HITACHI ZX 210W-3, 220W-3

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, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-29-832-7084 FAX: 81-29-831-1162

ADDITIONAL REFERENCES • Please refer to the materials listed below in addition to this manual. • The Operator’s Manual • The Parts Catalog

• The Engine Manual • Parts Catalog of the Engine • Hitachi Training Material

MANUAL COMPOSITION • This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual. • Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.

• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures. • Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/disassemble procedures.

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 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual

W: Workshop Manual

IN-01

INTRODUCTION SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

•

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

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

•

NOTE: Indicates supplementary technical information or know-how.

UNITS USED • SI Units (International System of Units) are used in

Example : 24.5 MPa (250 kgf/cm2, 3560 psi)

this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units.

Quantity Length Volume

Weight Force Torque

To Convert From mm mm L L m3 kg N N N⋅m N⋅m

Into in ft US gal US qt yd3 lb kgf lbf kgf⋅m lbf⋅ft

A table for conversion from SI units to other system units is shown below for reference purposees.

Quantity

Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375

Pressure Power Temperature Velocity Flow rate

IN-02

To Convert From MPa MPa kW kW °C km/h min-1 L/min mL/rev

Into kgf/cm2 psi PS HP °F mph rpm US gpm cc/rev

Multiply By 10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0

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

001-E01A-0001 SA-688

UNDERSTAND SIGNAL WORDS • On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol. • DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. • WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. • CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. • DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. • Some safety signs don’t use any of the designated signal words above after the safety alert symbol are occasionally used on this machine. • To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine. •

NOTE indicates an additional explanation for an element of information. 002-E01A-1223

SA-1

SA-1223

SAFETY FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the machine and all safety messages in this manual. • Safety signs should be installed, maintained and replaced when necessary. • If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering). Learn how to operate the machine and its controls correctly • and safely. • Allow only trained, qualified, authorized personnel to operate the machine. • Keep your machine in proper working condition. • Unauthorized modifications of the machine may impair its function and/or safety and affect machine life. • Do not modify any machine parts without authorization. Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Hitachi Warranty Policy. • Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void Hitachi Warranty Policy. • The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine. 003-E01B-0003

SA-2

SA-003

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

SA-437

004-E01A-0437

WEAR PROTECTIVE CLOTHING • Wear close fitting clothing and safety equipment appropriate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances. • Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine. • Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine. 005-E01A-0438

PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing. • Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

006-E01A-0434 SA-434

SA-3

SAFETY INSPECT MACHINE • Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury. • In the walk-around inspection be sure to cover all points described in the “PRE-START INSPECTION” chapter in the operator’s manual.

007-E01A-0435

GENERAL PRECAUTIONS FOR CAB • Before entering the cab, thoroughly remove all dirt and/ or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident. • Do not leave parts and/or tools lying around the operator’ s seat. Store them in their specified locations. • Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire. • Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine. • Keep all flammable objects and/or explosives away from the machine. • After using the ashtray, always cover it to extinguish the match and/or tobacco. • Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.

524-E01A-0000

SA-4

SA-435

SAFETY USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury. • When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. • Do not use any controls as hand-holds. • Never jump on or off the machine. Never mount or dismount a moving machine. • Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine. SA-439 008-E01A-0439

ADJUST THE OPERATOR'S SEAT • A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations. • The seat should be adjusted whenever changing the operator for the machine. • The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back. • If not, move the seat forward or backward, and check again. • Adjust the rear view mirror position so that the best rear visibility is obtained from the operator’s seat. If the mirror is broken, immediately replace it with a new one. 009-E01A-0462

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

SA-5

SA-378

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

SA-237

010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over. • Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine. • Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move. • Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine. • Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it.

SA-083

011-E01A-0398

HANDLE STARTING AIDS SAFELY Starting fluid: • Starting fluid is highly flammable. • Keep all sparks and flame away when using it. • Keep starting fluid well away from batteries and cables. • Remove container from machine if engine does not need starting fluid. • To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it in a cool, well-protected location. • Do not incinerate or puncture a starting fluid container. 036-E01A-0293-3

SA-6

SA-293

SAFETY OPERATE ONLY FROM OPERATOR'S SEAT • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. • Start the engine only when seated in the operator's seat. • NEVER start the engine while standing on the track or on ground. • Do not start engine by shorting across starter terminals. • Before starting the engine, confirm that all control levers are in neutral. • Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders. SA-084 012-E01B-0431

JUMP STARTING • Battery gas can explode, resulting in serious injury. • If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual. • The operator must be in the operator’s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation. • Never use a frozen battery. • Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine. SA-032 S013-E01A-0032

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

014-E01B-0427 SA-091

SA-7

SAFETY PRECAUTIONS FOR OPERATIONS • Investigate the work site before starting operations. • Be sure to wear close fitting clothing and safety equipment appropriate for the job, such as a hard hat, etc. when operating the machine. • Clear all persons and obstacles from area of operation and machine movement. Always beware of the surroundings while operating. When working in a small area surrounded by obstacles, take care not to hit the upperstructure against obstacles. • When loading onto trucks, bring the bucket over the truck beds from the rear side. Take care not to swing the bucket over the cab or over any person.

M202-05-014

SA-8

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

SA-085

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

SA-9

M202-05-015

SAFETY EQUIPMENT OF HEAD GUARD, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure

SA-686

PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES • For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

018-E01A-0481

SA-481

CONFIRM DIRECTION OF MACHINE TO BE DRIVEN • Incorrect steering wheel/forward/reverse pedal operation may result in serious injury death. • Before driving the machine, confirm the position of the undercarriage in relation to the operator’s position. If the travel motors are located in front of the cab, the machine will move in reverse when steering wheel is operated to the front.

017-E01A-0491

SA-10

SA-092

SAFETY DRIVE MACHINE SAFELY • Before driving the machine, always confirm that the steering wheel/forward/reverse switch direction corresponds to the direction you wish to drive. • Be sure to detour around any obstructions. • Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Do not allow personnel to stay around the machine while traveling. • Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.

SA-090

• Never attempt to ascend or descend 35 degrees or steeper slopes. • Be sure to fasten the seat belt. • When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.5 to 1.0 m (A) above the ground. • If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.

SA-288

AVOID INJURY FROM ROLLAWAY ACCIDENTS • Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: • Select level ground when possible to park machine. • Do not park the machine on a grade. • Lower the bucket and/or other work tools to the ground. • Place FNR switch in neutral, and put the brake switch in the P (parking brake) position. • Turn the auto-idle switch off. • Run the engine at slow idle speed without load for 5 minutes to cool down the engine. • Stop the engine and remove the key from the key switch. • Pull the pilot control shut-off lever to LOCK position. • Block both tires and lower the bucket to the ground. Thrust the bucket teeth into the ground if you must park on a grade. • Position the machine to prevent rolling. • Park a reasonable distance from other machines.

020-E02A-0493

SA-11

SA-278

SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: • Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR. • Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE. • USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person. • No machine motions shall be made unless signals are clearly understood by both signalman and operator. • Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling. • Keep windows, mirrors, and lights clean and in good condition. • Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting. • Read and understand all operating instructions in the operator’s manual.

021-E01A-0494

SA-12

SA-383

SA-384

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

022-E01A-0386

M202-05-014

NEVER POSITION BUCKET OVER ANYONE • Never lift, move, or swing bucket above anyone or a truck cab. Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.

023-E01A-0487

SA-682

AVOID UNDERCUTTING • Always confirm that ground conditions are strong enough to support the machine weight when operating near a cliff. Operate the machine with the chassis frame positioned perpendicular to the cliff face so that the machine can more easily evacuate if the cliff face collapses. • If the footing starts to collapse and if retreat is not possible, do not panic. Often, the machine can be secured by lowering the front attachment, in such cases.

024-E01A-0488

SA-13

SA-683

SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT • The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death. To avoid tipping: • Be extra careful before operating on a grade. • Prepare machine operating area flat. • Keep the bucket low to the ground and close to the machine. • Reduce operating speeds to avoid tipping or slipping. • Avoid changing direction when traveling on grades. • NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable. • Reduce swing speed as necessary when swinging loads.

SA-088

• Be careful when working on frozen ground. • Temperature increases will cause the ground to become soft and make ground travel unstable.

025-E03B-0463

SA-684

NEVER UNDERCUT A HIGH BANK • The edges could collapse or a land slide could occur causing serious injury or death.

026-E01A-0519

SA-685

SA-14

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

SA-086

027-E01A-0382

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

028-E01A-0389

SA-15

SA-087

SAFETY AVOID POWER LINES • Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. • When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length. • Check and comply with any local regulations that may apply. • Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site. SA-089 029-E01A-0381

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

SA-1241

OBJECT HANDLING • If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death. • When using the machine for craning operations, be sure to comply with all local regulations. • Do not use damaged chains or frayed cables, sables, slings, or ropes. • Before craning, position the upperstructure with the travel motors at the rear. • Move the load slowly and carefully. Never move it suddenly. • Keep all persons well away from the load. • Never move a load over a person's head. • Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground. • Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall. 032-E01A-0132 SA-014

SA-16

SAFETY PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result. • Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. • Keep bystanders away from the working area before striking any object.

031-E01A-0432 SA-432

PARK MACHINE SAFELY To avoid accidents: • Park machine on a firm, level surface. • Lower bucket to the ground. • Place FNR switch in neutral, and put the brake switch in the P (parking brake) position. • Turn auto-idle switch OFF. • Run engine at slow idle speed without load for 5 minutes. • Turn key switch to OFF to stop engine. • Remove the key from the key switch. • Pull the pilot control shut-off lever to the LOCK position. • Close windows, roof vent, and cab door. • Lock all access doors and compartments.

SA-093

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

SA-018

034-E01A-0496

SA-019

SA-17

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

Less than 15°

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

SA-094

3. Turn auto-idle switch OFF. 4. Always select the slow speed mode with the travel mode switch. 5. Never load or unload the machine onto or off a truck or trailer using the front attachment functions when driving up or down the ramp. 6. Never steer the machine while on the ramp. If the traveling direction must be changed while the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again. 7. The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it. 8. Place blocks in front of and behind the tires. Securely hold the machine to the truck or trailer deck with wire ropes. Be sure to further follow the details described in the TRANSPORTING section.

035-E07A-0454

SA-18

Less than 15° SA-095

SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before starting work. • Keep the work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving. • Keep hands, feet and clothing away from power-driven parts. Before servicing the machine: 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Run the engine at slow idle speed without load for 5 minutes. 5. Turn the key switch to OFF to stop engine. 6. Relieve the pressure in the hydraulic system by moving the control levers several times.

SA-028

7. Remove the key from the switch. 8. Attach a “Do Not Operate” tag on the control lever. 9. Pull the pilot control shut-off lever to the LOCK position. 10. Allow the engine to cool. • If a maintenance procedure must be performed with the engine running, do not leave machine unattended. • If the machine must be raised, maintain a 90 to 100˚ angle between the boom and arm. Securely support any machine elements that must be raised for service work. • Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter in the operator’s manual. • Keep all parts in good condition and properly installed. • Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris. • When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces. • Disconnect battery ground cable (−) before making adjustments to electrical systems or before performing welding on the machine.

500-E02C-0520

SA-19

SA-527

SAFETY • Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine. • Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

SA-037

WARN OTHERS OF SERVICE WORK • Unexpected machine movement can cause serious injury. • Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever. This tag is available from your authorized dealer.

501-E01A-0287 SS3076175

SS2045102

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

SA-527

519-E01A-0527

STAY CLEAR OF MOVING PARTS • Entanglement in moving parts can cause serious injury. • To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

502-E01A-0026 SA-026

SA-20

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

503-E01B-0344

SA-344

STORE ATTACHMENTS SAFELY • Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death. • Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.

504-E01A-0034

SA-034

SUPPORT MAINTENANCE PROPERLY • Explosive separation of a tire and rim parts can cause serious injury or death. • Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Have it done by your authorized dealer or a qualified repair service. • Always maintain the correct tire pressure. DO NOT inflate tire above the recommended pressure. • When inflating tires, use a chip-on chuck and exten-sion hose long enough to allow you to stand to one side and not in front of or over the tire assembly. Use a safety cage it available. • Inspect tires and wheels daily. Do not operate with low pressure, cuts bubbles, damaged rims, or missing lug bolts and nuts. • Never cut or weld on an inflated tire or rim assembly. Heat from welding could cause an increase in pressure and may result in tire explosion. 521-E02A-0249

SA-21

SA-249

SAFETY PREVENT BURNS Hot spraying fluids: • After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. • To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap. • The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.

SA-039

Hot fluids and surfaces: • Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well. • Wait for the oil and components to cool before starting any maintenance or inspection work. SA-225 505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY • Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. • Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.) • Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death. S506-E01A-0019

SA-22

SA-019

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

SA-031

507-E03A-0499

SA-292

SA-044

SA-23

SAFETY PREVENT FIRES Check for Oil Leaks: • Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts. • Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts. • Do not bend or strike high-pressure lines. • Never install bent or damaged lines, pipes, or hoses. SA-019

Check for Shorts: • Short circuits can cause fires. • Clean and tighten all electrical connections. • Check before each shift or after eight(8) to ten(10) hours operation for loose, kinked, hardened or frayed electrical cables and wires. • Check before each shift or after eight(8) to ten(10) hours operation for missing or damaged terminal caps. • DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.. Clean up Flammables: • Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires. • Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately. Check Key Switch: • If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. Always check key switch function before operating the machine every day: 1. Start the engine and run it at slow idle. 2. Turn the key switch to the OFF position to confirm that the engine stops. • If any abnormalities are found, be sure to repair them before operating the machine. 508-E02B-0019

Check Heat Shields: • Damaged or missing heat shields may lead to fires. • Damaged or missing heat shields must be repaired or replaced before operating the machine. 508-E02A-0393

SA-24

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

SA-393

18-E02B-0393

SS-1510

BEWARE OF EXHAUST FUMES • Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. • If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

509-E01A-0016

SA-016

PRECAUTIONS FOR WELDING AND GRINDING • Welding may generate gas and/or small fires. • Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding. • Only qualified personnel should perform welding. Never allow an unqualified person to perform welding. • Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding. • After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering. 523-E01A-0818

SA-25

SA-818

SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. • Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. • Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fireresistant guards to protect hoses or other materials before engaging in welding, soldering, etc..

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS

SA-030

• Do not weld or flame cut pipes or tubes that contain flammable fluids. • Clean them thoroughly with nonflammable solvent before welding or flame cutting them.

510-E01B-0030

REMOVE PAINT BEFORE WELDING OR HEATING • Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness. • Avoid potentially toxic fumes and dust. • Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly. • Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

511-E01A-0029

SA-26

SA-029

SAFETY BEWARE OF ASBESTOS DUST • Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer. • Depending on the wok site conditions, the risk of inhaling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Do not use compressed air. • When operating the machine in a work site where asbestos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos. • Keep bystanders out of the work site during operation. • Asbestos might be present in imitation parts. Use only genuine Hitachi Parts.

SA-029

PREVENT BATTERY EXPLOSIONS • Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery. • Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. • Do not charge a frozen battery; it may explode. Warm the battery to 16˚C ( 60˚ F ) first. • Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result. • Loose terminals may produce sparks. Securely tighten all terminals.

SA-032

• Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness. • Be sure to wear eye protection when checking electrolyte specific gravity. 512-E01B-0032

SERVICE AIR CONDITIONING SYSTEM SAFELY • If spilled onto skin, refrigerant may cause a cold contact burn. • Refer to the instructions described on the container for proper use when handling the refrigerant. • Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere. • Never touch the refrigerant. 513-E01A-0405 SA-405

SA-27

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

SA-309

515-E01A-0309

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

516-E01A-0226

SA-28

SA-226

SAFETY BEFORE RETURNING THE MACHINE TO THE CUSTOMER • After 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

S517-E01A-0435

SA-435

SA-29

SAFETY (Blank)

SA-30

SECTION AND GROUP CONTENTS

SECTION 1 GENERAL INFORMATION Group 1 Precautions for disassembling and Assembling Group 2 Tightening Group 3 Painting Group 4 Bleeding Air from Hydraulic Oil Tank

SECTION 2 UPPERSTRUCTURE WORKSHOP MANUAL

Group 1 Cab Group 2 Counterweight Group 3 Main Frame Group 4 Pump Device Group 5 Control Valve Group 6 Swing Device Group 7 Pilot Valve Group 8 Electric Lever Group 9 Signal Control Valve Group 10 Travel Shockless Valve Group 11 Solenoid Valve Group 12 Pilot Shut-Off Solenoid Valve Group 13 Steering Valve Group 14 Brake Valve Group 15 Accumulator Charging Valve

SECTION 3 UNDERCARRIAGE

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

Group 1 Swing Bearing Group 2 Travel Motor Group 3 Center Joint Group 4 Transmission Group 5 Axle Group 6 Axle Lock Cylinder Group 7 Operate-Check Valve Group 8 Solenoid Valve Group 9 Transmission Changeover Solenoid Valve Group 10 Propeller Shaft

SECTION 4 FRONT ATTACHMENT COPYRIGHT(C)2007 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved

Group 1 Front Attachment Group 2 Cylinder Group 3 Hose-Rupture Valve Group 4 Operate-Check Valve

TECHNICAL MANUAL (Operational Principle) SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION Group 1 Specifications Group 1 Pump Device Group 2 Component Layout Group 2 Swing Device Group 3 Component Specifications Group 3 Control Valve Group 4 Pilot Valve SECTION 2 SYSTEM Group 5 Electric Lever Group 1 Controller Group 6 Transmission Group 2 Control System Group 7 Axle Group 3 ECM System Group 8 Travel Motor Group 4 Hydraulic System Group 9 Signal Control Valve Group 5 Electrical System Group 10 Steering Valve Group 11 Brake Valve Group 12 Others (Upperstructure) Group 13 Others (Undercarriage)

TECHNICAL MANUAL (Troubleshooting) SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Monitor Unit Group 3 Dr. ZX Group 4 ICF Group 5 Component Layout Group 6 Troubleshooting A Group 7 Troubleshooting B Group 8 Electrical System Inspection

SECTION 1

GENERAL — CONTENTS — Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling ................................................ W1-1-1 Maintenance Standard Terminology ......... W1-1-7

Group 2 Tightening Tightening Torque Specification.................. W1-2-1 Torque Chart................................................ W1-2-3 Piping Joint .................................................. W1-2-6 Periodic Replacement of Parts ............... W1-2-10

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

Group 4 Bleeding Air from Hydraulic Oil Tank Bleeding Air from Hydraulic Oil tank ...........W1-4-1

CJBW-1-1

(Blank)

CJBW-1-2

GENERAL / Precautions for Disassembling and Assembling PRECAUTIONS FOR AND ASSEMBLING

DISASSEMBLING

Precautions for Disassembling and Assembling

• Clean the Machine

• Precautions for Disassembling

Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work.

• Inspect the Machine Be sure to thoroughly understand all disassem-bling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future. • The machine model, machine serial number, and hour meter reading. • Reason for disassembly (symptoms, failed parts, and causes). • Clogging of filters and oil, water or air leaks, if any. • Capacities and condition of lubricants. • Loose or damaged parts.

• Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work.

W1-1-1

• To prevent dirt from entering, cap or plug the removed pipes. • Before disassembling, clean the exterior of the components and place on a work bench. • Before disassembling, drain gear oil from the reduction gear. • Be sure to provide appropriate containers for draining fluids. • Use matching marks for easier reassembling. • Be sure to use the specified special tools, when instructed. • If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause(s), then take the appropriate measures to remove it. • Orderly arrange disassembled parts. Mark and tag them as necessary. • Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. • Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. • Measure and record the degree of wear and clearances.

GENERAL / Precautions for Disassembling and Assembling • Precautions for Assembling

Bleeding Air from Hydraulic System

• Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part. • Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces. • Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing. • Be sure that liquid-gasket-applied surfaces are clean and dry. • If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent. • Utilize matching marks when assembling. • Be sure to use the designated tools to assemble bearings, bushings and oil seals. • Keep a record of the number of tools used for disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no forgotten tools remain in the assembled machine.

When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and installation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures: IMPORTANT: If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result. If the hydraulic motor is operated with air trapped in the hydraulic motor housing, damage to the motor may result. If the cylinder is operated with air trapped in the cylinder tube, damage to the cylinder may result. Be sure to bleed air before starting the engine.

• Bleeding Air from Hydraulic Pump • Remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil. • After the pump housing is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run at slow idle speed. • Slightly loosen the plug to bleed air from the pump housing until hydraulic oil oozes out. • After bleeding all the air, securely tighten the plug.

• Bleeding Air from Travel Motor / Swing Motor • With the drain plug / hose on travel motor / swing motor removed, fill the motor case with hydraulic oil.

W1-1-2

GENERAL / Precautions for Disassembling and Assembling • Bleeding Air from Hydraulic Circuit • After refilling hydraulic oil, start the engine. While operating each cylinder, swing motor and travel motor evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes. • Reposition the front attachment to check hydraulic oil level. • Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary.

W1-1-3

WCJB-01-04-001

GENERAL / Precautions for Disassembling and Assembling Floating Seal Precautions A

1. In general, replace the floating seal with a new one after disassembling. If the floating seal is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. (2) Check the slide surface on seal ring (A) for scuffing, scoring, corrosion, deformation or uneven wear. (3) Check O-ring (B) for deformation or hardening.

tears,

B

W105-03-05-019

breaks,

2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble. (1) Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air.

Correct

Incorrect

(2) Clean the floating seal and seal mounting bores. Check the bore surface for scuffing or scoring by touching the surface with touch. (3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring. (4) After installing the floating seal, check that seal ring surface (A) is parallel with seal mating face (C) by measuring the distances (A) and (C) at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating.

Correct

C

W105-03-05-020

Incorrect

a

a

A B

b

a=b

b

a≠b W110-03-05-004

W1-1-4

GENERAL / Precautions for Disassembling and Assembling Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely. • Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from being damaged and the lifted load from slipping. • Lower the temperature of the lifted load to lower than 100 °C (212 °F). If unavoidably lifting a load with a temperature of 100 °C (212 °F) or more, reduce the load weight. • Do not lift acid or alkali chemicals. • Take care not to allow the sling to become wet. The load may slip. • When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced. • When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force. • Avoid using twisted, bound, connected, or hitched slings. • Do not place any object on twisted or bent slings. (Refer to the right illustration.) • When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions. • Avoid dragging slings on the ground, throwing slings or pushing slings with a metal object. • When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged. • Store the nylon slings indoors so they won’t deteriorate with heat, sun light, or chemicals.

Correct Eyehole Lifting Method

W102-04-02-016

Incorrect Eyehole Lifting Method

W105-04-01-008

Bent Sling

W1-1-5

W162-01-01-009

GENERAL / Precautions for Disassembling and Assembling CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using.

Damaged Appearance

2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If any damage is found, cut and discard the sling. Even if no damage is found, do not use slings older than 7-years.

Broken Sewing Thread

W162-01-01-002

Scuffing

W162-01-01-003

Fuzz Broken Sewing Thread

W162-01-01-004

Broken Sewing Thread

W162-01-01-005

Broken Sewing Thread

Scoring

Fuzz

Separation of Belt

Scuffing

W162-01-01-006

W162-01-01-007

Broken Warp

W162-01-01-008

W1-1-6

GENERAL / Precautions for Disassembling and Assembling MAINTENANCE STANDARD TERMINOLOGY “Standard” 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies adjusted to specification.

“Allowable Limit” 1. Normal machine performance cannot be accomplished after exceeding this limit. 2. Repair or adjustment is impossible after exceeding this limit. 3. Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching the “Allowable Limit”.

W1-1-7

GENERAL / Precautions for Disassembling and Assembling (Blank)

W1-1-8

GENERAL / Tightening TIGHTENING TORQUE SPECIFICATION No.

Bolt Dia

Descriptions

mm

Torque

Q’ty

Wrench Size (mm)

N⋅m

(kgf⋅m)

(lbf⋅ft)

(Pump Upper)

18

2

27

360

(37)

(265)

(Pump Lower)

16

4

24

210

(21.5)

(155)

Engine cushion rubber mounting nut (Fan Side)

14

4

22

140

(14.0)

(103)

2

Engine bracket mounting bolt and nut

10

8

17

50

(5.1)

(37)

3

Hydraulic oil tank mounting bolt

16

4

24

210

(21.5)

(155)

4

Fuel tank mounting bolt

16

4

24

210

(21.5)

(155)

17

24.5

(2.5)

(18)

19

30

(3.1)

(22)

22

40

(4.1)

(30)

27

95

(9.7)

(70)

32

140

(14.3)

(105)

36

175

(17.8)

(130)

41

210

(21.5)

(155)

1

5

Engine cushion rubber mounting bolt

ORS and metal face seal fittings for hydraulic hoses and piping

6

Pump mounting bolt

10

8

17

50

(5.1)

(37)

7

Control valve mounting bolt

16

4

24

210

(21.5)

(155)

8

Control valve bracket mounting bolt

16

4

24

210

(21.5)

(155)

9

Swing device mounting bolt

20

12

30

500

(51)

(370)

10

Swing motor mounting bolt

12 (Hex. Wrench)

8

10

90

(9.2)

(66)

11

Battery mounting nut

10

2

17

50

(5.1)

(37)

12 13

Cab mounting nut

16

4

24

210

(21.5)

(155)

Swing bearing mounting bolt to upperstructure

20

32

30

510

(52)

(380)

Swing bearing mounting bolt to chassis

20

36

30

490

(50)

(360)

Center joint lock mounting bolts

16

5

24

270

(27.5)

(200)

-

-

-

-

-

-

14

Ú

15 16

Travel motor mounting bolts

Ú

16 (Hex. Wrench)

4

14

270

(27.5)

(200)

17

Propel shaft mounting nuts

Ú

10

16

14

76

(8)

(60)

18

Center Bearing mounting bolt

10

2

17

50

(5.1)

(37)

19

Rear axle mounting bolts

24

8

36

950

(97.0)

(700)

20

Wheel pin nuts

22

40

30

600

(61)

(440)

21

Cover mounting bolt

6 10 12

-

10 17 19

10 50 90

(1) (6.1) (9.2)

(7.4) (37) (66)

22

Flexible master coupling of piping

8

4 pairs

13

10.3 to 12.4

(1.05 to 1.26)

(7.59 to 9.11)

23

Jubilee Clamp of low pressure piping T-bolt clamp of low pressure piping

-

-

7 11

5.9 5.9

(0.6) (0.6)

(4.3) (4.3)

Ú

Ú Apply LOCTITE to the threads.

W1-2-1

GENERAL / Tightening NOTE 1.Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to reduce friction coefficient of them. (Except for Sprocket mounting bolt.) 2.Make sure bolt and nut threads are clean before installing.

W1-2-2

GENERAL / Tightening TORQUE CHART CAUTION: Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injury. Bolt Types Tighten nuts or bolts correctly to torque specifications. Four different types and grades of bolt are employed. Make sure to employ correct bolts and tighten them correctly when assembling the machine or components. Hexagon T Bolt

SA-040

Hexagon H Bolt

Hexagon M Bolt

Socket Bolt

W162-01-01-001

Specified Tightening Torque Chart

Bolt Dia.

Wrench Size

Hexagon Wrench Size

M552-07-091

M552-07-092

M552-07-090

Socket Bolt N⋅m

(kgf⋅m)

(lbf⋅ft)

N⋅m

(kgf⋅m)

(lbf⋅ft)

N⋅m

(kgf⋅m)

(lbf⋅ft)

M6

10

5

M8

13

6

30

(3.0)

(21.5)

20

(2.0)

(14.5)

10

(1.0)

(7.2)

M10

17

8

65

(6.5)

(47)

50

(5.0)

(36)

20

(2.0)

(14.5)

3.3 to 4.2

(0.3 to 0.4) (2.4 to 3.0)

M12

19

10

110

(11)

(80)

90

(9.0)

(65)

35

(3.5)

(25.5)

M14

22

12

180

(18)

(130)

140

(14)

(101)

55

(5.5)

(40)

M16

24

14

270

(27)

(195)

210

(21)

(152)

80

(8.0)

(58)

M18

27

14

400

(40)

(290)

300

(30)

(215)

120

(12)

(87)

M20

30

17

550

(55)

(400)

400

(40)

(290)

170

(17)

(123)

M22

32

750

(75)

(540)

550

(55)

(400)

220

(22)

(159)

M24

36

950

(95)

(690)

700

(70)

(510)

280

(28)

(205)

M27

41

1400

(140)

(1010)

1050

(105)

(760)

400

(40)

(290)

M30

46

1950

(195)

(1410)

1450

(145)

(1050)

550

(55)

(400)

M33

50

2600

(260)

(1880)

1950

(195)

(1410)

750

(75)

(540)

M36

55

3200

(320)

(2310)

2450

(245)

(1770)

950

(95)

(690)

W1-2-3

GENERAL / Tightening IMPORTANT: The following items are applied to both fine and coarse pitch threads. 1. Apply lubricant (i. e. white zinc B dissolved Into Spindle oil) to nuts and bolts to reduce their friction coefficients. The plated bolts require no lubricant. 2. Torque tolerance is ±10 %. 3. 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 sufficient tightening force. 4. The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application. 5. Make sure that nut and bolt threads are clean before installing. 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 and lower alternately

Tighten diagonally 1

1st to 4th

Tighten from center and diagonally 12

9

4

1

6

7

14

13

8

5

2

3

10

11

3

6

5

4 2 2nd to 3rd

W105-01-01-003

W1-2-4

GENERAL / Tightening Service Recommendations for Split Flange IMPORTANT: 1. Be sure to clean and Inspect sealing surfaces. Scratches / roughness cause leaks and seal wear. Unevenness causes seal extrusion. If defects cannot be polished out, replace the component. 2. Be sure to use only specified O-rings. Inspect O-rings for any damage. Take care not to file O-ring surfaces. When installing an O-ring into a groove, use grease to hold it in place. 3. While lightly tightening split flange halves, check that split is centered and perpendicular to the port. Hand-tighten bolts to hold parts in place. Take care not to pinch the O-ring. 4. Tighten bolts alternately and diagonally, as shown, to ensure even tightening. 5. Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before tightening of the others, resulting in damage to O-rings or uneven tightening of bolts.

W105-01-01-015

WRONG

W105-01-01-016

W105-01-01-008

WRONG

RIGHT

Nut and Bolt Locking

Do not bend it round

Bend along edge sharply

RIGHT

WRONG

RIGHT

• Lock Plate IMPORTANT: Do not reuse lock plates. Do not try to bend the same point twice. • Cotter Pin IMPORTANT: Do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening.

Bend along edge sharply

RIGHT

• Lock Wire IMPORTANT: Apply wire to bolts in the bolt-tightening direction, not in the bolt-loosening direction. RIGHT

RIGHT

WRONG

Loosen

W105-01-01-009

WRONG

Tighten

W105-01-01-010

W1-2-5

GENERAL / Tightening PIPING JOINT

1

4

3

5

IMPORTANT: The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application.

2

M202-07-051

Joint Body

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

37° 30°

IMPORTANT: 1. Do not over-tighten nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adapter (1). Be sure to tighten nut (3) to specifications. 2. Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting/disconnecting.

Description 30°male

37°female

Male Union Joint

Female Union Joint W105-01-01-017

Wrench Size mm Union Nut 17 19 22 27 32 36 41 17 19 22 27 32 36 41

Wrench Size mm Joint Body 17 19 22 27 32 36 41 14 17 19 22 27 32 36

Tightening Torque N⋅m (kgf⋅m, lbf⋅ft) 24.5 (2.5, 18) 29.5 (3.0, 21.5) 39 (4.0, 28.5) 78 (8.0, 58) 137 (14.0,101) 175 (18.0, 129) 205 (21.0,1 51) 24.5 (2.5, 18) 29.5 (3.0, 21.5) 39 (4.0, 28.5) 78 (8.0, 58) 137 (14.0, 101) 175 (18.0, 129) 205 (21.0, 151)

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

W1-2-6

GENERAL / Tightening Torque O-ring Seal Joint

7

9

6

O-ring (6) seats against the end face of adapter (7) to seal pressure oil. IMPORTANT: 1. Be sue to replace O-ring (6) with a new one when reconnecting. 2. Before tightening nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (e). Tightening nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage. 3. Take care not to damage O-ring groove (e) or sealing surface (10). Damage to O-ring (6) will cause oil leakage. 4. If nut (9) is loose and oil is leaking, do not re-tighten nut (9). Replace O-ring (6) with a new one and check that O-ring (6) is correctly seated in place, tighten nut (9).

W1-2-7

8

Wrench Size mm Union Nut 19 22 27 32 36 41 46

Wrench Size mm Joint Body 17 19 22 27 30, 32 36 41

1

Hose Fittings M104-07-033

Tightening Torque N⋅m (kgf⋅m, lbf⋅ft) 29.5 (3.0, 21.5) 69 (7.0, 51) 93 (9.5, 69) 137 (14.0, 101) 175 (18.0, 129) 205 (21.0, 151) 205 (21.0, 151)

GENERAL / Tightening Torque Screw-In Connection Depending on types of screw and sealing, different types of screw fittings are used. IMPORTANT: Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection.

PT

30°

Male Tapered Thread

PF

Male Straight Thread

W105-01-01-018

Wrench Size mm Hose Fittings 19 22 27 36 41 50 60

Male Tapered Thread Tightening Torque N⋅m (kgf⋅m, lbf⋅ft) FC material SS material 14.5 (1.5,10.5) 34 (3.5,25) 29.5 (3.0,21.5) 49 (5.0,36) 49 (5.0,36) 93 (9.5,69) 69 (7.0,51) 157 (16,116) 108 (11,80) 205 (21,151) 157 (16,116) 320 (33,235) 195 (20,144)

Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leaks between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap.

Internal Thread

External Thread

Clearance

• Application Procedure

W105-01-01-019

Confirm that the thread surface is clean and, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads.

Leave one to two pitch threads uncovered

Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp. T-Bolt Type Band Clamp: 4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft ) Worm Gear Type Band Clamp: 5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)

M114-07-041

T-Bolt Type

M114-07-043

W1-2-8

Worm Gear Type

M114-07-042

GENERAL / Tightening Torque Connecting Hose RIGHT

WRONG CAUTION: When replacing hoses, be sure to use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leaks, hose rupture or Separation of fitting, possibly resulting in a fire on the machine. Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting. Utilize Print marks on hoses when installing to prevent hose from being kinked.

W105-01-01-011

RIGHT

WRONG Rubbing Against Each Other

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. W105-01-01-012

Take care so that hoses do not come into contact with moving parts or sharp objects.

WRONG Clamp

RIGHT Clamp

Rubbing Against Each Other W105-01-01-013

WRONG

Rubbing Against Each Other

RIGHT

Clamp W105-01-01-014

W1-2-9

GENERAL / Tightening Torque PERIODIC REPLACEMENT OF PARTS The parts listed below deteriorate as the machine ages and are worn out or fatigued by repeated loads, resulting in possible severe personal injury and/or machine trouble. The service life of these parts cannot be detected through machine operation or visual inspection. Therefore, these parts should be replaced at regular intervals even if no abnormalities are noticed. In case any abnormalities are found on a part at any time regardless of its specified replacement interval, immediately replace the part.

Periodic Replacement Parts Engine

Base Machine Hydraulic System Front-End Attachment

Fuel hose (Fuel tank to filter) Oil filter hose (Engine to oil filter) Heater hose (Heater to engine) Pump suction hose Pump delivery hose Swing hose Travel Hose Boom cylinder line hose Arm cylinder line hose Bucket cylinder line hose Pilot hose

NOTE: Be sure to replace seals, such as O-rings and gaskets, when replacing hoses.

W1-2-10

Replacement Intervals Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years

GENERAL / Painting PAINTING Painting specification Surfaces to Be Painted

• Main surface of upperstructure (except cab) Main frame Internal parts • Front attachment • Track (including swing bearing) • Floor plate

Painting Colour YR-01 [TAXI yellow] HG Beige Deep Black YR-01 [TAXI yellow] N1.0 [Black] M/F Cation (allowed)

Final painted color

• Inside and outside surface of cab • Shaded area on cab outside • Right window guards, U-Bolt • • • • • • • • •

Suspension lifter (chair bottom) Lever (Pilot shut-off, foot rest) Engine cover Cover, Step Handrail on upperstructure right side Mirror stay: cab side, right side Nonslip cover Rear camera cover Head light bracket

HG Beige Deep Shining Silver [KANSAI PAINT LF-113-230B (Charcoal series black, half glossy)] [N2.0 (Black)] High Grade Black High Grade Black HG Beige Deep HG Beige Deep High Grade Brack KANSAI PAINT Amilac 1400 (Deep Black) HG Beige Deep HG Beige Deep

W1-3-1

GENERAL / Painting

Engine Cover

Mirror Stay

Camera Cover

WCJB-01-03-002

Decal [TAXI Yellow]

Head Light Bracket

Mirror Stay

Handrail

Step

Mirror Stay

WCJB-01-03-001

Decal [Shining Silver]

Decal [Shining Silver]

W1-3-2

Right Side Cover

Head Light Bracket

GENERAL / Painting Paint all circumference in the hinge swing position shining silver. Shaded Area [Shining Silver] Door

Panel Behind the Door 10

A

Painting Area of the Door YR-01 (TAXI Yellow)

W178-01-03-005

Section A

WCJB-01-03-004

Nonslip Cover KANSAI PAINT Amilac 1400 (Deep Black)

Align with the panel. [Shining Silver]

Panel

WCEB-01-03-003

Front Attachment YR-01 (TAXI Yellow)

WCJB-01-03-003

IMPORTANT: When cleaning arm, cylinder, etc. fitted with HN bushing, take care not to pour washing liquid directly on them. The ambient temperature should not exceed 70 °C when painting and drying.

W178-01-03-007

W1-3-3

GENERAL / Painting (Blank)

W1-3-4

GENERAL / Bleeding Air from Hydraulic Oil Tank BLEEDING AIR FROM HYDRAULIC OIL TANK 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, and may spurt, possibly causing severe burns. Be sure to wait for oil to cool before starting work. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release valve on top of the hydraulic oil tank to release any remaining pressure. Preparation 1. Place the machine on a firm, level surface and lower the bucket to the ground.

WCJB-01-04-001

1 2

2. Stop the engine. Push the air bleed valve (1) on the air breather to release any remaining pressure from hydraulic oil tank (3). 3. Remove cap (2) of hydraulic oil tank (3). 3

WCEB-01-04-001

4. Connect a vacuum pump with the hole removed cap (2) to maintain negative pressure in the hydraulic oil tank (3). NOTE: Be sure to run the vacuum pump continuously while working.

Vacuum Pump Hose

Adapter

W562-02-03-008

W1-4-1

GENERAL / Bleeding Air from Hydraulic Oil Tank (Blank)

W1-4-2

MEMO ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................

MEMO ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................

SECTION 2

UPPERSTRUCTURE — CONTENTS — Group 1 Cab

Group 5 Control Valve

Removal and Installation of Cab ............ W2-1-1 Dimensions of Cab Glass .................... W2-1-12

Removal and Installation of Control Valve ........................................W2-5-1 Disassembly of Control Valve 4-Spool Side .........................................W2-5-6 Assembly of Control Valve 4-Spool Side .......................................W2-5-18 Disassembly of Control Valve 5-Spool Side .......................................W2-5-36 Assemble of Control Valve 5-Spool Side .......................................W2-5-48 Disassembly of Housing.......................W2-5-60 Assembly of Housing............................W2-5-62 Removal and Installation of Positioning Control Valve....................W2-5-65 Disassembly of Position Control Valve ......................................W2-5-66 Assembly of Positioning Control Valve ......................................W2-5-68

Group 2 Counterweight Removal and Installation of Counterweight ...................................... W2-2-1

Group 3 Main Frame Removal and Installation of Main Frame .......................................... W2-3-1

Group 4 Pump Device Removal and Installation of Pump Device ........................................ W2-4-1 Disassembly of Pump Device .............. W2-4-14 Assembly of Pump Device ................... W2-4-26 Disassembly of Regulator .................... W2-4-46 Assembly of Regulator......................... W2-4-48 Structure of Pilot Pump ........................ W2-4-50

Group 6 Swing Device Removal and Installation of Swing Device ........................................W2-6-1 Disassembly of Swing Device ................W2-6-4 Assembly of Swing Device ...................W2-6-10 Disassembly of Swing Motor ..............W2-6-18 Assembly of Swing Motor .....................W2-6-22 Structure of Swing Dampener Valve.....W2-6-26 Maintenance Standard..........................W2-6-27

CJBW-2-1

Group 7 Pilot Valve

Group 12 Pilot Shut-Off Solenoid Valve

Removal and Installation of Pilot Valve.. W2-7-1 Removal and Installation of Travel Pilot Valve................................ W2-7-11 Disassembly of Front/Swing Pilot Valves......................................... W2-7-16 Assembly of Front/Swing Pilot Valves.. W2-7-20 Disassembly of Travel and Auxiliary/Positioning Pilot Valves ....... W2-7-24 Assembly of Travel and Auxiliary/Positioning Pilot Valves ....... W2-7-26

Removal and Installation of Pilot Shut-Off Solenoid Valve......................W2-12-1 Structure of Pilot Shut-Off Solenoid Valve ....................................W2-12-3

Group 13 Steering Valve Removal and Installation of Steering Valve.....................................W2-13-1

Group 14 Brake Valve Removal and Installation of Brake Valve.........................................W2-14-1 Disassembly of Brake Valve .................W2-14-4 Assembly of Brake Valve......................W2-14-8

Group 8 Electric Lever Removal and Installation of Electric Lever........................................ W2-8-1 Disassembly of Electric Lever................ W2-8-8 Assembly of Electric Lever................... W2-8-10

Group 15 Accumulator Charge Valve

Group 9 Signal Control Valve Removal and Installation of Signal Control Valve ........................................ W2-9-1 Structure of Signal Control Valve ........... W2-9-4

Group 10 Travel Shockless Valve Removal and Installation of Travel Shockless Valve ...................... W2-10-1 Structure of Travel Shockless Valve .... W2-10-4

Group 11 Solenoid Valve Removal and Installation of 4-Spool Solenoid Valve Unit ............................ W2-11-1 Structure of 4-Spool Solenoid Valve Unit ..................................................... W2-11-3 Disassembly and Assembly of 4-Spool Solenoid Valve Unit.............. W-2-11-4 Removal and Installation of Solenoid Valve Unit (For Electric Lever Operation) .... W2-11-6 Structure of Solenoid Valve Unit (For Electric Lever Operation)............ W2-11-8

CJBW-2-2

Removal and Installation of Accumulator Charge Valve .................W2-15-1 Structure of Accumulator Charge Valve ......................................W2-15-4

UPPERSTRUCTURE / Cab REMOVAL AND INSTALLATION OF CAB Removal CAUTION: Seat (1) weight: 40 kg (90 lb) 1

2

3

4

5

1. Remove sems bolts (4) (2 used) from safety belts (6) (2 used). Remove safety belts (6) (2 used) from brackets (5) (2 used). : 16 mm 6

WCEB-02-01-001

4

5

2

3

6

WCEB-02-01-017

2. Remove socket bolts (3) (4 used) from seat (1). Remove seat (1) from plate (2). : 6 mm

3

1

2 WCEB-02-01-002

7

3. Remove mat (8) from the inside of cab (7).

8

W2-1-1

WCEB-02-01-003

UPPERSTRUCTURE / Cab 4. Remove sems bolts (10) (2 used) from cover (9). : 13 mm

9

10

W1JB-02-01-004

5. Remove caps (11) (6 used) from cover (9). Remove screws (12) (6 used) from cover (9).

7

6. Remove cover (9) from cab (7).

11, 12

9

11, 12

7. Remove sems bolts (16) (4 used) from cover (14). Remove cover (14) from brackets (13, 15). : 17 mm

W1JB-02-01-005

13

14

16

8. Remove sems bolts (17) (5 used) from bracket (13). Move the bracket (13) assembly forward from bracket (15). : 13 mm, 17 mm

13

16

15 17

WCEB-02-01-008

13

17

15

17

W2-1-2

WCEB-02-01-018

WCEB-02-01-019

UPPERSTRUCTURE / Cab 18

9. Remove screws (19) (2 used) from cover (18). Remove cap (20) and screw (21) from cover (18). Remove cover (18) from cab (7).

19

20, 21

W1JB-02-01-001

7

22

10. Remove sems bolts (23) (2 used) from bracket (24). Remove bracket (24) from cab (7) and duct (22). Remove duct (22) from bracket (15). : 13 mm

7

23 24 15 WCEB-02-01-016

23

25

26

11. Open covers (25, 26).

WCJB-02-01-001

12. Attach a nylon sling onto cover (25). Hoist and hold cover (25). 13. Remove nuts (28) (4 used), spring washers (29) (4 used) and washers (30) (4 used) from cover (25). Remove cover (25) from support (27). : 17 mm

25

27

28, 29, 30

WCJB-02-01-003

W2-1-3

UPPERSTRUCTURE / Cab 31

14. Disconnect vinyl hose (32) from washer tank (31). Cap the open ends.

32

WCJB-02-01-004

15. Remove sems bolts (35) (7 used) from cover (33). Remove cover (33) from main frame (34). : 17 mm

33

34

35

WCJB-02-01-005

16. Remove anchor bolt (38), washer (37) and spacer (36) from cab (7) and main frame (34). : 32 mm

7 36 37

34

38

WCEB-02-01-013

17. Remove vinyl hose (32) through the cab (7) side.

32

WCJB-02-01-004

W2-1-4

UPPERSTRUCTURE / Cab 39

18. Open cover (40).

40

41

42

19. Remove sems bolts (41) (4 used) from cover (39). Remove cover (39) from stay (42). : 17 mm

WCJB-02-01-002

43

20. Remove clamps (44) (3 used) from the outside of the cab (7) rear. Disconnect connectors (43) (5 used).

44

7

WCEB-02-01-014

Lifting Bracket

CAUTION: Cab (7) weight: 550 kg (1220 lb)

47

7

Lifting Bracket

21. Attach a nylon sling onto the bracket in cab (7). Hold cab (7). 22. Remove nuts (45) (4 used) and washers (46) (4 used) from cab (7). : 24 mm

45, 46

45, 46

23. Remove socket bolts (47) (6 used) from cab (7). : 8 mm 24. Remove bolts (48) (5 used) and washers (49) (5 used) from cab (7). : 17 mm

47 45, 46 W1JB-02-01-006

48, 49

47

CAUTION: Cab (7) weight: 550 kg (1220 lb) 25. Remove cab (7) from main frame (34).

7

34 WCJB-02-01-006

W2-1-5

UPPERSTRUCTURE / Cab Installation CAUTION: Cab (7) weight: 550 kg (1220 lb) 1. Attach a nylon sling onto cab (7). Hoist and align cab (7) with the mounting hole on main frame (34).

7

34 WCJB-02-01-006

Lifting Bracket

2. Install cab (7) to main frame (34) with nuts (45) (4 used) and washers (46) (4 used). : 24 mm : 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft) 3. Install cab (7) to main frame (34) with socket bolts (47) (6 used). : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

47

Lifting Bracket

7

45, 46

45, 46

4. Install cab (7) to main frame (34) with bolts (48) (5 used) and washers (49) (5 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

47 45, 46 W1JB-02-01-006

48, 49

47

22

7

5. Install duct (22) to bracket (15). 6. Install bracket (24) to cab (7) and duct (22) with sems bolts (23) (2 used). : 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

23 24 15 23

W2-1-6

WCEB-02-01-016

UPPERSTRUCTURE / Cab 18

7. Install cover (18) to cab (7) with screws (19) (2 used). Install cover (18) to cab (7) with screw (21). Install cap (20) to screw (21).

19

20, 21

8. Align the bracket (13) assembly with the mounting hole on bracket (15). Install the bracket (13) assembly to bracket (15) with sems bolts (17) (5 used). : 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

7

13

17

W1JB-02-01-001

13

17

15

17

9. Install cover (14) to brackets (13, 15) with sems bolts (16) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-01-018

WCEB-02-01-019

13

14

16

10. Install cover (9) to cab (7) with screw (12) (6 used). Install caps (11) (6 used) to screws (12) (6 used).

16

15

WCEB-02-01-008

7 11, 12

9

11, 12

W1JB-02-01-005

W2-1-7

UPPERSTRUCTURE / Cab 11. Install cover (9) to cab (7) with sems bolts (10) (2 used). : 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

7

9

10

W1JB-02-01-004

12. Connect connectors (43) (5 used). Secure connectors (43) (3 used) with clamps (44) (3 used).

43 44

7

WCEB-02-01-014

13. Secure cab (7) to main frame (34) with anchor bolt (38), washer (37) and spacer (36). : 32 mm : 550 N⋅m (55 kgf⋅m, 406 lbf⋅ft)

7 36 37

34

38

WCEB-02-01-013

31

14. Pass vinyl hose (32) through main frame (34). Connect vinyl hose (32) to washer tank (31). 32

WCJB-02-01-004

W2-1-8

UPPERSTRUCTURE / Cab 15. Install cover (33) to main frame (34) with sems bolts (35) (7 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

33

34

35

WCJB-02-01-005

16. Attach a nylon sling onto cover (25). Hoist and align cover (25) with the mounting hole on support (27). Secure cover (25) to support (27) with washers (30) (4 used), spring washers (29) (4 used) and nuts (28) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

25

27

28, 29, 30

WCJB-02-01-003

25

17. Shut covers (25, 26).

26

WCJB-02-01-001

3

CAUTION: Seat (1) weight: 40 kg (90 lb)

1

18. Install seat (1) to plate (2) with socket bolts (3) (4 used). : 6 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

2 WCEB-02-01-002

W2-1-9

UPPERSTRUCTURE / Cab 1

19. Install safety belts (6) (2 used) to brackets (5) (2 used) with sems bolts (4) (2 used). : 16 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2

3

4

5

6

WCEB-02-01-001

4

5

2

3

6

WCEB-02-01-017

7

20. Install mat (8) to the inside of cab (7).

8

21. Install cover (39) to stay (42) with sems bolts (41) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

39

40

WCEB-02-01-003

41

42

22. Shut cover (40).

WCJB-02-01-002

W2-1-10

UPPERSTRUCTURE / Cab (Blank)

W2-1-11

UPPERSTRUCTURE / Cab DIMENSIONS OF CAB GLASS NOTE: Unit: mm (1 mm=0.039 in)

Black Ceramic Coating Range

115 70

21 60

C0.5

107

2-R50 2-R250

2-R50

2-R20 2-R10

2-R127

70

C0.5 Black Ceramic Coating Surface

A

106.6 1081

W1JB-02-01-013

R50

(4 mm)

R2975

Section A

R800

φ28

B

R75 R120

Black Ceramic Coating Surface

R40

2R-5

271

268

20 70

16.5

50

W1JB-02-01-011

21 847

214

21

Black Ceramic Coating Range

R1075 W1JB-02-01-009

372.9

C

(4 mm) 22

50

54.1

25

W1JB-02-01-012

84

25 865

C0.5 R2

C0.5

W1JB-02-01-014

W1JB-02-01-019

Black Ceramic Coating Surface Section C

Section B

W2-1-12

UPPERSTRUCTURE / Cab NOTE: Unit: mm (1 mm=0.039 in) 360.7

4-R4 3-R4

(4 mm)

R150

2-φ12.2 +0.5 -0

139.7

50

6445

(4 mm)

50

40±0

WCEB-02-01-012

631 37

228.2

50 50

WCEB-02-01-011

383.2

312.6

C0.5 4Ｒ-4

C0.5 R2800

Black Ceramic Coating Surface

(4 mm) Section A

W1JB-02-01-013

644.5

40±0.5 WCEB-02-01-004

228.2 93°

50 50

WCEB-02-01-010

460.2 Glass Mark (Back)

860.8

Black Ceramic Coating Range

833 506 63.5

581

64.5 R50

448

R964

R75 R58 R250 185 R103 R42 R329

R10

17

2-R4

R150

R2854

498.5

26.5

438.5 353.5

50 2-φ21

327.5 173

109.5

(4 mm)

R60

R25 1

102.5

R60

W2-1-13

R10 R5004

A

152.5

R5031

118

336

34

82

W1JB-02-01-018

UPPERSTRUCTURE / Cab NOTE: Unit: mm (1 mm=0.039 in)

Black Ceramic Coating Range

30

R30

39

29 652

87.5

(4 mm)

R200

87.5

R200

R500

A

R500

R50 185

185 45 70 R50

4-R10

205

848

W1JB-02-01-021

WCEB-02-01-015

Black Ceramic Coating Range

567.5 496 123.5 80

C0.5

3-R4 75.5

Black Ceramic Coating Surface Section A

R25

100

C0.5

R25 R20 R25 87.7° R75

W1JB-02-01-013

B

R25

R4139.5

887 1008

R4044.5

19.5

1127.3

59.5

85

1099

1145.5

(4 mm) R40

C0.5

R35 R135

C0.5

R100

R35

R550

φ83 13° 112 109°

W1JB-02-01-014

A 228

105 65°

Section B

R250

R20

102° W1JB-02-01-017

R60

R70

76 140

78.5

57

195 447 483

W2-1-14

UPPERSTRUCTURE / Cab NOTE: Unit: mm (1 mm=0.039 in)

C1

C1 Black Ceramic Coating Surface Section A

W1JB-02-01-013

W1JB-02-01-009

1646.47 1599.44

Black Ceramic Coating Range 80

50 106

2-R25

50

R75

R3025

R20

R30

90

R30

R50 158

R2875

R575 R125 R1040

R10

R50

R30 R50

28°

R1525 R30

R55

393 400 807.65 963.7

W2-1-15

1636.3

40

A 1496.7

R2940

(5 mm)

R25

1205

50

873.14

R30

150 145

696.73

R300

R2145

1230

R20

313.6

900

187

W1JB-02-01-020

UPPERSTRUCTURE / Cab Removal of Cab Glass

Right-Hand Glass

Procedures to Remove Right-Hand Glass, Rear Left-Hand Glass, Lower Door Glass and Rear Glass CAUTION: When removing the broken or cracked glass, the glass shards may cause serious injury. Before removing, use the gummed tape or something like in order to paste the broken or cracked glass and reinforce them. Remove the glass pieces away.

W1JB-02-01-009

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

Rear Glass Rear Left-Hand Glass

Garnish

Garnish

2. Prick a hole in the adhesive by using an awl (or cutter knife).

Lower Door Glass

Resin Panel

WCEB-02-01-015

3. Pass a piano wire (or a wire) through the hole. Cab Cab Glass Awl

Adhesive

W1SE-02-01-033

Piano Wire (or Metal Wire)

W1SE-02-01-034

W2-1-16

UPPERSTRUCTURE / Cab 4. Wind the both ends of piano wire onto the screwdriver. Draw the wire back and forth in order to cut the adhesive between cab and glass. Remove the glass from the cab. NOTE: Cut off the middle of adhesive between glass and cab. Piano wire is easily broken if a part of piano wire turns hot. Change the position and cut the adhesive.

Glass (Cab Outside)

Cab

Cab Glass

Adhesive (Cab Inside) W1SE-02-01-035

W2-1-17

UPPERSTRUCTURE / Cab Installation of Cab Glass

Right-Hand Glass

Procedures to Install Right-Hand Glass, Rear Left-Hand Glass, Lower Door Glass and Rear Glass 1. Cut off residual adhesive at the cab side to make 1 to 2 mm (0.04 to 0.08 in) deep all around by using a cutter knife or similar. NOTE: Do not damage the cab paint.

W1JB-02-01-009

Rear Glass

Lower Door Glass

Rear Left-Hand Glass

W1JB-02-01-010

Cab

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

Cutter Knife

Cut off adhesive by 1 to 2 mm （0.04 to 0.08 in） deep. W1SE-02-01-036

IMPORTANT: Primer should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer, apply Primer as quickly as possible and replace the cap immediately after using. After opening Primer, all the contents should be used within 180 days (or 2 hours with the cap off). 3. Apply Primer for paint (Sika Aktivator DM-1) to the cutting edge of adhesive at cab side by using a brush. Wait for about 15 minutes in order to let it dry by itself. NOTE: The painting primer should be applied evenly in order to leave no blemishes.

W2-1-18

Cab

Apply Primer 24 by using a brush. Cutting Edge of Adhesive at Cab Side W1SE-02-01-038

UPPERSTRUCTURE / Cab 4. Clean the mating edge of new glass by using clean rag and ethyl alcohol. IMPORTANT: Primer (Sika Primer Z06G+P) should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer, apply Primer as quickly as possible and replace the cap immediately after using. After opening Primer, all the contents should be used within 180 days (or 2 hours with the cap off). 5. Apply Primer for glass (Sika Primer Z06G+P) to the cutting edge of adhesive at cab side by using a brush. Wait for about 15 minutes in order to let it dry by itself. (As for the position to apply Primer, refer to W2-1-21.)

11. Suck, raise the glass by using sucker lifter 4355282 (refer to W2-1-21), and adhere it to the cab within 5 minutes. NOTE: Install the glass while aligning the spacer position on the glass. Remove all adhesive except the mounting surface, before solidifying by using white spirit. 12. Secure the glass by using the gummed tape until the adhesive becomes solid in order to prevent them from being mispositioned or coming off. (Refer to W2-1-20.) NOTE: Time for adhesive (Sika Tack-Drive) to become solid: 8 hours (just for reference)

6. Install the spacer with facing to the glass surface by using the instant adhesive. (As for the positions to install spacers A, B and C dam rubber, refer to W2-1-21.) 7. Cut off the nozzle of adhesive cartridge (Sika Tack-Drive) into V-shaped by using a knife. (Refer to W2-1-21.) 8. Remove the seal of cartridge. Install the V-shaped nozzle. 9. Install the cartridge to the manual coking gun. 10. Evenly apply adhesive to the old adhesive left at cab side. (As for the position to apply adhesive, refer to W2-1-21.)

W2-1-19

UPPERSTRUCTURE / Cab NOTE: Unit: mm (1 mm=0.039 in) Right-Hand Glass

Rear Glass 250

350

300

500 100

200 200

500

200 200

200

200

250

300

W1JB-02-01-029

200 200 100

100

W1JB-02-01-030

Rear Left-Hand Glass 150 200

Lower Door Glass 200

500

200

W1JB-02-01-035

W2-1-20

W1JB-02-01-038

UPPERSTRUCTURE / Cab NOTE: Unit: mm (1 mm=0.039 in)

Spacer C Spacer B

Spacer A

20 20

20

6

6

6

6

Two Side Adhesive Tape

R0.5

R5

84°

8

75°

R0.5

R10

78°

10.5

12

Two Side Adhesive Tape

3

R8

R0.5

3

6

4

4

4

2

W1JB-02-01-024 W1JB-02-01-023

10.5 W1JB-02-01-022

Dam Rubber 30

6.4 6 W1JB-02-01-025

Lower Door Grass Rear Left-Hand Glass

Right-Hand Glass

Suction Lifter

Spacer A Rubber

Dam Rubber Spacer A

Spacer A Spacer B

Spacer B Dam Rubber

W1JB-02-01-039

Spacer B

Rear Glass

Spacer C

W1JB-02-01-027 W1JB-02-01-026

W1JB-02-01-042

8 to 9 mm

13 to 15 mm

Adhesive Cut nozzle end into V-shaped.

W1SE-02-01-027

Apply adhesive evenly.

9

Remove the seal.

12 W1JB-02-01-031

Adhesive Cartridge

W1SE-02-01-028

W2-1-21

W1SE-02-01-043

Panel

UPPERSTRUCTURE / Cab 13. The required amount (just for reference) of adhesive and primer

Upper Front Glass Lower Door Glass Rear Left-Hand Glass Rear Right-Hand Glass Rear Glass

Adhesive Sika Tack-Drive (Sika Tack-Drive) 310 ml Cartridge 310 ml 150 ml 250 ml 100 ml 210 ml

Painted Surface or Adhesive Surface Primer Sika Aktivator DM-1 (Sika Aktivator DM-1) 250 ml Can 0.75 ml 0.5 ml 0.65 ml 1 ml 0.5 ml

W2-1-22

Glass Surface Primer Sika Primer 206G+P 30 ml Bottle 0.67 ml 0.45 ml 0.6 ml 0.9 ml 0.45 ml

UPPERSTRUCTURE / Cab Installation of Upper Door Glass 1. Before installing the glass, remove the garnish around sash assembly from the cab inside for easy removal. Push the sash assembly by hands and remove the sash outside.

Sash Assembly

Garnish

2. Install glass A and glass B into the sash grooves. 3. Install the sash assembly, which the glass is installed on, onto the door from the outside of cab. Secure the sash assembly at the inside of cab by using the garnish.

W2-1-23

Glass A

Glass B W1JB-02-01-010

UPPERSTRUCTURE / Cab Installation of Upper Front Glass

Adhere the glass in the same method as right-hand glass.

1. Stick seal (1) to the lower side of front upper glass by using Cemedine Super X. Stick and secure both right and left ends (the thicker part) of seal (1) to the glass by using Cemedine Super X. Stick the mating surface of seal (1) and the glass by using Cemedine Super X so that no visible undulation or boss can be found. NOTE: Cemedine Super X Black No.8008 Glue-state adhesive, tubed IMPORTANT: The upper front glass is arched-fringed. When replacing the glass, contact with the nearest HITACHI Office and replace it as an assembly.

W1JB-02-01-034

Cemedine Super X Seal Here

Upper Glass

Cemedine Super X

Seal (1)

Seal (1)

Lower Glass

Lower Glass

W1JB-02-01-032

W2-1-24

Upper Glass

W1JB-02-01-033

UPPERSTRUCTURE / Counterweight REMOVAL AND COUNTERWEIGHT

INSTALLATION

OF

Removal 1. Open cover (1).

1

WCJB-02-02-002

2. Disconnect plugs (2, 3).

2

WCJB-02-02-003

3

WCJB-02-02-004

3. Open cover (4). 4

WCJB-02-02-001

5

4. Disconnect connector (5).

WCJB-02-02-005

W2-2-1

UPPERSTRUCTURE / Counterweight 6

5. Open covers (6, 7).

7

WCJB-02-01-001

6. Disconnect connector (8). 8

WCEB-02-02-006

9

CAUTION: Counterweight (10) weight: ZX210W-3: 3850 kg (8490 lb) ZX220W-3: 4950 kg (11000 lb)

10

7. Remove caps (9) (2 used) from counterweight (10). Install FLENO RINK BOLT into the holes where caps (9) (2 used) were removed. NOTE: Dimension of FLENO RINK BOLT (B-42, M42, Pitch 4.5 mm) 8. Attach a wire rope onto FLENO RINK BOLT. Hoist and hold counterweight (10).

11 12

CAUTION: When using a power wrench, do not pinch your fingers by its reaction bar.

WCEB-02-02-004

9. Remove bolts (12) (4 used) and washers (11) (4 used) from counterweight (10) by using a power wrench. : 60 mm

10

10. Hoist and remove counterweight (10) from main frame (13). 11

12 13

W2-2-2

WCEB-02-02-005

UPPERSTRUCTURE / Counterweight Installation CAUTION: Counterweight (10) weight: ZX210W-3: 3850 kg (8490 lb) ZX220W-3: 4950 kg (11000 lb) 1. Hoist and align counterweight (10) with the mounting holes on main frame (13).

10

2. Temporarily tighten counterweight (10) to main frame (13) with bolts (12) (4 used) and washers (11) (4 used). 11

CAUTION: When using a power wrench, do not pinch your fingers by its reaction bar. 12

3. Remove the wire rope and FLENO RINK BOLT from counterweight (10). Tighten bolts (12) (4 used) by using a power wrench and torque wrench. : 60 mm : 3600 N⋅m (367 kgf⋅m, 2660 lbf⋅ft)

13

WCEB-02-02-005

10

Torque Wrench Power Wrench

WCEB-02-02-006

9

4. Install caps (9) (2 used) to counterweight (10).

10

WCEB-02-02-007

W2-2-3

UPPERSTRUCTURE / Counterweight 5

5. Connect connectors (5, 8).

8

WCJB-02-02-005

WCEB-02-02-006

6. Shut cover (4). 4

WCJB-02-02-001

6

7

7. Shut covers (7, 6).

WCJB-02-01-001

3

8. Connect plug (3).

WCJB-02-02-004

W2-2-4

UPPERSTRUCTURE / Counterweight 9. Connect plug (2).

2

WCJB-02-02-003

1

10. Shut cover (1).

WCJB-02-02-002

W2-2-5

UPPERSTRUCTURE / Counterweight (Blank)

W2-2-6

UPPERSTRUCTURE / Main Frame REMOVAL AND INSTALLATION OF MAIN FRAME CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal

Counterweight

CAUTION: Counterweight weight: ZX210W-3: 3850 kg (8490 lb) ZX220W-3: 4950 kg (11000 lb) Washer

1. Remove the counterweight. (Refer to the REMOVAL AND INSTALLATION OF COUNTERWEIGHT on W2-2-1.) : 60 mm

Bolt

WCEB-02-02-005

Monoblock Boom

CAUTION: The front attachment assembly weight: Monoblock boom: 3430 kg (7570 lb) 2-piece boom: 4190 kg (9240 lb) 2. Remove the front attachment assembly. (Refer to the REMOVAL AND INSTLLATION OF FRONT ATTACHMENT on W4-1-1.) : 27 mm, 30 mm, 36 mm WCJB-02-03-001

2-Piece Boom

WCJB-02-03-002

W2-3-1

UPPERSTRUCTURE / Main Frame CAUTION: Center joint weight: 90 kg (200 lb)

Connector

Slip Ling

Hose

3. Remove the bolts, the stopper and the slip ring from the center joint. Disconnect the hose from the center joint. (Refer to the Remove and Install Center Joint group on W3-3-1.) : 10 mm, 19 mm, 22 mm, 27 mm, 36 mm

Stopper

Bolt

Center Joint

CAUTION: Upperstructure weight: 5400 kg (12000 lb) IMPORTANT: IMPORTANT: Do not damage the engine due to the wire ropes attached from the rear side of the frame. 4. Attach the wire ropes onto the rear side of the frame and the boom mounting part. Take up slack of the wire rope. NOTE: If chain block is used, it is not only easy to adjust the length of wire rope, but also easy to level the center of gravity.

WCJB-03-03-001

Wire Rope

Rear Side of Frame

WCEB-02-03-003

Wire Rope

WCEB-02-03-005

5. Put the matching marks on the upperstructure and the outer race of the swing bearing. Remove the swing bearing mounting bolt. : 30 mm 6. Adjust a chain block in order to level the center of gravity. Hoist and remove the frame.

WCJB-02-03-003

Bolt

W2-3-2

UPPERSTRUCTURE / Main Frame Installation

CAUTION: Upperstructure weight: 5400 kg (12000 lb) 1. Attach the wire ropes onto the frame. Adjust the chain block in order to level the center of gravity. Hoist and place the frame onto the undercarriage. (Refer to the Removal procedures.) 2. Align the matching marks on the upperstructure and the outer race of the swing bearing. Install and temporarily tighten the mounting bolts for the swing bearing. Remove the wire ropes. Tighten the mounting bolts for the swing bearing. : 30 mm : 520 N·m (53 kgf·m, 390 lbf·ft)

WCJB-02-03-003

Bolt Connector

Slip Ling

Hose

3. Connect the hoses (13 used) to the center joint. : 10 mm : 3.3 to 4.2 N·m (0.3 to 0.4 kgf·m, 2 to 3 lbf·ft) : 19 mm : 29.5 N·m (3 kgf·m, 22 lbf·ft) : 22 mm : 39 N·m (4 kgf·m, 29 lbf·ft) : 27 mm : 78 N·m (8 kgf·m, 58 lbf·ft) : 36 mm : 175 N·m (18 kgf·m, 129 lbf·ft) 4. Apply LOCTITE #262 onto the bolts (5 used). Install the stopper to the center joint. : 24 mm : 265 N·m (27 kgf·m, 195 lbf·ft) 5. Install the slip ring to the stopper. : 10 mm : 3.3 to 4.2 N·m (0.3 to 0.4 kgf·m, 2 to 3 lbf·ft)

W2-3-3

Stopper

Bolt

Center Joint

WCJB-03-03-001

UPPERSTRUCTURE / Main Frame CAUTION: Counterweight weight: ZX210W-3: 3850 kg (8490 lb) ZX220W-3: 4950 kg (11000 lb)

Counterweight

6. Install the counterweight. (Refer to the REMOVAL AND INSTALLATION OF COUNTERWEIGHT on W2-2-1.) : 60 mm : 3530 N·m (360 kgf·m, 2610 lbf·ft)

Washer

Bolt WCEB-02-02-005

CAUTION: The front attachment assembly weight: Monoblock boom: 3430 kg (7570 lb) 2-piece boom: 4190 kg (9240 lb) 7. Install the front attachment assembly to the upperstructure. Add hydraulic oil. (Refer to the REMOVAL AND INSTALLATION OF FRONT ATTACHMENT on W4-1-1.) : 27 mm : 93 N·m (9.5 kgf·m, 69 lbf·ft) : 30 mm : 540 N·m (55 kgf·m, 398 lbf·ft) : 36 mm : 175 N·m (18 kgf·m, 129 lbf·ft)

Monoblock Boom

WCJB-02-03-001

2-Piece Boom

8. Start the engine. Set the front attachment in posture for checking hydraulic oil level. Check for hydraulic oil level and any oil leakage.

WCJB-02-03-002

W2-3-4

UPPERSTRUCTURE / Pump Device REMOVAL AND INSTALLATION OF PUMP DEVICE CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) 1

Removal 1. Open cover (1).

WCJB-02-02-002

2. Open cover (2). 2

WCJB-02-02-001

3

4

5

3. Remove sems bolts (3) (4 used) from cover (4). Remove cover (4) from main frame (5). : 17 mm

WCJB-02-04-007

W2-4-1

UPPERSTRUCTURE / Pump Device 6

4. Remove sems bolts (6) (2 used) from bracket (7). : 17 mm

5. Remove sems bolts (9) (6 used) from cover (8). Remove cover (8) from bracket (7) and supports (10, 11). : 17 mm

7

7

8

9

10

11

6. Remove sems bolts (12) (6 used) and sems bolts (15) (2 used) from bracket (7). Remove bracket (7) from supports (13, 14) and cover (16). : 17 mm

WCJB-02-04-003

7

9 12

14

WCJB-02-04-001

13

12

7

WCJB-02-04-001

15

WCJB-02-04-002

7 16

WCJB-02-04-003

W2-4-2

UPPERSTRUCTURE / Pump Device 7. Disconnect hoses (18) (2 used) from filter (19). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 27 mm

18

19

18

17

16

8. Remove sems bolts (20) (2 used) from clips (21) (2 used). Remove clips (21) (2 used) from hoses (22) (4 used). : 17 mm

20, 21 22

WCJB-02-04-003

9. Disconnect connector (17). : 17 mm

23

10. Disconnect connectors (24) (7 used) from pump device (23).

24

WCEB-02-04-009

11. Remove socket bolts (26) (3 used) and clips (28) (3 used). Remove harness (27) from pump device (23). : 5 mm

24

23

28 29

12. Remove socket bolts (30) (8 used) and split flanges (31) (4 used). Disconnect hoses (29) (2 used) from pump device (23). Cap the open ends. : 10 mm

27

WCJB-02-04-004

26 29

30 31

23

WCEB-02-04-009

W2-4-3

UPPERSTRUCTURE / Pump Device 32

13. Disconnect hose (34) from suction pipe (32). Cap the open ends. : 41 mm

33 23

14. Remove socket bolts (33) (4 used) from suction pipe (32). Disconnect suction pipe (32) from pump device (23). : 10 mm

34

WCEB-02-04-009

15. Disconnect hoses (35) (2 used) from regulators (36) (2 used). Cap the open ends. : 19 mm

35

WCJB-02-04-003

36

16. Disconnect hoses (38) (4 used) from pilot pump (37). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 27 mm

37

38

WCEB-02-04-009

17. Disconnect hoses (39) (3 used) from filter (40). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 22 mm, 27 mm

40

W2-4-4

39

WCJB-02-04-003

UPPERSTRUCTURE / Pump Device 13

18. Remove sems bolts (42) (5 used) from covers (41) (2 used). Remove covers (41) (2 used) from support (13) and cover (16). : 17 mm

19. Remove sems bolts (43) (2 used) from cover (16). Remove the cover (16) assembly from support (13). : 17 mm

41

42

16

WCJB-02-04-004

43

16

WCJB-02-04-003

23

20. Remove socket bolts (45) (8 used) and split flanges (44) (4 used). Disconnect hoses (46) (2 used) from pump device (23). Cap the open ends. : 8 mm

44 45 46

WCEB-02-04-009

21. Remove sems bolts (47) (2 used) from plate (48). Remove plate (48) and the bracket (49) assembly from pump device (23). : 17 mm

47

48

23

46

49

WCEB-02-04-008

W2-4-5

UPPERSTRUCTURE / Pump Device 22. Remove nuts (51) (2 used), spring washers (52) (2 used) and bolts (53) (2 used) from clamp (55). : 19 mm

51, 52, 53 50

CAUTION: The muffler (50) assembly weight: 23 kg (51 lb)

54

23. Attach a nylon sling onto muffler (50). Hoist and hold muffler (50). 55

24. Remove sems bolts (56) (3 used) from bracket (57). Remove the muffler (50) assembly from pump device (23).

WCJB-02-04-006

50

CAUTION: Pump device (23) weight: 164 kg (370 lb)

57

56

WCJB-02-04-005

23 23

25. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to pump device (23). Attach a nylon sling onto eyebolt. Hoist and hold pump device (23).

Eyebolt Mounting Hole

26. Remove sems bolts (59) (3 used) from pump device (23). Remove pump device (23) from engine (58). : 17 mm

WCEB-02-04-003

58

59

23

W2-4-6

WCJB-02-04-005

UPPERSTRUCTURE / Pump Device Installation 23

CAUTION: Pump device (23) weight: 164 kg (370 lb)

Eyebolt Mounting Hole

1. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to pump device (23). Attach a nylon sling onto eyebolt. Hoist and hold pump device (23).

WCEB-02-04-003

2. Align pump device (23) with the mounting hole on engine (58). Install pump device (23) to engine (58) with sems bolts (59) (3 used). : 17 mm : 65 N⋅m (6.5 kgf⋅m, 48 lbf⋅ft)

58

50

CAUTION: The muffler (50) assembly weight: 23 kg

59

3. Attach a nylon sling onto muffler (50). Hoist and align muffler (50) with the mounting hole on pump device (23). Install bracket (57) to pump device (23) with bolts (56) (3 used). : 17 mm : 65 N⋅m (6.5 kgf⋅m, 48 lbf⋅ft)

4. Align clamp (55) with the center of exhaust pipe (54) and the muffler (50) pipe. Secure exhaust pipe (54) and muffler (50) with bolts (53) (2 used), spring washers (52) (2 used) and nuts (51) (2 used). : 19 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

57

56

23

WCJB-02-04-005

51, 52, 53

50

54

55 WCJB-02-04-006

W2-4-7

UPPERSTRUCTURE / Pump Device 47

5. Install the bracket (49) assembly to pump device (23) with sems bolts (47) (2 used) and plate (48). : 17 mm : 65 N⋅65 N⋅m (6.5 kgf⋅m, 48 lbf⋅ft)

48

23

49

WCEB-02-04-008

23

6. Connect suction pipe (32) to pump device (23) with socket bolts (33) (4 used). : 10 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

32

33

7. Connect hose (34) to suction pipe (32). : 41 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft) 8. Connect hoses (46) (2 used) to pump device (23) with split flanges (44) (4 used) and socket bolts (45) (8 used). : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 9. Connect hoses (39) (4 used) to pilot pump (37). : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

34

WCEB-02-04-009

23

44

37

45 46

WCEB-02-04-009

38

W2-4-8

UPPERSTRUCTURE / Pump Device 10. Install the cover (16) assembly to support (13) with sems bolts (43) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

43

16

WCJB-02-04-003

11. Install covers (41) (2 used) to support (13) and cover (16) with sems bolts (42) (5 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

13

41

42

16

36 24

12. Install clips (28) (3 used) to harness (27). Install clips (28) (3 used) to pump device (23) with socket bolts (26) (3 used). : 5 mm : 10 N⋅m (1 kgf⋅m, 7 lbf⋅ft) 13. Connect connectors (24) (7 used) to regulator (36) and pump device (23).

23

28 29

14. Connect hoses (29) (2 used) to pump device (23) with split flanges (31) (4 used) and socket bolts (30) (8 used). : 10 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

27

WCJB-02-04-004

26 29

30 31

23 24

WCEB-02-04-009

W2-4-9

UPPERSTRUCTURE / Pump Device 15. Connect hoses (39) (3 used) to filter (40). : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

35

16. Connect hoses (35) (2 used) to regulators (36) (2 used). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) WCJB-02-04-003

40

17. Connect hoses (18) (2 used) to filter (19). : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

18

18. Connect connector (17) to filter (19). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

17

19. Install clips (21) (2 used) to hoses (22) (4 used). Secure clips (21) (2 used) to cover (16) with sems bolts (20) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

39

36

19

18

16

20, 21 22

WCJB-02-04-003

W2-4-10

UPPERSTRUCTURE / Pump Device 20. Install bracket (7) to supports (13, 14) and cover (16) with sems bolts (12) (6 used) and sems bolts (15) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

7

12

14

13

12

7

WCJB-02-04-001

15

WCJB-02-04-002

16

21. Install cover (8) to supports (10, 11), cover (16) and bracket (7) with sems bolts (9) (6 used) and sems bolts (6) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

7

8

9

WCJB-02-04-003

10

11

9

WCJB-02-04-001

7 6 16

WCJB-02-04-003

W2-4-11

UPPERSTRUCTURE / Pump Device 22. Install cover (4) to main frame (5) with sems bolts (3) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

3

4

5

WCJB-02-04-007

23. Shut covers (2, 1). 2

WCJB-02-02-001

1

WCJB-02-02-002

W2-4-12

UPPERSTRUCTURE / Pump Device (Blank)

W2-4-13

UPPERSTRUCTURE / Pump Device DISASSEMBLY OF PUMP DEVICE 1

2

4

3

5

6

18

15 16 17

14 13

12 58

7

10

11 14

9

57

15

56 54

55

16 17

19

8 12

53 51

10

9

52 51

50 22

21

24

23

22

11

20

21 28

27 26 49

25

30 48

37

29 26 35

31

36

40

39

38

34

47 33

32

41 44 46 44

W2-4-14

43

42

45 WCEB-02-04-014

UPPERSTRUCTURE / Pump Device

68

67

66

69

72

71

70

73 74 71

65

75 60

62

63

64 63

60

61

69 62

68

60 62

82

59

78

63

76

81 63

60 60

83

61 60

59

77

62

79

82

80 60

72

83 WCEB-02-04-011

1 - Socket Bolt (4 Used) 2 - Right Regulator 3 - Socket Bolt (2 Used) 4 - Socket Bolt (2 Used) 5 - Socket Bolt (2 Used) 6 - Left Regulator 7 - O-Ring (4 Used) 8 - O-Ring (6 Used) 9 - Bearing Nut (2 Used) 10 - Bearing (2 Used) 11 - Ring (2 Used) 12 - Bearing (2 Used) 13 - Shaft 14 - Pin (2 Used) 15 - Center Shaft (2 Used) 16 - Spring (2 Used) 17 - Plunger (14 Used) 18 - Rotor (2 Used) 19 - Shaft 20 - Slide Ring 21 - O-Ring (2 Used)

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 -

Plug (2 Used) O-Ring Stopper Plug Retaining Ring (2 Used) Gear Gasket Gear Plug Elbow Plug O-Ring Gasket Socket Bolt (2 Used) Pipe Level Gauge Socket Bolt (2 Used) Spring Washer (2 Used) Washer (2 Used) Pilot Pump Retaining Ring

43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 -

W2-4-15

Retaining Ring Ball Bearing (2 Used) Gear Gear Shaft Retaining Ring Oil Seal Gear Casing Spring Pin (2 Used) Oil Seal (2 Used) Retaining Ring (2 Used) Pump Casing Spring Washer (6 Used) Bolt (6 Used) Spring Pin (2 Used) O-Ring (2 Used) O-Ring (2 Used) Pin (2 Used) Retaining Ring (12 Used) Pin (2 Used) Lever (4 Used) Pin (4 Used)

64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 -

Right Valve Plate Backup Ring O-Ring Spring Pin (2 Used) Pressure Sensor (2 Used) O-Ring (2 Used) Selector Head O-Ring (4 Used) Socket Bolt (16 Used) Stopper S (2 Used) O-Ring (2 Used) Socket Bolt (12 Used) Set Screw (2 Used) Servo Piston (2 Used) Pin (2 Used) O-Ring (2 Used) Stopper L (2 Used) Left Valve Plate Pin (4 Used) Link (2 Used)

UPPERSTRUCTURE / Pump Device 1

2

4

3

5

6 70

58

7 57

53

49

25 37 30

35

31

36

40

39

38

34 32 41

WCEB-02-04-013

W2-4-16

UPPERSTRUCTURE / Pump Device 7. Hoist the pump casing (53) assembly. Place the pump casing (53) assembly with gear casing (49) facing downward. Place the wooden block (80 mm (3.1 in) or more square) under gear casing (49).

Disassembly of Pump Device 1. Remove plug (25) from gear casing (49). : 17 mm 2. Remove plug (32) from gear casing (49). Drain off gear oil from gear casing (49). (Approx. 1.0 L, 0.3 US gal) : 22 mm 3. Remove socket bolts (1) (4 used) from right regulator (2). Raise right regulator (2) to the direction of selector head (70). Remove right regulator (2) from pump casing (53). : 8 mm 4. Remove socket bolts (3) (2 used) and socket bolts (5) (2 used) from left regulator (6). Raise left regulator (6) to the direction of selector head (70). Remove left regulator (6) from pump casing (53). Do not remove socket bolt (4). : 8 mm 5. Remove O-rings (7) (4 used) and O-rings (57, 58) (2 used for each) from pump casing (53).

8. Remove socket bolts (35) (2 used) from pipe (36). Remove level gauge (37), pipe (36) and gasket (34) from gear casing (49). : 6 mm 9. Remove socket bolts (38) (2 used), spring washers (39) (2 used) and washers (40) (2 used) from pilot pump (41). Tap the flange of pilot pump (41) by using a plastic hammer and remove pilot pump (41) from gear casing (49). : 8 mm NOTE: THREEBOND has been applied onto the mounting surface of pilot pump (41). 10. Remove plug (30) and elbow (31) from gear casing (49). : 30 mm

CAUTION: The pump casing (53) assembly weight: 160 kg (360 lb) CAUTION: When hoisting the pump casing (53) assembly, turn to the gear casing (49) side and do not take pump casing (53) off the ground. 6. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to the thread hole for socket bolts (1, 3) of pump casing (53). Attach a nylon sling onto eyebolts (2 used).

W2-4-17

UPPERSTRUCTURE / Pump Device 16

8

16

53

72

68 66 65

69

70

73

71

74 71 75

69 68

79 80 72

WCEB-02-04-012

W2-4-18

UPPERSTRUCTURE / Pump Device 11. Remove the pressure sensors (68) (2 used) assembly from selector head (70). : 27 mm 12. Remove socket bolts (72) (16 used) from stoppers S (73) (2 used) and stoppers L (80) (2 used). Remove stoppers S (73) (2 used) and stoppers L (80) (2 used) from selector head (70). : 6 mm NOTE: O-rings (74, 79) are installed to stopper S (73) and stopper L (80). If it is difficult to remove the stopper, tap the outer periphery of the stopper. Turn the stopper until about half of the hole for the mounting bolt can be seen. Insert a screwdriver into the mounting bolt hole. Remove the stopper by using a screwdriver.

15. Record the clearance between pump casing (53) and selector head (70). Remove socket bolts (75) (12 used) from selector head (70). : 10 mm NOTE: While loosening socket bolt (75), selector head (70) will push out due to the force of spring (16).

CAUTION: Selector head (70) weight: 28 kg (62 lb) 16. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the bolt hole on the upper surface of selector head (70). Hoist and remove selector head (70) from pump casing (53). O-ring (66) may be removed with the lower surface of selector head (70) attached. Check O-ring (66). 17. Remove O-rings (8) (6 used), O-ring (66) and backup ring (65) from pump casing (53).

Stopper

W178-02-11-082

13. Remove O-rings (71) (4 used) from selector head (70). 14. Remove O-rings (74, 79) (2 used for each) from stoppers S (73) (2 used) and stoppers L (80) (2 used).

W2-4-19

UPPERSTRUCTURE / Pump Device 15

18

16 17

13

54

15

55

16 17

19

53

50

28

27 49

70

29

62

60

63

75

64 63

60

61

62

60 62

82

59

78

63

76

81 63

60 60

83

61 60

59

62

77

82 60

83 WCEB-02-04-012

W2-4-20

UPPERSTRUCTURE / Pump Device 18. Warm up set screws (76) (2 used) by using a drier. Remove set screws (76) (2 used) from servo pistons (77) (2 used). Remove pins (78) (2 used) from servo pistons (77) (2 used). : 6 mm 19. Remove servo pistons (77) (2 used) from selector head (70). 20. Both right valve plate (64) and left valve plate (81) are very similar and their installing directions are determined. Record the position and the direction of right valve plate (64) and left valve plate (81) before removing. Remove retaining rings (60) (4 used) from pins (63) (4 used). Remove right valve plate (64) and left valve plate (81) from links (83) (2 used). Do not remove pins (63) (4 used) unless necessary.

CAUTION: Pump casing (53) weight: 105 kg (240 lb) 24. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the socket bolt (75) hole on pump casing (53). Hoist and remove pump casing (53) from gear casing (49). Shafts (13, 19) and gears (27, 29) are removed with pump casing (53) together. Place pump casing (53) with the mounting surface for the regulator facing upward. 25. Remove spring pins (50) (2 used) and gasket (28) from gear casing (49).

21. Remove rotor (18), spring (16), the center shaft (15) assembly and plungers (17) (7 used) from pump casing (53) in this order. (Both right and left pumps) NOTE: When removing plunger (17), turn plunger (17) inside and remove plunger (7). IMPORTANT: As the pump performance may be changed, do not deform link (83). 22. Remove the link (83) assemblies (2 used) from pump casing (53). Do not disassemble the link (83) assembly unless necessary. NOTE: If it is difficult to remove the link (83) assembly, use a screwdriver. 23. Remove bolts (55) (6 used) and spring washer (54) from pump casing (53). : 24 mm

W2-4-21

UPPERSTRUCTURE / Pump Device

13 12 10

19

53

12 10

21

24

23

22

21

22 27 26 70

26

29

WCEB-02-04-012

W2-4-22

UPPERSTRUCTURE / Pump Device 26. Put the matching marks on the meshed position of splines on shafts (13, 19) and gears (27, 29). Put the matching marks on the meshed position of gears (27, 29). 27

13

CAUTION: Pump casing (53) weight: 70 kg (160 lb) 31. Attach a nylon sling onto pump casing (53). Hoist and place pump casing (53) on the wooden blocks with the pump transmission side facing downward. Use the wooden block: 100 mm (3.9 in) or more square.

29

32. Remove shafts (13, 19) from pump casing (53) by using special tools (ST 1470, ST 1471). Bearings (10, 12) are removed with shafts (13, 19) together.

19 W137-02-04-007

27. Remove retaining rings (26) (2 used) from shafts (13, 19). Remove gears (27, 29) from shafts (13, 19).

CAUTION: Pump casing (53) weight: 70 kg (160 lb) 28. Attach a nylon sling onto pump casing (53). Hoist and place pump casing (53) with the mounting side for selector head (70) facing downward. 29. Remove stoppers (24) (2 used) from pump casing (53). Remove O-rings (23) (2 used) from stoppers (24) (2 used). : 19 mm 30. Remove plugs (22) (2 used) from pump casing (53). Remove O-rings (21) (2 used) from plugs (22) (2 used). : 8 mm

W2-4-23

ST 1470 ST 1471

13 19

53

W178-02-04-054

UPPERSTRUCTURE / Pump Device

13

10

11

12

9

19

12

53

20 10

51

11

9

52 51

49

48 47

44 46 44

W2-4-24

43

42

45 WCEB-02-04-014

UPPERSTRUCTURE / Pump Device 33. Remove slide ring (20) from pump casing (53). 34. Remove bearing nuts (9) (2 used) from shafts (13, 19) by using special tool (ST 3058).

39. Remove ball bearing (44) and gear shaft (46) from the upper side of gear casing (49) by using special tool (ST 1393).

ST 3058

9

46 44

W137-02-04-023 W178-02-11-085

35. Remove bearings (10, 12) (2 used for each) and rings (11) (2 used) from shafts (13, 19) by using a press.

40. Remove gear (45) and ball bearing (44) from gear casing (49).

CAUTION: Pump casing (53) weight: 42 kg (93 lb)

41. Install a shackle to the bolt hole on the periphery of gear casing (49). Hoist and turn over gear casing (49) by using a nylon sling.

36. Attach a nylon sling onto pump casing (53). Hoist and place pump casing (53) with the mounting surface for the regulator facing upward.

42. Remove retaining ring (47) and oil seal (48) from gear casing (49).

37. Remove retaining rings (52) (2 used) and oil seals (51) (2 used) from pump casing (53). 38. Remove retaining ring (42) from gear casing (49). Remove retaining ring (43) from gear shaft (46).

W2-4-25

UPPERSTRUCTURE / Pump Device ASSEMBLY OF PUMP DEVICE 81

66

65

18

16

15

17

12

20

11

10

9

51

29

26

19

52

13 26 27 64 72 73 71 74

60, 63 8

7

62 56

57

18

82

16

15

17

12

61

60

59

58

67 22

21

83

14

11 10

9

51

53

70 79

76

78 79 W178-02-11-086

80

72

W2-4-26

24

23

UPPERSTRUCTURE / Pump Device

38, 39, 40

41

32, 33

34, 35, 36 31

30

6

5

4

3

43

42

45

44

37 46 25

47

48 50 49 68

12345678910 11 12 13 14 15 16 17 18 19 20 21 -

Socket Bolt (4 Used) Right Regulator Socket Bolt (2 Used) Socket Bolt (2 Used) Socket Bolt (2 Used) Left Regulator O-Ring (4 Used) O-Ring (6 Used) Bearing Nut (2 Used) Bearing (2 Used) Ring (2 Used) Bearing (2 Used) Shaft Pin (2 Used) Center Shaft (2 Used) Spring (2 Used) Plunger (14 Used) Rotor (2 Used) Shaft Slide Ring O-Ring (2 Used)

75

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 -

2

Plug (2 Used) O-Ring Stopper Plug Retaining Ring (2 Used) Gear Gasket Gear Plug Elbow Plug O-Ring Gasket Socket Bolt (2 Used) Pipe Level Gauge Socket Bolt (2 Used) Spring Washer (2 Used) Washer (2 Used) Pilot Pump Retaining Ring

43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 -

W2-4-27

1

55

Retaining Ring Ball Bearing (2 Used) Gear Gear Shaft Retaining Ring Oil Seal Gear Casing Spring Pin (2 Used) Oil Seal (2 Used) Retaining Ring (2 Used) Pump Casing Spring Washer (6 Used) Bolt (6 Used) Spring Pin (2 Used) O-Ring (2 Used) O-Ring (2 Used) Pin (2 Used) Retaining Ring (12 Used) Pin (2 Used) Lever (4 Used) Pin (4 Used)

54

64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 -

28

WCEB-02-04-004

Right Valve Plate Backup Ring O-Ring Spring Pin (2 Used) Pressure Sensor (2 Used) O-Ring (2 Used) Selector Head O-Ring (4 Used) Socket Bolt (16 Used) Stopper S (2 Used) O-Ring (2 Used) Socket Bolt (12 Used) Set Screw (2 Used) Servo Piston (2 Used) Pin (2 Used) O-Ring (2 Used) Stopper L (2 Used) Left Valve Plate Pin (4 Used) Link (2 Used)

UPPERSTRUCTURE / Pump Device 43

42

44

45

44

32, 33

49 WCEB-02-04-004

12

11 10

19

13

12

W2-4-28

11 10

W178-02-11-089

UPPERSTRUCTURE / Pump Device Assembly of Pump Device 1. Tap and install ball bearing (44) into gear casing (49) with the stamped mark facing inside by using a bar and hammer. Tap and listen to ring in order to check that ball bearing (44) is installed completely. 2. Place gear (45) on ball bearing (44). Insert gear shaft (46) while aligning with the spline.

CAUTION: Be careful as bearing (10) is too hot. 9. Apply hydraulic oil onto the inside of bearings (10) (2 used). Install bearings (10) (2 used) to shafts (13, 19) by using a press.

3. Tap and install ball bearing (44) into gear shaft (46) with the stamped mark facing outside by using a bar and hammer. Tap and listen to ring in order to check that ball bearing (44) is installed completely. 4. Install retaining ring (42) to gear casing (49). Install retaining ring (43) to gear shaft (46). 5. Install O-ring (33) to plug (32). Install plug (32) to gear casing (49). : 22 mm : 70 N⋅m (7 kgf⋅m, 52 lbf⋅ft) 6. Warm up bearings (10, 12) (2 used for each) to 50 to 80 °C (122 to 176 °F). CAUTION: Be careful as bearing (12) is too hot. 7. Apply hydraulic oil onto the inside of bearings (12) (2 used). Install bearings (12) (2 used) to shafts (13, 19) by using a press. 8. Install rings (11) (2 used) to shafts (13, 19).

W2-4-29

UPPERSTRUCTURE / Pump Device

WCEB-02-04-004

53

12

20

10

9

19

13

12

W2-4-30

10

9

W178-02-11-089

UPPERSTRUCTURE / Pump Device 10. Set the pre-loads of bearings (10, 12) installed on shaft (13) according to the following procedures. • Apply hydraulic oil onto the thread part of bearing nut (9). Tighten bearing nut (9) until bearing nut (9) comes in contact with bearing (10) by using special tool (ST 3058). ST 3058

9

10

W178-02-11-090

• Install special tool (ST 3070) to bearing (10). Rotate 2 to 3 turns and measure the starting torque. ST 3070

10

W178-02-11-091

• Adjust bearing nut (9) until the starting torque reaches specification. : 1.96±0.49 N⋅m (0.20±0.05 kgf⋅m, 1.45±0.36 lbf⋅ft) NOTE: If the starting torque is higher than the limit of specified torque, loosen bearing nut (9). Tap the shaft end and release the load of bearing (10). 11. Set the pre-loads of bearings (10, 12) installed on shaft (19) in the same way as step 10. 12. Install slide ring (20) to the side to insert shaft (19) in pump casing (53).

W2-4-31

UPPERSTRUCTURE / Pump Device 53

12

10

51

19

52

13

51 Regulator Mounting Surface

24

W2-4-32

53

23

W178-02-11-092

UPPERSTRUCTURE / Pump Device 13. Warm up pump casing (53) to 50 to 80 °C (122 to 176 °F). 14. Apply hydraulic oil onto the outside of bearings (10, 12) installed on shaft (19). Install shaft (19) to pump casing (53) by using special tool. If it is difficult to insert shaft (19), tap shaft (19) by using a bar.

19. Install special tools (ST 2649, ST 2650) over the spline parts of shafts (13, 19). NOTE: If special tools are not available, wind the vinyl tape over the spline part of the shaft in order not to damage oil seal (51).

Special Tool

ST 2650

51 M8, Pitch 1.25 mm

53 19 W178-02-11-094

ST 2649 Wooden Block

Wooden Block

W178-02-11-093

20. Apply grease onto the inside of oil seals (51) (2 used). Evenly tap and install oil seals (51) (2 used) to shafts (13, 19).

15. Install shaft (13) to pump casing (53) in the same way as step 14.

21. Remove special tools (ST 2649, ST 2650) from shafts (13, 19).

16. Wait for pump casing (53) in order to cool down to the temperature lower than 40 °C (104 °F).

22. Install retaining rings (52) (2 used) to pump casing (53).

17. Install O-ring (23) to stopper (24). Install stopper (24) to pump casing (53). : 19 mm : 34.5 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)

CAUTION: Pump casing (53) weight: 65 kg (150 lb) 18. Attach a nylon sling onto pump casing (53). Hoist and place pump casing (53) with the mounting surface for the regulator facing upward.

W2-4-33

UPPERSTRUCTURE / Pump Device 45

50

49 WCEB-02-04-004

75

53

55

54

28

29

53

26

19

13

26

17

W2-4-34

27

W178-02-11-096

UPPERSTRUCTURE / Pump Device 23. Align the matching marks and install gears (27, 29) to shafts (13, 19). Install retaining rings (26) (2 used) to shafts (13, 19). When replacing the shaft and the gear, install the gear according to the following procedure. • Secure special tool (ST 7934) to the plunger (17) mounting side of shafts (13, 19). 19 ST 7934

13

M8, Pitch 1.25 mm

CAUTION: Pump casing (53) weight: 70 kg (160 lb) 25. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the socket bolt (75) hole on pump casing (53). Hoist pump casing (53). While engaging gear (45) with gear (29), install pump casing (53) to gear casing (49) with bolts (55) and spring washers (54) (6 used for each). : 24 mm : 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)

W178-02-11-097

• Turn shafts (13, 19) clockwise, viewed from the

• •

• •

mounting side for gears (27, 29), until shafts (13, 19) come into contact with special tool. (Remove a play in periphery direction.) Install gear (27) and retaining ring (26) to the spline of shaft (13). Insert gear (29) into the spline of shaft (19) and engage with gear (27). If gear (29) does not engage, turn and adjust shaft (19) in a play range of special tool. Install retaining ring (26) to the spline of shaft (19). Remove special tool (ST 7934).

24. Install spring pins (50) (2 used) to gear casing (49). Install gasket (28).

W2-4-35

UPPERSTRUCTURE / Pump Device 34, 35, 36 38, 39, 40

41

41

38

39, 40

49 WCEB-02-04-004

62

83

15

14

17

53

70

19

13

62

59, 61

83

15

14

W2-4-36

17

W178-02-11-096

UPPERSTRUCTURE / Pump Device 26. Apply THREEBOND #1215 onto the mounting surface of pilot pump (41). Install pilot pump (41) to gear casing (49) with socket bolts (38), spring washers (39) and washers (40) (2 used for each). : 8 mm : 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 27. Install gasket (34) and pipe (36) to gear casing (49) with socket bolts (35) (2 used). : 6 mm : 19.5 N⋅m (2 kgf⋅m, 14 lbf⋅ft)

30. Insert plungers (17) (7 used for each) into shafts (13, 19). 31. Apply grease onto pins (14) (2 used). Install pin (14) to center shafts (15) (2 used). 32. Apply grease onto the spherical surface of center shafts (15) (2 used). Install center shafts (15) (2 used) to shafts (13, 19).

IMPORTANT: As the pump performance may be changed, do not deform link (83). 28. Align with the groove for pin (59) on pump casing (53) and install the link (83) assemblies (2 used) with lever (62) facing to the selector head (70) side. NOTE: Both surfaces of pin (59) are parallel to each other. Align the parallel surface with the groove. 83

59

61

53

Parallel Surface

Parallel Surface

W178-02-11-098

29. Apply hydraulic oil onto the plunger (17) mounting surface of shafts (13, 19).

W2-4-37

UPPERSTRUCTURE / Pump Device 60

62

16 79 18 15

14

17

53

63

81

64

60, 63 8

65

62 18

83 16 15 14 17

18

W178-02-11-099

53

19

70

67

14

W2-4-38

W178-02-04-016

UPPERSTRUCTURE / Pump Device 33. Install springs (16) (2 used) to center shafts (15) (2 used).

38. Install backup ring (65), O-ring (66) and O-rings (8) (6 used) to pump casing (53).

34. Insert center shafts (15) (2 used) and plungers (17) (14 used) into rotors (18) (2 used).

39. Install spring pins (67) (2 used) to pump casing (53).

35. Insert the round file into the center hole on center shaft (15). While rotating center shaft (15) by using the round file, insert pin (14) into the groove of rotor (18). (Both right and left pumps) NOTE: If pin (14) does not enter into the groove on rotor (18), selector head (70) cannot be installed to pump casing (53). 36. Insert pins (63) (2 used) of right valve plate (64) into the hole on levers (62) (2 used) for right regulator (2). Install retaining rings (60) (2 used). Check the direction to install right valve plate (64). 81

64 Upward

W178-02-11-100

37. Insert pins (63) (2 used) of left valve plate (81) into the hole on levers (62) (2 used) for left regulator (6). Install retaining rings (60) (2 used). Check the direction to install left valve plate (81).

W2-4-39

UPPERSTRUCTURE / Pump Device

Eyebolt Mounting Hole

75

WCEB-02-04-004

70

72

71

73

74

75

18

53

70 77

76

78 Mounting Surface for Suction Pipe W178-02-04-016

79

72

64, 81

80

67

14

W2-4-40

UPPERSTRUCTURE / Pump Device 40. Apply hydraulic oil onto servo pistons (77) (2 used). Insert servo pistons (77) (2 used) into selector head (70). 41. Apply LOCTITE LI829 onto the thread part of set screws (76) (2 used). Install pins (78) (2 used) to servo pistons (77) (2 used) with set screws (76) (2 used). : 6 mm : 34.3 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)

CAUTION: Selector head (70) weight: 29 kg (64 lb)

45. Install O-rings (74) (2 used) to stoppers S (73) (2 used). Apply grease onto O-rings (74) (2 used). Install stoppers S (73) (2 used) to selector head (70) with socket bolts (72) (8 used). : 6 mm : 19.5 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft) 46. Install O-rings (79) (2 used) to stoppers L (80) (2 used). Apply grease onto O-rings (79) (2 used). Install stoppers L (80) (2 used) to selector head (70) with socket bolts (72) (8 used). : 6 mm : 19.5 N⋅m (2 kgf⋅m, 14 lbf⋅ft)

42. Install eyebolts (M12, Pitch 1.75 mm) (2 used) into the thread hole for the suction pipe on selector head (70). Attach a nylon sling onto eyebolts (2 used). Hoist selector head (70). Place selector head (70) on pump casing (53) while aligning selector head (70) with spring pin (67). NOTE: Check the clearance between selector head (70) and pump casing (53) in order to compare with the clearance before disassembling. If the clearance is larger, pin (14) may not be inserted into the groove on rotor (18), or pin (78) may not be inserted into the holes on valve plates (64, 81). 43. Install selector head (70) to pump casing (53) with socket bolts (75) (12 used). : 10 mm : 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft) 44. Install O-rings (71) (4 used) to selector head (70).

W2-4-41

UPPERSTRUCTURE / Pump Device

47

19 48

49 WCEB-02-04-004

53

7

56

57

61

58 5

83

W2-4-42

6

3

2

1

WCEB-02-04-015

UPPERSTRUCTURE / Pump Device 47. Install O-rings (58) (2 used), O-rings (57) (2 used), O-rings (7) (4 used) and spring pins (56) (2 used) to pump casing (53). 48. Install right regulator (2) to pump casing (53) according to the following procedure. • Adjust the sleeve position so that two grooves in both sleeves on right regulator (2) are in a line. • Place right regulator (2) on pump casing (53). Insert pin (61) for link (83) into two grooves on the sleeve. • Move right regulator (2) so that spring pin (56) out of pump casing (53) can enter into right regulator (2). • Install right regulator (2) to pump casing (53) with socket bolts (1) (4 used). : 8 mm : 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

CAUTION: Pump device weight: 160 kg (360 lb) 50. Hoist and place selector head (70) with the regulator mounting side facing upward. 51. Insert special tool (ST 2650) to shaft (19). Apply grease onto oil seal (48). Install oil seal (48) to shaft (19). Remove special tool (ST 2650). Tap and install oil seal (48). NOTE: If special tool (ST 2650) is not available, wind the vinyl tape over the spline parts of shaft (19) in order to protect oil seal (48). Install oil seal (48). ST 2650

61

53

48

Sleeve

2

83

56

W178-02-11-101

49. Install left regulator (6) to pump casing (53) with socket bolts (3) (2 used) and socket bolts (5) (2 used) in the same way as step 48. : 8 mm : 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

W178-02-11-103

52. Install retaining ring (47) to gear casing (49).

W2-4-43

UPPERSTRUCTURE / Pump Device

31

30

37

36

25

49

WCEB-02-04-004

68

W178-02-04-016

W2-4-44

UPPERSTRUCTURE / Pump Device 53. Wind the seal tape onto elbow (31). Install elbow (31) to gear casing (49). Add engine oil (1.0 L, 0.3 US gal) through the elbow (31) hole. 54. Wind the seal tape onto plug (30). Install plug (30) to elbow (31). : 30 mm : 39.5 N⋅m (4 kgf⋅m, 29 lbf⋅ft) 49

30

31

W1V1-02-04-010

IMPORTANT: The breather hole of plug (25) is located at the left side, viewed from the front of gear casing (49). 55. Wind the seal tape onto plug (25). Install plug (25) to gear casing (49). : 17 mm : 39.5 N⋅m (4 kgf⋅m, 29 lbf⋅ft) 56. Insert level gauge (37) into pipe (36). 57. Install pressure sensors (68) (2 used) to selector head (70). : 27 mm : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)

W2-4-45

UPPERSTRUCTURE / Pump Device DISASSEMBLY OF REGULATOR

Left Regulator

1

2

Right Regulator

13

3

WCEB-02-04-016

9

10

11

14

12

15

4 16 17 6

5

7 8

24

20

23 22

19

18

28

21

25 29

26

30

32

31

34

27 37 28

39

36

33

35

38

40 41 WCEB-02-04-019

42

12345678910 11 -

Pipe Socket Bolt (2 Used) Solenoid Valve O-Ring Low Pressure Sensor O-Ring O-Ring O-Ring Piston O-Ring Backup Ring

12 13 14 15 16 17 18 19 20 21 22 -

Cylinder O-Ring Piston Sleeve Spool Spring Spring O-Ring Stopper O-Ring Adjuster

23 24 25 26 27 28 29 30 31 32 -

W2-4-46

Lock Nut Lock Nut Cover Set Bolt Lock Nut Socket Bolt (8 Used) O-Ring Cylinder Piston Casing

33 34 35 36 37 38 39 40 41 42 -

Lock Nut Lock Nut Cover Adjuster O-Ring Stopper O-Ring Spring Spool Sleeve

UPPERSTRUCTURE / Pump Device Disassembly of Regulator • The regulators are used for right pump and left pump. The inner structure in the regulator is fully identical, and the difference is only in its accessories. Here the left regulator is explained. IMPORTANT: As the setting changes, do not disassemble adjusting screws (23, 24, 26, 27, 33 and 34). When adjusting screws (23, 24, 26, 27, 33 and 34) must be disassembled, carry out adjustment according to the procedure of performance test after assembling.

IMPORTANT: As the setting changes, do not turn lock nuts (33, 34). 4. Remove socket bolts (28) (4 used) from cover (35). Remove cover (35) and piston (14) from casing (32). The stopper (38) assembly is removed with cover (35) together. : 6 mm 5. Remove springs (17, 18) from casing (32). 6. Insert a round bar into the hole on casing (32). Push the spool (16) end. Remove cylinder (12), sleeve (15) and spool (16) from casing (32). Piston (9) is removed with cylinder (12) together. 7. Remove piston (9) from cylinder (12).

1. Clamp casing (32) in a vise. Remove pipe (1) from casing (32). : 22 mm 2. Remove socket bolts (2) (2 used) from solenoid valve (3). Remove the solenoid valve (3) assembly and O-rings (6, 7, 8) from casing (32). : 8 mm

8. Remove spring (40) from casing (32). 9. Insert a round bar into the hole on casing (32). Push the spool (41) end. Remove cylinder (30), sleeve (42) and spool (41) from casing (32). Piston (31) is removed with cylinder (30) together. 10. Remove piston (31) from cylinder (30).

IMPORTANT: As the setting changes, do not turn set bolt (26), lock nuts (23, 24 and 27). 3. Remove socket bolts (28) (4 used) from cover (25). Remove cover (25) from casing (32). Set bolt (26) and the stopper (20) assembly are removed with cover (25) together. : 6 mm

W2-4-47

UPPERSTRUCTURE / Pump Device ASSEMBLY OF REGULATOR 2

3, 6, 7, 8 4, 5

1

WCEB-02-04-016

24

23

22 19

21

20

18

17

15

16 32

9

10 11

12

13

14

35

26 38 27 28

WCEB-02-04-017

25

29

1 - Pipe 2 - Socket Bolt (2 Used) 3 - Solenoid Valve 4 - O-Ring 5 - Low Pressure Sensor 6 - O-Ring 7 - O-Ring 8 - O-Ring 9 - Piston 10 - O-Ring 11 - Backup Ring

30

12 13 14 15 16 17 18 19 20 21 22 -

31

Cylinder O-Ring Piston Sleeve Spool Spring Spring O-Ring Stopper O-Ring Adjuster

41

42

23 24 25 26 27 28 29 30 31 32 -

W2-4-48

40

37

Lock Nut Lock Nut Cover Set Bolt Lock Nut Socket Bolt (8 Used) O-Ring Cylinder Piston Casing

39

33 34 35 36 37 38 39 40 41 42 -

34

Lock Nut Lock Nut Cover Adjuster O-Ring Stopper O-Ring Spring Spool Sleeve

36 33

UPPERSTRUCTURE / Pump Device Assembly of Regulator IMPORTANT: Two holes for sleeves (15, 42) on casing (32) are the same bores. The shapes of various parts in casing (32) are very similar. Check the illustration and assemble the regulator. 1. Clean all parts and apply hydraulic oil. 2. Insert spool (41) into sleeve (42). Install sleeve (42) to the center of casing (32) by using a round bar. Check the direction to install sleeve (42), spool (41) and piston (31). 3. Install O-ring (29) to cylinder (30). 4. Insert piston (31) into cylinder (30). Install cylinder (30) to casing (32). 5. Insert spool (16) into sleeve (15). Install sleeve (15) to the center of casing (32) by using a round bar. Check the direction to install sleeve (15) and spool (16). 6. Install O-rings (10, 13) and backup ring (11) to cylinder (12).

9. Install O-ring (37) and spring (40) to the stopper (38) assembly with cover (35) attached. Install cover (35) to casing (32) with socket bolts (28) (4 used). : 6 mm : 19.6 N⋅m (2 kgf⋅m, 14 lbf⋅ft) 10. Install O-ring (21) and springs (17, 18) to the stopper (20) assembly with cover (25) attached. Install cover (25) to casing (32) with socket bolts (28) (4 used). : 6 mm : 19.6 N⋅m (2 kgf⋅m, 14 lbf⋅ft) 11. Apply grease onto O-rings (6, 7 and 8). Install O-rings (6, 7 and 8) to solenoid valve (3). Install solenoid valve (3) to casing (32) with socket bolts (2) (2 used). : 8 mm : 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 12. Apply grease onto the thread part of pipe (1). Install pipe (1) to casing (32). : 22 mm : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)

7. Insert piston (9) into cylinder (12). Install cylinder (12) to casing (32). 8. Install piston (14) to cover (35) from the mounting side for casing (32).

W2-4-49

UPPERSTRUCTURE / Pump Device STRUCTURE OF PILOT PUMP

9 8 6 3

1

2

7

2

4

3

5

6

1

10 11 12

13

3

1

2

6

7 14 2

6

3

1 15 17

WCEB-02-04-018

16

3

3

3

9

15

13

5

17 16 14

4

8

1

2

7

10

12

7

1

W2-4-50

2

WCEB-02-04-010

UPPERSTRUCTURE / Pump Device

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part Name Plate Seal Backup Ring Side Plate Rear Drive Gear Driven Gear Kmock Pin Gear Plate Cover Socket Bolt Coupling Stabilizer Center Plate Driven Gear Front Drive Gear Flange Oil Seal Retaining Ring

Q’ty

Wrench Size (mm)

4 4 4 1 1 8 2 1 4 1 2 1 1 1 1 1 1

W2-4-51

Tightening Torque N⋅m (kgf⋅m, lbf⋅ft)

Remark

UPPERSTRUCTURE / Pump Device (Blank)

W2-4-52

UPPERSTRUCTURE / Control Valve REMOVAL AND CONTROL VALVE

INSTALLATION

OF

CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Open cover (3).

1

2

3

2

4

2. Remove sems bolts (2) (4 used) from cover (4). Remove cover (4) from bracket (1). : 17 mm

WCJB-02-01-002

5

3. Disconnect hoses (5) (3 used) from piping (6). Cap the open ends. : 19 mm, 27 mm, 50mm

6

4. Remove signal control valve (7) from bracket (8). (Refer to REMOVAL AND INSTALLATION OF SIGNAL CONTROL VALVE on W2-9-1.)

7

5. Remove 4-spool solenoid valve unit from control valve (9). (Refer to REMOVAL AND INSTALLATION OF 4-SPOOL SOLENOID VALVE UNIT on W2-11-1.) 6. Disconnect all connectors, hoses and pipings from control valve (9). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 17 mm, 19 mm, 22 mm, 36 mm : 8 mm

W2-5-1

10

9

8

WCJB-02-05-001

UPPERSTRUCTURE / Control Valve Eyebolt Mounting Hole

Eyebolt Mounting Hole

CAUTION: The control valve (9) assembly weight: 238 kg (560 lb)

9

7. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to control valve (9). Attach a nylon sling onto eyebolts. Hoist and hold control valve (9).

WCJB-02-05-022

8. Remove bolts (12) (4 used) and washers (11) (4 used) from brackets (13, 16). Hoist and remove the control valve (9) assembly from the main frame. : 24 mm CAUTION: Control valve (9) weight: 216 kg (480 lb) 9. While holding the control valve (9) assembly, remove bolts (15) (4 used) and spacers (14) (4 used) from brackets (13, 16). Remove brackets (13, 16) from control valve (9). : 24 mm

9

12 11

12 11

16 14 15

13 14 15 WCJB-02-05-002

W2-5-2

UPPERSTRUCTURE / Control Valve Eyebolt Mounting Hole

Installation

Eyebolt Mounting Hole

9

CAUTION: Control valve (9) weight: 216 kg (480 lb) 1. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to control valve (9). Attach a nylon sling onto the eyebolt. Hoist and hold control valve (9).

WCJB-02-05-022

2. Install brackets (13, 16) to control valve (9) with bolts (15) (4 used) and spacers (14) (4 used). : 24 mm : 210 N⋅m (21.5 kgf⋅m, 165 lbf⋅ft)

9

12 11

11

CAUTION: The control valve (9) assembly weight: 238 kg (560 lb) 16

3. Hoist and align the control valve (9) assembly with the mounting hole on the main frame. Install the control valve (9) assembly to the main frame with bolts (12) (4 used) and washers (11) (4 used). : 24 mm : 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)

W2-5-3

12

14 15

13 14 15 WCJB-02-05-002

UPPERSTRUCTURE / Control Valve 4. Connect all connectors, hoses and pipings to control valve (9). : 17 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 40 N⋅m (4 kgf⋅m, 30 lbf⋅ft) : 36 mm : 180 N⋅m (18 kgf⋅m, 133 lbf⋅ft) : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

9

WCJB-02-05-001

5. Install the 4-spool solenoid valve unit to control valve (9). (Refer to REMOVAL AND INSTALLATION OF 4-SOOL SOLENOID VALVE on W2-11-1.) 6. Install signal control valve (7) to control valve (9). (Refer to REMOVAL AND INSTALLATION OF SIGNAL CONTROL VALVE on W2-9-1.)

7

8

10

WCJB-02-05-001

9

5

6

7. Connect hoses (5) (3 used) to piping (6). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) : 50 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

WCJB-02-05-001

W2-5-4

UPPERSTRUCTURE / Control Valve 8. Install cover (4) to bracket (1) with sems bolts (2) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

1

2

3

2

4

9. Shut cover (3).

WCJB-02-01-002

W2-5-5

UPPERSTRUCTURE / Control Valve DISASSEMBLY OF CONTROL VALVE 4-SPOOL SIDE 6 5 3

4

Check Valve (Arm Regenerative Circuit)

2

7

13

6

12

8

11

10 9

4

3

1

14 11

12 15

16

15 17 18

19 8 11

42 48

7

15

12

43

44

45

20

21

17

22

43

35

44

45

24

26

27

28

Boom Anti-Drift Valve

29

30

23

36

46

37

47

49

25

38

39

31

32

33

34

6 40

51

39

50 39

39

40 39

52 53

39 40

Bucket

39

40 52 54

55

56

39

Arm (2)

57 58

Boom (1)

41 59

Travel

41

41

41 59 63

Arm Regenerative Valve

4

60

62 61 WCJB-02-05-003

W2-5-6

UPPERSTRUCTURE / Control Valve 68 69 4

70

63 67

63

Flow Combiner Valve

71

72 71

67

63

73

67

59 59 59

63

16 15

74

1 66

65

15

74

64

15

59 Bypass Shut-Out Valve

103 104

106

4

107

11 11 11

105

12

108

12

6

12

Arm 2 Flow Rate Control Valve (Switch Valve)

113

99

109

87

114 115 116

117

115 116

122

77

77 119

117

118 120 121

123 124

Bucket Flow Rate Control Valve

100 101 102 87 77 18

110 111 112

127

75

85 86 87 88 89 77

78 18

Boom Anti-Drift Valve

84

18

128 129 90 121 91 120 125 126 116 121 120 115 117 98

76 83

82

77 18 78

92 93

79 94

80 95

96

81 97 6

98 WCJB-02-05-004

W2-5-7

UPPERSTRUCTURE / Control Valve 12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 -

Housing Poppet Spring (2 Used) O-Ring (4 Used) Flange Socket Bolt (13 Used) Plug (2 Used) O-Ring (2 Used) Poppet Spring O-Ring (6 Used) Plug (6 Used) Flange Poppet O-Ring (6 Used) Valve (2 Used) Overload Relief Valve (2 Used) O-Ring (12 Used) O-Ring Spring Seat Poppet Backup Ring O-Ring O-Ring Backup Ring Sleeve Spool O-Ring Body Spring Poppet O-Ring

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 -

Plug Spool O-Ring Backup Ring Plug Spring Seat (8 Used) Spring (4 Used) Bolt (4 Used) Plug Backup Ring (2 Used) O-Ring (2 Used) Spring (2 Used) Poppet Spool Plug Poppet Spool Spool Spring Seat (2 Used) Spring Spool O-Ring Backup Ring Spool Spring O-Ring (8 Used) O-Ring Plug Cap Socket Bolt (14 Used) Cap O-Ring

66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 -

W2-5-8

Plug Cap (3 Used) Socket Bolt (2 Used) Cap Bolt Spring Seat (2 Used) Spring Spool Overload Relief Valve (2 Used) Poppet Spring O-Ring (5 Used) O-Ring (2 Used) Body O-Ring Plug O-Ring Plug Poppet Poppet Spring Plug Spring (3 Used) Sleeve Plug O-Ring Body Spool Spring Spring Seat O-Ring Plug

98 - Socket Bolt (12 Used) 99 - Poppet 100 - Poppet 101 - Spring 102 - Plug 103 - Spool 104 - Spring 105 - Flange 106 - O-Ring 107 - Cap 108 - Socket Bolt (4 Used) 109 - Poppet 110 - Poppet 111 - Spring 112 - Plug 113 - Poppet 114 - Spring 115 - Plug (3 Used) 116 - O-Ring (3 Used) 117 - Spring Seat (3 Used) 118 - Spring 119 - Spool 120 - Plug (3 Used) 121 - O-Ring (3 Used) 122 - Spring 123 - Spool 124 - Body 125 - Spool 126 - Spring 127 - Plug 128 - Plug 129 - O-Ring

UPPERSTRUCTURE / Control Valve (Blank)

W2-5-9

UPPERSTRUCTURE / Control Valve 6 5 3

4

Check Valve (Arm Regenerative Circuit)

2 7

13

6

12

8 10

11

9

3

1

4

14 11

12 15

16

15 17 18 8 11

12

7

15

20

21

17

22

24

25

26

27

28

29

23

Boom Anti-Drift Valve

30

31

32

35

34

6

47 51

33

50

54

55

56

59 57

63

59

58 Arm Regenerative Valve

4

62

WCJB-02-05-003

W2-5-10

UPPERSTRUCTURE / Control Valve Disassembly of Control Valve 4-Spool Side

• Disassembly of Spool 1. Remove socket bolts (63) (6 used) from cap (62). Remove cap (62), O-rings (59) (4 used) and O-ring (4) from housing (1). : 8 mm 2. Put the matching marks on the spool (35, 47, 50, 51, 54) assemblies and housing (1). Remove the spool (35, 47, 50, 51) assemblies, spring (58) and the spool (54) assembly from housing (1). NOTE: Do not disassemble the spool (54) assembly unless necessary.

• Disassembly of Boom Anti-Drift Valve

• Disassembly of Overload Relief Valve (17) IMPORTANT: Do not disassemble the overload relief valve. When disassembling the overload relief valve, pressure must be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test) 7. Remove overload relief valves (17) (2 used) from housing (1). : 32 mm 8. Remove valve (16) from housing (1). : 32 mm

• Disassembly of Check Valve

3. Loosen plug (34) from body (30). : 38 mm 4. Remove socket bolts (6) (3 used) from body (30). Remove the body (30) assembly, O-rings (18) (6 used) and O-ring (29) from housing (1). : 8 mm 5. Remove piston (32) and spring (31) from body (30). 6. Remove the sleeve (27) assembly, seat (21) and spring (20) from housing (1). Remove backup rings (23, 26), O-rings (24, 25), poppet (22) and spool (28) from sleeve (27).

9. Remove plug (12), spring (10) and poppet (9) from housing (1). : 6 mm 10. Remove socket bolts (6) (2 used) from flange (5). Remove flange (5), O-ring (4), spring (3) and poppet (2) from housing (1). : 8 mm 11. Remove socket bolts (6) (2 used) from flange (13). Remove flange (13), O-ring (4), spring (3) and poppet (14) from housing (1). : 8 mm 12. Remove plugs (7, 12) (2 used for each) from housing (1). : 6 mm, 10 mm

W2-5-11

UPPERSTRUCTURE / Control Valve

42 48

43

44

45

43

44

35 45

36

46

37

47

49

38

39 40

51

39

50 39

39

40 39

52 53

39 40

Bucket

39

40 52

39

Arm (2)

Boom (1)

Travel

41

41

41

41

WCJB-02-05-003

W2-5-12

UPPERSTRUCTURE / Control Valve • Disassembly of Travel Spool (35)

• Disassembly of Boom 1 Spool (50)

13. Clamp spool (35) in a vise by using wooden pieces. Remove bolt (41), spring seat (39), spring (40) and spring seat (39) from spool (35). : 8 mm

17. Clamp spool (50) in a vise by using wooden pieces. Remove bolt (41), spring seat (39), spring (40) and spring seat (39) from spool (50). : 8 mm

• Disassembly of Bucket Spool (47)

18. Warm up the plug (48) part of spool (50) by using a drier. Remove plug (48) from spool (50) by using special tool (ST 5909). Remove O-ring (44) and backup ring (43) from plug (48).

14. Clamp spool (47) in a vise by using wooden pieces. Remove bolt (41), spring seat (39), spring (40) and spring seat (39) from spool (47). : 8 mm 15. Warm up the plug (42) part of spool (47) by using a drier. Remove plug (42) from spool (47) by using special tool (ST 5909). Remove O-ring (44) and backup ring (43) from plug (42). ST 5909

19. Remove spring (45) and poppet (49) from spool (50).

• Disassembly of Arm 2 Spool (51) 20. Clamp spool (51) in a vise by using wooden pieces. Remove bolt (41), spring seats (39, 52), springs (53, 40) and spring seats (52, 39) from spool (51). : 8 mm

W157-02-05-049

16. Remove spring (45) and poppet (46) from spool (47).

W2-5-13

UPPERSTRUCTURE / Control Valve 68 69 4 63

70

67

63

Flow Combiner Valve

71

72 71

67

63

73

67

59 59 59

63

16 15

74

1 66

65

15

74

64

15

59

Arm 2 Flow Rate Control Valve (Switch Valve)

113

99

109 110 111 112 87

114 115 116

77 119 117

115 116

122

117

118 120 121

123 124

100 101 102 87 77 18

77

Bucket Flow Rate Control Valve

84 85 86 87 88 89 77

78 18

127 18 128 129 90 121 91 120 125 126 116 121 120 115 117 98

92 93

94

95

96

97

98 WCJB-02-05-004

W2-5-14

UPPERSTRUCTURE / Control Valve 21. Remove socket bolts (63) (8 used) from caps (67) (3 used) and cap (64). Remove caps (67) (3 used), cap (64) and O-rings (59) (4 used) from housing (1). : 8 mm

• Disassembly of Flow Combiner Valve 22. Remove socket bolts (68) (2 used) from cap (69). Remove cap (69), O-ring (4) and the spool (73) assembly from housing (1). Remove bolt (70), spring seats (71) (2 used) and spring (72) from spool (73). : 5 mm

• Disassemble Overload Relief Valve IMPORTANT: Do not disassemble the overload relief valve. When disassembling the overload relief valve, pressure must be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test) 23. Remove overload relief valves (74) (2 used) from housing (1). : 32 mm

27. Remove sleeve (89), spring (88), plug (87), spring (86) and poppets (85, 84) from housing (1).

• Disassembly of Arm 2 Flow Rate Control Valve 28. Remove socket bolts (98) (8 used) from body (124). Remove body (124), O-rings (77) (3 used), O-rings (18) (2 used) (78) and plug (127) from housing (1). : 8 mm 29. Remove plugs (115) (3 used), spring seats (117) (3 used), springs (118, 122, 126) and spools (119, 123, 125) from body (124). : 24 mm 30. Remove plugs (120) (3 used) and plug (129) from body (124). 31. Remove poppet (113) and spring (114) from housing (1). 32. Remove the poppets (99, 109) assemblies and springs (87) (2 used) from housing (1). Remove plugs (102, 112), springs (101, 111) and poppets (100, 110) from poppets (99, 109).

24. Remove valve (16) from housing (1). : 32 mm

• Disassembly of Bucket Flow Rate Control Valve 25. Remove socket bolts (98) (4 used) from body (92). Remove body (92) and O-rings (18, 77) from housing (1). : 8 mm 26. Remove plug (97), spring seat (95), spring (94) and spool (93) from body (92). Remove plug (90) from body (92). : 27 mm

W2-5-15

UPPERSTRUCTURE / Control Valve

1

103

Bypass Shut-Out Valve

104

106

4

107

11 11 11

105

12

108

12

6

12

Boom Anti-Drift Valve

75 76 77 18 78 79

6

WCJB-02-05-004

W2-5-16

UPPERSTRUCTURE / Control Valve • Disassembly of Boom Anti-Drift Valve 33. Remove socket bolts (6) (4 used) from body (79). Remove body (79), O-rings (18) (3 used) and O-rings (78, 77) from housing (1). : 8 mm 34. Remove spring (76) and poppet (75) from housing (1).

• Disassembly of Bypass Shut-Out Valve 35. Remove socket bolts (6) (2 used) from flange (105). Remove flange (105) and O-ring (4) from housing (1). : 8 mm 36. Remove spring (104) and spool (103) from housing (1). 37. Remove socket bolts (108) (4 used) from cap (107). Remove cap (107) and O-ring (106) from housing (1). : 8 mm 38. Remove plugs (12) (3 used) from housing (1). : 8 mm

W2-5-17

UPPERSTRUCTURE / Control Valve ASSEMBLY OF 4-SPOOL SIDE

CONTROL

VALVE

B

63 60, 61

15, 16

15, 17

124 34

6

15, 17

63

1

59, 67

59, 62

63 59, 67

63

59, 64

1

65, 66 WCJB-02-05-006

Control Valve (Upper)

15, 17

79

6

A

Control Valve (Lower)

WCJB-02-05-005

15, 17

11, 12

9, 10, 11, 12

6

3, 4, 13, 14

6 105 92 11, 12

1

7, 8 106, 107

108

98

124

View A

15, 74

98

6

2, 3, 4, 5

1 WCJB-02-05-007

W2-5-18

View B

WCJB-02-05-008

UPPERSTRUCTURE / Control Valve

H

J I

G

F

E

D

C

1

7

8 A W1V1-02-05-038

J I

H

G

F

E

D

C

Section C-C (4-Spool Side)

WCJB-02-05-005

Control Valve (Upper)

Bucket

Travel

Boom 1

41 39

C

40 39

17 16

1

15

15

50

47 B

1 35

15 16 WCJB-02-05-020

Section D-D (4-Spool Side)

46

49

45

45

D

1 15

43, 44

15

43, 44

42

74

48

Section E-E (4-Spool Side)

W2-5-19

W1V1-02-05-036

74

Section F-F (4-Spool Side)

W1V1-02-05-028

UPPERSTRUCTURE / Control Valve

61

Arm 2

62

60 41 39

17

52 53 52

15

39

1

51

F

E

1 65 W1V1-02-05-029

Section G-G (4-Spool Side)

66 Section H-H (4-Spool Side)

W1V1-02-05-030

62 58 57

103

104

4 105

56, 55 54

107, 108 106

Section I-I (4-Spool Side)

W1V1-02-05-071

W2-5-20

Section J-J (4-Spool Side)

WCJB-02-05-021

UPPERSTRUCTURE / Control Valve

97

1

73

96 95 94 92 93

4 71 72

1

91

71

90 89

69 84

70

85

77 18

W1V1-02-05-033 W1V1-02-05-040

Detail A

86 87 88

Detail B

34 33 30 32

77

1

18

120

31 28

29

27

22

18 26 25 24 23 21 20

121 1 18 78

119 124

81

118

80

117 116

79

115

82 75

77

76

99 100 101

102

87

83 Detail C

78

W1V1-02-05-032

Detail D

W1V1-02-05-031

115

127

1

120

116 117

121

126 125

123 122 117 116

121 109

110 111

77 112

120 87 Detail E

115

124 W1V1-02-05-042

W2-5-21

113

114

77 Detail F

18

124 W1V1-02-05-034

UPPERSTRUCTURE / Control Valve 1 - Housing 2 - Poppet 3 - Spring (2 Used) 4 - O-Ring (4 Used) 5 - Flange 6 - Socket Bolt (13 Used) 7 - Plug (2 Used) 8 - O-Ring (2 Used) 9 - Poppet 10 - Spring 11 - O-Ring (6 Used) 12 - Plug (6 Used) 13 - Flange 14 - Poppet 15 - O-Ring (6 Used) 16 - Valve (2 Used) 17 - Overload Relief Valve (2 Used) 18 - O-Ring (12 Used) 19 - O-Ring 20 - Spring 21 - Seat 22 - Poppet 23 - Backup Ring 24 - O-Ring 25 - O-Ring 26 - Backup Ring 27 - Sleeve 28 - Spool 29 - O-Ring 30 - Body 31 - Spring 32 - Poppet 33 - O-Ring

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 -

Plug Spool O-Ring Backup Ring Plug Spring Seat (8 Used) Spring (4 Used) Bolt (4 Used) Plug Backup Ring (2 Used) O-Ring (2 Used) Spring (2 Used) Poppet Spool Plug Poppet Spool Spool Spring Seat (2 Used) Spring Spool O-Ring Backup Ring Spool Spring O-Ring (8 Used) O-Ring Plug Cap Socket Bolt (14 Used) Cap O-Ring

66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 -

W2-5-22

Plug Cap (3 Used) Socket Bolt (2 Used) Cap Bolt Spring Seat (2 Used) Spring Spool Overload Relief Valve (2 Used) Poppet Spring O-Ring (5 Used) O-Ring (2 Used) Body O-Ring Plug O-Ring Plug Poppet Poppet Spring Plug Spring (3 Used) Sleeve Plug O-Ring Body Spool Spring Spring Seat O-Ring Plug

98 - Socket Bolt (12 Used) 99 - Poppet 100 - Poppet 101 - Spring 102 - Plug 103 - Spool 104 - Spring 105 - Flange 106 - O-Ring 107 - Cap 108 - Socket Bolt (4 Used) 109 - Poppet 110 - Poppet 111 - Spring 112 - Plug 113 - Poppet 114 - Spring 115 - Plug (3 Used) 116 - O-Ring (3 Used) 117 - Spring Seat (3 Used) 118 - Spring 119 - Spool 120 - Plug (3 Used) 121 - O-Ring (3 Used) 122 - Spring 123 - Spool 124 - Body 125 - Spool 126 - Spring 127 - Plug 128 - O-Ring 129 - Plug

UPPERSTRUCTURE / Control Valve (Blank)

W2-5-23

UPPERSTRUCTURE / Control Valve

K

K

1

63

65, 66

WCJB-02-05-005

1

59, 67

63

Control Valve (Upper)

59, 67

63

59, 64

Control Valve (Lower)

Arm 2

Boom 1

Buckets

WCJB-02-05-006

Travel

41

39

41

39

52 40

40

53

39 52

1

39

47

51

35 50

49

46

45

45

43, 44

43, 44 59 63 64

59 67 65

66

63

48 Section K-K

W2-5-24

42

WCJB-02-05-009

UPPERSTRUCTURE / Control Valve Assembly of Control Valve 4-Spool Side

• Assembly of Travel Spool

• Assembly of Boom 1 Spool

1. Clamp spool (35) in a vise by using wooden pieces. Install spring seat (39), spring (40), spring seat (39) and bolt (41) to spool (35). : 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

• Assembly of Bucket Spool 2. Clamp spool (47) in a vise by using wooden pieces. Install poppet (46) and spring (45) to the lower side of spool (47). 3. Install O-ring (44) and backup ring (43) to plug (42). Apply LOCTITE #271 onto the thread part of plug (42). 4. Install plug (42) to spool (47) by using special tool (ST 5909). : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft) ST 5909

W157-02-05-049

5. Install spring seat (39), spring (40), spring seat (39) and bolt (41) to the upper side of spool (47). : 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

6. Clamp spool (50) in a vise by using wooden pieces. Install poppet (49) and spring (45) to the lower side of spool (50). 7. Install O-ring (44) and backup ring (43) onto plug (48). Apply LOCTITE #271 onto the thread of part of plug (48). 8. Install plug (48) to spool (50) by using special tool (ST 5909). : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft) 9. Install spring seat (39), spring (40), spring seat (39) and bolt (41) to the upper side of spool (50). : 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

• Assembly of Arm 2 Spool 10. Clamp spool (51) in a vise by using wooden pieces. Install spring seats (39, 52), springs (53, 40), spring seats (52, 39) and bolt (41) to spool (51). : 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft) 11. Install O-ring (65) to plug (66). Install plug (66) into cap (64). : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 12. Install O-rings (59) (4 used) onto housing (1). Install caps (67) (3 used) and cap (64) to housing (1) with socket bolts (63) (8 used).

W2-5-25

UPPERSTRUCTURE / Control Valve

63

60, 61

59, 62 Control Valve (Upper)

63

1

WCJB-02-05-005

Control Valve (Lower)

WCJB-02-05-006

61 60

62

58 57

59

59

1

4 55, 56

54

WCJB-02-05-009

Section K-K

W2-5-26

UPPERSTRUCTURE / Control Valve 13. Clamp spool (54) in a vise by using wooden pieces. Install O-ring (55) and backup ring (56) onto spool (57). Install spool (57) to spool (54). Install spool (54) and spring (58) to housing (1). 14. Install the spool (51, 50, 47, 35) assemblies, O-rings (59) (4 used) and O-ring (4) to housing (1). Install cap (62) to housing (1) with socket bolts (63) (6 used). : 8 mm : 42 N⋅m (4.3 kgf⋅m, 31 lbf⋅ft) 15. Install O-ring (60) to plug (61). Install plug (61) into cap (62). : 22 mm : 54±3 N⋅m (5.5±0.3 kgf⋅m, 40±2 lbf⋅ft)

W2-5-27

UPPERSTRUCTURE / Control Valve 15, 17

6 105 98

92

15, 74

69

68

1 Control Valve (Front)

WCJB-02-05-007

Control Valve (Side)

103

97

1

WCJB-02-05-008

104

4

96 95 94 92 93

105, 6

91 1

90 89 84

85

77 18

86 87 88

W1V1-02-05-033

WCJB-02-05-021

Section of Bypass Shut-Out Valve

Bucket Flow Rate Control Valve (Detail B)

73 4

71 1

72 71

70

68, 69

Section of Flow Combiner Valve (Detail A)

W2-5-28

W1V1-02-05-040

UPPERSTRUCTURE / Control Valve • Assembly of Bucket Flow Rate Control Valve

• Assembly of Bypass Shut-Out Valve

16. Install O-rings (96, 91) to plugs (97, 90).

23. Install spool (103), spring (104) and O-ring (4) to housing (1). Install flange (105) to housing (1) with socket bolts (6) (4 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

17. Install spring (94), spool (93), spring seat (95) and plug (97) to body (92). 18. Install plug (90) to body (92). 19. Install poppet (85), spring (86) and plug (87) to poppet (84). Install the poppet (84) assembly, spring (88) and sleeve (89) into housing (1). 20. Install O-rings (18, 77) into housing (1). Install body (92) to housing (1) with socket bolts (98) (4 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

• Assembly of Flow Combiner Valve 21. Install spring seat (71), spring (72) and spring seat (71) to bolt (70). Install bolt (70) to spool (73).

• Assembly of Overload Relief Valve IMPORTANT: If the overload relief valve is disassembled, pressure must be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 24. Install O-rings (15) (4 used) to overload relief valves (17, 74) (2 used for each). Install overload relief valves (17, 74) (2 used for each) to housing (1). : 32 mm : 83±5 N⋅m (8.5±0.5 kgf⋅m, 61±4 lbf⋅ft)

22. Install spool (73) and O-ring (4) to housing (1). Install cap (69) to housing (1) with socket bolts (68) (2 used). : 5 mm : 10 N⋅m (1 kgf⋅m, 7 lbf⋅ft)

W2-5-29

UPPERSTRUCTURE / Control Valve

9, 10, 11, 12

6

3, 4, 13, 14

11, 12

1 7, 8 106, 107

108 Control Valve (Side)

1 WCJB-02-05-007

6

2, 3, 4, 5 Control Valve (Front)

W1V1-02-05-033

Bucket Flow Rate Control Valve (Detail B)

WCJB-02-05-008

WCJB-02-05-021

Section of Bypass Shut-Out Valve

Section of Flow Combiner Valve (Detail A)

W2-5-30

W1V1-02-05-040

UPPERSTRUCTURE / Control Valve • Assembly of Check Valve 25. Install O-ring (11) to plug (12). Install poppets (9) (2 used), spring (10) and plug (12) into housing (1). : 6 mm : 76±3 N⋅m (7.7±0.3 kgf⋅m, 56±2 lbf⋅ft) 26. Install plugs (7, 12) (2 used for each) to housing (1). : 6 mm : 76±3 N⋅m (7.7±0.3 kgf⋅m, 56±2 lbf⋅ft) : 10 mm : 106 to 141 N⋅m (10.8 to 14.4 kgf⋅m, 78 to 104 lbf⋅ft) 27. Install poppets (2, 14), springs (3) (2 used) and O-rings (4) (2 used) to housing (1). 28. Install flanges (5, 13) to housing (1) with socket bolts (6) (4 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft) 29. Install O-ring (106) to housing (1). Install cap (107) to housing (1) with socket bolts (108) (4 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

W2-5-31

UPPERSTRUCTURE / Control Valve 79

6

34

30

6

(Arm 2 Flow Rate Control Valve) 124

1

WCJB-02-05-007

Control Valve (Side) 34 33 30 32

77

1

18

120 121

31 28

29

27

22

18 26 25 24 23 21 20

1 18 78

119

81

118

80

117

124

116 79

115

82 75

77 76 Boom Anti-Drift Valve (Detail C) 78

99 100

101

102

87 W1V1-02-05-032

83 W1V1-02-05-031

Arm 2 Flow Rate Control Valve (Detail D)

115

127

1

120

116 117

121

126

109

110 111

77 112

125

123

121

122 117 116

120 87

124

W1V1-02-05-042

115 113

114

77

18

124 W1V1-02-05-034

Arm 2 Flow Rate Control Valve (Detail E)

Arm 2 Flow Rate Control Valve (Detail F)

W2-5-32

UPPERSTRUCTURE / Control Valve • Assembly of Boom Anti-Drift Valve

• Assembly of Arm 2 Flow Rate Control Valve

30. Install backup rings (23, 26) and O-rings (24, 25) to sleeve (27).

39. Install O-rings (116, 121) (3 used for each) to plugs (115, 120) (3 used for each) as shown in detail D, E and F.

31. Face the hole on spool (28) to the poppet (22) side. Install spool (28), poppet (22), seat (21) and spring (20) to sleeve (27). Install the sleeve (27) assembly to housing (1). NOTE: Apply grease onto seat (21) and spring (20)in order to fall off.

40. Install spool (119), spring (118) and spring seat (117) to body (124) as shown in detail D. Temporarily tighten plugs (115, 120) to body (124).

32. Install O-ring (33) to plug (34). Install spring (31), piston (32), O-ring (29) and plug (34) to body (30).

41. Install spool (123), spring (122) and spring seat (117) to body (124) as shown in detail F. Temporarily tighten plugs (115, 120) to body (124).

33. Install O-rings (18) (3 used) to housing (1). Install the body (30) assembly to housing (1) with socket bolts (6) (3 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

42. Install plug (127), spool (125), spring (126) and spring seat (117) to body (124) as shown in detail E. Temporarily tighten plugs (115, 120) to body (124). 43. Install poppet (100), spring (101) and plug (102) to poppet (99)as shown in detail D. Install the poppet (99) assembly, spring (87) O-rings (18, 77) to housing (1).

34. Tighten plug (34). 35. Install O-rings (80, 82) to plugs (81, 83). 36. Install poppet (75), spring (76), O-rings (77, 78) and O-rings (18) (3 used) to housing (1). 37. Install body (79) to housing (1) with socket bolts (6) (4 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

44. Install poppet (99), poppet (110), spring (111) and plug (112) to poppet (109) as shown in detail E. Install the poppet (109) assembly, spring (87), O-ring (77, 78) into housing (1). 45. Install poppet (113), spring (114) and O-rings (77, 18) to housing (1) as shown in detail F.

38. Tighten plugs (81, 83).

W2-5-33

UPPERSTRUCTURE / Control Valve

(Arm 2 Flow Rate Control Valve)124

98 Control Valve (Side)

WCJB-02-05-007

120

124

115 Boom Anti-Drift Valve (Detail C)

W1V1-02-05-031

Arm 2 Flow Rate Control Valve (Detail D)

115

W1V1-02-05-032

120

120 115

W1V1-02-05-042

Arm 2 Flow Rate Control Valve (Detail F)

Arm 2 Flow Rate Control Valve (Detail E)

W2-5-34

W1V1-02-05-034

UPPERSTRUCTURE / Control Valve 46. Install body (124) to housing (1) with socket bolts (98) (8 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft) 47. Tighten plugs (115, 120) (3 used for each) to body (124).

W2-5-35

UPPERSTRUCTURE / Control Valve DISASSEMBLY OF CONTROL VALVE 5-SPOOL SIDE 3

2

8

7 6 5

4

11

10

7

8

9 12

13 14

15

1 16 14

17

15

18

12 19

13 20 21 31 27

28

29

26

33

35 30

32

Arm Anti-Drift Valve

25

24

Check Valve (5-Spool Side Parallel Circuit)

23 37 22

34

38 36

39

40

41

42

8 46

43 44

48

43

47 43

43 44

50

45 43

43

49

Blade/Outrigger

45

44

51

43

44 49

43

Auxiliary

45 43

Boom 2

45

44 43

Arm 1

45 Swing

53

52

54

52

55

56 WCJB-02-05-010

W2-5-36

UPPERSTRUCTURE / Control Valve 58

57

58

57

59

79

60 62

63

64

9 66 67 68 69 70 71

63

64

8

65

72

77

8 73

8

7 6

9

5

10 9

76

Check Valve

85

78

75

Load Check Valve (Blade/Outrigger)

20

8

Arm Anti-Drift Valve

92

89

6

93 94

6

97

90 94

3 2 53

13 96

53

102

99

104 53 105 106 107

52

100

87 Load Check Valve (Travel)

91

95

98

101 103

86

88

92

93

65

9 66 67 81 82 83 84

Load Check Valve (Boom 2 Parallel Circuit)

74

13

12 25

12

107 13 12

52 1

99

53

80

20

20

102

60

Arm 1 Flow Rate Control Valve

61

101

59

Auxiliary Flow Rate Control Valve

52

53

99 52 52

13

12

99

WCJB-02-05-011

W2-5-37

UPPERSTRUCTURE / Control Valve 12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 -

Housing O-Ring Plug Poppet Spring O-Ring (3 Used) Flange (3 Used) Socket Bolt (22 Used) O-Ring (5 Used) Spring (2 Used) Poppet O-Ring (4 Used) Plug (4 Used) O-Ring (2 Used) Overload Relief Valve (2 Used) O-Ring Backup Ring Plug Main Relief Valve O-Ring (6 Used) O-Ring Spacer Backup Ring O-Ring Spring Poppet Spring

28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 -

Seat Poppet Backup Ring O-Ring O-Ring Backup Ring Sleeve Spool O-Ring Body Spring Piston O-Ring Plug Spool Spring Seat (10 Used) Spring (5 Used) Bolt (5 Used) Spool Spool Spool Spring Seat (2 Used) Spring Spool O-Ring (10 Used) Socket Bolt (16 Used) O-Ring

55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 -

W2-5-38

Plug Cap Socket Bolt (8 Used) Plug (2 Used) O-Ring (2 Used) Body (2 Used) Spool Spring Spring Seat (2 Used) O-Ring (2 Used) Plug (2 Used) Sleeve (2 Used) Spring (2 Used) Plug Spring Poppet Poppet Plug O-Ring Flange Spring Poppet Flange (2 Used) Poppet (2 Used) Spool Spring Plug

82 - Spring 83 - Poppet 84 - Poppet 85 - Poppet 86 - Cover (2 Used) 87 - O-Ring (2 Used) 88 - Plug 89 - O-Ring 90 - Spring 91 - Poppet 92 - Socket Bolt (4 Used) 93 - Cap (2 Used) 94 - Spring Seat (2 Used) 95 - Spring 96 - Spool 97 - Spring 98 - Spool 99 - Cap (4 Used) 100 - Cap 101 - Overload Relief Valve (2 Used) 102 - O-Ring (2 Used) 103 - Plug 104 - Backup Ring 105 - O-Ring 106 - Plug 107 - O-Ring

UPPERSTRUCTURE / Control Valve (Blank)

W2-5-39

UPPERSTRUCTURE / Control Valve 8

7 6 4

5 11

10

7

8

9 14

15

1 14 15

19 20 21 31 27

28

29

26

33

35 30

32

Arm Anti-Drift Valve

34

25

23 37 22 38

36

Check Valve (5-Spool Side Parallel Circuit)

24

39

40

41

42

8 46 48

47

Blade/Outrigger

51

Auxiliary Boom 2 Arm 1

Swing

53

52

52

56 WCJB-02-05-010

W2-5-40

UPPERSTRUCTURE / Control Valve Disassembly of Control Valve 5-Spool Side

• Disassembly of Spool 1. Remove socket bolts (53) (6 used) from cap (56). Remove cap (56) and O-rings (52) (5 used) from housing (1). : 8 mm 2. Put the matching marks on spools (42, 46, 47, 48, 51) and housing (1). Remove the spools (42, 46, 47, 48, 51) assemblies from housing (1).

• Disassembly of Arm Anti-Drift Valve 3. Remove plug (41) from body (37). : 38 mm 4. Remove socket bolts (8) (3 used) from body (37). Remove the body (37) assembly, O-rings (21, 36) and O-rings (20) (4 used) from housing (1). : 8 mm 5. Remove piston (39) and spring (38) from body (37). : 38 mm 6. Remove spool (35), sleeve (34), poppet (29), seat (28) and spring (27) from housing (1). Remove backup rings (30, 33) and O-rings (31, 32) from sleeve (34).

• Disassembly of Overload Relief Valve (15) IMPORTANT: Do not disassemble the overload relief valve. When disassembling the overload relief valve, pressure must be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 7. Remove overload relief valves (15) (2 used) from housing (1). Remove O-rings (14) (2 used) from overload relief valves (15) (2 used). : 32 mm • Disassembly of Main Relief Valve (19) IMPORTANT: Do not disassemble the main relief valve. When disassembling the main relief valve, pressure must be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 8. Remove main relief valve (19) from housing (1). : 32 mm • Disassembly of Check Valve 9. Remove spacer (22), spring (25) and poppet (26) from housing (1). Remove backup ring (23) and O-ring (24) from spacer (22). 10. Remove socket bolts (8) (2 used) from flange (7). Remove flange (7), O-ring (6), spring (5) and poppet (4) from housing (1). : 8 mm 11. Remove socket bolts (8) (2 used) from flange (7). Remove flange (7), O-ring (9), spring (10) and poppet (11) from housing (1). : 8 mm

W2-5-41

UPPERSTRUCTURE / Control Valve

2

3

12

13

1 16

17

18

12 13

42 46

43 44

48

43

47 43

43 44

50

45

44

51

43

44 49

43

45 43

43

49

Blade/Outrigger

Auxiliary

45 43

Boom 2

45

44 43

Arm 1

45 Swing

WCJB-02-05-010

W2-5-42

UPPERSTRUCTURE / Control Valve 12. Remove plugs (13) (2 used) and plug (3) from housing (1). Remove O-rings (12) (2 used) and O-ring (2) from plugs (13) (2 used) and plug (3). : 8 mm

• Disassembly of Swing Spool (51) 18. Clamp spool (51) in a vise by using wooden pieces. Remove bolt (45), spring seat (43), spring (44) and spring seat (43) from spool (51). : 8 mm

13. Remove plug (18) from housing (1). Remove backup ring (17) and O-ring (16) from plug (18). : 24 mm

• Disassembly of Blade/Outrigger Spool (42) 14. Clamp spool (42) in a vise by using wooden pieces. Remove bolt (45), spring seat (43), spring (44) and spring seat (43) from spool (42). : 8 mm

• Disassembly of Auxiliary Spool (46) 15. Clamp spool (46) in a vise by using wooden pieces. Remove bolt (45), spring seat (43), spring (44) and spring seat (43) from spool (46). : 8 mm

• Disassembly of Boom 2 Spool (47) 16. Clamp spool (47) in a vise by using wooden pieces. Remove bolt (45), spring seat (43), spring (44) and spring seat (43) from spool (47). : 8 mm

• Disassembly of Arm 1 Spool (48) 17. Clamp spool (48) in a vise by using wooden pieces. Remove bolt (45), spring seats (43, 49), springs (44, 50) and spring seats (43, 49) from spool (48). : 8 mm

W2-5-43

UPPERSTRUCTURE / Control Valve 58

57

58

57

Auxiliary Flow Rate Control Valve

59

60 79

Arm 1 Flow Rate Control Valve

59

60

20 61

62

20

63

64

9 66 67 81 82 83 84

65

9 66 67 68 69 70 71

8

80

63

64

65 8

7 6 5

Check Valve

74

85

9

75 76 92

Digging Regenerative Valve

92

93

93 Auxiliary Flow Combiner Valve

6 94

6

97

94 95

98

101

96 53

102

99

53

52

100

101

52

53 102

20

Arm Anti-Drift Valve

1

99

53

52

53

99 52 52 99

WCJB-02-05-011

W2-5-44

UPPERSTRUCTURE / Control Valve 19. Remove socket bolts (53) (10 used) from caps (99) (4 used) and cap (100). Remove caps (99) (4 used), cap (100) and O-rings (52) (5 used) from housing (1). : 8 mm

• Disassembly of Arm Anti-Drift Valve

• Disassembly of Digging Regenerative Valve and

• Disassembly of Arm 1 Flow Rate Control Valve and

Auxiliary Flow Combiner Valve 20. Remove socket bolts (92) (4 used) from caps (93) (2 used). Remove caps (93) (2 used), O-rings (6) (2 used), spring seats (94) (2 used), springs (95, 97) and spools (96, 98) from housing (1). : 5 mm

Auxiliary Flow Rate Control Valve 24. Loosen plugs (58, 65) (2 used for each) from bodies (60) (2 used).

• Disassembly of Overload Relief Valve (101) IMPORTANT: Do not disassemble overload relief valve (101). When disassembling the overload relief valve, pressure must be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 21. Remove overload relief valves (101) (2 used) from housing (1). Remove O-rings (102) (2 used) from overload relief valves (101) (2 used). : 32 mm • Disassembly of Check Valve

23. Remove socket bolts (8) (4 used) from flange (74). Remove flange (74), O-rings (20) (3 used), O-ring (9), spring (75) and poppet (76) from housing (1). : 8 mm

25. Remove socket bolts (57) (8 used) from body (60) (2 used). Remove O-rings (20, 9) (2 used for each) from housing (1). : 8 mm 26. Remove plugs (65) (2 used), spring seats (63) (2 used), springs (63, 80) and spools (61, 79) from bodies (60) (2 used). Remove plugs (58) (2 used) from bodies (60) (2 used). 27. Remove O-rings (59, 64) (2 used for each) from plugs (58, 65) (2 used for each). 28. Remove sleeves (66) (2 used), springs (67) (2 used), plugs (68, 81), springs (69, 82) and poppets (70, 71, 83, 84) from housing (1).

22. Remove socket bolts (8) (2 used) from flange (7). Remove flange (7), O-ring (6), spring (5) and poppet (85) from housing (1). : 8 mm

W2-5-45

UPPERSTRUCTURE / Control Valve

Load Check Valve (Boom 2 Parallel Circuit)

8 77

9 10 78 8

Load Check Valve (Blade/Outrigger)

88

86

89

87

90 91

Load Check Valve (Travel)

13

103 104 105

3

13

12 25

12

107 13

2

12

1

99

WCJB-02-05-011

W2-5-46

UPPERSTRUCTURE / Control Valve • Disassembly of Load Check Valve 29. Remove socket bolts (8) (4 used) from flange (77). Remove flange (77), O-ring (9), spring (10) and poppet (78) from housing (1). : 8 mm

35. Remove plugs (13) (2 used) from housing (1). Remove O-rings (12) (2 used) from plugs (13) (2 used). : 8 mm

30. Remove socket bolts (8) (4 used) from cover (86). Remove cover (86) and O-ring (87) from housing (1). : 8 mm 31. Remove plug (88), spring (90) and poppet (91) from housing (1). Remove O-ring (89) from plug (88). : 24 mm 32. Remove plug (13), spring (25) and poppet (107) from housing (1). Remove O-ring (12) from plug (13). : 8 mm 12

25

107

13

W1V1-02-05-016

33. Remove plug (103) from housing (1). Remove backup ring (104) and O-ring (105) from plug (103). : 24 mm 34. Remove plug (3) from housing (1). Remove O-ring (2) from plug (3). : 10 mm

W2-5-47

UPPERSTRUCTURE / Control Valve ASSEMBLY OF 5-SPOOL SIDE

CONTROL

VALVE

A

53

54, 55

52, 56

53

53

1

52, 99

53 52, 100

53

52, 99 53

52, 99 53 52, 99 1

B

WCJB-02-05-006 WCJB-02-05-005

Control Valve (Upper)

19

15

18

15

41

Control Valve (Lower)

12, 13

37

8 7, 9, 10, 11

8 1 8 8 74

2, 3 57 57

4, 5, 6, 7 12, 13

93

W1V1-02-05-068

101

60 103 77 93 View A

60

101

99

53

WCJB-02-05-012

W2-5-48

View B

UPPERSTRUCTURE / Control Valve

J

I

H

G

F

E

D

C

19 1 12, 13 5 6 7

98 6 97 94 93

85

J

I

H

G

F

E

D

C

W1V1-02-05-043 WCJB-02-05-005

Section C-C (5-Spool Side)

Control Valve (Upper)

Blade/Outrigger

Boom 2

Auxiliary

56

55

45 43

14, 15

54

14, 15

44 43

86

52

8

78 10 47 46

A

42

1

52 99

107

8 86

1

Section D-D (5-Spool Side)

1 99

106

WCJB-02-05-013

101, 102

9 77 8

101, 102 Section E-E (5-Spool Side)

W2-5-49

WCJB-02-05-014

W1V1-02-05-046

Section F-F (5-Spool Side)

UPPERSTRUCTURE / Control Valve

Arm 1

Swing

45 43 49 50

C

44 15

49

78

14

43 48

10

51

9 D

8

1

77 1 102

B

1

101 W1V1-02-05-052 W1V1-02-05-051

Section G-G (5-Spool Side)

Section H-H (5-Spool Side)

W1V1-02-05-050

Section I-I (5-Spool Side)

88

89

90

91

65

1

64 63 80 60 79

1

59 58 66 84

83

9

20

82 81 67

W1V1-02-05-033

Detail A

13

12 2 Detail B

W2-5-50

3

W1V1-02-05-053

UPPERSTRUCTURE / Control Valve

41 40 39 37 65

38

29

35

20

9

70

71

63 62 61

30 28 27 60

73

1

64

36 34 33 32 31

20

66 67

72

9

75

76

58

59

68

20

69

WCJB-02-05-015

Detail D

W1V1-02-05-054

Detail C

12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 -

Housing O-Ring Plug Poppet Spring O-Ring (3 Used) Flange (3 Used) Socket Bolt (22 Used) O-Ring (5 Used) Spring (2 Used) Poppet O-Ring (4 Used) Plug (4 Used) O-Ring (2 Used) Overload Relief Valve (2 Used) O-Ring Backup Ring Plug Main Relief Valve O-Ring (6 Used) O-Ring Spacer Backup Ring O-Ring Spring Poppet Spring

28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 -

Seat Poppet Backup Ring O-Ring O-Ring Backup Ring Sleeve Spool O-Ring Body Spring Piston O-Ring Plug Spool Spring Seat (10 Used) Spring (5 Used) Bolt (5 Used) Spool Spool Spool Spring Seat (2 Used) Spring Spool O-Ring (10 Used) Socket Bolt (16 Used) O-Ring

55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 -

W2-5-51

Plug Cap Socket Bolt (8 Used) Plug (2 Used) O-Ring (2 Used) Body (2 Used) Spool Spring Spring Seat (2 Used) O-Ring (2 Used) Plug (2 Used) Sleeve (2 Used) Spring (2 Used) Plug Spring Poppet Poppet Plug O-Ring Flange Spring Poppet Flange (2 Used) Poppet (2 Used) Spool Spring Plug

82 - Spring 83 - Poppet 84 - Poppet 85 - Poppet 86 - Cover (2 Used) 87 - O-Ring (2 Used) 88 - Plug 89 - O-Ring 90 - Spring 91 - Poppet 92 - Socket Bolt (4 Used) 93 - Cap (2 Used) 94 - Spring Seat (2 Used) 95 - Spring 96 - Spool 97 - Spring 98 - Spool 99 - Cap (4 Used) 100 - Cap 101 - Overload Relief Valve (2 Used) 102 - O-Ring (2 Used) 103 - Plug 104 - Backup Ring 105 - O-Ring 106 - Plug 107 - O-Ring

UPPERSTRUCTURE / Control Valve

53

54, 55

52, 56

53

1

53

52, 99

53 52, 100

53

52, 99 53

52, 99 53 52, 99 1

L

L

WCJB-02-05-005

Control Valve (Upper)

Blade/Outrigger

WCJB-02-05-006

Control Valve (Lower)

Auxiliary Boom 2

55 54

Arm 1

Swing

45

45 43 49 50 44 49 43

56

1

43 44 43 52

51 42

48 46 47 52

52 53 99

107

106

100

99 Section L-L

W2-5-52

99

99 WCJB-02-05-016

UPPERSTRUCTURE / Control Valve • Assembly of Blade/Outrigger Spool 1. Secure spool (42) in a vise by using wooden pieces. Install spring seat (43), spring (44), spring seat (43) and bolt (45) to spool (42). : 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

6. Install O-rings (52) (5 used) onto housing (1). Install cap (100) and cap (99) (4 used) to housing (1) with socket bolts (53) (10 used). : 8 mm : 42±2 N⋅m (4.3±0.2 kgf⋅m, 31±1 lbf⋅ft) 7. Install the spools (42, 46, 47, 48, 51) assemblies to housing (1).

• Assembly of Auxiliary Spool 2. Secure spool (46) in a vise by using wooden pieces. Install spring seat (43), spring (44), spring seat (43) and bolt (45) to spool (46). : 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

• Assembly of Boom 2 Spool 3. Secure spool (47) in a vise by using wooden pieces. Install spring seat (43), spring (44), spring seat (43) and bolt (45) to spool (47). : 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

• Assembly of Arm 1 Spool 4. Secure spool (48) in a vise by using wooden pieces. Install spring seats (43, 49), springs (44, 50), spring seats (43, 49) and bolt (45) to spool (48). : 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

8. Install O-rings (52) (5 used) to housing (1). Install cap (56) to housing (1) with socket bolts (53) (6 used). : 8 mm : 42±2 N⋅m (4.3±0.2 kgf⋅m, 13±1 lbf⋅ft) 9. Install O-rings (54, 107) to plugs (55, 106). Install plug (106) to cap (100). : 22 mm : 53±3 N⋅m (5.4±0.3 kgf⋅m, 39±2lbf⋅ft) 10. Install plug (55) to cap (56). : 22 mm : 54±3 N⋅m (5.5±0.3 kgf⋅m, 40±2 lbf⋅ft)

• Assembly of Swing Spool 5. Secure spool (51) in a vise by using wooden pieces. Install spring seat (43), spring (44), spring seat (43) and bolt (45) into spool (51). : 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

W2-5-53

UPPERSTRUCTURE / Control Valve 8

16, 17, 18

86, 87

7

6

5

85

57

60

7 8 92 1 93

86, 87

8 77 Control Valve (Side)

8

Check Valve

W1V1-02-05-047

WCJB-02-05-012

65

66 67

1

9

83

84

64 63

98

80

6

79 1 97 94 66

58

59

81

20

82

WCJB-02-05-015

93 Auxiliary Flow Combiner Valve

8

77

9

10

WCJB-02-05-017

78

1 Load Check Valve

W1V1-02-05-049

W2-5-54

Section of Auxiliary Flow Rate Control Valve (Detail A)

UPPERSTRUCTURE / Control Valve • Assembly of Auxiliary Flow Rate Control Valve

• Assembly of Load Check Valve

11. Install O-rings (59, 64) to plugs (58, 65).

18. Install poppet (78), spring (10) and O-ring (9) to housing (1).

12. Install spring (80), spool (79), spring seat (63) and plug (65) to body (60). 13. Install plug (58) to body (60). 14. Install poppet (83), spring (82) and plug (81) to poppet (84). Install the poppet (84) assembly, spring (67) and sleeve (66) to housing (1). 15. Install O-rings (9, 20) into housing (1). Install body (60) to housing (1) with socket bolts (57) (4 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

• Assembly of Check Valve

19. Install flange (77) to housing (1) with socket bolts (8) (4 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft) 20. Install O-ring (16) and backup ring (17) to plug (18). Install plug (18) to housing (1). 21. Install O-rings (87) (2 used) to housing (1). Install covers (86) (2 used) to housing (1) with socket bolts (8) (8 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

16. Install poppet (85), spring (5) and O-ring (6) to housing (1). Install flange (7) to housing (1) with socket bolts (8) (2 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

• Assembly of Auxiliary Flow Combiner Valve 17. Install spool (96), spring (95) and spring seat (94) to housing (1). Install cap (93) to housing (1) with socket bolts (92) (2 used). : 5 mm : 10±1 N⋅m (1±0.1 kgf⋅m, 7±4 lbf⋅ft)

W2-5-55

UPPERSTRUCTURE / Control Valve 37

8

1

60 57

Control Valve (Front) Control Valve (Side)

W1V1-02-05-068

WCJB-02-05-012

41 40 39 78 38 35

29 1

36 34 33 32 31

20 20

30 28 27 Section of Load Check Valve (Detail B)

W1V1-02-05-053

73

72

9

75

76

W1V1-02-05-054

Section of Anti-Drift Valve (Detail C) 65

66 67

1

9

70

71

64 63 62 61

W1V1-02-05-055

60

58

59

68

20

69

WCJB-02-05-015

Section of Arm Flow Rate Control Valve (Detail D)

W2-5-56

Section of Load Check Valve

UPPERSTRUCTURE / Control Valve • Assembly of Arm Anti-Drift Valve 22. Install backup rings (30, 33) and O-rings (31, 32) to sleeve (34). 23. Face the hole on spool (35) to the poppet (29) side. Install spool (35), poppet (29), seat (28) and spring (27) to sleeve (34). Install the sleeve (34) assembly to housing (1). NOTE: Apply grease to seat (28) and spring (27) in order not to drop.

31. Install O-rings (20) (3 used) and O-ring (9) to housing (1). Install body (60) to housing (1) with socket bolts (57) (4 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

24. Install O-ring (40) onto plug (41). Install spring (38), piston (39), O-ring (36) and plug (41) to body (37). 25. Install O-rings (20) (3 used) and O-ring (21) to housing (1). Install the body (37) assembly to housing (1) with socket bolts (8) (2 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft) 26. Tighten plug (41).

• Assembly of Arm Flow Rate Control Valve 27. Install O-rings (59, 64) to plugs (58, 65). 28. Install spring (62), spool (61), spring seat (63) and plug (65) to body (60). 29. Install plug (58) to body (60). 30. Install poppet (70), spring (69) and plug (68) to poppet (71). Install the poppet (71) assembly, spring (67) and sleeve (66) to housing (1).

W2-5-57

UPPERSTRUCTURE / Control Valve 19

14, 15

14, 15

12, 13

8 7, 9, 10, 11

8

2, 3

4, 5, 6, 7

1 101, 102

103, 104, 105

101, 102

Control Valve (Side)

88

89

90

12

2

12, 13 Control Valve (Front)

WCJB-02-05-012

W1V1-02-05-068

91

1

13 3

W1V1-02-05-053

Section of Load Check Valve (Detail B) Section of Arm Anti-Drift Valve (Detail C)

8

77

9

10

W1V1-02-05-054

78

1 WCJB-02-05-015

Section of Arm Flow Rate Control Valve (Detail D)

W2-5-58

Section of Load Check Valve

W1V1-02-05-055

UPPERSTRUCTURE / Control Valve • Assembly of Load Check Valve 32. Install O-ring (89) to plug (88). Install poppet (91), spring (90) and plug (88) to housing (1). 33. Install poppet (78), spring (10) and O-ring (9) to housing (1). Install flange (77) to housing (1) with socket bolts (8) (4 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft) 34. Install O-rings (2, 12) to plugs (3, 13). Install plugs (3, 13) to housing (1).

• Assembly of Overload Relief Valve IMPORTANT: If the overload relief valve is disassembled, pressure must be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 35. Install O-rings (14, 102) (2 used for each) to overload relief valves (15, 101) (2 used for each). Install overload relief valves (15, 101) (2 used for each) to housing (1). : 32 mm : 83±5 N⋅m (8.5±0.5 kgf⋅m, 61±4 lbf⋅ft) 36. Install O-ring (105) and backup ring (104) to plug (103). Install plug (103) to housing (1).

• Assembly of Main Relief Valve IMPORTANT: If the main relief valve is disassembled, pressure must be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 37. Install main relief valve (19) to housing (1). : 32 mm : 83±5 N⋅m (8.5±0.5 kgf⋅m, 61±4 lbf⋅ft) • Assembly of Check Valve 38. Install poppet (4), spring (5) and O-ring (6) to housing (1). Install flange (7) to housing (1) with socket bolts (8) (2 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft) 39. Install poppet (11), spring (10) and O-ring (9) to housing (1). Install flange (7) to housing (1) with socket bolts (8) (2 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft) 40. Install O-rings (12) (2 used) to plugs (13) (2 used). Install plugs (13) (2 used) to housing (1). 41. Install O-ring (2) to plug (3). Install plug (3) into housing (1).

W2-5-59

UPPERSTRUCTURE / Control Valve DISASSEMBLY OF HOUSING

3

3

1

4 4 4

5 4

5

5

4

4 4

4 6

6 5

5

4

2

W1V1-02-05-023

1 - Housing (5-Spool Side) 2 - Housing (4-Spool Side)

3 - Socket Bolt (9 Used) 4 - O-Ring (16 Used)

5 - O-Ring (12 Used)

W2-5-60

6-

O-Ring (3 Used)

UPPERSTRUCTURE / Control Valve Disassembly of Housing CAUTION: Housing (1, 2) weight: 150 kg (340 lb) for each 1. Remove socket bolts (3) (9 used) from housing (1). Remove O-rings (4) (16 used), O-rings (5) (12 used) and O-rings (6) (3 used) from housing (1 or 2). : 14 mm 2. Divide housing (1) and (2).

W2-5-61

UPPERSTRUCTURE / Control Valve ASSEMBLY OF HOUSING 4

5

2

4 4 5

5

6

4

5

6

6

5

5

4

4

4

5

W1V1-02-05-011

1

2 3

3

3 3

3 WCJB-02-05-018

1 - Housing (5-Spool Side) 2 - Housing (4-Spool Side)

3 - Socket Bolt (9 Used) 4 - O-Ring (16 Used)

5 - O-Ring (12 Used)

W2-5-62

6-

O-Ring (3 Used)

UPPERSTRUCTURE / Control Valve Assembly of Housing 1. Install O-rings (4) (16 used), O-rings (5) (12 used) and O-rings (6) (3 used) to the housing (2) mounting surface. CAUTION: Housing (1, 2) weight: 150 kg (340 lb) for each 2. Install housing (1) to housing (2) with socket bolts (3) (9 used). : 14 mm : 205 to 215 N·m (21 to 22 kgf·m, 152 to 159 lbf⋅ft)

W2-5-63

UPPERSTRUCTURE / Control Valve (Blank)

W2-5-64

UPPERSTRUCTURE / Control Valve REMOVAL AND INSTALLATION POSITIONING CONTROL VALVE

OF

CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Disconnect hoses (1) (6 used) from valve (3). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 27 mm

3

2. Remove sems bolts (2) (3 used) from valve (3). Remove valve (3) from bracket (4). : 17 mm

WCJB-02-05-019

1

2

3

4

1

WCEB-02-05-011

Installation 1. Install valve (3) to bracket (4) with sems bolts (2) (3 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

1

2

3

4

1

2. Connect hoses (1) (6 used) to valve (3). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

WCEB-02-05-011

W2-5-65

UPPERSTRUCTURE / Control Valve DISASSEMBLY CONTROL VALVE

OF

POSITIONING

7

6

1

2

9

24

5

4

3

8

10

27

28

26

23

22

21

20

19

25

37

15

14 12

16

17

34

33

32

31

30

29

35

41

13

36

42 43 44

11

51

38 39 18 40

52

53

54

55

56

45 46 47

48

62 61 60

50 49 58

59

57 W198-02-05-001

12345678910 11 12 13 14 15 16 -

Nut Bolt O-Ring Spring Valve Sleeve Backup Ring (2 Used) O-Ring O-Ring Spring Spring Pin Valve O-Ring Backup Ring (2 Used) Valve

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -

Sleeve O-Ring Nut Bolt O-Ring Spring Valve Sleeve Backup Ring (2 Used) O-Ring O-Ring Spring Spring Pin Valve O-Ring

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 -

W2-5-66

Backup Ring (2 Used) Valve Sleeve O-Ring Seat O-Ring Valve Spring Sleeve O-Ring Spring Poppet Socket Bolt (2 Used) Cover O-Ring

48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 -

Socket Bolt Socket Bolt Cover End Spool Seat Spring Spring Seat O-Ring Spool O-Ring Plug Rivet Plate Housing

UPPERSTRUCTURE / Control Valve Disassembly of Positioning Control Valve 1. Remove socket bolts (45) (2 used) and socket bolts (48, 49) from covers (46, 50). Remove covers (46, 50) and O-rings (47, 56) from housing (62). IMPORTANT: Turn and remove the spools. If they stick even a little, try again instead of pulling roughly.

6. Remove sleeve assembly (37 to 42) from housing (62). : 36 mm 7. Remove spring (43) and poppet (44) from housing (62). 8. Secure seat (37) in a vise. Remove sleeve (41), spring (40) valve (39) and O-rings (38, 42) from seat (37). : 36 mm

2. Remove spool assembly (51 to 59) from housing (62). 3. Clamp spool (57) in a vise by using wooden pieces. Remove end spool (51), seat (52), springs (53, 54) and seat (55) from spool (57). : 8 mm 4. Remove plug (59) from spool (57). Remove O-ring (58) from plug (59). IMPORTANT: Do not disassemble overload relief valve assemblies (1 to 18), (19 to 36) as since they have been preset at the set pressures. 5. Remove overload relief valve assemblies (1 to 18), (19 to 36) from housing (62). : 32 mm NOTE: Each of overload relief valve assemblies (1 to 18), (19 to 36) has a different set pressure. Thus they should be identified for reassembling.

W2-5-67

UPPERSTRUCTURE / Control Valve ASSEMBLY OF POSITIONING CONTROL VALVE Section X-X

37

39 40

38 41 43 42

A1

44

A1

1 to 18

62 19 to 36

B1

B1

X

X

W198-02-05-003

57 W198-02-05-002

Section W-W

50 51

48

53 55 56 62 47

45

W

W

Nut Bolt O-Ring Spring Valve Sleeve Backup Ring (2 Used) O-Ring O-Ring Spring Spring Pin Valve O-Ring Backup Ring (2 Used) Valve

57 59 58 46

W198-02-05-004

49

12345678910 11 12 13 14 15 16 -

54 52

W198-02-05-005

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -

Sleeve O-Ring Nut Bolt O-Ring Spring Valve Sleeve Backup Ring (2 Used) O-Ring O-Ring Spring Spring Pin Valve O-Ring

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 -

W2-5-68

Backup Ring (2 Used) Valve Sleeve O-Ring Seat O-Ring Valve Spring Sleeve O-Ring Spring Poppet Socket Bolt (2 Used) Cover O-Ring

48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 -

Socket Bolt Socket Bolt Cover End Spool Seat Spring Spring Seat O-Ring Spool O-Ring Plug Rivet Plate Housing

UPPERSTRUCTURE / Control Valve Assembly of Positionnig Control Valve 1. Clamp seat (37) in a vise. Install O-ring (38), valve (39), spring (40), sleeve (41) and O-ring (42) to seat (37). : 36 mm : 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft) 2. Insert poppet (44) and spring (43) into housing (62). 3. Install the seat (37) assembly to housing (62). : 36 mm : 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft) IMPORTANT: Each of overload relief valve assemblies (1 to 18), (19 to 36) has a different set pressure. Do not install at an incorrect position. 4. Install overload relief valve assemblies (1 to 18), (19 to 36) to housing (62). : 32 mm : 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft)

IMPORTANT: Install the spool (57) assembly into housing (62) and check if it moves smoothly by hand. 7. Insert spool (57) assemblies (51 to 59) into housing (62) from the port A1 side. NOTE: If any of spool assembly (51 to 59) is not straight inserted, forced insertion can result in flaws on the bore of housing (62) or spool (57). Insert it straight. 8. Install O-rings (47, 56) to covers (46, 50). Install covers (46, 50) to housing (62) with socket bolts (45) (2 used) and socket bolts (48, 49). : 6 mm : 25.5 N⋅m (2.6 kgf⋅m, 19 lbf⋅ft)

5. Install O-ring (58) to plug (59). 6. Clamp spool (57) in a vise by using wooden pieces. Install plug (59) to spool (57). Install seat (55), springs (53, 54), seat (52) and end spool (51) from the opposite side. : 9.8 N⋅m (1 kgf⋅m, 7 lbf⋅ft) : 8 mm : 18.6 N⋅m (1.9 kgf⋅m, 14 lbf⋅ft)

W2-5-69

UPPERSTRUCTURE / Control Valve (Blank)

W2-5-70

UPPERSTRUCTURE / Swing Device REMOVAL AND INSTALLATION OF SWING DEVICE CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Open cover (2).

1

2

3

4

2. Remove sems bolts (3) (4 used) from cover (1). Remove cover (1) from stay (4). : 17 mm 3. Remove socket bolts (7) (8 used) and split flanges (6) (4 used). Disconnect hoses (8) (12 used) from swing motor (2). Remove O-rings (9) (2 used) from hose (8). Remove swing dampener valve (10) and O-ring (11) from swing motor (12). : 8 mm

WCJB-02-01-002

5

6

7

8, 9

4. Disconnect hoses (5) (4 used) from swing motor (12). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 36 mm 5. Disconnect connector (14) from pressure switch (13). 6. Remove pressure switch (13) from swing motor (12). : 24 mm 7. Attach a nylon sling onto the body of swing motor (12). Hoist and hold the swing motor (12) assembly. Nylon sling (eye-type at both ends): 2 pieces

W2-6-1

10, 11 5

12

14

13

WCJB-02-06-005

UPPERSTRUCTURE / Swing Device CAUTION: Swing device (15) weight: 220 kg (490 lb) 8. Disconnect hose (19) from center joint (20). Cap the open ends. : 27 mm 9. Remove bolts (16) (12 used) and washers (17) (12 used) from swing device (15). Remove swing device (15) from main frame (18). : 30 mm

16, 17

15

18 19

NOTE: When hoisting swing device (15), the machine may float up. If this occurs, remove plugs (21) (2 places) and float swing device (15) from main frame (18) by using the pulling-out bolts (M20, Pitch 2.5 mm) (2 used). NOTE: The number of hoses around the swing device is different according to specification of the front attachment. Do not damage the hoses when removing and installing the swing device.

20 21

WCJB-02-06-006

Installation CAUTION: Swing device (15) weight: 220 kg (490 lb) 1. Hoist and align swing device (15) with the mounting holes on main frame (18). Install swing device (15) to main frame (18) with bolts (16) (12 used) and washers (17) (12 used). : 30 mm : 500 N⋅m (50 kgf⋅m, 37 lbf⋅ft) IMPORTANT: Apply THREEBOND #1102 onto the mounting surface of the swing device and main frame (18).

W2-6-2

15

16, 17 18

WCJB-02-06-006

UPPERSTRUCTURE / Swing Device 2. Connect hose (19) to center joint (20). : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

14

13

3. Install pressure switch (13) to swing motor (12). : 24 mm : 16 N⋅m (1.6 kgf⋅m, 12 lbf⋅ft) 12

4. Connect connector (14) to pressure switch (13).

19 20 WCJB-02-06-006

5

5. Connect hoses (5) (4 used) to swing motor (12). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

6

7

8, 9

6. Apply grease onto O-rings (9, 11). Install O-rings (9, 11) to hoses (8) (2 used) and swing dampener valve (10). 7. Install swing dampener valve (10) and hoses (8) (2 used) to swing motor (12) with split flanges (6) (4 used) and socket bolts (7) (8 used). : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

10, 11 5

12 WCJB-02-06-005

8. Install cover (1) to stay (4) with sems bolts (3) (4 used). Shut cover (2). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) IMPORTANT: After completing the work, fill the swing motor with hydraulic oil. Check the hydraulic oil level. Start the engine and check for any oil leaks.

W2-6-3

1

2

3

4

WCJB-02-01-002

UPPERSTRUCTURE / Swing Device DISASSEMBLY OF SWING DEVICE

22 23

1

24

2 3

32

25

21

4

31

5 20

6

26

7 19

8

27 9

18 28

10 17

29

30

11

16

12

15

13

14

W178-02-06-004

12345678-

Motor First Stage Planetary Gear Thrust Plate Pin (3 Used) Spring Pin (3 Used) Needle Bearing (3 Used) Planetary Gear (3 Used) Thrust Plate (3 Used)

910 11 12 13 14 15 16 -

Pin (3 Used) Spring Pin (3 Used) Thrust Plate (6 Used) Needle Bearing (6 Used) Planetary Gear (3 Used) Roller Bearing Bearing Nut Lock Plate

17 18 19 20 21 22 23 24 -

W2-6-4

Bolt (2 Used) Second Stage Carrier Thrust Plate Second Stage Sun Gear First Stage Carrier Socket Bolt (8 Used) Socket Bolt (12 Used) Ring Gear

25 26 27 28 29 30 31 32 -

Housing Roller Bearing Oil Seal Sleeve O-Ring Shaft Drain Plug Pipe

UPPERSTRUCTURE / Swing Device Disassembly of Swing Device CAUTION: Swing device weight: 220 kg (490 lb) CAUTION: When hoisting the swing device, do not string the rope suddenly. 1. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to motor (1). Attach a nylon sling onto eyebolts. Hoist motor (1). Eyebolt Mounting Position

5. Put the matching marks at the jointed part between motor (1) and ring gear (24), between ring gear (24) and housing (25). CAUTION: Motor (1) weight: 47 kg (110 Ib) 6. Remove socket bolts (22) (8 used) from motor (1). Remove motor (1) from ring gear (24). : 10 mm NOTE: THREEBOND has been applied onto the jointed surface. For easy removal, insert a screwdriver into the gap around the jointed part in order to float. 7. Remove first stage sun gear (2) from first stage carrier (21).

W178-02-06-005

2. Place the swing device on bracket (ST 5097). Secure the swing device onto the bracket by using the bolts (M22, Pitch 2.5 mm) (2 used). At this time, insert the stopper at the bottom of the bracket between teeth of the pinion gear. Secure the bracket on a workbench in order to reduce the reaction force. : 30 mm Swing Device

Stopper

ST 5097

W178-02-06-012

8. Remove the first stage carrier (21) assembly from ring gear (24). 9. Remove socket bolts (23) (12 used) from ring gear (24). : 14 mm CAUTION: Ring gear (24) weight: 23 kg (51 Ib) 10. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the motor (1) mounting thread part on ring gear (24). Attach a nylon sling onto eyebolts. Hoist and remove ring gear (24) from housing (25). NOTE: THREEBOND has been applied onto the jointed surface. For easy removal, insert a screwdriver into the gap around the jointed part in order to float. 11. Remove second stage sun gear (20) from second stage carrier (18).

3. Remove drain plug (31) from pipe (32). Drain off oil from the swing device. : 8 mm 4. Remove pipe (32) from housing (25). : 18 mm

W2-6-5

UPPERSTRUCTURE / Swing Device

23

3

25

21

4 5 6 7 8

18

10 17 16 30

11 12

15

W178-02-06-004

W2-6-6

UPPERSTRUCTURE / Swing Device 12. Remove the second stage carrier (18) assembly from shaft (30).

20. Remove bearing nut (15) from shaft (30), by using special tool (ST 2926). ST 2926

IMPORTANT: The hole for spring pin (5) located on first stage carrier (21) is not a through one. Check the tapping-in distance of spring pin (5). 13. Tap spring pins (5) (3 used) installed to the first stage carrier (21) assembly into pin (4) by using special tool (ST 1462). At this time, stop tapping when spring pin (5) reaches the middle of pin (4) hole and do not tap spring pin (5) to the end.

15

14. Remove pin (4), planetary gear (7), needle bearing (6) and thrust plate (8) from first stage carrier (21). 15. Remove other two sets of pin (4), planetary gear (7), needle bearing (6) and thrust plate (8) from first stage carrier (21) in the same order as steps 13 and 14. 16. Remove thrust plate (3) from first stage carrier (21). IMPORTANT: Do not damage the rotating surface for the needle bearing of pin (4) except for the both ends. 17. Secure the end of pins (4) (3 used) opposite the spring pin (5) hole in a vise. Tap and remove spring pins (5) (3 used) by using special tool (ST 1462).

W178-02-06-008

CAUTION: The housing weight: 122 kg (270 lb)

(25)

assembly

21. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to the bolt (23) hole on housing (25). Attach a nylon sling onto eyebolts. Hoist and remove bracket (ST 5097) from housing (25). : 30 mm 22. After removing bracket (ST 5097), install bracket (ST 1464). Set housing (25) to a press. : 30 mm

18. Disassemble the second stage carrier (18) assembly in the same way as the first stage carrier (21) assembly. Note that second stage carrier (18) assembly includes of needle bearings (12) (6 used) and thrust plates (11) (6 used). Use special tool (ST 1463) when removing spring pins (10) (3 used).

Press

25

ST 1464

19. Remove bolts (17) (2 used) from lock plate (16). Remove lock plate (16) from bearing nut (15). W178-02-06-006

W2-6-7

UPPERSTRUCTURE / Swing Device

25

26

27

28

29

30 14

W178-02-06-004

W2-6-8

UPPERSTRUCTURE / Swing Device 23. Push shaft (30) by using a press. Remove shaft (30) from housing (25). At this time, the inner race of roller bearing (26) and sleeve (28) are removed with shaft (30) together.

26. Remove the splined side of shaft (30) by using a press. Remove the inner race of roller bearing (26) and sleeve (28) from shaft (30). 27. Remove O-ring (29) from sleeve (28).

24. Place special tool (ST 1460) for removing roller bearing (26) onto the stepped part of special tool (ST 1461) for removing roller bearing (26). ST 1460

28. Insert a round bar into the oil passage in housing (25). Tap and remove outer race of roller bearing (26).

Outer Race of Roller Bearing (26)

ST 1461

Oil Passage

W178-02-06-001

W178-02-06-010

CAUTION: Housing (25) weight: 60 kg (140 lb) CAUTION: Shaft (30) weight: 40 kg (90 lb) 25. Insert the pinion gear of shaft (30) into tooth-hole of special tool (ST 1460). Set them onto a press. Press

30

30. Insert a screwdriver into the notch on housing (25), where oil seal (27) is mounted. Remove oil seal (27) from housing (25). NOTE: THREEBOND has been applied onto the periphery of oil seal (27). Therefore, oil seal (27) cannot be reused. 31. Tap and remove the outer race of roller bearing (14) from housing (25) by using a bar and hammer.

26 ST 1460

29. Fasten the body of housing (25) by using a nylon sling. Hoist and turn over housing (25).

28

ST 1461

W178-02-06-009

W2-6-9

UPPERSTRUCTURE / Swing Device ASSEMBLY OF SWING DEVICE

1

4

5

2

22

3 21

7 6

20

8

18

10

24

11

19

12

23

13

17

11

16

9

15

14

32 26

25

31

27 28 29

30

12345678-

Motor First Stage Planetary Gear Thrust Plate Pin (3 Used) Spring Pin (3 Used) Needle Bearing (3 Used) Planetary Gear (3 Used) Thrust Plate (3 Used)

WCJB-02-06-001

910 11 12 13 14 15 16 -

Pin (3 Used) Spring Pin (3 Used) Thrust Plate (6 Used) Needle Bearing (6 Used) Planetary Gear (3 Used) Roller Bearing Bearing Nut Lock Plate

17 18 19 20 21 22 23 24 -

Bolt (2 Used) Second Stage Carrier Thrust Plate Second Stage Sun Gear First Stage Carrier Socket Bolt (8 Used) Socket Bolt (12 Used) Ring Gear

W2-6-10

25 26 27 28 29 30 31 32 -

Housing Roller Bearing Oil Seal Sleeve O-Ring Shaft Drain Plug Pipe

UPPERSTRUCTURE / Swing Device Assembly of Swing Device 1. Apply grease onto O-ring (29). Install O-ring (29) onto sleeve (28). CAUTION: Shaft (30) + sleeve (28) + roller bearing (26) outer race weight: 36 kg (80 lb) 2. Install sleeve (28) and the inner race of roller bearing (26) to shaft (30). Install sleeve (28) and the inner race together by using special tool (ST 2923) and a press. NOTE: The press-in distance of inner race of roller bearing (26) can be assured by using special tool.

5. Apply THREEBOND #1215 onto the outer surface of oil seal (27). Place oil seal (27) flat on housing (25) and push by hands in gently. Place special tool (ST 2925) on oil seal (27). Tap in special tool by using a hammer straight. NOTE: The seal can be replaced by using special tool (ST2925) without removing the sleeve. ST 2925

27

25

Press

W178-02-06-007

6. Apply grease onto the inner surface of oil seal (27). Apply grease onto the outer surface of sleeve (28) attached with shaft (30). NOTE: Apply grease carefully when installing shaft (30) in order not to curl the lip.

ST 2923

26 28 30

CAUTION: Housing (25) + outer race weight: 63 kg (140 lb) W178-02-06-013

CAUTION: Housing (25) weight: 60 kg (140 lb) 3. Fasten the body of housing (25) by using a nylon sling. Hoist and place housing (25) with the sleeve (28) mounting side facing upward.

7. Fasten the body of housing (25) by using a nylon sling. Hoist and place housing (25) with the ring gear (24) side facing upward. 8. Tap and install the outer race of roller bearing (14) to housing (25) by using a bar and hammer. Tap and listen to ring in order to check if the installation is completed.

4. Evenly tap and install the outer race of roller bearing (26) into housing (25) by using a bar and hammer. Tap and listen to ring in order to check if the installation is completed.

W2-6-11

UPPERSTRUCTURE / Swing Device

24

23

15

14

25 27

30

WCJB-02-06-001

W2-6-12

UPPERSTRUCTURE / Swing Device CAUTION: Housing (25) + outer races (2 used) weight: 65 kg (150 lb) 9. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to the bolt (23) hole on housing (25). Hoist and place housing (25) on shaft (30) so that they are matched. At this time, check and align carefully in order to prevent the oil seal (27) lip from curling.

14. Place special tool (ST 2924) on the inner race of roller bearing (14). Install the inner race by using a press. NOTE: The press-in distance of inner race can be assured by using special tool. ST 2924

14

10. Tap and install the inner race of roller bearing (14) into shaft (30) by using a bar and hammer. Tap the inner race until the upper end of inner race reaches two threads for bearing nut (15) in shaft (30). NOTE: The fitting between inner race and shaft (30) is tight. 11. Tighten bearing nut (15) to shaft (30) by hand. NOTE: Prevent shaft (30) from falling off when hoisting housing (25). CAUTION: Housing (25) + shaft bearing total weight: 122 kg (270 lb)

(30)

+

W178-02-06-011

15. Hoist and place the housing (25) assembly on bracket (ST 5097). Install bolts (M20, Pitch 2.5 mm) (2 used). At this time, insert the stopper at the bottom of the bracket between teeth of the pinion gear. Secure the bracket on a workbench in order to reduce the reaction force. : 30 mm

12. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to the ring gear (24) mounting thread part on housing (25). Hoist and place housing (25) on a press.

25

ST 5097

13. Remove bearing nut (15) from shaft (30).

Stopper

W2-6-13

W178-02-06-012

UPPERSTRUCTURE / Swing Device

4

5 22

3 21

7 6 8

18

10 11

19

12 13

17

11

16

9

15

30

WCJB-02-06-001

W2-6-14

UPPERSTRUCTURE / Swing Device IMPORTANT: Check the direction to install bearing nut (15). 16. Apply a film of grease onto the thread part of bearing nut (15). Install bearing nut (15) to shaft (30). At this time, face the stepped side of bearing nut (15) to the roller bearing (14) side. Tighten bearing nut (15) by using special tool (ST 2926) to the specified torque. : 490 N⋅m (50 kgf⋅m, 361 lbf⋅ft) NOTE: Apply grease for keeping correct tightening torque.

20. Install pin (9) to the position where planetary gear (13) has been installed onto second stage carrier (18) with the spring pin hole facing front. At this time, the spring pin holes both in second stage carrier (18) and pin (9) should be in line. IMPORTANT: Check the direction of spring pin (10). 21. Install spring pin (10) to second stage carrier (18) by using spring pin removal and installation special tool (ST 1463). At this time, face the slit of spring pin to the end of pin (9). 10

ST 2926

9

15

Slit W178-02-06-002

W178-02-06-008

17. Install lock plate (16) to bearing nut (15) with bolts (17) (2 used). In case the splines of lock plate (16 and shaft (30) are not aligned, tighten bearing nut (15) in tightening direction until both splines are aligned. IMPORTANT: Check the direction to install thrust plate (19). 18. Install thrust plate (19) to second stage carrier (18) with the oil groove surface facing outside.

22. Install planetary gears (13) (2 used), needle bearings (12) (4 used), thrust plates (11) (4 used), pins (9) (2 used) and spring pins (10) (2 used) into other holes (2 places) on second stage carrier (18) in the same way as steps 19 to 21. IMPORTANT: Check the position to install thrust plate (8). 23. Install thrust plate (3), planetary gears (7) (3 used), needle bearings (6) (3 used), thrust plates (8) (3 used), pins (4) (3 used) and spring pins (5) (3 used) to the first stage carrier (21) in the same way as steps 19 to 21. At this time, install thrust plate (8) under needle bearing (6). Use special tool (ST 1462).

19. Clamp planetary gear (13) and needle bearings (12) (2 used) with thrust plates (11) (2 used). Install them to second stage carrier (18).

W2-6-15

UPPERSTRUCTURE / Swing Device

1

2

22

21

20 18 24

23

16

32

31 25

30

WCJB-02-06-001

W2-6-16

UPPERSTRUCTURE / Swing Device IMPORTANT: Check the direction to install second stage carrier (18). 24. Install the second stage carrier (18) assembly to the spline of shaft (30). At this time, the concave part of the boss in bottom side of second stage carrier (18) should come in contact with lock plate 18 Concave (16). Part

16

30

IMPORTANT: Check the direction to install first stage sun gear (2). 30. Install first stage sun gear (2) into the first stage carrier (21) assembly. At this time, face the stepped part facing downward. 31. Wind the seal tape onto the thread part of pipe (32). Install pipe (32) to housing (25). Face the pipe (32) downward. : 18 mm 32. Wind the seal tape onto drain plug (31). Install drain plug (31) to pipe (32). : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

W178-02-06-014

25. Install second stage sun gear (20) to the second stage carrier (18) assembly with the small diameter part facing upward.

33. Add gear oil to ring gear (24) until gear oil reaches the middle part of first stage sun gear (2). (Approx. 6.9 L, 1.8 US gal) 34. Apply THREEBOND #1215 onto the motor (1) mounting surface of ring gear (24). Clean old adhesive in advance.

26. Apply THREEBOND #1215 onto the ring gear (24) mounting surface of housing (25). Clean off old adhesive in advance. 27. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the motor mounting thread part on ring gear (24). Hoist and align ring gear (24) with the mounting holes on housing (25). At this time, align the matching marks made when disassembling.

CAUTION: Motor (1) weight: 47 kg (110 Ib) 35. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to motor (1). Hoist and install motor (1) to ring gear (24) with socket bolts (22) (8 used) while aligning the matching marks. : 10 mm : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

28. Install ring gear (24) into housing (25) with socket bolts (23) (12 used). : 14 mm : 210 N⋅m (21.5 kgf⋅m, 16 lbf⋅ft)

Eyebolt Mounting Position

29. Install the first stage carrier (21) assembly onto the spline of second stage sun gear (20). W178-02-06-005

W2-6-17

UPPERSTRUCTURE / Swing Device DISASSEMBLY OF SWING MOTOR 10 9 8 7 6 5 4

11

3 2

24

25

1

26

29 27

15

14

27

17

Casing Oil Seal Bearing Shaft Shoe Plate Plunger (9 Used) Plate Retainer

910 11 12 13 14 15 16 -

26

25

24

12

16

12345678-

31

28

23

13

30

Rotor Friction Plate (3 Used) Plate (4 Used) O-Ring Piston Spring Ball Plug (2 Used)

17 18 19 20 21 22 23 24 -

18

19

20

O-Ring O-Ring Brake Piston Spring (24 Used) Valve Plate Bearing O-Ring Plug (2 Used)

W2-6-18

21

22

32 W178-02-06-015

25 26 27 28 29 30 31 32 -

O-Ring (2 Used) Spring (2 Used) Poppet (2 Used) Valve Casing Socket Bolt (4 Used) O-Ring (2 Used) Plug (2 Used) Relief Valve (2 Used)

UPPERSTRUCTURE / Swing Device Disassembly of Swing Motor CAUTION: The swing weight: 47 kg (110 lb)

motor

assembly

IMPORTANT: Do not disassemble relief valve (32). 1. Remove relief valves (32) (2 used) from valve casing (28). : 41 mm 2. Remove plugs (24) (2 used) from valve casing (28). : 14 mm

IMPORTANT: Do not damage the mating surfaces when separating valve plate (21) from valve casing (28) or rotor (9) by using a screwdriver. (Check the surfaces of valve plate (2) in order not to make a mistake for assembling.) 7. If valve plate (21) is still on rotor (9) in step 5, remove valve plate (21) from the rotor (19) side. Remove springs (20) (24 used) from brake piston (19). CAUTION: There is also a method of applying air from port B in order to float brake piston (19). Prevent piston (13) from flying out.

3. Remove springs (26) (2 used) and poppets (27) (2 used) from valve casing (28). 4. Put the matching marks on the jointed surface between valve casing (28) and casing (1). Remove socket bolts (29) (4 used) from valve casing (28). At this time, as the clearance exists between valve casing (28) and casing (1), record this clearance. : 17 mm

8. Install special tool (ST 1468) to notch A of brake piston (19). Remove brake piston (19) from casing (1).

Notch A

5. Remove valve casing (28) from casing (1). NOTE: At this time, as valve casing (28) may be removed with valve plate (21) together, do not drop valve plate (21). 6. Remove O-ring (23) from valve casing (28).

Port B

WCJB-02-06-003

9. Remove O-rings (17, 18) from casing (1).

W2-6-19

UPPERSTRUCTURE / Swing Device

10 9 8 7 6 5 4

11

3 2 1

15

14

13

W178-02-06-015

W2-6-20

UPPERSTRUCTURE / Swing Device IMPORTANT: Do not damage the sliding surfaces of rotor (9) and plunger (6). 10. Place casing (1) horizontally. Remove rotor (9), retainer (8), plate (7) and plungers (6) (9 used) from shaft (4). 11. Remove plates (11) (4 used) and friction plates (10) (3 used) from casing (1). IMPORTANT: Do not damage the sliding surface of shoe plate (5). 12. Remove shoe plate (5) from casing (1). 13. Lightly tap and remove shaft (4) from casing (1) by using a plastic hammer. 14. Remove the outer race of bearing (3) from casing (1) by using a bar. 15. Remove oil seal (2) from casing (1). 16. Remove the inner race of roller bearing (3) from shaft (4) by using a press. IMPORTANT: Although the filter and the orifice are installed to piston (13), do not disassemble piston (13) unless they are clogged or deformed. When replacing the internal parts, replace as an assembly. 17. Remove piston (13) from casing (1) by using a pair of pliers. 18. Remove spring (14) and ball (15) from casing (1).

W2-6-21

UPPERSTRUCTURE / Swing Device ASSEMBLY OF SWING MOTOR 27

26

25

12 24

13 14 15

16

29

WCJB-02-06-003 WCJB-02-06-002

31 30

32

28 22

21

23

20

18

19

17

11

10

6

9

8

7 5

3 1

2

4 12345678-

Casing Oil Seal Bearing Shaft Shoe Plate Plunger (9 Used) Plate Retainer

WCJB-02-06-004

910 11 12 13 14 15 16 -

Rotor Friction Plate (3 Used) Plate (4 Used) O-Ring Piston Spring Ball Plug (2 Used)

17 18 19 20 21 22 23 24 -

O-Ring O-Ring Brake Piston Spring (24 Used) Valve Plate Bearing O-Ring Plug (2 Used)

W2-6-22

25 26 27 28 29 30 31 32 -

O-Ring (2 Used) Spring (2 Used) Poppet (2 Used) Valve Casing Socket Bolt (4 Used) O-Ring (2 Used) Plug (2 Used) Relief Valve (2 Used)

UPPERSTRUCTURE / Swing Device Assembly of Swing Motor IMPORTANT: Install the inner race of bearing (3) with the flange part facing to the stepped side of shaft (4). 1. Install the inner races of bearings (3, 22) to shaft (4) by using a press. IMPORTANT: Install oil seal (2) with the lip part facing upward. 2. Install oil seal (2) to casing (1) by using a plate. 3. Install the outer race of bearing (3) into casing (1) by using a bar.

8. Place casing (1) horizontally. Install the rotor (9) assembly to shaft (4) by turning shaft (4). IMPORTANT: There are 4 notches on the outer side of plate (11), and 4 notches at the spline teeth side of friction plate (10). Align each notch at the same place when installing. 9. Place casing (1) vertically. Alternately install plates (11) (4 used) and friction plates (10) (3 used) to casing (1). 10. Install O-rings (17, 18) onto casing (1).

IMPORTANT: Wind the tape onto the spline at the end of shaft (4) in order not to damage oil seal (2). 4. Install shaft (4) with casing (1). 5. Place casing (1) with the valve casing (28) mounting surface facing upward. Install shoe plate (5) with the chamfered surface facing inside. IMPORTANT: Install retainer (8) to plunger (6) with the notch facing to the shoe plate (5) side. 6. Align the notches on plate (7) and retainer (8). Install plungers (6) (9 used).

11. Align the matching marks and install brake piston (19) into casing (1). NOTE: If it is not easy to install brake piston (19) due to the resistant force from O-rings (17, 18), tap them evenly by using a plastic hammer. 12. Install springs (20) (24 used) to brake piston (19).

IMPORTANT: Install plunger (6) to after applying hydraulic oil onto the plunger (6) hole on rotor (9). 7. Install plungers (6) (9 used) to rotor (9).

W2-6-23

UPPERSTRUCTURE / Swing Device

27

26

25

24

13 14 15

29

WCJB-02-06-003 WCJB-02-06-002

32

28 22

21

23

9

1 4

WCJB-02-06-004

W2-6-24

UPPERSTRUCTURE / Swing Device IMPORTANT: When replacing the inner parts of piston (13), replace the piston (13) as an assembly. Install so that the ends of piston (13) and casing (1) may be in the same position. 13. Install ball (15), spring (14) and piston (13) to casing (1). IMPORTANT: Tap the bearing type indicated surface by using a plastic hammer and install roller bearing (22). 14. Install the outer race of bearing (22) to valve casing (28) by using a plastic hammer.

18. Install valve casing (28) to casing (1) with socket bolts (29) (4 used). : 17 mm : 430 N⋅m (44 kgf⋅m, 317 lbf⋅ft) 19. Install poppets (27) (2 used) and springs (26) (2 used) into valve casing (28). Install plug (24) with O-ring (25) attached. : 14 mm : 330 N⋅m (34 kgf⋅m, 243 lbf⋅ft) 20. Install relief valves (32) (2 used) into valve casing (28). : 41 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

IMPORTANT: Check the surfaces of valve plate (21). (Face the notch of the port to rotor (9).) 15. Install O-ring (23) to valve casing (28). Install valve plate (21) to valve casing (28). NOTE: Apply grease onto valve plate (21) in order to prevent valve plate (21) from falling off from valve casing (28). 16. Apply grease onto the needle part of bearing (22). NOTE: Shaft (4) can be inserted easily by holding the needle with grease. 17. Align the matching marks on valve casing (28) and casing (1). Place valve casing (28) onto casing (1). Check that the clearance between valve casing (28) and casing (1) is equal to that before disassembling. At this time, if the clearance is larger than that before disassembling, repeat the installation from step 5.

W2-6-25

UPPERSTRUCTURE / Swing Device STRUCTURE OF SWING DAMPENER VALVE

1

2

3

4

5

6

7

WCJB-02-06-007

Item 1 2 3 4 5 6 7

Parts Name Swing Damperner Assembly Plug Casing O-Ring Backup Ring Case Plug

Q’ty valve

Wrench Size (mm)

N⋅m

Tightening Torque (kgf⋅m) (lbf⋅ft)

2 3 1 2 2 2 2

: 4

9

(0.9)

(7)

: 24 : 8

69

(7)

(51)

W2-6-26

Remark

UPPERSTRUCTURE / Swing Device MAINTENANCE STANDARD Swing Motor 1. Clearance between plunger outer diameter and rotor inner bore

d

D-d Standard

Allowable Limit

0.027 mm (0.001 in)

0.052 mm (0.002 in) W107-02-06-138

D

D

W107-02-06-139

2. Clearance between plunger and shoe bottom Standard

Allowable Limit

0 mm

0.3 mm (0.012 in)

Plunger

δ

Shoe

W107-02-06-140

W2-6-27

UPPERSTRUCTURE / Swing Device 3. Shoe thickness Standard

Allowable Limit

5.5 mm (0.22 in)

5.3 mm (0.2 in)

t

W107-02-06-142

4. Friction plate thickness Standard

Allowable Limit

2.0 mm (0.08 in)

1.8 mm (0.07 in)

W107-02-06-143

W2-6-28

UPPERSTRUCTURE / Pilot Valve REMOVAL AND INSTALLATION OF PILOT VALVE CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal of Left Pilot Valve

1

2

3

4

5

CAUTION: Seat (1) weight: 40 kg (90 lb) 1. Remove sems bolts (4) (2 used) from seat belts (6) (2 used). Remove seat belt (6) from brackets (5) (2 used). : 16 mm

6

WCEB-02-01-001

6

4

5

2

3

WCEB-02-01-017

1

2. Remove socket bolts (3) (4 used) from seat (1). Remove seat (1) from plate (2). : 6 mm

3

WCEB-02-01-002

2 7

3. Remove screws (9) (4 used) from boot (7). Raise boot (7) from bracket (8).

8

9

W1JB-02-07-002

W2-7-1

UPPERSTRUCTURE / Pilot Valve 4. Remove screw (10) from covers (11, 12). 10

12

11

WCEB-02-07-001

5. Remove sems bolt (14) from cover (11). Remove screws (13) (3 used) from covers (11, 12). Remove covers (11, 12) from bracket (8). : 10 mm

12 11

13

14

WCEB-02-07-003

11

13 12

8

W2-7-2

13

WCEB-02-07-004

UPPERSTRUCTURE / Pilot Valve 6. Remove clip bands (17) (2 used) from lever (15) and harness (18). Disconnect a connector from harness (18).

15

16

17

7. Loosen lock nut (16). Remove lever (15) assembly from pilot valve (19). : 19 mm, 22 mm

18

8. Disconnect hoses (20) (6 used) from pilot valve (6). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm

19

20

W1JB-02-07-005

9. Remove sems bolts (21) (4 used) from bracket (8). Remove pilot valve (19) from bracket (8). : 13 mm

21

8

19

W1JB-02-07-005

21

W2-7-3

UPPERSTRUCTURE / Pilot Valve Installation of Left Pilot Valve

21

8

1. Install pilot valve (19) to bracket (8) with sems bolts (21) (4 used). : 13 mm : 20 N·m (2 kgf·m, 15 lbf·ft) 2. Connect hoses (20) (6 used) onto pilot valve (6). : 19 mm : 29.5 N·m (3 kgf·m, 22 lbf·ft)

19

20

W1JB-02-07-005

21 15

3. Install lever (15) assembly to pilot valve (19). Secure lever (15) assembly to pilot valve (19) with lock nut (16). : 22 mm : 55 N·m (5.5 kgf·m, 41 lbf·ft)

16

17

18

4. Connect harness (18) connector. 5. Install harness (18) to bracket (8) of pilot valve (19) with clip band (17).

8 19

W1JB-02-07-005

6. Install cover (11, 12) to bracket (8) with round head screws (13) (3 used) and sems bolt (14). : 10 mm : 3.3 to 4.2 N·m (0.3 to 0.4 kgf·m, 2 to 3 lbf·ft)

12 11

13 8 14 WCEB-02-07-003

W2-7-4

UPPERSTRUCTURE / Pilot Valve 7. Install cover (11, 12) to bracket (8) with round head screw (10). 10

8

12

11

WCEB-02-07-001

7

8. Install boot (7) to bracket (8) with round head screws (9) (4 used).

8

9

W1JB-02-07-002

1

CAUTION: Seat (1) weight: 40 kg (90 lb) 9. Install seat (1) to plate (2) with socket bolts (3) (4 used). : 6 mm : 20 N·m (2 kgf·m, 15 lbf·ft)

3

10. Install seat belt (6) (2 used) to bracket (5) (2 used) with sems bolts (4) (2 used). : 16 mm : 50 N·m (5 kgf·m, 37 lbf·ft)

WCEB-02-01-002

2 1

2

3

4

5

6

WCEB-02-01-001

W2-7-5

UPPERSTRUCTURE / Pilot Valve Removal of Right Pilot Valve 1. Remove the seat. (Refer to W2-7-1.) 2. Remove cap (3) (2 used) and round head screws (1, 4) (1 each used) from cover (2). Remove cover (2) from bracket (7).

1

2

3, 4

5

3. Remove sems bolt (6) from cover (5). : 10 mm 4. Remove round head screw (9) from cover (8). 7

6 WCEB-02-07-006

8 3, 4 2 1 7 9

WCEB-02-07-005

10

5. Remove round head screws (11) (4 used) from boot (10). Remove boot (10) from bracket (7).

7 11

8

W1JB-02-07-002

6. Remove round head screw (12) from cover (5, 8). Remove covers (5, 8) from bracket (7).

12 7 8

5

W1JB-02-07-016

W2-7-6

UPPERSTRUCTURE / Pilot Valve 7. Remove clip bands (15) (2 used) from lever (13) and harness (16). Disconnect a connector from harness (16).

13

14

15

8. Loosen lock nut (14). Remove lever (13) assembly from pilot valve (17). : 19 mm, 22 mm

16

17

W1JB-02-07-005

9. Remove sems bolts (19) (3 used) from bracket (7). Remove bracket (7) assembly from stand (18). Hoist bracket (7) assembly. : 17 mm

7 19

18 WCEB-02-07-009

10. Disconnect hoses (20) (6 used) from pilot valve (6). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm

21

7

11. Remove sems bolts (21) (4 used) from bracket (7). Remove pilot valve (17) from bracket (7). : 13 mm

17

20

W1JB-02-07-005

21

W2-7-7

UPPERSTRUCTURE / Pilot Valve Installation of Right Pilot Valve

21

7

1. Install pilot valve (17) to bracket (7) with sems bolts (21) (4 used). : 13 mm : 20 N·m (2 kgf·m, 15 lbf·ft)

17

2. Connect hoses (20) (6 used) onto pilot valve (6). : 19 mm : 29.5 N·m (3 kgf·m, 22 lbf·ft) 20

W1JB-02-07-005

21 13

3. Install lever (13) assembly to pilot valve (17). Secure lever (13) assembly to pilot valve (17) with lock nut (14). : 22 mm : 56 N·m (5.5 kgf·m, 41 lbf·ft)

14

15

16

4. Connect harness (16) connector. 7

5. Install harness (16) to pilot valve (17) and bracket (7) with clip band (15) (2 used).

17

W1JB-02-07-005

6. Install cover (5) to bracket (7) with sems bolts (6). : 10 mm : 3.3 to 4.2 N·m (0.3 to 0.4 kgf·m, 2 to 3 lbf·ft)

5

7

6 WCEB-02-07-006

W2-7-8

UPPERSTRUCTURE / Pilot Valve 7. Install bracket (7) assembly to stand (18) with sems bolts (19) (3 used). : 17 mm : 50 N·m (5 kgf·m, 37 lbf·ft) 8. Install cover (8) to bracket (7) with round head screw (9).

7 9

19

9. Install covers (5, 8) to bracket (7) with round head screw (12).

18

8

WCEB-02-07-009

12 7 5

8

W1JB-02-07-016

10

10. Install boot (10) to bracket (7) with round head screws (11) (4 used).

7 11

W1JB-02-07-002

11. Install cover (2) to bracket (7) with round head screws (1, 4) (2 each used). Attach cap (3) (2 used) to cover (2).

2 1

3, 4

8

5

7

6 WCEB-02-07-006

W2-7-9

UPPERSTRUCTURE / Pilot Valve 21

CAUTION: Seat (21) weight: 40 kg (90 lb) 12. Install seat (21) to plate (23) with socket bolts (22) (4 used). : 6 mm : 20 N·m (2 kgf·m, 15 lbf·ft)

22

WCEB-02-01-002

23

13. Install seat belts (26) (2 used) to brackets (25) (2 used) with sems bolts (24) (2 used). : 16 mm : 50 N·m (5 kgf·m, 37 lbf·ft)

21

23

22

24

25

26

WCEB-02-01-001

26

24

25

23

22

WCEB-02-01-017

W2-7-10

UPPERSTRUCTURE / Pilot Valve REMOVAL AND INSTALLATION TRAVEL PILOT VALVE

OF

CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Remove mat (1) from cab (2) inside.

1

2 WCEB-02-01-003

2. Remove sems bolts (4) (2 used) from pedal (3). Remove pedal (3) from bracket (5). : 13 mm

3

Auxiliary Pedal

Brake Pedal

3. Remove sems bolts (7) (2 used) from bracket (5). Remove bracket (5) from travel pilot valve (6). : 13 mm

WCEB-02-07-002

3 4

5

7

W2-7-11

6

WCEB-02-07-007

UPPERSTRUCTURE / Pilot Valve 8

4. Remove sems bolts (8) (6 used) from cover (9). Remove cover (9) from main frame (10). : 17 mm

9

8

10

WCEB-02-13-001

5. Disconnect hoses (11) (4 used) from travel pilot valve (14). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm 6. Remove sems bolts (12) (2 used) from travel pilot valve (14). Remove travel pilot valve (14) from plate (13). : 17 mm

11

12

13

14

11 WCEB-02-07-008

W2-7-12

UPPERSTRUCTURE / Pilot Valve Installation 1. Install travel pilot valve (14) to plate (13) with sems bolts (12) (2 used). : 17 mm : 50 N·m (5 kgf·m, 37 lbf·ft)

11

12

13

14

2. Connect hoses (11) (4 used) onto travel pilot valve (14). : 19 mm : 29.5 N·m (3 kgf·m, 22 lbf·ft)

11 WCEB-02-07-008

3. Install bracket (5) to travel pilot valve (6) with sems bolts (7) (2 used). : 13 mm : 20 N·m (2 kgf·m, 15 lbf·ft)

3 4

4. Install pedal (3) to bracket (5) with sems bolts (4) (2 used). : 13 mm : 20 N·m (2 kgf·m, 15 lbf·ft)

5

7

6

WCEB-02-07-007

3

Auxiliary Pedal

Brake Pedal

WCEB-02-07-002

5. Install mat (1) to the cab (2) inside. 1

2 WCEB-02-01-003

W2-7-13

UPPERSTRUCTURE / Pilot Valve 6. Install cover (9) to main frame (10) with sems bolts (8) (6 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf·ft)

8

9

10

WCJB-02-13-001

W2-7-14

UPPERSTRUCTURE / Pilot Valve (Blank)

W2-7-15

UPPERSTRUCTURE / Pilot Valve DISASSEMBLY OF FRONT/SWING PILOT VALVES 10 10 11

1 11

12

12

2

13

13 3

14

4

5 5 15

6 6

16

7

7

17 8

8

18 9

9

19 19 20 20 W1F3-02-07-001

12345-

Screw Joint Cam Universal Joint Plate Oil Seal (4 Used)

678910 -

Bushing (4 Used) O-Ring (4 Used) Pusher (4 Used) Spring Seat (4 Used) Spring (4 Used)

11 12 13 14 15 -

W2-7-16

Spring (4 Used) Washer (4 Used) Spool (4 Used) Casing O-Ring

16 17 18 19 20 -

Bushing Spring Pin Port Plate Sealing Washer (2 Used) Socket Bolt (2 Used)

UPPERSTRUCTURE / Pilot Valve Disassembly of Front/Swing Pilot Valves • Spool (13) has been selected to match the hole of casing (14). Therefore, the parts cannot be replaced individually. • Indicate the port number of the removed in order not to confuse parts. The port numbers are stamped on the outer surface of casing (14).

3. Install special tool (ST 7260) to universal joint (3). Remove universal joint (3) from casing (14) by turning. : 24 mm

1. Clamp the pilot valve in a vice. Secure the plot valve with the port plate (18) facing downward.

Section A-A

2. Put the matching marks on plate (4) and casing (14). Secure cam (2) by using a spanner. Remove screw joint (1) and cam (2) from universal joint (3). : 32 mm

ST 7260

CAUTION: Springs (10) (4 used) are in the compressed condition. Therefore, when loosening universal joint (3), plate (4), bushings (6) (4 used), and pushers (8) (4 used) are raised at the same time. Do not fly out them.

A

A

3

W577-02-06-003

4. Remove plate (4) from casing (14). IMPORTANT: When bushing (6) (4 used) are still in casing (14), remove pusher (8) by moving left and right. Do not damage pusher (8). IMPORTANT: Indicate the port numbers of the spool (13) assembly and springs (10) (4 used) in order not to confuse the parts. Do not damage spool (13). 5. Remove the pusher (8) assembly, the spool (13) assembly and springs (10) (4 used) from casing (14). 6. Remove pushers (8) (4 used), O-rings (7) (4 used) and oil seals (5) (4 used) from bushings (6) (4 used).

W2-7-17

UPPERSTRUCTURE / Pilot Valve

11 11 12

12 13

13

14

15

16

17

18 9

9

20

W1F3-02-07-001

W2-7-18

UPPERSTRUCTURE / Pilot Valve IMPORTANT: Do not disassemble the spool (13) assembly unless necessary. IMPORTANT: When removing spring seats (9) (4 used) from spool (13), push in spring seat (9) once and remove it by moving to a larger hole of 2 holes on spring seat (9). At this time, do not push in spring seat (9) for more than 6 mm (0.2 in).

13

11

9

WCEB-02-07-010

7. Remove spring seats (9) (4 used), springs (11) (4 used) and washers (12) (4 used) from spool (13). 8. Clamp the pilot valve in a vice. Secure the pilot valve with port plate (18) facing upward. 9. Remove socket bolts (20) (2 used) and seal washers (19) (2 used) from port plate (18). 10. Remove port plate (18), O-ring (15), bushing (16) and spring pin (17) from casing (14).

W2-7-19

UPPERSTRUCTURE / Pilot Valve ASSEMBLY OF FRONT/SWING PILOT VALVES

1 3

2 8 5 4 6 7

9 11 10 12 13

14 16 15 17

18 19 20

12345-

Screw Joint Cam Universal Joint Plate Oil Seal (4 Used)

678910 -

Bushing (4 Used) O-Ring (4 Used) Pusher (4 Used) Spring Seat (4 Used) Spring (4 Used)

11 12 13 14 15 -

Spring (4 Used) Washer (4 Used) Spool (4 Used) Casing O-Ring

W2-7-20

16 17 18 19 20 -

W1F3-02-07-002

Bushing Spring Pin Port Plate Sealing Washer (2 Used) Socket Bolt (2 Used)

UPPERSTRUCTURE / Pilot Valve IMPORTANT: Install spring (10) to the same position before disassembling. 4. Install springs (10) (4 used) to casing (14).

Assembly of Front/Swing Pilot Valves • Replace the seals with the new ones. 1. Install bushing (16) and O-ring (15) to casing (14). 2. Install spring pin (17) to port plate (18). Install port plate (18) to casing (14) with socket bolts (20) (2 used) and seal washers (19) (2 used). : 20.5±2 N·m (2.1±0.2 kgf·m, 15±2 lbf·ft) IMPORTANT: When installing spring seats (9) (4 used) to spool (13), insert spool (13) from a larger hole of 2 holes on spring seat (9) and move to a smaller hole direction. At this time, do not push in spool (13) for more than 6 mm (0.2 in).

13

9

WCEB-02-07-010

3. Install washers (12) (4 used), springs (11) (4 used) and spring seats (9) (4 used) to spools (13) (4 used) in this order.

IMPORTANT: Install the spool (13) assemblies (4 used) to the same position as it was before disassembling. 5. Install the spool (13) assemblies (4 used) to casing (14). 6. Install O-rings (7) (4 used) and oil seals (5) (4 used) to bushings (6) (4 used). IMPORTANT: Apply hydraulic oil onto the outer surface of pushers (8) (4 used). 7. Install pushers (8) (4 used) to bushings (6) (4 used). IMPORTANT: If installing plate (4) is difficult due to strong springs (10) (4 used), place the bushing (6) assemblies (4 used) on 4 holes of casing (14). Place plate (4) on them. Temporarily secure the bushing (6) assemblies (4 used). While holding it with universal joint (3). 8. Install the bushing (6) assemblies (4 used) to casing (14), by aligning the matching marks before disassembly.

W2-7-21

UPPERSTRUCTURE / Pilot Valve

1 3

2 8

14

W1F3-02-07-002

W2-7-22

UPPERSTRUCTURE / Pilot Valve 9. Install universal joint (3) to casing (14) by using special toll (ST 7260). : 24 mm : 47.1±2.9 N·m (4.8±0.3 kgf·m, 35±2 lbf·ft) 10. Screw in universal joint (3) until pushers (8) (4 used) come in contact with cam (2) evenly. IMPORTANT: When tightening screw joint (1), do not move cam (2). 11. Secure cam (2) by using a spanner. Install screw joint (1) to universal joint (3). : 32 mm : 68.6±4.9 N·m (7.0±0.5 kgf·m, 51±4 lbf·ft) 12. Apply grease onto the rotating part of universal joint (3) and the top of pusher (8).

W2-7-23

UPPERSTRUCTURE / Pilot Valve DISASSEMBLY OF TRAVEL AND AUXILIARY/POSITIONING PILOT VALVES

20

7

20

8 6

19

9

19 18

10

4

18

5

17 16

17 16

15

6 15 4 11

14 14

3 12

3

13

2

2 21

1

1

W1LA-02-06-001

123456-

O-Ring (2 Used) Bushing (2 Used) Packing (2 Used) Bushing (2 Used) Steel Ball (2 Used) Socket Bolt (2 Used)

78910 11 -

Boot Set Screw Cam Pin Cover

12 13 14 15 16

-

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

W2-7-24

17 18 19 20 21

-

Shim (2 Used) Spring (2 Used) Spring Guide (2 Used) Pusher (2 Used) Casing

UPPERSTRUCTURE / Pilot Valve Disassembly of Travel and Auxiliary/Positioning Pilot Valves • Spool (15) has been selected to match the hole of casing (21). Therefore, the parts cannot be replaced individually. • Indicate the port number of the removed in order not to confuse. IMPORTANT: Before disassembling, put the matching marks on cam (9), pin (10), cover (11) and casing (21). 1. Secure the pilot valve in a vise. Remove boot (7) from cover (11). 2. Remove set screw (8) from cam (9). Remove pin (10) from cover (11). Remove cam (9) from cover (11). NOTE: LOCTITE is applied onto the set screw part. NOTE: Steel ball (5) cannot be disassembled from cam (9).

7. Remove spring guides (19) (2 used), springs (18) (2 used), washers (16) (2 used) and shims (17) (2 used) from the spool (15) assemblies (2 used). IMPORTANT: As the spool (15) assemblies (2 used) are adjusted by shim (17), do not disassemble the spool (15) assembly unless necessary. If the spool (15) assembly is disassembled, record the quantity and thickness of shim (17). IMPORTANT: Do not remove bushing (4) from cover (11) unless bushing (4) is damaged. 8. Remove bushings (4) (2 used) from cover (11).

3. Loosen and remove socket bolts (6) (2 used) from cover (11) alternately. Remove cover (11) from casing (21). 4. Remove the pusher (20) assemblies (2 used) from casing (21). 5. Remove bushings (2) (2 used) from the pusher (20) assembly. Remove O-rings (1) (2 used) and packings (3) (2 used) from bushings (2) (2 used). IMPORTANT: Indicate the port numbers in order not to confuse the parts. 6. Remove the spool (15) assemblies (2 used) and springs (14) (2 used) from casing (21).

W2-7-25

UPPERSTRUCTURE / Pilot Valve ASSEMBLY OF TRAVEL AND AUXILIARY/POSITIONING PILOT VALVES 7

8

10

9

5

20 3 6 2 11

1 19 18 14

17 16

12 13 15 W1LA-02-06-002

21 123456-

O-Ring (2 Used) Bushing (2 Used) Packin (2 Used) *Bushing (2 Used) Steel Ball (2 Used) Socket Bolt (2 Used)

78910 11 -

Boot Set Screw Cam Pin Cover

12 13 14 15 16 -

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

NOTE: *Refer to W2-7-24.

W2-7-26

17 18 19 20 21 -

Shim (2 Used) Spring (2 Used) Spring Guide (2 Used) Pusher (2 Used) Casing

UPPERSTRUCTURE / Pilot Valve Assembly of Travel and Auxiliary/Positioning Pilot Valve • Clean not to confuse the parts. Arrange the parts by port in order.

8. Apply LOCTITE #241 onto setscrew (8). Secure cam (9) to pin (10) with setscrew (8). : 5 N·m (0.5 kgf·m, 41 lbf·ft) 9. Install boot (7) to cover (11).

1. Install bushings (4) (2 used) to cover (11). IMPORTANT: Install shim (17) as its thickness becomes same before disassembling. 2. Install washers (16) (2 used), shims (17) (2 used), springs (18) (2 used) and spring guides (19) (2 used) to spools (15) (2 used) in this order. IMPORTANT: Install the spool (15) assembly into the same hole before disassembling. 3. Install spring (14) (2 used) to casing (21). Install the spool (15) assemblies (2 used) to casing (21). 4. Install O-rings (1) (2 used) and packings (3) (2 used) to bushings (2) (2 used). 3 2 1

Lip

W585-02-06-005

5. Install pushers (20) (2 used) to the bushing (2) assemblies (2 used). Install the pusher (20) assemblies (2 used) to casing (21). 6. Secure casing (21) in a vise. Install cover (11) to casing (21) with socket bolts (6) (2 used). : 23.5 N·m (2.4 kgf·m, 17 lbf·ft) 7. Install cam (9) to cover (11). Secure cam (9) to cover (11) with pin (10).

W2-7-27

UPPERSTRUCTURE / Pilot Valve (Blank)

W2-7-28

UPPERSTRUCTURE / Electric Lever REMOVAL AND ELECTRIC LEVER

INSTALLATION

OF 1

Removal of Auxiliary/Positioning Electric Lever

2

1. Remove sems bolts (2) (6 used) from cover (1). Remove cover (1) from main frame (3). : 17 mm

3

WCJB-02-13-001

2. Disconnect connector (4). 4

WCEB-02-08-002

5

3. Remove mat (6) from the inside of cab (5).

6

WCEB-02-01-003

4. Remove sems bolts (8) (2 used) from pedal (9). Remove pedal (9) from bracket (10). : 13 mm 5. Remove sems bolts (7) (2 used) from bracket (10). Remove bracket (10) from electric lever (11). : 13 mm

8

7

9

11

W2-8-1

10

WCEB-02-08-001

UPPERSTRUCTURE / Electric Lever 6. Remove sems bolts (13) (4 used) from bracket (12). Remove the bracket (12) assembly from plate (14). : 17 mm

14

13

12

WCEB-02-08-001

11

7. Remove sems bolts (15) (2 used) from electric lever (11). Remove electric lever (11) from bracket (12). : 17 mm

15

WCEB-02-08-002

Installation of Auxiliary/Positioning Electric Lever 1. Install electric lever (11) to bracket (12) with sems bolts (15) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

11

15

WCEB-02-08-002

2. Install the bracket (12) assembly to plate (14) with sems bolts (13) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

14

W2-8-2

13

12

WCEB-02-08-001

UPPERSTRUCTURE / Electric Lever 3. Install bracket (10) to electric lever (11) with sems bolts (7) (2 used). : 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 4. Install pedal (9) to bracket (10) with sems bolts (8) (2 used). : 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

8

7

9

11

5. Install mat (6) to the inside of cab (5).

10

WCEB-02-08-001

5

6

WCEB-02-01-003

6. Connect connector (4). 4

WCEB-02-08-002

1

7. Install cover (1) to main frame (3) with sems bolts (2) (6 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2 3

WCJB-02-13-001

W2-8-3

UPPERSTRUCTURE / Electric Lever Removal of Blade/Outrigger Electric Lever 1. Remove caps (4) (2 used) from cover (2). Remove screws (5, 7) (2 used for each) from cover (2). : 17 mm

2

3

1

2. Remove sems bolt (6) from cover (3). : 10 mm

4, 5

8

7

6

WCEB-02-07-006

3. Remove screw (9) from cover (1).

1

9 WCEB-02-07-009

10

4. Remove screws (11) (4 used) from boot (10). Raise boot (10) from bracket (8).

8 11 3 1

W1JB-02-07-002

5. Remove screw (12) from cover (1). Remove covers (1, 3) from bracket (8).

12

10 8

1

W1JB-02-07-016

W2-8-4

UPPERSTRUCTURE / Electric Lever 6. Disconnect connector (13).

WCEB-02-08-004

13

14

7. Remove socket bolts (18) (2 used) from lever (14). Remove lever (14) from electric lever (17). : 6 mm

15

8. Remove sems bolts (16) (2 used) from bracket (15). Remove the bracket (15) assembly from bracket (8). : 17 mm

16

18

9. Remove sems bolts (19) (2 used) from electric lever (17). Remove electric lever (17) from bracket (15). : 17 mm

17

8

WCEB-02-08-003

19

15

17 WCEB-02-08-004

W2-8-5

UPPERSTRUCTURE / Electric Lever Installation of Blade/Outrigger Electric Lever 1. Install electric lever (17) to bracket (15) with sems bolts (19) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

19

2. Connect connector (13). 15

17 WCEB-02-08-004

13

3. Install the bracket (15) assembly to bracket (8) with sems bolts (16) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

14

15

4. Install lever (14) to electric lever (17) with socket bolts (18) (2 used). : 6 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

16

18

5. Install covers (1, 3) to bracket (8) with screw (12).

17

WCEB-02-08-003

8

10

12

8 3

1

6. Install boot (10) to bracket (8) with screws (11) (4 used).

W1JB-02-07-016

10 8 11

W1JB-02-07-002

W2-8-6

UPPERSTRUCTURE / Electric Lever 7. Install cover (1) to bracket (8) with screw (9).

8 9 1

8. Install cover (3) to bracket (8) with sems bolt (6). : 10 mm : 3.3 to 4.2 N⋅m (0.3 to 0.4 kgf⋅m, 2.4 to 3 lbf⋅ft)

2

WCEB-02-07-009

3

9. Install cover (2) to bracket (8) with screws (5, 7) (2 used for each).

4, 5

10. Install caps (4) (2 used) to cover (2).

8

W2-8-7

7

6

WCEB-02-07-006

UPPERSTRUCTURE / Electric Lever DISASSEMBLY OF ELECTRIC LEVER

9 10

8

11

7

12

6 5

13 14 15 16 17

4

18

3 2 1

19 20

W1MG-02-07-003

12345-

Screw (2 Used) Plate Screw (2 Used) Potentiometer Pin

678910 -

Bushing (2 Used) Screw Arm Boot Set Screw

11 12 13 14 15 -

W2-8-8

Cam Socket Bolt (2 Used) Holder O-Ring (2 Used) Bushing (2 Used)

16 17 18 19 20 -

Bushing (2 Used) Spring (2 Used) Housing Clip Screw

UPPERSTRUCTURE / Electric Lever Disassembly of Electric Lever IMPORTANT: Housing (18) is made of aluminum. As too strong a force may deform or damage it, handle it with care.

IMPORTANT: Keep the disassembled parts carefully in order to install them to their original ports. 10. Remove the pusher (16) assemblies (2 used) and springs (17) (2 used) from housing (18).

1. Secure housing (18) in a vise. 2. Remove screws (1) (2 used) from plate (2). Remove plate (2) from housing (18).

IMPORTANT: Do not damage bushing (15).

3. Remove screws (20) from clip (19). Remove clip (19) from housing (18).

11. Remove pushers (16) (2 used) and O-rings (14) (2 used) from bushings (15) (2 used).

4. Remove screws (3) (2 used) from potentiometer (4). Remove potentiometer (4) from housing (18).

IMPORTANT: Bushing (6) cannot be reused. 12. Remove bushings (6) (2 used) from holder (13).

5. Remove boot (9) from holder (13). 6. Remove set screw (10) from cam (11). : 2.5 mm 7. Remove pin (5) from holder (13). Remove cam (11) from holder (13). 8. Remove screw (7) from arm (8). Remove arm (8) from cam (11). IMPORTANT: The pusher (16) assembly may fly out by spring (17). 9. Remove socket bolts (12) (2 used) from holder (13). Remove holder (13) from housing (18). : 5 mm

W2-8-9

UPPERSTRUCTURE / Electric Lever ASSEMBLY OF ELECTRIC LEVER

7

8

9 11

5, 6

16 14

12

15 13

3

17

4

18

T1MG-03-09-008

20

12345-

*Screw (2 Used) *Plate Screw (2 Used) Potentiometer Pin

678910 -

Bushing (2 Used) Screw Arm Boot *Set Screw

11 12 13 14 15 -

19

Cam Socket Bolt (2 Used) Holder O-Ring (2 Used) Bushing (2 Used)

NOTE: As for the item with mark*, refer to W2-7-8.

W2-8-10

16 17 18 19 20 -

Pusher (2 Used) Spring (2 Used) Housing Clip Screw

UPPERSTRUCTURE / Electric Lever Assembly of Electric Lever

2. Install O-rings (14) (2 used) to bushings (15) (2 used).

13. Install pin (5) to holder (13). Secure pin (5) to cam (11) with screw (10). : 2.5 mm : 7 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft)

3. Apply grease onto the inner surface of bushings (15) (2 used).

14. Apply grease to the gap between arm (8) and the link part of potentiometer (4).

4. Install pushers (16) (2 used) to bushings (15) (2 used).

15. Apply LOCTITE #262 onto screws (3) (2 used).

1. Apply grease onto O-rings (14) (2 used).

5. Install springs (17) (2 used) and the pusher (16) assemblies (2 used) to housing (18). 6. Install bushings (6) (2 used) to holder (13). 7. Install holder (13) to housing (18) with socket bolts (12) (2 used). : 5 mm : 7 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft) 8. Apply grease onto the end of pushers (16) (2 used).

IMPORTANT: Adjust the gap between arm (8) and the link of potentiometer (4) to 0.4 mm on one side. 16. Install potentiometer (4) to housing (18) with screws (3) (2 used). : 1.0 N⋅m (0.1 kgf⋅m, 0.7 lbf⋅ft) 17. Secure the harness of potentiometer (4) with clip (19). 18. Apply LOCTITE #262 onto screw (20). 19. Install clip (19) to housing (18) with screw (20). : 0.8 N⋅m (0.1 kgf⋅m, 0.6 lbf⋅ft)

9. Install arm (8) to cam (11) with screw (7). : 3 N⋅m (0.3 kgf⋅m, 2 lbf⋅ft) 10. Apply grease onto the mounting surfaces of holder (13) and cam (11).

20. Apply THREEBOND #1104 onto the mating surfaces of housing (18) and plate (2).

11. Install cam (11) to holder (13).

21. Install plate (2) to housing (18) with screws (1) (2 used).

12. Apply LOCTITE #262 onto screw (10).

22. Install boot (9) to holder (13).

W2-8-11

UPPERSTRUCTURE / Electric Lever (Blank)

W2-8-12

UPPERSTRUCTURE / Signal Control Valve REMOVAL AND INSTALLATION SIGNAL CONTROL VALVE

OF

CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Open cover (2).

1

2

3

4

2. Remove sems bolts (3) (4 used) from cover (1). Remove cover (1) from stay (4). : 17 mm

WCJB-02-01-002

3. Disconnect connectors (5) (2 used) from signal control valve (6). 4. Disconnect hoses (7) (32 used) from signal control valve (6). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 17 mm, 19 mm

5

6

7

5. Remove socket bolts (8) (4 used) from signal control valve (6). Remove signal control valve (6) from bracket (9). : 8 mm 8 9 7

W2-9-1

WCJB-02-09-001

UPPERSTRUCTURE / Signal Control Valve Installation 1. Install signal control valve (6) to bracket (9) with socket bolts (8) (4 used). : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

5

6

7

2. Connect hoses (7) (32 used) to signal control valve (6). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

8

3. Connect connectors (5) (2 used) to signal control valve (6).

9 WCJB-02-09-001

7

4. Install cover (1) to stay (4) with sems bolts (3) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

1

2

3

4

5. Shut cover (2).

WCJB-02-01-002

W2-9-2

UPPERSTRUCTURE / Signal Control Valve (Blank)

W2-9-3

UPPERSTRUCTURE / Signal Control Valve STRUCTURE OF SIGNAL CONTROL VALVE 13

4

12 7 11

7

4 10

9 8

7

7

7 6

5

4

4

3

2 4

1

W1JB-02-10-002

W2-9-4

UPPERSTRUCTURE / Signal Control Valve

15

16

14

16

16

17

17

17

18

19

21

19

18

19

20

20

20 14 22 23 24 25 26 27 19

20 5

19

21

20 19

18

17

16 29

18

20 19

28

17

17

17

14 16

16

16

W1JB-02-10-003

Detail of Body 2 (5)

12345678-

Bolt (3 Used) Body 1 Gasket Filter (17 Used) Body 2 Gasket Shuttle Valve (2 Used) Spring (4 Used)

910 11 12 13 14 15 16 -

Body 3 Gasket Body 4 Gasket Body 5 Socket Bolt (11 Used) Plate Plug (7 Used)

17 18 19 20 21 22 23 24 -

W2-9-5

O-Ring (7 Used) Spring (4 Used) Spring Guide (7 Used) Spool (6 Used) Spring (2 Used) Plate O-Ring Shuttle Valve

25 26 27 28 29 -

O-Ring Spring Spool Spring Plate

UPPERSTRUCTURE / Signal Control Valve (Blank)

W2-9-6

UPPERSTRUCTURE / Travel Shockless Valve REMOVAL AND INSTALLATION OF TRAVEL SHOCKLESS VALVE

2

1

3

CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal of Travel Shockless Valve WCJB-02-15-001

1. Remove sems bolts (1) (6 used) from cover (2). Remove cover (2) from main frame (3). : 17 mm 4

5

6

7

2. Disconnect connector (4) from pressure sensor (5).

8

3. Disconnect connectors (6) (2 used). 4. Disconnect hoses (7) (6 used) from travel shockless valve (8). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm

7

10

WCEB-02-10-003

9

10

3

5. Remove sems bolts (10) (4 used) from bracket (9). Remove the travel shockless valve (8) assembly from main frame (3). : 17 mm 6. Remove sems bolts (11) (2 used) from bracket (9). Remove travel shockless valve (8) from bracket (9). : 17 mm

W2-10-1

8, 11

WCEB-02-10-003

UPPERSTRUCTURE / Travel Shockless Valve Installation of Travel Shockless Valve 10

1. Install travel shockless valve (8) to bracket (9) with sems bolts (11) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

9

10

2. Install the bracket (9) assembly to main frame (3) with sems bolts (10) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

3 8, 11

WCEB-02-10-003

3. Connect hoses (7) (6 used) to travel shockless valve (8). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

4

5

6

7

4. Connect connector (4) to pressure sensor (5). 5. Connect connectors (6) (2 used).

8

WCEB-02-10-003

7

6. Install cover (2) to main frame (3) with sems bolts (1) (6 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

1

2

3

WCJB-02-15-001

W2-10-2

UPPERSTRUCTURE / Travel Shockless Valve (Blank)

W2-10-3

UPPERSTRUCTURE / Travel Shockless Valve STRUCTURE OF TRAVEL SHOCKLESS VALVE

A

13

1 14 2 3 B

4 4 T1F3-03-08-004

5

T1F3-03-08-005

Section A

6 7 T1F3-03-08-006

8

9

10

11

12 Section B

W2-10-4

UPPERSTRUCTURE / Travel Shockless Valve

Part Name 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Solenoid O-Ring Spool Body Spring Plug Orifice Plug Steel Ball Spring O-Ring Plug Nut Tube

Q’ ty 2 2 2 1 2 6 2 2 2 2 4 2 2 2

Wrench Size

N⋅m

Tightening Torque (kgf⋅m)

(lbf⋅ft)

1B P14

1.6 to 2.0 13.2 to 17.6

(0.16 to 0.2) (1.3 to 1.8)

(1.2 to 1.5) (9.7 to 13)

13.2 to 17.6 4.9 30 to 37

(1.3 to 1.8) (0.5) (3 to 4)

(9.7 to 13) (3.6) (22 to 27)

9/32 1B P8 : 19 mm

W2-10-5

UPPERSTRUCTURE / Travel Shockless Valve (Blank)

W2-10-6

UPPERSTRUCTURE / Solenoid Valve REMOVAL AND INSTALLATION 4-SPOOL SOLENOID VALVE UNIT

OF

CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Open cover (2).

1

2

3

4

2. Remove sems bolts (3) (4 used) from cover (1). Remove cover (1) from stay (4). : 17 mm

WCJB-02-01-002

5

3. Disconnect connectors (9) (4 used).

6

7

4. Disconnect hoses (6) (16 used) from 4-spool solenoid valve unit (8). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 22 mm 6

5. Disconnect pipings (5) (3 used) from 4-spool solenoid valve unit (8). : 19 mm

9

8

WCJB-02-11-001

8

6. Remove socket bolts (10) (2 used) and washers (11) (2 used) from 4-spool solenoid valve unit (8). Remove 4-spool solenoid valve unit (8) from control valve (7). : 8 mm

WCJB-02-11-002

10, 11

W2-11-1

7

UPPERSTRUCTURE / Solenoid Valve Installation 1. Install 4-spool solenoid valve unit (8) to control valve (7) with socket bolts (10) (2 used) and washers (11) (2 used). : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

8

WCJB-02-11-002

10, 11

2. Connect pipings (5) (3 used) to 4-spool solenoid valve unit (8). : 19 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

7

5

6

7

3. Connect hoses (6) (16 used) to 4-spool solenoid valve unit (8). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

6

4. Connect connectors (9) (4 used). 9

5. Install cover (1) to stay (4) with sems bolts (3) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

1

8

2

WCJB-02-11-001

3

4

6. Shut cover (2).

WCJB-02-01-002

W2-11-2

UPPERSTRUCTURE / Solenoid Valve STRUCTURE OF 4-SPOOL SOLENOID VALVE UNIT

WCJB-02-11-003

Proportional Solenoid Valve

B A

Proportional Solenoid Valve

WCJB-02-11-004

Filter

Plug Plug

Filter

WCEB-02-11-011

View A

Section B WCEB-02-11-010

W2-11-3

UPPERSTRUCTURE / Solenoid Valve DISASSEMBLY AND ASSEMBLY OF 4-SPOOL SOLENOID VALVE UNIT 1 2 3

4 5 6 7 8 9

12 14

13 10

15 11

16

17

18

19

W18G-02-08-012

4

2

3, 5

6

1

8

12

13

17

10

18

19 W18G-02-08-013

7 12345-

Socket Bolt (4 Used) Lock Nut O-Ring Adjusting Bolt Spring

678910 -

Solenoid Spring O-Ring Diaphragm Spool

9

14 11 12 13 14 15 -

W2-11-4

Orifice Washer Spring O-Ring O-Ring

15

16 16 17 18 19 -

11 O-Ring Sleeve Plate Wave Spring

UPPERSTRUCTURE / Solenoid Valve Assembly of 4-Spool Solenoid Valve Unit

Disassembly of 4-Spool Solenoid Valve Unit IMPORTANT: Do not lose spring (7) in the hole of solenoid (6) when removing solenoid (6). Do not disassemble pressure adjusting lock nut (2) and adjusting bolt (4). 1. Remove socket bolts (1) (2 used) from solenoid (6). Remove solenoid (6) and O-ring (8) from the housing. : 4 mm IMPORTANT: Do not remove orifice (11) from spool (10). 2. Remove spool (10) from sleeve (17). Remove diaphragm (9), washer (12) and spring (13) from spool (10). 3. Remove sleeve (17) from the housing. Remove plate (18) and wave spring (19) from the housing by using a magnet.

1. Install wave spring (19) and plate (18) to the housing. IMPORTANT: When inserting sleeve (17) into the housing, align the hole on sleeve (17) with that on the housing. 2. Install O-rings (14, 15, 16) to sleeve (17). Insert sleeve (17) into the housing. IMPORTANT: When inserting spool (10) into sleeve (17), do not damage the edge on sleeve (17). After inserting spool (10), try to push it about 3 to 5 mm (0.1 to 0.2 in) by fingers. Check if spool (10) moves smoothly. 3. Install diaphragm (9), washer (12) and spring (13) to spool (10). Insert spool (10) into sleeve (17). IMPORTANT: When installing solenoid (6), prevent spring (7) from falling off.

4. Remove O-rings (14, 15, 16) from sleeve (17). 4. Install spring (7) to solenoid (6). Install solenoid (6) to the housing with socket bolts (1) (2 used). : 4 mm : 5+2−0 N⋅m (0.5+0.2−0 kgf⋅m, 4+1.5−0 lbf⋅ft)

W2-11-5

UPPERSTRUCTURE / Solenoid Valve REMOVAL AND INSTALLATION OF SOLENOID VALVE UNIT (FOR ELECTRIC LEVER OPERATION) CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Open cover (1). 1

WCEB-02-05-002

2. Remove sems bolts (3) (2 used) from cover (4). Remove cover (2) from cover (4). : 17 mm

2

3

4

WCJB-02-11-005

3. Disconnect connectors (7) (5 used) from solenoid valve unit (6). 4. Disconnect hoses (5) (12 used) from solenoid valve unit (6). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm NOTE: The number of solenoid valve units, the connectors and the hoses differ depending on the front attachment specifications.

5

6

7

WCJB-02-11-006

W2-11-6

UPPERSTRUCTURE / Solenoid Valve 6

5. Remove bolts (8) (4 used) and washers (9) (4 used) from bracket (10). Remove solenoid valve unit (6) from bracket (10). : 17 mm

8, 9

10

Installation 1. Install solenoid valve unit (6) to bracket (10) with bolts (8) (4 used) and washers (9) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

5

6

WCJB-02-11-006

8, 9

2. Connect hoses (5) (12 used) to solenoid valve unit (6). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

7

3. Connect connectors (7) (5 used) to solenoid valve unit (6).

10

4. Install cover (2) to cover (4) with sems bolts (3) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCJB-02-11-006

2

3

4

WCJB-02-11-005

5. Shut cover (1) 1

WCEB-02-05-002

W2-11-7

UPPERSTRUCTURE / Solenoid Valve STRUCTURE OF SOLENOID VALVE UNIT (FOR ELECTRIC LEVER OPERATION) 2

3

4

5

6

7

A

A

A

A

A

A

A

A

1 WCEB-02-11-006

8

Section A

Wrench Size (mm)

WCEB-02-11-007

N⋅m

Tightening Torque (kgf⋅m)

(lbf⋅ft)

19.5+5−0

(2+0.5−0)

(14+4−0)

18

4.9+5−0

(0.5+0.5−0)

(4+4−0)

8

4.9+5−0

(0.5+0.5−0)

(4+4−0)

Item

Part Name

Q’ty

1

Solenoid Valve Assembly

1

2

Solenoid Valve Assembly

2

3

Solenoid Valve Assembly

1

4

Socket Bolt

4

5

Washer

4

6

End Plate

1

7

Socket Bolt

8

Lock Nut

:6

W2-11-8

Remark

UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve REMOVAL AND INSTALLATION OF PILOT SHUT-OFF SOLENOID VALVE CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Remove sems bolts (1) (6 used) from cover (2). Remove cover (2) from main frame (3). : 17 mm

1

2

3

WCJB-02-15-001

2. Disconnect hoses (4) (9 used) from pilot shut-off solenoid valve (5). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 17 mm, 19 mm

3

4

5

6 7

8

3. Disconnect connector (8). 4. Remove sems bolts (6) (4 used) from bracket (7). Remove the bracket (7) assembly from main frame (3). : 17 mm

WCEB-02-12-001

5

7, 9

5. Remove sems bolts (9) (2 used) from bracket (7). Remove bracket (7) from pilot shut-off solenoid valve (5). : 17 mm

WCEB-02-12-001

W2-12-1

UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve Installation 1. Install bracket (7) to pilot shut-off solenoid valve (5) with sems bolts (9) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

5

3

7, 9

6

2. Install the bracket (7) assembly to main frame (3) with sems bolts (6) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) WCEB-02-12-001

3. Connect hoses (4) (9 used) to pilot shut-off solenoid valve (5). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

4

5

8

4. Connect connector (8).

WCEB-02-12-001

5. Install cover (2) to main frame (3) with sems bolts (1) (6 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

1

2

3

WCJB-02-15-001

W2-12-2

UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve STRUCTURE OF PILOT SHUT-OFF SOLENOID VALVE

W1JB-02-08-001

3

4

5

6

7

8

2 1

9 W1JB-02-08-002

Item 1 2 3 4 5 6 7 8 9

Part Name Plug O-Ring Spring Spool Filter Body O-Ring Solenoid Socket Bolt

Q’ty 1 1 1 1 1 1 1 1 2

Wrench Size (mm) : 6

: 4

Tightening Torque N⋅m (kgf⋅m) (lbf⋅ft) 26.5 (2.7) (20)

3.92

W2-12-3

(0.4)

(3)

Remarks

UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve (Blank)

W2-12-4

UPPERSTRUCTURE / Steering Valve REMOVAL AND STEERING VALVE

INSTALLATION

OF

CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

2

3

Removal 1. Open door (4) and upper front glass (2). 2. Remove lower front glass (1) from cab (3). 4 1

WCEB-02-01-004

3. Remove mat (5) from the inside of cab (3). 3

5

4. Remove sems bolts (6) (2 used) from pedal (7). Remove pedal (7) from bracket (8). : 13 mm

WCEB-02-01-003

6

7

8

W2-13-1

WCEB-02-08-001

UPPERSTRUCTURE / Steering Valve 5. Remove caps (10) (5 used) from cover (9). Remove screws (11) (5 used) from cover (9). Remove cover (9) from stand (15). 6. Remove caps (13) (3 used) from cover (12). Remove screws (14) (5 used) from cover (12). Remove cover (12) from stand (15).

10, 11

12, 13, 14 9

15 WCEB-02-13-002

7. Remove screws (17) (4 used) from cover (16). Remove cover (16) from stand (15). 16

15

8. Remove sems bolts (18) (6 used) from cover (19). Remove cover (19) from main frame (20). : 19 mm

18

17

19

WCEB-02-13-003

20

WCJB-02-13-001

9. Disconnect hoses (22) (5 used) from steering valve (21). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 22 mm, 27 mm

21

22

WCEB-02-13-006

W2-13-2

UPPERSTRUCTURE / Steering Valve 10. Remove sems bolts (23) (4 used) from stand (15). Remove the steering valve (21) assembly from stand (15). : 17 mm 23 15

WCEB-02-13-004

21

WCEB-02-13-006

24

11. Remove socket bolts (24) (2 used) from priority valve (25). Remove priority valve (25) and O-rings (26) (5 used) from steering valve (21).

25, 26

21

WCEB-02-13-005

W2-13-3

UPPERSTRUCTURE / Steering Valve 24

Installation 1. Install priority valve (25) to steering valve (21) with O-rings (26) (5 used) and socket bolts (24) (2 used). : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

25, 26

21

WCEB-02-13-005

2. Install the steering valve (21) assembly to stand (15) with sems bolts (23) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

23 15

WCEB-02-13-004

3. Connect hoses (22) (5 used) to steering valve (21). : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

21

22

WCEB-02-13-006

4. Install cover (19) to main frame (20) with sems bolts (18) (6 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

18

19

20

WCJB-02-13-001

W2-13-4

UPPERSTRUCTURE / Steering Valve 5. Install cover (16) to stand (15) with screws (17) (4 used).

16

15

6. Install cover (9) to stand (15) with screws (11) (5 used). Install caps (10) (5 used) to cover (9).

17

WCEB-02-13-003

10, 11

9

15 WCEB-02-13-002

7. Install cover (12) to stand (15) with screws (14) (5 used). Install caps (13) (3 used) to cover (12). 12, 13, 14

15 WCEB-02-13-002

8. Install pedal (7) to bracket (8) with sems bolts (6) (2 used). : 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

6

7

8

W2-13-5

WCEB-02-08-001

UPPERSTRUCTURE / Steering Valve 9. Install mat (5) to the inside of cab (3). 3

5

WCEB-02-01-003

2

3

10. Install lower front glass (1) to cab (3). 11. Shut upper front glass (2) and door (4). 4 1

WCEB-02-01-004

W2-13-6

UPPERSTRUCTURE / Brake Valve REMOVAL AND BRAKE VALVE

INSTALLATION

OF

CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Remove mat (1) from the inside of cab (2).

1

2

WCEB-02-01-003

3

2. Remove sems bolts (4) (6 used) from cover (3). Remove cover (3) from main frame (5). : 17 mm

4

5

WCJB-02-13-001

6, 7

3. Disconnect connector (11).

8

9 10

4. Remove socket bolts (7) (2 used) from bracket (6). Remove the bracket (6) assembly from bracket (8). : 6 mm 5. Disconnect hoses (9) (6 used) from brake valve (10). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 17 mm, 22 mm, 27 mm 11

6. Remove rubber (14) from brake pedal (15).

12

WCEB-02-14-005

10

13

7. Remove sems bolts (12) (4 used) from plate (13). Remove the brake valve (10) assembly from plate (13). : 17 mm

14, 15

W2-14-1

12

WCEB-02-14-006

UPPERSTRUCTURE / Brake Valve Installation 1. Align the brake valve (10) assembly with the mounting hole on plate (13). Install the brake valve (10) assembly to plate (13) with sems bolts (12) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

12

10

13

2. Install rubber (14) to brake pedal (15). 14, 15

12

6, 7

WCEB-02-14-006

8

9 10

3. Connect hoses (9) (6 used) to brake valve (10). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m,58 lbf⋅ft) 4. Install the bracket (6) assembly to bracket (8) with socket bolts (7) (2 used). : 6 mm : 58.8 to 73.5 N⋅m (6 to 7.5 kgf⋅m, 43 to 54 lbf⋅ft)

11

WCEB-02-14-005

5. Connect connector (11). 6. Install cover (3) to main frame (5) with sems bolts (4) (6 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

3

4

5

WCJB-02-13-001

7. Install mat (1) to the inside of cab (2).

1

2

WCEB-02-01-003

W2-14-2

UPPERSTRUCTURE / Brake Valve (Blank)

W2-14-3

UPPERSTRUCTURE / Brake Valve DISASSEMBLY OF BRAKE VALVE 1 2

29

11

3 28 5

4

8

7

6

27

10 9

12 13 14

15 16

26 25

17 3 30

3

24

16

31 23

32

22

33

18

34

43

35

36

42

37

19

41

44

45

38

20

40 46

47 48

21 29

39 44

45

46

47

49 48

W2-14-4

WCEB-02-14-004

UPPERSTRUCTURE / Brake Valve 12345678910 11 12 13 -

Rubber Brake Pedal Split Pin (4 Used) Stopper Bolt Bushing Lock Nut Bushing (2 Used) Pin Bushing (2 Used) Pin Boot Pin Spring Pin

14 15 16 17 18 19 20 21 22 23 24 25 -

Bushing Yoke Pin (2 Used) Link Roller Assembly Bracket Brake Switch Socket Bolt (2 Used) Seat Stopper Boot Socket Bolt (4 Used)

26 27 28 29 30 31 32 33 34 35 36 37 -

W2-14-5

Bracket Oil Seal Flange O-Ring (2 Used) (1B, G45) Rod Return Spring Holder Spring Balance Spring Retainer Retainer Pilot Piston

38 39 40 41 42 43 44 45 46 47 48 49 -

Push Rod Cylinder Cylinder O-Ring (1B, P32) Plug Socket Bolt (4 Used) Spring (2 Used) Retaining Ring (2 Used) Retainer (2 Used) Plunger (2 Used) Spool (2 Used) Spring

UPPERSTRUCTURE / Brake Valve 1 2

29

11

3 28 4

5

7

8

6

27

10 9

12 13 14

15 16

26 25

17 3 30

3

24

16

31 23

32

22

33

18

34

43

35

36

42

37

19

41

44

45

38

20

40 46

47 48

21 29

39 44

45

46

47

49 48

W2-14-6

WCEB-02-14-004

UPPERSTRUCTURE / Brake Valve Disassembly of Brake Valve IMPORTANT: Put the matching marks onto bracket (26), flange (28), cylinder (39) and cylinder (40) before disassembling. 1. Secure the brake valve in a vise with the cylinder (40) side facing downward. 2. Remove socket bolts (21) (2 used) from bracket (19). Remove bracket (19) and brake switch (20) from bracket (26). : 6 mm 3. Remove split pins (3) (3 used) from pins (8, 10 and 16) except the roller assembly (18) part. Remove pins (8, 10 and 16) from bracket (26) and link (17).

IMPORTANT: The spool (48) assembly is also used inside cylinder (39). Keep them in order not to confuse. 9. Remove plug (42), spring (44) and the spool (48) assembly from cylinder (40). 10. Remove plunger (47), retaining ring (45) and retainer (46) from the spool (48) assembly. IMPORTANT: The reaction force of spring (44) acts on socket bolt (43). While holding cylinder (40), slowly remove socket bolt (43). 11. Remove socket bolts (43) (4 used) from cylinder (40). 12. Remove cylinder (40) and the cylinder (39) assembly from flange (28).

4. Remove spring pin (13) from yoke (15). Remove pin (12) from yoke (15).

13. Remove the spool (48) assembly from cylinder (39).

5. Remove split pin (3) from pin (16). Remove pin (16) and the roller (18) assembly from link (17).

14. Remove plunger (47), spring (44), retaining ring (45) and retainer (46) from the spool (48) assembly.

6. Remove seat (22), stopper (23) and boot (24) from flange (28). 7. Remove socket bolts (25) (4 used) from bracket (26). Remove bracket (26) from flange (28). 8. Secure the flange (28) part in a vise with the push rod (38) side facing downward.

15. Remove return spring (31), holder (32), rod (30), balance spring (34), spring (33), retainers (35, 36), pilot piston (37) and push rod (38) from flange (28). 16. Remove oil seal (27) from flange (28). 17. Remove O-rings (29) (2 used) from flange (28) and cylinder (39).

W2-14-7

UPPERSTRUCTURE / Brake Valve ASSEMBLY OF BRAKE VALVE 1

12

2

11

8 15 14

26

28

39

43

40

16 A

10

42

21 17 19 16 18 20 22

22 23

24

25

31

30

29

48

49

47

45

46

44

WCEB-02-14-001

42 47 41

38

27

37

36

35

13

33

34

32

46

29

48

45

WCEB-02-14-002

5 12

7

15

3

8 9

26

17

10

21

3

16

3

18

19 View A

W2-14-8

WCEB-02-14-003

UPPERSTRUCTURE / Brake Valve 12345678910 11 12 13 -

Rubber Brake Pedal Split Pin (4 Used) * Stopper Bolt Bushing * Lock Nut Bushing (2 Used) Pin Bushing (2 Used) Pin Boot Pin Spring Pin

14 15 16 17 18 19 20 21 22 23 24 25 -

Bushing Yoke Pin (2 Used) Link Roller Assembly Bracket Brake Switch Socket Bolt (2 Used) Seat Stopper Boot Socket Bolt (4 Used)

26 27 28 29 30 31 32 33 34 35 36 37 -

Bracket Oil Seal Flange O-Ring (2 Used) (1B, G45) Rod Return Spring Holder Spring Balance Spring Retainer Retainer Pilot Piston

NOTE: As for the item with mark *, refer to W2-14-4.

W2-14-9

38 39 40 41 42 43 44 45 46 47 48 49 -

Push Rod Cylinder Cylinder O-Ring (1B, P32) Plug Socket Bolt (4 Used) Spring (2 Used) Retaining Ring (2 Used) Retainer (2 Used) Plunger (2 Used) Spool (2 Used) Spring

UPPERSTRUCTURE / Brake Valve 1

12

2

11

8 15 14

26

28

39

43

40

16 A

10

42

21 17 19 16 18 20

22

22 23

24

25 31

30

29

48

49

47

45

46

44

WCEB-02-14-001

42 47 41

38

27

37

36

35

13

33

34

32

46

29

48

45

WCEB-02-14-002

5 12

7

15

3

8 9

26

17

10

21

3

16

3

18

19 View A

W2-14-10

WCEB-02-14-003

UPPERSTRUCTURE / Brake Valve Assembly of Brake Valve 10. Install spring (49), plunger (47) and spring (44) to cylinder (39).

1. Install oil seal (27) to flange (28). 2. Secure flange (28) in a vise with the oil seal (27) side facing downward.

11. Align the matching marks and place cylinder (40) onto cylinder (39).

3. Install O-ring (29) to flange (28). 4. Apply hydraulic oil onto rod (30), pilot piston (37), push rod (38), plungers (47) (2 used) and spools (48) (2 used).

12. Install retainer (46) and retaining ring (45) to spool (48). 13. Install the spool (48) assembly to cylinder (40).

5. Install push rod (38), pilot piston (37), retainer (36), retainer (35), return spring (31), balance spring (34), spring (33), holder (32) and rod (30) to flange (28) in this order.

14. Install plunger (47), spring (44) and plug (42) to cylinder (40). : 130 to 180 N⋅m (13 to 18 kgf⋅m, 96 to 133 lbf⋅ft)

6. Install O-ring (29) to cylinder (39).

15. Connect flange (28), cylinder (39) and cylinder (40) with socket bolts (43) (4 used). : 60 to 75 N⋅m (6 to 7.5 kgf⋅m, 44 to 55 lbf⋅ft)

7. Align the matching marks and place cylinder (39) onto the flange (28) assembly. 8. Install retainer (46) and retaining ring (45) to spool (48). 9. Install the spool (48) assembly to cylinder (39).

W2-14-11

UPPERSTRUCTURE / Brake Valve 1

12

2

11

8 15 26

28

40

16 A

10 21 17 19 16 18 20 22

22 23

WCEB-02-14-001

24

25

WCEB-02-14-002

13 12 15 3

8

26 17

10

21

3

16

3

18

19 View A

W2-14-12

WCEB-02-14-003

UPPERSTRUCTURE / Brake Valve 16. Secure the cylinder assembly in a vise with the cylinder (40) side facing downward. 17. Install flange (28) to bracket (26) with socket bolts (25) (4 used). : 60 to 75 N⋅m (6 to 7.5 kgf⋅m, 44 to 55 lbf⋅ft) 18. Install boot (24), stopper (23) and seat (22) to flange (28). 19. Apply grease onto all pin holes on brake pedal (2), bracket (26), yoke (15) and link (17).

26. Secure stopper bolt (4) to link (17) with lock nut (6). : 6.0 to 10 N⋅m (0.6 to 1 kgf⋅m, 4 to 7 lbf⋅ft) 27. Install rubber (1) to brake pedal (2). 28. Install brake switch (20) to bracket (19). Install the bracket (19) assembly to bracket (26) with socket bolts (21) (2 used). : 6 mm : 58.8 to 73.5 N⋅m (6 to 7.5 kgf⋅m, 43 to 54 lbf⋅ft)

20. Install yoke (15) to brake pedal (2) with pin (12) and spring pin (13). 21. Install roller assembly (18) to link (17) with pin (16). Secure pin (16) to link (17) with split pin (3). 22. Install the link (17) assembly to bracket (26) with pin (10). Secure pin (10) to bracket (26) with split pin (3). 23. Install boot (11) to the brake pedal (2) assembly. Install brake pedal (2) to bracket (26) with pin (8). Secure pin (8) to bracket (26) with split pin (3). 24. Install yoke (15) to link (17) with pin (16). Secure pin (16) to link (17) with split pin (3). 25. Adjust play of link (17) to 0 mm with stopper bolt (4).

W2-14-13

UPPERSTRUCTURE / Brake Valve (Blank)

W2-14-14

UPPERSTRUCTURE / Accumulator Charge Valve REMOVAL AND INSTALLATION OF ACCUMULATOR CHARGE VALVE CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Remove sems bolts (1) (6 used) from cover (2). Remove cover (2) from main frame (3). : 17 mm

1

2

3

WCJB-02-15-001

2. Disconnect hoses (4) (8 used) from accumulator charge valve (5). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 17 mm, 22 mm, 27 mm

4

5, 6

7 8

3. Remove sems bolts (7) (4 used) from bracket (8). Remove the bracket (8) assembly from main frame (3). : 17 mm 4. Remove sems bolts (6) (4 used) from bracket (8). Remove accumulator charge valve (5) from bracket (8). : 17 mm

W2-15-1

3

WCEB-02-15-001

UPPERSTRUCTURE / Accumulator Charge Valve Installation 1. Install accumulator charge valve (5) to bracket (8) with sems bolts (6) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

4

5, 6

7 8

2. Install the bracket (8) assembly to main frame (3) with sems bolts (7) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 3. Connect hoses (4) (8 used) to accumulator charge valve (5). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) 4. Install cover (2) to main frame (3) with sems bolts (7) (6 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

3

1

2

WCEB-02-15-001

3

WCJB-02-15-001

W2-15-2

UPPERSTRUCTURE / Accumulator Charge Valve (Blank)

W2-15-3

UPPERSTRUCTURE / Accumulator Charge Valve STRUCTURE OF ACCUMULATOR CHARGE VALVE 1, 2

3, 4

5, 6

1, 2

7

A B C D

3, 4 5, 6

WCEB-02-15-002

8

8

9

9

10

10

11

11 1

6 5 2

Section A

18 15

19 20

5

Section B

6

16 17

21

22

23

14

24

26

6 5

13

9 27

25

28

12

29

37 36 35

34

33 32

31

1

2

30

3

Section D

W2-15-4

4

WCEB-02-15-003

Section C

UPPERSTRUCTURE / Accumulator Charge Valve No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Part Name Plug O-Ring Plug O-Ring Plug O-Ring Body Plug O-Ring Spring Plunger Plug Screw Lock Nut O-Ring Spring Needle Valve O-Ring Backup Ring O-Ring O-Ring Backup Ring Sleeve Piston Orifice Plug Spring Plunger Sleeve Plunger O-Ring Washer Spring Spring Plug O-Ring Plug

NOTE: Tools

Q’ty

Wrench Size (mm)

4 4 3 3 5 5 1 2 3 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

: 22 mm, 24 mm, 32 mm : 1/8, 4 mm, 5 mm, 6 mm

W2-15-5

Tightening Torque N⋅m (kgf⋅m) (lbf⋅ft) 4.9 (0.5) (4) 26.5

(3)

(20)

9.8

(1)

(7)

12

(1.2)

(9)

58.8

(6)

(43)

9.8 12

(1) (1.2)

(7) (9)

48.5

(5)

(36)

48.5

(5)

(36)

Remark

UPPERSTRUCTURE / Accumulator Charge Valve (Blank)

W2-15-6

MEMO ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ 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........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................

MEMO ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................

SECTION 3

UNDERCARRIAGE ―CONTENTS― Group 1 Swing Bearing

Group 6 Axle Lock Cylinder

Removal and Installation of Swing Bearing ......................................W3-1-1 Disassembly of Swing Bearing ................W3-1-4 Assembly of Swing Bearing.....................W3-1-6

Group 2 Travel Motor

Removal and Installation of Axle Lock Cylinder .............................. W3-6-1 Disassembly and Assembly of Axle Lock Cylinder .............................. W3-6-4

Group 7 Operate Check Valve

Removal and Installation of Travel Motor .........................................W3-2-1 Disassembly of Travel Motor...................W3-2-4 Assembly of Travel Motor ..................... W3-2-12 Disassembly of Brake Valve.................. W3-2-20 Assembly of Brake Valve ...................... W3-2-22

Removal and Installation of Operate Check Valve (for Axle Lock Cylinder) .................W3-7-1 Structure of Operate Check Valve (For Axle Lock Cylinder)..........................W3-7-2

Group 8 Solenoid Valve Removal and Installation of Outrigger/BladeSolenoid Valve Unit......W3-8-1 Structure of Solenoid Valve Unit ...............W3-8-3

Group 3 Center Joint Removal and Installation of Cebter Joint ..........................................W3-3-1 Disassembly of Center Joint....................W3-3-6 Assembly of Center Joint ......................W3-3-8

Group 9 Transmission Changeover Solenoid Valve Removal and Installation of Transmission Changeover Solenoid Valve..................W3-9-1

Group 4 Transmission Removal and Installation of Transmission.........................................W3-4-1 Disassembly of Transmission ..................W3-4-6 Assembly of Transmission..................... W3-4-18

Group 10 Propeller Shaft

Group 5 Axle Removal and Installation of Axle .............W3-5-1 Disassembly of Front Axle .................... W3-5-10 Assembly of Front Axle......................... W3-5-18 Disassembly of Rear Axle ..................... W3-5-28 Assembly of Rear Axle ......................... W3-5-34 Disassembly of Differential ................... W3-5-42 Assembly of Differential........................ W3-5-44 Disasembly of Steering Cylinder ........... W3-5-46 Assembly of Steering Cylinder .............. W3-5-48

CJBW-3-1

Removal and Installation of Propeller Shaft.....................................W3-10-1

(Blank)

CJBW-3-2

UNDERCARRIAGE / Swing Bearing REMOVAL AND SWING BEARING

INSTALLATION

OF

Before removing and installing the swing bearing, the upperstructure must be removed first. For removal and installation of the upperstructure, refer to the REMOVAL AND INSTALLATION OF MAIN FRAME on W2-3-1. The procedure starts on the premise that the upperstructure has already been removed. 1

Matching Mark

Removal 1. Put the matching marks on inner race (1) of the swing bearing and track frame (2).

2

WCJB-02-03-003

2. Remove knock pin (3) from outer race (4) of the swing bearing.

3

3. Remove bolts (5) (36 used) from track frame (2). : 30 mm

4

5

2

WCJB-03-01-003

CAUTION: Swing bearing weight: 230 kg (510 lb) 4. Install special tools (ST 0050) (3 used) to swing bearing. Attach a wire rope onto special tool. Hoist and remove swing bearing from track frame (2).

ST 0050 W110-03-01-004

Swing Bearing

W3-1-1

UNDERCARRIAGE / Swing Bearing Installation Clean the mounting surfaces of track frame (2) and swing bearing.

Swing Bearing

1. Apply THREEBOND #1102 onto the swing bearing mounting surface of track frame (2).

2

W110-03-01-004

CAUTION: Swing bearing weight: 230 kg (510 lb)

Machine Front

Position for Grease Fitting

IMPORTANT: If the matching mark do not align, the soft zone position of the inner race will be dislocated. 2. Hoist and align swing bearing with the mounting holes on track frame (2).

25°

49° 25.8° 31° Position for Grease Fitting

“S” (Soft Zone) Marking Position Position for Plug

3

3. Install inner race (1) of the swing bearing to track fame (2) with bolts (5) (36 used). : 30 mm : 500 N⋅m (51 kgf⋅m, 368 lbf⋅ft)

Position for Knock Pin

4

5

WCJB-03-01-002

1

2

4. Install knock pin (3) to outer race (4) of the swing bearing. WCJB-03-01-003

W3-1-2

UNDERCARRIAGE / Swing Bearing 5. After installing swing bearing, add grease (Shell Alvania EP2 or equivalent) up to 28 mm (1.1 in) height from the bottom of the grease bath.

Swing Bearing

Grease Level

Pinion

28 mm (1.1 in)

Grease Bath

W3-1-3

WCEB-03-01-004

UNDERCARRIAGE / Swing Bearing DISASSEMBLY OF SWING BEARING 2

3

4

1

7

8

6

5

WCJB-03-01-001

9

4

9 3

8

7

5

6

W157-03-01-002

123-

Plug Pin Seal

45-

Outer Race Ball (111 Used)

67-

W3-1-4

Seal Inner Race

89-

Support (111 Used) Grease Fitting (2 Used)

UNDERCARRIAGE / Swing Bearing Disassembly of Swing Bearing 1. Tap and remove pin (3) of plug (4) upward from the bottom side. NOTE: After installing pin (3), pin (3) was crimped. Grind off the crimped part.

2

CAUTION: Swing bearing weight: 230 kg (510 lb) 3. Place inner race (7) of the swing bearing onto a wooden block by using special tool (ST 0050). Hoist and hold outer race (4) slightly. 4. Remove balls (5) (111 used) and supports (8) (111 used) from the plug hole while rotating outer race (4). Use magnet (A) when removing ball (5). Use wire (B) and remove support (8).

1

4 3 A

7

W105-03-01-007

2. Remove plug (1) from outer race (5). NOTE: Install the bolt into the screw hole (M10, Pitch 1.5 mm) of plug (1). Tap or pull the bolt from the inner side.

5

6

W105-03-01-009

4

B 1

8

W105-03-01-010

W105-03-01-008

5. Separate outer race (4) from inner race (7). 6. Remove seals (3, 6) from outer race (4) and inner race (7) respectively by using a scrapper.

W3-1-5

UNDERCARRIAGE / Swing Bearing ASSEMBLY OF SWING BEARING 2

3

4

1

7

8

6

5

WCJB-03-01-001

9

4

9 3

8

7

5

6

W157-03-01-002

123-

Plug Pin Seal

45-

Outer Race Ball (111 Used)

67-

W3-1-6

Seal Inner Race

89-

Support (111 Used) Grease Fitting (2 Used)

UNDERCARRIAGE / Swing Bearing Assembly of Swing Bearing IMPORTANT: Apply grease onto balls (5) (111 used) and supports (8) (111 used)

2. Tap and install plug (1) into outer race (4). Secure plug (1) to outer race (4) with pin (2). Crimp the head of pin (2) by using a punch.

CAUTION: Outer race (4) weight: 96 kg (211 lb) Inner race (7) weight: 114 kg (251 lb)

2 4

1. Hoist outer race (4) horizontally and align outer race (4) with inner race (7) coaxially. While rotating outer race (4), insert balls (5) and supports (8) into the plug hole by using a round bar.

1

4

W142-03-01-007

3

CAUTION: Swing bearing weight: 230 kg (510 lb)

5 6

W142-03-01-005

4

3. Install lifting tool (ST 0050) to outer race (4). Hoist outer race (4). Thoroughly degrease the slots for seals (3, 6). Apply THREEBOND #1745 to seal (3) and #1530D to seal (6). Install seals (3, 6) to outer race (4) and inner race (7). 4. Add grease 0.5 L (0.1 US gal.) (Alvania EP2 grease or equivalent) to the swing bearing through grease fitting (9). At this time, rotate outer race (4) and add grease.

8

W142-03-01-006

W3-1-7

UNDERCARRIAGE / Swing Bearing (Blank)

W3-1-8

UNDERCARRIAGE / Travel Motor REMOVAL AND TRAVEL MOTOR

INSTALLATION

OF

CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Before removing and installing travel motor (7), the propeller shaft must be removed first. For removal and installation of the propeller shaft, refer to REMOVAL AND INSTALLATION OF PROPELLER SHAFT on W3-10-1. Therefore, in this section, the procedure starts from the premise that the propeller shaft has already been removed. Removal IMPORTANT: Attach an identification tag onto the disconnected hoses for assembling. 1. Disconnect hoses (1) (7 used) and connector (3) from travel motor (2). Cap the disconnected hoses. : 19 mm, 22 mm, 27 mm

2 3 1

CAUTION: Travel motor (2) weight: 80 kg (180 lb) 2. Loosen socket bolts (4) (4 used) of travel motor (2). While holding the lower side of travel motor (2) by using a forklift, remove socket bolts (4) (4 used). : 14 mm 3. Remove travel motor (2) from transmission (5).

W3-2-1

4

WCGB-03-05-030

5

UNDERCARRIAGE / Travel Motor Installation CAUTION: Travel motor (2) weight: 80 kg (180 lb) 1. Install travel motor (2) to transmission (5) with socket bolts (4) (4 used). : 14 mm : 270 N·m (27.5 kgf·m, 199 lbf·ft) 2. Connect hoses (1) (7 used) and connector (3) to travel motor (2). : 19 mm : 29.5 N·m (3 kgf·m, 22 lbf·ft) : 22 mm : 39 N·m (4 kgf·m, 29 lbf·ft) : 27 mm : 64 N·m (6.5 kgf·m, 47 lbf·ft) : 12 mm : 180 N·m (18 kgf·m, 133 lbf·ft) 3. Install the propeller shaft to transmission (5). (Refer to REMOVAL AND INSTALLATION OF PROPELLER SHAFT on W3-10-1.) IMPORTANT: After installing the travel motor (2), fill hydraulic oil into the travel motor (2). Perform break-in operation after installing the travel motor (2) in order to prevent the travel motor (2) and/or travel reduction gear from seizuring. Condition 1.Engine control dial: Slow idle 2.Travel speed mode switch: Slow speed 3.Operation duration: Over 2 minutes

W3-2-2

2 3 1

4

WCGB-03-05-030

5

UNDERCARRIAGE / Travel Motor (Blank)

W3-2-3

UNDERCARRIAGE / Travel Motor DISASSEMBLY OF TRAVEL MOTOR

47

1

2

3

4

5

6

7

8

9

10

11

12

13

46 45 44

14

43 42

15

41 40 39 16

37, 38

17

36

18

35

19

34

20 33

32

31

30

29

28

27

26

25

24

23

22

21

WCGB-03-02-004

A

37, 38

48

37, 38

View A

56 28, 53, 54

4, 55

49

52

49 50

50

8

51 WCGB-03-02-002

51

8

W3-2-4

WCGB-03-02-001

UNDERCARRIAGE / Travel Motor 12345678910 11 12 13 14 -

Adjusting Screw Lock Nut Pin Solenoid Valve O-Ring Adjusting Screw Lock Nut Housing Plunger (7 Used) Retainer Plate Bearing Ring Bearing Oil Seal

15 16 17 18 19 20 21 22 23 24 25 26 27 28 -

Shim Retaining Ring Adjusting Shim Retaining Ring Screw Bolt (7 Used) Drive Shaft Center Shaft Spring Rotor Lock Nut Adjusting Screw O-Ring Piston Cover

29 30 31 32 33 34 35 36 37 38 39 40 41 42 -

W3-2-5

Socket Bolt Ring (2 Used) Servo Piston Lock Pin Pin Valve Plate Spring Head Cover Brake Valve O-Ring (2 Used) Spring Collar Bushing Spring

43 44 45 46 47 48 49 50 51 52 53 54 55 56 -

Spring Collar Retaining Ring Control Piston Sleeve Retaining Ring Socket Bolt (2 Used) Relief Valve (2 Used) Plug (2 Used) Socket Bolt (8 Used) Socket Bolt (4 Used) O-Ring O-Ring O-Ring (4 Used) Socket Bolt (4 Used)

UNDERCARRIAGE / Travel Motor

47

1

2

3

4

5

46 45 44 43 42 41 40 39 37, 38 36 35

20 WCGB-03-02-004

28

A

48

37, 38

View A

37, 38

56 28, 53, 54 52

49

4, 55

50

49 50

WCGB-03-02-001 WCGB-03-02-002

W3-2-6

UNDERCARRIAGE / Travel Motor Disassembly of Travel Motor CAUTION: Travel motor weight: 80 kg (180 lb) 1. Set the travel motor onto a wooden block (100×500 mm, 3.9×19.7 in) with the drive shaft (20) side facing downward. NOTE: When the workbench is used. Workbench: ST 5092 Upper Plate: ST 7333 2. Remove socket bolts (48) (2 used). Remove brake valve (37) and O-rings (38) (2 used). : 5 mm IMPORTANT: Do not disassemble relief valves (49) (2 used). 3. Remove relief valves (49) (2 used) and plugs (50) (2 used) from head cover (36). : 27 mm, 32 mm 4. Before removing, record the dimension of part A. 1

6. Remove the bushing (41) assembly, spring (39), collar (40) and spring (35) from head cover (36) in this order. 7. Remove spring collar (43) and spring (42) from the bushing (41) assembly. 8. Remove O-ring (5), O-rings (55) (4 used), adjusting screw (1), lock nut (2) and pin (3) from solenoid valve (4). 9. Remove retaining ring (44) from solenoid valve (4). Remove the sleeve (46) assembly. 10. Remove control piston (45) from sleeve (46). Remove retaining ring (47) from control piston (45). 11. Remove socket bolts (52) (4 used). Remove cover (28) and O-rings (53, 54) from head cover (36). : 6 mm

2

A

W1GL-03-02-006

5. Remove socket bolts (56) (4 used). Remove solenoid valve (4) from head cover (36). When removing solenoid valve (4), prevent spring (39) from flying out. : 6 mm

W3-2-7

UNDERCARRIAGE / Travel Motor

6

7

8

9

14 15

16

36

20 26

25

24

23

21

WCGB-03-02-004

A View A

8

51 WCGB-03-02-002

51

8

W3-2-8

WCGB-03-02-001

UNDERCARRIAGE / Travel Motor 12. Before removing, record the dimensions of part B and part C. B

16. Secure rotor (23), center shaft (21) and plungers (9) (7 used) by using a screw bar (M8, Pitch 1.25 mm, Length 120 mm). Remove adjusting screw (25) from housing (8). 23

Screw Bar Lock Nut Washer

C

9 26

25

21 9

7

8

6 W1GL-03-02-003

W1GL-03-02-005

13. Loosen lock nuts (7, 24). Remove adjusting screws (6, 25) from housing (8).

17. Remove retaining ring (16) and shim (15) from housing (8).

14. Install adjusting screw (25) (M12, Pitch 1.75 mm, Length 100 mm) to adjusting screw (6) mounting part, so that the angle of center shaft (21) should be zero.

18. Set the housing (8) assembly in a vise with the rotor (23) side facing downward. Remove the drive shaft (20) assembly from housing (8). 19. Remove oil seal (14) from housing (8).

25 21

W1GL-03-02-004

15. Put the matching marks on the contacting surface of head cover (36) and housing (8). Remove socket bolts (51) (8 used). Remove head cover (36) from housing (8).

W3-2-9

UNDERCARRIAGE / Travel Motor

36

34

33

32

31

30

29

WCGB-03-02-004

27

A View A

WCGB-03-02-001 WCGB-03-02-002

W3-2-10

UNDERCARRIAGE / Travel Motor 20. Set head cover (36) in a vise with the valve plate (34) side facing upward. 21. Remove socket bolt (29) and piston (27) from servo piston (31). 22. Remove rings (30) (2 used) from piston (27). CAUTION: Warm up lock pin (32). Take care not to burn yourself. 23. Warm up the mounting part of lock pin (32) by using a torch. NOTE: Adhesive has been applied onto lock pin (32). Warm up the adhesive by using slow fire. 24. Remove pin (33) from servo piston (31). 25. Remove servo piston (31) from head cover (36).

W3-2-11

UNDERCARRIAGE / Travel Motor ASSEMBLY OF TRAVEL MOTOR

47

1

2

3

4

5

6

7

8

9

10

11

12

13

46 45 44

14

43 42

15

41 40 39 16

37, 38

17

36

18

35

19

34

20 33

32

31

30

29

28

27

26

25

24

23

22

21

WCGB-03-02-004

A

48

37, 38

37, 38

View A

56 28, 53, 54

49

52

4, 55

49

50

50

8

51 WCGB-03-02-002

51

8

W3-2-12

WCGB-03-02-001

UNDERCARRIAGE / Travel Motor

1 - Adjusting Screw 2 - Lock Nut 3 - Pin 4 - Solenoid Valve 5 - O-Ring 6 - Adjusting Screw 7 - Lock Nut 8 - Housing 9 - Plunger (7 Used) 10 - Retainer Plate 11 - Bearing 12 - Ring 13 - Bearing 14 - Oil Seal

15 16 17 18 19 20 21 22 23 24 25 26 27 28 -

Shim Retaining Ring Adjusting Shim Retaining Ring Screw Bolt (7 Used) Drive Shaft Center Shaft Spring Rotor Lock Nut Adjusting Screw O-Ring Piston Cover

29 30 31 32 33 34 35 36 37 38 39 40 41 42 -

W3-2-13

Socket Bolt Ring (2 Used) Servo Piston Lock Pin Pin Valve Plate Spring Head Cover Brake Valve O-Ring (2 Used) Spring Collar Bushing Spring

43 44 45 46 47 48 49 50 51 52 53 54 55 56 -

Spring Collar Retaining Ring Control Piston Sleeve Retaining Ring Socket Bolt (2 Used) Relief Valve (2 Used) Plug (2 Used) Socket Bolt (8 Used) Socket Bolt (4 Used) O-Ring O-Ring O-Ring (4 Used) Socket Bolt (4 Used)

UNDERCARRIAGE / Travel Motor

47

1

2

3

4

5

28

27

46 45 44 43 42 41 40 39

36 35 34

33

32

31

30

29

WCGB-03-02-004

A View A

56 28, 53, 54

4, 55

52

WCGB-03-02-001 WCGB-03-02-002

W3-2-14

UNDERCARRIAGE / Travel Motor Assembly of Travel Motor 1. Set head cover (36) in a vise with the valve plate (34) side facing upward.

7. Install retaining rings (47, 44) to control piston (45) and sleeve (46).

2. Apply hydraulic oil onto servo piston (31). Insert servo piston (31) into head cover (36). Install pin (33).

8. Apply hydraulic oil onto solenoid valve (4), control piston (45) and sleeve (46). 9. Install O-ring (5) to solenoid valve (4).

3. Apply LOCTITE #241 onto lock pin (32). Insert lock pin (32) into servo piston (31). Secure pin (33). 4. Install rings (30) (2 used) to piston (27). Install piston (27) to servo piston (31) with socket bolt (29). 5. Install O-rings (53, 45) and cover (28) to head cover (36). Install cover (28) to head cover (36) with socket bolts (52) (4 used). : 6 mm : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 6. Install adjusting screw (1) and lock nut (2) to solenoid valve (4) with the dimension of part A recorded before disassembling. 1

10. Install control piston (45) to sleeve (46). Insert the sleeve (46) assembly and pin (3) into solenoid valve (4). 11. Install spring collar (43) and spring (42) to the solenoid valve (4) assembly. 12. Install O-rings (55) (4 used) to the mounting surface of head cover (36) and solenoid valve (4). 13. Install springs (35, 39), collar (40) and bushing (41) to the large chamber side of head cover (36). 14. Install the solenoid valve (4) assembly to head cover (36) with socket bolts (56) (4 used).

2

A

W1GL-03-02-006

W3-2-15

UNDERCARRIAGE / Travel Motor

6

7

8

14 15

16

36

20 25

24

23

21

WCGB-03-02-004

A View A

8

51 WCGB-03-02-002

51

8

W3-2-16

WCGB-03-02-001

UNDERCARRIAGE / Travel Motor CAUTION: After warming up housing (8), start the work. 15. Warm up housing (8) to 50 to 80 °C (122 to 176 °F). Install the drive shaft (20) assembly to housing (8). If the drive shaft (20) assembly cannot be inserted, insert it by using a bar.

19. Temporarily install adjusting screw (25) (M12, Pitch 1.75 mm, Length 100 mm) to the adjusting screw (6) mounting part, so that the angle of center shaft (21) should be zero.

21

16. Face the rotor (23) side in housing (8) downward. Install oil seal (14), shim (15) and retaining ring (16) to housing (8).

25

17. Set the travel motor onto a wooden block (100×500 mm, 3.9×19.7 in) with the drive shaft (20) side facing downward. NOTE: When the workbench is used. Workbench: ST 5092 Upper Plate: ST 7333

20. Align the matching marks. Install head cover (36) to housing (8) with socket bolts (51) (8 used).

18. Remove the screw bar, the lock nut and the washer from rotor (23).

21. Remove temporarily installed adjusting screw (25) from housing (8).

23

W1GL-03-02-008

22. Install adjusting screw (25), lock nut (24), adjusting screw (6) and lock nut (7) to housing (8) so that the dimensions of part B and part C should be the same dimensions before disassembling.

Screw Bar Lock Nut Washer

B

C W1GL-03-02-003

25 8

24 7

6

W1GL-03-02-005

W3-2-17

UNDERCARRIAGE / Travel Motor

WCGB-03-02-004

A

48

37, 38

View A

37, 38

49

49

50

50

WCGB-03-02-001 WCGB-03-02-002

W3-2-18

UNDERCARRIAGE / Travel Motor 23. Install relief valves (49) (2 used) and plugs (50) (2 used) to head cover (36). : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) : 32 mm : 83±5 N⋅m (8.5±0.5 kgf⋅m, 61±4 lbf⋅ft) 24. Install brake valve (37) and O-rings (38) (2 used) to head cover (36) with socket bolts (48) (2 used). : 5mm

W3-2-19

UNDERCARRIAGE / Travel Motor DISASSEMBLY OF BRAKE VALVE A

View A

B

Brake Valve

7 Brake Valve

5, 6

C

WCGB-03-02-001 WCGB-03-02-002

2

3

4

8

9

10 1

Section C

11

12 13 17

16

15

14 7

Section B

WCGB-03-02-005

12345-

Cover Socket Bolt (4 Used) Valve Casing Counterbalance Valve Plug

6789-

Orifice Plug O-Ring (2 Used) Cover

10 11 12 13 -

W3-2-20

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

14 15 16 17 -

O-Ring (2 Used) O-Ring Shuttle Valve Check Valve (2 Used)

UNDERCARRIAGE / Travel Motor Disassembly of Brake Valve 1. Remove socket bolts (2) (4 used). Remove cover (1) and O-ring (8) from valve casing (3). : 10 mm 2. Remove socket bolts (10) (4 used). Remove cover (9) and O-ring (8) from valve casing (3). : 10 mm

7. Remove shuttle valve (16) from valve casing (3) by using a socket wrench. : 4 mm 8. Remove plug (5) from valve casing (3). 9. Remove orifice (6) from valve casing (3). : 3 mm

IMPORTANT: When removing counterbalance valve (4), remove counterbalance valve (4) by turning in order to prevent it from bounding. 3. Slowly remove counterbalance valve (4) from valve casing (3) by turning. CAUTION: When removing plug (11), prevent spring (12) from flying out. 4. Remove plugs (11) (2 used), O-rings (14) (2 used), springs (12) (2 used) and check valve (13). : 36 mm 5. Remove check valve (17) from valve casing (3) by using a socket wrench. 6. Remove plug (7) and O-ring (15) from valve casing (3).

W3-2-21

UNDERCARRIAGE / Travel Motor ASSEMBLY OF BRAKE VALVE A

View A

B

Brake Valve

7 Brake Valve

5, 6

C

WCGB-03-02-001 WCGB-03-02-002

2

3

4

8

9

10 1

Section C

11

12 13 17

16

15

14 7

Section B WCGB-03-02-005

12345-

Cover Socket Bolt (4 Used) Valve Casing Counterbalance Valve Plug

6789-

Orifice Plug O-Ring (2 Used) Cover

10 11 12 13 -

W3-2-22

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

14 15 16 17 -

O-Ring (2 Used) O-Ring Shuttle Valve Check Valve (2 Used)

UNDERCARRIAGE / Travel Motor Assembly of Brake Valve 1. Install orifice (6) and plug (5) to valve casing (3). : 3 mm 2. Install shuttle valve (16) and plug (7) to valve casing (3). 3. Install check valves (17) (2 used) to valve casing (3). 4. Install check valve (13) to check valve (17). 5. Install springs (12) (2 used) to plugs (11) (2 used). Install the plug (11) assemblies (2 used) and O-rings (14) (2 used) to valve casing (3). : 36 mm : 167 N⋅m (17 kgf⋅m, 123 lbf⋅ft) IMPORTANT: Slowly insert counterbalance valve (4) into valve casing (3) by turning. Check if counterbalance valve (4) moves smoothly. 6. Insert counterbalance valve (4) into valve casing (3). 7. Install cover (1) and O-ring (8) to valve casing (3) with socket bolts (2) (4 used). : 10 mm : 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft) 8. Install cover (9) and O-ring (8) to valve casing (3) with socket bolts (10) (4 used). : 10 mm : 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)

W3-2-23

UNDERCARRIAGE / Travel Motor (Blank)

W3-2-24

UNDERCARRIAGE / Center Joint REMOVAL AND INSTALLATION OF CENTER JOINT CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal NOTE: If disconnecting the hoses (5 used) for the front attachment, the center joint can be removed easily. The number of hoses differs depending on the front attachment specifications. 1. Disconnect connectors (2) (2 used).

2

2. Remove bolt (3) and washer (4) from clips (1) (2 used). Remove clips (1) (2 used) from center joint (5). : 10 mm

3, 4

5

1

WCJB-03-03-002

2

6

3. Disconnect connector (6).

7

8

4. Remove bolt (9) and washer (10) from clip (7). Remove clip (7) from stopper (8). : 17 mm 5. Remove sems bolts (11) (3 used) from slip ring (12). Remove the slip ring (12) assembly from stopper (8). (Length: approx. 670 mm (26.4 in)) : 10 mm

9, 10 11 12

WCJB-03-03-001

W3-3-1

UNDERCARRIAGE / Center Joint 5

6. Remove bolts (14) (5 used) and washers (15) (5 used) from stopper (8). Remove stopper (8) from center joint (5). : 24 mm

13

8

7. Disconnect hoses (13) (13 used) from center joint (5). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 22 mm, 27 mm, 36 mm

14, 15

13

WCJB-03-03-001

8. Disconnect hoses (16) (23 used) from center joint (5). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 22 mm, 27 mm, 41 mm

5

9. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to the hole on bolt (14) of center joint (5). Attach a nylon sling onto eyebolts. Hoist and hold center joint (1). CAUTION: The center joint (1) assembly weight: 90 kg (200 lb) IMPORTANT: The propeller shaft and the travel transmission are located under center joint (5). When hoisting and removing center joint (5), do not hit them. 10. Remove bolts (18) (4 used) and washers (19) (4 used) from center joint (5). Hoist and remove the center joint (5) assembly from track frame (17). : 22 mm

16

16

WCJB-03-03-002

18, 19 5 17

WCJB-03-03-003

W3-3-2

UNDERCARRIAGE / Center Joint Installation CAUTION: The center joint (5) assembly weight: 90 kg (200 lb) IMPORTANT: The propeller shaft and the travel transmission are located under the center joint (5). Hoist center joint (5) in order not to hit them. 1. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to center joint (5). Attach a nylon sling onto eyebolt. Hoist and align center joint (5) with the mounting hole on track frame (17). 2. Apply LOCTITE #262 onto bolts (18) (4 used). Install center joint (5) to track frame (17) with bolts (18) (4 used) and washers (19) (4 used). : 22 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

16 18, 19

5 17

16

WCJB-03-03-003

5

3. Connect hoses (16) (23 used) to center joint (5). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

16

16

W3-3-3

WCJB-03-03-002

UNDERCARRIAGE / Center Joint 4. Connect hoses (13) (13 used) to center joint (5). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

5

13

8

14, 15

5. Apply LOCTITE #262 onto bolts (14) (5 used). Install stopper (8) to center joint (5) with bolts (14) (5 used) and washers (15) (5 used). : 24 mm : 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)

13

WCJB-03-03-001

6. Install the slip ring (12) assembly to center joint (5). Install slip ring (12) to stopper (8) with sems bolts (11) (3 used). : 10 mm : 3.3 to 4.2 N⋅m (0.3 to 0.4 kgf⋅m, 2 to 3 lbf⋅ft)

6

7

8

9, 10

7. Install clip (7) to stopper (8) with bolt (9) and washer (10). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

11 12

8. Connect connector (6). 5

W3-3-4

WCJB-03-03-001

UNDERCARRIAGE / Center Joint 9. Install clips (1) (2 used) to center joint (5) with bolt (3) and washer (4). : 10 mm : 3.3 to 4.2 N⋅m (0.3 to 0.4 kgf⋅m, 2 to 3 lbf⋅ft)

2

3, 4

5

1

10. Connect connectors (2) (2 used).

2

W3-3-5

WCJB-03-03-002

UNDERCARRIAGE / Center Joint DISASSEMBLY OF CENTER JOINT

1, 2 3 3

3 4 5 6

5

5

13 12

7

11 11

11

8 WCGB-03-03-001

7

1234-

Plug (2 Used) O-Ring (2 Used) Spindle O-Ring

567-

10

Body Oil Seal (15 Used) Cover

9

8 - Bolt (4 Used) 9 - O-Ring 10 - Plate

W3-3-6

7

11 - Socket Bolt (4 Used) 12 - O-Ring 13 - O-Ring

UNDERCARRIAGE / Center Joint Disassembly of Center Joint CAUTION: Center joint weight: 90 kg (200 lb)

6. Install eyebolts (M14, Pitch 1.75 mm) (2 used) to the bolt (8) hole (2 places) on spindle (3). Hoist and place spindle (3) onto the wooden blocks horizontally.

1. Attach a nylon sling onto the body of body (5). Hoist the center joint. Secure the center joint on a workbench (ST 5109).

7. Remove O-ring (9), plugs (1) (2 used) and O-rings (2) (2 used) from spindle (3). : 12 mm

2. Remove socket bolts (11) (4 used) from cover (7). Remove cover (7) and O-ring (12) from body (5). : 12 mm

IMPORTANT: For easy removal, use the pins (2 used). Do not damage the seal groove by the pins. 8. Remove O-rings (4, 13) and oil seals (6) (15 used) from body (5).

3. Remove bolts (8) (4 used) from plate (10). Remove plate (10) from spindle (3). : 19 mm 4. Install eyebolts (M14, Pitch 2.0 mm) (2 used) to the socket bolt (11) hole (2 places) on body (5). Hoist and hold body (5). IMPORTANT: Do not damage the seal sliding surface of spindle (3). 5. Install the puller to the body (5). Remove body (5) from spindle (3). NOTE: There is a hole for the harness at the center of spindle (3). Prepare a cover in order to cover the hole on spindle (3). Place the cover between the puller and spindle (3). Remove spindle (3). Puller

5 4, 13, 6

W105-03-03-015

W202-03-03-011

W3-3-7

UNDERCARRIAGE / Center Joint ASSEMBLY OF CENTER JOINT

1, 2 3 3

3 4 5 6

5

5

13 12

7

11 11

11

8 WCGB-03-03-001

7

1234-

Plug (2 Used) O-Ring (2 Used) Spindle O-Ring

567-

10

Body Oil Seal (15 Used) Cover

9

8 - Bolt (4 Used) 9 - O-Ring 10 - Plate

W3-3-8

7

11 - Socket Bolt (4 Used) 12 - O-Ring 13 - O-Ring

UNDERCARRIAGE / Center Joint Assembly of Center Joint IMPORTANT: After installing the seals, apply grease onto the inner surface of body (5), the inner surface of the circuit and the seals. 1. Install O-rings (4, 13) and oil seals (6) (15 used) to body (5). 2. Apply grease onto O-rings (2) (2 used). Install O-rings (2) (2 used) to plugs (1) (2 used). 3. Apply grease onto O-ring (9). Install plugs (1) (2 used) and O-ring (9) to spindle (3). : 12 mm : 147±14.7 N·m (15±1.5 kgf·m, 108±11 lbf⋅ft)

8. Install plate (10) to spindle (3) with bolts (8) (4 used). : 19 mm : 51 to 59 N⋅m (5.2 to 6.0 kgf⋅m, 38 to 44 lbf⋅ft) 9. Install O-ring (12) to cover (7). 10. Install cover (7) to body (5) with socket bolts (11) (4 used). : 12 mm : 206 to 216 N⋅m (21 to 22 kgf⋅m, 152 to 159 lbf⋅ft)

4. Install eyebolts (M14, Pitch 1.75 mm) (2 used) into the bolt (8) hole (2 places) on spindle (3). 5. Hoist spindle (3). Secure spindle (3) on a workbench (ST 5109). IMPORTANT: There is almost no clearance between body (5) and spindle (3). Insert body (5) along the axis straight and slowly. 6. Apply hydraulic oil onto the outer surface of spindle (3). Install eyebolts (M14, Pitch 2.0 mm) (2 used) to the bolt (8) hole (2 places) on body (5). Hoist and install body (5) to spindle (3). 7. Lightly tap body (5) by using a plastic hammer. Insert body (5) until body (5) comes in contact with the flange of spindle (3).

W3-3-9

UNDERCARRIAGE / Center Joint (Blank)

W3-3-10

UNDERCARRIAGE / Transmission REMOVAL AND TRANSMISSION

INSTALLATION

OF

CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) When removing and installing the transmission, the propeller shaft, the pipings of the travel motor and one part of the rear axle should be removed first. Refer to REMOVAL AND INSTALLATION OF PROPELLER SHAFT on W3-10-1, REMOVAL AND INSTALLATION OF TRAVEL MOTOR on W3-2-1 and REMOVAL AND INSTALLATION OF AXLE on W3-5-1. IMPORTANT: When removing and installing the transmission, bleed air from the hydraulic port and the brake before doing any work. Refer to TROUBLESHOOTING / T5-7 Troubleshooting B in Technical Manual.

4

3

2

Removal IMPORTANT: Remove the transmission with the travel motor together in order to keep the balance of weight. 1. Loosen nuts (1) (20 used). Raise the machine until tire (3) at the rear axle side is raised. Place a stand under frame (4). CAUTION: Tire (3) weight: 98 kg (220 lb) Tire ring (2) weight: 25 kg (60 lb) 2. Remove nuts (1) (20 used). Remove tires (3) (4 used) and tire rings (2) (2 used).

W3-4-1

1

3

W1GL-03-05-003

UNDERCARRIAGE / Transmission 3. Remove plugs (8, 9). Drain oil from the transmission. : 14 mm

7

6

Transmission

5

CAUTION: Propeller shaft (11) weight: 35 kg (80 lb)

8

4. Place a wooden block under propeller shaft (11). Remove nuts (10) (8 used). Remove propeller shaft (11) from the transmission. : 14 mm 5. Disconnect hoses (7) (9 used) and connectors (6) (2 used) from the transmission and travel motor (5). Cap the disconnected hoses. : 19 mm, 22 mm, 27 mm : 12 mm CAUTION: The transmission weight: 220 kg (490 lb)

12

WCGB-03-05-033

11

assembly

10

9

Transmission

6. Loosen bolts (13) (14 used). : 19 mm

Rear Axle

7. Support the travel motor (5) part by using a forklift and remove bolts (13) (14 used). Remove the transmission assembly from the rear axle. : 19 mm CAUTION: Travel motor (5) weight: 80 kg (180 lb) 8. Remove socket bolts (12) (4 used). Remove travel motor (5) from the transmission. : 14 mm

W3-4-2

13

WCGB-03-05-032

UNDERCARRIAGE / Transmission Installation CAUTION: Transmission weight: 135 kg (300 lb)

6

7

Transmission

5

1. Install plug (9) to the transmission. Temporarily install plug (8). : 14 mm : 79 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

8

CAUTION: Travel motor (5) weight: 80 kg (180 lb) 2. Install travel motor (5) onto the transmission with socket bolts (12) (4 used). : 14 mm : 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft) 3. Install the transmission assembly to the rear axle with bolts (13) (14 used). : 19 mm : 230 N⋅m (23 kgf⋅m, 170 lbf⋅ft) 4. Connect hoses (7) (9 used) and connectors (6) (2 used) to the transmission. : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 27 mm : 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft) : 12 mm : 140 N⋅m (14 kgf⋅m, 103 lbf⋅ft)

W3-4-3

12

WCGB-03-05-033

11

10

9 Transmission

Rear Axle

13

WCGB-03-05-032

UNDERCARRIAGE / Transmission CAUTION: Propeller shaft (11) weight: 35 kg (80 lb) Transmission

5. Install propeller shaft (11) to the transmission with nuts (10) (8 used). : 14 mm : 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft) 6. Remove temporarily installed plug (8). Add oil to the transmission. After adding oil, install plug (8) to the transmission. NOTE: Gear oil: 2.5 L (0.7 US gal.) : 14 mm : 79 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

W3-4-4

WCGB-03-05-033

11

10

9

UNDERCARRIAGE / Transmission (Blank)

W3-4-5

UNDERCARRIAGE / Transmission DISASSEMBLY OF TRANSMISSION

Part A

WCGB-03-04-001

Part A 3

4

5

6

7

8

9

10 9 11 12 13 14, 15

16, 17, 18, 19

20

21

22

23

2

24

1

25 26

54

27, 28 52, 53 51 50

27, 28

49 29

48

30, 31

47

46

45

44 43 42

41 40

39 38

37 36

35

34

33

32

WCGB-03-04-002

W3-4-6

UNDERCARRIAGE / Transmission

Part B

55

Part B

56

57

WCGB-03-04-001

58 59 60 61

74

62

73

72

70, 71

63 69

68

22

67

66

W3-4-7

65

64

WCGB-03-04-003

UNDERCARRIAGE / Transmission

12345678910 11 12 13 14 15 16 17 18 19 20 -

Cover Bolt (5 Used) O-Ring (5 Used) Oil Seal Pin (2 Used) Oil Seal Oil Seal Seal Ring O-Ring (2 Used) Gasket Plate (7 Used) Friction Plate (6 Used) Disc Plate Retaining Ring Shim Planetary Gear (3 Used) Retaining Ring (3 Used) Washer (3 Used) Bearing Retaining Ring

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 -

Bearing Housing Bearing O-Ring (2 Used) Bolt (4 Used) Shift Interlock Controller Socket Bolt (5 Used) Washer (5 Used) Plate Bearing Washer (2 Used) Planetary Carrier Slot Pin (6 Used) Ring Gear Retaining Ring Retaining Ring Bearing Collar Disc Plate Plate (9 Used)

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 -

W3-4-8

Friction Plate (10 Used) O-Ring Ring Ring Brake Piston Disc Spring Clutch Piston Oil Seal Shaft Spring Holder Bearing Plate (2 Used) Disc Spring Bearing Ring Final Gear O-Ring (3 Used) O-Ring Cover

61 62 63 64 65 66 67 68 69 70 71 72 73 74 -

Bearing Pinion Shim Bushing Shaft Seal Cover Screen Sheet Flange O-Ring Bolt (2 Used) Washer (2 Used) Plate Plate Shaft Seal

UNDERCARRIAGE / Transmission (Blank)

W3-4-9

UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A 22

24

26

27, 28

27, 28

WCGB-03-04-002

W3-4-10

UNDERCARRIAGE / Transmission Disassembly of Transmission CAUTION: Transmission weight: 135 kg (300 lb) 1. Attach a nylon sling onto the transmission. Hoist the transmission. Lower the transmission onto a workbench. 2. Remove bolts (75, 77) (2 used for each) and seal rings (76, 78) (2 used for each) from the transmission. Disconnect pipes (79) (2 used) from the transmission. : 22 mm, 24 mm Transmission

4. Remove socket bolts (27) (5 used) and washers (28) (5 used). : 6 mm 5. Remove shift interlock controller (26) and O-rings (24) (2 used) from the transmission. 6. Remove socket bolt (83). Remove travel N sensor (82) and O-rings (84) (2 used) from housing (22). : 6 mm 83, 84

82

22

79

77, 78

75, 76 WCGB-03-04-005

3. Remove plugs (80) (2 used) and seal rings (81) (2 used) from housing (22). : 8 mm 22 80, 81

WCGB-03-04-013

W3-4-11

WCGB-03-04-006

UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A 3

4

5

7

22

2 1 54

47

46

45

WCGB-03-04-002

W3-4-12

UNDERCARRIAGE / Transmission 7. Remove bleeder (85), spring (87), steel ball (88), plug (90) and O-rings (86, 89) from housing (22). : 27 mm : 8 mm 2

10. Remove spring (94), O-ring (95) and piston (96) from housing (22). 22

85

94, 95, 96

1 86

22

87 88 90

89 WCGB-03-04-014 WCGB-03-04-007

8. Remove bleeder valve (93) and plugs (91, 92) from housing (22). : 17 mm : 8 mm 22

11. Remove disc springs (46, 54) from housing (22). Remove clutch piston (47). 12. Remove pins (5) (2 used) from housing (22). 13. Apply air to the hole of bleeder valve (93) on housing (22). Remove brake piston (45). Remove fitting (97) from housing (22). : 17 mm 22

91

93

92

97 WCGB-03-04-013

9. Remove bolts (2) (5 used). Remove cover (1) and O-ring (3) from housing (22). : 19 mm

93

WCGB-03-04-013

14. Remove oil seals (4, 7) from housing (22).

W3-4-13

UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A 6

8

9

10

11

12 13

14, 15 16, 17, 18, 19

21

20

22 23 25

52, 53 51 50 49 29

48

30, 31

45

44 43 42

41 40

39 38

37 36

35

34

33

32

WCGB-03-04-002

W3-4-14

UNDERCARRIAGE / Transmission 15. Remove oil seals (6, 48) from brake piston (45). IMPORTANT: Do not remove bearing (52) unless necessary. 16. Remove bearing (52) and plales (53) (2 used) from shaft (49). 17. Remove holder (51) and spring (50) from shaft (49).

26. Remove retaining ring (20) from shaft (49). Remove collar (38). IMPORTANT: Do not remove bearing (37) unless necessary. 27. Remove retaining rings (35, 36) from ring gear (34). Remove bearing (37). 28. Remove bearing (30) and washers (31) (2 used) from planetary carrier (32).

18. Remove the ring (44) assembly from housing (22). 19. Remove ring (43), seal ring (8), O-rings (9) (2 used), O-ring (42) and gasket (10) from the ring (44) assembly.

29. Remove bolts (25) (4 used). Remove plate (29) from housing (22). : 17 mm 30. Remove planetary carrier (32) from housing (22).

20. Remove friction plates (12) (6 used), plates (11) (7 used) and disc plate (13) from housing (22). 21. Remove retaining ring (14) and shim (15) from housing (22). 22. Remove friction plates (41) (10 used) and plates (40) (9 used) from housing (22). 23. Remove disc plate (39) from housing (22). 24. Remove the shaft (49) assembly from housing (22). 25. Remove shaft (49) from ring gear (34).

IMPORTANT: Do not remove bearings (21, 23) unless necessary. 31. Remove the inner races of bearings (21, 23) from planetary carrier (32). IMPORTANT: Do not remove bearings (21, 23) unless necessary. 32. Remove the outer races of bearings (21, 23) from housing (22). IMPORTANT: Do not remove bearing (19) unless necessary. 33. Remove retaining rings (17) (3 used), washers (18) (3 used) and bearings (19) (3 used) from planetary gears (16) (3 used). 34. Remove slot pins (33) (6 used) from planetary gear (16).

W3-4-15

UNDERCARRIAGE / Transmission

Part B

55

Part B

56

57

WCGB-03-04-001

58 59 60 61

74

62

73

72

70, 71

63 69

68

22

67

66

W3-4-16

65

64

WCGB-03-04-003

UNDERCARRIAGE / Transmission 35. Remove bleeder valves (98) (2 used), plugs (99) (2 used), plugs (101) (3 used), seal rings (100) (2 used) and O-rings (102) (3 used) from housing (22). : 17 mm 22 99, 100 : 8 mm

40. Remove O-ring (59) and bushing (64) from pinion (62). IMPORTANT: Do not remove bearing (61) unless necessary. 41. Remove the inner race of bearing (61) from pinion (62). IMPORTANT: Do not remove bearing (61) unless necessary. 42. Remove shim (63) and the outer race of bearing (61) from cover (60).

98

43. Remove cover (60) from housing (22). 44. Remove O-rings (58) (3 used) and shaft seal (65) from cover (60). 101, 102 WCGB-03-04-008

36. Remove bolts (70) (2 used) and washers (71) (2 used). Remove plate (72) and O-ring (69) from housing (22). : 17 mm 37. Remove flange (68) and plate (73) from housing (22). 38. Remove shaft seal (74) from housing (22).

45. Remove the final gear (57) assembly from housing (22). 46. Remove cover (66) from final gear (57). 47. Remove screen sheet (67) from housing (22). IMPORTANT: Do not remove bearing (55) unless necessary. 48. Remove bearing (55) and ring (56) from housing (22).

39. Remove pinion (62) from housing (22).

W3-4-17

UNDERCARRIAGE / Transmission ASSEMBLY OF TRANSMISSION

Part A

WCGB-03-04-001

Part A

3

4

5

6

7

8

9

20

10 9 11 12 13 14, 15 16, 17, 18, 19

21

22

23

2

24 25

1

26 54 27, 28 52, 53 51 50

27, 28

49 29

48

30, 31

47

46

45

44 43 42

41 40

39 38

37 36

35

34

33

32

WCGB-03-04-002

W3-4-18

UNDERCARRIAGE / Transmission

Part B

55

Part B

56

57

WCGB-03-04-001

58 59 60 61

74

62

73

72

70, 71

63 69

68

22

67

66

W3-4-19

65

64

WCGB-03-04-003

UNDERCARRIAGE / Transmission

12345678910 11 12 13 14 15 16 17 18 19 20 -

Cover Bolt (5 Used) O-Ring (5 Used) Oil Seal Pin (2 Used) Oil Seal Oil Seal Seal Ring O-Ring (2 Used) Gasket Plate (7 Used) Friction Plate (6 Used) Disc Plate Retaining Ring Shim Planetary Gear (3 Used) Retaining Ring (3 Used) Washer (3 Used) Bearing Retaining Ring

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 -

Bearing Housing Bearing O-Ring (2 Used) Bolt (4 Used) Shift Interlock Controller Socket Bolt (5 Used) Washer (5 Used) Plate Bearing Washer (2 Used) Planetary Carrier Slot Pin (6 Used) Ring Gear Retaining Ring Retaining Ring Bearing Collar Disc Plate Plate (9 Used)

40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 -

W3-4-20

Friction Plate (10 Used) O-Ring Ring Ring Brake Piston Disc Spring Clutch Piston Oil Seal Shaft Spring Holder Bearing Plate (2 Used) Disc Spring Bearing Ring Final Gear O-Ring (3 Used) O-Ring Cover

61 62 63 64 65 66 67 68 69 70 71 72 73 74 -

Bearing Pinion Shim Bushing Shaft Seal Cover Screen Sheet Flange O-Ring Bolt (2 Used) Washer (2 Used) Plate Plate Shaft Seal

UNDERCARRIAGE / Transmission (Blank)

W3-4-21

UNDERCARRIAGE / Transmission

Part B

55

Part B

57

WCGB-03-04-001

58

60 61

63

22

67

66

W3-4-22

65

WCGB-03-04-003

UNDERCARRIAGE / Transmission Assembly of Transmission 1. Hoist housing (22) with the rear axle mounting side facing upward. 2. Install the outer race of bearing (55) to housing (22).

5. Apply grease onto the seal and the dust lip part of shaft seal (65). Apply gear oil onto the outer circumference of shaft seal (65). Install shaft seal (65) to cover (60). NOTE: Dimension A: 69.5-0.5 mm (2.7-0.02 in)

3. Install screen sheet (67) to housing (22). At this time, the slot pin should pass through the hole on screen sheet (67).

65

A

60 22

WCGB-03-04-015

6. Install shim (63) to cover (60). 7. Install the outer race of bearing (61) to cover (60). Slot Pin

4. Install final gear (57) to housing (22).

WCGB-03-04-009

8. Apply hydraulic oil onto O-ring (58). Install O-rings (58) (3 used) to cover (60). IMPORTANT: Install cover (66) so that the convex part of the cover (60) back side can enter the groove of cover (60). 9. Install cover (66) to cover (60).

66

60

WCGB-03-04-016

W3-4-23

UNDERCARRIAGE / Transmission

Part B

55

Part B

WCGB-03-04-001

56 59 60 61 62

72

70

69

68

22

64

W3-4-24

WCGB-03-04-003

UNDERCARRIAGE / Transmission 10. Install the cover (60) assembly to housing (22). Temporarily tighten with nuts (103) (2 used) and washers (104) (2 used). : 19 mm 60

22 103, 104

WCGB-03-04-010

11. Install the inner race of bearing (61), bushing (64) and O-ring (59) to pinion (62). 12. Install pinion (62) to housing (22). Install special tool (ZF special tool No. 5870 654 049) to housing (22). Tighten pinion (62). 13. Hoist and turn over housing (22) with the rear axle mounting side facing downward. 14. Install ring (56) and the inner race of bearing (55) to pinion (62).

15. Install O-ring (69) and plate (72) to housing (22). Temporarily tighten with bolts (70) (2 used). At this time, turn pinion (62) to both directions 7 times and take up slack. : 17 mm : 46 N⋅m (4.7 kgf⋅m, 34 lbf⋅ft) 16. Turn pinion (62) and measure the preload. If the proper preload cannot be obtained, reassemble from step 14. NOTE: Proper preload: 1.5 to 3.0 N⋅m (0.2 to 0.3 kgf⋅m, 1.0 to 2.0 lbf⋅ft) 17. Tighten pinion (62) in a direction opposite to step 12 by using special tool (ZF special tool No. 5870 654 049). Remove special tool (ZF special tool No. 5870 654 049). 18. Turn pinion (62) and measure the preload. If the proper preload cannot be obtained, reassemble from step 14. NOTE: Proper preload: 1.5 to 3.0 N⋅m (0.2 to 0.3 kgf⋅m, 1.0 to 2.0 lbf⋅ft) 19. Remove temporarily installed bolts (70) (2 used). Remove flange (68) and plate (72) from housing (22). : 17 mm

W3-4-25

UNDERCARRIAGE / Transmission

Part B

WCGB-03-04-001

55

Part B

60 74 62

73

72

70, 71

69

68

WCGB-03-04-003

22

W3-4-26

UNDERCARRIAGE / Transmission 20. Apply grease onto the seal and the dust lip part of shaft seal (74). Apply gear oil onto the outer circumference of shaft seal (74). Install shaft seal (74) to housing (22). 21. Install plate (73) to housing (22). NOTE: Dimension B: 17.6-0.5 mm (0.7-0.02 in) Dimension C: 27.5+0.3 mm(1.1+0.01 in) 74

23. Remove nuts (103) (2 used) and washers (104) (2 used) which are installed temporarily. : 19 mm

22 103, 104

55 22

B

C WCGB-03-04-010

24. Hoist housing (22) with the rear axle mounting side facing upward.

73

WCGB-03-04-011

22. Install flange (68), O-ring (69) and plate (72) to housing (22) with bolts (70) (2 used) and washers (71) (2 used). : 17 mm : 46 N⋅m (4.7 kgf⋅m, 34 lbf⋅ft)

25. Install the steel ball (diameter: 7.0 mm (0.3 in)) to the center hole on pinion (62). Measure the dimension. If the proper dimension cannot be obtained, reassemble from step 12. NOTE: Dimension D: 115.6 mm (4.6 in) Dimension E: 73±0.05 mm (2.9±0.002 in) 62

D E

60 22 WCGB-03-04-012

W3-4-27

UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A 13 14, 15

16, 17, 18, 19

20

22

21

23 25

49 29 30, 31

39 38

37 36

35

34

33

32

WCGB-03-04-002

W3-4-28

UNDERCARRIAGE / Transmission 26. Install the outer race of bearing (23) to housing (22).

34. Hoist housing (22) with the rear axle mounting side facing upward.

27. Hoist housing (22) with the rear axle mounting side facing downward.

35. Install the inner race of bearing (23) to housing (22).

28. Install the outer race of bearing (21) to housing (22).

36. Install plate (29) to housing (22) with bolts (25) (4 used). At this time, turn planetary carrier (32) to both directions several times. : 17 mm : 46 N⋅m (4.7 kgf⋅m, 34 lbf⋅ft)

29. Apply grease onto slot pin (33). Install slot pins (33) (6 used) to planetary carrier (32). NOTE: Dimension F: 28-1.0 mm (1.1-0.04 in) 33 32

37. Install collar (38) to shaft (49). Secure with retaining ring (20). 38. Secure bearing (37) to ring gear (34) with retaining rings (36) (2 used).

F

39. Install shaft (49) to ring gear (34). Secure with retaining ring (35). 40. Hoist housing (22) with the rear axle mounting side facing downward. WCGB-03-04-017

30. Install planetary gears (16) (3 used), bearings (19) (3 used) and washers (18) (3 used) to planetary carrier (32) with retaining rings (17) (3 used). 31. Install the inner race of bearing (21) to planetary carrier (32).

41. Install bearing (30) and washers (31) (3 used) to planetary carrier (32). 42. Install the shaft (49) assembly to housing (22). 43. Secure the shaft (49) assembly to housing (22) with retaining ring (14) and shim (15). 44. Install disc plates (13, 39) to housing (22).

32. Install planetary carrier (32) to housing (22). 33. Tighten planetary carrier (32) to housing (22) by using special tool (ZF special tool No. 5870 654 049).

W3-4-29

UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A 11

12

22

54 52, 53 51

49

47

46

45

41 40

WCGB-03-04-002

W3-4-30

UNDERCARRIAGE / Transmission 45. Install friction plates (12) (6 used) and plates (11) (7 used) to housing (22). 46. Remove friction plates (41) (10 used) and plates (40) (9 used) from housing (22).

52. Measure dimension I of housing (22) and clutch piston (47). NOTE: Dimension I: 22.5 mm (0.9 in)

47. Apply hydraulic oil onto plate (53). Install holder (51), bearing (52) and plates (53) (2 used) to shaft (49).

I

48. Install brake piston (45) without the seals to housing (22).

47 22

49. Install clutch piston (47) without the seals to housing (22). 50. Install disc springs (46, 54) to housing (22). 51. Install special tool (ZF special tool No. 5870 200 131) to housing (22) with the bolts (2 used). Measure dimensions G and H of disc springs (46, 54). : 19 mm : 80 N⋅m (8 kgf⋅m, 59 lbf⋅ft) NOTE: Dimension G: 2.4+0.3 mm (0.09+0.01 in) Dimension H: 1.8+0.3 mm (0.07+0.01 in) 54

WCGB-03-04-018

53. Measure dimension J of housing (22) and brake piston (45). NOTE: Dimension J: 11.9 mm (0.47 in)

J

45

46

22 WCGB-03-04-018

H G

22 WCGB-03-04-018

54. Remove the bolts (2 used). Remove special tool (ZF special tool No. 5870 200 131) and disc springs (46, 54) from housing (22). : 19 mm 55. Remove brake piston (45), clutch piston (47), holder (51), bearing (52) and plates (53) (2 used) from housing (22).

W3-4-31

UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A

3

4

5

6

7

8

9

10 9

22

2 1 54 52, 53 51 50 49 48 47

46

45

44 43 42

WCGB-03-04-002

W3-4-32

UNDERCARRIAGE / Transmission 56. Apply hydraulic oil onto the seal surface of ring (43) and O-ring (9). Install O-ring (9) to ring (43). 57. Install ring (43) to housing (22) by using a plastic hammer.

66. Install clutch piston (47) to housing (22). Push clutch piston (47) toward the shaft. Install plugs (80) (2 used) and seal rings (81) (2 used) to housing (22). 80, 81

22

58. Apply hydraulic oil onto the seal surface of ring (44) and O-rings (9, 42). Install O-rings (9, 42), oil seal (8) and gasket (10) to ring (44). 59. Install ring (44) to housing (22) by using a plastic hammer. 60. Install spring (50) and holder (51) to shaft (49). 61. Apply hydraulic oil onto bearing (52). Install bearing (52) and plates (53) (2 used) to shaft (49). 62. Apply hydraulic oil onto the seal surface of housing (22). Install oil seals (4, 7) to housing (22). 63. Apply hydraulic oil onto the seal surface of brake piston (45). Install oil seals (6, 48) to brake piston (45). 64. Install brake piston (45) to housing (22) by using a plastic hammer.

WCGB-03-04-013

67. Install disc springs (46, 54) to housing (22). 68. Install piston (96), spring (94) and O-ring (95) to housing (22). 22

94, 95, 96

65. Install pins (5) (2 used) to brake piston (45).

WCGB-03-04-014

69. Apply hydraulic oil onto O-ring (3). Install O-ring (3) to cover (1). 70. Install cover (1) to housing (22) with bolts (2) (5 used). : 19 mm : 80 N⋅m (8 kgf⋅m, 59 lbf⋅ft)

W3-4-33

UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A 22

WCGB-03-04-002

W3-4-34

UNDERCARRIAGE / Transmission 71. Install O-rings (86, 89), plug (90), steel ball (88) and spring (87) to housing (22). : 8 mm : 24 N⋅m (2.4 kgf⋅m, 18 lbf⋅ft) 2

1 86

22

87 88 90

89

73. Install bleeder (85), bleeder valve (93), fitting (97) and plugs (91, 92) to housing (22). Bleeder (85) : 27 mm : 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft) Bleeder valve (93) : 17 mm : 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft) Fitting (97) : 17 mm : 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft) Plugs (91, 92) : 8 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) 22

WCGB-03-04-007

72. Install bleeder valves (98) (2 used), plugs (99) (2 used), plugs (101) (3 used), seal rings (100) (2 used) and O-rings (102) (3 used) to housing (22). Bleeder valve (98) : 17 mm : 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft) Plug (99) : 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft) Plug (102) : 8 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) 22

99, 100

98

101, 102 WCGB-03-04-008

W3-4-35

97 85

93

92

91

WCGB-03-04-013

UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A 22

26

27, 28

27, 28

WCGB-03-04-002

W3-4-36

UNDERCARRIAGE / Transmission 74. Install travel N sensor (82) to housing (22) with socket bolt (83) and O-ring (84). : 6 mm : 23 N⋅m (2.3 kgf⋅m, 17 lbf⋅ft) 85, 86

84

22

WCGB-03-04-006

75. Install shift interlock controller (26) to housing (22) with socket bolts (27) (5 used) and washers (28) (5 used). : 6 mm : 23 N⋅m (2.3 kgf⋅m, 17 lbf⋅ft) 76. Connect pipes (81) (2 used) to the transmission with bolts (75, 77) (2 used for each) and seal rings (76, 78) (2 used for each). : 22 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 24 mm : 45 N⋅m (4.5 kgf⋅m, 33 lbf⋅ft) Transmission

79

77, 79

75, 76 WCGB-03-04-005

W3-4-37

UNDERCARRIAGE / Transmission (Blank)

W3-4-38

UNDERCARRIAGE / Axle REMOVAL AND INSTALLATION OF AXLE Removal of Front Axle

3

2

3

3

2

3

4

1. Loosen nuts (1) (20 used) for tires (3) (4 used) and tire rings (2) (2 used). : 30 mm

2. Swing the machine by 90º. Raise the front axle side of frame (4) until tire (3) is raised. Place a stand under frame (4).

1

W1GL-03-05-003

CAUTION: Tire (3) weight: 98 kg (220 lb) Tire ring (2) weight: 25 kg (60 lb)

5

Steering Cylinder

Front Axle

3. Remove nuts (1) (20 used). Remove tires (3) (4 used) and tire rings (2) (2 used) from frame (4). : 30 mm 4. Disconnect brake hoses (5) (2 used) from the right and left sides of the front axle. : 22 mm WCEB-03-05-021

W3-5-1

UNDERCARRIAGE / Axle 5. Disconnect grease hose (8) from pin (7). : 17 mm

4

7

6

8

6. Disconnect steering hoses (6) (2 used) from the steering cylinder. : 22 mm CAUTION: Propeller shaft (11) weight: 35 kg (80 lb) Steering Cylinder

7. Place a wooden block under propeller shaft (11). Remove bolts (10) (8 used) and nuts (9) (8 used). Remove propeller shaft (11) from the front axle. : 14 mm

WCGB-03-05-024

Front Axle

11 9, 10

WCGB-03-05-028

4

8. Remove nuts (12) (2 used). Remove bolt (13) from pin (7). : 24 mm 9. Hold the lower side of the front axle by using a forklift. CAUTION: Front axle weight: ZX210W-3: 750 kg (1660 lb) ZX220W-3: 770 kg (1700 lb)

13

7 12

WCGB-03-05-027

CAUTION: Pin (7) weight: 18 kg (40 lb) (outer diameter 70 mm (2.8 in)) 10. Remove pin (7) from the front axle. Remove the front axle from frame (4).

W3-5-2

UNDERCARRIAGE / Axle Installation of Front Axle 4

CAUTION: Front axle weight: ZX210W-3: 750 kg (1660 lb) ZX220W-3: 770 kg (1700 lb)

13

CAUTION: Pin (7) weight: 18 kg (40 lb) (outer diameter 70 mm (2.8 in))

7 12

1. Hold the front axle by using a forklift. Install the front axle to frame (4) with pin (7). 2. Secure pin (7) with bolt (13) and nuts (12) (2 used). : 24 mm : 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)

WCGB-03-05-027

4

6

7

8

3. Connect steering hoses (6) (2 used) to the steering cylinder. : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) Steering Cylinder

4. Connect brake hoses (5) (2 used) to the right and left sides of the front axle. : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) 5. Connect grease hose (8) to pin (7). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

5

WCGB-03-05-024

6

Front Axle

Steering Cylinder

WCEB-03-05-021

CAUTION: Propeller shaft (11) weight: 35 kg (80 lb) 6. Install propeller shaft (11) to the front axle with bolts (10) (8 used) and nuts (9) (8 used). : 14 mm : 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

Front Axle

11 9, 10

WCGB-03-05-028

W3-5-3

UNDERCARRIAGE / Axle CAUTION: Tire (3) weight: 98 kg (220 lb) Tire ring (2) weight: 25 kg (60 lb)

3

2

3

3

2

3

4

7. Install tire (3), tire ring (2) and tire (3) to the front axle in this order. Temporarily tighten with nuts (1) (10 used). : 30 mm 8. Install tire ring (2) and tires (3) (2 used) to the other side of the front axle in the same way as step 7.

1

9. Remove the stand from frame (4). W1GL-03-05-003

10. Tighten tires (3) (4 used) and tire rings (2) (2 used) with nuts (1) (20 used). : 30 mm : 600 N⋅m (60 kgf⋅m, 440 lbf⋅ft)

W3-5-4

UNDERCARRIAGE / Axle Removal of Rear Axle 1. Loosen nuts (1) (20 used) for tires (3) (4 used) and tire rings (2) (2 used). : 30 mm

4 3

2. Swing the machine by 90°. Raise the rear axle side of frame (4) until tire (3) is raised. Place a stand under frame (4).

2 3

1

CAUTION: Tire (3) weight: 98 kg (220 lb) Tire ring (2) weight: 25 kg (60 lb)

W1GL-03-05-003

5

3. Remove nuts (1) (20 used). Remove tires (3) (4 used) and tire rings (2) (2 used) from frame (4). : 30 mm

7, 8

CAUTION: Propeller shaft (6) weight: 30 kg (70 lb)

6

WCGB-03-05-033

10

4. Place a wooden block under propeller shaft (6). Remove bolts (8) (8 used) and nuts (7) (8 used). Remove propeller shaft (6) from transmission (5). : 14 mm 5. Disconnect hoses (9) (9 used) and connectors (11) (2 used) from transmission (5) and travel motor (10). : 19 mm, 22 mm, 27 mm

W3-5-5

11 9

5

WCGB-03-05-030

UNDERCARRIAGE / Axle CAUTION: The transmission (5) assembly weight: 220 kg (490 lb) 6. Hold the lower side of the transmission (5) assembly by using a forklift. Remove bolts (12) (14 used). Remove the transmission (5) assembly from the rear axle. : 19 mm 7. Disconnect brake pipings (13) (2 used) from the right and left sides of the rear axle. : 19 mm

Rear Axle

5 12

WCGB-03-05-032

4

13

CAUTION: Rear axle weight: ZX210W-3: 600 kg (1330 lb) ZX220W-3: 630 kg (1390 lb) 8. Hold the lower side of the rear axle by using a forklift.

WCGB-03-05-023

14

9. Remove nuts (15) (8 used) from the right and left sides of the rear axle. Remove bolts (14) (8 used) from frame (4). : 30 mm

15

4

10. Remove the rear axle from frame (4).

WCGB-03-05-022

4

W1GL-03-05-003

W3-5-6

UNDERCARRIAGE / Axle Installation of Rear Axle

4

13

CAUTION: Rear axle weight: ZX210W-3: 600 kg (1330 lb) ZX220W-3: 630 kg (1390 lb) 1. Hold the rear axle by using a forklift. Install the rear axle to frame (4) with bolts (14) (8 used) and nuts (15) (8 used). : 30 mm : 560 N⋅m (57 kgf⋅m, 410 lbf⋅ft)

WCGB-03-05-023

14 15

2. Connect brake pipings (13) (2 used) to the right and left sides of the rear axle. : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

4

CAUTION: The transmission (5) assembly weight: 220 kg (490 lb) WCGB-03-05-022

3. While holding the transmission (5) assembly by using a forklift, align it with the rear axle. Install the transmission (5) assembly to the rear axle with bolts (12) (14 used). : 19 mm : 250 N⋅m (26 kgf⋅m, 185 lbf⋅ft) 4. Connect hoses (9) (9 used) and connector (11) to transmission (5) and travel motor (10). (Hose): : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) (Socket bolt): : 12 mm : 140 N⋅m (14 kgf⋅m, 105 lbf⋅ft)

W3-5-7

Rear Axle

5 12

WCGB-03-05-032

10 11 9

WCGB-03-05-030

UNDERCARRIAGE / Axle CAUTION: Propeller shaft (6) weight: 35 kg (80 lb)

5

5. Install propeller shaft (6) to transmission (5) with nuts (7) (8 used) and bolts (8) (8 used). : 14 mm : 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft) 7, 8

CAUTION: Tire (3) weight: 98 kg (220 lb) Tire ring (2) weight: 25 kg (60 lb) 6. Install tire (3), tire ring (2) and tire (3) to the rear axle in this order. Temporarily tighten with nuts (1) (10 used). : 30 mm

6

WCGB-03-05-033

7. Install tire ring (2) and tires (3) (2 used) to the other side of the rear axle in the same way as step 6.

4 3

8. Remove the stand from frame (4). 9. Tighten tires (3) (4 used) and tire rings (2) (2 used) with nuts (1) (20 used). : 30 mm : 600 N⋅m (60 kgf⋅m, 440 lbf⋅ft)

2 1

W3-5-8

3

W1GL-03-05-003

UNDERCARRIAGE / Axle (Blank)

W3-5-9

UNDERCARRIAGE / Axle DISASSEMBLY OF FRONT AXLE 6

7 8

9

10

1

5 4 2

11

3

1

9

8

12

7 21

20

22

19

13

23

25 26 27

24 17

18 29

28

16 14

15

30 31 32 33 43

37 38

34

35

39

40

41 42

44

36

45

46 48

69

68 67 66

65

64

63

59 58 62 61 60

W3-5-10

57

51 56 55 54 53 52

50

47

49

WCGB-03-05-001

UNDERCARRIAGE / Axle 1 - Axle Casing 2 - Bolt (16 Used) 3 - Washer (16 Used) 4 - Plug (2 Used) 5 - O-Ring (2 Used) 6 - Drive Housing 7 - Roller Bearing 8 - Shim 9 - O-Ring 10 -Bearing 11 -Bearing 12 -Tie Rod 13 -Tie Rod 14 -Bushing 15 -Shaft Seal 16 -Double Joint Shaft 17 -Shaft Seal 18 -Bushing

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 -

Knuckle Bolt (4 Used) Bearing Pin O-Ring Seal O-Ring Bearing Nut Thrust Plate Thrust Plate Socket Bolt Retaining Ring Seal O-Ring Shim Bearing Pin O-Ring Shaft Seal Bearing

37 - Hub Carrier 38 - Bushing 39 - Bearing 40 - O-Ring 41 - Friction Plate (6 Used) 42 - Plate (5 Used) 43 - Disc Plate 44 - Planetary Carrier 45 - Plug 46 - O-Ring 47 - Socket Bolt (2 Used) 48 - Retaining Ring (3 Used) 49 - Planetary Gear (3 Used) 50 - Washer (3 Used) 51 - Roller Bearing (3 Used) 52 - Washer (3 Used) 53 - Retaining Ring (3 Used) 54 - Retaining Ring (3 Used)

W3-5-11

55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 -

Washer O-Ring Ring Gear Knock Pin (4 Used) Backup Ring U-Ring U-Ring Backup Ring Piston Spring (8 Used) Spring (8 Used) Spring Seat (8 Used) Bolt (8 Used) Disc Carrier O-Ring

UNDERCARRIAGE / Axle

6 5 4

12

19

13

25 26 27

29

28

43

40

41 42

37 44 45

46 47

69

68

67 66

65

62 64 63

61

60 59

W3-5-12

58

54 53 52 57 56 55

51 50

48 49

WCGB-03-05-001

UNDERCARRIAGE / Axle Disassembly of Front Axle 8. Remove retaining ring (29) and thrust plates (26, 27) from knuckle (19).

CAUTION: Front axle weight: ZX210W-3: 750 kg (1660 lb) ZX220W-3: 770 kg (1700 lb)

9. Remove socket bolt (28) from bearing nut (25). : 8 mm

1. Hoist the front axle. Lower the front axle on a workbench. 2. Remove plugs (4) (2 used) and O-rings (5) (2 used) from drive housing (6). Remove plug (45) and O-ring (46) from planetary carriers (44) in the left and right sides. Drain gear oil from the front axle. : 14 mm 3. Disassemble tie rods (12, 13). (Refer to DISASSEMBLY OF STEERING CYLINDER on W3-5-46.) CAUTION: Planetary carrier (44) weight: 30 kg (70 lb) 4. Attach a nylon sling onto planetary carrier (44). Hoist and hold planetary carrier (44). 5. Remove socket bolts (47) (2 used) from planetary carrier (44). Hoist and remove planetary carrier (44) from the front axle. : 8 mm

10. Remove bearing nut (25) and O-ring (56) from knuckle (19). : 41 mm 11. Pry the clearance between piston (63) and hub carrier (37) by using a pry bar. Remove the ring gear (57) assembly from hub carrier (37). IMPORTANT: Before removing bolt (67), record the dimension of bolt (67) extended from piston (63). 12. Remove bolts (67) (8 used), spring seats (66) (8 used) and springs (64, 65) (8 used for each) from ring gear (57). 13. Remove piston (63) from ring gear (57). Remove U-rings (60, 61), backup rings (59, 62) and knock pins (58) (4 used) from ring gear (57). 14. Remove disc plate (43) from hub carrier (37). Remove plates (42) (5 used) and friction plates (41) (6 used). 15. Remove O-ring (40). Remove disc carrier (68) from knuckle (19). Remove O-ring (69).

6. Remove retaining rings (54) (3 used). Remove planetary gears (49) (3 used) and washer (55) from planetary carrier (44). IMPORTANT: Do not remove roller bearing (51) unless necessary. 7. Remove retaining rings (48, 53) (3 used for each), washers (50, 52) (3 used for each) and roller bearings (51) (3 used) from planetary gears (49) (3 used).

W3-5-13

UNDERCARRIAGE / Axle 10

1

11 1

20 19

21 22 23 24

16 30 31 32 33

37 38

34

35

39

36

WCGB-03-05-001

W3-5-14

UNDERCARRIAGE / Axle CAUTION: Hub carrier (37) weight: 38 kg (84 lb) 16. Attach a nylon sling onto hub carrier (37). Hold hub carrier (37). Hoist and remove hub carrier (37) from knuckle (19). 17. Remove O-ring (34) from knuckle (19). IMPORTANT: Do not remove bearings (36, 39) unless necessary. 18. Remove shaft seal (35) from hub carrier (37). Remove the outer race of bearing (36) and bearing (39). IMPORTANT: Do not remove bearing (36) unless necessary. 19. Remove bushing (38). Remove the inner race of bearing (36) from knuckle (19). IMPORTANT: When removing bearing pin (21), the inner race of bearing (10) is removed with bearing pin (21) together. Do not damage the inner race of bearing (10) and bearing pin (21). 20. Remove bolts (20) (4 used) from the upper side of knuckle (19). Remove bearing pin (21), O-rings (22, 24) and seal (23) from knuckle (19). : 24 mm

IMPORTANT: When removing bearing pin (33), the inner race of bearing (11) is removed with bearing pin (33) together. Do not damage the inner race of bearing (11) and bearing pin (33). 22. Remove bolts (20) (4 used) from the lower side of knuckle (19). Remove bearing pin (33), shim (32), O-ring (31) and seal (30) from knuckle (19). : 24 mm IMPORTANT: Do not remove bearings (10, 11) unless necessary. 23. Remove the inner races of bearings (10, 11) from bearing pins (21, 33). IMPORTANT: When removing double joint shaft (16), do not damage the seal of axle casing (1). 24. Pull out knuckle (19) with double joint shaft (16) attached about 200 mm from axle casing (1). Hold the axis of double joint shaft (16). Hoist and remove the knuckle (19) assembly.

CAUTION: The knuckle (19) assembly: 76 kg (170 lb) 21. Install eyebolts (M16, Pitch 1.75 mm) (2 used) to the bolt (20) hole on the upper side of knuckle (19). Attach a nylon sling onto eyebolts (2 used). Hoist and hold knuckle (19).

W3-5-15

16

19

WCGB-03-05-002

UNDERCARRIAGE / Axle

6

2

7 8

9

1

10

11

3

1

9

8

7

19

17

18

16 14

15

WCGB-03-05-001

W3-5-16

UNDERCARRIAGE / Axle 25. Remove double joint shaft (16) from knuckle (19).

32. Remove differential (70) from drive housing (6).

26. Remove shaft seal (17) and bushing (18) from knuckle (19).

6

27. Remove shaft seal (15) and bushing (14) from axle casing (1). IMPORTANT: Do not remove bearings (10, 11) unless necessary. 28. Remove the outer races of bearings (10, 11) from axle casing (1).

70

WCGB-03-05-003

CAUTION: Axle casing (1) weight: ZX210W-3: 98 kg (220 lb) ZX220W-3: 107 kg (240 lb) 29. Attach a nylon sling onto axle casing (1). Hoist and hold axle casing (1). Remove bolts (2) (16 used) and washers (3) (16 used). Hoist and remove axle casing (1) from drive housing (6). : 27 mm IMPORTANT: Do not remove roller bearing (7) unless necessary. 30. Remove O-ring (9), shim (8) and roller bearing (7) from axle casing (1). 31. Disassemble the other side of the front axle in the same way as steps 4 to 30.

W3-5-17

UNDERCARRIAGE / Axle ASSEMBLY OF FRONT AXLE 6

Detail of Drive Housing Inside 9

9

2, 3

2, 3 1

16

Planetary Carrier

8

7

7

Detail of Planetary Carrier Inside 21

35 24

36

40 38 37 68

WCGB-03-05-019

8

41 42 43 61, 62 63

Detail A

A

22, 23

53

54

52

50 44

10 48 1 49 51

Drive Housing

25 27 29

16

55 14

26

15

28 45

30, 31 20

11

33

32 19 17

18 39 69 34

64, 65, 66, 67

W3-5-18

59, 60

56

57

46

WCGB-03-05-005

UNDERCARRIAGE / Axle 1 - Axle Casing 2 - Bolt (16 Used) 3 - Washer (16 Used) 4* - Plug (2 Used) 5* - O-Ring (2 Used) 6 - Drive Housing 7 - Roller Bearing 8 - Shim 9 - O-Ring 10 - Bearing 11 - Bearing 12* - Steering Cylinder 13* - Steering Cylinder 14 - Bushing 15 - Shaft Seal 16 - Double Joint Shaft 17 - Shaft Seal 18 - Bushing

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 -

Knuckle Bolt (4 Used) Bearing Pin O-Ring Seal O-Ring Bearing Nut Thrust Plate Thrust Plate Socket Bolt Retaining Ring Seal O-Ring Shim Bearing Pin O-Ring Shaft Seal Bearing

37 - Hub Carrier 38 - Bushing 39 - Bearing 40 - O-Ring 41 - Friction Plate (6 Used) 42 - Plate (5 Used) 43 - Disc Plate 44 - Planetary Carrier 45 - Plug 46 - O-Ring 47* - Socket Bolt (2 Used) 48 - Retaining Ring (3 Used) 49 - Planetary Gear (3 Used) 50 - Washer (3 Used) 51 - Roller Bearing (3 Used) 52 - Washer (3 Used) 53 - Retaining Ring (3 Used) 54 - Retaining Ring (3 Used)

NOTE: As for the item with mark*, refer to W3-5-10.

W3-5-19

55 - Washer 56 - O-Ring 57 - Ring Gear 58*- Knock Pin (4 Used) 59 - Backup Ring 60 - U-Ring 61 - U-Ring 62 - Backup Ring 63 - Piston 64 - Spring (8 Used) 65 - Spring (8 Used) 66 - Spring Seat (8 Used) 67 - Bolt (8 Used) 68 - Disc Carrier 69 - O-Ring

UNDERCARRIAGE / Axle

6 9

9

2, 3

2, 3 1

16

Planetary Carrier

8

7

7

A

21

WCGB-03-05-019

8

Detail A

22, 23 10 1 Drive Housing

16 14 15 30, 31 11

33

32

19 17

WCGB-03-05-005

18

W3-5-20

UNDERCARRIAGE / Axle Assembly of Front Axle 5. Tap and install the outer races of bearings (10, 11) to axle casing (1) by using a plastic hammer.

1. Install differential (70) to drive housing (6). 6

IMPORTANT: When installing double joint shaft (16), do not damage the seal of axle casing (1). 6. Install double joint shaft (16) to axle casing (1). 70

WCGB-03-05-003

2. Install roller bearing (7), shim (8) and O-ring (9) to the drive housing (6) mounting side on axle casing (1).

7. Apply grease onto the seal and the dust lip part of shaft seal (17). Apply LOCTITE #574 onto the shaft seal (17) contact surface on knuckle (19). Install bushing (18) and shaft seal (17) to knuckle (19). 8. Install seal (30), O-ring (31), the inner race of bearing (11) and washer (32) to bearing pin (33). 9. Apply anticorrosive (Weicon Antiseize (Never Seez) ZF special tool No. 0671 196 001) onto the collar part of bearing pin (33). Install seal (23) and O-ring (22) to bearing pin (21).

CAUTION: Axle casing (1) weight: ZX210W-3: 98 kg (220 lb) ZX220W-3: 107 kg (240 lb) 3. Hoist axle casing (1). Install axle casing (1) to drive housing (6) with bolts (2) (16 used) and washers (3) (16 used). : 27 mm : 390 N⋅m (40 kgf⋅m, 860 lbf⋅ft) 4. Apply grease onto the seal and the dust lip part of shaft seal (15). Apply LOCTITE #574 onto the shaft seal (15) contact surface on axle casing (1). Install bushing (14) and shaft seal (15) to axle casing (1).

W3-5-21

UNDERCARRIAGE / Axle

1

Planetary Carrier

WCGB-03-05-019

21

35

24

36

40

38 37 68

A

Detail A

1

Drive Housing

25

16

20

33

19

39

69

W3-5-22

57

WCGB-03-05-005

UNDERCARRIAGE / Axle CAUTION: Knuckle (19) weight: 55.5 kg (130 lb) IMPORTANT: When inserting double joint shaft (16) to knuckle (19), do not damage the seal. 10. Apply grease onto bearing pin (33). Install eyebolts (M16, Pitch 1.75 mm) (2 used) to the bolt (20) hole on the upper side of knuckle (19). Hoist knuckle (19). Install knuckle (19) to axle casing (1). Install bearing pin (33) to the lower side of knuckle (19) with bolts (20) (4 used). : 24 mm : 280 N⋅m (28 kgf⋅m, 205 lbf⋅ft)

IMPORTANT: When installing shaft seal (35), check the mounting position and dimension A. Install shaft seal (35) with the marking of OUT-SIDE facing upward and outward. 14. Apply LOCTITE #574 onto the shaft seal (35) contact surface on hub carrier (37). Install shaft seal (35) to hub carrier (37). NOTE: Dimension A: 0 to 0.3 mm (0 to 0.01 in) A

37

35

11. Apply grease onto bearing pin (21). Remove eyebolts (2 used) from the upper side of knuckle (19). Install bearing pin (21) and O-ring (24) to knuckle (19) with bolts (20) (4 used). : 24 mm : 280 N⋅m (28 kgf⋅m, 205 lbf⋅ft)

CAUTION: Hub carrier (37) weight: 38 kg (84 lb)

12. Install the inner race of bearing (36) and bushing (38) to knuckle (19).

15. Hoist hub carrier (37). Install hub carrier (37) to knuckle (19).

13. Apply hydraulic oil onto O-ring (40). Install O-ring (40), the outer race of bearing (36) and bearing (39) to hub carrier (37).

16. Install O-ring (69) and disc carrier (68) to knuckle (19).

WCGB-03-05-006

17. Install ring gear (57) to knuckle (19). 18. When installing bearing nut (25), apply lubricant (ZF special tool No. 0671 195 042 MOLYKOTE PASTE 1000) onto the thread part of knuckle (19). Install bearing nut (25) to knuckle (19) by using special tool (ZF special tool No. 5870 656 097). At this time, turn hub carrier (37) in both directions several times in order to fit the rotor. : 1400 N⋅m (140 kgf⋅m, 1040 lbf⋅ft)

W3-5-23

UNDERCARRIAGE / Axle

Planetary Carrier

WCGB-03-05-019

37

41 42 43 61, 62 63

A

Detail A

44

Drive Housing

25 27 29 55 26 28

19

64, 65, 66, 67

W3-5-24

59, 60

56

57

WCGB-03-05-005

UNDERCARRIAGE / Axle 19. Remove bearing nut (25) from knuckle (19). Remove ring gear (57) from knuckle (19). : 41 mm

25. Align the marks and install the ring gear (57) assembly to knuckle (19). 57

Mark

19

IMPORTANT: Check the mounting positions of friction plate (41) and plate (42). 20. Install friction plates (41) (6 used) and plates (42) (5 used) to hub carrier (37) alternately. Install disc plate (43). 21. Apply grease onto O-ring (34). Install O-ring (34) to knuckle (19). 22. Apply hydraulic oil onto U-rings (60, 61) and backup rings (59, 62). Install U-rings (60, 61) and backup rings (59, 62) to ring gear (57).

26. Apply hydraulic oil onto O-ring (56). Install O-ring (56) to knuckle (19).

23. Install knock pins (58) (4 used) to piston (63). NOTE: Dimension B: 16 mm (0.6 in) 63

WCGB-03-05-008

27. When installing bearing nut (25), apply lubricant (ZF special tool No. 0671 195 042 MOLYKOTE PASTE 1000) onto the thread part of knuckle (19). Install bearing nut (25) to knuckle (19) by using special tool (ZF special tool No. 5870 656 097). Align the socket bolt (28) holes on knuckle (19) and bearing nut (25). If it is difficult to align the holes, retighten bearing nut (25). : 1400+200 N⋅m (140+20 kgf⋅m, 1040+150 lbf⋅ft)

58 B

WCGB-03-05-007

IMPORTANT: When tightening bolt (67), align with the dimension before disassembling. 24. Install piston (63) to ring gear (57). Secure piston (63) with bolts (67) (8 used), spring seats (66) (8 used) and springs (64, 65). : 10 mm : 11 N⋅m (1 kgf⋅m, 8 lbf⋅ft)

28. Install socket bolt (28) to bearing nut (25). : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 29. Install thrust plates (26, 27) to knuckle (19). Secure with retaining ring (29). 30. Install washer (55) to planetary carrier (44).

W3-5-25

UNDERCARRIAGE / Axle

6

Planetary Carrier

WCGB-03-05-019

Detail A

A

54

53

52

50 44 48 49 51

Drive Housing

45 46

W3-5-26

WCGB-03-05-005

UNDERCARRIAGE / Axle 31. Install retaining rings (48, 53) (3 used for each), washers (50, 52) (3 used for each) and roller bearings (51) (3 used) to planetary gears (49) (3 used). 32. Install planetary gears (49) (3 used) to planetary carrier (44) with retaining rings (54) (3 used). CAUTION: Planetary carrier (44) weight: 30 kg (70 lb) 33. Hoist planetary carrier (44). Install planetary carrier (44) to the front axle with socket bolts (47) (2 used). : 10 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft) 34. Assemble the other side of the front axle in the same way as steps 2 to 33. 35. Assemble tie rods (12, 13). (Refer to ASSEMBLY OF STEERING CYLINDER on W3-5-48.) 36. Add gear oil to drive housing (6) and planetary carriers (44) in the left and right sides. Install plugs (4) (2 used) and O-rings (5) (2 used) to drive housing (6). Install plug (45) and O-ring (46) to planetary carriers (44) in the left and right sides. : 14 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

W3-5-27

UNDERCARRIAGE / Axle DISASSEMBLY OF REAR AXLE 1 5 1

2

4

2

3

4

3

7

6

10

8 9

12

8

13 14

15

16

11

17 18 19

20

28

24 21 22 23

25

26 27 29 30 31

54 53 52

51 50 49 48 47 46

43 42 45 44

W3-5-28

40 39 38 37 36 41

34 35

33

32

WCGB-03-05-009

UNDERCARRIAGE / Axle 1 - Axle Casing 2 - O-Ring 3 - Shim 4 - Roller Bearing 5 - Drive Housing 6 - Washer (14 Used) 7 - Bolt (14 Used) 8 - Axle Shaft 9 - Plug 10 - O-Ring 11 - Washer (16 Used) 12 - Bolt (16 Used) 13 - O-Ring 14 - Knuckle

15 - Bearing Nut 16 - Washer 17 - Socket Bolt 18 - Sun Gear Shaft 19 - O-Ring 20 - Shaft Seal 21 - Bearing 22 - Hub Carrier 23 - Bushing 24 - Bearing 25 - O-Ring 26 - Friction Plate (6 Used) 27 - Plate (5 Used) 28 - Disc Plate

29 - Planetary Carrier 30 - Plug 31 - O-Ring 32 - Socket Bolt (2 Used) 33 - Retaining Ring (3 Used) 34 - Planetary Gear (3 Used) 35 - Washer (3 Used) 36 - Roller Bearing (3 Used) 37 - Washer (3 Used) 38 - Retaining Ring (3 Used) 39 - Retaining Ring (3 Used) 40 - Washer 41 - O-Ring 42 - Ring Gear

W3-5-29

43 44 45 46 47 48 49 50 51 52 53 54 -

Knock Pin (4 Used) Backup Ring U-Ring U-Ring Backup Ring Piston Spring (8 Used) Spring (8 Used) Spring Seat (8 Used) Bolt (8 Used) Disc Carrier O-Ring

UNDERCARRIAGE / Axle

1 5 1 10 9

29

22

14

15

18

17

30

31

52

51

50

49

48 47

45 44 43 42 46

W3-5-30

41

35 36 39 38 37 40

33 34

32

WCGB-03-05-009

UNDERCARRIAGE / Axle Disassembly of Rear Axle 1. Remove transmission (55) from the rear axle. (Refer to REMOVAL OF TRANSMISSION on W3-4-1.) CAUTION: Rear axle weight: ZX210W-3: 600 kg (1330 lb) ZX220W-3: 630 kg (1390 lb)

IMPORTANT: Do not remove roller bearing (36) unless necessary. 7. Remove retaining rings (33, 38) (3 used for each), washers (35, 37) (3 used for each) and roller bearings (36) (3 used) from planetary gears (34) (3 used). 8. Remove sun gear shaft (18) from axle casing (1).

2. Hoist the rear axle. Lower the rear axle on a workbench. 3. Remove plugs (9, 30) and O-rings (10, 31) from drive housing (5) and planetary carriers (29) in the left and right sides. Drain gear oil from the rear axle. : 14 mm CAUTION: Planetary carrier (29) weight: 30 kg (70 lb) 4. Attach a nylon sling onto planetary carrier (29). Hoist and hold planetary carrier (29). 5. Remove socket bolts (32) (2 used) from planetary carrier (29). Hoist and remove planetary carrier (29) from the rear axle. : 8 mm

9. Remove socket bolt (17) from bearing nut (15). : 8 mm 10. Remove O-ring (41) from knuckle (14). 11. Pry the clearance between piston (48) and hub carrier (22) by using a pry bar. Remove the ring gear (42) assembly from hub carrier (22). IMPORTANT: Before removing bolt (52), record the dimension of bolt (52) extended from piston (48). 12. Remove bolts (52) (8 used), spring seats (51) (8 used) and springs (49, 50) (8 used for each) from ring gear (42). 13. Remove piston (48) from ring gear (42). Remove U-rings (45, 46), backup rings (44, 47) and knock pins (43) (4 used) from ring gear (42).

6. Remove retaining rings (39) (3 used). Remove planetary gears (34) (3 used) and washer (40) from planetary carrier (29).

W3-5-31

UNDERCARRIAGE / Axle

1 5 2

1

3

4

3

2

4 7

6 8

12

13

28

22

8

14

11

19

54

20

23 24

25

26 27

21

53

WCGB-03-05-009

W3-5-32

UNDERCARRIAGE / Axle 14. Remove disc plate (28) from hub carrier (22). Remove plates (27) (5 used) and friction plates (26) (6 used).

21. Remove axle shaft (8) from axle casing (1). CAUTION: Axle casing (1) weight: ZX210W-3: 108 kg (240 lb) ZX220W-3: 122 kg (270 lb)

15. Remove disc carrier (53) from knuckle (14). Remove O-ring (54). CAUTION: Hub carrier (22) weight: 38 kg (84 lb) 16. Attach a nylon sling onto hub carrier (22). Hold hub carrier (22). Hoist and remove hub carrier (22) from knuckle (14). 17. Remove O-ring (19) from knuckle (14). IMPORTANT: Do not remove bearings (21, 24) unless necessary. 18. Remove shaft seal (20), O-ring (25), the outer race of bearing (21) and bearing (24) from hub carrier (22).

22. Attach a nylon sling onto axle casing (1). Hold axle casing (1). Remove bolts (12) (16 used) and washers (11) (16 used). Hoist and remove axle casing (1) from drive housing (5). : 27 mm IMPORTANT: Do not remove roller bearing (4) unless necessary. 23. Remove O-ring (2), shim (3) and roller bearing (4) from axle casing (1). 24. Disassemble the other side of the rear axle in the same way as steps 4 to 23. 25. Remove differential (55) from drive housing (5).

IMPORTANT: Do not remove bearing (21) unless necessary. 19. Remove bushing (23) and the inner race of bearing (21) from knuckle (14).

5

CAUTION: Knuckle (14) weight: 34 kg (75 lb) 20. Attach a nylon sling onto knuckle (14). Hold knuckle (14). Remove bolts (7) (14 used) and washers (6) (14 used). Hoist and remove knuckle (14) and O-ring (13) from the rear axle. : 24 mm

W3-5-33

55

WCGB-03-05-011

UNDERCARRIAGE / Axle ASSEMBLY OF REAR AXLE Detail of Drive Housing Inside 1

12

11

3

2

4

5

4

3

2

11

12

1

Planetary Carrier

8

8

WCGB-03-05-012

Detail of Planetary Carrier Inside 6

7

13 14 20 21

22

25

23

24

26 27 28 49, 50, 51, 52

48

44, 45 42 29

1

46, 47 41 15 40

Drive Housing

16 18

34

8

54

53

19 T21W-03-05-022

W3-5-34

UNDERCARRIAGE / Axle 1 - Axle Casing 2 - O-Ring 3 - Shim 4 - Roller Bearing 5 - Drive Housing 6 - Washer (14 Used) 7 - Bolt (14 Used) 8 - Axle Shaft 9* - Plug 10* - O-Ring 11 - Washer (16 Used) 12 - Bolt (16 Used) 13 - O-Ring 14 - Knuckle

15 - Bearing Nut 16 - Washer 17* - Socket Bolt 18 - Sun Gear Shaft 19 - O-Ring 20 - Shaft Seal 21 - Bearing 22 - Hub Carrier 23 - Bushing 24 - Bearing 25 - O-Ring 26 - Friction Plate (6 Used) 27 - Plate (5 Used) 28 - Disc Plate

29 - Planetary Carrier 30* -Plug 31* -O-Ring 32* -Socket Bolt (2 Used) 33* -Retaining Ring (3 Used) 34 - Planetary Gear (3 Used) 35* -Washer (3 Used) 36* -Roller Bearing (3 Used) 37* -Washer (3 Used) 38* -Retaining Ring (3 Used) 39* -Retaining Ring (3 Used) 40 - Washer 41 - O-Ring 42 - Ring Gear

NOTE: As for the item with mark*, refer to W3-5-28.

W3-5-35

43* - Knock Pin (4 Used) 44 - Backup Ring 45 - U-Ring 46 - U-Ring 47 - Backup Ring 48 - Piston 49 - Spring (8 Used) 50 - Spring (8 Used) 51 - Spring Seat (8 Used) 52 - Bolt (8 Used) 53 - Disc Carrier 54 - O-Ring

UNDERCARRIAGE / Axle

1

2

3

4

5

4

3

2

11

12

1

Planetary Carrier

8

8

WCGB-03-05-012

7

6 13

14 20 21

22

23

24 42

1

Drive Housing

16 18

8

54

53

19 T21W-03-05-022

W3-5-36

UNDERCARRIAGE / Axle Assembly of Rear Axle 1. Install differential (55) to drive housing (5).

6. Install the inner race of bearing (21) and bushing (23) to knuckle (14).

5

55

IMPORTANT: When installing shaft seal (20), check the mounting position and dimension A. Install shaft seal (20) with the marking of OUT-SIDE facing upward and outward. 7. Apply LOCTITE #574 onto the shaft seal (20) contact surface on hub carrier (22). Install shaft seal (20) to hub carrier (22). NOTE: Dimension A: 0 to 0.3 mm (0 to 0.01 in) A

WCGB-03-05-011

2. Install O-ring (2), shim (3) and roller bearing (4) to axle casing (1).

22

20

CAUTION: Axle casing (1) weight: ZX210W-3: 108 kg (240 lb) ZX220W-3: 122 kg (270 lb)

WCGB-03-05-006

3. Attach a nylon sling onto axle casing (1). Hoist axle casing (1). Install axle casing (1) to drive housing (5) with bolts (12) (16 used) and washers (11) (16 used). : 27 mm : 300 N⋅m (30 kgf⋅m, 220 lbf⋅ft)

8. Install the outer race of bearing (21) and bearing (24) to hub carrier (22). 9. Apply hydraulic oil onto O-ring (19). Install O-rings (19, 54) and disc carrier (53) to knuckle (14). 10. Install ring gear (42) to knuckle (14).

4. Install axle shaft (8) to axle casing (1). 11. Install washer (16) to sun gear shaft (18). CAUTION: Knuckle (14) weight: 34 kg (75 lb) 5. Install O-ring (13) to knuckle (14). Hoist knuckle (14). Install knuckle (14) to the rear axle with bolts (7) (14 used) and washers (6) (14 used). : 24 mm : 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft)

W3-5-37

UNDERCARRIAGE / Axle

Planetary Carrier

WCGB-03-05-012

14

22

25

26 27 28 49, 50, 51, 52

48 44, 45 42 46, 47 41 15

Drive Housing

18

T21W-03-05-022

W3-5-38

UNDERCARRIAGE / Axle 12. When installing bearing nut (15), apply lubricant (ZF special tool No. 0671 195 042 MOLYKOTE PASTE 1000) onto the thread part of knuckle (14). Install sun gear shaft (18) and bearing nut (15) to knuckle (14) by using special tool (ZF special tool No. 5870 656 097). At this time, turn hub carrier (22) in both directions several times in order to fit the rotor. : 1400 N⋅m (140 kgf⋅m, 1040 lbf⋅ft) 13. Remove bearing nut (15) from knuckle (14). Remove ring gear (42). : 41 mm

IMPORTANT: When tightening bolt (52), align with the dimension before disassembling. 18. Install piston (48) to ring gear (42). Secure piston (48) with bolts (52) (8 used), spring seats (51) (8 used) and springs (49, 50). : 10 mm : 11 N⋅m (1 kgf⋅m, 8 lbf⋅ft) 19. Align the marks and install the ring gear (42) assembly to knuckle (14). 42

Mark

14

IMPORTANT: Check the mounting positions of friction plate (26) and plate (27). 14. Install friction plates (26) (6 used) and plates (27) (5 used) to hub carrier (42) alternately. Install disc plate (28). 15. Apply grease onto O-ring (25). Install O-ring (25) to hub carrier (42). 16. Apply hydraulic oil onto U-rings (45, 46) and backup rings (44, 47). Install U-rings (45, 46) and backup rings (44, 47) to ring gear (42). 17. Install knock pins (43) (4 used) to piston (48). NOTE: Dimension B: 16 mm (0.6 in) 48

WCGB-03-05-008

20. Apply hydraulic oil onto O-ring (41). Install O-ring (41) to knuckle (14). 21. When installing bearing nut (15), apply lubricant (ZF special tool No. 0671 195 042 MOLYKOTE PASTE 1000) onto the thread part of knuckle (14). Install bearing nut (15) to knuckle (14) by using special tool (ZF special tool No. 5870 656 097). Align the holes on knuckle (14) and bearing nut (15). Secure with socket bolt (17). : 1400+200 N⋅m (140+20 kgf⋅m, 1040+150 lbf⋅ft)

43

B

WCGB-03-05-007

W3-5-39

UNDERCARRIAGE / Axle

5

Planetary Carrier

WCGB-03-05-012

14

29

15 40 Drive Housing

34

T21W-03-05-022

W3-5-40

UNDERCARRIAGE / Axle 22. Install socket bolt (17) into bearing nut (15). If it is difficult to align the holes on knuckle (14) and bearing nut (15), retighten bearing nut (15). : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 23. Install washer (40) to planetary carrier (29). 24. Install retaining rings (33, 38) (3 used for each), washers (35, 37) (3 used for each) and roller bearings (36) (3 used) to planetary gears (34) (3 used). 25. Install planetary gears (34) (3 used) to planetary carrier (29) with retaining rings (39) (3 used). CAUTION: Planetary carrier (29) weight: 30 kg (70 lb) 26. Hoist planetary carrier (29). Install planetary carrier (29) to the rear axle with socket bolts (32) (2 used). : 10 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft) 27. Assemble the other side of the rear axle in the same way as steps 2 to 26. 28. Add gear oil to drive housing (5) and planetary carriers (29) in the left and right sides. Install plugs (9, 30) and O-rings (8, 31) to drive housing (5) and planetary carriers (29) in the left and right sides. : 14 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

W3-5-41

UNDERCARRIAGE / Axle DISASSEMBLY OF DIFFERENTIAL NOTE: Disassembly of the differential is common to the front axle and the rear axle. The illustration shows the front axle. 13

2

3

5

4

6

7

8 9

10 11

12

1 15 16 18

17

6

14

7

8

5

19

20 21

22

23

24 25 26 27

28

WCGB-03-05-013

1234567-

Bevel Gear Differential Case Washer (2 Used) Side Gear (2 Used) Pinion Gear (2 Used) Washer (2 Used) Washer (2 Used)

8910 11 12 13 14 -

Pinion Gear (2 Used) Spider Side Gear (2 Used) Washer (2 Used) Differential Case Drive Housing Socket Bolt (12 Used)

15 16 17 18 19 20 21 -

W3-5-42

Washer (12 Used) Spider Spring Pin (4 Used) Spring Pin (4 Used) Drive Pinion Bearing Shim

22 23 24 25 26 27 28 -

Spacer Bearing Seal Guard Flange Washer Nut

UNDERCARRIAGE / Axle Disassembly of Differential 1. Remove nut (28) and washer (27) from drive pinion (19). : 41 mm

IMPORTANT: Do not remove bearings (29, 30) unless necessary. 8. Secure the differential in a vise. Remove the inner races of bearings (29, 30) from the differential.

2. Remove flange (26) and guard (25) from drive housing (13).

30

Differential

3. Float seal (24) by using a screwdriver. Remove drive pinion (19) from drive housing (13). 29

4. Remove spacer (22) from drive pinion (19). IMPORTANT: Do not remove bearing (20) unless necessary. 5. Remove the inner race of bearing (20) from drive pinion (19). IMPORTANT: Do not remove bearing (20) unless necessary. 6. Remove the outer race of bearing (20) from drive pinion (19). IMPORTANT: Do not remove bearing (23) unless necessary. 7. Remove shim (21) and bearing (23) from drive pinion (19).

WCGB-03-05-014

9. Remove socket bolts (14) (12 used) and washers (15) (12 used). Remove differential case (12). : 10 mm 10. Remove spring pins (17, 18) (4 used for each), washers (3, 6, 7, 11) (2 used for each), pinion gears (5, 8) (2 used for each), side gears (4, 10) (2 used for each) and spiders (9, 16) from differential case (2). 11. Secure differential case (2) in a vise with bevel gear (1) facing upward. Remove bevel gear (1) from differential case (2).

W3-5-43

UNDERCARRIAGE / Axle ASSEMBLY OF DIFFERENTIAL NOTE: Assembly of the differential is common to the front axle and the rear axle. The illustration shows the front axle. 14

15

12

13

7

8

2

1

17, 18

3

11 4

10

16

9 19 20 21 22

23 24 25

27

1 - Bevel Gear 2 - Differential Case 3 - Washer (2 Used) 4 - Side Gear (2 Used) 5* - Pinion Gear (2 Used) 6* - Washer (2 Used) 7 - Washer (2 Used)

28

8 - Pinion Gear (2 Used) 9 - Spider 10 - Side Gear (2 Used) 11 - Washer (2 Used) 12 - Differential Case 13 - Drive Housing 14 - Socket Bolt (12 Used)

15 16 17 18 19 20 21 -

NOTE: As for the item with mark*, refer to W3-5-42.

W3-5-44

Washer (12 Used) Spider Spring Pin (4 Used) Spring Pin (4 Used) Drive Pinion Bearing Shim

WCGB-03-05-015

26

22 23 24 25 26 27 28 -

Spacer Bearing Seal Guard Flange Washer Nut

UNDERCARRIAGE / Axle Assembly of Differential 1. Install spring pins (17, 18) (4 used for each) to differential case (2).

6. Install shim (21) and bearing (23) to drive pinion (19).

2. Secure differential case (2) in a vise. Install bevel gear (1) to differential case (2).

7. Install the outer race of bearing (20) to drive pinion (19).

IMPORTANT: Install washers (3, 11) and washers (7) (2 used) with the lugs facing upward. 3. Install washers (3, 6, 7, 11) (2 used for each), pinion gears (5, 8) (2 used for each), side gears (4, 10) (2 used for each) and spiders (9, 16) to differential case (2).

8. Install the inner race of bearing (20) to drive pinion (19).

4. Install differential case (12) to the differential case (2) assembly. Secure socket bolt (14) and washer (15). : 10 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

9. Install spacer (22) to drive pinion (19). 10. Install drive pinion (19) to drive housing (13). 11. Install guard (26) and flange (25) to drive housing (13). 12. Install washer (27) and nut (28) to drive pinion (19). : 41 mm : 1050 N⋅m (105 kgf⋅m, 770 lbf⋅ft)

5. Secure the differential in a vise. Install the inner races of bearings (29, 30). 30

Differential

29

WCGB-03-05-014

W3-5-45

UNDERCARRIAGE / Axle DISASSEMBLY OF STEERING CYLINDER 1

2

1

T1GL-03-05-020

3

5

7

6

8

9

Connection Part

10

4

Connection Part

3

11

15

14

13

12

16

19

18

17

20 WCGB-03-05-016

12345-

Axle Casing Drive Housing Tie Rod Piston Rod Retaining Ring

6 - U-Ring 7 - Wiper Ring 8 - O-Ring 9 - Guide Ring 10 - Piston

11 12 13 14 15 -

W3-5-46

Rod Wiper Ring U-Ring Retaining Ring Flange

16 17 18 19 20 -

Cylinder Tube Guide Ring Guide Ring Seal Bolt (5 Used)

UNDERCARRIAGE / Axle Disassembly of Steering Cylinder 1. Remove nut (21). Remove tie rod (3) from axle casing (1). : 41 mm 3

21

5. Remove bolts (20) (5 used). Warm up the connection part of the piston rod (4) assembly and drive housing (2) by using a drier. 6. Tap and remove the piston rod (4) assembly from drive housing (2) by using a plastic hammer. 7. Remove bolts (20) (5 used). Remove flange (15) and retaining ring (14) from the piston rod (4) assembly.

1 WCGB-03-05-017

2. Warm up the connection part of piston rod (4) and tie rod (3) by using a drier. Attach a spanner onto the connection part. Remove tie rod (3) from piston rod (4). : 46 mm

8. Remove retaining ring (5) from the piston rod (4) assembly. Tap piston (10) to the position where O-ring (8) can be removed by using a plastic hammer. Remove O-ring (8) from the piston rod (4) assembly. 9. Remove rod (11) and piston (10) from cylinder tube (16). Remove piston (10) from rod (11).

3. Remove other tie rod (3) in the same way as steps 1 to 2.

10. Remove U-ring (13) and wiper ring (12) from cylinder tube (16).

4. Remove elbows (22) (2 used) from drive housing (2).

11. Remove U-ring (6), wiper ring (7), guide rings (9, 17, 18) and seal (19) from piston (10) and rod (11).

2

22

1 4 Connection Part WCGB-03-05-018

W3-5-47

UNDERCARRIAGE / Axle ASSEMBLY OF STEERING CYLINDER 1

2

1

T1GL-03-05-020

3

11

6

5

12345-

Axle Casing Drive Housing Tie Rod Piston Rod Retaining Ring

7

9

15

8

4

Connection Part

14

16

Connection Part

19 18 17

3

13

12

T21W-03-05-020

10

6 - U-Ring 7 - Wiper Ring 8 - O-Ring 9 - Guide Ring 10 - Piston

11 12 13 14 15 -

NOTE: As for the item with mark*, refer to W3-5-46.

W3-5-48

Rod Wiper Ring U-Ring Retaining Ring Flange

16 - Cylinder Tube 17 - Guide Ring 18 - Guide Ring 19 - Seal 20* - Bolt (5 Used)

UNDERCARRIAGE / Axle Assembly of Steering Cylinder 1. Install U-ring (13) and wiper ring (12) to cylinder tube (16).

9. Install elbows (22) (2 used) to drive housing (2). 2

2. Install U-ring (6), wiper ring (7), guide rings (9, 17, 18) and seal (19) to piston (10) and rod (11). 3. When installing the rod (11) assembly to cylinder tube (16), apply hydraulic oil onto the seals. Install the rod (11) assembly to cylinder tube (16).

22

1

4. When installing piston (10) to rod (11), apply hydraulic oil onto the seals. Install piston (10) to rod (11). Push piston (10) to the position where O-ring (8) can be installed.

4 Connection Part WCGB-03-05-018

5. Install retaining ring (5) to the piston rod (4) assembly. 6. Install flange (15) and retaining ring (14) to the piston rod (4) assembly. 7. Apply LOCTITE #574 onto the drive housing (2) contact surface (2 places) on the piston rod (4) assembly. Install piston rod (4) to drive housing (2). 8. Apply LOCTITE #243 onto bolt (20). Install bolts (20) (5 used). : 19 mm : 79 N⋅m (7.9 kgf⋅m, 58 lbf⋅ft)

IMPORTANT: Check the direction to install tie rod (3). 10. Apply LOCTITE #243 onto the tie rod (3) connection part of piston rod (4). Attach a spanner onto the connection part of piston rod (4) and tie rod (3). Install tie rod (3) to piston rod (4). : 46 mm : 450 N⋅m (45 kgf⋅m, 330 lbf⋅ft) 11. Secure tie rod (3) to axle casing (1) with nut (21). : 41 mm : 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft) 3

21

1 WCGB-03-05-017

12. Install other tie rod (3) in the same way as steps 10 to 11.

W3-5-49

UNDERCARRIAGE / Axle (Blank)

W3-5-50

UNDERCARRIAGE / Axle Lock Cylinder REMOVAL AND INSTALLATION OF AXLE LOCK CYLINDER CAUTION: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) The procedure starts on the premise that the front axle has already been removed. 1

2

3

Removal 1. Disconnect hoses (1) (2 used) from operate check valve (3). Cap the open ends. : 19 mm IMPORTANT: Do not remove operate check valve (3). If removing operate check valve (3), rod (4) may come off due to the entering air. 2. Remove socket bolts (2) (2 used) from operate check valve (3). Install eyebolts (M8, Pitch 1.25 mm) (2 used) into the hole. Attach a nylon sling onto eyebolts. Hoist and hold operate check valve (3). : 6 mm

4

WCEB-03-06-001

2

WCEB-03-06-003

CAUTION: Axle lock cylinder (5) weight: 61 kg (134 lb) 3. Remove socket bolts (6) (3 used), washers (7) (3 used), bolt (8) and spacer (9) from axle lock cylinder (5). : 19 mm : 36 mm

5 Pulling-Out Hole

6, 7 9 Pulling-Out Hole

8

WCEB-03-06-001

W3-6-1

UNDERCARRIAGE / Axle Lock Cylinder 10

CAUTION: Axle lock cylinder (5) weight: 61 kg (134 lb) 4. Install the bolts (M12, Pitch 1.75 mm) (2 used) into the pulling-out hole on axle lock cylinder (5). Tighten the bolts (2 used) alternately. Remove axle lock cylinder (5) from track frame (10). : 19 mm

5 Pulling-Out Hole

Pulling-Out Hole

WCEB-03-06-001

W3-6-2

UNDERCARRIAGE / Axle Lock Cylinder Installation CAUTION: Axle lock cylinder (5) weight: 61 kg (134 lb)

10

1. Apply LOCTITE #262 onto socket bolts (6) (3 used) and bolt (8). 2. Hoist and align axle lock cylinder (5) with the mounting hole on track frame (10). Install axle lock cylinder (5) to track frame (10) with socket bolts (6) (3 used), washers (7) (3 used), bolt (8) and spacer (9). : 19 mm : 950 N⋅m (97 kgf⋅m, 701 lbf⋅ft) : 36 mm : 950 N⋅m (97 kgf⋅m, 701 lbf⋅ft)

5

6, 7

9

8

WCEB-03-06-001

2

3. Remove eyebolts (2 used) from axle lock cylinder (5).

3

5

4. Install operate check valve (3) to axle lock cylinder (5) with socket bolts (2) (2 used). : 6 mm : 29.4 to 34.3 N⋅m (3 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft)

WCEB-03-06-003

1

3

5. Connect hoses (1) (2 used) to operate check valve (3). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

WCEB-03-06-001

W3-6-3

UNDERCARRIAGE / Axle Lock Cylinder DISASSEMBLY AND ASSEMBLY OF AXLE LOCK CYLINDER

8, 9

10 A

7

6 8, 9

10

7

3

5 4 3 2

View A

1

123-

WCEB-03-06-003

WCEB-03-06-002

Retaining Ring Dust Seal Air Ring (4 Used)

456-

Dust Seal Seal Ring Rod

78-

W3-6-4

Housing Operate Check Valve

9 - O-Ring 10 - Socket Bolt (4 Used)

UNDERCARRIAGE / Axle Lock Cylinder Assembly of Axle Lock Cylinder

Disassembly of Axle Lock Cylinder CAUTION: Axle lock cylinder weight: 61 kg (134 lb) 1. Place the axle lock cylinder onto the workbench horizontally. 2. Remove socket bolts (10) (4 used) from operate check valve (8). Remove operate check valve (8) and O-ring (9) from housing (7).

1. Install seal ring (5), dust seal (4) and air rings (3) (4 used) to housing (7). 2. Install dust seal (2) and retaining ring (1) to housing (7). IMPORTANT: Apply hydraulic oil onto the inner surface of housing (7), dust seals (2, 4), seal ring (5) and air ring (3). 3. Install rod (6) to housing (7).

3. Apply air to the port hole on housing (7) and remove rod (6). 4. Remove retaining ring (1) and dust seal (2) from housing (7). 5. Remove air rings (3) (4 used), dust seal (4) and seal ring (5) from housing (7).

CAUTION: Axle lock cylinder weight: 61 kg (134 lb) 4. Install operate check valve (8) to housing (7) with socket bolts (10) (4 used) and O-ring (9). : 6 mm : 29.4 to 34.3 N⋅m (3 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft)

W3-6-5

UNDERCARRIAGE / Axle Lock Cylinder (Blank)

W3-6-6

UNDERCARRIAGE / Operate Check Valve REMOVAL AND INSTALLATION OF OPERATE CHECK VALVE (FOR AXEL LOCK CYLINDER) CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Disconnect hoses (1) (2 used) from operate check valve (3). Cap the open ends. : 19 mm

1

2

3, 4

5

2. Remove socket bolts (2) (4 used) from operate check valve (3). Remove operate check valve (3) and O-ring (4) from axle lock cylinder (5). Cap the open ends. : 6 mm

WCEB-03-06-001

Installation 1. Apply grease onto O-ring (4). Install O-ring (4) to operate check valve (3). 2. Install operate check valve (3) to axle lock cylinder (5) with socket bolts (2) (4 used). : 6 mm : 29.4 to 34.3 N⋅m (3 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft)

1

2

3, 4

5

3. Connect hoses (1) (2 used) to operate check valve (3). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) WCEB-03-06-001

W3-7-1

UNDERCARRIAGE / Operate Check Valve STRUCTURE OF OPERATE CHECK VALVE (FOR AXEL LOCK CYLINDER)

1

2

3

4

5

6

7

8

9

10

11

12

13

WCEB-03-06-004

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Part Name Plug O-Ring Plug O-Ring Piston Body Poppet Sleeve Spring O-Ring Plug O-Ring Plug

Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1

Wrench Size (mm) : 6.2

N⋅m 2±0.5

Tightening Torque (kgf⋅m) (lbf⋅ft) (0.2±0.05) (1.5±0.4)

Remark 1A P11

: 27

120±12

(12±1.2)

(89±9) 1B P18

1B P11 : 36

500±50

(51±5)

(369±37) 1B P26

:6

34.3±3.4

W3-7-2

(3.5±0.3)

(25±2.5)

UNDERCARRIAGE / Solenoid Valve REMOVAL AND INSTALLATION OF OUTRIGGER / BLADE SOLENOID VALVE UNIT CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Solenoid Valve Unit

IMPORTANT: One side of the solenoid valve unit cannot be removed. Remove the plate (2) assembly.

Solenoid Valve Unit

Removal 1. Disconnect hoses (3) (8 used) from solenoid valve units (4) (2 used). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 22 mm 2. Disconnect connectors (1) (4 used) from solenoid valve units (4) (2 used). 3. Remove sems bolts (7) (4 used) from plate (2). Remove the plate (2) assembly from track frame (6). : 17 mm

W1F3-04-04-004

Solenoid Valve Unit

1

2

3 Solenoid Valve Unit

4. Remove sems bolts (5) (4 used) from plate (2). Remove solenoid valve units (4) (2 used) from plate (2). : 17 mm

1

3

7

W3-8-1

3

6

4, 5

WCEB-03-08-001

UNDERCARRIAGE / Solenoid Valve Installation 1. Install solenoid valve units (4) (2 used) to plate (2) with sems bolts (5) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

Solenoid Valve Unit Solenoid Valve Unit

2. Install the plate (2) assembly to track frame (6) with sems bolts (7) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 3. Connect hoses (3) (8 used) to solenoid valve units (4) (2 used). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

W1F3-04-04-004

4. Connect connectors (1) (4 used) to solenoid valve units (4) (2 used). Solenoid Valve Unit

1

2

3

Solenoid Valve Unit

1

3

7

W3-8-2

3

6

4, 5

WCEB-03-08-001

UNDERCARRIAGE / Solenoid Valve STRUCTURE OF SOLENOID VALVE UNIT

1

2

3

4

T1F3-03-08-001

5 6

No. 1 2 3 4 5 6

Part Name Solenoid Piston O-Ring Body Spool Spring

Q’ty

Wrench Size (mm)

N·m

2 2 2 1 2 2

Tightening Torque (kgf·m) (lbf·ft)

Remarks

1B P14

W3-8-3

UNDERCARRIAGE / Solenoid Valve (Blank)

W3-8-4

UPPERSTRUCTURE / Transmission Changeover Solenoid Valve REMOVAL AND INSTALLATION OF TRANSMISSION CHANGEOVER SOLENOID VALVE CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

1

2

Removal 1. Disconnect connectors (1) (2 used). 2. Disconnect hoses (2) (4 used) from transmission changeover solenoid valve (3). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm 3. Remove socket bolts (4) (3 used) from transmission changeover solenoid valve (3). Remove transmission changeover solenoid valve (3) from bracket (5). : 6 mm

5

Installation 1. Install transmission changeover solenoid valve (3) to bracket (5) with socket bolts (4) (3 used). : 6 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

4

WCEB-03-09-001

3

1

2

2. Connect hoses (2) (4 used) to transmission changeover solenoid valve (3). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 3. Connect connectors (1) (2 used) to transmission changeover solenoid valve (3).

W3-9-1

5

4

3

WCEB-03-09-001

UPPERSTRUCTURE / Transmission Changeover Solenoid Valve (Blank)

W3-9-2

LOWERSTRUCTURE / Propeller Shaft REMOVEAL AND INSTALLATION PROPELLER SHAFT

OF

Preparation 1. Place the machine on a solid, level surface. Lower the front attachment onto the ground. 2. Lower the blade and the outrigger onto the ground. 3. Place the blocks in front of and behind the axle in order to secure the machine. WCJB-03-10-004

W3-10-1

LOWERSTRUCTURE / Propeller Shaft Removal and Installation of Propeller Shaft Front Axle

5 3 Rear Axle

6 8

B A

C D

W1GL-03-08-001

3

4

5

8

2

6

9

3

10 1

7

View A

WCJB-03-10-001

View B

12

11

WCJB-03-10-002

View D

WCJB-03-10-003

8

13

3 Detail C

1234-

Flange Nut (8 Used) Propeller Shaft Socket Bolt (4 Used)

5678-

14

15

16

Detail B WCJB-03-10-005

Sems Bolt (2 Used) Bracket Flange Propeller Shaft

910 11 12 -

W3-10-2

Nut (8 Used) Flange Bearing Assembly Yoke

13 14 15 16 -

Nut Spline Seal Grease Fitting Fork

WCEB-03-10-007

LOWERSTRUCTURE / Propeller Shaft Removal 1. Remove grease fitting (15) from propeller shaft (3). : 10 mm

5. Remove nuts (9) (8 used) from the flange part of propeller shaft (8). : 14 mm

IMPORTANT: Propeller shaft (3) cannot be removed individually. If removing propeller shaft (3) individually, spline seal (14) is damaged. Remove the propeller shaft (3) assembly. 2. Remove nuts (2) (8 used) from the flange part of propeller shaft (3). : 14 mm

6. Remove sems bolts (5) (2 used) from bracket (6). Place bearing assembly (11) onto bracket (6). : 17 mm

3. Insert a pry bar between flange (1) and the flange part of propeller shaft (3). Pry propeller shaft (3) toward fork (16) and place propeller shaft (3) on the ground. 4. Remove socket bolts (4) (4 used) from the flange part of propeller shaft (3). Remove propeller shaft (3) from flange (7). : 8 mm

7. Move propeller shaft (8) toward bracket (6) side. Pull out propeller shaft (8). IMPORTANT: Do not remove bearing assembly (11) unless necessary. When removing bearing assembly (11), follow the procedure below. Dispose removed bearing assembly (11). 8. Remove nut (13) from propeller shaft (8). Remove yoke (12) from propeller shaft (8). : 32 mm 9. Remove bearing assembly (11) from propeller shaft (8).

W3-10-3

LOWERSTRUCTURE / Propeller Shaft

Front Axle

5 3 Rear Axle

6 8

B A

C D

W1GL-03-08-001

3

4

5

8

2

6

9

3

10 1

7

View A

WCJB-03-10-001

View B

12

11

WCJB-03-10-002

View D

WCJB-03-10-003

8

13

3 Detail C

14

15 Detail B

WCJB-03-10-005

W3-10-4

16

WCEB-03-10-007

LOWERSTRUCTURE / Propeller Shaft Installation 1. Install bearing assembly (11) to propeller shaft (8). 2. Install yoke (12) to propeller shaft (8). Secure yoke (12) to propeller shaft (8) with nut (13). : 32 mm : 370 to 440 N⋅m (38 to 45 kgf⋅m, 273 to 325 lbf⋅ft) 3. Apply LOCTITE #262 onto nuts (9) (8 used). 4. Insert the yoke (12) mounting side of propeller shaft (8) into bracket (6). Install the flange part of propeller shaft (8) to flange (10). Install propeller shaft (8) to flange (10) with nuts (9) (8 used). : 14 mm : 76 N⋅m (7.8 kgf⋅m, 56 lbf⋅ft)

6. Apply LOCTITE #262 onto socket bolts (4) (4 used). Align the flange part of propeller shaft (3) with the mounting hole on flange (7). Secure propeller shaft (3) to flange (7) with socket bolts (4) (4 used). : 8 mm : 62 N⋅m (6.3 kgf⋅m, 46 lbf⋅ft) 7. Apply LOCTITE #262 onto nuts (2) (8 used). Align the flange part of propeller shaft (3) with the mounting hole on flange (1). Secure propeller shaft (3) to flange (1) with nuts (2) (8 used). : 14 mm : 76 N⋅m (7.8 kgf⋅m, 56 lbf⋅ft) 8. Install grease fitting (15) to fork (16). Apply grease.

5. Apply LOCTITE #262 onto sems bolts (5) (2 used). Install the propeller shaft (8) assembly to bracket (6) with sems bolts (5) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m,37 lbf⋅ft)

W3-10-5

LOWERSTRUCTURE / Propeller Shaft (Blank)

W3-10-6

MEMO ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................

MEMO ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ 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........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................

SECTION 4

FRONT ATTACHMENT — CONTENTS — Group 1 Front Attachment

Group 3 Hose Rupture Valve

Hydraulic Circuit Pressure Release Procedure .............................. W4-1-1 Removal and Installation of Front Attachment .................................. W4-1-2 Maintenance Standard ......................... W4-1-12 Standard Dimensions for Arm and Bucket Connection .............. W4-1-15 Standard Dimensions for Arm and Boom Connection ................ W4-1-16

Hydraulic Circuit Pressure Release Procedure ...............................W4-3-1 Removal and Installation of Hose Rupture Valve for Arm Cylinder ............W4-3-2 Removal and Installation of Hose Rupture Valve for Positioning Cylinder ...............W4-3-3 Removal and Installation of Hose Rupture Valve for Boom Cylinder .........W4-3-5 Structure of Hose Rupture Valve for Arm Cylinder ....................................W4-3-8 Structure of Hose Rupture Valves for Boom Cylinder ...............................W4-3-12 Structure of Hose Rupture Valves for Positioning Cylinder.......................W4-3-16

Group 2 Cylinder Hydraulic Circuit Pressure Release Procedure .............................. W4-2-1 Removal and Installation of Cylinder ..... W4-2-2 Disassembly of Boom, Arm and Bucket Cylinders ................................ W4-2-26 Assembly of Boom, Arm and Bucket Cylinders ................................ W4-2-32 Disassembly of Positioning Cylinder.... W4-2-38 Assembly of Positioning Cylinder ........ W4-2-42 Disassembly of Outrigger and Blade Cylinders .................................. W4-2-46 Assembly of Outrigger and Blade Cylinder .................................... W4-2-48 Maintenance Standard ......................... W4-2-54

Group 4 Operate Check Valve

CJBW-4-1

Remove and Install Operate Check Valve (for Blade and Outrigger) ............W4-4-1 Structure of Operate Check Valve ..........W4-4-3

(Blank)

CJBW-4-2

FRONT ATTACHMENT / Front Attachment HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE NOTE: Operate the pilot pump by using the power from the battery without starting the engine and deliver the pilot pressure to the spool of the control valve. 1. Turn the pilot shut-off lever to the UNLOCK position. 2. Turn the engine stop switch ON. NOTE: Perform steps 1, 2 and turn the key switch to the START position. Although the starter rotates, the engine does not start. IMPORTANT: The battery will deplete. Operate the key switch for short period. 3. With the key switch in the START position, operate the lever 4 to 5 times in order to release any pressure in the hydraulic circuit. 4. Return the pilot shut-off lever to the LOCK position. 5. Turn the engine stop switch OFF.

W4-1-1

Engine Stop Switch

WCEB-02-01-002

FRONT ATTACHMENT / Front Attachment REMOVAL AND INSTALLATION FRONT ATTACHMENT

OF

Removal 1. As for the lubrication hoses to the front attachment, disconnect hoses (1) (2 used) to the boss at the boom cylinder (3) rod side from the adapter. : 17 mm

2. Remove nuts (7) (4 used) from bolts (4) (2 used). Remove bolts (4) (2 used) and stoppers (5) (2 used) from pin (6). : 24 mm CAUTION: Boom cylinder (3) weight: Mono block boom: 172kg (380 lb) 2-piece boom: 161kg (360 lb)

1

1

3

3 WCGB-04-01-001

1

2

3

4

5 6

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. 3. Attach a nylon sling onto the end of the boom cylinder (3) tube. Hoist and hold the boom cylinder (3) tube. By using a bar and a hammer, tap pin (6) into the position where thrust plate (2) can be removed. Remove thrust plate (2). NOTE: When pin (6) cannot be removed, start the engine and operate the boom lever. Adjust the rod pin hole on the boom cylinder.

W4-1-2

7

WCGB-04-01-002

FRONT ATTACHMENT / Front Attachment 4. Place the tube end of boom cylinder (3) on a stand of 1 m (39 in) height. Start the engine. Operate the boom lever and retract boom cylinder (3). In order not to extend the rod, pass a wire through the rod hole and secure the rod to the cylinder tube. Stop the engine. 5. Remove boom cylinder (3) from the boom. Refer to Removal of Boom Cylinder on W4-2-10.

Stand

3 Wire

6. Remove other boom cylinder (3) in the same way as steps 3, 4 and 5. W554-02-03-007

CAUTION: Do not stand toward the removal direction of the pins as the pins may fly off suddenly.

2

7. Slowly tap and remove pin (6) by using a bar and a hammer. Remove thrust plate (2). 8. After stopping the engine, push the air bleed valve. Bleed air from the hydraulic oil tank and remove the cap. Release the pressure in the hydraulic circuit. Refer to HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE on W4-1-1.

3

6

WCGB-04-01-002

Air Bleed Valve

Cap Hydraulic Oil Tank

WCJB-01-04-002

9. Disconnect hoses (8) (6 used), (9) (4 used) (2) from the bucket cylinder and the arm cylinder. Cap the disconnected hoses and pipings. : 19 mm, 27 mm, 36 mm, 41 mm NOTE: The number of the hoses may differ depending on the front attachment specifications. 8 WCJB-04-01-001

8

W4-1-3

9

8

9

FRONT ATTACHMENT / Front Attachment 10. Open cover (10).

10

WCEB-02-05-002

11. Remove sems bolts (12) (4 used) from cover (13). : 17 mm

11

12

13

12. Remove sems bolts (16) (5 used) from cover (15). : 17 mm

14

16

13. Remove cover (13) from cover (11), bracket (14) and support (117). 13

15

WCJB-04-01-002

12 15 16

17

WCJB-04-01-003

18 WCJB-04-01-004

14. Disconnect harness (20) from clips (21) (4 used) at the back of cover (15). 15. Remove sems bolts (22) (2 used) from bracket (19). Remove cover (15) from bracket (19) cover (18).

19

20

15 21

22

WCJB-04-01-005

W4-1-4

FRONT ATTACHMENT / Front Attachment CAUTION: Boom foot pin (26) weight: 46 kg

26

16. Remove bolt (23), spring washer (27), plate (24) and block (25) from the plate of boom foot pin (26). : 27 mm 25 24 23 27 W178-04-01-001

Mono block Boom

CAUTION: Front attachment weight: Mono block boom: 3430 kg (7570lb) 2-piece boom: 4190 kg (9240 lb)

Boom

17. Attach a wire rope onto the boom. Hoist and hold the boom.

WCJB-02-03-001

2-Piece Boom Boom

WCJB-02-03-002

W4-1-5

FRONT ATTACHMENT / Front Attachment CAUTION: Boom foot pin (26) weight: 46 kg 18. Insert a pry bar between the plate of boom foot pin (26) and the bracket. Pull out the plate a little. : 30 mm 19. While turning the plate gradually by hand, remove boom foot pin (26). NOTE: When boom foot pin (26) cannot be removed, adjust the position by using a lifting rope for the front attachment.

26

Plate

20. Hoist the front attachment assembly and move the machine backward. 21. Place a wooden block. Lower the front attachment assembly onto the wooden block.

W4-1-6

Insert a Bar. Bracket

W178-04-01-001

FRONT ATTACHMENT / Front Attachment Installation Mono block Boom Boom

CAUTION: Front attachment weight: Mono block boom: 3430 kg (7570lb) 2-piece boom: 4190 kg (9240 lb) 1. Hoist the front attachment assembly and move the machine forward. Align the boom foot with the mounting hole on the frame. Insert the thrust plate into the left and right sides of the boom. Adjust the clearance between the plate and the frame within 1 mm (0.04 in). (Adjust the position by using a lifting rope for the front attachment.)

WCJB-02-03-001

2-Piece Boom Boom

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. CAUTION: Boom foot pin (26) weight: 46 kg (101 lb) 2. Install boom foot pin (26).Secure boom foot pin (26) to the main frame with bolt (23), washer (27). Plate (24) and block (25). : 27 mm : 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)

WCJB-02-03-002

26

25 24 23 27 W178-04-01-001

W4-1-7

FRONT ATTACHMENT / Front Attachment 3. Install cover (15) to bracket (19) with sems bolts (22) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

19

20

15 21

4. Secure harness (20) to cover (15) with clips (21) (4 used). 22

WCJB-04-01-005

5. Align cover (13) with the mounting holes on cover (11), bracket (14) and support (17).Install cover (13) to cover (11), bracket (14) and support (17) with sems bolts (12) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

13

12 15 16

17

WCJB-04-01-003

18 WCJB-04-01-004

6. Install cover (15) to covers (13, 18) with sems bolts (16) (5used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

11

12

13

14

16

15

WCJB-04-01-002

7. Shut cover (10). 10

WCEB-02-05-002

W4-1-8

FRONT ATTACHMENT / Front Attachment 8. Remove the caps from the hoses and the pipings. Connect hoses (8) (6 used) and hoses (9) (4 used) to the bucket cylinder and the arm cylinder. : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

8

CAUTION: Boom cylinder (3) weight: Mono block boom: 172kg (380 lb) 2-piece boom: 161kg (360 lb)

WCJB-04-01-001

8

9. Install boom cylinder (3). Refer to Installation of Boom Cylinder on W4-2-12.

Wire

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury.

3

10. Remove the wire from boom cylinder (3). Attach a nylon sling onto the end of the boom cylinder (3) tube. Hoist and align the boom cylinder (3) tube with the mounting hole on the boom. 11. Insert thrust plate (2) between the boom and boom cylinder (3), and between boom cylinder (3) and collar (5). Install pin (6). Install boom cylinder (3) to the both sides. 12. Install stoppers (5) (2 used) to pin (6). Secure stoppers (5) (2 used) to pin (6) with bolts (4) (2 used) and nuts (7) (4 used). : 24 mm : 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)

9

8

9

WCEB-04-01-003

6

4

2

3

5 7 W178-04-01-004

W4-1-9

FRONT ATTACHMENT / Front Attachment 13. Connect lubrication hoses (1) (2 used) to the boom cylinder (3) rod side. : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

1

1

3

3 WCGB-04-01-001

14. Apply grease onto the boom cylinder (3) rod side, the bottom side and the boom foot side.

Left Boom Cylinder Rod Side Boom Foot Side

Arm Cylinder Bottom Side

Right Boom Cylinder Rod Side

WCGB-04-01-004

W4-1-10

FRONT ATTACHMENT / Front Attachment CAUTION: Arm bucket assembly weight: Mono block boom: 1650 kg (3640 lb) 2-piece boom : 1560 kg (3440lb)

Mono block Boom Boom

IMPORTANT: When removing the arm from the boom, perform the following steps when installing the arm. 15. Install thrust plates (28) to the left and right sides of the arm. Adjust total clearance of the left and right sides within 1.5 mm (0.06 in).

Arm

16. After installing the arm, apply grease onto grease fitting (29) in the boom connecting boss of the arm. IMPORTANT: For handling of HN bushing for the front attachment, check the followings. Precautions when installing the bushing If a hammer is used, the bushing may be damaged. Use a press.

WCJB-02-03-001

Piece Boom

Boom

Arm

Precautions when reinforcing the arm The heat when welding in order to reinforce the arm may cause oil leakage from HN bushing and decrease lubrication performance. When the welding heat causes the oil leakage of the bushing, replace the bushing. WCJB-02-03-002

Use the special tool when removing or installing the bushing. Special tool: ST 1454

23

23

24

24

M157-07-157

W4-1-11

FRONT ATTACHMENT / Front Attachment MAINTENANCE STANDARD Pin and Bushing F

F C

E A B

E D G

K

C D E

F

M

I

A B

K J H

WCJB-02-03-001

Part Name

B

G

J

H

A

D

D I

C

Pin Bushing Pin Boss (Main Frame) Bushing (Boom Cylinder) Pin Bushing (Boom Cylinder) Boss (Boom) Pin Bushing Pin Boss (Arm) Bushing (Arm Cylinder) Pin Boss (Boom) Bushing (Arm Cylinder)

Standard 90 (3.5) 90 (3.5) 80 (3.1) 80 (3.1) 80 (3.1) 90 (3.5) 90 (3.5) 90 (3.5) 90 (3.5) 90 (3.5) 80 (2.8) 80 (2.8) 80 (2.8) 80 (2.8) 80 (2.8) 80 (2.8)

W4-1-12

Allowable Limit 89.0 (3.5) 91.5 (3.6) 79.0 (3.1) 81.5 (3.2) 81.5 (3.2) 89.0 (3.5) 91.5 (3.6) 91.5 (3.6) 89.0 (3.5) 91.5 (3.6) 79.0 (3.1) 81.5 (3.2) 81.5 (3.2) 79.0 (3.1) 81.5 (3.2) 81.5 (3.2)

WCJB-02-03-002

Unit: mm (in) Remedy

Replace

FRONT ATTACHMENT / Front Attachment

Part Name G

H I J K L M

Standard 71 (2.8) 71 (2.8) 71 (2.8) 80 (3.1) 80 (3.1) 80 (3.1) 71 (2.8) 71 (2.8) 80 (3.1) 80 (3.1) 80 (3.1) 80 (3.1) 100 (3.9) 100 (3.9) 100 (3.9) 100 (3.9)

Pin Boss (Arm) Bushing (Bucket Cylinder) Pin Bushing Bushing (Bucket Cylinder) Pin Bushing Pin Bushing Pin Bushing Pin Bushing Pin Bushing

IMPORTANT: When replacing HN bushing for the front attachment, install it by using a press and special tool (ST 1454).

W4-1-13

Allowable Limit 70.0 (2.9) 72.5 (2.9) 72.5 (2.9) 79.0 (3.1) 81.5 (3.2) 81.5 (3.2) 70.0 (2.9) 72.5 (2.9) 79.0 (3.1) 81.5 (3.2) 79.0 (3.1) 81.5 (3.2) 99.0 (3.9) 101.5 (4.0) 99.0 (3.9) 101.5 (4.0)

Unit: mm (in) Remedy

Replace

FRONT ATTACHMENT / Front Attachment Point

B

C

A

D

W105-04-01-020

A B C D

Standard 215 95 (3.7) 108 95

Allowable Limit 107.5 (4.2) -

Unit: mm (in) Remedy Replace

Side Cutter B

C D A

W155-04-01-002

A B C D

Standard 278 (10.9) 295 (11.6) 433 (17) 135 (5.3)

Allowable Limit 181 (7.0) -

W4-1-14

Unit: mm (in) Remedy Replace

FRONT ATTACHMENT / Front Attachment STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION

Section A

Section B W1CF-04-01-007

a b c d e f g h i j k l m n o p q

Unit: mm (in) 450 (17.7) 0 604 (23.8) 580 (22.8) 1471 (57.9) 433 (17) 305.5 (12) 80 (3.2) 475 (18.7) 31 (1.2) 433 (17) 307 (12) 80 (3.2) 3.7° 3.7° 449 (17.7)

W4-1-15

FRONT ATTACHMENT / Front Attachment STANDARD DIMENSIONS FOR ARM AND BOOM CONNECTION

C WCJB-04-01-006

Section C W1GL-04-01-010

s t u

Unit: mm (in) 90 (3.5) 352 (13.9) 490 (19.3)

W4-1-16

FRONT ATTACHMENT / Cylinder HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE NOTE: Operate the pilot pump by using the power from the battery without starting the engine and deliver the pilot pressure to the spool of the control valve. 1. Turn the pilot shut-off lever to the UNLOCK position. 2. Turn the engine stop switch ON. NOTE: Perform steps 1, 2 and turn the key switch to the START position. Although the starter rotates, the engine does not start. IMPORTANT: The battery will deplete. Operate the key switch for short period. 3. With the key switch in the START position, operate the lever 4 to 5 times in order to release any pressure in the hydraulic circuit. 4. Return the pilot shut-off lever to the LOCK position. 5. Turn the engine stop switch OFF.

W4-2-1

Engine Stop Switch

WCEB-02-01-002

FRONT ATTACHMENT / Cylinder REMOVAL AND INSTALLATION OF CYLINDER

1

Removal of Bucket Cylinder 1. Insert wooden block (3) between the ground and the end of arm (2), and between arm (2) and bucket cylinder (1).

3 2

2. Stop the engine. Push the air bleed button and bleed air from the hydraulic oil tank. Remove the cap. Release the pressure in the bucket circuit. Refer to HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE on W4-2-1.

3 W554-04-02-006

CAUTION: Before removing pin (7), fasten the link by using a wire in order not to fall off. 4

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury.

5

3. Remove nuts (6) (2 used) and bolt (4). Remove pin (7) by tapping. Remove thrust plates (5) (4 used). : 30 mm 4. In order not to extend rod (8) of bucket cylinder (1), pass wire (9) through the cylinder rod hole and secure to the bucket cylinder (1) tube.

7

6 W158-04-02-006

8

9

W4-2-2

1

W102-04-02-005

FRONT ATTACHMENT / Cylinder 5. Disconnect bucket cylinder hoses (12) (2 used) at the bottom of bucket cylinder (1). Cap the open ends : 30 mm

10

CAUTION: Bucket cylinder (1) weight: 150 kg (340 lb)

15

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. 6. Hoist and hold bucket cylinder (1). Remove nuts (13) (2 used) and bolt (15). Remove pin (11) by tapping. Remove thrust plates (10) (2 used). : 24 mm

11 13

1

7. Remove bucket cylinder (1). 12

W4-2-3

W187-04-02-004

FRONT ATTACHMENT / Cylinder Installation of Bucket Cylinder

10

CAUTION: Bucket cylinder (1) weight: 150 kg (340 lb) CAUTION: Metal fragments may fly off when a hammer is used when installing pin (11). Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury.

15 14

11

13

1. Hoist bucket cylinder (1). Align the hole on the cylinder tube side with the cylinder mounting hole on the arm. Install thrust plates (10) (2 used) and pin (11). 1

Arm

2. Install stopper (14) and pin (11) to the arm. Secure with bolt (15) and nuts (13) (2 used). : 24 mm : 270 N⋅m (27.5 kgf⋅m, 200 lbf·ft) 3. Connect bucket cylinder hoses (12) (2 used). : 36 mm : 175 N⋅m (18 kgf⋅m, 140 lbf·ft)

12

8

W187-04-02-004

1

4. Remove wire (9) from rod (8) of bucket cylinder (1).

9

W4-2-4

W102-04-02-005

FRONT ATTACHMENT / Cylinder CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury.

16

4

17

7

18

5

5. Start the engine. Operate the lever and align the hole on the bucket cylinder (1) rod side with those on links (16, 18). Install thrust plates (5) (4 used) and pin (7). 6. Secure stopper (17) and pin (7) with bolt (4) and nuts (6) (2 used). : 30 mm : 550 N⋅m (56 kgf⋅m, 410 lbf·ft) IMPORTANT: In case link (18) has been removed from the arm, insert thrust plate (19) when installing link (18). IMPORTANT: After completing the work, add hydraulic oil to the specified level. Operate bucket cylinder (1) to the stroke end several times and bleed air from the circuit. At the same time, check each connection of the hoses for any oil leaks.

W4-2-5

6 W158-04-02-006

19

19

18

18

W157-04-01-015

FRONT ATTACHMENT / Cylinder Removal of Arm Cylinder

1

1. Insert wooden block (3) between arm cylinder (1) and boom (2). 2. Stop the engine. Push the air bleed button and bleed air from the hydraulic oil tank. Remove the cap. Release the pressure in the arm circuit. Refer to HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE on W4-2-1.

2

3

3. Remove nuts (8) (2 used) and bolt (10) from pin (5) at the rod side in arm cylinder (1). : 30 mm

10

4

W187-04-02-005

5 1

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. 4. Remove pin (5) by tapping. Remove thrust plates (4) (4 used). 8 W187-04-02-006

6

1

5. In order not to extend rod (6) of arm cylinder (1), pass wire (7) through the cylinder rod hole and secure to the arm cylinder (1) tube.

7

W4-2-6

W187-04-02-010

FRONT ATTACHMENT / Cylinder 6. Disconnect pipings (11) (2 used) at the bottom of arm cylinder (1). Cap the open ends. (When a hose rupture valve is provided, refer to REMOVAL AND INSTALLATION OF HOSE RUPTURE VALVE on W4-3-1.) : 36 mm, 41 mm 7. Disconnect lubrication hose (12) from arm cylinder (1). : 17 mm

1 11

12

CAUTION: Arm cylinder (1) weight: 255 kg (570 lb) 8. Attach a nylon sling at the center of gravity of arm cylinder (1). Hoist and hold arm cylinder (1).

WCGB-04-01-001

1

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. 9. Remove nuts (15) (2 used) and bolt (17) from the tube side in arm cylinder (1). Remove pin (14). Remove thrust plate (13). Hoist and remove arm cylinder (1). : 30 mm

W102-04-02-016

17

13

14

1

15

W187-04-02-007

W4-2-7

FRONT ATTACHMENT / Cylinder Installation of Arm Cylinder 17

CAUTION: Arm cylinder (1) weight: 255 kg (5700 lb)

16

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury.

W4-2-8

15

W187-04-02-007

1 11

2. Install thrust plate (13) and pin (14). Secure pin (14) and stopper (16) with bolt (17) and nuts (15) (2 used). : 30 mm : 550 N⋅m (56 kgf⋅m, 410 lbf·ft)

IMPORTANT: Fill hydraulic oil to the specified level. Start the engine and check for any oil leaks at the hose connections.

14

1

1. Attach a nylon sling at the center of gravity of arm cylinder (1). Hoist arm cylinder (1). Align the hole on the cylinder tube side hole with the cylinder mounting hole on the boom.

3. Connect lubrication hose (12) and pipings (11) (2 used) of arm cylinder (1). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf·ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf·ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 151 lbf·ft)

13

12

WCGB-04-01-001

FRONT ATTACHMENT / Cylinder 4. Remove wire (7) from rod (6) of arm cylinder (1). Hold arm cylinder (1) and start the engine. Operate the lever and align the hole at the rod (6) side with the mounting hole on arm (18). CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury.

6

1

1

5. Install thrust plate (4) and pin (5). Secure pin (5) and stopper (9) with bolt (10) and nuts (8) (2 used). : 30 mm : 550 N⋅m (56 kgf⋅m, 410 lbf·ft) IMPORTANT: When completing the work, operate arm cylinder (1) to the stroke end several times and bleed air from the circuit.

3 9

10

4

W187-04-02-010

5

18

8 W187-04-02-006

W4-2-9

FRONT ATTACHMENT / Cylinder Removal of Boom Cylinder 1

1. Disconnect lubrication hose (1) from boom cylinder (2). : 17 mm CAUTION: Boom cylinder (2) weight: Monoblock boom: 175 kg (390 lb) 2-piece boom: 165 kg (370 lb)

2

2. Attach a wire rope onto boom cylinder (2). Hoist and hold boom cylinder (2).

Boom

WCGB-04-01-002

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. 3. Remove nuts (5) (2 used), bolt (7) and stopper (6) from the boom cylinder (2) rod side. Remove pin (4) by tapping. Remove thrust plates (3) (2 used). : 30 mm

7

4. Place the rod side of boom cylinder (2) on a stand. Remove other boom cylinder (2) in the same way.

6

5. Operate the lever and retract boom cylinder (2). In order not to extend the rod, pass a wire through the rod hole and secure to the cylinder tube.

5

3

4

3

2 W158-04-02-013

6. Stop the engine. Push the air bleed button and bleed air from the hydraulic oil tank. Release the pressure in the circuit. Refer to HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE on W4-2-1.

Stand

2 W105-04-02-035

W4-2-10

FRONT ATTACHMENT / Cylinder 7. Disconnect hoses (12) (4 used) at the bottom of boom cylinder (2). Attach a plug onto the open end of the hose. Cap the open end of boom cylinder (2). (When a hose rupture valve is provided, refer to REMOVEAL AND INSTALLATION OF HOSE RUPTURE VALVE on W4-3-1.) Plug 1 3/16-12UN : 36 mm CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. 8. Remove nuts (10) (2 used) and bolt (8) from the cylinder bottom side of the main frame. Remove pin (9) by tapping. Remove thrust plate (11). : 24 mm

2 W105-04-02-036

2

11

8

9

CAUTION: Boom cylinder (2) weight: Monoblock boom: 175 kg (390 lb) 2-piece boom: 165 kg (370 lb)

9 12

9. Attach a wire rope at the center of gravity of boom cylinder (2). Hoist and remove boom cylinder (2). Remove other boom cylinder (2) in the same way.

10

10 W178-04-02-009

2 W105-04-02-040

W4-2-11

FRONT ATTACHMENT / Cylinder Installation of Boom Cylinder CAUTION: Boom cylinder (2) weight: Monoblock boom: 175 kg (390 lb) 2-piece boom: 165 kg (370 lb) 1. Attach a wire rope at the center of gravity of boom cylinder (2). Hoist boom cylinder (2). Align the hole at the boom cylinder tube side with the mounting hole on the main frame. CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. 2. Install thrust plate (11) and pin (9). Secure with bolt (8) and nuts (10) (2 used). : 24 mm : 270 N⋅m (27.5 kgf⋅m, 200 lbf·ft)

2 W105-04-02-040

11

2

8

3. Install other boom cylinder (2) in the same way. 4. Connect hoses (12) (4 used) to boom cylinders (2) (2 used). : 36 mm : 175 N⋅m (18 kgf⋅m, 130 lbf·ft) IMPORTANT: Fill hydraulic oil to the specified level. Start the engine and check for any oil leaks at the hose connections.

W4-2-12

9 9 12

10

10 W178-04-02-009

FRONT ATTACHMENT / Cylinder 5. Hoist boom cylinder (2). Start the engine. Operate the lever and align the hole at the cylinder rod side with the mounting hole on the boom. 7

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. 6. Insert thrust plate (3) and install pin (4).

6

7. Secure pin (4) and stopper (6) with bolt (7) and nut (5). : 30 mm : 550 N⋅m (56 kgf⋅m, 410 lbf·ft)

5

3

4

3

2 W158-04-02-013

1

8. Connect lubrication hose (1). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf·ft)

7 4 6

9. Install other boom cylinder (2) in the same way. IMPORTANT: When completing the work, operate boom cylinder (2) to the stroke end several times and bleed air from the circuit.

W4-2-13

5

2 Boom

WCGB-04-01-002

FRONT ATTACHMENT / Cylinder Removal of Positioning Cylinder (2-Piece Boom Only) 1. Disconnect lubrication hose (1) from positioning cylinders (3) (2 used). : 17 mm, 19 mm

1

2

CAUTION: Positioning cylinder (3) weight: 170 kg (375 lb) 2. Attach a nylon sling onto positioning cylinder (3). Hoist and hold positioning cylinder (3).

3 6, 7

4, 5

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. 3. Remove nuts (7) (2 used) and bolt (6) from stopper (4) of the second boom. : 30 mm

W1GL-04-01-008

4. Install pin (2) 160 mm by tapping. Remove thrust plate (5). 5. Disconnect hoses (8) (3 used) and hoses (9) (3 used) from positioning cylinder (3). Cap the open ends of the disconnected hoses. : 22 mm, 36 mm

8

9

9

W4-2-14

3

W1GL-04-03-004

FRONT ATTACHMENT / Cylinder 6. Remove nuts (13) (2 used) and bolt (14) from stopper (11) of the first boom. Install pin (12) 160 mm by tapping by using a hammer and a bar. Remove thrust plate (10). : 30 mm

10

CAUTION: Positioning cylinder (3) weight: 170 kg (375 lb)

11

7. Hoist and remove positioning cylinder (3). 3

8. Remove other positioning cylinder (3) in the same way steps 2 to 7.

W4-2-15

14

13

12 W1GL-04-03-004

FRONT ATTACHMENT / Cylinder Installation of Positioning Cylinder (2-Piece Boom Only) 8

9

CAUTION: Positioning cylinder (3) weight: 170 kg (375 lb) 10

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. 1. Hoist positioning cylinder (3). Align the pin holes at the bottom side with those of the first boom. Insert thrust plate (10) and install pin (12) by tapping. 2. Align the pin holes of stopper (11) and pin (12). Install and secure with bolt (14) and nuts (13) (2 used). : 30 mm : 550 N⋅m (56 kgf⋅m, 410 lbf·ft) IMPORTANT: Fill hydraulic oil to the specified level. Start the engine and check for any oil leaks at the hose connections. 3. Connect hoses (8) (3 used) and hoses (9) (3 used) to positioning cylinder (3). : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf·ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 130 lbf·ft)

W4-2-16

11

9

3

14

13

12 W1GL-04-03-004

FRONT ATTACHMENT / Cylinder 4. Start the engine and extend positioning cylinder (3). Align the rod hole of positioning cylinder (3) with the hole of the second boom. Insert thrust plate (5) and install pin (4) by tapping.

1

2

5. Align the pin holes of stopper (4) and pin (2). Install bolt (6) and nuts (7) (2 used). : 30 mm : 550 N⋅m (56 kgf⋅m, 410 lbf·ft) 6. Connect lubrication hose (1) to positioning cylinder (3). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

3 6, 7

IMPORTANT: When completing the work, operate positioning cylinder (3) to the stroke end several times and bleed air from the circuit.

W4-2-17

4, 5

W1GL-04-01-008

FRONT ATTACHMENT / Cylinder Removal of Blade Cylinder IMPORTANT: Before starting the work, lower the blade onto the ground. CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. Removal 1. Remove bolts (2) (4 used) and washers (3) (4 used) from cover (4). Remove cover (4) from bracket (1). : 19 mm

1

2, 3 4

WCEB-04-02-001

5

6

7

8

9

2. Disconnect hoses (5) (4 used) from blade cylinder (6). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 27 mm

10 11

CAUTION: Blade cylinder (6) weight: 50 kg (110 lb) 3. Attach a nylon sling onto blade cylinder (6). Hoist and hold blade cylinder (6). 4. Remove nuts (10) (4 used) from bolts (8) (2 used). Remove bolts (8) (2 used) from pins (9, 13). Remove pins (9, 13) from bracket (11) and link (12). : 24 mm 5. Remove thrust plates (7) (6 used) between the bottom part and bracket (11) and between the rod part and link (12) in blade cylinder (6).

WCEB-04-02-002

6

8

7 12

13

W4-2-18

10

WCEB-04-02-001

FRONT ATTACHMENT / Cylinder CAUTION: Blade cylinder (6) weight: 50 kg (110 lb)

6

11

6. Remove blade cylinder (6) from bracket (11) and link (12). 12

WCEB-04-02-002

6

7

8

9

Installation of Blade Cylinder

10

CAUTION: Blade cylinder (6) weight: 50 kg (110 lb)

11

1. Attach a nylon sling onto blade cylinder (6). Hoist blade cylinder (6). Align the bottom and rod parts of blade cylinder (6) with the mounting holes on bracket (11) and link (12). 2. Install thrust plates (7) (6 used) to the bottom and rod parts of blade cylinder (6). Install blade cylinder (6) to bracket (11) and link (12) with pins (9, 13). 3. Secure pins (9, 13) to bracket (11) and link (12) with bolts (8) (2 used) and nuts (10) (4 used). : 24 mm : 210 N⋅m (21.5 kgf⋅m, 155 lbf·ft)

WCEB-04-02-002

6

8

7 12

5

6

13

10

WCEB-04-02-001

4. Connect hoses (5) (4 used) to blade cylinder (6). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf·ft)

WCEB-04-02-002

W4-2-19

FRONT ATTACHMENT / Cylinder 5. Install cover (4) to bracket (1) with bolts (2) (4 used) and washers (3) (4 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf·ft)

1

2, 3 4

IMPORTANT: When completing the work, operate the blade cylinder to the stroke end several times and bleed air from the circuit.

WCEB-04-02-001

W4-2-20

FRONT ATTACHMENT / Cylinder Removal of Outrigger Cylinder CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. 1. Remove sems bolts (4) (3 used), washers (5) (2 used) and collars (6) (2 used) from cover (3). Remove cover (3) from outrigger cylinder (2). : 17 mm

1

2

3

4, 5, 6

4

2. Disconnect hoses (1) (4 used) from outrigger cylinder (2). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 27 mm 3. Remove operate check valve (9) from outrigger cylinder (2). (Refer to REMOVAL AND INSTALLATION OF OPERATE CHECK VALVE on W4-4-1.)

9

7, 8

WCEB-04-02-004

4. Disconnect piping (7) from outrigger cylinder (2). Remove O-ring (8) from piping (7). : 6 mm CAUTION: Outrigger cylinder (2) weight: 90 kg (200 lb)

2

5. Attach a nylon sling onto the rod side of the outrigger cylinder (2) tube. Hoist and hold outrigger cylinder (2).

WCEB-04-02-003

W4-2-21

FRONT ATTACHMENT / Cylinder CAUTION: Outrigger cylinder (2) weight: 90 kg (200 lb)

2

10, 11

6. Remove bolts (14) (3 used) and washers (15) (3 used) from pin (13). Remove pin (13) and thrust plates (14) (3 used) from outrigger (12). : 19 mm

12 13, 14

7. Hoist outrigger cylinder (2) a little. Insert a wooden block under outriger cylinder (2). Lower outrigger cylinder (2).

CAUTION: The outrigger weight: 145 kg (320 lb)

(12)

15, 16

assembly

WCEB-04-02-003

17

17

8. Attach a nylon sling onto outrigger (12). Hoist and hold outrigger (12). Remove lock pin (11) from pin (10). Remove pin (10) from outrigger beam (17). Lower the outrigger (12) assembly.

10, 11

2 Wooden Block

12

W1GL-04-02-006

CAUTION: Outrigger cylinder (2) weight: 90 kg (200 lb)

18

17

9. Attach a nylon sling onto outrigger cylinder (2). Hoist and hold outrigger cylinder (2). 10. Remove ring (18) from pin (19). Remove lock pin (20) from pin (19). Remove pin (19) and thrust plates (21) (3 used) from outrigger beam (17). 11. Remove outrigger cylinder (2) from outrigger beam (17). 19, 20, 21

W4-2-22

2

WCEB-04-02-003

FRONT ATTACHMENT / Cylinder Installation of Outrigger Cylinder CAUTION: Outrigger cylinder (2) weight: 90 kg (200 lb)

18

17

1. Attach a nylon sling onto outrigger cylinder (2). Hoist and align the hole on the bottom side with the outrigger beam (17) mounting hole. Install outrigger cylinder (2) to outrigger beam (17) with thrust plates (21) (3 used) and pin (19). 2. Secure pin (19) to outrigger beam (17) with lock pin (20) and ring (18).

19, 20, 21

3. Install O-ring (8) to piping (7). Connect piping (7) to outrigger cylinder (2). : 6 mm : 78±19 N⋅m (8±2 kgf⋅m, 58±6 lbf·ft)

1

2

WCEB-04-02-003

2

4. Install operate check valve (9) to outrigger cylinder (2). (Refer to REMOVAL AND INSTALLATION OF OPERATE CHECK VALVE on W4-4-1.) 5. Connect hoses (1) (4 used) to operate check valve (9). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf·ft) 6. Install cover (3) to outrigger cylinder (2) with sems bolts (4) (3 used), washers (5) (2 used) and collars (6) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf·ft)

9

7, 8

2

3

WCEB-04-02-004

4, 5, 6

4

WCEB-04-02-004

W4-2-23

FRONT ATTACHMENT / Cylinder IMPORTANT: After the hose is connected, operate the outrigger cylinder to the stroke end several times and bleed air from the circuit. 7. Extend the rod of outrigger cylinder (2) and align with the mounting hole on outrigger (12). Install the rod part of outrigger cylinder (2) to outrigger (12) with thrust plates (14) (3 used) and pin (13). 8. Install pin (13) to outrigger (12) with bolts (15) (3 used) and washers (16) (3 used). : 19 mm : 90 N⋅m (9 kgf⋅m, 66 lbf·ft)

17

10, 11

13, 14 2

15, 16

Wooden Block

12

W1GL-04-02-006

9. Remove the wooden block from the inside of outrigger beam (17).

17

10, 11

10. Operate outrigger cylinder (2) and align the mounting hole on outrigger (12) with that on outrigger beam (17). Secure outrigger (12) to outrigger beam (17) with pin (10) and lock pin (11).

12

2

W4-2-24

WCEB-04-02-003

FRONT ATTACHMENT / Cylinder (Blank)

W4-2-25

FRONT ATTACHMENT / Cylinder DISASSEMBLY OF BOOM, ARM AND BUCKET CYLINDERS Boom Cylinder

1

20

22 23

26

25

17

18

24

19

21

2

19

18

5

6

7

8

9

10

11

W1V1-04-02-007

17 1

20 19

4

12

Arm Cylinder

22 23

3

16

15

2

14

13

3

4

5

6

7

8

9

10

11

12

W1V1-04-02-008

26

25

17

18

24

19

21

18

17

W4-2-26

FRONT ATTACHMENT / Cylinder Bucket Cylinder 1

19

22 23

2

18

3

4

5

6

7

8

9

10 11

12

W1V1-04-02-009

17

1234567-

18

24

Piston Rod Wiper Ring Backup Ring U-Ring Buffer Ring Socket Bolt (12 Used) Cylinder Head

19

21

8910 11 12 13 14 -

20

Bushing Snap Ring Backup Ring O-Ring Cylinder Tube Stopper (2 Used) Cushion Bearing

17

15 16 17 18 19 20 -

W4-2-27

Cushion Seal Snap Ring Slide Ring (2 Used) Slide Ring (2 Used) Backup Ring (2 Used) O-Ring

21 22 23 24 25 26 -

Seal Ring Set Screw Steel Ball Piston Nut Cushion Bearing Cushion Seal

FRONT ATTACHMENT / Cylinder

1

6

14

7

12

W1V1-04-02-008

24

W4-2-28

FRONT ATTACHMENT / Cylinder Disassembly of Boom, Arm and Bucket Cylinders • The disassembling procedure starts on the premise that the hydraulic pipings and the bands securing the pipings have been removed. NOTE: The procedure for the arm cylinder is explained.

IMPORTANT: Pull out piston rod (1) straight in order not to damage the sliding surface. 3. Tap and remove cylinder head (7) with piston rod (1) together from cylinder tube (12) by using a plastic hammer. 4. Secure piston rod (1) to special tool (ST 5908). Put the matching marks on piston rod (1) and the end of piston (24) (Arm cylinder: cushion bearing (14)).

CAUTION: Boom cylinder weight: Monoblock boom: 175 kg (390 lb) 2-piece boom: 165 kg (370 lb) Arm cylinder weight: 225 kg (550 lb) Bucket cylinder weight: 150 kg (335 lb) 1. Hoist the cylinder. Secure the cylinder horizontally on a workbench. Drain hydraulic oil from the cylinder.

Special Tool: ST 5908

W102-04-02-027

2. Fully extend piston rod (1). Attach a nylon sling onto piston rod (1). Hold piston rod (1). Remove socket bolts (6) (12 used) from cylinder head (7). : 14 mm

W4-2-29

W158-04-02-022

FRONT ATTACHMENT / Cylinder

1

20

22 23

19

16

18

17

2

15

14

3

4

5

6

7

8

9

10

11

13

W1V1-04-02-008

26

25 17

18

24

19

21

W4-2-30

FRONT ATTACHMENT / Cylinder 5. Cut away the crimped part by using a hand drill and remove set screw (22). Remove steel ball (23). NOTE: Set screw (22) has been crimped by using a punch at 2 places after installing. : 6 mm 6. Remove piston nut (24) by using special tool (ST 5908) and the special tool. Remove cushion bearing (25) and cushion seal (26) from piston rod (1). (Cushion bearing (25) and cushion seal (26) are not equipped for the bucket cylinder.) Special tool (outer diameter at nut part): Bucket cylinder: (ST 3244: 90 mm) Boom cylinder: Monoblock boom: (ST 3245: 95 mm) 2-piece boom: (ST 3246: 100 mm) Arm cylinder: (ST 3249: 110 mm)

Special Tool: ST 5908

7. Remove slide rings (17) (2 used), slide rings (18) (2 used), backup rings (19) (2 used), O-ring (20) and seal ring (21) from piston nut (24). 8. Remove cylinder head (7) from piston rod (1). 9. Remove O-ring (11) and backup rings (10, 3) from cylinder head (7). Remove wiper ring (2), U-ring (4), buffer ring (5), snap ring (9) and bushing (8) by using the special tool. Special tool (rod outer diameter): Bucket cylinder: (ST 8019: 80 mm) Boom cylinder: (ST 8020: 85 mm) Arm cylinder: (ST 8025: 95 mm) 10. (Arm cylinder only) Remove stoppers (13) (2 used) from piston rod (1) by using a screwdriver. Remove cushion bearing (14), cushion seal (15) and snap ring (16).

W158-04-02-022

W4-2-31

FRONT ATTACHMENT / Cylinder ASSEMBLY OF BOOM, ARM AND BUCKET CYLINDERS

Boom Cylinder 1

2

4

5

6

8

3

7

9

12

25

17

10, 11

26

18

19

24

18

17

20, 21

23

22

W1V1-04-02-005

Arm Cylinder 1

2

4

3

5

6

8

9

5

6

7

12

10, 11

25

17

26

18

24

19

18

20, 21

17 22

23 16

14

15

W1V1-04-02-003

Bucket Cylinder 1

2

4

7

12

17

18

19

18

17 22

3

8

9

20, 21

10, 11

23 W1V1-04-02-001

W4-2-32

FRONT ATTACHMENT / Cylinder 1234567-

Piston Rod Wiper Ring Backup Ring U-Ring Buffer Ring Socket Bolt (12 Used) Cylinder Head

8910 11 12 13 14 -

Bushing Snap Ring Backup Ring O-Ring Cylinder Tube Stopper (2 Used) Cushion Bearing

15 16 17 18 19 20 -

W4-2-33

Cushion Seal Snap Ring Slide Ring (2 Used) Slide Ring (2 Used) Backup Ring (2 Used) O-Ring

21 22 23 24 25 26 -

Seal Ring Set Screw Steel Ball Piston Nut Cushion Bearing Cushion Seal

FRONT ATTACHMENT / Cylinder

1

2

4

5

7

17

18

19

18

17

14

13

3

8

9

10, 11

24

NOTE: The illustration shows the arm cylinder.

W4-2-34

20, 21

16

15

W1V1-04-02-003

FRONT ATTACHMENT / Cylinder Assembly of Boom, Arm and Bucket Cylinders NOTE: The procedure for the arm cylinder is explained. 1. Install bushing (8) to cylinder head (7) by using the special tool. Special tool (rod outer diameter): Bucket cylinder: (ST 8019: 80 mm) Boom cylinder: (ST 8020: 85 mm) Arm cylinder: (ST 8025: 90 mm) IMPORTANT: Check the direction to install. 2. Install U-ring (4), backup ring (3), buffer ring (5) and snap ring (9) to cylinder head (7). 3. Install wiper ring (2) to cylinder head (7) by using the special tool and a plastic hammer. Special tool (rod outer diameter): Bucket cylinder: (ST 8019: 80 mm) Boom cylinder: (ST 8020: 85 mm) Arm cylinder: (ST 8025: 90 mm) 4. Install O-ring (11) and backup ring (10) to cylinder head (7).

5. Install O-ring (20) and seal ring (21) to piston nut (24) by using special tool A. After installing seal ring (21), adjust seal ring (21) by using special tool B. Special tools A and B (tube inner diameter): Bucket cylinder: (ST 2963, 2207: 115 mm) Boom cylinder: Monoblock boom: (ST 2964, 2208: 120 mm) 2-piece boom: (ST 2965, 2088: 125 mm) Arm cylinder: (ST 2978, 2535: 135 mm) 6. Install backup rings (19) (2 used), slide rings (17) (2 used) and slide rings (18) (2 used) to piston nut (24). 7. Install the cylinder head (7) assembly to piston rod (1) by using the special tool. Special tool (rod outer diameter): Bucket cylinder: (ST 8019: 80 mm) Boom cylinder: (ST 8020: 85 mm) Arm cylinder: (ST 8025: 90 mm) IMPORTANT: Face the slit in cushion seal (15) to the piston nut (24) side. Check the direction of the oil groove in cushion bearing (14). 8. (Arm cylinder only) Install snap ring (16) and cushion seal (15) to piston rod (1). Install cushion bearing (14) and stoppers (13) (2 used).

W4-2-35

FRONT ATTACHMENT / Cylinder

1

6

7

12

25

26

NOTE: The illustration shows the arm cylinder.

W4-2-36

22

24

23

W1V1-04-02-003

FRONT ATTACHMENT / Cylinder IMPORTANT: Face the slit in cushion seal (26) to the piston nut (24) side. Check the direction of the oil groove in cushion bearing (25). 9. Install cushion seal (26) and cushion bearing (25) to piston rod (1). (Cushion bearing (25) and cushion seal (26) are not equipped for the bucket cylinder.) 10. Align the matching marks and tighten piston nut (24) by using special tool (ST 5908) and the special tool. Special tool (outer diameter at nut part): Bucket cylinder: (ST 3244: 90 mm) : 5600 N⋅m (570 kgf⋅m, 4130 lbf·ft) Boom cylinder: Monoblock boom: (ST 3245: 95 mm) : 5340 N⋅m (545 kgf⋅m, 3940 lbf·ft) 2-picece boom: (ST 3245: 95 mm) : 6000 N⋅m (610 kgf⋅m, 4430 lbf·ft) Arm cylinder: Monoblock boom: (ST 3245: 95 mm) : 8860 N⋅m (900 kgf⋅m, 6540 lbf·ft) 2-picece boom: (ST 3245: 95 mm) : 7900 N⋅m (810 kgf⋅m, 5380 lbf·ft)

Special Tool: ST 5908

11. Install steel ball (23) to piston rod (1). Tighten with set screw (22). Crimp set screw (22) by using a punch at 2 places. : 6 mm : 57 N⋅m (5.8 kgf⋅m, 42 lbf·ft) CAUTION: Align the piston rod (1) assembly with the center of cylinder tube (12) and insert straight in order not to damage the rings. 12. Secure cylinder tube (12) horizontally on a workbench. Insert the piston rod (1) assembly into cylinder tube (12). 13. Install cylinder head (7) to cylinder tube (12) with socket bolts (6) (12 used). : 14 mm : 265 N⋅m (27 kgf⋅m, 195 lbf·ft) IMPORTANT: When replacing the bushing from piston rod (1) or cylinder tube (12) by using a hammer, the bushing may be damaged. Use a press and special tool (ST 1454) when removing and installing the bushing.

W158-04-02-022

W4-2-37

FRONT ATTACHMENT / Cylinder DISASSEMBLY OF POSITIONING CYLINDER 1

2

14

15

16

17

18

3

19

4

20

5

6

7

8

9

10

11

12

13

21

22

WCGB-04-02-010

123456-

Piston Rod Socket Bolt (14 Used) Cylinder Head Retaining Ring Dust Seal Backup Ring

78910 11 12 -

U-Ring Buffer Ring Bushing Retaining Ring O-Ring O-Ring

13 14 15 16 17 -

Backup Ring Piston Slide Ring (2 Used) Wear Ring (2 Used) Seal Ring

W4-2-38

18 19 20 21 22 -

O-Ring Backup Ring (2 Used) Set Screw Piston Nut Cylinder Tube

FRONT ATTACHMENT / Cylinder Disassembly of Positioning Cylinder NOTE: The disassembling procedure starts on the premise that the hydraulic pipings and the bands securing the pipings have been removed. CAUTION: Positioning cylinder weight: 170 kg (375 lb) 1. Hoist the cylinder. Secure the cylinder horizontally on a workbench. Drain hydraulic oil from the cylinder.

CAUTION: Do not drop piston rod (1) by tilting. IMPORTANT: Pull out piston rod (1) straight in order not to damage the sliding surface. 4. Slowly remove piston rod (1) from cylinder tube (22). At this time, cylinder head (3) is removed with piston rod (1) together. Set a cloth onto a wooden block. Place piston rod (1) horizontally on the wooden block.

W102-04-02-027

2. Fully extend piston rod (1). Attach a nylon sling onto piston rod (1). Hold piston rod (1). Remove socket bolts (2) (14 used) from cylinder head (3). : 14 mm 3. Remove cylinder head (3) from cylinder tube (22) by using a pry bar.

W4-2-39

FRONT ATTACHMENT / Cylinder

1

2

14

15

16

17

18

3

19

4

20

5

6

7

8

9

10

11

12

13

21

22

WCGB-04-02-010

W4-2-40

FRONT ATTACHMENT / Cylinder 5. Cut away the crimped part by using a hand drill and remove set screw (20) from piston nut (21). NOTE: Set screw (20) has been crimped by using a punch at 2 places after installing. : 4 mm

9. Remove bushing (9) from cylinder head (3) by using special tool (ST 2613). Remove O-rings (11, 12), backup rings (6, 13), dust seal (5), U-ring (7), buffer ring (8) and retaining rings (4, 10) from bushing (9).

6. Remove piston nut (21) from piston rod (1) by using special tool (ST 3327). Remove piston (14) from piston rod (1) by using special tool (ST 3339). 7. Remove seal ring (17), slide ring (15), wear ring (16), O-ring (18), retaining rings (19) (2 used) and backup rings (17) (2 used) from piston (14). 8. Remove cylinder head (3) from piston rod (1).

W4-2-41

FRONT ATTACHMENT / Cylinder ASSEMBLY OF POSITIONING CYLINDER

6, 7

8

9, 10

2, 11

3

12, 13

22

14

15

16

17

18, 19

21

20

4, 5 1

WCJB-04-02-002

123456-

Piston Rod Socket Bolt (14 Used) Cylinder Head Retaining Ring Dust Seal Backup Ring

78910 11 12 -

U-Ring Buffer Ring Bushing Retaining Ring O-Ring O-Ring

13 14 15 16 17 -

Backup Ring Piston Slide Ring (2 Used) Wear Ring Seal Ring

W4-2-42

18 19 20 21 22 -

O-Ring Backup Ring (2 Used) Set Screw Piston Nut Cylinder Tube

FRONT ATTACHMENT / Cylinder Assembly of Positioning Cylinder 1. Install bushing (9) to cylinder head (3) by using special tool (ST 2613). Install retaining ring (10). 2. Tap and install dust seal (5) to cylinder head (3) by using special tool (ST 2614) and a plastic hammer.

5. Install O-ring (18), backup rings (19) (2 used), seal ring (17), slide rings (15) (2 used) and wear ring (16) to piston (14) by using special tools (ST 2588, 2589). 6. Install the cylinder head (3) assembly to piston rod (1) by using special tool (ST 2696).

IMPORTANT: Check the installing direction. 3. Install U-ring (7), backup ring (2), buffer ring (8) and retaining ring (4) to cylinder head (3). 4. Install O-rings (11, 12) and backup ring (13) to cylinder head (3).

W4-2-43

FRONT ATTACHMENT / Cylinder

2

3

22

14

21

20

1

WCJB-04-02-002

W4-2-44

FRONT ATTACHMENT / Cylinder 6. Apply hydraulic oil onto the inner surface of piston (14). Install piston (14) to piston rod (1) by using special tool (ST 3339). : 980±98 N⋅m (100±10 kgf⋅m, 720±72 lbf·ft) 7. Apply hydraulic oil onto piston nut (21). Install piston nut (21) to piston rod (1) by using special tool (ST 3327). : 1860±185 N⋅m (190±19 kgf⋅m, 1380±137 lbf·ft) 8. Apply LOCTITE #242 onto two to three threads of set screw (20). Install set screw (20) to piston nut (21). After tightening set screw (20), crimp set screw (20) by using a punch at 2 places. : 4 mm : 15±1.5 N⋅m (1.5±0.15 kgf⋅m, 11±1 lbf·ft)

IMPORTANT: Align the piston rod (1) assembly with the center of cylinder tube (22) and insert straight in order not to damage the rings. 10. Apply hydraulic oil onto the outer surface of piston (14). Hoist cylinder tube (22). Secure cylinder tube (22) horizontally on a workbench. Insert the piston rod (1) assembly into cylinder tube (22). 11. Install cylinder head (3) to cylinder tube (22) by using special tool (ST 2696). Tighten cylinder head (3) with socket bolts (2) (14 used). : 14 mm : 340 to 360 N⋅m (35 to 37 kgf⋅m, 255 to 270 lbf·ft) IMPORTANT: When replacing the bushing from piston rod (1) or cylinder tube (22) by using a hammer, the bushing may be damaged. Use a press and special tool (ST 1454) when removing and installing the bushing.

W4-2-45

FRONT ATTACHMENT / Cylinder DISASSEMBLY OF OUTRIGGER AND BLADE CYLINDERS 1

2 3

4

5

6

7

8

9

10

11 12

13

14

15

16

17 18

19

20

WCGB-04-02-002

12345-

Piston Rod Cylinder Head Retaining Ring Dust Seal U-Ring

678910 -

Seal Bushing Retaining Ring O-Ring Backup Ring

11 12 13 14 15 -

W4-2-46

O-Ring Piston Seal Ring Wear Ring Dust Ring

16 17 18 19 20 -

O-Ring Set Screw Piston Nut Backup Ring (2 Used) Cylinder Tube

FRONT ATTACHMENT / Cylinder Disassembly of Outrigger and Blade Cylinders NOTE: The disassembling procedure starts on the premise that the hydraulic pipings and the bands securing the pipings have been removed. CAUTION: Outrigger cylinder weight: 90 kg (200 lb) Blade cylinder weight: 50 kg (110 lb) 1. Hoist the cylinder. Secure the cylinder horizontally on a workbench. Drain hydraulic oil from the cylinder.

4. Cut away the crimped part by using a hand drill and remove set screw (17) from piston nut (18). NOTE: Set screw (17) has been crimped by using a punch at 2 places after installing. : 4 mm 5. Remove piston nut (18) by using special tool (ST 3334). Remove piston (12) from piston rod (1) by using special tool (ST 3337). 6. Remove cylinder head (2) from piston rod (1). IMPORTANT: When removing the seals, do not damage the parts. 7. Remove seal ring (13), wear ring (14), dust ring (15) and O-ring (16) from piston (12). 8. Remove retaining rings (3, 8), U-ring (5), dust seal (4) and backup ring (10) from the inside of cylinder head (2). Remove bushing (7) by using special tool (ST 2685).

W102-04-02-027

9. Remove O-rings (9, 11) and backup ring (10) from the outside of cylinder head (2).

2. Raise a detent (a part of cylinder tube (20)) in the groove on cylinder head (2). Pry and remove cylinder head (2) from cylinder tube (20) by using a pry bar. R wrench: (ST 3221) CAUTION: Do not drop piston rod (1) by tilting. IMPORTANT: Remove piston rod (1) straight in order not to damage the rod surface. 3. Fully extend piston rod (1). Attach a nylon sling onto piston rod (1). Hold piston rod (1). Slowly remove piston rod (1) from cylinder tube (20). Set a cloth onto a wooden block. Place piston rod (1) horizontally on the wooden block.

W4-2-47

FRONT ATTACHMENT / Cylinder ASSEMBLY OF OUTRIGGER AND BLADE CYLINDER Outrigger Cylinder 1

5

3, 4

9

6

7, 8

2

10, 11

20 12

13

14

15

16, 19

18

17

WCGB-04-02-004

Blade Cylinder

1

3, 4

5

9

6

7, 8

2

10, 11

20 12

13 14 15

16, 19

18

17

WCGB-04-02-003

W4-2-48

FRONT ATTACHMENT / Cylinder 12345-

Piston Rod Cylinder Head Retaining Ring Dust Seal U-Ring

678910 -

Seal Bushing Retaining Ring O-Ring Backup Ring

11 12 13 14 15 -

W4-2-49

O-Ring Piston Seal Ring Wear Ring Dust Ring

16 17 18 19 20 -

O-Ring Set Screw Piston Nut Backup Ring (2 Used) Cylinder Tube

FRONT ATTACHMENT / Cylinder

1

3, 4

5

9

6

7, 8

2

10, 11

12

13

14

15

16, 19

18

17

WCGB-04-02-004

NOTE: The illustration shows the outrigger cylinder.

W4-2-50

FRONT ATTACHMENT / Cylinder Assembly of Outrigger and Blade Cylinders 1. Install bushing (7) to cylinder head (2) by using special tool (ST 2685). Install retaining ring (8). IMPORTANT: Install U-ring (5) with its lip part facing to the bushing (7) side. Install seal (6) with its projection part and slit part facing to the bushing (7) side. 2. Install U-ring (5) and seal (6) to cylinder head (2). 3. Install dust seal (4) and retaining ring (3) to cylinder head (2) by using special tool (ST 2689). IMPORTANT: Install backup ring (10) to the pin hole side on piston rod (1). 4. Install O-rings (9, 11) and backup ring (10) to cylinder head (2). 5. Install the cylinder head (2) assembly to piston rod (1) by using special tool (ST 2693).

IMPORTANT: After installing O-ring (16), check that O-ring (16) is not twisted. 6. Install O-ring (16), backup rings (19) (2 used), seal ring (13), wear ring (14) and dust ring (15) to piston (12). 7. Apply hydraulic oil onto the inner surface of piston (12). Install piston (12) to piston rod (1) by using special tool (ST 3337). : 740±69 N⋅m (75±7 kgf⋅m, 550±51 lbf·ft) 8. Apply hydraulic oil onto the threads of piston nut (18). Install piston nut (18) to piston rod (1) by using special tool (ST 3334). : 1270±98 N⋅m (130±10 kgf⋅m, 940±72 lbf·ft) 9. Apply LOCTITE #242 onto set screw (17). Install set screw (17). After tightening set screw (17), crimp set screw (17) by using a punch at 2 places. : 4 mm : 15±1.5 N⋅m (1.5±0.15 kgf⋅m, 11±1 lbf·ft)

W4-2-51

FRONT ATTACHMENT / Cylinder

1

20

2

WCGB-04-02-004

NOTE: The illustration shows the outrigger cylinder.

W4-2-52

FRONT ATTACHMENT / Cylinder IMPORTANT: Align the piston rod (1) assembly with the center of cylinder tube (20) and insert straight in order not to damage the rings. 10. Secure cylinder tube (20) horizontally on a workbench. Insert the piston rod (1) assembly into cylinder tube (20). 11. Apply hydraulic oil onto the threads of cylinder head (2). Install cylinder head (2) to cylinder tube (20). Bend the detent and secure cylinder head (2). R wrench: (ST 3223) : 490 to 690 N⋅m (50 to 70 kgf⋅m, 360 to 510 lbf·ft) IMPORTANT: When replacing the bushing from piston rod (1) or cylinder tube (20) by using a hammer, the bushing may be damaged. Use a press and special tool (ST 1454) when removing and installing the bushing.

W4-2-53

FRONT ATTACHMENT / Cylinder MAINTENANCE STANDARD Rod Bend and Run Out of Piston Rod

Piston Rod

Dial Gauge

A Piston Rod

W166-04-02-022

W105-04-02-094

1m

Cylinder Name

Unit: mm (in) Recommended Size After Re-Manufacturing (A)

Boom

85

Arm

95

Bucket

80

Positioning

95

Blade

120

Outrigger

120

+0.027 -0.057 +0.027 -0.057 +0.027 -0.053 +0.027 -0.057 +0.023 -0.043 +0.023 -0.043

(3.3 (3.7 (3.1 (3.7 (4.7 (4.7

+0.001 -0.002 +0.001 -0.002 +0.001 -0.002 +0.001 -0.002 +0.001 -0.002 +0.001 -0.002

) )

V Block

Bend

Unit: mm (in) Run Out

Remedy

0.5 (0.02) 1.0 (0.04)

Repair

1.0 (0.04) 2.0 (0.08)

Replace

) ) ) )

W4-2-54

FRONT ATTACHMENT / Hose Rupture Valve HYDRAULIC CIRCUIT RELEASE PROCEDURE

PRESSURE

NOTE: Operate the pilot pump by using the power from the battery without starting the engine and deliver the pilot pressure to the spool of the control valve. 1. Turn the pilot shut-off lever to the UNLOCK position. 2. Turn the engine stop switch ON. NOTE: Perform steps 1, 2 and turn the key switch to the START position. Although the starter rotates, the engine does not start. IMPORTANT: The battery will deplete. Operate the key switch for short period. 3. With the key switch in the START position, operate the lever 4 to 5 times in order to release any pressure in the hydraulic circuit. 4. Return the pilot shut-off lever to the LOCK position. 5. Turn the engine stop switch OFF.

W4-3-1

Engine Stop Switch

WCEB-02-01-002

FRONT ATTACHMENT / Hose Rupture Valve REMOVAL AND INSTALLATION OF HOSE RUPTURE VALVE FOR ARM CYLINDER CAUTION: Loosen the relief valve of hose rupture valve (3) slowly and release the pressure.

1

2

3, 4

5

Removal 1. Disconnect hoses (1) (2 used) from hose rupture valve (3). Cap the open ends. : 19 mm

6

2. Remove socket bolts (6) (4 used) from piping (5). : 8 mm 3. Remove socket bolts (2) (4 used) from hose rupture valve (3). Remove hose rupture valve (3) and O-ring (4) from arm cylinder (7). : 8 mm

Installation 1. Apply grease onto O-ring (4). Install O-ring (4) to hose rupture valve (3). 2. Align hose rupture valve (3) with the mounting holes on arm cylinder (7) and piping (5). Install hose rupture valve (3) to arm cylinder (7) and piping (5) with socket bolts (2, 6) (4 used for each). : 8 mm : 52±10 N⋅m (5.2±1 kgf⋅m, 38±7 lbf⋅ft) 3. Connect hoses (1) (2 used) to hose rupture valve (3). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

W4-3-2

7 WCEB-04-03-003

1

2

3, 4

5

6

7 WCEB-04-03-003

FRONT ATTACHMENT / Hose Rupture Valve REMOVAL AND INSTALLATION OF HOSE RUPTURE VALVE FOR POSITIONING CYLINDER CAUTION: Loosen the relief valve of hose rupture valve (8) slowly and release the pressure.

2

1

3

Removal 1. Remove bolts (4) (2 used) from clamp (5). Remove clamp (5) from bracket (6). : 22 mm 2. Disconnect hoses (3) (3 used) from hose rupture valve (8). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm 3. Remove socket bolts (1) (4 used). Disconnect piping (2) from positioning cylinder (7). Remove hose rupture valve (8) and O-ring (9) from positioning cylinder (7). Cap the open ends. : 10 mm

W4-3-3

4

5

6

8, 9

7

WCJB-04-03-003

FRONT ATTACHMENT / Hose Rupture Valve Installation 1. Apply grease onto O-ring (9). Install O-ring (9) to hose rupture valve (8).

2

1

3

2. Install hose rupture valve (8) and piping (2) to positioning cylinder (7) with socket bolts (1) (4 used). : 10 mm : 93±1.8 N⋅m (9.3±0.2 kgf⋅m, 69±1 lbf⋅ft) 3. Connect hoses (3) (3 used) to hose rupture valve (8). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) 4. Secure piping (2) to bracket (6) with clamp (5) and bolts (4) (2 used). : 22 mm : 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

W4-3-4

4

5

6

8, 9

7

WCJB-04-03-003

FRONT ATTACHMENT / Hose Rupture Valve REMOVAL AND INSTALLATION OF HOSE RUPTURE VALVE FOR BOOM CYLINDER CAUTION: Loosen the relief valve of hose rupture valve (8) slowly and release the pressure.

1

2

3

4

5

Removal 1. Remove bolt (4) from clamps (3) (2 used). Remove clamps (3) (2 used) from bracket (2) and piping (5). : 19 mm 2. Disconnect hoses (6) (6 used) from hose rupture valve (8). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 17 mm, 19 mm, 27 mm 3. Remove socket bolts (7) (4 used) from piping (5). Disconnect piping (5) from boom cylinder (1). Remove hose rupture valve (8) and O-ring (9) from boom cylinder (1). Cap the open ends. : 10 mm

W4-3-5

6

8, 9

6

7

WCEB-04-03-002

FRONT ATTACHMENT / Hose Rupture Valve Installation 1. Apply grease onto O-ring (9). Install O-ring (9) to hose rupture valve (8).

1

2

3

4

5

2. Install hose rupture valve (8) and piping (5) to boom cylinder (1) with socket bolts (7) (4 used). : 10 mm : 93±1.8 N⋅m (9.3±0.2 kgf⋅m, 69±1 lbf⋅ft) 3. Connect hoses (6) (6 used) to hose rupture valve (8). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) 4. Secure piping (5) to bracket (2) with clamps (3) (2 used) and bolt (4). : 19 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

W4-3-6

6

8, 9

6

7

WCEB-04-03-002

FRONT ATTACHMENT / Hose Rupture Valve (Blank)

W4-3-7

FRONT ATTACHMENT / Hose Rupture Valve STRUCTURE OF HOSE RUPTURE VALVE FOR ARM CYLINDER

9

2

3

4

5

6

7

10

11

12

13

14

15

16

8 17

1

18 19

47

20 21

46

22

45

23

44

24

43

25

42

26

41

27

40

28 29

39

30

38

31

37 32

36

35

33

34

WCEB-04-03-006

W4-3-8

FRONT ATTACHMENT / Hose Rupture Valve

No.

Part Name

Q’ty

1

Spacer

1

2

Plug

3

3

O-Ring

3

4

Backup Ring

1

5

O-Ring

1

6

Orifice

2

7

Backup Ring

2

8

O-Ring

1

9

Lock Nut

1

10

Poppet

1

11

Set Screw

1

12

Spring

1

13

O-Ring

1

14

Washer

1

15

Adapter

1

16

O-Ring

1

17

Backup Ring

1

18

O-Ring

1

19

Casing

1

20

O-Ring

1

21

Plug

1

22

Stopper

1

23

Spool

1

24

Sleeve

1

25

Backup Ring

1

26

O-Ring

1

27

O-Ring

3

28

Plug

1

Wrench Size (mm) :5

: 17 :6

: 24

: 32

W4-3-9

Tightening Torque N⋅m

(kgf⋅m, lbf⋅ft)

Remark

FRONT ATTACHMENT / Hose Rupture Valve

47

46 45 44 43 42 41 40 29

39

30

38

31

37 32

36

35

33

34

WCEB-04-03-006

W4-3-10

FRONT ATTACHMENT / Hose Rupture Valve

No.

Part Name

Q’ty

Wrench Size (mm)

29

Backup Ring

1

30

Spring

1

31

Holding Valve

1

32

Orifice

2

33

Body

1

34

O-Ring

1

35

O-Ring

1

36

Backup Ring

1

37

O-Ring

1

38

Backup Ring

1

39

Spring Seat

1

40

O-Ring

1

41

Piston

1

42

O-Ring

1

43

Cover

1

44

Stopper

1

45

Set Screw

1

:3

46

Lock Nut

1

: 10

47

Spring

1

Casing (19) and body (33) mounting socket bolt

4

: 32

:8

W4-3-11

Tightening Torque N⋅m

(kgf⋅m, lbf⋅ft)

Remark

FRONT ATTACHMENT / Hose Rupture Valve STRUCTURE OF HOSE RUPTURE VALVES FOR BOOM CYLINDER

9 3

4

5

6

7

10

11

8

12 13 14

15

16 17

2 18

1

19 47

20

46

21

45

22 23

44

24 25

43

26 27

42

28

41

29

40

30

39 38

31

37

32

36 35 33 34 W1V1-04-03-001

W4-3-12

FRONT ATTACHMENT / Hose Rupture Valve

No.

Part Name

Q’ty

1

Spacer

1

2

Plug

3

3

O-Ring

3

4

Backup Ring

1

5

O-Ring

1

6

Orifice

2

7

Backup Ring

2

8

O-Ring

1

9

Lock Nut

1

10

Poppet

1

11

Set Screw

1

12

Spring

1

13

O-Ring

1

14

Washer

1

15

Adapter

1

16

O-Ring

1

17

Backup Ring

1

18

O-Ring

1

19

Casing

1

20

O-Ring

1

21

Plug

1

22

Stopper

1

23

Spool

1

24

Sleeve

1

25

Backup Ring

1

26

O-Ring

1

27

O-Ring

3

28

Plug

1

Wrench Size (mm)

:5

: 17 :6

: 24

: 32

W4-3-13

Tightening Torque N⋅m

(kgf⋅m, lbf⋅ft)

Remark

FRONT ATTACHMENT / Hose Rupture Valve

47 46 45

44 43 42 41

29

40

30

39 38

31

37

32

36 35 33 34 W1V1-04-03-001

W4-3-14

FRONT ATTACHMENT / Hose Rupture Valve

No.

Part Name

Q’ty

Wrench Size (mm)

29

Backup Ring

1

30

Spring

1

31

Holding Valve

1

32

Orifice

2

33

Body

1

34

O-Ring

1

35

O-Ring

1

36

Backup Ring

1

37

O-Ring

1

38

Backup Ring

1

39

Spring Seat

1

40

O-Ring

1

41

Piston

1

42

O-Ring

1

43

Cover

1

44

Stopper

1

45

Set Screw

1

:3

46

Lock Nut

1

: 10

47

Spring

1

Casing (19) and body (33) mounting socket bolt

4

: 32

:8

W4-3-15

Tightening Torque N⋅m

(kgf⋅m, lbf⋅ft)

Remark

FRONT ATTACHMENT / Hose Rupture Valve STRUCTURE OF HOSE RUPTURE VALVES FOR POSITIONING CYLINDER 9 3

4

5

6

7

10

11

8

12 13 14

15

16 17

2 18 1 19 50

20

49

21

48

22 23

47

24

46

25 26

45

27

44

28 29

43

30

42

31 32

41

33

40

34

39 35

38

36

37

WCJB-04-03-002

W4-3-16

FRONT ATTACHMENT / Hose Rupture Valve

No.

Part Name

Q’ty

1

Spacer

1

2

Plug

3

3

O-Ring

3

4

Backup Ring

1

5

O-Ring

1

6

Orifice

2

7

Backup Ring

2

8

O-Ring

1

9

Lock Nut

1

10

Poppet

1

11

Set Screw

1

12

Spring

1

13

O-Ring

1

14

Washer

1

15

Adapter

1

16

O-Ring

1

17

Backup Ring

1

18

O-Ring

1

19

Casing

1

20

O-Ring

1

21

Plug

1

22

Stopper

1

23

Spool

1

24

Sleeve

1

25

Backup Ring

1

26

O-Ring

1

27

O-Ring

3

28

Plug

1

29

Backup Ring

1

30

O-Ring

1

31

Plug

1

32

Orifice

1

Wrench Size (mm)

:5

: 17 :6

: 24

: 32

W4-3-17

Tightening Torque N⋅m

(kgf⋅m, lbf⋅ft)

Remark

FRONT ATTACHMENT / Hose Rupture Valve

50 49 48

47 46 45 44 43 42 41 33

40

34

39 35

38

36

37

WCJB-04-03-002

W4-3-18

FRONT ATTACHMENT / Hose Rupture Valve

No.

Part Name

Q’ty

Wrench Size (mm)

33

Spring

1

34

Holding Valve

1

35

Orifice

2

36

Body

1

37

O-Ring

1

38

O-Ring

1

39

Backup Ring

1

40

O-Ring

1

41

Backup Ring

1

42

Spring Seat

1

43

O-Ring

1

44

Piston

1

45

O-Ring

1

46

Cover

1

47

Stopper

1

48

Set Screw

1

:3

49

Lock Nut

1

: 10

50

Spring

1

Casing (19) and body (36) mounting socket bolt

4

: 32

:8

W4-3-19

Tightening Torque N⋅m

(kgf⋅m, lbf⋅ft)

Remark

FRONT ATTACHMENT / Hose Rupture Valve (Blank)

W4-3-20

FRONT ATTACHMENT / Operate Check Valve REMOVAL AND INSTALLATION OF OPERATE CHECK VALVE (FOR BLADE AND OUTRIGGER)

Outrigger Beam

Lock Pin

Float

Removal CAUTION: Lower the blade onto the ground before doing any work.

Outrigger

CAUTION: Secure the outrigger beam and the outrigger by using the lock pin before doing any work. 1. Remove bolts (1) (4 used) and washers (2) (4 used) from guard cover (3). Remove guard cover (3) from brackets (4) (2 used). : 19 mm

WCEB-04-04-002

1, 2 3

4

WCEB-04-02-001

5

6

2. Disconnect hoses (5) (4 used) from operate check valve (7). Cap the open ends. : 19 mm, 27 mm

7, 8

3. Remove socket bolts (10) (4 used) from piping (9). : 6 mm

9

4. Remove socket bolts (6) (4 used) from operate check valve (7). Remove operate check valve (7) and O-rings (8) (2 used) from cylinder (11). Cap the open ends. : 6 mm

10

5

11

WCEB-04-02-002

9

10

11 6

W4-4-1

7, 8

WCEB-04-04-001

FRONT ATTACHMENT / Operate Check Valve Installation 1. Apply grease onto O-rings (8) (2 used).

5

6

2. Install O-rings (8) (2 used) to operate check valve (7). 7, 8

3. Install operate check valve (7) to cylinder (11) with socket bolts (6) (4 used). : 6 mm : 26.5 N⋅m (2.7 kgf⋅m, 20 lbf⋅ft)

9

4. Connect piping (9) to operate check valve (7) with socket bolts (10) (4 used). : 6 mm : 26.5 N⋅m (2.7 kgf⋅m, 20 lbf⋅ft)

10

5

11

WCEB-04-02-002

9

5. Connect hoses (5) (4 used) to operate check valve (7). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

10

6. Install guard cover (3) to brackets (4) (2 used) with bolts (1) (4 used) and washers (2) (4 used). : 19 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

11 6

7, 8

WCEB-04-04-001

1, 2 3

4

WCEB-04-02-001

Outrigger Beam

Lock Pin

Float

11 Outrigger

WCEB-04-04-002

W4-4-2

FRONT ATTACHMENT / Operate Check Valve STRUCTURE OF OPERATE CHECK VALVE 1

2

3

4

5

6

7

8

9

10

11

12

13

WCEB-04-03-001

Item

Part Name

Q’ty

1

Plug

2

2

O-Ring

2

3

Plug

2

4

O-Ring

2

5

Spring

2

6

Sleeve

2

7

Poppet

2

8

Piston

2

9

O-Ring

1

10

Plug

1

11

Casing

1

12

Plug

1

13

O-Ring

Wrench Size (mm) : 6 mm

Tightening Torque N⋅m (kgf⋅m) (lbf⋅ft) 34.3±3.4 (3.5±0.3) (25±3)

Remark 1B P11

: 36 mm

500±50

(51±5)

(369±37) 1B P26

1B P18 : 36 mm

240±24

(24±2.4)

(18±2)

: 36 mm

240±24

(24±2.4)

(18±2) 1B P18

W4-4-3

FRONT ATTACHMENT / Operate Check Valve (Blank)

W4-4-4

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