Zx330 Workshop w1hh e 01

Manual No. : KM-1HH-E Vol. No. : W1HH-E-01

330 • 330LC • 350H • 350LCH • 370MTH Excavator Workshop Manual

Workshop Manual 330 • 330LC 350H • 350LCH 370MTH Excavator Service Manual (Manual No. KM-1HH-E) consists of the following three separate volumes; Technical Manual (Operational Principle) : Vol. No. TO1HH-E Technical Manual (Troubleshooting) : Vol. No. TT1HH-E Workshop Manual : Vol. No. W1HH-E

PRINTED IN SINGAPORE (PS) 2005.06

Zaxis330/350/370-WSM

1

1/7/05, 16:28

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: 81-29-832-7173 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

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

MANUAL COMPOSITION • This manual consists of three portions: the Techni-

• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.

• 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 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.

cal Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.

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

• SI Units (International System of Units) are used in 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 • This is the SAFETY ALERT SYMBOL. • When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. • Follow recommended precautions and safe operating practices.

001-E01A-0688

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.

• CAUTION also calls attention to safety messages in this manual.

• To avoid confusing machine protection with per-

sonal 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-E01C-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). SA-003

• 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.

• 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

PREPARE FOR EMERGENCIES • Be prepared if a fire starts or if an accident occurs. • Keep a first aid kit and fire extinguisher on hand. • Thoroughly read and understand the label attached on the fire extinguisher to use it properly.

• To ensure that a fire-extinguisher can be always used when necessary, check and service the fire-extinguisher at the recommended intervals as specified in the fire-extinguisher manual. • Establish emergency procedure guidelines to cope with fires and accidents. • Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone. 004-E01A-0437

SA-2

SA-437

SAFETY 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.

SA-438

• 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 atten-

tion 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

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.

S007-E01A-0435

SA-3

SA-435

SAFETY 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.

• Don’t leave parts and/or tools lying around the operator’s seat. Store them in their specified locations.

• Avoid storing transparent bottles in the cab. Don’t 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.

• Don’t leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode. 524-E01A-0000

SA-4

SAFETY USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury. • When you mounting and dismounting 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,

SA-439

steps, and handrails when mounting and dismounting the machine. 008-E01B-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. 009-E01A-0378

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. 011-E01A-0426

SA-6

SA-426

SAFETY OPERATE SEAT

ONLY

FROM

OPERATOR'S

• 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

SA-444

levers are in neutral. 012-E01B-0444

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. S013-E01A-0032

SA-7

SA-032

SAFETY 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-0379

SA-379

PROVIDE SIGNALS FOR FOBS 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 travel pedal/lever 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 travel pedals/levers are operated to the front. SA-491 017-E01A-0491

SA-8

SAFETY DRIVE MACHINE SAFELY • Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direction you wish to drive.

• Be sure to detour around any obstructions. • Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Don’t allow personnel to stay around the machine while traveling. SA-387

• Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.

• When driving up or down a slope, keep the bucket facing the direction of travel, approximately 200 to 300 mm (A) above the ground. • If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop traveling.

SA-388

SA-441

• Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure sage operation.

019-E01D-0492

SA-9

SA-589

SAFETY AVOID INJURY ACCIDENTS

FROM

ROLLAWAY

• 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. • Turn the auto-idle / acceleration seleclter and the H/P mode switch off. • Run the engine at slow idle speed without load for 5 minutes to cool down the engine. • Stop the engine and remove the key from the key switch. • Pull the pilot control shut-off lever to LOCK position. • Block both tracks and lower the bucket to the ground. Thrust the bucket teeth into the ground if you must park on a grade. • Position the machine to prevent rolling. • Park a reasonable distance from other machines.

SA-391

SA-392 020-E08A-0493

SA-10

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

SA-383

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. S021-E01A-0494

SA-11

SA-384

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.

SA-012

To avoid tipping:

• Be extra careful before operating on a grade. • Prepare machine operating area flat. • Keep the bucket low to the ground and close to the machine.

• Reduce operating speeds to avoid tipping or slipping.

• Avoid changing direction when traveling on grades.

• NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable. • Reduce swing speed as necessary when swinging loads.

• Be careful when working on frozen ground. • Temperature increases will cause the ground to become soft and make ground travel unstable. S025-E01B-0495

SA-12

SA-440

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 (10 ft) 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-381

029-E01A-0381

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-0014

SA-13

SA-014

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. • Turn auto-idle / acceleration selector and H/P mode 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. 033-E09B-0390

SA-14

SA-390

SAFETY 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

SA-018

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.

034-E01A-0496

SA-15

SA-019

SAFETY SAFETY TRANSPORTING • The danger of tipping is present when load-

ing/unloading the machine onto/from a truck or trailer bed.

• Be sure to observe local regulations when transporting the machine on public roads.

• Provide an appropriate truck or trailer for transporting the machine. Take the following precautions when loading / unloading the machine: 1) Select firm level ground. 2) Be sure to use a loading dock or ramp. 3) Be sure to have a signal person when loading/unloading the machine. 4) Always turn the auto-idle / acceleration selector and the H/P mode switch OFF when loading or unloading the machine, to avoid unexpected speed increase due to unintentional operation of a control lever. 5) Always select the slow speed mode with the travel mode switches. In the high speed mode, travel speed may automatically increase. 6) Avoid steering while driving up or down the ramp as it is extremely dangerous. If steering is unavoidable, first move back to the ground or flatbed, modify traveling direction, and begin to drive again. 7) Do not operate any levers besides the travel levers when driving up or down the ramp. 8) The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it. 9) Prevent possible injury from machine tipping while the upperstructure is rotating. 10) Keep the arm tucked under and rotate the upperstructure slowly for best stability. 11) Securely fasten chain or cables to the machine frame. Refer to "transporting" chapter in the operator's manual for details. S035-E08A-0395

SA-16

SA-395

SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents:

• Understand service procedures before doing work.

• Keep 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) 2) 3) 4) 5) 6) 7) 8) 9) 10)

Park the machine on a level surface. Lower the bucket to the ground. Turn the auto-idle / acceleration selecltor off. Run the engine at slow idle speed without load for 5 minutes. Turn the key switch to OFF to stop engine. Relieve the pressure in the hydraulic system by moving the control levers several times. Remove the key from the switch. Attach a “Do Not Operate” tag on the control lever. Pull the pilot control shut-off lever to the LOCK position. Allow the engine to cool.

SA-028

• 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 110 angle between the boom and arm. Securely support any machine elements that must be raised for service work. Never work under a machine raised by the boom. 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 frammable oil such as fuel oil and gasoline to clean parts or surfaces. Disconnect battery ground cable (-) before making adjustments to electrical systems or before welding on the machine. Illuminate your work area adequately but safely.

S500-E02B-0497

SA-17

SA-527

SAFETY • Use a portable safety light for working inside or under the machine.

• Make sure that the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. • Sufficiently illuminate the work site. Use a maintence 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

S500-E02B-0497

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.

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-18

SAFETY PREVENT PARTS FROM FLYING • Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in serious injury, blindness, or death.

• Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY.

• As pieces may fly off, be sure to keep body and face away from valve.

• Travel reduction gears are under pressure. • As pieces may fly off, be sure to keep body and

SA-344

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

STORE ATTACHMENTS SAFELY • Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.

• Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.

SA-034 504-E01A-0034

USE TOOLS PROPERLY • Use tools appropriate for the work to be done. • Makeshift tools, parts, and procedures can create safety hazards.

• For loosening and tightening hardware, use the correct size tools to avoid injury caused by slipping wrenches. • Use only recommended replacement parts. (See the parts catalog.)

S522-E01A-0040

SA-19

SA-040

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

SA-225

starting any maintenance or inspection work. 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-20

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

SA-292

507-E03A-0499

SA-044

SA-21

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. Check for Shorts:

• Short circuits can cause fires. • Clean and tighten all electrical connections. • Check before starting work for loose, kinked, hardened or frayed electrical cables and wires.

• Check before starting work 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, ac-

cumulated 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. S508-E02B-0019

SA-22

SA-019

SAFETY Check Emergency Engine Stop Switch:

• If a fire breaks out, failure to release pressurized air inside the hydraulic tank will escalate fire, hampering fire fighting. • Check the emergency engine stop switch function every 250 hours: 1) Start the engine and run it at slow Idle. 2)

Turn the emergency engine stop switch to the EMERG. STOP position.

3)

Confirm that both engines stop and that pressurized air inside the hydraulic oil tank is released (a hissing sound should be heard).

• If any abnormalities are found, be sure to repair them before operating the machine. Check Heat Shields:

• Damaged or missing heat shields may lead to fires. • Damaged or missing heat shields must be repaired or machine.

replaced

before

operating

the

S508-E02B-0019

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 and/or the front

SA-393

window cannot be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer to the explanation page on “EMERGENCY EXIT” in Operator’s Manual. 518-E02B-0393

SS-1510

SA-23

SAFETY 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

PRECAUTIONS GRINDING

FOR

WELDING

SA-016

AND

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

SA-818

523-E01A-0818

AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders.

• Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. • Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc..

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids. them thoroughly with nonflammable solvent before welding or flame cutting them.

• Clean

510-E01B-0030

SA-24

SA-030

SAFETY REMOVE PAINT BEFORE WELDING OR HEATING • Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.

• Avoid potentially toxic fumes and dust. • Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly.

• Remove paint before welding or heating: 1) If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2) If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

SA-029

511-E01A-0029

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.

• 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-E01C-0032

SA-25

SA-032

SAFETY SERVICE AIR CONDITIONING SYSTEM SAFELY • If spilled onto skin, refrigerant may cause a cold contact burn.

• Refer to the freon container for proper use when servicing the air conditioning system.

• Use a recovery and recycling system to avoid venting freon into the atmosphere.

• Never let the freon stream make contact with the skin. SA-405 513-E01A-0405

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. S515-E01A-0309

SA-26

SA-309

SAFETY DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the en-

vironment 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.

SA-226

S516-E01A-0226

BEFORE RETURNING THE MACHINE TO THE CUSTOMER • After maintenance or repair work is complete, con-

firm that: • The machine is functioning properly, especially the safety systems. • Worn or damaged parts have been repaired or replaced

S517-E01A-0435

SA-27

SA-435

SAFETY (Blank)

SA-28

SECTION AND GROUP CONTENTS

SECTION 1 GENERAL INFORMATION Group 1 Precautions for Disassembling and Assembling Group 2 Tightening Torque Group 3 Painting

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 Pilot Shut-Off Valve Group 9 Shockless Valve Group 10 Solenoid Valve

SECTION 3 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Center Joint Group 4 Track Adjuster Group 5 Front Idler Group 6 Upper and Lower Roller Group 7 Track 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.

COPYRIGHT(C)2005 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved

SECTION 4 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder

SECTION 5 ENGINE

TECHNICAL MANUAL (Operational Principle) SECTION 1 GENERAL Group 1 Specifications Group 2 Component Layout Group 3 Component Specifications SECTION 2 SYSTEM Group 1 Control System Group 2 Hydraulic System Group 3 Electrical System

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Pilot Valve Group 5 Travel Device Group 6 Others (Upperstructure) Group 7 Others (Undercarriage)

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

SECTION 5 TROUBLESHOOTING Group 1 General Group 2 Component Layout Group 3 Troubleshooting A Group 4 Troubleshooting B Group 5 Troubleshooting C Group 6 Electrical System Inspection Group 7 ICX

SECTION 1

GENERAL INFORMATION — 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 Torque 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

1HHW-1-1

(Blank)

1HHW-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

M104-07-021

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. Apply oil to the sliding surface (C) on seal ring (A). (2) Check the slide surface (C) 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. (3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring.

Correct

(4) After installing the floating seal, check that seal ring surface (C) is parallel with seal mating face (D) by measuring the distances (C) and (D) at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating.

D

W105-03-05-020

Incorrect

a

a

C

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 Torque TIGHTENING TORQUE SPECIFICATION No. 1 2 3 4 5 6

7

8 9 10 11 12 13 14 15 16

17

18

19

20

21 22

Descriptions Engine cushion rubber mounting bolt (Fan Side) Engine bracket mounting bolt (Pump Side) Engine oil filter mounting bolt Radiator mounting bolt Hydraulic oil tank mounting bolt Fuel tank mounting bolt

ORS fittings for hydraulic hoses and piping

Pump mounting bolt Control valve mounting bolt Control valve bracket mounting bolt Swing device mounting bolt Swing motor mounting bolt Battery mounting nut Cab mounting nut Swing bearing mounting bolt to upperstructure Swing bearing mounting bolt to undercarriage ZAXIS330, 330LC, 350H, Travel device 350LCH mounting bolt ZAXIS370MTH ZAXIS330, 330LC, 350H, Sprocket 350LCH mounting bolt ZAXIS370MTH ZAXIS330, 330LC, 350H, Upper roller 350LCH mounting bolt ZAXIS370MTH ZAXIS330, 330LC Lower roller ZAXIS350H, 350LCH mounting bolt ZAXIS370MTH ZAXIS330, 330LC Track shoe bolt ZAXIS350H, 350LCH ZAXIS370MTH ZAXIS330, 330LC Track guard ZAXIS350H, 350LCH mounting bolt ZAXIS370MTH Coupling, Jubilee and T-bolt clamp of low pressure piping

23

Front pin-retaining bolt and nut

24

Counterweight mounting bolt

Bolt Dia Wrench Q’ty Size (mm) mm 18 4 27 10 10 17 12 8 19 10 4 17 16 4 24 18 4 27 16 6 24 3 −12UNF 1− 36 16 7 −12UNF 1− 41 16 11 −12UNF 1− 50 16 10 8 17 16 4 24 16 4 24 22 12 32 12 12 10 10 2 17 16 4 24 27 36 36 27 36 36

ZAXIS330, 330LC ZAXIS350H, 350LCH, 370MTH

Nxm 400 60 90 50 210 300 210

Torque (kgfxm) (41) (6) (9) (5.1) (21) (30.5) (21)

(lbfxft) (300) (43) (65) (37) (151) (220) (151)

175

(18)

(130)

210

(21.5)

(155)

255

(26)

(188)

50 210 210 640 90 50 210 1226 1226

(5.1) (21.5) (21.5) (65) (9.2) (5.1) (21.5) (125) (125)

(37) (155) (155) (470) (66) (37) (155) (905) (905)

20

40

30

620

(63)

(460)

22

40

32

740

75

(540)

20

32

30

490

(50)

(360)

22

48

32

740

75

(540)

16

16

24

270

(27.5)

(200)

18 20 20 22 22 22 24 20 20 22 8 6 18 20 22 32 36

16 64 72 64 360 384 392 8 24 28 － － － － － 4 4

27 30 30 32 30 30 32 30 30 32 13 11 27 30 32 50 55

390 670 670 740 1130 1130 1370 620 620 740

40 (68) (68) 75 (115) (115) (140) (63) (63) (75)

(290) (490) (490) (540) (830) (830) (1010) (460) (460) (540)

NOTE 1.Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to

W1-2-1

10.3 to 12.4 (1.05 to 1.26) (7.59 to 9.11)

5.9 400 550 750 2260 2840

(0.6) (41) (56) (76.5) 230 290

(4.3) (300) (405) (550) (1665) (2100)

reduce friction coefficient of them. (Except for Sprocket mounting bolt.)

GENERAL / Tightening Torque 2.Make sure bolt and nut threads are clean before installing.

W1-2-2

GENERAL / Tightening Torque 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 T Bolt Bolt Wrench Hexagon Wrench Dia. Size N⋅m (kgf⋅m) Size M 8 13 6 29.5 (3) M 10 17 8 64 (6.5) M 12 19 10 108 (11) M 14 22 12 175 (18) M 16 24 14 265 (27) M 18 27 14 390 (40) M 20 30 17 540 (55) M 22 32 17 740 (75) M 24 36 19 930 (95) M 27 41 19 1370 (140) M 30 46 22 1910 (195) M 33 50 24 2550 (260) M 36 55 27 3140 (320)

H Bolt, Socket bolt (lbf⋅ft) (22) (47) (80) (130) (195) (290) (400) (540) (690) (1010) (1410) (1880) (2310)

N⋅m 19.5 49 88 137 205 295 390 540 690 1030 1420 1910 2400

W1-2-3

(kgf⋅m) (lbf⋅ft) (2) (14.5) (5) (36) (9) (65) (14) (101) (21) (152) (30) (220) (40) (290) (55) (400) (70) (505) (105) (760) (145) (1050) (195) (1410) (245) (1770)

M Bolt N⋅m 9.8 19.5 34 54 78 118 167 215 275 390 540 740 930

(kgf⋅m) (1) (2) (3.5) (5.5) (8) (12) (17) (22) (28) (40) (55) (75) (95)

(lbf⋅ft) (7.2) (14.5) (25.5) (40) (58) (87) (123) (159) (205) (290) (400) (540) (690)

GENERAL / Tightening Torque 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 alter-

Tighten diagonally 1

1st to 4th

Tighten from center and diago12

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 Torque 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 Torque 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 Hose Fittings 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) 93 (9.5,69) 137 (14.0,101) 175 (18.0,129) 205 (21.0,151) 24.5 (2.5,18) 29.5 (3.0,21.5) 39 (4.0,28.5) 93 (9.5,69) 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 Hose Fittings 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 To ensure safe operation, be sure to conduct periodic inspection of the machine. In addition, the parts listed below, if defective, may pose serious safety/fire hazards. It is very difficult to gauge the extent of deterioration, fatigue, or weakening of the parts listed below simply by visual inspection alone. For this reason, replace these parts at the intervals shown in the table below. However, if any of these parts are found to be defective, replace before starting operation, regardless of the interval. Also, when replacing hoses, check the clamps for deformation, cracks, or other deterioration, and replace as necessary. Be sure to perform periodic inspection of all hoses, as shown below, and replace or retighten any defective parts found, as necessary. Consult your authorized dealer for correct replacement.

Periodic Replacement Parts

Engine

Base Machine Hydraulic System Front Attachment

Fuel hose (Fuel tank to filter) Fuel hose (Fuel tank to injection pump) Oil filter hose (Engine to oil filter) Heater hose (Heater to engine) Pump suction hose Pump delivery hose Swing 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 Surfaces to Be Painted • Main surface of upperstructure Bed cover Tool box cover Inner face • Front attachment • Track (undercarriage) • Floor plate • Rear left portion of cab

Painting Colour YR-01 [TAXI yellow] High Grade Beige YR-01 [TAXI yellow] Grey YR01 [TAXI yellow] N1.0 [Black] M/F cation colour YR-01 [TAXI yellow]

Final painted colour • Inside and outside surface of cab

High Grade Beige [KASAI PAINT LF-113-230B (Charcoal series black, half glossy)] [N2.0 (Black) ] [N2.0 (Black) ]

• Right window beam • Suspension lifter (chair bottom) • Lever (Travel, lock, foot rest) • Engine cover • Ladder rail on right side of upperstructure • Mirror stay • Antislip cover

High Grade Black High Grade Black High Grade Black KASAI PAINT Amilack 1400 deep black.

Cab Inside and Outside

Engine Cover

Engine Cover

Right Window Beam Right Ladder Rail

Mirror Stay

900 350 Main Surface of Upperstructure

Tool Box Cover

Bed Cover

W178-01-03-002

W1-3-1

720 Main Surface of Upperstructure

W178-01-03-001

GENERAL / Painting A

YR-01 (TAXI Yellow)

Out Surface of Hinge Swing Portion YR-01 (TAXI Yellow)

185

B

Door Catch Cover YR-01 (TAXI Yellow) 720

Section A

W178-01-03-003

5

Section B Mask Garnished Portion

YR-01(TAXI Yellow)

Door

Panel Behind the Door 10 Painting Area of the Door YR-01 (TAXI Yellow)

W178-01-03-004

W178-01-03-005

Antislip Cover KASAI PAINT Amilack 1400 Deep Black

Front Attachment YR-01 (TAXI Yellow)

W178-01-03-007

Upper Side of Frame

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

W1HH-01-03-001

Track (Undercarriage) N1.0 (Black)

W178-01-03-008

W1-3-2

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MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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SECTION 2

UPPERSTRUCTURE —CONTENTS— Group 1 Cab

Group 5 Control Valve

Remove and Install Cab.............................W2-1-1 Dimensions of the Cab Glass.....................W2-1-8

Group 2 Counterweight Remove and Install Counterweight..........................................W2-2-1

Group 3 Main Frame Remove and Install Main Frame..............................................W2-3-1

Group 4 Pump Device Remove and Install Pump Device ..............W2-4-1 Disassemble Pump Device ........................W2-4-2 Assemble Pump Device .............................W2-4-8 Disassemble Main Pump ........................W2-4-16 Assemble Main Pump ............................W2-4-24 Disassemble Regulator............................W2-4-38 Assemble Regulator.................................W2-4-40 Disassemble and Assemble Pilot Pump .............................................W2-4-42 Maintenance Standard .............................W2-4-46

Remove and Install Control Valve ............. W2-5-1 Disassemble Control Valve (1) .................. W2-5-4 Assemble Control Valve (1) ....................... W2-5-6 Disassemble Control Valve (2) .................. W2-5-8 Assemble Control Valve (2) ..................... W2-5-10 Disassemble Control Valve (3) ................ W2-5-12 Assemble Control Valve (3) ..................... W2-5-14 Disassemble Control Valve (4) ................ W2-5-18 Assemble Control Valve (4) ..................... W2-5-20 Disassemble Control Valve (5) ................ W2-5-22 Assemble Control Valve (5) ..................... W2-5-24 Disassemble Control Valve (6) ................ W2-5-26 Assemble Control Valve (6) ..................... W2-5-28 Structure of Valves .................................. W2-5-30

Group 6 Swing Device Remove and Install Swing Device ............. W2-6-1 Disassemble Swing Device ....................... W2-6-4 Assemble Swing Device .......................... W2-6-14 Disassemble Swing Motor ....................... W2-6-22 Assemble Swing Motor............................ W2-6-26 Disassemble and Assemble Parking Brake Release Valve ................ W2-6-30 Maintenance Standard ............................ W2-6-31

1HHW-2-1

Group 7 Pilot Valve

Group 10 Solenoid Valve

Remove and Install Right Pilot Valve ................................................W2-7-1 Remove and Install Left Pilot Valve ................................................W2-7-5 Remove and Install Travel Pilot Valve .....................................W2-7-9 Disassemble Right and Left Pilot Valves (Up to serial No.320880) ........................W2-7-12 Disassemble Right and Left Pilot Valves (Serial No.320881 and up) .....................W2-7-16 Assemble Right and Left Pilot Valves (Up to serial No.320880) ........................W2-7-20 Assemble Right and Left Pilot Valves (Serial No.320881 and up) .....................W2-7-24 Disassemble Travel Pilot Valve (Suitable for the machine before March in 2003)..............W2-7-28 Disassemble Travel Pilot Valve (Suitable for the machine after April in 2003.) ..................W2-7-32 Assemble Travel Pilot Valve (Suitable for the machine before March in 2003)..............W2-7-36 Assemble Travel Pilot Valve (Suitable for the machine after April in 2003.) ..................W2-7-42

Remove and Install Solenoid Valve Unit ............................... W2-10-1 Disassemble Propotional Solenoid Valves (SC, SI and SG) ......................... W2-10-4 Assemble Propotional Solenoid Valves (SC, SI and SG) ......................... W2-10-6 Disassemble Proportional Solenoid Valves (Torque Control Solenoid Valve, Maximum Pump2 Flow Rate Limit Solenoid Valve) ..................................... W2-10-8 Assemble Proportional Solenoid Valves (Torque Control Solenoid Valve, Maximum Pump2 Flow Rate Limit Solenoid Valve) ................................... W2-10-10 Disassemble and Assemble Pilot Relief Valve ................................. W2-10-12

Group 8 Pilot Shut-Off Valve Remove and Install Pilot Shut-off Valve...................................W2-8-1 Disassemble Pilot Shut-off Valve ...............W2-8-4 Assemble Pilot Shut-off Valve ....................W2-8-6

Group 9 Shockless Valve Remove and Install Shockless Valve .......................................W2-9-1 Disassemble and Assemble Shockless Valve .......................................W2-9-2

1HHW-2-2

UPPERSTRUCTURE / Cab REMOVE AND INSTALL CAB

ZAXIS330, 330LC, 350H, 350LCH:

Removal 1. Remove nuts (2) to remove seat (1). : 17 mm

2

1

W178-02-07-006

2. Remove bolts (4) behind the cab to remove rear box (3). : 17 mm

ZAXIS370MTH:

2

3. Raise duct (5) to remove it. 1

W1HH-02-01-004

3 4 5

W178-02-01-012

W2-1-1

UPPERSTRUCTURE / Cab 4. Remove filter (6) to remove screws (7) with a screwdriver, then remove duct (8) from the cab.

6

7 8

W178-02-01-013

5. Disconnect harness connectors (10, 11, 12, and 13) on the right side in the cab and remove bolt to remove ground (9) at rear inside of the cab. : 17 mm 9

10 11 12

13

W178-02-01-014

6. Remove washer vinyl hose (14) at rear inside of the cab. 14

W178-02-01-015

16

7. Remove cap (15) from duct cover (17) with a screwdriver. Use a screwdriver to loosen screws (16) to remove duct cover (17).

17

15

W178-02-01-016

W2-1-2

UPPERSTRUCTURE / Cab 8. Remove screws (18) and bolts (21) to remove duct (19) and duct (20). : 17 mm

18

Mating Surface of Duct

19

20

CAUTION: Cab weight: ZAXIS330, 330LC, 350H, 350LCH: 290 kg (640 lb) ZAXIS370MTH: 395 kg (870 lb)

21

W178-02-01-017

ZAXIS330, 330LC, 350H, 350LCH

22

9. Attach the cab upside with lifting straps (22).

W178-02-01-018

ZAXIS370MTH:

A A

W1HH-02-01-003

Section A-A Lifting Strap

W1HH-02-01-002

W2-1-3

UPPERSTRUCTURE / Cab 10. Remove cab mounting bolts (23) and nut (24) from the cab. : 17 mm : 24 mm : 8 mm

23

24

W157-02-01-010

11. Carefully hoist the cab to remove it.

W157-02-01-001

W2-1-4

UPPERSTRUCTURE / Cab Installation CAUTION: Cab weight: ZAXIS330, 330LC, 350H, 350LCH: 290 kg (640 lb) ZAXIS370MTH: 395 kg (870 lb) 1. Attach the cab with lifting straps to hoist it by crane. W157-02-01-001

23

2. Install bolts (23) and nuts (24) to the cab. : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) : 24 mm : 205 N⋅m (21 kgf⋅m, 150 Ibf⋅ft) : 8 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

24

W157-02-01-010

6

7

3. Install duct (8) to the rear console of the cab with screws (7). Install filter (6) into duct (8). : 4.9 N⋅m (0.5 kgf⋅m, 3.6 Ibf⋅ft)

8

W178-02-01-013

4. Install harness connectors (10, 11, 12 and 13) at the right side of the cab and install ground (9) with bolt at rear side in the cab. : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

9

10 11 12

13

W178-02-01-014

W2-1-5

UPPERSTRUCTURE / Cab 5. Connect washer vinyl hose (14) at the rear of the cab inside.

14

W178-02-01-015

6. Aligning the mounting hole for duct (5). While pressing duct downward, install it.

3 4 5

7. Install rear box (3) with bolts (4). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

W178-02-01-012

8. Install duct (20) with bolts (21). Install duct (19) into duct (20) and fix them with bolt (18). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

18

Mating Surface of Duct

19

20

W2-1-6

21

W178-02-01-017

UPPERSTRUCTURE / Cab 9. Install duct cover (17) with screws (16). Install caps (15) onto duct cover (17).

16 17

15

W178-02-01-016

ZAXIS330, 330LC, 350H, 350LCH:

10. Secure seat (1) with nut (2). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

2

1

ZAXIS370MCH:

W178-02-07-006

2

1

W1HH-02-01-004

W2-1-7

UPPERSTRUCTURE / Cab DIMENSIONS OF THE CAB GLASS A

NOTE: Unit: mm (1 mm=0.039 in)

Chamfer Here 67

303.5

Chamfer along the periphery unless otherwise specified

11

R2

R35

R98 4-φ13 0-1 R3018 30

405

Section A

Chamfer both sides

W178-02-01-019

375 238

612

51

R118 (5 mm) 343.5

148.5

196 100 50

R70

370.5

W178-02-01-006

Along the Periphery c1

Along the Periphery

W178-02-01-002

Suitable for the standard machine after March in 2002 B

c1

(60.3)

261.6±1

(9.4)

R42

R72

Section C

W178-02-01-019

366 R2992

C

546±1

14

733

R92 (4 mm)

R58 R58 170.6 R11508

70 50 R1808

882.5

R42

997

321.9±1

(4 mm)

R308

W178-02-01-024

Remove sharp edges along the periphery

R1898 R258

100

150

Section B

943 W178-02-01-007

W2-1-8

W178-02-01-019

UPPERSTRUCTURE / Cab Unit: mm Chamfer Slightly unless the Periphery Polish Chamfered

Chamfer Here Chamfer Here

85.4 343.3

213

R105 R10

R72 R105

(4 mm)

Chamfer Slightly unless the Periphery Polish Chamfered

C

39.5

D 733

733

R2465

2-φ12.2

Section C and D

(4 mm)

+0.5

-0

6.754°

40

W178-02-01-019

Polish Chamfer the Both Fringes 289.5 50

3-R4

2-R4 86.9

50

50

556.3 50

W178-02-01-011

423 W178-02-01-008

366.1 R12

104.5

R95

(5 mm) 982.7

Chamfer along the Periphery

W178-02-01-004

R2002 872

R123

R5 for 3 Places

38.2 51

364.7 R2475 (5 mm)

Chamfer along the Periphery

R115

888.58 W178-02-01-010

W2-1-9

R14 470.6 W178-02-01-009

UPPERSTRUCTURE / Cab Suitable for the standard machine after March in 2002

W178-02-01-005

A 753

R63

R63 610.5 490 (4 mm)

R115

R115 R167

50 50 512.5 R167 W178-02-01-025

Remove Sharp edges along the periphery

Section A

W2-1-10

W178-02-01-019

UPPERSTRUCTURE / Cab Remove Cab Glass Procedures to remove left-hand cab glass, lower glass of the door and upper front glass

Mounting Rubber Section

Mounting Rubber

CAUTION: When removing broken or cracked glass beware of the danger of glass shards that may cause serious injury. Before removing, gummed tape or similar should be used to tape the broken or cracked glass ready to reinforce them so as to prevent injury from occurring. Be sure to remove all glass fragments. Take protective measures before removing. Reinforce broken or cracked glass with gummed tape to assist in safe removal.

Cab Seal Rubber

W178-02-01-022

1. Insert bamboo spatula into position A in mounting rubber to pry the mounting rubber apart along all periphery. It is easier to remove glass when air is entered between cab and mounting rubber. 2. Tap glass from the side in cab by palm of hand to take the glass off. Two men are required to do the work.

Glass

W178-02-01-004

A

Mounting Rubber

IMPORTANT: Be sure to install the cab glass and mounting rubber using the special bonding agent. The cab glass may fall if the special bonding agent is not used. The cab glass assembly cannot be replaced individually. Be sure to change the cab glass as an assembly. The upper front glass is arched-fringed. If this glass needs to be replaced, contact with the nearest HITACHI Office to replace it as an assembly.

W2-1-11

Glass

Cab Seal Rubber

W178-02-01-022

UPPERSTRUCTURE / Cab Procedures to Remove Right-Hand Cab Glass

Mounting Rubber Section Cab Inside

1. Insert a bamboo spatula into position A in mounting rubber to pry the mounting rubber apart along all periphery. It is easier to remove the glass when air is entered between cab and mounting rubber.

Glass

Mounting Rubber

A Cab

2. Tap glass from the side in cab by palm of the hand to take the glass off. Two men are required to do the work.

W216-02-01-005

W178-02-01-002

Mounting Rubber Section Mounting Rubber

Method to remove rear side cab glass 1. Remove stopper (groove rubber) with a minus screwdriver.

Glass

Cab Inside A

2. Insert a bamboo spatula into position A in mounting rubber to pry the mounting rubber apart along all periphery.

Stopper (Groove Rubber) A

Cab W216-02-01-003

3. Tap glass from the side in cab by palm of the hand to take the glass off. Two men are required to do the work.

W178-02-01-005

W2-1-12

UPPERSTRUCTURE / Cab Cab Glass Installation Procedure Procedure of installing left-hand cab glass, lower glass of the door and upper front glass.

Left-Hand Cab Glass

A

IMPORTANT: Be sure to install the cab glass and mounting rubber using the special bonding agent. The cab glass may fall if the special bonding agent is not used. The cab glass assembly can’t be replaced individually. Be sure to change the cab glass as an assembly. The upper front glass is arched-fringed. If this glass needs to be replaced, replace it as an assembly.

CSE Braid

Seal Rubber

Put Connect End in Center of Glass Edge and Then Stick It. W178-02-01-021

1. Install the seal rubber on the left-hand cab glass and lower glass of the door.

Lower Glass of Door 50

Section A A CSE Braid

Seal Rubber 10

10

Mounting Rubber Section

Mounting Rubber

W178-02-01-020

Cab Glass

5 W178-02-01-023

Cab

2. When the mounting rubber is already on the glass, pull and fasten the mounting rubber onto the mounting face of cab.

Seal Rubber

W178-02-01-022

W178-02-01-004

W2-1-13

UPPERSTRUCTURE / Cab Procedures of installing right-hand cab glass

Mounting Rubber Section

IMPORTANT: Be sure to install the cab glass and mounting rubber using the special bonding agent. The cab glass may fall if the special bonding agent is not used. The cab glass assembly can’t be replaced individually. Be sure to change the cab glass as an assembly. The upper front glass is arched-fringed. If this glass needs to be replaced, replace it as an assembly. 1. Install the mounting rubber into the surrounding of cab glass. Bond the connectors of mounting rubber with the bonding agent (Cemedine 366 Standard or equivalent).

Cab Glass

Mounting Rubber

Cab

W216-02-01-005

NOTE: Rubber aging will cause the contraction of rubber, be sure to leave a little extra, install by pressing with hands. 2. Put and fasten the mounting rubber on the mounting face of cab after installing rubber.

W178-02-01-002

Mounting Rubber Section

Mounting Rubber

Procedures of installing rear cab glass IMPORTANT: Be sure to install the cab glass and mounting rubber using the special bonding agent. The cab glass may fall if the special bonding agent is not used. The cab glass assembly can’t be replaced individually. Be sure to change the cab glass as an assembly. The upper front glass is arched-fringed. If this glass needs to be replaced, replace it as an assembly. 1. Insert mounting rubber around the cab glass. Install the connectors or mounting rubber with the bonding agent (Cemedine 366 Standard or equivalent). NOTE: Rubber aging will cause the contraction of rubber, be sure to leave a little extra, install by pressing with hands. 2. After installing the glass assembly on the cab, insert the stopper into rubber.

W2-1-14

Cab Glass

Stopper

Cab W216-02-01-003

W178-02-01-005

UPPERSTRUCTURE / Counterweight REMOVE AND INSTALL COUNTERWEIGHT

1

Removal

3

CAUTION: Counterweight weight: ZAXIS330, 330LC: 6800 kg (15000 lb) ZAXIS350H, 350LCH 370MTH: 7550 kg (16650 lb) 1. Remove caps (1) from counterweight (3) top. Install sling bolts (FLENO RINK BOLT B-42, M42, Pitch 4.5) to counterweight (3).

W178-02-02-001

Wire Rope

Sling Bolt

2. Attach wire ropes to the sling bolts as illustrated. Take up slack of wire ropes.

W178-02-02-002

3. Remove bolts (2) and washers (4). Hoist and remove counterweight (3). ZAXIS330, 330LC: : 50 mm ZAXIS350H, 350LCH, 370MTH: : 55 mm

3

4 2

W178-02-02-003

W2-2-1

UPPERSTRUCTURE / Counterweight Installation CAUTION: Counterweight weight: ZAXIS330, 330LC: 6800 kg (15000 lb) ZAXIS350H, 350LCH, 370MTH: 7550 kg (16650 lb) 1. Hoist and install counterweight (3) onto the main frame. Install washers (4) and tighten bolts (2) to counterweight (3) temporarily.

3 2

ZAXIS330, 330LC: : 50 mm ZAXIS350H, 350LCH, 370MTH: : 55 mm

4 W178-02-02-003

2. Remove the wire ropes. Tighten bolts (2) by using a power wrench and torque wrench. ZAXIS330, 330LC: : 50 mm : 2260 N⋅m (230 kgf⋅m, 1660 lbf⋅ft) ZAXIS350H, 350LCH, 370MTH: : 55 mm : 2840 N⋅m (290 kgf⋅m, 2100 lbf⋅ft)

Torque Wrench Power Wrench

1

W178-02-02-004

3

W178-02-02-001

3. Remove the sling bolts. Install caps (1) to counterweight (3).

W2-2-2

UPPERSTRUCTURE / Main Frame REMOVE AND INSTALL MAIN FRAME IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

5

Removal CAUTION: Cab weight: ZAXIS330, 330LC, 350H, 350LCH: 290 kg (640 lb) ZAXIS 370MTH: 395kg (870 lb) W157-02-01-001

1. Remove cab (5). (Refer to “Remove and Install Cab” in this section.) : 24 mm, 17 mm, 13 mm : 8 mm 6

CAUTION: Counterweight weight: ZAXIS330, 330LC: 6800 kg (15000 lb) ZAXIS350H, 350LCH, 370MTH: 7550 kg (16650 lb)

W178-02-02-002

2. Remove counterweight (6). (Refer to “Remove and Install Counterweight” in this section.) ZAXIS330, 330LC: : 50 mm ZAXIS350H, 350LCH, 370MTH: : 55 mm

W2-3-1

UPPERSTRUCTURE / Main Frame CAUTION: Front attachment weight: ZAXIS330, 330LC: 6440 kg (14200 lb) ZAXIS350H, 350LCH: 7050 kg (15540 lb) ZAXIS 370MTH: 7120 kg (15700 lb)

7

3. Remove front attachment assembly (7). (Refer to “Remove and Install Front Attachment” in this section.) : 19, 27, 30, 41 mm W105-02-03-002

4. Remove all hoses from upper side of the center joint. Remove stopper (4) and bolts (3) from the center joint. : 17, 22, 27, 41 mm

3

4

CAUTION: Upperstructure weight: 6560 kg (14460 lb) 5. Attach wire ropes to the rear (counterweight bracket) of main frame and boom bracket. Take up slack of wire ropes. If chain block (1) is used, it is not only easy to adjust the length of wire rope, but also easy to level the main frame.

W173-03-03-001

Rear of Main Frame

Boom Bracket

W105-02-03-004

W105-02-03-005

1

W157-02-03-001

W2-3-2

UPPERSTRUCTURE / Main Frame 6. The mounting angle of swing bearing is specified. (Refer to W3-1.) Put the matching marks on the upperstructure and the outer race of swing bearing. Remove bolt (2) from the swing bearing. : 41 mm

2

W105-02-03-007

7. Adjust chain block (1) in order to level the main frame. Hoist and remove the main frame from the undercarriage.

1

W157-02-03-002

W2-3-3

UPPERSTRUCTURE / Main Frame Installation CAUTION: Upperstructure weight: 6560 kg (14460 lb)

1

1. Attach wire ropes to the main frame. Adjust chain block (1) in order to level the main frame. Hoist and install the main frame to the undercarriage. As for lifting method, refer to the “Removal” section.

W157-02-03-002

2. Align the matching marks on the upperstructure and the outer race of swing bearing. Install and temporarily tighten bolts (2) to the swing bearing. Remove wire ropes and tighten bolts (2) to the swing bearing. : 41 mm : 1226 N⋅m (125 kgf⋅m, 900 lbf⋅ft)

2

W105-02-03-007

3. Install all hoses to the center joint. : 17 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 27 mm : 118 N⋅m (12 kgf⋅m, 87 lbf⋅ft) : 41 mm : 295 N⋅m (30 kgf⋅m, 220 lbf⋅ft)

3 4

4. Install stopper (4) to the center joint with bolts (3). : 22 mm : 54 N⋅m (5.6 kgf⋅m, 41 lbf⋅ft)

W173-03-03-001

W2-3-4

UPPERSTRUCTURE / Main Frame CAUTION: Cab weight: ZAXIS330, 330LC, 350H, 350LCH: 290 kg (640 lb) ZAXIS370MTH: 395 kg (870 lb)

5

5. Install cab (5). (Refer to “Remove and Install Cab” in this section.) : 24 mm : 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) : 8 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

W157-02-01-001

CAUTION: Counterweight weight: ZAXIS330, 330LC: 6800 kg (15000 lb) ZAXIS350H, 350LCH, 370MTH: 7550 kg (16650 lb) 6. Install counterweight (6). (Refer to “Remove and Install Counterweight” in this section.) 6

ZAXIS330, 330LC: : 50 mm : 2260 N⋅m (230 kgf⋅m, 1660 lbf⋅ft) ZAXIS350H, 350LCH, 370MTH: : 55 mm : 2840 N⋅m (290 kgf⋅m, 2100 lbf⋅ft)

W178-02-02-002

W2-3-5

UPPERSTRUCTURE / Main Frame CAUTION: Front attachment assembly weight: ZAXIS330, 330LC: 6440 kg (14200 lb) ZAXIS350H, 350LCH: 7050 kg (15540 lb) ZAXIS370MTH: 7120 kg (15700 lb) 7. Install front attachment assembly (7). Add hydraulic oil. (Refer to “Remove and Install Front Attachment” in this section.) : 19 mm : 44 N⋅m (4.5 kgf⋅m, 33 lbf⋅ft) : 27 mm : 295 N⋅m (30 kgf⋅m, 220 lbf⋅ft) : 30 mm : 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

7 W105-02-03-002

8. Start the engine. Set the front attachment in posture for checking hydraulic oil level in its tank. Check the hydraulic oil level and any oil leakage. M104-07-021

W2-3-6

UPPERSTRUCTURE / Pump Device REMOVE AND INSTALL PUMP DEVICE IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Air Bleed Plug

Removal 1. Remove the connectors from the pump device. CAUTION: Pump device weight: 205 kg (452 lb) 2. Remove all hoses and pipes from the pump device. : 17 mm, 27 mm, 36 mm : 10 mm W110-02-04-002

3. Install eyebolts (M12, Pitch 1.75 mm) to the pump device and hold the pump device. 4. Remove the pump device mounting bolts and remove the pump device. : 17 mm Installation 1. Install eyebolts on the pump device. Hoist the pump device. 2. Install the pump device with the pump device mounting bolts. 3. Install all hoses and pipes to the pump device. 4. Install the connectors to the pump device. 5. Remove the air bleed plugs (2 used) on top of the regulators. Fill hydraulic oil. (Refer to W1-1-2.) 6. After completing the work, check hydraulic oil level and any oil leakage.

W2-4-1

Wrench Size (mm) : 36 : 27 : 10 : 17

Tightening Torque Remarks N⋅m (kgf⋅m) (lbf⋅ft) 175 (18) (130) Hose 93 (9.5) (69) Hose 88 (9) (65) Bolt 49 (5) (36) Bolt

UPPERSTRUCTURE / Pump Device DISASSEMBLE PUMP DEVICE

14 13 20

12

13

22 15

13

21

18 17 16

22 19 10 9 7 8

22 11

1

6 5 3 4

2 37

19

36 32

23

33

10

31 1

39

22

2

34 35

42

40

41

28

45

38 24

43 26 30

25

27

44

29

W1HH-02-04-004

12345678910 11 12 -

Drive Gear (2 Used) Retaining Ring (2 Used) N Sensor O-Ring Washer Socket Bolt Socket Bolt Spring Washer Spring Washer (4 Used) Bolt (8 Used) Main Pump (2 Used) Pipe

13 14 15 16 17 18 19 20 21 22 23 24 -

Fitting (4 Used) Pipe Bolt Nut Washer Clamp (2 Used) Pipe (2 Used) Pipe Fitting Fitting (5 Used) Flange Bearing

25 26 27 28 29 30 31 32 33 34 35 -

W2-4-2

Seal Cover Retaining Ring Oil Seal Center Shaft Coupling Assembly O-Ring Seal Washer (4 Used) Socket Bolt (2 Used) Spring Washer (2 Used) Washer (2 Used) Pilot Pump

36 37 38 39 40 41 42 43 44 45 46 -

Adapter Plug Center Gear Level Gauge Pipe Socket Bolt (2 Used) Packing Drain Plug Retaining Ring Bearing P Sensor (2 Used)

UPPERSTRUCTURE / Pump Device Disassemble Pump Device 1. Remove socket bolts (6, 7) and remove N sensor (3). : 5 mm 2. Remove P sensors (46) (2 used). : 27 mm 3. Remove bolts (E) (4 used) of coupling assembly (29). Remove insert (H) from hub (A). : 6 mm 4. Remove screws (B) (2 used) from hub (A). Remove hub (A) and insert (D) from center shaft (28). : 8 mm

46

W173-02-04-002

NOTE: Inserts (F) are installed by using spring pins (C) and bolts (G). 5. Remove drain plug (43) and drain gear oil. : 22 mm

D

A

G F

C

E

CAUTION: Pump device weight: 205 kg (452 lb) 6. Secure the pump device workbench. Workbench : ST 5050

assembly

on

a B

W2-4-3

H

W110-02-04-006

UPPERSTRUCTURE / Pump Device

14

20

12 18 16

19

15 17

10 9

11

19 36 32

33

31 34

35 40

41

W1HH-02-04-004

W2-4-4

UPPERSTRUCTURE / Pump Device 7. Remove bolt (15). Remove nut (16), washer (17), and clamp (18) from the pipe. : 13 mm 8. Remove pipes (12, 14, 19, 20). : 19 mm, 22 mm 9. Remove adapter (36) from pilot pump (35). : 27 mm 10. Remove socket bolts (32) (2 used), spring washers (33), and washers (34). Remove pilot pump (35). : 8 mm 11. Remove bolts (10) (4 used), spring washers (9), and seal washers (31). : 24 mm CAUTION: Main pump weight: 67 kg (148 lb) 12. Install eyebolt (M12, Pitch 1.75 mm) to main pump (11). Hoist and remove main pump (11). 13. Remove the other main pump in the same procedures as steps 11 and 12. 14. Remove socket bolts (41) (2 used) and remove pipe (40). : 6 mm

W2-4-5

UPPERSTRUCTURE / Pump Device

23

28

45

38 24

26

30

25

27

44

W1HH-02-04-004

W2-4-6

UPPERSTRUCTURE / Pump Device CAUTION: Flange assembly weight: 48 kg (106 lb) 15. Remove flange (23) from the workbench. Turn over flange (23). Place flange (23) on the workbench. Remove retaining ring (26) from flange (23). 16. Remove seal cover (25) from flange (23). 17. Remove oil seal (27) from seal cover (25) by using special tool (ST 1234). 18. Remove O-ring (30) from flange (23). Remove retaining ring (44) from center shaft (28). CAUTION: Flange weight: 39 kg (86 lb) 19. Turn over flange (23). Place flange (23) onto the press. Remove center shaft (28) and bearing (24) from flange (23) by using special tool (ST 1236).

ST 1236

20. Remove center gear (38) from flange (23).

W173-02-04-003

21. Remove bearing (45) from flange (23) by using special tool (ST 1235).

ST 1235

22. Remove bearing (24) from center shaft (28) by using a press or puller.

W173-02-04-004

W2-4-7

UPPERSTRUCTURE / Pump Device ASSEMBLE PUMP DEVICE

1 22

2

21 20 19 A

18

B B

17, 16, 15

3, 4 5, 6 14

7, 8

13 W1HH-02-04-001

12

10

11

37

Section B-B

9

45

38

23

24

25

26 44 27 28

29

46

30

36

35

32, 33, 34

31 W1HH-02-04-002

W2-4-8

UPPERSTRUCTURE / Pump Device

View A

W1HH-02-04-003

41, 42

43

12345678910 11 12 -

Drive Gear (2 Used) Retaining Ring (2 Used) N Sensor O-Ring Washer Socket Bolt Socket Bolt Spring Washer Spring Washer (4 Used) Bolt (8 Used) Main Pump (2 Used) Pipe

13 14 15 16 17 18 19 20 21 22 23 24 -

Fitting (4 Used) Pipe Bolt Nut Washer Clamp (2 Used) Pipe (2 Used) Pipe Fitting Fitting (5 Used) Flange Bearing

25 26 27 28 29 30 31 32 33 34 35 -

W2-4-9

40

Seal Cover Retaining Ring Oil Seal Center Shaft Coupling Assembly O-Ring Seal Washer (4 Used) Socket Bolt (2 Used) Spring Washer (2 Used) Washer (2 Used) Pilot Pump

39

36 37 38 39 40 41 42 43 44 45 46 -

Adapter Plug Center Gear Level Gauge Pipe Socket Bolt (2 Used) Packing Drain Plug Retaining Ring Bearing P Sensor (2 Used)

UPPERSTRUCTURE / Pump Device 45

38

23

24

25

26 44 27 28

46 30

W1HH-02-04-002

W2-4-10

UPPERSTRUCTURE / Pump Device Assemble Pump Device CAUTION: Flange weight: 39kg (86 lb)

ST 2307

1. Face input shaft side of flange (23) upward. Install bearing (45) by using special tool (ST 2307). 2. Insert center gear (38) into flange (23) from the main pump mounting hole. Set center gear (38) onto bearing (45). 3. Place flange (23) on a press. Align center shaft (28) with the center gear (38) spline. Install center shaft (28) into bearing (45). 4. Install bearing (24) into flange (23) and center shaft (28) by using special tool (ST 2308) and a press.

W173-02-04-005

ST 2308

W173-02-04-006

CAUTION: Flange assembly weight: 48 kg (106 lb) 5. Remove flange (23) from a press. Place flange (23) on the workbench. Install retaining ring (44) onto center shaft (28). Install O-ring (30) into flange (23). 6. Install oil seal (27) into seal cover (25) by using special tool (ST 2248). 7. Insert special tool (ST 2280) onto center shaft (28) and install seal cover (25) into flange (23). 8. Install retaining ring (26) into flange (23).

W2-4-11

UPPERSTRUCTURE / Pump Device

W1HH-02-04-001

11

10

9

23

36

35

W2-4-12

32, 33, 34

31

W1HH-02-04-002

UPPERSTRUCTURE / Pump Device 9. Turn over flange (23) and place flange (23) on the workbench. Apply THREEBOND #1215 onto the pump mounting surface. Workbench : ST 5050 CAUTION: Main pump weight: 67 kg (148 lb) 10. Install eyebolt (M12, Pitch 1.75 mm) to main pump (11). Hoist and install main pump (11) to flange (23). 11. Tighten bolts (10) (4 used) with spring washers (9) and seal washes (31). : 24 mm : 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft) 12. Install the other main pump in the same procedures as steps 10 and 11. 13. Apply THREEBOND #1215 onto the pilot pump mounting surface of flange (23). Install pilot pump (35) to flange (23). Tighten socket bolts (32) (2 used) with spring washers (33) and washers (34). : 8 mm : 49 N⋅m (5 kgf⋅m, 136 lbf⋅ft) 14. Install pipe (40) and packing (42) to flange (23) and tighten socket bolts (41). : 6 mm : 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

40 41, 42

W1HH-02-04-003

15. Install adapter (36) to pilot pump (35). : 27 mm : 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)

W2-4-13

UPPERSTRUCTURE / Pump Device

20 19 18 17, 16, 15 3

14

W1HH-02-04-001

12

37

28

46

W1HH-02-04-002

W2-4-14

UPPERSTRUCTURE / Pump Device 16. Install pipes (12, 14, 19, 20). : 19 mm : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft) : 22 mm : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft) 17. Install clamp (18) with bolt (15), nut (16), and washer (17). : 13 mm : 3 N⋅m (0.3 kgf⋅m) Assemble Coupling

D

18. Place the pump device horizontal. Install hub (A) to center shaft (28) with screws (B) (2 used). : 8 mm : 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

A

G F

C

E

19. Install inserts (H, D) to hub (A) with bolts (E) (4 used). : 6 mm : 310 N⋅m (32 kgf⋅m, 232 lbf⋅ft) 20. Install N sensor (3). : 5 mm : 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)

B

21. Install P sensor (46). : 27 mm : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) CAUTION: Pump device weight: 205 kg (452 lb) 22. Place the pump device horizontally. Remove plug (37). Add engine oil. Engine oil : 1.4 L (0.37 US gal.) 23. Install the pump device with the plug (37) hole facing to the counterweight. : 17 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

W2-4-15

H

W110-02-04-006

UPPERSTRUCTURE / Pump Device DISASSEMBLE MAIN PUMP 47, 48 4 31

41

6

43 42

31

1 3

10

11 17

15

16

5

14

30

44

49

24 25

25 23

39 40

19 7

22

34

25 21 20

13

37 38 46 31 45

29 27

25

25 33 32

18 9

12 8

21

25

2

20

22

28 26

48 36 35 40 39 W173-02-04-026

12345678910 11 12 13 -

Casing Drive Disc Roller Bearing (2 used) Roller Bearing Spacer Bearing Nut Plunger (7 used) Cylinder Block Center Shaft Drive Gear Retaining Ring Spring Pin

14 15 16 17 18 19 20 21 22 23 24 25 26 -

Oil Seal Seal Cover O-Ring Retaining Ring Valve Plate Link Lever (2 Used) Pin (2 Used) Pin (2 Used) Pin Feedback Pin Retaining Ring (6 Used) Servo Piston

27 28 29 30 31 32 33 34 35 36 37 38 39 -

Servo Pin Set Screw Head Cover Spring Pin (2 Used) O-Ring (10 Used) Bolt (8 Used) Spring Washer (8 Used) Plug Stopper L O-Ring Stopper S O-Ring Bolt (8 Used)

W2-4-16

40 41 42 43 44 45 46 47 48 49 50 -

Spring Washer (8 Used) Regulator O-Ring Spring Pin (2 Used) Plug Name Plate Screw (2 Used) Bolt (4 Used) Spring Washer (4 Used) Packing P Sensor

UPPERSTRUCTURE / Pump Device Disassemble Main Pump Remove Drive Gear 1. Remove retaining ring (11) from the main pump. 2. Remove drive gear (10) by using a puller. CAUTION: Main pump weight: 67 kg (148 lb) 3. Secure the main pump on the workbench (ST 5050). 4. Remove bolts (47) (4 used) and spring washer (48). Remove regulator (41). : 8 mm 5. Remove O-rings (31) (5 used), O-ring (42), and spring pins (43) (2 used). 6. Remove bolts (32) (8 used) and spring washers (33). Remove head cover (29). : 10 mm 7. Remove O-rings (31) (3 used) from casing (1). 8. Place valve plate (18) on casing (1). 9. Remove cylinder block (8) upward and remove valve plate (18) and link (19). 10. Remove spring (12).

W2-4-17

UPPERSTRUCTURE / Pump Device

1 16 17

15

14

7

13

9 2

W173-02-04-026

W2-4-18

UPPERSTRUCTURE / Pump Device 11. Remove center shaft (9). Do not lose pin (13). 12. Incline plungers (7) (7 used) to the center of drive disc (2). Remove plungers (7) upward. 13. Place casing (1) on the workbench. Remove retaining ring (17). 14. Place casing (1) on the workbench with the drive disc side upward. Remove seal cover (15) by using a screwdriver.

14

15. Remove oil seal (14) from seal cover (15) by using a screwdriver. 16. Remove O-ring (16) from casing (1).

W173-02-04-007

17. Turn over casing (1) and place casing (1) on a press. Remove drive disc (2) and the bearing by using a press and special tool (ST 1239). ST 1239

W173-02-04-008

W2-4-19

UPPERSTRUCTURE / Pump Device

4 6

3 5

2

W173-02-04-026

W2-4-20

UPPERSTRUCTURE / Pump Device 18. Place drive disc (2) on special tool (ST 5905) as illustrated in order to remove bearing nut (6).

2

ST 5905

W173-02-04-009

19. Install special tool (ST 3054) on the spline of drive disc (2) and loosen bearing nut (6).

ST 3054

W173-02-04-010

20. Remove bearing nut (6) from drive disc (2). 21. Remove roller bearing (4) and spacer (5) from drive disc (2) by using a puller.

Puller

5

4

W173-02-04-011

22. Remove the outer race of roller bearing (3). 23. Remove roller bearing (4) from spacer (5) by using special tool (ST 1271).

ST 1271

W173-02-04-012

W2-4-21

UPPERSTRUCTURE / Pump Device

3

39 40

37 38

27

29

28 2

26

36 35 40 39 W173-02-04-026

W2-4-22

UPPERSTRUCTURE / Pump Device 24. Install special tool (ST 1272) between drive disc (2) and roller bearing (3). Clamp the assembly in a vise. Adjust the clearance in order to use a puller.

ST 1272

3

2 W173-02-04-013

25. Set a puller. Remove roller bearings (3) (2 used) from drive disc (2) at the same time.

Puller

26. Remove bolts (39) (4 used) and spring washers (40) (4 used) from stopper S (37). Remove O-ring (38) and stopper S (37) from head cover (29). : 6 mm 27. Remove bolts (39) (4 used) and spring washers (40) (4 used) from stopper L (35). Remove O-ring (36) and stopper L (35) from head cover (29). : 6 mm 28. Remove set screw (28) from servo piston (26) and remove servo pin (27) from head cover (29). : 8 mm NOTE: LOCTITE #829 is applied to set screw (28). Heat set screw (28) before disassembling.

W2-4-23

3 W173-02-04-014

UPPERSTRUCTURE / Pump Device ASSEMBLE MAIN PUMP 39, 40

37

31

43

47, 48

41

42 24

23

19

1

3

5

4

6

2

38

10 11

A 28 27 15

B

26

B

29 35

36

Section B-B

49

18

30

44

12

7

21 25

8

9

20

22

13

16

17

14 W1HH-02-04-005

W1HH-02-04-006

W2-4-24

UPPERSTRUCTURE / Pump Device

45 46

View A

34

50

32, 33

W173-02-04-002

12345678910 11 12 13 -

Casing Drive Disc Roller Bearing (2 used) Roller Bearing Spacer Bearing Nut Plunger (7 used) Cylinder Block Center Shaft Drive Gear Retaining Ring Spring Pin

14 15 16 17 18 19 20 21 22 23 24 25 26 -

Oil Seal Seal Cover O-Ring Retaining Ring Valve Plate Link Lever (2 Used) Pin (2 Used) Pin (2 Used) Pin Feedback Pin Retaining Ring (6 Used) Servo Piston

27 28 29 30 31 32 33 34 35 36 37 38 39 -

Servo Pin Set Screw Head Cover Spring Pin (2 Used) O-Ring (10 Used) Bolt (8 Used) Spring Washer (8 Used) Plug Stopper L O-Ring Stopper S O-Ring Bolt (8 Used)

W2-4-25

40 41 42 43 44 45 46 47 48 49 50 -

Spring Washer (8 Used) Regulator O-Ring Spring Pin (2 Used) Plug Name Plate Screw (2 Used) Bolt (4 Used) Spring Washer (4 Used) Packing P Sensor

UPPERSTRUCTURE / Pump Device

39, 40

37 3

4

38

28 27 26 29 W1HH-02-04-005

W2-4-26

UPPERSTRUCTURE / Pump Device Assemble Main Pump 1. Insert servo piston (26) into head cover (29). Install servo pin (27) into the servo piston (26) hole from the suction port in head cover (29). Apply LOCTITE #829 to the thread part of set screw (28). Tighten set screw (28) and secure servo pin (27). : 8 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) 2. Install O-ring (38) on stopper S (37). Install stopper S (37) to head cover (29) with bolts (39) (4 used) and spring washers (40) (4 used). : 6 mm : 30 N⋅m (3.1 kgf⋅m, 22.4 lbf⋅ft) 3. Install special tool (ST 7923) on the large chamber side of head cover (29). Set servo piston (26) so that servo pin (27) is at the center of the suction port. CAUTION: The inner race becomes too hot. Avoid being burned. 4. Heat roller bearings (3) (2 used) and the inner race of bearing (4) to 50 to 80 °C (122 to 176 °F). Apply hydraulic oil to roller bearings (3, 4) inside.

ST 7923

W173-02-04-015

W2-4-27

UPPERSTRUCTURE / Pump Device

3

5

4

6

2

W1HH-02-04-005

W2-4-28

UPPERSTRUCTURE / Pump Device 5. Place drive disc (2) on a workbench with the spline side up. Install roller bearings (3) (2 used) on drive disc (2). Apply hydraulic oil to the bearing race surfaces. 6. Install the outer race of roller bearing (4) to spacer (5) by using special tool (ST 2408). ST 2408

5

7. Install roller bearing (4) and spacer (5) on drive disc (2).

W173-02-04-016

Check that roller bearings (3, 4) are securely installed on drive disc (2) after they have cooled down to atmosphere temperature. Apply hydraulic oil to the bearing race surfaces.

ST 7102

Install the inner race of roller bearing (4) by using special tool (ST 7102).

8. Place drive disc (2) on special tool (ST 5905). Install bearing nut (6) on the thread part in drive disc (2). Tighten bearing nut (6) until it contacts bearing (4). Apply lubricating oil to the thread part in bearing nut (6).

W173-02-04-017

6 ST 5905

W173-02-04-018

W2-4-29

UPPERSTRUCTURE / Pump Device

1

3

4

6

2

15

16

W2-4-30

14

W1HH-02-04-005

UPPERSTRUCTURE / Pump Device 9. Insert special tool (ST3054) into the spline in drive disc (2). Turn drive disc (2) and tighten bearing nut (6). When tightening bearing nut (6), tighten counterclockwise.

ST 3054

W173-02-04-023

10. Measure the preload of roller bearings (3, 4). Set special tool (ST5905). Install a torquemeter and adapter (ST 3055) on the spline of drive disc (2). Rotate drive disc (2) two or three times before recording, for smoother movement of drive disc (2) and make a record of the torque.

ST 3055

Starting Torque Specification: 2.94±0.49 N⋅m (0.30±0.05 kgf⋅m, 2.17±0.36 lbf⋅ft)

ST 5905

CAUTION: Casing (1) becomes too hot. When applying grease, avoid being burned. 11. Heat casing (1) to 50 to 80 °C (122 to 176 °F). Apply grease to the inside of casing (1).

W173-02-04-024

12. Install drive disc (2) into casing (1). Check that drive disc (2) is securely installed in casing (1) after the casing has cooled down to atmosphere temperature. 13. Install O-ring (16) into the groove on casing (1). Apply grease to O-ring (16). ST 2409

14. Install oil seal (14) into seal cover (15) by using special tool (ST 2409). Apply grease to the oil seal (14) lip. 15

W173-02-04-019

W2-4-31

UPPERSTRUCTURE / Pump Device

23

19

1

2

15

12

7

9

13

17

W1HH-02-04-005

18

W1HH-02-04-006

W2-4-32

UPPERSTRUCTURE / Pump Device 15. Install special tool (ST 2410) on the spline of drive disc (2). Install seal cover (15) in casing (1). Tap seal cover (15) into casing (1) by using a plastic hammer until the retaining ring (17) groove on casing (1) is visible. 16. Install retaining ring (17) to casing (1). Check that retaining ring (17) seats well in the groove after installing. 17. Turn over casing (1) and place casing (1) on a workbench with the drive disc side down. Apply hydraulic oil to the spherical surface of drive disc (2). Incline plunger (7) to the center of drive disc (2). Install plungers (7). 18. Apply grease in order not to fall off pin (13) and install pin (13) to center shaft (9). 19. Install center shaft (9) on drive disc (2). 20. Install spring (12) on center shaft (9). 21. Connect link (19) to valve plate (18). Place valve plate (18) on casing (1) inside. Insert pin (23) in link (19) to the mounting end for the casing (1) regulator.

W2-4-33

14

15 ST 2410

W173-02-04-020

UPPERSTRUCTURE / Pump Device

23

19

1

27

29 49

18

7

8

9

13

W1HH-02-04-005

30

W1HH-02-04-006

W2-4-34

UPPERSTRUCTURE / Pump Device 22. Install plungers (7) (7 used) and center shaft (9) into cylinder block (8). Install pin (13) into the groove of cylinder block while rotating the end of center shaft (9) by using a radio plier. 23. Apply hydraulic oil to the speherical surfaces of valve plate (18) and cylinder block (8). Face the spherical surface of valve plate (18) to cylinder block (8) and insert into the end of center shaft (9) into the hole on value plate (18). 24. Apply grease to O-rings (31) (3 used). Install O-rings (31) (3 used) and packing (49) on casing (1). NOTE: As for O-rings (31), refer to W2-4-16. 25. Install special tool (ST 7094) on the drain port of casing (1). Secure valve plate (18) at the center position.

1

18

26. Align servo pin (27) on head cover (29) with the valve plate (18) hole.

27. Align the holes of spring pins (30). Install head cover (29) on casing (1). Tighten bolts (32) (8 used) with spring washers (33) (8 used). : 12 mm : 110 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

ST 7094 W173-02-04-021

32, 33 W173-02-04-002

W2-4-35

UPPERSTRUCTURE / Pump Device

47, 48

43 41

42

24

39, 40

1

2 10 11

29 35

W1HH-02-04-005

36

44

W2-4-36

UPPERSTRUCTURE / Pump Device 28. Remove special tool (ST 7094) from casing (1). Install plug (44). Remove special tool (ST 7923) from head cover (29). Install O-ring (36) on stopper L (35). Install stopper L (35) with spring washers (40) (4 used) and bolts (39) (4 used). : 6 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) : 8 mm : 49 N⋅m (5 kgf⋅m, 36.2 lbf⋅ft) 29. Apply grease to O-rings (31, 42). Install O-rings (31) (5 used) and O-ring (42) onto the regulator mounting surface of casing (1). NOTE: Check that spring pins (43) (2 used) are installed. As for O-rings (31), refer to W2-4-16. CAUTION: Main Pump weight: 67 kg (148 lb) 30. Align feedback pin (24) in the pump with the notches on sleeves (2 used) in regulator (41). Install regulator (41) to casing (1). 31. Install bolts (47) (4 used) and spring washers (48) (4 used) to regulator (41). : 8 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 32. Install drive gear (10) into drive disc (2). 33. Install retaining ring (11) into drive disc (2).

W2-4-37

35, 36

39, 40

44

ST 7923

ST 7094

W173-02-04-022

UPPERSTRUCTURE / Pump Device DISASSEMBLE REGULATOR 25 26

27

11 12 20 22

24

23

21 18 30

19

31

28

15

6

2

14

1

29

4

17 16

3

13 15

7

5

8 2

14

2

26 25

11

12

10

32 W173-02-04-029

9 12345678-

Stopper O-Ring (3 Used) Sleeve Spool Casing Spring Piston Cylinder

910 11 12 13 14 15 16 -

Nut Screw Nut (2 Used) Nut (2 Used) Stopper Stopper (2 Used) O-Ring (2 Used) Spring

17 18 19 20 21 22 23 24 -

Spring Sleeve Spool Cylinder Piston O-Ring Backup Ring O-Ring

W2-4-38

25 26 27 28 29 30 31 32 -

Socket Bolt (8 Used) Spring Washer (8 Used) Front Cover Bolt (4 Used) Spring Washer (4 Used) Air Bleed Plug O-Ring Rear Cover

UPPERSTRUCTURE/Pump Device Disassemble Regulator 1. Clamp casing (5) in a vise. 2. Remove air bleed plug (30) and O-ring (31) from casing (5). Remove elbows (4 used) from casing (5). : 19 mm, 41 mm 3. Remove socket bolts (25) (8 used). Remove front cover (27) and rear cover (32). : 6 mm IMPORTANT: If loosening stoppers (1, 13, 14), nuts (9, 11, 12), and screw (10), the regulator setting will change. Do not loosen stoppers (1, 13, 14), nuts (9, 11, 12), and screw (10). 4. Remove springs (16, 17) from the rear cover (32) side in casing (5). 5. Push spool (19). Remove cylinder (20) from the front cover (27) side in casing (5). 6. Remove piston (21), O-ring (22), and backup ring (23) from cylinder (20). 7. Remove sleeve (18) and spool (19) from the front cover (27) side in casing (5). 8. Remove spool (19) from sleeve (18). 9. Remove spring (6) from the front cover (27) side in casing (5). 10. Push spool (4). Remove piston (7) and cylinder (8) from the rear cover (32) side in casing (5). 11. Remove piston (7) and O-ring (2) from cylinder (8). 12. Remove sleeve (3) and spool (4) from the front cover (27) side in casing (5). Remove spool (4) from sleeve (3) .

W2-4-39

UPPERSTRUCTURE/Pump Device ASSEMBLE REGULATOR

24 23

25, 26

27

6

1

22

21 20

4

3

5

19

18

7

17

16

28, 29

8

2

9

15 14 13 12

30

31

10

11

T173-03-01-005

32

W173-02-04-001

12345678-

Stopper O-Ring (3 Used) Sleeve Spool Casing Spring Piston Cylinder

910 11 12 13 14 15 16 -

Nut Screw Nut (2 Used) Nut (2 Used) Stopper Stopper (2 Used) O-Ring (2 Used) Spring

17 18 19 20 21 22 23 24 -

Spring Sleeve Spool Cylinder Piston O-Ring Backup Ring O-Ring

W2-4-40

25 26 27 28 29 30 31 32 -

Socket Bolt (8 Used) Spring Washer (8 Used) Front Cover Bolt (4 Used) Spring Washer (4 Used) Plug O-Ring Rear Cover

UPPERSTRUCTURE/Pump Device Assemble Regulator 1. Clamp casing (5) in a vise. 2. Install spool (19) into sleeve (18). 3. Install sleeve (18) and spool (19) from the front cover (27) side in casing (5). 4. Install spool (4) into sleeve (3). Install sleeve (3) from the front cover (27) side in casing (5). 5. Install piston (7) into cylinder (8). 6. Install O-ring (2) to cylinder (8). Apply grease to O-ring (2). Install cylinder (8) from the rear cover (32) side in casing (5). 7. Install the rear cover (32) assembly and springs (16, 17) to casing (5). Tighten socket bolts (25) (4 used) with spring washers (26). : 6 mm : 19.6 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 8. Install O-ring (22), backup ring (23), and piston (21) to cylinder (20). 9. Apply grease to O-ring (22). Install cylinder (20) from the front cover (27) side in casing (5). 10. Install the front cover (27) assembly and spring (6) into casing (5). Tighten socket bolts (25) (4 used) with spring washers (26). : 6 mm : 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 11. Apply grease to O-ring (31). Install O-ring (31) to plug (30). 12. Tighten plug (30). : 41 mm : 78.5 N⋅m (8 kgf⋅m, 58 lbf⋅ft) 13. Install elbows (4 used) to casing (5).

W2-4-41

UPPERSTRUCTURE/Pump Device DISASSEMBLE AND ASSEMBLE PILOT PUMP

14 10 15 12 13 6 9

8 1 16 5

7

15 11 14 5 7 9 4

3

2 W110-02-04-022

1234-

Housing Flange Oil Seal Retaining Ring

5678-

Seal (2 Used) Cover Backup Ring (2 Used) Key (2 Used)

910 11 12 -

O-Ring (2 Used) Gear Drive Gear Washer (4 Used)

W2-4-42

13 14 15 16 -

Bolt (4 Used) Bushing (2 Used) Bushing (2 Used) Knock Pin (2 Used)

UPPERSTRUCTURE/Pump Device Disassemble Pilot Pump 1. Clamp flange (2) in the pilot pump in a vise with cover (6) up. 2. Remove bolts (13) (4 used). : 17 mm 3. Remove cover (6) from housing (1). 4. Remove O-ring (9) from cover (6). 5. Remove flange (2) from housing (1). 6. Remove O-ring (9) from flange (2). 7. Remove retaining ring (4) from flange (2). 8. Remove oil seal (3) from flange (2) by using a screwdriver. 9. Remove seal (5) and backup ring (7) from bushings (14, 15) in cover (6) side. 10. Lightly push drive gear (11). Remove bushings (14, 15) in cover (6) side from housing (1). Do not fall off the key between the bushings. 11. Remove seal (5) and backup ring (7) in flange (2) side from bushings (14, 15). 12. Remove bushings (14, 15) in frange (2) side from housing (1). Remove gear (10) and drive gear (11) from housing (1).

W2-4-43

UPPERSTRUCTURE/Pump Device

14 10 15 12 13 6 9

8 1 16 5

7

15 11 14 5 7 9 4

3

2 W110-02-04-022

1234-

Housing Flange Oil Seal Retaining Ring

5678-

Seal (2 Used) Cover Backup Ring (2 Used) Key (2 Used)

910 11 12 -

O-Ring (2 Used) Gear Drive Gear Washer (4 Used)

W2-4-44

13 14 15 16 -

Bolt (4 Used) Bushing (2 Used) Bushing (2 Used) Knock Pin (2 Used)

UPPERSTRUCTURE/Pump Device Assemble Pilot Pump 1. Install oil seal (3) into flange (2) by using special tool. 2. Install retaining ring (4) to flange (2). 3. Install bushings (14, 15) in cover (6) side to housing (1) with the seal groove side down. 4. Install gear (10) and drive gear (11) to housing (1). 5. Install bushings (14, 15) in flange (2) side to housing (1) with the seal groove side up. 6. Install seal (5) and backup ring (7) into the seal groove on bushings. 7. Install O-ring (9) on flange (2). 8. Install flange (2) on housing (1). 9. Turn over the housing and flange assembly. Clamp the flange in a vise. Do not fall off the bushings and gears when turning over. Install seal (5) and backup ring (7) into the seal groove on bushings. 10. Install O-ring (9) on cover (6). 11. Install cover (6) on housing (1). 12. Tighten washers (12) and bolts (13). : 17 mm : 39 to 44 N⋅m (4 to 4.5 kgf⋅m, 29 to 32.5 lbf⋅ft)

W2-4-45

UPPERSTRUCTURE/Pump Device MAINTENANCE STANDARD Pump Device Unit : mm (in)

Gear backlash

Standard

Allowable Limit

Remedy

0.48 (0.019)

1.5 (0.059)

Replace

Main Pump 1. Drive disc: Spline tooth thickness Unit : mm (in)

Standard

Allowable Limit

4.9 (0.193)

3.5 (0.138)

2. Drive disc: Oil seal outer diameter Unit : mm (in)

Standard

Allowable Limit

60.0 (2.362)

59.8 (2.354)

3. Spherical joint: Clearance between plunger and drive disc Unit : mm (in)

Standard

Allowable Limit

0.060 (0.0024)

0.4 (0.0016)

W157-02-04-016

4. Cylinder block: Clearance between plunger outer diameter and cylinder block bore D

Unit: mm (in)

D-a

Standard

Allowable Limit

0.044 (0.0017)

0.08 (0.0031)

a

W157-02-04-017

W2-4-46

UPPERSTRUCTURE/Pump Device 5. Plunger: Clearance between plunger and connecting rod Unit : mm (in)

Standard

Allowable Limit

0.1 (0.0039)

0.4 (0.0016)

W157-02-04-033

6. Clearance between center shaft and valve plate Unit : mm (in)

D-a

Standard

Allowable Limit

0.081 (0.0032)

0.3 (0.012)

a Center Shaft W110-02-04-013

D

Valve Plate

7. Clearance between small diameter and servo piston

chamber

inner

D a

W110-02-04-014

Unit : mm (in)

D-a

Standard

Allowable Limit

0.089 (0.0035)

0.2 (0.0079)

8. Clearance between large diameter and servo piston

chamber

inner

Unit : mm (in)

D-a

Standard

Allowable Limit

0.090 (0.0035)

0.2 (0.0079)

a D

W157-02-04-018

9. Clearance between servo pin and valve plate D

Unit : mm (in)

D-a

Standard

Allowable Limit

0.051 (0.0020)

0.3 (0.012)

a

W157-02-04-019

W2-4-47

UPPERSTRUCTURE/Pump Device (Blank)

W2-4-48

UPPERSTRUCTURE / Control Valve REMOVE AND INSTALL CONTROL VALVE IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Arm 2 Boom 1 Bucket Right Travel

4-Spool Section 5-Spool Section

Main Relief valve

Removal

Swing Arm 1 Boom 2 Auxiliary Left Travel

1. Remove all hoses, pipes, and connectors from the control valve. Attach identification tags to the removed hoses for reassembling. Cap all the removed hoses and pipes. : 17 mm, 19 mm, 27 mm, 41 mm : 8 mm, 10 mm Machine Front

T1HH-01-02-005

CAUTION: Control valve weight: 210 kg (460 lb) 2. Remove bolts (1) and remove the control valve. : 24 mm

1

W2-5-1

W1HH-02-05-001

UPPERSTRUCTURE / Control Valve Installation 1. Install the control valve on the main frame with bolts (1). : 24 mm : 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

Arm 2 Boom 1 Bucket Right Travel Main Relief valve

2. Install all hoses, pipes, and connectors to the control valve. 3. After completing the work, check hydraulic oil level. Start the engine and check for any oil leaks. : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) : 27 mm : 93 N⋅m (9.5 kgf⋅m, 68.5 lbf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft) : 8 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) : 10 mm : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

4-Spool Section 5-Spool Section

Swing Arm 1 Boom 2 Auxiliary Left Travel

Machine Front

T1HH-01-02-005

1

W2-5-2

W1HH-02-05-001

UPPERSTRUCTURE / Control Valve (Blank)

W2-5-3

UPPERSTRUCTURE / Control Valve DISASSEMBLE CONTROL VALVE (1) 13 4

12

4

43

41 5 7

46 12a

4 13a

32

35

30

31

29

15

17 15 14

6 4

15

4

5

38 25

28 37

47

17

23

33

14 34

30

4

42

15

15

12

20

31

21 27 22

2

10 15

35 31 40

44

19 24 26

18

45

1

16 8 17

11 15 15

8

39 16

36

8

8 9

8

31

17

5

9

3 W173-02-05-021

12345678910 11 12 -

Casing A Casing B Plug Plug (4 Used) O-Ring (6 Used) Spring Cover A Spring Cover B Spool Cover (5 Used) Spool Cover (2 Used) Spool Cover: Arm 2 Spool Cover: Boom 1 Anti-Drift Valve (2 Used): Boom Bottom, Arm Rod 12a - O-Ring (6 Used)

13 - Needle Valve 13a - O-Ring (3 Used) 14 - O-Ring (10 Used) 15 - O-Ring (11 Used) 16 - O-Ring (8 Used) 17 - Socket Bolt (32 Used) 18 - Spool: Left Travel 19 - Spool: Arm 1 20 - Spool: Boom 1 21 - Spool: Bucket 22 - Spool: Swing 23 - Spool: Arm 2

25 26 27 28 29 30 31 32 33 34 35 36 -

24 - Spool: Boom 2

37 - Spring (7 Used)

W2-5-4

Spool: Bypass Shut-Off Spool: Auxiliary Spool: Right Travel Spring (2 Used) Spring (2 Used) Spring Seat (4 Used) Spring Seat (16 Used) Spacer Bolt (2 Used) Stopper (2 Used) Stopper (7 Used) Spacer Bolt (8 Used) Stopper

38 39 40 41 42 43 44 45 46 47 -

Spring (7 Used) Spring Spring Plug Plug Plug Plug O-Ring Socket Bolt (4 Used) Socket Bolt (4 Used)

UPPERSTRUCTURE / Control Valve Disassemble control valve (1)

• Anti-drift Valve and Needle Valve

1. Remove socket bolt (46). Remove needle valve (13) and anti-drift valve (12) from spring cover B (7). : 5 mm 2. Remove socket bolt (47) and remove anti-drift valve (12) from spring cover A (6). : 5 mm

• Spring Cover

• Spool Cover

10. Put the matching marks in order not to make a mistake when assembling casing and spool cover. 11. Remove socket bolts (17) (2 used) and remove spool cover (11) from casing B (2). : 6 mm

12. Disassemble spool covers (8) to (10) in the same procedures. : 6 mm

3. Remove socket bolts (17) (7 used) and remove spring cover A (6) from casing A (1). Remove spring cover B (7) from casing B (2). : 6 mm

• Spool IMPORTANT: Turn and remove the spools. If the spools stick even a little, try again instead of pulling roughly. 4. As spool and hole of casing are a matched fit, put the matching marks for reassembling. 5. Remove the spool (18) assembly from casing A (1). 6. Remove the spool (19) to (27) assemblies in the same procedures. 7. Clamp spool (18) in a vise. 8. Remove spacer bolt (32) and disassemble spring seat (30), springs (28, 29), and stopper (33). : 10 mm 9. Disassemble the spool (19) to (27) assemblies in the same procedures. : 10 mm

W2-5-5

UPPERSTRUCTURE / Control Valve ASSEMBLE CONTROL VALVE (1) 21

Machine Front

27

15, 14

B A

16 4

5, 42

8 11 46 12, 12a 13, 13a

47 12

A

B

17

35

5, 43

31

5, 41

40 39

T1HH-03-03-002

10

7

36 31

2 25 Section B-B

23

20

W1HH-02-05-017

Control Valve Upper View 18

Machine Front

26

15, 14

30 33

28

29 30

16

32 8 3 5 44, 45 9 35 15 8 17 Control Valve Lower View

12345678910 11 12 -

Casing A Casing B Plug Plug (4 Used) O-Ring (6 Used) Spring Cover A Spring Cover B Spool Cover (5 Used) Spool Cover (2 Used) Spool Cover: Arm 2 Spool Cover: Boom 1 Anti-Drift Valve (2 Used) Boom Bottom, Arm Rod 12a - O-Ring (6 Used)

W1HH-02-05-005

24

19 22

13 - Needle Valve 13a - O-Ring (3 Used) 14 - O-Ring (10 Used) 15 - O-Ring (11 Used) 16 - O-Ring (8 Used) 17 - Socket Bolt (32 Used) 18 - Spool: Left Travel 19 - Spool: Arm 1 20 - Spool: Boom 1 21 - Spool: Bucket 22 - Spool: Swing 23 - Spool: Arm 2

25 26 27 28 29 30 31 32 33 34 35 36 -

24 - Spool: Boom 2

37 - Spring (7 Used)

W2-5-6

Spool: Bypass Shut-Off Spool: Auxiliary Spool: Right Travel Spring (2 Used) Spring (2 Used) Spring Seat (4 Used) Spring Seat (16 Used) Spacer Bolt (2 Used) Stopper (2 Used) Stopper (7 Used) Spacer Bolt (8 Used) Stopper

1 6 Section A-A

38 39 40 41 42 43 44 45 46 47 -

31 38 37 W1HH-02-05-004 31 34

Spring (7 Used) Spring Spring Plug Plug Plug Plug O-Ring Socket Bolt (4 Used) Socket Bolt (4 Used)

UPPERSTRUCTURE / Control Valve Assemble Control Valve (1)

• Spool Cover IMPORTANT: Install spool covers (8) to (11) while aligning the matching marks. 1. Install O-rings (15, 16) to spool cover (11). 2. Install spool cover (11) to casing B (2) with socket bolts (17) (2 used) while aligning the matching marks. : 6 mm : 24 to 34 N⋅m (2.5 to 3.5 kgf⋅m, 18 to 25.5 lbf⋅ft) 3. Install spool covers (8) to (10) in the same procedures. : 6 mm : 24 to 34 N⋅m (2.5 to 3.5 kgf⋅m, 18 to 25.5 lbf⋅ft)

• Spool

4. Clamp spool (18) in a vise. 5. Clean the thread part of spacer bolt (32) and apply LOCTITE #262. 6. Install spring seat (30), springs (28, 29), stopper (33), and spacer bolt (32) to spool (18). 7. Tighten spacer bolt (32). : 10 mm : 15 to 18 N m (1.6 to 1.8 kgf⋅m, 11.5 to 13 lbf⋅ft)

• Spring Cover

10. Install O-rings (14) (5 used) and O-rings (15) (4 used) to spring cover A (6) 11. Install spring cover A (6) to casing A (1) with socket bolts (17) (7 used). : 6 mm : 24 to 34 N⋅m (2.5 to 3.5 kgf⋅m, 18 to 25.5 lbf⋅ft)

12. Install spring cover B (7) in the same procedures. : 6 mm : 24 to 34 N⋅m (2.5 to 3.5 kgf⋅m, 18 to 25.5 lbf⋅ft)

• Anti-drift Valve and Needle Valve

13. Install O-rings (12a) (3 used) to anti-drift valve (12). Install anti-drift valve (12) to spring cover A (6) with socket bolts (47) (4 used). : 5 mm : 9.8 to 14 N⋅m (1 to 1.4 kgf⋅m, 7.2 to 10 lbf⋅ft) 14. Install O-rings (12a) (3 used) to anti-drift valve (12). Install O-rings (13a) (3 used) to needle valve (13). Install needle valve (13) and anti-drift valve (12) to spring cover B (7) with socket bolts (46) (4 used). : 5 mm : 9.8 to 14 N⋅m (1 to 1.4 kgf⋅m, 7.2 to 10 lbf⋅ft)

8. Assemble the spool (18) to (27) assemblies while aligning the matching marks. : 10 mm : 15 to 18 N⋅m (1.6 to 1.8 kgf⋅m, 11.5 to 13 lbf⋅ft) 9. Install the spool (18) to (27) assemblies to casing A (1) and casing B (2) respectively.

W2-5-7

UPPERSTRUCTURE / Control Valve DISASSEMBLE CONTROL VALVE (2) 1

5

23

22

12 6 19

13 18 20 7

24 3

11

21a

4

14

9 8

9

21

14 25

16 Casing A

11

25

17 10

15

2

W173-02-05-022

1 - Anti-Drift Valve Assembly: Arm Bottom Side 2 - Casing 2 3 - Casing 3 4 - Casing 4 5 - O-Ring 6 - O-Ring 7 - O-Ring (3 Used)

8 - O-Ring (2 Used)

15 - Plug

21a - O-Ring

910 11 12 13 14 -

16 17 18 19 20 21 -

22 23 24 25 -

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

W2-5-8

Poppet Spring Spool Spring Bushing Relief Valve

Piston Piston Socket Bolt (4 Used) Socket Bolt (8 Used)

UPPERSTRUCTURE / Control Valve Disassemble Control Valve (2)

• Arm Anti-Drift Valve

1. Put the matching marks in order to install correctly. 2. Remove socket bolts (25) (4 used) and remove casing 2 (2) from casing 4 (4). : 10 mm 3. Remove socket bolts (25) (4 used) and remove casing 4 (4) from casing A. : 10 mm 4. Clamp casings 2 (2) and 3 (3) in a vise. 5. Remove socket bolts (24) (4 used) and remove casing 3 (3) from casing 2 (2). : 5 mm 6. Remove plug (15). Remove poppet (16) and spring (17) from casing 2 (2). : 17 mm

IMPORTANT: Do not loosen the lock nut. 7. Remove relief valve (21) from casing 3 (3). : 22 mm 8. Remove plug (13). Remove pistons (23, 22) from casing 3 (3). Check the order when removing pistons (22, 23). : 10 mm 9. Remove plug (12). Remove bushing (20), spool (18), and spring (19) from casing 3 (3). : 22 mm

W2-5-9

UPPERSTRUCTURE / Control Valve ASSEMBLE CONTROL VALVE (2)

9

Machine Front

14

5

13

9 14

23 22

7

F F

21

21a

20

3

19

6

T1HH-03-03-002

18 Control Valve Upper View

Section Y-Y

12 W1HH-02-05-006

Arm 1

Arm 2

24

15

Y

Y

17 10 Casing B

16

Casing A

2 1 - Anti-Drift Valve Assembly: Arm Bottom Side 2 - Casing 2 3 - Casing 3 4 - Casing 4 5 - O-Ring 6 - O-Ring 7 - O-Ring (3 Used)

25 11

4

25

Section F-F

11

T1HH-03-03-007

8 - O-Ring (2 Used)

15 - Plug

21a - O-Ring

910 11 12 13 14 -

16 17 18 19 20 21 -

22 23 24 25 -

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

Poppet Spring Spool Spring Bushing Relief Valve

W2-5-10

Piston Piston Socket Bolt (4 Used) Socket Bolt (8 Used)

UPPERSTRUCTURE / Control Valve Assemble Control Valve (2)

• Arm Anti-Drift Valve

10. Install casing 3 (3) to casing 2 (2) with socket bolts (24) (4 used). : 5 mm : 9.8 to 13.5 N⋅m (1 to 1.4 kgf⋅m, 7.2 to 10 lbf⋅ft)

1. Install O-rings (7) (3 used) to bushing (20). 2. Install O-ring (6) to plug (12). 3. Install bushing (20), spool (18), and spring (19) into casing 3 (3). Install plug (12). : 22 mm : 69 to 79 N⋅m (7 to 8 kgf⋅m, 50.5 to 58 lbf⋅ft) 4. Install O-ring (5) to plug (13). 5. Install pistons (22, 23) into casing 3 (3). Install plug (13). : 10 mm : 127 to 147 N⋅m (13 to 15 kgf⋅m, 94 to 108 lbf⋅ft) 6. Install O-ring (21a) to relief valve (21). Tighten and install relief valve (21) in casing 3 (3). : 22 mm : 69 to 79 N⋅m (7 to 8 kgf⋅m, 50.5 to 58 lbf⋅ft)

11. Install O-ring (11) to casing 4 (4). 12. Install casing 4 (4) to casing A with socket bolts (25) (4 used). : 10 mm : 98 to 118 N⋅m (10 to 12 kgf⋅m, 72 to 87 lbf⋅ft) 13. Install O-ring (11) to casing 2 (2). 14. Install casing 2 (2) to casing 4 (4) with socket bolts (25) (4 used). : 10 mm : 98 to 118 N⋅m (10 to 12 kgf⋅m, 72 to 87 lbf⋅ft)

IMPORTANT: Do not tighten relief valve (21) by using the lock nut. 7. Install O-ring (10) to plug (15). 8. Install poppet (16) and spring (17) into casing 2 (2). Install plug (15). : 17 mm : 370 to 410 N⋅m (38 to 42 kgf⋅m, 275 to 300 lbf⋅ft) 9. Install O-rings (8) (2 used) to casing 3 (3).

W2-5-11

UPPERSTRUCTURE / Control Valve DISASSEMBLE CONTROL VALVE (3) 16

18

19

21

13 13a

7 25

3

23

16

17 25

19

20

29 29a

Casing A

1 6

4

9

14

6

1

9

4

22

24

33 14a 6 9

26

1

8 12 31

32

15

10

27

5

12

27

11 31

25

28a 28

2

30a

30b 30c 30

W1HH-02-05-019

1 - Plug (4 Used) 2 - Plug

11 - P3 Cover 12 - Flange (2 Used)

19 - Spring (4 Used) 20 - Spring (2 Used)

3 - Plug

21 - Spring

4 - Plug (2 Used)

13 - Travel Flow Rate Control Valve Assembly 13a - O-Ring

5678910 -

14 - Blank Flange Assembly 14a - O-Ring (2 Used) 15 - Socket Bolt (4 Used) 16 - Poppet (4 Used) 17 - Poppet (2 Used) 18 - Poppet

23 24 25 26 27 28 -

Plug (3 Used) O-Ring (4 Used) O-Ring O-Ring (2 Used) O-Ring (3 Used) Cover

22 - Spacer Plug (3 Used) Plug O-Ring (5 Used) O-Ring O-Ring (2 Used) Overload Relief Valve: Boom Side

W2-5-12

28a - O-Ring 29 - Overload Relief Valve: Arm Side 29a - O-Ring 30 - Pump Control Valve: 5-Spool Section 30a - O-Ring 30b - O-Ring 30c - O-Ring 31 - Socket Bolt (8 Used) 32 - Socket Bolt (4 Used) 33 - Socket Bolt (4 Used)

UPPERSTRUCTURE / Control Valve Disassemble Control Valve (3)

2. Remove poppet (16), spring (19), and spacer (22) from casing A.

• Blank Flange Assembly

3. Remove socket bolts (33) (4 used) and remove blank flange assembly (14). : 8 mm 4. Remove poppet (17) and spring (20) from casing A.

• Overload Relief Valve

9. Check that there are two kinds of overload relief valves. Put the matching marks on to each port and part.

IMPORTANT: Loosen the valve of overload relief valve. If loosening the lock nut and adjusting screw, the set pressure will change. Do not loosen the lock nut and adjusting screw. 10. Remove overload relief valves (28, 29) from casing B by using the tool below. : 32 mm

32 mm

5. Remove the plug. Remove the piston, sleeve, poppet, and spring from casing A. : 32 mm

• Arm Anti-Drift Check Valve

(45 mm)

6. Remove plug (24). Remove spring (21) and poppet (18) from casing A. : 12 mm

• Left Travel, Boom 2, Swing Load Check Valve (common to three places)

(80 mm)

(43 mm)

• Travel Flow Rate Control Valve Assembly

(12.7 mm)

1. Remove socket bolts (32) (4 used) and remove P3 cover (11). : 8 mm

(Wrench Size: 32 mm)

• P3 Cover

• Pump Control Valve (5-Spool Section) 11. Remove pump control valve (30). : 36 mm

7. Put the matching marks onto each port and part. 8. Remove plug (23). Remove poppet (16) and spring (19) from casing A. : 12 mm

W2-5-13

W1HH-02-05-002

UPPERSTRUCTURE / Control Valve ASSEMBLE CONTROL VALVE (3) Machine Front X

C

5

B

C

D

D E F

F

W1HH-02-05-003

G

30

30a

30c

Casing A

Section B

T1HH-03-03-002

X

30b

Control Valve Upper View Auxiliary

Left Travel

Bucket

31

Right Travel

12 27 16 19 22 2

13a 13

23

25 32 11 8

25

27

19

31

16 Section C-C

T1HH-03-03-004

12

W2-5-14

T1HH-03-03-005

Section D-D

UPPERSTRUCTURE / Control Valve Boom 2

Boom 1

1

Arm 1

6

Arm 2

18 21 24 25 17 20 14

29 29a 25 23

28 28a

14a

33

28a

19 16 28

3 7

Section F-F T1HH-03-03-006

29a

29

T1HH-03-03-007

Section E 15

10

9, 26

4

9

Swing

Left Travel Auxiliary

16 19

Boom 2

23

Arm 1

25

Swing

W1HH-02-05-004

Section G

Section X-X

T1HH-03-03-006

1 - Plug (4 Used) 2 - Plug

11 - Cover 12 - Flange (2 Used)

19 - Spring (4 Used) 20 - Spring (2 Used)

3 - Plug

21 - Spring

4 - Plug (2 Used)

13 - Travel Flow Rate Control Valve Assembly 13a - O-Ring

5678910 -

14 - Blank Flange 14a - O-Ring (2 Used) 15 - Socket Bolt (4 Used) 16 - Poppet (4 Used) 17 - Poppet (2 Used) 18 - Poppet

23 24 25 26 27 28 -

Plug (3 Used) O-Ring (4 Used) O-Ring O-Ring (2 Used) O-Ring (3 Used) Cover

22 - Spacer Plug (3 Used) Plug O-Ring (5 Used) O-Ring O-Ring (2 Used) Overload Relief Valve: Boom Side

W2-5-15

28a - O-Ring 29 - Overload Relief Valve: Arm Side 29a - O-Ring 30 - Pump Control Valve: 5-Spool Section 30a - O-Ring 30b - O-Ring 30c - O-Ring 31 - Socket Bolt (8 Used) 32 - Socket Bolt (4 Used) 33 - Socket Bolt (4 Used)

UPPERSTRUCTURE / Control Valve Machine Front X

5 B

C

C

D

D E W1HH-02-05-003

F

F

30

30a

30c

31

Casing A

12 Auxiliary

T1HH-03-03-002

X

30b Section B

G

Bucket

Control Valve Upper View Left Travel

Right Travel

27 16 19 22

13a 13 15 23

2 25 32 11 8 27

19 16 Section C-C Boom 2

T1HH-03-03-004

Boom 1

31 12 21

Section D-D 1

6

Arm 1

T1HH-03-03-005

Arm 2

18

28 17

29

24

20

25

29a

28a

14

25 23

14a 33

28a

19 28

16 3

Section F-F

7 Section E 29a

T1HH-03-03-006

29

W2-5-16

T1HH-03-03-007

UPPERSTRUCTURE / Control Valve Assemble Control Valve (3)

• Pump Control Valve

1. Install O-rings (30a, 30b, 30c) to pump control valve (30). Tighten and install pump control valve (30). : 36 mm : 69 to 78 N⋅m (7 to 8 kgf⋅m, 51 to 58 lbf⋅ft)

• Overload Relief Valve

(12.7 mm)

(Wrench Size: 32 mm)

43 mm

3. Install O-ring (28a) to overload relief valve (28). Install O-ring (29a) to overload relief valve (29). Tighten and install overload relief valves (28, 29) by using special tool below. : 32 mm : 69 to 78 N⋅m (7 to 8 kgf⋅m, 51 to 58 lbf⋅ft)

32 mm

7. Install O-ring (25) to plug (24). 8. Install poppet (18) and spring (21) into casing A. Install plug (24). : 12 mm : 226 to 265 N⋅m (23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)

• Travel Flow Rate Control Valve Assembly

2. Check that there are two kinds of overload relief valves. Align the matching marks.

(45 mm)

• Arm Anti-Drift Check Valve

(80 mm)

9. Install O-ring (13a) to the plug. Install the piston, sleeve, poppet, and spring into casing A. Install the plug. : 32 mm : 147 to 177 N⋅m (15 to 18 kgf⋅m, 108 to 130 lbf⋅ft)

• Blank Flange Assembly

10. Install O-rings (14a) (2 used) to blank flange (14). Install poppet (17) and spring (20) into casing A. Install blank flange assembly (14) with socket bolts (33) (4 used). : 8 mm : 49 to 65 N⋅m (5 to 6.6 kgf⋅m, 36 to 48 lbf⋅ft)

• P3 Cover

11. Install O-rings (8) to cover (11).

W1HH-02-05-002

• Left Travel, Boom 2, Swing Load Check Valve (common to 3 places)

4. Align the matching marks and install it.

12. Install poppet (16), spring (19), and spacer (22) into casing A. Install P3 cover (11) with socket bolts (32) (4 used). : 8 mm : 49 to 65 N⋅m (5 to 6.6 kgf⋅m, 36 to 48 lbf⋅ft)

5. Install O-ring (25) to plug (23). 6. Install poppet (16) and spring (19) into casing A. Install plug (23). : 12 mm : 226 to 265 N⋅m (23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)

W2-5-17

UPPERSTRUCTURE / Control Valve DISASSEMBLE CONTROL VALVE (4) 3 21

11 11a

18 21 15 12 19 21

2

16

7

4

14

8 5

1 18

6 21 15 12 10 9 23

9a 20 22 17 13

5

Casing B W173-02-05-024

1234567-

Plug (2 Used) Plug Plug (3 Used) Plug Plug (2 Used) O-Ring (2 Used) O-Ring

8 - O-Ring (2 Used) 9 - Switch Valve 9a - O-Ring (2 Used) 10 - Poppet Valve 11 - Load Check Valve 11a - O-Ring 12 - Poppet (2 Used)

13 14 15 16 17 18 19 -

Poppet Poppet Spring (2 Used) Spring Spring Plug (2 Used) Plug

W2-5-18

20 21 22 23 -

Plug O-Ring (6 Used) O-Ring Socket Bolt (4 Used)

UPPERSTRUCTURE / Control Valve Disassemble Control Valve (4)

• Bucket Flow Rate Control Valve

1. Remove socket bolts (23) (4 used) and remove switch valve (9). : 8 mm 2. Remove poppet valve (10) from casing B.

• Arm 2 Load Check Valve (with Orifice)

3. Remove the plug and remove load check valve (11) from casing B. : 12 mm

• Boom 1, Arm 2 Load Check Valve (common to 2 places)

IMPORTANT: Put the matching marks to each port and part. 4. Remove plug (18). Remove poppet (12) and spring (15) from casing B. : 12 mm

• Boom Anti-Drift Check Valve

5. Remove plug (19). Remove poppet (14) and spring (16) from casing B. : 12 mm

• Check Valve with Orifice (Bucket Combination)

6. Remove plug (20). Remove poppet (13) and spring (17) from casing B. : 10 mm

W2-5-19

UPPERSTRUCTURE / Control Valve ASSEMBLE CONTROL VALVE (4) Machine Front

Left Travel

Right Travel

C

C

13

D

D

22

E

20

F

F

17

G

Control Valve Upper View

T1HH-03-03-002

Section C-C

Bucket

Auxiliary

Boom 2

T1HH-03-03-004

Boom 1

6 1

10 9a

23

15 21 12 Section E

Section D-D Arm 1

9

14 16 19 21 18

T1HH-03-03-005

T1HH-03-03-006

Swing

Arm 2

11a 11

21

12 15

3

18

7

21

2

4 8 Section G

Section F-F

T1HH-03-03-008

T1HH-03-03-007

1234567-

Plug (2 Used) Plug Plug (3 Used) Plug Plug (2 Used) O-Ring (2 Used) O-Ring

8 - O-Ring (2 Used) 9 - Switch Valve 9a - O-Ring (2 Used) 10 - Poppet Valve 11 - Load Check Valve 11a - O-Ring 12 - Poppet (2 Used)

13 14 15 16 17 18 19 -

Poppet Poppet Spring (2 Used) Spring Spring Plug (2 Used) Plug

W2-5-20

20 21 22 23 -

Plug O-Ring (6 Used) O-Ring Socket Bolt (4 Used)

UPPERSTRUCTURE / Control Valve Assemble Control Valve (4)

• Check Valve with Orifice (Bucket Combination)

• Bucket Flow Rate Control Valve

1. Install O-ring (22) to plug (20).

2. Install poppet (13) and spring (17) into the casing. Install plug (20). : 10 mm : 128 to 147 N⋅m (13 to 15 kgf⋅m, 94 to 108 lbf⋅ft)

8. Install O-rings (9a) (2 used) to switch valve (9). Install poppet valve (10) into the casing. Install switch valve (9) with socket bolts (23) (4 used). : 8 mm : 52 to 62 N⋅m (5.3 to 6.3 kgf⋅m, 38 to 46 lbf⋅ft)

• Boom Anti-Drift Check Valve

3. Install O-ring (21) to plug (19). 4. Install poppet (14) and spring (16) into the casing. Install plug (19). : 12 mm : 226 to 265 N⋅m (23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)

• Boom 1, Arm 2 Load Check Valve (common to 2 places)

IIMPORTANT: Align the matching marks and install it. 5. Install O-ring (21) to plug (18). 6. Install poppet (12) and spring (15) into the casing. Install plug (18). : 12 mm : 226 to 265 N⋅m (23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)

• Arm 2 Load Check Valve (with Orifice)

7. Install O-ring (11a) to the plug. Install load check valve (11). : 12 mm : 226 to 265 N⋅m (23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)

W2-5-21

UPPERSTRUCTURE / Control Valve DISASSEMBLE CONTROL VALVE (5) 1

Casing B

21 21a

5

19 6

20 18 17

5 19

20

7

18

11

17 7

14

6

16

6 4

22 23

3

8

15

2

15

17 18 20 19

9 10 12 13

W173-02-05-025

1 - Flow Combiner Valve Assembly 2 - Block 3 - Plug 4 - Plug 5 - O-Ring (3 Used) 6 - O-Ring (4 Used)

7 - O-Ring (2 Used)

13 - Spring

19 - Plug (3 Used)

8910 11 12 -

14 15 16 17 18 -

20 - O-Ring (3 Used) 21 - Main Relief Valve 21a - O-Ring 22 - Socket Bolt (5 Used) 23 - Name Plate

O-Ring Plug O-Ring O-Ring Spring

Stopper Orifice (2 Used) Spool Poppet (3 Used) Spring (3 Used)

W2-5-22

UPPERSTRUCTURE / Control Valve Disassemble Control Valve (5)

• Flow Combiner Valve

1. Remove socket bolts (22) (5 used) and remove flow combiner valve assembly (1). : 14 mm 2. Clamp block (2) in a vise. 3. Remove main relief valve (21) from block (2). : 32 mm 4. Remove plug (9). Remove spool (16), stopper (14), and springs (12, 13) from block (2). : 32 mm 5. Put the matching marks onto each port and part. 6. Remove plug (19). Remove poppet (17) and spring (18) from block (2). (common to 3 places) : 12 mm 7. Remove plug (3). : 5 mm 8. Remove orifices (15) (2 used) from block (2). : 4 mm

W2-5-23

UPPERSTRUCTURE / Control Valve ASSEMBLE CONTROL VALVE (5)

Machine Lower

Machine Front

3, 8, 15

22

A

T1HH-03-03-002

W1HH-02-05-007

Control Valve Upper View

Control Valve Front View 15

16

10

9

12

13

14 20 7

19

6

18 17

20

4

19

11 2 18 17 5

21a 21 Section A 1 - Flow Combiner Valve Assembly 2 - Block 3 - Plug 4 - Plug 5 - O-Ring (3 Used) 6 - O-Ring (4 Used)

W1HH-02-05-010

7 - O-Ring (2 Used)

13 - Spring

19 - Plug (3 Used)

8910 11 12 -

14 15 16 17 18 -

20 - O-Ring (3 Used) 21 - Main Relief Valve 21a - O-Ring 22 - Socket Bolt (5 Used) 23 - Name Plate

O-Ring Plug O-Ring O-Ring Spring

Stopper Orifice (2 Used) Spool Poppet (3 Used) Spring (3 Used)

W2-5-24

UPPERSTRUCTURE / Control Valve Assemble Control Valve (5)

• Flow Combiner Valve

1. Clamp block (2) in a vise.

10. Install O-rings (5) (3 used), O-rings (6) (4 used), O-rings (7) (2 used), and O-ring (11) to block (2).

2. Install orifices (15) (2 used) in block (2). : 4 mm : 7.8 to 9.8 N⋅m (0.8 to 1.0 kgf⋅m, 5.8 to 7.2 lbf⋅ft)

11. Install flow combiner valve assembly (1) with socket bolt (22) (5 used). : 14 mm : 215 to 255 N⋅m (22 to 26 kgf⋅m, 159 to 188 lbf⋅ft)

3. Install O-ring (8) to plug (3). 4. Install plug (3). : 5 mm : 12.7 to 16.7 N⋅m (1.3 to 1.7 kgf⋅m, 9.4 to 12.3 lbf⋅ft) 5. Install O-ring (20) to plug (19). 6. Install poppet (17) and spring (18) into block (2). Align the matching marks and install plug (19). (common to 3 places) : 12 mm : 225 to 265 N⋅m (23 to 27 kgf⋅m, 166 to 195 lbf⋅ft) 7. Install O-ring (10) to plug (9). 8. Install spool (16), stopper (14), and springs (12, 13) into block (2). Install plug (9). : 32 mm : 68.6 to 78.4 N⋅m (7 to 8 kgf⋅m, 50 to 58 lbf⋅ft) 9. Install O-ring (21a) to main relief valve (21). Install main relief valve (21) in block (2). : 32 mm : 68.6 to 78.4 N⋅m (7 to 8 kgf⋅m, 50 to 58 lbf⋅ft)

W2-5-25

UPPERSTRUCTURE / Control Valve DISASSEMBLE CONTROL VALVE (6) 9a 10

9 9c 9b 7

11

8

7a 2

1

8a

Casing B

1 3 3

6

4

5

6

Casing A

5 6

4 6 6

7a

4

7

7a 7

W173-02-05-026

1 - Plug (2 Used)

5 - O-Ring (6 Used)

2 - Plug 3 - O-Ring (2 Used)

6 - O-Ring (5 Used) 7 - Overload Relief Valve (3 Used): Bucket Rod, Arm Bottom, Boom Bottom Side 7a - O-Ring (3 Used)

4 - O-Ring (6 Used)

8 - Overload Relief Valve: Bucket Bottom Side 8a - O-Ring 9 - Pump Control Valve: (4-Spool Section)

9b - O-Ring

9a - O-Ring

11 - Socket Bolt (8 Used)

W2-5-26

9c - O-Ring 10 - Socket Bolt

UPPERSTRUCTURE / Control Valve Disassemble Control Valve (6)

• Pump Control Valve (4-Spool Section) 1. Remove pump control valve (9). : 36 mm

• Overload Relief Valve 2. Check that there are two kinds of overload relief valve. Put the matching marks on to each port and part. IMPORTANT: Loosen the valve of overload relief valve. If loosening the lock nut and adjusting screw, the set pressure will change. Do not loosen the lock nut and adjusting screw.

(80 mm)

(12.7 mm)

(Wrench Size: 32 mm)

(45 mm)

43 mm

32 mm

3. Remove overload relief valve (7, 8) from casing B by using special tool below. : 32 mm

W1HH-02-05-002

• Casing IMPORTANT: Do not disassemble socket bolts (10, 11) unless necessary. 4. Remove socket bolt (10) and socket bolts (11) (8 used). Disassemble casing A and casing B. : 12 mm

W2-5-27

UPPERSTRUCTURE / Control Valve ASSEMBLE CONTROL VALVE (6) Boom 2

Boom 1

10

Machine Front

5 C

C

D

D

6

E F

4

F G

Control Valve Upper View Left Travel

Section E

T1HH-03-03-002

Right Travel

Arm 1

T1HH-03-03-006

Arm 2

4 7

6

7a 5

5 6

4 7a 7

4 Section C-C

Section F-F

T1HH-03-03-004

T1HH-03-03-007

Auxiliary

Bucket

6

Swing 8

9

8a

9a

5

9c 9b

6

b

7a 7 Section D-D

4

1 - Plug (2 Used)

5 - O-Ring (6 Used)

2 - Plug 3 - O-Ring (2 Used)

6 - O-Ring (5 Used) 7 - Overload Relief Valve (3 Used): Bucket Rod, Arm Bottom, Boom Bottom Side 7a - O-Ring (3 Used)

4 - O-Ring (6 Used)

Section G

T1HH-03-03-005

T1HH-03-03-008

8 - Overload Relief Valve: Bucket Bottom Side 8a - O-Ring 9 - Pump Control Valve: (4-Spool Section)

9b - O-Ring

9a - O-Ring

11 - Socket Bolt (8 Used)

W2-5-28

9c - O-Ring 10 - Socket Bolt

UPPERSTRUCTURE / Control Valve Assemble Control Valve (6)

• Casing

1. Install O-rings (4) (6 used), O-rings (5) (6 used), and O-rings (6) (5 used) to casing B. 2. Connect casing A and casing B. Tighten socket bolt (10) and socket bolts (11) (8 used). : 12 mm : 137 to 177 N⋅m (14 to 18 kgf⋅m, 101 to 130 lbf⋅ft)

• Overload Relief Valve 3. Check that there are two kinds of overload relief valve. Align the matching marks and install it.

(80 mm)

(12.7 mm)

(Wrench Size: 32 mm)

(45 mm)

43 mm

32 mm

4. Install O-ring (7a) to overload relief valve (7). Install O-ring (8a) to overload relief valve (8). Install overload relief valves (7, 8) by using special tool below. : 32 mm : 69 to 78 N⋅m (7 to 8 kgf⋅m, 50 to 58 lbf⋅ft)

W1HH-02-05-002

• Pump Control Valve (4-Spool Section)

5. Install O-rings (9a, 9b, 9c) to pump control valve (9). Install pump control valve (9). : 36 mm : 69 to 78 N⋅m (7 to 8 kgf⋅m, 50 to 58 lbf⋅ft)

W2-5-29

UPPERSTRUCTURE / Control Valve STRUCTURE OF VALVES Main Relief Valve

ITEM

2 9

6

5

1

8 16 7 4

PL

PART NAME

QTY

1

Lock Nut

1

2

Lock Nut

1

3

O-Ring

1

4

O-Ring

1

5

O-Ring

1

6

Adjusting Screw

1

7

Spring

1 1

8

Piston

3

9

Stopper

1

22

10

Poppet

1 1

10

23

11

20

12

21

17

13

18

14

19 R

15 P

11

Backup Ring

12

O-Ring

1

13

Seat

1

14

Spring

1

15

Plunger

1

16

O-Ring

1

17

Filter

1

18

Filter Stopper

1

19

C-Ring

1

20

Spacer

1

21

C-Ring

1

22

Adjusting Plug

1

23

Plug

1

W173-02-05-030

ITEM

Overload Relief Valve 1

5 2

10

18 13

R

15

1 1

3

Adjusting Screw

1 1 1

21

6

Poppet

1

7

Backup Ring

1

19

8

O-Ring

1

9

Backup Ring

1

10

O-Ring

1

11

Seat

1

12

Spring

1

13

Spring

1

14

Plunger

1

20

15

Piston

1

12

16

Filter

1

17

Filter Stopper

1

14

18

C-Ring

1

19

O-Ring

1

20

O-Ring

1

21

Plug

1

22

Body

1

8 7

O-Ring Spring

11

17

Lock Nut

2

Spring Seat

22

16

1

5

6 9

QTY

4

3

4

PART NAME

P W173-02-05-031

W2-5-30

UPPERSTRUCTURE / Control Valve Flow Combiner Valve

B

10 15 14

11 5

8

12

6

7

7

6

5

4

2

3

4

1 9

22

16 W1HH-02-05-011

B

21

4

5

7

6

9 Section B-B

W1HH-02-05-012

Section A-A

ITEM A

A

20 W1HH-02-05-013

18 17

13 18 19

19

19

18

18 17

W1HH-02-05-014

W2-5-31

PART NAME

QTY

1

Name Plate

1

2

Socket Bolt

5

3

Main Relief

1

4

O-Ring

3

5

ROMH Plug

3

6

Spring

3

7

Poppet

3

8

Spool

1

9

Orifice

2

10

Stopper

1

11

Spring

1

12

Spring

1

13

O-Ring

1

14

O-Ring

1

15

Plug

1

16

O-Ring

1

17

O-Ring

2

18

O-Ring

4

19

O-Ring

3

20

Plug

1

21

ROH Plug

1

22

Block

1

UPPERSTRUCTURE / Control Valve Switch Valve (Bucket Flow Rate Control Valve) 2

1

4

3

9

5

6

8

11

10

7

ITEM

PART NAME

QTY

1

Spring

2

Spring

1 1

3

Spool

1

4

Spring Seat

1

5

Plug

1

6

Plug

1

7

Socket Bolt

4

8

O-Ring

1

9

O-Ring

1

10

O-Ring

2

11

Casing

1

W173-02-05-007

Anti-Drift Valve 4 2 7 ITEM

3 5 1

6

8

W173-02-05-008

W2-5-32

PART NAME

QTY

1

Bushing

2

Spring

1 1

3

Spool

1

4

Plug

1

5

O-Ring

3

6

O-Ring

3

7

O-Ring

1

8

Casing

1

UPPERSTRUCTURE / Control Valve Travel Flow Rate Control Valve Assembly Pi

3 ITEM

1 6 DR

2

PART NAME

QTY

1

O-Ring

1

2

Spring

1

3

Plug

1

4

Poppet

1

5

Sleeve

1

6

Piston

1

5

B

4 A W173-02-05-009

Poppet Valve (Bucket Flow Rate Control Valve) B

4

2

ITEM

3 1 A

5

PART NAME

QTY

1

Spring

2

Spring

1 1

3

Plug

1

4

Spring Seat

1

5

Poppet

1

6

Logic Poppet

1

6 P W173-02-05-010

Arm 2 Load Check Valve 3 1 6

ITEM

2 5

B

4

A W173-02-05-011

W2-5-33

PART NAME

QTY

1

O-Ring

1

2

Spring

1

3

Plug

1

4

Poppet

1

5

Sleeve

1

6

Piston

1

UPPERSTRUCTURE / Control Valve Needle Valve A

5 4 2 6 7

1

3

Section A-A

A ITEM

W173-02-05-012

PART NAME

W173-02-05-013

QTY

1

O-Ring

2

O-Ring

3 1

3

Plug

2

4

Nut

1

5

Adjusting Screw

1

6

Poppet

1

7

Casing

1

Blank Flange

1

W1HH-02-05-016

5

4

4

5

2

4

3

5

ITEM

3

LCAT1

LCAP1

W1HH-02-05-015

W2-5-34

PART NAME

QTY

1

Socket Bolt

4

2

Blank Flange

1

3

O-Ring

2

4

O-Ring

3

5

ROH Plug

3

UPPERSTRUCTURE / Control Valve Arm Anti-Drift Valve A

12

13

17

21 PL

B1

B

3

17

4 12 2

5

19

B

24

6

20

8

7

14

18

Section A-A Dr

Dr W1HH-02-05-006

A

W1HH-02-05-008

ITEM+ 1

9

16

11

10

23

22

15

1 A1

W1HH-02-05-009

15 Section B-B

W2-5-35

PART NAME

QTY

Socket Bolt

8

2

Socket Bolt

4

3

Piston

1

4

Piston

1

5

Relief Valve

1

6

Bushing

1

7

Spring

1

8

Spool

1

9

Spring

1

10

Poppet

1

11

Plug

1

12

Plug

2

13

Plug

1

14

Plug

1

15

O-Ring

2

16

O-Ring

1

17

O-Ring

2

18

O-Ring

2

19

O-Ring

3

20

O-Ring

1

21

O-Ring

1

22

Casing

1

23

Casing

1

24

Casing

1

UPPERSTRUCTURE / Control Valve Boom 1 Spool Assembly

2

3

6

9

7

4

8

5

1 W173-02-05-015

ITEM

PART NAME

QTY

1

Plug 2

1

2

Plug 1

1

3

Spring B3

1

4

Spring B2

1

5

Spring B1

1

6

Plunger 3

1

7

Plunger 2

1

8

Plunger 1

1

9

Spool

1

Arm 2 Spool Assembly 8

3

10

9

4

6

ITEM

11 PART NAME

1

12 QTY

1

Spring Seat (1)

1

2

Plug

1

3

Plug

1

4

Stopper (2)

1

5

Stopper (1)

1

6

C-Ring

1

7

Spring A2

1

8

Spring A1

1

9

Sleeve (1)

1

10

Sleeve (2)

1

11

Sub Spool

1

12

Spool

1

W2-5-36

7

5

2

W173-02-05-016

UPPERSTRUCTURE / Control Valve Bucket Spool Assembly

W1HH-02-05-018

2

5

8

4

7

9

ITEM 1

PART NAME

QTY

Plug 2

1

2

Plug 1

1

3

Spring B3

1

4

Spring B2

1

5

Spring B1

1

6

Plunger 3

1

7

Plunger 2

1

8

Plunger 1

1

9

Spool

1

W2-5-37

6

3

1

UPPERSTRUCTURE / Control Valve Pump Control Valve 3 1

4 8 9

Dr

2

Pc

6

PE

5

R

7 P W173-02-05-017

ITEM

PART NAME

QTY

1

Lock Nut

2

O-Ring

1

3

Adjusting Plug

1

4

Spring

1

5

Spool

1

6

O-Ring

1

7

O-Ring

1

8

O-Ring

1

9

Body

1

W2-5-38

1

UPPERSTRUCTURE / Swing Device REMOVE AND INSTALL SWING DEVICE 7

IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

6 1 2

Removal 1. Remove hoses (1 to 3 and 5 to 7). : 41 mm, 19 mm, 17 mm : 8 mm 5

2. Cap the removed hoses and pipes. Attach a nylon sling to the swing motor. Nylon sling (eye-type at both ends): 2 pieces

3 4

CAUTION: Swing device weight: 390 kg (800 Ib)

W1HH-02-06-001

3. Remove bolt (4). Hoist and remove the swing device. : 32 mm : 640 N⋅m (65 kgf⋅m, 470 Ibf⋅ft)

Nylon Sling

W176-02-06-002

W2-6-1

UPPERSTRUCTURE / Swing Device Installation NOTE: Refer to “Removal” section for wrench sizes and tightening torques.

7 6 1

1. Apply THREEBOND #1102 to both mounting surfaces on the swing device and main frame. Install the swing device with bolts (4). 2. Install hoses (1 to 3 and 5 to 7). : 41 mm : 205 N⋅m (21 kgf⋅m) : 19 mm : 29.5 N⋅m (3 kgf⋅m) : 17 mm : 24.5 N⋅m (2.5 kgf⋅m) : 8 mm : 50 N⋅m (5.1 kgf⋅m)

2

5 3 4 W1HH-02-06-001

3. After completing the work, fill the swing motor with hydraulic oil. Check hydraulic oil level. Start the engine and check for any oil leaks.

W2-6-2

UPPERSTRUCTURE / Swing Device (Blank)

W2-6-3

UPPERSTRUCTURE / Swing Device DISASSEMBLE SWING DEVICE

32 1 22 2

23 3 4 5

31

6

21

7 30 29

8

24

18

25

20

9 7

28

10

19

11

27

12

26

18

13

17

14

16

13 12

15

W1HH-02-06-002

1 - Socket Bolt (12 used) 23456-

Motor Retaining Ring First Stage Sun Gear Pin (3 Used) Spring Pin (3 Used)

7 - Thrust Plate (6 used) 8 - Needle Bearing (3 Used)

9 - First Stage Planetary Gear (3 used) 10 - Pin (3 Used) 11 - Spring Pin (3 Used) 12 - Thrust Plate (6 used) 13 - Needle Bearing (6 Used) 14 - Second Stage Planetary Gear (3 used) 15 - Nut 16 - Lock Plate

17 - Bolt (2 Used)

25 - Drain Plug

18 19 20 21 22 -

26 27 28 29 30 -

Thrust Plate (2 used) Second Stage Carrier Second Stage Sun Gear First Stage Carrier Ring Gear

23 - Roller Bearing 24 - Pipe

W2-6-4

Shaft O-Ring Oil Seal Sleeve Roller Bearing

31 - Housing 32 - Socket Bolt (12 used)

UPPERSTRUCTURE / Swing Device Disassemble Swing Device CAUTION: Ring gear (22) weight: 34 kg (75 lb)

CAUTION: Swing device weight: 390 kg (860 lb) 1. Attach a nylon sling to the swing motor. Hoist the swing device. 2. Place the swing device on bracket (ST 5100). Secure the swing device with bolts (M22) (2 used). Secure the bracket on a workbench. : 32 mm Swing Device

7. Remove socket bolt (32). Install eyebolt (M12, Pitch 1.75 mm) to the motor mounting thread position of ring gear (22). THREEBOND has been applied on the jointed surfaces between housing (31) and ring gear (22). Insert a screwdriver into the notch between jointed portion. Hoist and remove ring gear (22) from housing (31). : 17 mm CAUTION: Second stage weight: 42 kg (93 lb)

ST 5100

sun

gear

(20)

8. Remove second stage sun gear (20) and the second stage carrier (19) assembly.

W1HH-02-06-011

3. Remove drain plug (25) and drain off oil. : 8 mm 4. Remove pipe (24) from housing (31). : 18 mm CAUTION: Motor (2) weight: 71 kg (160 lb) 5. Put the matching marks at the jointed portions between motor (2) and ring gear (22), between ring gear (22) and housing (31). Remove socket bolt (1). Hoist and remove motor (2). : 10 mm NOTE: Insert the screwdriver between motor (2) and ring gear (22). Float motor (1). Remove motor (2) easily. 6. Remove first stage sun gear (4) from first stage carrier (21). Remove the first stage carrier (21) assembly from ring gear (22). : 8 mm

W2-6-5

UPPERSTRUCTURE / Swing Device

31

17 26 16 15

W1HH-02-06-002

W2-6-6

UPPERSTRUCTURE / Swing Device CAUTION: Housing (31) assembly weight: 200 kg (440 lb) 9. Remove bolt (17). Remove lock plate (16). : 17 mm 10. Remove nut (15) from shaft (26) by using special tool (ST 3167). ST 3167

15

W178-02-06-008

W2-6-7

UPPERSTRUCTURE / Swing Device

32

23

31

30 29

26

W1HH-02-06-002

W2-6-8

UPPERSTRUCTURE / Swing Device 11. Install eyebolt (M20, Pitch 2.5 mm) into the bolt (32) hole of housing (31). Remove bolts (M22) (2 used) securing the housing and bracket. Hoist the housing (31) assembly and remove the bracket.

CAUTION: If pushing shaft (26) by using a press, provide a protection cover (outer diameter: 369 mm (14.5 in), inner diameter: 90 mm (3.5 in), thickness: 25 to 30 mm (1.0 to 1.2 in)). Push shaft (26) with the protection cover on by using a press. When housing (31) and/or roller bearing (23) are broken and flown off, the metal fragments may result in personal injury. Use a press with the capacity less than 30 tons (66000 lb). Degrease the housing inside before heating roller bearing (23). Failure to degrease may cause a fire.

12. Set the blocks on the press. Set the housing (31) assembly on the blocks.

3

13. Put the protection cover onto housing (31) and remove shaft (26) by using a press. The inner race of roller bearing (30) and sleeve (29) are removed with shaft (26) together. Shaft (26) Roller Bearing (23)

Housing (31)

W1HH-02-06-012

Block Protection Cover

Press

W157-02-06-010

Protection Cover

Special Tool

W157-02-06-011

14. Remove the inner race of roller bearing (23) from housing (31).

W2-6-9

UPPERSTRUCTURE / Swing Device

31

30 29

27

26

W1HH-02-06-002

W2-6-10

UPPERSTRUCTURE / Swing Device 15. Set special tool to the shaft (26) assembly. NOTE: Use the following parts as special tool for roller bearing (30).

CAUTION: When pushing shaft (26) by using a press, set the shaft into the guide. 16. Set shaft (26) with special tool to a press. Remove roller bearing (30).

Part Size Shaft Length: 220 mm or Bolt (8.7 in) Diameter: 19 mm (3/4 in)

Remarks 8 used. All should be identical in length with no wear and deformation on both ends. Material: S35C Hose Standard Diame- 2 used. Clamp ter: 8-1/2” (Applicable Diameter: 185 to 215 mm) Guide Height: 160 mm (6.3 in) Outer Diameter: 292 mm (11.5 in) Inner Diameter: 272 mm (10.7 in)

Press

Shaft (26) Roller Bearing (30) Sleeve (29)

Guide

W157-02-06-014

Hose Clamp

17. Remove sleeve (29) from shaft (26). Remove O-ring (27) from sleeve (29).

Shaft

18. Insert a round bar into the oil passage in housing (31). Tap and remove the outer race of roller bearing (30).

Oil Passage W157-02-06-012

Outer Race

Shaft (26) Roller Bearing (30) W1HH-02-06-007

Sleeve (29)

Guide

Hose Clamp

Shaft W157-02-06-01

W2-6-11

UPPERSTRUCTURE / Swing Device

23

5

31 21

6 7 8 9

10

28 19

11

18 14 13 12

W1HH-02-06-002

W2-6-12

UPPERSTRUCTURE / Swing Device CAUTION: Housing (31) weight: 104 kg (230 lb) 19. Fasten the housing (31) body by using a nylon sling. Hoist and turn over housing (31). Insert a screwdriver into the notch on housing (31) where oil seal (28) is mounted. Remove oil seal (28). THREEBOND has been applied on the periphery of oil seal (28). The oil seal cannot be reused. 20. Remove the outer race of roller bearing (23) from housing (31) by using a bar and hammer. 21. Remove spring pin (6) from first stage carrier (21) by using a round bar and hammer. 22. Remove pins (5) (3 used), first stage planetary gears (9) (3 used), thrust plates (7) (6 used), and needle bearings (8) (3 used) from first stage carrier (21). 23. Remove thrust plates (18) from first stage carrier (21). 24. Remove spring pin (11) from second stage carrier (19) by using a round bar and hammer. 25. Remove pins (10) (3 used), second stage planetary gears (14) (3 used), thrust plates (12) (6 used), and needle bearings (13) (6 used) from second stage carrier (19). 26. Remove thrust plate (18) from second stage carrier (19).

W2-6-13

UPPERSTRUCTURE / Swing Device ASSEMBLE SWING DEVICE 3 5 6 1

2

4

7 8

21

9 7

18

11 12

20

13 32

19 14

22

10

18 17 16 15

23 30

24 31 25 26

27

28 29

T1HH-03-02-001

1 - Socket Bolt (12 used) 23456-

Motor Retaining Ring First Stage Sun Gear Pin (3 Used) Spring Pin (3 Used)

7 - Thrust Plate (6 used) 8 - Needle Bearing (3 Used)

9 - First Stage Planetary Gear (3 used) 10 - Pin (3 Used) 11 - Spring Pin (3 Used) 12 - Thrust Plate (6 used) 13 - Needle Bearing (6 Used) 14 - Second Stage Planetary Gear (3 used) 15 - Nut 16 - Lock Plate

17 - Bolt (2 Used)

25 - Drain Plug

18 19 20 21 22 -

26 27 28 29 30 -

Thrust Plate (2 used) Second Stage Carrier Second Stage Sun Gear First Stage Carrier Ring Gear

23 - Roller Bearing 24 - Pipe

W2-6-14

Shaft O-Ring Oil Seal Sleeve Roller Bearing

31 - Housing 32 - Socket Bolt (12 used)

UPPERSTRUCTURE / Swing Device Assemble Swing Device 1. Install needle bearing (8) in first stage planetary gears (9) (3 used) respectively. 2. Install thrust plates (18) in first stage carrier (21) with the oil groove up.

8. Install sleeve (29) and the inner race of roller bearing (30) into shaft (26). Install sleeve (29) and the inner race by using special tools (ST 7289, ST 7292) and a press.

3. Install first stage planetary gears (9) (3 used) and thrust plates (7) (6 used) into first stage carrier (21).

Press

4. Align the hole on pin (5) with spring pin hole on first stage carrier (21). Install pins (5) (3 used) by using a hammer.

ST 7292 ST 7289

29

5. Face the slit of spring pin (6) to the end of pin (5). Install spring pin (6) into first stage carrier (21) and pin (5) by using a hammer. 5

30

26

6

WIHH-02-06-008

Slit

NOTE: In case only oil seal (29) is replaced, be sure to use the special tool (ST 7300 or ST 7296).

W178-02-06-002

6. Assemble second stage carrier (19) in the same procedures as steps 1 to 5. Assemble second stage planetary gears (14) (3 used), needle bearings (13) (6 used), thrust plates (12) (6 used), (18), pins (10) (3 used), and spring pins (11) (3 used). 7. Install O-ring (27) onto sleeve (29).

CAUTION: Housing (31) weight: 104 kg (230 lb) 9. Fasten the housing (31) body by using a nylon sling. Hoist and place housing (31) with the sleeve (29) mounting side up. 10. Tap and install the outer race of roller bearing (30) into housing (31) by using a bar and hammer evenly. Tap and listen to ring in order to check if the installation is completed.

W2-6-15

UPPERSTRUCTURE / Swing Device

32

22

15

23

31

26 28 29 T1HH-03-02-001

W2-6-16

UPPERSTRUCTURE / Swing Device 11. Apply THREEBOND #1102 on the outer surface of oil seal (28). Place oil seal (28) flat on housing (31) and push the oil seal in gently by hand. Place special tool (ST 7291) on oil seal (28). Tap in special tool by using a hammer directly. ST 7291

19. Place special tool (ST 7290) onto the inner race of roller bearing (23). Install the inner race by using a press.

28

23 ST 7290

31

WIHH-02-06-009

WIHH-02-06-010

12. Apply grease to the inner surface of oil seal (28). Apply grease to the outer surface of sleeve (29) on shaft (26). 13. Install eyebolt (M20, Pitch 2.5 mm) into the bolt (32) hole in housing (31). Hoist and place housing (31) on shaft (26). Check and align carefully in order to prevent the oil seal (28) lip from curling. 14. Tap and install the outer race of roller bearing (23) into housing (31) by using a bar and hammer evenly. Tap and listen to ring in order to check if the installation is completed. 15. Tap and install the inner race of roller bearing (23) into shaft (26) by using a bar and hammer. Tap the inner race until two threads of shaft for nut (15) appear. 16. Tighten nut (15) to shaft (26) by hand. Prevent shaft (26) from falling off when hoisting housing (31). CAUTION: Housing (31) + shaft (26) + bearing (23) weight: 193 kg (425 lb) 17. Install eyebolt (M20, Pitch 2.5 mm) into the bolt (32) hole in housing (31). Hoist and place housing (31) on a press. 18. Remove nut (15) from shaft (26).

W2-6-17

UPPERSTRUCTURE / Swing Device

20 19 22

17 16 23

15

31 26

T1HH-03-02-001

W2-6-18

UPPERSTRUCTURE / Swing Device 20. Hoist and place the housing (31) assembly on bracket (ST 5100). Install the housing (31) assembly with bolts (M22) (2 used). Insert the stopper at the bottom of bracket between teeth of the pinion gear. Secure the bracket on a workbench. 31 : 32 mm

CAUTION: Second stage carrier weight: 42 kg (93 lb) 23. Install the second stage carrier (19) assembly onto the spline of shaft (26). The concave part of the boss in bottom side of the carrier comes in contact with lock plate (16).

ST 5100

Concave

Stopper

19 16

26

W178-02-06-012

21. Apply a firm of grease on the thread part of nut (15). Install nut (15) on shaft (26) with the stepped side facing to roller bearing (23). Tighten nut (15) by using special tool (ST 3167). : 735 N⋅m (75 kgf⋅m, 540 lbf⋅ft) NOTE: Apply grease for keeping correct tightening torque. ST 3167

15

W178-02-06-014

24. Install second stage sun gear (20) into the second stage carrier (19) assembly. 25. Clean off old adhesive. Apply THREEBOND #1215 onto the ring gear (22) mounting surface of housing (31).

W178-02-06-008

22. Install lock plate (16) onto nut (15) with bolt (17). In case the spline of lock plate (16) and that of shaft (26) are not aligned, tighten nut (15) in tightening direction until both splines are aligned. : 17 mm : 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

W2-6-19

UPPERSTRUCTURE / Swing Device

2

1 4

21

20 32

22

24

31

25

T1HH-03-02-001

W2-6-20

UPPERSTRUCTURE / Swing Device CAUTION: Ring gear weight: 34 kg (75 lb) 26. Install eyebolt (M12, Pitch 1.75 mm) to the motor mounting thread part on ring gear (22). Hoist and install ring gear (22) on housing (31) while aligning the matching marks. Tighten socket bolts (32) (12 used). : 17 mm : 390 N⋅m (40 kgf⋅m) 27. Install the first stage carrier (21) assembly onto the spline of second stage sun gear (20). 28. Install first stage sun gear (4) into the first stage carrier (21) assembly with the stepped side down. 29. Wind the seal tape onto the thread part of pipe (24). Install pipe (24) into housing (31) with the pipe down. : 18 mm 30. Wind the seal tape onto drain plug (25). Install drain plug (25) into pipe (24). : 8 mm : 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft) 31. Add gear oil. Geal oil: 16.3 L (4.31 US gal) 32. Apply THREEBOND #1215 onto the motor mounting surface of ring gear (22). CAUTION: Motor weight: 71 kg (160 Ib) 33. Hoist motor (2). Align the matching marks and install motor (2) into ring gear (22) with socket bolts (1) (12 used). : 10 mm : 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)

W2-6-21

UPPERSTRUCTURE / Swing Device DISASSEMBLE SWING MOTOR 12 11 10 9 8 7 6 3 2

13

5 4 21

1

22

23

26 24

27 28

25

20

24

16

17

18

23

22

19

21

29 W1HH-02-06-005

15 14

1 - Casing 2 - Parking Brake Release Valve 3 - Socket Bolt (3 Used) 4 - Oil Seal 5 - Bearing 6 - Shaft 7 - Shoe Plate 8 - Plunger (9 Used)

9 - Plate 10 - Retainer

17 - Spring (24 Used) 18 - Valve Plate

24 - Poppet (2 Used) 25 - Valve Casing

11 12 13 14 15 16 -

19 20 21 22 23 -

26 27 28 29 -

Rotor Friction Plate (3 Used) Plate (4 Used) O-Ring O-Ring Brake Piston

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

W2-6-22

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

UPPERSTRUCTURE / Swing Device Disassemble Swing Motor CAUTION: Swing motor assembly weight: 70 kg (155 Ib)

7. Attach special tool (ST 7288) onto the brake piston (16) groove and hoist brake piston (16). 26

IMPORTANT: Do not disassemble relief valve (29). 1. Remove relief valves (29) (2 used) from valve casing (25). : 41 mm

ST 7288

16

2. Remove plugs (21) (2 used) from valve casing (25). : 17 mm

1

3. Remove springs (23) (2 used) and poppets (24) (2 used) from valve casing (25). 4. Remove socket bolts (3) (3 used) from casing (1). Remove parking brake release valve (2). : 5 mm

W1HH-02-06-006

8. Remove O-rings (14, 15) from casing (1).

5. Put the matching marks on the mounting surfaces between valve casing (25) and casing (1). Remove socket bolts (26) (4 used). Remove valve casing (25) from casing (1). : 17 mm NOTE: Check that valve casing (25) is floated by spring (17). Valve plate (18) may be removed with valve casing (25). When removing valve casing (25), do not fall off valve plate (18). IMPORTANT: Do not damage the mating surfaces when separating valve plate (18) from valve casing (25) or rotor (11) by using a screwdriver. 6. If valve plate (18) is still attached with the rotor in step 5, remove valve plate (18) from the rotor. Remove springs (17) (24 used).

W2-6-23

UPPERSTRUCTURE / Swing Device

12 11 10 9 8 7 6

13

5 4 1 25

19

W1HH-02-06-005

W2-6-24

UPPERSTRUCTURE / Swing Device IMPORTANT:

Do not damage the slide surfaces of rotor (11) and plunger (8). 9. Place casing (1) horizontally. Remove rotor (11) from shaft (6). Remove retainer (10), plate (9), and plungers (8) (9 used) from shaft (6).

10. Remove plates (13) (4 used) and friction plates (12) (3 used) from casing (1). 11. Remove shoe plate (7) from casing (1). Do not damage the slide surface of shoe plate (7). 12. When removing shaft (6), the spline damages the oil seal. Wind the tape onto the spline of shaft (6) before removing shaft (6). Tap and remove shaft (6) from casing (1) by using a plastic hammer lightly. 13. Remove oil seal (4) from casing (1). 14. Remove the outer race of bearing (5) from casing (1) by using a bar and plastic hammer. 15. Remove the inner race of bearing (5) from shaft (6) by using a press. 16. Remove bearing (19) from valve casing (25) by using a bearing puller.

W2-6-25

UPPERSTRUCTURE / Swing Device ASSEMBLE SWING MOTOR 24 23 22 21

26

28 27 T1HH-03-02-003

25 29 17 16 15 19

14

20 18

12 3

13

2

8 10

11

7

9

5

1

4

6 T1HH-03-02-002

1 - Casing 2 - Parking Brake Release Valve 3 - Socket Bolt (3 Used) 4 - Oil Seal 5 - Bearing 6 - Shaft 7 - Shoe Plate 8 - Plunger (9 Used)

9 - Plate 10 - Retainer

17 - Spring (24 Used) 18 - Valve Plate

24 - Poppet (2 Used) 25 - Valve Casing

11 12 13 14 15 16 -

19 20 21 22 23 -

26 27 28 29 -

Rotor Friction Plate (3 Used) Plate (4 Used) O-Ring O-Ring Brake Piston

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

W2-6-26

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

UPPERSTRUCTURE / Swing Device Assemble Swing Motor 1. Install the inner races of bearings (5, 19) into shaft (6) by using a press. Install the inner race of bearing (5) with the flange facing to the stepped side of shaft (6). 2. Push oil seal (4) into casing (1) by using a plate. Install oil seal (4) with the lip facing to the bearing (5) mounting side.

10. Install brake piston (16) into casing (1). 11. If it is not easy to install brake piston (16) due to the resistant force from O-rings (14, 15), tap O-rings evenly by using a plastic hammer. Install springs (17) (24 used) onto brake piston (16).

3. Install the outer race of bearing (5) into casing (1) by using a bar. 4. Wind the tape onto the spline at the end of shaft (6) in order not to damage the lip of oil seal (4). Place casing (1) horizontally. Install shaft (6) into casing (1). 5. Place casing (1) with the valve casing (25) mounting side up. Install shoe plate (7). 6. Align the notches on retainer (10) and plate (9). Assemble plate (9) and retainer (10). Install plungers (8) (9 used). Apply hydraulic oil onto the plunger hole in rotor (11). Instert the plunger (8) assembly into rotor (11). 7. Place casing (1) horizontally. Install the rotor (11) assembly onto shaft (6). IMPORTANT: 4 notches are on the outer side of plate (13). 4 notches are at the spline teeth side of friction plate (12). Align each notch at the same place when installing. 8. Place casing (1) vertically. Alternately install plates (13) (4 used) and friction plates (12) (3 used) into casing (1). 9. Apply a film of grease to O-rings (14, 15). Install O-rings (14, 15) onto casing (1).

W2-6-27

UPPERSTRUCTURE / Swing Device 24 23 22 21

26

T1HH-03-02-003

25 29

19 20 18

3 2

1

T1HH-03-02-002

W2-6-28

UPPERSTRUCTURE / Swing Device 12. Install the outer race of bearing (19) into valve casing (25) by using a bar and plastic hammer. Tap the bearing type indicated surface by using a plastic hammer and install bearing (19). 13. Install O-ring (20) onto valve casing (25). Apply grease onto valve plate (18) in order not to fall off. Install valve plate (18) to value casing (25). 14. Align the matching marks on valve casing (25) and casing (1). Install valve casing (25) with socket bolts (26) (4 used). : 17 mm : 431 N⋅m (44 kgf⋅m, 320 lbf⋅ft) 15. Install poppets (24) (2 used) and springs (23) ( 2 used) into valve casing (25). Tighten plug (21) with O-ring (22) attached. : 17 mm : 539 N⋅m (55 kgf⋅m, 400 lbf⋅ft) 16. Install relief valves (29) (2 used) into valve casing (25). : 41 mm : 177 N⋅m (18 kgf⋅m, 130 lbf⋅ft) 17. Install parking brake release valve (2) into casing (1) with socket bolts (3) (3 used). : 5 mm : 12 N⋅m (1.2 kgf⋅m, 8.68 lbf⋅ft)

W2-6-29

UPPERSTRUCTURE / Swing Device DISASSEMBLE AND ASSEMBLE PARKING BRAKE RELEASE VALVE

10

4

9

11

8 3 7

12

6 2

5

1

13 W110-02-06-005

1234-

Casing Spool Spring Plunger

5 - Bushing 6 - Filter 7 - Spacer

8 - Orifice 9 - Spring 10 - O-Ring

W2-6-30

11 - O-Ring (2 used) 12 - Steel Ball 13 - Bolt (3 used)

UPPERSTRUCTURE / Swing Device MAINTENANCE STANDARD Swing Motor d

1. Clearance between piston outer diameter and rotor inner bore.

D-d

Standard 0.028 (0.001)

Unit:m (in) Allowable Limit 0.058 (0.002) W107-02-06-138

Use the piston and rotor for the motor. Use the plunger and cylinder block for the pump.

D

D

W107-02-06-139

2. Clearance between piston and shoe Unit: mm (in) Standard Allowable Limit δ 0 (0) 0.3 mm (0.0118) δ

W107-02-06-140

δ

W107-02-06-141

W2-6-31

UPPERSTRUCTURE / Swing Device 3. Shoe thickness

t

Standard 5.5 (0.22)

Unit: mm (in) Allowable Limit 5.3 (0.21)

t

4. Friction plate thickness

t

Standard 2.0 (0.08)

Unit: mm (in) Allowable Limit 1.8 (0.07)

W107-02-06-142

t

W107-02-06-143

W2-6-32

UPPERSTRUCTURE / Pilot Valve REMOVE AND INSTALL RIGHT PILOT VALVE IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Remove seat mounting bolts (2) (4 used). Remove seat (1) (with seat stand). : 17 mm

2 1

W178-02-07-006

2. Remove screws (24) (4 used) and cover (23). Move boot (29) up. : 17 mm

30 3

29

3. Remove caps (17) (2 used) from cover (18).

4

28 5

27

4. Remove screws (21)(4 used) and (16) (2 used). Move cover (18) up. Remove each harness for key switch (20), air controller (19), and grip (3). Remove cover (18). Remove screws (22, 15, 13) and remove cover (14).

26 25

6 7

10

24 23 21 20 19 18

5. Remove the connector and bolt (11) for switch box (12). Remove switch box (12). : 13 mm

8 9 11

12

22

17 16

15 14 13 W178-02-07-001

W2-7-1

UPPERSTRUCTURE / Pilot Valve 6. Remove hoses (31 to 36). Attach identification tags onto the removed hoses for reassembling. Cap the ends of all removed hoses. : 19 mm

30 3

29

7. Remove nut (4) and remove crips (5, 27). Remove connector (6) and remove grip (3) (with the harness). Remove nut (28). Remove lever (30), washers (25, 26), and boot (29). : 22 mm : 19 mm

4

28 5

27 26 25

6 7

10

24 23 21 20 19 18

8. Remove bolts (9) (3 used) and (8) (with spring pin (7)) from pilot valve (10). Remove pilot valve (10). : 13 mm

8 9 11

12

22

17 16

15 14 13 W178-02-07-001

35

36

31 32 33 34

W178-02-07-002

31 32 33 34 35 36 -

Hose T6: (To pilot shut-off valve) Hose B: (To shockless valve port B for boom lower) Hose G: (To shockless valve port G for bucket roll-in) Hose P3: (From pilot shut-off valve) Hose A: (To shockless valve port A for boom raise) Hose H: (To shockless valve port H for bucket roll-out)

NOTE: Piping location shows that of JIS pattern.

W2-7-2

UPPERSTRUCTURE / Pilot Valve Installation 1. Install bolts (9) (3 used) and (8) (with spring pin (7)) to pilot valve (10). : 13 mm : 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft) 35

2. Install hoses (31 to 36). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)

31

36

32 33 34

IMPORTANT: If the harness is arranged to the inside of spring pin (7), the harness makes contact with the moving part of the pilot valve and the harness is damaged. Arrange the harness to the outside of spring pin (7).

W178-02-07-002

30

3. Temporarily tighten nut (28) to lever (30) and install washers (25, 26). Install lever (30) onto pilot valve (10) with nut (28). Install boot (29). Temporarily tighten nut (4) to lever (30) and install grip (3) with nut (4). Pass the harness of grip (3) through the upper hole of boot (29) and install lever (30) with clips (5, 27). Arrange the harness to the outside of spring pin (7) over bolt (8) head. Install connector (6). : 22 mm : 26 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft) : 19 mm : 26 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft)

3

29 4

28 5

27 26 25

6 7

10

24 23 21 20 19 18

8 9 11

12

22

17 16

15 14 13 W178-02-07-001

W2-7-3

UPPERSTRUCTURE / Pilot Valve 4. Install switch box (12) with bolt (11). Install the connector. : 13 mm : 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft)

30 3

29 4

28

5. Install each harness of key switch (20) and air controller (19).

5

27 26 25

6. Install cover (14) with screws (22, 15, 13). Install cover (18) with screws (21) (4 used) and (16) (2 used). Install caps (17) (2 used) onto cover (18).

6 7

10

24 23 21 20 19 18

7. Install boot (29) and cover (23) with screws (24) (4 used).

8 9 11

12

22

17 16

15 14 13 W178-02-07-001

8. Install seat (1) (with the seat stand) with bolts (2) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft) 9. After completing the work, check the oil level. Start the engine and check for any oil leaks. 2 1

W178-02-07-006

W2-7-4

UPPERSTRUCTURE / Pilot Valve REMOVE VALVE

AND

INSTALL LEFT

PILOT

IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

1

Removal 1. The console is at the most front position. Remove screws (2) (4 used) and cover (3). Move boot (1) up. : 17 mm

10 9

2. Remove screws (7, 8) and remove cover (9).

2

Radio

3 4

8

3. Remove cap (10) from cover (6). 4. Remove screws (4) (3 used) and (5). Move cover (6) up. Remove the radio connector and remove cover (6).

7

6

5 W178-02-07-003

15

16

11 12 13

5. Remove hoses (11 to 16). Cap the ends of all removed hoses. Attach an identification tag onto the removed hoses to for reassembling. : 19 mm

14

W178-02-07-004

11 12 13 14 15 16 -

Hose T5 : (To pilot shut-off valve) Hose F : (To shockless valve port F for right swing) Hose C : (To shockless valve port C for arm roll-out) Hose P2 : (From pilot shut-off valve) Hose E : (To shockless valve port E for left swing) Hose D : (To shockless valve port D for arm roll-in)

NOTE: Piping location shows that of JIS pattern.

W2-7-5

UPPERSTRUCTURE / Pilot Valve 6. Remove nut (18). Remove clips (29, 21). Remove connector (28) and remove grip (17) (with the harness). Remove nut (20). Remove lever (19), washers (25, 26), and boot (1). : 22 mm : 19 mm 7. Remove bolts (24) and (23) (with pin (22)). Remove pilot valve (27). : 13 mm

17

29 18 19

28

1 20 21 22 23 24 25 26 27

W178-02-07-003

W2-7-6

UPPERSTRUCTURE / Pilot Valve Installation 1. Install pilot valve (27) with bolts (24) and (23) (with pin (22)). : 13 mm : 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft)

17

2. Install hoses (11 to 16). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)

29

28

IMPORTANT: If the harness is arranged to the inside of spring pin (22), the harness makes contact with the moving part of pilot valve and the harness is damaged. Arrange the harness to the outside of spring pin (22).

1

8

3. Temporarily tighten nut (20) to lever (19) and install washers (25, 26). Install lever (19) onto pilot valve (27) with nut (20). Install boot (1). Temporarily tighten nut (18) to lever (19) and install grip (17) with nut (18). Pass the harness of grip (17) through the upper hole of boot (1) and install lever (19) with grips (29, 21). Arrange the harness to the outside of spring pin (22) over bolt (23) head. Install connector (28). : 13 mm : 10 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅ft) : 22 mm : 55 N⋅m (5.6 kgf⋅m, 40.5 lbf⋅ft) : 19 mm : 35 N⋅m (3.6 kgf⋅m, 26 lbf⋅ft)

W2-7-7

18 19

9

10

20 21 22 23 24 25 26 27 2 3 4 5

7

6

W178-02-07-003

UPPERSTRUCTURE / Pilot Valve 4. Install the connector of radio. Install cover (6) with screws (4) (4 used) and (5). Install cap (10). Install cover (9) with screws (7, 8).

17

5. Install boot (1) and cover (3) with screws (2) (4 used).

29

6. After completing the work, check the oil level. Start the engine and check for any oil leaks.

18 19

28

1

8

9

10

20 21 22 23 24 25 26 27 2 3 4 5

7

W2-7-8

6

W178-02-07-003

UPPERSTRUCTURE / Pilot Valve REMOVE AND INSTALL TRAVEL PILOT VALVE IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

1

Removal 1. Remove floor mat (1). WIHH-02-07-001

2. Remove bolts (3) (6 used) from the swing frame. Remove under cover (2). : 17 mm 3. Remove bolts (4) (2 used). Remove pedals (5) (2 used) and levers (16, 17). : 17 mm

2 3

4. Remove pipes (6, 7) and hoses (8 to 11). Cap the ends of all removed pipes and hoses. Attach an identification tag onto the removed pipes and hoses for reassembling. : 17 mm, 19 mm 5. Remove socket bolt (14), spring washer (13), and plain washer (12). Remove pilot valve (15). : 8 mm

WIHH-02-07-002

4

17

16

5

4 5 15

14

14

13

13

12

12

6

11

10

9

7

8

W178-02-07-005

678910 11 -

W2-7-9

Pipe T4: Pipe P1: Hose 11: Hose 12: Hose 10: Hose 9:

(To pilot shut-off valve) (From pilot shut-off valve) (To control valve port RF for right travel (forward)) (To control valve port RR for right travel (reverse)) (To control valve port LR for left travel (reverse)) (To control valve port LF for left travel (forward))

UPPERSTRUCTURE / Pilot Valve Installation 1. Install pilot valve (15) with socket bolt (14), spring washer (13), and plain washer (12). : 8 mm : 49 N⋅m (5.0 kgf⋅m, 36 Ibf⋅ft)

1

2. Install pipes (6, 7) and hoses (8 to 11). : 17 mm : 35 N⋅m (3.5 kgf⋅m, 25 Ibf⋅ft) : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft) WIHH-02-07-001

3. Install pedal (5) and levers (16, 17) with bolts (4). : 17 mm : 49 N⋅m (5.0 kgf⋅m, 36 Ibf⋅ft) 4. Install under cover (2) with bolts (3) (6 used). : 17 mm : 49 N⋅m (5.0 kgf⋅m, 36 Ibf⋅ft)

2 3

5. Install floor mat (1). WIHH-02-07-002

6. After completing the work, check the oil level. Start the engine and check for any oil leaks. 4

17

16

5

4 5 15

14

14

13

13

12

12

6

11

10

9

7

8

W178-02-07-005

12 13 14 15 16 17 -

W2-7-10

Pipe T4: Pipe P1: Hose 11: Hose 12: Hose 10: Hose 9:

(To pilot shut-off valve) (From pilot shut-off valve) (To control valve port RF for right travel (forward)) (To control valve port RR for right travel (reverse)) (To control valve port LR for left travel (reverse)) (To control valve port LF for left travel (forward))

UPPERSTRUCTURE / Pilot Valve (Blank)

W2-7-11

UPPERSTRUCTURE / Pilot Valve DISASSEMBLE RIGHT AND LEFT PILOT VALVES ZAXIS330, 330LC: Up to serial No. 320880 ZAXIS350 ZAXIS350LCH ZAXIS370MTH

13

12 14

11

15

11 10 9

8

8 9

7

21

6

20

21

16

5

20

4

5

3

6

19

3 2

18

4

1

17

W176-02-07-001

123456-

Spacer (4 Used) Shim (Several) Balance Spring A (2 Used) Balance Spring B (2 Used) Return Spring A (2 Used) Return Spring B (2 Used)

78910 11 -

Retaining Ring (4 Used) Push Rod A (2 Used) Push Rod B (2 Used) Block Socket Bolt (2 Used)

12 13 14 15 16 -

Cam Screw Joint Universal Joint Oil Seal (4 Used) Spring Guide (4 Used)

W2-7-12

17 18 19 20 21 -

Spool (4 Used) Housing O-Ring Knock Pin (2 Used) O-Ring (2 Used)

UPPERSTRUCTURE / Pilot Valve Disassemble Right and Left Pilot Valves IMPORTANT: Block (10) and housing (18) are made of aluminium. Too strong a force can deform or damage them. Be careful while handling them. IMPORTANT: Spool (17) has been selected to match the hole of housing (18). The dimensions of balance springs A (3), B (4) and return springs A (5), B (6) as well as those of push rods A (8), B (9) are different. Indicate the port number from which it is removed. Port numbers are stamped on housing (18).

4. Remove push rods (8, 9) from block (10). Two kinds of push rods are used. They must be handled in order of port number after removing. 5. By using a bamboo spatula, remove oil seals (15) (4 used) from block (10). 6. Push the springs by using special tool (ST 7257) from the top of spring guide (16). Retaining ring (7) will appear. Remove retaining ring (7) by using a screwdriver or similar tool. (4 places) 7

IMPORTANT: Do not remove screw joint (13) while clamping housing (18) in a vise. The strong torque may act on the screw joint.

16 ST 7257

1. Clamp screw joint (13) in a vise. Turn cam (12) by using a spanner. Remove screw joint (13). : 19 mm, 32 mm 2. Clamp the flat surface of housing (18) in a vise slightly. Remove cam (12) from universal joint (14). : 32 mm

W176-02-07-005

NOTE: The number of shims has been determined for each port during the performance testing at the factory. Do not lose shims. Keep shims carefully in order to install shims to each former port when reassembing.

NOTE: Universal joint (14) has been secured on block (10) by using LOCTITE. Do not remove universal joint (14) unless necessary. 3. Remove socket bolt (11) and remove block (10). Push rods (8, 9) are removed with the block together. : 6 mm

7. Remove spring guide (16), balance springs (3, 4), return springs (5, 6), shim (2), and spacer (1) from spool (17).

W2-7-13

UPPERSTRUCTURE / Pilot Valve

21 20

21 20 19

18

17

W176-02-07-001

W2-7-14

UPPERSTRUCTURE / Pilot Valve 8. Remove spool (17) from housing (18). Slowly turn and remove spool (17). As spool (17) has been selected to match the hole in housing (18), keep spool (17) carefully in order to install spool (17) to the former port when reassembling. 9. Remove O-rings (19, 21) from housing (18). Do not remove knock pin (20) unless necessary.

W2-7-15

UPPERSTRUCTURE / Pilot Valve DISASSEMBLE RIGHT AND LEFT PILOT VALVES 17

ZAXIS330, 330LC: Serial No.320881 and up ZAXIS350H ZAXIS350LCH ZAXIS370MTH

16 15

14

13 12 11 10 22

9 8 7 6

21

5 4

20

3

18

19

2 1

W178-02-07-064

123456-

Spacer (4 Used) Shim (Several) Balance Spring A (2 Used) Balance Spring B (2 Used) Return Spring A (2 Used) Return Spring B (2 Used)

78910 11 12 -

Spring Guide (4 Used) Retaining Ring (4 Used) Pusher A (2 Used) Pusher B (2 Used) Oil Seal (4 Used) Sleeve (4 Used)

13 14 15 16 17 -

W2-7-16

O-Ring (4 Used) Plate Universal Joint Cam Screw Joint

18 19 20 21 22 -

Retaining Ring Plug O-Ring Spool (4 Used) Casing

UPPERSTRUCTURE / Pilot Valve Disassemble Right and Left Pilot Valves IMPORTANT: Casing (22) is made of aluminium. As too strong a force can deform, or damage them, handle them with care. IMPORTANT: Spool (21) has been selected to match the hole of casing (22). The dimensions of balance springs A (3), B (4) and return springs A (5), B (6) as well as those of pushers A (9), B (10) are different. Indicate the port number from which it is removed. Port numbers are stamped on casing (22). IMPORTANT: Do not remove screw joint (17) while clamping casing (22) in a vise. The strong torque may act on the screw joint. 1. Clamp screw joint (17) in a vise. Turn cam (16) by using a spanner. Remove screw joint (17). : 19 mm, 32 mm

IMPORTANT: Insert a soft rubber between sleeve (12) and the tool in order not to damage the surface of sleeve (12). Oil seal (11) cannot be removed from sleeve (12). Sleeve (12) and oil seal (11) must be replaced as an assembly. 5. Pull out sleeve (12) upward by using a pair of plier. IMPORTANT: As pushers (9, 10) are used for ports 1, 3 and for ports 2, 4, the dimensions are different. Indicate the port number from which it is removed in order to keep by the port number. 6. Remove pushers (9, 10) from casing (22).

2. Clamp the flat surface of casing (22) in a vise lightly. Remove cam (16) from universal joint (15). : 32 mm 3. Attach a spanner onto the upper surface and remove universal joint (15). : 17 mm NOTE: Universal joint (15) has been secured on casing (22) by using LOCTITE. 4. Remove plate (14).

W2-7-17

UPPERSTRUCTURE / Pilot Valve

17 16

22

7 6

21

5 4

19

3

18

2 1

W178-02-07-064

W2-7-18

UPPERSTRUCTURE / Pilot Valve 7. Install special tool (ST 4146) to the port hole on casing in order not to lower the spool when pushing the spring. : 6 mm 8. Install special tool (ST 4146) to the pusher hole on casing (22). Push special tool (ST 4146) and push the spring. Tighten special tool (ST 4146) by using bolt (M14, Pitch 2 mm). : 12 mm

ST 4146

22

ST 4145

IMPORTANT: Spool (21) has been selected to match the hole of casing (22). Replace spool (21) and casing (22) as an assembly. 11. Remove special tool (ST 4145) from casing (22). Slowly turn and remove spool (21). IMPORTANT: Retaining ring (18) may come off while disassembling. Do not fall off retaining ring (18) inside the casing. If falling off retaining ring (18) inside the casing, remove retaining ring (18). Retaining ring (18) cannot be reused. 12. Remove retaining ring (18) by using a screwdriver. Install bolt (M8, Pitch 1.25 mm) and remove plug (19). : 13 mm

W178-02-07-048

IMPORTANT: The quantity of shims (2) has been determined for each port during the performance testing at the factory. Do not lose shims. Keep shims carefully in order to install shims to each former port when reassembing. 9. Remove special tool (ST4146). Remove spring guides (7) (4 used), balance springs A (3) (2 used), B (4) (2 used), return springs A (5) (2 used) and B (6) (2 used). 10. Remove shim (2) and spacer (1) (4 used) from spool (21).

W2-7-19

UPPERSTRUCTURE / Pilot Valve ASSEMBLE RIGHT AND LEFT PILOT VALVES ZAXIS330, 330LC: Up to serial No.320880 ZAXIS350H ZAXIS350LCH ZAXIS370MTH

14

13

10

12 15 11 8, 9 7 16 3, 4 5, 6 2 19 1

17 W176-02-07-006

21

123456-

Spacer (4 Used) Shim (Several) Balance Spring A (2 Used) Balance Spring B (2 Used) Return Spring A (2 Used) Return Spring B (2 Used)

78910 11 -

20

Retaining Ring (4 Used) Push Rod A (2 Used) Push Rod B (2 Used) Block Socket Bolt (2 Used)

18

12 13 14 15 16 -

Cam Screw Joint Universal Joint Oil Seal (4 Used) Spring Guide (4 Used)

W2-7-20

17 18 19 20 21 -

Spool (4 Used) Housing O-Ring Knock Pin (2 Used) O-Ring (2 Used)

UPPERSTRUCTURE / Pilot Valve Assemble Right and Left Pilot Valves NOTE: Table below shows the relations between each port and the components. Do not confuse them when assembling.

4. Install retaining ring (7) onto ring holder (ST 7255). 7

Port No. 1 2

Spool (17)

Shim (2)

Push Rods (8, 9)

Same to Same to the former the former one one

3 4

ST 7255

With outer groove Without outer groove With outer groove Without outer groove

Port No.

Return Springs (5, 6)

Balance Springs (3, 4)

1 2 3 4

43 mm 48 mm 43 mm 48 mm

29.9 mm 30.1 mm 29.9 mm 30.1 mm

W176-02-07-008

5. Insert the spool (17) head into the hole of special tool (ST 7257). Push the spring from the top of spring guide (16). Install retaining ring (7) with the ring holder (ST 7255) onto the head of spool. ST 7255

ST 7257

17

Packing Material

W176-02-07-009

1. Insert the thinner end of spool (17) to housing (18) while rotating. Check the port hole number and insert the spool to the former port. NOTE: Spool (17) has been selected to match the port hole. Spool (17) and housing (18) must be replaced as an assembly. IMPORTANT: Refer to the table in order to assemble them correctly. 2. Install spacer (1), shim (2), balance spring (3) or (4), and return spring (5) or (6) onto spool (17) installed in housing (18). 3. Install spring guide (16) onto return spring (3) or (4) with the protrusion up.

W2-7-21

NOTE: Insert approx. dia.8 mm, length 10 mm of packing material into the port hole in order to not only make the work easy to do, but also prevent spool (17) from lowering to the bottom when compressing the spring.

UPPERSTRUCTURE / Pilot Valve

13

14 10

12 15 11 8, 9

W176-02-07-006

20

W2-7-22

18

UPPERSTRUCTURE / Pilot Valve 6. Assemble other spools (17) (3 used) into housing (18) in the same procedures as step 2 to 5.

IMPORTANT:

Check the tightness of cam.

8. Apply grease to the inner surface of oil seals (15) (4 used). Install the oil seals (4 used) into block (10) by using a bamboo spatula.

13. Clamp housing (18) carefully in a vise. Install cam (12) to universal joint (14). Tighten universal joint (14) so that the clearance between cam (12) and push rods (8, 9) become 0 to 0.2 mm. : 19 mm, 32 mm : 88.2 N⋅m (9 kgf⋅m)

NOTE: Insert push rods (8, 9) first as illustrated in order to prevent oil seal (15) from coming into the endmost of hole during operating.

IMPORTANT: Do not clamp housing (18) in a vise when operating. The strong torque may act on the screw joint (13).

7. Install O-rings (19) and (21) (2 used) to housing (18).

Oil Seal Mounting Hole

10

8, 9

14. Clamp screw joint (13) in a vise. Tighten universal joint (14). Tighten cam (12) by using a spanner. : 32 mm : 88.2 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)

W176-02-07-007

9. Install push rods (8, 9) to block (10). Install the push rods with outer groove to ports # 1 and # 3. Install the push rods without outer groove to ports # 2 and # 4. 10. Apply grease to the ball at the ends of push rods (8, 9). 11. Apply grease to the joint part of universal joint (14). 12. Align the position of knock pin (20). Install the block (10) assembly to housing (18) with socket bolts (11) (2 used). : 6 mm : 19.6 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

W2-7-23

UPPERSTRUCTURE / Pilot Valve ASSEMBLE RIGHT AND LEFT PILOT VALVES ZAXIS330, 330LC: Serial No.32088 and up ZAXIS350H ZAXIS350LCH ZAXIS370MTH

17

15

16

14

9, 10

11

12

13

8 7 3, 4 5, 6 2

19 19

1

22

21

18 W178-02-06-055

123456-

Spacer (4 Used) Shim (Several) Balance Spring A (2 Used) Balance Spring B (2 Used) Return Spring A (2 Used) Return Spring B (2 Used)

78910 11 12 -

Spring Guide (4 Used) Retaining Ring (4 Used) Pusher A (2 Used) Pusher B (2 Used) Oil Seal (4 Used) Sleeve (4 Used)

13 14 15 16 17 -

W2-7-24

O-Ring (4 Used) Plate Universal Joint Cam Screw Joint

18 19 20 21 22 -

Retaining Ring Plug O-Ring Spool (4 Used) Casing

UPPERSTRUCTURE / Pilot Valve Assemble Right and Left Pilot Valves IMPORTANT: The pilot valve is susceptible to contamination. Keep the parts clean when assembling. NOTE: Table below shows the relations between each port and the components. Do not confuse them when assembling. Port No. 1 2

Spool (21)

Shim (2)

Same to the former one

Same to the former one

3 4

Pushers A, B (9, 10) Outer grooves (3 Used) Without outer groove Outer grooves (3 Used) Without outer groove

Port No.

Return Springs (5, 6)

Balance Springs A, B (3, 4)

1 2 3 4

Short Long Short Long

Short Long Short Long

IMPORTANT: Refer to the table in order to assemble them correctly. 3. Install spacer (1), shim (2) and balance springs (3, 4) to spool (21). Install return springs (5, 6) to casing (22). 4. Install spring guide (7) onto return springs (5, 6) with the protrusion facing upward. 5. Install special tool (ST 4146) to the pusher hole on casing. Push special tool (ST 4146) and push the spring. Tighten special tool (ST 4146) by using bolt (M14, Pitch 2 mm). : 12 mm ST 4146 ST 4144

ST 4145

1. Check the port hole number and insert spool (21) to the original port. Insert the thinner end of spool (21) to the port hole in casing (22) while rotating. NOTE: Spool (21) has been selected to match the port hole. Spool (21) and casing (22) must be replaced as an assembly.

W178-02-07-049

6. Install retaining ring (8) to ring holder (ST 4144).

2. Install special tool (ST 4145) to the port hole on casing (22) in order not to lower the spool when pushing the spring. : 6 mm

W2-7-25

UPPERSTRUCTURE / Pilot Valve

17

15

16

14

11 13

9, 10 12 8

3, 4

22

W178-02-06-055

W2-7-26

UPPERSTRUCTURE / Pilot Valve 7. Install retaining ring (8) on ring holder (ST 4144) to the groove on the head of spool (21) out of special tool (ST 4146) IMPORTANT: Check the mounting positions of pushers (9, 10). 8. Install pushers (9, 10). Push pushers (9, 10) by hand and remove pushers (9, 10). Check if retaining ring (8) falls off or the positions of balance springs (3, 4) are correct. After checking, install pushers (9, 10) to casing (22). 9. Apply grease to the ball at the ends of pushers (9, 10). 10. Apply grease to the joint part of universal joint (15).

IMPORTANT: Align the bolt hole of plate (14) with the screw hole on casing (22) completely. 14. Place plate (14) onto casing (22) and tighten universal joint (15). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) IMPORTANT: Check the tightness of cam (16). 15. Install cam (16) to universal joint (15). The clearance between cam (16) and pushers (9, 10) should be 0 to 0.2 mm. 16. Secure cam (16) by using a spanner. Tighten screw joint (17) by using a spanner. : 19 mm, 32 mm : 68.4 N⋅m (7.0 kgf⋅m, 50 Ibf⋅ft)

11. Apply grease to the inner surface of oil seals (11) (4 used). NOTE: Sleeve (12) and oil seal (11) must be replaced as an assembly. 12. Install oil seal (11) and sleeve (12). Push sleeve (12) until O-ring (13) is inserted into the hole on casing. 13. Clamp casing (22) in a vise lightly.

W2-7-27

UPPERSTRUCTURE / Pilot Valve DISASSEMBLE TRAVEL PILOT VALVE Suitable for the machine before March in 2003.

1 2

35 34 33 32 31 30

3 4 5 28

6

29

7

27

8 9 10

26 11 12 25

13

23

24

22 21 20 19 18 14 17 15 16

W176-02-07-002

123456789-

Bolt (2 Used) Cover Pin (2 Used) O-Ring (2 Used) O-Ring (2 Used) Damper (2 Used) Rubber Seat (2 Used) Socket Bolt (2 Used) Spring Washer (2 Used)

10 11 12 13 14 15 16 17 18 -

Holder Oil Seal (4 Used) O-Ring (4 Used) Bushing (4 Used) Casing O-Ring Plug Spool (4 Used) Spring (4 Used)

19 20 21 22 23 24 25 26 27 -

Spacer (4 Used) Shim (Several) Balance Spring (4 Used) Spring Guide (4 Used) Pusher (4 Used) Spring Pin (2 Used) Spring Pin (2 Used) Bracket (2 Used) Spring Pin (2 Used)

W2-7-28

28 29 30 31 32 33 34 35 -

Socket Bolt (4 Used) Spring Washer (4 Used) Adjusting Bolt (4 Used) Bushing (4 Used) Cam (2 Used) Lock Nut (4 Used) Spring Pin (2 Used) Spring Pin (2 Used)

UPPERSTRUCTURE / Pilot Valve Disassemble Travel Pilot Valve 1. Clamp casing (14) in a vise. Remove bolt (1) and remove cover (2) from holder (10). : 10 mm 2. Remove socket bolts (8) (2 places). Remove holder (10) from casing (14). : 8 mm 3. Remove pusher (23) from casing (14). (4 places) Bushing (13) and oil seal (11) are removed with pusher (23) together.

8. Place a stand under bracket (26). The hole insides of spring pins (24, 25) in bracket (26) are in stepped-shape. The spring pin can only be removed in one direction. Remove both spring pins (24, 25) from bracket (26) at the same time by using special tool (ST 1237). Remove bracket (26) from pin (3). (2 places) Do not remove spring pin (27) with bracket unless necessary. The outside end of spring pin (27) has been caulked.

4. Remove pusher (23) from bushing (13). By using a bamboo spatula, remove oil seal (11). (4 places) 24, 25

5. Turn and remove the spool (17) assembly from casing (14). (4 places) Spring guide (22), balance spring (21), shim (20), and spacer (19) are removed with spool (17) together. Put the marks on spools (17) (4 used) in order to easily install spools (17) to their former position. 6. Push balance spring (21). Remove spring guide (22), balance spring (21), shim (20), and spacer (19) from spool (17). (4 places) The number of shims (20) has been determined during the performance testing at the factory. They must be kept together with spool (17). 7. Remove spring (18) from casing (14). (4 places)

26 3

27 Caulked Here Stand

W176-02-07-019

9. Remove socket bolts (28) (2 used). Remove damper (6) and rubber seat (7) from pin (3). O-ring (4) is removed together. (2 places) : 5 mm

IMPORTANT: Place a stand under bracket (26) and form an reaction force. If holder (10) bears the reaction force, a strong force acts on pin (3) and pin (3) may be deformed.

W2-7-29

UPPERSTRUCTURE / Pilot Valve

35 34 33 32 31 30 3 5

10

14

W176-02-07-002

W2-7-30

UPPERSTRUCTURE / Pilot Valve 10. Remove O-ring (5) from pin (3). (2 places) 11. Place holder (10) with the casing (14) mounting surface up. IMPORTANT: As the holes for spring pins (34, 35) in cam (32) are stepped-shape, tap the bottom of cam. 12. Remove spring pins (34, 35) from cam (32) at the same time by using special tool (ST 1237). (2 places) As the holes of spring pins (34, 35) are caulked, spring pins (34, 35) may feel tight when removing. 13. Remove pin (3) by using a bar and hammer. At the same time cam (32) is also removed. (2 places) Do not remove bushings (31) (4 used) left on holder (10) unless necessary. When removing, tap bushing (31) by using special tool (ST7256). 14. Remove lock nuts (33) (2 used) from cam (32). Remove adjusting bolts (30) (2 used). (2 places) : 13 mm : 4 mm

W2-7-31

UPPERSTRUCTURE / Pilot Valve DISASSEMBLE TRAVEL PILOT VALVE Suitable for the machine after April in 2003.

1

2 3 4 5 6 35 34

7

33 32

8

31 30

9 10

29

11 28 27

14 12

26 15

13

25 16 24

17 18

23 19 20 21

22 W178-02-07-063

123456789-

Bolt (2 Used) Cover Spring Pin (2 Used) Spring Pin (2 Used) Cam (2 Used) Bushing (4 Used) Holder Spring Washer (4 Used) Socket Bolt (4 Used)

10 11 12 13 14 15 16 17 18 -

Spring Pin Bracket (2 Used) Spring Pin (2 Used) Spring Pin (2 Used) O-Ring (4 Used) Bushing (4 Used) Pusher (4 Used) Spring Guide (16 Used) Balance Spring (4 Used)

19 20 21 22 23 24 25 26 27 -

W2-7-32

O-Ring (2 Used) Plug (2 Used) Plug (2 Used) O-Ring (2 Used) Casing Spool Spring (4 Used) Spacer (4 Used) Shim (12 Used)

28 29 30 31 32 33 34 35 -

Oil Seal (2 Used) Spring Washer (2 Used) Socket Bolt (2 Used) Rubber Seat (2 Used) Damper (2 Used) O-Ring (2 Used) O-Ring (2 Used) Pin

UPPERSTRUCTURE / Pilot Valve Disassemble Travel Pilot Valve IMPORTANT: Casing (23) is made of aluminium. As too strong a force can deform, or damage them, handle them with care. IMPORTANT: Spool (24) has been selected to match the hole of casing. Indicate the port number from which it is removed. Port numbers are stamped on the periphery of casing (23). 1. Clamp casing (23) in a vise. Remove bolts (1) (2 used), and remove cover (2) from holder (7). : 10 mm

IMPORTANT: The quantity of shim has been determined during the performance testing at the factory. Keep the shim together with the spool. 6. Push balance spring (18). Remove spring guide (17), balance spring (18), shim (27) and spacer (26) from spool (24) (4 places). 7. Remove spring (25) from casing (23). (4 places)

2. Remove socket bolt (30) (2 places), and remove spring washer (29) (2 places). Remove holder (7) from casing (23). : 8 mm 3. Remove pushers (16) (4 used) from casing (23) (4 places). 4. Remove pusher (16) from bushing (15). By using a bamboo spatula, remove oil seal (28) (4 places). Remove O-ring (14) from bushing (15). IMPORTANT: Put the mark on spools (24) (4 used) in order to easily install spool (24) into the original hole. 5. Turn and remove the spool (24) assembly from casing (23) (4 places). Spring guide (17), balance spring (18), shim (27) and spacer (26) are removed with spool (24) together. NOTE: Spool (24) has been selected to match the hole of casing (23). Replace spool (24) and casing (23) as an assembly.

W2-7-33

UPPERSTRUCTURE / Pilot Valve

3 4 6

3 4

10

5

11

5

6

12

6

13

35 34

7

33 32 31

9 10

31

11

32 33 34 35 12

13

23 19 20 21

22 W178-02-07-063

W2-7-34

UPPERSTRUCTURE / Pilot Valve IMPORTANT: Place a stand under bracket (11) and form a reaction force. If holder (7) bears the reaction force, a strong force acts on pin (35) and pin (35) may be deformed. 8. Place a stand under bracket (11). The hole insides of spring pins (12, 13) in bracket (11) are in stepped-shape. The spring pin can only be removed in one direction. Remove both spring pins (12, 13) from bracket (11) at the same time by using special tool (ST 1237). Remove bracket (11) from pin (35) (2 places). Do not remove spring pin (10) on bracket (11) unless necessary. The outside end of spring pin (10) has been crimped.

10. Remove O-ring (33) from pin (35) (2 places). 11. Place holder (7) with the casing (23) mounting surface up. 12. Remove spring pins (3, 4) from cam (5) at the same time by using special tool (ST 1237) (2 places). The hole insides for spring pins (3, 4) on cam (5) are the stepped-shape. Tap the bottom of cam (5). As the holes of spring pins (3, 4) are crimped, spring pins (3, 4) may feel tight when removing. 13. Remove pin (35) by using a round bar and hammer. At the same time cam (5) is also removed (2 places). Do not remove bushings (6) (4 used) in holder (7) unless necessary. When removing, tap bushing (6) by using special tool (ST7256).

12, 13

14. Remove plug (20) from casing (23) (2 places). O-ring (19) is removed with plug (20) together.

11 35

10 Crimped Here

15. Remove plug (21) from casing (23) (2 places). O-ring (22) is removed with plug (21) together.

Stand

W176-02-07-019

9. Remove socket bolts (9) (2 used). Remove damper (32) and rubber seat (31) from pin (35). O-ring (34) is removed together (2 places). : 5 mm

W2-7-35

UPPERSTRUCTURE / Pilot Valve ASSEMBLE TRAVEL PILOT VALVE Suitable for the machine before March in 2003.

26

6

7

1

2

3

31

25 27

24

10

32

30

34, 35

33

8

9

13 22

4 28

5

29

11

21

12

18

23

20 19 17

14

W176-02-07-010

15, 16

123456789-

Bolt (2 Used) Cover Pin (2 Used) O-Ring (2 Used) O-Ring (2 Used) Damper (2 Used) Rubber Seat (2 Used) Socket Bolt (2 Used) Spring Washer (2 Used)

10 11 12 13 14 15 16 17 18 -

Holder Oil Seal (4 Used) O-Ring (4 Used) Bushing (4 Used) Casing O-Ring Plug Spool (4 Used) Spring (4 Used)

19 20 21 22 23 24 25 26 27 -

Spacer (4 Used) Shim (Several) Balance Spring (4 Used) Spring Guide (4 Used) Pusher (4 Used) Spring Pin (2 Used) Spring Pin (2 Used) Bracket (2 Used) Spring Pin (2 Used)

W2-7-36

28 29 30 31 32 33 34 35 -

Socket Bolt (4 Used) Spring Washer (4 Used) Adjusting Bolt (4 Used) Bushing (4 Used) Cam (2 Used) Lock Nut (4 Used) Spring Pin (2 Used) Spring Pin (2 Used)

UPPERSTRUCTURE / Pilot Valve Assemble Travel Pilot Valve 1. Assemble spool (17) into the assembly. (4 used) Insert spacer (19), shim (20), and balance spring (21) into spool (17) in this order. Install the shim (20) as the same condition before disassmbling. Push balance spring (21) by hand. Install spring guide (22) to spool (17) with the stepped-end down.

• Install bushing (31) on the opposite side in the same procedure. 31 ST 7256

2. Insert spring (18) to casing (14). (4 places)

10

W176-02-07-015

3. Insert the spool (17) assembly into the former port. Turn and install the spool (17) assembly into casing (14). (4 places)

• Install bushing (31) in near side as illustrated. Stop tapping when the bushing (31) end is flush with the outside of holder (10).

4. Assemble pusher (23) into the assembly. (4 used) Install oil seal (11) onto bushing (13). Apply grease to the inner surface on oil seal (11). Install O-ring (12) to bushing (13). Insert pusher (23) to bushing (13). Apply grease to the head of pusher (23). 5. Insert the pusher (23) assembly to holder (10). (4 places)

31 ST 7256

10

Outside of Holder W176-02-07-014

• Install bushing (31) in the near and opposite side

6. If bushing (31) has been removed from holder (10), install bushing (31) on holder (10) by using special tool (ST 7256) in the following procedures.

as illustrated. 31 ST 7256

10

• Insert bushing (31) into special tool (ST 7256). Tap special tool (ST 7256) and install bushing (31) into the hole of holder (10) by using a hammer. Stop tapping when bushing (31) end is flush with the inside wall. ST 7256

10

31 W176-02-07-016

W2-7-37

W176-02-07-013

UPPERSTRUCTURE / Pilot Valve

10

3

32

30

33

34, 35

8

9

5

23

14 W176-02-07-010

W2-7-38

UPPERSTRUCTURE / Pilot Valve 7. Install adjusting bolt (30) to cam (32). Tighten adjusting bolt (30) by hand and lightly secure adjusting bolt (30) temporarily with lock nut (33). (2 places)

IMPORTANT: Do not adjust adjusting bolt (30) while pushing the pusher (23) head. The standard clearance between adjusting bolt (30) and pusher (23) must be 0 to 0.2 mm (0 to 0.008 in).

NOTE: Adjust the dimensions later. 8. Apply grease on the head (mounting surface for pusher (23)) of adjusting bolt (30). (2 places) 9. Apply grease onto pin (3). Install O-ring (5) to pin (3). Assemble pin (3) to holder (10) with cam (32). (2 places) 10. Install spring pins (34, 35) to cam (32) by using special tool (ST 1237). Secure cam (32) and pin (3). Spring pins (34, 35) should be displaced with their slits at 90°. (2 places) Tap spring pins (34, 35) until they come in contact with the step in hole. 34

35

Slit

Slit

13. Adjust adjusting bolt (30) in the following procedures. (2 places) : 13 mm : 4 mm Loosen lock nut (33). Move cam (32) and check that there is play. If there is no play, turn and adjust adjusting bolt (30). Turn both adjusting bolts (30) on the left and right alternatively and keep cam (32) horizontal. Measure sizes A and B from both left and right caves on cam (32) to holder (10). Fine adjust adjusting bolt (30) in order to get same distance for both left and right. Secure adjusting bolt (30) by using a hexagon wrench. Tighten lock nut (33) to specified torque and secure adjusting bolt (30). When adjustment is finished, move cam (32) and check that there is a little play. If there is no play, pusher (23) may be in compressed condition. Adjust adjusting bolt (30) again. : 9.8 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft)

W176-02-07-017

11. Caulk the hole edge of cam (32) where spring pins (34, 35) are inserted by using a punch. (2 places)

30

A

33

32

10

B

12. Place and install holder (10) on the casing (14) assembly with socket bolts (8) (2 used) and spring washers (9) (2 used). : 8 mm : 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft) W176-02-07-003

W2-7-39

UPPERSTRUCTURE / Pilot Valve

26

6

7

1

2

3

25 27

24

10

4 28

5

29

W176-02-07-010

W2-7-40

UPPERSTRUCTURE / Pilot Valve 14. Install rubber seat (7) to pin (3). (2 places) 15. Apply grease to O-ring (5). (2 places) IMPORTANT: The inner bore of damper (6) is edged-shape. If damper (6) is pried when installing, O-ring (5) will be damaged. 16. Install damper (6) to pin (3) with the lever up. (2 places)

IMPORTANT: Place a stand under bracket (26) and form a reaction force. If holder (10) bears the reaction force, a strong force acts on pin (3) and the pin may be deformed. 20. Place a stand under bracket (26). Tap spring pins (24, 25) into bracket (26) until the spring pins (24, 25) comes to the stepped end by using special tool (ST 1237). The spring pins (2 used) are displaced with their slits in 90°.

17. Secure damper (6) to holder (10) with socket bolts (28) (2 used) and spring washers (29) (2 used). (2 places) : 8 mm : 7 N⋅m (0.7kgf⋅m, 5.1 Ibf⋅ft)

Caulked Here

26

18. Apply grease to O-ring (4). Push O-ring (4) to the endmost of pin (3). (2 places) 19. As for the direction to install the bracket, refer to the figure in the disassembly section. Do not misassemble it. Install bracket (26) to pin (3). Align the inserting holes of spring pins (24, 25).

Stand

Caulked Here

3

24, 25

W176-02-07-011

21. Caulk the hole edge of bracket (26) where spring pins (24, 25) are inserted by using a punch. (2 places) (Refer to the figure above.) 22. Install bracket (26) on the opposite side to pin (3) in the same procedures as steps 19 to 21. 23. Install cover (2) to holder (10) with bolts (1) (2 used). : 10 mm : 5 N⋅m (0.5 kgf⋅m, 3.6 Ibf⋅ft) 24. Apply grease to the spring pin (27) contact part of damper (6). (2 places)

W2-7-41

UPPERSTRUCTURE / Pilot Valve ASSEMBLE TRAVEL PILOT VALVE Suitable for the machine after April in 2003.

11

32

31 1

2

35

6

12

10

13

7

5

3, 4

29

34 9

15

33 28

8

30

17 18

14

25 27

16

26 24 23

W178-02-06-056

123456789-

Bolt (2 Used) Cover Spring Pin (2 Used) Spring Pin (2 Used) Cam (2 Used) Bushing (4 Used) Holder Spring Washer (4 Used) Socket Bolt (4 Used)

10 11 12 13 14 15 16 17 18 -

Spring Pin Bracket (2 Used) Spring Pin (2 Used) Spring Pin (2 Used) O-Ring Bushing (4 Used) Pusher (4 Used) Spring Guide (16 Used) Balance Spring (4 Used)

19 20 21 22 23 24 25 26 27 -

NOTE: As for the parts with * mark, refer to W2-7-32.

W2-7-42

*O-Ring (2 Used) *Plug (2 Used) *Plug (2 Used) *O-Ring (2 Used) Casing Spool (4 Used) Spring (4 Used) Spacer (4 Used) Shim (12 Used)

28 29 30 31 32 33 34 35 -

Oil Seal (2 Used) Spring Washer (2 Used) Socket Bolt (2 Used) Rubber Seat (2 Used) Damper (2 Used) O-Ring (2 Used) O-Ring (2 Used) Pin

UPPERSTRUCTURE / Pilot Valve Assemble Travel Pilot Valve IMPORTANT: Check the direction to install spring guide (17). 1. Assemble spool (24) into the assembly (4 used). • Insert spacer (26), shim (27), and balance spring (18) into spool (24) in this order. Install the shim as the same condition before disassembling. • Push the balance spring by hand. Install spring guide (17) to spool (24) with the stepped part facing downward.

6. If bushing (6) has been removed from holder (7), install bushing (6) on holder (7) by using special tool (ST 7256) in the following procedures. NOTE: Bushings (6) (4 used) are identical. • Insert bushing (6) into special tool (ST 7256). Tap special tool (ST 7256) and install bushing (6) into the hole of holder (7) by using a hammer. Stop tapping when bushing (6) end is flush with the inside wall. ST 7256

7

2. Insert spring (25) to casing (23) (4 places). 3. Insert the spool (24) assembly into the former port. Turn and install the spool (24) assembly into casing (23) (4 places). 4. Assemble pusher (16) into the assembly (4 used). • Install oil seal (28) to bushing (15). • Apply grease to the inner surface on oil seal (28). • Install O-ring (14) to bushing (15). • Insert pusher (16) into bushing (15). • Apply grease to the head of pusher (16). 5. Insert the pusher (16) assembly into casing (23) (4 places).

6

W176-02-07-016

• Install bushing (6) on the opposite side in the same procedure.

6

ST 7256

7

W176-02-07-015

• Install bushing (6) in near and opposite side as illustrated. Stop tapping when the bushing (6) end is flush with the outside of holder (7). 6 ST 7256

7

Outside of Holder W176-02-07-014

• Install bushing (6) in the near and opposite side as illustrated. ST 7256

6 7

W176-02-07-01313

W2-7-43

UPPERSTRUCTURE / Pilot Valve

32

31

35

31 32

7

5

3, 4

30

29 9

34

8

33

23

W178-02-06-056

W2-7-44

UPPERSTRUCTURE / Pilot Valve 7. Install O-ring (33) to pin (35). Assemble pin (35) to holder (7) with cam (5) (2 places). IMPORTANT: Check the direction to install spring pins (3, 4). 8. Install spring pins (3, 4) to cam (5) by using special tool (ST 1237). Secure cam (5) and pin (35). Spring pins (3, 4) should be displaced with their slits at 90° (2 places). Tap and install spring pins (3, 4) until spring pins (34, 35) make contact with the stepped part in the hole. 3

Slit

Slit

11. Install rubber seat (31) to pin (35) (2 places). IMPORTANT: Check the direction of damper (32). The inner bore of damper (32) is edged-shape. If damper (32) is pried when installing, O-ring (33) will be damaged. 12. Install damper (32) to pin (35) with the lever up (2 places). 13. Secure damper (32) and rubber seat (31) to holder (7) with socket bolts (9) (2 used) and spring washers (8) (2 used) (2 places). : 5 mm : 7 N⋅m (0.7 kgf⋅m, 5.2 Ibf⋅ft) 14. Apply grease to O-ring (34). Push O-ring (34) to the endmost of pin (35) (2 places).

4

W178-02-07-050

9. Crimp the hole edge of cam (5) where spring pins (3, 4) are inserted by using a punch. 10. Place holder (7) on the casing (23) assembly. Install holder (7) with socket bolts (30) (2 used) and spring washers (29) (2 used). Check the mark direction and install holder (7). : 8 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

W2-7-45

UPPERSTRUCTURE / Pilot Valve

11

32

1

2

35

12

10

13

7

1

1

W178-02-06-056

W2-7-46

UPPERSTRUCTURE / Pilot Valve 16. As for the direction to install bracket (11), refer to the figure in the disassemble section. Install bracket (11) to pin (35). Align the inserting holes of spring pins (12, 13). IMPORTANT: Place a stand under the bracket and form a reaction force. If holder (7) bears the reaction force, a strong force acts on pin (35) and pin (35) may be deformed. 17. Place a stand under bracket (11). Tap spring pins (12, 13) into bracket (11) until the spring pins (12, 13) comes to the stepped end by using special tool (ST 1237). The spring pins (2 used) are displaced with their slits in 90°.

Crimped Here

11

Stand

Crimped Here

35

12, 13

W176-02-07-011

18. Caulk the hole edge of bracket (11), where spring pins (12, 13) are inserted, by using a punch (2 places). (Refer to the figure.) 19. Install bracket (11) on the opposite side to pin (35) in the same procedures as steps 16 to 18. 20. Install cover (2) to holder (7) with bolts (1) (2 used). : 10 mm : 5 N⋅m (0.5 kgf⋅m, 3.7 Ibf⋅ft) 21. Apply grease to the spring pin (10) contact part of damper (32) (2 places).

W2-7-47

UPPERSTRUCTURE / Pilot Valve (Blank)

W2-7-48

UPPERSTRUCTURE / Pilot Shut-Off Valve REMOVE AND INSTALL PILOT SHUT-OFF VALVE IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

1

Removal 1. Remove spring (3).

2 3 5

2. Remove hoses (6 to 13) and pipes (14, 15). Attach an identification tag to the removed hoses and pipes for reassembling. : 19 mm

4

3. Remove spring pin (5) and remove lever (1).

W178-02-08-001

4. Remove bolt (2) and remove pilot shut-off valve (4). : 17 mm

2 View A

6 10

7 8

9

WIHH-02-08-001

14

View A

15

W2-8-1

12

13

11

WIHH-02-08-002

UPPERSTRUCTURE / Pilot Shut-Off Valve Installation 1. Install pilot shut-off valve (4) with bolt (2). 2. Install lever (1) with spring pin (5). 3. Install hoses (6 to 13) and pipes (14, 15).

1

4. Install spring (3). 2

Wrench Size (mm) : 17 : 19 : 19 678910 11 12 13 14 15 -

Tightening Torque N⋅m (kgf⋅m) (lbf⋅ft) 49 (5) (36) 35 (3.6) (26) 29.5 (3) (21.5)

3 5

Remark Bolt Pipe Hose

4

W178-02-08-001

Hose DP: (To solenoid valve unit (hydraulic oil tank)) Hose PF: (To solenoid valve unit) Hose: (To shockless valve) Hose PD: (To pilot filter) Hose T6: (To right pilot valve) Hose P2: (To left pilot valve) Hose T5: (To left pilot valve) Hose P3: (To right pilot valve) Hose P1: (To travel pilot valve) Hose T4: (To travel pilot valve)

2 View A

6 10

7 8

9

WIHH-02-08-001

14

View A

15

W2-8-2

12

13

11

WIHH-02-08-002

UPPERSTRUCTURE / Pilot Shut-Off Valve (Blank)

W2-8-3

UPPERSTRUCTURE / Pilot Shut-Off Valve DISASSEMBLE PILOT SHUT-OFF VALVE 5

4

3

6

2

7

1

8 9

13

10 11

12

W178-02-08-005

1234-

Washer Backup Ring O-Ring Body

5678-

Socket Bolt Retaining Ring Washer Backup Ring

910 11 12 -

W2-8-4

O-Ring Spool Bracket Pin

13 - Socket Bolt

UPPERSTRUCTURE / Pilot Shut-Off Valve Disassemble Pilot Shut-Off Valve 1. Put the matching marks on body (4) and bracket (11). Remove retaining ring (6), washer (7), backup ring (8), and O-ring (9) from body (4). Remove the spool (10) assembly. 2. Remove washer (1), backup ring (2), and O-ring (3) from body (4). 3. Clamp spool (10) by using wooden pieces in a vise. Remove socket bolt (13) and bracket (11). Do not remove pin (12) unless necessary. : 4 mm 4. Remove socket bolt (5) from body (4). : 8 mm

W2-8-5

UPPERSTRUCTURE / Pilot Shut-Off Valve ASSEMBLE PILOT SHUT-OFF VALVE 12 13 11

4

5

Z

Z

Section Z－Z 10

6

7

8

9

4

W178-02-08-006

3

2

1

11

13

T178-03-07-002

1234-

Washer Backup Ring O-Ring Body

5678-

Socket Bolt Retaining Ring Washer Backup Ring

910 11 12 -

W2-8-6

O-Ring Spool Bracket Pin

13 - Socket Bolt

UPPERSTRUCTURE / Pilot Shut-Off Valve Assemble Pilot Shut-Off Valve 1. Apply LOCTITE # 262 on socket bolt (5). Install socket bolt (5) to body (4). : 8 mm : 29.4 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) 2. Clamp spool (10) by using wooden pieces in a vise. Apply LOCTITE #262 on socket bolt (13). Install bracket (11) onto spool (10). : 4 mm : 3.9 N⋅m (0.4 kgf⋅m, 2.9 lbf⋅ft) 3. Install O-ring (3), backup ring (2), and washer (1) onto body (4). 4. Apply hydraulic oil to spool (10). Install spool (10) to body (4). 5. Install O-ring (9), backup ring (8), and washer (7) to body (4). Install retaining ring (6) to spool (10).

W2-8-7

UPPERSTRUCTURE / Pilot Shut-Off Valve (Blank)

W2-8-8

UPPERSTRUCTURE / Shockless Valve REMOVE AND INSTALL SHOCKLESS VALVE

14

IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

15 16

17 18 19

13

20

9

Removal

21

12

1. Remove hoses (1 to 9, 13 to 20). Attach identification tags to the removed hoses for reassemblig. : 19, 22 mm

11

1

2. Remove pressure sensors (11, 12, 21). : 24 mm

10

3. Remove bolts (10) and remove the shockless valve. : 17 mm Installation 1. Apply LOCTITE to bolts (10). shockless valve with bolts (10).

Install

the

2. Install hoses (1 to 9, 13 to 20). 3. Install pressure sensors (11, 12, 21). Wrench Size (mm) : 17 : 19 : 22 : 24

Tightening Torque N⋅m (kgf⋅m) (lbf⋅ft) 20 (2) (14.5) 29.5 (3) (21.5) 39 (4) (29) 79

(8)

(58)

Remark Bolt Hose Hose Pressure Sensor

8B

7

8A

6

5

4

3

2 W173-02-09-001

1 - Hose (To right swing control valve) 2 - Hose (To left swing control valve) 3 - Hose (To bucket roll-in control valve) 4 - Hose (To bucket roll-out control valve) 5 - Hose (To boom lower control valve) 6 - Hose (To boom raise control valve) 7 - Hose (To arm roll-in control valve) 8 A - Hose (To arm roll-out control valve) 8 B - Hose (To arm roll-out control valve) 9 - Hose (From pilot shut-off valve) 10 - Bolt 11 - Pressure Sensor (For boom raise) 12 - Pressure Sensor (For arm roll-in) 13 - Hose (From arm roll-in pilot valve) 14 - Hose (From arm roll-out pilot valve) 15 - Hose (From boom lower pilot valve) 16 - Hose (From boom raise pilot valve) 17 - Hose (From bucket roll-in pilot valve) 18 - Hose (From bucket roll-out pilot valve) 19 - Hose (From right swing pilot valve) 20 - Hose (From left swing pilot valve) 21 - Pressure Sensor (For swing)

W2-9-1

UPPERSTRUCTURE / Shockless Valve DISASSEMBLE AND ASSEMBLE SHOCKLESS VALVE 18

17 16

D

B

G

F

14 15 C

A E

H

Section T

Section S

14

1

2

2

15

1 S2

S4

S7

7 S3

6

Section U

14

5

4

3

S1

Y

W

U

X

Section V

T

V

S

15

Z 3

7

4

5

A4

6 3

8

1

Z

4

5

2

7

6

Section W 2

12,13 11 10 9

9

2

19

Section Z-Z

8

1 14 15

7 6 5

7 6

5

4

Section X

3

3

4

Section Y

W2-9-2

WIHH-02-09-001

UPPERSTRUCTURE / Shockless Valve Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Part Name 10. Plug O-Ring Steel Ball Steel Ball Spring O-Ring Plug Orifice Spring Ring Orifice Plunger Plunger Assembly O-Ring Plug Body Seat Steel Ball Plug

Qty 3 4 4 4 4 4 4 1 2 1 1 1 1 4 4 1 1 1 1

Wrench Size (mm) :8

Tightening Torque N⋅m (kgf⋅m) (lbf⋅ft) 49 (5) (36.2)

:5 :5

14.7 14.7

(1.5) (1.5)

(10.8) (10.8)

:6

24.5

(2.5)

(18.1)

:5

9.8

(1.0)

(7.2)

:8

49

(5)

(36.2)

W2-9-3

Remark

Use LOCTITE #262.

UPPERSTRUCTURE / Shockless Valve (Blank)

W2-9-4

UPPERSTRUCTURE / Solenoid Valve REMOVE AND VALVE UNIT

INSTALL

2

SOLENOID

IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

3 4 5

10 1

Removal 1. Remove each harness of solenoid valves from connectors.

7 9

8

2. Remove pilot lines (1 to 6, 11 to 18, 20 to 23, 25, and 27). : 17, 19, 27 mm

View A

16

A

15

14

6 13

12 11

17

3. Remove bolts (7, 19) and remove the solenoid valve unit. : 6, 8 mm

WIHH-02-10-001

20 21

22

23 18 19

24

25

26

27 WIHH-02-10-002

1 - Pipe PF: From pilot shutoff valve

8 - Proportional solenoid valve (SG)

15 - Pipe PH: To pump control valve (5-spool section)

22 - Hose PI: To control valve

2 - Pipe SC: To arm regenerative valve 3 - Pipe SG: To main relief valve 4 - Hose SI: To travel motor

9 - Proportional solenoid valve (SI) 10 - Proportional solenoid valve (SC) 11 - Pipe DD: From arm regenerative valve 12 - Pipe PE: To pump control valve (4-spool section) 13 - Pipe DE: From bucket flow rate control valve (valve B) 14 - Pipe DH: From bucket flow rate control valve (switch valve A)

16 - Hose PG: To swing parking brake release spool 17 - Hose DG: From arm anti-drift valve 18 - Hose ST: To main pump 1

23 - Hose TA: To hydraulic oil tank 24 - Torque control solenoid valve 25 - Hose DI: To hydraulic oil tank 26 - Maximum pump 2 flow rate limit solenoid valve 27 - Hose SP: To pump control valve (5-spool section)

5 - Hose DS: To hydraulic oil tank 6 - Hose DP: From pilot shutoff valve 7 - Socket bolt

19 - Socket bolt 20 - Hose SB: To main pump 2 21 - Hose PD: To pilot shut-off valve

W2-10-1

UPPERSTRUCTURE / Solenoid Valve 2

Installation 1. Install the solenoid valve unit with bolts (7, 19). 2. Install pilot lines (1 to 6, 11 to 18, 20 to 23, 25 and 27).

3 4

3. Install all harnesses of solenoid valves to connectors. Wrench Size (mm) : 17 : 19 : 27 :6 :8

5

Tightening Torque Remark N⋅m (kgf⋅m) (Ibf⋅ft) 24.5 (2.5) (18) Pipe, Hose 29 (3) (22) Hose 93 (9.5) (43) Hose 20 (2) (16) Bolt 20 (2) (16) Bolt

10 1 7 9

8 View A

16

A

15

14

6 13

12 11

17

WIHH-02-10-001

20 21

23 18 19

22 24

25

26

27 WIHH-02-10-002

1 - Pipe PF: From pilot shut- off valve

8-

Proportional solenoid valve (SG)

15 - Pipe PH: To pump control valve (5-spool section)

22 - Hose PI: trol valve

2 - Pipe SC: To arm regenerative valve 3 - Pipe SG: To main relief valve 4 - Hose SI: To travel motor

9-

Proportional solenoid valve (SI) Proportional solenoid valve (SC) Pipe DD: From arm regenerative valve Pipe PE: To pump control valve (4-spool section) Pipe DE: From bucket flow rate control valve (valve B) Pipe DH: From bucket flow rate control valve (switch valve A)

16 - Hose PG: To swing parking brake release spool 17 - Hose DG: From arm anti-drift valve 18 - Hose ST: To main pump 1

23 - Hose TA: To hydraulic oil tank 24 - Torque control solenoid valve 25 - Hose DI: To hydraulic oil tank 26 - Maximum pump 2 flow rate limit solenoid valve 27 - Hose SP: To pump control valve (5-spool section)

5 - Hose DS: To hydraulic oil tank 6 - Hose DP: From pilot shutoff valve 7 - Socket bolt

10 11 12 13 14 -

19 - Socket bolt 20 - Hose SB: To main pump 2 21 - Hose PD: To pilot shut-off valve

W2-10-2

To con-

UPPERSTRUCTURE / Solenoid Valve (Blank)

W2-10-3

UPPERSTRUCTURE / Solenoid Valve DISASSEMBLE PROPORTIONAL SOLENOID VALVES (SC, SI, and SG)

1 2 3 4 5 6 7 8 9

10

11

12 13

14 15 16

17

18

19

W178-04-05-001

12345-

Socket Bolt (2 Used) Lock Nut O-Ring Adjusting Screw Spring

678910 -

Solenoid Spring O-Ring Diaphragm Washer

11 12 13 14 15 -

Spring Spool Orifice O-Ring O-Ring

W2-10-4

16 17 18 19 -

O-Ring Sleeve Plate Wavespring

UPPERSTRUCTURE / Solenoid Valve Disassemble Proportional Solenoid Valves (Solenoid Valves SC, SI, and SG) IMPORTANT: Do not disassemble lock nut (2) and adjusting screw (4). 1. Remove socket bolts (1) (2 used) and remove solenoid (6). : 3 mm IMPORTANT: Do not remove orifice (11) from spool (10). 2. Remove spool (10). Remove diaphragm (9), washer (10), and spring (11). 3. Remove sleeve (17). Remove O-rings (14,15, 16) from sleeve (17). Remove plate (18) and wavespring (19).

W2-10-5

UPPERSTRUCTURE / Solenoid Valve ASSEMBLE PROPORTIONAL SOLENOID VALVES (SC, SI, and SG)

4

2

6

1

8

9

3, 5

17

7

14

15

12

16

13

10 11

19

18

W157-02-11-001

12345-

Socket Bolt (2 Used) Lock Nut O-Ring Adjusting Screw Spring

678910 -

Solenoid Spring O-Ring Diaphragm Washer

11 12 13 14 15 -

Spring Spool Orifice O-Ring O-Ring

W2-10-6

16 17 18 19 -

O-Ring Sleeve Plate Wavespring

UPPERSTRUCTURE / Solenoid Valve Assemble Proportional Solenoid Valve (Solenoid Valves SC, SI, and SG) 1. Apply grease to O-rings (14, 15, 16) and apply a film of hydraulic oil to sleeve (17). Install washer (10), plate (18) into the housing. Install O-rings (14, 15) and (16) on sleeve (17), then insert it into the housing. When inserting the sleeve, be sure to align the ports of the sleeve with the ports in the housing. Install sleeve so that the end faces of sleeve and body come to the same point.

2. Install spring (11), washer (10), diaphragm (9) to spool (12) and install it into sleeve (17). Take care not to damage the edge portion in the bore of sleeve (17) when inserting the spool (12) to sleeve. After inserting spool (12) in, check that the spool (12) slides in and out smoothly without any restriction about 3 to 5 mm (0.12 to 0.20 in). Apply hydraulic oil to the spool (12). 12

14

15

16

11

17 9

10

17 W178-02-10-002

Housing W157-02-11-005

10

W157-02-11-010

IMPORTANT: Lock nut (2), adjusting screw (4), spring (5) and O-ring (3) are not separated, so no need to assemble them. 3. Install solenoid (6) with socket bolts (1) (2 used). When assembling solenoid (6), take care not to drop spring (7). : 3 mm : 2.9 N⋅m (0.3 kgf⋅m, 2.2 lbf⋅ft) 6

7

1 W157-02-11-011

W2-10-7

UPPERSTRUCTURE / Solenoid Valve DISASSEMBLE PROPORTIONAL SOLENOID VALVES (TORQUE CONTROL SOLENOID VALVE, MAXIMUM PUMP 2 FLOW RATE LIMIT SOLENOID VALVE)

3

1 12 2

13

14

4 5 6 7 8 9

10 11 15 16 17 18

WIHH-02-10-003

19 12345-

Socket Bolt (2 Used) Lock Nut O-Ring Adjusting Screw Spring

678910 -

Solenoid Spring O-Ring Diaphragm Retaining Ring

11 12 13 14 15 -

Spring O-Ring O-Ring O-Ring Sleeve

W2-10-8

16 17 18 19 -

Spool Orifice Plate Wavespring

UPPERSTRUCTURE / Solenoid Valve Disassemble Proportional Solenoid Valves (Torque Control Solenoid Valve, Maximum Pump 2 Flow Rate Limit Solenoid Valve) IMPORTANT: Do not lose spring (7) in solenoid hole when removing solenoid. Do not disassemble lock nut (2) and adjusting screw (4). 1. Remove socket bolts (1) (2 used) and remove solenoid (6). : 3 mm IMPORTANT: Do not remove orifice (17) from spool (16). 2. Remove spool (16). Remove diaphragm (9), retaining ring (10), and spring (11). 3. Remove sleeve (15). Remove O-rings (12, 13, and 14) from sleeve (15). Remove plate (18) and wavespring (19).

W2-10-9

UPPERSTRUCTURE / Solenoid Valve ASSEMBLE PROPORTIONAL SOLENOID VALVES (TORQUE CONTROL SOLENOID VALVE) (MAXIMUM PUMP 2 FLOW RATE LIMIT SOLENOID VALVE)

4

6

2

8

15

12

13

16

14

17

19

18 WIHH-02-10-007

7

3, 5

12345-

Socket Bolt (2 Used) Lock Nut O-Ring Adjusting Screw Spring

678910 -

1

Solenoid Spring O-Ring Diaphragm Retaining Ring

9

11 12 13 14 15 -

Spring O-Ring O-Ring O-Ring Sleeve

W2-10-10

10

11

16 17 18 19 -

Spool Orifice Plate Wavespring

UPPERSTRUCTURE / Solenoid Valve Assemble Proportional Solenoid Valve (Torque Control Solenoid Valve Maximum Pump 2 Flow Rate Limit Solenoid Valve) 1. Apply grease to O-rings (12, 13, 14) and apply a film of hydraulic oil to sleeve (15). Install wavespring (19), plate (18) into the housing. Install O-rings (12, 13) and (14) on sleeve (15), then insert it into the housing. When inserting the sleeve, be sure to align the ports of the sleeve with the ports in the housing. Install sleeve so that the end faces of sleeve and body come to the same point.

2. Install spring (11), retaining ring (10), diaphragm (9) to spool (16) and install it into sleeve (15). Take care not to damage the edge portion in the bore of sleeve (15) when inserting the spool (10) to sleeve. After inserting spool (16) in, check that the spool (16) slides in and out smoothly without any restriction about 3 to 5 mm (0.12 to 0.20 in). Apply hydraulic oil to the spool (16). 16 11

14

15

16

17

9

10

15 W178-02-10-002

Housing W157-02-11-005

10

W157-02-11-010

IMPORTANT: Lock nut (2), adjusting screw (4), spring (5) and O-ring (3) are not separated, so no need to assemble them. 3. Install solenoid (6) with socket bolts (1) (2 used). When assembling solenoid (6), take care not to drop spring (7). : 3 mm : 2.9 N⋅m (0.3 kgf⋅m, 2.2 lbf⋅ft) 6

7

1 W157-02-11-011

W2-10-11

UPPERSTRUCTURE / Solenoid Valve DISASSEMBLE AND ASSEMBLE PILOT RELIEF VALVE

1

2

3 4 5 6 7

8

WIHH-02-10-004

1 - Plug 2 - Shim

3 - Spring 4 - O-Ring

5 - Poppet 6 - Sleeve

W2-10-12

7 - Gasket 8 - Housing

UPPERSTRUCTURE / Solenoid Valve Assemble Pilot Relief Valve

Disassemble Pilot Relief Valve NOTE: Do not lose shim (2) in plug (1) when removing plug (1). 1. Remove plug (1) from housing (8). : 22 mm 2. Remove spring (3) and O-ring (4) from the relief valve. NOTE: Sleeve (6) with poppet (5) attached is provided in the relief valve. 3. Remove the assembly of poppet (5) and sleeve (6) from housing (8).

1. Insert gasket (7) into housing (8). 2. Insert poppet (5) into sleeve (6). Install spring (3) and O-ring (4) into the relief valve. Insert the relief valve assembly into housing (8). NOTE: Sleeve (6) with poppet (5) attached is provided in the relief valve. 3. Install shim (2) into plug (1). Install plug (1) into housing (8). : 22 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

4. Remove gasket (7) from housing (8).

W2-10-13

UPPERSTRUCTURE / Solenoid Valve (Blank)

W2-10-14

MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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SECTION 3

UNDERCARRIAGE —CONTENTS— Group 1 Swing Bearing

ZAXIS370MTH

Remove and Install Swing Bearing .......... W3-1-1

Remove and Install Travel Device ..........W3-2-68

Disassemble Swing Bearing .................... W3-1-4

Disassemble Travel Device ....................W3-2-72

Assemble Swing Bearing ......................... W3-1-6

Assemble Travel Device .........................W3-2-78 Disassemble Travel Motor ......................W3-2-86

Group 2 Travel Device

Assemble Travel Motor...........................W3-2-90

ZAXIS330, 330LC, 350H, 350LCH

Disassemble Brake Valve.......................W3-2-96

Up to Serial No.31357

Assemble Brake Valve ...........................W3-2-98

Remove and Install Travel Device............ W3-2-1

Maintenance Standard ........................W3-2-100

Disassemble Travel Device...................... W3-2-4 Assemble Travel Device ........................ W3-2-10

Group 3 Center Joint

Disassemble Travel Motor ..................... W3-2-18

Remove and Install Center Joint ..............W3-3-1

Assemble Travel Motor .......................... W3-2-22

Disassemble Center Joint ........................W3-3-4

Disassemble Brake Valve ...................... W3-2-30

Assemble Center Joint .............................W3-3-6

Assemble Brake Valve ........................... W3-2-32

Maintenance Standard .............................W3-3-9

Maintenance Standard ......................... W3-2-34

Group 4 Track Adjuster ZAXIS330, 330LC, 350H, 350LCH

ZAXIS330, 330LC, 350H, 350LCH

Serial No.31358 and up

Remove and Install Track Adjuster ...........W3-4-1

Remove and Install Travel Device.......... W3-2-35

Disassemble Track Adjuster .....................W3-4-2

Disassemble Travel Device.................... W3-2-38

Assemble Track Adjuster........................W3-4-10

Assemble Travel Device ........................ W3-2-44 Disassemble Travel Motor ..................... W3-2-52

ZAXIS370MTH

Assemble Travel Motor .......................... W3-2-56

Remove and Install Track Adjuster .........W3-4-17

Disassemble Travel Brake Valve............ W3-2-62

Disassemble Track Adjuster ...................W3-4-18

Assemble Travel Brake Valve ................ W3-2-64

Assemble Track Adjuster........................W3-4-24

Maintenance Standard ......................... W3-2-66

1HHW-3-1

Group 5 Front Idler Remove and Install Front Idler ................. W3-5-1 Disassemble Front Idler ........................... W3-5-2 Assemble Front Idler................................ W3-5-6 Maintenance Standard ........................... W3-5-10

Group 6 Upper and Lower Roller Remove and Install Upper Roller ............. W3-6-1 Remove and Install Lower Roller ............. W3-6-4 Disassemble Lower Roller ....................... W3-6-8 Assemble Lower Roller .......................... W3-6-10 Maintenance Standard ........................... W3-6-12

Group 7 Track Remove and Install Track ........................ W3-7-1 Maintenance Standard ............................. W3-7-7

1HHW-3-2

UNDERCARRIAGE / Swing Bearing REMOVE AND INSTALL SWING BEARING Before removing the swing bearing, the upperstructure must be removed first. For removal and installation of the upperstructure, refer to “Remove and Install Main Frame” section. In this section, the procedure starts on the premise that the upperstructure has already been removed. Removal 1. Put the matching marks on inner race (1) of swing bearing and track frame (2).

Matching Mark

1

2 W105-03-01-001

2. Remove bolts (3) (36 used) from the inner race of swing bearing. : 41 mm

3 W158-03-01-001

CAUTION: Swing bearing weight: 500 kg (1100 Ib) ST 0050

3. Attach lifting tools (ST 0050) onto swing bearing (4). Hoist and remove swing bearing (4).

4

W3-1-1

W110-03-01-004

UNDERCARRIAGE / Swing Bearing Installation Clean the mounting surfaces of track frame and swing bearing. 1. Apply THREEBOND # 1102 to the mounting surfaces of track frame and swing bearing. CAUTION: Swing bearing weight: 500 kg (1100 Ib) 2. Hoist the swing bearing. Align the matching marks on track frame and inner race of swing bearing.

W110-03-01-004

Machine Front

“S” (Soft Zone) Marking Position Position for Plug

15°

3. Tighten bolts (3) (36 used) to the inner race of swing bearing. : 41 mm : 1230 N⋅m (125 kgf⋅m, 900 lbf⋅ft)

20°

Position for Grease Fitting 5° W110-03-01-001

3 W158-03-01-001

W3-1-2

UNDERCARRIAGE / Swing Bearing 4. Add the grease bath with grease (Shell Alvania EP2 or equivalent) until the pinion of swing bearing is covered 5 mm in grease.

Swing Bearing Grease Level

Pinion

5 mm

Grease Bath

W3-1-3

W175-03-01-002

UNDERCARRIAGE / Swing Bearing DISASSEMBLE SWING BEARING 1

2

3

4

9

7

6

5

W157-03-01-003

8

1

8 2

9 7 6

5

W157-03-01-002

1 - Outer Race 2 - Seal 3 - Pin

4 - Plug 5 - Seal

6 - Ball (95 Used) 7 - Inner Race

W3-1-4

8 - Grease Fitting (2 Used) 9 - Support (95 Used)

UNDERCARRIAGE / Swing Bearing Disassemble Swing Bearing 3

CAUTION: Swing bearing weight: 500 kg (1100 lb) 1. Place the swing bearing onto the flat workbench. 2. Grind off the caulked part of pin (3). Tap and remove pin (3) from the bottom side of plug (4).

A

4 W1HH-03-01-006

3. Install the hand tap (M10, pitch 1.5 mm) into part A in the hole on plug (4). Install the bolt (M10, pitch 1.5 mm) into the hole on plug (4). Tap the bolt from its back or pull out plug (4).

4

W1HH-03-01-001

2

1

CAUTION: Swing bearing outer race (1) weight: 210 kg (465 lb) 4. Hoist outer race (1) of swing bearing horizontally. Remove seals (2, 5).

C

6

5. Rotate outer race (1). Remove balls (6) and supports (9) from the plug (4) hole. When removing balls (6), use rod magnet (C). Use wire (D) and remove support (9).

5

D

9

W3-1-5

W1HH-03-01-002

W1HH-03-01-007

UNDERCARRIAGE / Swing Bearing ASSEMBLE SWING BEARING 1

2

3

4

9

7

6

5

W157-03-01-003

8

1

8 2

9 7 6

5

W157-03-01-002

1 - Outer Race 2 - Seal 3 - Pin

4 - Plug 5 - Seal

6 - Ball (95 Used) 7 - Inner Race

W3-1-6

8 - Grease Fitting (2 Used) 9 - Support (95 Used)

UNDERCARRIAGE / Swing Bearing Assemble Swing Bearing 1. Clean (degrease) the grooves on outer race (1) and inner race (7) for seals (2, 5). Apply THREEBOND #1530D to the groove on seals (2, 5) in outer race (1) and inner race (7). Install seals (2, 5).

2 1

7

6

5 W1HH-03-01-003

CAUTION: Swing bearing outer race (1) weight: 210 kg (465 lb) 2. Hoist the outer race horizontally. Align the outer race with the inner race coaxially. Apply grease to balls (6) and supports (9). While rotating the outer race, insert balls (6) and support (9) into the plug (4) hole one by one by using a round bar.

3. Install plug (4) into outer race (1) and install pin (3). Caulk the head of pin (3) by using a punch. Add grease 0.9 L (Alvania EP2 grease or equivalent) into the swing bearing through the grease fitting.

9

W1HH-03-01-004

3 1

4 W1HH-03-01-005

W3-1-7

UNDERCARRIAGE / Swing Bearing (Blank)

W3-1-8

UNDERCARRIAGE / Travel Device REMOVE AND INSTALL TRAVEL DEVICE

4

ZAXIS330, 330LC, 350H, 350LCH (Up to serial No.31357)

5

IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

1

Removal The procedure starts on the premise that the track link has already been removed. Refer to page W3-7-1 for track removal.

3 2

1. Loosen bolts (7) to remove cover (6). : 22 mm IMPORTANT: Attach identification tags to aid in assembling. 2. Disconnect hoses (2) to (5). : 19 mm, 27 mm, 41 mm NOTE: Install caps on all disconnected hose and line ends. 3. Attach the travel device to a crane with a wire rope. CAUTION: Travel device weight: 480 kg (1060 lb) 4. Remove bolts (1). Remove the travel device by crane. : 30 mm

W3-2-1

6

7

W157-03-02-006

UNDERCARRIAGE / Travel Device Installation 4

1. Install the travel device with bolts (1). : 30 mm : 620 N⋅m (63 kgf⋅m, 460 lbf⋅ft) 2. Connect hoses (2) to (5). : 19 mm : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft) : 27 mm : 95 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

5

1

3 2

3. Install cover (6) with bolts (7). : 22 mm : 180 N⋅m (18 kgf⋅m, 130 lbf⋅ft) IMPORTANT: After completing travel motor installation, be sure to fill the travel motor with hydraulic oil (1.3 L (0.34 US gal.)). After completing installation of the travel motor or the travel device, be sure to perform test driving to prevent motor seizure. Test drive as follows: Perform break-in operation as follows: 1. Run the engine with the engine control dial in the slow idle position. 2. Turn the travel speed mode switch to the slow speed position. 3. Test drive the machine for two minutes or more.

W3-2-2

6

7

W157-03-02-006

UNDERCARRIAGE / Travel Device (Blank)

W3-2-3

UNDERCARRIAGE / Travel Device 16

DISASSEMBLE TRAVEL DEVICE ZAXIS330, 330LC, 350H, 350LCH (Up to serial No.31357)

15 17

13 12 37

4 3

3

7

6

14

38

11 10

40

5 9 23

1

8

2

18

8

19

27 26

27

26

25

20

21

19

22

35 31

24

28

30 41

43

39

42

29

34 33 36 31

32

W1HH-03-02-001

1234-

Third Stage Carrier Third Stage Sun Gear Thrust Plate (6 Used) Second Stage Planetary Gear (3 Used) 5 - Needle Bearing (3 Used) 6 - Pin (3 Used)

16 - Bolt (16 Used) 17 - Plug (3 Used)

78910 -

18 19 20 21 -

Spring Pin (3 Used) Spacer (2 Used) Second Stage Sun Gear First Stage Carrier

11 - Propeller Shaft

12 13 14 15 -

Ring Gear Bolt (28 Used) Stopper Pin Cover

23 24 25 26 -

Spring Pin (3 Used) Thrust Plate (6 Used) Needle Bearing (3 Used) First Stage Planetary Gear (3 Used) 22 - Pin (3 Used)

Second Stage Carrier Spring Pin (3 Used) Pin (3 Used) Thrust Plate (6 Used)

27 - Needle Bearing (6 Used) 28 - Third Stage Planetary Gear (3 Used) 29 - Motor 30 - Floating Seal 31 - Roller Bearing (2 Used) 32 - Drum 33 - Washer (20 Used)

W3-2-4

34 35 36 37 -

Bolt (20 Used) Bearing Nut Sprocket Retaining Ring

38 - Bearing 39 - O-Ring 40 41 42 43 -

Spacer Housing Lock Plate Bolt (2 Used)

UNDERCARRIAGE / Travel Device Disassemble Travel Device CAUTION: Pressure may remain in the travel device. Slowly loosen the air bleed plug to completely release the residual pressure. Then, remove the drain plug to drain gear oil into a container. If the air bleed plug is loosened quickly, the plug may fly off and/or gear oil may gush out. Position your face and body away from the plug. CAUTION: Travel device weight: 480 kg (1060 lb) 1. Turn over the travel device. Place the travel device securely on a work bench so that the brake valve does not come into contact with the work bench, with the motor side downward. 2. Remove bolts (16) to remove cover (15) from ring gear (12). : 19 mm 15 16 12

W107-03-02-008

NOTE: THRREEBOND is applied between cover (15) and ring gear (12). For easy separation of cover (15), apply a chisel between cover (15) and ring gear (12) and lightly tap on the end of the chisel. Do not remove stopper pin (14) unless it is damaged or excessively worn. 3. Remove propeller shaft (11) and first stage carrier (10) assembly from ring gear (12). 4. Remove second stage sun gear (9), second stage carrier (23) assembly and third stage sun gear (2) from ring gear (12).

W3-2-5

UNDERCARRIAGE / Travel Device

16

13 12

35 31

30 41

43 42

36

31

32

W1HH-03-02-001

W3-2-6

UNDERCARRIAGE / Travel Device CAUTION: Ring gear (12) weight: 55 kg (121 lb) 5. Remove bolts (13) (28 used). Attach eyebolt (M12, Pitch 1.75 mm) to bolt (16) hole of ring gear (12). Remove ring gear (12) from drum (32). : 24 mm NOTE: THREEBOND is applied between ring gear (12) and drum (32). Use the screw driver for easy removal.

10. Remove the inner race of roller bearing (31) from drum (31). NOTE: Do not attempt to remove the inner race of roller bearing (31) which remained in housing (41) side unless it is to be replaced. 11. Remove floating seal (30) from drum (32) and housing (41).

CAUTION: Third stage carrier (1) assembly weight: 52 kg (115 lb) 6. Remove third stage carrier (1) assembly. 7. Remove bolt (43) and lock plate (42) from bearing nut (35). : 19 mm 8. Hold the travel device securely. Remove bearing nut (35) using special tools. Special Tools: ST 3050, ST 3051, ST 3052 Bolt: M16 (60 to 90 mm in length): 2 pieces

ST 3052 ST 3050

35

ST 3051

W157-03-02-005

CAUTION: Drum (32) + sprocket (36) weight: 135 kg (300 lb) IMPORTANT: The housing (41) matching surface of drum (32) is the sliding surface. Place the drum assembly onto a wooden block not to damage it. 9. Attach eyebolt (M16, Pitch 2.0 mm) to drum (32). Remove drum (32) from housing (41) by crane.

W3-2-7

UNDERCARRIAGE / Travel Device

3

5

4

3

7

6

40 10

23 8 1

19

20

21

19

22

18

31

24 25 27 26

27

26

28

34

36 32

W1HH-03-02-001

W3-2-8

UNDERCARRIAGE / Travel Device 12. Apply a metal bar to the outer race of roller bearing (31) on drum (32) side, and tap the bar end with a hammer to drive the outer race out. 13. Apply a round bar to spring pin (18), and tap the end of the bar to drive spring pin (18) out of first stage carrier (10) assembly. (3 places) 14. Remove pins (22) (3 used). Remove first stage planetary gears (21) (3 used), needle bearings (20) (3 used), and thrust plates (19) (6 used). 15. Remove spacer (40) from first stage carrier (10). 16. Disassemble second stage carrier (23) assembly following steps 13 to 15 above. Remove spring pins (7) (3 used), pins (6) (3 used), second stage planetary gears (4) (3 used), thrust plates (3) (6 used), needle bearings (5) (3 used), and spacers (8) (2 used). 17. Disassemble third stage carrier (1) assembly following steps 13 to 15 above. Remove spring pins (24) (3 used), pins (25) (3 used), thrust plates (26) (6 used), third stage planetary gears (28) (3 used), and needle bearings (27) (6 used). CAUTION: Sprocket (36) weight: 68 kg (150 lb) 18. Loosen and remove bolts (34) (20 used). Remove sprocket (36) by crane after attaching a nylon sling to sprocket (36). : 30 mm NOTE: LOCTITE is applied to bolt (34).

W3-2-9

UNDERCARRIAGE / Travel Device ASSEMBLE TRAVEL DEVICE ZAXIS330, 330LC, 350H, 350LCH (Up to serial No.31357)

33, 34 32 12 13 29

8

1

2

8

23

9

10

39

17 40 11 15 14 38 37 19 18 20 22 21 16

41

30

36

1234-

Third Stage Carrier Third Stage Sun Gear Thrust Plate (6 Used) Second Stage Planetary Gear (3 Used) 5 - Needle Bearing (3 Used) 6 - Pin (3 Used)

16 - Bolt (16 Used) 17 - Plug (3 Used)

78910 -

18 19 20 21 -

Spring Pin (3 Used) Spacer (2 Used) Second Stage Sun Gear First Stage Carrier

11 - Propeller Shaft

12 13 14 15 -

6

31

35

42

Ring Gear Bolt (28 Used) Stopper Pin Cover

Spring Pin (3 Used) Thrust Plate (6 Used) Needle Bearing (3 Used) First Stage Planetary Gear (3 Used) 22 - Pin (3 Used)

43

28 27 25 26

23 24 25 26 -

Second Stage Carrier Spring Pin (3 Used) Pin (3 Used) Thrust Plate (6 Used)

24

27 - Needle Bearing (6 Used) 28 - Third Stage Planetary Gear (3 Used) 29 - Motor 30 - Floating Seal 31 - Roller Bearing (2 Used) 32 - Drum 33 - Washer (20 Used)

W3-2-10

4

5

3

3

34 35 36 37 -

W164-03-02-002

Bolt (20 Used) Bearing Nut Sprocket Retaining Ring

38 - Bearing 39 - O-Ring 40 41 42 43 -

7

Spacer Housing Lock Plate Bolt (2 Used)

UNDERCARRIAGE / Travel Device Assemble Travel Device 1. If replacing roller bearing (31), warm the inner race (2 used) 50 to 70 °C (122 to 158 °F) with a heater, then install one of them into housing (41). Wait for the bearing to cool. Then, drive it in position completely with a metal bar and hammer.

CAUTION: Drum (32) + sprocket (36) weight: 135 kg (300 lb)

NOTE: Check if the inner race is driven in completely by listening to the sound.

5. Attach eyebolt (M16, Pitch 2.0 mm) to the bolt (13) hole of drum (32), then hoist and install drum (32) onto housing (41) with motor (29). At this time check if the clearance between the motor and drum is equal.

2. Apply grease to the O-ring outer surface of floating seal (30). Install one half of floating seal (30) on housing (41).

6. Warm the inner race of roller bearing (31) 50 to 70 °C (122 to 158 °F) with a heater. Install it between drum (32) and housing (41).

NOTE: For easier insertion of floating seal (30) O-ring, use a bamboo (wooden) spatula to guide it along the periphery. IMPORTANT: Be sure to tap only the outer race. 3. Install the outer races (2 used) of roller bearing (31) on drum (32) in position completely with a metal bar and hammer. Install the half of floating seal (30) into drum (32). NOTE: Check if the roller bearing is installed completely by listening to the sound. CAUTION: Sprocket (36) weight: 68 kg (150 lb) IMPORTANT: Align the chamfered side of sprocket (36) with drum (32). 4. Attach sprocket (36) with a nylon sling. Hoist it and place it on drum (32). Apply LOCTITE #262 to bolts (34) (20 used). Tighten bolts (34) and washers (33) (20 used). : 30 mm : 490 N⋅m (50 kgf⋅m, 360 lbf⋅ft)

W3-2-11

UNDERCARRIAGE / Travel Device

8

1

41

32

36

35 42 43 26 28 27

W3-2-12

26

24

W164-03-02-002

UNDERCARRIAGE / Travel Device IMPORTANT: Face bearing nut (35) stepped to the bearing. Apply grease to the threaded part of bearing nut (35). 7. Install bearing nut (35) to housing (41) and tighten manually.

12. Apply LOCTITE #262 to the thread of bolts (43) (2 used). Install lock plate (42) to bearing nut (35) with bolts (43) (2 used) : 19 mm : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft) 43 42 35

NOTE: Apply grease to the threaded part of bearing nut (35) to tighten the torque to correct specification. 8. Hold the travel device securely. Attach the special tools to bearing nut (35). Then, tighten with a torque wrench. Special Tools: ST 3050, ST 3051, ST 3052 Bolt: M16 (60 to 90 mm in length) ×2 pieces : 790 N⋅m (80 kgf⋅m, 580 lbf⋅ft)

13. Install two needle bearings (27) (2 used) into each third stage planetary gears (28) (3 used). IMPORTANT: One side of third stage planetary gear (28) is the marked groove. Install third stage planetary gear (28) with the side with marked groove facing to the spring pin (24) hole. 14. Install spacer (8) into third stage carrier (1). Putting thrust plates (26) (6 used) on both ends of each third stage planetary gears (28) (3 used), install them into third stage carrier (1).

ST 3052 ST 3050

35

W140-03-02-001

ST 3051

36

W157-03-02-005

9. After tighten bearing nut (35) to specification, tap on drum (32) with a plastic hammer to secure appropriate play. Then, rotate sprocket (36) 4 to 5 turns clockwise and then counterclockwise. 10. Repeat step 8 and 9. 11. Repeat step 9 above. Then, tighten bearing nut (35) to specification. Special Tools: ST 3050, ST 3051, ST3052, Bolt: M16 (60 to 90 mm in length): ×2 pieces : 790 N⋅m (80 kgf⋅m, 580 lbf⋅ft)

W3-2-13

UNDERCARRIAGE / Travel Device

12 13

1

2

8

23

9

15

16

41

32

28

W3-2-14

25

24 6

4

5

3

7

W164-03-02-002

UNDERCARRIAGE / Travel Device 15. Insert pins (25) (3 used) into third stage carrier (1) to secure third stage planetary gears (28) (3 used). At this time align third stage carrier (1) with the spring pin (24) hole on pin (25). 16. Drive spring pins (24) (3 used) into the spring pin hole on third stage carrier (1) and pin (25). Be sure that the slit part of spring pin (24) faces to the end of pin (25). 24

25

Slit

W178-02-06-002

CAUTION: Third stage weight: 52 kg (115 lb)

carrier

assembly

17. Install third stage carrier (1) assembly, aligning splines with housing (41). 18. Install third stage sun gear (2) into third stage carrier (1). Be sure that the lower tooth end faces to cover (15). Cover (15)

CAUTION: Ring gear (12) weight: 55 kg (121 lb) 20. Install eyebolt (M12, Pitch 1.75 mm) into the bolt (16) hole on ring gear (12). Hoist ring gear (12). Install ring gear (12) onto drum (32). Apply LOCTITE #262 to bolts (13) (28 used). Tighten bolts (13). : 24 mm : 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft) 21. Install spacer (8), second stage planetary gears (4) (3 used), needle bearings (5) (3 used), thrust plates (3) (6 used), pins (6) (3 used), and spring pins (7) (3 used) into second stage carrier (23) following step 13 to 16 above. 22. Install second stage carrier (23) assembly into ring gear (12). 23. Install second stage sun gear (9) into second stage carrier (23). Be sure that the lower tooth end faces to cover (15). Cover (15)

2

W166-03-02-001

19. Clean (degrease) ring gear (12) mounting surface of drum (32). Apply THREEBOND #1389B to the mounting surface.

W3-2-15

9

W166-03-02-002

UNDERCARRIAGE / Travel Device

29

12

9

10

17

40 11

21 15 22 18 19

16

20

W164-03-02-002

W3-2-16

UNDERCARRIAGE / Travel Device IMPORTANT: Face the lower tooth height side of first stage planetary gear (21) to spacer (40) side. 24. Install spacer (40), first stage planetary gears (21) (3 used), needle bearings (20) (3 used), thrust plates (19) (6 used), pins (22) (3 used), spring pins (18) (3 used) into first stage carrier (10) following step 13 to 16. 25. Install first stage carrier (10) assembly into ring gear (12), aligning splines between first stage carrier (10) and second stage sun gear (9). 26. Add gear oil to ring gear (12). Gear oil: 9.2 L (2.43 US gal) 27. Insert propeller shaft (11) into the center of carrier. Be sure that the propeller shaft correctly meshes with first stage planetary gears (21) and the shaft of motor (29). 28. Clean (degrease) the cover (15) mounting surface of ring gear (12). Apply THREEBOND #1389B to the mounting surface. Install cover (15) to ring gear (12). Apply LOCTITE #262 to bolts (16) (16 used). Tighten bolts (16) (16 used). : 19 mm : 110 N⋅m (11.5 kgf⋅m, 83 lbf⋅ft) 29. Wrap seal tape around plugs (17) (3 used). Install plugs (17) into cover (15). : 10 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

W3-2-17

UNDERCARRIAGE / Travel Device DISASSEMBLE TRAVEL MOTOR ZAXIS330, 330LC, 350H, 350LCH (Up to serial No.31357)

12 10

13

14

11

9 8 7

Brake Releasing Oil Passage

6 3 1

2

5

4

15

16

25 26 27 20

18

19 21

17

22 23

28

24 32

29 30 31

40

39 38

37

36 33 34 35

12345678910 -

O-Ring Disc Spring D-Ring Piston D-Ring Plate (5 Used) Spacer Drive Disc Bearing Spacer

11 12 13 14 15 16 17 18 19 20 -

W164-03-02-003

Bearing Housing Oil Seal Retaining Ring O-Ring Bearing Nut Plunger (7 Used) Rotor Plug (2 Used) Friction Plate (4 Used)

21 22 23 24 25 26 27 28 29 30 -

Link Reamer Bolt Plug (2 Used) O-Ring (2 Used) Pin Center Shaft Center Spring Bushing Valve Plate Plate

W3-2-18

31 32 33 34 35 36 37 38 39 40 -

Knock Pin (2 Used) Socket Bolt (4 Used) Brake Valve O-Ring Plug Servo Piston Piston Ring (2 Used) O-Ring Cover Socket Bolt (4 Used)

UNDERCARRIAGE / Travel Device Disassemble Travel Motor CAUTION: Travel motor weight: 87 kg (190 lb) Brake valve weight: 43 kg (90 lb)

4. Remove valve plate (29) from brake valve (33). At this time, the valve plate is still with link (21) attached.

IMPORTANT: Valve plate (29) is easily cracked and scratched, so handle it with care. 1. Place the travel motor longitudinally. Remove socket bolts (32) (4 used) to remove brake valve (33) from housing (12). At this time, the brake valve side is still with valve plate (29) attached. : 14 mm 2. Remove socket bolts (40) (4 used) from brake valve (33) to remove cover (39) and O-ring (38).

NOTE: The valve plate (29) is with bushing (28) attached, but do not remove the bushing unless necessary. 5. Remove plate (30) from brake valve (33). 6. Remove servo piston (36) from brake valve (33). At this time, the servo piston is still with piston rings (37) (2 used) attached. 7. Remove O-Rings (1), (15) from housing (12).

3. Turn brake valve (33) over to remove plug (23) and O-ring (24), then insert a hexagon wrench into the plug (23) hole to remove reamer bolt (22). : 8 mm, 10 mm

8. Remove disc spring (2) from housing (12). CAUTION: When removing piston (4) from the housing filled with air, cover the housing with cloth to prevent the brake piston from flying out.

33 22

9. Apply 100 to 300 kPa (1 to 3 kgf/cm2, 14 to 43 psi) pressure air to brake releasing oil passage in housing (12), so that brake piston (4) will float up to be removed.

23

W178-03-02-014

IMPORTANT: Plug (19) has been bound with LOCTITE. If removing it by force, its hexagon hole may be damaged. Do not remove plug (19) unless necessary.

NOTE: There is an air seat on brake piston (4). Be sure to place it with the air seat facing up. Air Seat

4

19

W178-03-02-009

NOTE: Piston (4) is with D-rings (3), (5) attached, do not remove the D-ring unless necessary.

W107-03-02-098

W3-2-19

UNDERCARRIAGE / Travel Device

12 10

13

14

11

9 8 7 6

16

25 26 27 20

18

17

33 W164-03-02-003

W3-2-20

UNDERCARRIAGE / Travel Device 10. Remove plates (6) (5 used), friction plates (20) (4 used) from housing (12). IMPORTANT: When removing center shaft (26), the center shaft will be with pin (25) attached. Be sure not to lose it. 11. Remove rotor (18), spring (27), center shaft (26), and plungers (17) (7 used) from housing (12).

CAUTION: Drive disc (8) assembly weight: 7.0 kg (15 lb) 15. Install drive disc (8) assembly into special tools (ST 3058, 5904) to remove bearing nut (16).

NOTE: Tilt plunger (17) in the direction of motor center, the more tilting, the easier removing.

ST 3058

ST 5904

8

12. Remove spacer (7) from housing (12). CAUTION: Housing + drive disc (8) + others weight: 49 kg (110 lb)

W107-03-02-119

CAUTION: Drive disc (8) assembly weight: 7.0 kg (15 lb) IMPORTANT: As drive disc (8) has tendency to drop off, keep it with wooden block. 13. Place housing (12) with the brake valve (33) mounting surface facing downward. Tap and remove drive disc (8) from housing (12) with a plastic hammer lightly. At this time, the drive disc is still with bearings (9), (11), bearing nut (16), and spacer (10) attached.

IMPORTANT: The inner race of bearing (9) is left on drive disc (8). Don’t remove it unless replacing. In case the inner race of bearing (9) has been removed, don’t reuse it. 16. Place the outer race of bearing (9) on wooden block. Press drive disc (8) with a press to remove the outer race of bearing (9) bearing (11), and spacer (10) from drive disc (8). Press

14. Remove retaining ring (14) from housing (12) to remove oil seal (13) with a screw-driver and hammer.

8 11 10 9 Thrust Block

W107-03-02-121

W3-2-21

UNDERCARRIAGE / Travel Device ASSEMBLE TRAVEL MOTOR ZAXIS330, 330LC, 350H, 350LCH (Up to serial No.31357)

35, 34

1

28

15

3

2

4

5 6

7

30 29 31 33

8 9 10 11 12 13

14

16 18 25 17 20

36 37 38 39

40

23, 24

27

19

26

32

21 W178-03-02-016

22 12345678910 -

O-Ring Disc Spring D-Ring Piston D-Ring Plate (5 Used) Spacer Drive Disc Bearing Spacer

11 12 13 14 15 16 17 18 19 20 -

Bearing Housing Oil Seal Retaining Ring O-Ring Bearing Nut Plunger (7 Used) Rotor Plug (2 Used) Friction Plate (4 Used)

21 22 23 24 25 26 27 28 29 30 -

Link Reamer Bolt Plug (2 Used) O-Ring (2 Used) Pin Center Shaft Center Spring Bushing Valve Plate Plate

W3-2-22

31 32 33 34 35 36 37 38 39 40 -

Knock Pin (2 Used) Socket Bolt (4 Used) Brake Valve O-Ring Plug Servo Piston Piston Ring (2 Used) O-Ring Cover Socket Bolt (4 Used)

UNDERCARRIAGE / Travel Device ASSEMBLE TRAVEL MOTOR CAUTION: Drive disc (8) weight: 4.1 kg (9 lb) 1. Heat the inner race of bearing (9) to 70° to 90°C (158 °F to 194 °F) in a oil bath or drier. Press the inner race of bearing (9) into drive disc (8) with special tool (ST 2155) and a press.

7. Secure drive disc (8) onto special tools (ST 3058, ST 5904), tighten bearing nut (16) to the specified torque. : 3.5±0.5 N⋅m (0.35±0.05 kgf⋅m, 2.53±0.36 lbf⋅ft)

2. Put the outer race onto the inner race of bearing (9). ST 3058

3. Tap and insert the outer race of bearing (11) into spacer (10) lightly with a plastic hammer.

16 ST 5904

4. Put spacer (10) on the outer race of bearing (9).

8

5. Heat the inner race of bearing (11) to 70° to 90°C (158 °F to 194 °F) in a oil bath or drier, and press the inner race of bearing into drive disc (8) with special tool (ST 2308) and a press. Tap the inner race lightly and listen to ring to confirm they are fitting tightly. IMPORTANT: Apply grease onto bearing nut (16). 6. Apply grease to the screw part and the side surface of bearing nut (16). Install bearing nut (16) onto drive disc (8), then tighten it by hand. NOTE: Apply grease to tighten it to the specified torque.

W107-03-02-119

CAUTION: Housing (12) weight: 46 kg (100 lb) 8. Place housing (12) with its brake valve mounting side facing down. IMPORTANT: Apply OCEAN grease #7 to the inner surface of oil seal (13), and apply THREEBOND #104 or 1215 to the outer surface of the oil seal. 9. Tap oil seal (13) evenly and lightly with a plastic hammer to insert oil seal (13) into housing (12). The replaced oil seal can be used as a mat then. 10. Install retaining ring (14).

W3-2-23

UNDERCARRIAGE / Travel Device

27

18

2

12 4

18

6

7

8

13

25

Oil Slit (4 Places)

17

3

5

Slit (4 Places)

20 26

W178-03-02-019

W3-2-24

UNDERCARRIAGE / Travel Device CAUTION: Housing (12) weight: 46 kg (100 lb)

15. Install plungers (17) (7 used) into the spherical handle hole in drive disc (8) one by one. Be sure to confirm plungers (17) (7 used) move smoothly.

11. Turn housing (12) over and place it with its oil seal (13) side facing down. Tap drive disc (8) assembly lightly with a plastic hammer and brass bar to install it into housing (12).

17

IMPORTANT: Be sure to align the oil slot (slit part) in spacer (7) with that in housing (12). 12. Install spacer (7) into housing (12) with its oil slot (slit part) facing the travel reduction gear side.

8

Spherical Handle Hole

W107-03-02-146

IMPORTANT: Align 5 teeth of plate (6) with the inner grooves in housing (12). In addition, the 4 teeth on friction plate (20) should be placed at same position when installation is carried out. 13. Install plates (6) (5 used) and friction plates (20) (4 used) into housing (12) alternately. Be sure to align the teethless part (no teeth part ) of plate (6) (4 places) with the inner slots inside of housing (12) and install them together. Moreover, the teethless part of friction plate (20) should be put at same position to form a straight line when installation is carried out.

16. Apply grease to the center shaft (26) spherical part. Install center shaft (26) into drive disc (8). Then install center spring (27) onto c enter shaft (26). 17. Apply grease to pin (25) to prevent it from coming off. Then install it into center shaft (26). 18. Put center shaft (26) to rotor (18) shallowly. Rotate center shaft (26) so as to align pin (25) just beneath the slot in rotor (18). 18 Groove

NOTE: In case the teethless part or slot position fail to align with each other, heating may be resulted to motor failure. Groove (4 Places)

26

25

12

W178-03-02-015

19. Insert plungers (17) (7 used) into rotor (18).

W178-03-02-018

14. Install D-rings (3, 5) into piston (4), then tap to install them into housing (12) with a plastic hammer.

W3-2-25

UNDERCARRIAGE / Travel Device

29

28

15

12

2

18

30 31 33

25

36 37

23

17

1

19

26 21

W178-03-02-016

W3-2-26

UNDERCARRIAGE / Travel Device 20. Press plunger (17) slowly and install pin (25) into the rotor (18) groove. NOTE: If pin (25) can’t be installed into the groove, insert the end of round rotor into the top hole of center shaft (26), rotate the center shaft. When doing this work, be sure to remove the dirt and metallic debris from the former rotor first.

IMPORTANT: Pay attention to the direction of link (21) assembly. 29. Install link (21) assembly into brake valve (33) while aligning the groove in valve plate (29) with the groove in plate (30). At this time, the sticking part of link (21) should face the brake valve side. 21

Rotor (18) Side

29

21. Install O-rings (1, 15) into housing (12). Plate (30) Side

IMPORTANT: Install disc spring (2) into housing (12) with the outer surface side of the disc spring facing the brake valve (33) mounting surface. 22. Install disc spring (2) into housing (12). 23. Fill hydraulic oil into housing (12). Hydraulic oil: 1.3 L (0.34 US gal)

W178-03-02-017

30. Insert special tool (ST 7131) into the mounting hole of plug (23), then align the hole of link (21) with that of servo piston (36).

24. Install plate (30) onto brake valve (33).

36

ST 7131

21

25. Install piston rings (37) (2 used) onto servo piston (36). 26. Insert servo piston (36) into brake valve (33). IMPORTANT: Assemble bushing (28) with the chamfered side facing inside. 27. Install bushing (28) onto valve plate (29) with a plastic hammer. 28. Apply LOCTITE #262 on plugs (19) (2 used), then install link (21) onto valve plate (29) with plugs (19) (2 used). : 6 mm : 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)

W3-2-27

22

W107-03-02-174

UNDERCARRIAGE / Travel Device

12

33

A

B

C

36 38 39

40

23, 24

32 21 W178-03-02-016

22

W3-2-28

UNDERCARRIAGE / Travel Device 31. Apply additive grease, Johnson wax JP103, to the end of reamer bolt (22) in order to prevent it from seizing. Install reamer bolt (22) to link (21) and servo piston (36) through the opposite mounting hole of plug (23). : 8 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 32. Install O-ring (24) onto plug (23), then install it to brake valve (33). : 10 mm : 118 N⋅m (12 kgf⋅m, 87 lbf⋅ft) 33. Install O-ring (38) onto cover (39) and install it to brake valve (33) with socket bolts (40) (4 used). : 10 mm : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

CAUTION: Brake valve (33) weight: 43 kg (90 lb) 36. Hoist and install brake valve (33) onto housing (12), while aligning the hole in removed plug (A) with special tool (ST 7085). 37. Remove special tool (ST 7085) from brake valve (33). 38. Install spool (B), spring (C) and plug (A) into brake valve (33). : 8 mm : 34 N⋅m (3.5 kgf⋅m, 25.5 Ibf⋅ft) 39. Install brake valve (33) onto housing (12) with socket bolts (32) (4 used). : 14 mm : 390 N⋅m (40 kgf⋅m, 290 Ibf⋅ft)

34. Install special tool (ST 7085) into the end of center shaft (26).

ST 7085

26 12

W107-03-02-183

35. Remove plug (A) from brake valve (33) to remove spool (B) and spring (C). : 8 mm

W3-2-29

UNDERCARRIAGE / Travel Device DISASSEMBLE BRAKE VALVE ZAXIS330, 330LC, 350H, 350LCH (Up to serial No.31357) Counter Balance Valve

8 9

Shuttle Valve for Parking Brake Check Valve

10 11

16

12

15 14 13

4 5 6

Overload Relief Valve

7

1, 2

3

11 10 20 19

13 14 15 16

7

9

6

8

5

18

1, 2

4

17 Shuttle Valve for Servo Piston Reducing Valve 12345-

O-Ring (2 Used) Overload Relief Valve (2 Used) Casing Plug (2 Used) O-Ring (2 Used)

W140-03-02-003

678910 -

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

11 12 13 14 15 -

W3-2-30

Stopper (2 Used) Spool Ball (2 Used) Seat (2 Used) O-Ring (2 Used)

16 17 18 19 20 -

Plug (2 Used) Plug O-Ring Spool Spring

UNDERCARRIAGE / Travel Device Disassemble Brake Valve CAUTION: Brake valve weight: 43 kg (90 lb)

• Counter Balance Valve

1. Remove plugs (8) (2 used) from casing (3). : 41 mm

2. Remove springs (10) (2 used), stoppers (11) (2 used) from casing (3). 3. Remove spool (12) from casing (3).

• Shuttle valve for servo piston and for parking brake IMPORTANT: LOCTITE was applied on seat (14). Do not remove the seat unless necessary. 6. Remove plugs (16) (2 used) from casing (3) to remove balls (13) (2 used) and seats (14) (2 used). : 5 mm, 6 mm

• Reducing Valve

• Overload Relief Valve IMPORTANT: Be sure to loosen and remove overload relief (2). Do not turn the lock nut for adjusting screw on overload relief valve, or its setting pressure may change. 4. Remove overload relief valves (2) (2 used) from casing (3). : 27 mm

7. Remove plug (17) from casing (3) to remove spool (19) and spring (20). : 8 mm

Lock Nut

Adjusting Screw

• Check Valve

W140-03-02-005

5. Remove plug (4) from casing (3) to remove springs (6) (2 used) and poppets (7) (2 used). : 12 mm

W3-2-31

UNDERCARRIAGE / Travel Device ASSEMBLE BRAKE VALVE ZAXIS330, 330LC, 350H, 350LCH (Up to serial No.31357) 13 14

15 13

14

16 15 16

Section B

2

A

1

7

Section C

6

19

17

20

18

3 4 5

C 8 9

B

Section A-A A

12

1 - O-Ring (2 Used) 2 - Overload Relief Valve (2 Used) 3 - Casing 4 - Plug (2 Used) 5 - O-Ring (2 Used)

11

10

6 - Spring (2 Used) 7 - Poppet (2 Used)

11 - Stopper (2 Used) 12 - Spool

16 - Plug (2 Used) 17 - Plug

8 - Plug (2 Used) 9 - O-Ring (2 Used) 10 - Spring (2 Used)

13 - Ball (2 Used) 14 - Seat (2 Used) 15 - O-Ring (2 Used)

18 - O-Ring 19 - Spool 20 - Spring

W3-2-32

W164-03-02-005

UNDERCARRIAGE / Travel Device ASSEMBLE BRAKE VALVE

• Reducing Valve

1. Insert spring (20) and spool (19) into casing (3). Install O-ring (18) onto plug (17) to casing (3). : 8 mm : 69 N⋅m (7 kgf⋅m, 51 lbf⋅ft)

• Shuttle Valve for Servo Piston and for Parking Brake (Section B-B, Section C-C) IMPORTANT: Before inserting ball (13), put ball (13) on seat (14) and tap on the ball with a hammer to obtain a tight fitting between ball (13) and seat (14). Also, after inserting ball (13) and before tightening seat (14), insert a metal bar into the plug hole to ball (13), then tap the other end of the bar to obtain tight fitting between ball (13) and casing (3). 2. Install balls (13) (2 used) with casing (3) titled. Apply LOCTITE #262 onto seats (14) (2 used) and install the seats into casing (3). Install O-rings (15) (2 used) onto plugs (16) (2 used) and install the plugs into casing (3). : 5 mm : 14.5 N⋅m (1.5 kgf⋅m, 11.0 lbf⋅ft) : 6 mm : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)

• Overload Relief Valve

4. Install overload relief valves (2) (2 used) into casing (3). : 27 mm : 540 N⋅m (55 kgf⋅m, 400 lbf⋅ft)

• Counter Balance Valve IMPORTANT: Apply hydraulic oil to spool (12) before assembling. If any resistant force is felt, move it back and reassemble it. Never assemble it by force. 5. Insert spool (12) into casing (3). Be sure that spool (12) can move smoothly in casing (3). 6. Install spring (10) onto stoppers (11) (2 used), then insert the stoppers into casing (3). 7. Install O-rings (9) (2 used) onto plugs (8) (2 used), then install the plugs into casing (3). : 41 mm : 340 N⋅m (35 kgf⋅m, 250 lbf⋅ft)

• Check Valve IMPORTANT: After inserting poppet (7), insert a metal bar into the plug hole to poppet (7), then tap the other end of the bar to obtain tight fitting between poppet (7) and casing (3). 3. Install springs (6) (2 used) into poppets (7) (2 used) and insert the poppets into casing (3). Install O-rings (5) (2 used) onto plugs (4) (2 used) and install the plugs into casing (3). : 12 mm : 235 N⋅m (24 kgf⋅m, 174 Ibf⋅ft)

W3-2-33

UNDERCARRIAGE / Travel Device MAINTENANCE STANDARD Sprocket

C

B

D

E

A

W1HH-03-02-002

A B C D E

Standard Allowable Limit 87 (3.4) [77 (3.0)] 89.15 (3.5) 84.15 (3.3) 125.75 (5) 133.55 (5.3) 128.55 (5.1) 216.0 (8.5) -

NOTE: Values in [ ] is just for reference.

W3-2-34

Unit: mm (in) Remedy Cladding by welding and finishing

UNDERCARRIAGE / Travel Device REMOVE AND INSTALL TRAVEL DEVICE

4

ZAXIS330, 330LC, 350H, 350LCH (Serial No.31358 and up)

5

IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

1

Removal The procedure starts on the premise that the track link has already been removed. Refer to page W3-7-1 for track removal.

3 2

1. Loosen bolts (7) to remove cover (6). : 22 mm IMPORTANT: Attach identification tags to aid in assembling. 2. Disconnect hoses (2) to (5). : 19 mm, 27 mm, 50 mm NOTE: Install caps on all disconnected hose and line ends. 3. Attach the travel device to a crane with a wire rope. CAUTION: Travel device weight: 460 kg (1020 lb) 4. Remove bolts (1). Remove the travel device by crane. : 30 mm

W3-2-35

6

7

W157-03-02-006

UNDERCARRIAGE / Travel Device Installation

4

5

1. Install the travel device with bolts (1). : 30 mm : 620 N⋅m (63 kgf⋅m, 460 lbf⋅ft) 2. Connect hoses (2) to (5). : 19 mm : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft) : 27 mm : 95 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft) : 50 mm : 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

1

3 2

3. Install cover (6) with bolts (7). : 22 mm : 180 N⋅m (18 kgf⋅m, 130 lbf⋅ft) IMPORTANT: After completing travel motor installation, be sure to fill the travel motor with hydraulic oil (1.3 L (0.34 US gal.)). After completing installation of the travel motor or the travel device, be sure to perform test driving to prevent motor seizure. Test drive as follows: Perform break-in operation as follows: 1. Run the engine with the engine control dial in the slow idle position. 2. Turn the travel speed mode switch to the slow speed position. 3. Test drive the machine for two minutes or more.

W3-2-36

6

7

W157-03-02-006

UNDERCARRIAGE / Travel Device (Blank)

W3-2-37

UNDERCARRIAGE / Travel Device DISASSEMBLE TRAVEL DEVICE ZAXIS330, 330LC, 350H, 350LCH (Serial No. 31358 and up) 17

13 12 37

4 3

3

6

7

14

38

11 10

40

5 9 23

1

2

8 18

8

19

27 26

27

26

25

20

21

19

22

35 31

24

28

30 43

29

42 34 33 36 31

32

W1HH-03-02-004

1234-

Third Stage Carrier Third Stage Sun Gear Thrust Plate (6 Used) Second Stage Planetary Gear (3 Used) 5 - Needle Bearing (3 Used) 6 - Pin (3 Used)

16 - Bolt (16 Used) 17 - Plug (3 Used)

78910 -

18 19 20 21 -

Spring Pin (3 Used) Spacer (2 Used) Second Stage Sun Gear First Stage Carrier

11 - Propeller Shaft

12 13 14 15 -

Ring Gear Bolt (28 Used) Stopper Pin Cover

23 24 25 26 -

Spring Pin (3 Used) Thrust Plate (6 Used) Needle Bearing (3 Used) First Stage Planetary Gear (3 Used) 22 - Pin (3 Used)

Second Stage Carrier Spring Pin (3 Used) Pin (3 Used) Thrust Plate (6 Used)

27 - Needle Bearing (6 Used) 28 - Third Stage Planetary Gear (3 Used) 29 - Motor 30 - Floating Seal 31 - Roller Bearing (2 Used) 32 - Drum 33 - Washer (20 Used)

W3-2-38

34 35 36 37 -

Bolt (20 Used) Bearing Nut Sprocket Retaining Ring

38 - Bearing 39 - Spacer 42 - Lock Plate 43 - Bolt (2 Used)

UNDERCARRIAGE / Travel Device Disassemble Travel Device CAUTION: Pressure may remain in the travel device. Slowly loosen the air bleed plug to completely release the residual pressure. Then, remove the drain plug to drain gear oil into a container. If the air bleed plug is loosened quickly, the plug may fly off and/or gear oil may gush out. Position your face and body away from the plug. CAUTION: Travel device weight: 460 kg (1020 lb) 1. Turn over the travel device. Place the travel device securely on a work bench so that the brake valve does not come into contact with the work bench, with the motor side downward. 2. Remove bolts (16) to remove cover (15) from ring gear (12). : 19 mm NOTE: THRREEBOND is applied between cover (15) and ring gear (12). For easy separation of cover (15), apply a chisel between cover (15) and ring gear (12) and lightly tap on the end of the chisel. Do not remove stopper pin (14) unless it is damaged or excessively worn.

15 16 12

3. Remove propeller shaft (11) and first stage carrier (10) assembly from ring gear (12). W107-03-02-008

4. Remove second stage sun gear (9), second stage carrier (23) assembly and third stage sun gear (2) from ring gear (12).

W3-2-39

UNDERCARRIAGE / Travel Device

13 12

1

35 31

30 43

29

42

36

31

32

W1HH-03-02-004

W3-2-40

UNDERCARRIAGE / Travel Device CAUTION: Ring gear (12) weight: 55 kg (121 lb)

CAUTION: Drum (32) + sprocket (36) weight: 135 kg (300 lb)

5. Remove bolts (13) (28 used). Attach eyebolt (M12, Pitch 1.75 mm) to bolt (16) hole of ring gear (12). Remove ring gear (12) from drum (32) by crane. : 24 mm

IMPORTANT: The motor (29) matching surface of drum (32) is the sliding surface. Place the drum assembly onto a wooden block not to damage it.

NOTE: THREEBOND is applied between ring gear (12) and drum (32). Use the screw driver for easy removal.

9. Attach eyebolt (M16, Pitch 2.0 mm) to drum (32). Remove drum (32) from housing (41) by crane.

CAUTION: Third stage carrier (1) assembly weight: 52 kg (115 lb)

10. Remove the inner race of roller bearing (31) from drum (32). NOTE: Do not attempt to remove the inner race of roller bearing (31) which remained in housing (41) side unless it is to be replaced.

6. Remove third stage carrier (1) assembly. 7. Remove bolt (43) and lock plate (42) from bearing nut (35). : 19 mm 8. Hold the travel device securely. Remove bearing nut (35) using special tools. Special Tools: ST 3050, ST 3051, ST 3052 Bolt: M16 (60 to 90 mm in length):2 pieces

11. Remove floating seal (30) from drum (32) and motor (29).

ST 3052 ST 3050

35

ST 3051

W157-03-02-005

W3-2-41

UNDERCARRIAGE / Travel Device

4 3

3

7

6

40 10

5 23 8

18

1

19

27 26

27

26

25

20

21

19

22

31

24

28

34

36 32

W1HH-03-02-004

W3-2-42

UNDERCARRIAGE / Travel Device 12. Apply a metal bar to the outer race of roller bearing (31) on drum (32) side, and tap the bar end with a hammer to drive the outer race out. 13. Apply a round bar to spring pin (18), and tap the end of the bar to drive spring pin (18) out of first stage carrier (10) assembly. (3 places) 14. Remove pins (22) (3 used). Remove first stage planetary gears (21) (3 used), needle bearings (20) (3 used), and thrust plates (19) (6 used). 15. Remove spacer (40) from first stage carrier (10). 16. Disassemble second stage carrier (23) assembly following steps 13 to 15 above. Remove spring pins (7) (3 used), pins (6) (3 used), second stage planetary gears (4) (3 used), thrust plates (3) (6 used), needle bearings (5) (3 used), and spacers (8) (2 used). 17. Disassemble third stage carrier (1) assembly following steps 13 to 15 above. Remove spring pins (24) (3 used), pins (25) (3 used), thrust plates (26) (6 used), third stage planetary gears (28) (3 used), and needle bearings (27) (6 used). CAUTION: Sprocket (36) weight: 68 kg (150 lb) 18. Loosen and remove bolts (34) (20 used). Remove sprocket (36) by crane after attaching a nylon sling to sprocket (36). : 30 mm NOTE: LOCTITE is applied to bolt (34).

W3-2-43

UNDERCARRIAGE / Travel Device ASSEMBLE TRAVEL DEVICE ZAXIS330, 330LC, 350H, 350LCH (Serial No.31358 and up)

33, 34 32 12 13 8

29

1

2

8

23

9

10

17 40 11 15 14 38 37 19 18 20 22 21 16

30 31 36 35 42 43 28 27 25 26 24 3

6

4 5

3

7 W1HH-03-02-003

1234-

Third Stage Carrier Third Stage Sun Gear Thrust Plate (6 Used) Second Stage Planetary Gear (3 Used) 5 - Needle Bearing (3 Used) 6 - Pin (3 Used)

16 - Bolt (16 Used) 17 - Plug (3 Used)

78910 -

18 19 20 21 -

Spring Pin (3 Used) Spacer (2 Used) Second Stage Sun Gear First Stage Carrier

11 - Propeller Shaft

12 13 14 15 -

Ring Gear Bolt (28 Used) Stopper Pin Cover

23 24 25 26 -

Spring Pin (3 Used) Thrust Plate (6 Used) Needle Bearing (3 Used) First Stage Planetary Gear (3 Used) 22 - Pin (3 Used)

Second Stage Carrier Spring Pin (3 Used) Pin (3 Used) Thrust Plate (6 Used)

27 - Needle Bearing (6 Used) 28 - Third Stage Planetary Gear (3 Used) 29 - Motor 30 - Floating Seal 31 - Roller Bearing (2 Used) 32 - Drum 33 - Washer (20 Used)

W3-2-44

34 35 36 37 -

Bolt (20 Used) Bearing Nut Sprocket Retaining Ring

38 - Bearing 40 - Spacer 42 - Lock Plate 43 - Bolt (2 Used)

UNDERCARRIAGE / Travel Device Assemble Travel Device 1. If replacing roller bearing (31), warm the inner race (2 used) 50 to 70 °C (122 to 158 °F) with a heater, then install one of them into motor (29). Wait for the bearing to cool. Then, drive it in position completely with a metal bar and hammer. NOTE: Check if the inner race is driven in completely by listening to the sound. 2. Apply grease to the O-ring outer surface of floating seal (30). Install one half of floating seal (30) on motor (29).

CAUTION: Drum (32) + sprocket (36) weight: 135 kg (300 lb) 5. Attach eyebolt (M16, Pitch 2.0 mm) to the bolt (13) hole of drum (32), then hoist and install drum (32) onto motor (29). At this time check if the clearance between the motor and drum is equal. 6. Warm the inner race of roller bearing (31) 50 to 70 °C (122 to 158 °F) with a heater. Install it between drum (32) and motor (29).

NOTE: For easier insertion of floating seal (30) O-ring, use a bamboo (wooden) spatula to guide it along the periphery. IMPORTANT: Be sure to tap only the outer race. 3. Install the outer races (2 used) of roller bearing (31) on drum (32) in position completely with a metal bar and hammer. Install the half of floating seal (30) into drum (32). NOTE: Check if the roller bearing is installed completely by listening to the sound. CAUTION: Sprocket (36) weight: 68 kg (150 lb) IMPORTANT: Align the chamfered side of sprocket (36) with drum (32). 4. Attach sprocket (36) with a nylon sling. Hoist it and place it on drum (32). Apply LOCTITE #262 to bolts (34) (20 used). Tighten bolts (34) and washers (33) (20 used). : 30 mm : 490 N⋅m (50 kgf⋅m, 360 lbf⋅ft)

W3-2-45

UNDERCARRIAGE / Travel Device

29

8

1

32 36 35 42 43 26 28 27 25 26 24 W1HH-03-02-003

W3-2-46

UNDERCARRIAGE / Travel Device IMPORTANT: Face bearing nut (35) stepped to the bearing. Apply grease to the threaded part of bearing nut (35). 7. Install bearing nut (35) to motor (29) and tighten manually.

12. Apply LOCTITE #262 to the thread of bolts (43) (2 used). Install lock plate (42) to bearing nut (35) with bolts (43) (2 used) : 19 mm : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft) 43 42 35

NOTE: Apply grease to the threaded part of bearing nut (35) to tighten the torque to correct specification. 8. Hold the travel device securely. Attach the special tools to bearing nut (35). Then, tighten with a torque wrench. Special Tools: ST 3050, ST 3051, ST 3052 Bolt: M16 (60 to 90 mm in length) ×2 pieces : 790 N⋅m (80 kgf⋅m, 580 lbf⋅ft)

13. Install two needle bearings (27) (2 used) into each third stage planetary gears (28) (3 used). IMPORTANT: One side of third stage planetary gear (28) is the marked groove. Install third stage planetary gear (28) with the side with marked groove facing to the spring pin (24) hole. 14. Install spacer (8) into third stage carrier (1). Putting thrust plates (26) (6 used) on both ends of each third stage planetary gears (28) (3 used), install them into third stage carrier (1).

ST 3052 ST 3050

35

W140-03-02-001

ST 3051

36

W157-03-02-005

9. After tighten bearing nut (35) to specification, tap on drum (32) with a plastic hammer to secure appropriate play. Then, rotate sprocket (36) 4 to 5 turns clockwise and then counterclockwise. 10. Repeat step 8 and 9. 11. Repeat step 9 above. Then, tighten bearing nut (35) to specification. Special Tools: ST 3050, ST 3051, ST3052, Bolt: M16 (60 to 90 mm in length): ×2 pieces : 790 N⋅m (80 kgf⋅m, 580 lbf⋅ft)

W3-2-47

UNDERCARRIAGE / Travel Device

29

12 13

1

2

8

23

9

15

16

32

28

25

24

6

4 5

3

7 W1HH-03-02-003

W3-2-48

UNDERCARRIAGE / Travel Device 15. Insert pins (25) (3 used) into third stage carrier (1) to secure third stage planetary gears (28) (3 used). At this time align third stage carrier (1) with the spring pin (24) hole on pin (25). 16. Drive spring pins (24) (3 used) into the spring pin hole on third stage carrier (1) and pin (25). Be sure that the slit part of spring pin (24) faces to the end of pin (25). 24

25

CAUTION: Ring gear (12) weight: 55 kg (121 lb) 20. Install eyebolt (M12, Pitch 1.75 mm) into the bolt (16) hole on ring gear (12). Hoist ring gear (12) by crane. Install ring gear (12) onto drum (32). Apply LOCTITE #262 to bolts (13) (28 used). Tighten bolts (13). : 24 mm : 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)

Slit

W178-02-06-002

CAUTION: Third stage weight: 52 kg (115 lb)

carrier

assembly

17. Install third stage carrier (1) assembly, aligning splines with motor (29). 18. Install third stage sun gear (2) into third stage carrier (1). Be sure that the lower tooth end faces to cover (15). Cover (15)

21. Install spacer (8), second stage planetary gears (4) (3 used), needle bearings (5) (3 used), thrust plates (3) (6 used), pins (6) (3 used), and spring pins (7) (3 used) into second stage carrier (23) following step 13 to 16 above. 22. Install second stage carrier (23) assembly into ring gear (12). 23. Install second stage sun gear (9) into second stage carrier (23). Be sure that the lower tooth end faces to cover (15).

2

Cover (15)

9

W166-03-02-001 W166-03-02-002

19. Clean (degrease) ring gear (12) mounting surface of drum (32). Apply THREEBOND #1389B to the mounting surface.

W3-2-49

UNDERCARRIAGE / Travel Device

29

12

9

10

17 40 11 15

19 18 20 22 21 16

W1HH-03-02-003

W3-2-50

UNDERCARRIAGE / Travel Device IMPORTANT: Face the lower tooth height side of first stage planetary gear (21) to spacer (40) side. 24. Install spacer (40), first stage planetary gears (21) (3 used), needle bearings (20) (3 used), thrust plates (19) (6 used), pins (22) (3 used), spring pins (18) (3 used) into first stage carrier (10) following step 13 to 16. 25. Install first stage carrier (10) assembly into ring gear (12), aligning splines between first stage carrier (10) and second stage sun gear (9). 26. Add gear oil to ring gear (12). Gear oil: 9.2 L (2.43 US gal) 27. Insert propeller shaft (11) into the center of carrier. Be sure that the propeller shaft correctly meshes with first stage planetary gears (21) and the shaft of motor (29). 28. Clean (degrease) the cover (15) mounting surface of ring gear (12). Apply THREEBOND #1389B to the mounting surface. Install cover (15) to ring gear (12). Apply LOCTITE #262 to bolts (16) (16 used). Tighten bolts (16) (16 used). : 19 mm : 110 N⋅m (11.5 kgf⋅m, 83 lbf⋅ft) 29. Wrap seal tape around plugs (17) (3 used). Install plugs (17) into cover (15). : 10 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

W3-2-51

UNDERCARRIAGE / Travel Device DISASSEMBLE TRAVEL MOTOR ZAXIS330, 330LC, 350H, 350LCH (Serial No.31358 and up) 6 Brake Releasing Oil Passage

5 4 3

Piston Pushing Oil Passage

2 1

8

16

5

28 7

15 14

17

13 19

12

18

20

11 10 9

21

22 23 24 25 26 27

1234567-

Shaft Retaining Ring Retaining Ring Oil Seal O-Ring (2 Used) Housing Piston

8910 11 12 13 14 -

Roller Bearing Disc Spring Brake Piston O-Ring O-Ring Plate (4 Used) Rotor

15 16 17 18 19 20 21 -

Bushing Swash Plate Ball (2 Used) Plunger (9 Used) Retainer Spring (6 Used) Friction Plate (4 Used)

W3-2-52

W1HH-03-02-005

22 23 24 25 26 27 28 -

Socket Bolt (8 Used) O-Ring Valve Plate Knock Pin Needle Bearing Brake Valve Spring

UNDERCARRIAGE / Travel Device Disassemble Travel Motor 6. Remove rotor (14), springs (20) (9 used), bushing (15), retainer (19) and plungers (18) (9 used) from housing (6).

CAUTION: Travel motor weight: 135 kg (300 lb) IMPORTANT: When removing brake valve (27) assembly from the motor, valve plate (24) is also removed with the brake valve side. Don’t drop the valve plate as it easily comes off. 1. Place the travel motor longitudinally. After removing socket bolt (22), remove brake valve (27) from housing (6). : 17 mm IIMPORTANT: The valve plate easily becomes cracked and scratched, so handle it with care. 2. Remove valve plate (24) and knock pins (25) from brake valve (27). Do not remove needle bearing (26) unless necessary. NOTE: Even if small removing tool is used for removing the needle bearing, the outer race may be deformed. Do not reuse the needle bearing. 3. Wrap tape on the needle bearing (26) rotation surface of shaft (1) for protection.

7. Remove plates (13) (4 used) and friction plates (21) (4 used) from housing (6). CAUTION: Housing weight: 87 kg (200 lb) 8. Place housing (6) with the brake releasing oil passage facing downward and horizontal. NOTE: When the brake releasing oil passage is positioned upward, the thick portion of swash plate (16) faces upward. When housing (6) is placed horizontally, the swash plate may come off suddenly. 9. Remove swash plate (16) from housing (6). 10. With a magnet, remove balls (17) (2 used), piston (7) and spring (28) from housing (6). 11. Remove retaining ring (2) from housing (6). 12. Tap the bottom in the spline bore of shaft (1) using a bar and plastic hammer to push the shaft out with roller bearing (8) from housing (6).

4. Remove disc spring (9) from housing (6). CAUTION: When removing the brake piston from the housing filled with air, cover the housing with cloth to prevent the brake piston from flying off. 5. Apply pressure air 100 to 300 kPa (1 to 3 kgf/cm2, 14 to 43 psi) to the brake releasing oil passage of housing (6), so that the brake piston will float up to be removed. NOTE: It is possible to using bicycle pump. Do not pry with a screwdriver, or components will be damaged.

W3-2-53

UNDERCARRIAGE / Travel Device

6

4 3

1

8

W1HH-03-02-005

W3-2-54

UNDERCARRIAGE / Travel Device 13. Insert a slotted head screwdriver into the shaft (1) hole of housing (6) and push out oil seal (4). NOTE: Since the oil seal has been covered with adhesive, it cannot be used again. 14. Remove retaining ring (3) from shaft (1). CAUTION: When the shaft is removed from the roller bearing, be sure to avoid dropping it. 15. Balance the inner race of roller bearing (8) remained on shaft (1) on a vice. With a bar and plastic hammer, tap the shaft slightly, to remove the roller bearing. Bar

8 1

W172-03-02-003

W3-2-55

UNDERCARRIAGE / Travel Device ASSEMBLE TRAVEL MOTOR ZAXIS330, 330LC, 350H, 350LCH (Serial No.31358 and up)

Brake Releasing Oil Passage

27

25

5

23

11

12

10

14 18

16

17

2

8

3 4 1

26

22

24

5

9

13

21

20

15

19

7

Piston Pushing Oil Passage 1234567-

Shaft Retaining Ring Retaining Ring Oil Seal O-Ring (2 Used) Housing Piston

8910 11 12 13 14 -

Roller Bearing Disc Spring Brake Piston O-Ring O-Ring Plate (4 Used) Rotor

15 16 17 18 19 20 21 -

Bushing Swash Plate Ball (2 Used) Plunger (9 Used) Retainer Spring (6 Used) Friction Plate (4 Used)

W3-2-56

28

6 W1HH-03-02-006

22 23 24 25 26 27 28 -

Socket Bolt (8 Used) O-Ring Valve Plate Knock Pin Needle Bearing Brake Valve Spring

UNDERCARRIAGE / Travel Device Assemble Travel Motor CAUTION: Housing weight: 87 kg (200 lb) 1. Place housing (6) with the brake valve (27) mating surface facing upward. IMPORTANT: Apply OCEAN grease #7 to the inner circumference of the oil seal, and apply THREEBOND #1104 or #1215 to the outer circumference of the oil seal. 2. Neatly clean oil seal (4) fitting part of housing (6). Using tool (ST 7270, ST 7271), install the oil seal into the housing.

IMPORTANT: Pay attention to assembly direction. 4. Insert the inner ring plate side of roller bearing (8) into the inner bore spline end of shaft (1) first. Then push the shaft until the bearing comes into the tight fitting part. Be sure not to damage the seal lip surface of the shaft. 5. Insert the inner bore spline end of the shaft into bearing assemble tool (ST 7268). Tap the other end of the shaft with a plastic hammer to install roller bearing (8) onto the shaft. 1

ST 7270 Inner Bore Spline Inner Ring Plate

4 6

ST 7268

ST 7271

12

W176-03-02-007 W176-03-02-008

IMPORTANT: Pay attention to the direction when assembling. 3. Assemble roller bearing (8) so that all marked surfaces are on the outer race, inner race, inner ring plate facing outward. Outer Race Marked Surface

Inner Race Marked Surface

6. Install retaining ring (3) on shaft (1), while taking care to avoid damaging the oil seal (4) slide surface. 7. Apply grease to the ball (17) surface sufficiently and assemble balls (2 used) to housing (6). 8. Install spring (28), piston (7) to housing (6) with the stepped side of the piston facing inside.

W176-02-06-014

Inner Ring Plate Marked Surface

W3-2-57

UNDERCARRIAGE / Travel Device

27

25

5

23

11

12

10

14 18

16

17

2

1

5

9

13

21

20

15

19

6 W1HH-03-02-006

W3-2-58

UNDERCARRIAGE / Travel Device IMPORTANT:

The small diameter side of the shaft is the inner race of the needle bearing. Take care not to damage it. 9. With a plastic hammer, tap shaft (1) lightly to install it into housing (6).

CAUTION: Housing weight: 105 kg (240 lb) 15. Place housing (6) with the brake valve (27) mounting surface facing upward.

10. Install retaining ring (2) in housing (6) to stop shaft (1).

16. Install plates (13) (4 used) and friction plates (21) (4 used) on housing (6) alternately. Install the friction plate (21) first.

NOTE: If keep open the retaining ring and move it to the lowest bottom of the housing, installation of the retaining ring becomes easy.

17. Apply grease to O-rings (11), (12). Install them into brake piston (10).

11. Apply grease to the ball hole of swash plate (16). Install the swash plate on housing (6), while align with balls (17) (2 used). CAUTION: Housing weight: 95 kg (210 lb) 12. Place housing (6) horizontally with its brake releasing oil passage facing downward. NOTE: If placed opposite, swash plate (16) may come off. IMPORTANT: Pay attention to the retainer direction. 13. Install springs (20) (6 used), bushing (15), retainer (19), plungers (18) (9 used) onto the rotor (14), with the chamfered side of the retainer facing the bushing.

IMPORTANT: Pay attention to the disc spring assembly direction. 19. Put disc spring (9) on brake piston (10) with the inner diameter of the disc spring facing the brake piston. 20. Install O-rings (5) (2 used), (23) onto the brake valve (27) contact surface of housing (6). Install O-ring (23) onto the brake valve (27). 21. Fill hydraulic oil into housing (6) until plate (13) is submerged. IMPORTANT: Pay attention to the knock pin assembly direction. 22. Install the large diameter side of knock pins (25) (2 used) to the knock pin hole of brake valve (27).

19

Chamfered

18. Push brake piston (10) into housing (6) with a plastic hammer by tapping evenly. NOTE: Since the O-ring is positioned around the brake piston, the brake piston cannot be fully fitted. When installing brake valve (27), push the brake piston with tightening bolts.

15

W172-03-02-001

14. Assemble the rotor (14) assembly into housing (6).

W3-2-59

UNDERCARRIAGE / Travel Device

27

25

26

22

24

6 W1HH-03-02-006

W3-2-60

UNDERCARRIAGE / Travel Device IMPORTANT:

Pay attention to the needle bearing assembly direction. 23. Using drive tool (4472142), tap needle bearing (26) with a hammer into brake valve (27). Face the mark on the needle bearing outward. 4472142

27

26

W176-03-02-012

24. Apply grease on the flat surface of valve plate (24). Install the valve plate onto brake valve (27), aligning knock pin (25). NOTE: Apply grease sufficiently so that valve plate adheres to the brake valve. It prevents the valve plate from coming off while turning over the brake valve. IMPORTANT: Take care not to let the valve plate fall as this can damage it resulting in oil leaks. 25. Install brake valve (27) to housing (6) and secure it with socket bolts (22) (8 used). : 17 mm : 392 N⋅m (40 kgf⋅m, 290 Ibf⋅ft)

W3-2-61

UNDERCARRIAGE / Travel Device DISASSEMBLE TRAVEL BRAKE VALVE ZAXIS330, 330LC, 350H, 350LCH (Serial No.31358 and up)

1 2 3 4 5

6

4 16 14

3

15

2

13

1

8

9

7

10 11

W1HH-03-02-007

12

1234-

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

5678-

Spool Valve Housing Plug O-Ring

910 11 12 -

Poppet (2 Used) Spring (2 Used) O-Ring (2 Used) Overload Relief Valve (2 Used)

W3-2-62

13 14 15 16 -

Plug O-Ring Spring Spool

UNDERCARRIAGE / Travel Device Disassemble Travel Brake Valve 1. Remove plug (1) from valve housing (6). (2 places). : 41 mm 2. Remove spring (3) and stopper (4) from valve housing (6) with a magnet. (2 places) 3. Remove spool (5) from valve housing (6) with a magnet.

6. Remove springs (10), poppets (9) from valve housing (6) with a magnet. (2 places) 7. Remove plug (13) from valve housing (6). : 6 mm 8. Remove spring (15), spool (16) from valve housing (6) with a magnet.

4. Remove plug (7) from valve housing (6). The plug coated with LOCTITE has been inserted into the hole. Do not remove it unless necessary. : 6 mm IMPORTANT: Do not disassemble the overload relief valve. By disassembling it, its setting pressure may be changed. IMPORTANT: Do not move the piston on the overload relief valve, otherwise the O-ring may be damaged by the hole of cartridge. 5. Remove relief valves (12) from overload valve housing (6). (2 places) : 41 mm 12

W176-03-02-011

Piston

W3-2-63

UNDERCARRIAGE / Travel Device ASSEMBLE TRAVEL BRAKE VALVE ZAXIS330, 330LC, 350H, 350LCH (Serial No.31358 and up)

6

13

1

14

15

16

2

9

3

10

4

5

11

12

4

3

8

2

1

7 W1HH-03-02-008

1234-

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

5678-

Spool Valve Housing Plug O-Ring

910 11 12 -

Poppet (2 Used) Spring (2 Used) O-Ring (2 Used) Overload Relief Valve (2 Used)

W3-2-64

13 14 15 16 -

Plug O-Ring Spring Spool

UNDERCARRIAGE / Travel Device Assemble Travel Brake Valve 1. Install spool (5) approximately half way into valve housing (6).

7. Install O-ring (11) (2 used) into overload relief valve (12).

2. Install O-ring (2), spring (3), stopper (4) onto plug (1) on one side. Install the plug into valve housing (6) with pitch a couple of threads left out.

8. Press poppet (9) installed in step 6 with overload relief valve (12) into valve housing (6), while slowly rotating the relief valve. (2 places) : 41 mm : 440 N⋅m (45 kgf⋅m, 325 lbf⋅ft)

NOTE: If the plug is fully installed, it is difficult to assemble the plug on other side as spool (5) may be pushed out. 3. Install O-ring (2), spring (3) and stopper (4) into other plug (1). Install plug (1) into valve housing (6). Tighten the plug by hand. 4. Tighten plug (1) on both sides. : 41 mm : 343 N⋅m (35 kgf⋅m, 253 lbf⋅ft) 5. Install O-ring (8) into plug (7), then install plug (7) into valve housing (6). : 6 mm : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)

IMPORTANT: Pay attention to the assembly spool direction. 9. Install spool (16) into valve housing (6) with the hole end facing forward. 10. Install spring (15) into valve housing (6). 11. Install O-ring (14) onto plug (13) into valve housing (6). : 6 mm : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)

6. Install spring (10) into poppet (9). Install poppet (9) flush with the hole entrance of valve housing (6). (2 places) NOTE: If the poppet is installed into the farthest end, the spring may come off from the poppet.

W3-2-65

UNDERCARRIAGE / Travel Device MAINTENANCE STANDARD

Sprocket

C

B

D

E

A

W1HH-03-02-002

A B C D E

Standard Allowable Limit 87 (3.4) [77 (3.0)] 89.15 (3.5) 84.15 (3.3) 125.75 (5) 133.55 (5.3) 128.55 (5.1) 216.0 (8.5) -

NOTE: Values in [ ] is just for reference.

W3-2-66

Unit: mm (in) Remedy Cladding by welding and finishing

UNDERCARRIAGE / Travel Device Shoe

Travel Motor 1. End play between plunger and shoe. Standard 0 ε ≤ 0.2 mm (0.008 in)

Allowable Limit 0.2 mm (0.008 in)

ε

Plunger

W105-02-06-130

2. The clearance between plunger and rotor bore. Standard

D

Allowable Limit

0 0.04 mm (0.0016 in) D-d ≤ 0.04 mm (0.0016 in)

W105-02-06-134

Plunger Assembly

d Rotor

W105-02-06-135

Shoe

3. Shoe thickness Standard

Allowable Limit

5.5 mm (0.22 in)

5.3 mm (0.21 in) Plunger

W105-02-06-130

W3-2-67

UNDERCARRIAGE / Travel Device REMOVE AND INSTALL TRAVEL DEVICE ZAXIS370MTH IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

1

Removal Before removing the travel device, the tracks must be removed first. For removal and installation of the tracks, refer to “Remove and Install Tracks” section on page W3-7-1. In this section, the procedure starts on the premise that the track have already been removed.

2 W16J-03-02-006

3

1. Remove bolts (1) (6 used) to remove cover (2) from the track frame. : 22 mm

Track Frame

4

10

IMPORTANT: Attach identification tags to hoses for reassembly. 2. Disconnect hoses (3 and 4) from travel device (6) and cap all disconnected hose ends. : 27 mm, 17 mm 3. Remove socket bolts (8) (8 used) from split flanges (7) (4 used) to disconnect hoses (9 and 10) from travel device (6). Cap all disconnected hoses. : 10 mm

5

6 9

8

7

W16J-03-02-005

W111-03-02-002

W3-2-68

UNDERCARRIAGE / Travel Device CAUTION: Travel Device weight: 670 kg (1480 lb)

3

4. Attach wire ropes on travel device (6), and hoist the travel device by crane.

Track Frame

4

10 5

5. Put matching marks on travel device (6) and the track frame. Remove bolts (5) (20 used). Hoist and remove the travel device by crane. : 32 mm

6 9

8

7

W16J-03-02-005

W111-03-02-002

W3-2-69

UNDERCARRIAGE / Travel Device Installation 3

CAUTION: Travel device weight: 670 kg (1480 lb) IMPORTANT: Be sure to align the matching marks made during disassembling. By failing to do so, it is difficult to install hoses (3 and 4). 1. Install travel device (6) onto the track frame with bolts (5) (20 used). : 32 mm : 750 N⋅m (76.5 kgf⋅m, 550 Ibf⋅ft) 2. Connect hoses (9 and 10) to travel device (6) with split flanges (7) (4 used) and tighten the split flange with socket bolts (8) (8 used). : 10 mm : 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft) 3. Connect hoses (3 and 4) onto travel device (6). : 27 mm : 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft) : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) 4. Install cover (2) onto the track frame with bolts (1) (6 used). : 22 mm : 180 N⋅m (18.5 kgf⋅m, 134 Ibf⋅ft)

4

Track Frame

10 5

6 9

8

7

W16J-03-02-005

1

2 W16J-03-02-006

IMPORTANT: After installation, check the oil level. Start the engine and check for oil leaks. After completing installation of the travel device, be sure to perform running-in to prevent motor seizure. Perform break-in operation as follows: 1. Run the engine with the engine control dial in the slow idle position. 2. Turn the travel speed mode switch to the slow speed position 3. Drive the machine for 2 minutes or more

W3-2-70

UNDERCARRIAGE / Travel Device (Blank)

W3-2-71

UNDERCARRIAGE / Travel Device DISASSEMBLE TRAVEL DEVICE

8

ZAXIS370MTH 7

6

5 4 3 2 1 21

22

24

23

20 17 16

15 13

18

25

19

14

26 27

12

28 29

10

9

11

37 40

39

36

34 33 35

32

31

30

38

49

48 47

44

45

46

43 41 42 12345678910 11 12 13 -

Motor O-Ring Housing Floating Seal Roller Bearing Drum Roller Bearing O-Ring Nut Lock Plate Bolt (2 Used) Sprocket Washer (24 Used)

14 15 16 17 18 19 20 21 22 23 24 25 -

Bolt (24 Used) 3rd Stage Carrier 3rd Stage Sun Gear 2nd Stage Carrier Spacer 2nd Stage Sun Gear Thrust Plate (3 Used) Needle Bearing (3 Used) Pin (3 Used) 1st Stage Planetary Gear (3 Used) Thrust Plate (3 Used) Spring Pin (3 Used)

26 27 28 29 30 31 32 33 34 35 36 37 -

Spacer 1st Stage Carrier Thrust Plate (3 Used) Spring Pin (3 Used) 2nd Stage Planetary Gear (3 Used) Pin (3 Used) Needle Bearing (3 Used) Thrust Plate (3 Used) Thrust Plate (4 Used) 3rd Stage Planetary Gear (4 Used) Spring Pin (4 Used) Pin (4 Used)

W3-2-72

W16J-03-02-004

38 39 40 41 42 43 44 45 46 47 48 49 -

Needle Bearing (4 Used) Needle Bearing (4 Used) Thrust Plate (4 Used) Shaft Ring Gear Bolt (30 Used) Retaining Ring Stopper Pin Ball Bearing Cover Bolt (16 Used) Plug (3 Used)

UNDERCARRIAGE / Travel Device Disassemble Travel Device CAUTION: Pressure may remain in the travel device. Slowly loosen the air bleed plug to completely release the residual pressure. Then, remove the drain plug and drain the gear oil into a container. If the air bleed plug is loosened quickly, the plug may fly off and/or gear oil may spurt. Keep your face and body away from the plug.

CAUTION: Motor (1) weight: 130 kg (300 Ib) 2. Put matching marks on the mounting surface of motor (1) and housing (3). Install eyebolts (M12, Pitch 1.75 mm) (2 used) into the motor. Remove bolts (4 used), then hoist and remove the motor. Remove O-ring (2) from the motor. : 27 mm 3

CAUTION: Travel device weight: 670 kg (1480 lb)

Motor Mounting Bolt

1. After loosening plug (49-B) 2 to 3 turns, remove plug (49-A) to drain gear oil from the travel device. Lay the travel device on a work bench with motor (1) facing up. : 14 mm

1

49-B

Eyebolt Mounting Position W16J-03-02-002

CAUTION: Travel device weight: 540 kg (1190 Ib) 49-A W111-03-02-006

3. Attach a wire rope to the middle of drum (6) and ring gear (42). Hoist the travel device and place it on the work bench with cover (47) facing up. CAUTION: Cover (47) weight: 25 kg (55 Ib) 4. Put matching marks on the mounting surface of cover (47) and ring gear (42). Install eyebolts (PT 3/4) into the plug (49) holes. (2 places) Remove bolts (48) (16 used), then hoist and remove cover (47) from ring gear (42). : 22 mm NOTE: Since THREEBOND has been applied to the mating surfaces of ring gear (42) and cover (47), it is better to insert a screw driver between the ring gear and the cover to pry the cover up for easier removal.

W3-2-73

UNDERCARRIAGE / Travel Device 8 7

6

4 3

21

22

24

23

20 17 16

18

25

19

15 26 12

27 28 29

9

10

11

37 40

39

36

34 33 35

32

31

30

38

48

43 41 42

W3-2-74

W16J-03-02-004

UNDERCARRIAGE / Travel Device 10. Install special tool (ST 3136) onto bearing nut (9) to loosen and remove the bearing nut.

CAUTION: Ring gear (42) weight: 70 kg (150 lb)

ST 3136

5. Put matching marks on the mating parts of ring gear (42) and drum (6). Install eyebolts (M14, Pitch 2.0 mm) into the bolt (48) holes (2 places) in ring gear (42). Remove bolts (43) (30 used) to hoist and remove the ring gear. Remove O-ring (8) from drum (6). : 27 mm 6. Remove shaft (41) from first stage carrier (27). Remove first stage carrier assemblies (20 to 27) and second stage sun gear (19) from second stage carrier (17).

W111-03-02-018

CAUTION: The second stage carrier (17) assembly weight: 25 kg (50 Ib)

CAUTION: Drum (6), sprocket (12) and other parts weight: 180 kg (400 Ib)

7. Wind nylon slings (2 used) onto second stage carrier (17). Hoist and remove second stage carrier assemblies (17, 18, 28 to 33). Remove third stage sun gear (16).

IMPORTANT: The mating parts of drum (6) and housing (3) are sliding seal surface. Take care not to damage the sliding seal surface and put the removed drum assembly onto wooden blocks.

CAUTION: The third stage carrier (15) assembly weight: 70 kg (150 Ib) 8. Wind nylon slings (2 used) onto third stage carrier (15). Hoist and remove third stage carrier assemblies (15 and 34 to 40) by crane. 9. Remove bolts (11) (2 used) to remove lock plate (10). : 19 mm

11. Put matching marks on the mating parts of drum (6) and housing (3). Install eyebolts (M18, Pitch 2.5 mm) into the bolt (43) holes (2 places) in the drum. Hoist and remove the drum assembly from the housing. At this time, the inner race of roller bearing (7) is also removed along with it. 12. Remove floating seals (4) from housing (3) and drum (6).

W3-2-75

UNDERCARRIAGE / Travel Device

7

6

5

3

1 25 17

18

15 12

14

26 27

29

37 40

39

36

34 35

38

W16J-03-02-004

W3-2-76

UNDERCARRIAGE / Travel Device IMPORTANT: Do not remove the inner race of roller bearing (5) from housing (3) unless necessary. In case the inner race of roller bearing (5) has been removed, it must be replaced with a new one. 13. Remove the inner race of roller bearing (5) from housing (3) with a bar and hammer. NOTE: If the inner race of roller bearing (5) can not be removed, it can be cut by gas torch. However care should be taken to protect housing (3) from being damaged while doing this work. CAUTION: Sprocket (12) weight: 85 kg (190 Ib) 14. Put matching marks on the mating surface of sprocket (12) and drum (6). Attach nylon slings (2 used) on the sprocket. Remove bolts (14) (24 used). Hoist and remove the sprocket. : 32 mm

17. Pull spring pin (36) out from third stage carrier (15) with a round bar (Dia: 8mm (0.3 in)). Remove pin (37) to remove third stage planetary gear (35) and thrust plates (34 and 40) from the third stage carrier. Remove needle bearings (38 and 39) from the third stage planetary gear. 18. Remove spring pins (36) (3 used), pins (37) (3 used), third stage planetary gears (35) (3 used), thrust plates (34) (3 used) and (40) (3 used), needle bearings (38) (3 used) and (39) (3 used) from third stage carrier (15) according to the steps in procedure 17. 19. Disassemble the first stage carrier (27) assembly and second stage carrier (17) assembly according to the steps in procedures 17 and 18. The diameter of round bar for spring pin (25): 4 mm (0.16 in) The diameter of round bar for spring pin (29): 5 mm (0.20 in) 20. Remove spacer (26) from first stage carrier (27). Remove spacer (18) from second stage carrier (17).

IMPORTANT: Do not remove the outer race of roller bearings (5) and (7) from drum (6) unless necessary. If the bearing is pressed in insufficiently, the service life of the bearing may be affected. In case the outer race has been removed, it must be replaced with a new one. 15. Remove the outer race of roller bearing (5) from drum (6) with a bar and hammer. CAUTION: Drum (6) including other parts weight: 100 kg (220 Ib) 16. Install eyebolts (M22, Pitch 2.5 mm) into the bolt (14) holes (2 places) in drum (6) from the motor (1) side. Hoist and turn the drum over. Remove the outer race of roller bearing (7) from the drum with a bar and hammer.

W3-2-77

UNDERCARRIAGE / Travel Device ASSEMBLE TRAVEL DEVICE 3 1

4

6

13 14

12

ZAXIS370MTH 5

7

9

8

43 42

15 16

18

2

17

19

26 27

49 47 44 46 45 41 23 24 25 22 21 20 48

33 30 32 31 34

40 35 39 38

10 11

12345678910 11 12 13 -

Motor O-Ring Housing Floating Seal Roller Bearing Drum Roller Bearing O-Ring Nut Lock Plate Bolt (2 Used) Sprocket Washer (24 Used)

14 15 16 17 18 19 20 21 22 23 24 25 -

Bolt (24 Used) 3rd Stage Carrier 3rd Stage Sun Gear 2nd Stage Carrier Spacer 2nd Stage Sun Gear Thrust Plate (3 Used) Needle Bearing (3 Used) Pin (3 Used) 1st Stage Planetary Gear (3 Used) Thrust Plate (3 Used) Spring Pin (3 Used)

26 27 28 29 30 31 32 33 34 35 36 37 -

36

T16J-03-05-001

37

Spacer 1st Stage Carrier Thrust Plate (3 Used) Spring Pin (3 Used) 2nd Stage Planetary Gear (3 Used) Pin (3 Used) Needle Bearing (3 Used) Thrust Plate (3 Used) Thrust Plate (4 Used) 3rd Stage Planetary Gear (4 Used) Spring Pin (4 Used) Pin (4 Used)

W3-2-78

28 29

38 39 40 41 42 43 44 45 46 47 48 49 -

Needle Bearing (4 Used) Needle Bearing (4 Used) Thrust Plate (4 Used) Shaft Ring Gear Bolt (30 Used) Retaining Ring Stopper Pin Ball Bearing Cover Bolt (16 Used) Plug (3 Used)

UNDERCARRIAGE / Travel Device Assemble Travel Device CAUTION: Housing (3) weight: 90 kg (200 Ib) 1. Wind a nylon sling on housing (3) body. Hoist and place the housing with motor (1) side facing down. IMPORTANT: For handling of the floating seal, refer to the section “Precautions for Floating Seal Handling” on page W1-1-4. 2. Install one half of floating seal (4) on housing (3) with a wooden spatula or similar tool to guide the seal along the periphery. Install the inner race of roller bearing (5) into the housing by tapping it with a bar and hammer evenly. NOTE: Tap the bearing and listen to ring to see if the installation of the inner race is completed into housing (3). CAUTION: Drum (6) weight: 96 kg (210 Ib) 3. Install eyebolts (M22, Pitch 2.5 mm) into the bolt (14) holes (2 places) in drum (6) from the motor (1) side. Hoist and place the drum (6) with the ring gear (42) side facing down. Tap the outer race of roller bearing (5) with a bar and hammer evenly to install it onto the drum(6). NOTE: Tap the bearing and listen to ring to see if the installation of the outer race is completed into drum (6). IMPORTANT: Apply grease to the O-ring of floating seal (4) on the drum (6) side. 4. Install one half of floating seal (4) on drum (6).

5. Install eyebolts (M18, Pitch 2.5 mm) into the bolt (43) holes (2 places) in drum (6). Hoist and place the drum (6) with the ring gear (42) side facing up. Install the outer race of roller bearing (7) onto the drum by tapping it with a bar and hammer evenly. NOTE: Tap the bearing and listen to ring to see if the installation of the outer race is completed into drum (6). CAUTION: Sprocket (12) weight: 85 kg (190 lb) 6. Attach nylon slings (2 used) on sprocket (12). Hoist the sprocket and place it carefully onto drum (6). IMPORTANT: Apply LOCTITE #262 on degreased bolt (14). 7. Install spring washer (13) to each bolts (14) (24 used). Tighten the bolts and install sprocket (12) onto drum (6). : 32 mm : 750 N⋅m (75 kgf⋅m, 550 lbf⋅ft) CAUTION: Drum (6), sprocket (12), plus other parts weight: 180 kg (400 Ib) IMPORTANT: Align the matching marks made before disassembling. Be sure the clearance all around drum (6) in housing (3) is equal. 8. Hoist the drum (6) assembly and put it onto housing (3). 9. Install the inner race of roller bearing (7) onto the housing by tapping it with a bar and hammer evenly.

W3-2-79

UNDERCARRIAGE / Travel Device

12 3

6

7

9

8

15

47

34

10 11

40 35 39 38

W3-2-80

37

36

T16J-03-05-001

UNDERCARRIAGE / Travel Device IMPORTANT: Install bearing nut (9) with the stepped part facing roller bearing (7). Apply a film of grease at the threaded part of the bearing nut. 10. Install bearing nut (9) onto housing (3) and tighten it by hand. NOTE: Apply a film of grease to the threaded part of bearing nut (9) so as to tighten the nut to the specified torque. 11. Install special tool (ST 3136) onto bearing nut (9) and tighten it with a wrench. : 785 N⋅m (80 kgf⋅m, 580 lbf⋅ft) ST 3136

IMPORTANT: If lock plate (10) fails to engage the spline of housing (3), tighten bearing nut (9) further in the tightening direction to align with the spline. Apply LOCTITE #262 to bolts (11). 14. Install lock plate (10) onto bearing nut (9) with degreased bolts (11) (2 used). : 19 mm : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft) IMPORTANT: Apply grease on O-ring (8). 15. Install O-ring (8) onto drum (6). IMPORTANT: There is an identification groove on one half of third stage planetary gear (35). Install the third stage planetary gear with the identification groove facing cover (47). 16. Install needle bearings (38) (4 used) and (39) (4 used) onto third stage planetary gears (35) (4 used). Install the third stage planetary gear onto third stage carrier (15) by clamping it with thrust plates (34) (4 used) and (40) (4 used). 17. Align the spring pin (36) holes in third stage carrier (15) and pins (37) (4 used), then install the spring pins.

W111-03-02-018

12. Rotate sprocket (12) both clockwise and counterclockwise 4 to 5 turns. Tap on drum (6) with a plastic hammer to secure appropriate play.

IMPORTANT: When installing spring pin (36), be sure to let its slit face the end of pin (37). 18. Install spring pins (36) (4 used) into third stage carrier (15) and pin (37) with a round bar (Dia: 8 mm (0.3 in)).

13. Perform procedures 11 and 12 twice and tighten bearing nut (9) to the specified torque. : 785 N⋅m (80 kgf⋅m, 580 lbf⋅ft)

36 37 Slit W178-02-06-002

W3-2-81

UNDERCARRIAGE / Travel Device

3

6

43 42

15 16

17 19

26

27

47

41 23 24 25 22 21 20 48

33 30 32 31 34

40 35 39 38

W3-2-82

37

28 29

36

T16J-03-05-001

UNDERCARRIAGE / Travel Device 19. Install spacer (26) to first stage carrier (27). 20. Install needle bearings (21) (3 used) onto first stage planetary gears (23) (3 used). Clamp the first stage planetary gear with thrust plates (24) (3 used) and (20) (3 used) and install the first stage planetary gear onto first stage carrier (27). IMPORTANT: When installing spring pin (25), be sure to let its slit face the end of pin (22). 21. Install spring pins (25) (3 used) into first stage carrier (27) and pin (22) by a round bar (Dia: 4 mm (0.16 in)).

CAUTION: The second stage carrier (17) assembly weight: 25 kg (60 Ib) 25. Wind nylon slings (2 used) onto second stage carrier assemblies (17, 18 and 28 to 33). Hoist the second stage carrier assemblies and lower it onto third stage sun gear (16). 26. Install second stage sun gear (19) onto second stage carrier (17) with the smaller end facing cover (47). Cover (47) Side

25 22 19

Slit W178-02-06-002

22. Assemble second stage carrier (17) according to the procedures 19 to 21. Round Bar Dia: 5 mm (0.20 in)

27. Install first stage carrier assemblies (20 to 27) onto second stage carrier (17). 28. Insert shaft (41) into the center of carrier and be sure to let it engage with the first stage planetary gears (23) (3 used).

CAUTION: The third stage carrier (15) assembly weight: 70 kg (150 Ib) 23. Wind nylon slings (2 used) onto third stage carrier assemblies (15 and 34 to 40). Hoist the third stage carrier assemblies and lower it onto housing (3) carefully. 24. Install third stage sun gear (16) onto third stage carrier (15) with the smaller end facing cover (47).

W166-03-02-002

CAUTION: Ring gear (42) weight: 70 kg (150 Ib) IMPORTANT: Align the matching marks made when disassembling. 29. Install eyebolts (M14, Pitch 2.0 mm) into the bolt (48) hole in ring gear (42). Hoist ring gear by crane and lower it to drum (6). IMPORTANT: Apply LOCTITE #262 on degreased bolt (43). 30. Install ring gear (42) onto drum (6) with bolts (43) (30 used). : 27 mm : 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)

Cover (47) Side

W166-03-02-001

16

W3-2-83

UNDERCARRIAGE / Travel Device

3 1

42

2

49 47 44 46 45 41

48

T16J-03-05-001

W3-2-84

UNDERCARRIAGE / Travel Device 31. Attach a tube bar on ball bearing (46). Tap a tube bar with a hammer and install the ball bearing onto cover (47). Ball Bearing Inner Diameter: 45 mm (1.77 in) Outer Diameter: 68 mm (2.68 in) 32. Attach a tube bar on stopper pin (45). Tap a tube bar with a hammer to install the stopper pin into ball bearing (46). Stopper Pin Inner Diameter: 26 mm (1.02 in) Outer Diameter: 50 mm (1.97 in) IMPORTANT: Install retaining ring (44). Be sure to let the chamfered part face cover (47). 33. Install retaining ring (44) onto cover (47). CAUTION: Cover (47) weight: 25 kg (55 Ib) IMPORTANT: Apply THREEBOND #1389B to the cover (47) mounting surface of ring gear (42). 34. Install eyebolts (PT 3/4) into the plug (49) holes (2 places) in cover (47). Hoist the cover by crane and lower it to ring gear (42).

CAUTION: Travel reduction gear weight: 540 kg (1190 Ib) 37. Install eyebolts (M18, Pitch 2.5 mm) into the bolt holes (2 places) in the housing (3) flange. Hoist the travel reduction gear and turn it over. 38. Fill gear oil 11.5 L (3.0 US gal.) into the travel reduction gear. 39. Install O-ring (2) to motor (1). CAUTION: Motor (1) weight: 135 kg (300 Ib) 40. Install eyebolts (M12, Pitch 1.75 mm) (2 used) into the bolt holes in motor (1). Hoist the motor and install it onto housing (3) while aligning the splines on shaft (41) with the splines on the motor. 3 Motor Mounting Bolt

1

IMPORTANT: Apply LOCTITE #262 on degreased bolt (48). 35. Install cover (47) onto ring gear (42) with bolts (48) (16 used). : 22 mm : 177 N⋅m (18 kgf⋅m, 130 lbf⋅ft) 36. Wrap the seal tape to plugs (49) (3 used) and install the plugs into cover (47). : 14 mm : 69 N⋅m (7 kgf⋅m, 51 lbf⋅ft)

Eyebolt Mounting Position W16J-03-02-002

41. Install spring washers to each bolt (4 used), then install motor (1) into housing (3) with the bolts (4 used). : 27 mm : 300 N⋅m (30 kgf⋅m, 220 lbf⋅ft)

W3-2-85

UNDERCARRIAGE / Travel Device DISASSEMBLE TRAVEL MOTOR ZAXIS370MTH 4 2

3

1

7 5

2

6

15

16

17

14 13 11

12

10 9 8

28

22 27

20 26 25 24

23 18

19 33 32 21 30 29

123456789-

Casing O-Ring (4 Used) Spring (2 Used) Piston (2 Used) Oil Seal Roller Bearing Shaft Steel Ball (2 Used) Swash Plate

10 11 12 13 14 15 16 17 -

Piston (9 Used) Retainer Holder Spring (9 Used) Cylinder Block Valve Plate Collar Roller Bearing

18 19 20 21 22 23 24 25 -

Friction Plate Friction Plate Disc Plate (4 Used) Friction Plate (3 Used) Friction Plate Backup Ring O-Ring O-Ring

W3-2-86

26 27 28 29 30 31 32 33 -

31

W16J-03-02-001

Backup Ring Brake Piston O-Ring Spring (10 Used) Pin Pin (4 Used) Valve Housing Socket Bolt (9 Used)

UNDERCARRIAGE / Travel Device Disassemble Travel Motor (ZAXIS370MTH) CAUTION: Valve housing (32) weight: 39 kg (90 Ib) IMPORTANT: Loosen socket bolts (33) (9 used) evenly. When loosening the socket bolts, valve housing (32) may come up from casing (1) since there is a spring force coming from springs (13) and (29). Take down the clearance between the casing and the valve housing. When removing the valve housing from the casing, valve plate (15) will come out with the valve housing, do not let the plate come off. 1. Put matching marks on the mating part of valve housing (32) and casing (1). Install eyebolts (M12, Pitch 1.75 mm) onto the valve housing. Remove socket bolts (33) (9 used). Hoist the valve housing and remove it from the casing. : 14 mm 1

32

IMPORTANT: Fix casing (1) securely. 4. Install eyebolts (M12, Pitch 1.75 mm) into the pin (31) holes (2 places) in brake piston (27). Hoist the brake piston and remove it from casing (1). 5. Remove O-rings (24 and 25), backup rings (23 and 26) from brake piston (27). IMPORTANT: Since friction plates (18, 19, 21 and 22) are different in thickness and the order to install them has been determined, they should be kept in order while removing. 6. Remove friction plate (22) from casing (1). Remove disc plates (20) (4 used) and friction plates (21) (3 used) one by one alternately. Remove friction plates (19 and 18). CAUTION: The cylinder block (14) assembly weight: 20 kg (40 Ib) IMPORTANT: If cylinder block (14) needs to be replaced, cylinder block assemblies (10 to 15) with valve plate (15) should be replaced. 7. Remove cylinder block (14) assemblies (10 to 15) from casing (1).

33

NOTE: Hold cylinder block (14) and turn it left and right lightly by two hands to take it out slowly.

Eyebolt Mounting Position W16J-03-02-002

2. Remove springs (29) (10 used), O-rings (2) (4 used), pins (31) (4 used) and O-ring (28) from casing (1). IMPORTANT: Take care not to damage valve plate (15). 3. Remove collar (16) and valve plate (15) from cylinder block (14).

8. Remove retainer (11), pistons (10) (9 used), holder (12) and springs (13) (9 used) from cylinder block (14). IMPORTANT: Do not damage the friction surface of swash plate (9). Piston (4) and steel ball (8) may come out with the swash plate. Be sure to keep the piston and the steel ball from dropping. 9. Remove swash plate (9) from casing (1).

W3-2-87

UNDERCARRIAGE / Travel Device

4 3

1

7 5

6

8

W16J-03-02-001

W3-2-88

UNDERCARRIAGE / Travel Device 10. Remove pistons (4) (2 used), springs (3) (2 used) and steel balls (8) (2 used) from casing (1). NOTE: If it is difficult to remove steel ball (8), that means the ball has been set in casing (1), so use some kerosene or thinner, etc. to clean grease first, and then with a magnet to take it out from casing (1). IMPORTANT: Do not damage the spline part of shaft (7) and contact part of oil seal (5). Oil leakage will occur if they are damaged. 11. Remove shaft (7) from casing (1). At this moment, the inner race of roller bearing (6) is connecting with the shaft. IMPORTANT: Do not remove the inner race of roller bearing (6) from shaft (7) and the outer race of roller bearing (6) from casing (1) unless necessary. 12. Remove the inner race of roller bearing (6) from shaft (7) with a press. IMPORTANT: Keep the outer race of roller bearing (6) properly so that it can be installed in the same direction before disassembling. 13. Remove the outer race of roller bearing (6) from casing (1) with a bar and a hammer. 14. Remove oil seal (5) from casing (1).

W3-2-89

UNDERCARRIAGE / Travel Device ASSEMBLE TRAVEL MOTOR ZAXIS370MTH

27 33

29

25,26

23,24

22

7

19 18

4

3

30

8

16

32

17

1 15

31 5

28

T16J-03-05-003

2

6

Brake Release Circuit

123456789-

Casing O-Ring (4 Used) Spring (2 Used) Piston (2 Used) Oil Seal Roller Bearing Shaft Steel Ball (2 Used) Swash Plate

10 11 12 13 14 15 16 17 -

14 10 20 21

Piston (9 Used) Retainer Holder Spring (9 Used) Cylinder Block Valve Plate Collar Roller Bearing

13

18 19 20 21 22 23 24 25 -

11

12

9

Friction Plate Friction Plate Disc Plate (4 Used) Friction Plate (3 Used) Friction Plate Backup Ring O-Ring O-Ring

W3-2-90

26 27 28 29 30 31 32 33 -

Backup Ring Brake Piston O-Ring Spring (10 Used) Pin Pin (4 Used) Valve Housing Socket Bolt (9 Used)

UNDERCARRIAGE / Travel Device Assemble Travel Motor IMPORTANT: Apply grease on inside periphery of oil seal (5) for casing (1) at the pressed-in part and outside periphery of the oil seal. In addition, the oil seal should be pressed in straight to prevent it from deforming. 1. Press oil seal (5) into casing (1). IMPORTANT: Install the outer race of roller bearing (6) with the stamp mark on the outer race facing the swash plate (9) side. 2. Tap the outer race of roller bearing (6) evenly with a bar and hammer while installing the outer race into casing (1). NOTE: Tap the bearing and listen to ring to confirm if installation is completed. IMPORTANT: Install the inner race of roller bearing (6) with its collar facing swash plate (9). 3. Tap the inner race of roller bearing (6) evenly with a bar and hammer while installing it into shaft (7). Tap and install the shaft assembly into casing (1) with a hammer. IMPORTANT: Apply hydraulic oil on outside periphery of steel ball (8) and piston (4). Apply hydraulic oil the piston (4) and the steel ball (8) mounting surfaces of casing (1). 4. Install springs (3) (2 used), pistons (4) (2 used) and steel balls (8) (2 used) into casing (1).

IMPORTANT: Align the spherical hole in swash plate (9) with steel ball (8), then install the swash plate. Apply grease to matching part of casing (1) for the swash plate. 6. Install swash plate (9) onto casing (1) with its thicker side facing down. IMPORTANT: Apply hydraulic oil on the piston (10) mounting hole of cylinder block (14). Pay attention to the mounting direction of retainer (11). 7. Install springs (13) (9 used) and holder (12) into cylinder block (14). Install pistons (10) (9 used) onto retainer (11) and install them into the cylinder block. CAUTION: The cylinder block (14) assembly weight: 20 kg (40 Ib) IMPORTANT: Apply hydraulic oil to the piston (10) sliding surface of swash plate (9) and the spherical surface of holder (12). There is the inner race for roller bearing (17) on the tip of shaft (7). Take care to keep it away from being damaged. Align the shaft splines to those of cylinder block (14). 8. Install the cylinder block (14) assembly onto shaft (7). CAUTION: The casing (1) assembly weight: 54 kg (120 Ib)

CAUTION: The casing (1) assembly weight: 54 kg (120 Ib) 5. Install eyebolts (M18, Pitch 2.5 mm) into the bolts (33) holes in casing (1) (2 places). Hoist the casing (1) assembly up and place it with the brake release circuit facing down.

9. Install eyebolts (M18, Pitch 2.5 mm) into the socket bolts (33) holes (2 places) in casing (1). Hoist the casing (1) and place it vertically.

W3-2-91

UNDERCARRIAGE / Travel Device

27 29 25, 26

23, 24 22

19 18

30

16

32

17

1 15

31

T16J-03-05-003

14

20 21

W3-2-92

UNDERCARRIAGE / Travel Device 10. Install friction plates (18 and 19) into casing (1). Then install disc plates (20) (4 used) and friction plates (21) (3 used) alternately and finally install friction plate (22) into the casing.

IMPORTANT: As for springs (29) (10 used), there are twelve spring mounting holes in brake piston (27), so pay attention to where the spring should be inserted and not make mistakes.

NOTE: Friction plates (18, 19, 21 and 22) are different in thickness. (18), (22): 4.8 mm (0.2 in) (19): 6.5 mm (0.3 in) (21): 3 mm (1.0 in) So they should be installed while aligning with their own notch respectively in casing (1). When installing disc plate (20), its inner splines shall be aligned with those of cylinder block (14). IMPORTANT: Apply grease to O-rings (24 and 25) and backup rings (23 and 26). 11. Install backup rings (26 and 23) and O-rings (25 and 24) onto brake piston (27). IMPORTANT: Pay attention to the mounting direction for brake piston (27), so that the notch shall be square to the pin (31) holes in casing (1). 1

27

27 Free Hole

29

29

W16J-03-02-003

Free Hole

13. Install springs (29) (10 used) onto brake piston (27). IMPORTANT: Install the outer race of roller bearing (17) with the stamp mark on the outer race facing the valve plate (15) side. 14. Tap the outer race of roller bearing (17) evenly with a bar and hammer to install the outer race into valve housing (32). NOTE: Tap the bearing and listen to ring to confirm if the outer race is installed to the most end of valve housing (32).

Notch

W16J-03-02-003

31

IMPORTANT: Apply grease to the mating surfaces of valve plate (15) and valve housing (32). 15. Install collar (16) into valve housing (32). Align the pin holes in pin (30) and valve plate (15) to install the valve plate into the valve housing (32).

12. Tap brake piston (27) with a plastic hammer to install it into casing (1).

W3-2-93

UNDERCARRIAGE / Travel Device

33

27

32

1

31

28

T16J-03-05-003

2

W3-2-94

UNDERCARRIAGE / Travel Device IMPORTANT: Apply grease to O-rings (2 and 28). 16. Install O-rings (28) and (2) (4 used) into casing (1) and install pins (31) (4 used) to valve housing (32). CAUTION: Valve housing (32) weight: 39 kg (90 Ib) IMPORTANT: When installing valve housing (32) into casing (1), be sure to confirm the clearance value between the casing and the valve housing is equal to that noted on disassembling. If the value is different, disassemble them and reassemble again. IMPORTANT: Align the matching marks made when disassembling. If the matching marks cannot be aligned with each other, brake piston (27) may be installed in wrong direction. 17. Install eyebolt (M12, Pitch 1.75 mm) into the bolt hole in valve housing (32). Hoist valve housing (32) to put it onto casing (1) while aligning the pin (31) hole in brake piston (27) by crane. Install the valve housing onto the casing with socket bolts (33) (9 used). : 14 mm : 440±21.5 N⋅m (45±2.2 kgf⋅m, 330±16 lbf⋅ft ) NOTE: Tighten socket bolts (33) (9 used) evenly. 1

32 33

Eyebolt Mounting Position W16J-03-02-002

W3-2-95

UNDERCARRIAGE / Travel Device DISASSEMBLE BRAKE VALVE ZAXIS370MTH 1

6 2

5

3

7

8

4

9

10

11

Plug

10

35

9

Orifice

12 13

36 37

14

38

16

39

15

18 20

40

21

48

17

24

26

47

49 10 9 41

5

42

23 30 25

28

46

32

27 43

29

44 45

4

43

34

3 2

36

33

31

Orifice

44

40

22

19

42

1

41 50

39 38

35 37 W183-03-02-010

12345678910 11 12 13 -

Plug (2 Used) O-Ring (2 Used) Spring (2 Used) Check Valve (2 Used) Overload Relief Valve (2 Used) Plug O-Ring Spring Plug (6 Used) O-Ring (6 Used) Orifice Socket Bolt (9 Used) Valve Assembly

14 15 16 17 18 19 20 21 22 23 24 25 26 -

O-Ring Plug Poppet Seat (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Backup Ring (2 Used) Poppet (2 Used) Relief Housing (2 Used) Piston (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Backup Ring (2 Used) Spring Seat (2 Used)

27 28 29 30 31 32 33 34 35 36 37 38 -

W3-2-96

Spring (2 Used) Spring Guide (2 Used) O-Ring (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Plug (2 Used) Nut (2 Used) Set Screw (2 Used) Socket Bolt (8 Used) Cap (2 Used) O-Ring (2 Used) Spring Seat (2 Used)

39 40 41 42 43 44 45 46 47 48 49 50 -

Spring (2 Used) Spring Seat (2 Used) Plug (2 Used) O-Ring (2 Used) Spring (2 Used) Check Valve (2 Used) Spool Valve Housing Pin (4 Used) Pin Orifice Spool Assembly

UNDERCARRIAGE / Travel Device Disassemble Brake Valve CAUTION: The valve housing (46) assembly weight: 39 kg (90 Ib) 1. Secure the valve housing (46) assembly on a firm work bench. 2. Remove plugs (6 and 15) and O-rings (7 and 14). Then remove spring (8). : 10 mm IMPORTANT: Remove valve assembly (13) while rotating it. If a little resistance is felt while removing, do not try to remove it by force, return to original position and retry. In addition, do not disassemble the valve assembly (13). In case replacement should be carried out to any parts of it, be sure to replace it with the valve housing (46) assembly including spool assembly (50), valve assembly (13), orifices (11 and 49) and the plug. 3. Press valve assembly (13) out carefully and rotate the valve assembly by hand to remove it from valve housing (46). 4. Remove plug (1). Then remove O-ring (2), spring (3) and check valve (4). (2 places at right and left) : 14 mm

IMPORTANT: Do not disassemble overload relief valves (5) (2 used). The overload relief valve should be replaced as assembly. Attach tags on each overload relief valves so that they can be installed to their original positions. In addition, do not rotate set screw (34), or the setting pressure can change. 5. Loosen plug (32) to remove overload relief valve (5) from valve housing (46). (2 places at right and left) : 36 mm 6. Press cap (36) while loosening socket bolts (35) (4 used) to remove the cap (36) from valve housing (46). (2 places at right and left) : 10 mm NOTE: In case cap (36) cannot be removed, a plastic hammer can be used to tap the cap, however, the loosened socket bolts (35) should be still on the cap while tapping. 7. Remove spring seat (38), spring (39) and spring seat (40) from valve housing (46). (2 places at right and left) IMPORTANT: Remove spool assembly (50) while rotating it. In case a little resistance is felt while removing, do not try to remove it by force, return to original position and retry. 8. Press spool assembly (50) out carefully. Rotate the spool assembly by hand to remove it from valve housing (46). 9. Clamp spool assembly (50) in a vice with a chip of wood inserted at both side. 10. Remove plugs (41) (2 used), then remove springs (43) (2 used) and check valves (44) (2 used) from spool (45).

W3-2-97

UNDERCARRIAGE / Travel Device ASSEMBLE BRAKE VALVE ZAXIS370MTH

Overload Relief Valve (5) 16

18

21

26

24

27 31

29

32

33 34

17, 19

20

22

23, 25

30

28

36

38 41

6

37 39

35

42 A

A

7

A

40 43

8

44 45

13

50 14 48

47

12

15

46 5

12345678910 11 12 13 -

Plug (2 Used) O-Ring (2 Used) Spring (2 Used) Check Valve (2 Used) Overload Relief Valve (2 Used) Plug O-Ring Spring *Plug (6 Used) *O-Ring (6 Used) *Orifice Socket Bolt (9 Used) Valve Assembly

14 15 16 17 18 19 20 21 22 23 24 25 26 -

O-Ring Plug Poppet Seat (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Backup Ring (2 Used) Poppet (2 Used) Relief Housing (2 Used) Piston (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Backup Ring (2 Used) Spring Seat (2 Used)

2

27 28 29 30 31 32 33 34 35 36 37 38 -

NOTE: As for parts with *, refer to W3-2-96.

W3-2-98

1

3

A-A-A 断面

Spring (2 Used) Spring Guide (2 Used) O-Ring (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Plug (2 Used) Nut (2 Used) Set Screw (2 Used) Socket Bolt (8 Used) Cap (2 Used) O-Ring (2 Used) Spring Seat (2 Used)

4 W183-03-02-016

39 40 41 42 43 44 45 46 47 48 49 50 -

Spring (2 Used) Spring Seat (2 Used) Plug (2 Used) O-Ring (2 Used) Spring (2 Used) Check Valve (2 Used) Spool Valve Housing Pin (4 Used) Pin *Orifice Spool Assembly

UNDERCARRIAGE / Travel Device Assemble Brake Valve (ZAXIS370MTH) 1. Install O-rings (7 and 14) to plugs (6 and 15) respectively. Install valve assembly (13) and plugs (6 and 15) into valve housing (46). : 10 mm : 64±4.9 N⋅m (6.5±0.5 kgf⋅m, 47±3.6 lbf⋅ft) 2. Install O-ring (2) to plug (1) and install check valve (4), spring (3) and the plug into valve housing (46). (2 places at right and left) : 14 mm : 410±19.5 N⋅m (42±2 kgf⋅m, 300±14.5 lbf⋅ft) IMPORTANT: Install overload relief valve (5) to the former position before disassembled. 3. Install overload relief valves (5) (2 used) onto valve housing (46). : 36 mm : 410±19.5 N⋅m (42±2 kgf⋅m, 300±14.5 lbf⋅ft) 4. Rotate spool assembly (50) slowly to insert it into valve housing (46). 5. Install O-ring (37) into cap (36). (2 places at right and left) 6. Install spring seat (40), spring (39) and spring seat (38) into valve housing (46). Then install cap (36) with socket bolts (35) (4 used). (2 places at right and left) : 10 mm : 108±4.9 N⋅m (11±0.5 kgf⋅m, 80±3.6 lbf⋅ft)

W3-2-99

UNDERCARRIAGE / Travel Device MAINTENANCE STANDARD ZAXIS370MTH 1. The clearance between the inner diameter of cylinder block and the outer diameter of the piston:

Cylinder Block

(D-d): 0.06 mm or less

D

d

W507-02-04-009

Piston

2. The clearance between the piston and shoe when engaging:

Piston

δ: 0.4 mm or less

Shoe δ

W107-02-06-140

3. The clearance between the inner diameter and outer diameter at the matching position of casing and piston:

Piston

D

(D-d): 0.03 mm or less Casing D

4. The wear allowance on the sliding surfaces of cylinder block and valve plate: Check there is no abnormal scratch, wear or score. The wear allowance shall be within 0.02 mm or less.

W3-2-100

W162-03-02-005

UNDERCARRIAGE / Travel Device Sprocket

C

B

D

E

A

W1HH-03-02-002

Unit: mm (in)

Standard Dimension Allowable Limit

Remedy

A

92 (3.62)

[82 (3.23)]

B

86.1 (3.39)

81.1 (3.19)

Cladding by

C

122.1 (4.8)

-

welding and

D

132 (5.2)

127 (5.0)

finishing

E

215.9 (8.46)

-

NOTE: Value in [ ] is for reference only.

W3-2-101

UNDERCARRIAGE / Travel Device (Blank)

W3-2-102

UNDERCARRIAGE / Center Joint REMOVE AND INSTALL CENTER JOINT IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

1

2

Removal 1. Attach an identification tag to all the hoses of center joint for reassembling. Remove all the hoses and adapters from the center joint. Cap all the removed ends of hoses. : 17 mm, 27 mm, 41 mm 2. Remove bolt (1) from the center joint and remove stopper plate (2). 3. Install eyebolt to the center joint. Attach a wire rope and hoist the center joint.

W157-03-03-003

CAUTION: Center joint weight: 27 kg (60 lb) 3

4. Remove bolts (3) (3 used). Remove the center joint.

W105-03-03-003

W3-3-1

UNDERCARRIAGE / Center Joint Installation 1

1. Install the center joint with bolts (3). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 67 lbf⋅ft)

2

2. Install stopper plate (2) to the center joint with bolts (1). : 22 mm : 140 N⋅m (14.5 kgf⋅m, 105 lbf⋅ft) 3. Install all the hoses to the center joint. : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) : 27 mm : 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

W157-03-03-003

3

4. After completing the work, start the engine and check for any oil leaks.

W105-03-03-003

W3-3-2

UNDERCARRIAGE / Center Joint (Blank)

W3-3-3

UNDERCARRIAGE / Center Joint DISASSEMBLE CENTER JOINT

1 2

3 4 5

6

12

11 10 7

8

9

W157-03-03-002

1 - Plug (with Ball) 2 - Spindle 3 - Dust Seal

4 - O-Ring 5 - Bushing 6 - Oil Seal (6 Used)

7 - O-Ring 8 - Cover 9 - Bolt (4 Used)

W3-3-4

10 - Retaining Ring 11 - Ring 12 - Body

UNDERCARRIAGE / Center Joint Disassemble Center Joint CAUTION: Center joint weight: 26.5 kg (60 lb) 1. Remove bolt (9) from cover (8) diagonally. By using eyebolts M10 (Pitch 1.5, Length 18 mm), hoist and place the center joint on a workbench.

IMPORTANT: For easy removal, use the pins (2 used) when removing oil seals (6). Do not damage the seal groove by the pins. 7. Remove oil seals (6) (6 used) and O-ring (4) from body (12).

2. Put the matching marks on body (12) and spindle (2). 3. Remove bolts (9) and remove cover (8) from body (12). : 17 mm 4. Remove O-ring (7), retaining ring (10), and O-ring (7) from body (12). 5. Attach special tools (ST 1033, ST 1020) to body (12) with bolts (9) (2 used). : 17 mm ST 1020 ST 1033

W105-03-03-015

8. Remove dust seal (3) from spindle (2). 9. While welding, cover the seal surface in order to prevent it from being spattered. When replacing bushing (5), build-up weld at 4 places in its inner diameter by using a welding rod. Shrink and remove bushing (5).

W506-03-03-002

IMPORTANT: Do not damage the sliding surface of spindle (2) seal. 6. Remove spindle (2) from body (12).

W3-3-5

UNDERCARRIAGE / Center Joint ASSEMBLE CENTER JOINT

1 2

3 4

5

6 12

11 10

7

8

9 W178-03-03-001

1 - Plug (with Ball) 2 - Spindle 3 - Dust Seal

4 - O-Ring 5 - Bushing 6 - Oil Seal (6 Used)

7 - O-Ring 8 - Cover 9 - Bolt (4 Used)

W3-3-6

10 - Retaining Ring 11 - Ring 12 - Body

UNDERCARRIAGE / Center Joint Assemble Center Joint IMPORTANT: If removing bushing (5), install bushing (5) by using a press first. (Refer to page W3-3-8.) 1. Install dust seal (3) into spindle (2) with its lip part facing to body (12).

4. As the clearance between body (12) and spindle (2) is approximately 0.1 mm (0.004 in), insert spindle (2) along axis straight and slowly. Tap and install body (12) by using a plastic hammer until surface A of body (12) is flush with that of spindle (2). Surface A

2

0.1 mm

Dust Seal (3)

12

Lip

Body (12)

W105-03-03-024

W178-03-03-002

2. Install oil seals (6) (6 used) and o-ring (4) into body (12). 3. Place spindle (2) onto a workbench. Align the matching marks and install body (12) on spindle (2).

5. Install ring (11) to body (12) with the chamfered side facing the spindle (2). Install O-ring (7) to body (12). 6. Install retaining ring (10) to spindle (2). 7. Install cover (8) with bolts (9) (4 used). : 17 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

W3-3-7

UNDERCARRIAGE / Center Joint When replacing the body or spindle with the new one, the following procedures are required. In case of body (12)

In case of spindle (2)

1. Clean body (12) and bushing (5).

1. Clean spindle (2).

2. When pushing bushing (5) into body (12), apply grease or molybdenum disulphide to the fitting surface. Push bushing (5) into body (12) by using a press. Pushing force: 0.5 to 1.5 t (1100 to 3300 lb) Pushing tool: ST 2558

2. Tap and install plug (1) into spindle (2) by using special tool (ST 2559). 3. Tap the balls of plug (1) so that the top of each ball is 0.4 mm (0.016 in) or more than the respective sleeve edge as illustrated in detail D.

1

ST 2558

Sleeve

2

12

0.4 mm or More

5

Detail D

W135-03-03-001

W136-03-03-031 W105-03-03-029

ST 2559

Ball

W157-03-03-004

W3-3-8

UNDERCARRIAGE / Center Joint MAINTENANCE STANDARD

Item

Allowable limit (basis for judgment)

Remedy

1. Wear more than 0.2 mm (0.008 in)

Replace

2. Scored, abnormal wear

Replace

3. Uneven wear (wear range is within 180°)

Replace

Wear range is within one half

Bushing

T157-01-01-040

Body ⋅ Spindle

Cover

Sliding surface Scored or serious damage and sealed part Sliding surface of 1) Scored or abnormal wear of more than body and spindle, 0.1 mm (0.004 in) except sealed 2) Scored less than 0.1 mm (0.004 in) deep part 1) Wear more than 0.5 mm (0.02 in) deep and abnormal wear Sliding surface 2) Wear less than 0.5 mm (0.02 in) deep and ring 3) Scored or abnormal wear less than 0.5 mm (0.02 in) and repairable. 1) Wear more than 0.5 mm (0.02 in) Sliding surface 2) Wear less than 0.5 mm (0.02 in) and ring 3) Scored or abnormal wear less than 0.5 mm (0.02 in) and repairable.

W3-3-9

Replace Replace Repair and finish with oil stone Replace Repair and finish Repair and finish Replace Repair and finish Repair and finish

UNDERCARRIAGE / Center Joint (Blank)

W3-3-10

UNDERCARRIAGE / Track Adjuster REMOVE AND INSTALL TRACK ADJUSTER (ZAXIS330, 330LC, 350H, 350LCH) Before removing and installing the track adjuster, the tracks, and the front idler must be removed first. For removal and installation of the tracks and front idler, refer to "Remove and Install Front Idler" (W3-5-1) and "Remove and Install Track" (W3-7-1). In this section, the procedure starts on the premise that the tracks and front idler have already been removed. Removal CAUTION: Track adjuster weight: 180 kg (400 lb) CAUTION: The front idler may fly off due to the strong spring force when removing track adjuster (1). Do not stand in the same direction to track adjuster (1) or where the track adjuster flies off. Particularly, a strong spring force is always applied to the thread part of rod. If the rod and/or the threads are damaged, metal fragments under spring force may fly off.

2 1

1. Pry and remove track adjuster (1) from track frame (2) by using a pry bar. Installation 1. As illustrated, install track adjuster (1) into spring guide (3) on track frame (2). Check that the end of track adjuster (1) comes into contact with that of plate (4).

3

W157-03-04-003

4

W157-03-04-002

2

Section A

W3-4-1

3

W157-03-04-001

UNDERCARRIAGE / Track Adjuster DISASSEMBLE TRACK ADJUSTER (ZAXIS330, 330LC, 350H, 350LCH) 17 1 2 3 4 5

6 7

8

9

10

16

11 12

15 14 13 W173-03-04-001

12345-

Socket Bolt (4 Used) Flange Dust Seal Piston Rod Wear Ring

6789-

U-Ring Retaining Ring Rod O-Ring

10 11 12 13 -

W3-4-2

Cylinder Plug Valve Nut

14 15 16 17 -

Washer Spacer Spring Holder

UNDERCARRIAGE / Track Adjuster Disassemble Track Adjuster (ZAXIS330, 330LC, 350H, 350LCH) IMPORTANT: Use special tool (ST 4920) when assembling and disassembling the track adjuster. CAUTION: The spring force of the track adjuster is extremely large. Inspect the special tool for any damage thoroughly in order to perform the work safely. Special Tool (ST 4290)

CAUTION: Special tool weight: 225 kg (496 lb) 1. Place an oil jack (30 t) between the holder and base.

Holder Oil Jack

Base W105-03-04-006

2. Remove the nuts (4 used) of special tool and remove plate (ST 4036). : 46 mm

Plate (ST 4036)

W105-03-04-007

CAUTION: Track adjuster weight: 180 kg (400 lb) 3. Attach a wire rope onto the track adjuster as illustrated. Hoist and place the track adjuster onto the holder of special tool.

W105-03-04-009

W3-4-3

UNDERCARRIAGE / Track Adjuster

8

11 12

14 13 W173-03-04-001

W3-4-4

UNDERCARRIAGE / Track Adjuster 4. Install plate (ST 4036) on the track adjuster. Plate (ST 4036)

5. Operate an oil jack.

W105-03-04-011

Jack up the specified amount (122 m). Specified Amount 122 mm = (Free length of spring: 679 mm) - (Set length of spring : 557 mm)

Oil Jack

NOTE: 1 mm = 0.03937 in 6. Tighten the nuts of special tool and secure the track adjuster. Operate the oil jack and compress the track adjuster until a clearance is observed between washer (14) and nut (13). (Approximately 10 mm (0.4 in)) : 46 mm

W105-03-04-013

7. Remove plug (11) from nut (13). Remove nut (13) and valve (12) from rod (8). : 5 mm : 85 mm : 24 mm W105-03-04-012

13

8

11

W105-03-04-014

W3-4-5

UNDERCARRIAGE / Track Adjuster

17 1 2 3 4 5 6

7

8

9

10

16

15 14 W173-03-04-001

W3-4-6

UNDERCARRIAGE / Track Adjuster 8. Lower the oil jack and release the spring force.

Oil Jack

W105-03-04-015

9. Remove the nuts of special tool. Remove plate (ST 4036) and washer (14).

Plate (ST 4036)

1

CAUTION: Spring assembly weight: 168 kg (370 lb) 10. Install eyebolt (M16, Pitch 1.5) to rod (8). Hoist the track adjuster and remove the spring (16) assembly from special tool.

W105-03-04-016

Eyebolt

CAUTION: Spring weight: 95 kg (209 lb) 11. Remove eyebolt. Remove spring (16) from rod (8). 12. Remove spacer (15) from rod (8). 13. Remove socket bolts (1) (4 used). Move flange (2) to holder (17). Remove flange (2) from cylinder (10). : 8 mm

W3-4-7

W105-03-04-017

UNDERCARRIAGE / Track Adjuster

17

2 3 4 5 6

7

8

9

10

W173-03-04-001

W3-4-8

UNDERCARRIAGE / Track Adjuster 14. Remove the piston rod (4) assembly from cylinder (10).

4

15. Holder (17) is pushed into piston rod (4). Remove holder (17) from the piston rod (4) assembly by using a press. 16. Remove flange (2) from piston rod (4). Remove dust seal (3) from flange (2). 17. Remove rod (8) and O-ring (9) from cylinder (10). 18. Remove wear ring (5), retaining ring (7), and U-ring (6) from piston rod (4).

W3-4-9

5

6 7 W105-03-04-023

UNDERCARRIAGE / Track Adjuster ASSEMBLE TRACK ADJUSTER (ZAXIS330, 330LC, 350H, 350LCH)

12

11

14

8

15

9

16

13

7

Chamber B

5

10

6

Chamber A

4

1

3

2

17

557 mm (Free Length 679 mm) 1ft 9.9 in (Free Lenght 2ft 2.7 in) W1HH-03-04-001

778 mm (2 ft 6.6 in)

12345-

Socket Bolt (4 Used) Flange Dust Seal Piston Rod Wear Ring

6789-

U-Ring Retaining Ring Rod O-Ring

10 11 12 13 -

Cylinder Plug Valve Nut

W3-4-10

14 15 16 17 -

Washer Spacer Spring Holder

UNDERCARRIAGE / Track Adjuster Assemble Track Adjuster (ZAXIS330, 330LC, 350H, 350LCH) 1. Install dust seal (3) on flange (2).

4 5

2. Fill chamber (A) of flange (2) with grease. Install flange (2) on piston rod (4).

6 7

3. Apply grease to inner surface of holder (17). Push holder (17) into piston rod (4). 4. Clean all parts. Install U-ring (6), retaining ring (7), and wear ring (5) to piston rod (4). 5. Apply grease to O-ring (9). Install O-ring (9) into cylinder (10). Install rod (8) into cylinder (10). 6. Apply grease to U-ring (6) and wear ring (5). Fill chamber (B) in cylinder (10) with grease. Apply grease to cylinder (10) and piston rod (4). Install the piston rod (4) assembly into cylinder (10). Insert the piston rod (4) assembly and completely bleed air from chamber (B) and rod (8). 7. Tighten flange (2) with socket bolts (1) (4 used). : 8 mm : 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

W3-4-11

W105-03-04-025

10 6 5

4

W105-03-04-021

UNDERCARRIAGE / Track Adjuster

14

8

15

16 557 mm (Free Length 679 mm) 1ft 9.9 in (Free Lenght 2ft 2.7 in) W1HH-03-04-001

778 mm (2 ft 6.6 in)

W3-4-12

UNDERCARRIAGE / Track Adjuster 8. Install spacer (15) on rod (8). 8

CAUTION: Spring (16) weight: 95 kg (209 lb) 9. Install spring (16) on rod (8). CAUTION: Spring (16) assembly weight: 168 kg (370 lb) 10. Install eyebolt (M16, Pitch1.5 mm) into rod (8). Hoist and place the spring (16) assembly onto special tool. 11. Remove eyebolt. Place washer (14) onto spring (16). Install plate (ST 4036).

W105-03-04-017

Plate (ST 4036)

14 16

W105-03-04-016

12. Tighten the nuts of special tool and secure the spring assembly. : 46 mm

W105-03-04-012

W3-4-13

UNDERCARRIAGE / Track Adjuster

12

13

11

8

16

557 mm (Free Length 679 mm) 1ft 9.9 in (Free Lenght 2ft 2.7 in) W1HH-03-04-001

778 mm (2 ft 6.6 in)

W3-4-14

UNDERCARRIAGE / Track Adjuster 13. Operate the oil jack and compress spring (16) to the specification. Specified Length: 557 mm (1 ft 9.9 in)

16

Oil Jack

14. Install nut (13) to rod (8). Install plug (11). : 85 mm : 5 mm : 14.5 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

W105-03-04-026

13

8

11

W105-03-04-014

15. Install valve (12) to rod (8). : 24 mm : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

Oil Jack

16. Lower the oil jack.

W105-03-04-013

17. Remove the nuts of special tool and remove plate (ST 4036). : 46 mm

Plate (ST 4036)

W105-03-04-011

W3-4-15

UNDERCARRIAGE / Track Adjuster CAUTION: Track adjuster weight: 180 kg (397 lb)

Wire Rope

18. Attach a wire rope to the track adjuster as illustrated. Hoist and remove the track adjuster from special tool. CAUTION: If only the track adjusted is transported, use special tool as illustrated in order to carry the track adjuster safely.

W105-03-04-009

W105-03-04-028

W3-4-16

UNDERCARRIAGE / Track Adjuster REMOVE AND INSTALL TRACK ADJUSTER (ZAXIS370MTH) Before removing and installing the track adjuster, the tracks and the front idler must be removed first. For removal and installation of the tracks and front idler, refer to "Remove and Install Front Idler" (W3-5-1) and "Remove and Install track" (W3-7-1). In this section, the procedure starts on the premise that the tracks and front idler have already been removed. CAUTION: The front idler may fly off due to the strong force when removing track adjuster (1). Do not stand in the same direction to track adjuster (1) or where the track adjuster flies off. Particularly, a strong spring force is always applied to the thread part of rod. If the rod and/or the threads are damaged, metal fragments under spring force may fly off.

2 1

W142-03-04-002

Removal CAUTION: Track adjuster weight: 250 kg (550 lb)

3

4

1. Pry and remove track adjuster (1) from track frame (2) by using a pry bar. Installation 1. As illustrated, install track adjuster (1) into spring guide (3) on track frame (2). Check that the end of track adjuster (1) comes into contact with that of plate (4).

A

W16J-03-04-002

3

2

View

W3-4-17

W16J-03-04-001

UNDERCARRIAGE / Track Adjuster DISASSEMBLE TRACK ADJUSTER (ZAXIS370MTH)

1

2

3 4 5

6

7 8

9 10

16

11 15 12

14

W166-03-04-003

13

1234-

Socket Bolt (4 Used) O-Ring Guide Piston Rod

5678-

Wear Ring U-Ring Retaining Ring Rod

910 11 12 -

Cylinder O-Ring Bolt Valve

W3-4-18

13 14 15 16 -

Nut Bracket Spring Spacer

UNDERCARRIAGE / Track Adjuster Disassemble Track Adjuster (ZAXIS370MTH) • Use a pump unit which has the maximum pressure of 69 Mpa (700 kgf/cm2, 9950 psi) and the flow rate of 8 to 10 liters (2.1 to 2.6 US gal). Be sure to set the main relief pressure to 49 Mpa (500 kgf/cm2, 7110 psi) (80 tons) or lower. IMPORTANT: Use special tool (ST4932) when assembling and disassembling the track adjuster.

Track Adjuster ST 4932

CAUTION: The spring force of track adjuster is extremely large. Inspect the special tool for any damage thoroughly in order to perform the work safely. CAUTION: Track adjuster weight: 250 kg (550 lb) 1. Hoist and place the track adjuster on the holder of special tool (ST 4932).

Holder

2. Loosen valve (12). Compress spring (15) of track adjuster by using special tool (ST 4932) until the clearance between bracket (14) and nut (13) is approximately 10 mm (0.4 in).

W142-03-04-019

15

3. Put the matching marks on rod (8) and nut (13). : 24 mm 4. Remove valve (12) and bolt (11). Remove nut (13). : 24 mm, 17 mm, 100 mm

14

Clearance 10 mm (0.39 in)

8 13 11 12

W142-03-04-020

W3-4-19

UNDERCARRIAGE / Track Adjuster

4

9

16

15

14

W3-4-20

W166-03-04-003

UNDERCARRIAGE / Track Adjuster 5. Slowly return the piston of special tool (ST 4932). Extend spring (15) to its free length. NOTE: Spring (15) free length: 774 mm (30.5 in) 15

ST 4932

CAUTION: Track adjuster weight: 250 kg (550 lb) 6. Fasten bracket (14) and spring (15) together by using a wire. Attach a nylon sling to spring (15) in the track adjuster. Hoist and remove the track adjuster from special tool (ST 4932).

14

7. Install eyebolt (M10, Pitch 1.5 mm) onto piston rod (4). Attach a nylon sling to spring (15) and pass the nylon sling through eyebolt. Hoist and place the assembly on the holder as illustrated.

W142-03-04-005

4

15

Holder

CAUTION: Cylinder (9) assembly weight: 80 kg (180 lb) 8. Hoist and remove the cylinder (9) assembly (1 to 10) from spring (15).

W142-03-04-006

CAUTION: Spring weight: 140 kg (310 lb) 9

9. Remove the wire fastening spring (15) and bracket (14). Hoist and remove spring (15). CAUTION: Bracket weight: 22 kg (50 lb) 10. Remove spacer (16) and bracket (14) from the holder.

15

Holder

W142-03-04-007

W3-4-21

UNDERCARRIAGE / Track Adjuster

1

2

3 4 5

6

7 8

9 10

W166-03-04-003

W3-4-22

UNDERCARRIAGE / Track Adjuster 11. Remove socket bolts (1) (4 used) and remove guide (3) from piston rod (4). : 12 mm

2

3 1

12. Remove piston rod (4) from cylinder (9). 4 10

13. Remove O-ring (2) from guide (3). CAUTION: Cylinder (9) weight: 40 kg (88 lb) Rod (8) weight: 21 kg (50 lb)

9

14. Install eyebolt (M16, Pitch 2.0 mm) into rod (8). Hoist and remove rod (8) from cylinder (9). Remove O-ring (10) from the inside of cylinder (9).

8 W142-03-04-010

4

15. Remove wear ring (5), retaining ring (7), and U-ring (6) from piston rod (4).

5 6

7

W166-03-04-001

W3-4-23

UNDERCARRIAGE / Track Adjuster ASSEMBLE TRACK ADJUSTER (ZAXIS370MTH)

2

3

9

6

10

16

Chamber A

4

1234-

Socket Bolt (4 Used) O-Ring Guide Piston Rod

1

5678-

Wear Ring U-Ring Retaining Ring Rod

8

14

Chamber B

11 12

Grease Outlet W16J-03-04-003

5

7

910 11 12 -

15

Cylinder O-Ring Bolt Valve

W3-4-24

13

13 14 15 16 -

Nut Bracket Spring Spacer

UNDERCARRIAGE / Track Adjuster Assemble Track Adjuster (ZAXIS370MTH)

4

1. Clean all the parts. Apply grease onto wear ring (5) and U-ring (6). Install wear ring (5), U-ring (6), and retaining ring (7) onto piston rod (4). Install U-ring with the lip part facing to rod (8).

5 6

7

CAUTION: Rod (8) weight: 21 kg (50 lb) 2. Apply grease to O-ring (10). Install O-ring (10) onto cylinder (9). Install eyebolt (M16, Pitch 2.0 mm) into rod (8). Hoist and install rod (8) into cylinder (9).

W166-03-04-001

10

8

CAUTION: Piston rod (4) weight: 16 kg (40 lb)

9

3. Fill chamber (B) in cylinder (9) with grease. Apply hydraulic oil to the inner surface of cylinder (9) and piston rod (4). Install eyebolt (M10, Pitch 1.5 mm) into piston rod (4). Hoist and install piston rod (4) into cylinder (9). Push piston rod (4) and completely release pressure in chamber (B) and rod (8).

W142-03-04-012

3

4. Fill chamber (A) in guide (3) with grease. Apply grease to O-ring (2). Apply LOCTITE #262 to socket bolts (1) (4 used). Install O-ring (2) onto guide (3). Install guide (3) onto cylinder (9) with socket bolts (1) (4 used). : 12 mm : 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)

2 1

4

W142-03-04-018

W3-4-25

UNDERCARRIAGE / Track Adjuster

9

16

8

14

Grease Outlet

4

15

W3-4-26

W16J-03-04-003

UNDERCARRIAGE / Track Adjuster CAUTION: Bracket (14) weight: 22 kg (50 lb) Spring (15) weight: 140 kg (310 lb) 9

5. Attach a nylon sling onto bracket (14). Hoist and place bracket (14) and spacer (16) on the holder. Hoist and place spring (15) onto bracket (14). Fasten bracket (14) and spring (15) together by using a wire. 16

CAUTION: Cylinder (9) assembly weight: 60 kg (130 lb)

15

6. Install eyebolt (M10, Pitch 1.5 mm) to piston rod (4). Hoist the cylinder (9) assembly. Align spacer (16) with bracket (14) and install the cylinder (9) assembly.

14

Holder

W142-03-04-007

CAUTION: Track adjuster weight: 250 kg (550 lb)

4

7. Attach a nylon sling to spring (15) and pass the nylon sling through the eyebolt on piston rod (4). Hoist and place the assembly horizontally and slowly.

15

W142-03-04-006

8. Hoist and place the track adjuster on special tool (ST 4932). Set rod (8) with its grease outlet down. Remove eyebolt.

ST 4932

W142-03-04-005

W3-4-27

UNDERCARRIAGE / Track Adjuster

8

15

14

11 12

620 mm (Free Length 774 mm) 24.5 in (Free Length 30.5 in) 884 mm (35 in)

W3-4-28

Grease Outlet

13

W16J-03-04-003

UNDERCARRIAGE / Track Adjuster 9. Operate the cylinder of special tool (ST4932). Remove a wire from spring (15). Compress spring (15) until the specified spring length is obtained. Slowly compress spring (15) while aligning the center of rod (8) with that of bracket (14) by using a pry bar. Do not damage the threads on rod (8). (Specified Spring Length: 620 mm (24.5 in)) 10. Align the matching marks made when disassembling. Install nut (13) to rod (8). Install bolt (11). Check that the grease outlet in rod (8) align with that in nut (13). : 100 mm : 17 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

15 ST 4932

14

Wire

11. Tighten valve (12). : 24 mm : 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)

W142-03-04-015

12. Retract the cylinder of special tool (ST 4932). 13

CAUTION: Track adjuster weight: 250 kg (550 lb)

8

13. Attach a sling belt to the track adjuster. Hoist and remove the track adjuster from special tool. CAUTION: If only the track adjuster is transported, use a firm steel box and take any other precautions in order to carry the track adjuster safely.

W3-4-29

11 12

W142-03-04-020

UNDERCARRIAGE / Track Adjuster (Blank)

W3-4-30

UNDERCARRIAGE / Front Idler REMOVE AND INSTALL FRONT IDLER Before removing the front idler, the tracks must be removed first. For removal and installation of the tracks, refer to “Remove and Install Track” section (W3-7-1). In this section, the procedure starts on the premise that the tracks have already been removed.

Removal CAUTION: Front idler weight: ZAXIS330, 330LC: 160 kg (350 lb) ZAXIS350H, 350LCH: 160 kg (350 lb) ZAXIS370MTH: 210 kg (460 lb)

W142-03-05-002

CAUTION: The front idler may fly off due to the strong spring force when removing the track adjuster. Do not stand in the same direction to remove the adjuster or where the track adjuster flies off. 1. Pry and remove the front idler and yoke (2) from track frame (3) by using a pry bar.

3

1 2 4 5

2. Attach sling belts to bearing (1) and yoke (2) sections. Hoist and remove the front idler from track frame (3). 3. Remove bolts (5) and remove guard (4) from yoke (2). (ZAXIS370MTH only) : 19 mm : 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)

W17P-03-05-001

Wooden Block

4. When storing the front idler, place the front idler on wooden blocks as illustrated. W105-03-05-003

Installation 1. Install the front idler in the reverse procedures when removing. Clean and apply grease to the bearing (1) sliding surface on track frame (3).

3

1

W17P-03-05-001

W3-5-1

UNDERCARRIAGE / Front Idler DISASSEMBLE FRONT IDLER 2 3 1

6 7

6

8

4 5 4 3 2

9

1

10 11

8

W16J-03-05-001

14

1234-

Bearing (2 Used) Pin (2 Used) Floating Seal (2 Used) O-Ring (2 Used)

5678-

12

13

Axle Bushing (2 Used) Idler Plug (2 Used)

9 - Guard 10 - Bolt (3 Used) 11 - Spring Washer (3 Used)

NOTE: Guard (9), bolt (10) (3 used), spring washer (11) (3 used), and (14) (4 used) are equipped for ZAXIS370MTH only.

W3-5-2

12 - Yoke 13 - Bolt (4 Used) 14 - Spring Washer (4 Used)

UNDERCARRIAGE / Front Idler Disassemble Front Idler 1. Remove bolts (10) (3 used) and remove guard (9) from yoke (12). (ZAXIS370MTH only) : 19 mm CAUTION: Yoke (12) weight: ZAXIS330, 330LC, 350H, 350LCH: 25 kg (55 lb) ZAXIS370MTH: 56 kg (120 lb) 2. Attach a nylon sling to yoke (12) and hold yoke (12). Remove bolts (13) (4 used). Remove yoke (12). ZAXIS330, 330LC, 350H, 350LCH: : 24 mm ZAXIS370MTH: : 30 mm

IMPORTANT: For handling of floating seal (3), refer to the section “Precautions for Floating Seal Handling” on page W1-1-4. 6. Remove bearing (1) from the upper side of idler (7). Remove floating seals (3) (2 used) from both sides of idler (7) and bearing (1).

3. Place idler (7) horizontally. Remove plug (8) from the lower side and drain oil. : 6 mm 4. Remove pin (2) from bearing (1) by using a bar and hammer.

1 3 7

3 4 5 1

CAUTION: ZAXIS330, 330LC, 350H, 350LCH: Idler assembly weight: 115 kg (250 lb) Axle (5) weight: 17 kg (37 lb) Bearing (1) weight: 15 kg (33 lb)

W105-03-05-009

ZAXIS370MTH: Idler assembly weight : 150 kg (330 lb) Axle (5) weight: 28 kg (62 lb) Bearing (1) weight: 14 kg (31 lb) 5. Put the matching marks on bearing (1) and axle (5). Remove the axle (5) assembly from idler (7) by using a press. 1

5

7

W105-03-05-008

W3-5-3

UNDERCARRIAGE / Front Idler

2

6

1

6 4 5 4 2

1

W16J-03-05-001

W3-5-4

UNDERCARRIAGE / Front Idler CAUTION: Axle (5) assembly weight: ZAXIS330, 330LC, 350H, 350LCH: 32 kg (71 lb) ZAXIS370MTH: 42 kg (93 lb) 7. Wind a nylon sling onto the axle (5) assembly. Hoist and place bearing (1) onto wooden blocks.

IMPORTANT: Do not remove bushing (6) unless necessary. 9. When replacing bushing (6), remove bushing (6) by using special tool and a press. Special tool: ZAXIS330, 330LC, 350H, 350LCH: ST 1425 ZAXIS370MTH: ST 1973

8. Remove pin (2) by using a bar and hammer. Put the matching marks on bearing (1) and axle (5). Remove axle (5) from bearing (1) by using a press. Remove O-rings (4) (2 used) from axle (5). Special Tool

2

4 1 6

Wooden Block

W105-03-05-011

5

4 W105-03-05-010

W3-5-5

UNDERCARRIAGE / Front Idler ASSEMBLE FRONT IDLER

1

2

4

3

5

6

8

7

9

10

11

12 13 14

1234-

Bearing (2 Used) Pin (2 Used) Floating Seal (2 Used) O-Ring (2 Used)

5678-

Axle Bushing (2 Used) Idler Plug (2 Used)

9 - Guard 10 - Bolt (3 Used) 11 - Spring Washer (3 Used)

NOTE: Guard (9), bolt (10) (3 used), spring washer (11) (3 used), and (14) (4 used) are equipped for ZAXIS370MTH only.

W3-5-6

W16J-03-05-002

12 - Yoke 13 - Bolt (4 Used) 14 - Spring Washer (4 Used)

UNDERCARRIAGE / Front Idler Assemble Front Idler CAUTION: Axle (5) assembly weight: ZAXIS330, 330LC, 350H, 350LCH: 32 kg (71 lb) ZAXIS370MTH: 42 kg (93 lb)

CAUTION: Idler (7) weight: ZAXIS330, 330LC: 115 kg (250 lb) ZAXIS350H, 350LCH: 115 kg (250 lb) ZAXIS370MTH: 150 kg (330 lb)

5. Wind a nylon sling onto bearing (1) of the axle (5) assembly. Hoist and insert the axle (5) assembly into idler (7) where floating seal (3) was installed. Apply LOCTITE #503 to plug (8). Install plug (8) into bearing (1). : 6 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)

1. Install bushing (6) into idler (7). CAUTION: ZAXIS330, 330LC, 350H, 350LCH: Axle (5) weight: 17 kg (37 lb) Bearing (1) weight: 15 kg (33 lb) ZAXIS370MTH: Axle (5) weight: 28 kg (62 lb) Bearing (1) weight: 14 kg (31 lb)

7 3

1

2. Wind a nylon sling onto axle (5). Hoist and place axle (5) vertically. Install O-ring (4) onto the upper side of axle (5). 3. Align the matching marks made when disassembling. Evenly tap and install bearing (1) into axle (5) by using a plastic hammer. Insert pin (2) by using a bar and hammer.

2

5

1

4

W105-03-05-014

IMPORTANT: For handling of floating seal (3), refer to the section “Precautions for Floating Seal Handling” on page W1-1-4. 4. Apply grease to O-ring on floating seal (3). Install a pair of floating seals (3) into idler (7) and bearing (1).

W3-5-7

5

W157-03-05-006

UNDERCARRIAGE / Front Idler

1

2

4

3 5

8

7

9

10

11

12 13 14

NOTE: Guard (9), bolt (10) (3 used), spring washer (11) (3 used), and (14) (4 used) are equipped for ZAXIS370MTH only.

W3-5-8

W16J-03-05-002

UNDERCARRIAGE / Front Idler CAUTION: Idler (7) assembly weight: ZAXIS330, 330LC: 115 kg (250 lb) ZAXIS350H, 350LCH: 115 kg (250 lb) ZAXIS370MTH: 150 kg (330 lb)

12. Install spring washer (14) onto bolts (13) (4 used) respectively. (ZAXIS370MTH only) Install yoke (12) into bearing (1) on both sides with the bolts (4 used). ZAXIS330, 330LC, 350H, 350LCH: : 24 mm : 210 N⋅m (21 kgf⋅m, 150 lbf⋅ft) ZAXIS370MTH: : 30 mm : 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)

6. Wind a nylon sling onto the idler (7) assembly. Hoist and turn over the idler (7) assembly. Install O-ring (4) onto axle (5). 7. Apply grease to O-ring of floating seal (3). Install the other floating seal (3) into idler (7) and bearing (1). 1

3

4

7 1

13. Install spring washer (11) onto bolts (10) (3 used) respectively. Install guard (9) onto yoke (12) with the bolts (3 used). (ZAXIS370MTH only) : 19 mm : 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)

5 W157-03-05-005

8. Align the matching marks made when disassembling. Tap the other bearing (1) evenly by using a plastic hammer. Install bearing (11) into axle (5). Insert pin (2) by using a bar and hammer. 9. Add engine oil (API CD grade SAE30) through the plug (8) hole in bearing (1). Engine oil amount: ZAXIS330, 330LC, 350H, 350LCH: 0.3 L (0.32 US gt.) ZAXIS370MTH: 0.45 L (0.48 US gt.) 10. Apply LOCTITE #503 to plug (8). Install plug (8) into bearing (1). : 6 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) CAUTION: Yoke (12) weight: ZAXIS330, 330LC, 350H, 350LCH: 25 kg (55 lb) ZAXIS370MTH: 56 kg (120 lb) 11. Wind a nylon sling onto yoke (12). Hoist yoke (12) and align the bolt (13) holes on yoke (12) and bearing (1).

W3-5-9

UNDERCARRIAGE / Front Idler MAINTENANCE STANDARD

C

D

E A

W166-03-05-001

B

Unit: mm (in) ZAXIS330, 330LC, 350H, 350LCH Allowable Standard Limit 102 (402) [80.4 (3.17)] 200 (7.87) － 572 (22.51) [550.4 (21.77)] 617 (24.29) － 22.5 (0.89) －

A B C D E

ZAXIS370MTH Standard 102 (4.02) 200 (7.87) 630 (24.80) 675 (26.57) 22.5 (0.89)

Allowable Limit [92 (3.62)] － 610 (24) － －

Remedy

Cladding by welding and finish or replace

Axle and Bushing Unit: mm (in)

Axle Bushing

Outside Dia. Inside Dia Flange Thickness

ZAXIS330, 330LC, 350H, 350LCH Allowable Standard Limit 85.0 (3.35) 84.2(3.31) 85.0 (3.35) 86.0 (3.39)

110 (4.33) 110 (4.33)

Allowable Limit 109.2 (4.30) 111 (4.37)

2.0 (0.08)

6.0 (0.24)

5.2 (0.20)

1.2 (0.05)

NOTE: Values in [ ] are just for reference.

W3-5-10

ZAXIS370MTH Standard

Remedy

Replace

UNDERCARRIAGE / Upper And Lower Roller REMOVE AND INSTALL UPPER ROLLER Removal CAUTION: Grease pressure in the adjuster cylinder is high. Do not loosen valve (1) quickly or too much as the valve may fly off or high-pressure grease in the adjusting cylinder may gush out. Keep body parts and face away from the valve and loosen the valve carefully. Do not loosen grease fitting (2). W105-03-06-001

IMPORTANT: Remove gravel or mud between sprockets and tracks before loosening valve (1). It is enough to loosen the valve by 1 to 1.5 turns. Do not loosen the valve over that degree. 1. Loosen valve (1) on the track adjuster and drain grease. : 24 mm

2

１

Grease Outlet

M116-07-094

Oil Jack

3

CAUTION: Use a nonskid cloth between track frame (5) and oil jack in order not to slip. 2. Jack up track (3) in order to get enough clearance between upper roller (4) and track (3).

Nonskid Cloth

5

4 W105-03-06-002

3

3. Insert the wooden blocks between track (3) and track frame (5).

5 Wooden Block W105-03-06-003

W3-6-1

UNDERCARRIAGE / Upper And Lower Roller 4. Remove bolts (6) (4 used) on upper roller (4). ZAXIS330, 330LC, 350H, 350LCH: : 24 mm ZAXIS370MTH: : 27 mm

4

6

W157-03-06-001

CAUTION: Upper roller weight: ZAXIS330, 330LC, 350H, 350LCH: 25 kg (55 lb) ZAXIS370MTH: 34 kg (75 lb) 4

5. Remove upper roller (4) from track frame (5).

5 W105-03-06-005

Installation 1. Install upper roller (4) onto track frame (5) with bolts (6) (4 used). ZAXIS330, 330LC, 350H, 350LCH: : 24 mm : 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft) ZAXIS370MTH: : 27 mm : 400 N⋅m (41 kgf⋅m, 300 Ibf⋅ft)

4

6 5 3

W157-03-06-001

2. Remove the wooden blocks and oil jack between track (3) and track frame (5).

5 W105-03-06-002

W3-6-2

UNDERCARRIAGE / Upper And Lower Roller 3. Tighten valve (1) on the track adjuster. : 24 mm : 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)

2

CAUTION: Support the jacked up machine firmly by using wooden blocks.

１

Grease Outlet

4. Jack up the track to be adjusted. Rotate the track in reverse direction slightly.

M116-07-094

5. Apply grease through grease fitting (2) and adjust tracks tension. ZAXIS330, 330LC, 350H, 350LCH: Track sag specifications (A): 340 to 380 mm (13.4 to 15.0 in) ZAXIS370MTH: Track sag specifications (A): 380 to 430 mm (15.0 to 16.9 in)

IMPORTANT: Replace the upper roller as an assembly. 6. Add engine oil (API CD class SAE30) to the plug (8) hole in cover (7). Engine oil amount: ZAXIS330, 330LC, 350H, 350LCH: 75 mL (0.079 US gt.) ZAXIS370MTH: 120 mL (0.13 US gt.)

W157-03-06-002

7

8

7. Apply LOCTITE #503 to plug (8). Tighten plug (8). : 6 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)

W158-03-06-001

W3-6-3

UNDERCARRIAGE / Upper And Lower Roller REMOVE AND INSTALL LOWER ROLLER Removal 1. Remove the track guard. Remove bolts (1) (4 used) of lower roller (5). ZAXIS330, 330LC, 350H, 350LCH: : 30 mm ZAXIS370MTH: : 32 mm

5 1

W105-03-06-008

2. Jack up one side of the track frame high enough (90° to 110° between boom and arm is obtained when the bucket is lowered with the round bottom contacting with ground). Insert the wooden blocks under track frame (2) and support the machine.

90° to 110°

2

CAUTION: Grease pressure in the adjuster cylinder is high. Do not loosen valve (3) quickly or too much as the valve may fly off or high-pressure grease in the adjusting cylinder may gush out. Keep body parts and face away from the valve and loosen the valve carefully. Do not loosen grease fitting (4).

M104-07-067

W105-03-06-001

4

3

IMPORTANT: It is enough to loosen valve (3) by 1 to 1.5 turns. Do not loosen the valve over that degree. 3. Loosen valve (3) on the track adjuster. Drain grease and adjust the track sag enough to permit roller (5) to be removed. : 24 mm

Grease Outlet

M116-07-094

W3-6-4

UNDERCARRIAGE / Upper And Lower Roller

CAUTION: Lower roller weight: ZAXIS330, 330LC, 350H, 350LCH: 54 kg (120 lb) ZAXIS370MTH: 80 kg (180 lb) 4. Remove lower roller (5) by using a fork lift.

5 W105-03-06-010

Installation 1. Set lower rollers (5) below track frame (2) by using a fork lift.

2

5 W105-03-06-011

2

2. Lower the machine so that track frame (2) may keep a little away from collar (6).

6

3. Align the bolt (1) holes and tighten bolts (1) (4 used). ZAXIS330, 330LC, 350H, 350LCH: : 30 mm : 670 N⋅m (68.5 kgf⋅m, 500 lbf⋅ft) ZAXIS370MTH: : 32 mm : 750 N⋅m (76.5 kgf⋅m, 550 Ibf⋅ft)

W105-03-06-012

1

W105-03-06-008

W3-6-5

UNDERCARRIAGE / Upper And Lower Roller 4

4. Tighten valve (3) on the track adjuster. : 24 mm : 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)

3

Grease Outlet

CAUTION: Support the jacked up machine firmly by using wooden blocks.

M116-07-094

5. Jack up the track to be adjusted. Rotate the track in reverse direction slightly. 6. Apply grease through valve fitting (4) and adjust tracks tension. ZAXIS330, 330LC, 350H, 350LCH: Track sag specifications (A): 340 to 380 mm (13.4 to 15.0 in) ZAXIS 370MTH: Track sag specifications (A): 380 to 430 mm (15.0 to 16.9 in) W157-03-06-002

W3-6-6

UNDERCARRIAGE / Upper And Lower Roller (Blank)

W3-6-7

UNDERCARRIAGE / Upper And Lower Roller DISASSEMBLE LOWER ROLLER

5

4

6

3

2

1

7

8

7 1 3 4

W166-03-06-006

1 - Floating Seal (2 Used) 2 - Axle

3 - O-Ring (2 Used) 4 - Collar (2 Used)

5 - Pin (2 Used) 6 - Plug (2 Used)

W3-6-8

7 - Bushing (2 Used) 8 - Roller

UNDERCARRIAGE / Upper And Lower Roller Disassemble Lower Roller 1. Remove plug (6) from the end of collar (4) and drain oil. : 6 mm

4. Remove pin (5) from the axle (2) assembly. Remove axle (2) from collar (4) by using a press. 3

4

2. Put the matching marks on collar (4) and axle (2). Remove pin (5) from collar (4) at one side by using a round bar and hammer. Remove axle (2) from roller (8) by using a press from the side where pin (5) is removed. The pin and collar at opposite are removed together. 2

Round Bar: ZAXIS330, 330LC, 350H, 350LCH: Dia. 14 mm (0.6 in) ZAXIS370MTH: Dia. 25 mm (1 in) 4

1

8

1 W105-03-06-027

5. Remove O-rings (3) (2 used) from axle (2). 1

6. When replacing bushing (7), remove bushing (7) by using special tool and a press. Special tool: ZAXIS330, 330LC, 350H, 350LCH: ST 1475 ZAXIS370MTH: ST 1955

4

2 W105-03-06-026

IMPORTANT: For handling of floating seal (1), refer to the section “Precautions for Floating Seal Handling” on page W1-1-4. 3. Remove floating seal (1) from both sides of roller (8) and collars (4) (2 used) respectively.

Special Tool

7

W105-03-06-028

W3-6-9

UNDERCARRIAGE / Upper And Lower Roller ASSEMBLE LOWER ROLLER ZAXIS330, 330LC, 350H, 350LCH: 4

5

6

W1HH-03-06-001

8

7

2

1

3

ZAXIS370MTH: 4

5

6

W162-03-06-002

8

1 - Floating Seal (2 Used) 2 - Axle

2

3 - O-Ring (2 Used) 4 - Collar (2 Used)

7

5 - Pin (2 Used) 6 - Plug (2 Used)

W3-6-10

1

3

7 - Bushing (2 Used) 8 - Roller

UNDERCARRIAGE / Upper And Lower Roller Assemble Lower Roller 1. Install bushings (7) (2 used) onto roller (8). Do not dent the flange surface of bushing (7). Apply grease to O-ring (3). Install O-ring (3) onto axle (2). 2. Align the matching marks made when disassembling. Install one side of collar (4) onto axle (2) with pin (5). Do not damage O-ring (3).

5. Insert axle (2) into roller (8). Install O-ring (3). Install the other collar (4) with pin (5) in the same procedures. 6. Add engine oil (API CD class SAE30) through the plug (6) hole in collar (4). Engine oil amount: ZAXIS330, 330LC, 350H, 350LCH: 0.42 L (0.44 US gt.) ZAXIS370MTH: 0.5 L (0.53 US gt.)

5 2

7. Apply LOCTITE #503 to plug (6). Install plug (6) into collar (4). : 6 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)

3

5 4

W16J-03-06-001

8

4

3. Apply LOCTITE #503 to plug (6). Install plug (6) to one side of collar (4). : 6 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) IMPORTANT: For handling floating seal (1), refer to the section “Precautions for Handling Floating Seal” on page W1-1-4. 4. Apply grease to O-ring (3) on floating seal (1). Install floating seal (1) to roller (8) and collar (4). 8

1

1

4

W157-03-06-008

W3-6-11

W105-03-06-024

UNDERCARRIAGE / Upper And Lower Roller MAINTENANCE STANDARD Upper Roller

C C

A B

A B

ZAXIS330, 330LC, 350H, 350LCH

ZAXIS370MTH W173-03-06-001

W166-03-06-007

Unit: mm (in) ZAXIS330, 330LC, 350H, 350LCH Allowable Standard Limit

ZAXIS370MTH Standard

Allowable Limit

A

98 (3.86)

−

103 (4.06)

−

B

165 (6.50)

−

190 (7.48)

−

C

120 (4.72)

110 (4.33)

160 (6.30)

150 (5.90)

Remedy

Cladding by welding and finish or replace

Axle and Bushing Unit: mm (in) ZAXIS330, 330LC, 350H, 350LCH Allowable Standard Limit Axle

ZAXIS370MTH Standard

Allowable Limit

Outside Dia.

45 (1.77)

[44.2 (1.74)]

60 (2.36)

[59.2 (2.37)]

Inside Dia.

45 (1.77)

[46.0 (1.81)]

60 (2.36)

[61 (2.37)]

Flange Thickness

2 (0.079)

[1.2 (0.047)]

4.5 (0.177)

[3.7 (0.146)]

Bushing

NOTE: Values in [

] are just for reference.

W3-6-12

Remedy

Replace

UNDERCARRIAGE / Upper And Lower Roller Lower Roller

D

A

C

D

C

A

C

B

C

B

ZAXIS330, 330LC, 350H, 350LCH

ZAXIS370MTH

W1HH-03-06-002

W157-03-06-003

Unit: mm (in) ZAXIS330, 330LC, 350H, 350LCH

ZAXIS 370MTH

Standard

Allowable Limit

Standard

Allowable Limit

A

203(7.99)

[229.5 (9.06)]

214 (8.43)

[249 (9.80)]

B

256 (10.08)

−

284 (11.18)

−

C

26.5 (1.04)

[13.25 (0.52)]

35 (1.38)

[17.5 (0.69)]

D

175 (6.89)

[157 (6.18)]

200 (7.87)

182 (7.17)

Remedy

Cladding by welding and finish or replace

Axle and Bushing Unit: mm (in) ZAXIS330, 330LC, 350H, 350LCH Allowable Standard Limit Axle

ZAXIS 370MTH Standard

Allowable Limit

Outside Dia.

75 (2.95)

[74.2 (2.92)]

85 (3.35)

[84.2 (3.31)]

Inside Dia.

75 (2.95)

[76 (2.99)]

85 (3.35)

[86.0 (3.39)]

Flange Thickness

2 (0.079)

[1.2 (0.047)]

6 (0.24)

[5.2 (0.20)]

Bushing

NOTE: Values in [

] are just for reference.

W3-6-13

Remedy

Replace

UNDERCARRIAGE / Upper And Lower Roller (Blank)

W3-6-14

UNDERCARRIAGE / Track REMOVE AND INSTALL TRACK Removal CAUTION: Grease pressure in the adjuster cylinder is high. Do not loosen valve (1) quickly or too much as the valve may fly off or high-pressure grease in the adjusting cylinder may gush out. Keep body parts and face away from the valve and loosen the valve carefully. Do not loosen grease fitting (2).

5

1. Rotate the tracks so that master pin (3) is positioned over front idler (4). Place a wooden block under shoe (5) and support shoe (5).

4

3

W105-03-07-006

2. Loosen the track tension. Turn valve (1) in the adjuster by one turn and drain grease from the grease outlet. : 24 mm

1

W105-03-07-002

1 2

Grease Outlet

M116-07-094

W3-7-1

UNDERCARRIAGE / Track CAUTION: The front idler may fly off due to the spring force when removing the track. Particularly, a strong force is always applied to the thread part of rod. If the rod and/or the threads are damaged, metal fragments under spring force may fly off. 3. ZAXIS330, 330LC, 350LCH: Remove retaining ring (6) to prevent master pin (3) from coming off. NOTE: If retaining ring (6) interferes with master link (7), push in master pin (3) in order to make clearance between retaining ring (6) and master pin (3). Remove retaining ring (6).

ZAXIS370MTH: Remove split pin (8) to prevent master pin (3) from coming off. NOTE: If split pin (8) interferes with master link (7), push in master pin (3) in order to make clearance between split pin (8) and master pin (3). Remove split pin (8).

7 3

6

ZAXIS330, 330LC, 350H, 350LCH

W105-03-07-009

7 3 8

ZAXIS370MTH

W3-7-2

W166-03-07-001

UNDERCARRIAGE / Track IMPORTANT: Master pin (3) is directional. Be sure to install it in the correct direction. 4. Remove master pin (3) by using special tool (ST 1970).

ST 1970

W105-03-07-008

Direction for removing the master pin.

Split Pin

Corner

Direction for removing the master pin.

3

3

Retaining Ring Track Link Master Link

ZAXIS370MTH

ZAXIS330, 330LC, 350H 350LCH W105-03-07-010

W166-03-07-002

CAUTION: Support the jacked up machine firmly by using wooden blocks. 5. Operate the boom and arm so that the angle between them is 90 to 110 degrees. Lower the boom with the round bottom contacting with the ground. Jack up the machine and remove the track.

Boom Arm

90° to 110°

W105-03-07-012

6. Slowly operate the travel lever for the track to be removed in the reverse direction. Extend and remove the track.

W105-03-07-011

W3-7-3

UNDERCARRIAGE / Track Installation 1. Jack up the machine. Set the track under the lower roller so that the sprocket meshes with the track end. Check the direction of track.

Sprocket Side

Idler Side

W105-03-07-013

2. Hoist and place the track on sprocket (8).

8

W105-03-07-014

3. With the machine jacked up, slowly operate the lever for the track to be installed in the forward direction. Turn travel device (9) and wind the track.

9

W105-03-07-015

4

4. Wind the track until the connecting part of track link reaches front idler (4). Lower the machine. Place a wooden block under shoe (5) and support shoe (5). 5 Wooden Block

W3-7-4

W105-03-07-016

UNDERCARRIAGE / Track 5. Install special tool (ST 1970). Install master pin (3) by using a hammer.

ST 1970

3

W105-03-07-017

Split Pin

Corner Direction for installing the master pin.

3

Direction for installing the master pin.

3 Retaining Ring Track Link Master Link

ZAXIS370MTH

ZAXIS330, 330LC, 350H, 350LCH

W166-03-07-002

W105-03-07-010

IMPORTANT: Replace retaining ring (6) and split pin (8) with new one.

7

6. ZAXIS330, 330LC, 350H, 350LCH: Install retaining ring (6) to the groove of master link (7) with the chamfered side for the plier facing forward.

6

ZAXIS370MTH: Install split pin (8). ZAXIS330, 330LC, 350H, 350LCH

W105-03-07-009

8

ZAXIS370MTH

W3-7-5

W166-03-07-001

UNDERCARRIAGE / Track IMPORTANT: If disassembling the links, fill grease (Daphne Epones SR) into the clearance between the pin and bushing. Apply grease onto the bushing end. Stand the bushing on a flat plate. Fill the bushing bore with grease. Insert the pin into the bushing while pushing the bushing onto the plate in order not to move because of grease. After inserting the pin, wipe off excess grease. Check the direction to install the seal.

Bushing

Seal Pin

Do not Apply Grease

Grease

Do not Apply Grease

W197-03-07-001

1

Seal

7. Tighten valve (1) on the track adjuster. Apply grease through grease fitting (2) and adjust the tracks tension. : 24 mm : 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft) 8. Check the track sag after cleaning the track frame and track. Grease Outlet

Track sag specifications: ZAXIS330, 330LC, 350H, 350LCH: 340 to 380 mm (13.4 to 15.0 in) ZAXIS370MTH: 380 to 430 mm (15.0 to 16.9 in)

M116-07-094

W105-03-07-018

W157-03-06-002

W3-7-6

UNDERCARRIAGE / Track MAINTENANCE STANDARD Link • Measure the length of four links as illustrated. • Do not measure the master-pin-included part of the track. • Measure the length with tension on the track.

B

A W155-03-07-001

Unit: mm (in) ZAXIS330, 330LC, 350H, 350LCH

ZAXIS370MTH

Standard

Allowable Limit

Standard

Allowable Limit

A

865.92 (34.09)

882 (34.72)

863.6 (34.00)

845.6 (33.29)

B

116 (4.57)

109 (4.29)

129 (5.08)

122 (4.80)

Remedy Cladding by welding and finish or replace

Master Pin

B

A

W105-03-07-021

ZAXIS370MTH

ZAXIS330, 330LC, 350H, 350LCH

W142-03-07-003

Unit: mm (in) ZAXIS330, 330LC, 350H, 350LCH

ZAXIS370MTH

Standard

Allowable Limit

Standard

Allowable Limit

A

237 (9.33)

−

308 (12.1)

−

B

45 (1.77)

[42 (1.65)]

47.3 (1.86)

[44.3 (1.40)]

NOTE: Values in [

] are just for reference.

W3-7-7

Remedy

Replace

UNDERCARRIAGE / Track Master Bushing

W105-03-07-023

Unit: mm (in) ZAXIS330, 330LC, 350H, 350LCH

ZAXIS370MTH

Standard

Allowable Limit

Standard

Allowable Limit

A

148.3 (5.84)

−

160.80 (6.33)

−

B

45.45 (1.79)

48.5 (1.91)

47.90 (1.89)

50.90 (2.00)

C

66.91 (2.63)

61.91 (2.44)

71.35 (2.81)

66.35 (2.61)

Remedy

Replace

Grouser Shoe

W105-03-07-024

Unit: mm (in) ZAXIS330, 330LC, 350H, 350LCH Shoe Size

ZAXIS370MTH

600 mm Grouser Shoe Standard

Allowable Limit

Standard

Allowable Limit

A

250 (9.84)

−

247 (9.72)

−

B

11 (0.43)

−

13 (0.51)

−

C

30 (1.18)

20 (0.79)

36 (1.42)

21 (0.83)

W3-7-8

Remedy

Replace

UNDERCARRIAGE / Track Bushing

W105-03-07-023

Unit: mm (in) ZAXIS330, 330LC, 350H, 350LCH Standard A B C

158.9(6.26) 45.45(1.79) 66.91(2.63)

Allowable Limit 46.5(1.83) 61.9(2.44)

ZAXIS370MTH Standard 177(6.97) 48.4(1.91) 71.35(2.81)

Allowable Limit 49.43(1.95) 66.35(2.61)

Remedy Replace

Pin

W105-03-07-020

Unit: mm (in) ZAXIS330, 330LC, 350H, 350LCH Standard A B

242(9.53) 44.69(1.76)

Allowable Limit 41.7(1.64)

ZAXIS370MTH Standard 254(10.00) 47.57(1.87)

W3-7-9

Allowable Limit 44.57(1.76)

Remedy Replace

UNDERCARRIAGE / Track (Blank)

W3-7-10

MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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SECTION 4

FRONT ATTACHMENT — CONTENTS — Group 1 Front Attachment Remove and Install Front Attachment .........W4-1-1 Maintenance Standard ................................W4-1-7 Standard Dimensions for Arm and Bucket Connection....................W4-1-10 Standard Dimensions for Arm and Boom Connection...................... W4-1-11

Group 2 Cylinder Remove and Install Cylinder........................W4-2-1 Hydraulic Circuit Pressure Release Procedure ..................................W4-2-13 Up to serial No.33099 and up Disassemble Cylinder ................................W4-2-14 Assemble Cylinder .....................................W4-2-20 Maintenance Standard...............................W4-2-24 Serial No.33100 and up Disassemble Cylinder ................................W4-2-26 Assemble Cylinder .....................................W4-2-32 Maintenance Standard...............................W4-2-36

1HHW-4-1

(Blank)

1HHW-4-2

FRONT ATTACHMENT / Front Attachment REMOVE AND TACHMENT

INSTALL

FRONT

AT1

IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Adapter Boom Cylinder

Removal 1. Remove pipe (1) of lubrication pipes to the front attachment on the boss at the boom cylinder rod side from the adapter. (2 places on both left and right) : 19 mm

W105-04-01-002

3

2. Remove nuts (4) and stopper pin (6) from boom cylinder rod front pin (3). Remove stopper (5). (2 places on both left and right) : 30 mm CAUTION: Boom cylinder weight: 320 kg (710 lb) Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc in order to prevent personal injury. Check the direction to remove the pins as the pins may fly off suddenly. 3. Hoist and hold the boom cylinder tube. By using a bar and hammer tap pin (3) into the position where thrust plate (2) can be removed. Remove thrust plate (2). NOTE: When pin (3) is impossible to remove, start the engine and slightly operate the boom lever. Adjust the boom cylinder rod pin hole while hoisting/lowering the front attachment.

W4-1-1

6

2

Boom Cylinder

5 4 W178-04-01-004

FRONT ATTACHMENT / Front Attachment IMPORTANT: Insert a plate which does not come in contact with the grease fitting in the boom cylinder. 4. Insert a plate between the boom cylinder and main frame. Hold and lower the boom cylinder. 5. Remove the boom cylinder. Refer to “Remove Boom Cylinder” (W4-2-10). 6. Remove the other boom cylinder in the same procedures as steps 3 to 5. 7. After stopping the engine, push the air bleed valve on the top of hydraulic oil tank and release any remaining pressure from the hydraulic oil tank. Remove the cap. Completely release the residual pressure from the hydraulic circuit. Refer to the “Hydraulic Circuit Pressure Release Procedure” (W4-2-15).

Plate W157-04-01-005

Air Bleed Valve

8. Remove hoses (7, 8) of the bucket cylinder and arm cylinder. Cap the removed hoses and pipes. : 36, 41, 50 mm

M157-07-173

7

8

W157-04-01-001

W4-1-2

FRONT ATTACHMENT / Front Attachment 9. Remove bolt (12), spring washer (13), plate (11), and block (10) from the plate of boom foot pin (9). : 27 mm

9

10 11

CAUTION: Front attachment weight: ZAXIS330, 330LC: 6440 kg (14200 lb) ZAXIS350, 350LCH: 7050 kg (15540 lb) ZAXIS370MTH: 7120 kg (15700 lb)

12 13 W178-04-01-001

10. Attach a wire rope to the boom. Slightly hoist the boom in order to take up any wire rope slack.

11. Insert a pry bar between the plate of boom foot pin (9) and the bracket. Slightly pull out the plate. 12. Turn the plate upward by hand. Turn the plate left and right in order to pull out boom foot pin (9). (Adjust the position of the boom foot pin hole while hoisting/lowering the front attachment.) W105-04-01-008

13. Hoist the front attachment and move the machine backward.

9

14. Place the front attachment on wooden blocks.

Plate

Insert Bar Bracket

W178-04-01-001

W178-04-01-005

W4-1-3

FRONT ATTACHMENT / Front Attachment Installation CAUTION: Front attachment weight: ZAXIS330, 330LC: 6440 kg (14200 lb) ZAXIS350, 350LCH: 7050 kg (15540 lb) ZAXIS370MTH: 7120 kg (15700 lb) 1. Hoist the front attachment. Move the machine forward and align the boom foot pin holes. Insert the thrust plates into both left and right sides of boom and adjust the clearance between the plate and frame within 1 mm. (Adjust the position of the boom foot pin hole while hoisting / lowering the front attachment.) 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.

10 11 12

2. Install boom foot pin (9). Install stopper bolt (12), washer (13), plate (11), and block (10). : 27 mm : 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft) 3. Remove the caps from hoses and pipes. Install hoses (7, 8) of the bucket cylinder and arm cylinder. : 36 mm : 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) : 50 mm : 255 N⋅m (26 kg f⋅m)

W178-04-01-005

9

13 W178-04-01-001

8

7

W157-04-01-001

CAUTION: Boom cylinder weight: 320 kg (710 lb) 4. Install the boom cylinder. Refer to “Install Boom Cylinder” (W4-2-12). Boom Cylinder W105-04-02-040

W4-1-4

FRONT ATTACHMENT / Front Attachment 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

5. Hoist and hold the boom cylinder tube. Insert thrust plates (2) (2 used). Install pin (3) and install the boom cylinders to both sides.

6. Install stopper (5) with stopper pin (6) and nuts (4) (2 used). (2 places on both left and right) : 30 mm : 550 N⋅m (56 kgf⋅m, 405 lbf⋅ft)

2

6

Boom Cylinder

5 4 W178-04-01-004

7. Install lubrication pipe (1) onto the boom cylinder rod side. (2 places on both left and right) : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

1

W105-04-01-002

8. Apply grease to the boom cylinder rod side, bottom side, and boom foot side.

Boom Cylinder Rod Side Boom Foot Side

M157-07-155

9. Fill hydraulic oil to specified level. Start the engine and check the connections for any oil leakage. 10. After completing the work, run each cylinder several times to stroke end in order to release any pressure in the circuit.

Boom Cylinder Bottom Side

W4-1-5

M157-07-156

FRONT ATTACHMENT / Front Attachment IMPORTANT: When removing the arm from the boom, perform the following steps when installing the arm. • Install thrust plates (14) into left and right sides of arm. Adjust total clearance of left and right within 1.5 mm.

14

14

15

15

• After installing the arm, apply grease to grease fitting (15) on the boom connecting boss of arm. IMPORTANT: For handling of HN bushing for the front attachment, pay attention to following requirements. Precautions for pressing the bushing in: If a hammer is used to drive the bushing in, the bushing may be damaged. Use a press. Precautions when reinforcing the arm: Welding heat for arm reinforcement may cause oil to leak from the bushing and decrease lubrication performance. If oil leak occurs because of heated bushing after welding, replace the bushing. Special tools should be used to pull the bushing out or press it in. Tool: ST 1478

W4-1-6

M157-07-157

FRONT ATTACHMENT / Front Attachment MAINTENANCE STANDARD Pin and Bushing

F

E G

C D

H

A I

B

J K

W105-04-01-018

Unit: mm (in) Parts Name A

B

C

D

E

F

Standard

Allowable Limit

Pin

110 (4.33)

109.0 (4.31)

Bushing

110 (4.33)

111.5 (4.39)

Pin

110 (4.33)

109.0 (4.31)

Boss (Main Frame)

110 (4.33)

111.5 (4.39)

Bushing (Boom Cylinder)

110 (4.33)

111.5 (4.39)

Pin

110 (4.33)

109.0 (4.31)

Bushing (Boom Cylinder)

110 (4.33)

111.5 (4.39)

Boss (Boom)

110 (4.33)

111.5 (4.39)

Pin

110 (4.33)

109.0 (4.31)

Bushing

110 (4.33)

111.5 (4.39)

Pin

110 (4.33)

109.0 (4.31)

Boss (Arm)

110 (4.33)

111.5 (4.39)

Bushing (Arm Cylinder)

110 (4.33)

111.5 (4.39)

Pin

110 (4.33)

109.0 (4.31)

Boss (Boom)

110 (4.33)

111.5 (4.39)

Bushing (Arm Cylinder)

110 (4.33)

111.5 (4.39)

W4-1-7

Remedy

Replace

FRONT ATTACHMENT / Front Attachment Unit: mm (in) Parts Name G

H

I J K

Standard

Allowable Limit

Pin

90 (3.54)

89.0 (3.50)

Boss (Arm)

90 (3.54)

91.5 (3.60)

Bushing (Bucket Cylinder)

90 (3.54)

91.5 (3.60)

Pin

100 (3.94)

99.0 (3.90)

Bushing

100 (3.94)

101.5 (4.00)

Bushing (Bucket Cylinder)

100 (3.94)

101.5 (4.00)

Pin

90 (3.54)

89.0 (3.50)

Bushing

90 (3.54)

91.5 (3.60)

Pin

100 (3.94)

99.0 (3.90)

Bushing

100 (3.94)

101.5 (4.00)

Pin

100 (3.94)

99.0 (3.90)

Bushing

100 (3.94)

101.5 (4.00)

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

W4-1-8

Remedy

Replace

FRONT ATTACHMENT / Front Attachment Side Cutter B

C D A

W105-04-01-019

Unit: mm (in) Standard

Allowable Limit

A

258 (10.2)

168 (6.61)

B

300 (11.8)



C

400 (15.7)



D

300 (11.8)



Remedy

Replace

Point

B

C

A

D

W105-04-01-020

Unit: mm (in) Standard

Allowable Limit

A

240 (9.45)

120 (4.72)

B

96 (3.78)



C

130 (5.12)



D

105 (4.13)



W4-1-9

Remedy

Replace

FRONT ATTACHMENT / Front Attachment STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION

Section B

Section A

T137-01-03-001

Unit : mm (in) ZAXIS330

ZAXIS350H

ZAXIS370MTH

EX300-5

a

575 (22.6)

←

←

←

b

10 (0.39)

←

←

←

c

700 (27.6)

←

←

←

d

695 (27.4)

←

←

←

e

－

－

－

－

f

1661 (65.4)

1666 (65.6)

←

1661 (65.4)

g

581 (22.9)

←

←

573 (22.6)

h

442 (17.4)

←

←

←

i

100 (3.94)

←

←

←

j

578 (22.7)

←

←

←

k

90 (3.54)

←

←

←

l

581 (22.9)

←

←

573 (22.6)

m

420 (16.5)

←

←

←

n

100 (3.94)

←

←

←

o

8.85°

←

←

←

p

8.85°

←

←

←

q

592 (23.3)

600 (23.6)

←

592 (23.3)

W4-1-10

FRONT ATTACHMENT / Front Attachment STANDARD DIMENSIONS FOR ARM AND BOOM CONNECTION

Section C

W187-04-01-002

Unit: mm (in)

ZAXIS330

ZAXIS350H

ZAXIS370MTH

EX300-5

s

90 (3.5)

←

←

←

t

418.5 (16.5)

←

←

←

u

571 (22.5)

←

←

←

IMPORTANT: If the front attachment of a previous model machine is used, use the grease intervals for previous model machine.

W4-1-11

FRONT ATTACHMENT / Front Attachment (Blank)

W4-1-12

FRONT ATTACHMENT / Cylinder REMOVE AND INSTALL CYLINDER IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

1

Remove Bucket Cylinder 1. Insert wooden block (3) between bucket cylinder (1) and arm (2).

3 2 3

2. Stop the engine. Push the air bleed valve and release any remaining pressure from the hydraulic oil tank. Remove the cap. Release the bucket circuit pressure. Refer to “Hydraulic Circuit Pressure Release Procedure” on page W4-2-15.

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.

W554-04-02-006

Link A

4

5

3. Fasten links A and B by using a wire in order not to fall off before removing pin (7). 6

4. Remove nuts (6) (2 used) and stopper pin (4). Remove pin (7) by using a round bar. Remove thrust plates (5). : 32 mm

Link B

7 1

W158-04-02-006

8

5. In order not to extend rod (8) of bucket cylinder (1), pass wire (9) through the cylinder rod hole and secure rod (8) to the bucket cylinder (1) tube.

9

W4-2-1

W102-04-02-005

FRONT ATTACHMENT / Cylinder 6. Remove bucket cylinder hoses (12) (2 used) at the bottom of bucket cylinder (1). Cap all open ends. : 41 mm 10

CAUTION: Bucket cylinder (1) weight: 255 kg (560 lb)

11 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.

13

1

7. Hoist bucket cylinder (1). Remove nuts (13) (2 used) and stopper pin (15). Remove pin (11). Remove thrust plate (10). : 30 mm 8. Remove bucket cylinder (1).

W4-2-2

W1HH-04-02-009

12

FRONT ATTACHMENT / Cylinder Install Bucket Cylinder IMPORTANT: When installing the bushing, if a hammer is used, the bushing may be damaged. Use a press.

10

CAUTION: Bucket cylinder (1) weight: 255 kg (560 lb)

11

CAUTION: When installing pin (11), metal fragments may fly off by using a hammer. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury.

15 14

1. Hoist bucket cylinder (1). Align the hole on cylinder tube side with the cylinder mounting hole on arm. Insert thrust plate (10) and install pin (11). 2. Insert stopper pin (15) into arm stopper (14) and pin (11). Install nuts (13) (2 used). : 30 mm : 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft)

13

1

3. Install bucket cylinder hoses (12) (2 used). Fill hydraulic oil to specified level. Start the engine and check for any oil leaks : 41 mm : 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

W1HH-04-02-009

12

8

1

4. Remove wire (9) from rod (8) of bucket cylinder (1).

9

W4-2-3

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 and operate the bucket lever. Align the hole on cylinder rod side with those of links (16, 18). Insert thrust plate (5) and pin (7).

6 W158-04-02-006

19

19

6. Insert stopper pin (4) into stopper (17) and pin (7). Install nuts (6) (2 used). : 32 mm : 550 N⋅m (56.0 kgf⋅m, 405 lbf⋅ft) 7. After completing the work, operate the bucket cylinder several times to the stroke end and release the pressure in the circuit. IMPORTANT: In case link (18) has been removed from the arm, insert thrust plate (19) when installing.

W4-2-4

18

18

W157-04-01-015

FRONT ATTACHMENT / Cylinder Remove Arm Cylinder 1. Insert wooden block (3) between arm cylinder (1) and boom (2). 2. Stop the engine. Push the air bleed valve and release any remaining pressure in the hydraulic oil tank. Remove the cap. Release arm circuit pressure. Refer to “Hydraulic Circuit Pressure Release Procedure” on page W4-2-13.

4

3. Remove bolt (8) from pin (5) at the arm cylinder (1) rod side. Remove spring washer (7) and plate (6). : 27 mm 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). Remove thrust plate (4).

8

7

6

5 9

2

3

W1HH-04-02-001

1

5. In order not to extend rod (9) of arm cylinder (1), pass a wire through the cylinder rod hole and secure rod (9) to the arm cylinder (1) tube.

10 11

6. Remove hoses (10) (2 used) at the bottom of arm cylinder (1). Cap all open ends. : 41 mm, 50 mm 7. Remove lubrication pipe (11) from arm cylinder (1). : 19 mm

W4-2-5

10 W1HH-04-02-002

FRONT ATTACHMENT / Cylinder 12

CAUTION: Arm cylinder (1) weight: 460 kg (1010 lb) 1

8. Attach a sling belt at the center of gravity of arm cylinder (1). Hoist arm cylinder (1) and take up sag. CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggle, hard hats, etc in order to prevent personal injury. 9. Remove bolt (16) from tube side pin (13) of arm cylinder (1). Remove spring washer (15) and plate (14). Remove pin (13) and remove thrust plates (12). Remove arm cylinder (1). : 27 mm

W4-2-6

13 14 15 16

W1HH-04-02-004

FRONT ATTACHMENT / Cylinder 12

Install Arm Cylinder IMPORTANT: When installing the bushing and if a hammer is used, the bushing may be damaged. Install the bushing by using a press.

1

CAUTION: Arm cylinder (1) weight: 460 kg (1010 lb) 1. Attach a sling belt at the center of gravity of arm cylinder (1). Hoist arm cylinder (1). Align the cylinder tube side hole with the cylinder mounting hole on the boom.

13 14 15

W1HH-04-02-004

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.

1 10

2. Insert thrust plate (12) and install pin (13). Install plate (14) and spring washer (15) into pin (13) with bolt (16). : 27 mm : 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft) 3. Install lubrication pipe (11) and hoses (10) (2 used) of arm cylinder (1). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) : 50 mm : 255 N⋅m (26 kgf⋅m, 190 lbf⋅ft) 4. Fill hydraulic oil to specified level. Start the engine and check for any oil leaks.

W4-2-7

11

10 W1HH-04-02-002

FRONT ATTACHMENT / Cylinder 5. Remove a wire from rod (9) of arm cylinder (1). Hoist arm cylinder (1). Start the engine and operate arm lever. Align the hole on arm cylinder rod side with the mounting hole on arm (17).

4 17

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 (4) and install pin (5). Install plate (6) and spring washer (7) into pin (5) with bolt (8). : 27 mm : 300 N⋅m (30.5 kgf⋅m, 220 lbf⋅ft) 7. When completing the work, operate the arm cylinder several times to the stroke end and release the pressure in the circuit.

W4-2-8

1

8

7

6

5 9

W1HH-04-02-001

FRONT ATTACHMENT / Cylinder Remove Boom Cylinder 1. Remove lubrication pipes (1) from the boom cylinder. : 19 mm

1

CAUTION: Boom cylinder (2) weight: 315 kg (690 lb) 2. Attach a wire rope onto boom cylinder (2). Hoist boom cylinder (2). W105-04-02-032

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), stopper pin (7), and stopper (6) from the boom cylinder (2) rod. Remove pin (4). Remove thrust plate (3). : 30 mm 4. Place boom cylinder (2) on a support. Remove the other boom cylinder in the same procedures.

7

6 5

3

4

3

2 W158-04-02-013

5. Operate the boom lever and retract the boom cylinder. In order not to extend the boom cylinder rod, pass a wire through the cylinder rod hole and secure the rod to the cylinder tube. 6. Stop the engine. Push the air bleed valve and release any remaining pressure in the hydraulic oil tank. Release the circuit pressure. Refer to “Hydraulic Circuit Pressure Release Procedure” on page W4-2-13.

W4-2-9

2

W178-04-02-011

FRONT ATTACHMENT / Cylinder 7. Remove hoses (12) (4 used) at the bottom of boom cylinder (2). Cap all open ends. : 41 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 bolt (8) at the cylinder tube side of main frame. Remove spring washer (9) and plate (10). Remove pin (11). Remove thrust plate (13). : 27 mm

2

W178-04-02-011

2 13

CAUTION: Boom cylinder (2)weight: 315 kg (690 lb) 9. Attach a wire rope at the center of gravity of boom cylinder (2). Hoist and remove the boom cylinder. Remove the other boom cylinder in the same procedures.

11 10 9 12

2

W4-2-10

8

W1HH-04-02-003

W178-04-02-013

FRONT ATTACHMENT / Cylinder Install Boom Cylinder IMPORTANT: When installing the bushing and if a hammer is used, the bushing may be damaged. Install the bushing by using a press. CAUTION: Boom cylinder weight: 320 kg (710 lb) 1. Attach a wire rope at the center of gravity of boom cylinder (2). Hoist boom cylinder (2). Align the pin hole at 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.

W178-04-02-013

2 2 13

2. Insert thrust plate (13) and pin (11). Install spring washer (9) and plate (10) with bolt (8). : 27 mm : 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft) 3. Install the other boom cylinder in the same procedures. 4. Install hoses (12) (4 used) onto boom cylinders (2) (2 used). : 41 mm : 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) 5. Fill hydraulic oil to specified level. Start the engine and check for any oil leaks.

W4-2-11

11 10 9 12

8

W1HH-04-02-003

FRONT ATTACHMENT / Cylinder 6. Hoist boom cylinder (2). Operate the boom lever and align the pin hole at cylinder rod side with the mounting hole of boom cylinder. CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggle, hard hats, etc in order to prevent personal injury.

7

7. Install thrust plate (3). Install pin (4) and connect boom cylinder (2) with the boom. 8. Install stopper (6), stopper pin (7), and nuts (5) (2 used). : 30 mm : 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft)

6 5

3

4

3

2 W158-04-02-013

9. Install lubrication pipes (1). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) 10. Install the other boom cylinder in the same procedures.

1

11. When completing the work, operate the boom cylinder several times to the stroke end and release the pressure in the circuit.

W105-04-02-032

W4-2-12

FRONT ATTACHMENT / Cylinder HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE NOTE: Do not start the engine. Operate the pilot pump by using the power from battery and deliver the pilot pressure to the spool of control valve. 1. Push the lock lever forward. 2. Pull the handle for stopping engine completely and secure the handle.

Handle for Stopping Engine

IMPORTANT: Battery will deplete. Operate the key switch for short period. 3. Turn the key switch to the START position. Operate the lever in order to release any pressure in hydraulic circuit 4 to 5 times. 4. Reset the handle for stopping engine.

W178-04-02-010

W4-2-13

FRONT ATTACHMENT / Cylinder DISASSEMBLE CYLINDER Boom Cylinder Up to serial No.33099 1

8

9

10

11 12

13

14

15

13

12

2

17

3

4

5

6

7

18

16

W1HH-04-02-007

Bucket Cylinder Up to serial No.33099 1

8

9 10

11

12 13

14

15

13

12

2

16

17

3

4

5

6

7

18

W1HH-04-02-006

12345-

Piston Rod Retaining Ring Dust Seal Seal Ring

678910 -

Bushing Retaining Ring Socket Bolt (8 Used) Cylinder Head O-Ring

11 12 13 14 -

Cushion Ring Teflon Ring (2 Used) Wear Ring (2 Used) Piston

NOTE: Socket bolt (8) (9 used) are equipped for the boom cylinder only.

W4-2-14

15 16 17 18 -

Seal Ring Set Screw Nut Cylinder Tube

FRONT ATTACHMENT / Cylinder Arm Cylinder Up to serial No.33099

1 2

3

4

8 9 10

11

12

13

14

5

6

7

15 13

12

16

17

19

20 18

W1HH-04-02-005

12345-

Piston Rod Retaining Ring Dust Seal Seal Ring

678910 -

Bushing Retaining Ring Socket Bolt (8 Used) Cylinder Head O-Ring

11 12 13 14 15 -

Cushion Ring Teflon Ring (2 Used) Wear Ring (2 Used) Piston Seal Ring

W4-2-15

16 17 18 19 20 -

Set Screw Nut Cylinder Tube Cushion Ring Plug

FRONT ATTACHMENT / Cylinder Arm Cylinder As the other hydraulic oil cylinders are very similar in construction, the procedures of arm cylinder are shown as an example.

1 2

3

4

8 9 10

11

12

13

14

5

6

7

15 13

12

16

17

19

20 18

W1HH-04-02-005

NOTE: Cushion ring (19) and plug (20) are equipped for the arm cylinder only.

W4-2-16

FRONT ATTACHMENT / Cylinder Disassemble Cylinders As the other hydraulic oil cylinders are very similar in construction, the procedures of arm cylinder are shown as an example. The disassembling procedure starts on the premise that the hydraulic lines and the bands securing lines have been removed. CAUTION: Cylinder weight: Boom cylinder: 320 kg (710 lb) Bucket cylinder: 255 kg (560 lb) Arm cylinder: 460 kg (1010 lb)

3. Tap cylinder head (9) by using a plastic hammer. Remove cylinder head (9) and piston rod (1) from cylinder tube (18). Remove piston rod (1) straight in order not to damage the sliding surfaces. 4. Secure piston rod (1) on special tool (ST5908). Put the matching marks on piston rod (1) and nut (17). ST 5908

1. Hoist and place the cylinder on a workbench horizontally. Drain hydraulic oil from the cylinder.

W158-04-02-022

5. Remove cushion ring (19) and plug (20) from nut (17). (arm cylinder only) : 10 mm

W102-04-02-027

2. Fully extend piston rod (1). Support the piston rod (1) end. Remove socket bolts (8) (8 used) from cylinder head (9). : 19 mm (Boom, arm, and bucket cylinder) NOTE: Socket bolts (8) (9 used) are equipped for the boom cylinder only.

W4-2-17

FRONT ATTACHMENT / Cylinder

1 2

3

4

9 10

5

6

7

11 14

15 13

12

16

17

19

20 18

W1HH-04-02-005

W4-2-18

FRONT ATTACHMENT / Cylinder 6. As set screw (16) was mushroomed by using a punch and hammer at two places after set screw (16) had been screwed in, cut away its mushroomed part by using a drill first. Remove set screw (16). : 6 mm (Boom, arm and bucket cylinder) 7. Remove nut (17) by using special tool (ST5908). Remove piston (14). Special tools when turning nut: Boom cylinder : 120 mm (ST 3267) Arm cylinder : 125 mm (ST 3268) Bucket cylinder : 105 mm (ST 3266) ST 5908

W158-04-02-022

8. Remove seal ring (15), wear rings (13) (2 used), and teflon rings (12) (2 used) from piston (14). When removing the seals, do not damage piston (14). 9. Remove cushion ring (11) from piston rod (1). 10. Wind the tape onto the thread part of piston rod (1) in order to protect the seal of cylinder head (9). Remove cylinder head (9) from piston rod (1). 11. Remove O-ring (10) and retaining rings (2, 7) from cylinder head (9). Remove dust seal (3), ring (5), seal (4), and bushing (6). Special tools when removing bushing (6): Boom cylinder : 110 mm (ST 1399) Arm cylinder : 120 mm (ST 1429) Bucket cylinder : 100 mm (ST 1288)

W4-2-19

FRONT ATTACHMENT / Cylinder ASSEMBLE CYLINDER Arm Cylinder As the other hydraulic oil cylinders are very similar in construction, the procedures of arm cylinder are shown as an example. 2

3

4

6

5

8

7

12

10

1

18

13

11

15

13

16

12

14

17

9

19 20

W1HH-04-02-008

12345-

Piston Rod Retaining Ring Dust Seal Seal Ring

678910 -

Bushing Retaining Ring Socket Bolt (8 Used) Cylinder Head O-Ring

11 12 13 14 15 -

Cushion Ring Teflon Ring (2 Used) Wear Ring (2 Used) Piston Seal Ring

NOTE: Cushion ring (19) and plug (20) are equipped for the arm cylinder only. Socket bolts (8) (9 used) are equipped for the boom cylinder only.

W4-2-20

16 17 18 19 20 -

Set Screw Nut Cylinder Tube Cushion Ring Plug

FRONT ATTACHMENT / Cylinder Assemble Cylinder 1. Apply hydraulic oil onto the inside of cylinder head (9). Install bushing (6) into cylinder head (9). Special tools when installing bushing: Boom cylinder : 110 mm (ST 2393) Arm cylinder : 110 mm (ST 2393) Bucket cylinder : 100 mm (ST 2360) 2. Face the grooves of ring (5) and seal (4) to piston (14). Install ring (5), seal (4), and retaining ring (7) to cylinder head (9). 3. Install dust seal (3) to cylinder head (9) by using a plastic hammer. Special tools when installing dust seal: Boom cylinder : (ST 2392) Arm cylinder : (ST 2672) Bucket cylinder : (ST 2357) 4. Install O-ring (10) and retaining ring (2) to cylinder head (9). 5. Install wear rings (13) (2 used), seal ring (15), teflon rings (12) (2 used) to piston (14). 6. Wind the tape onto the thread part of piston rod (1) in order to protect the seal of cylinder head (9). Install the cylinder head (9) assembly to piston rod (1). 7. Install cushion ring (11) to piston rod (1) with “R” part facing to cylinder head (9). Install the piston (14) assembly to piston rod (1).

W4-2-21

FRONT ATTACHMENT / Cylinder

8

1

18

16

17

9

19 20

W1HH-04-02-008

W4-2-22

FRONT ATTACHMENT / Cylinder 8. Secure piston rod (1) on special tool (ST 5908). Align the matching marks made when disassembling and tighten nut (17). Special Tools when turning nut: : Boom cylinder: 8825±883 N⋅m (900±90 kg f⋅m, 6500±650 lbf⋅ft) 120 mm (ST 3267) Arm cylinder: 21867±2187 N⋅m (2230±223 kg f⋅m, 16100±1610 lbf⋅ft) 125 mm (ST 3268) Bucket cylinder: 10003±1000 N⋅m (1020±102 kg f⋅m, 7380±740 lbf⋅ft) 105 mm (ST 3266)

11. Secure cylinder tube (18) horizontally on a workbench. Align the piston rod (1) assembly with the center of cylinder tube (18). Insert the piston rod (1) assembly into cylinder tube (18) in order to not to damage the rings. 12. Install cylinder head (9) to cylinder tube (18) with socket bolts (8) (8 used). : 19 mm : 834±83 N⋅m (85±8.5 kgf⋅m, 615±62 lbf⋅ft) (Boom cylinder, Bucket cylinder) : 1226±123 N⋅m (125±12.5 kgf⋅m, 905±90 lbf⋅ft) (Arm cylinder)

ST 5908

NOTE: Socket bolts (8) (9 used) are equipped for the boom cylinder only.

W158-04-02-022

9. Tighten nut (17) with set screw (16). Mushroom the head of set screw (16) at two places by using a punch. : 6 mm : 63.7±6.4 N⋅m (6.5±0.65 kgf⋅m, 47±4.7 lbf⋅ft) 10. Install cushion ring (19) to piston rod (1) with “R” part facing to plug (20) by using plug (20). (arm cylinder only) : 10 mm : 109.8±11 N⋅m (11.2±1.1 kgf⋅m, 181±8 lbf⋅ft)

W4-2-23

FRONT ATTACHMENT / Cylinder MAINTENANCE STANDARD Wear to Outer Diameter of Rod

Rod Bend and Run Out Dial Gauge

A

Cylinder Rod

W166-04-02-022

W105-04-02-094

1m

Unit: mm (in) Cylinder Name

V Block

Recommended Size After Re-manufacturing (A)

Boom

105

Arm

115

Bucket

95

-0.036 -0.090 -0.036 -0.090 -0.036 -0.090

(4.13

-0.001 -0.004

)

(4.53

-0.001 -0.004

)

(3.74

-0.001 -0.004

)

Unit: mm (in) Bend Allowable limit Allowable limit

Run Out

Remedy

0.5 (0.020) 1.0 (0.039)

Repair

1.0 (0.039) 2.0 (0.079)

Replace

Wear to Inner Diameter of Rod Bushing Unit: mm (in) Cylinder Name Boom

Standard Inner Diameter (C) 110

Arm

120

Bucket

100

+0.180 +0.115 +0.180 +0.115 +0.165 +0.100

)

(4.33

)

(4.72

)

(4.72

+0.007 +0.005 +0.007 +0.005 +0.006 +0.004

Allowable Limit

Remedy

) +0.3 (+0.012)

Replace

) +0.3 (+0.012)

Replace

) +0.3 (+0.012)

Replace

W4-2-24

C

FRONT ATTACHMENT / Cylinder (Blank)

W4-2-25

FRONT ATTACHMENT / Cylinder DISASSEMLBE CYLINDER Boom Cylinder Bucket Cylinder Serial No. 33100 and up

12

7

6

2

3

8

9

10

13

12

11

5

4

1 15 14

Boom Cylinder

24

20

19

22

16

17

18

17

19

20

21

23 Bucket Cylinder

*24

W1HH-04-02-014

123456-

Piston Rod Snap Ring Dust Seal Slide Ring Cylinder Head Buffer Ring

78910 11 12 -

Bushing Snap Ring Backup Ring O-Ring Collar Backup Ring (2 Used)

13 14 15 16 17 18 -

NOTE: The items without mark * are same.

W4-2-26

O-Ring Bolt (12 Used) Washer (12 Used) Cushion Ring Backup Ring (2 Used) O-Ring

19 20 21 22 23 24 -

Ring (2 Used) Wear Ring (2 Used) Piston Ring Piston Set Screw Cylinder Tube

FRONT ATTACHMENT / Cylinder Arm Cylinder Serial No. 33100 and up

14

10

11

12

15

16

15

13

9 8 7 6 3

4

5

2 1 17

18

27

22 23 25

19

20

21

20

22

23

24

26

W1HH-04-02-012

1234567-

Piston Rod Cap Ball (12 Used) Plunger Snap Ring Dust Seal Slide Ring

8910 11 12 13 14 -

Cylinder Head Buffer Ring Bushing Snap Ring Backup Ring O-Ring Collar

15 16 17 18 19 20 21 -

Backup Ring O-Ring Bolt (12 Used) Washer (12 Used) Cushion Ring Backup Ring (2 Used) O-Ring

W4-2-27

22 23 24 25 26 27 -

Ring (2 Used) Wear Ring (2 Used) Piston Ring Piston Set Screw Cylinder Tube

FRONT ATTACHMENT / Cylinder Arm Cylinder Serial No. 33100 and up As the other hydraulic oil cylinders are very similar in construction, the procedures of arm cylinder are shown as an example .

16 14

10

11

12

15

15

13

9 8 7 6 3

4

5

2 1 17

18

27

22 23 25

19

20

21

20

22

23

24

26

W1HH-04-02-012

NOTE: Cap (2), balls (3) (12 used) and plunger (4) are equipped for the arm cylinder only.

W4-2-28

FRONT ATTACHMENT / Cylinder Disassemble Cylinder • As the other hydraulic oil cylinders are very similar in construction, the procedures of arm cylinder are shown as an example. The disassembling procedure starts on the premise that the hydraulic lines and the bands securing lines have been removed.

IMPORTANT: As set screw (26) was crimped by using a punch and hammer at two places after set screw (26) had been screwed in, cut away its crimped part by using a drill first. 4. Remove set screw (26). : 6 mm (Boom, arm and bucket) 5. Remove the piston (25) assembly from piston rod (1).

CAUTION: Cylinder weight: Boom cylinder: 320 kg (710 lb) Arm cylinder: 460 kg (1020 lb) Bucket cylinder: 255 kg (570 lb) 1. Hoist and place the cylinder on a workbench horizontally. Drain hydraulic oil from the cylinder.

6. Remove cap (2) from the upper surface of piston rod (1) end. Remove balls (3) (12 used) from the open part by using a magnet. 7. Remove plunger (4) from piston rod (1). NOTE: Cap (2), balls (3) (12 used) and plunger (4) are equipped for the arm cylinder only.

W102-04-02-027

2. Fully extend and support piston rod (1). Remove bolts (17) (12 used) and washers (18) (12 used) from cylinder head (8). : 30 mm (Boom, bucket) : 36 mm (Arm) IMPORTANT: Remove piston rod (1) straight in order not to damage the sliding surfaces. 3. Tap and remove cylinder head (8) with piston rod (1) together from cylinder tube (27) by using a plastic hammer.

W4-2-29

FRONT ATTACHMENT / Cylinder

10

11

12

13

9 8 7

3

4

5

6

2 1

25

19

20

21

20

22

23

24

W1HH-04-02-012

W4-2-30

FRONT ATTACHMENT / Cylinder IMPORTANT:

When removing the rings, do not damage piston (25). 8. Remove piston ring (24), wear rings (23) (2 used) and rings (22) (2 used) from the piston (25) assembly. 9. Remove O-ring (21), backup ring (20) and cushion ring (19) from piston rod (1).

10. Wind the tape onto the thread part of piston rod (1) in order to protect the seal of cylinder head (8). Remove cylinder head (8) from piston rod (1). 11. Remove the collar (14) assembly from piston rod (1). 12. Remove O-ring (13) and backup rings (12) (2 used) from the collar (14) assembly. 13. Remove the cylinder head (8) assembly from piston rod (1). 14. Remove O-ring (13), backup ring (12), snap ring (5), dust seal (6), slide ring (7) and buffer ring (9) from cylinder head (8). Remove snap ring (11) and bushing (10) from cylinder head (8). Special tools when removing bushing: Boom 110 mm (ST 1399) Arm 110 mm (ST 1399) Bucket 100 mm (ST 1288)

W4-2-31

FRONT ATTACHMENT / Cylinder ASSEMBLE CYLINDER Arm Cylinder As the other hydraulic oil cylinders are very similar in construction, the procedures of arm cylinder are shown as an example.

5

17, 18

6

12, 13

7

9

10

11 15, 16

22

14

19

23

20, 21

24

23

22

2

3

W1HH-04-02-027

1

1234567-

Piston Rod Cap Ball (12 Used) Plunger Snap Ring Dust Seal Slide Ring

8

27

8910 11 12 13 14 -

Cylinder Head Buffer Ring Bushing Snap Ring Backup Ring O-Ring Collar

15 16 17 18 19 20 21 -

25 26

Backup Ring O-Ring Bolt (12 Used) Washer (12 Used) Cushion Ring Backup Ring (2 Used) O-Ring

NOTE: Cap (2), balls (3) (12 used) and plunger (4) are equipped for the arm cylinder only.

W4-2-32

4

22 23 24 25 26 27 -

Ring (2 Used) Wear Ring (2 Used) Piston Ring Piston Set Screw Cylinder Tube

FRONT ATTACHMENT / Cylinder Assemble Cylinder IMPORTANT: Apply hydraulic oil onto the inside of cylinder head (8). 1. Install bushing (10) to cylinder head (8). Special tool when installing bushing: Boom 110 mm (ST 2393) Arm 110 mm (ST 2393) Bucket 100 mm (ST 2360) 2. Install slide ring (7) and buffer ring (9) to cylinder head (8). 3. Install dust seal (6) to cylinder head (8) by using a plastic hammer. Special tools when installing dust seal: Boom (ST 2392) Arm (ST 2672) Bucket (ST 2357) 4. Install backup ring (12), O-ring (13) and snap rings (5, 11) to cylinder head (8). 5. Wind the tape onto the thread part of piston rod (1) in order to protect the seal of cylinder head (8). Install the cylinder head (8) assembly to piston rod (1). 6. Install the cylinder head (8) assembly to piston rod (1). 7. Install backup ring (15) and O-ring (16) to collar (14). 8. Install the collar (14) assembly to piston rod (1).

W4-2-33

FRONT ATTACHMENT / Cylinder

22

17, 18

19

23

20, 21

24

23

22

2

3

W1HH-04-02-027

1

8

27

W4-2-34

25

4

FRONT ATTACHMENT / Cylinder 9. Install piston ring (24), wear rings (23) (2 used) and rings (22) (2 used) to piston (25). 10. Install the piston (25) assembly to piston rod (1). 11. Install cushion ring (19) onto piston rod (1). 12. Install plunger (4), balls (3) (12 used) and O-ring (21) to piston (25). 13. Install backup rings (20) (2 used) and O-ring (21) to piston (25). IMPORTANT: Align with the center of cylinder tube (18) and insert the piston rod (1) assembly in order not to damage the rings. 14. Secure cylinder tube (27) horizontally on a workbench. Insert the piston rod (1) assembly into cylinder tube (27). 15. Install cylinder head (8) to cylinder tube (27) with bolts (17) (12 used) and washers (18) (12 used). : 30 mm : 529.7±78.5 N⋅m (54.8± kgf⋅m, 390±57.5 Ibf⋅ft) (Boom, bucket) : 36 mm : 892±137 N⋅m (91±14 kgf⋅m, 658±101Ibf⋅ft) (Arm)

W4-2-35

FRONT ATTACHMENT / Cylinder MAINTENANCE STANDARD Wear to Outer Diameter of Rod

Rod Bend and Run Out Dial Gauge A

Cylinder Rod

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

Unit: mm (in) Cylinder Name

1m V Block

Recommended Size After Re-manufacturing (A)

Boom

105

Arm

115

Bucket

95

-0.036 -0.090 -0.036 -0.090 -0.036 -0.090

(4.134

-0.001 -0.004

)

(4.528

-0.001 -0.004

)

(3.74

-0.001 -0.004

)

Unit: mm (in) Bend Allowable limit Allowable limit

Run Out

Remedy

0.5 (0.020) 1.0 (0.039)

Repair

1.0 (0.039) 2.0 (0.079)

Replace

Wear to Inner Diameter of Rod Bushing Unit: mm (in) Cylinder Name

Standard Inner Diameter (C)

Boom

110

Arm

110

Bucket

100

+0.250 +0.050 +0.250 +0.050 +0.250 +0.050

)

(4.331

+0.01 +0.002

) (4.331

+0.01

)

+0.01

(3.937

+0.002 +0.02

Allowable Limit

Remedy

) +0.3 (+0.012)

Replace

) +0.3 (+0.012)

Replace

) +0.3 (+0.012)

Replace

W4-2-36

C

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SECTION 5

ENGINE AND ACCESSORY — CONTENTS — General Information

Alternator ...................................................6A-13

General Repair Instruction ........................... 0A-1

Injection Pump ...........................................6A-14

Illustration Arrows ........................................ 0A-2

Bearing Case .............................................6A-18

Abbreviations ............................................... 0A-3

Oil Cooler ...................................................6A-20

Nut and Bolt Angular Tightening Method ...... 0A-4

Rocker Arm and Shaft Assembly ................6A-23

Standard Bolt Torque Specifications............. 0A-6

Camshaft....................................................6A-32

Recommended Thread Locking Agents ....... 0A-8

Cylinder Head ............................................6A-39

Main Data and Specifications....................... 0A-9

Crank Pulley and Flywheel .........................6A-62

Performance Curve.................................... 0A-11

Timing Gears..............................................6A-66

External View Drawing ............................... 0A-12

Flywheel Housing .......................................6A-71

Service Standard ....................................... 0A-13

Oil Pan .......................................................6A-76

Torque Specifications ................................. 0A-17

Front Cover ................................................6A-78

Special Tools.............................................. 0A-25

Piston .........................................................6A-82

Troubleshooting ......................................... 0A-26

Crankshaft..................................................6A-94

Lubricant Application.................................. 0A-36

Cylinder Block .......................................... 6A-106

Sealant Application .................................... 0A-36

Engine Cooling

Service Information Identification ................................................ 0B-1 Lubrication System ...................................... 0B-2 Fuel System................................................. 0B-2 Cooling System............................................ 0B-6 Valve Clearance Adjustment ........................ 0B-6 Compression Pressure Measure.................. 0B-8 Recommended Lubricants ........................... 0B-9 Engine Oil Viscosity Chart ........................... 0B-9

Service Precaution .......................................6B-1 General Description .....................................6B-2 Thermostat ...................................................6B-3 Water Pump .................................................6B-6

Engine Fuel Service Precaution .......................................6C-1 General Description .....................................6C-2 Fuel Filter .....................................................6C-5 Injection Nozzle............................................6C-7

Engine Mechanical Service Precautions ..................................... 6A-2 General Description ..................................... 6A-2 Turbocharger ............................................... 6A-4 Exhaust Manifold ......................................... 6A-5 Intake Cover ................................................ 6A-7 Water Pump ................................................. 6A-9

Injection Pump ...........................................6C-17 Injection Pump Calibration Data .................6C-18

Starting and Charging Service Precaution .....................................6D3-1 Alternator ...................................................6D3-2 Starter Motor ............................................ 6D3-11

1HHW-5-1

Engine Lubrication Service Precaution.......................................6G-1 General Description .....................................6G-2 Oil Pump ......................................................6G-4 Oil Coolor.....................................................6G-8 Oil Port Cover ............................................ 6G-11

Engine Induction Service Precaution........................................6J-1 Turbocharger ................................................6J-2 Troubleshooting ............................................6J-4 Inspection and Repair ...................................6J-6

1HHW-5-2

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Hitachi Construction Machinery Co. Ltd Attn: Publications, Marketing & Product Support Fax: 81-298-31-1162

Hitachi Ref. No.

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