Manual No. : KM-192E Vol. No. : W192E-00 orkshop Manual EX75U2.3 Excavator ‘Service Manual (Manual No. KM-192E) consists of the following three separate volumes; Technical Manual (Operational Principle): Vol. No. TO192E Technical Manual (Troubleshooting) Vol. No. TT192E Workshop Manual Vol. No. W192E HITACHI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 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 Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the ‘Workshop Manual, + Information included in the Technical Manual (Operational Principle) technical information needed for redelivery and delivery, operation and activation of all devices and systems, PAGE NUMBER ‘Each page has a number, located on the center lower part of the page, and each number contains the following information: + Example; 4-3-5 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: 81-298-32-7173 FAX: 81-298-31-1162 + Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and _ troubleshooting procedures. + Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and —removal/nstallation and assemble/disassemble procedures. = Consecutive Page Number for Each Group Group Number Secion Number T: Technical Manual \W: Workshop Mnanual IN-1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 injyury or machine damage. Aitris is te safety alert symbol. When you see this symbol, be alert o 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 see appropriate lifting techniques and equipment when lifting heavy pats. UNITS USED ‘* SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parentheses just behind SI units. + Aicaution: indicaied 2 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 information or know-how. supplementary technical Example: 24.5 MPa (250 kgf/cm’, 3560 psi) A table for conversion from SI units to other system Units is shown below for reference purposes. "Te Convert Miltiply Te Convert Matipiy Quantity | From Into B Quantity | From Into By mim in 0,088 37 MPa__| Katiem®” [10.197 Length mm ft 0.003287 | Pressure MPa psi [145.0 L US gal_[ 0.2642 Jo ii PS 4.360 Volume L US at} 1.057 KW HP 434 m a 7.308 [Temperature] °C oF | Gxt. 8982 Weight kg ib 2.205 nla __[ mph 0.6214 Force N kgf ‘o.101e7 | Velocity min" Tp 1.0 N Bf 02248 | Flowrate | _Umin | US gpm | 0.2642 — Nm | kgtm [1.0197 murev | colrev [1.0 a Nm ibtat__|_0.7378 IN-2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. 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 serious injury. + WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. + CAUTION indicates 2 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. ‘* CAUTION also calls attention to safety messages in this manual. To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine. © @ NOTE indicates an additional explanation for an element of information. A DANGER A WARNING A CAUTION IMPORTANT @ NOTE SAA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. + Ifa safety sign or operator's manual is damaged or missing, replace it with new one. * 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 andior 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. PREPARE FOR EMERGENCIES * Be prepared if@ 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. + 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. veo ee, SA-2SAFETY WEAR PROTECTIVE CLOTHING ‘© Wear close fitting ciothing and safety equipment appropriate to the job. You may need: ‘Ahard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear on Respirator or iter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances. 98 «a =~ PLS + Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine. * Operating equipment safely requires the full attention of the operator. Do not wear radio or music, headphones while operating the machine. 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. 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 SA-3SAFETY USE HANDHOLDS AND STEPS + When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. «Falling is one of the major causes of personal injury | + Do not use any controls as hand-holds. + Never jump on or off the machine. Never mount or dismount a moving machine. * Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine. 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 ony SA-4SAFETY FASTEN YOUR SEAT BELT If the machine should overtum, the operator may become injured and/or thrown from the cab. Reaian tases ales areca overturning machine, resulting in serious injury or lj death Z hee If any item is damaged or worn, replace the seat + We recommend that the seat belt be replaced 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 hom in working condition (if equipped). It wams people when the e machine starts to move, + Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting tne ——_»_ machine. sxsr SA-5__ SAFETY OPERATE ONLY FROM OPERATOR'S SEAT '* Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious. injury or death + Start the engine only when seated in the operator's seat. + NEVER start the engine while standing on the track or on ground. + Do not start engine by shorting across starter terminals, uae * Before starting the engine, confirm that all control levers are in neutral 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 oe could result in a battery explosion or a runaway machine, SA-6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 e in the machine being operated in an unsafe manner. PROVIDE SIGNALS FOR FOBS INVOLV- ING 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. 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 po- sition. 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-7SAFETY DRIVE MACHINE SAFELY '* Before moving the machine, confirm which way to move travel pedals/levers for the corresponding direction you wish to go. + Pushing down on the front of the travel pedals or pushing the levers forward moves the machine towards the idlers. (Refer to the Steering the Machine Using PedalsiLevers section in the ‘operator's manual for correct travel operation.) ‘* Traveling on a grade may cause the machine to slip or to overturn, possibly resulting in serious injury or death + When traveling up or down a grade, keep the bucket in the direction of travel, approximately 200 to 300 mm (approximately 8 to 12 in)(A) above the ground, + If machine starts to skid or becomes unstable, lower the bucket immediately. + Traveling across the face of a slope may cause the machine to skid or to tumover. When traveling (ascending/descending) on a slope, be sure to point the tracks uphill/downhil, + Turing on an incline may cause the machine to tip over. If turing on an incline is absolutely unavoidable, do so at a place where the slope is gentle and the surface is firm. SA-8AVOID. INJURY FROM ROLLAWAY ACCIDENTS * Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways + Select level ground when possible to park machine. Do not park the machine on a grade. Lower the bucket and/or other work tools to the ground, Tur the auto-idle switch off + Run the engine at slow idle speed without load for 5 minutes to cool down the engine. + Stop the engine and remove the key from the key switch Pull the pilot control shut-off lever to LOCK positon. + 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. SAFETY BS SA-9SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS ‘© If any person is present near the machine when backing or swinging the upperstructure, the machine ‘may hit or run over that person, resulting in serious injury or death To avoid back-over and swing accidents: + Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR. + Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE + USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS: KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person, + No machine motions shall be made unless signals are clearly understood by both signaiman and operator. + Lear the meanings of all flags, signs, and markings used on the job and confirm who has the responsibilty 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. SA-10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, sosas To avoid tipping: ‘© Be extra careful before operating on a grade. + Prepare machine operating area fat. + 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. SA-11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 cioser 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 Va OBJECT HANDLING * If@ 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 operation, be sure to comply with all local regulations. + Do not use damaged chains of frayed cabs, sables, sings, of ropes, Before craning, position the upperstructure with a J 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 itis safely and securely situated on supporting blocks el ‘ron the ground. + Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall. SA-12SAFETY PROTECT AGAINST FLYING DEBRIS ‘If fying debris hit eyes or any other part of the body, serious injury may result + Guard against injury from fying pieces of metal or debris: wear goggles or safety glasses. + Keep bystanders away from the working area before striking any object. PARK MACHINE SAFELY To avoid accidents: + Park machine on a firm, level surface. + Lower bucket to the ground. + Tum auto-idie switch off + Run engine at siow idle speed without load for § minutes. + Tum key switch to OFF to stop engine, Remove the key from the key switch, Pull the pilot control shut-off lever to the LOCK position Close windows, roof vent, and cab door. Lock all access doors and compartments, SA-13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 flammable + Store flammable fluids well away from fire hazards. (fo + Do. not incinerate or puncture pressurized 6, containers + Do not store oily rags; they can ignite and burn 4 spontaneously. SA-14SAFETY SAFETY TRANSPORTING «The danger of tipping is present when Fpainglulescng the mectine ontofton 8 tuck o water bod iw + 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: 4). Select firm level ground. 2) Be sure to use a loading dock or ramp. 3) Be sure to have a signal person when Joading/unioading the machine. 4) Always tum the auto-idle 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 fiatbed 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. SA-15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 itis moving, + Keep hands, feet and clothing away from power- driven parts. + Before servicing the machine: 4) Park the machine on a level surface. 2) Lower the bucket to the ground, 3) Turn the auto-iale switch off 4) Run the engine at slow idle speed without load for 5 minutes, 5) Turn the key switch to OFF to stop engine. 6) Relieve the pressure in the hydraulic system by moving the contro! levers several times. 7) Remove the key from the switch 8) Attach a "Do Not Operate” tag on the control lever. 8) Pull the pilot control shut-off lever to the LOCK postion. 10) Allow the engine to cool + If a maintenance procedure must be performed with the engine running, do not leave machine unattended. + If window is missing or broken replace immediately. + 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. * Disconnect battery ground cable (-) before making adjustments to electrical systems or before welding on the machine. + luminate your work area adequately but safely. + Use a portable safety light for working inside or under the machine. SA-16+ Make sure that the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or ol. 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. 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 SAFETY 4 \ fy Vy (ANGER) DO NOT OPERATE SA-17SAFETY STAY CLEAR OF MOVING PARTS + Entanglement in moving parts can cause serious a injury. cs + To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating pars, Prams’ 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 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. 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-18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.) 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. Hot fuids and surfaces: + Engine ol, gear oil and hydraulic oil also become hot during operation. The engine, hoses, ines and other parts become hot as well * Wait for the oil and components to cool before starting any maintenance or inspection work SAFETY AA SA-19SAFETY REPLACE RUBBER HOSES PERIODICALLY « Rubber hosae tht conn farmate fui under if pressure may break due to aging, fatigue, and 6, abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of P 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 bums, gangrene, or otherwise serious injury or death, AVOID HIGH-PRESSURE FLUIDS ‘Fluids such as diesel fuel or hydraulic oll 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, Relieve the pressure by moving the control levers several times. Tighten all connections before applying pressure. snes + 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-20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 oll, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires, + Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately. Check Key Switch: If a fire breaks out, fallure to stop the engine will escalate the fre, hampering fire fighting + Always check key switch function before operating the machine every day: 41) 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. _ SAFETY SA-21SAFETY Check Heat Shields: * Damaged or missing heat shields may lead to fires. + Damaged or missing heat shiekis must be repaired or replaced before operating the machine, EVACUATING IN CASE OF FIRE e If a fire breaks out, evacuate the machine in the following way: + Stop the engine by tuming the key switch to the OFF position if there is time. + Use a fire extinguisher if there is time. + Exit the machine. SA-22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, AVOID HEATING NEAR PRESSURIZED FLUID LINES + Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe bums 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 seo 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. + Clean them thoroughly with nonflammable solvent before welding or lame cutting them, SA-23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 furnes and dust. + Do alll such work outside or in @ well-ventilated area. Dispose of paint and solvent property. + Remove paint before welding or heating: 4) 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. 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. * Battery electrolyte is poisonous. If the battery should explode battery electrolyte may be splashed into eyes, possibly resulting in biindness. + Be sure to wear eye protection when checking electrolyte specific gravity. SA-24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. AVOID HARMFUL ASBESTOS DUST ‘© Inhaled asbestos fibers may cause lung cancer, + Avoid breathing dust that may be generated when han-dling components containing asbestos fibers. + Components that may contain asbestos fibers are some gaskets. The asbestos used in these ‘components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airbome dust containing asbestos is not generated, + Avoid creating dust. Never use compressed air for leaning. Avoid brushing or grinding asbestos- containing materials. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, wet the asbestos containing materials with a mist of oil or water. + Be sure to comply with all applicable rules and regulations for the work piace Follow all local environmental rules and regulations for the disposal of asbestos. + Keep bystanders away from the areas where asbestos particles may be in the ai. SA-25SAFETY HANDLE CHEMICAL PRODUCTS SAFELY * Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives, + A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and ‘emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment. DISPOSE OF WASTE PROPERLY © Improperly disposing of waste can threaten the envifonment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, fiters, and batteries. + Use leakproof containers when draining fluids. Do ot 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-26SAFETY BEFORE RETURNING THE MACHINE TO THE CUSTOMER La ‘After maintenance or repair work is complete, confirm that * The machine is functioning properly, especially the safety systems. + Worn or damaged parts have been repaired or replaced SA-27SAFETY (Blank) SA-28SECTION AND GROUP CONTENTS WORKSHOP MANUAL All information, illustrations and speci fications 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)1998 Hitachi Construction Machinery Co., Ltd Tokyo, Japan All rights reserved SECTION 1 GENERAL INFORMATION Group 1 Precautions for disassembling Group 8 Pilot Shut-Off Valve 3 Group 9 Shockless Valve a Group 11 Pilot Relief Valve Unit__ i Group 12 Swing Mode Control Valve SECTION 3 UNDERCARRIAGE Group 1 Swing Bearin Group 2 Travel Device Group 3 Center Joint 4 Track Adjuster 5 Front Idler 6 Upper and Lower Roller 7 Track Grou Grou Grout Grou SECTION 4 FRONT ATTACHMENT Group 1 Front Attachment SECTION 5 ENGINE TECHNICAL MANUAL (Operational Principle) SECTION 4 GENERAL SECTION 3 COMPONENT OPERATION Group 1 Specification Group 1 Pump Device Group 2 Component Layout Group 2 Swing Device SECTION 2 SYSTEM Group 3 Control Valve Group 1 Control System Group 4 Pilot Valve Group 2 Hydraulic System Group 5 Travel Device Group 3 Electrical System Group 6 Others (Upperstructure) Group 7 Others (Undercarriage) TECHNICAL MANUAL (Troubleshooting) SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING FORMANCE TEST Group 1 Diagnosing Procedure Group 1 introduction Group 2 Component Layout Group 2 Engine Test Group 3 Troubleshooting A Group 3 Excavator Test Group 4 Troubleshooting B Group 4 Component Test Group 5 Troubleshooting C Group 5 Standard Group 6 Electrical System InspectionSECTION 1 GENERAL INFORMATION —CONTENTS— Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling W1-1-1 Group 2 Tightening Torque Tightening Torque Specification Torque Chart. Piping Joint. W1-2-5 192W-1-1(Blank) 192W-1-2GENERAL INFORMATION / Precautions for Disassembling and Assembling a PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING Preparations for Disassembling ‘* Clean the Machine ‘Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to become contaminated during disassembly/assembly, resulting in damage to machine components, as well as decreased efficiency in service work. Inspect the Machine Be sure to thoroughly understand all disassem- blyfassembly procedures beforehand, to help avoid incorrect disassembling of components 2s well as personal injury. Check and record the items listed below to prevent problems from occurring in the future. + The machine model, setial 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 Precautions for Disassembling and Assembling ‘* Precautions for Disassembling + To prevent dirt from entering, cap or plug removed pipes. + Before disassembling, clean the exterior of the ‘components and place on a work bench, * Before disassembling, drain gear oil from the reduction geer. * Be sure to provide appropriate containers for draining fluids. Use matching marks for easier reassembly. Be sure to use the specified special tools, when instructed. + If @ part or component cannot be removed after Temoving 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, * Precautions for Assembling + Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace the 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 after 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 disassemblylassembly. After assembling is ‘complete, count the number of tools, so as to make sure that no tools are missing, W1-1-1GENERAL INFORMATION / Precautions for Disassembling and Assembling Bleeding Air from Hydraulic System When hydraulic oil is drained, the suction fitter or the suction lines are replaced, or the removal and install ation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures: '* Bleeding Air from Hydraulic Pump IMPORTANT: If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result. Be sure to bleed air before starting the engine. + Remove the air bieeding plug from the top of the pump and fil he 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 unt 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, fil the motor case with hydraulic oll * Bleeding Air from Hydraulic Circuit + After refiling 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 intial operation stage). As the pilot oil circult has an air bleed device, air trapped in the pilot cil circuit will be bled while performing the above operation for approx. 5 minutes. Reposition the front attachment to check hydraulic oillevel. * Stop the engine. Recheck hydraulic oil level Replenish oil as necessary, W1-1-2GENERAL INFORMATION / Precautions for Disassembling and Assembling Floating Seal Precautions A 1. In general, replace the fioating seal with a new one when re-assembling, If the floating is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces (2) Check the seal ring face (A) for scuffing, scoring, corrosion, deformation or uneven wear, ‘wosmnacore (3) Check O-ring (B) for tears, breaks, deformation or hardening 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. ees wie bush oramove mid, rstordit. care Ata’ cleaning, Goroaih ay por Wah =, compressed air. Clemens ene eee oreetas fe ane ceay eon SS 2a Shawano 6) Check ha he Ong is ck vst a hat SS is installed correctly on the seal ring, (4) After installing the floating seal, check that seal Incorrect ring surface (A) is parallel with idler face (C) by measuring distances (A) and (C) at point (a) and (b), a8 illustrated. If these distances differ, correct the O-ring seating. W1-1-3GENERAL INFORMATION / Precautions for Disassembling and Assembling (Blank) W1-1-4GENERAL INFORMATION / Tightening _ TIGHTENING TORQUE SPECIFICATIONS Wrench T Descriptions ee Qty, Size 7 —— un) mm | Nem | kgm | ibtft caishion rubber mounting nut vm [4 | 2 774 707 Engine cushion rubber mounting bol 16 | 2 | 24 265 | 27, 795; Engine bracket mounting bolt 70 [7 | 17 49 3 36 Engine bracket mounting nut so | + | 7 49 5 36 Hydraulic oll tank mounting bolt te | 4 | 26 206 Fl 152 Fue! tank mounting bolt 16 [6 | 24 206) 21 152, 7 | 2s) 3 28 2 4 29 ar 93 95 60 UNION fitings for hydraulic hoses and piping nf & oo le 36 7 18130 “1 206; 24 152 Pump mounting bolt 2 [4] 28 @ 65 ‘Control valve mounting bolt 14. 3 22. 437 | 4 701 Control valve bracket mounting bolt 2 [4 | 19 88 2 65 ‘Swing device mounting Bolt 16 10 | 24 206) 21) 182 Battery mounting nut 70 | 4 | 17 20) 2 745) (Cab mounting nut 16 | 4 | 26 20624 152 ‘Swing bearing mounting bolo upperstucture 16 | 22 | 26 285 27 795; ‘Swing bearing mounting bolt to undercarriage 16 | 24 | 26 265 27) 195 Travel device mounting bolt 16 [20 | 24 308 3t 225 Travel motor cover mounting Bots ‘2 [8 | 10 108; 1 20 ‘Sprocket mounting bolt 16 | 24 | 26 265 27 195) Upper roller mounting bat 72) 8 | 19 108; 1 | 80 Lowe roller mounting bolt 14_[ 40 | 22 | 245, 25 180 Track shoe mounting bolt 14 | 296 | 22 245 25) 160 6 10 10 + | 72 ‘Access cover mounting bolt 10 7 49 5 8 12 19 88 9 65 @ | - | 18 | t0at124 | 10510726 | 7.95108-11 Low pressure piping flex waster coupling s |-| 3 29° (03 24 es | - | 10 44 04s 33 Q nore:(1) Apply ubricant (e.g. white zine B dissolved into spindle oil) to bolts and nuts to reduce the friction coefficient of them. (2) Make sure that all bolt and nut threads are clean before installing. (3) Apply Loctite to threads before installing and tightening swing bearing mounting bolts and lower roller mounting bolt. W1-2-1TORQUE CHART Eee work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use only the correct tools. Avoid bodily injury. Bolt Types Tighten nuts or bolts correctly to torque specifications. Four kinds of bolts, hexagon bolts T, H, M and socket bolt, each made of different material, are used. Make sure to use the correct bolts and tighten them to GENERAL INFORMATION / Tightening ‘specification when assembling the machine or ae components Hexagon T Bot Hexagon Holt Hexagon M Bot —_—Socket Bolt tening Torque Chart Bott | Wrench | Me%28°" | T Bolt, Socket bot HBolt M Bott Dia. | Sze | Move” | Nm | kgtm | bet | Nm | kgfm | bth | Nm | kofm | WER w8| 13 6 m5 3 | 195) 2 sl 88) 1 72, Mio] 17 8 6465) 47 | 49 5.36 | 195) 2 145 M12] 19 70 | 4087178088 965 | a4 | 35285 Mia] 22 72 [175,18 130_| 137) _44__t01_| 64 55.40 Mte[ 24 74_| 26527195 | 205) 21452 | 78 858 Mig | 27 1439040290 [205 | 30220 | 7187287 M20 | 30 17| 54065, 400] 360] 40-200 [ 467-17 2253, M22 [32 a7_[7ao_ {751 840_| 540) 55 400 | 215 | 22 189 M24] 36 19 | 93095 690 | 690 70 605 | 27528 205 M27] 41 19 | 4370; 140: 4010 | 1030105 760 | ~390_- 40.290, M30] 46 22 | 1910_|_195 1410 1420/4145 | 1060_[ 540, 55400, M33 [60 24 [2550260 1880 | 1910195 1410 740) 75 540. M36] 55 27__[ 3140; 3201 2310 2400) 245 1770 _[ 930 | 95 | 690, W1-2-2GENERAL INFORMATION / Tightening IMPORTANT: (1) (2) (3) (4) (5) Apply lubricant (j. e. white zinc B dissolved into spindle oil) to nuts and bolts to stabilize their friction coefficients. Torque tolerance is +10 %. Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes in contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force. The torque given in the chart is for general use only. Be sure to use the torque which is given for a specific application. Make sure that the nut and bolt threads are clean before installing. Remove any dirt or corrosion. Bolt Tightening Order ‘When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening, Equally tighten upper Tighten diagonally and lower alternately O © © © @ 3 Tighton from center and diagonally e00hece 0009000 } W1-2-3GENERAL INFORMATION / Tightening ‘Service Recommendations for Split Flange IMPORTANT: (1) Be sure to clean and inspect sealing surfaces. Scratches and rough surfaces can cause leaks and seal wear. Unevenness can cause seal extrusion. If defects cannot be removed, 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) Loosely assemble split flange halves. Make sure that the sj centrally located and Perpendicular to the port. Hand- tighten the bolts to hold the parts in place. Take care not to pinch the O-ring. (4) Tighten bolts altemately and diagonally, as shown, to ensure even tightening. (6) Do not use an air wrench. Using an air wrench often causes tightening of one bolt fully before tighten the others, resulting in damage to O-rings or uneven tightening. Nut and Bolt Lockings ** 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. # Lock Wire IMPORTANT: Apply wire to bolts in the bolt- tightening direction, not in the bolt- loosening direction. RIGHT R Bend along edge sharply pe eotuend ere PCy CY i Bend along edge sharply WRON' 6 Q (oR RIGHT RIGHT ~é RIGHT Loosen ._ WRONG ~ nan’ 3S 4 W1-2-4GENERAL INFORMATION / Tightening PIPING JOINT Pipe Thread Connection / Union Joint Tightening Torque Specifications Union Joint Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to seal pressure cil. Union joints are used to join small-diameter lines. IMPORTANT: (1) Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adaptor (1). Be sure to tighten union nut (3) to 1 4 378 aj ae 30° oF 37° 30° of 37° specifications. Male Union Joint (2) Scratches or other damage to sealing surfaces (4) or (5) will cause oil leaks at the joint. Take care not to damage them when connecting /disconnecting. ae Wrench Size Tightening Torque bus Union Nut Joint Body Nim (kgtm) | _IbFf 30° or 37° 19 19 39(6) «8 Male Union Joint 2 2 98 (10) 2 27 27 118 (12) a7 36 36 235 (24) 134 4 a 295 (30) 215 50 50 490 (50) 360 60 60 670 (68) 490 70 70 980 (100) 720 30° or 37° 19 17 44 (4.5) 2.5 Female Union 2 19 59 (6) 43 Joint 27 22 198 (12) 87 36 30, 32 236 (24) 134 41 36 295 (30) 216 50 46 490 (50), 360 @ NOTE: Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint. Joint Body IE Female Union Joint W1-2-5GENERAL INFORMATION / Tightening O-ring Seal Joint 7 6 8 O-ring (6) seats against the end face of adaptor (7) to seal pressure oil a IMPORTANT: (1) Be sure to replace O-ring (6) with fh ‘a new one when reconnecting. EN U (2) Before tightening union nut (8), confirm that O-ring (6) is seated 8 10 Souaaet correctly in O-ring groove (8). oe Tightening union nut (9) with O- ring (6) displaced will damage Q© | ring (6), resulting in oil leakage. Went Tightening Torque Union Nut | Joint Body | Nem (kgm) | IbFft (3) Take care not to damage O-ring 19 7 59(6) 43 groove (8) or sealing face (10). 2 19 98(10) R Damage to O-ring (6) will cause 27 2 118(12) 87 oil leakage. 36 30,92 | 235(24) 134 (4) If union nut (9) is found loose, as eo 295(30) 218 causing oll leakage, do not 50 46 490(50) 360, tighten it to stop the leak. Instead, replace O-ring (6) with a new one, then tighten union nut (9) aft confirming that O-ring (6) is securely seated in place. W1-2-6GENERAL INFORMATION / htening Screwed-In Connection IMPORTANT: Many types of screwed-in connec- tions are used for hose connections. Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. Seal Tape Application Seal tape is used to seal clearances between male and female threads, to prevent any leakage between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap. * Application Procedure Confirm that the thread surface is clean, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads. Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp. ‘See below for correct tightening torque of each type of low-pressure-hose clamp. T-Bolt Type Band Clamp: 4.4 Nim (0.45 kgfm, 3.25 Ibfft) ‘Worm Gear Type Band Clamp: 6.9 to6.9N-m (0.6 to 0.7 kgfm, 4.3 to 6.1 Ibfft) b Ih Male Tapered Thresé Male Straight Thread ‘Male Tapered Thread Wrench [Tightening Torque Joint Body [Nm (kgfm)| Toft 17,19 | 59(6) a3 19,22 | 98(10) | 72 27,22 | 118(12) 87 36,32 | 235(24) | 134 4 295 (30) 215 50 490 (50) 360 60 | 670(68) | 490 7o___| 980(100) | __720 Internal Thread S External Thread Clearance Leave one to two pitch threads uncovered IT OG Worm Gear Type T-Bolt Type W1-2-7GENERAL INFORMATION / Tighte Connecting Hose A caution: (1) When replacing hoses, be sure to use only genuine Hitachi service parts. Using parts other than genuine Hitachi parts may cause oll leakage, hose rupture or ‘separation of fittings, possibly resulting in damage or fire. (2) Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leakage, hose rupture or separation of fittings. Use the print marks on hoses When installing to prevent kinks. (3) 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 Take care so that hoses do not come in contact with moving parts or sharp edges or objects. WRONG RIGHT WRONG RIGHT Rubbing Against WRONG RIGHT clamp clamp po ‘Rubbing WRONG aE = Rubbing W1-2-8MEMOSECTION 2 UPPERSTRUCTURE —CONTENTS— Group 1 Cab Remove and Install Cab Dimensions of the Cab Glass we-1-1 w2-1-5 Group 2 Counterweight Remove and Install Counterweight... oo W2-2-4 Group 3 Main Frame Remove and Install Main Frame W2-3-4 Group 4 Pump Device Remove and Install Pump Device. ee Disassemble Main Pump. Assemble Main Pump .... Disassemble and Assemble Gear Pump. Maintenance Standard W2-4-18 Group 5 Control Valve Remove and Install Control Valve...... W2-5-1 Disassemble Control Valve ... W2-5-8 Assemble Control Valve Disassemble Blade Control Valve W2-5-28 Assemble Blade Control Valve. W2-5-30 Group 6 Swing Device Remove and Install ‘Swing Device. Disassemble Swing Reduction Gear. Assemble Swing Reduction Gear Disassemble Swing Motor Assemble Swing Motor. Maintenance Standard Group 7 Pilot Valve Remove and Install Pilot Valve Disassemble Right and Left Pilot Valve . ‘Assemble Right and Left Pilot Valve... Disassemble Offset Pilot Valve. Assemble Offset Pilot Valve Group 8 Pilot Shut-Off Valve Remove and Install Pilot Shut-off Valve Disassemble Pilot Shut-off Valve Assemble Pilot Shut-off Valve.. Group 9 Shockless Valve Remove and Install Shockless Valve... Disassemble and Assemble ‘Assemble Shookless Valve. 2-6-1 W2-6-4 W2-6-8 W2-6-12 W2-7-4 W2-7-12 W2-7-14 w2-8-4 2-8-4 ~ W2-8-6 2-9-1 W2-9-4 2.9.6 192W-2-1Group 10 Solenoid Valve Remove and Install Solenoid Valve Unit W2-10-4 Disassemble and Assemble 7-Spool Solenoid Valve Unit... W2-10-4 Disassemble Proportional Solenoid Valve. “ 2-10-68 Assemble Proportional Solenoid Valve. W2-10-6 Group 11 Pilot Relief Valve Unit Remove and Install Pilot Relief Valve Unit W2-11-1 Disassemble and Assemble Pilot Relief Valve Unit.. W2-11-4 Group 12 Swing Mode Control Valve Remove and Install Swing Mode Control Valve. W2-12-1 Disassemble and Assemble Swing Mode Control Valve W2-12-4 192W-2-2UPPERSTRUCTURE / Cab REMOVE AND INSTALL CAB Remove Cab 1, Remove seat-mounting bolts (1) (2 used) to remove the seat. me: 17mm 2. Disconnect connectors (4) (8 used) from controller (2). Disconnect ground wire (3). oe: 13mm 8. Loosen screws (7) (9 used) to remove cover (8), located behind the seat Remove heater controller (5) and fuse box (6). ae: 13mm 4, Attach sling belts to the cab top. a i = = q W2-1-15. Loosen bolts (11) (2 used) to remove footrest (9). Remove cab-mounting bolts (10) (13 used) me: 17mm r—: 8mm BA cauTiON: cab weight: 174 kg (964 1b) 6. Raise and remove cab (12) slowly, using a crane. W2-1-2UPPERSTRUCTURE / Cab Install the Cab AA cauTION: cab weight: 174 kg (384 Ib). 12 1. Attach sling beits to the cab top. Using a crane, lft cab (12) and lower it onto the frame. 2. Install cab-mounting bolts (10) (13 used). Install foot rest (9) with bolts (11) (2 used). 17mm 49 Nem (5 kgfm, 36 IbF ft) 8mm 49 Nem (5 kgfim, 36 Ibf-t) hil 3, Install heater controller (5) and fuse box (6) Install cover (8), located behind the seat, with screws (7) (9 used). ome: 13mm Pome: 20 Nom (2 kgm, 14.5 IbFft) —o 4, Connect connectors (4) (3 used) to controller (2), Connect ground wire (3) onto the floor. me: 13mm Pmt: 20 Nim (2 kgFim, 14.5 IDF) W2-1-3_UPPERSTRUCTURE / Cab 5. Install the seat with bolts (1) (2 used). me: 17mm Poet: 49 Nim (5 kgfim, 36 IbFt) W2-1-4UPPERSTRUCTURE / Cab DIMENSIONS OF THE CAB GLASS. Unit: mm Yoon YL Q@ NOTE: Material: JIS-R3211, R3212 ANSI-AS2 ECE-ANNEXS or equivalent Jee (om) eas Detail A en ‘yee W2-1-5UPPERSTRUCTURE / Cab (Blank) W2-1-6UPPERSTRUCTURE / Counterweight REMOVE AND INSTALL COUNTER- WEIGHT Remove Counterweight 1. Remove four engine cover mounting bolts (1) to remove engine cover (2) me: 17mm ~ Remove battery-cover-mounting bolts (3) (3 used) to remove battery cover (4). ome: 17mm Remove screw (6), located on right-side cover 6). —: 8mm - Remove bolts (8) (2 used), located on right-side cover (6). ame 17 mm W2-2-1UPPERSTRUCTURE / Counterweight 5. Remove bolt (9), located on right-side cover (5). me 17 mm 6. Remove bolts (10) (2 used) to remove right-side cover (5). es 17mm 7. Remove mufflerside-bulkhead-mounting bolts (11) (4 used). me 7mm 8, Remove side-cover-mounting bolts (12) (5 used; total of upper and lower) to remove side cover (13). W2-2-2UPPERSTRUCTURE / Counterweight 9. Remove cover-mounting bolts (15) (2 used) to remove cover (14), located in front of the radiator. ome: 17mm 10. Remove cab-side-cover-mounting bolts (17) (7 used; upper 3 and lower 4) to remove cab-side cover (16). 8mm 11. Attach eye-bolts (18) onto counterweight (19). Attach wire ropes to the eye-bolts. Use a crane to support the counterweight. Ai caution: counterweight weight: 1100 kg (2425 Ib). 20 12, Remove counterweight-mounting bolts (20) (3 used). Using a crane, lif the counterweight slightly, slide it rearward to remove it. —— me: 41 mm W2-2-3UPPERSTRUCTURE / Counterweight Install Counterweight CAUTION: Counterweight weight: 1100 kg (2425 Ib) 1. Install eye-bolts (18) onto counterweight (19). Use wire ropes and a crane to raise and hold the counterweight. Slide the counterweight forward and align the counterweight-mounting holes. Tighten bolts (20) (3 used). =e: 41mm emt: 1370 Nom (140 kgf'm, 1013 IbF-ft) 2. Install cab-side cover (16) with bolts (17) (7 used; upper 3 and lower 4). i: 8mm ant: 64 Nem (6.5 kgm, 47 Ibfft) 3. Install cover (14), located in front of the radiator, with bolts (15) (2 used), ome: 17mm =e: 49 Nm (5 kgFim, 36 loft) 20 W2-2-4UPPERSTRUCTURE / Counterweight 4, Install side cover (13), located at the right side of the main frame, with bolts (12) (5 used; upper 2 and lower 3) ome: 7mm poet: 49 Nem (5 kofim, 36 loft) 5, Install muffler-side bulkhead (21) with bolts (11) (4 used). ame: 17 mm poem: 49 Nim (6 kgf, 36 IDF) 6. Install cover (5), located at the right side of the main frame, with bolts (10) (2 used). (Do not tighten to specification yet) oe: 17mm 7. Install cover (5) with bolt (9). (Do not tighten to specification yet.) ome 7 mm W2-2-5UPPERSTRUCTURE / Counterweight 8 Install bolts (8) (2 used) to cover (6). (Do not tighten to specification yet.) ome: 17mm 9. Install screw (6) to cover (5) iso azan coe Tighten all the bolts in steps 6 to 9, to specification. 8mm P=: 49.Nim (5 kgm, 36 lof) 10. Install battery cover (4) with bolts (3) (3 used). oe 17mm Pmt: 49. Nim (5 kgf, 36 IF) 14. Install engine cover (2) with bolts (1) (4 used). me: 17 mm Po|n: 49 Nim (5 kgm, 36 loft) W2-2-6UPPERSTRUCTURE / Main Frame REMOVE AND INSTALL MAIN FRAME Remove Main Frame 14. Hydraulic fluid under pressure can penetrate the skin or eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting any hydraulic lines. 2. Hydraulic oll becomes hot during operation. Disconnecting hydraulic lines soon after operation can cause severe burns. Wait for the oll and components to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off by remaining pressure if removed. 4, Prevent personal injury. Metal fragments may fly off when a hammer is used to remove pins. Be sure to wear necessary protection, such as goggles, hardhat, etc. 4, Select a firm level surface to park the machine. Fully retract the bucket and arm cylinders, and lower the boom so that the bucket teeth come in contact with the ground. 2. Connect boom cylinder (4) to a crane using a sling belt. While slightly raising boom cylinder (4), remove ring (2), stopper pin (3) and pin (1) -s 3. Place the rod side of boom cylinder (4) on a supporting block. Start the engine. Operate the boom control lever to retract the rod to prevent the rod from extending, fasten it to the cylinder with a wire, as illustrated, Stop the engine. W2-3-1UPPERSTRUCTURE / Main Frame 4, Remove cover (6) by loosing bolt (7). Push air release button (6) to relase the air in the hydraulic oll tank. Then remove cap (8) ome: 17mm 5. Install a vacuum pump (8) in the cap opening on the hydraulic oll tank. Operate the pump to create negative pressure in the tank, @NOTE: Keep the vacuum pump running continuously while removing the front atttachment. 6. Disconnect eight hoses (10) from the front piping on the boom surface. Puta plug on each hose (10) end. Connect boom cylinder (4) to a crane using a sling belt. Position the sling belt in the center of gravity ‘of boom cylinder (4) for balance and stable liting Remove ting, stopper, and pin (11). Remove boom cylinder (4) using the crane, oe: 22mm, 27 mm -s 7. Connect the boom to a crane with sling belts. Slightly raise the boom so that the sling belts are tighit, but with the bucket teeth still the ground. W2-3-2UPPERSTRUCTURE / Main Frame 8. Remove boom-angle-sensor mounting bolt (12), (13). Remove bolts (15), stopper (14), and foot pin, —: 8mm, tomm oe: 24mm 9. Operate the crane to slightly raise the boom. Start the engine. Move the machine in reverse to separate from the boom. Lower the boom to the ground and lay it down. 10. Remove bolts (17) (4 used) to remove engine cover (18) me 17mm 11. Remove cover-mounting bolts (19) (2 used) to remove cover (20), located in front of the radiator, oe 17mm W2-3-3UPPERSTRUCTURE / Main Frame 12. Remove the cab. (Refer to the REMOVE CAB section.) me 17 mm 28mm 1. Remove bolts (21) (4 used) to remove cover (22) located behind the boom. me 17mm 14, Remove the hoses connecting the center joint and control valve at the center joint end, Remove the drain hoses and fittings from the cen- ter joint top. me: 22mm, 27 mm 15, Remove stopper-mounting bolts (23) (2 used) to remove stopper (24) me 17mm W2-3-4UPPERSTRUCTURE / Main Frame 16. Attach a shackle to each top side of the boom- foot-pin-mounting bracket Connect wire rope ends to the shackles. Connect the wire rope to a crane. CAUTION: Upperstructure wei 4000 kg (8820 Ib) 417. Attach eye bolts to the counterweight. Connect wire rope end to the eye bolts. Connect the wire rope to the crane. IMPORTANT: Make matching marks on the mating surface of the swing bearing and frame. wieoaaenor2 48. Remove swing-bearing-mounting bolts (25) (24 used), The center of gravity of upperstructure is con- firmed, and remove it using a crane. me: 24mm W2-3-5UPPERSTRUCTURE / Main Frame Install Main Frame CAUTION: Upperstructure weight: 4000 kg (8820 Ib) 1, Attach wire rope ends to the upperstructure, as il- lustrated. Then, attach the wire rope to a crane. While maintaining the upperstructure balance slowly lift and lower the upperstructure on the un- dercarriage using the crane. Be sure to align the matching marks on the awing bearing and frame. 2. Install_swing-bearing-mounting bolts (22) (24 used). Remove the wire ropes me: 24mm Pmt: 265 Nom (27 kgm, 195 loft) 3. Install stopper (24) using bolts (23) (2 used) me: 17mm an: 49 N-m (5 kgf, 36 bf) W2-3-6UPPERSTRUCTURE / Main Frame 4, Install the hoses connecting the center joint and control valve at the center joint end, Install drain hose (26), fiting (28), blade hose (27), and fitting (29) ame: 22mm oan: 49 Nim (5 kgfim, 36 lbFft) me: 27 mm Pen: 93 Nem (9.5 kgf, 69 IDF) @NOTE: Keep the vacuum pump continuously ‘unning while instaling the hoses. 5. Install cover (22) to the original place located behind the boom, using botts (21) (4 used) ame: 17 mm Pom: 49. Nim (5 kgf, 36 Ibft) A caution: cab weig 2174 kg (384 Ib) 6. Install the cab. (Refer to the INSTALL CAB section.) 217mm + 64 N-m (6.5 kgm, 47 Ibf-tt) 28mm 2 64 Nem (6.5 kgm, 47 IbFt) ni 7. Install cover (20) using bolts (19). oe: 17mm P=: 49 Nim (5 kgm, 36 Ibf ft) W2-3-7UPPERSTRUCTURE / Main Frame 8. Install engine cover (18) with bolts (17) (4 used). ome: 17mm Pmt: 49 Nem (5 kgtim, 36 IDF) 8. Connect boom oylinder (4) to a crane using a sling belt. Position the sling belt in the center of gravity cof boom cylinder (4) for balance and stable lifting. Connect boom cylinder (4) to the boom cylinder bracket using pin (11) Install the ring and stopper pin. me —. 410. Attach a sling belt to the boom. Raise the boom 80 that the boom foot pin hole height is as high as the mounting part on the frame. Start the engine. Slowly drive the base machine forward so that the boom foot comes close to the boom end 11. Align the pin holes on the boom foot and frame. Install the boom foot pin. Install stopper (14) and bolts (15) Install boom-angle-sensor mounting bolt (12), Te 28mm 64 Nim (6.5 kgfim, 47 Ibf ft) Cc cm 10mm oem: 108 (11 kgm, 80 Ibf ft) —_ ro 24mm 205 N-m (21 kgfm, 152 Ibf ft) W2-3-8UPPERSTRUCTURE / Main Frame 12. Connect hoses to the front piping on the boom surface. 22mm 1 49 Nem (5 kgm, 36 Ibf ft) 27mm 1 93.Nem (9.5 kgf, 69 Ibf-ft) Wl 18. Connect boom cylinder (4) to a crane using a sling belt. Raise boom cylinder (4) to align the holes of the cylinder rod and boom bracket, as illustrated. Install pin (1). Install stopper pin (3) and ring (2). — -e Q NOTE: Atter filing hydraulic oll to the specitied level, check hose connections for oil leaks. W2-3-9UPPERSTRUCTURE / Main Frame (Blank) W2-3-10UPPERSTRUCTURE / Pump Device REMOVE AND INSTALL PUMP DEVICE B cawr0on: 1. Hydraulic fluid under pressure can penetrate the skin or eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting any hydraulic lines. 2. Hydraulic oil becomes hot during operation. Disconnecting hydraulic lines soon after operation can cause severe burs. Wait for the oil and components to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off by remaining pressure if removing. Preparation 1. Park the machine on on a solid level surface, Lower the bucket to the ground. 2. Stop the engine. Move all control levers to release any pressure remaining in the system. Push the air release valve on top of the hydraulic oil tank cap to release any remaining pressure. 3, Remove the cap and install vacuum pump to be negative-pressurize the hydraulic oil tank. W2-4-1UPPERSTRUCTURE / Pump Device Remove Pump Device 1. Remove the counterweigt (Refer to the REMOVE COUNTERWEIGHT section.) BA CAUTION: counterweight: 1100 kg (2425 Ib) 2. Loosen bolts (2) (3 used) to remove muffler cover ). oe: 17mm 3. Disconnect all hose ends connected to main pump (8). Remove suction pipe mounting bolts (8) (4 used) to remove the suction pipe =e: 19 mm, 22 mm, 27 mm, 36 mm r: 8mm Bi cauTION: main pump weight: 56 kg (123 Ib) 4. Connect main pump (8) to a crane using a sling belt. With crane, remove slack from the sling belt so that the belt is faut. Remove bolts (10) (4 used). Remove main pump (8) using the crane. me 19mm W2-4-2UPPERSTRUCTURE / Pump Device Install Pump Device 4. Connect pump (8) to a crane. Using the crane, bring pump (8) in to position, Then, secure pump (8) using bolts (10) oe: 19mm P=: 88 Nim (9 kgfim, 65 loft) Connect suction pipe (11) using bolts (9) (4 used) Connect all hoses to main pump (8). 19mm 34 Nem (3.5 kgf-m, 25 Ibtt) 22mm 49 Nem (5 kgm, 36 loft) 27mm 93 Nem (9.5 kgf-m, 69 Ibfft) 36mm 157 Nem (16 kgm, 116 Ibfft) watocanaone 8mm 64 Nem (6.5 kgm, 47 IbF-ft) 6mm 29 Nem (3 kgf, 22 Ibf-ft) HHOUNAU IMPORTANT: Bleed air from main pump. (Refer to W1-1-2) After work, check oil level and for oil leaks. 26mm poe: 29 Nem (3 kgf, 22 IDF ft) 3, Install muffier cover (1) using bolts (2) (3 used) ome: 7 mm P|: 49. Nim (5 kgf, 36 IbFt) W2-4-3UPPERSTRUCTURE / Pump Device 4, Install the counterweight (Refer to the INSTALL COUNTERWEIGHT sec- tion.) me: 41mm Fon: 1370 Nem (140 kgf, 1010 IbFt) CAUTION: Counterweight weight: 1100 kg (2425 Ib) W2-4-4_ UPPERSTRUCTURE / Pump Device (Blank) W2-4-5UPPERSTRUCTURE / Pump Device DISASSEMBLE MAIN PUMP 1 Housing 20- Needle Beating 30 Spring Seat 58- Cover, 2- Plug 21 Spring 40 Spring 59. Packing 3- O-Ring 22- Spoo! 41 Spring 50- Vaive Plate 4- Plug (2 Uses) 23- Socket Bot (2 Used) 42 Shim (3 Used) Bt Pin 5- O-Ring (2 Used) 24. Plug 43- Spring Seat 2- Retainer 6- Seal 2 Used) 25- O-Ring 44- O-Ring 63. Plate T= Stoel Ball (2 Use) 28- Pug 45- Cover 84 Guide B- Guide (2 Used) 27- O-Ring 48- Lock Nut 85- Cylinder 9- Shaft 28- Orifice 47- Adjusting Screw 86 - Pin (2 Used) 10- Ol Seal 29- Retaining Ring 48- Socket Bolt (2 Used) 87 - Socket Bolt (2 Used) 11- Retaining Ring 30- Distance Piece 49 Socket Bolt (2 Used) 68 - O-Ring (2 Used) 12- O-Ring 31- Socket Bot (4 Used) '50- Solenoid {69 - Piston (2 Used) 18 Bearing 32- O-Ring 51 - Socket Bolt (6 Used) 70 Cone Spring (8 Used) 14- Retaining Ring (2 Uses) 33 Taper Bearing (2Used) —-52- O-Ring 71 Shim 418- Washer (2 Used) 34+ Seal Case. 53- Body 72.- Piston (2 Used) 16 - Cylinder Block 35 Hanger 54~ Spool 73+ O-Ring (2 Used) 47 Spring 36- Rod 55 Guide 74: O-Ring (2 Used) 18 - Socket Bok (3 Used) 37 Pin (3 Uses) 58 Spring 75- Cover 19 Socket Bot 2 Used) 38 Plunger (10 Used) 57-- Knock Pin ( Used) W2-4-6UPPERSTRUCTURE / Pump Device Disassemble Main Pump Be sure to thoroughly read all precautions for dis- assemblylassembly work on page W1-1-1 before starting any repair work. 1. Loosen socket bolt (51) to remove body (53) from cover (58). 28mm 2. Loosen socket bolt (48) to remove the gear pump assembly from cover (58) ir: 8mm 8. Loosen socket bolts (18 and 19). Then, tapping cover (58) with a plastic hammer, remove cover (88). ro: 12mm ee IMPORTANT: When removing cover (58), take care to prevent cylinder block (16) from damage by pin (66). Valve plate (60) is attached to the rear of cover (58). Do not drop valve plate (60). 4, Remove packing (58), spring seat (43), shim (42), springs (40 and 41), and spring seat (39) from housing (1) in this order. Remove O-ring (44) from spring seat (43). If pin (66) has dropped into hous- ing (1), take it out. 5. Lay housing (1) down. Remove cylinder block (16), plunger (38), guide (64), retainer (62) and plate (63) as a unit from shatt (9). Q@ NOTE: Three pins (37) may sometimes be left in housing (1). Check that three pins (37) has been removed. Ay caution: when retaining ring (29) is re moved, hold washer (15) using a press. It is very dangerous so that washer (15) and retaining ring (29) may fly out, when only re~ taining ring (29) is removed. 6. Press washer (15). Remove retaining ring (29), washer (15), spring (17) and washer (18) in this order. 10. " Remove retaining ring (11), seal case (34), and ‘O-ring (12) from housing (1). Remove oil seal (10) from seal case (34). = -e . Remove shaft (9) together with bearing (13) from housing (1). Remove retaining ring (14) (2 used) and bearing (13) from shatt (9). 1. Loosen socket bolt (31) to remove cover (75), O- ring (32), distant piece (30), and outer race of taper bearing (33). ‘Tap inner race of taper bearing (33) with a round bar to remove it from hanger (38). — 210mm Remove hanger (35) together with inner race of taper bearing (33) from housing (1). Remove the outer race. W2-4-7UPPERSTRUCTURE / Pump Device W2-4-8UPPERSTRUCTURE / Pump Device 42. Remove valve piate (60) from cover (58). 43. Remove piston (72), shim (71), cone spring (70), and piston (69) from cover (58). Remove pin (68) from cylinder (65) IMPORTANT: Mark each part to identify either right or left side, and keep in order. 14. Loosen socket bolt (67) to remove cylinder (66). Remove O-ring (68) from cylinder (68). @ NOTE: Socket bolt (67) is coated with LOCTITE 8mm 45, Remove plug (4). Loosen seat (6) to remove steel ball (7) and guides (8). Remove O-ring (6) from plug (4). (—: 4mm, 6mm 16. Loosen socket bolt (23) to remove solenoid (50) —: 3mm 17. Remove spool (54), guide (55). spring (56), and ‘O-ring (52) from body (53). 18, Remove plug (24). Then, remove spool (22) and spring (21) from body (53). Remove O-ring (25) from plug (24). rm: 6mm 19. Remove plug (26). Loosen orifice (28), then re- move O-ring (27) from plug (26). i: 3mm, 4mm 20. Remove O-ring (73), (74) from body (53), W2-4-9UPPERSTRUCTURE / Pump Device ASSEMBLE MAIN PUMP 1" 10 34 12p13-14 (18-16-17 748 19-20 24722 723 7 s, [ Ono \ = - a . Te. bh fl ; a tee he 58 a RB tee 29. ma Bout 40- span teres ems ites 3s feet oes ioe com sires eae) moe ere om eee Broa ic ogane caer OEE gece ey eee ees Beet Scott umn Bee moa Zi scaaboraumy Secon ea ua ioaaram gees Ss oats sea eae ie: Soademt umn 3 Feta un Sige faeces 19- Socket Bolt (2 Used) 38 Plunger (10 Used) 57 Knock Pin (2 Used) W2-4-10UPPERSTRUCTURE / Pump Device Assemble Main Pump Before assembling, clean each part with cleaning solvent, and dry with compressed air. Apply a film of hydraulic oil to inner parts and install. Especially, be sure to apply hydraulic oll to sliding surfaces to prevent seizure. Always replace O-rings and oll seals with new ones after disassembly. 1. Install outer race of taper bearing (33) into housing (1). — 2. Install inner race of taper bearing (33) onto hanger (35) — 3. Apply a film of grease to the reverse side of plate (63). Then install plate (63) onto hanger (35). IMPORTANT: The reverse side of plate (63) has no chamfer. 4, Install hanger (35) to housing (1). Install inner race of taper bearing (33) to one side of hanger 38) Ke 5. Install outer race of taper bearing (33), distant piece (30), O-ring (32), and cover (75) into housing (1) —:6mm pam: 28 to 38 Nim (2.9 to 3.9 kgm, 21 to 28 IbFt) 6. Install retaining ring (14), bearing (13), retaining ring (14) on to shaft (9) in this order. Then, instal shaff (9) into housing (1). ere —= 7. Apply grease to O-ring (12), then install it into housing (1). 8. Apply a film of grease around outer diameter of oll seal (10). Using a pushing plate, install i into seal case (34). — 9. After applying a film of grease to lip of cll seal (10), install seal case (34) into housing (1). 10. "1 12, 13, 14, 15, Install retaining ring (11) into housing (1). at Apply grease to three pins (37), and install it into cylinder block (16). Install ten plungers (38) into retainer (62). Apply grease to guide (64), and install into retainer (62). Install washer (15), spring (17), washer (16), and retaining ring (28) into cylinder block (16) in this order. - i Immediately after placing retainer (62) assembly on three pins (37), insert plunger (38) into holes of cylinder block (16). ‘Apply grease to the end face of plunger (38). Lay housing (1) down. Align spline pitch of cylinder block (16) assembly with that of shaft (8). Then install cylinder block (16) assembly into housing (1). Reise housing (1) W2-4-11UPPERSTRUCTURE / Pump Device 38 36: 39 40-41 42/43/44 45-46-4748 66-67-68. 69770, 71 2 72 Dotall:@ 1/ 68-/c0/5958. 53 wsosnoceee Wa2-4-12UPPERSTRUCTURE / Pump Device 16. "7 18, 19, 20. 24 22. 23, 24, Apply grease to spherical bore of spring seat (39) and install it onto rod (38) on hanger (35). Install springs (41 and 40), and three shims (42) to spring seat (39) Install O-ring (44) onto spring seat (43). Install spring seat (43) into cover (58). Install guide (8) into cover (58). Apply grease to steel ball (7) and install it to seat (6) Apply THREE-BOND #1306 to seat (6), and install itinto cover (58). —: 4mm Pam: 9.8 Nem (1.0 kgm, 7 IDFR) Install O-ring (6) onto plug (4), and install it into cover (58). —: 6mm PH=n: 18.5 to 22.5.Nm (1.9 to 2.3 kgf, 14 to 17 IDF) Install two O-rings (68) into cylinder (65). Apply LOCTITE # 270 to socket bolt (67). Install cylinder (65) to cover (58) with socket bolt (67). 8mm P=: 55 to. 69 Nm (8.6 to 7.0 kgf-m, 41 to 64 Ibft) Install piston (68) into cover (58). ‘As shown on the below, install four cone springs (70) and shims (71) onto piston (69). Then, install piston (72) into cover (58). 70. T1758 25. Apply a film of grease to pin (66) and install them into cylinder (65). 26. Apply grease to the cover side surface of valve plate (60), and install it onto cover (58). 27. After installing packing (59) to housing (1), install cover (58) to housing (1) IMPORTANT: Do not drop valve plate (60) and pin (66). 28. Tighten socket bolts (18 and 19), —: 12mm Fmt: 147 10175. Nm (15 to 18 kgm, 108 to 130 Ibf-t) 29. Install the gear pump assembly to cover (58) with socket bolt (48). —: 8mm poem: 55 10.69 Nm (6.6 to 7.0 kof¢m, 41 to 61 Ibf ft) 30. Apply LOCTITE #241 to orifice restriction plate (28) and install it into body (53). 23mm p= 5.1t06.4Nm (0.5 to 0.6 kgf-m, 4 to 4.3 loft) 31. Install O-ring (27) onto plug (26) and install the plug into body (53). i: 4mm Fm 7.41093 Nm (0.8 to 0.9 kgf-m, 6 to 7 lott) W2-4-13UPPERSTRUCTURE / Pump Device Details W2-4-14UPPERSTRUCTURE / Pump Device 32. Install spring (21) and spool (22) into body (53). 33. Install O-ring (25) onto plug (24) and install the plug into body (83). 26mm Pom 18.5 to 22.5 Nm (1.9 to 2.3 kgfm, 14 to 17 IbFft) 34. Install spring (56), spool (54), and guide (55) into body (53) in this order. 23mm P=: 3.40.44 Nim (0.4 to 0.5 kgfm, 3 to 4 Ibf-t) 36, Install body (53) to cover (58) with socket bolt 1), —: 8mm poet: 55 to 69 Nm (8.6 to 7.0 kgf, 41 to 1 IbF ft) W2-4-15.UPPERSTRUCTURE / Pump Device DISASSEMBLE AND ASSEMBLE GEAR PUMP W2-4-16UPPERSTRUCTURE / Pump Device Clean disasser Coupling Bushing O-Ring Frame Pin Ring doint Side Frame Metal Drive Gear Side Frame Guide Casing O-Ring Plate Driven Gear Socket Bolt Socket Bolt Metal Backup Ring Ring Drive Gear Pin Socket Bolt Housing Driven Gear Side Frame O-Ring Frame O-Ring Coupling Socket Bolt Plate the exterior smiling. Parts Name of Flats rm: 8mm 26mm rm: 6mm rm: 8mm the gear pump before Before assembling, clean each part with a cleaning solvent and dry with compressed air. Apply a film of hydraulic oll to inner parts. Especially, be sure to apply hydraulic ol to sliding surfaces to prevent seizure. Aways replace O-rings and oil seals with new ones when reassembling. Width Across Nm 55 10 69 281035 29.0 69.0 Tightening Torque kgtm 5.6 107.0 2.91036 | 30 bf 441051 21 1026 22 W2-4-17UPPERSTRUCTURE / Pump Device MAINTENANCE STANDARDS i -— t ATT} by weeraeosces Main Pump Cylinder Block 1. Clearance between the plunger outer diameter and cylinder block bore. (0d) must be 0.060 mm or less 2. Clearance between the plunger end and shoe surface at clamped section. 5 must be 0.2 mm or less 3. Allowable wear limit of the shaft diameter atthe oil ‘seal mounting section (the shaft shall be free from any scoring or abnormal wear). Re eee al CT I @ Note: 1 mm = 0.03937 Oil seal mounting section W2-4-18UPPERSTRUCTURE / Pump Device 4, Valve Plate The valve plate should be free from abnormal re emma scoring, wear, and seizuring. If the depth of scoring is large, replace with new one. \\ W2-4-19UPPERSTRUCTURE / Pump Device (Blank) W2-4-20UPPERSTRUCTURE / Control Valve REMOVE AND INSTALL CONTROL VALVE BA carrion: 1. Hydraulic fluid under pressure can penetrate the skin or eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting any hydraulic lines. 2. Hydraulic oil become hot during operation. Disconnecting hydraulic lines soon after operation can result in severe burns. Wait for the oil and aomponents to cool before starting any repairwork. 3. The hydraulic oil tank cap may fly off by remaining pressure if removed quickly. Slowly loosen the cap to completely release any remaining pressur Preparation 4. Park the machine on a firm, level surface. Lower the front attachment to the ground with the arm. cylinder fully refracted and the bucket cylinder fully, extended, 2. Stop the engine, Move all contro! levers to release pressure remaining in the system. Push the air release valve on top of the hydraulic oil tank cap to release any remaining pressure. 3. Remove the cap and install vacuum pump to be negative-pressurize the hydraulic oil tank. @NorTE: Be sure to run the vacuum pump continuously while working on the hydraulic systom. W2-5-1UPPERSTRUCTURE / Control Valve Remove Control Valve (For Front, Swing, Travel) 1, Remove four engine cover mounting bolts (1) to remove engine cover (2) me 17mm 2. Remove bolts cover (4). (8) ( used) to remove battery me 17mm 3, Remove screw (7), located on right-side cover (5). —: 8mm 4, Remove bolts (8) (2 used), located on right-side cover (5). me: 17mm W2-5-2UPPERSTRUCTURE / Control Valve 5. Remove bolt (9), located on right-side cover (6). me 17mm 6. Remove bolts (10) (2 used) to remove right-side cover (5) ae: 17mm 7. Remove bolts (12) (5 used; total of upper and lower) to remove right-side cover (11). 8. Drain the hydraulic oil tank. Disconnect all house from control valve (13). Remove pressure switch (14) together with elbow (18). ame: 17 mm, 19 mm, 22 mm, 27 mm, 36 mm W2-5-3UPPERSTRUCTURE / Control Valve 9. Remove bolts (16) (4 used) to disconnect return hose. 28mm A cnt. ib) : Control valve weight: 63 kg (139 10. Remove cotter pin (19) and pin (20) from both travel spools (18) to disconnect the cables. Remove bolts (17) (4 used). Remove control valve (13) using a crane. me: 22mm Remove Blade Control Valve 1. Disconnect all hoses from control valve (21) Remove the control cable cotter pin and the pin to disconnect the control cable. voeneso Remove control valve mounting bolts (22) (4 used). ae: 22 mm, 27 mm 28mm A Install Blade Control Valve 4. Install control valve (21) using bolts (2) (4 used). Connect the control cable using the pin and cotter pin. Connect all house to control valve (21) : 8mm 64 Nem (6.5 kgfm, 47 IbF-) 22mm 49 Nom (Skgf'm, 36 lott) £27 mm £94 Nem (9.5 kgf-m, 69 IDF‘) MUN W2-5-4Install Control Valve (For Front, Swing, Travel) CAUTION: Control valve weight: 63 kg (140 Ib) 4. Connect control vaive (13) to a crane using a sling belt. Using the crane, place control valve (13) in position on the frame. Secure control vaive (13) Using bolts (17) (4 used). Connect the cables to travel spools (18) using pins (20) and cotter pins (19) 22mm o_: 137 Nem (14 kgm, 101 Ibftt) <= 2. Connect return hose (23) using bolts (16) (4 used). 17mm Pom: 34 Nem (3.5 kgm, 25 loft) 3. Connect all houses to control valve (13). Install elbow (15) and pressure switch (14) oe mm Pome: 20 Nem (2 kgf, 14.5 IbFt) oe: 19mm Pome: 34. Nem (3.5 kgfim, 25 lb-ft) ame: 22mm Poa 49 Nem (5 kam, 47 loft) ame: 27mm Pomme: 94 Nim (9.5 kgm, 69 IbF) ame 36mm Poemt: 157 Nem (16 kgtm, 116 Ibt ft) 4, Fill the hydraulic oil tank with oil to the specified level. Remove plug (24) from the pump top, fil the pump housing with hydraulic oil, and then lightly retighten plug (24), Start the engine and run at idle speed to bleed air until oll seeps out from plug (24) ‘Then, stop the engine and retighten plug (24). ‘Also, check hose connections for any oil leaks while the engine is running, —: 6mm P=: 29 Num (3 kgf, 22 Ibf-ft) _UPPERSTRUCTURE / Control Valve W2-5-5UPPERSTRUCTURE / Control Valve 5. Install right-side cover (11), located at the right side of the main frame, with bolts (12) (6 used; ‘upper 2 and lower 3). me 17mm P=: 49 Nim (5 kgfim, 36 Ibf tt) 6. Install right-side cover (5), located at the right side of the main frame, with bolts (10) (2 used). (Do rot tighten to specification yet.) oe: 7mm 7. Install right-side cover (5) with bolt (9). (D0 not tighten to specification yet.) me 17mm 8. Install bolts (8) (2 used) to cover (5). (Do not tighten to specification yet.) ome 7mm W2-5-6___UPPERSTRUCTURE / Control Valve 9. Install screw (7) to cover (5). Tighten all the bolts insteps 6 to 9, specification, —: 8mm p=: 49 Nim (5 kgtm, 36 Ibf-t) 10, Install battery cover (4) with bolts (3) (3 used). me 7mm pomt: 49 Nem (5 kgtm, 36 Ibft) 11. Install engine hood (2) with bolts (1) (4 used). me: 17mm Poa: 49 Nim (5 kgf, 36 Itt) W2-5-7UPPERSTRUCTURE / Control Valve DISASSEMBLE CONTROL VALVE 2—___ | 1 ——I “i 1 a v_ | s——__] w—___| 1+5—____| 13. 12 Detail B " 1+ Housing 14- Spring (2 Used) 2+ Spool 15. Spring Seat (4 Uses) 3- Spool 46- Cap Serew (3 Used) 44> Spool 17 Cap (3 Used) 5 Spool 19- O-Ring (14 Uses) 6- Spool 20- Cep 7+ Spool 21 Spring Seat (14 Used) 8~ Spool 22 Spring (7 Used) 9- Spool 23- Spool End (7 Used) 410- Spool 24- Cap 11 Seal (4 Used) 25- Shutle 42 Wiper (4 Usec) 26- Spring (2 Used) 13- Seal Plate (4 Used) 27 - O-Ring (2 Used) 28 - Plug 2 Used) 29- Shuttle 30- Plug 31 - Poppet 32- Spring 33 - O-Ring (3 Used) 34 Plug (2 Used) 35- Sleave 36 - Poppet 37 Spring 38 - Poppet (@ Used) 39 Spring (3 Used) 40- O-Ring 04 41 Plug (3 Used) 42. Stee! Ball (4 Uses) 43- Poppet 44 Spring 45 - O-Ring (13 Used) 48 Plug 48. Poppet 52- Plug 59- Poppet (6 Used) 54 Spring (6 Used) 55- Plug (6 Used) 56. Plug 57 Sleeve W2-5-8UPPERSTRUCTURE / Control Valve W2-5-9UPPERSTRUCTURE / Control Valve 58 - Poppet 65~ Socket Bot (2 Used) 72 Main Relief Vane 85- Plug (igh Pressure) 59- Spring 66 Screw (4 Used) 73+ O-Ring (5 Used) ‘91 - Poppet (2 Used) 60- Plug 67 - Phig (6 Used) ‘74- Overload Relef Valve 92 Spring (3 Used) (8 Usec) 61- Pg 68- O-Ring 75- Plate 98- Backup Ring ( Used) 62- Sleeve 69. Plig 78 - Screw (4 Used) 94 Cap 163 - Socket Bott (4 Used) 70 Plug (2 Used) (82 Main Relief Valve 95- Cap (Low Pressure) 4- Socket Bolt(18 Used) 71 - Plug (6 Uses) 84 O-Ring W2-5-10__UPPERSTRUCTURE / Control Valve (Blank) W2-5-11UPPERSTRUCTURE / Control Valve Disassemble Control Valve 1+ Housing 10- poo! 20-Cap 30- Plug 2- Spool 11- Seal (4 Used) 21 Spring Seat (14 Used) 63 - Socket Bot (4 Used) 3+ Spool 12+ Wiper (4 Used) 22- Spring (7 Used) 64- Socket Bolt (18 Used) 4 Spool 13- Seal Plate (4 Used) 23- Spool End (7 Used) 685- Socket Bolt (2 Used) 5- Spool 14- Spring 2 Used) 24- Cap 68- Screw (4 Used) 8 Spool 15- Spring Seat (4 Used) 25- Shuttle 67- Plug 7 Spool 16 Cap Screw (3 Used) 28 Spring 94: Cap 8- Spool 17 Cap (3 Used) 27- O-Ring 95- Cap 8- Spool 18+ O-Ring (14 Used) 28- Plug W2-5-12UPPERSTRUCTURE / Control Valve + Be sure to thoroughly read all precautions for disassemblylassembry work on page Wi-1-1 before starting any repair work. 1. Loosen socket bolts (64) and (65) to remove caps (20), (24), (94) and (95) from housing (1). 2. Remove O-ring (19) from cap (20), (24), (94) and (95), —:5mm 3. Remove spool assemblies (3) to (9) from housing (1), 4. Loosen socket bolt (63) to remove cap (17) from housing (1). —: 5mm IMPORTANT: Each spool is made fitted to the original position of the housing. Be sure to put a tag on each spool to identify its original position in the housing. 5, Remove spool assemblies (2) and (10) from housing (1), Disassemble Spool IMPORTANT: As LOCTITE was applied to the threaded part of the spools, be sure to heat the spool/spoo! end part to 200 to 250 °C (392 to 482 °F) before loosening the spool end. Take care not to deform the spool end when loosening. 6. Put spool assemblies (3) to (9) in a vise. Carefully loosen spool end (23) from each spool oe: 13 mm 7. Remove spring seat (21) and spring (22) from the spools. 8. Put spool assemblies (2) and (10) in wooden Plates and put sets (spoolWwooden plates)in a vise IMPORTANT: Be careful of spring (14) load, do not to let cap screw (16) fly off because of spring pressure. 9, Loosen cap screw (16) to remove spring seat (18) and spring (14) from spools (2) and (10). —: 8mm 10. Loosen screw (66) to remove seal plate (13), wiper (12), and seal (11) from housing (1). 14. Remove plug (30) from housing (1). me 22mm Disassemble Switch Valve 42. Loosen plug (28) to remove spring (26) and shuttle (25) from housing (1) Remove O-ring (27) from plug (28) me 27mm W2-5-13UPPERSTRUCTURE / Control Valve 1+ Housing 36- Poppet 45 - O-Ring (13 Used) 62 Sleeve 28 Shute 37-- Spring 46 Plug 67- Plug 2 Spring 38- Poppet 3 Used) 53- Poppet (6 Uses) 88 - O-Ring 27- ORing 39- Spring (3 Uses) 54 - Spring (6 Useo) 69- Plug 28- Plug 40- O-Ring (3 Used) 6 70- Plug (3 Used) 29- Shuttle 41 Plug @ Used) 74 Plug (6 Used) 33- O-Ring (3 Used) 43 - Poppet ‘58 - Poppet 35- Sleeve 44 Spring '59- Spring W2-5-14UPPERSTRUCTURE / Control Valve Disassemble Check Valve 1. Loosen plug (28) to remove spring (26) and shuttle (29) from housing (1). Remove O-ring (27) from plug (28). ome: 27mm 14. Loosen plug (88) to remove spring (54) and poppet (53) from housing (1). lemove O-ring (45) ‘rom plug (55). ome: 7mm 45. Loosen plug (46) to remove spring (44) and poppet (43) from housing (1). Remove O-ring (45) from plug (46). me: 27mm 16. Loosen plug (41) to remove springs (37), (39) and (69), poppets (36), (38), and (58), and sleeves (85), (57), and (62) from housing (1). Remove O- ring (40) from piug (41). me: 27 mm 17. Remove plugs (69), (70), and (71) from housing (1). Remove O-ring (68), (83), (45) from plug (63), (70), (71). ae 19mm ame: 22mm ame: 27mm 18. Do not remove plug (67) unless oil leakage or other defects are found. oe: 24mm me: 32mm W2-5-15UPPERSTRUCTURE / Control Valve = Housing = Plug + Poppet + Spring = O-Ring (Used) 56. 60- ~ Poppet ~ Plug Pug Prog 72- Main Relief Velve (High Pressure) 73- O-Ring (5 Used) 74- Ovetioad Relief Vave (8 Used) 8 ° 92. 98- - Main Relief Valve (Low Pressure) = Poppet (2 Used) Spring (3 Used) Backup Ring (3 Used) W2-5-16UPPERSTRUCTURE / Control Valve 19. Attach M6 bolts to plugs (52), (66), and (61) to remove them from housing (1). 20. Remove O-ring (73) and backup ring (93) from plug (52), (58), (61). 21. Remove spring (92) and poppets (48) and (91) from housing (7). 22. Loosen plug (60) to remove spring (32) and poppet (31) from housing (1). Remove O-ring (33) from plug (60). me: 22mm IMPORTANT: Main relief valves (72) and (82) have pressure settings different from each other. Take necessary measures to insure that they are replaced in their original positions. 23. Remove main relief valves (72) and (82) and overload relief vaive (74) from housing (1) me: 24mm me: 32mm W2-5-17UPPERSTRUCTURE / Control Valve ASSEMBLE CONTROL VALVE 235214 22, 21> 19. 1 19 6 33 34: 33 34. 95 94" 10 12 14 23/1 a 2 26\-25\-28 1+ Housing 8- Spool 11- Seal (4 Uses) 16 - Cap Screw (3 Used) 2- Spool 7- Spool 12- Wiper (4 Used) 17 Cap @ Used) 3+ Spool B= Spool 13- Seal Piate (4 Used) 18- O-Ring (14 Used) 4+ Spool 8- Spool 14 Spring (2 Used) 20- Cap 5+ Spoo! 10 Spool 15- Spring Seat (4 Used) W2-5-18UPPERSTRUCTURE / Control Valve 204 19705 33) 4 3370 19-24-22 p21 23-24 ‘ 3 : = eH 7 ol 16 13: 16 14 1 2 i L tits! Lastsalsoss! Lasledtss i) leo 21- SpingSentt4 Ves) 28- Steg 24. Pug @uteo $8. Pug 6 Use Song ruses a Sram ‘Song (suse 7: Pugl Used) . gpoatatrcey 38 Pug £3: poet Used) ase 2a. ap 33: be 5 Spat Used) ae 2. Shae $8: otha @ Uses W2-5-19UPPERSTRUCTURE / Control Valve Travel 35> 36> 394 41738/40 37 42 42 vinmaeactore n 45 wesocnoscee Boom Arm TA 575839, 74173840 89 74 67. 9192/73/93 86 73 73 67 61 60. i) o1\e2\73\83 33: 74 457 55: 83 N84 32 31/e2/39/ Laiselao7tas 28- Spring 33 O-Ring (3 Used) 40- O-Ring (4 Used) 48- Plug 27- O-Ring 38- Sleeve 41 Plug (3 Used) 48 - Poppet 28- Plug 36 Poppet 42. Stee! Ball 52- Plug 29- Shuttle 37- Spring 43- Poppet 53 - Poppet (6 Used) 30- Poppet 38 Poppet (3 Used) 44. Spring 54 - Spring (6 Used) 31 Spring 39 Spring (3 Used) 45 O-Ring (13 Use) W2-5-20UPPERSTRUCTURE / Control Valve “eye Es a ss f Bucket Offset 52—_____ 42 = 92 — T 74. ss) a GH I 1 4 45/55! \sq\53 as/ 55. ‘Swing 53\84. 755-45 45 = n : 68 ea 69 35 \84 wenn 2. vwonaanasane 98- Plug (6 Used) 61- Plug 71 Plug (6 Usea) 84- Ong 56 Plog &2- Sleeve 72> Main Relit Vane 85- Pig (igh Pressure) 57- Sleeve 67 - Pg (4 Used) 73- O-Ring (6 Used) 91 - Poppet @ Uses) 58. Poppet 68- O-Ring 742 Overload Relat Vale 92 Spring (3 Used) (@Usea) 58 Spring 69. Plug 82. Main Relie Vave 93 - Backup Ring (3 Used) (Cow Pressure) 60- Pug 70- Pig (2 Used) W2-5-21UPPERSTRUCTURE / Control Valve 19. 19-6 aaeieanat “4 ff 7 ie 47, 17 95 63. 40 1s—__| 12 4—_| an 4 | 43 13. pl art laeos\28 13. a1h30\413 1 Housing 11 Seal (4 Uses) 21 Spring Seat (14 Used) 63 - Socket Bolt (4 Uses) 2- Spool 12- Wiper (4 Used) 22- Spring (7 Used) 64~ Socket Bolt (18 Used) 3- Spool 18- Seal Plate (4 Used) 23 Spocl End (7 Used) 185 Socket Bolt (2 Usec) 4 Spool 14 Spring 2 Used) 24--Cap 66- Screw (4 Used) 5+ Spoo! 18- Spring Seat (4 Uses) 25- Shuttle 67- Plug 5- Spool 46 - Cap Screw (2 Used) 28- Spring 947 Cap 7- Spool 17 Cap @ Used) 27- O-Ring 95. Cap 8- Spoo! 19+ O-Ring (14 Used) 28- Plug 8- Spool 20- Cap 20- Plug 10- Spoo! W2-5-22‘Assemble Control Valve Before reassembling, thoroughly clean disassembled parts using cleaning solvent and dry with compressed air. Apply hydraulic oil to the inner parts, especially to the sliding surfaces in order to protect the parts from seizure. Replace all O-rings and seals with new ones. 1. Install spring seat (21) and spring (22) to spool end (23). Apply LOCTITE #271 to the threaded part. 2. Put spools (3) to (9) in wooden plates and put each set (spooliwoaden plates) in a vise to secure it. Install spool end (28) into each spool (3) to (9) ome 13mm p=: 19 t0.22N'm (1.9 to 2.2 kgfm, 14 to 16 IbFft) 3. Put spools (2) and (10) in wooden plates and put each set (spool/wooden plates) in a vise. 4, Install seal (11), wiper (12), and seal plate (13) to spools (2) and (10), as illustrated. 5. Install spring seat (15), spring (14), and spring seat (15) to spools (2) and (10), in that order. Install cap screw (16) to spools (2) and (10) 6mm poet: 1910.22 Nm (1.9 to 2.2 kgf, 14 to 16 lott) IMPORTANT: Be sure that each spool assembly is, replaced in its original position. 6. Install spool assemblies (2) and (10) to housing a). UPPERSTRUCTURE / Control Valve ML Oh Tl W2-5-23UPPERSTRUCTURE / Control Valve Boom 91592) 77379356 Ke a SS : 13 95 410 wieaszosor 12 4 13 0 shy 2 a ~ 205 195 1 iat was * 9 a CT) mi ¥_¢@ i, Ale i 65: “Ne “ : pote NS oop eens “ oe a a Bucket Offset By 73 1+ Housing 19- O-Ring (14 Used) 52- Plug 168- Screw (4 Used) 2- Spool 20- Cap 56 Plug 73 O-Ring (5 Used) 410 Spool 24- Cap 80- Pug 91 - Poppet (2 Used) 11 Seal (4 Used) 31 - Poppet 61 Plug 92 Spring (3 Used) 12- Wiper (4 Used) 32 Spring 63 - Socket Bott (4 Used) 99 Backup Ring (3 Used) 19- Seal Plate (4 Used) 33- O-Ring 64 Socket Bat (18 Used) ——94- Cap. 14: Spring (2 Used) 148 - Poppet {65 - Sockot Bott (2 Used) 95- Cap 17 Cap (3 Usea) W2-5-24UPPERSTRUCTURE / Control Valve 7. Install poppets (48) and (81) and spring (92) to housing (1). 8. Install backup ring (93) and O-ring (73) to plugs (52), (56), and (61). Install the plugs to housing (1), 9. Install O-ring (73) to plugs (56) and (61). 10. Install O-rings (19) to caps (20), (24), (94), and, (95). Install the caps to housing (1) using socket bolts (64) and (65). ome: 5mm Pome 88 to 11 Nm (0.9 to 4.1 kgtm, 7 t0 8 Ibfft) 14. Apply grease to spring (14). Install cap (17) to housing (1) using socket bolt (63). me: 5mm Pan: 88 to 11 Nm (0.9 to 1.1 kgtm, 7 to 8 Ibf ft) 42, Install seal (11), wiper (12), and seal plate (13) to spools (2) and (10). Tighten screw (66). 5 Poet: 25 102.9Nm (0.25 to 0.3 kgf-m, 1.8 to 2.1 Ibft) 418. Install poppet (31) and spring (32) to housing (1), Install O-ring (33) to plug (60). Install the plug to housing (1) ome: 22mm Pom: 49 to 59 Nm (5 to 6 kgfm, 14 to 16 Ibft) W2-5-25UPPERSTRUCTURE / Control Valve Travel eae sere 1, 738 4571 “ 74 Boom am ™ 14 f @ a i eS 40: uu 7. as—“ést \s3\54 wrens aot la\oe wmnceasare Bucket Onset 43. 93-70-46 -45 Swing 45.55 54-53 74, 14 =I mo 68 ala BS ay 3g 69 ye 54 - 33 28 = wososeor 27. 2625 astss 0 vrecssos 4885! L653 imeacsow — wimanesons mance 1 Housing 26- Popeet 45 O-Ring (19 Use) 2. Steve 25- Shute 37. Spring 45- Pug 88 O-Ring 26- Spring 2 Uses) 38 Poppet (9 Uses) 53. Poppet 6 Used) 69 Plog 27 - O-Ring (2 Used) 28 - Plug (2 Used) 29. Shuttle 30- Plug 33- O-Ring (2 Used) 35. Sleeve 39- Spring (3 Used) '54~ Spring (6 Used) 40 - O-Ring (3 Used) 455 - Plug (6 Used) 41 - Plug (3 Used) 57 Sleeve 43. Poppet 58 Poppet 44 Spring 58 Spring 70 Plug (2 Used) 71 - Plug (6 Used) 72 Main Relief Vae (igh Pressure) ‘74 Overload Rekef Valve (8 Use0) 82 Main Relief Valve (Low Pressure) W2-5-2614, 16. 16, 17. 18, 19. 20. 2 22, 23, Install spring (37) and poppet (36) to sleeve (35) Install spring (38) and poppet (38) to sleeve (57) Install spring (59) and poppet (58) to sleeve (62). Install sleeves (35), (57), and (62) into housing (1). Install O-ring (40) into plug (41). Install the plug into housing (1). 27 mm Pan: 78 to 83 Nm (8 to 9 kgf-m, 58 to 65 Ibtt) Install poppets (43) and (53), and springs (44) and (64) into housing (1), Install O-ring (45) to plugs (46) and (65). Install the plugs into housing (1). me: 27 mm Pome: 59 10.69 Nim (6 to 7 kgf, 43 to 51 IbFft Install shuttles (25) and (28), and spring (26) into housing (1). Install O-ring (27) to plug (28). Install the plug into housing (1). me: 27 mm Pom: 59 to 69 Nm (6 to 7 kgfm, 43 to 51 Ibfft) Install plug (30) into housing (1). ee: 22mm Pom 34 to 39. Nem (3.5 to 4 kgfm, 25 to 29 Ibtft) Install O-ring (68) to plug (69). Install the plug into. housing (1). =: 19mm p=: 69 Nm (7 kgm, 51 lbFt) Install O-ring (33) to plug (70). Install the plug into housing (1). 22mm, Pome: 49 t0 59 Nim (5 to 6 kgtm, 36 to 43 Ibfft) UPPERSTRUCTURE / Control Valve 24, Install O-ring (45) to plug (71). Install the plug into housing (1). ome: 27 mm Poet 5910 69 N-m (6 to7 kgm, 43 to 51 IF) IMPORTANT: Main Relief valve is installed in the ‘same position before removing. 25. Install main relief vaive assemblies (72) and (82). 224mm Pat: 49 to 59. Nm (5 t0 5.5 kgf-m, 36 to 40 Ibftt) IMPORTANT: Overload Relief valve is installed in the same position before removing. 26. install overload relief valve assembly (74) into housing (1). ame: 32mm PomE: 78 to 88 Nm {8 to 9 kgf'm, 58 to 65 Ib) IMPORTANT: Be sure that the main relief valve assemblies and overload relief valve assembly are replaced in their al positions. W2-5-27UPPERSTRUCTURE / Control Valve DISASSEMBLE BLADE CONTROL VALVE A716 718 16. a 1+ Spool Head 9- Cap 17- Wiper (2 Used) 24. Socket Bot (4 Used) 2- Overload Relet Valve 10 - Socket Bolt (2 Used) 18- O-Ring (2 Used) 25- O-Ring (2 Uses) (2Useq) 3+ Body #4 11 Spring Seat (2 Used) 19- Spoo! 26 - Spring Seat (2 Used) 4 Boay #3 12- Spring 2 Used) 20- Spring 27 - Spool 5. Main Relief Vave 13- Check Valve (2Used) 21 - Cap Screw 28- Spring 8 Nut (@ Used) 14- O-Ring 2 Used) 22 Body #2 23. Cap Te Bogy #1 15- Screw (2 Used) 23- Cap 30- Cap Screw B= Bolt (3 Used) 16 - Seal Pate (2 Used) W2-5-28UPPERSTRUCTURE | Control Valve Disassemble Blade Control Valve + Be sure to thoroughly read all precautions for disassemblyjassembry work on page W1-1-1 before starting any repair work. 4. Loosen socket bolt (10) and (24) to remove cap (®), (23), (28), from body #2 (22) and body #3 (4). 24mm 2, Remove spool assembly (19) from body #3 (4) Be sure to remove seal plate (16), wiper (17), and (O-ring (18) together with spool (19). 3, Remove spool assembly (27) from body #2 (22). 4, Loosen screw (15) to remove seal plate (16), wiper (17), and O-ring (18) from body #3 (4). a 5, Remove O-ring (25) from body #2 (22). 8, Remove overload relief valve (2) from body #3 (4) Remove main relief valve (6) from body #1 (7). ae: 24mm 7. Put spool assembly (19) in wooden plates and put the set (spool/wooden plates) in a vise. 8. Loosen spool head (1) and cap screw (21) to remove spring seat (11), spring (20), wiper (17), and O-ring (18) from spool assembly (19). fr: 5mm 9. Put spool assembly (27) in wooden plates and put the set (spoolwooden plate) in a vise Q@ NOTE: Be careful of spring (20) load, do not to let cap screw (21) fly off because of spring pressure. 10. Loosen cap screw (30) to remove spring seat (26) and spring (28) from spool assembly (27). 5mm 11. Loosen nut (6) to separate body #1 (7), body #3 (4), body #4 (3) and body #2 (22). Remove spring (12), check valve (13), and O-ring (14) from body #2 (22) and body #3 (4). me 12mm W2-5-29UPPERSTRUCTURE / Control Valve ASSEMBLE BLADE CONTROL VALVE 2 A716 18 rT) 18 17 20 a 4 1 Spool Head 8- Cap 17- Wiper (2 Used) 24 Socket Bol (4 Used) 2 Overicad Relief Valve 10 Socket Bol (2 Used) 18 O-Ring (2 Used) 25- O-Ring (2 Used) (2 Used) 3+ Body #4 11- Spring Seat @ Used) 19- Spool 28 - Spring Seat 2 Used) 4 Body #3 42- Spring 2 Used) 20- Spring 27 - Spool 5- Main Relief Vaio 13- Check Valve (Used) 21- Cap Screw 28- Spring 5- Nut(6 Uses) 14. O-Ring (2 Used) 22- Body #2 29- Cap 7- Body #1 418+ Screw (2 Used) 23 Cap 30- Cap Screw B- Bot (3 Used) 16 - Seal Plate (2 Used) W2-5-30Assemble Blade Control Valve 1. Install spring (12), check valve (13), and O-ing (14) to body #2 (22). ‘Assemble body #1 (7), body #3 (4), body #4 (3) and body #2 (22) using bolt (8) and nut (6). 12mm 18.5 N.m (1.9 kgfm, 14 IbFft) _— rm Put spool (19) in wooden plates and put the set (spoolwooden plates) in a vise. Install O-ring (18), wiper (17), seal plate (16) to spool (19). Apply LOCTITE #242 to the threaded part of spool (19). . Install spring seat (11), spring (20), spring seat (11) to spool (19), in that order. Install cap screw (21) to spool (19). . Put spool assembly (27) in wooden plates and put the set (spoolwooden plates) in the vise. Apply LOCTITE #242 to the threaded part of spool (27). Install spring seat (26), spring (28), spring seat (26) to spool (27), in that order. Install cap screw (30) to spool (27) 5mm Pome: 5.2 107.4 Nm (0.53 to 0.75 kgm, 4 to 5 Ibf) . Apply LOCTITE #242 to spool! head (1). Install the spool head (1) to spool (19). pom: 69N-m (7 kgm, 51 bE) Insert spool assembly (19) into body #3 (4). Install cap (9) using socket bolt (10) 4mm PSU: 7.25 to 10 Nm (0.74 to 1.02 kgfm, 5 to 7 IbF-ft) UPPERSTRUCTURE / Control Valve 10. Insert spool assembly (27) into body #2 (22). In- stall O-ring (25) to cap (23) and install cap (23) us~ ing socket bolt (24), 4mm Pome 7.25 to 10 Nem (0.74 to 1.02 kam, 5 to 7 tof) 11. Install O-ring (18), wiper (17), seal plate (16) to body #3 (4) and tighten screw (15). 5 poet: 2.5102.9Nm (0.26 to 0.3 kgf'm, 2 to 2.2 Ib) 42. Install O-ring (28) to cap (29) and install cap (29) to body #2 (22) using socket bolt (24), 4mm =U: 7.25 to 10m (0.74 to 1.02 kgf-m, 5 to 7 Ibft) 13. Vise blade control valve in wooden plates and in- stall overioad relief valve (2) to body #4 (3). me: 24mm P-=4: 49 to 59 Nem (5 to 6 kgf'm, 36 to 43 IbF ft) 414, Install main relief valve (5) to body #1 (7). me: 24mm Pom: 49 to 59 Nem (5 to 6 kof, 36 to 43 IbF ft) W2-5-31UPPERSTRUCTURE | Control Valve (Blank) W2-5-32UPPERSTRUCTURE / Swing De REMOVE AND INSTALL SWING DEVICE CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid this hazard by relieving pr Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting work. Preparation 1. Park the machine on a firm, level surface. Lower the front attachment to the ground with the arm cylinder fully reftracted and the bucket cylinder fully extended. 2. Stop the engine. Move all control levers to release pressure remaining in the system. Push the air release valve on top of the hydraulic oil tank cap to release any remaining pressure. 3. Remove hydraulic oil tank cap. Connect a vacuum pump to maintain negative pressure in the hydraulic oll tank. Q@NOTE: Be sure to mun the vacuum pump continuously while working. W2-6-1UPPERSTRUCTURE / Swing Device Remove Swing Device 1. Loosen four socket bolts (2) to remove cover (1). me: 10mm 2. Disconnect all hoses from the swing motor. ae: 17 mm, 22 mm, 36 mm Ay caution: swing device weight: 93 kg (205 Ib) 3. Remove mounting bolts (3) (10 used). Attach a sling belt to the swing device. Using a crane, remove the swing device. ome: 24mm W2-6-2UPPERSTRUCTURE / Swing Device Install Swing Device CAUTION: Swing device weight: 93 kg (205 Ib) 1. Attach a sling belt to the swing device. Using a crane, place the swing device in position on the frame. Tighten bolts (3) to secure the swing de- vice. me: 24mm P=: 265 Nem (27 kgf-m, 195 Ibftt) 2. Connect all hoses. 17mm £20 Nem (2 kgf, 15 Ibft) 222mm 2-49 Nem (5 kgm, 36 loft) 36mm 187 Nem (16 kgf, 116 Ibft) HAT 8, Install cover (1) in position above the swing device using bolts (2) (4 used) mes 7mm Pome: 49 Nm (6 kgtm, 36 Ibe) W2-6-3UPPERSTRUCTURE / Swing Device DISASSEMBLE SWING REDUCTION GEAR 1 Swing Motor 10- Thrust Pate (6 Used) 19- Bearing 28- Shaft 2- First Stage Sun Gear ‘11+ Second Stage Planetary 20 Retaining Ring 29- Sleeve Gear (3 Used) 3- Thrust Plate 12- Piping 21 Ring Gear 30- O-Ring 4 Pin @ Used) 18- Drain Piping 22- Balt (16 Used) 31- Ol Seal 3 Spring Pin (6 Used) 14- Drain Plug 23- Second Stage Carer 32 Cover 8- Thust Plate (6 Used) 18 Housing 24- Thrust Plate 33- O-Ring 7 Needle Bearing (3 Used) 16 - Washer (10 Used) 25~ Second Stage Sun Gear 34 Beating 8- First Stage Planetary Gear 17- Bok (10 Used) 26. First Stage Carter 38 - Socket Bolt (8 Used) (Used) 9- Pin(3 Used) 18- O-Ring 27-- Bol (8 Used) W2-6-4UPPERSTRUCTURE / Swing Device Disassemble Swing Reduction Gear Before disassembling, thoroughly real Precautions for NOTE: Extract cover (32) by inserting @ screw Disassembling and Assembling, (W1-1-1) driver arounding outer circumstance of housing (15). 4. Drain gear oil Remove drain plug (14) to drain gear oil, 8, Remove shaft (28) from housing (15) using a Disconnect drain pipe (13) press. co: 8mm 9. Remove oil seal (31) from cover (32). me: 27mm @ NOTE: Be sure to replace oil seal (31) with new one when reassembling Ay caution: ‘swing motor weight: 27 kg (60 Ib) 2, Remove socket bolts (35). Install wire to swing motor (1), and sling it with a crane to remove swing motor (1), 28mm @ NOTE: Be sure to put alignment marks on swing ‘motor (1) and ring gear (21) for reference when assembling 3. Remove first stage sun gear (2) from ring gear 20). Remove first stage carrier (26) assembly 4, Remove second stage sun gear (25) from ring gear (21). Remove second stage carrier (23) assembly. 5. Loosen sixteen socket bolts (22) and remove ring gear (21) from housing (15). ome: 19mm @ NOTE: Be sure to put alignment marks on ring gear (21) and housing (18) fo aid in assem- bling. 6. Remove O-ring (18) from housing (15). Remove retaining ring (20) from shaft (28). <= 7. Overturn housing (15) and loosen bolts (27). Re- move cover (32). Then, remove O-ring (33) from housing (15) me 7mm W2-6-5UPPERSTRUCTURE / Swing Device _ W2-6-6UPPERSTRUCTURE / Swing Device 40. Tum shaft (28) upside down, Using @ press, remove bearing (24) and sleeve (28) from shaft (28) 11. Remove O-ring (30) from sleeve (28). 412, Remove bearing (19) from housing (16). Bearing (19) can be removed with your hand. If bearing (19) cannot be removed with your hand, tu housing (15) upside down, and then lightly tap bearing (19) using a punch and a hammer to remove bearing. 13, Push spring pin (6) out from first stage carrier (26) using special tool (ST 1388) and a hammer. Special Tool: ST 1388 (Dia. 5.0 mm, L: 50 mm or longer) — 14. Remove pin (4), first stage planetary gear (8), and thrust plates (6) and (3) from first stage carrier (28), @ NOTE: Put identification marks on pin (4) and first stage carrier (26). 415. Push spring pin (5) out from second stage carrier (23) using special tool (ST 1388) and a hammer. Special Took ST 1388 (Dia. 6.0 mm, L: 60 mm or longer) @ NOTE: Be sure to make matching marks on the ‘mating surface of pin (9) and second stage carrier (23) to aid in reassembly. 16. Remove pin (9), second stage planetary gear (11), and thrust plates (10) and (24) from second stage carrier (23), W2-6-7UPPERSTRUCTURE / Swing Device ASSEMBLE SWING REDUCTION GEAR 1 Swing Motor 10- Thrust Plate (6 Used) 19- Bearing 28- Shaft 2. First Stage Sun Gear 411 Second Stage Planetary 20 Retaining Ring 20- Sleeve Gear (3 Used) 3- Thrust Plate 12+ Pipe 21 Ring Gear 20- O-Ring 4 Pin G Used) 13- Drain Pipe 22 Bolt (16 Used) 31- Oil Seal 5 Spring Pin (6 Used) 14: Drain Plug 23- Second Stage Carrier 32 Cover 8- Thrust Plate (6 Used) 18- Housing 24- Thrust Plate 33- O-Ring 7+ Needle Bearing (3 Used) 16- Washer (10 Used) 25- Second Stage Sun Gear 34 Beating 8- First Stage Planetary Gear 17- Bolt (10 Used) 26- First Stage Carior 38 - Socket Bot (8 Used) (Used) 9- Pin @ Used) 18- O-Ring 27 - Bok (8 Used) W2-6-8UPPERSTRUCTURE / Swing Device Assemble Swing Reduction Gear IMPORTANT: Be sure that the grooved side of thrust plate (3) faces upward, as shown. 1. Insert needle bearing (7) into first stage planetary gear (8) Insert thrust plate (3) into first stage carrier (26). 2. Insert first stage planetary gear (8) and thrust plate (6) into first stage carrier (26). Insert spring pin (5) while aligning spring pin holes on pin (4) and on first stage carrier (26). IMPORTANT: Be sure that the slit of spring pin (5) faces upward, as illustrated. 3. Drive spring pin (5) through first stage carrier (26) and pin (4) into the spring pin hole using a ham- mer. | 4 sit IMPORTANT: Be sure that the grooved side of thrust plate (24) faces upward. 4. Insert thrust plate (24) into second stage carrier (23). IMPORTANT: Be sure that the grooved side of thrust plate (10) faces planetary gear ends. 5. Insert second stage planetary gear (11) and thrust plates (10) into second stage carrier (23). IMPORTANT: Be sure that the slit of spring pin (5) faces upward, as illustrated. 6. Insert pin (9) while aligning spring pin holes on pin (8) and on second stage carrier (23). Drive spring pin (5) through second stage carrier (23) and pin (@) into the spring pin hole using @ hammer. -— sit 7. Apply a film of grease to O-ring (30) lp. Install O-ring (30) to sleeve (28) IMPORTANT: Be sure that the grooved side of sleeve (29) faces upward, 8, Insert sleeve (28) and bearing (34) onto shaft (28) using a press. 9, Sling housing (15) and insert it onto shaft (28). 40. Overtum housing (15) and press bearing (19) into housing (15) using a press. 411, Install retaining ring (20) in the groove on shaft (28). <= 12, Apply a film of grease to oll seal (31) lip. Apply liquid packing (Threebond #1215) to oik ‘seal-mating surface of cover (32). Install oil seal (31) to cover (32) W2-6-9UPPERSTRUCTURE / Swing Device W2-6-10UPPERSTRUCTURE / Swing Device 43. Install O-ring (33) to housing (18). 44, Install cover (32) to housing (15). Tighten bolts (27). ome 17mm Foam: 49 Nem (5 kgfim, 36 lbf-ft) 45, Tum housing (15) upside down. Install O-ring (18) to housing (15). 16. Attach eye bolts (M10, Pitch 1.5) on ring gear (21). Using a crane, lft ring gear (21) and install it into housing (15) with bolts (22) IMPORTANT: Be sure to align the matching marks. me: 19mm Poe: 8B Nem (9 kgfim, 65 loft) 17. Install second stage carrier assembly (23) to Storter-Gear-Tooth housing (15). aI IMPORTANT: Install the shorter-gear-tooth end of, second stage sun gear (25). a, | 418. Install second stage sun gear (25) Install first stage carrier (26) assembly. IMPORTANT: Install the having a circular protru- sion of first stage sun gear (2) downward, 19, Install first stage sun gear (2). 20. Tighten drain plug (14) to drain pipe (13). Install ” drain pipe (13) to housing (15). cheutar Protea 8mm 49 Nem (5 kgm, 36 IDF) 27mm 49 Nem (5 kgf, 36 Ibfft) nh 24. Install pipe (12) 22. Fill the reduction gear with gear oil to the middle of the first planetary gear tooth wic Required Gear Oil Quantity: 1.8 L 23, Install swing motor (1) on the swing reduction gears with socket bolts (35). —:8mm pant: 64 Nem (6.5 kgf-m, 47 It) Q NOTE: Check oil level with @ level gauge and add oll if necessary. W2-6-11UPPERSTRUCTURE / Swing Device DISASSEMBLE SWING MOTOR 1 Friction Piste (@ Used) «9 Oil Seat 17- O-Ring 25- Retainer 2- Thrust Pate 10- Retaining Ring 18- Ring 26 - Puunger Assembly 9 Used) 3° Shaft 11- Retaining Ring 19- O-Ring 27-- Spring (18 Used) 4 Bearing 12- Inner Race 20- O-Ring 28- Socket Bok (4 Used) 5 Socket bot (2 Used) 13- Dise Pate (3 Usec) 21- Cylinder block 29- Brake Vawe Assembly 8 Parking Brake Switch Valve 14- O-Ring 22- Sea 230- Knock Pin (2 Used) 7+ O-Ring (2 Used) 18+ Valve Plate 28- Disc Spring 8- Housing 18. Piston 24- Guide W2-6-12UPPERSTRUCTURE / Swing Device Disassemble Swing Motor 1. Remove the motor assembly using a crane, Make matching mark on the mating surfaces of brake valve assembly (29) and housing (8). Loosen socket bolts (5) and (28) to remove brake valve assembly (29) and parking brake switch valve (6). 5mm, 22mm 2. Remove brake valve assembly (29). Remove valve plate (18) from brake valve as- sembly (29). @ NOTE: Take care not to drop valve plate (15) when removing brake vaive assembly (29) 3. Remove spring (27) and O-ring (7) (14). 4. Remove piston (16) from housing (8) using socket bott. Puller: Socket bolt (M 6, Pitch, 1.0 Length 40) 5. Remove ring (18) from the housing (8). Remove O-rings (19) and (20) from ring (18). 6. Lay housing (8) on its side. Remove cylinder block (21) and its relevant parts shown below. Cylinder Block (21) Plunger Assembly (26) Retainer (26) Guide (24) Disc Spring (23) Seat (22) Friction Piate (1) Disc Piate (13) 7. Remove thrust plate (2) from housing (8) 8. Tap shaft (3) from the reduction gear side using a plastic hammer to remove it from housing (8). Remove retaining ring (11) from shaft (3) _ <= 9, Push out bearing (4) and inner race (12) from shaft (3) using a pressing tool (ST 1401). 40. Tum housing (8) upside down, remove retaining ring (10) from housing (8). <= IMPORTANT: Be sure to replace oil seal (9) with a new one when reassembling. 11, Remove oil seal (9) from housing (8) using special tool (ST 1402) and a hammer. W2-6-13UPPERSTRUCTURE / Swing Device Disassemble Parking Brake Switch Valve 1 2) 73-4 75 ° fl, Joy uk 1+ Vee 4 Once 6- Plug 8- Spring 2. Fier 5: O-Ring 7+ Ofiice 8- Housing 3 Washer IMPORTANT: Be sure not to clamp the motor side of housing (8). S 6 41. Clamp housing (9) in a vise. Remove plug (6), spring (8), valve (1) from hous- e— 0 ing (9) 28mm g IMPORTANT: When clamping valve (1) in a vise, take care not to scratch or deform the sliding surface, 2. Clamp valve (1) in a vise. Loosen orifice (7) to remove orifice (7), orifice (4), washer (3), and fiter (2) fr: 3mm W2-6-14UPPERSTRUCTURE / Swing Device Disassembly Brake Valve 1 Overload Relief Vale == 5- Bearing Used) 2- Cover 6 Spring Pin 3 Parking Brake Switch VaWe 7 Knock Pin (2 Used) 4 Swing Motor 8- Plug @ Used) 1, Remove bearing (5) from cover (2). Toot: Puller + Disassemble make-up valve 2. Remove plug (8), spring (10) and poppet (11). eote | 27 mm 9 O-Ring 2 Uses) 12 Socket Bott (¢ Used) 13+ Plug (2 Used) 410 Spring (2 Used) " 14 O-Ring (2 Used) + Poppet (2 Used) W2-6-15UPPERSTRUCTURE / Swi + Disassemble Overload Relief Valve zat 23 22 2aitao\i9 lisa7, 16 15/14 1+ Adjust Screw 7- Spring 13- Seat 19 Backup Ring 2 Lock Nut 8- Piston 14 O-Ring 20- O-Ring 3. Pg 9- Piston Guide 15- Backup Ring 21 - Backup Ring 42 Spring Guide 10- Spring Seat 48- Backup Ring 22- O-Ring 5 Backup Ring 11 Poppet 17- O-Ring 23- O-Ring 6 ORing 12 Housing 18- Spring 24 Backup Ring IMPORTANT: When housing (12) is hard to pull out, wrap a piece of soft cloth around it and remove it using a pair of pliers. 3 Take care not to damage the housing and other parts. 4, Remove plug (3) to remove piston (8), springs (7) and (18), piston guide (9), and housing (12). bpided dee W2-6-16__UPPERSTRUCTURE / Swing Device 2. Hold plug (3) with a vise. Measure and record the height of adjust screw (1) from plug (3). IMPORTANT: Do not disassemble if not necessary. wioaccasor? 3. Loosen lock nut (2) Remove adjust screw (1) —: 6mm ame: 19mm 4. Remove spring guide (4) from plug (3). Remove 3 4 O-ring (23) and backup ring (24) from spring guide (4) 2d las W2-6-17UPPERSTRUCTURE / Swing Device ASSEMBLE SWING MOTOR 15. 29 30 ar 14 16 a7 18 20 13 26 25 1+ Friction Plate Used) 8- OS 17- O-Ring 25. Retainer 2- Thrust Plate 40- Retaining Ring 18- Ring 28 - Plunger (9 Used) 3: Shaft 11 Retaining Ring 18- O-Ring 27 - Spring (18 Used) 4 Boaring 12- Inner Race 20- O-Ring 28 - Socket Bolt (4 Used) 5 Socket bol (2 Used) 13- Disc Plate (3 Used) 21 = Cylinder block 29- Brake Valve Assembly 8+ Parking Brake Switch Vae 14 O-Ring 22- Seat 30 Knock Pin (2 Used) T+ O-Ring (2 Used) 18- Valve Pate 23- Dise Spring B- Housing 46- Piston 24 Guide W2-6-18UPPERSTRUCTURE / Swing Device Assemble Swing Motor Before assembling wash all parts with solvent. Thor- oughly dry with compressed air and apply clean hy- draulic Be sure replace O-ring, cil seals and needle bearings with new ones when the assembling, 1. Apply a film of grease to oil seal (9) lip and hous ing (8) groove. Insert oil seal (9) to housing (8) using special too! (ST 2616) and a press. e ST 2516 2. Install retaining ring (10) to housing (8). a 3. Apply LOCTITE #572 to inside of inner race (12). Press shaft (3) in bearing (4) and inner race (12) using special tool (ST 2615). Install retaining ring (11), = IMPORTANT: Be sure that surface treated side of thrust plate (2) face upwards. IMPORTANT: Before installing thrust plate (2), be ‘sure to apply grease to the non- ‘Surface treated side in order to pre- vent thrust plate (2) from coming off when housing (8) is laid on its side. 4, Install shaft (3) and thrust plate (2) into housing (8). 5. Install seat (22), disc spring (23) and guide (24) into cylinder block (21), IMPORTANT: Be sure to align notched parts of plates (13). The notches must be aligned for lubrication purposes. 6. Install disc plates (13) (3 Used) and friction plates, (1) (2 Used) alternately to cylinder block (24), IMPORTANT: Note that retainer (25) has two sides. 7. Insert plungers (26) into retainer (25) holes. Apply lubricating oil to cylinder block (21) holes before inserting the plungers. Install them to cylinder block (21). W2-6-19UPPERSTRUCTURE / Swing Device W2-6-20UPPERSTRUCTURE / Swing Device 8. Lay housing (8) on its side. Install cylinder block (21) assembly onto shaft (3). IMPORTANT: After installing cylinder block (21), ‘set housing (8) upright and confirm that the rotary group is installed in position. Approximately 3 to § mm (0.42 100.2 In u < Housing rotor 9. Install last friction plate (1) IMPORTANT: Be sure to use a press to install ri (18). Do not attempt to use a plastic hammer or the like to install ring (18). It may cause disc plate (13) to come off as cylinder block (21) rattles. 410. Install O-ring (19) and (20) to ring (18). Install ring (18) into housing (8) using special tool (ST 2617) and a press. 11, Install O-ring (17) to piston (16). Install piston (16) into housing (8) using special tool (ST 2617) and a press. 12. Install spring (27) and O-ring (7), (14) into housing (8). 13. Apply grease to valve plate (16). Then, Install it to brake valve assembly (28). Install knock pin (30) to housing (8). Install brake valve assembly (28) to housing (8).. @ NOTE: When installing brake valve assembly (29), take care not to drop valve plate (15). 44. Install parking brake switch valve (6) to motor housing (8). Tighten socket bolts (5) and (28) 5mm 9.8 N-m (1 kgtm, 7 Ibfft) 12mm 177 Nem (18 kgim, 130 IbFf) hh Parking Brake Switch Valve Mounting Surtace 16. ST 2617 W2-6-21UPPERSTRUCTURE / Swing Device Assemble Parking Brake Switch Valve 1 Housing > Washer 6- O-Ring 8- Oriice 2- ave 5. Pug 7 Spring 9 Orie 3: Fier W2-6-22UPPERSTRUCTURE | Swing Device IMPORTANT: Take care not to apply too much LOCTITE to oritice (8). It may cause the orifice to become clogged. When clamping valve (2) in a vise, take care not to scratch or deform the sliding surface. 41. Clamp valve (2) in a vise. Install filter (3), washer (4), and orifice (9) into valve (2). Apply LOCTITE #572 to orifice (8) and tighten it into valve (2). i: 3mm P=: 9.8 Nem (1 kgm, 7 Ibtt) IMPORTANT: Be sure not to clamp the motor si of housing (1). 2, Clamp housing (1) in a vise. Install valve (2) and spring (7) into housing (1). Install O-ring (6) to plug (6). Tighten plug (5) into housing (1). 8mm =e: 64 Nim (6.5 kgtm, 47 Ibfm) W2-6-23UPPERSTRUCTURE / Swing Device Assemble Brake Valve 1+ Overload Relist Vave —5-_ Bearing 8- O-Ring (2 Used) 12- Socket Bott (4 Used) (2 Uses) 2- Cover 6- Spring Pin 10 Spring 2 Used) 13- Plug (2 Uses) 3 Parking Brake Switch Vee 7 Knock Pin (2 Used) 11 Poppat (2 Used) 14- O-Ring (2 Used) 42 Swing Motor 8- Plug (2 Usea) W2-6-24UPPERSTRUCTURE / Swing Device + Assemble make-up valve 1, Install spring (10) to poppet (11) and insert them into cover (2). 2. Attach O-ring (9) to plug (8) and install them into cover (2). Tighten plug (6). Install opposite side of make-up valve as same. ake = 27 mm pom: 157 Nem (16 kgm, 116 Ibe) 3. Install bearing (5) into cover (2) using special too! (ST 2618) and a press. Install spring pin (6) to cover (2). IMPORTANT: Be sure that the slit part or spring pin (6) faces the circumference of cover (2). — W2-6-25UPPERSTRUCTURE / Swing Device + Assemble Overload Relief Valve 1 O-Ring 8 Spring Seat 18- Backup Ring 21- O-Ring 2- Backup Ring 8 Spring 18- ORing 22- Backup Ring 3 Seat 10- Piston Guide 17 Backup Ring 23- Piston 4 Poppet 41- Spring 18- O-Ring 28 Backup Ring 3 Backup Ring 12 Lock Nut 18- Spring Guide 25- O-Ring 8- O-Ring 413- Adjust Screw 20- Backup Ring 26 - Backup Ring 7 Housing 14 Plug W2-6-26__UPPERSTRUCTURE / Swing Device 41. Install O-ring (18) and backup ring (17) to spring guide (19). Install spring guide (19) assembly into plug (14). 2. Install adjust screw (13) and lock nut (12) onto plug (14) Be sure to adjust the height “to the dimension measured when disassembling the overload relief valve. Tighten lock nut (12) 6mm ome: 19mm pram: 39 Nim (4 kgfim, 29 IbF ft) 3, Install O-ring (16) and backup ring (15) to plug (14). Install O-ring (21) and backup rings (20) and (22) onto the outer surface of piston (23), Install O-ring (25) and backup rings (24) and (26) to the inner surface of piston (23) Install O-ring (6) and backup ring (5) to housing (7) Install O-ring (1) and backup ring (2) to seat (3). 4. Install housing (7), piston guide (10), spring (9) and (11), piston (23), and plug (14) to the cover. eke: 32mm ant: 275 Nem (28 kgfm, 208 IbF ft) 43 14 4 14) 18/167 21723 ‘ fl T1241 a ~ W2-6-27UPPERSTRUCTURE ! Swing Device MAINTENANCE STANDARD ‘Swing Motor 1. The clearance between the plunger diameter (d) and the rotor bore diameter (D) Dd ‘Standard Allowable Limit mm) in mm in 0.015 | 0.0006 | 0.04 | 0.0016 Plunger Assembly 1a’ yinder sack | 2. Plunger and shoe clearance Ba shoe Standard ‘Allowable Limit mm in mm in 0015 | 0.0006 | 004 | 0.0016 Plunger Overload Relief Valve The clearance between the piston diameter and the piston guide bore diameter D-d ty Standard Allowable Limit : a | mm in mm in | 0.015 | 0.0006 | 004 | 0.0016 Piston Piston Guide W2-6-28UPPERSTRUCTURE / Swing Device Parking Brake Change Valve Housing and valve clearance D4 ‘Standard Allowable Limit mm in mm in 0.01 | 0.0006 | 004 | 0.0016 \ Housing ra) \ Vane W2-6-29UPPERSTRUCTURE / Swing Device (Blank) W2-6-30UPPERSTRUCTURE / Pilot Valve REMOVE AND INSTALL PILOT VALVE Ad cauTioN: Escaping fiuid under pressure can penetrate the skin, causing serious in- jury. Avoid this hazard by relieving pressure be- fore disconnecting hydraulic or other lines. Hydraulic oif may be hot after operation. Hot hydraulic oil may spout, possibly causing se- vere burns. Be sure to wait for oil to cool be- fore starting any repair work. The hydraulic oil tank cap may fly off by re- maining pressure if removed quickly. Slowly loosen the cap to completely release any re- maining pressure. Preparation 1. Park the machine on a firm, level surface. Lower the front attachment to the ground with the arm cylinder fully retracted and the bucket cylinder fully extended. 2. Stop the engine. Move all control levers to release pressure remaining in the system. Push the air re- ease valve on top of the hydraulic oil tank cap to release any remaining pressure. 3. Remove hydraulic oil tank cap. Connect a vacuum pump to maintain negative pressure in the hydrau- lic oll tank, @ NOTE: Be sure to run the vacuum pump continu- ously while working. Removal 1. Remove four screws (2) to remove cover (1). — 2. Remove rubber cap (3), located on panel (4). Remove three screws (5) to remove panel (4). se W2-7-1UPPERSTRUCTURE / Pilot Valve 3. Disconnect wire connectors (6). Cut clips (9) (2 used) to remove them from the cable. Loosen lock nut (8) to remove lever (7). * ae: 22mm Remove Right Pilot Valve 5. Remove bolts (11) (6 used) to remove cover (10). ee 13mm, 17 mm. 6. Remove switch-panel-mounting bolts (13) (2 used) from the bottom of switch panel (12) me: 17mm W2-7-2UPPERSTRUCTURE / Pilot Valve 7. Remove lever-stand-mounting bolt (14) =: 19mm Remove Left Pilot Valve 8. Pull the control shut-off lever to raise the lever stand, Remove mounting bolt (16). oe: 19mm 9. Disconnect all pilot hoses from the pilot valve. —: 19mm Q NOTE: Pug each hose end. Put @ ia indicating hose connection port on aah hose 10. Remove pilot vaive mounting bolts (16) (4 used), Pull on the bottom of pilot valve (17) to remove it. ae: 13mm W2-7-3UPPERSTRUCTURE / Pilot Valve Install Pilot Valve (For Swing, Arm, Boom and Bucket Functions) 1. Install pilot valve (17) in position on the lever stand, them tighten bolts (16) to secure it. me: 13mm Poet: 19.5 Nem (2 kgtim, 14.5 IbF tt) 2, Connect all pilot hoses. ome: 19mm Pam: 20.5 Nem (3 kgfim, 22 lb-ft) @ NOTE: Fill the hydraulic oll tank with hydraulic oil to the specified level. Run the engine at idle. Check pilot hose connections for any oil leakage. 3. Install lever stand (18) using bolt (15). ome: 19mm PO=X: 88 Nim (9 kgm, 65 lot) Install Right Pilot Valve 4, Install switch panel (12) using bolts (13) (2 used). me: 17mm Poa: 49. Nim (5 kgm, 36 IbF*t) 2 W2-7-4UPPERSTRUCTURE / Pilot Valve 6. Install cover (10) using bolts (11) (6 used). ome 13mm Pmt 19.5 Nem (2 kgtim, 14.5 bff) 17mm Poe: 49 Nem (5 kgfim, 36 IbF ft) 6. Install lever (7) to pilot valve (17). Tighten lock nut ®), Attach clips (9) (2 used) to secure the cable. ame 22mm pam 137 Nem (14 kgf, 101 IDE) 7. Securely connect wire connectors (6). 8, Install panel (4) using screw (5) (3 used). 3 Install rubber cap (3). —o 4 8 W2-7-5UPPERSTRUCTURE / Pilot Valve 8. Install cover (1) using screw (2) (4 used). Set boot in position, —o W2-7-6UPPERSTRUCTURE / Pilot Valve Remove Offset Pilot Valve 1. Remove side-cover-mounting bolts (2) (top side: 3 used), bottom side: 4 used) to remove side cover (1) from the side of the cab. —: 8mm 2. Remove cab-front-side-cover-mounting bolts (3) (top side: 2 used, bottom side:2 used) to remove the cab-front-side cover. ome: 17mm 8mm 3, Disconnect all hoses from pilot vaive (4) 19mm @ NOTE: Place a cap on each hose end. Attach a tag to each hose identifying the part of the pilot valve from which the hose was discon- nected to aid in reassembly. 4, Remove cover (5). oon W2-7-7UPPERSTRUCTURE / Pilot Valve 5. Remove bolt (6) and boot (7). Remove bolts (8) and pilot valve (4). 8mm W2-7-8UPPERSTRUCTURE / Pilot Valve Install Offset Pilot Valve 4. Install pilot valve (4) and tighten bolts (8). Install boot (7), then install pedal (10) and tighten bolt (6). oe: 8mm Pom: 49 Nim (6 kgfim, 36 Ib ft) 2, Connect all hoses to pilot valve (4). ome: 19mm Poem: 29.5 Nim (2 kgfim, 14.5 toFft) me: 2mm pam: 39 Nem (4 kgfim, 29 Ibi) @ NOTE: After connecting the hoses, fil the hydraulic oil tank with oil to correct level. Start the engine and check the hoses for leakage. 3. Install the cab-front-side cover using bolts (3) (4 used). 17mm 49 Nom (5 kgf-m, 36 Ibft) 8mm 64 Nim (6.5 kgf, 47 Ibf-ft) nil 4. Install cab-left-side cover (1) using bolts (2) (top side: 3 used, bottom side: 4 used) —: 8mm poen: 64 Nim (6.5 kgf, 47 IbFft) W2-7-9UPPERSTRUCTURE / Pilot Valve 5. Install cover (5) on the pedal W2-7-10UPPERSTRUCTURE / Pilot Valve __ (Blank) W2-7-11UPPERSTRUCTURE / Pilot Valve DISASSEMBLE RIGHT AND LEFT PILOT VALVE 1+ Screw Joint 8- Pusher (2 Used) 2: Cam 9 Spring Guide A (2 Used) 3 Universal Joint 10- Spring Guide B (2 Used) 4 Plate 11 Pusher B (2 Used) ~ Balance Spring A (2 Used) 5- Oil Seal (4 Used) 12 Bushing B (2 Used) 18: Piston (4 Used) ~ Retum Spring B (2 Used) 8 O-Ring (4 Uses) 13 Socket Bot 419- Spool (4 Used) ~ Balance Spring B (2 Used) 7 Bushing A @ Used) W2-7-12UPPERSTRUCTURE / Pilot Valve _ Disassemble Right and Left Pilot Valve + Be sure to thoroughly read “Precautions for Dis- assembly and Assembly" on page W1-1-1 before starting the disassembly work. + As casing (17) and spools (19) are precision parts specially made to fit each other, they must be re- placed as a set. Do not attempt to replace these parts individually + Note that return spring A (22) and balance spring ‘A (23), which are used in ports 1 and 3, differ from retum spring B (24) and balance spring B (25), Which are used in ports 2 and 4, respectively + For this reason, be sure to indicate the port num- ber from which it is removed. Port numbers are stamped on casing (17). 4. Remove screw joint (1) and cam (2) seme: 19 mm, 32mm, 2. Temporarily tighten plate (4) using two bolts (MB Pitch 1.25). Loosen universal joint (3) to remove it from casing (17). 3. Turn over casing (17) and place it in a vice. Re- move socket bolt (13). —: 10mm 4, Pull out plate (14) using a pulling bolt (M16 Pitch 2). Remove O-ring (16) from the plate. Remove seal washer (16) from casing (17). 5. Remove piston (18) from spool (19) in each port, (Four pistons in total) 6. Tum over casing (17). Attach special tool (ST 7824) to the universal joint connecting hole. Tighten plate (4) using the special tool 7. Remove the bolts (2 used) temporarily installed in the step 2. Gradually loosen the special tool until pushers A (8), B (11) and plate (4) are fully raised, unloading spring compression. 8. Remove plate (4) and pushers A (8), B (11) from casing (17). 9, Remove pusher A (8), O-ring (6), and oil seal (5) from each bushing A (7). Remove pusher B (11) (O-ring (6), and oil seal (5) from each bushing B (12). 40. Remove spools (19) (4 used) from casing (17). ‘11. Compress balance spring A (23) or B (25) to re- move spacer (20) from each spool (19). Remove balance spring A (23) or B (25), shim (21), spring guide A (8) or B (10), and return spring A (22) or B (24) from each spool! (2). W2-7-13UPPERSTRUCTURE / Pilot Valve ASSEMBLE RIGHT AND LEFT PILOT VALVE 1 2 3 " 8 jO) 5 <—_—_——_7 8 to, Th Hub 23 = [UA pte | 24 f P 18 13 \a M16 \1s 1 Ser Jot 8 Pusner A @ Used) 14. Plate 20- Spacer (4 Used) 2° cam 9° Spin Gude A(2 Uses) 15. O-Ring 21- Sh @0 Uses) 3. Univers! Joint {0--Sping Gude B(2 Used) 16 Seal Washer 22 Return Spring A @ Used) 4 Plate 41- Pisher (2 Used) 47. Casag 23. Balance Snng A 2 Used) 52 Of Seal Uses) {2-BishngB@Used) 18. Piston 4 Used) 24: Retum Spring 8 @ Used) = ORing (4 Uses) 192 Soekel Bot 419: Spocl Use) 25. Balance Sing 8 (2 Used) 7 Bushing A (2 Used) W2-7-14UPPERSTRUCTURE / Pilot Valve Assemble Pilot Valve for Front Attachment 1. Insert special tool (ST 7098) into each port on cas- ing (17) with the smaller end facing casing (17) IMPORTANT: The number of shims (21) are de- cided through performance testing. Be careful not to lose the shims. In- stall spacer (20) with the stepped face toward the balance spring. 2. Install shims (21), and balance spring A (23) or B (25) to spool (19). While compressing balance spring A (23) or B (25), install spacer (20) in the position between spool (19) and balance spring A. (23) or B (25) IMPORTANT: Install spring guide A (8) or B (10) with the stepped face toward the re- turn spring. 3. Install spring guide A (9) or B (10) and retum spring A (22) or B (24) onto spool (19). IMPORTANT: Install the spool in the same port where the spool was previously lo- cated. 4, Install spool (19) into casing (17) 5. Install oil seals (5) and O-rings (6) to bushings A (7) and B (12). Insert pushers A (8) and B (11) into bushings A (7) and B (12). Oil seal pusher: ST 2292 6. Place the pusher assembly on the spool assem- bly. 7. Install plate (4) on bushings A (7) and B (12). In- stall special tool (ST 7924) to the universal joint ‘mounting hole on casing (17). 8. Slowly tighten special tool (ST 7924) until the bot- tom faces of bushings A (7) and B (12) are flush with the top face of casing (17). Then, remove special tools (ST 7099) from casing (17) pors. Tighten special tool (ST 7924) until plate (4) ‘comes in contact with the top face of casing (17). 9. Using bolts (M8, pitch 1.25), temporarily tighten plate (4). Remove special tool (ST 7924), ST 7924, W2-7-15UPPERSTRUCTURE / Pilot Valve 1 2 3. a 5: 6 7 ‘Screw Joint cam Unwversal Joint Plate il Seal (4 Used) ‘O-Ring (4 Used) Bushing A (2 Used) 8- Pusher A (2 Used) 8- Spring Guide A (2 Used) 410- Spring Guide 8 2 Used) 11 Pusher B (2 Used) 12- Bushing B (2 Used) 13- Socket Bott 13 \4g 16 14- Plate 18- O-Ring 16- Seal Washer 47 Casing 18. Piston (4 Used) 19 Spool (4 Uses) 20- Spacer (4 Used) 21 Shim (20 Used) 22 Retum Spring A (2 Used) 23- Balance Spring A 2 Used) 24 Return Spring B (2 Used) 25. Balance Spring B (2 Used) W2-7-16_UPPERSTRUCTURE / Pilot Valve 10. Insert piston (18) into spool (19) with the smaller end facing the pusher. 11, Install O-ring to casing (17) and O-ring (15) to plate (14). 12. Secure plate (14) to casing (17) with socket bolt (13). Tm: 10mm FOU: 49 Nom (5 kgf, 36 IDF) 13. Apply LOCTITE #262 to universal joint (3). Turn casing (17) over and install universal joint (3) into casing (17). me: 7mm Poem: 24.5 Nem (2.5 kgm, 18 bt) 14, Apply grease sufficiently in the clearance at the atticulation of universal joint (3). Coat the top faces of pushers A (8) and B (11) with grease. 15. Install cam (2) to universal joint (3) 16. Adjust the clearance between pushers A (8) and cam (2) or pushers B (11) and cam (2) to 0 to 0.2 mm. Then, tighten screw joint (1). Remove tem- porarily Used bolts (2 Used). Thickness Gauge ame: 17 mm, 32mm PSE: 69 to 88 Nim (7 to 9 kgfm, 51 10.65 br) W2-7-17UPPERSTRUCTURE / Pilot Valve DISASSEMBLE OFFSET PILOT VALVE 4+ Dust Seal (2 Uses) 7+ Spring Guide (2 Used) ——13- Casing 18 Lock Nut (2 Used) 2+ Bushing (2 Used) 8- Return Spring 2Used) 14 Bushing (2 Used) 18- Set Scrow (2 Used) il Seal (2 Used) 8 Balance Spring (2 Used) 18- Pin 20- Cam O-Ring (2 Uses) 10+ Spacer (2 Used) 21 Set Screw Pusher (2 Used) 11 Shim (2 Used) 22 Boot 6+ Washer (4 Used) 12+ Spool (2 Used) W2-7-18UPPERSTRUCTURE / Pilot Valve Disassemble Offset Pilot Valve 1. Clamp the pilot valve in a vise. Loosen set screw (21) and remove pin (15). Remove cam (20) as- sembly from plate (16) 23mm mem: 8mm or less — IMPORTANT: Record the positions, related to cas- ing (13), of the disassembled parts. Slowly remove socket bolts (17) and plate (16) as pusher (5) assemblies may fly out by the force of return springs (8). 2. Alternately loosen and remove socket bolts (17). Remove plate (16) and pusher (5) assemblies from casing (13). 6mm 3. After removing pusher (5) assemblies, remove O- ring (4), pusher (5), oil seal (3) and dust seal (1) from each bushing (2). IMPORTANT: In order to avoid mixing them up, be sure to indicate the port number from which each disassembled part came, 4, Remove spool (12) assemblies and return spring (8) from casing (13) 5. Compress balance spring (9) to remove washer (6) and spring guide (7) from spool (12). Remove spacer (10) and shims (11) from spool (12) Disassemble the other spools (12) in the same manner. IMPORTANT: Do not disassemble set screws (19), unless replacement is required, as neutral adjustment is necessary when reassembling them. 6. Clamp cam (20) assembly in a vise. Remove lock nuts (18) and set screws (19) from cam (20) as- sembly, ome: 7mm 25mm W2-7-19UPPERSTRUCTURE / Pilot Valve ASSEMBLE OFFSET PILOT VALVE 1 Dust Seal (2 Uses) 7+ Spring Guide (2Used) —13- Casing 18 Lock Nut (2 Used) 2+ Bushing (2 Used) 8 Retum Spring 2 Used) 14 Bushing (2 Used) 19- Set Screw (@ Used) 3+ OllSeal (2 Used) 9~ Balance Spring (@ Used) 18- Pin 20-Cam 4- O-Ring (2 Used) 10- Spacer (2 Used) 16- Pate 21- Set Screw 5- Pusher (2 Used) 411 Shim (2 Usea) 17 Socket Bolt (2 Used) 22- Boot 8 Washer (4 Used) 12 Spool (2 Uses) W2-7-20UPPERSTRUCTURE / Assemble Offset Pilot Valve Clean all disassembled parts with cleaning Solvent. In order to avoid mixing them up, arrange them by port number. After disassembling, always replace used O- rings, oll seals and dust seals with new ones. IMPORTANT: Install washer (6) with its sharp edge side facing away from balance spring (9). Do not compress balance spring (9) with spring guide (7) more than 4 mm (0.157 in) when installing spring guide (7). One face of spring guide (7) is the spring seat. Be sure to install spring guide (7) with the spring seat side facing spring (9). 4. Install shims (11), spacer (10) and balance spring (@) on spool (12). Compress balance spring (9), and install spring guide (7) and washer (6) be- tween spool (12) and balance spring (9) IMPORTANT: Be sure to confirm the port number before inserting each spool (12) as- sembly, to be sure that the spool as- sembly Is inserted into its correct port. 2. Insert return springs (8) and spool (12) assem- blies into casing (13) IMPORTANT: Install oil seal (3) and dust seal (1) in their correct directions. Apply grease to the lips of oil seal (3) and dust seal (1), and to the inside of bushing (2). 8, Install oil seal (3), dust seal (1) and O-ring (4) on bushing (2). Insert pusher (5) into bushing (2). Use one of the following greases: *Apollol Autorex C (Idemitsu) *Ocean 7 (Nihon Ore Louve) *Screw Bar L60 (NOK) 4, Place pusher (5) assemblies onto each spoo! (12) assembly. Install plate (16) and alternately tighten two socket bolts (17) I: 6mm pom: 2943 Nim (8,040.3 kgtim, 2242 Ibttt) 5, Install set screws (19) on cam (20) and temporar- ily tighten lock nuts (18). Install cam (20) on plate (16) and insert pin (18), —: 5mm 6. Apply LOCTITE #241 to set screw (21) and install it into cam (20) —: 3mm Nm (0.740.1 kgtm, 540.7 Ibf-ft) 7. Adjust set screws (19) so that the clearabce be- tween pushers (6) and set screws (19) is 0 mm, then tighten lock nuts (18). ame: 17mm 25mm poet: 83:3 Nm (8.420.4 kgt-m, 2523 Ibft) 8. Tilt cam (20) and apply grease to pusher (5) as- semblies. 9. Install boot (22) on plate (16). W2-7-21UPPERSTRUCTURE / Pilot Valve (Blank) W2-7-22_UPPERSTRUCTURE / Pilot Shut-Off Valve REMOVE AND INSTALL PILOT SHUT-OFF VALVE Ay caution: Escaping fluid under pressure can penetrate the skin, causing serious in- jury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibly causing se- vere burns. Be sure to wait for oll to cool be- fore starting any repair work. The hydraulic oil tank cap may fly off by re- maining pressure if removed quickly. Slowly loosen the cap to completely release any re- maining pressure. Preparation 1. Park the machine on a firm, level surface. Lower the front attachment to the ground with the arm cylinder fully retracted and the bucket cylinder fully extended 2. Stop the engine. Move all control levers to release pressure remaining in the system. Push the air re- lease valve on top of the hydraulic ol tank cap to release any remaining pressure 3. Remove hydraulic oll tank cap. Connect a vacuum pump to maintain negative pressure in the hydrau- lic oll tank, @ NOTE: Be sure to run the vacuum pump continu- ously while working, Removal 1. Remove side-cover-mounting bolts (2) (top side: 3 Used, bottom side: 4 used) to remove side cover (1) from the side of the cab, —: 8mm W2-8-12. UPPERSTRUCTURE / Pilot Shut-Off Valve Remove control-cable mounting socket bolt (4). Disconnect all hoses from pilot shut-off vaive (3). Remove socket bolts (5) (2 used) to remove pilot shut-off vaive (3). me: 22mm f—: 5mm, 8mm @ NOTE: Puta plug on each hose end. Attach an identification tag to each hose. Sie Cover 5- Socket Bot (2 used) Bot 6- Hose SP (10 7-Spool Solenoid Valve) Pilot Shut-Off Valve 7 Hose OP (To Offset Pct Vale) ‘Socket Bolt 8 Hose Ps R (To Boom and Bucket Pls Vaive) e. 10- Me 12 Hose Tt (To Hydraulic Tank) Hose PA (From Plot Pump) Hose OT (From Offset Plot Valve) Hose Ts L (From Swing ‘and Arm Pilot Valve) 19+ Hose Ta L (From Boom and Bucket Pilot Valve) 14 Hose TH (From 7-Spo0! Solenoid Vane) 18- Cable 16 Hose PL (From Swing and ‘Aim Plot Valve) W2-8-2UPPERSTRUCTURE / Pilot Shut-Off Valve Installation 1. Install pilot shut-off valve (3) using bolt (6). Con- rect all hoses to pilot shut-off valve (3), and con- ect the control cable using bolt (4). ame: 22mm poem: 49 Nem (5 kgfim, 36 IDFR) 25mm Pome: 20 Nem (2 kgfim, 15 Ib) rm: 8mm Pome: 64 Nem (6.5 kot, 47 IbFft) @ NOTE: Fill the hydraulic oil tank with hydrauloc oil to the specified level Run the engine at idle. Check hose connec- tions for any oil leaks. 2. Install side cover (1) to the side of the cab using bolts (2) (top side: 3 used), bottom side: 4 used) 8mm Po=H: 64 Nom (6.5 kgfm, 47 Ib) W2-8-3UPPERSTRUCTURE / Pilot Shut-Off Valve DISASSEMBLE PILOT SHUT-OFF VALVE 10. 1 Retaining Ring 5- O-Ring 8- Spring Pin 12- Socket Bott 2- Washer 8- Backup Ring 40- Lever 13- Stee! Bal 3 Backup Ring 7 Washer 11 Spoo! 14- Body 42 O-Ring 8- Retaining Ring W2-8-4UPPERSTRUCTURE / jot Shut-Off Valve Disassemble Pilot Shut-Off Valve + Be sure to thoroughly read all the precautions for disassembling and assembling wrk, on page W1- 4-1 before starting any repair work, 4. Remove retaining ring (1) and washer (2) and pull ‘out spool (11) 2. Pull out spring pin (9) trom spool (11), and remove lever (10). @ NOTE: Put matching marks on spoo! (11) and lever (0) 3. Remove washer (7) and retaining ring (8) from ‘spool (11). 4, Remove backup ring (3), (6) and O-ring (4), (6) from body (14). W2-8-5UPPERSTRUCTURE / Pilot Shut-Off Valve ASSEMBLE PILOT SHUT-OFF VALVE \W PAZ por 2 1+ Retaining Ring 5+ O-Ring 8 Spring Pin 12- Socket Bolt 2 Washer 8- Backup Ring 10- Lever 13- Steel Sal 3- Backup Ring 7 Washer 11 Spool 14- Body 4 ORing 8 Retaining Ring W2-8-6UPPERSTRUCTURE / Pilot Shut-Off Valve Assemble Pilot Shut-Off Valve IMPORTANT: Apply a film of grease to O-ring (5) and backup ring (6). 4. Install O-ring (8), backup ring (6), washer (7), and retaining ring (8) to body (14) 2. With matching marks on spool (11) and lever (10) aligned, drive spring pin (9) in spool (11) and lever (10). IMPORTANT: Apply a film of hydraulic oil to spool (11). 3. Install spool (11) to body (14). IMPORTANT: Apply a film of grease to O-ring (4) and backup ring (3). 4, Install O-ring (4), backup ring (4), and washer (2) to body (14). Install retaining ring (1) to spool (11), W2-8-7UPPERSTRUCTURE / Pilot Shut-Off Valve (Blank) W2-8-8UPPERSTRUCTURE / Shockless Valve REMOVE AND INSTALL SHOCKLESS VALVE BA caution: Escaping ftuid under pressure can penetrate the skin, causing serious in- jury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other Hydraulic oil may be hot after operation, Hot hydraulic oil may spout, possibly causing se- vere burns, Be sure to wait for oil to cool be- fore starting any repair work. ‘The hydraulic oll tank cap may fly off by re- maining pressure if removed quickly. Slowly loosen the cap to completely release any re- maining pressure. Preparation 1. Park the machine on a firm, level surface. Lower the front attachment to the ground with the arm cylinder fully retracted and the bucket cylinder fully extended. 2. Stop the engine. Move all control levers to release pressure remaining in the system. Push the air re- lease valve on top of the hydraulic oil tank cap to release any remaining pressure 3. Remove hydraulic oll tank cap. Connect a vacuum pump to maintain negative pressure in the hydrau- fic oll tank, Q@NOTE: Be sure to run the vacuum pump continu- ously while working. Remove Shockless Valve 1. Remove side-cover-mounting bolts (2) (top side: 3 used, bottom side: 4 used) to remove side cover (1) from the side of the cab. —:8mm IMPORTANT: Attach a identification tag to each hose. 2. Remove all hoses from the shockless valve. Remove bolts (3) (2 used) to remove shockless valve (4). oe: 17 mm, 22 mm ‘W2-9-1UPPERSTRUCTURE / Shockless Valve Install shockless Valve 1. Install shockless valve (4) and tighten bolts (3). Connect all hoses to shockless valve (4), ome: 7mm P=: 49 Nim (6 kgm, 36 Ibtt) ae: 22mm Po=t 98 Nim (10 kgfm, 72 tht) @ NOTE: Fill the hydraulic oll tank with hydrautic ol to the specified level. Run the engine at idle. Check hose conneo- tions for any oil leaks. cy 2, Install side cover (1) using bolts (2) (top side: 3 used, bottom side: 4 used). 17mm pra: 49. Nem (6 kgtim, 36 Ibft) W2-9-2UPPERSTRUCTURE / Shockless Valve (Blank) W2-9-3UPPERSTRUCTURE / Shockless Valve DISASSEMBLE SHOCKLESS VALVE + Plug (SUsed) + O-Ring (19 Used) ~ Spring (6 Used) + Stoo! Ball (5 Used) + Plunger (4 Used) Spool (4 Used) Spring (4 Used) 10- " 12- 13 4 + Plug (4 Used) 15- Plug (8 Used) ‘Spring (4 Used) 16+ Body Plunger (4 Used) 17 Phunger + Guide (4 Used) 48- Spring (O-Ring 4 Used) 19- O-Ring (2 Used) Nipple (4 Used) 20- Nipple Spool (¢ Used) Ring ter Element 23- Distance Piece 24 Plug 25 Spool (4 Used) 28 - Spring (4 Used) W2-9-4UPPERSTRUCTURE / Shockless Valve Disassemble Shockless Valve Before disassembling throughly read Precautions for Disassemble and assembly (W1-1-1) 1, Remove nipple (13) from body (16) Remove O-ring (12) from nipple (13). me: 7mm 2. Remove guide (11), plunger (10), spring (9), and plunger (5) assembly from body (16). 3. Remove plug (8) from plunger (5) assembly. —: 5mm 4, Remove spool (6) and spring (7) from plunger (5) assembly, 5. Apply the same step, for the other plunger (5) as- semblies. 6. Remove plugs (15) from body (16). —: 4mm 7. Remove spool (25), spring (26) and spool (14) from body (16). in that order. 8 Remove nipple (20) from body (16). me: 22mm 9. Remove spring (18) and plunger (17) from body (16). Remove O-ring (19) from nipple (20). 10. Remove plug (1) from body (16). Remove spring (3) and stee! ball (4) from body (18). 25mm 11. Remove plug (24) from body (16). Remove distant piece (23), filer element (22), and O-ring (21) from body (16). Remove O-ring (19) from plug (24). rm :8mm W2-9-5UPPERSTRUCTURE / Shockless Valve ASSEMBLE SHOCKLESS VALVE BA8A718 9410) ptt pt2r43 os A 2 , 2 SSE UL 151 rj 15, a5 astes |i 25/2614 2 ce f 45 18 Mi ol to oo ‘s sfeSite+e ios lartielss zo! tf |v 58) p78 PB pt0/t1-12/13 25/26 tar 2 718 ee FF 2 ste : Hi l Ht | lle 15% ast oot tatat lis sletried Lelia 1+ Pg 6 Used) 8 Pug 4 Uses 15- Plug (Use) 21-ofing 2. Oring (18 Used 8. Spin Vood) 18. Bog 22 Fier Element 2: Spng (3 Uses {o- Pango (4 Used) 17: unger 25. Distance Plece 42 StelBal Guna) tt -Guao 4 Used) 18. Song Paris 3. Pungo Used) 12- OF (4 Used) 10. ortng @ Use) 25 Spee (4 Uses) 8. Spec a Usee) 13. Nipou ts Use) 20. Nowe 28. Spray (4 Used) 7+ Spring (4 Used) 14 Spool (4 Used) W2-9-6UPPERSTRUCTURE / Shockless Valve Assemble Shockless Valve 1. Install O-ring (21), filter element (22), and distant piece (23) into body (16), in that order. 2. Install O-ring (19) onto plug (24). Tighten plug (24) to body (16). —: 8mm pom: 3010.37 Nm {8-4 to 3.8 kgfm, 22 to 28 Ibt*t) 3. Insert steel ball (4) and spring (3) into body (16). 4, Insert O-ring (2) onto plug (1). Tighten plug (1) to body (16). rm: 5mm Pome: 7.4109.3Nm (0.75 to 0.95 kgtm, 5 to 7 Ibt*tt) 6. Install plunger (17) and spring (18) into body (16). 6. Insert O-ring (18) onto nipple (20). Tighten nipple (20) onto body (16). —: 22mm P-=x: 54 to. 69 Nm (6.5 to 7.0 kgm, 40 to 51 Ibf-ft) 7. Install spoot (25), spring (26), and spoo! (14) into body (16), in that order. 8. Insert O-rings (2) onto plugs (15). Tighten plugs (15) onto body (16). 24mm pom: 7.4 09.3. (0.75 to 0.95 kgm, 5 to 7 Ibt ft) 8. Insert spool (6) and spring (7) into plunger (5). Tighten plug (8) onto plunger (5). —: 5mm P=: 9.8 to 13 Nm (1.0 t0 1.8 kgtm, 7 to 9 tht) 10. Install plunger (5) assembly, spring (9), plunger (10), and guide (11) into body (16). 11. Insert O-ring (12) onto nipple (13). Tighten nipple (13) onto body (16). me: 7 mm Pome: 5410 69.Nm (65 to 7.0 kgtm, 40 to 51 Ib W2-9-7,UPPERSTRUCTURE / Shockless Valve (Blank) W2-9-8UPPERSTRUCTURE / Solenoid Valve REMOVE AND INSTALL SOLENOID VALVE UNIT Ad caution: Escaping tid under pressure can penetrate the skin, causing serious in- jury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibly causing se- vere burns, Be sure to wait for oil to cool be- fore starting any repair work. The hydraulic oll tank cap may fly off by re- maining pressure if removed quickly. Slowly loosen the cap to completely release any re- maining pressure. Preparation 1. Park the machine on a firm, level surface. Lower the front attachment to the ground with the arm cyfinder fully retracted and the bucket oylinder fully extended. 2. Stop the engine. Move all control levers to release pressure remaining in the system. Push the air re- ease valve on top of the hydraulic oil tank cap to release any remaining pressure 8. Remove hydraulic ol tank cap. Connect a vacuum pump to maintain negative pressure in the hydrau- lic oil tank. @ NOTE: Be sure to run the vacuum pump continu- ously while working. Removal 1. Remove side-cover-mounting bolts (2) (op side: 3 used, bottom side: 4 used) to remove side cover (1) from the side of the cab. rm: 8mm 2, Remove all hoses from 7-spool solenoid valve unit (3). Disconnect pressure sensor connector. Remove bolt (4) (2 used) from 7-spool solenoid valve unit @ NOTE: Cap each hose end. W2-10-1UPPERSTRUCTURE / Solenoid Valve Installation 4. Install 7-spool solenoid valve unit (3) with bolts (4). Connect all hoses to 7-spool solenoid valve unit (3). Connect pressure sensor connector. ome: 7mm Pam: 49 Nem (5 kgtim, 36 Ibfft) =e: 22mm Po_m: 98 N-m (10 kgm, 72 IbFA) 2. Tighten bolts (2) (top side: 3 used, bottom side: 4 used) to install side cover (1) to the side of the cab. oe: 17mm Pmt: 49 N-m (5 kgm, 36 loft) W2-10-2UPPERSTRUCTURE / Solenoid Valve (Blank) W2-10-3UPPERSTRUCTURE / Solenoid Valve DISASSEMBLE AND ASSEMBLE 7-SPOOL. SOLENOID VALVE UNIT 1+ Plug (6 Used) 6- Body (3 Used) 11 Orice 18+ Ontice 2- O-Ring (6 Used) 7- ORing (@ Used) 12- Plug 16- Housing ‘3 Spring (6 Used) 8 Steel Bal (3 Used) 13- Plug 2 Used) 17-- Solenoid Valve (6 Used) 4 Valve (6 Uses) 8 Seat (3 Used) 4 O-Ring (2 Used) 18- Solenoid Valve 5- Plug (13 Uses) 10- O-Ring (3 Used) W2-10-4UPPERSTRUCTURE / Solenoid Valve Disassemble 7-Spool Solenoid Valve Unit 4. Loosen plugs (1) (6 used) to remove spring (3) and valve(4), Remove O-ring (2) from plug (1). ame 14mm. 2. Loosen plugs (5) (13 used) to remove body (6), steel ball (8) and seat (9) (each 3 used) from housing (16) Remove O-ring (7) and (10) from body (6) and seat (9) rm: 10mm 3. Loosen plugs (12) to remove orifice (11) from housing (16) 26mm 4, Loosen plugs (13) (2 used) to remove orifice (15) from housing (16) using a minus screw driver. Remove O-ring (14) from plug (13) —: 5mm scene 1-850] Solna Valve Unt |. Install orice (16) to housing(16) using @ minus, screw driver. Pome 3N-m (0.3 kgfm, 2.2 IbF) 2, Install O-ring (14) to plug (13). Install plug (13) to housing (16). 5mm Pan: 6 Nem (0.6 kgf'm, 4.4 IbEA) 3, Install orifice (11) to housing (16). Install plug (12) to housing (16). 6mm Pee: 10 Nim (1 ktm, 7 IF ft) 4, Install O-ring (7) to body (6). Install O-ring (10) to seat (9). Install seat (9), steel ball (8) and body (6) to hous- ing (16), in that order. 5. Install plug (5) (13 used) to housing (16) i: 10mm FH=X: 20 Nem (2 kgf, 14 IbFtt) 6. Install spring (3) and valve (4) to plugs (1) (6 used). 7. Install O-ring (2) to plug (1) (6 used). 4mm P=: 10 Nem (1 kgm, 7 Ibft) W2-10-5UPPERSTRUCTURE / Solenoid Valve DISASSEMBLE PROPORTIONAL SOLE- NOID VALVE 1+ Socket Bolt (2 Used) 6- Solenoid 15- O-Ring 2 Lock Nut 7. Spring 18- Sleeve 3: O-Ring 8. O-Ring ate 4 Agust Screw 8 Diaphragm 18 Washer 5 Spring 10+ Spoo! W2-10-6UPPERSTRUCTURE / Solenoid Valve 1. Loosen socket bolts (2) and remove solenoid (6) IMPORTANT: When removing solenoid (6), take care not to lose spring (7). Do not disassemble lock nut (2) and adjust screw (4). —: 4mm 2. Pull spool (10) out. Remove diaphragm (9), washer (11) and spring (12). IMPORTANT: Make identification marks on sleeve (16) as 2 types of sleeves are used. One has 4 holes in the center. The others (6 used) have 2 holes in the center. 3, Remove sieeve (16), plate (17) and washer (18) Remove O-ring (13), (14), (15) from sleeve (16) (4 Holes) W2-10-7UPPERSTRUCTURE / Solenoid Valve ASSEMBLE PROPORTIONAL SOLENOID VALVE 1 Socket Bot (2 Uses) 6- Solenoid 41- Washer 15- O-Ring 2- Lock Nut 7 Spring 42- Spring 18- Sleeve O-Ring 8- O-Ring 13- ORng 17- Plate Adjust Screw 8 Diaphragm 14- O-Ring 18- Washer Spring 40- Spool W2-10-8UPPERSTRUCTURE / Solenoid Valve IMPORTANT: When inserting sleeve (16), be sure to align the ports of sleeve (16) with the ports of the housing. 41. Install plate (17) and washer (18) to housing. Apply grease to O-ring (18), (14), (15) and install to sleeve (16). ‘Apply hydraulic oll to sleeve (16) and install in housing. IMPORTANT: When inserting spool (10) to sleeve (16), take care not to damage th F edge of sleeve (16). After insert- ing spool (10), stide spool (10) for 3 to 5 mm. Check that spool (10) moves smoothly 2. Apply hydraulic oil to spool (10). Install diaphragm (9), washer (11) and spring (12) to spool (10). Insert spool (10) into sleeve (16). a 3, Insert spring (7) to solenoid (6). Install solenoid (6) with socket bolt (1). x IMPORTANT: Lock nut (2), adjust screw (4), spring ® (8) and O-ring (3) should not be re- moved during disassembly, so they 1 are not required to be reassembled. 4mm POSE 6 Nim (0.6 kgfim, 4.4 IbFt) W2-10-9UPPERSTRUCTURE / Solenoid Valve (Blank) W2-10-10UPPERSTRUCTURE / Pilot Relief Valve Unit REMOVE AND INSTALL PILOT RELIEF VALVE UNIT AA caution: Escaping ftuid under pressure can penetrate the skin, causing serious in- Jury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibly causing se- vere burns. Be sure to wait for oil to cool be- fore starting and repair work. The hydraulic oil tank cap may fly off by re- maining pressure if removed quickly. Slowly loosen the cap to completely release any re- maining pressure. Preparation 1. Park the machine on a firm, level surface. Lower the front attachment to the ground with the arm cylinder fully refracted and the bucket cylinder fully extended. 2, Stop the engine. Move all control levers to release pressure remaining in the system. Push the air re- lease valve on top of the hydraulic oil tank cap to release any remaining pressure 3. Remove hydraulic oll tank cap. Connect a vacuum pump to maintain negative pressure in the hydrau- lic oil tank Q NOTE: Be sure to run the vacuum pump continu- ously while working, Removal 1, Remove battery-cover-mounting bolts (1) (3 used) to remove battery cover (2). oe: 17mm 2. Remove bolts (4) (2 used), located on right-side vec ae one cover (3). ome 17mm 3, Remove bolt (6), located on right-side cover (3). me: 17mm W2-11-1UPPERSTRUCTURE / Pilot Relief Valve Unit 4, Remove screw (6), located on right-side cover (3) 5. Remove bolts (7) (2 used) to remove right-side cover (3), ome: 17 mm 6. Disconnect pilot hoses (8), (10) to (14) and sole- noid valve (9) connector. 7. Loosen bolt (15). Remove pilot relief valve unit. ame: 17 mm, 22 mm, 27 mm Installation 1. Install pilot relief valve unit with bolt (15). 2. Connect pilot hoses (8), (10) to (14) and solenoid valve connector. Torave Wrench Size rn) |-S—Pee| Paats i 49 [5 [36 | bor 9 so | 6 [43 | Hose 22 s0_| 6 | 43 | Hose tor us| 2 | 67 | Hose 10 u 13 4 18 + Hose PO ~ Solenoid Vaive Hose PS Hose PA Hose T Hose TA Hose PA Bott To Swing Mode Control Valve ‘To Pump Regulator + To Plot Shut Of Valve To Hydraulic Ol Tank + To Hydraulic Ol Tank 2 From Pilot Pump W2-11-2UPPERSTRUCTURE / Pilot Relief Valve Unit 3. Install cover (3), located at the right side of the main frame, with bolts (7) (2 used). (Do not tighten to specification yet.) me: 17mm 4, Install cover (3) with bolt (5). (Do not tighten to specification yet.) ome: 7mm 5, Install bolts (4) (2 used) to cover (3). (Do not tighten to specification yet) me 17mm 34 6 vera sago4 6. Install screw (6) to cover (3) Tighten all the bolts in steps 3 to 6, to specifica- tion, me 7mm Pan: 49 Nom (5 kgfim, 36 IbFf) 7. Install battery cover (2) with botts (1) (3 used) ome 17mm Poa: 49 Nem (5 kgtim, 36 IbFf) W2-11-3UPPERSTRUCTURE / lot Relief Valve Unit DISASSEMBLE AND ASSEMBLE PILOT RELIEF VALVE W2-11-4UPPERSTRUCTURE / Pilot Relief Valve Unit Tightening Torque KeyNo. | PartName | ary | Wrench Size Remarks (rom) Nm kgfim tof 1 [Solenois Vane | 1 2 [o-ring 1 3 _|Speo! 1 ms at 42 30 4 [Pao 1 3 [org 1 6 [Boxy 1 7 [Pus 3 Dive Use three bond #1305 3 [RetetVave 1 | ome=30 8 a 58 _ | Donot aisassembie unless necessary a [Pua 1 Drive Use three bond #1305 10 [Guise 1 11 | Spring 1 12 [Socket Bott 2 ms “4 0.45 33 W2-11-5UPPERSTRUCTURE / Pilot Relief Valve Unit (Blank) W2-11-6UPPERSTRUCTURE / Swing Mode Control Valve REMOVE AND INSTALL SWING MODE CONTROL VALVE UNIT A caution: Escaping fluid under pressure can penetrate the skin, causing serious in- jury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibly causing se- vere burns. Be sure to wait for oil to cool be- fore starting and repair work. The hydraulic oil tank cap may fly off by re- maining pressure if removed quickly. Slowly loosen the cap to completely release any re~ maining pressure. Preparation 1. Park the machine on a firm, level surface. Lower the front attachment to the ground with the arm cylinder fully refracted and the bucket cylinder fully extended. 2. Stop the engine. Move all control levers to release pressure remaining in the system. Push the air re- lease valve on top of the hydraulic oil tank cap to release any remaining pressure 9. Remove hydraulic oil tank cap. Connect a vacuum pump to maintain negative pressure in the hydrau- lic oil tank, @ NOTE: Be sure to run the vacuum pump continu- ously while working. Removal 1, Remove battery-cover-mounting bolts (1) (8 used) to remove battery cover (2). oe 17mm 2. Remove bolts (4) (2 used), located on right-side iso seczcos cover (3). me 17mm. 3, Remove bolt (6), located on right-side cover (3). oe 17mm W2-12-14, Remove screw (6), located on right-side cover (3) 5. Remove bolts (7) (2 used) to remove right-side cover (3). ome: 17mm IMPORTANT: Attach an identification tag to each house. 6. Disconnect all pilot hoses and solenoid valve (9) connector. 7. Loosen bolt (10) and remove swing mode control valve unit (8) ame: 17 mm, 19 mm, 22 mm Installation 1. Install swing mode control valve (8) with bolt (10). 2, Connect all pilot hoses and solenoid valve con- nector. Torque ‘Wrench Size (mm jemarks nen Sze nm) |e Tagten | rm | ome = | 5 | 36 | pot ae 9 so | 6 | «3 | Hose wae 2 so | 6 | «3 | Hose W2-12-2UPPERSTRUCTURE / Swing Mode Control Valve 3. Install cover (3), located at the right side of the main frame, with bolts (7) (2 used). (Do net tighten to specification yet.) oe 17mm 4, Install cover (3) with bolt (6). (Do not tighten to specification yet.) ames 7mm 5. Install bolts (4) (2 used) to cover (3). (Do not tighten to specification yet.) oe 17mm 6. Install screw (6) to cover (3) Tighten all the bolts in steps 3 to 5, to specifica- tion. 17mm Foam: 49 Nim (5 kgtm, 36 Ibf tt) 7. Install battery cover (2) with bolts (1) (3 used). ome: 17mm Pat: 49 Nim (5 kgtm, 36 thf) W2-12-3UPPERSTRUCTURE / Swing Mode Control Valve DISASSEMBLE AND ASSEMBLE SWING MODE CONTROL VALVE | | ae Po Section: A-A, Section: 8-8 1- O-Ring 6- O-Ring 10- Plug (3 Used) 14+ Spring 2- Retainer 7 Solenoid Valve 11- ORing 15- Spool 3. Skeve 8 Socket Bot 12: Set Screw 18- Spring 44> Spring 9- Body 13+ Set Screw (7 Used) 17- Spock 5~ Spool W2-12-4UPPERSTRUCTURE / Swing Mode Control Valve Disassemble and Assemble 7. Install spring (14) and spool (15) to body (9) * Before disassemble, read thoroughly all precau- Install O-ring (11) to plug (10). tions for disassembiylassembly work on W1-1-1 Install plug (10) to body (9) Disassemble 6mm 1. Remove plug (10) from body (9), oem 41 Nm (4.2 kgf m, 30 Ibf ft) —: 6mm 2. Remove O-ring (11) from plug (10). Remove spring (14) and spool (16) from body (9). 3. Loosen socket bolt (8) and remove solenoid valve (7) from body (2). i: 4mm 4, Remove spool (6), spring (4), sleeve (3), retainer (2), and O-ring (1) from body (9). 5. Remove O-ring (6) from body (9), 6. Remove plug (10) from body (9) 6mm 7. Remove O-ring (11) from plug (10) (2 used) Remove spring (18) and spool (17) from body (2). 8. Do not remove set screw (12) and (13) (7 used) because they are tapped into body (8). Assemble 4. Install spring (16) and spool (17) to body (9). 2. Install O-ring (11) to plug (10) (2 used). Install two plugs (10) to body (8) at the same time 6mm POSE 41. Nm (4.2 kgf m, 30 IDFR) 3. Install O-ring (1) to retainer (2) 4, Insert spring (4) and spool (5) to sleeve (3) Install retainer (2) and sleeve (3) to body (9), in that order. 5. Install O-ring (6) to body (9) 6. Install solenoid valve (7) to body (9) with socket bolt (8) (2 used). 4mm Pome: Nm (0.6 kof m, 4.3 IbF ft) W2-12-5UPPERSTRUCTURE / Swing Mode Control Valve (Blank) W2-12-6Group 1 Swing Bearing Remove And Install Swing Bearing. Disassemble Swing Bearing Assemble Swing Bearing.. Group 2 Travel Device Remove And Install Travel Device.. Disassemble Travel Device Assemble Travel Device. Disassemble Travel Motor. Assemble Travel Motor Maintenance Standard Group 3 Center Joint Remove And Install Center Joint. Disassemble Center Joint Assemble Center Joint Group 4 Track Adjuster Remove And Install Track Adjuster Disassemble Track Adjuster. Assemble Track Adjuster Group 5 Front Idler Remove And Install Front idler Disassemble Front Idler Assemble Front Idier Maintenance Standard SECTION 3 UNDERCARRIAGE —CONTENTS— Group 6 Upper Roller and Lower Roller 3-4-4 W3-1-4 3-1-6 W3-2-4 W3-2-4 .WN3-2-8 W3-2-12 W3-2-14 W3-2-18 W3-3-4 W3-3-6 W3-3-8 W3-4-1 W3-4-2 W3-4-10 3-5-1 3-5-2 W3-5-6 W3-5-8 Remove And Install Upper Roller. Remove And Install Lower Roller. Disassemble Upper Roller. Assemble Upper Roller Disassemble Lower Roller Assemble Lower Roller. Maintenance Standard Group 7 Track Link Remove And Install Rubber Track Maintenance Standard 3-6-1 W3-6-3 W3-6-6 W3-6-8 W3-6-10 W3-6-12 W3-6-14 W374 3-7-4 192W-3-1(Blank) 192W-3-2me UNDERCARRIAGE / Swing Bearing REMOVE AND INSTALL SWING BEARING Before removing the swing bearing, the upperstructure must be removed. 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 Mare removed. Removal q 1. Put matching marks on swing bearing (1) and track frame (2) 1 Booey 2. Remove swing bearing inner race mounting bolts (3) (24 used). me 24mm CAUTION: Swing bearing weight: 92 kg (203 tb) 3, Attach ling tools (ST 0050) to swing bearing (4), hoist swing bearing (4) and remove it W3-1-1UNDERCARRIAGE / Swing Bearing Installation Clean the mating surface of swing bearing and the frame. CAUTION: Swing bearing weight: 92 kg (203 tb) IMPORTANT: Inner race soft zone (S) and the ball F port should be placed on the ‘same position. 1. Hoist the swing bearing. Align the marks on the track frame and the swing bearing Front Side ‘si {Soh Zone Marking Peston) Plug Position Grease Fitting Position 2. Install swing bearing inner race mounting bolts (3) (24 used) and tighten to specification. me: 24mm Pmt: 265 N-m (27 kgm, 195 IbF-t) W3-1-2UNDERCARRIAGE / Swing Bearing (Blank) W3-1-3UNDERCARRIAGE / Swing Bearing DISASSEMBLE SWING BEARING 1+ Outer Race 4- Plug 6- Ball (66 Used) 8 Suppor (16 Used) 2- Seal 5- Seal 7 Inner Race 8+ Suppor (50 Used) 3- Pin W3-1-4UNDERCARRIAGE / Swing Bearing + Be sure to thoroughly read “Precautions for Dis- assembly and Assembly” on page W1-1~1 before starting any repair work. ‘After pin (3) was installed, the top of the pin was, crimped. Remove the crimped part using a grinder. Drive pin (3) out from the bottom side of the swing bearing Screw bolt (M10, pitch 1.25) in plug (4). Hit the Under side of the bolt or pull the bolt to remove plug (4). Hoist swing bearing outer race (1) slightly using a crane. Remove seais (2), (5) While rotating outer race (1), remove balls (6) and supports (8 and 9). Remove balls (6) using bar magnet (A). Remove support (8) and (9) using wire (B) W3-1-5__ UNDERCARRIAGE / Swing Bearing ASSEMBLE SWING BEARING 1 Outer Race 4 Plug 6- Bal (66 Used) 8- Support (16 Used) 2+ Seal 5. Seal 7 Inner Race 8 Support (60 Used) 3: Pin W3-1-6UNDERCARRIAGE / Swing Bearing Assemble Swing Bearing Before installing the swing bearing inner and outer races, completely remove oil from the oll seals (2 and §) groove surfaces. Then, coat THREEBOND #1745 to the groove surfaces before installing seals (Zand 5) IMPORTANT: Apply a film of grease to balls (6), and supports (8 and 9). Two kinds of supports are used. The wider one is support (8) and narrower one is support (8). After installing three supports (9), install one support (8). Depending on the gap between the last ball, adjust the gap using either support (8) or support (9). 1. Install ball (6) and support (8) or (9) one by one al- ternately through the plug (4) hole. 2. Drive plug (4) into the plug hole on outer race (1). Then, drive pin (3) into the pin hole, as illustrated, Mushroom a few points along the periphery of the pin head using a pounch and a hammer. 3. Sufficiently lubricate the swing bearing using grease. (Refer to the OPERATOR'S MANUAL) W3-1-7UNDERCARRIAGE / Swing Bearing (Blank) W3-1-8_UNDERCARRIAGE / Travel Device REMOVE AND INSTALL TRAVEL DEVICE AX caution: escaping fluid under pressure can penetrate the skin, causing serious in- jury. ‘Avoid this hazard by relieving pressure be- fore disconnecting hydraulic lines. Hydraulic oil may be hot after operation. Hot hydraulic oil may sport, possibly causing se- vere burns. Be sure to wait for oil to cool be- fore starting any repair work. The hydraulic oll tank cap may fly off by re- maining pressure if removed quickly. Slowly loosen the cap to completely release any remaining pressure. Preparation 1, Park the machine on a solid level surface. Lower the bucket to the ground 2. Stop the engine, Move all control levers to release pressure remaining in the system. Push the air re- lease valve on the hydraulic oil tank to release any pressure remaining in the hydraulic tank. 3. Remove the cap and install vacuum pump to be negative-pressurize the hydraulic oil tank. Q@NOTE: Be sure to run the vacuum pump continuously while working on the hydraulic system, W3-2-1UNDERCARRIAGE / Travel Device Removal 4. Disconnect hoses (1), (2), (4). me: 22mm, 36 mm By cauTION: Travel device weight: 125 kg (253 Ib) 2. Attach travel device to a hoist. 3, Remove bolts (3) me: 24mm. 4, Remove travel device using hoist, Installation 1. Install travel device and tighten bolts (3) to specifications. 2. Connect hoses (1), (2), (4). Tightening torque specifications Bolt (3) — — 24mm 300 N-m (31 kgm, 224 Ibft) 36mm 175 Nm (18 kgm, 130 Ibe) 22mm 69Nm (7 kgf-m, 51 lot) Hose (2), (4) =e om Hose (1) me rm = Hose Dr: (To hydraulic OW Tank) = Hose: (To Travel Control Valve) Bott = Hose: (To Travel Control Valve) W3-2-2