Hitachi ZX200-5G Workshop Manual Download Page 159

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Group 4 Engine

SECTION 3 UPPERSTRUCTURE

W3-4-1-3

11. Remove bolt (14) and washer (15). Disconnect

terminal (16).

: 17 mm

12. Remove bolt (17) and washer (18). Disconnect

terminal (19).

: 17 mm

13. Remove bolt (20) and washer (21). Disconnect

terminal (22).

: 17 mm

CAUTION: Battery (24) weight: 28 kg (62 lb)

14. Remove bolts, washers (23) (2 used). Remove

batteries (24) (2 used).

: 17 mm

15. Open stoppers (25) (2 used). Remove net (26).

16. Remove pins (27) (2 used). Remove cover (28).
17. Remove bolts, washers (29, 30) (2 used for each).

Remove cover (31).

: 17 mm

18. Remove bolts, washers (32) (2 used). Remove cover

(33).

: 17 mm

19. Place a container under hose (34). Loosen cock (35).

Drain off coolant.

NOTE: Coolant amount: 26 L (6.87 US gal)

Detail A

WDCD-03-04-006

WDCD-03-04-005

WDCD-03-04-004

Summary of Contents for ZX200-5G

Page 1: ...tachi c m com 200 5G 200LC 5G 210H 5G 210LCH 5G 210K 5G 210LCK 5G ZX Service Manual consists of the following separate Part No Technical Manual Operational Principle Vol No TODCD EN Technical Manual Troubleshooting Vol No TTDCD EN Workshop Manual Vol No WDCD EN Engine Manual Vol No EDCD EN WDCD EN 00 PART NO Hydraulic Excavator Workshop Manual ...

Page 2: ......

Page 3: ...T 1 3 5 T Technical Manual 1 Section Number 3 Group Number 5 Consecutive Page Number for Each Group If you have any questions or comments at if you found any errors regarding the contents of this manual please contact using Service Manual Revision Request Form at the end of this manual Note Do not tear off the form Copy it for usage Publications Marketing Product Support Hitachi Construction Machi...

Page 4: ... situation which if not conformed to the instructions could result in damage to the machine fNOTE Indicates supplementary technical information or know how Units Used Quantity To Convert From Into Multiply By Length mm in 0 03937 mm ft 0 003281 Volume L US gal 0 2642 L US qt 1 057 m3 yd3 1 308 Weight kg lb 2 205 Force N kgf 0 10197 N lbf 0 2248 Torque N m kgf m 0 10197 Pressure MPa kgf cm2 10 197 ...

Page 5: ...ation controller GSM is a type of wireless communication system is used in more than on 100 countries around Europe and Asia and becomes the factual global standards of the mobile telephone GPS Global Positioning System Global positioning system CAN Controller Area Network CAN communication CAN is a serial communications protocol internationally standardized by ISO International Organization for S...

Page 6: ...SYMBOL AND ABBREVIATION SY 2 Blank ...

Page 7: ...otentially 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 do not use any of the designated signal words above after ...

Page 8: ...sed by unauthorized modifications will void Hitachi Warranty Policy Never attempt to modify or disassemble the inlet exhaust parts and the muffler filter Avoid giving shocks on the muffler filter by striking elements with other objects or dropping the elements Failure to do so may affect the exhaust gas purifying device possibly damaging it or lowering its performance Do not use attachments and or...

Page 9: ...ctors ambulance service hospital and fire department posted near your telephone Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job You may need A hard hat Safety shoes Safety glasses goggles or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask Be sure to wear the correct equipment and clothing fo...

Page 10: ...s to protect against objectionable or uncomfortably loud noises Inspect Machine Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury In the walk around inspection be sure to cover all points described in the Inspect Machine Daily Before Starting section in the operator s manual SA 434 SAFETY SA 4 SA 435 ...

Page 11: ... them in their specified locations Avoid storing transparent bottles in the cab Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight possibly starting a fire Refrain from listening to the radio or using music headphones or mobile telephones in the cab while operating the machine Keep all flammable objects and or explosives away from the machine After ...

Page 12: ...ith tools in your hands Adjust the Operator s Seat A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations The seat should be adjusted whenever changing the operator for the machine The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back If not mo...

Page 13: ... the LOCK position Turn the key switch OFF to stop the engine Before leaving the machine close all windows doors and access covers and lock them up Fasten Your Seat Belt If the machine should overturn the operator may become injured and or thrown from the cab Additionally the operator may be crushed by the overturning machine resulting in serious injury or death Prior to operating the machine thor...

Page 14: ...ws doors and covers are securely locked Check the mirrors and the monitor in the CAB for problems If there is replace the problem part s or clean the mirror camera and the monitor Refer to Rear View Monitor section on the cleaning of the camera and the monitor in the operator s manual Operate Only from Operator s Seat Inappropriate engine starting procedures may cause the machine to runaway possib...

Page 15: ... starts Jump starting is a two person operation Never use a frozen battery Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine Keep Riders off Machine Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine Only the operator should be on the machine Keep riders off Riders also obstruct ...

Page 16: ...ine Clear all persons and obstacles from area of operation and machine movement Always beware of the surroundings while operating When working in a small area surrounded by obstacles take care not to hit the upperstructure against obstacles When loading onto trucks bring the bucket over the truck beds from the rear side Take care not to swing the bucket over the cab or over any person SAFETY SA 10...

Page 17: ... edges and road shoulders as necessary Keep the machine well back from the edges of excavations and road shoulders When working on an incline or on a road shoulder employ a signal person as required Confirm that your machine is equipped with 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 ...

Page 18: ...ound first using large pieces of steel plates strong and firm enough to easily support the machine Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes Prevent machine tipping over from occurring When operating on rough terrain or on slopes Reduce the engine speed Select slow travel speed mode Operate the machine slowly and be cautious with mac...

Page 19: ...el obey the signal person s directions Confirm Direction of Machine to Be Driven Incorrect travel pedal lever operation may result in serious injury or death Before driving the machine confirm the position of the undercarriage in relation to the operator s position If the travel motors are located in front of the cab the machine will move in reverse when travel pedals levers are operated to the fr...

Page 20: ...sibly resulting in serious injury or death Never attempt to ascend or descend 35 degrees or steeper slopes Be sure to fasten the seat belt When driving up or down a slope keep the bucket facing the direction of travel approximately 0 2 to 0 3 m A above the ground If the machine starts to skid or becomes unstable immediately lower the bucket to the ground and stop Driving across the face of a slope...

Page 21: ...hine forward towards the idlers An arrow mark seal is stuck on the inside surface of the side frame to indicate the machine front direction Select a travel route that is as flat as possible Steer the machine as straight as possible making small gradual changes in direction Before traveling on them check the strengths of bridges and road shoulders and reinforce if necessary Use wood plates in order...

Page 22: ...d Turn the auto idle switch OFF and the power mode switch E or P 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 machin...

Page 23: ... BEFORE MOVING MACHINE USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED ALWAYS KEEP THE SIGNAL PERSON IN VIEW Use hand signals which conform to your local regulations when work conditions require a signal person No machine motions shall be made unless signals are clearly understood by both signalman and operator Learn the meanings of all flags signs and markings used on the job and c...

Page 24: ...r from the area of operation and machine movement Before operating the machine set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area 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 SAFETY...

Page 25: ...R FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT The danger of tipping is always present when operating on a grade possibly resulting in serious injury or death To avoid tipping Be extra careful before operating on a grade Prepare machine operating area flat Keep the bucket low to the ground and close to the machine Reduce operating speeds to avoid tipping or slipping Avoid changing direction...

Page 26: ...d water lines If a fiber optic cable should be accidentally severed do not look into the end Doing so may result in serious eye injury Contact your local diggers hot line if available in your area and or the utility companies directly Have them mark all underground utilities Operate with Caution If the front attachment or any other part of the machine hits against an overhead obstacle such as a br...

Page 27: ...he area that could cause any person on it to be affected by electric shock Keep all bystanders or co workers away from the site Precautions for Lightning The machine is vulnerable to lightning strikes In the event of an electrical storm immediately stop operation and lower the bucket to the ground Evacuate to a safe place far away from the machine After the electrical storm has passed check all of...

Page 28: ... well away from the load Never move a load over a person s head Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground Never attach a sling or chain to the bucket teeth They may come off causing the load to fall Protect Against Flying Debris If flying debris hit eyes or any other part of the body serious injury may result Guard again...

Page 29: ...artments Handle Fluids Safely Avoid Fires Handle fuel with care it is highly flammable If fuel ignites an explosion and or a fire may occur possibly resulting in serious injury or death Do not refuel the machine while smoking or when near open flame or sparks Always stop the engine before refueling the machine Fill the fuel tank outdoors All fuels most lubricants and some coolants are flammable St...

Page 30: ...4 Always select the slow speed mode with the travel mode switch 5 Never load or unload the machine onto or off a truck or trailer using the front attachment functions when driving up or down the ramp 6 Never steer the machine while on the ramp If the traveling direction must be changed while the ramp unload the machine from the ramp reposition the machine on the ground then try loading again 7 The...

Page 31: ...off lever to the LOCK position 10 Allow the engine to cool If a maintenance procedure must be performed with the engine running do not leave the machine unattended If the machine must be raised maintain a 90 to 110 angle between the boom and arm Securely support any machine elements that must be raised for service work Inspect certain parts periodically and repair or replace as necessary Refer to ...

Page 32: ...ine attach a Do Not Operate tag on the control lever This tag is available from your authorized dealer 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 cin...

Page 33: ...GREASE FITTING or VALVE ASSEMBLY Do not attempt to remove grease fitting securing cover As pieces may fly off be sure to keep body and face away from valve Never attempt to disassemble the track adjuster Inadvertent disassembling of the track adjuster may cause the parts such as a spring to fly off possibly resulting in severe personal injury or death Travel reduction gears are under pressure As p...

Page 34: ...ping hot water or steam can cause severe burns To avoid possible injury from hot spraying water DO NOT remove the radiator cap until the engine is cool When opening turn the cap slowly to the stop Allow all pressure to be released before removing the cap The hydraulic oil tank is pressurized Again be sure to release all pressure before removing the cap Hot fluids and surfaces Engine oil gear oil a...

Page 35: ...n severe burns gangrene or otherwise serious injury or death Avoid High Pressure Fluids Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury blindness or death Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard ta...

Page 36: ...Never install bent or damaged lines pipes or hoses Replace fuel hoses and hydraulic hoses periodically even if there is no abnormality in their external appearance 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...

Page 37: ...from entering However flammables which have passed through the wire screen may cause fires Check and clean the machine every day and immediately remove accumulated flammables Check Key Switch If a fire breaks out failure to stop the engine will escalate the fire hampering fire fighting Always check key switch function before operating the machine every day 1 Start the engine and run it at slow idl...

Page 38: ...nt or rear window panes with the emergency evacuation hammer to escape from the cab Refer to the explanation pages on the Emergency Evacuation Method in the operator s manual Beware of Exhaust Fumes Prevent asphyxiation Engine exhaust fumes can cause sickness or death If you must operate in a building be sure there is adequate ventilation Either use an exhaust pipe extension to remove the exhaust ...

Page 39: ...re starting welding Only qualified personnel should perform welding Never allow an unqualified person to perform welding Grinding on the machine may create fire hazards Store flammable objects in a safe place before starting grinding After finishing welding and grinding recheck that there are no abnormalities such as the area surrounding the welded area still smoldering SA 818 SAFETY SA 33 ...

Page 40: ...Containing Flammable Fluids Do not weld or flame cut pipes or tubes that contain flammable fluids Clean them thoroughly with nonflammable solvent before welding or flame cutting them Precautions for Handling Accumulator and Gas Damper High pressure nitrogen gas is sealed in the accumulator and the gas damper Inappropriate handling may cause explosion possibly resulting in serious injury or death S...

Page 41: ...ilicon Dust and Other Contamination Take care not to inhale dust produced in the work site Inhalation of asbestos fibers may be the cause of lung cancer Inhalation of silicon dust or other contamination may cause sickness Depending on the work site conditions the risk of inhaling asbestos fiber silicon dust or other contamination may exist Spray water to prevent asbestos fibers silicon dust or oth...

Page 42: ...ll terminals Connect terminals to the correct electrical poles Failure to do so may cause damage to the electrical parts or fire Battery electrolyte is poisonous If the battery should explode battery electrolyte may be splashed into eyes possibly resulting in blindness Be sure to wear eye protection when checking electrolyte specific gravity Service Air Conditioning System Safely If spilled onto s...

Page 43: ... products used with your machine Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology Potentially harmful waste used with HITACHI equipment includes such items as oil fuel coolant brake fluid filters and batteries Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not p...

Page 44: ...s practice Precautions for Communication Terminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices Inquire the device manufacturer for electrical wave disturbance upon using an electronic device near the communication terminal SAFETY SA 38 ...

Page 45: ...erson in charge stop the communication terminal equipment from functioning completely and confirm that it is not emitting electrical waves Specific Absorption Rate SAR measured by 10 g per unit of communication terminal equipments E GSM900 0 573 W Kg 914 80 MHz DCS 1800 0 130 W Kg 1710 20 MHz WCDMA Band I 0 271 W Kg 1950 00 MHz This data was measured by having each type of communication terminal e...

Page 46: ...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 ...

Page 47: ...oup 5 Pressure Release Procedure Group 6 Preparation SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Group 2 Undercarriage Group 3 Front Attachment SECTION 3 UPPERSTRUCTURE Group 1 Cab Group 2 Counterweight Group 3 Main Frame Group 4 Engine Group 5 Radiator Assembly Group 6 Hydraulic Oil Tank Group 7 Fuel Tank Group 8 Pump Device Group 9 Control Valve Group 10 Swing Device Group 11 Pilot Val...

Page 48: ... 5 Travel Device Group 6 Signal Control Valve Group 7 Others Upperstructure Group 8 Others Undercarriage TECHNICAL MANUAL Operational Principle TECHNICAL MANUAL Troubleshooting SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test Group 6 Adjustment SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group ...

Page 49: ...W1 2 1 4 Group 3 Painting Painting W1 3 1 1 Group 4 Bleeding Air Bleeding Air from Hydraulic Oil Tank W1 4 1 1 Bleeding Air from Hydraulic System W1 4 1 2 Bleeding Air from Fuel System W1 4 1 3 Group 5 Pressure Release Procedure Hydraulic Circuit Pressure Release Procedure W1 5 1 1 Group 6 Preparation Preparation before Inspection and Maintenance W1 6 1 1 SECTION 1 GENERAL CONTENTS ...

Page 50: ...DCDW 1 2 Blank ...

Page 51: ...ainers for draining fluids Use matching marks for easier reassembling if necessary Be sure to use the specified special tools when instructed If a part or component cannot be removed after removing its securing nuts and bolts do not attempt to remove it forcibly Find the cause s then take the appropriate measures to remove it Orderly arrange disassembled parts Mark and tag them if necessary Store ...

Page 52: ...an the floating seal and seal mounting bores with cleaning solvent Use a wire brush to remove mud rust or dirt from seal mounting bores After cleaning thoroughly dry parts with compressed air Clean seal ring 1 and O ring 2 mounting bores Check the bore surface for scuffing or scoring by touching the surface with finger After installing the floating seal check that O ring 2 is not twisted and that ...

Page 53: ...eep the lifted load balanced When lifting a load using an eyehole be sure to eliminate any gaps between the sling and load Refer to the right illustration Reduce the load weight so that it is less than 80 of the sling breaking force Avoid using twisted bound connected or hitched slings Do not place any object on twisted or bent slings Refer to the right illustration When removing the slings from u...

Page 54: ...sling for any damage corresponding to examples shown to the right If any damage is found cut and discard the sling Even if no damage is found do not use slings older than 7 years Damaged Appearance a a a e f b b c c g d a Broken Sewing Thread a Broken Sewing Thread e Separation of Belt b Scuffing f Scoring b Scuffing c Fuzz d Broken Sewing Thread c Fuzz g Broken Warp a Broken Sewing Thread W162 01...

Page 55: ...ation Allowable errors will be indicated if necessary Allowable Limit 1 Normal machine performance cannot be accomplished after exceeding this limit 2 Repair or adjustment is difficult after exceeding this limit 3 Repair or adjustment is impossible after exceeding this limit Therefore in consideration of operation efficiency and maintenance expense proper maintenance shall be carried out before re...

Page 56: ...Group 1 Precautions for Disassembling and Assembling SECTION 1 GENERAL W1 1 1 6 Blank ...

Page 57: ...ghten the correct bolts correctly when assembling the machine or components Specified Tightening Torque Chart Bolt Dia Wrench Size Hexagon Wrench Size Socket Bolt N m kgf m lbf ft N m kgf m lbf ft N m kgf m lbf ft M6 10 5 3 to 4 0 3 to 0 4 2 2 to 3 M8 13 6 30 3 22 20 2 15 10 1 7 4 M10 17 8 65 6 5 48 50 5 37 20 2 15 M12 19 10 110 11 81 90 9 66 35 3 5 26 M14 22 12 180 18 133 140 14 103 55 5 5 41 M16...

Page 58: ...ttom of bolt hole Also the bolts that are too short cannot develop sufficient tightening force The torque given in the chart on the previous page are for general use only however a different torque is given for a specific application Use the specified torque Clean the nut and bolt threads and remove dirt or corrosion before installing Tightening Order When tightening two or more bolts tighten them...

Page 59: ...ified torque Do not use air wrenches Using an impact wrench often causes tightening of one bolt fully before tighten the others resulting in damage to O rings or uneven tightening of bolts Nut and Bolt Locking Lock Plate IMPORTANT Do not reuse the lock plates Do not try to bend the same point twice Split Pin IMPORTANT Do not turn in the loosening direction in order to align the grooves and holes o...

Page 60: ...Tighten union nut 3 to the specifications Scratches or other damage to sealing surfaces 4 or 5 will cause oil leakage at the joint Take care not to damage them when connecting disconnecting Description Wrench Size mm Tightening Torque Union Nut N m kgf m lbf ft 30 male 17 25 2 5 18 19 30 3 22 22 40 4 30 27 80 8 59 32 140 14 103 36 180 18 133 41 200 20 148 50 270 27 200 55 380 38 280 60 380 38 280 ...

Page 61: ...w one when reinstalling Before tightening union nut 9 confirm that O ring 6 is seated correctly in O ring groove 8 Tightening union nut 9 with O ring 6 displaced will damage O ring 6 resulting in oil leakage Do not damage O ring groove 8 of adapter 7 or sealing surface 10 on the hose side Damage to O ring 6 may cause oil leakage If union nut 9 is found to be loose causing oil leakage do not tighte...

Page 62: ...edure Remove the hose by rotating socket ring 1 fully counterclockwise and then pulling it Because no check function is attached inside be careful that oil flows out Cap the removed hoses using special plug dCAUTION When disconnecting do not damage joint surface When disconnecting clean the joint part and thoroughly wipe off the cleaning solution to prevent any foreign material from entering Compl...

Page 63: ...pply the seal tape around threads in order to leave one to two pitch threads uncovered Wrap the seal tape in the same direction as the threads Low Pressure Hose Clamp Tightening Low pressure hose clamp tightening torque differs depending on the type of clamp T Bolt Type Band Clamp 4 5 N m 0 45 kgf m 3 3 lbf ft Worm Gear Type Band Clamp 6 to 7 N m 0 6 to 0 7 kgf m 4 4 to 5 2 lbf ft R a c f d b G 30...

Page 64: ...e or separation of fitting Utilize the print marks on hoses when installing in order to prevent hose from being kinked Take necessary measures to protect hoses from rubbing against each other If the hoses rub against each other wear to the hoses may result and lead to hose rupture Take care so that the hoses do not come into contact with the moving parts or sharp objects a a Rubbing Against Each O...

Page 65: ...d Final painted color Inside and outside surface of cab High Grade Black Shaded area on cab Only the left side 11 Shining Silver Right window beam Charcoal Black Seat stand N2 0 Black Lever Travel pilot shut off N2 5 Warm Gray Engine cover 8 High Grade Black Tool box 6 Tool box cover 4 High Grade Black Cover 2 Step 3 High Grade Black Handrail on upperstructure right side 1 High Grade Black Mirror ...

Page 66: ...er hinge swing position shining silver Handrail on Upperstructure 1 Right Side Cover 2 Step 3 Tool Box Cover 4 Mirror Stay 5 Tool Box 6 Decal TAXI Yellow 7 Engine Cover 8 Camera Cover 9 Decal TAXI Yellow 10 Shaded Area Shining Silver 11 WDCD 01 03 001 WDCD 01 03 002 WDAA 01 03 003 ...

Page 67: ...ly Cap 2 may fly off by internal pressure Release any remaining pressure before removing cap 2 Preparation 1 Park the machine on a solid and level surface Set the front attachment in position for checking hydraulic oil level 2 Stop the engine Push air bleed button 1 of hydraulic oil tank 3 and bleed air from hydraulic oil tank 3 3 Remove cap 2 of hydraulic oil tank 3 4 Install vacuum pump a to the...

Page 68: ...ccumulated inside of the motor and if the engine starts in lacking of hydraulic oil the motor may be damaged Bleeding Air from Travel Motor Swing Motor Remove the air bleed plug top from the travel motor and swing motor Fill the motor case with hydraulic oil IMPORTANT If air is accumulated inside of the cylinder and if the cylinder is operated suddenly in lacking of hydraulic oil the seal may be d...

Page 69: ...e minutes Therefore the fuel solenoid pump operates and starts to bleed air 3 While holding the key switch in the ON position reciprocate fuel main filter priming pump 2 After air is bled from the main filter return priming pump 2 to the original position 4 After the main filter is filled with fuel hold the key switch in the ON position for 30 seconds 5 Start the engine Check the fuel system for f...

Page 70: ... 4 After tightening air bleed plug 4 reciprocate priming pump 2 approx 150 strokes 5 Wipe off any spilled fuel 6 Start the engine Check that no fuel leaks are present If the engine does not start repeat the above procedures from step 1 Air Bleeding by Cranking Bleed air from the fuel system after changing the common rail 1 Bleed air until the engine supply pump entrance enough according to the abo...

Page 71: ...system has cooled Hot steam may spout out and cause severe burns Wait until coolant cools and loosen the cap slowly Release all pressure and remove the cap Preparation 1 Park the machine on a solid and level surface Set the front attachment in position for checking hydraulic oil level 2 Stop the engine Remove the radiator cap ...

Page 72: ...Group 4 Bleeding Air SECTION 1 GENERAL W1 4 1 6 Blank ...

Page 73: ...stop switch 2 ON fNOTE Perform step 1 and step 2 and set the key switch to the START position Although the starter rotates the engine does not start IMPORTANT Battery will deplete Operate the key switch for short period 3 With the key switch set in the START position operate the control lever in order to release any pressure in the hydraulic circuit 4 to 5 times 4 Return pilot shut off lever 1 to ...

Page 74: ...Group 5 Pressure Release Procedure SECTION 1 GENERAL W1 5 1 2 Blank ...

Page 75: ...3 Turn the auto idle switch OFF 4 Set the engine control dial to the slow idle position Run the engine at slow idle speed without load for five minutes 5 Set the key switch to the OFF position Stop the engine Remove the key from the key switch If maintenance should be performed with the engine running do not leave the machine unattended 6 Set pilot shut off lever 1 to the LOCK position 7 Before pe...

Page 76: ...Group 6 Preparation SECTION 1 GENERAL W1 6 1 2 Blank ...

Page 77: ...MEMO ...

Page 78: ...MEMO ...

Page 79: ...2 2 2 1 Upper Roller W2 2 3 1 Lower Roller W2 2 3 2 Track W2 2 4 1 Group 3 Front Attachment Pin and Bushing W2 3 1 1 Side Cutter 2014503 2014504 W2 3 1 3 Point 4427919 W2 3 1 4 Standard Dimensions for Arm and Bucket Connection W2 3 1 5 Standard Dimensions for Arm and Boom Connection W2 3 1 6 Cylinder W2 3 2 1 SECTION 2 MAINTENANCE STANDARD CONTENTS ...

Page 80: ...DCDW 2 2 Blank ...

Page 81: ...erstructure SECTION 2 MAINTENANCE STANDARD Pump Device 1 3 4 9 2 5 6 7 8 10 Gear 1 Shaft 2 Gear 3 Shaft 4 Plunger 14 Used 5 Rotor 2 Used 6 Valve Plate Right Left 7 Pin 2 Used 8 Gear 9 Servo Piston 2 Used 10 WDCD 02 01 002 ...

Page 82: ... 5 4 0 213 3 8 0 150 2 Oil seal outer diameter d1 d2 of shafts 2 4 Unit mm in Standard Allowable Limit d1 45 1 77 44 8 1 76 d2 55 2 17 54 8 2 16 3 Clearance between plunger 5 and shafts 2 4 Unit mm in Standard Allowable Limit 0 058 0 002 0 4 0 016 4 Clearance between outer diameter a of plunger 5 and inner diameter D of rotor 6 Unit mm in Standard Allowable Limit D a 0 043 0 002 0 08 0 003 d2 T1 d...

Page 83: ...dard Allowable Limit D a 0 083 0 003 0 2 0 008 7 Clearance between inner diameter D of servo large chamber and outer diameter a of servo piston 10 Unit mm in Standard Allowable Limit D a 0 079 0 003 0 2 0 008 8 Clearance between inner diameter D of valve plate 7 and outer diameter a of pin 8 Unit mm in Standard Allowable Limit D a 0 051 0 002 0 3 0 012 b 5 b Connecting Rod c Small Diameter Side d ...

Page 84: ...Group 1 Upperstructure SECTION 2 MAINTENANCE STANDARD W2 1 1 4 Blank ...

Page 85: ...Group 1 Upperstructure SECTION 2 MAINTENANCE STANDARD W2 1 2 1 Swing Motor 3 1 2 Rotor 1 Plunger 9 Used 2 Friction Plate 3 Used 3 W178 02 11 153 ...

Page 86: ...r diameter d of plunger 2 and inner diameter D of rotor 1 Unit mm in Standard Allowable Limit D d 0 027 0 001 0 052 0 002 2 Clearance δ between plunger 2 and shoe a bottom Unit mm in Standard Allowable Limit 0 0 0 3 0 012 d 2 D D 1 2 a δ a Shoe W178 02 11 155 W178 02 11 156 W107 02 06 140 ...

Page 87: ...MAINTENANCE STANDARD W2 1 2 3 3 Shoe a thickness t Unit mm in Standard Allowable Limit 5 5 0 22 5 3 0 21 4 Friction plate 3 thickness t Unit mm in Standard Allowable Limit 2 0 0 08 1 8 0 07 t t a a Shoe 3 W178 02 11 157 W178 02 11 158 ...

Page 88: ...Group 1 Upperstructure SECTION 2 MAINTENANCE STANDARD W2 1 2 4 Blank ...

Page 89: ...Group 2 Undercarriage SECTION 2 MAINTENANCE STANDARD W2 2 1 1 Travel Motor 1 2 Rotor 1 Plunger 9 Used 2 WDCD 04 02 004 ...

Page 90: ...it 0 0 0 5 0 02 2 Clearance between outer diameter d of plunger 2 and inner diameter D of rotor 1 Unit mm in Standard Allowable Limit 0 03 0 001 0 08 0 003 D d 0 08 mm 0 003 in 3 Shoe a thickness t Unit mm in Standard Allowable Limit 6 0 0 236 5 6 0 220 ε 2 a Shoe D a 2 1 d t 2 a Shoe a W1V1 03 02 005 W1V1 03 02 005 W105 02 06 134 W105 02 06 135 ...

Page 91: ...D W2 2 1 3 Sprocket Unit mm in Standard Allowable Limit A 70 2 8 62 2 4 Build up welding and hand finishing B 80 3 3 2 75 3 3 0 C 119 7 4 7 114 7 4 5 C 644 6 25 4 D 190 0 7 5 fNOTE Values in are just for reference D B A C C W178 02 11 235 W178 02 11 236 ...

Page 92: ...Group 2 Undercarriage SECTION 2 MAINTENANCE STANDARD W2 2 1 4 Blank ...

Page 93: ...ild up welding and hand finishing B 159 6 26 C 500 19 7 488 19 2 D 538 21 2 E 19 0 75 25 0 98 Axle and Bushing Unit mm in Standard Allowable Limit Remedy Axle Outer Diameter 75 0 2 95 74 2 2 93 Replace Bushing Inner Diameter 75 0 2 95 76 2 99 Flange Thickness 2 0 08 1 2 0 05 fNOTE Values in are just for reference A E C D B W166 03 05 001 ...

Page 94: ...Group 2 Undercarriage SECTION 2 MAINTENANCE STANDARD W2 2 2 2 Blank ...

Page 95: ...dercarriage SECTION 2 MAINTENANCE STANDARD W2 2 3 1 Upper Roller Unit mm in Standard Allowable Limit Remedy A 84 3 3 Replace B 165 6 5 C 120 4 7 110 4 3 fNOTE Values in are just for reference C A B WDDE 02 02 001 ...

Page 96: ...elding and hand finishing or replace B 218 0 8 6 C 24 5 1 0 15 5 0 6 D 150 0 5 9 132 5 2 fNOTE Values in are just for reference Axle and Bushing Unit mm in Standard Allowable Limit Remedy Axle Outer Diameter 65 2 6 64 2 2 5 Replace Bushing Inner Diameter 65 2 6 66 0 2 6 Flange Thickness 2 0 08 1 2 0 05 fNOTE Values in are just for reference W157 03 06 003 ...

Page 97: ...finishing or replace B 105 4 1 98 3 9 fNOTE Values in are just for reference Grouser Shoe ZX210H 5G 210K 5G ZX210LCH 5G 210LCK 5G Unit mm in Shoe Size 600 mm Grouser Standard Allowable Limit Remedy A 219 8 6 Build up welding or replace B 10 0 39 C 26 1 02 18 0 71 ZX200 5G 200LC 5G Unit mm in Shoe Size 600 mm Grouser Standard Allowable Limit Remedy A 219 8 6 Build up welding or replace B 8 5 0 34 C...

Page 98: ...ndard Allowable Limit Remedy A 129 2 5 08 Replace B 38 7 1 52 41 7 1 64 C 59 2 32 54 2 13 fNOTE Values in are just for reference Master Pin Unit mm in Standard Allowable Limit Remedy A 203 7 99 Replace B 38 4 1 51 35 4 1 39 fNOTE Values in are just for reference W105 03 07 023 W105 03 07 021 ...

Page 99: ...rd Allowable Limit Remedy A 212 8 35 Replace B 38 1 50 35 1 4 fNOTE Values in are just for reference Bushing Unit mm in Standard Allowable Limit Remedy A 137 5 5 41 Replace B 38 7 1 52 39 7 1 56 C 59 2 32 54 2 13 fNOTE Values in are just for reference B A W142 03 07 004 W105 03 07 023 ...

Page 100: ...Group 2 Undercarriage SECTION 2 MAINTENANCE STANDARD W2 2 4 4 Blank ...

Page 101: ... Main Frame 80 3 15 81 5 3 21 Bushing Boom Cylinder 80 3 15 81 5 3 21 C Pin 90 3 54 89 0 3 50 Bushing Boom Cylinder 90 3 54 91 5 3 60 Boss Boom 90 3 54 91 5 3 60 D Pin 90 3 54 89 0 3 50 Bushing Boom 90 3 54 91 5 3 60 Bushing Arm 90 3 54 91 5 3 60 E Pin 80 3 15 79 0 3 11 Boss Arm 80 3 15 81 5 3 21 Bushing Arm Cylinder 80 3 15 81 5 3 21 F Pin 80 3 15 79 0 3 11 Boss Boom 80 3 15 81 5 3 21 Bushing Arm...

Page 102: ...ss Link B 80 3 15 81 5 3 21 Bushing Link A 80 3 15 81 5 3 21 Bushing Bucket Cylinder 80 3 15 81 5 3 21 I Pin 71 2 80 70 0 2 76 Boss Link B 71 2 80 72 5 2 85 Bushing Arm 71 2 80 72 5 2 85 J Pin 80 3 15 79 0 3 11 Boss Bucket 80 3 15 81 5 3 21 Bushing Link A 80 3 15 81 5 3 21 K Pin 80 3 15 79 0 3 11 Boss Bucket 80 3 15 81 5 3 21 Bushing Arm 80 3 15 81 5 3 21 IMPORTANT When replacing HN bushing for th...

Page 103: ...Front Attachment SECTION 2 MAINTENANCE STANDARD W2 3 1 3 Side Cutter 2014503 2014504 Unit mm in Standard Allowable Limit Remedy A 278 10 9 181 7 1 Replace B 295 11 6 C 433 17 0 D 135 5 3 B D A C W155 04 01 002 ...

Page 104: ...Group 3 Front Attachment SECTION 2 MAINTENANCE STANDARD W2 3 1 4 Point 4427919 Unit mm in Standard Allowable Limit Remedy A 215 8 5 107 5 4 2 Replace B 95 3 7 C 108 4 3 D 95 3 7 C D B A W105 04 01 020 ...

Page 105: ...a previous model machine is used use the grease intervals for previous model machine Unit mm in ZX200 5G Class ZX200 3 Class a 450 17 7 b 10 0 39 c 604 23 8 d 580 22 8 e 476 18 7 f 1471 57 9 g 433 17 0 h 305 12 00 i 80 3 15 j 475 18 7 k 31 1 2 l 433 17 0 m 307 12 1 n 80 3 1 o 15 3 7 p 15 3 7 q 449 17 7 Section A Section B WDCD 02 03 003 WDCD 02 03 005 ...

Page 106: ...m and Boom Connection Unit mm in ZX200 5G Class ZX200 3 Class s 90 3 54 t 354 13 93 352 13 85 u 490 19 3 IMPORTANT If the front attachment of a previous model machine is used use the grease intervals for previous model machine Section C s Pin Hole Inner Diameter WDCD 02 03 001 WDCD 02 03 004 ...

Page 107: ...y 0 5 0 020 1 0 0 039 Repair 1 0 0 039 2 0 0 079 Replace Unit mm in Cylinder Name Recommended Size After Re manufacturing A Boom 85 0 012 0 027 3 35 0 0005 0 001 Arm 95 0 012 0 027 3 74 0 0005 0 001 Bucket 80 0 01 0 023 3 15 0 0004 0 0009 b a c d a Cylinder Rod b Dial Gauge c V Block d 1 m 39 4 in A W166 04 02 022 W105 04 02 094 ...

Page 108: ...Group 3 Front Attachment SECTION 2 MAINTENANCE STANDARD W2 3 2 2 Blank ...

Page 109: ...MEMO ...

Page 110: ...MEMO ...

Page 111: ... 4 Spool Side W3 9 3 1 Assembly of Control Valve 4 Spool Side W3 9 3 8 Disassembly of Control Valve 5 Spool Side W3 9 4 1 Assembly of Control Valve 5 Spool Side W3 9 4 8 Group 10 Swing Device Removal and Installation of Swing Device W3 10 1 1 Disassembly of Swing Device W3 10 2 1 Assembly of Swing Device W3 10 2 6 Disassembly of Swing Motor W3 10 3 1 Assembly of Swing Motor W3 10 3 4 Group 11 Pilo...

Page 112: ...DCDW 3 2 Blank ...

Page 113: ...r assembling Connect the hoses and install the clips in case the clips which secure the hoses have been removed Removal 1 Set the machine position for inspection and maintenance Refer to W1 6 1 2 Open door 1 dCAUTION Seat 2 weight 42 kg 93 lb 3 Remove socket bolts 3 4 used Remove seat 2 l 6 mm 4 Remove floor mat 4 5 Remove bolts washers 5 4 used Remove travel control levers 6 2 used j 17 mm 6 2 3 ...

Page 114: ...CTION 3 UPPERSTRUCTURE W3 1 1 2 6 Remove cover 9 7 Disconnect plug 10 and connectors 11 2 used 8 Remove bolt washer 12 and screw 13 Remove cover 14 j 13 mm 9 11 11 10 14 12 Detail A 13 A WDAA 03 01 050 WDAA 03 01 051 ...

Page 115: ...rs 20 2 used and washers 21 2 used j 13 mm 12 Remove caps 22 3 used Remove seals 23 3 used and screws 24 3 used Remove cover 25 13 Remove caps 26 2 used Remove seals 27 2 used and screws 28 2 used Remove cover 29 and duct 33 14 Remove bolts washers 30 2 used j 17 mm 15 Remove bolt washer 31 Remove cover 32 j 13 mm 16 Remove screws 68 2 used Remove duct 69 17 Remove bolt washer 70 Remove duct 71 j ...

Page 116: ...RSTRUCTURE W3 1 1 4 A B Detail A Detail B 34 34 35 37 36 37 34 18 Remove clip 35 19 Disconnect connectors 34 7 used 20 Remove clip 36 21 Disconnect connectors 37 4 used WDAA 03 01 063 WDAA 03 01 054 WDAA 03 01 064 WDAA 03 01 055 ...

Page 117: ...crews 40 6 used Remove filter case 41 26 Open engine cover 42 27 Remove bolts washers 79 5 used Remove cover 80 j 17 mm 28 Remove bolts washers 43 2 used Remove cover 44 j 17 mm 29 Remove bolt 45 Disconnect connector 46 j 13 mm 30 Push the lock and shift lever 47 Disconnect connector 48 31 Open door 1 TDAA 05 08 006 WDCD 03 01 003 WDCD 03 01 002 WDCD 03 01 001 ...

Page 118: ...e cab 49 assembly weight 420 kg 930 lb 32 Attach nylon slings onto lifting brackets a 4 places of cab 49 Hoist and hold the cab 49 assembly dCAUTION Remove cover 72 while holding it Do not drop cover 72 33 Remove bolts washers 73 6 used Remove cover 72 j 17 mm WDAA 03 01 058 WDAA 03 13 005 ...

Page 119: ... washer 75 and spacer 76 at the rear side j 32 mm 35 Remove socket bolts 50 2 used and washers 51 2 used l 8 mm 36 Remove socket bolts 52 5 used and washers 53 5 used l 8 mm 37 Remove bolts washers 54 5 used j 17 mm 38 Remove nuts 55 4 used and washers 56 4 used Remove the cab 49 assembly j 24 mm WDAA 03 01 059 WDAA 03 01 066 ...

Page 120: ...ove monitor controller 59 41 Remove bolt washer 77 j 17 mm 42 Remove screws 60 4 used Disconnect connector 61 43 Remove screws 62 4 used Remove cover 63 44 Remove bolts washers 64 4 used Remove MC 65 j 13 mm dCAUTION Bracket assembly 67 weight 29 kg 64 lb 45 Remove bolts washers 66 6 used Remove bracket assembly 67 j 17 mm 67 WDAA 03 01 060 WDAA 03 01 061 WDAA 03 01 067 ...

Page 121: ...50 N m 5 kgf m 37 lbf ft 2 Install MC 65 with bolts washers 64 4 used j 13 mm m 20 N m 2 kgf m 15 lbf ft 3 Install cover 63 with screws 62 4 used 4 Connect connector 61 with screws 60 4 used 5 Install clamp 78 with bolt washer 77 j 17 mm m 50 N m 5 kgf m 37 lbf ft 6 Install monitor controller 59 with screws 58 4 used 7 Connect connectors 57 5 used Detail A 66 66 67 WDAA 03 01 061 WDAA 03 01 067 77...

Page 122: ...s of cab 49 Hoist the cab 49 assembly 9 Install the cab 49 assembly with washers 56 4 used and nuts 55 4 used j 24 mm m 210 N m 21 kgf m 155 lbf ft 10 Install bolts washers 54 5 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 11 Install washers 53 5 used and socket bolts 52 5 used j 8 mm m 50 N m 5 kgf m 37 lbf ft 12 Install washers 51 2 used and socket bolts 50 2 used j 8 mm m 50 N m 5 kgf m 37 lbf ft WD...

Page 123: ... W3 1 1 11 74 75 76 WDAA 03 01 066 73 72 WDAA 03 13 005 13 Install spacer 76 washer 75 and bolt 74 at the rear side j 32 mm m 550 N m 55 kgf m 410 lbf ft 14 Install cover 72 with bolts washers 73 6 used j 17 mm m 50 N m 5 kgf m 37 lbf ft ...

Page 124: ...45 j 13 mm m 10 N m 1 kgf m 7 4 lbf ft 17 Install cover 44 with bolts washers 43 2 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 18 Install cover 80 with bolts 79 5 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 19 Shut engine cover 42 20 Open cover 38 21 Install filter case 41 with screws 40 6 used 22 Install filter 39 23 Shut cover 38 24 Open door 1 41 1 39 38 42 79 80 40 A 44 43 Detail A 46 45 48 47 TDAA 05...

Page 125: ...ERSTRUCTURE W3 1 1 13 A B Detail A Detail B 34 34 35 37 36 37 34 25 Connect connectors 37 4 used 26 Install clip 36 27 Connect connectors 34 7 used 28 Install clip 35 WDAA 03 01 063 WDAA 03 01 054 WDAA 03 01 064 WDAA 03 01 055 ...

Page 126: ...shers 30 2 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 33 Install duct 33 and cover 29 with screws 28 2 used Install seals 27 2 used and caps 26 2 used 34 Install cover 25 with screws 24 3 used Install seals 23 3 used and caps 22 3 used 35 Install washers 21 2 used and bolts washers 20 2 used j 13 mm m 20 N m 2 kgf m 15 lbf ft 36 Open cover 15 37 Install cover 19 with screws 18 3 used Install seals 17...

Page 127: ...TRUCTURE W3 1 1 15 38 Install cover 14 with screw 13 and bolt washer 12 j 13 mm m 20 N m 2 kgf m 15 lbf ft 39 Connect connectors 11 2 used and plug 10 40 Install cover 9 9 11 11 10 14 12 Detail A 13 WDAA 03 01 050 WDAA 03 01 051 A ...

Page 128: ...levers 6 2 used with bolts washers 5 4 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 42 Install floor mat 4 dCAUTION Seat 2 weight 42 kg 93 lb 43 Install seat 2 with socket bolts 3 4 used j 6 mm m 20 N m 2 kgf m 15 lbf ft 44 Close door 1 6 2 3 5 3 4 1 WDAA 03 01 023 WDAA 03 01 047 ...

Page 129: ...W3 1 2 1 Dimensions of Cab Glass Section A Unit mm Section B Detail C a Black Ceramic Painted Surface b Black Ceramic Painted Range a Black Ceramic Painted Surface WDAA 03 01 030 WDAA 03 01 036 WDAA 03 01 001 WDAA 03 01 035 WDAA 03 01 002 ...

Page 130: ...Group 1 Cab SECTION 3 UPPERSTRUCTURE W3 1 2 2 Unit mm Section A WDAA 03 01 030 a Black Ceramic Painted Surface a Black Ceramic Painted Surface WDAA 03 01 034 WDAA 03 01 037 ...

Page 131: ...Group 1 Cab SECTION 3 UPPERSTRUCTURE W3 1 2 3 Unit mm Section A a Chamfer along the Periphery WDAA 03 01 004 WDAA 03 01 003 WDAA 03 01 031 ...

Page 132: ...Group 1 Cab SECTION 3 UPPERSTRUCTURE W3 1 2 4 Unit mm Section A a Chamfer along the Periphery WDAA 03 01 031 WDAA 03 01 006 WDAA 03 01 005 ...

Page 133: ... Section A Section B Section C a Black Ceramic Painted Surface d Shaded Paint along the Periphery Here a Black Ceramic Painted Surface b Black Ceramic Painted Range c Chamfer here WDAA 03 01 031 WDAA 03 01 038 WDAA 03 01 007 WDAA 03 01 008 WDAA 03 01 009 ...

Page 134: ...TURE W3 1 2 6 Unit mm WDAA 03 01 031 a Black Ceramic Painted Surface b Black Ceramic Painted Range a Black Ceramic Painted Surface d Dotted edge along the Periphery Here Section A Detail B WDAA 03 01 010 WDAA 03 01 038 WDAA 03 01 011 ...

Page 135: ...1 2 7 Unit mm a Black Ceramic Painted Surface b Black Ceramic Painted Range c Chamfer here a Black Ceramic Painted Surface d Dotted edge along the Periphery Here Section A Section B WDAA 03 01 031 WDAA 03 01 012 WDAA 03 01 038 WDAA 03 01 008 ...

Page 136: ...3 UPPERSTRUCTURE W3 1 2 8 Unit mm Section A a Black Ceramic Painted Surface d Shaded Paint along the Periphery Here a Black Ceramic Painted Surface b Black Ceramic Painted Range WDAA 03 01 030 WDAA 03 01 038 WDAA 03 01 013 ...

Page 137: ...erious injury Before removing use the duct tape or equivalent in order to paste the broken or cracked glass and reinforce them Remove the glass pieces away 1 Remove resin panel 5 garnish 6 and the spacer around the glass 2 Prick a hole in adhesive b by using awl a or a knife 3 Pass piano wire c or a metal wire through the hole 1 6 3 5 6 2 4 7 8 a c b 7 Cab 8 Glass a Awl b Adhesive c Piano Wire WDA...

Page 138: ...hange the position and cut the adhesive 4 Wind the both ends of the piano wire onto the screwdriver Draw the wire back and forth in order to cut adhesive b between cab 7 and glass 8 Remove glass 8 from cab 7 fNOTE Cut off the middle of adhesive between glass and cab 7 8 a b c a Cab Outside b Adhesive c Cab Inside W1SE 02 01 035 ...

Page 139: ...aken for about 1 minute and mix thoroughly before opening the cap After opening Primer apply Primer as quickly as possible and close the cap immediately after using After opening Primer all the contents should be used within 180 days or 2 hours with the cap off 3 Apply Primer for paint Sika Aktivator DM 1 to the cutting edge of adhesive at cab 7 side by using a brush Wait for about 15 minutes in o...

Page 140: ...er to W3 1 2 14 to W3 1 2 16 7 Cut off the nozzle of adhesive cartridge Sika Tack Go into V shaped by using a knife As for the cutting procedure of nozzle refer to W3 1 2 17 8 Remove the seal of the cartridge end Install the V shaped nozzle 9 Install the cartridge to the manual coking gun 10 Apply adhesive to the adhesive position at cab side so that the bead triangle may be even As for the positi...

Page 141: ...ss Rear Left Hand Glass Spacer A Dam Rubber Spacer B Spacer C Right Hand Glass Lower Door Glass a Two Side Adhesive Tape a Two Side Adhesive Tape WDAA 03 01 039 WDAA 03 01 040 WDAA 03 01 041 WDAA 03 01 042 WDAA 03 01 046 WDAA 03 01 043 WDAA 03 01 044 WDAA 03 01 045 ...

Page 142: ...opper a From Radius Curve End b Glass External Form Line c Adhesive Range Section A Section D Detail E Section B Section C d Clearance between glass and panel 6 mm e Glass e Glass f Apply Super X e Glass e Glass WDAA 03 01 014 WDAA 03 01 017 WDAA 03 01 018 WDAA 03 01 019 WDAA 03 01 020 WDAA 03 01 024 ...

Page 143: ...pacer A 2 Spacer C 3 Dam Rubber a From Radius Curve End b Glass External Form Line c Adhesive Range Section A Section B Section C d Glass and panel Clearance OR 02 8 mm e Glass e Glass a From Radius Curve End e Glass WDAA 03 01 016 WDAA 03 01 022 WDAA 03 01 027 WDAA 03 01 028 ...

Page 144: ...Glass 1 Spacer B a From Radius Curve End b Glass External Form Line c Adhesive Range a From Radius Curve End e Glass d Glass and panel Clearance OR 02 8 mm e Glass e Glass Section A Section B Section C WDAA 03 01 015 WDAA 03 01 021 WDAA 03 01 025 WDAA 03 01 026 ...

Page 145: ...reference of adhesive and primer Painted Surface or Adhesive Surface Glass Surface Adhesive Primer Primer Sika Tack Go Sika Tack Go Sika Aktivator DM 1 Sika Aktivator DM 1 Sika Primer 206G P Sika Primer 206G P 310 ml Cartridge 250 ml Can 30 ml Bottle Lower Door Glass 170 ml 0 6 ml 0 5 ml Rear Left Hand Glass 220 ml 0 55 ml 0 5 ml Rear Right Hand Glass 105 ml 1 ml 0 9 ml Rear Glass 205 ml 0 5 ml 0 ...

Page 146: ...ish 2 around sash assembly 1 from the cab inside for easy removal Push sash assembly 1 by hands and remove the sash outside 2 Install glass A 3 and glass B 4 into the sash grooves 3 Install sash assembly 1 onto the door from the outside of cab Secure sash assembly 1 at the inside of cab by using garnish 2 1 3 4 2 WDAA 03 01 031 ...

Page 147: ...no visible undulation or boss can be found fNOTE Cemedine Super X No 8008 Glue state adhesive tubed Cemedine 366 Deluxe IMPORTANT The front glass is arched fringed When replacing the glass contact with the nearest HITACHI Office and replace it as an assembly Detail A Inside Detail A Outside a Cemedine Super X No 8008 b Cemedine 366 Deluxe c Fill seal for the inside of installation point here d Do ...

Page 148: ...Group 1 Cab SECTION 3 UPPERSTRUCTURE W3 1 2 20 Blank ...

Page 149: ...mbly j 17 mm dCAUTION Counterweight 4 weight ZX200 5G 200LC 5G 4260 kg 9400 lb ZX210H 5G 210LCH 5G 4670 kg 10300 lb ZX210K 5G 210LCK 5G 5480 kg 12100 lb 6 Remove caps 5 2 used Install Freno Linkbolts B 42 M42 Pitch 4 5 mm 2 used to the cap 5 mounting hole 2 places Attach wire ropes onto the Freno Linkbolts Hoist and hold counterweight 4 7 Remove bolts 6 4 used and washers 7 4 used Remove counterwe...

Page 150: ...e Freno Linkbolts Hoist counterweight 4 2 Install counterweight 4 with washers 7 4 used and bolts 6 4 used j 46 mm m 1570 N m 157 kgf m 1160 lbf ft 3 Remove the Freno Linkbolts 2 used from the cap 5 mounting hole 2 places Install caps 5 2 used 4 Install the rearview camera 3 assembly with bolts washers 2 4 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 5 Connect connector 1 6 Install cover 9 with bolts w...

Page 151: ...and pipes for assembling Connect the hoses and install the clips in case the clips which secure the hoses have been removed Removal 1 Set the machine for inspection and maintenance Refer to W1 6 1 dCAUTION Bleed air from the hydraulic oil tank Refer to W1 4 1 2 Remove cab 1 Refer to W3 1 1 3 Remove counterweight 2 Refer to W3 2 1 4 Remove front attachment 3 Refer to W5 1 1 5 Remove boom cylinder 4...

Page 152: ...g washers 10 2 used Remove stopper 11 j 22 mm dCAUTION Main frame 12 weight ZX200 5G 200LC 5G 4620 kg 10200 lb ZX210H 5G 210LCH 5G 4780 kg 10600 lb ZX210K 5G 210LCK 5G 4880 kg 10800 lb 10 Attach wire ropes onto counterweight mounting part a 2 places of the main frame 12 rear side and boom mounting bracket hole b 2 places a Counterweight Mounting Part b Boom Mounting Bracket Hole 12 a b WDAA 03 03 ...

Page 153: ...ing a chain block Put the matching marks onto main frame 12 and outer race 13 of the swing bearing 12 Remove bolts 14 32 used bolts 15 5 used and spacers 16 5 used j 30 mm 13 Adjust the chain block in order to level main frame 12 Hoist and remove main frame 12 12 13 14 15 16 WDAB 03 03 003 ...

Page 154: ... places of the main frame 12 rear side and boom mounting bracket hole b 2 places 2 Adjust the chain block in order to level main frame 12 3 Fit the matching marks made when disassembling and install main frame 12 to outer race 13 of the swing bearing Install spacers 16 5 used bolts 15 5 used and bolts 14 32 used j 30 mm m 510 N m 51 kgf m 380 lbf ft a Counterweight Mounting Part b Boom Mounting Br...

Page 155: ...11 with spring washers 10 2 used and bolts 9 2 used j 22 mm m 140 N m 14 kgf m 103 lbf ft 5 Connect hose 8 j 17 mm m 25 N m 2 5 kgf m 18 lbf ft 6 Connect hose 7 j 27 mm m 80 N m 8 kgf m 59 lbf ft 7 Connect hoses 6 4 used j 36 mm m 180 N m 18 kgf m 133 lbf ft WDAA 03 03 005 ...

Page 156: ...W5 2 1 9 Install front attachment 3 Refer to W5 1 1 10 Install counterweight 2 Refer to W3 2 1 11 Install cab 1 Refer to W3 1 1 12 Bleed air from the hydraulic system Refer to W1 4 1 IMPORTANT Check the hydraulic oil level Start the engine and check for any oil leaks 2 1 4 3 WDCD 03 03 001 ...

Page 157: ...t the machine position for inspection and maintenance Close the fuel cock Refer to W1 6 1 dCAUTION Bleed air from the hydraulic oil tank Refer to W1 4 1 2 Open covers 1 2 3 Remove wing nuts 3 4 used and washers 4 4 used Remove covers 5 2 used 4 Remove bolt 6 and washer 7 Disconnect ground 8 j 17 mm 5 Remove bolts washers 112 6 used Remove the cover 113 assembly and O ring 114 from the top of hydra...

Page 158: ...ine cover 9 8 Remove pins 115 2 used and washers 116 2 used Remove the support 118 side of stopper 117 9 Remove bolts washers 10 4 used from the inside of engine cover 9 Remove engine cover 9 j 17 mm 10 Remove bolts washers 11 8 used and bolts washers 12 2 used Remove cover 13 j 17 mm 10 11 13 9 A Detail A 118 117 115 116 WDCD 03 04 019 WDDE 03 04 002 ...

Page 159: ...ight 28 kg 62 lb 14 Remove bolts washers 23 2 used Remove batteries 24 2 used j 17 mm 15 Open stoppers 25 2 used Remove net 26 16 Remove pins 27 2 used Remove cover 28 17 Remove bolts washers 29 30 2 used for each Remove cover 31 j 17 mm 18 Remove bolts washers 32 2 used Remove cover 33 j 17 mm 19 Place a container under hose 34 Loosen cock 35 Drain off coolant fNOTE Coolant amount 26 L 6 87 US ga...

Page 160: ...d Remove cover 44 j 17 mm 26 Remove nuts 49 4 used Disconnect exhaust pipe 50 j 13 mm dCAUTION The muffler 52 assembly weight 25 kg 56 lb 27 Attach nylon slings onto muffler 52 Hoist and hold the muffler 52 assembly 28 Remove bolts 53 3 used and spring washers 54 3 used Remove the muffler 52 assembly and gasket 51 j 17 mm 29 Remove pump device 55 Refer to W3 8 1 30 Remove the coupling of the engin...

Page 161: ...iator side of hose 62 and the engine side of hose 63 34 Remove bolts washers 64 2 used Remove the pipe 65 assembly j 17 mm 35 Remove clamps 66 2 used Disconnect hose 67 36 Remove clamps 68 2 used Disconnect the radiator side of hose 69 and the engine side of hose 70 37 Remove bolts washers 71 2 used Remove the pipe 72 assembly j 17 mm 38 Remove clamps 73 2 used Disconnect hose 74 WDCD 03 04 007 WD...

Page 162: ...sed Remove cover 76 j 13 mm 40 Remove bolts washers 77 5 used Remove cover 78 j 17 mm 41 Remove bolts washers 79 7 used Remove cover 80 j 17 mm 42 Remove clamps 81 82 Remove bolts washers 83 2 used Remove the duct 84 assembly j 17 mm 43 Remove band 85 Remove rubber 86 WDCD 03 04 011 WDCD 03 04 010 ...

Page 163: ...3 4 1 7 94 91 92 93 87 88 89 90 44 Disconnect cables 87 88 45 Remove clips 89 2 used Disconnect hoses 90 2 used 46 Remove clips 91 2 used Disconnect hoses 92 2 used 47 Disconnect hoses 93 2 used j 36 mm 48 Disconnect terminal 94 WDCD 03 04 012 ...

Page 164: ...e the belt tension by moving tension pulley 108 by using adjusting bolt 110 55 Remove bolts 99 119 2 used for each spring washers 100 120 2 used for each and washers 101 121 2 used for each Place the compressor 102 assembly horizontally j 17 mm 96 95 97 98 102 99 100 101 108 109 110 a 8 to 12 mm 0 31 to 0 47 in 100 N 10 kgf 23 lbf b Crank Pulley c Compressor Pulley M1G6 07 013 a 119 120 121 c b WD...

Page 165: ... nuts 104 2 used and washers 105 2 used from the front attachment side and counterweight side of engine 103 j 22 mm 58 Remove bolts 106 2 used and washers 107 2 used from the front attachment side and counterweight side of engine 103 j 27 mm 59 Hoist engine 103 by 15 mm 60 Move engine 103 to the pump device mounting side by 50 mm Remove engine 103 61 Remove the adapter with engine 103 attached if ...

Page 166: ...les to lifting brackets a 2 places of engine 103 Attach nylon slings onto the shackles Hoist engine 103 3 Install engine 103 with washers 107 2 used and bolts 106 2 used j 27 mm m 360 N m 36 kgf m 265 lbf ft 4 Install engine 103 with washers 105 2 used and nuts 104 2 used j 22 mm m 140 N m 14 kgf m 103 lbf ft a Lifting Bracket a a 103 104 105 106 107 WDCD 03 04 014 ...

Page 167: ... 108 by using adjusting bolt 110 8 Tighten lock bolt 109 of tension pulley 108 IMPORTANT The belt does not fit when replacing with a new one Therefore adjust the belt tension again after running the engine at slow idle for 3 to 5 minutes 9 Connect terminals 98 2 used 10 Connect connector 97 11 Connect terminals 96 2 used 12 Connect connector 95 96 95 97 98 102 99 100 101 WDCD 03 04 013 108 109 110...

Page 168: ...12 94 91 92 93 87 88 89 90 13 Connect terminal 94 14 Connect hoses 93 2 used j 36 mm m 180 N m 18 kgf m 133 lbf ft 15 Connect hoses 92 2 used with clips 91 2 used 16 Connect hoses 90 2 used with clips 89 2 used 17 Connect cables 88 87 WDCD 03 04 012 ...

Page 169: ...shers 83 2 used and clamps 82 81 j 17 mm m 50 N m 5 kgf m 37 lbf ft 20 Install cover 80 with bolts washers 79 7 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 21 Install cover 78 with bolts washers 77 5 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 22 Install cover 76 with bolts washers 75 2 used j 13 mm m 20 N m 2 kgf m 15 lbf ft WDCD 03 04 011 WDCD 03 04 010 ...

Page 170: ...the radiator side of hose 69 with clamps 68 2 used 26 Connect hose 67 with clamps 66 2 used 27 Install the pipe 65 assembly with bolts washers 64 2 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 28 Connect the engine side of hose 63 and the radiator side of hose 62 with clamps 61 60 29 Install bracket 59 with bolts washers 58 4 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 30 Connect terminals 57 3 used and co...

Page 171: ...hers 54 3 used and bolts 53 3 used j 17 mm m 65 N m 6 5 kgf m 48 lbf ft 35 Connect gasket 51 and exhaust pipe 50 with nuts 49 4 used j 13 mm m 20 N m 2 kgf m 15 lbf ft 36 Install cover 44 with bolts washers 43 3 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 37 Install cover 42 with bolts washers 41 5 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 38 Install clamps 108 2 used with bolts washers 40 2 used j 17 m...

Page 172: ...8 with pins 27 2 used 43 Install net 26 Close stoppers 25 2 used dCAUTION Battery 24 weight 28 kg 62 lb 44 Install batteries 24 2 used with bolts washers 23 2 used 45 Connect terminal 22 with washer 21 and bolt 20 j 17 mm m 20 N m 2 kgf m 15 lbf ft 46 Connect terminal 19 with washer 18 and bolt 17 j 17 mm m 20 N m 2 kgf m 15 lbf ft 47 Connect terminal 16 with washer 15 and bolt 14 j 17 mm m 20 N m...

Page 173: ...draulic oil tank fNOTE Total oil amount of hydraulic oil tank 201 L 53 1 US gal 52 Install O ring 114 53 Install the cover 113 assembly to the top of hydraulic oil tank with bolts washers 112 6 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 54 Bleed air from the fuel system Refer to W1 4 1 55 Bleed air from the hydraulic system Refer to W1 4 1 IMPORTANT Check the hydraulic oil level Start the engine and ...

Page 174: ...d bolts washers 11 8 used j 17 mm m 50 N m 5 kgf m 37 lbf ft dCAUTION Engine cover 9 weight 31 kg 69 lb 59 Attach nylon slings onto engine cover 9 Hoist engine cover 9 60 Install engine cover 9 with bolts washers 10 4 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 61 Install the support 118 side of stopper 117 with washers 116 2 used and pins 115 2 used 62 Shut covers 2 1 WDCD 03 04 001 Detail A 46 45 WD...

Page 175: ...rs hoses and pipes for assembling Connect the hoses and install the clips in case the clips which secure the hoses have been removed Removal 1 Set the machine for inspection and maintenance Refer to W1 6 1 dCAUTION Bleed air from the hydraulic oil tank Refer to W1 4 1 2 Open covers 1 2 3 Remove wing nuts 3 4 used and washers 4 4 used Remove covers 5 2 used 4 Remove bolt 6 and washer 7 Disconnect g...

Page 176: ...ver 9 Hoist and hold engine cover 9 6 Remove pins 11 2 used and washers 12 2 used Remove the support 72 side of stopper 13 7 Remove bolts washers 10 4 used from the inside of engine cover 9 Remove engine cover 9 j 17 mm 8 Remove bolts washers 76 5 used Remove cover 77 j 17 mm 10 9 A Detail A 72 13 11 12 WDCD 03 04 019 WDDE 03 04 002 77 76 ...

Page 177: ...hers 23 2 used Remove batteries 24 2 used j 17 mm 13 Open stoppers 25 2 used Remove net 26 14 Remove pins 27 2 used Remove cover 28 15 Remove bolts washers 29 30 2 used for each Remove cover 31 j 17 mm 16 Remove bolts washers 32 2 used Remove cover 33 j 17 mm 17 Bleed air from radiator Refer to W1 4 1 18 Place a container under hose 34 Loosen cock 35 Drain off coolant fNOTE Coolant amount 26 L 6 8...

Page 178: ... cover 36 j 17 mm 20 Remove clamps 38 39 Disconnect the radiator side of hoses 40 41 21 Remove clamps 42 43 Disconnect the radiator side of hoses 44 45 dCAUTION Remove cover 73 while holding it Do not drop cover 73 22 Remove bolts washers 74 2 used Remove cover 73 j 17 mm 37 36 43 45 42 44 39 41 38 40 A Detail A 74 73 WDCD 03 05 001 WDCD 03 05 002 WDCD 03 05 017 ...

Page 179: ... Remove the cover 52 assembly j 17 mm 26 Remove bolts washers 49 3 used Remove the cover 75 assembly j 17 mm 27 Remove bolts washers 53 7 used Remove cover 54 j 17 mm 28 Place a container under the disconnecting part of pipes 55 56 Remove couplings 57 58 Disconnect the oil cooler side of pipes 55 56 j 17 mm 49 56 58 52 50 51 51 46 47 48 49 53 54 75 57 55 WDCD 03 05 014 WDCD 03 05 015 ...

Page 180: ...tach nylon slings onto shackles Hoist and hold intercooler 69 33 Remove bolts 65 2 used rubbers 66 67 and collars 68 2 used Remove intercooler 69 j 13 mm dCAUTION Oil cooler 71 weight 26 kg 58 lb 34 Install eyebolts M8 Pitch 1 25 mm 3 used to eyebolt mounting holes c 3 places of oil cooler 71 Attach nylon slings onto the eyebolts Hoist and hold oil cooler 71 35 Remove bolts washers 70 6 used Move ...

Page 181: ... Attach nylon slings onto shackles Hoist intercooler 69 4 Install intercooler 69 with collars 68 2 used rubbers 66 67 and bolts 65 2 used j 13 mm m 18 N m 1 8 kgf m 13 5 lbf ft 5 Install packings 64 63 2 used for each to radiator 62 6 Install shackles 2 used to lifting holes a 2 places of radiator 62 Attach nylon slings onto shackles Hoist radiator 62 7 Install radiator 62 with collars 61 4 used r...

Page 182: ...7 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 10 Install the cover 75 assembly with bolts washers 49 3 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 11 Install the cover 52 assembly with bolts washers 51 4 used and bolts washers 50 2 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 12 Install hose 47 with clamp 46 13 Install clips 48 2 used 49 56 58 52 50 51 51 46 47 48 49 53 54 57 55 WDCD 03 05 014 WDCD 03 05 015 7...

Page 183: ... 40 with clamps 39 38 16 Add coolant to the radiator fNOTE Coolant amount 26 L 6 87 US gal 17 Install cover 33 with bolts washers 32 2 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 18 Install cover 31 with bolts washers 30 29 2 used for each j 17 mm m 50 N m 5 kgf m 37 lbf ft 19 Install cover 28 with pins 27 2 used 43 45 42 44 39 41 38 40 WDCD 03 05 002 WDCD 03 05 016 ...

Page 184: ...lbf ft 22 Connect terminal 19 with washer 18 and bolt 17 j 17 mm m 20 N m 2 kgf m 15 lbf ft 23 Connect terminal 16 with washer 15 and bolt 14 j 17 mm m 20 N m 2 kgf m 15 lbf ft 24 Connect ground 8 with washer 7 and bolt 6 j 17 mm m 20 N m 2 kgf m 15 lbf ft 25 Install covers 5 2 used with washers 4 4 used and wing nuts 3 4 used 26 Install net 26 Close stoppers 25 2 used WDCD 03 04 004 WDCD 03 04 00...

Page 185: ...1 4 1 IMPORTANT Check the hydraulic oil level Start the engine and check for any oil leaks 28 Install cover 73 with bolts washers 74 2 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 29 Install cover 36 with bolts washers 37 7 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 37 36 WDCD 03 05 001 Detail A 74 73 WDCD 03 05 017 A ...

Page 186: ...e cover 9 weight 31 kg 69 lb 31 Attach nylon slings onto engine cover 9 Hoist engine cover 9 32 Install engine cover 9 with bolts washers 10 4 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 33 Install the support 13 side of stopper 72 with washers 12 2 used and pins 11 2 used 34 Close covers 2 1 10 9 A Detail A 72 13 11 12 WDCD 03 04 019 WDDE 03 04 002 2 1 77 76 ...

Page 187: ...e any remaining pressure and remove the cap IMPORTANT Cap the open ends in case the hoses and pipes have been disconnected In addition attach an identification tag onto the connectors hoses and pipes for assembling Connect the hoses and install the clips in case the clips which secure the hoses have been removed Removal 1 Set the machine position for inspection and maintenance Refer to W1 6 1 dCAU...

Page 188: ...move cover 7 j 17 mm dCAUTION Remove cover 9 while holding it Do not drop cover 9 6 Remove bolts washers 8 3 used Remove cover 9 j 17 mm 7 Remove bolts washers 10 2 used j 17 mm 8 Open engine cover 11 9 Remove bolts washers 12 5 used Remove cover 13 j 17 mm 10 Remove bolts washers 14 6 used Remove cover 15 j 17 mm 9 11 13 15 7 8 10 12 14 6 5 WDCD 03 06 002 WDCD 03 06 003 ...

Page 189: ... Place a container under hydraulic oil tank 1 and suction pipe 16 Slowly turn drain plug 17 Drain off hydraulic oil completely j 27 mm 12 Remove hose clamps 18 4 used Disconnect hose 19 13 Remove bolts washers 20 4 used Move cover assembly 21 j 17 mm WDCD 03 06 004 ...

Page 190: ...es 26 27 at the hydraulic oil tank 1 end j 13 mm 17 Disconnect hoses 28 4 used j 19 mm dCAUTION Hydraulic oil tank 1 weight 97 kg 215 lb 18 Install eyebolts 2 used and nuts 2 used to lifting holes a 2 places of hydraulic oil tank 1 Attach nylon slings onto the eyebolts Hoist and hold hydraulic oil tank 1 19 Remove bolts washers 29 4 used Hoist and remove hydraulic oil tank 1 j 27 mm a Lifting Hole...

Page 191: ...ydraulic oil tank 1 2 Install hydraulic oil tank 1 with bolts washers 29 4 used j 27 mm m 400 N m 40 kgf m 300 lbf ft 3 Connect hoses 28 4 used j 19 mm m 30 N m 3 kgf m 22 lbf ft 4 Connect pipes 27 26 with couplings 25 2 used j 13 mm m 10 to 13 N m 1 to 1 3 kgf m 7 4 to 9 6 lbf ft 5 Install clamps 30 2 used with bolts washers 24 2 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 6 Connect connector 23 of h...

Page 192: ...e 19 with hose clamps 18 4 used 9 Check that drain plug 17 is tightened 10 Fill hydraulic oil tank 1 with hydraulic oil fNOTE Hydraulic oil tank 1 capacity 201 L 53 1 US gal 11 Install O ring 4 12 Install the cover 3 assembly to the upper part of hydraulic oil tank 1 with bolts washers 2 6 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 2 1 3 4 WDCD 03 06 005 WDCD 03 06 001 ...

Page 193: ... 15 Install bolts washers 14 4 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 16 Install cover 13 with bolts washers 12 5 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 17 Shut engine cover 11 18 Install bolts washers 10 2 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 19 Install cover 9 with bolts washers 8 3 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 20 Install cover 7 with bolts washers 6 6 used j 17 mm m 50 N m 5 kgf...

Page 194: ...Group 6 Hydraulic Oil Tank SECTION 3 UPPERSTRUCTURE W3 6 1 8 Blank ...

Page 195: ...ich secure the hoses have been removed Removal 1 Set the machine position for inspection and maintenance Refer to W1 6 1 2 Remove cap 1 3 Place a container Drain off fuel by using an oil feed pump fNOTE Amount of oil 400 L 106 US gal 4 Open cover 2 5 Remove bolts 3 2 used and washers 4 2 used j 22 mm 6 Remove bolts 5 2 used and washers 6 2 used Remove handrail 7 j 19 mm 7 Remove bolts washers 8 4 ...

Page 196: ...ove hose clip 17 Disconnect hose 18 dCAUTION Fuel tank 19 weight 160 kg 355 lb 13 Install an eyebolt M10 Pitch 1 5 mm to mounting hole a of fuel tank 19 Install an eyebolt M10 Pitch 1 5 mm and a nut to mounting hole b of fuel tank 19 Attach nylon slings onto the eyebolts Hoist and hold fuel tank 19 12 13 19 14 15 16 19 17 18 a b a Mounting Hole b Mounting Hole WDCD 03 07 002 WDCD 03 07 003 ...

Page 197: ... 21 j 17 mm dCAUTION Remove cover 23 while holding it Do not drop cover 23 15 Remove bolts washers 22 2 used Remove cover 23 j 17 mm 16 Place a container under fuel tank 19 Remove hose clips 24 25 Disconnect hoses 26 27 Drain fuel completely 17 Remove bolts 28 6 used and washers 29 6 used Remove fuel tank 19 j 24 mm 19 20 21 23 22 WDCD 03 07 005 WDCD 03 07 004 ...

Page 198: ...160 kg 355 lb 1 Install an eyebolt M10 Pitch 1 5 mm to mounting hole a of fuel tank 19 Install an eyebolt M10 Pitch 1 5 mm and a nut to mounting hole b of fuel tank 19 Attach nylon slings onto the eyebolts Hoist fuel tank 19 19 WDCD 03 07 002 19 a b a Mounting Hole b Mounting Hole WDCD 03 07 003 ...

Page 199: ...lts 28 6 used j 24 mm m 270 N m 27 kgf m 200 lbf ft 3 Connect hoses 27 26 with hose clips 25 24 4 Install cover 23 with bolts washers 22 2 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 5 Install cover 21 with bolts washers 20 6 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 19 20 21 23 22 WDCD 03 07 005 WDCD 03 07 004 ...

Page 200: ... hose 18 with hose clip 17 7 Install clip 16 with bolt washer 15 j 17 mm m 50 N m 5 kgf m 37 lbf ft 8 Connect connector 14 9 Install cover 13 with bolts washers 12 2 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 12 13 19 14 15 16 19 17 18 WDCD 03 07 002 WDCD 03 07 003 ...

Page 201: ... m 5 kgf m 37 lbf ft 12 Install handrail 7 with washers 6 2 used and bolts 5 2 used j 19 mm m 110 N m 11 kgf m 81 lbf ft 13 Install washers 4 2 used and bolts 3 2 used j 22 mm m 180 N m 18 kgf m 133 lbf ft 14 Shut cover 2 15 Fill fuel tank 19 with fuel fNOTE Amount of oil 400 L 106 US gal 16 Install cap 1 17 Bleed air from the fuel system Refer to W1 4 1 WDCD 03 07 001 7 1 19 10 11 5 6 3 4 2 9 8 ...

Page 202: ...Group 7 Fuel Tank SECTION 3 UPPERSTRUCTURE W3 7 1 8 Blank ...

Page 203: ...dCAUTION Bleed air from hydraulic oil tank 1 Refer to W1 4 1 2 Remove bolts washers 2 6 used Remove the cover 3 assembly and O ring 4 from the top of hydraulic oil tank 1 j 17 mm 3 Place a container Drain off hydraulic oil by using an oil feed pump fNOTE Total oil amount of hydraulic oil tank 1 201 L 53 1 US gal 4 Open cover 5 and engine cover 6 5 Remove bolts washers 7 8 used and bolts washers 8 ...

Page 204: ...7 and pipe 24 Disconnect hose 18 j 36 mm 12 Disconnect hoses 19 2 used j 19 mm 13 Disconnect hose 20 j 17 mm 14 Disconnect hose 28 j 27 mm 15 Remove clamps 21 4 used Disconnect rubber hose 22 16 Remove socket bolts 23 4 used Disconnect pipe 24 l 10 mm 17 Remove socket bolts 25 8 used and flanges 26 4 used Disconnect hoses 27 2 used l 10 mm WDCD 03 08 010 WDCD 03 08 011 ...

Page 205: ...s 35 3 used Remove the muffler 33 assembly j 17 mm dCAUTION Pump device 17 weight 170 kg 375 lb 21 Remove bolts 36 2 used and washers 37 2 used Install eyebolts M12 Pitch 1 75 mm 2 used to the bolt 36 holes 2 places Attach nylon slings onto the eyebolts Hoist and hold pump device 17 j 19 mm 22 Remove bolts 38 5 used and spring washers 39 5 used Remove pump device 17 j 17 mm 23 Remove the adapter w...

Page 206: ... lbf ft 4 Remove the eyebolts 2 used from the bolt 36 holes 2 places Install washers 37 2 used and bolts 36 2 used j 19 mm dCAUTION The muffler 33 assembly weight 25 kg 56 lb 5 Attach nylon slings onto muffler 33 Hoist the muffler 33 assembly 6 Install the muffler 33 assembly with spring washers 35 3 used and bolts 34 3 used j 17 mm m 65 N m 6 5 kgf m 48 lbf ft 7 Install gasket 32 and clamp 31 to ...

Page 207: ...10 Connect rubber hose 22 with clamps 21 4 used 11 Connect hose 28 j 27 mm m 80 N m 8 kgf m 59 lbf ft 12 Connect hose 20 j 17 mm m 25 N m 2 5 kgf m 18 lbf ft 13 Connect hoses 19 2 used j 19 mm m 30 N m 3 kgf m 22 lbf ft 14 Connect hose 18 j 36 mm m 180 N m 18 kgf m 133 lbf ft 15 Connect connectors 16 7 used 16 Install clamps 41 3 used with bolts washers 15 3 used j 10 mm m 3 to 4 N m 0 3 to 0 4 kg...

Page 208: ...o W1 4 1 IMPORTANT Check the hydraulic oil level Start the engine and check for any oil leaks 21 Install cover 11 with bolts washers 13 3 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 22 Install cover 12 with bolts washers 11 5 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 23 Install clamps 42 2 used with bolts washers 10 2 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 24 Install cover 9 with bolts washers 8 2 used...

Page 209: ...d from insert 1 Remove inserts 1 4 used from cylinder hub 4 l 14 mm 3 Remove socket bolts 6 4 used from insert 5 Remove inserts 5 4 used from the engine flywheel l 14 mm 4 Remove spring pins 7 4 used from the engine flywheel 5 Remove clamping screws 8 2 used from cylinder hub 4 Remove cylinder hub 4 from the pump device l 10 mm 7 8 4 8 2 1 3 7 6 5 WDCD 03 08 021 WDCD 03 09 001 ...

Page 210: ... Install spring pins 7 4 used to the engine flywheel 4 Install inserts 5 4 used to the engine flywheel with socket bolts 6 4 used l 14 mm m 210 to 230 N m 21 to 23 kgf m 155 to 170 lbf ft 5 Install inserts 1 4 used to cylinder hub 4 with socket bolts 3 4 used l 14 mm m 210 to 230 N m 21 to 23 kgf m 155 to 170 lbf ft 6 Install element 2 to inserts 1 4 used at the pump side 7 8 WDCD 03 09 001 4 8 2 ...

Page 211: ...p Device 3 1 56 51 49 50 58 27 26 57 57 78 78 2 4 17 19 12 20 11 10 9 21 22 23 60 24 62 58 59 61 61 60 58 59 60 63 64 80 66 67 68 69 70 67 71 81 72 73 75 76 68 65 74 61 77 61 60 58 26 29 50 58 58 58 49 22 21 16 14 15 5 6 7 9 10 11 12 13 14 15 16 17 18 54 55 8 WDCD 03 08 019 ...

Page 212: ...Pilot Pump 39 Retaining Ring 40 Retaining Ring 41 Ball Bearing 2 Used 42 Gear 43 Gear Shaft 44 Retaining Ring 45 Oil Seal 46 Gear Casing 47 Spring Pin 2 Used 48 Oil Seal 2 Used 49 Retaining Ring 2 Used 50 Pump Casing 51 Spring Washer 6 Used 52 Bolt 6 Used 53 Spring Pin 4 Used 54 O Ring 10 Used 55 O Ring 2 Used 56 Pin 2 Used 57 Retaining Ring 12 Used 58 Pin 2 Used 59 Lever 4 Used 60 Pin 4 Used 61 V...

Page 213: ...ead 66 Remove regulator 2 from pump casing 51 l 8 mm 7 Remove socket bolts 3 5 2 used for each Raise regulator 6 to the direction of selector head 66 Remove regulator 6 from pump casing 51 Do not remove socket bolt 4 l 8 mm 8 Remove O rings 56 2 used O rings 55 10 used O rings 7 4 used and spring pins 54 4 used from pump casing 51 dCAUTION Pump device weight 160 kg 355 lb dCAUTION When hoisting th...

Page 214: ...emove socket bolts 91 8 used from covers 92 2 used Remove covers 92 2 used and O rings 93 2 used l 8 mm 14 Remove socket bolts 68 16 used from selector head 66 Remove stoppers S 69 2 used and stoppers L 76 2 used from selector head 66 l 6 mm fNOTE O rings 70 75 are installed on stopper S 69 and stopper L 76 If it is difficult to remove stopper c tap the outer periphery of stopper c by using a plas...

Page 215: ...from pump casing 51 20 Both valve plates 62 77 are very similar and their installing directions are determined Record the position and the direction to install valve plates 62 77 before removing Remove retaining rings 58 4 used from pins 61 4 used Remove valve plates 62 77 from links 78 2 used Do not remove pins 61 4 used unless necessary 21 Remove rotors 18 2 used springs 16 2 used center shafts ...

Page 216: ...d position of gears 27 29 27 Remove retaining rings 26 2 used from shafts 13 19 Remove gears 27 29 from shafts 13 19 dCAUTION The pump casing 51 assembly weight 65 kg 145 lb 28 Attach nylon slings onto pump casing 51 Hoist and place the pump casing 51 assembly with the selector head 66 mounting side down 29 Remove plug 24 from pump casing 51 Remove O ring 23 from plug 24 j 19 mm dCAUTION The pump ...

Page 217: ... and place pump casing 51 with the regulator mounting side up 37 Remove retaining rings 50 2 used and oil seals 49 2 used from pump casing 51 38 Remove retaining ring 40 from gear casing 47 Remove retaining ring 41 from gear shaft 44 39 Remove ball bearing 42 at the upper side and gear shaft 44 from gear casing 47 by using the special tool ST 1393 40 Remove gear 43 and ball bearing 42 from gear ca...

Page 218: ...ERSTRUCTURE W3 8 3 8 Assembly of Pump Device 77 64 63 18 16 15 17 20 11 10 9 49 29 19 26 50 13 26 27 62 60 18 58 57 56 51 59 55 54 7 8 70 67 69 68 66 73 72 74 75 76 68 65 22 21 78 14 24 23 16 15 17 12 11 10 9 49 58 61 12 W178 02 11 086 ...

Page 219: ... 38 Pilot Pump 39 Retaining Ring 40 Retaining Ring 41 Ball Bearing 2 Used 42 Gear 43 Gear Shaft 44 Retaining Ring 45 Oil Seal 46 Gear Casing 47 Spring Pin 2 Used 48 Oil Seal 2 Used 49 Retaining Ring 2 Used 50 Pump Casing 51 Spring Washer 6 Used 52 Bolt 6 Used 53 Spring Pin 4 Used 54 O Ring 10 Used 55 O Ring 2 Used 56 Pin 2 Used 57 Retaining Ring 12 Used 58 Pin 2 Used 59 Lever 4 Used 60 Pin 4 Used ...

Page 220: ...y using a bar and a hammer Tap and listen to ring in order to check that ball bearing 42 is installed to the end fNOTE Insert ball bearing 42 with the stamped mark facing to the engine side 4 Install retaining ring 40 to gear casing 47 Install retaining ring 41 to gear shaft 44 5 Install O ring 31 to plug 30 Install plug 30 to gear casing 47 j 22 mm m 50 N m 5 kgf m 37 lbf ft 6 Warm up bearings 10...

Page 221: ...ST 3070 to bearing 10 After rotating 2 to 3 turns measure the starting torque Adjust bearing nut 9 until the starting torque reaches the specification m 2 0 5 N m 0 2 0 05 kgf m 1 5 0 4 lbf ft fNOTE If the starting torque is higher than the limit of specified torque loosen bearing nut 9 Tap the shaft end and release the load of bearing 10 12 Set the preload of bearings 10 12 with shaft 19 attached...

Page 222: ... m 26 lbf ft dCAUTION The pump casing 51 assembly weight 65 kg 145 lb 18 Attach nylon slings onto pump casing 51 Hoist and place the pump casing 51 assembly with the regulator mounting side up 19 Install the special tools ST 2649 ST 2650 over the spline parts of shafts 13 19 fNOTE If the special tools are not available install a vinyl tape onto the spline part of the shaft in order not to damage o...

Page 223: ...ng ring 26 to the spline of shaft 13 Install gear 29 to the spline of shaft 19 and engage it with gear 27 If gear 29 does not engage adjust shaft 19 within a play of the special tool by turning Install retaining ring 26 to the spline of shaft 19 Remove the special tool ST 7934 24 Install spring pins 48 2 used to gear casing 47 Install gasket 28 dCAUTION The pump casing 51 assembly weight 71 kg 160...

Page 224: ...t deform link 78 28 Install the link 78 assemblies 2 used to the grooves of pins 57 2 used in pump casing 51 fNOTE Install the link 78 assemblies 2 used with lever 60 facing to the selector head 66 side Fit parallel surface a of pin 57 to the groove 29 Apply hydraulic oil onto the plunger 17 mounting surface of shafts 13 19 30 Insert plungers 17 7 used for each into shafts 13 19 31 Apply grease on...

Page 225: ... into the hole of levers 60 2 used at the regulator 6 side Install retaining rings 58 2 used 38 Install O rings 56 2 used O rings 55 10 used O rings 7 4 used and spring pins 54 4 used to pump casing 51 39 Install regulator 2 to pump casing 51 according to the following procedures Adjust sleeves b 2 used in regulator 2 so that the grooves of pin 59 are in a line Place regulator 2 onto pump casing 5...

Page 226: ...sed may not be inserted into the grooves of rotors 18 2 used or pins 74 2 used may not be inserted into the holes of valve plates 62 77 46 Install selector head 66 to pump casing 51 with socket bolts 71 12 used l 10 mm m 110 N m 11 kgf m 81 lbf ft 47 Install O rings 67 4 used to selector head 66 48 Install O rings 70 2 used to stoppers S 69 2 used Install stoppers S 69 2 used to selector head 66 w...

Page 227: ... of oil 1 L 1 06 US qt 55 Install a seal tape onto plug 82 Install plug 82 to elbow 83 j 30 mm m 40 N m 4 kgf m 30 lbf ft IMPORTANT The breather hole of plug 25 is located at the left side viewed from the front of gear casing 47 56 Install a seal tape onto plug 25 Install plug 25 to gear casing 47 j 17 mm m 40 N m 4 kgf m 30 lbf ft 57 Install bracket 88 O ring 84 and N sensor 85 to pump casing 51 ...

Page 228: ...Group 8 Pump Device SECTION 3 UPPERSTRUCTURE W3 8 3 18 Blank ...

Page 229: ...Socket Bolt 2 Used 2 Solenoid Valve 3 Lock Nut 4 Lock Nut 5 Stopper Assembly 6 O Ring 7 Spring 8 Casing 9 Spool 10 Sleeve 11 Piston 12 Cylinder 13 O Ring 14 Cover 15 Set Bolt 16 Lock Nut 17 Lock Nut 18 Lock Nut 19 Socket Bolt 8 Used 20 Stopper Assembly 21 O Ring 22 Spring 23 Spring 24 Sleeve 25 Spool 26 Piston 27 Cylinder 28 O Ring 29 Backup Ring 30 O Ring 31 WDCD 03 08 003 WDCD 03 08 004 TDCD 03 ...

Page 230: ...mbly 21 are removed with the cover 15 assembly together at this time l 6 mm 3 Remove O ring 22 from stopper assembly 21 IMPORTANT Do not turn lock nuts 4 5 If turning the setting changes 4 Remove socket bolts 20 4 used from cover 1 Remove the cover 1 assembly from casing 9 Stopper assembly 6 is removed with the cover 1 assembly together at this time l 6 mm 5 Remove O ring 7 from stopper assembly 6...

Page 231: ...ocket Bolt 2 Used 2 Solenoid Valve 3 Lock Nut 4 Lock Nut 5 Stopper Assembly 6 O Ring 7 Spring 8 Casing 9 Spool 10 Sleeve 11 Piston 12 Cylinder 13 O Ring 14 Cover 15 Set Bolt 16 Lock Nut 17 Lock Nut 18 Lock Nut 19 Socket Bolt 8 Used 20 Stopper Assembly 21 O Ring 22 Spring 23 Spring 24 Sleeve 25 Spool 26 Piston 27 Cylinder 28 O Ring 29 Backup Ring 30 O Ring 31 WDCD 03 08 003 WDCD 03 08 004 TDCD 03 0...

Page 232: ... 13 Install cylinder 13 to casing 9 IMPORTANT Check the direction to install sleeve 25 and spool 26 4 Insert spool 26 into sleeve 25 Install sleeve 25 to the center of casing 9 by using a round bar 5 Install O rings 29 31 and backup ring 30 to cylinder 28 6 Insert piston 27 into cylinder 28 Install cylinder 28 to casing 9 7 Install O ring 7 and spring 8 to stopper assembly 6 with cover 1 attached ...

Page 233: ...bly of Solenoid Valve Solenoid 2 Used 1 Socket Bolt 2 Sleeve 3 O Ring 4 O Ring 5 Wave Washer 6 Plate 7 O Ring 8 O Ring 9 Filter 3 Used 10 O Ring 2 Used 11 O Ring 12 O Ring 13 Body 14 1 10 12 13 14 10 3 4 5 6 7 8 9 11 2 WDCD 03 08 007 WDCD 03 08 006 WDCD 03 08 005 ...

Page 234: ... it straight 1 Remove socket bolts 2 2 used Remove solenoid 1 and O ring 9 l 4 mm IMPORTANT Do not drop plate 7 and wave washer 6 2 Remove plate 7 and wave washer 6 from body 14 3 Remove O rings 4 5 and 8 from sleeve 3 4 Remove filters 10 3 used O rings 11 2 used and O rings 12 13 from body 14 l 6 mm fNOTE When cleaning filter 10 blow it from the both surfaces by using air Finally blow it from the...

Page 235: ...ly of Solenoid Valve Solenoid 2 Used 1 Socket Bolt 2 Sleeve 3 O Ring 4 O Ring 5 Wave Washer 6 Plate 7 O Ring 8 O Ring 9 Filter 3 Used 10 O Ring 2 Used 11 O Ring 12 O Ring 13 Body 14 1 10 12 13 14 10 3 4 5 6 7 8 9 11 2 WDCD 03 08 007 WDCD 03 08 006 WDCD 03 08 005 ...

Page 236: ... 7 to body 14 fNOTE When assembling body 14 in a horizontal position apply grease onto wave washer 6 and plate 7 in order not to fall off After assembling check that plate 7 is installed straight 3 Install O rings 4 5 and 8 to sleeve 3 4 Install O ring 9 to body 14 5 Install solenoid 1 to body 14 with socket bolts 2 2 used l 4 mm m 5 2 N m 0 5 0 2 kgf m 3 7 1 5 lbf ft 6 Assemble another solenoid 1...

Page 237: ...Group 8 Pump Device SECTION 3 UPPERSTRUCTURE W3 8 6 1 6 Structure of Pilot Pump 14 4 15 1 2 3 4 5 6 13 12 11 10 8 9 3 2 7 10 15 W137 02 04 034 ...

Page 238: ...orque Remark N m kgf m lbf ft 1 Housing 1 2 Backup Ring 2 Apply grease when installing 3 Seal 2 Apply grease when installing 4 Bushing 2 Apply hydraulic oil when installing 5 Gear 1 6 Bushing 2 Apply hydraulic oil when installing 7 Flange 1 8 Oil Seal 1 Apply grease onto the lip part when installing 9 Retaining Ring 1 10 O Ring 2 Apply grease when installing 11 Cover 1 12 Washer 4 13 Bolt 4 j 17 3...

Page 239: ...t the hoses and install the clips in case the clips which secure the hoses have been removed Removal 1 Set the machine position for inspection and maintenance Refer to W1 6 1 dCAUTION Bleed air from the hydraulic oil tank Refer to W1 4 1 dCAUTION Release any pressure in the hydraulic circuit Refer to W1 5 1 2 Open engine cover 1 3 Remove bolts washers 2 2 used Remove cover 3 j 17 mm 4 Remove bolts...

Page 240: ...washers 8 3 used and clamps 77 3 used j 17 mm 7 Remove 3 spool solenoid valve unit 9 Refer to W3 12 2 8 Disconnect the connectors and hoses connected to signal control valve 10 Refer to W3 13 1 9 Disconnect connectors 11 2 used WDCD 03 09 012 WDCD 03 09 002 9 10 11 8 77 11 ...

Page 241: ... Place a container under the disconnecting part of pipe 16 Remove couplings 17 18 Disconnect the both ends of pipe 16 j 13 mm 14 Place a container under the disconnecting part of pipe 19 Remove coupling 20 Disconnect the oil cooler side of pipe 19 j 13 mm 15 Remove socket bolts 21 2 used Disconnect the control valve 22 side of pipe 19 Remove O ring 23 l 8 mm WDCD 03 09 003 WDCD 03 09 004 ...

Page 242: ...8 mm 20 Remove socket bolts 31 4 used and flanges 32 2 used Disconnect hose 33 Remove O ring 34 l 10 mm 21 Remove socket bolts 35 16 used flanges 36 2 used and flanges 37 6 used Disconnect hoses 38 4 used Remove O ring 39 and O rings 40 3 used l 8 mm 22 Place a container under the disconnecting part of pipe 41 Remove coupling 42 Disconnect the hydraulic oil tank side of pipe 41 j 13 mm 23 Remove s...

Page 243: ...t the front attachment side of hose 54 j 41 mm 28 Disconnect the center joint side of hoses 55 2 used j 36 mm dCAUTION The control valve 22 assembly weight 280 kg 620 lb 29 Install eyebolts M10 Pitch 1 75 mm 2 used to eyebolt mounting holes a 2 places of control valve 22 Attach nylon slings onto the eyebolts Hoist and hold the control valve 22 assembly 30 Remove bolts 56 2 used bolts 57 2 used was...

Page 244: ...ol valve 10 assembly j 22 mm 32 Remove socket bolts 62 24 used flanges 63 10 used and flanges 64 2 used Disconnect hoses 51 2 used hoses 55 2 used and hoses 53 54 Remove O rings 65 5 used and O ring 66 l 8 mm 33 Disconnect the both ends of hose 67 j 17 mm 34 Disconnect hoses 68 2 used j 17 mm 68 67 WDCD 03 09 008 WDCD 03 09 009 ...

Page 245: ...ses 74 6 used j 19 mm dCAUTION Control valve 22 weight 240 kg 530 lb 41 Install eyebolts M10 Pitch 1 75 mm 2 used to eyebolt mounting holes a 2 places of control valve 22 Attach nylon slings onto the eyebolts Hoist and hold control valve 22 42 Remove bolts 75 4 used and washers 76 4 used Remove control valve 22 from brackets 78 79 j 24 mm 43 Remove the adapter with control valve 22 attached if nec...

Page 246: ...ed j 24 mm m 210 N m 21 kgf m 155 lbf ft 4 Connect the control valve 22 side of hoses 74 6 used j 19 mm m 30 N m 3 kgf m 22 lbf ft 5 Connect the control valve 22 side of hoses 73 2 used j 17 mm m 25 N m 2 5 kgf m 18 lbf ft 6 Connect the both ends of hose 72 j 17 mm m 25 N m 2 5 kgf m 18 lbf ft 7 Connect the control valve 22 side of hoses 71 6 used j 19 mm m 30 N m 3 kgf m 22 lbf ft 8 Connect the b...

Page 247: ... 2 5 kgf m 18 lbf ft 12 Install O ring 66 and O rings 65 5 used Connect the control valve 22 side of hoses 54 53 and hoses 55 51 with flanges 64 2 used flanges 63 10 used and socket bolts 62 24 used l 8 mm m 65 N m 6 5 kgf m 48 lbf ft 13 Install the signal control valve 10 assembly with washers 61 3 used and bolts 60 3 used j 22 mm m 140 N m 14 kgf m 103 lbf ft 68 67 22 WDCD 03 09 008 WDCD 03 09 0...

Page 248: ...hers 58 2 used bolts 57 2 used and bolts 53 2 used j 24 mm m 270 N m 27 kgf m 200 lbf ft 16 Connect hoses 55 2 used j 36 mm m 180 N m 18 kgf m 133 lbf ft 17 Connect hose 54 j 41 mm m 200 N m 20 kgf m 148 lbf ft 18 Connect hose 53 j 36 mm m 180 N m 18 kgf m 133 lbf ft 19 Install O ring 52 Connect hoses 51 2 used with flanges 50 4 used and socket bolts 49 8 used l 8 mm m 65 N m 6 5 kgf m 48 lbf ft 2...

Page 249: ...h flanges 37 6 used flanges 36 2 used and socket bolts 35 16 used l 8 mm m 65 N m 6 5 kgf m 48 lbf ft 24 Install O ring 34 Connect hose 33 with flanges 32 2 used and socket bolts 31 4 used l 10 mm m 110 N m 1 1 kgf m 81 lbf ft 25 Install O rings 30 2 used Connect hoses 29 2 used with flanges 28 4 used and socket bolts 27 8 used l 8 mm m 65 N m 6 5 kgf m 48 lbf ft 26 Connect hose 26 j 36 mm m 180 N...

Page 250: ...ide of pipe 19 with coupling 20 j 13 mm m 10 to 13 N m 1 to 1 3 kgf m 7 4 to 9 6 lbf ft 31 Connect pipe 16 with couplings 18 17 j 13 mm m 10 to 13 N m 1 to 1 3 kgf m 7 4 to 9 6 lbf ft 32 Install clamp 15 with bolts washers 14 2 used j 19 mm m 90 N m 9 kgf m 66 lbf ft 33 Connect hose 13 j 19 mm m 30 N m 3 kgf m 22 lbf ft 34 Connect hoses 12 2 used j 27 mm m 80 N m 8 kgf m 59 lbf ft WDCD 03 09 003 W...

Page 251: ...sed 36 Connect all removed connectors and hoses to signal control valve 10 Refer to W3 13 1 37 Install 3 spool solenoid valve unit 9 Refer to W3 12 2 38 Install clamps 77 3 used with bolts washers 8 3 used j 17 mm m 50 N m 5 kgf m 37 lbf ft WDCD 03 09 012 WDCD 03 09 002 9 10 11 8 77 11 ...

Page 252: ...art the engine and check for any oil leaks 40 Install cover 7 with bolts washers 6 7 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 41 Install cover 5 with bolts washers 4 5 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 42 Install cover 3 with bolts washers 2 2 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 43 Shut engine cover 1 WDCD 03 06 001 WDCD 03 04 010 1 5 4 6 7 2 3 ...

Page 253: ...CTION 3 UPPERSTRUCTURE W3 9 2 1 Housing 5 Spool Side 1 Housing 4 Spool Side 2 Socket Bolt 9 Used 3 O Ring 16 Used 4 O Ring 12 Used 5 O Ring 3 Used 6 3 3 1 4 4 6 5 4 2 4 4 5 4 4 4 6 5 5 4 5 Disassembly of Housing W1V1 02 05 023 ...

Page 254: ... Housing dCAUTION The housing 1 assembly weight 130 kg 290 lb The housing 2 assembly weight 120 kg 265 lb 1 Remove socket bolts 3 9 used l 14 mm 2 Remove housing 2 from housing 1 3 Remove O rings 4 16 used O rings 5 12 used and O rings 6 3 used from housing 1 or housing 2 ...

Page 255: ...ERSTRUCTURE W3 9 2 3 Housing 5 Spool Side 1 Housing 4 Spool Side 2 Socket Bolt 9 Used 3 O Ring 16 Used 4 O Ring 12 Used 5 O Ring 3 Used 6 Assembly of Housing 4 5 4 6 5 4 4 5 2 4 5 6 6 5 4 5 4 5 1 2 3 3 3 3 3 W1V1 02 05 011 W1V1 02 05 001 ...

Page 256: ...o prevent them from seizing 1 Install O rings 4 16 used O rings 5 12 used and O rings 6 3 used to the mounting surface of housing 2 dCAUTION The housing 1 assembly weight 130 kg 290 lb The housing 2 assembly weight 120 kg 265 lb 2 Install housing 1 to housing 2 with socket bolts 3 9 used l 14 mm m 210 to 220 N m 21 to 22 kgf m 155 to 162 lbf ft ...

Page 257: ...pool Side W1V1 02 05 024 1 2 3 4 5 6 9 10 7 8 16 6 a b d 12 11 15 3 31 6 10 9 20 19 c e f g h i 4 8 7 13 13 14 19 21 22 37 47 38 38 38 53 51 52 50 45 45 44 44 43 43 42 48 49 46 38 38 38 38 38 52 41 63 41 41 41 58 57 56 55 54 39 39 39 39 23 30 24 32 33 34 35 36 25 26 28 29 20 7 8 4 59 59 62 ...

Page 258: ...5 106 107 108 109 110 112 113 77 118 4 19 4 70 71 72 71 73 1 7 7 7 8 8 8 75 91 92 93 94 95 96 77 88 87 86 85 84 98 99 87 77 13 100 101 128 127 126 120 119 115 114 116 119 120 123 122 116 121 115 114 120 119 117 116 115 114 125 124 83 76 77 78 40 79 80 6 97 97 13 74 74 59 59 59 k j n o m p l 81 82 90 13 89 13 87 111 77 78 ...

Page 259: ...4 Overload Relief Valve 2 Used 75 Poppet 76 Spring 77 O Ring 5 Used 78 O Ring 2 Used 79 O Ring 80 Plug 81 O Ring 82 Plug 83 Poppet 84 Poppet 85 Spring 86 Plug 87 Spring 3 Used 88 Sleeve 89 Plug 90 O Ring 91 Body 92 Spool 93 Spring 94 Spring Seat 95 O Ring 96 Plug 97 Socket Bolt 12 Used 98 Poppet 99 Poppet 100 Spring 101 Plug 102 O Ring 103 Cap 104 Socket Bolt 4 Used 105 Spool 106 Spring 107 Flange...

Page 260: ...e sleeve 29 assembly seat 22 and spring 21 from housing 1 Remove backup rings 24 28 O rings 25 26 poppet 23 and spool 30 from sleeve 29 Disassembly of Overload Relief Valve 20 IMPORTANT Do not disassemble the overload relief valve If the overload relief valve has been disassembled pressure should be adjusted Refer to TROUBLESHOOTING Operational Performance Test in the separated volume T M 7 Remove...

Page 261: ...and poppet 46 from spool 47 Disassembly of Boom 1 Spool 50 17 Secure spool 50 in a vise by using wooden pieces Remove bolt 41 spring seats 38 2 used and spring 39 from spool 50 l 8 mm 18 Warm the plug 48 part of spool 50 by using a drier Remove plug 48 by using the special tool ST 5909 Remove O ring 44 and backup ring 43 from plug 48 19 Remove spring 45 and poppet 49 from spool 50 Disassembly of A...

Page 262: ...w Rate Control Valve 25 Remove socket bolts 97 4 used Remove the body 91 assembly and O rings 13 77 from housing 1 l 8 mm 26 Remove plug 96 O ring 95 spring seat 94 spring 93 and spool 92 from body 91 Remove plug 89 and O ring 90 from body 91 j 27 mm 27 Remove sleeve 88 springs 85 87 plug 86 and poppets 84 83 from housing 1 Disassembly of Arm 2 Flow Rate Control Valve 28 Remove socket bolts 97 8 u...

Page 263: ...e plugs 80 82 and O rings 79 81 from body 40 35 Remove spring 76 and poppet 75 from housing 1 Disassembly of Bypass Shut Out Valve 36 Remove socket bolts 6 2 used Remove flange 107 and O ring 4 from housing 1 l 8 mm 37 Remove spring 106 and spool 105 from housing 1 38 Remove socket bolts 104 4 used Remove cap 103 and O ring 102 from housing 1 l 8 mm 39 Remove plugs 8 3 used and O rings 7 3 used fr...

Page 264: ...trol Valve Upper Control Valve Side Control Valve Lower Control Valve Front W1V1 02 05 065 W1V1 02 05 066 W1V1 02 05 067 W1V1 02 05 068 63 6 36 123 19 20 59 67 59 67 59 67 59 64 63 63 19 20 59 62 63 63 6 6 7 8 11 12 7 8 11 12 3 4 15 16 6 107 40 19 20 19 20 7 8 1 6 2 3 45 97 97 91 123 104 103 19 74 1 ...

Page 265: ...4 Spool Side Section E E 4 Spool Side Section F F 4 Spool Side Section C C 4 Spool Side C C D D E E F F G G H H I I J J W1V1 02 05 065 1 8 7 A e f g W1V1 02 05 038 38 38 41 51 1 39 W1V1 02 05 035 W1V1 02 05 036 W1V1 02 05 028 46 45 42 43 44 19 50 19 1 20 B D C 74 47 49 45 48 43 44 1 19 74 ...

Page 266: ...W3 9 3 10 Section G G 4 Spool Side Section I I 4 Spool Side Section H H 4 Spool Side Section J J 4 Spool Side W1V1 02 05 029 W626 02 05 001 E F h 1 20 19 1 65 66 37 38 38 41 60 61 52 52 53 W1V1 02 05 071 W1V1 02 05 037 58 57 54 56 55 105 106 4 107 1 ...

Page 267: ...9 72 1 96 95 94 93 91 92 90 89 88 87 86 85 13 77 84 83 W1V1 02 05 031 W1V1 02 05 032 W1V1 02 05 042 W1V1 02 05 034 31 23 1 13 78 80 79 40 114 119 120 122 121 116 115 114 115 116 125 120 119 124 81 82 77 76 75 36 35 32 34 33 30 29 13 28 26 25 24 22 21 1 119 117 116 115 114 120 118 123 13 77 87 99 98 101 100 123 112 113 123 77 13 111 110 87 77 109 108 78 128 1 ...

Page 268: ... Ring 57 Spool 58 Spring 59 O Ring 8 Used 62 Cap 63 Socket Bolt 14 Used 64 Cap 67 Cap 3 Used 68 Socket Bolt 2 Used 69 Cap 70 Bolt 71 Spring Seat 2 Used 72 Spring 73 Spool 74 Overload Relief Valve 2 Used 75 Poppet 76 Spring 77 O Ring 5 Used 78 O Ring 2 Used 79 O Ring 80 Plug 81 O Ring 82 Plug 83 Poppet 84 Poppet 85 Spring 86 Plug 87 Spring 3 Used 88 Sleeve 89 Plug 90 O Ring 91 Body 92 Spool 93 Spri...

Page 269: ...1 lbf ft 5 Install spring seats 38 2 used spring 39 and bolt 41 to the top of spool 47 l 8 mm m 15 N m 1 5 kgf m 11 lbf ft Assembly of Boom 1 Spool 50 6 Secure spool 50 in a vise by using wooden pieces Install poppet 49 and spring 45 to the bottom of spool 50 7 Install O ring 44 and backup ring 43 to plug 48 Apply LOCTITE 271 onto the thread part of plug 48 8 Install plug 48 to spool 50 by using t...

Page 270: ...ieces Install O ring 56 and backup ring 55 to spool 57 Install spool 57 to spool 54 Install the spool 54 assembly and spring 58 to housing 1 Assembly of Spool 13 Install the spool 51 50 47 37 assemblies O rings 59 4 used and O ring 4 to housing 1 Install cap 62 to housing 1 with socket bolts 63 6 used l 8 mm m 43 N m 4 3 kgf m 31 5 lbf ft ...

Page 271: ... Install spool 73 and O ring 4 to housing 1 Install cap 69 to housing 1 with socket bolts 68 2 used l 5 mm m 10 N m 1 kgf m 7 4 lbf ft Assembly of Bypass Shut Out Valve 21 Install spool 105 spring 106 and O ring 4 to housing 1 Install flange 107 to housing 1 with socket bolts 6 4 used l 8 mm m 62 N m 6 2 kgf m 46 lbf ft 22 Install plugs 8 3 used and O rings 7 3 used to housing 1 Assembly of Overlo...

Page 272: ...lugs 8 2 used to housing 1 l 10 mm 26 Install O ring 7 to plug 8 Install poppet 11 spring 12 and plug 8 to housing 1 l 10 mm 27 Install poppets 2 15 springs 3 2 used and O rings 4 2 used to housing 1 28 Install flanges 5 16 to housing 1 with socket bolts 6 4 used l 8 mm m 62 N m 6 2 kgf m 46 lbf ft 29 Install O ring 102 to housing 1 Install cap 103 to housing 1 with socket bolts 104 4 used l 8 mm ...

Page 273: ...7 Install body 40 to housing 1 with socket bolts 6 4 used l 8 mm m 62 N m 6 2 kgf m 46 lbf ft 38 Tighten plugs 80 82 Assembly of Arm 2 Flow Rate Control Valve 39 Install O rings 115 120 3 used for each to plugs 114 119 3 used for each as shown in detail D E and F 40 Install spool 118 spring 117 and spring seat 116 to body 123 as shown in detail D Temporarily tighten plugs 114 119 to body 123 j 24 ...

Page 274: ...9 Control Valve SECTION 3 UPPERSTRUCTURE W3 9 3 18 47 Install body 123 to housing 1 with socket bolts 97 8 used l 8 mm m 62 N m 6 2 kgf m 46 lbf ft 48 Tighten plugs 114 119 3 used for each to body 123 j 24 mm ...

Page 275: ... Valve 5 Spool Side 1 2 3 4 5 6 13 12 11 7 17 16 10 20 a b e f g h i d 14 22 23 24 30 25 33 34 35 36 44 44 44 52 55 44 44 51 51 42 42 42 42 42 42 50 42 47 48 48 42 42 42 43 43 43 43 43 49 41 45 46 27 28 29 31 32 18 19 15 8 8 7 9 26 20 37 38 39 28 40 20 21 8 10 9 W1V1 02 05 026 c ...

Page 276: ...2 99 10 9 100 56 j p o l n q r s m k 57 59 70 71 56 104 57 77 78 61 62 63 60 61 62 63 104 13 8 8 75 13 87 88 89 90 13 64 65 79 80 81 82 8 8 10 10 10 9 9 9 95 51 51 51 51 51 98 98 98 98 103 52 97 96 16 52 52 52 52 15 3 2 14 93 6 94 93 6 92 91 91 38 86 84 85 6 5 83 7 12 76 13 64 65 66 67 68 69 20 ...

Page 277: ...sed 62 O Ring 2 Used 63 Plug 2 Used 64 Sleeve 2 Used 65 Spring 2 Used 66 Plug 67 Spring 68 Poppet 69 Poppet 70 Plug 71 O Ring 72 Flange 73 Spring 74 Poppet 75 Flange 2 Used 76 Poppet 2 Used 77 Spool 78 Spring 79 Plug 80 Spring 81 Poppet 82 Poppet 83 Poppet 84 Cover 2 Used 85 O Ring 2 Used 86 Poppet 87 Plug 88 O Ring 89 Spring 90 Poppet 91 Socket Bolt 4 Used 92 Cap 2 Used 93 Spring Seat 2 Used 94 S...

Page 278: ...19 IMPORTANT Do not disassemble the overload relief valve If the overload relief valve has been disassembled pressure should be adjusted Refer to TROUBLESHOOTING Operational Performance Test in the separated volume T M 7 Remove overload relief valve 19 and O ring 18 from housing 1 j 32 mm Disassembly of Main Relief Valve 17 IMPORTANT Do not disassemble the main relief valve If the main relief valv...

Page 279: ...Auxiliary Spool 45 16 Secure spool 45 in a vise by using wooden pieces Remove bolt 44 spring seats 42 2 used and spring 43 from spool 45 l 8 mm Disassembly of Boom 2 Spool 46 17 Secure spool 46 in a vise by using wooden pieces Remove bolt 44 spring seats 42 2 used and spring 43 from spool 46 l 8 mm Disassembly of Arm 1 Spool 47 18 Secure spool 47 in a vise by using wooden pieces Remove bolt 44 spr...

Page 280: ...assembly of Check Valve Auxiliary Flow Combiner Circuit 23 Remove socket bolts 8 2 used Remove flange 7 O ring 6 spring 5 and poppet 83 from housing 1 l 8 mm Disassembly of Arm Anti Drift Valve 24 Remove socket bolts 8 4 used Remove flange 72 O rings 20 3 used spring 73 and poppet 74 from housing 1 Remove plug 70 and O ring 71 from flange 72 l 8 mm Disassembly of Arm 1 Flow Rate Control Valve and ...

Page 281: ...d O rings 85 2 used from housing 1 l 8 mm Disassembly of Load Check Valve Travel Left Parallel Circuit 31 Remove plug 10 O ring 9 spring 38 and poppet 86 from housing 1 l 8 mm Disassembly of Check Valve Digging Regenerative Circuit 32 Remove plug 87 O ring 88 spring 89 and poppet 90 from housing 1 j 24 mm 33 Remove plug 16 backup ring 15 and O ring 14 from housing 1 j 24 mm 34 Remove plug 3 and O ...

Page 282: ...5 Spool Side Control Valve Upper Control Valve Side Control Valve Lower Control Valve Front W1V1 02 05 065 W1V1 02 05 066 W1V1 02 05 068 51 55 51 98 51 98 51 98 51 98 51 103 52 52 52 52 52 52 17 19 36 32 8 9 10 7 11 12 13 4 5 6 7 1 8 8 58 72 75 99 100 9 10 10 104 W1V1 02 05 070 8 2 3 ...

Page 283: ...ection E E 5 Spool Side Section F F 5 Spool Side Section C C 5 Spool Side C C D D E E F F G G H H I I J J W1V1 02 05 065 97 6 96 93 92 55 54 53 45 103 46 44 42 43 42 51 41 51 A W1V1 02 05 043 83 5 7 6 1 17 9 10 e f g W1V1 02 05 044 98 1 84 8 8 84 14 15 16 1 W1V1 02 05 045 W1V1 02 05 046 1 8 75 13 12 76 ...

Page 284: ...ection H H 5 Spool Side Section I I 5 Spool Side Detail A Detail B W1V1 02 05 053 W1V1 02 05 033 1 63 62 61 78 104 77 57 56 64 65 79 80 20 13 81 82 1 10 9 2 3 88 89 90 W1V1 02 05 050 W1V1 02 05 051 W1V1 02 05 052 1 18 19 B 21 h i C D 47 42 48 50 43 49 48 42 44 99 1 100 8 13 12 76 75 1 ...

Page 285: ... 49 Spring 50 Spool 51 O Ring 10 Used 52 Socket Bolt 16 Used 55 Cap 56 Plug 2 Used 57 O Ring 2 Used 58 Socket Bolt 8 Used 59 Spool 60 Spring 61 Spring Seat 2 Used 62 O Ring 2 Used 63 Plug 2 Used 64 Sleeve 2 Used 65 Spring 2 Used 66 Plug 67 Spring 68 Poppet 69 Poppet 70 Plug 71 O Ring 72 Flange 73 Spring 74 Poppet 75 Flange 2 Used 76 Poppet 2 Used 77 Spool 78 Spring 79 Plug 80 Spring 81 Poppet 82 P...

Page 286: ...Install spring seats 42 2 used spring 43 and bolt 44 to spool 46 l 8 mm m 15 N m 1 5 kgf m 11 lbf ft Assembly of Arm 1 Spool 47 4 Secure spool 47 in a vise by using wooden pieces Install spring seats 42 48 2 used for each springs 43 49 and bolt 44 to spool 47 l 8 mm m 15 N m 1 5 kgf m 11 lbf ft Assembly of Swing Spool 50 5 Secure spool 50 in a vise by using wooden pieces Install spring seats 42 2 ...

Page 287: ...sembly of Digging Regenerative Valve and Auxiliary Flow Combiner Valve 15 Install spool 97 95 springs 96 94 O rings 6 2 used and spring seats 93 2 used to housing 1 Install caps 92 2 used to housing 1 with socket bolts 91 4 used l 5 mm m 10 N m 1 kgf m 7 4 lbf ft Assembly of Check Valve Digging Regenerative Circuit 16 Install O ring 88 to plug 87 Install poppet 90 spring 89 and plug 87 to housing ...

Page 288: ...4 seat 23 and spring 22 to sleeve 29 Install the sleeve 29 assembly to housing 1 27 Install O ring 35 to plug 36 Install spring 33 piston 34 O ring 31 and plug 36 to body 32 j 38 mm 28 Install O rings 20 5 used and O ring 31 to housing 1 Install the body 32 assembly to housing 1 with socket bolts 8 3 used l 8 mm m 62 N m 6 2 kgf m 46 lbf ft 29 Tighten plug 36 j 38 mm Assembly of Arm 1 Flow Rate Co...

Page 289: ...s been disassembled pressure should be adjusted Refer to TROUBLESHOOTING Operational Performance Test in the separated volume T M 38 Install main relief valve 17 to housing 1 j 32 mm m 60 N m 6 kgf m 44 lbf ft Assembly of Load Check Valve Arm Regenerative Circuit 39 Install poppet 4 spring 5 and O ring 6 to housing 1 Install flange 7 to housing 1 with socket bolts 8 2 used l 8 mm m 62 N m 6 2 kgf ...

Page 290: ...Group 9 Control Valve SECTION 3 UPPERSTRUCTURE W3 9 4 16 Blank ...

Page 291: ...ification tag onto the connectors hoses and pipes for assembling Connect the hoses and install the clips in case the clips which secure the hoses have been removed Removal 1 Set the machine position for inspection and maintenance Refer to W1 6 1 dCAUTION Bleed air from the hydraulic oil tank Refer to W1 4 1 2 Open engine cover 1 3 Remove bolts washers 2 5 used Remove cover 3 j 17 mm 1 3 2 WDCD 03 ...

Page 292: ...move socket bolts 8 8 used and flanges 9 4 used Disconnect hoses 10 2 used Remove O rings 11 2 used l 8 mm dCAUTION Swing device 5 weight 220 kg 490 lb 8 Attach a nylon sling onto the body of swing motor Hoist and hold swing device 5 9 Remove bolts 12 14 used and washers 13 14 used Remove swing device 5 j 30 mm 10 Remove the adapter with swing device 5 attached if necessary WDCD 03 10 001 ...

Page 293: ...lon sling onto the body of swing motor Hoist swing device 5 3 Install swing device 5 with washers 13 14 used and bolts 12 14 used j 30 mm m 500 N m 50 kgf m 370 lbf ft 4 Install O rings 11 2 used Connect hoses 10 2 used with flanges 9 4 used and socket bolts 8 8 used l 8 mm m 58 N m 5 8 kgf m 43 lbf ft 5 Connect hoses 7 2 used j 19 mm m 30 N m 3 kgf m 22 lbf ft 6 Connect hose 6 j 36 mm m 180 N m 1...

Page 294: ...Bleed air from the hydraulic system Refer to W1 4 1 IMPORTANT Check the hydraulic oil level Start the engine and check for any oil leaks 9 Install cover 3 with bolts washers 2 5 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 10 Shut engine cover 1 1 3 2 WDCD 03 06 001 ...

Page 295: ...g 6 Used 11 Planetary Gear 3 Used 12 Thrust Plate 3 Used 13 Roller Bearing 14 Bearing Nut 15 Lock Plate 16 Bolt 2 Used 17 Second Stage Carrier 18 Thrust Plate 19 Second Stage Sun Gear 20 First Stage Carrier 21 Retaining Ring 22 Socket Bolt 8 Used 23 Socket Bolt 12 Used 24 Ring Gear 25 Housing 26 Roller Bearing 27 Oil Seal 28 Sleeve 29 O Ring 30 Shaft 31 Drain Plug 32 Pipe 33 33 23 22 21 20 19 18 1...

Page 296: ...h bolts M20 Pitch 2 5 mm 2 used so that stopper c at the bottom of special tool ST 5097 should be inserted into the clearance between teeth of the pinion gear in shaft 31 Secure the special tool ST 5097 on a workbench in order to receive the reaction force j 30 mm 3 Remove drain plug 32 Drain off oil from swing device b l 8 mm 4 Disconnect pipe 33 from housing 26 j 18 mm 5 Put the matching marks a...

Page 297: ...IMPORTANT The hole for spring pin 5 located on first stage carrier 21 is not a through one Check the tapping in distance of spring pin 5 14 Install spring pin 5 with the first stage carrier 21 assembly attached to pin 4 by using the special tool ST 1462 Stop tapping when spring pin 5 reaches the middle of pin 4 hole and do not tap spring pin 5 to the end 15 Remove pins 4 3 used planetary gears 7 3...

Page 298: ... Hoist the housing 26 assembly and remove the special tool ST 5097 j 30 mm 23 Install the special tool ST 1464 to housing 26 Place housing 26 on press a j 30 mm 24 Push the spline side of shaft 31 by using press a Remove the shaft 31 assembly and the inner race of roller bearing 14 from housing 26 The inner race of roller bearing 27 and sleeve 29 are removed with shaft 31 together 25 Place the spe...

Page 299: ...e outer race a of roller bearing 27 by using a round bar and a hammer dCAUTION The housing 26 assembly weight 60 kg 135 lb 30 Attach nylon slings onto the body of the housing 26 assembly Hoist and turn over the housing 26 assembly 31 Insert a screwdriver into the notch on housing 26 where oil seal 28 is mounted Remove oil seal 28 from housing 26 fNOTE THREEBOND 1215 or LOCTITE 5020 has been applie...

Page 300: ... 6 Used 11 Planetary Gear 3 Used 12 Thrust Plate 3 Used 13 Roller Bearing 14 Bearing Nut 15 Lock Plate 16 Bolt 2 Used 17 Second Stage Carrier 18 Thrust Plate 19 Second Stage Sun Gear 20 First Stage Carrier 21 Retaining Ring 22 Socket Bolt 8 Used 23 Socket Bolt 12 Used 24 Ring Gear 25 Housing 26 Roller Bearing 27 Oil Seal 28 Sleeve 29 O Ring 30 Shaft 31 Drain Plug 32 Pipe 33 1 22 4 5 23 6 7 8 10 12...

Page 301: ...t personal injury 4 Evenly tap and install the outer race of roller bearing 27 to housing 26 by using a bar and a hammer Tap and listen to ring in order to check if the installation is completed dCAUTION Metal fragments may fly off when a hammer is used Wear necessary protection such as goggles helmets etc in order to prevent personal injury 5 Apply THREEBOND 1215 onto the outer surface of oil sea...

Page 302: ...f oil seal 28 dCAUTION Metal fragments may fly off when a hammer is used Wear necessary protection such as goggles helmets etc in order to prevent personal injury 10 Install the inner race of roller bearing 14 to shaft 31 by using a bar and a hammer Tap the inner race until the upper end on the inner race of roller bearing 14 reaches two threads for bearing nut 15 in shaft 31 fNOTE The fitting bet...

Page 303: ... the bolts M20 Pitch 2 5 mm 2 used which secure housing 26 and the special tool ST 5097 j 30 mm 19 Turn housing 26 to both sides five times Tap housing 26 several times by using a plastic hammer 20 Install housing 26 to the special tool ST 5097 with bolts M20 Pitch 2 5 mm 2 used j 30 mm 21 Tighten bearing nut 15 by using the special tool ST 2926 m 500 N m 50 kgf m 370 lbf ft 22 Repeat step 18 and ...

Page 304: ...r 18 and pin 9 should be in line IMPORTANT Check the direction of spring pin 10 32 Install spring pin 10 to second stage carrier 18 by using the special tool ST 1463 with slit a of spring pin 10 facing to the end of pin 9 33 Install planetary gears 12 2 used needle bearings 11 4 used thrust plates 13 2 used pins 9 2 used and spring pins 10 2 used to second stage carrier 18 in the same way as step ...

Page 305: ... screw part of ring gear 25 Hoist ring gear 25 Fit the matching marks Install ring gear 25 to housing 26 with socket bolts 24 12 used l 14 mm m 210 N m 21 kgf m 155 lbf ft 43 Fit the spline and install the first stage carrier 21 assembly to second stage sun gear 20 IMPORTANT Check the direction to install first stage sun gear 2 44 Install first stage sun gear 2 to the first stage carrier 21 assemb...

Page 306: ...TION Motor 1 weight 48 kg 110 lb 50 Install eyebolts M10 Pitch 1 5 mm 2 used to motor 1 Hoist motor 1 Fit the matching marks Install motor 1 to ring gear 25 with socket bolts 23 8 used l 10 mm m 90 N m 9 kgf m 66 lbf ft a a Eyebolt Mounting Position W178 02 06 005 ...

Page 307: ...11 O Ring 12 Piston 13 Spring 14 Ball 15 Plug 2 Used 16 O Ring 17 O Ring 18 Brake Piston 19 Spring 24 Used 20 Valve Plate 21 Bearing 22 O Ring 23 Plug 2 Used 24 O Ring 2 Used 25 Spring 2 Used 26 Poppet 2 Used 27 Valve Casing 28 Socket Bolt 4 Used 29 O Ring 2 Used 30 Plug 2 Used 31 Relief Valve 2 Used 32 1 16 15 14 13 12 2 3 4 23 5 7 24 25 26 27 32 22 21 20 19 18 17 28 29 27 26 25 24 30 31 8 9 10 1...

Page 308: ...e between valve casing 28 and casing 1 l 17 mm IMPORTANT Do not remove bearing 22 unless necessary 6 Remove valve casing 28 from casing 1 As valve plate 21 may be removed with valve casing 28 together do not drop valve plate 21 Remove O ring 23 IMPORTANT Do not damage the mating surfaces when separating valve plate 21 from valve casing 28 or rotor 9 by using a screwdriver 7 If valve plate 21 is st...

Page 309: ...seal 2 from casing 1 dCAUTION Metal fragments may fly off when a hammer is used Wear necessary protection such as goggles helmets etc in order to prevent personal injury 15 Remove the outer race of bearing 3 from casing 1 by using a bar and a hammer 16 Remove the inner race of bearing 3 from shaft 4 by using a press IMPORTANT The filter and orifice are installed inside piston 13 Do not disassemble...

Page 310: ...12 Piston 13 Spring 14 Ball 15 Plug 2 Used 16 O Ring 17 O Ring 18 Brake Piston 19 Spring 24 Used 20 Valve Plate 21 Bearing 22 O Ring 23 Plug 2 Used 24 O Ring 2 Used 25 Spring 2 Used 26 Poppet 2 Used 27 Valve Casing 28 Socket Bolt 4 Used 29 O Ring 2 Used 30 Plug 2 Used 31 Relief Valve 2 Used 32 27 26 25 24 29 12 13 14 15 16 31 30 28 22 23 18 17 11 9 7 5 1 4 32 21 20 19 10 6 8 3 2 W178 02 11 151 W17...

Page 311: ...lly with the valve casing 28 mounting side up Install shoe plate 5 to casing 1 with the chamfered surface facing inside 6 Fit the notches on plate 7 and retainer 8 Install plungers 6 9 used Install retainer 8 to plunger 6 with the notch facing to the shoe plate 5 side 7 Apply hydraulic oil onto the plunger hole on rotor 9 Insert the plunger 6 assembly into rotor 9 8 Place casing 1 horizontally Ins...

Page 312: ...ling off from valve casing 28 16 Apply grease onto the needle part of bearing 22 in order to install shaft 4 to bearing 22 easily 17 FIt the matching marks on valve casing 28 and casing 1 Place valve casing 28 onto casing 1 Check that a clearance between valve casing 28 and casing 1 is equal to that before disassembling If the clearance is larger than that before disassembling repeat the procedure...

Page 313: ...nect the hoses and install the clips in case the clips which secure the hoses have been removed Removal 1 Set the machine position for inspection and maintenance Refer to W1 6 1 dCAUTION Bleed air from the hydraulic oil tank Refer to W1 4 1 2 Open door 1 3 Remove bolts washers 2 2 used Remove seat belts 3 2 used and spacers 4 2 used j 24 mm dCAUTION Seat 5 weight 20 kg 45 lb 4 Remove socket bolts ...

Page 314: ...nd washers 11 2 used Remove armrest 12 l 6 mm 7 Raise boot 13 and remove screws 14 3 used 8 Raise cover 15 Disconnect connector 16 Remove cover 15 9 Remove screw 17 bolt washer 18 and washer 19 Remove cover 20 j 10 mm 10 Remove screws 21 22 2 used for each Remove cover 23 16 Detail B 14 14 21 23 22 10 11 12 19 18 20 7 8 13 15 17 9 B WDAA 03 12 001 WDAA 03 12 002 ...

Page 315: ...t 26 Remove the lever 27 assembly j 19 mm 22 mm 13 Disconnect hoses 28 6 used j 19 mm 14 Remove socket bolts 30 4 used and washers 31 4 used Remove pilot valve 29 and boot 32 l 6 mm 15 Remove the adapter with pilot valve 29 attached if necessary 25 28 29 32 27 26 24 30 31 WDAA 03 12 023 WDAA 03 12 019 ...

Page 316: ...29 and boot 32 with washers 31 4 used and socket bolts 30 4 used l 6 mm m 20 N m 2 kgf m 15 lbf ft 3 Connect hoses 28 6 used j 19 mm m 30 N m 3 kgf m 22 lbf ft 4 Tighten lock nut 26 and install the lever 27 assembly j 19 mm 22 mm m 55 N m 5 5 kgf m 40 lbf ft 5 Install clip bands 25 24 25 28 29 32 27 26 24 30 31 WDAA 03 12 023 WDAA 03 12 019 ...

Page 317: ...r 16 10 Bleed air from the hydraulic system Refer to W1 4 1 IMPORTANT Check the hydraulic oil level Start the engine and check for any oil leaks 11 Install screws 14 3 used Lower boot 13 12 Install armrest 12 with washers 11 2 used and socket bolts 10 2 used l 6 mm m 20 N m 2 kgf m 15 lbf ft 13 Install lever 9 with washers 8 2 used and socket bolts 7 2 used l 6 mm m 20 N m 2 kgf m 15 lbf ft 16 Det...

Page 318: ...ight 20 kg 45 lb 14 Install seat 5 with socket bolts 6 4 used l 6 mm m 20 N m 2 kgf m 15 lbf ft 15 Install spacers 4 2 used and seat belts 3 2 used with bolts washers 2 2 used j 24 mm m 210 N m 21 kgf m 155 lbf ft 16 Shut door 1 3 5 3 2 6 2 4 6 1 WDAA 03 01 023 WDAA 03 01 047 ...

Page 319: ...nect the hoses and install the clips in case the clips which secure the hoses have been removed Removal 1 Set the machine position for inspection and maintenance Refer to W1 6 1 dCAUTION Bleed air from the hydraulic oil tank Refer to W1 4 1 2 Open door 1 3 Remove bolts washers 2 2 used Remove seat belts 3 2 used and spacers 4 2 used j 24 mm dCAUTION Seat 5 weight 20 kg 45 lb 4 Remove socket bolts ...

Page 320: ... used and washers 8 2 used Remove armrest 9 l 6 mm 6 Remove tray 10 Remove screws 11 3 used 7 Raise cover 12 Disconnect connectors 13 2 used Remove cover 12 8 Raise boot 14 Remove screws 15 2 used Remove cover 16 14 11 Detail A 15 16 10 A 12 13 11 9 8 7 WDAA 03 12 005 WDAA 03 12 006 ...

Page 321: ...10 Loosen lock nut 19 Remove the lever 20 assembly j 19 mm 22 mm 11 Remove bolts washers 21 3 used Tilt the bracket 22 assembly with the cover 23 side up j 17 mm 12 Remove screws 24 3 used and washer 25 Remove cover 23 19 20 17 18 20 24 23 24 24 25 22 21 WDAA 03 12 007 WDAA 03 12 005 ...

Page 322: ... 13 Disconnect hoses 26 6 used j 19 mm 14 Remove socket bolts 28 4 used and washers 29 4 used Remove pilot valve 27 and boot 30 l 6 mm 15 Remove the adapter with pilot valve 27 attached if necessary Detail A 26 27 26 30 28 29 A WDAA 03 12 008 WDAA 03 12 020 ...

Page 323: ... all removed adapters to pilot valve 27 2 Install pilot valve 27 and boot 30 with washers 29 4 used and socket bolts 28 4 used l 6 mm m 20 N m 2 kgf m 15 lbf ft 3 Connect hoses 26 6 used j 19 mm m 30 N m 3 kgf m 22 lbf ft Detail A 26 27 26 30 28 29 A WDAA 03 12 008 WDAA 03 12 020 ...

Page 324: ... screws 24 3 used 5 Install bracket 22 with bolts washers 21 3 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 6 Tighten lock nut 19 and install the lever 20 assembly j 19 mm 22 mm m 55 N m 5 5 kgf m 40 lbf ft 7 Install clip bands 18 17 19 20 17 18 20 24 23 24 24 25 22 21 WDAA 03 12 007 WDAA 03 12 005 ...

Page 325: ...ed air from the hydraulic system Refer to W1 4 1 IMPORTANT Check the hydraulic oil level Start the engine and check for any oil leaks 12 Install boot 14 13 Install screws 11 3 used Install tray 10 14 Install armrest 9 with washers 8 2 used and socket bolts 7 2 used l 6 mm m 20 N m 2 kgf m 15 lbf ft 14 11 Detail A 15 16 10 A 12 13 11 9 8 7 WDAA 03 12 005 WDAA 03 12 006 ...

Page 326: ...ight 20 kg 45 lb 15 Install seat 5 with socket bolts 6 4 used l 6 mm m 20 N m 2 kgf m 15 lbf ft 16 Install spacers 4 2 used and seat belts 3 2 used with bolts washers 2 2 used j 24 mm m 210 N m 21 kgf m 155 lbf ft 17 Shut door 1 3 5 3 2 6 2 4 6 1 WDAA 03 01 023 WDAA 03 01 047 ...

Page 327: ...ps which secure the hoses have been removed Removal 1 Swing the upperstructure by 90 degrees and set the machine position for inspection and maintenance Refer to W1 6 1 dCAUTION Bleed air from the hydraulic oil tank Refer to W1 4 1 2 Open door 1 3 Remove the floor mat dCAUTION Remove cover 3 while holding it Do not drop cover 3 4 Remove bolts washers 2 6 used Remove cover 3 j 17 mm 5 Place a conta...

Page 328: ... 7 Remove bolts washers 7 4 used Remove levers 8 2 used and pedals 9 2 used j 17 mm 8 Remove socket bolts 10 2 used and washers 11 2 used Remove pilot valve 4 l 8 mm 9 Remove the adapter with pilot valve 4 attached if necessary WDAA 03 12 017 WDAA 03 12 018 ...

Page 329: ...l removed adapters to pilot valve 4 2 Install pilot valve 4 with washers 11 2 used and socket bolts 10 2 used l 8 mm m 50 N m 5 kgf m 37 lbf ft 3 Install pedals 9 2 used and levers 8 2 used with bolts washers 7 4 used j 17 mm m 50 N m 5 kgf m 37 lbf ft WDAA 03 12 017 WDAA 03 12 018 ...

Page 330: ... 4 used j 19 mm m 30 N m 3 kgf m 22 lbf ft 6 Bleed air from the hydraulic system Refer to W1 4 1 IMPORTANT Check the hydraulic oil level Start the engine and check for any oil leaks 7 Install cover 3 with bolts washers 2 6 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 8 Install the floor mat 9 Shut door 1 3 2 1 WDAA 03 13 005 WDAA 03 12 016 ...

Page 331: ... 4 Return Spring 2 Used 5 Return Spring 2 Used 6 Spring Guide 4 Used 7 Retaining Ring 4 Used 8 Pusher 2 Used 9 Pusher 2 Used 10 Oil Seal 4 Used 11 Sleeve 4 Used 12 O Ring 4 Used 13 Plate 14 Universal Joint 15 Cam 16 Screw Joint 17 Casing 18 Spool 4 Used 19 O Ring 20 Plug 21 Retaining Ring 22 Filter 23 17 16 15 14 13 12 11 10 9 8 7 6 5 3 2 1 23 22 21 20 19 18 4 WDAA 03 12 021 ...

Page 332: ...m 16 by using a spanner Remove screw joint 17 j 19 mm 32 mm 2 Secure the flat surface of casing 18 in a vise Remove cam 16 from universal joint 15 j 32 mm 3 Attach a spanner onto the upper part of universal joint 15 Remove universal joint 15 j 17 mm fNOTE Universal joint 15 has been secured on casing 18 by using LOCTITE 262 4 Remove plate 14 IMPORTANT Do not damage sleeve 12 Insert a soft rubber b...

Page 333: ...4146 Remove spring guides 7 4 used return springs 5 6 2 used for each and balance springs 3 4 2 used for each from spools 19 4 used 10 Remove shim 2 and spacers 1 4 used from spools 19 4 used IMPORTANT Spool 19 has been selected to match the hole on casing 18 Spool 19 and casing 18 should be replaced as an assembly 11 Remove the special tool ST 4145 from casing 18 Slowly turn and remove spool 19 f...

Page 334: ... Return Spring 2 Used 5 Return Spring 2 Used 6 Spring Guide 4 Used 7 Retaining Ring 4 Used 8 Pusher 2 Used 9 Pusher 2 Used 10 Oil Seal 4 Used 11 Sleeve 4 Used 12 O Ring 4 Used 13 Plate 14 Universal Joint 15 Cam 16 Screw Joint 17 Casing 18 Spool 4 Used 19 O Ring 20 Plug 21 Retaining Ring 22 Filter 23 17 16 20 21 18 13 11 23 22 14 15 9 10 12 8 7 3 4 5 6 2 1 19 WDAA 03 12 022 ...

Page 335: ...ssembling Install the thinner end of spool 19 into the port hole on casing 18 by turning slowly fNOTE Spool 19 has been selected to match the port hole Spool 19 and casing 18 should be replaced as an assembly 2 Install the special tool ST 4145 to the port hole on casing 18 in order not to lower spool 19 when the spring is compressed j 6 mm IMPORTANT Refer to the table in the left in order to assem...

Page 336: ... seals 11 4 used fNOTE Sleeve 12 and oil seal 11 should be replaced as an assembly 14 Install oil seals 11 4 used to sleeves 12 4 used Push the sleeve 12 assemblies 4 used by hand until O ring 13 is inserted into the hole on sleeves 12 4 used 15 Secure casing 18 in a vise lightly IMPORTANT Fit the bolt hole on plate 14 to the screw hole on casing 18 16 Apply LOCTITE 262 onto the screw part of univ...

Page 337: ...Used 13 O Ring 4 Used 14 Bushing 4 Used 15 Pusher 4 Used 16 Spring Guide 16 Used 17 Balance Spring 4 Used 18 O Ring 2 Used 19 Plug 2 Used 20 Plug 2 Used 21 O Ring 2 Used 22 Casing 23 Spool 24 Spring 4 Used 25 Spacer 4 Used 26 Shim 12 Used 27 Oil Seal 4 Used 28 Spring Washer 2 Used 29 Socket Bolt 2 Used 30 Rubber Seat 2 Used 31 Damper 2 Used 32 O Ring 2 Used 33 O Ring 2 Used 34 Pin 35 Filter 36 1 2...

Page 338: ...rom bushings 15 4 used Remove oil seals 28 4 used and O rings 14 4 used from bushings 15 4 used by using a bamboo spatula IMPORTANT Spool 24 has been selected to match the hole of casing 23 Spool 24 and casing 23 should be replaced as an assembly IMPORTANT Put the mark on spools 24 4 used when keeping in order to easily install spools 24 4 used to the original hole 5 Remove the spool 24 assembly f...

Page 339: ...acket 11 attached unless necessary The hole end of spring pin 10 has been crimped 10 Remove socket bolts 9 2 used and spring washers 8 2 used Remove damper 32 and rubber seat 31 from pin 35 O ring 34 is removed together l 5 mm 11 Remove O ring 33 from pin 35 12 Remove other bracket 11 in the same way as step 9 to step 11 13 Place holder 7 with the casing 23 mounting surface up dCAUTION Metal fragm...

Page 340: ...in 35 by using a bar and a hammer At the same time cams 5 2 used are removed Do not remove bushings 6 4 used with holder 7 attached unless necessary If removing remove bushings 6 4 used by tapping by using the special tool ST 7256 16 Remove plugs 20 2 used from casing 23 Remove O rings 19 2 used from plugs 20 2 used l 5 mm 17 Remove plugs 21 2 used from casing 23 Remove O rings 22 2 used from plug...

Page 341: ...ing 4 Used 15 Pusher 4 Used 16 Spring Guide 16 Used 17 Balance Spring 4 Used 18 O Ring 2 Used 19 Plug 2 Used 20 Plug 2 Used 21 O Ring 2 Used 22 Casing 23 Spool 4 Used 24 Spring 4 Used 25 Spacer 4 Used 26 Shim 12 Used 27 Oil Seal 4 Used 28 Spring Washer 2 Used 29 Socket Bolt 2 Used 30 Rubber Seat 2 Used 31 Damper 2 Used 32 O Ring 2 Used 33 O Ring 2 Used 34 Pin 35 Filter 36 11 9 8 36 28 14 16 23 32 ...

Page 342: ... original port before disassembling Insert the spool 24 assembly into casing 23 by rotating 5 Install oil seal 28 to bushing 15 6 Apply grease onto the inner surface of oil seal 28 7 Install O ring 14 and pusher 16 to bushing 15 8 Apply grease onto the head of pusher 16 9 Insert the pusher 16 assembly into casing 23 10 Install other spools 24 in the same way as step 1 to step 9 11 When bushing 6 h...

Page 343: ...y protection such as goggles helmets etc in order to prevent personal injury IMPORTANT Check the direction to install spring pins 3 4 13 Install spring pins 3 4 to cam 5 by using the special tool ST 1237 Secure cam 5 and pin 35 At this time the slits a of spring pins 3 4 should be positioned 90 away each other Tap and install spring pins 3 4 until spring pins 3 4 come in contact with the stepped p...

Page 344: ...9 4 used and spring washers 8 4 used l 5 mm m 7 N m 0 7 kgf m 5 lbf ft 20 Apply grease onto O ring 34 Push O rings 34 2 used to the end of pin 35 21 As for the direction to install bracket 11 refer to the figure in Disassembly of Travel Pilot Valve on W3 12 5 1 Install bracket 11 to pin 35 Fit the holes to insert spring pins 12 13 IMPORTANT Place a stand under bracket 11 and receive a reaction for...

Page 345: ...ver 2 to holder 7 with bolts washers 1 2 used j 10 mm m 5 N m 0 5 kgf m 3 5 lbf ft 26 Apply grease onto the spring pin 10 contact part of dampers 32 2 used 27 Install O rings 19 2 used to plugs 20 2 used Install plugs 20 2 used to casing 23 j 5 mm m 10 N m 1 kgf m 7 5 lbf ft 28 Install O rings 22 2 used to plugs 21 2 used Install plugs 21 2 used to casing 23 j 6 mm m 20 N m 2 kgf m 15 lbf ft 29 In...

Page 346: ...Group 11 Pilot Valve SECTION 3 UPPERSTRUCTURE W3 11 5 10 Blank ...

Page 347: ...ps which secure the hoses have been removed Removal 1 Swing the upperstructure by 90 degrees and set the machine position for inspection and maintenance Refer to W1 6 1 dCAUTION Bleed air from the hydraulic oil tank Refer to W1 4 1 2 Open door 1 3 Remove the floor mat dCAUTION Remove cover 3 while holding it Do not drop cover 3 4 Remove bolts washers 2 6 used Remove cover 3 j 17 mm 5 Disconnect co...

Page 348: ...UCTURE W3 12 1 2 7 Disconnect hoses 8 7 used j 19 mm 8 Remove bolts washers 9 2 used Remove pilot shut off solenoid valve 5 j 17 mm 9 Remove the adapter with pilot shut off solenoid valve 5 attached if necessary 9 WDAA 03 13 007 WDAA 03 13 008 ...

Page 349: ...ation 1 Install all removed adapters to pilot shut off solenoid valve 5 2 Install pilot shut off solenoid valve 5 with bolts washers 9 2 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 3 Connect hoses 8 7 used j 19 mm m 30 N m 3 kgf m 22 lbf ft 9 WDAA 03 13 007 WDAA 03 13 008 ...

Page 350: ... 5 Connect connector 4 6 Bleed air from the hydraulic system Refer to W1 4 1 IMPORTANT Check the hydraulic oil level Start the engine and check for any oil leaks 7 Install cover 3 with bolts washers 2 6 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 8 Install the floor mat 9 Shut door 1 1 3 2 WDAA 03 13 005 WDAA 03 13 006 ...

Page 351: ...tach an identification tag onto the connectors hoses and pipes for assembling Connect the hoses and install the clips in case the clips which secure the hoses have been removed Removal 1 Set the machine for inspection and maintenance Refer to W1 6 1 dCAUTION Bleed air from the hydraulic oil tank Refer to W1 4 1 2 Open engine cover 1 3 Remove bolts washers 2 5 used Remove cover 3 j 17 mm 1 3 2 WDCD...

Page 352: ...it 5 Disconnect hoses 6 5 used j 17 mm 6 Disconnect both ends of pipes 7 6 used j 17 mm 7 Disconnect hoses 8 3 used j 19 mm 8 Disconnect hoses 9 2 used j 17 mm 9 Remove socket bolts 10 2 used Remove 3 spool solenoid valve unit 5 l 8 mm 10 Remove the adapter with 3 spool solenoid valve unit 5 attached if necessary WDCD 03 12 001 WDCD 03 12 002 ...

Page 353: ...it 5 with socket bolts 10 2 used l 8 mm m 50 N m 5 kgf m 37 lbf ft 3 Connect hoses 9 2 used j 17 mm m 25 N m 2 5 kgf m 18 lbf ft 4 Connect hoses 8 3 used j 19 mm m 30 N m 3 kgf m 22 lbf ft 5 Connect pipes 7 6 used j 17 mm m 25 N m 2 5 kgf m 18 lbf ft 6 Connect hoses 6 5 used j 17 mm m 25 N m 2 5 kgf m 18 lbf ft 7 Connect connectors 4 3 used WDCD 03 12 001 WDCD 03 12 002 ...

Page 354: ... Bleed air from the hydraulic system Refer to W1 4 1 IMPORTANT Check the hydraulic oil level Start the engine and check for any oil leaks 9 Install cover 3 with bolts washers 2 5 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 10 Shut engine cover 1 1 3 2 WDCD 03 06 001 ...

Page 355: ...enoid Valve SECTION 3 UPPERSTRUCTURE W3 12 3 1 Disassembly of Pilot Shut Off Solenoid Valve Socket Bolt 2 Used 1 Solenoid 2 O Ring 3 Body 4 Spool 5 Spring 6 O Ring 7 Plug 8 Filter 9 1 2 3 5 9 6 7 8 4 WDAA 03 13 014 ...

Page 356: ...IMPORTANT Filter 9 cannot be removed 1 Put the matching marks on body 4 and solenoid 2 Secure body 4 in a vise Remove socket bolts 1 2 used from body 4 Remove solenoid 2 and O ring 3 from body 4 l 4 mm 2 Remove plug 8 from body 4 Remove O ring 7 from plug 8 l 6 mm 3 Remove spring 6 and spool 5 from body 4 ...

Page 357: ...lenoid Valve SECTION 3 UPPERSTRUCTURE W3 12 3 3 Assembly of Pilot Shut Off Solenoid Valve Socket Bolt 2 Used 1 Solenoid 2 O Ring 3 Body 4 Spool 5 Spring 6 O Ring 7 Plug 8 Filter 9 4 9 2 1 3 5 6 7 8 T1V1 03 07 012 ...

Page 358: ... a vise Insert spool 5 and spring 6 into body 4 2 Install O ring 7 to plug 8 Install plug 8 to body 4 l 6 mm m 27 N m 2 7 kgf m 20 lbf ft IMPORTANT When solenoid 2 is installed after installing O ring 3 to body 4 O ring 3 may be damaged 3 Install O ring 3 to solenoid 2 Fit the matching marks and install solenoid 2 to body 4 4 Install solenoid 2 to body 4 with socket bolts 1 2 used l 4 mm m 4 N m 0...

Page 359: ...Group 12 Solenoid Valve SECTION 3 UPPERSTRUCTURE W3 12 4 1 Structure of 3 Spool Solenoid Valve Unit 1 3 4 5 2 5 6 7 8 9 10 11 15 14 13 12 WDAA 03 13 013 WDCD 03 12 003 ...

Page 360: ... Tightening Torque Remark N m kgf m lbf ft 1 Body 1 2 Orifice 3 l 6 10 3 1 0 3 7 4 2 2 3 Orifice 1 l 10 20 5 2 0 5 15 3 7 4 Socket Bolt 8 l 4 5 2 0 5 0 2 3 7 1 5 5 Solenoid 3 6 Washer 1 7 Spring 1 8 Spool 1 9 Sleeve 1 10 Plate 1 11 Wave Spring 1 12 O Ring 1 13 O Ring 1 14 O Ring 1 15 O Ring 1 ...

Page 361: ...g onto the connectors hoses and pipes for assembling Connect the hoses and install the clips in case the clips which secure the hoses have been removed Removal 1 Set the machine for inspection and maintenance Refer to W1 6 1 dCAUTION Bleed air from the hydraulic oil tank Refer to W1 4 1 2 Open engine cover 1 3 Remove bolts washers 2 5 used Remove cover 3 j 17 mm 4 Disconnect connectors 4 2 used 1 ...

Page 362: ...e a container under signal control valve 5 Disconnect hoses 6 5 used j 19 mm 6 Disconnect hoses 7 3 used j 17 mm 7 Disconnect hoses 8 3 used j 19 mm 8 Disconnect hose 9 j 17 mm 9 Disconnect hoses 10 4 used j 19 mm 10 Disconnect hose 11 j 17 mm WDCD 03 13 002 WDCD 03 13 003 ...

Page 363: ...UCTURE W3 13 1 3 11 Disconnect hoses 12 17 used j 19 mm 12 Remove socket bolts 13 4 used and washers 14 4 used Remove signal control valve 5 l 8 mm 13 Remove the adapter with signal control valve 5 attached if necessary WDCD 03 13 004 WDCD 03 13 005 ...

Page 364: ...lation 1 Install all removed adapters to signal control valve 5 2 Install signal control valve 5 with washers 14 4 used and socket bolts 13 4 used l 8 mm m 50 N m 5 kgf m 37 lbf ft 3 Connect hoses 12 17 used j 19 mm m 30 N m 3 kgf m 22 lbf ft WDCD 03 13 004 WDCD 03 13 005 ...

Page 365: ...Connect hoses 10 4 used j 19 mm m 30 N m 3 kgf m 22 lbf ft 6 Connect hose 9 j 17 mm m 25 N m 2 5 kgf m 18 lbf ft 7 Connect hoses 8 3 used j 19 mm m 30 N m 3 kgf m 22 lbf ft 8 Connect hoses 7 3 used j 17 mm m 25 N m 2 5 kgf m 18 lbf ft 9 Connect hoses 6 5 used j 19 mm m 30 N m 3 kgf m 22 lbf ft WDCD 03 13 002 WDCD 03 13 003 ...

Page 366: ...4 2 used 11 Bleed air from the hydraulic system Refer to W1 4 1 IMPORTANT Check the hydraulic oil level Start the engine and check for any oil leaks 12 Install cover 3 with bolts washers 2 5 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 13 Shut engine cover 1 1 2 3 WDCD 03 06 001 WDCD 03 13 001 ...

Page 367: ...Group 13 Signal Control Valve SECTION 3 UPPERSTRUCTURE W3 13 2 1 Structure of Signal Control Valve 4 4 4 4 1 13 10 9 3 2 6 5 4 8 7 12 11 7 7 7 7 W1JB 02 10 002 ...

Page 368: ... W1JB 02 10 003 Bolt 12 Used 1 Body 1 2 Gasket 3 Filter 17 Used 4 Body 2 5 Gasket 6 Shuttle Valve 21 Used 7 Spring 4 Used 8 Body 3 9 Gasket 10 Body 4 11 Gasket 12 Body 5 13 Socket Bolt 11 Used 14 Plate 15 Plug 7 Used 16 O Ring 7 Used 17 Spring 4 Used 18 Spring Guide 7 Used 19 Spool 5 Used 20 Spring 2 Used 21 Plate 22 O Ring 23 Shuttle Valve 24 O Ring 25 Spring 26 Spool 27 Spring 28 Plate 29 Spool ...

Page 369: ...MEMO ...

Page 370: ...MEMO ...

Page 371: ... Center Joint W4 3 1 1 Disassembly of Center Joint W4 3 2 1 Assembly of Center Joint W4 3 2 3 Replacement of Body and Spindle W4 3 2 6 Group 4 Track Adjuster Removal and Installation of Track Adjuster W4 4 1 1 Disassembly of Front Idler W4 4 2 1 Assembly of Front Idler W4 4 2 4 Disassembly of Track Adjuster W4 4 3 1 Assembly of Track Adjuster W4 4 3 5 Precautions for Using Floating Seal W4 4 4 1 G...

Page 372: ...DCDW 4 2 Blank ...

Page 373: ...erstructure has already been removed here Removal 1 Put the matching marks a on inner race 2 of swing bearing 1 and track frame 3 2 Remove bolts 4 36 used and spring washers 5 36 used j 30 mm dCAUTION Swing bearing 1 weight 230 kg 510 lb 3 Install special tools ST 0050 3 used to swing bearing 1 Attach a wire rope onto special tools ST 0050 3 used Hoist swing bearing 1 Remove swing bearing 1 a Matc...

Page 374: ...l tools ST 0050 3 used to swing bearing 1 Attach a wire rope onto special tools ST 0050 3 used Hoist swing bearing 1 IMPORTANT If the matching marks a do not fit the soft zone position of inner race will be dislocated 4 Fit the matching marks a on track frame 3 and inner race 2 of swing bearing 1 a Position for Grease Fitting b Soft Zone Marking Position c Position for Plug d Front Side a Matching...

Page 375: ...lts 4 36 used j 30 mm m 500 N m 50 kgf m 370 lbf ft 6 After installing swing bearing 1 add grease Alvania EP2 or equivalent to grease bath 6 until pinion 7 of the swing device is 5 mm 0 2 in under grease fNOTE Grease amount 17 L 4 49 US gal 1 7 6 b a 4 5 WDAA 04 01 001 a Swing Bearing b Grease Level W175 03 01 002 5mm ...

Page 376: ...Group 1 Swing Bearing SECTION 4 UNDERCARRIAGE W4 1 1 4 Blank ...

Page 377: ...ON 4 UNDERCARRIAGE W4 1 2 1 Disassembly of Swing Bearing Outer Race 1 Seal 2 Pin 3 Plug 4 Seal 5 Ball 111 Used 6 Inner Race 7 Support 111 Used 8 Grease Fitting 2 Used 9 2 3 5 4 8 1 9 8 6 5 2 7 6 7 1 W178 02 11 193 W178 02 11 194 ...

Page 378: ...side of pin 3 of plug 4 by using a bar and a hammer Remove pin 3 of plug 4 2 Thread hole a of plug 4 by using a tap M10 Pitch 1 5 mm 3 Install bolt 10 to the screw hole M10 Pitch 1 5 mm of plug 4 Tap or pull bolt 10 and remove plug 4 from outer race 1 dCAUTION Swing bearing weight 230 kg 510 lb 4 Place inner race 7 of the swing bearing on a wooden block by using the special tool ST 0050 Hoist oute...

Page 379: ...11 used and supports 8 111 used from the plug 4 hole while rotating outer race 1 fNOTE Remove ball 6 by using magnet 11 Use wire 12 and remove support 8 6 Remove seals 2 5 from outer race 1 and inner race 7 by using a scrapper W178 02 11 197 W178 02 11 198 1 6 8 5 2 7 11 12 ...

Page 380: ...TION 4 UNDERCARRIAGE W4 1 2 4 Assembly of Swing Bearing Outer Race 1 Seal 2 Pin 3 Plug 4 Seal 5 Ball 111 Used 6 Inner Race 7 Support 111 Used 8 Grease Fitting 2 Used 9 2 3 5 4 8 1 9 8 6 5 2 7 6 7 1 W178 02 11 193 W178 02 11 194 ...

Page 381: ...e turning outer race 1 dCAUTION Metal fragments may fly off when a hammer is used Wear necessary protection such as goggles helmets etc in order to prevent personal injury 2 Install plug 4 to outer race 1 by using a hammer Secure plug 4 to outer race 1 with pin 3 Crimp the head of pin 3 by using a punch 3 Degrease the groove part for seals 2 5 completely Apply THREEBOND 1530D onto seals 2 5 Instal...

Page 382: ...Group 1 Swing Bearing SECTION 4 UNDERCARRIAGE W4 1 2 6 Blank ...

Page 383: ...ION Bleed air from the hydraulic oil tank Refer to W1 4 1 2 Disconnect track 1 Refer to W4 6 1 3 Remove bolts 2 6 used and washers 3 6 used Remove cover 4 j 22 mm 4 Place a container under travel device 5 Disconnect hoses 6 2 used j 36 mm 5 Disconnect hose 7 j 27 mm 6 Disconnect hose 8 j 17 mm dCAUTION Travel Device 5 weight 310 kg 685 lb 7 Attach a nylon sling onto travel device 5 Hoist and hold ...

Page 384: ...5 lb 2 Attach a nylon sling onto travel device 5 Hoist travel device 5 Install travel device 5 with washers 10 14 used and bolts 9 14 used j 30 mm m 630 N m 63 kgf m 460 lbf ft 3 Connect hose 8 j 17 mm m 25 N m 2 5 kgf m 18 lbf ft 4 Connect hose 7 j 27 mm m 80 N m 8 kgf m 59 lbf ft 5 Connect hoses 6 2 used j 36 mm m 180 N m 18 kgf m 133 lbf ft WDAA 04 02 002 ...

Page 385: ...ydraulic oil level Start the engine and check for any oil leaks In order to prevent the travel motor from seizing perform the break in operation after installing Condition 1 Engine speed Slow idle speed 2 Travel mode switch Slow speed 3 Operation duration Over 2 minutes 9 Install cover 4 with washers 3 6 used and bolts 2 6 used j 22 mm m 180 N m 18 kgf m 133 lbf ft 10 Install another cover in the ...

Page 386: ...Group 2 Travel Device SECTION 4 UNDERCARRIAGE W4 2 1 4 Blank ...

Page 387: ...ry Gear 3 Used 15 Thrust Plate 6 Used 16 Pin 3 Used 17 Spring Pin 3 Used 18 Sun Gear 20 Ring Gear 21 Bolt 24 Used 23 Second Stage Carrier 24 Spacer 25 Planetary Gear 3 Used 26 Needle Bearing 3 Used 27 Thrust Plate 6 Used 28 Pin 3 Used 29 Spring Pin 3 Used 30 Sun Gear 32 First Stage Carrier 33 Spacer 34 Planetary Gear 3 Used 35 Needle Bearing 3 Used 36 Thrust Plate 6 Used 37 Pin 3 Used 38 Spring Pi...

Page 388: ... 5 mm 2 used j 30 mm dCAUTION Travel device weight 310 kg 685 lb 2 Attach a nylon sling onto the body of travel device Hoist the travel device Place the travel device on a workbench with the travel motor 00 side down fNOTE Secure the spacer to the workbench tightly in order to receive a reaction force when disassembling 3 Remove plugs 44 3 used l 10 mm IMPORTANT Do not remove stopper 42 unless dam...

Page 389: ... claws a of the special tool ST 0916 onto the outer surface of third stage carrier 12 Hoist the third stage carrier 12 assembly from drum 04 IMPORTANT Do not remove knock pin 10 unless necessary 11 Remove bearing nut 09 from travel motor 00 by using special tools ST 7248 ST 7249 dCAUTION Sprocket 05 drum 04 weight 96 kg 215 lb IMPORTANT The travel motor 00 side of drum 04 is the seal sliding surfa...

Page 390: ...er to W4 2 5 17 Remove one side of floating seal 02 from drum 04 dCAUTION Metal fragments may fly off when a hammer is used Wear necessary protection such as goggles helmets etc in order to prevent personal injury IMPORTANT Do not remove roller bearing 03 unless necessary 18 Remove the outer races of roller bearings 03 2 used from drum 04 by using a bar and a hammer 19 Remove spring pins 38 3 used...

Page 391: ...g Pin 3 Used 18 Sun Gear 20 Ring Gear 21 Bolt 24 Used 23 Second Stage Carrier 24 Spacer 25 Planetary Gear 3 Used 26 Needle Bearing 3 Used 27 Thrust Plate 6 Used 28 Pin 3 Used 29 Spring Pin 3 Used 30 Sun Gear 32 First Stage Carrier 33 Spacer 34 Planetary Gear 3 Used 35 Needle Bearing 3 Used 36 Thrust Plate 6 Used 37 Pin 3 Used 38 Spring Pin 3 Used 39 Shaft 41 Cover 42 Stopper 43 Bolt Washer 12 Used...

Page 392: ... travel motor 00 side to travel motor 00 fNOTE Check that the inner race of roller bearing 03 on the travel motor side is installed completely IMPORTANT Handle floating seal 02 with care Refer to W4 2 5 2 Apply grease onto O ring of one side of floating seal 02 Install one side of floating seal 02 to travel motor 00 Apply gear oil onto the whole sliding surface on floating seal 02 fNOTE If it is d...

Page 393: ...g seal 02 Install one side of floating seal 02 to drum 04 fNOTE If it is difficult to install O ring of floating seal 02 push O ring to the periphery direction by using a bamboo spatula dCAUTION Drum 04 assembly weight 59 kg 135 lb 7 Install eyebolts M20 Pitch 2 5 mm 2 used to the bolt 06 holes on drum 04 Attach nylon slings onto the eyebolts Hoist drum 04 assembly Place drum 04 assembly with the ...

Page 394: ...cools install roller bearing 03 of the cover 00 side to travel motor 00 fNOTE Install roller bearing 03 until the inner race side of roller bearing 03 reaches three threads for bearing nut 09 fNOTE Check that the inner race of roller bearing 03 on the cover 41 side is installed completely IMPORTANT Check the direction to install bearing nut 09 13 Apply grease onto the thread part of bearing nut 09...

Page 395: ...ier 12 At this time fit the spring pin 17 hole of third stage carrier 12 and the pin 16 hole 22 Install spring pin 17 to third stage carrier 12 with the slit b side facing to the second stage carrier 23 side 23 Install other planetary gears 13 2 used to third stage carrier 12 in the same way as steps 19 to 22 dCAUTION The third stage carrier 12 assembly weight 31 kg 69 lb dCAUTION Third stage carr...

Page 396: ... 28 hole 32 Install spring pin 29 to second stage carrier 23 with the slit a side facing to the cover 41 side 33 Install other planetary gears 25 2 used to second stage carrier 23 in the same way as steps 29 to 32 34 Install the second stage carrier 23 assembly to ring gear 20 35 Install sun gear 30 to second stage carrier 23 with the thinner diameter part up 36 Install spacer 33 to first stage ca...

Page 397: ... the first stage carrier 32 assembly to ring gear 20 44 Fill ring gear 20 with gear oil SAE 90 GL 4 fNOTE Oil amount 6 8 L 1 8 US gal 45 Clean the mating surfaces of ring gear 20 and cover 41 and apply THREEBOND 1215 or LOCTITE 5020 Install cover 41 to ring gear 20 with bolts washers 43 12 used j 19 mm m 110 N m 11 kgf m 81 lbf ft 46 Install a seal tape onto plugs 44 3 used Install plugs 44 3 used...

Page 398: ...Group 2 Travel Device SECTION 4 UNDERCARRIAGE W4 2 2 12 Blank ...

Page 399: ...ng 09 Ball 2 Used 10 Roller Bearing 14 Plunger 9 Used 16 Retainer 17 Bushing 18 Swash Plate 19 Spring 6 Used 21 Rotor 22 Friction Plate 4 Used 23 Plate 4 Used 25 Brake Piston 26 O Ring 28 O Ring 29 Disc Spring 30 O Ring 31 O Ring 2 Used 32 Brake Valve 33 Needle Bearing 37 Knock Pin 2 Used 39 Valve Plate 40 Socket Bolt 9 Used WDAA 04 02 007 ...

Page 400: ...33 cannot be reused as the outer race is deformed IMPORTANT Do not damage valve plate 39 4 Remove valve plate 39 and knock pins 37 2 used from brake valve 32 5 Install a tape onto the thrust surface of shaft 07 and needle bearing 33 in order to protect 6 Remove disc spring 29 from housing 00 7 Remove O ring 30 and O rings 31 2 used from housing 00 dCAUTION When removing brake piston 25 hold brake ...

Page 401: ... through the piston oil passage hole Swash plate 18 and piston 03 are removed 13 Remove swash plate 18 from housing 00 14 Remove balls 09 2 used and piston 03 from housing 00 by using a magnet 15 Attach a bar onto the bottom of the spline hole of shaft 07 Tap and remove shaft 07 and roller bearing 10 from housing 00 by using a bar and a plastic hammer IMPORTANT Oil seal 01 cannot be reused 16 Remo...

Page 402: ...lunger 9 Used 16 Retainer 17 Bushing 18 Swash Plate 19 Spring 6 Used 21 Rotor 22 Friction Plate 4 Used 23 Plate 4 Used 25 Brake Piston 26 O Ring 28 O Ring 29 Disc Spring 30 O Ring 31 O Ring 2 Used 32 Brake Valve 33 Needle Bearing 37 Knock Pin 2 Used 39 Valve Plate 40 Socket Bolt 9 Used 32 40 37 31 30 25 21 14 16 18 09 10 01 07 00 08 03 17 19 22 23 26 28 29 39 33 WDCD 04 02 004 ...

Page 403: ...nstall inner ring plate a to roller bearing 10 with the stamped mark facing outside dCAUTION Metal fragments may fly off when a hammer is used Wear necessary protection such as goggles helmets etc in order to prevent personal injury 6 Install roller bearing 10 to shaft 07 from the large diameter side of shaft 07 by using the special tool ST 2654 and a hammer 7 Install retaining ring 08 to shaft 07...

Page 404: ...swash plate 18 becomes topside If placing housing 00 horizontally swash plate 18 may suddenly come out IMPORTANT Install retainer 16 with the chamfered side facing to the bushing 17 side 13 Install springs 19 6 used bushing 17 retainer 16 and plungers 14 9 used to rotor 21 14 Install the rotor 21 assembly to housing 00 dCAUTION The housing 00 assembly weight 67 kg 150 lb 15 Attach a nylon sling on...

Page 405: ...rted When installing brake valve 32 tighten brake piston 25 with socket bolt 40 IMPORTANT Check the direction to install disc spring 29 19 Place disc spring 29 to brake piston 25 with the inner diameter contacting to brake piston 25 20 Install O rings 31 2 used and O ring 30 to housing 00 21 Add hydraulic oil to housing 00 until plate 23 is submerged IMPORTANT Check the direction to install knock ...

Page 406: ...ge may occur dCAUTION Brake valve 32 weight 21 kg 47 lb 25 Remove plugs a 2 used Install the adapters A852122 2 used to the holes of plugs a 2 used Install the special tools ST 0261 2 used to the adapters A852122 2 used Attach nylon slings onto the special tools ST 0261 Hoist brake valve 32 l 6 mm j 19 mm 26 Install brake valve 32 to housing 00 with socket bolts 40 9 used l 14 mm m 300 N m 30 kgf ...

Page 407: ...sassembly of Brake Valve 01A Casing 01B Spool 01C Spool 02 Stopper 2 Used 03 Spring 2 Used 05 Plug 2 Used 07 O Ring 2 Used 08 Poppet 2 Used 10 Spring 2 Used 11 Ball 13 Seat 15 Relief Valve 2 Used 16 Spring 17 Plug 17A O Ring 22 Plug 22A O Ring WDAA 04 02 009 ...

Page 408: ...1A Remove O ring 22A from plug 22 l 6 mm 5 Remove seat 13 from casing 01A l 5 mm 6 Remove ball 11 by using a magnet IMPORTANT As the setting changes do not disassemble relief valve 15 IMPORTANT Do not move piston a with the outer surface of relief valve 15 attached O ring may be damaged 7 Remove relief valves 15 2 used from casing 01A j 36 mm 8 Remove springs 10 2 used and poppet 08 2 used from ca...

Page 409: ...ing 01B Spool 01C Spool 02 Stopper 2 Used 03 Spring 2 Used 05 Plug 2 Used 07 O Ring 2 Used 08 Poppet 2 Used 10 Spring 2 Used 11 Ball 13 Seat 15 Relief Valve 2 Used 16 Spring 17 Plug 17A O Ring 22 Plug 22A O Ring 05 02 03 07 05 15 11 13 15 17 16 01C 17A 10 08 22A 22 01B 01A WDAA 04 02 010 ...

Page 410: ...hten by hand 4 Tighten plugs 05 2 used j 36 mm m 450 N m 45 kgf m 330 lbf ft 5 Install ball 11 to casing 01A 6 Install seat 13 to casing 01A l 5 mm m 15 N m 1 5 kgf m 11 lbf ft 7 Install O ring 22A to plug 22 Install plug 22 to casing 01A l 6 mm m 35 N m 3 5 kgf m 26 lbf ft 8 Install springs 10 2 used to poppets 08 2 used Install poppets 08 2 used to the hole of casing 01A completely 9 Install rel...

Page 411: ...ng seal and seal mounting bores with cleaning solvent Use a wire brush to remove mud rust or dirt from seal mounting bores After cleaning thoroughly dry parts with compressed air Clean seal ring 1 and O ring 2 mounting bores Check the bore surface for scuffing or scoring by touching the surface with finger After installing the floating seal check that O ring 2 is not twisted and that it is install...

Page 412: ...Group 2 Travel Device SECTION 4 UNDERCARRIAGE W4 2 5 2 Blank ...

Page 413: ...nectors hoses and pipes for assembling Connect the hoses and install the clips in case the clips which secure the hoses have been removed Removal 1 Set the machine position for inspection and maintenance Refer to W1 6 1 dCAUTION Bleed air from the hydraulic oil tank Refer to W1 4 1 2 Place a container under center joint 1 Disconnect hoses 2 4 used j 36 mm 3 Disconnect hose 3 j 27 mm 4 Disconnect h...

Page 414: ... 2 used Remove stopper 10 j 22 mm 9 Remove rubber 11 dCAUTION Center joint 1 weight 27 kg 60 lb 10 Install an eyebolt M14 Pitch 2 0 mm to the bolt 8 hole 2 places on center joint 1 Attach a nylon sling onto an eyebolt of center joint 1 Hoist and hold center joint 1 11 Remove bolts washers 12 4 used Remove center joint 1 j 19 mm 12 Remove the adapter with center joint 1 attached if necessary WDCD 0...

Page 415: ...sling onto an eyebolt Hoist center joint 1 3 Install the center joint with bolts washers 12 4 used j 19 mm m 90 N m 9 kgf m 66 lbf ft 4 Install rubber 11 5 Install stopper 10 with spring washers 9 2 used and bolts 8 2 used j 22 mm m 140 N m 14 kgf m 103 lbf ft 6 Connect hoses 7 2 used j 17 mm m 25 N m 2 5 kgf m 18 lbf ft 7 Connect hoses 6 4 used j 36 mm m 180 N m 18 kgf m 133 lbf ft 8 Connect hose...

Page 416: ... 5 kgf m 18 lbf ft 10 Connect hose 3 j 27 mm m 80 N m 8 kgf m 59 lbf ft 11 Connect hoses 2 4 used j 36 mm m 180 N m 18 kgf m 133 lbf ft 12 Bleed air from the hydraulic system Refer to W1 4 1 IMPORTANT Check the hydraulic oil level Start the engine and check for any oil leaks WDAA 04 03 001 ...

Page 417: ...UNDERCARRIAGE W4 3 2 1 Disassembly of Center Joint 00A Spindle 00B Plug with Ball Attached 01 Body 02 Dust Seal 03 O Ring 04 Oil Seal 6 Used 05 Bushing 06 Ring 07 Retaining Ring 08 O Ring 09 Cover 10 Bolt Washer 4 Used WDAA 04 03 003 ...

Page 418: ...move cover 09 from body 01 j 17 mm 3 Remove O ring 08 retaining ring 07 and ring 06 from body 01 4 Install the special tools ST 1033 ST 1020 to body 01 with bolts washers 10 2 used j 17 mm IMPORTANT Do not damage the seal sliding surface of spindle 00A 5 Remove spindle 00A from body 01 IMPORTANT For easy removal of oil seal 04 use the pins 2 used Do not damage the seal groove 6 Remove oil seals 04...

Page 419: ... 2 3 Assembly of Center Joint 00A Spindle 00B Plug with Ball Attached 01 Body 02 Dust Seal 03 O Ring 04 Oil Seal 6 Used 05 Bushing 06 Ring 07 Retaining Ring 08 O Ring 09 Cover 10 Bolt Washer 4 Used 01 00B 00A 02 03 04 07 08 09 10 05 06 W178 03 03 001 ...

Page 420: ...st seal 02 to spindle 00A with lip part a of dust seal 02 facing to body 01 side 2 Install O ring 03 and oil seals 04 6 used to body 01 IMPORTANT Do not damage bushing 05 IMPORTANT The clearance between body 01 and spindle 00A is approximately 0 1 mm Insert body 01 along axis straight and slowly Do not damage the seal IMPORTANT Do not make a step on ring 06 mounting part b 3 Place spindle 00A on a...

Page 421: ...l ring 06 with the chamfered side facing to the spindle 00A side 4 Install ring 06 and O ring 08 to body 01 5 Install retaining ring 07 to spindle 00A 6 Install cover 09 to body 01 with bolts washers 10 4 used j 17 mm m 50 N m 5 kgf m 37 lbf ft 01 00A 08 06 WDAA 04 03 004 ...

Page 422: ...cial tool ST 2558 and a press fNOTE Pushing force 0 5 to 1 5 t 1110 to 3310 lb In case of spindle 00A 1 Clean spindle 00A 2 Install plug 00B to spindle 00A by using the special tool ST 2559 3 Install ball a of plug 00B so that the top of each ball is 0 4 mm 0 02 in or more lower than the respective sleeve c edge as illustrated in detail C 01 C 00A 00B ST 2558 05 a ST 2559 c b Detail C a Ball b 0 4...

Page 423: ...ssembly weight 250 kg 555 lb 2 Attach a vise onto hoisting position a of front idler 1 Hoist and hold the track adjuster 7 assembly 3 Attach a weight onto part b of the special tool ST 1650 Set the track adjuster 7 assembly horizontally 4 Pull out the track adjuster 7 assembly until nylon slings can be attached onto hoisting position c of track adjuster 7 5 Attach nylon slings onto hoisting positi...

Page 424: ...2 used j 24 mm dCAUTION The track adjuster 7 assembly weight 250 kg 555 lb 8 Turn over the track adjuster 7 assembly dCAUTION Take care not to turn over track adjuster 7 dCAUTION Front idler 1 weight 110 kg 245 lb 9 Remove bolts 5 2 used and washers 6 2 used Remove front idler 1 j 24 mm a Block 7 a a 5 6 3 4 1 WDCD 04 04 004 WDCD 04 04 003 ...

Page 425: ...djuster 7 and front idler 1 onto blocks a 4 used with the bolt 5 hole side up 2 Install front idler 1 with washers 6 2 used and bolts 5 2 used j 24 mm m 270 N m 27 kgf m 200 lbf ft dCAUTION The track adjuster 7 assembly weight 250 kg 555 lb 3 Turn over the track adjuster 7 assembly 4 Install washers 4 2 used and bolts 3 2 used j 24 mm m 270 N m 27 kgf m 200 lbf ft a Block 7 a a 3 4 5 6 1 WDCD 04 0...

Page 426: ...ches where nylon slings can be removed 7 Remove nylon slings dCAUTION Special tool ST 1650 weight 53 kg 120 lb 8 Install the special tool ST 1650 to the yoke 2 part of front idler 1 dCAUTION The track adjuster 7 assembly Special tool ST 1650 weight 310 kg 685 lb 9 Hoist and hold the track adjuster 7 assembly Attach a weight onto part b of the special tool ST 1650 Set the track adjuster 7 assembly ...

Page 427: ...ack Adjuster SECTION 4 UNDERCARRIAGE W4 4 2 1 Disassembly of Front Idler 00 Bearing 2 Used 01 Axle 02 O Ring 2 Used 03A Idler 03B Bushing 2 Used 04 Pin 2 Used 05 Floating Seal 2 Used 06 Plug 2 Used WDCD 04 04 006 ...

Page 428: ... such as goggles helmets etc in order to prevent personal injury 2 Remove pin 04 from bearing 00 on the upper side by using a round bar and a hammer fNOTE Diameter of round bar 16 mm dCAUTION The axle 01 assembly weight 25 kg 56 lb 3 Put the matching marks on bearing 00 and axle 01 Remove the axle 01 assembly from the idler 03A assembly by using a press IMPORTANT Handle floating seals with care Re...

Page 429: ... a hammer is used Wear necessary protection such as goggles helmets etc in order to prevent personal injury 6 Remove pin 04 by using a bar and a hammer fNOTE Diameter of round bar 16 mm 7 Put the matching marks on bearing 00 and axle 01 Remove axle 01 from bearing 00 by using a press 8 Remove O rings 02 2 used from axle 01 dCAUTION Idler 03A weight 70 kg 155 lb IMPORTANT Do not remove bushing 03B ...

Page 430: ... SECTION 4 UNDERCARRIAGE W4 4 2 4 Assembly of Front Idler 00 Bearing 2 Used 01 Axle 02 O Ring 2 Used 03A Idler 03B Bushing 2 Used 04 Pin 2 Used 05 Floating Seal 2 Used 06 Plug 2 Used WDCD 04 04 005 06 03A 03B 04 01 05 02 00 ...

Page 431: ... helmets etc in order to prevent personal injury 4 Install pin 04 by using a bar and a hammer IMPORTANT Handle floating seal 05 with care Refer to W4 4 4 5 Apply engine oil onto the O ring of floating seal 05 Install floating seal 05 to idler 03A and bearing 00 dCAUTION The axle 01 assembly weight 25 kg 56 lb 6 Attach nylon slings onto bearing 00 of the axle 01 assembly Hoist the axle 01 assembly ...

Page 432: ...to idler 03A and bearing 00 11 Fit the matching marks on axle 01 and bearing 00 Evenly tap and install bearing 00 to axle 01 by using a plastic hammer dCAUTION Metal fragments may fly off when a hammer is used Wear necessary protection such as goggles helmets etc in order to prevent personal injury 12 Install pin 04 by using a bar and a hammer 13 Add engine oil API CD class SAE 30 through the plug...

Page 433: ...ter SECTION 4 UNDERCARRIAGE W4 4 3 1 Disassembly of Track Adjuster 00A Cylinder 00B Rod 01 Spacer 02 Spring 03 Yoke 04 Seal 05 Dust Seal 07 Nut 08 Bracket 09 Bolt 10 Washer 14 Piston Rod 15 Valve 16 Bracket WDCD 04 04 007 ...

Page 434: ...nstall 4 Place an oil jack 30 tons between holder a and base b of the special tool ST 4950 dCAUTION Special tool ST 4052 weight 32 kg 71 lb 5 Remove nuts d 4 used from the special tool ST 4950 Attach nylon slings onto the eyebolts 2 used of the special tool ST 4052 Hoist the special tool ST4052 Remove the special tool ST 4052 j 46 mm dCAUTION The spring 02 assembly weight 120 kg 265 lb 6 Install e...

Page 435: ...ssembly Operate the oil jack Compress spring 02 to the position where nut 07 is loose fNOTE Spring 02 compressed length Spring free length 560 mm 22 in Spring set length 460 mm 18 1 in Spring compressed length 100 mm 3 94 in 10 Remove bolt 09 and washer 10 from bracket 08 Remove bracket 08 from nut 07 j 17 mm 11 Remove nut 07 from rod 00B j 75 mm 12 Lower the oil jack slowly 13 Remove nuts a 4 use...

Page 436: ...g 02 assembly weight 91 kg 205 lb 17 Install eyebolts M10 Pitch 1 5 mm to rod 00B Attach nylon slings onto the eyebolts Hoist the spring 02 assembly 18 Remove the spring 02 assembly from the special tool ST 4950 dCAUTION Spring 02 weight 61 kg 135 lb 19 Remove spring 02 from the rod 00B assembly 20 Remove spacer 01 from rod 00B IMPORTANT Rod 06 has been installed in cylinder 00A 21 Remove rod 06 f...

Page 437: ...Assembly of Track Adjuster Detail A 00A Cylinder 00B Rod 01 Spacer 02 Spring 03 Yoke 04 Seal 05 Dust Seal 07 Nut 08 Bracket 09 Bolt 10 Washer 14 Piston Rod 15 Valve 16 Bracket 08 07 02 04 05 14 A 00B 00A 09 10 03 01 15 16 10 09 WDCD 04 04 008 WDCD 04 04 011 ...

Page 438: ...o the bolt 09 holes of rod 00B Attach nylon slings onto the eyebolts Hoist the spring 02 assembly Place the spring 02 assembly on the special tool ST 4950 6 Remove the eyebolts from rod 00B dCAUTION Yoke 03 weight 21 kg 47 lb 7 Install eyebolts M16 Pitch 2 0 mm 2 used and nuts 2 used to the bolt holes 2 places of yoke 03 diagonally Attach nylon slings onto the eyebolts Hoist the yoke 03 8 Place yo...

Page 439: ...14 Remove nuts a 4 used of the special tool ST 4950 dCAUTION Special tool ST 4052 weight 32 kg 71 lb 15 Attach nylon slings onto the eyebolts 2 used of the special tool ST 4052 Hoist and hold the special tool ST4052 Remove bolts J921650 4 used and washers J222016 4 used Remove the special tool ST4052 dCAUTION The spring 02 assembly weight 120 kg 265 lb 16 Install eyebolts M16 Pitch 2 0 mm 2 used a...

Page 440: ...rease 19 Install piston rod 14 to cylinder 00A 20 Bleed air from part A of cylinder 00A and cylinder 00A 21 Install bracket 16 and valve 15 to piston rod 14 j 24 mm m 90 N m 9 kgf m 66 lbf ft 22 Install washer 10 and bolt 09 to bracket 16 j 17 mm m 60 N m 6 kgf m 44 lbf ft A 00A WDCD 04 04 014 ...

Page 441: ...ing seal and seal mounting bores with cleaning solvent Use a wire brush to remove mud rust or dirt from seal mounting bores After cleaning thoroughly dry parts with compressed air Clean seal ring 1 and O ring 2 mounting bores Check the bore surface for scuffing or scoring by touching the surface with finger After installing the floating seal check that O ring 2 is not twisted and that it is instal...

Page 442: ...Group 4 Track Adjuster SECTION 4 UNDERCARRIAGE W4 4 4 2 Blank ...

Page 443: ...ut Keep body parts and face away from valve 1 and loosen valve 1 carefully Do not loosen grease fitting 2 IMPORTANT When gravel or mud is packed between sprockets and track links remove them before loosening IMPORTANT Loosening valve 1 by 1 to 1 5 turns is enough Do not loosen valve 1 over those turns Removal 1 Set the machine position for inspection and maintenance Refer to W1 6 1 2 Loosen valve ...

Page 444: ...h b between track frame 3 and oil jack a in order not to slip 3 Raise the track in order to get clearance between upper roller 4 and track 5 4 Place wooden block c between track 5 and track frame 3 5 Loosen bolts 6 4 used of upper roller 4 Remove upper roller 4 j 24 mm 5 a b 3 4 3 c 6 4 4 W105 03 06 003 W1V7 03 06 001 W105 03 06 005 ...

Page 445: ... track adjuster j 24 mm m 90 N m 9 kgf m 66 lbf ft dCAUTION Securely support the raised machine by using blocks 4 Raise the track to be adjusted Rotate the track in the reverse direction a little 5 Apply grease through grease fitting 2 and adjust the track tension fNOTE Track sag specification a 300 to 335 mm 11 8 to 13 2 in a Track sag specification a WXXX 03 07 001 5 a 3 4 c W105 03 06 003 a Oil...

Page 446: ...PORTANT Upper roller 4 cannot be disassembled Replace it as an assembly 7 Add engine oil API CD class SAE 30 through the plug 8 hole of cover 7 fNOTE Amount of oil 65 mL 0 069 US qt 8 Apply THREEBOND 2353 onto plug 8 9 Tighten plug 8 l 6 mm m 30 N m 3 kgf m 22 lbf ft 7 8 W158 03 06 001 ...

Page 447: ...ack guard 1 track guard 1 will come off 3 Place wooden blocks a under track guard 1 4 Remove bolts 3 4 used spring washers 4 4 used and washers 5 4 used j 27 mm 5 Swing the upperstructure by 90 and set the angle between boom and arm to 90 to 110 Lower the boom with the round bottom of the bucket contacting with the ground Raise the track frame At this time place stand b under the track frame and s...

Page 448: ... Do not loosen grease fitting 2 IMPORTANT Loosening valve 1 by 1 to 1 5 turns is enough Do not loosen it over those turns IMPORTANT When gravel or mud is packed between sprockets and track links remove them before loosening 6 Loosen valve 1 in the track adjuster Drain grease and loosen the track tension until the clearance in the track is enough to remove track guard 3 j 24 mm dCAUTION Track guard...

Page 449: ...nd track frame 2 dCAUTION When removing bolt 3 without holding lower roller 1 lower roller 1 will come off 9 Place wooden blocks a under lower roller 1 10 Remove bolts 3 4 used j 27 mm dCAUTION Lower roller 1 weight 35 kg 78 lb 11 Remove lower roller 1 by using a forklift a 2 1 a Wooden Block WDCN 04 05 002 3 ...

Page 450: ... by using a forklift 2 Raise lower roller 1 in order to adjust its mounting position by using a forklift and place wooden blocks a under it 3 Fit the bolt 3 holes and the matching marks of track frame 2 and lower roller 1 Install lower roller 1 with bolts 3 4 used j 27 mm m 460 N m 46 kgf m 340 lbf ft 4 1 WDCN 04 05 003 a 2 1 a Wooden Block WDCN 04 05 002 3 ...

Page 451: ...UTION Securely support the raised machine by using the blocks 5 Lower the machine in order to adjust the track guard 1 mounting position 6 Fit the bolt 3 holes and the matching marks of track frame 6 and track guard 1 by using a bar Install track guard 1 with washers 5 4 used spring washers 4 4 used and bolts 3 4 used j 27 mm m 500 N m 50 kgf m 370 lbf ft 3 4 5 3 4 5 6 WDAA 04 05 003 ...

Page 452: ...t dCAUTION Securely support the raised machine by using the blocks 8 Raise the track to be adjusted Rotate the track in the reverse direction a little 9 Apply grease through grease fitting 2 and adjust the track tension fNOTE Track sag specification a 300 to 335 mm 11 8 to 13 2 in 2 1 TDAA 03 08 002 a Track Sag Specification Wxxx 03 07 001 ...

Page 453: ...er Rollers SECTION 4 UNDERCARRIAGE W4 5 3 1 Disassembly of Lower Roller Plug 1 Collar 2 Pin 2 Used 3 O Ring 2 Used 4 Floating Seal 2 Used 5 Bushing 2 Used 6 Roller 7 Axle 8 Collar 9 1 7 6 8 5 4 9 3 2 3 4 5 6 W157 03 06 010 ...

Page 454: ... Remove axle 8 from the side of roller 7 where pin 3 has been removed by using a press At this time pin 3 and collar 9 on the opposite side are removed with axle 8 together fNOTE Diameter of round bar 14 mm 0 55 in IMPORTANT Handle floating seal 5 with care Refer to W4 5 4 3 Remove floating seals 5 2 used from both sides of roller 7 and collars 2 9 4 Remove pin 3 from the axle 8 assembly Remove ax...

Page 455: ...nd Lower Rollers SECTION 4 UNDERCARRIAGE W4 5 3 3 Assembly of Lower Roller 7 6 5 4 3 8 9 1 2 Plug 1 Collar 2 Pin 2 Used 3 O Ring 2 Used 4 Floating Seal 2 Used 5 Bushing 2 Used 6 Roller 7 Axle 8 Collar 9 W105 03 06 023 ...

Page 456: ...efer to W4 5 4 4 Install floating seal 5 to roller 7 and collar 2 5 Install the axle 8 assembly to roller 7 6 Apply grease onto O ring 4 at the other side Install O ring 4 to the roller 7 assembly IMPORTANT Handle floating seal 5 with care Refer to W4 5 4 7 Install floating seal 5 to roller 7 and collar 9 IMPORTANT Do not damage O ring 4 8 Fit the pin 3 hole and install collar 9 to axle 8 with pin...

Page 457: ...loating seal and seal mounting bores with cleaning solvent Use a wire brush to remove mud rust or dirt from seal mounting bores After cleaning thoroughly dry parts with compressed air Clean seal ring 1 and O ring 2 mounting bores Check the bore surface for scuffing or scoring by touching the surface with finger After installing the floating seal check that O ring 2 is not twisted and that it is in...

Page 458: ...Group 5 Upper and Lower Roller SECTION 4 UNDERCARRIAGE W4 5 4 2 Blank ...

Page 459: ...er is high As valve 4 may fly out and the high pressure grease may spout out do not loosen valve 4 quickly and or excessively Keep body parts and face away from valve 4 and loosen valve 4 carefully Do not loosen grease fitting 5 IMPORTANT Loosening valve 4 1 to 1 5 turns is enough Do not loosen valve 4 over those turns IMPORTANT When gravel or mud is packed between sprockets and track links remove...

Page 460: ...stand in the same direction to remove the track adjuster or where it may fly out Particularly strong force is always applied to the thread part of the rod If the rod and or the threads are damaged metal fragments may fly out due to the spring force dCAUTION Metal fragments may fly off when a hammer is used Wear necessary protection such as goggles helmets etc in order to prevent personal injury IM...

Page 461: ... frame and pull out the track Place stand a under the track frame and support the machine at this time dCAUTION The track assembly weight ZX200 5G 1260 kg 2780 lb ZX210H 5G 210K 5G 1330 kg 2940 lb ZX200LC 5G 1350 kg 2980 lb ZX210LCH 5G 210LCK 5G 1420 kg 3140 lb 7 Slowly operate a travel control lever on the side to be removed the track to the reverse position and extend the track W105 03 07 011 M1...

Page 462: ...5G 1260 kg 2780 lb ZX210H 5G 210K 5G 1330 kg 2940 lb ZX200LC 5G 1350 kg 2980 lb ZX210LCH 5G 210LCK 5G 1420 kg 3140 lb 2 Hoist and mesh the track with the claws of sprocket 8 3 Slowly operate a travel control lever on the side to install the track in the forward direction with the machine raised off the ground Wind the track while rotating travel device 9 a b a Front Idler Side b Sprocket 8 Side 8 ...

Page 463: ... be installed to only one direction Check direction b to install master pin 1 5 Install master pin 1 to the track IMPORTANT Replace snap ring 6 with the new one 6 Install snap ring 6 Snap ring 6 has the direction to install Install snap ring 6 to the groove of master link 7 with the flat surface of a pair of pliers hole facing the near side a Wooden Block a 3 2 b Direction to Install 1 b 7 6 7 6 W...

Page 464: ...d bushing 11 Stand them on a flat plate dCAUTION Take care not to come off link 10 9 Fill the bushing 11 inside with grease 10 Install pin 12 to link 10 and bushing 11 while holding them in order not to move due to grease 11 Wipe off excess grease after installing pin 12 12 Tighten valve 4 Apply grease through grease fitting 5 and adjust the track tension j 24 mm m 90 N m 9 kgf m 66 lbf ft fNOTE T...

Page 465: ...MEMO ...

Page 466: ...MEMO ...

Page 467: ...2 Cylinder Removal and Installation of Boom Cylinder W5 2 1 1 Removal and Installation of Arm Cylinder W5 2 2 1 Removal and Installation of Bucket Cylinder W5 2 3 1 Disassembly of Boom Arm Bucket Cylinder W5 2 4 1 Assembly of Boom Arm Bucket Cylinder W5 2 4 5 SECTION 5 FRONT ATTACHMENT CONTENTS ...

Page 468: ...DCDW 5 2 Blank ...

Page 469: ...efore doing any work Refer to W1 4 1 2 Disconnect lubrication hose 1 from adapter a connecting to the boss at the boom cylinder rod side 2 places on both left and right j 17 mm dCAUTION Boom cylinder b weight 170 kg 375 lb 3 Hoist and hold boom cylinder b Remove nuts 4 2 used and bolt 6 from pin 3 of the boom cylinder rod end Remove stopper 5 2 places on both left and right j 30 mm 1 a b b a Adapt...

Page 470: ...nder b while raising lowering the front attachment 5 Place the tube top of boom cylinder b on a stand of 1 m 39 4 in height Start the engine Operate the boom control lever and retract boom cylinder b In order not to extend the rod pass wire a through the rod hole and secure the rod to the cylinder tube 6 Stop the engine Remove boom cylinder b Refer to W5 2 1 7 Remove other boom cylinder b in the s...

Page 471: ...ct hoses 7 8 of the bucket cylinder and arm cylinder Cap the open ends of the removed pipes and hoses j 36 mm 41 mm 9 Remove the mounting bolts 9 used for tool box b and cover a Remove tool box b and cover a j 17 mm 8 7 a b a Cover b Tool Box W1V1 04 01 001 W1V1 04 01 002 ...

Page 472: ...pry bar between plate a of boom foot pin 11 and bracket c Slightly pull out plate a dCAUTION Boom foot pin 11 weight 45 kg 100 lb 13 Turn plate a upward by hand Turn left and right and pull out boom foot pin 11 Adjust the position by using the lifting ropes for the front attachment 14 Hoist front attachment assembly d and move the machine backward 15 Place wooden blocks Place front attachment asse...

Page 473: ...just the clearance between plate and frame within 1 mm 0 039 in Adjust the position by using the lifting ropes for the front attachment dCAUTION Metal fragments may fly off when a hammer is used Wear necessary protection such as goggles helmets etc in order to prevent personal injury 2 Install boom foot pin 11 by using a hammer Install bolt 14 washer 15 plate 13 and block 12 j 27 mm m 400 N m 40 k...

Page 474: ...nd pipes Connect hoses 7 8 of the bucket cylinder and arm cylinder j 36 mm m 180 N m 18 kgf m 133 lbf ft j 41 mm m 210 N m 21 kgf m 155 lbf ft dCAUTION Boom cylinder a weight 170 kg 375 lb 5 Hoist and install boom cylinder a Refer to W5 2 1 8 7 W1V1 04 01 001 a a Boom Cylinder W105 04 02 040 ...

Page 475: ...on both sides 7 Install stopper 5 Tighten bolt 6 and nuts 4 2 used 2 places on both left and right j 30 mm m 170 N m 17 kgf m 125 lbf ft 8 Connect hose 1 to boom cylinder rod side b 2 places on both left and right j 17 mm m 30 N m 3 kgf m 22 lbf ft 9 Apply grease onto rod side b and bottom side d of the boom cylinder and boom foot side c 1 a a Boom Cylinder b Boom Cylinder Rod Side b Boom Cylinder...

Page 476: ...ittings 15 16 on the boom connecting boss of arm and the arm cylinder rod side IMPORTANT For handling of HN bushing for the front attachment check the followings Precautions when installing the bushing If a hammer is used the bushing may be damaged Use a press Precautions when reinforcing the arm The heat when welding in order to reinforce the arm may cause oil leakage and decrease lubrication per...

Page 477: ... protection such as goggles helmets etc in order to prevent personal injury 3 Remove nuts 5 2 used bolt 7 and stopper 6 from the boom cylinder 2 rod side Push pin 4 into the boom by using a bar and hammer Remove thrust plates 3 j 30 mm 4 Place boom cylinder 2 on a stand Remove the other boom cylinder in the same way 5 Operate the boom control lever and retract boom cylinder 2 In order not to exten...

Page 478: ...nds j 36 mm 41 mm dCAUTION Metal fragments may fly off when a hammer is used Wear necessary protection such as goggles helmets etc in order to prevent personal injury 8 Remove nuts 10 2 used and bolt 8 from the cylinder bottom side Remove pin 9 by using a bar and hammer Remove thrust plates 11 j 24 mm dCAUTION Boom cylinder 2 weight 170 kg 375 lb 9 Hoist and remove boom cylinder 2 10 Remove the ot...

Page 479: ...fragments may fly off when a hammer is used Wear necessary protection such as goggles helmets etc in order to prevent personal injury 2 Fit thrust plate 11 and pin 9 with the mounting hole on the main flame Install pin 9 by using a hammer Install bolt 8 to pin 9 with nuts 10 2 used j 24 mm m 80 N m 8 kgf m 59 lbf ft 3 Install the other boom cylinder in the same way 4 Connect hoses 12 4 used to boo...

Page 480: ...ssary protection such as goggles helmets etc in order to prevent personal injury 6 Fit thrust plates 3 and pin 4 with the mounting hole on boom Install pin 4 by using a bar and hammer 7 Install bolt 7 to pin 4 and stopper 6 with nuts 5 2 used j 30 mm m 170 N m 17 kgf m 125 lbf ft 8 Connect hose 1 to boom cylinder 2 j 17 mm m 25 N m 2 5 kgf m 18 lbf ft 9 Install the other boom cylinder in the same ...

Page 481: ...protection such as goggles helmets etc in order to prevent personal injury 3 Remove pin 5 by using a bar and hammer Remove thrust plates 4 4 Operate the arm lever and retract arm cylinder 1 In order not to extend rod 6 pass a wire 7 through the rod hole and secure rod 6 to the arm cylinder 1 tube 5 Stop the engine dCAUTION Bleed air from the hydraulic oil tank Refer to W1 4 1 dCAUTION Release any ...

Page 482: ...connect hoses 11 2 used and hose 12 from the bottom of arm cylinder 1 Cap the open ends j 17 mm 36 mm dCAUTION Arm cylinder 1 weight 260 kg 575 lb 7 Attach a nylon sling onto arm cylinder 1 Hoist and hold arm cylinder 1 1 11 12 1 W178 02 11 290 W102 04 02 016 ...

Page 483: ...d Wear necessary protection such as goggles helmets etc in order to prevent personal injury 8 Remove nuts 15 2 used and bolt 17 from stopper 16 and pin 14 at the bottom side j 30 mm 9 Remove pin 14 by using a bar and hammer Remove thrust plates 13 Hoist and remove arm cylinder 1 14 13 17 16 15 1 W187 04 02 007 ...

Page 484: ...linder bottom side with the cylinder mounting hole on the boom dCAUTION Metal fragments may fly off when a hammer is used Wear necessary protection such as goggles helmets etc in order to prevent personal injury 2 Fit thrust plates 13 and pin 14 with the cylinder mounting hole on the boom Install pin 14 by using a hammer 3 Install bolt 17 to pin 14 and stopper 16 with nuts 15 2 used j 30 mm m 170 ...

Page 485: ...e at cylinder rod side with the mounting hole on arm 18 dCAUTION Metal fragments may fly off when a hammer is used Wear necessary protection such as goggles helmets etc in order to prevent personal injury 6 Fit thrust plate 4 and pin 5 with the mounting hole on arm 18 Install pin 5 by using a hammer 7 Install bolt 10 to pin 5 and stopper 9 with nuts 8 2 used j 30 mm m 170 N m 17 kgf m 125 lbf ft I...

Page 486: ...Group 2 Cylinder SECTION 5 FRONT ATTACHMENT W5 2 2 6 Blank ...

Page 487: ...tion such as goggles helmets etc in order to prevent personal injury 2 Remove nuts 6 2 used and bolt 4 Remove pin 7 with using a bar and hammer Remove thrust plates 5 j 30 mm 3 Operate the bucket control lever and retract bucket cylinder 1 In order not to extend rod 8 pass wire 9 through the rod hole and secure rod 8 to the bucket cylinder 1 tube 4 Stop the engine dCAUTION Bleed air from the hydra...

Page 488: ...ylinder 1 weight 160 kg 355 lb dCAUTION Metal fragments may fly off when a hammer is used Wear necessary protection such as goggles helmets etc in order to prevent personal injury 7 Hoist bucket cylinder 1 Remove nuts 13 2 used and bolt 15 Remove pin 11 by using a bar and hammer Remove thrust plate 10 j 24 mm 8 Hoist and remove bucket cylinder 1 10 15 13 1 12 11 W187 04 02 004 ...

Page 489: ...ion such as goggles helmets etc in order to prevent personal injury 1 Hoist bucket cylinder 1 Fit the hole at the cylinder bottom side with the cylinder mounting hole on the arm Fit thrust plate 10 and pin 11 with the cylinder mounting hole on the arm Install pin 11 by using a hammer 2 Install bolt 15 to stopper 14 of the arm and pin 11 with nuts 13 2 used j 24 mm m 80 N m 8 kgf m 59 lbf ft 3 Conn...

Page 490: ...ver Fit the hole at cylinder rod side with the holes of link A 16 and link B 18 Fit thrust plates 5 and pin 7 with the holes of link A 16 and link B 18 Install pin 7 by using a hammer 6 Install bolt 4 to stopper 17 and pin 7 with nuts 6 2 used j 30 mm m 170 N m 17 kgf m 125 lbf ft IMPORTANT In case link B 18 has been removed from the arm insert thrust plate 19 when installing IMPORTANT After compl...

Page 491: ... 2 4 1 Disassembly of Boom Arm Bucket Cylinder Arm Cylinder Boom Cylinder 1 2 3 4 5 12 19 20 7 8 9 10 11 6 23 22 17 18 21 19 24 18 17 25 26 1 2 3 4 5 12 16 15 14 13 19 20 7 8 9 10 11 6 23 22 17 18 21 19 24 18 17 25 26 W1V1 04 02 007 W1V1 04 02 008 ...

Page 492: ...ylinder Head 7 Bushing 8 Snap Ring 9 Backup Ring 10 O Ring 11 Cylinder Tube 12 Stopper 2 Used Only Arm 13 Cylinder Cushion Bearing Only Arm 14 Cylinder Cushion Seal Only Arm 15 Cylinder Snap Ring Only Arm Cylinder 16 Slide Ring 2 Used 17 Slide Ring 2 Used 18 Backup Ring 2 Used 19 O Ring 20 Seal Ring 21 Set Screw 22 Steel Ball 23 Piston Nut 24 Cushion Bearing Only Boom 25 Arm Cylinders Cushion Seal...

Page 493: ...cylinder horizontally on a workbench Drain hydraulic oil from the cylinder 2 Fully extend and support cylinder rod 1 Remove socket bolts 6 12 used Bucket Cylinder 10 used from cylinder head 7 l 14 mm IMPORTANT Pull out cylinder rod 1 straightly in order not to damage the sliding surface 3 Tap and remove cylinder head 7 with cylinder rod 1 together from cylinder tube 12 by using a plastic hammer 4 ...

Page 494: ...t ST 3352 95 mm Boom Cylinder ST 3318 110 mm Arm Cylinder ST 3263 90 mm Bucket Cylinder 7 Remove slide rings 17 2 used slide rings 18 2 used backup rings 19 2 used O ring 20 and seal ring 21 from piston nut 24 8 Remove cylinder head 7 from cylinder rod 1 9 Remove O ring 11 and backup rings 10 3 from cylinder head 7 Remove wiper ring 2 U ring 4 buffer ring 5 snap ring 9 and bushing 8 Special tool w...

Page 495: ...NT W5 2 4 5 Assembly of Boom Arm Bucket Cylinder Arm Cylinder Boom Cylinder 6 6 5 5 4 4 2 2 1 1 7 7 12 12 25 25 17 17 17 17 22 22 14 18 18 18 18 19 19 23 23 16 15 24 24 26 26 9 9 8 8 3 3 20 21 20 21 10 11 10 11 13 W1V1 04 02 005 W1V1 04 02 003 ...

Page 496: ...nder 10 Used Cylinder Head 7 Bushing 8 Snap Ring 9 Backup Ring 10 O Ring 11 Cylinder Tube 12 Stopper 2 Used Only Arm 13 Cylinder Cushion Bearing Only Arm 14 Cylinder Cushion Seal Only Arm 15 Cylinder Snap Ring Only Arm Cylinder 16 Slide Ring 2 Used 17 Slide Ring 2 Used 18 Backup Ring 2 Used 19 O Ring 20 Seal Ring 21 Set Screw 22 Steel Ball 23 Piston Nut 24 Cushion Bearing Only Boom 25 Arm Cylinder...

Page 497: ...ylinder 4 Install O ring 11 and backup ring 10 to cylinder head 7 5 Install O ring 20 and seal ring 21 to piston nut 24 by using the special tool A After installing seal ring 21 adjust seal ring 21 by using the special tool B Special tool A Special tool B tube inner diameter ST 2964 ST 2208 120 mm Boom Cylinder ST 2978 ST 2535 135 mm Arm Cylinder ST 2963 ST 2207 115 mm Bucket Cylinder 6 Install ba...

Page 498: ...0 mm Arm Cylinder m 7900 N m 790 kgf m 5830 lbf ft ST 3263 90 mm Bucket Cylinder m 5660 N m 566 kgf m 4170 lbf ft 11 Install steel ball 23 to cylinder rod 1 and tighten with set screw 22 Crimp set screw 22 by using a punch 2 places l 6 mm m 58 N m 5 8 kgf m 43 lbf ft dCAUTION Fit the cylinder rod 1 assembly with the center of cylinder tube 12 and install in order not to damage the rings 12 Secure ...

Page 499: ...MEMO ...

Page 500: ...MEMO ...

Page 501: ... 81 29 831 1162 E mail dc hitachi kenki com COMPANY NAME YOUR NAME DATE FAX E mail MODEL PUBLICATION PART NO Located at the left top corner in the cover page PAGE NO Located at the bottom center in the page If two or more revisions are requested use the comment column YOUR COMMENTS SUGGESTIONS Attach photo or sketch if required If your need more space please use another sheet REPLY ...

Page 502: ......

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Hitachi ZX200-5G, Workshop Manual

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