Hyundai HX220 L Disassembly And Assembly Download Page 1 | Manualshive

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SECTION 8 DISASSEMBLY AND ASSEMBLY

Group 1 Precaution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1

Group 2 Tightening Torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4

Group 3 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7

Group 4 Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-36

Group 5 Swing Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-50

Group 6 Travel Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-81

Group 7 RCV Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-113

Group 8 Turning Joint - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-127

Group 9 Boom, Arm and Bucket Cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-132

Group 10 Undercarriage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-151

Group 11 Work Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-164

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Summary of Contents for HX220 L

Page 1: ...g Torque 8 4 Group 3 Pump Device 8 7 Group 4 Main Control Valve 8 36 Group 5 Swing Device 8 50 Group 6 Travel Device 8 81 Group 7 RCV Lever 8 113 Group 8 Turning Joint 8 127 Group 9 Boom Arm and Bucke...

Page 2: ...vent any mistake when installing Check the number and thickness of the shims and keep in a safe place When raising components be sure to use lifting equipment of ample strength When using forcing scre...

Page 3: ...connector to remove all oil dirt or water then connect securely When using eyebolts check that there is no deformation or deterioration and screw them in fully When tightening split flanges tighten un...

Page 4: ...en removed and installed again add engine oil to the specified level Run the engine to circulate the oil through the system Then check the oil level again If the piping or hydraulic equipment such as...

Page 5: ...5 1 333 36 9 11 Turning joint mounting bolt nut M12 1 75 12 3 1 3 89 0 9 4 12 Power train system Swing motor mounting bolt M20 2 5 57 9 5 8 419 42 13 Swing bearing upper part mounting bolt M20 2 5 57...

Page 6: ...M22 2 5 46 8 63 2 339 457 65 8 88 8 476 642 78 9 106 570 766 M24 3 0 60 2 81 4 436 588 436 588 612 824 102 137 738 991 M30 3 5 120 161 868 1164 168 227 1216 1641 202 272 1461 1967 Bolt size 8 8T 10 9...

Page 7: ...size 1 4 3 8 1 2 3 4 1 1 1 4 Width across flat mm 19 22 27 36 41 50 kgf m 4 5 9 5 18 21 35 lbf ft 28 9 36 2 68 7 130 2 151 9 253 2 Thread size UNF 9 16 18 11 16 16 13 16 16 1 3 16 12 1 7 16 12 1 11 16...

Page 8: ...hydraulic tank Hydraulic tank quantity 160 Remove socket bolts 24 and disconnect pipe 10 11 Disconnect pilot line hoses 2 3 4 5 6 7 8 9 Remove socket bolts 23 and disconnect pump suction tube 1 When...

Page 9: ...o the hydraulic tank to the specified level Bleed the air from the hydraulic pump Remove the air vent plug 2EA Tighten plug lightly Start the engine run at low idling and check oil come out from plug...

Page 10: ...53 433 156 157 468 313 124 711 116 312 885 314 401 141 725 723 726 A A 123 724 B B C C 717 806 467 981 534 272 Pump casing R 312 Valve block 313 Valve plate R 314 Valve plate L 401 Hexagon socket bolt...

Page 11: ...26 with PTO SECTION A A without PTO 220S2MP06 05 PTO unit with PTO 079 Proportional reducing valve 326 Cover without PTO 414 Hexagon socket bolt without PTO 419 Hexagon socket bolt 537 Servo cover S 5...

Page 12: ...728 220S2MP07 115 Idler shaft 117 Gear No 2 118 Gear No 3 125 Ball bearing 126 Roller bearing 128 Bearing spacer 262 Cover 326 Gear case 414 Socket head screw 435 Flange head socket bolt 468 Plug 710...

Page 13: ...P plug Parallel thread Hexagon socket head setscrew Name Tool name size Part name B 6 8 10 14 17 Adjustable angle wrench Screw driver Hammer Pliers Torque wrench Medium size 1 set Minus type screw dri...

Page 14: ...M 5 M 6 M 8 M10 M12 M14 M16 M18 M20 PF 1 4 PF 3 8 PF 1 2 PF 3 4 0 7 1 2 3 0 5 8 10 0 16 3 23 5 33 7 43 8 3 0 7 5 10 0 15 3 5 1 8 7 21 7 42 0 72 3 118 170 244 317 21 7 54 2 72 3 111 0 16 0 20 0 24 0 3...

Page 15: ...ce Spread rubber sheet cloth or so on Make workbench top clean to prevent parts from being damaged Remove dust rust etc from pump surfaces with cleaning oil or so on Remove drain port plug 468 and let...

Page 16: ...spread rubber sheet on workbench to avoid damaging the surface 6 Remove flange sockets 435 and the gear pump 04 220S8MP13 220S8MP14 220S8MP15 7 Loosen hexagon socket head bolts 401 which tighten pump...

Page 17: ...e of cylinder block 141 spherical bush 156 piston shoes 011 swash plate 212 drive shaft 111 113 etc 10 220S8MP18 Remove hexagon socket head bolts 406 and seal cover F 261 In the case it is difficult t...

Page 18: ...ash plates with turning shown in this picture from casing 13 220S8MP21 220S8MP22 220S8MP23 Remove swash plate supports 251 from pump casing In this case it is difficult to remove tap the opposite side...

Page 19: ...o covers 537 stopper L 534 stopper S 535 and servo piston sub 530 from pump casing 271 272 Do not remove needle bearing 124 as far as possible except the case that the bearing is considered to be out...

Page 20: ...ns bearings etc before assem bling them In general rule replace the sealing parts such as O ring oil seal etc For fitting bolts plug etc prepare a torque wrench or so on and tighten them with torque s...

Page 21: ...and shoe plate Confirm that swash plate can moved smoothly with fingers of both hands Apply grease to sliding sentions of swash plate and swash plate support to assemble the drive shaft easily Take ca...

Page 22: ...into pump casing 220S8MP18 6 Fit valve plate 313 to valve block 312 according to pin 885 Take care not to mistake suction delivery directions of valve plate 220S8MP27 7 Place pump horizontally on work...

Page 23: ...ing 271 with hexagon socket head bolts 10 220S8MP15 Attach the PTO unit 05 by fastening the flange socket to the valve block 312 Be careful about the attaching direction of the PTO unit 11 220S8MP13 I...

Page 24: ...it regulator with hexagon socket head bolts Take care not to mix up regulator of front pump with another 12 220S8MP28 Fit proportional valve block 079 to valve block 312 with hexagon socket head bolts...

Page 25: ...15 V 413 436 412 414 437 497 611 876 726 614 874 A A B B VIEW D VIEW E E Pi 220S2MP08 412 Hexagon socket screw 413 Hexagon socket screw 436 Hexagon socket screw 437 Hexagon socket screw 497 Plug 611 F...

Page 26: ...1 Pilot cover 642 Pilot spool 643 Pilot sleeve 644 Spring seat Q 645 Adjust stem Q 646 Pilot spring 650 Sleeve pi 708 O ring 728 O ring 730 O ring 753 O ring 755 O ring 756 O ring 758 Square ring 801...

Page 27: ...Hexagon socket head bolt VP 3 8 ROH VP UNF Parallel thread Hexagon socket head setscrew Name Tool name size Part name B 4 5 6 19 22 Adjustable angle wrench Torque wrench Hexagon socket head bolt Medi...

Page 28: ...8 PT 1 4 PT 3 8 PT 1 2 PF 1 4 PF 3 8 PF 1 2 PF 3 4 PPU916 W 0 7 1 2 3 0 5 8 10 0 16 3 23 5 33 7 43 8 64 2 1 2 2 2 4 5 6 6 3 5 7 5 11 2 17 3 1 6 5 1 8 7 21 7 42 72 3 118 170 244 317 464 8 7 15 9 32 5...

Page 29: ...e special reason read thro ugh this manual to the end before starti ng disassembling Since the regulators on the front pump and the rear pump are set at different pressure and flow values mark each of...

Page 30: ...remove C D hexagon socket head cap screws 436 equally As spring force is strong casting 601 and adjust stem C 627 may be damaged if cover C 629 is inclined 220S8MP30 5 220S8MP31 220S8MP32 Pilot secti...

Page 31: ...nd Pi sleeve 650 from pilot cover If the regulator was used for a long time the Pf sleeve 631 or the Pf sleeve 650 may stuck with pliot cover Take care not to damage these sleeves while removing them...

Page 32: ...8 31 Remove the compensator sleeve 622 and the pilot sleeve 643 from the casing 601 This completes operation Since component parts are small take care not to lose them 10...

Page 33: ...en screws plugs etc with their specified torques Replace seals such as O ring with new ones as a general rule 4 1 Select a place for assembling Select clean place Spread rubber sheet or cloth to cover...

Page 34: ...nfirm that the sleeves slide smootly in casing with sticking or excess play among parts 220S8MP39 5 Direction for fitting the compensator spool into the compensator sleeve Fit the compensator spool 62...

Page 35: ...1 Tighten cover C 629 with hexagon socket head cap screws 436 Adjusting screw C 628 adjust stem C 627 hexagon nut 801 802 set screw 924 are fixed on cover C 629 Do not loosen screw and nut If they are...

Page 36: ...for the pressure sensor and so on Remove bolts and disconnect pipe Disconnect pilot line hoses Disconnect pilot piping Sling the control valve assembly and remove the control valve mounting bolt and...

Page 37: ...1 spool kit 6 Bucket spool kit 8 Arm 2 spool kit 12 Arm regen spool kit 16 Holding valve assy 18 Port relief valve assy 23 Arm 2 logic valve assy 24 Main relief valve assy 25 Negacon relief valve 27 O...

Page 38: ...18 55 36 57 25 34 57 55 17 6 17 2 17 4 17 5 17 3 17 9 17 8 17 7 17 1 17 Regen valve assy 18 Port relief valve assy 25 Negacon relief valve 27 Overload plug 34 Spool cap 36 Bucket stroke limit 55 O rin...

Page 39: ...Travel spool kit 5 Arm 1 spool kit 7 Swing spool kit 9 Boom 2 spool kit 10 Travel straight spool kit 11 Option spool kit 13 Swing priority spool kit 15 BC2 spool kit 16 Holding valve assy 21 Port reli...

Page 40: ...34 55 57 34 55 69 18 20 67 14 Housing P2 14 BC1 spool kit 18 Port relief valve assy 20 Port relief valve assy 26 Orifice signal plug assy 31 Plug 32 Plug 34 Spool cap 35 Spool cap 55 O ring 57 Socket...

Page 41: ...2 70 30 41 42 29 30 38 37 30 38 37 46 61 56 62 22 Swing logic valve assy 29 Plug 30 Load check valve 37 L C poppet 1 38 L C spring 1 41 Poppet 42 Spring 46 Port plug flange 56 O ring 61 Socket bolt 62...

Page 42: ...ch and disassemble the valve on it Support the body section carefully when carrying or transferring the control valve Do not lift by the exposed spool end cover section etc After disassembling and ass...

Page 43: ...Y DISASSEMBLY The figure in shown after the part name in explanation sentence shows its number in the construction figures 8 31 3 Disassembling of main spool assy 1 Pilot cover B side Travel R L 3 Swi...

Page 44: ...ssemble holding valve block assy pay attention not to miss the pilot poppet 4 Disassembling of bypass cut spool BC Bucket BC 14 Option BC 15 Loosen bypass cut plug assy 36mm socket wrench Pull out the...

Page 45: ...A 32 and O ring 43 Pull out the swing priority spool 13 Remove the pilot cover A 32 7 Disassembling of regen valve block assy Loosen the hexagon socket head bolts 46 3EA Hexagon key wrench 6 mm Remove...

Page 46: ...nner 32 mm 9 Disassembling of port relief valve Except the option side Loosen and remove the port relief valve 18 Spanner 34 mm 10 220S8MC18 220S8MC19 Disassembling of port relief valve Option side 1...

Page 47: ...ogic valve Arm logic valve 22 Swing logic valve 21 Loosen the hexagon socket head bolts 56 4EA and remove the logic valve Hexagon key wrench 8 mm 12 220S8MC23 Remove the swing logic poppet Remove the...

Page 48: ...ted jig and take it apart Spacer bolt spring stopper spring seat Hexagon key wrench 8 mm 14 220S8MC26 220S8MC27 Disassembling of check valve Plug 27 2EA Loosen the plug 27 and remove the poppet 37 spr...

Page 49: ...8 48 Disassembling of housing Loosen the hexagon socket head bolts 49 50 each 2EA 8EA Except when required specially do not disassemble housing P1 P2 for sanitation 15 220S8MC28 220S8MC29...

Page 50: ...ee from foreign matter If any spring is broken or deformed replace it with new one When a relief valve does not function properly repair it following its inspection procedures Replace all the O rings...

Page 51: ...he swing motor assembly 1 and remove the swing motor mounting socket bolts 9 Motor device weight 61 kg 135 lb Tightening torque 57 9 5 8 kgf m 419 42 lbf ft Remove the swing motor assembly When removi...

Page 52: ...bearing 7 Swash plate 8 Cylinder block 9 Spring 10 Ball guide 11 Retainer plate 12 Piston assy 13 Friction plate 14 Separate plate 15 Parking piston 16 Spring 17 Spring pin 18 O ring 19 O ring 20 Val...

Page 53: ...mble spring 16 and using a jig disassemble parking piston 15 from casing 1 DISASSEMBLY Disassemble drive shaft Unloosing socket bolt time delay valve 42 and disassemble time delay valve assy 35 from c...

Page 54: ...semble respectively cylinder block sub 8 friction plate 13 separate plate 14 from casing 1 Disassemble swash plate 7 from casing 1 Using a plier jig disassemble snap ring 4 from casing 1 Disassemble s...

Page 55: ...asing sub Disassemble spring pin 17 21 valve plate 20 O ring 22 from valve casing 23 2 3 2209A8SM59 2209A8SM60 2209A8SM61 2209A8SM62 Disassemble ball guide 10 and spring cylinder block 9 from cylinder...

Page 56: ...g 32 from valve casing 23 and dis assemble O ring 33 34 and reaction less valve assy 31 Using a torque wrench disassemble check valve 24 from valve casing 23 2209A8SM63 2209A8SM64 2209A8SM65 Disassemb...

Page 57: ...nveyor 120 C for 3 5 minutes 3 1 2209A8SM66 2209A8SM67 Using a robot machine assemble and press preheated roller bearing 3 into shaft 5 Assemble cylinder block sub Assemble 9 springs cylinder block 9...

Page 58: ...up check valve sub Assemble check valve 24 O ring 27 plug 26 in that order and then screw it torque wrench Make up check valve 2EA Spring 2EA Plug 2EA O ring 2EA 3 2209A8SM72 2209A8SM73 Assemble react...

Page 59: ...and O ring 27 into valve casing 23 Plug 28 3EA O ring 27 3EA 2209A8SM74 2209A8SM75 2209A8SM76 2209A8SM77 Assemble needle bearing 6 into valve casing 23 and assemble spring pin 17 21 into valve casing...

Page 60: ...ling 2 into casing 1 4 2209A8SM78 2209A8SM79 Fit shaft sub shaft roller bearing into casing 1 Using a plier jig assemble snap ring 4 to shaft 3 Snap ring 1EA Apply some grease swash plate 7 and assemb...

Page 61: ...der block 8 into casing 1 2209A8SM84 2209A8SM85 Assemble separate plate 14 and friction plate 13 4 sets into casing 1 and fit parking piston 15 into casing 1 by a jig or a press Separate plate 4EA Fri...

Page 62: ...8 Assemble level gauge 36 and plug 39 into casing 1 2209A8SM88 2209A8SM89 Assemble time delay valve assy 35 into valve casing 23 with socket bolt 42 Time delay valve 1EA Socket bolt 3EA Air pressing t...

Page 63: ...2209A8SM91 Leakage check Place motor on a bench tester and after cleaning motor by color check No 1 paint No 3 and be sure of leakage Mount test bench Mounting motor a test bench test the availabilit...

Page 64: ...motor assembly Sling reduction gear assembly 1 and remove dowel pin 3 and mounting bolts 2 Remove the reduction gear assembly Reduction gear device weight 75 kg 165 lb INSTALL Carry out installation...

Page 65: ...per bearing 5 Ring nut 6 Lock plate 7 Hexagon bolt 8 Casing 9 Socket bolt 10 Carrier 2 11 Planetary gear 2 12 Needle bearing 2 13 Thrust washer 2 14 Carrier pin 2 15 Spring pin 2 16 Sun gear 2 17 Carr...

Page 66: ...hile disassembling not let fall parts on your foot while lifting them fall parts on your foot while lifting them 2 1 2209A8SM01 2209A8SM02 Disassembly Disassembly Remove every Socket bolt M10 that sec...

Page 67: ...g it gradually maintaining it vertical with ground It s impossible to disassemble No 2 spring pin If No 2 spring pin has problem change whole No 2 carrier sub assy c d 2209A8SM04 2209A8SM05 2209A8SM06...

Page 68: ...ssy Unscrew every hex head bolt M12 to remove lock plate a Rolling ring nut for removing them from drive shaft sub assy b 2209A8SM08 A VIEW A 36 40 68 2 9 7 35 113 P C D 135 161 Use special tool to ro...

Page 69: ...a rack for flange of casing and remove drive shaft sub assy from casing by using press Remove oil seal taper bearing small from casing Do not re use oil seal It is impossible to dis assemble drive sha...

Page 70: ...ls while assembling nor let fall parts on your foot while lifting them on your foot while lifting them Inspection before assembling Inspection before assembling Thrust washer Thrust washer Check the s...

Page 71: ...e in line press No 1 spring pin into the holes Make No 1 spring pin hole head for No 1 planetary gear Caulk carrier holes to make No 1 spring pin settle down stably Refer to Caulking details Use paint...

Page 72: ...s of bearing and install them to No 2 carrier Align No 2 spring pin hole and No 2 carrier spring pin hole put No 2 spring pin into the holes Make No 2 spring pin cutting line face to No 2 planetary ge...

Page 73: ...groove of sleeve Be sure to maintain it vertical with ground when assembling it Put O ring into O ring groove of sleeve Fully apply grease on O ring Assemble taper bearing and sleeve into drive shaft...

Page 74: ...ttom bearing cup into casing Use special jig for pressing Pay attention to foreign materials while assembling bearing cup Flip over casing to assemble oil seal 1 2209A8SM25 2209A8SM26 ASSEMBLING BEARI...

Page 75: ...ASSEMBLING OIL SEAL Be sure to set dust seal to gear oil Before assembling charge enough grease in oil seal Before assembling apply enough grease inside and outside of oil seal 2 1 2 3 2209A8SM27 220...

Page 76: ...ing it 2 2209A8SM30 Put taper bearing into it Rotate bearing by hands for checking after assembly Put ring nut into drive shaft sub assy by using special jig The tightening torque M95 3 5 0 4 kgf m 3...

Page 77: ...screw of ring nut and make it in line by increasing tighten ing torque Screw 4 bolts M12 16 to connect ring nut and lock plate by using torque wrench Bolt M12 4EA 10 9T The tightening torque 8 8 0 9 k...

Page 78: ...acting with ring gear without disconnec tion Refer to loctite detail Put parallel pin into hole of casing sub assy Mark parallel pin position using paint marker Align ring gear with parallel pin to pu...

Page 79: ...nd ring gear 01 by using torque wrench Bolt M16 12EA 12 9T The tightening torque 27 2 7 kgf m 195 19 5 lbf ft Apply enough loctite 242 before screwing bolts Use paint marker for checking surplus parts...

Page 80: ...e shaft spline Screw M10 I bolt to No 2 carrier sub assy Lifting up No 2 carrier sub assy and align planetary gear and tooth of ring gear by rotating planetary gear by hands Rotate No 2 carrier sub as...

Page 81: ...y by hands to t No 1 carrier into No 2 sun gear spline Put No 1 sun gear into No 1 carrier sub assy Be sure to maintain it vertical with ground And align with No 1 planetary gear spline Rotate No 1 ca...

Page 82: ...ls see removal of track shoe removal of track shoe assembly Remove the cover Remove the hoses Fit blind plugs to the disconnected hoses Remove the bolts and the sprocket Sling travel device assembly 1...

Page 83: ...Swash plate 18 Cylinder block 19 Spring 20 Ball guide 21 Retainer plate 22 Piston assy 23 Friction plate 24 Separated plate 25 Parking piston 26 D ring 27 D ring 28 Valve plate 29 Parallel pin 30 Spri...

Page 84: ...ic hammer 1 piece Screw dirver Minus medium size 2 pieces Torque wrench 10 kgf m 72 3 lbf ft 33 kgf m 238 6 lbf ft 45 kgf m 325 4 lbf ft Gig for inserting oil seal Gig for inserting parking piston M10...

Page 85: ...M12 1 0 1 0 72 3 7 2 42 Relief valve 1 5 16 34 3 4 246 24 6 44 Plug PF 1 4 2 8 0 3 20 3 2 17 48 Plug PF 3 8 5 5 0 5 39 8 3 6 52 Connector PF 3 8 5 5 0 5 39 8 3 6 54 Hexagon socket head bolt M18 38 3 8...

Page 86: ...reat care When motor is removed from the host machine wash around the ports sufficiently and put the plugs so that no dust and or water may invade Take off these plugs just before the piping works whe...

Page 87: ...eparate the casing 1 and rear cover 34 3 Disassemble the brake spring 30 18EA from the piston 4 25098TM036 25098TM037 25098TM118 Disassemble the wrench bolt 39 to tighten the spool cover 36 and rear c...

Page 88: ...the casing 1 horizontal by using the assemble truck and disassemble the cylinder block kit form the casing 1 7 Disassemble the parking piston 25 by using the jig for disassembling parking piston 5 DI...

Page 89: ...uide 20 and spring 19 from the cylinder block kit 8 25098TM046 25098TM049 25098TM047 25098TM050 25098TM048 Disassemble the swash plate 17 from the casing 9 25098TM052 25098TM051 Disassemble the steel...

Page 90: ...le the snap ring 11 from the shaft 8 with the pryer for retaining ring 11 Disassemble the shaft 8 from the casing 1 12 Disassemble the snap ring 5 from the casing 1 with the pryer for retaining ring 1...

Page 91: ...m the casing 1 15 Disassemble the O ring 31 from the casing 1 Disassemble the valve plate 28 from the casing 1 17 18 Disassemble the oil seal 3 from the casing 1 with suitable tool 16 25098TM062 25098...

Page 92: ...Disassemble the relief valve 42 2EA from the rear cover 34 by using the torque wrench Disassemble both side of the plug 48 and connector 52 from the rear cover 34 by using the torque wrench and then...

Page 93: ...1 2 4 REASSEMBLING ASSEMBLING MOTOR REAR COVER ASSY 1 25098TM076 25098TM078 25098TM075 25098TM077 Assemble the relief valve 42 2EA into rear cover 34 Assemble the spool 47 parallel pin 50 spring seat...

Page 94: ...er 6 Assemble the valve plate 28 into rear cover 34 Before assembling apply some grease on contact surface of the valve plate 7 Apply some grease on the O ring and fit it into groove 8 25098TM086 2509...

Page 95: ...truck Assemble the thrust plate 4 into the casing 1 Assemble the snap ring 5 into the casing 1 with the plier for retaining ring 11 12 Tight fit the oil seal 3 into the casing 1 by using jig Be carefu...

Page 96: ...15 16 Assemble the heat fitted shaft 8 into casing 1 14 25098TM097 25098TM098 25098TM099 Heat the roller bearing 9 and fit it into the shaft with shrink fitting Shrink fitting can be used induction he...

Page 97: ...r tie Loosen the band or tie and assemble it to the casing 1 Apply a little grease on the steel ball 15 and assemble it into the swash plate 17 Apply some grease on the steel ball hole of the swash pl...

Page 98: ...r 25098TM106 25098TM109 25098TM107 25098TM110 25098TM108 20 Tilt the casing 1 sideways and assemble the cylinder block kit into the casing 1 21 25098TM111 Assemble the separated plate 24 and friction...

Page 99: ...Apply some grease on the D ring and assemble it parking piston Insert the parking piston into the casing and assemble it by using jig 23 24 25098TM116 25098TM117 Assemble the brake spring 30 18EA int...

Page 100: ...25098TM120 Confirm the insert direction of the main spool assy 35 exactly and assemble it into the rear cover 34 A s s u r e t h a t four balance hole is directed VA port 28 25098TM121 25098TM122 Ass...

Page 101: ...Hexagon socket head bolt 9 Coupling 10 Carrier 2 11 Planetary gear 2 12 Needle bearing 2 13 Thrust washer 2 14 Carrier pin 2 15 Spring pin 2 16 Solid pin 2 17 Sun gear 2 18 Carrier 1 19 Planetary gea...

Page 102: ...Therefore disassembling and assembling works should be performed on the clean place where dusts hardly gather Tools and kerosene to wash parts should also be clean and handled with great care Bofore d...

Page 103: ...cover As the cover is adhered to ring gear disassemble ring gear and cover by lightly hammering slantwise upward using sharpen punch inserted between the cover and ring gear 2 3 Preparation for disas...

Page 104: ...ub assembly Screw three M10 eye bolt in No 2 carrier and lift up and remove No 2 carrier assy Remove No 1 sun gear Be sure to maintain it vertical with the ground when disassembling No 1 sun gear Remo...

Page 105: ...k plate 7 25098TM134 Removing housing sub assembly ring gear Screw 7 16 14UNC eye bolt in housing and lift up ring gear and housing assembly including anguler bearing and floating seal 8 25098TM135 A...

Page 106: ...Lift up a piece of floating seal of motor side 9 25098TM138 25098TM139 Removing housing sub assembly Setting housing assembly on work stand for disassembling After setting housing lift up a piece of...

Page 107: ...pring pin fully into No 1 pin 25098TM141 Remove planetary thrust washer No 1 pin bearing from carrier 25098TM142 25098TM143 Disassembling No 2 carrier Knock spring pin fully into No 2 pin Remove No 2...

Page 108: ...efore reassembling Thrust washer Thrust washer Check if there are seizure abnormal wear or uneven wear Check if wear is over the allowable limit Gear Gear Check if there are pitting or seizure on the...

Page 109: ...l solid pin into the holes install No 2 pin into No 1 carrier where the holes for No 1 pin are to be in line with those of No 1 carrier and then install spring pins into the holes Caulk carrier holes...

Page 110: ...SEMBLING HOUSING ASSY AND RING GEAR Setting ring gear on work stand for assembling Apply loctite 515 on ring gear for housing without gap 5 6 1 2 1 25098TM150 25098TM152 25098TM153 Assemble floating s...

Page 111: ...ctite 242 on M12 hexagon head bolt and then bolt Tighten M12 hexagon head bolt to specified torque with torque wrench ASSEMBLING MAIN BEARING Assemble angular bearing into housing by use of pressing j...

Page 112: ...e planetary gear by hands and install on ring gear Rotate No 2 carrier assembly by hands and install on motor Match pin hole of No 2 carrier with main A B port of motor 10 12 11 1 1 1 2 3 4 25098TM158...

Page 113: ...f thrust plate direction turns to cover side ASSEMBLING COVER Apply loctite 515 on the ring gear for cover without gap 14 15 16 1 2 1 1 25098TM162 25098TM163 25098TM164 Put cover on ring gear apply lo...

Page 114: ...sure can penetrate the skin causing serious injury Loosen the socket bolt 1 Tightening torque 1 05 0 2 kgf m 7 6 1 45 lbf ft Remove the cover of the console box Disconnect pilot line hoses 3 Remove th...

Page 115: ...Spring seat 7 Spring 8 Plug 9 Push rod 10 O ring 11 Rod seal 12 Plate 13 Spacer 14 Boot 15 Joint assembly 16 Swash plate 17 Adjusting nut 18 Bushing 19 Plug 20 Handle assembly 21 Handle bar 22 Nut 23...

Page 116: ...nch 6 Spanne 22 27 Driver Length 150 Driver Width 4 5 Torque wrench Capable of tightening with the specified torques B Part name Item Size Torque kgf m lbf ft Joint 15 M14 3 5 25 3 Swash plate 16 M14...

Page 117: ...vise with copper or lead sheets Remove end of boot 23 from case 1 and take it out upwards 1 2 3 Loosen lock nut 22 and adjusting nut 17 with spanners on them respectively and take out handle section...

Page 118: ...ool When return spring 7 is strong in force plate 12 plug 8 and push rod 9 will come up on loosening joint Pay attention to this 7 Loosen adjusting nut 17 and swash plate 16 with spanners on them resp...

Page 119: ...ver Take it out utilizing external periphery groove of plug and paying attention not to damage it by partial loading During taking out plug may jump up due to return spring 7 force Pay attention to th...

Page 120: ...8 119 Remove O ring 10 and seal 11 from plug 8 Use small minus screwdriver or so on to remove this seal 13 Take push rod 9 out of plug 8 12 36078RL11 36078RL12 36078RL13...

Page 121: ...8 120 Remove lock nut 22 and then boot 23 14 36078RL14 2507ARL10...

Page 122: ...functions of reassembled valve will be degraded Therefore control cleanliness of kerosene fully Put parts in final cleaning vessel filled with kerosene turning it slowly to clean them even to their i...

Page 123: ...sing Assemble them to their original positions 2 ASSEMBLY Put shim 4 springs 5 and spring seat 6 onto spool 3 in this order 1 4 36078RL16 36078RL18 Assemble O ring 10 onto plug 8 3 36078RL19 Assemble...

Page 124: ...g 6 Assemble push rod 9 to plug 8 Apply working oil on push rod surface 5 36078RL21 36078RL22 When return spring is strong in force assemble 4 sets at the same time utilizing plate 12 and tighten join...

Page 125: ...h 4 push rods evenly Do not screw it over 10 Assemble adjusting nut 17 apply spanner to width across flat of plate 16 to fix it and tighten adjusting nut to the specified torque During tightening do n...

Page 126: ...in direction 60 to 120 from casing hole 14 Fit boot 23 and lock nut 22 and handle subassembly is assembled completely 13 2507ARL10 36078RL27 1408DA66 Assemble bushing 18 to plate and pass cord and tu...

Page 127: ...eventives through all ports and then put blind plugs in ports 18 19 Apply grease to rotating section of joint and contacting faces of disk and push rod 17 Determine handle direction tighten lock nut 2...

Page 128: ...ide the piping will flow out so catch it in oil pan Disconnect all hoses Sling the turning joint assembly 1 and remove the mounting bolt 2 Weight 57 kg 125 lb Tightening torque 12 3 1 3 kgf m 90 0 9 4...

Page 129: ...D ASSEMBLY STRUCTURE 1 1 Hub 2 Shaft 3 Cover 4 Spacer 5 Shim 6 Shim 7 Slipper seal 8 O ring 9 O ring 10 O ring 11 Wear ring 12 Retainer ring 13 Plug 14 Hexagon bolt 15 Spring washer 14 3 15 6 10 4 5 1...

Page 130: ...er at the shaft end hit out shaft 2 to about 1 2 from the body with a hammer Take care not to damage the shaft 2 when remove hub 1 or rest it sideway Put a fitting mark on hub 1 and shaft 2 4 Remove s...

Page 131: ...et shaft 2 on block tap hub 1 with a plastic hammer to install 3 Fix seven slipper seal 7 and O ring 9 two wear ring 11 to hub 1 Fit O ring 8 to shaft 2 1 2 ASSEMBLY Clean all parts As a general rule...

Page 132: ...8 131 14 15 3 Install cover 3 to body 1 and tighten bolts 14 Torque 10 12 5 kgf m 72 3 90 4 lbf ft 7 21078DA10...

Page 133: ...lease the remaining pressure in the hydraulic piping Loosen the breather slowly to release the pressure inside the hydraulic tank Escaping fluid under pressure can penetrate the skin causing serious i...

Page 134: ...ting position of the pin do not insert your fingers in the pin hole Bleed the air from the bucket cylinder Confirm the hydraulic oil level and check the hydraulic oil leak or not 2 Sling bucket cylind...

Page 135: ...piping Loosen the breather slowly to release the pressure inside the hydraulic tank Escaping fluid under pressure can penetrate the skin causing serious injury Fit blind plugs in the hoses after disco...

Page 136: ...mounting position of the pin do not insert your fingers in the pin hole Bleed the air from the arm cylinder Confirm the hydraulic oil level and check the hydraulic oil leak or not 2 Sling arm cylinde...

Page 137: ...piping Loosen the breather slowly to release the pressure inside the hydraulic tank Escaping fluid under pressure can penetrate the skin causing serious injury Fit blind plugs in the hoses after disc...

Page 138: ...osition of the pin do not insert your fingers in the pin hole Bleed the air from the boom cylinder Conformed the hydraulic oil level and check the hydraulic oil leak or not 2 Remove bolt 9 and pull ou...

Page 139: ...ing 5 Snap ring 6 Rod seal 7 Back up ring 8 Buffer ring 9 Dust wiper 10 Snap ring 11 O ring 12 Back up ring 13 Cushion ring 14 Piston 15 Piston seal 16 Wear ring 17 Dust ring 18 O ring 19 Back up ring...

Page 140: ...Back up ring 8 Buffer ring 9 Dust wiper 10 Snap ring 11 O ring 12 Back up ring 13 Cushion ring 14 Piston 15 Piston seal 16 Wear ring 17 Dust ring 18 O ring 19 Back up ring 20 Lock nut 21 Hexagon socke...

Page 141: ...ston seal 16 Wear ring 17 Dust ring 18 O ring 19 Back up ring 20 Lock nut 21 Hexagon socket set screw 22 O ring 23 Hexagon socket head bolt 24 Pin bushing 25 Dust seal 26 Check valve 27 Coil spring 28...

Page 142: ...0 Back up ring 21 Lock nut 22 Hexagon socket set screw 23 Cushion spear 24 Stop ring 25 Check valve 26 Coil spring 27 Plug 28 Hexagon socket head bolt 29 Safety lock valve 30 Pipe assembly RV 31 O rin...

Page 143: ...iston 15 Piston seal 16 Wear ring 17 Dust ring 18 O ring 19 Back up ring 20 Lock nut 21 Hexagon socket set screw 22 O ring 23 Hexagon socket head bolt 24 Pin bushing 25 Pin bushing 26 Dust seal 27 Ban...

Page 144: ...16 M10 M16 M10 M18 M12 M8 M8 M10 23 2 0 5 4 0 5 23 2 0 5 4 0 5 32 3 0 9 4 1 0 100 10 100 10 150 15 150 15 150 15 200 20 2 7 0 3 2 7 0 3 5 4 0 5 166 14 5 39 1 3 6 166 14 5 39 1 3 6 232 21 7 68 7 2 723...

Page 145: ...y together from tube assembly 1 Since the rod assembly is heavy in this case lift the tip of the rod assembly 2 with a crane or some means and draw it out However when rod assembly 2 has been drawn ou...

Page 146: ...4 and lock nut 20 are tightened to a high torque use a hydraulic and power wrench that utilizers a hydraulic cylinder to remove the piston 14 and lock nut 20 Remove piston assembly 14 back up ring 19...

Page 147: ...re in this operation not to damage the grooves 3 2907A8CY03 Disassemble cylinder head assembly Remove back up ring 12 O ring 11 and O ring 22 Remove snap ring 10 dust wiper 9 Remove back up ring 7 rod...

Page 148: ...in that order Coat each packing with hydraulic oil before fitting it Insert the backup ring until one side of it is inserted into groove Coat dust wiper 9 with grease and fit dust wiper 9 to the botto...

Page 149: ...and dust ring 17 to piston 14 Fit piston seal 15 to piston Put the piston seal in the warm water of 60 100 C for more than 5 minutes After assembling the piston seal press its outer diameter to fit in...

Page 150: ...ssembly to rod assembly Tightening torque Insert cushion ring 13 to rod assembly Note that cushion ring 13 has a direction in which it should be fitted Install piston and cylinder head Fix the rod ass...

Page 151: ...ar through the clevis pin hole to lock the assembly Insert the rod assembly in to the tube assembly while lifting and moving the rod assembly with a crane Be careful not to damage piston seal by threa...

Page 152: ...ipple grease is not leaking until the grease nipple is completely coming out If the tension is not released in advance the grease nipple can be suddenly popped out by pressurized grease Push out maste...

Page 153: ...Carry out installation in the reverse order to removal 2 1 Loosen the lock nut 1 Open bracket 2 with a screwdriver push out from inside and remove carrier roller assembly Weight 21 kg 46 lb Tightenin...

Page 154: ...ation in the reverse order to removal 2 1 Remove the mounting bolt 1 and draw out the track roller 2 Weight 46 kg 106 lb Tightening torque 57 9 8 7 kgf m 419 62 9 lbf ft 3 Using the work equipment pus...

Page 155: ...Make sure that the boss on the end face of the recoil cylinder rod is in the hole of the track frame 2 1 Remove the bolts 2 washers 3 and separate ilder from recoil spring Tightening torque 29 7 4 5 k...

Page 156: ...8 155 8 155 DISASSEMBLY AND ASSEMBLY OF IDLER Structure 1 3 1 Shell 2 Shaft 3 Seal assembly 4 Bushing 5 Bracket 6 O ring 7 Spring pin 8 Plug 1 4 3 8 7 5 4 3 7 6 2 5 6 220S8DA43...

Page 157: ...a special tool Only remove bushing if replacement is necessity Pull out the shaft 2 with a press Remove seal 3 from idler 1 and bracket 5 Remove O ring 6 from shaft Disassembly Remove plug and drain o...

Page 158: ...into shell 1 Do not press it at the normal temperature or not knock in with a hammer even after the cooling 3 Press 6 2 5 7 3 2 1 1 4 Install shaft 2 to shell 1 Install seal 3 to shell 1 and bracket...

Page 159: ...8 8 158 5 5 7 1 5 Lay bracket 5 on its side Supply engine oil to the specified level and tighten plug Knock in the spring pin 7 with a hammer Install bracket 5 attached with seal 3 8 168 1 8 168 2 8 1...

Page 160: ...ASSEMBLY OF RECOIL SPRING Structure Structure standard 1 4 1 Body 2 Tie bar 3 Spring 4 Bracket 5 Lock nut 6 Lock plate 7 Bolt 8 Spring washer 9 Rod seal 10 Back up ring 11 Dust seal 12 Rod 13 Grease...

Page 161: ...gh walker 1 Body 2 Tie bar 3 Spring 4 Bracket 5 Lock nut 6 Lock plate 7 Bolt 8 Spring washer 9 Rod seal 10 Back up ring 11 Dust seal 12 Rod 13 Grease valve 14 Spring pin 15 Stopper 4 7 8 6 3 15 14 1 9...

Page 162: ...spring washer 8 and lock plate 6 Remove lock nut 5 Take enough notice so that the press which pushes down the spring should not be slipped out in its operation Lighten the press load slowly and remove...

Page 163: ...d 13716 kg 30239 lb High walker 16315 kg 35968 lb Apply sealant before assembling During the operation pay attention specially to prevent the press from slipping out Pour grease into body 1 then push...

Page 164: ...hten the press load and confirm the set length of spring 3 Standard 431 1 5 mm High walker 508 1 5 mm After the setting of spring 3 install lock plate 6 spring washer 8 and bolt 7 Tightening torque 15...

Page 165: ...1 STRUCTURE 8 164 GROUP 11 WORK EQUIPMENT B SECTION C SECTION B SECTION A C C A B A 21078DA44 SECTION A SECTION B SECTION C...

Page 166: ...l When aligning the mounting position of the pin do not insert your fingers in the pin hole Adjust the bucket clearance For detail see operation manual 2 Remove nut 3 bolt 4 and draw out the pin B Tig...

Page 167: ...ve spring pin stopper and pull out pin Tie the rod with wire to prevent it from coming out For details see removal of arm cylinder assembly Place a wooden block under the cylinder and bring the cylind...

Page 168: ...lifting the arm assembly always lift the center of gravity Bleed the air from the cylinder 2 Remove bolt 4 plate 5 and pull out the pin 6 then remove boom assembly Weight 1950 kg 4300 lb Tightening t...

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