Workshop Manual EX8 €X22 E€Xl2 EX30 €xX15 Excavator HITACHIINTRODUCTION SAFETY ALERT SYMBOL AND HEAD- LINE OF NOTATION nhs manus tefotowing sale le yb and tha header ntaton so ed woane mpaaee ina an tongs BA Biss esate symbol. When you se tts sym e let othe poeta for persona ijn. Avert ow the sity Inerctons pesobed sang wth he ioty aa ym “The word "NOTE" is heading to supplement an a ional toctscal formation or ku how TO UPDATE THE CONTENTS OF THE TECHNICAL MANUAL “Tho each technical nana is seraly numbered and is embers racorded by us wih the name of te orson wo ecetvod tho acres! manual Jd they ae refered when the desverd tochrial ‘manuals ae roquited fo bo revised by up toca n+ formation as such formation must be supped quickly and corey. Pasa, advice us the nana of person who keeps tho technical manual and s responsi to Koop & tp toda by sonding back Yo ue th sp of he ship: Ping iformation shoot onsen ho totes! Irate that the personal administration change Is ‘ao, pnaso ior uso the namo a he person ‘who new appointed te maa te technics, manual ‘TO KEEP CONFIDENTIAL Pease, keop he octea formations and know: how contaned nthe chris manual confient to the outaders, Iwo1INTRODUCTION| Safety FOLLOW SAFE PROCEDURES Lnsale work practices ae dangerous. Undectae s ee provedie belore doing work dont atop shat PREPARE FOR EMERGENCIES Kap a est ait and eo extinguish handy. Keep emergency numbers for doctors, sul ———— ———— HANDLE FLUIDS SAFELY AVOID FIRES anil ue wit cares is high farmable, Oo no reinenceys ate tamon cone Sm | aks. Ansys ston engine belore rtuelng mach, Sie annie fide nay hom fe hazards, Do et | — | | sao1Safety PREVENT BATTERY EXPLOSIONS Koop soaks, lighted matches, and ae away fom the top of Daley. Bary gas can explode, | Never check batty charge by lacing ® meat object ‘across the posta. Use a voter ee hyomete, | 0 not charge a fazen batty: may expe, Warm ator to 18°C (60°F), so PREVENT ACID BURNS Sullric acid in avery eectolne & poisonous. eh tas sh, et Pes ncn, a Cause bindnese splashed ito eyes "Flog bates ia wall vena aoa, 2. Wearing eye protection and rubber gloves. 3. Reoding eating fume when electeyto is 4 aidog spill oF dipping ela '5 Use proper jump stat procedure, yo st 0 or sh your skin wih water 2. sop balag Soda fee 1 blp nese the oo 8. Fish your eyes with water for 10-15 minutes. Get ‘mesial alent immed. I acid is swale 1 Dink age anaunts of water or mi, 2 Than ok ml of maga, ese ep, ve 3. Get medic! steton immediately.Safety AVOID HIGH-PRESSURE FLUIDS Escaping tit under pressure ean penetrate the skin ‘vod the hazard by rabeing presse Belore dco ectnghydraue or afer nas. Tighten all conmectons betere appv pressure. Search for leaks with a piece of cardboard, Protect hhands and body fom high pressure ids. | 1 an scien acu, so a doce ody. yt = itt tow paws oraugrone oy eats WARN OTHERS OF SERVICE WORK LUneapected machine movement can cause sao i tag on tha night side controle Iver.Safety PARK MACHINE SAFELY Before working onthe machine: Park machine on a fove surface Lower buckat the rou. Turn a swish of Fn engie at 12 spend without load for 2 mis, Turn kay sich 16 OFF Yo stop engine, Rove koy from sch ‘Move pt cont shut iver to locke postion, ‘Alou engine 0 oo ‘SUPPORT MACHINE PROPERLY ‘ways lower the attchento¢enpement to the ground toe you work on the mace. H you must wor on ited racine attachment, seeutly suppor Be ma Do not work undar a machine that is supported sty by a jack Folow recommended procedures ths ma OPERATE ONLY FORM OPERATOR'S SEAT | Avoid posse inuy and mactine damage, Oo not stat ‘gine by shring across starter rma, NEVER slat engine we standing ground, Start on ‘ne only rom operators ea sA04STAY CLEAR OF MOVING PARTS Enlangloments in moving pans can cause serious hy To prevent accidents, use cio whan working arcund rotating pats. Safety AVOID POWER LINES Serius sry oF deat can result fom contact wit Never move any prt ofthe mactiow of fad closer to tect tw than 3m (10) pu ic the ne ssuator tent USE HANDHOLDS AND STEPS tives point contact wits the stops and handrails and ioe Never jump on or of he machine, Never mount or dis mount a meng machine. Be carlut of slippery conations on platforms, stops, fd handrals when geting of th macsineSafety KEEP RIDERS OFF EXCAVATOR Oniy alow tne operator en the excavator Keep siders of ‘ides on excavator aro subject to jury such a8 being | struck by foreign obec ang lng tows of he exca Vator, Riders aso obenit the operator’ view resting MOVE AND OPERATE MACHINE SAFETY Bystanders can be run over. Know the lcaion of by. Slander blows mowng, swinging, oF operating te a Aye heap te vol tm wring condo, ie Use a signal person whan moving, swinaing, or opera ing the machine n congested seas, Coordinate rand sionals before staring the excavator, WEAR PROTECTIVE CLOTHING ~ ® a % Q @ e& 8A.06Safety PROTECT AGAINST FLYING DEBRIS. Guard aginst injury trom fying pieces of metal or de ths; wear goggles or saat glass. PROTECT AGAINST NOISE td eae ILLUMINATE WORK AREA SAFELY urinate your work sea adequately but slay. Use Pty gt otra nse Shine, Make aie tho ube enone by 2 age cS Tn ho aman fon accdotay broken ula ean Ro ite spied tue or 08 “ee | | SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, | ‘scart, loose clothing, or necklace when you work near C} SA.o7Satety REMOVE PAINT BEFORE WELDING OR HEATING Avoid potontaly tole Kanes and st Hazardous fumes can be generated wien paint is hes (03 by welng, sidering, or Uang a toch. o all work outside ori 8 wo ventilated arb, Dispose of pala solvent propery, Femove pa before waking cheating I you sond or grind pint avok esting tho ds Wor an approved reaprae 1 you use solont or paint stripper remove stinger wih Soap and wator bolo weling Remove sant Pt stopper contanors and other ammatie mato from aroa: ow fumes to aisperse atleast 16 minutos bots welding or hating, AVOID HEATING NEAR PRESSURIZED FLUID LINES. FFammatle spray can be ganerated by hosting ner resurized fu nes, costing In sovere brat you Sal! and bystanders. Oo not heat by weldes, soloing, ‘areata sterile Prossczod Uns can be accidentally cut when heat 00s beyond the immediate tame ara. sta ee ‘sng quads to protect hoses or oor mataSafety Froventasphysiaon. Engin aust tes an cause It you must operate a bung, be postive there is fduate veniaton. Ear uso an exaust pe extn ‘Son to remove the oxhaust Tunes or open coors and twodows to Bing enough ouside ait he area BEWARE OF EXHAUST FUMES ‘SERVICE COOLING SYSTEM SAFELY Explosive etase of tis ro prossrizod cooing sys tem can cause serious burs, Shut off engine. Only remove filer cap when cool fought ouch with bare Pans Inpropedy disposing of ids can har the envio: inant and ecology Before dsog any this, tnd out the proper way to iepose of waste fom your local en ronmental agency Use proper continars when daring fide. Do nt use food or beverage consinere that may misled someone ino dking tam ten 120 NOT pour ai into tho ground, down ain, oF ito ‘steam, pond, or ake, Ose rolvant rman fal protacton roguatons when oposing oto 1 Coolat brake fad fates, Bates and other harm sA.09 DISPOSE OF FLUIDS PROPERLYSafety WORK IN A CLEAN AREA Before staring a job, clean the work ara. Remove ob jects that may be a safety Hazard tothe mechan oF bystandre USE TOOLS PROPERLY Use tools sppoptite to the work. Makestit tools Pats, and procedwres can crate salty hazards. oe Use power oa ony to loasen threaded too las For loosening and totaning hardware, use the const size tose DO NOT use U.S. measuromert tol on ‘otc Tastonors. Avoid boy inry caused by spin, ‘irons. Use ony recommonded replacement pats, (See Part Cataoo.) REPLACE SAFETY SIGNS a Replace missing or damaged safety signe. Sa the so a chine operator's mata or covet sey fn pc ee SA10Safety LIVE WITH SAFETY Before returning machine to customer, mako sore ma ‘chine is funcbong propery, especialy the ste Sy5- toms, fal al guards and sheds, satsat2KMs206-01 seo: WORKSHOP MANUAL EXCAVATOR ‘SECTION 03 SPECIFICATIONS moe ft SECTION 02 UPPERSTRUCTURE worm kat te Gl oe ‘SECTION 03 UNDERCARRIAGE moxie Fb HT fe Lo “TION 04 FRONT ATTACHMENT am | POD hP RY FAYE ‘SECTION 05 SPECIAL TOOL mos | AR ‘SECTION 06 ENGINE AND ACCESSORY (Ex8) SECTION 07 ENGINE AND ACCESSORY (EX12, 15, 22, 30)SECTION Group oF (Group 02 ‘SECTION Group oF crop 02 Group 03 Group 0¢ Group 05 Group 08 Group 07 Group 08 Group 08 SECTION Group 01 Group 02 Grovp 03 Group 04 Group 05 Group 08 (Group 07 ‘SECTION Group oF ‘Group 02 EXCAVATORS WORKSHOP MANUAL SECTION AND GROUP CONTENTS: 01-SPECIFICATIONS: Tightening Torque Name plato 02-UPPERSTRUCTURE ‘cab ‘Counter Weight ump Device Conta Vave Swing Dovicos Plot Vato Lock Valve Solenid Va (09-UNDERCARRIAGE Swing Boson ‘Travel Device Center Joint “Track Adjustor Front er Upper and Lower Ror “Track Link 04-FRONT ATTACHMENT Front Attachment Hyeraul Cyr SECTION 05-SPECIAL TOOL Group 01 Special Too st Group 02 Drawing ol speci! too! SECTION 06-ENGINE AND ‘ACCESSORIES (EX8) (Group 01 General rormaton Grou 02 Engine Group 02 Lubieatng System (Group 04 Cocing Sytem Group 05 Fuel System (Group 05 Troubleshooting (Group 07 Special Tot ‘SECTION 07-ENGINE AND ACCESSORIES (€x12,15,22,20) Group 01 Genera oration Group 02 Engine Croup 02 Luriatiny Systom Group 04 Cocing System (Group 05 Fuel Sysiom (Group 08 Troutestaoting Group 07 Specie Too! ‘sB0w-01ss0w-02SECTION 01 SPECIFICATIONS Be CONTENTS Group 01-Tightening Torque “ong Tee woro1e | GGroup 02- Name Plate | ue te wor.0201 | 580W-01-01‘s80W-01-02SPECIFICATIONS / ightening Torque Tightening Torque Spectications Exe tude |g, [wow sm] Taam las mma mn OY | ine) [Nem (kgm, ttt) 7 [rae eon nor mga ee Casio | ar 20, 1aasy 2 mie tckt moun om ioe | eenim | e904 50, 26 3 yan of nk retig ta 1 [os [enn | ss04 sa. 3617) 7 ]Fut rk wring bat wo [2 | eanin | 400m 6a, 3617) z _ 2 | | sit | “see 10.720 3 vn ona in oi ay area) | aaa 80, 2170) prose cure | aan 40, 1179) pve toner | ena 68, 2709 = pre awe) | feran t40, 10126 |e ania tak . asia) | aan, 10,72 7 | on! ao mou ak ° esi) 1a. 7a Covel ave tact ong tok te ann s0_a6in Seng not onig bat ‘0 asm 50.3617] 9 | ate rnin on ¢ “a2at0 a5, 36 70] Sxing boing mourn bao wopwerice | — 10 oer 50, 361 Sung being noting toto tearege | 10 cen eo Ti ave deve ing ak ‘a 0948 5036.7 12] Socket nonin bok ‘0 316) | aa0u 80.617) 13 [Crit os mating Sa z ~ | [74 Teck oer mouning bok ya |axa| earn) | 166701 17.0, 12296) 15 act swe mong bak. a 16] cover mrtg bot 2 aay | 38 40,73 erin | sso 0.261 77 [casei ning we ab oveie. | aaa 25 250 ae: (1) Aly ant (69 he cn 8 sso spe i) fo ta an aso staize he on {@) Make sure bot and rut dvoads ae clean belo instaling {2} Aoply Locite to Beads beore nealing and ightonng Swing beating mowing bots fod wor-01-01‘SPECIFICATIONS / Tightening Torque Tightening Torque Specifications X12, EX 15, 7 = Bot ia | gy | Winch io Tore ("| came cs inom | _ tem gtr, ety 1 | Enane coshion rubber mauning naan) 2 | 2] 07509 | 902% 90, e509) Engine bracket meuring boost v2 | 2] ores | sez6 90.65.05) 2 | Myer of tank mounting botlront) | 7 | asm | 4904 6.0, 96.17) 2 | Hyco tank mowing bot 10 | 3 | o.6nr7) | ao0a 50.36.17) | Foot tank mounting bot e+ | oss) | 1970 20, 1446) 5 | Mydrauiehooses and Union Janis Pra 075119) | 2040 90, 21.79) Peaee oar) | s02q 40, 11.79) Prva 1o8e7) | 63.7% 65, 47.02) Pear 1.26(92) 137.90 180, 101.26) PEMA 1.41135) 176.52 180, 190.19) 6 | Main pup morting bok wo | 2] esr | 90a 50, 3617 Pilot pump mounting bt wo | 2] osm | 904 50, 36.37) Pump cover mounting bot w | 6] osm | soy 50, 3617 Pump cover mounting rut | | 2] enn | 904 so 2617) 7 |Contct valve mounting bolt 10 | 2] 0677) | 904 50, 9617) Contr! valve mounting nt wo | 2] oom | oom so 61 Contre valve base mounting bl wo | 2] osm | sou 50361 8 | Swing Device mounting bot v2 | 4] eve) | 6261 9.0, 68.09) 13 | Contr pwn moi bo 8 | osnrs) [or 20, 1446) 10] Barory mosting bot 5 2 | ose | 490105, 3.61) 11 | Sa nna ta |e | eereer | vars v8.0, 101 2) 12 | Swing bearing mounting bat (Carer) ro [16 | o6nr7) | saew 60, 43.39) Swing bearing mounting bot_(Track) so_| | osm | se0K 60.4339) 73] Travel dovce mounting bl wo | 6] o3ne | 904 50 3617) Sprocket mounting bolt wo | osn | s0% 5036.17) [74 eu mouning bo wo | 8 | 0677 | 204 50, 36.17) 16 | Track roller owning bo 4 [v2 | onnea | 106.70 7.0, 122.86) 16 Cover mounting bot ® ‘osi3) | 1971 20, 1446) 10 067117) | «08 50, 36:17) 77 | Coonterwaight mounting Union bo we [4] 07s | vo787625@0, 65.05) Counteweight mousing belt 2 | 3] ove | 926 90, 65.05) ote (1) Apply lubvicant (eg white ane 8 cisoled into sina oto Boks and ts to stabilize tak ton ooticiont, (2) Mako suro bolt and nut toads ae clean before instaling. (2) Aoply Loctite to Breads bore insaling and ightning swing beating mounting bots, ‘wo1-01-02SPECIFICATIONS / Tightening Torque natcont (2) Make sure bolt rut toeds ao clon bolre instating. {3} Aoply Loci to treads Belore installing and Ughtning swing boaring mounting bolt. ‘Tightening Torque Specifications x22 i a Gon | gy | Wrench Sa] Torque me in rm) | _ Wm Gt, my 7 | Engine eustion rubber mounting nut 2 | o7sri9) [3826 9.0, 65.09) | 2 | Engine bracket mountog bot wo | 7 | csr | 4904 50, 36.17) Engine bracket mounting rut wo_| 1] osni7 | so0K 5.0, 36.17 3 [Tank mounting bo wo | + os7a7 | ao0u 5.0, 36.17) «| Hycrauehooses and Union Jone Peve ore) | 2942 30, 2173) Praer oor) | 392 40, 1173) Pevee 067 | 6975 65, 4702) Pra 12632) | 19730( 140, 101.26) Pewee van@6) | 17652 180, 130.19) Pern s.41(96)_| 20804 2.0, 161.09 3 [Pump movnting Bat so [2] oensy | «oom 0.3617) 1 | snp cover mounting bot wo | 6] asra7 | 400% 60, 36:17) Pap cover mounting nt so _| 2] os | sou 50.3617 7 | Contra valve mousing bolt so | +) os7a7 | aoa 50, 36.17) onto valve bracket movetng bot w_| 6] osra7 | som 50. 3617 2 Swing device mounting bt ve [4 | 075) [2826 90, 05.00) | 12 | Sing moter runing sockat ba e+] ozye) | 3235133, 2508) 10] Botery mounting nut 6 [+] osauo) [404 05, 3.61) $1] Canopy mourn bat 34) «| ora) | 197.0( 140, 101.26) 12] Cab mounting bot 16 | «| onatzay | 197.90 140, 101.26) 13 | Smog bearing mounting bot to upperstuchxo | 12 | 13 | 0.76(19) | 10287 105, rev) Swing bearng mounting botio undercariage | 12 | 16 | o7stia) | 10297 105. 75.94) 14 [Travel device meuniing bot v2 [18 | over | 6269.0, 65.08) 15 | Sprocket mounting socket bot 12 [| os) | 926( 2.0. 66.09) 16 Track roter mounting bat ve | v2 | oanea) | 166711 17.0, 122.96) 17 | Cover mounting bot 10 ‘osni7) | 4908 80, 36.7) 2 o7sis) | 0.26 90. 65.09) 78 | Coutorwaight mounting bot v4 [| osnea) [rar201 140, 101.26) Note: (1) Apply Morcant (emit zine 8 assolved ino spindle al to Lots and us o stabilize thet ction 1wo1-01-03.conticint, (2) Make sure batt and rut had ae clean before isting (@) Apply Locte to treads befor insaling and ightening swing bearing mounting bots. SPECIFICATIONS/Tightening Torque Tightening Torque Specifications x30 Bot 18 vrenen Size Torque 7 ranean mm | O | item | nem aot, | Engie custion mibber mounting nat 2 | «| 07609 | exam 90, 650) 2 Engine back mounting bok a ee Engine bracket moueing nut wo | +] osm | «ou 50.361 a Tank mount bot wo | «csr | 900 5.0, 96.17) “¢] Paulie hooses and Union Jams cag 0.7518) | 204% 30, 21.79) Pesce oara2) | 3924 40, 11.79) Pever sos) | sa7{ 65, 47.00) Pra s.ze(a2) | 197.90 149, 101.26) Prave arias) | 17652( 180, 120.19) - Per 1.41196) | 205.04 210, 151.69 5 Pump mouning bat 2 [2] eres) | 0826 9.0, 65.00) 6 Pump cover mounting ba w | 6] asm7 | 904 50, 36.17 Pump cover mouming bl so | 2] osm | sou 603617) ‘Cont! vale mounting bolt wo | | o6m7 | «90a 60, 36.17) Cont valve bracket mounting ble wo_| 6] osm | soa 50.3617 @ ‘Swing device mounting bot 2 | 6] 0751 | 0269.0, 65.09) [2] Sing moter mounting socket bol e+ | ozs) [32064 33,2586) 10 Batery mouting nut 6 | 4] soo) | 494 05,360, 1" “canopy mounting bot v6 || conan) | 9790 140, 10126) 2 ‘Cab mounting bot se [| ose) | 197.0( 140, 101.26) 13] Swing bearing mourong bor wo uppersmucure | 12 | 20 | ven | ruzwq vue, rose) Swing boarng mowing bot to wndercariago | 12 _| 20 | 076119) | 1297 105, 75:94) a “Travel device mounting bot v2 [ve | ors [10297 108, 75.94) 15| Sprocket mounting socket bot 2 [re | esai0) | 826( 3.0, 65.08) 16 Caio rotor mounting bat sa] 2 | ogra) | 197.001 140, 101.25) v7 “Track rol mounting bok 14 [ss | owrea) | 166.70 17.0, 122.98) 18 ‘Cover mounting bot 0 centr) | 40a 50, 36.17) 2 ars) | 22 90, 65.00) 79 ‘Counterwight moaning bat 4 [4 anes) [1730 140, 10.20) "Note: (1) Apply lubricant (eg. white ne 8 dissolved into spindle 0) to bots and nuts to stabil ther on wo1-01-04SPECIFICATIONS / Tightening Torque Torque Chart (1) Be sure to use bots of correct length. Bots that ate too long cannot be gone, as th bolt Hp comos in to cortact with the bottom oft Bat ole Bls thal are too shot cannot develop sufciont tightening orca td to shoror tread lng (2) Tilton bots or nts conecty to torque spacications. vee kinds of bots, T, Hand M, each diferent in Inatoral re used. Make aur o employ coroct bolls and Ughan corey when asorbing tho mac oF @- @- @- Metic Bolt Torque Chart ‘Nomina! Tit (SONS) bot (400) bor (6541) [Wrench Sizo ia remy | __ Nem that tt) am hn, a) Nm (agi, (nm) 6 ‘30042 10 (0360.43, 2468.19) 8 | asa a0, 2.70] r981¢ 20, 1447) sass8i 13 (0.90.00, 651-723) 10 | 6a75( 4s, 4702)| an0a( s0, 98.17} 961 20 144) 17 12 | sree (110, 7956) | a8.26( 90, 05.10) | 4a2( 3, 2502) ) 19 14 | 17659(190, 19089) | 19790( 140, 101.26} sage ss, 997) 2 we | 26479( 27.0, 19629) | 20595(21.0, 151.89) | 7846( 80 87.86) | 24 sa_| aorncaon, 20932) | 2042r(an0. 216.00 | 7.08 126, assy | 27 ‘Note: ex. EXB Swing bearing mounting bots Bat cia (10 en) ‘Tigo oq 388.54 New(6.0 kam, 48:99) wo1-01-05SPECIFICATIONS / Tightening Torque Inch Bott Torque Chor Nominal eit (SONS) ‘bat (8541) lary) | Nem kgm a) Nem (kgm 4) ae 137s W785( 14 18, 1048 1008) we 39.34 4707( 34 48, 2459. 94.72) se 6963. 87.20( 71. 89, 6269- 6497) ar | s0939( 650,397.82) | 12749.15691 (190-160, 9809-11579 Note: The torques given are standard gues. Any tows specifically dasccbed his manual have price ite (2) When tightening two or more bos, tigton them atlemately as shown below to be sire that they are ight ‘ned even. at on ped ato onconte ‘ter tion eto gray massa _ 8009008 Rad s0e¢eoo ‘wo1-01-06,SPECIFICATIONS / Tightening Torque ee yess cnerten- dno Jon Tome mone Para e eoanewne wes nee gece» — pee vt metus mst, roe eee ee ee mesma rym tmernios, = wee, ee och ram cant oe Mat Teper Noo sae “Tightening Torque Specifications me ee “Tohtoning Torqve Nominal Toad Size neem irnch Sizo - Union Joint Pipe Threads = (igh pressure) (om pressure) v8 sarc 15, tag | 10 7 aaoac ao asin | saerc 20 tan | 19 3° e965( 70, 5069 | 2042 30. arm | wi7( 95, ary | a90a 50, 6am | 7 19790(140, 10125 | aes 70, sos | 17659( 180, 190.19 | aes; 70, soe | a 205.95(210, 18109 | worse( 10, yes | 4 243.25 (250, 269.16 | 15691(160, 11579 | 30.90 (550, 097.80) | 106.14 (200, vance) | 6° z ‘eae (600, 42308) | 25498(260, 108.00 | 7 ‘Note: The torques given are for fre tread of SSAT, Horna weed i f cast en, Uo longue must be r= ced eppronaty 10%. ‘wo1-01-07SPECIFICATIONS / Tightening Torque (9) Aoply Teflon tape to treads just enough 10 tl up teas clearances, as shown. ‘Dp not t0 apply 100 much 1 evo loosening o he screw. on tent ‘wor-01-08SPECIFICATIONS / Name Plate LOCATION OF NAME PLATE covet 00% on sear SE e @ 1 age te er 1 rae 1 tamer ame st 28~ tara rateeT. 3H Hama NTE: Dea ©, ave ecto atch. 2 Name ite (ame ot ‘te vO. OH «17- Name Pate (Lover——31~ Name Pate ving «25 Nome Pat (STO, Smee ° tae" too a ‘mean (eSEreanon 3 Name me (Acar) Name ne 14 Naa te (Opaction) 18 Home ate Kame Pa 80k ee (30) (Speco ‘hse 5+ amen (ezen) 16 Name te Gpaeon) wor-02.01SPECIFICATIONS / Name Plate exrzexis ras ohn sti 2 SE ho INSDE vw oF sear ‘MEWenow ABOVE OF FOOT \VSW ROW TOP OFTHE FUE LEVER BOTTOM OF THE Seer $1 Name te a 19 Nameiate(iLe) NOTE: Detal ©, ®, ©, @ ore crecon of ateching. $2 Name ate (HF Nay 20 manera (Sung V4 Nome lte Laver 18 Name a ame ot cay Ensen ~ [Gpucamso) wor-02-02SPECIFICATIONS / Name Plate x22 €x90 NOTE: Deal ®, ®, ©, @ wo direction of actin, wo1-02-03‘SPECIFICATIONS / Name Plate wor-02.04Group 01-Cab Removal lastalaton Group 02-Counterweight Removal and lstalaon| Group 03-Main Frame ‘Removal and instalation Group 04-Pump Device Removal and isan of Pump Device Disassembly acd Ascobly of ump Devico Maintenance standord SECTION 02 UPPERSTRUCTURE CONTENTS wo20101 wo2.2.01 wo2-02-01 wo2-0401 wo2-04.08 wo2.04.24 Group 05-Control Valve Removal and instalation of CContorl Valve Disassomby and Assembly of (Control Valve Group 06-Swing Device Removal and Instaiton of ‘Sing Device Disassembly and Assmbly of Swing Moto Group 07-Pilot Valve Removal and istaaton of Pot Valo Disassembly and Assembly of ‘580W-02-01 Wo2-06.01 Wo2.0513 wo2.06.01 wo206-13 woo.07-01, Wo2-07.04UPPERSTRUCTURE / Cab REMOVE CAB (on2ens622600) [A iqures shown i Wis Section are for EX 30. {Remove Tour seat mounting bos (1) 1 rove the me IT <= 2.Discannect wire harnossos. me 220m | 2. tach the ng bis tothe ca, A caution: cas wean [EXIZEXIS: 297 (100 ka) X22 E120; 419 (100 6) oe 4 Rove the cat mousing tli | Showy eit and remove the cab using a crane. me: 2 00 | | | [oe wo2.0-01UPPERSTRUCTURE / Cab INSTALL CAB '5.Atach the sg bats tothe ca, Host the cab’ and put i on the fame using the 6 instal four cab mounting bots (2 to secure tho oa, me 24.01 at 187 Nem (108 Bt 14 ktm) “Put he seat back Install four seat mouning bots (1) to secure the ‘oat ee Tom ae 249 Hn 8 kot) 8.Connect wire harnesses ‘wo2-01-02UPPERSTRUCTURE / Counterweight REMOVE COUNTERWEIGHT (ouzexisex22 2x20) [igus anown nis secon are for EX. 30. 1.Romove four engine cover connecting plas (1) and tw stopper pins (2) to emove engine cover (3) eee mm =< 2.Remove wo counterwaight mounting Bos (1), Ie 22 009 ‘.Atach wire rope to counterasight (1) and hold it tip using & crane. Remove two. remaining ‘ounlonealght mounting Bots (2) A. crvti0s: cao wesenr Sxo:e8b 124) Sia! foo (eee) xis: rf 041) ‘a2: 25 fe (0519) x30 90 1 (10 KD) ome: 20m ‘4.Belore heisteg the counterigh, ws the cane 0 ‘move away tom the machine. ‘wo2-02-01UPPERSTRUCTURE / Counterweight INSTALL COUNTERWEIGHT Stach a wie ope tothe counterweight ‘Using a erane, host the countorwaight away frm the machine belore mowing t back into pace “Tomporety inal two Countarwnight mounting bat, Remove te we rp, ae 20m instal wo remaining countormeght mounting bots {2} the tighton a four bots 1),(2) 0 specication, PO ex exi2EXI5: 19 mm {522 E390: 22 mm SEEK 341m (251, kgf) [EXIDEXIS: aa Nn (6 bt, Seen) {EX22 EXO: 197 Ne (101 i, Akt) insta four engaw cover atahing bots (1) and two Stopper pins (2 sal the engine cove. me 17 om =< SE; 49 No (86H, Seg) ‘wo2-02-02UPPERSTRUCTURE / Main Frame REMOVE MAIN FRAME (DBEXHENSELLO0) [igus show ts Secton a0 for EX 90, Ai cavTion: escaping tis under pressure can K | BSG ne evar by fling pressure betes disconnecting hydtaute or ote ines. Tighten Si connections betore appiying pressure Search for leaks vith 3 pce of casos | Fake"eare to protect hands. and body tom igheressure fra oo an accident occurs, get immediate medica tktention. Any id injected Into the ek must be surgeally removed within a few hours or ‘angrene may result Toosoning cap (1) located on te op of bo ok Remove cap (1 2.Remove mounting bots (1}(2,(9,4) to remove the oor patos. amet wo2-03-01UPPERSTRUCTURE / Main Frame ‘Remove eght 0! mounting bots to remove the ro me irom Using vacuum pump, reduce tho hydause tank pressure into the negative range and! conine to ‘pera te pur wil working “Remove al vpperstucura side hoses except conor Font ete hosts (1)(2)(0) ‘Als, be sue To nove the swing bearing easing hose De: torn, 22M, S21, 980mm ‘Attach wire ropes as iustated to balance thy ein a ‘rame, 5. Romove rane mounting bol (1). O17 mm SHB EXIZEKIB), 19 rn (OH22) 20 mm (X30) ‘wo2-03-02UPPERSTRUCTURE / Main Frame 7Hoist main kame (1) use a eran. AdcauTion: main Frame ( Upperstucture+ Front ‘tachment ) Weight EX 8 1043 fb (473 kg) Ext2: 1702 6 (72 K9) xis: 1241 (2x22: 2873 2X00: 3011 1 (1502 kg) INSTALL MAIN FRAME fa.tach wire ropes as illustrated to balance te rain | ‘ame. 8.Slowy put the mainframe onto tho undercariane Using crane. Take ‘care not 10 damage the Undoreariage side hose, me SERB ERIZEXIS) 17 mm (©226%49) 19 mm =H: (EX8) 49 Nm (6B, 5 hat) {EXIDEXTG) 69 Nm (49 Br Bhat) {622.600} 109 em (75, 105 Koh) 10st he main rae mounting bot Remove the wee pes. ae sri aH: 42m 6A, Skate wo2-03-08in Frame UPPERSTRUCTURE / M ‘last a uppersvuctute side hoses ‘iso, be sur to instal the swing Bearing greasing PX 519.00, 22mm, 92, mn Zot 22 3 gm) oN (29 ry aes) aN (a7 bf, 85 4ghm) 17 (101 A, 14 aah) {2install the floor plates using mounting bolts C.2}.0}. met mm mt 480 (9 BA 5 kam) {8.osta the roof using eight bots (1), me aT ae 488m (6 5 kam) wo2-03.04UPPERSTRUCTURE / Pump Device REMOVE PUMP Xa EXIBEXB2 X20) iyues shown Hs section ae or EX 30 Bi cxxTi0s: escaping tld under pressure can x pene the sin, causing serious ur. fold ths hazard y velovng pressure Deore Gioconmecting hydrate or other tines. Tighten SI connections before applying pressure Search or leoke wih 9 plece of cardboas {Tone care to protect hands and body tom on ‘atepressore fs Wan ident occurs, got immediate medical ‘Any fluid injected ito the skin must ically removed within a few Now's oF ‘angrene may result ‘ease ai presse fom tho hysrauic ol tank by Toosening cap (3) lated on te oy of He a omove cap () a ~—E—rtétéi‘_sés—SO _ ho cpp fn 1) 1 anor gine covet 2 2 ee Tim ie < ‘wo2.04.01UPPERSTRUCTURE / Pump Device S.Romove moving bots (1) snd (2) to remove the et countwesght me: 218 ~15(12 an), B422~90414 mm) Remove muffler mouning bots (1/2 pieca2}4 pies) and nus (3,4 pcos) a romove io (3). ‘oe: On model EXS, removing the muller is not necessary. me 17m Using a vacuum pump, reduce the hydrauie tae pressure Ilo the nogave range and continue to parte the pnp wie woking. 5.Romove two detvery side hoses (1) and pl tater ‘de nose (2, me 191m, 22 0 wo2-04.02UPPERSTRUCTURE / Pump Device plot pump side hose). ‘mouning Bots (2) 10 remove tho suction sie pipe ame 19 ne Fo 8 {8.Tghtan sng bet (1) around pune (2) ‘ach ling bo (3 10a crane fo Secu pump (2. A caution: pump vevice weichr: 12X90: 86 (9.4 ko) x22: 47 i (1.4K) XYZ EXI6: 36 8 (16 ko) x8: 1616 (akg) 9-Romove mounting bos (1) Remove pump (2) using Yh crane me 19 ne INSTALL PUMP 10,Using a eran, hoist pump (1) and secur it wit mounting bots (2. le: 18.0 pe 98 Wm (72, Tate) wo2-04-03UPPERSTRUCTURE /Pump Device ‘natal ot pump side hose (1, Insta the suction se pipe using mounting bots (2). 19m, pam 29 8m 22 WH, 3 kgm) [8,98 Nm (72 HB Hay "instal Wo dBvery side hoses (1) and pit ol ier ‘de nose (2, ame 2191, 22 mm at: 20 Ni (22, 9 Kg), 38 Nem (29 Bt, 4 kgtm) 12. insta the mute and sooue using mauntng bots : a OA). mest nm 4 Nn (96, 6 atm) 14. Rumove sit tossing plug (1). Fil hyraute ol from ‘ho pg hole ntl te ol comes ou om the ha ‘Tighten log (1) tmperay Fun te engin at sowie, lee ai om tne pomp by loosening pl (1) vs the ol comes out Sap the eng. Tghton pug (1) to pectic, I 390m a5 Nm (40 1, 58k) ‘wo2-04-04UPPERSTRUCTURE / Pump Device ‘Sita Tol counteweight (1) using mounting bois Ao. PE 519 mene E19), 226220) at He (25 3.5 kg NEE) Bos): 108 Wn (@D 1 KymyEX12~EX5) Bots (2): 88 Nim (65 tt, 9 ken EX12~EXIB) {37 Nim (10 Bi, #4 Kal 22~ EXO) 16: Intal engine cover (1) sing four bls (2) and two pins me stom =e 49 Nem (95 ot 5 kat) <= ‘wo2-04-08UPPERSTRUCTURE / Pump Device DISASSEMBLE AND ASSEMBLE PUMP DEVICE (EX8, EX12, EX15, Ex22) xe ‘wo2-04.06UPPERSTRUCTURE / Pump DeviceUPPERSTRUCTURE / Pump Device ie eS a ale shUPPERSTRUCTURE / Pump Device DISASSEMBLE Clean the ouside of tbe pump and place it on a work bone Belre dsassembiing, make matting ‘marks ‘on Dodes 119}, 2(8). pat (2), boos 1 ron cover (16), and cover (8 10 ad i assy. 1. Clamp front cover (16) ina vio. Loosen socket 2, Remove the pump tom tho vise. Pull out bats (1 feckat bos (11) to dsassembie tho pump to Sub assembles of: ont cover (18), boay 1 (1). Noe: For EX8, clamp body 1 (1) n a vise pinto (22) and bodies 2 8) and 3 (9), T— : mm Note: Subascombies fr EX8 ave: bodes (1) and 2(@), and cove (21, Sabssembles fr 2X72 and B15 ae: tort over (16) and boas 1 (7) ad 2 8). xz t= boos 7 wen Genet 1 water Be bose a Ghat 105 Seven Gewr 2 18= Sovping 2 Pow wo2-04-09UPPERSTRUCTURE / Pump Device 8, Remove retaining ring (18) and ol sal (14) rom cover (18), 4. Remove gasket (2) om tont cover (16). 5. Remove side plate (2) and sto! bal (6) rom body (th ese: For EX8, remove plate (2) te: On sie plate (2), mark the sucton port side and the dotvry pore fo ain ctmgusting thor nasser 15. Remove dive gor 1 (6) and ven gear 1 (7) from boay 110) 17, Remove side plato (2) om Boy 11) Noro: For EXB, remove plate (18) retaining rng (13) ‘and of 09114). Noe: On side plato (2), mark the suction por side at te dovery por side fo aid cstngushing thom in assoney. {8 Remove gasket (4 rom body 1 (1). 9, Remove coupling (15) and col (23) rom pate 2). 10, Remove gaskot (4) rom pat 22). 11. Remove sept (2), sto! bals (6), oars 2 (8) nd (10), se plate (2), and gasket @) tom body (0) nha onder long to stop 6128. ‘Noo: For EX, move plate (2), dowel pn (5), goars 2 (9) and (10) plete (18, couping (15), sea (4) ing (7a boy 2) ren 1 ss, 12, Ramove sido plato (2), ston bal (6), gors 9 (20) ‘and (21), and sido plat (2) rom body 3 (18) 0 {at oxdr rong fo saps 8 07. Note: For EXB, remove dowel pin (5), so (4, ning (17) rom cover (19} ering stops 5 and 8. wo2-04-10+ toys oor 9 wo2-04-11UPPERSTRUCTURE / Pump Device Betore assombing. clean the isassombiod pans with solvent and rythm wth compressed a iso, apply sof hydra o othe ner pats pce al gaskets, seas, Oogs, an of saa with ASSEMBLE 1. Ins of sal (14) ito ot cover (16), then instal ‘etaning neg (13 10 ont cover (18) Nee: For EX8, insta ol sat (14) and retaining ing (13) 10 boay (1) 2. Clamp ont cover (16) wh ts of saa ite facing the ground n ase. Note: For EX, clamp body 1 (1) with itso sea side facing te round in a vie 23. tnstall gaskot (4), sido plat 2), and soot bas (6) to hoot cover (8), te: For EX 8, insert plat (18) ino ody 1 (1), thon Insta dowel pis (5) Noto: Apply grease to gasket (4), ste! bas (5), and ‘owe! pine (3 Note: Apply fm of ya to side poe (2). ‘When instatng side plate (2), take care nfo Cntise es surson side ant deiory si. neal "ide plate (2) wh is gasket sie facing onnwera. ‘Nee: For EXB, apply atin of yr oo plate (1) When instatng plate (18) tae care nat 0 Contise te sueson sie And dohvory de. sal plate (18) wh is copper aly sie facing Cowra 4, testa drive gear (6) and kvengoar (7) front cover (18) Note: For EXB, insta gears (6) and (7), and plate (2) to body # (1 Instalcouping (15) to goa”). Be sure fo apy afi of hydra of plate (2) botorehana. Wan istating plato (2), Take care otto cantuse ts sucton se and devon Instat plete (18) with ts copper ay side facing downward te: Apply Sn of Pca 10 the contact areas (of cars (6) and (7), and plate (2) beforehand wo2.04-125 Inn side plat (2) into body 1 (1) 7. Roply grease to gat (2) and instal into booy 1h exe: Apply tin of hyrautic 0 ste plate (2) linen instatng Sie pate (2), take care not Conluse de sucton sie and devery side Instat sio plate (2) withts gasket de facing downward: ete: For EXB, instal seat), ng (17), plate (18), and dowel ns (5 10 body 2 (8). ‘ote: Be cure to apy grease fo soa (2) and ving (G2) leo, apy ati of hycabe a plate (18). Wn stag plate (8) tke care rot {o conse ts sucton side and delvery se. Instn plate (18) ith &e copper ay 830 acing downward 6, infront cover subagsombly (16) and body 1 Zbassombly (0, algnog tbe matching marks te: For EXB, i Body 1 subassembly (1) and body 2 (8 eae 1 boars Dives Gear se waoe 2 aerate Boar 2 fain Reg te Gate ines ew 48 Souping 12> oor 3UPPERSTRUCTURE / Pump Device {Inset cll (28) and coupling (15) to body 1 (1) 8, din boxy 1 subassembly (1) and plate (2), Aigning the matching masks. 10. Apply grease to gesket (4) and sto! balls (5), ‘ply aim af hye oso plato (2), Insta gasket (4), ie plate (2, and sel tals (5) to plate (2 oe: When instating side plate 2), take care no to Contuse is sucton tide and daivery Instat Sint 2 tga 8 1% Install dive gear (8) and even goa (10) t plate 22 ese: For EXB, instal gear (2) and (10), ad plate (2) to body 2 @). Apply 9 lim of hydraute oo pate (2) belsehand, When inetaling late (2), ake fore otto conte ts sucton aie and dear ‘Sie. sal plate (2) wh is copper aly side facing downward Note: Apply 9 Sn of Pac of 0 to contact ares (af 9oo' (2) and 10), and se plate (2). 12, Aoply a kn of hydaute ol side plto (2) ond insert tint body 2 (8), ‘Note: For EX 8. apply grease to seal (4) and ing (17) ‘and instal ham fo cover (9). ove: When instating side plate 2), take care nfo Conse ts sveton sie and Gaivey et ‘Sie pao (2) wih is gasket sito Tocing owns 1, Join plate subassontiy (22) and body 2 ‘aiasombly (@), kgrng the matching marks, Nese: For EX 8, jin body 2 subassomtiy (8) and cover subassomby (19). 14 oly grease to gasket (8) and sts! bal (6). ‘Apply tim of you oft side pet (2) rsa gasket (side plate (2), nd stool als (5) to body 2 (8 Nee: When insating side plat 2), take care no to confise ts sucton de and devory sx. natal ‘io plot (2) with Hs gasket se facing ownwora wo2-04-1416. instal hive gear (2) and diven gear 24) 10 ody 2 Note: Apply a fim of arate ao the contact {7088 of gears (20) and 21), and sd plate @)betorenana. 16, Apply fn of hyau ot sido pat (2) and Insert int body 319), ete: When intaing sid plato (2 take care not 0 canfise #8 suchon de and delivery 06 Insta site pst (2) wih ts gasket se facing dowd 17, soln wody 2 subassembly (8) and body 3 Subassembl (19), aligning he matching ark, 1 To secure tha jit bodies, ahen socket, ots (1) wth war (12) Fs 800m ts 4-49 18m (4.5~5.0GF) (09-985 woe (©) 38~23 Nm (99~44 Hg) (28~82 ree (EXt2, Bxt5, 2), Feng Rg 2B bnew 9, wo2-04-15UPPERSTRUCTURE / Pump DeviceUPPERSTRUCTURE / Pump Device DISASSEMBLE CGiean the outside of the pump. Bolo asassembing ‘make matching marks on body 8 2), body it8), body {WO}, and oove (14) to dn assemty. 1 Hoist the pump using a crane and securly put it fon a work bench 2, Remove socket bol (26) an body (40) T : 5mm 8, Remove O-ing (14 rom body (40. 4, Remove diva gear (38), bushings A (89) and 8 (27), ad riven oar (2) om oy (0) 5. Remove bushings A (69) and B (37) tom body (40. @ 2 f @ 4 Ot @-| TF ® fax fini @ 3@® toes 25- Seat sot 28- bre oar 1 Save i ocog Se some 1 too aa eran ‘wo2-04-17,UPPERSTRUCTURE / Pump Device {6 Remove socket bos (18) and sloove (14. T— : Gam 7. Remove rods (16) and Oving (15) fom soove (i 8. Remove spring cover (27. me: 20mm 8, Remove convo piston (17) om Boy H (1). 10, Remove spring holder (92, erings (30) ant (3), ‘nd spring guide 29) rom body H (18), 11, Remove O-ing (28 rm spring guido (2). 12, Loosen sockt bolts (12) to rove body § (4) and shat (0) aesombly 98 packing (2). T : 8mm 13, Remove retaining tng (10) tom oxy (4). at 14. Bush out shat () and ball bearing (6) assembly and sol holder (9) Hom body 8 (A) by tapENg thom witha plas hammer eH 16, Reenove of sal (7) and Ong (8 rom seal holder @. 18, Remove pis (3) and swash plato (1) om boy H (9, 17, Remove rer (24) and piston (35) assomy tom boy H (8) 18, Romove pistons (5), hold (34, busting (9) and neadies (25) rom rotor 28). 18. Remove retaing sng (2), retainers (22) and sping (23) for ror (24) at 20, Remove valve pat (20) rom body H (18) wo2-04-18& Q® Oe DO) G oor =) Bs Nowe SP Seater ES come ‘wo2-04-19UPPERSTRUCTURE / Pump Devi ASSEMBLE Belov assembling, clan disassembled pats wih sot ‘ont and dy them wah compressed at ‘Reply af of hyraute of the ne pats Replace af O-ngs of seal, packing, and needle boar. tng with now ones, disassombiod. 1. Insta valve pat (20) nto body (1). 2 Incr roainors (22) ad spring 29) no roar (24). Push down an hol retainers (22) and Sp (23) ting a e035 Bon tal rtaing ng (21) 1 0 tor 2, at 8. Intl needs (25) to ror (24). Paco tshing (3) onto noodle (25). “4 Reply atm of hydra o to pistons (35). Insta piston (25) and holder (04) assembly int ro tor 4 5, Install rotor (24) and piston (25) assembly nto ody H (18), Nese: Apply a fin of raul of to the contact areas (of vale plate (20) aed tor (24). 6, Plo swash plate (1) ont rotor (24) and plston (95) assomby Note: Apply a Km of tydraulc of fo the contact areas of piston (85) and swash pat (1). 7. nso ins (8) into body H (18). £8, Place packing (2) onto body H (1) 9, Push shat (6) and ball bering (5) assembly into body (4) by tapping the assembly with 2 laste ame — 10, Aoply grease to Oring (8) and ol seal (7) and in- ‘or thom nto sol hair (9), 11. Tap soa holder (2) no body S (4) wih plastic hammer, ten instal rotiing Hg (10). te sot ‘wo2-04-20,12, din body 5 () and sat (6) assembly and body H(i), aging tho matching marks ‘Tignon socket bots (12) wih washers (1). a Fmt SI =64 Nn (5565 ha) (40-47 13. Apply groaso to Oring (15) and a tn of hydric cto rds {sort Oring (1) and rods (16) io sleve (14), 2 pasangUPPERSTRUCTURE / Pump Device 14, Aoply a fim of hydrate lo conte piston (17) fd nse tino body H (18). 15. Insta loo (14) to body H 18) aging the ‘matching marks, then tighten socket bos (13). T— : 60m + 20-24 Nm (2.0~25 kat) (22~25 Bt) 18. Aon grease to Ong (28) and inset into spring 0 (2) 17 tnsor spring olor (82), springs (80) and (31), and soring guido (28) into ody H (18), then titan spring cover (27) mt: 20mm =e 490-590 Nim (60~70 ken (260~610 win) 18, Apply a fn of hyrauic oo bushings & (37) and £8 (28) and inson ta into body (0) Note: Insert bushings (37) and (38) wiht Osing ‘ie acing dowrward. 18, Inco deve gar (88) and criven gear (42) into body (40, Noe: Insta cive goa (28) to bushing B (29) and hve goar (12) fo bushing A (37). 20, Insta bushing A (7) hve gar (98) and ahing (2) todo gem 3). te: Apply of Pyrat ol to bushings (27) and (30) betoehand, and be suet instal hom with {hte Oving sie facing downward. 21. Apply orease 1 Ong (96) and insert into body () wo2-04.22.22, Inaall the assombiy of body (0) and gors (38) ‘a (42) wo body (18), aging the matching f~ : 6mm Fae 5 29-98 Nim (3.0~35 kan (22~25 Hh) 2 Q@QOOD® @ @ © @ r @ peo @) + fect a [ @ soot ot 27 spreacovr 38 seena 38 oi com Soe Sa pmo soe a7 Sung A wo2-04.23UPPERSTRUCTURE / Pump Device MAINTENANCE STANDARDS (EX30) 1. The clsrance between the ouside damtr of he ‘ston and th ise ameter othe roto ( id). 0.420.060 mm 2, The clearance between he piston and the shoe 45020 al 4 T 2, War ofthe ol sal contact srtce Mossore the simoters ofthe worn areas an an \uawornafea on the shat. The diforonco i he ‘wear of the of ea contact sac ‘Th service iit of wer ofthe al sea contact suracs ie 20025 mm ‘wo2-04-24UPPERSTRUCTURE / Pump Device 4. The clearance betwoan the outside ameter of tho oy Can Pat ounva contol pat a the nso daete ofthe r bushing (0-9) monn Se cc wo2-04-25UPPERSTRUCTURE / Pump DeviceUPPERSTRUCTURE /Control Valve REMOVE CONTROL VALVE (oo E02En622060) Ja igures shown Bus secon ae for EX 30. Brcaution: escaping tid under pressure can mK enewato the skin, causing serious injury fold this hazard by flioving pressure beloro | disconnecting hysraute or other lines. Tighten Sil connections Detore. applying. pressure Search tor leake with a plece of caraboar Take care to protect hands and. body from high-pressure an accident occurs, get immediate medion! tention. Any fig injected into the ekin must be suigeally removed within a few hours of Gangrene may result, ‘.Release a pressure frm the hyroule of tank by Teosenng cap (1) located on the tp of he tank Remove csp (1), 2.Reenove mounting bolts (1)~(8) to rrnove the Noor me trem wo2-05.01UPPERSTRUCTURE / Control Valve 8.Usig a vacuum pump, reduce the tydraulic tank ‘rescure ta the nega a ‘porate the pap who woking ‘and continue 10 > S ee 27 00m assonby 4. Remove aval hoses (1)~(8). Note: (1) Make a note of disassembly order and port umber and atach it each hose fo 34 Noe: 2) Port locations may dif for each mode [Reler t.ho. confol valve socton of the TECHNICAL. part of Be manual for each model's pot locations. Pk 21 nen, 22 en §.Ramove boo, arm, and bucket hoses (1)~(@) ‘is, remove srs hose (7). ame 20 0m S.Romove boom-swing hoses (1}(2), blade hoses (Gha), and swing hoses (5.6)UPPERSTRUCTURE / Control Valve {Remove ol cote pings (1,2) ae 27 @.Ramove solenoid value pit Nose (1), me 1910 9.Romove pnp noses (2). ee 20 10. Rernave right sie pot valve hoses (1)~ (8 me 19m ‘wo2-05-03UPPERSTRUCTURE /Control Valve 11, Remow ft sg plot vv hoses (1) (4), ae 19.0 12,Remove outs (11,2). Remove cotter pn (94) and ins (5.6). Note: Ex employs mecharical conta! levers, 20 that thre ere more lever inks" Remove all over links, eering fo We above sm wo2-05-04UPPERSTRUCTURE / Control Valve “Bones at) ph bom oO move ut (3) and pn (2 me 7m "For Bx, remove mounting bls (1) to remove the ‘engine cover. ae 0m 15.For EXE, omove buttery terminals and brackst ‘mounting nuts (1) me 10mm ‘W02-05-05,UPPERSTRUCTURE / Control Valve 16 Remave bracket mounting bat (1). me 70 ‘Atach oye bats 10 Nast the conto valve withthe ‘late and remove Irom the machine ising & cane ae 1mm 1.Romove bots (8,4 © disconnect corr valve (2) ‘rom plat (1) me 17m INSTALL CONTROL VALVE 18.PUt the contol valve 00 the plate and tigen four ‘mounting ols (1.2. me Nim aH 49 im 6 bt, 5 kgm) wo2-05-06UPPERSTRUCTURE / Control Valve ‘2.Atach aye bots (7), Host ho cool valve with the ato using a crane ut ton the fro and bon bots (2) e170 ae 49 Nin (86S kgm) 21.Connect the bade spool tthe red using eater pn (8) and pin (2, Insta not (1) to he lave. me 17 mm at AS Hen 85 Bi, Skah =< 22.Cennact the booming spo0! to joa (1) using ‘ter pn (3) and pin 2). Ia nt) to th love. est7 0m ana nm (stom, Sate ox wo2-05-07UPPERSTRUCTURE /Control Valve 28.Connact the spool to the ro (2) using pin (2) anc cater pin 3). Inet ut (1) me 17 mn eam (96. Shae Noto: EX employs mechanical conte lovers, 0 that ‘hore are. move lever links. Ist aloe Inks, relent the above 24, Isa ight sept valve hoses (1)~(4 ame 18 mm Fa 201m (221 3 Ham 25, Isa td pot vv hoses (1)~(- me 190mm ae 220 (2 9g) ‘wo2-05-08UPPERSTRUCTURE / Control Valve 26 neal ole valve pot hose (1), me 19mm ae 28 Nin 22 bt hat 27 Intl boom ‘swing ho 19 hos 8.6. (1,2, bade hoses (9.4, eI mm at: 98 Nim (69st, 95 Fon) 26.intal boom, am, and bucket hoses (1}~() Ina ran hase (7). me 27 mm, 22m at 80 Nm 69, 85 kok), 230 Nn (20 Bo 4H) 29, travel hoses (1)~(). oe 27 mm a 99 Nim (69, 95 kghm) ‘wo2-05-09UPPERSTRUCTURE /Control Valve 30.nstal ol cooler pipings (2/2). me 190mm pe 29 Ne (2, 9h) “Floste pup hoses (1),(2, me 27 A185 Ne (69 HH, 95 kgm) ‘2.nsal the floor covers ung bots (1) (2 me trom 149 fm 96 ot 6 kgm) 35.For EX, secre he battery using bos (1), ‘Aach th trminl, ae 10mm PHS Nm (35 05 tam ‘Wo2-05-10UPPERSTRUCTURE / Control Valve {94.For EX8, instal bo engine cover using bats (2. ome AT wen ae Nem (96 i, 5 Agen) 26.netal cap (1) loeated on the top ofthe hycaube of tank Note: Check hyraut ol evel. Ads oi necossay wo2-05-11UPPERSTRUCTURE /Control Valve ‘wo2-05-12UPPERSTRUCTURE / Control Valve DISASSEMBLE AND ASSEMBLE CONTROL VALVE exe wo2-05-13exens UPPERSTRUCTURE / Control Valve joonwee)UPPERSTRUCTURE / Control ValveUPPERSTRUCTURE / Control ValveUPPERSTRUCTURE / Control Valve DISASSEMBLE CONTROL VALVE Ctosn the contol va ‘work ban Xmen desscembing, take care not to mix parts ‘among sections. and place & securely on 2 “REMOVE RELIEF VALVES , MAKE-UP VALVE, BND SHUT-OFF VALVE® 1. Remove the rain cole valves (6), overload abel valves (Oh makeup vale (27) and shut ‘oF vals (4. Main at vaio vers roi valve 49 mm (€X8, 0) pent 181m 20) 22 mm (22) 22 men (EXE, X22) 24 mm (©x12, EXI8) 24 mm (EX, 8115) Make-up vale Shuto valve pene: 4. mm (220) me 24 mm (612, X15) 47m (6X2) 2B mm (X12, X15) x2, 615, Eno OAS! OOO I d to oh wo2-05-17UPPERSTRUCTURE / Control Valve “DISASSEMBLE MECHANICAL-TYPE SPOOL ee [A Sections, except the Remove wiper (15) and Ong (45). (EX 12 Swizh Valo Section) Cy (2x12, £418, 22, 90: Right Travel, Boom: ——— “Trav, lage Sections en dsessembling socket bolt “st 7 (10), Soeke batt (10) andor spring seat (11) may fly off by spring (22), force. Kexp pressure on sping seat (11) and spring (12), while Slowly loorening socket bot) omove ol sal (1). X22, 490) 1. Remove socket bots (7), (8), cover (9), and at (19) aba egie accom I: 4mm (2x9, 2x12, Bx) 5 ren (E322, BXD0) 4 Paco spool (14) ina vse. To prvent the spo0t trom being damaged, pace 2 Soft otal plate { as: (2x12, x15) ‘aninum, copper )batwean the spodl and vse furlacos. Romove socket bol (10). sping seat — (19) tang (35), spina (12) and ae (19). 2, Pullout spoo (14) wih socket bolt 30), spring seats (11), etainer (85), spring (12) and plato [= 5am (13) as a singe assomby NOTE: For spool (14) ofthe EXI2 and EXIS, 3. Remove packing (1) rom body (1). (EXE) remove spect head (46) 9 adson 10 the above exe(alede) SOOO oor 2 come 12 Spang 5- Peing Soaks ba 11> Sing Sant 1 Seon, wo2-05-18UPPERSTRUCTURE / Control Valve DISASSEMBLE PILOT PRESSURE-TYPE ‘SPOOL > 2. Place spoot (23) in a vise, To provent the spoct from beng damaged, ace a Sat meta plate ( (2112, 15 + Bucket, Boom, Switeh Valve, Arm, slum, copper) between the spool and vse ‘Swing Sections) Surfaces” Remove so:kat bot (20), spong Seat (oar Boom 1, Bucket, Arm, Boomtt (21) and. spring 2. Swing Sections) (oa0 Boom, Bucket, Arm, Swing fee sections) — ay 6 mm (EX, 5, EXD) 1. Remove socket bois (16), covers (17), (18) and Oxngs (19), 4 Pul out spacer (48) spring (48) and poppet FH 5 4m x2, 215) (60) fom spool 23} fom (2X22, © ee NOTE: Uso 2 tonporary bot (MXPich 0.8) 2, Pull out spoo (25) wth socket bok (20), spx9 remove space (4). Sons (21) and ping (22) a single asso. Ai caution: when disassembling socket bolt {20}, socket bolt (20) andor spring feat (21) may fly of by spring (22) foree. Keep pressure on spring seat (21) and spring (22), while Slowly loosening socket bolt (20). x12, x15 (Arm) PEW : aq © \ ® © 3d6 Mi ‘wo02-05-19UPPERSTRUCTURE / Control Valve -< DISASSEMBLE SWITCH VALVE » 1. Remove lua (80). Pul out sping (81, spool (22), and shen (20) [— : ame me! 4 rn (2x22, 2180) 2. Pace spo (92) @ visa To prevent the spo0! from being damaged, piace sot met pate { aluminum, copper } between the spo and vile Selnces. Remove pug (37). Pu ou sping (38) Bd tl bal (39) For spot (32). {8 Remove plug (40), Pullout sping (81), srg oat (42), and 56h (9), me: 22 mm xB (Switch valve) @ 1 boy sping a= Spieg StH Spina 0 Pia ‘wo2-05-20UPPERSTRUCTURE / Control Valve “4 DISASSEMBLE LOAD CHECK VALVE > 4. Remove plug (28). Pull out spring (25) and chock vate (28) fm ©, 820 — 8 mm (EX30) x8 Blade) ° oy 1+ ty Pn 2s-somma wo2.05-21UPPERSTRUCTURE / Control Valve “DISASSEMBLE BODY > 1. Remove nuts @) to pull ou rods (8) so that: mm exe body (1) ean be cided ito sens. 32 mm (EX12, X15) 14 rm (B22) 2 Pull owt Oving (2), spring (28), check vale 37 tam (30) (29), and valve (5) kom boy (1) E12, EXIS, ad ame Bote vane wo2-05-22UPPERSTRUCTURE / Control Valve [ASSEMBLE CONTROL VALVE Befor reassembling, thoroughly cleen csassered 2, Polton bodies in the ordr thoy wore botre pars and ry thom wih compressed a. Roplace ddeacserby trom or damaged parts with naw ones. Inoert rode (4 ito bose (1) and secure them Prepare new seis ( O-rngs, of sons and back-up veth nuts ngs) fo oplace od ones. “ASSEMBLE BODY = NOTE: Apply LOCTIE t the treads of rods @. 1. nal va (61), check valve (29, sping (28) fd Oring (2) © each body. FT = 10mm 2x9) NOTE: Apply a Sm of hye fo valve (51) 2mm (EX'2, X15) ‘an eheck valve (2) belorhand, 4m (E322), ‘iso, be sure fo apply grease 1 spring $7 ton 2) (28) and Oving (2 OMT ig (XB) 19201. kgf X12, X15) 85 Kin (22) eas ghn (E20) x12, EXIS 1= oy 3 mw some svat wo2-05-23UPPERSTRUCTURE / Control Valve “< ASSEMBLE LOAD CHECK VALVE » 1. sort check vate (25) 2nd spring (25) into body (1). Thon pg 24 NOTE: Apply a Sim of hysrautis ol fo check valve (2) betorehand 6mm x, ex22) ‘mm (x30) Pt 19225 tate 68) ‘85-08 kghm (x22, €%30) xa lade) 4 ao0y zr 2-Sem0 ss-chmah vie wo2-05-28UPPERSTRUCTURE / Control Valve “< ASSEMBLE SWITCH VALVE > 1. Insaspoo! (49) into body (3). Inset sping (43) and spring seat (42) ta lug 0}, and tgren 1 body (1 NOTE: Apply afin offal ot poo! (4) me: 22 mn 8) mt: dS. ex) 2, Place spo (22) n 8 vse. To prevent he spool ‘rom being damaged, pace a soft metal plate ( ‘minum, copper) betwoon the spool and vise Surfaces, ioe steal bat (39) and spring (28) ‘Spool 2), then ight pug (27 NOTE: Apply a tim of hycraulc ot ste! bat (G3): Aeply LOCTITE to pg (97) mnie x8 (Switch valve) 3, neat spool (22), she (36) and spring (1) into ody (1) Tihton plug (30). Fo eam exe, me 514 mm x22, £430) pat 81-88 tan (x8) 3-08 igh (x2, £30) @ st Se 2 Sng eat Spe ‘wo2-05-25UPPERSTRUCTURE / Control Valve “SASSEMBLE PILOT PRESSURE-TYPE SPOOL» (092, 8X15 + Bucket, Boom, swith Valve, Arm, Swing Sections) (war Boom 1, Bucket, Arm, Boom, Sing Section) (eo Boom, Bucket, em, Swing Sections) 1. Insert poppet (50), sping (49) and spacor (48) Into spoo (2). NOTE: Apply a tn of hydra a © poppet (80) and spacer (48). 2 Pace spel (28) ina vis. To proven ho spo from being damaged, place & So maa plate { _aninum, copper) between th spool and we Surfaces. instal spring (22) and peng seat (21) to spect (23) Tighten eocket bot (20, NOTE: Be sure to apply LOCTITE to socket bot rc a 09~05 sot (exr2 EXI8) Dor gh (E22) "Tees kgf (€a0) 4m (Ex22) ‘5mm (X12, Ex15, X90) 3, Inspect assembly it body (1). NOTE: Apply a fim of arate o fo spo0 (23). 4, Install Onings (19) to cove (17h, 18. Install cover (17), (18) 19 oy (1) wih socket Bois (15) and (1), NOTE: Apply 2 tim of roase to Ovings (19) beforehand ‘Also, be sure 10 apply LOCTITE to so0ket Bs (1516). @ 4 12, 48) To Si ti 2) ae: 0741.02 hot x2, 2x15) 158 Agr (2X12, EXt8) ban, BAIS Am) @Q @ poe =) ® ® (masa SS a @ EnZ" 2 J oS i 1 07 12 come 2 Sina Sot > Suet 1 Sean 1 nn 2 Ss Se tn te Sen > Sco 3 Spot 5 Povet ‘wo2-05.26UPPERSTRUCTURE / Control Valve 4 ASSEMBLE MECHANICAL-TYPE SPOOL » ee [A Sections, excpt the Switch Vaio Section) (2412, X16, 122, X90: Right Travel, Boom: owing, Spare, Lett “Tra, Blade Sections) 1. Place p00! (14 i 2 iso. To provont the spoo! fro being damaged, piace a so mola pato ( flumnam, capper) betwoon Dra soa and Vo faces, natal pate (19), sping (12). otainor (85) and sping Seat (11). Tighten scekor bale 0) NOTE: For EX12, EX16, remove spool head (46) in adaton fo above. NOTE: Apply LOCTITE tothe toads of socket ‘ol (0) and spool head (4). I = & mm 22) ‘mm (EXB, O12, EXIS.EXIS) me 005 ten (EX) 880.75 kgm (X12, EXI8) (0.6 +02 kg (2X22) Te kghen (©30) exa(slede) 2, Inst packings (15) ints body (1). NOTE: Apply grease ‘0 packing (15), O-ring (49), par g (19), and oi oat (18). {, Inset he spon! assembly nto Body (1 NOTE: Apply atin of yaa of fo poo! (14) bofrehana 4 last cove (9 a pt (19) to Body (1), 298 Ughten socket bots (7; 2 (8) NOTE: Apply LOCTITE othe Oveads of socket bats) ana [= 4mm ©, E12, BxI5) 5 n (€22, X30) an: 412, B11) pan: 05-08 kan (EXE) 0.74~1.02 gh (EX02, X15) 1 +n ngtm 22, E00) me 026-03 gH (x8) : 2 Some > ie ‘wo2-05-27UPPERSTRUCTURE / Control Valve {INSTALL RELIEF VALVES, MAKE-UP VALE AND SHUT-OFF VALVES 1. Instat main ret vaves (6), overioad rai ales (6) make-up vae (27), and. shut ves (44 0 booy (1). Main oi ate vores rot vave ame: 390mm 8, 20) ame 19 mm ©) zamm (6x22) 22 mm (Ex, E122) 2a mm (x12, EXI5) 2a mm (X12, B19) me 3-4 katm Ex) a2 4kgtn 0x8) 42-5 ptm (X12, B15) 42-5 gh (6x12, Bx15) 35 ¢0bkghm (82, B20) a0 kgm (0128, E00) Makeup vave Shuto vate ame th (20) mies 24 men (EX, £15) a7 em (2), 2a mn (BX32, X16) Fae: 42-5 kim (0x12, X15) Pome 42s kate (xi2, x15) 35 e8 hgh (E422, 30) EX EXI5, é Shy co oe eae GOGO” OOOO wo2-05-28UPPERSTRUCTURE / Swing Device REMOVE SWING DEVICE | e250 [AF gues shown in tis section are for EX 90. A. caution: escaping tu under pressure can m penewato the skin, causing serous inn. Avoid tis nazrd by relieving pressure befor loconnecting hydaute or ote ines. Tghen | Sr" conmectone before appying pressure Search for leaks with 2 pice. of cacboard Sane care to protect hands and body om ghepessure ta Wan aceldent occurs, get immediate mastcal tention: Any fuld injected into the skin must be surgically removed within & Yow hours or ‘engrene may result “Release air pressure tom the hydra ng ca (1) cated on he top cap) 2.Remove mounting bolts (3) to remove the ‘oomlates mer me ‘wo2.06.01UPPERSTRUCTURE / Swing Device 3.Using a vacuum pun, resica he hale tsk = ‘ressue ‘othe regis ange and conn To < NE ‘operate the pun wie woking. ug them. Pe 191, 22 mm §5.Rerove swing dovce mounting bots (1) me 10 0m 2x22: €0 b emg) B00: 62 (24k) 6-Rerove pi (1) Install eye bot (2) nto he plug hoo ‘tach a wie rope to oye bal (2), ost the swing dove using cane. [— :80m ‘wo2-06-02UPPERSTRUCTURE / Swing Device INSTALL SWING DEVICE “Install eye bo (1) tote swing vice. tach @ wie rope to oye bolt (1) o hast he swing davis. Put the swing dove onthe mounting locaton. E10 my at 4 Ne (96 5k) CAUTION: SWING DEVICE WEIGHT: {©x22: 601 (27 4a) EXa0: 62 (28 kg) .Remove the oye bot bal ug (1). esa ol 2) secure th suing davis. E518 me pa £291 (221, OH [28m ae :99 Nem (20, 4h) atch hoses (1) pes 19 mm, 22 m ae 29 Nm (22 et 3 atm, ‘39 Nem (29,4 wae) 1st the tor pate using mounting bots (1)~(. move tw vacuum pump. Reinstall the cap on he yer a ak. metre at 240th (96 et, 5 glen) ‘wo2-06-03UPPERSTRUCTURE / Swing Device REMOVE SWING DEVICE (@eexi2E) ‘Al igues shown inthis section ae for X 16. A.caurion: escaping tui under pressure can 6G enetrate the skim. causing serous. Injury, Svold this Marad by releving pressure befor iaconnecting hydraulic or other lines Tighten fll connections before applying pressure, Search for leaks with a plece of cardbosre; Take care to protect hands and body tom high-pressure fu so Wan accident occurs, get immediate medical attention, Any uid Injected ino the skin must be surgically removed within 8 few hows oF ‘angrene may rel, “Release ait passe fom the hydauc al tank by Toasering cap (1) local on the fp othe tn Remove cap (0 2.Romovo si mounting bots (1) t9 remove the Hoot ates, ett ‘wo2-08-04UPPERSTRUCTURE / Swing Device Remove fou hago mounting bots (1) two bos (2). ‘ad wr rope (3) to romove Sea (). ame 17 om Remove = (ak) terina (1) fst then romove + (ted) teina (1), Usosen four mounting bolls 2) © remove batiory ©. es? men S.Remove sx bots (1,2) 10 romove cover (8) and He (8. me 19 0m {6.Rmove bat (1) t0 remove ralay bracket 2. mt 190mUPPERSTRUCTURE / Swing Device 7-Remove 10 bolts (1),(2)(8) 10 remove covers (5). me 7mm 8.Using a vacuum pump, reduce the hycraule tank ‘rosso to the negeive range and continse 10 ‘pera the pump whe working, me iT '8.Rermove swing mato: hoses (1)~ (4) and lua thom me 19 mm, 22 10,Remove for swing device mourtng bolt (1). ame 19mm rz: 45 (20.540) BOB: 47 b 18g) ‘wo2-06-06UPPERSTRUCTURE / Swing Device 11Remave plug (1st oye batt 2) into tho plug ole. ‘tach @ wire rope to oye bet (2), and host the fing dvi using ears. e INSTALL SWING DEVICE 12.Use a crane to hoist the swing dviea end place it ‘on te mounting postion me 9m pa 49H BIR Sha) A cxurion: sua pence wera: X12: 45 fb (20.5 ka) EXIS: 47 1b (21.5 Ha) 144Remove tho oy bots and instal the pug. ‘Tighon bal (1) socuro be swing dvi. me 1mm Pam 49 Nn (95 HFS Kgl ltl hoses (1)~(4. me 101mm, 220m et: 20 Nm (221, shat), ‘30 Nem (29,4 age) ‘wo2-06-07UPPERSTRUCTURE / Swing Ds 15.istl covers (1(2,(9) using 10 bots 4)(6)(0, SEITE A 16. Intl olay bracket (2) using bit (1) ET ren ae: 49 Nem (96 BH, Sham) 17.Intal cover (9) and pat 8) using si bots (1,2. ET me pam: 49 Nh (86 i Sham) 18.Put atiory (1) back. Tighten bots (2) to secure ‘batory (1) Connect bateyteninas (84, E17 me pa: 49 Nm 8 WH 5 am) ‘wo2-06-08UPPERSTRUCTURE / Swing Device 18.Put sas (1) back. Intl hinge mounting bas (2), weo rap (3), and bot EAT pa 248 Nem 95 Bt Shot) 2oLinstall the Foor pao using sx tots (. ET en AH 4B Nim (86 HS Hg m) 21.Tghtenc9p (1) Sate on he hyaute ol an ae 19 mm Note: Check hyeraute ol lve. Als necessary. wo2-06-09UPPERSTRUCTURE / Swing Device ‘wo2-06-10UPPERSTRUCTURE / Swing DeviceDISASSEMBLE SWING MOTOR Clean the outside ofthe swing motor ae put & on 8 work bench Bolore aeassombing, make matching marks en housing (2). valve pate (10), gerter (13), ‘wea plato (15). ana housing (18 10 ad assem. 1. Using eran, host the meter and clamp it in 2 2, Ramove bots (11, ek: oti, 8. Remove housing (2, 4, Remove O-ing (6 rom housing (2). 5. Remove springs (3), pins (4). sols (6) and (7) at (8), and valve (9 6. move vate dive (12) and valve pao (10, 7. Remove Oxing (1) rom vale plat (10). 1, Remove goo (19). 2, Remove dive (1) and wear plat (15). 10. Romove Oring (11) and soa (16) fom wear pte (5) 11, Remove retaining rt at 12, Remove housing (18) fom the vise. 1 Pull out pron goa (24) om housing (18) using a prose 14 Remove Oxing (11) rom housing (18). 15. Clamp housing (18) in a vise agin. Remove sock: ‘et bl (21) and retainer 2. 55mm 18. Remove back-up rng (29) and sing (22) hom ro ‘anor (20), wo2-06-12 UPPERSTRUCTURE / Swing Device_. MONDE CVO © ei | 6 Jsbbbb bbb. bbs et —@ ‘wo2-06-13UPPERSTRUCTURE / Swing Device ASSEMBLE SWING MOTOR. loan disessemtiad parts with solvent and dry thom wih compressed ai. Apply 2 fn of Pyrat 10 i Prowde now Oring, seae, end ote to replace used 1. ply grease to back-up ring (23), Hing (22), and (ring (1) ac insta thor to retainer (20), 2. Aoply LOCTITE to sockt bats 21, Insta retainer (20) to housing (18), then ghten socket bot (21) T— : smn ae 212216 Nm 1.21.5 kan) (9~11 HY 3. Push pinion gear (24) into housing (18) using a press. 4, Insta retaining ing (17) pion oar (24) at 5. Apply grease to Oring (1) and neal to hows nota) 6. Clamp housing (18) in vise, wih He gear side ang dowd 7. Insert ive (14 int pion gear (24. 8. Aopty grease to sal (16) and Osing (1 ‘or thm into wear pate (15). 8. Jen housing (18). wear plate (15), and geotor (13), ang matching mars. wo2-06-14ittiaia i t wo2.06-15UPPERSTRUCTURE / Swing Device 10, Inert wave drive (12) into gevoter (13) 11, Apply grease to Oxing (11) andinsertitint valve plate(io 12, nal geo aning ne ‘matching marks. " 13, Place valve (3) ont valve pate (10) IMPORTANT: Refer tothe lilustration below to correctly instal valve (3). 14 Apply grease to O-ring (5), spring (3), and pin) and inser them into housing (2). 15. Apply grease to seal (6) and (7 and install her replace). ‘wo2-08-16UPPERSTRUCTURE / Swing Device 16. Insert plat () into housing (2. Note: Apply a pony of grease to the contact euraces ‘of hovsing (2) and plate (8) 17. Join va plato (10) and housing (2), again the matching marks and ighien bts (1) at. : 216% S54 Nm (50~6.5 kfm) (36~40 be) wo2-06-18‘wo2-08-19UPPERSTRUCTURE / Swing Device (EX12, EX15, EX22, X30) x12, xisUPPERSTRUCTURE / Swing Device x22, £xI0 wo2-06-21UPPERSTRUCTURE / Swing Device DISASSEMBLE Clean the ouside of the swing motor and securely place ion @ work bone 1. Gam the motor aa vise Remove socket bolt (6), bake valve (8), and vave plat (12) — : 0mm 2 Remove pin (7) and Ong (3) rom housing (8 3. Remove housing (4 from the vee. Remove rotor (17) nd pston (20) sesombly and the wut plato en, 4. Remove pistons (20, retainer (19) bushing (18), sd in (8) rom rotor (17). |Acaution: nen removing retning sn (9, rere to pace snd NOM eens (0 Sd Sarin (15 ating the spe ot an eve Wma te opel Wook retain ng 2) reaher (1) ant sing (19) may Ren ou! gin severe prone nr 5. Remove retaning rg (12) whde holding down washer (14) and spring (15) with to oped tool and a press Specie Toot ST 4114 at 6. Push out shaft (1) and tlt bearing (2) assembly from housing (4) using a pase aren. — 7. Remove Oxing (5) from housing (4) wo2-06-22E12, EXIS ‘wo2-06-23UPPERSTRUCTURE / Swing Device ASSEMBLE Coan cisassombled parts with sohent and dry thom vei compress a. Apply 2 Mn of rau of 10 er pats Prowde now Orings, seals, and etc to replace used 1. Roply grease to Ong (6) and instal to hosing 2, Push shaft (1) and ball bearing (2) assembty ito hosing () us laste hme. ‘Noe: Apply af of hyaule oo the contact area of ‘bal Bearing (2) Dowsing (4). — 2. Insta colar (16), spring (15), and washer (14) no rotor (17). 4. Install retaining tog (13) whl holding down wash fr (14) a apg (15) wit tho spocal oot and & press. ‘Soncal Took ST 4114 at ‘5, Install pin (8) to rotor (17), thon put bushing (18) onpin 6, Aopty fn of hyde ci to piston (20) {eta pet (20) and rotamer (10) sezombly ite voter (7 7. Install trust plat (21) into housing (4. 18. Appt afm of hyrauc of to he contact surtaces ot piston (20) and rust plats (21), Insta rotor (17) and. piston (20) assembly ito ving 8. Clamp hosing (in vis, 10. Apo groaso fo Oring (8), fsa! Ong (9) and fn ino Dosing (A 11, Agply grase to the contact sutaces of brake ‘ae (8) and vave plate (12) Insta vale plate (12) ono brake valve (9) ‘wo02-06-2412 tata cake vate (9) and valve plato (12) ‘ssembly to housing (4) and igton socket BOS ©. — : 10mm a 119 Nem (11.8 fm) (891 ’ 5 0 fl} 6 A 0 38 3 oSSU I PTE 3 am -® GG {| } | Le RS DeUPPERSTRUCTURE / Swing Device ‘wo2-06-26UPPERSTRUCTURE /Pilot Valve ——————— REMOVE PILOT VALVE (eEc2O086x220100) | fatigues shown Bis section ae for EX 50 i. cavni0n: excaing ta under pressure can i Mets is hacar by slevg presse bets | Giscenneeting hydrate or other tines. Tighten Sl connections ‘before applying pressure, ‘Search for leaks with a plece of cardboarG; ‘Take care to. protect hands and body from high-pressure tld get immediate medical Sted Into the skin must ‘within s few hours — ‘.Reloase ar pressure from the hydric ol tank by ‘Gosening cap (1 located on Bu Top of he a5 Remove cap (1), 2.Loogen lock ut (1) 10 removo lve (2) {Loosen tot (3 6 remove boot () 19:0 Note: For the to cont lever, also remove wire hamesses a clps wo2.07-01UPPERSTRUCTURE /Pilot Valve {Remove moxeting bol (1) to remove the sand 19mm 4.Disconect pot hoses (1)~(6). Rameve mounting bolts 710 romeve pilot va (8), mt 9.0m INSTALL PILOT VALVE S5Tighten bolt (2) to sooure pct valve (1). Connect lot hoses ()~ (8. 190mm Blot ho stand using bo (1) me 19:00 wo2-07-02UPPERSTRUCTURE /Pilot Valve 7 instal boot (8) using mouring ols (4) instal lover (1) using lock nu 2). ® pee On os wo2-07-03UPPERSTRUCTURE / Pilot Valve FRONT PILOT VALVE DRAWING FOR DISASSEMBLY (EX12, EX15, EX22, EX30)UPPERSTRUCTURE / Pilot Valve - 1. Wie off he boot cari and cean the outs of j av, hen place Wo valve unt on aio wih fo peo ace Lb the bck ot, and remove tho conve Sever atta’ me 191mm, 22m 2. Remove jot sere (1). 7 19m, 24 mm , ame : 190m, 24 on, : —_UPPERSTRUCTURE / Pilot Valve 3. Remove cam (2, ‘Secure the plate with wo MB xpitch 1.25 bol O- i“ me 2b wen 4 Locsin universal jit 2) nd remove i rom the cing. me 7 01 6. Turn over casing (16) Disassembling of easing > 6, Loosen and remove socket bot (14), 1: 100m wo2-07-06UPPERSTRUCTURE / Pilot Valve 7. Pa ot pile (1) ng 8 ig WOH OE « 2, on ee < ir — 8, Remove O-ng (11) kom he plate { ee 8, Remove Oring (12) rom to casing, wo2-07-07UPPERSTRUCTURE / Pilot Valve 11, Tur over casing (1) - 12, instal he to the eiversl jit mounting halo of the casing hon ighton pat (23). Jig No: ST 7924 14. Groduaty loosen the jg, The spook assembly and at (29) are ited by sping pressure wo2-07-08UPPERSTRUCTURE / Pilot Valve Remove thei tom the casing ia No: ST 7928 Remove plate (2) omove the pusher assembiy. 18. Remove pushers (4) and (27) kom bushings (6) nd 28),UPPERSTRUCTURE / Pilot Valve 18. Romove O-ings (7) and (4 trom bushings (6) ad 5) 20, Romove ol seals (6) and (26) om bushings (6) and (25), @ ‘Disassembling of spoot assembly > 21. Remove tho spool assembly fom each por. NOTE: Do not torget 10 cae the port No. on ach pot femoved, inorder 1 avoid them from becoming med up.UPPERSTRUCTURE / Pilot Valve 22. Compress sping (9) and (2), and romove spacer (22) tom soot (17), 28, Remove springs (9) and (20) and shim (18) kom spoat (17). 24, Remove sping guides (8) and (2) and springs (10) fan (19) rom each por. wo2.07-11UPPERSTRUCTURE / Pilot Valve FRONT PILOT VALVE DRAWING FOR ASSEMBLYUPPERSTRUCTURE / Pilot Valve <¢Aasembiing pilot valve fot font contol > Po + Wash al parts, and ne them up by port No. 2, Tur ove casing (18) and place it wih the cast No etre so down, 8, nse the guide fy ito each pot, wit ts thinner side dows sig No: $17098 < 4. Pat shins (25) (29) so spn (27) ae (1) @e- mid weap 2 2h NOTE: Since the numberof shims (25) and 20) ‘determined performance testing, take care: 7 otto se tom wo2-07-13UPPERSTRUCTURE / Pilot Valve 5. Compress springs (27) and (3), and pul spacers (25) and (2) botwoon spools (21) and (22) and Springs (27) nd (4), NOTE: The tes of spacers (25) ad (20) are ct. ferent. Be sure place tham with the spring seat ‘se down, 6. Pace springs (26) and (90) in each port of casing (9, 7. Place spring guides (8) and (10) on spengs (25) and (20) NOTE: Tho tacos and backs of spring guides (9) ‘and (10) are citer Be sue place thom with the spring seat ‘de down. ', Inset the spool assembly into the canter of sping (ies (9) and (10), NOTE: Check the port No. before inserting the ‘ ‘spool assombly and make sure that the Spool assomby is insered ino ts covect ee por. wo2-07-14UPPERSTRUCTURE / Pilot Valve < 8. Apply grease to ol seals (5) and (14, and ital {tom i bushing (7) and (12, NOTE: The faces snd backs of oi soais (5) and » com tn igo 1 a2 4 O® O@ oo—- 10, Install ing (6) an (19) 0 bushing (7) and (12) 11. tnsert pushers 2) and (11) nto bushings (7) 2nd (G2) am the side of ol sal 5) and (14. NOTE: Anply grease 1 the Ips ofthe seals and Gust seals as wal as 10 Be inside of te boshiogsUPPERSTRUCTURE / Pilot Valve 12, Pace the four pusher assembles on the four spool sssembuos one by one. 1 ttl plats (4 tothe top ofthe pushes 14, Install he jig to the universal jit fing hole of casing (19), sig Nos ST 7024 18. Gradually tighten the jg unl tho undor sidos of bushings (7) and (1) reach the aight f he top of easing (19). wo2-07-16UPPERSTRUCTURE / Pilot Valve 16. Romove the uid i fom the casing port (18). sig No: ST 7009 17, Then the Fg until plate (4) touches the top of cng (19). "2 Tana sexo pa (9) wh wo Mi 1.28 ota (A) ae ‘wo2-07-17UPPERSTRUCTURE / Pilot Valve 18, Remove tho jp, and tr over easing (19, Jig No: ST 7326 20, insert the smal end of pistons (20) and (23) into spools (21) and (22), wih the smal aston ends fang the pusher 6, 24, Install Ong (18) to casing (19). 22, Install Ong (17 10 plat (16), wo2-07-18UPPERSTRUCTURE / Pilot Valve 23. Apply grease to tha Oring, and instal pate (16) to aA asig (19). 24, Secure the plate with socket bo Sg (48 Na) (96 HE) ame : 240m 25, Tum over casing (19) “ ft 26, Apply LOCTITE to univers! ot 2) and instal to © 25mg (19). a me: 25 kat 24 Nam) (18 88) | ne 17 & _mosazerosr ‘wo2-07-19UPPERSTRUCTURE / Pilot Valve 27. ep grease scat oe ts te ver Va so , > 28. Apply grease to to contact tacos of cam (2) with ow the pushers, thn instal on te uve £28, Tighton joint serow (1) s0 thatthe clsrance be twoon pushers (8) and (11) and cam (2) becomas tontatvely 01002 am. FRomove the two MB" 1.25 bolts of usd tempo ‘Fam 7 10 9 kgm (68 to 88 Nm) (506 65 Bim) me 524 0 NOTE: Be sure to hold cam (2) whon tottering joint screw (1) t9 prevent universal oi (3) from being tahtened toot. 20. Intl the boot, wo2-07-20UPPERSTRUCTURE / Pilot Valve 3 Install the lover to jit Serow (1) and tighten the look ut 219,22 0m wo2-07-21UPPERSTRUCTURE / Pilot Valve ‘wo2.07-22SECTION 03 UNDERCARRIAGE CONTENTS: Group 01-Swing Bearing Group 05-Front Idler ‘Removal and instalation wa3.01.01 Removal and hatin of Front ior Wo3-05.01 Group 02-Travel Device Maintenance Standre Wos-05-02 Removal and italian of Travel Dower ‘wos.0201 Group 06-Upper and Lower Roller Disassmbly and Assonty of Removal ad instalitin Travel Device wos.02-04 ‘of Upper Ror Wo3.0601 Maintenance Standard Wos-2.82 Maictanance Stand Wo3.06.04 Group 03-Conter Joint Group 07-Track Link Removal ae instalation of Removal and istalaton of Cotar Joint 03.00.01 Track Unk wos.7.01 Mantanance Standard Wos-07-08 Group 04-Track Adjuster Removal and lstaation of Track Austr wos-oe01 ‘580W-03-01‘s80W-.09-02UNDERCARRIAGE / Swing Bearing REMOVE AND INSTALL SWING BEARING Remove swing bearing (e@En2Exrs=220:90) ‘Altigura sown in ths soeton are fr the EX 30. Ie is nacessary to tomove the upperstucture betore femoving tho swing bearing. Refer tothe pperstructee” secon of tis manual whan removing 1. Mako matching make on swing besing (1) snee race, olor race, ad he tack ram. 2, Remove ewe boxing inner race mung bls () pe NEXIS: 17 mm me 802 O00: 19am ‘2. Atach sing lool to swing bearing (1). Hest owing bearing (1 | ACAUTION: Suing bearing weight Exe kg (0) EXI2EXI5:21 hg (880) xz: 38 kg (Ba) xno: 45 ig (915) wos-01-01UNDERCARRIAGE / Swing Bearing Install Swing Bearing Chan the mouning suroce of the track fame and ‘swing bearing, Aoy sean to the mouring surace, 1. Hoist swing boating. Aign the matching marks onthe ‘rack ram and swng bearing, = Note: te matchiog marks ar rot alpne, be sot a parsed Ersde'e check tt Beto poston — As: bxa(11*18) ExY2-E«15(12°50) x72(12"81) AP SEXO) 2. Tight swing boarng mexrtng bot (1). me 8, &%12, 5: Tm 8, BA12, EXIB: 69 Nm (6 kal, 96.2 to) me 2122, 810017 mm ae 25122, £50:109 Nem (1.5 hat, 78) wos-01-02UNDERCARRIAGE / Travel Device DISASSEMBLE AND ASSEMBLE TRAVEL DEVICE Remove travel device (oe m2 505522600) [Al iyzes shown nth aachon are for tho EX 90, D |X CAUTION: Escaping tluid under pressure can penetrate the skin, ctusing serious injury. Avola | thie hazard by relieving pressure before | aisconneeting hydraulic or other lines.Tighten | stlconneetions Betere appving pressure Search for eaks with @ plece of cardboard; Take care to protect hands’ and body from high-pressure Wan sceldent occurs, get immediate medical fttenuon, Any flid Injected into the skin must be surgically removed within 2 fow hours ot | ‘Sengrene may result 1. Step the engine. Operate the contol lovers few Ames to reloase the prossure in Hw orcu Li fap (1) on the fyérutic ol tank to rolease ar pressure 2, Remove mauning bos (2) to remove cove (1). [ome wos-02-01UNDERCARRIAGE / Travel Device 5. Disconnect wave ppg (1) 10 (4) 9g (3) 10 x S$ ame 19 mm 4. Remove mountng bots (2) 1 remove Yavel device a 5. Atach sing wie, 35 shown. Hoist tavel device ssa (1. “Travo deviceassomy woight rg (81) (EX6) 40.4g (80) (E02, B16) ‘8.049 196) (EX, X30) ‘wos-02-02UNDERCARRIAGE / Travel Device Install Travel Device 6. Hoist travel device (1). instal wavel davice (1) to machin Tighten mounting bats (2 [A o0 ae 498m 6 kgm, 96.51) ae 10mm =: bom (8 kal, 65 1OM 7. asta wave piping (1) to (8) 0 vavel dove. pe 19m Fs 29.5im (kai, 22 bt) me sz me :305Wm (hatin, 28.) 8 tach cover (1). Tight bos (2), 80m =: 490m (5 kgm, 36101) ‘wo3-02-03UNDERCARRIAGE / Travel Device DISASSEMBLE AND ASSEMBLE TRAVEL DEVICE (EX8, EX12, EX15) Ee ‘wo3-02.04Ee oer Secon Bs Onseat Sr tng Bae! ‘emer et Sige) a ome eter Feng 2 Rowing Sona Son Gen (rt Soe) a Pe ‘yma oct etn ng 50- Penta ar Fane eee {Secon Ste) y= Og t= ewe baoeng Senne ‘Stoning 35 SoatrBoe nese So Tua waar Seo aang ein a 12 Pantry Ge Pre ‘Soe ‘wo2-02.05,UNDERCARRIAGE / Travel Device 2x12, x15 ‘wo3-02-06“et Cate eae Beatng Ste no ee Carer (Few Stage) 15 Pen ‘etanin ing 1 Ona SonGeor(reeStage) 17= Sea ec ing Me Orme ving ses ng Sip ng etn ing Pe og ea Trt Waster oun ing Pantry Gare ‘tn coaeg ona ese Sage, ‘wo3-02-07UNDERCARRIAGE / Travel Device DISASSEMBLE Clean the wravel device entarir and uoe a hoist to place it ona workbench 1. Use a hoist it the vavel device, Clamp & in a 2, Remave socket bots (8), brake vale (9), and vv plat (26), T : 6mm 3. Remove O-ing (27) rom housing (2) 4. Remove the mator and the reduction gears 2 @ Unt om the vis, 5. Remove cylinder block (40) and piston (43) a5- sorely and swash lato (4) tom Rousing (28). 6. Remove pone (4), shoe sale (2) tine Por hd pe) wen as 0) |Arcturion: vnen removing ean to (7, eictatne pee ste tod roars fo ood mean) oangs pes Sineee, vets (8) and sping (28) may fc oct errs prtona ao 7. Remove resiner rng (37) tom cyl block (40), thon remove rotainas (38) and spring (3). oak 8, Remove stp ing 9) rm ing goa (22), 8. Remove pl (1) om cover (8) 10, Ramave cover () 11, Ramave retaining ring (6) and sun goar (6) from ve shat (25), came 12 Remove retaining ting (4), planetary gears (12) ‘and car (3) a 8 unt om Sun goar (2) at ‘wo2-02-0812, Remove thst ola (1) rm sun gor (2 14. Remove sun goa 2) rom dive shat (28) exams 46 DOQOOOH © Fo givaeer(etcond 12> ary Gaw (Fiat Sk Sata Ve ‘So etn Hoe se = ee eee eerie Sem ilo pcre = SESE OC cwoy e Bietion ee oe © mtg "Be oe 3 Senn Sanne wos-02-09” 24 UNDERCARRIAGE / Travel Device ‘Remove retaining ings (14), tus washor (32), planetary gears (20). noodle boarings (1), and Set washers (1), at esmove dive salt (25) a bal boring (24) a8 8 ‘unit em housing (28) by tapping crv shit (25) fend wit a plas hammer eR ae eee enna at Inset two oF tron 10 fo 1Sick ton plats in Charanes Aso at he patos merourd ho eave ‘vice evenly and ar posonod just under ‘sprocket mooning bl holes. Insot tao oF txoo bots (M0 1.5) ito the Sprocket mounting bl hols so tat each bot wi Contact aeteront plato. Tight te Bats evenly to remove housing (28) ro ring gear (22). a Remove bl bearing (20), sat (17), an O-ring (08) rom housing (28), Fomove oi sea 26) rn housing (28). Remove © ving (7) om sing goer (2) Remove searing (1) fom rng goar (2) Remove Oring (18) ra sea tog (19) wos-02-10UNDERCARRIAGE / Travel Device ASSEMBLE (Clan yin sock a wos-02-1312, Apply greaso tothe contact seas bow value (8) and valve plat (36). Install valve plato (3) ro brake ve (24, brake 1, Join brake valve (8, va plato (36) assembly and housing (28). Tighten socket bot (2). [— : onm Ft 25-02 Nin 26-39 he) (19~24 ey "4 Apply grease to O-ring (18) and instal 0 sot fig (19) Insta searing (19) t sing gee (2. 18. Clamp housing (28) and tng gose (2) ves to yon hom togehor, 3s usrates, ete: Apply 2 en of hyraute ot the howsinging ‘gear contac! araae of bal baring (20). 16 Insta retaining fing (23) 10 osing 28, co 17, instal ust washers (1), neale beatings (2), anotrygoasr (0) thst mashors (2). and Fotaning rigs (14) to pi (29), ot 18, Insta sun gear (2) to tive shat (25, 18, Instat ust calla (1 to sun gar (2) UNDERCARRIAGE / Travel Ds wos-02-1420. Install caro (9, planetary gear (12) assembly a ‘taiing ving (4) to sun gear (2) ot 21, Install sun ger (6) an retaining Hing (6) eve (25). att x2, EXIS = bd6% Le TM 22- ing Gear 21 Nese ening {acne ge) a) ‘wo3-02-15UNDERCARRIAGE / Travel Device 2. fey eae to ig (7a ta ong gear . 23, Inetal cover (8) and stop rng (2) 10 ing gee 22), 24, Apply sal tape to plugs (15) and ight pags (9) 1 : 6mm ae: 25-82 Nm (26~33 kg) (19~24 BA) wos-02-16UNDERCARRIAGE / Travel Device wos.02-18‘socket oa 14 ean oer 25 ening nat 38 nor eae vee 1s Pe 2 Tom Water See eciang Ose Po 16 Peon Sa Conar Comer Fw Sige) ‘Sa eeerng 7 Sante ae ote Beng to bowen Vivesen 50 Pantry Ge So Rom beng (eee ew eee 6 tang Set 19 aang ra Porta Ss 1 Seen HO Ome i oe a serng Seat 22 Stet nat 10 Gyan Bock Homme Sse Ste eat it uw, Et Renin So! 2 mau wos-02-19UNDERCARRIAGE / Travel Device DISASSEMBLE oan the travel device exter and use at to place Iona work boneh 1. Use a hoist 10 the travel doves Clamp iin a vise. 2, Remove socket bots (1), brake valvo (2), valve Plat (6), Orang (1, 2 pin (12). FT : em 9, Use a hoist tot and remove the motor snd the reduction gears 252 unit am the ise 4. Remove gins (8) and Oring (21) tom housing ) 5. Remove cylinder block (10), piston (16) asso, ‘anh plato (17), stot bale @2), swash pate co Urol pistons (83), end spings (24) from housing (2a) 8. Remove pistons (16), plate (15), retainer holder (14), apne (19) rom eyindor lock (1), 7. Rexave rearing ring (6) rom cylinder black (10), fen cove water (sng (a sng a). at 8, Remove pli (48) Kom cover (47) and ps (97) trom ing gear (8). ven for ps 97) Um '8 mm (for plugs (48)) 8, Atach eye bot (ST 0018) to the ply hole on cov ‘(47 Ineort a ron ba into the eye-bl hoe. 10. snort sezowsrvr into the pg hole on rng goar (25) to pull out wr (85) whe rong cover (47) sing te kon ba 11, Remove cover (47) em Hog gear (36). 12, Remove O-ing (46) kom cove (46). 13. Romovs trust plato (4), drive gear (49), carer (40), and planetary goars (88) 8 2 unit and son ‘9227 (88) trom rng gear (6). wos-02-2014, Remove socket bo (22), dust plato (3), laotary oars (30), ole beanngs (2), clans feo), and twust washers 27) om hosing 23, TH Arm QOO® ® G | _® A 9) ) OOGSEHOHS Serna Seat wos-02-21UNDERCARRIAGE / Travel Device 15. Place an con br atte ond of shat (18) ta ‘wth a harmor to dev ot sha (18) and bal Toaving (1) ae 2 unt hom housing (28). te 18, Remove plogs (27) fom rng gear (6) Fo stom 17. Remove stool balls (95) ro the pg holes. 18, Inert two © tree 1010 15mm hick won plates Clearance A so that tho pats sround the tavel ‘ive ovoly and ae positioned jot under sprocket mounting bl hes 18, Insert wo a Hv bots (12% 1.7) it the sprocket mounting bt holes so that each bot wil Contact alae plate, Tighten the bots event to emove housing (23) rom ring gear (26). ot: mi2% 1.78 Bo: 18mm 20, Clamp housing (28) a vee. Use bosing nut Lightning to! (ST 9145) 10 remove bearing nut . enwwig ind Thing To. 97 48 es 21. Remove bearing (25) rom hosing (23), using an iron bor and a hammer ft 22, Remove loaing sal (24) fom housing (2). 23, Remove ot seal (20) om hosing (28).se sue owing 25 beng net 56 ng oar Be Selbenn 3 owt so Br Ste tah ao Py ‘wos-02-23UNDERCARRIAGE / Travel Device ASSEMBLE Clean cisassombled parts with schent and ty thom wih a compressed at. Apply a fim of hydaute ol to the anor pat. lace al Ovings, ol sols, and ote wih new ones, i (denscembled. 1. op grase to ol sa! (20) and insta i Yo ows 99 G3. 2. Apply grease to fosting sea! (24) and instal to houshea (23). 3, Apply @ ttn of hyérauc ol to the contact areas tpebwoon housing (29) ad baring (25) Drive bearing (25) onto housing (25) sing @ ham ‘mor aan on bar. Tighten bearing bt (2) by tr 4. esta ing gear (26) ono housing (23), using @ plastic hare. —36 og oar 25 eng 36 Bearag Met sing ea ‘wo3-02.25UNDERCARRIAGE / Travel Device 6, Uso a spring seao, bearing tightening tol (ST = 23146), anda torque wrench lo sot beareg prota, as tuseted fl Rotate the rng goar two tres tans. Using 2 sping scale, measure proiad Fat te poet the a ring gear is about o lum. ( Ro tighten txque is LW ppd to bearng ut (25) at is point} “Tighten Bearing nut (25) a i,t moasure the bearing preload. Ropoat his procedure unl he ~ boaing pelos around F+{ 1.72.) kt af TA, ot | Note: Iho bearing pelos exceeded the epaciiod wero value of #25 age ‘© oaeen beanng nut 26). 2 Remove housing (23) rom the vse, (@ Taps plastic hammeron ring gear side housing end to release the bearing prelosd @ Reset the bearing preload 9O® Spring Seale Bearinginet Tightening Tool $7 3146 o 6. opty Sal tape ops (27) sets {rom tn pug holes and ttn plugs (27, [— : sam aH: 67 88 Nem (0.7~09 Agim) (4~65 BHM) bal (25) 7 Intl trust washors (27), clas (2), lh earings (29) planetary gars (90). ae tut plato (31). Apply seal tape to socket bot (22). "ghtensockot bot (22). Ts sen Pt A.05~ 8.10 Nan (0.419~0.096 kgm) (299-37 Wi) 8. Insta sun gor (38) into sng gear (6), 8 Instal cai (40) to sun gear (28 wos-02-2610. Instalinner roe (4), ler boaings (82), and Planetary gears (2) carrer (0) 11. instal hve goar (4) into ing ger (26). 12 instal rust plato) t cari 0 » doe 23 Hoteeg ‘~ anetary oose a om 2 Rater ewtng (soca So) Strut Pe sm nour 48 anata Gear (Pet 26 Bears nat a co 27 Tha Waster 22~ sostt Bot 12 Sa ets) Tt ate wos-02.27UNDERCARRIAGE / Travel Device 19. Aapy reas to O-ing (46) and instal to cover , 14, Insta cover (47) 0 rng goat (96, 15, Atach oye bol (ST 0018 othe sg le on (over (4) Insert an won br int Eye Bott: ST 0018 18. Bend wire (4) 90° point about 6 mm fram the wre lop. sort the Benttop side of we (8) nt. The log hole on ng goa (8). Feta cover (47), using then Ba, o wind wire (4s) on cover (47 17. Reply seal tape on pgs 87). Tighten plugs (7), [som FS 6 9-88 Nm (07~09 Kah) (GI ~E5 "or 1. Aoply atm of hydraulic oto he contact aro between olor bearing (19) and Rousing (23). Install shat (18) and aller bearing (19) 35 vit io housing (23) by tapping onthe shat wd wih plas hammer me 19, Insta ste! balls (2), springs (24), swash pao conta pistons (95), 2d swash pat 17) 0, Fusing (2), 20, Install ping seat (8), srg (8), and washer (7) ‘nt eye lock (10, 21. Push down and hold washer (7) and spring (@) sing prossing too! (ST 4816) anda prs to remove retaining ring (8 Prossing Took $1 4116 at 22, Install pins (13) eyinder tack (10). Prave rotaner holder (14) onto pins (i). ‘wo3-02.2828, Apply a fim of hydraulic oo pistons (18) Inet pistons (1) and plato (15) asa unit cylinder tock (10). 10 oyingr took 17 Swan te ae See er com ‘wos-02-29UNDERCARRIAGE / Travel Device 24, Apply fr of yeas ot to contact areas between piston (15) and swash pat (17). Insta eyinder block (10) are pistons (1) as @ unit ro housg (23) 25. Reply groaso to O-ing (20, Insta Ong (2) and pins (2) 0 housing (2), 26, Aoply greas to Osing (11) in (12) and he ‘contact reas between brake valve (2) and vale plate (5). Instat Ong (11) pin (12), and vv plate (6) 0 brake vale (2) 27. on housing (23) and the assembly of bake valve {2} and va pate (5. Tighten socket bts (3). T— : em aH §9~08 Nim (6—9 kam (2964 MY ‘wos-02-20DODDS @ ‘wos-02-31UNDERCARRIAGE / Travel Device MAINTENANCE STANDARDS aszo(r 2) [caso (rr e 1018 (2.007) ‘wos-02-34UNDERCARRIAGE / Center Joint REMOVE AND INSTALL CENTER JOINT Remove Center Joint (peexEnsEe2e%s0 [Ab igurs shown in Bos secon ae for tha EX 90. Acrur0n: escaping tid under pressure can ent the ak, caning serious ty. Avo {iis hazard by rllewing pressure before ‘lacennesing nyaue oF other tines Tah | Streonnectonsbetreappiying pressure Seorch for leans wih 2 plece of corboord Take cre te protect hands and body tom hgheressie tats ian accident occurs. get immediate medial Senvon. Any fui njated ino the sin must be" turgealy removed witin a few hows oF Sangrene may eau 1. Stop the engine. Operate the contol fevers a fow times to relase tha prossure in tho cul Loosen ap (1) on the hyéralo ol tank (0 roleese ar rosso. (30 oly) Note: Bofors removing tho conte pint, remove tho ‘operators seat. Son the “swing device’ Sbeton oF the anus, when mowing. the ‘operator's sot (X12, EX 15, EX 8) 2. Remove mounting bots (1,2) 10 remove flor cover. etm ‘wo3-03.01UNDERCARRIAGE / Center Joint ‘eco the hyaut of tan ve range and continue 10 ‘operate the pup we working. 4. Remove pipes (1) 1 (8). Note: Pipe (2) use EX 22, £X 30 on. me 190, 22 65. Remove bots (1). me Tam 66 Remove bots (2. Remove tack frame under cover a == SS ‘wos-02.02UNDERCARRIAGE / Center Joint 7. Remove pipes (hese, adaptor et.) (1) 10 (10, Neto?) Make marks pipes and cere an. eter) Pipes (1, 2) use EX 22 aed EX 30 any me 19 0, 22 ©. Remove cone joint mauning bake (1). Hoist the conto it mer om Install Canter Joint 9. instal bots (1) 0 contort. eT om at 49H (kgm, 96) 10 Insta pos (1) t0 (10) ‘Standard torque specications rank an [Tomarern [Torgniatn | Toe be ‘wo3-03-03UNDERCARRIAGE / Center Joint 11. Insta he cone joint ook plat, me 70m at 49 Nem (gh, 96.2) 1. instal pipes (1) (8) 10 te center joint. Stop tho acum pam, ne 19 0mm, 22 mn oat 20. tm kate, 21.7 BA) 39.2 Nm (kgm, 29 bt) 1. Insta ho under cove ofthe rack frame, eT mm oN a 40 Non sigh, 95.21) a ; “4 Insal te Noor cover. arm 49 nh (shot, 36.2 1) ‘Note: 80 sure to check he oi level in the Deut of tak wos-03-04UNDERCARRIAGE / Track Adjuster REMOVE AND INSTALL TRACK ADJUSTER (@EKI2EKI8 Be? 0) Remove track adjuster fora removing the wack adjuster, romows the wack fi assomy. and font ser. Roler to the sections fenitlod “ack ink” (WO3.07) and “ont idle” (709-05), when removing he 1. Takeout task adjuster assombly (1), “rack adjuster assembly weight + 6.2 kg (18 1b) (©190) Insaltrack adjuster 1. sal track acustr assembly (1 to ack rae (2) "Take care not to contact sprig guid (8) win to track tare Be sure to contact wt late (4) ete: The EX@ has not spring within te wack tame, wos-04.01UNDERCARRIAGE / Track Adjuster ‘wos-04.02UNDERCARRIAGE / Front Idler REMOVE AND INSTALL FRONT IDLER. (o@ex2ExisE<2O0) I be show in tis Seton ar forth EX 30. ‘Remove Front ler Before removing the front idlorzemove tho Wack tk ‘szombly, Role: 10 the section ened “wack tink” (v02.07 when rmoung track Ink. 4. Use a cronteto pry ut the rnt er and yoke use, By CAUTION: From ter weioht x30 902 (665 ©) Exae tng (75) Exi2 exis feo (65) Bra. 7ig (81) 2. Remove the tent il ren the ack amo Note: Wn kooping te Font idler of the machine fora porod of tne, be sur sabize the front ter by pacing it on @ wooden Hock natal Front aler 8. Insal the root ilar to wack fame in the opposite ops for removing. ImpontaNr: ection of he yoke, ‘ean the font ler mounting sutaco of th tack frame and bearing sing soso. Apply groase To both euraces, ko the upward Idownward wos-05-01UNDERCARRIAGE / Front Idler MAINTENANCE STANDARD ee LU: Lin of Use NO. w Remedy 14 069 A 20,0787) cata ae 8 52 (205) sod Aishiog c zara7e) | 241 (08)UNDERCARRIAGE / Front Idler 2, EXIS, NO: Nomina mension LU: Limit of Use NO w omedy & 24 (0.946) 18 (0708) 8 60 235) e aaa) : Sut wos . 216 (850) 210 (826), fishing e 1010294 : F ‘249 (9.80) : - a w Remedy ole ‘Ouse oa | 250,090) | 242 0952) trae oa | 250(0904) | 255 (100) Replace Bushing ange Taekness | 2.000787) | 15 (0.0580)UNDERCARRIAGE / Front idl 0+) NNO: Nomina. Dimension LU: Limi of Use nts emt NO w Remedy a 311227) 8 00 15") : © eres : ay wot ° aoa sos) | 260,103") ‘ishing e 10 0394") - F oor (ro) : a ND w Remedy ie OusioBe | soorr) | 292 (1.18) Inside Oia so) | 905 (120) Replace Busting ange Thess | 2000787) | 1.5 (0.0580)UNDERCARRIAGE / Front Idler A NO: Nomina. Oimansion e LU: Limit of Use ras mee NO w emedy a arc) | 5 (090) 5 206.157) - ce aoc.) : ‘udp wold ‘ond > aoa 0s") | 269 1000") tiishing E 10 0.396") : F oor) : ND w Remoay ae ‘Ouside Da | 960(196) | 942 (1.95) tna Dia 350198) | 95.51.99) Replce Bushing Fenge Tackness | 2.000767) | _ 1.5 (0.0680)UNDERCARRIAGE / Front Idler wo3-05-06UNDERCARRIAGE / Carrier and Track Roller REMOVE AND INSTALL CARRIER ROLLER (©30) Remove Carter Rllr 1. Loosen valve (1) of he wack adjuster and allow prossuized grease to escape, me 9 mn 2. To romows car roller (1) inset the jack between tho track tame and vack Ink (2) assomby. Jack up tweak nkt2) assay. By ATION: tn order to avoid sipping, insect ‘wooden block (@) or ether material between the base of the jack and the wack trame, .Ingert wooden black (9) between tack tink (1) sembly and wack rae, mom ND. w emody ‘le ouside De | 250098 | 242.0852) ‘wide 0 [ 250(00n | 2mm (100) place sting Fenge Tieknoss | 2000767) | 160.0690) |UNDERCARRIAGE / Carrier and Track RollersUNDERCARRIAGE / Track Link REMOVE AND INSTALL TRACK LINK ASSEMBLY Cautions When Removing Track Link Assembly ‘The Following instructions are vety important for remeval and instalation of vack inks. (0) Be sure to understand the removal an instalation frocedues baore undertaking ns work, espocally Satoty procedures. (2) Taka car when ssassomblng the Yack adjuster. improper disassembly 1s used, may causes enous personal uy A\cAUTION: sony looten ne vale 0 release grease, nen creasing the Wook tenon the wale te foosened abrupt, the grease may be vilonty ejecta 1. Looten vate (1 10 decrease the rack tension Just ‘one to on: al tr a val (1) 6 enough 1 leas the grease kom the cynder B.c20710N: Never ions tng). Remove Track Link Assembly (oo ExzExtsBe25%0) It igure shown nth secton so forte EX 30. 4. Mov the rack nk unt the master pin is over the ‘roti. Place a wooden tock, ag shown wos-07-01UNDERCARRIAGE / Track Link 2, Loosan valve tallow grease to How out ae 19.00 8. Push out master pin uslog @ maser pin remove tol Novo: (1) Make sure to recon af to aster pin Note: 2) Betore pushing ou the master pin, to ‘romove lock pin EX 8, EX 12 X 18, 4. Operate the machine backward 5. Jack up the machine as shown wooden Blocks under the machine Pl cut te wack in ‘wo3-07-02UNDERCARRIAGE / Track Link Install Track Link 6, Jack up the machine and poston the wack ink under the wack ole, Mako sro the decton ofthe rack inks as shown, am seems Tod 7 Lit the wack ink and place ion te sprocket, “Track nk weight (One so) EXIZEXIS: 7aKg (174 1x22: 1394g 08 xa0:1664g (965 1) 12. Stonly operate th sprocket nthe forward direction '9,Keap on turing the sprocket unl he wack Ink ed Is over tho front ler Place» wooden tock, a8 shown. wos-07-03UNDERCARRIAGE / Track Link 10 stl ho master pin using a master pn sort tok a Noe: (1) Make sue the decton ofthe master pis as shown, Nose: (2) “Ator"instaling the master pin, into Ie tock pin n €X'8, EX 12, EX 15. Replace the lack pin witha new one 11, A grease othe eyo Hough the ing to adjust ho rack Ink tonsa e191 2anhm (8 tot, 05 ‘Standard rack onson TEC 15, EX 16.85~ 100 mm @3~4 ia) Ex 22" 10~130 an (635.1 n) EX 30: 120~140 an (47~55 in) wo3-07-04UNDERCARRIAGE / Track Link MAINTENANCE STANDARD Link shoe? ND: Nemina Dimension U0: Lat Ue ox, bats ou: mmo nO w Fea m wos) | waco 8 wocen | ace e eres = ‘Replace > 10208) E wes | _1.0os a 1003) x w dy A 7018 400) | 1050147) 8 coon | e010 © 190 (423) ep ° seam = ves 0850 | 7510208) F 75,0230 ‘wo03-07-05UNDERCARRIAGE / Track Link x12, xs NNO: Nomina Dimension LU: Lait of Use NO. w Romody a 7350 (289) Replace 8 1395 0649 | 10.95 (0481) x22, x30 NO: Nomina. Oimension LU: Umit of Use ND. w Fomody a 8250 (3.68) Replace 8 1890 (0744) | 16:90 (0625) ‘wo3-07-06UNDERCARRIAGE / Track Link Link Pin T i 2D: Nomina Omonsion LU: Limtot Use x12, O15 No w omedy 77.00 (8.05) : * ) Replace 8 vas ser | 1215 (0478) x2, £90 NO w A 92.50 (3.68) : A 8 49.17 (0766) | 17.00 (0659) wos-07-07UNDERCARRIAGE / Track Link NNO: Nomina. Dimension LU: Lit of Us x12, EXIS a_i NO Ww Remody * 3.0 (1.65) : 1440 (0567) | 15.00.0590) | Replaor c 22.18 0.872) | 20.16 (0.790) x22, 190 NO w emod a 520 (205) 7 8 135 (0,768 | 208 (807 | — Reoce © saz. | 902(1.18)SECTION 04 fi FRONT ATTACHMENT CONTENTS: Group 1- Front Attachment Removal and italaion of Front attachment wosoror Maintenance Standard Wot.01-06 Group 2- Hydraulic Cylinder Removal and isan of wor-02-01 ylnder Maintenance Standana wot.o24‘s80W-04-02FRONT ATTACHMENT /Front Attachment REMOVE FRONT ATTACHMENT (ee Exi2Ex6 B20 Figures sown nth Secon ar for EX 20. AX CAUTION: Escaping fuid under prossure ean penetrate the skin. causing serious injury v IRvold this hazard by ralleving pressure Before fisconmecting hydraulic or other tines. Tighten Si connections ‘before. applying pressure | ‘Search for leake with & place of cardboard: Fake care to protect hands and body trom high pressure td son | Wan accident occurs, get imme te medical ‘tention. Any lla injacted Into the ekin must be surgically removed within a few hours or ‘angrene may result +.Park tha machine ona fr, oe! ground. Retract arm and bucket eyes ay. ‘oom 0 al the art tp comes into ‘contact withthe gruel. Extond the buckot ein So that tho bucket to comes info contact wth the ‘round 2.Atach a wire cope to the boom cylinder, 38 Sustatod, and had using a crane Fesmove it bo (1) 2p 2). ee tt ft wo4-01-01FRONT ATTACHMENT /Front Attachment ‘.Lomer the cyindor and put the tube top onto a bonch to secure to oyna. Use the boom lover to ‘erat the boom cyindor Tuy Put a wie trough ‘ho rod hee an to 16 the eyinder tbe 30 tha the yao wl nt extend, A. caution: boom eyinder weight: "EXGD 73 1b (33 Ka) ‘ap (1 located on Be hydraulic of tank to release . S.Remove th bucket eyloder hoses, axm eylnder hoses, and boo eyinder hoses, and plug te, me 22 8.Te wi ropes around the boom and use the crane to host tho Wont atfachmect to taaneed poston Be sure to place a protector betwoon te wire ropes ‘andthe boom. ‘CAUTION: Front attachment weight: aA 'Ex30: 6811 (208 kg) X22: 555 Ib (251 bg) EXIS: $50 (159 ka) ‘wo4-01-02FRONT ATTACHMENT /Front Attachment T-Loosen rut (2) to remove boomfoot in securing cn me Tem aT —— \ % iS 1.Remove the rot attachment, and putt on @ sale wos-01-03FRONT ATTACHMENT /Front Attachment INSTALL FRONT ATTACHMENT 11. wire ropas around the boom and vse te crane to ais the ont ascent to baled poston. Bo sur to place a protcta Between thn rps and the boom _— {2Aign the boom foot hole with the. boom-foot ‘rong hla onthe rae. X 2 Give tore pe he ae \\y X 5 b aR ‘install boor-eot pin securing bol {1}, and tighten rut 2. ame 7 mm S49 Nm (96 Int, 5 ktm "Remove pgs from arm eynder and bucket cylnder Connect arm eyodor se toom eylnder hoses to respective ppings ae 22m 299 Ne (201 Rot secre woa.01-08FRONT ATTACHMENT /Front Attachment 15.Rach a wre rope to the boom eyinder. aise tho boom cylinder to aigh the rod hole wih the cylinder red instang ele on the bom, (rive pin 2) na th Ho, aaa jot bl (1), ome mm B49 26 N, Skghm 6.Conten bat eap (3) s soewely installed ‘Choc nya of lve idol necessary woa.01-05 exe MAINTENANCE STANDARD FRONT ATTACHMENT / Front Attachment ND: Neowin. Dinanson 0: Ltt Ute Pats ae NO w Remedy rae 000) | a0 0se [Busing (Boon) 25.0909 [255 (108 aa 23.0920) | 2.00900 Busing (oon Gf) 25.000) | 265 00 | (Pm 25,0984) | 240 (090 using (oom Oykrdo 25,0984) | 255 (1.08 Engle 75,090 | 24000946 | peptco esting amy 25,0004) | 2650.00 Pe 25,0984 | 240 0944) . | Bushing (Arm Cylinder) 25 (0.984) 26.5 (1.04) . (ee 25 (0984) | 240 549 Busting Gr Gyn) 25 0984) | 205.00 ee ( 2s,oaee) | 2400949 | Busting Bucket Cylnder 2s 030) | 268 0.00 ‘wo4-01-06Fars Nano % w Tay Pe omy | m0 0m) 4 [Postna eoier oye | s51000y | zo5 100 esing (A 20m) | 265 180 en 20386) | 288 060 Pe 0080) | 240 054) + [ing am 250586) | _=85 49 me 20900) | 288 64 > fa 0000) | 240 0014) eating tea N zs ooe) | 265 48 a 2s 0384) | 240 0549), Bost 250984) | as 0.09 Ie 01110) | 28000- | pane eur in Far) 00138) | a8 00 v Pn ~ 30 (1.18) 230 (14) using oa Fae) on | 31502) w Po 25 (0.984) 24.0 (0.944), Busing oro Grae | 25,0900) | 266,008) Pn zee | aos N _[sssting Gooraving Grind [25,0989 | 265 0.00 Pe zon | 008 a Busting (Biade) 90 (1.18) 31.5 (1.24) Pe 201136) | 280 4) 7 | Bushing (Blade Cylinder) 30 (1.18) 31.5 (1.24) Pn sora) | m0 ° | Bushing (Blade Cylinder) 30(1.18) 31.5 (1.24) Ze wo4-01-07FRONT ATTACHMENT / Front Attachment exe IND: Nomina Dimension LU: Lint of Use Pane Nome ND w Remedy agin soit) | _ aac Buse (Boom) 00.1 | ais > Pin soca | 2001 Bushing (Boom Cylinder 305) | asc. : Pan soe) | 2000.19) [euching (oom Cynder aoe) | ensign) > [ee 301176) | 2800019 | pepiece sting (am) aon | 51520) 2 Pie song) | 2800.10) Bushing Gm Gyno soma | 31s (12H 7 Pin soci | 2900.19 Bushing (arn Cyt sone | aus aH ° Pie soe | 2900.19 Bushing (Bucket Oyinden) ous | ose wo4-01-08Parts Name NO w Remedy Pin mse | 290009 Bushing (Bucket Cylinder) soca | 918024 Busting (Link A) soca | ss 02H unk 8 aocie | 915020 Pin soci | 2900038 Busting Gm) soci) sus (12) unk & aoc | sus a24) Pia aoc | 290094) ‘sting (Uk A) ani | 502) Pa wou. | 290010 Busting Ar) anc | 3151129 | Replace Pin “5077, 14.0 (073) Busting (Main Frame) way | #550089) Pin soe) | 2900099) Busing Goonawing Cynder) | 30 (16) [31.5 (124) Pin ~ [| nr [zone [Bushing Boom-saing Oyindon) | 90 (0.8) | 945 (126) Pe sou | 90010) Bushing (lade) sou. | 315020 Pa gon) | 290014) Bushing Bade Cyinden) aon) | sus za) Pin aoe | 290 004) Bushing (Olde Cylnder) aouaa | 9150124 ‘wo4-01-09FRONT ATTACHMENT / Front Attachment NO: Noming Dimension LU: Li of Use vane Parts Name i w Resnody oe soe | 290018 Bushing (Boom) sone) | 3s (128 : Pin soe) | 290(118 Bushing Gaam Oyler) soci | sis (i20 om o(1 | 2000.14 [Bushing (Doom Gyoder soci | on 02s > en 00319) | 2900.14 i sting vm) aos | ais 024 = Pin aocie | 2900.44 Busing (rm Gye woe | ssc. : Pin soe) | 220; Busting (am Cyl) soe sus (124 oP soe | aoc Busting (Bucket Cylinder) soe | 318 028 wo401-10Parts Name ND. wu Remedy Pa soe) | 2800.) Bushing Bucket Cylinder) aoqiaey | 915 (12) ‘Bushing (Link A) aoc | ssa ink 8 aoc | susan [po 20.19) | 2900.14) shina (An) zac. | 315 (024) ink 8 soca) | 315 (4) Pea oc.1) | 2000010 sting (Link A) soe) | 918028 Pin aoue | ocr eushing (mn aoa | 31524 Replace Pa wom | #007 Bushing (Main rao) wc) | 65089 Pa aoqiaey | 790014) [Bosting Boomawing Oyindon) | 208.16 | 915 1.28) Pn soci | 2900.14 Busting Goonrawing Gyarder) | 90.%6) [1.61.28 Pin soca | 29004 Bushing (Bie) aoue | 31824 Pi aoc.1a | 290 (014 Busting (lade Ove) go(iaey | 915 (128) Pin aca | 290010 Bushing (Blade Cyne) soy | 315020) wooo1-11we FRONT ATTACHMENT / Front Attachment NNO: Noming Oimandon LU: Unio Use ad Pans Nae NO, w esmody A Pa aousn | _s900sa Bushing (Boom) aocsn | asc. aes ous | 390159 Busting Boom Cynder sos | 45 (165 = Pin ousn | ss00sa_| Bushing (Goom Gyno) 101857) | ane (n6a) : Pa ousn | 3900056 Replace Bushing (Arn) aousy | ass ef aocsy | 990158 [Bushing rm Gyo) aona7) | a4 (160 ; Pin aousn | 390 158 |__ [Busting vm Cynder) worn | ass es 35138) | 3203s Busing Bucket Oyinder) 35138) | 965 (1481 wo4-01-12at em Parts Name No. w. Remedy Pe asciay | 3400039) Bushing Bucket Cynder) sca | 965 049) Bushing (Link A) 35138) | 96.5 (149) ink 8 3536) | 36.5 (149) Pin 535) | 940139) Busting Ve) 25.95) | 965 (149) Link 35 (1.90) | 36.5 (145) Pin 359 | 9400139) Busting (Unk A) 35 (138) | 96. (149) Pia 3595) | 640039) Busting Ym) 35135) | 965(148) | Replace Pin eseiy | 54021) Bushing (Min Frame) ein | 985 @2 Pi 2osn | 29.0059 [Busting (Goom-wing Oyinder) | _a0(ns7) | 4180.89) Pan wousn | _s90059) Busting Goomewng Gyoder | 40cnm [41.5 (169) Pin sous [| 9005) Busting (Bide) wousn | 45 (189) Pin wousr | 990(159) Bushing (Blode Cytnder) aous7 | 415 (189) Pin wousn | s90059 bushing (Blade Cykndon ous | ase, wo4-01-13,FRONT ATTACHMENT / Front Attachment ND: Nomin Dimension LU: Lei of Us ano) Pants Name "0. w. Remedy ne asm | sour Busting (oom) asc7y | 455 (185) 3 Pin aor [390 (0881 Bushing (Boom Cynder) ‘ous | #151169, ° Pn aonsy |_s90(59, Bushing (Boom Cyne) wousn | nscen ° Pin aocisn | se0cisy | Foner Bushing (Ar) wousn | asa : Pin os) | 90059, Bushing (rm Gyider aocsy | 415 (69) Pe aocsn | 3900059) Busting vr Cynder wos | #5089) ere wasn | 390059) Bushing (Bucket Gyinder) wasn | #15069) ‘wo4-01-14oa: nme Pars Name ND. w. omedy Pia wousy | 900) Bushing (Buckt Grinder) aousn | sce [Bushing (Link A) onsen | Hs ie) unk 8 wasn | 500) Pin 400s | sone [Bushing Arm) 4015) 415 (183) ink 8 ous | 1508) Pin wus | 9008) Busing (Unk woosn | #508) Pa ausy | 90089 Busting em onsen | asc) Replace Pn oe | 90 asa Bushing (Mn Frame) eos | 615 (ey Pa ors | 990008) | Bushing (Boom-swing Oyinder) | 40 (1.57) 4150) Pen wousry | 39.0159) Bushing Booreawing Gyinaery | 40 (057) | 41.5 1.85) Pin sary | 40079 | eusting (ase) sun | 465080 Pin som | 4007) Busing (Bld Cynder) asm) | #650089) Pin asm | #007 Bushing Bind Cylinder) “scm | 65089) wo4-01-15FRONT ATTACHMENT / Front Attachment Polat (er, EX, B22, BX30 ND: Norrina. Dimension WU: Lint of Use "D. w Femody A 90 (748) [nis 453) 8 aoqusn, Replace ce 50 (197) : ° 20.57) - Side Cuner> pez, X30 NO: Nomina. Dimension LU Limit of Use NO. w ese a vias | 75205) 8 198 649) Replace c 159 (602) : ° 90 (54) : ‘wo4.01-16FRONT ATTACHMENT / Cylinder REMOVE CYLINDER (o@exizextsBe2 00) [A hgues shown nts section are for EX 20. VA. cAUTION: Escaping tuid under pressure can rs Denetrate the skin. causing serious. injury. n bivovd this hazar by relleving pressure Before fisconnecting hydric or other lines. Tighten fll connections before applying pressure. Bearch for leaks with a ploce of cardboard: Fake care to protect hands and body tom high-pressure tua exon It an accident occurs, get immediate medical tention. Any fla Injacted Into the skin must be surgically removed within a fow hours of ‘Gangrene may result Remove Bucket Cyladar 1.ark the machine on & fir, ovl ground | ""Retactetm eyinr (1) an bucks ond (2 fy lower boom (3) 20 that am (3) top comes ito ‘ontaet ‘wi the ground. Extend the bucket cylinder So tat the bucket op comes slo comact wih He [ zrace wooden tock btn bucket yd () | *andame ‘wo4-02-01FRONT ATTACHMENT/ Cylinder ‘.St0p the engine. Operate the contol levers a few times to release the pressure in tre cet. Loosen ap (1) on the hygralie ol tank to releaSo ar 4.Remove pin securing bot (1) onthe rod side, me stm AA CRITION: Links (2),¢) may move suddenly 2¢ they are disconnected from the rod, resulting in personal injury. Be caetul when removing pin §5.Romow gin (1) to disconect tks (2)(2) rom the Bt 6.Put mio (2) trough od (1) hole and to ito einer tube (8) $0 tat Gye oa (1 wl not extn ‘wo4-02-02FRONT ATTACHMENT/ Cylinder ‘Disconnect mo cyindor hoses (2) trom. bucket ‘inde (1). Put plage (3) on Note and piping {8.Te wre rope (2) to bucket ender (1) atthe point ‘Ot balance, Holt cylinder (1) using 8 rane aa CAUTION: Bucket cylinder weight: = X30 51 b (23 kg) X22 37 lb (17 kg) EXI6: 2218 (10 kd) EXI2: 22h (10 kg) — Exe = 1718 7SHQ) 8.Remove pin soewing bo (0) Pl ot pn 2) 10 remove eye (9) Install Buokst Oyindor 10.7 wie rope (2) 0 bucket cylinder (1) atthe point ‘of balance. Host oyinder (1) mi 8 crane, and align the yinderbottom side hele with the cylinder ‘mountng ele on to amFRONT ATTACHMENT Cylinder ‘aso pi (1) ao the ole Tnsal pin securing bt (2, etm 49 Nm 96, Som 12.Gonneet two cyindor hase (2) to eylindr (1) me 20 pe: 39 Nm 29 ot, & ken) =e Sere "4. pin securing bo (1. ‘wo4-02.04FRONT ATTACHMENT Cylinder Remove Am Cynder 1.avk the machine on ir, level ground atrct the arm syindor ond the Bucks cylndor ay [Lower boom so that ar tp comes so contact wh tho ground. Extend the bucket cyl: so that the Dekel tp comes ito conta! wh the gourd, ‘2.Place wooden block (9) between rm oylndr (1) ‘and boom @). ‘2St0p the engine. Oporto tho conte lovers a fow times to release the pressure inthe cre Loosen tap (1) on the fystauic ol tank to release a pee oi & f° 4.Ramove pin socutig bat (1) onthe rod 5, at tam 49 Nm 5 5 gm) ‘wo4-02-05FRONT ATTACHMENT Cylinder ‘5.Pul ot pin (1) on tha arm einer ro sie, 5.Put wire (1) trough od 2 holo and tito cylinder tube (} #0 Bat eyinder rd 2) wil pot extend Ie 36:1 ‘Disconnect wo cyinde hoses rom arm eylnder (1) Put plugs 2),(3) on hose and piping openings me: 2 m0 8.7 a wire rop6 10 arm oyinder at the point of ‘blnee, Hoist the cylinder using a crane, A.cxxti0w: am yinder wean Boe atta, ize ssi sa) Ene ssa) Ente 2 (0%) corbin wos.02.06FRONT ATTACHMENT! Cylinder ‘Remove pin securing bat (1) on tho elinderbotom ‘so, Pl out pin (2) 0 Yemowe eyo (3). Insta tm Cyr 10.Tia wio rope to the arm cylinder at te point of alnce, Hat the eyieder usng a erane to alg the tyler bot 8 hole ath the eyinermaunting tole on the boom, ‘Lins pi (1) nto the hol. Inaal pin securing tot (2) e170 a+ 49 Nm (5B Skat) 12,Gonnec wo eyinder boss (1) 1 the eye. woa.02.07FRONT ATTACHMENT / Cylinder 18.Start th engine. Operate he am conta ove while hing the oyinder wih tha wie and the crane to ign the rod ih the meaning hol onthe sn, “las pin (1) ato We hole Insal pin sscuring ba (2) Hm Remo Guckot Cylinder |.Park tbe machine on fir, lov ground the bucket eyledor boom so thatthe arn op comes ito th tha ground. Extend the bucks eye {0 tal tha Puckett mee Inca the round 2.Atoch a wire ope 1 the boom eyinder and secre Tsing» crane, A caution: B00m cyinser weight 'EX30: 7310 (99g) 22 62 0 (28 kg) EXIS: 34 (15.5 Hg) ExI2 28 0 (12580) FXO: 2015 (9a) ‘wo4-02-08FRONT ATTACHMENT Cylinder ‘Remove pin sacuing bl (2) to ps out jolt AsLower the cyleder and put the tube top onto a bench to sacra tie onder S5.Operata the boom lve 1 atract the boom cylinder hily, Pu are tough te od ele and too the ‘ylnder tbe so tal tho cylinder wil not extend 6.St0p the engine. Operate the contol lors a fow tes to release the prossute inthe crew Loosen tap (1) on the hyorauie ol tank to releoee ar pressure. ‘wo4-02-09FRONT ATTACHMENT Cylinder 7.Rlmove the boom cylinder hoses, Pag hose and piping openings. ame Bn a 58 Hh 29.01 4 gh) ‘Remove gin securing bat (8) to pullout pin (2) on ‘main rar (1), 9.7 wie rope around the boom eyinder atthe ont of balance. Heit th cyseder using one. NX Insta Boom Cyne 10.7} @ wire rope around the boom cylinder atthe point of balance. Host he cylinder sing a rane to Sign the cynderbotom se hale Yo the mounting fa onthe man ame ‘wo4.02-10FRONT ATTACHMENT Cylinder 1a int pin (1. Instat pn securng bl (2) me 1mm a 49 Ne (6 et, 5 haf) 12.Gonneet eyes hoses (1,2). me 220m ae 29 Nan (29, 4 ghey 1a.Stat the engine. Operate the boom cont lover ‘le oidng th ender wth the wie rope and he ‘ave io alg tho vod ale with boo meuntng Pol. ‘unser jon pin (1) 1 eonneeteylndor (2) © boo (tsa pn securing bt). “Tighten the cap onthe hyeaulic tank erm ae 49 Ne (6 i, 5 Ham) Note: Check yarauic of evel. Atel of if recessay. wos.o2-11MAINTENANCE STANDARD FRONT ATTACHMENT / Cylinder NO: Nomiea Oimension LU: Lit of Use ee ts mm Noa w eens ‘00m 25 (0.984) fen 250.984) Replace plate Bucket 250.904) | 0.08 (0.0028) | wh chromium, Boom-swing | 25 (0.904) Blade 30 0.38) ext No w Remy ‘oom 90.18) a 300.10) Repiace pate Bucket 30.18) | 206 2.0020) | wit chromium. Boom-swing | 95 (1.38) Blade 35 (198) wo402-12exis wa ws ened oom 030) a 351138) Rete pa cha aorta) | 008,0002) ean owontm. Soong | _ 960030 Be 130) ema on w ened ean wasn os = ae | place ote aera |_asc.ae | c0sce0o1 [nim crontm Boon-awng | a00t87 ec wouen exo wow w enedy een e070 an tee Replace or plate act | esr | 00s (00016) [aim deem tonevng | O05) hve 807) ‘wo4-02-13FRONT ATTACHMENT / CylinderSECTION 05 SPECIAL TOOL CONTENTS Group 01-Drawing of Special Too! Drawing of Special Too! Wos-01-01 S580W-05-01‘580W-05-02| SPECIAL TOOL / Drawing of Special Too! SPECIAL TOOL @nracn Reduce the original drawing (ST-4114) to 69 % of s ‘and attach iton the top half of es | syusgens— erste eee SPECIAL TOOL @urmacen Redues the original drawing (ST-4115) to 60 of its original size and attach {ton the bottom half of this page. i's | Syosrn ms stans | wos-01-01SPECIAL TOOL / Drawing of Spe s#eaaL TOOL onmors Reduce the original drawing (ST-0018) 1060 of {Usoriginal size and attach iton the top halfof isa Noa i afre] [oe [reo «Lom [aaa [| PO erence a] oe [Sete | + ramen) anaauane spect Toot onmon es | spusgestece zane wos-01-02Group 01-General Information Specieatons wo6-01.02 Pertrmance Curves wo5.01.03 Dimnensons wo6-01.04 MECHANISM Group 02-Engine Body Engine Boy Woe-02.01 (0 nde Block wo5-0203 (2) Oylndor Head Wos-02.03 (aycrankstat Wos-02.08 (@)Pon and ison Rings Woe-02.06 (61Comecting Rod Woe 92.08 (6iCamstatt Wos-02.05 (yee! Woe 02.05 (@yrcker Ara ‘woe.09.08 (@)¥aive Timing Woe 2.05 Group 03-Luburicating System (Gener Wo6-02.01 )01 Pome wo 03.03 (@yRetet ave Wo8-08.03 (01 Fiter Cannio 05-03. (6101 Pressure Sach W503. SECTION 06 ENGINE AND ACCESSORY EX8 CONTENTS Group 04-Cooling System (1}Generat (2yWater Pump (9)Thermostat (syRadator (e)Radiator Cap Group 05-Fuel System (Genera (2)F va Flor {9)F vl Food Pump (jection Pum {opbjecton Nozzle (61Governor Group 06-Electorical System (stating Syst (2)Charging System ‘5B0W-06-01 wo6-0401 ‘wo6-06.02 wo6-04.02 wo5-06.02 Wo5-05.01 06-0501 Wos06-02 Woe. Wo 0506-05 W606.Group 07-General (Fagin onsteaton {2)Goneral Precautions {@)Tghtering Toros (4yTrouteshooting {6iSenvcing Specticatons (@)Maintonance Check List (7) Check and Maintenance (@)Spocil Tools Group 08-Engine Body CChocking and Acstings ‘isassembing and Assombing ()Beainieg Water and (@}External Components (@)Cylnder Head and Vales (4yTiming Goar and Carstatt (Piston and Connocing Rod (@)Fyutoo and Crankshatt SERVIENG ()Oyinder Hood and Vales {@yPiston and Connecting Red {@)Timing Goar and Gamshatt (yceankshat (i0yinder ‘checking Disassernbng and ASsembing Serving (HoH Fume Group 10-Cooling System CChocking and Adjusting (Fan Bet (@yRedater (@yThermostat Dsassembing and Assombing (Thermostat and Wate Pump Group 09-Luburicating System DISASSEMBLING AND SERVICING wo6-07.01 w05-07.093 Wo5-07-08 Woe 07-08 06-07-12 wos-07-19 ‘wo6-07-20 ‘w06-00-01 W608 03 wo05-06.63 5-08-03 5-08.09 060-08 06-08-09 0608-12 Wo 08-14 wo5-08-14 wo608-18 woe-08-21 wo6-08.24 W006. 06-08-01 o6-09.01 w06-09.01 Woe-00-01 woe-10.01 wo6-10-01 Woe-10-01 wo5-10.02 wos 10-02 wo5- 10.02 Group 11-Fuel System Checking and Acsting {lection Nozze {2ijecion Pump Disassembing and Assembing (yhoo Nezzle Group 12-Electorical Syster Checking (yDyeamo 2nd Regulate (@ystarer {@iGlow Plog Disassombing and Assembling (ystener Serving (Stator ‘s80W-06-02 wo6-11.01 wo6-1105 woe-11-02 Wo5-17.04 Wo5-11-04 wo5-12.01 Wo-12.01 Wos5-12.02 woe-12.02 Woe-12.03 Wos-12.03 Wo6-12.08 Wor 1208ENGINE/General information TO THE READER information on the mechan, sence and maintenance of KUBOTs Distel Engine 8 mn STROKE SERS” sen Sige into two ports “Weechona” ond "Dlhencmsing and Serecing” fm Meehan Information on construction and functions ate included for each engine secion Ths part should he uncerstood before procesing wits rouble ‘Hootng. duowembling and Yering 18 Disassembling and Servicing Under the heeding "Genera” come general precautions, twoublestooting, lias of tring spetieatone an pero pectin items. Tar ech engine ‘ca, there ate Cheking and rment”,“busmembing and Astening” Sd *Sercng’ which cover prcadute,precauon, factory specication snd ‘Slowable ints A ifoxation, atrations and specications co ted onthe tet production information avaae {The right ierezeved to make Cunger inal inform own hit manual ae the time of publation duly "90 fot ‘wos-01-01ENGINE/General SPECIFICATIONS Te Tae ns 29 Sd Tenis OF 2 i ‘ Bence Tow Fest near Fun ‘Gag Ba Wachaiel Govear ‘ourilochvie hens hy ston Feng 25m Oe aw 27 ow TOO nestor Pres awe ao an mat obit Str Faced Laban by Far Steing Sten et Sring wn Cal Sane Ty Glow Pg in Gonuson Chav Labeing Ot apse oat Bo A171 Popewton enw ener Sout ‘wos-01-02ENGINE/General information PERFORMANCE CURVES 11809 Gon Wow ewe wos-01-03ENGINE/General information DIMENSIONS a woe alten esoamlile Bien ‘wos-01-04| ENGINE/Engine body ENGINE BODY woe-02.01ENGINE/Engine body ‘wos-02-02ENGINE/Engine body [1] CYLINDER BLOCK [2] CYLINDER HEAD “he engine hos high durability wnnehtype “nde lec in wich te crank bearing component conic body Fohemora, hoe! te ype iw elecve coaling less datoron and greater reuiance. The neste level teduced 103 ‘num becouse ach gyncehas is own camber ‘he cotflow typ intaavexhaust pots in thie engine‘hare tl eninge bath Ses ot the ‘Gnd as "Beate ovetan onsets haut Porta aie tan np ther pes eh protected an beng hesed snd arpanded by Feces ether te cot hgh deny ston tor peli stfelogy anaes te power of the cones Foard ft fer ited heatea cxnst gu cauced Decese Imabe peta avangeaatternatty ihe {Wes comburton chamber type Stn a whut abe med ety eth oe prompting ‘Snmuaon aren ue Cooumpn whe combustion Chamber ae eed tote Ube glow log ss slow Sg ase ei Salada een at ACO ‘3 Ghwtag 1 Comustion System These engine ue he “NIVES® (New Three Vortex Combunson ste) to achieve perfect combustion {ex manimum power The NV combustion system Pronderunique shape of host inthe set or omston chamber, to produce thre tears (8) ot rin chamber (0) when compressing ng an eal mintureo ade. In aditon fan shaped concave (7) provides ‘on tapo the pst ols smooth ejection of theemauttgenolfenng hgh efcent combustion ‘wos-02.03ENGINE/Engine body [3] CRANKSHAFT ‘he cankahat with the nating rod converts “ne eranishaitismode of ough special aly ss egies pir rg pes induc Redondo ncnase te Rene, “ihe Tron joursl is supported by a solid type ‘bearing th intermediate ural by api type, ane {thereat jounal bys ype th ret beige “the ankahatt i prouded with an 2 galery tneough mich engine i tad to the rsa Bi portion a iubiate [4] PISTON AND PISTON RINGS The pton made of slmiour alloy “Meorecee forthe valves are roid on op of ] the paton A lenshaped depron faa gen op the piston inorder to alow combustion ga isPinahiy he to pis sight ot hie TIO | Snerat he pen hideign, te rout ot te | — | FDP | sito she op and bonen dd pols con be | NE SSE? | Feces sebyrenenaoa oan ne | ~~ BR | conasraton of hernal enpanton) bod» oncare Thien arietaeingrovern he itn | Thetopring hs aueynon ype atic anand a gn ney oats a the al ae nthe | = ‘eto iene wall he cond hg (0 1 undercut type, whieh 7 shy poh a ont > ‘ec ig camieed oat oer rd 29 {AX ‘expander ting, which increase the pressure ofthe oi (KN SepTpsat tpn "Sveral grooves are cut‘on the topland to help [5] CONNECTING ROD Conectng ro (2) i ved to connect the piston withthe erakshal the igen ofthe connecting fod hats crank pin bering) (pli type and the {inallend aca stall end ating) ke yee.ENGINE/Engine body [6] CAMSHAFT ‘he camshal (3) is made 3f seca cat ir and te jovnal an arm socions bre ehiled forest neat the journal sechons se frcelubcaed, The ioe cami) contrat the recreating {Rade of carton see! ane the cam set ‘quenched and tempored to provide giester wast (7) FLYWHEEL The flywheel stoves the rotating force in the combustion stroke 35 inertial energy, reduces fankohattrtatingvpeed Huctaation nd maintane ‘hemooth rotating Condition. | “ine vel perpery inact with Ue marks showing op des center mat 1 The tywheet has gear teat around its cuter vim, | whch ech wath eve ion the starter (0 rocker arm brackets) sod rocker rm sha (9) bind anverts the reciprocating movement af the fest am peor maven of the nat be _ nested satigenuy, oe Smuts stem oe ho? grace gm a SS 9} VALVE TIMING The timing for opening and closing the valve is enromelyimportans to aeheve ellecive a inte Sault gos eshaust signing he mars onthe rank eve and the co keds [oe aterENGINE/Engine body ‘wos-02-06LUBRICATING ‘SYSTEM [1] GENERAL Thi engi’ ucating tem pustreds fet nd eshouat valves Ending ge | carne ‘wos-03.01ENGINE/Lubricating system ‘wos-03-02ENGINE/Lubricating system [2] on pump {4] OIL FILTER CARTRIDGE Teil pump is 9 wochotl pump, whose rotors roses Teeter oe, centrally engaged with tech ether” The inner on by the canis though he ‘outer torn te se econ, ‘ring he space between thelober Iie ete a 0 sae ‘When the roars rotate fo(C) the space between both rotor ute rom tenet pot tothe sit oy, the space decreases and the sucked oil ‘scnrged trom the out part Ise tle provers the damage to the lubricating stam duet hahigh pressure othe oi Me rll valve bal cue sing type, ands bettie Foriow presse "when the presse ne i ored by the pum, nce he speciied value, the pushes back the Bol Gand escapee the ofpan After lubricating, the lubricating ail brings back ‘tou pier fit and rt to eo pare Those Exit wear or sizure ofthe engine pare may a ‘aetia Syualschrat ropei l The uticting ol which ace ted bythe pump, (yukon tne titer lament aecumulster 9m cceuave amount of aed the i preture n the Inlet lve bur up by 98 oa C18 Kaen 38 ps) ‘orem tat trey ae) ae Ine bypassing the iter eee. ‘wos-03-03ENGINE/Lubricating system [5] OWL PRESSURE SWITCH The ol presure switch it mounted on the liner ‘ck and ne ote otiating a posage “hen thao pressure fall Below the specie value theo prenure ering ight 1 atthepeperaieeine 8 Alone pane Eat « roma & cmt Be 1 tse odyENGINE/Cooling system COOLING SYSTEM | [1] GENERAL a WATER PUMP wos-04.01(3) THERMOSTAT ENGINE/Cooling system the thermostat maintains the cooling water ot correc temparture, KUBOTA engine eho tat Plt ype thermostat" Waniendatedin the peer The wats seid at ow temperature, bv fumed athigh temper (ay Stow ter a} As'the thermostat cored, cooling water relatein the engine trough the water vers nin thou rng he ado nthe ican) ofthe therm ee (@) Athightemperatores ger than #2 (1807), ‘nen the temperature of cooing wae! exceeds APC (130, wor in the slet tan gd ond 5) suche expands Secon the inde is fied, the fe ci fale 0) i lowered the valve (2) i separated 1 at Fro the seat (an hen cooing water tnt ‘a vost) tothe isto gine) ‘cluded in the basic er [5] RADIATOR CAP The radiator core conse af water canning tuber and tie) a amghe angie te te uber (He ‘otaater nthe tubes ode om he te a ‘Seren at ar Corugsted tre ” {he caditor cop is for metainng the internal rere of the cooing Sst atthe speed evel Beltre pa ae te aie in peration Th cap consis oa presnne ale (1) ‘SScsum valve) valvespring, geet ee ‘Coaiog water presen by thecal expansion of team, ang ar ite boiirg temperature, nace, Sevetation of ar bubbles wil be tupprewes” (a Babbler coating water lower the cooing eect) wos-04.02ENGINE/Fuel system FUEL SYSTEM [1] GENERAL url fromthe fuel tank () patos through the fuel Par ofthe ful fea tthe injection nozale (8) Ser} and then ater the jection pump () afer Wubecaer the moving pare ofthe plunger ade the Impuritessucnar rt ater, stare removes Ione, then rennet fetta eroug the fot "ie uel presi by te injection parm tothe overflow pipe (8) Hom the apper par of the nezle ‘opening pressure (1373 0 1471 MPa eto 150 holder 81 102062 pd, of the jection no23 (9) geygTe ito te comburon chamber. Component marked * not included in the basic ‘model ‘Component marked * s Included only in the tee modet [2] FUEL FILTER (not included in the besic model) fath moving part ofthe injection pump ane orale ertemely preston machined, ond ‘ebtaee f ther siding part av eeemely al ‘salu ranting roth ren Grader cetredn fu nt Yel hte wh ss very fine fits pape, see is Spaie bh te in fo a se “AP en ploy ited to he cock body. Belare sartng'r ier dawning snd resting. Ieper lg a eed theo ih ue te {omen Wo6-05-01ENGINE/Fuel system [3] FUEL FEED PUMP [4] INJECTION PUMP. pm fie fe ed tte icon pum by The ehamber()encovedwihthe ine valve (2), the eullet wave) a the Saphvgen (whch linked to he rocker arn wot Oe pl fed Oh The focer ms Suinged by on ecco Othe ieee Shen the Sephram pled down, vaccum ia tnedamb (i cate the st vie Gh cose nse somo psa fe ot vate : ten the captvagm is puted op by the premure inne chorabe Coes the niet Flos and forces out the ful, opening the outst ae icon po, ‘The plunger 8) with rihtnand lead recpro ‘ates wa the tappetroer (3) by means of the “arsnat fel cam eavang We fuel to be delivered jntweight and e057 10 wos-05-02ENGINE/Fuel system (1) Pump Element (2) Delivery Valve ea, P ow (3) Dumping Valve The pump element (1) scant ofthe plunge (3) andlnder ‘he ssing trlaces are nperprection machined {eg maintain ection resure st engine low speeds Sc the ving face (7) si the conal Seve the unger (3) totstod by tne movement of the ach wo crete or decease of fel delivery ‘hs esribed above, the purges) machuned to have the dot () ad the contol root (0) 12 Site ‘ie dolar valve comets the valve (1) an the valve set 2. “ie dlvery wave previ the fue rm ling bockint the delivery chamber trough te injection Pe. prevent the ful fom Grilng 9 he "When te delivery stoke ends the relief plunger mover nga the bore of the valve seat and seas the ‘fatvery tine iam the delivery somber The reel lunge lowers further rte vave sai Dek {hua to prevent onbbingat te ection nazae 1. Attuelin “pring, fue is premure fed to injection moctle the Sine without sumpngvaive [Atsvelcback IN uccback by delivery sive a ‘resuetoetoseacon of sien presse Sop fod ine bay dey vane eventing thes secon ection evict By ing valve snd dnalving nozse clogging iy of ection oae eimprowed