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3-014

ENGINE REMOVAL AND INSTALLATION

2-10. Bolts and Hoses Removal

(NOTICE)

Remove below bolts and hoses before removing
engine.

•

Engine oil drain hose. (U bolt. 13 box)

Pay attention on hose.

Unscrew hose clamp. (13 box, 3 clamps.)

Engine earth cables. (19 box)

Starter cable. (13 spanner)

2 bolts are on the other side.

Engines 4 bolts.
(24 box. Torque 265 N·m (194 lbf·f)

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Summary of Contents for SW770

Page 1: ...SW770 770HF 770ND TENTATIVE SHOP MANUAL 3498 64315 0 This manual is a preliminary version Please replace with the officially published version once it is available...

Page 2: ...SAFETY...

Page 3: ...achine if you fail to observe or important point to maintain of quality in maintenance works Indicates standard value to judge whether measured value is good or not Items that indicate the weight of a...

Page 4: ...guidance of a skilled electrician and according to electrical engineering rules and regulations Work on the frame brakes hydraulic and steering systems must be performed by skilled personnel with spec...

Page 5: ...eadable Never fill the fuel tank with the engine running or while near an open flame or while smoking Always clean up any spilled fuel Check for any warning tags placed on the machine do not operate t...

Page 6: ...nging banks or on grades that could cause the compactor to slide or roll over Avoid any areas that may be a risk to machine stability Avoid side hill travel Always operate up and down the slope Always...

Page 7: ...t until the machine has cooled down Use care when attaching and securing lifting tackle to individual parts and large assemblies being removed or repositioned for repair purposes to avoid the risk of...

Page 8: ...or perform grinding on the machine unless expressly authorized as there may be a risk of fire or explosion Disconnect the battery when welding on the machine Clean the machine and its surrounding fro...

Page 9: ...dth Block the drums or tires front and rear of the hauling vehicle when loading and unloading the compactor Ensure that the haul vehicle is on level ground and approach the loading ramps squarely to m...

Page 10: ...SPECIFICATIONS...

Page 11: ......

Page 12: ...2 210 mm 87 in ROPS 3 080 mm 121 in Wheelbase 3 600 mm 142 in Compaction width 1 700 mm 67 in Minimum height above ground 280 mm 11 in Curb clearance 838 mm 32 5 in Speed Forward reverse 0 to 12 km h...

Page 13: ...al system Alternator 24 V 50 A Starter 24 V 4 0 kW Battery 12 V 80 Ah 2 pcs 24 V Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow de...

Page 14: ...mm 142 in Compaction width 1 700 mm 67 in Minimum height above ground 280 mm 11 in Curb clearance 838 mm 32 5 in Speed Forward reverse 0 to 14 km h 0 to 8 7 mph Vibration performance Frequency Low amp...

Page 15: ...al system Alternator 24 V 50 A Starter 24 V 4 0 kW Battery 12 V 80 Ah 2 pcs 24 V Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow de...

Page 16: ...el 2 210 mm 87 in ROPS 3 080 mm 121 in Wheelbase 3 600 mm 142 in Compaction width 1 700 mm 67 in Minimum height above ground 280 mm 11 in Curb clearance 838 mm 32 5 in Speed Forward reverse 0 to 12 km...

Page 17: ...system Alternator 24 V 50 A Starter 24 V 4 0 kW Battery 12 V 80 Ah 2 pcs 24 V Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow deli...

Page 18: ...3 253 20 2 5 294 217 392 289 539 398 539 398 22 2 5 441 325 539 398 686 506 686 506 24 3 0 539 398 637 470 883 651 883 651 27 3 0 785 579 981 724 1324 977 1324 977 30 3 5 1079 796 1324 977 1765 1302 1...

Page 19: ...ENGINE REMOVAL AND INSTALLATION...

Page 20: ...torque table When installing hoses do not twist them or allow them to interfere with other parts Replace gaskets O rings split cotter pins and lock plates with new parts Properly bend split cotter pi...

Page 21: ...ut 6 hours 2 people Tools and equipment you need Box 10 mm 12 mm 13 mm 17 mm 19 mm 24 mm Ratchet big and small Nippers Screw Driver Phillips big and small flat big 10mm Box driver Spanner 10 mm 13 mm...

Page 22: ...d Right Side Cover Removal Uninstall left and right side cover 7 bolts 17 box 2 people Uninstall 2 small and 1 big cover under radiator 17 box Uninstall left cover 17 box Remove engine coolant Open up...

Page 23: ...INSTALLATION 2 2 Radiator Removal Step 1 Remove coolant tank with hose Uninstall hoses connected to radiator except oil hose Intake hose 10 box screw driver Coolant hose 10 box screw driver Remove cle...

Page 24: ...3 005 ENGINE REMOVAL AND INSTALLATION 2 2 Radiator Removal Step 2 Uninstall CAC hose Uninstall hose connected to upper part of radiator Oil cooler hose uninstall 36 spanner Install the cap...

Page 25: ...tank Please use vacuum effect or put cap for oil hose to avoid oil leakage from the hose Remove plate 5 bolts 17 box 2100 12020 1 4 bolts 2100 12020 1 4 bolts Move radiator to make a space to remove...

Page 26: ...and Air Cleaner Removal Unscrew 4 bolts 12 mm box Correct position of fan Priority order of fan elements Remove clamp of air cleaner 17 mm spanner Use flat screw driver Keep this configuration of hose...

Page 27: ...AND INSTALLATION 2 4 Battery Relay Bracket Removal Unscrew 2 earth cables 13 box Unscrew battery cable positive 14 spanner Remove battery relay with bracket 17 box Put electric wires in a safe positi...

Page 28: ...MOVAL AND INSTALLATION 2 5 Engine Hoses Removal Turbo charger hose keep in this position Pay attention on air sensor CAC hose clamp 10 box Lower hose clamp 10 box CAC hose clamp 10 box Remove from cir...

Page 29: ...frame and take out bolts and remove the frame Unscrew 2 front bolts 24 box torque 265 N m 194 lbf f Keep free hose Be careful on water sensor temperature Be careful Washers inside Unscrew back side 4...

Page 30: ...Removal Disconnect vibration pressure oil hose and put cap 36 Spanner Remove 2 clamp hose brackets Remove pipe frame above the engine 4 bolts 19 box Need two people for this operation Lift up hydr an...

Page 31: ...ND INSTALLATION 2 8 Exhaust System Removal Unscrew 4 bolts 17 box Make loose of the clamp and remove exhaust pipe Remove clamp 17 box and wrench Unscrew 3 nuts of exhaust pipe and rotate the pipe remo...

Page 32: ...ain hydr pump use 24 22 wrench 24 box and handle bar Remove carefully cables 10 box spanner 19 spanner 2 Do it with two people Unscrew and push aside electric harness Fix pump and hoses by ropes Use w...

Page 33: ...Remove below bolts and hoses before removing engine Engine oil drain hose U bolt 13 box Pay attention on hose Unscrew hose clamp 13 box 3 clamps Engine earth cables 19 box Starter cable 13 spanner 2 b...

Page 34: ...nnect Unscrew oil tank hose 41 spanner Use vacuum effect if possible Connect flowing high pressure air to the oil tank to avoid leakage of hydraulic hose during unscrew the hose from oil cooler Keep e...

Page 35: ...oval Step 1 Pay attention during lifting up the engine Use crane Fix 2 ropes in special lifting points Hydraulic Pump must be separate Pay attention on all cables harness and hoses After you will lift...

Page 36: ...Step 2 Keep fuel hose clean Protect against dust Keep clean other hoses Protect engine intake system 3 ENGINE INSTALLATION Installation process of the engine is exactly opposite order of removing pro...

Page 37: ...SYSTEM CIRCUIT DIAGRAMS...

Page 38: ...3 8 1 4 1 4 Lo i 1 0MPa 9 16 18UNF 5 8 1 1 16 12UN BETA5 m 2 1 2 3 4 7 8 14UNF 7 8 14UNF 1 2 3 8 3 4 1 2 3 4 FRONT 23 5 cc rev MP 23 5 cc rev 9 6 18UNF G1 4 G1 4 3 4 16UNF 1 1 16 12UN 1 1 16 12UN 1 1...

Page 39: ...1 0MPa Lo i 1 0MPa 9 16 18UNF 5 8 1 1 16 12UN BETA5 m 2 1 2 3 4 7 8 14UNF 7 8 14UNF 1 2 3 4 1 2 3 4 FRONT 23 5 cc rev MP 23 5 cc rev 31 5MPa 9 16 18UNF G1 4 G1 4 3 4 16UNF 1 1 16 12UN 1 1 16 12UN 1 1...

Page 40: ...2 GR 11 GW 2 B 9 WR 9 WR 9 WR FUEL PUMP 2 B 2 B 2 B 2 B 2 B 2 B 2 B 2 B 2 B 2 B 2 B 2 B 8 7 LR 7 LR 5 BrW 5 BrW 1 5R FUSE 10A FUEL PUMP RELAY 3 5 1 2 FUSE 30A F L 65A GLOW PLUG STARTER SWITCH BOOST LA...

Page 41: ...5WR 31 5WR 30 GW 15 2RB 30 GW 30 GW 28 5G 27 RG 27 27 26 YL 26 YL 25 RB 23 YB 20 Y 84 BY 19 LW 17 G 17 G 18 L COM NO NC WR WR 9 15 RB 15 2RB 15 RB 15 RB 15 RB 14 RL 14 RL 14 RL 14 RL 12 GR 11 GW 2 B 9...

Page 42: ...HYDRAULIC PUMP AND MOTORS LOCATION...

Page 43: ...FDB PB SEE STEERING HYD SYS NO 8 NO 18 NO 1 NO 8 NO 2 NO 3 NO 1 NO 2 NO 3 NO 14 NO 17 NO 15 NO 16 NO 13 FD4 BE NO 2 NO 17 NO 3 NO 15 NO 18 NO 14 NO 1 NO 16 NO 8 NO 13 NO 2 NO 17 NO 3 NO 15 NO 18 NO 14...

Page 44: ...W MOTOR FVA HIGH PRESSURE VIB HIGH MOTOR FVB HIGH PRESSURE NO 4 NO 6 TO NO 7 NO 1 SEE STEERING HYD SYS NO 15 NO 3 NO 6 NO 5 NO 4 NO 7 NO 1 NO 3 NO 4 NO 15 NO 3 NO 4 NO 15 NO 7 NO 3 NO 6 NO 5 NO 4 TO T...

Page 45: ...DR PA1 FROM PA1 VALVE OIL COOLER BC1 OUT RIN BA 15 14 17 16 SVP PX2 ROUT TANK 20 9 TANK 1 40 39 38 37 FROM FROM FROM TO BA PT PT1 OUT BOTTOM TOP CONNECT HOSES AS FOLLOWS NO 1 Hydraulic oil tank Valve...

Page 46: ...5 004 HYDRAULIC PUMP AND MOTORS LOCATION 4 location 4 5 0431 49801 0 10081 C PB2 PA2 CONNECT HOSES AS FOLLOWS TO TO TANK 13 12 8 7 1 Hydraulic pump Hydraulic pump Valve block assembly...

Page 47: ...2 7 R1 R2 R3 L2 L1 3 6 5 P PT2 R R3 L2 R1 IN T L L3 L1 R2 8 TANK Hydraulic tank CONNECT HOSES AS FOLLOWS SECTION A A NO 6 NO 2 TO TO TO TO FROM FROM TANK Steering Charge pump 5 Location 5 5 5 005 HYDR...

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