Hitachi EX135 Workshop Manual

Page 1

EXCAVATOR

Models

WORKSHOP MANUAL EXCAVATOR

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

FIAT-HITACHI EXCAVATORS S.p.A. - ENGINEERING - FORM No. 604.06.837 Edition - XI - 1997

Page 2

TO THE READER

IN-1

INTRODUCTION

• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.

- Be sure to thoroughly read this manual for correct

information concerning the service procedures.

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition to this service manual:

- The Operator’s Manual

- The Spare Parts Catalog

- If you have any questions or comments, or if you found any errors regarding the contents of this manual, please contact:

FIAT-HITACHI S.p.A. San Mauro Torinese (TO) 10099 ITALIA PRODUCT SUPPORT Fax. ++39 11 6877357

SERVICE MANUAL COMPOSITION

• The complete service manual consists of four books:

- Technical Manual - Operational Principle

- Technical Manual - Troubleshooting

- Excavator Workshop Manual

- Engine Workshop Manual

- The Technical Manual (Operational Principle) includes the technical information concerning the operation of main devices and systems.

- The Technical Manual (Troubleshooting) includes the technical information needed for operational

BOOK PART NUMBER

- Technical Manual - Operational Principle 604.06.827

- Technical Manual - Troubleshooting 604.06.822

- Workshop Manual - Excavator 604.06.837

- Workshop Manual - Engine 604.06.832

performance tests, and troubleshooting procedures.

- The Excavator and the Engine Workshop Manuals include information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, removal/installation and assembly/disassembly procedures.

• The Service Manual for EX135 Excavator consists of the following book/print numbers:

Page 3

IN-2

INTRODUCTION

PAGE NUMBER

• Each page has a number, located on the external upper corner of the page. Each page number contains the following information:

Example: T 1-2-3

Consecutive page number for each group Group number (if exist) Section number

T : Technical Manual W : Excavator Workshop Manual EW: Engine Workshop Manual

SYMBOLS

In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury or machine damage.

This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attentio in to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

UNITS USED

SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parentheses just behinds SI units.

Example: 24.5 Mpa (250 kgf/cm2, 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposes.

Quantity convert Into Multiply by Quantity convert Into Multiply by

Lenght mm in 0.039 37 Pressure MPa kgf/cm

Volume L US qt 1.057 kW HP 1.341

Weight Kg lb 2.205 Velocity Km/h mph 0.621 4

Force N kgf 0.101 97 min

Torque N.m Kgf.m 0.101 97 ML/rev Cc/rev 1.0

To To

from (SI) (Others) from (SI) (Others)

mm ft 0.003 281 MPa psi 145.0

L US gal 0.264 2 Power kW PS 1.360

m yd 1.308 Temperature °C °F °C x 1.8 + 32

-1

N lbf 0.224 8 Flow rate L/min US gpm 0.264 2

N.m lbf.ft 0.737 5

rpm 1.0

10.197

Page 4

SAFETY PRECAUTIONS

RECOGNISE SAFETY INFORMATION

• This is your SAFETY ALERT SYMBOL.

- When you see this symbol on your machine or in this Manual, be alert of the potential for personal injury.

- Follow recommended precautions and safe operating practices.

UNDERSTAND SIGNAL WORDS

• In this Manual you will find the following words:

S-1

S0021

- DANGER;

- WARNING;

- CAUTION. referring to different hazard risks.

These words are always accompanied by the safety alert symbol.

DANGER: indicates an imminent hazardous situation which, if not avoided, will result in death or serious injury.

WARNING: indicated a potential hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION: indicates a potential hazardous situation which, if not avoided, may result in minor or moderate injury.

IMPORTANT: indicates a situation which, if not avoided, may cause damage to the machine.

NOTE: indicates an additional explanation for information purposes.

DANGER

WARNING

CAUTION

IMPORTANT

NOTE

ENVIRONMENTAL PROTECTION

• This Manual also contains this symbol accompanying instructions for correct behaviour as regards environmental protection.

S0024

Page 5

S-2

SAFETY PRECAUTIONS

FOLLOW SAFETY PRECAUTIONS

• Carefully read and observe all safety signs on the machine and read all safety precautions in this Manual.

• Safety signs should be installed, maintained, and replaced when necessary.

- If a safety sign or this Manual are damaged or

missing, obtain a replacement from your FIAT- HITACHI Dealer in the same way you order a spare part (be sure to detail machine model and serial number upon ordering).

• Learn how to operate the machine and its controls correctly and safely.

• Allow only trained, qualified, authorised personnel to operate the machine.

• Keep the machine in proper working conditions.

- Unauthorised changes to the machine may

impair function and/or safety and affect machine life.

• Safety messages in this Chapter “SAFETY PRECAUTIONS”, are intended to illustrate basic safety procedures of the machine. However, it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any doubts, consult your direct supervisor prior to operating or servicing the machine.

S0022

PREPARE FOR EMERGENCIES

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

- Keep the first-aid kit and fire extinguisher on hand.

- Thoroughly read and understand the label

attached to the fire extinguisher to use it properly.

- Establish emergency priority procedures to cope

with fires and accidents.

- Keep emergency numbers for doctors,

ambulance service, hospitals and fire department posted near the telephone.

S0023

Page 6

SAFETY PRECAUTIONS

WEAR PROTECTIVE CLOTHING

• Wear close-fitting clothing and safety equipment appropriate to the job.

You need:

- A hard hat;

- Safety shoes;

- Safety glasses or face shield;

- Heavy gloves;

- Ear protection;

- Reflective clothing;

- Waterproof clothing;

- Respirator or filter mask;

Be sure to correctly wear equipment and clothing for the job .

- Do not take any chances.

- Avoid wearing loose clothing, jewellery, or other

items that can catch on control levers or other parts of the machine.

S-3

S0025

• Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impairment or loss of hearing.

- Wear a suitable hearing protection such as

earmuffs or earplugs to protect objectionable or uncomfortably loud noise.

INSPECT THE MACHINE

S0026

• Inspect the machine carefully every day or work-

shift by an attentive visual inspection of machine outside prior to starting it to prevent damages and personal injuries.

- In the walk-around inspection, be sure to cover all points detailed in the OPERATION AND

MAINTENANCE INSTRUCTION MANUAL.

S0027

Page 7

S-4

SAFETY PRECAUTIONS

USE HAND HOLDS AND STEPS

• Falling is one of the major causes of personal injury.

- When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.

- Do not use any control as a handhold.

- Never jump off the machine. Never get on and off a moving machine,

- Be careful of slippery conditions of platforms, steps, and handrails when leaving the machine.

ADJUST THE OPERATOR'S SEAT

• A seat poorly adjusted for operator or work requirements may quickly fatigue the operator leading to improper operations.

S0028

- The seat should be adjusted whenever machine

operator changes.

- The operator should be able to fully press the

pedals and correctly move the control levers with his back resting against the seat back.

- If not, move the seat fore and aft, and check again.

S0029

Page 8

SAFETY PRECAUTIONS

FASTEN SEAT BELT

• Should the machine overturn, the operator may become injured and/or thrown from the cab. Not only, the operator may be crushed by the overturning machine resulting in serious injury or even death.

- Prior to operating the machine, thoroughly

examine belt webbing, buckle, and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine.

- Be sure to remain seated with the seat belt

securely fastened at all times when the machine is in operation to minimise injury hazard in case of accident.

- After a significant accident, replace the seat belts

even though they do not look damaged.

S-5

S0030

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

- Pay the utmost attention not to run over

bystanders.

- Be sure and aware of the location of bystanders

before moving, swinging or operating the machine.

- If fitted, keep the travel alarm and horn sounding

to warn people that the machine is about to move.

- When operating, swinging, or moving the

machine in a congested area use a signal man.

- Co-ordinate hand signals before starting the

machine.

S0031

Page 9

S-6

SAFETY PRECAUTIONS

OPERATE ONLY FROM THE DRIVER'S SEAT

• Inappropriate engine starting procedures may cause the machine unexpected movement, possibly resulting in serious injury and even death.

- Start the engine only from the operator’s seat.

- NEVER start the engine while standing on the

track or on the ground.

- Do not start the engine by shorting across starter

motor terminals.

- Before starting the engine, ensure that all control

levers are in the neutral position.

STARTING THE ENGINE WITH BOOSTER BATTERIES

S0032

• Battery gas may explode causing serious damages and injuries.

- If the engine is to be started using booster

batteries, ensure to comply with all procedures detailed in the OPERATION AND MAINTE-

NANCE INSTRUCTION MANUAL.

- The operator should be sitting in the driver’s seat

to keep the machine under control when the engine starts. Starting the engine with booster batteries is a two man operation.

- Do not use batteries that have been stored in the

cold for a long time.

- Mistakes in following procedures detailed for

starting the engine with slave batteries may cause the batteries to explode or machine to move unexpectedly.

DON'T CARRY RIDERS ON THE MACHINE

S0001

• Riders on the machine are subject to injuries such as being struck by foreign objects and being thrown off the machine.

- Only machine operator is allowed on the

machine. Keep riders off.

- Riders also obstruct the operator’s visibility,

resulting in the machine being operated unsafely.

S0033

Page 10

SAFETY PRECAUTIONS

PROVIDE SIGNALS FOR JOBS INVOLVING A NUMBER OF MACHINES

• For jobs involving several machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to co-ordinate the job site. Make sure that all personnel obey the signal person’s directions.

S-7

S0036

CONFIRM DIRECTION WHERE THE MACHINE IS TO BE DRIVEN

• Incorrect travel controls operation may result in serious injury and even death.

- Before driving the machine, be aware of the

undercarriage position relative to the operator’s position. If travel motors are located at the front of the cab, the machine will move reverse when travel controls are moved towards cab front.

S0037

Page 11

S-8

SAFETY PRECAUTIONS

DRIVE MACHINE SAFELY

• Before moving the machine, confirm which way to move travel pedals/levers for the corresponding direction you wish to go.

- Pushing down on the front of the travel pedals or

pushing the levers forward moves the machine towards the idlers. (Refer to the OPERATION

AND MAINTENANCE INSTRUCTION MANUAL).

• Traveling on a grade may cause the machine to slip or to overturn, possibly resulting in serious injury or death.

- When traveling up or down a grade, keep the

bucket in the direction of travel, approximately 200 to 300 mm (A) above the ground.

S0038

- If machine starts to skid or becomes unstable,

lower the bucket immediately.

- Traveling across the face of a slope may cause

the machine to skid or to overturn. When travelling (ascending/descending) on a slope, be sure to point the tracks uphill/downhill.

- Turning on an incline may cause the machine to

tip over. If turning on an incline is absolutely unavoidable, do so at a place where the slope is gentle and the surface is firm.

S0039

S0004

WRONG

S0005

Page 12

SAFETY PRECAUTIONS

AVOID INJURY FROM UNEXPECTED MACHINE MOVEMENT

• Death or serious injury may result if you attempt to get on or off a moving machine.

• To avoid roll-aways:

-Select level ground when possible to park

machine.

- Do not park the machine on a grade.

- Lower the bucket and/or other work tools to the

ground. Thrust the bucket teeth into the ground if you must park on a grade.

- Turn the auto-idle switch off.

- Run the engine at slow idle speed without load for

5 minutes to cool down the engine.

- Stop the engine and remove the key from the key

switch.

- Pull the pilot shut-off lever to LOCK position.

- Block both tracks.

- Position the machine to prevent overturning.

- Park a reasonable distance from other machines.

S-9

S0040

S0041

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S-10

SAFETY PRECAUTIONS

AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS

• If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death.

• To avoid back-over and swing accidents:

- Always look around BEFORE YOU BACK UP

AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR.

- Keep the travel alarm in working condition (if

equipped).

- ALWAYS BE ALERT FOR BYSTANDERS

MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE.

S0042

- 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 confirm with the person in charge of signalling.

- Keep windows, mirrors, and lights clean and in

good condition.

- Dust, heavy rain, fog, etc., can reduce visibility.

As visibility decreases, reduce speed and use proper lighting.

- Read and understand all operating instructions in

the OPERATION AND MAINTENANCE INSTRUCTION MANUAL.

S0043

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SAFETY PRECAUTIONS

AVOID OVERTURNING

• 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 by grading.

- Keep the bucket low to the ground and close to the

machine.

- Reduce machine operating speed to avoid tipping

or slipping.

- Avoid changing direction when travelling on

grades.

- NEVER attempt to travel across a grade steeper

than 15 degrees.

- Reduce swing speed as necessary when

swinging loads.

S-11

S0002

• Be careful when working on frozen ground.

- Temperature increases will cause the ground to

become soft and make ground travel unstable.

AVOID ELECTRIC LINES

• Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines.

- When operating near an electric line, NEVER

move any part of the machine or load closer than 3 m plus twice the line insulator length.

- Check and comply with any local regulations that

may apply.

- Wet ground will expand the area that could cause

any person on it to be affected by electric shock.

- Keep all bystanders or co-workers away from the

site.

S0047

S0010

Page 15

S-12

SAFETY PRECAUTIONS

PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body, serious injury may result.

- Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.

- Keep bystanderds away from the working area

before striking any object.

PARK MACHINE SAFELY

S0046

• To avoid accidents:

- Park machine on a level surface.

- Lower bucket to the ground.

- Turn auto-idle (A/I) switch off.

- Run engine at slow idle speed without load for 5 minutes.

- Turn key-start switch to OFF to stop engine.

- Remove the ignition key from the key switch.

- Pull the safety lever (pilot-control shut-off lever) to the LOCK position.

- Close windows, roof window, and cab door.

- Lock all access doors and compartments.

S0049

Page 16

SAFETY PRECAUTIONS

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 injuty or death.

- Do not refuel the machine while smoking or when

near open flame or sparks.

- Always stop the engine before refuelling the

machine.

- Fill the tank outdoors.

S-13

• All fuels, most lubrificants, and some antifreeze fluids are flammable.

- Store flammable fluids well away from fire

hazards.

- Do not burn or puncture pressurized containers.

- Do not store oily rags; they can ignite and burn

spontaneously.

S0050

S0051

Page 17

S-14

SAFETY PRECAUTIONS

SAFE MAINTENANCE

• To avoid accidents:

- Understand maintenance procedure before starting the work.

- Kepp the working area clean and dry.

- Do not spray water or steam inside the cab.

- Do not lubricate or service the machine when it is in motion.

- Kepp hands, feet and clothes far from moving parts.

Prior to service in the machine:

1. Park the machine on the level ground.

2. Lower the bucket to the ground.

3. Switch off the Auto-Idle (A/I).

4. Let the engine idle with no load for at least five

minutes until it has cooled down.

5. Move the key-start switch to the OFF position

to stop the engine.

6. Relieve pressure from the hydraulic system by

cycling control levers several times.

7. Remove the ignition key from the start switch.

8. Apply the "Maintenance in progress" tag . This

tag can be applied o the left-hand control lever, safety lever or cab door.

9. Move the safety lever (pilot-control shut-off

lever to the LOCK position.

10. Let the engine cool down.

- Do not leave the machine unattended if servicing requires the engine running .

- If the machine is to be raised, place boom and arm at an angle 90 to 110°. Lock machine components which should be raised for maintenance or repair using suitable supporting means.

- Never work under a machine kept raised by the boom.

- Inspect certain component regularly, repair or replace as necessary. Refer to the the OPERATION AND

MAINTENANCE INSTRUCTION MANUAL.

- Keep all components in good condition and properly install. Immediately repair any fault.

- Immediately repair any damage.Replace worn or failed components. Remove grease, oil, debris build-ups.

- Disconnect the negative cable (−) from the battery before carry out any work on he electrical sysem or arc-welding on he machine.

S0053

S0054

Page 18

SAFETY PRECAUTIONS

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious injury.

- Before performing any work on the machine,

attach a maintenance in progress tag. This tag can be applied o the left-hand control lever, safety lever or cab door.

S-15

S0055

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without securing the machine first.

- Always lower the attachment or tool to the ground

before working on the machine.

- If you must work on a lifted machine or

attachment, securely support the machine or attachment.

- Do not support the machine on cinder blocks,

bollow tires, or props that may crumble under continuous load.

- Do not work under a machine that is supported

solely by a jack.

STAY CLEAR OF MOVING PARTS

• Entanglements in moving parts can cause serious injury.

S0054

• To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working near rotating parts.

S0056

Page 19

S-16

SAFETY PRECAUTIONS

PREVENT PARTS FROM FLYING OFF

• Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death.

- NEVER attempt to remove GREASE FITTING or

VALVE ASSEMBLY.

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

face away from valve.

• Travel reduction gears are under pressure.

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

face away from AIR RELEASE PLUG to avoid injury. REDUCTION GEAR OIL is hot. Wait for gear oil to cool down, then gradually loosen the air release plug to release pressure.

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic breakers, and blades can fall and cause serious injury or death.

- Securely store attachments and implements to

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

S0057

S0058

Page 20

SAFETY PRECAUTIONS

PREVENT BURNS

Hot spraying fluids:

• After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns.

- To prevent 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.

S-17

S0019

Hot fluids and surfaces:

• Engine oil, reduction gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well.

- Wait for the oil and components to cool down

before starting any maintenance or inspection work.

S0059

Page 21

S-18

SAFETY PRECAUTIONS

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.

- Relieve the pressure by moving the control levers

several times. Tighten all connections before applying pressure.

- Search for leaks with a piece of cardboard; take

care to protect hands and body from highpressure fluids. Wear a face shield or goggles for eye protection.

- In an accident occurs, see a doctor familiar with

this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

SA0016

• In case of accident, immediately seek appropriate medical attention.

• Any fluid penetrated under the skin should be removed within a few hours to prevent serious infections.

SA0017

SA0018

Page 22

SAFETY PRECAUTIONS

PREVENT FIRES

• Check for Oil Leaks:

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

- Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts which may cause oil leaks.

- Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oilcooler flange bolts.

- Do not bend or strike high-pressure lines.

- Never install bent or damaged lines, pipes, or hoses.

• Check for Shorts:

- Short circuits can cause fires.

- Clean and tighten all electrical connections.

- Check before each shift or after about ten (10) hour operation for loose, kinked, hardened or frayed electrical cables and wires.

- Check before each shift or after about ten (10) hour operation for missing or damaged terminal caps.

- DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc..

• Clean up Flammables:

- Spilled fuel and lubricans, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.

- Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately.

• Check Key-start Switch:

- If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting.

- Always check key-start switch function before operating the machine every day:

1. Start the engine and run it at slow idle.

2. Turn the key-start switch to the OFF position to

confirm that the engine stops.

- If any abnormalities are found, be sure to repair them before operating the machine.

• Check Heat Shields:

- Damaged or missing heat shields may lead to fires.

- Damaged or missing heat shields must be repaired or replaced before operating the machine.

S-19

S0051

Page 23

S-20

SAFETY PRECAUTIONS

EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the following way:

- Stop the engine by turning the key-start switch to

the OFF position if there is time.

- Use a fire extinguisher if there is time.

- Exit the machine.

BEWARE OF EXHAUST FUMES

S0060

• Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

- If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

S0061

Page 24

SAFETY PRECAUTIONS

AVOID HEATING NEAR PRESSURIZED FLUID LINES

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders.

Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire resistant guards to protect hoses or other materials when welding, soldering, etc.

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS

S-21

S0062

- Do not weld or flame cut pipes or tubes that contain flammable fluids.

- Clean them thoroughly with non-flammable solvent before welding or flame cutting them.

REMOVE PAINT BEFORE WELDING OR HEATING

• Hazardous fumes can be generated when paints is heated by weiding, soldering, or using a torch. If inhaled, these fumes may cause sickness.

- Avoid breathing potentially toxic fumes and dust.

- Do all such work outside or in a well-ventilated

area.

- Dispose of paint and solvents properly.

- Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.

2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

S0063

Page 25

S-22

SAFETY PRECAUTIONS

PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.

- Keep sparks, lighted matches, and flames away from the top of battery.

- Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

- Do not charge a frozen battery; it may explode. Warm battery to 16°C.

• 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.

S0001

DISPOSE OF WASTE IN THE APPROPRIATE MANNER

• Waste improperly disposed of represents a danger for the envinronment. Potentially dangerous waste used on the FIAT - HITACHI excavators includes lubricants, fuel, coolant, brake fluid, filters and batteries.

- Used sealed containers when discharging fluids.

Do not use containers for food or beverages which may induce drinking.

- Do not spill waste over the ground, into drains, or

water beds.

- Obtain information about the correct methods to

recycle or dispose of waste from local Authorities, collection centres or your Dealer.

S0064

Page 26

SAFETY PRECAUTIONS

BEFORE RETURNING THE MACHINE TO THE CUSTOMER

• After maintenance or repair work is complete, confirm that:

- The machine is functioning, especially the safety

system

- Worn or damaged parts have been repaired or

replaced.

S-23

S0027

Page 27

S-24

NOTES

SAFETY PRECAUTIONS

Page 28

WORKSHOP MANUAL

ESCAVATOR

SECTION AND GROUP CONTENTS

Section 1 - GENERAL INFORMATION

Group 1 - Precautions for Disassembling and Assembling Group 2 - Tightening Torque

Section 2 - UPPERSTRUCTURE

Group 1 - Cab Group 2 - Counterweight Group 3 - Main Frame Group 4 - Pump Device Group 5 - Control Valve Group 6 - Swing Device Group 7 - Pilot Valve Group 8 - Pilot Shut-Off Valve Group 9 - Shockless Valve Group 10 - Solenoid Valve Group 11 - Pilot Relief Valve Unit

EX135

Section 3 - UNDERCARRIAGE

Group 1 - Swing Bearing Group 2 - Travel Device Group 3 - Center Joint Group 4 - Track Adjuster Group 5 - Front Idler Group 6 - Upper and Lower Roller Group 7 - Tracks

Section 4 - FRONT ATTACHMENT

Group 1 - Front Attachment Group 2 - Cylinders

Page 29

SECTION 1 EX135

GENERAL INFORMATION

CONTENTS

Group 1 - Precautions for Disassem-

bling and Assembling

Precautions for Disassembling and

Assembling.......................................... W1-1-1

Group 2 - Tightening Torque

Tightening Torque Specification ........... W1-2-1

Torque Chart ........................................ W1-2-2

Pipe Thread Connection / Union joint

Tightening Torque Specifications ......... W1-2-5

Page 30

PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING

W1-1-1

Precautions for Disassembling

• Clean the Machine

Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work.

• Inspect the Machine

Be sure to thoroughly understand all disassembling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future.

- The machine model, machine serial number, and hour meter reading.

- Reason for disassembly (symptoms, failed parts, and causes).

- Clogging of filters and oil, water or air leaks, if any.

- Capacities and condition of lubricants.

- Loose or damaged parts.

Precautions for Disassembling and Assembling

• Precautions for Disassembling

- To prevent dirt from entering, cap or plug the removed pipes.

- Before disassembling, clean the exterior of the components and place it on a work bench.

- Before disassembling, drain gear oil from the reduction gear.

- Be sure to provide appropriate containers for draining fluids.

- Use matching marks for easier reassembling.

- 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 as necessary.

- Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss.

- Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage.

- Measure and record the degree of wear and clearances.

• Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the

area for disassembling work.

• Precautions for Assembling

- Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace it.

- Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces.

- Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing.

- Be sure that liquid-gasket-applied surfaces are clean and dry.

- If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent.

- Utilize matching marks when assembling.

- Be sure to use the designated tools to assemble bearings, bushings and oil seals.

- Keep a record of the number of tools used for disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no tools are missing.

Page 31

W1-1-2

PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING

Bleeding Air from Hydraulic System

When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and installation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures:

• Bleeding Air from Hydraulic Pump

IMPORTANT -

If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result. Be sure to bleed air before starting the engine.

- Remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil.

- After the pump housing is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run at slow idle speed.

- Slightly loosen the plug to bleed air from the pump housing until hydraulic oil oozes out.

- After bleeding all the air, securely tighten the plug.

• Bleeding Air from Travel Motor / Swing Motor

- With the drain plug / hose on travel motor / swing motor removed, fill the motor case with hydraulic oil.

• Bleeding Air from Hydraulic Circuit

- After refilling hydraulic oil, start the engine. While operating each cylinder, swing motor and travel motor evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes.

- Reposition the front attachment to check hydraulic oil level.

- Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary.

SM1000

Page 32

PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING

W1-1-3

Floating Seal Precautions

1. In general, replace the floating seal with a new one. If the floating is to be reused, follow these procedures:

(1)Keep seal rings together as a matched set with

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

(2)Check the seal ring face (A) for scuffing,

scoring, corrosion, deformation or uneven wear.

(3)Check O-ring (B) for tears, breaks,

deformation or hardening.

2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble.

(1)Clean the floating seal and seal mounting

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

CORRECTLY

INCORRECTLY

SM1001

(2)Clean the floating seal and seal mounting

bores, as dust on them tends to enter the floating seal when installing it.

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

is installed correctly on the seal ring.

(4)After installing the floating seal, check that seal

ring surface (A) is parallel with idler face (C) by measuring the distances (A) and (C) at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating.

CORRECTLY INCORRECTLY

a = b

a ≠ b

SM1002

SM1003

Page 33

W1-1-4

NOTES

PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING

Page 34

TIGHTENING TORQUE

TIGHTENING TORQUE SPECIFICATIONS

No. Descriptions Bolt Diam. Wrench Torque

Size

mm mm N m Kgf m lbf ft

1 Engine cushion rubber mounting bolt 16 24 210 21 152

2 Engine bracket mounting bolt 14 22 160 16 115

12 19 120 12 88 3 Hydraulic oil tank mounting bolt 16 24 210 21 152 4 Fuel tank mounting bolt 16 24 210 21 152 5 ORS fittings for hydraulic hoses and piping * 1-3/16"-12 36 180 18 130

* 1-7/16"-12 41 210 21 152

6 Pump device mounting bolt 10 17 49 5 36

W1-2-1

7 Control valve mounting bolt 16 24 210 21 152 8 Control valve bracket mounting bolt 14 22 140 14 103 9 Swing device mounting bolt 20 30 490 50 362 10 Battery mounting bolt 10 17 50 5 36 11 Cab mounting nut 16 24 210 21 152 12 Swing bearing mounting bolt to upperst. 18 27 300 31 224

Swing bearing mounting bolt to undercar. 16 24 270 27 199 13 Travel device mounting bolt 16 24 320 33 236 14 Sprocket mounting bolt 20 30 480 49 354 15 Upper roller mounting bolt 12 19 110 11 81 16 Lower roller mounting bolt 16 24 320 33 236 17 Track shoe mounting bolt 16 24 400 41 295 18 Low pressure coupling and clamp 8 13

5 8 2.90 0.30 2 6 10 4.40 0.45 3

10.3 to 12.4 1.05 to 1.26 8 to 16

*: UNF thread

NOTE -

(1) Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to stabilize friction (2) Make sure bolt and nut threads are clean before installing.

(3) Apply Loctite to threads before installing and tightening swing bearing mounting bolts.

coefficient of them.

Page 35

W1-2-2

TIGHTENING TORQUE

TORQUE CHART

CAUTION

Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use the correct tools. Avoid bodily injury caused by slipping wrenches.

Bolt Types

Tighten nuts or bolts correctly to torque specifications. Four kinds of bolts, hexagon bolts T, H, M and socket bolt, each made of different material, are used. Make sure to employ the correct bolts and tighten them to specification when assembling the machine or components.

SM1004

Hexagon T Bolt Hexagon H Bolt

Specified Tightening Torque Chart

Bolt Wrench Hexagon T Bolt, Socket bolt H Bolt M Bolt Dia. Size Wrench

Size N m kgf m lbf ft N m kgf m lbf ft N m kgf m lbf ft

M8 13 6 29.5 3 22 19.5 2 14.5 9.8 1 7.2 M10 17 8 64 6.5 47 49 5 36 19.5 2 14.5 M12 19 10 108 11 80 88 9 65 34 3.5 25.5 M14 22 12 175 18 130 137 14 101 54 5.5 40 M16 24 14 265 27 195 205 21 152 78 8 58 M18 27 14 390 40 290 295 30 220 118 12 87 M20 30 17 540 55 400 390 40 290 167 17 123 M22 32 17 740 75 540 540 55 400 215 22 159 M24 36 19 930 95 690 690 70 505 275 28 205 M27 41 19 1 370 140 1 010 1 030 105 760 390 40 290 M30 46 22 1 910 195 1 410 1 420 145 1 050 540 55 400 M33 50 24 2 550 260 1 880 1 910 195 1 410 740 75 540 M36 55 27 3 140 320 2 310 2 400 245 1 770 930 95 690

Hexagon M Bolt Socket Bolt

SM1005

Page 36

TIGHTENING TORQUE

IMPORTANT

(1)Apply lubricant (i. e. white zinc B dissolved into

spindle oil) to nuts and bolts to stabilize their

friction coefficients. (2)Torque tolerance is ±10 %. (3)Be sure to use bolts of correct length. Bolts that

are too long cannot be tightened, as the bolt tip

comes into contact with the bottom of the bolt hole.

Bolts that are too short cannot develop sufficient

tightening force. (4)The torques given in the chart are for general use

only.

Do not use these torques if a different torque is

given for a specific application.

(5)Make sure that the nut and bolt threads are clean

before installing. Remove dirt or corrosion, if any.

Bolt Tightening Order

W1-2-3

When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.

Equally tighten upper and lower alternately

1,4

2,3

Tighten diagonally Tighten from center and diagonally

SM1006

263

Page 37

W1-2-4

TIGHTENING TORQUE

Service Recommendations for Split Flange

IMPORTANT

(1)Be sure to clean and inspect sealing surfaces.

Scratches / roughness cause leaks and seal wear. Unevenness causes seal extrusion. If defects cannot be polished out, replace the component.

(2)Be sure to use only specified O-rings. Inspect O-

rings for any damage. Take care not to file O-ring surfaces. When installing an O-ring into a groove, use grease to hold it in place.

(3)Loosely assemble split flange halves. Make sure

that the split is centrally located and perpendicular to the port. Hand-tighten the bolts to hold the parts in place. Take care not to pinch the O-ring.

(4)Tighten bolts alternately and diagonally, as

shown, to ensure even tightening.

(5) Do not use air wrenches. Using an air wrench

often causes tightening of one bolt fully before tighten the others, resulting in damage to O-rings or uneven tightening of bolts.

SM1007

WRONG

SM1008

Nut and Bolt Lockings

• Lock Plate

IMPORTANT-

Do not reuse lock plates. Do not try to

bend the same point twice.

• Cotter Pin

IMPORTANT-

Do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening.

• Lock Wire

IMPORTANT -

Apply wire to bolts in the bolttightening direction, not in the bolt-loosening direction.

SM1009

RIGHT WRONG

Bend along edge sharply Do not bend it round

RIGHT RIGHT WRONG

Bend along edge sharply

RIGHT RIGHT WRONG

SM1010

RIGHT WRONG

Loosen

Tighten

SM1011

Page 38

PIPING JOINT

W1-2-5

TIGHTENING TORQUE

Pipe Thread Connection / Union Joint Tightening Torque Specifications

Union Joint

Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines.

IMPORTANT

(1)Do not over-tighten union nut (3). Excessive force

will be applied to metal sealing surfaces (4) and (5), possibly cracking adaptor (1). Be sure to tighten union nut (3) to specifications.

(2)Scratches or other damage to sealing surfaces (4)

or (5) will cause oil leakage at the joint. Take care not to damage them when connecting / disconnecting

1 4 3 5 2

Joint Body

37°

Male Union Joint Female Union Joint

SM1012

SM1013

Type

37° Union Joint

NOTE -

Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint.

Wrench Size

Union Nut

Joint Body

19 22 27 36

30, 32 41 50

17 19 22

36 46

Tightening Torque

N m kgf m lbf ft

29 3 22 39 4 29

78.5 8 69 157 16 116 205 21 152.5 255 26 188

Page 39

W1-2-6

O-ring Seal Joint

TIGHTENING TORQUE

O-ring (6) seats against the end face of adaptor (7) to seal pressure oil.

IMPORTANT

(1)Be sure to replace O-ring (6) with a new one when

reconnecting.

(2)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.

(3) Take care not to damage O-ring groove (8) or

sealing face (10). Damage to O-ring (6) will cause oil leakage.

(4)If union nut (9) is found to be loose, causing oil

leakage, do not tighten it to stop the leak. Instead, replace O-ring (6) with a new one, then tighten union nut (9) after confirming that O-ring (6) is securely seated in place.

7 6 9

Wrench Size

Union

Nut

27 36 41 50

Joint

Body

30, 32

36 46

7 6 Joint body

SM1014

Tightening Torque

N m kgf m lbf ft

93 9.5 69 175 18 130 205 21 152 320 33 240

Page 40

TIGHTENING TORQUE

W1-2-7

Screwed-In Connection

IMPORTANT -

Many types of screwed-in connections are used for hose connections. Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection.

PT PF

30°

Male Tapered Thread Male Straight Thread

Male Tapered Thread

Wrench

Joint Body

17, 19 19, 22 27, 22 36, 32

41 50 60

Tightening Torque

N m kgf m lbf ft

34 3.5 25 49 5 36

93 9.5 69 157 16 116 205 21 152.5 320 33 240 410 42 300

SM1015

Seal Tape Application

Seal tape is used to seal clearances between male and female threads, so as to prevent any leakage between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap.

• Application Procedure Confirm that the thread surface is clean, free of dirt

or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads.

Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs depending on the type of clamp. See below for correct tightening torque of each type of low-pressure-hose clamp.

Internal Thread

Clearance

Leave one to two pitch threads uncovered

T-Bolt Type

External Thread

SM1016

SM1017

Worm Gear Type

T-Bolt Type Band Clamp:

4.4 N m (0.45 kgf m, 3.25 lbf ft )

Worm Gear Type Band Clamp:

5.9 to 6.9 N m (0.6 to 0.7 kgf m, 4.3 to 5.1 lbf ft )

SM1018

SM1019

Page 41

W1-2-8

TIGHTENING TORQUE

Connecting Hose

CAUTION

(1) When replacing hoses, be sure to use only

genuine parts. Using hoses other than genuine hoses may cause oil leakage, hose rupture or separation of fitting, possibly resulting in a fire on the machine.

(2)Do not install hoses kinked. Application of high

oil pressure, vibration, or an impact to a kinked hose may result in oil leakage, hose rupture or separation of fitting. Utilize print marks on hoses when installing hoses to prevent hose from being installed kinked.

(3)If hoses rub against each other, wear to the

hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing against each other. Take care that hoses do not come into contact with moving parts or sharp objects.

WRONG RIGHT

SM1020

WRONG RIGHT

Rubbing Against Each Other

SM1021

WRONG RIGHT

Clamp Clamp

Rubbing

WRONG RIGHT

Rubbing

Clamp

SM1022

SM1023

Page 42

SECTION 2 EX135

UPPERSTRUCTURE

CONTENTS

Group 1 - Cab

Remove and Install Cab ......................W2-1-1

Group 2 - Counterweight

Remove and Install Counterweight .... W2-2-1

Group 3 - Main Frame

Remove and Install Main Frame ........ W2-3-1

Group 4 - Pump Device

Remove and Install Pump Device ...... W2-4-1

Disassemble Pump Device .................W2-4-2

Assemble Pump Device ....................W2-4-10

Disassemble Regulator .....................W2-4-22

Assemble Regulator ..........................W2-4-24

Disassemble and Assemble

Pilot Pump ...................................W2-4-26

Maintenance Standard ......................W2-4-28

Group 5 - Control Valve

Remove and Install Control Valve ...... W2-5-1

Disassemble Control Valve 1 ............ W2-5-2

Assemble Control Valve 1 ...................W2-5-4

Disassemble Control Valve 2 ..............W2-5-8

Assemble Control Valve 2-1 ..............W2-5-12

Assemble Control Valve 2-2 ..............W2-5-14

Disassemble Control Valve 3 ............W2-5-18

Assemble Control Valve 3 .................W2-5-20

Disassemble Control Valve 4 ............W2-5-24

Assemble Control Valve 4-1 ..............W2-5-28

Assemble Control Valve 4-2 ..............W2-5-32

Group 7 - Pilot Valve

Remove and Install Right Pilot Valve.. W2-7-1

Remove and Install Left Pilot Valve .... W2-7-4

Remove and Install Travel Pilot Valve W2-7-7 Disassemble Right and Left

Pilot Valve .....................................W2-7-8

Assemble Right and Left

Pilot Valve ...................................W2-7-10

Disassemble Travel Pilot Valve ........ W2-7-14

Assemble Travel Pilot Valve ..............W2-7-16

Group 8 - Pilot Shut-Off Valve

Remove and Install

Pilot Shut-off Valve ..............................W2-8-1

Disassemble Pilot Shut-off Valve........ W2-8-2

Assemble Pilot Shut-off Valve ............ W2-8-4

Group 9 - Shockless Valve

Remove and Install

Shockless Valve ..................................W2-9-1

Disassemble and Assemble

Shockless Valve ..................................W2-9-2

Group 10 - Solenoid Valve

Remove and Install

Solenoid Valve Unit ...........................W2-10-1

Disassemble Propotional

Solenoid Valve...................................W2-10-2

Assemble Propotional

Solenoid Valve...................................W2-10-4

Group 6 - Swing Device

Remove and Install Swing Device...... W2-6-1

Disassemble Swing Device .................W2-6-2

Assemble Swing Device......................W2-6-6

Disassemble Swing Motor.................W2-6-10

Assemble Swing Motor......................W2-6-14

Maintenance Standard ......................W2-6-18

Disassemble Brake Valve..................W2-6-20

Assemble Brake Valve ......................W2-2-22

Group 11- Pilot Relief Valve Unit

Remove and Install Pilot Relief

Valve Unit ................................... W2-11-1

Disassemble Pilot Relief Valve ..........W2-11-2

Assemble Pilot Relief Valve...............W2-11-4

Page 43

REMOVE AND INSTALL CAB

Remove Cab

1. Remove nuts (2) and seat (1).

: 13 mm

W2-1-1

CAB

SM1125

2. Loosen bolts ( 6) (3 used) and bolts (4) (4 used) behind the cab and remove rear cover (5).

: 13 mm

3. Loosen bolts (8) to remove rear under cover (7).

: 13 mm

4. Remove filter (20). Loosen screws (9) to remove duct (10) from the cab.

8 7 8

4 5

SM1126

SM1127

Page 44

W2-1-2

5. Disconnect cable connectors (11, relais), (12, antenna, ceiling lamp and windshield wiper), (13, loudspeaker) behind the cab and ground (14) inside the cab.

6. Remove washer vinyl hose (15) behind the cab.

CAB

SM2147

7. Remove cap ( 21) from duct cover (16). Loosen screws (17) to remove duct cover (16).

8. While pushing the mating surface of duct (18) toward the rear side of the cab, remove duct (18).

21 17 16

Mating Surface of Duct

SM1129

SM1130

➞

SM1131

Page 45

9. Attach cab to hoist using lifting straps.

CAUTION

The approximate weight of cab:

250 kg (551 lb)

10. Remove bolts (19) and nuts (22). : 17 mm

: 24 mm

W2-1-3

CAB

SM1132

: 8 mm

11. Carefully remove cab.

SM1133

SM1134

Page 46

W2-1-4

Installation

CAUTION

The approximate weight of cab:

250 kg (551 lb)

1. Attach cab to hoist using straps. Install cab onto frame.

2. Tighten bolts (19) and nuts (22).

: 17 mm

CAB

SM1134

: 49 N m (5 kgfm, 36 lbf ft) : 24 mm : 205 N m (21 kgf m, 152 lbf ft) : 8 mm : 64 N m (6.5 kgf m, 47 lbf ft)

3. Install duct (10) to the cab with screws (9). Install filter (20) into duct (10).

: 4.9 N m (0.5 kgf m, 3.6 lbf ft)

SM1133

SM1127

4. Install harness connectors (11, relais), (12, antenna, ceiling lamp and windshield wiper), (13, loudspeaker) behind the cab and ground (14) inside the cab.

: 19.5 N m (2 kgf m, 14.5 lbf ft)

SM2147

Page 47

5. Connect washer vinyl hose (15) at the rear of the cab inside.

W2-1-5

CAB

6. Install rear under cover (7) with bolts (8).

: 13 mm : 19.5 N m (2 kgf m, 14.5 lbf ft)

7. Install rear cover (5) with bolts (6 ) (3 used) and bolts (4) (4 used).

: 13 mm : 19.5 N m (2 kgf m, 14.5 lbf ft)

4 5

SM1129

8 7 8

SM1126

8. Push duct (18) toward the front of the cab to insert it into the front duct.

Mating Surface of Duct

➞

SM1131

Page 48

W2-1-6

9. Install duct cover (16) with screws (17). Install caps (21) onto duct cover (16).

10. Secure seat (1) with nuts (2).

: 13 mm : 19.5 N m (2 kgf m, 14.5 lbf ft)

CAB

21 17 16

SM1130

SM1125

Page 49

COUNTERWEIGHT

REMOVE AND INSTALL COUNTERWEIGHT

Removal

CAUTION

Approximate weight of counterweight:

2250 kg (4960 lb)

W2-2-1

1. Remove caps (1) from counterweight. Install eye-bolts to the counterweight.

Eye-bolts: M27, Pitch 3.0

2. Attach wire rope (2) to eye-bolts using shackles. Take out slack of wire rope by applying tension slowly with a crane or hoist.

3. Remove bolts (3). Lift counterweight using a crane or hoist.

: 41 mm

SM1135

SM1136

4. Lower the counterweight on proper stand.

SM1137

SM1138

Page 50

W2-2-2

COUNTERWEIGHT

Install counterweight

CAUTION

Approx. weight of counterweight:

2 250 kg (4 960 lb)

1. Attach lifting tools to counterweight. Lift counterweight (4) and install it onto the frame. Install bolts (3) and washers to counterweight and tighten temporarily.

: 41 mm

SM1137

2. Remove wire rope. Tighten the bolts with a power wrench (6) and torque wrench (7).

: 41 mm : 1 130 N m (115 kgf m, 830 lbf ft)

3. Remove the eye-bolts. Install caps (1) to counterweight.

6 7

SM1139

SM1135

Page 51

W2-3-1

MAIN FRAME

REMOVE AND INSTALL MAIN FRAME

CAUTION

Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil and components to cool before starting work. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on a firm, level surface.

2. Stop the engine. Move all control levers to release pressure remaining in the system. Push the air release valve on top of the hydraulic oil tank to release any remaining pressure. Refer to "Bleed Pressure from Hydraulic Circuit" on page W4-2-9

Removal

CAUTION

Approximate weight of cab: 250 kg (551 lb)

1. Remove cab assembly. (See Cab section.)

: 24 mm, 17 mm, 13 mm : 8 mm

3. Remove hydraulic oil tank cap. Connect a vacuum pump to maintain negative pressure in the hydraulic oil tank.

NOTE -

continuously while working.

Be sure to run the vacuum pump

CAUTION

Approximate weight of counterweight:

2 250 kg (4 960 lb)

2. Remove the counterweight. (See Counterweight section.)

41 mm

SM1134

SM1136

Page 52

W2-3-2

MAIN FRAME

CAUTION

Approximate weight of front attachment

assembly: 2 090 kg (4 610 lb)

3. Remove front attachment assembly from the upperstructure. (See Front Attachment section.)

: 19 mm, 27 mm, 30 mm, 36 mm

SM1140

4. Drain hydraulic oil from the hydraulic oil tank, and disconnect hydraulic lines from the control valve to the center joint on top of the center joint. Disconnect drain hose, and remove the fitting and stopper from the center joint.

: 19 mm, 22 mm, 27 mm, 36 mm

SM1141

Page 53

MAIN FRAME

W2-3-3

CAUTION

Approximate weight of main frame:

2 444 kg (5 388 lb)

5. Attach wire ropes to the front and rear of main frame. See wire ropes taut using a crane. Use chain blocks for easy adjustment of wire rope lengths and to level the frame.

IMPORTANT -

Make sure rear slings do not touch

engine.

Rear

Front

SM1142

SM1143

6. Put matching marks on swing bearing and main frame. Remove bolts (14) from the swing bearing.

: 27 mm

SM1144

SM1380

Page 54

W2-3-4

7. Lift main frame slightly from undercarriage. Level main frame by adjusting the chain blocks.

Remove main frame.

MAIN FRAME

SM2148

Page 55

Installation

W2-3-5

MAIN FRAME

CAUTION

Approximate weight of main frame:

2 444 kg (5 388 lb)

1. Fasten hoist to front and rear of main frame. Level main frame by adjusting chain blocks (13) and lower main frame onto undercarriage. Align the matching mark on the swing bearing with that on the main frame.

2. Install bolts (14) on the swing bearing and tighten temporary. Install main frame and tighten bolts to specification.

: 27 mm

SM2148

Upperstructure side

: 300 N m (31 kgf m, 224 lbf ft)

3. Install fitting (10) and connect hose (8) to the center joint.

: 19 mm : 34 N m (3.5 kgf m, 25 lbf ft)

Connect lines (4 to 7).

: 22 mm, 27 mm, 36 mm : 39 N m (4 kgf m, 29 lbf ft) : 93 N m (9.5 kgf m, 69 lbf ft)

SM1380

4 5

Install stopper (9).

: 36 mm

: 175 N m (18 kgf m, 130 lbf ft)

7 6

SM1141

Page 56

W2-3-6

CAUTION

Approximate weight of cab: 250 kg (551 lb)

4. Install cab (2). (See Cab in this section.)

: 24 mm : 205 N m (21 kgf m, 159 lbf ft) : 17 mm : 49 N m (5 kgf m, 36 lbf ft) : 13 mm : 20 N m (2 kgf m, 14 lbf ft) : 8 mm

MAIN FRAME

SM1134

: 64 N m (6.5 kgf m, 47 lbf ft)

CAUTION

Approximate weight of counterweight:

2 250 kg (4 960 lb)

5. Install counterweight (1). (See Counterweight in this section)

: 41 mm : 1 130 N m (115 kgf m, 830 lbf ft)

CAUTION

Approximate weight of front attachment assembly:

2 090 kg (4 608 lb)

SM1136

6. Install front attachment assembly (3). (See front Attachment in this section)

: 30 mm : 540 N m (55 kgf m, 400 lbf ft) : 36 mm : 137 N m (14 kgf m, 101 lbf ft) : 27 mm : 93 N m (9.5 kgf m, 69 lbf ft)

SM1140

Page 57

MAIN FRAME

7. Fill the hydraulic oil tank with hydraulic oil to the specified level. Run the engine at slow idle. Check hose connections for any oil leakage.

W2-3-7

SM1147

Page 58

W2-3-8

NOTES

MAIN FRAME

Page 59

W2-4-1

PUMP DEVICE

REMOVE AND INSTALL PUMP DEVICE

CAUTION

Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting work. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on a firm, level surface.

2. Stop the engine. Move all control levers to release pressure remaining in the system. Push the air release valve on top of the hydraulic oil tank to release any remaining pressure.

Removal

1. Disconnect connectors.

CAUTION

Pump device weight: 111 kg (245 lb)

2. Disconnect hoses (1 to 4 , 6 and 7) and pipe (5) from the pump device.

: 19 mm, 27 mm, 36 mm : 8 mm, 10 mm

3. Attach eyebolts (M12, Pitch 1.75, Length 22) to the pump device, then connect to a hoist.

4. Remove pump device mounting bolts to remove pump device.

3. Remove hydraulic oil tank cap. Connect a vacuum pump to maintain negative pressure in the hydraulic oil tank.

NOTE -

continuously while working.

Be sure to run the vacuum pump

1 2

Air bleed plug

: 17 mm

Installation

1. Install the pump device with pump device mounting bolts.

2. Connect hoses (1 to 4, 6 and 7) and pipes (5).

3. Connect connectors.

IMPORTANT -

and oil leakage, after assembling. Bleed the air from the pump. (Refer to W1-1-2)

Be sure to check hydraulic oil level

SM2118

Wrench Remark

Size (mm) N m kgf m lbf ft

Tightening Torque

: 27 78 8 58 Hose : 36 176 18 130 Hose : 10 108 11 80 Bolt : 17 49 5 36 Bolt : 8 49 5 36 Bolt : 19 29 3 22 Hose

Page 60

W2-4-2

DISASSEMBLE PUMP DEVICE

PUMP DEVICE

67 73

69 97

74 20

66 68 19

SM2122

26 25

14 41

5 4

32 31 30

SM2119

Page 61

PUMP DEVICE

W2-4-3

76 78

35 33

75 29

71 33

77 29

85 86 64

33 75

35 90

44 92

57 58

56 59

1 - Gear Casing 2 - Pump Casing 3 - Pilot Gear 4 - Gear Shaft 5 - Bearing 6 - Retaining Ring 7 - Retaining Ring 8 - Bearing

9 - Bearing Nut 11 - Drive Disc 12 - Oil Seal 13 - Retaining Ring 14 - Gear 15 - Gear 16 - Retaining Ring 17 - Drive Disc

18 - Spring Pin 19 - Plunger

20 - Spacer Ring 21 - Bolt 22 - Spring Washer 23 - Packing 24 - Bearing 25 - Oil Seal 26 - Retaining Ring 27 - Valve Plate 28 - Pilot Pump 29 - Pin (4 Used) 30 - Socket Bolt 31 - Spring Washer 32 - Washer

33 - Pin 34 - Adapter 35 - Retaining Ring 36 - Plug 37 - Level Gauge 39 - Pipe Gauge 40 - Socket Bolt 41 - Packing 42 - Servo Piston 43 - Plug 44 - Set Screw 50 - O-Ring 51 - Stopper 52 - Plug 53 - Adapter 54 - Plug 55 - Fitting plug 56 - Servo Pipe 57 - Clamp 58 - Bolt 59 - Spring Washer 60 - Socket Bolt 61 - O-Ring 62 - Thrust Ring 64 - Pump Pressure Sensor 65 - Pin 66 - Center Shaft 67 - Plug 68 - Spring 69 - Regulator 70 - Cylinder Block

71 - Valve Plate 73 - O-Ring 74 - O-Ring 75 - Lever 76 - Pin 77 - Link 78 - Pin 85 - Backup Ring 86 - O-Ring 87 - O-Ring 88 - Socket Bolt 89 - Spring Pin 90 - Stopper 91 - O-Ring 92 - Pin 93 - Selector Head 96 - Spring Washer 97 - Socket Bolt 98 - Spring Washer

SM2120

Page 62

W2-4-4

PUMP DEVICE

SM2122

57 58

44 92

56 59

SM2121

SM2119

Page 63

Disassemble Pump Device

W2-4-5

PUMP DEVICE

1. Remove plug (43) to drain oil. Drain oil: Approx. 0.8 L (0.85 US qt)

: 8 mm

2. Remove plug (36).

: 17 mm

CAUTION

Pump device weight: 111 kg (245 lb)

3. Place the pump device with the transmission side positioned to the bottom side and secure it.

4. Remove bolt (58), adapter (53 ) and fitting plug (55). Remove spring washer (59), clamp (57) and servo pipe (56) from selector head (93).

IMPORTANT -

remove it. LOCTITE 829 was applied to set screw (44) when installed.

8. Remove set screw (44), pin (92) and servo piston (42) from selector head (93).

Be sure to heat set screw (44) to

: 6 mm

: 13 mm, 19 mm, 22 mm

CAUTION

Selector head weight: 20 kg (44 lb)

5. Remove socket bolts (60) from selector head (93). Remove selector head (93) assembly from pump casing (2).

: 10 mm

6. Remove pump pressure sensors (64) from selector head (93).

: 27 mm

7. Remove socket bolts ( 88), spring washers (96), stoppers (90), (51) and O-rings (91), (50), (87) from selector head (93).

: 6 mm

Page 64

W2-4-6

PUMP DEVICE

85 86

75 29

76 78

35 33

71 33

77 29

33 75

SM2120

66 68 19

SM2122

Page 65

PUMP DEVICE

9. Loosen socket bolts (97) and remove spring

washers (98), regulators (69) and O-rings (73), (74), from pump casing (2).

: 8 mm

10. Remove backup ring (85), O-ring (86) and spring

pin (89).

W2-4-7

IMPORTANT -

exclusively used in the right and left pumps respectively. Take care not to mistake the up and down positions.

11. Remove retaining rings (35) and pins (29) to

remove valve plates (27), (71).

12. Remove cylinder blocks (70), center shafts (66),

springs (68) and plungers (19) from pump casing (2).

13. Remove links (77) assembly from pump casing

(2).

14. Remove retaining rings (35), pins (78), (33), (76)

and levers (75) from links (77) assembly.

Valve plates (27) and (71) are

: 7 mm

CAUTION

Pump casing weight: 27 kg (60 lb)

15. Loosen bolts (21) and remove pump casing (2)

from gear casing (1).Attach the pump casing to crane or hoist using wire ropes.

: 22 mm

Page 66

W2-4-8

PUMP DEVICE

SM2122

26 25

5 4

32 31 30

SM2119

Page 67

PUMP DEVICE

16. Remove spring pin (18) from pump casing (2).

Remove packing (23) from gear casing (1).

15 14

Aligning Mark

W2-4-9

IMPORTANT -

If aligning marks are not made, it is

very hard to align pump timing when reassembling.

17. Put three aligning marks on each mashed parts:

between gear (14) and drive disc (11) spline, gear (15) and drive disc (17) spline, and gear (14) and (15), as illustrated.

18. Remove retaining rings (16) and gears (14 and

15) from drive discs (11 and 17).

19. Remove retaining rings (13) and oil seals (12)

from drive discs (11 and 17).

20. Loosen plugs (52) to remove O-rings (61). Using

a press, pull drive discs (11 and 17) assembly out of pump casing (2). Then, remove thrust ring (62).

21. Using special tool (75301648), remove bearing

nuts (9) from drive discs (11 and 17).

75301648

SM1049

22. Using a press, remove bearings (8), (24) and

spacer rings (20) from drive discs (11 and 17).

23. Loosen bolt (30) to remove pilot pump (28) from

gear casing (1).

: 6 mm

24. Remove retaining rings (6 and 7) from gear

casing (1). Pull off upper side bearing (5) and gear shaft (4) using special tool (75301488).

25. Remove pilot gear (3) from gear casing (1). Then,

pull off the other side bearing (5).

26. Remove retaining ring (26) and oil seal (25) from

gear casing (1).

SM1050

75301488

SM1051

Page 68

W2-4-10

ASSEMBLE PUMP DEVICE

34 36

PUMP DEVICE

55 43 60 64

37 39 40 41 28 30 31 32

SM2123

98 97

14 18 15

SM2124

Page 69

PUMP DEVICE

87 51 50 88 86-85 74 69 73 76-35 78 77 65 66 8 9 12

W2-4-11

29 42 93

1 - Gear Casing 2 - Pump Casing 3 - Pilot Gear 4 - Gear Shaft 5 - Bearing (2 Used) 6 - Retaining Ring 7 - Retaining Ring 8 - Bearing (2 Used)

9 - Bearing Nut (2 Used) 10 - Main Pump 11 - Drive Disc 12 - Oil Seal (2 Used) 13 - Retaining Ring (2 Used) 14 - Gear 15 - Gear 16 - Retaining Ring (2 Used) 17 - Drive Disc 18 - Spring Pin (2 Used) 19 - Plunger (14 Used) 20 - Spacer Ring (2 Used) 21 - Bolt (6 Used) 22 - Spring Washer (6 Used) 23 - Packing 24 - Bearing (2 Used) 25 - Oil Seal 26 - Retaining Ring 27 - Valve Plate 28 - Pilot Pump 29 - Pin (4 Used) 30 - Socket Bolt (2 Used) 31 - Spring Washer (2 Used)

96 90 71 89 33 70 19 52 24 62 22-21

32 - Washer (2 Used) 33 - Pin (4 Used) 34 - Adapter (2 Used) 35 - Retaining Ring (12 Used) 36 - Plug 37 - Level Gauge 39 - Pipe Gauge 40 - Socket Bolt (2 Used) 41 - Packing 42 - Servo Piston (2 Used) 43 - Plug 44 - Set Screw (2 Used) 50 - O-Ring (2 Used) 51 - Stopper (2 Used) 52 - Plug (2 Used) 53 - Adapter 55 - Fitting plug (2 Used) 56 - Servo Pipe 57 - Clamp (2 Used) 58 - Bolt 59 - Spring Washer 60 - Socket Bolt (12 Used) 61 - O-Ring (2 Used) 62 - Thrust Ring 64 - Pump Pressure Sensor

65 - Pin (2 Used) 66 - Center Shaft (2 Used) 68 - Spring (2 Used) 69 - Regulator (2 Used) 70 - Cylinder Block (2 Used)

(2 Used)

SM2125

71 - Valve Plate 73 - O-Ring (2 Used) 74 - O-Ring (20 Used) 75 - Lever (4 Used) 76 - Pin (2 Used) 77 - Link (2 Used) 78 - Pin (2 Used) 85 - Backup Ring 86 - O-Ring 87 - O-Ring (4 Used) 88 - Socket Bolt (16 Used) 89 - Spring Pin (2 Used) 90 - Stopper (2 Used) 91 - O-Ring (2 Used) 92 - Pin (2 Used) 93 - Selector Head 96 - Spring Washer(16 Used) 97 - Socket Bolt (8 Used) 98 - Spring Washer(8 Used)

Page 70

W2-4-12

34 36

PUMP DEVICE

SM2123

SM2124

8 9

24 20

SM2126

Page 71

PUMP DEVICE

W2-4-13

Assemble Pump Device

1. Drive bearing (5) into gear casing (1). Install pilot

gear (3). Drive in gear shaft (4) so that the spline aligns with that of pilot gear (3).

2. Drive the other bearing (5) onto gear shaft (4).

3. Install retaining ring (7) to gear casing (1) and

retaining ring (6) to gear shaft (4).

4. Wind seal tape around adapters (34) (2 used) and

tighten them to gear casing (1).

: 36 mm : 69 N m (7 kgf m, 51 Ibf ft)

5. Tighten plug (43).

: 8 mm : 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)

7 6 4

SM1056

6. Heat inner race of bearings (24 and 8 ) to 50 to

80 °C (122 to 176 °F). Apply a film of hydraulic oil to inner race of bearing (24), then install bearings (24) onto drive discs (11 and 17) using a press.

7. Apply a film of hydraulic oil to inner race of bearing

(8), then install spacer rings (20) and bearings (8) onto drive discs (11 and 17) using a press.

Preset preload of bearings (24 and 8) using the following procedure:

8. Apply a film of hydraulic oil to bearing nuts (9) (2

used) thread. Tighten bearing nuts (9) until they come in contact with bearings (8), using special tool (75301648).

9. Rotate bearings (8) 2 to 3 turns for break-in, using

special tool (75301491).

10.Follow the above three steps to adjust starting

torque to specification. Starting torque specification:

1.47±0.49 N⋅m (0.15±0.05 kgf ⋅m, 1.08±0.36 Ibf⋅ft)

75301648

SM1057

SM1050

75301491

9 24

IMPORTANT -

If starting torque is increased over the specification, loosen bearing nut (9) then tap drive discs (11 and 17) shaft end to release load. Retry steps 8. to 10. to adjust the starting torque.

11-17

SM1058

Page 72

W2-4-14

PUMP DEVICE

62 2 8 11

SM2127

SM2124

61 52

SM2126

Page 73

PUMP DEVICE

11. Install thrust ring (62) into pump casing (2). (Drive

disc (11) side only.)

12.

Heat pump casing (2) to 50 to 80 °C (122 to 176 °F). Apply a film of hydraulic oil to the outer circumference of roller bearings (8) and (24). Install drive disc (11) and (17) assemblies into pump casing (2).

13. Apply a film of grease to O-rings (61) (2 used)

then install them onto plugs (52) (2 used). Tighten plugs (52) to pump casing (2).

: 19 mm : 34 N m (3.5 kgf m, 25 Ibf ft)

W2-4-15

75301649

14. Install special tools (75301649 and 75301650)

over the spline parts of drive discs (11) and (17) to protect oil seals (12) from being damaged. If the special tools are not available, wind adhesive tapes over the spline parts.

IMPORTANT -

Apply a film of grease to oil seal (12)

(2 used) lip.

15. Drive oil seal (12) (2 used) as illustrated. Remove

the special tools.

16. Install retaining rings (13) (2 used).

• When replacing drive discs (11), (17) and / or transmission gears (14), (15).

IMPORTANT -

Install special tool with the D mark

facing toward long drive disc (11) side.

17. Install special tool (75301651) to drive discs (11,

17).

18. Rotate drive discs (11, 17) clockwise, as viewed from the shaft end side to remove circumferential play between the special tool and drive discs (11,17).

75301651

M8x1,25

75301650

Shaft side

→

Long Shaft Side

SM1060

Short Shaft Side

SM1061

19. Install gear (15) and retaining ring (16) onto drive disc (17).

20. Install gear (14) so that both splines on drive disc (11) and gear (15) teeth, can correctly engage with those of gear (14). Install retaining ring (16) onto drive disc (11).

IMPORTANT -

Although drive disc (11) is held unrotable with special tool (75301651) it may be necessary to jolt drive disc (11) in order to install gear (14).

• When not replacing drive discs (11), (17) and /or transmission gears (14), (15).

21. Align the marks for drive disc (11) and gear (14). Also, align the marks for drive disc (17) and gear (15).

15 14

Aligning Mark

SM1049

Page 74

W2-4-16

PUMP DEVICE

32-31-30 1 2

53 55

SM2123

41-40-39

21-22

SM2124

76-35 78 77

33-35

SM2125

Page 75

PUMP DEVICE

W2-4-17

22. Install spring pins (18) (2 used) and packing (23) to gear casing (1).

CAUTION

Pump casing weight: 27 kg (60 Ib)

23. Sling pump casing (2) with a crane and install it to gear casing (1) so that pilot gear (3) engages gear (14).

24. Tighten bolts (21) (6 used) and spring washers (22) (6 used).

: 24 mm : 147 N m (15 kgf m, 109 Ibf ft)

25. Apply THREEBOND 1215 to gear casing (1) surface. Install pilot pump (28) to gear casing (1), then tighten with spring washers (31) (2 used), washers (32) (2 used) and socket bolts (30) (2 used).

28. With retaining rings (35) (2 used) installed to the one side of pins (76) (2 used), drive pins (76) (2 used) into links (77) (2 used). Then, install retaining rings (35) (2 used) to the other side of pins (76) (2 used).

29. Install levers (75) (4 used), pins (33) (4 used), and retaining rings (35) (4 used) to the U type end of links (77) (2 used).

30. Install pins (78) (2 used) to links (77) (2 used).

: 8 mm : 49 N m (5 kgf m, 36 Ibf ft)

26. Install adapter (53) and fitting plug (55) onto pilot pump (28).

: 27 mm : 93 N m (9.5 kgf m, 69 Ibf ft)

: 6 mm : 34 N m (2 kgf m, 15 Ibf ft)

27. Install packing (41) and pipe gauge (39) to gear casing (1). Then tighten with socket bolts (40) (2 used).

: 6 mm : 19.5 N m (2 kgf m, 15 Ibf ft)

Page 76

W2-4-18

PUMP DEVICE

87 86-85 65 78 77 69 66

35-29

42 93

SM2125

71 89 70 19 2

SM2124

Page 77

PUMP DEVICE

W2-4-19

31. Apply a film of hydraulic oil to the spherical surface of drive discs (11 and 17) and insert plungers (19) (7 used).

32. After applying grease to the hole of center shafts (66) (2 used), install pins (65). Install center shafts (66) into the center spherical surface section of drive discs (11 and 17). Then, install springs (68) (2 used).

33. Assemble plungers (19) (14 used) and center shafts (66) (2 used) into cylinder blocks (70) (2 used).

34. Pinch the tip of center shafts (66) with pliers to rotate the center shaft and install pins (65) (2 used) into the groove on cylinder blocks (70) (2 used).

IMPORTANT -

Take care not to damage the O-ring

groove when driving in pins (78).

38. Install backup ring (85), spring pins (89) (2 used) and O-ring (86) into pump casing (2). Install O-rings (87) to selector head (93).

39. Assemble servo pistons (42) (2 used) and pins (92) (2 used) to selector head (93).

IMPORTANT -

Apply LOCTITE LI829 to set screws

(44).

40. Tighten set screws (44) (2 used) to the smaller diameter side of servo pistons (42) (2 used) to secure pins (92) (2 used).

: 6 mm : 34 N m (3.5 kgf m, 25 lbf ft)

35. After installing links (77) (2 used) assembly into pump casing (2), drive pins (78) (2 used) into the groove on the mounting surface of regulators (69) so that the pin end is flush with the mounting surface.

36. Apply a film of LOCTITE LI829 to the threads of pins (29) (4 used). Then, tighten the pins (2 used) into valve plates (27 and 71).

: 7 mm : 9.8 N m (1 kgf m, 7.2 lbf ft)

37. Install pins (29) into the hole of levers (75). Install retaining rings (35) (4 used).

IMPORTANT -

Valve plates (27) and (71) are exclusively used in the right and left pumps respectively. Replacing the right with the left or up-side-down is not applicable. Install the valve plates so that the suction port is positioned to the upper side of the center when viewed from the front.

Page 78

W2-4-20

PUMP DEVICE

88 51 50 2

SM1054

91 88 90 89

34 36 1

59 58 57

SM1052

56 64 60

Page 79

PUMP DEVICE

W2-4-21

41. Apply a film of grease to stoppers (51) (2 used),

(90) (2 used) and O-rings (50) (2 used), (91) (2 used). Assemble O-rings (50) (2 used), (91) (2 used) to stoppers (51) (2 used), (90) (2 used). Install stoppers (51) (2 used), (90) (2 used) to selector head (93), then tighten with spring washers (96) (16 used) and socket bolts (88) (16 used).

: 6 mm : 19.5 N m (2 kgf m, 15 lbf ft)

CAUTION

Selector head weight: 20 kg (44 lb)

42. Sling selector head (93) assembly with a crane.

Install the selector head onto pump casing (2) so that spring pins (89) (2 used) align with the pin holes on the selector head. Then tighten socket bolts (60) (12 used).

: 10 mm : 108 N m (11 kgf m, 80 lbf ft)

48. Install special tool (75301649) to drive disc (11). Apply a film of grease to oil seal (25) and install the oil seal to drive disc (11). Remove special tool (75301649) and drive in oil seal (25). Install retaining ring (26). If special tool (75301649) is not available, wind tape around the spline of drive disc (11) to protect the oil seal from being damaged when installing.

49. Supply oil into gear casing (1) through adapter (34) about 0.8 liters (0.85 US qt). Tighten plug (36) to adapter (34).

: 17 mm : 69 N m (7 kgf m, 51 lbf ft)

50. Install level gauge to pipe gauge.

75301649

43. Tighten pump pressure sensors (64) (2 used) to selector head (93).

: 27 mm : 98 N m (10 kgf m, 72 lbf ft)

44. Temporarily tighten clamps (57) (2 used) to selector head (93) with washer (59) and bolt (58).

45. Insert servo pipe (56) between clamps (57) (2 used) and tighten the nut for fitting plug (55).

: 19 mm : 34 N m (3.5 kgf m, 25 lbf ft)

46. Tighten servo pipe (56).

: 17 mm : 34 N m (3.5 kgf m, 25 lbf ft)

47. Connect servo pipe (56) then clamp it using bolt (58) and clamp (57).

SM1062

: 13 mm

: 2.9 N m (0.3 kgf m, 25 lbf ft)

Page 80

W2-4-22

DISASSEMBLE REGULATOR

49 24 27 28 20 21 14 34

PUMP DEVICE

SM2128

8 7 6 5 3 2 1 47 48 14 15 13 12

35 37-38 97-98 40 41 36

1 - Regulator Casing 2 - Sleeve A 3 - Spool A 5 - Load Cylinder 6 - Load Piston 7 - O-Ring

8 - Backup Ring 12 - Stopper (2 Used) 13 - Stopper 14 - O-Ring (3 Used) 15 - O-Ring (2 Used)

16 - Nut (2 Used) 17 - Nut (2 Used) 20 - Piston 21 - Cylinder 24 - Inner Stopper 27 - Sleeve B 28 - Spool B 29 - Set Screw 34 - Nut 35 - Cover 36 - Cover

SM2129

37 - Socket Bolt (8 Used) 38 - Spring Washer (8 Used) 40 - Plug 41 - O-Ring 47 - Spring 48 - Spring 49 - Spring 97 - Socket Bolt (4 Used) 98 - Spring Washer(4 Used)

Page 81

Disassemble Regulator

W2-4-23

PUMP DEVICE

IMPORTANT -

When disassembling the regulator, do not disassemble adjusting parts (12), (13), (16), (17), (29), (34) unless necessary. If disassembled the performance curve of the regulator is changed. To adjust the regulator, refer to the Operational Performance Test section in the Technical Manual (Troubleshooting).

1. Hold regulator casing ( 1) of regulator with a vice

and remove plug (40).

: 41 mm

2. Loosen socket bolts (37 ) to remove covers (36),

(35) assembly.

: 6 mm

3. Remove springs (47), (48) from regulator casing

(1).

4. Remove load cylinder (5) from regulator casing

(1) by pushing spool A (3).

5. Remove load piston ( 6), O-ring (7), and backup

ring (8) from load cylinder (5).

6. Remove sleeve A (2) with spool A (3) from

regulator casing (1).

7. Remove spool A (3) from sleeve A (2).

8. Remove sleeve B (27) spring (49) by spool B (28).

9. Remove piston (20), O-ring (14) and cylinder (21)

from sleeve B (27).

Page 82

W2-4-24

ASSEMBLE REGULATOR

49 24 27 28 20 21 14 34

PUMP DEVICE

8 7 6 5 3 2 1 47 48 14 15 13 12

35 37-38 97-98 40 41 36

SM2128

1 - Regulator Casing 2 - Sleeve A 3 - Spool A 5 - Load Cylinder 6 - Load Piston 7 - O-Ring

8 - Backup Ring 12 - Stopper (2 Used) 13 - Stopper 14 - O-Ring (3 Used) 15 - O-Ring (2 Used) 16 - Nut (2 Used) 17 - Nut (2 Used)

74-87 73

20 - Piston 21 - Cylinder 24 - Inner Stopper 27 - Sleeve B 28 - Spool B 29 - Set Screw 34 - Nut 35 - Cover 36 - Cover 37 - Socket Bolt (8 Used) 38 - Spring Washer (8 Used) 40 - Plug 41 - O-Ring

SM2130

47 - Spring 48 - Spring 49 - Spring 73 - O-Ring

74 - O-Ring 87 - O-Ring 97 - Socket Bolt (4 Used) 98 - Spring Washer (4 Used)

Page 83

Assemble Regulator

W2-4-25

PUMP DEVICE

IMPORTANT -

Take care not to mistake the combi-

nation and direction of spool B (28) and sleeve B (27).

1. Apply a film of hydraulic oil to spool B (28 ) and sleeve B (27). Install spool B (28) into sleeve B (27) and install into regulator casing (1).

2. Apply a film of hydraulic oil to spool A (3) and sleeve A (2), install into regulator casing (1).

3. Apply a film of grease to O-ring (7), then install Orings (7), and backup ring (8) to load cylinder (5).

4. Install load cylinder (5 ) into load piston (6) and install into regulator casing (1).

5. Apply a film of grease to O-rings (14) then install on stoppers (12) (2 used).

IMPORTANT -

Stopper (13) length is different from that of inner stopper (24). The shorter one is inner stopper (24).

10. Install regulator casing assembly to pump casing, then tighten with socket bolts (97) (4 used) and spring washers (98) (4 used).

: 8 mm : 49 N m (5 kgf m, 36 lbf ft)

IMPORTANT -

Install the pin for the link in the groove for sleeve B (27) and sleeve A (2) in regulator casing (1). Using tape, hold the grooves for sleeve B (27) and sleeve A (2) so that both grooves are aligned. Then, after installing, be sure to remove the tape. Check through the hole of plug (40) that pin is surely installed into sleeve B (27) and sleeve A (2).

11. Install O-ring (41) onto plug (40), tighten it onto

regulator casing (1).

: 41 mm : 78 N m (8 kgf m, 58 lbf ft)

IMPORTANT -

Before operating the pump, bleed air trapped in the pump casing and fill the pump casing with hydraulic oil.

6. Install cover (35) with spring (49 ) onto regulator casing (1). Install and tighten socket bolts (37) (4 used) and spring washers (38) (4 used).

: 6 mm : 19.8 N m (2 kgf m, 15 lbf ft)

7. Install O-ring (14), piston (20) in cylinder (21), and install into regulator casing (1).

8. Install cover (36) with springs (48), (47) onto regulator casing (1) Install and tighten socket bolts (37) (4 used) and spring washers (38) (4 used).

: 6 mm : 19.8 N m (2 kgf m, 15 lbf ft)

9. Apply a film of grease to O-rings (73), (74), (87) and install them onto the pump casing.

Page 84

W2-4-26

PUMP DEVICE

DISASSEMBLE AND ASSEMBLE PILOT PUMP

SM1066

Page 85

PUMP DEVICE

W2-4-27

Item

1 2 3

5 6

7 9

10 12

Part Name

Housing Flange Oil Seal

Retaining Ring Seal

Cover Backup Ring

Key O-ring

Q.ty

Wrench Size

mm 1 1 1

1 2

2 2

Tightening Torque

N m

kgf m

Remarks

lbf ft

Apply grease to oil seal lip when installing

Apply grease to seal when installing

Apply grease to backup ring when installing

Apply grease to O-ring when

installing 13 14 15 16 26

Gear Gear Washer Bolt Bushing

Bushing

1 1 4 4 2

:17

39 to 44

4 to 4.5

29 to 33

Apply a film of hydraulic oil to

bushing when installing

Apply a film of hydraulic oil to

bushing when installing

Page 86

W2-4-28

PUMP DEVICE

MAINTENANCE STANDARD

Pump device

Unit: mm (in)

Standard Allowable Limit Remedy

Gear Backlash 0.68 (0.03) 1.5 (0.06) Replace

Main Pump

1. Tooth thickness (Drive disc splines). Unit: mm (in)

Standard Allowable Limit

3.6 (0.14) 2.6 (0.10)

2. Sleeve diameter (Drive disc). Unit: mm (in)

Standard Allowable Limit

1 34 (1.34) 33.8 (1.33)

2 42 (1.65) 41.8 (1.64)

3 42 (1.65) 41.8 (1.64)

3. Clearance between plunger and drive disc (b). Unit: mm (in)

Standard Allowable Limit

0.054 (0.002) 0.4 (0.016)

SM1068

4. Clearance between plunger (a) and cylinder

block (D).

(D - a) Unit: mm (in)

Standard Allowable Limit

0.036 (0.001) 0.08 (0.003)

SM1069

SM1070

Page 87

PUMP DEVICE

5. Clearance between plunger and connecting rod. Unit: mm (in)

Standard Allowable Limit

W2-4-29

Plunger

0.15 (0.006) 0.4 (0.016)

6. Clearance between small chamber (D) and servo

piston (a).

D - a Unit: mm (in)

Standard Allowable Limit

0.083 (0.003) 0.2 (0.008)

7. Clearance between large chamber (D) and servo

piston (a).

D - a Unit: mm (in)

Connecting rod

SM1071

Small Chamber Side

Standard Allowable Limit

0.079 (0.003) 0.2 (0.008)

8. Clearance between valve plate (D) and servo

piston (a). D - a Unit: mm (in)

Standard Allowable Limit

0.051 (0.002) 0.3 (0.011)

Large Chamber Side

SM1072

SM1073

Page 88

W2-4-30

NOTES

PUMP DEVICE

Page 89

W2-5-1

CONTROL VALVE

REMOVE AND INSTALL CONTROL VALVE

CAUTION

Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting work. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on a firm, level surface.

2. Stop the engine. Move all control levers to release

pressure remaining in the system. Push the air release valve on top of the hydraulic oil tank to release any remaining pressure. Refer to “Bleed Pressure from Hydraulic Circuit” on page W4-2-9.

Removal

1. Disconnect all hoses, pipes and connectors from

the control valve.

: 17 mm : 9.8 N m (1 kgf m, 7 lbf ft) : 19 mm : 34 N m (3.5 kgf m, 25 lbf ft) : 22 mm : 49 N m (5 kgf m, 36 lbf ft) : 36 mm

3. Remove hydraulic oil tank cap. Connect a vacuum pump to maintain negative pressure in the hydraulic oil tank.

NOTE -

Be sure to run the vacuum pump continuously

while working.

Installation

1. Install control valve to frame and tighten bolts (1)

(4 used).

2. Connect all hoses, pipes and connectors to the

control valve.

IMPORTANT -

After completing installation: Check hydraulic oil level. Add oil if necessary. Run the engine. Check the engine components for any oil leakage.

: 175 N m (18 kgf m, 130 lbf ft) : 6 mm : 29 N m (3 kgf m, 22 lbf ft) : 8 mm : 64 N m (6.5 kgf m, 47 lbf ft)

NOTE -

Attach caps to hoses and pipes. Attach labels or tags to hoses and pipes, to aid in assembly.

CAUTION

Control valve assembly weight: 170 kg (375 lb)

2. Remove control valve mounting bolts (1).

: 22 mm : 140 N m (14 kgf m, 101 lbf ft)

A = Arm II B = Boom I C = Bucket D = Travel (R) E = Travel (L) F = Auxiliary G = Boom II H = Arm I L = Swing

SM2084

SM2085

Page 90

W2-5-2

DISASSEMBLE CONTROL VALVE 1

CONTROL VALVE

SM2086

1 - Housing (4-spool side) 2 - Housing (5-spool side) 3 - Lock Nut 4 - Body 5 - O-Ring 6 - O-Ring 7 - O-Ring 8 - Adjusting Screw

9 - Valve 10 - Spring 11 - Piston 12 - Bushing

13 - Spring 14 - O-Ring 15 - Snap Ring 16 - Filter 17 - Adapter 18 - O-Ring 19 - Check Valve 20 - Spring 21 - Seat 22 - Backup Ring 23 - O-Ring 24 - Valve Seat

25 - Check Valve 26 - Spring 27 - O-Ring 28 - Plug 29 - Spring 30 - O-Ring 31 - Backup Ring 32 - Bushing 33 - Pilot Plate 34 - Socket Bolt 35 - Filter 36 - Screw

37 - Socket Bolt 38 - Spool 39 - Washer 40 - Spring 41 - O-Ring 42 - Plug 43 - Plug 44 - O-Ring 45 - Spring 46 - Washer 47 - Spool

Page 91

CONTROL VALVE

W2-5-3

Disassemble Control Valve 1

• Be sure to thoroughly read “Precautions for Disassembly and Assembly” on page W1-1-1 before starting the disassembly work.

• Bucket Flow Control Valve

1. Remove plugs (42) and (43) from pilot plate

(33).

: 27 mm, 36 mm

2. Remove springs (40) and (45) and washers (39)

and (46) together with spools (38) and (47) from pilot plate (33).

3. Remove screw (36) to remove filter (35) from

pilot plate (33).

: 4 mm

4. Loosen socket bolts (34) and (37) to remove

pilot plate (33) from housing (1). Bushing (32) will also come off together with pilot plate (33).

• Pump Control Valve

8. Remove body (4) from housing (1). Remove valve (9) from body (4).

: 27 mm

NOTE

- Do not remove lock nut (3) and adjusting

screw (8).

9. Remove bushing (12) and spring (13) from housing (1).

10.Use a bolt (M8, Pitch 1.25) to remove piston (11) from housing (1).

11. Remove spring (10) from housing (1).

12. Remove adapter (17) from housing (1).

: 19 mm

: 6 mm, 8 mm

5. Remove spring (29) and valve seat (24) from housing (1).

6. Remove plug (28) to remove check valve (25) and spring (26).

: 10 mm, 14 mm

• Check Valve (4-spool side)

7. Remove seat (21), spring (20), and check valve (19) from four places on housing (1).

Page 92

W2-5-4

ASSEMBLE CONTROL VALVE 1

CONTROL VALVE

SM2087

3 4 8 5 7 14 9 13 10

SM2090

SM2088

20 44 45

46-

36-

A = Side View of 4-Spool Control Valve B = Arm II C = Boom I D = Bucket Flow Control Valve

(Switch Valves A) E = Pump Control Valve F = Bucket G = Bucket Flow Control Valve

(Switch Valves B) H = Bucket Flow Control Valve

(Restriction)

SM2089

17 15 16 18 6 12 11

1 - Housing (4-Spool Side) 3 - Lock Nut 4 - Body 5 - O-Ring 6 - O-Ring 7 - O-Ring 8 - Adjusting Screw

9 - Valve 10 - Spring 11 - Piston

42 7 33

12 - Bushing 13 - Spring 14 - O-Ring 15 - Snap Ring 16 - Filter 17 - Adapter 18 - O-Ring 19 - Check Valve 20 - Spring 21 - Seat

SM2092

22 - Backup Ring 23 - O-Ring 24 - Valve Seat 25 - Check Valve 26 - Spring 27 - O-Ring 28 - Plug 29 - Spring 30 - O-Ring 31 - Backup Ring

30 29 30 27 24

31 26 25

32 - Bushing 33 - Pilot Plate 34 - Socket Bolt 35 - Filter 36 - Screw 37 - Socket Bolt 38 - Spool 39 - Washer 40 - Spring 41 - O-Ring

SM2091

42 - Plug 43 - Plug 44 - O-Ring 45 - Spring 46 - Washer 47 - Spool

Page 93

CONTROL VALVE

Assemble Control Valve 1

• Pump Control Valve

1. Install spring (10) and piston (11) into housing (1). Install bushing (12) and spring (13) onto piston (11).

2. Install O-rings (5) and (6) on body (4). Insert valve (9) into body (4).

3. Install body (4) onto housing (1).

: 27 mm : 177 N m (18 kgf m, 130 lbf ft)

4. Install adapter (17) onto housing (1).

: 19 mm : 29 N m (3 kgf m, 22 lbf ft)

W2-5-5

• Check Valve (4-spool side)

5. Install check valve (19), spring (20), seat (21) at four places on housing (1).

• Bucket Flow Control Valve

6. Install O-ring (27) on plug (28). Install spring (26) and check valve (25) into plug (28). Install plug (28) onto valve seat (24).

: 10 mm, 14 mm : 15 N m (1.5 kgf m, 11 lbf ft)

7. Install valve seat (24) onto housing (1).

8. Install O-ring (30) and backup ring (31) onto bushing (32). Install bushing (32) onto pilot plate (33).

9. Install backup ring (22) and O-ring (7) , (23) onto pilot plate (33).

10. Install spring (29) into bushing (32). Install pilot plate (33) onto housing (1).

: 6 mm : 25 N m (2.5 kgf m, 18 lbf ft) : 8 mm : 49 N m (5 kgf m, 36 lbf ft)

11. Install filter (35) into pilot plate (33). Tighten screw (36).

: 4 mm : 9.8 N m (1 kgf m, 7 lbf ft)

Page 94

W2-5-6

CONTROL VALVE

46-

44 45

47 33

SM2087

SM2088

SM2089

A = Side View of 4-Spool Control Valve B = Arm II C = Boom I D = Bucket Flow Control Valve

(Switch Valves A)

E = Pump Control Valve

SM2090

F = Bucket G = Bucket Flow Control Valve

(Switch Valves B)

H = Bucket Flow Control Valve

(Restriction)

42 33

SM2091

SM2092

Page 95

CONTROL VALVE

12. Install washers (39) and (46) onto spools (38) and (47), respectively.

13. Install spools (38) and (47) and springs (40) and (45) into pilot plate (33).

14. Install O-rings (41) and (44) onto plugs (42) and (43), respectively. Install them onto pilot plate (33).

: 27 mm : 118 N m (12 kgf m, 87 lbf ft) : 36 mm : 177 N m (18 kgf m, 130 lbf ft)

W2-5-7

Page 96

W2-5-8

DISASSEMBLE CONTROL VALVE 2

CONTROL VALVE

19 20

1 2

13 14

21 22 23 24 25

3 4 5 6 7 8

9 10 11 12

16 17 18

30 31

34 35 36

37 38

30 31 39 40

62 43 42

45 63

SM2093

30 31 39 40 51

1 - Lock Nut 2 - Body 3 - O-Ring 4 - O-Ring 5 - O-Ring 6 - Adjusting Screw 7 - Valve 8 - O-Ring

9 - Spring 10 - Bushing 11 - Piston 12 - Spring 13 - Adapter 14 - O-Ring

15 - Spring 16 - Screw 17 - Filter 18 - Throttle Valve 19 - Socket Bolt 20 - Socket Bolt 21 - Spool 22 - Washer 23 - Spring 24 - O-Ring 25 - Plug 29 - Pilot Plate 30 - O-Ring 31 - Backup Ring

32 - Backup Ring 33 - Snap Ring 34 - Filter 35 - Adapter 36 - O-Ring 37 - Spring 38 - Check Valve 39 - Seat 40 - Spring 41 - Check Valve 42 - O-Ring 43 - Backup Ring 45 - Spring 51 - Check Valve

52 - Housing (4-Spool Side) 53 - Overload Relief Valve 54 - Throttle Valve 55 - Plug 56 - Check Valve 57 - Pilot Housing 58 - Pilot Housing 59 - O-Ring 60 - Main Relief Valve 61 - Housing (5-Spool Side) 62 - Plug 63 - Check Valve

Page 97

CONTROL VALVE

Disassemble Control Valve 2

• Be sure to thoroughly read “Precautions for Disassembly and Assembly” on page W1-1-1 before starting the disassembly work.

• Travel Flow Control Valve

1. Remove plug (25) from pilot plate (29).

: 36 mm

2. Remove spring (23) from pilot plate (29).

Remove washer (22) together with spool (21) from pilot plate (29).

• Hydraulic Timer

3. Remove adapter (13) from pilot plate (29).

W2-5-9

: 27 mm

4. Remove spring (15) and throttle valve (18) from

pilot plate (29).

5. Loosen screw (16) to remove filter (17) from

throttle valve (18).

: 8 mm : 4 mm

Page 98

W2-5-10

1 2

CONTROL VALVE

19 20

11 12

37 38

39 40

62 43 42 45 63

39 40 51

SM2093

Page 99

CONTROL VALVE

W2-5-11

• Auxiliary Flow Rate Check Valve

6. Loosen socket bolts (19) and (20) to remove

pilot plate (29) from housing (61).

: 6 mm, 8 mm

7. Remove plug (62) from housing (61).

8. Remove spring (45) and check valve (63) from

housing (61).

• Check Valve (5-spool side)

9. Remove seats (39) (4 used), springs (37)

(3 used) and (40) (4 used) from housing (61).

10. Remove check valves (38) (3 used), (41) (2 used), and (51) (2 used) from housing (61).

• Pump Control Valve

11. Remove body (2) from housing (61). Remove valve (7) from body (2).

• Check Valve (Located on the bottom of the

control valve)

16. Loosen socket bolts (19) to remove pilot housings (57) and (58) from housings (61) and (52), respectively.

: 6 mm

17. Remove plugs (55) (2 used) from housing (52).

: 14 mm

18. Remove spring (37), throttle valve (54), and check valve (56) from housing (52).

• Main Relief Valve - Overload Relief Valve

19. Remove main relief valve (60) and overload relief valves (53) (3 used) from housings (52) and (61).

: 27 mm

NOTE -

Do not remove lock nut (1) and adjusting

screw (6).

12. Remove bushing (10) and spring (9) from housing (61).

13. Remove piston (11) from housing (61) using a bolt (M8, Pitch 1.25).

14. Remove spring (12) from housing (61).

15. Remove adapter (35) from housing (61).

: 19 mm

Page 100

W2-5-12

ASSEMBLE CONTROL VALVE 2-1

CONTROL VALVE

53 19 58

53 57 19

SM2094

11 10 4 36 34 33

12 9 7 8 5 3 2

SM2095

52 53 59 58 55 57 59

5-32

32-5

SM2097

52 55 60

SM2096

A = Control Valve Bottom View B = Pump Control Valve C = Bucket D = Auxiliary E = Main Relief Valve

1 - Lock Nut 2 - Body 3 - O-Ring 4 - O-Ring 5 - O-Ring 6 - Adjusting Screw 7 - Valve 8 - O-Ring

9 - Spring 10 - Bushing 11 - Piston 12 - Spring 19 - Socket Bolt 32 - Backup Ring 33 - Snap Ring 34 - Filter

35 - Adapter 36 - O-Ring 37 - Spring 52 - Housing (4-Spool Side) 53 - Overload Relief Valve 54 - Throttle Valve 55 - Plug 56 - Check Valve

57 - Pilot Housing 58 - Pilot Housing 59 - O-Ring 60 - Main Relief Valve 61 - Housing (5-Spool Side)