DOC-20230111-WA0038.

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UPPERSTRUCTURE / Pump DeviceAssemble Pump Device• Be sure to read “Precautions for Disassembly andAssembly” thoroughly on page W1-1-1 beforestarting the assembly work.1. Install O-ring (39) and cover (40) to housing(42) with socket bolts (41) (4 used).:6 mm: 8 to 35 N⋅m(2.9 to 3.6 kgf⋅m, 21.0 to 26.0 lbf⋅ft)2. Install retaining ring (46) to shaft (43), and thenpress fit bearing (45). Install retaining ring (44)on the shaft.3. Press fit the shaft (43) assembly to housing (42).Install O-ring (47), the cover (49) assembly andretaining ring (50) to the housing.4. Install the cylinder block (29) assembly tohousing (42).IMPORTANT: Apply grease to the rod portion ofhanger (36).5. Install spring seat (17) , spring (16) and spring(15) to the rod portion of hanger (36).6. Install O-ring (13) and shim (14) to spring seat(12). Then install the spring seat to cover (1).7. Install the cover (11) assembly to cover (1) withsocket bolts (9) (2 used).:8 mm: 55 to 69 N⋅m(5.6 to 7.0 kgf⋅m, 41 to 51 lbf⋅ft)IMPORTANT: Apply the grease to the matingsurfaces of valve plate (24) andcover (1). Align the valve plate withknock pins (21) (2 used) and the porthole of the cover.8. Install valve plate (24) to cover (1).IMPORTANT: When installing cover(1) on housing(42), take care not to drop controlpistons (7) (2 used) and valve plate(24).9. Install packing (23) and the cover (1) assemblyto housing (42) with socket bolts (18) (2 used)and socket bolts (20) (3 used).: 12 mm: 150 to 180 N⋅m(15 to 18 kgf⋅m, 108 to 130 lbf⋅ft)10. Install the body (4) assembly to cover (1) withsocket bolts (5) (6 used).:8 mm: 55 to 69 N⋅m(5.6 to 7.0 kgf⋅m, 41 to 51 lbf⋅ft)11. Install O-ring (19) to cover (1) and install pilotpump (2) with socket bolts (3) (2 used).:6 mm: 28 to 35 N⋅m(2.9 to 3.6 kgf⋅m, 21.0 to 26.0 lbf⋅ft)NOTE: Refer to page W2-4-5 for O-ring (19).W2-4-11
DISASSEMBLE AND ASSEMBLE VALVEBLOCKUPPERSTRUCTURE / Pump Device412635112910178W1CC-02-04-0031 - O-Ring 4 - Socket Bolt (6 Used) 7 - Spring 10 - O-Ring2 - O-Ring (2 Used) 5 - Orifice 8 - Spool 11 - Solenoid3 - Body 6 - Plug 9 - Sleeve 12 - Socket Bolt (2 Used)W2-4-12
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INTRODUCTIONTO THE READER• This m
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SAFETYRECOGNIZE SAFETY INFORMATION
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SAFETYWEAR PROTECTIVE CLOTHING• W
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SAFETYUSE HANDHOLDS AND STEPS• Fa
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OPERATE ONLY FROM OPERATOR'SSEAT•
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SAFETYDRIVE MACHINE SAFELY• Befor
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AVOID INJURY FROM BACK-OVER ANDSWIN
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SAFETYAVOID POWER LINES• Serious
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HANDLE FLUIDS SAFELY−AVOID FIRES
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SAFETYPRACTICE SAFE MAINTENANCETo a
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SAFETYPREVENT PARTS FROM FLYING•
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SAFETYAVOID HIGH-PRESSURE FLUIDS•
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SAFETYCheck Emergency Engine Stop S
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REMOVE PAINT BEFORE WELDING ORHEATI
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SAFETYDISPOSE OF WASTE PROPERLY•
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SECTION AND GROUPCONTENTSWORKSHOP M
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SECTION 1GENERAL INFORMATIONGroup 1
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GENERAL / Precautions for Disassemb
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TIGHTENING TORQUE SPECIFICATIONSGEN
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IMPORTANT: The following items are
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GENERAL / TighteningPIPING JOINT1 4
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GENERAL / TighteningScrew-In Connec
Page 52 and 53: PERIODIC REPLACEMENT OF PARTSGENERA
Page 54 and 55: GENERAL / PaintingPAINTINGPainting
Page 56 and 57: MEMO...............................
Page 58 and 59: SECTION 2UPPERSTRUCTURECONTENTSGrou
Page 60 and 61: UPPERSTRUCTURE / CabREMOVE AND INST
Page 62 and 63: UPPERSTRUCTURE / Cab9. Disconnect c
Page 64 and 65: UPPERSTRUCTURE / CabInstallationCAU
Page 66 and 67: UPPERSTRUCTURE / Cab7. Install viny
Page 68 and 69: DIMENSIONS OF THE CAB GLASSUPPERSTR
Page 70 and 71: UPPERSTRUCTURE / CabMethod for Remo
Page 72 and 73: UPPERSTRUCTURE / CabMethod for Inst
Page 74 and 75: UPPERSTRUCTURE / CabSpacer a (44584
Page 76 and 77: Install upper door glass as follows
Page 78 and 79: Install upper front glass as follow
Page 80 and 81: UPPERSTRUCTURE / CounterweightREMOV
Page 82 and 83: UPPERSTRUCTURE / Counterweight8. In
Page 84 and 85: UPPERSTRUCTURE / Counterweight5. In
Page 86 and 87: REMOVE AND INSTALL MAIN FRAMEUPPERS
Page 88 and 89: UPPERSTRUCTURE / Main FrameCAUTION:
Page 90 and 91: UPPERSTRUCTURE / Main FrameCAUTION:
Page 92 and 93: REMOVE AND INSTALL PUMP DEVICEUPPER
Page 94 and 95: UPPERSTRUCTURE / Pump DeviceInstall
Page 96 and 97: UPPERSTRUCTURE / Pump DeviceW2-4-5W
Page 98 and 99: UPPERSTRUCTURE / Pump DeviceDisasse
Page 100 and 101: UPPERSTRUCTURE / Pump Device1 - Cov
Page 108 and 109: UPPERSTRUCTURE / Pump Device(Blank)
Page 110 and 111: UPPERSTRUCTURE / Pump DeviceNo Part
Page 112 and 113: REMOVE AND INSTALLE CONTROLVALVE 1U
Page 114 and 115: UPPERSTRUCTURE / Control ValveInsta
Page 116 and 117: UPPERSTRUCTURE / Control ValveDISAS
Page 118 and 119: UPPERSTRUCTURE / Control Valve95838
Page 120 and 121: Disassemble Control Valve 1• Be s
Page 122 and 123: 5. Remove plug (26), O-ring (27), s
Page 124 and 125: UPPERSTRUCTURE / Control Valve13. L
Page 126 and 127: ASSEMBLE CONTROL VALVE 1UPPERSTRUCT
Page 128 and 129: UPPERSTRUCTURE / Control ValveSecti
Page 130 and 131: UPPERSTRUCTURE / Control ValveAssem
Page 132 and 133: UPPRERSTRUCTURE / Control Valve11.
Page 134 and 135: UPPERSTRUCTURE / Control Valve17. I
Page 136 and 137: UPPERSTRUCTURE / Control ValveRemov
Page 138 and 139: UPPERSTRUCTURE / Control ValveDisas
Page 140 and 141: UPPERSTRUCTURE / Control Valve1 - S
Page 142 and 143: UPPERSTRUCTURE / Control ValveAssem
Page 144 and 145: REMOVE AND INSTALLE SWING DEVICEUPP
Page 146 and 147: UPPERSTRUCTURE / Swing Device(Blank
Page 148 and 149: UPPERSTRUCTURE / Swing DeviceDisass
Page 150 and 151: UPPERSTRUCTURE / Swing DeviceCAUTIO
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UPPERSTRUCTURE / Swing DeviceCAUTIO
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UPPERSTRUCTURE / Swing DeviceAssemb
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UPPERSTRUCTURE / Swing Device9. Adj
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UPPERSTRUCTURE / Swing Device10. Re
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UPPERSTRUCTURE / Swing DeviceIMPORT
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UPPERSTRUCTURE / Swing DeviceDisass
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UPPERSTRUCTURE / Swing Device12. Re
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UPPERSTRUCTURE / Swing DeviceAssemb
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UPPERSTRUCTURE / Swing Device18. Ap
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UPPERSTRUCTURE / Swing DeviceDisass
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REMOVE AND INSTALL RIGHT PILOTVALVE
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UPPERSTRUCTURE / Pilot ValveIMPORTA
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REMOVE AND INSTALL LEFT PILOTVALVEU
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REMOVE AND INSTALL TRAVEL PILOTVALV
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UPPERSTRUCTURE / Pilot ValveInstall
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REMOVE AND INSTALL BLADE PILOTVALVE
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UPPERSTRUCTURE / Pilot ValveInstall
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Disassemble Right and Left Pilot Va
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Assemble Right and Left Pilot Valve
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UPPERSTRUCTURE / Pilot Valve8. Appl
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UPPERSTRUCTURE / Pilot ValveDisasse
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UPPERSTRUCTURE / Pilot Valve10. Rem
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Assemble Travel Pilot ValveUPPERSTR
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UPPERSTRUCTURE / Pilot Valve7. Plac
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UPPERSTRUCTURE / Pilot Valve14. Ins
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Disassemble Blade Pilot Valve• Be
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UPPERSTRUCTURE / Pilot ValveAssembl
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UPPERSTRUCTURE / Pilot Shut-Off Val
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InstallationUPPERSTRUCTURE / Pilot
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UPPERSTRUCTURE / Pilot Shut-Off Val
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Assemble Pilot Shut-Off ValveUPPERS
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REMOVE AND INSTALL SHOCKLESSVALVEUP
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DISASSEMBLE AND ASSEMBLE SHOCK-LESS
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UPPERSTRUCTURE / Shockless Valvekey
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REMOVE AND INSTALL SOLENOID VALVEUN
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UPPERSTRUCTURE / Solenoid Valve(Bla
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Disassemble Proportional Solenoid V
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Assemble Proportional Solenoid Valv
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UPPERSTRUCTURE / Solenoid ValveDisa
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MEMO...............................
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SECTION 3UNDERCARRIAGECONTENTNSGrou
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REMOVE AND INSTALL SWING BEARINGUND
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UNDERCARRIAGE / Swing Bearing(Blank
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UNDERCARRIAGE / Swing BearingDisass
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UNDERCARRIAGE / Swing BearingAssemb
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REMOVE AND INSTALL TRAVEL DEVICEUND
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UNDERCARRIAGE / Travel DeviceInstal
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UNDERCARRIAGE / Travel DeviceDisass
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IMPORTANT: For handling of floating
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UNDERCARRIAGE / Travel DeviceAssemb
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UNDERCARRIAGE / Travel Device11. In
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UNDERCARRIAGE / Travel DeviceDisass
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12. Remove retaining rings (23) and
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UNDERCARRIAGE / Travel DeviceAssemb
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IMPORTANT: When needle bearing (7)
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Disassemble Brake Valve• Be sure
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Assemble Brake Valve• Be sure to
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REMOVE AND INSTALL CENTER JOINTUNDE
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UNDERCARRIAGE / Center JointInstall
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UNDERCARRIAGE / Center JointDisasse
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UNDERCARRIAGE / Center JointAssembl
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MAINTENANCE STANDARDUNDERCARRIAGE /
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REMOVE AND INSTALL TRACKADJUSTERBef
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Disassemble Track Adjuster• Be su
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UNDERCARRIAGE / Track AdjusterCAUTI
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UNDERCARRIAGE / Track AdjusterAssem
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REMOVE AND INSTALL FRONT IDLERBefor
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UNDERCARRIAGE / Front IdlerDisassem
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UNDERCARRIAGE / Front IdlerAssemble
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UNDERCARRIAGE / Upper And Lower Rol
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REMOVE AND INSTALL TRACKSRemovalUND
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UNDERCARRIAGE / TrackCAUTION: Secur
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UNDERCARRIAGE / TrackIMPORTANT: Ins
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UNDERCARRIAGE / TrackMAINTENANCE ST
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UNDERCARRIAGE / TrackPinBAW142-03-0
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MEMO...............................
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SECTION 4FRONT ATTACHMENTGroup 1 Fr
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FRONT ATTACHMENT / Front Attachment
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STANDARD DIMENSIONS FOR ARMAND BUCK
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REMOVE AND INSTALL CYLINDERFRONT AT
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FRONT ATTACHMENT / CylinderInstall
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FRONT ATTACHMENT / CylinderCAUTION:
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FRONT ATTACHMENT / Cylinder4. Remov
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4. Disconnect hoses (6) (2 used) fr
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5. Hoist boom cylinder (4). Start t
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FRONT ATTACHMENT / CylinderInstall
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FRONT ATTACHMENT / CylinderDisassem
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FRONT ATTACHMENT / CylinderAssemble
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FRONT ATTACHMENT / CylinderIMPORTAN
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11. Align the holes on piston rod (
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MEMO...............................
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SECTION 5ENGINE AND ACCESSORYSECTIO
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MEMO...............................
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Hitachi Construction Machinery Co.
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