be sure to put identifcation marks on each valve assembly. oat W02-05-25UPPERSTRUCTURE / Control Valve © Shuttle Valve 5, Remove plug (39) and O-ring, Remove shuttle (40). [7 :5 mm ¢ System Pressure Regulator (Unloading Relief Vaive) 6. Remove unloading relief valve (47). me 27 mm 7. Remove plug (16) and O-ring. Remove filters (14, 15) [7 :8 mm W02-05-26UPPERSTRUCTURE / Control Valve 8. Remove bolts (10) — :8 mm 9. Remove cap (42) and O-rings (41), NOTE: Do not disassemble parts (48 to 52) unless they are to be replaced. 17> Nut 20— o-ing 18— Plug 21— Adjuster 19— O-ing © Spool Assembly 10. Remove spool assemblies (33, 44), Wo02-05-27UPPERSTRUCTURE / Control Valve 11, Remove spool end (A), seat (B), and spring (C) from spoo! (0). ame 17 mm etm HINT Serr 12, Remove bolts (6), cap (84), spacers (97, 98) and O-rings (86) [— 8mm NOTE: Spacer (37): for swing Spacer (38): for travel W02-05-28UPPERSTRUCTURE / Control Valve W02-05-29UPPERSTRUCTURE / Control Valve ASSEMBLE THREE-SPOOL CONTROL VALVE 'W02-05-30Bott o-ring Spacer Collar Spoo! Bott cap o-ring Spacer Spacer Unloading Reliet Valve Adjuster cap 14— O-ring 15— Spool Assembly 16— Spool Assembly 47— Oring 48— Plug 49- Nut 20~ Cap 21— Bolt 22— Flange 23— Plug 24— Plug 25— Plug ackup Ring O-ring 28— Plug 29— Plug 30— Shuttle 31— Plug 32— Filter 33 Plug 34 Plug 35— Filter 36- O-ring 37— Collar 38— Backup Ring 39 O-ring 40— Spoot 41— Spring 42~ Backup Ring a a 45— 46— ar 48— ae 51 A= SE pa o-ring Plug Spring Poppet Housing O-ring O-ring O-ring ing O-ring O-ring O-ring O-ring Bott Wo02-05-31UPPERSTRUCTURE / Control Valve Thoroughly clean all inner parts and before assembling arrange them in order by section group. * Spool Assembly 1. Apply LOCTITE onto spool end (@) threads. Install seat (H), spring (I), seat (H), and spool end (G) to spoo! (J), then tighten spool end (G). G8 mm ae 14.5 Nm (1.5. kgtm, 11. Ib) 2. Apply a film of hydraulic oil to spools (18, 16), then install them into housing (47). NOTE: Spool (15): for swing ‘Spo! (16): for travel 3. Apply a film of grease to O-rings (2), then install O- rings (2) to cap (13) W02-05-32aye UPPERSTRUCTURE / Control Valve 4, Install cap (13), then tighten bolts (1). [— :8mm =n 61 Nim (6.2 kgtm, 45 Itt) 6. Install filters (32, 35) into housing (47). 6. Install O-ring onto plugs (83, 34), then install them into housing (47). [— 6mm St: 29.5 Nem (3 kgti, 22 IbFtt) © System Pressure Regulator (Unloading Relief Valve) 7. Tighten unloading rilief valve (11) to the control valve, amet 32 mm =": 79 to 88 Nim (8 to9 kghm, 58 to 65 Ibfft) W02-05-33UPPERSTRUCTURE / Control Valve © Shuttle Valve 8. Apply a film of hydraulic oil to shuttle (90), then in- stall it nto housing (47). Install O-ring to plug (29), then install it into housing 47), [— :smm P= | 15.5 to 18.5 Nem (1.6 to 1.9 kgtm, 11.5 to 13.5 Ibttt) © Variable Pressure Compensated Valve in 3-Spool Side 9, Install O-ring (39) and backup ring (38) to collars (4, 37). Install spring (41), collar (4) and spacer (3) to spool (8). Install spring (41), collar (37) and spacer (3) to spool (40). 10. Apply a film of hydraulic oil to spools (5, 40), then install it into housing (47). Wo2-05-34au UPPERSTRUCTURE / Control Valve © Load Check Valve 11. Install O-ring (43) and backup ring (42) onto plugs (44). Install spring (45) into poppet (46). Apply a flm of hydraulic oil to plug (44), Install poppet (46) and plug (44) into housing (47). NOTE: Spring (45) and poppet (46) are used in the ‘swing valve only. 12. Apply a film of grease to O-rings (36), then install it to flange (22) Install flange (22), then tighten bolts (21). [25mm ae 14.5 Nem (1.5 kghm, 11 Ibe) W02-05-35UPPERSTRUCTURE / Control Valve 13, Install spacer (10) onto both of spool assembly 5). Install spacer (9) onto spool assembly (16). Apply a film of grease to O-rings (8), then install it conto cap (7) install cap (7) to housing (47) and tighten bolts (6). Fo 24 mm =n 8 Nim (0.8 kgtm, 5.5 Ibtft) O@ ce 14 Inge bask ng 8) ant One 7 oe uo RAL ET si 25). : ss IT 25mm Nc an 14.5 Nem (4.5 kgtm, 11 IbFft) WO02-05-36UPPERSTRUCTURE / Control Vaive 15. Apply a film of grease to O-rings (48 to 55), then in- stall them onto the mating surfaces on the three- spool side housing (47). 16. Joint three-spool side housing and four-spool side housing, then tighten bolts (56). [— 12mm at 167 Nim (17 kgf, 123 Ibtt) 17. Install the differential pressure sensor (DP sensor) and arm bottom pressure sensor (ABP sensor) tO agp sensoy the control valve. amt 527.30 mm =" 69 Nim (7 kgm, 51 IbFt) (ABP sensor) DP Sensor an: 118 Nem (12 kgtm, 87 Ibft) (DP sensor) WO02-05-37UPPERSTRUCTURE / Control Valve ADJUSTMENT DIFFERENTIAL PRESSURE SENSOR 1. Clamp the hexagon section of sensor (1) with a vise. IMPORTANT: Do not hold neither the cylinder nor sensor body lest should damage it. 1. Attach test harness (ST 1729) in between the har- nesses of DP sensor (1) and the PVC. Applying the (+) side test probe of the circuit test- er to the red terminal and the (—-) side test probe to the black terminal measure the voltage. 1 DP Sensor 4— 5V (Power Supply Sv) 2— Ground '5~ Connector (Sensor Side) 3— Output Signal 6~ Connector (Harness Side) WO02-05-38oh UPPERSTRUCTURE / Control Valve 3. Adjust adjusting sorew (9) to 0.4V#0.2 (Voltage wil be increased if you turn the clockwise) After completion of adjustment, tighten lock nut (19), IMPORTANT: 1. Be careful not over-tighten adjust ing screw (9), because output pow- er easily change. 2. Adjust voltage at 20°C (68 °F) pm 13 mm 4 mm Fa 9.8 f0 19.5 Nim (1 t02 kgm, 7.2 to 14.5 loft) 4, Be sure to check following procedures installing to the control valve, after adjusting (1) Be sure not indicate code 26, using Dr.EX. (2) Be sure to check adjusted voltage, if code 26 is indicated W02-05-39UPPERSTRUCTURE / Control Valve WO02-05-40om UPPERSTRUCTURE / Swing Device REMOVE AND INSTALL SWING DEVICE AX caution: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other Hydrau 8. I may be hot Just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil ta cool before starting work. Removal 1. Stop the engine. Move all control levers to release pressure remaining in the system. Push the air re- lease valve on top of the hydraulic oil tank to re- lease any remaining pressure. 2. Disconnect hoses (1, 3, 5 t0 7) A caution: swing device assembly weight: 230 kg ( 507 Ib) ‘Swing motor assembly weight: 50 kg (110 Ib) ‘Swing reduction gear weight: 180 kg (397 Ib) 3. Remove adapter (2) and install an eyebolt to the swing device assembly to sing it with a wire rope. 4, Remove swing device mounting bolts (4) 5. Sling the swing device assembly with a crane or hoist. Installation IMPORTANT: Before installing the swing device as- sembly, apply liquid packing to both mounting surfaces on the swing re- duction gears and frame. 1. Install the swing device assembly to frame and tighten botts (4). 2. Install adapter (2). 3. Connect hoses (1, 3, § to 7) Torque Specifications Hose (1) 175 Nem (18 kgfm, 190 lott) Hose (3) 939 Nm(4 kghm, 29 Ibtft) Hose (6,7) 245 Nem (25 kgtm, 18 lott) Hose (5) 295 Nem(3 kgm, 22 loft) Bot) 540 Nm (55 kgf, 400 Ibttt) Make-up Hose: (To control vaNve) ‘Adaptor Drain Hose: (To hycraue ol tank) Bolt Hose PG: (To solencid valve) Hose A: (To right swing side contro valve) Hose B: (To left swing side control valve) W02-06-01UPPERSTRUCTURE / Swing Device DISASSEMBLE SWING REDUCTION GEARS 1— Second Stage Sun Gear 9 Spring Pin (3 Used) 17-O-Ing 2 First Stage Sun Gear 10—Second Stage Planetary -18—O-ring Gear (3 Uses) 3 Needle Bearing (8 Used) _-—_11—~Socket Bolt (12 Used) 4— O-ring 12— Thrust Piate (6 Used) 5~ Spring Pin (3 Used) 13- 6~ First Stage Planetary Gear 14—Pin (3 Used) (3Used) t 15— Thrust Plate 23—Bolt (10 Used) 16—Retaining Ring 24—Housing rst Stage Carrier 30—Thrust Plate 31—Drain Pipe 32—Drain Plug Wo02-06-02UPPERSTRUCTURE / Swing Device Disassembly of swing device Clean the swing device before disassembling, 1. Loosen drain plug (82) to drain gear oil. Remove drain pipe (31). [7:10 mm (Drain plug) —=+ : 29 mm (Drain pipe) A CAUTION: Swing device weight: 230 kg (507 Ib) 2, Place the swing device on a work bench (ST 5088) and remove the eight motor mounting bolts. F— 210 mm ont 3. Insert a screwdriver ete. in the groove around the swing motor to pry up the swing motor housing, then hoist the motor. NOTE: Make mating marks for the ease of assembling. BA CAUTION: swing motor weig (110 Ib) aay Wo02-06-03UPPERSTRUCTURE / Swing Device 4, Remove O-ring (4) from ring gear (28). ma ® NE 107-020-006 5. Remove first stage sun gear (2). 2 4 6. Remove first stage carrier (29) assembly from ring gear (28). NOTE: At this time, the thrust plate is removed together. 7. Loose 12 socket bolts (11), and remove ring gear (28). 7 :14 mm 'W107-02-06.000, W02-06-04UPPERSTRUCTURE / Swing Device 8, Attach ring gear (28) to a hoist using eyebolts (ST ‘ . 002). Remove ring gear (28). AA CAUTION: Ring gear weight: 25 kg (55 Ib) NOTE: if ring gear (28) is sticking to the housing (24), insert @ screwdriver etc. in a cut part of the housing (24) to pry it up. 8, Remove O-ring (13) form the housing (24) 10. Remove second stage sun gear (1) from second stage carrier (27). or 2206007 11. Remove second stage carrier (27) assembly from housing (24) s = aa afb WO02-06-05UPPERSTRUCTURE / Swing Device 12, Remove retaining ring (16) from shaft (19). at 13. Tur over housing (24) and loosen eight bolts (23) to remove cover (22) ae 19 mm NOTE: Insert a screwotiver etc. in the periphery of cov- er (22) to pry it up. 14, Remove O-ring (17) from cover (22). 15, Remove oil seal (21) from cover (22). NOTE: The oii seal which is removed forcedly with a screwdriver etc. cannot be used again. Wo02-06-06297 UPPERSTRUCTURE / Swing Device 16. Pull out shaft (19) from housing (24) using a press. 17. Remove bearing (25) from shaft (19). 18. Remove O-ring (18) from sleeve (20). 7 02.06.016 19, Pull out bearing (26) from housing (24). NOTE: Bearing (26) can be removed easily by hands. Wo02-06-07UPPERSTRUCTURE / Swing Device 20. Pull spring pin (51) out of the first stage carrier us- ing a pin punch (ST 1389). 21. Remove pins (@), first stage planetary gears (6), thrust plates (7) and needle bearings (3) /p 22, Remove thrust plate (30) from first stage carrier &. “ @ _® 23. Remove second stage cartier (27) assembly. Drive spring pins (8) out of second stage carrier en, Remove pins (14), second stage planetary gear (10) and thrust plates (12). Driving tool: ST 1389 (@ 6.0 mm, ¢=over 65 mm) ‘W02-06-08ope UPPERSTRUCTURE / Swing Device ASSEMBLE SWING REDUCTION GEARS 1— Swing Motor 11 First Stage Planetary Gear 22 O-ring (Used) 2— Socket Bolt (8 Used) _13— Socket Bolt (12 Used) 23— Ring Gear 3 O-ring 14— Pin (2 Used) 4— Retaining Ring 15~_ Spring Pin (3 Uses) 5~ First Stage Sun Gear 16 Thrust Plate (6 Used) 27— Knock Pin &~ Thrust Plate (2 Used) 17 Second Stage Planetary Gear 28— Pipe (3 Used) 7— Pin (@ Used) 29— Plug 8~ Spring Pin (3 Used) 30 Bolt (10 Used) 9— Thrust Plate (6 Used) 21 Second Stage Cartier 31— OllSeal 40— Needle Bearing @Used) 3- ae a5 26 a 30— 40~ ae Cover o-ring Shatt o-ring Sleeve Bearing ‘Washer (12 Used) Bolt (12 Used) Housing W02-06-09UPPERSTRUCTURE / Swing Device Precautions for assembling Observe the following points before assembling the swing reduction gears. Wash each part with cleaning solvent and dry Apply sufficient lubricant to sliding or rotating with compressed air. parts. Check that metal powder or cleaning solvent is Any damaged or discolored parts must be re- completely removed from the housing. placed with new ones. Be sure to remove oil from surfaces to which liq- uid packing will be applied. Apply grease to the needle bearing inner bores when inserting them. Before assembling the swing reduction gears, assemble the carrier. 1. Install needle bearing (10) to first stage planetary gear (11). 2. Put thrust plate (6) in first stage carrier (26). IMPORTANT: Set thrust plate (6) with its groove side upwards. ° wi07.c2.06.091 WO02-06-10UPPERSTRUCTURE / Swing Device 3. Install first stage planetary gear (11) and thrust plates (9) to first stage carrier (26). IMPORTANT: Set thrust plates (9) with their oil groove side positioned towards the gear. (Set the thrust plates with their bent parts along the periphery of the flange of the carrier.) 19197.0206-006 4, Align pin hole and carrier hole. Drive pin (7) into first stage carrier (26). 5. With spring pin (8) slit facing upward, use a ham- mer to tap spring pin (8) into first carrier (26) and pin (7) IMPORTANT: If spring pin (8) slit is not facing up- ward, damage may occur during op- eration. — OD ® Le ss 6. Install thrust plate (6) into second stage carrier 21) NOTE: Be sure to face the oil groove side up wards. 299 W02-06-11UPPERSTRUCTURE / Swing Device 7. Install second stage planetary gear (17) and thrust Plates (16) to second stage carrier (21). 8. Align the pin hole and the cartier hole. Drive pin (14) into second stage carrier (21). te 9, With spring pin (16) slit facing upwards, use a ham- mer to tap spring pin (15) into second stage carrier (21) and pin (14), as illustrated. IMPORTANT: If spring pin (15) slit is not facing up- ward, damage may occur during op- eration, es -— eg. 0 msrgomeon 10. Install O-ring (35) to sleeve (96). NOTE: Apply grease to O-ring (35). Wo2-06-12pee UPPERSTRUCTURE / Swing Device 11. Install sleeve (36) and bearing (87) to shaft (34). Using tool (ST 2562) to press down on shaft. wror.02.06.00 12. Attach housing (41) to hoist using two eyebolts {ST 0007). Mount housing (41) on bearing (87) to fit By caution: Housing weight: 65 kg (143. Ib) 18. Insert bearing (19) into housing (41) using tool (ST 563) WO02-06-13UPPERSTRUCTURE / Swing Device 14. install retaining ring (20) to shaft (34). = 16. Install O-ring (33) on cover (32). 16. Apply grease to oll seal (31) lip. Install oil seal (31) on cover (32), IMPORTANT: Apply liquid packing (THREEBOND 1215) to the fitting part of the cover. e 17. Tum over housing (41) and install cover (32) to it, then secure cover (32) with eight bolts (30) ae 19 mm =": 88 Nim (9 kgm, 6.5 loft) IMPORTANT: When installing the cover, take care that the oll seal (31) lip will not touch jooth end of shaft (34). W02-06-143H) UPPERSTRUCTURE / Swing Device 17. Turn over housing (41) and install second stage am carrier (21) assembly to the spline of shaft (34), then install O-ring (22) to housing (41). Ses 18. Insert second stage sun gear (25) into second- stage carrier (21) assembly. ee oS 19. Attach ring gear (23) to a hoist using two eyebolts (ST 0002). Install ring gear (23) onto housing (41), then secure it with 12 bolts (13). IMPORTANT: When installing, match the mating marks of ring gear (23) and housing (41) to each other. [114mm =: 205 Nem (21 kgtm, 152 Ibfft) = cee i ~ W02-06-15UPPERSTRUCTURE / Swing Device 20. Install first stage carrier (26) assembly to ring gear 2), 21. Install O-ring (8) to ring gear (23), then insert first stage sun gear (6) flat side facing upwards into first stage cartier (26) _® a , ee O @ 22. Install plug (29) to drain pipe (28). then install them to housing (44). ‘Supply gear oil to the swing reduction gears. Gear oil: Approx. 8.2 L (2.1 US gai) [— :10 mm ar 93 Nim (9.5 kgfm, 69 Toft) amet 27 mm pat 49 Nim (5 kgm, 36 Ibft ) and secure it with eight socket bolts (2) [— :10 mm =": 88 Nem (9 kgfm, 65 lott) Check the oil level gauge. 23. Checking the mating marks, install swing motor (1) Wo02-06-16UPPERSTRUCTURE / Swing Device REMOVE AND INSTALL SWING MOTOR Ad cauTiON: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing burns. Be sure to wait for oil to cool before starting work. Removal 1. Stop the engine. Move all control levers to release pressure remaining in the system. Push the air re- lease valve on top of the hydraulic oil tank to re- lease any remaining pressure. 2. Disconnect hoses (1, 3, 5 to 7). A caution: swing motor assembly weight: 50 kg (110 Ib) 3. Remove adapter (2) and install an eyebolt to the swing motor assembly to sling it wth a wire rope. 4, Remove swing motor mounting bolts (4). 5. Sling the swing motor assembly with a crane or hoist. Installation IMPORTANT: Before installing the swing motor as- sembly, apply liquid packing to mounting surfaces on the swing re- duction gears. 1. Install the swing motor assembly to swing reduc- tion gears. Apply LOCTITE to bolts (4) and tighten them. 2. Install adapter (2) 3. Connect hoses (1, 3, 5 to 7). Torque Spectications Hose (1) 475 Nm (18 kgf, 190 IF) waren Hose (9) 99. Nem(4 kgm, 29 itt) 4+ Make-up Hose: (To contro valve) Bott) 88 Nem(9 kgf, 65 lbrtt) 2 Adapter Hose (6.7) 245 Nm (25 kofm, 18 lift) Hose (5) 205 Nm(3 kgm, 22 Ib) 3. Drain Hose: (To hyeraule olan) 4 Bot 5+ Hose PG: (To solenoid valve} (6 Hose A: (To right swing side contol valve) 7- Hose B: (To let swing side control v ) W02-06-17UPPERSTRUCTURE / Swing Device DISASSEMBLE SWING MOTOR Spacer Bearing Plug O-ring Valve Casing (Brake Valve) Retaining Ring Valve Plate Pin (2 Used) 9 Spring 10—Plate (4 Used) 1 2 Cross Section A-A 21— Spacer 22—Plunger (9 Used) 23— Thrust Plate '39—Poppet (2 Used) Wo02-06-18UPPERSTRUCTURE / Swing Device Before disassembling the swing motor, clean its outside. Sling the motor assembly and place it on workbench (ST 5088). A cauTION: swing motor assembly weight: 50 kg (110 Ib). 1. Remove plug (26) and drain the oil from the motor. 19 mm + Relief Valve 2, Remove relief valve assembly (34) from valve cas- ing (6). NOTE: Do not disassemble relief valve assembly (34). If any parts of the assembly is removed, the set pressure changes. Ce ‘+ Make up Valve 3. Remove plug (36) [214 mm 103 W02-06-19UPPERSTRUCTURE / Swing Device 4, Take out spring (38) and poppet (39). 5. Make the mating marks to the edge of break valve ‘casing (5) and casing (14) to aid in assembly. Remove four socket bolts (35). [17 mm NOTE: Note that vaive casing (5) will be raised by spring (33) for parking brake. 6. Remove valve casing (5) from casing (14). NOTE: Since valve plate (7) may be removed together at this time, carefully remove valve casing (5) so that vaive plate (7) will not drop. 7. If valve plate (7) is not removed from the cylinder in step 6 above, remove it, then remove spring (33). NOTE: In case prying up the valve plate with a screw- fiver, etc., take care not to damage the sliding faces. (Note that both sides of the valve plate are diferent from each other.) Wo02-06-2030g UPPERSTRUCTURE / Swing Device Using the special tool (ST 1385), install the bolt to brake piston (80), and tighten it to remove brake piston (80) from casing (14) Remove O-rings (28) and (29) from casing (14).. 10. Remove cylinder block assembly (31) from shaft (17). Wo2-06-21UPPERSTRUCTURE / Swing Device 11. Remove friction plates (11) and plates (10) from casing (14) 12, Remove thrust plate (23). 13. Place casing (14) on its side, and tap shaft (17) with a plastic hammer to push it out W02-06-22206 UPPERSTRUCTURE / Swing Device 14. Remove retaining ring (16) from casing (14), then remove seal cover (18). at 15. Install special tool (ST 1390) to oil seal (15) to pull it out. 16. Remove the outer race of bearing (19) from casing (14), 'W02-06-23UPPERSTRUCTURE / Swing Device 17. Pull out inner race of bearing (19) out from shaft (17) 18, Disassemble cylinder block assembly (31) pulled out in step 10. PARTS: Cylinder block (31), plunger (22), shoe (24), retainer plate (13), holder (20), spac- er (21), push rod (12). W02-06-24UPPERSTRUCTURE / Swing Device 19. Press spacer (1) with tool (ST 4113) to remove re- taining ring (6). ae Ay CAUTION: When removing retaining ring (6), be sure to press spacer (1). In case of trying to remove retaining ring (6) without pressing spacer (1) or | and retaining ring (6) may jump out. Thus, severe injury could result. 20. Remove spacer (1), spring (9), and spacer (25). NOTE: The thicker spacer (1) is on retaining ring (6) side. W02-06-25UPPERSTRUCTURE / Swing Device ASSEMBLE SWING MOTOR “ok 1— Pin @ Used) 14—O-rIng 27—Holder 2— Valve Casing 18 Spring (24 Used) 28—Retaining Ring 3— Socket Bott (4 Used) 16—Vaive Plate 29—Plate 4— Poppet (2 Uses) 17—Brake Piston 30—Oil Seal 5— Spring (2 Used) 18 31~Casing O-ring @ 32—Plug 7— Plug 2 Used) 38— O-ring — Plug 34—Bearing 9 O-ring 35~Shatt 10—Roliet Valve Assembly (2 Used) pa 36—Shoe 11 O-ring 24—Cylinder Block 37—Plunger (8 Used) 12—Bearing 25—Push Rod (12 Used) 38—Retainer Plate ‘13—Friction Plate (3 Used) 28—Spacer 39—Thrust Plate W02-06-26387 UPPERSTRUCTURE / Swing Device Before assembling, wash each part with cleaning sok vent and dry with compressed air. Apply clean hydraulic oil to the internal parts before installing them. Be sure to replace o-rings, cil seals and needle bearings with new ones. 1. Install inner race of bearing (34) to shatt (35) using tool (ST 2318). 2. Install retaining ring (28) to casing (31). ate W02-06-27UPPERSTRUCTURE / Swing Device 8, Turn over casing (31) and put plate (29) init. Install oll seal (30) into casing (31) using tool (ST 2564) IMPORTANT: Take care of the fitting direction of the 4, Install the outer race of bearing (34) to casing (31) using tool (ST 2568). 'W02-06-28308 UPPERSTRUCTURE / Swing Device 5. Place casing (31) on its side and insert shaft (35) in it W107.0206.194 6. Install thrust plate (39) in casing (31). 7. Install spacer (23), spring (22), and spacer (21) in that order into cylinder block (24). IMPORTANT: Thicker spacer (21) is on retaining ring (20) side. @——~ er} ~-_ 2 pr WO2-06-29UPPERSTRUCTURE / Swing Device 8. Push spacer (21) down using tool (ST 4113) to in- stall retaining ring (20). ate 9. Insert push rod (25) in cylinder block (24), then in- eo apm stall spacer (26) and holder (27) in that order. Me 10. Install nine plungers (37) to retainer plate (98), then insert them in cylinder block (24). IMPORTANT: Before inserting plungers (37), apply hydraulic oil to the plungers and holes of cylinder block (24). Wo02-06-3037 UPPERSTRUCTURE / Swing Device 11. Place casing (31) on its side, then install cylinder block assembly (24) to shatt (35). 12. Install plate (19) and friction plate (13) alternately. Number of piates (19): 4 Number of friction plates (19): 3 IMPORTANT: Each plate (19) has four cut parts on its outside, and each friction plate (13) has four cut parts on teeth on the spline side. Set them with those cut parts in the same direction. Wo02-06-31UPPERSTRUCTURE / Swing Device 13, Install O-rings (18) and (14) to casing (31). 14, Install brake piston (17) to casing (31). If the brake piston does not enter the casing smoothly because of the resistance of the O-rings (18) and (14), evenly tap it with a plastic hammer. — 15. Install springs (15) to brake piston (17). 'W02-06-32UPPERSTRUCTURE / Swing Device 16. Insert bearing (12) into valve casing (2) using too! {ST 2319) IMPORTANT: Press the type stamped side of the bearing. 17. Install O-ring (11) and valve plate (16) to valve cas- ing (2). NOTE: Apply grease to valve plate (16) to prevent it from dropping. 18, Install valve casing (2) to casing (31) ‘Secure valve casing (2) with four socket bolts (3). @ IMPORTANT: Take care that valve plate (16) will not drop, and match the mating marks. [A 217 mm at: 432 Nem (44 Kgtm, 318 Ibtft) 30 Wo2-06-33UPPERSTRUCTURE / Swing Device 19, Install O-ring (6) to plug (7), then install poppet (4), spring (5) and plug (7) to valve casing (2). . -o 7 rc 14 mm Pa 333. Nim (34 kgfm, 246 IbFft) ‘wior9206-122 20. install relief valve assembly (10) to valve casing (2). ome 41 mm at 177 Nem (18 kgm, 130 IbFtt) W02-06-34an UPPERSTRUCTURE / Swing Device MAINTENANCE STANDARD ‘Swing motor 1. Piston and cylinder bore clearance + Subtract (D) of plunger from (d) of cylinder bore. Standard Clearance Maximum Allowable 0.027 mm (0.0011 in) 0.052 mm (0.0020 in) D-d<0.05 mm (0-d=0.0020 in) NOTE: 1 mm=0.03937 in a wio7<2.06 198 2, Plunger and shoe clearance + Move plunger up and down to measure clear- ance between plunger and shoe. Standard Clearance Maximum Allowable 0 0.3 mm (0.01 NOTE: 1 mm=0.03937 in ioro2 0516 'W02-06-35UPPERSTRUCTURE / Swing Device 3, Thickness of shoe Standard Clearance Maximum Allowable 6.0 mm (0.24 in) 5.8 mm (0.23 in) NOTE: 1 mm=0.03937 in IW 4, Thickness of friction plate Standard Clearance Maximum Allowable 3.78 mm (0.15 in) 3.38 mm (0.13 in) NOTE: 1 mm=0.03937 in 5, Total clearance of retainer plate (1) and holder (2) Standard Clearance Maximum Allowable 7.0 mm (0.28 in) 65 mm(0.26 in) H-h<7.0 mm (H-h0.28 in) If the dimension is reduced to below 6.5 mm ( 0.26 in), replace retainer plate (1) and holder (2). NOTE: 1 mm=0.03937 in wnorceonae W02-06-36anh UPPERSTRUCTURE / Swing Device Tools Required For Disassembly And Assembly 1. Tightening tools Unit: mm Tool Name Size Remarks lame Wrench 19, 27, 29, 41 WD Sockets for sockets | 19, 41 wrenches [7 Hexagonal wrench | 10, 14, 17 2. General tools Unit: mm Tool Name Puller = ——@3_ Screw driver 4 Prastic hammer §-——= Small hammer SefS_ Snap ring pliers (for bore and for shaft) 3, Measuring instrument Instrument Name = Torque wrench 4, Lubricants and liquid packing used for assem- bling. 41. Grease (general purpose lithium grease ) 2. THREEBOND # 1215 38. Gear oil (SAE 90, GL-5 class) Wo02-06-37UPPERSTRUCTURE / Swing Device W02-06-38UPPERSTRUCTURE / Pilot Valve REMOVE AND INSTALL LEFT PILOT VALVE A cauTION: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other line: Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting work. Removal 1. Stop the engine. Move all control levers to release pressure remaining in the system. Push the air re- lease valve on top of the hydraulic oll tank to re- lease any remaining pressure. 2. Loosen screw joint (1) and remove the control le- ver. 3. Loosen screw and remove cover (9) of the control box. . Disconnect hoses (3 to 8). . Remove bolts (2) to remove the pilot valve assem- bly. Installation 1. Install the pilot valve assembly using bolts (2) 2. Connect hoses (3 to 8). 3. Install the control lever it with screw joint (1), then install the cover with bot. 4. Install the cover (9) of the control box. “Torque Specications wiose2.or0e1 Bott) 88 Nem(1.9 kghm,72 Ibi) * Screw Joint Hose (302) ss 99, Nm (40 kgm, 29 thet) 2 Bot 3+ Hose H (To bucket rin contol valve) 4: Hoae Pa: (From pit shut-off valve) 5+ Hose A: (To boom raise contol vale) 6. Hose B (To boom tower contol valve) 7 Hose G : (To bucket ro out contol valve) 6. Hose TS: (To hydraute ol tank) &- Cover 2 Wo2-07-01