HITACHI EX1800-3 EXCAVATOR Service Repair Manual PDF

EX1800-3
Workshop Manual
SECTION 1
GENERAL INFORMATION
—CONTENTS—
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling........................................... W1-1-1
Group 2 Tightening
Tightening Torque Specification.............. W1-2-1
Torque Chart .......................................... W1-2-2
Piping Joint ............................................ W1-2-5
144W-1-1
(Blank)
144W-1-2
GENERAL INFORMATION / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
• Clean the Machine • Precautions for Disassembling
Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the re-
the shop. Bringing a dirty machine into the shop may moved pipes.
cause machine components to be contaminated dur- • Before disassembling, clean the exterior of the
ing disassembling/assembling, resulting in damage components and place it on a work bench.
to machine components, as well as decreased effi- • Before disassembling, drain gear oil from the re-
ciency in service work. duction gear.
• Be sure to provide appropriate containers for
• Inspect the Machine draining fluids.
• Use matching marks for easier reassembling.
Be sure to thoroughly understand all disassem- • Be sure to use the specified special tools, when
bling/assembling procedures beforehand, to help instructed.
avoid incorrect disassembling of components as well • If a part or component cannot be removed after
as personal injury. removing its securing nuts and bolts, do not at-
Check and record the items listed below to prevent tempt to remove it forcibly. Find the cause(s), then
problems from occurring in the future. take the appropriate measures to remove it.
• Orderly arrange disassembled parts. Mark and
• The machine model, machine serial number, and tag them as necessary.
hour meter reading. • Store common parts, such as bolts and nuts with
• Reason for disassembly (symptoms, failed parts, reference to where they are to be used and in a
and causes). manner that will prevent loss.
• Clogging of filters and oil, water or air leaks, if any. • Inspect the contact or sliding surfaces of disas-
• Capacities and condition of lubricants. sembled parts for abnormal wear, sticking, or
• Loose or damaged parts. other damage.
• Measure and record the degree of wear and
• Prepare and Clean Tools and Disassembly Area clearances.
Prepare the necessary tools to be used and the area • Precautions for Assembling
for disassembling work.
• Be sure to clean all parts and inspect them for any
damage. If any damage is found, repair or replace
it.
• Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding sur-
faces.
• Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassembled.
Apply a film of grease before installing.
• Be sure that liquid-gasket-applied surfaces are
clean and dry.
• If an anti-corrosive agent has been used on a new
part, be sure to thoroughly clean the part to re-
move the agent.
• Utilize matching marks when assembling.
• Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
• Keep a record of the number of tools used for dis-
assembly/assembly. After assembling is complete,
count the number of tools, so as to make sure that
no tools are missing.
W1-1-1
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the

suction lines are replaced, or the removal and instal-
lation of the pump, swing motor, travel motor or cylin-
der is done, bleed air from the hydraulic system in the
following procedures:
• Bleeding Air from Hydraulic Pump
IMPORTANT: If the engine is started with air

trapped in the hydraulic pump hous-
ing, damage to the pump may result.
Be sure to bleed air before starting
the engine.
• Remove the air bleeding plug from the top of the

pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the pump
housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the plug.
• Bleeding Air from Travel Motor/Swing Motor
• With the drain plug/hose on travel motor/swing

motor removed, fill the motor case with hydraulic
oil.
• Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes.
• Reposition the front attachment to check hydraulic
oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
M104-07-021
W1-1-2
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one.
If the floating is to be reused, follow these proce-
dures:
(1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of card-
board to protect surfaces.
W105-03-05-019
(2) Check seal ring face (C) for scuffing, scoring, B
corrosion, deformation or uneven wear.
(3) Check O-ring (B) for tears, breaks, deformation

or hardening.
2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.
(1) Clean floating seal (A) and seal mounting

bores with cleaning solvent.
Correctly
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with com-
pressed air.
Incorrectly
(2) Clean the floating seal and seal mounting

bores, as dust on them tends to enter the float-
ing seal when installing it.
(3) Check that the O-ring is not twisted, and that it

is installed correctly on the seal ring. W105-03-05-020
(4) After installing the floating seal, check that seal Correctly Incorrectly
face (C) is parallel with seal mounting bores D
ring face (D) by measuring the distances (C) a a
and (D) at point (a) and (b), as illustrated. If C
these distances differ, correct the O-ring seat-
ing.
B
b b
a=b aҐb
W110-03-05-004
W1-1-3
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of components or assemblies adjusted

to specification.
Both dimensions are shown with tolerances as neces-

sary.
“Allowable Limit”
1. Normal machine performance cannot be accom-

plished after exceeding this limit.
2. Repair or replacement is required before reaching

this limit.
Machine performance will decrease, and maintenance

and down time expense will increase as machine op-
erating hours accumulate. It is recommended that
parts are repaired or replaced before reaching the
“Allowable Limit”.
W1-1-4
GENERAL INFORMATION / Tightening
TIGHTENING TORQUE SPECIFICATIONS
Wrench Torque
Bolt Dia
No. Descriptions Q'ty Size
mm
(mm) N⋅m kgf⋅m lbf⋅ft
Engine cushion rubber mounting bolt 33 4 50 2550 260 1880
1
22 4 32 740 75 540
Engine bracket mounting bolt 27 24 41 1030 105 760
2
18 4 27 390 40 290
3 Hydraulic oil tank mounting bolt 30 8 46 1420 145 1050
4 Fuel tank mounting bolt 30 12 46 1420 145 1050
5 Pump transmision mouting bolt 1/2-13UNC 28 19 118 12 87
Pump device mounting bolt 20 24 Hexagonbar 390 40 290
6
wrench 17
Gear pump mounting bolt 14 4 Hexagonbar 137 14 101
7
wrench 12
Air-con. Compressor drive pump mounting bolt 14 4 Hexagonbar 137 14 101
8
wrench 12
9 Control valve mounting nut 20 8 30 390 40 290
Swing device mounting bolt 33 48 50 2550 260 1880
10
24 48 36 690 70 510
11 Swing motor mounting bolt 20 8 30 390 40 290
12 Battery mounting bolt 10 16 17 19.5 2 14.5
13 Cab mounting bolt 18 8 27 295 30 215
14 Cab bed mounting bolt 16 36 24 205 21 152
Swing bearing mounting bolt to upperstructure 45 58 70 4710 480 3470
15
Swing bearing mounting bolt to undercarriage 45 60 70 4710 480 3470
16 Counterweight mounting nut 45 7 70 3920 400 2890
17 Radiator mounting nut 27 8 41 1030 105 760
Travel device mounting bolt (A) 22 32 32 740 75 540
18 (B) 33 64 50 2550 260 1880
(C) 30 60 46 1910 195 1410
19 Travel motor mounting bolt 20 8 30 390 40 290
20 Upper roller mounting bolt 20 25 30 390 40 290
21 Lower roller mounting bolt 30 64 46 1910 195 1410
22 Track guard mounting bolt 30 12 46 1910 195 1410
23 Track shoe bolt 33 392 50 3190 325 2350
24 Side frame mounting bolt 45 68 70 4710 480 3470
Loader front pin-retaining bolt (A) 20 32 30 390 40 290
25 Loader front pin-retaining bolt (B) 16 4 24 205 21 152
Loader front pin-retaining bolt (C) 24 4 36 690 70 510
Backhoe front pin-retaining bolt (A) 20 24 30 390 40 290
26
Backhoe front pin-retaining bolt (B) 16 12 24 205 21 152
NOTE: (1) Apply lubricant (e.g. white Zinc B

dissolved into spindle oil) to bolts and
nuts to stabilize friction coefficient of
them.
(2) Make sure bolt and nut threads are
clean before installing.
W1-2-1
TORQUE CHART
CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and
procedures can create safety hazards. For
loosening and tightening nuts and bolts, use
the correct tools. Avoid bodily injury caused
by slipping wrenches.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.

Four kinds of bolts, hexagon bolts T, H, M and socket
bolt, each made of different material, are used. Make SA-040
sure to employ the correct bolts and tighten them to
specification when assembling the machine or
components.
Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt
W105-01-01-007
Specified Tightening Torque Chart

Hexagon T Bolt, Socket bolt H Bolt M Bolt
Bolt Wrench
Wrench
Dia. Size N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft
Size
M 8 13 6 29.5 3 22 19.5 2 14.5 9.8 1 7.2
M 10 17 8 64 6.5 47 49 5 36 19.5 2 14.5
M 12 19 10 108 11 80 88 9 65 34 3.5 25.5
M 14 22 12 175 18 130 137 14 101 54 5.5 40
M 16 24 14 265 27 195 205 21 152 78 8 58
M 18 27 14 390 40 290 295 30 220 118 12 87
M 20 30 17 540 55 400 390 40 290 167 17 123
M 22 32 17 740 75 540 540 55 400 215 22 159
M 24 36 19 930 95 690 690 70 505 275 28 205
M 27 41 19 1370 140 1010 1030 105 760 390 40 290
M 30 46 22 1910 195 1410 1420 145 1050 540 55 400
M 33 50 24 2550 260 1880 1910 195 1410 740 75 540
M 36 55 27 3140 320 2310 2400 245 1770 930 95 690
W1-2-2
IMPORTANT: (1) Apply lubricant (i. e. white zinc B
dissolved into spindle oil) to nuts
and bolts to stabilize their friction
coefficients.
(2) Torque tolerance is ±10 %.
(3) Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts that
are too short cannot develop suf-
ficient tightening force.
(4) The torques given in the chart
are for general use only.
Do not use these torques if a dif-
ferent torque is given for a spe-
cific application.
(5) Make sure that the nut and bolt
threads are clean before install-
ing. Remove dirt or corrosion, if
any.
Bolt Tightening Order
When tightening two or more bolts, tighten them

alternately, as shown, to ensure even tightening.
Equally tighten upper Tighten diagonally Tighten from center

and lower alternately and diagonally
1,4 1 12 9 4 1 6 7 14
6 3
4 5
2 13 8 5 2 3 10 11
2,3
W105-01-01-003
W1-2-3
Service Recommendations for Split Flange
IMPORTANT: (1) Be sure to clean and inspect seal-

ing surfaces. Scratches/rough-
ness cause leaks and seal wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
nent.
(2) Be sure to use only specified O- W105-01-01-015
rings. Inspect O-rings for any WRONG

damage. Take care not to file O-
ring surfaces. When installing an
O-ring into a groove, use grease
to hold it in place.
(3) Loosely assemble split flange
halves. Make sure that the split is
centrally located and perpendicu-
lar to the port. Hand-tighten the W105-01-01-016
bolts to hold the parts in place.

Take care not to pinch the O-ring.
(4) Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
(5) Do not use air wrenches. Using
an air wrench often causes tight-
ening of one bolt fully before
tighten the others, resulting in W105-01-01-008
damage to O-rings or uneven RIGHT WRONG

tightening of bolts.
Nut and Bolt Lockings

Bend along edge sharply Do not bend it round
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try RIGHT RIGHT WRONG
to bend the same point twice.
• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while
tightening, not while loosening. Bend along edge sharply
W105-01-01-009
• Lock Wire
IMPORTANT: Apply wire to bolts in the bolt- RIGHT RIGHT WRONG
tightening direction, not in the bolt-
loosening direction.
RIGHT Loosen WRONG
Tighten
W105-01-01-010
W1-2-4
PIPING JOINT 1 4 3 5 2
Pipe Thread Connection/Union Joint Tightening

Torque Specifications
Union Joint
Metal sealing faces (4) and (5) of adaptor (1) and Joint Body
hose (2) fit together to seal pressure oil. Union joints M202-07-051
are used to join small-diameter lines.

30 ° or 37 °
IMPORTANT: (1) Do not over-tighten union nut (3).
Excessive force will be applied to
30 ° or 37 °
metal sealing surfaces (4) and (5),
possibly cracking adaptor (1). Be
sure to tighten union nut (3) to
specifications. Male Union Joint Female Union Joint
W105-01-01-017
(2) Scratches or other damage to
sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them
when connecting/disconnecting.
Wrench Size Tightening Torque

Type
Union Nut Joint Body N⋅m kgf⋅m Ibf⋅ft
30 ° Male Union 19 19 59 6 43
Joint 22 22 98 10 72
27 27 118 12 87
36 36 235 24 134
41 41 295 30 215
50 50 490 50 360
60 60 670 68 490
70 70 980 100 720
37 ° Female 19 17 44 4.5 32.5
Union Joint 22 19 59 6 43
27 22 118 12 87
36 30, 32 235 24 134
41 36 295 30 215
50 46 490 50 360
NOTE: Tightening torque for the non-union type

37° male joint is the same as the 37°
female union joint.
W1-2-5
O-ring Seal Joint
7 6 9
O-ring (6) seats against the end face of adaptor (7) to
seal pressure oil.
IMPORTANT: (1) Be sure to replace O-ring (6) with

a new one when reconnecting.
(2) Before tightening union nut (9),

Joint Body
confirm that O-ring (6) is seated 8 10
correctly in O-ring groove (8). M104-07-033
Tightening union nut (9) with O-
ring (6) displaced will damage O-
Wrench Size Tightening Torque
ring (6), resulting in oil leakage.
Union Nut Joint Body N⋅m kgf⋅m Ibf⋅ft
(3) Take care not to damage O-ring 19 17 59 6 43
groove (8) or sealing face (10). 22 19 98 10 72
Damage to O-ring (6) will cause 27 22 118 12 87
oil leakage.
36 30, 32 235 24 134
(4) If union nut (9) is found to be 41 36 295 30 215
loose, causing oil leakage, do not 50 46 490 50 360
tighten it to stop the leak. Instead,
replace O-ring (6) with a new one,
then tighten union nut (9) after
confirming that O-ring (6) is
securely seated in place.
W1-2-6
Screwed-In Connection
PT PF
IMPORTANT: Many types of screwed-in connec-

30°
tions are used for hose connections.
Be sure to confirm that the thread
pitch and thread type (tapered or
straight) are the correct type before
using any screw-in connection.
Male Tapered Thread Male Straight Thread
W105-01-01-018
Male Tapered Thread

Wrench Tightening Torque
Joint Body N⋅m kgf⋅m Ibf⋅ft
17, 19 59 6 43
19, 22 98 10 72
27, 22 118 12 87
Seal Tape Application 36, 32 235 24 134
41 295 30 215
Seal tape is used to seal clearances between male 50 490 50 360
and female threads, so as to prevent any leakage 60 670 68 490
between threads. 70 980 100 720
Be sure to apply just enough seal tape to fill up thread
Internal Thread
clearances. Do not overwrap.
• Application Procedure
External Thread Clearance
Confirm that the thread surface is clean, free of dirt
or damage. W105-01-01-019
Apply seal tape around threads as shown. Wrap Leave one to two pitch threads uncovered
seal tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs

M114-07-041
depending on the type of clamp.
See below for correct tightening torque of each type
of low-pressure-hose clamp. T-Bolt Type Worm Gear Type
T-Bolt Type Band Clamp:

4.4 N⋅m (0.45 kgf⋅m, 3.25 lbf⋅ft)
Worm Gear Type Band Clamp:
5.9 to 6.9 N⋅m (0.6 to 0.7 kgf⋅m, 4.3 to 5.1 lbf⋅ft)
M114-07-042 M114-07-043
W1-2-7
Connecting Hose
WRONG RIGHT
CAUTION:
(1) When replacing hoses, be sure to use
only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses
may cause oil leakage, hose rupture or
separation of fitting, possibly resulting in
a fire on the machine.
(2) Do not install hoses kinked. Application
of high oil pressure, vibration, or an
impact to a kinked hose may result in oil W105-01-01-011
leakage, hose rupture or separation of
fitting. Utilize print marks on hoses when
installing hoses to prevent hose from
being installed kinked. WRONG RIGHT
(3) If hoses rub against each other, wear to Rubbing Against
the hoses will result, leading to hose Each Other
rupture. Take necessary measures to
protect hoses from rubbing against each
other.
Take care that hoses do not come into
contact with moving parts or sharp
objects.
W105-01-01-012
WRONG RIGHT
Clamp Clamp
Rubbing
W105-01-01-013
WRONG RIGHT
Rubbing
Clamp
W105-01-01-014
W1-2-8
SECTION 2
UPPERSTRUCTURE
—CONTENTS—
Group 1 Cab
Windowpane Dimensions ................. W2-1-1 Main Hydraulic Line
Locatinos (Backhoe) ....................... W2-3-6
Group 2 Pump Device Disassemble and Assemble
Remove and Install Control Valve .................................. W2-3-7
Pump Device .................................. W2-2-1
Disassemble Group 4 Swing Device
Pump Transmission ........................ W2-2-8 Remove and Install Swing Device..... W2-4-1
Assemble Disassemble Swing Device............... W2-4-3
Pump Transmission ........................ W2-2-12 Assemble Swing Device ................... W2-4-11
Disassemble Main Pump .................. W2-2-16 Disassemble Swing Motor ................ W2-4-21
Assemble Main Pump....................... W2-2-20 Assemble Swing Motor ..................... W2-4-23
Maintenance Standards.................... W2-2-24 Maintenance Standards .................... W2-4-27
Disassemble Disassemble and Assemble
Main Pump Regulator ..................... W2-2-26 Relief Block .................................... W2-4-28
Assemble
Main Pump Regulator ..................... W2-2-32 Group 5 Pilot Valve
Disassemble Remove and Install
Swing Pump Regulator ................... W2-2-38 Front and Swing Pilot Valves........... W2-5-1
Assemble Remove and Install Travel and Bucket
Swing Pump Regulator ................... W2-2-44 Pilot Valves ..................................... W2-5-3
Disassemble and Assemble Pilot Line Connections
Triple Gear Pump ........................... W2-2-50 (Loading Shovel) ............................ W2-5-5
Disassemble and Assemble Pilot Line Connections
Center Gear Pump ......................... W2-2-52 (Backhoe) ....................................... W2-5-6
Disassemble and Assemble
Group 3 Control Valve Pilot Valves ..................................... W2-5-8
Remove and Install
Control Valve .................................. W2-3-1 Group 6 Pilot Shut-Off Valve
Pilot Line Remove and Install Pilot
Locations (Loading Shovel) ............ W2-3-3 Shut-Off Valve ................................ W2-6-1
Main Hydraulic Line Disassemble Pilot Shut-Off Valve ..... W2-6-3
Locations (Loading Shovel) ............ W2-3-4 Assemble Pilot Shut-Off Valve .......... W2-6-5
Pilot Line Locations (Backhoe) ......... W2-3-5
144W-02-01
Group 7 Solenoid Valve
Remove and Install
Solenoid Valves .............................. W2-7-1
Disassemble and Assemble Travel Speed
Change Solenoid Valve and Swing
Pi Control Solenoid Valve ............... W2-7-3
Disassemble and Assemble Swing
Inter Lock Solenoid Valve ............... W2-7-4
Group 8 Fuel Cooler Fan Motor

Remove and Install
Fuel Cooler Fan Motor .................... W2-8-1
Fuel Cooler Fan Motor .................... W2-8-3
Group 9 Compressor Drive Motor

Remove and Install
Compressor Drive Motor................. W2-9-1
Compressor Drive Motor................. W2-9-3
Group 10 Air Conditioner

Work After Component
Replacement .................................. W2-10-1
Add Compressor Oil ......................... W2-10-1
Charge Air Conditioner with
Refrigerant ..................................... W2-10-2
Group 11 Shuttle Valve

Remove and Install
Multi Shuttle Valve .......................... W2-11-1
144W-02-02
UPPERSTRUCTURE / Cab
WINDOWPANE DIMENSIONS
Material : JIS R 3211, ANSI AS2, ECE ANNEX5 or

equivalent
NOTE: 1 mm=0.03937 in 1378±1.5
4−R61
6
1
1
7 Laminated glass
Color : Transparent
1679+2.0 -0
Thickness : 10 mm
Chamfer all fringe Corners.
3 5
4
W117-02-01-001
W117-02-01-002
1369±1.5
4−R61
2 4−R61 3
Tempered glass Tempered glass

Color : Bronze Color : Bronze
769±1.0
917±1.0 Thickness : 6 mm (Serial No. from 000501 Thickness : 5 mm
to 000516) Chamfer all fringe
5 mm (Serial No. from 000517 Corners.
and later)
433±1.0 W117-02-01-004
1256±1.5
W117-02-01-003
W2-1-1
UPPERSTRUCTURE / Cab
NOTE: 1 mm=0.03937 in
422±1.0
4−R61
4−R61
4 5
Tempered glass 777±1.0 Tempered glass

934±1.0 Color : Bronze Color : Bronze
Thickness : 5 mm Thickness : 5 mm
Chamfer all fringe Corners. Chamfer all fringe Cor-
ners.
514±1.0
W117-02-01-006
W117-02-01-005
667±1.0
1400±1.0
7
4−R61
4−R61
Tempered glass
6 Color : Bronze
Thickness : 5 mm
848±1.0 Chamfer all fringe
Tempered glass Corners.
Color : Bronze 645±1.0
Thickness : 6 mm
185 403±1.0
1296±1.0 W117-02-01-008
W117-02-01-007
W2-1-2
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
CAUTION: Escaping fluid under pressure

can penetrate the skin or eyes, causing seri-
ous injury.
Avoid this hazard by relieving pressure be-
fore disconnecting hydraulic lines.
Hydraulic oil may be hot after operation. Hot

hydraulic oil may spout, possibly causing se-
vere burns. Be sure to wait for oil to cool be-
fore starting any repair work.
The hydraulic oil tank cap may fly off by re-

maining pressure if removed quickly. Slowly
loosen the cap to completely release any re-
maining pressure.
Preparation
1. Stop the engine. Move all control levers to release

pressure remaining in the system. Rotate the hy-
draulic oil tank cap approx. 30 ° counterclockwise
to release any pressure remaining in the hydraulic
oil tank.
W2-2-1
Main Pumps
Triple Gear
Swing Pump Pump
Engine
Main Frame
W144-02-02-010
Pump Transmission
Mounting Bolts Lifting Bracket Manifold
Center Gear Pump
Check Valve
T144-03-01-001
W144-02-02-009
Pump Transmission
Engine Bracket
Mounting Bolts
Engine Bracket
M144-07-013
W2-2-2
Remove Pump Device
1. Disconnect all hydraulic lines and electric wires CAUTION: The approximate weight of the
from the hydraulic pumps and transmission. pump device is 1100 kg (2430 lb).
Tightening Torque Specifications
Tightening Torque
Wrench Size Remarks 4. Remove the pump transmission mounting bolts
Nxm kgfxm lbfxft
and engine bracket mounting bolts. Remove the
: 17 mm 49 5 36 Hydraulic Lines
pump device using a crane.
: 19 mm 88 9 65 Bolts ȀȚ 41 mm
: 22 mm 98 10 72 Bolts ȀȚ 1030 Nxm (105 kgfxm, 760 lbfxft)
ȀȚ 19 mm
: 24 mm 205 21 152 Bolts
ȀȚ 118 Nxm (12 kgfxm, 87 lbfxft)
: 8 mm 64 6.5 47 Socket Bolts CAUTION: The approximate weight of each
: 10 mm 108 11 80 Socket Bolts component pump is as follows:
Main Pump: 159 kg (350 lb)
Swing Pump: 155 kg (340 lb)
2. Remove check valves from the main pumps. Re- Triple Gear Pump: 9 kg (20 lb)
move manifold from swing pump. Center Gear Pump: 5 kg (11 lb)
Tightening Torque Specifications
5. Remove each component pump from the pump
Tightening Torque
Wrench Size Remarks transmission using a crane.
Nxm kgfxm lbfxft
: 19 mm 88 9 65 Bolts ȀȚ 12 mm
ȀȚ 17 mm
IMPORTANT: The engine brackets are installed
onto the pump transmission. Be
sure to insert a steel plate (100 mm
(3.9 in) length x 65 mm (2.6 in) width
x 25 mm (1 in) thickness) between
the engine and main frame to pre-
vent the engine from falling off when
removing the pump transmission.
3. Connect the pump device to a crane using chain

slings attached to the lifting brackets and straps
attached to the main pump. The chain sling at-
tached to the swing pump side lifting bracket is
approximately 22 mm (0.8 in) shorter in length.
W2-2-3
Main Pumps
Triple Gear
Pump
Check Valve
Swing Pump
Engine
Main Frame
W144-02-02-010
Manifold
Pump Transmission
Mounting Bolts Lifting Bracket
Center Gear Pump
Check Valve
T144-03-01-001
Pump Transmission
Oil Seal
Hub
W144-02-02-009
Pump Transmission
Engine Bracket
Mounting Bolts
Engine Bracket
W144-02-02-011
M144-07-013
W2-2-4
Install Pump Device
CAUTION: The approximate weight of each IMPORTANT: After installing the pumps, always
component pump is as follows: perform break-in operation to pre-
Main Pump: 159 kg (350 lb) vent seizure.
Swing Pump: 155 kg (340 lb)
Triple Gear Pump: 9 kg (20 lb) 7. Start the engine and run at slow idle for 20 min-
Center Gear Pump: 5 kg (11 lb) utes. Check all connections for oil leaks while
running at slow idle.
1. Install each component pump onto the pump 8. Then, run the engine at full speed and slowly raise
transmission, aligning the splines of the pumps and lower the boom for 20 minutes. Slowly oper-
and transmission. ate the control lever to full stroke while avoiding
abrupt lever operation.
ȀȚ 12 mm
ȀȚ 17 mm
CAUTION: The approximate weight of the

pump device is 1100 kg (2430 lb).
IMPORTANT: Be careful not to damage the pump

transmission oil seal with the engine
side hub when installing the pump
device onto the pump transmission.
2. Install the pump transmission onto the engine

shaft, aligning the splines and tighten the pump
transmission mounting bolts. Install the engine
brackets on the pump transmission and tighten
the engine bracket mounting bolts.
ȀȚ 41 mm
ȀȚ 19 mm
3. Remove the steel plate inserted between the en-

gine and main frame.
4. Install the check valve on the main pump delivery
end. Install the manifold on the swing pump deliv-
ery end.
5. Connect all hydraulic lines and electric wires to
the pumps and transmission.
6. Purge air from the main pumps and swing pump
(Refer to the next page).
W2-2-5
Main Pump Air Bleeding Procedure
1. Disconnect connector (2) of contamination sensor

(1).
1
IMPORTANT: Never loosen contamination sensor
(1) completely as hydraulic oil will
spout.
2. Loosen contamination sensor (1) plug 2 to 3

turns.
2
ȀȚ 36 mm
3. Start the engine and run at slow idle. Purge air

from the main pump until oil flows out from sensor
(1) plug.
4. Stop the engine and tighten contamination sensor M144-07-089

(1) plug.
ȀȚ 36 mm
5. Connect connector (2) of contamination sensor 3

(1).
Swing Pump Air Bleeding Procedure
IMPORTANT: Never loosen drain hose plug (3)

completely as hydraulic oil will
spout.
1. Loosen drain hose plug (3) 2 to 3 turns.
ȀȚ 36 mm
M144-07-113
2. Start the engine and run at slow idle. Purge air un-
til oil flows out from drain hose plug (3).
3. Stop the engine and tighten drain hose plug (3).
ȀȚ 36 mm
W2-2-6
(Blank)
W2-2-7
DISASSEMBLE PUMP TRANSMISSION
38
37
36
35
34
33
32
31
25 30
26 27 29
39
28
5
4
3
2
1
10
40
9
8
7
6 12
11 24
23
22
13 21
20
5
7 4
19 3
18 2
17 1
16 6
15
W144-02-02-008
14
1- Cartridge (2 Used) 11 - Bolt (3 Used) 21 - Retaining Ring 31 - Retaining Ring

2- O-Ring (2 Used) 12 - Spring Washer (3 Used) 22 - Bearing 32 - Coupling
3- Bearing (2 Used) 13 - Plug 23 - Spacer 33 - Retaining Ring
4- Gear (2 Used) 14 - Socket Bolt (4 Used) 24 - Bearing 34 - Gear
5- Bearing (2 Used) 15 - Cartridge 25 - Bolt (8 Used) 35 - Bearing
6- Socket Bolt (8 Used) 16 - O-Ring 26 - Bracket (2 Used) 36 - O-Ring
7- Plug (2 Used) 17 - Bearing 27 - Case 37 - Cartridge
8- Spacer 18 - Gear 28 - Disc Spring 38 - Bolt (10 Used)
9- Cover 19 - Bearing 29 - Spacer 39 - Oil Seal
10 - O-Ring 20 - Spacer 30 - Bearing 40 - Gear
W2-2-8
Disassemble Pump Transmission
• Before starting any disassembly or assembly work,

carefully read “Precautions for Disassembling and
Assembling” shown on page W1-1-1 of this man-
ual.
CAUTION: The approximate weight of car-

tridge (1) is 24 kg (53 lb).
1. Remove socket bolts (6) and remove cartridge (1)

and O-ring (2) from the pump transmission. (2
places)
ȀȚ 17 mm

2. Remove socket bolts (14) and remove cartridge

(15) and O-ring (16) from the pump transmission.
ȀȚ 17 mm
3. Remove bolts (11), spring washers (12) and re-

move cover (9), O-ring (10) from the pump trans-
mission.
ȀȚ 22 mm

gear assemblies is as follows:
Gear (4) Assembly : 25 kg (55 lb)
Gear (18) Assembly: 32 kg (71 lb)
4. Remove gear (4) assembly and gear (18) assem-

bly from case (27).
5. Remove bearings (3, 5) from gear (4) using a
press or puller.
press or puller.
7. Remove bolts (25) and bracket (26).(2 places)
ȀȚ 19 mm
CAUTION: The approximate weight of case

(27) assembly is 360 kg (790 lb).
8. Turn over case (27) assembly.

9. Remove bolts (38) and remove cartridge (37) and

O-ring (36).
ȀȚ 19 mm
W2-2-9
35
34
33
32
31
30
27 29
28
40
24
23
22
21
20
W144-02-02-008
W2-2-10
CAUTION: The approximate weight of gear

10. Remove gear (34) assembly from case (27).
11. Remove retaining rings (31, 33) from gear (34).

Remove coupling (32) using a press or puller.

press or puller.
13. Remove spacer (29) and disc spring (28) from

case (27).

15. Remove retaining ring (21) and remove gear (40)

using a press.
16. Remove spacers (20, 23) and bearings (22, 24)

from case (27) using a puller.
W2-2-11
ASSEMBLE PUMP TRANSMISSION
13 6 7 11, 12 6 7 27 1 2 4 33 5 36 37 39
A
26
25
3
30
29
9
32
A 31
10
14 28
B
34
Section B 35
17
15
20
21 16 18 19 38
Section A-A
W144-02-02-007
22 23 24 40
1- Cartridge (2 Used) 11 - Bolt (3 Used) 21 - Retaining Ring 31 - Retaining Ring
2- O-Ring (2 Used) 12 - Spring Washer (3 Used) 22 - Bearing 32 - Coupling
3- Bearing (2 Used) 13 - Plug 23 - Spacer 33 - Retaining Ring
4- Gear (2 Used) 14 - Socket Bolt (4 Used) 24 - Bearing 34 - Gear
5- Bearing (2 Used) 15 - Cartridge 25 - Bolt (8 Used) 35 - Bearing
6- Socket Bolt (8 Used) 16 - O-Ring 26 - Bracket (2 Used) 36 - O-Ring
7- Plug (2 Used) 17 - Bearing 27 - Case 37 - Cartridge
8- Spacer 18 - Gear 28 - Disc Spring 38 - Bolt (10 Used)
9- Cover 19 - Bearing 29 - Spacer 39 - Oil Seal
10 - O-Ring 20 - Spacer 30 - Bearing 40 - Gear
W2-2-12
Assemble Pump Transmission
1. Install gear (40) in case (27) and place a support

under gear (40).
NOTE: If gear (40) is not supported, gear (40) will

fall off when installing bearing (24), spacer
(23) and bearing (22) in case (27).
2. Press bearing (24), spacer (23) and bearing (22)

in case (27). Install retaining ring (21) on gear
(40).
Remove the support under gear (40).
3. Install spacer (20) in case (27).


5. Install retaining ring (33), coupling (32) and retain-
ing ring (31) in gear (34).
6. Heat bearings (30, 35) to approximately 90 °C
(194 °F) and press them on gear (34).
CAUTION: The approximate weight of gear

7. Install disc spring (28) and spacer (29) in case

(27). Press gear (34) assembly in case (27).

8. Install O-ring (36) on cartridge (37). Apply LOC-

TITE #262 to bolts (38). Install cartridge (37) on
case (27) and tighten bolts (38).
ȀȚ 19 mm
ȀȚ ȑȑȘ Nxm (12 kgfxm, 87 lbfxft)
9. Apply grease to oil seal (39) lip. Install oil seal (39)
in cartridge (37) with the lip towards cartridge (37).

W2-2-13
6 11, 12 6 27 1 2 4 5
A
10
14
B
34
Section B
17
15
16 18 19
Section A-A
W144-02-02-007
W2-2-14
11. Heat bearings (17, 19) to approximately 90 °C
(194 °F) and press them on gear (18).
12. Heat bearings (3, 5) to approximately 90 °C (194

°F) and press them on gear (4).

gear assemblies is as follows:
Gear (4) Assembly : 25 kg (55 lb)
Gear (18) Assembly: 32 kg (71 lb)
13. Press gear (18) and gear (4) in case (27) keeping
the teeth of gear (34) meshed.
NOTE: Pressing in case (27) after gear (18) and

gear (4) have cooled is recommended.
14. Install spacer (8) in cover (9). Install O-ring (10)

on cover (9). Install cover (9) in case (27). Install
spring washers (12) and tighten bolts (11).
ȀȚ 22 mm

15. Install O-ring (16) on cartridge (15). Apply LOC-

TITE #262 to socket bolts (14). Install cartridge
(15) on case (27) and tighten socket bolts (14).
ȀȚ 17 mm

16. Install O-ring (2) on cartridge (1). Apply LOCTITE

#262 to socket bolts (6). Install cartridge (1) on
case (27) and tighten socket bolts (6).
ȀȚ 17 mm
W2-2-15
Thank you very much
for your reading.
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EX1800-3

• Clean the Machine • Precautions for Disassembling

When hydraulic oil is drained, the suction filter or the

• Bleeding Air from Hydraulic Pump

IMPORTANT: If the engine is started with air

• Remove the air bleeding plug from the top of the

• Bleeding Air from Travel Motor/Swing Motor

• With the drain plug/hose on travel motor/swing

• Bleeding Air from Hydraulic Circuit

• After refilling hydraulic oil, start the engine. While

(1) Keep seal rings together as a matched set with

(3) Check O-ring (B) for tears, breaks, deformation

2. If incorrectly assembled, oil leakage or damage

(1) Clean floating seal (A) and seal mounting

(2) Clean the floating seal and seal mounting

(3) Check that the O-ring is not twisted, and that it

1. Dimension for parts on a new machine.

2. Dimension of components or assemblies adjusted

Both dimensions are shown with tolerances as neces-

1. Normal machine performance cannot be accom-

2. Repair or replacement is required before reaching

Machine performance will decrease, and maintenance

NOTE: (1) Apply lubricant (e.g. white Zinc B

CAUTION: Use tools appropriate for the

Tighten nuts or bolts correctly to torque specifications.

Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt

Specified Tightening Torque Chart

Bolt Tightening Order

When tightening two or more bolts, tighten them

Equally tighten upper Tighten diagonally Tighten from center

IMPORTANT: (1) Be sure to clean and inspect seal-

rings. Inspect O-rings for any WRONG

bolts to hold the parts in place.

damage to O-rings or uneven RIGHT WRONG

Nut and Bolt Lockings

RIGHT Loosen WRONG

Pipe Thread Connection/Union Joint Tightening

are used to join small-diameter lines.

Wrench Size Tightening Torque

NOTE: Tightening torque for the non-union type

IMPORTANT: (1) Be sure to replace O-ring (6) with

(2) Before tightening union nut (9),

IMPORTANT: Many types of screwed-in connec-

Male Tapered Thread Male Straight Thread

Male Tapered Thread

Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs

T-Bolt Type Band Clamp:

Group 8 Fuel Cooler Fan Motor

Group 9 Compressor Drive Motor

Group 10 Air Conditioner

Group 11 Shuttle Valve

Material : JIS R 3211, ANSI AS2, ECE ANNEX5 or

NOTE: 1 mm=0.03937 in 1378±1.5

Tempered glass Tempered glass

Tempered glass 777±1.0 Tempered glass

CAUTION: Escaping fluid under pressure

Hydraulic oil may be hot after operation. Hot

The hydraulic oil tank cap may fly off by re-

1. Stop the engine. Move all control levers to release

Center Gear Pump

3. Connect the pump device to a crane using chain

CAUTION: The approximate weight of the