Hyundai R80-7 User manual

SERVICE MANUAL
HYUNDAI
EXCAVATOR
R80-7

http://marengine.com/r80-7-excavator

CONTENTS
SECTION 1 GENERAL
Group 1 Safety Hints
---------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications
-------------------------------------------------------------------------------------------------
1-9
SECTION 2 STRUCTURE AND FUNCTION
Group 1 Pump Device ------------------------------------------------------------------------------------------------- 2-1
Group 2 Main Control Valve ----------------------------------------------------------------------------------------- 2-9
Group 3 Swing Device ------------------------------------------------------------------------------------------------- 2-28
Group 4 Travel Device -------------------------------------------------------------------------------------------------- 2-38
Group 5 RCV Lever ----------------------------------------------------------------------------------------------------- 2-45
Group 6 RCV Pedal ----------------------------------------------------------------------------------------------------- 2-52
SECTION 3 HYDRAULIC SYSTEM
Group 1 Hydraulic Circuit --------------------------------------------------------------------------------------------- 3-1
Group 2 Main Circuit ---------------------------------------------------------------------------------------------------- 3-2
Group 3 Pilot Circuit -----------------------------------------------------------------------------------------------------
3-5
Group 4 Single Operation -------------------------------------------------------------------------------------------- 3-10
Group 5 Combined Operation ------------------------------------------------------------------------------------- 3-22
SECTION 4 ELECTRICAL SYSTEM
Group 1 Component Location ------------------------------------------------------------------------------------- 4-1
Group 2 Electrical Circuit --------------------------------------------------------------------------------------------- 4-3
Group 3 Electrical Component Specification --------------------------------------------------------------- 4-23
Group 4 Connectors ---------------------------------------------------------------------------------------------------- 4-31
SECTION 5 MECHATRONICS SYSTEM
Group 1 Outline ------------------------------------------------------------------------------------------------------------ 5-1
Group 2 Mode Selection System -------------------------------------------------------------------------------- 5-3
Group 3 Travel Speed Control System ------------------------------------------------------------------------ 5-4
Group 4 Automatic Warming Up Function
------------------------------------------------------------------ 5-5
Group 5 Engine Overheat Prevention Function ---------------------------------------------------------- 5-6
Group 6 Anti-Restart System -------------------------------------------------------------------------------------- 5-7
Group 7 Self-Diagnostic System --------------------------------------------------------------------------------- 5-8
Group 8 Engine Control System --------------------------------------------------------------------------------- 5-10

Group 9 Monitoring system ------------------------------------------------------------------------------------------ 5-16
SECTION 6 TROUBLESHOOTING
Group 1 Before Trobleshooting ------------------------------------------------------------------------------------ 6-1
Group 2 Hydraulic and Mechanical System ---------------------------------------------------------------- 6-4
Group 3 Electrical System ------------------------------------------------------------------------------------------- 6-24
Group 4 Mechatronics System ------------------------------------------------------------------------------------ 6-40
SECTION 7 MAINTENANCE STANDARD
Group 1 Operational Performance Test ----------------------------------------------------------------------- 7-1
Group 2 Major Components ---------------------------------------------------------------------------------------- 7-20
Group 3 Track and Work Equipment --------------------------------------------------------------------------- 7-28
SECTION 8 DISASSEMBLY AND ASSEMBLY
Group 1 Precaution ------------------------------------------------------------------------------------------------------
8-1
Group 2 Tightening Torque ------------------------------------------------------------------------------------------ 8-4
Group 3 Pump Device ------------------------------------------------------------------------------------------------- 8-7
Group 4 Main Control Valve ---------------------------------------------------------------------------------------- 8-25
Group 5 Swing Device ------------------------------------------------------------------------------------------------- 8-37
Group 6 Travel Device
------------------------------------------------------------------------------------------------- 8-58
Group 7 RCV Lever
----------------------------------------------------------------------------------------------------- 8-83
Group 8 Turning Joint -------------------------------------------------------------------------------------------------- 8-98
Group 9 Boom, Arm and Bucket Cylinder
------------------------------------------------------------------- 8-103
Group 10 Undercarriage
------------------------------------------------------------------------------------------------ 8-121
Group 11 Work Equipment -------------------------------------------------------------------------------------------- 8-133
SECTION 9 COMPONENT MOUNTING TORQUE
Group 1 Introduction Guide -----------------------------------------------------------------------------------------
9-1
Group 2 Engine System
----------------------------------------------------------------------------------------------
9-2
Group 3 Electric System
---------------------------------------------------------------------------------------------- 9-4
Group 4 Hydraulic System ------------------------------------------------------------------------------------------- 9-6
Group 5 Undercarriage ------------------------------------------------------------------------------------------------ 9-8
Group 6 Structure -------------------------------------------------------------------------------------------------------- 9-9
Group 7 Work Equipment -------------------------------------------------------------------------------------------- 9-13

0-1
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
SECTION 1 GENERAL
This section explains the safety hints and gives the specification of the machine and major
components.
SECTION 2 STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
SECTION 3 HYDRAULIC SYSTEM
This section explains the hydraulic circuit, single and combined operation.
SECTION 4 ELECTRICAL SYSTEM
This section explains the electrical circuit, monitoring system and each component. It serves not
only to give an understanding electrical system, but also serves as reference material for trouble
shooting.
SECTION 5 MECHATRONICS SYSTEM
This section explains the computer aided power optimization system and each component.
SECTION 6 TROUBLESHOOTING
This section explains the troubleshooting charts correlating problems to causes.
SECTION 7 MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
SECTION 8 DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
SECTION 9 COMPONENT MOUNTING TORQUE
This section shows bolt specifications and standard torque values needed when mounting
components to the machine.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.

0-2
Revised edition mark(
①②③… )
When a manual is revised, an edition mark is
recorded on the bottom outside corner of the
pages.
R
Revisions
Revised pages are shown at the list of revised
pages on the between the contents page and
section 1 page.
Symbols
So that the shop manual can be of ample
practical use, important places for safety and
quality are marked with the following symbols.
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating
Any additions, amendments or other changes will
be sent to HYUNDAI distributors.
Get the most up-to-date information before you
start any work.
Filing method
See the page number on the bottom of the
page.
File the pages in correct order.
Following examples shows how to read the
page number.
Example 1
2 - 3
Item number(2. Structure and
Function)
Consecutive page number for
each item.
Additional pages : Additional pages are
indicated by a hyphen(-) and number after the
page number. File as in the example.
1.
2.
3.
Symbol Item Remarks
Special safety precautions are
necessary when performing the
work.
Extra special safety precautions
are necessary when performing
the work because it is under
internal pressure.
Special technical precautions or
other precautions for preserving
standards are necessary when
performing the work.
Safety
Caution
※
10 - 4
10 - 4 - 1
10 - 4 - 2
10 - 5
Added pages

0-3
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
Method of using the Conversion Table to convert from millimeters to inches
Convert 55
mm
into inches.
Locate the number 50
in the vertical column at the left side, take this as ⓐ , then draw a
horizontal line from
ⓐ .
Locate the number 5
in the row across the top, take this as ⓑ , then draw a perpendicular line
down from
ⓑ .
Take the point where the two lines cross as
ⓒ . This point ⓒ gives the value when converting
from millimeters to inches. Therefore, 55
mm = 2.165 inches.
Convert 550
mm into inches.
The number 550 does not appear in the table, so divide by 10(Move the decimal point one place
to the left) to convert it to 55
mm .
Carry out the same procedure as above to convert 55mm to 2.165 inches.
The original value(550
mm ) was divided by 10, so multiply 2.165 inches by 10(Move the decimal
point one place to the right) to return to the original value.
This gives 550
mm = 21.65 inches.
1.
2.
(1)
(2)
(3)
(1)
(2)
(3)
Millimeters to inches 1
mm = 0.03937 in
ⓑ
ⓐ
01 2 345 678 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
ⓒ

0-4
Millimeters to inches 1
mm = 0.03937 in
01 2 345 678 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound 1
kg = 2.2046 lb
01 2 345 678 9
0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.5. 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

0-5
Liter to U.S. Gallon 1
ℓ = 0.2642
U.S.Gal
01 2 345 678 9
0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.631 25.625 25.889 26.153
Liter to U.K. Gallon 1
ℓ = 0.21997 U.K.Gal
01 2 345 678 9
0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

0-6
kgf·m to lbf·ft
1
kgf·m = 7.233 lbf·ft
01 2 345 678 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 10005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

0-7
kgf/cm2 to lbf/in2
1 kgf / cm2 = 14.2233 lbf / in
2
01 2 345 678 9
14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 5603 2617 2631 2646 2660 2674 2688
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

SECTION 8 DISASSEMBLY AND ASSEMBLY
Group 1 Precaution ------------------------------------------------------------------------------------------------------ 8-1
Group 2 Tightening Torque ------------------------------------------------------------------------------------------ 8-4
Group 3 Pump Device ------------------------------------------------------------------------------------------------- 8-7
Group 4 Main Control Valve ----------------------------------------------------------------------------------------- 8-25
Group 5 Swing Device ------------------------------------------------------------------------------------------------- 8-37
Group 6 Travel Device
-------------------------------------------------------------------------------------------------- 8-58
Group 7 RCV Lever
------------------------------------------------------------------------------------------------------ 8-83
Group 8 Turning Joint --------------------------------------------------------------------------------------------------- 8-98
Group 9 Boom, Arm and Bucket Cylinder ------------------------------------------------------------------- 8-103
Group 10 Undercarriage ------------------------------------------------------------------------------------------------ 8-121
Group 11 Work Equipment -------------------------------------------------------------------------------------------- 8-133

1. REMOVAL WORK
Lower the work equipment completely to the ground.
If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the
necessary places before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws alternately.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
When removing hydraulic equipment, first release the remaining pressure inside the hydraulic tank
and the hydraulic piping.
If the part is not under hydraulic pressure, the following corks can be used.
8-1
SECTION 8 DISASSEMBLY AND ASSEMBLY
06
08
10
12
14
16
18
20
22
24
27
6
8
10
12
14
16
18
20
22
24
27
5
6.5
8.5
10
11.5
13.5
15
17
18.5
20
22.5
8
11
12
15
18
20
22
25
28
30
34
GROUP 1 PRECAUTIONS
1)
2)
3)
4)
5)
6)
7)
8)
9)
Nominal
number
Dimensions
DdL
10)
11)
12)
Taper 1/8
øD
L
ød

8-2
2. INSTALL WORK
Tighten all bolts and nuts(Sleeve nuts) to the specified torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pin or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2-3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with antifriction compound(LM-P).
After installing snap rings, check that the snap ring is fitted securely in the ring groove(Check that
the snap ring moves in the direction of rotation).
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
When using eyebolts, check that there is no deformation or deterioration, and screw them in fully.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
When operating the hydraulic cylinders for the first time after repairing and reassembling the
hydraulic cylinders, pumps, or other hydraulic equipment or piping, always bleed the air from the
hydraulic cylinders as follows:
Start the engine and run at low idling.
Operate the control lever and actuate the hydraulic cylinder 4-5 times, stopping 100
mm before the
end of the stroke.
Next, operate the piston rod to the end of its stroke to relieve the circuit. (The air bleed valve is
actuated to bleed the air.)
After completing this operation, raise the engine speed to the normal operating condition.
If the hydraulic cylinder has been replaced, carry out this procedure before assembling the rod to
the work equipment.
Carry out the same operation on machines that have been in storage for a long time after
completion of repairs.
10)
11)
12)
13)
14)
1)
2)
3)
4)
5)
6)
7)
8)
9)
(1)
(2)
(3)
(4)
※
※

8-3
3. COMPLETING WORK
If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
Add the specified amount of grease(Molybdenum disulphied grease) to the work equipment related
parts.
1)
2)
3)
4)

1. REMOVAL AND INSTALL
REMOVAL
Lower the work equipment to the ground
and stop the engine.
Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping
Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious
injury.
Loosen the drain plug under the hydraulic
tank and drain the oil from the hydraulic
tank.
· Hydraulic tank quantity : 75 ℓ
Disconnect hoses(4) and remove connec-
tors(3).
Disconnect pilot line hoses(6,8) and
remove connectors(5,7).
Remove socket bolts(2) and disconnect
pump suction tube(1).
When pump suction tube is disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.
Sling the pump assembly and remove the
pump mounting bolts.
· Weight : 50 kg (110 lb )
Pull out the pump assembly from housing.
When removing the pump assembly,
check that all the hoses have been
disconnected.
8-7
G
GROUP 3 PUMP DEVICE
1
2
A2
A1
3
S
4
R1
PP
5
8
7
6
1)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
※
(8)
※
13031GE18
7078MP101

8-10
NECESSARY TOOLS AND JIGS
The following tools and jigs are necessary to disassemble and assemble the pump.
Tools
2)
(1)
Jigs (2)
Name
Hexagon socket screw keys
Spanner
Screwdrivers for slotted-head screws
Pliers for retaining rings
Grease
Adhesive
Plastic hammer
6, 8, 10, 12 mm
14, 17, 24, 27
Middle
Bore use 80
-
Three Bond #1305
Medium size
Size(nominal)
70
7078MP50
This is a table to stand the pump facing downward
CAUTIONS DURING DISASSEMBLING AND ASSEMBLING
Cautions for disassembling
Never attempt operating the adjusting screws unless absolutely necessary.
Take utmost care during disassembly not to knock or drop each part.
Cautions for assembling
Wash each part thoroughly.
During assembling take utmost care not to damage the part or allow foreign materials to enter.
As a rule the O-ring and oil seal should not be reused.
In our assembly work the torque wrench is used to control the torque.
Be sure to use the torque wrench.
3)
(1)
①
②
(
(2)
①
②
③
④
Ø 220 or more
Ø 130

1. REMOVAL AND INSTALL
BUCKET CYLINDER
Removal
Expand the arm and bucket fully, lower the
work equipment to the ground and stop
the engine.
Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
Loosen the breather slowly to release
the pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering.
Set block between bucket cylinder and
arm.
8-103
GROUP 9 BOOM, ARM AND BUCKET CYLINDER
1)
①
(
(1)
※
※
※
Disconnect bucket cylinder hoses(4) and
put plugs(5) on cylinder pipe.
③
Remove bolt(2), nut(3) and pull out pin
(1).
Tie the rod with wire to prevent it from
coming out.
②
※
Wooden block
Arm
Bucket Cylinder
3
2
1
4
4
5
13031GE18
R5577CY02
R5577CY03
R5577CY04

8-104
Install
Carry out installation in the reverse order
to removal.
When aligning the mounting position
of the pin, do not insert your fingers in
the pin hole.
Bleed the air from the bucket cylinder.
Confirm the hydraulic oil level and check
the hydraulic oil leak or not.
8
6
5
①
※
※
(
(2)
Sling bucket cylinder assembly(8) and
remove bolt(6) then pull out pin (5).
Remove bucket cylinder assembly(8).
· Weight : 50 kg (110 lb )
④
⑤
R5577CY05

8-125
DISASSEMBLY AND ASSEMBLY OF IDLER
Structure
(1)
3)
1 Shell
2 Shaft
3 Seal assembly
4 Bushing
5 Bracket
6 O-ring
7 Spring pin
8 Plug
1
4
3
8
7
5
4
3
7
6
2
5
6
21078DA43