g. Set piston rod assembly (2) in tool U1.
Bottom hole drill diameter
Bottom
hole depth Tap used Tap depth
10.3 24 12x1.75 20
Bucket Cyl. 8.5 27 10x1.5 20
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of hydraulic cylinder
h. Assemble the cylinder tube to piston rod as- sembly (2).
★ Align axial center of the cylinder tube, then insert.
★ Check that the ring is not broken and has not come out, then push in fully.
i. Tighten head assembly (1) with mounting bolts.
Mounting bolt:
j. Install piping.
Cylinder name Tightening torque Bucket 172±24.5Nm {17.5±2.5kgm}
Arm 270±39Nm {27.5±4.0kgm}
Boom 172±24.5Nm {17.5±2.5kgm}
*Adjust
cylinder 373±54Nm {38.0±5.5kgm}
* Variable 2 pieces boom specification
Removal and installation of monoboom work equipment DISASSEMBLY AND ASSEMBLY
Removal and installation of monoboom work equipment
Special tools
Removal
Extend the arm and bucket fully. Lower the work equipment to the ground and set the safety lock lever to the lock position.
Release the residual pressure in the hydraulic circuit. Refer to the Release of Remaining Pres- sure in Hydraulic Circuit section in the TESTING AND ADJUSTING chapter of this manual.
1. Disconnect grease hose (1).
2. Sling boom cylinder assembly (2), and remove lock bolt (3).
3. Remove plate (4), then remove head pin (5). [*1]
★ There are shims installed, so check the number and thickness, and keep them in a safe place.
4. Start the engine and retract the piston rod.
★ Fasten the piston rod with wire so that it will not slip out and lower the cylinder onto a stand, or place a support under the bottom of the cylinder to support it. In the latter case, remove the grease fitting on the bottom side first.
★ Remove the boom cylinder on the other side in the same manner.
5. Disconnect HCU hose (6), arm cylinder and bucket cylinder hoses (7), attachment hoses (8).
★ Disconnect any SV drain or PPC hoses and quick coupler hoses where necessary.
★ Plug the hoses to prevent oil flow-out, and fasten them on the valve side.
6. Disconnect intermediate connector CN-A86 (9) for a working lamp.
7. Lift off the work equipment and remove plate (10) and then pin (11) at the foot. [*2]
• When removing them, first remove plate (10) and then remove pin (11) at the foot, using Tool R.
★ Shims are installed, so do not forget to check their number and each location of installa-
Mark Part No. Part Name
Nece- ssity
Qt y
Distinc- tion* Sketch
R
796-900-1200 Remover 1
790-101-4000
Puller (490 kN 50-T-long)
1
790-101-1102
Pump (294 kN
30 T)
1
*Distinction between new and existing part.
1
5
2
4 3
7
6
8 9
11
10
DISASSEMBLY AND ASSEMBLY Removal and installation of monoboom work equipment
8. Lift off work equipment assembly (12) and disas- semble it.
Work equipment assembly 1,900 kg
Installation
• Install in reverse order of removal.
[*1]
★ When tightening the locknut, tighten so that clearance a between the plate and nut is 0.5 - 1.5 mm.
Inside surface of bushing when assembling pin:
Anti-friction compound (LM-P) Grease after assembling pin:
Grease (LM-G)
When aligning the position of the pin hole, never insert your fingers into the pin hole.
★ Adjust the shim thickness so that clearance a between cylinder rod (13) and plate (4) is below 1 mm.
★ Standard shim thickness: 1.0 mm and 2.0 mm.
Inside surface of bushing when assembling pin:
Anti-friction compound (LM-P) Grease after assembling pin:
Grease (LM-G)
When aligning the position of the pin hole, never insert your fingers into the pin hole.
Bleeding air
★ Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING, Air Bleeding of Var- ious Parts.
Refilling with oil (hydraulic tank)
★ Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
11
4
12
15
Removal and installation of 2 piece boom work equipment DISASSEMBLY AND ASSEMBLY
Removal and installation of 2 piece boom work equipment
Special tools
Removal
Extend the arm and bucket fully. Lower the work equipment to the ground and set the safety lock lever to the lock position.
Release the residual pressure in the hydraulic circuit. Refer to the Release of Remaining Pres- sure in Hydraulic Circuit section in the TESTING AND ADJUSTING chapter of this manual.
1. Disconnect grease hose (1).
2. Sling boom cylinder assembly (2), and remove lock bolt (3).
3. Remove plate (4), then remove head pin (5). [*1]
★ There are shims installed, so check the number and thickness, and keep them in a safe place.
★ Fasten the piston rod with wire so that it will not slip out and lower the cylinder onto a stand, or place a support under the bottom of the cylinder to support it. In the latter case, remove the grease fitting on the bottom side first.
★ Remove the boom cylinder on the other side in the same manner.
5. Disconnect all 2 piece boom cylinder hoses (6), arm cylinder hoses, bucket cylinder hoses (7), service hoses (8) HCU return (9), safety valve drain hoses, PPC hoses and quick coupler hoses where necessary.
★ Plug the hoses to prevent oil flow-out, and fasten them on the valve side.
6. Disconnect intermediate connector CN-A86 (11) for a working lamp.
7. Lift off the work equipment and remove plate (12) and then pin (13) at the foot. [*2]
★ When removing them, first remove plate (12) and then remove pin (13) at the foot, using Tool R.
★ Shims are installed, so do not forget to check their number and each location of installa-
Mark Part No. Part Name
Nece- ssity
Qt y
Distinc- tion* Sketch
R
796-900-1200 Remover 1
790-101-4000
Puller (490 kN 50-T-long)
1
790-101-1102
Pump (294 kN
30 T)
1
*Distinction between new and existing part.
1 5
2 4
3
6
7 7
8 8 9
10
11
13
12
DISASSEMBLY AND ASSEMBLY Removal and installation of 2 piece boom work equipment
8. Lift off work equipment assembly (14) and disas- semble it.
Work equipment assembly 2,200 kg
Installation
• Install in reverse order of removal.
[*1]
★ When tightening the locknut, tighten so that clearance a between the plate and nut is 0.5 - 1.5 mm.
Inside surface of bushing when assembling pin:
Anti-friction compound (LM-P) Grease after assembling pin:
Grease (LM-G)
When aligning the position of the pin hole, never insert your fingers into the pin hole.
★ Adjust the shim thickness so that clearance a between cylinder rod (15) and plate (4) is below 1 mm.
★ Standard shim thickness: 1.0 mm and 2.0 mm.
Inside surface of bushing when assembling pin:
Anti-friction compound (LM-P) Grease after assembling pin:
Grease (LM-G)
When aligning the position of the pin hole, never insert your fingers into the pin hole.
Bleeding air
★ Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING, Air Bleeding of Var- ious Parts.
Refilling with oil (hydraulic tank)
★ Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
13
4
14
15
Removal and installation of air conditioner unit DISASSEMBLY AND ASSEMBLY
Removal and installation of air conditioner unit
Special tools
Removal
First, disconnect the cable from the negative ter- minal (- ) of the battery.
1. Drain cooling water.
Cooling water: Approx. 22.8 l
2. Bleed gas from the air conditioner, using tool S.
3. Remove floor mat (1).
4. Pull down outside air filter cover opening-closing lever (2).
5. Remove outside air filter (3).
6. Remove monitor panel lower covers (4) and (5).
★ When removing cover (4), first remove the M19 wiring for cigarette lighter.
Mark Part No. Part Name Nece
ssity Qty Distinc- tion* Sketch
S
799-703-1200 Service
tool kit 1
799-703-1100
Vacuum Pump (100 V)
1
799-703-1111
Vacuum Pump (220 V)
1
799-703-1110
Vacuum Pump (240 V)
1
799-703-1401 Gas leak
tester 1
*Distinction between new and existing part.
6
2
3
4 5
DISASSEMBLY AND ASSEMBLY Removal and installation of air conditioner unit
7. Remove duct (6) on the right side.
8. Remove operator seat by removing 4 mounting bolts (7). When removing the seat be sure to dis- connect connector G33 (if fitted), then remove carefully.
9. Remove rear covers (8), (9) and (10).
10. Remove plate (11).
11. Remove plate (12) and then remove duct (13).
12. Remove plate (14) and right duct (15).
13. Disconnect cab intermediate connectors at the following two points. (Refer to page 20-222)
• H09: Upper side
• H08: Lower side 14. Remove duct (16).
15. Remove cover (17).
6
7
9
10 8
11
13 12
15
14
16
17
Removal and installation of air conditioner unit DISASSEMBLY AND ASSEMBLY
16. Disconnect connectors at the following seven points.
Refer to "Troubleshooting" section on "Connec- tor location chart and electrical circuit diagram by system" on page 20-222.
• D01
(Assembled-type diode connector)
• D02
(Assembled-type diode connector)
• C09 (Model selection switch connector)
• Air conditioner unit connector
From top to bottom, M26, M27, M29 and M33 option power source connector
17. Remove 2 hoses (18) and remove connector (19).
18. Remove the 8 mounting bolts (20) and remove air conditioner unit assembly (21) carefully.
★ When removing the air conditioner unit as- sembly, do not forget to disconnect the two air conditioner hoses connected to the bot- tom.
18
19
20 20 20 20
20
20
21
DISASSEMBLY AND ASSEMBLY Removal and installation of air conditioner unit
Installation
• Install in reverse order of removal.
★ Install hoses in the air conditioner circuit with care so that dirt, dust, water, etc. may not enter them.
★ Install air conditioner hoses only after checking that an O-ring is in place at the connecting part.
★ Check that there is no damage on O-rings, or that they have not deteriorated.
[*1]
★ Coat the threads of the refrigerant piping at the connecting part with compressor oil (ND- OIL8), and then tighten the piping with a dou- ble-ended spanner.
Hose clamp screw:
8.83 - 14.7 Nm (0.9 - 1.5 kgm) Hose screw M16 x 1.5:
11.8 - 14.7 Nm (1.2 - 1.5 kgm) Hose screw M24 x 1.5:
29.4 - 34.3 Nm (3.0 - 3.5 kgm)
• Filling air conditioner gas
Fill the air conditioner circuit with air conditioner gas (R134a), using tool S.
Removal and installation of counterweight DISASSEMBLY AND ASSEMBLY
Removal and installation of counterweight
★ Before beginning with removal of all the counter- weight make sure all electrical connectors are disconnected.
★ Attach tags to all wires to avoid confusion when installing counterweight.
Removal
1. Open hood (1) and remove, see page 30-50.
2. Remove caps (2) from counterweight.
3. Insert lifting eye’s into holes. The lifting eye’s you require are:
Thread - 48x3
Must have safe working load of - 2,352 Kg (min).
4. Loosen 4 bolts (3).
5. Ensure lifting equipment is supporting the weight of the counterweight.
6. Remove mounting bolts (3).
7. Remove counterweight in the direction shown.
★ Be careful not to hit the engine or cooler.
Counterweight assembly PW140: 2,352 kg 1
2
3
4
DISASSEMBLY AND ASSEMBLY Removal and installation of counterweight
Installation
• Install in reverse order of removal.
Thread of counterweight mounting bolt:
Thread tightener (LT-2) Counterweight mounting bolt:
1,520 - 1,910 Nm {155 - 195 kgm}
[*2]
★ Installing and adjusting counterweight.
Sling counterweight with crane and place in position on the frame.
Push counterweight, install mounting bolts, and ad- just to the following dimensions.
• Clearance from revolving frame:
10 ± 5 mm (left and right)
• Clearance from bodywork door:
10 ± 5 mm (left and right)
• Stepped difference b from revolving frame in left- to right direction: Max. 5 mm
• Stepped difference a from bodywork door in left- to right direction: 10 ± 4
• Stepped difference c from bodywork top cover in up-down right direction:
Max. 5 mm
Removal and installation of operator cab assembly DISASSEMBLY AND ASSEMBLY
Removal and installation of operator cab assembly
Removal
First, disconnect the cable from the negative ter- minal (-) of the battery.
Release the residual pressure in the hydraulic circuit. Refer to the Release of Remaining Pres- sure in Hydraulic Circuit section in the TESTING AND ADJUSTING chapter of this manual.
1. Remove floor mat (1).
2. Remove covers (2) and (3) under the monitor panel.
★ When removing cover (2), first disconnect the M19 wiring for cigarette lighter.
3. Remove air conditioner unit, for details see page 30-224.
4. Disconnect all PPC hoses at (4).
5. Remove plate (5) by removing bolts (6).
6. Disconnect hoses (7) from orbitrol valve.
1
2
3
4
5
6 5
6
7 7
DISASSEMBLY AND ASSEMBLY Removal and installation of operator cab assembly
7. Disconnect hoses (8) from brake valve.
8. Label each electrical connector (9)then discon- nect (10 places) A01, A02, A03, A04, A05, A06, A07, A08, A09 and A99.
9. Remove 3 hoses (10) from engine and 1 hose from the dryer (11).
10. Ensure operator cabin door is securely fastened.
11. Disconnect window washer hose (12). Ensure it is clear of operator cab before lifting operation.
12. Ensure all hoses and cables, where applicable, are loose and all clips have been removed.
13. Attach lifting equipment at points (13).
14. Loosen off 4 mounting bolts (14) inside the cab.
15. Have lifting equipment take the weight of the op- erator cab.
16. Remove mounting bolts (14) and lift operator cab off.
Operator cab assembly: 662 kg
Installation
• Install in reverse order of removal.
8 8
8
9
10 11
10
12
13 13
14
14
4
Removal and installation of monitor assembly DISASSEMBLY AND ASSEMBLY
Removal and installation of monitor assembly
Removal
First, disconnect the cable from the negative ter- minal (-) of the battery.
1. Remove 2 bolts (1) from cab wall to remove monitor assembly (2).
2. Remove cover (3).
★ To remove cover just lift the top of the cover to unclip.
3. Remove 2 bolts (4) then slide monitor panel (5) down to remove from bracket. Remove 3 con- nectors from the back of the monitor panel as- sembly (5) to completely remove monitor panel assembly (5).
Installation
• Install in reverse order of removal.
1 2
3
4 5
DISASSEMBLY AND ASSEMBLY Removal and installation of pump controller assembly
Removal and installation of pump controller assembly
Removal
First, disconnect the cable from the negative ter- minal (-) of the battery. Then disconnect the cable from positive terminal (+) of the battery.
1. Remove covers (1) by removing bolts (2).
2. Remove plate (3).
3. Disconnect 3 electrical connectors C01 (4), C02 (5), C03 (6).
4. Make sure controller is fully supported.
5. Remove bolts (7) then remove bolts (8).
6. Carefully remove controller from cab.
Installation
• Install in reverse order of removal.
1 2
1
2
1 1
3
4 5
6 5 4
7
8
Removal and Installation of KOMTRAX terminal DISASSEMBLY AND ASSEMBLY
Removal and Installation of KOMTRAX terminal
Removal
Disconnect the cable from the negative (–) termi- nal of the battery.
1. Remove covers (1), (2) and (3).
2. Disconnect GPS connector (4) and antenna wire (5).
3. Disconnect connector G01 (6).
4. Remove the 4 bolts and KOMTRAX terminal as- sembly (7).
Installation
Install in reverse order of removal.