Hyundai HX220L Disassembly And Assembly
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Hyundai HX220L Disassembly And Assembly

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SECTION 8 DISASSEMBLY AND ASSEMBLY
Group 1 Precaution ---------------------------------------------------------------------------------------------------------- 8-1
Group 2 Tightening Torque ---------------------------------------------------------------------------------------------- 8-4
Group 3 Pump Device ------------------------------------------------------------------------------------------------------ 8-7
Group 4 Main Control Valve --------------------------------------------------------------------------------------------- 8-36
Group 5 Swing Device ----------------------------------------------------------------------------------------------------- 8-50
Group 6 Travel Device ------------------------------------------------------------------------------------------------------ 8-81
Group 7 RCV Lever ---------------------------------------------------------------------------------------------------------- 8-113
Group 8 Turning Joint ------------------------------------------------------------------------------------------------------- 8-127
Group 9 Boom, Arm and Bucket Cylinder ---------------------------------------------------------------------- 8-132
Group 10 Undercarriage ---------------------------------------------------------------------------------------------------- 8-151
Group 11 Work Equipment ------------------------------------------------------------------------------------------------ 8-164

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  • Page 1: Table Of Contents

    SECTION 8 DISASSEMBLY AND ASSEMBLY Group 1 Precaution ---------------------------------------------------------------------------------------------------------- 8-1 Group 2 Tightening Torque ---------------------------------------------------------------------------------------------- 8-4 Group 3 Pump Device ------------------------------------------------------------------------------------------------------ 8-7 Group 4 Main Control Valve --------------------------------------------------------------------------------------------- 8-36 Group 5 Swing Device ----------------------------------------------------------------------------------------------------- 8-50 Group 6 Travel Device ------------------------------------------------------------------------------------------------------ 8-81 Group 7 RCV Lever ---------------------------------------------------------------------------------------------------------- 8-113 Group 8 Turning Joint ------------------------------------------------------------------------------------------------------- 8-127 Group 9 Boom, Arm and Bucket Cylinder ---------------------------------------------------------------------- 8-132...

  • Page 2: Group 1 Precaution

    SECTION 8 DISASSEMBLY AND ASSEMBLY GROUP 1 PRECAUTIONS 1. REMOVAL WORK Lower the work equipment completely to the ground. If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
  • Page 3 2. INSTALL WORK Tighten all bolts and nuts (sleeve nuts) to the specified torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pin or lock plate securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2-3 drops of adhesive.
  • Page 4 3. COMPLETING WORK If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.

  • Page 5: Group 2 Tightening Torque

    GROUP 2 TIGHTENING TORQUE 1. MAJOR COMPONENTS Torque Descriptions Bolt size kgf m lbf ft Engine mounting bolt (engine-bracket) 1.75 11.45 82.8 Engine mounting bolt (bracket-frame, FR) 52.1 36.2 Engine mounting bolt (bracket-frame, RR) 65.1 Engine Radiator mounting bolt 29.7 32.5 Coupling mounting socket bolt Fuel tank mounting bolt...
  • Page 6 2. TORQUE CHART Use following table for unspecified torque. BOLT AND NUT Coarse thread 8.8T 10.9T 12.9T Bolt size kgf m lbf ft kgf m lbf ft kgf m lbf ft M 6 1.0 0.8 ~ 1.2 5.8 ~ 8.6 1.2 ~ 1.8 8.7 ~ 13.0 1.5 ~ 2.1...
  • Page 7 PIPE AND HOSE (FLARE TYPE) kgf m lbf ft Thread size (PF) Width across flat (mm) 28.9 1/4" 36.2 3/8" 68.7 1/2" 130.2 3/4" 151.9 1" 253.2 1-1/4" PIPE AND HOSE (ORFS TYPE) Thread size (UNF) Width across flat (mm) kgf m lbf ft 9/16-18...

  • Page 8: Group 3 Pump Device

    GROUP 3 PUMP DEVICE 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 9 INSTALL Carry out installation in the reverse order to removal. Remove the suction strainer and clean it. Replace return filter with new one. Remove breather and clean it. After adding oil to the hydraulic tank to the specified level. Bleed the air from the hydraulic pump. Remove the air vent plug (2EA).
  • Page 10 2. MAIN PUMP (1/3) STRUCTURE 497 953 537 789 732 535 532 548 531 214 808 901 954 792 702 271 212 153 433 156 157 468 313 124 711 116 312 885 314 401 141 220S2MP05 Section A-A, B-B, view C : see next page. 04 Gear pump 272 Pump casing (R) 711 O-ring...
  • Page 11 MAIN PUMP (2/3) 537 953 806 419 VIEW C 414 326 SECTION A-A SECTION A-A SECTION B-B without PTO with PTO 220S2MP06 05 PTO unit (with PTO) 537 Servo cover (S) 724 Square ring 079 Proportional reducing valve 541 Seat 806 Hexagon head nut 326 Cover (without PTO) 544 Stopper 1...
  • Page 12 MAIN PUMP (3/3) 220S2MP07 115 Idler shaft 262 Cover 711 O-ring 117 Gear No. 2 326 Gear case 728 O-ring 118 Gear No. 3 414 Socket head screw 825 Retainer ring 125 Ball bearing 435 Flange head socket bolt 826 Retainer ring 126 Roller bearing 468 Plug 885 Spring pin...
  • Page 13 TOOLS AND TIGHTENING TORQUE Tools The tools necessary to disassemble/reassemble the pump are shown in the following list. Tool name & size Part name Hexagon socket ROH, VP plug Hexagon socket Name head bolt (Parallel thread) head setscrew PF 1/4 M12, M14 Allen wrench PF 3/8...
  • Page 14 Tightening torque Torque Wrench size Part name Bolt size kgf m lbf ft 0.16 Hexagon socket head bolt (Material : SCM435) 0.20 21.7 0.24 42.0 0.31 10.0 72.3 0.39 16.3 0.47 23.5 0.55 33.7 0.55 43.8 0.67 ROH Plug PF 1/4 21.7 0.24 PF 3/8 or under : S45C...
  • Page 15 DISASSEMBLY For disassembling the pump, read this section thoughly and then disassemble it in the following sequence. The figure in parentheses after part names show the item in structure drawing. Select place suitable to disassembling. Select clean place. Spread rubber sheet, cloth or so on. Make workbench top clean to prevent parts from being damaged.
  • Page 16 P l a c e t h e p u m p h o r i z o n t a l l y o n workbench with its regulator-fitting surface down, and remove PTO unit from valve block. Before bringing regulator-fitting surface down, spread rubber sheet on workbench to avoid damaging the surface.
  • Page 17 Separate pump casing (F, 271), pump casing (272), from valve block (312) Remove the 1st gear (116), when pump casings are separated from valve block. 220S8MP17 (10) Pull out cylinder block (141), piston-shoes (011), set plate (153), spherical bush (156), and cylinder spr ings (157) simultaneously from pump casing (F, 271) and (R, 272), straightly over drive shaft (111, 113)
  • Page 18 (13) Remove the swash plates (212) and shoe plates (211) from swash plate support (251), and pull out the swash plates with turning shown in this picture from casing. 220S8MP21 220S8MP22 220S8MP23 (14) Remove swash plate supports (251) from pump casing. In this case it is difficult to remove, tap the opposite side of the swash plate support (251) with plastic hammer to remove it...
  • Page 19 (15) Remove valve plates (313, 314) from valve block (312) There may be removed in work (8). 220S8MP25 (16) If necessary, remove the servo covers (537), stopper (L, 534), stopper (S, 535), and servo piston sub (530) from pump casing (271, 272). Do not remove needle bearing (124) as far as possible, except the case that the bearing is considered to be out of its life-...
  • Page 20 REASSEMBLY REASSEMBLY For reassembling reverse the disassembli- ng procedures, paying attention to the following. Do not fail to repair the parts damaged during dissassembling, and repair replacement part in advance. Clean each part fully with cleaning oil and dry it with compressed air. Apply clean working oil to sliding sections, bearings, etc.
  • Page 21 Attach shoe plate (211) to swash plate (212) and insert tilting pin (531) to tilting bush (214) of servo piston (532). As shown in the right figure, attach to swash plate support (251) correctly, leaning swash plate and shoe plate. Confirm that swash plate can moved smoothly with fingers of both hands.
  • Page 22 Assemble seal cover (F, 261) to pump casing (271) and fix it with hexagon socket head bolts (406). Apply grease lightly to oil seal in seal cover (F). Assemble oil seal, taking full care not to damage it. 220S8MP26 Assemble piston cylinder sub assembly [cylinder (141), piston sub assembly (151, 152), set plate (153), spherical bush (156) and cylinder spring (157)].
  • Page 23 Fit valve block (312) to pump casing (271, 272) with hexagon socket head bolts (401, 402). 220S8MP16 (10) Fit gear pump (04) to pump casing (271) with hexagon socket head bolts. 220S8MP15 (11) Attach the PTO unit (05) by fastening the flange socket to the valve block (312).
  • Page 24 (12) Putting feedback lever of regulator into feedback pin (548) of servo piston (532), fit regulator with hexagon socket head bolts. Take care not to mix up regulator of front pump with another. 220S8MP28 (13) Fit proportional valve block (079) to valve block (312) with hexagon socket head bolts.
  • Page 25 3. REGULATOR STRUCTURE (1/2) A Psv KG7G-9N15-V VIEW E VIEW D 220S2MP08 412 Hexagon socket screw 497 Plug 874 Pin 413 Hexagon socket screw 611 Feed back lever 876 Pin 436 Hexagon socket screw 614 Adjust plug 437 Hexagon socket screw 726 O-ring 8-24...
  • Page 26 REGULATOR (2/2) SECTION B-B SECTION A-A 220S2MP09 414 Hexagon socket screw 630 Lock nut 730 O-ring 497 Plug 631 Sleeve, pf 753 O-ring 601 Casing 641 Pilot cover 755 O-ring 621 Compensator piston 642 Pilot spool 756 O-ring 622 Compensator sleeve 643 Pilot sleeve 758 Square ring 624 Spring seat (C)
  • Page 27 TOOLS AND TIGHTENING TORQUE Tools The tools necessary to disassemble/reassemble the pump are shown in the following list. Tool name & size Part name Hexagon socket ROH, VP, UNF Hexagon socket Name head bolt (Parallel thread) head setscrew Allen wrench ROH 1/4 M12, M14 VP 3/8...
  • Page 28 Tightening torque Torque Wrench size Part name Bolt size kgf m lbf ft 0.16 Hexagon socket head bolt (Material : SCM435) 0.20 21.7 0.24 0.31 10.0 72.3 0.39 16.3 0.47 23.5 0.55 33.7 0.55 43.8 0.67 64.2 0.67 PT 1/8 0.20 PT Plug (Material : S45C) Wind a seal tape 1 1/2 to...
  • Page 29 DISASSEMBLY Preparation for disassembling Since the regulator consists of small, precision, and well-finished par ts, disassembling and assembling are rather complicated. For this reason, replacem- ent of a regulator assembly is recomme- nded, unless there is a special reason. If in case disassembling is necessary for an unavoidable special reason, read thro- ugh this manual to the end before starti-...
  • Page 30 Remove hexagon socket head cap screw (436). Then remove cover (C, 629). Adjusting screw (C, 628), adjust stem (C, 627), hexagon nut (801, 802), set screw (924) are fixed to cover (C, 629). Do not loosen each screw and nut. If they are loosened, adjusted pressure-flow setting will be changed.
  • Page 31 Remove hexagon socket head cap screw (437) and remove pilot cover (641). Then remove Pf piston (897), Pf sleeve (631), Pi pistion (898), and Pi sleeve (650) from pilot cover. If the regulator was used for a long time, the Pf sleeve (631) or the Pf sleeve (650) may stuck with pliot cover.
  • Page 32 (10) Remove the compensator sleeve (622) and the pilot sleeve (643) from the casing (601). This completes operation. Since component parts are small, take care not to lose them. 8-31...
  • Page 33 REASSEMBLY REASSEMBLY For assembling, reverse disassembling procedures. But pay attention to the following. Repair parts that were damaged at disassembling. Prepare replacement parts beforehand. Contamination will cause malfunction. Therefore, wash parts well with cleaning oil, let them dry with jet air and handle them in clean place.
  • Page 34 Insert the pin (876) fixed on feedback lever (611) to the oval shaped hole of the pilot sleeve (643). Then, fit the hole of the feedback lever to the pin (874) fixed inside the casing (601). At the same time, insert the pin (876) to the oval shaped hole of the compensator sleeve (622).
  • Page 35 Put the spring seat (C, 624) the outer Apply grease spring (625), and the inner spring (626) into compensator section of the casing. By the same way, put the spring seat (Q, 644) into pilot section of the casing. The spring seat (C, 624) may fall. Apply grease to the spring seat (C, 624), the outer spring (625) and the inner spring (626) to prevent falling.

  • Page 36: Group 4 Main Control Valve

    GROUP 4 MAIN CONTROL VALVE GROUP 4 MAIN CONTROL VALVE 1. REMOVAL AND INSTALL OF MOTOR 1. REMOVAL AND INSTALL OF MOTOR REMOVAL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
  • Page 37 2. STRUCTURE (1/5) 16-16 16-15 16-14 16-12 16-13 16-17 16-11 16-10 16-9 16-8 16-7 16-5 16-6 16-3 16-4 16-2 16-1 220S8MC04 P1 housing 27 Overload plug 56 O-ring Travel spool kit 28 Plug 57 Socket bolt Boom 1 spool kit 30 Load check plug 59 Socket bolt Bucket spool kit...
  • Page 38 STRUCTURE (2/5) Housing P1 17-9 17-5 17-7 17-8 17-1 17-6 17-3 17-2 17-4 220S8MC05 17 Regen valve assy 34 Spool cap 58 Socket bolt 18 Port relief valve assy 36 Bucket stroke limit 75 Plug assy 25 Negacon relief valve 55 O-ring 27 Overload plug 57 Socket bolt...
  • Page 39 STRUCTURE (3/5) 16-16 16-15 16-14 16-12 16-13 16-11 16-10 16-9 16-8 16-7 16-5 16-6 16-3 16-4 16-2 16-1 220S8MC06 P2 housing 29 Plug 54 O-ring Travel spool kit 32 Plug 55 O-ring Arm 1 spool kit 33 Plug 56 O-ring Swing spool kit 35 Cap spool 57 Socket bolt...
  • Page 40 STRUCTURE STRUCTURE (4/5) Housing P2 220S8MC07 14 BC1 spool kit 31 Plug 55 O-ring 18 Port relief valve assy 32 Plug 57 Socket bolt 20 Port relief valve assy 34 Spool cap 67 BC plug assy 26 Orifice signal plug assy 35 Spool cap 69 Opt stroke limit plug kit 2 8-39...
  • Page 41 STRUCTURE STRUCTURE (5/5) Housing P2 220S8MC08 22 Swing logic valve assy 41 Poppet 62 Socket bolt 29 Plug 42 Spring 70 O-ring 30 Load check valve 46 Port plug flange 71 Socket bolt 37 L/C poppet 1 56 O-ring 38 L/C spring 1 61 Socket bolt 8-40...
  • Page 42 3. DISASSEMBLY AND ASSEMBLY 3. DISASSEMBLY AND ASSEMBLY GENERAL PRECAUTIONS GENERAL PRECAUTIONS All hydraulic components are manufactured to a high precision. Consequently, before disassembling and assembling them, it is essential to select an especially clean place. In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it. When a control valve is to be removed from the machine, apply caps and masking seals to all ports.
  • Page 43 DISASSEMBLY DISASSEMBLY The figure in ( ) shown after the part name in explanation sentence shows its number in the construction figures (8-31) Place main control valve on working Place main control valve on working bench bench Disassemble it in clean place and pay attention not to damage flange faces and plate faces.
  • Page 44 Disassembling of main spool assy 2 (Pilot cover B side) (Boom 1 (5), Arm 1 (4) ) Loosen the hexagon socket head bolts (47) 5EA and remove the O-ring (44) and holding valve block assy (16) [ Hexagon key wrench : 6 mm ] Pull out the main spool, spring, spring seat stopper and spacer bolt in the spool assembly condition from the housing P1...
  • Page 45 Disassembling of swing priority spool & pilot cover A ( Travel R/L (3), Swing (7), Boom1 (5), Arm 1 (4), Bucket (6), Option (11), Boom2 (9), Arm 2 (8) ) Loosen the hexagon socket head bolts (45) 2EA and remove the pilot cover A (32) and O-ring (43).
  • Page 46 Disassembling of main relief valve Loosen and remove the main relief valve (23). [ Spanner 32 mm ] 220S8MC18 (10) Disassembling of port relief valve (Except the option side) Loosen and remove the port relief valve (18). [ Spanner 34 mm ] 220S8MC19 (11) Disassembling of port relief valve (Option...
  • Page 47 (12) Disassembling of logic valve (Arm logic valve (22), Swing logic valve (21) ) Loosen the hexagon socket head bolts (56) 4EA and remove the logic valve. [ Hexagon key wrench 8 mm ] 220S8MC21 Remove the swing logic poppet. 220S8MC22 Remove the Arm logic poppet and spring by same method.
  • Page 48 (13) Disassembling of check valve ( Plug (27) 2EA ) Loosen the plug (27) and remove the poppet (37), spring (38). [ Hexagon key wrench 10 mm ] 220S8MC24 220S8MC25 (14) Main spool disassembly Fix the spool to the dedicated jig and take it apart.
  • Page 49 (15) Disassembling of housing Loosen the hexagon socket head bolts (49, 50) each 2EA, 8EA Except when required specially, do not disassemble housing P1&P2 for sanitation. 220S8MC28 220S8MC29 8-48...
  • Page 50 (16) Inspection after disassembly Clean all disassembled parts with clean mineral oil fully, and dry them with compressed air. Then, place them on clean papers or cloths for inspection. Control valve Check whole surfaces of all parts for burrs, scratches, notches and other defects. Confirm that the seal groove faces of the housing and the covers are smooth and free of dust, dent, rust etc.

  • Page 51: Group 5 Swing Device

    GROUP 5 SWING DEVICE (TYPE 1, 2) 1. REMOVAL AND INSTALL OF MOTOR REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the pressure inside the hydraulic tank.
  • Page 52 2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR STRUCTURE 19 18 29 28 26 27 39K6-10150 9 12 34 32 220S2SM02 Casing 15 Parking piston 29 O-ring Oil seal 16 Spring 30 Relief valve assy Shaft 17 Spring pin 31 Reactionless valve assy Snap ring 18 O-ring 32 Plug...
  • Page 53 DISASSEMBLY Disassemble drive shaft Unloosing socket bolt (time delay valve, 42) and disassemble time delay valve assy (35) from casing (1). 2209A8SM51 Disassemble level gauge (36) from cas- ing (1). 2209A8SM52 Hang valve casing (23) on hoist, unloose socket bolt (37, 38) and disassemble from casing (1).
  • Page 54 Disassemble respectively cylinder block sub (8), friction plate (13), separate plate (14) from casing (1). 2209A8SM55 Disassemble swash plate (7) from casing (1). 2209A8SM56 Using a plier jig, disassemble snap ring (4) from casing (1). 2209A8SM57 Disassemble shaft assy (3), oil seal (2) and O-ring (18, 22) from casing (1).
  • Page 55 Disassemble cylinder block sub Disassemble piston assy (12) from cylin- der block (8). 2209A8SM59 Disassemble ball guide (10) and spring (cylinder block, 9) from cylinder block (8). Ball guide 1EA Spring 9EA 2209A8SM60 Disassemble valve casing sub Disassemble spring pin (17, 21), valve plate (20), O-ring (22) from valve casing (23).
  • Page 56 Using a torque wrench, disassemble plug (32) from valve casing (23) and dis- assemble O-ring (33, 34) and reaction- less valve assy (31). 2209A8SM63 Using a torque wrench, disassemble check valve (24) from valve casing (23). 2209A8SM64 Disassemble plug (28), O-ring (29) from valve casing (23).
  • Page 57 ASSEMBLING Assemble shaft sub Put roller bearing (3) on preheater and provide heat to inner race. (Temperature in conveyor : 120 C for 3~5 minutes) 2209A8SM66 Using a robot machine, assemble and press preheated roller bearing (3) into shaft (5). 2209A8SM67 Assemble cylinder block sub Assemble 9 springs (cylinder block, 9)
  • Page 58 Assemble 9 piston assy (12) into retainer plate (11). Piston assy 9EA Retainer plate 1EA 2209A8SM70 Assemble parts of procedure 2209A8SM71 Assemble valve casing sub Assemble make up check valve sub Assemble check valve (24), O-ring (27), plug (26) in that order and then screw it torque wrench.
  • Page 59 Using a torque wrench, assemble relief valve (30) 2 sets into valve casing (23). Relief valve (30) 2EA 2209A8SM74 Assemble plug (28) and O-ring (27) into valve casing (23). Plug (28) 3EA O-ring (27) 3EA 2209A8SM75 Assemble needle bearing (6) into valve casing (23) and assemble spring pin (17, 21) into valve casing (23).
  • Page 60 Assemble drive shaft sub Using a jig, assemble oil sealing (2) into casing (1). 2209A8SM78 Fit shaft sub (shaft roller bearing) into casing (1). 2209A8SM79 Using a plier jig, assemble snap ring (4) to shaft (3). Snap ring 1EA 2209A8SM80 Apply some grease swash plate (7) and assemble it into casing (1).
  • Page 61 Insert O-ring (18, 19) into casing (1). O-ring (18) 1EA O-ring (19) 1EA 2209A8SM82 Assemble cylinder block (8) into casing (1). 2209A8SM83 Assemble separate plate (14) and friction plate (13) 4 sets into casing (1) and fit parking piston (15) into casing (1) by a jig or a press.
  • Page 62 Lift up valve casing (23) on casing (1) by a crane and assemble it with socket bolts (37, 38). 2209A8SM86 Assemble level gauge (36) and plug (39) into casing (1). 2209A8SM87 Assemble time delay valve assy (35) into valve casing (23) with socket bolt (42). Time delay valve 1EA Socket bolt 3EA 2209A8SM88...
  • Page 63 Leakage check Place motor on a bench tester and after cleaning motor by color check No.1, paint No.3 and be sure of leakage. 2209A8SM90 Mount test bench Mounting motor a test bench, test the availability of each part. 2209A8SM91 8-62...
  • Page 64 3. REMOVAL AND INSTALL OF REDUCTION GEAR REMOVAL Remove the swing motor assembly. For details, see removal of swing motor assembly. Sling reduction gear assembly (1) and remove dowel pin (3) and mounting bolts (2). Remove the reduction gear assembly. Reduction gear device weight : 75 kg (165 lb) 13031GE18...
  • Page 65 3. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR STRUCTURE 26 28 18 19 20 25 24 9 220L2SM03 Ring gear 11 Planetary gear 2 21 Thrust washer 1 Drive shaft 12 Needle bearing 2 22 Carrier pin 1 Taper bearing 13 Thrust washer 2 23 Spring pin 1 Taper bearing 14 Carrier pin 2...
  • Page 66 DISASSEMBLY DISASSEMBLY Preparation Preparation The reduction gear removed from machine is usually covered with mud. Wash out side of reduction gear and dry it. Setting reduction gear on work stand for dis- assembling. Mark for mating Put marks on each mating parts when dis- assembling so as to reassemble correctly as before.
  • Page 67 Removing No.2 sun gear from No.2 carrier sub assy. Be sure maintaining it vertical with ground when disassembling No.2 sun gear. 2209A8SM04 Removing No.2 carrier sub assy screwing I-bolt to tab hole (M10) in No.2 carrier. Lifting it gradually maintaining it vertical with ground.
  • Page 68 Removing drive shaft sub assy Unscrew every hex head bolt (M12) to remove lock plate. 2209A8SM07 Rolling ring nut for removing them from drive shaft sub assy. 2209A8SM08 Use special tool to roll ring nut to counter clockwise. VIEW A Ø113 2-Ø9.7 P.C.D Ø135...
  • Page 69 Remove drive shaft sub assy from casing. Set a rack for flange of casing, and remove drive shaft sub assy from casing by using press. 2209A8SM09 Remove oil seal & taper bearing (small) from casing. Do not re-use oil seal. It is impossible to dis- assemble drive shaft sub assy.
  • Page 70 4. ASSEMBLY REDUCTION UNIT 4. ASSEMBLY REDUCTION UNIT GENERAL NOTES GENERAL NOTES Clean every part by kerosene and dry them in a cool and dry place. Loctite on surface must be removed by solvent. Check every part for any abnormal. Each hexagon socket head bolt should be used with loctite #242 applied on its threads.
  • Page 71 Make of spring pin hole No.1 pin and No.1 carrier of spring pin hole in line, press No.1 spring pin into the holes. Make No.1 spring pin hole head for No.1 planetary gear. 2209A8SM14 Caulk carrier holes to make No.1 spring pin settle down stably.
  • Page 72 ASSEMBLING NO.2 CARRIER SUB ASSY Put thrust plate in firmly No.2 carrier. 2209A8SM17 After assembling No.2 needle bearing to No.2 planetary gear, put 2 pieces of No.2 thrust washer on both sides of bearing and install them to No.2 carrier. 2209A8SM18 Align No.2 spring pin hole and No.2 carrier spring pin hole, put No.2 spring pin into the...
  • Page 73 ASSEMBLING PINION GEAR SUB ASSY Prepare drive shaft pinion gear vertical with ground. 2209A8SM21 Fully apply grease (albania EP02) to O-ring groove of sleeve. Be sure to maintain it vertical with ground when assembling it. Put O-ring into O-ring groove of sleeve. Fully apply grease on O-ring.
  • Page 74 2209A8SM24 ASSEMBLING BEARING CUP & OIL SEAL (PRESSING) Put top, bottom bearing cup into casing. Use special jig for pressing. Pay attention to foreign materials while assembling bearing cup. Flip over casing to assemble oil seal. 2209A8SM25 2209A8SM26 8-73...
  • Page 75 Assemble oil seal to casing. Use special jig for pressing. Pay attention to direction of dust seal and dent. 2209A8SM27 WHILE ASSEMBLING OIL SEAL Be sure to set dust seal to gear oil. Before assembling, charge enough grease in oil seal. Before assembling, apply enough grease inside and outside of oil seal.
  • Page 76 Put drive shaft sub assy into casing. Be sure to maintain it vertical with ground when assembling it. 2209A8SM30 Put taper bearing into it. Rotate bearing by hands for checking after assembly. 2209A8SM31 Put ring nut into drive shaft sub assy by using special jig.
  • Page 77 Align bolt screw of ring nut with lock plate’s hole. In case of misalign between bolt screw ring nut and lock plate’s hole, put lock plate as near as possible to hole of bolt screw of ring nut and make it in line by increasing tighten- ing torque.
  • Page 78 ASSEMBLING RING GEAR Apply loctite #515 bottom of casing sub assy contacting with ring gear without disconnec- tion. 2209A8SM38 Refer to loctite detail. 2209A8SM39 Put parallel pin into hole of casing sub assy. Mark parallel pin position using paint marker. 2209A8SM40 Align ring gear with parallel pin to put them into casing sub assy.
  • Page 79 Screw 12 bolts (M16 45) to connect casing sub assy and ring gear (01) by using torque wrench. Bolt (M16, 12EA) = 12.9T The tightening torque = 27 2.7 kgf·m (195 19.5 lbf·ft) Apply enough loctite #242 before screwing bolts. 2209A8SM42 Use paint marker for checking surplus parts after assembling.
  • Page 80 ASSEMBLING CARRIER SUB ASSY & SUN GEAR Put No.2 carrier sub assy along spline of drive shaft spline. Screw M10 I-bolt to No.2 carrier sub assy. Lifting up No.2 carrier sub assy and align planetary gear and tooth of ring gear by rotating planetary gear by hands.
  • Page 81 Put No.1 carrier sub assy into No.2 sun gear along spline. Screw M10 I-bolt to No.1 carrier sub assy. Lifting up No.1 carrier sub assy and align planetary gear and tooth of ring gear by rotating planetary gear by hands. Rotate No.1 carrier sub assy by hands to fit No.1 carrier into No.2 sun gear spline.

  • Page 82: Group 6 Travel Device

    GROUP 6 TRAVEL DEVICE GROUP 6 TRAVEL DEVICE (TYPE 1, 2) 1. REMOVAL AND INSTALL 1. REMOVAL AND INSTALL REMOVAL REMOVAL Swing the work equipment 90 and lower it completely to the ground. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
  • Page 83 2. TRAVEL MOTOR STRUCTURE 22 20 23 24 1 59 31 61,62 32 29 2 55 42 41 52 35 53 47 50 54 58 2209A2TM21 Casing 23 Friction plate 44 Plug Plug 24 Separated plate 45 O-ring Oil seal 25 Parking piston 46 O-ring Thrust plate...
  • Page 84 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Hexagon wrench Width across flat 5, 6, 8, 10, 14 mm Snap ring prier For shaft 60~80 mm Snap ring prier For bore 32~58 mm Plastic hammer 1 piece Screw dirver Minus (-), medium size, 2 pieces 10 kgf·m (72.3 lbf·ft), 33 kgf·m (238.6 lbf·ft), 45 kgf·m (325.4 lbf·ft) Torque wrench Gig for inserting oil seal...
  • Page 85 Tightening torque Torque Item Name Size kgf m lbf ft Plug NPTF 1/16 1.1 0.1 7.9 0.72 Hexagon socket head bolt 1.0 1.0 72.3 7.2 Relief valve 1 5/16 34 3.4 246 24.6 Plug PF 1/4 2.8 0.3 20.3 2.17 Plug PF 3/8 5.5 0.5...
  • Page 86 3. DISASSEMBLING GENERAL INSTRUCTIONS Combustibles such as white kerosene are used for washing parts. These combustibles are easily ignited, and could result in fire or injury. Be very careful when using. Internal parts are coated with hydraulic fluid during disassembling and are slippery. If a part slips out of your hand and fails, it could result in bodily injury or could damage the park.
  • Page 87 DISASSEMBLING TRAVEL MOTOR Disassemble the wrench bolt (39) to tighten the spool cover (36) and rear cover (34) by using the L-wrench or impact wrench and then disassemble the spring (37), spring seat (41) and main spool assy (35) in order. 25098TM034 25098TM035 Disassemble the wrench bolt (54, 55) to...
  • Page 88 Disassemble the parking piston (25) by using the jig for disassembling parking piston. DISASSEMBLING JIG 25098TM039 25098TM040 Disassemble the separated plate (24, 5EA) and friction plate (23, 4EA) from the casing. 25098TM041 25098TM042 25098TM043 25098TM044 Turn the casing (1) horizontal by using the assemble truck and disassemble the cylinder block kit form the casing (1).
  • Page 89 Disassemble the cylinder block (18), retainer plate (21), piston assy (22), ball guide (20) and spring (19) from the cylinder block kit. 25098TM046 25098TM047 25098TM048 25098TM049 25098TM050 Disassemble the swash plate (17) from the casing. 25098TM051 25098TM052 (10) Disassemble the steel ball (15) and swash piston (6) from the casing.
  • Page 90 (11) Disassemble the pivot (16, 2EA) from the casing. 25098TM056 (12) Disassemble the snap ring (11) from the shaft (8) with the pryer for retaining ring. 25098TM057 (13) Disassemble the shaft (8) from the casing (1). 25098TM058 25098TM059 (14) Disassemble the snap ring (5) from the casing (1) with the pryer for retaining ring.
  • Page 91 (15) Disassemble the thrust plate (4) from the casing (1). 25098TM061 (16) Disassemble the oil seal (3) from the casing (1) with suitable tool. 25098TM062 25098TM063 (17) Disassemble the O-ring (31) from the casing (1). 25098TM064 (18) Disassemble the valve plate (28) from the casing (1).
  • Page 92 (19) Disassemble the relief valve (42, 2EA) from the rear cover (34) by using the torque wrench. 25098TM066 25098TM067 25098TM068 (20) Disassemble both side of the plug (48) and connector (52) from the rear cover (34) by using the torque wrench and then disassemble the spring (51), spring seat (49), parallel pin (50) and spool (47) in order.
  • Page 93 4. REASSEMBLING ASSEMBLING MOTOR - REAR COVER ASSY Assemble the check valve (56) and the spring (57) to the rear cover and then tighten the plug (60) by using the L-wrench. 25098TM075 25098TM076 Apply the loctite #242 on the NPTF 1/16 plug (2, 12EA) and tighten it.
  • Page 94 Tight fit the needle bearing (10) into rear cover (34) by using pressing jig. 25098TM085 Assemble the spring pin (32) and parallel pin (29) into rear cover (34) by using round bar or small hammer. 25098TM086 Assemble the valve plate (28) into rear cover (34).
  • Page 95 Assemble the casing (1) on the assembling Assembling truck truck. 25098TM089 (10) Tight fit the oil seal (3) into the casing (1) by using jig. Be careful direction of the oil seal. 25098TM090 25098TM091 (11) Assemble the thrust plate (4) into the casing (1).
  • Page 96 (13) Heat the roller bearing (9) and fit it into the shaft with shrink fitting. Shrink fitting can be used induction heating system and set the temperature at 100 C. Be careful not to damage the sliding surface of the oil seal of the shaft. 25098TM096 25098TM094 25098TM095...
  • Page 97 (17) Heat the piston seal (7) and fit it into the swash piston (6) and then tighten it a few minutes by band or tie. Loosen the band or tie and assemble it to the casing (1). 25098TM100 25098TM101 (18) Apply a little grease on the steel ball (15) and assemble it into the swash plate (17).
  • Page 98 (20) Assemble the spring (19), ball guide (20), retainer plate (21) and piston assy (22) into cylinder block (18) in order. 25098TM106 25098TM107 25098TM108 25098TM109 25098TM110 (21) Tilt the casing (1) sideways and assemble the cylinder block kit into the casing (1). 25098TM111 (22) Assemble the separated plate (24) and...
  • Page 99 25098TM114 25098TM115 (23) Apply some grease on the D-ring and assemble it parking piston. 25098TM116 (24) Insert the parking piston into the casing and assemble it by using jig. 25098TM117 (25) Assemble the brake spring (30, 18EA) into the piston. 25098TM118 8-98...
  • Page 100 (26) Place the rear cover (34) on the casing (1). 25098TM119 (27) Tighten the casing (1) and rear cover (34) specified torque with wrench bolt (54, 55) by using the impact wrench and torque wrench. 25098TM120 (28) Confirm the insert direction of the main spool assy (35) exactly and assemble it into the rear cover (34).
  • Page 101 TRAVEL REDUCTION GEAR 8,33 28,32,34 220S8TM02 Ring gear 13 Thrust washer 2 25 Thrust plate Ball bearing 14 Carrier pin 2 26 Cover Floating seal assy 15 Spring pin 2 27 Hexagon socket head bolt Ring nut 16 Solid pin 2 28 Plug Lock plate 17 Sun gear 2...
  • Page 102 6. DISASSEMBLING GENERAL INSTRUCTIONS Combustibles such as white kerosene are used for washing parts. These combustibles are easily ignited, and could result in fire or injury. Be very careful when using. Internal parts are coated with gear oil during disassembling and are slippery. If a part slips off from your hand and fails, it could result in bodily injury or could damage the park.
  • Page 103 DISASSEMBLING TRAVEL REDUCTION GEAR Preparation for disassembling The reduction units removed from excavator are usually covered with mud. Wash outside of propelling unit and dry it. Locate reducer in order for drain port to be at the lowest level, loosen taper screw plug of drain port, and drain oil from reduction gear.
  • Page 104 Removing No.1 carrier sub assembly Screw three M10 eye-bolt in No.1 carrier and lift up and remove No.1 carrier assy. 25098TM129 Remove No.1 sun gear. Be sure to maintain it vertical with the ground when disassembling No.1 sun gear. 25098TM130 Removing No.2 carrier sub assembly Screw three M10 eye-bolt in No.2 carrier and lift up and remove No.2 carrier assy.
  • Page 105 Removing coupling Remove coupling. 25098TM133 Removing ring nut & lock plate Remove M12 hexagon head bolts that secure ring nut and lock plate. Remove lock plate. 25098TM134 Remove ring nut from motor casing. Remove the ring nut by using the special tool for removing the ring nut.
  • Page 106 Setting reduction unit on work stand for disassembling. Remove M16 hexagon socket head bolts that secure ring gear and housing assembly. 25098TM136 As the ring gear is adhered to housing assy, disassemble housing assy and ring gear by lightly hammering slantwise upward using sharpen punch inserted between the housing assy and ring gear.
  • Page 107 (11) Disassembling No.1 carrier Remove thrust plate. 25098TM140 Knock spring pin fully into No.1 pin. 25098TM141 Remove planetary, thrust washer, No.1 pin, bearing from carrier. 25098TM142 (12) Disassembling No.2 carrier Knock spring pin fully into No.2 pin. Remove No.2 solid pin. Remove planetary, thrust washer, No.2 pin, bearing from carrier.
  • Page 108 7. ASSEMBLY REDUTION UNIT 7. ASSEMBLY REDUTION UNIT GENERAL NOTES GENERAL NOTES Clean every part by kerosene and dry them by air blow. Surfaces to be applied by loctite must be decreased by solvent. Check every part for any abnormal. Each hexagon socket head bolt should be used with loctite No.242 applied on its threads.
  • Page 109 Caulk carrier holes as shown on the picture. 25098TM146 ASSEMBLING CARRIER 2 ASSY Put No.2 carrier on a flat place. Install No.2 needle bearing into No.2 planetary gear, put 2EA of No.2 thrust washer on both sides of planetary gear, and then, install it into carrier.
  • Page 110 ASSEMBLING HOUSING Heat housing at 60~70˚C while clearing it out and then, assemble floating seal into housing by use of pressing jig. Setting housing assembly on work stand for assembling. Assemble angular bearing into housing by use of pressing jig. 25098TM150 Assemble floating seal into housing by use of pressing jig.
  • Page 111 Install M16 eye-bolt on the tap of housing. Lift housing and then, assemble into housing in order for bolt hole of ring gear and bolt hole of housing to be in line. Apply loctite #242 on M16 hexagon socket head bolt, and then, bolt. 25098TM154 ASSEMBLING HOUSING ASSY AND MOTOR...
  • Page 112 ASSEMBLING COUPLING Install coupling on spline of the motor. 25098TM158 A S S E M B L I N G N O. 2 C A R R I E R S U B ASSEMBLY Install M10 eye-bolt on No.2 carr ier assembly.
  • Page 113 ASSEMBLING NO.1 SUN GEAR Put down No.1 sun gear on No.1 carrier, maintaining it vertical with spline of coupling. Install No.1 sun gear on No.1 planetary gear, matching their teeth. 25098TM162 ASSEMBLING THRUST PLATE Assembly thrust plate into No.1 carrier. Edge of thrust plate direction turns to cover side.

  • Page 114: Group 7 Rcv Lever

    GROUP 7 RCV LEVER 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 115 2. DISASSEMBLY AND ASSEMBLY STRUCTURE Case Bushing Spool Shim Spring Spring seat Spring Plug Push rod 10 O-ring 11 Rod seal 12 Plate 13 Spacer 14 Boot 15 Joint assembly 16 Swash plate 17 Adjusting nut 18 Bushing 19 Plug 20 Handle assembly 21 Handle bar 22 Nut...
  • Page 116 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench Spanne (+) Driver Length 150 (-) Driver Width 4~5 Torque wrench Capable of tightening with the specified torques Tightening torque Torque Part name Item Size kgf m lbf ft Joint 25.3 Swash plate 5.0 0.35...
  • Page 117 DISASSEMBLY Procedures are based on the type M1. Clean pilot valve with kerosene. Put blind plugs into all ports Fix pilot valve in a vise with copper (or lead) sheets. Remove end of boot (23) from case (1) and take it out upwards. 300E8RL01 For valve with switch, remove cord also through hole of casing.
  • Page 118 Loosen adjusting nut (17) and swash plate (16) with spanners on them respectively, and remove them. 36078RL01 36078RL02 Turn joint anticlockwise to loosen it, utilizing jig (Special tool). When return spring (7) is strong in force, plate (12), plug (8) and push rod (9) will come up on loosening joint.
  • Page 119 Remove plate (12). 36078RL05 When return spring (7) is weak in force, plug (8) stays in casing because of sliding resistance of O-ring. Take it out with minus screwdriver. Take it out, utilizing external periphery groove of plug and paying attention not to damage it by partial loading.
  • Page 120 (12) Take push rod (9) out of plug (8). 36078RL11 (13) Remove O-ring (10) and seal (11) from plug (8). Use small minus screwdriver or so on to remove this seal. 36078RL12 36078RL13 8-119...
  • Page 121 (14) Remove lock nut (22) and then boot (23). 36078RL14 2507ARL10 8-120...
  • Page 122 (15) Cleaning of parts Put all parts in rough cleaning vessel filled with kerosene and clean them (rough cleaning). If dirty part is cleaned with kerosene just after putting it in vessel, it may be damaged. Leave it in kerosene for a while to loosen dust and dirty oil.
  • Page 123 ASSEMBLY Put shim (4), springs (5) and spring seat (6) onto spool (3) in this order. 36078RL16 Assemble spring (7) into casing (1). Assemble reducing valve subassembly into casing. Assemble them to their original positions. 36078RL18 Assemble O-ring (10) onto plug (8). 36078RL19 Assemble seal (11) to plug (8).
  • Page 124 Assemble push rod (9) to plug (8). Apply working oil on push-rod surface. 36078RL21 Assemble plug subassembly to casing. When return spring is weak in force, subassembly stops due to resistance of O-ring. 36078RL22 When return spring is strong in force, assemble 4 sets at the same time, utilizing plate (12), and tighten joint (15) temporarily.
  • Page 125 (10) Assemble swash plate (16) to joint (15). Screw it to position that it contacts with 4 push rods evenly. Do not screw it over. 36078RL25 (11) Assemble adjusting nut (17), apply spanner to width across flat of plate (16) to fix it, and tighten adjusting nut to the specified torque.
  • Page 126 (13) Fit boot (23) and lock nut (22), and handle subassembly is assembled completely. 2507ARL10 36078RL27 (14) Pull out cord and tube through adjusting nut hole provided in direction 60 to 120 from casing hole. 1408DA66 (15) Assemble bushing (18) to plate and pass cord and tube through it.
  • Page 127 (16) Determine handle direction, tighten lock nut (22) to specified torque to fix handle. 300E8RL05 (17) Apply grease to rotating section of joint and contacting faces of disk and push rod. 300E8RL06 (18) Assemble lower end of bellows to casing. (19) Inject volatile rust-preventives through all ports and then put blind plugs in ports.

  • Page 128: Group 8 Turning Joint

    GROUP 8 TURNING JOINT 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 129 2. DISASSEMBLY AND ASSEMBLY STRUCTURE 21098TJ01 Shim 11 Wear ring Shaft Slipper seal 12 Retainer ring Cover O-ring 13 Plug Spacer O-ring 14 Hexagon bolt Shim 10 O-ring 15 Spring washer 8-128 8-128...
  • Page 130 DISASSEMBLY Before the disassembly, clean the turning joint. Remove bolts (14), washer (15) and cover (3). 21078DA10 Remove shim (6) and O-ring (10). Remove retainer ring (12), spacer (4) and shim (5). 21078DA11 Place hub (1) on a V-block and by using a Secure with hand wood buffer at the shaft end, hit out shaft Wooden block...
  • Page 131 ASSEMBLY Clean all parts. As a general rule, replace oil seals and O-ring. Coat the sliding surfaces of all parts with engine oil or grease before installing. Fix seven slipper seal (7) and O-ring (9), two wear ring (11) to hub (1). Fit O-ring (8) to shaft (2).
  • Page 132 Install cover (3) to body (1) and tighten bolts (14). Torque : 10~12.5 kgf m (72.3~90.4 lbf ft) 21078DA10 8-131...

  • Page 133: Group 9 Boom, Arm And Bucket Cylinder

    GROUP 9 BOOM, ARM AND BUCKET CYLINDER 1. REMOVAL AND INSTALL BUCKET CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
  • Page 134 Sling bucket cylinder assembly (8) and remove bolt (6) then pull out pin (5). Remove bucket cylinder assembly (8). Weight : 175 kg (390 lb) 220S8DA17 Install Carry out installation in the reverse order to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
  • Page 135 ARM CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. 13031GE18 Loosen the breather slowly to release the pressure inside the hydraulic tank.
  • Page 136 Sling arm cylinder assembly(8) and remove bolt (7) then pull out pin (6). Remove arm cylinder assembly (8). Weight : 290 kg (640 lb) 220S8DA21 Install Carry out installation in the reverse order to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
  • Page 137 BOOM CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 138 Disconnect boom cylinder hoses (7) and put plugs on cylinder pipe. 220S8DA25 Remove bolt (9) and pull out pin (8). Remove boom cylinder assembly (6). Weight : 198 kg (436 lb) 220S8DA26 Install Carry out installation in the reverse order to removal.
  • Page 139 2. DISASSEMBLY AND ASSEMBLY STRUCTURE Bucket cylinder Standard 9,10 6,7 8 4,5 23 22 11,12 2 13 14 17 15 18,19 20 21 Internal detail 24,26 25,26 21098CY01 Tube assembly 12 Back up ring 23 Hexagon socket head bolt Rod assembly 13 Cushion ring 24 Pin bushing Gland...
  • Page 140 Long reach 9,10 6,7 8 4,5 22 11,12 2 13 14 17 15 18,19 20 21 Internal detail 27,29 28,29 31Q6-66102GG Tube assembly 12 Back up ring 27 Pin bushing Rod assembly 13 Cushion ring 28 Pin bushing Gland 14 Piston 29 Dust seal DD2 bushing 15 Piston seal...
  • Page 141 Arm cylinder Without safety valve 9,10 6,7 8 4,5 23 33 22 11,12 13 14 17 16 15 18,19 20 Internal detail 24,25 24,25 26,27,28,29 21098CY02 Tube assembly 13 Cushion ring 25 Dust seal Rod assembly 14 Piston 26 Check valve Gland 15 Piston seal 27 Coil spring...
  • Page 142 With safety valve 6,7 8 9,10 11,12 14 15 18 17 16 18,20 21 23,24 Internal detail 38,39 38,39 29,32 35,36,37 30,31,32 25,26,27 31K6-52130E Tube assembly 14 Cushion ring 27 Plug Rod assembly 15 Piston 28 Hexagon socket head bolt Gland 16 Piston seal 29 Safety lock valve...
  • Page 143 Boom cylinder 9,10 6,7 8 4,5 23 31 30 22 11,12 13 14 17 16 15 18,19 20 21 Internal detail 24,26 25,26 21098CY03 Tube assembly 12 Back up ring 23 Hexagon socket head bolt Rod assembly 13 Cushion ring 24 Pin bushing Gland 14 Piston...
  • Page 144 TOOLS AND TIGHTENING TORQUE Tools Tools Remark Allen wrench Spanner (-) Driver Small and large sizes Torque wrench Capable of tightening with the specified torques Tightening torque Torque Part name Item Size kgf m lbf ft 1 23 23 2.0 166 14.5 Bucket cylinder 5.4 0.5...
  • Page 145 DISASSEMBLY Remove cylinder head and piston rod Procedures are based on the bucket cylinder. Hold the clevis section of the tube in a vise. Use mouth pieces so as not to damage the machined surface of the cylinder tube. Do not make use of the outside piping as a locking means.
  • Page 146 Note that the plated surface of rod assembly (2) is to be lifted. For this reason, do not use a wire sling and others that may damage it, but use a strong cloth belt or a rope. Place the removed rod assembly on a wooden V-block that is set level.
  • Page 147 Disassemble the piston assembly Remove wear ring (16). Remove dust ring (17) and piston seal (15). Exercise care in this operation not to damage the grooves. 2907A8CY03 Disassemble cylinder head assembly 9 6 7 8 Remove back up ring (12), O-ring (11) and O-ring (22).
  • Page 148 ASSEMBLY Assemble cylinder head assembly Check for scratches or rough surfaces if found smooth with an oil stone. Coat the inner face of gland (3) with hydraulic oil. 21078DA37 Coat dust wiper (9) with grease and fit Press here dust wiper (9) to the bottom of the hole of (Straight down) dust seal.
  • Page 149 Fit back up ring (12) to gland (3). Put the backup ring in the warm water of 30~50˚C . Fit O-ring (11) and O-ring (22) to gland (3). 220S8DA39 Assemble piston assembly Check for scratches or rough surfaces. If found smooth with an oil stone. Coat the outer face of piston (14) with hydraulic oil.
  • Page 150 Install piston and cylinder head Cylinder head assembly Fix the rod assembly to the work bench. Apply hydraulic oil to the outer surface of Rod assembly rod assembly (2), the inner surface of piston and cylinder head. Insert cylinder head assembly to rod assembly.
  • Page 151 Overall assemble Fix with a bar Place a V-block on a rigid work bench. Mount the tube assembly (1) on it and Lift fix the assembly by passing a bar through the clevis pin hole to lock the Straight assembly. Insert the rod assembly in to the tube assembly, while lifting and moving the Appply liquid packing...

  • Page 152: Group 10 Undercarriage

    GROUP 10 UNDERCARRIAGE 1. TRACK LINK REMOVAL Move track link until master pin is over front idler in the position put wooden Master pin block as shown. Loosen tension of the track link. If track tension is not relieved when the grease valve is loosened, move the machine backwards and forwards.
  • Page 153 2. CARRIER ROLLER Frame REMOVAL Grease Loosen tension of the track link. valve 8-162(1) Jack up the track link height enough to permit carrier roller removal. Jack Carrier roller 8-162(2) Loosen the lock nut (1). Carrier roller Open bracket(2) with a screwdriver, push out from inside, and remove carrier roller assembly.
  • Page 154 3. TRACK ROLLER Frame REMOVAL Grease Loosen tension of the track link. valve 8-163(1) Using the work equipment, push up track frame on side which is to be removed. After jack up the machine, set a block under the unit. 90-110 8-163(2) Remove the mounting bolt (1) and draw...
  • Page 155 4. IDLER AND RECOIL SPRING REMOVAL Remove the track link. For detail, see removal of track link. 8-164(1) Sling the recoil spring (1) and pull out idler and recoil spring assembly from track frame, using a pry. Weight : 310 kg (680 lb) 8-164(2) Remove the bolts (2), washers (3) and separate ilder from recoil spring.
  • Page 156 DISASSEMBLY AND ASSEMBLY OF IDLER Structure 220S8DA43 Shell Bushing Spring pin Shaft Bracket Plug Seal assembly O-ring 8-155 8-155...
  • Page 157 Disassembly Press Remove plug and drain oil. Draw out the spring pin (7), using a press. 8-166(1) Pull out the shaft (2) with a press. Press Remove seal (3) from idler (1) and bracket (5). Remove O-ring (6) from shaft. 8-166(2) Remove the bushing (4) from idler, using a special tool.
  • Page 158 Assembly Before assembly, clean the parts. Press Coat the sliding surfaces of all parts with oil. Cool up bushing (4) fully by some dry ice and press it into shell (1). Do not press it at the normal temperature, or not knock in with a hammer even after the cooling.
  • Page 159 Install bracket (5) attached with seal (3). 8-168(1) Knock in the spring pin (7) with a hammer. 8-168(2) Lay bracket (5) on its side. Supply engine oil to the specified level, and tighten plug. 8-168(3) 8-158 8-158...
  • Page 160 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING Structure Structure (standard) 7, 8 9, 10 220L8UC100 Body Lock plate 11 Dust seal Tie bar Bolt 12 Rod Spring Spring washer 13 Grease valve Bracket Rod seal 14 Spring pin Lock nut 10 Back up ring...
  • Page 161 Structure Structure (high walker) 7, 8 9, 10 220L8UC101 Body Lock plate 11 Dust seal Tie bar Bolt 12 Rod Spring Spring washer 13 Grease valve Bracket Rod seal 14 Spring pin Lock nut 10 Back up ring 15 Stopper 8-160...
  • Page 162 Disassembly Press The illustrations are base on the standa- Apply pressure on spring (3) with a press. 7, 8 The spring is under a large installed load. This is dangerous, so be sure to set properly. Remove bolt (7), spring washer (8) and lock plate (6).
  • Page 163 Assembly Install dust seal (11), back up ring (10) 9 10 and rod seal (9) to body (1). When installing dust seal (11) and rod seal (9), take full care so as not to damage the lip. 220S8UCG03 Pour grease into body (1), then push in rod (12) by hand.
  • Page 164 Lighten the press load and confirm the Press set length of spring (3). - Standard : 431 1.5 mm - High walker : 508 1.5 mm After the setting of spring (3), install lock 7, 8 plate (6), spring washer (8) and bolt (7). Tightening torque : 15 0.5 kgf m (108 3.6 lbf ft) 220S8UCG06...

  • Page 165: Group 11 Work Equipment

    GROUP 11 WORK EQUIPMENT 1. STRUCTURE SECTION A SECTION B SECTION C SECTION A SECTION B SECTION C 21078DA44 8-164...
  • Page 166 2. REMOVAL AND INSTALL BUCKET ASSEMBLY Removal Lower the work equipment completely to ground with back of bucket facing down. 36078AT04 Remove nut (1), bolt (2) and draw out the pin (A). Tightening torque (1) : 29.7 45 kgf m (215 32.5 lbf ft) 36078AT01...
  • Page 167 ARM ASSEMBLY Removal Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrated the skin causing serious injury. Remove bucket assembly. For details, see removal of bucket 8-175(1) assembly. Disconnect bucket cylinder hose (1). Fit blind plugs (5) in the piping at the chassis end securely to prevent oil from spurting out when the engine is started.
  • Page 168 BOOM ASSEMBLY Removal Remove arm and bucket assembly. For details, see removal of arm and bucket assembly. Remove boom cylinder assembly from boom. For details, see removal of boom cylind- er assembly. 8-176(1) Disconnect head lamp wiring. Disconnect bucket cylinder hose (2) and arm cylinder hose (1).

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