This document provides instructions for removing and installing a pump device on an excavator. It describes disconnecting hydraulic lines and electrical connectors, loosening mounting bolts, and lifting the pump device off the machine using a crane. The installation instructions describe lowering the pump device into place, tightening the mounting bolts, and reconnecting the hydraulic lines and electrical connectors. Safety precautions are provided, such as relieving hydraulic pressure before disconnecting lines and waiting for hydraulic oil to cool.
HITACHI EX550-5 EXCAVATOR Service Repair Manualjksndmde
This is the Highly Detailed factory service repair manual for theHITACHI EX550-5 EXCAVATOR , this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.HITACHI EX550-5 EXCAVATOR Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Workshop Manual Covers:
General Information
Upperstructure
Undercarriage
Front Attachment
Technical Manual Covers:
General
System
Component Operation
Operational Performance Test
Troubleshooting
Electrical Circuit Diagram
Hydraulic Circuit Diagram
Engine Harness
Relay Harness
Cab Harness
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveHITACHI EX550-5 EXCAVATOR Service Repair Workshop Manual.
Looking for some other Service Repair Manual,please check:
https://www.aservicemanualpdf.com/
Thanks for visiting!
HITACHI EX550-5 EXCAVATOR Service Repair Manualjksndmde
This is the Highly Detailed factory service repair manual for theHITACHI EX550-5 EXCAVATOR , this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.HITACHI EX550-5 EXCAVATOR Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Workshop Manual Covers:
General Information
Upperstructure
Undercarriage
Front Attachment
Technical Manual Covers:
General
System
Component Operation
Operational Performance Test
Troubleshooting
Electrical Circuit Diagram
Hydraulic Circuit Diagram
Engine Harness
Relay Harness
Cab Harness
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveHITACHI EX550-5 EXCAVATOR Service Repair Workshop Manual.
Looking for some other Service Repair Manual,please check:
https://www.aservicemanualpdf.com/
Thanks for visiting!
Toyota 42-6FGU25 Forklift Service Repair Manualjkksemd yeuyhd
This is the Highly Detailed factory service repair manual for theTOYOTA 42-6FGU25 FORKLIFT , this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.TOYOTA 42-6FGU25 FORKLIFT Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
Foreword
Section Index
General
Engine
Torque Converter
Propeller Shaft
Differential
Front Axle
Rear Axle
Steering
Brake
Body
Material Handling System
Mast
Cylinder
Oil Pump
Oil Control Valve
Appendix
Wire Diagrams
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveTOYOTA 42-6FGU25 FORKLIFT Service Repair Workshop Manual.
Looking for some other Service Repair Manual,please check:
https://www.aservicemanualpdf.com/
Thanks for visiting!
8
Toyota 42-6FGU25 Forklift Service Repair Manualjkksemd yeuyhd
This is the Highly Detailed factory service repair manual for theTOYOTA 42-6FGU25 FORKLIFT , this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.TOYOTA 42-6FGU25 FORKLIFT Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
Foreword
Section Index
General
Engine
Torque Converter
Propeller Shaft
Differential
Front Axle
Rear Axle
Steering
Brake
Body
Material Handling System
Mast
Cylinder
Oil Pump
Oil Control Valve
Appendix
Wire Diagrams
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveTOYOTA 42-6FGU25 FORKLIFT Service Repair Workshop Manual.
Looking for some other Service Repair Manual,please check:
https://www.aservicemanualpdf.com/
Thanks for visiting!
8
Comprehensive program for Agricultural Finance, the Automotive Sector, and Empowerment . We will define the full scope and provide a detailed two-week plan for identifying strategic partners in each area within Limpopo, including target areas.:
1. Agricultural : Supporting Primary and Secondary Agriculture
• Scope: Provide support solutions to enhance agricultural productivity and sustainability.
• Target Areas: Polokwane, Tzaneen, Thohoyandou, Makhado, and Giyani.
2. Automotive Sector: Partnerships with Mechanics and Panel Beater Shops
• Scope: Develop collaborations with automotive service providers to improve service quality and business operations.
• Target Areas: Polokwane, Lephalale, Mokopane, Phalaborwa, and Bela-Bela.
3. Empowerment : Focusing on Women Empowerment
• Scope: Provide business support support and training to women-owned businesses, promoting economic inclusion.
• Target Areas: Polokwane, Thohoyandou, Musina, Burgersfort, and Louis Trichardt.
We will also prioritize Industrial Economic Zone areas and their priorities.
Sign up on https://profilesmes.online/welcome/
To be eligible:
1. You must have a registered business and operate in Limpopo
2. Generate revenue
3. Sectors : Agriculture ( primary and secondary) and Automative
Women and Youth are encouraged to apply even if you don't fall in those sectors.
Things to remember while upgrading the brakes of your carjennifermiller8137
Upgrading the brakes of your car? Keep these things in mind before doing so. Additionally, start using an OBD 2 GPS tracker so that you never miss a vehicle maintenance appointment. On top of this, a car GPS tracker will also let you master good driving habits that will let you increase the operational life of your car’s brakes.
"Trans Failsafe Prog" on your BMW X5 indicates potential transmission issues requiring immediate action. This safety feature activates in response to abnormalities like low fluid levels, leaks, faulty sensors, electrical or mechanical failures, and overheating.
Core technology of Hyundai Motor Group's EV platform 'E-GMP'Hyundai Motor Group
What’s the force behind Hyundai Motor Group's EV performance and quality?
Maximized driving performance and quick charging time through high-density battery pack and fast charging technology and applicable to various vehicle types!
Discover more about Hyundai Motor Group’s EV platform ‘E-GMP’!
What Exactly Is The Common Rail Direct Injection System & How Does It WorkMotor Cars International
Learn about Common Rail Direct Injection (CRDi) - the revolutionary technology that has made diesel engines more efficient. Explore its workings, advantages like enhanced fuel efficiency and increased power output, along with drawbacks such as complexity and higher initial cost. Compare CRDi with traditional diesel engines and discover why it's the preferred choice for modern engines.
What Does the Active Steering Malfunction Warning Mean for Your BMWTanner Motors
Discover the reasons why your BMW’s Active Steering malfunction warning might come on. From electrical glitches to mechanical failures and software anomalies, addressing these promptly with professional inspection and maintenance ensures continued safety and performance on the road, maintaining the integrity of your driving experience.
5 Warning Signs Your BMW's Intelligent Battery Sensor Needs AttentionBertini's German Motors
IBS monitors and manages your BMW’s battery performance. If it malfunctions, you will have to deal with an array of electrical issues in your vehicle. Recognize warning signs like dimming headlights, frequent battery replacements, and electrical malfunctions to address potential IBS issues promptly.
𝘼𝙣𝙩𝙞𝙦𝙪𝙚 𝙋𝙡𝙖𝙨𝙩𝙞𝙘 𝙏𝙧𝙖𝙙𝙚𝙧𝙨 𝙞𝙨 𝙫𝙚𝙧𝙮 𝙛𝙖𝙢𝙤𝙪𝙨 𝙛𝙤𝙧 𝙢𝙖𝙣𝙪𝙛𝙖𝙘𝙩𝙪𝙧𝙞𝙣𝙜 𝙩𝙝𝙚𝙞𝙧 𝙥𝙧𝙤𝙙𝙪𝙘𝙩𝙨. 𝙒𝙚 𝙝𝙖𝙫𝙚 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙥𝙡𝙖𝙨𝙩𝙞𝙘 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙪𝙨𝙚𝙙 𝙞𝙣 𝙖𝙪𝙩𝙤𝙢𝙤𝙩𝙞𝙫𝙚 𝙖𝙣𝙙 𝙖𝙪𝙩𝙤 𝙥𝙖𝙧𝙩𝙨 𝙖𝙣𝙙 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙛𝙖𝙢𝙤𝙪𝙨 𝙘𝙤𝙢𝙥𝙖𝙣𝙞𝙚𝙨 𝙗𝙪𝙮 𝙩𝙝𝙚 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙛𝙧𝙤𝙢 𝙪𝙨.
Over the 10 years, we have gained a strong foothold in the market due to our range's high quality, competitive prices, and time-lined delivery schedules.
In this presentation, we have discussed a very important feature of BMW X5 cars… the Comfort Access. Things that can significantly limit its functionality. And things that you can try to restore the functionality of such a convenient feature of your vehicle.
What Does the PARKTRONIC Inoperative, See Owner's Manual Message Mean for You...Autohaus Service and Sales
Learn what "PARKTRONIC Inoperative, See Owner's Manual" means for your Mercedes-Benz. This message indicates a malfunction in the parking assistance system, potentially due to sensor issues or electrical faults. Prompt attention is crucial to ensure safety and functionality. Follow steps outlined for diagnosis and repair in the owner's manual.
Symptoms like intermittent starting and key recognition errors signal potential problems with your Mercedes’ EIS. Use diagnostic steps like error code checks and spare key tests. Professional diagnosis and solutions like EIS replacement ensure safe driving. Consult a qualified technician for accurate diagnosis and repair.
Why Is Your BMW X3 Hood Not Responding To Release CommandsDart Auto
Experiencing difficulty opening your BMW X3's hood? This guide explores potential issues like mechanical obstruction, hood release mechanism failure, electrical problems, and emergency release malfunctions. Troubleshooting tips include basic checks, clearing obstructions, applying pressure, and using the emergency release.
Why Is Your BMW X3 Hood Not Responding To Release Commands
Hitachi ex600 lch 5 excavator service repair manual
1. 167W-2-1
SECTION 2
UPPERSTRUCTURE
—CONTENTS—
Group 1 Cab
Remove and Install Cab ...................... W2-1-1
Dimensions of the Cab Glass .............. W2-1-7
Group 2 Counterweight
Remove and Install
Counterweight ................................... W2-2-1
Group 3 Pump Device
Remove and Install
Pump Device ..................................... W2-3-1
Disassemble Pump Transmission........ W2-3-4
Assemble Pump Transmission ............ W2-3-6
Remove and Install
Main Pump ........................................ W2-3-8
Disassemble Main Pump................... W2-3-10
Assemble Main Pump........................ W2-3-16
Disassemble and Assemble
Pilot Pump....................................... W2-3-24
Group 4 Control Valve
Remove and Install
Control Valve ..................................... W2-4-1
Disassemble
Control Valve 1 .................................. W2-4-4
Assemble
Control Valve 1 .................................. W2-4-8
Disassemble
Control Valve 2 ................................ W2-4-14
Assemble
Control Valve 2 ................................ W2-4-16
Disassemble
Control Valve 3 ................................ W2-4-18
Assemble
Control Valve 3 ................................ W2-4-24
Disassemble
Control Valve 4 ................................ W2-4-30
Assemble
Control Valve 4 ................................ W2-4-32
Disassemble
Control Valve 5 ................................ W2-4-34
Assemble
Control Valve 5 ................................ W2-4-36
Group 5 Swing Device
Remove and Install
Swing Device..................................... W2-5-1
Disassemble Swing Device.................. W2-5-4
Assemble Swing Device ...................... W2-5-8
Disassemble Swing Motor ................. W2-5-12
Assemble Swing Motor ...................... W2-5-16
Maintenance Standard....................... W2-5-20
2. 167W-2-2
Group 6 Pilot Valve
Remove and Install Right
Pilot Valve ......................................... W2-6-1
Remove and Install Left
Pilot Valve ......................................... W2-6-4
Remove and Install
Travel Pilot Valve............................... W2-6-7
Disassemble Front Attachment
Pilot Valve ......................................... W2-6-8
Assemble Front Attachment
Pilot Valve ....................................... W2-6-10
Disassemble Travel
Pilot Valve ....................................... W2-6-14
Assemble Travel
Pilot Valve ....................................... W2-6-16
Group 7 Pilot Shut-Off Valve
Remove and Install
Pilot Shut-off Valve ............................ W2-7-1
Disassemble Pilot Shut-off Valve ......... W2-7-4
Assemble Pilot Shut-off Valve.............. W2-7-6
Group 8 Shockless Valve
Remove and Install Front
Attachment Shockless Valve.............. W2-8-1
Disassemble and Assemble Front
Attachment Shockless Valve.............. W2-8-4
Remove and Install
Travel Shockless Valve...................... W2-8-7
Disassemble and Assemble
Travel Shockless Valve...................... W2-8-8
Group 9 Solenoid Valve
Remove and Install
Three-Spool Solenoid Valve............... W2-9-1
Disassemble and Assemble
Three-Spool Solenoid Valve............... W2-9-3
3. UPPERSTRUCTURE / Cab
W2-1-1
REMOVE AND INSTALL CAB
Remove Cab
1. Remove seat mounting nut (2) to remove seat (1).
: 13 mm
2. Loosen bolt (5) in the cab rear section and bolt (6)
in rear boxes (3 and 4) to remove rear boxes (3
and 4).
: 13 mm
3. Loosen bolt (8) to remove lower cover (7) of the
rear box.
: 13 mm
4. Remove filter (24) and loosen screw (9) to remove
duct (10) from the cab.
W157-02-01-005
W157-02-01-017
W158-02-01-001
1
2
3
6
5
6
5
4
7
8
24
10 9
4. UPPERSTRUCTURE / Cab
W2-1-2
5. Disconnect harness connectors (11) located at the
rear inside the cab.
6. Disconnect connectors for wiper limit switch (12),
cab light (13), speaker (14), antenna (15) and
ground (17) located in the cab.
Remove washer vinyl hose (16) located behind
the cab.
7. Remove cap (20) from duct cover (18). Loosen
screws (19) to remove duct cover (18).
8. While pushing the mating face of duct (21) back-
ward, remove duct (21).
W167-02-01-001
W162-02-01-002
W158-02-01-002
W157-02-01-011
Duct Mating Face
13 14
12
15
16
17
18
19
20
21
11
5. UPPERSTRUCTURE / Cab
W2-1-3
9. Attach a sling belt to the top of the cab.
CAUTION: Cab weight: 260 kg (573 lb)
10. Remove cab mounting bolt (22) and nuts (23).
: 17 mm
: 24 mm
: 8 mm
11. Slowly lift the cab with a crane to remove the cab
from the machine.
W157-02-01-009
W157-02-01-010
W157-02-01-001
22
23
23
6. UPPERSTRUCTURE / Cab
W2-1-4
Install Cab
1. Attach cab to crane with sling belts and install cab
onto the machine.
CAUTION: Cab weight: 260 kg (573 lb)
2. Tighten cab mounting bolts (22) and nuts (23).
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
: 24 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
: 8 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
3. Install duct (10) into the cab and tighten screw (9).
Install filter (24).
: 4.9 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
4. Connect harness connectors (11) at the rear, in-
side the cab.
W157-02-01-001
W157-02-01-010
W158-02-01-001
W167-02-01-001
22
23
23
11
24
10
9
7. UPPERSTRUCTURE / Cab
W2-1-5
5. Connect wiper limit switch (12), cab light (13),
speaker (14), antenna (15) and ground (17) in the
cab.
Connect washer vinyl hose (16) behind the cab.
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
6. Install rear box lower cover (7) and tighten bolts
(8).
: 13 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
7. Install rear boxes (3 and 4) and tighten bolts (5
and 6).
: 13 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
8. Push duct (21) to the cab front until the duct mat-
ing face comes in contact.
W162-02-01-002
W157-02-01-017
W157-02-01-011
13 14
12
15
16
17
3
6
5
6
5
4
7
8
Duct Mating Face
21
8. UPPERSTRUCTURE / Cab
W2-1-6
9. Install duct cover (18). Tighten screw (19) and put
cap (20) on.
10. Install seat (1) and tighten nut (2).
: 13 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
W158-02-01-002
W157-02-01-005
18
19
20
1
2
9. UPPERSTRUCTURE / Cab
W2-1-7
DIMENSIONS OF THE CAB GLASS
W157-02-01-013
NOTE: Material: JIS- R3211,R3212
ANSI - AS2
ECE - ANNEX5 or
equivalent
Unit : mm
NOTE : 1 mm=0.03937 in
Section B
Section A
4-φ13
+0
-1
(5 mm)
51.03
360.78
30
142.25
221.399
580
R9487
4°
(87.81)
(64.74)
3.015
154.81
43.59
66.84
(5 mm)
(4 mm)
R9509
R209
R4009
R84
R509
R1009
R4009
R2309
R11509
2-R59
87.84
66.41
905
4-R62
756
612
63.97
35.73
947.152
900.7
15
216.73
222.65
230.50
558.78
164.12
188.5
391.8
25.106
R118
R15
R3018
R78
R11516
R70
R2
Chamfer fringe
comers.
Chamfer
both
fringes
All Around
c1
All Around
c1
B
A
11. UPPERSTRUCTURE / Counterweight
W2-2-1
REMOVE AND INSTALL COUNTER-
WEIGHT
Removal
CAUTION: Approximate counterweight
weight: 10500 kg (23200 lb)
1. Install lifting accessories and wire ropes to sling
brackets on the top of the counterweight. Set the
wire rope taut using a crane.
CAUTION: Watch out the power-wrench re-
action bar movement. Take care not to be hit
the reaction bar.
2. Loosen bolts (10) using a power wrench to re-
move bolts (10), nuts (8), shims (7), and washers
(9).
NOTE: Shims (7) are used only when any gap be-
tween nuts (8) and the lock brackets exist.
When no gap exists, shims are not re-
quired.
: 65 mm
3. Loosen bolts (1) to remove lock washers (2),
washers (3), and spacers (4). If shims (5 and 6)
are provided, remove shims (5 and 6).
: 36 mm
4. Remove the counterweight using a crane.
W166-02-02-002
W166-02-02-003
W166-02-02-001
1
10
9
8
7
9
2
6
4
5
3
1
2
7
3
4
5
9
8
6
10
9
2,1
6,5,4
3
8
7
9
12. UPPERSTRUCTURE / Counterweight
W2-2-2
Installation
CAUTION: Approximate counterweight
weight: 10500 kg (23200 lb)
1. Install lifting accessories and wire ropes to sling
brackets on the top of the counterweight. Then, lift
the counterweight by crane.
CAUTION: Do not allow anyone under the
lifted counterweight.
2. Insert protrusions on the counterweight into holes
on the frame to install the counterweight.
CAUTION: Watch out the power-wrench re-
action bar movement. Take care not to be hit
the reaction bar.
IMPORTANT: Apply lubricant to bolts (10) before
installing. Install shims (7) between
nuts (4) and the lock brackets with
the flange positioned in the upper
side.
3. Install bolts (10), nuts (4), shims (7), and washers
(9). Using a power wrench, tighten bolts (10).
: 65 mm
: 2750 N⋅m (280 kgf⋅m, 2030 lbf⋅ft)
4. Install shims (5 and 6), spacers (4), washers (3)
lock washers (2), and bolts (1). Remove wire
ropes and lifting accessories.
: 36 mm
: 440 N⋅m (45 kgf⋅m, 330 lbf⋅ft)
W166-02-02-002
W166-02-02-003
W166-02-02-001
1
10
9
8
7
9
2
6
4
5
3
1
2
7
3
4
5
9
8
6
10
9
2,1
6,5,4
3
8
7
9
13. UPPERSTRUCTURE / Pump Device
W2-3-1
REMOVE AND INSTALL PUMP DEVICE
CAUTION:
1. Escaping fluid under pressure can
penetrate the skin, causing serious
injury. Avoid this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after operation.
Hot hydraulic oil may spout, possibly
causing severe burns. Be sure to wait
for oil to cool before starting any repair
work.
3. The hydraulic oil tank cap may fly off by
remaining pressure if removed quickly.
Slowly loosen the cap to completely
release any remaining pressure.
Preparation
1. Stop the engine. Move all control levers to release
pressure remaining in the system.
Turn the hydraulic oil tank cap approx. 30° coun-
terclockwise to release any pressure remaining in
the hydraulic tank.
14. UPPERSTRUCTURE / Pump Device
W2-3-2
Removal
1. Disconnect all hoses and electrical cables from
the pump.
Tightening Torque
Wrench size (mm)
N⋅m kgf⋅m lbf⋅ft
Remark
: 19 29.5 3 22 Piping
: 22 59 6 44 Piping
: 27 93 9.5 69 Piping
: 36 175 18 130 Piping
: 10 108 11 80 Piping
: 12 175 18 130 Piping
: 14 265 27 195 Piping
: 30 390 40 290 Bolt
: 16 69 7 50 Bolt
: 32 540 55 400 Bolt
2. Lay a wooden block (300 mm long, 200 mm wide,
and 20 mm thick) under the engine oil pan.
CAUTION: Main pump weight:
125 kg (276 lb)
3. Remove the main pump mounting bolts to remove
the main pump.
CAUTION: Pump transmission weight:
150 kg (330 lb)
4. Remove the pump transmission mounting bolts
and the engine rear mounting bolts to remove the
pump transmission.
Installation
NOTE: Refer to the “removal” section above for
wrench sizes and tightening torque.
1. Secure the pump device with the mounting bolts.
2. Re-connect all hoses and electrical cables to the
pump device.
3. Bleed any trapped air from the pump (refer to
page W1-1-2).
IMPORTANT: After installing the pump, be sure to
perform break-in operation to pre-
vent seizure.
Break-In Operation Process:
1. Start the engine and run at slow idle speed for
20 minutes. Check for oil leaks while running
at slow idle.
2. Increase the engine speed to the fast idle
speed. Raise and lower the boom for 20 min-
utes repeatedly. (Do not operate the control
levers quickly. Slowly move the levers to full
stroke.)
W167-02-03-005
W167-02-03-003
Wooden
Block
Engine Rear
Mounting Bolt
Main Pump
Mounting Bolt
Pump Transmission
Mounting Bolt
17. UPPERSTRUCTURE / Pump Device
W2-3-5
Disassemble Pump Transmission
• Be sure to thoroughly read all precautions for disas-
sembly/assembly work on page W1-1-1 before start-
ing any repair work.
1. Loosen drain plug (12) to drain gear oil from the
pump transmission. Remove the pilot pump from
casing (1).
: 27 mm
: 8mm
CAUTION: Pump transmission weight:
150 kg (330 lb)
2. Place casing (1) on a work bench with the main
pump mounting side facing downward.
3. Remove bolts (10).
: 19 mm
CAUTION: Pump transmission weight:
150 kg (330 lb)
4. Turn casing (1) over and place it on a work bench.
NOTE: At this time, set a wooden block (100 mm
high) so that it does not come in contact
with cartridge (9).
5. Attach a protection plate (Dia. 50 mm) to coupling
(4). While tapping the protection plate, remove
cartridge (9), bearing (2 and 7) and gear (6) from
casing (1).
6. Remove bearing (7), O-ring (8) and oil seal (11)
from cartridge (9).
7. Remove retaining ring (3), coupling (4) and retain-
ing ring (5) from gear (6).
8. Using a press or a puller, remove bearings (2 and
7) from gear (6).
19. UPPERSTRUCTURE / Pump Device
W2-3-7
Assemble Pump Transmission
1. Press bearings (2 and 7) into gear (6).
2. Install retaining ring (5), coupling (4), and retaining
ring (3) to gear (6).
CAUTION: Casing (1) weight:
95 kg (210 lb)
3. With the main pump mounting face .downward,
place casing (1) on a work bench.
4. Press bearing (2) along with gear (6) into casing
(1).
5. Using a protection plate, press oil seal (11)into
cartridge (9).
6. Coat the inner diameter of oil seal (11) with
grease.
7. Install O-ring (8) to cartridge (9).
IMPORTANT: Position the casting imprint on car-
tridge (9) upward (the oil filler side)
and install the cartridge on casing
(1).
8. Install cartridge (9) on casing (1).
9. Tighten bolts (10) (10 used).
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
10. Install the pilot pump on casing (1).
: 8 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
W167-02-03-006
Casting Imprint
Upward
20. UPPERSTRUCTURE / Pump Device
W2-3-8
REMOVE AND INSTALL MAIN PUMP
CAUTION:
1. Escaping fluid under pressure can
penetrate the skin, causing serious
injury. Avoid this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after operation.
Hot hydraulic oil may spout, possibly
causing severe burns. Be sure to wait
for oil to cool before starting any repair
work.
3. The hydraulic oil tank cap may fly off by
remaining pressure if removed quickly.
Slowly loosen the cap to completely
release any remaining pressure.
Preparation
1. Stop the engine. Move all control levers to release
pressure remaining in the system.
Turn the hydraulic oil tank cap approx. 30° coun-
terclockwise to release any pressure remaining in
the hydraulic tank.
21. UPPERSTRUCTURE / Pump Device
W2-3-9
Removal
1. Disconnect all hoses and electrical cables from
the pump.
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
: 10 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
: 12 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
: 14 mm
: 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)
CAUTION: Main pump weight:
Approx. 125 kg (276 lb)
2. Remove the main pump mounting bolts to remove
the main pump.
: 30 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
Installation
NOTE: Refer to the “Removal” section above for
wrench sizes and tightening torque.
1. Secure the pump device with the mounting bolts.
2. Re-connect all hoses and electrical cables to the
pump device.
3. Bleed any trapped air from the pump (refer to
page W1-1-2).
IMPORTANT: After completing installation of the
pump device, be sure to perform
break-in operation to prevent pump
seizure during initial machine opera-
tion.
Procedure:
1. Start the engine. Run at slow idle speed for 20
minutes. Check for oil leaks during this opera-
tion.
2. Increase the engine speed to the first idle
speed and raise or lower the boom for 20 min-
utes. (Do not operate the control lever quickly.
Slowly operate the lever full stroke.)
T167-01-02-003
Main Pump
Mounting Bolt
22. UPPERSTRUCTURE / Pump Device
W2-3-10
DISASSEMBLE MAIN PUMP
W116-02-04-048
Pump displacement Angle Sensor (6)
W116-02-04-049
1 - Retaining Ring 8 - Socket Bolt 15 - Shaft 22 - Washer
2 - Seal Case 9 - Socket Bolt (4 Used) 16 - Spring 23 - Socket Bolt (2 Used)
3 - Oil Seal 10 - Regulator 17 - Oil Seal 24 - Spring
4 - O-Ring 11 - Control Plate 18 - Retainer 25 - Spring Seat
5 - Housing 12 - Rotary Group 19 - Retaining Ring 26 - Arm
6 - Pump Displacement Angle
Sensor (A-Sensor)
13 - Socket Bolt (3 Used) 20 - O-Ring 27 - Set Screw (2 Used)
7 - Socket Bolt (3 Used) 14 - Case 21 - Potentiometer 28 - O-Ring
1
4
3
2
5
A
6
7 8
9
12
10
9
11
13
14
28
23
22
21
15
24
25
26
27
20
16
17
18
19
25. UPPERSTRUCTURE / Pump Device
W2-3-13
Disassemble Main Pump
• Be sure to thoroughly read all precautions for disas-
sembly/assembly work on page W1-1-1 before start-
ing any repair work.
CAUTION: Main pump weight:
125 kg (276 lb)
1. Loosen plug (A) to drain-hydraulic oil from the
pump. Place the pump on a work bemch with
regulator (10) positioned upward.
: 10 mm
Regulator (10)
CAUTION: Regulator (10) weight:
45 kg (100 lb)
2. Remove socket bolts (7, 8, and 9). Install eye bolt
(M16, pitch 2.0) to regulator (10).
: 14 mm
IMPORTANT: When removing regulator (10) from
housing (5), take care not to allow
control plate (11) to drop Off.
3. Using a crane, remove regulator (10) from hous-
ing (5).
4. Secure cylinder block to the center pin with a rub-
ber washer and bolt (M6, 55mm long) so that the
cylinder block does not come off when housing (5)
is turned over.
: 10 mm
Rotary Group (12)
CAUTION: Housing (5) and rotary group (12)
assembly weight: 80 kg (176 lb)
5. Turn housing (5) over to remove retaining ring (1)
from housing (5).
6. Remove seal case (2) from housing (5). Remove
O-ring (4) and oil seal (3) from seal case (2).
IMPORTANT: Do not disassemble rotary group
(12).
7. Install special tool (ST 1428) to the drive shaft
threaded hole (M16, pitch 2.0) of rotary group (12)
to remove rotary group (12) from housing (5).
Special Tool: ST 1428
Pump Displacement Angle Sensor (A-Sensor)
8. Remove socket bolts (13) to remove A-sensor (6)
from regulator (10).
: 5 mm
9. Remove socket bolts (23) to remove potentiome-
ter (21) from case (14).
: 5 mm
10. Remove spring (16) from shaft (15).
11. Remove O-ring (20), retaining ring (19) and re-
tainer (18) from case (14).
12. Remove set screws (27). Remove arm (26), shaft
(15), spring seat (25) and spring (24) from case
(14).
: 3 mm
13. Remove oil seal (17) from case (14).
27. UPPERSTRUCTURE / Pump Device
W2-3-15
Regulator (10)
14. Remove pin (46) and bushing (45) from body (35).
15. Loosen socket bolts (A) to dismount pump control
solenoid valve (34).
: 3 mm
16. Remove socket bolts (30) (4 used) to remove
regulator cover (29) from body (35).
: 8 mm
17. Remove spring seat (31) and springs (32 and 33)
from body (35).
18. Remove retainer (61) from body (35).
Regulator Cover (29)
IMPORTANT: When holding regulator cover (29)
with a vise, hold faces other than the
mating face with body (35).
19. Hold regulator cover (29) with a vise. Loosen and
remove guide (48)from regulator cover (29).
: 24 mm
20. Remove O-ring (49) from guide (48).
IMPORTANT: Do not remove lock nut (47) and ad-
justing screw (50). Failure to do so
will change the pump flow rate.
21. Remove spring (52), distant piece (53) and spool
(54) from regulator cover (29).
22. Remove barrel (55) from regulator cover (29).
23. Remove plug (59) from regulator cover (29).
: 8 mm
24. Remove plug (58) to remove steel ball (57) and
guide (56) from regulator cover (29).
: 6 mm
25. Remove filter (63) from regulator cover (29).
28. UPPERSTRUCTURE / Pump Device
W2-3-16
ASSEMBLE MAIN PUMP
W116-02-04-015
A-Sensor (6)
W116-02-04-016
1 - Retaining Ring 8 - Socket Bolt 15 - Shaft 22 - Washer
2 - Seal Case 9 - Socket Bolt (4 Used) 16 - Spring 23 - Socket Bolt (2 Used)
3 - Oil Seal 10 - Regulator 17 - Oil Seal 24 - Spring
4 - O-Ring 11 - Control Plate 18 - Retainer 25 - Spring Seat
5 - Housing 12 - Rotary Group 19 - Retaining Ring 26 - Arm
6 - Pump Displacement Angle
Sensor (A-Sensor)
13 - Socket Bolt (3 Used) 20 - O-Ring 27 - Set Screw (2 Used)
7 - Socket Bolt (3 Used) 14 - Case 21 - Potentiometer 28 - O-Ring
A
Packing (42)
5 12
4 11 10
9
6
8
7
9
Section A-A
Section B-B
Pin (46)
Bushing (45)
28
27 26 14 13 15
24
25
A
A
B
B
16
21 20
22
23
17
18
19
1
2
3
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32. UPPERSTRUCTURE / Pump Device
W2-3-19
Assemble Main Pump
Rotary Group (12)
CAUTION: Housing (5) weight:
35 kg (77 lb)
1. Set housing (5) on a work bench with regulator
(10) side downward.
CAUTION: Rotary group (12) weight:
45 kg (100 lb)
2. Install eye bolt (M16, pitch 2.0) to the drive shaft
of rotary group (12).
3. Attach rotary group (12) to a crane and install it
into housing (5).
4. Install O-ring (4) to housing (5).
5. Using a protection plate, press oil seal (3) into
seal case (2). Install seal case (2) to housing (5).
IMPORTANT: Check that retaining ring (1) is in-
stalled securely.
6. Install retaining ring (1) to housing (5).
CAUTION: Housing (5) and rotary group (12)
assembly weight: 80 kg (176 lb)
7. Turn housing (5) over and set it on a Work bench.
Remove a bolt and rubber washer from rotary
group (12) center pin.
: 10 mm
8. Apply a film of THREEBOND #1215 to regulator
(10) mounting face on housing (5). Then, install
packing (42) on housing (5). Apply a film of
THREEBOND #1215 to packing (42).
Regulator (10)
9. Install control plate (11) on the slide surface on
regulator (10).
NOTE: Coat control plate (11) with grease.
CAUTION: Regulator (10) weight:
Approx. 40 kg (88 lb)
10. Attach regulator (10) to a crane and install it on
housing (5).
11. Tighten socket bolts (7) (3 used), (8) and (9) (4
used).
: 14mm
: 310 to 390 N⋅m
(32 to 40 kgf⋅m, 230 to 290 lbf⋅ft)
IMPORTANT: Make sure that pin (46) moves
smoothly.
12. Install bushing (45) and pin (46) into regulator
(10).