SH210-5 ShopManual [PDF]

Zitiervorschau

Contents Contents

SH200-5

Contents Engine Procedures for Replacing Consumable Parts Engine Oil ................................................................................................................... 1 Removal and Installation of Engine Oil Filter Element................................................ 4 Fuel Filter.................................................................................................................... 5 Charge Fuel Pump Filter ............................................................................................ 9 Removal and Installation of Fan Belt ....................................................................... 11 Removal and Installation of Air Conditioner Belt ...................................................... 13

Assembly and Disassembly Removal and Installation of Engine Hood................................................................. 15 Removal and Installation of Engine Assembly.......................................................... 17 Removal and Installation of Starter Motor ................................................................ 29 Removal and Installation of Alternator...................................................................... 31 Removal and Installation of Supply Pump ................................................................ 33 Removal and Installation of Common Rail................................................................ 47 Removal and Installation of Injector.......................................................................... 50 Removal and Installation of Muffler .......................................................................... 62 Removal and Installation of Turbo Charger .............................................................. 64 Removal and Installation of EGR Cooler and EGR Valve......................................... 69 Removal and Installation of Engine Sensors ............................................................ 73 Removal and Installation of Fuel Cooler................................................................... 74 Removal and Installation of Engine Inter Cooler ...................................................... 75

Air Conditioner Assembly and Disassembly Removal and Installation of Compressor.................................................................... 1 Removal and Installation of Condenser...................................................................... 3 Removal and Installation of Receiver Dryer ............................................................... 5 Assembly and Disassembly of Unit ............................................................................ 7

Procedures for Gas Filling Work Precautions ..................................................................................................... 13 Work Procedures ...................................................................................................... 14 Procedures for Filling................................................................................................ 16

Maintenance Procedure for Electrical Equipment Judgment Procedure for Electricity Measurement ...................................................................... 1

Maintenance Standards Check Sheet ............................................................................................................... 3

1

RSM-00-00-001E 1

Contents Assembly and Disassembly Track Shoe Removal and Installation of Shoe Assembly .............................................................. 1 Removal and Installation of Shoe Plate...................................................................... 6

Travel Unit Removal and Installation of Travel Motor.................................................................... 7 Assembly and Disassembly of Travel Motor ............................................................. 15 Travel Motor Internal Structure Diagram................................................................... 81 Travel Motor Part Table ............................................................................................. 82

Take-up Roller Removal and Installation of Take-up Roller .............................................................. 83 Assembly and Disassembly of Take-up Roller ......................................................... 86

Upper Roller Removal and Installation of Upper Roller ................................................................. 98 Assembly and Disassembly of Upper Roller........................................................... 101

Lower Roller Removal and Installation of Lower Roller ............................................................... 112 Assembly and Disassembly of Lower Roller........................................................... 115

Swing Unit SH210-5 Removal and Installation of Swing Unit ................................................... 125 SH210-5 Assembly and Disassembly of Swing Unit .............................................. 131 SH210-5 Assembly and Disassembly of Swing Motor............................................ 136 SH210-5 Assembly and Disassembly of Swing Reduction Gear............................ 160 SH240-5 Removal and Installation of Swing Unit ................................................... 173 SH240-5 Assembly and Disassembly of Swing Unit .............................................. 178 SH240-5 Assembly and Disassembly of Swing Motor............................................ 183 SH240-5 Assembly and Disassembly of Swing Reduction Gear............................ 203

Center Joint Removal and Installation of Center Joint ................................................................ 217

Counterweight Removal and Installation of Counterweight ............................................................ 222

Hydraulic Pump Removal and Installation of Pump .......................................................................... 225 Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit............. 231 Pump Main Unit Maintenance Standards ............................................................... 239 Explanation of Regulator Operation........................................................................ 242 Procedures for Assembly and Disassembly of Regulator....................................... 248

RSM-00-00-001E

2 2

Contents Remote Control Valve Removal and Installation of Operation Remote Control Valve ............................... 257 Procedures for Assembly and Disassembly of Operation Remote Control Valve... 266 Removal and Installation of Travel Remote Control Valve ...................................... 279 Procedures for Assembly and Disassembly of Travel Remote Control Valve ......... 283

Control Valve Removal and Installation of Control Valve .............................................................. 302 Procedures for Assembly and Disassembly of Control Valve ................................. 312

Other Valves Removal and Installation of 5 Stack Solenoid ........................................................ 335 Removal and Installation of Cushion Valve............................................................. 339 Assembly and Disassembly of Cushion Valve ........................................................ 343

Radiator and Oil Cooler Removal and Installation of Radiator...................................................................... 351 Removal and Installation of Oil Cooler ................................................................... 361

Tank Removal and Installation of Hydraulic Oil Tank....................................................... 365 Removal and Installation of Fuel Tank.................................................................... 375

Attachments Removal and Installation of Bucket......................................................................... 381 Removal and Installation of Bucket Link ................................................................. 383 Removal and Installation of Bucket Cylinder .......................................................... 386 Removal and Installation of Arm Cylinder............................................................... 390 Removal and Installation of Arm............................................................................. 395 Removal and Installation of Boom Cylinder............................................................ 397 Removal and Installation of Boom .......................................................................... 402 Removal and Installation of Arm HBCV.................................................................. 408 Removal and Installation of Boom HBCV ............................................................... 410 Procedures for Operation / Assembly and Disassembly of Hydraulic Cylinder ...... 413

Lights Removal and Installation of Boom Light ................................................................. 442 Removal and Installation of Tool Box Light ............................................................. 443

Procedures for Removal and Installation of Cab Inner and Outer Parts Removal and Installation of Cab Assembly ............................................................ 444 Removal and Installation of Operator's Seat .......................................................... 452 Removal and Installation of Wiper .......................................................................... 454 Removal and Installation of Wiper Controller ......................................................... 455 Removal and Installation of Wiper Motor................................................................ 458 Removal and Installation of Monitor ....................................................................... 462 Removal and Installation of Cab Front Glass ......................................................... 463 Procedure for Window Lock Adjustment................................................................. 466 3

RSM-00-00-001E 3

Contents Hydraulic Equipment-related Parts Accumulator............................................................................................................ 468 Suction Filter........................................................................................................... 469 Return Filter............................................................................................................ 471 Pilot Filter................................................................................................................ 473

Other Removal and Installation of Side Door ................................................................... 474 Draining Oil from Hydraulic Oil Tank....................................................................... 475

RSM-00-00-001E

4 4

Procedures for Replacing Consumable Parts Procedures for Replacing Consumable Parts

SH200-5

Procedures for Replacing Consumable Parts Engine Oil Warning ・ Keep away from fire.

Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Wrench (19 mm) • Special plug (drainer plug) • Waste oil can • Rag • Cleaning fluid

1. Engine Oil Draining [1] Use a wrench (19 mm) to remove the 4 bolts (1), and then remove the under cover (2).

[2] Remove the drain cap (3).

1

1

Bolt

2

Under cover

3

Drain cap

RSM-06-10-001E 1

Procedures for Replacing Consumable Parts [3] Prepare a waste oil can (4). [4] When the drainer plug (5) is screwed in, engine oil will drain.

4

Waste oil can

5

Drainer plug

1

Oil level gauge

2

Pressure cap

2. Engine Oil Filling [1] Remove the drainer plug used for draining oil. [2] Attach the drain cock cap removed when oil was drained. [3] Fill at the feed port (3) with new engine oil. Next, wait about 15 min. for the oil to completely travel down to the oil pan, remove the oil level gauge (1), and wipe the tip of the gauge off with a rag before fully inserting the gauge again. [4] Gently pull out the oil level gauge (1). If oil is adhered to the area between the "upper limit" and "lower limit", the amount of oil is appropriate.

RSM-06-10-001E

3

Feed port

4

Engine

5

Radiator

6

Correct oil volume

7

Upper limit

8

Lower limit

2 2

Procedures for Replacing Consumable Parts 3. Inspection After Engine Oil and Element Replacement Oil leak inspection [1] Start the engine. Slowly raise the rotation from idling rotation. [2] Check the oil pan drain cock and each installation section of the oil filter for oil leaks. Rechecking the oil volume Stop the engine and wait 10 - 20 min. to recheck the engine oil volume. If the volume is low, fill up with oil to the stipulated level. The oil level will decrease due to engine oil entering the oil filter and oil path when the engine is started. Refill with oil if the oil level is low.

3

RSM-06-10-001E 3

Procedures for Replacing Consumable Parts Removal and Installation of Engine Oil Filter Element Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Filter wrench • Rag • Cleaning fluid

1. Removal of Oil Filter Element [1] Use a filter wrench (1) to remove the oil filter element (2).

1

Filter wrench

2

Oil filter element

2. Installation of Oil Filter Element Use the following procedure to install a new cartridge. [1] Apply a thin layer of grease to the cartridge gasket. [2] After the cartridge is screwed in and the gasket is touching the seal surface, use the filter wrench to tighten cartridge 1 rotation.

RSM-06-10-001E

4 4

Procedures for Replacing Consumable Parts Fuel Filter Warning ・ Keep away from fire.

Caution

・ Always do air bleeding when the fuel tank has been emptied, water has been drained from fuel, the element has been replaced, or any other similar work has been done. ・ Be sure to stop the engine before beginning work.

Items to prepare • Wrenches (10 mm, 22 mm) • Filter wrench • Waste oil can • Rag • Cleaning fluid [1] Tighten the cock (1).

1

5

Cock

RSM-06-10-001E 5

Procedures for Replacing Consumable Parts [2] Prepare a waste oil can (2). [3] Use a wrench (22 mm) to loosen the air bleed plug (3).

[4] Remove the drain plug (4).

RSM-06-10-001E

2

Waste oil can

3

Air bleed plug

4

Drain plug

6 6

Procedures for Replacing Consumable Parts [5] Drain the fuel.

[6] Use the filter wrench (5) to remove the cover (6).

[7] Replace the element (7) and O-ring (8). The O-ring cannot be reused. Always replace it with a new one.

7

5

Filter wrench

6

Cover

7

Element

8

O-ring

RSM-06-10-001E 7

Procedures for Replacing Consumable Parts [8] After replacing the filter, use the filter wrench (5) to attach the cover (6).

[9] Use a wrench (10 mm) to loosen the air bleed plug (3). [10] When the filter case priming pump (9) is turned in the direction of the arrow, the knob pops out.

[11] Move the priming pump in and out until the fuel filter is filled with fuel (more than 10 times). When fuel appears inside the filter case, gently tighten the air bleed plug. Press the knob a few times with the plug tightened. Finally, hold the knob pressed in and slightly loosen the air bleed plug. Fuel will ooze out from the hose (10) like bubbles. [12] Repeat the operation in [11] until no more bubbles appear. [13] Tighten the air bleed plug, and then turn the knob and lock it.

RSM-06-10-001E

3

Air bleed plug

5

Filter wrench

6

Cover

9

Priming pump

10

Hose

8 8

Procedures for Replacing Consumable Parts Charge Fuel Pump Filter Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Wrench (10 mm) • Pliers • Caps • Rag • Cleaning fluid [1] Remove the connector (1).

[2] Use pliers or another tool to loosen the hose bands (2), and then remove the hoses (3) and (4). • Use caps to cover the charge fuel pump filter and hoses to prevent the entry of water, dust or dirt.

9

1

Connector

2

Hose band

3

Hose

4

Hose

RSM-06-10-001E 9

Procedures for Replacing Consumable Parts [3] Use a wrench (10 mm) to remove the 2 installation bolts (5), and then turn the filter cover (7) to the left and remove the element (6).

RSM-06-10-001E

5

Bolt

6

Element

7

Filter cover

10 10

Procedures for Replacing Consumable Parts Removal and Installation of Fan Belt Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Wrenches (14 mm, 17 mm) • Rag • Cleaning fluid [1] Remove the air conditioner belt. (For details, see "Removal and Installation of Fan Belt".)

[2] Use a wrench (14 mm) to remove the bolts (1) and (2), and then remove the fan guard (3).

[3] Use a wrench (17 mm) to loosen the nut (4).

11

1

Bolt

2

Bolt

3

Fan guard

4

Nut

RSM-06-10-001E 11

Procedures for Replacing Consumable Parts [4] Use a wrench (17 mm) to loosen the tension bolt (5).

[5] Use a wrench (17 mm) to remove the nut (4), and then remove the tension bolt (5).

[6] Pass the fan belt (6) over each of the fans and remove it.

RSM-06-10-001E

4

Nut

5

Tension bolt

6

Fan belt

12 12

Procedures for Replacing Consumable Parts Removal and Installation of Air Conditioner Belt Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Wrench (19 mm) • Box wrench (14 mm) • Rag • Cleaning fluid [1] Use a wrench (19 mm) to remove the 4 bolts (2), and then remove the under cover (1).

[2] Use a box wrench (14 mm) to loosen the nut (3).

13

1

Under cover

2

Bolt

3

Nut

RSM-06-10-001E 13

Procedures for Replacing Consumable Parts [3] Use a box wrench (14 mm) to loosen the tension bolt (4), and then remove the air conditioner belt (5).

RSM-06-10-001E

4

Tension bolt

5

Air conditioner belt

14 14

Assembly and Disassembly Assembly and Disassembly

SH200-5

Assembly and Disassembly Removal and Installation of Engine Hood ・ Be sure to stop the engine before beginning work. ・ Do not perform this operation in strong wind. Caution ・ Be sure to inspect the nylon sling and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare • Wrench (19 mm) • Nylon sling (with the required breaking load) • Crane (with the required lifting capacity) [1] Open the engine hood, and then remove the Matsuba pin (1) and the flat washer (2).

[2] Pull out the lock arm (4) from the engine hood (3).

15

1

Matsuba pin

2

Flat washer

3

Engine hood

4

Lock arm

RSM-06-11-001E 15

Assembly and Disassembly

[3] After closing the engine hood, use a wrench (19 mm) to remove the 6 installation bolts (5) from the engine hood.

[4] Wrap the nylon sling (6) around the engine hood, and then use the crane to lift the engine hood (7).

RSM-06-11-001E

3

Engine hood

4

Lock arm

5

Bolt

6

Nylon sling

7

Engine hood

16 16

Assembly and Disassembly Removal and Installation of Engine Assembly ・ Keep away from fire. ・ Be sure to release hydraulic pressure before beginning work. Warning ・ The air conditioner circuit is filled with high-pressure gas, so beware of the gas released when loosening lines. ・ Do not use open flames and do not allow sparks near the battery. ・ Be sure to stop the engine before beginning work. Caution ・ Be sure to inspect the wire rope and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare • • • • • • • • • • • •

Wrenches (7 mm, 8 mm, 10 mm, 12 mm, 13 mm, 14 mm, 17 mm, 36 mm) Box wrench (24 mm) Shackle (with the required lifting capacity) x 2 Wire rope (with the required breaking load) Crane (with the required lifting capacity) Marking pen Caps Plugs Waste oil can Rag Cleaning fluid Wood planks, etc.

[1] Remove the counterweight. (For details, see "Removal and Installation of Counterweight".) [2] Remove the pump. (For details, see "Removal and Installation of Hydraulic Pump".) [3] Use a wrench (14 mm) to remove the bolts (1) and (2), and then remove the fan shroud (3).

17

1

Bolt

2

Bolt

3

Fan shroud

RSM-06-11-001E 17

Assembly and Disassembly [4] Use a wrench (14 mm) to remove the bolts (4), and then remove the fan guard (5).

[5] Use a wrench (7 mm) to loosen the hose band (6) on the radiator, and then remove the upper hose (7).

[6] Use a wrench (7 mm) to loosen the hose band (6) on the radiator, and then remove the lower hose (8). • Use caps to cover the radiator and hoses to prevent the entry of water, dust or dirt. • Before removing the radiator hoses, completely drain the coolant.

RSM-06-11-001E

4

Bolt

5

Fan guard

6

Hose band

7

Upper hose

8

Lower hose

18 18

Assembly and Disassembly [7] Use a wrench (12 mm) to loosen the line bolts (9) in 2 locations, and then remove the 2 lines (10) and (11) from the compressor. • Always remove the low-pressure (suction side) line (10) first. • Attach caps or plugs to the compressor and lines to prevent any entry of water, dust or dirt.

[8] Use a wrench (8 mm) to loosen the hose band (12) on the inter cooler, and then remove the hose (13). • Use caps to cover the line and hose to prevent the entry of water, dust or dirt.

[9] Remove the hose bands (14) in the 3 locations.

9

19

Bolt

10

Line (suction side)

11

Line (discharge side)

12

Hose band

13

Hose

14

Hose band

RSM-06-11-001E 19

Assembly and Disassembly [10] Take the breather hose (15) that is on the outside and insert it inside.

[11] Prepare a waste oil can (16). • Drain the engine oil before removing the engine oil hose.

[12] Use a wrench (36 mm) to remove the 2 engine oil remote hoses (17). • Mark the engine and hoses so that the connectors match at the time of assembly. • Attach caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt. • Clean the engine and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

RSM-06-11-001E

15

Breather hose

16

Waste oil can

17

Engine oil remote hose

20 20

Assembly and Disassembly [13] Use a wrench (17 mm) to remove the bolt (18), and then remove the negative-side battery cable (19). • When removing the terminal and harness, secure them so that they do not interfere with the frame. Also, cover with a rubber cap to protect against sparks.

[14] Use a wrench (8 mm) to remove the 1 nut (20), and then remove the wiring (21) from the starter motor.

[15] Use a wrench (14 mm) to remove the 1 nut (22), and then remove the wiring (23) from the starter motor.

18

21

Bolt

19

Battery cable

20

Nut

21

Wiring

22

Nut

23

Wiring

RSM-06-11-001E 21

Assembly and Disassembly [16] Remove the hose band (24), and then remove the fuel hose (25). • Attach caps or plugs to the engine and hose to prevent any entry of water, dust or dirt.

[17] Remove the hose band (26), and then remove the fuel hose (27). • Attach caps or plugs to the engine and hose to prevent any entry of water, dust or dirt.

[18] Use a wrench (13 mm) to remove the 3 bolts (28), and then remove the box cover (29).

24

RSM-06-11-001E

Hose band

25

Fuel hose

26

Hose band

27

Fuel hose

28

Bolt

29

Box cover

22 22

Assembly and Disassembly [19] Remove the connectors (30) in the box. • Wrap the removed connectors in plastic after tying them together.

[20] Use a wrench (7 mm) to loosen the hose band (31), and then remove the heater hose (32). • Attach caps or plugs to the engine and hose to prevent any entry of water, dust or dirt.

[21] Use a wrench (7 mm) to loosen the hose band (33), and then remove the heater hose (34). • Attach caps or plugs to the engine and hose to prevent any entry of water, dust or dirt.

23

30

Connector

31

Hose band

32

Heater hose

33

Hose band

34

Heater hose

RSM-06-11-001E 23

Assembly and Disassembly [22] Use a wrench (7 mm) to loosen the hose band (35), and then remove the radiator hose (36). • Use caps to cover the line and hose to prevent any entry of water, dust or dirt.

[23] Use a wrench (7 mm) to loosen the hose band (37), and then remove the air hose (38). • Use caps to cover the line and hose to prevent any entry of water, dust or dirt.

[24] Use a wrench (8 mm) to loosen the hose band (39), and then remove the air hose (40). • Use caps to cover the line and hose to prevent any entry of water, dust or dirt.

RSM-06-11-001E

35

Hose band

36

Radiator hose

37

Hose band

38

Air hose

39

Hose band

40

Air hose

24 24

Assembly and Disassembly [25] Remove the connectors (41) from the alternator.

[26] Use a wrench (10 mm) to remove the nut (42), and then remove the wiring from the alternator (43).

[27] Use a wrench (13 mm) to remove the bolt (44), and then remove the radiator hose clamp (45).

25

41

Connector

42

Nut

43

Wiring

44

Bolt

45

Clamp

RSM-06-11-001E 25

Assembly and Disassembly [28] Use a wrench (13 mm) to remove the bolt (44), and then remove the breather hose clamp (46).

[29] Install the 2 shackles (47), and then use the wire rope (48) and crane to secure the engine.

44

RSM-06-11-001E

Bolt

46

Clamp

47

Shackle

48

Wire rope

26 26

Assembly and Disassembly [30] Use a box wrench (24 mm) to remove the 4 bolts (49) from the mount.

[31] Use the wire rope (48) and crane to lift the engine. [32] Thoroughly check that the location is safe before lowering the engine on wood planks, etc.

27

48

Wire rope

49

Bolt

RSM-06-11-001E 27

Assembly and Disassembly [33] To install the engine, perform the reverse of the removal procedure. After installing the engine, resupply coolant and engine oil, perform fuel line air bleeding, and perform filling for the air conditioner gas. For details, see the individual explanations for each procedure. [34] Run the engine at no-load idling and check for any water or oil leaks. [35] Attach the hydraulic pump, covers, and counterweight. For details, see the individual explanations for each procedure.

RSM-06-11-001E

28 28

Assembly and Disassembly Removal and Installation of Starter Motor Warning ・ Do not use open flames and do not allow sparks near the battery.

Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Wrenches (8 mm, 14 mm, 17 mm) • Rag • Cleaning fluid [1] Use a wrench (17 mm) to remove the bolt (1), and then remove the battery cable (2) on the negative side. • When removing the terminal and harness, secure them so that they do not interfere with the frame. Also, cover with a rubber cap to protect against sparks.

[2] Use a wrench (8 mm) to remove the nut (3), and then remove the wiring (4).

29

1

Bolt

2

Battery cable

3

Nut

4

Wiring

RSM-06-11-001E 29

Assembly and Disassembly [3] Use a wrench (14 mm) to remove the nut (5), and then remove the wiring (6).

[4] Use a wrench (14 mm) to remove the bolt (7), and then remove the wiring on the ground side (6).

[5] Use a wrench (17 mm) to remove the nut (8), and then remove the starter motor (9).

5

Nut

6

Wiring

7

Bolt

8

Nut

9

Starter motor

[6] To install, perform the reverse of the removal procedure. Mount nut tightening torque: 82.4 N•m

RSM-06-11-001E

30 30

Assembly and Disassembly Removal and Installation of Alternator Warning ・ Do not use open flames and do not allow sparks near the battery.

Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Wrenches (10 mm, 17 mm, 20 mm) • Rag • Cleaning fluid [1] Remove the fan belt. (For details, see "Removal and Installation of Fan Belt".) [2] Use a wrench (17 mm) to remove the bolt (1), and then remove the battery cable (2) on the negative side. • When removing the terminal and harness, secure them so that they do not interfere with the frame. Also, cover with a rubber cap to protect against sparks.

[3] Remove the connectors (3).

31

1

Bolt

2

Battery cable

3

Connector

RSM-06-11-001E 31

Assembly and Disassembly [4] Use a wrench (10 mm) to remove the bolt (4), and then remove the wiring (5).

[5] Use a wrench (10 mm) to remove the nut (6), and then remove the wiring (5).

[6] Use a wrench (20 mm) to remove the bolt (7), and then remove the alternator (8).

4

Bolt

5

Wiring

6

Nut

7

Bolt

8

Alternator

[7] To install, perform the reverse of the removal procedure. Adjust the fan belt according to the tension adjustment procedure.

RSM-06-11-001E

32 32

Assembly and Disassembly Removal and Installation of Supply Pump Warning ・ Be sure to release hydraulic pressure before beginning work.

Caution ・ Be sure to stop the engine before beginning work.

Caution

Each part of the fuel system is a high-precision part. Damage may result if foreign matter, etc. enters the fuel system, so use extreme caution when handling these parts.

When high-pressure lines in the fuel system are removed, replace them with new lines. Replace gaskets or O-rings with new ones. Warning Fuel leaks may cause fires. Thoroughly wipe off fuel after work is completed, and carefully check for any leaks after starting the engine.

Items to prepare • Wrenches (8 mm, 10 mm, 12 mm, 14 mm, 17 mm, 19 mm, 22 mm) • Hexagon wrench (4 mm) • Gear puller • Caps • Plugs • Rag • Cleaning fluid

1. Removal of Supply Pump [1] Use a wrench (10 mm) to remove the bolt (1), and then remove the hole cover (2).

33

1

Bolt

2

Hole cover

RSM-06-11-001E 33

Assembly and Disassembly [2] Turn the crankshaft in the correct rotation direction and align the reference mark of the 1st or 4th cylinder with the compression top dead center position.

[3] Use a wrench (8 mm) to loosen the hose bands (3), and then remove the air hose (4). • Use caps and plugs to cover the hose and line to prevent any entry of water, dust or dirt.

[4] Remove the connector (5).

RSM-06-11-001E

3

Hose band

4

Air hose

5

Connector

34 34

Assembly and Disassembly [5] Use a wrench (12 mm) to remove the 3 bolts (6), and then remove the inlet pipe (7). • Cover the line to prevent the entry of water, dust or dirt. • Clean the line by spraying it with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[6] Use a wrench (10 mm) to remove the bolts (6) on the clamps (8). [7] Remove the connectors (9) and (10).

[8] Use a hexagon wrench (4 mm) to remove the bolt (11) on the clamp (12).

35

6

Bolt

7

Inlet pipe

8

Clamp

9

Connector

10

Connector

11

Bolt

12

Clamp

RSM-06-11-001E 35

Assembly and Disassembly [9] Use a wrench (12 mm) to remove the bolts (13), and then remove the oil gauge line (14). • Use caps and plugs to cover the lines to prevent any entry of water, dust or dirt. • Clean the line by spraying it with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[10] Use a wrench (19 mm) to remove the sleeve nuts (15), and then remove the injection pipe (16). • Use caps and plugs to cover the lines to prevent any entry of water, dust or dirt. • Clean the line by spraying it with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[11] Remove the fuel hose (17). • Use caps and plugs to cover the lines to prevent any entry of water, dust or dirt.

13

RSM-06-11-001E

Bolt

14

Oil gauge line

15

Sleeve nut

16

Injection pipe

17

Fuel hose

36 36

Assembly and Disassembly [12] Use a wrench (10 mm) to remove the bolt (19) on the leak-off pipe (20). [13] Use a wrench (12 mm) to remove the eye bolt (18) on the leak-off pipe (20).

[14] Use a wrench (14 mm) to remove the eyebolts (21) and (22) on the leak-off pipe (20).

[15] Remove the leak-off pipe (20). • Use caps and plugs to cover the lines to prevent any entry of water, dust or dirt. • Clean the line by spraying it with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

37

18

Eyebolt

19

Bolt

20

Leak-off pipe

21

Eyebolt

22

Eyebolt

RSM-06-11-001E 37

Assembly and Disassembly [16] Remove the connectors (23) and (24). [17] Use a wrench (22 mm) to remove the eyebolt (25) on the fuel pipe (26).

[18] Use a wrench (14 mm) to remove the nuts (27). [19] Use a wrench (17 mm) to remove the bolts (28) and (29). [20] Remove the supply pump assembly (30). • Use caps and plugs to prevent any entry of water, dust or dirt. • Clean the assembly by spraying it with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

23

RSM-06-11-001E

Connector

24

Connector

25

Eyebolt

26

Fuel pipe

27

Nut

28

Bolt

29

Bolt

30

Supply pump assembly

38 38

Assembly and Disassembly [21] Remove the nut securing the supply pump gear (31) and use the gear puller (32) to remove the gear from the supply pump assembly (30).

[22] Remove the 3 bolts (36), and then remove the supply pump (33). Also remove the O-ring (34) at the same time.

39

30

Supply pump assembly

31

Supply pump gear

32

Gear puller

33

Supply pump

34

O-ring

35

Bracket

36

Bolt

RSM-06-11-001E 39

Assembly and Disassembly 2. Installation of Supply Pump [1] Install the O-ring (2) on the supply pump (1). Install the pump on the bracket (3) and tighten the 3 bolts (4) to the specified torque. Tightening torque: 19 N•m

[2] Align the key of the supply pump shaft with the gear (5), install the gear, and tighten the nut (6) to the specified torque. Tightening torque: 64 N•m

[3] A reference mark circle has been stamped onto the end face surface of the gear. Paint the upper part of the gear tooth just above the stamped "0" mark white. This paint is very important for checking the correct position.

RSM-06-11-001E

1

Supply pump

2

O-ring

3

Bracket

4

Bolt

5

Gear

6

Nut

40 40

Assembly and Disassembly [4] Install the O-ring (7) on the supply pump assembly (8). Align the supply pump gear position with the reference mark (0 mark) on the gear end face surface and the slit on the pump bracket side. Install the supply pump assembly on the engine so that the alignment position is correct. Temporarily tighten the bolts (10) and (11) and the nut (9).

[5] When looking from the plug hole, check that the gear tooth with the reference mark (0 mark) and white paint is at the center of the hole and in the position shown in the diagram. If alignment is not correct, adjust the gear position again and install the pump on it. Temporarily tighten bolts (10) and (11) and nut (9) to the specified torque. Tightening torque Nut: 50 N•m Bolt: 76 N•m

7

41

O-ring

8

Supply pump assembly

9

Nut

10

Bolt

11

Bolt

RSM-06-11-001E 41

Assembly and Disassembly [6] Install the hole cover (13) in the plug hole. Tighten the bolt (12) to the specified torque. Tightening torque: 8 N•m

[7] Connect the connectors (14) and (15). Install the line (17) with the eyebolt (16).

RSM-06-11-001E

12

Bolt

13

Hole cover

14

Connector

15

Connector

16

Eyebolt

17

Line

42 42

Assembly and Disassembly [8] Install the leak-off pipe (18) with eyebolts (19), (21) and (22) and bolt (20). • Be careful not to allow entry of any water, dust or dirt. • Clean the line by spraying it with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors. Always replace seals.

[9] Install the fuel hose (23). • Be careful not to allow entry of any water, dust or dirt.

43

18

Leak-off pipe

19

Eyebolt

20

Bolt

21

Eyebolt

22

Eyebolt

23

Fuel hose

RSM-06-11-001E 43

Assembly and Disassembly [10] Install the injection pipe (25). This injection pipe cannot be reused, so always replace it with a new one. Tighten the sleeve nuts (24). • Be careful not to allow entry of any water, dust or dirt. • Clean the line by spraying it with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[11] Install the clamp (27) with the bolt (26).

[12] Install the oil gauge line (29) with the bolt (28). • Be careful not to allow entry of any water, dust or dirt. • Clean the line by spraying it with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

24

RSM-06-11-001E

Sleeve nut

25

Injection pipe

26

Bolt

27

Clamp

28

Bolt

29

Oil gauge line

44 44

Assembly and Disassembly [13] Install each wiring clamp (33) with a bolt (32) and install the wiring connectors (30) and (31).

[14] Install the inlet pipe (35) with the 3 bolts (34) and tighten to the specified torque. Tightening torque: 24 N•m

[15] Connect the connector (36).

30

45

Connector

31

Connector

32

Bolt

33

Wiring Clamp

34

Bolt

35

Inlet pipe

36

Connector

RSM-06-11-001E 45

Assembly and Disassembly [16] Install the air hose (38), and tighten the hose bands (37). • Be careful not to allow entry of any water, dust or dirt.

RSM-06-11-001E

37

Hose band

38

Air hose

46 46

Assembly and Disassembly Removal and Installation of Common Rail Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Wrenches (10 mm, 12 mm, 14 mm, 17 mm) • Marking pen • Caps • Plugs • Rag • Cleaning fluid See "Removal and Installation of Supply Pump" for procedures for removal and installation of the oil level gauge pipe, intake hose, manifold, etc. [1] Remove the connector (1).

[2] Use a wrench (12 mm) to remove the bolts (2) on the wiring clamp. [3] Use a wrench (10 mm) to remove the bolts (3) on the wiring clamp.

47

1

Connector

2

Bolt (M8)

3

Bolt (M6)

RSM-06-11-001E 47

Assembly and Disassembly [4] Use a wrench (14 mm) to remove the eyebolts (4) and (5) on the leak-off pipe (6), and remove the leak-off pipe.

[5] Use a wrench (10 mm) to remove the nuts (8) on the line clamps (7). [6] Use a wrench (17 mm) to remove each sleeve nut (9) in the 4 locations. • Replace the removed line in the same way as the common rail. • Use caps and plugs to cover the lines to prevent any entry of water, dust or dirt. • Clean the line by spraying it with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[7] Use a wrench (12 mm) to remove bolts (11) and (12) and nuts (10).

RSM-06-11-001E

4

Eyebolt

5

Eyebolt

6

Leak-off pipe

7

Line clamp

8

Nut

9

Sleeve nut

10

Nut

11

Bolt

12

Bolt

48 48

Assembly and Disassembly [8] Remove the common rail (13).

13

Common rail

[9] To install the common rail, perform the reverse of the removal procedure. High-pressure lines that have been removed cannot be reused. Always replace them with new ones.

49

RSM-06-11-001E 49

Assembly and Disassembly Removal and Installation of Injector Warning Do not use open flames and do not allow sparks near the battery.

Warning Injector wirings are high voltage wirings, so make sure to remove the battery.

Caution ・ Be sure to stop the engine before beginning work.

Caution ・ Be careful not to drop any removed parts inside the engine.

Items to prepare • Wrenches (7 mm, 10 mm, 12 mm, 14 mm, 17 mm, 19 mm) • Pliers • Marking pen • Torx wrench (T40) • Caps • Plugs • Waste oil can • Rag • Cleaning fluid

1. Removal of Injector Removal and installation of the No. 1 injector is explained here as a representative example. Use the same procedure for other cylinder injectors. Be extremely careful when handling injectors. The nozzle tips are especially delicate. Hitting the nozzles or wiping them with a rag may cause the hole to clog. Also, injector wiring use high voltage, so make sure to remove the battery terminals before beginning work. High-pressure lines, seals, and packing that have been removed cannot be reused, so always replace them with new parts. [1] Use a wrench (17 mm) to remove the bolt (1), and then remove the battery cable (2) on the negative side. • When removing the terminal and harness, secure them so that they do not interfere with the frame. Also, cover with a rubber cap to protect against sparks.

RSM-06-11-001E

1

Bolt

2

Battery cable

50 50

Assembly and Disassembly [2] Use a wrench (12 mm) to remove the bolt (3), and then remove the oil gauge line (4). • Use caps and plugs to cover the lines to prevent any entry of water, dust or dirt. • Clean the line by spraying it with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[3] Use pliers to loosen the hose band, and then remove the blow-by hose (5). • Use caps and plugs to cover the hose and line to prevent any entry of water, dust or dirt.

[4] Use a wrench (12 mm) to remove the bolt (6) on the hose clamp (7).

51

3

Bolt

4

Oil gauge line

5

Blow-by hose

6

Bolt

7

Hose clamp

RSM-06-11-001E 51

Assembly and Disassembly [5] Use a wrench (12 mm) to remove the 9 bolts (8) on the cylinder head cover (10) and the 2 nuts (9), and then remove the cylinder head cover.

[6] Remove the connector (11).

RSM-06-11-001E

8

Bolt

9

Nut

10

Cylinder head cover

11

Connector

52 52

Assembly and Disassembly [7] Use a wrench (7 mm) to remove the 2 nuts (13) at each of the 4 injector terminal locations. [8] Use a wrench (14 mm) to loosen the 3 bolts (12), and then remove the harness bracket (14). • When removing the nuts, loosen them equally a little bit a time to simultaneously remove them.

[9] Use wrenches (12 mm, 17 mm) to remove the 5 bolts (15) and (16) and the 5 gaskets (17) and (18), and then remove the nozzle leak-off pipe (19).

12

53

Bolt

13

Nut

14

Harness bracket

15

Bolt

16

Bolt

17

Gasket

18

Gasket

19

Nozzle leak-off pipe

RSM-06-11-001E 53

Assembly and Disassembly [10] Use a wrench (10 mm) to remove the bolt (20) on the line clamp (23). [11] Use a wrench (17 mm) to remove the sleeve nut (21) of the injector-side line. [12] Use a wrench (19 mm) to remove the sleeve nut (22) of the common rail-side line. • Use caps and plugs to cover the lines to prevent any entry of water, dust or dirt. • Clean the line by spraying it with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[13] Use a Torx wrench (T40) to remove the bolt (24) on the injector clamp (26). [14] Remove the injector (25).

RSM-06-11-001E

20

Bolt

21

Sleeve nut

22

Sleeve nut

23

Line clamp

24

Bolt

25

Injector

26

Clamp

54 54

Assembly and Disassembly [15] Use the injector remover (28) when it is difficult to remove the injector (29). Install the injector remover on the injector line connection section. Also connect the sliding hammer (27) and then remove the injector. 1) Sliding hammer Isuzu Part No.: 5-8840-0019-0 2) Injector remover Isuzu Part No.: 5-8840-2826

55

27

Sliding hammer

28

Injector remover

29

Injector

RSM-06-11-001E 55

Assembly and Disassembly 2. Installation of Injector [1] Record the "QR code" (2) that appears on the top of the QR plate (1) of the replacement injector. The "QR code" is different for each injector, so match the cylinder to be installed with the injector and record the code.

[2] Always replace the gasket (5) and O-ring (7). Apply Molybdenum to the threaded section of the bolt (4) on the injector clamp (6) and seating surface. Install the injector (3) on the cylinder head. As shown in the diagram, insert the injector by pressing it in with the clamp. Temporarily tighten the bolt on the injector clamp.

RSM-06-11-001E

1

QR plate

2

QR code

3

Injector

4

Bolt

5

Gasket

6

Clamp

7

O-ring

56 56

Assembly and Disassembly [3] Apply a small amount of engine oil to the outside surface of the injector-side sleeve nut (10). Install the line. Carefully tighten each of the sleeve nuts (9) and (10) until the line is touching the common rail and injector. Tighten the bolt (8) on the line clamp (11) to the specified torque. Tightening torque: 6 N•m

Fully tighten the bolt (4) on the injector clamp to the specified torque. Tightening torque: 30 N•m Tighten the line sleeve nuts to the specified torque. Tightening torque: 44 N•m

57

4

Bolt

8

Bolt

9

Sleeve nut

10

Sleeve nut

11

Line clamp

RSM-06-11-001E 57

Assembly and Disassembly [4] Install the nozzle leak-off pipe (16) with the bolts (12) and (13). Replace the gaskets (14) and (15). Tighten each of the lines to the specified torque. Tightening torque: 12 N•m

[5] Secure the harness bracket (19) with the bolts (17). Secure the bolts in sequence from the inside to the outside. Tightening torque: 48 N•m [6] Install the injector terminal nuts (18) on each injector. Tighten to the specified torque. Tightening torque: 2 N•m Be careful not to tighten the nuts too much. Tightening all at once with a ratchet wrench, etc. may cause damage to the terminal stud.

12

RSM-06-11-001E

Bolt

13

Bolt

14

Gasket

15

Gasket

16

Nozzle leak-off pipe

17

Bolt

18

Nut

19

Harness bracket

58 58

Assembly and Disassembly [7] Connect the injector harness connector (20).

[8] Install the head gasket (24) on the cylinder head cover (23) and tighten with each of the bolts (21) and nuts (22). Tighten in the order shown in the diagram. Specified torque: 18 N•m

59

20

Connector

21

Bolt

22

Nut

23

Cylinder head cover

24

Head gasket

RSM-06-11-001E 59

Assembly and Disassembly [9] Install the hose clamp (26) with the bolt (25).

[10] Install the blow-by hose (27).

[11] Install the oil gauge line (29) with the bolt (28). • Be careful not to allow entry of any water, dust or dirt. • Clean the line by spraying it with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

RSM-06-11-001E

25

Bolt

26

Hose clamp

27

Blow-by hose

28

Bolt

29

Oil gauge line

60 60

Assembly and Disassembly [12] Install the negative-side battery cable (31) terminal. Be careful of shorts with the terminal and harness.

30

Bolt

31

Battery cable

[13] When replacing an injector (3) with a new one, make sure to enter the QR code of the replaced injector into the ECM. [14] See the Service Text for this procedure.

61

RSM-06-11-001E 61

Assembly and Disassembly Removal and Installation of Muffler Warning

・ The muffler is extremely hot just after stopping the engine. Wait for it to sufficiently cool before beginning work.

Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Wrenches (14 mm, 17 mm) • Caps • Rag • Cleaning fluid

1. Removal of Muffler [1] Use a wrench (17 mm) to remove the 9 bolts (1), and then remove the covers (2) and (3).

[2] Use a wrench (14 mm) to loosen the nut (5) to remove the 2 bolts (4), remove the seal clamp from the exhaust pipe, and then remove the line. • Use caps to cover the line to prevent any entry of water, dust or dirt.

RSM-06-11-001E

1

Bolt

2

Cover

3

Cover

4

Bolt

5

Nut

62 62

Assembly and Disassembly [3] Use a wrench (14 mm) to remove the 2 nuts (6).

[4] Remove the U-bolts (7), and then remove the muffler (8).

6

Nut

7

U-bolt

8

Muffler

2. Installation of Muffler Perform the reverse of the removal procedure. After installation, check for any leaks or vibration.

63

RSM-06-11-001E 63

Assembly and Disassembly Removal and Installation of Turbo Charger The turbo charger is extremely hot just after stopping the engine. Warning Wait for it to sufficiently cool before beginning work. Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Wrenches (7 mm, 10 mm, 14 mm, 17 mm) • Caps • Plugs • Rag • Cleaning fluid

1. Removal of Turbo Charger The engine oil line and coolant line wil be removed, so either drain the engine oil and coolant beforehand or use stoppers on the ends of the lines to prevent leaking. [1] Remove the muffler. (For details, see "Removal and Installation of Muffler".) [2] Use a wrench (7 mm) to loosen the hose band (1), and then remove the intake hose (2). • Use caps to cover the turbo charger and hose to prevent any entry of water, dust or dirt.

[3] Use a wrench (7 mm) to loosen the hose band (3), and then remove the hose (4). • Use caps to cover the turbo charger and hose to prevent any entry of water, dust or dirt.

RSM-06-11-001E

1

Hose band

2

Intake hose

3

Hose band

4

Hose

64 64

Assembly and Disassembly [4] Use a wrench (10 mm) to remove the 4 bolts (5), and then remove the heat shield (6).

[5] Use a wrench (14 mm) to remove the eyebolt (7), and then remove the oil feed pipe (8). • Use caps and plugs to cover the turbo charger and oil feed pipe to prevent any entry of water, dust or dirt. • When removing the oil feed pipe, take care not to damage or lose the packing.

[6] Use a wrench (17 mm) to remove the eyebolt (9), and then remove the water return pipe (10). • Use caps and plugs to cover the turbo charger and water return pipe to prevent any entry of water, dust or dirt.

65

5

Eyebolt

6

Heat shield

7

Eyebolt

8

Oil feed pipe

9

Eyebolt

10

Water return pipe

RSM-06-11-001E 65

Assembly and Disassembly [7] Use a wrench (17 mm) to remove the eyebolt (11), and then remove the water feed pipe (12). Use caps and plugs to cover the turbo charger and water feed pipe to prevent any entry of water, dust or dirt.

[8] Use a wrench (10 mm) to remove the 2 bolts (13), and then remove the oil return pipe (14). Use caps and plugs to cover the turbo charger and oil return pipe to prevent any entry of water, dust or dirt.

[9] Use a wrench (14 mm) to remove the 4 nuts (15), and then remove the turbo charger (16).

11

RSM-06-11-001E

Eyebolt

12

Water feed pipe

13

Bolt

14

Oil return pipe

15

Nut

16

Turbo charger

66 66

Assembly and Disassembly [10] Use a wrench (13 mm) to remove the 8 nuts (17), and then remove the line (18) from the turbo charger.

67

17

Nut

18

Line

RSM-06-11-001E 67

Assembly and Disassembly 2. Installation of Turbo Charger To install, perform the reverse of the removal procedure. During installation, replace each gasket and the packing with new ones. Make sure to check the engine oil and coolant levels and resupply as necessary. Each of the installation tightening torque values are indicated below. Check carefully for exhaust leaks, water leaks, and oil leaks.

RSM-06-11-001E

1

Oil feed pipe

16.7 N•m

2

Water return pipe

34.5 N•m

3

Exhaust manifold

4

Water feed pipe

－ 34.5 N•m / 41.2 N•m

5

Turbo charger assembly

6

Exhaust adapter

7

Oil return pipe

52 N•m 32.4 N•m 8.8 N•m / 21.6 N•m

68 68

Assembly and Disassembly Removal and Installation of EGR Cooler and EGR Valve The EGR cooler and EGR valve are extremely hot just after stopping the engine. Warning Wait for them to sufficiently cool before beginning work.

Caution

・ Be sure to stop the engine before beginning work. ・ Be sure to drain coolant before beginning work.

Items to prepare • Wrench (12 mm) • Pliers • Caps • Plugs • Rag • Cleaning fluid

1. Removal of EGR Cooler and EGR Valve [1] Use a wrench (12 mm) to remove the 2 bolts (1).

[2] Use a wrench (12 mm) to remove the 3 bolts (2).

69

1

Bolt

2

Bolt

RSM-06-11-001E 69

Assembly and Disassembly [3] Use pliers to loosen the hose band (3), and then remove the hose (4). • Use caps and plugs to cover the line hose to prevent any entry of water, dust or dirt.

[4] Use a wrench (12 mm) to remove the 2 bolts (5).

[5] Use a wrench (12 mm) to remove the bolts (6) and (7).

RSM-06-11-001E

3

Hose band

4

Hose

5

Bolt

6

Bolt

7

Bolt

70 70

Assembly and Disassembly [6] Use pliers to loosen the hose band (8) to remove the hose (9), and then remove the EGR cooler (10). • Use caps and plugs to cover the line and hose to prevent any entry of water, dust or dirt. • Clean the line by spraying it with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[7] Use a wrench (12 mm) to remove the nuts (12), and then separate the manifold (11) and the EGR cooler (10).

[8] Remove the connector (13). Use a wrench (12 mm) to remove the bolts (14), and then remove the EGR valve (15).

8

71

Hose band

9

Hose

10

EGR cooler

11

Manifold

12

Nut

13

Connector

14

Bolt

15

EGR valve

RSM-06-11-001E 71

Assembly and Disassembly 2. Installation of EGR Cooler and EGR Valve To install, perform the reverse of the removal procedure. During installation, replace gaskets with new ones. Check that there is sufficient coolant and resupply as necessary. Each of the installation tightening torque values are indicated below. Check carefully for exhaust leaks and water leaks.

RSM-06-11-001E

72 72

Assembly and Disassembly Removal and Installation of Engine Sensors Sensor name

Bolt or nut

Tool size

1

Engine coolant temperature sensor

Lock nut x 1

Wrench (19 mm)

2

Boost pressure sensor

Bolt x 2 Clip x 1

Wrench (10 mm) Pliers

3

Overheat switch

Lock nut x 1 Wiring fastener nut

Wrench (22 mm) Wrench (7 mm)

4

Common rail pressure sensor

Lock nut x 1

Wrench (27 mm)

5

EGR valve DC motor

Installation screw x 4

Phillips screwdriver

6

Boost temperature sensor

Lock nut

Wrench (19 mm)

7

Starter motor

Installation nut x 2

Wrench (17 mm)

8

Engine hydraulic pressure sensor

Lock nut x 1

Wrench (27 mm)

9

Suction control valve

Installation bolt x 2

Hexagon wrench (5 mm)

10

Fuel temperature sensor

Lock nut x 1

Wrench (19 mm)

11

Cam position sensor

Installation bolt x 1

Wrench (10 mm)

12

Crank position sensor

Installation bolt

Wrench (10 mm)

73

Remarks

Tightening torque: 82.4 N•m

RSM-06-11-001E 73

Assembly and Disassembly Removal and Installation of Fuel Cooler Caution

・ Be sure to stop the engine before beginning work. ・ As the fuel hose will be removed, strictly prohibit open flames.

Items to prepare • Wrench (12 mm) • Screwdriver • Pliers • Marking pen • Caps • Plugs • Rag • Cleaning fluid • Drip pan

1. Removal of Fuel Cooler [1] Mark the fuel cooler (5) and hoses (1) and (2) so that the connectors match at the time of assembly. • Use pliers to loosen the hose bands (3) and (4), and then remove the hoses. • Fuel will spill out, so place a drip pan directly below the area. • Attach caps or plugs to the fuel cooler and hoses to prevent any entry of water, dust or dirt.

[2] Use a wrench (12 mm) to remove the 4 bolts (6), and then remove the fuel cooler (5).

1

Hose

2

Hose

3

Hose band

4

Hose band

5

Fuel cooler

6

Bolt

2. Installation of Fuel Cooler Perform the reverse of the removal procedure. [1] After connecting the hoses, carefully check for any fuel leaks. RSM-06-11-001E

74 74

Assembly and Disassembly Removal and Installation of Engine Inter Cooler Caution

・ Be sure to stop the engine before beginning work. ・ As the fuel hose will be removed, strictly prohibit open flames.

Items to prepare • Wrenches (8 mm, 14 mm) • Flathead screwdriver • Wire cutters • Caps • Rag • Cleaning fluid

1. Removal of Inter Cooler [1] Remove the fuel cooler. (For details, see "Removal and Installation of Fuel Cooler".) [2] Use wire cutters to cut the hose band on the fuel cooler.

[3] Use a wrench (14 mm) to remove the 4 bolts (1), and then remove the bracket (2) from the fuel cooler.

75

1

Bolt

2

Bracket

RSM-06-11-001E 75

Assembly and Disassembly [4] Use a wrench (8 mm) or flathead screwdriver to loosen the hose bands (3) in the 2 locations, and then remove the 2 hoses (4) and (5). • Use caps to cover the inter cooler and hose to prevent the entry of water, dust or dirt.

[5] Use a wrench (14 mm) to remove the 4 bolts (6), and then remove the inter cooler (7).

3

Hose band

4

Hose

5

Hose

6

Bolt

7

Inter cooler

2. Installation of Inter Cooler Perform the reverse of the removal procedure. Check for any air leaks.

RSM-06-11-001E

76 76

Assembly and Disassembly Assembly and Disassembly

SH200-5

Assembly and Disassembly Removal and Installation of Compressor Warning

・ The air conditioner circuit is filled with high-pressure gas, so there is the danger of gas splaying out when loosening lines.

Caution

・ Be sure to stop the engine before beginning work. ・ When removing and installing the compressor, check the compressor oil quantity.

Items to prepare • Wrench (12 mm) • Box wrench (12 mm) • Rag • Cleaning fluid

1. Removal of Compressor [1] Remove the counterweight. (For details, see "Removal and Installation of Counterweight page 222”. [2] Remove the connector (1).

[3] Use a box wrench (12 mm) to loosen the bolts (2) on the lines in the 2 locations, and then remove the 2 lines (3) and (4). • Always remove the low-pressure line (3) first. • Attach caps or plugs to the compressor and line to prevent any entry of water, dust or dirt.

1

1

Connector

2

Bolt

3

Line (low-pressure side)

4

Line (high-pressure side)

RSM-07-07-001E 1

Assembly and Disassembly [4] Use a wrench (12 mm) to remove the 4 bolts (5), and then remove the compressor (6).

5

Bolt

6

Compressor

2. Installation of Compressor [1] To install, perform the reverse of the removal procedure. Compressor installation bolt tightening torque: 19.6 - 29.4 N•m [2] Check the compressor oil quantity. The compressor contains 135 cc of oil. The oil quantity being low will cause seizing and a reduction in durability. The oil quantity being high will cause a reduction in cooling capabilities. Make sure to check the oil quantity and adjust if needed. Measure the oil quantity of the removed compressor. Only this oil quantity is necessary, so subtract this quantity from 135 cc to determine the amount by which the oil quantity of the new compressor should be reduced. Example) If the remaining oil quantity of the removed compressor is 30 cc: Remove 135 cc - 30 cc = 105 cc from the new compressor to be installed. Resupply oil: SP-10 or SP-20 (P.A.G. oil) [3] Perform air conditioner gas charging. For details, see "Procedures for Gas Filling".

RSM-07-07-001E

2 2

Assembly and Disassembly Removal and Installation of Condenser Warning

・ The air conditioner circuit is filled with high-pressure gas, so there is the danger of gas splaying out when loosening lines.

Caution ・ Be sure to stop the engine before beginning work.

Caution ・ When removing and installing the condenser, resupply and check the compressor oil quantity.

Items to prepare • Wrenches (13 mm, 17 mm, 19 mm, 22 mm) • Caps • Plugs • Rag • Cleaning fluid

1. Removal of Condenser [1] Use a wrench (17 mm) to press the condenser side line (1), and then use a wrench (19 mm) to loosen and remove the sleeve nut of the lowpressure line (2). • Always remove the low-pressure line first. • Attach caps or plugs to the condenser and line to prevent any entry of water, dust or dirt. • Clean the line by spraying it with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[2] Use a wrench (22 mm) to press the condenser side line (3), and then use a wrench (22 mm) to loosen and remove the sleeve nut (4) of the high-pressure line. • The "H" cap indicates the high-pressure line. • Attach caps or plugs to the condenser and line to prevent any entry of water, dust or dirt. • Clean the line by spraying with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

3

1

Line (condenser side)

2

Sleeve nut

3

Line (condenser side)

4

Sleeve nut

RSM-07-07-001E 3

Assembly and Disassembly [3] Use a wrench (13 mm) to remove the 4 bolts (5), and then remove the condenser (6).

5

Bolt

6

Condenser

2. Installation of Condenser [1] To install, perform the reverse of the removal procedure. Condenser installation bolt tightening torque: 19.6 N•m [2] Make sure to resupply and check the compressor oil quantity. The compressor contains 135 cc of oil. The oil quantity being low will cause seizing and a reduction in durability. The oil quantity being high will cause a reduction in cooling capabilities. Make sure to check the oil quantity and adjust if needed. Resupply quantity: 40 cc Resupply oil: SP-10 or SP-20 (P.A.G. oil) [3] Perform air conditioner gas charging. For details, see "Procedures for Gas Filling".

RSM-07-07-001E

4 4

Assembly and Disassembly Removal and Installation of Receiver Dryer Warning

・ The air conditioner circuit is filled with high-pressure gas, so there is the danger of gas splaying out when loosening lines.

Caution ・ Be sure to stop the engine before beginning work.

Caution ・ When replacing the receiver dryer, resupply and check the compressor oil quantity.

Items to prepare • Wrench (10 mm) • Caps • Plugs • Rag • Cleaning fluid

1. Removal of Receiver Dryer [1] Remove the connector (1).

[2] Use a wrench (10 mm) to remove the 2 bolts (2) and the washers (3) of the lines (4). • Attach caps or plugs to the receiver dryer and lines to prevent any entry of water, dust or dirt. • Clean the receiver dryer and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

5

1

Connector

2

Bolt

3

Washer

4

Line

RSM-07-07-001E 5

Assembly and Disassembly [3] Use a wrench (10 mm) to remove the 1 bolt (5), and then remove the receiver dryer (6).

5

Bolt

6

Receiver dryer

2. Installation of Receiver Dryer [1] To install, perform the reverse of the removal procedure. Receiver dryer installation bolt tightening torque: 6.9 N•m [2] Check the compressor oil quantity. The compressor contains 135 cc of oil. The oil quantity being low will cause seizing and a reduction in durability. The oil quantity being high will cause a reduction in cooling capabilities. Make sure to check the oil quantity and adjust if needed. Resupply quantity: 20 cc Resupply oil: SP-10 or SP-20 (P.A.G. oil) [3] Perform air conditioner gas charging. For details, see "Procedures for Gas Filling".

RSM-07-07-001E

6 6

Assembly and Disassembly Assembly and Disassembly of Unit Caution ・ Be sure to stop the engine before beginning work.

Caution ・ When replacing the evaporator, resupply and check the compressor oil quantity.

1. Removal of Blower Unit [1] Remove the connectors connected to the refresh/recirculate motor actuator, blower motor, blower controller, and inside air sensor, and also the harness in which the blower case is installed.

[2] Remove the inside air filter (8) from the intake duct (12), and remove the 3 T4 x 14 (T1) Phillips screws (16) to remove the intake duct. [3] Remove the filter clog sensor (11) along with the nylon clip (17) from the intake case (13). [4] Remove the 4 T5 x 14 (T1) Phillips screws (14) and remove the intake case (13). [5] Remove the 3 T5 x 14 (T1) Phillips screws (18) and separate the blower case (10) and air conditioner unit.

7

1

Evaporator sensor connector

2

Blower controller connector

3

Blower motor connector

4

Harness

5

Filter clog sensor

6

Inside / outside air motor actuator connector

7

Inside air sensor connector

8

Inside air filter

9

Unit

10

Blower case

11

Filter clog sensor

12

Intake duct

13

Intake case

14

Phillips screw

15

Inside air sensor

16

Phillips screw

17

Nylon clip

18

Phillips screw

RSM-07-07-001E 7

Assembly and Disassembly 2. Replacement of Blower Motor [1] Remove the coolant hose (4) connecting the blower motor (5) and the blower case (6). [2] Remove the 3 N5 x 16 (W) Phillips screws (3) installed at the bottom of the blower unit case and remove the blower motor (5). [3] The installation procedure is the reverse of the removal procedure. Caution

Do not remove the fan from the blower motor.

3. Replacement of Blower Controller [1] Remove the 2 T4 x 14 (T1) Phillips screws (2) installed at the bottom of the blower case and remove the blower controller (1). [2] The installation procedure for the new blower controller (1) is the reverse of the removal procedure. Caution

Never disassemble the blower controller.

1

Blower controller

2

Phillips screw

3

Phillips screw

4

Coolant hose

5

Blower motor

6

Blower case

1

Unit

2

Phillips screw

3

Pipe clamp

4

Heater core

4. Removal of Heater Core [1] Drain the coolant. [2] Remove the 1 N5 x 16 (T2) Phillips screw (2), and remove the pipe clamp (3) fixing the heater core (4) to the unit (1) to remove the heater core from the unit. [3] To install, perform the reverse of the removal procedure.

RSM-07-07-001E

8 8

Assembly and Disassembly 5. Removal of Air Conditioner Case Front, Rear and Bottom [1] Remove the mode motor actuator (4) and evaporator sensor connector. [2] Remove the mode rod (1) from the rod holder installed on the mode motor actuator (4) lever MAL 1 (3). [3] Remove the 3 N4 x 30 (T1) Phillips screws (6) and remove the mode motor actuator (4) installed on the bottom (5) and rear (7) of the unit case.

[4] Remove the 11 N5 x 16 (T2) Phillips screws (8) and remove the bottom (5) and front (12) of the unit case. While being careful not to let the evaporator sensor cord get caught by the case, pull the front of the unit case upwards to remove it. Caution

At this time, perform work with the heater core removed from the unit case.

9

1

Mode rod

2

Rod holder

3

Lever MAL 1

4

Mode motor actuator

5

Unit case bottom

6

Phillips screw

7

Unit case rear

8

Phillips screw

9

Evaporator sensor

10

Expansion valve

11

Evaporator

12

Unit case front

RSM-07-07-001E 9

Assembly and Disassembly 6. Replacement of Evaporator and Expansion Valve [1] Remove the evaporator assembly from the case with the case heat insulating material and expansion valve attached to the evaporator. [2] After removing the case heat insulating material from the top and bottom of the evaporator, remove the evaporator sensor (1) as one piece with the sensor holder. [3] Use a hexagon wrench (4 mm) to remove the 2 M5 x 40 hexagon socket head bolts (2), and remove the expansion valve (3) from the evaporator (5). [4] Install O-rings (4) on the new evaporator (5) (1 NF O-ring 5/8 and 1NF O-ring 1/2). (Tightening torque 6.9 N•m) Caution

Be careful of the O-rings getting caught, etc. when installing the expansion valve.

1

Evaporator sensor

2

Hexagon socket head bolt

3

Expansion valve

4

O-ring

5

Evaporator

7. Installation of Evaporator Sensor [1] Make sure to install the evaporator sensor (1) in the original position of the evaporator (2), as in the figure. Caution

RSM-07-07-001E

Be careful that the sensor cord does not get squeezed in the case when the case is assembled.

1

Evaporator sensor

2

Evaporator

10 10

Assembly and Disassembly 8. Replacement of Motor Actuator [1] Replacement of mode motor actuator Remove the connector connected to the motor actuator (4). Remove the mode rod (1) connecting the motor actuator and mode cam from the rod holder (2). Remove the 3 N4 x 30 (T1) Phillips screws (13) that are used to install the motor actuator, remove the motor actuator from the unit with the rod holder and lever MAL 1 (12) attached to the actuator, remove the rod holder and lever MAL 1 from the motor actuator, and then install the new motor actuator. To install, perform the reverse of the removal procedure. [2] Replacement of air mix motor actuator Remove the connector connected to the motor actuator (11). Remove the AM rod (9) connecting the motor actuator and lever AM (8) from the rod holder (10). Remove the 12 N4 x 30 (T1) Phillips screws (13) that are used to install the motor actuator, remove the motor actuator from the unit with the rod holder and lever MAL 1 (3) attached to the actuator, remove the rod holder and lever MAL 1 from the motor actuator, and then install the new motor actuator. To install, perform the reverse of the removal procedure.

11

1

Mode rod

2

Rod holder

3

Lever MAL 1

4

Mode motor actuator

5

Unit case bottom

6

Phillips screw

7

Unit case rear

8

Lever AM

9

AM rod

10

Rod holder

11

Air mix motor actuator

12

Lever MAL 1

13

Phillips screw

RSM-07-07-001E 11

Assembly and Disassembly [3] Replacement of refresh/recirculate motor actuator Remove the connector connected to the motor actuator (15). Remove the 3 N4 x 28 (T1) Phillips screws (16) that are used to install the motor actuator and remove the motor actuator from the unit with the lever MAL 2 (14) attached. Remove the lever MAL 2 from the motor actuator and attach the new motor actuator. To install, perform the reverse of the removal procedure.

RSM-07-07-001E

14

Lever MAL 2

15

Refresh / recirculate motor actuator

16

Phillips screw

12 12

Procedures for Gas Filling Procedures for Gas Filling

SH200

Procedures for Gas Filling Work Precautions ・ Refrigerant gas filling involves handling dangerous high-pressure gas, so make sure that a experienced and qualified worker with the procedure performs this operation. ・ Always wear protective eyewear. Warning ・ Gas entering the eyes may cause blindness. ・ Refrigerant in the liquid state is very cold (about -26 ℃ ), so be very careful during handling. ・ Refrigerant coming in contact with skin may cause frostbite.

Always use R134a refrigerant. • Storage Keep service cans (hereinafter, cans) with refrigerant in them at 40 ℃ or below. The insides of the cans are highly pressurized and filled with refrigerant, so if the temperature rises there is the danger of internal pressure rising sharply and an explosion occurring. Never store in direct sunlight, in a closed vehicle, or near open flames. Be careful not to drop cans or have them collide with other objects. • Filling operation When cans are heated in order to fill them with refrigerant, make sure that the service can valve and gauge manifold low-pressure valve are open and heat with water at 40 ℃ or below. Direct heating or heating to 40 ℃ or higher may cause explosions, so use caution. If refrigerant filling is done after the engine is started, never open the gauge manifold high-pressure valve. This is very dangerous, as the high-pressure gas will flow in the opposite direction and may cause a can or charging hose explosion. Be careful not to allow the entry of dust or dirt into the air conditioner circuit. Air, moisture and dirt are very bad for the cooling cycle. Perform work quickly and accurately, and be especially careful to prevent the entry of foreign matter. Be careful not to overfill with gas.

13

RSM-07-08-001E 1

Procedures for Gas Filling Work Procedures 1. Air Conditioner Refrigerant Filling is Divided into the "Vacuum Operation" and "Gas Filling Operation". [1] The "vacuum operation" consists of eliminating moisture in the air conditioner circuit. If there is any moisture left inside the air conditioner circuit, various problems may occur during operation such as freezing in the small hole of the expansion valve causing the circuit to clog and rust developing in the circuit. For this reason, perform vacuuming before filling the circuit with refrigerant. This operation consists of eliminating moisture inside the circuit through boiling and evaporation. [2] The "gas filling operation" consists of filling the circuit with refrigerant after the vacuum operation. Gas filling does not only affect the cooling capabilities of the air conditioner, it also affects the life of the parts which make up the circuit. Severely overfilling the circuit will cause pressure inside the circuit to be abnormally high, and this will cause reductions in the cooling ability of the air conditioner. Additionally, if pressure is extremely low, the circulation of lubricating oil within the compressor will be poor and this will cause seizing with sliding parts of the compressor. Because the gas filling operation itself involves handling high-pressure gas, performing the operation using an incorrect procedure is very dangerous. Follow the operation and observe all precautions indicated in this text to correctly perform refrigerant filling.

2. Operation Chart

RSM-07-08-001E

14 2

Procedures for Gas Filling 3. Tools No.

Part name

Q'ty

Shape

Application

1

Gauge manifold

1

2

Charging hose

3

3

Quick joint

1

4

Quick joint

1

Low-pressure side

5

T joint

1

For service can valve

6

Service can valve

2

For service can

7

Vacuum pump adapter

1

For vacuum pump

Red: high-pressure side Blue: low-pressure side Yellow: vacuum pump side

15

RSM-07-08-001E 3

Procedures for Gas Filling Procedures for Filling ・ Because gauge manifold specifications such as hose color are different depending on the manufacturer, please read the Operator's Manual for the gauge manifold to be used for Caution details.

1. Charging Hose Connection Positions

RSM-07-08-001E

1

High-pressure side (DIS) service valve

2

Low-pressure side (SUC) service valve

3

Air conditioner compressor

4

Condenser

5

Receiver dryer

6

Air conditioner unit

16 4

Procedures for Gas Filling 2. Gauge Manifold Connection [1] Close the high-pressure valve (HI) (8) and low-pressure valve (LO) (7) of the gauge manifold (9). [2] Connect the charging hoses (red and blue) to the service valve. Red hose (1): Gauge manifold high-pressure side (HI) → compressor high-pressure side (DIS) service valve (10) Blue hose (2): Gauge manifold low-pressure side (LO) → compressor low-pressure side (SUC) service valve (11) Push in the connections for the high-pressure and low-pressure sides until a "click" is heard to make sure they are secure and in the correct position. [3] Connect the charging hose (yellow) (3) to the vacuum pump (4).

17

1

Charging hose (red)

2

Charging hose (blue)

3

Charging hose (yellow)

4

Vacuum pump

5

Low-pressure gauge

6

High-pressure gauge

7

Low-pressure valve (LO)

8

High-pressure valve (HI)

9

Gauge manifold

10

High-pressure side (DIS) service valve

11

Low-pressure side (SUC) service valve

RSM-07-08-001E 5

Procedures for Gas Filling 3. Vacuuming [1] Open the high-pressure valve (HI) (3) and lowpressure valve (LO) (2) of the gauge manifold (1). [2] Turn the vacuum pump (4) switch on and vacuum for at least 30 min. [3] After the prescribed vacuuming time has elapsed (degree of vacuuming achieved: -750 mmHg or less), close the gauge manifold (1) high-pressure valve (3) and low-pressure valve (2). [4] Next, turn the vacuum pump (4) switch off. [5] Perform a check of air-tightness. Let the gauge manifold (1) sit for at least 5 min. with the high-pressure valve (3) and low-pressure valve (2) closed, and check that the gauge indicator does not go back to 0. If the gauge indicator starts to swing back to 0, this indicates there is a leak. Tighten the line connections, perform vacuuming again, and check to see if there is still a leak.

1

Gauge manifold

2

Low-pressure valve (LO)

3

High-pressure valve (HI)

4

Vacuum pump

1

Gauge manifold

2

Air purge valve

3

Charging hose (yellow)

4

High-pressure valve (HI)

5

Low-pressure valve (LO)

6

Service can

7

Valve for service can

4. Gas Filling Operation, High-pressure Side First, start the filling operation from the high-pressure side. [1] After repeating vacuuming, switch the charging hose (yellow) (3) of the gauge manifold (1) from the vacuum pump to the service can (6). [2] Air purging Open the valve for the service can (7). (However, keep the gauge manifold high-pressure and low-pressure valves closed.) Next, press the air purge valve (2) of the side service port on the gauge manifold low-pressure side with a screwdriver to discharge the air inside the charging hose using the refrigerant pressure. (Complete after the swooshing sound stops.) [3] Open the high-pressure valve (4) of the gauge manifold (1), and fill with coolant. (Fill with refrigerant gas up to a gauge pressure of 0.098 MPa.) After filling, close the gauge manifold high-pressure valve and valve for the service can (7). Never operate the compressor. (This is very dangerous, as the refrigerant will flow in the opposite direction and may cause a service can or hose explosion.) [4] Gas leak check Check for gas leaks in the cycle using the gas leak tester. If there are leaks, eliminate them through tightening. Always use the tester for R134a.

RSM-07-08-001E

18 6

Procedures for Gas Filling 5. Gas Filling Operation, Low-pressure Side Caution

・ Never open the gauge manifold high-pressure valve. ・ Never tip over the service can. This may cause damage to the compressor.

After finishing the high-pressure side filling operation, perform the operation for the low-pressure side. [1] Check that the high-pressure valve (4) and low-pressure valve (5) of the gauge manifold (1) and the valve for the service can (2) are closed. [2] Start the engine, increase speed to 1500±100 min-1, and completely open the cab door and window. [3] Turn the air conditioner switch on, move the fan switch to the maximum position, and move the temperature adjustment switch to the maximum cooling position. [4] During filling, set the degree of discharge for the compressor at 1.37 - 1.57 MPa. [5] Open the low-pressure valve (5) of the gauge manifold (1) and valve for the service can (2), and fill with refrigerant until the air bubbles in the receiver sight glass (9) are gone. ・ Judging the amount of refrigerant from the receiver dryer sight glass When the amount is correct

After the AC is turned ON, a few air bubbles are visible. The glass then becomes transparent and turns to a pale, milkywhite color.

When overfilling occurred

After the AC is turned ON, no air bubbles at all are visible.

When filling was insufficient

After the AC is turned ON, air bubbles are seen continuously.

(Total gas filling amount: 950±50 g)

[6] After refrigerant filling is complete, close the low-pressure valve (5) of the gauge manifold (1) and the valve for the service can (2), and stop the engine. • If the air conditioner is operated with very little refrigerant (R134a), this will have a damaging effect on the compressor. • If the air conditioner is filled with too much refrigerant (overcharge), this will actually cause insufficient cooling and there is the danger of pressure in the circuit becoming abnormally high. Be sure to use an appropriate amount of refrigerant. • Never open the gauge manifold high-pressure valve (4). • Never invert the service can. (Gas is suctioned in liquid form, so this may cause damage to the compressor valve.)

19

RSM-07-08-001E 7

Procedures for Gas Filling [7] After refrigerant filling and inspection, remove the gauge manifold and hoses. Quickly remove the low-pressure side charge hose (blue) (8) from the low-pressure side (SUC) service valve. Do not do anything on the high-pressure side until the high-pressure gauge indicator falls to 0.98 MPa or below. After confirming that the indicator has fallen below this point, quickly remove the high-pressure side charge hose (red) (7) from the high-pressure side (DIS) service valve.

RSM-07-08-001E

1

Gauge manifold

2

Valve for service can

3

Charging hose (yellow)

4

High-pressure valve (HI)

5

Low-pressure valve (LO)

6

Service can

7

Charging hose (red)

8

Charging hose (blue)

9

Sight glass

20 8

Procedure for Electrical Equipment Judgment Procedure for Electrical Equipment Judgment

SH200-5

Procedure for Electrical Equipment Judgment Procedure for Electricity Measurement Items to prepare • Service connectors • Tester [1] Use service connector (female) (1) and service connector (male) (2) for voltage measurement.

[2] Remove the connector (3) in which voltage is to be measured.

1

1

Service connector (female)

2

Service connector (male)

3

Connector

RSM-09-13-001E 1

Procedure for Electrical Equipment Judgment [3] Connect the service connector (female) (1) to the removed connector, and attach the tester (4) to measure voltage.

[4] Also attach the service connector (male) (2) to the removed connector on the opposite side and measure voltage with the tester (4).

1

RSM-09-13-001E

Service connector (female)

2

Service connector (male)

4

Tester

2 2

Maintenance Standards Maintenance Standards

SH200

Maintenance Standards Check Sheet 1. Drive sprocket

* See the gauge list for measurement gauges. * Use the maintenance standard values table for judgment. Part name

Code

Measured dimensions (mm)

a

Drive sprocket

Standard value (mm)

Usage limit (mm)

Judgment

66

60

Acceptable / Unacceptable

b

φ

φ585.5

φ579.5

Acceptable / Unacceptable

c

φ

φ659

φ653

Acceptable / Unacceptable

d

φ

φ644.6

－

Acceptable / Unacceptable

190

－

Acceptable / Unacceptable

p

3

Action

Cladding by welding or replacement

RSM-09-14-001E 1

Maintenance Standards 2. Take-up Roller

* See the gauge list for measurement gauges. * Use the maintenance standard values table for judgment. Part name

Take-up roller

Shaft

Code

Measured dimensions (mm)

Standard value (mm)

Usage limit (mm)

Judgment

a

φ

φ494

φ490

Acceptable / Unacceptable

b

19

－

Acceptable / Unacceptable

c

84

80

Acceptable / Unacceptable

d

φ

φ65

φ64.5

Acceptable / Unacceptable

d

φ

φ65

φ65.8

Acceptable / Unacceptable

e

69

68.6

Acceptable / Unacceptable

f

12.4

11.9

Acceptable / Unacceptable

Bushing

Hub

RSM-09-14-001E

Action

Cladding by welding or replacement

Replacement

Replacement

Replacement

4 2

Maintenance Standards 3. Upper Roller

* See the gauge list for measurement gauges. * Use the maintenance standard values table for judgment. Part name

Carrier roller

Shaft

Code

Measured dimensions (mm)

Standard value (mm)

Usage limit (mm)

Judgment

a

φ

φ120

φ112

Acceptable / Unacceptable

b

10

－

Acceptable / Unacceptable

c

85

79

Acceptable / Unacceptable

d

φ

φ46

φ45.5

Acceptable / Unacceptable

d

φ

φ46

φ46.8

Acceptable / Unacceptable

Bushing

Action

Cladding by welding or replacement

Replacement

Replacement

e

83

82.6

Acceptable / Unacceptable

Thrust plate

f

5.5

5

Acceptable / Unacceptable

Replacement

Cover

g

29.7

29.2

Acceptable / Unacceptable

Replacement

5

RSM-09-14-001E 3

Maintenance Standards 4. Lower Roller

* See the gauge list for measurement gauges. * Use the maintenance standard values table for judgment. Part name

Track roller

Shaft

Code

Measured dimensions (mm)

Standard value (mm)

Usage limit (mm)

Judgment

a

φ

φ150

φ142

Acceptable / Unacceptable

b

15

－

Acceptable / Unacceptable

d

173

179

Acceptable / Unacceptable

e

φ

φ65

φ64.5

Acceptable / Unacceptable

e

φ

φ65

φ65.8

Acceptable / Unacceptable

f

69

68.6

Acceptable / Unacceptable

g

23.3

22.8

Acceptable / Unacceptable

Bushing

Collar

RSM-09-14-001E

Action

Cladding by welding or replacement

Replacement

Replacement

Replacement

6 4

Maintenance Standards 5. Track Shoe (grouser shoe)

* See the gauge list for measurement gauges. * Use the maintenance standard values table for judgment. Part name Shoe plate

Link

Standard value (mm)

Usage limit (mm)

a

34.5

21.5

Acceptable / Unacceptable Replacement

b

106

101

Acceptable / Unacceptable

c

37.985

36

d

17.95

16

Code

Measured dimensions (mm)

Judgment

Action

Cladding by Acceptable / Unacceptable welding or replacement Acceptable / Unacceptable

e

φ

φ58.72

φ57.5

Acceptable / Unacceptable

f

φ

φ37.3

φ38.3

Acceptable / Unacceptable

Master pin

g

φ

φ36.3

φ35.5

Acceptable / Unacceptable Replacement

Link pitch

h

190

195

Acceptable / Unacceptable Replacement

Master bushing

e'

φ

φ58.72

φ57.5

Acceptable / Unacceptable

f'

φ

φ37.3

φ38.3

Acceptable / Unacceptable

g'

φ

φ36.65

φ35.5

Acceptable / Unacceptable Replacement

Track bushing Track pin

Replacement

7

Replacement

RSM-09-14-001E 5

Maintenance Standards 6. Attachment (backhoe)

* Use the maintenance standard values table for judgment. (1) Boom and swing frame installation section Part name

Measured Code dimensions (mm)

Standard value (mm)

Usage limit (mm)

Judgment

Action

Swing frame

a

684

692

Acceptable / Unacceptable

－

Boom

b

681.5

679.5

Acceptable / Unacceptable

Replacement

Clearance

c

0.5 - 3.0

Adjust with shims

Acceptable / Unacceptable

Adjust with shims

Pin

d

φ

φ90

φ89

Acceptable / Unacceptable

Replacement

Bushing (boom)

e

φ

φ90

φ91.5

Acceptable / Unacceptable

Replacement

(2) Boom cylinder and swing frame installation section Part name

Measured Code dimensions (mm)

Standard value (mm)

Usage limit (mm)

Judgment

Action

Swing frame

a

106

112

Acceptable / Unacceptable

－

Boom cylinder (foot section)

b

105

103

Acceptable / Unacceptable

Replacement

Clearance

c

1.0 - 2.5

Adjust with shims

Acceptable / Unacceptable

Adjust with shims

Pin

d

φ

φ80

φ79

Acceptable / Unacceptable

Replacement

Bushing (boom cylinder)

e

φ

φ80

φ81.5

Acceptable / Unacceptable

Replacement

RSM-09-14-001E

8 6

Maintenance Standards

* Use the maintenance standard values table for judgment. (3) Boom and boom cylinder installation section Part name

Measured Code dimensions (mm)

Standard value (mm)

Usage limit (mm)

Judgment

Action

Boom cylinder (top section)

a

100

98

Acceptable / Unacceptable

－

Boom

b

525

521

Acceptable / Unacceptable

Replacement

Clearance

c

1.0 - 2.5

Adjust with shims

Acceptable / Unacceptable

Adjust with shims

Pin

d

φ

φ85

φ84

Acceptable / Unacceptable

Replacement

Bushing (boom cylinder)

e

φ

φ85

φ86.5

Acceptable / Unacceptable

Replacement

(4) Boom and arm cylinder installation section Part name

Measured Code dimensions (mm)

Standard value (mm)

Usage limit (mm)

Judgment

Action

Boom

a

121

127

Acceptable / Unacceptable

－

Boom cylinder (foot section)

b

120

118

Acceptable / Unacceptable

Replacement

Clearance

c

0.5 - 2.0

Adjust with shims

Acceptable / Unacceptable

Adjust with shims

Pin

d

φ

φ80

φ79

Acceptable / Unacceptable

Replacement

Bushing (arm cylinder)

e

φ

φ80

φ81.5

Acceptable / Unacceptable

Replacement

9

RSM-09-14-001E 7

Maintenance Standards

* Use the maintenance standard values table for judgment. (5) Boom and arm installation section Part name

Code

Measured dimensions (mm)

Standard value (mm)

Usage limit (mm)

Judgment

Action

Boom

a

310

313

Acceptable / Unacceptable

－

Arm

b

307.5

305.5

Acceptable / Unacceptable

Replacement

Clearance

c

0.5 - 1.1

Adjust with shims

Acceptable / Unacceptable

Adjust with shims

Pin

d

φ

φ90

φ89

Acceptable / Unacceptable

Replacement

Bushing (arm)

e

φ

φ90

φ91.5

Acceptable / Unacceptable

Replacement

Boom

f

φ

φ90

φ91.5

Acceptable / Unacceptable

Replacement

Boom

g

68

66

Acceptable / Unacceptable

Replacement

RSM-09-14-001E

10 8

Maintenance Standards

* Use the maintenance standard values table for judgment. (6) Arm and arm cylinder installation section Part name

Measured Code dimensions (mm)

Standard value (mm)

Usage limit (mm)

Judgment

Action

Arm

a

121

127

Acceptable / Unacceptable

－

Arm cylinder (top section)

b

120

118

Acceptable / Unacceptable

Replacement

Clearance

c

0.5 - 3.0

Adjust with shims

Acceptable / Unacceptable

Adjust with shims

Pin

d

φ

φ80

φ79

Acceptable / Unacceptable

Replacement

Bushing (arm cylinder)

e

φ

φ80

φ81.5

Acceptable / Unacceptable

Replacement

(7) Arm and bucket cylinder installation section Part name

Measured Code dimensions (mm)

Standard value (mm)

Usage limit (mm)

Judgment

Action

Arm

a

101

107

Acceptable / Unacceptable

－

Bucket cylinder (foot section)

b

100

98

Acceptable / Unacceptable

Replacement

Clearance

c

0.5 - 3.0

Adjust with shims

Acceptable / Unacceptable

Adjust with shims

Pin

d

φ

φ75

φ74

Acceptable / Unacceptable

Replacement

Bushing (bucket cylinder)

e

φ

φ75

φ76.5

Acceptable / Unacceptable

Replacement

11

RSM-09-14-001E 9

Maintenance Standards

* Use the maintenance standard values table for judgment. (8) Arm and arm link installation section Part name

Measured Code dimensions (mm)

Standard value (mm)

Usage limit (mm)

Judgment

Action

Arm link

a

32

30

Acceptable / Unacceptable

－

Arm

b

296

294

Acceptable / Unacceptable

Replacement

Clearance

c

1.0 - 1.5

Adjust with shims

Acceptable / Unacceptable

Adjust with shims

Pin

d

φ

φ75

φ74

Acceptable / Unacceptable

Replacement

Bushing (arm)

e

φ

φ75

φ76.5

Acceptable / Unacceptable

Replacement

(9) Bucket and bucket link installation section Part name

Measured Code dimensions (mm)

Standard value (mm)

Usage limit (mm)

Judgment

Action

Bucket

a

307

313

Acceptable / Unacceptable

－

Bucket link

b

306

304

Acceptable / Unacceptable

Replacement

Clearance

c

1.0 - 3.5

Adjust with shims

Acceptable / Unacceptable

Adjust with shims

Pin

d

φ

φ80

φ79

Acceptable / Unacceptable

Replacement

Bushing (bucket link)

e

φ

φ80

φ81.5

Acceptable / Unacceptable

Replacement

RSM-09-14-001E

12 10

Maintenance Standards

* Use the maintenance standard values table for judgment. (10) Bucket link and bucket cylinder installation section Part name

Measured Code dimensions (mm)

Standard value (mm)

Usage limit (mm)

Judgment

Action

Arm link

a

32

30

Acceptable / Unacceptable -

Bucket link

b

296

294

Acceptable / Unacceptable Replacement

Clearance

c

1.0 - 1.5

Adjust with shims

Bucket link

d

φ

96

98

Acceptable / Unacceptable Replacement

Bucket cylinder (top section)

e

φ

95

93

Acceptable / Unacceptable Replacement

Clearance

f

-0.5 - 2.0

Adjust with shims

Pin

g

φ85

φ84

Acceptable / Unacceptable Replacement

Bushing (bucket link)

h

φ85

φ86.5

Acceptable / Unacceptable Replacement

Bushing (bucket cylinder)

i

φ85

φ86.5

Acceptable / Unacceptable Replacement

13

Acceptable / Unacceptable Adjust with shims

Acceptable / Unacceptable Adjust with shims

RSM-09-14-001E 11

Maintenance Standards

* Use the maintenance standard values table for judgment. (11) Bucket and arm installation section Part name

Measured Code dimensions (mm)

Standard value (mm)

Usage limit (mm)

Judgment

Action

Bucket

a

307

313

Acceptable / Unacceptable

－

Arm

b

306

304

Acceptable / Unacceptable

Replacement

Clearance

c

1.0 - 3.5

Adjust with shims

Acceptable / Unacceptable

Adjust with shims

Bushing (bucket)

d

16

8

Acceptable / Unacceptable

Replacement

Pin

e

φ80

φ79

Acceptable / Unacceptable

Replacement

Bushing (arm)

f

φ80

φ81.5

Acceptable / Unacceptable

Replacement

Bushing (bucket)

g

φ80

φ81.5

Acceptable / Unacceptable

Replacement

RSM-09-14-001E

14 12

Maintenance Standards Inspection Gauge 1. For Drive Sprocket

2. For Take-up Roller

15

RSM-09-14-001E 13

Maintenance Standards 3. For Upper Roller

RSM-09-14-001E

16 14

Maintenance Standards 4. For Lower Roller SH210-5

SH240-5

17

RSM-09-14-001E 15

Track Shoe Track Shoe

SH200-5

Track Shoe Removal and Installation of Shoe Assembly ・ When loosening the grease cylinder check valve, loosen it a little bit at a time. ・ The pressure inside the cylinder is very high, so there is the danger of grease being expelled and the plug flying off. The check valve adjustment procedure should not be done in front of Warning the check valve. ・ Do not get under the main unit when it is jacked up. Make sure to place the main unit on crossties to prevent falling. Caution ・ Make sure to stop the engine for loosening shoes and when removing master pins.

Items to prepare • • • • • • • • •

Wrenches (17 mm, 19 mm) Box wrench (19 mm) Hammer Wood planks, etc. Striking rod Crowbar Rag Lifting equipment (with the required breaking load) Crane (with the required lifting capacity)

1. Removal of Shoe Assembly [1] Rotate the shoe and align it so that the master pin (1) is next to the idler.

[2] Use a box wrench (19 mm) to loosen the check valve (2) to slowly release grease, and then loosen the shoe tension. Do not loosen the check valve all at once. Loosen it slowly while monitoring the grease output and shoe loosening. Use a rag to catch grease that trickles out of the check valve. If the check valve is loosened too much at this time, it may fly off. Be careful not to work in front of the check valve.

1

1

Master pin

2

Check valve

RSM-13-01-001E 1

Track Shoe [3] Use a wrench (17 mm) to remove the check valve stopper (4). • If the check valve is removed, it is easier to loosen the track shoe tension.

[4] Straighten out the S-pin (5) attached to the master pin by striking one side of it with a hammer, and use a crowbar, etc. to remove it.

[5] Use a hammer (6) and striking rod (7) to push the master pin (1) out.

RSM-13-01-001E

1

Master pin

3

Bolt

4

Stopper

5

S-pin

6

Hammer

7

Striking rod

2 2

Track Shoe [6] Remove the track shoe (8). At this time, place a wood plank (9) under the bottom track shoe so that it does not fall.

[7] Start the engine, raise the lower side frame of the track shoe removal side about 20 cm, slowly set the travel lever to backwards, and move the track shoe to remove it from the lower frame.

3

8

Track shoe

9

Wood plank

RSM-13-01-001E 3

Track Shoe 2. Installation of Shoe Assembly [1] Raise the lower side frame about 20 cm. Lift the track shoe (1) and align it with the sprocket (2). Pay attention to the backwards and forward direction of the track shoe.

[2] Slowly set the travel lever to forward and feed the track shoe to the take-up roller side as shown in the diagram. In the middle of this procedure when the track shoe passes the upper roller, use a crowbar, etc. to lift the track shoe while it is being fed. Lower the lower side frame after the shoe has reached position A shown in the diagram.

[3] Wrap the edge of the track shoe (4) onto the take-up roller (3). Place a wood plank (5) on the ground and lift the bottom-side link to align the position where the master pin is inserted.

RSM-13-01-001E

1

Track shoe

2

Sprocket

3

Take-up roller

4

Track shoe

5

Wood plank

4 4

Track Shoe [4] Insert the master pin (7). Insert the S-pin (6) and bend it so that it cannot slip out.

[5] Tighten the check valve (8). While monitoring the track shoe tension, inject grease into the grease cylinder.

[6] To adjust the track shoe tension, raise the lower side frame as shown in the diagram. Adjust the tension so that the distance indicated with A between the frame bottom (9) of the center area of lower side frame and the lowest hanging part of the top of the shoe plate (10) is 280 - 300 mm.

5

5

Wood plank

6

S-pin

7

Master pin

8

Check valve

9

Frame lower section

10

Topside of shoe plate

RSM-13-01-001E 5

Track Shoe Removal and Installation of Shoe Plate Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Box wrench (30 mm) • Grease • Rag • Cleaning fluid [1] Use a box wrench (30 mm) to remove the 4 shoe bolts (1), and then remove the shoe plate (2).

RSM-13-01-001E

1

Shoe bolt

2

Shoe plate

6 6

Travel Unit Travel Unit

SH200-5

Travel Unit Removal and Installation of Travel Motor Warning

・ When loosening the check valve, loosen it a little at a time and stop when any grease appears. (The pressure inside the cylinder is very high, so there is the danger of grease being expelled and the plug flying off if the check valve is loosened too much.）

・ Before removing the shoes, be sure to bleed off any air in the hydraulic circuits. Caution ・ Be sure to inspect the wire rope and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare • Box wrenches (19 mm, 24 mm) • Wrenches (17 mm, 19 mm, 27 mm, 36 mm) • Hammer (to remove the master pin) • Striking jig (to remove the master pin) • Crane (with the required lifting capacity) • Wire rope (with the required breaking load) • Loctite #262 • Wood planks, etc. • Rag • Cleaning fluid

1. Removal of Travel Motor [1] Allow the bucket (1) to touch the ground so as to elevate the side with the shoe (2) to be removed as in the diagram on the right.

7

1

Bucket

2

Shoe

RSM-13-02-001E 1

Travel Unit [2] Slowly rotate the shoe so that the shoe joint section (3) is aligned as in the diagram on the right. [3] Place wood planks (4) under the shoe and return the bucket to its original position. [4] Perform air bleeding for the hydraulic line. For details, see Air Bleed Procedure.

[5] Use a box wrench (19 mm) to rotate the grease cylinder check valve (5) and loosen the shoe tension. • Grease will flow out, so have rags ready. If the check valve is loosened too much at this time, it may fly off. Be careful not to work in front of the check valve.

[6] Pull out the S-pin (6) from the rear of the joint section.

RSM-13-02-001E

3

Shoe joint section

4

Wood plank

5

Check valve

6

S-pin

8 2

Travel Unit [7] Place a striking jig (9) against the master pin (7) and hit it with a hammer (8) to push the master pin out.

[8] Open the shoe (2) to the rear.

[9] Use a wrench (19 mm) to remove the 4 bolts (10), and then remove the cover (11).

9

2

Shoe

7

Master pin

8

Hammer

9

Striking jig

10

Bolt

11

Cover

RSM-13-02-001E 3

Travel Unit [10] Use wrenches (27 mm for drain hose, 36 mm for high-pressure hose) to remove the drain hose (13) and 3 high-pressure hoses (12). • Be sure to use plugs on the removed drain and high-pressure hoses.

[11] Use a wrench (17 mm) to remove the pilot hose (15) and elbow joint (14) as in the diagram.

[12] Attach the wire rope (17) to the travel motor (16) as in the diagram. Adjust the wire rope so that it is located at the center of mass and lift it with the crane so that it is slightly tensed.

RSM-13-02-001E

12

High-pressure hose

13

Drain hose

14

Elbow joint

15

Pilot hose

16

Travel motor

17

Wire rope

10 4

Travel Unit [13] Use a box wrench (24 mm) to remove all 30 bolts (18).

[14] Remove the travel motor (16).

11

16

Travel motor

18

Bolt

RSM-13-02-001E 5

Travel Unit 2. Installation of Travel Motor [1] Attach the travel motor to the lower frame as in the diagram. Be careful of the installation angles.

[2] Apply Loctite #262 to the installation bolt (2) threaded sections and temporarily tighten them. Tighten top and bottom alternately to the specified torque so that an even tightening force acts on opposing corners as shown in the diagram below.

[3] Use a wrench (17 mm) to remove the elbow joint (3) and pilot hose (4) and as in the diagram.

RSM-13-02-001E

1

Travel motor

2

Bolt

3

Elbow joint

4

Pilot hose

12 6

Travel Unit [4] Use wrenches (27 mm for drain hose, 36 mm for high-pressure hose) to install the drain hose (6) and high-pressure hose (5).

[5] Use a wrench (19 mm) to remove the 4 bolts (7), and then install the cover (8).

[6] Wrap the shoe (9).

13

5

Main hose

6

Drain hose

7

Bolt

8

Cover

9

Shoe

RSM-13-02-001E 7

Travel Unit [7] Insert the master pin (11). Insert the S-pin (10) and bend it so that it cannot slip out.

[8] Tighten the check valve (12). While monitoring the track shoe tension, inject grease into the grease cylinder.

[9] To adjust the track shoe tension, raise the lower side frame as shown in the diagram. Place a wood plank (13) under the lower frame to prevent falling. Adjust the tension so that the distance indicated with A between the frame bottom (14) of the center area of the lower side frame and the lowest hanging part of the top of the shoe plate (15) is 280 - 300 mm.

RSM-13-02-001E

10

S-pin

11

Master pin

12

Check valve

13

Wood plank

14

Frame lower section

15

Topside of shoe plate

14 8

Travel Unit Assembly and Disassembly of Travel Motor 1. To Ensure Safe Use

Please follow these precautions. When transporting the motor with a crane, do not use the tap on top of the base plate to suspend the motor. The motor falling may cause personal injury or damage the machine.

When disassembling the motor for transport, installation or maintenance inspection, make sure to wear a helmet, protective shoes, gloves and safety goggles. When there is little hydraulic oil in the hydraulic tank and the oil surface is near the inlet port or there is no hydraulic oil, do not run the motor. The motor will take in air and may run out of control, which could cause personal injury or damage the machine.

Warning

Do not operate the motor when there is no hydraulic oil in the lines. The motor will take in air and may run out of control, which could cause personal injury or damage the machine. For 1 hr. after operating the motor, do not remove the plugs for the oil fill, oil drain and oil check ports for reduction gear lubrication oil. Hot lubricating oil may spray out and cause burns. Hot lubricating oil spraying out and entering the eyes may cause blindness.

15

RSM-13-02-001E 9

Travel Unit Please follow these precautions. When pressure is applied inside the lines, do not remove the motor pressure detection port plug or the drain port plug. Pressurized oil spraying out and entering the eyes may cause blindness. When removing plugs, always let out the pressure inside the lines.

Do not remove the reduction gear cover with the motor left installed in the machine main unit. Fingers or hands may get caught in gears and this could result in injury.

Warning

Do not disassemble the motor with the motor left installed in the machine main unit. The machine may run out of control, which could result in personal injury. For motor disassembly, be sure to remove the motor from the machine main unit.

Do not remove the spool of the double counter balance valve with the motor left installed in the machine main unit. The motor may run out of control, which could cause personal injury or damage the machine.

RSM-13-02-001E

16 10

Travel Unit Please follow these precautions. Do not tamper with the relief valve adjuster. The set pressure of the relief valve may change and cause the motor to run out of control, which could cause personal injury or damage the machine.

Warning

17

RSM-13-02-001E 11

Travel Unit

Please follow these precautions. Do not operate the motor at settings beyond its specified range. This could cause damage to the machine. Do not touch the motor for 1 hr. after operation. The surface of the motor is very hot due to operation. Touching the surface could cause burns.

Do not suddenly remove the plugs for the oil fill, oil drain and oil check ports on the reduction gear. A plug may fly off and cause injury. Align the port positions with the specified positions and slowly loosen the plug for each port, starting with oil fill port on top, to release air inside the reduction gear.

Caution

When handling lines, make sure to confirm the input and output flow of the hydraulic oil and the motor rotation direction. It is extremely dangerous if the motor rotates in the opposite direction.

Do not use hydraulic oil other than the type specified. Doing so could cause damage to the machine. RSM-13-02-001E

18 12

Travel Unit Please follow these precautions. Do not use reduction gear lubricating oil other than the type specified. Doing so could cause damage to the machine. Do not let foreign matter into the motor. This will damage the machine. Caution

Perform motor maintenance and inspection after the motor has cooled down.

19

RSM-13-02-001E 13

Travel Unit 2. Tools for Assembly and Disassembly Use the tools indicated below for assembly and disassembly of the motor. (1)Standard tools The necessary standard tools for assembly and disassembly of this motor are indicated in Table 1. Table 1. Standard tools for assembly and disassembly No.

Tool name

Standardized number Manufacturer name

Type and dimensions

Part used with

1

Nominal size 60

1-2-6-6, 1-2-17, 1-2-18, 1-2-19

2

Nominal size 120

1-2-8

3

Nominal size 230

1-2-6-5

4

Nominal size 450

1-2-20

Nominal size 900

24, 28

6

Nominal size 1800

1-2-2-4, 1-2-6-3, 1-2-11, 1-2-14, 29

7

Nominal size 2800

11

8

Nominal size 4200

1-2-7

9

Nominal size 5600

8, 14

11

Bolt width 2.5 mm

1-2-6-6, 1-2-17, 1-2-18, 1-2-19

12

Bolt width 4 mm

1-2-8

13

Bolt width 6 mm

1-2-20

5

10

14

Preset-type torque wrench

JIS B4650

Rachet handle for socket wrench JIS B4641

Hexagon bit for socket wrench

Bolt width 8 mm

28

15

Bolt width 10mm

1-2-6-3, 1-2-11

16

Bolt width 12 mm

11, 29

17

Bolt width 14 mm

1-2-2-4, 1-2-6-5

18

Size T50

24

Size T90

8, 14

Bolt width 10 mm

1-2-14

Bolt width 27 mm

1-2-7

22

Bolt width 2.5 mm

1-2-6-6, 1-2-17, 1-2-18, 1-2-19

23

Bolt width 4 mm

1-2-8

24

Bolt width 6 mm

1-2-20

Bolt width 8 mm

28

26

Bolt width 10 mm

1-2-6-3, 1-2-11

27

Bolt width 12 mm

11, 29

28

Bolt width 14 mm

1-2-2-4, 1-2-6-5

Bolt width 10 mm

1-2-14

19 20 21

25

29

Torx T-shaped bit

JASO F116-89

Socket for socket wrench

JIS B4636

Hexagon bar wrench

JIS B4648

Wrench

JIS B4630

31

Longnose pliers

JIS B4631

32

Snap ring pliers

33

Flathead screwdriver

34

Plastic hammer

35

Punch

Length of about 10 mm

36

Press

200 kgf or higher

37

Crane

For 400 kg

30

38 39 40

Bolt width 27 mm

1-2-7 1-2-7

S-2 type

1-4-5

JIS B4609

6×100

2, 1-27, 1-2, 1-21

OF-05

Nominal size #3

For M20

Eyebolt

For M12

1-2

Chain string (wire)

RSM-13-02-001E

20 14

Travel Unit (2)Secondary materials The necessary secondary materials for disassembly and assembly of this motor are indicated in Table 2. Table 2. Secondary materials No.

Secondary materials name

Standardized number Manufacturer name

1

Seal tape

2

Adhesive

Loctite

3

Gear oil

GL-4#90 equivalent

4

Hydraulic oil

ISO VG46 equivalent

5

Grease

Lithium-series

6

White kerosene

No.2 equivalent oil

7

Liquid packing

ThreeBond

8

Lapping plate

Type and dimensions

Part used with 1-2-8

271

8, 14 1-1, 1-7, 1-6 1-2-1, 1-2-2, 1-2-9, 1-4-1, 1-4-2, 1-21, 1-4-4, 1-4-3, 1-5, 1-4-2, 1-6 1-2-2-5, 1-2-6-2, 1-2-6-4, 1-2-12, 1-2-21, 1-2-24, 1-16, 1-17, 1-23, 1-12, 1-15, 1-21

1211

4, 27

For sliding surface repair 1-4-1, 1-4-2, 1-5, 1-21 For sliding surface repair

9

Lapping agent

10

Copper plate

#1000

11

Tube brush

For cleaning

12

Bamboo brush

For cleaning

13

Oil pan

For receiving oil

14

Plastic container

For grease

15

Rag

1-2-1, 1-4-1

(3)Special tools The necessary special tools for assembly and disassembly of this motor are indicated in Table 3. Table 3. Special tools No.

Tool name

Standardized number Manufacturer name

Type and dimensions

Part used with

1

Pulley remover

1-8, 1-9

2

Bearing press-fit jig

1-8

3

Bearing press-fit jig

1-9

4

Floating seal mounting jig

2

5

Rod

3

6

Angular bearing press-fit jig

3

7

Shim thickness adjustment jig

5

8

Rod

1-2-2

10

Thrust plate selection jig

26

11

Oil seal press-fit jig

1-12

12

Brake piston positioning jig

1-15

13

Snap ring removal jig

1-4-5

14

Poppet seat removal jig

1-2-7-3

21

RSM-13-02-001E 15

Travel Unit (4)Measurement device The necessary measurement devices for assembly of this motor are indicated in Table 4. Table 4. Measurement devices No.

Tool name

Standardized number Manufacturer name

Type and dimensions

Part used with

1

Dial gauge

JIS B7503

5, 26

2

Micrometer caliper

JIS B7502

5, 26

RSM-13-02-001E

22 16

Travel Unit 3. Disassembly of Motor (1)Precautions before motor disassembly Begin motor disassembly only after thoroughly reading the precautions below. [1] When performing disassembly, always wear protective devices such as a helmet, goggles and safety shoes. [2] Use the specified tools when performing disassembly. [3] Remove all lines connected to the motor and remove the motor from the mother machine only after making sure that the machine is on a level surface and there are no external forces acting on rotating parts so that the mother machine does not operate uncontrollably when the motor is removed. [4] To prevent foreign matter from entering the lines and motor when removing the motor from the mother machine, sufficiently clean off mud and dirt adhered around the motor before removing lines connected to the motor. [5] When removing lines connected to the motor, hydraulic oil from inside the lines will spray out. For this reason, remove these lines only after removing pressure from inside the lines and preparing an oil pan. To prevent injuries due to the motor falling when transporting it by lifting the motor with a crane, lift the machine with the eyebolts mounted in the positions indicated in the diagram below. [6] The motor is filled with hydraulic oil. Before disassembling the motor, prepare an oil pan and drain the hydraulic oil from the motor. [7] To prevent injuries during disassembly, prepare a waist-high, stable work platform to perform work on. [8] The motor comprises high-precision parts. For this reason, foreign matter adhering to parts can be damaging. Motor disassembly should be done in an inside space without dust, and mud and dirt should be prevented from adhering to parts. [9] The motor comprises high-precision parts. For this reason, dents and scratching on part surfaces can be damaging. Be very careful when handling parts during disassembly and do not create any dents or scratching. [10] To prevent personal injury and damage to parts during disassembly, do not force disassembly of parts which are especially tight to disassemble.

Motor lifting positions

23

RSM-13-02-001E 17

Travel Unit (2)Tightening torque Table 5 indicates tightening torque for each connection section. Table 5. Tightening torque for each section Reference number

Part name

Screw size

Bolt width

Tightening torque

1-2-2-4

Plug

M24 x 1.5

14

137 ± 10 N•m

1-2-6-3

Hexagon socket head bolt

M12 x 1.75 x 40L

10

108 ± 10 N•m

1-2-6-5

Plug

G1/8

14

20.6 ± 1.0 N•m

1-2-6-6

Orifice

M5 x 0.8 x 5L

2.5

2.45 ± 0.49 N•m

1-2-7

Relief valve assembly

1-5/16 12UNF

27

373 ± 20 N•m

1-2-8

Plug

NPTF 1/16

4

9.8 ± 1.0 N•m

1-2-11

Plug

G1/2

10

118 ± 6 N•m

1-2-14

Plug

G1/2

10

118 ± 6 N•m

1-2-17

Orifice

M5 x 0.8 x 5L

2.5

2.45 ± 0.49 N•m

1-2-18

Orifice

M5 x 0.8 x 5L

2.5

2.45 ± 0.49 N•m

1-2-19

Orifice

M5 x 0.8 x 5L

2.5

2.45 ± 0.49 N•m

1-2-20

Plug

G1/4

6

36.8 ± 2.5 N•m

1-11

Hexagon socket head bolt

M14 x 2.0 x 35L

12

205 ± 10 N•m

8

Bolt

M20 x 2.0 x 70L

Torx T90

539 ± 28 N•m

14

Bolt

M20 x 2.0 x 130L

Torx T90

539 ± 28 N•m

24

Screw

M10 x 1.5

Torx T50

58.8 ± 4.9N•m

28

Hexagon socket head bolt

M10 x 1.5 x 16L

8

73.4 ± 3.63 N•m

29

Plug

G3/4

12

157 ± 8 N•m

RSM-13-02-001E

24 18

Travel Unit (3)Disassembly procedure Perform disassembly by observing the precautions listed in Section 1 and following the procedure indicated below. [1] Removal of cap assembly Secure the motor on top of the stable work platform, loosen the 8 hexagon socket head bolts (1-2-6-4), and remove the 2 cap assemblies (1-2-6). Next, remove the spring seats (1-2-5), springs (1-2-4), and spring seats (1-2-3). Cautions: The cap assemblies are pushed out by the spring. For this reason, observe the following precautions when working. a. Loosen the hexagon socket head bolts evenly. b. Loosen the hexagon socket head bolts while pressing down the cap assemblies. [2] Removal of plunger assembly Lightly press the end of the plunger assembly (1-2-2), and eject one part of the plunger assembly out from the base plate (1-2-1). Next, grasp the end of the plunger assembly by hand and remove the plunger assembly from the base plate while rotating it. Cautions: The plunger assembly and base plate are fit together with a very small gap. For this reason, observe the following precautions when working. a. Do not try to force out the plunger with extreme force if the plunger assembly becomes stuck when it is being removed. If it is forced out, this could scratch the inner diameter surface of the base plate hole or the outer diameter surface of the plunger assembly. If the plunger assembly becomes stuck, lightly hit the end surface of it with a plastic hammer to insert it once into the base plate. After this, check that the plunger assembly moves smoothly and remove it again while rotating it. b. Do not perform disassembly of the plunger assembly if it is not necessary. Disassembly can cause scratching on the outside diameter surface of the plunger assembly. When disassembly is necessary, contact our company.

25

RSM-13-02-001E 19

Travel Unit [3] Removal of relief valve assembly Loosen the plug (1-2-7-6) to remove the relief valve assemblies (1-2-7). At this time, each poppet seat (1-2-7-3) remains in the base plate (1-2-1). Cautions: The relief valve assemblies are at a set pressure. The motor driving force and braking force are both determined by this set pressure. For this reason, do not perform the following actions. a. Loosen the nut (1-2-7-16), and do not tamper with the set screw (1-2-7-15). If this part is tampered with, the set pressure of the relief valve will change and the machine will no longer display prescribed capabilities. b. Do not perform disassembly of the relief valve assemblies. The set pressure will change and the machine will no longer display prescribed capabilities. [4] Poppet seat removal Use the poppet seat removal jig to remove each poppet seat (1-2-7-3) from the base plate (1-2-1). Caution: Do not perform disassembly if it is not necessary.

RSM-13-02-001E

26 20

Travel Unit [5] Removal of valve assembly Loosen the plugs (1-2-11) and (1-2-14) and remove the plugs and spring (1-2-10). Lightly press the end of the valve assembly (1-2-9), and eject one part of the valve assembly out from the base plate (1-2-1). Next, grasp the end of the valve assembly by hand and remove the valve assembly from the base plate while rotating it. Cautions: The valve assembly and base plate are fit together with a very small gap. For this reason, observe the following precautions when working. a. Do not try to force out the plunger with extreme force if the valve assembly becomes stuck when it is being removed. If it is forced out, this could scratch the inner diameter surface of the base plate hole or the outer diameter surface of the valve assembly. If the valve assembly becomes stuck, lightly hit the end surface of it with a plastic hammer to insert it once again into the base plate. After this, check that the valve assembly moves smoothly and remove it again while rotating it. b. Do not perform disassembly of the valve assembly if it is not necessary. When disassembly is necessary, contact our company. [6] Do not remove the plugs (1-2-8) if it is not necessary. Each orifice (1-2-22) (1-2-23) (1-2-19) is caulked to prevent loosening. Do not perform disassembly.

27

RSM-13-02-001E 21

Travel Unit [7] Removal of base plate Loosen the hexagon socket head bolts (111) and remove the base plate (1-2-1). Cautions: When removing the base plate, observe the following precautions. a. The base plate is pushed upwards by the springs (1-18). For this reason, loosen the hexagon socket head bolts evenly when loosening. b. Positioning knock pins (1-19) are mounted between the base plate and main unit. For this reason, pull the base plate (1-2-1) straight off in alignment with the center axis of the motor when removing it so that it does not become stuck with the knock pins. If it becomes stuck, lightly strike the base plate with a plastic hammer to put the knock pins in the correct position, and then remove the base plate. c. When removing the base plate, the valve plate (1-21) is attached to the base plate. The valve plate sliding surface is easily scratched, so be careful not to let the valve plate fall. [8] Removal of valve plate Use a flathead screwdriver to remove the valve plate (1-21) from the base plate (12-1). Caution: When removing the valve plate, observe the following precaution. a. The valve plate sliding surface is easily scratched. If the sliding surface is scratched, prescribed capabilities will disappear so prevent scratching from occurring.

RSM-13-02-001E

28 22

Travel Unit [9] Removal of O-ring, knock pin and spring Remove the O-rings (1-22) and (1-23), knock pins (1-19), and springs (1-18).

[10] Removal of brake piston Attach a pressured air nozzle to the flange (1-1) oil path for the parking brake, and inject compressed air to the parking brake cylinder chamber to raise the brake piston (1-15) and remove it. After removing the brake piston, remove the disk plates (1-13) and friction plates (1-14), and remove the O-rings (1-16) and (1-17) from the brake piston.

Cautions: When removing the brake piston, observe the following precautions. a. When injecting compressed air from the flange oil path for the parking brake, do not let any compressed air leak out. b. When injecting compressed air from the flange oil path for the parking brake, the brake piston may fly off if the pressure of the compressed air is high, and this may cause injury. For this reason, set the air pressure at 0.29 MPa or below, and hold down the brake piston while performing work so that it does not fly off.

29

RSM-13-02-001E 23

Travel Unit [11] Removal of cylinder block assembly Remove the cylinder block assembly (1-4) from the flange (1-1). Cautions: When removing the cylinder block assembly, observe the following precautions. a. Grasp the cylinder block assembly with both hands and lightly rotate it left and right to slowly remove it. b. Be careful not to scratch the surface of the cylinder block (1-4-1) that slides against the valve plate (1-21). If this surface is scratched, the machine will no longer display prescribed capabilities. c. Be careful not to scratch the piston assembly (1-4-2) shoe sliding surfaces. If this surface is scratched, the machine will no longer display prescribed capabilities. [12] Disassembly of cylinder block assembly 1) Mark the piston assemblies (1-4-2) and cylinder block (1-4-1) with permanent ink so that parts can be reassembled in the exact same configuration, and remove the piston assemblies and retainer plate (1-4-3) from the cylinder block.

2) Mark the piston assemblies (1-4-2) and retainer plate (1-4-3) with permanent ink so that parts can be reassembled in the exact same configuration, and remove the piston assemblies from the retainer plate.

RSM-13-02-001E

30 24

Travel Unit 3) Remove the retainer holder (1-4-4) from the cylinder block (1-4-1) and remove the pins (1-4-9) from the cylinder block.

4) Secure the cylinder block (1-4-1) on the manual press platform with the sliding surface facing up, remove the snap ring (1-4-5), press the collar (1-4-8) with the removal jig to make the spring (1-4-7) bend, and use snap ring pliers to remove the snap ring. Caution: When removing the snap ring, observe the following precaution. a. The snap ring is stiff and may come off from the snap ring pliers when the snap ring is being removed, which could cause injury. When removing the snap ring, make sure to use a disassembly jig and check that the nails of the snap ring pliers are in the snap ring hole before removal. 5) Remove the collar (1-4-8), spring (1-47), and spring seat (1-4-6) from the cylinder block (1-4-1).

31

RSM-13-02-001E 25

Travel Unit [13] Removal of swash plate Remove the swash plate (1-5) from the flange (1-1). Cautions: When removing the swash plate, observe the following precautions. a. Be careful not to scratch the swash plate sliding surface. If this surface is scratched, the machine will no longer display prescribed capabilities. b. Piston assemblies (1-7) and steel balls (1-6) may be attached to the swash plate. When these are attached, be careful not to let them fall. [14] Removal of piston assembly and steel ball Remove the piston assemblies (1-7) from the flange (1-1) and remove the springs (1-20). Remove the steel balls (1-6) from the flange. Caution: The steel balls are difficult to remove, so use the following procedure to do this. a. With the steel balls mounted on the flange, use white kerosene or thinner to degrease. b. Use a magnet to remove the steel balls from the flange. [15] Removal of shaft Remove the shaft (1-3) and ball bearing (1-8) from the flange (1-1). Cautions: When removing the shaft, observe the following precautions. a. Be careful not to scratch the spines on the shaft. b. Be careful not to scratch the sliding section of the shaft oil seal (1-12). Scratching this surface may cause oil leaking.

RSM-13-02-001E

32 26

Travel Unit [16] Draining reduction gear lubricating oil Before disassembling the reduction gear section, use the tap for securing the flange (1-1) and mount two eyebolts in opposing positions to lift the reduction gear with a crane. Remove the plugs (29) in the 2 locations and drain the reduction gear lubricating oil. Cautions: a. Prepare an oil pan before performing work. b. Do not lift to too high position when lifting with the crane. Perform work with the reduction gear at the lowest possible position (at about knee height). [17] Removal of cover Loosen and remove the hexagon socket head bolts (28). After this, remove the cover (27). Cautions: Use the following procedure when removing the cover. a. Liquid packing has been applied between the cover and housing (4). For this reason, it is difficult to remove the cover. Loosen the socket head bolt and strike the top and side of the cover with a plastic hammer after removing the bolt. b. Insert a flathead screwdriver in the gap between the cover and housing and remove the cover. [18] Removal of thrust plate Remove the thrust plate (26) from the thrust plate (23) top surface.

33

RSM-13-02-001E 27

Travel Unit [19] Removal of drive gear Remove the driver gear (25).

[20] Removal of 1st stage holder assembly Remove the 1st stage holder assembly comprising the holder B (17), planetary gears B (21), needle bearings (20), inner races (19), thrust plates (18), thrust plates (22), thrust plate (23), and screws (24). Caution: When removing the 1st stage holder assembly, observe the following precaution. When removing the assembly, be careful of fingers getting caught. [21] Disassembly of 1st stage holder assembly Secure the 1st stage holder assembly with a vice and warm the screws (24) with a dryer to loosen them. Remove the screws, thrust plate (23), thrust plates (22), planetary gears B (21), needle bearings (20), inner races (19) and thrust plates (18) from holder B (17), in that order. Cautions: When loosening the screws, observe the following precautions. Loctite has been applied to the screws. For this reason, they do not loosen easily. If they are scratched due to being forcibly loosened, they cannot be used again. Before loosening, warm the screws sufficiently with a dryer.

RSM-13-02-001E

34 28

Travel Unit [22] Removal of sun gear C Remove sun gear C (15).

[23] Removal of planetary gear C Secure the flange (1-1) and loosen the bolts (14) to remove them. Next, remove the thrust plates (13), planetary gears C (12), needle bearings (11), inner races (10), and thrust plates (9), in that order. Cautions: When loosening bolts, observe the following precautions. a. Loctite has been applied to the bolts to prevent loosening. For this reason, securely fix the flanges. b. When loosening bolts, use a tool such as a steel pipe that is long enough to reach the bolts. Straining excessively may cause back pain or injury.

35

RSM-13-02-001E 29

Travel Unit [24] Disassembly of holder C Secure the flange (1-1) and loosen and remove the bolts (8). Holder C (6) is secured to the flange with the pins (31). Mount the removal jig from the motor side and use the press to remove holder C. Cautions: When loosening bolts, observe the following precautions. a. Loctite has been applied to the bolts to prevent loosening. For this reason, securely fix the flanges. b. When loosening bolts, use a tool such as a steel pipe to reach the bolts. Straining excessively may cause back pain or injury.

[25] Separation of flange and housing Mount the jig on the outer circumference brim end surface of the housing (4), and then press the flange (1-1) with the press to separate the housing and flange.

RSM-13-02-001E

36 30

Travel Unit [26] Removal of floating seal Raise the outer circumference of the floating seals (2) with a flathead screwdriver and remove the floating seals.

[27] Parts storage This completes the entire disassembly. When storing disassembled parts, place parts in plastic bags in a cool, dark and dry location after cleaning the parts and applying anti-rust oil. If parts are stored in a hot, moist location, rust will develop even if anti-rust oil is applied. Also store them in a way so that dust does not collect on them.

37

RSM-13-02-001E 31

Travel Unit 4. Maintenance Standards (1)Motor parts maintenance standards Table 6 shows maintenance standards for motor parts. Check each part according to the motor parts maintenance standards in Table 6. When a permissible limit has been exceeded or is near being exceeded, perform part repair or replacement according to repair and solution procedures. Table 6. Motor parts maintenance standards Applicable part

Inspection and measurement location

Piston assemblies 1. Shoe sliding sur(1-4-2) faces

Permissible limit value

0.8 a degree of roughness Lap the shoe sliding surface(s) (#1000) Or the surface is rough and If the scratching cannot be removed, there is scratching of at least replace the cylinder block assembly (4). 0.02 mm deep.

2. Piston outer circum- 1.2 a degree of roughness Or the surface is rough and ferences there is scratching at least 0.02 mm deep. 3. Piston outer diameters and cylinder block (4-1) bore inner diameters

Repair, solution procedure

Replace the cylinder block assembly (4).

Gap 0.060 mm

4. Shoe bore backlash 0.4 mm of backlash Cylinder block (1-4-1)

1. Surface that slides against the valve plate

0.8 a degree of roughness Or the surface is rough and there is scratching at least 0.02 mm deep.

2. Bore inner diameter 1.6 a degree of roughness Or the surface is rough and there is scratching at least 0.02 mm deep.

Lap the sliding surface (#1000) If the scratching cannot be removed, replace the cylinder block assembly (4). Replace the cylinder block assembly (4).

3. Bore inner diameter Gap 0.060 mm and piston assembly (4-2) outer diameter Cylinder block (1-4-1)

3. Shaft bonding sec- Diameter between parts tion spline 38.749 mm Diameter of measurement pin φ3.333 (V1=2.80) mm Or breaking damage is occurring.

Valve plate (1-21)

1. Sliding surface

Lap the sliding surface (#1000) 0.8 a degree of roughness If the scratching cannot be removed, There is scratching at least replace the valve plate (22). 0.02 mm deep on the sliding surface. Or seizing is occurring. There is abnormal wear on the sliding surface.

Retainer plate (1-4-3) Retainer holder (1-4-4)

1. Sliding surface

0.8 a degree of roughness There is scratching at least 0.02 mm deep on the sliding surface. Or seizing is occurring.

Swash plate (1-5)

1. Sliding surface

0.8 a degree of roughness Lap the sliding surface (#1000) There is abnormal wear or If the scratching cannot be removed, scratching least 0.02 mm deep replace the valve plate (22). on the sliding surface.

2. Steel ball mounting section spherical hole

1.6 a degree of roughness There is scratching at least 0.02 mm deep on the ball surface or the surface is rough.

3. Steel ball mounting section spherical hole

Ball depth 14.5 mm

RSM-13-02-001E

Replace the cylinder block assembly (4).

Replace the retainer plate and retainer holder.

Replace the swash plate.

38 32

Travel Unit Applicable part Shafts (1-3)

Inspection and measurement location

Permissible limit value

1. Oil seal sliding sur- 1.6 a degree of roughness face outer diameters Aside from the oil seal lip sliding imprint, there is scratching at least 0.02 mm deep or the surface is rough.

Repair, solution procedure Replace the shaft(s).

2. Cylinder block bond- Over-pin diameter ing section spines 47.380 mm Diameter of measurement pin φ3.00 mm Or breaking damage is occurring.

Break piston (1-15)

3. Drive gear bonding section spines

Diameter between parts 30.498 mm Diameter of measurement pin φ3.33 mm Or breaking damage is occurring.

1. Appearance dimensions

Height 38.2 mm

2. Sliding surface

2.5 a degree of roughness

3. Appearance

There is scratching at least 0.02 mm deep or the surface is rough.

Disk plates (1-13) 1. Appearance dimensions

Ball bearing (1-8) Ball bearing (1-9)

Thickness 3.2 mm

2. Appearance

There is deep scratching or friction material is peeling off.

1. Rotation surface

Flaking or pressure imprinting is occurring.

2. Operation

There are rotation abnormalities (abnormal noises, rotation unevenness)

Piston assemblies 1. Shoe sliding sur(1-7) faces

1.6 a degree of roughness Or the surface is rough and there is scratching at least 0.02 mm deep.

2. Piston outer circum- 1.2 a degree of roughness ferences Or the surface is rough and there is scratching at least 0.02 mm deep. 3. Piston outer diameters and flange holder (1-1) inner diameters

Replace the brake piston.

Replace the disk plate(s).

Replace the ball bearing.

Lap the shoe sliding surface(s) (#1000) If the scratching cannot be removed, replace using the flange holder kit. Replace using the flange holder kit.

Gap 0.040 mm

4. Shoe bore backlash 1.0 mm of backlash Plunger assembly 1. Plunger outer diam- 0.8 a degree of roughness (1-2-2) eter There is scratching at least 0.02 mm deep or the surface is rough.

Replace using the base plate kit.

2. Plunger outer diam- Gap 0.060 mm eter and base plate inner diameter

39

RSM-13-02-001E 33

Travel Unit Applicable part

Inspection and measurement location

Base plate (1-2-1) 1. Plunger assembly (2-2) mounting hole

Permissible limit value 0.8 a degree of roughness There is scratching at least 0.02 mm deep or the surface is rough.

2. Base plate inner diameter and plunger outer diameter

Gap 0.060

3. Spool assembly (211) mounting hole

0.8 a degree of roughness There is scratching at least 0.02 mm deep or the surface is rough.

4. Base plate inner diameter and spool outer diameter

Gap 0.060 mm

5. Relief valve assembly free piston sliding and seat sections

There is scratching at least 0.02 mm deep or the surface is rough.

1. Spool outer diameter

0.8 a degree of roughness There is scratching at least 0.02 mm deep or the surface is rough.

2. Spool outer diameter and base plate inner diameter

Gap 0.060 mm

Free piston (1-2-7-9)

1. Surface that slides against the base plate and seat section

There is scratching at least 0.02 mm deep or the surface is rough.

Housing (1-2-7-1)

1.Surface that slides against free piston (outer diameter)

There is scratching at least 0.02 mm deep or the surface is rough.

Spring (1-4-7)

1.Appearance dimensions

Free length 61.0 mm

2.Appearance

There is deformation and scratching on the coil surface.

1.Appearance dimensions

Free length 39.0 mm

2.Appearance

There is deformation and scratching on the coil surface.

1.Appearance dimensions

Free length 41.5 mm

2.Appearance

There is deformation and scratching on the coil surface.

1.Appearance dimensions

Free length 48.5 mm

2.Appearance

There is deformation and scratching on the coil surface.

1.Appearance dimensions

Free length 28.3 mm

2.Appearance

There is deformation and scratching on the coil surface.

Spool assembly (1-2-9)

Springs (1-18)

Springs (1-20)

Springs (1-2-4)

Spring (1-2-10)

Each O-ring and oil seal

RSM-13-02-001E

During disassembly

Repair, solution procedure Replace using the base plate kit.

Replace using the base plate kit.

Replace using the relief valve assembly.

Replace each O-ring and oil seal.

40 34

Travel Unit (2)Reduction gear parts maintenance standards Table 7 shows maintenance standards for reduction gear parts. Check each part according to the reduction gear parts maintenance standards in Table 7. When a permissible limit has been exceeded or is near being exceeded, perform part repair or replacement according to repair and solution procedures. Table 7. Reduction gear maintenance standards Applicable part Planetary gears (21)

Inspection and measurement location

Permissible limit value

Repair, solution procedure

Tooth thicknesses

Across 6 teeth 66.649 mm

Tooth surfaces

There is pitching on 10 % or more of the tooth surface or breaking damage is occurring.

Inner diameters

Flaking is occurring on the inner diameter surface.

Needle bearings (20)

Roller rotation surfaces

Flaking is occurring on the surface.

Inner races (19)

Outer diameter surfaces

Flaking is occurring on the surface.

Drive gear (25)

Tooth thickness

Across 3 teeth 29.908 mm

Tooth surface

There is pitching on 10 % or more of the tooth surface or breaking damage is occurring.

Spline section

Over-pin diameter 38.989 mm Diameter of measurement pin φ3.00 mm Or breaking damage is occurring.

If replacing the drive gear(s), inspect the shaft at the same time.

Holder (17)

Tooth thickness of internal tooth

Diameter between parts 66.742 mm Diameter of measurement pin φ7.00 mm Or breaking damage is occurring.

Replace the holder.

Sun gear (I5)

Tooth thickness

Across 4 teeth 41.371 mm

Replace the sun gear.

Tooth surface

There is pitching on 10 % or more of the tooth surface or breaking damage is occurring.

Tooth thicknesses

Across 6 teeth 65.662 mm

Tooth surfaces

There is pitching on 10 % or more of the tooth surface or breaking damage is occurring.

Inner diameters

Flaking is occurring on the inner diameter surface.

Needle bearings (11)

Roller rotation surfaces

Flaking is occurring on the surface.

Inner races (10)

Outer diameter surface Flaking is occurring on the surface.

Planetary gears (12)

41

Replace the planetary gear(s).

Replace the planetary gear(s), needle bearing(s) and inner race(s).

Replace the drive gear.

Replace the planetary gear(s).

Replace the planetary gear(s), needle bearing(s) and inner race(s).

RSM-13-02-001E 35

Travel Unit Applicable part Housing (4)

Inspection and measurement location

Permissible limit value

Tooth thickness

Diameter between parts 330.449 mm Diameter of measurement pin φ7.000 mm

Tooth surface

There is pitching on 10 % or more of the tooth surface or breaking damage is occurring.

Shim (5)

Repair, solution procedure Replace the housing.

During disassembly

Replace the shim.

2-speed piston hole inner diameter and piston assembly outer diameter

Gap 0.040 mm

Replace using the flange kit.

2-speed piston hole inner diameter

1.2 a degree of roughness Or the surface is rough or there is scratching at least 0.02 mm deep.

Thrust plate (26)

Thickness

Plate thickness 3.3 mmPlate thickness 2.5 mm Plate thickness 2.9 mmPlate thickness 2.0 mm Plate thickness 2.7 mm Or there is deep scratching on the sliding surface.

Replace the thrust plate.

Angular bearings (3)

Ball rotation surfaces

Flaking is occurring.

Replace the angular bearing(s).

Operation

Abnormal noise or unsmooth rotation occurs with rotation.

Floating seals (2)

Sliding surfaces

There is deep scratching that may cause oil leaking.

O-rings

Cracking is occurring on the surface.

Replace the floating seal(s). When doing more disassembly beyond this, because oil leaking may occur due to the seal ring slide imprints not matching up of reused seals when reassembly is done, replace these seals before reassembly.

During disassembly

Replace each O-ring.

Flange (1-1)

Each O-ring

RSM-13-02-001E

42 36

Travel Unit 5. Assembly of Motor (1)Precautions before motor assembly Begin motor assembly only after thoroughly reading the precautions below. [1] When performing assembly, always wear protective devices such as a helmet, goggles and safety shoes. [2] Use the specified tools when performing assembly. [3] To prevent injuries during disassembly, prepare a waist-high, stable work platform to perform work on. [4] The motor comprises high-precision parts. For this reason, foreign matter adhering to parts can be damaging. Motor assembly should be done in an inside space without dust, and mud and dirt should be prevented from adhering to parts. [5] The motor comprises high-precision parts. For this reason, dents and scratching on part surfaces can be damaging. Be very careful when handling parts during assembly and do not create any dents or scratching. [6] Be sure to repair any damage discovered during disassembly, and prepare replacement parts before beginning assembly. [7] Remove metal fragments and foreign matter from all parts, and check that there are no burrs or nicks on parts before beginning assembly. If there are burrs or nicks, use a whetstone to remove them. [8] When performing assembly, apply clean hydraulic oil to each sliding and rotating section before assembly. [9] Thoroughly degrease areas where Loctite and liquid packing is used, and remove oil and water before assembly. [10] As a rule, replace all seal parts such as O-rings and backup rings with new parts. [11] Be careful not to damage O-rings and backup rings during assembly. When assembling Orings and backup rings, apply a small amount of grease for assembly. [12] It is recommended that petroleum jelly or grease be used to prevent parts from falling during assembly. [13] Tighten each type of bolt at the connection sections to the tightening torque indicated in Table 5 in 3. (2). Tightening torque should be controlled with a torque wrench. [14] After assembly is complete, plug all ports leading into the motor to prevent dirt from entering.

43

RSM-13-02-001E 37

Travel Unit (2)Assembly procedures Perform assembly by observing the precautions listed in Section 1 and following the procedure indicated below. [1] Assembly of reduction gear section 1) Attaching floating seal to flange After confirming the items below concerning the floating seals (2), use the floating seal installation jig to attach the floating seals to the flange (1-1). Confirmation items: a. Check that there is no dirt adhered to the floating seal mounting surfaces on the flange. b. Thoroughly degrease the floating seal mounting surfaces on the flange. c. Check that there is no dirt adhered to the O-ring surfaces on the floating seals. d. Thoroughly degrease the O-ring surfaces on the floating seals. 2) Attaching angular bearing to housing Use the press-fit jig or press to press fit the angular bearings (3) to the housing (4).

RSM-13-02-001E

44 38

Travel Unit 3) Attaching floating seal to housing After confirming the items below concerning the floating seals (2), use the floating seal installation jig to attach the floating seals to the housing (4). Confirmation items: a. Check that there is no dirt adhered to the floating seal mounting surface on the housing. b. Thoroughly degrease the floating seal mounting surface on the housing c. Check that there is no dirt adhered to the O-ring surfaces on the floating seals. d. Thoroughly degrease the O-ring surfaces on the floating seals. 4) Attaching the housing to the flange After confirming the items below, use a crane to attach the housing to the flange so that the floating seal (2) section of the flange (1-1) is aligned with the floating seal section of the housing (4). Confirmation items: a. Check that there is no dirt adhered to the seal ring sliding surfaces of the floating seals. b. Apply reduction gear lubricating oil or hydraulic oil all around the seal ring sliding surfaces of the floating seals (1-2). c. When attaching the flange holder and housing (1-6), attach them after checking that the axis center is aligned.

45

RSM-13-02-001E 39

Travel Unit 5) Shim thickness selection Select the precompression adjustment shim (5) thickness according to the following procedure. 1. Use the shim thickness adjustment jig to press the inner ring end sections of the angular bearings (3) with a load of 2.94 kN. 2. Measure the H level dimensions at this time for the angular bearings inner ring end surfaces and flange end surface. 3. Measure the h level dimensions of the holder (6). 4. Select a shim and install it so that the shim thickness is appropriate to the dimensions (H-h). Cautions: a. Do not reuse shims. b. Be sure to perform this procedure properly. If precompression adjustment is not done properly, reduction gear damage could occur during operation. c. Clean the measurement surfaces.

RSM-13-02-001E

1

Press load of 2.94 kN

2

H dimensions

3

h dimensions

46 40

Travel Unit 6) Holder attachment Secure the flange (1-1) and stand the pins (31) straight up on the flange in 4 locations. Use grease to attach the shim selected in 5) to the holder (6), and press fit the shim with it on the holder in alignment with the pin holes. Mount the washers (7) on the holder, apply Loctite to the threaded sections, and tighten the bolts (8) to the specified torque. Cautions: a. Check that the pins (31) have not fallen. b. The loosening stop spikes should be attached to the washers. Put the spikes on the holder seating surface side to mount them. c. Thoroughly clean the bolt threaded sections and apply Loctite after degreasing. d. Also thoroughly clean the internal areas of the screw holes of the flange, and thoroughly degrease them.

47

*

Be careful to attach the washers (7) in the correct direction. Attach them in the direction shown in the diagram above.

*1

Holder side

*2

Bolt seating surface side

RSM-13-02-001E 41

Travel Unit 7) Planetary gear attachment Attach the thrust plates (9) to the planetary gears (12). Next, attach the needle bearings (11) to the planetary gears. Finally, after attaching the inner races (10), join the flange trunnion sections (4 locations) with the internal diameter sections of the inner races to attach the planetary gears. Cautions: a. When attaching the thrust plates to the planetary gears, make sure the shear droop on the thrust plates created by the press is facing the 1-1 flange side. b. When finally attaching the planetary gears to the flange, attach them so that the internal teeth of the housing (4) engage with the planetary gear teeth. c. Be careful with the attachment directions of the planetary gears.

RSM-13-02-001E

*1

Make the shear droop side face the planetary gear C (6) side.

*2

Thrust plate (9) attachment direction

48 42

Travel Unit 8) Thrust plate attachment Mount the thrust plates (13) on the planetary gears (12) in such a way that the chamfers of the bolt hole sections are the neck bottom section of the bolts (14). After mounting, mount the bolts that have had Loctite applied to the threaded sections and tighten them to the specified torque. Cautions: a. Be careful with the mounting direction of the thrust plates. Mistakes could cause scratching on the bolt neck sections and this could result in damage. b. Thoroughly clean the bolt threaded sections and apply Loctite after degreasing. c. Also thoroughly clean the internal areas of the screw holes of the flange (1-1), and thoroughly degrease them.

*1

Mount so that the C2 chamfer side is the seating surface side for the hexagon socket head bolts.

9) Sun gear C attachment After checking that the snap ring (16) is mounted on sun gear C (15), mount the sun gear C in the middle of the 4 planetary gears (12). Caution: Mount the sun gear C so that the teeth engage with the teeth of the planetary gears.

49

RSM-13-02-001E 43

Travel Unit 10)Holder attachment Engage the internal teeth of the holder (17) with the teeth of sun gear C (15) and attach sun gear C.

11)Planetary gear attachment Attach the thrust plates (18) to the planetary gears (21). Next, attach the needle bearings (20) to the planetary gears. Finally, after attaching the inner races (19), join the holder (17) trunnion sections (3 locations) with the internal diameter sections of the inner races to attach the planetary gears to the holder. Cautions: a. When attaching the thrust plates to the planetary gears, make sure the shear droop on the thrust plates created by the press is facing the holder side. b. When finally attaching the planetary gears to the holder, attach so that the internal teeth of the housing (4) engage with the planetary gear teeth. c. Be careful with the attachment directions of the planetary gears.

RSM-13-02-001E

*1

Make the shear droop side face the holder B (17) side.

*2

Thrust plate (18) attachment direction

50 44

Travel Unit 12)Drive gear attachment Attach the thrust plates (22) to the planetary gears (21), and attach the thrust plate (23). Insert the screws (24) with Loctite applied in the threaded sections and tighten them to the specified torque. Make the spline-side of the drive gear (25) face the motor section attachment side and attach the drive gear in the middle of the 3 planetary gears. Also engage the teeth of the planetary gears with the drive gear teeth. Cautions: a. Be careful with the attachment direction of the thrust plates. b. Thoroughly clean and degrease the screw holes and threaded sections of the holder (17)

51

*1

Make the shear droop side face the planetary gear C (12) side.

*2

Thrust plate (13) attachment direction

RSM-13-02-001E 45

Travel Unit 13)Thrust plate attachment Measure the level difference between the housing (4) end surface and the thrust plate (23) end surface with the thrust plate selection jig, and select and attach a thrust plate (26) according to the table below. Level difference dimensions

Appropriate thrust plate

1.20 － 0.67

20941-62306

0.66 － 0.04

20941-62307

0.03 － -0.16

20941-62308

-0.17 － -0.41

20941-62309

-0.42 － -0.80

B0841-23017

Caution: Align the center hole of the thrust plate with the protruding section of the drive gear (25) and attach.

*1

Measure the level difference

14)Cover attachment Thoroughly clean off any foreign matter from the housing (4) end surface and cover (27) matching surface. Next, thoroughly degrease the housing end surface and cover matching surface. Additionally, apply liquid packing to the centering location corners on the housing attachment surface-side of the cover, and align the housing screw holes and bolt openings on the cover to mount the cover on the housing. Finally, mount the hexagon socket head bolts (28) and tighten them to the specified torque.

RSM-13-02-001E

52 46

Travel Unit 15)Plug attachment Remove the O-rings (30) attached to the plugs (29), and replace them with new O-rings. Next, attach plugs to the oil fill, oil drain and oil check ports (3 total) on the cover (27) and tighten them to the specified torque.

This completes assembly of the reduction gear parts. Next is assembly of motor parts. Perform assembly while referring to "[2] Assembly of motor parts".

53

RSM-13-02-001E 47

Travel Unit [2] Assembly of motor parts 1) Oil seal attachment Check whether the oil seal is mounted on the flange (1-1), and use an oil seal press-fit jig to press fit the oil seal (1-12) to the flange if it is not mounted already. Cautions: a. Press fit the oil seal after applying grease to the internal diameter surface of flange oil seal press-fit section and the oil seal outside diameter section. b. Press fit the oil seal after applying grease to the lip section of the oil seal inner diameter. c. When press fitting the oil seal, push it vertically with the press. Slanting will cause damage to the oil seal outer diameter surface. d. When press fitting the oil seal, be careful not to scratch the lip section of the oil seal internal diameter. Scratching may cause oil leaking and reduction gear internal damage could occur during motor operation. 2) Piston assembly attachment Attach the springs (1-20) to the flange (1-1) holes for attaching the piston assemblies (1-7). Next, attach the piston assemblies to the flange. Cautions: a. Attach springs in the center of the hole when attaching. b. When attaching the piston assemblies, have the cylinder sections facing down. c. Before attaching the piston assemblies, apply hydraulic oil to the internal diameter surface of the flange mounting holes and the outer diameter of the piston assembly cylinder sections. d. After attaching the piston assemblies, check that the piston assemblies move smoothly.

RSM-13-02-001E

54 48

Travel Unit 3) Steel ball attachment Attach steel balls (1-6) to the spherical hole sections of the flange (1-1). Caution: Before attaching the steel balls, apply hydraulic oil to the inner diameter surface of the spherical holes of the flange.

4) Shaft attachment Use the bearing press-fit jig to press fit the ball bearing (1-8) to the shaft (1-3). Next, attach the shaft to the center of the flange (1-1). Cautions: a. When attaching the ball bearing, attach it vertically. b. After attaching the shaft, check that it rotates smoothly.

55

RSM-13-02-001E 49

Travel Unit 5) Swash plate attachment Point the slanted surface of the swash plate (1-5) upwards and attach the swash plate to the flange (1-1). Cautions: a. Attach by matching the rear surface spherical holes of the swash plate with the steel balls (1-6). b. Attach the swash plate after applying hydraulic oil to the surface of the steel balls. c. After attaching the swash plate, check that it moves smoothly. 6) Assembly of cylinder block assembly 1. Point the surface of the cylinder block (1-4-1) that slides against the valve plate (1-21) upwards and place the cylinder block on the work platform of the hand press. Point the slanted surface of the spring seat (1-4-6) down and attach it to the cylinder block. Place both the spring (1-4-7) and collar (1-4-8) on top of spring seat with the collar on top.

*1

RSM-13-02-001E

Cylinder block attachment direction

56 50

Travel Unit 2. Use the jig to press the top surface of the collar (1-4-8) to attach the snap ring (1-4-5). Cautions: a. The snap ring is stiff and may come off from the snap ring pliers when the snap ring is being attached, which could cause injury. Make sure to use a jig when attaching the snap ring, and check that the nails of the snap ring pliers are in the snap ring before attachment. b. When retracting the snap ring is difficult, use the snap ring pliers that are one size bigger. c. When pressing in the collar (1-48), make the centers of the cylinder block and press align with each other. 3. Point the surface of the cylinder block (1-4-1) that slides against the valve plate (1-21) down and place the cylinder block on the work platform. Insert the 3 pins (1-4-9) into the diagonal holes of the cylinder block (1-41). Cautions: a. When placing the cylinder block on top of the work platform, check that there is no foreign matter on top of the work platform. b. Be careful not to scratch the surface of the cylinder block that slides against the valve plate. Scratching may cause a reduction in motor performance and early damage to the motor. c. Apply grease to the pin holes before attaching the pins.

57

RSM-13-02-001E 51

Travel Unit 4. Attach the retainer holder (1-4-4) to the cylinder block (1-4-1).

5. Place the side of the retainer plate (14-3) with a taper on the outer circumference down, and attach the 9 piston assemblies (1-4-2) to the retainer plate.

6. Attach the piston assemblies (1-4-2) to the cylinder block (1-4-1). Cautions: a. Apply hydraulic oil to the 9 cylinder block piston attachment holes before attaching the piston assemblies. b. Apply hydraulic oil to the spherical surface of the retainer holder (1-44) before attaching it.

RSM-13-02-001E

58 52

Travel Unit 7) Cylinder block assembly attachment Place the valve plate (1-21) sliding surface side of the cylinder block assembly (1-4) upwards, engage the internal teeth spines of the retainer holder (1-4-4) and cylinder block (1-4-1) with the external teeth spines of the shaft (1-3), and attach the cylinder block assembly to the inside of the flange (1-1). Cautions: a. When performing attachment, check that the piston assemblies (1-4-2), retainer plate (1-4-3) and retainer holder do not come off from the cylinder block assembly. b. Before performing attachment, apply hydraulic oil to the swash plate (1-5) surface and sliding surfaces of the piston assemblies. 8) Disk plate attachment Engage the internal teeth of the disk plates (1-13) with the external teeth of the cylinder block (1-4-1) and attach the disk plates to the flange. Also, align the arc sections on the external circumference of the friction plates (1-14) with the notch sections of the flange and attach the friction plates to the flange. Attach in this manner with the disk plates being attached before the friction plates. Caution: The disk plates are wet type disk. Before attachment, immerse the friction material parts in hydraulic oil and have the friction materials thoroughly absorb the hydraulic oil.

59

RSM-13-02-001E 53

Travel Unit 9) Brake piston attachment Attach O-rings (1-16) and (1-17) to the brake piston (1-15). Next, place the large bore side of the brake piston upwards and attach it to the flange (1-1). Cautions: a. Thoroughly apply grease when attaching the O-rings. b. Attach the brake piston after using a positioning jig to align the flange base plate (1-2-1) knock pin hole and brake piston knock pin hole so that they are arranged in a straight line. c. When attaching the brake piston, apply grease to the outer circumference of the brake piston and inner diameter section of the flange. d. Push and attach the brake piston evenly all around so that it does not become slanted. If the brake piston is attached at a slant, this could cause operational problems or the O-rings to break.

10)Spring attachment Insert the springs (1-18) into the 8 spring mounting holes on the brake piston (1-15).

RSM-13-02-001E

60 54

Travel Unit 11)Valve plate attachment Place the base plate (1-2-1) on top of the work platform and press fit the bearing (1-9) in the center of the base plate using the bearing press-fit jig. Attach the valve plate (1-21) to the base plate after checking that the knock pins (1-19) are mounted to the base plate. Cautions: a. Place the copper alloy side of the valve plate up to attach it. b. Thoroughly apply grease to the matching surface between the base plate and valve plate to prevent the valve plate from falling. c. Be careful not to scratch the copper alloy surface of the valve plate.

61

RSM-13-02-001E 55

Travel Unit 12)Base plate attachment Attach O-ring (1-23) and the 4 O-rings (1-22) to the top surface of the flange (11). Attach the knock pins (1-19) to the base plate (1-2-1). Place the valve plate (1-21) mounting surface of the base plate downwards and tighten it to the flange with the hexagon socket head bolts (1-11). Cautions: a. Apply grease to the O-ring (1-23). b. Do not apply grease to the O-rings (1-22). c. Attach the knock pins with their tapered sections up. d. Attach the base plate after applying hydraulic oil to the valve plate surface and cylinder block (1-4-1) surface. e. Be careful that the valve plate does not fall because the valve plate mounting surface of the base plate is pointing down when the base plate is attached. f. Check the mounting position of the O-rings on the flange and the position of the holes for the oil path on the base plate to attach the base plate. g. Check the position of the knock pins mounted to the base plate, the spring (1-18) mounting holes on the base plate and the flange-side knock pin holes, and the spring positions to attach the base plate. h. When tightening the socket head bolts, screw in all of the bolts around the circumference evenly.

RSM-13-02-001E

62 56

Travel Unit 13)Valve assembly attachment Attach the spring (1-2-10) to the valve assembly (1-2-9) and attach the assembly to the base plate (1-2-1). After attaching the valve assembly, check that the O-rings (1-2-12) are mounted to the plug (1-2-11), attach the plug to the base plate and tighten it to the specified torque. Next, check that the O-rings (1-2-12) are mounted to the plug (1-2-14), attach the spring guide (1-2-13) and washer (1-215), and then attach the plug to the base plate and tighten it to the specified torque. Cautions: a. Attach the valve assembly to the base plate so that the base plate line port side is on the nearest to the installer and the valve assembly spring mounting side is on the right. Attaching in the opposite direction may cause problems such as switching errors. b. Attach the valve assembly after applying hydraulic oil to the outer circumference. c. After attaching the valve assembly, check that it moves smoothly. 14)Relief valve assembly attachment Attach the relief valve assemblies (1-27) to the base plate (1-2-1) and tighten to the specified torque after checking that poppet seat (1-2-7-3) is mounted on the end of each relief valve assemblies. Cautions: a. Replace the O-ring (1-2-7-7) with new one before attaching the relief valve assemblies. b. Check that the O-ring (1-2-7-17) and backup rings (1-2-7-18) are mounted on the each poppet seat (1-2-7-3). c. Apply grease to the O-rings and backup rings before attaching the relief valve assemblies.

63

RSM-13-02-001E 57

Travel Unit 15)Plunger assembly attachment Attach the base plate (1-2-1) to the plunger assembly (1-2-2). Cautions: a. Apply hydraulic oil to the plunger assembly outer circumference before attachment. b. Attach the plunger assembly slowly and in a straight line while rotating it. c. If the plunger assembly becomes stuck, do not force it too much and lightly strike it with a hammer. 16)Cap assembly attachment Attach the spring seats (1-2-3) and springs (1-2-4) to the plunger assembly (1-2-2) in that order. After checking that the O-ring (1-2-6-2) is mounted to the cap assemblies (1-26) and that the O-ring (1-2-24) is mounted to the base plate, mount the spring seats (1-2-5) on the cap assemblies and attach the cap assemblies to the base plate. Finally, tighten the hexagon socket head bolts (1-2-6-4) to the specified torque. Cautions: a. Apply grease to the O-rings. b. The cap assemblies are pushed by the springs. Push the cap assemblies down by hand when tightening the socket head bolts. c. When tightening the hexagon socket head bolts, evenly tighten the 4 bolts. If the cap assemblies are tightened at a slant, this could cause damage Orings and cause oil leaking. This completes assembly of the motor. When installing the motor in the machine body, see "7. Installation of Motor", "8. Operation Check", and the Operator's Manual for the machine.

RSM-13-02-001E

64 58

Travel Unit 6. Motor Section Names

Diagram 1. Motor section names

65

RSM-13-02-001E 59

Travel Unit 7. Installation of Motor (1)Motor inspection Before placing the motor in the mother machine, perform inspection for the following items. If there is a problem, perform the given procedure. Table 14. Motor inspection and solving problems before installation Solution for solving problem Inspection item before installation

When installing a new motor

When installing a motor stored after maintenance inspection

Are there any damaged areas?

Contact our company's service plant concerning damage that occurred during shipping. Replace parts that have been damaged during storage.

Replace damaged parts.

Are there any missing parts?

Contact our company's service plant concerning parts lost during shipping. Purchase parts that have been lost during storage.

Purchase lost parts.

Is there any looseness in the tightening sections of the bolts?

If there is looseness in bolts just after delivery of the motor, contact our company's service plant for instructions on tightening bolts to the specified torque. If there is bolt loosening on a stored motor, contact our company's service plant as there is a chance that rust has formed internally.

When there is looseness with bolts, disassemble again and inspect the motor for rust on the inside.

Dirt around ports

When ports for lines are dirty, perform air blowing with compressed air or a high-pressure jet or cleaning with water vapor to remove dirt.

When ports for lines are dirty, perform air blowing with compressed air or a high-pressure jet or cleaning with water vapor to remove dirt.

Are all of the port areas completely air-tight?

When checking just after delivery When the plugs for each of the ports are loose, use the plugs after removing dirt adhered to the ports. When there are no plugs on the ports, contact our company's service plant as dirt has probably entered the motor.

When the plugs for each of the ports are loose or there are no plugs on the ports, perform disassembly for confirmation that dirt has not entered the motor or there is no rust.

When checking after storage Contact our company's service plant as rust has probably formed inside the motor. Is there any rust on the port sections or the installation sections on the mother machine?

Contact our company's service plant If there is light rusting, use the motor after confirming the presence of rust. after removing the rust. If rusting is severe, replace parts.

Oil leaking from ports and connection surfaces

Contact our company's service plant if oil leaking is discovered.

RSM-13-02-001E

If oil leaking is discovered, there is probably a problem with air-tightness and rust has formed inside the motor, so perform disassembly again to check for rust.

66 60

Travel Unit 8. Operation Check Before performing work driving after installing the new motor or post-inspection motor in the machine main unit and completing all line operations, perform a driving check according to the procedure listed below. (1)Check before driving check [1] Fill the inside of the piston motor case with hydraulic oil Before performing a driving check, fill the inside of the piston motor case with about 500 cc of hydraulic oil from the piston motor drain port to prevent problems at the start of driving in sliding sections of the piton motor. When using a hand pump or a small-quantity electric pump for oil filling, make the internal case pressure of the piston motor 0.3 MPa or less. [2] Reduction gear lubricating oil check Use the oil fill, oil drain and oil check ports for reduction gear lubricating oil shown in the Diagram 8 to check that the reduction gear case contains the stipulated level of lubricating oil.

Remove the lubricating oil check port plug and check that lubricating oil flows out. If lubricating oil seems to be flowing out, return the oil check port plug to its original position and tighten it to the specified torque. If lubricating oil does not flow out even though the oil check port is open, open the oil fill port and fill with oil until reduction gear lubrication oil flows out from the oil check port. After filling with oil, return the plugs for the oil fill port and oil check port and tighten them to the specified torque.

When motors are shipped from the plant they are filled with Mitsubishi Diamond Hypoid Gear Oil 90 to the stipulated volume (3.5 L).

67

RSM-13-02-001E 61

Travel Unit

Diagram 8. Oil fill, oil drain and oil check ports for reduction gear lubricating oil and stipulated oil volume

(2)Motor operation check Slowly operate the machine and perform air-bleeding for inside the motor circuit and inside the line according the Operator's Manual for the machine main unit. First, perform an operation check by repeating "C direction rotation and stopping and A direction rotation and stopping" a number of times at low speed. At this time, remaining air inside the circuit may cause abnormal noises from the valves, etc. The abnormal noises will stop as air is bled out while operation is done repeatedly at low speed. If abnormal noises go away through repeated operation over a while, there is no problem with the motor and it can be used as is. If operation is done repeatedly and abnormal noises do not stop, there is an abnormality within the motor and it should be replaced. Check for the presence of oil leaking from the motor, line port sections, each line and each piece of equipment. When oil leaking has been confirmed, retighten the bolts and line joints at the location where the leak is occurring to the specified torque. After checking is completed, raise the pressure and perform load operation, and check that no abnormal noises or vibrations, etc. are occurring in the motor. • When tightening lines, etc. after confirming oil leaking, make sure to have operation of hydraulic devices stopped. • Make sure that the pressure operating on the motor is low when checking for oil leaking. If the operating pressure is high and there is oil leaking, there is the danger of oil spraying out.

RSM-13-02-001E

68 62

Travel Unit 9. Troubleshooting See the troubleshooting section below to perform checking, countermeasures and to solve problems when any kind of problem occurs in the motor during operation. [1] Piston motor troubleshooting Problem The motor does not rotate

Motor rotation speed is insufficient

Motor rotation variation is high

Possible cause

Countermeasure and solution

There is an operation problem in a piece of equipment other than the piston motor or reduction gear.

After investigating whether pressure is reaching the motor inlet side, investigate the causes of problems and countermeasures for each piece of equipment and perform inspection and repair.

If the cause is in the motor itself, there is dirt clogging an operation section or there is an operation problem.

Perform disassembly and clean and remove dirt from parts before reassembling the motor. If parts are damaged due to dirt, replace the parts.

Motor inlet side pressure is low.

Operate the main relief valve of the circuit and raise the set pressure.

There is abnormal wear on the sliding sections of the piston motor and pressurized oil is escaping.

Perform disassembly and replace abnormally worn parts. After completely removing surface scratching, burrs, etc. and cleaning, perform reassembly.

Damage is occurring with the main parts of the piston motor. In this instance, abnormal noise is coming from the piston motor.

Perform disassembly and replace damaged parts. Perform reassembly after cleaning parts.

The load on the piston motor is too large and the relief valve is operating.

Investigate the load conditions and adjust the load to an amount appropriate to the set pressure of the relief valve.

The cause resides in the hydraulic pump, pressure control valve, flow control valve, etc. Required oil flow is not being supplied to the piston motor and rotation is insufficient.

After investigating whether the required flow is being supplied to the piston motor inlet side, investigate the causes of problems and countermeasures for each piece of equipment and perform inspection and repair.

pressurized oil is moving from the highpressure side to the low-pressure side due to wear on the sliding sections of the piston motor (volume efficiency reduction), and speed is insufficient.

Perform disassembly, investigate the status of wear on the sliding sections of the piston motor, and perform repair and replacement according to the Maintenance Procedures.

There is looseness in the piston motor base plate fastening bolts. Internal leaking is increased and speed is insufficient.

Retighten the base plate fastening bolts to the specified torque.

There is wear on the sliding sections of the piston motor and high-pressurized oil is leaking and flowing out from the drain port, which is causing speed to greatly decrease and causing rotation variation.

Perform disassembly, investigate the status of wear on the sliding sections, and perform repair and replacement according to the Maintenance Procedures.

When going down an incline, the double counter balance valve is causing hunting and rotation variation.

Perform disassembly, investigate the status of wear on the double counter balance valve, and perform repair and replacement according to the Maintenance Procedures.

69

RSM-13-02-001E 63

Travel Unit Problem Noise is high

Oil leaking

Cavitations is causing abnormal noise, rotation variation and pressure variation.

Motor rotation stopped during operation

RSM-13-02-001E

Possible cause

Countermeasure and solution

The shaft is touching driven parts due to problems with shaft core alignment, and this is producing noise.

Make the shaft core alignment accurate.

There is wear or damage on the piston motor bearing or damage has occurred with a spring, etc. and noise is being produced.

Perform disassembly and replace damaged parts such as bearings or springs. Perform reassembly after cleaning parts.

There is looseness in bolts on matching surfaces, etc. and oil leaking is occurring.

Retighten the fastening bolts the specified torque.

Oil leaking is occurring due to damage to oil seals, O-rings, packing, etc.

Perform disassembly and replace seals. Check the hydraulic oil temperature. When the temperature of the hydraulic oil is 80 ℃ or higher during operation, recheck the cooler and reduce the temperature of the hydraulic oil to below 80 ℃ .

The amount of drain oil is high due to wear on the sliding sections of the piston motor, and oil leaking is occurring due to damage to the oil seals.

Perform disassembly, investigate the status of wear on the sliding sections, and perform repair and replacement according to the Maintenance Procedures. Replace oil seals. Perform reassembly after cleaning parts.

Drain pressure has increased due to clogging in the drain line or because the drain line is long and thin, and this has damaged the oil seals and oil leaking is occurring.

Perform disassembly and replace oil seals. Perform drain line cleaning and remove foreign matter. Recheck lines and minimize resistance in line paths.

The amount of hydraulic oil in the hydraulic tank has decreased, and aeration is occurring due to tank taking in air.

Check the amount of hydraulic oil in the hydraulic tank, and crisply with hydraulic oil according to the instructions on the machine main unit.

Hydraulic oil within the motor lines and motor circuit is flowing out while hydraulic devices are turned off because the motor installation direction is inappropriate or the hydraulic tank position is inappropriate, and this is causing aeration to occur within the motor just after the motor is started.

Check the motor installation direction and correct it. Check that the oil surface within the hydraulic tank is above the motor, and either modify it so that it is above the motor or set up a self-supply circuit so that the insides of the motor circuit and lines are fully supplied with oil before driving.

When the motor is pumping, pressure on the motor inlet side becomes negative due to double counter balance valve operation problem and cavitation occurs.

Perform disassembly and perform repair and replacement according to the double counter balance valve Maintenance Procedures.

The load is too large and this caused the engine to stall.

Check the load conditions and change the load to an appropriate amount.

Seizing occurred in the sliding sections of the piston motor and the motor stopped rotating.

Investigate specifications values (especially flow amount and motor speed). If the motor speed has exceeded the upper limit, lower the flow amount. It is not possible to reuse the inside of the motor, so the motor should be replaced.

70 64

Travel Unit [2] Parking brake troubleshooting Problem The motor rotates if it is stopped with an external load acting on the motor.

Motor drive force is not being produced. Motor is heating up to an abnormal degree

Possible cause

Countermeasure and solution

Parking brake torque has decreased due to disk wear.

Perform disassembly and replace the parking brake disk. Perform reassembly after cleaning parts.

The disk surface has been altered due to contact errors, etc., and the parking brake torque has decreased.

Perform disassembly and replace the disk. Also, repair the surface of the disk companion parts and perform reassembly.

The spring is worn or damaged and the parking brake torque is reduced.

Perform disassembly and replace the spring. Perform reassembly after cleaning parts.

The external load is too large and the parking brake capabilities are insufficient.

Check the external load and change the load to an appropriate amount.

O-rings are damaged and pressurized oil is escaping, so the parking brake cannot be released.

Perform disassembly and replace the Orings. Perform reassembly after cleaning parts.

Foreign matter is clogging the orifice inside the parking brake release oil path and pressurized oil is not reaching the parking brake cylinder chamber, which prevents the parking brake from being released.

Perform disassembly and remove foreign matter from the orifice. Perform reassembly after cleaning parts. Also, flush the inside of the line.

Drain pressure has increased due to clogging in the drain line or because the drain line is long and thin, and this has increased drain pressure and the parking brake cannot be released.

Clean the drain line. Also, recheck the line system and minimize resistance in the line path.

71

RSM-13-02-001E 65

Travel Unit [3] Relief valve troubleshooting Problem

Possible cause

Countermeasure and solution

The motor does not rotate or motor rotation is slow.

There is foreign matter caught between the poppet seat and poppet on the relief valve, which is causing seating problems, and high-pressurized oil is leaking to the lowpressure side.

Perform disassembly and remove foreign matter. Perform reassembly after cleaning parts.

The relief valve spring is damaged and high-pressurized oil is leaking to the lowpressure side.

Replace the relief valve. Disassemble the motor and reassemble it after cleaning each part.

The relief valve spring is worn and the set pressure is decreased, which causes the relief to operate at low pressure.

Replace the relief valve.

There is foreign matter caught in the seat section of the free piston and base plate of the relief valve, and the set pressure decreasing.

Remove the relief valve and remove foreign matter.

There is foreign matter clogging the orifice set in the poppet of the relief valve, and the set pressure has decreased.

Remove the relief valve and remove foreign matter.

There is foreign matter caught in between the poppet seat and poppet on the relief valve, which is causing seating problems, and the relief valve will not close.

Perform disassembly and remove foreign matter. Perform reassembly after cleaning parts.

The relief valve spring is damaged and the relief will not close.

Replace the relief valve. Disassemble the motor and reassemble it after cleaning each part.

The relief valve spring is worn and the set pressure has decreased, which has caused the brake force to decrease.

Replace the relief valve.

There is foreign matter caught in the seat section of the free piston and base plate of the relief valve, and the set pressure and brake force have decreased.

Remove the relief valve and remove foreign matter.

There is foreign matter clogging the orifice set in the poppet of the relief valve, and the set pressure and brake force have decreased.

Remove the relief valve and remove foreign matter.

There is foreign matter caught in the sliding section of the poppet and the poppet is not moving.

Replace the relief valve.

There is foreign matter caught in the free piston and the piston is not moving.

Remove the relief valve and reassemble after removing foreign matter.

The relief set pressure is too high.

Replace the relief valve.

The motor does not stop or stopping is slow.

Shock at stopping is high

RSM-13-02-001E

72 66

Travel Unit [4] Counter balance valve troubleshooting Problem The motor does not rotate or motor rotation is slow.

The motor does not stop or stopping is slow.

When an external load acts on the motor and pumping operation is done, rotation variation occurs.

Possible cause

Countermeasure and solution

pressurized oil is not reaching the motor inlet and the plunger is not switching.

After investigating whether pressurized oil is reaching the motor inlet side, investigate the causes of problems and countermeasures for each piece of equipment and perform inspection and repair.

Pressure is reaching the motor inlet, but foreign matter is clogging the orifice in the pilot oil path and the plunger is not switching.

Measure the pressure of the return side inside the motor circuit, and check that the pressure has increased. After this, perform disassembly and remove foreign matter. Next, perform reassembly.

There is foreign matter caught in the plunger and it is not switching.

Perform disassembly and remove foreign matter. Investigate the degree of damage according to Maintenance Procedures and reassemble the plunger if reusing is possible. If scratching make the plunger unusable, replace it using the base plate kit.

There is foreign matter caught in the plunger, so the plunger will not return and brake force has decreased.

Perform disassembly and remove foreign matter. Investigate the degree of damage according to Maintenance Procedures and reassemble the plunger if reusing is possible. If it is unusable, replace it using the base plate kit.

There is damage to the plunger spring, so the plunger will not return and brake force has decreased.

Perform disassembly and replace the spring after removing foreign matter.

Foreign matter is clogging the orifice in the pilot oil path, and the plunger will not return or return is slow.

Perform disassembly and remove foreign matter. Next, perform reassembly.

The plunger spring is not fit in place.

Fit the spring correctly in place.

The check valve is not fit in place.

Fit the check valve correctly in place.

The check valve spring is damaged.

Perform disassembly and replace the spring after removing foreign matter.

The check valve spring is not fit in place.

Fit the spring correctly in place.

There is foreign matter caught in the plunger and plunger movement is not smooth.

Perform disassembly and remove foreign matter. After this, clean the plunger and perform reassembly.

The diameter of the pilot oil path orifice is wrong.

Attach the correct orifice.

The pilot oil path orifice is not fit in place.

Attach the orifice in the correct position.

73

RSM-13-02-001E 67

Travel Unit Problem When an external load acts on the motor and pumping operation is done, cavitation occurs and abnormal noise is created.

RSM-13-02-001E

Possible cause

Countermeasure and solution

There is foreign matter caught in the plunger, plunger movement is poor, and counter balance functions are not fulfilled.

Perform disassembly and remove foreign matter. Investigate the degree of damage according to Maintenance Procedures and reassemble the plunger if it is useable. If reusing is impossible, perform replacement with the base plate kit.

There is damage to the plunger spring and counter balance functions are not fulfilled.

Perform disassembly and replace the spring and perform reassembly after removing foreign matter.

The plunger spring is not fit correctly in place and counter balance functions are not fulfilled.

Fit the spring correctly in place.

There is damage to the check valve spring and counter balance functions are not fulfilled.

Perform disassembly and replace the spring after removing foreign matter.

The check valve spring is not fit correctly in place and counter balance functions are not fulfilled.

Fit the spring correctly in place.

Foreign matter is clogging the orifice in the pilot oil path, and counter balance functions are not fulfilled.

Perform disassembly and reassemble after removing foreign matter.

74 68

Travel Unit [5] 2-speed control function section troubleshooting Problem Will not switch to high-speed rotation

Possible cause

Countermeasure and solution

Pilot pressure oil is not reaching the Ps port.

After investigating whether pilot pressure oil is reaching the Ps port, investigate the causes of problems and countermeasures for each piece of equipment and perform inspection and repair.

There is foreign matter caught between the spool and base plate, and the spool will not switch.

After performing disassembly and removing foreign matter, investigate the degree of damage according to the Maintenance Procedures and perform reassembly if reusing is possible. If reusing is impossible, perform replacement with the base plate kit.

There is abnormal wear in the sliding sections of the 2-speed control piston section, and pressurized oil is leaking into the case.

Perform disassembly and replace using the flange holder kit.

The 2-speed control piston is not fit in place.

Attach the 2-speed pistons in the correct position.

Foreign matter is clogging the orifice in the 2-speed oil path, and pressurized oil is not reaching the 2-speed control piston.

Perform disassembly and reassemble after removing foreign matter.

Switching to high-speed rotation occurs, but switching to low-speed rotation occurs if the hydraulic oil temperature increases.

There is abnormal wear in the sliding sections of the 2-speed control piston section, and pressurized oil is leaking into the case.

Perform disassembly and replace using the flange holder kit.

Will not switch to low-speed rotation

Even if the speed control switch is set to low speed, the Ps port pressure does not decrease.

Investigate whether the Ps port pressure is 0.5 MPa or lower and recheck the line system.

The 2-speed control valve spring is damaged.

Perform disassembly and replace the spring after removing foreign matter.

The 2-speed control valve spring is not fit in place.

Attach the spring in the correct position.

There is foreign matter caught between the spool and base plate, and the spool will not return.

After performing disassembly and removing foreign matter, investigate the degree of damage according to the Maintenance Procedures. Perform reassembly if reusing is possible. If reusing is impossible, perform replacement with the base plate kit.

Foreign matter is clogging the orifice in the 2-speed oil path, and pressure cannot escape from inside the 2-speed control piston chamber.

Perform disassembly and reassemble after removing foreign matter.

The 2-speed control valve spring is worn and the switching pressure is reduced.

Perform disassembly and replace the spring.

Foreign matter is clogging the pilot line, and the pilot pressure increases up to switchover pressure due to leaking from the 2-speed control valve.

Clean the inside of the line and remove foreign matter. Also, recheck the line system.

Switching to lowspeed rotation occurs, but switching to highspeed rotation occurs during operation.

75

RSM-13-02-001E 69

Travel Unit [6] Reduction gear troubleshooting Problem Rotation does not occur

Possible cause

Countermeasure and solution

There is an operation problem in a piece of equipment other than the piston motor or reduction gear.

After investigating whether pressure is reaching the motor inlet side, investigate the causes of problems and countermeasures for each piece of equipment and perform inspection and repair.

There is an operation problem in the motor aside from the reduction gear.

See [1] - [5] in Troubleshooting.

A load exceeding the motor output torque is operating.

After investigating the load, remove the load acting on the motor.

The reduction gear angular bearing is damaged and will not rotate.

Replace the reduction gear. Investigate whether an excessive external load is acting on the motor. If the external load is excessive, remove this load.

The gear inside the reduction gear is damaged and it will not rotate.

Replace the reduction gear.

The bearing inside the reduction gear is damaged and it will not rotate. The spline inside the reduction gear is damaged and it will not rotate. Abnormal noise is coming from the reduction gear during driving.

The gear inside the reduction gear is damaged. The bearing inside the reduction gear is damaged. There is abnormal wear on the sliding sections of the reduction gear and interference between parts is occurring.

The reduction gear section is heating up to an abnormal degree.

RSM-13-02-001E

Replace the reduction gear.

Perform disassembly and check the status of damage. If damage is discovered, replace the reduction gear. In there are no parts that are especially damaged, replace worn parts and reassemble after cleaning.

Reduction gear lubricating oil is insufficient. Check that there are no locations from which oil is leaking. Perform disassembly and check the status of damage within the reduction gear. If damage is discovered, replace the reduction gear. Fill with lubricating oil to the stipulated volume. There is too much reduction gear lubricating oil.

Adjust the lubricating oil amount to the stipulated volume.

The bearing inside the reduction gear is damaged.

Replace the reduction gear.

An abnormal thrust load is occurring in the reduction gear due to inappropriate thrust plate selection.

Perform disassembly and check the status of internal damage. If damage is discovered, replace the reduction gear. If no especially notable amount of damage is discovered, replace the thrust plate with another one of the correct thickness.

76 70

Travel Unit Problem Oil leaking is occurring

Possible cause

Countermeasure and solution

There is looseness in fastening bolts on the reduction gear cover, and oil leaking is occurring.

Remove the cover, reapply liquid packing, and tighten the cover to the specified torque. Fill with lubricating oil to the stipulated volume.

Plugs for the oil fill, oil drain and oil check ports on the reduction gear cover are loose, and oil leaking is occurring.

Retighten the plugs to the specified torque. After tightening, fill with lubricating oil to the stipulated volume.

O-rings for oil fill, oil drain and oil check ports on the reduction gear cover are deteriorating, and oil leaking is occurring.

Replace the O-rings for the plugs. After replacement, tighten the plugs to the specified torque and fill with lubricating oil to the stipulated volume.

There is cracking in the housing and oil leaking is occurring.

Replace the reduction gear.

There is foreign matter caught on the sliding surface of the floating seal and oil leaking is occurring.

Disassemble the reduction gear, remove foreign matter from the floating seal and perform reassembly.

Oil leaking is occurring due to corrosion on the sliding surface of the floating seal.

Disassemble the reduction gear and replace the floating seal.

The O-ring of the floating seal is deteriorated or damaged and oil leaking is occurring. The seal collar of the floating seal is split and oil leaking is occurring.

10.Motor Repair Kit See the attached Parts List for the contents of the repair kit.

77

RSM-13-02-001E 71

Travel Unit

RSM-13-02-001E

78 72

Travel Unit

79

RSM-13-02-001E 73

Travel Unit

RSM-13-02-001E

80 74

Travel Unit Travel Motor Internal Structure Diagram

81

RSM-13-02-001E 75

Travel Unit Travel Motor Part Table Code 1 1-1 1-2 1-2-1 1-2-2 1-2-2-1 1-2-2-2 1-2-2-3 1-2-2-4 1-2-2-5 1-2-3 1-2-4 1-2-5 1-2-6 1-2-6-1 1-2-6-2 1-2-6-4 1-2-6-5 1-2-6-6 1-2-6-7 1-2-6-8 1-2-7 1-2-7-1 1-2-7-2 1-2-7-3 1-2-7-4 1-2-7-5 1-2-7-6 1-2-7-7 1-2-7-9 1-2-7-10 1-2-7-11 1-2-7-13 1-2-7-14 1-2-7-15 1-2-7-16 1-2-7-17 1-2-7-18 1-2-8 1-2-9 1-2-9-1 1-2-9-2 1-2-10 1-2-11 1-2-12 1-2-13 1-2-14 1-2-19 1-2-20 1-2-21 1-3

Part name Piston motor Flange Base plate assembly Base plate Spool assembly Spool Check valve Spring Plug O-ring Spring seat Spring Spring seat Cap assembly Cap O-ring Hexagon socket head bolt Steel ball Spring Plug O-ring Relief valve assembly Relief housing Poppet Poppet seat Spring seat Spring Plug O-ring Free piston O-ring Backup ring Spring guide O-ring Locking screw Nut O-ring Backup ring Plug Spool assembly Spool A Spool C Spring Plug O-ring Spring guide Plug Orifice Plug O-ring Seat

Q'ty 1 1 1 1 1 1 2 2 2 2 2 2 2 2 1 1

Code 1-4 1-4-1 1-4-2 1-4-3 1-4-4 1-4-5 1-4-6 1-4-7 1-4-8 1-4-9 1-5 1-6 1-7 1-8 1-9 1-10

4 1-11 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 8 1 1 1 1 1 2 1 1 2 5 5 1

1-12 1-13 1-14 1-15 1-16 1-17 1-18 1-19 1-20 1-21 1-22 1-23 1-24 1-25 1-26 1-27 1-28 1-29 2 3 4 5* 5* 5* 5* 5* 6 7 8 9 10 11 12

Part name Cylinder block assembly Cylinder block Piston assembly Retainer plate Retainer holder Snap ring Spring seat Spring Collar Pin Swash plate Steel ball Piston assembly Ball bearing Ball bearing Pin Hexagon socket head bolt Oil seal Disk plate Friction plate Brake piston O-ring O-ring Spring Pin Spring Valve plate O-ring O-ring Nameplate Rivet Plug Plug Plug Spacer Floating seal Angular bearing Housing Shim t=3.6 Shim t=2.3 Shim t=2.8 Shim t=3.0 Shim t=3.2 Holder C Washer Bolt Thrust plate Inner race Needle bearing Planetary gear C

82

Q'ty 1 1 9 1 1 1 1 1 1 3 1 2 2 1 1 1 10 1 3 2 1 1 1 8 4 2 1 4 1 1 2 2 1 1 1 2 2 1 1 1 1 1 1 1 8 8 4 4 4 4

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

Part name Q'ty Thrust plate 4 Bolt 4 Sun gear C 1 Snap ring 1 Holder B 1 Thrust plate 3 Inner race 3 Needle bearing 3 Planetary gear B 3 Thrust plate 3 Thrust plate 1 Screw 3 Drive gear 1 Thrust plate t=3.6 1 Thrust plate t=2.3 1 Thrust plate t=2.8 1 Thrust plate t=3.0 1 Thrust plate t=3.2 1 Cover 1 Hexagon socket head 28 16 bolt 29 Plug 3 30 O-ring 3 31 Pin 4 The * mark indicates 1 size is selected and used.

RSM-13-02-001E 76

Take-up Roller Take-up Roller

SH200-5

Take-up Roller Removal and Installation of Take-up Roller ・ When loosening the grease cylinder check valve, loosen it a little at a time. ・ The pressure inside the cylinder is very high, so there is a danger of grease being expelled and the plug flying off. The check valve adjustment procedure should not be done in front of the check valve. Warning ・ Do not get under the machine when the main unit is jacked up. ・ Make sure to place the main unit on wood planks or the like to prevent falling. ・ Align the shoe assembly feed location and stop the engine except when working.

Items to prepare • Wrench (24 mm) • Hammer • Lifting equipment • Loctite #262 • Striking jig • Crane • Crowbar • Wood planks, etc. • Rag

1. Removal of Take-up Roller [1] Remove the shoe assembly. See the "Removal and Installation of Shoe Assembly" procemdure. [2] Use a crowbar (3) to pull off the take-up roller (1) and recoil spring assembly from the side frame (2).

1

83

Take-up roller

2

Side frame

3

Crowbar

RSM-13-03-001E 1

Take-up Roller [3] Install the lifting equipment (5) on the take-up roller (1) and recoil spring assembly (4) and hang them from the side frame (2) with the crane.

[4] Place the take-up roller (1) and recoil spring assembly (4) onto wood planks (7) as in the diagram. Use a wrench (24 mm) to remove the take-up roller bolt (6) and separate the roller and the recoil spring assembly.

1

RSM-13-03-001E

Take-up roller

2

Side frame

4

Recoil spring assembly

5

Lifting equipment

6

Bolt

7

Wood plank

84 2

Take-up Roller 2. Installation of Take-up Roller [1] Use a wrench (24 mm) to fasten the take-up roller (1) and recoil spring assembly (2) with the bolt (3). At this time, be sure to coat the bolt with Loctite #262.

[2] Install the lifting equipment (6) on the take-up roller and recoil spring assembly (2) as in the diagram, lift them up with the crane, and insert them into the side frame (5). Push in with the crowbar until the recoil spring assembly contacts the grease cylinder.

1

Take-up roller

2

Recoil spring assembly

3

Bolt

4

Wood plank

5

Side frame

6

Lifting equipment

[3] Install the shoe assembly. For details on installation, see the "Removal and Installation of Shoe Assembly" procedure.

85

RSM-13-03-001E 3

Take-up Roller Assembly and Disassembly of Take-up Roller ・ To ensure safe operations, wear protective devices before beginning work and follow all precautions. ・ When removing devices or positioning devices at the time of installation, use a removal jig and a hammer or steel rod. ・ Follow the precautions below when suspending the load. ・ The crane must be operated by a qualified operator. ・ Do not stand or pass under the suspended load. ・ Check the weight of the roller to determine whether it can be carried by hand or whether a crane must be used. ・ Fix the roller to a level surface so it does not roll. ・ Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. ・ If any parts are significantly rusted or dirty, clean them before disassembling. Caution ・ Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. ・ When assembling sliding (5) parts, be sure to coat them with new hydraulic oil. ・ As a rule, replace all O-rings and other seal parts with new parts. ・ The take-up roller is a heavy object and requires at least 2 workers to handle.

・ Be careful not to drop precision parts or let bump them with other parts during work. ・ Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention and proceed with caution so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment. ・ Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust.

Items to prepare • Hexagon wrench (6 mm) • Hammer • Wire clips • Pliers • Gear puller • Screwdriver • Engine oil (Shell Rimula Oil #30) • Specialty jigs • Pressing machine • Loctite • Special fiber cloth (Kimwipe) • Micrometer caliper • Caliper • Cylinder gauge • Seal tape • Oil pan (drip pan) • Water container for inspection

RSM-13-03-001E

86 4

Take-up Roller Configuration diagram 6

8 4 3 2

1

2 3 5 7

Part name

5 9 6

Part number

Q'ty

1

Roller

KRA1768

1

2

Bushing

KRA1201

2

3

Floating seal

BLA2371

2

4

Hub

KRA1200

1

5

O-ring 1A-G50

BHA0863

2

6

Wire clip

KNA0180

2

7

Shaft

KRA0988

1

8

Plug with seal nylon

KHJ0300

1

9

Hub (without plug)

KRA1594

1

Dimension diagram

284 202

7

9

1

2

3

5

4

6

.5 C0

C0

.5

Jig dimension diagram

40

30

10

X

5 C3

20

15

0.5

50

87

A

Bushing removal jig

B

Bushing press-fit jig

C

Floating seal installation jig

RSM-13-03-001E 5

Take-up Roller Disassembly procedure [1] Stand the roller vertically and use a hexagon wrench (1) (6 mm) to remove the plug (2). • The plug is coated with seal nylon, which comes off when the plug is removed. To reuse the plug, use seal tape.

[2] Face down the part of the roller from which the plug was removed and empty the oil from within the roller. • It may take a few hours to completely empty the roller of oil. • Place an oil pan (3) under the roller to catch the oil.

[3] Remove the wire clip (4). Tap with the hammer (6) and use another wire (5) to push out from the outside the wire clip that is in the roller. • Securely fasten the roller before doing this work. • The wire in the roller is very securely fixed, so prepare several wire clips. Also be sure to coat with lubricant.

RSM-13-03-001E

1

Hexagon wrench

2

Plug

3

Oil pan

4

Wire clip

5

Wire

6

Hammer

88 6

Take-up Roller [4] Use pliers (7) to remove the pushed out wire clip (4).

[5] Use a gear puller (8) to remove the hub (9). • If the hub has rusted or is difficult to remove due to an accumulation of debris, subject it to a shock, for example by hitting it with a hammer, to make it easier to move. • When hitting the hub with a hammer, be careful not to dent it.

[6] Check whether the surface of the floating seal (10) sliding against the removed hub has rusted or is damaged. Also check whether the O-ring (11) is twisted. • The O-ring cannot be reused. Always replace it with a new one.

89

4

Wire clip

7

Pliers

8

Gear puller

9

Hub

10

Floating seal

11

O-ring

12

Ring

RSM-13-03-001E 7

Take-up Roller [7] Remove the floating seal (10) on the roller. As described in Step [6] above, check whether the surface of the floating seal sliding against the roller shaft has rusted or is damaged. Also check whether the O-ring is twisted.

[8] Remove the O-ring (13) on the roller shaft (14). • The O-ring cannot be reused. Always replace it with a new one.

[9] Remove the shaft (14). [10] As described in Steps [3] - [6], remove the hub (15) on the opposite side and check that floating seal sliding surface is not rusted and that the O-ring is not twisted.

10

RSM-13-03-001E

Floating seal

13

O-ring

14

Shaft

15

Hub

90 8

Take-up Roller [11] As described in Step [7], remove the floating seal (16) on the opposite side.

[12] Use a micrometer caliper to measure the roller (with bushing) (18), hubs (15) and (17), and shaft (14) for wear and deformation. Replace with new parts as necessary.

91

14

Shaft

15

Hub

16

Floating seal

17

Hub

18

Roller

19

Micrometer caliper

20

Cylinder gauge

21

Caliper

RSM-13-03-001E 9

Take-up Roller [13] When replacing the bushing (23), remove it by placing a striking rod (22) against the end surface and striking that with a hammer (6) uniformly left and right as in the diagram.

[14] Invert the roller (18), use jig A (24) to push up against the bushing (23), and press with a rod-shaped object (14) (such as a shaft). The bushing comes off.

6

RSM-13-03-001E

Hammer

14

Shaft

18

Roller

22

Striking rod

23

Bushing

24

Jig A

92 10

Take-up Roller Assembly procedure [1] Clean all parts. • Find a clean location. • Place a rubber plate or cloth on the work surface so as not to damage the parts.

[2] After cleaning the parts, air blow them to remove any remaining cleaning fluid or debris.

[3] If the bushing (3) was removed during disassembly, put it into the roller (2). Use a pressing machine (4) to press in both the left and right sides.

93

1

Cleaning fluid

2

Roller

3

Bushing

4

Pressing machine

RSM-13-03-001E 11

Take-up Roller [4] Use the jigs (5) and (6) attached to the pressing machine to attach the bushing (3). Use the pressing machine to press from the opposite side. Next, use a special fiber cloth to remove all dust and debris.

[5] Attach the floating seal (8) to the hub (7). Use jig C (9) to press the floating seal into position.

[6] Use jig C (9) to attach the floating seal (8) to the roller (2) side.

RSM-13-03-001E

2

Roller

3

Bushing

5

Jig

6

Jig

7

Hub

8

Floating seal

9

Jig C

94 12

Take-up Roller [7] Use a special fiber cloth to thoroughly wipe the sliding surface of the floating seal to prevent any dust or scratches.

[8] Apply engine oil to the floating seals (8) on the hubs.

[9] Attach O-rings (12) to the shaft (11) and mount them on the roller side.

7

95

Hub

8

Floating seal

10

Hub

11

Shaft

12

O-ring

RSM-13-03-001E 13

Take-up Roller [10] Install the hubs (7) and (10) on both sides.

[11] Attach the wire clip (13) to the hub.

[12] Inject compressed air (0.2 MPa) from the oil fill port and immerse in water to check that there are no leaks.

RSM-13-03-001E

7

Hub

10

Hub

13

Wire clip

96 14

Take-up Roller [13] Insert a wire clip and fill the engine oil (120 cc) into the roller main unit. • The roller main unit can be very unstable, so give consideration to securing it.

[14] After filling the oil, use a hexagon wrench (6 mm) (14) to tighten the plug (15) with the nylon seal applied. • To reuse a plug, wrap it with seal tape.

97

14

Hexagon wrench

15

Plug

RSM-13-03-001E 15

Upper Roller Upper Roller

SH200-5

Upper Roller Removal and Installation of Upper Roller ・ When loosening the check valve, loosen it a little at a time and stop when any grease appears. (The pressure inside the cylinder is very high, so there is the danger of grease Warning being expelled and the plug flying off if the check valve is loosened too much.) The check valve adjustment procedure should not be done in front of the check valve. Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Box wrenches (19 mm, 30 mm) • Jack (That meets the lifting weight.) • Rag • Cleaning fluid • Wood planks, etc.

1. Removal of Upper Roller [1] Use a box wrench (19 mm) to loosen the grease cylinder check valve (1), then loosen the shoe tension. • Grease drains out, so provide rag (2) close to the drain port. Do not loosen the check valve all at once. Loosen it slowly while monitoring the grease output and shoe loosening.

[2] Use a jack (3) to lift the top of the shoe, and then insert wood planks (4) to separate the shoe (5) and upper roller (6) by about 10 mm.

98

1

Check valve

2

Rag

3

Jack

4

Wood plank

5

Shoe

6

Upper roller

RSM-13-04-001E 1

Upper Roller [3] Use a box wrench (30 mm) to remove the 2 bolts (7), and then remove the upper roller (6).

RSM-13-04-001E

6

Upper roller

7

Bolt

99 2

Upper Roller 2. Removal of Upper Roller [1] Perform the reverse of the removal procedure. Apply Loctite to the bolts and tighten them to the specified torque. Installation specified tightening torque: 521 608 N•m [2] Tighten the check valve (1). While monitoring the track shoe tension, inject grease into the grease cylinder.

[3] To adjust the track shoe tension, raise the lower side frame as shown in the diagram. Place a wood plank (2) under the lower frame to prevent falling. Adjust the tension so that the distance indicated with A between the frame bottom (3) of the center area of the lower side frame and the lowest hanging part of the top of the shoe plate (4) is 280 - 300 mm.

100

1

Check valve

2

Wood plank

3

Frame lower section

4

Topside of shoe plate

RSM-13-04-001E 3

Upper Roller Assembly and Disassembly of Upper Roller ・ To ensure safe operations, wear protective devices before beginning work and follow all precautions. ・ When removing devices or positioning devices at the time of installation, use a removal jig and a hammer or steel rod. ・ Follow the precautions below when suspending the load. ・ The crane must be operated by a qualified operator. ・ Do not stand or pass under the suspended load. ・ Check the weight of the roller to determine whether it can be carried by hand or whether a crane must be used. ・ Fix the roller to a level surface so it does not roll. ・ Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. Caution ・ If any parts are significantly rusted or dirty, clean them before disassembling. ・ Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. ・ When assembling touching parts, be sure to coat them with new hydraulic oil. ・ As a rule, replace all O-rings and other seal parts with new parts.

・ Be careful not to drop precision parts or let bump them with other parts during work. ・ Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention and proceed with caution so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment. ・ Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust.

Items to prepare • Hexagon wrench (6 mm) • Hammer • Wrenches (13 mm, 17 mm) • Box wrench (17 mm) • Screwdriver • Engine oil (Shell Rimula Oil #30) • Specialty jigs • Pressing machine • Loctite 262 • Special fiber cloth (Kimwipe) • Marking pen • Micrometer caliper • Caliper

RSM-13-04-001E

101 4

Upper Roller Configuration diagram 13

12

Part name 10

8 7 1 5 3

4

6

Q'ty

102R010Y016N

2

1 2

Loctite #262

KRC5007

Q'ty reqd.

3

Cover (bolt stopper)

KRA1719

1

4

Plug with seal nylon

KHJ0300

1

5

O-ring

UHA0049

1

6

High strength bolt M8X25

102R008

3

7

Thrust plate

KRA1123

1

8

Shaft

KRA1252

1

11

9

Part number

High strength bolt M10X16

9

Bushing

KRA1248

1

10

Bushing

KRA1249

1

11

Roller

KRA1718

1

12

Floating seal

KBA0783

1

13

Bracket

KRA1305

1

Dimension diagram 114.5

65

11.5 13

12

1 2 3 4

5 2 6

7

8

9

10

11

Jig dimension diagram

102

A

Bushing removal jig

B1

Bushing press-fit jig (10)

B2

Bushing press-fit jig (9)

C

Floating seal installation jig

RSM-13-04-001E 5

Upper Roller Disassembly procedure [1] Stand the roller vertically and use a hexagon wrench (6 mm) (1) to remove the plug (2). • The plug is coated with seal nylon, which comes off when the plug is removed. To reuse the plug, be sure to use seal tape.

[2] Face down the part of the roller from which the plug was removed and empty the oil from within the roller. • It may take a few hours to completely empty the roller of oil. • Place an oil pan (3) under the roller to catch the oil.

[3] Use a wrench (13 mm) to remove the 3 bolts (4) from the cover (5).

RSM-13-04-001E

1

Hexagon wrench

2

Plug

3

Oil pan

4

Bolt

5

Cover

103 6

Upper Roller [4] Remove the cover (5). If the cover is difficult to remove, it is possible to use an adapter to apply compressed air or to pry it open by inserting a flathead screwdriver into either end of the cover. • When using compressed air, be careful of flying parts.

[5] Use a box wrench (17 mm) to remove the 2 bolts (7) inside the roller, and then remove the thrust plate (8).

[6] Lift the roller (9) and the shaft (10) comes off.

104

5

Cover

6

Air hose

7

Bolt

8

Thrust plate

9

Roller

10

Shaft

RSM-13-04-001E 7

Upper Roller [7] Remove the floating seal (11) on the roller. Check whether the surface of the floating seal sliding against the roller has rusted or is damaged. Also check whether the O-ring (12) is twisted.

[8] Remove the floating seal (11) on the shaft (10). • The shaft and bracket (14) cannot be removed.

[9] Remove the O-ring (15) on the cover (16) side. • Check whether the O-ring is twisted. If it is twisted, replace it with a new O-ring.

9

RSM-13-04-001E

Roller

10

Shaft

11

Floating seal

12

O-ring

13

Ring

14

Bracket

15

O-ring

16

Cover

105 8

Upper Roller [10] Use a micrometer caliper to measure the roller (with bushing) (9), bracket (14), and shaft (10) for wear and deformation. Replace with new parts as necessary.

[11] When replacing a bushing (22) and (23), use jig A (21) to restrain it from the side where the shaft (10) was removed and press it out with a pressing machine (20).

106

9

Roller

10

Shaft

14

Bracket

17

Caliper

18

Micrometer caliper

19

Cylinder gauge

20

Pressing machine

21

Jig (A)

22

Bushing [10]

23

Bushing [9]

RSM-13-04-001E 9

Upper Roller Assembly procedure [1] Clean all parts. • Find a clean location. • Place a rubber plate or cloth on the work surface so as not to damage the parts.

[2] After cleaning the parts, air blow them to remove any remaining cleaning fluid or debris.

[3] If the bushing (2) was removed during disassembly, put it into the roller (5). Face up the thrust plate installation side, restrain from above using jig B2 (3), and push in with the pressing machine (4).

RSM-13-04-001E

1

Cleaning fluid

2

Bushing

3

Jig (B2)

4

Pressing machine

5

Roller

107 10

Upper Roller [4] Invert the roller (5) and insert the bushing (6). Restraining from above using jig B1 (7), push in with the pressing machine (4). Push in all the way to the position where jig B1 stops.

[5] Insert the floating seal (8) into the roller (5) and bracket (10). Use jig C (9) to press the floating seal into position.

[6] Use a special fiber cloth to wipe the surfaces of the floating seals so as to increase adhesion and prevent dust from entering.

108

4

Pressing machine

5

Roller

6

Bushing

7

Jig (B1)

8

Floating seal

9

Jig (C)

10

Bracket

RSM-13-04-001E 11

Upper Roller [7] Apply hydraulic oil to the roller (5).

[8] Attach the shaft (11) to the roller (5).

[9] Use a special fiber cloth to thoroughly wipe the thrust plate (12) to prevent any dust or scratches.

5

RSM-13-04-001E

Roller

11

Shaft

12

Thrust plate

109 12

Upper Roller [10] Use a box wrench (17 mm) to fasten the thrust plate (12) with the 2 bolts (13). Degrease the bolts well, apply Loctite (14) to the bolt openings, and tighten the bolts. After tightening the bolts, mark them (15). • The bolt tightening torque is 62.8 - 72.6 N•m.

[11] Use a wrench (13 mm) to fasten the cover (18) with the 3 bolts (17). Degrease the bolts, apply Loctite (14) to the bolt openings, and tighten the bolts. After tightening the bolts, mark them (16). • The bolt tightening torque is 31.4 - 37.2 N•m.

[12] Rotate the roller in the direction of the arrow and check that it rotates smoothly.

110

12

Thrust plate

13

Bolt

14

Loctite

15

Marking

16

Marking

17

Bolt

18

Cover

RSM-13-04-001E 13

Upper Roller [13] Inject compressed air (0.2 MPa) from the oil fill port and immerse in water to check that there are no leaks.

[14] Fill engine oil (50 - 55 cc) into the roller. After filling the engine oil, use a hexagon wrench (20) to tighten the plug (21) (coated with seal nylon). After tightening the bolts, mark them (19). • To reuse a plug, wrap it with seal tape.

19

Marking

20

Hexagon wrench

21

Plug

This completes the assembly.

RSM-13-04-001E

111 14

Lower Roller Lower Roller

SH200-5

Lower Roller Removal and Installation of Lower Roller ・ Do not get under the main unit when it is jacked up. Make sure to place the main unit on wood planks to prevent falling. Warning ・ When loosening the grease cylinder check valve, loosen it a little at a time and stop when any grease appears. (The pressure inside the cylinder is very high, so there is the danger of grease being expelled and the plug flying off if the check valve is loosened too much.) Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Box wrenches (19 mm, 27 mm) • Rag • Cleaning fluid • Wood planks, etc.

1. Removal of Lower Roller [1] Use a box wrench (19 mm) to loosen the check valve (1), and then loosen the shoe tension. Do not loosen the check valve all at once. Loosen it slowly while monitoring the grease output and shoe loosening. • Grease drains out, so provide rag (2) close to the drain port.

112

1

Check valve

2

Rag

RSM-13-05-001E 1

Lower Roller [2] Jack up the side frame as in the diagram on the side where the roller is being replaced. Jack up so that the shoe is floating about 5 cm and insert wood planks (3) under the lower frame to prevent falling.

[3] If it is impossible to insert wood planks (3) under the lower frame, insert wood planks (4) between the side frame and the link shoe (5) to separate the link shoe and lower roller (6) by about 15 mm.

[4] Use a box wrench (27 mm) to remove the 4 bolts (7), and then remove the lower roller (6).

RSM-13-05-001E

3

Wood plank

4

Wood plank

5

Link shoe

6

Lower roller

113 2

Lower Roller 2. Installation of Lower Roller [1] Perform the reverse of the removal procedure. Apply Loctite to the bolts and tighten them to the specified torque. Tightening torque: 371 - 432 N•m [2] Tighten the check valve (1). While monitoring the track shoe tension, inject grease into the grease cylinder.

[3] To adjust the track shoe tension, raise the lower side frame as shown in the diagram. Place a wood plank (2) under the lower frame to prevent falling. Adjust the tension so that the distance indicated with A between the lower frame (3) of the center area of the lower side frame and the lowest hanging part of the shoe plate (4) is 280 - 300 mm.

114

1

Check valve

2

Wood plank

3

Frame

4

Shoe plate

RSM-13-05-001E 3

Lower Roller Assembly and Disassembly of Lower Roller ・ To ensure safe operations, wear protective devices before beginning work and follow all precautions. ・ When removing devices or positioning devices at the time of installation, use a removal jig and a hammer or steel rod. ・ Follow the precautions below when suspending the load. ・ The crane must be operated by a qualified operator. ・ Do not stand or pass under the suspended load. ・ Check the weight of the roller to determine whether it can be carried by hand or whether a crane must be used. ・ Fix the roller to a level surface so it does not roll. ・ Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. Caution ・ If any parts are significantly rusted or dirty, clean them before disassembling. ・ Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. ・ When assembling sliding parts, be sure to coat them with new hydraulic oil. ・ As a rule, replace all O-rings and other seal parts with new parts.

・ Be careful not to drop precision parts or let bump them with other parts during work. ・ Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention and proceed with caution so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment. ・ Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust.

Items to prepare • Hexagon wrench (6 mm) • Hammer • Wire clips • Pliers • Gear puller • Screwdriver • Gear oil (Mobile Gear Oil SHC320) • Specialty jigs • Pressing machine • Loctite • Special fiber cloth (Kimwipe) • Micrometer caliper • Caliper • Cylinder gauge

RSM-13-05-001E

115 4

Lower Roller Configuration diagram 8 6 4 5 3 2 7

1

Part name 3 5 4 9 8

Part number

Q'ty

1

Roller

KRA10370

1

2

Shaft

KRA11260

1

3

Bushing

KRA1197

2

4

Floating seal

BHA1099

2

5

O-ring 1A-G60

BHA0863

2

6

Collar

KRA1196

1

7

Plug with seal nylon

KHJ0300

1

8

Wire clip

KNA0180

2

9

Collar (without plug)

KRA1595

1

Dimension diagram 318 246

9

1

2

3

4

5

6

7

8

Jig dimension diagram

116

A

Bushing removal jig

B

Bushing press-fit jig

C

Floating seal installation jig

RSM-13-05-001E 5

Lower Roller Disassembly procedure [1] Stand the roller vertically and use a hexagon wrench (6 mm) (1) to remove the plug (2). • The plug is coated with seal nylon, which comes off when the plug is removed. To reuse the plug, be sure to use seal tape.

[2] Face down the part of the roller from which the plug was removed and empty the oil from within the roller. • It may take a few hours to completely empty the roller of oil. • Place an oil pan (3) under the roller to catch the oil. • Securely fasten so that the roller does not fall over.

[3] Remove the wire clip (4). Tap another wire (5) with the hammer (6) from the outside to push out the wire clip that is already in the roller. • Place the roller horizontally and secure it so it does not roll before doing this work. • The wire in the roller is very securely fixed, so prepare several wire clips. Also be sure to coat with lubricant.

RSM-13-05-001E

1

Hexagon wrench

2

Plug

3

Oil pan

4

Wire clip

5

Wire

6

Hammer

117 6

Lower Roller [4] Use pliers (7) to remove the pushed out wire clip (4).

[5] Use a gear puller (8) to remove the collar (9). If the collar is difficult to remove, hook the collar on the bolt and catch the puller on that part. • If the collar has rusted or is difficult to remove due to an accumulation of debris, subject it to a shock, for example by hitting it with a hammer, to make it easier to move. • When hitting the collar with a hammer, be careful not to dent it.

[6] Check whether the surface of the floating seal (10) sliding against the removed collar has rusted or is damaged. Also check whether the O-ring (11) is twisted. • The O-ring cannot be reused. Always replace it with a new one.

118

4

Wire clip

7

Pliers

8

Gear puller

9

Collar

10

Floating seal

11

O-ring

12

Ring

RSM-13-05-001E 7

Lower Roller [7] Remove the floating seal (10) on the roller. As described in Step [6] above, check whether the surface of the floating seal sliding against the roller has rusted or is damaged. Also check whether the O-ring is twisted.

[8] Remove the O-ring (13) on the shaft (14). • The O-ring cannot be reused. Always replace it with a new one.

[9] Remove the shaft (14).

10

RSM-13-05-001E

Floating seal

13

O-ring

14

Shaft

119 8

Lower Roller [10] As described in Step [7], remove the floating seal (10) on the opposite side.

[11] Use a micrometer caliper to measure the roller (with bushing) (17), collars (9) and (18), and shaft (14) for wear and deformation. Replace with new parts as necessary.

[12] When replacing a bushing, insert jig A (15) into the bushing (16), and use a cylindrical object (such as a shaft) (14) to push from the top. The bushing comes off.

9

Collar

17

Roller

10

Floating seal

18

Collar

14

Shaft

19

Caliper

15

Jig (A)

20

Micrometer caliper

16

Bushing

21

Cylinder gauge

120

RSM-13-05-001E 9

Lower Roller Assembly procedure [1] Clean all parts by immersing them in cleaning fluid. • Find a clean location. • Place a rubber plate or cloth on the work surface so as not to damage the parts.

[2] After cleaning the parts, air blow them to remove any remaining cleaning fluid or debris.

[3] If the bushing (2) was removed during disassembly, put it into the roller (5). Restraining from above using jig B (3), push in with the pressing machine (4). Invert the roller and insert the bushing on the opposite side in the same manner.

RSM-13-05-001E

1

Cleaning fluid

2

Bushing

3

Jig (B)

4

Pressing machine

5

Roller

121 10

Lower Roller [4] Use jig C (8) to push the floating seal (6) into the collar (7) and roller (5).

[5] Use a special fiber cloth to wipe the surfaces of the floating seals so as to increase adhesion and prevent dust from entering.

[6] Apply gear oil to the floating seals (6) on the collars (7) and (9).

122

5

Roller

6

Floating seal

7

Collar

8

Jig (C)

9

Collar

RSM-13-05-001E 11

Lower Roller [7] Attach O-rings (11) to the shaft (10) and mount into the roller (5).

[8] Install the collars (7) and (9) on both sides.

[9] Attach the wire clip (12). • When attaching the wire clip, secure the roller main unit so that it does not roll.

RSM-13-05-001E

5

Roller

7

Collar

9

Collar

10

Shaft

11

O-ring

12

Wire clip

123 12

Lower Roller [10] Turn the main unit and check that the roller rotates properly.

[11] Inject compressed air (0.2 MPa) from the oil fill port and immerse in water to check that there are no leaks.

[12] Fill gear oil (125 cc) into the roller. Use a hexagon wrench (6 mm) (14) to tighten the plug (13) with the nylon seal applied. • Mobile Gear Oil SHC320 is recommended for use. • The plug tightening torque is 24.5 N•m. • To reuse a plug, wrap it with seal tape.

13

Plug

14

Hexagon wrench

This completes the assembly.

124

RSM-13-05-001E 13

Swing Unit Swing Unit

SH200-5

Swing Unit SH210-5 Removal and Installation of Swing Unit Warning ・ Be sure to release hydraulic pressure before beginning work. ・ Be sure to stop the engine before beginning work. ・ Be sure to inspect the wire rope and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load. ・ When removing this product from the equipment it is mounted on, stop that equipment Caution system and wait for the surface temperature of this product to fall to about 40 ℃ or below before removing it. Working on this product while it is still hot can cause burns. Additionally, always bleed out the pressure before removing any line from this product. Removing a pressurized line can result in oil spraying out and causing burns and oil leaking.

Items to prepare • Wrenches (14 mm, 19 mm, 22 mm, 27 mm, 36 mm, 41 mm) • Hexagon wrench (5 mm) • Box wrench (30 mm) • Pliers • Hammer • Grease • Specialty adapter for vacuum pump connection • Vacuum pump (vacuum pump power supply) • Extension cable • Wire rope (with the required breaking load) • Marking pen • Caps • Plugs • Crane (with the required lifting capacity) • Rag • Cleaning fluid • Wood planks, etc.

1. Removal of Swing Unit [1] Use a hexagon wrench (5 mm) to remove the 4 bolts (1), and then remove the air breather (2) on the hydraulic oil tank.

125

1

Bolt

2

Air breather

RSM-13-06-001E 1

Swing Unit [2] Attach the specialty adapter (3) to the area where the air breather was removed, and set the vacuum pump. Create negative pressure in the hydraulic oil tank using the vacuum pump (4).

[3] Use a wrench (19 mm) to remove the 6 bolts (5), and then remove the center cover (6).

RSM-13-06-001E

3

Specialty adapter

4

Vacuum pump

5

Bolt

6

Center cover

126 2

Swing Unit [4] Use the wrenches [22 mm, 27 mm, 36 mm, 41 mm] to remove the hoses (7), (8), (9), (10), (11) and (12) from the swing motor. • Mark the swing motor and hoses so that the connectors can be matched during assembly. • Attach caps or plugs to the swing motor and hoses to prevent any entry of water, dust or dirt. • Clean the swing motor and hoses by spraying them with a parts cleaner to prevent scratching and prevent dirt from accumulating on the connectors.

[5] Use a wrench (19 mm) to remove the grease hose (13) that feeds grease to the swing motor reduction gear bearing.

[6] Use a wrench (19 mm) to remove the 3 bolts (14), and then remove the under cover (15).

127

7

Make-up hose (use 41 mm)

8

Main hose (right) (use 36 mm)

9

Main hose (left) (use 36 mm)

10

Drain hose (use 27 mm)

11

Drain hose (use 27 mm)

12

Pilot hose (use 22 mm)

13

Grease hose

14

Bolt

15

Under cover

RSM-13-06-001E 3

Swing Unit [7] Use a wrench (14 mm) to remove the bolt (16) on the clamp (17) for the hose.

[8] After removing all of the hoses, use pliers to cut the wire band (19) that binds the hoses.

[9] Use a box wrench (30 mm) to remove the 11 bolts (20) from the swing unit.

16

RSM-13-06-001E

Bolt

17

Clamp

18

Drain hose

19

Wire band

20

Bolt

21

Knock pin

128 4

Swing Unit [10] Wrap the wire rope (22) around the swing motor and lift it with a crane. • A knock pin (21) is driven into the installation section of the swing unit. Apply lubricating oil to the knock pin and pull it out together with the main unit of the swing motor while hitting with a hammer.

[11] Thoroughly check that the location is safe before lowering the swing unit on wood planks (23). • Thoroughly secure the swing unit so that it does not fall over.

129

21

Knock pin

22

Wire rope

23

Wood plank

RSM-13-06-001E 5

Swing Unit 2. Installation of Swing Unit [1] Perform the reverse of the removal procedure. When installing the swing unit, be careful with the position of the knock pin. The tightening torque for the bolts for installing the swing unit on the swing frame is 539 - 630 N•m. [2] Before driving, be sure to fill the inside of the motor casing with hydraulic oil from the drain port (1). Thoroughly perform air bleeding from the air bleed port (2). Use the level gauge (3) to check that gear oil for the reduction gear is filled to the stipulated volume.

RSM-13-06-001E

1

Drain port

2

Air bleed port

3

Level gauge

130 6

Swing Unit SH210-5 Assembly and Disassembly of Swing Unit

Caution

1. Read and understand the contents of this Maintenance Manual before performing disassembly, reassembly, inspection, repair, or other such work of this product. 2. Handle this product according to the separate "Usage Cautions". 3. When removing this product from the equipment it is mounted on, stop that equipment system and wait for the surface temperature of this product to fall to about 40 ℃ or below before removing it. Working on this product while it is still hot can cause burns. Additionally, always bleed out the pressure before removing any line from this product. Removing a pressurized line can result in oil spraying out and causing burns and oil leaking. 4. Use the specialty tools and measurement instruments for disassembly, reassembly, inspection, and repair, etc. of this product. Using an inappropriate tool may result in injury or product damage. 5. Be careful of parts falling when performing disassembly, reassembly, inspection or repair, etc. of this product. This may result in injury or parts damage. 6. Do not directly touch with bare hands the machined edges or threaded sections of parts during disassembly, reassembly, inspection, or repair etc. of this product. This may result in injury. 7. Check performance after reassembly. Do not resume use unless performance is fully recovered. Using this product at a sub-par performance level may result in product damage. 8. The cautions (mark !) listed in this Maintenance Manual do not cover all possible dangers. Always think of safety first during disassembly, inspection, reassembly, repair, or other such work.

131

RSM-13-06-001E 7

Swing Unit 1. Disassembly [1] Making a reference mark on the unit matching surface It is useful to place a reference mark (*1) on the matching surface of the housing (25) and ring gear (73) with paint, etc.

[2] Removal of level gauge assembly Remove the level gauge assembly (42), cap (44) (27 mm hex diameter), and cap (34) (10 mm hex socket diameter).

[3] Gear oil draining Loosen the drain hose (*1) end plug, and then drain the gear oil. • Gear oil cannot be reused.

RSM-13-06-001E

132 8

Swing Unit [4] Removal of hose Remove the drain hose (*1) and grease hose (*2).

[5] Removal of motor Loosen the hexagon bolts (75) (19 mm hex diameter) and remove them along with the washers (74). Use the make-up port (G1) to raise the motor and remove it. • Liquid packing has been applied to the matching surfaces of the housing (25) and ring gear (73), so use the notch sections (*1) in the diagram on the right to remove the motor.

This completes the disassembly.

133

RSM-13-06-001E 9

Swing Unit 2. Assembly [1] Liquid packing application After cleaning and degreasing the reduction gear ring gear (73) and the motor housing (25) matching surfaces, apply (*1) liquid packing (ThreeBond Co.,Ltd. "1215" gray or the equivalent) as shown in the diagram on the right.

[2] Installation of motor Lift the motor and softly install it in the reduction gear, tighten the hexagon bolts (75) (19 mm hex diameter) holding the washers (74) in place to the tightening torque of 103 N•m. • Align the housing (25) and ring gear (73) according to the reference mark (*1) made before disassembly.

RSM-13-06-001E

134 10

Swing Unit [3] Installation of level gauge assembly Install the cap (44) (27 mm hex diameter) into the housing by tightening it to a torque of 49 N•m, and insert the level gauge assembly (42).

[4] Gear oil filling Install a plug in the female side of the hose, and install a hose (*1) in the drain port on the side of the gear case. Fill with gear oil (5 L) from the housing (25) gear oil fill port. Tighten the gear oil fill port cap (34) (10 mm hex socket diameter) to the housing to a tightening torque of 49 N•m.

[5] Grease-up Remove the plug (68) (5 mm hex socket diameter) from the gear case (66) and inject grease (1 L) from the grease fill port. • When injecting grease, there is the possibility of the reduction gear oil seal being damaged by internal pressure, so remove the air bleed port plug before injecting grease. Tighten the plug to the gear case to a tightening torque of 20 N•m. After injecting grease, install the grease hose in the grease fill port. This completes the assembly.

135

RSM-13-06-001E 11

Swing Unit SH210-5 Assembly and Disassembly of Swing Motor

Caution

RSM-13-06-001E

1. Read and understand the contents of this Maintenance Manual before performing disassembly, reassembly, inspection, repair, or other such work of this product. 2. Handle this product according to the separate "Usage Cautions". 3. When removing this product from the equipment it is mounted on, stop that equipment system and wait for the surface temperature of this product to fall to about 40 ℃ or below before removing it. Working on this product while it is still hot can cause burns. Additionally, always bleed out the pressure before removing any line from this product. Removing a pressurized line can result in oil spraying out and causing burns and oil leaking. 4. Use the specialty tools and measurement instruments for disassembly, reassembly, inspection, and repair, etc. of this product. Using an inappropriate tool may result in injury or product damage. 5. Be careful of parts falling when performing disassembly, reassembly, inspection or repair, etc. of this product. This may result in injury or parts damage. 6. Do not directly touch with bare hands the machined edges or threaded sections of parts during disassembly, reassembly, inspection, or repair etc. of this product. This may result in injury. 7. Check performance after reassembly. Do not resume use unless performance is fully recovered. Using this product at a sub-par performance level may result in product damage. 8. The cautions (mark !) listed in this Maintenance Manual do not cover all possible dangers. Always think of safety first during disassembly, inspection, reassembly, repair, or other such work.

136 12

Swing Unit 1. Causes of Trouble and Solutions This list consists of actions to be taken when an abnormality is sensed or there are problems with functions during use of the hydraulic motor. Additionally, details concerning disassembly inspection and reassembly are listed after this, but sufficient caution should be exercised in handling during these actions so as to prevent scratching of sliding parts of the motor. Table 1 Symptom

No rotation

Severe slipping

Abnormal noise due to insufficient torque

Cause

External inspection

Solution

Internal motor damage

Measure the amount of drained oil.

It is very likely that sliding section is damaged when the oil fed to the motor is mostly being drained, so disassembly inspection is necessary.

Internal motor damage

Open the motor inlet and outlet ports and apply 3.2 4.9 MPa of pilot pressure to the brake release port, and attempt to turn the output shaft using about 30 - 40 N•m of torque.

It is very likely that there is internal damage if the output shaft does not turn smoothly at the torque listed to the left, so disassembly inspection is necessary.

Setting problem with relief valve within the circuit

Measure the load pressure with the pressure gauge.

Reset to the correct set pressure.

Wear or damage on sliding section or high-pressure seal section of the motor

Measure the amount of drained oil.

The leaking amount is high if the amount of drained oil is 2.5 L/min or more, so disassembly inspection is necessary.

High oil temperature and high internal motor leaking

Measure the oil temperature.

Lower the oil temperature.

Wear or seizing on motor sliding section

Open the motor inlet and outlet ports and apply 3.2 4.9 MPa of pilot pressure to the brake release port, and attempt to turn the output shaft using about 30 - 40 N・ m of torque.

It is very likely that there is internal damage if the output shaft does not turn smoothly at the torque listed to the left, so disassembly inspection is necessary.

Setting problem with relief valve within the circuit

Measure the load pressure with the pressure gauge.

Reset to the correct set pressure.

Internal motor damage

Check for metallic foreign matter in oil drained from the motor and within the return filter.

It is very likely that there is internal motor damage if metallic foreign matter is discovered, so disassembly inspection is necessary.

Large amount of air in oil

Inspect oil within the tank and motor case.

Thoroughly perform air bleeding.

Looseness in tightening section

Check for looseness in line fitting, fitting installation bolt, motor installation bolt and each bolt on the motor.

Tighten the bolt(s) to the appropriate torque.

137

Correction

See Table 2

Replace damaged part(s) or motor assembly.

See Table 2

Inspect the parts and bearings in a - e of Table 2, and perform replacement if there are any abnormalities.

Repair or replace damaged part(s). Replace motor assembly.

RSM-13-06-001E 13

Swing Unit Symptom

Abnormal generation of heat

Oil leaking from matching surface

Cause

External inspection

Solution

Correction

Seizing in motor sliding or rotating section

Check for metallic foreign matter in oil drained from the motor and within the return filter. Also, apply 3.2 - 4.9 MPa of pilot pressure to the brake release port and attempt to turn the output shaft using about 30 - 40 N•m of torque.

It is very likely that there is internal motor damage if metallic foreign matter is discovered or the output shaft does not turn smoothly at the torque listed to the left, so disassembly inspection is necessary.

Repair or replace damaged part(s). Replace motor assembly.

Scratched O-ring

Replace Oring(s).

Scratched seal surface

Repair seal surface(s) or replace seal(s).

Looseness in bolt.

Oil leaking from oil seal

Inspect looseness in bolt.

Tighten the bolt(s) to the appropriate torque.

Scratching or wear on the oil seal lip section

Replace oil seal(s).

Scratching or wear on the seal section of the shaft

Repair part(s) or replace the motor assembly.

Abnormal internal case pressure

Check the internal case pressure and amount of drained oil.

Lower the internal case pressure to 0.3 MPa or below. If the amount of drained oil is high, disassembly inspection is necessary.

Replace oil seal(s). Repair or replace damaged part(s). Replace motor assembly.

Table 2 No.

Inspection part

Correction

a

Wear on balance plate (21) sliding section

Repair or replace part.

b

Damage to cam plate (5) sliding section

Repair part or replace motor.

c

Damage to piston assembly (7) sliding section(s)

Repair part(s) or replace motor.

d

Wear on piston outer diameters of piston assembly (7)

Repair part(s) or replace motor

e

Wear on cylinder (24) piston hole(s)

Replace motor

f

Damage to teflon ring(s) (19)

Replace part(s)

RSM-13-06-001E

138 14

Swing Unit 2. Maintenance Standard Table Table 1 Part name

Inspection and measurement location

Reference value (permissible limit value)

Measurement device

Repair, solution procedure

Shoe sliding surface roughness

0.8 S

Surface roughness gauge

Repair with sandpaper lapping.

Shoe sliding surface groove depth(s)

0.4 mm or greater

Micrometer caliper

Replace it (them) with new part(s).

Piston and shoe spherical coupling section backlash

0.4 mm or less

Dial gauge

Replace it (them) with new part(s).

Piston bore(s)

There is almost no wear. If there are any scratching or seizing, replace it (them) with new part(s).

Surface roughness

0.8 S

Surface roughness gauge

Lap

End surface roughness

0.4 S

Surface roughness gauge

Lap

Piston holes

There is almost no wear. If there are any scratching or seizing, replace the motor.

Balance plate (21)

Surface roughness

0.8 S

Surface roughness gauge

Lap

Piston assemblies (7) Cylinder (24)

Gaps between piston bore and cylinder hole

0.04 mm or less

Micrometer caliper Air micrometer caliper

Replace motor.

Piston assemblies (7)

Cam plate (5)

Cylinder (24)

Table 2 Part name

Inspection and maintenance standards

Tapered roller bearing (3) Needle bearing (22) Auto aligning roller bearing (65) Auto aligning roller bearing (71)

Even with normal use, bearings need to be replaced with new parts every 3000 hr. of use. Also, make sure to replace them with new parts even within the 3000 hr. limit during reassembly after disassembly.

Oil seals (2) (70)

If there is scratching on lip(s), replace it (them) with new part(s). Also, even with normal use without any leaks, replace them with new parts every 3000 hr. of use. Also, make sure to replace the O-rings with new ones even within the 3000 hr. limit during reassembly after disassembly.

O-rings (10) (12) (16) (30) (31) (36) (43) (91) (93)

If there is any scratching on O-ring(s), replace it (them) with new part(s). Also, even with normal use without any leaking, replace the O-rings with new ones every 3000 hr. of use. Also, make sure to replace the O-rings with new ones even within the 3000 hr. limit during reassembly after disassembly.

Backup rings (29) (41)

When reassembling after disassembly, always replace them with new parts.

139

RSM-13-06-001E 15

Swing Unit 3. Disassembly [1] Removal of relief assembly, etc. Remove the relief valve assemblies (35) (14 mm hex socket diameter), caps (40) (14 mm hex socket diameter), springs (39), checks (38), caps (28) (10 mm hex socket diameter), and plugs (33) from the cover (32). • When reassembling the disassembled relief assemblies, caps, springs, checks, and plugs, make sure to install them in their original locations.

[2] Making a reference mark on the motor matching surface It is useful for reassembly to make a reference mark (*1) with paint etc. on the matching surface of the cover (32) and housing (25).

RSM-13-06-001E

140 16

Swing Unit [3] Loosening the tightening bolts Loosen the hexagon socket head bolts (37) (14 mm hex socket diameter), place the motor with the output shaft facing down, and lift up and remove the cover (32).

[4] Removal of inner race Remove the snap ring (23) with the mark-off pin, and remove the needle bearing (22) inner race and balance plate (21). At this time, the inner race of the needle bearing is press fit into the male shaft of the cover (32), so place the gear puller in the archshaped groove sections of the balance plate and on the male shaft of the cover to remove the inner race. Next, take out the pistons (14) from the balance plate. • Be careful not to scratch the sliding surface of the balance plate or apply a great deal of force and cause deformation. • The attachment direction of the balance plate in relation to the cover is set, so place a mark on the balance plate and cover to confirm the attachment direction during reassembly.

141

RSM-13-06-001E 17

Swing Unit [5] Removal of O-ring Remove the O-ring (12) from the cover (32).

[6] Removal of bushing Remove the bushings (20) with the teflon rings (19) attached and the Scrowave springs (18) from the cover (32).

[7] Removal of spring Take out the springs (13) from the brake piston (11). • Make sure the spring positions for installation on the piston can be determined.

RSM-13-06-001E

142 18

Swing Unit [8] Removal of brake piston When taking the piston (11) out from the housing (25), sliding resistance occurs due to the force-fitting effect of O-rings (10) and (12). The piston is difficult to remove, so use a monkey wrench (*1) with the tap holes (M6) on the piston as shown in the diagram to remove the piston. Next, remove O-ring (10) from the housing and O-ring (12) from the piston. • Place the metal blocks (*2) outside the housing inner diameter.

[9] Removal of friction plate and partner plate Remove the friction plates (8) and partner plates (9).

143

RSM-13-06-001E 19

Swing Unit [10] Removal of cylinder assembly Grasp the end of the cylinder (24) by hand and remove the cylinder assembly from the housing. • Oil on the cylinder (24) makes it easy for it to slide, so be careful not to let it fall. • The tapered roller bearing (3) outer race and the oil seal (2) should be left within the housing. • The "A" end surface of the cylinder is the sliding surface, so cover this surface with a soft rag, etc. to prevent scratching. • Place reference marks or numbers on the cylinder piston holes and piston assemblies (7) so that during reassembly piston assemblies are placed in the same holes they were in at disassembly.

[11] Removal of tapered roller bearing outer race Remove the tapered roller bearing (3) outer race from the housing (25). Next, strike the oil seal (2) with a screwdriver and hammer to remove it. • The oil seal cannot be reused.

RSM-13-06-001E

144 20

Swing Unit [12] Disassembly of cylinder assembly 1) Remove the inner race (1) and tapered roller bearing. Remove the snap ring (27) with the mark-off pin, use the gear puller on the two locations on the tapered roller bearing (3) inner race and the cylinder (24) spline end to remove the bearing along with the inner race (1).

2) Remove the collar (26) from the cylinder (24). Remove the cam plate (5), return plate (6), and piston assemblies (7) all together from the cylinder.

3) Remove the cam plate (5) so that it slides on the piston assembly (7) sliding surfaces. • Be very careful with handling to prevent scratching of the cam plate or piston assembly sliding surfaces.

145

RSM-13-06-001E 21

Swing Unit 4) Remove the receiving spring (4) from the cylinder (24).

This completes the disassembly.

RSM-13-06-001E

146 22

Swing Unit 4. Assembly [1] Preparation before operation Execute the following preparations before reassembly. 1) Check each part for scratches from use or from disassembly. If there are any scratches, remove them with a whetstone or sandpaper of the necessary grain, clean with cleaning oil, then dry off with an air blower.

2) Replace seal parts with new ones. 3) Lap the piston assemblies (7), cam plate (5), and balance plate (21) sliding surfaces on a surface plate with #2000 sandpaper.

4) When assembling sliding sections, apply clean hydraulic oil to the parts to assemble them.

147

RSM-13-06-001E 23

Swing Unit [2] Assembly of cylinder assembly 1) Apply hydraulic oil to the spherical section (interference section with receiving spring) (*1) of the cylinder (24) and install the receiving spring (4).

2) Insert the piston assemblies (7) into the return plate (6) holes.

3) Install the piston assemblies (7) and return plate (6) together onto the cylinder (24). • At this time, install the piston assemblies in the same holes they were in before disassembly. • When installing, apply hydraulic oil to the cylinder piston holes.

RSM-13-06-001E

148 24

Swing Unit 4) Apply hydraulic oil to the shoe sliding surfaces of the piston assemblies (7), and then install the cam plate (5) on the cylinder assembly (24). Next, install the collar (26) on the cylinder assembly.

5) Use the press-fit jig 1 (*1) to install the tapered roller bearing (3) inner race on the cylinder (24) with a hand press, etc. • When press fitting, use a soft rag (*2) under the cylinder end surface to prevent scratching.

149

RSM-13-06-001E 25

Swing Unit 6) Clean the inner race installation section (*2) of the cylinder (24), lightly apply sealant (Loctite 515, 518, or the equivalent) after degreasing, and use the press-fit jig 1 (*1) to install the cleaned and degreased inner race (1). Next, install the snap ring (27). • Be careful not to let sealant adhere to the roller of the tapered roller bearing (3). • Thoroughly wipe off any sealant coming out from in between the inner race and tapered roller bearing.

[3] Installation of oil seal Clean and degrease the housing (25) oil seal installation section. Next, degrease the oil seal (2) outer circumference, apply liquid packing (ThreeBond Co.,Ltd. "1211" white or the equivalent), and use the press-fit jig 2 (*1) to install it on the housing. • Be careful to install the oil seal in the correct direction.

RSM-13-06-001E

150 26

Swing Unit [4] Installation of tapered roller bearing outer race Install the tapered roller bearing (3) outer race on the housing (25). • Be careful to install the tapered roller bearing outer race in the correct direction.

[5] Installation of cylinder assembly Lightly apply grease to the oil seal (2) lip surface, and then grasp the sides of the cylinder (24) to gently install the cylinder assembly into the housing (25). • Oil on the cylinder makes it easy for it to slide, so be careful not to let it fall. • When installing the cylinder assembly, check that the receiving spring (4) is down in the spot facing section of the return plate (6). • When the cylinder assembly is installed, the spline shaft of the cylinder will stick out from the bottom surface of the housing, so place blocks of 30 - 40 mm (*4) under the surface. • Check that the end surface of the cylinder (*1) is sunk about 15.5 mm below the end surface of the housing (*3). If this distance is small, this means the cam plate is not completely placed in the spot facing section of the housing. Gently move the housing on its side so that the steeply diagonal side of the housing is on the bottom and lightly swing the cylinder up and down to put the cam plate in place. • When installing the cylinder assembly, place the jig 3 (*2) on the end of the spline to prevent scratching of the oil seal by the spline.

151

RSM-13-06-001E 27

Swing Unit [6] Installation of friction plate and partner plate Install the friction plates (8) and partner plates (9). • Apply hydraulic oil to both sides of each of these plates.

[7] Installation of O-ring Attach the O-ring (10) to the housing (25). Attach the O-ring (12) to the piston (11). • Apply grease to the O-rings.

RSM-13-06-001E

152 28

Swing Unit [8] Installation of brake piston Apply hydraulic oil to the outer circumference sliding section of the piston (11) and install it in the housing (25). • The O-ring force fits the piston, and this results in the piston being stiff during assembly. Make the entire piston level and use the installation jig 4 (*1) to press the piston down by hand in one push.

[9] Installation of spring Install the springs (13) into the brake piston (11). • Install the springs in the same locations they were in before disassembly.

[10] Installation of balance plate Install the bushings (20) with the Scrowave springs (18) and teflon rings (19) attached into the bushing holes on the cover (32). Apply grease to the pistons (14) and install the pistons into the balance plate (21). Install the balance plate on the cover. • Be careful to install in the correct direction according to the marks made on the balance plate and cover before disassembly.

153

RSM-13-06-001E 29

Swing Unit [11] Installation of inner race Press fit the needle bearing (22) inner race onto the cover (32) and install the snap ring (23).

[12] Installation of O-ring Attach the O-ring (12) to the cover (32). • Apply grease to the O-ring.

[13] Installation of cover Clean the matching surfaces of the cover (32) and the housing (25) and lift the cover by hand to gently install it in the housing. • Align the housing and cover using the reference mark (*1) made before disassembly. • At this time, there is a space of about 4.5 mm between the housing and cover.

RSM-13-06-001E

154 30

Swing Unit [14] Bolt tightening Install the cover (32) in the housing (25) by tightening the hexagon socket head bolts (37) to a torque of 284 N•m. • At this time, tighten each of the 4 bolts evenly a little at a time to straightly install the housing and cover.

[15] Installation of relief assembly, etc. Install the relief assemblies (35) (14 mm hex socket diameter) into the cover (32) to a tightening torque of 78 N・m. Install the checks (38) and springs (39) into the cover and tighten the caps (40) (14 mm hex socket diameter) to the cover to a tightening torque of 137 N・m. Install the plugs (33) and caps (28) (10 mm hex socket diameter) into the cover to a tightening torque of 78 N・m. • Install the disassembled relief assemblies, caps, springs, checks and plugs so they are in their original locations.

155

RSM-13-06-001E 31

Swing Unit [16] Assembly confirmation Open the input/output ports, apply 3.2 - 4.9 MPa of pilot pressure to the brake release port to check if the output shaft rotates smoothly for at least 1 rotation with about 30 - 40 N•m of torque. There is an assembly problem if it does not rotate, so disassemble the swing unit again and adjust it. • At this time, have the drain port open.

This completes the assembly. • Check that the set pressure of the relief assembly is at the correct pressure after the hydraulic motor is installed in the actual machine.

RSM-13-06-001E

156 32

Swing Unit Jig 1 (For assembly of tapered roller bearing (3) and inner race (1))

Jig 2 (For assembly of oil seal (2))

Jig 3 (For assembly of cylinder assembly (24))

Jig 4 (For assembly of brake piston (11))

157

RSM-13-06-001E 33

Swing Unit

SH210-5 Swing motor internal structure diagram

RSM-13-06-001E

158 34

Swing Unit

Relief internal structure diagram 1

Inner race

20

Bushing

39

2

Oil seal

21

Balance plate

40

Spring Cap

3

Tapered roller bearing

22

Needle bearing

41

Backup ring

4

Receiving spring

23

Snap ring

42

Level gauge assembly

5

Cam plate

24

Cylinder

43

O-ring

6

Return plate

25

Housing

44

Cap

7

Piston assembly

26

Collar

45

Seat

8

Friction plate

27

Snap ring

46

Poppet

9

Partner plate

28

Cap

47

Spring

10

O-ring

29

Backup ring

48

Spring seat

11

Piston

30

O-ring

49

Shim

12

O-ring

31

O-ring

50

Liner

13

Spring

32

Cover

51

Piston

14

Piston

33

Plug

52

Cap

15

Parallel pin

34

Cap

53

Backup ring

16

O-ring

35

Relief assembly

54

O-ring

17

Cap

36

O-ring

55

Holder

18

Scrowave spring

37

Hexagon socket head bolt

19

Teflon ring

38

Check

159

RSM-13-06-001E 35

Swing Unit SH210-5 Assembly and Disassembly of Swing Reduction Gear

Caution

RSM-13-06-001E

1. Read and understand the contents of this Maintenance Manual before performing disassembly, reassembly, inspection, repair, or other such work of this product. 2. Handle this product according to the separate "Usage Cautions". 3. When removing this product from the equipment it is mounted on, stop that equipment system and wait for the surface temperature of this product to fall to about 40C or below before removing it. Working on this product while it is still hot can cause burns. Additionally, always bleed out the pressure before removing any line from this product. Removing a pressurized line can result in oil spraying out and causing burns and oil leaking. 4. Use the specialty tools and measurement instruments for disassembly, reassembly, inspection, and repair, etc. of this product. Using an inappropriate tool may result in injury or product damage. 5. Be careful of parts falling when performing disassembly, reassembly, inspection or repair, etc. of this product. This may result in injury or parts damage. 6. Do not directly touch with bare hands the machined edges or threaded sections of parts during disassembly, reassembly, inspection, or repair etc. of this product. This may result in injury. 7. Check performance after reassembly. Do not resume use unless performance is fully recovered. Using this product at a sub-par performance level may result in product damage. 8. The cautions (mark !) listed in this Maintenance Manual do not cover all possible dangers. Always think of safety first during disassembly, inspection, reassembly, repair, or other such work.

160 36

Swing Unit 1. Disassembly [1] Remove the sun gear (76), thrust plate (77) and holder 1 assembly (82). • The opening is caulked by the press after press fitting the shaft 1 assembly (78) to holder 1 (81), so disassembly beyond this is impossible. [2] Remove the spur tooth 4 (72) and holder 2 assembly (88). [3] Hammering the spring pin in Hammer the spring pin (86) into the shaft 2 assembly (83). • The spring pin cannot be reused.

[4] Disassembly of holder 2 assembly Remove the shaft 2 assembly (83) from holder 2 (87) while supporting the spur tooth 5 (84) by hand, and then remove the thrust plate 2 (85) and spur tooth 5. Remove the spring pin (86) from the shaft 2 assembly.

161

RSM-13-06-001E 37

Swing Unit [5] Removal of ring gear Remove the ring gear (73) from the gear case (66). Liquid packing (ThreeBond Co.,Ltd. "1215" gray) is applied to the matching surfaces of the ring gear and gear case to prevent gear oil leaking, so use the notch section (*1) on the gear case to remove the ring gear. • Place a reference mark (*2) on the matching surface of the ring gear and gear case so the attachment position can be determined during reassembly.

[6] Removal of snap ring Use the gear case (66) notch section to remove the snap ring (64) with a flathead screwdriver.

RSM-13-06-001E

162 38

Swing Unit [7] Removal of shaft assembly To ensure the distance that the pinion shaft (61) is removed from the gear case (66) flange section, use blocks of about 300 mm to hold up the gear case. Press the end surface of the shaft with a hydraulic press etc., and remove the pinion shaft (61), collar (62), plate (63), auto aligning roller bearing (65), collar (67), and snap ring (69) as one assembly. • Do not reuse the oil seal (70). • Place a cushion such as a rag (*1) under the pinion shaft before removing it.

[8] Removal of auto aligning roller bearing Remove the auto aligning roller bearing (71) from the gear case (66). [9] Removal of oil seal Strike the oil seal (70) using a screwdriver and hammer to remove it from the gear case (66). • Do not reuse the oil seal.

163

RSM-13-06-001E 39

Swing Unit [10] Removal of collar Remove the snap ring (69) from the pinion shaft (61) using a mark-off pin and remove the collar (67). • Do not perform disassembly of the pinion shaft assembly beyond this. If abnormalities are found amongst the parts of the pinion shaft assembly, replace the assembly.

This completes the disassembly.

RSM-13-06-001E

164 40

Swing Unit 2. Assembly [1] Preparation before operation Execute the following preparations before reassembly. 1) Check each part for scratches from use or from disassembly. If there are any scratches, remove them with a whetstone or sandpaper of the necessary grain, clean with cleaning oil, then dry off with an air blower. 2) Replace seal parts with new ones. [2] Installation of collar Install the collar (67) onto the pinion shaft (61) and install the snap ring (69). • Be careful to install the collar in the correct direction. (See the diagram)

[3] Grease application Apply grease to the roller section within the auto aligning roller bearing (65) and to the outer circumference (*1). Brand: Product equivalent to Shell Alvania EP2 Capacity: 400 cc • A total of about 1 L of grease is injected into the unit. The remaining grease is injected during unit assembly.

165

RSM-13-06-001E 41

Swing Unit [4] Oil seal press fitting Degrease the oil seal installation section of the gear case (66) and oil seal (70), and apply liquid packing (ThreeBond Co.,Ltd. "1211" white or equivalent product) to the oil seal outer diameter. Use the seal press-fit jig 1 (*1) to install the seal on the gear case. Apply a thin layer of grease to the oil seal lip section after press-fitting. • Be careful to install the oil seal in the correct direction. (See the diagram below)

[5] Installation of pinion shaft assembly Place the gear case (66) so that the output shaft side is pointing upwards, and screw an eyebolt into the tap hole (M8) on the end surface of the pinion shaft (61) output shaft side to lift the pinion shaft assembly and install it in the gear case. Install the jig 2 (*1) on the spline section so that the pinion shaft spline does not scratch the oil seal. • Place an object of about 130 mm under the bottom surface of the gear case when installing the pinion shaft assembly.

RSM-13-06-001E

166 42

Swing Unit [6] Installation of snap ring Install the snap ring (64) in the gear case (66). • To make disassembly easier later, install the snap ring with the open ends meet about 30 mm away from the notch section of the gear case.

[7] Installation of auto aligning roller bearing Place the entire gear case (66) so that the output shaft points downwards, heat the auto aligning roller bearing (71) to "ambient temperature + 50 ℃ " and install it into the pinion shaft (61). • Be careful about burns when handling the heated auto aligning roller bearing. Be sure to wear heat-resistant gloves and do not directly touch the bearing.

[8] Application of liquid packing Degrease the matching surface of the gear case (66). Apply liquid packing along the ring gear centering location section (*1) (ThreeBond Co.,Ltd. "1215" gray or equivalent product). Evenly apply liquid packing so that the diameter of the liquid packing extracted from the nozzle is about φ1.5.

167

RSM-13-06-001E 43

Swing Unit [9] Installation of ring gear Degrease the matching surface of the ring gear (73). Align the parallel pins (89) with the ring gear parallel pin installation holes along with aligning the angles of the bolt holes, and gently install the ring gear on the gear case (66). • Align the gear case and ring gear using the reference mark made before disassembly.

[10] Assembly of holder 2 assembly Install the spur tooth 5 (84) and thrust plate 2 (85) into holder 2 (87). Next, install the shaft 2 assembly (83) into holder 2. • At this time, apply gear oil to the inner diameter of spur tooth 5 and outer diameter of the shaft 2 assembly. • Align the pin hole of the shaft 2 assembly with the holder 2 pin hole and install.

RSM-13-06-001E

168 44

Swing Unit [11] Installation of spring pin Hammer the spring pin (86) into the shaft 2 assembly (83). • Hammer the spring pin in with the crevice facing the spur tooth 5 (84) side. • After hammering in the spring pin, caulk the 2 opening locations of holder 2 (87) using a punch. (To stop the spring pin from coming out) (*1)

[12] Installation of holder 2 assembly and spur tooth 4 Insert the holder 2 assembly (88) assembled in [10] while gently engaging the assembly with the inner teeth of the ring gear (73). Additionally, insert the holder 2 assembly while turning it lightly so that spline of the pinion shaft (61) engages correctly. Gently engage the spur tooth 5 (84) with the spur teeth 4 (72) and insert. Make the groove on the thrust plate (77) face the spur teeth 4 side and insert it into the spur teeth 4.

169

RSM-13-06-001E 45

Swing Unit [13] Installation of holder 1 assembly and sun gear Insert the holder 1 assembly (82) while gently engaging the assembly with the inner teeth of the ring gear (73). Additionally, insert the holder 1 assembly while turning it lightly so that teeth of the holder 1 assembly engage with the teeth of spur tooth 4 (72). Make the groove on the sun gear (76) face the thrust plate (77) side and gently engage the groove with spur tooth 2 (79) to insert the sun gear. [14] Assembly confirmation Rotate the holder 1 assembly (82) by hand and check that the output shaft rotates smoothly.

This completes the assembly.

RSM-13-06-001E

170 46

Swing Unit Jig 1 (For assembly of oil seal (70))

Jig 2 (For assembly of pinion shaft (61))

171

RSM-13-06-001E 47

Swing Unit

SH210-5 Swing reduction gear internal structure diagram 61

Pinion shaft

72

Spur tooth 4

83

Shaft 2 assembly

62

Collar

73

Ring gear

84

Spur tooth 5

63

Plate

74

Lock washer

85

Thrust plate 2

64

Snap ring

75

Hexagon bolt

86

Spring pin

65

Auto aligning roller bearing

76

Sun gear

87

Holder 2

66

Gear case

77

Thrust plate

88

Holder 2 assembly

67

Collar

78

Shaft 1 assembly

89

Parallel pin

68

Plug

79

Spur tooth 2

90

Cap

69

Snap ring

80

Thrust plate 1

91

O-ring

70

Oil seal

81

Holder 1

92

Cap

71

Auto aligning roller bearing

82

Holder 1 assembly

93

O-ring

RSM-13-06-001E

172 48

Swing Unit SH240-5 Removal and Installation of Swing Unit Warning ・ Be sure to release hydraulic pressure before beginning work. ・ Be sure to stop the engine before beginning work. ・ Be sure to inspect the wire rope and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load. ・ When removing this product from the equipment it is mounted on, stop that equipment sysCaution tem and wait for the surface temperature of this product to fall to about 40 ℃ or below before removing it. Working on this product while it is still hot can cause burns. Additionally, always bleed out the pressure before removing any line from this product. Removing a pressurized line can result in oil spraying out and causing burns and oil leaking.

Items to prepare • Wrenches (13 mm, 14 mm, 19 mm, 22 mm, 27 mm, 36 mm, 41 mm) • Hexagon wrench (5 mm) • Box wrench (36 mm) • Pliers • Hammer • Grease • Specialty adapter for vacuum pump connection • Vacuum pump (vacuum pump power supply) • Extension cable • Wire rope (with the required breaking load) • Marking pen • Caps • Plugs • Crane (with the required lifting capacity) • Rag • Cleaning fluid • Wood planks, etc.

1. Removal of Swing Unit [1] Use a hexagon wrench (5 mm) to remove the 4 bolts (1), and then remove the air breather (2) on the hydraulic oil tank.

173

1

Bolt

2

Air breather

RSM-13-06-001E 49

Swing Unit [2] Attach the specialty adapter (3) to the area where the air breather was removed, and set the vacuum pump. Create negative pressure in the hydraulic oil tank using the vacuum pump (4).

[3] Use a wrench (19 mm) to remove the 6 bolts (5), and then remove the center cover (6).

RSM-13-06-001E

3

Specialty adapter

4

Vacuum pump

5

Bolt

6

Center cover

174 50

Swing Unit [4] Use the wrenches (22 mm, 27 mm, 36 mm, 41 mm) to remove the hoses (7), (8), (9), (10), (11) and (12) from the swing motor. • Mark the swing motor and hoses so that the connectors can be matched during assembly. • Attach caps or plugs to the swing motor and hoses to prevent any entry of water, dust or dirt. • Clean the swing motor and hoses by spraying them with a parts cleaner to prevent scratching and prevent dirt from accumulating on the connectors.

[5] Use a wrench (19 mm) to remove the 3 bolts (13), and then remove the under cover (14).

[6] Use a wrench (13 mm) to remove the bolt (15) on the clamp (16) for the hose.

175

7

Make-up hose (use 41 mm)

8

Main hose (right) (use 36 mm)

9

Main hose (left) (use 36 mm)

10

Drain hose (use 27 mm)

11

Drain hose (use 27 mm)

12

Pilot hose (use 22 mm)

13

Bolt

14

Under cover

15

Bolt

16

Clamp

17

Drain hose

RSM-13-06-001E 51

Swing Unit [7] Use a box wrench (36 mm) to remove the 9 bolts (18) from the swing unit.

[8] Wrap the wire rope (20) around the swing motor and lift it with a crane. • A knock pin (19) is driven into the installation section of the swing unit. Apply lubricating oil to the knock pin and pull it out together with the main unit of the swing motor while hitting with a hammer.

[9] Thoroughly check that the location is safe before lowering the swing unit on wood planks (21). • Thoroughly secure the swing unit so that it does not fall over.

RSM-13-06-001E

18

Bolt

19

Knock pin

20

Wire rope

21

Wood plank

176 52

Swing Unit 2. Installation of Swing Unit [1] Perform the reverse of the removal procedure. When installing the swing unit, be careful with the position of the knock pin. The tightening torque for the bolts for installing the swing unit on the swing frame is 784 - 914 N•m. [2] Before driving, be sure to fill the inside of the motor casing with hydraulic oil from the oil fill port (1). Use the level gauge (2) to check that gear oil for the reduction gear is filled to the stipulated volume.

177

1

Drain port

2

Level gauge

RSM-13-06-001E 53

Swing Unit SH240-5 Assembly and Disassembly of Swing Unit

Caution

RSM-13-06-001E

1. Read and understand the contents of this Maintenance Manual before performing disassembly, reassembly, inspection, repair, or other such work of this product. 2. Handle this product according to the separate "Usage Cautions". 3. When removing this product from the equipment it is mounted on, stop that equipment system and wait for the surface temperature of this product to fall to about 40 ℃ or below before removing it. Working on this product while it is still hot can cause burns. Additionally, always bleed out the pressure before removing any line from this product. Removing a pressurized line can result in oil spraying out and causing burns and oil leaking. 4. Use the specialty tools and measurement instruments for disassembly, reassembly, inspection, and repair, etc. of this product. Using an inappropriate tool may result in injury or product damage. 5. Be careful of parts falling when performing disassembly, reassembly, inspection or repair, etc. of this product. This may result in injury or parts damage. 6. Do not directly touch with bare hands the machined edges or threaded sections of parts during disassembly, reassembly, inspection, or repair etc. of this product. This may result in injury. 7. Check performance after reassembly. Do not resume use unless performance is fully recovered. Using this product at a sub-par performance level may result in product damage. 8. The cautions (mark !) listed in this Maintenance Manual do not cover all possible dangers. Always think of safety first during disassembly, inspection, reassembly, repair, or other such work.

178 54

Swing Unit 1. Disassembly [1] Making a reference mark on the unit matching surface It is useful to place a reference mark (*1) on the matching surface of the casing K1 (301) and ring gear (22) with paint, etc.

[2] Removal of level gauge and cap Remove the level gauge (08) and cap (06).

[3] Gear oil draining Loosen the plug (25) (10 mm hex socket diameter) to drain the gear oil. • Gear oil cannot be reused.

179

RSM-13-06-001E 55

Swing Unit [4] Removal of motor Remove the pipe (06) and the pipe (04), and loosen and remove the hexagon socket head bolts (01) (10 mm hex diameter). Use the make-up port (G1) to raise the motor and remove it. • Liquid packing has been applied to the matching surfaces of the casing K1 (301) and ring gear (22), so use the notch sections (*1) in the diagram on the right to remove the motor.

This completes the disassembly.

RSM-13-06-001E

180 56

Swing Unit 2. Assembly [1] Application of liquid packing After cleaning and degreasing the reduction gear ring gear (22) and the motor casing K1 (301) matching surfaces, apply (*1) liquid packing (ThreeBond Co.,Ltd. "1215" gray or the equivalent) as shown in the diagram on the right.

[2] Installation of motor Lift the motor and softly install it in the reduction gear, and tighten the hexagon socket head bolts (01) (10 mm hex diameter) to the tightening torque of 90 N•m. Install pipes (06) and (04). • Align the casing K1 (301) and ring gear (22) according to the reference mark (*1) made before disassembly.

181

RSM-13-06-001E 57

Swing Unit [3] Installation of level gauge Insert the level gauge (08).

[4] Gear oil filling Tighten the plug of the oil drain hose. Fill with gear oil (9.7 L) from the gear oil fill port. Tighten the gear oil fill port cap (06).

This completes the assembly.

RSM-13-06-001E

182 58

Swing Unit SH240-5 Assembly and Disassembly of Swing Motor

Caution

1. Read and understand the contents of this Maintenance Manual before performing disassembly, reassembly, inspection, repair, or other such work of this product. 2. Handle this product according to the separate "Usage Cautions". 3. When removing this product from the equipment it is mounted on, stop that equipment system and wait for the surface temperature of this product to fall to about 40 ℃ or below before removing it. Working on this product while it is still hot can cause burns. Additionally, always bleed out the pressure before removing any line from this product. Removing a pressurized line can result in oil spraying out and causing burns and oil leaking. 4. Use the specialty tools and measurement instruments for disassembly, reassembly, inspection, and repair, etc. of this product. Using an inappropriate tool may result in injury or product damage. 5. Be careful of parts falling when performing disassembly, reassembly, inspection or repair, etc. of this product. This may result in injury or parts damage. 6. Do not directly touch with bare hands the machined edges or threaded sections of parts during disassembly, reassembly, inspection, or repair etc. of this product. This may result in injury. 7. Check performance after reassembly. Do not resume use unless performance is fully recovered. Using this product at a sub-par performance level may result in product damage. 8. The cautions (mark !) listed in this Maintenance Manual do not cover all possible dangers. Always think of safety first during disassembly, inspection, reassembly, repair, or other such work.

183

RSM-13-06-001E 59

Swing Unit 1. Causes of Trouble and Solutions [1] General cautions This list consists of actions to be taken when an abnormality is sensed during use of the hydraulic motor. General cautions are listed below. 1) Think before attempting to fix a problem. Determine the nature of the abnormality before beginning work and think whether this same kind of problem has occurred before. Also, reconfirm whether the motor is the source of the problem. 2) Be careful about dust and dirt. The cause of wear is very often dust and dirt. So be careful that dust and dirt do not get into parts during disassembly. 3) Parts handling Parts are manufactured with a high degree of precision, so be careful not to scratch them during handling. 4) Do not damage O-rings or gasket surfaces while performing work. Also, it is recommended that O-rings are replaced for new ones during disassembly. [2] Investigating abnormalities in the motor main unit It is very difficult to search for the source of troubles in the hydraulic circuits. Inspect the following items and thoroughly investigate whether the motor is the source of troubles. 1) Inspecting oil within the casing Remove the drain plug and inspect the hydraulic oil within the casing. If a large amount of metal particles come out at the same time as oil, it is very likely that there is damage with parts within the motor. 2) Abnormal noise Check whether abnormal noise is coming from the motor main unit. 3) Measure pressure for each part. Do not perform disassembly inspection carelessly. Measure pressure for each part and look for abnormalities in each area. 4) Measure the amount of oil drained from the motor. 1. Operation is normal if about 30 L/min or less of oil drains from the motor when pressurized oil is applied after the swing is locked. 2. 2 L/min or less of drained oil at constant swing is normal.

RSM-13-06-001E

184 60

Swing Unit [3] Trouble conditions and countermeasures 1) Hydraulic motor does not rotate. Symptom

Cause

Solution

No pressure rise

1. Incorrect setting of the circuit safety 1. Reset safety valve correctly. valve 2. Disassemble and inspect. 2. Operation problems with relief valve 1) Repair or replace sticking section(s). 1) Plunger sticking 2) Disassemble and clean. 3. Check seating sections and replace 2) Clogged plunger orifice 3. Plunger seating problem scratched part(s).

Pressure rises

1. 2. 3. 4. 5. 6.

Overload Seizing of driving part No release pressure acting on the brake Piston sticking to the brake Spool for brake release sticking Friction plate seizing

1. Eliminate load. 2. Inspect and repair piston/shoe, cylinder/ valve plate, etc. 3. Inspect and repair circuit. 4. Disassemble and inspect. 5. Disassemble and inspect. 6. Disassemble and inspect. Replace seizing part(s).

2) Rotation direction is reversed. Symptom Reversed rotation direction

Cause

Solution

1. Motor rotation direction reversed. 2. Input and output for line reversed.

1. Check the rotation direction and assemble the motor correctly. 2. Correct line configurations.

3) Motor speed is not reaching the set value. Symptom Motor speed not reaching the set value

Cause

Solution

1. Check the pump discharge volume and 1. Insufficient oil flow amount the circuit up to the motor. 2. High temperature and severe leaking of 2. Lower the temperature of the oil. oil 3. Wear or damage on each sliding sec- 3. Replace part(s). tion

4) Hydraulic motor does not rotate. Symptom Insufficient braking torque

Cause

Solution

1. Disassemble and inspect. 1. Wear on the friction plate parts worn beyond the limit. 2. Brake piston sticking 3. Brake release pressure cannot be 2. Disassemble and inspect. 3. Inspect and repair circuit. released. 4. Disassemble and inspect. 4. Spool for brake release sticking 5. Disassemble and inspect. 5. Damaged friction plate spline damaged part(s).

185

Replace

Replace

RSM-13-06-001E 61

Swing Unit 5) Severe hydraulic motor slipping Investigate the amount of oil drained from the hydraulic motor. Motor operation is normal if the amount is 500 cc/min or less. Symptom Slipping is severe when an external driving torque acts on the hydraulic motor.

Cause

Solution

1. Operation problems with relief valve 1) Plunger sticking 2) Clogged plunger orifice 2. Plunger seating problem

1. Disassemble and inspect. 1) Repair or replace sticking section(s). 2) Disassemble and clean. 2. Check seating sections and replace scratched part(s).

6) Oil leaking 1) Oil leaking from oil seal. Symptom

Cause

Solution

Oil leaking from 1. Debris lodged in lip causing scratching. oil seal 2. Shaft scratched or worn 3. Pressure within the casing becoming abnormally high caused oil seal lip to turn up. 4. Shaft rusted.

1. Replace oil seal(s). 2. Stagger the position(s) of the lip and shaft(s) or replace it (them). 3. Repair any clogged drain line(s). 4. Disassemble and repair.

2) Oil leaking from matching surface Symptom

Cause

Solution

Oil leaking from 1. O-ring has not been inserted. matching surface 2. Scratched O-ring 3. Scratched seal surface 4. Loosened or damaged bolt

RSM-13-06-001E

1. 2. 3. 4.

Insert O-ring(s) and assemble. Replace part(s). Disassemble and repair. Tighten to the specified torque or replace.

186 62

Swing Unit 2. Maintenance Procedures [1] Replacement standards for worn parts If wear on any part exceeds the standard values below, replace or readjust that part. However, parts should be replaced regardless of these standards if it appear to be extremely worn based on appearance. Table 1. Part replacement standards Standard dimensions (mm)

Value at which replacement is recommended (mm)

0.028

0.058

Replace the piston(s) or cylinder(s).

0

0.3

Replace the piston shoe assembly.

Shoe thickness (t)

5.5

5.3

Replace the piston shoe assembly.

Friction plate thickness

2.0

1.6

Replace the part(s).

Item

Clearances between piston and cylinder bore (D-d) Piston and shoe caulking section backlash (δ)

Clearance (D-d)

Solution

Piston and shoe backlash (δ)

Shoe thickness (t)

187

RSM-13-06-001E 63

Swing Unit [2] Sliding surface repair standards If the roughness of the sliding surface in any section exceeds the standard values below, repair or replace that part. Table 2. Sliding surface repair standards Part name

Standard surface roughness

Surface roughness requiring repair

Shoe

0.8-Z (Ra=0.2) (Lapping)

3-Z (Ra=0.8)

Shoe plate

0.4-Z (Ra=0.1) (Lapping)

3-Z (Ra=0.8)

Cylinder

1.6-Z (Ra=0.4) (Lapping)

12.5-Z (Ra=3.2)

Valve plate

0.8-Z (Ra=0.2) (Lapping)

6.3-Z (Ra=1.6)

Note: 1) Using lapping, make the degree of surface roughness of each sliding surface equal to or lower than the standard value. 2) If the plate spring and cylinder spherical surface sliding section are rough, these should be replaced as a set.

RSM-13-06-001E

188 64

Swing Unit 3. Assembly and Disassembly [1] Bolt tightening torque Tightening torque values for bolts used in the motor are indicated in Table 3. When assembling, securely tighten bolts to these values. Table 3 Screw size

Name

Tightening torque N•m

Applicable part code

M20

Hexagon socket head bolt

431

401

M33XP1.5

Relief valve

177

051

M36XP1.5

ROMH plug

539

469

PF1/4

ROH plug

36

467

If there is a variance with the part codes listed above, see the assembly cross-section diagram. [2] Tools for assembly and disassembly The necessary tools for assembly and disassembly are indicated in Tables 4 and 5. The bolts and plugs used vary for each type, so prepare tools based on examination beforehand. Table 4 Wrenches Name

Size

Bolt width

Applicable part code

Tool

Hexagon socket head bolt

M20

17

401

Hexagon wrench

Relief valve

M33XP1.5

41

051

Hexagon wrench, socket wrench

ROMH plug

M36XP1.5

17

469

Hexagon wrench

ROH plug

PF1/4

6

467

Hexagon wrench

If there are variances with the plugs and bolts listed above, see the assembly cross-section diagram. Table 5 Other Tool

Dimensions

Screwdriver

Medium-sized flathead x 2

Steel rod

About size 10 x 8 x 200 x 1

Hammer

Plastic hammer Metal hammer 1 each

Torque wrench

Torque adjustment range ・ For 5 - 10 N•m ・ For 10 - 45 N•m ・ For 40 - 275 N•m ・ For 75 - 550 N•m

Slide hammer bearing puller Brake piston removal jig

See the next page

189

RSM-13-06-001E 65

Swing Unit

Brake piston removal specialty tool

RSM-13-06-001E

*1

Brake piston removal jig

*2

Brake piston

*3

Casing

190 66

Swing Unit [3] Disassembly procedure When disassembling the motor, disassemble using the sequence indicated below. The numbers in parentheses after the part names are the codes used in the structure diagram. 1) Wrap the wire rope around the outer circumference of the motor, lift the motor with a crane, and clean with white kerosene. After cleaning, dry the motor using compressed air. • To prevent foreign matter from entering the motor, mask each port with tape, etc. before cleaning off adhered dirt and dust. 2) From the drain plug, drain the oil inside the casing (301). 3) Point the shaft end of the drive shaft (101) downwards and secure the motor on a surface which makes disassembly easy. At this time, place reference marks on the sections of the casing (301) and valve casing (303) that match with each other. • Select a clean location for disassembly. Place a rubber plate or cloth on the platform so as not to damage the parts. 4) Loosen the relief valves (051) and remove them from the valve casing (303). • O-rings will be damaged when the relief valves are loosened, so be sure to replace the O-rings.

5) Remove the ROMH plugs (469) from the valve casing (303) and take out the springs (355) and plungers (351). • Be careful not to scratch the plunger seating sections.

191

RSM-13-06-001E 67

Swing Unit 6) Loosen the hexagon socket head bolts (401) and remove the valve casing (303) from the casing. (The valve casing will rise up from the casing when the bolts are removed due to the force of the brake springs (712).) Additionally, remove the valve plate (131) from the valve casing. • Do this carefully so as not to let the valve plate fall from the valve casing. (The valve plate may be attached to the cylinder side.) When prying open the matching surface with a screwdriver, etc., be careful not to scratch the surface. 7) Take out the brake springs (712) from the brake piston (702).

8) Use a jig and remove the brake piston (702) from the casing (301). • Apply the tips of the jig to the sides of the brake piston. Pull the brake piston out straight up.

RSM-13-06-001E

192 68

Swing Unit 9) Move the motor on its side so that it is horizontal with the ground and remove the cylinder (111) from the drive shaft (101). Additionally, remove the pistons (121), holder plate (123), plate spring (114), and shoe plate (124). • Be careful not to scratch the sliding surfaces of the cylinder, shoe, etc. If the shoe plate cannot be removed, proceed to 11) and remove.

10) Take out the friction plates (742) and separator plates (743) from the casing (301).

11) Take out the drive shaft (101) and shoe plate (124). • The spline will damage the oil seal (491) when the drive shaft is removed, so wrap the spline section of the drive shaft with vinyl tape, etc. (*1).

193

RSM-13-06-001E 69

Swing Unit 12) Perform the following as necessary. 1. Use a press (*1) to remove the inner race of the cylinder roller bearing (443) from the drive shaft (101). • It is acceptable to strike the inner race of the cylinder roller bearing using a steel rod, but be careful to strike the inner race evenly and to not damage the bearing.

Do not reuse removed bearing. 2. Lightly strike the outer race of the cylinder roller bearing (443) from the oil seal (491) housing section side using a steel rod to remove the outer race from the casing (301). • Do not reuse removed bearing.

3. Use the slide hammer bearing puller (*1) to remove the cylinder roller bearing (444) from the valve casing (303). • Do not reuse removed bearing.

This completes the disassembly. Thoroughly inspect each section for abnormalities.

RSM-13-06-001E

194 70

Swing Unit Swing motor internal structure diagram (SH240-5)

195

RSM-13-06-001E 71

Swing Unit [4] Assembly procedure The assembly procedure is the reverse of the disassembly procedure. However, follow the precautions below. 1) Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. 2) Thoroughly clean all parts with cleaning fluid and dry with compressed air. 3) Be sure to apply clean hydraulic oil on sliding parts and bearings before assembling. 4) As a rule, replace all O-rings, oil seals, and other seal parts with new parts. 5) Use a torque wrench to tighten all installation bolts and plugs to the torque values specified in Table 3. The assembly procedure is indicated below. 1) Place the casing (301) on an appropriate platform with the valve casing (303) side facing up. 2) (This section is only necessary when the cylinder roller bearing (443) is removed.) Shrink fit the inner race of the cylinder roller bearing to the drive shaft (101). • Be careful with the direction of the collar of the cylinder roller bearing.

3) Use a jig to insert the oil seal (491) into the casing (301). • Be careful with the direction of the oil seal. (See the diagram below) Apply a thin layer of grease to the oil seal lip section. Evenly strike the oil seal and be careful not to scratch the outer circumference.

4) Install the outer race of the cylinder roller bearing (443) in the casing (301) by lightly striking it with a steel rod.

RSM-13-06-001E

196 72

Swing Unit 5) Mount the drive shaft (101) in the casing (301). • Carefully insert it so as not to scratch the lip section of the oil seal (491). Wrapping vinyl tape, etc. around the shaft spline section to protect it is recommended.

6) Lay the casing (301) horizontal and insert the shoe plate (124). • Install with the larger chamfered side of the shoe plate on the casing side. Apply a thin layer of grease to the matching surface to prevent it from falling out.

7) Set the holder plate (123) and plate spring (114) and also set the piston subassembly (10).

197

RSM-13-06-001E 73

Swing Unit 8) Install the piston subassembly (10) set in the holder plate (123) into the cylinder (111). Then align the cylinder with the spline of the drive shaft (101) and insert it.

RSM-13-06-001E

198 74

Swing Unit 9) Set the casing (301) down with the oil seal (491) side facing downwards and alternately install separator plates (743) and friction plates (742) in that order. Install the 4 separator plates and 3 friction plates.

10) Mount the O-rings (706) and (707) on the casing (301). • If a thin layer of grease is applied to the Orings, they will not break easily when inserting brake piston.

199

RSM-13-06-001E 75

Swing Unit 11) Install the brake piston (702) into the casing (301).

12) Install the brake springs (712) into the brake piston (702).

13) (This section is only necessary when the cylinder roller bearing (444) is removed.) Install the outer race of the cylinder roller bearing into the valve casing (303) with a steel rod by lightly striking the rod with a hammer. • Evenly strike the outer circumference of the outer race completely in until it stops at the stepped section of the valve casing.

RSM-13-06-001E

200 76

Swing Unit 14) Install the valve plate (131) into the valve casing (303) and also mount the O-ring (472). • Apply a thin layer of grease to the valve plate matching surface. (To prevent falling off) (*1)

15) Install the valve casing (303) on the casing (301) and tighten with the hexagon socket head bolts (401). Tightening torque: 430 N•m • Be careful with the installation direction of the valve casing. Make sure that the valve plate (131) does not come off. Make sure that the brake springs (712) do not fall over. Tighten the hexagon socket head bolts equally. 16) Insert the plungers (351) and springs (355) into the valve casing (303) and tighten the ROMH plugs (469) with the O-rings (488) mounted on them to the valve casing. Tightening torque: 539 N•m • Check that the plungers move smoothly.

201

RSM-13-06-001E 77

Swing Unit 17) Mount the relief valves (051) on the valve casing (303) and tighten them. Tightening torque: 177 N•m

This completes the assembly.

RSM-13-06-001E

202 78

Swing Unit SH240-5 Assembly and Disassembly of Swing Reduction Gear

Caution

1. Read and understand the contents of this Maintenance Manual before performing disassembly, reassembly, inspection, repair, or other such work of this product. 2. Handle this product according to the separate "Usage Cautions". 3. When removing this product from the equipment it is mounted on, stop that equipment system and wait for the surface temperature of this product to fall to about 40C or below before removing it. Working on this product while it is still hot can cause burns. Additionally, always bleed out the pressure before removing any line from this product. Removing a pressurized line can result in oil spraying out and causing burns and oil leaking. 4. Use the specialty tools and measurement instruments for disassembly, reassembly, inspection, and repair, etc. of this product. Using an inappropriate tool may result in injury or product damage. 5. Be careful of parts falling when performing disassembly, reassembly, inspection or repair, etc. of this product. This may result in injury or parts damage. 6. Do not directly touch with bare hands the machined edges or threaded sections of parts during disassembly, reassembly, inspection, or repair etc. of this product. This may result in injury. 7. Check performance after reassembly. Do not resume use unless performance is fully recovered. Using this product at a sub-par performance level may result in product damage. 8. The cautions (mark !) listed in this Maintenance Manual do not cover all possible dangers. Always think of safety first during disassembly, inspection, reassembly, repair, or other such work.

203

RSM-13-06-001E 79

Swing Unit 1. Disassembly [1] Put the nylon sling around the swing motor section and lift it with a crane. Caution

Swing unit weight: about 301 kg

[2] Place the swing unit on the bracket (8098413), and secure it with the 2 bolts (M24). Secure the bracket to the work platform so that reactive force is absorbed. : 36 mm

*1

Swing unit

*2

Bracket (8098413)

[3] Remove the drain plug (25), and then drain oil. : 22 mm [4] Remove the hose (24) from the housing (31). : 22 mm [5] Place reference marks on the matching sections of the motor (2) and ring gear (22) and the ring gear and housing (31). Loosen and remove the hexagon socket head bolts (1) and lift the motor with a crane to remove it. : 10 mm Caution

Motor weight: 71 kg

Tip: Inserting a flathead screwdriver in the gap between the motor and ring gear will make the motor rise up and make it easier to remove. [6] Remove the 1st stage sun gear (4) and 1st stage carrier (21) assembly from the ring gear (22). : 8 mm [7] Loosen and remove the hexagon socket head bolts (32) and install eyebolts (M12, 1.75 mm pitch) on the motor installation screw section of the ring gear (22). Remove the ring gear from the housing (31) lifted by the crane. : 14 mm Caution

Ring gear weight: 27 kg

Tip: ThreeBond has been applied to the matching surfaces of the housing and ring gear. Placing a flathead screwdriver in the notch section of the matching section outer circumference raises the ring gear and makes it easier to remove. [8] Remove the 2nd stage sun gear (20) and 2nd stage carrier (19) assembly. Caution

RSM-13-06-001E

2nd stage carrier assembly weight: 32 kg

204 80

Swing Unit [9] Remove the bolts (17), and then remove the lock plate (16). [10] Use the nut removal and installation jig (8083297) (*1) to remove the nut (15) from the shaft (26).

[11] Install eyebolts (M18, 2.5 mm pitch) in the bolt holes on the housing (31). Remove the 2 bolts (M24) securing the housing and bracket. Lift the housing assembly with a crane and remove the bracket. Caution

Housing assembly weight: 148 kg

[12] Set the housing assembly on top of the blocks (*1) set on the press platform.

205

RSM-13-06-001E 81

Swing Unit [13] Place an upper lid (*1) on the housing (31) before removing the shaft (26) with the press (*2). At this time, the roller bearing (30) inner race and sleeve (29) will become attached to the shaft.

Caution

When pressing on the shaft with the press, make sure to produce an upper lid (outer diameter 369 mm, inner diameter 90 mm, thickness 25 - 30 mm) and do pressing with the upper lid in place. There is a possibility of the housing and roller bearing breaking and fragments flying off, which may cause injury. Also, the upper limit of the press is 30 t. When heating the roller bearing, thoroughly degrease the inside of the housing before heating. If heating is done without degreasing, there is the danger of fires occurring.

[14] Remove the roller bearing (30) inner race from the housing (31). [15] Set a jig on the shaft assembly (26). Tip: Use the following items for the roller bearing removal jig. Shafts (bolts are also useable): length 220 mm, diameter 19 mm x 8 (*1) (All should be the same length and have no wear deformation on either end) Raw materials: S35C Hose clamp: (standard diameter of 8-1/2 inches, tightening range of 185 - 215 mm) x 2 (*2) Guide: height 160 mm, outer diameter 250 mm, inner diameter 230 mm (*3) Bearing removal jig

RSM-13-06-001E

206 82

Swing Unit [16] Set the shaft (26) with the jig attached in the press (*1) to remove the roller bearing (30). [17] Remove the sleeve (29) from the shaft (26), and remove the O-ring (27) from the sleeve.

Caution

When pressing the shaft with the press, be sure to do this within the guide.

[18] Insert the round rod into the internal oil path (*2) of the housing (31), and strike the outer race (*1) of the roller bearing (23) to remove it.

[19] Bind the body of the housing (31) with the nylon sling, lift it with a crane, and turn the housing around. Insert a screwdriver into the notch section of the oil seal (28) installation section of the housing and remove the oil seal. Caution

Housing (31) weight: 104 kg

Tip: ThreeBond has been applied to the outer circumference of the oil seal. Accordingly, the oil seal cannot be reused. [20] Use a striking rod and hammer to strike the back surface of the roller bearing (30) outer race, and remove the outer race from the housing (31). [21] Use a round rod and hammer to remove the spring pins (6) from the 1st stage carrier (21). [22] Remove the 3 pins (5), 3 1st stage planetary gears (9), 3 thrust plates (7), and 3 needle bearings (8) from the 1st stage carrier (21). [23] Remove the thrust plate (18) from the 1st stage carrier (21). [24] Use a round rod and hammer to remove the spring pins (11) from the 2nd stage carrier (19).

207

RSM-13-06-001E 83

Swing Unit [25] Remove the 3 pins (10), 3 2nd stage planetary gears (14), 3 thrust plates (12), and 6 needle bearings (13) from the 2nd stage carrier (19). [26] Remove the thrust plate (18) from the 2nd stage carrier (19). This completes the disassembly. Thoroughly inspect each section for abnormalities.

RSM-13-06-001E

208 84

Swing Unit 2. Assembly [1] Preparation before operation Execute the following preparations before reassembly. 1) Check each part for scratches from use or from disassembly. If there are any scratches, remove them with a whetstone or sandpaper of the necessary grain, clean with cleaning oil, then dry off with an air blower. 2) Replace seal parts with new ones. 3) When assembling sliding sections, apply clean hydraulic oil before assembling. [2] Install 1 needle bearing (8) into each of the 3 1st stage planetary gears (9). [3] Install the thrust plate (18) into the 1st stage carrier (21) with the side of the thrust plate with the oil groove facing upwards. [4] Install the 3 1st stage planetary gears (9) and 3 thrust plates (7) into the 1st stage carrier (21). [5] Align the 3 pins (5) with the spring pin holes of the 1st stage carrier (21) and strike the pins with a hammer to install them. Important:

Be careful with the direction of the spring pins.

[6] Arrange the spring pins (6) so that the slit section (*1) faces the end surface of the pins, and drive the spring pins into the 1st stage carrier (21) and pins (5) with a hammer.

[7] Assemble the 2nd stage carrier in the same sequence as shown in Step [2] - [6]. Assemble the 3 2nd stage planetary gears (14), 6 needle bearings (13), 3 thrust plates (12), 1 thrust plate (18), 3 pins (10), and 3 spring pins (11). [8] Install the O-ring (27) into the sleeve (29).

209

RSM-13-06-001E 85

Swing Unit [9] Install the sleeve (29) and inner race of the roller bearing (30) into the shaft (26). Use the bearing press-fit jig (ST A) (ST B) to press fit the sleeve and inner race with the press (*1).

Tip: The press-fit amount of the bearing inner race is preserved by using the press-fit jig. [10] Bind the body of the housing (31) with the nylon sling. Lift the housing with a crane, and set it down with the sleeve (29) installation side facing up. Caution

Housing weight: 104 kg

[11] Use a striking rod and hammer to evenly strike the roller bearing (30) outer race and install it in the housing. Listen for the sound of the outer race striking the bottom to check that it is fully in. [12] Apply ThreeBond #1205 to the outer circumference of the oil seal (28). Place the oil seal on the housing (31) so that it is level, and press the oil seal in a small amount by hand. Place the seal installation jig (8026527) (*1) on top of the oil seal and strike it straight with the hammer.

[13] Apply grease to the inner circumference of the oil seal (28). Additionally, also apply grease to the outer circumference surface of the sleeve (29) attached to the shaft (26).

RSM-13-06-001E

210 86

Swing Unit [14] Install eyebolts (M18, 2.5 mm pitch) in the bolt holes on the housing (31). Lift the housing and slowly lower it over the shaft (26) to fit it on the shaft. At this time, carefully perform centering during assembly so that the oil seal (28) lip does not get turned up. [15] Use a striking rod and hammer to evenly strike the roller bearing (23) outer race and install it in the housing (31). Listen for the sound of the outer race striking the bottom to check that it is fully in. [16] Use a striking rod and hammer to hammer the roller bearing (23) inner race into the shaft (26). Hammer in the inner race so that the top surface of the inner race is 2 threads down from the threaded section for the shaft nut (15). [17] Tighten the nut (15) onto the shaft (26) to the maximum degree it can be tighten by hand. Tip: This prevents the shaft from falling when the housing is lifted. [18] Attach eyebolts (M18, 2.5 mm pitch) into the bolt holes of the housing (31), and lift the housing with a crane and set it on the press. Caution

Housing + shaft + bearing weight: 148 kg

[19] Remove the nut (15) from the shaft (26). [20] Place the inner race press-fit jig (ST C) on the roller bearing (23) inner race and press-fit the inner race with the press. Tip: The specified amount to which the inner race is pressed in can be preserved by using the press-fit jig.

211

RSM-13-06-001E 87

Swing Unit [21] Lift the housing (31) assembly with a crane, place it on the bracket (8098413) (*2), and install it using the 2 bolts (M24). At this time, the stopper on the bottom section of the bracket (*1) should be arranged so that it can be inserted in between the pinion gear teeth. Additionally, secure the bracket to the work platform so that reactive force is absorbed. : 36 mm

Important:

Be careful with the attachment direction of the bearing nut.

[22] Apply a small amount of grease to the threaded section of the nut (15) and install it on the shaft (26). At this time, place the stepped end surface of the nut on the roller bearing (23) side. Use the nut tightening jig (8083297) (*1) to tighten it to the specified torque. : 735 N•m

Tip: Be sure to apply grease to preserve the correct tightening torque. [23] Install the lock plate (16) on the nut (15) using the bolts (17). When the lock plate spline does not fit with the shaft (26) spline, retorque the lock plate in the nut tightening direction to align the splines. : 17 mm : 50 N•m

RSM-13-06-001E

212 88

Swing Unit [24] Attach the 2nd stage carrier (19) assembly to the shaft (26) spline.

Caution Important:

2nd stage carrier weight: 32 kg Be careful to install the carrier in the correct direction.

[25] Install the 2nd stage sun gear (20) into the 2nd stage carrier (19) assembly. [26] Apply ThreeBond #1215 to the ring gear (22) installation surface of the housing (31). At this time, thoroughly remove old adhesive. [27] Attach eyebolts (M12, 1.75 mm pitch) to the motor installation threaded sections of the ring gear (22), lift with a crane, and align the reference marks made during disassembly to install the ring gear to the housing (31). Tighten the 12 hexagon socket head bolts (32). : 14 mm : 300 N•m Caution

Ring gear weight: 27 kg

[28] Align the 1st stage carrier (21) assembly with the spline of the 2nd stage sun gear (20) to install the assembly. Important:

Be careful with the attachment direction of the sun gear.

[29] Attach the 1st stage sun gear (4) to the 1st stage carrier (21) assembly with the stepped end surface facing downwards. [30] Wrap the hose (24) threaded section with seal tape and install it on the housing (31). : 22 mm [31] Install the drain plug (25) on the hose. : 22 mm : 50 N•m [32] Fill with gear oil (9.7 L). [33] Apply liquid packing (ThreeBond #1215) to the ring gear (22) motor installation surface.

213

RSM-13-06-001E 89

Swing Unit [34] Lift the motor with a crane, align the reference marks made during disassembly, and install it onto the ring gear (22) with the 12 hexagon socket head bolts (1). : 10 mm : 90 N•m Caution

Motor weight: 71 kg

This completes the assembly.

RSM-13-06-001E

214 90

Swing Unit Swing Reduction Gear Breakdown Diagram

215

RSM-13-06-001E 91

Swing Unit Swing Reduction Gear Structure Diagram

1

Hexagon socket head bolt (12)

12

Thrust plate (3)

23

Roller bearing

2

Swing motor

13

Needle bearing (6)

24

Hose

3

Retaining ring

14

2nd stage planetary gear (3)

25

Drain plug

4

1st stage sun gear

15

Nut

26

Shaft

5

Pin (3)

16

Lock plate

27

O-ring

6

Spring pin (3)

17

Bolt (2)

28

Oil seal

7

Thrust plate (3)

18

Thrust plate (2)

29

Sleeve

8

Needle bearing (3)

19

2nd stage carrier

30

Roller bearing

9

1st stage planetary gear (3)

20

2nd stage sun gear

31

Housing

10

Pin (3)

21

1st stage carrier

32

Hexagon socket head bolt (12)

11

Spring pin (3)

22

Ring gear

RSM-13-06-001E

216 92

Center Joint Center Joint

SH200-5

Center Joint Removal and Installation of Center Joint ・ Be sure to stop the engine before beginning work. Caution ・ Be sure to inspect the wire rope and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare • Wrenches (17 mm, 19 mm, 27 mm, 36 mm) • Hexagon wrench (5 mm) • Box wrench (19 mm) • Specialty adapter for vacuum pump connection • Vacuum pump (vacuum pump power supply) • Extension cable • Marking pen • Caps • Plugs • Wire rope (with the required breaking load) • Crane (with the required lifting capacity) • Wood planks, etc. • Rag • Cleaning fluid

1. Removal of Center Joint [1] Use a hexagon wrench (5 mm) to remove the 4 bolts (1), and then remove the air breather (2) on the hydraulic oil tank.

[2] Attach the specialty adapter (3) to the area where the air breather was removed, and set the vacuum pump (4). Create negative pressure in the hydraulic oil tank using the vacuum pump.

217

1

Bolt

2

Air breather

3

Specialty adapter

4

Vacuum pump

RSM-13-07-001E 1

Center Joint [3] Use a box wrench (19 mm) to remove the 8 bolts (5), and then remove the lower under covers (6).

[4] Prepare a waste oil can (7) to receive the oil that spills out under the center joint.

[5] Use a wrench (36 mm) to remove the travel hoses (8) and another wrench (27 mm) to remove the drain hoses (9). • Mark the center joint and hoses so that the connectors match at the time of assembly. • Attach caps or plugs to the center joint and hoses to prevent any entry of water, dust or dirt. • Clean the center joint and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

RSM-13-07-001E

5

Bolt

6

Lower under cover

7

Waste oil can

8

Travel hose

9

Drain hose

218 2

Center Joint [6] Use a wrench (19 mm) to remove the pilot hoses (10) and another wrench (27 mm) to remove the drain hose (11). • Attach caps or plugs to the center joint and hoses to prevent any entry of water, dust or dirt. • Clean the center joint and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[7] Use a wrench (19 mm) to remove the 2 bolts (12), and then remove the center joint lock bar (13).

[8] Use a wrench (36 mm) to remove the 4 travel hoses (14). • Mark the hoses so that the connectors can be matched during assembly. • Attach caps or plugs to the hoses to prevent any entry of water, dust or dirt. • Clean the hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

10

219

Pilot hose

11

Drain hose

12

Bolt

13

Lock bar

14

Travel hose

RSM-13-07-001E 3

Center Joint [9] Wrap a wire rope (15) around the center joint and suspend it with a crane so that the center joint does not fall during removal and installation operations.

[10] Use a wrench (17 mm) to remove the 4 bolts (16) from the center joint.

[11] Use the wire rope (15) and crane to lift the center joint (17). [12] Thoroughly check that the location is safe before lowering the center joint on wood planks.

RSM-13-07-001E

15

Wire rope

16

Bolt

17

Center joint

220 4

Center Joint 2. Installation of Center Joint [1] Perform the reverse of the removal procedure. The tightening torque for the center joint bolts (1) is 109 - 127 N•m. [2] The tightening torque for the lock bar (2) bolt (3) is 88.3 - 107 N•m. Also, apply Loctite #262 to the bolts.

221

1

Bolt

2

Lock bar

3

Bolt

RSM-13-07-001E 5

Counterweight Counterweight

SH200-5

Counterweight Removal and Installation of Counterweight ・ Be sure to stop the engine before beginning work. ・ Be sure to inspect the wire rope and other lifting equipment before beginning work. Caution ・ Do not stand or pass under the suspended load. ・ Thoroughly secure the removed counterweight with the wire ropes and crane so that it does not fall over.

Items to prepare • Box wrench (50 mm) • Eyebolts (M36 mm) • Balance lifting device • Shackle (with the required lifting capacity) x 4 • Wire rope (with the required breaking load) x 4 • Crane (with the required lifting capacity) • Wood planks, etc. • Rag • Cleaning fluid

1. Removal of Counterweight [1] Remove the 2 rubber plugs (2) from the top of the counterweight (1).

[2] Install the 2 eyebolts (M36) (3) in place of the 2 removed rubber plugs. • Apply lubricating oil to the eyebolts. • Fully tighten the eyebolts, and then loosen them by a half turn.

222

1

Counterweight

2

Rubber plug

3

Eyebolt

RSM-13-08-001E 1

Counterweight [3] Connect the eyebolts to the shackles (4), and then use the wire ropes (5) and crane to secure the counterweight so that it does not fall during removal and installation operations.

[4] Use a box wrench (50 mm) to remove the 4 bolts (6) and spacers (7) on the lower section of the counterweight.

RSM-13-08-001E

4

Shackle

5

Wire rope

6

Bolt

7

Spacer

223 2

Counterweight [5] Use the wire ropes and crane to lift and remove the counterweight. • Move the counterweight about 50 cm to the rear while lifting it so that it does not interfere with the housing, engine parts and pipes.

[6] Thoroughly check that the location is safe before lowering the counterweight on wood planks (8). • Thoroughly secure the counterweight with the wire ropes and crane so that it does not fall over.

8

Wood plank

2. Installation of Counterweight Perform the reverse of the removal procedure. The tightening torque for the counterweight bolts is 1862 - 2058 N 疥 . Do not apply oil, etc. to the bolts. 224

RSM-13-08-001E 3

Hydraulic Pump Hydraulic Pump

SH200-5

Hydraulic Pump Removal and Installation of Hydraulic Pump Warning ・ Be sure to release hydraulic pressure before beginning work. ・ Be sure to stop the engine before beginning work. Caution ・ Be sure to inspect the wire rope and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare • Wrenches (13 mm, 14 mm, 17 mm, 19 mm, 22 mm, 30 mm, 36 mm) • Hexagon wrenches (8 mm, 10 mm) • Nylon sling (with the required breaking load) • Crane (with the required lifting capacity) • Marking pen • Caps • Plugs • Rag • Cleaning fluid • Wood planks, etc.

1. Removal of Hydraulic Pump [1] Use a wrench (19 mm) to remove the 6 bolts (1), and then remove the under cover (2).

[2] Remove the engine hood. For procedure, see "Removal and Installation of Engine Hood". [3] Use a wrench (19 mm) to remove the 4 bolts (3) from the top cover.

1

225

Bolt

2

Under cover

3

Bolt

RSM-13-09-001E 1

Hydraulic Pump [4] Use a wrench (13 mm) to remove the 2 bolts (3), and then remove the torsion bar bracket (4) for the engine hood.

[5] Use a wrench (19 mm) to remove the 4 bolts (5) from the inside of the top cover.

[6] Remove the top cover (6).

RSM-13-09-001E

3

Bolt

4

Torsion bar bracket

5

Bolt

6

Cover

226 2

Hydraulic Pump [7] Use a wrench (19 mm) to remove the 9 bolts (7), and then remove the 4 covers (8), (9), (10), and (11).

[8] Use a wrench (14 mm) to remove the 2 bolts (12) and 2 nuts (13), and then remove the exhaust pipe seal clamp (14).

[9] Use a wrench (17 mm) to remove the 3 bolts (15), and then remove the muffler installation bracket (16).

227

7

Bolt

8

Cover

9

Cover

10

Cover

11

Cover

12

Bolt

13

Nut

14

Seal clamp

15

Bolt

16

Muffler bracket

RSM-13-09-001E 3

Hydraulic Pump [10] Remove the muffler (17).

[11] Remove the hoses and connectors that are connected to the pump. Use a hexagon wrench (8 mm) to remove the 8 hose bolts (18), and remove the pressure hoses (19). Use a wrench (36 mm) to remove the drain hose (20). Use a wrench (22 mm) to remove the pilot hose (21). Use a wrench (30 mm) to remove the suction hoses (24) and (25). Remove the connectors (23). Use a wrench (19 mm) to remove the pilot hoses (22) and (25). Remove the connectors (26). Use a hexagon wrench (10 mm) to remove the suction line bolts (27) (2 in front, 2 in back), and remove the suction line (28). • Mark the pump and hoses so that the connectors match at the time of assembly. • Attach caps or plugs to the pump and hoses to prevent any entry of water, dust or dirt. • Clean the pump and hoses by spraying with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

RSM-13-09-001E

17

Muffler

23

Connector

18

Bolt

24

Pilot suction hose

19

Pressure hose

25

Pilot hose

20

Drain hose

26

Connector

21

Pilot hose

27

Bolt

22

Pilot hose

28

Suction line

228 4

Hydraulic Pump [12] Secure the pump with a crane and nylon sling (29) so that it does not fall during removal and installation operations.

[13] Use a wrench (17 mm) to remove the 9 bolts (30) from the pump.

[14] Use a crane and the nylon sling (29) to pull the pump out from the shaft and lift the pump.

229

29

Nylon sling

30

Bolt

RSM-13-09-001E 5

Hydraulic Pump [15] Thoroughly check that the location is safe before lowering the pump on wood planks (31). • Thoroughly secure the pump so that it does not fall over.

31

Wood plank

1

Bolt

2. Installation of Hydraulic Pump Perform the reverse of the removal procedure. The tightening torque for the pump bolt (1) is 63.7 - 72.6 N•m. Fill the pump case with hydraulic oil from the drain port so that no air remains in the pump case. Additionally, when there is a 2nd option gear pump, bleed off air from the air bleed port on the top surface of the power take-off case.

RSM-13-09-001E

230 6

Hydraulic Pump Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit 1. Tools The table below shows the tools required for assembly and disassembly of the K3V pump. The bolts and plugs may vary by pump type. Tool name and dimensions

Pump type (The ○ indicates a necessary part)

Name

K3V63 K5V80

Hexagon wrench

B

Hexagon Rc mounted K3V112 K3V140/180 socket head valve K5V140 K5V200 bolt (Rc screw)

PO plug (G screw)

Hexagon socket head locking screw

2

－

－

－

M4

2.5

－

－

－

M5

3

－

－

－

M6

4

○

○

○

M5

BP-1/16

－

M8

5

○

○

○

M6

BP-1/8

－

M10

6

○

○

○

M8

BP-1/4

PO-1/4

M12 M14

8

○

○

○

M10

BP-3/8

PO-3/8

M16 M18

10

M12

BP-1/2

PO-1/2

M20

12

M14

－

－

－

M16 M18

BP-3/4

PO-3/4

14

○ ○

17

○

1/

－ 11

－

M20 M22

BP-1

19

M24 M27

－

－

－

21

－

－

－

－

22

M30

－

PO-2

－

M12

M12

VP-1/4

－

－

－

VP-3/8

－

19

Closed wrench Socket wrench Double-head (single-head) wrench

Part name

○

○

○

PO-1, 1

4,

/2

22

○

24

○

○

M16

M16

－

－

27

○

○

M18

M18

VP-1/2

－

○

M20

M20

－

－

30

○

36

○

○

－

－

VP-3/4

－

41

○

○

－

－

VP-1

－

50

－

－

VP-11/4

－

55

－

－

VP-11/2

－

Monkey wrench

－

○

○

○

Medium-sized x 1

Screwdriver

－

○

○

○

Medium-sized flathead screwdriver x 2

Hammer

－

○

○

○

Plastic hammer x 1

Pliers

－

○

○

○

For stop ring, TSR-160

Steel rod

－

○

○

○

Key material steel rod, about 10X8X200

Torque wrench

－

○

○

○

With adjustable specified torque tightening

231

RSM-13-09-001E 7

Hydraulic Pump 2. Disassembly Procedure When disassembling the pump, read the disassembly procedure thoroughly before following the sequence below. The numbers in parentheses after the part names are the codes indicated in Attached diagram 1. Pump assembly cross-section diagram . [1] Select the location for disassembling the pump. • Find a clean location. • Place a rubber plate or cloth on the work platform so as not to damage the parts. [2] Use cleaning oil to remove any dirt or rust from the surface of the pump. [3] Remove the drain port plugs (468) and drain the oil from the pump casing. • Remove the plugs from both the front and rear pumps. [4] Remove the hexagon socket head bolts (412) and (413) to remove the regulators, and then remove the hexagon socket head bolts (414) to remove the cover (326). Loosen the 3 hexagon socket head bolts securing the electromagnetic proportional pressure reducing valve and casing subassembly (079), and remove the electromagnetic proportional pressure reducing valve and casing subassembly. • See the manual for the regulator for how to disassemble the regulators. [5] Loosen the 4 hexagon socket head bolts securing the gear pump and remove the gear pump.

RSM-13-09-001E

232 8

Hydraulic Pump [6] Loosen the hexagon socket head bolts (401) fastening the swash plate support boards (251), pump casings (271), and valve block (312) together.

[7] Face down the pump regulator installation surface horizontally on the work platform, and separate the pump casings (271) and valve block (313). • When placing the regulator installation surface with the face down, be sure to place a rubber plate or similar material on the work platform so as not to damage the regulator installation surface. • When separating the pump casings and valve block, remove the 1st gear (116) at the same time. [8] Remove the cylinder blocks (141) out from the pump casings (271) in a straight line in relation to the drive shafts (F) (111) and (R) (113), and remove the piston subassemblies (011), holder plates (153), spherical bushings (156), and cylinder springs (157) at the same time. • Be careful not to damage the sliding surfaces of the cylinder blocks, spherical bushings, shoes (152), and swash plates (212).

[9] Remove the hexagon socket head bolts (406), and remove the seal cover (F) (261). • The seal cover (F) can be easily removed by inserting a bolt into the hole (M6 tap) on the seal cover and then pulling the bolt out. • The seal cover (F) has an oil seal, so be careful not to damage the oil seal when removing the seal cover.

233

RSM-13-09-001E 9

Hydraulic Pump [10] Lightly strike the rear end sections of the drive shafts (F) (111) and (R) (113) to remove them from the swash plate support boards (251).

[11] Remove the shoe plates (211) and swash plates (212) from the pump casings (271).

[12] Lightly strike the installation flange sections of the swash plate support boards (251) on the pump casing (271) sides, and separate the swash plate support boards and the pump casings. [13] Remove the valve plates (R) (313) and (L) (314) from the valve block (312). • These can also be removed in Step [7].

[14] If necessary, remove the stoppers (L) (534), stoppers (S) (535), servo pistons (532), and tilting pins (531) from the pump casings (271), and remove the needle bearing (124) from the valve block (312). • To avoid damaging the heads of the tilting pins, use a jig when removing them. • Loctite has been applied to the sections where the tilting pins and servo pistons are bonded, so be careful not to damage the servo pistons. • Try to avoid removing the needle bearings unless they are at the end of their service life. • Do not loosen the hexagon nuts of the valve block or swash plate support boards. This changes the flow volume setting.

RSM-13-09-001E

234 10

Hydraulic Pump 3. Assembly Procedure The assembly procedure is the reverse of the disassembly procedure. However, follow the precautions below. (1) Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. (2) Thoroughly clean all parts with cleaning oil and air blow them before assembly. (3) Be sure to apply clean hydraulic oil to sliding parts and bearings before assembly. (4) As a rule, replace all O-rings, oil seals, and other seal parts with new parts. (5) Use a torque wrench to tighten all installation bolts and plugs to the torque specified in “Maintenance Standards.” (6) Be careful not to mix up the pump parts for the front and rear of the tandem pump. [1] Install the swash plate support boards (251) in the pump casings (271) by lightly striking them with a hammer. • When the servo pistons (532), tilting pins (531), stoppers (L) (534), and stoppers (S) (535) are removed, install these parts in the pump casings in advance. • To avoid damaging the heads of the tilting pins and the feedback pins (548), use a jig when tightening the servo pistons and tilting pins. Also be sure to apply Loctite (moderate strength) to the threaded sections.

[2] Attach the shoe plates (211) to the swash plates (212). Place the pump casings (271) with the regulator installation surfaces facing down, insert the tilting bushings (214) of the swash plates onto the tilting pins (531), and correctly mount the swash plates and shoe plates on the swash plate support boards (251). • Use the fingertips of both hands to check that the swash plates move smoothly. • Apply grease to sliding sections of swash plates and swash plate support boards for easier installation of the drive shafts (F) (111)and (R) (113). • Be careful not to damage the sliding surfaces of the shoe plates. [3] Install the drive shafts (F) (111) and (R) (113) with cylinder roller bearings (123), bearing spacers (127), and springs (824) set on them to the swash plate support boards (251).

235

RSM-13-09-001E 11

Hydraulic Pump [4] Attach the seal cover (F) (261) to the pump casings (271), and secure the cover with the hexagon socket head bolts (406). Tightening torque: 29 N・m • Apply a thin layer of grease to the oil seal (774) inside the seal cover (F). • Be careful not to damage the oil seal when attaching it.

[5] Assemble the piston cylinder subassemblies (cylinder blocks (141), piston subassemblies (011), holder plates (153), spherical bushings (156), cylinder springs (157)), align piston subassemblies with the spherical bushings and cylinder splines and insert them into the pump casings.

[6] Install the valve plates (R) (313) and (L) (314) on the valve block (312) in alignment with the pins (885). • Be careful not to mistake the suction and discharge directions of the valve plates.

RSM-13-09-001E

236 12

Hydraulic Pump [7] Place the pump regulator horizontally on the work platform with the regulator installation surface facing down, and install the pump casings (271) and the valve block (312). • When placing the regulator installation surface with the face down, be sure to place a rubber plate or similar material on the work platform so as not to damage the regulator installation surface. • Install the valve block in the correct direction. (Install the valve block so that the regulator faces up and the suction flange faces right when looking at the valve block from the front.） • When installing the pump casings and valve block, install the 1st gear (116) at the same time. [8] Install the gear pump (04) with the 4 hexagon socket head bolts.

237

RSM-13-09-001E 13

Hydraulic Pump [9] Tighten the valve block (312) and pump casings (271) with the hexagon socket head bolts (401). Tightening torque: 430 N•m • Assembly is easier when starting with the rear side pump.

[10] Tighten the hexagon socket head bolts (414) to the valve block (312) to attach the cover (326). Tightening torque: 57 N•m

[11] Insert the feedback pins (548) of the tilting pins (532) into the feedback lever (611) of the regulators, install the regulators, and tighten the hexagon socket head bolts (412) and (413). Tightening torque: 29 N•m • Install the regulator, making sure not to mistake the front and the rear of the regulator. [12] Tighten the 3 hexagon socket head bolts to the valve block (312) to install the electromagnetic proportional pressure reducing valve and casing subassembly (079). Tightening torque: 11.8 N•m [13] Attach the drain port plugs (468) to finish assembly. Tightening torque: 170 N•m

RSM-13-09-001E

238 14

Hydraulic Pump Pump Main Unit Maintenance Standards 1. Standards for Replacing Worn Parts If any part exceeds the standard values below and is worn, replace or readjust that part. If, however, the appearance of the part shows significant damage, replace that part. (Units: mm) Standard dimensions/recommended replacement value Part name and inspection item

Piston and cylinder bore clearance (D-d) Piston, shoes, and caulking section backlash (δ)

Pump type K3V63, K5V80

K3V112

0.028/0.056

0.039/0.067

0 ～ 0.1/0.3

Solution

K5V140, K3V140 K5V200, K3V180

0 ～ 0.1/0.3

0.043/0.070

0 ～ 0.1/0.3

0.0375/0.078

Replace the piston or cylinder.

0 ～ 0.1/0.35

Replace piston and shoe assembly. Replace piston and shoe assembly.

Shoe thickness (t)

3.9/3.7

4.9/4.7

5.4/5.0

5.4/5.0

Free height of cylinder spring (L)

31.3/30.2

41.1/40.3

47.9/47.1

40.9/40.1

Replace cylinder spring.

23.8/22.8

Replace holder plate or spherical bushing.

Assembled height of holder plate and spherical bushing (H-h)

19.0/18.2

23.0/22.0

23.8/22.8

Cylinder opening diameter (spline in cylinder) Spline in spherical bushing

35.17 (φ5) / 35.57

239

Replace cylinder and spherical bushing.

RSM-13-09-001E 15

Hydraulic Pump 2. Standards for Repairing Cylinder, Valve Plate, and Swash Plate (Shoe plate) Valve plate (sliding section) Swash plate (shoe plate section) Cylinder (sliding section) Surface roughness

Surface roughness requiring repair

3-Z

Standard surface roughness (repair value)

0.4 Z or lower (lapping)

3. Tightening torque Part name

Hexagon socket head bolt (material SCM435)

Rc plug (material S45C) Note:Wrap seal tape around the plug 1.5 - 2 times

PO plug (material S45C)

RSM-13-09-001E

Size

Tightening torque (N•m)

M5

6.9

B=4

M6

12

B=5

M8

29

B=6

M10

57

B=8

M12

98

B=10

M14

160

B=12

M16

240

B=14

M18

330

B=14

M20

430

B=17

Rc1/16

6.9

B=4

Rc1/8

10

B=5

Rc1/4

17

B=6

Rc3/8

34

B=8

Rc1/2

49

B=10

G1/4

29

B=6

G1/2

98

B=10

G3/4

150

B=14

G1

190

B=17

G1 1/4

260

B=17

G1 1/2

270

B=17

Tool name (mm)

Hexagon wrench

Same as above

Same as above

240 16

Hydraulic Pump

Attached diagram 1. Pump assembly cross-section diagram 241

RSM-13-09-001E 17

Hydraulic Pump Explanation of Regulator Operation 1. Regulator Adjustment The adjusting screws on the regulators can be used to adjust the maximum flow, minimum flow, horsepower control characteristics, and flow control characteristics. (Attached table 1 shows the adjustments and changes that can be made.) (1)Maximum flow adjustment (on the pump main unit) Loosen the hexagon nuts (808) and tighten (or loosen) the locking screws (954) to adjust the maximum flow. This only changes the maximum flow. It does not change the other control characteristics.

(2)Minimum flow adjustment (on the pump main unit) Loosen the hexagon nuts (806) and tighten (or loosen) the hexagon socket head locking screws (953) to adjust the minimum flow. Similar to the maximum flow adjustment, this does not change other control characteristics. However, the required power may increase at the time of maximum discharge pressure (during relief) if the hexagon socket head locking screws are tightened too much, so adjust these carefully. (3)Input horsepower adjustment These regulators use the simultaneous fullhorsepower method. Therefore, when changing the horsepower setting, adjust the adjusting screw of both the front and rear pump to the same amount. The adjusted pressure value is the value when pressure in both pumps is simultaneously increased. [1] Outer spring adjustment Loosen the lock nuts (630) and tighten (or loosen) the adjusting screws (C) (628) to adjust the outer springs. As the adjusting screws (C) are tightened, the control line graph shifts to the right as shown in the diagram, and the input horsepower increases. When the adjusting screws (C) are rotated N times, the inner spring (626) settings also change. Therefore, return the adjusting rings (C) (627) by rotating them N x A times in the opposite direction.

RSM-13-09-001E

242 18

Hydraulic Pump [2] Inner spring adjustment Loosen the hexagon nuts (802) and tighten (or loosen) the adjusting rings (C) (627) to adjust the inner springs. As the adjusting rings (C) are tightened, the flow increases as shown in the diagram, and the input horsepower increases.

(4) Flow control characteristics adjustment Loosen the hexagon nuts (801) and tighten (or loosen) the hexagon socket head locking screws (924) to adjust the flow control characteristics. As the hexagon socket head locking screws (924) are tightened, the control line graph shifts to the right as in the diagram on the right.

2. Causes and Solutions for Regulator Trouble If a malfunction occurs that is thought to be caused by the regulators, disassemble and inspect the regulators while referring to the Maintenance Procedures. (1) Flow control characteristics adjustment Apply a load to each individual pump and investigate whether there is a problem with the front or rear pump. If there is a problem with both pumps, see Steps (1) and (2) below. If there is a problem with only one, start from Step (3). (1) Inspect whether the power shift command milliamp value I is correct. (2) Power shift pressure (Pf) is low.

→

Inspect the amp dither. Replace the electromagnetic proportional pressure reducing valve.

(3) Compensation piston (621) and compensation rod (623) are sticking.

→

Disassemble and clean.

(4) Pin (898) is sticking.

→

Disassemble and clean.

(2) Pilot piston (643) is sticking.

→

Disassemble and clean.

(3) Spool (652) is sticking.

→

Disassemble and clean.

(2) When maximum flow is not output (1) Check whether the pilot pressure Pi is correct.

(Note) If any parts have deep scratches, replace those parts.

243

RSM-13-09-001E 19

Hydraulic Pump 3. Attached Table and Diagram Rotation speed (min-1) Maximum flow adjustment

Minimum flow adjustment

Outer spring adjustment Input horsepower adjustment

Inner spring adjustment

Flow control characteristics adjustment

1800 Adjusting screw (954) tightening amount (rotation)

+1/4

Flow amount change (L/min)

-5.2

Adjusting screw (953) tightening amount (rotation)

+1/4

Flow amount change (L/min)

+4.1

Adjusting screw (628) tightening amount (rotation)

+1/4

Compensation control start pressure change amount (MPa)

+1.88

Input torque change amount (N•m)

+57.9

A

1.87

Adjusting ring (627) tightening amount (rotation)

+1/4

Flow amount change (L/min)

+8.5

Input torque change amount (N•m)

+44.2

Adjusting screw (924) tightening amount (rotation)

+1/4

Flow control start pressure change amount (MPa)

+0.15

Flow amount change (L/min)

+11.7

Attached table 1. Regulator adjustment amount list

RSM-13-09-001E

244 20

Hydraulic Pump

Front side regulator (KR3G-9Y04-HV)

Rear side regulator (KR3G-9X04-HV)

Hydraulic circuit diagram

Hydraulic circuit diagram

Attached diagram 1. Regulator operation explanation diagram

245

RSM-13-09-001E 21

Hydraulic Pump

Attached diagram 2-1. Regulator breakdown diagram (KR3G-9X04-HV)

RSM-13-09-001E

246 22

Hydraulic Pump

Attached diagram 2-2. Regulator breakdown diagram (KR3G-9Y04-HV)

247

RSM-13-09-001E 23

Hydraulic Pump Procedures for Assembly and Disassembly of Regulator 1. Tools The table below shows the tools required for the assembly and disassembly of KR3G-9*04-HV. Tool name and dimensions

Name

Hexagon wrench

Closed wrench Socket wrench Double-head (single-head) wrench

Required tools are indicated with ○

Part name

B

Hexagon socket head bolt (shouldered bolt)

Rc mounted valve (Rc screw)

ROH plug (G screw)

Hexagon socket head locking screw

2

－

－

－

M4

2.5

－

－

－

M5

3

－

－

－

M6

4

M5

BP-1/16

－

M8

5

M6

BP-1/8

－

M10

6

M8

BP-1/4

RHO-1/4

M12 M14

8

M10

BP-3/8

RHO-3/8

M16 M18

10

M12

BP-1/2

RHO-1/2

M20

12

M14

－

－

－

14

M16 M18

BP-3/4

RHO-3/4

－

17

M20 M22

BP-1

RHO-1

－

19

M24 M27

－

－

－

22

－

－

VP-3/8

－

24

M16

M16

27

M18

M18

M20

M20

36

－

－

VP-3/4

－

41

－

－

VP-1

－

46

M30

M30

－

－

50

－

－

VP-11/4

－

55

－

－

VP-11/2

－

30

○

－ VP-1/2

－

Monkey wrench

－

○

Medium-sized x 1

Screwdriver

－

○

Medium-sized flathead screwdriver x 1

－

○

For stop ring, TSR-160

－

○

For locking ring, TRR-150

Torque wrench

－

○

With adjustable specified torque tightening

Steel rod

－

○

Diameter φ4 or less L=100

Hexagon socket head bolt

－

○

M4 for pulling out adjusting ring, L=about 50

Pliers

RSM-13-09-001E

－

248 24

Hydraulic Pump 2. Disassembly Preparations [1] These regulators comprise small precision parts, so disassembly and assembly operations are somewhat complex. [2] The pressure-flow settings of the front side regulator and rear side regulator differ, so mark the regulators when disassembling to differentiate between the drive side and the driven side. [3] When disassembling the regulators, read the disassembly procedure thoroughly before following the sequence below. The numbers in parentheses after the part names are the codes indicated in "Attached diagram 1. Front-side regulator assembly cross-section diagram (KR3G-9Y04-HV)" and "Attached diagram 2. Rear-side regulator assembly cross-section diagram (KR3G-9X04-HV)".

3. Disassembly Procedure [1] Select a location for disassembly. • Select a clean location. • Place a rubber plate or cloth on the work platform so as not to damage the parts. [2] Use cleaning oil to remove any debris or rust from the surface of the regulators. [3] Remove the hexagon socket head bolts (438), and remove the covers (C) (629). • The covers (C) (629) are assembled with adjusting screws (C) (628), adjusting rings (C) (627), lock nuts (630), hexagon nuts (801) and (802), and hexagon socket head locking screws (924). Do not loosen these screws and nuts. Doing so changes the adjusted pressureflow setting. [4] After removing the cover (C) (629) subassemblies, remove the outer springs (625), inner springs (626), and spring seatings (C) (624) from the compensation sections, and pull out the adjusting rings (Q) (645), pilot springs (646), and spring seatings (644) from the pilot sections. • The adjusting rings (Q) can be easily removed by pulling them out with an M4 bolt.

249

RSM-13-09-001E 25

Hydraulic Pump [5] Remove the hexagon socket head bolts (436), and remove the pilot covers (641). After removing the pilot covers, remove the pins (898) and Pf sleeves (631) from the compensation sections and the set springs (655) from the pressure adjustment sections. [6] Remove the stop rings (814), and remove the spring seatings (653), return springs (654), and sleeves (651). • The sleeves are assembled with retaining rings (836). • When removing the stop rings, the return springs fly out, so be careful not to lose these parts. [7] Remove the locking rings (858), and remove the fulcrum plugs (614) and adjusting plugs (615). • The fulcrum plugs and adjusting plugs can be easily removed by pulling them out with an M6 bolt.

[8] Remove the levers 2 (613). Do not pull out the pins (875). • These can be easily removed by using a pair of tweezers.

RSM-13-09-001E

250 26

Hydraulic Pump [9] Pull out the pins (874), and remove the feedback levers (611). • Use a fine steel rod to push out the pins (874) (pin diameter φ4) from above without touching the levers 1 (612).

[10] Remove the levers 1 (612). Do not pull out the pins (875). [11] Pull out the pilot pistons (643) and spools (652). [12] Pull out the piston cases (622), compensation pistons (621), and compensation rods (623). • The piston cases can be removed by pushing out the compensation rods from the opposite side of the piston cases. [13] Remove the hexagon socket head bolts (418), and remove the electromagnetic proportional pressure reducing valve (079) from the pilot cover (641). This completes the disassembly of the regulator main units. • This operation is only for the front-side regulator (KR3G-9Y04-HV). • Be careful not to damage the connector section of the electromagnetic proportional pressure reducing valve. (Caution) The component parts are small, so be very careful not to lose them.

251

RSM-13-09-001E 27

Hydraulic Pump 4. Assembly Procedure The assembly procedure is the reverse of the disassembly procedure. However, follow the precautions below. (1)Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. (2)Any foreign matter entering the equipment can create a malfunction. Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and perform assembly in a clean location. (3)Be sure to apply clean hydraulic oil to sliding sections before assembly. (4)As a rule, perform replacement for all O-rings and other seal parts. (5)Use a torque wrench to tighten all installation bolts and plugs to the torque specified in “Maintenance Standards”. [1] Select a location for assembly. • Select a clean location. • Place a rubber plate or cloth on the work platform so as not to damage the parts. [2] Install the compensation rods (623) into the compensation holes on the casings (601). [3] Insert the pins (875) press fit in the levers 1 (612) into the grooves on the compensation rods (623), and install the levers 1 on the pins press fit in the casings (601). [4] Install the spools (652) and sleeves (651) in the casing spool holes. • Check that the spools and sleeves slide smoothly in the casings without catching. • Be careful to assemble the spools in the correct direction. [5] Install the feedback levers (611), and insert the pins (874) in alignment with the pin holes on the feedback levers. • Assembly is easier if the pins are inserted into the feedback levers in advance. • Be careful to assemble the feedback levers in the correct direction. [6] Install the pilot pistons (643) into the pilot holes on the casings (601). • Check that the pilot pistons (643) slide smoothly without catching. [7] Insert the pins (875) press fit in the levers 2 (613) into the grooves on the pilot pistons (643), and assemble the levers 2.

RSM-13-09-001E

252 28

Hydraulic Pump [8] Assemble the fulcrum plugs (614) and install the locking rings (858) so that the pins (875) press fit in the fulcrum plugs (614) are inserted into the pin holes on the levers 2 (613).

[9] Insert the adjusting plugs (615), and install the locking rings (858). • Be careful to insert the fulcrum plugs (614) and adjusting plugs (615) into the correct holes. • At this time, check that the backlash from the movement of the feedback levers (611) is not too great and that the feedback levers do not catch on anything.

[10] Install the return springs (654) and spring seatings (653) into the spool holes, and install the stop rings (814).

[11] Install the set springs (655) into the spool holes, and install the compensation pistons (621), piston cases (622), Pf sleeves (631), and pins (622) into the compensation holes. • Check that the Pf sleeves and pins move smoothly.

253

RSM-13-09-001E 29

Hydraulic Pump [12] Install the electromagnetic proportional pressure reducing valve (079) in the pilot cover (641), and tighten the hexagon socket head bolts (418). Tightening torque: 6.9 N•m • This operation is only for the front-side regulator (KR3G-9Y04-HV). • Be careful not to damage the connector section of the electromagnetic proportional pressure reducing valve.

[13] Install the pilot covers (641), and tighten the hexagon socket head bolts (436). Tightening torque: 12 N•m [14] Install the spring seatings (Q) (644), pilot springs (646), and adjusting rings (Q) (645) into the pilot holes, and install the spring seatings (Q) (624), inner springs (626), and outer springs (625) into the compensation holes. • Be careful to install the spring seatings (Q) in the correct direction. [15] Assemble the covers (C) (629) set with the adjusting screws (C) (628), adjusting rings (C) (627), lock nuts (630) ,hexagon nuts (801) and (802), hexagon socket head locking screws (924), and tighten the hexagon socket head bolts (438). Tightening torque: 12 N•m This completes the assembly of the regulator main units.

RSM-13-09-001E

254 30

Hydraulic Pump

Attached diagram 1. Front-side regulator assembly cross-section diagram (KR3G-9Y04-HV) 255

RSM-13-09-001E 31

Hydraulic Pump

Attached diagram 2. Rear-side regulator assembly cross-section diagram (KR3G-9X04-HV) RSM-13-09-001E

256 32

Remote Control Valve Remote Control Valve

SH200-5

Remote Control Valve Removal and Installation of Operation Remote Control Valve Warning ・ Be sure to release hydraulic pressure before beginning work.

Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Wrenches (19 mm, 22 mm) • Box wrench (10 mm) • Hexagon wrench (5 mm) • Phillips screwdriver • Marking pen • Caps • Plugs • Rag • Cleaning fluid

1. Removal of Operation Remote Control Valve (Left Side) [1] Roll up the boot (1) of the control lever and use the Phillips screwdriver or box wrench (10 mm) to remove the 2 bolts (2) of the console top cover.

[2] Use the Phillips screwdriver to remove the 2 screws (3), and then remove the handle of the tilt lever (4).

257

1

Boot

2

Bolt

3

Screw

4

Tilt lever

RSM-13-10-001E 1

Remote Control Valve [3] Use a hexagon wrench (5 mm) to remove the 2 bolts (5), and remove the grip (6) of the gate lock lever.

[4] Use the Phillips screwdriver to remove the 2 screws (7) of the console top cover.

[5] Remove the 3 connectors (8) and remove the console top cover (9).

RSM-13-10-001E

5

Bolt

6

Gate lock lever grip

7

Screw

8

Connector

9

Console top cover

258 2

Remote Control Valve [6] Use the Phillips screwdriver or box wrench (10 mm) to remove the 5 bolts (10). [7] Remove the cover (11).

[8] Roll up the boot (12) of the control lever, remove the connector (13) of the horn switch, and cut the wire band (14).

[9] While securing the nut (15) with a wrench (22 mm), use another wrench (19 mm) to remove the lock nut (16) and remove the control lever (17).

259

10

Bolt

11

Cover

12

Boot

13

Connector

14

Wire band

15

Nut

16

Lock nut

17

Control lever

RSM-13-10-001E 3

Remote Control Valve [10] Roll back the hose cover (18).

[11] Use a wrench (22 mm) to remove the 6 hoses (19). • Mark the joystick remote control valve and hoses so that the connectors match at the time of assembly. • Use caps and plugs to cover the joystick remote control valve and hoses to prevent any entry of water, dust or dirt. • Clean the joystick remove control valve and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[12] Use the hexagon wrench (5 mm) to remove the 4 bolts (20).

18

RSM-13-10-001E

Hose cover

19

Pilot hose

20

Bolt

260 4

Remote Control Valve [13] Remove the joystick remote control valve (21).

21

261

Remote control valve

RSM-13-10-001E 5

Remote Control Valve 2. Removal of Operation Remote Control Valve (Right Side) [1] Roll up the boot (1) of the control lever and use the Phillips screwdriver or box wrench (10 mm) to remove the 2 bolts (2) of the console top cover.

[2] Use the Phillips screwdriver to remove the 2 screws (3), and then remove the handle of the tilt lever (4).

[3] Use the Phillips screwdriver to remove the 2 screws (5) of the console top cover.

RSM-13-10-001E

1

Boot

2

Bolt

3

Screw

4

Tilt lever

5

Screw

262 6

Remote Control Valve [4] Remove the 3 connectors (6) and remove the console top cover (7).

[5] Use the Phillips screwdriver or box wrench (10 mm) to remove the 5 bolts (8). [6] Remove the cover (9).

[7] Roll up the boot (10) of the control lever, remove the connector (11) of the horn switch, and cut the wire band (12).

263

6

Connector

7

Console top cover

8

Bolt

9

Cover

10

Boot

11

Connector

12

Wire band

RSM-13-10-001E 7

Remote Control Valve [8] While securing the nut (13) with a wrench (22 mm), use another wrench (19 mm) to remove the lock nut (14) and remove the control lever (15).

[9] Roll back the hose cover (16).

[10] Use a wrench (22 mm) to remove the 6 hoses (17). • Mark the joystick remote control valve and hoses so that the connectors match at the time of assembly. • Use caps and plugs to cover the joystick remote control valve and hoses to prevent any entry of water, dust or dirt. • Clean the joystick remove control valve and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors. 13

RSM-13-10-001E

Nut

14

Lock nut

15

Control lever

16

Hose cover

17

Pilot hose

264 8

Remote Control Valve [11] Use the hexagon wrench (5 mm) to remove the 4 bolts (18) and 4 washers (19).

[12] Remove the joystick remote control valve (20).

18

Bolt

19

Washer

20

Remote control valve

3. Installation of Operation Remote Control Valve To install, perform the reverse of the removal procedure. Be careful not to connect the hydraulic hoses in incorrect locations. Before installing the hoses, check that the hose adapters are not loose and retighten them to the specified torque. P port Hose adapter tightening torque ：28.4 ± 2.9 N•m Hydraulic hose tightening torque ：49 ± 4.9 N•m T port, Ports 1 - 4 Hose adapter, hydraulic hose tightening torque ：49 ± 4.9 N•m

265

RSM-13-10-001E 9

Remote Control Valve Procedures for Assembly and Disassembly of Operation Remote Control Valve 1. Maintenance Procedures (1) Required tools and tightening torque Tool

Dimensions (mm)

Part number

Part name

Screw size

Tightening torque (N•m)

22

312

Adjusting nut

M14

68.6 ± 4.9

32

302

Disk

M14

24

301

Joint

M14

Wrench Special jig (diagram in Attached diagram 2. Joint disassembly jig page 278)

47.1 ± 2.9

Other ・ Vapor corrosion inhibitor

・Sandpaper (#1000, #2000)

・White kerosene

・Whetstone

・Heat-resistant grease

・Vice

(2)Maintenance standards Maintenance inspection item

Standard

Remarks

Leak amount

When handle is in neutral 1000 cc/min or more During operation 2000 cc/min or more If either condition occurs, replace the remote control valve as one unit.

Conditions Primary pressure 2.94 MPa Oil viscosity 23 mm2/s

Spool

When wear on the sliding sections exceeds wear on the non-sliding sections by 10 μm or more, replace the remote control valve as one unit.

The same approximate conditions as those listed above for leak amount are expected when the condition on the left occurs.

If the end section is worn by 1 mm or more, perform replacement.

Push rod

Replace the operation section disk (302) and joint Operation section (301) if there is backlash of 2 mm or more section backlash due to wear.

Operation stability

Make adjustments if the backlash is due to looseness in the tightening sections.

If abnormal noise, hunting, or a drop in primary pressure occurs and the problem cannot be resolved with "4. Causes of Trouble and Countermeasures", replace the remote control valve as one unit.

Note: It is desirable for seal materials such as O-rings to be replaced with each disassembly, but it is acceptable to reuse these after it is confirmed that they are not damaged.

RSM-13-10-001E

266 10

Remote Control Valve 2. Disassembly Procedures [1] Preparations 1) Prepare a sufficiently spacious, solid and stable work platform so that parts will not fall or move during work. 2) Prepare the tools and materials indicated in "1. Maintenance Procedures (1) Required tools and tightening torque". 3) When disassembling the valve, read the disassembly procedures thoroughly before following the sequence below. The numbers in the parentheses after the part names indicate codes in "Attached diagram 1. Remote control valve assembly cross-section diagram Attached diagram 1. Remote control valve assembly cross-section diagram”. [2] General work precautions 1) Each part has been manufactured with a high degree of precision, so be careful not to let parts bump each other or fall when handling them. 2) If parts are struck or pulled with excessive force during work because they are tight, this may cause burrs or damage which lead to faulty assembly causing reduction in performance or oil leaking. Perform work carefully and thoroughly. 3) Rust may form on parts due to moisture or debris if the valve is left disassembled or if work is abandoned in the middle of disassembly. If work must be halted, be careful about preventing rust from forming and dust settling on parts. [3] Disassembly procedure 1) Clean the remote control valve with white kerosene. • Place plugs in each port. 2) Use copper plate (or lead plate) to secure the remote control valve in a vise. 3) Remove the bellows (501). • Be careful not to tear the bellows.

267

RSM-13-10-001E 11

Remote Control Valve 4) Use a wrench on the bolt width of the adjusting nut (312) and disk (302) to loosen them, and remove the adjusting nut and disk.

RSM-13-10-001E

268 12

Remote Control Valve 5) Use a jig to rotate the joint (301) to the left and loosen it. • The diagram shows the valve with the jig installed. • If the return springs (221) are strong, the plate (151), plugs (211), and push rods (212) will rise at the same time the joint is loosened, so be careful of parts flying off when removing the joint.

6) Remove the plate (151).

7) If the return springs (221) are weak, the plugs (211) will remain in the casing (101) due to the sliding resistance of the O-rings (214), so use a flathead screwdriver to remove them. • Use the groove in the outer circumference of the plugs and remove them while making sure they are not damaged by an unbalanced load. • Use caution as plugs may fly off when they are being removed due to the return springs.

269

RSM-13-10-001E 13

Remote Control Valve 8) Remove the push rods (212), plugs (211), pressure reducing valve assemblies and the return springs (221) from the casing (101). • Record the relation of parts to the casing hole positions through marking, etc.

9) For disassembly of pressure reducing valves, press in the spring seatings, move the spring seatings (216) to the side while bending the secondary pressure springs (241), and remove the springs from the spools (201) by passing the springs through the larger hole of the spring seatings. Next, separate the spools, spring seatings, secondary pressure springs, and washers (217). • Be careful not to scratch the surface of the spools. • Do not lower the spring seatings by 6 mm or more. • Handle these parts as assemblies until assembly of the remote control valve.

10) Remove push rods (212) from the plugs (211).

RSM-13-10-001E

270 14

Remote Control Valve 11) Remove O-rings (214) and seals (213) from the plugs (211). Use a small flathead screwdriver, etc. to remove seals. • O-rings and seals cannot be reused. Replace them with new parts.

12) Cleaning parts 1. Clean all parts by placing them in a rough cleaning container filled with white kerosene. (rough cleaning) 2. Clean all parts by placing them in a finish cleaning container filled with white kerosene, and thoroughly clean them up to the interior while slowly rotating them. (finish cleaning) Use a rag to thoroughly remove white kerosene adhered to parts. • Scratching can easily occur if cleaning of parts is begun just after parts are immersed in white kerosene, so let parts sit in white kerosene until debris and grease sufficiently loosen off from the surface of parts and float to the surface.

• If the white kerosene is dirty, this will encourage damage to parts and result in reduced performance after reassembly. Thoroughly manage the level of cleanliness of the white kerosene. • Do not dry parts with compressed air, as this will damage parts and cause rust to form due to debris and moisture being dispersed into the atmosphere. 13) Preventing rust on parts Apply an anti-rust agent to each part. • Rust will form on parts if they are left as is after cleaning, and this will cause reduced performance of functions after reassemly.

271

RSM-13-10-001E 15

Remote Control Valve 3. Assembly Procedures [1] Preparations 1) As with disassembly, prepare a work platform, tools and materials. [2] General work precautions 1) Observe the same general work precautions as with disassembly. 2) When performing assembly, remove metal fragments and foreign matter from all parts, and check that there are no burrs or nicks on parts. If there are burrs or nicks, use a whetstone to remove them. 3) As a rule, replace all O-rings and backup rings with new parts. 4) When installing O-rings and backup rings, be careful not to damage them. (Apply a thin layer of grease to ensure smooth installation.) 5) When installing parts, using grease is good for preventing parts from falling. 6) Tighten bolts, etc. to the torque values indicated in page 277 "Attached diagram 1. Remote control valve assembly cross-section diagram". Use the torque wrench to measure the tightening torque. 7) After assembly is complete, place plugs in all of the ports to prevent entry of debris. [3] Assembly procedures 1) Insert washers (217), secondary pressure springs (241) and spring seatings (216) onto each of the spools (201) in that order.

Additionally, press in the spring seatings and move them to the side while bending the secondary pressure springs to pass the seatings over the larger holes and install them on each of the spools. • Do not lower the spring seatings by 6 mm or more.

RSM-13-10-001E

272 16

Remote Control Valve 2) Install the return springs (221) in the casing (101). Install the pressure reducing valve assemblies in the casing. • Install them in the positions they were in before disassembly.

3) Install O-rings (214) on the plugs (211).

4) Install seals (213) on the plugs (211). • Install so that the seal lips are as shown in the diagram below.

*1

Seal

*2

Plug

*3

Push rod

*4

Hydraulic oil application

273

RSM-13-10-001E 17

Remote Control Valve 5) Install push rods (212) into the plugs (211). • Apply hydraulic oil to surface of the push rods.

6) Install the plug assemblies into the casing (101). If the return springs (221) are weak, they will be stopped by the sliding resistance of the Orings (214). • Be careful not to scratch the casing holes by forcing in the spools (201).

If the return springs are strong, use the plate (151) to install all 4 plug assemblies at the same time and temporarily tighten them with the joint (301). • Be careful of the plug assemblies and plate flying off.

7) Install the plate (151). 8) Use a jig, and tighten the joint (301) to the casing (101) to the specified torque. Tightening torque: 47.1 ± 2.9 N・m

RSM-13-10-001E

274 18

Remote Control Valve 9) Install the disk (302) onto the joint (301). • Screw the disk in until it is equally touching each of the 4 push rods (212). Secondary pressure will cause faulty operation of the machine if the disk is screwed in too much, so pay attention to adjustment of the tightening position.

10) Install the adjusting nut (312), use a wrench on the bolt width of the disk (302) to secure it, and tighten the adjusting nut to the specified torque. Tightening torque: 68.6 ± 4.9 N・m • During tightening, do not move the disk position.

11) Apply grease to the rotating section of the joint (301) and to the top of the push rods (212).

12) Install the bellows (501). • Be careful not to tear the bellows.

13) Inject vapor corrosion inhibitor into each port and then place plugs in the ports. 275

RSM-13-10-001E 19

Remote Control Valve 4. Causes of Trouble and Countermeasures It is not always easy to find where the source of trouble is located. A few problems that may sometimes occur are listed in the table below. Repair of these problems can be difficult, so see the suggested causes and solutions in the table for assistance. The table below shows general symptoms, suggested causes and also solutions. However, the cause of machine problems are often not rooted in just a single part. Problems are often due to the relationship of one part with another. Also keep in mind that solutions other than those listed in the table may sometimes be necessary. The table below does not include all possible causes and countermeasures. Accordingly, further investigation of problems and causes should be done by an experienced and qualified repair person, as necessary. Symptom

Cause

Solution

1. Insufficient primary pressure 2. Secondary pressure spring(s) (241) is (are) broken or worn. Secondary pressure is 3. The gap between spool(s) (201) and the not rising. casing (101) is abnormally large. 4. There is backlash in the handle section.

1. Maintain primary pressure. 2. Replace it (them) with new part(s). 3. Replace the remote control valve as one unit. 4. Disassemble and assemble or replace the handle section.

1. Sliding parts are sticking. Secondary pressure is 2. Tank line pressure is variable. unstable. 3. Air is getting into lines.

1. Repair the sticking sections. 2. Return directly to the oil tank. 3. Perform operation several times and let out air.

Secondary pressure is 1. Tank line pressure is high. high. 2. Sliding parts are sticking.

1. Return directly to the oil tank. 2. Repair the sticking sections.

RSM-13-10-001E

276 20

Remote Control Valve

Attached diagram 1. Remote control valve assembly cross-section diagram Code

Q'ty

Code

101

Casing

Part name

1

217

Part name

151

Plate

1

201

Spool

4

221-2 Return spring (port 3)

1

211

Plug

4

221-3 Return spring (port 2, 4)

2

212-1 Push rod (port 1, 3)

2

241-1 Secondary pressure spring (port 1, 3)

2

212-2 Push rod (port 2, 4)

2

241-2 Secondary pressure spring (port 2, 4)

2

Washer

Q'ty 4

221-1 Return spring (port 1)

1

213

Seal

4

301

Joint

1

214

O-ring

4

302

Disk

1

216-1 Spring seating (port 1, 3)

2

312

Adjusting nut

1

216-2 Spring seating (port 2, 4)

2

501

Bellows

1

277

RSM-13-10-001E 21

Remote Control Valve

Attached diagram 2. Joint disassembly jig

RSM-13-10-001E

278 22

Remote Control Valve Removal and Installation of Travel Remote Control Valve Warning ・ Be sure to release hydraulic pressure before beginning work.

Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Wrenches (17 mm, 19 mm) • Hexagon wrench (8 mm) • Phillips screwdriver • Marking pen • Caps • Plugs • Rag • Cleaning fluid

1. Removal of Travel Remote Control Valve [1] Remove the 3 screws (1) on the cover (2) and remove the cover.

[2] Remove the floor mat (3).

279

1

Screw

2

Cover

3

Floor mat

RSM-13-10-001E 23

Remote Control Valve [3] Use a hexagon wrench (8 mm) to remove the 2 bolts (4) on both the left and right sides, and then remove the left and right travel pedals (5).

[4] Use a hexagon wrench (8 mm) to remove the 2 bolts (6) on both the left and right sides of the lever, and then remove the levers (7).

[5] Use a wrench (19 mm) to remove the 5 bolts (8), and then remove the under cover (9).

RSM-13-10-001E

4

Bolt

5

Pedal

6

Bolt

7

Lever

8

Bolt

9

Under cover

280 24

Remote Control Valve [6] Use a wrench (19 mm) to remove the 6 hoses (10). • Mark the valve and hoses so that the connectors match at the time of assembly. • Attach caps or plugs to the valve and hoses to prevent any entry of water, dust or dirt. • Clean the valve and hoses by spraying with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[7] Use a wrench (19 mm) to remove the 2 hose adapters (11).

[8] Use a box wrench (17 mm) to remove the 2 bolts (12) on both the left and right sides of the travel lever .

10

281

Pilot hose

11

Hose adapter

12

Bolt

RSM-13-10-001E 25

Remote Control Valve [9] Pull up the travel remote control valve (13) into the cab, and then remove the travel remote control valve.

13

Travel remote control valve

2. Installation of Travel Remote Control Valve To install, perform the reverse of the removal procedure. Be careful not to connect the hydraulic hoses in incorrect locations. Before installing the hoses, check that the hose adapters are not loose and retighten them to the specified torque. Hose adapter, hydraulic hose tightening torque ：36.3 ± 2.0 N•m

RSM-13-10-001E

282 26

Remote Control Valve Procedures for Assembly and Disassembly of Travel Remote Control Valve When disassembling the valve, read the disassembly procedures thoroughly before following the sequence below. The numbers in the parentheses after the part names indicate codes in page 300 "Attached diagram 1. Remote control valve assembly cross-section diagram".

1. Maintenance Procedures (1) Disassembly procedures [1] Preparations 1) Prepare a sufficiently spacious, solid and stable work platform so that parts will not fall or move during work. 2) Prepare tools and materials. [2] General work precautions 1) Each part has been manufactured with a high degree of precision, so be careful not to let parts bump each other or fall when handling them. 2) If parts are struck or pulled with excessive force during work because they are tight, this may cause burrs or damage which may then cause reductions in performance or oil leaking due to faulty assembly. Perform work carefully and thoroughly. 3) Rust may form on parts due to moisture or debris if the valve is left disassembled or if work is abandoned in the middle of disassembly. If work must be halted, be careful about preventing rust from forming and dust settling on parts. [3] Disassembly procedure 1) Clean the remote control valve with white kerosene. • Place plugs in each port. 2) Use shock plate to secure the remote control valve in a vise. Remove the bellows (501) from the covers (201) and remove the covers by pulling upwards. 4/

3) Use a hexagon wrench on the hexagon socket head locking screws (423) to loosen them. Be careful, as application of Loctite #241 makes the loosening torque high.

4/

283

RSM-13-10-001E 27

Remote Control Valve 4) Place a round rod (φ8 mm or less) against one end of the cam shafts (413) and lightly strike it with a hammer to remove the shafts.

4/

5) Remove the cams (420) as an assembly with the locking screws (471) and lock nuts (472) left attached. Record the positions of the cams in relation to the covers (201). Be careful when removing, as the push rods (214) may fly off.

4/

6) Use a hexagon wrench on the hexagon socket head bolts (271) to loosen and remove them.

4/

7) Remove the covers (201). Record the positions of the covers in relation to the casing (101). Be careful when removing, as the push rods (214) or plugs (202) may fly off due to the damping springs (336) and (337). (The plugs are only kept in the casing by the sliding resistance of the O-rings (212).) 4/

RSM-13-10-001E

284 28

Remote Control Valve 8) Remove push rods (214) from the plugs (202). Record the positions of the plugs in relation to the push rods. Be careful not to scratch the surface of the push rods. Be careful when removing, as plugs may fly off.

4/

9) Remove the plugs (202) with the grease caps (203) and NHU packings (210) left attached. Record the positions of the plugs in relation to the casing holes. Be careful when removing, as the pistons (224) may fly off due to the damping springs (336) and (337).

4/

10) Remove the pistons (224). Record the positions of the pistons in relation to the casing holes.

4/

11) Remove the damping springs (336) and (337) from the casing (101). Record the positions of the damping springs in relation to the casing holes.

4/

285

RSM-13-10-001E 29

Remote Control Valve 12) Remove the spring seatings (218) from the casing (101). Record the position of the spring seatings in relation to the casing holes.

4/

13) Use a magnet, etc. to remove steel balls (225). Be careful not to lose steel balls.

4/

14) Use pliers to remove the locking rings (221) from the casing (101). Record the positions of the locking rings in relation to the casing holes. Be careful when removing, as the bushings (223) may fly off due to the return springs (335). Be careful not to scratch the inner surface of the casing. 4/

15) Use tweezers, etc. to remove the bushings (223) from the casing (101). Record the positions of the bushings in relation to the casing holes.

4/

RSM-13-10-001E

286 30

Remote Control Valve 16) Remove the pressure reducing valve assemblies and returns springs (335) from the casing (101). Record the positions of these parts in relation to the casing holes.

4/

4/

17) Lay the covers (201) on their sides on a level surface, place the special tool 1 against the bushings (412), and remove the bushings by lightly strike them with a hammer.

4/

18) Secure each cam assembly in a vise, use a wrench to loosen the lock nuts (472), and remove the lock nuts and locking screws (471). If it is not necessary to adjust, the locking screws due to backlash occurring during neutral operation, handle the cam assembly as one unit without performing disassembly. 4/

287

RSM-13-10-001E 31

Remote Control Valve 19) For disassembly of the pressure reducing valve assemblies, place the bottom end of the spools (301) perpendicular on a level work platform, lower the spring seatings (311), and use the end of a small flathead screwdriver to remove the 2 half-circle washers 1 (215). Be careful not to scratch the surface of the spools. Do not lower the spring seatings by 4 mm or more. 20) Separate the spools (301), spring seatings (311), secondary pressure springs (324), washers 2 (217), and washers 3 (313). Handle these parts as assemblies until assembly of the remote control valve. Washers 2 are used for pre-set adjustment of the secondary pressure springs, so thickness is different for each spool assembly. Additionally, these are sometimes not used, so record the status for each assembly.

4/

4/

21) Remove the grease cups (203) from the plugs (202).

4/

22) Remove the NHU packings (210) from the plugs (202). Use a small flathead screwdriver, etc. to remove the packings. Be careful not to scratch the inner surface of the plugs.

4/

RSM-13-10-001E

288 32

Remote Control Valve 23) Remove the O-rings (212) from the plugs (202).

4/

24) Cleaning parts • Clean all parts by placing them in a rough cleaning container filled with white kerosene. (rough cleaning) 25) Scratching can easily occur if cleaning of parts is begun just after parts are immersed in white kerosene, so let parts sit in white kerosene until debris and grease sufficiently loosen off from the surface of parts and float to the surface. If the white kerosene is dirty, this will encourage damage to parts and result in reduced performance after reassembly. Thoroughly manage the level of cleanliness of the white kerosene. • Clean all parts by placing them in a finish cleaning container filled with white kerosene, and thoroughly clean them up to the interior while slowly rotating them. (finish cleaning) Use a rag to thoroughly remove white kerosene adhered to parts. 26) Do not dry parts with compressed air, as this will damage parts and cause rust to form due to debris and moisture being dispersed into the atmosphere. 27) Preventing rust on parts Apply an anti-rust agent to each part. Rust will form on parts if they are left as is after cleaning, and this will cause reduced performance of functions after reassemly.

289

RSM-13-10-001E 33

Remote Control Valve (2)Assembly procedures [1] Preparations 1) As with disassembly, prepare a work platform, tools and materials. [2] General work precautions 1) Observe the same general work precautions as with disassembly. 2) When performing assembly, remove metal fragments and foreign matter from all parts, and check that there are no burrs or nicks on parts. If there are burrs or nicks, use a whetstone to remove them. 3) As a rule, replace all O-rings and NHU packings. 4) When installing O-rings and NHU packings, be careful not to damage them. (Apply a thin layer of grease to ensure smooth installation.) 5) When installing parts, using grease is good for preventing parts from falling. 6) Tighten bolts, etc. to the torque values indicated in the assembly cross-section diagram. 7) After assembly is complete, place plugs in all of the ports to prevent entry of debris. [3] Assembly procedures 1) Install the washers 3 (313), washers 2 (217), secondary pressure springs (324), and the spring seatings (311) onto each of spools (301) in that order. Washers 2 are used for pre-set adjustment of the secondary pressure springs, so thickness is different for each spool assembly. Additionally, these are sometimes not used. Check the status recorded during disassembly and attach parts accordingly.

4/

2) Place the bottom end of the spools (301) perpendicular on a level work platform, push the spring seatings (311) down, and install the 2 half-circle washers 1 (215) onto the spring seatings in such a way that they are not on top of each other.

4/

Install the washers 1 so that the sharp edge side faces up and the washer catches the head of the spool. Do not lower the spring seatings by 4 mm or more.

RSM-13-10-001E

290 34

Remote Control Valve 3) Install the return springs (335) in the casing (101). Install them in the positions they were in before disassembly.

4/

4) Install the pressure reducing valve subassemblies assembled in the previous steps 1) and 2) into the casing (101). Install them in the positions they were in before disassembly.

4/

When installing the pressure reducing valve subassemblies, be careful not to strongly strike the casing corners with the bottom ends of the spools.

5) Install the bushings (223) in the casing (101) on top of the spring seatings (311). Install them in the positions they were in before disassembly.

4/

291

RSM-13-10-001E 35

Remote Control Valve 6) Use pliers to temporarily install the locking rings (221) into the casing holes. Install them in the positions they were in before disassembly. Place them so that they are horizontal. Be careful not to scratch the inner surface of the casing. Place the locking rings in such a way that the sharp edge sides faces up. 4/

7) Set the special tool 2 in each casing hole, and press in the return springs (335) and bushings (412) together until the locking rings (221) click into place in the grooves. Slowly press in with caution so as to not scratch the inner surface of the casing.

4/

8) Install the steel balls (225) into the bushings (412).

4/

9) Install the spring seatings (218) into the bushings (412). Install them in the positions they were in before disassembly.

4/

RSM-13-10-001E

292 36

Remote Control Valve 10) Install the damping springs (336) in the casing (101). Install them in the positions they were in before disassembly.

4/

11) Install the damping springs (337) in the casing (101). Install them in the positions they were in before disassembly. Be careful that they do not become entangled with damping springs (336).

4/

12) Install the pistons (224). Install them in the positions they were in before disassembly.

4/

13) Install O-rings (212) on the plugs (202).

4/

293

RSM-13-10-001E 37

Remote Control Valve 14) Install NHU packings (210) into the plugs (202). When installing the NHU packings, be careful of the installation direction. (See the diagram.) Before installing NHU packings, apply a thin layer of grease.

4/

NHU packing

15) Install grease cups (203) into the plugs (202).

4/

16) Install push rods (214) into the plugs (202). Before installing push rods, apply hydraulic oil to the rod surfaces. Do not press the rods in strongly, as this may damage the NHU packing lip sections.

4/

RSM-13-10-001E

294 38

Remote Control Valve 17) Install the push rod subassemblies assembled in the previous steps 13), 14), 15), and 16) into the casing (101).

4/

18) Use special tool 1 on the covers (201) to press down the bushings, and lightly strike the bushings with a hammer to press fit them. Be careful that the ends of the bushings do not stick out from within the cover.

4/

19) Install the covers (201) on the casing (101). Install them in the positions they were in before disassembly. Be careful of the cover rising up due to the damping springs (336) and (337).

4/

20) Tighten the hexagon socket head bolts (271) to the specified torque. Tightening torque: 78.5 ± 9.8 N・m Be careful that the covers are horizontal.

4/

295

RSM-13-10-001E 39

Remote Control Valve 21) Temporarily install the locking screws (471) and lock nuts (472) on the cams (420).

4/

22) Install the cams (420) on the covers (201). Install them in the positions they were in before disassembly.

4/

23) While holding the cams (420), insert the cam shafts (413) from the outside.

4/

24) Apply Loctite #241 or the equivalent to the surfaces of the hexagon socket head locking screws (423).

4/

RSM-13-10-001E

296 40

Remote Control Valve 25) Tighten the hexagon socket head locking screws (423) to the specified torque. Tightening torque: 6.9 ± 1 N・m

4/

26) Adjust the height of the locking screws (471) so that the top surface of the cams (420) and the bottom surface of the covers (201) are parallel, and tighten the lock nuts (472) to the specified torque after rotating the cams left and right to check if there is any neutral backlash. Tightening torque: 33.3 ± 3.4 N・m Even if the push rods (214) are pressed in too much by the locking screws, backlash during neutral will occur. Use caution as this may cause the sudden movement when starting the engine.

4/

27) Tilt the cams (420) and fill the grease cups (203) of the plugs (202) with grease while applying grease to the top of the push rods (214). For grease application and filling, use a flat object made of soft material so as to not scratch the push rod or plug surfaces.

4/

28) After mounting the top end of the bellows (501) on the cams (420), mount the bottom end into the grooves on the covers (201). Before mounting the bottom end of the bellows into the grooves of the covers, spray anti-rust oil on the parts within the bellows.

4/

297

RSM-13-10-001E 41

Remote Control Valve Be careful that the bellows are properly mounted in the grooves and not twisted, as this may reduce anti-rust and antimoisture protection.

4/

RSM-13-10-001E

298 42

Remote Control Valve 2. Causes of Trouble and Countermeasures It is not always easy to find where the source of trouble is located. A few problems that may sometimes occur are listed in the table below. Repair of these problems can be difficult, so see the suggested causes and solutions in the table for assistance. The table below shows general symptoms, suggested causes and also solutions. However, the cause of machine problems are often not rooted in just a single part. Problems are often due to the relationship of one part with another. Also keep in mind that solutions other than those listed in the table may sometimes be necessary. The table below does not include all possible causes and countermeasures. Accordingly, further investigation of problems and causes should be done by an experienced and qualified repair person, as necessary. Symptom

Cause

Solution

Secondary pressure is not rising.

1. Insufficient primary pressure 2. Secondary pressure spring(s) (324) is (are) worn. 3. The gap between spool(s) and the casing is abnormally large. 4. There is backlash in the operation section.

1. Maintain primary pressure. 2. Replace it (them) with new part(s). 3. Replace spool(s) and casing assembly. 4. Disassemble and assemble or replace operation section parts.

Secondary pressure is unstable.

1. Sliding parts are sticking. 2. Tank line pressure is variable. 3. Air is getting into lines.

1. Repair the sticking sections. 2. Return directly to the oil tank. 3. Perform operation several times and let out air.

Secondary pressure is high.

1. Tank line pressure is high. 2. Sliding parts are sticking.

1. Return directly to the oil tank. 2. Repair the sticking sections.

Damping is not working.

1. Air is gathering in the piston chamber. 2. Sliding parts are sticking. 3. Damping spring(s) (336) and/or (337) are worn. 4. The gap between piston(s) (224) and the casing is abnormally large. 5. There are check valve operation problems. 6. The piston metering hole(s) is (are) abnormally large.

1. Perform operation several times and let out air. 2. Repair the sticking sections. 3. Replace it (them) with new part(s). 4. Replace piston(s) and casing assembly. 5. Disassemble and adjust the check valve section(s). 6. Replace piston(s).

Damping torque is high.

1. Sliding parts are sticking. 1. Repair the sticking sections. 2. Piston metering hole(s) is (are) clogged. 2. Repair or replace piston(s).

299

RSM-13-10-001E 43

Remote Control Valve

Note 1. Apply anti-rust oil to the inside of the bellows with a spray.

Attached diagram 1. Remote control valve assembly cross-section diagram Tightening torque list

Code

Code Screw size Tightening torque

Part name

Q'ty Code

Part name

Q'ty

101

Casing

1

271

Hexagon socket head bolt

2

Plug

2

301

Spool

4

151

NPTF1/16

6.9 ± 1 N•m

151

271

M12

78.5 ± 9.8 N•m

201

Cover

2

311

Spring seating

4

6.9 ± 1 N•m (Loctite coating)

202

Plug

4

313

Washer 3

4

203

Grease cup

4

324

Secondary pressure spring

4

33.3 ± 3.4 N•m

210

NHU packing

4

335

Return spring

4

212

O-ring

4

336

Damping spring

4

214

Push rod

4

337

Damping spring

4

215

Washer 1

8

412

Bushing

4

217

Washer 2

4

413

Camshaft

2

218

Spring seating

4

420

Cam

2

221

Locking ring

4

423

Hexagon socket head locking screw

2

223

Bushing

4

471

Locking screw

4

224

Piston

4

472

Lock nut

4

225

Steel ball

12

501

Bellows

2

423

M6

472

M10

RSM-13-10-001E

300 44

Remote Control Valve [1] Special jig 1 (for bushing removal)

[2] Special jig 2 (for locking ring installation)

Attached diagram 2. Jig for assembly and disassembly

301

RSM-13-10-001E 45

Control Valve Control Valve

SH200-5

Control Valve Removal and Installation of Control Valve Warning

・ Keep away from fire. ・ Be sure to release hydraulic pressure before beginning work.

・ Be sure to stop the engine before beginning work. Caution ・ Be sure to inspect the wire rope and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare • Wrenches (7 mm, 8 mm, 13 mm, 17 mm, 19 mm, 22 mm, 24 mm, 28 mm, 41 mm) • Hexagon wrenches (8 mm, 10 mm) • Wire cutters • Eyebolts (M10) x 2 • Shackle (with the required lifting capacity) x 2 • Wire rope (with the required lifting capacity) • Crane (with the required lifting capacity) • Marking pen • Caps • Plugs • Rag • Cleaning fluid • Wood planks, etc.

1. Removal of Control Valve [1] Extend the attachment and bring in contact with the ground.

[2] Drain the oil from the hydraulic oil tank. (For details, see "Draining Oil from Hydraulic Oil Tank".)

302

RSM-13-11-001E 1

Control Valve [3] Use a wrench (19 mm) to remove the 6 bolts (1), and then remove the center cover (2).

[4] Use a wrench (19 mm) to remove the 3 bolts (3), and then remove the under cover (4).

[5] Use wire cutters to cut the wire band (5).

RSM-13-11-001E

1

Bolt

2

Center cover

3

Bolt

4

Under cover

5

Wire band

303 2

Control Valve [6] Use wire cutters to cut the wire band (6).

[7] Disconnect the connector (7) and use wire cutters to cut the wire band (8).

[8] Use a wrench (17 mm) to remove the bolt (9), and then remove the clamp (10).

304

6

Wire band

7

Connector

8

Wire band

9

Bolt

10

Clamp

RSM-13-11-001E 3

Control Valve [9] Use a wrench (13 mm) to remove the bolt (11), and then remove the clamp (12).

[10] Remove the connector (13).

[11] Use wire cutters to cut the wire band (14).

RSM-13-11-001E

11

Bolt

12

Clamp

13

Connector

14

Wire band

305 4

Control Valve [12] Use a wrench (19 mm) to remove the bolt (15), and then remove the clamp (16).

[13] Use a wrench (19 mm) to remove the bolt (17), and then remove the clamp (18).

[14] Use a wrench (19 mm) to remove the bolt (19), and then remove the clamp (20).

15

306

Bolt

16

Clamp

17

Bolt

18

Clamp

19

Bolt

20

Clamp

RSM-13-11-001E 5

Control Valve [15] Use a wrench (7 mm) to loosen the hose band (21).

[16] Use a wrench (19 mm) to remove the bolt (22) on the line.

[17] Use a wrench (17 mm) to remove the bolt (23), and then remove the clamp (24).

RSM-13-11-001E

21

Hose band

22

Bolt

23

Bolt

24

Clamp

307 6

Control Valve [18] Use a wrench (8 mm) to remove the bolt (25) on the line.

[19] Use a wrench (17 mm) to remove the 2 installation bolts (26), and then remove the clamp (27).

308

25

Bolt

26

Bolt

27

Clamp

RSM-13-11-001E 7

Control Valve [20] Use wrenches (19 mm, 22mm, 41 mm) and hexagon wrenches (8 mm, 10 mm) to remove the control valve lines and hoses. • Mark the lines and hoses so that the connectors match at the time of assembly. • Use caps and plugs to cover the lines and hoses to prevent any entry of water, dust or dirt. • Clean the line by spraying with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

RSM-13-11-001E

309 8

Control Valve [21] Use a wrench (24 mm) to remove the 4 bolts (28) from the control valve.

[22] Install the 2 eyebolts (29) (M10) on the control valve.

[23] Install the shackles (30) on the eyebolts, then use the crane and wire rope (31) to lift the control valve (32).

310

28

Bolt

29

Eyebolt

30

Shackle

31

Wire rope

32

Control valve

RSM-13-11-001E 9

Control Valve [24] Place the control valve (32) on wood planks (33).

32

Control valve

33

Wood plank

2. Installation of Control Valve To install, perform the reverse of the removal procedure.

RSM-13-11-001E

311 10

Control Valve Procedures for Assembly and Disassembly of Control Valve 1. Disassembly (1)Cautions for disassembly [1] On a level ground, with the main machine horizontal, bring all the operating machines into contact with the ground. Check that the machine is in such a state that it will not travel or swing on its own. Then stop the engine and bleed out the pressure from each actuator.

Caution

Do not replace a valve assembly or disassemble a valve with pressure remaining in the system. This would be dangerous. High-pressure oil might spray out or parts might suddenly come out. For disassembly, bring the bucket to the ground and adequately bleed out any pressure in the circuits.

[2] Bleed the oil pressure from the tank. [3] Clean well around the location to be disassembled and keep foreign matter from getting into the valve during disassembly. [4] Identify disassembled parts with shipping tags to show their position for re-assembly. [5] Do not reuse any disassembled seals (O-rings, backup rings). Replace them with new ones. [6] The spool was selected to fit with the valve housing and sleeve, so do not replace the spool. (2)Disassembly procedure (The reference numbers are from the parts list.) a) Removal of long cap and pull out of main spool [1] Loosen the hexagon socket head bolts (74) (8 mm hex socket diameter) for the caps (8) (9 locations) and the cap (9) (1 location) and remove them. When pulling out the spool only, do not loosen the M6 screws on the plate except for the hexagon socket head bolts (75) (4 locations) and (94) fastening the plate assemblies. [2] Loosen and remove the plugs (91) (19 mm hex diameter) attached to the ports as necessary. [3] Remove the O-rings (7) (one in each section) from the plate assemblies (10) and (11). [4] Pull out each spool from the valve housing still in the sub-assembly state.

Caution

1. When pulling out the spool, be careful not to cause any dents or scratches. 2. Identify each spool with a shipping tag so that there will be no mistake about their positions when they are re-assembled.

[5] Loosen and remove the hexagon socket head bolts (75) (8 mm hex socket diameter) and hexagon socket head bolts (94) (5 mm hex socket diameter) those fastens the plate assemblies (10), (11), (28) and (29) to the housing. Remove the plate assemblies still in the assembly state. Do not disassemble them. [6] Loosen and remove the plugs (91) (19 mm hex socket diameter) as necessary. [7] Remove the O-rings (7) and (41) from the valve housings (1) and (13).

312

RSM-13-11-001E 11

Control Valve [8] Disassembly of spool assembly

Caution

1. In order to avoid damaging the outer edge of the spool, sandwich the spool with wooden blocks (as in the diagram on the right) and fasten with a vise before starting the work. 2. Since adhesive is applied to the spool end thread section, heat up the outer edge of the spool thread section to break down the adhesive. 3. Heat the spool to 200 - 250 ℃ . Heat until the spool end loosens easily immediately after the heating. 4. If overheating occurs, replace the spring with a new one. (Wooden blocks for spool assembly/disassembly)

1) Loosen the spool assembly (2) - (6) and (14) - (17) spool ends (8 mm hex socket diameter) and disassemble the spring seat and spring. 2) The spools in spool assemblies (3), (4), (6) and (14) have poppets, springs, plugs, and filters in the spools, but do not disassemble them unless necessary. When disassembly is required, heat up the outer edge of the spool to break down the adhesive on the thread section, then remove the plug. When assembling, always replace O-rings and backup rings with new ones. b) Disassembly of arm 1 parallel-tandem spool, neutral cut spool section [1] Loosen and remove the hexagon socket head bolts (78) (5 mm hex socket diameter) for the caps (18) and (86). [2] Remove the O-ring (23) from the cap (18). Remove the O-rings (65) from the housing (1). [3] Pull out the spools (19) and (84) from the valve housing still in the sub-assembly state. [4] Disassembly of spool assembly

Caution

1. In order to avoid damaging the outer edge of the spool, sandwich the spool with wooden blocks for assemble (as in the diagram) and fasten with a vise before starting the work. 2. Since adhesive is applied to the spool end thread section, heat up the outer edge of the spool thread section to break down the adhesive. 3. Heat the spool to 200 - 250 ℃ . Heat until the spool end loosens easily immediately after the heating. 4. If overheating occurs, replace the spring with a new one.

1) Loosen the spool (19) spool end (22) (5 mm hex socket diameter) and disassemble the spring seats (20) and spring (21). c) Disassembly of arm regeneration release valve section (Sub-parts in the assembly are expressed as [main number - sub-number].)

Caution

1. When removing the plug, pressure left within can make parts fly out dangerously. 2. Slowly loosen the plug to check that there is no resistance due to residual pressure, then disassemble.

[1] Loosen and remove the plug (24) (32 mm hex diameter) and remove the O-ring (25). [2] Remove the spring (26) and spool (27-1) from the sleeve (27-2). [3] Pull out the sleeve (27-2) from the valve housing. [4] Remove the piston (27-3), O-ring (30), and backup rings (31) from the sleeve (27-2).

RSM-13-11-001E

313 12

Control Valve d) Disassembly of load check valve section Caution

1. When removing the plug, pressure left within can make parts fly out dangerously. 2. Slowly loosen the plug to check that there is no resistance due to residual pressure, then disassemble.

[1] Loosen and remove the hexagon socket head bolts (75) (4 locations in each section, 8 mm hex socket diameter) for the flanges (37) (6 locations) and (61) (1 location). The (61) flange has a different shape from the other flanges, so keep it separate from (37). [2] Remove the springs (35), poppets (34) and (51) and O-rings (36) from the valve housing. Remove the arm 2 (E-E cross section) poppet (59), spring (60), and sleeve (58). [3] Loosen and remove the hexagon socket head bolts (75) (8 mm hex socket diameter) for the flanges (52) (2 locations) . [4] Remove the spacers (53) from the valve housing and remove the O-rings (54) and backup rings (55) from the spacers (53). [5] Remove the springs (35) and poppets (34) from the valve housing. [6] Loosen and remove the plugs (72) (8 mm hex socket diameter). (D-D cross section) [7] Remove the springs (33) and poppets (32) from the valve housing. [8] Loosen and remove the plugs (72) (8 mm hex socket diameter). (D-D cross section) [9] Remove the spacer (57), springs (33), and poppets (32) from the valve housing. [10] Loosen and remove the plug assemblies (92) (36 mm hex diameter). (P4 section, H-H cross section) [11] Loosen and remove the hexagon socket head bolts (74) (4 locations, 8 mm hex socket diameter) for the flange (43) . [12] Remove the spring (45), poppet (44), and O-rings (36) from the valve housing. [13] Loosen and remove the plug (46) (27 mm hex diameter) and remove the O-ring (47). (HH cross section) [14] Remove the spring (48) and poppet (49) from the valve housing. e) Disassembly of antidrift valve section (Sub-parts in the assembly are expressed as [main number - sub-number].)

Caution

1. When removing the antidrift valve assembly, pressure left within can make seals and other parts fly out dangerously. 2. Slowly loosen the hexagon socket head bolt to check that there is no resistance due to residual pressure, then disassemble.

[1] Loosen and remove the hexagon socket head bolts (74) (4 locations in each section, 8 mm hex socket diameter) for the antidrift valve assemblies (67) (2 locations). [2] Remove the O-rings (36) and (41) from the valve housing. [3] Remove the springs (39) and poppets (38) from the valve housing. [4] Disassembly of antidrift valve assembly

Caution

1. If parts inside the antidrift valve are disassembled with the antidrift valve installed in the valve housing, pressure left within can make parts fly out dangerously. 2. Slowly loosen the plug assembly (67-12) to check that there is no resistance due to residual pressure, then disassemble.

1) Loosen and remove the plug assembly (67-14) (38 mm hex diameter) and remove the O-rings. 2) Remove the piston (67-3), spool (67-4), and spring (67-6). 3) Loosen and remove the plug (67-14) (12 mm hex diameter). 4) Remove the sleeve (67-5) and poppet (67-2) from the body and remove the O-rings (67-8) and (67-9), backup rings (67-10) and (67-11) from the outer edge of the sleeve. 5) Remove the spring seat (67-13) and spring (67-7) from deep in the hole. 314

RSM-13-11-001E 13

Control Valve f) Disassembly of relief valve Caution

1. When removing the relief valve, loosen and remove the main unit installation section plug. 2. Do not loosen the set pressure adjustment plug or lock nut. 3. Doing so would be dangerous because the set pressure changes if the set pressure adjustment plug turns.

[1] Loosen and remove the overload relief valve (69) (32 mm hex diameter). [2] Loosen and remove the main relief valve (68) (32 mm hex diameter). [3] Loosen and remove the relief valve assemblies (70) (2 locations, 32 mm hex diameter). Remove the O-rings (70-5) and (70-8). g) Disassembly of option section [1] Loosen and remove the hexagon socket head bolts (75) (8 mm hex socket diameter) for the caps (88) (2 locations) and remove the O-rings (89). [2] Loosen and remove the plug assemblies (93) (2 locations, 24 mm hex diameter) and remove the O-rings and backup rings. h) Disassembly of straight travel signal control valve [1] Remove the hexagon socket head bolts (83) (5 mm hex socket diameter) and remove the body assembly (42). [2] Loosen and remove the plug assembly (42-5) (5 mm hex socket diameter) and remove the O-ring. [3] Pull out the spools (42-2) and (42-3) and spring (42-4). [4] Loosen the orifice plug (42-7) (36 mm hex diameter) and remove it from the body (42-1). i) Disassembly of other plugs [1] Loosen and remove the plug assemblies (71) (10 mm hex socket diameter) and remove the O-rings. [2] Loosen and remove the plug assemblies (72) (8 mm hex socket diameter) and remove the O-rings. [3] Loosen and remove the orifice plug (40) (5 mm hex socket diameter). (D-D cross section) [4] Loosen and remove the plug assemblies (92) (36 mm hex diameter) and remove the Orings. [5] Loosen and remove the plug assemblies (73) (6 mm hex socket diameter) and remove the O-rings. j) Disassembly of add-on section [1] Loosen and remove the hexagon nuts (97) (4 locations, 22 mm hex diameter). [2] Remove the outlet housing (95). Execute Steps [3] - [5] below as necessary. [3] Remove the spool section assembly (98) and remove the matching surface O-rings (9810) and (98-11). [4] Remove the inlet section assembly (99) and remove the matching surface O-rings (99-3) and (99-4). [5] Remove the spool section assembly (111) and remove the matching surface O-rings (110-10) and (110-11). [6] Remove the main unit body matching surface O-rings (56) and (64). [7] Loosen the tie rods (96) and remove them from the main unit valve housing (1). (Use a pipe wrench.)

Caution

RSM-13-11-001E

When removing the add-on section, be careful not to cause any dents, scratches, or the like on matching surfaces. Any dents, scratches, or the like on matching surfaces have a danger of allowing oil to leak from those surfaces and causing malfunction. Also, be careful not to let any foreign matter enter the oil path. Such foreign matter has a danger of the spool sticking due to biting of the spool sliding section or a load check seat defect making the actuator run wild or stop disabled. 315 14

Control Valve k) Disassembly of valve housing union bolt Caution

1. Do not disassemble the union bolt (77) unless necessary. 2. If such disassembly is necessary, place the main unit on a flat table to do the work. 3. Prepare the replacement O-rings (65) and (66).

[1] Loosen and remove the hexagon socket head bolts (77) (8 locations, 14 mm hex socket diameter). Tightening torque: 166 - 177 N•m [2] Remove the valve housing matching surface O-rings (65) and (66). (3)Cleaning Completely clean all the disassembled parts with clean mineral oil. Dry with compressed air and place each part on clean paper or vinyl for inspection. (4)Inspection Inspect all surfaces of each part for burrs, scratches, gouges, and other defects. [1] Inspect the valve housing load check seat surface for scratches, gouges, and also for debris, dents, rust. Repair any minor scratches with an oilstone. [2] Check that there are no scratches, dents, etc. on the outer edge of the spool. Repair any small scratches with an oilstone. [3] Sliding parts must all move easily. Also, all grooves and paths must be free of foreign matter. [4] If a spring is broken or extremely deformed or worn, replace it. [5] If relief valve operation is poor, inspect according to "(9) Troubles and countermeasures Relief valve". [6] Replace all O-rings and backup rings from disassembled parts. [7] After removing caps and plugs, check for any paint fragments around the body opening or plug seating surface. (If paint fragments were to get inside the valve, they could jam up or clog up the valve, resulting in operation defects and oil leaks.）

316

RSM-13-11-001E 15

Control Valve (5)Assembly 1) Cautions for assembly a) Cautions for O-Ring handling [1] Do not use any O-ring with a molding defect or damage caused by handling. [2] Apply enough grease or hydraulic oil to the O-ring and the section where it is mounted so that it can be mounted smoothly. [3] Do not stretch an O-ring so far that this causes permanent deformation. [4] When assembling an O-ring, be careful not to roll the O-ring into place. (If an O-ring is mounted twisted, it is difficult for it to naturally recover to its normal state and that twist causes oil leaks.) b) Cautions for spool handling [1] Excessive torque on thread sections causes spool operation defects, so always tighten to just the specified torque. [2] Be careful to assemble all spools, springs, and spool ends in the same combinations as before disassembly. c) Adhesive application method (for male thread section and female thread section of parts requiring adhesion) [1] Cleaning (degreasing) Either use vapor degreasing with acetate, ether or clean with an alkali cleaning agent. [2] Drying Dry the surface to be glued, either by blowing clean air on it or letting it dry naturally. Inadequate drying reduces the effectiveness of the adhesive. [3] Applying the adhesive Apply a small amount of adhesive (equivalent to Loctite #638) to the first 2 - 3 threads at the entrance of the spool female threads. At this time, install being careful that the application section does not touch the spring seat. Caution

Do not use "Loctite Primer T" hardening accelerator. It causes insufficient adhesion strength.

[4] Adhesive hardening time In order to ensure the hardening of the adhesive, after fastening the spool end, leave the part out in the air for the following period of time. - Ambient temperature around 22 ℃ : 8 hr. or longer - Ambient temperature around 40 ℃ : 3 hr. or longer - Ambient temperature around 5 ℃ : 24 hr. or longer Caution

RSM-13-11-001E

If the parts are not left out in the air for the above period, adequate adhesive strength may not be achieved.

317 16

Control Valve 2) Procedure for assembly of sub-assembly Caution

Before starting the assembling, check the quantity of each part, the installation location, the required tools, etc.

a) Assembly of spool assembly (main spool) [1] Apply adhesive to the thread sections of the spools (2) - (6), (14) - (17) and assembly the spring seat, spring, and spool end. [2] Sandwich the spool with the wooden blocks (the same ones used for disassembly), fasten in place with a vise, then tighten the spool ends to the specified torque. Tightening torque: 20 - 22 N•m [3] For spools (3), (4), and (14), insert the poppets and springs from the end opposite from the spool end, then apply adhesive to the thread sections of the plugs with the O-rings and backup rings mounted, and tighten. Also, for each spools (5), the plug with filter is mounted at this location. Tightening torque: 10 - 12 N•m

Caution

1. Be careful not to apply so much adhesive that it drips into the spool. 2. Be careful not to tighten any spool end with excessive torque. Excessive torque there would deteriorate spool operation. 3. There are two types of spring. Be careful to assemble each in its correct location. (only boom 2 different)

b) Assembly of arm 1 parallel-tandem spool assembly [1] Apply adhesive to the thread sections of the spool (19) and assemble the spring seats (20), spring (21), and spring end (22). [2] Sandwich the spool with the wooden blocks (the same ones used for disassembly), fasten in place with a vise, then tighten the spool ends to the specified torque. Tightening torque: 19 - 22 N•m

Caution

1. Be careful not to apply so much adhesive that it drips into the spool. 2. Be careful not to tighten any spool end with excessive torque. Excessive torque there would deteriorate spool operation.

c) Assembly of neutral cut spool assembly [1] Apply adhesive to the thread sections of the spool (84-1) and assemble the spring seat (84-2), spring (84-3), and spring end (84-4). [2] Sandwich the spool with the wooden blocks (the same ones used for disassembly), fasten in place with a vise, then tighten the spool ends to the specified torque. Tightening torque: 19 - 22 N•m

Caution

1. Be careful not to apply so much adhesive that it drips into the spool. 2. Be careful not to tighten any spool end with excessive torque. Excessive torque there would deteriorate spool operation.

d) Assembly of antidrift valve assembly [1] Assemble the O-rings (67-8) and (67-9) and backup rings (67-10) and (67-11) into the grooves on the outer edge of the sleeve (67-5).

Caution

1. Be careful to assemble O-rings and backup rings in the correct locations. 2. If they are assembled backwards, there is a danger of an O-ring being damaged and the drop of the actuator from its own weight increasing.

[2] Insert the poppet (67-2) and spool (67-4) in the sleeve hole. Be careful to assemble the spool in the correct direction.

318

RSM-13-11-001E 17

Control Valve [3] Install the spring seat (67-13) at the small-diameter section at the tip of the poppet, mount on the spring (67-7), and insert into the body (67-1) together with the sleeve. Caution

Apply grease to the poppet seat so that the spring and spring seat can be installed correctly on the poppet seat.

[4] Screw the plug (67-14) into the body (67-1) and tighten it. Tightening torque: 78 - 88 N•m [5] Assemble the spring (67-6) and piston (67-3) on the plug (67-14). [6] Tighten the plug assembly (67-12) with O-ring mounted to the body (67-1). Tightening torque: 147 - 157 N•m 3) Procedure for assembly of control valve main unit a) Assembly of relief valve

Caution

1. When installing the relief valve, be sure to tighten the main unit installation section plug. 2. Do not tighten the set pressure adjustment plug or lock nut. 3. Doing so would be dangerous because the set pressure changes if the set pressure adjustment plug turns.

[1] Screw in and tighten the main relief valve (68). Tightening torque: 78 - 88 N•m [2] Screw in and tighten the overload relief valves (69) (6 locations) at each section. Tightening torque: 78 - 88 N•m [3] Screw in and tighten the relief valve assemblies with O-rings mounted (70) (2 locations). Tightening torque: 103 - 113 N•m b) Assembly of load check valve [1] Mount the O-rings (36) in the arm 1 section (E-E cross section), Boom 1 and 2 sections (F-F cross sections), swing section, and bucket section (G-G cross sections) and assemble the poppets (34) and springs (35). Mount the flanges (37) and tighten with the hexagon socket head bolts (75). Tightening torque: 58 - 64 N•m For the arm 2 section (E-E section), assemble the sleeve (58), poppet (59) and spring (60), mount the flange (61), and tighten with the hexagon socket head bolts (75). Tightening torque: 58 - 64 N•m [2] Mount the O-rings (36) in the travel section (I-I cross section) and assemble the poppet (51) and springs (35). Tighten the flanges (37) with the hexagon socket head bolts (75). Tightening torque: 58 - 64 N•m [3] Assemble the poppets (34) and springs (35) on the common check section (J-J cross section), then insert the spacers (53) with the O-rings (54) and backup rings (55) mounted. Tighten the flanges (52) with the hexagon socket head bolts (75). Tightening torque: 39 - 44 N•m

Caution

1. Be careful to assemble O-rings and backup rings in the correct locations. 2. If they are assembled backwards, there is a danger of an O-ring being damaged and causing external leaks.

[4] Mount the O-rings (36) in the option section (H-H cross section) and assemble the poppet (44) and spring (45). Mount the flange (43) and tighten with the hexagon socket head bolts (74). Tightening torque: 58 - 64 N•m [5] Assemble the poppet (49) and spring (48) in the travel section (H-H cross section). Screw in and tighten the plug (46) with O-ring (47) mounted. Tightening torque: 107 - 117 N•m RSM-13-11-001E

319 18

Control Valve [6] Assemble the poppets (32) and springs (33) in the arm 1 parallel-tandem section (D-D cross section). Screw in and tighten the plug assemblies (72) with O-rings mounted. Tightening torque: 73 - 79 N•m [7] Assemble the poppets (32), springs (33), and spacer (57) in the arm 2 parallel-tandem section (D-D cross section). Screw in and tighten the plug assemblies (72) with O-rings mounted. Tightening torque: 73 - 79 N•m c) Assembly of antidrift valve [1] Mount the O-rings (36) and (41) on the antidrift valve installation surfaces in the arm 1 section (E-E cross section) and boom 1 section (F-F cross section). [2] Assemble the poppets (38) and springs (39). [3] Install the antidrift valve assemblies (67) (2 locations) and tighten with the hexagon socket head bolts (74). Tightening torque: 39 - 44 N•m d) Assembly of option section [1] Install the caps (88) (2 locations) with O-rings (89) mounted and tighten with the hexagon socket head bolts (75). Tightening torque: 58 - 64 N•m [2] Screw in and tighten the plug assemblies (93) (2 locations) with O-rings and backup rings mounted. Tightening torque: 78 - 88 N•m e) Assembly of arm regeneration release valve [1] Mount the O-ring (30) and backup rings (31) (2 locations) in the sleeve (27-2). [2] Assemble the piston (27-3) and spool (27-1) in the sleeve and insert into the valve housing. [3] Put the spring (26) into the plug (24) with O-ring (25) mounted, then screw into the valve housing and tighten. Tightening torque: 103 - 113 N•m f) Assembly of arm 1 parallel-tandem spool [1] Assemble the spool (19) in the sub-assembly state into the valve housing. Caution

After inserting the spool, slide it to check for any sticky or rough feeling.

[2] Mount the cap (18) with O-ring mounted (23) and tighten with the hexagon socket head bolts (78). Tightening torque: 8.8 - 10.8 N•m g) Assembly of neutral cut spool [1] Assemble the spool assembly (84) into the valve housing. Caution

After inserting the spool, slide it to check for any sticky or rough feeling.

[2] Mount the O-rings (65) into the housing and tighten the cap (86) with the hexagon socket head bolts (78). Tightening torque: 8.8 - 10.8 N•m

320

RSM-13-11-001E 19

Control Valve h) Assembly of main spool [1] Mount the O-rings (7) and (41) on the valve housing cap matching surface. [2] Assemble the spool assemblies (2) - (6), (14) - (17) in the sub-assembly state into the same location as before disassembly.

Caution

1. Line up the spool straight with the opening and insert it slowly. 2. After inserting the spool, slide it to check for any sticky or rough feeling. 3. If a spool is left inserted that feels sticky or rough, there is a danger of a spool operation defect.

[3] Install the plate assemblies (28) and (29) and tighten the hexagon socket head bolts in the order (75), (94). Be careful not to apply excessive tightening torque to (94). Tightening torque: (75) 39 - 44 N•m, (94) 8.8 - 10.8 N•m [4] Install the plate assemblies (10) and (11), and tighten with the hexagon socket head bolts (75). Tightening torque: 39 - 44 N•m [5] Install the caps (8) and (9), and tighten with the hexagon socket head bolts (74). Tightening torque: 39 - 44 N•m [6] Screw in the plug assembly (110) with O-ring mounted into the option section (H-H cross section) short cap and tighten it. Tightening torque: 19 - 22 N•m [7] Screw in the plugs (91) with O-rings (90) mounted into the option section (H-H cross section) and straight travel section (I-I cross section) long caps and tighten them. Tightening torque: 19 - 22 N•m Caution

1. Be careful not to apply excessive torque when tightening a plug to a cap. 2. Applying excessive torque could crush the cap threads.

i) Assembly of straight travel signal control valve [1] Screw the orifice plug (42-7) (36 mm hex diameter) into the body (42-1) and tighten it. Tightening torque: 3.0 - 3.8 N•m [2] Being careful about the insertion orientation, assemble the spools (42-2) and (42-3) and spring (42-4). [3] Tighten the plug assembly (42-5) (5 mm hex socket diameter) with O-ring mounted to the body. Tightening torque: 13.5 - 16.5 N•m [4] Install the body assembly (42) with the hexagon socket head bolts (83) (5 mm hex socket diameter). Tightening torque: 8.8 - 10.8 N•m j) Assembly of add-on section [1] Screw the tie rods (96) into the main unit valve housing (1). [2] Install the main unit body matching surface O-rings (56) and (64). Execute Steps [3] - [5] below as necessary. [3] Remove the spool section assembly (111) and remove the matching surface O-rings (110-10) and (110-11). [4] Remove the inlet section assembly (99) and remove the matching surface O-rings (99-3) and (99-4). [5] Remove the spool section assembly (98) and remove the matching surface O-rings (9810) and (98-11). [6] Install the outlet housing (95). [7] Tighten the hexagon nuts (97) (4 locations, 22 mm hex diameter). RSM-13-11-001E

321 20

Control Valve k) Assembly of other plugs [1] Screw in and tighten the plug assemblies (71) with O-rings mounted. Tightening torque: 116 - 128 N•m [2] Screw in and tighten the plug assemblies (72) with O-rings mounted. Tightening torque: 39 - 44 N•m [3] Screw in and tighten the orifice plug (40). Tightening torque: 14 - 18 N•m [4] Screw in and tighten the plug assemblies (92) with O-rings mounted. Tightening torque: 205 - 227 N•m [5] Screw in and tighten the plug assemblies (72) with O-rings mounted. Tightening torque: 73 - 79 N•m [6] Screw in and tighten the plug assemblies (73) with O-rings mounted. Tightening torque: 31 - 41 N•m

322

RSM-13-11-001E 21

Control Valve Internal Structure Diagram

323

RSM-13-11-001E 22

Control Valve

324

RSM-13-11-001E 23

Control Valve

325

RSM-13-11-001E 24

Control Valve Part list Code

Part name

Q'ty

Code

Part name

Q'ty

1

Valve housing

1

48

Spring

1

2

Spool assembly

1

49

Poppet

1

3

Spool assembly

1

51

Poppet

1

Flange

2

4

Spool assembly

1

52

5

Spool assembly

2

53

Spacer

2

6

Spool assembly

1

54

O-ring

2

7

O-ring

20

55

Backup ring

2

O-ring

1

8

Cap

9

56

9

Cap

1

57

Spacer

1

10

Plate assembly

1

58

Sleeve

1

11

Plate assembly

1

59

Poppet

1

Spring

1

13

Valve housing

1

60

14

Spool assembly

1

61

Flange

1

15

Spool assembly

1

64

O-ring

3

16

Spool assembly

1

65

O-ring

14

O-ring

12

17

Spool assembly

1

66

18

Cap

1

67

Antidrift valve assembly

2

19

Spool

1

68

Relief valve kit

1

20

Spring seat

2

69-1 Relief valve kit

5

69-2 Relief valve kit

1

21

Spring

1

22

Spool end

1

70

Relief valve kit

2

23

O-ring

1

71

Plug assembly

3

24

Plug

1

72

Plug assembly

10

Plug assembly

3

25

O-ring

1

73

26

Spring

1

74

Hexagon socket head bolt

24

27

Spool assembly

1

75

Hexagon socket head bolt

74

28

Plate assembly

1

77

Hexagon socket head bolt

8

Hexagon socket head bolt

4

29

Plate assembly

1

78

30

O-ring

1

79

Nameplate

1

31

Backup ring

2

80

Drive screw

2

32

Poppet

2

82

Metal plug

5

Hexagon socket head bolt

4

33

Spring

2

83

34

Poppet

7

84

Spool assembly

1

35

Spring

8

86

Cap

1

36

O-ring

10

88

Cap

2

O-ring

2

37

Flange

6

89

38

Poppet

2

90

O-ring

2

39

Spring

2

91

Plug

2

40

Orifice plug

1

92

Plug assembly

2

Plug assembly

2

41

O-ring

27

93

42

Body assembly

1

94

Hexagon socket head bolt

2

43

Flange

1

95

Outlet housing

1

44

Poppet

1

96

Tie rod

4

Nut

4

Plug assembly

1

45

Spring

1

97

46

Plug

1

110

47

O-ring

1 326

RSM-13-11-001E 25

Control Valve (6)Relief valve 1) Procedures for assembly and disassembly of main relief valve

1

Plug (32 mm hex diameter)

7

Hexagon nut (30 mm hex diameter)

2

O-ring

8

Plug (27 mm hex diameter)

3

O-ring

9

1-1/16-12UN-2A

4

Hexagon nut (36 mm hex diameter)

10

Piston

5

O-ring

11

PF1/4 JIS O-ring type

6

Plug (27 mm hex diameter)

[1] Disassembly This part is replaced as an assembly. When replacing, loosen the plug (1) (32 mm diameter) with a wrench and remove the O-ring (2). If oil leaks from the nut (4) (36 mm hex diameter), loosen the nut (4) (36 mm hex diameter) and the plug (1) (32 mm hex diameter), and replace the O-ring (3). If oil leaks from the nut (7) (30 mm hex diameter), loosen the nut (7) (30 mm hex diameter) and the plug (8) (27 mm hex diameter), and replace the O-ring (5). [2] Assembly Carefully check to make sure there is no debris, paint fragments around the thread sections of the plugs (1) (32 mm hex diameter), (6) (27 mm hex diameter), (8) (27 mm hex diameter) and nuts (4) (36 mm hex diameter), (7) (30 mm hex diameter) and assemble the new O-rings. Also clean the valve housing relief valve installation section well, install the relief valve, and tighten the plug (1) (32 mm hex diameter). Tightening torque: 78 - 88 N•m When the plug has been disassembled, adjust the pressure according to 5) a) Main relief valve.

RSM-13-11-001E

327 26

Control Valve 2) Procedures for assembly and disassembly of overload relief valve

1

Cap

6

Spring

2

O-ring

7

1-1/16-12UN-2A

3

Adjuster kit section

8

Cap (31.75 mm hex diameter)

4

O-ring

9

Lock nut (17 mm hex diameter)

5

Poppet

10

Adjuster (6 mm hex diameter)

[1] Disassembly This part is replaced as an assembly. When replacing, loosen the cap (1) (31.75 mm hex diameter) with a wrench and remove the O-ring (2). Also, if oil leaks from the adjuster kit section, loosen the adjuster kit and replace the O-ring (4). Caution

Be careful when disassembling the adjuster kit. The spring may make parts fly out and the poppet could be lost.

[2] Assembly Check carefully that there is no debris, paint fragments around the thread section of the cap and assemble a new O-ring (2). Also clean the valve housing relief valve installation section well, install the relief valve, and tighten the cap (1) (31.75 mm hex diameter). Tightening torque: 78 - 88 N•m When the adjuster kit has been disassembled, clean around the thread sections well and adjust the pressure according to 5) b) Overload relief valve.

328

RSM-13-11-001E 27

Control Valve 3) Procedures for assembly and disassembly of low-pressure relief valve

1

Plug

7

Plug

2

Poppet

8

O-ring

3

Plug

9

PF1/4

4

Spring

10

PF3/4

5

O-ring

11

1 3/16-12UN-2A

6

Piston

[1] Disassembly Fasten the assembly with a vise, loosen the plug, and remove the piston (6), spring (4), and poppet (2). Then loosen the plug and take out the O-rings (5) and (8) from each part. [2] Assembly Check carefully that there is no debris, paint fragments around the thread section of the plug and assemble a new O-ring. Install new O-rings (5) and (8) on the plug and install the plug. Assemble the poppet (2), spring (4), and piston (6) and screw in and tighten the plug. Tightening torque: 103 - 113 N•m Also clean the valve housing relief valve installation section well and tighten the relief valve assembly plug (1) (36 mm hex diameter). Tightening torque: 103 - 113 N•m

RSM-13-11-001E

329 28

Control Valve 4) Procedures for assembly and disassembly of add-on main relief valve

1

Plug (32 mm hex diameter)

6

Spring

2

O-ring

7

1-5/16-12UN-2A

3

Adjuster kit section

8

Plug (24 mm hex diameter)

4

O-ring

9

Lock nut (17 mm hex diameter)

5

Poppet

10

Adjuster (6 mm hex diameter)

[1] Disassembly This part is replaced as an assembly. When replacing, loosen the plug (1) (32 mm hex diameter) with a wrench and remove the Oring (2). Also, if oil leaks from the adjuster kit section, loosen the adjuster kit and replace the O-ring (4). Caution

Be careful disassembling the adjuster kit. The spring may make parts fly out and the poppet could be lost.

[2] Assembly Check carefully that there is no debris, paint fragments around the thread section of the plug and assemble a new O-ring (2). Also clean the valve housing relief valve installation section well, install the relief valve, and tighten the plug. Tightening torque: 59 - 69 N•m When the adjuster kit has been disassembled, clean around the thread sections well and adjust the pressure according to 5) c) Add-on main relief valve.

330

RSM-13-11-001E 29

Control Valve 5) Relief valve adjustment Caution

This part is neither disassembled nor adjusted. (It is replaced as an assembly.) Therefore, be aware that proper operation is not guaranteed if pressure is adjusted.

a) Main relief valve [1] Install an accurate pressure gauge in the entry circuit. [2] Run the pump at its rated rotation rate. [3] Switch the control valve spool and read the pressure gauge at the cylinder stroke end. Caution

Switch the spool for the actuator with the overload relief valve set pressure higher than the main relief valve set pressure.

[4] High pressure setting (1st stage) (See the diagram on “Relief valve page 327”.) 1) Tighten the plug (8) until the piston (10) touches the plug (6) end surface (section marked *). At this time, the plug (8) (27 mm hex diameter) tightening torque must be 19.6 N•m or less. However, when tightening the plug (8), be careful that the plug does not turn too. (The A dimension must be at least 4 mm.) 2) With the plug (6) in the state in [4] 1), tighten and adjust the pressure. (While watching the pressure gauge, tighten in the plug (6) gradually: One turn of the plug raises the pressure 28.4 MPa.) After setting the pressure, lock with the hexagon nut. [5] Low pressure setting (2nd stage) With the high pressure set in [4], loosen the plug (8) and adjust the pressure. (When the plug is loosened, the piston moves to the right in the diagram and the spring load drops: 21.3 MPa pressure drop per one rotation.) After setting the pressure, lock with the hexagon nut (7). [6] Again raise the pressure and check that it reaches the specified pressure. b) Overload relief valve

Caution

If the set pressure is higher than the main relief valve, when adjusting as below, the main relief valve operates, so the overload relief valve cannot be adjusted. That is why the relief valve is not disassembled and adjusted but is replaced as an assembly with an assembly that has already been set.

[1] Switch the control valve spool and read the pressure gauge at the cylinder stroke end. [2] Turn the adjuster clockwise until the required pressure is obtained. [3] Reference number 69, total of 6 locations: The pressure rises 21.2 MPa for one rotation of the adjuster. [4] When the specified pressure is reached, restrain the adjuster so that it does not turn, then tighten the lock nut. Tightening torque: 27.5 - 31.4 N•m [5] Again raise the pressure and check that it reaches the specified pressure.

RSM-13-11-001E

331 30

Control Valve c) Add-on main relief valve [1] Install an accurate pressure gauge in the entry circuit. [2] Run the pump at its rated rotation rate. [3] Switch the control valve spool and read the pressure gauge at the cylinder stroke end. Caution

Switch the spool for the actuator with the overload relief valve set pressure higher than the main relief valve set pressure.

[4] Turn the adjuster clockwise until the required pressure is obtained. The pressure rises 17.8 MPa for one rotation of the adjuster. [5] When the specified pressure is reached, restrain the adjuster so that it does not turn, then tighten the lock nut. Tightening torque: 27 - 31 N•m [6] Again raise the pressure and check that it reaches the specified pressure. (7)Installation [1] Be careful that the line does not apply excessive force to the valve. [2] Tighten all the bolts the same. [3] Be careful. Welding close to a valve can damage its seal due to excess heat and sputter. [4] In order to keep out debris, do not remove the cap for a port until it is time to work on the line. (8)Operation [1] Check that the hydraulic circuits and hydraulic oil are clean, then gradually raise the pressure (inch the operating machine in low idle) and check that no oil leaks to the outside. [2] For the oil, use hydraulic oil with an aniline point of 82 - 113 ℃ . [3] Do not raise the relief valve above the specified set pressure. [4] Set a difference of at least 2.0 MPa between the set pressure for the main relief valve and for the overload relief valve. [5] Warm up the machine adequately before starting the actual work. Pay attention to the following points in order to avoid sticking due to spool heat shock particularly when starting up with the hydraulic oil temperature or valve temperature low. • Do not operate the main relief valve and overload relief valve right too suddenly after each other. Raise the temperature of each section uniformly and operate in such a way that the hydraulic oil circulates within each actuator. • Fine operations and compound operations generate heat locally due to throttling of individual sections, so do not suddenly perform these operations with the machine still at low temperature.

332

RSM-13-11-001E 31

Control Valve (9)Troubles and countermeasures Control valves overall Trouble content

Conceivable cause

Countermeasure

The spool does not 1. The oil temperature is abnormally Eliminate the section that is providing move through its stroke. resistance to the oil flow in the line. high. 2. Dirty hydraulic oil

Replace the hydraulic oil and at the same time, clean the circuits.

3. Line port joint tightened too much

Check the torque.

4. The valve housing was warped dur- Loosen the installation bolts and check. ing installation. 5. The pressure is too high.

Attach a pressure gauge to the pump and the cylinder port and check the pressure.

6. The spool is bent.

Replace the spool as an assembly.

7. Return spring damage

Replace the damaged part.

8. The spring or cap is out of place.

Loosen the cap, center it, then tighten it.

9. The temperature distribution within Warm up the circuits as a whole. the valve is not uniform. 10.Debris is clogging inside the valve.

Remove (flush out) the debris.

11.Pilot pressure insufficient

Inspect for the pilot valve and pilot relief pressure.

The load cannot be 1. Oil leak from cylinder held. 2. Oil from the spool is bypassing.

Check the cylinder seal section. Check for spool damage.

3. Oil leak from overload relief valve

Clean the valve housing seat section and relief valve seat section.

4. Oil leak from antidrift valve

Disassemble the antidrift valve and clean the seat section for each part. If a seat section is damaged, replace the poppet or lap the poppet and seat section. If the antidrift valve spool is abnormal, since the spool and the sleeve are mating parts, replace them both at the same time.

When the spool is 1. There is debris jammed in the load Disassemble and clean the check valve. switched from the check valve. neutral to the raise 2. The check valve poppet or seat sec- Replace the poppet or lap the poppet and seat position, the load falls. section. tion is damaged.

RSM-13-11-001E

333 32

Control Valve Relief valve Trouble content

Conceivable cause

Countermeasure

Pressure does not rise 1. Either the main poppet, sleeve, or Replace the relief valve. at all. pilot poppet is stuck open or there is debris jammed in the valve seat section. The relief pressure is 1. The pilot poppet seat section is damunstable. aged. 2. The piston or main poppet is stuck. The relief pressure is 1. Seat section worn by debris wrong. 2. The lock nut and adjuster are loose. Oil leak

1. Relief valve seat section damage

Set the pressure again, then tighten the lock nut to the specified torque. Replace the relief valve.

2. Each part is stuck due to debris. 3. An O-ring is worn.

Replace the adjuster or installation section Oring.

Hydraulic system overall Trouble content

Conceivable cause

Countermeasure

The hydraulic system is 1. Pump trouble not working properly or 2. Relief valve trouble is not working at all. 3. Cylinder trouble

Check the pressure or replace the pump. Replace the relief valve. Repair or replace.

4. Pump load pressure is high.

Check the circuit pressure.

5. There is a crack in the valve.

Replace the valve as an assembly.

6. The spool does not move through its Check the spool movement. full stroke. 7. The tank oil level is too low.

Fill the hydraulic oil.

8. The filter in the circuit is clogged.

Clean or replace the filter.

9. The circuit line is throttled.

Check the line.

334

RSM-13-11-001E 33

Other Valves Other Valves

SH200-5

Other Valves Removal and Installation of 5 Stack Solenoid Warning ・ Be sure to release hydraulic pressure before beginning work.

Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Wrenches (13 mm, 17 mm, 19 mm, 22 mm) • Marking pen • Caps • Plugs • Rag • Cleaning fluid

1. Removal of 5 Stack Solenoid Valve [1] Attach the specialty adapter (1) to the area where the air breather was removed, and set the vacuum pump (2). Create negative pressure in the hydraulic oil tank using the vacuum pump.

[2] Use a wrench (13 mm) to remove the 2 cover bolts (3), and then remove the cover (4).

335

1

Specialty adapter

2

Vacuum pump

3

Bolt

4

Cover

RSM-13-12-001E 1

Other Valves [3] Remove the 5 connectors (5).

[4] Use wrenches (19 mm, 22 mm) to remove the hoses (6), (7) and (8). • Mark the solenoid valve and hoses so that the connectors match at the time of assembly. • Use caps and plugs to cover the solenoid valve and hose to prevent any entry of water, dust or dirt. • Clean the solenoid valve and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors. [5] Use a wrench (22 mm) to remove the hoses (9) and (10). • Mark the solenoid valve and hoses so that the connectors match at the time of assembly. • Use caps and plugs to cover the solenoid valve and hose to prevent any entry of water, dust or dirt. • Clean the solenoid valve and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

RSM-13-12-001E

5

Connector

6

Pilot hose (use 22 mm wrench)

7

Pilot hose (use 19 mm wrench)

8

Pilot hose (use 19 mm wrench)

9

Pilot hose (use 22 mm wrench)

10

Drain hose (use 22 mm wrench)

336 2

Other Valves [6] Use wrenches (19 mm, 22 mm) to remove the hoses (11), (12) and (13). • Mark the solenoid valve and hoses so that the connectors match at the time of assembly. • Use caps and plugs to cover the solenoid valve and hose to prevent any entry of water, dust or dirt. • Clean the solenoid valve and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[7] Use a wrench (17 mm) to remove the 2 bolts (14), and then remove the 5 stack solenoid valve (15).

337

11

Pilot hose (use 19 mm wrench)

12

Pilot hose (use 19 mm wrench)

13

Pilot hose (use 22 mm wrench)

14

Bolt

15

5 stack solenoid valve

RSM-13-12-001E 3

Other Valves 2. Installation of 5 Stack Solenoid Valve Perform the reverse of the removal procedure. The hose connections and electrical connector connections are indicated below.

RSM-13-12-001E

338 4

Other Valves Removal and Installation of Cushion Valve Warning ・ Be sure to release hydraulic pressure before beginning work.

Caution

・ Be sure to stop the engine before beginning work.

Items to prepare • Wrenches (17 mm, 19 mm, 22 mm) • Marking pen • Caps • Plugs • Waste oil can • Rag • Cleaning fluid

1. Removal of Cushion Valve [1] Attach the specialty adapter (1) to the area where the air breather was removed, and set the vacuum pump (2). Create negative pressure in the hydraulic oil tank using the vacuum pump.

[2] Use a wrench (19 mm) to remove the 5 bolts (3), and then remove the under cover (4).

339

1

Specialty adapter

2

Vacuum pump

3

Bolt

4

Under cover

RSM-13-12-001E 5

Other Valves [3] Prepare a waste oil can.

5

RSM-13-12-001E

Waste oil can

340 6

Other Valves [4] Remove the connector (8). [5] Use wrenches (17 mm, 19 mm, 22 mm) to remove each hose and line. • Mark the cushion valve, hoses and lines so that the connectors match at the time of assembly. • Use caps and plugs to cover the cushion valve, hoses and lines to prevent any entry of water, dust or dirt. • Clean the cushion valve, hoses and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

341

6

Pilot hose

7

Line

8

Connector

9

Use 17 mm wrench

10

Use 19 mm wrench

11

Use 22 mm wrench

RSM-13-12-001E 7

Other Valves [6] Use a wrench (17 mm) to remove the 4 bolts (12) on the cushion valve bottom, then remove the cushion valve.

12

Bolt

2. Installation of Cushion Valve Perform the reverse of the removal procedure. The connections are as follows.

RSM-13-12-001E

1

Arm in

7

Boom down

2

Boom up

8

Swing left

3

Swing right

9

Bucket open

4

Bucket close

10

Pressure sensor (swing)

5

Heat circuit line

11

Swing priority switching pilot line

6

Arm out

12

Drain line

342 8

Other Valves Assembly and Disassembly of Cushion Valve 1. Disassembly Procedure This valve has a structure that forms small gaps. It is precision processed and the parts are carefully selected and fit together, so do not disassemble it as much as possible. If assembly and disassembly is unavoidable, pay attention to the following. (Failure to follow these instructions may invalidate the product warranty.) [1] Only disassemble in a clean location with minimal dirt. [2] Use only clean tools and cleaning oil and handle them with care. [3] Use plugs, caps to cover ports to prevent any entry of dirt and clean the outside of the assembly. [4] Check the internal structure before starting work, and carefully study the disassembly objective and scope. (1)Reverse operation spool section [1] Remove the plugs (1) and O-rings (2). [2] Remove the springs (3). [3] Remove the spools (4) with the cap screw and O-ring assembled in them.

Diagram 10 1

Plug

2

O-ring

3

Spring

4

Spool

[4] Use a vise to fasten the spools (4) assembly taken out in [3]. [Caution] Use a piece of wood (jig) to prevent scratches.

343

RSM-13-12-001E 9

Other Valves [5] Remove the cap screw (1) and O-ring (2).

Diagram 11

1

Cap screw

2

O-ring

3

Spool

4

Piece of wood (jig)

(2)Check plunger section with throttle [1] Remove the plugs (1) and O-rings (2). [2] Remove the springs (3) and remove the check plungers (4). [Caution] The check plungers have similar shapes, so identify them in such a way that no one will mix them up with each other.

Diagram 12

RSM-13-12-001E

1

Plug

2

O-ring

3

Spring

4

Check plunger

344 10

Other Valves (3)Shuttle valve section [1] Remove the plugs (1) and O-rings (2) and (3). [2] Remove the steel balls (4).

Diagram 13

345

1

Plug

2

O-ring

3

O-ring

4

Steel ball

RSM-13-12-001E 11

Other Valves 2. Assembly Procedure This valve has a structure that forms small gaps. It is precision processed and the parts are carefully selected and fit together, so do not disassemble it as much as possible. If assembly and disassembly is unavoidable, pay attention to the following. (Failure to follow these instructions may invalidate the product warranty.) [1] Only assemble in a clean location with minimal dirt. [2] Use only clean tools and cleaning oil and handle them with care. [3] Clean the disassembled parts and prepared parts. [4] Study the internal structure before starting the work and prepare the parts required by the disassembly objective and scope. (1)Reverse operation spool section [1] Assemble on the spool (3) the cap screw (1) with O-ring (2) attached. Tightening torque: 9.8 - 14.7 N•m [Caution] Use a piece of wood (jig) (4) to prevent scratches.

Diagram 14

RSM-13-12-001E

1

Cap screw

2

O-ring

3

Spool

4

Piece of wood (jig)

346 12

Other Valves [2] Insert the spool assembly (1) assembled in [1] into the body. [Caution] The spool assembly is symmetrical left/right, so the insertion direction does not matter. [3] Insert the springs (2) and assemble the plugs (3) with the O-rings (4) attached. Tightening torque: 39.2 - 49.0 N•m

Diagram 15 1

Spool assembly

2

Spring

3

Plug

4

O-ring

(2)Check plunger section with throttle [1] Insert the check plungers (1). [Caution] The check plungers have similar shapes, so be careful to insert each one in its correct position. [2] Insert the springs (2) and assemble the plugs (4) with the O-rings (3) attached. Tightening torque: 29.4 - 31.4 N•m

Diagram 16

347

1

Check plunger

2

Spring

3

O-ring

4

Plug

RSM-13-12-001E 13

Other Valves (3)Shuttle valve section [1] Insert the steel balls (1). [2] Assemble the plugs (2) with the O-rings (3) and (4) attached. Tightening torque: 39.2 - 49.0 N•m

Diagram 17

RSM-13-12-001E

1

Steel ball

2

Plug

3

O-ring

4

O-ring

348 14

Other Valves 3. Written Materials [1] Check plunger table Part number

Name

Orifice diameter (φ)

65301-11705

Check plunger

0.5

65301-11706

Check plunger

0.6

65301-11707

Check plunger

0.7

SH240-5

65301-11708

Check plunger

0.8

SH210-5

65301-11709

Check plunger

0.9

SH210/240-5

65301-11710

Check plunger

1.0

65301-11711

Check plunger

1.1

65301-11712

Check plunger

1.2

65301-11713

Check plunger

1.3

65301-11714

Check plunger

1.4

65301-11715

Check plunger

1.5

349

Remarks

SH240-5

RSM-13-12-001E 15

Other Valves [2] Cushion valve assembly diagram

External shape diagram

Cross-section diagram Part name

Code

Code

Part name

Part name

Code

1

Body

9

Check plunger

17

Plug

2

Spool

10

Check plunger

18

O-ring

3

Spring

11

Check plunger

19

Name plate

4

Plug

12

Check plunger

20

Drive screw

5

O-ring

13

Spring

21

Plug

6

Cap screw

14

Plug

22

Plug

7

O-ring

15

O-ring

8

Plug

16

Steel ball

RSM-13-12-001E

350 16

Radiator and Oil Cooler Radiator and Oil Cooler

SH200-5

Radiator and Oil Cooler Removal and Installation of Radiator Warning

・ Do not remove the radiator cap when the radiator coolant temperature is high. Hot liquid could spray out.

・ Be sure to release hydraulic pressure before beginning work. ・ Be sure to stop the engine before beginning work. Caution ・ Be sure to inspect the wire rope and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare • Wrenches (7 mm, 8 mm, 13 mm, 14 mm, 19 mm) • Box wrenches (8 mm, 12 mm) • Pliers • Shackle (with the required lifting capacity) x 2 • Wire rope (with the required breaking load) • Crane (with the required lifting capacity) • Caps • Plugs • Drain tank • Drain hose • Rag • Cleaning fluid • Wood planks, etc.

1. Removal of Radiator [1] Use a wrench (19 mm) to remove the 3 bolts (1), and then remove the under cover (2).

351

1

Bolt

2

Under cover

RSM-13-13-001E 1

Radiator and Oil Cooler [2] Install the drain hose (3), and then prepare the drain tank (4).

[3] To make it easier to drain the coolant, remove the radiator cap (5).

[4] Loosen the drain plug (6), and then drain the coolant.

RSM-13-13-001E

3

Drain hose

4

Drain tank

5

Radiator cap

6

Drain plug

352 2

Radiator and Oil Cooler [5] Use a wrench (8 mm) to loosen the hose band (7), and then remove the hose (8). • Use caps to cover the line and hose to prevent any entry of water, dust or dirt.

[6] Use a wrench (8 mm) to loosen the hose band (7), and then remove the hose (9). • Use caps to cover the line and hose to prevent any entry of water, dust or dirt.

[7] Use a wrench (19 mm) to remove the 2 bolts (10), and then remove the wiring box (11).

353

7

Hose band

8

Hose

9

Hose

10

Bolt

11

Wiring box

RSM-13-13-001E 3

Radiator and Oil Cooler [8] Use a wrench (13 mm) to remove the 3 bolts (12), bolt (14), washer (15), and seal retainer (16), and then remove the cover.

[9] Use a wrench (13 mm) to remove the 4 bolts (17), and then remove the cover (18).

[10] Use a box wrench (12 mm) to remove the 8 bolts (19) from the radiator cover.

12

RSM-13-13-001E

Bolt

13

Cover

14

Bolt

15

Washer

16

Seal retainer

17

Bolt

18

Cover

19

Bolt

354 4

Radiator and Oil Cooler [11] Use a wrench (7 mm) to loosen the hose band (20), and then remove the upper hose (21) and lower hose (22) from the radiator. • Use caps to cover the radiator and hoses to prevent the entry of water, dust or dirt.

[12] Remove the drain plug (23), loosen the hose band (25), and then remove the hose (24).

[13] Loosen the hose band (27), and then remove the hose (26) from the radiator cap. • Attach caps or plugs to the hose to prevent any entry of water, dust or dirt.

20

355

Hose band

21

Upper hose

22

Lower hose

23

Drain plug

24

Hose

25

Hose band

26

Hose

27

Hose band

RSM-13-13-001E 5

Radiator and Oil Cooler [14] Turn up the rubber band (28) on the fan.

[15] Use a wrench (7 mm) to loosen the hose band (29), and then remove the hose (31) from the hose bracket (30). • Use caps to cover the hoses and line to prevent any entry of water, dust or dirt.

[16] Remove the connector (32) from the sensor.

28

RSM-13-13-001E

Rubber band

29

Hose band

30

Hose bracket

31

Hose

32

Connector

356 6

Radiator and Oil Cooler [17] Use a wrench (19 mm) to remove the 4 bolts (33), and then remove the hose bracket (34).

[18] Use a wrench (19 mm) to remove the 3 bolts (33), and then remove the cover (35).

[19] Move the radiator cover (36) towards the cover removed in Step [18].

33

357

Bolt

34

Hose bracket

35

Cover

36

Radiator cover

RSM-13-13-001E 7

Radiator and Oil Cooler [20] Use a wrench (14 mm) to remove the 3 bolts (37), and then remove the fan shroud (38).

[21] Use a wrench (14 mm) to remove the bolts (39) from the fan guard (40), and then move the fan guard towards the engine.

37

RSM-13-13-001E

Bolt

38

Fan shroud

39

Bolt

40

Fan guard

358 8

Radiator and Oil Cooler [22] Use a wrench (14 mm) to remove the 2 bolts (44), 2 bolts (41), and 4 washers (42), and then remove the radiator cover (45). • The washers (42) are installed to hold the rubber cushion (43) in place. Be careful not to drop the opposite side washer.

[23] Remove the 2 butterfly bolts (46), and then remove the front anti-insect net (47).

[24] Install the 2 shackles (48) to the top of the radiator, and then use the wire rope (49) and crane to lift the radiator.

41

359

Bolt

42

Washer

43

Rubber cushion

44

Bolt

45

Radiator cover

46

Butterfly bolt

47

Anti-insect net

48

Shackle

49

Wire rope

RSM-13-13-001E 9

Radiator and Oil Cooler [25] Lift the radiator together with the radiator cover (51) until the fixtures (50) at the bottom of the radiator become disconnected.

[26] Thoroughly check that the location is safe before lowering the radiator on square wooden pieces. When laying down the radiator, be careful not to bend or crush the bottom fixtures (50).

50

Fixture

51

Radiator cover

2. Installation of Radiator To install, perform the reverse of the removal procedure. For details on the method for coolant filling, see the Engine Shop Manual. Use 25.6 L of coolant for the SH210-5 and 25.2 L for the SH240-5. Finally, check that the level of coolant is correct.

RSM-13-13-001E

360 10

Radiator and Oil Cooler Removal and Installation of Oil Cooler Warning ・ Keep away from fire. ・ Be sure to stop the engine before beginning work. Caution ・ Be sure to inspect the wire rope and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare • Wrenches (17 mm, 19 mm) • Pliers • Screwdriver • Eyebolts (M12) x 2 • Shackle (with the required lifting capacity) x 2 • Wire rope (with the required breaking load) • Crane (with the required lifting capacity) • Caps • Waste oil can • Rag • Cleaning fluid • Wood planks, etc.

1. Removal of Oil Cooler [1] Drain the hydraulic oil from the hydraulic oil tank. See the "Draining Oil from Hydraulic Oil Tank" for details of this procedure. [2] Use a wrench (19 mm) to remove the 2 bolts (1), and then remove the under cover (2).

361

1

Bolt

2

Under cover

RSM-13-13-001E 11

Radiator and Oil Cooler [3] Prepare a waste oil can (3).

[4] Remove the 2 butterfly bolts (4), and then remove the anti-insect net (5).

[5] Use a wrench (17 mm) to remove the 2 upper bolts (6) and 2 lower bolts (6), and then remove the lines (7) and (8). • Use caps to cover the oil cooler and lines to prevent the entry of water, dust or dirt.

RSM-13-13-001E

3

Waste oil can

4

Butterfly bolt

5

Anti-insect net

6

Bolt

7

Line

8

Line

362 12

Radiator and Oil Cooler [6] Use a wrench (17 mm) to remove the 2 upper bolts (9) and 2 lower bolts (9).

[7] Install the 2 eyebolts (M12) (10) on the top of the oil cooler. • Fully tighten the eyebolts, and then loosen them by a half turn.

[8] Use a screwdriver to push in the connecting part of the line at the bottom of the oil cooler by about 5 cm.

363

9

Bolt

10

Eyebolt

RSM-13-13-001E 13

Radiator and Oil Cooler [9] Install the 2 shackles (11) to the eyebolts, and then use the wire rope (12) and crane to lift the oil cooler main unit.

[10] Thoroughly check that the location is safe before lowering the oil cooler on wood planks, etc.

11

Shackle

12

Wire rope

2. Installation of Oil Cooler To install, perform the reverse of the removal procedure.

RSM-13-13-001E

364 14

Tank Tank

SH200-5

Tank Removal and Installation of Hydraulic Oil Tank ・ Keep away from fire. ・ Bleed off the pressure in the hydraulic oil tank before beginning work. Warning ・ The temperature of the hydraulic oil is high immediately after stopping the engine. Wait until the hydraulic oil temperature has decreased (to 40 ℃ or less) before beginning work. ・ Be sure to stop the engine before beginning work. Caution ・ Be sure to inspect the nylon sling and other lifting equipment before beginning work. ・ Do not go under the suspended load.

Items to prepare • Wrenches (7 mm, 19 mm, 22 mm, 27 mm, 36 mm) • Eyebolts (M12) x 2 • Shackle (with the required lifting capacity) x 2 • Wire rope (with the required breaking load) • Crane (with the required lifting capacity) • Marking pen • Caps • Plugs • Waste oil can • Rag • Cleaning fluid • Wood planks, etc.

1. Removal of Hydraulic Oil Tank [1] Drain the oil from the hydraulic oil tank. (For details, see "Drauning Oil from Hydraulic Oil Tank".) [2] Use a wrench (19 mm) to remove the 6 bolts (1), and then remove the under cover (2).

365

1

Bolt

2

Under cover

RSM-13-14-001E 1

Tank [3] Prepare a waste oil can (3) under the hydraulic oil tank.

[4] Use a wrench (7 mm) to loosen the hose bands (4), and then remove the hose (5). • Use caps to cover the hose to prevent any entry of water, dust or dirt.

[5] Use a wrench (19 mm) to remove the 6 bolts (6), and then remove the center cover (7).

RSM-13-14-001E

3

Waste oil can

4

Hose band

5

Hose

6

Bolt

7

Center cover

366 2

Tank [6] Use a wrench (7 mm) to loosen the hose bands (8), and then remove the drain hoses (9) and (10). • Use caps to cover the lines to prevent any entry of water, dust or dirt.

367

8

Hose band

9

Hose

10

Hose

RSM-13-14-001E 3

Tank [7] Use wrenches (19 mm, 22 mm, 27 mm, 36 mm) to remove the drain hoses. • Mark the hydraulic oil tank and hoses so that the connectors match at the time of assembly. • Attach caps or plugs to the hydraulic oil tank and hoses to prevent any entry of water, dust or dirt. • Clean the hydraulic oil tank and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

RSM-13-14-001E

11

Drain hose (use 27 mm wrench)

12

Drain hose (use 27 mm wrench)

13

Drain hose (use 22 mm wrench)

14

Drain hose (use 19 mm wrench)

15

Drain hose (use 19 mm wrench)

16

Drain hose (use 19 mm wrench)

17

Drain hose (use 19 mm wrench)

18

Drain hose (use 19 mm wrench)

19

Drain hose (use 22 mm wrench)

20

Pump drain hose (use 36 mm wrench)

368 4

Tank [8] Cut the hose bands on the tank side, and tie the hoses together.

[9] Use a wrench (19 mm) to remove the 6 bolts (21), and then remove the top cover (22) from the hydraulic oil tank.

369

21

Bolt

22

Cover

RSM-13-14-001E 5

Tank [10] Use a wrench (22 mm) to remove the 4 bolts (23) for the L-shaped frame (24) between the control valve and the hydraulic oil tank, and then remove the L-shaped frame.

RSM-13-14-001E

23

Bolt

24

Frame

370 6

Tank [11] Use a wrench (22 mm) to remove the 4 bolts (25) and 4 collars (26) from the bottom of the hydraulic oil tank. • Depending on the machine, there may be height adjustment shims between the tank and the frame. Do not lose them. Also, mark or write down the location where they are and how many.

[12] Use a wrench (19 mm) to remove the 2 bolts (27) from the fuel tank front cover (tank) (28), and then remove the cover (tank).

25

371

Bolt

26

Collar

27

Bolt

28

Cover (tank)

RSM-13-14-001E 7

Tank [13] Use a wrench (19 mm) to remove the 5 bolts (29) from the fuel tank side cover, and then remove the side cover (30).

[14] Use a wrench (19 mm) to remove the 4 bolts (31), and then remove the side cover (tank) (32).

29

RSM-13-14-001E

Bolt

30

Side cover

31

Bolt

32

Side cover (tank)

372 8

Tank [15] Connect the 2 eyebolts (M12) (33) to the top of the hydraulic oil tank, and then use the shackles (34), wire rope (35) and crane to lift the hydraulic oil tank (36). • When lifting, be careful that the level gauge (37) does not interfere with the frame at the side of the hydraulic oil tank. • Fully tighten the eyebolts, and then loosen them by a half turn.

[16] Thoroughly check that the location is safe before lowering the hydraulic oil tank on wood planks (38). • Thoroughly secure the hydraulic oil tank so that it does not fall down.

373

33

Eyebolt

34

Shackle

35

Wire rope

36

Hydraulic oil tank

37

Level gauge

38

Wood plank

RSM-13-14-001E 9

Tank 2. Installation of Hydraulic Oil Tank To install, perform the reverse of the removal procedure. For the tightening torque, check the "Bolt tightening torque list" in the Service Text .

RSM-13-14-001E

374 10

Tank Removal and Installation of Fuel Tank Warning ・ Keep away from fire. ・ Be sure to stop the engine before beginning work. Caution ・ Be sure to inspect the wire rope and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare • Wrenches (19 mm, 24 mm) • Eyebolts (M12) x 4 • Shackle (with the required lifting capacity) x 4 • Wire ropes (with the required breaking load) • Crane (with the required lifting capacity) • Caps • Plugs • Drum can (for draining fuel) • Rag • Cleaning fluid • Wood planks, etc.

Removal of fuel tank [1] Remove the cap (1) and filter (2).

[2] Drain out all the fuel from the fuel tank into a drum can.

375

1

Cap

2

Filter

RSM-13-14-001E 11

Tank [3] Use the drain cock (3) on the bottom of the tank to drain out any fuel that does not drain out but remains at the bottom of the tank.

[4] Use a wrench (19 mm) to remove the 7 bolts (4), and then remove the top cover (5).

[5] Use a wrench (19 mm) to remove the 2 bolts (6) from the fuel tank front cover (tank) (7), and then remove the cover (tank).

RSM-13-14-001E

3

Drain cock

4

Bolt

5

Cover

6

Bolt

7

Cover (tank)

376 12

Tank [6] Use a wrench (19 mm) to remove the 6 bolts (8) and clamp (9), and then remove the handle (10).

[7] Use a wrench (19 mm) to remove the 5 bolts (11) from the fuel tank side cover (12), and then remove the side cover.

377

8

Bolt

9

Clamp

10

Handle

11

Bolt

12

Side cover

RSM-13-14-001E 13

Tank [8] Use a wrench (19 mm) to remove the 5 bolts (13), and then remove the under cover (14).

[9] Loosen the hose band (15), and then remove the hose (16). • Mark the fuel tank and hoses so that the connectors match at the time of assembly. • Attach caps or plugs to the fuel tank and hoses to prevent any entry of water, dust or dirt.

[10] Remove the connector (17).

RSM-13-14-001E

13

Bolt

14

Under cover

15

Hose band

16

Hose

17

Connector

378 14

Tank [11] Use a wrench (24 mm) to remove the 6 bolts (18) and 6 collars (19) from the bottom of the hydraulic oil tank. • Depending on the machine, there may be height adjustment shims between the tank and the frame. Do not lose them. Also, mark or write down the location where they are and how many.

[12] Use a wrench (19 mm) to remove the 4 bolts (20), and then remove the side cover (tank) (21).

[13] Install the 4 eyebolts (M12) (22) on top of the fuel tank. • Fully tighten the eyebolts, and then loosen them by a half turn.

18

379

Bolt

19

Collar

20

Bolt

21

Side cover (tank)

22

Eyebolt

RSM-13-14-001E 15

Tank [14] Connect the 4 shackles (23) to the eyebolts, then use the wire ropes (24) and crane to lift the fuel tank. [15] Thoroughly check that the location is safe before lowering the fuel tank (25) on wood planks.

23

Shackle

24

Wire rope

25

Fuel tank

Installation of fuel tank To install, perform the reverse of the removal procedure. Finally, carefully check for any fuel leaks. For the tightening torque, check the "Bolt tightening torque list" in the Service Text .

RSM-13-14-001E

380 16

Attachments Attachments

SH200-5

Attachments Removal and Installation of Bucket ・ Stop the machine on a level location with good footing. ・ Be sure to stop the engine before beginning work. ・ When working together with others, always be sure to exchange signals and pay adequate Caution attention to safety. ・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working with a hammer.

Items to prepare • Hammer • Striking rod • Screwdriver • Grease • Rag • Cleaning fluid

1. Removal of Bucket [1] Place the back of the bucket parallel to the ground. [2] Use a screwdriver to remove the pin (2) rings (1), and then remove the bucket side and boom side pins.

381

1

Ring

2

Pin

RSM-13-15-001E 1

Attachments [3] Use a hammer (3) and striking rod (4) to push the bucket side pin (6) and arm side pin (5) out, and then remove the bucket (7). • If a pin is hard to remove, there is a load on the pin. Do not force it. Adjust the bucket position. • When removing the pins, be careful not to damage the O-rings or dust seals.

3

Hammer

4

Striking rod

5

Pin

6

Pin

7

Bucket

2. Installation of Bucket Perform the reverse of the removal procedure. • Clean each pin and pin hole. • If a pin is hard to insert, do not force it. Adjust the bucket position. • When insetting pins, be careful not to damage the O-rings or dust seals. • As the final step, always grease up.

RSM-13-15-001E

382 2

Attachments Removal and Installation of Bucket Link ・ Stop the machine on a level location with good footing. ・ Be sure to stop the engine before beginning work. ・ When working together with others, always be sure to exchange signals and pay adequate Caution attention to safety. ・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working with a hammer.

Items to prepare • 2 wrenches (30 mm) • Hammer • Striking rod • Grease • Rag • Cleaning fluid

1. Removal of Bucket Link [1] Remove the bucket. (For details, see "Removal and Installation of Bucket".) [2] Place the bucket link (1) parallel to the ground.

[3] Use 2 wrenches (30 mm) to remove the double nuts (2), and then pull out the bolts (3) and (4).

383

1

Bucket link

2

Nut

3

Bolt

4

Bolt

RSM-13-15-001E 3

Attachments [4] Use a hammer (5) and striking rod (6) to push the pin (7) out and remove the bucket link (8).

RSM-13-15-001E

5

Hammer

6

Striking rod

7

Pin

8

Bucket link

384 4

Attachments [5] Use a hammer (5) and striking rod (6) to push the pin (9) out and remove the arm links (10) and (11). • If a pin is hard to remove, there is a load on the pin. • When removing the pins, be careful not to damage the O-rings or dust seals.

5

Hammer

6

Striking rod

9

Pin

10

Arm link (left)

11

Arm link (right)

2. Installation of Bucket Link To install, perform the reverse of the removal procedure. • Clean each pin and pin hole. • When insetting pins, be careful not to damage the O-rings or dust seals. • As the final step, always grease up.

385

RSM-13-15-001E 5

Attachments Removal and Installation of Bucket Cylinder ・ Stop the machine on a level location with good footing. ・ Be sure to stop the engine before beginning work. ・ When working together with others, always be sure to exchange signals and pay adequate attention to safety. Caution ・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working with a hammer. ・ Be sure to inspect the nylon sling and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare • Wrenches (19 mm, 36 mm) • Hammer • Striking rod • Crane (with the required lifting capacity) • Nylon sling (with the required lifting capacity) • Grease • Rag • Cleaning fluid • Crossties • Wire

1. Removal of Bucket Cylinder [1] Remove the bucket. (For details, see "Removal and Installation of Bucket".) [2] Remove the bucket link. (For details, see "Removal and Installation of Bucket".) [3] Bring the arm top in contact with the ground. Retract the bucket cylinder rod.

[4] Tie the cylinder rod with wire (2) so that it cannot come out.

RSM-13-15-001E

1

Arm

2

Wire

386 6

Attachments [5] Switch the key switch (3) OFF to stop the engine. Switch the key switch ON again, and then turn the control lever (4) about 10 times to bleed off any pressure. Note: Do not operate the bucket at this time.

[6] Move the travel lever (5) back and forth about 5 times to bleed out the pressure. [7] Return the key switch to OFF.

387

3

Key switch

4

Control lever

5

Travel lever

RSM-13-15-001E 7

Attachments [8] Press the air breather button (6) on top of the hydraulic oil tank to release the pressure inside the tank.

[9] Use 2 wrenches (36 mm) to remove the hoses (7) and (8). • Use caps and plugs to cover the hoses and line to prevent any entry of water, dust or dirt. • Clean the hoses and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[10] Use a crane and nylon sling (9) to secure the bucket cylinder (10). • Wrap the nylon sling to the inside of the line so that it is not crushed.

RSM-13-15-001E

6

Air breather button

7

Hose

8

Hose

9

Nylon sling

10

Bucket cylinder

388 8

Attachments [11] Use a wrench (19 mm) to remove the bolt (11) and washer (12).

[12] Use a hammer (13) and striking rod (14) to push the pin (15) out. • If a pin is hard to remove, there is a load on the pin. • When removing the pins, be careful not to damage the O-rings or dust seals.

[13] Lift the bucket cylinder (10) and remove it. [14] Place the bucket cylinder on crossties.

10

Bucket cylinder

11

Bolt

12

Washer

13

Hammer

14

Striking rod

15

Pin

2. Installation of Bucket Cylinder To install, perform the reverse of the removal procedure. • Clean each pin and pin hole. • When inserting pins, be careful not to damage the dust seals. • As the final step, always grease up.

389

RSM-13-15-001E 9

Attachments Removal and Installation of Arm Cylinder ・ Stop the machine on a level location with good footing. ・ Be sure to stop the engine before beginning work. ・ When working together with others, always be sure to exchange signals and pay adequate attention to safety. Caution ・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working with a hammer. ・ Be sure to inspect the nylon sling and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare • Wrenches (19 mm, 36 mm, 41 mm) • Nylon sling (with the required lifting capacity) • Crane (with the required lifting capacity) • Caps • Plugs • Hammer • Striking rod • Grease • Rag • Cleaning fluid • Crossties • Wire

1. Removal of Arm Cylinder [1] Use a crane and nylon sling (1) to secure the arm cylinder (2).

RSM-13-15-001E

1

Nylon sling

2

Arm cylinder

390 10

Attachments [2] Use a wrench (19 mm) to remove the bolt (3) and washer (4).

[3] Use a hammer (5) and striking rod (6) to remove the pin (7). Be careful. The arm and arm cylinder rod may come out of place.

[4] Start the engine, move the arm out at idle, and retract the arm cylinder (2) rod.

391

2

Arm cylinder

3

Bolt

4

Washer

5

Hammer

6

Striking rod

7

Pin

RSM-13-15-001E 11

Attachments [5] Tie the cylinder rod with wire (8) so that it cannot come out.

[6] Switch the key switch (9) OFF to stop the engine. Switch the key switch ON again, and then turn the control lever (10) about 10 times to bleed off any pressure. Do not operate the arm at this time.

[7] Move the travel lever (11) back and forth about 5 times to bleed out the pressure. [8] Switch the key switch OFF.

RSM-13-15-001E

8

Wire

9

Key switch

10

Control lever

11

Travel lever

392 12

Attachments [9] Press the air breather button (12) on top of the hydraulic oil tank to release the pressure inside the tank.

[10] Use a wrench (41 mm) to remove the hose (13) and use a wrench (36 mm) to remove the hose (14). • Use caps and plugs to cover the hoses and lines to prevent any entry of water, dust or dirt. • Clean the hoses and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[11] Use a wrench (19 mm) to remove the grease hose (15). • Use caps and plugs to prevent any entry of water, dust or dirt.

393

12

Air breather button

13

Hose

14

Hose

15

Grease hose

RSM-13-15-001E 13

Attachments [12] Use a wrench (19 mm) to remove the bolt (16) and washer (17).

[13] Use a hammer (18) and striking rod (19) to push the pin (20) out. • If a pin is hard to remove, there is a load on the pin. • When removing the pins, be careful not to damage the O-rings or dust seals.

[14] Lift the arm cylinder (2). [15] Place the arm cylinder (2) on crossties.

2

Arm cylinder

16

Bolt

17

Washer

18

Hammer

19

Striking rod

20

Pin

2. Installation of Arm Cylinder To install, perform the reverse of the removal procedure. • Clean each pin and pin hole. • When insetting pins, be careful not to damage the O-rings or dust seals. • As the final step, always grease up.

RSM-13-15-001E

394 14

Attachments Removal and Installation of Arm ・ Stop the machine on a level location with good footing. ・ Be sure to stop the engine before beginning work. ・ When working together with others, always be sure to exchange signals and pay adequate attention to safety. Caution ・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working with a hammer. ・ Be sure to inspect the nylon sling and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare • Wrench (19 mm) • Hammer • Striking rod • Nylon sling (with the required lifting capacity) • Crane (with the required lifting capacity) • Grease • Rag • Cleaning fluid • Crossties

1. Removal of Arm [1] Remove the bucket. (For details, see "Removal and Installation of Bucket".) [2] Remove the bucket cylinder. (For details, see "Removal and Installation of Bucket Cylinder".) [3] Remove the arm cylinder. (For details, see "Removal and Installation of Arm Cylinder".) [4] Bring the arm (1) top in contact with the ground and use a crane and nylon sling (2) to secure it. At this time, insert the arm cylinder pin (3) and secure with the nylon sling.

395

1

Arm

2

Nylon sling

3

Pin

RSM-13-15-001E 15

Attachments [5] Use a wrench (19 mm) to remove the bolt (4) and washer (5).

[6] Use a hammer (6) and striking rod (7) to push the pin (8) out and remove the arm (9). • If a pin is hard to remove, there is a load on the pin. • When removing the pins, be careful not to damage the O-rings or dust seals. • Be very careful. When the pin is removed, the arm may fall slightly. • Be very careful. The arm may fall over to the side.

4

Bolt

5

Washer

6

Hammer

7

Striking rod

8

Pin

9

Arm

[7] Lift the arm. [8] Place the arm on crossties.

2. Installation of Arm To install, perform the reverse of the removal procedure. • Clean each pin and pin hole. • When inserting pins, be careful not to damage the dust seals. • As the final step, always grease up.

RSM-13-15-001E

396 16

Attachments Removal and Installation of Boom Cylinder ・ Stop the machine on a level location with good footing. ・ Be sure to stop the engine before beginning work. ・ When working together with others, always be sure to exchange signals and pay adequate attention to safety. Caution ・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working with a hammer. ・ Be sure to inspect the nylon sling and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare • Wrenches (19 mm, 30 mm, 36 mm) • Crowbar • Wire rope (with the required lifting capacity) • Crane (with the required lifting capacity) • Marking pen • Caps • Plugs • Hammer • Striking rod • Grease • Rag • Cleaning fluid • Crossties • Wire

1. Removal of Boom Cylinder • When removing only the boom cylinder, put the attachments in the temporary decommissioning posture. • When removing as far as the boom, first remove the bucket, bucket cylinder, arm, and arm cylinder according to their respective removal procedures. Bring the boom top in contact with the ground. [1] Use a crane and nylon sling (1) to secure the boom cylinder (2).

397

1

Nylon sling

2

Boom cylinder (right)

2

Boom cylinder (left)

RSM-13-15-001E 17

Attachments [2] Use a wrench (19 mm) to remove the grease hose (4). • Use caps and plugs to prevent any entry of water, dust or dirt.

[3] Use 2 wrenches (30 mm) to remove the 2 double nuts (5) and bolt (6), and then remove the fastening ring (7).

[4] Use a hammer (8) and striking rod (9) to push the pin (10) out. [5] Start the engine, lower the boom at idle, and retract the boom cylinder rod.

RSM-13-15-001E

4

Grease hose

5

Nut

6

Bolt

7

Ring

8

Hammer

9

Striking rod

10

Pin

398 18

Attachments [6] Tie the cylinder rod with wire (11) so that it cannot come out.

[7] Switch the key switch (12) OFF to stop the engine. Switch the key switch ON again, and then turn the control lever (13) about 10 times to bleed off any pressure.

[8] Move the travel lever (14) back and forth about 5 times to bleed out the pressure. [9] Switch the key switch OFF.

399

11

Wire

12

Key switch

13

Control lever

14

Travel lever

RSM-13-15-001E 19

Attachments [10] Press the air breather button (15) on top of the hydraulic oil tank to release the pressure inside the tank.

[11] Use a wrench (36 mm) to remove the hose (16). • Mark the lines and hoses so that the connectors match at the time of assembly. • Use caps and plugs to cover the hoses and lines to prevent any entry of water, dust or dirt. • Clean the hoses and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[12] Use a wrench (19 mm) to remove the bolt (17) and washer (18).

15

RSM-13-15-001E

Air breather button

16

Hose

17

Bolt

18

Washer

400 20

Attachments [13] Use a crowbar to remove the pin (19).

[14] Use a crane and nylon sling (1) to lift up and remove the boom cylinder (2). [15] Place the boom cylinder (2) on crossties. [16] Remove the cab side cylinder (3) with the same procedure.

1

Nylon sling

2

Boom cylinder (left)

3

Boom cylinder (right)

19

Pin

2. Installation of Boom Cylinder To install, perform the reverse of the removal procedure. • Clean each pin and pin hole. • When inserting pins, be careful not to damage the dust seals. • As the final step, always grease up.

401

RSM-13-15-001E 21

Attachments Removal and Installation of Boom ・ Stop the machine on a level location with good footing. ・ Be sure to stop the engine before beginning work. ・ When working together with others, always be sure to exchange signals and pay adequate attention to safety. Caution ・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working with a hammer. ・ Be sure to inspect the nylon sling and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare • Wrenches (10 mm, 19 mm, 22 mm, 30 mm, 36 mm, 41 mm) • Slide hammer (24 mm) • Nylon sling (with the required lifting capacity) • Crane (with the required lifting capacity) • Marking pen • Caps • Plugs • Rag • Cleaning fluid • Batten • Square wooden pieces • Wire

1. Removal of Boom [1] Remove the bucket. (For details, see "Removal and Installation of Bucket".) [2] Remove the bucket cylinder. (For details, see "Removal and Installation of Bucket Cylinder".) [3] Remove the arm cylinder. (For details, see "Removal and Installation of Arm Cylinder".) [4] Remove the arm. (For details, see "Removal and Installation of Arm".) [5] When removing the boom cylinder too, see "Removal and Installation of Boom". [6] This section explains the procedure for when not removing the boom cylinder. Bring the boom (1) top in contact with the ground.

RSM-13-15-001E

1

Boom

402 22

Attachments [7] Use a wrench (19 mm) to remove the grease hose (2). • Use caps and plugs to prevent any entry of water, dust or dirt.

[8] Use a wrench (30 mm) to remove the double nuts (3) and bolt (4), and then remove the fastening ring (5).

[9] Use a hammer (6) and striking rod (7) to push the pin (8) out. Use a crane and nylon sling (9) to hold the boom cylinder so that it does not fall.

403

2

Grease hose

3

Nut

4

Bolt

5

Ring

6

Hammer

7

Striking rod

8

Pin

9

Nylon sling

RSM-13-15-001E 23

Attachments [10] Tie the cylinder rod with wire (10) so that it cannot come out.

[11] Use a wrench (10 mm) to remove the grease nipple (11), and then secure the base of the boom cylinder with the batten (12).

[12] Lower the boom cylinder and let it rest on the batten (12). [13] Remove the cab side boom cylinder from the boom in the same way.

RSM-13-15-001E

10

Wire

11

Grease nipple

12

Batten

404 24

Attachments [14] Install the pin (8) removed in Step [9]. Use a wrench (30 mm) to install the bolt (4) with the 2 double nuts (3), and then install the fastening ring (5).

[15] Wrap the nylon sling (9) around the pin installed in Step [13] and secure with the crane.

405

3

Nut

4

Bolt

5

Ring

8

Pin

9

Nylon sling

RSM-13-15-001E 25

Attachments [16] Use wrenches (22 mm, 36 mm, 41 mm) to remove the hoses (13), (14), (15), (16), (17) and (18). • Mark the hoses and lines so that the connectors match at the time of assembly. • Use caps and plugs to cover the hoses and lines to prevent any entry of water, dust or dirt. • Clean the hoses and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[17] Use a wrench (19 mm) to remove the bolt (19) and washer (20).

[18] Use a slide hammer (21) (24 mm) to remove the pin (22).

13

RSM-13-15-001E

Bucket hose (use 36 mm wrench)

14

Bucket hose (use 36 mm wrench)

15

Arm hose (use 36 mm wrench)

16

Arm hose (use 41 mm wrench)

17

2nd option hose (use 22mm wrench)

18

2nd option hose (use 22mm wrench)

19

Bolt

20

Washer

21

Slide hammer

22

Pin

406 26

Attachments [19] Back up the machine and remove the boom (1).

1

Boom

2. Installation of Boom Cylinder To install, perform the reverse of the removal procedure. • Clean each pin and pin hole. • When inserting pins, be careful not to damage the dust seals. • As the final step, always grease up.

407

RSM-13-15-001E 27

Attachments Removal and Installation of Arm HBCV ・ Stop the machine in the temporary decommissioning posture on a level location with good footing. ・ Be sure to stop the engine before beginning work. Caution ・ When working together with others, always be sure to exchange signals and pay adequate attention to safety. ・ Be sure to release hydraulic pressure before beginning work.

Items to prepare • Wrench (22 mm) • Hexagon wrench (10 mm) • Marking pen • Caps • Plugs • Rag • Cleaning fluid

1. Removal of Arm HBCV [1] Use a wrench (22 mm) to remove the hoses (1) and (2). • Mark the HBCV and hoses so that the connectors match at the time of assembly. • Use caps and plugs to cover the hoses and HBCV to prevent any entry of water, dust or dirt. • Clean the hoses and HBCV by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[2] Use a hexagon wrench (10 mm) to remove the 4 hexagon socket head bolts (3), and then remove the line (4). • Use caps and plugs to cover the HBCV and lines to prevent any entry of water, dust or dirt. • Clean the HBCV and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

RSM-13-15-001E

1

Pilot hose

2

Drain hose

3

Bolt

4

Line

408 28

Attachments [3] Use a hexagon wrench (10 mm) to remove the 4 hexagon socket head bolts (5), and then remove the arm HBCV (6).

5

Bolt

6

Arm HBCV

2. Installation of Arm HBCV To install, perform the reverse of the removal procedure. The tightening torque for line installation and HBCV installation is 92.4 ± 17.5 N•m.

409

RSM-13-15-001E 29

Attachments Removal and Installation of Boom HBCV ・ Stop the machine on a level location with good footing. ・ Be sure to stop the engine before beginning work. Caution ・ When working together with others, always be sure to exchange signals and pay adequate attention to safety. ・ Be sure to release hydraulic pressure before beginning work.

Items to prepare • Wrenches (19 mm, 22 mm, 27 mm) • Hexagon wrench (8 mm) • Marking pen • Caps • Plugs • Rag • Cleaning fluid • Crossties

1. Removal of Boom HBCV [1] Use wrenches (19 mm, 22 mm) to remove the hoses (1), (2), (3) and (4) from the tool box side boom HBCV. • Mark the HBCV and hoses so that the connectors match at the time of assembly. • Use caps and plugs to cover the HBCV and lines to prevent any entry of water, dust or dirt. • Clean the HBCV and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

[2] Use a hexagon wrench (8 mm) to remove the 4 hexagon socket head bolts (5), and then remove the line (6). • Use caps and plugs to cover the HBCV and line to prevent any entry of water, dust or dirt. • Clean the HBCV and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

RSM-13-15-001E

1

Pilot hose (use 19 mm wrench)

2

Drain hose (use 22 mm wrench)

3

Drain hose (use 22 mm wrench)

4

Pilot hose (use 22 mm wrench)

5

Bolt

6

Line

410 30

Attachments [3] Use a hexagon wrench (8 mm) to remove the 4 hexagon socket head bolts (7), and then remove the boom HBCV (8).

[4] Use wrenches (19 mm, 22 mm) to remove the hoses (1), (3), (4) and (9) from the cab side boom HBCV in Step [1]. [5] Use a wrench (27 mm) to remove the boom bottom pressure sensor (10). • Mark the HBCV and hoses so that the connectors match at the time of assembly. • Use caps and plugs to cover the HBCV and lines to prevent any entry of water, dust or dirt. • Clean the HBCV and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors. [6] Use a hexagon wrench (8 mm) to remove the 4 hexagon socket head bolts (11), and then remove the line (12). • Use caps and plugs to cover the HBCV and lines to prevent any entry of water, dust or dirt. • Clean the HBCV and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

411

1

Pilot hose (use 22 mm wrench)

3

Drain hose (use 19 mm wrench)

4

Pilot hose (use 22 mm wrench)

7

Bolt

8

Boom HBCV

9

Pilot hose (use 22 mm wrench)

10

Boom bottom pressure sensor

11

Bolt

12

Line

RSM-13-15-001E 31

Attachments [7] Use a hexagon wrench (8 mm) to remove the 4 hexagon socket head bolts (13), and then remove the boom HBCV (14).

13

Bolt

14

Boom HBCV

2. Installation of Arm HBCV To install, perform the reverse of the removal procedure. The tightening torque for line installation and HBCV installation is 51.2 ± 9.6 N•m.

RSM-13-15-001E

412 32

Attachments Procedures for Operation / Assembly and Disassembly of Hydraulic Cylinder 1. Specifications and Structure Diagram (including the assembly diagram and parts table) This manual explains the KCH-6 model construction machine hydraulic cylinder, which has a structure typical of such cylinders. For details on the specifications and structure of the product being used, see the delivery diagram (including the assembly diagram and parts table) given separately.

2. Operation Explanation (1) Basic functions Hydraulic cylinders are a type of hydraulic actuator. A hydraulic cylinder converts the energy of pressure supplied from the hydraulic pump into a large force of linear motion. By operating the hydraulic pressure direction switchover valve, one can switch the direction of operation between extension and retraction. This linear motion with large force and the switchover of the operation direction are the basic functions. (2) Function of each location This manual explains the functions of each section of the cylinder using one of our products with a typical structure. There may be some slight differences with the product being used, but the functions are the same. 1) Cylinder head assembly The cylinder head assembly has the function of bearing the piston rod (2) by the bushing (4) press fit into the interior diameter of the cylinder head (3). The seal system of the interior diameter of the cylinder head prevents oil from leaking to the outside and prevents foreign matter from getting into the cylinder. The cylinder head assembly also has the function of supplying and discharging high-pressure oil from inside the cylinder tube to the retraction side port.

1

Cylinder tube

7

U-ring

2

Piston rod

8

Backup ring

3

Cylinder head

9

Wiper ring

4

Bushing

10

O-ring

5

O-ring

11

Backup ring

6

Buffer ring

12

Installation bolt

• Bushing Press fit to the inside surface of the cylinder head (3) and contacts the piston rod (2). Together with the slide rings (18) and (19) on the outer circumference of the piston, the bushing divides the lateral load applied to the cylinder and moves linearly relative to the piston rod. Furthermore, it supports one end of the piston rod and has the function of minimizing eccentricity which has a negative impact on the sealing. • Buffer ring The buffer ring (6) has the function of buffering the pressure and heat applied on the U-ring (7) by the hydraulic oil to improve durability.

413

RSM-13-15-001E 33

Attachments • U-ring and backup ring The U-ring (7) seals the pressurized oil within the cylinder. The U-ring also has the function of forming an appropriate oil film on the surface of the piston rod in order to prevent rust of the piston rod (2). The backup ring (8) has the function of suppressing extrusion of the U-ring into the gap between the piston rod and the cylinder head (3) when the pressure operates and of improving durability. • Wiper ring The wiper ring (9) is positioned in the opening where the piston rod (2) comes out from and goes into the cylinder and prevents dust and water from getting into the cylinder from the outside. It also has the function of wiping off any mud sticking to the surface of the piston rod as the piston rod moves. 2) Piston assembly The piston assembly has the function of transmitting the propulsion of the cylinder. A seal ring (16) is mounted on the center of the piston (15) to prevent the flow of pressurized oil from either the left or right chamber to the other chamber. There are slide rings (18) and (19) mounted at each end of the seal ring. They have the function of a bearing to receive the cylinder lateral load.

RSM-13-15-001E

1

Cylinder tube

19

Slide ring

2

Piston rod

20

Locking screw

13

Cushion ring

21

Steel ball

14

Cushion seal

22

Cushion ring

15

Piston

23

Cushion seal

16

Seal ring

24

Stopper

17

Backup ring

25

Snap ring

18

Slide ring

414 34

Attachments For some cylinder sizes, the piston (15) and nut (21) are separate.

1

Cylinder tube

20

Shim

2

Piston rod

21

Nut

13

Cushion ring

22

Locking screw

14

Cushion seal

23

Steel ball

15

Piston

24

Cushion ring

16

Seal ring

25

Cushion seal

17

Backup ring

26

Stopper

18

Slide ring

27

Snap ring

19

Slide ring

Example of parts numbers for separated piston and nut • Seal ring and backup ring The seal ring (16) is positioned at the center of the piston (15) and uses the tension force of the O-ring to seal the ring-shaped gap between the piston and the cylinder tube (1) and form chambers with a high-pressure side and a low-pressure side with the piston as the boundary. The backup ring (17) has the function of suppressing extrusion of the seal ring into the gap between the piston and the cylinder tube when the pressure operates and of improving durability. • Slide ring Slide rings are positioned at both ends of the seal ring (16) and contact the inside surface of the cylinder tube (1). Together with the bushing (4) positioned on the inside surface of the cylinder head (3), the slide ring divides the lateral load applied to the cylinder and moves linearly relative to the inside surface of the cylinder tube. Furthermore, it supports one end of the piston rod (2) and has the functions of minimizing eccentricity, which has a negative impact on the sealing, and buries and captures any impurities trapped between the cylinder tube and the slide rings (18) and (19). • Cushion ring When the cylinder is fully extended, the cylinder head (3) and the cushion ring (13) fit together. When it is fully retracted, the cylinder bottom and the cushion ring fit together. In both cases, this forms a ring-shaped gap and squeezes the oil to reduce the cylinder collision speed at full extension or full retraction and thus soften the impact.

415

RSM-13-15-001E 35

Attachments 3) Pipe assembly The pipe assembly is mounted on the extension side and retraction side ports of the cylinder tube assembly. It has the function of supplying and discharging high-pressure oil by connecting with the hydraulic circuits of the machine body.

28 Pipe assembly 29 Pipe assembly

RSM-13-15-001E

416 36

Attachments 3. Handling Precautions (1) Precautions for installing the cylinder on the machine body • When installing the cylinder on the machine body or removing it from the machine body, secure the piston rod at the fully retracted position, check safety, and suspend.

Caution

Never suspend the cylinder from the line section. This would not only pose the danger of falling but could also damage the cylinder. Use a band to secure the piston rod in the fully retracted state. If the piston rod is not in the fully retracted state, it could be easily damaged. This could create the need for repair or make the piston rod unusable. Also, not securing the piston rod is dangerous because the piston rod might fly out unexpectedly.

• Do not weld after the cylinder has been mounted on the machine body. Caution

Electric welding on the cylinder or even at a position separated from the cylinder can generate a spark within the cylinder and damage parts. This could cause extensive damage, making it necessary to replace parts or replace the cylinder.

• When painting the machine body, mask the piston rod and wiper ring.

Caution

If the cylinder is operated with paint sticking to the piston rod surface and the wiper ring, the wiper ring does not function adequately, greatly interfering with cylinder functions. For example, dirt and paint from the outside may get into the cylinder easily and damage seal parts and cause an oil leak.

• Clean the cylinder before installing it. (2)Usage cautions • Use under the determined conditions.

Caution

Use of hydraulic oil other than that specified can cause rapid deterioration of and damage to seal parts. If the relief valve is set to a value higher than that on the assembly diagram, there is a danger of this leading to cylinder damage. General sealing materials cannot handle high ambient temperature (about 100 ℃ or higher) or low ambient temperature (-20 ℃ or lower), so the cylinder would be damaged if used at such temperatures. Such temperatures require special seal materials, so check if the cylinder being used complies with this requirement. The number one cause of cylinder trouble is oil leaks due to piston rod scratches. Operate very carefully to avoid scratching the piston rod. If the piston rod is scratched, handle this according to "5. Trouble Diagnostics".

• Warm up the equipment adequately before work.

Caution

After the cylinder has been stopped for a long time, the seal parts inside the cylinder are stuck to the metal of sliding surfaces, so do not suddenly pressurize or operate such a cylinder. A new cylinder or one that has been left unused for a long time has much air built up inside, so it does not operate smoothly. Also, if one suddenly operates or pressurizes the cylinder without bleeding out the air, the adiabatic compression of the air generates high temperatures, which may burn and carbonize seal parts, leading to a drastic drop in functioning. Before starting work, always warm up the cylinder by moving slowly through a few full strokes under no load to bleed off any air in the cylinder.

417

RSM-13-15-001E 37

Attachments • Always put the machine in a safely secured posture when stopping it temporarily or storing it.

Caution

When extended, the cylinder cannot hold a load for a long time in a fixed position. This is because the cylinder is extended and retracted by very minor oil leaks from hydraulic circuits and from inside the cylinder and changes in the volume of the hydraulic oil due to oil temperature variation. This results in the danger of machine moving unexpectedly, which can lead to serious accidents. Always put the machine in a safely secured position before stopping it temporarily or storing it.

(3)Maintenance and inspection cautions • Always carry out daily maintenance inspections.

Caution

The most important point for realizing the cylinder functions for a longer time is "daily maintenance inspections". In order to ensure adequate cylinder functioning, execute "4. Maintenance Inspection and Service". Constantly clean off any mud, water, dust, oil or grease stuck to the piston rod and keep the piston rod in a clean state. However, do not use water or the like to clean the wiper ring section and seal section. Wipe with a rag. When leaving the machine unused for a week or longer, apply anti-rust oil to the surface of the piston rod in order to prevent rusting.

• Use genuine KYB parts for replacement parts.

Caution

If replacement parts are used that are not genuine KYB parts, adequate functioning cannot be attained. Always use genuine KYB parts. Specialty jigs have been produced so that assembly work and disassembly work can be done safely and quickly, so order them.

• Be careful about assembly and disassembly too.

Caution

Disassembling a cylinder still installed on the machine body is extremely dangerous because it can cause unexpected movement of the machine body. Always remove the cylinder from the machine body before disassembling it. Assembling with dirty hands can get dirt inside the cylinder and not only reduce the cylinder service life but also damage other hydraulic equipment. Assemble under clean conditions. Use the thread part tightening torque indicated in the diagram. If the torque is either too low or too high, this can cause thread damage.

• Strictly observe the cylinder storage standards. Caution

RSM-13-15-001E

Execute according to "7. Assembly and Disassembly Procedures".

418 38

Attachments 4. Maintenance Inspection and Service In order to ensure a hydraulic cylinder functions properly for a long time, periodically carry out maintenance inspection and service based on the "Autonomous inspection table". Repair any trouble locations quickly based on the trouble diagnostics. Caution Inspection and service location

For periodic inspection and service, first work to prevent any hazard to operators. Strive to prevent hazards by working with an attitude based on good sense. Inspection and service detail Is the cylinder clean (especially rod sliding sections)?

Appearance

Operation

Hydraulic oil

Main unit installation section

Cylinder tube section (including line sections)

Monthly

Yearly

Remarks

○

Is any oil leaking from line installation sections or other fixed sections?

○

Is there missing or peeling paint, or rust?

○

Is operation smooth and free of abnormal noise and any other abnormality?

○

Is the responsiveness good?

○

Is any oil leaking from sliding sections?

○ ○

Are there internal leaks? Is the pressure used normal?

○

Is the overload relief valve set pressure normal?

○

Is hydraulic oil dirty or deteriorated?

○ ○

Is hydraulic oil replaced periodically? Are filters inspected periodically?

○

Is the supply of grease to pins adequate?

○

Do pin sections have any abnormal noises or seizing?

○

Do pin sections have any backlash or wear?

○ ○

Are pin seals normal? Are any installation screws loose or fallen out?

Piston rod section

Daily

○

Retighten installation screws.

○

Are sliding sections worn?

○

Are sliding sections scratched or dented?

○

Is sliding section plating peeling off?

○

When leaving piston rod sliding sections exposed for long periods, apply antirust oil to the piston rod.

○

Are sliding sections bent? Are there any welding section cracks or damage?

○

Are there any loose bolts or nuts (threaded parts)?

○

Retighten threaded installation parts (bolts and nuts (threaded parts)).

○

Are there any welding section cracks or damage?

○

Are there large dents on the tube?

○ 419

RSM-13-15-001E 39

Attachments 5. Trouble Diagnostics Hydraulic cylinder trouble, countermeasure and solution It is not easy to discover trouble locations. The table below shows general symptoms, suggested causes and also solutions. For repairs, see the possible causes and solutions in the table. The cause of machine problems are often not rooted in just a single part. Problems are often due to the relationship of one part with another. In some cases, solutions are required other than those given in the table. In such a case, contact with our company to investigate the problem and its cause further and take appropriate measures. Item

Item

Symptom

1

Piston rod sliding section oil leak (For the judgment values, see "7. (4) Inspection after assembly".)

2

Cylinder head matching section oil leak

3

Pipe and cylinder tube welding section oil leak

4

Operation defect

Symptom

Related part

Piston rod

Symptom

Countermeasure and solution

① Remove the scratches with a whetstone to make the sliding surface smooth (1.5 s max.). If the oil leak continues, the rod scratches may have damaged the U-ring or other seal, so A sliding surface has disassemble and inspect. rust and scratches that catch on a fingernail. ② If the scratches or rust cover too large an area to be repaired with a whetstone, replace the piston rod and the U-ring, wiper ring, or other seal and the piston rod bearing part. Plating is peeling off.

① Replate or replace the piston rod. ② At this time, inspect the seals and piston rod bearing part as well and replace any that are damaged.

There is foreign matter ① Remove the foreign matter. caught in the interior or ② If the packing is damaged, replace it. exterior diameter section. There are scratches on Replace the part. the interior or exterior diameter section. 1

Piston rod sliding section oil leak

① This may be scorching due to adiabatic compression of air The lips and groove remaining in the cylinder. section are locally ② When operating the cylinder for the first time after replacing a carbonized (scorched). packing, run at low pressure and low speed to adequately Rod packing bleed off the air. (Buffer ring The packing has lost its and U-ring) ① Replace the part. rubber elasticity and is ② This may be the end of the packing service life, deterioration of in tatters. the hydraulic oil, or high temperature of the hydraulic oil. a. Replace the hydraulic oil. The lip section is b. Check the temperature of the hydraulic oil. (The oil defective all the way temperature should be no higher than 80 ℃ .) around. c. Check for local high temperature.

Backup ring

RSM-13-15-001E

There is major extrusion of the packing heel section.

① Replace the part. ② Abnormally high pressure may be operating on the packing. a. Check the pressure during operation. b. There may be trouble with the buffer ring section. Inspect the buffer ring section.

The part is greatly deformed.

① As a rule, replace the rod packing too at the same time. ② Abnormally high pressure is often the cause. The check items for this are the same as those given above for packing heel section extrusion.

420 40

Attachments Item

Symptom

Related part

Wiper ring

1

2

Piston rod sliding section oil leak

Cylinder head matching section oil leak

Symptom

Countermeasure and solution

There is foreign matter caught in the lip.

Remove the foreign matter.

The lip is damaged. There is other abnormal damage.

Replace the part.

There is major wear of the bushing and the gap with the piston rod Replace the part. exceeds the limit on Bearing part interior diameter wear (bushing) in "8.-(9) Usage limits". There are large scratches on a sliding surface.

① Replace the part. ② Inspect the piston rod sliding surfaces for scratches and rust.

Cylinder head

A seal mounting section has scratches and rust.

① Remove the scratches or rust with a whetstone. ② If the repair does not solve the problem, replace the cylinder head.

O-ring

① Remove the foreign matter. ② If the O-ring is damaged, replace it. There is foreign matter caught in the interior or ③ Tube interior surface inspection: If there are any scratches or rust, use a whetstone to make the surface smooth. exterior diameter. There is damage to the ④ Cylinder head O-ring groove inspection: Same as above ⑤ Backup ring inspection: If the backup ring is deformed or O-ring. extruded, replace it. Check the above and replace the O-ring.

Backup ring

The part is deformed or Replace the backup ring together with the O-ring. extruded. ① Disassemble the cylinder head and inspect the O-ring and backup ring. If there is damage, replace. ② Check the tube and cylinder head threads for damage and if there is any damage, replace. ③ When the inspection is complete, tighten to the specified torque. See "7. (7) Assembly procedure". ④ Stop rotation.

Cylinder head

A part is loose.

Bolt

There is looseness, Replace all the bolts and tighten to the specified torque. stretching or breakage.

Cylinder tube

There is abnormal swelling.

① Replace with a new one. ② Oil leaks at matching sections may be caused by abnormally high pressure (including cushion pressure), so if the tube is swollen or deformed, replace it with a new one. Also inspect the circuit pressure. Replace with a new one.

Pipe and cylinder Pipe and tube welding cylinder section oil tube leak

Caution (See page 421.) There are cracks on the welding section.

3 Oil leak from cylinder line Pipe connection assembly section

The crack progresses and ultimately the part fractures. A fracture is extremely dangerous, so if a crack is seen, quickly stop work and replace that part. Welding over a crack is ineffective.

Line fastening bolt is loose.

Tighten to the specified torque according to the work procedure.

The line is bent.

Replace with a new one.

There are scratches on ① Use a whetstone to make the surface smooth. a contact surface. ② If the oil leak does not stop, replace.

421

RSM-13-15-001E 41

Attachments Item

Symptom

Related part Piston rod Cylinder tube

Operation Cylinder defect tube Movement is not smooth.

Symptom

Countermeasure and solution

The bending is large ① Replace with a new one. and exceeds the ② There may also be damage to seals and sliding parts, so stipulated bend warp. inspect them. If there is any abnormality, replace. (Bend warp: See "7. (3) Maintenance standards".) Replace with a new one. Inspect the seal and sliding parts the same as above.

There are dents.

① Replace with a new one. Inspect the seal and sliding parts the same as above. ② Remove the foreign matter. Inspect the seal and sliding parts the same as above.

Abnormal wear of sliding parts and Piston rod damaged piston Cylinder section or foreign tube matter caught at the Sliding parts cylinder head sliding section Piston seal

There are scratches, Replace with a new one. wear, or other damage. Also inspect the cylinder tube interior surfaces.

Cylinder tube

There are scratches and rust on interior surface.

① Use honing or a whetstone to eliminate the scratches and rust and make the surface smooth. If the scratches cover too large an area to be repaired, replace the cylinder tube with a new one. ② Replace with a new piston seal.

Piston nut

Tightening is insufficient.

① Tighten to the specified torque.¢7.-See "7. - (7) Assembly procedure". ② The piston rod thread section could be stretched. Measure the diameter where the rod and piston fit together and if this area is tapered, replace the piston rod assembly.

Valves

Leak from valve.

Inspect the amount of valve leakage and service.

Operation is Air unsteady.

There is air remaining in the cylinder.

Bleed out the air. a. Cylinder with no air bleeding Bleed out the air by moving the cylinder back and forth at few times at low pressure and low speed. b. Cylinder with air bleeding (air breather) After securing the machine so that the cylinder does not move, bleed the air from the air breather. [Tip] The cylinder extends or retracts somewhat when the cylinder stops suddenly. This phenomenon occurs due to the compressibility of the hydraulic oil. This occurs particularly easily for cylinders with long strokes.

The impact is high when switching Pin bushing over between Pin extension and retraction.

The gap between the installation section and Measure the pin and pin bushing dimensions and replace any part the pin bushing is that exceeds its stipulated dimension. enlarged.

Internal oil leak The piston rod extends and retracts on its own and drops abnormally during operation. Also, the stipulated speed is not output. 4

Cylinder sliding operations make sounds.

Pin bushing Pin

The oil or grease feed is inadequate.

Apply oil or grease.

There is galling matching section.

Replace with a new part and apply oil or grease.

at

Caution The hydraulic oil expands and contracts with changes in temperature and pressure. This causes the cylinder to extend and retract too, so it can be mistaken for an internal oil leak. For internal oil leaks, always check the temperature and pressure under the same conditions.

RSM-13-15-001E

422 42

Attachments 6. Storage Standards When a hydraulic cylinder is shipped from the plant, every measure is taken, but in order to prevent trouble during storage and to extend the product service life, pay attention to the following items. 1) Storing the cylinder alone (In principle, store indoors.) • Store the cylinder off the floor and do not store in any location with high temperature and humidity, corrosive gas or liquids. • Before shipment, we operates the cylinder with hydraulic oil to which a fixed quantity of vaporizing anti-rust agent has been added (in order to prevent rust within the cylinder), carries out the pre-shipping inspection, then retracts the piston rod with ultra-dry air (condensation point -35 ℃ or lower) (in order to prevent condensation due to temperature difference), and then puts caps on the ports and line joints before shipping the cylinder. • Any product that has been storage in our product warehouse longer than the standard storage period is disassembled and inspected before being shipped. Therefore, do not store or leave a cylinder unused with a cap removed or with the remaining oil in the cylinder drained. Storage for one month or longer

Storage for six months or longer (3 months for cylinder alone)

Storage for one year or longer

Clean any dust from the cylinder, and then apply anti-rust oil to the pin bushings, flange sections, piston rod, and other sections that rust easily.

Operate the cylinder back and forth with clear hydraulic oil, and then pour anti-rust oil into the cylinder and store in compliance with the items on the left for storage of one month.

Since there is a danger of packing deterioration, disassemble, inspect, and replace packings. Also, check for rust inside the cylinder.

②

-

If the cylinder cannot be operated, seal in anti-rust oil.

If a cylinder that has been stored for a long time is used as is, oil may leak due to temporary running-in defects of seals.

③

When storing a cylinder, be extremely careful not to drop it, let it collide with anything, strike it.

①

2) Mounted on vehicle body ① Operate the cylinder at least once per month ② Retract the cylinder so that as much as possible outside air does not touch the piston rod and apply anti-rust oil at least once per month to the exposed part of the piston rod. ③ Handle carefully to absolutely avoid scratching the piston rod. ④ When putting the cylinder into an environment where rust occurs particularly easily, for example due to exposure to sea breezes during export, always apply anti-rust oil to the piston rod and as much as possible protect with polyethylene sheets or VCI paper (vaporizing anti-rust paper). ⑤ Anti-rust oil and other solvents can have negative impacts on seals, so select anti-rust oil carefully and as much as possible keep it off dust seals etc. (For details on anti-rust oil to select, see "6.3) Recommended anti-rust oil".)

3) Recommended anti-rust oil Vaporizing anti-rust oil a. Ferro Gard #1009 (from USC Limited) a. Knuckle Oil #105S (from Parker Industries, Inc.) For inside cylinder

For piston rod

For both a. and b., add 3 % - 5 % of the hydraulic oil. By volume, Ferro Gard: 5/100 Knuckle Oil: 3/100 Anti-rust P-1300 (from the Nippon Oil Corporation)

For machine worked surfaces Select from JIS K 2246 (anti-rust oil) NP-1 through NP-6. other than parts with oil sealed in

423

RSM-13-15-001E 43

Attachments 7. Assembly and Disassembly Procedures (1) Preparations ・・・・・ Prepare the following before starting disassembly. [1] Work platform preparation Prepare a sufficiently spacious, solid and stable work surface so that parts will not fall or move during work. [2] Tool and materials preparation Prepare the tools and materials shown on the following pages. (2) General work precautions [1] Clean any dirt or mud from the outside walls of the cylinder before starting disassembly. [2] Each part has been manufactured with a high degree of precision, so be careful not to let parts bump each other or fall when handling them. [3] If parts are struck or pulled with excessive force during work because they are tight, this may cause burrs or damage which causing reduction in performance or oil leaking. Perform work carefully and thoroughly. [4] If a cylinder is left disassembled, humidity and dirt can cause rust on parts. If a pause in the work is unavoidable, be careful to prevent rust and keep off dust. (3) Maintenance standards Replace sliding parts and seal parts as follows. [1] BushingWhen 1/4 of the circumference is worn brown over the entire length [2] Seals and slide ringsReplace with new parts when the cylinder is disassembled. [3] Pin bushingWhen there is drastic galling [4] Piston rodWhen the piston rod is bent more than 0.5 mm/1 m

RSM-13-15-001E

424 44

Attachments (4)Inspection after assembly Dimension inspection Pressure inspection

Check the fully retracted length and stroke as instructed on the diagram.

withstand Check for looseness, permanent deformation, and external leaks when the test pressure instructed on the diagram is applied to each stroke end for at least 3 min. Check the amount of oil leak at the rod section. ・ Judgment value for rod section oil leak Move the piston rod back and forth 20 times with the oil at a temperature from 20 ℃ to 40 ℃ , and then judge by the state of the oil ring formed on the rod surface. If the oil ring is in a broken down A state, this is judged to be trouble. See "5. Trouble Diagnostics" for information on how to solve this.

External leak inspection

Oil leak unit: ml/10 min.

Internal leak inspection

Interior diameter mm

Interior diameter mm

Oil leak amount

160

10.0

4.0

180

12.6

125

5.6

200

15.6

140

6.0

220

20.0

250

22.0

Interior diameter mm

Oil leak amount

32

0.4

40

0.6

100

50

1.0

63

1.6

80

2.3

425

Oil leak amount

RSM-13-15-001E 45

Attachments (5)Required tools 1) General tools

No.

Tool name

Q'ty

1

Screwdriver (flathead screwdriver)

2

Hexagon wrench

3

Vise

4

Wrench (for piston nuts)

5

Punch

6

Torque wrench

7

Hammer (plastic hammer)

1

8

Monkey wrench

1

9

scoop

RSM-13-15-001E

1

1 set

1

1 set

1

1 set

1 set

426 46

Attachments 2) Special jig Cylinder assembly requires the following special jigs. Jig name

Sketch

For bushing removal and press fitting

For wiper ring press fitting

Seal ring insertion jig

Seal ring calibration jig

For cylinder head insertion

For piston insertion

Consult with our company about jigs. (The following page has a list of jig part numbers.)

427

RSM-13-15-001E 47

Attachments 3) Special jigs part number list [1] Select jigs for the cylinder head according to the rod diameter. [2] Select jigs for the piston according to the cylinder bore.

Cylinder head assembly and disassembly jig

Seal ring insertion and calibration jig

RSM-13-15-001E

Applicable rod diameter

Set part number

65

3006J-56001

70

3007J-06001

75

3007J-56001

80

3008J-06001

85

3008J-56001

90

3009J-06001

95

3009J-56001

100

3010J-06001

105

3010J-56001

110

3011J-06001

115

3011J-56001

120

3012J-06001

Applicable cylinder bore

Set part number

95

3009J-51001

100

3010J-01001

105

3010J-51001

110

3011J-01001

115

3011J-51001

120

3012J-01001

125

3012J-51001

130

3013J-01001

135

3013J-51001

140

3014J-01001

145

3014J-51001

150

3015J-01001

160

3016J-01001

170

3017J-01001

428 48

Attachments (6)Disassembly procedure 1) Drain the oil. 2) Secure the cylinder. Secure the cylinder in a vertical or horizontal position. A vertical position makes assembly and disassembly easier. Secure the cylinder using the bottom pin hole and stop rotation and secure the axis position. (When securing the cylinder, if a line or the like interferes, remove it.) 3) Removal of cylinder head Use a hexagon wrench to loosen the cylinder head tightening bolts and remove them. Passing a pipe through the hexagon wrench as in the diagram below makes the work easier.

429

RSM-13-15-001E 49

Attachments 4) Pull out the piston rod. [1] Check that the line caps are removed. [2] Put the oil pan at the retraction side (cylinder head side) port. [3] With the piston rod pulled out all the way, slowly pull out the cylinder head and remove it. [4] Pull out the piston rod together with the cylinder head and place them on crossties.

・ When assembling and disassembling with the cylinder secured vertically, work paying particular attention to the following points. In the work of removing the piston rod, the cylinder head may come out of the cylinder tube ahead of the piston due to Caution friction with the packing, creating a condition in which there is space between the cylinder head and the piston. If the work is done in that state, the cylinder head may suddenly slip out and injure the operator. Always work with the cylinder head touching the piston. Working in the vertical state

・ When assembling and disassembling with the cylinder secured horizontally, work paying particular attention to the following points. In the work of removing the piston rod, Caution there is a danger of the piston rod falling and damaging parts right after it is removed. Work carefully while holding the rod horizontal and in contact with the crossties.

5) Secure the piston rod. Use the rod head bolt width or pin hole to set up a rotation stopper.

RSM-13-15-001E

430 50

Attachments 6) Remove the piston nut. [1] Remove the locking screw (3). Locking screw is caulked in with a punch at 2 locations on the outer circumference. Cut away the caulked sections with a hand drill, and then loosen the locking screw. [2] Remove the steel ball (2) at the bottom of the locking screw (3).

[3] Remove the piston nut. • The piston nut is tightened with the torque specified in the assembly diagram. • Loosening a piston nut requires about 1.5 times that torque. Prepare the power wrench (6) that uses the hydraulic jack (4) and hydraulic cylinder (5). * For a one piece piston and nut, apply the wrench to the hexagonal section of the piston and loosen the piston directly. 7) Removal of piston etc. Remove the piston (9), cushion ring (8), and cylinder head (7) in that order.

431

1

Drill

2

Steel ball

3

Locking screw

4

Hydraulic jack

5

Hydraulic cylinder

6

Wrench

7

Cylinder head

8

Cushion ring

9

Piston

RSM-13-15-001E 51

Attachments 8) Retraction side cushion ring disassembly

[1] Remove the piston nut. The cushion ring cannot be disassembled with the piston nut attached. [2] Remove the snap ring (12). Remove by gently tapping with a plastic hammer in such a way as to not scratch the piston rod (11) or cushion ring (14). [3] When the cushion ring (14) is slid to the piston rod thread (11) side, the stopper (split in two) (15) can be removed. [4] Remove the cushion ring (14). [5] The cushion seal (13) has a split opening, so spread the opening wide and remove the cushion seal. 9) Remove the piston seal. [1] The slide rings (22) and backup ring (20) can be removed easily by hand. [2] Stand up a flathead screwdriver (23) as in the diagram on the right and tap with a hammer to cut through the seal ring (16), and then remove the seal ring. [3] Pull out the O-ring (19) with a scoop. * The removed seal parts cannot be reused.

RSM-13-15-001E

10

Screw

11

Piston rod

12

Snap ring

13

One cushion seal split opening

14

Cushion ring

15

Stopper (split in two)

16

Seal ring

17

Piston

18

Vise

19

O-ring

20

Backup ring

21

Hardwood

22

Slide ring

23

Screwdriver

432 52

Attachments 10)Disassembly of buffer ring [1] The buffer ring (27) is mounted in the groove on the interior diameter of the cylinder head. When removing this seal, stick in a sharp tool and lift it up, and then insert a scoop and take it out. * The removed seal parts cannot be reused.

11)Disassembly of U-ring and wiper ring [1] Use a screwdriver to remove the U-ring (26) and backup ring (25). [2] The wiper ring (24) is press fit. Stick a screwdriver straight down into the rubber and tap it to remove the wiper ring. * The removed seal parts cannot be reused. 12)Removal of O-ring and backup ring [1] Pull out the O-ring (29) and backup ring (30) with a scoop. 13)Disassembly of bushing [1] Raise the snap ring (28) with a screwdriver, and then remove it from the cylinder head. [2] For the bushing (33), use the bushing removal jig (32) as in the diagram on the right and press out the bushing with a press.

24

433

Wiper ring

25

Backup ring

26

U-ring

27

Buffer ring

28

Snap ring

29

O-ring

30

Backup ring

31

Bushing

32

Bushing removal jig

33

Bushing

RSM-13-15-001E 53

Attachments 14)Removal of pin bushing [1] Remove the wiper ring (24) from the tube and piston rod. Remove it by using a screwdriver in the same manner as for the cylinder head. [2] Use the metal block (35) to remove the pin bushing (37).

34

Press

35

Metal block

36

Jig

37

Pin bushing

15)Cleaning and storage Clean the removed parts with white kerosene, and then apply hydraulic oil, cover the parts, and store them. If they are left disassembled, there is a danger of their collecting rust and dust and not being able to function adequately after they are assembled again.

RSM-13-15-001E

434 54

Attachments (7)Assembly procedure Caution

If a part with peeling paint is assembled, the peeled off paint can get inside the cylinder. This causes oil leaks, so work being very careful to prevent this.

1) Installation of pin bushing [1] Use the installation jig to press fit onto the piston rod (4) and into the tube. (Apply hydraulic oil in advance.) [2] Use the metal block (5) to install the wiper ring (6).

2) Replacement of seal [1] When reassembling the cylinder, replace all the seals. [2] O-rings • Clean the mounting groove well, and then mount the backup ring (7) and O-ring (8). Foreign matter in the grove section would cause an oil leak. • Be careful about the location of the backup ring. • Apply grease or hydraulic oil to the backup ring and O-ring so that they slide easily, and then assemble them. If they are sliding poorly, O-ring may become twisted during assembly, which causes oil leaks.

435

1

Press

2

Installation jig

3

Pin bushing

4

Piston rod

5

Metal block

6

Wiper ring

7

Backup ring

8

O-ring

9

Cylinder head

RSM-13-15-001E 55

Attachments 3) Assembly of cylinder head assembly [1] Use the bushing press fit jig (10) to press fit the bushing (11). Apply hydraulic oil to the inside surface of the cylinder head in advance and after press fitting, check that there is no level difference at the bushing. [2] Use the wiper ring press fit jig (15) to press fit the wiper ring (16). [3] Mount the backup ring (18) and U-ring (19) in the U-ring groove (17) in that order. • Check the assembly direction of the U-ring and mount it carefully so as not to scratch it. Installing the U-ring backwards would cause an oil leak. • After mounting, check that there are no wrinkles or other permanent deformation remaining in the U-ring.

[4] Mount the buffer ring (20). Be careful with the attachment directions of the seals. If the seal is installed backwards, extraordinarily high pressure will be generated between the seal and the U-ring (19), causing deformation and breakage of the cylinder. [5] Assemble the bushing retainer snap ring (21). 10

RSM-13-15-001E

Jig

11

Bushing

12

Cylinder head

13

Pressing base

14

Press

15

Wiper ring press-fit jig

16

Wiper ring

17

U-ring groove

18

Backup ring

19

U-ring

20

Buffer ring

21

Snap ring

436 56

Attachments 4) Assembly of piston assembly [1] Assemble the seal ring (24). • Assemble the back-up ring (23) for one side and the O-ring (25) on the piston (26) in advance, place on the press platform, and use the seal ring insertion jig (22) as in the diagram to assemble the seal ring. [2] Correct the seal ring. • Mount the seal ring (24) and the other backup ring (23), and then immediately correct with the seal ring calibration jig (27) so that the seal ring does not remain expanded. (Strictly observe this instruction.) Since the seal ring is stretched when it is mounted, if it is not calibrated, "6) Insertion of piston rod into the tube" is not possible. [3] Assemble the slide ring. • Spread the cut section of the slide ring the minimum with both hands and install from the axial direction. If it is spread too wide, it cannot be mounted. * Consult with our company about jigs. 5) Assembly of piston rod assembly [1] Secure the piston rod (31). [2] Assemble the cylinder head (32) on the piston rod (31). Be careful that the wiper ring and U-ring lips do not catch on the stepped section. Use the cylinder head insertion jig (30) as in the diagram on the right to assemble the cylinder head on the piston rod. • Apply grease or oil and assemble being careful not to scratch the packing.

437

22

Seal ring insertion jig

23

Backup ring

24

Seal ring

25

O-ring

26

Piston

27

Seal ring calibration jig

28

Metal block

29

Press

30

Cylinder head insertion jig

31

Piston rod

32

Cylinder head

RSM-13-15-001E 57

Attachments [3] If there is a cushion on the extension side, assemble the cushion ring (33) and cushion seal (34) with the following procedure. 1) Insert into the groove with the side of the cushion seal with the slit (*2) facing the piston side. 2) Assemble with the part of the cushion ring processed to be flat facing as in the diagram.

[4] When there is a cushion on the retraction side Assemble the cushion ring (39) and cushion seal (38) with the following procedure. 1) Assemble the cushion ring before assembling the piston nut. The cushion ring cannot be assembled with the piston nut attached. 2) Mount in the groove with the side of the cushion seal with the slit (*4) facing the thread side. 3) Assemble with the part of the cushion ring processed to be flat facing as in the diagram below. 4) Insert the stopper (40) into the groove. Press the cushion ring (39) all the way to the stopper and strike in the snap ring (37). Strike gently with a plastic hammer in such a way as to not scratch the piston rod (4) or cushion ring.

Caution

RSM-13-15-001E

*1

Flat surface processing

*2

Face the slit to the flat side.

*3

Face the slit to the thread side.

*4

Slit side

4

Piston rod

33

Cushion ring

34

Cushion seal

35

Piston

36

Thread

37

Snap ring

38

Cushion seal

39

Cushion ring

40

Stopper (split in two)

Make sure that the cushion seal and cushion ring face the correct direction. If they are installed backwards, the cushion will not be effective. After installing the cushions, check that the extension and retraction cushion rings move up and down and left and right.

438 58

Attachments [5] Tighten the piston nut. • Always tighten the piston nut to the specified torque given on the assembly diagram. • If the tightening torque is insufficient, this causes internal leaks, nut looseness, and thread cutting • Also, if the tightening torque is excessive, extension side cushion ring swelling and piston contact surface deformation occur. • In order to tighten correctly, clean and degrease the piston and nut and piston rod thread section adequately (with paint thinner) before tightening the nut. [6] Stop the piston from turning. • After tightening the piston nut, put in the steel ball (43), tighten the locking screw (42) to the specified torque given on the assembly diagram, and then caulk (41) with the punch (44) at 2 locations on the outer circumference.

6) Insertion of piston rod into the tube [1] Secure the tube (47) vertically or horizontally. [2] Insert the piston rod (4) into the tube (47). • If the tube is secured vertically, the piston rod enters the tube due to its own weight. • When the piston section is entering the tube, be careful that the slide rings (46) do not fall out.

4

439

Piston rod

41

Caulking

42

Locking screw

43

Steel ball

44

Punch

45

Jig (nylon pipe (split in two))

46

Slide ring (Shift the abutment phase 180 珵 rom one ring to the next.)

47

Tube

RSM-13-15-001E 59

Attachments 7) Cylinder head tightening Align the cylinder head with the position on the assembly diagram, and then tighten the bolts to the specified torque given on the assembly diagram in the order shown in the diagram below.

Bolt tightening order

8) Installation of line [1] Check that the O-ring is in the groove correctly. [2] Tighten the port section bolts to the specified torque given on the assembly diagram. [3] Tighten the bands for securing the line to the torque on the assembly diagram, the same on both sides, so that no abutment gap occurs.

Caution

*5

Tighten the bolts.

*8

Normal: OK

*6

Be careful about the O-rings.

*9

There is a gap: Not OK

*7

No abutment opening gap

*10 Band for securing the line

When installing the cylinder lines and the machine body rubber hoses, nipples, etc., assemble securing the cylinder line port section with a wrench. If one tightens without securing the port section, the line may bend, oil may leak, and the machine body may get in the way.

(8) Test operation [1] In order to fill the inside of the cylinder with oil, after it is installed on the machine body, move the cylinder through its full stroke slowly 8 times or more. If the cylinder is suddenly moved from the start, the hydraulic oil may be aerated. [2] If the cylinder has air bleeding, pressurize so that the air bleed side is the pressure side (return oil side) and bleed off the air. [3] Apply oil and grease to the pins at both ends.

RSM-13-15-001E

440 60

Attachments (9)Usage limits Below are the usage limits for sliding sections. Use them for reference for maintenance. • Piston rod exterior diameter wear limit Nominal diameter (mm)

Minimum outer diameter (mm)

65 ～ 80

-0.023

Replace or replate.

85 ～ 120

-0.027

Replace or replate.

Solution

• Rod bushing interior diameter wear limit Nominal diameter (mm)

Standard interior diameter (mm)

Maximum inner diameter (mm)

55 ～ 75

+0.060 ～ +0.190

+0.30

Replace the bushing.

80 ～ 120

+0.060 ～ +0.195

+0.30

Replace the bushing.

Solution

• Piston slide ring thickness wear limit Nominal diameter (mm)

Standard thickness (mm)

Minimum thickness (mm)

95 ～ 160

t2.42 - 2.48

t2.37

Replace the slide ring.

165 ～ 250

t2.92 - 2.98

t2.87

Replace the slide ring.

441

Solution

RSM-13-15-001E 61

Lights Lights

SH200-5

Lights Removal and Installation of Boom Light Caution ・ Be sure to stop the engine before beginning work.

Items to prepare • Wrench (19 mm) • Rag • Cleaning fluid [1] Remove the connector (1).

[2] Use a wrench (19 mm) to remove the nut (2), spring washer (3), and washer (4), and then remove the boom light (5).

442

1

Connector

2

Nut

3

Spring washer

4

Washer

5

Boom light

RSM-13-16-001E 1

Lights Removal and Installation of Tool Box Light Items to prepare • Wrench (13 mm) • Rag • Cleaning fluid [1] Open the tool box (1).

[2] Remove the connector (2).

[3] Use a wrench (13 mm) to remove the nut (3), and then remove the tool box light (4).

RSM-13-16-001E

1

Tool box

2

Connector

3

Nut

4

Light

443 2

Procedures for Removal and Installation of Cab Inner and Outer Parts Procedures for Removal and Installation of Cab Inner and Outer Parts

SH200-5

Procedures for Removal and Installation of Cab Inner and Outer Parts Removal and Installation of Cab Assembly ・ Be sure to stop the engine before beginning work. Caution ・ Be sure to inspect the wire rope and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare • Wrenches (13 mm, 19 mm) • Box wrenches (10 mm, 13 mm, 19 mm) • Eyebolt (M24) x 4 • Chains (wire ropes) (with the required breaking load) • Crane (with the required lifting capacity) • Lubricating oil • Rag • Cleaning fluid • Wood planks, etc.

1. Removal of Cab Assembly [1] Remove the operator's seat. (For details, see "Removal and Installation of Operator's Seat".) [2] Use a box wrench (10 mm) to remove the 4 bolts (1) and another box wrench (13 mm) to remove the 2 bolts (2), and then remove the rear cover (3).

[3] Use a box wrench (10 mm) to remove the 2 bolts (4), and then remove the air conditioner ducts on both sides (5).

444

1

Bolt

2

Bolt

3

Rear cover

4

Bolt

5

Duct

RSM-13-17-001E 1

Procedures for Removal and Installation of Cab Inner and Outer Parts [4] Remove the air conditioner ducts (6) and (7) by pulling them forward.

[5] Use a wrench (13 mm) to remove the 4 bolts (8), and then remove the brackets (9).

[6] Remove the air conditioner duct (10).

RSM-13-17-001E

6

Duct

7

Duct

8

Bolt

9

Bracket

10

Duct

445 2

Procedures for Removal and Installation of Cab Inner and Outer Parts [7] Remove the radio antenna (11).

[8] Use a wrench (13 mm) to remove the bolts (12) for the ground wire (13) connecting the cab and frame.

[9] Remove the connectors (14) and (15).

446

11

Radio antenna

12

Bolt

13

Ground wire

14

Connector

15

Connector

RSM-13-17-001E 3

Procedures for Removal and Installation of Cab Inner and Outer Parts [10] Remove the washer fluid hose (16).

[11] Use a wrench (13 mm) to remove the 4 bolts (17) each, and then remove the rear brackets (right and left) (18) and (19).

[12] Remove the 3 butterfly screws (20), and then remove the cover (21).

RSM-13-17-001E

16

Hose

17

Bolt

18

Rear bracket (right)

19

Rear bracket (left)

20

Butterfly screw

21

Cover

447 4

Procedures for Removal and Installation of Cab Inner and Outer Parts [13] Remove the 2 butterfly screws (22), and then open the cover (23) of the outside air filter.

[14] Remove the outside air filter (24). Slide the suction duct connected with the air conditioner unit in the cab from the duct flange and remove it.

[15] Remove the 4 caps (25) from the top of the cab.

448

22

Butterfly screw

23

Cover

24

Filter

25

Cap

RSM-13-17-001E 5

Procedures for Removal and Installation of Cab Inner and Outer Parts [16] Install the 4 eyebolts (M24) (26) in place of the removed caps. • Fully tighten the eyebolts, and then loosen them by a half turn.

[17] Use chains (27) and crane to secure the cab.

[18] Use a Phillips screwdriver to remove the 3 screws (28), and then remove the cover (29).

RSM-13-17-001E

26

Eyebolt

27

Chain

28

Screw

29

Cover

449 6

Procedures for Removal and Installation of Cab Inner and Outer Parts [19] Use a wrench (19 mm) to remove the 7 bolts (30) from the cab.

[20] Use chains (32) and crane to remove the cab (31).

450

30

Bolt

31

Cab

32

Chain

RSM-13-17-001E 7

Procedures for Removal and Installation of Cab Inner and Outer Parts [21] Thoroughly check that the location is safe before lowering the cab on wood planks (33). • Thoroughly secure the cab with the chains and crane so that it does not fall down.

33

Wood plank

2. Installation of Cab Assembly To install, perform the reverse of the removal procedure. The tightening torque for the cab assembly installation bolts is 157 N•m.

RSM-13-17-001E

451 8

Procedures for Removal and Installation of Cab Inner and Outer Parts Removal and Installation of Operator's Seat Items to prepare • Wrench (13 mm)

1. Removal of Operator's Seat [1] Pull the slide lever (1) to slide the seat (2) to the rear. [2] Use a wrench (13 mm) to remove the 2 bolts (3) from the front of the seat.

[3] Pull the slide lever (1) to slide the seat forward, and then pull the reclining lever (4) to fold the seatback forward.

[4] Use a wrench (13 mm) to remove the 2 bolts (5) from the rear of the seat.

452

1

Slide lever

2

Seat

3

Bolt

4

Reclining lever

5

Bolt

RSM-13-17-001E 9

Procedures for Removal and Installation of Cab Inner and Outer Parts [5] Remove the operator's seat (6).

6

Operator's seat

2. Installation of Operator's Seat To install, perform the reverse of the removal procedure. The tightening torque for the seat installation bolts is 19.6 N•m.

RSM-13-17-001E

453 10

Procedures for Removal and Installation of Cab Inner and Outer Parts Removal and Installation of Wiper Items to prepare • Wrench (17 mm) • Phillips screwdriver

1. Removal of Wiper [1] Use a wrench (17 mm) to remove the nut (1), and then remove the wiper arm (2).

[2] Use the Phillips screwdriver to remove the screw (3), and then remove the wiper (4).

1

Nut

2

Wiper arm

3

Screw

4

Wiper

2. Installation of Wiper To install, perform the reverse of the removal procedure.

454

RSM-13-17-001E 11

Procedures for Removal and Installation of Cab Inner and Outer Parts Removal and Installation of Wiper Controller Items to prepare • Wrench (10 mm) • Box wrenches (10 mm, 13 mm) • Phillips screwdriver • Flathead screwdriver

1. Removal of Wiper Controller [1] Use the Phillips screwdriver to remove the 2 installation screws (2) for the side upper trim (1).

[2] Lift the side upper trim (1), remove the connectors (3), and then remove the side upper trim. Some models have no connector.

[3] Use a box wrench (13 mm) to remove the 2 turn clips (4) and the 4 bolts (5), and then remove the side rear cover (6).

RSM-13-17-001E

1

Side upper trim

2

Screw

3

Connector

4

Turn clip

5

Bolt

6

Side rear cover

455 12

Procedures for Removal and Installation of Cab Inner and Outer Parts [4] Use the Phillips screwdriver or box wrench (10 mm) to remove the 4 bolts (7), and then remove the side rear B trim (8).

[5] Use a wrench (10 mm) to remove the 3 bolts (9), and then remove the side lower trim (10).

[6] Use the Phillips screwdriver or box wrench (10 mm) to remove the 4 bolts (11), and then remove the side rear A trim (12).

7

456

Bolt

8

Side rear B trim

9

Bolt

10

Side lower trim

11

Bolt

12

Side rear A trim

RSM-13-17-001E 13

Procedures for Removal and Installation of Cab Inner and Outer Parts [7] Remove the connector (14) from the wiper controller (13).

[8] Use a flathead screwdriver to slightly bend the 4 installation clips (15), and then remove the wiper controller (13).

13

Wiper controller

14

Connector

15

Installation clip

2. Installation of Wiper Controller To install, perform the reverse of the removal procedure.

RSM-13-17-001E

457 14

Procedures for Removal and Installation of Cab Inner and Outer Parts Removal and Installation of Wiper Motor Items to prepare • Hexagon wrench (4 mm) • Wrenches (10 mm, 17 mm) • Box wrench (10 mm) • Flathead screwdriver (longnose pliers) • Phillips screwdriver

1. Removal of Wiper Motor [1] Use a wrench (10 mm) to remove the 3 bolts (1), and then remove the side lower trim (2).

[2] Use a flathead screwdriver or longnose pliers to remove the clip pins (3), and then remove ducts B (4).

1

458

Bolt

2

Side lower trim

3

Clip pin

4

Duct B

RSM-13-17-001E 15

Procedures for Removal and Installation of Cab Inner and Outer Parts [3] Use a Phillips screwdriver or box wrench (10 mm) to remove the 3 bolts (5). Use a hexagon wrench (4 mm) to remove the 3 bolts (6). Remove the front upper trim assembly (7).

[4] Lift the front upper trim assembly (7), and then remove the connector (8).

[5] Remove the connector (9).

RSM-13-17-001E

5

Bolt

6

Bolt

7

Front upper trim

8

Connector

9

Connector

459 16

Procedures for Removal and Installation of Cab Inner and Outer Parts [6] Use a wrench (10 mm) to remove the 3 bolts (10), and then remove the cover (11).

[7] Use a wrench (17 mm) to remove the nut (12), and then remove the wiper arm (13).

[8] Use a wrench (17 mm) to remove the nut (14).

460

10

Bolt

11

Cover

12

Nut

13

Wiper arm

14

Nut

RSM-13-17-001E 17

Procedures for Removal and Installation of Cab Inner and Outer Parts [9] Use a box wrench (10 mm) to remove the 2 bolts (15) and 2 nuts (16), and then remove the wiper motor assembly (17).

15

Bolt

16

Nut

17

Wiper motor

2. Installation of Wiper Motor To install, perform the reverse of the removal procedure. • Be careful about the wiper link and wiper arm installation location. • Check the wiper arm wipe location and stop location.

RSM-13-17-001E

461 18

Procedures for Removal and Installation of Cab Inner and Outer Parts Removal and Installation of Monitor Items to prepare • Wrench (10 mm) [1] Use a wrench (10 mm) to remove the bolt (1) on the monitor (2).

[2] Lift the monitor main unit (2), and then remove the connector (3) underneath.

462

1

Bolt

2

Monitor

3

Connector

RSM-13-17-001E 19

Procedures for Removal and Installation of Cab Inner and Outer Parts Removal and Installation of Cab Front Glass Caution

Reinforced glass is used for the front window. Be extremely careful not to damage it when touching it during removal or installation.

Items to prepare • Wrench (10 mm) • Rag • Cleaning fluid [1] Use a wrench (10 mm) to remove the 2 bolts (1) each, and then remove the brackets (2) and (3).

[2] Remove the covers (4) and (5) for the bracket.

1 2 3 4 5

RSM-13-17-001E

Bolt Bracket Bracket Cover Cover

463 20

Procedures for Removal and Installation of Cab Inner and Outer Parts [3] Use a wrench (10 mm) to remove the 3 bolts (6), and then remove the front glass left lower bracket (7).

[4] Use a wrench (10 mm) to remove the 3 bolts (8), and then remove the front glass right lower bracket (9).

[5] Move the front glass right upper bracket (11) to a position where the wire (10) is not pulled on.

464

6

Bolt

7

Bracket

8

Bolt

9

Bracket

10

Wire

11

Bracket

RSM-13-17-001E 21

Procedures for Removal and Installation of Cab Inner and Outer Parts [6] Remove the cab front glass (12).

12

RSM-13-17-001E

Cab front glass

465 22

Procedures for Removal and Installation of Cab Inner and Outer Parts Procedure for Window Lock Adjustment Items to prepare • Wrench (10 mm) • Rag • Cleaning fluid [1] Remove the cover (1).

[2] Use a wrench (10 mm) to remove the 3 bolts (2).

[3] Set the cab front glass (3) in place.

466

1

Cover

2

Bolt

3

Cab front glass

RSM-13-17-001E 23

Procedures for Removal and Installation of Cab Inner and Outer Parts [4] Use a wrench (10 mm) to retighten the 3 bolts (2).

2

RSM-13-17-001E

Bolt

467 24

Hydraulic Equipment-related Parts Hydraulic Equipment-related Parts

SH200-5

Hydraulic Equipment-related Parts Accumulator Warning ・ Be sure to release the hydraulic pressure in the circuits.

Items to prepare • Wrench (30 mm) • Rag • Cleaning fluid [1] Use a wrench (30 mm) to remove the accumulator (1).

1

468

Accumulator

RSM-13-18-001E 1

Hydraulic Equipment-related Parts Suction Filter Caution

・ Be careful to keep dirt, water, sand, and all other foreign matter out of the tank. ・ When replacing the hydraulic oil, always replace with new oil.

Items to prepare • Wrench (17 mm) • Rag • Cleaning fluid [1] Press the air breather button (1) on top of the hydraulic oil tank to release the pressure inside the tank.

[2] Use a wrench (17 mm) to remove the 4 bolts (2), and then remove the feed port cover (3). [3] Drain the oil from the hydraulic oil tank. (For details, see "Draining Oil from Hydraulic Oil Tank".)

[4] Remove the O-ring (4).

RSM-13-18-001E

1

Air breather button

2

Bolt

3

Cover

4

O-ring

469 2

Hydraulic Equipment-related Parts [5] Remove the suction filter (5).

[6] Clean the suction filter (5) with clean cleaning fluid, dry it well, and then inspect it. If there is any damage on the surface, replace the suction filter with a new one. • If the O-ring on the rear of the cover is worn or damaged, replace it. • To install, perform the reverse of the removal procedure. • Always replace the suction filter with a new one every 5000 hr. and when replacing the hydraulic oil.

5

470

Suction filter

RSM-13-18-001E 3

Hydraulic Equipment-related Parts Return Filter Caution

・ Be careful to keep dirt, water, sand, and all other foreign matter out of the tank. ・ When replacing the hydraulic oil, always replace with new oil.

Items to prepare • Wrench (17 mm) • Rag • Cleaning fluid [1] Press the air breather button (1) on top of the hydraulic oil tank to release the pressure inside the tank.

[2] Use a wrench (17 mm) to remove the 4 bolts (2), and then remove the cover (3). • There is a spring inside the cover, so restrain the spring by hand and remove the cover.

RSM-13-18-001E

1

Air breather button

2

Bolt

3

Cover

471 4

Hydraulic Equipment-related Parts [3] Remove the O-ring (4). Take the spring (5) and valve (6) out from the tank.

[4] Take the return filter (7) out from the tank and replace it. • If the O-ring on the rear of the cover is worn or damaged, replace it. • To install, perform the reverse of the removal procedure.

472

4

O-ring

5

Spring

6

Valve

7

Return filter

RSM-13-18-001E 5

Hydraulic Equipment-related Parts Pilot Filter Warning ・ Be sure to release the hydraulic pressure in the circuits.

Items to prepare • Wrench (19 mm) • Rag • Cleaning fluid [1] Use a wrench (19 mm) to remove the pilot filter (1).

1

RSM-13-18-001E

Pilot filter

473 6

Other Other

SH200-5

Other Removal and Installation of Side Door Items to prepare • Wrench (19 mm) [1] Use a wrench (19 mm) to remove the 4 bolts (1), and then remove the side door (left front) (2).

[2] Use a wrench (19 mm) to remove the 4 bolts (1), and then remove the side door (left rear) (3).

[3] Use a wrench (19 mm) to remove the 4 bolts (1), and then remove the side door (right) (4).

474

1

Bolt

2

Side door (left front)

3

Side door (left rear)

4

Side door (right)

RSM-13-19-001E 1

Other Draining Oil from Hydraulic Oil Tank ・ Keep away from fire. ・ Be sure to stop the engine before beginning work. Warning ・ The temperature of the hydraulic oil is high immediately after stopping the engine. Wait until the hydraulic oil temperature has decreased (to 40 ℃ or less) before beginning work.

Items to prepare • Wrenches (17 mm, 19 mm, 36 mm) • Feed pump (power source for feed pump) • Extension cable • Waste oil tank • Waste oil can • Rag • Cleaning fluid [1] Press the air breather button (1) on top of the hydraulic oil tank to bleed off the pressure in the tank.

[2] Use a wrench (17 mm) to remove the 4 bolts (2), and then remove the feed port cover (3).

RSM-13-19-001E

1

Air breather button

2

Bolt

3

Cover

475 2

Other [3] Insert the feed pump (4) into the feed port.

[4] Transfer the oil inside the hydraulic oil tank to the waste oil tank (5).

[5] Use a wrench (19 mm) to remove the 6 bolts (6), and then remove the under cover (7).

476

4

Feed pump

5

Waste oil tank

6

Bolt

7

Under cover

RSM-13-19-001E 3

Other [6] Prepare a waste oil can (8) under the hydraulic oil tank.

[7] Use a wrench (36 mm) to remove the drain plug (9).

[8] Drain any remaining oil that has settled at the bottom of the hydraulic oil tank.

RSM-13-19-001E

8

Waste oil can

9

Plug

477 4