Pw180-7e0 H55051-Up Disassembly & Assembly
Pw180-7e0 H55051-Up Disassembly & Assembly
Pw180-7e0 H55051-Up Disassembly & Assembly
• This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
• Materials and specifications are subject to change without notice.
• PW180-7E0 mount the SAA6D107E-1 engine.
• For details of the engine, see the 107 Series Engine Shop Manual.
© 2007
All Rights Reserved
Printed in Europe 01-07
30 DISASSEMBLY AND
ASSEMBLY
30-2 PW180-7E0
DISASSEMBLY AND ASSEMBLY
PW180-7E0 30-3
DISASSEMBLY AND ASSEMBLY
30-4 PW180-7E0
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ASSEMBLIES
30-6 PW180-7E0
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
• Special tools which are deemed necessary for • Section titled ASSEMBLY contain procedures,
disassembly and assembly are listed in this sec- precautions and the know-how for the work, as
tion. well as the amount of oil or water to be added.
• List of the special tools contains the following • Various symbols used in the ASSEMBLY Section
kind of information. are explained and listed below.
1) Necessity
■: Special tools which cannot be substituted, This mark indicates safety-related precau-
should always be used. tions which must be followed when doing the
●: Special tools which are very useful if work.
available, can be substituted with com-
mercially available tools. ★ This mark gives guidance or precautions
2) Distinction of new and existing special tools when doing the procedure.
N: Tools with new part numbers, newly
developed for this model.
This mark stands for a specific coating
R: Tools with upgraded part numbers, agent to be used.
remodeled from already available tools
for other models.
This mark indicates the specified torque.
Blank: Tools already available for other models,
used without any modification.
3) Circle mark ( ) in sketch column: This mark indicates an amount of oil or
A circle mark means that a sketch of the spe- water to be added.
cial tool is presented in the section of
Sketches for Special Tools. SKETCHES OF SPECIAL TOOLS
4) Part No. of special tools starting with 79*T
means that they are locally made parts and 1) Various special tools are illustrated for the
as such not interchangeable with those convenience of local manufacture.
made by Komatsu in Japan e.g. 79*T--- xxx -
-- xxxx.
DISASSEMBLY
PW180-7E0 30-7
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
Cate- Komatsu
Part number Q’ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packing of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Features: Silicon-based, heat and cold-resis-
ThreeBond tant, vibration-resistant, impact-resistant seal-
419-15-18131 100 g Tube
1207B ant.
• Used to seal transfer case, etc.
30-8 PW180-7E0
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
Cate-
Komatsu code Part number Q’ty Container Main features and applications
gory
• Used to lubricate sliding portions.
disulfide lubricant
SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PW180-7E0 30-9
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
Cate-
Komatsu code Part number Q’ty Container Main features and applications
gory
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
30-10 PW180-7E0
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
Symbol
Component Part number Part name Nature of work, remarks
Engine front seal 1 795-799-6400 Seal puller Installation of engine front seal
Engine rear seal 2 795-799-6500 Seal puller Installation of engine rear seal
3 795-799-6700 Primer Removal of fuel injector
Cylinder head
Positioning with 3RD and 4TH
assembly, fuel 4 795-799-1131 Gear
cylinder Top
injector assembly
5 795-799-8150 Remover Removal of inlet connector
Wrench
6 790-331-1120 Angle tightening of bolt
Cylinder head (Angle)
assembly Judgment of cylinder head bolt
A 7 795-790-4510 Gauge
length
8 796T-401-1110 Plate Removal and installation of
Engine and hydrau-
engine and hydraulic pump
lic pump assembly 9 795-790-9300 Lifting tool assembly
Hydraulic pump 10 796-460-1210 Oil stopper
assembly, Engine
and hydraulic pump
assembly, Control Stopping oil
valve assembly, 11 796-770-1320 Adaptor
Center swivel joint
assembly
1 796T-626-1110 Push tool Press fitting of bearing
3 790-201-2480 Push tool Press fitting of bearing
PW180-7E0 30-11
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
Symbol
Component Part number Part name Nature of work, remarks
796-946-1310 Guide
(For 723-46-40100, 723-46-40601)
796-946-1810 Guide
(For 723-46-43100, 723-46-43400)
1
796-946-2110 Guide
(For 723-46-44100)
796-946-2210 Guide
(For 723-46-45100)
796-946-1320 Guide
(For 723-46-40100, 723-46-40601)
796-946-1820 Guide
(For 723-46-43100, 723-46-43400)
796-946-2120 Guide
2
Control valve (For 723-46-44100) Replacement of pressure com-
M
assembly 796-946-2220 Guide pensation valve seal
(For 723-46-45100)
796-946-1420 Guide
(For 723-46-42800)
796-946-1330 Sleeve
(For 723-46-40100, 723-46-40601)
796-946-1830 Sleeve
(For 723-46-43100, 723-46-43400)
796-946-2130 Sleeve
3
(For 723-46-44100)
796-946-2230 Sleeve
(For 723-46-45100)
796-946-1430 Sleeve
(For 723-46-42800)
30-12 PW180-7E0
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
Symbol
Component Part number Part name Nature of work, remarks
PW180-7E0 30-13
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
E1 push tool
E5 push tool
30-14 PW180-7E0
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
12
LIST OF TOOLS
PW180-7E0 30-15
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
30-16 PW180-7E0
12
2. Precautions when carrying out installation work 3. Precautions when completing the operations
• Tighten all bolts and nuts (sleeve nuts) to the • If the engine coolant water has been
specified (KES) torque. drained, tighten the drain valve, and add
• Install the hoses without twisting or interfer- coolant water to the specified level. Run the
ence. engine to circulate the coolant water through
• Replace all gaskets, O-rings, cotter pins, and the system. Then check the coolant water
lock plates with new parts. level again.
• Bend the cotter pin or lock plate securely. • If the hydraulic equipment has been
removed and installed again, add engine oil
• When coating with adhesive, clean the part
to the specified level. Run the engine to cir-
and remove all oil and grease, then coat the
culate the oil through the system. Then
threaded portion with two or three drops of
check the oil level again.
adhesive.
• If the piping or hydraulic equipment, have
• When coating with gasket sealant, clean the
been removed for repair, Bleed the air from
surface and remove all oil and grease, check
the system after reassembling the parts.
that there is no dirt or damage, then coat uni-
formly with gasket sealant. ★ For details, see TESTING AND ADJUSTING,
Bleeding air.
• Clean all parts, and correct any damage,
dents, burrs, or rust. • Add the specified amount of grease (molyb-
denum disulphide grease) to the work equip-
• Coat rotating parts and sliding parts with
ment related parts.
engine oil.
• When press-fitting parts, coat the surface
with anti-friction compound (LM-P).
• After installing snap rings, check that the
snap ring is installed securely in the ring
groove.
• When connecting wiring connectors, clean
the connector to remove all oil, dirt, or water,
then connect securely.
• When using eye bolts, check that there is no
deformation or deterioration, screw them in
fully, and align the direction of the hook.
• When tightening split flanges, tighten uni-
formly in turn to prevent excessive tightening
on one side.
★ When operating the hydraulic cylinders for the
first time after reassembling cylinders, pumps
and other hydraulic equipment removed for
repair, bleed the air as follows:
1) Start the engine and run it at low idle.
2) Operate the work equipment control lever to
operate the hydraulic cylinders, 4 - 5 times,
stopping the cylinders 100 mm from the end
of their stroke.
3) Next operate the hydraulic cylinder 3 - 4
times to the end of its stroke.
4) After doing this run the engine at normal
speed.
★ When using the machine for the first time
after repair or long storage, follow the same
procedure.
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel supply pump assembly
WARNING
Disconnect the negative terminal (–) of the battery
before starting with the work.
30-18 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel supply pump assembly
[*3]
Fuel block mounting bolt:
32 ± 4 Nm {3.26 ± 0.41 kgm}
[*4]
Fuel supply pump mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
PW180-7E0 30-19
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel injector assembly
Part number Part name 5. Remove hose, tube and air intake connector
assembly (7). [*2]
3 795-799-6700 Primer Remove it without separating from the
A 4 795-799-1131 Gear bracket.
5 795-799-8150 Remover Mark the hose edge and tube to show the
original hose installation positions. (See fig-
Removal ure below.)
When removing the cylinder head cover only,
WARNING it is not necessary to remove hose, tube and
air intake connector assembly (7).
Disconnect the negative terminal (–) of the battery
before starting with the work. 6. Remove fan guard (8).
Remove it for checking the 3rd and 4th cylin-
der tops.
1. Remove cover (1). 6 7 8
30-20 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel injector assembly
PW180-7E0 30-21
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel injector assembly
30-22 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel injector assembly
PW180-7E0 30-23
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel injector assembly
1.2. Coat O-ring (42) and the head side of fuel injec- 1.10. Tighten retainer (32).
tor (41) with engine oil (EO15W-40).
Retainer:
O-ring (42) and the head side of fuel injector 50 ± 5 Nm {5.1 ± 0.5 kgm}
(41):
engine oil (EO15W-40)
30-24 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel injector assembly
[*3]
[*4]
[*5]
Fuel block mounting bolt:
32 ± 4 Nm {3.3 ± 0.4 kgm}
Carry out the rest of installation in the reverse [*6]
order to removal.
[*1] WARNING
When installing, keep the distance of more than 10 mm
Bracket mounting bolt: between the high-pressure pipe and the harness.
43 ± 6 Nm {4.4 ± 0.6 kgm}
PW180-7E0 30-25
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel injector assembly
[*7], [*8], [*9], [*10], [*11] 2.7. Tighten clamp (21) of high-pressure pipe (22).
High-pressure pipes and common rail
Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
WARNING
2.8. Tighten common rail (25) with four bolts.
● Do not use high-pressure pipes with bending
Coat the two bolt threads on the inner side of
modification.
the engine with sealant (LG-7).
● Be sure to use a genuine high-pressure pipe
fixing clamp and observe strictly the tighten- Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
ing torque.
2.9. Install bellows (23) to each high-pressure pipe.
A high-pressure pipe which has depressions (14 pieces)
such as visible vertical slit scar (b), patchy scars Set the slits of each bellows out and down.
(c) etc. on the taper seal section of its connector The bellows are installed so that fuel will not
((a) part: within 2mm from the tip), or a high-pres- spout over the hot parts of the engine and
sure pipe whose (d) part (end of the taper seal catch fire when it leaks for some reason.
section: 2mm from the tip) catches on a finger
FSP: Fuel supply pump
nail due to fatigue, may cause fuel leakage. In
these cases, replace the high-pressure pipe.
30-26 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel injector assembly
[*14]
a Harness installation position
Harness color Cylinder No.
White 1, 3, 5
Black 2, 4, 6
PW180-7E0 30-27
DISASSEMBLY AND ASSEMBLY Removal and installation of engine front seal
1 H2
8. Remove fan guards (6).
30-28 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of engine front seal
[*2]
a Refer to the Inspection and Adjustment of Air
Compressor Belt Tension section in the Testing
and adjusting chapter in this manual.
PW180-7E0 30-29
DISASSEMBLY AND ASSEMBLY Removal and installation of engine front seal
Removal and installation of engine rear 6. Lift off flywheel assembly (4) to remove it.
seal
Flywheel assembly: 35 kg
Special tools
Symbol
Removal
1. Remove the hydraulic pump assembly referring
to the section of Removing Hydraulic Pump
Assembly.
2. Remove mounting bolt (1) and set guide bolt [1].
3. Remove damper assembly (2).
30-30 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of engine front seal
Installation
1. Install the oil seal according to the following pro-
cedure.
Do not remove pilot [5] which is attached to
oil seal (5) until oil seal (5) is inserted to the
crankshaft.
Before installing the oil seal, de-grease,
clean and dry the crankshaft sealing face
and the seal lip face to prevent oil leakage.
PW180-7E0 30-31
DISASSEMBLY AND ASSEMBLY Removal and installation of engine front seal
Carry out the rest of installation in the reverse 4.4. As in the case of measurement of radial run out,
order to removal. bring the dial gauge probe into contact with end
surface b near the outer perimeter of the flywheel
[*1] at a right angle.
Tighten the eight flywheel mounting bolts in the
order of (1) through (8) as shown in the figure Conduct measurement pulling the crankshaft
to either the front or rear side to prevent
below.
errors caused by shakiness.
Flywheel assembly mounting bolt: 4.5. Rotate the flywheel 360° and measure the differ-
137 ± 7 Nm {13.97 ± 0.71 kgm} ence of the maximum swing of the dial gauge
indicator.
30-32 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of cylinder head assembly
3 795-799-6700 Primer
4 795-799-1131 Gear
A 5 795-799-8150 Remover
6 790-331-1120 Wrench (Angle)
7 795-790-4510 Gauge
Removal
WARNING
Disconnect the negative terminal (–) of the battery 6. Remove cover (6).
before starting with the work. 7. Remove clamp (7).
8. Remove the mounting bolt and lift off muffler
assembly (8) to remove it. [*1]
1. Remove cover (1). Space for winding the lifting tool is small.
Muffler assembly: 35 kg
30-34 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of cylinder head assembly
PW180-7E0 30-35
DISASSEMBLY AND ASSEMBLY Removal and installation of cylinder head assembly
30-36 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of cylinder head assembly
PW180-7E0 30-37
DISASSEMBLY AND ASSEMBLY Removal and installation of cylinder head assembly
42. Remove blow-by duct (45). 46. Remove nuts (49) for the harnesses from the
43. Disconnect fuel return tube (46). injector.
Harness color Cylinder No.
White 1, 3, 5
Black 2, 4, 6
30-38 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of cylinder head assembly
Installation
1. Cylinder head assembly
1.1. Measure under head length a of all the cylinder
head mounting bolts to check that they are within
the length limit.
Bolt length limit: less than 132.1 mm
If a bolt is longer than the using limit, do not
reuse it but replace it.
Tool A7: gauge is adopted for the measure-
ment. (Refer to the tool list.)
PW180-7E0 30-39
DISASSEMBLY AND ASSEMBLY Removal and installation of cylinder head assembly
How to tighten mounting bolts (60) 2. Install rocker housing assembly (59).
Tighten the bolts in the order shown below.
Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
1]
3. Install push rods (57).
90 ± 3 Nm {9.2 ± 0.3 kgm}
4. Install rocker arm support (58).
2] .
Recheck the torque:
90 ± 3 Nm {9.2 ± 0.3 kgm}
3]
90° ± 5° (Tighten with an angle tightening
tool.)
• When an angle tightening tool is not used: 5.3. Install holder (65) to fuel injector (62) with con-
Put marks on the cylinder head and bolts with a cavity and convexity (A) fitted together.
felt-tip pen, and then tighten the bolts an addi-
tional 90° ± 5°.
30-40 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of cylinder head assembly
5.4. Assemble fuel injector assembly (56) to the cyl- 6. Rocker arm and crosshead assembly
inder head with its fuel inlet hole facing the intake 6.1. Install rocker arm and crosshead assembly (52).
manifold side. When reusing the crosshead, install the
5.5. Tighten bolts (55) three or four turns. same intake and exhaust valves in the same
direction because the shapes of its holes a
5.6. Coat the head side (B part) of inlet connector
and b are different,
(54) with engine oil (EO15W-40).
Tighten the mounting bolt after checking that
5.7. Coat O-ring (C) of inlet connector (54) with the ball portion of adjustment screw (51) is
engine oil (EO15W-40). Then insert inlet connec- well seated in the push rod socket.
tor (54) completely, aligning (D part) with the side
groove of the head. Mounting bolt: 36 ± 5 Nm {3.7 ± 0.5 kgm}
PW180-7E0 30-41
DISASSEMBLY AND ASSEMBLY Removal and installation of cylinder head assembly
7. Install harnesses (49). Carry out the following installation in the reverse
Harness installation position order to removal.
Harness color Cylinder No. [*1]
White 1, 3, 5 Install muffler (8) after coating it with thermosetting
sealant.
Black 2, 4, 6
Entire perimeter of E section: thermosetting
sealant (equivalent of Holts Firegum)
[*2]
Bracket mounting bolt:
8. Fit the O-ring and install head cover (48). 43 ± 6 Nm {4.4 ± 0.6 kgm}
30-42 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of cylinder head assembly
[*9], [*10]
High-pressure pipes and common rail
WARNING
● Do not use high-pressure pipes with bending
modification.
[*6]
[*7]
Fuel block mounting bolt:
32 ± 4 Nm {3.3 ± 0.4 kgm}
[*8]
WARNING
When installing, keep the distance of more than 10 mm
between the high-pressure pipe and the harness.
PW180-7E0 30-43
DISASSEMBLY AND ASSEMBLY Removal and installation of cylinder head assembly
[*12]
10.6. Tighten common rail (25) with four bolts. MIKALOR clamp
Coat the two bolt threads on the inner side of Reference
the engine with sealant (LG-7).
Length of insertion: 40 mm (turbocharger side)
Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} Refer to [*3].
[*13]
10.7. Install bellows (23) to each high-pressure pipe. Lubrication inlet hose tightening nut:
(14 pieces) 35 ± 5 Nm {3.5 ± 0.5 kgm}
Set the slits of each bellows out and down.
The bellows are installed so that fuel will not
spout over the hot parts of the engine and Lubrication outlet hose mounting bolt:
catch fire when it leaks for some reason. 24 ± 4 Nm {2.4 ± 0.4 kgm}
30-44 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of cylinder head assembly
[*14]
Tighten the bolts in the order shown below.
[*15]
Fan mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}
[*16]
Refer to the Inspection and Adjustment of Air
Compressor Belt Tension section in the Testing
and adjusting chapter of this manual.
Refilling engine coolant
Refill water through the water filler port up to the
specified level. Start the engine and circulate the
water, and then check the water level.
PW180-7E0 30-45
DISASSEMBLY AND ASSEMBLY Removal and installation of combination cooler assembly
4 4
Remove the hydraulic tank strainer, and using
tool B stop the oil. 5
When not using tool B, remove the drain plug,
and drain the oil from the hydraulic tank and
inside the system. 3
1
6 6
8
2
30-46 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of combination cooler assembly
8. Disconnect pipes (7) and (8) at point (9), also 12. Remove 4 hoses (13).
remove brackets (10).
13 13
9 8
12
PW180-7E0 30-47
DISASSEMBLY AND ASSEMBLY Removal and installation of combination cooler assembly
Centre of
fan
30-48 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel cooler assembly
4
4
4
4
PW180-7E0 30-49
DISASSEMBLY AND ASSEMBLY Removal and installation of engine and hydraulic pump assemblies
2
3
30-50 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of engine and hydraulic pump assemblies
8. Remove fuel filter and bracket assembly (7). 12. Disconnect air cleaner tube (11). [*2]
Put it on the engine. 13. Remove after cooler hose and tube assembly
(35).
Mark the hose edge and tube to show the
original hose installation positions. (See fig-
ure below.)
8
9 10
11
C
15. Disconnect fuel supply hose (14).
16. Disconnect fuel return hose (15).
Disconnect the clamp.
PW180-7E0 30-51
DISASSEMBLY AND ASSEMBLY Removal and installation of engine and hydraulic pump assemblies
17. Remove fan (16). [*3] 24. Disconnect connectors CE02 (22) and (23) from
18. Loosen air conditioner compressor bracket the engine controller.
adjusting bolt (17). The connector is locked with the inside hex
There is another bolt behind. head bolt L6 (4 mm).
19. Move air conditioner compressor assembly (18). Connector (23) is attached at the engine
[*4] side, however it needs to be removed not to
be ob str uctiv e in rem oving the engine
20. Remove fan belt (19).
mounting bolts.
25. Disconnect connector (24) from the engine con-
troller by pushing the lock.
26. Disconnect connector E06 (25).
30-52 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of engine and hydraulic pump assemblies
27. Disconnect bracket (26) and remove spacer (27). 32. Disconnect four hoses.
q (33): Pump delivery hose
q (34): EPC basic pressure port hose
q (35): Pump pressure input port hose
q (36): Drain port hose
33. Disconnect suction elbow (37).
36
35
34 33
28. Disconnect terminals (28) from the starter B and
C.
29. Disconnect connectors E12 and alternator termi-
nal’B’ (29) and E03 (30).
37
30. Disconnect clamp (31).
34. Disconnect remote oil filter from frame (38).
38
31. Remove filter and bracket assembly (32). 35. Disconnect pump wiring connectors at two
points.
q V21 PC-EPC solenoid valve
q A55 hydraulic oil temperature
q V22 LS-EPC solenoid valve
36. Remove fan belt (39) from the alternator with
wrench [1].
32
PW180-7E0 30-53
DISASSEMBLY AND ASSEMBLY Removal and installation of engine and hydraulic pump assemblies
[*2]
Tube clamp:
10.0 – 11.0 Nm {1.02 – 1.12 kgm}
[*3]
Fan mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}
Reference
Inserted radiator hose length: 40 mm
[*6]
a The bolt length of the engine front side is shorter
than that of rear side.
Check that there is no wiring or piping still a The engine mounting rubber size of the engine
connected. front side is smaller than that of rear side.
43. Lift out engine and hydraulic pump assembly
(46).
Engine and hydraulic pump assembly:
800 kg
30-54 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of engine and hydraulic pump assemblies
Reference
Coolant:Approx. 17.6
• Air bleeding
Bleed the air from the circuit between the valve
and the hydraulic cylinder. For details, see Test-
ing and adjusting, Air Bleeding of Various Parts.
PW180-7E0 30-55
DISASSEMBLY AND ASSEMBLY Removal and installation of travel motor assembly
Blanking Kit
Description Part Number Qty Where Used
Cap Plug 07376-70422 1
O-ring 02896-11012 1 Top Drain Hose
8
Cap Plug 07376-70210 1 Top Pilot Pressure
O-ring 02896-11008 1 Hose
Flange 07379-01260 2
O-ring 07000-13038 2 Front Main Travel
Bolt 01010-51245 8 Hoses
Washer 01643-51032 8
1. Remove cover (1) by removing bolts (2).
10
6
7
3
4 5
30-56 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of travel motor assembly
Installation
Install in reverse order of removal.
Tightening torque for propshaft nuts is: 25 - 31.5
kgf-m
Refill the transmission oil to the required level
(4.85 litres).
Top up hydraulic through oil filler port to the spec-
ified level and let the oil circulate in the hydraulic
system by starting the engine. Then check oil
again.
Air bleeding
Refer to the Air Bleeding of Various Part section
in the TESTING AND ADJUSTING chapter of
this manual.
PW180-7E0 30-57
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of travel motor assembly
Counterbalance
Qmax adjustment
valve assembly
screw
30-58 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of travel motor assembly
1. Put the unit in a bench with a hole or place it on a 3. Before removing the port plate measure and
fixture for assembly. record dimension X of the Qmin adjustment
screw and dimension Y of the Qmax adjustment
screw.
X
Y
Qmin
screw
Qmax
screw
Fixing
bolt
PW180-7E0 30-59
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of travel motor assembly
Insert
Qmin
screw
New
o-ring
Port plate
Fixing screw
Control Sliding
lens surface
30-60 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of travel motor assembly
3. Assemble the port plate by locating the lens plate 5. Assemble the counterbalance valve assembly
onto the rotary group. using the six fixing bolts.
Secure the port plate by tightening the eight fix- Tightening torque - 205 Nm.
ing bolts.
Tightening torque - 310 Nm
Counterbalance
Port plate valve Fixing
bolt
Fixing
bolt
PW180-7E0 30-61
DISASSEMBLY AND ASSEMBLY Removal and installation of swing motor and swing machinery
3
4
5
30-62 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of swing motor and swing machinery
Installation
Carry out installation in the reverse order to
removal.
• Refilling with oil
Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
• Bleeding air
For details, see TESTING AND ADJUSTING,
Bleeding air from each part.
PW180-7E0 30-63
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing machinery
1 KBATZ080080 Wrench
G 2 KBATZ030190 Adapter
3 KBATZ060400 Stopper
Disassembly
1. Draining oil
Loosen the drain plug and drain the oil from the
swing machinery case.
2 3
4 4. Cover
Remove cover (16).
16 Make match marks on cover (16) and ring
gear (26) for reassembly.
30-64 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing machinery
6. Ring gear
Remove ring gear (26).
Make match marks on ring gear (26) and
housing (28) for reassembly.
7.4. Fix tool G2. Using power wrench (25-time
power) [2], turn tool G1 to loosen the ring nut.
Ring nut (Reference):
1100 – 1200 Nm {112.2 – 122.3 kgm}
PW180-7E0 30-65
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing machinery
7.5. Remove ring nut (27). 8.3. Using a press, separate pinion shaft assembly
(29) and bearing (30).
30-66 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing machinery
8.6. Remove bearing (34) and oil seal (35) from Assembly
housing (28). 1. Housing and pinion shaft
1.1. Using tool G3, install oil seal (35) to housing (28)
as shown in the following figure.
Press fit the oil seal until its end reaches the
housing end.
1.2. Using push tool [4], press fit spacer (36) to pinion
shaft (29).
PW180-7E0 30-67
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing machinery
1.4. Set front cover (31) to pinion shaft (29). 1.7. Using push tool [6], press fit pinion shaft assem-
bly (29) to housing (28).
Press fit the bearing until the end of bearing
(30) reaches the end of housing (28).
1.5. Using push tool [5], press fit bearing (30) to pin-
ion shaft (29).
Press fit the bearing until the inner race end
reaches the spacer. 1.8. Tighten 6 front cover mounting screws (32).
Housing: Grease
(SHELL RETINAX HD-2 or equivalent)
30-68 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing machinery
1.9. Using push tool [7], press fit bearing (34). 2.4. Fix tool G2. Using power wrench (25-time
Press fit bearing (34) until its end reaches power) [2], turn tool G1 to tighten the ring nut.
the shoulder of pinion shaft (29).
Ring nut:
1100 – 1200 Nm {112.2 – 122.3 kgm}
2. Ring nut
2.1. Install ring nut (27) to the pinion shaft.
2.5. Using a punch, etc., bend the inside parts of ring
nut (27) toward the spline of pinion shaft (29).
• Bend 3 parts at intervals of 120°.
PW180-7E0 30-69
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing machinery
4. Ring gear
4.1. Fit the O-ring to the housing.
4.2. Install ring gear (26). 6.2. Install No. 1 sun gear (5).
30-70 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing machinery
Mounting bolt:
85 ± 4.3 Nm {8.7 ± 0.44 kgm}
2 3
16
PW180-7E0 30-71
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing motor assembly
Disassembly
1. Set the swing motor and swing machinery
assembly on blocks.
2. Reverse prevention valve assembly
Remove reverse prevention valve assembly (1).
30-72 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing motor assembly
4. Springs
Remove 16 springs (9).
There are outer springs (large) and inner
springs (small). Only the outer springs
(large) are installed to 4 places a.
5. Brake piston
Using tool D1, supply compressed air to port PB
of the case to float and remove brake piston (10).
When installing the cover, make match
marks on the brake piston and case so that
the dowel pin of the cover will not shift from
the dowel pin hole of the brake piston.
WARNING
If high-pressure air is supplied, the brake piston jumps
out. Accordingly, supply very low-pressure air at first
and check the movement of the brake piston, and then
adjust the air pressure. 8. Cylinder block assembly
8.1. Place case (21) on its side.
8.2. Pull out cylinder block assembly (11).
When removing the cylinder block assembly,
slant the case down a little so that the inter-
nal parts (piston, retainer holder, and pin) will
not be left in the case.
6. Collar
Using a puller, etc., remove collar (13).
Remove 1 disc (14) so that you can remove
the collar easily.
PW180-7E0 30-73
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing motor assembly
8.3. Lift up retainer plate (17) and remove it and pis- 8.7. Press down collar (30) with a press, etc. and
ton (18) together from cylinder block (11). remove snap ring (31).
8.4. Separate retainer plate (17) and piston (18). 8.8. Remove collar (30), spring (32), and collar (33).
30-74 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing motor assembly
1.2. Using push tool [2], press fit oil seal (24) to case
(21) as shown in the following figure.
Press fit the oil seal until its end reaches the
case end.
PW180-7E0 30-75
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing motor assembly
1.3. Press the end of shaft (23) with a press, etc. to 3. Cylinder block assembly
press fit it to case (21).
3.1. Install collar (33), spring (32), and collar (30).
Press fit the shaft until the end of the bearing
3.2. Press down collar (30) with a press, etc., and
outer race reaches the case end.
install snap ring (31).
1.4. Install snap ring (22).
2. Thrust plate
Install thrust plate (19).
Install the thrust plate with small hole side b 3.4. Install retainer holder (16).
up.
30-76 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing motor assembly
3.5. Install piston (18) to retainer plate (17). 4. Discs and plates
Set chamfered periphery c of retainer plate Install 3 discs (14) and 2 plates (15) alternately.
(17) toward the cylinder block side. When installing discs, set their wider no-
spline teeth sides d and narrower no-spline
3.6. Install the retainer plate and piston assembly to
teeth sides e to each other respectively.
the cylinder block assembly (11).
The wider and narrower no-spline teeth
Apply engine oil (EO10-CD) fully to the slid-
sides may be installed in any direction of the
ing surfaces of the piston and cylinder block.
cylinder block.
PW180-7E0 30-77
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing motor assembly
5.2. Using push tool [3], press fit collar (13) evenly.
7. Springs
6. Brake piston Install 16 springs (9).
There are outer springs (large) and inner
6.1. Fit the O-ring to brake piston (10).
springs (small). Install only the outer springs
(large) to 4 places a.
6.2. Using push tool [4], press fit brake piston (10)
evenly.
When press fitting the brake piston, align the
intermediate point between tap hole (f) of the
brake piston and dowel pin hole (g) with the
center of port (h) of the case so that the
dowel pin of the cover will be aligned with the
dowel pin hole of the brake piston when the
cover is installed (in step 8). (Match the
match marks made when the brake piston
was removed.)
8. Cover assembly
6.3. Fit the O-ring to the case.
8.1. Using push tool [5], press fit bearing outer race
(8) to cover (2).
Press fit the bearing outer race until its end
Periphery of O-ring: Grease (G2-LI) reaches the cover end.
30-78 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing motor assembly
8.3. Fit the backup ring and O-ring and install 2 relief
valve assemblies (7).
Mounting bolt:
32.4 ± 2.0 Nm {3.3 ± 0.2 kgm}
PW180-7E0 30-79
DISASSEMBLY AND ASSEMBLY Removal and installation of front axle assembly
1
1
1 1 7. Remove pin (5).
30-80 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of front axle assembly
Installation
Install in reverse order of removal.
Grease all cylinders before installation
PW180-7E0 30-81
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
WARNING
Reject the used split pins.
30-82 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
7. Remove the head of the cylinder (8). Strike by 10. Remove the rod complete with cylinder (16) and
means of a plastic hammer. cylinder liner (17).
8. Remove the gaskets (11), (12) and the scraper 11. Remove the head of the cylinder (14).
ring.
PW180-7E0 30-83
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
WARNING
The gasket cuts (18) should not coincide.
3. Thicknesses to be fitted.
30-84 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
4. Measuring of value F1. 8. Assemble the thicknesses x (24) and the O-ring
(20).
PW180-7E0 30-85
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
12. Lubricate with grease the contact surface. 15. Lubricate with grease the gaskets of the right cyl-
inder rod.
30-86 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
18. Assemble head of cylinder (8). Strike by means 21. Screw heads of steering cylinder (6).
of a plastic hammer. Apply Loctite® 510.
PW180-7E0 30-87
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
30-88 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
Disassembly of epicyclic reduction gear and 4. Remove the planetary gear carrier cover (3) and
brake O-ring (30).
1. Before draining the oil, position the wheel hub (1)
with the plug on the upper part and loosen it off
some turns in order to eliminate any possible
inner pressure, then remove it completely. Turn
the wheel hub upside down till the hole is in the
lowest point.
Drain the oil completely.
30-90 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
7. Remove brake discs (6). 10. Remove seal rings (9) and (10) from piston (8).
8. Remove fastening screws of piston (7) and 11. Remove snap ring (24).
springs (15).
PW180-7E0 30-91
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
13. Remove screws (11) and washers (21) from 16. Remove seal rings (13) and (14) from brake car-
brake carrier (12). rier (12).
14. Assemble carrier (28) and split ring (4). Remove 17. Remove shims (26).
brake carrier (12).
30-92 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
19. Remove the drain valve (17). 22. Remove outer cup of bearing (20).
20. Remove seal ring (19). 23. Remove outer cup of bearing (18).
21. Remove inner cup of bearing (18). 24. Remove snap ring (31). Remove planetary gears
(23) from planetary gear carrier cover (3).
PW180-7E0 30-93
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
Assembly of Epicylic Reduction Gear and Brake 4. Apply Loctite® 510 on seal ring (19).
30-94 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
7. Assemble the whole wheel hub (16). Alternately 10. Assemble the tool 2897013, 3 draw plates M10 x
strike bearings (18). 285 and 3 nuts M10.
WARNING
The roller bearing should be rested on the beam trum-
pet.
WARNING
Wear gloves to avoid getting burnt.
PW180-7E0 30-95
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
13. Calculate shims X1 of adjustment shims by using 16. Assemble O-rings (13) and (14) on brake carrier
the following procedure: X1 (G-F) + 0.05. (12).
14. Assemble previously calculated shims (26) X1. 17. Fit piston (8) on brake carrier (12) with springs
(15) and screws (7). Apply Loctite® 638 on the
screws (7).
WARNING
The brake carrier and beam trumpet holes should coin-
cide.
30-96 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
19. Assemble brake discs (6). 22. Test the brake by temporarily fitting two screws
(11).
WARNING
WARNING
During assembly operations all the inner disc slots
should coincide. Warning: Do not assemble bushes (22).
20. Assemble brake discs (6). 23. Fit snap ring (4).
WARNING
Warning: During assembly operations all the outer
disc slots should coincide.
21. Fit ring bevel gear (5) with carrier (28) and split
ring (29).
PW180-7E0 30-97
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
25. Fit an adapter instead of the plug. 28. Apply Loctite® 242 inside slots.
26. Test the brakes by considering that pressure 29. Fit screws (11) and shims (21).
should be 100-5 0 bar for about one minute.
Screws (11) tightening torque: 68Nm
30-98 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
31. Put brakes under pressure to avoid outer disc 34. Assemble snap ring.
misalignment.
PW180-7E0 30-99
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
37. Apply Loctite® 242 on screw. 40. Apply pressure of 45-50 bar and check the dis-
tance between brake locking and unlocking (Min:
1.7mm; Max: 3.8 mm)
39. Remove oil drain plug and turn the final drive up
to meeting item (28) hole.
30-100 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
Disassembly of joint box 4. Remove the planetary gear carrier cover (3) and
1. Before draining the oil, position the wheel hub (1) O-ring (6).
with the plug on the upper part and loosen it off
some turns in order to eliminate any possible
inner pressure, then remove it completely. Turn
the wheel hub upside down till the hole is in the
lowest point.
Drain the oil completely.
30-102 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
7. Remove the screw (7). 10. Screw two screws M12 x 100 and remove the
pivot.
PW180-7E0 30-103
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
13. Remove the complete joint (11). 16. Remove gasket (30).
14. Remove the gasket (12). 17. Use an extractor to remove bush (18).
15. Remove the gasket (13). 18. Remove the O-ring (20).
30-104 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
19. Remove the disk (20). 22. Remove the gasket (24).
20. Remove the bush (21). 23. Remove the bush (25).
21. Remove the O-ring (22) and the disk (23). 24. Remove pins (26).
PW180-7E0 30-105
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
30-106 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
4. Assemble the O-ring (22) and the disk (23). Pay 7. Apply Loctite® 510 on the gasket (24).
attention to assembling direction.
PW180-7E0 30-107
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
10. Apply Loctite® 510 on the gasket (28). 13. Grease and assemble the spacer (27).
30-108 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
16. Assemble the gasket (13). Pay attention to 19. Lubricate and assemble the pivot.
assembling direction.
PW180-7E0 30-109
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
22. Apply Loctite® 242 and assemble the screw (8). 25. Line up brake discs. Use tool 2897014.
Torque - 285 (29kgf-m)
WARNING
A tooth should coincide with a brake fastening screw
(7)
30-110 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
28. Lubricate with grease the contact surface of 31. Fit screws (2).
planetary gear cover (3). Torque - 55 Nm (6 kgf-m)
Apply Loctite® 510 in the holes.
PW180-7E0 30-111
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
30-112 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
7. Remove shims (6). 10. Use an extractor to remove bearing (7) from dif-
ferential unit.
WARNING
This operation makes both differential half boxes free,
so take care not to drop the inner components.
PW180-7E0 30-113
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
13. Remove ring bevel gear (2) by means a mallet. 16. Remove differential pins (13 and (14), planetary
gears (15), (16), (17) and (18) and spheric wash-
ers (19), (20), (21), and (22).
30-114 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
19. Remove planetary gear (30). 22. Remove discs (42) and (43).
PW180-7E0 30-115
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
Assembly of beam trumpet and differential unit. 4. Fit the differential unit pin (13) and planetary
NOTE: Without differential torque limiter. gears (15) and (16) and washers (19) and (20).
WARNING
Remove rests do dope.
30-116 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
7. Apply a thin layer of Molicote G-n plus paste on 10. Assemble planetary gears (41).
half boxes of differential (44) and (45).
WARNING
Remove rests of dope.
PW180-7E0 30-117
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
13. Assemble planetary gears (30). 16. Fit ring bevel gear (2) by using a hammer.
14. Assemble discs (28) and (29). 17. Apply Loctite® 242 on thread of screws (10).
15. Fit the two half boxes of differential unit (11) and 18. Tighten screws (10)
(12). Torque - 205 Nm (21 kgf-m)
NOTE: Fix differential housing in the vice.
WARNING
Carefully check that the marks of both differential half
boxes coincide.
30-118 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
19. Press bearing (7) or assemble after preheating. 22. Use tool 2897004 to fit bearing washer (5) on
beam trumpet (4).
PW180-7E0 30-119
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
25. Use tool 2897004 to fit the bearing outer washer 28. While Screwing the tool nut until the value of
(7) on beam trumpet (3). 10Nm has been reached turn the ring bevel gear
and strike it with a hammer to fix whole unit.
30-120 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
31. Drawing used to determine backlashes between 33. Apply Loctite® 510 on contact surface of beam
the bevel gear pair teeth for 20K-23-31000. trumpet (4).
X1 = 1.8
Check adjusting shims X2 through the suggested
procedure for 20K-23-31000 axles
X2 = G - (19 + F1) + 0.15 / 0.1
F1 = addition of the dimensions printed on the
housings 19 + 0.1 / 0.15 is the bearing pre-load-
ing
PW180-7E0 30-121
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
30-122 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
7. Remove the nut (6) and the flange (10). 10. Once the bevel pinion (2) has been removed,
collect shims (9) and spacer (8).
PW180-7E0 30-123
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
13. Remove the outer cup of the taper roller bearing Assembly of pinion group
(13) and shims (9) from the central body. Use a
chisel and a hammer. 1. Bevel pinion adjustment for 20K-23-31000.
30-124 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
PW180-7E0 30-125
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
5. To determine shim S2. 8. Position half bearing (11) on beam trumpet (4).
S2 = B1 - (L1 - S - G - L2)
S = previously detected shims
G = beam value
30-126 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
11. Press inner bearing (13) on pinion (2). 14. Fit bearing (11) in relevant housing on beam
Use tool 2897009. trumpet (4).
WARNING
Use a special glove to protect from scorching.
PW180-7E0 30-127
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
17. Assemble the oil seal by slightly striking with a 20. Assemble the flange (10) and the nut (6).
plastic hammer.
NOTE: Clean the box with a rolling brush.
30-128 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
23. Carry out the pre-loading measurement (P) of 26. Apply Loctite® 510 on contact surface of beam
the pinion taper roller using a dynamometer trumpet (4).
whose cord is wound on the flange diameter. The
adjustment is performed by gradually increasing
shims (12) mounted under bearing (11).
WARNING
All pre-loadings should be measured without the seal
ring.
P = 2/3 Nm
PW180-7E0 30-129
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
30-130 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
30-132 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
PW180-7E0 30-133
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle
Steering angle adjustment 4. Steer completely towards the other side and
1. Use the same bars assembled for the toe-in repeat the previous operations.
adjustment and a long bar perfectly balanced
over the machined part of the central body (pin-
ion side), so that the 2 bars form an acute angle
at the maximum steering.
30-134 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of rear axle and transmission
Blanking Kit
Description Part Number Qty Where Used
Cap Plug 07376-70422 1
O-ring 02896-11012 1 Top Drain Hose
8
Cap Plug 07376-70210 1 Top Pilot Pressure
O-ring 02896-11008 1 Hose
Flange 07379-01260 2
O-ring 07000-13038 2 Front Main Travel
Bolt 01010-51245 8 Hoses
Washer 01643-51032 8
1. Remove cover (1) by removing bolts (2).
10
6 12
7
Retract
13
3
4 5
30-136 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of rear axle and transmission
15
16
16
10. Use work equipment to lift undercarriage above Disengage from
transmission
the axle.
PW180-7E0 30-137
DISASSEMBLY AND ASSEMBLY Removal and installation of rear axle and transmission
Installation
Install in reverse order of removal.
Grease all cylinders before installation.
30-138 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
Disassembly
Removal of Epicyclic Reduction Gear and Brake
4. Remove the planetary gear carrier cover (3) and
1. Before draining the oil, position the wheel hub (1)
O-ring (30).
with the plug on the upper part and loosen it off
some turns in order to eliminate any possible
inner pressure, then remove it completely. Turn
the wheel hub upside down till the hole is in the
lowest point.
Drain the oil completely.
30-140 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
PW180-7E0 30-141
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
14. Remove seal rings (13) and (14) from brake car-
rier (12).
17. Remove the drain valve (17).
30-142 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
18. Remove seal ring (19). 21. Remove outer cup of bearing (18).
19. Remove inner cup of bearing (18). 22. Remove sleeve (25).
20. Remove outer cup of bearing (20). 23. Remove shaft and pinion (24).
PW180-7E0 30-143
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
24. Remove snap ring (32) planetary gears (33). Installation of Epicylic Reduction Gear and Brake
30-144 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
4. fit the remaining part of bearing 18) on wheel hub 7. Lubricate axle shaft to assemble the wheel hub
(16).
WARNING
Polish hub and oil holes.
WARNING
The roller bearing should be rested on the beam trum-
pet.
PW180-7E0 30-145
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
10. Fit bearing (20) inside beam trumpet. 13. Use a depth gauge to measure dimension F of
brake carrier (12).
WARNING
Wear gloves to avoid getting burnt.
30-146 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
16. Assemble O-rings (9) and (10) on piston (8). 19. Fit the whole unit of the brake carrier on wheel
hub.
WARNING
The brake carrier and beam trumpet holes should coin-
cide.
WARNING
During assembly operations all the inner disc slots
should coincide.
PW180-7E0 30-147
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
21. Assemble brake discs (6). 24. Fit snap ring (4).
WARNING
Warning: During assembly operations all the outer
disc slots should coincide.
22. Fit ring bevel gear (5) with carrier (28) and split
ring (29).
WARNING
Do not assemble bushes (22).
30-148 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
27. Test the brakes by considering that pressure 30. Fit screws (11) and shims (21).
should be 100-50 bar for about one minute.
Screws (11) - 68Nm
PW180-7E0 30-149
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
33. Lubricate with grease and fit O-ring (30). 36. Fit pinion shaft (24).
34. Heat planetary gear bearing at 110ºC. Assemble 37. Fit sleeve (25).
planetary gear (23).
30-150 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
39. Fit the planetary gear cover (3) and discharge 42. Remove oil drain plug and turn the final drive up
pressure from the hydraulic pump. to meeting the item (28) hole.
Note:Brakes wear check.
PW180-7E0 30-151
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
12
Disassembly of Beam Trumpet and Differential 4. Remove O-ring (9).
Unit
30-152 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
7. Remove shims (6). 10. Use and extractor to remove bearing (7) from dif-
ferential unit.
WARNING
This operation makes both differential half boxes free,
so take care not to drop the inner components.
PW180-7E0 30-153
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
13. Remove ring bevel gear (2) by means of a mal- 16. Remove differential pins (13) and (14), planetary
let. gears (15), (16), (17) and (18) and spheric wash-
ers (19), (20), (21) and (22).
NOTE: Without differential torque limiter NOTE: With differential torque limiter
15. Remove planetary gear (23) and shim (25). 18. Remove discs (28) and (29).
30-154 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
19. Remove planetary gear (30). 22. Remove discs (42) and (43).
PW180-7E0 30-155
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
30-156 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
30-158 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
9. Remove O-ring (18), ring (19) and seal (20). 12. Remove the disc (17).
PW180-7E0 30-159
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
13. Take the bevel pinion out of its housing, by beat- 16. Take the cup of the taper roller bearing (11) out of
ing with a hammer made of soft material on the the central body using a chisel and hammer.
splined end.
15. Take the bearing cone (13) out of the bevel pin-
ion end, using a suitable extractor.
30-160 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
Installation of Pinion Group 3. To determine shim (S) between pinion and bear-
ing it is enough to add value (V) printed on pinion
1. Bevel pinion adjustment. head (V = prescribed conical distance) to value B
- bearing width - and subtract X from the value
X 163.50 163.50 163.70 printed on beam.
S=X - (V+B)
B 29.25 29.45 29.25
Example: shim S = 163.6 - (132.80 + 29.25) =
V 133.00 133.20 132.80 1.55mm.
A 162.25 162.65 162.05
S 1.25 0.85 1.65
4. Bearings adjustment.
PW180-7E0 30-161
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
6. L1 = bearing height
L2 = bearing height
30-162 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
11. Fit the whole pinion of bearing on beam trumpet 14. Grease bevel pinion.
(4), spacer (14) and shims (12).
WARNING
Use a special glove to protect from scorching.
PW180-7E0 30-163
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
18. Assemble O-ring (18), ring (19) and seal (20). 21. Assemble sleeve (7) and grease surface.
19. Grease gear wheel (9) and assemble. 22. Assemble flange (10) and nut (6). (Tightening
torque - 400Nm).
30-164 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
23. Carry out the pre-loading measurement (P) of 26. Apply Loctite® 510 on contact surface of beam
pinion taper roller using a dynamometer whose trumpet (4).
cord is wound on the flange diameter. The
adjustment is performed by gradually increasing
shims mounted under bearing.
WARNING
Warning: All pre-loadings should be measured without
the seal ring.
P = 2 / 3 Nm
PW180-7E0 30-165
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly
30-166 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
Disassembly
Removal of Travel Motor and Flange
1. Remove drain plug and drain oil from transmis-
sion and travel motor.
30-168 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
PW180-7E0 30-169
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
30-170 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
4. Assemble flange protection (9) on flange (7). 7. Apply Loctite® 242 on nut (6).
PW180-7E0 30-171
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
10. Assemble O-ring (5). 13. Assemble the travel motor (2).
11. Assemble spring (4). 14. Apply Loctite® 242 on screws (1).
12. Assemble disc (3). 15. Assemble screws (1). (Tightening torque -
285Nm)
30-172 PW180-7E0
12510.
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
30-174 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
PW180-7E0 30-175
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
13. Remove thrust plate (13) from bush (11). 16. Remove complete planetary gears carrier.
30-176 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
19. Use an extractor to remove the bearing (17). 22. Use an extractor to remove bering inner cup
(20).
PW180-7E0 30-177
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
30-178 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
31. Remove bearing outer cup (31). 34. Remove piston (35) and springs (36), (37).
33. Remove gasket (33) and O-ring (34). 36. Remove gasket (39).
PW180-7E0 30-179
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
30-180 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
43. Remove snap ring (45). 46. Remove discs (49), (50), (51) and (52).
44. Remove external geared wheel (46) from hollow 47. Remove piston assembly.
wheel (47).
PW180-7E0 30-181
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
49. Remove piston gasket (54) and O-ring (55). 52. Loosen screw (60).
50. Remove outer ring (56) from piston (57). 53. Remove screw (60), washer (61), spring (62),
and ball (63).
30-182 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
56. Remove the cover (67). 59. Remove snap ring (70).
PW180-7E0 30-183
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
30-184 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
7. Apply Loctite® 242 on screws (66). NOTE: To unlock the transmission in case of need,
turn the eccentric pin 180° (notch upward).
PW180-7E0 30-185
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
12. Assemble gasket (58) and O-ring (59) in the ring 15. Assemble O-ring (53).
(56).
WARNING
Make sure that the piston does not key.
30-186 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
NOTE: Check the sequence of discs. 20. Assemble snap ring (45).
18. Assemble disc (48). 21. Assemble bearing (44) on hollow wheel assem-
bly.
PW180-7E0 30-187
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
30-188 PW180-7E0
29. Install O-ring (38) and gasket (39).
Use tool 2912484. WARNING
Springs are assembled as follows:
N.1 series with 1 spring;
N.1 series with 2 spring;
N.1 series with 1 spring;
N.3 series with 2 spring;
N.1 series with 1 spring;
N.1 series with 2 spring.
Repeat this operation twice.
35. Assemble bearing (31). 38. Assemble bearing outer cup (20).
30-190 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
41. Assemble gears (26), bearings (25), pins(24) 44. Align the holes of the wheel (21) with the holes of
and washers (23) on the planetary gears carrier the planetary gears carrier (22).
(22).
PW180-7E0 30-191
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
45. Apply Loctite® 638 on inner race of bearing(20) 48. Measure the distance (A) between supporting
plate and the bearing detent (17).
30-192 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
51. Apply Loctite® 638 on inner race of bearing (17) 54. Assemble the planetary gears carrier.
and assemble it.
PW180-7E0 30-193
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
30-194 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
63. Assemble the ring (8). 66. Assemble snap ring (7).
64. Unlock the clutch by pressing 50 - 100 bar. 67. Assemble springs (4), (5) and (6).
65. Measure the lowering of the discs using a digital 68. Assemble O-ring (3).
gauge. the stroke should be between 1.7 and 1.9 Apply Loctite® 510.
mm. Otherwise replace the ring (8) with one of
different thickness.
PW180-7E0 30-195
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
69. Assemble transmission box. 72. Apply Loctite® 242 on screws (1).
70. Apply Loctite® 242 on screws (2). 73. Assemble screws (2).
(Tightening torque - 285Nm)
30-196 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission
PW180-7E0 30-197
DISASSEMBLY AND ASSEMBLY Removal and installation of propshaft assembly
2 2
Retract
3
4. Ensure propshaft is supported safely.
5. Remove nuts (4), then retract from the studs on
the axle housing.
.
Retract
30-198 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of propshaft assembly
Installation
Install in reverse order of removal.
Tightening torque of propshaft nuts (58.8-73.5
Nm).
PW180-7E0 30-199
DISASSEMBLY AND ASSEMBLY Removal and installation of wheel assembly
1 2
3. Lower onto stands and deflate tyre completely by
removing valve (3) with appropriate tool.
WARNING
Always stand to the side while deflating the tyre.
30-200 PW180-7E0
Installation
Install in reverse order of removal.
When inflating tyres, inflate to:
2 2
30-202 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of suspension lock cylinder
WARNING
Do not damage rod surface!
WARNING
Do not damage groove!
PW180-7E0 30-203
DISASSEMBLY AND ASSEMBLY Removal and installation of outrigger assembly
4
8. Remove all bolts (5) and remove outriggers.
1 5
5. Remove 2 pipes (2).
30-204 PW180-7E0
Installation
Install in reverse order of removal.
Grease all pins and cylinders before installing.
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of outriggers
30-206 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of outriggers
Assembly
Install in reverse order of removal.
Grease all pins and cylinders before installing.
Grease bearing points after assembly.
PW180-7E0 30-207
DISASSEMBLY AND ASSEMBLY Removal and installation of dozer blade assembly
1 1
2
2
30-208 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of dozer blade
30-210 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of dozer blade
Assembly
Install in reverse order of removal.
Grease all pins and cylinders before installing.
Grease bearing points after assembly.
PW180-7E0 30-211
DISASSEMBLY AND ASSEMBLY Removal and installation of swing circle assembly
Outer race
soft zone
Front of machine
Inner race
soft zone
30-212 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of swing circle assembly
PW180-7E0 30-213
DISASSEMBLY AND ASSEMBLY Removal and installation of revolving frame assembly
1 1
30-214 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of revolving frame assembly
7 14
9 8
17
10 11
16
18 19
PW180-7E0 30-215
DISASSEMBLY AND ASSEMBLY Removal and installation of revolving frame assembly
20
30-216 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of centre swivel joint
14
2 1 13
3 12
30-218 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of centre swivel joint
19 18
27
20 21
26
28 29
PW180-7E0 30-219
DISASSEMBLY AND ASSEMBLY Removal and installation of centre swivel joint
Front
9. Sling centre swivel joint then remove 2 remaining
mounting bolts (30) and remove.
30-220 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of centre swivel joint assembly
Disassembly
1. Remove the electric slip-ring (1) on the enclosure
flange. 3
4
2. Remove all 4 screws (2) TE M10 x 30 on enclo-
sure flange.
5. Prevent any possibility of damage on chromium
plated surface of spool.
6. Remove all of the wearing (5) seals from the
grove of housing.
30-222 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of centre swivel joint assembly
7. Remove the seals (6) from the end and top grove Assembly
of housing. Assemble in reverse order of disassembly.
Replace any seals that have been removed.
6 6
PW180-7E0 30-223
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel tank assembly
Buzzer
Fuel: 325 l Horns
1
2
6. Remove tank side cover (8) by removing 4 bolts
(9) and (10).
1
2 8
3. Remove tool box top cover/lid assembly (3) by
removing 3 bolts (4).
9
6
6
6
6
30-224 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel tank assembly
Fuel: 325
13
13
PW180-7E0 30-225
DISASSEMBLY AND ASSEMBLY Removal and installation of hydraulic tank assembly
6
Hydraulic oil: 160
1 2
10
4. Remove handrail (2) by removing 8 bolts (3).
2
3
3 9
3
5. Remove toolbox top cover lid assembly (4) by
removing 3 bolts (5).
5
4
30-226 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of hydraulic tank assembly
8. Remove main valve cover plate (11) by removing 12. Disconnect hose (17) from hydraulic tank.
4 bolts (12).
9. Remove centre partition (13) by removing 2 bolts
(14).
17
9
12
15
14. Loosen 6 mounting bolts (19).
19
16
15
15. Ensure lifting equipment takes the weight of the
hydraulic tank.
16 16. Once the lifting equipment has taken the weight
remove mounting bolts (19).
17. Remove hydraulic tank.
PW180-7E0 30-227
DISASSEMBLY AND ASSEMBLY Removal and installation of hydraulic tank assembly
30-228 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of control valve assembly
1 14 15 16 17
1
19
18
5. Disconnect hoses 2 through 10. (Hoses 2, 3, 7 8. Disconnect hoses (20 through 24) from top of
and 8 are options) control valve.
9. Also disconnect hoses (23 and 24) from swing
machinery to aid removal of control valve and
7 2 improve accessibility.
8 3
9 4
10 5 20 21 22
6
23
24
30-230 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of control valve assembly
10. Disconnect hoses (25 through 29). 13. Disconnect hoses (38 through 42).
38
39 40
25
26
29
28
27
41 42
30
43
44
32
33
31
34
35
45
36 46
37
47
PW180-7E0 30-231
DISASSEMBLY AND ASSEMBLY Removal and installation of control valve assembly
16. Disconnect hoses (48 through 50). 19. Loosen off mounting bolts (54).
50
48
49
53
51 53
55
53
52
21. Remove mounting bolts (54)
22. Remove control valve.
30-232 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of control valve assembly
PW180-7E0 30-233
DISASSEMBLY AND ASSEMBLY Removal and installation of LS separation valve assembly
4
3
1
30-234 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of pressure compensation valve assembly
2
1
PW180-7E0 30-235
DISASSEMBLY AND ASSEMBLY Removal and installation of main relief valve assembly
30-236 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of LS control EPC valve
PW180-7E0 30-237
DISASSEMBLY AND ASSEMBLY Removal and installation of EPC solenoid valve assembly
30-238 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of PPC solenoid valve block assembly
9 11
10
2 1 2
30-240 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of PPC solenoid valve block assembly
Installation
Install in reverse order of removal.
PW180-7E0 30-241
DISASSEMBLY AND ASSEMBLY Removal and installation of oil seal in hydraulic pump input shaft
Removal
Oil seal lip portion: Grease (G2-LI)
1. Remove the hydraulic pump assembly. Refer to
see “Removal and installation of engine and
Oil seal outer circumference:
hydraulic pump assemblies” on page 30- 50.
Grease (G2-LI)
2. Remove snap ring (1) and then remove spacer
(2). Coat the oil seal outer circumference thinly
3. Pry off oil seal (3) with a screwdriver. with grease.
Press-fit oil seal (3), using tool N.
When attempting to pry off the seal, do not
damage the shaft.
30-242 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of work equipment PPC valve
PW180-7E0 30-243
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of hydraulic cylinder
6 • 01010-50816 bolt
790-201-1980 Plate (for boom)
790-201-1990 Plate (for arm)
790-101-5021 Grip
01010-50816 Bolt
Disassembly
1. Piston rod assembly If the caulking of screw (3) is too strong and
it cannot be removed, tighten the screw fully,
1.1. Remove piping from cylinder assembly. then fit a tap to the thread and remove the
1.2. Remove mounting bolts and disconnect head screw.
assembly (1).
1.3. Pull out piston rod assembly (2).
Place a container under the cylinder to catch
the oil.
30-244 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of hydraulic cylinder
Using tool Q2, remove piston assembly (4). 2. Disassembly of piston assembly
When not using tool Q2, use the drill holes 2.1. Remove rings (11).
( ∅ 10, 4 places) and loosen the piston 2.2. Remove wear rings (12).
assembly.
2.3. Remove piston ring (13).
2.4. Remove O-ring and backup ring (14).
PW180-7E0 30-245
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of hydraulic cylinder
30-246 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of hydraulic cylinder
3.1. Set piston rod assembly (2) to tool Q1. When using rod piston (2) again:
Wash thoroughly and remove all metal parti-
cles and dirt.
3.6.1 Screw in piston assembly (4), then use tool Q2
to tighten piston assembly (2) so the position of
the screw thread hole matches
Remove all burrs and flashes with a file.
PW180-7E0 30-247
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of hydraulic cylinder
When using a new part for either or both of rod D. Tighten screw (3).
piston assembly (2)
Screw: 58.9 - 73.6 Nm {6 - 7 kgm}
For the rod with bottom cushion, mark the
cushion plug position on the end of the rod.
E. Caulk thread at 4 places with punch.
Arm cylinder only
A. Screw in until piston assembly (4) contacts end
face of rod, then use tool to tighten.
10.3 27 12 x 1.75 20
30-248 PW180-7E0
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of hydraulic cylinder
Mounting bolt:
PW180-7E0 30-249
DISASSEMBLY AND ASSEMBLY Removal and installation of monoboom work equipment
Removal
WARNING
7
● Extend the arm and bucket fully. Lower the
work equipment to the ground and set the
7 8
safety lock lever to the lock position
5
4
30-250 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of monoboom work equipment
11
WARNING
When aligning the position of the pin hole, never insert
your fingers into the pin hole.
12
15
PW180-7E0 30-251
DISASSEMBLY AND ASSEMBLY Removal and installation of monoboom work equipment
12
WARNING
When aligning the position of the pin hole, never insert
your fingers into the pin hole.
Bleeding air
Bleed the air from the cylinder. For details,
see TESTING AND ADJUSTING, Air Bleed-
ing of Various Parts.
Refilling with oil (hydraulic tank)
Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then check the oil level
again.
30-252 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of 2 piece boom work equipment
Removal
WARNING
● Extend the arm and bucket fully. Lower the 7
8
work equipment to the ground and set the
safety lock lever to the lock position. 7 8
1 12
5
3
When removing them, first remove plate (12) and
then remove pin (13) at the foot, using Tool R.
30-254 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of 2 piece boom work equipment
14
WARNING
When aligning the position of the pin hole, never insert
your fingers into the pin hole.
15
PW180-7E0 30-255
DISASSEMBLY AND ASSEMBLY Removal and installation of 2 piece boom work equipment
12
WARNING
When aligning the position of the pin hole, never insert
your fingers into the pin hole.
Bleeding air
Bleed the air from the cylinder. For details,
see TESTING AND ADJUSTING, Air Bleed-
ing of Various Parts.
Refilling with oil (hydraulic tank)
Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then check the oil level
again.
30-256 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of air conditioner unit
Removal
WARNING
First, disconnect the cable from the negative terminal
(-) of the battery.
30-258 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of air conditioner unit
12
7. Remove duct (6) on the right side. 10. Remove plate (11).
11
6
12
15
13
7
14
17
16
PW180-7E0 30-259
DISASSEMBLY AND ASSEMBLY Removal and installation of air conditioner unit
16. Disconnect connectors at the following seven 18. Remove the 8 mounting bolts (20) and remove
points. (Refer to TROUBLESHOOTING section air conditioner unit assembly (21) carefully.
on “CONNECTOR LOCATION CHART AND When removing the air conditioner unit
ELECTRICAL CIRCUIT DIAGRAM BY SYS- assembly, do not forget to disconnect the two
TEM” on page 221) air conditioner hoses connected to the bot-
D01 tom.
(Assembled-type diode connector)
D02 20 20 20 20
(Assembled-type diode connector)
C09 (Model selection switch connector)
Air conditioner unit connector
From top to bottom, M26, M27, M28 and
M33 option power source connector
17. Remove 2 hoses (18) and remove connector
(19).
21
20
19
18
20
30-260 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of air conditioner unit
Installation
Install in reverse order of removal.
Install hoses in the air conditioner circuit with
care so that dirt, dust, water, etc. may not enter
them.
Install air conditioner hoses only after checking
that an O-ring is in place at the connecting part.
Check that there is no damage on O-rings, or
that they have not deteriorated.
PW180-7E0 30-261
DISASSEMBLY AND ASSEMBLY Removal and installation of counterweight
1 3
30-262 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of counterweight
Installation
Install in reverse order of removal.
PW180-7E0 30-263
DISASSEMBLY AND ASSEMBLY Removal and installation of operator cab assembly
WARNING
● First, disconnect the cable from the negative
terminal (-) of the battery.
6
5 5
1
6
7
7
30-264 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of operator cab assembly
7. Disconnect hoses (8) from brake valve. 9. Remove 3 hoses (10) from engine and 1 hose
from the dryer (11).
8
10
8
8
10 11
9
12
12
9
13
9
9
13
PW180-7E0 30-265
DISASSEMBLY AND ASSEMBLY Removal and installation of operator cab assembly
15. Remove mounting bolts (13) and lift operator cab Installation
off. Install in reverse order of removal.
30-266 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of monitor assembly
2 4
30-268 PW180-7E0
DISASSEMBLY AND ASSEMBLY Removal and installation of monitor assembly
Installation
• Install in reverse order of removal.
PW180-7E0 30-269
DISASSEMBLY AND ASSEMBLY Removal and installation of pump controller assembly
5
1. Remove covers (1) by removing bolts (2).
6
2
1 4. Make sure controller is fully supported.
5. Remove bolts (7) then remove bolts (8).
1
1
7
30-270 PW180-7E0