HITACHI EX5500 EXCAVATOR Service Repair Manual PDF

EX5500
Workshop Manual
SECTION 1
GENERAL INFORMATION
—CONTENTS—
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling........................................... W1-1-1
Group 2 Tightening
Torque Specification ............................... W1-2-1
Torque Chart .......................................... W1-2-2
Piping joint ............................................. W1-2-5
118W-1-1
(Blank)
118W-1-2
GENERAL INFORMATION / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Preparations for Disassembling Precautions for Disassembling and Assembling
• Clean the Machine • Precautions for Disassembling
Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop may removed pipes.
cause machine components to be contaminated • Before disassembling, clean the exterior of the
during disassembling/assembling, resulting in components and place it on a work bench.
damage to machine components, as well as • Before disassembling, drain gear oil from the
decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all disassem- instructed.
bling/assembling procedures beforehand, to help • If a part or component cannot be removed after
avoid incorrect disassembling of components as well removing its securing nuts and bolts, do not
as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if any. disassembled parts for abnormal wear, sticking,
• Capacities and condition of lubricants. or other damage.
• Loose or damaged parts. • Measure and record the degree of wear and
clearances.
• Prepare and Clean Tools and Disassembly Area
• Precautions for Assembling
Prepare the necessary tools to be used and the area
for disassembling work. • Be sure to clean all parts and inspect them for any
damage. If any damage is found, repair or replace
it.
• Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding
surfaces.
• Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassembled.
Apply a film of grease before installing.
• Be sure that liquid-gasket-applied surfaces are
clean and dry.
• If an anti-corrosive agent has been used on a new
part, be sure to thoroughly clean the part to
remove the agent.
• Utilize matching marks when assembling.
• Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
• Keep a record of the number of tools used for
disassembly/assembly. After assembling is
complete, count the number of tools, so as to
make sure that no tools are missing.
W1-1-1
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the

suction lines are replaced, or the removal and
installation of the pump, swing motor, travel motor or
cylinder is done, bleed air from the hydraulic system
in the following procedures:
• Bleeding Air from Hydraulic Pump
IMPORTANT: If the engine is started with air

trapped in the hydraulic pump
housing, damage to the pump may
result. Be sure to bleed air before
starting the engine.
• Remove the air bleeding plug from the top of the

pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the
engine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the pump
housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the plug.
• Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic
oil.
• Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each
operation (never fully stroke the cylinders during
initial operation stage). As the pilot oil circuit has
an air bleed device, air trapped in the pilot oil
circuit will be bled while performing the above
operation for approx. 5 minutes.
• Reposition the front attachment to check hydraulic
oil level.
• Stop the engine. Recheck hydraulic oil level.
Replenish oil as necessary.
M104-07-021
W1-1-2
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one.
If the floating is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of
cardboard to protect surfaces.
(2) Check the seal ring face (A) for scuffing, B

scoring, corrosion, deformation or uneven
wear. W105-03-05-019
(3) Check O-ring (B) for tears, breaks, deformation

or hardening.
2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.
(1) Clean the floating seal and seal mounting

bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with Correct
compressed air.
(2) Clean the floating seal and seal mounting Incorrect

bores, as dust on them tends to enter the
floating seal when installing it.
(3) Check that the O-ring is not twisted, and that it

is installed correctly on the seal ring. Correct Incorrect
W105-03-05-020
C
(4) After installing the floating seal, check that seal
a a
ring surface (A) is parallel with idler face (C) by
measuring the distances seal ring surface (A) A
and idler face (C) at point (a) and (b), as
illustrated. If these distances differ, correct the B
O-ring seating.
b b
a=b aҐb
W110-03-05-004
W1-1-3
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings

safely.
• Attach protectors (soft material) on the corners of Correct Eyehole
the load so that the nylon sling does not directly Lifting Method
contact the corners. This will prevent the nylon
sling from damage and the lifted load from slip-
ping.
• Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load
with a temperature of 100 °C (212 °F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
slings with the same width and length to keep the W102-04-02-016
lifted load balanced. Incorrect Eyehole

• When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load. W105-04-01-008
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or hitched
slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions. Bent Sling W162-01-01-009
• Avoid dragging slings on the ground, throwing
slings or pushing slings with a metal piece.
• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.
W1-1-4
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-5
Maintenance Standard Terminology
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of components or assemblies adjusted
to specification. Tolerances are indicated as nec-
essary.
“Allowable Limit”
1. Machine cannot operate normally with the parts
exceeding this dimension installed.
2. Repair or adjustment is impossible if this dimen-
sion is exceeded.
3. To maintain high machine availability and to save
the repair expense, the machine parts should be
repaired or replaced before reaching the
“Allowable Limit.”
Ȁ
W1-1-6
GENERAL INFORMATION / Tightening Torque
TIGHTENING TORQUE SPECIFICATIONS
Wrench Torque
Bolt Dia
Descriptions Qty Size
(mm) N⋅m kgf⋅m lbf⋅ft
(mm)
1 Engine cushion rubber mounting bolt 36 12 55 3140 320 2310
2 Engine bracket mounting bolt 30 24 46 1420 145 1050
22 8 36 740 75 540
UNC 3/4 32 28.6 440 45 330
3 Hydraulic oil tank mounting bolt 36 10 55 2400 245 1770
4 Fuel tank mounting bolt 36 22 55 2400 245 1770
5 Pump transmission mounting bolt UNC 1/2 32 19 118 12 87
6 Pump device mounting bolt 24 24 36 690 70 510
7 Fan drive pump mounting bolt 20 8 30 390 40 290
8 Gear pump mounting bolt 12 8 19 88 9 65
9 Control valve mounting nut 20 24 30 390 40 290
10 Swing device mounting bolt 36 56 55 3140 320 2310
11 Swing motor mounting bolt 20 16 30 390 40 290
12 Battery mounting bolt 10 24 17 49 5 36
13 Cab mounting bolt 18 8 27 295 30 215
14 Cab bed mounting bolt 12 50 19 88 9 65
15 Swing bearing mounting bolt 56 142 85 9800 1000 7230
16 Counterweight mounting nut 56 14 85 6860 700 5060
17 Engine bed mounting bolt 36 84 55 3140 320 2310
18 Oil cooler mounting bolt 27 8 41 1370 140 1010
19 Radiator mounting nut 27 8 41 1370 140 1010
20 Fan motor housing mounting bolt 16 8 24 205 21 152
21 Fan motor bracket mounting bolt 12 12 19 88 9 65
22 Travel device mounting bolt 36 24 55 3140 320 2310
56 56 85 9800 1000 7230
24 40 36 690 70 510
20 46 30 390 40 290
23 Travel motor mounting bolt 22 16 32 740 75 540
24 Upper roller mounting bolt 30 24 46 1910 195 1410
25 Lower roller mounting bolt 56 56 85 9800 1000 7230
26 Track pin-retaining bolt 30 156 46 1910 195 1410
27 Side frame mounting bolt 64 80 95 14700 1500 10850
28 Track guard mounting bolt 45 22 70 4710 480 3470
24 48 36 690 70 510
29 Travel motor cover mounting bolt 36 30 55 3140 320 2310
(backhoe)
30 Front pin lock bolt 24 36 36 930 95 690
(loading shovel) 20 8 30 390 40 290
27 10 19 1030 105 760
(Hexagon
bar wrench)
31 Front pin lock bolt (backhoe) 24 20 36 930 95 690
20 22 30 390 40 290
NOTE: 1. Apply lubricant (e.g.white zinc B dis- 3. Apply loctite to threads of engine cush-
solved into spindle oil)to bolts and nuts ion rubber mounting bolts, and lower
to stabilize friction coefficient of them. roller mounting bolts before installing.
2. Make sure bolt and nut threads are
clean before installing.
W1-2-1
TORQUE CHART
CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and proce-
dures can create safety hazards. For loosen-
ing and tightening nuts and bolts, use correct
size tools. Otherwise, tightening tools may
slip, potentially causing personal injury.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.

Four different types and grades of bolt are employed.
Make sure to employ correct bolts and tighten them SA-040
correctly when assembling the machine or compo-

nents.
Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt
W162-01-01-001
Specified Tightening Torque Chart

Hexagon T Bolt, Socket Bolt H Bolt M Bolt
Bolt Wrench
Wrench
Dia. Size N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft
Size
M 8 13 6 29.5 3 22 19.5 2 14.5 9.8 1 7.2
M 10 17 8 64 6.5 47 49 5 36 19.5 2 14.5
M 12 19 10 108 11 80 88 9 65 34 3.5 25.5
M 14 22 12 175 18 130 137 14 101 54 5.5 40
M 16 24 14 265 27 195 205 21 152 78 8 58
M 18 27 14 390 40 290 295 30 220 118 12 87
M 20 30 17 540 55 400 390 40 290 167 17 123
M 22 32 17 740 75 540 540 55 400 215 22 159
M 24 36 19 930 95 690 690 70 505 275 28 205
M 27 41 19 1370 140 1010 1030 105 760 390 40 290
M 30 46 22 1910 195 1410 1420 145 1050 540 55 400
M 33 50 24 2550 260 1880 1910 195 1410 740 75 540
M 36 55 27 3140 320 2310 2400 245 1770 930 95 690
W1-2-2
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to nuts
and bolts to reduce their friction
coefficients.
The plated bolts require no lubri-
cant.
2. Torque tolerance is Ѱ 10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts that
are too short cannot develop suf-
ficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them alter-

nately, as shown, to ensure even tightening.
Tighten from center and diagonally
Equally tighten upper and lower alternately Tighten diagonally
1 12 9 4 1 6 7 14
6 3
1st to 4th
4 5
2 13 8 5 2 3 10 11
2nd to 3rd
W105-01-01-003
W1-2-3
GENERAL INFORMATION / Tightening
Service Recommendations for Split Flange
IMPORTANT: (1) Be sure to clean and inspect

sealing surfaces. Scratches /
roughness cause leaks and seal
wear. Unevenness causes seal
extrusion. If defects cannot be
polished out, replace the
component.
(2) Be sure to use only specified O- W105-01-01-015
rings. Inspect O-rings for any WRONG

damage. Take care not to file O-
ring surfaces. When installing an
O-ring into a groove, use grease
to hold it in place.
(3) Loosely assemble split flange
halves. Make sure that the split is
centrally located and
perpendicular to the port. Hand- W105-01-01-016
tighten the bolts to hold the parts

in place. Take care not to pinch
the O-ring.
(4) Tighten bolts alternately and
diagonally, as shown, to ensure
even tightening.
(5) Do not use air wrenches. Using
an air wrench often causes
W105-01-01-008
tightening of one bolt fully before
RIGHT WRONG
tighten the others, resulting in
damage to O-rings or uneven
tightening of bolts.
Bend along edge sharply Do not bend it round

Nut and Bolt Lockings
RIGHT RIGHT WRONG
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
Bend along edge sharply

W105-01-01-009
• Cotter Pin RIGHT RIGHT WRONG

IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while
tightening, not while loosening.
• Lock Wire RIGHT Loosen WRONG

IMPORTANT: Apply wire to bolts in the bolt-
tightening direction, not in the bolt- Tighten
loosening direction.
W105-01-01-010
W1-2-4
PIPING JOINT 1 4 3 5 2
IMPORTANT: The torques given in the chart are

for general use only.
Do not use these torques if a
different torque is given for a
specific application.
Joint Body
Pipe Thread Connection / Union Joint Tightening M202-07-051
Torque Specifications
30° or 37°
Union Joint
30° or 37°
Metal sealing faces (4) and (5) of adaptor (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
Male Union Joint Female Union Joint
IMPORTANT: (1) Do not over-tighten union nut (3). W105-01-01-017
Excessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adaptor (1). Be
sure to tighten union nut (3) to
specifications.
(2) Scratches or other damage to

sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them
when connecting /disconnecting.
Wrench Size Tightening Torque

Type
Union Nut Joint Body N⋅m (kgf⋅m) Ibf⋅ft
30° Male Union 19 19 59 (6) 43
Joint 22 22 98 (10) 72
27 27 118 (12) 87
36 36 235 (24) 134
41 41 295 (30) 215
50 50 490 (50) 360
60 60 670 (68) 490
70 70 980 (100) 720
37° Female Union 19 17 44 (4.5) 32.5
Joint 22 19 59 (6) 43
27 22 118 (12) 87
36 30, 32 235 (24) 134
41 36 295 (30) 215
50 46 490 (50) 360
NOTE: Tightening torque for the non-union type 37 ° male joint is the same as the 37 °
female union joint.
W1-2-5
O-Ring Seal Joint
7 6 9
O-ring (6) seats against the end face of adaptor (7) to
seal pressure oil.
IMPORTANT: (1) Be sure to replace O-ring (6) with

a new one when reconnecting.
(2) Before tightening union nut (9),

confirm that O-ring (6) is seated
Joint Body
correctly in O-ring groove (8). 8 10
Tightening union nut (9) with O- M104-07-033
ring (6) displaced will damage O-
ring (6), resulting in oil leakage.
Wrench Size Tightening Torque
(3) Take care not to damage O-ring Union Nut Joint Body N⋅m (kgf⋅m) Ibf⋅ft
groove (8) or sealing face (10). 19 17 59 (6) 43
Damage to O-ring (6) will cause 22 19 98 (10) 72
oil leakage. 27 22 118 (12) 87
36 30, 32 235 (24) 134
(4) If union nut (9) is found to be
loose, causing oil leakage, do not 41 36 295 (30) 215
tighten it to stop the leak. Instead, 50 46 490 (50) 360
replace O-ring (6) with a new one,
then tighten union nut (9) after
confirming that O-ring (6) is
securely seated in place.
W1-2-6
Screwed-In Connection
PT PF
IMPORTANT: Many types of screwed-in connec-
tions are used for hose connections.
30°
Be sure to confirm that the thread
pitch and thread type (tapered or
straight) are the correct type before
using any screw-in connection.
Male Tapered Thread Male Straight Thread
W105-01-01-018
Male Tapered Thread

Wrench Tightening Torque
Joint Body N⋅m (kgf⋅m) Ibf⋅ft
17, 19 59 (6) 43
19, 22 98 (10) 72
Seal Tape Application 27, 22 118 (12) 87
Seal tape is used to seal clearances between male 36, 32 235 (24) 134
and female threads, so as to prevent any leakage 41 295 (30) 215
between threads. 50 490 (50) 360
Be sure to apply just enough seal tape to fill up thread 60 670 (68) 490
clearances. Do not overwrap. 70 980 (100) 720
Internal Thread
• Application Procedure
Confirm that the thread surface is clean, free of dirt

or damage. External Thread Clearance
Apply seal tape around threads as shown. Wrap
seal tape in the same direction as the threads. W105-01-01-019
Leave one to two pitch threads uncovered
Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs
depending on the type of clamp.
See below for correct tightening torque of each type
of low-pressure-hose clamp.
M114-07-041
T-Bolt Type Band Clamp: T-Bolt Type Worm Gear Type

4.4 N⋅m (0.45 kgf⋅m, 3.25 lbf⋅ft )
Worm Gear Type Band Clamp:
5.9 to 6.9 N⋅m (0.6 to 0.7 kgf⋅m, 4.3 to 5.1 lbf⋅ft )
M114-07-042 M114-07-043
W1-2-7
Connecting Hose
CAUTION: WRONG RIGHT
(1) When replacing hoses, be sure to use
only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses
may cause oil leakage, hose rupture or
separation of fitting, possibly resulting in
a fire on the machine.
(2) Do not install hoses kinked. Application
of high oil pressure, vibration, or an
impact to a kinked hose may result in oil
leakage, hose rupture or separation of W105-01-01-011
fitting. Utilize print marks on hoses when
installing hoses to prevent hose from
being installed kinked.
(3) If hoses rub against each other, wear to WRONG RIGHT
the hoses will result, leading to hose Rubbing Against
rupture. Take necessary measures to Each Other
protect hoses from rubbing against each
other.
Take care that hoses do not come into
contact with moving parts or sharp
objects.
W105-01-01-012
WRONG RIGHT
Clamp Clamp
Rubbing
W105-01-01-013
WRONG RIGHT
Rubbing
Clamp
W105-01-01-014
W1-2-8
* REFEREVCE: Major Parts to Be Replaced at
Regular Intervals.
The parts listed below deteriorate as the machine Therefore, these parts should be replaced at regular
ages and are worn out or fatigued by repeated loads, intervals even if no abnormalities are noticed. In case
resulting in possible severe personal injury and/or any abnormalities are found on a part at any time re-
machine trouble. The service life of these parts can gardless of its specified replacement interval, imme-
not be detected through machine operation or visual diately replace the part.
inspection.
Periodic Replacement Parts Replacement Intervals
Fuel hose (Fuel tank to filter) Every 2 years

Engine Fuel hose (Fuel tank to injection pump) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years
Basic Machine
Pump delivery hose Every 2 years
Hydraulic
Motor line hose Every 2 years
System Front-End
Cylinder line hose Every 2 years
Attachment
Pilot hose Every 2 years
IMPORTANT: Be sure to replace seals, such as O-

rings and hose clamp along with re-
placing hoses. Each hose has an in-
dividual service life. If any abnor-
malities are found during the regular
interval check and/or maintenance
service, be sure to replace with a
new one.
W1-2-9
(Blank)
W1-2-10
SECTION 2
UPPERSTRUCTURE
—CONTENTS—
Group 1 Cab Group 4 Swing Device
Windowpane Dimension ......................... W2-1-1 Remove and Install Swing Device........... W2-4-1
Disassemble Swing Device..................... W2-4-4
Group 2 Pump Device Assemble Swing Device ......................... W2-4-8
Remove and Install Pump Device ........... W2-2-1 Disassemble Swing Motor .................... W2-4-12
Disassemble Pump Transmission........... W2-2-8 Assemble Swing Motor ......................... W2-4-14
Assemble Pump Transmission ............. W2-2-10 Maintenance Standard.......................... W2-4-18
Disassemble Main Pump ...................... W2-2-12 Valve Unit Construction ........................ W2-4-20
Assemble Main Pump........................... W2-2-18
Maintenance Standard ......................... W2-2-20 Group 5 Pilot Valve
Disassemble Main Pump Regulator ...... W2-2-22 Remove and Install
Assemble Main Pump Regulator........... W2-2-28 Front/Swing Pilot Valve ......................... W2-5-1
Disassemble Oil Cooler Fan Remove and Install Travel and
Drive Pump ........................................ W2-2-36 Bucket Open/Close Pilot Valve.............. W2-5-3
Assemble Oil Cooler Fan Pilot Port Connections ............................ W2-5-5
Drive Pump ........................................ W2-2-38 Front/Swing Pilot Valve Construction ...... W2-5-6
Maintenace Standard ........................... W2-2-40 Travel and Bucket Open/Close
Disassemble Oil Cooler Fan Pilot Valve Construction ........................ W2-5-8
Drive Pump Regulator ........................ W2-2-42
Assemble Oil Cooler Fan Group 6 DQR Valve
Drive Pump Regulator ........................ W2-2-46 Remove and Install DQR Valve............... W2-6-1
DQR Valve Construction ......................... W2-6-4
Group 3 Control Valve
Remove and Install Control Valve ........... W2-3-1
Disassemble Control Valve ..................... W2-3-4 Group 7 Pilot Shut-Off Valve
Assemble Control Valve ....................... W2-3-12 Remove and Install
Pilot Shut-off Valve ............................... W2-7-1
Disassemble Pilot Shut-off Valve ............ W2-7-4
Assemble Pilot Shut-off Valve................. W2-7-6
118W-2-1
Group 8 Solenoid Valve
Remove and Install Solenoid Valve......... W2-8-1
Solenoid Valve Construction ................... W2-8-4
Group 9 Oil Cooler Fan Motor

Remove and Install
Oil Cooler Fan Motor ............................ W2-9-1
Disassemble
Oil Cooler Fan Motor ............................ W2-9-4
Assemble Oil Cooler Fan Motor .............. W2-9-6
Maintenance Standard ........................... W2-9-8
Group 10 Compressor Drive Motor

Remove and Install Compressor
Drive Motor......................................... W2-10-1
Disassemble Compressor
Drive Motor......................................... W2-10-4
Assemble Compressor
Drive Motor......................................... W2-10-6
Group 11 Air Conditioner

Work after Component
Replacement .......................................W2-11-1
Add Compressor Oil ..............................W2-11-1
Charge Air Conditioner with
Refrigerant ..........................................W2-11-2
118W-2-2
UPPERSTRUCTURE / Cab
WINDOWPANE DIMENSION
Unit: mm
Material: JIS R 3211, ANSI AS2, ECE ANNEX5 or equivalent
NOTE: 1 mm = 0.03937 in
1378±1.5
1 6
4-R91
7
1
Laminated glass
Color : Transparent
1679+2.0 -0 Thickness : 10 mm
Chamfer all fringe Corners
2
5
3
4
W117-02-01-001
W117-02-01-002
1369±1.5
4-R61
4-R61
2
3
Tempered glass
Color : Bronze Tempered glass
Thickness : 6 mm Color : Bronze
769±1.0 Thickness : 5 mm
Chamfer all fringe
917±1.0 Corners
W117-02-01-004
1256±1.5 433±1.0
W117-02-01-003
W2-1-1
UPPERSTRUCTURE / Cab
NOTE: 1 mm = 0.03937 in
422±1.0
4-R61 4-R61
4 5
Tempered glass Tempered glass
Color : Bronze Color : Bronze
934±1.0 Thickness : 5 mm 777±1.0 Thickness : 5 mm
Chamfer all fringe Corners Chamfer all fringe Corners
W117-02-01-006
514±1.0
W117-02-01-005
1400±1.0 667±1.0
4-R61
7
4-R61
Tempered glass
6 Color : Bronze
Tempered glass Thickness : 5 mm
Color : Bronze 645±1.0
Chamfer all fringe
848±1.0 Thickness : 6 mm Corners
185 403±1.0
W117-02-01-008
1296±1.0
W117-02-01-007
W2-1-2
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
1
CAUTION: 1. Escaping fluid under pressure
can penetrate the skin and
eyes,causing serious injury.
Avoid this hazard by relieving
pressure before disconnecting
hydraulic or other lines.
2. Hydraulic oil may be hot just
after operation. Hot hydraulic
oil may spout, possibly
causing severe burns. Be sure
to wait for oil to cool before
starting work.
3. Do not quickly loosen the air
breather cap on the hydraulic
oil tank. The air breather cap
may fly off due to internal
pressure. Always turn the air
2
breather cap slowly to release
any remaining pressure before 3 W118-02-03-018
removing it. 1
Port
Preparation:
4
1. Park the machine on a level solid surface. Lower
the front attachment to the ground.
2. Stop the engine. Turn the air breather cap on the

hydraulic oil tank approximately 30° counter-
clockwise to release any remaining pressure.
3. Close all hydraulic line stop valves.
4. Remove socket bolt (2) from one hydraulic tank

air breather cap to remove air breather cap (1).
Remove filter (3). Wind an adhesive tape around
bayonet assembly (4) approx. one and half turns
so that the port is plugged. Reinstall filter (3) and W118-02-05-001
air breather cap (1) to the original position.
4. Remove another side air breather cap (1). Con-

nect a vacuum pump. Operate the vacuum pump
continuously to create negative pressure in the
hydraulic oil tank.
NOTE: Keep the vacuum pump running continu- T142-05-03-007
ously while working on the hydraulic sys-

tem.
IMPORTANT: After completing the work, be sure

to remove the adhesive tape from
bayonet assembly (4).
T142-05-03-008
W2-2-1
DISASSEMBLE MAIN PUMP REGULATOR
13
12
11
10
9
8
7
6
5
4 22 32
3 23 31
2 24 30
1 25 29
20 26
19 21
18 27
17
16
15 28 62
14 61
33 60
34 35 59
58
36 57
56
55
54
43 53
40 74
42 41 39 75
38 76
37 73
48 51 72
46 71
45 47 70
44 52
69
68
67 78
49 50 77
66
Serial Number 79
000105 and later
80
81
63 98 82
83
64 97 84
65
85
96 89
95 91 86
90
92 87
93 88
94
62
61
60
59
58
57
56
55
54
49
48
47
53
Serial Number 50
from 000101 to 000104 45
46
99
44 W118-02-02-009
W2-2-22
1- Pin 26 - Lever 51 - O-Ring 76 - Lock Nut

2- Sleeve 27 - Pin 52 - Pin 77 - Adjusting Screw
3- O-Ring 28 - Pilot Piston 53 - Cover 78 - Lock Nut
4- O-Ring 29 - Spring Seat 54 - Spring Seat 79 - Socket Bolt (4 Used)
5- Sleeve 30 - Spring 55 - Spring 80 - Casing
6- Compensating Piston 31 - Spring Seat 56 - Spring 81 - Pin
7- Compensating Rod 32 - O-Ring 57 - Spring Seat 82 - Support Plug
8- Spring Seat 33 - Socket Bolt (4 Used) 58 - O-Ring 83 - O-Ring
9- Spring 34 - Cover 59 - Cover 84 - Lock Ring
10 - Spring 35 - Cover 60 - Socket Bolt (2 Used) 85 - Pin
11 - Piston 36 - O-Ring 61 - Lock Nut 86 - Support Plug
12 - Spring Seat 37 - Stopper 62 - Adjusting Screw 87 - O-Ring
13 - O-Ring 38 - Ball 63 - Cover 88 - Lock Ring
14 - Retaining Ring 39 - Seat 64 - Socket Bolt (2 Used) 89 - Pin
15 - Spring Seat 40 - O-Ring 65 - Socket Bolt (2 Used) 90 - O-Ring
16 - Spring 41 - O-Ring 66 - Socket Bolt (2 Used) 91 - Stopper
17 - Spring 42 - Plug 67 - Socket Bolt (2 Used) 92 - Ball
18 - Retaining Ring 43 - Plug 68 - O-Ring 93 - Seat
19 - Sleeve 44 - Nut 69 - O-Ring 94 - O-Ring
20 - Spool 45 - Screw 70 - Adjusting Screw 95 - O-Ring
21 - Pin 46 - O-Ring 71 - Adjusting Screw 96 - O-Ring
22 - Lever 47 - Sleeve 72 - Lock Nut 97 - O-Ring
23 - Feedback Lever 48 - Piston 73 - O-Ring 98 - Plug
24 - Pin 49 - Spool 74 - Plug 99 - Washer
25 - Pin 50 - Plug (2 Used) 75 - Cover
W2-2-23
13
12
11
10
9
8
6
5
32
31
2 30
1 29
17
61 62
33 60
34 35 59
58
36 57
56
55
54
53
40
39 75
38 76
37 72
48 51
46 71
45 47 70
44 52
67 78
49 77
66
Serial Number 79
000105 and later
80
63
64 97
65
96
95
62
61
60
59
58
57
56
55
54
49
48
47
53
Serial Number
from 000101 to 000104 45
46
44 W118-02-02-009
W2-2-24
Disassemble Main Pump Regulator
1. Remove socket bolts (66) and (67) to remove the 5. Remove socket bolts (79) from casing (80).
regulators. Remove cover (75), spring seat (12), piston (11),
spring (10), spring (9), spring seat (8), spring seat
: 6 mm (31), spring (30), and spring seat (29).
2. Remove socket bolts (33). Remove cover (34), IMPORTANT: Never attempt to remove adjusting
O-ring (40), cover (35), O-ring (36), cover (53), O- screw (70), lock nut (76), adjusting
ring (51), and pin (52). screw (71) and lock nut (72) from
cover (75). Setting for the power
: 5 mm reduce control and power increase
controls may be changed.
3. Remove stopper (37), ball (38), and seat (39) Also, never attempt to remove
from cover (35). adjusting screw (77) and lock nut
(78) from cover (75). Setting for the
4. Serial/No. Up to 000104: flow control may be altered.
Remove socket bolts (60) from cover (53).
Remove cover (59), O-ring (58), spring seat (57), : 5 mm
spring (56), spring (55), spring seat (54), spool
(49), piston (48) and sleeve (47). 6. Remove socket bolts (64) and (65) from casing
(80). Remove cover (63), O-rings (95), (96), and
Serial/No. 000105 and later: (97), spring (17), pin (1), sleeve (2), sleeve (5)
Remove socket bolts (60) from cover (53). and compensating piston (6).
Remove cover 59), O-ring (58), spring seat (57),
spring (56), spring (55) and spring seat (54). : 5 mm
Remove nut (44), screw (45), O-ring (46), piston
(48), spool (49) and sleeve (47) from cover (53).
IMPORTANT: Never attempt to remove lock nut

(61) and adjusting screw (62) from
cover (59). Setting for the relief oil
flow minimizing control may be
changed.
: 5 mm
W2-2-25
22
23
24
20 26
19 21
27
17
16
15 28
14
Serial Number
000105 and later 80
81
82
84
85
86
88
Serial Number
from 000101 to 000104
W118-02-02-009
W2-2-26
7. Remove retaining ring (14) to remove spring seat
(15), spring (16), spring (17), and sleeve (19).
8. Remove lock rings (84) and (88) from casing (80).

Remove support plugs (82) and (86) and pin (85)
using a M6 bolt.
9. Remove lever (26) from casing (80) with a pair of

tweezers.
IMPORTANT: Do not remove pin (27).
10. Remove pin (24) using a thin copper bar (less

than dia. 4). Remove feedback lever (23).
IMPORTANT: Take care not to hit pin (24) against

lever (22) when pulling it out.
11. Remove lever (22) from casing (80).
IMPORTANT: Do not remove pins(81) and (21)

when removing lever (22).
12. Remove pilot piston (28), spool (20), and

compensating rod (7) from casing (80).
W2-2-27
ASSEMBLE MAIN PUMP REGULATOR 79
A
51 36 37 38 39
C
33
40
A’ B C’ W117-02-02-004
Section A−B 53 35 34
16 18 19 20 24 81 22 8 9 11 82 83 84
73 68 74 69
97
17 10
75
15
76
14
3 70
1 72
2 71
86 87 88
4 6 5 7 23 21 90 89 12 13
W117-02-02-023
W117-02-02-007
Section A−A’ 63 80 28 85 25 26 27 30 31 32
64
78
96
65 77
29
W117-02-02-006
Section C-C Section C-C
(Serial Number from 000101 to 000104) (Serial Number 000105 and later)
53 59 60 46 53 59
46 50
44 44 60
61
45 45 61
62 62
99 48 47 49 54 55 56 57 58 48 47 49 54 55 56 57 58
W118-02-02-010
W118-02-02-011
W2-2-28
1- Pin 26 - Lever 51 - O-Ring 76 - Lock Nut

2- Sleeve 27 - Pin 52 - Pin 77 - Adjusting Screw
3- O-Ring 28 - Pilot Piston 53 - Cover 78 - Lock Nut
4- O-Ring 29 - Spring Seat 54 - Spring Seat 79 - Socket Bolt (4 Used)
5- Sleeve 30 - Spring 55 - Spring 80 - Casing
6- Compensating Piston 31 - Spring Seat 56 - Spring 81 - Pin
7- Compensating Rod 32 - O-Ring 57 - Spring Seat 82 - Support Plug
8- Spring Seat 33 - Socket Bolt (4 Used) 58 - O-Ring 83 - O-Ring
9- Spring 34 - Cover 59 - Cover 84 - Lock Ring
10 - Spring 35 - Cover 60 - Socket Bolt (2 Used) 85 - ∗ Pin
11 - Piston 36 - O-Ring 61 - Lock Nut 86 - Support Plug
12 - Spring Seat 37 - Stopper 62 - Adjusting Screw 87 - O-Ring
13 - O-Ring 38 - Ball 63 - Cover 88 - Lock Ring
14 - Retaining Ring 39 - Seat 64 - Socket Bolt (2 Used) 89 - Pin
15 - Spring Seat 40 - O-Ring 65 - Socket Bolt (2 Used) 90 - O-Ring
16 - Spring 41 - ∗ O-Ring 66 - Socket Bolt (2 Used) 91 - ∗ Stopper
17 - Spring 42 - ∗ Plug 67 - ∗ Socket Bolt (2 Used) 92 - ∗ Ball
18 - Retaining Ring 43 - ∗ Plug 68 - O-Ring 93 - ∗ Seat
19 - Sleeve 44 - Nut 69 - O-Ring 94 - ∗ O-Ring
20 - Spool 45 - Screw 70 - Adjusting Screw 95 - ∗ O-Ring
21 - Pin 46 - O-Ring 71 - Adjusting Screw 96 - O-Ring
22 - Lever 47 - Sleeve 72 - Lock Nut 97 - O-Ring
23 - Feedback Lever 48 - Piston 73 - O-Ring 98 - ∗ Plug
24 - Pin 49 - Spool 74 - Plug 99 - Washer
25 - Pin 50 - Plug (2 Used) 75 - Cover
NOTE: For the part names with mark ∗, see page

W2-2-22.
W2-2-29
A
C
A’ B C’ W117-02-02-004
Section A−B
16 19 20 24 22 82 83 84
97
17
15
14
3
1
86 87 88
4 6 5 7 23 21
W117-02-02-023
W117-02-02-007
Section A−A’ 63 80 28 85 26 27
64
96
65
W117-02-02-006
W118-02-02-010
W118-02-02-011
W2-2-30
Assemble Regulator
1. Install compensating rod (7) into casing (80). 8. Install spring (17), spring (16), spring seat (15),
and retaining ring (14) onto spool (20).
2. Attach pin (21) into the designated hole on lever
(22). Install lever (22) by inserting pin (21) into the 9. Install compensating piston (6), sleeve (5), O-ring
groove on compensating rod (7) and, at the same (4), O-ring (3), sleeve (2), and pin (85) into casing
time, by inserting pin (81), which is already (80).
attached on lever (22), into the designated hole on
casing (80). 10. Install O-rings (95), (96), and (97) onto casing
(80). Install cover (63) using socket bolts (64) and
3. Insert sleeve (19) and spool (20) into casing (80). (65).
IMPORTANT: Be sure to install spool (20) in the : 5 mm

correct direction. : 11.5 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
Also, confirm that spool (20) moves
smoothly in the casing.
4. Install feedback lever (23), aligning its pin hole

with that on spool (20). Insert pin (24) into the pin
hole.
IMPORTANT: Be sure to install feedback lever (23)

in the correct direction.
5. Insert pilot piston (28) into casing (80).
IMPORTANT: Confirm that pilot piston (28) moves

smoothly in casing (80).
6. Install lever (26) so that the lever attached pin (27)

fits in the groove on pilot piston (28). Install
support plug (86) so that pin (85) on the support
plug fits into the hole on lever (26). Install O-ring
(87) and lock ring (88) onto support plug (86).
7. Install adjusting plug (82), O-ring (83), and lock

ring (84) onto casing (80).
W2-2-31
79 51 36 37 38 39
A
C
33
40
A’ B C’ W117-02-02-004
Section A−B 53 35 34
8 9 10 11
75
12
W117-02-02-023
W117-02-02-007
Section A−A’ 80 30 31
29
W117-02-02-006
53 59 60 53 59
46
44 60
45
99 48 47 49 54 55 56 57 58 48 47 49 54 55 56 57 58
W118-02-02-010
W118-02-02-011
W2-2-32
11. Install spring seat (29), spring (30), and spring
seat (31) into casing (80).
12. Install spring seat (8), spring (9), and spring (10)
into casing (80).
13. Install spring seat (12) and seat (11) into cover
(75). Install cover (75) onto casing (80).
: 5 mm
: 11.5 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
14. Serial/Number Up to 000104:

Install sleeve (47), piston (48), spool (49), spring
seat (54), spring (55), spring (56), spring seat (57),
and O-ring (58) into cover (53). Install cover (59)
onto cover (53) using socket bolts (60).
Serial/Number 000105 or after:

Install spring seat (54), spring (55), spring (56),
spring seat (57), and O-ring (58) into cover (53).
Install cover (59) onto cover (53) using socket
bolts (60). Install sleeve (47), spool (49), piston
(48), O-ring (46), screw (45), washer (99), and nut
(44) int cover (53).
15. Install O-ring (36), O-ring (51) and pin (52) onto
cover (53). Install seat (39), ball (38), and stopper
(37) into cover (35). Install O-ring (40) onto cover
(35).
16. Assemble covers (53), (35), and (34). Install them

onto casing (80) using socket bolts (33).
: 5 mm
: 11.5 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
W2-2-33
(Blank)
W2-2-34
DISASSEMBLE AND ASSEMBLE 4-UNIT
PUMP
A B C D
T117-02-01-017
Left Engine
A- Oil Cooler Fan Drive Pump (Plunger Pump) C- Air Con. Compressor Drive Pump
(Tumdem Gar Pump: Tip End)
B- Pilot Pump (Tumdem Gear Pump: Transmission Side) D- Transmission Lubricating Pump (Gear Pump)
Right Engine
A- Oil Cooler Fan Drive Pump (Plunger Pump) C- Hydraulic Generator Drive Pump
B- Pilot Pump (Tumdem Gear Pump: Transmission Side) D- Transmission Lubricating Pump (Gear Pump)
W2-2-35
DISASSEMBLE OIL COOLER FAN DRIVE
PUMP 21
20 22
23
19 24
25
18 26
17
14 16
15
13
12 27
11 28
29
30
10
9
8 54
7
6 71 53
5
31 52
4
3 32 50 51
48 49
2
1 47
46
45 55
56
44
43
42
41 67 66
40
39 69 68
38 70
35 37 60
34 36
61
62
33 63
65 64
57
58
59
W118-02-02-007
1- Socket Bolt (4 Used) 19 - Displacement Angle Shift Pin 37 - Plunger (9 Used) 55 - O-Ring
2- Cover 20 - Regulator 38 - Retainer 56 - Coupling
3- O-Ring 21 - Socket Bolt (4 Used) 39 - Spherical Bushing 57 - Stopper
4- Oil Seal 22 - Stopper 40 - Spacer 58 - Steel Ball
5- Shaft 23 - Backup Ring 41 - Spring (9 Used) 59 - Seat
6- Spacer 24 - O-Ring 42 - Cylinder Block 60 - Plug
7- Bearing 25 - Servo Piston 43 - Valve Plate 61 - O-Ring (4 Used)
8- Spacer 26 - O-Ring 44 - Needle Bearing 62 - Casing
9- Retaining Ring 27 - O-Ring 45 - O-Ring 63 - Plug
10 - Cover 28 - Plug 46 - Stopper 64 - Socket Bolt
11 - Nut 29 - Lock Nut 47 - Steel Ball 65 - O-Ring
12 - Adjusting Screw 30 - Eye Bolt 48 - Seat 66 - Plug
13 - Spring 31 - Plug 49 - Valve Cover 67 - O-Ring
14 - O-Ring 32 - Socket Bolt (4 Used) 50 - Plug (3 Used) 68 - Plug
15 - Stopper 33 - Swash Plate 51 - Adjusting Screw 69 - Spring Pin (4 Used)
16 - Backup Ring 34 - Bushing 52 - Nut 70 - Pin
17 - O-Ring 35 - Shoe Plate 53 - Plate 71 - O-Ring (2 Used)
18 - Housing 36 - Shoe (9 Used) 54 - Socket Bolt (4 Used)
W2-2-36
Disassemble Oil Cooler Fan Drive Pump
IMPORTANT: Never attempt to remove adjusting 8. Tap on cover (10) using a plastic hammer to
screw (12), nut (11), adjusting screw remove it. Remove O-ring (14) and spring (13) at
(51) and nut (52). The set flow rate the same time.
may be changed.
9. Remove swash plate (33) and shoe plate (35)
1. Remove plug (68) and O-ring (67) to drain from housing (18).
hydraulic oil from the pump.
10. Remove stopper (15), stopper (22) and servo
: 36 mm piston (25) from housing (18).
2. Remove socket bolts (21) to remove regulator NOTE: As LOCTITE has been applied on the
(20). contacting part between servo piston (25)
and displacement angle shift pin (19), do
: 6 mm not separate them unless required.
3. Turn the housing (18) over so that the regulator 11. Tap on the end of shaft (5) using a plastic hammer
mounting side is on the bottom. Remove socket to remove it from cover (10).
bolts (54) (4 used) to remove plate (53), O-ring Remove oil seal (4) at the same time.
(55) and coupling (56).
12. Remove retaining ring (9), spacer (8), bearing (7),
: 10 mm and spacer (6) from shaft (5).
4. Remove socket bolts (32) to remove valve cover

(49) from housing (18).
IMPORTANT: Valve plate (43) may drop when

removing valve cover (49). Take care
not to drop valve plate (43).
5. Remove O-ring (45), stopper (46), steel ball (47),

seat (48), valve plate (43), pin (70), spring pin (69),
socket bolts (64), casing (62), stopper (57), steel
ball (58), and seat (59) from valve cover (49).
IMPORTANT: Do not remove needle bearing (44)

unless required.
6. Remove cylinder block (42), spring (41) (9 used),

spacer (40), spherical bushing (39), retainer (38),
plungers (37) (9 used), and shoes (36) from
housing (18).
7. Remove socket bolts (1) to remove cover (2) and

O-ring (3).
: 6 mm
W2-2-37
ASSEMBLE OIL COOLER FAN DRIVE
PUMP
17 24
16 15 35 25 33 19 18 34 22 23 45 43 52 51 53
10
11
12
13
14 54
6 55
56
4
2
3
32
W117-02-02-014
7 8 9 38 36 37 39 40 41 42 69 70 44 49
1 - Socket Bolt (4 Used) 19 - Displacement Angle Shift 37 - Plunger (9 Used) 55 - O-Ring

Pin
2- Cover 20 - ∗ Regulator 38 - Retainer 56 - Coupling
3- O-Ring 21 - ∗ Socket Bolt (4 Used) 39 - Spherical Bushing 57 - Stopper
4- Oil Seal 22 - Stopper 40 - Spacer 58 - Steel Ball
5- Shaft 23 - Backup Ring 41 - Spring (9 Used) 59 - Seat
6- Spacer 24 - O-Ring 42 - Cylinder Block 60 - Plug
7- Bearing 25 - Servo Piston 43 - Valve Plate 61 - O-Ring (4 Used)
8- Spacer 26 - O-Ring 44 - Needle Bearing 62 - Casing
9- Retaining Ring 27 - O-Ring 45 - O-Ring 63 - Plug
10 - Cover 28 - Plug 46 - Stopper 64 - Socket Bolt
11 - Nut 29 - Lock Nut 47 - Steel Ball 65 - O-Ring
12 - Adjusting Screw 30 - Eye Bolt 48 - Seat 66 - Plug
13 - Spring 31 - Plug 49 - Valve Cover 67 - O-Ring
14 - O-Ring 32 - Socket Bolt (4 Used) 50 - Plug (3 Used) 68 - Plug
15 - Stopper 33 - Swash Plate 51 - Adjusting Screw 69 - Spring Pin (4 Used)
16 - Backup Ring 34 - Bushing 52 - Nut 70 - Pin
17 - O-Ring 35 - Shoe Plate 53 - Plate 71 - O-Ring (2 Used)
18 - Housing 36 - Shoe (9 Used) 54 - Socket Bolt (4 Used)
NOTE: For the part names with mark ∗, see page

W2-2-36.
W2-2-38
Assemble Fan Drive Pump
1. Install displacement angle shift pin (19), servo 8. Install valve cover (49) onto housing (18) using
piston (25), stopper (22) and stopper (15) into socket bolts (32).
housing (18).
: 17 mm
2. If displacement angle shift pin (19) has been : 430 N⋅m (44 kgf⋅m, 320 lbf⋅ft)
separated from servo piston (25), apply LOCTITE
to the threaded part of servo piston (25). 9. Install coupling (56) onto shaft (5). Install O-ring
(55) and plate (53) onto valve cover (49) using
socket bolts (54).
3. Place housing (18) on a workbench with the : 10 mm

regulator mounting side on the bottom. Attach the : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
shoe plate (35) attached swash plate (33) to
displacement angle shift pin (19). 10. Install regulator (20) using socket bolts (21).
IMPORTANT: Check if swash plate (33) moves

smoothly after installing.
4. Install spacer (6), bearing (7), spacer (8), and

retaining ring (9) onto shaft (5). Install shaft (5)
into cover (10).
5. Install O-ring (3) onto cover (2). Install oil seal (4)
and cover (2) onto cover (10) using socket bolts
(1).
: 6 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
6. Install spring (41), spacer (40), spherical bushing

(39), retainer (38), plungers (37) and shoes (33)
into cylinder block (42). Install cylinder block (42)
onto shaft (5), aligning splines.
7. Install pin (70), valve plate (43), O-ring (45),

spring pin (69), stopper (46), steel ball (47), seat
(48), stopper (57), steel ball (58), seat (59), casing
(62), and socket bolt (64) onto valve cover (49).
W2-2-39
6
8
5
1 10
W118-02-02-005
1 - Bolt 4 - Lifting Bracket 7 - Step 9 - Engine
2 - Engine Bracket 5 - Bolt 8 - Pump Transmission 10 - Frame
3 - Engine Bracket Mounting 6 - Pump Transmission
Bolt Mounting Bolt
ȈRight Engineȉ (Left Engine)

Main Pump 3
12 (Transmission
Side)
Main Pump 4
(Outer Side)
Main Pump 9
(Transmission
Side)
Main Pump 10
(Outer Side)
11
Main Pump 11
(Transmission Main Pump 5
Side) (Transmission
Main Pump 7 Main Pump 12 Side)
(Outer Side) Main Pump 1
(Transmission (Transmission Main Pump 6
4-Unit Pump Side) 4-Unit Pump Side) (Outer Side)
Main Pump 8 T117-02-01-001 Main Pump 2 T117-02-01-001
(Outer Side) (Outer Side)
W2-2-2
Removal
1. Disconnect all hydraulic lines and electric wires

from the hydraulic pumps and transmission.
Wrench Size Remarks
2. Remove bolts (5) to remove step (7). ϖ17 mm Hydraulic Lines (Joint)
: 19 mm ϖ19 mm Hydraulic Lines
ϖ19 mm Bolts
IMPORTANT: Engine bracket (2) is installed on ϖ22 mm Hydraulic Lines (Joint)
pump transmission (8). Install sup-
ϖ27 mm Hydraulic Lines
porters (Width: 55 mm, Length: 130
ϖ30 mm Hydraulic Lines (Joint)
mm, Height: 650 mm) between en-
ϖ36 mm Hydraulic Lines
gine (9) and frame (10) when remov-
ing the pump transmission so that ϖ14 mm Socket Bolts
engine (9) does not fall.
3. Attach chains to lifting brackets (4) (2 used) and

straps around the main pumps to hold the pump
device with a crane.
CAUTION: Pump device weight: 2200 kg

(4850 lb)
4. Remove pump transmission mounting bolts (6)

and bolts (1), and engine bracket mounting bolts Wrench Size Remarks
(3). Lift to remove the pump device using a crane. ϖ3/4 inch Bolt (6)
ϖ28 mm Bolt (1)
CAUTION: Main pump weight: 300 kg ϖ55 mm Bolt (3)
(660 lb)
4-Unit pump weight: 100 kg
(220 lb)
5. Remove each component pump from the pump

transmission using a crane.
: 17 mm
: 36 mm
W2-2-3
6
8
5
1 10
W118-02-02-005
1 - Bolt 4 - Lifting Bracket 7 - Step 9 - Engine
2 - Engine Bracket 5 - Bolt 8 - Pump Transmission 10 - Frame
3 - Engine Bracket Mounting 6 - Pump Transmission
Bolt Mounting Bolt
ȈRight Engineȉ (Left Engine)

Main Pump 3
12 (Transmission
Side)
Main Pump 4
(Outer Side)
Main Pump 9
(Transmission
Side)
Main Pump 10
(Outer Side)
11
Main Pump 11
(Transmission Main Pump 5
Side) (Transmission
Main Pump 7 Main Pump 12 Side)
Main Pump 1
(Transmission (Outer Side) Main Pump 6
(Transmission
4-Unit Pump Side) 4-Unit Pump Side) (Outer Side)
Main Pump 8 T117-02-01-001 Main Pump 2 T117-02-01-001
(Outer Side) (Outer Side)
W2-2-4
Installation
CAUTION: Main pump weight: 300 kg

(660 lb)
4-Unit pump weight: 100 kg
(220 lb)
1. Install each component pump onto the pump

transmission (8), aligning the splines of the pumps
and transmission.
: 17 mm
: 540 Nxm (55 kgfxm, 400 lbf⋅ft)
: 36 mm
CAUTION: Pump device weight: 2200 kg

(4850 lb)
2. Install pump transmission (8) onto the engine Tightening Toque Remarks
Wrench Size
shaft, aligning the splines and tighten the pump N⋅m kgf⋅m lbf⋅ft
transmission mounting bolts (6). Install engine ϖ3/4 inch 118 12 87 Bolt (6)
brackets (2) on the pump transmission (8) and ϖ28 mm 440 45 330 Bolt (1)
tighten the engine bracket mounting bolts (1 and ϖ55 mm 3140 320 2310 Bolt (3)
3).
3. Remove the supports installed between the en-
gine and the mainframe to prevent the engine
from falling.
4. Secure step (7) with bolts (5). Tightening Toque Remarks
: 19 mm Wrench Size
N⋅m kgf⋅m lbf⋅ft
: 88 Nxm (9 kgfxm, 65 lbf⋅ft) Hydraulic lines
5. Connect all hydraulic lines and electric wires to ϖ17 mm - - -
(Joint)
the pumps and transmission.
ϖ19 mm 44 4.5 32.5 Hydraulic lines
6. Bleed air from the pumps. (Refer to the next
ϖ19 mm 88 9 65 Bolts
page.)
Hydraulic lines
ϖ22 mm - - -
(Joint)
IMPORTANT: Prevent pump seizure from
occurring. Be sure to perform break- ϖ27 mm 118 12 87 Hydraulic lines
in operation after installing the Hydraulic lines
ϖ30 mm - - -
pumps. (Joint)
7. Run the engine at slow idle for 20 ϖ36 mm 235 24 175 Hydraulic lines
minutes. Check for oil leaks ϖ14 mm 265 27 195 Socket Bolts
during the engine idling
operation.
8. Increase the engine speed to the
maximum speed. Slowly operate
the boom from stroke end to
stroke end repeatedly for 20
minutes.
W2-2-5
• Main Pump Air Bleeding Procedure
IMPORTANT: Never loosen the pipe completely.

Hydraulic oil will spout.
1. Loosen pipe connector (1) 2 to 3 turns. 1

: 17 mm
2. Start the engine and run at slow idle. Purge air

from the main pump until oil flows out from pipe 1
connector (1).
3. Stop the engine. Tighten pipe connector (1).

: 17 mm
: 34 Nxm (3.5 kgfxm, 25.5 lbf⋅ft)
M117-07-118
• Oil Cooler Fan Drive Pump Air Bleeding Proce-

dure
IMPORTANT: Never loosen drain hose plug (2)

completely. Hydraulic oil will sport. 2
1. Loosen drain hose connector (2) 2 to 3 turns.

: 27 mm
2. Start the engine and run at slow idle. Purge air

from the main pump until only hydraulic oil flows
out from drain hose connector (2) threads.
M117-07-163
3. Stop the engine and tighten drain hose plug (2).

: 27 mm
Oil Cooler Fan Drive Pump
T117-02-01-017
W2-2-6
(Blank)
W2-2-7
DISASSEMBLE PUMP TRANSMISSION
1
2
3
4
6
7
8
9
Pump Side
10
14
15
16
26
17
25 11
18
24
19
23
20
21 Engine Side
22
16
27 28
29
30 12
31
32
33 13
W118-02-02-006
1 - Bolt (6 Used) 10 - Roller Bearing 19 - Gear 28 - Spacer (3 Used)

2 - Cover 11 - Case 20 - Spacer 29 - Ball Bearing (3 Used)
3 - Spacer 12 - Cover 21 - Retaining Ring 30 - Gear (3 Used)
4 - Disc Spring 13 - Bolt (6 Used) 22 - Ball Bearing 31 - Spacer (3 Used)
5 - Spacer 14 - Bolt (31 Used) 23 - Elbow 32 - Retaining Ring (3 Used)
6 - Roller Bearing 15 - Washer Spring (31 Used) 24 - Adapter 33 - Ball Bearing (3 Used)
7 - Retaining Ring 16 - Knock Pin (2 Used) 25 - Reducer
8 - Stopper 17 - Spacer 26 - Air Breather
9 - Gear 18 - Ball Bearing 27 - Case
W2-2-8
Thank you very much
for your reading.
Please Click Here
Then Get More
Information.

HITACHI EX5500 EXCAVATOR Service Repair Manual PDF

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

HITACHI EX5500 EXCAVATOR Service Repair Manual PDF

Hochgeladen von

Copyright:

Verfügbare Formate

EX5500

• Clean the Machine • Precautions for Disassembling

When hydraulic oil is drained, the suction filter or the

• Bleeding Air from Hydraulic Pump

IMPORTANT: If the engine is started with air

• Remove the air bleeding plug from the top of the

• Bleeding Air from Travel Motor / Swing Motor

• With the drain plug / hose on travel motor / swing

• Bleeding Air from Hydraulic Circuit

• After refilling hydraulic oil, start the engine. While

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

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

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

2. If incorrectly assembled, oil leakage or damage

(1) Clean the floating seal and seal mounting

(2) Clean the floating seal and seal mounting Incorrect

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

1. Follow the precautions below to use nylon slings

lifted load balanced. Incorrect Eyehole

CAUTION: Use tools appropriate for the

Tighten nuts or bolts correctly to torque specifications.

correctly when assembling the machine or compo-

Specified Tightening Torque Chart

Bolt Tightening Order

When tightening two or more bolts, tighten them alter-

IMPORTANT: (1) Be sure to clean and inspect

rings. Inspect O-rings for any WRONG

tighten the bolts to hold the parts

Bend along edge sharply Do not bend it round

Bend along edge sharply

• Cotter Pin RIGHT RIGHT WRONG

• Lock Wire RIGHT Loosen WRONG

IMPORTANT: The torques given in the chart are

(2) Scratches or other damage to

Wrench Size Tightening Torque

IMPORTANT: (1) Be sure to replace O-ring (6) with

(2) Before tightening union nut (9),

Male Tapered Thread Male Straight Thread

Male Tapered Thread

Confirm that the thread surface is clean, free of dirt

Leave one to two pitch threads uncovered

Low-Pressure-Hose Clamp Tightening Torque

T-Bolt Type Band Clamp: T-Bolt Type Worm Gear Type

Periodic Replacement Parts Replacement Intervals

Fuel hose (Fuel tank to filter) Every 2 years

IMPORTANT: Be sure to replace seals, such as O-

Group 9 Oil Cooler Fan Motor

Group 10 Compressor Drive Motor

Group 11 Air Conditioner

2. Stop the engine. Turn the air breather cap on the

3. Close all hydraulic line stop valves.

4. Remove socket bolt (2) from one hydraulic tank

4. Remove another side air breather cap (1). Con-

NOTE: Keep the vacuum pump running continu- T142-05-03-007

ously while working on the hydraulic sys-

IMPORTANT: After completing the work, be sure

1- Pin 26 - Lever 51 - O-Ring 76 - Lock Nut

IMPORTANT: Never attempt to remove lock nut

8. Remove lock rings (84) and (88) from casing (80).

9. Remove lever (26) from casing (80) with a pair of

IMPORTANT: Do not remove pin (27).

10. Remove pin (24) using a thin copper bar (less

IMPORTANT: Take care not to hit pin (24) against