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INTRODUCTION

ADDITIONAL REFERENCES

Please refer to the materials listed below in addition • The Engine Manual
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog

MANUAL COMPOSITION

This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.

• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.

PAGE NUMBER

Each page has a number, located on the center


lower part of the page, and each number contains
the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group


Group Number
Section Number
T: Technical Manual W: Workshop Manual

IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS

In this manual, the following safety alert symbol and CAUTION:


signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.

UNITS USED

SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.

To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature C F C 1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgf m 1.0197 mL/rev cc/rev 1.0
Nm lbf ft 0.7375

IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION

These are the SAFETY ALERT SYMBOLS.

• When you see these symbols on your machine or in


this manual, be alert to the potential for personal in-
jury.
• Follow recommended precautions and safe operating
practices.

SA-688

001-E01A-0001

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 situa-


tion which, if not avoided, will result in death or seri-
ous injury.
• WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
• DANGER or WARNING safety signs are located
near specific hazards. General precautions are listed
on CAUTION safety signs.
• Some safety signs don’t use any of the designated
signal words above after the safety alert symbol are
occasionally used on this machine. SA-1223

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.

002-E01A-1223

SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS

Carefully read and follow all safety signs on the machine


and all safety messages in the operator’s manual.

Safety signs should be installed, maintained and re-


placed when necessary.

• If a safety sign or this manual is damaged or missing,


order a replacement from your authorized dealer in
the same way you order other replacement parts (be
sure to state machine model and serial number when
ordering). SA-003

Learn how to operate the machine and its controls cor-


rectly 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 im-


pair its function and/or safety and affect machine life.

The safety messages in this SAFETY chapter are in-


tended 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 operat-
ing or performing maintenance work on the machine.
003-E01B-0003

PREPARE FOR EMERGENCIES

Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.


• Thoroughly read and understand the label attached
on the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always used
when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
SA-437
• Establish emergency procedure guidelines to cope
with fires and accidents.
• Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near
your telephone.

004-E01A-0437

SA-2
SAFETY
WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment appro-


priate to the job.

You may need:


A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438

Respirator or filter mask.


Be sure to wear the correct equipment and clothing for
the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other items


that can catch on control levers or other parts of the
machine.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating the machine.
005-E01A-0438

PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause impairment


or loss of hearing.

• Wear a suitable hearing protective device such as


earmuffs or earplugs to protect against objectionable
or uncomfortably loud noises.

SA-434
006-E01A-0434

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-435
007-E01A-0435

SA-3
SAFETY
GENERAL PRECAUTIONS FOR CAB

• Before entering the cab, thoroughly remove all dirt


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

524-E01A-0000

SA-4
SAFETY
USE HANDHOLDS AND STEPS

Falling is one of the major causes of personal injury.

• When you get on and off the machine, always face


the machine and maintain a three-point contact with
the steps and handrails.
• Do not use any controls as handholds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• Be careful of slippery conditions on platforms, steps,
SA-439
and handrails when leaving the machine.

008-E01A-0439

ADJUST THE OPERATOR’S SEAT


A poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
misoperations.

• The seat should be adjusted whenever changing the


operator for the machine.
• The operator should be able to fully depress the ped-
als and to correctly operate the control levers with his
back against the seat back.
• If not, move the seat forward or backward, and check SA-378

again.

009-E01A-0378

SA-5
SAFETY
FASTEN YOUR SEAT BELT

If the machine should overturn, the operator may be-


come injured and/or thrown from the cab. Additionally
the operator may be crushed by the overturning ma-
chine, resulting in serious injury or death.

• Prior to operating the machine, thoroughly examine


webbing, buckle and attaching hardware. If any item
is damaged or worn, replace the seat belt or compo-
nent before operating the machine.
• Be sure to remain seated with the seat belt securely SA-237
fastened at all times when the machine is in operation
to minimize the chance of injury from an accident.
• We recommend that the seat belt be replaced every
three years regardless of its apparent condition.
010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY

Bystanders can be run over.

• Take extra care not to run over bystanders. Confirm


the location of bystanders before moving, swinging,
or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or oper-
ating the machine in congested areas. Coordinate
hand signals before starting the machine. SA-426

011-E01A-0426

HANDLE STARTING AIDS SAFELY

Starting fluid:

Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.


• Keep starting fluid well away from batteries and ca-
bles.
• Remove container from machine if engine does not
need starting fluid.
• To prevent accidental discharge when storing a pres-
surized container, keep the cap on the container, and
store it in a cool, well-protected location. SA-293

• Do not incinerate or puncture a starting fluid con-


tainer.
036-E01A-0293-3

SA-6
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 from the operator’s seat.


• NEVER start the engine while standing on the track or
on ground.
• Do not start engine by shorting across starter termi-
nals.
SA-444

• Before starting the engine, confirm that all control lev-


ers are in neutral.

012-E01B-0444

JUMP STARTING
Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to follow


the instructions shown in the “OPERATING THE EN-
GINE” 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.
SA-032

• Failure to follow correct jump starting procedures


could result in a battery explosion or a runaway ma-
chine.

S013-E01A-0032

KEEP RIDERS OFF MACHINE

Riders on machine are subject to injury such as being


struck by foreign objects and being thrown off the ma-
chine.

• Only allow the operator on the machine. Keep riders


off.
• Riders also obstruct the operator’s view, resulting in
the machine being operated in an unsafe manner.

SA-379

014-E01B-0379

SA-7
SAFETY
INVESTIGATE JOB SITE BEFOREHAND

When working at the edge of an excavation or on a road


shoulder, the machine could tip over, possibly resulting
in serious injury or death.

• Investigate the configuration and ground conditions of


the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles, or banks
from collapsing.
• Make a work plan. Use machines appropriate to the
work and job site.
SA-380
• Reinforce ground, edges, and road shoulders as nec-
essary. Keep the machine well back from the edges
of excavations and road shoulders.
• When working on an incline or on a road shoulder,
employ a signal person as required.
• Confirm that your machine is equipped a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert.
As ambient temperatures rise, footing becomes loose
and slippery.
• Beware the possibility of fire when operating the ma-
chine near flammable objects such as dry grass.
015-E01A-0380

PROTECT AGAINST FALLING STONES AND


DEBRIS

• Confirm that your machine is FOPS cab equipped


before working in areas where the possibility of falling
stones or debris exist.

SA-490

015-E01A-0380

SA-8
SAFETY
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES

For jobs involving multiple numbers of machines, pro-


vide signals commonly known by all personnel involved.
Also, appoint a signal person to coordinate the job site.
Make sure that all personnel obey the signal person’s
directions.

018-E01A-0481
SA-481

CONFIRM DIRECTION OF MACHINE TO BE


DRIVEN

Incorrect travel pedal/lever operation may result in seri-


ous injury death.

• Before driving the machine, confirm the position of the


undercarriage in relation to the operator’s position. If
the travel motors are located in front of the cab, the
machine will move in reverse when travel ped-
als/levers are operated to the front.

SA-491
017-E01A-0491

SA-9
SAFETY
DRIVE MACHINE SAFELY

Before driving the machine, always confirm that the


travel levers/pedals direction corresponds to the direc-
tion you wish to drive.

• Be sure to detour around any obstructions.


• Avoid traveling over obstructions. Soil, fragments of
rocks, and/or metal pieces may scatter around the
machine. Do not allow personnel to stay around the
machine while traveling.
SA-387

Driving on a slope may cause the machine to slip or


overturn, possibly resulting in serious injury or death.

• When driving up or down a slope, keep the bucket


facing the direction of travel, approximately 0.5 to 1.0
m (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.

SA-388

SA-441

• Driving across the face of a slope or steering on a


slope may cause the machine to skid or turnover. If
the direction must be changed, move the machine to
level ground, then, change the direction to ensure
sage operation.

SA-589

019-E01C-0492

SA-10
SAFETY
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.
• Turn the auto-idle switch and the H/P mode switch off. SA-391

• Run the engine at slow idle speed without load for 5


minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK position.
• Block both tracks and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must
park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
SA-392
020-E02A-0493

SA-11
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 BY-
STANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if SA-383
equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING
INTO THE WORK AREA. USE THE HORN OR
OTHER SIGNAL TO WARN BYSTANDERS BEFORE
MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP IF
YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE
SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local regula-
tions, when work conditions require a signal person.
• No machine motions shall be made unless signals are
clearly understood by both signalman and operator. SA-384

• Learn the meanings of all flags, signs, and markings


used on the job and confirm who has the responsibil-
ity for signaling.
• Keep windows, mirrors, and lights clean and in good
condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in the
operator’s manual.

021-E01A-0494

SA-12
SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA

A person may be hit severely by the swinging front at-


tachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.

• Keep all persons clear from the area of operation and


machine movement.
• Before operating the machine, set up barriers to the
sides and rear area of the bucket swing radius to pre-
vent anyone from entering the work area.

SA-386
022-E01A-0386

NEVER POSITION BUCKET OVER ANYONE

Never lift, move, or swing bucket above anyone or a


truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.

SA-487
023-E01A-0487

AVOID UNDERCUTTING

In order to retreat from the edge of an excavation if the


footing should collapse, always position the undercar-
riage perpendicular to the edge of the excavation with
the travel motors at the rear.

• If the footing starts to collapse and if retreat is not


possible, do not panic. Often, the machine can be
secured by lowering the front attachment, in such
cases.

SA-488
024-E01A-0488

SA-13
SAFETY
AVOID TIPPING

DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING


MACHINE --- SERIOUS OR FATAL CRUSHING INJU-
RIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN
JUMP FREE
FASTEN YOUR SEAT BELT
The danger of tipping is always present when operating
on a grade, possibly resulting in serious injury or death.

To avoid tipping: SA-012


Be extra careful before operating on a grade.

• Prepare machine operating area flat.


• Keep the bucket low to the ground and close to the
machine.
• Reduce operating speeds to avoid tipping or slipping.
• Avoid changing direction when traveling on grades.
• NEVER attempt to travel across a grade steeper than
15 degrees if crossing the grade is unavoidable.
• Reduce swing speed as necessary when swinging
loads. SA-440

Be careful when working on frozen ground.


• Temperature increases will cause the ground to be-
come soft and make ground travel unstable.
025-E01B-0495

NEVER UNDERCUT A HIGH BANK

The edges could collapse or a land slide could occur


causing serious injury or death.

SA-489

026-E01A-0489

SA-14
SAFETY
DIG WITH CAUTION

Accidental severing of underground cables or gas lines


may cause an explosion and/or fire, possibly resulting in
serious injury or death.

• Before digging check the location of cables, gas lines,


and water lines.
• Keep the minimum distance required, by law, from
cables, gas lines, and water lines.
• If a fiber optic cable should be accidentally severed,
do not look into the end. Doing so may result in seri-
SA-382
ous eye injury.
• Contact your local “diggers hot line” if available in
your area , and/or the utility companies directly.
Have them mark all underground utilities.
027-E01A-0382

OPERATE WITH CAUTION

If the front attachment or any other part of the machine


hits against an overhead obstacle, such as a bridge,
both the machine and the overhead obstacle will be
damaged, and personal injury may result as well.

• Take care to avoid hitting overhead obstacles with the


boom or arm.

SA-389
028-E01A-0389

AVOID POWER LINES

Serious injury or death can result if the machine or front


attachments are not kept a safe distance from electric
lines.

• When operating near an electric line, NEVER move


any part of the machine or load closer than 3 m plus
twice the line insulator length.
• Check and comply with any local regulations that may
apply.
• Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-381

029-E01A-0381

SA-15
SAFETY
OBJECT HANDLING

If a lifted load should fall, any person nearby may be


struck by the falling load or may be crushed underneath
it, resulting in serious injury or death.

• When using the machine for craning operations, be


sure to comply with all local regulations.
• Do not use damaged chains or frayed cables, sables,
slings, or ropes.
• Before craning, position the upperstructure with the
travel motors at the rear.
SA-014

• Move the load slowly and carefully. Never move it


suddenly.
• Keep all persons will away from the load.
• Never move a load over a person’s head.
• Do not allow anyone to approach the load until it is
safely and securely situated on supporting blocks or
on the ground.
• Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.

030-E01A-0014

PROTECT AGAINST FLYING DEBRIS

If flying debris hit eyes or any other part of the body, se-
rious injury may result.

• Guard against injury from flying pieces of metal or


debris; wear goggles or safety glasses.
• Keep bystanders away from the working area before
striking any object.

SA-432
031-E01A-0432

SA-16
SAFETY
PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a level surface.
• Lower bucket to the ground.
• Turn auto-idle switch and H/P mode switch off.
• Run engine at slow idle speed without load for 5 min-
utes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK posi- SA-390

tion.
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.

033-E08B-0390

HANDLE FLUIDS SAFELY AVOID FIRES

Handle fuel with care; it is highly flammable. If fuel ig-


nites, an explosion and/or a fire may occur, possibly re-
sulting 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 flam- SA-018
mable.

• Store flammable fluids well away from fire hazards.


• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn spon-
taneously.
• Securely tighten the fuel and oil filler cap.

SA-019

034-E01A-0496

SA-17
SAFETY
PRACTICE SAFE MAINTENANCE

To avoid accidents:
• Understand service procedures before doing work.
• Keep the work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is
moving.
• Keep hands, feet and clothing away from
power-driven parts.

Before servicing the machine:


1. Park the machine on a level surface.
SA-028
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for 5
minutes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by mov-
ing the control levers several times.
7. Remove the key from the switch.
8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK posi-
tion.
10. Allow the engine to cool.

• If a maintenance procedure must be performed with


the engine running, do not leave machine unattended.
• If the machine must be raised, maintain a 90 to 110
angle between the boom and arm. Securely support
any machine elements that must be raised for service SA-527

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 of the operator’s
manual.
• Keep all parts in good condition and properly in-
stalled.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or debris.
• When cleaning parts, always use nonflammable de-
tergent oil. Never use highly flammable oil such as
fuel oil and gasoline to clean parts or surfaces.
• Disconnect battery ground cable (–) before making
adjustments to electrical systems or before perform-
ing welding on the machine.
500-E02B-0497

SA-18
SAFETY
• Sufficiently illuminate the work site. Use a mainte-
nance work light when working under or inside the
machine.
• Always use a work light protected with a guard. In
case the light bulb is broken, spilled fuel, oil, anti-
freeze fluid, or window washer fluid may catch fire.

SA-037

WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause serious in-


jury.

• Before performing any work on the machine, attach a


“Do Not Operate” tag on the control lever.
This tag is available from your authorized dealer.

501-E01A-0287
SA-287

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 SA-527

a jack.
519-E01A-0527

STAY CLEAR OF MOVING PARTS


Entanglement in moving parts can cause serious injury.

• To prevent accidents, care should be taken to ensure


that hands, feet, clothing, jewelry and hair do not be-
come entangled when working around rotating parts.

502-E01A-0026

SA-026

SA-19
SAFETY
PREVENT PARTS FROM FLYING

Grease in the track adjuster is under high pressure.


Failure to follow the precautions below may result in se-
rious 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.

SA-344
Travel reduction gears are under pressure.

• As pieces may fly off, be sure to keep body and face


away from AIR RELEASE PLUG to avoid injury.
GEAR OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen AIR
RELEASE PLUG to release pressure.

503-E01B-0344

STORE ATTACHMENTS SAFELY

Stored attachments such as buckets, hydraulic ham-


mers, and blades can fall and cause serious injury or
death.

• Securely store attachments and implements to pre-


vent falling. Keep children and bystanders away from
storage areas.

SA-034

504-E01A-0034

SA-20
SAFETY
PREVENT BURNS

Hot spraying fluids:

After operation, engine coolant is hot and under pres-


sure. Hot water or steam is contained in the engine, ra-
diator 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.
SA-039
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 fluids and surfaces:

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

505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY

Rubber hoses that contain flammable fluids under pres-


sure may break due to aging, fatigue, and abrasion. It is
very difficult to gauge the extent of deterioration due to
aging, fatigue, and abrasion of rubber hoses by inspec-
tion alone.

• Periodically replace the rubber hoses. (See the page


of “Periodic replacement of parts” in the operator’s
manual).

SA-019

Failure to periodically replace rubber hoses may cause


a fire, fluid injection into skin, or the front attachment to
fall on a person nearby, which may result in severe
burns, gangrene, or otherwise serious injury or death.

S506-E01A-0019

SA-21
SAFETY
AVOID HIGH-PRESSURE FLUIDS

Fluids such as diesel fuel or hydraulic oil under pressure


can penetrate the skin or eyes causing serious injury,
blindness or death.

• Avoid this hazard by relieving pressure before dis-


connecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take care SA-031

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-292

SA-044
507-E03A-0499

SA-22
SAFETY
PREVENT FIRES

Check for Oil Leaks:


Fuel, hydraulic oil and lubricant leaks can lead to fires.

• Check for oil leaks due to missing or loose clamps,


kinked hoses, lines or hoses that rub against each
other, damage to the oil-cooler, and loose oil-cooler
flange bolts.
• Tighten, repair or replace any missing, loose or dam-
aged clamps, lines, hoses, oil-cooler and oil-cooler
flange bolts.
• Do not bend or strike high-pressure lines. SA-019

• 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 each shift or after eight (8) to ten (10)
hours operation for loose, kinked, hardened or frayed
electrical cables and wires.
• Check before each shift or after eight (8) to ten (10)
hours operation for missing or damaged terminal
caps.
• DO NOT OPERATE MACHINE if cable or wires are
loose, kinked, etc..

Clean up Flammables:
Spilled fuel, oil, antifreeze fluid and window washer fluid,
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 flam-
mables immediately.

Check Key Switch:


If fire breaks out, failure to stop the engine will escalate
fire, hampering fire fighting.
Always check key switch function before operating the
machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm
that the engine stops.
• If any abnormalities are found, be sure to repair them
before operating the machine.

508-E02B-0019

SA-23
SAFETY
Check Emergency Engine Stop Switch:
If a fire breaks out, failure to release pressurized air in-
side the hydraulic tank will escalate fire, hampering fire
fighting.
• Check the emergency engine stop switch function
every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to the
EMERG. STOP position.
3) Confirm that both engines stop and that pressur-
ized air inside the hydraulic oil tank is released (a
hissing sound should be heard).
• If any abnormalities are found, be sure to repair them
before operating the machine.

Check Heat Shields:


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

EVACUATING IN CASE OF FIRE

If a fire breaks out, evacuate the machine in the follow-


ing way:
• Stop the engine by turning the key switch to the OFF
position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
In an emergency, if the cab door or front window cannot
be opened, break the front or rear window panes with SA-393

the emergency evacuation hammer to escape from the


cab. Refer the explanation pages on the Emergency
Evacuation Method in the operator’s manual.
518-E02B-0393

SS-1510

BEWARE OF EXHAUST FUMES

Prevent asphyxiation. Engine exhaust fumes can cause


sickness or death.
• If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe ex-
tension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the
area.
SA-016
509-E01A-0016

SA-24
SAFETY
PRECAUTIONS FOR WELDING AND GRIND-
ING

Welding may generate gas and/or small fires.


• Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe
place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grind-
ing.
After finishing welding and grinding, recheck that there SA-818

are no abnormalities such as the area surrounding the


welded area still smoldering.

523-E01A-0818

AVOID HEATING NEAR PRESSURIZED FLUID


LINES

Flammable spray can be generated by heating near


pressurized fluid lines, resulting in severe burns to your-
self and bystanders.

• Do not heat by welding, soldering, or using a torch


near pressurized fluid lines or other flammable mate-
rials.
• Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install tem-
porary fire-resistant guards to protect hoses or other
materials before engaging in welding, soldering, etc..

AVOID APPLYING HEAT TO LINES CON- SA-030

TAINING FLAMMABLE FLUIDS

• Do not weld or flame cut pipes or tubes that contain


flammable fluids.
• Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.

510-E01B-0030

SA-25
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING

Hazardous fumes can be generated when paint is


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

• Avoid potentially toxic fumes and dust.


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

• Remove paint before welding or heating:


1. If you sand or grind paint, avoid breathing the dust. SA-029

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 ma-
terial from area. Allow fumes to disperse at least 15
minutes before welding or heating.
511-E01A-0029

BEWARE OF ASBESTOS DUST

Take care not to inhale dust produced in the work site.


Inhalation of asbestos fibers may be the cause of lung
cancer.
• Depending on the wok site conditions, the risk of in-
haling asbestos fiber may exist. Spray water to pre-
vent asbestos from becoming airborne. Do not use
compressed air.
• When operating the machine in a work site where
asbestos might be present, be sure to operate the
machine from the upwind side and wear a mask rated
to prevent the inhalation of asbestos.
• Keep bystanders out of the work site during opera- SA-029

tion.
• Asbestos might be present in imitation parts. Use only
genuine Hitachi Parts.

SA-26
SAFETY
PREVENT BATTERY EXPLOSIONS

Battery gas can explode.

• Keep sparks, lighted matches, and flame away from


the top of battery.
• Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
• Do not charge a frozen battery; it may explode. Warm
the battery to 16 C (60 F) first.
• Do not continue to use or charge the battery when
SA-032
electrolyte level is lower than specified. Explosion of
the battery may result.
• Loose terminals may produce sparks. Securely
tighten all terminals.

Battery electrolyte is poisonous. If the battery should


explode battery electrolyte may be splashed into eyes,
possibly resulting in blindness.

• Be sure to wear eye protection when checking elec-


trolyte specific gravity.

512-E01B-0032

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 ser-


vicing the air conditioning system.
• Use a recovery and recycling system to avoid venting
freon into the atmosphere.
• Never let the freon stream make contact with the skin.

SA-405

513-E01A-0405

SA-27
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY

Direct exposure to hazardous chemicals can cause se-


rious injury. Potentially hazardous chemicals used with
your machine include such items as lubricants, coolants,
paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides spe-


cific 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 SA-309
what the risks are and how to do the job safely. Then
follow procedures and use recommended equipment.
• See your authorized dealer for MSDS’s (available
only in English) on chemical products used with your
machine.

515-E01A-0309

DISPOSE OF WASTE PROPERLY

Improperly disposing of waste can threaten the envi-


ronment and ecology. Potentially harmful waste used
with HITACHI equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.

• Use leakproof containers when draining fluids. Do not


use food or beverage containers that may mislead
someone into drinking from them.
• Do not pour waste onto the ground, down a drain, or
into any water source.
• Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regula- SA-226

tions 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 cen-
ter, or from your authorized dealer.

516-E01A-0226

SA-28
SAFETY
BEFORE RETURNING THE MACHINE TO THE
CUSTOMER

After maintenance or repair work is complete, confirm


that:

• The machine is functioning properly, especially the


safety systems.
• Worn or damaged parts have been repaired or
replaced

SA-435

S517-E01A-0435

SA-29
SAFETY
(Blank)

SA-30
SECTION 1 GENERAL
SECTION AND GROUP
CONTENTS Group 1 Precautions for Disassembling and
Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air from Hydraulic
Oil Tank
SECTION 2 UPPERSTRUCTURE
WORKSHOP MANUAL
Group 1 Cab
Group 2 Counterweight
Group 3 Pump Device
Group 4 Control Valve
Group 5 Swing Device
Group 6 DQR Valve
Group 7 Shuttle Valve
Group 8 EHC Valve
Group 9 Oil Cooler Fan Motor
Group 10 Compressor Drive Motor
Group 11 Air Conditioner
Group 12 Grease Pump
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Travel Brake Valve
Group 4 Center Joint
Group 5 Adjuster Cylinder
Group 6 Front Idler
Group 7 Upper and Lower Rollers
Group 8 Track
Group 9 Accumulator
Group 10 Welding Repair Procedure
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
Group 3 Bushing and Point
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Control Equipment
Group 1 Controller Group 5 DQR Valve
Group 2 Control System Group 6 Travel Device
Group 3 ELU System Group 7 Others(Upperstructure)
Group 4 Hydraulic System Group 8 Others(Undercarriage)
Group 5 Electrical System
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 General
Group 1 Introduction Group 2 Cross Reference Table
Group 2 Standard Group 3 Component Layout
Group 3 Engine Test Group 4 Troubleshooting A
Group 4 Excavator Test Group 5 Troubleshooting B
Group 5 Component Test Group 6 Troubleshooting C
Group 7 Electrical System Inspection
SECTION 1
GENERAL

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

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

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

Group 4 Bleeding Air from Hydraulic Oil


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

18KW-1-1
(Blank)

18KW-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING

Precautions for Disassembling and Assembling

Clean the Machine Precautions for Disassembling

Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be • Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as • Before disassembling, drain gear oil from the
well as decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all instructed.
disassem-bling/assembling procedures beforehand, • If a part or component cannot be removed after
to help avoid incorrect disassembling of removing its securing nuts and bolts, do not
components as well as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
• Capacities and condition of lubricants. • Measure and record the degree of wear and
• Loose or damaged parts. clearances.

Prepare and Clean Tools and Disassembly Area

Prepare the necessary tools to be used and the


area for disassembling work.

W1-1-1
GENERAL / Precautions for Disassembling and Assembling
Precautions for Assembling Bleeding Air from Hydraulic System

• Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the
any damage. If any damage is found, repair or suction lines are replaced, or the removal and in-
replace part. stallation of the pump, swing motor, travel motor or
• Dirt or debris on the contact or sliding surfaces cylinder is done, bleed air from the hydraulic system
may shorten the service life of the machine. Take in the following procedures:
care not to contaminate any contact or sliding
surfaces. IMPORTANT: If the engine is started with air
• Be sure to replace O-rings, backup rings, and oil trapped in the hydraulic pump hous-
seals with new ones once they are disassembled. ing, damage to the pump may result.
Apply a film of grease before installing. If the hydraulic motor is operated
• Be sure that liquid-gasket-applied surfaces are
with air trapped in the hydraulic
clean and dry.
motor housing, damage to the mo-
• If an anti-corrosive agent has been used on a
tor may result.
new part, be sure to thoroughly clean the part to
remove the agent. If the cylinder is operated with air
• Utilize matching marks when assembling. trapped in the cylinder tube, dam-
• Be sure to use the designated tools to assemble age to the cylinder may result.
bearings, bushings and oil seals. Be sure to bleed air before starting
• Keep a record of the number of tools used for the engine.
disassembly/assembly. After assembling is
complete, count the number of tools, so as to Bleeding Air from Hydraulic Pump
make sure that no forgotten tools remain in the
assembled machine. • Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the
plug.

Bleeding Air from Travel Motor / Swing Motor

• With the drain plug / hose on travel motor / swing


motor removed, fill the motor case with hydraulic
oil.

W1-1-2
GENERAL / Precautions for Disassembling and Assembling
Bleeding Air from Hydraulic Circuit

• After refilling hydraulic oil, start the engine. While


operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
W18K-01-04-001
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.

W1-1-3
GENERAL / Precautions for Disassembling and Assembling
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:

(1) Keep seal rings together as a matched set


with seal ring faces together. Insert a piece of
cardboard to protect surfaces.

(2) Check the slide surface on seal ring (A) for


scuffing, scoring, corrosion, deformation or B W105-03-05-019

uneven wear.

(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. Correct
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air. Incorrect

(2) Clean the floating seal and seal mounting


bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.

(3) Check that the O-ring is not twisted, and that it


is installed correctly on the seal ring.
W105-03-05-020
Correct C Incorrect
(4) After installing the floating seal, check that
seal ring surface (A) is parallel with seal
a a
mating face (C) by measuring the distances
A
(A) and (C) at point (a) and (b), as illustrated.
If these distances differ, correct the O-ring
seating. B

b b

a=b a b
W110-03-05-004

W1-1-4
GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings


safely.
• Attach protectors (soft material) on the corners of Correct Eyehole
the load so that the nylon sling does not directly Lifting Method
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
• Lower the temperature of the lifted load to lower
than 100 C (212 F). If unavoidably lifting a load
with a temperature of 100 C (212 F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
slings with the same width and length to keep the W102-04-02-016

lifted load balanced. Incorrect Eyehole


• When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or
hitched slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing W105-04-01-008

slings or pushing slings with a metal object.


• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.

Bent Sling W162-01-01-009

W1-1-5
GENERAL / Precautions for Disassembling and Assembling

Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.

W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003

Fuzz

Broken Sewing
Thread

W162-01-01-004

Broken Sewing
Thread

W162-01-01-005
Broken Sewing
Thread

Separation of W162-01-01-006
Scoring
Belt

W162-01-01-007
Fuzz Scuffing
Broken Warp

W162-01-01-008

W1-1-6
GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOL-
OGY

“Standard”
1. Dimension for parts on a new machine.

2. Dimension of new components or assemblies


adjusted to specification.

“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.

2. Repair or adjustment is impossible after exceed-


ing this limit.

3. Therefore, in consideration of operation efficiency


and maintenance expense, proper maintenance
shall be carried out before reaching the “Allow-
able Limit”.

W1-1-7
GENERAL / Precautions for Disassembling and Assembling
(Blank)

W1-1-8
GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATION

No. Descriptions Bolt Dia Q’ty Wrench Torque


mm Size (mm) Nm (kgf m) (lbf ft)
1 Engine cushion rubber mounting bolt 36 6 55 3200 (320) (2310)
2 Engine bracket mounting bolt a 20 6 30 550 (55) (400)
b 3/4 6 28.6 440 (44) (320)
c 27 12 41 1050 (105) (760)
3 Hydraulic oil tank mounting bolt 30 8 46 1450 (145) (1050)
4 Fuel tank mounting bolt 30 15 46 1450 (145) (1050)
5 Pump transmission mounting bolt 1/2 16 19.1 120 (12) (90)
6 Pump device mounting bolt 20 12 30 550 (55) (400)
7 Fan drive pump mounting socket bolt 20 4 17 550 (55) (400)
8 Gear pump mounting bolt 12 4 19 90 (9) (65)
9 Control valve mounting nut 16 12 24 270 (27) (195)
10 Swing device mounting bolt 33 48 50 2600 (260) (1880)
11 Swing motor mounting nut 20 8 30 400 (40) (290)
12 Battery mounting bolt 10 16 17 50 (5) (36)
13 Cab mounting bolt 18 10 27 300 (30) (215)
14 Cab bed mounting bolt 16 42 24 270 (27) (195)
Swing bearing mounting bolt 45 58 70 4700 (470) (3400)
15
45 60 70 4700 (470) (3400)
16 Counterweight mounting nut 45 6 70 3920 (392) (2840)
17 Engine bed mounting bolt 30 20 30 1450 (145) (1050)
18 Oil cooler mounting nut 27 4 41 1400 (140) (1010)
19 Radiator mounting nut 27 4 41 1400 (140) (1010)
20 Fan motor mounting bolt 16 4 24 210 (21) (150)
21 Fan motor bracket mounting bolt 12 6 19 90 (9) (65)
22 Travel device mounting bolt a 22 32 32 750 (75) (540)
b 33 64 50 2600 (260) (1880)
c 30 60 46 1950 (195) (1410)
23 Sprocket mounting bolt 30 30 46 1950 (195) (1410)
24 Travel motor mounting bolt 20 8 30 400 (40) (290)
25 Upper roller mounting bolt 20 25 30 400 (40) (290)
26 Lower roller mounting bolt 30 64 46 1950 (195) (1410)
27 Track guard mounting bolt 30 12 46 1950 (195) (1410)
28 Track shoe bolt 33 392 50 3190 (319) (2300)
29 Side frame mounting bolt 45 68 70 4710 (471) (3400)
30 Loader Front pin-retaining bolt a 20 32 30 400 (40) (290)
b 16 4 24 210 (21) (150)
c 24 4 36 700 (70) (510)
31 Backhoe Front pin-retaining bolt 20 24 30 400 (40) (290)
16 12 24 210 (21) (150)

W1-2-1
GENERAL / Tightening

NOTE 1.Apply lubricant (e.g. white zinc B dis-


solved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
2.Make sure bolt and nut threads are clean
before installing.

W1-2-2
GENERAL / Tightening
TORQUE CHART

CAUTION: Use tools appropriate for the


work to be done. Makeshift tools and proce-
dures can create safety hazards. For loos-
ening and tightening nuts and bolts, use cor-
rect size tools. Otherwise, tightening tools
may slip, potentially causing personal injury.

Bolt Types

Tighten nuts or bolts correctly to torque specifications.


Four different types and grades of bolt are employed.
Make sure to employ correct bolts and tighten them SA-040

correctly when assembling the machine or compo-


nents.

Specified Tightening Torque Chart

Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M157-07-225

Socket Bolt
Nm (kgf m) (lbf ft) Nm (kgf m) (lbf ft) Nm (kgf m) (lbf ft)
M8 13 6 30 (3.0) (22) 20 (2.0) (15) 10 (1.0) (7.4)
M10 17 8 65 (6.5) (48) 50 (5.0) (37) 20 (2.0) (15)
M12 19 10 110 (11) (81) 90 (9) (66) 35 (3.5) (26)
M14 22 12 180 (18) (135) 140 (14) (103) 55 (5.5) (41)
M16 24 14 270 (27) (200) 210 (21) (155) 80 (8.0) (59)
M18 27 14 400 (40) (295) 300 (30) (220) 120 (12) (89)
M20 30 17 550 (55) (410) 400 (40) (295) 170 (17) (125)
M22 32 17 750 (75) (550) 550 (55) (410) 220 (22) (160)
M24 36 19 950 (95) (700) 700 (70) (520) 280 (28) (205)
M27 41 19 1400 (140) (1030) 1050 (105) (770) 400 (40) (295)
M30 46 22 1950 (195) (1440) 1450 (145) (1070) 550 (55) (410)
M33 50 24 2600 (260) (1920) 1950 (195) (1440) 750 (75) (550)
M36 55 27 3200 (320) (2360) 2450 (245) (1810) 950 (95) (700)

W1-2-3
GENERAL / Tightening
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lu-
bricant.
2. Torque tolerance is 10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.

Bolt Tightening Order

When tightening two or more bolts, tighten them al-


ternately, as shown, to ensure even tightening.
Tighten from center and diagonally
Equally tighten upper and lower alternately Tighten diagonally

1 12 9 4 1 6 7 14
6 3
1st to 4th

4 5
2 13 8 5 2 3 10 11

2nd to 3rd
W105-01-01-003

W1-2-4
GENERAL / Tightening
Service Recommendations for Spilt Flange

IMPORTANT: 1. Be sure to clean and Inspect


sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
W105-01-01-015
nent.
Incorrect
2. Be sure to use only specified
O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
W105-01-01-016
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using W105-01-01-008

an air wrench often causes tight- Correct Incorrect


ening of one bolt fully before
tightening of the others, result-
ing in damage to O-rings or un-
even tightening of bolts. Do not bend it round
Bend along edge sharply

Nut and Bolt Locking Correct Correct Incorrect

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 Bend along edge sharply
W105-01-01-009
holes in the bolt and nut while tight-
Correct Correct Incorrect
ening, not while loosening.

Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
Loosen Incorrect
Correct

Tighten

W 105-01-01-010

W1-2-5
GENERAL / Tightening
PIPING JOINT 1 4 3 5 2

IMPORTANT: The torques given in the chart are


for general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
M202-07-051
Joint Body
Union Joint

Metal sealing surfaces (4) and (5) of adapter (1) and


hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines. 37

30
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
W105-01-01-017
cations.
2. Scratches or other damage to
sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them
when connecting/disconnecting.

Wrench Size Wrench Size mm Tightening


Description mm Torque
Union Nut Hose Fittings N m (kgf m, lbf ft)
30 male 17 17 24.5 (2.5,18)
19 19 29.5 (3.0,22)
22 22 39 (4.0,29)
27 27 78 (8.0,58)
32 32 137 (14,101)
36 36 175 (18,129)
41 41 205 (21,151)
37 female 17 14 24.5 (2.5,18)
19 17 29.5 (3.0,22)
22 19 39 (4.0,29)
27 22 78 (8.0,58)
32 27 137 (14,101)
36 32 175 (18,129)
41 36 205 (21,151)
NOTE: Tightening torque of 37 male coupling without union is similar
to tightening torque of 37 female.

W1-2-6
GENERAL / Tightening
O-ring Seal Joint 9
7 6

O-ring (6) seats against the end face of adapter (7) to


seal pressure oil.

IMPORTANT: 1. Be sue to replace O-ring (6) with


a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly Hose Fittings
8 1
in O-ring groove (e). Tightening M104-07-033

nut (9) with O-ring (6) displaced


will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring Wrench Size Wrench Size Tightening Torque
groove (e) or sealing surface mm mm
(10). Union Nut Hose Fittings N m (kgf m, lbf ft)
Damage to O-ring (6) will cause 19 17 29.5 (3.0,21.5)
oil leakage. 22 19 69 (7.0,51)
4. If nut (9) is loose and oil is leak- 27 22 93 (9.5,69)
ing, do not re-tighten nut (9). Re- 32 27 137 (14,101)
place O-ring (6) with a new one 36 30,32 175 (18,129)
and check that O-ring (6) is cor- 41 36 205 (21,151)
rectly seated in place, tighten nut 46 41 205 (21,151)
(9).

W1-2-7
GENERAL / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30
types of screw fittings are used.

IMPORTANT: Be sure to confirm that the thread


pitch and thread type (tapered or
straight) are the correct type before Male Tapered Thread Male Straight Thread
using any screw-in connection.
W105-01-01-018

Male Tapered Thread


Wrench Size Tightening Torque
mm N m (kgf m, lbf ft)
Hose Fittings FC material SS material
19 14.5 (1.5,10.5) 34 (3.5,25)
22 29.5 (3.0,21.5) 49 (5.0,36)
27 49 (5.0,36) 93 (9.5,69)
36 69 (7.0,51) 157 (16,116)
41 108 (11,80) 205 (21,151)
50 157 (16,116) 320 (33,235)
60 195 (20,144)
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks be-
tween threads.
Be sure to apply just enough seal tape to fill up thread External Thread
Clearance
clearances. Do not overwrap.

Application Procedure W105-01-01-019

Leave one to two pitch threads uncovered


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

Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs


depending on the type of clamp. M114-07-041
T-Bolt Type Band Clamp:
4.4 N m ( 0.45 kgf m, 3.25 lbf ft )
T-Bolt Type Worm Gear Type
Worm Gear Type Band Clamp:
5.9 to 6.9 N m (0.6 to 0.7 kg m, 4.3 to 5.1 lbf ft)

M114-07-043 M114-07-042

W1-2-8
GENERAL / Tightening
Connecting Hose
Incorrect Correct
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation
of fitting, possibly resulting in a fire on the
machine.

Do not install hoses kinked. Application of W105-01-01-011

high oil pressure, vibration, or an impact to a


kinked hose may result in oil leaks, hose
rupture or separation of fitting. Utilize Print Incorrect Correct
marks on hoses when installing to prevent Rubbing Against
hose from being kinked. Each Other

If hoses rub against each other, wear to the


hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other. W105-01-01-012

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

Rubbing Against
Each Other

W105-01-01-013

Incorrect Correct

Rubbing Against
Each Other Clamp
W105-01-01-014

W1-2-9
GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS

To ensure safe operation, be sure to conduct periodic


inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deterio-
ration, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regard-
less of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace
as necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, as necessary.
Consult your authorized dealer for correct replace-
ment.
Replacement
Periodic Replacement Parts
Intervals
Pump to High Pressure Filter
High Pressure Filter to Control Valve
Control Valve to Front
Oil cooler to Hydraulic Oil Tank
Hydraulic hoses Transmission Oil Cooler Hose
Loading Shovel Main Frame to
Every 2 years, or
Front Hoses Boom
8000 hours
Backhoe Front Main Frame to
Hoses Boom
Fuel Tank to Water Separator Filter
Water Separator to Cooler
Fuel Hoses
Engine to Fuel Cooler
Fuel Cooler to Fuel Tank

NOTE: Be sure to replace seals, such as O-rings


and gaskets, when replacing hoses.

W1-2-10
GENERAL / Painting
PAINTING

Painting Specification
Surfaces to be Painted Painting Colour
• Upper Structure (Outside) YR-01 [TAXI Yellow]
Side fenders (left and right), Counterweight, Counter-
weight side and front step, Handrail of counterweight,
HG Beige Deep
Fuel tank side step, Handrail of upper side fenders (left
and right)
Handrail and step of upper side control valve support,
Handrail and step around the cab, Engine cover upper
HG Black
handrail and step, Handrail and step of fuel and hydraulic
tank upper, Handrail and step of battery cover upper.
Inside N-40 [Gray]
Muffler M/F Beige Deep
Air Cleaner HG Beige Deep
• Front Attachment YR-01 [TAXI Yellow]
• Track N-10 [Black]

Final Painting Colour


• Outside surface of cab
Around cab window for the front, left and right side N-30 [Gray]
Other outside HG Beige Deep
• Inside surface HG Beige Deep
• Inside surface of cab bed N-40 [Gray]

Masking Specification
• Engine number plate • Pilot Accumulator
• Each hydraulic moter number plate • Door, Catchs, Handles
• Each pump number plate • Ground line disconnection switch box
• Each valve number plate • Wring connector, Mark band
• Each reduction gear number plate • Escape equipment
• Control valve number plate • Handrail chain
• Back mirror

W1-3-1
GENERAL / Painting
Machine Front Side Machine Rear Side

1 1 3 2

1
2

W18K-01-03-001 W18K-01-03-002

W18K-01-03-005

Surfaces to be Painted Painting Colour


1- Upper handrail on the fuel tank, Handrail of engine cover, Step on the
engine cover rear, Handrail and step around the cab, Handrail on the HG Black
hydraulic oil tank upper, Upper handrail on the battery box
2- Sliding fold-in ladder, Sliding fold-in ladder front step, Right side fender,
Handrail of right side fenders, Upper handrail and step on the counter- HG Beige Deep
weight, Counterweight side handrail and step
3- Water tank, Upper and rear side of frame YR-01 [TAXI Yellow]

W1-3-2
GENERAL / Painting
Machine Right Side Machine Left Side

1 2 1 2 1

3
3

4 4

4 3

3
4

1 1 1
W18K-01-03-003 W18K-01-03-004
4 4

Surfaces to be Painted Painting Colour


1- Muffler, Muffler Cover, Right side of engine bed cover, Cover under the
fender, Left fender, Counterweight, Counterweight front side step, M/F Beige Deep
Counterweight side step
2- Side ladder on the hydraulic oil tank, Hand rail and step between the
hydraulic tank and engine cover, Hand rail and step between the fuel HG Black
tank and engine cover
3- Radiator grill, Oil cooler grill, Stay N-10 [Black]
4- Compressor cover, Upper fuel filter on the left fender, Condenser cover,
YR-01 [TAXI Yellow]
Upper fender cover, Grill

W1-3-3
GENERAL / Painting
Machine Right Side Machine Left Side

W18K-01-03-003 W18K-01-03-004

Fuel Tank
Shaded Area Shaded Area Out Side
YR-01 TAXI Yellow YR-01 TAXI Yellow YR-01 TAXI Yellow
(Gray for the parts other (Gray for the parts other (Inside)
than the shaded area) than the shaded area) N-40 Gray Lacquer

Side Surface of
Center Step
Side Surface of
Ladder Mounting
Bracket
HG Beige Deep

W18K-01-03-006
A W18K-01-03-007

Side Surface of Ladder Mounting Bracket


HG Beige Deep

View B View A
W18K-01-03-008

W1-3-4
GENERAL / Painting
Engine Unit Front Side

N-40 Gray Lacquer YR-01 TAXI Yellow N-40 Gray Lacquer

W18K-01-03-009

Main Frame

View D Shaded Area


D YR-01 TAXI Yellow
(Gray for the parts
other than the shaded
area)

C E

W18K-01-03-010
Shaded Area W18K-01-03-011

YR-01 TAXI Yellow


(Gray for the parts other
than the shaded area)

Shaded Area
YR-01 TAXI Yellow
(Gray for the parts other
than the shaded area)
View C View E

W18K-01-03-012

W1-3-5
GENERAL / Painting
(Blank)

W1-3-6
GENERAL / Bleeding Air from Hydraulic Oil Tank
BLEEDING AIR FROM HYDRAULIC OIL
TANK

CAUTION: 1. Escaping fluid under pressure


can penetrate the skin and
eyes, causing serious injury.
Avoid this hazard by relieving
pressure before disconnecting
hydraulic or other lines.
2. Hydraulic oil may be hot just
after operation. Hot hydraulic
oil may spurt, possibly causing
severe burns. Be sure to wait
for oil to cool before starting
maintenance / repair.
3. Do not loosen air breather cap
on hydraulic oil tank quickly. Air
breather cap may fly off due to
internal pressure. Always turn
the air breather cap slowly to
release any remaining pressure
before removing it.

Preparation

1. Park the machine on a level solid surface. Lower


the front attachment to the ground.

W18K-01-04-001

2. Stop the engine. Loosen the lock of the air


breather cap (1) on the hydraulic oil tank with a
hexagon wrench. Turn air breather cap (1) ap-
proximately 30 counterclockwise to release any
remaining pressure.
: 4 mm

Hexagon Wrench
W118-02-03-018

W1-4-1
GENERAL / Bleeding Air from Hydraulic Oil Tank

3. Remove socket bolt (2) of air breather cap (1) at 2


one side to remove air breather cap (1). Remove 3
filter (3). Wind an adhesive tape around bayonet 1
assembly (4) approx. one and half turns so that Port
the port is plugged. Reinstall filter (3) and air
breather cap (1) to the original position.
: 4 mm 4

4. Remove other side air breather cap (1). Connect


a vacuum pump. Operate the vacuum pump con-
tinuously to create negative pressure in the hy-
draulic oil tank. Run the vacuum pump continu-
ously while maintenance / repair period.

5. After completing the maintenance / repair, be


sure to remove the adhesive tape from bayonet
assembly (4).

W118-02-05-001

W1-4-2
MEMO

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MEMO

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SECTION 2
UPPERSTRUCTURE

CONTENTS
Group 1 Cab Maintenance Standard ........................W2-3-96
Removal and Installation Cab............... W2-1-1 Disassembly of Pump Transmission
Dimensions of the Cab Glass ............... W2-1-4 Oil Lubrication Pump.........................W2-3-98
Assembly of Pump Transmission
Group 2 Counterweight Oil Lubrication Pump.......................W2-3-100
Removal and Installation of Maintenance Standard ......................W2-3-102
Counterweight .................................... W2-2-1
Group 4 Control Valve
Group 3 Pump Device Removal and Installation of
Removal and Installation of Control Valve ......................................W2-4-1
Pump Device ...................................... W2-3-1 Disassembly of Control Valve ...............W2-4-6
Disassembly of Pump Transmission ... W2-3-22 Assembly of Control Valve ..................W2-4-14
Assembly of Pump Transmission........ W2-3-26 Disassembly and Assembly of
Disassembly of Main Pump ................ W2-3-30 Main Relief Valve and
Assembly of Main Pump ..................... W2-3-38 Overload Relief Valve .......................W2-4-18
Maintenance Standard........................ W2-3-46 Structure of Make-Up Valve ................W2-4-20
Disassembly of Regulator for
Main Pump ....................................... W2-3-48 Group 5 Swing Device
Assembly of Regulator for Removal and Installation of
Main Pump ....................................... W2-3-54 Swing Device ......................................W2-5-1
Structure of 4-Spool Pump.................. W2-3-61 Disassembly of Swing Device ...............W2-5-8
Disassembly of Oil Cooler Assembly of Swing Device..................W2-5-16
Fan Drive Pump................................ W2-3-62 Disassembly of Swing Motor...............W2-5-28
Assembly of Oil Cooler Assembly of Swing Motor ...................W2-5-32
Fan Drive Pump................................ W2-3-66 Maintenance Standard ........................W2-5-36
Maintenance Standard........................ W2-3-72 Disassembly and Assembly of
Disassembly of Regulator for Valve Unit..........................................W2-5-38
Oil Cooler Fan Drive Pump .................. 2-3-74
Assembly of Regulator for Group 6 DQR Valve
Oil Cooler Fan Drive Pump ............... W2-3-80 Removal and Installation DQR Valve ....W2-6-1
Disassembly of Air Conditioner Structure of DQR Valve.........................W2-6-4
Compressor Drive Pump and
Pilot Pump ........................................ W2-3-86
Assembly of Air Conditioner
Compressor Drive Pump
and Pilot Pump ................................. W2-3-92

18KW-2-1
Group 7 Shuttle Valve
Removal and Installation of
Shuttle Valve ...................................... W2-7-1
Structure of Shuttle Valve ..................... W2-7-3

Group 8 EHC Valve


Removal and Installation of
EHC Valve....................................... W2-8-1
Structure of EHC Valve......................... W2-8-7
Disassembly and Assembly of
Proportional Solenoid Valve................ W2-8-8
Structure of Solenoid .......................... W2-8-10

Group 9 Oil Cooler Fan Motor


Removal and Installation of
Oil Cooler Fan Motor .......................... W2-9-1
Disassembly of Oil Cooler Fan Motor ... W2-9-6
Assembly of Oil Cooler Fan Motor ........ W2-9-8
Maintenance Standard........................ W2-9-10

Group 10 Compressor Drive Motor


Removal and Installation of
Compressor Drive Motor................... W2-10-1
Disassembly of Compressor
Drive Motor ....................................... W2-10-4
Assembly of Compressor
Drive Motor ....................................... W2-10-6

Group 11 Air Conditioner


Work after Replacing Component....... W2-11-1
Charge Air Conditioner
with Refrigerant ................................ W2-11-2

Group 12 Grease Pump


Grease Pump Construction ................ W2-12-1

18KW-2-2
UPPERSTRUCTURE / Cab
REMOVAL AND INSTALLATION CAB

Removal

CAUTION: Cab (1) weight: 1210 kg (2668 lb)


Lifting Bracket 1 Lifting Bracket
1. Attach a nylon sling to the lifting bracket (4 places)
in cab (1). Hoist and hold cab (1).

W18M-02-01-003

W2-1-1
UPPERSTRUCTURE / Cab
2. Remove U-nuts (4) (10 used) and washers (5) (10 2 3 1
used) from cushions (2) (10 used).
: 27 mm

3. Remove sems bolts (3) (18 used) from cab (1).


: 19 mm

4, 5
W18M-02-01-009
2

4, 5

4, 5
W18M-02-01-008

Door 2 3

4, 5
W18M-02-01-010

4. Remove all connectors and plugs from cab (1). Lifting Bracket 1 Lifting Bracket

CAUTION: Cab (1) weight: 1210 kg (2668 lb)

5. Remove cab (1) from the cab bed.

W18M-02-01-003

W2-1-2
UPPERSTRUCTURE / Cab
Installation Lifting Bracket 1 Lifting Bracket

CAUTION: Cab (1) weight: 1210 kg (2668 lb)

1. Hoist and align cab (1) with the mounting hole on


cab bed.

W18M-02-01-003

Door 2 3
2. Install cab (1) to cushion (2) with U-nuts (4) (10
used) and washers (5) (10 used).
: 27 mm
: 300 N m (30.5 kgf m, 221 lbf ft)
1

4, 5
W18M-02-01-010
2
3. Install cab (1) to the cab bed with sems bolts (3)
(18 used).
: 19 mm
: 90 N m (9 kgf m, 66 lbf ft)

4. Install all connectors and plugs.


4, 5

4, 5
W18M-02-01-008

2 3 1

4, 5
W18M-02-01-009

W2-1-3
UPPERSTRUCTURE / Cab
DIMENSIONS OF THE CAB GLASS

NOTE: Material: JISR3211 or equivalent


Rubber Rubber
Bushing Bushing

Sems Bolt
1
A
Plate

W18M-02-01-002
B

Unit: mm
NOTE: 1 mm 0.03937 in

2.5 3.2
4.5

Wiper Motor
Shaft Core

Rubber C

35
17.5
10
6
35 8 12
77.5 60 12
36.5

Rubber A Adhesive
Rubber D
Rubber E 6
8 10
3.2 6 (Glass)
24 10 (Glass)
4.5 8 (Glass)
Rubber E
6 36.5 W18M-02-01-005 10 6
8
Rubber D
Rubber B Adhesive F
17.5 60

12
6 77.5

36.5 6
60 35
77.5
Section A
17.5

Rubber C

24 3.2
4.5

Section B-B W18M-02-01-006

W2-1-4
UPPERSTRUCTURE / Cab

NOTE: 1 mm 0.03937 in

Unit: mm
Chamfer the Corner
(4 Places)
80

80

Mark Position
(Outside)

1
Laminated Glass
1702 1
Color: Clear
Thichkness: 10.8 mm
Chamfer along the
Periphery

W18G-02-01-004
1734 1

W2-1-5
UPPERSTRUCTURE / Cab

Stopper Spacer

2 3

Connected
Position

Handrail
Connected
Position
W18M-02-01-003

Unit: mm
NOTE: 1 mm 0.03937 in

1355.8 1

4-R61

4-R61

3
2 Tempered Glass
769 1.0 Color: Green
Tempered Glass
Color: Green Thickness: 5 mm
Thickness: 5 mm Chamfer along the
Chamfer along the Periphery Periphery
Mark Position
NUB34413
50

W18G-02-01-005
50

1222.6 1

W117-02-01-004

433 1.0

W2-1-6
UPPERSTRUCTURE / Cab
Rubber
Bushing

4 5

Connected Connected
Position Position

W18M-02-01-004

NOTE: 1 mm 0.03937 in Unit: mm

129.7

4-R61

5-R61 129.7

5
Tempered Glass
4 Color: Green
Tempered Glass Thickness: 5 mm 769 1.0
Color: Green Chamfer along the
Thickness: 5 mm Periphery
962 Chamfer along the
Periphery

50 Mark Position
NUB34413
Outside

50
433 1.0 W18M-02-01-007

W18M-02-01-018
710.2

W2-1-7
UPPERSTRUCTURE / Cab

Connected
Position
Guide Pipe

W18M-02-01-001

Connected
Position

NOTE: 1 mm 0.03937 in Unit: mm

1355.8 1 478 1

4-R61
6
4-R61 Tempered Glass
Color: Green
Thickness: 5 mm
324 1 Chamfer along the
2 Periphery
Tempered Glass Mark Position
Color: Green 50 NUB34413
Thickness: 5 mm
Chamfer along the Periphery W18G-02-01-006
50
Mark Position
50 NUB34413 438.2 1

W18G-02-01-005
50

1222.6 1

W2-1-8
UPPERSTRUCTURE / Cab
Rubber A Rubber B Rubber C

1738 +5-0 1740 +5-0 1718 -0


+5

A A
A
6 8
6

+0
24 -1
36 +0-1
C5 24 -1
+0
W18M-02-01-012

Section A Section A
W18M-02-01-013
C5
W18M-02-01-011
Section A

Rubber D Rubber E Adhesive F


+5
1718 -0 1800
1300+100-0

A A

8 12 A
10
+0 6
36 -1
W18M-02-01-015
Section A +2
10 -0
W18M-02-01-016
Section A
W18M-02-01-014
Section A

NOTE: 1 mm 0.03937 in

W2-1-9
UPPERSTRUCTURE / Cab
(Blank)

W2-1-10
UPPERSTRUCTURE / Counterweight
REMOVAL AND INSTALLATION OF
COUNTERWEIGHT

CAUTION: Park the machine on a solid and


level surface. Lower the bucket to the ground
steady before doing any work.
Do not operate the machine or the front
attachment without the counterweight.
Otherwise the machine may tip over.

Removal

1. Park the machine on a solid and level surface. Set


the front attachment as illustrated.

T142-05-03-007

T142-05-03-008

2. Remove bolts (1) (8 used). Remove covers (2) (2


used) from the counterweight. Counterweight
: 17 mm

2 1

W18C-02-02-004

W2-2-1
UPPERSTRUCTURE / Counterweight

CAUTION: Counterweight weight: 25300 kg


(55800 lb)

3. Install a shackle and a wire into a hole on the


upper side of the counterweight. (2 places)
Hoist and hold the counterweight. A Counterweight

W18K-02-02-001

View A
4. Remove U-nuts (5) (6 used) and washers (6) (6
used).
: 70 mm
Lifting
NOTE: When removing U-nut (5) from bolt (3), Hole
washer (6) falls. Catch washer (6) with a 3, 4
tray.

5. Push up bolt (3) and washer (4) by hand. Wind a


nylon sling onto the neck of bolt (3). Hoist and
remove bolt (3) from the counterweight. (6 places)

W18C-02-02-003

5, 6
6. Hoist and remove the counterweight from the
main frame.

Counterweight

W141-02-02-003
Main Frame

W2-2-2
UPPERSTRUCTURE / Counterweight
Installation

CAUTION: Counterweight weight: 25300 kg


(55800 lb)
Counterweight

1. Install a shackle and a wire into a hole on the


upper side of the counterweight. (2 places)
Hoist the counterweight.

2. Place the counterweight onto the main frame


while aligning the bolt holes on the counterweight Main Frame W141-02-02-003

and the main frame.

IMPORTANT: Apply lubricant onto bolt (3).


Install washer (4) to bolt (3) with the
chamfered side inside washer (4)
facing to the bolt (3) head.
3. Install washer (4) to bolt (3). Wind a nylon sling
onto the neck of bolt (3). Hoist and insert bolt (3) A Counterweight
in to the bolt hole. (6 places)

IMPORTANT: Install washer (6) to bolt (3) with the


groove surface facing downward.
4. Temporarily tighten washers (6) (6 used) and A
U-nuts (5) (6 used) to bolts (3) (6 used).
W18K-02-02-001
5. Tighten bolts (3) (6 used).
: 70 mm
: 3920 N m (400 kgf m, 2900 lbf ft)
View A

Lifting
Hole
3, 4

W18C-02-02-003

5, 6

W2-2-3
UPPERSTRUCTURE / Counterweight
6. Install covers (2) (2 used) to the counterweight
with bolts (1) (8 used). Counterweight
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)

2 1

W18C-02-02-004

W2-2-4
UPPERSTRUCTURE / Pump Device
REMOVAL AND INSTALLATION OF PUMP
DEVICE

CAUTION: Bleed air from the hydraulic oil


tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

W2-3-1
UPPERSTRUCTURE / Pump Device
Removal of Pump Device

W18K-02-03-001

6 7 8
9
Machine
Front B

3 10

4 11
22
12
21
20
19
18 13
14, 15
17
16
5
View A (Engine Unit Upper Side)
W18K-02-03-002

1 W18C-02-03-001

Section B (Shield Plate Pump Side)

1- Pump Device 7- Cover 13 - Bracket 18 - Bracket


2- Engine 8- Cover 14 - Bolt (92 Used) 19 - Cover
3- Bolt (26 Used) 9- Bracket 15 - Washer (92 Used) 20 - Cover
4- Cover (3 Used) 10 - Cover 16 - Cover 21 - Cover
5- Cover (3 Used) 11 - Cover 17 - Cover 22 - Bracket
6- Cover 12 - Cover

W2-3-2
UPPERSTRUCTURE / Pump Device
Removal

1. Prepare a container. Remove the drain plug from


the lower side of the pump transmission. Open
the drain cock and drain oil.
Container volume: 30 L (7.9 US gal)

Drain Plug Drain Cock W18C-02-04-017

IMPORTANT: Attach an identification tag onto the


disconnected hose, piping and
harness for assembling.
2. Disconnect all hoses, pipings and connectors
from pump device (1). Install a plug or a cap onto
the open ends of the disconnected hoses and
pipings.

(Hose)
: 19 mm, 22 mm, 27 mm, 36 mm
(Piping)
: 17 mm
(Bolt)
: 17 mm, 19 mm
(Socket Bolt)
: 8 mm, 14 mm

W2-3-3
UPPERSTRUCTURE / Pump Device

W18K-02-03-001

Machine
Front B 6 7 8
3 9

10
4

11
22
12
21
20
19
5 18 13
14, 15
View A (Engine Unit Upper Side) 17
W18K-02-03-002 16

1 W18C-02-03-001

Section B (Shield Plate Pump Side)

W2-3-4
UPPERSTRUCTURE / Pump Device
7. Remove bolts (27) (16 used) and washers (28)
CAUTION: Cover (4) weight: 18 kg (40 lb) (16 used). Remove brackets (23, 26) from
Cover (5) weight: 23 kg (55 lb) bracket (9).
: 24 mm
3. Remove bolts (3) (29 used). Hoist and remove
covers (4, 5) (3 used for each) from the upper
side of the engine unit. CAUTION: Bracket (9) weight: 43 kg (95 lb)
: 19 mm
8. Attach a nylon sling onto bracket (9). Hoist and
4. Remove bolts (14) (92 used) and washers (15) hold bracket (9). Remove bolts (30) (8 used) and
(92 used). Remove covers (6 to 8), (10 to 12), (16, washers (31) (8 used). Hoist and remove bracket
17), (19 to 21) and brackets (13, 18, 22) from the (9) from the upper side of the engine unit.
upper side of pump device (1). : 19 mm
: 17 mm Nylon Sling
9

5. Remove bolts (24) (3 used). Disconnect the


connector of maintenance lamp (29).
: 17 mm

9 24 25 Connector 30, 31
W18B-02-04-024

23 26

27, 28
29

Shield Plate Engine Side W18C-02-03-006

6. Remove bolts (25) (4 used). Remove


maintenance lamp (29) from bracket (9).
: 17 mm

W2-3-5
UPPERSTRUCTURE / Pump Device

W18K-02-03-001

Machine
Front B

View A (Engine Unit Upper Side)


W18K-02-03-002

W18C-02-03-001

Section B (Shield Plate Pump Side)

W2-3-6
UPPERSTRUCTURE / Pump Device
9. Remove the oil cooler fan motor. (Refer to 12. Install the special tool (ST 7326) to engine (2)
REMOVAL AND INSTALLATION OF OIL with bolts (34) (2 used). (2 places)
COOLER FAN MOTOR on W2-9-1.)
CAUTION: Bracket (32) weight: 49 kg (110 lb)
CAUTION: Pump device (1) weight: 1540 kg
(3400 lb) 13. Remove bolts (36) (6 used), (38) (2 used),
washers (37) (6 used) and (39) (2 used).
10. Install a shackle and a wire to the lifting bracket Attach a wire and a shackle to the bolt (36) hole
(2 places) on the pump transmission. Attach a on bracket (32). Hoist and remove bracket (32)
nylon sling onto the bodies of the main pumps (2 from the frame. (2 places)
used). Install a lever block. Hoist and hold pump : 41 mm, 55 mm
device (1).
At this time, do not touch the lifting sling with the 32 36, 37
hoses.
Wire
Lever Block
Lifting
Bracket
Nylon Sling

Main Pump

38, 39 W18C-02-03-009

W146-02-03-033

11. Remove bolts (34) (4 used) and spring washers


(35) (4 used). Remove bracket (33) between
engine (2) and bracket (32). (2 places)
: 27 mm

32
2

33
34, 35

W18C-02-03-009

W2-3-7
UPPERSTRUCTURE / Pump Device

W18K-02-03-001

Machine
Front B

View A (Engine Unit Upper Side)


W18K-02-03-002

W18C-02-03-001

Section B (Shield Plate Pump Side)

W2-3-8
UPPERSTRUCTURE / Pump Device
IMPORTANT: Check the piping from the lower
CAUTION: Pump device (1) weight: 1540 kg side of pump device (1).
(3400 lb) 15. Place pump device (1) on the stable place by
using wooden blocks (approx 220 mm (8.7 in)
IMPORTANT: If shaft (42) is installed to the pump height).
device (1) side, the clearance is too 1
small to remove pump device (1).
When removing pump device (1)
from engine (2), push shaft (42) to
the engine (2) side by hand.
14. Remove bolts (40) (16 used) and spring washers
(41) (16 used).
Adjust the lever block and align the center of
pump device (1). Pull out pump device (1)
straightly from engine (2). Hoist and remove Wooden
pump device (1) from engine (2). Block
: 19 mm 40
W18C-02-04-015
41

16. Attach a nylon sling onto the body of shaft (42).


42 2 Hoist and remove shaft (42) from engine (2).

Nylon Sling

2
42

1
W18C-02-03-007

Lever Block

W146-02-03-018

W146-02-03-033

W2-3-9
UPPERSTRUCTURE / Pump Device

W18K-02-03-001

Machine
Front B

View A (Engine Unit Upper Side)


W18K-02-03-002

W18C-02-03-001

Section B (Shield Plate Pump Side)

W2-3-10
UPPERSTRUCTURE / Pump Device

CAUTION: Main pump (45) weight: Each


192 kg (430 lb) (for each)
Fan motor drive pump (46) weight: 96 kg (220
lb)

17. Install eyebolts (M12, Pitch 1.75 mm) (6 used) to


the bodies of main pumps (45) (3 used). Attach a
wire onto eyebolts (6 used). Hoist and hold main
pump (45).
Install eyebolts (M10, Pitch 1.5 mm) (2 used) to
the body of fan motor drive pump (46). Attach a
wire onto eyebolts (2 used). Hoist and hold fan
motor drive pump (46).

18. Remove bolts (43) (12 used), socket bolts (47) (4


used), spring washers (44) (12 used) and (48) (4
used). Hoist and remove main pumps (45) (3
used) and fan motor drive pump (46) from the
pump transmission.
: 30 mm
: 17 mm
Pump
Transmission

45
43, 44

47, 48

46 W18C-02-03-011

W2-3-11
UPPERSTRUCTURE / Pump Device
Installation of Pump Device

W18K-02-03-001

Machine
Front B
6 7 8
3 9

10
4

11
22
12
21
20
19
5 13
18
14, 15
View A (Engine Unit Upper Side) 17
W18K-02-03-002
16

1 W18C-02-03-001

Section B (Shield Plate Pump Side)

1- Pump Device 7- Cover 13 - Bracket 18 - Bracket


2- Engine 8- Cover 14 - Bolt (92 Used) 19 - Cover
3- Bolt (26 Used) 9- Bracket 15 - Washer (92 Used) 20 - Cover
4- Cover (3 Used) 10 - Cover 16 - Cover 21 - Cover
5- Cover (3 Used) 11 - Cover 17 - Cover 22 - Bracket
6- Cover 12 - Cover

W2-3-12
UPPERSTRUCTURE / Pump Device
Installation
IMPORTANT: Install shaft (42) with the screw hole
of the end facing to the pump device
CAUTION: Main pump (45) weight: Each (1) side. Apply hydraulic oil onto
192 kg (430 lb) (for each) shaft (42).
Fan motor drive pump (46) weight: 96 kg (220 2. Hoist shaft (42). Install shaft (42) to engine (2).
lb)
Nylon Sling
IMPORTANT: Apply THREEBOND #1215 onto the
pump transmission mounting 2
surface on each pump. 42
1. Hoist and install main pumps (45) (3 used) and
fan motor drive pump (46) to the pump
transmission with bolts (43) (12 used), socket
bolts (47) (4 used), spring washers (44) (12
used) and (48) (4 used).
: 30 mm W146-02-03-018

: 540 N m (55 kgf m, 398 lbf ft)


3. Install special tools (ST 7304, ST 7305) to the
: 17 mm
shaft (42) mounting position on pump device (1).
: 540 N m (55 kgf m, 398 lbf ft)
At this time, insert the special tool (ST 7304) into
the pump transmission while aligning the splines
Pump
Transmission
of the gear.
ST 7304 ST 7305

45
43, 44

47, 48

W18B-02-04-031

Pump
Transmission

46 W18C-02-03-011 ST7304,
ST7305

W18B-02-04-033

W2-3-13
UPPERSTRUCTURE / Pump Device

W18K-02-03-001

Machine
Front B

5
View A (Engine Unit Upper Side)
W18K-02-03-002

W18C-02-03-001

Section B (Shield Plate Pump Side)

W2-3-14
UPPERSTRUCTURE / Pump Device
8. Install pump device (1) to engine (2) with bolts
CAUTION: Pump device (1) weight: 1540 kg (40) (16 used) and spring washers (41) (16
(3400 lb) used).
: 19 mm
4. Hoist pump device (1). Align the spline on shaft : 90 N m (9 kgf m, 66 lbf ft)
(42) with that of the special tool (ST 7305). Insert
shaft (42) into the special tool (ST 7305). 40
41
1
ST 7305

42 2

W18C-02-03-007

CAUTION: Bracket (32) weight: 49 kg (110


lb)

W18B-02-04-032
9. Hoist bracket (32). Install bracket (32) to the
frame with bolts (36) (6 used), (38) (2 used),
IMPORTANT: Do not drop special tools (ST 7304,
washers (37) (6 used) and (39) (2 used). (2
ST 7305) and shaft (42) when
places)
removing pump device (1).
: 41 mm
5. Remove pump device (1) first. At this time, face
: 1030 N m (105 kgf m, 760 lbf ft)
shaft (42) to the engine (2) side and special tools
: 55 mm
(ST 7304, ST 7305) to the pump transmission
: 3140 N m (320 kgf m, 2320 lbf ft)
side.

6. Remove special tools (ST 7304, ST 7294) from 32 36, 37


pump device (1).

IMPORTANT: Apply THREEBOND #1215 onto the


engine mounting surface of pump
device (1).
7. Hoist pump device (1). Align the spline of shaft
(42).

38, 39 W18C-02-03-009

W2-3-15
UPPERSTRUCTURE / Pump Device

W18K-02-03-001

Machine
Front B 6 7 8
3 9

10
4

11
22
12
21
20
19
5 18 13
14, 15
View A (Engine Unit Upper Side) 17
W18K-02-03-002 16

1 W18C-02-03-001

Section B (Shield Plate Pump Side)

W2-3-16
UPPERSTRUCTURE / Pump Device
10. Remove bolts (34) (2 used). Remove the special 14. Install brackets (23, 26) to bracket (9) with bolts
tool (ST 7326) from engine (2). (27) (16 used) and washers (28) (16 used).
: 27 mm : 24 mm
: 210 N m (21.5 kgf m, 155 lbf ft)
11. Install bracket (33) between engine (2) and
bracket (32) with bolts (34) (4 used) and spring 9 24 25 Connector
washers (35) (4 used). (2 places)
: 27 mm
: 390 N m (40 kgf m, 290 lbf ft)
32 23 26

27, 28
29

33 Shield Plate Engine W18C-02-03-006


34, 35
15. Install maintenance lamp (29) to bracket (9) with
bolts (25) (4 used).
: 17 mm
: 50 N m (5 kgf m, .36 lbf ft)
W18C-02-03-009

16. Connect the connectors to maintenance lamp


12. Install the oil cooler fan motor. (Refer to (29) and secure with bolts (24) (3 used).
REMOVAL AND INSTALLATION OF OIL
COOLER FAN MOTOR on W2-9-1.) 17. Install covers (6 to 8), (10 to 12), (16, 17), (19 to
21) and brackets (13, 18, 22) to the upper side of
pump device (1) with bolts (14) (92 used) and
CAUTION: Bracket (9) weight: 43 kg (95 lb)
washers (15) (92 used).
: 17 mm
13. Hoist bracket (9). Install bracket (9) to the upper
: 50 N m (5 kgf m, 36 lbf ft)
side of the engine unit with bolts (30) (8 used)
and washers (31) (8 used).
18. Install covers (4, 5) (3 used for each) to the upper
: 19 mm
side of the engine unit with bolts (3) (29 used).
: 90 N m (9 kgf m, 66 lbf ft)
: 19 mm
9 : 90 N m (9 kgf m, 66 lbf ft))

30, 31
W18B-02-04-024

W2-3-17
UPPERSTRUCTURE / Pump Device

W18K-02-03-001

Machine
Front B

View A (Engine Unit Upper Side)


W18K-02-03-002

W18C-02-03-001

Section B (Shield Plate Pump Side)

W2-3-18
UPPERSTRUCTURE / Pump Device
19. Connect all hoses, pipings and connectors to
pump device (1).

(Hose)
: 19 mm
: 30 N m (3.0 kgf m, 22 lbf ft)
: 22 mm
: 40 N m (4.0 kgf m, 30 lbf ft)
: 27 mm
: 93 N m (9.5 kgf m, 69 lbf ft)
: 36 mm
: 175 N m (18 kgf m, 130 lbf ft)
(Piping)
: 17 mm
: 24.5 N m (2.5 kgf m, 18 lbf ft)
(Bolt)
: 17 mm
: 50 N m (5 kgf m, 36 lbf ft)
: 19 mm
: 90 N m (9 kgf m, 66 lbf ft)
(Socket bolt)
: 8 mm
: 50 N m (5 kgf m, 36 lbf ft)
: 14 mm
: 210 N m (21 kgf m, 155 lbf ft)

IMPORTANT: After installing pump device (1) and


before starting the engine, add oil to
the pump transmission (Refer to
Adding Oil to Pump Transmission
on W2-3-20) and bleed air from the
pump (Refer to Bleeding Air from
Pump on W2-3-21).

W2-3-19
UPPERSTRUCTURE / Pump Device
Adding Oil to Pump Transmission Nozzle

IMPORTANT: In case the pump transmission has 1


been disassembled and assembled
and after starting the engine, it will
take time to lubricate each part
inside the pump transmission with
oil. Finally it may cause a fault.
In order to protect each part of the
pump transmission, lubricate each
part before starting the engine.

1. Remove a nozzle of oil feed pump (1). Install the


special tool (ST 6651).

2. Disconnect hose (10) from pump transmission oil


lubrication pump (7). Oil Feed Pump W146-02-03-019
: 27 mm

3. Install oil feed pump (1) to hose (10) at the


delivery side of pump transmission oil lubrication 2 3 4 5 6
pump (7). Add approx. 10 liters (2.6 US gal) of oil.
Oil: Apollo oil diesel motive S-330 Hose Oil Feed
Side Pump
Side
4. Remove the special tool (ST 6651) from hose
(10). Connect hose (10) to pump transmission oil
lubrication pump (7). W146-02-03-020
ST 6651
: 27 mm
: 93 N m (9.5 kgf m, 69 lbf ft) 2- Adapter : (R 3/4)
3- Quick Coupling : (R 3/4)
5. Remove level gauge (8). Add oil to the specified 4- Quick Coupling : (R 3/4)
level through pipe (9). 5- Adapter : (R 1/4)
6- Adapter : (R 1/4)
Oil: Apollo oil diesel motive S-330
NOTE: Total oil amount: 26 L (6.9 US gal.)
NOTE: Add oil while checking the oil level with
level gauge (8).

10

W18C-02-03-010

W2-3-20
UPPERSTRUCTURE / Pump Device
Bleeding Air from Hydraulic Pump

IMPORTANT: As air is accumulated inside of the


pump and if the engine is start in
lacking of hydraulic oil, the pump
will be damaged. Bleed air from the
pump.
IMPORTANT: If hose opening clamps (1, 2) are
removed, hydraulic oil may spurt
out. Do not remove hose opening 2
clamps (1, 2).
1. Loosen hose opening clamp (1) (12 places) of
the main pump and hose opening clamp (2) of
the fan drive pump by 2 to 3 turns.
1
: 19 mm, 27 mm

2. Start and run the engine at the slow idle. Bleed


air until only hydraulic oil flows from the tread part
of the hose opening clamp.

3. Stop the engine. Tighten all hose opening


clamps.
: 19 mm W18C-02-04-018
: 29.5 N m (3 kgf m, 22 lbf ft)
: 27 mm
: 93 N m (9.5 kgf m, 69 lbf ft)

IMPORTANT: After completing the work, check


the hydraulic oil level. Start and run
the engine at idling speed for 20
minutes. Check for any oil leaks.

W2-3-21
UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF PUMP TRANSMISSION

1
2
3
4
5
6
7

8
9
10
11
12
13
20
19
18
17
16
15 Pump Side

14

33 31, 32 30

38 21
22
39, 40
23
24
34 25
29 26
27, 28
Lifting
Holes Pulling-Out Hole
W18C-02-04-003

Engine
Side
W18C-02-04-004

35 36, 37

1- O-Ring 11 - Washer (10 Used) 21 - O-Ring (3 Used) 31 - Bolt (16 Used)


2- Spacer 12 - Bolt (10 Used) 22 - Ball Bearing (3 Used) 32 - Spring Washer (16 Used)
3- Disc Spring 13 - Oil Seal 23 - Gear (3 Used) 33 - Cover (3 Used)
4- Spacer 14 - Case 24 - Spacer (3 Used) 34 - Cover
5- Roller Bearing 15 - Ball Bearing 25 - Retaining Ring (3 Used) 35 - Pipe Assembly
6- Retaining Ring 16 - Retaining Ring 26 - Ball Bearing (3 Used) 36 - Bolt (4 Used)
7- Stopper 17 - Spacer 27 - Bolt (2 Used) 37 - Spring Washer (4 Used)
8- Gear 18 - Gear 28 - Washer (2 Used) 38 - Hook (2 Used)
9- Roller Bearing 19 - Ball Bearing 29 - Cover 39 - Bolt (4 Used)
10 - Cover 20 - O-Ring 30 - Cork (8 Used) 40 - Spring Washer (4 Used)

W2-3-22
UPPERSTRUCTURE / Pump Device
Disassembly of Pump Transmission
10. Remove O-ring (1), O-rings (21) (3 used) and
O-ring (20) from cover (29), covers (33) (3 used)
CAUTION: Pump transmission weight: and cover (34).
780 kg (1720 lb)
11. Install an eyebolt (M10, Pitch 1.5 mm) to the
1. Place the pump transmission on the stable stand lifting hole (2 places for each) on gear (18) and
with the pump side facing upward. gears (23) (3 used).
2. Remove bolts (36) (4 used) and washers (37) (4
used). Disconnect pipe assembly (35) from case CAUTION: The gear (18) assembly weight:
(14). 22 kg (50 lb)
The gear (23) assembly weight: 31 kg (70 lb)
3. Remove bolts (39) (4 used) and spring washers
(40) (4 used). Remove hooks (38) (2 used) from 12. Hoist and remove the gear (18) assembly and the
case (14). gear (23) assemblies (3 used) from case (14).

4. Remove bolts (31) (16 used) and spring washers 13. Remove retaining ring (16), retaining rings (25) (3
(32) (16 used). used), spacer (17) and spacers (24) (3 used)
: 17 mm from gear (18) and gears (23) (3 used).

5. Remove corks (30) (8 used) from covers (33) (3 IMPORTANT: Put the matching mark onto gears
used) and cover (34). (18, 23) and ball bearings (15, 19),
(22) (3 used) and (26) (3 used).
14. Warm up the gear (18) assembly and the gear
CAUTION: Cover (33) weight: 38 kg (84 lb)
(23) assemblies (3 used) to 90 °C (194 °F) in an
Cover (34) weight: 37 kg (82 lb)
oil tank. Remove ball bearings (15, 19), (22) (3
used) and (26) (3 used) from gears (18) and
6. Install a bolt (M20, Pitch 2.5 mm) to the
gears (23) (3 used).
pulling-out hole (2 places for each) on covers
(33) (3 used) and cover (34) and float from case
(14).
: 30 mm

7. Install an eyebolt (M20, Pitch 2.5 mm) to the


lifting hole (2 places for each) on covers (33) (3
used) and cover (34).

8. Hoist and remove covers (33) (3 used) and cover


(34) from case (14).

9. Remove bolts (27) (2 used) and washers (28) (2


used). Remove cover (29) from case (14).
: 19 mm

W2-3-23
UPPERSTRUCTURE / Pump Device

2
3
4
5
6
7

8
9
10
11
12
13

Pump Side

14

Bolt Hole

W18C-02-04-003

Engine
Side
W18C-02-04-004

W2-3-24
UPPERSTRUCTURE / Pump Device
15. Install an eyebolt (M27, Pitch 3.0 mm) to the bolt 23. Hoist and remove the gear (8) assembly from
hole (2 places) on the side of case (14). case (14). At this time, the inner race of roller
bearing (5) is removed with gear (8) together.
CAUTION: The case (14) assembly weight: 24. Remove the outer race of roller bearing (5),
500 kg (1110 lb) spacer (4), disc spring (3) and spacer (2) from
case (14).
16. Hoist and turn over the case (14) assembly.
25. Remove retaining ring (6) and stopper (7) from
17. Remove oil seal (13) from cover (10). the gear (8) assembly.
18. Remove bolts (12) (10 used) and washers (11) IMPORTANT: Put the matching marks onto gear
(10 used). (8) and the inner races of roller
: 19 mm bearings (5, 9).
26. Warm up the gear (8) assembly to approx. 90 °C
CAUTION: Cover (10) weight: 31 kg (70 lb) (194 °F) in an oil tank. Remove the inner races of
roller bearings (5, 9) from gear (8).
19. Insert a bolt (M12, Pitch 1.75 mm) to the
pulling-out hole (2 places) on cover (10). Float
cover (10) from case (14).
: 19 mm

20. Install an eyebolt (M12, Pitch 1.75 mm) to the


pulling-out hole (2 places) on cover (10).

21. Hoist and remove cover (10) from case (14). At


this time, the outer race of roller bearing (9) is
removed with cover (10) together.

CAUTION: The gear (8) assembly weight: 50


kg (110 lb)

22. Install an eyebolt (M10, Pitch 1.5 mm) to the


lifting hole (2 places) on gear (8).

W2-3-25
UPPERSTRUCTURE / Pump Device
ASSEMBLY OF PUMP TRANSMISSION

Pump Side 21 23 26 Engine Side

33 31, 32 30

38
25
39, 40
22

34
29 24
27, 28
11, 12
8
4 10
3
13

W18C-02-04-004
1
35 36, 37 2
6
7

9
5

18

17
16
19
15

20
14

W18C-02-04-005

1- O-Ring 11 - Washer (10 Used) 21 - O-Ring (3 Used) 31 - Bolt (16 Used)


2- Spacer 12 - Bolt (10 Used) 22 - Ball Bearing (3 Used) 32 - Spring Washer (16 Used)
3- Disc Spring 13 - Oil Seal 23 - Gear (3 Used) 33 - Cover (3 Used)
4- Spacer 14 - Case 24 - Spacer (3 Used) 34 - Cover
5- Roller Bearing 15 - Ball Bearing 25 - Retaining Ring (3 Used) 35 - Pipe Assembly
6- Retaining Ring 16 - Retaining Ring 26 - Ball Bearing (3 Used) 36 - Bolt (4 Used)
7- Stopper 17 - Spacer 27 - Bolt (2 Used) 37 - Spring Washer (4 Used)
8- Gear 18 - Gear 28 - Washer (2 Used) 38 - Hook (2 Used)
9- Roller Bearing 19 - Ball Bearing 29 - Cover 39 - Bolt (4 Used)
10 - Cover 20 - O-Ring 30 - Cork (8 Used) 40 - Spring Washer (4 Used)

W2-3-26
UPPERSTRUCTURE / Pump Device
Assembly of Pump Transmission
• As for the method to hoist the parts and the
position of the lifting hole, refer to Removal. CAUTION: Case (14) weight: 420 kg (930 lb)

1. Warm up ball bearings (15, 19), (22) (3 used) and 6. Hoist and place case (14) with the engine side
(26) (3 used) to approx. 90 °C (194 °F) by using facing upward.
a bearing heater.
7. Install spacer (2), disc spring (3), spacer (4) and
IMPORTANT: Install ball bearings (15, 19) while the outer race of roller bearing (5) to case (14).
aligning the matching marks made
when disassembling. CAUTION: The gear (8) assembly weight: 50
2. Install spacer (17), retaining ring (16) and ball kg (110 lb)
bearings (15, 19) to gear (18).
8. Hoist and install gear (8) to case (14).
CAUTION: Gear (23) weight: 25 kg (60 lb)
9. Install oil seal (13) to cover (10) by using a plate
and a hammer.
IMPORTANT: Install ball bearings (22, 26) while
aligning the matching marks made
when disassembling. CAUTION: Cover (10) weight: 31 kg (70 lb)
3. Install spacers (24) (3 used), retaining rings (25)
(3 used), ball bearings (22) (3 used) and (26) (3 IMPORTANT: Apply THREEBOND #1215 onto the
used) to gears (23) (3 used). case (14) mounting surface of cover
(10).
4. Heat the inner races of roller bearings (5, 9) to Apply LOCTITE #242 onto the thread
approx. 90°C by using a bearing heater. part of bolt (12).
10. Hoist cover (10). Install cover (10) to case (14)
CAUTION: Gear (8) weight: 42 kg (93 lb) with bolts (12) (10 used) and washers (11) (10
used).
IMPORTANT: Install the inner races of roller : 19 mm
bearings (5, 9) while aligning the : 90 N m (9.2 kgf m, 66 lbf ft)
matching marks made when
disassembling. CAUTION: The case (14) assembly weight:
5. Install stopper (7), retaining ring (6) and the inner 500 kg (1110 lb)
races of roller bearings (5, 9) to gear (8).
11. Hoist and turn over the case (14) assembly.

W2-3-27
UPPERSTRUCTURE / Pump Device

Lubrication Pump Side 21 23 Engine Side


33 31, 32 30 Port

38
39, 40

34
29
Lubrication 27, 28
Port
Lubrication
Port

W18C-02-04-004

35 36, 37 1

18

20
14

W18C-02-04-005

W2-3-28
UPPERSTRUCTURE / Pump Device
15. Install cover (29) to case (14) with bolts (27) (2
CAUTION: The gear (18) assembly weight: used) and washers (28) (2 used).
22 kg (55 lb) : 19 mm
The gear (23) assembly weight: 31 kg (70 lb) : 90 N m (9.2 kgf m, 66 lbf ft)
12. Hoist and install the gear (18) assembly and the 16. Install hooks (38) (2 used) to case (14) with bolts
gear (23) assemblies (3 used) to case (14). (39) (4 used) and spring washers (40) (4 used).
13. Install O-ring (1), O-rings (21) (3 used) and IMPORTANT: Apply THREEBOND #1215 onto the
O-ring (20) to cover (29), covers (33) (3 used) pipe assembly (35) mounting
and cover (34). surface of case (14).
17. Connect pipe assembly (35) to case (14) with
CAUTION: Cover (33) weight: 38 kg (84 lb) bolts (36) (4 used) and spring washers (37) (4
Cover (34) weight: 37 kg (82 lb) used).

IMPORTANT: Install covers (33) (3 used) and 18. Install corks (30) (8 used) to covers (33) (3 used)
cover (34) with the lubrication port and cover (34).
on the side facing to the position as
illustrated on W2-3-28.
14. Hoist covers (33) (3 used) and cover (34). Install
covers (33) (3 used) and cover (34) to case (14)
with bolts (31) (16 used) and spring washers (32)
(16 used).
: 17 mm
: 550 N m (56 kgf m, 410 lbf ft)

W2-3-29
UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF MAIN PUMP
• The components of casing (26) are same as
those of casing (74). 16
15

14
13 17
18
12 19
11 20
9 10
8 21

22
23

7 25
24
26
5
6 27
5 28
4 47
3 29
46
30 45
2 44
1 43
42
49
41 48
40
39
38

36 37
51 50 66
35 52
67 68
34
33
32
31
65
64
63
62 69
70
60 71
59
58 61 72
56
55 73
54 74
75
57
76
53 77

78
79
80
82 81
84 83 W18C-02-04-006

W2-3-30
UPPERSTRUCTURE / Pump Device

1- Socket Bolt (4 Used) 22 - O-Ring (4 Used) 43 - Plug 64 - O-Ring


2- Seal Cover 23 - Plug (4 Used) 44 - Seat 65 - O-Ring (6 Used)
3- O-Ring 24 - Plug (4 Used) 45 - Steel Ball 66 - Regulator
4- Retaining Ring (2 Used) 25 - Screw (4 Used) 46 - Stopper 67 - Socket Bolt (4 Used)
5- Spacer (3 Used) 26 - Casing 47 - O-Ring 68 - Socket Bolt (4 Used)
6- Bearing (2 Used) 27 - O-Ring (4 Used) 48 - Adjusting Screw 69 - Seal Cover
7- Shaft 28 - O-Ring (2 Used) 49 - Lock Nut 70 - Oil Seal
8- Lock Nut (2 Used) 29 - Support 50 - Valve Cover 71 - O-Ring
9- Adjusting Screw (2 Used) 30 - Socket Bolt (4 Used) 51 - Spring Pin (2 Used) 72 - Shaft
10 - Spring Pin 31 - Swash Plate (2 Used) 52 - Pin 73 - Support
11 - Stopper (2 Used) 32 - Bushing (2 Used) 53 - O-Ring 74 - Casing
12 - Backup Ring (2 Used) 33 - Shoe Plate (2 Used) 54 - Stopper 75 - Socket Bolt (4 Used)
13 - O-Ring (2 Used) 34 - Plunger (18 Used) 55 - Steel Ball 76 - Pin
14 - Tilt Pin (2 Used) 35 - Retainer (2 Used) 56 - Seat 77 - Spring Pin
15 - Regulator 36 - Spherical Bushing (2 Used) 57 - O-Ring 78 - Valve Cover
16 - Socket Bolt (4 Used) 37 - Spring (18 Used) 58 - O-Ring (4 Used) 79 - O-Ring
17 - Stopper (2 Used) 38 - Cylinder Block (2 Used) 59 - Lock Nut 80 - Plug
18 - Backup Ring (2 Used) 39 - Valve Plate 60 - Adjusting Screw 81 - O-Ring
19 - O-Ring (2 Used) 40 - Needle Bearing 61 - Needle Bearing 82 - O-Ring
20 - Servo Piston (2 Used) 41 - O-Ring (2 Used) 62 - Socket Bolt (8 Used) 83 - Booster
21 - Set Screw (8 Used) 42 - O-Ring 63 - Valve Plate 84 - Coupling

W2-3-31
UPPERSTRUCTURE / Pump Device

16
15

9
8 21

22
23

26

29
30

49
41 48

39

50 66
52
67

64
63
62

60
59
58 61
73
74
75
57 76

78

82 81
84 83 W18C-02-04-006

W2-3-32
UPPERSTRUCTURE / Pump Device
Disassembly of Main Pump

IMPORTANT: Do not disassemble lock nuts (8) (2 IMPORTANT: Do not drop valve plate (63).
used), (49, 59), adjusting screws (9) 6. Remove socket bolts (75) (4 used). Separate
(2 used) and (48, 60) as the set flow casing (74) from valve cover (78).
rate may change. : 17 mm
1. Remove plugs (23) (4 used) and O-rings (22) (4
used) from casing (26, 74). Drain hydraulic oil 7. Remove socket bolts (62) (8 used). Separate
from the main pump. valve cover (50) from valve cover (78).
: 36 mm : 10 mm

2. Remove socket bolts (16) (4 used). Remove 8. Remove O-ring (57), O-rings (58) (4 used) and
regulator (15) from casing (26). At this time, (81, 82) from valve cover (78).
check that O-ring with the regulator (15) side at-
tached does not fall off. 9. Remove coupling (84) and booster (83) from
: 6 mm shaft (7).

3. Remove socket bolts (67) (4 used). Remove IMPORTANT: Do not drop valve plate (39).
regulator (66) from casing (74). At this time, 10. Remove socket bolts (30) (4 used). Separate
check that O-ring with the regulator (66) side at- casing (26) from valve cover (50).
tached does not fall off. : 17 mm
: 6 mm
11. Remove O-rings (41, 64) from valve covers (50,
4. Remove set screws (21) (8 used) from casings 78).
(26, 74).
IMPORTANT: Valve plate (39) and valve plate (63)
are similar. Do not confuse valve
CAUTION: Main pump weight: 195 kg (430 plates (39) and (63) when handling
lb) them.
12. Remove valve plates (39, 63) and pins (52, 76)
5. Hoist and turn over the main pump with the regu- from valve covers (50, 78).
lator mounting surface facing downward. At this
time, do not damage the regulator mounting sur-
face.
NOTE: Install a shackle to the hole on the flange
of support (29, 73). Turn over the main
pump.

W2-3-33
UPPERSTRUCTURE / Pump Device

10

26
5
6
5 28
4 47
3 29
46
45
2 44
1

40

38

36 37
51 50
35
34
33

31

61
56
55
54

53 77

78

W18C-02-04-006

W2-3-34
UPPERSTRUCTURE / Pump Device
13. Remove spring pins (51) (2 used) and spring pin 17. Remove retainer (35) from the cylinder block (38)
(77) from valve covers (50, 78). assembly. At this time, plungers (34) (9 used) are
removed with retainer (35) together.
IMPORTANT: Do not remove needle bearings (40,
61) unless necessary. 18. Remove plungers (34) (9 used) from retainer
14. Remove needle bearings (40, 61) from valve (35).
covers (50, 78).
19. Remove spherical bushing (36) from cylinder
IMPORTANT: Do not remove seats (44, 56). block (38). Remove springs (37) (9 used).
Check the flow of air through seats
(44, 56) with valve covers (50, 78) 20. Remove socket bolts (1) (4 used). Remove seal
attached from the stoppers (46, 54) cover (2) and O-ring (3) from support (29).
side. If the air cannot flow freely, : 6 mm
there may be dirt on seats (44, 56). NOTE: There are pulling-out holes on seal cover
15. Remove O-rings (47, 53), stoppers (46, 54) and (2). Remove seal cover (2) by using a bolt
steel balls (45, 55) from valve covers (50, 78). (M8, Pitch 1.25 mm).

IMPORTANT: Wind vinyl tape onto the rotating 21. Lightly tap and remove support (29) from the cas-
surface of needle bearing (40) on ing (26) side by using a plastic hammer.
shaft (7) in order to protect the sur-
face. 22. Remove spring pin (10) and O-ring (28) from
16. Remove cylinder block (38) from casing (26). At support (29).
this time, springs (37) (9 used), spherical bushing
(36), retainer (35) and plungers (34) (9 used) are 23. Remove swash plate (31) and shoe plate (33)
removed with cylinder block (38) together. from casing (26).
NOTE: Grasp and slowly remove cylinder block
(38) by hands while lightly turning cylinder 24. Tap the flange part of the casing (26) side of shaft
block (38) to left and right. (7) by using a plastic hammer and remove shaft
(7) from support (29). At this time, bearing (6) is
removed with shaft (7) together.

25. Remove retaining ring (4) from shaft (7). Remove


spacer (5) and bearing (6).

W2-3-35
UPPERSTRUCTURE / Pump Device

14
13 17
18
12 19
11 20

25
24
26

68

65

69
70
71

73
74

W18C-02-04-006

W2-3-36
UPPERSTRUCTURE / Pump Device
26. Remove stoppers (11, 17) from casing (26). IMPORTANT: The components of casing (26) are
NOTE: Install a bolt (M6, Pitch 1.0 mm) to the same as those of casing (74).
center hole of the stopper and remove the 33. Disassemble the casing (74) assembly in the
stopper. same way as steps 16 to 27.
NOTE: Spacer (5) in the seal cover (69) side is not
IMPORTANT: As LOCTITE has been applied onto equipped for casing (74).
the contacting part between servo
piston (20) and tilt pin (14). Do not
disassemble them unless neces-
sary.
27. Warm up tilt pin (14) by using a drier. Secure
servo piston (20) in order not to damage by using
a pair of pliers. Turn and remove tilt pin (14).
Remove servo piston (20) from casing (26).

28. Remove O-rings (13, 19) and backup rings (12,


18) from stoppers (11, 17).

29. Remove plugs (24) (4 used) and screws (25) (4


used) from casings (26, 74).
: 4 mm, 5 mm

30. Remove socket bolts (68) (4 used). Remove seal


cover (69) and O-ring (71) from support (73).
: 6 mm
NOTE: There are pulling-out holes on seal cover
(69). Remove seal cover (69) by using a
bolt (M8, Pitch 1.25 mm).

31. Remove oil seal (70) from seal cover (69).

32. Remove O-rings (65) (6 used) from casing (74).

W2-3-37
UPPERSTRUCTURE / Pump Device
ASSEMBLY OF MAIN PUMP

29 36 31 33 35 32 26 41 50 49 48 82 64 65 18, 19 17 20 14 11 12, 13 73
60
8 59

9
10
1 68
71
6
69
5

7
2
72
4 A A 70
3 75

30
A 77 A
W18C-02-04-007
28 34 37 38 76
39 51 52 40 84 83 78 61 63 74
79, 80

Section of Check Valve


Section A-A 44 46
45 47

W18B-02-04-040
25

24
W18C-02-04-008

53 54 55 56

W2-3-38
UPPERSTRUCTURE / Pump Device

1- Socket Bolt (4 Used) 22 - *O-Ring (4 Used) 43 - *Plug 64 - O-Ring


2- Seal Cover 23 - *Plug (4 Used) 44 - Seat 65 - O-Ring (6 Used)
3- O-Ring 24 - Plug (4 Used) 45 - Steel Ball 66 - *Regulator
4- Retaining Ring (2 Used) 25 - Screw (4 Used) 46 - Stopper 67 - *Socket Bolt (4 Used)
5- Spacer (3 Used) 26 - Casing 47 - O-Ring 68 - Socket Bolt (4 Used)
6- Bearing (2 Used) 27 - *O-Ring (4 Used) 48 - Adjusting Screw 69 - Seal Cover
7- Shaft 28 - O-Ring (2 Used) 49 - Lock Nut 70 - Oil Seal
8- Lock Nut (2 Used) 29 - Support 50 - Valve Cover 71 - O-Ring
9- Adjusting Screw (2 Used) 30 - Socket Bolt (4 Used) 51 - Spring Pin (2 Used) 72 - Shaft
10 - Spring Pin 31 - Swash Plate (2 Used) 52 - Pin 73 - Support
11 - Stopper (2 Used) 32 - Bushing (2 Used) 53 - O-Ring 74 - Casing
12 - Backup Ring (2 Used) 33 - Shoe Plate (2 Used) 54 - Stopper 75 - Socket Bolt (4 Used)
13 - O-Ring (2 Used) 34 - Plunger (18 Used) 55 - Steel Ball 76 - Pin
14 - Tilt Pin (2 Used) 35 - Retainer (2 Used) 56 - Seat 77 - Spring Pin
15 - *Regulator 36 - Spherical Bushing (2 Used) 57 - *O-Ring 78 - Valve Cover
16 - *Socket Bolt (4 Used) 37 - Spring (18 Used) 58 - *O-Ring (4 Used) 79 - O-Ring
17 - Stopper (2 Used) 38 - Cylinder Block (2 Used) 59 - Lock Nut 80 - Plug
18 - Backup Ring (2 Used) 39 - Valve Plate 60 - Adjusting Screw 81 - *O-Ring
19 - O-Ring (2 Used) 40 - Needle Bearing 61 - Needle Bearing 82 - O-Ring
20 - Servo Piston (2 Used) 41 - O-Ring (2 Used) 62 - *Socket Bolt (8 Used) 83 - Booster
21 - *Set Screw (8 Used) 42 - *O-Ring 63 - Valve Plate 84 - Coupling

NOTE: As for the parts with mark *, refer to W2-3-30.

W2-3-39
UPPERSTRUCTURE / Pump Device

65
29 31 33 26 50 18, 19 17 20 14 11 12, 13 73

10

6
69
5

72
4 A A

A A
W18C-02-04-007
28
78 74

Section of Check Valve


Section A-A

W18B-02-04-040
25

24
W18C-02-04-008

W2-3-40
UPPERSTRUCTURE / Pump Device
Assembly of Main Pump

IMPORTANT: Apply LOCTITE #1305N onto the IMPORTANT: Apply grease onto the mating sur-
thread part of servo piston (20). faces between swash plate (31) and
1. Install tilt pins (14) (2 used) and servo pistons shoe plate (33). After installing
(20) (2 used) to casings (26, 74). swash plate (31), check that swash
plate (31) can move smoothly by
2. Install O-rings (13) (2 used), (19) (2 used), hand.
backup rings (12) (2 used) and (18) (2 used) to 7. Attach a nylon sling onto the bodies of casings
stoppers (11) (2 used) and (17) (2 used). (26, 74). Hoist and place casings (26, 74) with
the regulator mounting surface facing downward.
3. Install the stopper (11) assembly and the stopper Install swash plates (31) (2 used) with shoe
(17) assembly to casings (26, 74). plates (33) (2 used) attached to tilt pins (14) (2
used).
4. Install spacers (5) (3 used), bearings (6) (2 used) NOTE: Install shoe plate (33) with the chamfered
and retaining rings (4) (2 used) to shafts (7, 72). side facing to the swash plate (31) side.
NOTE: Spacer (5) in the seal cover (69) side is not
equipped for shaft (72). 8. Install spring pins (10) (2 used) and O-rings (28)
(2 used) to supports (29, 73). Install O-rings (27)
5. Install screws (25) (4 used) and plugs (24) (4 (4 used) to casings (26, 74).
used) to casings (26, 74).
: 4 mm 9. Install O-ring (57), O-rings (58) (4 used), (65) (6
: 9 N m (0.9 kgf m, 7 lbf ft) used) and O-ring (81) among valve covers (50,
: 5 mm 78) and casing (74) respectively.
: 10 N m (0.9 kgf m, 7 lbf ft)
10. Align the support (29) assembly and the support
IMPORTANT: Do not tap shafts (7, 72) by using a (73) assembly with casings (26, 74).
hammer.
6. Install shafts (7, 72) to supports (29, 73), At this
time, lightly tap the outer race of bearing (6) by
using a plastic hammer. Tap the outer race into
the most inside by using a bar and a hammer.

W2-3-41
UPPERSTRUCTURE / Pump Device

36 35 26 41 50 82 64

72
A A

30
A 77 A
W18C-02-04-007
34 37 38 76
39 51 52 40 84 83 78 61 63 74

Section of Check Valve


Section A-A 46
45 47

W18B-02-04-040

W18C-02-04-008

53 54 55

W2-3-42
UPPERSTRUCTURE / Pump Device
11. Install springs (37) (18 used), spherical bushings 17. Install valve cover (50) to the casing (26) assem-
(36) (2 used), retainers (35) (2 used) and plung- bly with socket bolts (30) (4 used).
ers (34) (18 used) to cylinder blocks (38) (2 used) : 17 mm
in this order. : 430 N m (44 kgf m, 320 lbf ft)

12. Install the cylinder block (38) assemblies (2 used) 18. Install set screws (21) (4 used) to casing (26).
to casings (26, 74). : 4 mm
NOTE: For easy installation, align shafts (7, 72) : 12 N m (1.2 kgf m, 9 lbf ft)
with the spline grooves in cylinder block
(38) and spherical bushing (36) before in- 19. Install steel ball (45), stopper (46) and O-ring (47)
stalling. to valve cover (50).

13. Install needle bearings (40, 61) to valve covers 20. Install steel ball (55), stopper (54) and O-ring (53)
(50, 78). to valve cover (78).

14. Install spring pins (51) (2 used), pin (52) and 21. Install coupling (84) and booster (83) onto shaft
O-ring (41) to valve cover (50). (7).

15. Install spring pin (77), pin (76) and O-rings (64,
82) to valve cover (78).

IMPORTANT: Apply grease onto the mounting


surfaces before installing valve
plates (39, 63). Install valve plates
(39, 63) with the spherical side fac-
ing to the cylinder block (38) side.
16. Install vale plates (39, 63) to valve covers (50,
78).

W2-3-43
UPPERSTRUCTURE / Pump Device

29 26 50 73

1 68
71
69

2
A A 70
3 75

A A
W18C-02-04-007

78 74
79, 80

Section of Check Valve


Section A-A

W18B-02-04-040

W18C-02-04-008

W2-3-44
UPPERSTRUCTURE / Pump Device
22. Install valve cover (78) to the valve cover (50) 28. Install seal cover (69) to support (73) with socket
assembly with socket bolts (62) (8 used). bolts (68) (4 used).
: 17 mm : 6 mm
: 430 N m (44 kgf m, 320 lbf ft) : 30 N m (3 kgf m, 22 lbf ft)

23. Install the valve cover (78) assembly to the cas-


ing (74) assembly with bolts (75) (4 used). CAUTION: Main pump weight: 195 kg (430
lb)
24. Install set screws (21) (4 used) to the casing (74)
assembly. 29. Hoist and place the pump assembly with the
: 4 mm regulator mounting surface facing upward.
: 12 N m (1.2 kgf m, 9 lbf ft) NOTE: Install a shackle to the hole on the flange
part of supports (29, 73) before hoisting.
25. Install plugs (23) (4 used), O-rings (22) (4 used),
plugs (43, 80) and O-rings (42, 79) to the casing 30. Install regulators (15, 66) with socket bolts (16) (4
(26) assembly and the casing (74) assembly. used) and (67) (4 used).
: 19 mm : 6 mm
: 36 N m (3.7 kgf m, 27 lbf ft) : 30 N m (3 kgf m, 22 lbf ft)
: 36 mm
: 170 N m (17.5 kgf m, 125 lbf ft)

26. Install O-ring (3) to seal cover (2). Install seal


cover (2) to support (29) with socket bolts (1) (4
used).
: 6 mm
: 30 N m (3 kgf m, 22 lbf ft)

27. Install oil seal (70) and O-ring (71) to seal cover
(69).

W2-3-45
UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD

1. Clearance between plunger (34) outer diameter


(d) and cylinder block (38) bore (D)

D-d Unit: mm (in)


Standard Allowable Limit
d D
0.038 (0.001) 0.078 (0.003)

W117-02-02-009

2. Spring (37) free length (L)


Unit: mm (in)
Standard Allowable Limit
40.9 (1.6) 40.1 (1.6)

W117-02-02-010

3. Clearance (e) between plunger (34) and the


crimped part of the shoe, and shoe thickness (t)
e Unit: mm (in)
Standard Allowable Limit
0 to 0.1 0.35
(0 to 0.004) (0.014)
t Unit: mm (in)
Standard Allowable Limit e
5.4 (0.2) 5.0 (0.2) t

W117-02-02-011

Stand
4. Distance between retainer (35) bottom and
spherical bushing (36) top
H
H-h Unit: mm (in) h
Standard Allowable Limit
23.8 (0.9) 22.8 (0.9) W117-02-02-012

W2-3-46
UPPERSTRUCTURE / Pump Device
(Blank)

W2-3-47
UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF REGULATOR FOR
MAIN PUMP
12
11
10
9
8

7 66
6 13
15
5 16
4 17
3
19
2
1 14
20

21
22
26 18 23
24
27 25 46
28
29
31 30
32
45
47

44
43
42
37 39 41
34
40
33 48
49
35
36
38

63
51
64 52
53

57
65
50
62 61
56
60
58 55
54
59
W18C-02-04-009

W2-3-48
UPPERSTRUCTURE / Pump Device

1- Pin 18 - Pin 35 - O-Ring 51 - Supporting Plug


2- Sleeve 19 - Lever 36 - O-Ring (3 Used) 52 - O-Ring
3- O-Ring 20 - Pin 37 - Socket Bolt (2 Used) 53 - Lock Ring
4- O-Ring 21 - O-Ring 38 - Casing 54 - Lock Ring
5- Sleeve 22 - Stopper 39 - Socket Bolt (2 Used) 55 - O-Ring
6- Compensating Piston 23 - Spring 40 - O-Ring (2 Used) 56 - Supporting Plug
7- Compensating Rod 24 - Spring Seat 41 - Adjusting Screw 57 - Pin (2 Used)
8- Spring Seat 25 - Pilot Piston 42 - Adjusting Screw 58 - O-Ring
9- Spring 26 - Spool 43 - Lock Nut 59 - O-Ring
10 - Spring 27 - Sleeve 44 - O-Ring 60 - O-Ring
11 - Stopper 28 - Retaining Ring 45 - Cover 61 - O-Ring
12 - O-Ring 29 - Spring 46 - Socket Bolt (4 Used) 62 - O-Ring
13 - Pin 30 - Spring 47 - Lock Nut 63 - O-Ring
14 - Pin 31 - Spring Seat 48 - Lock Nut 64 - Cover
15 - Lever 32 - Retaining Ring 49 - Adjusting Screw 65 - Socket Bolt (4 Used)
16 - Feedback Lever 33 - Socket Bolt (4 Used) 50 - Pin 66 - Piston
17 - Pin 34 - Cover

W2-3-49
UPPERSTRUCTURE / Pump Device

12
11
10
9
8

3
2
1

26

27 46
28
29
31 30
32
45
47

44
43
42
37 39 41
34

33 48
49
35
36
38

63
51
64
53

57
65
50
62 61
56
60
58 54
59
W18C-02-04-009

W2-3-50
UPPERSTRUCTURE / Pump Device
Disassembly of Regulator for Main Pump

1. Remove socket bolts (37) (2 used) and (39) (2 8. Remove retaining ring (32) from spool (26). Re-
used). Remove the regulator from the pump body. move spring seat (31), spring (30) and sleeve
Remove pins (57) (2 used) and O-rings (58, 59) (27) from spool (26).
from casing (38).
: 6 mm 9. Remove retaining ring (28) from sleeve (27).

2. Remove socket bolts (33) (4 used). Remove 10. Remove pin (1), sleeve (2) and O-ring (3) from
cover (34), O-rings (35) and O-rings (36) (3 used) casing (38).
from casing (38).
: 5 mm 11. Remove lock rings (53, 54) from casing (38).

IMPORTANT: Do not disassemble lock nuts (43, IMPORTANT: Supporting plugs (51, 56) look quite
48, 47) and adjusting screws (42, 49, similar. Put the matching marks in
41) as the set flow rate changes. order to install correctly.
When removing cover (45), prevent 12. Insert a bolt (M6, Pitch 1.0 mm) into the center
springs (9, 10) inside from flying hole of supporting plugs (51, 56). Remove sup-
out. porting plugs (51, 56) from casing (38).
3. Remove socket bolts (46) (4 used). Remove the At this time, pin (50) is removed with supporting
cover (45) assembly and O-ring (44) from casing plug (51) together.
(38).
: 5 mm 13. Remove pin (50) from supporting plug (56).

4. Remove springs (9, 10) and spring seat (8) from


casing (38).

5. Remove stopper (11) and O-ring (12) from the


cover (45) assembly.

6. Remove socket bolts (65) (4 used). Remove


cover (64) from casing (38).
: 5 mm

7. Remove O-rings (60, 61, 62, 63) and spring (29)


from casing (38).

W2-3-51
UPPERSTRUCTURE / Pump Device

7 66
6
15
5 16
4 17
19

14
20

21
22
26 23
24
25

41

38

51
52

56
55

W18C-02-04-009

W2-3-52
UPPERSTRUCTURE / Pump Device
14. Remove O-rings (52, 55) from supporting plugs
(51, 56).

IMPORTANT: Do not remove pin (20) from lever


(19).
15. Remove lever (19) from casing (38) by using a
pair of pincers.

16. Remove pin (17) and feedback lever (16) by us-


ing a round bar (4 mm).

IMPORTANT: Do not remove pin (14) from lever


(15).
17. Remove lever (15) from casing (38).

18. Remove pilot piston (25) from casing (38).

19. Insert a round bar (Dia. 4 mm (0.2 in)) into the


pilot piston (25) side. Remove spring seat (24),
spring (23) and stopper (22) from casing (38).

20. Remove O-ring (21) from stopper (22).

21. Insert a round bar (Dia. 4 mm (0.2 in)) into the


adjusting screw (41) side. Remove compensating
rod (7) and the sleeve (5) assembly from casing
(38).

22. Remove compensating rod (7), compensating


piston (6) and O-ring (4) from sleeve (5).

23. Remove spool (26) from casing (38).

W2-3-53
UPPERSTRUCTURE / Pump Device
ASSEMBLY OF REGULATOR FOR MAIN
PUMP A 34 33

B C W117-02-02-016

Section A-B
64 38 25 18 19 20 23 22 21

61 48

49
65

37 24 39
W18C-02-04-010

Section A-C
63 29 30 28 27 26 17 15 8 40
D 45
9 44 47
10 66 43
32
42
31

3
4 5 6 7 14 57 11 12 41
58 16 50
D W117-02-02-007

13 51 52 53
Section D-D

14 56 55 54 W18B-02-04-043

W2-3-54
UPPERSTRUCTURE / Pump Device

1- Pin 18 - Pin 35 - *O-Ring 51 - Supporting Plug


2- Sleeve 19 - Lever 36 - *O-Ring (3 Used) 52 - O-Ring
3- O-Ring 20 - Pin 37 - Socket Bolt (2 Used) 53 - Lock Ring
4- O-Ring 21 - O-Ring 38 - Casing 54 - Lock Ring
5- Sleeve 22 - Stopper 39 - Socket Bolt (2 Used) 55 - O-Ring
6- Compensating Piston 23 - Spring 40 - O-Ring (2 Used) 56 - Supporting Plug
7- Compensating Rod 24 - Spring Seat 41 - Adjusting Screw 57 - Pin (2 Used)
8- Spring Seat 25 - Pilot Piston 42 - Adjusting Screw 58 - O-Ring
9- Spring 26 - Spool 43 - Lock Nut 59 - *O-Ring
10 - Spring 27 - Sleeve 44 - O-Ring 60 - *O-Ring
11 - Stopper 28 - Retaining Ring 45 - Cover 61 - O-Ring
12 - O-Ring 29 - Spring 46 - *Socket Bolt (4 Used) 62 - *O-Ring
13 - Pin 30 - Spring 47 - Lock Nut 63 - O-Ring
14 - Pin 31 - Spring Seat 48 - Lock Nut 64 - Cover
15 - Lever 32 - Retaining Ring 49 - Adjusting Screw 65 - Socket Bolt (4 Used)
16 - Feedback Lever 33 - Socket Bolt (4 Used) 50 - Pin
17 - Pin 34 - Cover
NOTE: As for the parts with mark *, refer to W2-3-48.

W2-3-55
UPPERSTRUCTURE / Pump Device

B C W117-02-02-016

Section A-B
38 25 19 20

W18C-02-04-010

Section A-C
29 30 28 27 26 17 15
D

32

31

7 14
16 50
D W117-02-02-007

51 52 53
Section D-D

56 55 54 W18B-02-04-043

W2-3-56
UPPERSTRUCTURE / Pump Device
Assembly of Regulator for Main Pump
IMPORTANT: After inserting, check that pilot pis-
IMPORTANT: Check the direction to install com- ton (25) moves smoothly.
pensating rod (7) as illustrated. 6. Insert pilot piston (25) into casing (38).
1. Insert compensating rod (7) into casing (38).
7. Install O-rings (52, 55) to supporting plugs (51,
2. Install pin (14) to lever (15). Insert lever (15) into 56).
casing (38). Install pin (14) while aligning with the
groove in compensating rod (7). IMPORTANT: Supporting plugs (51, 56) look quite
similar.
3. Install retaining ring (28) to sleeve (27). Install plugs (51, 56) while aligning
the matching marks made when
IMPORTANT: After inserting, check that spool (26) disassembling in order to install
moves smoothly. correctly.
4. Insert sleeve (27) and spool (26) into casing (38). 8. Align the groove on pilot piston (25) with pin (20)
on lever (19). Install lever (19).
IMPORTANT: Check the direction to install feed-
back lever (16). 9. Install pin (50) to supporting plug (56). Align pin
5. Align the pin hole (the hole in the upper side) on (50) with the hole on lever (19). Install supporting
feedback lever (16) with the pin hole on spool plug (56) to lever (19).
(26). Install pin (17).
10. Install lock ring (54) to supporting plug (56).

11. Install supporting plug (51) to casing (38). Install


lock ring (53).
Compensating Lever (26) Side
Rod (7) Side
12. Install spring (30) and spring seat (31) to spool
(26). Install retaining ring (32).

13. Install spring (29) to casing (38).

W18B-02-04-018

W2-3-57
UPPERSTRUCTURE / Pump Device

A 34 33

B C W117-02-02-016

Section A-B
64 38 23 22 21

61

65

37 24 39
W18C-02-04-010

Section A-C

63 8
D 45
9 44
10

3
4 5 6 7 57 11 12
58
D W117-02-02-007

Section D-D

W18B-02-04-043

W2-3-58
UPPERSTRUCTURE / Pump Device
IMPORTANT: Check the direction to install com- 25. Install pins (57) (2 used) and O-rings (58, 59) to
pensating piston (6) as illustrated. casing (38).
14. Install O-ring (4) and compensating piston (6) to
sleeve (5). 26. Install the regulator to the pump body with socket
bolts (37) (2 used) and (39) (2 used).
15. Install sleeve (5), O-ring (3), sleeve (2) and pin : 6 mm
(1) to casing (38). : 30 N m (3 kgf m, 22 lbf ft)

16. Install O-rings (60, 62, 61 and 63) to casing (38).

17. Install cover (64) to casing (38) with socket bolts


(65) (4 used).
: 5 mm
: 11.5 N m (1.2 kgf m, 8 lbf ft)

18. Install O-ring (35) and O-rings (36) (3 used) to


cover (34).

19. Install cover (34) to casing (38) with socket bolts


(33) (4 used).
: 5 mm
: 11.5 N m (1.2 kgf m, 8 lbf ft)

20. Install O-ring (21) to stopper (22).

21. Install spring seat (24), spring (23) and stopper


(22) to casing (38).

22. Install O-ring (12) to stopper (11).

23. Install spring seat (8) and springs (9, 10) to cas-
ing (38).

24. Install stopper (11) and O-ring (44) to the cover


(45) assembly. Install the cover (45) assembly to
casing (38) with socket bolts (46) (4 used).
: 5 mm
: 11.5 N m (1.2 kgf m, 8 lbf ft)

W2-3-59
UPPERSTRUCTURE / Pump Device
(Blank)

W2-3-60
UPPERSTRUCTURE / Pump Device
STRUCTURE OF 4-SPOOL PUMP

A B C D

T117-02-01-017

A - Oil Cooler Fan Motor Drive Pump (Plunger Pump) C - Compressor Motor Drive Pump (End Side Tandem Gear Pump)
B - Pilot Pump (Pump Transmission Side Tandem Gear) D - Pump Transmission Oil Lubrication Pump (Gear Pump)

W2-3-61
UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF OIL COOLER FAN
DRIVE PUMP 17
18

16 20 21 22

19
15 23
14
13
12
11
10 24 25
26
27

9 28
8
7
6
5 29
30
4 31
3 32 51
2
1 50
49
48

47
44 46
45
43
42
39 52
53
54
40 41
55

37 38 62
35
34 63 59 58
36 66 65 64 61 57 56
60
33

W18C-02-04-012

1- Socket Bolt (4 Used) 18 - Socket Bolt (4 Used) 35 - Shoe Plate 51 - Socket Bolt (4 Used)
2- Cover 19 - Servo Piston 36 - Plunger (9 Used) 52 - Plug
3- O-Ring 20 - O-Ring 37 - Retainer 53 - O-Ring
4- Oil Seal 21 - Backup Ring 38 - Spherical Bushing 54 - Casing
5- Shaft 22 - Stopper 39 - Retaining Ring 55 - Socket Bolt (3 Used)
6- Spacer 23 - O-Ring 40 - Spring (9 Used) 56 - O-Ring (4 Used)
7- Bearing 24 - O-Ring 41 - Cylinder Block 57 - Seat
8- Spacer 25 - Plug 42 - Stopper 58 - Steel Ball
9- Retaining Ring 26 - Lock Nut 43 - Steel Ball 59 - Stopper
10 - Lock Nut 27 - Eyebolt 44 - Seat 60 - Plug
11 - Adjusting Screw 28 - Housing 45 - Valve Cover 61 - O-Ring
12 - Spring Pin 29 - O-Ring (2 Used) 46 - Adjusting Screw 62 - Spring Pin
13 - Stopper 30 - O-Ring 47 - Lock Nut 63 - Pin
14 - Backup Ring 31 - Cover 48 - Coupling 64 - O-Ring
15 - O-Ring 32 - Socket Bolt (4 Used) 49 - O-Ring 65 - Needle Bearing
16 - Tilt Pin 33 - Swash Plate 50 - Plate 66 - Valve Plate
17 - Regulator 34 - Bushing

W2-3-62
UPPERSTRUCTURE / Pump Device
Disassembly of Oil Cooler Fan Drive Pump

IMPORTANT: Do not disassemble adjusting screw IMPORTANT: Do not remove needle bearing (65)
(11), lock nut (10), adjusting screw unless necessary.
(46) and lock nut (47) as the set flow 6. Remove valve plate (66) and O-ring (64) from
rate changes. valve cover (45).
1. Remove plug (60). Drain hydraulic oil from the
pump. 7. Remove socket bolts (55) (3 used). Remove
: 19 mm casing (54) and O-rings (56) (4 used) from valve
cover (45).
2. Remove socket bolts (18) (4 used). Remove : 5 mm
regulator (17).
: 6 mm 8. Remove plug (52) and O-ring (53) from casing
(54).
: 19 mm
CAUTION: Pump weight: 62 kg (140 lb)
IMPORTANT: Do not remove seats (44, 57).
IMPORTANT: Do not damage the regulator Check the flow of air through seats
mounting surface on housing (28). (44, 57) with valve cover (45) at-
3. Attach a nylon sling onto the body of housing (28). tached from the stoppers (42, 59)
Hoist and place housing (28) with the regulator side. If the air can not flow freely,
mounting surface facing downward. Remove there may be dirt on seats (44, 57).
socket bolts (51) (4 used). Remove socket bolts Clean seats (44, 57) by using a com-
(51) (4 used). Remove plate (50), O-ring (49) and pressor.
coupling (48) from valve cover (45). 9. Remove stoppers (42, 59) and steel balls (43,
: 10 mm 58) from valve cover (45).
4. Remove retaining ring (39) from coupling (48). IMPORTANT: Wind vinyl tape onto the rotating
surface of needle bearing (65) on
IMPORTANT: At this time, do not remove cover shaft (5) in order to protect the sur-
(31) from housing (28). face.
Do not drop valve plate (66). 10. Remove cylinder block (41) from housing (28). At
5. Remove socket bolts (32) (4 used). Remove this time, springs (40) (9 used), spherical bushing
valve cover (45) from housing (28). (38), retainer (37) and plungers (36) (9 used) are
: 17 mm removed with cylinder block (41) together.
NOTE: Remove cylinder block (41) while lightly
turning cylinder block (41) to left and right
by hands slowly.

W2-3-63
UPPERSTRUCTURE / Pump Device

16 20 21 22

19
14 15
13

9 28
8
7
6
5

4 31
3
2
1

45

40 41

37 38
35
34 36

33

W18C-02-04-012

W2-3-64
UPPERSTRUCTURE / Pump Device
11. Remove retainer (37) from the cylinder block (41) 21. Attach a nylon sling onto the body of housing (28).
assembly. At this time, plungers (36) (9 used) are Hoist and place housing (28) with the regulator
removed with retainer (37) together. mounting surface facing upward.

12. Remove plungers (36) (9 used) from retainer (37). 22. Install a bolt (M5, Pitch 0.75 mm) to the center of
stoppers (13, 22). Remove stoppers (13, 22)
13. Remove spherical bushing (38) from cylinder from housing (28).
block (41). Remove springs (40) (9 used).
IMPORTANT: LOCTITE has been applied onto the
14. Remove socket bolts (1) (4 used) from cover (31). joint part between servo piston (19)
Remove cover (2). and tilt pin (16). Do not remove them
: 6 mm unless necessary.
NOTE: Remove cover (2) by installing a bolt (M8, 23. Remove backup rings (14, 21) and O-rings (15,
Pitch 1.25 mm) into the pulling-out hole. 20) from stoppers (13, 22).

15. Remove O-ring (3) and oil seal (4) from cover (2). 24. Warm up tilt pin (16) by using a drier. Secure
servo piston (19) in order not to damage by using
16. Lightly tap the flange part of cover (31) at the a pair of pliers. Turn and remove tilt pin (16).
housing (28) side. Separate cover (31) from Remove servo piston (19) from housing (28).
housing (28).

IMPORTANT: Do not remove bushing (34) unless


necessary.
17. Remove swash plate (33) and shoe plate (35)
from the inside of housing (28).

18. Lightly tap shaft (5) at the valve cover (45) side
by using a plastic hammer. Remove shaft (5)
from cover (31).

19. Remove retaining ring (9) from shaft (5). Remove


spacer (8) and the inner ring plate and the outer
race of bearing (7).

20. Remove the inner race of bearing (7) and spacer


(6) from shaft (5).

W2-3-65
UPPERSTRUCTURE / Pump Device
ASSEMBLY OF OIL COOLER FAN DRIVE
PUMP

31 14, 15 13 35 19 33 16 28 34 22 20, 21 64 66 47 46 50
10

11
12

30
51
1

6
49

39

5
48

32

7 8 9 37 36 38 40 41 62 60, 61 63 65 45
W18C-02-04-013

42 43

44
23

57

58

54 59

W18B-02-04-044

52, 53 56 55

W2-3-66
UPPERSTRUCTURE / Pump Device

1- Socket Bolt (4 Used) 18 - *Socket Bolt (4 Used) 35 - Shoe Plate 51 - Socket Bolt (4 Used)
2- Cover 19 - Servo Piston 36 - Plunger (9 Used) 52 - Plug
3- O-Ring 20 - O-Ring 37 - Retainer 53 - O-Ring
4- Oil Seal 21 - Backup Ring 38 - Spherical Bushing 54 - Casing
5- Shaft 22 - Stopper 39 - Retaining Ring 55 - Socket Bolt (3 Used)
6- Spacer 23 - O-Ring 40 - Spring (9 Used) 56 - O-Ring (4 Used)
7- Bearing 24 - *O-Ring 41 - Cylinder Block 57 - Seat
8- Spacer 25 - *Plug 42 - Stopper 58 - Steel Ball
9- Retaining Ring 26 - *Lock Nut 43 - Steel Ball 59 - Stopper
10 - Lock Nut 27 - *Eyebolt 44 - Seat 60 - Plug
11 - Adjusting Screw 28 - Housing 45 - Valve Cover 61 - O-Ring
12 - Spring Pin 29 - *O-Ring (2 Used) 46 - Adjusting Screw 62 - Spring Pin
13 - Stopper 30 - *O-Ring 47 - Lock Nut 63 - Pin
14 - Backup Ring 31 - Cover 48 - Coupling 64 - O-Ring
15 - O-Ring 32 - Socket Bolt (4 Used) 49 - O-Ring 65 - Needle Bearing
16 - Tilt Pin 33 - Swash Plate 50 - Plate 66 - Valve Plate
17 - *Regulator 34 - Bushing
NOTE: As for the parts with mark *, refer to W2-3-62.

W2-3-67
UPPERSTRUCTURE / Pump Device

31 14, 15 13 35 19 33 16 28 34 22 20, 21

12

30

3 W18C-02-04-013

7 8 9

W18B-02-04-044

W2-3-68
UPPERSTRUCTURE / Pump Device
Assembly of Oil Cooler Fan Drive Pump

IMPORTANT: Apply LOCTITE #1303B onto the 9. Install spacer (6) and the inner race of bearing (7)
thread part of servo piston (19). to shaft (5).
1. Insert servo piston (19) into housing (28). Install
tilt pin (16) to servo piston (19). IMPORTANT: Install the outer race and the inner
ring plate of bearing (7) with the
2. Install O-ring (15) and backup ring (14) to stopper stamped marks facing to the hous-
(13). ing (28) side.
Install O-ring (20) and backup ring (21) to stopper 10. Install the outer race, the inner ring plate of bear-
(22). ing (7), spacer (8) and retaining ring (9) to shaft
(5) in this order.
3. Install stoppers (13, 22) to housing (28).
IMPORTANT: Do not tap shaft (5) by using a
IMPORTANT: Apply grease onto the mounting hammer.
surface. Install with the chamfered 11. Install shaft (5) to cover (31).
side of shoe plate (35) to swash At this time, lightly tap and install the outer race
plate (33). of bearing (7) by using a plastic hammer. Tap the
4. Install shoe plate (35) to swash plate (33). outer race into the most inside by using a bar and
a hammer.
5. Attach a nylon sling onto the body of housing (28).
Hoist and place housing (28) with the mounting 12. Install O-ring (3) and oil seal (4) to cover (2).
regulator surface facing downward.
13. Install cover (2) to cover (31) with socket bolts (1)
6. Insert swash plate (33) into housing (28). Insert (4 used).
tilt pin (16) into bushing (34) of swash plate (33). : 6 mm
: 29.4 N m (3 kgf m, 22 lbf ft)
IMPORTANT: After installing cover (31), check
that swash plate (33) moves
smoothly.
7. Install spring pin (12) and O-ring (30) to cover
(31).

IMPORTANT: Check that swash plate (33) is in-


serted in the sliding surface of
cover (31). Check that swash plate
(33) is inserted in tilt pin (16).
8. Install housing (28) to cover (31).

W2-3-69
UPPERSTRUCTURE / Pump Device

28 64 66 50

51

49

39

5
48

32 37 36 38 40 41 62 60, 61 63 65 45
W18C-02-04-013

42 43

44

57

58

54 59

W18B-02-04-044

52, 53 56 55

W2-3-70
UPPERSTRUCTURE / Pump Device
14. Install springs (40) (9 used), spherical bushing 22. Install O-ring (49) to plate (50).
(38), retainer (37) and plungers (36) (9 used) to
cylinder block (41) in this order. 23. Install retaining ring (39) to coupling (48).

IMPORTANT: For easy installation, align the 24. Install coupling (48) to the end of shaft (5).
spline in cylinder block (41) with the
spline in spherical bushing (38) be- 25. Install plate (50) to valve plate (45) and tighten
fore installing. with socket bolts (51) (4 used).
15. Install the cylinder block (41) assembly to shaft : 10 mm
(5). : 98 N m (10 kgf m, 72 lbf ft)

16. Install seat (44), steel ball (43) and stopper (42) 26. Install O-ring (53) and plug (52) to casing (54).
to valve cover (45). : 19 mm
: 90 N m (9 kgf m, 66 lbf ft)
17. Install seat (57), steel ball (58) and stopper (59)
to valve cover (45). 27. Install O-rings (56) (4 used) to valve cover (45).
Tighten casing (54) with socket bolts (55) (3
18. Install O-rings (61, 64) and plug (60) to valve used).
cover (45). : 5 mm
: 19 mm : 11.8 N m (1.2 kgf m, 9 lbf ft)
: 36.3 N m (3.7 kgf m, 27 lbf ft)
28. Install regulator (17) to valve cover (45) with
19. Install needle bearing (65) to valve cover (45). socket bolts (18) (4 used).
NOTE: For easy insertion of the shaft (5) end, ap- : 6 mm
ply grease onto the needle part of needle : 30 N m (3 kgf m, 22 lbf ft)
bearing (65).

IMPORTANT: Apply grease onto the flat side of


valve plate (66) in order not to fall
off.
20. Install spring pin (62) and pin (63) to valve cover
(45). Install valve plate (66).

21. Install the valve cover (45) assembly to housing


(28) and tighten with socket bolts (32) (4 used).
: 17 mm
: 431.2 N m (44 kgf m, 320 lbf ft)

W2-3-71
UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD

1. Clearance between plunger (36) outer diameter


(d) and cylinder block (41) bore (D)

D-d Unit: mm (in)


Standard Allowable Limit
d D
0.039 (0.002) 0.067 (0.003)

W117-02-02-009

2. Spring (40) free length (L)

Unit: mm (in)
Standard Allowable Limit
41.1 (1.6) 40.3 (1.6)

W117-02-02-010

3. Clearance (e) between plunger (36) and the


crimped part of the shoe, and shoe thickness (t)

e Unit: mm (in)
Standard Allowable Limit
0 to 0.1 0.3
(0 to 0.004) (0.012) e
t Unit: mm (in) t
Standard Allowable Limit
4.9 (0.2) 4.7 (0.2) W117-02-02-011

Stand
4. Distance between retainer (37) bottom and
spherical bushing (38) top
H
h
H-h Unit: mm (in)
Standard Allowable Limit W18C-02-04-019

23.0 (0.9) 22.0 (0.2)

W2-3-72
UPPERSTRUCTURE / Pump Device
(Blank)

W2-3-73
UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF REGULATOR FOR OIL
COOLER FAN DRIVE PUMP

12
11
10
9
8

7
6 13
5 15
4 16
3 17
2 18
1
14 19
20

21
22
26 23
24
27
28 25
29
30 46
31 47
32
45
44
43
42
37 39 41
34
40
33
48
35 49
36
38

50
63
51
52
53
64

65
66
57
62 61 56
60 58
55
59 54

W18C-02-04-014

W2-3-74
UPPERSTRUCTURE / Pump Device

1- Pin 18 - Pin 35 - O-Ring 51 - Supporting Plug


2- Sleeve 19 - Lever 36 - O-Ring (3 Used) 52 - O-Ring
3- O-Ring 20 - Pin 37 - Socket Bolt (2 Used) 53 - Lock Ring
4- O-Ring 21 - O-Ring 38 - Casing 54 - Lock Ring
5- Sleeve 22 - Stopper 39 - Socket Bolt (2 Used) 55 - O-Ring
6- Compensating Piston 23 - Spring 40 - O-Ring 56 - Supporting Plug
7- Compensating Rod 24 - Spring Seat 41 - Adjusting Screw 57 - Pin (2 Used)
8- Spring Seat 25 - Pilot Piston 42 - Adjusting Screw 58 - O-Ring
9- Spring 26 - Spool 43 - Lock Nut 59 - O-Ring
10 - Spring 27 - Sleeve 44 - O-Ring 60 - O-Ring
11 - Stopper 28 - Retaining Ring 45 - Cover 61 - O-Ring
12 - O-Ring 29 - Spring 46 - Socket Bolt (4 Used) 62 - O-Ring
13 - Pin 30 - Spring 47 - Lock Nut 63 - O-Ring
14 - Pin 31 - Spring Seat 48 - Lock Nut 64 - Cover
15 - Lever 32 - Retaining Ring 49 - Adjusting Screw 65 - Socket Bolt (2 Used)
16 - Feedback Lever 33 - Socket Bolt (4 Used) 50 - Pin 66 - Socket Bolt (2 Used)
17 - Pin 34 - Cover

W2-3-75
UPPERSTRUCTURE / Pump Device

12
11
10
9
8

3
2
1

26

27
28
29
30 46
31 47
32
45
44
43
42
37 39 41
34
33
48
35 49
36
38

50
63
51

53
64

65
66
57
62 61 56
60 58
59 54

W18C-02-04-014

W2-3-76
UPPERSTRUCTURE / Pump Device
Disassembly of Regulator for Oil Cooler Fan
Drive Pump
8. Remove retaining ring (32) from spool (26).
1. Remove socket bolts (37) (2 used) and (39) (2 Remove spring seat (31), spring (30) and sleeve
used). Remove the regulator from the pump body. (27).
Remove pins (57) (2 used) and O-rings (58, 59)
from casing (38). 9. Remove retaining ring (28) from sleeve (27).
: 6 mm
10. Remove pin (1), sleeve (2) and O-ring (3) from
2. Remove socket bolts (33) (4 used). Remove casing (38).
cover (34), O-ring (35) and O-rings (36) (3 used)
from casing (38). 11. Remove lock rings (53, 54) from casing (38).
: 5 mm
IMPORTANT: Supporting plugs (51, 56) look quite
IMPORTANT: Do not disassemble lock nuts (43, similar. Put the matching marks in
48, 47) and adjusting screws (41, 42, order to install correctly.
49) as the set flow rate changes. 12. Insert a bolt (M6, Pitch 1.0 mm) into the center
When removing cover (45), prevent hole of supporting plugs (51, 56). Remove
springs (9, 10) inside from flying supporting plugs (51, 56) from casing (38).
out. At this time, pin (50) is removed with supporting
3. Remove socket bolts (46) (4 used). Remove the plug (56) together.
cover (45) assembly and O-ring (44) from casing
(38). 13. Remove pin (50) from supporting plug (56).
: 5 mm

4. Remove springs (9, 10) and spring seat (8) from


casing (38).

5. Remove stopper (11) and O-ring (12) from the


cover (45) assembly.

6. Remove socket bolts (65) (2 used) and (66) (2


used). Remove cover (64) from casing (38).
: 5 mm

7. Remove O-rings (60, 61, 62, 63) and spring (29)


from casing (38).

W2-3-77
UPPERSTRUCTURE / Pump Device

7
6
5 15
4 16
17
19
14
20

21
22
26 23
24

25

41

38

51
52

56
55

W18C-02-04-014

W2-3-78
UPPERSTRUCTURE / Pump Device
14. Remove O-rings (52, 55) from supporting plugs
(51, 56).

IMPORTANT: Do not remove pin (20) from lever


(19).
15. Remove lever (19) from casing (38) by using a
pair of pincers.

16. Remove pin (17) and feedback lever (16) by


using a round bar (4 mm).

IMPORTANT: Do not remove pin (14) from lever


(15).
17. Remove lever (15) from casing (38).

18. Remove pilot piston (25) from casing (38).

19. Insert a round bar (4 mm) from the pilot piston


(25) side into casing (38). Remove spring seat
(24), spring (23) and stopper (22) from casing
(38).

20. Remove O-ring (21) from stopper (22).

21. Insert a round bar (4 mm) from the adjusting


screw (41) side into casing (38). Remove
compensating rod (7) and the sleeve (5)
assembly from casing (38).

22. Remove compensating rod (7), compensating


piston (6) and O-ring (4) from sleeve (5).

23. Remove spool (26) from casing (38).

W2-3-79
UPPERSTRUCTURE / Pump Device
ASSEMBLY OF REGULATOR FOR OIL
COOLER FAN DRIVE PUMP A 34 33

B C W117-02-02-016

Section A-B
64 38 25 18 19 20 23 22 21

65

61 48

49
66

37 24 39
W117-02-02-006

D Section A-C
63 29 30 28 27 26 17 15 8 9 10 44 40 45 47
31

32
3 41
1 43
2
42

4 6 5 7 D 16 14 50 58 57 11 12
W117-02-02-017

Section D-D
13 51 52 53

54

14 56 55 W18B-02-04-043

W2-3-80
UPPERSTRUCTURE / Pump Device

1- Pin 18 - Pin 35 - *O-Ring 51 - Supporting Plug


2- Sleeve 19 - Lever 36 - *O-Ring (3 Used) 52 - O-Ring
3- O-Ring 20 - Pin 37 - Socket Bolt (2 Used) 53 - Lock Ring
4- O-Ring 21 - O-Ring 38 - Casing 54 - Lock Ring
5- Sleeve 22 - Stopper 39 - Socket Bolt (2 Used) 55 - O-Ring
6- Compensating Piston 23 - Spring 40 - O-Ring 56 - Supporting Plug
7- Compensating Rod 24 - Spring Seat 41 - Adjusting Screw 57 - Pin (2 Used)
8- Spring Seat 25 - Pilot Piston 42 - Adjusting Screw 58 - O-Ring
9- Spring 26 - Spool 43 - Lock Nut 59 - *O-Ring
10 - Spring 27 - Sleeve 44 - O-Ring 60 - *O-Ring
11 - Stopper 28 - Retaining Ring 45 - Cover 61 - O-Ring
12 - O-Ring 29 - Spring 46 - *Socket Bolt (4 Used) 62 - *O-Ring
13 - Pin 30 - Spring 47 - Lock Nut 63 - O-Ring
14 - Pin 31 - Spring Seat 48 - Lock Nut 64 - Cover
15 - Lever 32 - Retaining Ring 49 - Adjusting Screw 65 - Socket Bolt (2 Used)
16 - Feedback Lever 33 - Socket Bolt (4 Used) 50 - Pin 66 - Socket Bolt (2 Used)
17 - Pin 34 - Cover
NOTE: As for the parts with mark *, refer to W2-3-74.

W2-3-81
UPPERSTRUCTURE / Pump Device

B C W117-02-02-016

Section A-B
38 25 19 20

W117-02-02-006

D Section A-C
29 30 28 27 26 17 15
31

32

7 D 16 14 50
W117-02-02-017

Section D-D
51 52 53

54

56 55 W18B-02-04-043

W2-3-82
UPPERSTRUCTURE / Pump Device
Assembly of Regulator for Oil Cooler Fan Drive
Pump IMPORTANT: After inserting, check that pilot
piston (25) moves smoothly.
IMPORTANT: Check the direction to install 6. Insert pilot piston (25) into casing (38).
compensating rod (7) as illustrated.
1. Insert compensating rod (7) into casing (38). 7. Install O-rings (52, 55) to supporting plugs (51,
56).
2. Install pin (14) to lever (15). Insert lever (15) into
casing (38). Install pin (14) while aligning with the IMPORTANT: Supporting plugs (51, 56) look quite
groove in compensating rod (7). similar.
Install plugs (51, 56) while aligning
3. Install retaining ring (28) to sleeve (27). the matching marks made when
disassembling in order to install
IMPORTANT: After inserting, check that spool (26) correctly.
moves smoothly. 8. Align the groove on pilot piston (25) with pin (20)
4. Insert sleeve (27) and spool (26) into casing (38). on lever (19). Install lever (19).

IMPORTANT: Check the direction to install 9. Install pin (50) to supporting plug (56). Align pin
feedback lever (16). (50) with the hole on lever (19). Install supporting
5. Align the pin hole (the hole in upper side) on plug (56) to lever (19).
feedback lever (16) with the pin hole on spool
(26). Install pin (17). 10. Install lock ring (54) to supporting plug (56).

11. Install supporting plug (51) to casing (54). Install


lock ring (53)
Compensating Lever (16) Side
Rod (7) Side 12. Install spring (30) and spring seat (31) to spool
(26). Install retaining ring (32).

13. Install spring (29) to casing (38).

W18B-02-04-018

W2-3-83
UPPERSTRUCTURE / Pump Device

A 34 33

B C W117-02-02-016

Section A-B
64 38 23 22 21

65

61

66

37 24 39
W117-02-02-006
D Section A-C
63 8 9 10 44 45

3
1
2

4 6 5 D 58 57 11 12
W117-02-02-017

Section D-D

W18B-02-04-043

W2-3-84
UPPERSTRUCTURE / Pump Device
IMPORTANT: Check the direction to install 25. Install pins (57) (2 used) and O-rings (58, 59) to
compensating piston (6) as casing (38).
illustrated.
14. Install O-ring (4) and compensating piston (6) to 26. Install the regulator to the pump body with socket
sleeve (5). bolts (37) (2 used) and (39) (2 used).
: 6 mm
15. Install sleeve (5), O-ring (3), sleeve (2) and pin : 30 N m (3 kgf m, 22 lbf ft)
(1) to casing (38).

16. Install O-rings (60, 62, 61 and 63) to casing (38).

17. Install cover (64) to casing (38) with socket bolts


(65) (2 used) and (66) (2 used).
: 5 mm
: 11.5 N m (1.2 kgf m, 8 lbf ft)

18. Install O-ring (35) and O-rings (36) (3 used) to


cover (34).

19. Install cover (34) to casing (38) with socket bolts


(33) (4 used)
: 5 mm
: 11.5 N m (1.2 kgf m, 8 lbf ft)

20. Install O-ring (21) to stopper (22).

21. Install spring seat (24), spring (23) and stopper


(22) to casing (38).

22. Install O-ring (12) to stopper (11).

23. Install spring seat (8) and springs (9, 10) to


casing (38).

24. Install stopper (11) and O-ring (44) to the cover


(45) assembly. Install the cover (45) assembly to
casing (38) with socket bolts (46) (4 used).
: 5 mm
: 11.5 N m (1.2 kgf m, 8 lbf ft)

W2-3-85
UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF AIR CONDITIONER
COMPRESSOR DRIVE PUMP AND PILOT
PUMP

16
15

14
13

12
10
9
8
7 30
11 29
5 6
28
4 27
3 26

2
1 25

24 44
23 43
22 42
21
20
41
17 40
18
39
38
37
19
36
35

34
33

31

32
45

W18B-02-04-015

W2-3-86
UPPERSTRUCTURE / Pump Device

1- Coupling 13 - O-Ring 24 - Coupling 35 - Plate


2- O-Ring 14 - Knock Pin (2 Used) 25 - O-Ring 36 - Knock Pin (2 Used)
3- Nut (4 Used) 15 - Plate 26 - Center Plate 37 - Pressure Plate
4- Spring Washer (4 Used) 16 - Knock Pin (2 Used) 27 - Backup Ring 38 - Seal Plate
5- Stud Bolt (4 Used) 17 - O-Ring 28 - Seal Plate 39 - Isolation Plate
6- Cover 18 - Cover 29 - Isolation Plate 40 - Backup Ring
7- Backup Ring 19 - Socket Bolt (2 Used) 30 - Pressure Plate 41 - O-Ring
8- Seal Plate 20 - Pressure Plate 31 - Driven Gear 42 - Flange
9- Isolation Plate 21 - Seal Plate 32 - Drive Gear 43 - Oil Seal
10 - Pressure Plate 22 - Isolation Plate 33 - O-Ring 44 - Snap Ring
11 - Drive Gear 23 - Backup Ring 34 - Knock Pin (2 Used) 45 - Stabilizer (4 Used)
12 - Driven Gear

W2-3-87
UPPERSTRUCTURE / Pump Device

15

14
13

12
10
9
8
7 30
11 29
6
28
4 27
3 26

2
1 25

24
23
22
21
20
17
18

19

35

33

31

32
45

W18B-02-04-015

W2-3-88
UPPERSTRUCTURE / Pump Device
Disassembly of Air Conditioner Compressor
Drive Pump and Pilot Pump 8. Remove plate (15) from center plate (26).
NOTE: Lightly tap and remove the outer race of
CAUTION: Pilot pump weight: 27 kg (60 lb) cover (6) by using a plastic hammer.

1. Remove O-ring (2) from cover (6). Remove 9. Remove backup ring (23), insulation plate (22),
coupling (1) from drive gear (11). seal plate (21) and pressure plate (20) from plate
(15).
2. Remove socket bolts (19) (2 used) from cover (6).
Remove cover (18) and O-ring (17) from cover 10. Remove O-ring (25) from center plate (26).
(6).
: 8 mm 11. Remove center plate (26) from plate (35).

3. Remove nuts (3) (4 used) and spring washers (4) 12. Remove coupling (24) from center plate (26).
(4 used) from cover (6).
: 22 mm 13. Remove stabilizers (45) (2 used) and O-ring (33)
from plate (35).
4. Remove cover (6) from plate (15).
14. Remove backup ring (27), seal plate (28) and
NOTE: Cover (6) has been secured with knock isolation plate (29) from plate (35) by using a
pins (14) (2 used). Lightly tap and remove bamboo spatula.
the outer race of cover (6) by using a
plastic hammer. IMPORTANT: Remove driven gear (31) and drive
gear (32) at the same time.
5. Remove backup ring (7), seal plate (8) and 15. Remove driven gear (31) and drive gear (32)
isolation plate (9) from plate (15) by using a from plate (35). At this time, pressure plate (30) is
bamboo spatula. also removed.
IMPORTANT: Do not confuse driven gears (12, 31)
when storing them.
Remove driven gear (12) and drive
gear (11) at the same time.
6. Remove driven gear (12) and drive gear (11)
from plate (15). At this time, pressure plate (10) is
also removed.

IMPORTANT: Do not remove knock pin (14)


unless necessary.
7. Remove O-ring (13) and stabilizers (45) (2 used)
from plate (15).

W2-3-89
UPPERSTRUCTURE / Pump Device

44
43
42

41
40
39
38
37
36
35

W18B-02-04-015

W2-3-90
UPPERSTRUCTURE / Pump Device
16. Remove plate (35) from flange (42).

IMPORTANT: Do not remove knock pin (36)


unless necessary.
17. Remove backup ring (40), isolation plate (39),
seal plate (38) and pressure plate (37) from plate
(35).

18. Remove O-ring (41) from flange (42).

19. Remove snap ring (44) and oil seal (43) from
flange (42).
NOTE: Stud bolt (5) is still left in flange (42). Do
not remove stud bolt (5) unless necessary.

W2-3-91
UPPERSTRUCTURE / Pump Device
ASSEMBLY OF AIR CONDITIONER
COMPRESSOR DRIVE PUMP AND PILOT
PUMP

B C B C

5 6 14 13 12 15 25 16 26 34 33 35 31 41 36 42
3
4

2 1 10 11 20 24 30 32 37 43 44
B C B C
38 40
19 17 45 39

18

View A 9

7
8
Section B Section C W18B-02-04-050

1- Coupling 13 - O-Ring 24 - Coupling 35 - Plate


2- O-Ring 14 - Knock Pin (2 Used) 25 - O-Ring 36 - Knock Pin (2 Used)
3- Nut (4 Used) 15 - Plate 26 - Center Plate 37 - Pressure Plate
4- Spring Washer (4 Used) 16 - Knock Pin (2 Used) 27 - *Backup Ring 38 - Seal Plate
5- Stud Bolt (4 Used) 17 - O-Ring 28 - *Seal Plate 39 - Isolation Plate
6- Cover 18 - Cover 29 - *Isolation Plate 40 - Backup Ring
7- Backup Ring 19 - Socket Bolt (2 Used) 30 - Pressure Plate 41 - O-Ring
8- Seal Plate 20 - Pressure Plate 31 - Driven Gear 42 - Flange
9- Isolation Plate 21 - *Seal Plate 32 - Drive Gear 43 - Oil Seal
10 - Pressure Plate 22 - *Isolation Plate 33 - O-Ring 44 - Snap Ring
11 - Drive Gear 23 - *Backup Ring 34 - Knock Pin (2 Used) 45 - Stabilizer (4 Used)
12 - Driven Gear

NOTE: As for the parts with mark *, refer to


W2-3-86.

W2-3-92
UPPERSTRUCTURE / Pump Device
Assembly of Air Conditioner Compressor Drive 10. Install pressure plate (30), isolation plate (29),
Pump and Pilot Pump seal plate (28) and backup ring (27) to plate (35)
through the center plate (26) side.
1. Install oil seal (43) and snap ring (44) to flange
(42). 11. Install O-ring (33), knock pins (34) (2 used) and
stabilizers (45) (2 used) to plate (35).
2. Install O-ring (41) and knock pins (36) (2 used) to
flange (42). IMPORTANT: Check that the mating surfaces of
plate (35) and center plate (26) are
3. Align plate (35) with center plate (26). matched closely.
Temporarily place plate (35). 12. Install center plate (26) to the plate (35) assembly.
NOTE: Temporarily install plate (35) to center Install coupling (24) to center plate (26).
plate (26) in order to prevent backup ring
(27) from coming out and to prevent 13. Install O-ring (25) and knock pins (16) (2 used) to
backup ring (27) from falling off due to the center plate (26).
gear movement during installation.
14. Align plate (15) with cover (6). Temporarily place
4. Install driven gear (31) and drive gear (32) to plate (15).
plate (35). NOTE: Temporarily install plate (15) to cover (6) in
order to prevent backup ring (7) from
5. Install pressure plate (37) to plate (35) with the coming out and to prevent backup ring (7)
groove side of pressure plate (37) facing to the from falling off due to the gear movement
flange (42) side. during installation.

6. Install seal plate (38), isolation plate (39) and 15. Install driven gear (12) and drive gear (11) to
backup ring (40) to pressure plate (37). plate (15).

7. Install flange (42) to the plate (35) assembly. 16. Install pressure plate (20) to plate (15) with the
groove side of pressure plate (20) facing to the
8. Remove center plate (26) from the plate (35) cover (6) side.
assembly. Secure the plate (35) assembly in a
vise with the oil seal (43) side facing downward. 17. Install seal plate (21), isolation plate (22) and
backup ring (23) to pressure plate (20).
9. Lightly tap and install plate (35) to flange (42) by
using a plastic hammer lightly. 18. Install the center plate (26) assembly to the plate
(15) assembly.

W2-3-93
UPPERSTRUCTURE / Pump Device

B C B C

5 6 14 13 15
3
4

2 1 10 11
B C B C

19 17 45

18

View A 9

7
8
Section B Section C W18B-02-04-050

W2-3-94
UPPERSTRUCTURE / Pump Device
19. Remove cover (6) from the plate (15) assembly.

20. Install O-ring (13), knock pins (14) (2 used) and


stabilizers (45) (2 used) to plate (15).

21. Install pressure plate (10), isolation plate (9), seal


plate (8) and backup ring (7) to plate (15).

22. Install cover (6) to plate (15). Tighten with stud


bolts (5) (4 used), spring washers (4) (4 used)
and nuts (3) (4 used).
: 22 mm
: 26 N m (2.6 kgf m, 19 lbf ft)

23. Install O-ring (17) to cover (6).

24. Install cover (18) to cover (6). Tighten with socket


bolts (19) (2 used).
: 8 mm
: 57 N m (5.8 kgf m, 42 lbf ft)

25. Install coupling (1) to drive gear (11).

26. Install O-ring (2) to cover (6).

W2-3-95
UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD

Drive Gears (11, 32), Driven Gears (12, 31)


Plates (15, 35) øb<ø27.48 mm (ø1.1 in)
a 0.15 mm (0.006 in)
a b

W117-02-02-022

W117-02-02-021

W2-3-96
UPPERSTRUCTURE / Pump Device
(Blank)

W2-3-97
UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF PUMP TRANSMISSION
OIL LUBRICATION PUMP 14
12 13

11
10
9
6 8
7

1 5
4
3
2

15

W18B-02-04-014

1- Bolt (4 Used) 5- Driven Gear 9- Gasket A 13 - Oil Seal


2- Cover 6- Knock Pin 10 - Gasket B 14 - Snap Ring
3- O-Ring 7- Plate 11 - Balance Seal 15 - Drive Gear
4- Side Plate B 8- Side Plate A 12 - Flange

W2-3-98
UPPERSTRUCTURE / Pump Device
Disassembly of Pump Transmission Oil
Lubrication Pump

IMPORTANT: If securing flange (12) in a vise by


too strong force, flange (12) may be
deformed.
1. Secure flange (12) in a vise. Remove bolts (1) (4
used). Remove cover (2) from plate (7).
: 14 mm
NOTE: Cover (2) is secured on plate (7) with
knock pin (6). Remove cover (2) while
tapping cover (2) by using a plastic
hammer.

2. Remove O-ring (3) from cover (2).

3. Remove side plate B (4) from driven gear (5) and


drive gear (15).

IMPORTANT: Remove driven gear (5) and drive


gear (15) by rotating slowly.
4. Remove driven gear (5) and drive gear (15) from
plate (7).

IMPORTANT: Do not remove knock pin (6) unless


necessary.
5. Remove plate (7) from flange (12).

6. Remove side plate A (8), gasket A (9), gasket B


(10) and balance seal (11) from flange (12).
NOTE: Use a bamboo spatula when removing
gasket A (9), gasket B (10) and balance
seal (11).

7. Remove snap ring (14) and oil seal (13) from


flange (12).

W2-3-99
UPPERSTRUCTURE / Pump Device
ASSEMBLY OF PUMP TRANSMISSION
OIL LUBRICATION PUMP
1 2 5 6 7 12
C

View D
15 3 4 8 13 14

Detail C

9 10 11

Section B-B Section A-A W117-02-02-020

1- Bolt (4 Used) 5- Driven Gear 9- Gasket A 13 - Oil Seal


2- Cover 6- Knock Pin 10 - Gasket B 14 - Snap Ring
3- O-Ring 7- Plate 11 - Balance Seal 15 - Drive Gear
4- Side Plate B 8- Side Plate A 12 - Flange

W2-3-100
UPPERSTRUCTURE / Pump Device
Assembly of Pump Transmission Oil Lubrication
Pump

1. Install oil seal (13) and snap ring (14) to flange


(12).

2. Apply grease onto the groove for balance seal


(11) on flange (12). Install balance seal (11),
gasket B (10), gasket A (9) and side plate A (8) to
flange (12).

3. Install plate (7) to flange (12).

4. Apply grease onto the inner surface of plate (7).

IMPORTANT: Install drive gear (15) by rotating


slowly.
5. Install drive gear (15) to flange (12).

6. Install driven gear (5) to flange (12).

7. Install O-ring (3) to cover (2).

IMPORTANT: Tighten bolt (1) evenly. Drive gear


(15) may not rotate.
8. Install cover (2) to plate (7) and tighten with bolts
(1) (4 used).
: 17 mm
: 34 to 39 N m
(3.5 to 4.0 kgf m, 25 to 29 lbf ft)

IMPORTANT: Check that drive gear (15) rotates


smoothly after installation.

W2-3-101
UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD

Plate (7) Drive Gear (15), Driven Gear (5)


a 0.15 mm (0.006 in) øb<ø14.96 mm (ø0.6 in) b
a

W117-02-02-022

W117-02-02-021

W2-3-102
UPPERSTRUCTURE / Control Valve
REMOVAL AND INSTALLATION OF
CONTROL VALVE

Removal

CAUTION: Bleed air from the hydraulic oil 3 4, 5 3


tank before doing any work. (Refer to BLEED 2
AIR FROM HYDRAULIC OIL TANK on 4, 5
W1-4-1.)
1
6
1. Remove bolts (4) (18 used). Remove clamps (5)
(9 used) from control valve bracket (2).
: 17 mm

2. Remove socket bolts (1) (12 used). Disconnect


pipings (6) (5 used) from control valves (3) (3
used). Cap the disconnected pipings.
: 10 mm 6
W18K-02-04-001

3. Remove bolts (8) (18 used). Remove clamps (9) 3


(9 used) from control valve bracket (2).
: 17 mm 2

4. Disconnect pipings (7) (24 used) from control 7


valves (3) (3 used). Install plugs or caps onto the
open ends. Attach an identification tag onto the 7 8, 9
disconnected pipings for assembling.
: 19 mm 7

W18K-02-04-002

W2-4-1
UPPERSTRUCTURE / Control Valve
5. Remove socket bolts (13) (4 used) from the
control valve (3) side. Remove flanges (14) (2 3 13, 14 3 15, 16
used). Disconnect hose (17). Install plugs or caps
onto the disconnected hose.
: 14 mm
2

11, 12
CAUTION: Piping (10) weight: 16 kg (40 lb) 3

6. Attach a nylon sling onto piping (10). Hold piping 17


(10). Remove socket bolts (11) (4 used) and 10
flanges (12) (2 used) from piping (10) on the 10
control valve (3) side.
: 14 mm
W18C-02-07-042

Main Frame
7. Disconnect piping (10) from the control valve (3)
side. Place piping (10) on the main frame slowly.

8. Disconnect other pipings (10) (24 used) from


control valves (3) (3 used) in the same way as
steps 6 to 7.

CAUTION: Control valve (3) weight: 260 kg


(580 lb)

9. Attach a nylon sling onto the body of control


valve (3). Hoist and hold control valve (3).

10. Remove bolts (15) (4 used) and U-nuts (16) (4


used). Hoist and remove control valve (3) from
control valve bracket (2).
: 24 mm

11. Remove other control valves (3) (2 used) from


control valve bracket (2) in the same way as
steps 8 to 9.

W2-4-2
UPPERSTRUCTURE / Control Valve
Installation

CAUTION: Control valve (3) weight: 260 kg


(580 lb) 3 13, 14 3 15, 16

1. Attach a nylon sling onto the body of control


valve (3). Hoist and hold control valve (3). 2

2. Install control valve (3) to control valve bracket 11, 12


3
(2) with bolts (15) (4 used) and U-nuts (16) (4
used).
: 24 mm 17
: 270 N m (27.5 kgf m, 200 lbf ft) 10

10
3. Install other control valves (3) (2 used) to control
valve bracket (2) in the same way as steps 1 to 2. W18C-02-07-042

CAUTION: Piping (10) weight: 16 kg (40 lb)

4. Attach a nylon sling onto piping (10). Hold piping


(10). Connect piping (10) to control valve (3) with
socket bolts (11) (4 used) and flanges (12) (2
used).
: 14 mm
: 210 N m (21 kgf m, 155 lbf ft)

5. Connect other pipings (10) (24 used) to control


valves (3) (3 used) in the same way as step 4.

6. Connect hose (17) to control valve (3) with


socket bolts (13) (4 used) and flanges (14) (2
used).
: 14 mm
: 210 N m (21 kgf m, 155 lbf ft)

W2-4-3
UPPERSTRUCTURE / Control Valve
7. Connect pipings (7) (24 used) to control valves 3
(3) (3 used).
: 14 mm 2
: 210 N m (21 kgf m, 155 lbf ft)
7
8. Install clamps (9) (9 used) to control valve
bracket (2) with bolts (8) (18 used). 7 8, 9
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft) 7

9. Connect pipings (6) (5 used) to control valves (3)


(3 used) with socket bolts (1) (12 used).
: 10 mm W18K-02-04-002
: 90 N m (9 kgf m, 66 lbf ft)

10. Install clamps (5) (9 used) to control valve 3 4, 5 3


bracket (2) with bolts (4) (18 used). 2
4, 5
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft) 1
6
IMPORTANT: After completing the work, check
hydraulic oil level and any oil
leakage.

6
W18K-02-04-001

W2-4-4
UPPERSTRUCTURE / Control Valve
(Blank)

W2-4-5
UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF CONTROL VALVE

2 3 4

T18C-01-02-005

1 - Control Valve Bracket 2 - Control Valve 3 - Control Valve 4 - Control Valve

W2-4-6
UPPERSTRUCTURE / Control Valve
Control Valve 4

10
9
8 11
7 12
6
2 5
4
3

13
14
15 22
16
17
20 18
1
19
25 22
23
21
26
27
22
24
22

23
23
22 28

42 23 32
41 43 33
29
40 23 34
37
38 35
39 23
30
31
36

W18C-02-05-005

1 - Outlet Section 12 - O-Ring (4 Used) 23 - Overload Relief Valve 34 - O-Ring


(6 Used)
2- Nut (4 Used) 13 - Spring Seat (4 Used) 24 - Housing (Arm) 35 - Inlet Section
3- Tie Rod (4 Used) 14 - Spool (4 Used) 25 - Socket Bolt (4 Used) 36 - Nut (4 Used)
4- Spring (4 Used) 15 - Socket Bolt (16 Used) 26 - Flange 37 - O-Ring (4 Used)
5- Spring (4 Used) 16 - Plate (4 Used) 27 - O-Ring 38 - Spacer (4 Used)
6- Spring Seat (4 Used) 17 - O-Ring (4 Used) 28 - Housing (Boom) 39 - Cap (4 Used)
7- Spool End (4 Used) 18 - Spring (3 Used) 29 - Housing (Bucket) 40 - Socket Bolt (8 Used)
8- O-Ring (4 Used) 19 - Poppet (3 Used) 30 - Housing (Left Travel) 41 - O-Ring (4 Used)
9- Cap (4 Used) 20 - O-Ring (10 Used) 31 - Main Relief Valve 42 - Plug (4 Used)
10 - Socket Bolt (8 Used) 21 - O-Ring (5 Used) 32 - Socket Bolt (4 Used) 43 - Plug
11 - Plug (4 Used) 22 - Make-Up Valve (5 Used) 33 - Flange

W2-4-7
UPPERSTRUCTURE / Control Valve
Control Valve 3

2 42
41
3
40
39
38
37
15 22
16
17
20 18
1
19
23 22
21

22
44
22

23
23
22 45

23 32
14 33
13 46
23 34
4
35
5 23
6 47
10 7 31
36
8
9
12
11 W18C-02-05-006

1 - Outlet Section 11 - Plug (4 Used) 21 - O-Ring (5 Used) 38 - Spacer (4 Used)


2 - Nut (4 Used) 12 - O-Ring (4 Used) 22 - Make-Up Valve (5 Used) 39 - Cap (4 Used)
3 - Tie Rod (4 Used) 13 - Spring Seat (4 Used) 23 - Overload Relief Valve 40 - Socket Bolt (8 Used)
(6 Used)
4- Spring (4 Used) 14 - Spool (4 Used) 31 - Main Relief Valve 41 - O-Ring (4 Used)
5- Spring (4 Used) 15 - Socket Bolt (16 Used) 32 - Socket Bolt (4 Used) 42 - Plug (4 Used)
6- Spring Seat (4 Used) 16 - Plate (4 Used) 33 - Flange 44 - Housing (Bucket)
7- Spool End (4 Used) 17 - O-Ring (4 Used) 34 - O-Ring 45 - Housing (Arm)
8- O-Ring (4 Used) 18 - Spring (3 Used) 35 - Inlet Section 46 - Housing (Boom)
9- Cap (4 Used) 19 - Poppet (3 Used) 36 - Nut (4 Used) 47 - Housing (Right Travel)
10 - Socket Bolt (8 Used) 20 - O-Ring (10 Used) 37 - O-Ring (4 Used)

W2-4-8
UPPERSTRUCTURE / Control Valve
Control Valve 2
10
9
8 11
7 12
6
2 5
4
3

13
14
15 22
16
17
20 18
1
19
25 22
23
21
26
27
22
48
22

23
23
22 49

23
42
41 22
50
40 23
37 23
38 35
39 23
51
31
36

23
W18C-02-05-007

1 - Outlet Section 11 - Plug (4 Used) 21 - O-Ring (5 Used) 38 - Spacer (4 Used)


2 - Nut (4 Used) 12 - O-Ring (4 Used) 22 - Make-Up Valve (6 Used) 39 - Cap (4 Used)
3 - Tie Rod (4 Used) 13 - Spring Seat (4 Used) 23 - Overload Relief Valve 40 - Socket Bolt (8 Used)
(8 Used)
4- Spring (4 Used) 14 - Spool (4 Used) 25 - Socket Bolt (4 Used) 41 - O-Ring (4 Used)
5- Spring (4 Used) 15 - Socket Bolt (16 Used) 26 - Flange 42 - Plug (4 Used)
6- Spring Seat (4 Used) 16 - Plate (4 Used) 27 - O-Ring 48 - Housing (Boom)
7- Spool End (4 Used) 17 - O-Ring (4 Used) 31 - Main Relief Valve 49 - Housing (Bucket)
8- O-Ring (4 Used) 18 - Spring (4 Used) 35 - Inlet Section 50 - Housing (Arm)
9- Cap (4 Used) 19 - Poppet (4 Used) 36 - Nut (4 Used) 51 - Housing (Swing)
10 - Socket Bolt (8 Used) 20 - O-Ring (10 Used) 37 - O-Ring (4 Used)

W2-4-9
UPPERSTRUCTURE / Control Valve
Control Valve 4
10
9
8 11
7 12
6
2 5
4
3

13
14
15 22
16
17
20 18
1
19
25 22
23
21
26
27
22
24
22

23
23
22 28

23 32
42
41 43 33
29
40 23 34
37
38 35
39 23
30
31
36

W18C-02-05-005

1 - Outlet Section 12 - O-Ring (4 Used) 23 - Overload Relief Valve 34 - O-Ring


(6 Used)
2- Nut (4 Used) 13 - Spring Seat (4 Used) 24 - Housing (Arm) 35 - Inlet Section
3- Tie Rod (4 Used) 14 - Spool (4 Used) 25 - Socket Bolt (4 Used) 36 - Nut (4 Used)
4- Spring (4 Used) 15 - Socket Bolt (16 Used) 26 - Flange 37 - O-Ring (4 Used)
5- Spring (4 Used) 16 - Plate (4 Used) 27 - O-Ring 38 - Spacer (4 Used)
6- Spring Seat (4 Used) 17 - O-Ring (4 Used) 28 - Housing (Boom) 39 - Cap (4 Used)
7- Spool End (4 Used) 18 - Spring (3 Used) 29 - Housing (Bucket) 40 - Socket Bolt (8 Used)
8- O-Ring (4 Used) 19 - Poppet (3 Used) 30 - Housing (Left Travel) 41 - O-Ring (4 Used)
9- Cap (4 Used) 20 - O-Ring (10 Used) 31 - Main Relief Valve 42 - Plug (4 Used)
10 - Socket Bolt (8 Used) 21 - O-Ring (5 Used) 32 - Socket Bolt (4 Used) 43 - Plug
11 - Plug (4 Used) 22 - Make-Up Valve (5 Used) 33 - Flange

W2-4-10
UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve
(Control Valve 4)

• The procedure to disassemble and assemble CAUTION: Inlet section (35) weight: 62 kg
control valve 4 is explained here. As for other (140 lb)
control valves, their basic structure are similar Outlet section (1) weight: 23 kg (55 lb)
except the shape of the spool. Housings (24, 28, 29, 30) weight: 59 kg (130
lb)
IMPORTANT: As many components of the control
valve are in similar shape and the 3. Loosen socket bolts (15) (16 used). Remove
direction to install many plates (16) (4 used) and O-rings (17) (4 used)
components is determined, from housings (24, 28, 29, 30).
disassemble the control valve while : 10 mm
putting the mark as for the direction
and the position to install for 4. Remove springs (18) (3 used) and poppets (19)
assembling. (3 used) from housings (24, 28, 29).

5. Remove socket bolts (25) (4 used) and (32) (4


CAUTION: Control valve weight: 260 kg (580 used). Remove flanges (26, 33) and O-rings (27,
lb) 34) from housing (28) and inlet section (35).
: 10 mm, 14 mm
1. Place the control valve assembly on a clean
workbench. 6. Loosen nuts (2) (4 used) and remove tie rods (3)
(4 used).
IMPORTANT: Do not disassemble overload relief : 30 mm
valve (23). When adjusting the
overload relief valve, use the special IMPORTANT: When hoisting each section and
tester. In addition, attach a spanner each housing of the control valve,
onto the body side when removing install an eyebolt (M16, Pitch 2.0
overload relief valve (23) and main mm) into the bolt hole for the piping,
relief valve (31). and hoist each section and each
2. Remove overload relief valves (23) (6 used), housing of the control valve. At this
make-up valves (22) (5 used) and plug (43) from time, do not drop O-ring.
housings (24, 28, 29). 7. Separate inlet section (35), housings (24, 28, 29,
Remove main relief valve (31) from inlet section 30) and outlet section (1) individually.
(35).
: 38 mm

W2-4-11
UPPERSTRUCTURE / Control Valve

10
9
8 11
7 12
6
5
4

13
14

20

21

24

28

42
41
29
40
37
38 35
39
30

W18C-02-05-005

W2-4-12
UPPERSTRUCTURE / Control Valve
8. Remove O-rings (20) (10 used) and (21) (5 used)
from inlet section (35) and housings (24, 28, 29,
30).

IMPORTANT: LOCTITE has been applied onto


plug (11). Do not remove plug (11)
unless necessary.
9. Loosen socket bolts (10) (8 used). Remove caps
(9) (4 used) and O-rings (8) (4 used) from
housings (24, 28, 29, 30).
: 10 mm

IMPORTANT: Rotate and remove spool (14)


slowly.
10. Remove spool (14) from housings (24, 28, 29,
30).

IMPORTANT: LOCTITE has been applied onto


plug (42). Do not remove plug (42)
unless necessary.
11. Loosen socket bolts (40) (8 used). Remove caps
(39) (4 used) and O-rings (37) (4 used) from
housings (24, 28, 29, 30). Remove spacers (38)
(4 used) from caps (39) (4 used).
: 10 mm

12. Secure spool (14) in a vise by using wooden


pieces. Warm up the outside at the spool end (7)
side of spool (14) up to 200 to 250°C (392 to
482°F). Attach a spanner onto spool end (7) and
rotate spool end (7). Remove spool end (7) from
spool (14). (4 places)
: 30 mm

13. Remove spring seats (6, 13) and springs (4, 5)


from spool end (7). (4 places)

W2-4-13
UPPERSTRUCTURE / Control Valve
ASSEMBLY OF CONTROL VALVE
(Control Valve 4)

1 2 3 22
40
39 9
41, 42 11, 12

24
10
25
26
28

29
A

30

31
W18C-02-05-008
35 36 33 32

29 17 15 16 18 19
Section A

38 37 8 13 6 7

4 5
14 W18C-02-05-009

1 - Outlet Section 12 - O-Ring (4 Used) 23 - Overload Relief Valve 34 - O-Ring


(6 Used)
2- Nut (4 Used) 13 - Spring Seat (4 Used) 24 - Housing (Arm) 35 - Inlet Section
3- Tie Rod (4 Used) 14 - Spool (4 Used) 25 - Socket Bolt (4 Used) 36 - Nut (4 Used)
4- Spring (4 Used) 15 - Socket Bolt (16 Used) 26 - Flange 37 - O-Ring (4 Used)
5- Spring (4 Used) 16 - Plate (4 Used) 27 - O-Ring 38 - Spacer (4 Used)
6- Spring Seat (4 Used) 17 - O-Ring (4 Used) 28 - Housing (Boom) 39 - Cap (4 Used)
7- Spool End (4 Used) 18 - Spring (3 Used) 29 - Housing (Bucket) 40 - Socket Bolt (8 Used)
8- O-Ring (4 Used) 19 - Poppet (3 Used) 30 - Housing (Left Travel) 41 - O-Ring (4 Used)
9- Cap (4 Used) 20 - O-Ring (10 Used) 31 - Main Relief Valve 42 - Plug (4 Used)
10 - Socket Bolt (8 Used) 21 - O-Ring (5 Used) 32 - Socket Bolt (4 Used) 43 - Plug
11 - Plug (4 Used) 22 - Make-Up Valve (5 Used) 33 - Flange

W2-4-14
UPPERSTRUCTURE / Control Valve
Assembly of Control Valve
(Control Valve 4)
4. When removing spool end (7), assemble spool
IMPORTANT: Align the marks made when end (7) as follows.
disassembling. • Secure spool (14) in a vise by using wooden
IMPORTANT: Apply grease onto O-rings in order pieces.
to prevent O-rings (20, 21) from • Apply LOCTITE #271 onto the thread part of
falling off. spool end (7).
1. Install O-rings (20) (10 used) and (21) (5 used) to • Install spring seats (6, 13) and springs (4, 5) to
housings (24, 28, 29, 30) and inlet section (35). spool end (7).
• Install spool end (7) to spool (14).
: 30 mm
CAUTION: Inlet section (35) weight: 62 kg : 27±1.5 N m (2.8±0.15 kgf m, 20±1 lbf ft)
(140 lb)
Outlet section (1) weight: 23 kg (55 lb) 5. Install spacers (38) (4 used) to caps (39) (4 used).
Housings (24, 28, 29, 30) weight: 59 kg (130 Install O-rings (37) (4 used) and caps (39) (4
lb) used) to housings (24, 28, 29, 30) with socket
bolts (40) (8 used).
IMPORTANT: Check and arrange the housings : 10 mm
and the sections in the correct order : 110 N m (11 kgf m, 81 lbf ft)
and direction.
IMPORTANT: Perform the work while checking IMPORTANT: Slowly rotate and insert spool (14)
O-ring in order not to fall off or into each housing.
come out. 6. Install the spool (14) assemblies (4 used) to
2. Hoist and place each section and housing in housings (24, 28, 29, 30).
order.
NOTE: When hoisting each section and housing,
install an eyebolt (M16, Pitch 2.0 mm) into
the bolt hole for the piping.

3. Pass tie rods (3) (4 used) through each section


and housing, and tighten with nuts (2) (4 used)
and (36) (4 used).
: 30 mm
: 414.5±20.6 N m
(42.3±2.1 kgf m, 306 to 15 lbf ft)

W2-4-15
UPPERSTRUCTURE / Control Valve

22

40
9
39

24

25 10

26 28

29
A

30

31
W18C-02-05-008
35 33 32

29 17 15 16 18 19
Section A

38 37 8

W18C-02-05-009

W2-4-16
UPPERSTRUCTURE / Control Valve
7. Install O-rings (8) (4 used) and caps (9) (4 used)
to housings (24, 28, 29, 30) with socket bolts (10)
(8 used).
: 10 mm
: 110 N m (11 kgf m, 81 lbf ft)

8. Install poppets (19) (3 used) and springs (18) (3


used) to housings (24, 28, 29, 30). Install O-rings
(17) (4 used) and plates (16) (4 used) to
housings (24, 28, 29, 30) with socket bolts (15)
(16 used).
: 10 mm
: 110 N m (11 kgf m, 81 lbf ft)

9. Install O-rings (27, 34) and flanges (26, 33) to


housing (28) and inlet section (35) with socket
bolts (25) (4 used) and (32) (4 used).
: 10 mm
: 110 N m (11 kgf m, 81 lbf ft)
: 14 mm
: 270 N m (27.5 kgf m, 200 lbf ft)

10. Install overload relief valves (23) (6 used) to


housings (24, 28, 29). Install main relief valve
(31) to inlet section (35).
: 38 mm
: 93 to 108 N m
(9.5 to 11 kgf m, 69 to 80 lbf ft)

11. Install make-up valves (22) (5 used) and plug


(43) to housings (24, 28, 29).
: 38 mm
: 147 to 167 N m
(15 to 17 kgf m, 108 to 123 lbf ft)

W2-4-17
UPPERSTRUCTURE / Control Valve
DISASSEMBLY AND ASSEMBLY OF MAIN
RELIEF VALVE AND OVERLOAD RELIEF
VALVE

3 4 7 11 12 5 1 11 2

14
13

15

W18B-02-04-009

17 16 9 10 6 8

1- Cap 6- Pilot Poppet 11 - O-Ring 16 - O-Ring


2- Plug 7- Spring 12 - Name Plate 17 - Backup Ring
3- Sleeve 8- Pilot Spring 13 - Lock Nut
4- Main Poppet 9- O-Ring 14 - O-Ring
5- Pilot Seat 10 - Backup Ring 15 - Adjusting Screw

W2-4-18
UPPERSTRUCTURE / Control Valve
Disassembly and Assembly of Main Relief Valve Assembly
and Overload Relief Valve
1. Install O-ring (16) and backup ring (17) to main
IMPORTANT: It is necessary to test the poppet (4).
performance of the overload relief
valve itself and adjust it. Do not 2. Install main poppet (4) to sleeve (3).
disassemble the overload relief
valve unless any problem occurs. 3. Install O-ring (9) and backup ring (10) to pilot
seat (5).
Disassembly
4. Install spring (7) to sleeve (3).
1. Put the matching marks onto plug (2) and
adjusting screw (15). 5. Install plug (2) to sleeve (3).
NOTE: Install plug (2) to sleeve (3) with sleeve (3)
2. Attach a spanner onto plug (2). Loosen lock nut vertical.
(13) and remove adjusting screw (15). At this
time, do not drop pilot spring (8) and pilot poppet IMPORTANT: When installing pilot poppet (6),
(6). check that pilot poppet (6) is
: 17 mm, 38 mm installed in pilot seat (5) securely.
: 6 mm 6. Install pilot poppet (6) and pilot spring (8) to plug
(2). Align the matching marks made when
IMPORTANT: As pilot seat (5) is secured to plug disassembling and install adjusting screw (15) to
(2), pilot seat (5) cannot be plug (2). Secure with lock nut (13).
disassembled. : 17 mm
3. Secure cap (1) in a vise. Loosen plug (2). : 50 N m (5 kgf m, 37 lbf ft)
Remove plug (2) from cap (1). At this time, pilot : 6 mm
seat (5) is removed with plug (2) together. : 20 N m (2 kgf m, 15 lbf ft)
: 38 mm
7. Install O-ring (1) to plug (2). Install plug (2) to cap
4. Remove spring (7) and sleeve (3) from cap (1). (1).
: 38 mm
5. Remove O-ring (9) and backup ring (10) from : 150 N m (15 kgf m, 111 lbf ft)
pilot seat (5).
IMPORTANT: After assembling, check that main
6. Remove main poppet (4) from sleeve (3). poppet (4) moves.

7. Remove O-ring (16) and backup ring (17) from


main poppet (4).

W2-4-19
UPPERSTRUCTURE / Control Valve
STRUCTURE OF MAKE-UP VALVE

3 7 8 2 6 9 1

W18B-02-04-008
4 5

Torque
Part Name Q’ty Remark
Nm (kgf m) (lbf ft)
1- Plug 1 100 (10) (72) : 38 mm
2- Sleeve 1
3- Poppet 1
4- Washer 1
5- Lock Nut 1
6- Spring 1
7- O-ring 1
8- Backup Ring 1
9- O-ring 1

W2-4-20
UPPERSTRUCTURE / Swing Device
REMOVAL AND INSTALLATION OF
SWING DEVICE
1
CAUTION: Bleed air from the hydraulic oil 8
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)
A 2
Removal 3 3

4 4
(Control valve side)
7
IMPORTANT: Attach identification tags onto the 5
disconnected hoses for reassem-
6
bling.

1. Disconnect pipings (4) (6 used) and hose (2)


from control valve (1). Install a plug or a cap to
the disconnected piping and hose.
W18K-02-05-001
: 14 mm

2. Remove bolts (9) (4 used), washes (10) (8 used) 1


and nuts (11) (4 used) from control bracket (8). View A
Remove brackets (3) (2 used). 8
: 24 mm

3. Disconnect the hoses (9 used) and the connector


from swing device (5). Install a plug or a cap to
the disconnected hose 3
3
(Hose)
: 19 mm, 22 mm, 36 mm, 41 mm
(Bolt)
9, 10, 11 9, 10, 11
: 19 mm W18K-02-05-002

W2-5-1
UPPERSTRUCTURE / Swing Device

CAUTION: Be careful to avoid getting your


hand caught by reaction force bar on the hy-
draulic wrench.

4. Remove bolts (7) (24 used) by using a hydraulic


wrench.
: 50 mm
5

5. Remove a cork from the pulling-out hole (2


places) on swing device (5).
7
CAUTION: Swing device (5) weight: 1420 kg
(3140 lb)
6
6. Install a bolt (M24, Pitch 3.0 mm) to the pull-
ing-out hole (2 places) on swing device (5). Float
swing device (5) from frame (6).
W18C-02-05-001

7. Install an eyebolt (M24, Pitch 3.0 mm) to the lift-


ing hole (2 places) on swing device (5). Lifting Hole
Pulling-Out
Hole
8. Hoist and hold swing device (5). Hoist and re-
move swing device (5) from frame (6).

Pulling-Out
Hole

W18C-02-05-002
Lifting Hole

W2-5-2
UPPERSTRUCTURE / Swing Device
(Front side)

1. Disconnect front hose (5). (backhoe: 10 used, 1


loading shovel: 12 used) Install a plug or a cap to
the disconnected hose.
: 17 mm 2

2. Disconnect hoses (3) (7 used) and the connector


from swing device (1). Install a plug or a cap to
the disconnected hose.
(Hose)
: 19 mm, 22 mm, 36 mm, 41 mm
(Bolt)
: 19 mm

5 4 3 W18K-02-05-003
3. Put the matching marks on swing device (1) and
frame (2).

CAUTION: Be careful to avoid getting your


hand caught by reaction force bar on the hy-
draulic wrench.

4. Remove bolts (4) (24 used) by using a hydraulic


wrench. 1
: 50 mm

5. Remove a cork from the pulling-out hole (2


places) on swing device (1). 4

CAUTION: Swing device (1) weight: 1420 kg


(3140 lb) 2

6. Install a bolt (M24, Pitch 3.0 mm) to the pull-


ing-out hole (2 places) on swing device (1). Float
W18C-02-05-001
swing device (1) from frame (2).

7. Install an eyebolt (M24, Pitch 3.0 mm) to the lift- Lifting


ing hole (2 places) on swing device (1). Hole
Pulling-Out
8. Hoist and hold swing device (1). Hoist and re- Hole
move swing device (1) from frame (2).

Pulling-Out
Hole

W18C-02-05-002
Lifting
Hole

W2-5-3
UPPERSTRUCTURE / Swing Device
Installation

(Control valve side)

1. Install an eyebolt (M24, Pitch 3.0 mm) to the lift-


ing hole (2 places) on swing device (5).

5
CAUTION: Swing device (5) weight: 1420 kg
(3140 lb)
CAUTION: Be careful to avoid getting your
7
hand caught by reaction force bar on the hy-
draulic wrench.

2. Hoist swing device (5). Install swing device (5) to


6
frame (6) with bolts (7) (24 used) by using a hy-
draulic wrench.
: 50 mm
: 2550 N m (260 kgf m, 1660 lbf ft) W18C-02-05-001

3. Install a cork to the pulling-out hole (2 places) on


Lifting
swing device (5). Hole
Pulling-Out
4. When removing the knock pin, install the knock Hole
pin to the knock hole (2 places) on swing device
(5) by using a hammer.

Pulling-Out
Hole

W18C-02-05-002
Lifting
Hole

W2-5-4
UPPERSTRUCTURE / Swing Device
5. Connect the hoses (9 used) and the connector to
swing device (5).
(Hose) 1
: 19 mm
: 59 N m (6 kgf m, 44 lbf ft) 8
: 22 mm
: 98 N m (10 kgf m, 72 lbf ft)
: 36 mm
A 2
: 235 N m (24 kgf m, 175 lbf ft)
: 41 mm 3 3
: 295 N m (30 kgf m, 220 lbf ft) 4 4
(Bolt)
: 19 mm
: 90 N m (9 kgf m, 66 lbf ft) 5

6. Install brackets (3) (2 used) to control bracket (8)


with bolts (9) (4 used), washers (10) (8 used) and
nuts (11) (4 used).
: 24 mm
: 210 N m (21 kgf m, 155 lbf ft) W18K-02-05-001

7. Connect pipings (4) (6 used) and hose (2) to con-


trol valve (1).
: 14 mm View A
8
: 210 N m (21 kgf m, 155 lbf ft)

3
3

9, 10, 11 9, 10, 11
W18K-02-05-002

W2-5-5
UPPERSTRUCTURE / Swing Device
(Front side)

CAUTION: Swing device (1) weight: 1420 kg 1


(3140 lb)
2
1. Install an eyebolt (M24, Pitch 3.0 mm) to the lift-
ing hole (2 places) on swing device (1). Hoist
swing device (1).

CAUTION: Be careful to avoid getting your


hand caught by reaction force bar on the hy-
draulic wrench.

2. Install swing device (1) to frame (2) with bolts (4) 4 3


5 W18K-02-05-003
(24 used) by using a hydraulic wrench.
: 50 mm
: 2550 N m (260 kgf m, 1890 lbf ft)

3. Install a cork to the pulling-out hole (2 places) on


swing device (1).

4. When removing the knock pin, install the knock


pin to the knock hole (2 places) on swing device
(1) by using a hammer. 1

5. Connect hoses (3) (7 used) and the connector to


swing device (1). 4
(Hose)
: 19 mm
: 59 N m (6 kgf m, 44 lbf ft)
: 22 mm 2
: 98 N m (10 kgf m, 72 lbf ft)
: 36 mm
: 235 N m (24 kgf m, 175 lbf ft)
W18C-02-05-001
: 41 mm
: 295 N m (30 kgf m, 200 lbf ft)
(Bolt) Lifting
: 19 mm Hole
: 90 N m (9 kgf m, 66 lbf ft) Pulling-Out
Hole
6. Connect front hose (5). (backhoe: 10 used, load-
ing shovel: 12 used)
: 17 mm
: 400 N m (40 kgf m, 295 lbf ft)
1

Pulling-Out
Hole

W18C-02-05-002
Lifting
Hole

W2-5-6
UPPERSTRUCTURE / Swing Device
(Blank)

W2-5-7
UPPERSTRUCTURE / Swing Device
DISASSEMBLY OF SWING DEVICE

2 15
16
17

60
18
19 44
20
21 43
22

23

24
25
3
26
4 45
2
28
6
29

7 30
31 46
32
8
33 47
9 34
48
10 32
31 49
50
11
35 51
36
37 52
38 53
12
36
54
13 35
39 55
14 40
41 56
42
57

58

59

W18C-02-05-003

W2-5-8
UPPERSTRUCTURE / Swing Device

1 - Valve Unit 17 - Stud Bolt (4 Used) 32 - Spacer (6 Used) 47 - Spherical Bearing


2 - Swing Motor 18 - Bolt (18 Used) 33 - First Stage Planetary Gear 48 - O-Ring
(3 Used)
3- First Stage Sun Gear 19 - Washer (18 Used) 34 - Retaining Ring (3 Used) 49 - Retainer
4- Thrust Plate 20 - Cover 35 - Spherical Bearing (8 Used) 50 - O-Ring
6- Retaining Ring 21 - Cork (2 Used) 36 - Spacer (8 Used) 51 - Oil Seal
7- First Stage Carrier 22 - First Stage Ring Gear 37 - Retaining Ring (4 Used) 52 - Cover
8- Second Stage Sun Gear 23 - Bolt (24 Used) 38 - Second Stage Planetary 53 - Lock Washer (6 Used)
Gear (4 Used)
9- Bolt (4 Used) 24 - Washer (24 Used) 39 - Pin (4 Used) 54 - Bolt (12 Used)
10 - Thrust Washer 25 - Cork (2 Used) 40 - Lock Plate (4 Used) 55 - Pinion Gear
11 - Second Stage Carrier 26 - Case 41 - Lock Washer (4 Used) 56 - Plate
12 - Retaining Ring 27 - Pin (3 Used) 42 - Bolt (8 Used) 57 - Washer (4 Used)
13 - Roller Bearing 28 - Bolt (6 Used) 43 - Cork (2 Used) 58 - Bolt (4 Used)
14 - Second Stage Ring Gear 29 - Lock Washer (3 Used) 44 - Housing 59 - Wire (2 Used)
15 - Nut (4 Used) 30 - Lock Plate (3 Used) 45 - Shaft 60 - O-Ring
16 - Spring Washer (4 Used) 31 - Spherical Bearing (6 Used) 46 - Deflector

W2-5-9
UPPERSTRUCTURE / Swing Device

Bolt

2 15
16
17

18
19
20
21
22

23

24
25
3
26
4

11

14

W18C-02-05-003

W2-5-10
UPPERSTRUCTURE / Swing Device
Disassembly of Swing Device 9. Install an eyebolt (M16, Pitch 2.0 mm) to the pull-
ing-out hole (2 places) on first stage ring gear
1. Remove the bolts (2 used) of swing motor (2) di- (22).
agonally. Install an eyebolt (M16, Pitch 2.0 mm).
: 24 mm 10. Hoist first stage ring gear (22). Remove first
stage ring gear (22) from case (26).
CAUTION: Swing motor (2) weight: 230 kg 11. Remove first stage sun gear (3) and thrust plate
(510 lb) (4) from first stage carrier (7).
IMPORTANT: Do not remove stud bolt (17) unless 12. Install an eyebolt (M16, Pitch 2.0 mm) to the lift-
necessary. ing hole (3 places) on first stage carrier (7).
2. Remove nuts (15) (4 used) and spring washers
(16) (4 used). Hoist swing motor (2). Remove
swing motor (2) from cover (20). CAUTION: The first stage carrier (7) assem-
: 30 mm bly weight: 100 kg (220 lb)

3. Remove bolts (18) (18 used) and washers (19) 13. Hoist the first stage carrier (7) assembly. Remove
(18 used). first stage carrier (7) from second stage carrier
: 24 mm (11). At this time, second stage sun gear (8) is
removed with first stage carrier (7) together.
4. Remove corks (21) (2 used) from cover (20).
14. Remove bolts (23) (24 used) and washers (24)
(24 used).
CAUTION: Cover (20) weight: 34 kg (75 lb)
: 36 mm
5. Install the bolts (M16, Pitch 2.0 mm) to the pull-
15. Remove corks (25) (2 used) from case (26).
ing-out hole (2 places) on cover (20). Float cover
(20) from first stage ring gear (22).
: 24 mm CAUTION: Case (26) weight: 45 kg (100 lb)

6. Install an eyebolt (M16, Pitch 2.0 mm) to the pull- 16. Install a bolt (M24, Pitch 3.0 mm) to the pull-
ing-out hole (2 places) on cover (20). ing-out hole (2 places) on case (26). Float case
(26) from second stage ring gear (14).
7. Hoist cover (20). Remove cover (20) from first : 36 mm
stage ring gear (22).

CAUTION: First stage ring gear (22) weight:


43 kg (95 lb)

8. Install a bolt (M16, Pitch 2.0 mm) to the pull-


ing-out hole (2 places) on first stage sun gear
(22). Float first stage ring gear (22) from case
(26).
: 24 mm

W2-5-11
UPPERSTRUCTURE / Swing Device

44

43

26
45

9
10

50
11

52

53
12
54
39 55
14
56
57

58

59

W18C-02-05-003

W2-5-12
UPPERSTRUCTURE / Swing Device
17. Install an eyebolt (M16, Pitch 3.0 mm) to the pull- 26. Remove corks (43) (2 used) from housing (44).
ing-out hole (2 places) on case (26).
27. Install an eyebolt (M24, Pitch 3.0 mm) to the pull-
18. Hoist case (26). Remove case (26) from second ing-out hole (2 places) on housing (44).
stage ring gear (14)
CAUTION: The housing (44) assembly
CAUTION: Second stage ring gear (14) weight: 700 kg (1550 lb)
weight: 85 kg (190 lb)
IMPORTANT: When turning over housing (44), do
19. Install a bolt (M16, Pitch 2.0 mm) to the pull- not drop roller bearing (13).
ing-out hole (2 places) on second stage ring gear 28. Hoist and turn over housing (44).
(14). Float second stage ring gear (14) from
housing (44). 29. Cut wires (59) (2 used). Remove wires (59) (2
: 24 mm used) from bolts (58) (4 used).

20. Install an eyebolt (M16, Pitch 2.0 mm) to the pull- 30. Remove bolts (58) (4 used) and washers (57) (4
ing-out hole (2 places) on second stage ring gear used). Remove plate (56) from shaft (45).
(14). : 41 mm

21. Hoist second stage ring gear (14). Remove sec- 31. Install an eyebolt (M12, Pitch 1.75 mm) to the lift-
ond stage ring gear (14) from housing (44). ing hole (2 places) on piston gear (55).

22. Remove bolts (9) (4 used). Remove thrust


CAUTION: Pinion gear (55) weight: 96 kg
washer (10) from shaft (45).
(230 lb)
: 30 mm
32. Hoist pinion gear (55). Remove pinion gear (55)
23. Install an eyebolt (M16, Pitch 2.0 mm) to the lift-
from shaft (45).
ing hole on pins (39) (2 used).

CAUTION: The second stage carrier (11) as- CAUTION: Cover (52) weight: 20 kg (44 lb)
sembly
weight: 150 kg (330 lb) 33. Remove bolts (54) (12 used) and lock washers
(53) (6 used). Remove cover (52) and O-ring (50)
24. Hoist the second stage carrier (11) assembly. from housing (44).
Remove the second stage carrier (11) assembly : 27 mm
from shaft (45).

25. Remove retaining ring (12) from housing (44).

W2-5-13
UPPERSTRUCTURE / Swing Device

44

45
27
28
6
29

7 30
31 46
32
8
33 47
34
48
32
31 49

11
35 51
36
37
52
38
36
13 35
39
40
41
42

W18C-02-05-003

W2-5-14
UPPERSTRUCTURE / Swing Device
34. Install an eyebolt (M27, Pitch 3.0 mm) to the bolt
(58) hole (2 places) on shaft (45). CAUTION: First stage carrier (7) weight: 54
kg (120 lb)

CAUTION: The shaft (45) assembly weight: 40. Remove retaining ring (6). Hoist and hold first
230 kg (510 lb) stage carrier (7). Remove first stage carrier (7)
from second stage sun gear (8).
35. Hoist the shaft (45) assembly. Remove the shaft
(45) assembly from housing (44). At this time, the IMPORTANT: Spherical bearings (31) (2 used)
inner races of spherical bearing (47) and roller with a pair have been installed. If
bearing (13) are removed with shaft (45) to- spherical bearing (31) is removed,
gether. put the mark onto each bearing for
assembling.
36. Remove deflector (46) from housing (44) by tap- 41. Remove spherical bearings (31) (6 used), spac-
ping by using a hammer. ers (32) (6 used) and retaining rings (34) (3 used)
from first stage planetary gears (33) (3 used).
37. Remove oil seal (51), retainer (49) and O-ring
(48) from cover (52). Remove spherical bearing
CAUTION: The second stage carrier (11) as-
(47) by using a press.
sembly weight: 150 kg (330 lb)
38. Remove the outer race of roller bearing (13) from
42. Extend lock washers (41) (4 used). Remove bolts
housing (44) by using a hammer.
(42) (8 used). Remove lock washers (41) (4
used), lock plates (40) (4 used), pins (39) (4
CAUTION: The first stage carrier (7) assem- used) and the second stage planetary gear (38)
bly weight: 100 kg (220 lb) assemblies (4 used) from the second stage car-
rier (11) assembly.
39. Extend lock washers (29) (3 used). Remove bolts : 24 mm
(28) (6 used). Remove lock washers (29) (3
used), lock plates (30) (3 used), pins (27) (3 IMPORTANT: Spherical bearings (35) (2 used)
used) and the first stage planetary gear (33) as- with a pair have been installed. If
semblies (3 used) from the first stage carrier (7) spherical bearing (35) is removed,
assembly. put the mark onto each bearing for
: 24 mm assembling.
43. Remove spherical bearings (35) (8 used), spac-
ers (36) (8 used) and retaining rings (37) (4 used)
from second stage planetary gears (38) (4 used).

W2-5-15
UPPERSTRUCTURE / Swing Device
ASSEMBLY OF SWING DEVICE

60
2
27
20 28
3 29, 30
4 18
19
6 31
22 32
7 34
8 33
26 23
14 24
9 35
10 37

11 36
38
12
40, 41
13
42
44
39

48 45

50 46

52 47

51

49 53

54

57
58

59 56 55

W144-02-06-022

W2-5-16
UPPERSTRUCTURE / Swing Device

1 - *Valve Unit 17 - *Stud Bolt (4 Used) 32 - Spacer (6 Used) 47 - Spherical Bearing


2 - Swing Motor 18 - Bolt (18 Used) 33 - First Stage Planetary Gear 48 - O-Ring
(3 Used)
3- First Stage Sun Gear 19 - Washer (18 Used) 34 - Retaining Ring (3 Used) 49 - Retainer
4- Thrust Plate 20 - Cover 35 - Spherical Bearing (8 Used) 50 - O-Ring
6- Retaining Ring 21 - *Cork (2 Used) 36 - Spacer (8 Used) 51 - Oil Seal
7- First Stage Carrier 22 - First Stage Ring Gear 37 - Retaining Ring (4 Used) 52 - Cover
8- Second Stage Sun Gear 23 - Bolt (24 Used) 38 - Second Stage Planetary 53 - Lock Washer (6 Used)
Gear (4 Used)
9- Bolt (4 Used) 24 - Washer (24 Used) 39 - Pin (4 Used) 54 - Bolt (12 Used)
10 - Thrust Washer 25 - *Cork (2 Used) 40 - Lock Plate (4 Used) 55 - Pinion Gear
11 - Second Stage Carrier 26 - Case 41 - Lock Washer (4 Used) 56 - Plate
12 - Retaining Ring 27 - Pin (3 Used) 42 - Bolt (8 Used) 57 - Washer (4 Used)
13 - Roller Bearing 28 - Bolt (6 Used) 43 - *Cork (2 Used) 58 - Bolt (4 Used)
14 - Second Stage Ring Gear 29 - Lock Washer (3 Used) 44 - Housing 59 - Wire (2 Used)
15 - *Nut (4 Used) 30 - Lock Plate (3 Used) 45 - Shaft 60 - O-Ring
16 - *Spring Washer (4 Used) 31 - Spherical Bearing 46 - Deflector
(6 Used)

NOTE: As for the parts with mark *, refer to W2-5-8.

W2-5-17
UPPERSTRUCTURE / Swing Device

27
20 28
3 29, 30
4
31
32
6

34
7
8 33

35
10 37

11 36
38
40, 41
42

39
45

W144-02-06-022

W2-5-18
UPPERSTRUCTURE / Swing Device
Assembly of Swing Device
IMPORTANT: Install thrust plate (4) with the oil
IMPORTANT: When installing spherical bearing groove facing to the shaft (45) side.
(31) to first stage planetary gear (33), 6. Install thrust plate (4) to first stage sun gear (3).
apply molybdenum disulphide onto Install first stage sun gear (3) to first stage carrier
the outer periphery of the outer race (7).
of spherical bearing (31). Install
spherical bearing (31) with the IMPORTANT: When installing spherical bearing
stamped mark of aligning code “A” (35) to second stage planetary gear
facing inside. (38), apply molybdenum disulphide
In addition, spherical bearings (31) onto the outer periphery of the outer
(2 used) are a pair. When replacing race of spherical bearing (35). Install
spherical bearing (31), replace with spherical bearing (35) with the
a pair (2 used). stamped mark of aligning code “A”
1. Install retaining rings (34) (3 used), spacers (32) facing inside.
(6 used) and spherical bearings (31) (6 used) to In addition, spherical bearings (35)
first stage planetary gears (33) (3 used). (2 used) are a pair. When replacing
spherical bearing (35), replace with
2. Install an eyebolt (M16, Pitch 2.0 mm) to the lift- a pair (2 used).
ing hole (3 places) on first stage carrier (7). 7. Install retaining rings (37) (4 used), spacers (36)
(8 used) and spherical bearings (35) (8 used) to
second stage planetary gears (38) (4 used).
CAUTION: First stage carrier (7) weight: 54
kg (120 lb) IMPORTANT: Install thrust plate (10) with the oil
groove facing to the cover (20) side.
3. Hoist first stage carrier (7). Install first stage car- 8. Install thrust plate (10) to second stage carrier
rier (7) to second stage sun gear (8) with retain- (11).
ing ring (6).
IMPORTANT: Face the detaching prevention
IMPORTANT: Face the detaching prevention groove for pin (39) outside.
groove for pin (27) outside. 9. Install the second stage planetary gear (38) as-
4. Install the first stage planetary gear (33) assem- semblies (4 used) to second stage carrier (11)
blies (3 used) to first stage carrier (7) with pins with pins (39) (4 used).
(27) (3 used).
IMPORTANT: Do not reuse lock washer (41).
IMPORTANT: Do not reuse lock washer (29). 10. Install lock plates (40) (4 used) and lock washers
5. Install lock plates (30) (3 used) and lock washers (41) (4 used) to pins (39) (4 used) with bolts (42)
(29) (3 used) to pins (27) (3 used) with bolts (28) (8 used). Bend lock washers (41) (4 used) along
(6 used). Bend lock washers (29) (3 used) along the bolt end.
the bolt end. : 24 mm
: 24 mm : 270 N m (27.5 kgf m, 200 lbf ft)
: 270 N m (27.5 kgf m, 200 lbf ft)

W2-5-19
UPPERSTRUCTURE / Swing Device

44

48 45

50 46

52 47

51

49

58

W144-02-06-022

W2-5-20
UPPERSTRUCTURE / Swing Device
11. Warm up spherical bearing (47) to approx. 90°C
by using a bearing heater. CAUTION: The shaft (45) assembly weight:
230 kg (510 lb)

CAUTION: Spherical bearing (47) weight: 16. Hoist the shaft (45) assembly. Install the shaft
58 kg (130 lb) (45) assembly to housing (44).

IMPORTANT: Apply molybdenum disulphide onto IMPORTANT: Install oil seal (51) with the lip part
the outer periphery of spherical facing to the spherical bearing (47)
bearing (47). In addition, the inner side. In addition, apply molybdenum
race is pushed by spherical bearing disulphide onto the outer periphery
(47). If the outer race is pushed, of oil seal (51).
spherical bearing (47) may be dam- 17. Install oil seal (51) to cover (52) by using the spe-
aged. cial tool (ST 2646). Apply grease onto the ring
12. Install spherical bearing (47) to shaft (45) with the groove of cover (52). Install O-ring (50).
stamped mark facing upward by using a press.

IMPORTANT: As for retainer (49), face the O-ring ST 2646


(48) groove side to the spherical
bearing (47) side.
13. Apply grease onto the ring groove of retainer (49). 51
Install O-ring (48). Install retainer (49) to shaft
50
(45).
52

45
49
W114-02-06-012
48
47

W114-02-06-011

14. Install deflector (46) to housing (44) by using a


bar and a hammer.
NOTE: Insert deflector (46) until deflector (46)
comes into contact with the end of housing
(44).

15. Install an eyebolt (M27, Pitch 3.0 mm) to the bolt


(58) hole (2 places) on shaft (45).

W2-5-21
UPPERSTRUCTURE / Swing Device

9
10

11
12
13
44
39
45

52

53

54

57
58

59 56 55

W144-02-06-022

W2-5-22
UPPERSTRUCTURE / Swing Device
IMPORTANT: Do not reuse the lock washer (53). IMPORTANT: Apply molybdenum disulphide onto
18. Install the cover (52) assembly to housing (44) the roller bearing (13) mounting part
with lock washers (53) (6 used) and bolts (54) of housing (44).
(12 used). Bend lock washer (53) in order to se- 24. Install the outer race of roller bearing (13) to
cure. housing (44) by using a bar and a hammer.
: 27 mm
: 300 N m (30.5 kgf m, 221 lbf ft) 25. Install retaining ring (12) to housing (44).

19. Install an eyebolt (M12, Pitch 1.75 mm) to the lift- 26. Install an eyebolt (M16, Pitch 2.0 mm) to pins
ing hole (2 places) on pinion gear (55). (39) (2 used).

CAUTION: Pinion gear (55) weight: 96 kg CAUTION: The second stage carrier (11) as-
sembly weight: 150 kg (330 lb)
20. Hoist pinion gear (55). Install plate (56) to shaft
(45) with washers (57) (4 used) and bolts (58) (4 IMPORTANT: Apply LOCTITE #242 onto the thread
used). part of bolt (9).
At this time, check that the clearance between 27. Hoist the second stage carrier (11) assembly. In-
pinion gear (55) and plate (56) is 0.3 to 1.1 mm. stall the second stage carrier (11) assembly to
: 41 mm shaft (45) while aligning the splines.
: 1370 N m (140 kgf m, 1010 lbf ft)
28. Install thrust washer (10) to shaft (45) with bolts
21. Install wires (59) (2 used) to bolts (58) (4 used). (9) (4 used).
: 30 mm
22. Install an eyebolt (M24, Pitch 3.0 mm) to the pull- : 550 N m (56 kgf m, 410 lbf ft)
ing-out hole (2 places) on housing (44).

CAUTION: The housing (44) assembly


weight: 700 kg (1550 lb)

23. Hoist and turn over the housing (44) assembly.

W2-5-23
UPPERSTRUCTURE / Swing Device

60
2

20
3
18
19

22
7

26 23
14 24

11

44

W144-02-06-022

W2-5-24
UPPERSTRUCTURE / Swing Device
29. Install an eyebolt (M16, Pitch 2.0 mm) to the pull-
ing-out hole (2 places) on second stage ring gear CAUTION: First stage ring gear (22) weight:
(14). 43 kg (95 lb)

IMPORTANT: Apply THREEBOND #1215 onto the


CAUTION: Second stage ring gear (14) mating surfaces of case (26) and
weight: 85 kg (190 lb) first stage ring gear (22).
IMPORTANT: Apply THREEBOND #1215 onto the 35. Hoist first stage ring gear (22). Install first stage
mating surfaces of housing (44) and ring gear (22) to case (26) while aligning the
second stage ring gear (14). splines of the gear.
30. Hoist second stage ring gear (14). Install second
stage ring gear (14) to housing (44) while align- 36. Install an eyebolt (M16, Pitch 2.0 mm) to the pull-
ing the splines of the gear. ing-out hole (2 places) on cover (20).

31. Install an eyebolt (M16, Pitch 3.0 mm) to the pull- 37. Install O-ring (60) to cover (20).
ing-out hole (2 places) on case (26).
CAUTION: Cover (20) weight: 34 kg (75 lb)
CAUTION: Case (26) weight: 45 kg (100 lb)
IMPORTANT: Apply THREEBOND #1215 onto the
IMPORTANT: Apply THREEBOND #1215 onto the mating surfaces of first stage ring
mating surfaces of second stage gear (22) and cover (20).
ring gear (14) and case (26). 38. Hoist cover (20). Install cover (20) to first stage
32. Hoist case (26). Install case (26) to second stage ring gear (22) with bolts (18) (18 used) and
ring gear (14) with bolts (23) (24 used) and washers (19) (18 used).
washers (24) (24 used). : 24 mm
: 36 mm : 210 N m (21.5 kgf m, 155 lbf ft)
: 700 N m (71.5 kgf m, 520 lbf ft) NOTE: Check that first stage sun gear (3) rotates
smoothly by hands.
CAUTION: The first stage carrier (7) assem-
bly weight: 100 kg (220 lb)

33. Hoist the first stage carrier (7) assembly. Install


the first stage carrier (7) assembly to second
stage carrier (11) while aligning the splines of the
gear.

34. Install an eyebolt (M16, Pitch 2.0 mm) to the pull-


ing-out hole (2 places) on first stage ring gear
(22).

W2-5-25
UPPERSTRUCTURE / Swing Device

W144-02-06-022

W2-5-26
UPPERSTRUCTURE / Swing Device
39. Install corks (21) (2 used), (25) (2 used) and (43)
(2 used) to each pulling-out hole on the swing
reduction gear by using a hammer.

CAUTION: Swing motor (2) weight: 178 kg


(395 lb)

40. Install swing motor (2) to the swing reduction


gear with nuts (15) (4 used) and spring washers
(16) (4 used). Add gear oil.
Gear oil: SP90
(Gear Lube)
Oil amount: 60 L (15.9 US gal)
: 24 mm
: 210 N m (21.5 kgf m, 155 lbf ft)

W2-5-27
UPPERSTRUCTURE / Swing Device
DISASSEMBLY OF SWING MOTOR
10
9 11

5
6
7
6
5 12
4 13
3
14
2 16 15
1

17 14
18
19
20
21
22
23 32

24
28 25
26 31
27

30

33
34
29
35
36
37
38
39
38

W118-02-04-002
39
38
1- Socket Bolt (6 Used) 11 - O-Ring (2 Used) 21 - Guide Ring 31 - Bolt (12 Used)
2- Cover 12 - Shim 22 - Valve Plate 32 - Socket Bolt (9 Used)
3- O-Ring 13 - Spacer 23 - Rotor 33 - Cover
4- Oil Seal 14 - Retaining Ring (2 Used) 24 - Disc Spring (4 Used) 34 - O-Ring
5- Retaining Ring (2 Used) 15 - Coupling 25 - Shim 35 - Piston
6- Spacer (2 Used) 16 - Socket Bolt (3 Used) 26 - Holder 36 - Piston Ring
7- Bearing 17 - Cover 27 - Retainer 37 - Piston Ring
8- Shaft 18 - Pin 28 - Plunger (9 Used) 38 - Plate (9 Used)
9- Casing 19 - O-Ring 29 - Shoe Plate 39 - Friction Plate (8 Used)
10 - Plug (2 Used) 20 - Bearing 30 - Spring (12 Used)

W2-5-28
UPPERSTRUCTURE / Swing Device
Disassembly of Swing Motor 7. Remove piston rings (36, 37) from piston (35).

8. Remove retaining ring (14) and coupling (15)


CAUTION: Swing motor weight: 195 kg (430 from shaft (8).
lb)
9. Remove plates (38) (9 used), friction plates (39)
1. Hoist and place the swing motor on a workbench. (8 used), shim (12) and spacer (13) from cover
Remove plug (10) from casing (9). Drain hydrau- (17).
lic oil.
: 36 mm 10. Remove retaining ring (14) from shaft (8).
2. Remove bolts (31) (2 used) diagonally. Install an IMPORTANT: When removing cover (17), valve
eyebolt (M16, Pitch 2.0 mm). plate (22) may be removed with
Hoist and place the swing motor on wooden cover (17) together. Remove cover
blocks (2 used) vertically. (17) carefully in order to prevent
: 24 mm valve plate (22) from falling off.
11. Remove socket bolts (16) (3 used) and (32) (9
used) from cover (17). Install an eyebolt (M16,
Swing Motor Pitch 2.0 mm) to the bolt (31) hole on cover (17).
Hoist cover (17). Remove cover (17) from casing
(9).
: 14 mm

Wooden 12. Remove valve plate (22), guide ring (21) and
Block
O-ring (19) from cover (17).
W18B-02-05-004 NOTE: Do not remove bearing (20) unless nec-
essary.
3. Put the matching marks on casing (9) and covers
(17, 33).

4. Loosen other bolts (31) (10 used) evenly. Re-


move cover (33) from cover (17). Remove O-ring
(34) from cover (33).
: 24 mm

5. Remove springs (30) (12 used) from cover (17).

6. Install an eyebolt (M16, Pitch 2.0 mm) to the cen-


ter hole on piston (35). Hoist piston (35). Remove
piston (35) from cover (17).

W2-5-29
UPPERSTRUCTURE / Swing Device

5
6
7
6
5
4
3
2
1

20

23

24
28 25
26
27

33

29

W118-02-04-002

W2-5-30
UPPERSTRUCTURE / Swing Device
13. Place casing (9) on a workbench horizontally with 21. Push shaft (8) by using a press and remove the
the main piping mounting surface facing upward. inner race of bearing (7).

22. Tap shoe plate (29) by using a copper bar. Re-


CAUTION: The rotor (23) assembly weight: move shoe plate (29) from casing (9).
41 kg (90 lb)
23. Tap the outer race of bearing (7) by using a cop-
14. Wind a nylon sling onto the body of rotor (23). per bar. Remove bearing (7) from casing (9).
Remove rotor (23) from casing (9). At this time,
plunger (28), holder (26) and retainer (27) are
removed with rotor (23) together.

15. Wind vinyl tape around the inner race of bearing


(20) in order to protect.

16. Remove plungers (28) (9 used), retainer (27),


holder (26), disc spring (24) and shim (25) from
rotor (23).

17. Remove socket bolts (1) (6 used). Remove cover


(2) from casing (9).
: 8 mm

18. Remove oil seal (4) and O-ring (3) from cover (2).

19. Remove shaft (8) from casing (9) by tapping by


using a plastic hammer from the cover (33) side.

20. Remove retaining rings (5) (2 used) from shaft (8).


Remove spacers (6) (2 used).

W2-5-31
UPPERSTRUCTURE / Swing Device
ASSEMBLY OF SWING MOTOR

16 34 30 14 35 33 15 31

36

Dimension A
37

38
39
17
32

12
13

19
20
18
21 22

9
23
11
10
10
11 24

25
26
28
5
6
27

W117-02-04-005
29 1 2 4 8 5 6 3

1- Socket Bolt (6 Used) 11 - O-Ring (2 Used) 21 - Guide Ring 31 - Bolt (12 Used)
2- Cover 12 - Shim 22 - Valve Plate 32 - Socket Bolt (9 Used)
3- O-Ring 13 - Spacer 23 - Rotor 33 - Cover
4- Oil Seal 14 - Retaining Ring (2 Used) 24 - Disc Spring (4 Used) 34 - O-Ring
5- Retaining Ring (2 Used) 15 - Coupling 25 - Shim 35 - Piston
6- Spacer (2 Used) 16 - Socket Bolt (3 Used) 26 - Holder 36 - Piston Ring
7- Bearing 17 - Cover 27 - Retainer 37 - Piston Ring
8- Shaft 18 - Pin 28 - Plunger (9 Used) 38 - Plate (9 Used)
9- Casing 19 - O-Ring 29 - Shoe Plate 39 - Friction Plate (8 Used)
10 - Plug (2 Used) 20 - Bearing 30 - Spring (12 Used)

W2-5-32
UPPERSTRUCTURE / Swing Device
Assembly of Swing Motor

1. Install retaining ring (5) and spacer (6) to the ro- IMPORTANT: The smooth surface of rotor (23) is
tor side of shaft (8). the sliding surface for the valve
plate. Do not damage the sliding
2. Assemble the inner race and the inner ring plate surface.
of bearing (7). Warm up them to approx. 60 °C 9. Assemble rotor (23) into an assembly in the fol-
(140 °F) by using a heater or an oil bath. lowing procedures.
• Place rotor (23) with the smooth surface facing
3. Install bearing (7) to shaft (8) with the inner ring downward.
plate facing inside by using a press. • Assemble disc springs (24) (4 used) so that the
outer surface is matching with the outer surface
4. Install spacer (6) and retaining ring (5) to shaft and the inner surface is matching with the inner
(8). surface. Place disc spring (24) on the projection
part of top in rotor (23).
5. Lightly tap the outer race of bearing (7) by using Place shim (25) on them and cover them with
a copper bar and install shaft (8) to casing (9). holder (26). At this time, align holder (26) with the
spline in rotor (23).
6. Install oil seal (4) to cover (2). Install O-ring (3).
25

7. Install cover (2) to casing (9) with socket bolts (1) 24


(6 used) 26
: 8 mm
23
: 57 N m (5.8 kgf m, 42 lbf ft)

IMPORTANT: Install shoe plate (29) with the


chamfered surface facing inside. W18B-02-04-010
IMPORTANT: After installing shoe plate (29), ro-
tate shoe plate (29) by hand. If shoe • Place retainer (27) on holder (26) with the cham-
plate (29) cannot be rotated, reas- fered surface facing downward.
semble shoe plate (29) as it may be
seized. 27
8. Apply grease onto the chamfered surface and the
outer periphery of shoe plate (29).
Install shoe plate (29) to casing (9).

Chamfered
26 Surface
W176-02-06-016

• Align the plunger hole on retainer (27) with that


on rotor (23). Insert plungers (28) (9 used).

CAUTION: The rotor (23) assembly weight:


41 kg (90 lb)

10. Install the rotor (23) assembly into shaft (8).

W2-5-33
UPPERSTRUCTURE / Swing Device

16 34 30 14 35 33 15 31

36
37

38
39
17
32

12
13

19
18
21 22

11
10
10
11

W117-02-04-005
8

W2-5-34
UPPERSTRUCTURE / Swing Device
11. Install guide ring (21) and O-ring (19) to cover IMPORTANT: Align the notches on plates (38) (9
(17). used) and friction plates (39) (8
used). In addition, adjust shim (12)
12. Apply grease onto the flat surface of valve plate so that dimension A between the
(22). Install valve plate (22) to cover (17) while stepped surface of cover (17) and
aligning with pin (18). top of plate (38) is 3.3 mm (0.1 in).

17
CAUTION: The casing (9) assembly weight:
120 kg (270 lb)
A
13. Install an eyebolt (M16, Pitch 2.0 mm) to the
cover mounting bolt (32) hole on casing (9).
Hoist and place casing (9) on a wooden block 38
vertically.

W18B-02-04-013

9
Wooden Block 17. Install plates (38) (9 used) and friction plates (39)
(Height: 200 mm)
(8 used) alternately in this order to cover (17) and
coupling (15).

18. Install piston rings (36, 37) to piston (35).

19. Install piston (35) to cover (17).

20. Install springs (30) (12 used) to piston (35).


W18B-02-04-011

21. Install O-ring (34) to cover (33). Install cover (33)


IMPORTANT: Do not drop valve plate (22) from
to cover (17) with bolts (31) (12 used).
cover (17).
: 24 mm
14. Install cover (17) to casing (9) with socket bolts
: 235 N m (24 kgf m, 173 lbf ft)
(16) (3 used) and (32) (9 used).
: 14 mm
22. Install O-rings (11) (2 used) to plugs (10) (2 used).
: 270 N m (27.5 kgf m, 200 lbf ft)
Install plugs (10) (2 used) to casing (9).
: 36 mm
15. Install retaining ring (14), coupling (15) and re-
: 167 N m (17 kgf m, 123 lbf ft)
taining ring (14) to shaft (8).

16. Install spacer (13) and shim (12) to cover (17).

W2-5-35
UPPERSTRUCTURE / Swing Device
MAINTENANCE STANDARD Dial Gauge

1. Clamp the plunger in a vise. Install a dial gauge


to the shoe. Measure clearance (A) between the
plunger spherical part and the shoe bottom while
moving the shoe up and down. A
If clearance (A) exceeds the allowable limit, re-
place the plunger and the shoe as an assembly. Guide

Unit: mm (in)
Standard Allowable Limit
0 0.3 (0.01)

2. Measure plunger diameter (B) around top, middle Vise W115-02-04-062


Plate
and skirt part in both vertically and horizontally by
using a micrometer.
Measure rotor bore (C) at two places (vertically
and horizontally) by using a cylinder gauge. (B) (B) (B)

(C)-(B) Unit: mm (in)


Standard Allowable Limit W115-02-04-065

0.026 (0.001) 0.056 (0.002)

3. Measure flange thickness (D) of the shoe by us-


ing a micrometer. (C) (C)

Unit: mm (in)
(C) (C)
Standard Allowable Limit
10.0 (0.4) 9.8 (0.4)

W115-02-04-066

4. Measure height H and h.


E=H-h

Unit: mm (in)
Standard Allowable Limit
E 35.6 (1.4) 34.8 (1.4) (D)

W115-02-04-068

26 27

H
h

W115-02-04-069

W2-5-36
UPPERSTRUCTURE / Swing Device
5. Measure dimension (A).
17
Unit: mm (in)
A
Standard Allowable Limit
3.3 (0.1) 4.3 (0.2)

Remedy: Adjust by using the shims. 38

6. Measure the disc spring thickness.

I-i Unit: mm (in)


W18B-02-04-013
Standard Allowable Limit
7.8 (0.3) 7.4 (0.3)
Cover

Casing
Valve Plate
i

W117-02-04-006

7. Measure the brake spring length.

Unit: mm (in)
Standard Allowable Limit
54 (2.1) 53.6 (2.1)

Remedy: Replace the spring.

8. Measure thickness of the plate and the friction


plate.(17 used)

Unit: mm (in)
Standard Allowable Limit
36.8 (1.4) 36.2 (1.4)

Remedy: Replace the plate and the friction plate.

W2-5-37
UPPERSTRUCTURE / Swing Device
DISASSEMBLY AND ASSEMBLY OF
VALVE UNIT

1 2 3 4 5 4 3 2

6 6

W118-02-04-003
11 10

1 - Plug (2 Used) 4 - Poppet (2 Used) 7 - O-Ring (2 Used) 10 - O-Ring (2 Used)


2 - O-Ring (2 Used) 5 - Housing 8 - Relief Valve (2 Used) 11 - Backup Ring (4 Used)
3 - Spring (2 Used) 6 - Plug (2 Used) 9 - Plug (2 Used)

W2-5-38
UPPERSTRUCTURE / Swing Device
Disassembly of Valve Unit Assemble Valve Unit

1. Install the relief valve (8) assemblies (2 used).


CAUTION: Valve unit weight: 31kg (68 lb) : 41 mm
: 176 N m (18 kgf m, 130 lbf ft)
1. Loosen plugs (1) (2 used). Remove springs (3) (2
used) and poppets (4) (2 used). 2. Install plugs (9) (2 used).
: 14 mm : 41 mm
: 176 N m (18 kgf m, 130 lbf ft)
2. Remove plugs (6) (2 used).
: 6 mm 3. Install plugs (6) (2 used).
: 6 mm
3. Remove plugs (9) (2 used). : 36 N m (3.7 kgf m, 27 lbf ft)
: 41 mm
4. Install spring (3) to poppet (4). Insert poppet (4)
IMPORTANT: Do not disassemble the relief valve into housing (5). (2 places)
(8) assembly. Install plugs (1) (2 used) to housing (5).
4. Attach a spanner onto the body of the relief valve : 14 mm
(8) assembly. Remove the relief valve (8) assem- : 334 N m (34 kgf m, 246 lbf ft)
bly from housing (5). (2 places)
: 41 mm

W2-5-39
UPPERSTRUCTURE / Swing Device
(Blank)

W2-5-40
UPPERSTRUCTURE / DQR Valve
REMOVAL AND INSTALLATION DQR EHC Valve
VALVE

CAUTION: Bleed air from the hydraulic oil


tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

(Pilot Panel Side) 1


3
Removal

1. Disconnect hoses (6) (15 used) from DQR valve Frame


2
(2). Cap the open ends. Attach an identification W18K-02-08-001

tag onto the disconnected hoses for assembling.


: 17 mm, 19 mm, 27 mm

2 6
CAUTION: DQR valve (2) weight: 28 kg (65 Ib)
5
2. Remove socket bolts (5) (4 used) from DQR valve
(2). Remove DQR valve (2) from pilot panel (1).
: 8 mm

3. Disconnect hoses (8) (15 used) from DQR valve


(3). Cap the open ends. Attach an identification 6 1
tag onto the disconnected hoses for assembling.
: 17 mm, 19 mm, 27 mm
6

CAUTION: DQR valve (3) weight: 28 kg (65 Ib)


W18L-02-06-001
4. Remove socket bolts (7) (4 used) from DQR valve
(3). Remove DQR valve (3) from pilot panel (4).
: 8 mm

3 7 8

8 4

8 W18L-02-06-002

W2-6-1
UPPERSTRUCTURE / DQR Valve
Installation
3 7 8

CAUTION: DQR valve (3) weight: 28 kg (65 Ib)

1. Install DQR valve (3) to pilot panel (4) with socket


bolts (7) (4 used). 8 4
: 8 mm
: 50 N m (5 kgf m, 37 Ibf ft)

2. Connect hoses (8) (15 used) to DQR valve (3).


: 17 mm
: 24.5 N m (2.5 kgf m, 18 Ibf ft)
: 19 mm
: 29.5 N m (3 kgf m, 21.5 Ibf ft)
8 W18L-02-06-002
: 27 mm
: 93 N m (9.5 kgf m, 70 Ibf ft)
2 6
CAUTION: DQR valve (2) weight: 28 kg (65 Ib)
5
3. Install DQR valve (2) to pilot panel (1) with socket
bolts (5) (4 used).
: 8 mm
: 50 N m (5 kgf m, 37 Ibf ft)
6 1
4. Connect hoses (6) (15 used) to DQR valve (2).
: 17 mm
: 24.5 N m (2.5 kgf m, 18 Ibf ft) 6
: 19 mm
: 29.5 N m (3 kgf m, 21.5 Ibf ft)
: 27 mm
W18L-02-06-001
: 93 N m (9.5 kgf m, 70 Ibf ft)
EHC Valve

2 Frame W18K-02-08-001

W2-6-2
UPPERSTRUCTURE / DQR Valve
(Blank)

W2-6-3
UPPERSTRUCTURE / DQR Valve
STRUCTURE OF DQR VALVE

8
3
9

W18G-02-06-010

W2-6-4
UPPERSTRUCTURE / DQR Valve

A A A A A A A

A A A A A A A
W18G-02-06-008

9
8
2
3

4
5

6
W18G-02-06-009
7 Section A-A

Wrench Size Tightening Torque


Item Part Name Q’ty Remarks
(mm) Nm (kgf m) Ibf ft
1 Adapter 7 : 22 50 (5.0) 37 PF 3/8
2 O-Ring 7
3 Body 1
4 Spool 6
5 Spring 6
6 O-Ring 6
7 Plug 6 :5 50 (5.0) 37 PF 3/8
8 Plug 14 :5 10 (1.0) 7 PF 1/8
9 O-Ring 14

W2-6-5
UPPERSTRUCTURE / DQR Valve
(Blank)

W2-6-6
UPPERSTRUCTURE / Shuttle Valve
REMOVAL AND INSTALLATION OF SHUT-
TLE VALVE

CAUTION: Bleed air from the hydraulic oil


tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on Pilot Panel Control Valve
W1-4-1.)

Removal

IMPORTANT: Attach an identification tag onto the


disconnected pipings and hose for
assembling.
1. Disconnect pipings (3) (16 used) and hoses (6)
(12 used) from shuttle valves (2) (4 used).
(Piping)
: 19 mm
(Hose)
: 22 mm

2. Remove pressure sensor (7) from shuttle valve W18K-02-07-001

(2).
3 2 1
3. Remove bolts (5) (8 used) from bracket (1). Re-
move the shuttle valve (2) assemblies (4 used).
: 10 mm, 17 mm 3
2 2

4. Remove bolts (7) (4 used for each) from brackets 4


(4) (4 used). Remove shuttle valves (2) (4 used) 4
from brackets (4) (4 used). 5
: 13 mm, 17 mm 5
6

W18K-02-07-002
7

W2-7-1
UPPERSTRUCTURE / Shuttle Valve
Installation
2 2
1. Install shuttle valves (2) (4 used) to brackets (4) 3
(4 used) with bolts (7) (4 used for each).
: 13 mm 4
4
: 20 N m (2 kgf m, 15 lbf ft)
: 17 mm 5
: 50 N m (5 kgf m, 37 lbf ft) 5
6

2. Install the shuttle valve (2) assemblies (4 used) to


bracket (1) with bolts (5) (2 used for each).
: 10 mm
: 3.3 to 4.2 N m
(0.3 to 0.4 kgf m, 2 to 3 lbf ft) W18K-02-07-002
7
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)

3. Install pressure sensor (7) to shuttle valve (2). Pilot Panel Control Valve

4. Connect pipings (3) (16 used) and hoses (6) (12


used) to shuttle valves (2) (4 used).
(Piping)
: 19 mm
: 30 N m (3 kgf m, 22 lbf ft)
(Hose)
: 22 mm
: 40 N m (4 kgf m, 30 lbf ft)

W18K-02-07-001

3 2 1

W2-7-2
UPPERSTRUCTURE / Shuttle Valve
STRUCTURE OF SHUTTLE VALVE

4
3
2
1

4
4 3
3 2
2 1
1 W18B-02-10-001
8

Wrench Size Tightening Torque


Part Name Q’ty Remark
(mm) Nm (kgf m) (lbf ft)
1- Plug 3 :6 20 (2.0) (15)
2- O-ring 3
3- Plug 3 :5
4- Steel ball 3 8
5- Seal 1
6- Steel ball 3
7- Body 1
8- Seal 1 -

W2-7-3
UPPERSTRUCTURE / Shuttle Valve
(Blank)

W2-7-4
UPPERSTRUCTURE / EHC Valve
REMOVAL AND INSTALLATION OF EHC
VALVE

CAUTION: Bleed air from the hydraulic oil


tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal

1. Remove bolts (3) (3 used). Remove the clips (3


used).
: 17 mm
1
2. Remove bolts (5) (2 used). Remove bracket (4)
from pilot panel (1).
: 17 mm

3. Disconnect hoses (6) (8 used), piping (7) and 2 Frame


W18K-02-08-001

connectors (9) (15 used) from EHC valve (2). Cap


the open ends of the hose and the piping. Attach
3 Clip 4, 5 6
an identification tag onto the disconnected hoses
and pipings for assembling.
: 17 mm, 19 mm, 22 mm 1

4. Remove bolts (8) (4 used). Remove EHC valve (2)


from pilot panel (1).
: 17 mm
2

9 7

6 9 8 W18L-02-08-002

W2-8-1
UPPERSTRUCTURE / EHC Valve
5. Remove bolts (12) (4 used). Remove the clips (4
used). Remove bolts (15) (2 used). Remove
bracket (14) from pilot panel (10).
11
: 17 mm

6. Disconnect hoses (13) (7 used), piping (16) and


connectors (18) (14 used) from EHC valve (11). 10
Cap the open ends of the hose and piping. Attach
an identification tag onto the disconnected hoses
and pipings for assembling.
: 17 mm, 19 mm, 22 mm
W18K-02-08-001
7. Remove bolts (17) (4 used). Remove EHC valve
Clip 12 13 14, 15
(11) from pilot panel (10).
: 17 mm

10

11

16

13

18 17 W18L-02-08-003

W2-8-2
UPPERSTRUCTURE / EHC Valve
Installation
3 Clip 4, 5 6
1. Install EHC valve (2) to pilot panel (1) with bolts
(8) (4 used). 1
: 17 mm
: 50 N m (5 kgf m, 37 Ibf ft)

2. Connect hoses (6) (8 used), piping (7) and


connectors (9) (15 used) to EHC valve (2).
: 17 mm 2
: 24.5 N m (2.5 kgf m, 18 Ibf ft)
: 19 mm 9 7
: 29.5 N m (3 kgf m, 21.5 Ibf ft)
: 22 mm
: 39 N m (4 kgf m, 30 Ibf ft)
6 9 8 W18L-02-08-002

3. Install bracket (4) to pilot panel (1) with bolts (5) (2


used).
: 17 mm
: 50 N m (5 kgf m, 37 Ibf ft)

4. Install the clips (3 used) to bracket (4) with bolts


(3) (3 used).
: 17 mm
: 50 N m (5 kgf m, 37 Ibf ft) 1

W18K-02-08-001
2 Frame

W2-8-3
UPPERSTRUCTURE / EHC Valve
5. Install EHC valve (11) to pilot panel (10) with bolts Clip 12 13 14, 15
(17) (4 used).
: 17 mm
: 50 N m (5 kgf m, 37 Ibf ft)
10
6. Connect hoses (13) (7 used), piping (16) and
connectors (18) (14 used) to EHC valve (11). 11
: 17 mm
: 24.5 N m (2.5 kgf m, 18 Ibf ft) 16
: 19 mm
: 29.5 N m (3 kgf m, 21.5 Ibf ft)
: 22 mm
: 39 N m (4 kgf m, 30 Ibf ft)
13

7. Install bracket (14) to pilot panel (10) with bolts 18 17 W18L-02-08-003

(15) (2 used).
: 17 mm
: 50 N m (5 kgf m, 37 Ibf ft)

8. Install the clips (4 used) to bracket (14) with bolts


(12) (4 used). 11
: 17 mm
: 50 N m (5 kgf m, 37 Ibf ft) 10

Frame
W18K-02-08-001

W2-8-4
UPPERSTRUCTURE / EHC Valve
Engine Bed Side (Pump Space)
2 3 4, 5 6
Removal Clip

1. Remove bolts (6) (5 used) from bracket (4). 1


Remove the clips (5 used).
: 17 mm

2. Remove bolts (5) (2 used). Remove bracket (4)


from pilot panel (1).
: 17 mm

3. Disconnect connectors (7) (11 used), pipings (9)


(6 used) and hose (8) from EHC valve (2).
: 17 mm, 19 mm
W18L-02-08-004
9 8 7
4. Remove bolts (3) (4 used). Remove EHC valve (2)
from pilot panel (1).
: 17 mm

W2-8-5
UPPERSTRUCTURE / EHC Valve
Installation
2 3 4, 5 6
1. Install EHC valve (2) to pilot panel (1) with bolts Clip
(3) (4 used).
: 17 mm 1
: 50 N m (5 kgf m, 37 Ibf ft)

2. Connect connectors (7) (11 used), pipings (9) (6


used) and hose (8) to EHC valve (2).
: 17 mm
: 24.5 N m (2.5 kgf m, 18 Ibf ft)
: 19 mm
: 29.5 N m (3 kgf m, 21.5 Ibf ft)

3. Install bracket (4) to pilot panel (1) with bolts (5) (2


used). 7 W18L-02-08-004
9 8
: 17 mm
: 50 N m (5 kgf m, 37 Ibf ft)

4. Secure the clips (5 used) to bracket (4) with bolts


(6) (5 used).
: 17 mm
: 50 N m (5 kgf m, 37 Ibf ft)

W2-8-6
UPPERSTRUCTURE / EHC Valve
STRUCTURE OF EHC VALVE

Section B

Proportional Plug
W18G-02-08-009
Solenoid Valve

W18G-02-08-010
Plug
Proportional Solenoid Valve

Section A W18G-02-08-011

W2-8-7
UPPERSTRUCTURE / EHC Valve
DISASSEMBLY AND ASSEMBLY OF PROPORTIONAL SOLENOID VALVE

1
2
3
4
5

7
8
9
12
13 14
10 15
11 16

17
18
19

W18G-02-08-012

4 2 3, 5 6 1 8 12 13 17 10 18

19
W18G-02-08-013

7 9 14 15 16 11

1- Socket Bolt (4 Used) 6- Solenoid 11 - Orifice 16 - O-Ring


2- Lock Nut 7- Spring 12 - Washer 17 - Sleeve
3- O-Ring 8- O-Ring 13 - Spring 18 - Plate
4- Adjusting Bolt 9- Diaphragm 14 - O-Ring 19 - Wave Spring
5- Spring 10 - Spool 15 - O-Ring

W2-8-8
UPPERSTRUCTURE / EHC Valve
Disassembly of Proportional Solenoid Valve Assembly of Proportional Solenoid Valve

IMPORTANT: Do not lose spring (7) inside 1. Install wave spring (19) and plate (18) to the
solenoid (6) when removing housing.
solenoid (6).
Do not disassemble lock nut (2) and IMPORTANT: Align the hole on sleeve (17) with
adjusting bolt (4) for pressure that on the housing when inserting
adjustment. sleeve (17) into the housing.
1. Remove socket bolts (1) (4 used). Remove 2. Install O-rings (14, 15, 16) to sleeve (17). Insert
solenoid (6). Remove O-ring (8). sleeve (17) into the housing.
: 3 mm
IMPORTANT: Do not damage the edge inside of
2. Remove spool (10) from sleeve (17). Remove sleeve (17) when inserting spool (10)
diaphragm (9), washer (12) and spring (13). into sleeve (17).
After inserting spool (10), push
3. Remove sleeve (17) from the housing. Remove about 3 to 5 mm (0.1 to 0.2 in) by
plate (18) and wave spring (19). fingers. Check that spool (10) moves
smoothly.
IMPORTANT: Do not remove orifice (11) from 3. Install diaphragm (9), washer (12) and spring (13)
sleeve (17). to spool (10). Insert spool (10) into sleeve (17).
4. Remove O-rings (14, 15, 16) from sleeve (17).
IMPORTANT: When installing solenoid (6), do not
drop spring (7).
4. Install spring (7) to solenoid (6). Install O-ring (8)
to the housing. Install solenoid (6) with socket bolt
(1).
: 3 mm
: 2.9 N m (0.3 kgf m, 2.1 lbf ft)

W2-8-9
UPPERSTRUCTURE / EHC Valve
STRUCTURE OF SOLENOID 1

W18G-02-09-006

10 9 8 7 6 5 4 3 2

Wrench Size Tightening Torque


Item Part Name Q’ ty Remark
(mm) Nm (kgf m) (Ibf ft)
1 Socket bolt 4 :4 7 (0.7) (5)
2 Plug 1 : 27 50 (5.0) (37)
3 O-Ring 2
4 Spring 2
5 Square Ring 4
6 Spool 1
7 Casing 1
8 Spring Seat 2
9 Solenoid 1
10 Nut 1 4 (0.4) (3)

W2-8-10
UPPERSTRUCTURE / Oil Cooler Fan Motor
REMOVAL AND INSTALLATION OF OIL
COOLER FAN MOTOR

CAUTION: Bleed air from the hydraulic oil


tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

Removal
Engine Unit Front Side

CAUTION: Cover (1) weight: 27 kg (60 lb)


Cover (2) weight: 18 kg (40 lb)

1. Remove bolts (3) (26 used) from covers (1) (3


used) and (2) (3 used) on the engine unit. Hoist 1 2
and remove covers (1) (3 used) and (2) (3 used)
from the engine unit.
: 19 mm

3 W18K-02-09-001

2. Remove bolt (11). Remove clamp (12) from the


oil cooler. 4 5 6 7, 8
: 17 mm

3. Remove bolts (7) (4 used) and clamps (8) (4


used) from piping (4) and bracket (10). 9
: 17 mm
10
4. Remove socket bolts (6) (4 used). Disconnect
piping (9) from piping (4).
: 10 mm
Oil Cooler
11, 12 W18K-02-09-002

5. Disconnect hose (5) and hoses (13) (2 used) Oil Cooler 5 13


from fan motor (14). Cap the disconnected
hoses.
: 27 mm, 36 mm 14

W18K-02-09-003
13

W2-9-1
UPPERSTRUCTURE / Oil Cooler Fan Motor
6. Remove bolts (16) (23 used). Remove nets (17) Bolt Hole for
15 Piping Clamp
(2 used) and plates (18) (4 used).
: 19 mm

CAUTION: The bracket (10) assembly 10


weight: 191 kg (421 lb)

7. Install eyebolts (M10, Pitch 1.5 mm) and (M12, 14


Pitch 1.75 mm) to the bolt hole (2 places) for the
piping clamp on bracket (10). Hoist and hold 16
bracket (10). Remove bolts (15) (6 used). Hoist
and remove the bracket (10) assembly.
: 19 mm
17

CAUTION: The fan (19) assembly weight: 68 18


kg (150 lb)

8. Attach a nylon sling onto fan (19). Hoist and hold W18C-02-09-001

fan (19). Remove socket bolts (20) (6 used) and


bolt (21). Remove the fan (19) assembly from fan
motor (14).
: 24 mm 19
: 10 mm

9. Remove coupling (22) from fan motor (14).

CAUTION: Fan motor (14) weight: 58 kg (130


A A
lb)

10. Attach a nylon sling onto the body of fan motor


(14). Hoist and hold fan motor (14).
14
11. Remove bolts (23) (4 used). Hoist and remove
fan motor (14) from bracket (10).
: 24 mm W18K-02-09-004

Section A 20

19

14

21

10 W18K-02-09-005
23 22

W2-9-2
UPPERSTRUCTURE / Oil Cooler Fan Motor
Installation
Section A 20
CAUTION: Fan motor (14) weight: 58 kg (130 19
lb)
14
1. Install fan motor (14) to bracket (10) with bolts
(23) (4 used). 21
: 24 mm
: 210 N m (21.5 kgf m, 155 lbf ft)

2. Install coupling (22) to fan motor (14).

CAUTION: The fan (19) assembly weight: 68 10 W18K-02-09-005

kg (150 lb) 23 22

3. Attach a nylon sling onto fan (19). Hoist the fan


(19) assembly. Install the fan (19) assembly to
19
fan motor (14) with socket bolts (20) (6 used) and
bolt (21).
: 24 mm
: 210 N m (21.5 kgf m, 155 lbf ft)
: 10 mm
: 110 N m (11 kgf m, 81 lbf ft) A A

CAUTION: The bracket (10) assembly


weight: 191 kg (421 lb)
14
4. Install eyebolts (M10, Pitch 1.5 mm) and (M12,
Pitch 1.75 mm) to the bolt hole (2 places) for the
piping clamp on bracket (10). Hoist the bracket
W18K-02-09-004
(10) assembly. Install the bracket (10) assembly
to the oil cooler with bolts (15) (6 used).
: 19 mm
: 90 N m (9 kgf m, 66 lbf ft) Bolt Hole for
15 Piping Clamp
5. Install plates (18) (4 used) and nets (17) (2 used)
Oil Cooler
to the oil cooler with bolts (16) (23 used).
: 19 mm
: 90 N m (9 kgf m, 66 lbf ft) 10

14

16

17

18

W18C-02-09-001

W2-9-3
UPPERSTRUCTURE / Oil Cooler Fan Motor
6. Connect piping (9) to piping (4) and secure with
socket bolts (6) (4 used). Oil Cooler 5 13
: 10 mm
: 90 N m (9 kgf m, 66 lbf ft)
14
7. Secure piping (9) to piping (4) and bracket (10)
with clamps (8) (4 used) and bolts (7) (4 used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)

8. Connect hose (5) and hoses (13) (2 used) to fan


motor (14).
: 27 mm
W18K-02-09-003
: 120 N m (12 kgf m, 89 lbf ft) 13
: 36 mm
: 240 N m (24 kgf m, 177 lbf ft)
4 5 6 7, 8
9. Secure hose (5) to the oil cooler with clamp (12)
and bolt (11).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft) 9

CAUTION: Cover (1) weight: 27 kg (60 lb) 10


Cover (2) weight: 18 kg (40 lb)

10. Hoist covers (1) (3 used) and (2) (3 used). Install


covers (1) (3 used) and (2) (3 used) to the engine Oil Cooler
unit with bolts (3) (26 used). 11, 12 W18K-02-09-002

: 19 mm
: 90 N m (9 kgf m, 66 lbf ft)

11. Start the engine. Loosen the drain hose a little.


Bleed air until only hydraulic oil comes out.
Engine Unit Front Side

1 2

3 W18K-02-09-001

W2-9-4
UPPERSTRUCTURE / Oil Cooler Fan Motor
(Blank)

W2-9-5
UPPERSTRUCTURE / Oil Cooler Fan Motor
DISASSEMBLY OF OIL COOLER FAN
MOTOR

1
2

5
6

7
8
9
16
17

10

11
12
13
14
18
15 19
20
21
22

23
24

25
26

27
28
29
30
W18B-02-11-005
31

1- Housing 9- Socket Bolt (6 Used) 17 - Plunger (7 Used) 25 - Bearing


2- O-Ring 10 - Valve Plate 18 - Socket Bolt (7 Used) 26 - Bearing Nut
3- Cover 11 - Cylinder Block 19 - Plate 27 - Shim (Several)
4- Valve Block 12 - Shim 20 - Shim 28 - O-Ring
5- Plug 13 - Spring Seat 21 - Shaft 29 - Oil Seal
6- Knock Pin 14 - Disc Spring (4 Used) 22 - Key 30 - Seal Case
7- Washer (6 Used) 15 - Center Pin 23 - Bearing 31 - Retaining Ring
8- Socket Bolt (6 Used) 16 - Piston Ring (14 Used) 24 - Case

W2-9-6
UPPERSTRUCTURE / Oil Cooler Fan Motor
Disassembly of Oil Cooler Fan Motor
IMPORTANT: Do not remove bearings (25, 23)
1. Remove plug (5). Drain hydraulic oil from the unless necessary. If removing
motor. bearings (25, 23), replace the motor
: 10 mm assembly with the new one.
6. Remove socket bolts (18) (7 used). Remove
2. Remove key (22) from shaft (21). Remove socket plate (19), center pin (15), plunger (17) and
bolts (9) (6 used). Remove valve block (4) from cylinder block (11) from shaft (21).
cover (3). : 6 mm
: 10 mm
IMPORTANT: Do not remove piston ring (16)
IMPORTANT: Do not drop valve plate (10) when unless necessary.
removing cover (3). Knock pin (6) is 7. Remove shim (12), spring seat (13) and disc
installed in cover (3). Do not remove spring (14) from cylinder block (11).
cover (3) unless necessary.
3. Remove socket bolts (8) (6 used) and washers
(7) (6 used). Remove cover (3), O-ring (2) and
valve plate (10) from housing (1).
: 14 mm

CAUTION: The shaft (21) assembly weight:


Approx. 25 kg (55 lb)

4. Remove retaining ring (31). Remove the shaft


(21) assembly from housing (1) by using a puller.

5. Remove seal case (30), oil seal (29), O-ring (28)


and shim (27) from the shaft (21) assembly.

W2-9-7
UPPERSTRUCTURE / Oil Cooler Fan Motor
ASSEMBLY OF OIL COOLER FAN MOTOR

30 26 28 25 24 23 20 19 15 17

21 22
1

29 4

9
31 27 5

11

6
7, 8
10
W18B-02-11-004

1- Housing 9- Socket Bolt (6 Used) 17 - Plunger (7 Used) 25 - Bearing


2- O-Ring 10 - Valve Plate 18 - Socket Bolt (7 Used) 26 - Bearing Nut
3- Cover 11 - Cylinder Block 19 - Plate 27 - Shim (Several)
4- Valve Block 12 - Shim 20 - Shim 28 - O-Ring
5- Plug 13 - Spring Seat 21 - Shaft 29 - Oil Seal
6- Knock Pin 14 - Disc Spring (4 Used) 22 - Key 30 - Seal Case
7- Washer (6 Used) 15 - Center Pin 23 - Bearing 31 - Retaining Ring
8- Socket Bolt (6 Used) 16 - Piston Ring (14 Used) 24 - Case

W2-9-8
UPPERSTRUCTURE / Oil Cooler Fan Motor
Assembly of Oil Cooler Fan Motor
NOTE: As for parts 12, 13, 14, 16 and 18, refer to 8. Install plug (5) to housing (1).
the illustration when disassembling on : 10 mm
W2-9-6. : 59 to 76 N m
(6 to 7.8 kgf m, 44 to 56 lbf ft)
1. Install shim (12), spring seat (13) and disc
springs (14) (4 used) to cylinder block (11). Pass
and install center pin (15) and plungers (17) (7
used) to cylinder block (11) through plate (19).

2. Install shim (20) and plate (19) to shaft (21) with


socket bolts (18) (7 used).
: 6 mm

CAUTION: The shaft (21) assembly weight:


Approx. 25 kg (55 lb)

3. Install the shaft (21) assembly to housing (1).

4. Install O-ring (28) and oil seal (29) to seal case


(30).

5. Install shim (27) and seal case (30) to housing


(1) with retaining ring (31).

6. Install valve plate (10) and O-ring (2) to cover (3).


Install cover (3) to housing (1) with socket bolts
(8) (6 used).
: 14 mm
: 230 to 270 N m
(23 to 28 kgf m, 170 to 200 lbf ft)

7. Install key (22) to shaft (21). Install valve block


(4) to cover (3) with socket bolts (9) (6 used).
: 10 mm
: 98 to 123 N m
(10 to 12.5 kgf m, 72 to 91 lbf ft)

W2-9-9
UPPERSTRUCTURE / Oil Cooler Fan Motor
MAINTENANCE STANDARD

1. Clearance between outer diameter (d) of center


pin (15) and bore (D) of cylinder block (11)
Clearance between outer diameter (d ) of piston
(17) and bore (D ) of cylinder block (11)
d D
D-d Unit: mm (in)
Standard Allowable Limit
0.004 to 0.022 0.05
(0.0002 to 0.001) (0.002)
W117-02-02-009

D -d Unit: mm (in)
Standard Allowable Limit
0.005 to 0.029 0.05
(0.0002 to 0.001) (0.002)

W2-9-10
UPPERSTRUCTURE / Compressor Drive Motor
REMOVAL AND INSTALLATION OF
COMPRESSOR DRIVE MOTOR
1 2 3

CAUTION: Bleed air from the hydraulic oil


tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal Adjusting Adjusting


Bolt Bolt
1. Remove bolts (4) (14 used). Remove guard cover
(5).
: 17 mm

2. Disconnect hoses (1) (3 used) from compressor


drive motor (2). W18C-02-11-002
: 27 mm, 36 mm
5 4
3. Loosen the adjusting bolts (3 used). Remove
V-belts (10) (6 used) from pulley (9).
: 13 mm 6 7 8 9 10

4. Remove center bolt (8), bolts (6) (3 used) and


plate (7). Remove pulley (9) from compressor
drive motor (2).
: 10 mm, 13 mm

5. Remove bolts (3) (4 used). Remove compressor


drive motor (2).
: 19 mm
W18C-02-11-001

W2-10-1
UPPERSTRUCTURE / Compressor Drive Motor
Installation

IMPORTANT: Do not tap pulley (9) by using a


6 7 8 9
hammer when installing pulley (9) to
compressor drive motor (2).
Warm up the inner surface of pulley
(9) by using a heater before installing
pulley (9).
1. Install a key to the shaft of compressor drive motor
(2). Install pulley (9) to the shaft.

2. Install plate (7), center bolt (8) and bolts (6) (3


used) to pulley (9). W18C-02-11-001
: 10 mm
: 3.3 to 4.2 N m
(0.3 to 0.4 kgf m, 2.4 to 3.0 lbf ft)
: 13 mm
: 10 N m (1 kgf m, 7.2 lbf ft)

W2-10-2
UPPERSTRUCTURE / Compressor Drive Motor
3. Install the compressor drive motor (2) assembly
1 2 3
with bolts (3) (4 used).

4. Attach V-belts (10) (6 used) onto pulley (9). Adjust


tension of V-belt (10) with the adjusting bolt (3
places).
NOTE: V-belt (10) tension adjustment procedure Adjusting
Push the V-belt at center (A) by fingers with Bolt Adjusting
Bolt
98 N (10 kgf, 72 Ibf) and adjust sag
dimension B to 13 to 14 mm (0.51 to 0.55
in).

5. Connect hoses (1) (3 used) to compressor drive 10


motor (2).
W18C-02-11-002
: 27 mm
: 95 N m (9.5 kgf m, 70 lbf ft) 10 5 4
: 36 mm
: 180 N m (18 kgf m, 130 lbf ft)
A
6. Install guard cover (5) with bolts (4) (14 used).
: 17 mm B
: 50 N m (5 kgf m, 36 lbf ft)

W18B-02-13-003

W2-10-3
UPPERSTRUCTURE / Compressor Drive Motor
DISASSEMBLY OF COMPRESSOR DRIVE MOTOR
9
8
7
6

4
3

21
20
2
1 12 19

18
11
10 17

16
22
15
14
13

23
24 31
30
29
28

27

26

25 W118-02-10-001

1- Plug (2 Used) 9- Spring Guide 17 - Plunger (9 Used) 25 - O-Ring


2- O-Ring (2 Used) 10 - Socket Bolt (4 Used) 18 - Swash Plate 26 - Pin (2 Used)
3- Cover 11 - Washer (4 Used) 19 - Shaft 27 - Housing
4- Needle Bearing 12 - Pin (2 Used) 20 - Key 28 - Spacer
5- Valve Plate 13 - Rotor 21 - Bearing 29 - Retaining Ring
6- Retaining Ring 14 - Pin (3 Used) 22 - Pin 30 - Oil Seal
7- Spring Guide 15 - Spherical Bushing 23 - Plug 31 - Retaining Ring
8- Spring 16 - Retainer 24 - O-Ring

W2-10-4
UPPERSTRUCTURE / Compressor Drive Motor
Disassembly

1. Remove plug (23) from housing (27). Drain oil 8. Remove retaining ring (29) and spacer (28) from
from housing (27). shaft (19). Remove bearing (21) from shaft (19).

IMPORTANT: When removing cover (3), valve 9. Remove bearing (21) from shaft (19) by using a
plate (5) is removed with cover (3) bar and a hammer.
together. Do not drop valve plate (5).
2. Remove socket bolts (10) (4 used) and washers IMPORTANT: In case oil seal (30) is removed,
(11) (4 used). Remove cover (3) from housing replace oil seal (30) with a new one.
(27). 10. Remove retaining ring (31) from housing (27).
: 10 mm Remove oil seal (30).

3. Remove valve plate (5), needle bearing (4) and


pins (12) (2 used) from cover (3).

IMPORTANT: The end of shaft (19) is the inner


race of needle bearing (4). Wind a
vinyl tape in order to protect.
4. Remove O-ring (25), rotor (13), spherical bushing
(15), retainer (16) and plungers (17) (9 used) from
housing (27).

IMPORTANT: Do not remove spring (8) unless


necessary.
5. Remove pins (14) (3 used) from rotor (13).

6. Remove key (20) from shaft (19).

7. Remove shaft (19) from the key (20) mounting


side by tapping by using a plastic hammer. At this
time, swash plate (18), pin (22) and bearing (21)
are removed with shaft (19) together from housing
(27).

W2-10-5
UPPERSTRUCTURE / Compressor Drive Motor
ASSEMBLY OF COMPRESSOR DRIVE MOTOR

10 1 23 24 15 17 16 18

28
29
20

1 2 4 3 12 26 25 5 6 7 19 13 8 9 14 27 21 22 30 31

W118-02-10-002

1- Plug (2 Used) 9- Spring Guide 17 - Plunger (9 Used) 25 - O-Ring


2- O-Ring (2 Used) 10 - Socket Bolt (4 Used) 18 - Swash Plate 26 - Pin (2 Used)
3- Cover 11 - Washer (4 Used) 19 - Shaft 27 - Housing
4- Needle Bearing 12 - Pin (2 Used) 20 - Key 28 - Spacer
5- Valve Plate 13 - Rotor 21 - Bearing 29 - Retaining Ring
6- Retaining Ring 14 - Pin (3 Used) 22 - Pin 30 - Oil Seal
7- Spring Guide 15 - Spherical Bushing 23 - Plug 31 - Retaining Ring
8- Spring 16 - Retainer 24 - O-Ring

W2-10-6
UPPERSTRUCTURE / Compressor Drive Motor
Assembly

IMPORTANT: Install oil seal (30) with the seal lip 11. Install plungers (17) (9 used) to retainer (16).
facing to the inside of housing (27).
1. Apply grease onto oil seal (30). Install oil seal (30) 12. Apply grease onto pins (14) (3 used). Install pins
to housing (27). (14) (3 used) to rotor (13).

2. Install retaining ring (31) to housing (27). 13. Install spherical bushing (15) and plungers (17) (9
used) to rotor (13).
IMPORTANT: The key groove on shaft (19) and the
outer surface on the opposite side of 14. Install the rotor (13) assembly to shaft (19) by
shaft (19) are the inner race of turning shaft (19).
needle bearing (4). Do not damage
them. 15. Place the housing (27) assembly with the cover
3. Install bearing (21) to shaft (19). (3) mounting surface facing upward.

4. Install spacer (28) and retaining ring (29) to shaft 16. Apply grease into the needle part of needle
(19). bearing (4) with cover (3) attached. Push the
needle to the outer surface direction.
5. Place housing (27) with the cover (3) side facing
upward. 17. Install pins (12) (2 used) to cover (3).

6. Install pin (22) to housing (27). IMPORTANT: Apply grease onto the cover (3) side
of valve plate (5) in order not to drop
7. Install the shaft (19) assembly to housing (27). valve plate (5).
18. Install valve plate (5) to cover (3).
8. Place housing (27) horizontally.
19. Install O-ring (25) and pins (26) (2 used) to
9. Install swash plate (18) to housing (27) by using a housing (27).
bar and a hammer.
20. Install cover (3) to housing (27) with socket bolts
IMPORTANT: Install swash plate (18) until its (10) (4 used) and washers (11) (4 used).
bottom surface comes in contact : 10 mm
with housing (27) completely. Check : 90 N m (9 kgf m, 67 lbf ft)
that shaft (19) is 18.5 mm (0.73 in)
out from the upper surface of 21. Install key (20) to shaft (19).
housing (27).
10. Install spring guide (9), spring (8), spring guide (7)
and retaining ring (6) to rotor (13).
NOTE: As the force of spring (8) is too strong to
install retaining ring (6), install retaining ring
(6) by using a press.

W2-10-7
UPPERSTRUCTURE / Compressor Drive Motor
(Blank)

W2-10-8
UPPERSTRUCTURE / Air Conditioner
WORK AFTER REPLACING COMPONENT

The following work is required after replacing


compressor, high pressure hose, low pressure hose,
condenser, receiver tank, liquid hose, and air
conditioner unit.
The same work is required when gas leakage is
found.

1. Add compressor oil

2. Charge air conditioner with refrigerant


Purging
Charge air conditioner with refrigerant
Warm up operation
Inspection

ADD COMPRESSOR OIL

Compressor oil quantity to be added after component


replacement:
220 cm3 (0.23 US qt) :
After replacement of the compressor, high
pressure hose, condenser, receiver tank, liquid
hose, or air conditioner unit.
100 cm3 (0.11 US qt) :
After replacement of the low pressure hose.

W2-11-1
UPPERSTRUCTURE / Air Conditioner
CHARGE AIR CONDITIONER WITH
REFRIGERANT

Necessity of Purging
Be sure to purge the air conditioner circuit with a
vacuum before charging with refrigerant (R134a)
because the following problems can arise if air or
other gases remain in the A/C circuit.

1. Pressure rise in the high pressure side


Air
If air remains in the air conditioner circuit, this
disturbs the heat exchange between refrigerant
and air in the condenser, causing pressure to rise
in the high pressure side (compressor side).
Usually, refrigerant gas is easily liquefied;
however, air cannot be liquefied and remains as
a gas in the condenser because the temperature
at which air liquefies is low. That is, liquidation of
the refrigerant gas in the condenser decreases
by the amount of air in the circuit, and the gas Pressure increases if air
W115-02-10-001
pressure in the high pressure side increases remains in the air
conditioner circuit
accordingly.

2. Metal corrosion

If air remains in the air conditioner circuit, a


chemical reaction between refrigerant and
moisture in the air takes place, and as a result,
hydrochloric acid, that corrodes metals such as
aluminum, copper and iron, is produced.

Hydrochloric acid Hydrochloric acid W115-02-10-002


corrodes metals if
moisture exists

Metal corrosion

3. Plugging of the expansion valve by moisture

When high pressure refrigerant gas passes


through the expansion valve, gas pressure
decreases and temperature drops. Moisture
included in high pressure refrigerant gas in the
air conditioner circuit freezes at the expansion
valve orifice, plugging refrigerant flow. Operation Plugged refrigerant
of the air conditioner becomes unstable and flow
Ice produced at the
cooling efficiency lowers. expansion valve disturbs
W115-02-10-003
refrigerant flow, lowering
cooling efficiency
Low cooling
efficiency

W2-11-2
UPPERSTRUCTURE / Air Conditioner
Purging Procedure Gauge Manifold

IMPORTANT: Never mistake the charge hose Low Pressure


connections. Valve
1. Close the high and low pressure valves on the Low Pressure
Charge Hose High Pressure
gauge manifold (Parts Number 4360564).
Valve
Connect the high-pressure-side charge hose and
the low-pressure-side charge hoses to the High Pressure
high-pressure-side charge valve (“D” marked) Charge Hose
and to the low-pressure-side charge valve (“S” Center Pressure
marked) located on the compressor, respectively. Charge Hose
Vacuum Pump
Connect the charge hose located on the center of
the manifold bottom to the vacuum pump (Parts
Number 4360565).
NOTE: Vacuum Pump Joint Adapter (Parts
Number 4360566).

W115-02-10-005

Low Pressure
Side S
Compressor
D
High Pressure
Side

T142-02-05-018

Fully Open
2. Open the high pressure and low pressure valves
in the gauge manifold. Perform purging for 10
minutes or more by operating the vacuum pump. Fully Open

In Operation

W115-02-10-005

W2-11-3
UPPERSTRUCTURE / Air Conditioner
IMPORTANT: If the pointer returns to 0, retighten
the line connections and perform
purging again. Close
3. When the low pressure gauge reading falls
below-755 mmHg, stop the vacuum pump and Close
close the high and low pressure valves. Wait for
approximately five minutes and confirm that the
pointer does not return to 0.

In Operation

W115-02-10-005

4. With the high pressure and low pressure valves


of the gauge manifold closed, connect the charge
hose to the refrigerant container (Parts Number
4347644).

Refrigerant Container

W115-02-10-007

5. Loosen the charge hose connection to the gauge


manifold and open the refrigerant container valve
to purge air in the charge hose with the
refrigerant pressure. Loosen

Open

W115-02-10-007

W2-11-4
UPPERSTRUCTURE / Air Conditioner
IMPORTANT: Always stop the engine when
High
charging the air conditioner with Pressure
refrigerant. Never position the Gauge
refrigerant container upside down Tighten
during charging operation. When
changing the refrigerant container
during charging operation, be sure Open
to purge air from the charge hose,
as shown in step 10.
6. Fully tighten the charge hose connection to the
gauge manifold. Open the high pressure valve
and refrigerant container valve to charge with Open
refrigerant (R134a).
Close the high pressure valve and refrigerant
container valve when the high pressure gauge
reading reaches 98 kPa (1 kgf/cm2, 14 psi).
NOTE: Use warm water of 40 C (104 F) or less
to warm the refrigerant container to aid in
charging operation.
W115-02-10-007

IMPORTANT: Use the leak tester for R134a.


7. After charging, check the line connections for gas
leaks using leak tester (Parts Number 4360567). W115-02-10-008

W2-11-5
UPPERSTRUCTURE / Air Conditioner
8. Confirm that the high pressure and low pressure
valves in the gauge manifold and the refrigerant
container valve are closed.
Start the engine and operate the air conditioner.

Operating Conditions of the Air Conditioner:


Engine Speed : Slow Idle
Cab Window : Fully Open
Air Conditioner Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum

IMPORTANT: Never open the high pressure valve


in the gauge manifold.
9. Open the low pressure valve in the gauge Open
manifold and the refrigerant container valve to
charge with refrigerant until the bubbles seen in
the receiver tank sight glass disappear.
NOTE: The required refrigerant quantity is 1400
g 50 g (3 0.01 lb).

Open

W115-02-10-007

10. If the refrigerant container becomes empty during


the charging work, replace it with a new Close
refrigerant container as follows:
(1) Close the high pressure and low pressure
valves on the manifold gauge.
(2) Replace the empty container with a new
one.
(3) Tighten, then slightly loosen the refrigerant
container joint.
(4) Slightly open the low pressure valve on the
manifold gauge. Close
(5) When the refrigerant container joint starts to
leak, immediately tighten the refrigerant
container joint and close the low pressure
valve on the manifold gauge.

11. After charging, close the low pressure valve in


the gauge manifold and the refrigerant container
valve, and stop the engine.
W115-02-10-007

W2-11-6
UPPERSTRUCTURE / Air Conditioner
IMPORTANT: If the air conditioner is operated
with very low refrigerant, the
compressor may be damaged. If the
air conditioner is overcharged with
refrigerant, cooling efficiency will
lower and abnormal high pressure
will arise in the air conditioner Sight Glass
circuit.
12. Start the engine and operate the air conditioner
again.
Observe the sight glass of the receiver tank to
check refrigerant quantity.
Operating Conditions of the Air Conditioner:
Engine Speed : Slow Idle
Receiver Tank
Cab Window : Fully Open
Air Conditioner Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
NOTE: As the bubbles in the sight glass vary
W115-02-10-009
depending on the ambient temperature,
check refrigerant quantity confirming the
changes in pressure .

Checking procedures: Stop the air conditioner and


wait until refrigerant returns to the balanced pressure.
Then, start the air conditioner again.
Relation between Refrigerant Quantity and
Refrigerant Flow in Sight Glass:
Refrigerant Flow in Sight Glass
Refrigerant
(approx. 1 min. after air conditioner Explanation for Refrigerant Flow in Sight Glass
Quantity
switch is turned ON)
(immediately after) (approx. 1 mm after) Immediately after the air conditioner is turned ON,
Adequate few bubbles are seen. Then the flow becomes trans-
parent and shows thin milk white color.
W115-02-10-016

No bubbles are seen after the air conditioner is


Overcharged turned ON.
W115-02-10-017

Bubbles are seen continuously after the air condi-


Not Enough tioner is turned ON.
W115-02-10-018

CAUTION: Wait until the high-pressure-side


W115-02-10-019
pressure drops to less than 980 kPa (10
Bubbles exist: Bubbles are seen in refrigerant flow
kgf/cm2, 142 psi) before attempting to dis-
as both liquid refrigerant and refrigerant gas exist,
connect the high-pressure-side charge hose.
being mixed.
Otherwise refrigerant and compressor oil
may gush out.
W115-02-10-020

Transparent: Refrigerant flow is transparent as only


liquid refrigerant exists. 13. After checking refrigerant quantity, disconnect the
low-pressure-side charge hose first. Wait for the
high-pressure-side pressure to drop to less than
2
980 kPa (10 kgf/cm , 142 psi). Disconnect the
115-02-10-021
high-pressure-side charge hose.
Milk white: Refrigerant flow shows thin milk white
as oil and refrigerant are separated.

W2-11-7
UPPERSTRUCTURE / Air Conditioner
Warm-Up Operation
After charging the air conditioner, carry out warm-up
operation for five minutes to lubricate system with
compressor oil.

Operating Conditions of the Air Conditioner


Engine Speed : Slow Idle
Cab Window : Fully Open
Air Conditioner Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum

Inspection
After warm-up operation, carry out gas leak check
and performance check.

CAUTION: Refrigerant will produce Leak Tester


poisonous material if exposed to heat of
1000 C (1800 F) or more. Never bring
refrigerant close to a fire.

1. Check the air conditioner for gas leaks using a


leak tester.
(1) Perform checking under well-ventilated
conditions.
(2) Thoroughly wipe off dust from the charge
hose connections of the compressor.
(3) Pay special attention to check the line
W115-02-10-013
connections.
(4) If any gas leaks are found, retighten the line
connections.

2. Performance Check
Carry out performance check of the air
conditioner after checking each air conditioner
component.
Retighten Line
(1) Check each component for abnormalities. Connection
(2) Carry out ON-OFF check of the compressor
clutch.
(3) Check compressor fan belt tension.
(4) Check the coolant level in the radiator.
(5) Operate the air conditioner and check the
W115-02-10-014
performance.

W2-11-8
UPPERSTRUCTURE / Air Conditioner
3. The checklist before the summer season is as
follows:
(1) Check each air conditioner component for
abnormalities.
(2) Check the line connections for oil leaks.
(3) Check refrigerant quantity.
(4) Check the engine cooling circuit.
(5) Check the V-belt for wear. Replace if
necessary.

4. Off-Season Maintenance
(1) During off-season, operate the idler pulley
and compressor at least once a month for a
short time to check for any abnormal
sounds.
(2) Do not remove the compressor belts during
off-season. Operate the compressor
occasionally at slow speed for 5 to 10
minutes with the belt slightly loosened in
order to lubricate the machine parts.

W2-11-9
UPPERSTRUCTURE / Air Conditioner
(Blank)

W2-11-10
UPPERSTRUCTURE / Grease Pump
GREASE PUMP CONSTRUCTION

• As for check grease level and supply method,


refer to “Operator’s Manual (Auto-Lubrication
System)”.

W2-12-1
UPPERSTRUCTURE / Grease Pump
Grease Pump Construction

1
2
3
4
29
5
6
30 7
32 8
34 33 6
31 4 9
3
58 2 10
35 1 11
36 60
37 39 12
59
13
38 14
45
61 46 15
40 16
47
41 48 49
42
17
43
51 50
44 52
53
54 18

19
20

55

21

56
57 22
23
24
25
26
27
28

W18C-02-14-001

W2-12-2
UPPERSTRUCTURE / Grease Pump

1- Screw 17 - Rod 33 - Screw 48 - O-Ring


2- Weight 18 - Spring 34 - Cartridge 49 - O-Ring
3- Weight 19 - Ball 35 - Coil 50 - Nut
4- Retaining Ring 20 - Plunger 36 - Connector 51 - Bearing
5- Rod 21 - Tube 37 - Manifold 52 - O-Ring
6- Retaining Ring 22 - Seal 38 - Reducing Valve 53 - Washer
7- Rod 23 - O-Ring 39 - Flow Control Valve 54 - O-Ring
8- Ball Bearing 24 - Cylinder 40 - O-Ring 55 - Tube
9- Pin 25 - Cage 41 - Gasket 56 - Plug
10 - O-Ring 26 - Ball 42 - Oil Motor 57 - Retaining Ring
11 - Tube 27 - O-Ring 43 - Washer 58 - Seal Kit
12 - Screw 28 - Check Seat 44 - Screw 59 - Seal Kit
13 - Bushing 29 - Screw 45 - Plug 60 - Seal Kit
14 - Anchor 30 - Cover 46 - Housing 61 - Fitting
15 - Washer 31 - Gasket 47 - Ring
16 - Seal 32 - Gauge

W2-12-3
UPPERSTRUCTURE / Grease Pump
(Blank)

W2-12-4
MEMO

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MEMO

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SECTION 3
UNDERCARRIAGE

CONTENTS
Group 1 Swing Bearing
Removal and Installation of Group 6 Front Idler
Swing Bearing ....................................... W3-1-1 Removal and Installation of Front Idler .... W3-6-1
Disassembly of Front Idler ....................... W3-6-6
Group 2 Travel Device Assembly Front Idler ................................ W3-6-8
Removal and Installation of Maintenance Standard ........................... W3-6-10
Travel Device......................................... W3-2-1
Disassembly of Travel Device................ W3-2-10 Group 7 Upper and Lower Rollers
Assembly of Travel Device .................... W3-2-24 Removal and Installation of
Disassembly of Travel Motor ................. W3-2-36 Upper/ Lower Rollers ............................. W3-7-1
Assembly of Travel Motor ...................... W3-2-42 Disassembly of Upper Roller ................... W3-7-8
Maintenance Standard........................... W3-2-48 Assembly of Upper Roller ...................... W3-7-10
Disassembly and Assembly of Disassembly of Lower Roller ................. W3-7-12
Travel Mode Selection Valve................ W3-2-50 Assembly of Lower Roller ...................... W3-7-14
Maintenance Standard ........................... W3-7-16
Group 3 Travel Brake Valve
Removal and Installation of Group 8 Track
Travel Brake Valve................................. W3-3-1 Removal and Installation of Track ............ W3-8-1
Disassembly of Travel Brake Valve.......... W3-3-6 Structure of Track..................................... W3-8-5
Assembly of Travel Brake Valve .............. W3-3-8 Maintenance Standard ............................. W3-8-6

Group 4 Center Joint Group 9 Accumulator


Removal and Installation of Center Joint . W3-4-1 Removal and Installation of
Disassembly of Center Joint .................... W3-4-8 Accumulator ........................................... W3-9-1
Assembly of Center Joint....................... W3-4-10 Disassembly of Accumulator .................... W3-9-4
Assembly of Accumulator......................... W3-9-6
Group 5 Adjuster Cylinder
Removal and Installation of Group 10 Welding Repair Procedure
Adjuster Cylinder ................................... W3-5-1 Welding Repair Procedure ..................... W3-10-1
Disassembly of Adjuster Cylinder ............ W3-5-8 Welding Rod Specification ..................... W3-10-2
Assembly of Adjuster Cylinder ............... W3-5-10 Repair Track Shoe (Shoe Lug)............... W3-10-3
Repair Front Idler................................... W3-10-6
Repair Sprocket ..................................... W3-10-8

18KW-3-1
(Blank)

18KW-3-2
UNDERCARRIAGE / Swing Bearing
REMOVAL AND INSTALLATION OF SWING
BEARING
5
Removal

1. Remove the front attachment, the counterweight


and the main frame. (Refer to REMOVAL AND
INSTALLATION OF FRONT ATTACHMENT on
W4-1-1, REMOVAL AND INSTALLATION OF 3
COUNTERWEIGHT on W2-2-1 and REMOVAL 1, 2, 3, 4 W18K-03-01-001

AND INSTALLATION OF FRAME on W2-3-1.)

2. Remove sems bolts (2) (8 used) from clamps (1) 8


(8 used). Remove clamps (1) (8 used), rubbers Track Frame
(3) (16 used) and spacers (4) (8 used) from lu-
brication pipings (5) (6 used). Remove lubrication 6, 7
pipings (5) (6 used) from swing bearing (8).
: 17 mm

CAUTION: Be careful to avoid getting yore


hand caught by reaction force bar on the hy-
draulic wrench.

3. Remove bolts (6) (60 used) and washers (7) (60 W18B-03-01-005

used) from swing bearing (8) by using a hydraulic Sling Belt


wrench.
: 75 mm

4. Put the matching marks between the inner race


and the outer race on swing bearing (8) and be-
tween the outer race and the track frame.

5. Pass the eye of the sling belt through the outer


bolt holes on the outer race of swing bearing (8).
Pass a steel rib through the eye. Steel Rib W18B-03-01-002

CAUTION: Swing bearing (8) weight: 4190 kg


(9240 lb)

6. Hoist and remove swing bearing (8) from the


track frame.

W141-03-01-001

W3-1-1
UNDERCARRIAGE / Swing Bearing
Installation

CAUTION: Swing bearing (2) weight: 4190 kg


(9240 lb)

IMPORTANT: Install swing bearing (8) with mark


(S) on the inner ring facing to the 8
right side of the machine.
1. Hoist swing bearing (8). Align the inner race with
knock pin (9) (2 places) while aligning the match-
ing marks before removal. Place swing bearing
(8) onto the track frame.
NOTE: As for details about hoisting swing bearing
(8), refer to Removal.

W141-03-01-001

8 9

CAUTION: Be careful to avoid getting your


hand caught by reaction force bar on the hy-
draulic wrench.

2. Apply lubricant onto the thread part of bolts (6) W141-03-01-002

(60 used). Install swing bearing (8) to the track 8


frame with bolts (6) (60 used) and washers (7) Track Frame
(60 used) by using a hydraulic wrench.
: 70 mm 6, 7
: 4700 N m (480 kgf m, 3470 Ibf ft)

3. Install Iubrication pipings (5) (6 used) to swing


bearing (8). Secure lubrication pipings (5) (6
used) with sems bolts (2) (8 used), clamps (1) (8
used), rubbers (3) (16 used) and spacers (4) (8
used).
: 17 mm W18B-03-01-005

: 20 N m (2 kgf m, 15 Ibf ft)

4. Install the main frame, the counterweight and the 5


front attachment. (Refer to REMOVAL AND IN-
STALLATION OF FRONT ATTACHMENT on
W4-1-1, REMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1 and REMOVAL
AND INSTALLATION OF FRAME on W2-3-1.)

1, 2, 3, 4 W18K-03-01-001

W3-1-2
UNDERCARRIAGE / Travel Device
REMOVAL AND INSTALLATION OF
TRAVEL DEVICE

Remove the track shoe on the sprocket side before


removing and installing the reduction gear at the
sprocket side. (Refer to REMOVAL AND
INSTALLATION OF TRACK on W3-8-1.)

CAUTION: Bleed air from the hydraulic oil


tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

Removal

1. Remove sems bolts (6) (8 used) from step (1). 1 2 3 4 5


Remove step (1) from cover (2).
: 19 mm

6 W18K-03-03-002

7 2, 5
2. Remove bolts (9) (6 used) and washers (10) (6
used) from clamps (7) (4 used). Remove clamps 8
(7) (4 used) and disconnect hoses (8) (4 used)
from covers (2, 5).
: 17 mm

9, 10 W18K-03-02-002

W3-2-1
UNDERCARRIAGE / Travel Device

2 3 4 5 11, 12, 13, 14


CAUTION: Cover (2) weight: 78 kg (175 lb)
Cover (3) weight: 31 kg (70 lb)
Cover (4) weight: 31 kg (70 lb)
Cover (5) weight: 71 kg (160 lb)

3. Attach a nylon sling onto covers (2, 3, 4 and 5).


Hoist and hold covers (2, 3, 4 and 5) by using a
forklift.
16 15 W18K-03-03-002
4. Remove sems bolts (15) (26 used) from covers
(2, 3, 4 and 5). Remove covers (2, 3, 4 and 5)
from track frame (16) and support (17).
: 19 mm
15 5

CAUTION: Support (17) weight: 78 kg (175


lb)

5. Attach a nylon sling onto support (17). Hoist and


hold support (17) by using a forklift.
W18K-03-03-003
15 4
6. Remove bolts (11) (4 used), spring washers (12)
(4 used) and washers (13) (4 used) from support
(17). Remove support (17) from brackets (14) (2
used). 8
: 24 mm

7. Disconnect hoses (8) (2 used) from travel motor


(18). Cap the open ends.
: 17 mm, 36 mm

17

18

W18K-03-02-001

W3-2-2
UNDERCARRIAGE / Travel Device
8. Remove socket bolts (19) (8 used) and split 19 20
flanges (21) (4 used) from hoses (20) (2 used).
Disconnect hoses (20) (2 used) from travel motor
(18). Cap the open ends.
: 14 mm

21

9. Remove drain plugs (22, 25) and level plug (24)


on the travel motor (18) side and the sprocket
side from cover (23) and the travel reduction gear.
Drain gear oil from cover (23). 18
: 14 mm, 17 mm, 22 mm
NOTE: Gear oil amount: 90 L (23.8 US gal.) W18K-03-02-001

18

23

22

Travel Motor Side W18K-03-02-003

24

25

Sprocket Side W144-03-01-005

CAUTION: Travel motor (18) weight: 260 kg


(580 lb)

10. Attach a nylon sling onto the body of travel motor


(18). Hoist and hold travel motor (18). Remove
bolts (26) (4 used) and washers (27) (4 used)
from travel motor (18). Remove travel motor (18) 26, 27
from cover (23).
: 30 mm

18

23 W18K-03-02-001

W3-2-3
UNDERCARRIAGE / Travel Device
11. Install an eyebolt (M20, Pitch 2.5 mm) to the bolt Eyebolt Mounting Position
(26) hole. Install an eyebolt (M22, Pitch 2.5 mm)
to the pulling-out hole on cover (23).
NOTE: Refer to the illustration in the right as for 26
the eyebolt mounting position.
18

CAUTION: Travel reduction gear at travel 23


motor (18) side weight: 310 kg (690 lb)
28, 29

12. Hoist and hold the travel reduction gear at the


travel motor (18) side. 30, 31

13. Remove bolts (28) (16 used) and washers (29)


(16 used). Hoist and remove the travel reduction
gear at travel motor (18) side from the travel
reduction gear at the sprocket side.
: 32 mm W18K-03-02-003

CAUTION: Travel reduction gear at sprocket


side weight: 2800 kg (6180 lb)
Side Frame

14. Hold the travel reduction gear at the sprocket


side by using a fork lift.

15. Remove bolts (30) (32 used) and spring washers


(31) (32 used). Remove the travel reduction gear
at the sprocket side from the side frame.
: 50 mm
28, 29
30, 31

W18C-03-02-002

W3-2-4
UNDERCARRIAGE / Travel Device
Installation Eyebolt Mounting Position

CAUTION: Travel reduction gear at sprocket


side weight: 2800 kg (6180 lb) 26, 27

18
1. Hold the travel reduction gear at the sprocket
side by using a fork lift. Install the travel reduction 23
gear at the sprocket side to the side frame with
28, 29
bolts (30) (32 used) and spring washers (31) (32
used).
: 50 mm 30, 31
: 2600 N m (265 kgf m, 1920 lbf ft)

2. Install an eyebolt (M20, Pitch 2.5 mm) to the bolt


(26) hole. Install an eyebolt (M22, Pitch 2.5 mm)
to the pulling-out hole on cover (23).
NOTE: Refer to the illustration in the right as for W18K-03-02-003

the eyebolt mounting position.

CAUTION: Travel reduction gear at travel


Side Frame
motor (18) side weight: 310 kg (690 lb)

3. Hoist and install the travel reduction gear at the


travel motor (18) side to the travel reduction gear
at the sprocket side with bolts (28) (16 used) and
washers (29) (16 used).
: 32 mm
: 750 N m (76.5 kgf m, 560 lbf ft)
28, 29
CAUTION: Travel motor (18) weight: 260 kg
30, 31
(580 lb)

4. Attach a nylon sling onto the body of travel motor


(18). Hoist and hold travel motor (18). W18C-03-02-002

5. Install travel motor (18) to cover (23) with bolts


(26) (4 used) and washers (27) (4 used).
: 30 mm
: 400 N m (41 kgf m, 295 lbf ft)

W3-2-5
UNDERCARRIAGE / Travel Device
6. Wind the seal tape onto drain plugs (22, 25).
Install drain plugs (22, 25) to cover (23) and the
travel reduction gear.
: 14 mm
18
: 69 N m (7 kgf m, 51 lbf ft)
: 17 mm
23
: 69 N m (7 kgf m, 51 lbf ft)

22

Travel Motor Side W18K-03-02-003

25

Sprocket Side W144-03-01-005

7. Connect hoses (20) (2 used) to travel motor (18) 8 19 20


with socket bolts (19) (8 used) and split flanges
(21) (4 used).
: 14 mm
: 210 N m (21.5 kgf m, 155 lbf ft)

8. Connect hoses (8) (2 used) to travel motor (18).


: 17 mm 21
: 24.5 N m (2.5 kgf m, 18 lbf ft)
: 36 mm
: 175 N m (18 kgf m, 129 lbf ft)

18

W18K-03-02-001

W3-2-6
UNDERCARRIAGE / Travel Device
9. Wind the seal tape onto level plug (24) and filler
plug (32). Add gear oil through level plug (24)
and filler plug (32). After adding, install level plug
(24) and filler plug (32) to cover (23) and the
travel reduction gear.
: 14 mm 23
: 69 N m (7 kgf m, 51 lbf ft)
: 22 mm
: 195 N m (20 kgf m, 144 lbf ft)
NOTE: Gear oil amount: 90 L (23.8 US gal.)
32
IMPORTANT: After installing the travel motor, fill
hydraulic oil in the travel motor.
Perform break-in operation after
installing the travel motor or the
travel device in order to prevent the Travel Motor Side W18K-03-02-003

travel motor from seizuring.


Condition: 1. Fuel control lever:
Slow idle
2. Travel mode: Slow
3. Operation duration: 24
More than 2 min.

CAUTION: Support (17) weight: 78 kg (175


lb)

10. Attach a nylon sling onto support (17). Hoist and


Sprocket Side W144-03-01-005
align support (17) with the mounting hole on
brackets (14) (2 used).
Install support (17) to bracket (14) with bolts (11)
(4 used), spring washers (12) (4 used) and
washers (13) (4 used).
: 24 mm
: 210 N m (21.5 kgf m, 155 lbf ft)

17

W18K-03-02-001

11, 12, 13, 14

W18K-03-03-002

W3-2-7
UNDERCARRIAGE / Travel Device
2 3 4 5
CAUTION: Cover (2) weight: 78 kg (175 lb)
Cover (3) weight: 31 kg (70 lb)
Cover (4) weight: 31 kg (70 lb)
Cover (5) weight: 71 kg (160 lb)

11. Attach a nylon sling onto covers (2, 3, 4 and 5).


Hoist covers (2, 3, 4 and 5) by using a forklift.
Align covers (2, 3, 4 and 5) with the mounting
hole on track frame (16) and support (17). 16 15 W18K-03-03-002

12. Install covers (2, 3, 4 and 5) to track frame (16)


and support (17) with sems bolts (15) (26 used).
: 19 mm
: 90 N m (9 kgf m, 66 lbf ft) 15 5

W18K-03-03-003
15 4

17

W18K-03-02-001

13. Secure hoses (8) (2 used) to covers (2, 5) with 7 2, 5


bolts (9) (6 used), washers (10) (6 used) and
clamps (7) (4 used). 8
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)

9, 10 W18K-03-02-002

W3-2-8
UNDERCARRIAGE / Travel Device
14. Install step (1) to cover (2) with sems bolts (6) (8 1 2
used).
: 19 mm
: 90 N m (9 kgf m, 66 lbf ft)

6 W18K-03-03-002

W3-2-9
UNDERCARRIAGE / Travel Device
DISASSEMBLY OF TRAVEL DEVICE

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

34
33

19 32
22 20
23 21
24
23
25
27
28
29

35
36
37
38
30 39 40 36
41 35
42
43 57
31
26
58
44
45 56
46 55
54
53
47
52

48
51
60
49 63 61
50 62
59

64
68 65
66
67
65 W18C-03-02-004
64

W3-2-10
UNDERCARRIAGE / Travel Device

1 - Retaining Ring 19 - Lock Plate 36 - Spacer (8 Used) 53 - Retaining Ring


2 - Bolt (10 Used) 20 - Lock Washer 37 - Retaining Ring (4 Used) 54 - First Stage Sun Gear
3 - Spring Washer (10 Used) 21 - Bolt (2 Used) 38 - Second Stage Planetary 55 - Retaining Ring
Gear (4 Used)
4- Roller Bearing 22 - Knock Pin (2 Used) 39 - Pin (4 Used) 56 - Stopper Pin
5- Gear 23 - Ball Bearing (2 Used) 40 - Lock Plate (4 Used) 57 - Cork (2 Used)
6- Roller Bearing 24 - Gear 41 - Lock Washer (4 Used) 58 - Ball Bearing
7- Housing 25 - Cork (2 Used) 42 - Bolt (8 Used) 59 - Retaining Ring
8- O-Ring 26 - Roller Bearing 43 - Ring Gear 60 - Bolt (20 Used)
9- Bearing Nut 27 - Cover 44 - Roller Bearing 61 - Spring Washer (20 Used)
10 - Spindle 28 - Spring Washer (16 Used) 45 - Bolt (30 Used) 62 - Cover
11 - Support 29 - Bolt (16 Used) 46 - Washer (30 Used) 63 - Pin (3 Used)
12 - Cork (2 Used) 30 - Cork (3 Used) 47 - Sprocket 64 - Roller Bearing (6 Used)
13 - Floating Seal 31 - Cork (2 Used) 48 - Drum 65 - Spacer (6 Used)
14 - Cork (2 Used) 32 - Second Stage Carrier 49 - Washer (28 Used) 66 - Retaining Ring (3 Used)
15 - Support 33 - Spacer 50 - Bolt (28 Used) 67 - First Stage Planetary Gear
(3 Used)
16 - Socket Bolt (12 Used) 34 - Second Stage Sun Gear 51 - Shaft 68 - Retaining Ring (3 Used)
17 - Socket Bolt (12 Used) 35 - Spherical Bearing (8 Used) 52 - First Stage Carrier

W3-2-11
UNDERCARRIAGE / Travel Device

10

19
20
21

30

43 57

47

48
51
60
61
62

W18C-03-02-004

W3-2-12
UNDERCARRIAGE / Travel Device
Disassembly of Travel Device IMPORTANT: Loosen bearing nut (9) without
removing.
Travel Reduction Gear at Sprocket Side 5. Loosen bearing nut (9) by using the special tool
(ST 3931).
IMPORTANT: Before disassembling, put the Details of ST 3931: ST 3147, ST 3148, ST 3149
matching marks onto the mating
part of sprocket (47), drum (48), ring
ST3148
gear (43) and cover (62).

1. Remove corks (30) (3 used) from drum (48). ST3147

2. Install an eyebolt (M16, Pitch 2.0 mm) to the


lifting hole (3 places) on drum (48). 9
ST3149

CAUTION: Travel reduction gear at sprocket


(47) side weight: 2800 kg (6180 lb)

3. Hoist and place the travel reduction gear at the W144-03-01-003

sprocket (47) side with cover (62) facing


downward. 6. Install an eyebolt (M16, Pitch 2.0 mm) to the
lifting hole (3 places) on drum (48).
4. Remove bolts (21) (2 used) from lock plate (19).
Remove lock washer (20) and lock plate (19) 7. Hoist and turn over the travel reduction gear at
from spindle (10). the sprocket (47) side. Place shaft (51) on the
: 30 mm wooden blocks in order not to contact with the
ground.
NOTE: Height of wooden block: 230 mm (9.1 in)

51

W18C-03-02-003
Wooden Block

8. Remove bolts (60) (20 used) and spring washers


(61) (20 used) from cover (62).
: 24 mm

9. Remove corks (57) (2 used) from cover (62).

W3-2-13
UNDERCARRIAGE / Travel Device

32

43

58
56
55
54
47
52

51
63
62
59

68

W18C-03-02-004

W3-2-14
UNDERCARRIAGE / Travel Device

CAUTION: Cover (62) weight: 120 kg (265 lb) CAUTION: The shaft (51) assembly weight:
57 kg (130 lb)
10. Install a bolt (M16, Pitch 2.0 mm) to the
pulling-out hole (2 places) on cover (62). Float 15. Hoist and remove shaft (51) from the travel
cover (62) from ring gear (43). reduction gear at the sprocket (47) side. At this
: 24 mm time, first stage sun gear (54) is removed with
shaft (51) together.
11. Install an eyebolt (M16, Pitch 2.0 mm) to the
pulling-out hole (2 places) on cover (62).
CAUTION: Shaft (51) weight: 48 kg (110 lb)
12. Hoist and remove cover (62) from ring gear (43).
IMPORTANT: Put the matching marks onto shaft
(51) and first stage sun gear (54).
13. Remove retaining ring (59) from cover (62).
16. Remove retaining ring (55) from shaft (51).
Remove stopper pin (56) and ball bearing (58)
Remove first stage sun gear (54) from shaft (51).
from cover (62) by using a puller.
17. Install an eyebolt (M16, Pitch 2.0 mm) to the
14. Install an eyebolt (M16, Pitch 2.0 mm) to the
lifting hole (3 places) on first stage carrier (52).
lifting hole on the shaft (51) end.

CAUTION: The first stage carrier (52)


assembly weight: 280 kg (620 lb)

18. Hoist and remove the first stage carrier (52)


assembly from second stage carrier (32).

19. Remove retaining rings (68) (3 used) from pins


(63) (3 used).

20. Remove pins (63) (3 used) from first stage carrier


(52).

W3-2-15
UNDERCARRIAGE / Travel Device

34
33
32

45
46
53
47
52

48

63

64
65
66
67
65 W18C-03-02-004
64

W3-2-16
UNDERCARRIAGE / Travel Device

CAUTION: The first stage planetary gear (67) CAUTION: First stage carrier (52) weight:
assembly weight: 35 kg (80 lb) 130 kg (290 lb)

IMPORTANT: Put the matching marks onto first 26. Hoist and remove first stage carrier (52) from
stage planetary gear (67) and first second stage sun gear (34).
stage carrier (52) as a pair for
assembling. 27. Remove spacer (33) from second stage carrier
21. Install an eyebolt (M10, Pitch 1.5 mm) to the (32).
lifting hole (2 places) while removing first stage
planetary gears (67) (3 used). 28. Remove bolts (45) (30 used) and washers (46)
(30 used) from sprocket (47).
22. Hoist and remove the first stage planetary gear : 46 mm
(67) assemblies (3 used) from first stage carrier
(52).
CAUTION: Sprocket (47) weight: 300 kg (660
lb)
CAUTION: First stage planetary gear (67)
weight: 26 kg (60 lb) 29. Install a bolt (M30, Pitch 3.0 mm) to the
pulling-out hole (2 places) on sprocket (47). Float
IMPORTANT: Put the matching marks onto first sprocket (47) from drum (48).
stage planetary gear (67) and roller : 46 mm
bearing (64) as a pair for
assembling. 30. Install an eyebolt (M30, Pitch 3.0 mm) to the
23. Remove roller bearings (64) (6 used), spacers pulling-out hole (2 places) on sprocket (47).
(65) (6 used) and retaining rings (66) (3 used)
from first stage planetary gears (67) (3 used). 31. Hoist and remove sprocket (47) from drum (48).

24. Remove retaining ring (53) from second stage


sun gear (34).

25. Attach a nylon sling onto the pin (63) holes (3


places) on first stage carrier (52).

W3-2-17
UNDERCARRIAGE / Travel Device

10

15

32

35
36
37
38
39 40 36
41 35
42
43
26
44
45

48
60

W18C-03-02-004

W3-2-18
UNDERCARRIAGE / Travel Device

CAUTION: The second stage carrier (32) CAUTION: Ring gear (43) + drum (48) +
assembly weight: 510 kg (1130 lb) others weight: 1010 kg (2230 lb)

32. Install an eyebolt (M16, Pitch 2.0 mm) to the 39. Attach a plate (Dia. 375 mm ( )) onto the ring
lifting hole (2 places) on second stage carrier (32). gear (43) side of spindle (10). Hoist and remove
Hoist and hold second stage carrier (32). ring gear (43), the drum (48) assembly and the
inner race of roller bearing (26) from spindle (10)
33. Remove bearing nut (9) from second stage by tapping by using a hammer. At this time, the
carrier (32). outer races of roller bearing (26, 44) are removed
with drum (48) together.
34. Hoist and remove the second stage carrier (32)
assembly from ring gear (43).
CAUTION: Inner race of roller bearing (26)
weight: 30 kg (70 lb)
35. Remove bolts (42) (8 used), lock washers (41) (4
used) and lock plates (40) (4 used) from second
40. Raise the inner race of roller bearing (26) by
stage carrier (32). Remove pins (39) (4 used)
hand. Make clearance between the inner race
from second stage carrier (32).
and the outer race. Pass a nylon sling through
: 30 mm
the clearance. Hoist and remove the inner race of
roller bearing (26) from drum (48).
36. Remove second stage planetary gears (38) (4
used) from second stage carrier (32).
CAUTION: Ring gear (43) + drum (48) +
IMPORTANT: Put the matching marks onto others weight: 990 kg (2190 lb)
second stage planetary gear (38)
and spherical bearing (35) as a pair 41. Install an eyebolt (M30, Pitch 3.0 mm) to the bolt
for assembling. (45) hole on drum (48). Hoist and place ring gear
37. Remove spherical bearings (35) (8 used), (43) and the drum (48) assembly with support
spacers (36) (8 used) and retaining rings (37) (4 (15) facing upward.
used) from second stage planetary gears (38) (4
used).

38. Install an eyebolt (M16, Pitch 2.0 mm) to the bolt


(60) hole (2 places) on ring gear (43).

W3-2-19
UNDERCARRIAGE / Travel Device

13
10
11

3 15
2 16
17
1

22

24
25
27

31 43

48

49
50

W18C-03-02-004

W3-2-20
UNDERCARRIAGE / Travel Device
42. Remove one side of floating seal (13) from Travel Reduction Gear at Travel Motor Side
support (15).
50. Remove retaining ring (1) from cover (27).
43. Remove corks (31) (2 used) from drum (48).
51. Remove bolts (2) (10 used) with mark H and
44. Install a bolt (M30, Pitch 3.0 mm) to the washers (3) (10 used) from cover (27).
pulling-out hole (2 places) on drum (48). Float : 32 mm
drum (48) from ring gear (43).

45. Remove socket bolts (16) (12 used) from support


(15). Remove support (15) from drum (48).
: 14 mm
2, 3
46. Install an eyebolt (M16, Pitch 2.0 mm) to the
lifting hole (3 places) on drum (48). 27

CAUTION: Drum (48) weight: 510 kg (1130


lb)

47. Remove bolts (50) (28 used) and washers (49)


(28 used) from drum (48). Hoist and remove W18C-03-02-005

drum (48) from ring gear (43).


: 46 mm 52. Remove corks (25) (2 used) from cover (27).

48. Remove one side of floating seal (13) from


CAUTION: Cover (27) weight: 86 kg (190 lb)
support (11).
53. Install a bolt (M22, Pitch 2.5 mm) to the
49. Remove socket bolts (17) (12 used) from support
pulling-out hole (2 places) on cover (27). Float
(11). Remove support (11) from spindle (10).
cover (27) from housing (7).
: 14 mm
: 32 mm

IMPORTANT: Do not remove knock pin (22) unless


necessary.
54. Install an eyebolt (M22, Pitch 2.5 mm) to the
pulling-out hole (2 places) on cover (27). Hoist
and remove cover (27) from housing (7).

55. Install an eyebolt (M16, Pitch 2.0 mm) to the


lifting hole (2 places) on gear (24).

W3-2-21
UNDERCARRIAGE / Travel Device

7
6
5
4

23
24
23

W18C-03-02-004

W3-2-22
UNDERCARRIAGE / Travel Device

CAUTION: The gear (24) assembly weight:


80 kg (180 lb)

IMPORTANT: Put the matching marks onto gear


(24) in order not to confuse the
direction when assembling.
56. Hoist and remove gear (24) from housing (7). At
this time, ball bearings (23) (2 used) are removed
with gear (24) together.

IMPORTANT: Put the matching marks onto gear


(5) in order not to confuse the
direction when assembling.
57. Remove gear (5) from housing (7) by using a
puller. At this time, roller bearings (4, 6) are
removed with gear (5) together.

IMPORTANT: Put the matching marks onto roller


bearings (4, 6).
58. Warm up the gear (5) assembly to approx. 90 °C
(194 °F) in an oil bath. Remove roller bearings (4,
6) from gear (5).

CAUTION: Gear (24) weight: 74 kg (165 lb)

IMPORTANT: Put the matching marks onto gear


(24) and ball bearing (23).
59. Warm up the gear (24) assembly to approx.
90 °C (194 °F) in an oil bath. Remove ball
bearings (23) (2 used) from gear (24).

W3-2-23
UNDERCARRIAGE / Travel Device
ASSEMBLY OF TRAVEL DEVICE

2, 3 7 8 10 11 15 44 26 32 34 43 68

4
62
6 52
53
13
54
9 58
56
33
55
51 59
23 39

24 40, 41

27
21
63
28
64

67

60, 61

W18C-03-02-008

19, 20 17 16 49, 50 47 45, 46 48 42 36, 37 35 38 65, 66

W3-2-24
UNDERCARRIAGE / Travel Device

1 - Retaining Ring 19 - Lock Plate 36 - Spacer (8 Used) 53 - Retaining Ring


2 - Bolt (10 Used) 20 - Lock Washer 37 - Retaining Ring (4 Used) 54 - First Stage Sun Gear
3 - Spring Washer (10 Used) 21 - Bolt (2 Used) 38 - Second Stage Planetary 55 - Retaining Ring
Gear (4 Used)
4- Roller Bearing 22 - *Knock Pin (2 Used) 39 - Pin (4 Used) 56 - Stopper Pin
5- Gear 23 - Ball Bearing (2 Used) 40 - Lock Plate (4 Used) 57 - *Cork (2 Used)
6- Roller Bearing 24 - Gear 41 - Lock Washer (4 Used) 58 - Ball Bearing
7- Housing 25 - *Cork (2 Used) 42 - Bolt (8 Used) 59 - Retaining Ring
8- O-Ring 26 - Roller Bearing 43 - Ring Gear 60 - Bolt (20 Used)
9- Bearing Nut 27 - Cover 44 - Roller Bearing 61 - Spring Washer (20 Used)
10 - Spindle 28 - Spring Washer (16 Used) 45 - Bolt (30 Used) 62 - Cover
11 - Support 29 - Bolt (16 Used) 46 - Washer (30 Used) 63 - Pin (3 Used)
12 - *Cork (2 Used) 30 - *Cork (3 Used) 47 - Sprocket 64 - Roller Bearing (6 Used)
13 - Floating Seal 31 - *Cork (2 Used) 48 - Drum 65 - Spacer (6 Used)
14 - *Cork (2 Used) 32 - Second Stage Carrier 49 - Washer (28 Used) 66 - Retaining Ring (3 Used)
15 - Support 33 - Spacer 50 - Bolt (28 Used) 67 - First Stage Planetary Gear
(3 Used)
16 - Socket Bolt (12 Used) 34 - Second Stage Sun Gear 51 - Shaft 68 - Retaining Ring (3 Used)
17 - Socket Bolt (12 Used) 35 - Spherical Bearing (8 Used) 52 - First Stage Carrier

NOTE: As for the parts with mark *, refer to W3-2-10.

W3-2-25
UNDERCARRIAGE / Travel Device

2, 3 7 10

23

24

27

W18C-03-02-008

NOTE: As for cork (25), refer to W3-2-10.

W3-2-26
UNDERCARRIAGE / Travel Device
Assembly of Travel Device IMPORTANT: Apply THREEBOND #1215 onto the
mounting surfaces of housing (7)
Travel Reduction Gear at Travel Motor Side and cover (27).
7. Hoist and install cover (27) to housing (7) with
bolts (2) (10 used) with mark H and washers (3)
CAUTION: Gear (24) weight: 74 kg (165 lb) (10 used).
: 32 mm
IMPORTANT: Install ball bearings (23) while : 550 N m (56 kgf m, 410 lbf ft)
aligning the matching marks made
when disassembling.
1. Warm up ball bearings (23) (2 used) to approx.
90 C (194 °F) by using a bearing heater. Install
ball bearings (23) (2 used) to gear (24).
2, 3
IMPORTANT: Install roller bearings (4, 6) while
aligning the matching marks made 27
when disassembling.
2. Warm up roller bearings (4, 6) to approx. 90 C
(194 °F) by using a bearing heater. Install roller
bearings (4, 6) to gear (5).
W18C-03-02-005
IMPORTANT: Install the gear (5) assembly while
aligning the matching marks made
8. Install corks (25) (2 used) to cover (27) by using a
when disassembling.
plastic hammer.
3. Install the gear (5) assembly to housing (7).
9. Install retaining ring (1) to cover (27).
4. Install an eyebolt (M16, Pitch 2.0 mm) to the
lifting hole (2 places) on gear (24).
Travel Reduction Gear at Sprocket Side
CAUTION: The gear (24) assembly weight:
80 kg (180 lb) 10. Install an eyebolt (M33, Pitch 3.0 mm) to the
outmost bolt hole (2 places) on spindle (10). Hoist
IMPORTANT: Install the gear (24) assembly while and place spindle (10) on the wooden blocks as
aligning the matching marks made illustrated below.
when disassembling. NOTE: Height of wooden block: 230 mm (9.1 in)
5. Hoist and install the gear (24) assembly to
housing (7).
10
CAUTION: Cover (27) weight: 86 kg (190 lb)

6. Install an eyebolt (M22, Pitch 2.5 mm) to the


pulling-out hole (2 places) on cover (27).

W18C-03-02-006
Wooden Block

W3-2-27
UNDERCARRIAGE / Travel Device

10 11 15 26 43

13

60

W18C-03-02-008

17 16 49, 50 45 48

W3-2-28
UNDERCARRIAGE / Travel Device
IMPORTANT: Apply LOCTITE #242 onto socket 16. Install corks (31) (2 used) to drum (48) by using a
bolt (17). plastic hammer.
11. Install support (11) to spindle (10) with socket
bolts (17) (12 used). IMPORTANT: Apply grease onto O-ring and the
: 14 mm seal ring part of floating seal (13),
: 270 N m (27.5 kgf m, 200 lbf ft) and the sliding surface of support
(15).
IMPORTANT: Apply grease onto O-ring and the 17. Install one side of floating seal (13) to support
seal ring part of floating seal (13), (15) by using a bamboo spatula.
and the sliding surface of support
(11). 18. Install an eyebolt (M30, Pitch 3.0 mm) to the bolt
12. Install one side of floating seal (13) to support (45) hole (2 places) on drum (48).
(11) by using a bamboo spatula.

13. Install an eyebolt (M16, Pitch 2.0 mm) to the CAUTION: Ring gear (43) + drum (48) +
lifting hole (3 places) on drum (48). others weight: 990 kg (2190 lb)
19. Hoist and place ring gear (43) and the drum (48)
assembly on the wooden blocks with support (15)
CAUTION: Drum (48) weight: 510 kg (1130 facing downward.
lb) NOTE: Height of wooden block: 230 mm (9.1 in)

IMPORTANT: Apply THREEBOND #1215 onto the


mounting surfaces of drum (48) and 43
ring gear (43). Apply LOCTITE #242
onto bolt (50).
48
Install drum (48) while aligning the
matching marks made when 15
disassembling.
14. Hoist and install drum (48) to ring gear (43) with
bolts (50) (28 used) and washers (49) (28 used).
: 46 mm
: 1950 N m (200 kgf m, 1440 lbf ft) Wooden Block W18C-03-02-007

IMPORTANT: Apply LOCTITE #242 onto socket CAUTION: Inner race of roller bearing (26)
bolt (16). weight: 30 kg (70 lb)
15. Install support (15) to drum (48) with socket bolts
(16) (12 used). 20. Attach a nylon sling onto the inner race of roller
: 14 mm bearing (26).
: 270 N m (27.5 kgf m, 200 lbf ft)
21. Hoist and install the inner race of roller bearing
(26) to drum (48).

22. Install an eyebolt (M16, Pitch 2.0 mm) to the bolt


(60) hole (2 places) on ring gear (43).

W3-2-29
UNDERCARRIAGE / Travel Device

10 32 34 43

33

39

40, 41

64

67

W18C-03-02-008

19, 20 17 16 49, 50 47 45, 46 48 42 36, 37 35 38 65, 66

W3-2-30
UNDERCARRIAGE / Travel Device
IMPORTANT: Tighten bearing nut (9) by hand as
CAUTION: Ring gear (43) + drum (48) + much as possible
others weight: 1010 kg (2230 lb) 29. Tighten bearing nut (9) to second stage carrier
(32).
23. Hoist and install ring gear (43) and the drum (48)
assembly to spindle (10). 30. Install an eyebolt (M30, Pitch 3.0 mm) to the
pulling-out hole (2 places) on sprocket (47).
IMPORTANT: Install spherical bearing (35) while
aligning the matching marks made
when disassembling. CAUTION: Sprocket (47) weight: 300 kg (660
24. Install retaining rings (37) (4 used), spacers (36) lb)
(8 used) and spherical bearings (35) (8 used) to
second stage planetary gears (38) (4 used). IMPORTANT: Apply LOCTITE #242 onto bolt (45).
Install sprocket (47) while aligning
25. Install the second stage planetary gear (38) the matching marks made when
assemblies (4 used) to second stage carrier (32) disassembling.
with pins (39) (4 used). 31. Hoist and install sprocket (47) to drum (48) with
bolts (45) (30 used) and washers (46) (30 used).
IMPORTANT: Do not reuse the lock washer. : 46 mm
26. Install lock plates (40) (4 used) and lock washers : 1950 N m (200 kgf m, 1440 lbf ft)
(41) (4 used) to pins (39) (4 used) with bolts (42)
(8 used). 32. Install spacer (33) and second stage sun gear
: 30 mm (34) to second stage carrier (32).
: 550 N m (56 kgf m, 410 lbf ft)
IMPORTANT: Install roller bearing (64) while
27. Install an eyebolt (M16, Pitch 2.0 mm) to the aligning the matching marks made
lifting hole (2 places) on second stage carrier when disassembling.
(32). 33. Install retaining rings (66) (3 used) and spacers
(65) (6 used) to first stage planetary gears (67) (3
used). Install roller bearings (64) (6 used) to first
CAUTION: The second stage carrier (32)
stage planetary gears (67) (3 used).
assembly weight: 510 kg (1130 lb)
34. Install an eyebolt (M10, Pitch 1.5 mm) to the
28. Hoist and install the second stage carrier (32)
lifting hole (2 places) on first stage planetary gear
assembly to ring gear (43) while aligning the
(67).
splines of the gear.

W3-2-31
UNDERCARRIAGE / Travel Device

34 43 68

62
52
53
54
58
56
55
51 59

63

67

60, 61

W18C-03-02-008

47 48

NOTE: As for cork (57), refer to W3-2-10.

W3-2-32
UNDERCARRIAGE / Travel Device

CAUTION: The first stage planetary gear (67) CAUTION: The shaft (51) assembly weight:
assembly weight: 35 kg (80 lb) 57 kg (130 lb)

IMPORTANT: Install the first stage planetary gear 42. Hoist and install the shaft (51) assembly to the
(67) assembly while aligning the travel reduction gear at the sprocket (47) side
matching marks made when while aligning the splines of the gear.
disassembling.
35. Hoist and install the first stage planetary gear 43. Install ball bearing (58), stopper pin (56) and
(67) assembly to first stage carrier (52) with pins retaining ring (59) to cover (62).
(63) (3 used).
44. Install an eyebolt (M16, Pitch 2.0 mm) to the
36. Install retaining rings (68) (3 used) to pins (63) (3 pulling-out hole (2 places) on cover (62).
used).
CAUTION: Cover (62) weight: 120 kg (265 lb)
37. Install an eyebolt (M16, Pitch 2.0 mm) to the
lifting hole (3 places) on first stage carrier (52).
IMPORTANT: Apply THREEBOND #1215 onto the
Attach a nylon sling onto the eyebolts (3 used).
mating surfaces of cover (62) and
ring gear (43).
CAUTION: The first stage carrier (52) Install cover (62) while aligning the
assembly weight: 280 kg (620 lb) matching marks made when
disassembling.
38. Hoist and install the first stage carrier (52) 45. Hoist and install cover (62) to ring gear (43) with
assembly to second stage sun gear (34). bolts (60) (20 used) and spring washers (61) (20
used).
39. Install retaining ring (53) to second stage sun : 24 mm
gear (34). : 210 N m (21.5 kgf m, 155 lbf ft)

46. Install corks (57) (2 used) to cover (62) by using a


CAUTION: Shaft (51) weight: 48 kg (110 lb) plastic hammer.
IMPORTANT: Install first stage sun gear (54) while 47. Install an eyebolt (M16, Pitch 2.0 mm) to the
aligning the matching marks made pulling-out hole (3 places) on drum (48).
when disassembling.
40. Install first stage sun gear (54) to shaft (51).
Secure first stage sun gear (54) to shaft (51) with CAUTION: Travel reduction gear at sprocket
retaining ring (55). (47) side weight: 2800 kg (6180 lb)

41. Install an eyebolt (M16, Pitch 2.0 mm) to the 48. Hoist and turn over the travel reduction gear at
lifting hole on the shaft (51) end. the sprocket (47) side.

W3-2-33
UNDERCARRIAGE / Travel Device

10

21

W18C-03-02-008

19, 20 48

NOTE: As for cork (30), refer to W3-2-10.

W3-2-34
UNDERCARRIAGE / Travel Device
49. Tighten bearing nut (9) by using the special tool
(ST 3931).
Details of ST 3931: ST 3147, ST 3148, ST 3149
: 5880±588 N m
(600±60 kgf m, 4340± 440 lbf ft)

ST3148

ST3147

9
ST3149

W144-03-01-003

IMPORTANT: Do not reuse lock washer (20).


50. Secure bearing nut (9) to spindle (10) with lock
plate (19), lock washer (20) and bolts (21) (2
used).
: 30 mm
: 400 N m (41 kgf m, 295 lbf ft)

51. Install corks (30) (3 used) to drum (48) by using a


plastic hammer.

W3-2-35
UNDERCARRIAGE / Travel Device
DISASSEMBLY OF TRAVEL MOTOR

10

9
8
7
6
5 11
4 12
3 13
2 19 14
1 18 15
17 16
17
16
15
14
13
12
11
21

22
20
38

37 39

23 36
35
34 40
24 33
41
32
25
26 31 43
30 42
29 61
28 44 60

45
59
27
58

46

57
56
55
54
53

52

51
50
49 W146-03-02-001
48
47

W3-2-36
UNDERCARRIAGE / Travel Device

1- Socket Bolt (6 Used) 17 - Piston (2 Used) 32 - Rotor 47 - Retaining Ring


2- Cover 18 - O-Ring (3 Used) 33 - Valve Plate 48 - Coupling
3- Oil Seal 19 - Plug (3 Used) 34 - Guide Ring 49 - Retaining Ring
4- O-Ring 20 - O-Ring 35 - Bearing 50 - Spacer
5- Retaining Ring 21 - Plate 36 - O-Ring 51 - Shim
6- Spacer 22 - Swash Plate 37 - Valve Cover 52 - Separator Plate (7 Used)
7- Roller Bearing 23 - Casing 38 - Socket Bolt (3 Used) 53 - Piston Ring
8- Spacer 24 - Screw (2 Used) 39 - Socket Bolt (9 Used) 54 - Piston Ring
9- Retaining Ring 25 - Front Casing 40 - O-Ring 55 - Piston
10 - Shaft 26 - Socket Bolt (14 Used) 41 - Plug 56 - O-Ring
11 - Socket Bolt (8 Used) 27 - Piston (9 Used) 42 - Plug 57 - Cover
12 - Cover (2 Used) 28 - Retainer 43 - O-Ring 58 - O-Ring
13 - Stopper (2 Used) 29 - Bushing 44 - Pin 59 - Plug
14 - O-Ring (2 Used) 30 - Shim 45 - Spring (12 Used) 60 - Plug
15 - Spring (2 Used) 31 - Disc Spring (4 Used) 46 - Friction Plate (6 Used) 61 - Socket Bolt (12 Used)
16 - Backup Ring (2 Used)

W3-2-37
UNDERCARRIAGE / Travel Device

10

19

20
38

37 39

23 36

34
33

25

61

45

46

57
56
55
54
53

52

51
50
49
W146-03-02-001
48
47

W3-2-38
UNDERCARRIAGE / Travel Device
Disassembly of Travel Motor 7. Remove piston rings (53, 54) from piston (55).

8. Remove retaining ring (49) and coupling (48)


CAUTION: Travel motor weight: 260 kg (195 from shaft (10).
lb)
9. Remove separator plates (52) (7 used), friction
1. Place the travel motor on a workbench. Remove plates (46) (6 used), shim (51) and spacer (50)
plugs (19) (2 used) from casing (23). Drain from valve cover (37).
hydraulic oil from casing (23).
: 36 mm 10. Remove retaining ring (47) from shaft (10).
2. Remove socket bolts (61) (2 used) diagonally IMPORTANT: When removing valve cover (37),
from cover (57). Install an eyebolt (M16, Pitch 2.0 valve plate (33) may be removed
mm). with cover (37) together. Remove
Hoist and place the travel motor on wooden valve cover (37) carefully in order to
blocks (2 used) vertically. prevent valve plate (33) from falling
: 24 mm off.
11. Remove socket bolts (38) (3 used) and (39) (9
used) from valve cover (37). Install an eyebolt
(M16, Pitch 2.0 mm) to the bolt (61) hole on valve
cover (37). Hoist and remove valve cover (37)
from casing (23).
: 14 mm

IMPORTANT: Do not remove bearing (35) unless


W18B-02-05-004
necessary.
3. Put the matching marks onto front casing (25), 12. Remove valve plate (33), guide ring (34) and
casing (23), valve cover (37) and cover (57). O-ring (36) from valve cover (37).

4. Evenly loosen and remove other bolts (61) (10 13. Attach a nylon sling onto the body of casing (23).
used) from cover (57). Remove cover (57) from Place casing (23) on a workbench horizontally
valve cover (37). Remove O-ring (56) from cover with the main piping mounting surface facing
(57). upward.
: 24 mm

5. Remove springs (45) (12 used) from piston (55).

6. Install an eyebolt (M16, Pitch 2.0 mm) to the


center hole on piston (55). Hoist and remove
piston (55) from valve cover (37).

W3-2-39
UNDERCARRIAGE / Travel Device

10

9
8
7
6
5 11
4 12
3 13
2 14
1 15
17 16
16 17
15
14
13
12
11
21

22
20

23
35

24
32
25
26 31
30
29
28

27

57

W146-03-02-001

W3-2-40
UNDERCARRIAGE / Travel Device

CAUTION: Rotor (32) weight: 37 kg (82 lb) CAUTION: Front casing (25) weight: 37 kg
(82 lb)
14. Attach a nylon sling onto the body of rotor (32). Casing (23) weight: 51 kg (115 lb)
Remove rotor (32) from casing (23). At this time,
pistons (27) (9 used), retainer (28) and bushing 24. Remove socket bolts (26) (14 used) from front
(29) are removed with rotor (23) together. casing (25). Hoist and remove front casing (25)
from casing (23).
15. Wind the vinyl tape around the inner race of : 12 mm
bearing (35) in order to protect.
25. Remove O-rings (20) and screws (24) (2 used)
16. Remove pistons (27) (9 used), retainer (28), from front casing (25).
bushing (29), shim (30) and disc springs (31) (4
used) from rotor (32). 26. Remove socket bolts (11) (8 used) from covers
(12) (2 used). Remove covers (12) (2 used) from
17. Remove socket bolts (1) (6 used) from cover (2). casing (23).
Remove cover (2) from casing (23). : 14 mm
: 8 mm
IMPORTANT: Keep stopper (13) in order to install
18. Remove oil seal (3) and O-ring (4) from cover (2). to the original position.
27. Remove stoppers (13) (2 used), springs (15) (2
19. Remove shaft (10) from casing (23) by tapping by used) and pitons (17) (2 used) from casing (23).
using a plastic hammer from the cover (57) side. NOTE: Remove stopper (13) and piston (17) from
casing (23) by pushing with the fingers.
20. Remove retaining rings (5, 9) from shaft (10).
Remove spacers (6, 8) from shaft (10). 28. Remove O-rings (14) (2 used) from stoppers (13)
(2 used).
21. Remove the inner ring plate and the outer race of
roller bearing (7) from shaft (10). 29. Remove backup rings (16) (2 used) from pistons
(17) (2 used).
22. Push shaft (10) by using a press. Remove the
inner race of roller bearing (7) from shaft (10). 30. Remove swash plate (22) from casing (23). At
this time, plate (21) is removed with swash plate
23. Install a shackle to the flange hole (2 places) on (22) together.
front casing (25).
31. Remove plate (21) from swash plate (22).

W3-2-41
UNDERCARRIAGE / Travel Device
ASSEMBLY OF TRAVEL MOTOR

13 12 14 15 17 21 19 18 16 11 33 36 35 37 53 54

25
38
9
8
46
2 52
6 47
5
49
55
10
59
48
57
3
7
4
1
45

20 61

26

22 30 28 31 29 27 32 23 44 34 39 50 51 56

W145-03-02-005

1- Socket Bolt (6 Used) 17 - Piston (2 Used) 32 - Rotor 47 - Retaining Ring


2- Cover 18 - O-Ring (3 Used) 33 - Valve Plate 48 - Coupling
3- Oil Seal 19 - Plug (3 Used) 34 - Guide Ring 49 - Retaining Ring
4- O-Ring 20 - O-Ring 35 - Bearing 50 - Spacer
5- Retaining Ring 21 - Plate 36 - O-Ring 51 - Shim
6- Spacer 22 - Swash Plate 37 - Valve Cover 52 - Separator Plate (7 Used)
7- Roller Bearing 23 - Casing 38 - Socket Bolt (3 Used) 53 - Piston Ring
8- Spacer 24 - *Screw (2 Used) 39 - Socket Bolt (9 Used) 54 - Piston Ring
9- Retaining Ring 25 - Front Casing 40 - *O-Ring 55 - Piston
10 - Shaft 26 - Socket Bolt (14 Used) 41 - *Plug 56 - O-Ring
11 - Socket Bolt (8 Used) 27 - Piston (9 Used) 42 - *Plug 57 - Cover
12 - Cover (2 Used) 28 - Retainer 43 - *O-Ring 58 - *O-Ring
13 - Stopper (2 Used) 29 - Bushing 44 - Pin 59 - Plug
14 - O-Ring (2 Used) 30 - Shim 45 - Spring (12 Used) 60 - *Plug
15 - Spring (2 Used) 31 - Disc Spring (4 Used) 46 - Friction Plate (6 Used) 61 - Socket Bolt (12 Used)
16 - Backup Ring (2 Used)

NOTE: As for the parts with mark *, refer to W3-2-36.

W3-2-42
UNDERCARRIAGE / Travel Device
Assembly of Travel Motor 9. Install piston (17), spring (15), stopper (13) and
cover (12) to the front casing (25) side. Secure
cover (12) with socket bolts (11) (4 used).
CAUTION: Casing (23) weight: 51 kg (115 lb) : 14 mm
: 235±35 N m (24±3.6 kgf m, 175±26 lbf ft)
1. Place casing (23) horizontally with plug (19)
facing sideways. 10. Install spacer (8) and retaining ring (9) to the rotor
side of shaft (10).
2. Apply grease onto the joint surfaces of swash
plate (22) and plate (21). Install plate (21) to 11. Assemble and warm up the inner race and the
swash plate (22). inner ring plate of roller bearing (7) to approx. 60
(140°F) by using a heater or an oil bath.
3. Install swash plate (22) to casing (23).
12. Install roller bearing (7) to shaft (10) with the
CAUTION: Front casing (25) weight: 37 kg inner ring plate facing inside by using a press.
(82 lb)
13. Install the outer race of roller bearing (7) to shaft
4. Install O-ring (20) and screws (24) (2 used) to (10).
front casing (25).
14. Install spacer (6) and retaining ring (5) to shaft
5. Install front casing (25) to casing (23) with socket (10).
bolts (26) (14 used) while aligning the matching
marks made when disassembling. 15. Install shaft (10) to front casing (25) while tapping
: 12 mm the outer race of roller bearing (7) by using a
: 180 N m (18.5 kgf m, 133 lbf ft) copper bar lightly.

6. Install O-rings (14) (2 used) to stoppers (13) (2 16. Install oil seal (3) to cover (2) by using a plate
used). and a hammer. Install O-ring (4) to cover (2).

7. Install backup rings (16) (2 used) to pistons (17) 17. Install cover (2) to front casing (25) with socket
(2 used). bolts (1) (6 used).
: 8 mm
IMPORTANT: Check that swash plate (22) moves : 57 N m (5.8 kgf m, 42 lbf ft)
in stopper (13). If swash plate (22)
cannot move, go back to step 2 and
assemble again.
8. Install piston (17), spring (15), stopper (13) and
cover (12) to the valve cover (37) side. Secure
cover (12) with socket bolts (11) (4 used).
: 14 mm
: 235±35 N m (24±3.6 kgf m, 175±26 lbf ft)

W3-2-43
UNDERCARRIAGE / Travel Device

33 36 37

38

47
49

10
48

61

30 28 31 29 27 32 23 44 34

W145-03-02-005

W3-2-44
UNDERCARRIAGE / Travel Device
IMPORTANT: The smooth surface of rotor (32) is
the sliding surface for the valve CAUTION: Rotor (32) weight: 37 kg (82 lb)
plate. Do not damage the sliding
surface. 19. Install the rotor (32) assembly to shaft (10).
18. Assemble rotor (32) into an assembly in the
following procedures. 20. Install guide ring (34), O-ring (36) and pin (44) to
• Place rotor (32) with the smooth surface facing valve cover (37).
downward.
• Assemble disc springs (31) (4 used) so that the 21. Apply grease onto the flat surface of valve plate
outer race is matching with the outer race and (33). Align the pin (44) positions and install valve
the inner race is matching with the inner race. plate (33) to valve cover (37).
Place disc springs (31) (4 used) on the projection
part in rotor (32). CAUTION: The casing (23) assembly weight:
Place shim (30) on them. Cover them with 51 kg (115 lb)
bushing (29). At this time, align bushing (29) with
the spline in rotor (32). 22. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
the bolt (61) hole on casing (23).
30 31
Hoist and place casing (23) on a wooden block
vertically.
29
23
32 Wooden Block
(Height: 200 mm)
(7.9 in)

W18B-02-04-010

• Place retainer (28) on bushing (29) with the


chamfered surface facing downward. W18B-02-04-011

28

Chamfered
Surface
W176-02-06-016

29

• Align the plunger hole on retainer (28) with that of


rotor (32). Insert pistons (27) (9 used).

W3-2-45
UNDERCARRIAGE / Travel Device

19 18 33 37 53 54

38

46
52
47
49
55
10
48
57

45

61

23 39 50 51 56

W145-03-02-005

W3-2-46
UNDERCARRIAGE / Travel Device
IMPORTANT: Do not drop valve plate (33) from 27. Install piston rings (53, 54) to piston (55).
valve cover (37).
23. Install valve cover (37) to casing (23) with socket 28. Install piston (55) to valve cover (37).
bolts (38) (3 used) and (39) (9 used).
: 14 mm 29. Install springs (45) (12 used) to piston (55).
: 270 N m (27.5 kgf m, 200 lbf ft)
30. Install O-ring (56) to cover (57). Install cover (57)
24. Install retaining ring (47), coupling (48) and to valve plate (37) with socket bolts (61) (12
retaining ring (49) to shaft (10). used).
: 24 mm
25. Install spacer (50) and shim (51) to valve cover : 235 N m (24 kgf m, 175 lbf ft)
(37).
31. Install O-rings (18) (3 used) to plugs (19) (3
IMPORTANT: Align the notches on separator used). Install plugs (19) (3 used) to casing (23).
plates (52) (7 used) and friction : 36 mm
plates (46) (6 used). Adjust shim (51) : 167 N m (17 kgf m, 123 lbf ft)
so that dimension A between the
stepped surface of valve cover (37)
and top of separator plate (52) is 3.3
mm (0.1 in).

37
A

52

W18B-02-04-013

26. Install separator plates (52) (7 used) and friction


plates (46) (6 used) alternately to valve cover
(37) and coupling (48).

W3-2-47
UNDERCARRIAGE / Travel Device
MAINTENANCE STANDARD
Dial Gauge

1. Clamp the plunger with a shoe in a vise. Shoe


Install a dial gauge to the shoe. Measure
spherical clearance between the plunger and the
shoe while moving the shoe up and down.
If the clearance exceeds the allowable limit,
replace the plunger and the shoe as an
assembly.
Guide
Unit: mm (in)
Standard Allowable Limit
0 0.3 (0.01)

W115-02-04-062
Vise
Plate Plunger

Plunger

2. Measure outer diameter d of the plunger at 3


places of upper, middle and skirt in cross
direction by using a micro meter. (d) (d) (d)
Measure inner diameter D of the rotor at 2 places
in cross direction by using a cylinder gauge.
W115-02-04-065

Unit: mm (in)
Standard D-d Allowable Limit
Rotor
0.059 (0.002) 0.118 (0.005)

(D) (D)

(D) (D)

W115-02-04-066

W3-2-48
UNDERCARRIAGE / Travel Device
3. Measure flange thickness B of the shoe by using Shoe Plunger
a micro meter.

Unit: mm (in)
Standard Allowable Limit
B 10.0 (0.4) 9.8 (0.4)
B

W115-02-04-068

4. Measure height E and h of retainer (28) and


28 29
bushing (29).
C=H-h Stand

Unit: mm (in)
Standard Allowable Limit H
h
C 35.6 (1.4) 34.8 (1.4)

5. Measure the free length of spring (45). W115-02-04-069

Unit: mm (in)
Standard Allowable Limit
Free Length 54.0 (2.1) 53.6 (2.1)

6. Measure height D of separator plates (52) (7


used) and friction plates (46) (6 used).

Unit: mm (in)
Standard Allowable Limit
D 27.9 (1.1) 27.3 (1.1)

7. Measure height E between the end of valve cover


(37) and separator plate (52).

Unit: mm (in)
Standard Allowable Limit
E 51.5 (2.0) 50.5 (2.0) E

W115-03-07-029

W3-2-49
UNDERCARRIAGE / Travel Device
DISASSEMBLY AND ASSEMBLY OF
TRAVEL MODE SELECTION VALVE

1 2 3 4 5 6 18 7 8 9 10 11

Screw Hole

17 16 15 14 13 12
W117-03-02-005

1- Plug 6- Valve Casing 11 - O-Ring (6 Used) 15 - Spacer (2 Used)


2- O-Ring 7- Piston 12 - O-Ring (3 Used) 16 - O-Ring (3 Used)
3- Spring 8- Plug 13 - Plug (3 Used) 17 - Plug (3 Used)
4- Spring Seat 9- Socket Bolt (4 Used) 14 - Piston 18 - O-Ring
5- Spool 10 - Orifice (2 Used)

W3-2-50
UNDERCARRIAGE / Travel Device
Disassembly of Travel Mode Selection Valve Assembly of Travel Mode Selection Valve

1. Remove socket bolts (9) (4 used) from the travel 1. Install O-rings (12) (3 used) to plugs (13) (3
mode selection valve. Remove the travel mode used). Install valve casing (6).
selection valve from the travel motor.
: 6 mm 2. Insert piston (14) and spacers (15) (2 used) to
valve casing (6).
2. Remove O-rings (11) (6 used) from valve casing
(6). 3. Install O-rings (16) (3 used) to plugs (17) (3
used). Install plugs (17) (3 used) to valve casing
3. Remove orifices (10) (2 used) from valve casing (6).
(6). : 6 mm
: 2.5 mm : 19.5 N m (2 kgf m, 14 lbf ft)

4. Remove plugs (17) (3 used) and plugs (1, 8) from 4. Install spring seat (4) and spring (3) to spool (5).
valve casing (6). Remove O-rings (16) (3 used) Insert the spool (5) assembly into valve casing
and O-rings (2, 18) from each plug. (6).
: 6 mm, 8 mm
: 24 mm 5. Install O-ring (2) to plug (1). Install plug (1) to
valve casing (6).
5. Remove piston (7) from plug (8). : 8 mm
: 39 N m (4 kgf m, 29 lbf ft)
6. Remove spring (3), spring seat (4) and spool (5)
from valve casing (6). 6. Install piston (7) and O-ring (18) to plug (8).
Install the plug (8) assembly to valve casing (6).
7. Remove spacers (15) (2 used) from valve casing : 24 mm
(6) through a screw hole (M5, Pitch 0.8 mm). : 19.5 N m (2 kgf m, 14 lbf ft)
Remove piston (14).
7. Install orifices (10) (2 used) to valve casing (6).
8. Remove plugs (13) (3 used) from valve casing : 2.5 mm
(6). Remove O-rings (12) (3 used) from plugs : 7 N m (0.7 kgf m, 5 lbf ft)
(13) (3 used).
8. Install O-rings (11) (6 used) to valve casing (6).

9. Install valve casing (6) to the travel motor with


socket bolts (9) (4 used).
: 6 mm
: 29.5 N m (3 kgf m, 22 lbf ft)

W3-2-51
UNDERCARRIAGE / Travel Device
(Blank)

W3-2-52
UNDERCARRIAGE / Travel Brake Valve
REMOVAL AND INSTALLATION OF
TRAVEL BRAKE VALVE

CAUTION: Bleed air from the hydraulic oil


tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

Removal
1
1. Remove clamps (2) (2 used), bolts (4) (3 used)
and washers (5) (3 used) from cover (1) and
hoses (3) (2 used).
: 17 mm

W18K-03-03-002
2 1

4, 5 W18K-03-02-002

CAUTION: Cover (1) weight: 71 kg (160 lb)


6 7 1
2. Attach a nylon sling onto cover (1). Hoist and
hold cover (1) by using a forklift.

3. Remove sems bolts (7) (8 used) from cover (1).


Remove cover (1) from track frame (6) and
support (8).
: 19 mm W18K-03-03-003

3 1

W18K-03-02-001

W3-3-1
UNDERCARRIAGE / Travel Brake Valve
4. Remove socket bolts (11) (8 used) and split
flanges (12) (4 used) from travel brake valve (9). 9 10 11 10
Disconnect hoses (10) (2 used) from travel brake
valve (9). Cap the open ends.
: 14 mm

12

W18L-03-03-005

5. Remove bolts (15) (4 used) and washers (16) (4 13 6 14 15, 16


used) from clamps (14) (4 used). Remove clamps
(14) (4 used) from pipings (13) (2 used).
: 19 mm

W18K-03-03-002

6. Remove socket bolts (18) (8 used) and split


9 17 13 18
flanges (17) (4 used) from travel brake valve (9).
Disconnect pipings (13) (2 used) from travel
brake valve (9). Cap the open ends.
: 14 mm
17

CAUTION: Travel brake valve (9) weight: 55


kg (125 lb)

7. Support travel brake valve (9) by using a forklift.

8. Remove bolts (19) (4 used) and washers (20) (4 21 19, 20 W18L-03-03-006

used) from travel brake valve (9). Remove travel


brake valve (9) from bracket (21).
: 24 mm

W3-3-2
UNDERCARRIAGE / Travel Brake Valve
Installation

CAUTION: Travel brake valve (9) weight: 55


kg (125 lb) 9 17 13 18

1. Align travel brake valve (9) with the mounting


hole on bracket (21) by using a forklift. Install
travel brake valve (9) to bracket (21) with bolts 17
(19) (4 used) and washers (20) (4 used).
: 24 mm
: 210 N m (21.5 kgf m, 155 lbf·ft)

2. Connect pipings (13) (2 used) to travel brake


valve (9) with socket bolts (18) (8 used) and split
flanges (17) (4 used). 21 19, 20 W18L-03-03-006

: 14 mm
: 210 N m (21.5 kgf m, 155 lbf·ft)

3. Secure pipings (13) (2 used) to track frame (6) 13 6 14 15, 16


with clamps (14) (4 used), bolts (15) (4 used) and
washers (16) (4 used).
: 19 mm
: 90 N m (9 kgf m, 66 lbf·ft)

W18K-03-03-002

4. Connect hoses (10) (2 used) to travel brake valve


9 10 11 10
(9) with socket bolts (11) (8 used) and split
flanges (12) (4 used).
: 14 mm
: 210 N m (21.5 kgf m, 155 lbf·ft)

12

W18L-03-03-005

W3-3-3
UNDERCARRIAGE / Travel Brake Valve

CAUTION: Cover (1) weight: 71 kg (160 lb)


1
5. Attach a nylon sling onto cover (1). Hoist and
align cover (1) with the mounting hole on track
frame (6) and support (8).

6 W18K-03-03-002

6. Install cover (1) to support (8) with sems bolts (7) 3


(4 used).
: 19 mm
: 90 N m (9 kgf m, 66 lbf·ft)

W18K-03-02-001

7. Install cover (1) to track frame (6) with sems bolts 6 7 1


(7) (4 used).
: 19 mm
: 90 N m (9 kgf m, 66 lbf·ft)

W18K-03-03-003

W3-3-4
UNDERCARRIAGE / Travel Brake Valve
1

W18K-03-03-002

8. Secure hoses (3) (2 used) to cover (1) with 2 1


clamps (2) (2 used), bolts (4) (3 used) and 3
washers (5) (3 used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf·ft)

4, 5 W18K-03-02-002

W3-3-5
UNDERCARRIAGE / Travel Brake Valve
DISASSEMBLY OF TRAVEL BRAKE
VALVE

1 2

13
12 2
11
10
9
7 1
8

5
6
14
15 4

16
17

18

17
16 8
9
10
26
11
25 12
24 13
23
22
21
20
15 19

14

W18B-03-03-002

1- Socket Bolt (8 Used) 8- Spring Seat (2 Used) 15 - Cap Assembly (2 Used) 22 - Spring (4 Used)
2- Relief Valve (2 Used) 9- Spring (2 Used) 16 - Spring (2 Used) 23 - Steel Ball (4 Used)
3- Body 10 - Spring Seat (2 Used) 17 - Check Valve (2 Used) 24 - Cap (2 Used)
4- Orifice 11 - O-Ring (2 Used) 18 - Plunger 25 - Backup Ring (2 Used)
5- O-Ring (3 Used) 12 - Backup Ring (2 Used) 19 - Plug (4 Used) 26 - O-Ring (2 Used)
6- Plug (3 Used) 13 - Plug (2 Used) 20 - O-Ring (4 Used)
7- Orifice 14 - Socket Bolt (8 Used) 21 - Spring Guide (4 Used)

W3-3-6
UNDERCARRIAGE / Travel Brake Valve
Disassembly 8. Remove the plunger (18) assembly from the vise.

1. Remove socket bolts (14) (8 used) from body (3). IMPORTANT: When removing plug (13), plug (13)
: 14 mm flies out a little by the reaction force
of spring (9). Do not drop plug (13),
IMPORTANT: Do not damage body (3) and cap spring seat (10) and spring (9).
assembly (15). 9. Remove plug (13) from plunger (18) by hand.
2. Lightly pry and remove cap assemblies (15) (2 Remove spring seat (10) and spring (9).
used) from both sides of body (3) by using a
screwdriver. 10. Remove O-rings (11) (2 used) and backup rings
(12) (2 used) from plugs (13) (2 used).
IMPORTANT: When removing plug (13), plug (13)
flies out a little by the reaction force 11. Remove spring (16), check valve (17) and spring
of spring (9). Do not drop plug (13), seat (8) from plunger (18).
spring seat (10) and spring (9).
3. Loosen plugs (13) (2 used) at both sides of 12. Remove O-rings (26) (2 used) and backup rings
plunger (18) at the same time. Remove plug (13) (25) (2 used) from caps (24) (2 used).
at one side only. Remove spring seat (10) and
spring (9) from body (3). 13. Remove plugs (19) (4 used) from caps (24) (2
: 36 mm used). Remove O-rings (20) (4 used) from plugs
(19) (4 used).
4. Remove spring (16) and check valve (17) from : 14 mm
plunger (18) at the side without plug (13).
14. Remove spring guides (21) (4 used), springs (22)
5. Slowly turn and remove the plunger (18) (4 used) and steel balls (23) (4 used) from caps
assembly from the side with plug (13) attached. (24) (2 used).
Remove spring seat (8) from body (3) at the
opposite side. 15. Remove socket bolts (1) (8 used) from body (3).
: 10 mm
6. Secure plug (13) in plunger (18) in a vise.
IMPORTANT: Do not disassemble relief valve (2)
7. Pass a bar through a cross hole on plunger (18). as the set flow rate changes.
Turn the bar. Loosen plug (13) without removing. 16. Remove relief valves (2) (2 used) from body (3).

W3-3-7
UNDERCARRIAGE / Travel Brake Valve
ASSEMBLY OF TRAVEL BRAKE VALVE

19 24 10 14 9 25 4 8 17 16 18 3 7 11 12 23 22 21

20

13 2

1
26
T144-03-05-002

1- Socket Bolt (8 Used) 8- Spring Seat (2 Used) 15 - Cap Assembly (2 Used) 22 - Spring (4 Used)
2- Relief Valve (2 Used) 9- Spring (2 Used) 16 - Spring (2 Used) 23 - Steel Ball (4 Used)
3- Body 10 - Spring Seat (2 Used) 17 - Check Valve (2 Used) 24 - Cap (2 Used)
4- Orifice 11 - O-Ring (2 Used) 18 - Plunger 25 - Backup Ring (2 Used)
5- O-Ring (3 Used) 12 - Backup Ring (2 Used) 19 - Plug (4 Used) 26 - O-Ring (2 Used)
6- Plug (3 Used) 13 - Plug (2 Used) 20 - O-Ring (4 Used)
7- Orifice 14 - Socket Bolt (8 Used) 21 - Spring Guide (4 Used)

W3-3-8
UNDERCARRIAGE / Travel Brake Valve
Assembly IMPORTANT: Install plug (13) by pushing against
the reaction force from spring (9).
1. Install relief valves (2) (2 used) to body (3) with 8. Install plug (13) to plunger (18) by hand.
socket bolts (1) (8 used).
: 10 mm 9. Slowly turn and insert the plunger (18) assembly
: 98 to 108 N m into body (3) from the side without plug (13).
(10 to 11 kgf m, 72 to 80 lbf·ft)
IMPORTANT: Install spring seat (8) with the larger
2. Install steel balls (23) (4 used), springs (22) (4 chamfered side facing to the
used) and spring guides (21) (4 used) to caps plunger (18) side.
(24) (2 used). 10. Install check valve (17), spring (16), spring seat
(8) and spring (9) to inserted plunger (18) at the
3. Install O-rings (20) (4 used) to plugs (19) (4 used). opposite side.
Install plugs (19) (4 used) to caps (24) (2 used).
: 14 mm IMPORTANT: Install spring seat (10) with the
: 14.7 to 16.7 N m chamfered side facing to the
(1.5 to 1.7 kgf m, 11 to 12 lbf·ft) plunger (13) side.
11. Slowly turn and install spring seat (10) to plug
4. Install backup rings (25) (2 used) and O-rings (13).
(26) (2 used) to caps (24) (2 used).
IMPORTANT: Install plug (13) by pushing against
IMPORTANT: Install spring seat (8) with the larger the reaction force from spring (9).
chamfered side facing to the 12. Install plug (13) to plunger (18) by hand.
plunger (18) side.
5. Secure plunger (18) in a vise. Install check valve 13. Tighten plugs (13) at both sides at the same time.
(17), spring (16), spring seat (8) and spring (9) to : 36 mm
the one side of plunger (18). : 255 to 274 N m
(26 to 28 kgf m, 188 to 202 lbf·ft)
6. Install backup rings (12) (2 used) and O-rings
(11) (2 used) to plugs (13) (2 used). 14. Install cap assemblies (15) (2 used) to body (3)
with socket bolts (14) (8 used).
IMPORTANT: Install spring seat (10) with the : 14 mm
chamfered side facing to the : 196 to 216 N m
plunger (13) side. (20 to 22 kgf m, 145 to 159 lbf·ft)
7. Slowly turn and install spring seat (10) to plugs
(13).

W3-3-9
UNDERCARRIAGE / Travel Brake Valve
(Blank)

W3-3-10
UNDERCARRIAGE / Center Joint
REMOVAL AND INSTALLATION OF
CENTER JOINT

Removal

CAUTION: Bleed air from the hydraulic oil


tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

1. Remove socket bolts (3) (16 used) and split 2 3 4 3


flanges (1) (8 used) from hoses (2) (4 used).
Disconnect hoses (2) (4 used) from center joint
2
(4). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 14 mm
5
2. Disconnect hoses (5) (7 used) from center joint
(4). Cap the open ends. Attach an identification 1
tag onto the disconnected hoses for assembling.
: 17 mm, 19 mm, 22 mm, 36 mm

5
W18K-03-04-002
2

3. Remove bolts (6) (3 used) and washers (7) (3


4
used) from stopper (8). Remove stopper (8) from
center joint (4).
: 32 mm

6, 7

6, 7 8 W18K-03-04-002

W3-4-1
UNDERCARRIAGE / Center Joint
4. Disconnect hoses (9) (2 used) from center joint 9 10 4 9
(4). Cap the open ends.
: 17 mm, 36 mm

5. Disconnect connectors (10) (2 used) from center 11


joint (4).
12
6. Remove sems bolts (11) (4 used) from clamps
(12) (4 used). Remove clamps (12) (4 used) and 13
harness (16) from bracket (13).
: 17 mm 14

7. Remove sems bolts (14) (2 used) from bracket


(13). Remove bracket (13) from bracket (15). 16 15 W18K-03-04-001

: 17 mm

8. Remove socket bolts (18) (16 used) and split


flanges (19) (8 used) from hoses (17) (4 used). 18 19 17
Disconnect hoses (17) (4 used) and blocks (20)
(4 used) from center joint (4). Cap the open ends.
: 17 mm

17

18

20 4 20 19 W18K-03-04-001

W3-4-2
UNDERCARRIAGE / Center Joint

CAUTION: Center joint (4) weight: 261 kg Pulling-Out Hole


(580 lb)

9. Install an eyebolt (M16, Pitch 2.0 mm) to the


pulling-out hole (2 places) on the upper part of 4
center joint (4). Attach a nylon sling onto the
eyebolt. Hoist and hold center joint (4).

W146-03-05-005

IMPORTANT: Put the matching marks onto the


body of center joint (4) and bracket
(15).
10. Remove bolts (21) (4 used) and washers (22) (4
used) from center joint (4). Remove center joint
(4) from bracket (15).
: 30 mm
21, 22

W18K-03-04-001
15 4

21, 22

15

W145-03-04-001

W3-4-3
UNDERCARRIAGE / Center Joint
Installation
Pulling-Out Hole

CAUTION: Center joint (4) weight: 261 kg


(580 lb)
4
1. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
center joint (4). Attach a nylon sling onto the
eyebolt. Hoist and align center joint (4) with the
matching mark on bracket (15). Install center joint
(4) to bracket (15) with bolts (21) (4 used) and
washers (22) (4 used).
: 30 mm
: 550 N m (56 kgf m, 406 lbf·ft)
W146-03-05-005

21, 22

15

W145-03-04-001

21, 22

W18K-03-04-001
15 4

W3-4-4
UNDERCARRIAGE / Center Joint
2. Install stopper (8) to center joint (4) with bolts (6) 4
(3 used) and washers (7) (3 used).
: 32 mm
: 750 N m (76.5 kgf m, 553 lbf·ft)

6, 7

6, 7 8 W18K-03-04-002

3. Connect hoses (5) (7 used) to center joint (4).


2 3 4 3
: 17 mm
: 24.5 N m (2.5 kgf m, 18 lbf·ft)
: 19 mm 2
: 29.5 N m (3 kgf m, 22 lbf·ft)
: 22 mm
: 39 N m (4 kgf m, 29 lbf·ft)
: 36 mm 5
: 175 N m (18 kgf m, 129 lbf·ft)
1
4. Connect hoses (2) (4 used) to center joint (4)
with socket bolts (3) (16 used) and split flanges
(1) (8 used). 5
: 14 mm
W18K-03-04-002
: 210 N m (21.5 kgf m, 155 lbf·ft) 2

W3-4-5
UNDERCARRIAGE / Center Joint
5. Install blocks (20) (4 used) and connect hoses 18 19 17
(17) (4 used) to center joint (4) with socket bolts
(18) (16 used) and split flanges (19) (8 used).
: 17 mm
: 400 N m (41 kgf m, 295 lbf·ft)

17

18

20 4 20 19 W18K-03-04-001

6. Install bracket (13) to bracket (15) with sems


bolts (14) (2 used). 9 10 4 9
: 17 mm
: 50 N m (5 kgf m, 37 lbf·ft)

7. Connect connectors (10) (2 used) to center joint 11


(4).
12
8. Secure clamps (12) (4 used) and harness (16) to
bracket (13) with sems bolts (11) (4 used). 13
: 17 mm
: 50 N m (5 kgf m, 37 lbf·ft) 14

9. Connect hoses (9) (2 used) to center joint (4).


: 17 mm 16 15 W18K-03-04-001

: 24.5 N m (2.5 kgf m, 18 lbf·ft)


: 36 mm
: 175 N m (18 kgf m, 129 lbf·ft)

W3-4-6
UNDERCARRIAGE / Center Joint
(Blank)

W3-4-7
UNDERCARRIAGE / Center Joint
DISASSEMBLY OF CENTER JOINT

13
1
14

12 15

11
16

2 17

18

19
3

10
W146-03-05-002

1- Body 6- Spindle 11 - Spring Washer (8 Used) 16 - O-Ring


2- Seal (5 Used) 7- O-Ring (4 Used) 12 - Bolt (8 Used) 17 - Plate
3- O-Ring 8- Plug (4 Used) 13 - Bolt (6 Used) 18 - O-Ring
4- Ball (39 Used) 9- O-Ring (3 Used) 14 - Spring Washer (6 Used) 19 - Ball (36 Used)
5- Ring Plate 10 - Plug (3 Used) 15 - Cover

W3-4-8
UNDERCARRIAGE / Center Joint
Disassembly of Center Joint
CAUTION: Body (1) weight: 140 kg (310 lb)
IMPORTANT: Put the matching marks onto body Spindle (6) weight: 100 kg (220 lb)
(1) and spindle (6).
1. Remove bolts (13) (6 used) and spring washers IMPORTANT: When removing spindle (6) from
(14) (6 used) from cover (15). Install bolts (13) (2 body (1), ball (4) may fall off from
used) to the pulling-out hole (2 places) on cover spindle (6). Do not damage ball (4).
(15). Tighten the bolt. Raise and remove cover 3. Install special tool (A) to spindle (6) and body (1).
(15) from body (1). Remove spindle (6) from body (1).
: 24 mm
Details of special tool (A): ST 2440, ST 2441, ST
2917
ST 2443, ST 2444
Pulling-Out Hole
J901232, J901650
ST 2440

ST 2917 ST 2441
J 901232 ST 2444
ST 2443

J 901650

W146-03-05-005

W146-03-05-003
2. Remove bolts (12) (8 used), spring washers (11)
(8 used) and plate (17) from body (1). Remove
4. Remove seals (2) (5 used) and O-ring (3) from
balls (19) (36 used) from body (1).
body (1).
: 19 mm
5. Remove balls (4) (39 used) and ring plate (5)
from spindle (6).

6. Remove plugs (8) (4 used) from spindle (6).


: 41 mm

W3-4-9
UNDERCARRIAGE / Center Joint
ASSEMBLY OF CENTER JOINT

13 16 12 11

14

15
17
18

19

4
5

10 9

T145-03-02-001

1- Body 6- Spindle 11 - Spring Washer (8 Used) 16 - O-Ring


2- Seal (5 Used) 7- O-Ring (4 Used) 12 - Bolt (8 Used) 17 - Plate
3- O-Ring 8- Plug (4 Used) 13 - Bolt (6 Used) 18 - O-Ring
4- Ball (39 Used) 9- O-Ring (3 Used) 14 - Spring Washer (6 Used) 19 - Ball (36 Used)
5- Ring Plate 10 - Plug (3 Used) 15 - Cover

W3-4-10
UNDERCARRIAGE / Center Joint
Assembly of Center Joint

1. Apply grease onto ring plate (5) and balls (4) (39 6. Install cover (15) to O-rings (16, 18). Install cover
used). Install ring plate (5) and balls (4) (39 used) (15) to body (1) with spring washers (14) (6 used)
to spindle (6). and bolts (13) (6 used).
: 24 mm
2. Install seals (2) (5 used) and O-ring (3) to body : 210 N m (21.5 kgf m, 155 lbf·ft)
(1).

CAUTION: Body (1) weight: 140 kg (310 lb)


Spindle (6) weight: 100 kg (220 lb)

3. Install body (1) to spindle (6) by using special tool


(A).

Details of Special tool (A): ST 2440, ST 2441, ST


2917
ST 2443, ST 2444
J901232, J901650
ST 2440

ST 2917 ST 2441
J 901232 ST 2444
ST 2443

J 901650

W146-03-05-003

4. Apply grease onto balls (19) (36 used). Insert


balls (19) (36 used) into the groove on spindle (6)
and body (1).

5. Place plate (17) onto balls (19) (36 used).


Tighten spring washers (11) (8 used) and bolts
(12) (8 used). Push balls (19) (36 used) into the
groove.
: 19 mm
: 90 N m (9.2 kgf m, 66 lbf·ft)

W3-4-11
UNDERCARRIAGE / Center Joint
(Blank)

W3-4-12
UNDERCARRIAGE / Adjuster Cylinder
REMOVAL AND INSTALLATION OF
ADJUSTER CYLINDER

IMPORTANT: Bleed air from the hydraulic oil tank


before doing any work. (Refer to
BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

Removal 1
CAUTION: Grease pressure in the adjuster
cylinder is high. Do not loosen valve (1)
quickly or too much as valve (1) may fly off
or high-pressure grease in the cylinder may
gush out. It is enough to loosen valve (1) by
1 turn.
Keep body parts and face away from valve
(1) and loosen valve (1) carefully. Do not 2
loosen grease fitting (2). W18C-03-05-001

1. Loosen valve (1) in the adjuster cylinder. Drain


grease and loosen the track tension.
: 24 mm

2. Place a container for hydraulic oil under stop


valve (6) of accumulator (3).
6
3. Remove plug (5) from stop valve (6) of 3
accumulator (3). 4
: 9 mm

CAUTION: Do not open handle (4) quickly as


high-pressure hydraulic oil in accumulator
(3) may gush out. Keep body parts and face 5 W18C-03-05-002

away from stop valve (6) and open handle (4)


carefully.

4. Open handle (4) and drain hydraulic oil from


accumulator (3).

W3-5-1
UNDERCARRIAGE / Adjuster Cylinder
5. Remove of the track. (Refer to REMOVAL AND 7
INSTALLATION OF TRACK on W3-8-1.)

6. Disconnect hoses (8) (2 used) from adjuster


cylinder (7). Cap the open ends.
: 19 mm, 27 mm
8

W18K-03-05-002

CAUTION: Front idler (10) weight: 860 kg


A
9 10
(1900 lb)

7. Remove front idler (10) from side frame (9).


(Refer to REMOVAL AND INSTALLATION OF
FRONT IDLER on W3-6-1.)

CAUTION: The yoke (11) assembly weight:


520 kg (1150 lb)

8. Attach a wire onto yoke (11). Pull out yoke (11) to


the position where yoke (11) can be removed 7 11 W18K-03-06-001
from adjuster cylinder (7).

13 14 15 16 17
9. Remove sems bolts (18) (2 used) from plate (19).
Remove plate (19) from brackets (17) (2 used).
: 17 mm
18
10. Remove bolts (14) (4 used) and spring washers
(13) (4 used) from brackets (17) (2 used). 19
Remove brackets (17) (2 used) from lock plates 12 20
(12) (2 used).
: 24 mm

W18K-03-06-002
View A

W3-5-2
UNDERCARRIAGE / Adjuster Cylinder
11. Remove valve (20) from piston rod (21). 21 A 20
: 24 mm

11 W18K-03-06-001

15 16
12. Remove bolts (16) (4 used) from lock washers
(15) (2 used). Remove lock washers (15) (2
used) and lock plates (12) (2 used) from yoke
(11).
: 30 mm

CAUTION: Yoke (11) weight: 175 kg (390 lb) 12 20

13. Hoist and remove yoke (11) from piston rod (21).

W18K-03-06-002
View A
CAUTION: Adjuster cylinder (7) weight: 350
kg (780 lb)

14. Attach a nylon sling onto the groove part on


7 9
piston rod (21). Pull out adjuster cylinder (7)
partway from side frame (9). Groove Part

15. Attach a nylon sling onto the body of adjuster


cylinder (7).

16. Hoist and remove adjuster cylinder (7) from side


frame (9).

21 W18K-03-05-002

W3-5-3
UNDERCARRIAGE / Adjuster Cylinder
Installation
• As for the method to hoist the parts and the 7 9
position of the lifting holes, refer to Removal.
11 Groove Part

CAUTION: Adjuster cylinder (7) weight: 350


kg (780 lb)

1. Hoist and insert adjuster cylinder (7) into the


position where the groove part on piston rod (21)
comes out from side frame (9).

21 W18K-03-05-002

CAUTION: Yoke (11) weight: 175 kg (390 lb)

21 A
2. Attach a nylon sling onto yoke (11). Hoist and
align yoke (11) with the mounting surface on
piston rod (21).

11 W18K-03-06-001

3. Install lock plates (12) (2 used) to the groove on


piston rod (21). Secure lock plates (12) (2 used)
to yoke (11) with bolts (16) (4 used) and lock 13 14 15 16 17
washers (15) (2 used).
: 30 mm
: 550 N m (56 kgf m, 406 lbf ft)
18
4. Install valve (20) to piston rod (21). 19
: 24 mm
12 20
: 147 N m (15 kgf m, 108 lbf ft)
21

W18K-03-06-002
View A

W3-5-4
UNDERCARRIAGE / Adjuster Cylinder

7 11 W18K-03-06-001

13 14 17
5. Install brackets (17) (2 used) to lock plates (12)
(2 used) with bolts (14) (4 used) and spring
washers (13) (4 used).
: 24 mm 18
: 270 N m (27.5 kgf m, 200 lbf ft)
19
6. Install plate (19) to brackets (17) (2 used) with 12
sems bolts (18) (2 used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)
W18K-03-06-002
View A
CAUTION: The adjuster cylinder (7)
assembly weight: 52 kg (115 lb)

7. Push adjuster cylinder (7) with yoke (11) attached


into side frame (9).

CAUTION: Front idler (10) weight: 860 kg


(1900 lb) 10 11

8. Install front idler (10) to side frame (9). (Refer to


REMOVAL AND INSTALLATION OF FRONT
IDLER on W3-6-1.)

9 7 W18K-03-05-003

W3-5-5
UNDERCARRIAGE / Adjuster Cylinder
9. Connect hoses (8) (2 used) to adjuster cylinder 7
(7).
: 19 mm
: 29.5 N m (3 kgf m, 22 lbf ft)
: 27 mm
: 78 N m (8 kgf m, 58 lbf ft)
8

W18K-03-05-002

10. Close handle (4) and install plug (5).


: 9 mm
: 30 N m (3 kgf m, 22 lbf ft)

11. Start the engine. Operate the travel control lever


in the forward direction slowly. Fill the adjuster 4
cylinder with hydraulic oil. At this time, a load is
applied so that the pressure of 12.7 MPa (130
kgf/cm2, 1850 psi) or more occurs in a travel
circuit.
W18C-03-05-002
5

1
12. Add grease through grease fitting (2) and adjust
the track tension. (Refer to REMOVAL AND
INSTALLATION OF TRACK on W3-8-1.)

2 W18C-03-05-001

W3-5-6
UNDERCARRIAGE / Adjuster Cylinder
(Blank)

W3-5-7
UNDERCARRIAGE / Adjuster Cylinder
DISASSEMBLY OF ADJUSTER CYLINDER

6
20
19 7
18
Cushion Side

17
Front Idler
Side
16

15
22 14
21 13
12
11
10
9
8

W144-03-03-002

1- Base Cylinder 7- Cylinder 13 - Plate 18 - Plug


2- Wear Ring (2 Used) 8- Flange 14 - U-Ring 19 - Flange
3- Backup Ring 9- Spring Washer (20 Used) 15 - Backup Ring 20 - O-Ring
4- U-Ring 10 - Bolt (20 Used) 16 - Wear Ring (2 Used) 21 - Spring Washer (8 Used)
5- Plate 11 - O-Ring 17 - Piston Rod 22 - Bolt (8 Used)
6- Retaining Ring 12 - Retaining Ring

W3-5-8
UNDERCARRIAGE / Adjuster Cylinder
Disassembly of Adjuster Cylinder
CAUTION: Flange (8) weight: 32 kg (71 lb)

CAUTION: Adjuster cylinder weight: 345 kg 5. Remove bolts (10) (20 used) and spring washers
(760 lb) (9) (20 used) from flange (8). Attach a nylon sling
onto flange (8). Hoist and remove flange (8) from
1. Place the adjuster cylinder vertically with the cylinder (7).
cushion side facing downward. : 30 mm

2. Remove bolts (22) (8 used) and spring washers


CAUTION: Base cylinder (1) weight: 107 kg
(21) (8 used) from flange (19). Remove flange
(240 lb)
(19) from base cylinder (1).
: 27 mm
6. Install an eyebolt (M18, Pitch 2.5 mm) to the bolt
(22) hole (2 places) on base cylinder (1). Hoist
CAUTION: Rod (17) weight: 67 kg (150 lb) and remove base cylinder (1) from cylinder (7).

3. Attach a nylon sling onto the groove on piston rod 7. Remove retaining ring (6), plate (5), backup ring
(17). Hoist and remove piston rod (17) from base (3), U-ring (4) and wear rings (2) (2 used) from
cylinder (1). base cylinder (1).

4. Remove retaining ring (12), plate (13), U-ring


(14), backup ring (15) and wear rings (16) (2
used) from piston rod (17).

W3-5-9
UNDERCARRIAGE / Adjuster Cylinder
ASSEMBLY OF ADJUSTER CYLINDER

20 22 21 1 11 16 15 14 13 5 6

12

17 19

10 9 8 2 3 4

Hose Valve, Hose


Mounting Hole Mounting Hole
17 18 7
8

Grease Fitting Valve


Mounting Hole
(M16, Pitch 1.5 mm)
W18K-03-06-001

1- Base Cylinder 7- Cylinder 13 - Plate 18 - Plug


2- Wear Ring (2 Used) 8- Flange 14 - U-Ring 19 - Flange
3- Backup Ring 9- Spring Washer (20 Used) 15 - Backup Ring 20 - O-Ring
4- U-Ring 10 - Bolt (20 Used) 16 - Wear Ring (2 Used) 21 - Spring Washer (8 Used)
5- Plate 11 - O-Ring 17 - Piston Rod 22 - Bolt (8 Used)
6- Retaining Ring 12 - Retaining Ring

W3-5-10
UNDERCARRIAGE / Adjuster Cylinder
Assembly of Adjuster Cylinder 5. Install wear rings (16) (2 used), backup ring (15),
• As for the method to hoist the parts and the U-ring (14), plate (13) and retaining ring (12) to
position of the lifting holes, refer to Removal. piston rod (17).

IMPORTANT: Assemble the adjuster cylinder so


that the position of the grease fitting CAUTION: Piston rod (17) weight: 67 kg (150
valve mounting hole on right and lb)
left piston rods (17) and that of the
hose mounting hole on cylinder (7) IMPORTANT: Fill the chamber in base cylinder (1)
are located on the outside of the with grease. Push piston rod (17)
side frame. into base cylinder (1) and
IMPORTANT: Do not expose backup ring (15) to completely bleed air from base
air until the moment just before cylinder (1).
assembly due to its moisture 6. Hoist and install piston rod (17) to base cylinder
absorbability. (1).

1. Install backup ring (3), U-ring (4) and plate (5) 7. Install O-ring (20) to flange (19). Fill the groove
and retaining ring (6) to base cylinder (1). on the inner diameter of flange (19) with grease.
Install flange (19) to base cylinder (1) with bolts
2. Install wear rings (2) (2 used) to base cylinder (22) (8 used) and spring washers (21) (8 used).
(1). : 27 mm
: 400 N m (41 kgf m, 295 lbf ft)

CAUTION: Base cylinder (1) weight: 107 kg


(240 lb)

3. Hoist and install base cylinder (1) to cylinder (7).

CAUTION: Flange (8) weight: 32 kg (71 lb)

4. Install O-ring (11) to flange (8). Fill the groove on


the inner diameter of flange (8) with grease.
Install flange (8) to cylinder (7) with bolts (10) (20
used) and spring washers (9) (20 used).
: 30 mm
: 550 N m (56 kgf m, 406 lbf ft)

W3-5-11
UNDERCARRIAGE / Adjuster Cylinder
(Blank)

W3-5-12
UNDERCARRIAGE / Front Idler
REMOVAL AND INSTALLATION OF FRONT
IDLER

CAUTION: Bleed air from the hydraulic oil 1


tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
CAUTION: The pressure inside the adjuster
cylinder is high. As valve (1) may fly out and
the highly pressurized grease may spout out,
do not loosen valve (1) quickly and/or
2
excessively. It is enough to loosen valve (1) W18C-03-05-001

by 1 to 1.5 turns. Keep body parts and face


away from valve (1), and loosen valve (1)
carefully. Do not loosen grease fitting (2).

1. Loosen valve (1) in the adjuster cylinder and drain 6


3
grease. Loose the track.
: 24 mm 4

2. Place a container for hydraulic oil under stop valve


(6) of accumulator (3).

3. Remove plug (5) from stop valve (6) of 5 W18C-03-05-002

accumulator (3).
: 9 mm

CAUTION: Do not open handle (4) quickly as


high-pressure hydraulic oil in accumulator (3)
may gush out. Keep body parts and face away
from handle (4), and open handle (4) carefully.

4. Open handle (4) and drain hydraulic oil from


accumulator (3).

W3-6-1
UNDERCARRIAGE / Front Idler
5. Remove the track. (Refer to REMOVAL AND
INSTALLATION OF TRACK on W3-8-1.) 7

6. Disconnect hoses (8) (2 used) from adjuster


cylinder (7).
: 19 mm, 27 mm

W18K-03-05-002

7. Attach a wire onto the hole on front idler (12).


9 10, 11 12

CAUTION: The front idler (12) assembly


weight: 1400 kg (3090 lb)

8. Hoist front idler (12). Pull out front idler (12) to the
position when bolt (10) of yoke (13) comes out
from side frame (9).

CAUTION: Front idler (12) weight: 860 kg


(1900 lb)
13 W18K-03-06-001

9. Remove bolts (10) (4 used) and washers (11) (4


used) from yoke (13). Remove front idler (12) from
yoke (13).
: 46 mm

W3-6-2
UNDERCARRIAGE / Front Idler
Installation
1. Attach a wire onto yoke (13). Pull out half of yoke
9 10, 11 12
(13) from side frame (9) by using a forklift.

2. Attach a wire onto the hole on front idler (12).

CAUTION: Front idler (12) weight: 860 kg


(1900 lb)

3. Hoist front idler (12). Install front idler (12) to yoke


(13) with bolts (10) (4 used) and washers (11) (4
used). Push front idler (12) and adjuster cylinder
(7) to side frame (9) by using a forklift. 7 13 W18K-03-06-001

4. Connect hoses (8) (2 used) to adjuster cylinder


(7).
: 19 mm 7
: 30 N m (3 kgf m, 22 lbf ft)
: 27 mm
: 80 N m (8 kgf m, 58 lbf ft)

5. Install the track. (Refer to REMOVAL AND


INSTALLATION OF TRACK on W3-8-1.)
8

W18K-03-05-002

W3-6-3
UNDERCARRIAGE / Front Idler
6. Close handle (4). Install plug (5).
: 9 mm
: 30 N m (3 kgf m, 22 lbf ft)

7. Tighten valve (1) of adjuster cylinder (7). 4


: 24 mm
: 150 N m (15 kgf m, 111 lbf ft)

8. Start the engine. Operate the travel lever in the


forward direction and fill adjuster cylinder (7) with W18C-03-05-002
5
hydraulic oil.
Add grease through grease fitting (2) and adjust
the track tension. (Refer to REMOVAL AND
INSTALLATION OF TRACK on W3-8-1.) 1

2 W18C-03-05-001

W3-6-4
UNDERCARRIAGE / Front Idler
(Blank)

W3-6-5
UNDERCARRIAGE / Front Idler
DISASSEMBLY OF FRONT IDLER

2
3
4
5
6

7
1

6
5
4
3
2

W144-03-04-003

1 - Pin (2 Used) 3 - Pedestal (2 Used) 5 - O-Ring (2 Used) 7 - Idler


2 - Plug (2 Used) 4 - Floating Seal (2 Used) 6 - Bushing (2 Used) 8 - Axle

W3-6-6
UNDERCARRIAGE / Front Idler
Disassembly of Front Idler
CAUTION: The axle (8) assembly weight:
140 kg (310 Ib)
CAUTION: Front idler weight: 860 kg
(1900 Ib) 6. Remove axle (8) from idler (7) by using a press.
Pedestal (3) at the opposite side is removed with
1. Secure the front idler in a stable condition. axle (8) together.
Press
2. Remove plugs (2) (2 used) from pedestal (3).
Drain oil from pedestals (3) (2 used).
8
6 mm

CAUTION: Pedestal (3) weight: 42 kg (93 Ib)


7
3. Remove pin (1) by using a bar and a hammer by
tapping. Attach a nylon sling onto pedestal (3).
Remove pedestal (3) from axle (8). (One side
only)
3
4. Remove O-ring (5) from axle (8). (One side only) W146-03-07-003

5. Remove floating seal (4) from idler (7) and 7. Remove pin (1) from axle (8) by using a bar and
pedestal (3). (One side only) a hammer by tapping. Remove pedestal (3) at the
opposite side.

8. Remove O-ring (5) from axle (8).

9. Remove floating seal (4) from idler (7) and


pedestal (3).

CAUTION: Idler (7) weight: 670 kg (1480 Ib)

10. When replacing bushing (6), weld four places, 90


apart from each others on the bushing (6) bore.
Shrink and remove bushing (6) from idler (7).

90

90

W105-03-05-012

W3-6-7
UNDERCARRIAGE / Front Idler
ASSEMBLY OF FRONT IDLER

3 2
1 5 4 6

W144-03-04-001

W144-03-04-002

1 - Pin (2 Used) 3 - Pedestal (2 Used) 5 - O-Ring (2 Used) 7 - Idler


2 - Plug (2 Used) 4 - Floating Seal (2 Used) 6 - Bushing (2 Used) 8 - Axle

W3-6-8
UNDERCARRIAGE / Front Idler
Assembly of Front Idler

IMPORTANT: Apply lubricant onto the inner 6. Install O-ring (5) and pedestal (3) on the opposite
diameter part of idler (7). side to axle (8). Align the holes on pedestal (3)
and axle (8). Install pin (1) by tapping.
1. Install bushings (6) (2 used) to idler (7) by using a
press. 3 4 5 7

2. Install O-ring (5) to axle (8). Install floating seal (4)


to idler (7) and pedestal (3). (One side only)

CAUTION: Pedestal (3) weight: 42 kg (93 Ib)


Axle (8) weight: 96kg (220 Ib)

3. Install pedestal (3) to axle (8) on the side where 8


O-Ring (5) has been installed. Align the holes on
pedestal (3) and axle (8). Install pin (1) by tapping.
(One side only) W157-03-05-005

8 7. Add engine oil through the hole on plugs (2) (2


used) of pedestals (3) (2 used).
1
Engine oil: 1.3 L (0.34 US gal,) (API class CD
SAE30)
3
8. Install plugs (2) (2 used) to pedestals (3) (2 used).
: 6 mm
: 3.3 to 4.2 N m
(0.3 to 0.4 kgf m, 2.2 to 2.9 Ibf·ft)
W105-03-05-014

CAUTION: The axle (8) assembly weight:


140 kg (310 Ib)

4. Attach a nylon sling onto the body of axle (8).


Hoist and install the axle (8) assembly to dler (7)
by using a press.

5. Install floating seal (4) to idler (7) and pedestal (3)


on the opposite side.

W3-6-9
UNDERCARRIAGE / Front Idler
MAITENANCE STANDARD

D
E F

B A
C

W18C-03-06-001
W144-03-04-002

Unit: mm (1 mm = 0.03937 in)


Item Standard Allowable Limit Remedy
A : Idler Outer Dia 1045 (1015) Repair or Replace
-0.085
B : Axle Outer Dia 160 -0.125 (159.2) Replace
+0.480
B’ : Bushing Inner Dia 160 +0.420 (161) Replace
C : Bushing Flange Thickness 15-0.1-0.2 (13.5) Replace
D : Idler Outer Thickness 304 (280) Repair or Replace
E : Tread Width 144 (115) Repair or Replace
F : Flange Height 27.5 37.5 Repair or Replace
G : Reference 379.5 - -

NOTE: If welding is required for repair, refer to


Welding Repair Procedure on W3-10-1 and
the pattern drawings attached in the back
of this book.
The values in ( ) are just for reference.

W3-6-10
UNDERCARRIAGE / Upper and Lower Rollers
REMOVAL AND INSTALLATION OF UP-
PER/LOWER ROLLERS
1
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

Removal of Upper Roller

CAUTION: The pressure inside the adjuster


2
cylinder is high. As valve (1) may fly out and W18C-03-05-001

the highly pressurized grease may spout out,


do not loosen valve (1) quickly and/or exces-
sively. It is enough to loosen valve (1) by 1 to
1.5 turns. Keep body parts and face away
from valve (1), and loosen valve (1) carefully.
Do not loosen grease fitting (2). 6
3

1. Loosen valve (1) in the adjuster cylinder and 4


drain grease. Loose the track.
: 24 mm

2. Place a container for hydraulic oil under stop


valve (6) of accumulator (3). 5 W18C-03-05-002

3. Remove plug (5) from stop valve (6) of accumu-


lator (3).
: 9 mm

CAUTION: Do not open handle (4) quickly as


high-pressure hydraulic oil in accumulator
(3) may gush out. Keep body parts and face
away from handle (4), and open handle (4)
carefully.

4. Open handle (4) and drain hydraulic oil from ac-


cumulator (3).

W3-7-1
UNDERCARRIAGE / Upper and Lower Rollers
5. Hoist the track as illustrated and make a gap
between the track and upper roller (8) so that Protector
upper roller (8) can be removed.
Wire rope: 36 mm 8 m (1.4 in 26 ft)

CAUTION: When using a power wrench, do


not injure hands by the reaction bar.

6. Remove bolts (7) (4 used) from pedestals (9) (2


used) by using a power wrench.
: 30 mm

W118-03-07-002
CAUTION: Upper roller (8) weight: 51 kg
(120 lb)
7
7. Remove upper roller (8) and pedestals (9)
(2used) from the side frame by using a forklift. 8

Side Frame

W18C-03-07-001

Installation of Upper Roller


7

CAUTION: Upper roller (8) weight: 51 kg 8


(120 lb)

1. Install pedestals (9) (2 used) to upper roller (8). 9


Install upper roller (8) to the side frame by using
a forklift or other tools.
Side Frame

CAUTION: When using a power wrench, do


not injure hands by the reaction bar.

2. Secure upper roller (8) to the side frame with


bolts (7) (4 used) by using a power wrench.
: 30 mm W18C-03-07-001

: 390 N m (40 kgf m, 290 Ibf·ft)

W3-7-2
UNDERCARRIAGE / Upper and Lower Rollers
3. Close handle (4). Install plug (5).
: 9 mm
: 30 N m (3 kgf m, 21.5 Ibf·ft)

4. Tighten valve (1) on the adjuster cylinder.


: 24 mm
: 147 N m (15 kgf m, 108 Ibf·ft)
4

5. Start the engine. Operate the travel lever in the


forward direction and fill the adjuster cylinder with
hydraulic oil. At this time, a load is applied so that
pressure of 12.7 MPa (110 kgf/cm2) or higher W18C-03-05-002
occurs in a travel circuit. 5

6. Apply grease through grease fitting (2) and adjust 1


the track sag. (Refer to REMOVAL AND IN-
STALLATION OF TRACK on W3-8-1.)

2 W18C-03-05-001

W3-7-3
UNDERCARRIAGE / Upper and Lower Rollers

CAUTION: The pressure inside the adjuster


cylinder is high. As valve (1) may fly out and 1
the highly pressurized grease may spout out,
do not loosen valve (1) quickly and/or exces-
sively. It is enough to loosen valve (1) by 1 to
1.5 turns. Keep body parts and face away
from valve (1), and loosen valve (1) carefully.
Do not loosen grease fitting (2).

7. Loosen valve (1) in the adjuster cylinder and


drain grease. Loose the track. 2 W18C-03-05-001
: 24 mm

8. Place a container for hydraulic oil under stop


valve (6) of accumulator (3).
6
9. Remove plug (5) from stop valve (6) of accumu- 3
lator (3). 4
: 9 mm

CAUTION: Do not open handle (4) quickly as


high-pressure hydraulic oil in accumulator
(3) may gush out. Keep body parts and face 5 W18C-03-05-002

away from handle (4), and open handle (4)


carefully.

10. Open handle (4) and drain hydraulic oil from ac-
cumulator (3).

W3-7-4
UNDERCARRIAGE / Upper and Lower Rollers
Removal of Lower Roller

1. Raise the machine as illustrated. Set a block un-


der the track frame.
90 to 110
CAUTION: Lower roller (10) weight: 320 kg
(710 Ib)

2. Hold lower roller (10) by using a forklift. W18K-03-07-001

CAUTION: When using a power wrench, do


not injure hands by the reaction bar.

3. Remove bolts (11) (4 used) by using a power


wrench.
: 46 mm

Side Frame

10

11
W117-03-07-004

W3-7-5
UNDERCARRIAGE / Upper and Lower Rollers
Installation of Lower Roller

CAUTION: Lower roller (10) weight: 320 kg


(710 Ib)
90 to 110

1. Align and hold lower roller (10) with the mounting


hole on the side frame by using a forklift.

2. Temporally tighten lower roller (10) with bolts (11) W18K-03-07-001

(4 used).
: 46 mm

3. Remove the forklift.

CAUTION: When using a power wrench, do


not injure hands by the reaction bar.

4. Secure lower roller (10) to the side frame with Side Frame
bolts (11) (4 used) by using a power wrench.
46 mm
1910 N m (195 kgf m, 1410 Ibf·ft) 10

11
W117-03-07-004

W3-7-6
UNDERCARRIAGE / Upper and Lower Rollers
5. Close handle (4). Install plug (5).
: 9 mm
: 30 N m (3 kgf m, 21.5 Ibf·ft)

6. Tighten valve (1) on the adjuster cylinder. 4


: 24 mm
: 147 N m (15 kgf m, 108 Ibf·ft)

7. Start the engine. Operate the travel lever in the


W18C-03-05-002
forward direction and fill the adjuster cylinder with 5
hydraulic oil. At this time, a load is applied so that
pressure of 12.7 MPa (110 kgf/cm2) or higher 1
occurs in a travel circuit.

8. Apply grease through grease fitting (2) and adjust


the track sag. (Refer to REMOVAL AND IN-
STALLATION OF TRACK on W3-8-1.)

2 W18C-03-05-001

W3-7-7
UNDERCARRIAGE / Upper and Lower Rollers
DISASSEMBLY OF UPPER ROLLER
7

5
4
3
2
1

1
8
2
3
4
5

9
W18C-03-07-002

3 4 5 6 7 9 2

A
B

C
W18C-03-07-003

1 - Cap (4 Used) 4 - Floating Seal (2 Used) 6 - Roller 8 - Set Screw (2 Used)


2 - Retainer (2 Used) 5 - Roller Bearing (2 Used) 7 - Plug 9 - Axle
3 - O-Ring (2 Used)

W3-7-8
UNDERCARRIAGE / Upper and Lower Rollers
Disassembly of Upper Roller

7. Remove retainer (2) at another side in the same


CAUTION: Upper roller weight: 51 kg (120 way as steps 2 to 4. Remove O-ring (3) and
lb) floating seal (4).
1. Remove plug (7) from roller (6). Drain engine oil 8. Remove the inner race of roller bearing (5) inside
from upper roller (6). axle (9) by using a bar and a hammer.
: 6 mm
9. Remove the outer race of roller bearing (5) from
2. Remove cap (1) and set screw (8) from retainer roller (6) by using a bar and a hammer.
(2). (One side only)

3. Install a bolt (M10, Pitch 1.25 mm) to the hole on


cap (1). (One side only)

4. Remove retainer (2) and O-ring (3) from axle (9)


by tapping and rotating the bolt counterclockwise
by using a plastic hammer. Remove floating seal
(4) from retainer (2). (One side only)

CAUTION: Roller (6) weight: 37 kg (82 lb)

5. Attach a nylon sling onto the body of upper roller


(6). Hoist and place roller (6) with the side with-
out retainer (2) facing upward.

6. Remove axle (9) from roller (6) by tapping the


axle (9) end by using a plastic hammer. At this
time, the inner race of roller bearing (5), retainer
(2) and floating seal (4) are removed with axle (9)
together. At the same time, the inner race of roller
bearing (5) at another side is removed from axle
(9).

W3-7-9
UNDERCARRIAGE / Upper and Lower Rollers
ASSEMBLY OF UPPER ROLLER
7

5
4
3
2
1

1
8
2
3
4
5

9
W18C-03-07-002

3 4 5 6 7 9 2

A
B

C
W18C-03-07-003

1 - Cap (4 Used) 4 - Floating Seal (2 Used) 6 - Roller 8 - Set Screw (2 Used)


2 - Retainer (2 Used) 5 - Roller Bearing (2 Used) 7 - Plug 9 - Axle
3 - O-Ring (2 Used)

W3-7-10
UNDERCARRIAGE / Upper and Lower Rollers
Assembly of Upper Lower

1. Install the outer races (2 used) of roller bearing IMPORTANT: Tighten retainer (2) until surface (B)
(5) to roller (6) by using a bar and a hammer. of retainer (2) is flush with surface
(A) of axle (9).
2. Install floating seals (4) (2 used) to roller (6) and 7. Install O-ring (3) to axle (9). Install retainer (2)
retainers (2) (2 used). at another side to axle (9) by rotating clockwise.

3. Install the inner race of roller bearing (5) to axle 8. Install set screws (8) (2 used) to retainers (2) (2
(9) by using a bar and a hammer. (One side only) used).

IMPORTANT: Tighten retainer (2) until surface (B) 9. Add engine oil through the plug (7) hole on roller
of retainer (2) is flush with surface (6).
(A) of axle (9). Engine oil : API class CD SAE30
4. Install O-ring (3) to axle (9). Install retainer (2) to Oil amount : 700 mL (0.18 US gal.)
axle (9) by rotating clockwise. (One side only)
10. Wind a seal tape onto plug (7). Install plug (7) to
roller (6).
CAUTION: Roller (6) weight: 37 kg (82 lb) : 6 mm
: 34 N m (3.5 kgf m, 25.5 lbf ft)
5. Install axle (9) to roller (6) by using a press.

6. Install the inner race of roller bearing (5) at an-


other side to axle (9) by using a bar and a ham-
mer.

W3-7-11
UNDERCARRIAGE / Upper and Lower Rollers
DISASSEMBLY OF LOWER ROLLER

3
4
5
7
8
2
7
1
6
5
4
W117-03-07-002
3

4 7 6 8 7 2 3 1 8 3

5 6 2
W118-03-07-004

1 - Plug (2 Used) 3 - Collar (2 Used) 5 - O-Ring (2 Used) 7 - Bushing (2 Used)


2 - Pin (2 Used) 4 - Floating Seal (2 Used) 6 - Axle 8 - Roller

W3-7-12
UNDERCARRIAGE / Upper and Lower Rollers
Disassembly of Lower Roller

9. Remove O-rings (5) (2 used) from axle (6).


CAUTION: Lower roller weight: 320 kg (710
lb) IMPORTANT: Do not damage roller (8) when cut-
ting bushing (7) by using gas.
1. Remove plugs (1) (2 used) from roller (8). Drain 10. If replacing bushing (7), weld four places, 90
engine oil from roller (8). apart from each other on the bushing (7) bore by
: 6 mm using a welding rod. Shrink and remove bushing
(7) from roller (8). Cut and remove bushing (7) by
2. Tap and remove pin (2) from collar (3) and axle using gas.
(6) at one side by using a bar and a hammer.
90
NOTE: In case pin (2) cannot be removed, use a
press.
90
CAUTION: Axle (6) + collar (3) weight: 110
kg (250 lb)

W105-03-05-012
3. Remove axle (6) from roller (8) by using a press.
At this time, collar (3) at another side is removed
with axle (6) together.

4. Remove collar (3) from roller (8).

5. Remove floating seal (4) from roller (8) and collar


(3).

6. Tap and remove pin (2) from collar (3) by using a


bar and a hammer.
NOTE: In case pin (2) cannot be removed, use a
press.

CAUTION: Axle (6) weight: 83 kg (190 lb)

7. Remove collar (3) at another side from axle (6)


by using a press.

8. Remove floating seal (4) from roller (8) and col-


lar (3).

W3-7-13
UNDERCARRIAGE / Upper and Lower Rollers
ASSEMBLY OF LOWER ROLLER

3
4
5
7
8
2
7
1
6
5
4
W117-03-07-002
3

4 7 6 8 7 2 3 1 8 3

5 6 2
W118-03-07-004

1 - Plug (2 Used) 3 - Collar (2 Used) 5 - O-Ring (2 Used) 7 - Bushing (2 Used)


2 - Pin (2 Used) 4 - Floating Seal (2 Used) 6 - Axle 8 - Roller

W3-7-14
UNDERCARRIAGE / Upper and Lower Rollers
Assembly of Lower Roller
9. Install collar (3) to axle (6). Align the pin (2) hole.
Tap and install pin (2) by using a hammer.
CAUTION: Roller (8) weight: 175 kg (390 Ib)
10. Add engine oil through the plug (1) hole on collar
1. Install bushings (7) (2 used) into roller (8) by us- (3).
ing a press. Engine oil : API class CD SAE30
Oil amount : 0.9 L (0.24 US gal.)
CAUTION: Axle (6) weight: 83 kg (190 Ib)
11. Wind a seal tape onto plugs (1) (2 used). Install
2. Apply grease onto O-ring (5). Install O-ring (5) to plugs (1) (2 used) to collars (3) (2 used).
only one side of axle (6). : 6 mm
: 34 N m (3.5 kgf m, 25.5 Ibf·ft)
3. Install collar (3) to axle (6) at the side with O-ring
(5) attached. Align the pin (2) hole. Tap and install
pin (2) by using a hammer.

4. Install floating seal (4) to roller (8) and collar (3)


at the side where axle (6) will be inserted.

CAUTION: Axle (6) + collar (3) weight: 110


kg (250 Ib)

5. Install the axle (6) assembly to roller (8) by using


a press.

CAUTION: The roller (8) assembly weight:


300 kg (670 Ib)

6. Attach a nylon sling onto the body of the roller (8)


assembly. Hoist and turn over the roller (8) as-
sembly.

7. Apply grease onto O-ring (5). Install O-ring (5) to


axle (6).

8. Install floating seal (4) to roller (8) and collar (3).

W3-7-15
UNDERCARRIAGE / Upper and Lower Rollers
MAINTENANCE STANDARD

Upper Roller

296

148

A B

W144-03-05-002

Unit: mm (1 mm = 0.03937 in)


Item Standard Allowable Limit Remedy
A: Roller (Outer Dia.) 200 180 Replace
B: Tread (Outer Dia.) 236 (214) Replace
C: Tread Width 21 (10) Replace
NOTE: The values in ( ) are for reference only.

W3-7-16
UNDERCARRIAGE / Upper and Lower Rollers
Lower Roller

426

C A 390

W144-03-05-004

Unit: mm (1 mm = 0.03937 in)


Item Standard Allowable Limit Remedy
A: Roller (Outer Dia.) 330 300 Replace
B: Tread Interval (Outer Dia.) 316 (350) Replace
-0.085
C: Axle (Outer Dia.) 145 -0.125 (144.2) Replace
-0.1
D: Bushing (Flange Thickness) 15 -0.2 (13.5) Replace
NOTE: The values in ( ) are for reference only.

W3-7-17
UNDERCARRIAGE / Upper and Lower Roller
(Blank)

W3-7-18
UNDERCARRIAGE / Track
REMOVAL AND INSTALLATION OF TRACK
Track Wooden Block Side Frame
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
1. Set a wooden block between the side frame and W146-03-09-006

the track.
NOTE: Size of wooden block (Reference)
L 600 mm (23.6 in), W 300 mm (11.8 in), H
430 mm (16.9 in)
1
CAUTION: The pressure inside the adjuster
cylinder is high. As valve (1) may fly out and
the highly pressurized grease may spout out,
do not loosen valve (1) quickly and/or
excessively. It is enough to loosen valve (1)
by 1 to 1.5 turns.
Keep body parts and face away from valve (1),
and loosen valve (1) carefully. Do not loosen
grease fitting (2). 2 W18C-03-05-001

2. Loosen valve (1) in the adjuster cylinder. Drain


grease and loosen the track.
: 24 mm
NOTE: Operate the machine in reverse with valve 6
3
(1) loosened and loosen the track more.
4
3. Place a container for hydraulic oil under stop valve
(6) of accumulator (3).

4. Remove plug (5) from stop valve (6) of


accumulator (3). 5 W18C-03-05-002

: 9 mm

W3-8-1
UNDERCARRIAGE / Track

CAUTION: Do not open handle (4) quickly as


high-pressure hydraulic oil in accumulator (3)
6
may gush out. Keep body parts and face away 3
from handle (4) and open handle (4) carefully.
4

W18C-03-05-002

5. Open handle (4) and drain hydraulic oil from


accumulator (3). 8
7
6. Close handle (4).
NOTE: If starting the engine and operating the
travel lever with handle (4) open, hydraulic 9
oil gushes out from stop valve (6).

W142-03-07-001

7. Extend lock pin (9). Remove lock pin (9) from


master pin (7).
: 46 mm

8. Remove master pin (7) from track link (8) by using


a bar and a hammer. Remove track link (8).

9. Raise the machine. Place a stand under the track


frame and support the machine. W18K-03-07-001

CAUTION: Track weight: 8640 kg (19100 lb) Wooden Block Side Frame
Front
10. Remove the track from the bottom of the side
frame.
Front Idler

W146-03-09-003

W3-8-2
UNDERCARRIAGE / Track
Installation
CAUTION: Track weight: 8640 kg (19100 lb) Side Frame Wooden Block 10

IMPORTANT: Check the direction of the track. Front


Face the casting number of the shoe
to the inside of the side frame.
1. Set a wooden blocks on the side frame. Raise the
machine.
NOTE: Size of wooden block (Reference)
L 600 mm (23.6 in), W 300 mm (11.8 in), H W146-03-09-004

430 mm (16.9 in)

10
Forward

2. Set the track under the side frame. Lower the Front
machine on the track. Hoist the travel device (10)
side of the track. Mesh the claws of the track with
travel device(10).

3. Start the engine and slowly operate the travel


W146-03-09-005
lever forward. Wind the track while rotating travel
device (10).
11 8
4. Install and tighten chain blocks (11, 12) to the joint
part of the track. Tighten them at the opposite side
in the same way.

CAUTION: When aligning the master pin (7) 7


hole on track link (8), do not insert the fingers
into the hole.

5. Align the master pin (7) hole on track link (8) while
adjusting chain blocks (11, 12). Install master pin
(7) by using a bar and a hammer. 12 W18C-03-08-001

W3-8-3
UNDERCARRIAGE / Track
6. Install lock pin (9) master pin (7) by using a
hammer.
Bend and secure lock pin (9). 7 8

W142-03-07-001

7. Install plug (5) to stop valve (6).


: 9 mm 6
: 30 N m (3 kgf m, 21.5 lbf ft)

5 W18C-03-05-002

1
8. Tighten valve (1) of the adjuster cylinder.
: 24 mm
: 147 N m (15 kgf m, 111 lbf ft)

9. Raise the machine. Turn the track forward and


reverse by two turns.

2 W18C-03-05-001
10. Turn the track reverse by 1/4 turn.
NOTE: Turn the track in reverse direction so that
the track sag faces downward.

11. Add grease through grease fitting (2) and adjust


the track tension.
Track sag specifications (A): 570 to 640 mm (22.4
to 25.2 in)
NOTE: Clean the side frame and the track before
measuring the track tension.
A

W18K-03-08-001

W3-8-4
UNDERCARRIAGE / Track
STRUCTURE OF TRACK

1 2 3

7 6 5 4

8 9 5 4

W18K-03-08-002

12 11 10

1 - Track Link 4 - Lock Pin 7 - Master Bushing 10 - Bolt


2 - Master Track Link 5 - Master Pin 8 - Nut 11 - Washer
3 - Bushing 6 - Collar 9 - Shoe 12 - Pin

W3-8-5
UNDERCARRIAGE / Track
MAINTENANCE STANDARD

W18K-03-08-003
350

Unit: mm (1 mm = 0.03937 in)


Item Standard Allowable Limit Remedy
A: Shoe Height 20 0 Replace
B: Link Height 197 186.6 Replace
C: Link Thickness 84 (70) Replace
+0.05
D: Link Pin Outer Diameter 70.51 0 (64) Replace
E: Master Pin Outer Diameter 70+0.030 (66) Replace
+0.5
F: Bushing Outer Diameter 110 0 100.3 Replace
+0.5
F’: Bushing Inner Diameter 71.2 0 (82) Replace
G: Link Pitch *1270 *1296.5 Replace
*: The dimension of four links.
NOTE: The values in ( ) are for reference.

W3-8-6
UNDERCARRIAGE / Accumulator
REMOVAL AND INSTALLATION OF AC-
CUMULATOR

IMPORTANT: Bleed air from the hydraulic oil tank 1


before doing any work. (Refer to
BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

Removal
CAUTION: The pressure Inside of adjuster
cylinder is high. As valve (1) may fly out and
the highly pressurized grease may spout out, 2 W18C-03-05-001
do not loosen valve (1) quickly and/or exces-
sively. It is enough to loosen valve (1) by only
one turn.
Keep body parts and face away from valve
(1) and loosen valve (1) carefully. Do not
loosen grease fitting (2). 6
3
1. Loosen valve (1) in the adjuster cylinder and 4
drain grease. Loose track as well.
: 24 mm

2. Place a container for hydraulic oil under stop


valve (6) of accumulator (3).
W18C-03-05-002
5
3. Remove plug (5) from stop valve (6) of accumu-
lator (3).
: 9 mm

CAUTION: Do not open handle (4) quickly as


high-pressure hydraulic oil in accumulator
(3) may gush out. Keep body parts and face
away from stop valve (6) and open stop valve
(4) carefully.

4. Open handle (4) and drain hydraulic oil from ac-


cumulator (3).

W3-9-1
UNDERCARRIAGE / Accumulator
5. Disconnect hose (7) from accumulator (3). Cap 7
the open ends. Attach an identification tag onto
the hose for assembling.
: 36 mm

CAUTION: Accumulator (3) weight:


95 kg (210 lb) 8

6. Hold accumulator (3) by using a chain block. 9


Remove nuts (9) (8 used) and U-bolts (8) (2 10
used) from accumulator (3). Remove accumula-
tor (3) from bracket (10).
: 24 mm
3
M144-07-109

W3-9-2
UNDERCARRIAGE / Accumulator
Installation 7
CAUTION: Accumulator (3) weight:
95 kg (210 lb)
1. Hoist accumulator (3) by chain block. Install ac-
cumulator (3) to bracket (10) with U-bolts (8) (2
used) and nuts (9) (8 used).
: 24 mm 8
: 210 N m (21.5 kgf m, 156 lbf ft)
9
2. Connect hose (7) to accumulator (3). 10
: 36 mm
: 175 N m (18 kgf m, 129 lbf ft)

3. Close handle (4). Install plug (5). 3


M144-07-109
: 9 mm
: 30 N m (3 kgf m, 21.5 Ibf·ft)

4. Tighten valve (1) in the adjuster cylinder.


: 24 mm
4
: 147 N m (15 kgf m, 108 Ibf·ft)

5. Start the engine. Operate the travel lever in the


forward direction. Fill the adjuster cylinder with
hydraulic oil. At this time, a load is applied so that W18C-03-05-002
2 5
the pressure of 12.7 MPa (130 kgf/cm , 1850 psi)
or more occurs in a travel circuit.
1
6. Add grease through grease fitting (2) and adjust
the track sag. (Refer to REMOVE AND INSTAL-
LATION OF TRACK on W3-8-1.)

2 W18C-03-05-001

W3-9-3
UNDERCARRIAGE / Accumulator
DISASSEMBLY OF ACCUMULATOR

26

25

24
23

22

21
1

20

19

18

17
16
2
15

3
14
4

13 7

10

11

12

W118-03-08-003

1 - Shell 8- Backup Ring 15 - O-Ring 22 - O-Ring


2 - Oil Port Assembly 9- Spacer 16 - Gas Plug 23 - Gas Valve
3 - Gasket 10 - Lock Nut 17 - Retaining Ring 24 - Cap
4 - Bleed Plug 11 - O-Ring 18 - Washer 25 - Wire
5 - Retaining Ring 12 - Bushing 19 - O-Ring 26 - Valve Guard
6 - Washer 13 - Bladder 20 - Backup Ring
7 - O-Ring 14 - Valve Stem 21 - Ring

W3-9-4
UNDERCARRIAGE / Accumulator
Disassembly of Accumulator
7. Remove backup ring (20), O-ring (19) and
washer (18) from gas plug (16).
CAUTION: As the accumulator is charged
with high pressure gas, do not weld or torch- 8. Turn over shell (1). (Face the oil port assembly
cut it, nor expose the accumulator to the (2) side upward.)
flame.
9. Remove bleed plug (4) from oil port assembly (2).
1. Before disassembling, clean the outer surface of Remove lock nut (10) from oil port assembly (2)
the accumulator. Cut and remove wire (25). Re- by using a hooked wrench.
move valve guard (26) from valve stem (14).
10. Remove spacer (9) from oil port assembly (2).
2. Remove cap (24) from valve stem (14) of bladder
(13). 11. Remove backup ring (8), O-ring (7) and washer
(6) from oil port assembly (2).
IMPORTANT: Before installing the charge valve,
turn handle (A) counterclockwise 12. Put the fingers in shell (1). Pick up and remove
and handle (B) clockwise. retaining ring (5) from shell (1) by fingers.
3. Install the charge valve (Parts Number: 4032854) 13. Remove oil port assembly (2) from shell (1).
to valve stem (14). Turn handle (A) clockwise.
Carefully turn handle (B) counterclockwise and 14. Put the fingers in shell (1) through the hole on the
release nitrogen gas from bladder (13) until the oil port assembly (2) side and pick up bladder
gauge shows zero pressure. (13) by fingers. Remove bladder (13) from shell
(1).
A
15. Remove retaining ring (17), gas plug (16) and
O-ring (15) from valve stem (14).
B

Charge Valve

Accumulator W115-03-08-029

4. Remove the charge valve from valve stem (14).

5. Carefully loosen gas valve (23) and remove gas


valve (23) from valve stem (14).

6. Remove ring (21) from valve stem (14) by using


a hooked wrench.

W3-9-5
UNDERCARRIAGE / Accumulator
ASSEMBLY OF ACCUMULATOR

12 11 2 10 9 5 13 1 17 16 21 14 25 26

3 4 8 7 6 15 18 19 20 22 23 24
W118-03-08-002

1 - Shell 8- Backup Ring 15 - O-Ring 22 - O-Ring


2 - Oil Port Assembly 9- Spacer 16 - Gas Plug 23 - Gas Valve
3 - Gasket 10 - Lock Nut 17 - Retaining Ring 24 - Cap
4 - Bleed Plug 11 - O-Ring 18 - Washer 25 - Wire
5 - Retaining Ring 12 - Bushing 19 - O-Ring 26 - Valve Guard
6 - Washer 13 - Bladder 20 - Backup Ring
7 - O-Ring 14 - Valve Stem 21 - Ring

W3-9-6
UNDERCARRIAGE / Accumulator
Assembly of Accumulator
12. Install gasket (3) and bleed plug (4) to oil port
1. Install O-ring (15), gas plug (16) and retaining assembly (2).
ring (17) to valve stem (14).
13. Turn over shell (1). (Face the valve stem (14)
2. Insert the head of a pulling chain into shell (1) side upward.)
through the hole on the valve stem (14) side.
Then, draw out the head of the pulling chain from IMPORTANT: After charging with nitrogen gas,
the opposite side. smear gas valve (23) with soap bub-
Install the head of the pulling chain to valve stem ble and check gas leakage.
(14). Insert bladder (13) and valve stem (14) into
shell (1). 14. Install gas valve (23) with O-ring (22) attached to
valve stem (14). Charge bladder (13) with nitro-
gen gas by using a charge valve. (Refer to
Charging Nitrogen Gas on W3-9-10.)

Head

Charge Valve

Pulling Chain

Nitrogen Gas
W145-03-09-003
Accumulator Cylinder
W18B-03-10-001

3. Remove valve stem (14) from shell (1) by using


the pulling chain. 15. Install cap (24) to gas valve (23).

4. Install washer (18), O-ring (19) and backup ring 16. Install valve guard (26) to valve stem (14).
(20) to gas plug (16). Tighten valve guard (26).

5. Tighten ring (21) to gas plug (16) by using a 17. Connect wire (25) to valve guard (26) and ring
hooked wrench. (21).

6. Turn over shell (1). (Face the oil port assembly


(2) mounting side upward.)

7. Install oil port assembly (2) to shell (1).

8. Pick up and insert retaining ring (5) into shell (1)


by fingers.

9. Remove oil port assembly (2). Align oil port as-


sembly (2) with retaining ring (5).

10. Install washer (6), O-ring (7) and backup ring (8)
to the groove on oil port assembly (2).

11. Install spacer (9) and lock nut (10) to oil port as-
sembly (2).
Tighten lock nut (10) by using a hooked wrench.

W3-9-7
UNDERCARRIAGE / Accumulator