33. UPPER SLEWING STRUCTURE 33.1.5 …. UPPER SLEWING STRUCTURE 33-17 33 (3)Removing control valve 33.1.7.3 INSTALLATION (1)Install the control valve in reverse order of the removal

33. UPPER SLEWING STRUCTURE

33-12

33.1.5 COUNTERWEIGHT

33.1.5.1 REMOVAL PREPARATION

33.1.5.2 REMOVAL

33.1.5.3 INSTALLATION

(1) Remove the cover assemblies (1), (3), (4) and (5)as well as the bonnet assembly (2) (See Section33.1.2).

(2) Lifting tools preparation-Lifting jigs for counterweight (see Tool list)-Two M20X35 screws (A)-Wire rope (Nylon sling)

(1) Remove the plate (9) and attach the lifting jigs forcounterweight.

(2) Put a rope through the lifting lugs and temporarilylift up the counterweight so that the rope is notslack.Counterweight weight: 370 kg (820 lbs) for CX31B665 kg (1,470 lbs) for CX36B

(3) Loosen one M20X90 capscrew (2) and twoM20X65 capscrews (3).Tools: Socket: 30 mm

(4) Remove the shims (5), (6) and (7).(5) Remove counterweight (1).

Counterweight removal

(1) Install the counterweight in reverse order of theremoval.

(2) Reinstall the shims (5), (6), and (7).(3) Lifting counterweight

Make sure that all the three fixing bolts can bemanually screwed.

(4) Apply Loctite #262 on the capscrews (2) and (3)and tighten them together with the washer (4).Tools: Socket: 30 mmTightening torque : 373 N-m (275 lbf-ft)

(5) Remove lifting jigs.

Counterweight installation

A

Lifting jig for counterweight

SLING

SCREW(A)

3 4

2

34

9

9

1

567

567

567


33-13

33

33.1.6 PUMP

33.1.6.1 REMOVAL PREPARATION

33.1.6.2 REMOVAL

(1) Remove the cover assembly (3) and (5) (SeeSection 33.1.2).

(2) Remove the counterweight (See Section 33.1.5).(3) Depressurize the hydraulic oil tank and drain the

hydraulic oil (See Section 33.1.12).-Spread a vinyl sheet under the pump to preventcontamination due to oil leakage.

(4) Loosen clip (B38) to remove the filler neck (B1) ofthe fuel supply port to improve workability.Two sems-bolts M8X20 (B39)Tools: Socket: 13 mmTightening torque : 23.5 N-m (17 lbf-ft) Filler neck removal

(1) Disconnecting hoses and fittings connected to thepump-Attach a tag to each hose for identification.1. Loosen four M12X35 capscrews (19) to removethe tube (14).Tools: Allen wrench: 10 mm2. Remove the pilot delivery hose (B23).Tools: Spanner: 22 mm3. Remove the main pump delivery hoses (8), (9)and (10).Tools: Spanner: 27 mm

(2) Loosen two M12X30 capscrews (C4) to remove thepump (C8).Tools: Allen wrench: Ball joint type 10 mmPump weight: 28 kg (62 lbs)

Pump removal

��

��

��

C/VP1

C/VP2

C/VP3

A1

A2 A3

14

19

12

108

9

25

25C4C8

ZA4B23

S/VP1


33-14

33.1.6.3 INSTALLATIONInstall the pump in reverse order of the removal according to the tightening torque and sealant instructions.(1) Apply grease to the spline part of the pump input shaft.

Grease : Shell Retinax AM Grease or equivalent (Molybdenum disulfide extreme pressure multipurpose grease)(2) Insert the pump spline part to the coupling.(3) Fix the pump by the capscrew (C4).

Tools: Allen wrench: Ball joint type 10 mm(4) Install the main pump delivery hoses (8), (9), and (10), and the pilot delivery hose (B23) (See Fig. "Pump

rermoval").

(5) Tighten the capscrew (19) to install the suction tube (14).Tools: Allen wrench: 10 mm

(6) When the suction hose (12) is removed, apply sealant on the inserted portion of the hose and fix the tube withthe clip (25).Tools: slotted screwdriverT=5.4 N-m (4.0 lbf-ft)

(7) Supply the tank with hydraulic oil [approximately 38 liters (10 gal)].(8) Loosen the air bleed valve of the pump to release air from the casing, and fill it with hydraulic oil (See Fig.

"Pump installation").Tools: Spanner: 10 mm

(9) Reinstall each component removed in the above removal preparation.(10)After starting the engine, release air (See Section 33.1.11.3).

Pump installation

73.5 (54)108 (80)

49.0 (36)78.5 (58)

Thread size

(PF)

Spanner used(mm)

2227

3/81/2

O-ring type fitting

flare type fitting

Tightening torque N m (lbf ft)


33-15

33

33.1.7 CONTROL VALVE

33.1.7.1 REMOVAL PREPARATION(1) Unlock and open the right upper cover (1).(2) Remove the right lower cover (4) [See Section 33.1.2.1-(3)].

-Spread a vinyl sheet under the control valve to prevent contamination due to oil leakage.(3) Release the residual pressure in the circuit and the pressure in the hydraulic oil tank.

33.1.7.2 REMOVAL(1) Disconnecting hoses

Disconnect all the hoses connecting to the control valve, and attach blind plugs and tags recording theinstallation place.-Remove the return hose to the hydraulic oil tank to improve workability.

Main hydraulic hose disconnection

S/JE

S/JF

S/JB

S/JA

S/JC

S/MB

S/MA

ARM(R)

ARM(H)

BUCKET(H)

BUCKET(R)

BOOM(R)

BOOM(H)

B1B2

B3

B7

B8

B9

B10

A10

A7

A5

A3

A2

A1

A6

SW/CYL(H)

A17

SEL/V

B8

A10

A10

A18

N&B(R)

B7A9

A10A15

A12

A5A8 A15

A7

A7

S/JDB5B6

SW/CYL(R)

A6

A14

H/P : Hydraulic pump

S/J : Swivel joint

S/M : Slewing motor

8

H/PA3

H/PA2

H/P

P1P2

P3

9

10

A1

21

23

24

COOLER OIL(UPPER)

S/MMHYDRAULIC TANK

T2

Dr1

T1

B4

A4


33-16

Pilot hydraulic hose disconnection

P/V8

2P/V

4

P/V1

P/V2

P/V3

P/V7

1

S/V

S/V

C5

D4E6

D8

D5

Pb10

Pa10

Pb8

Pb8'

Pa8

Pa7Pa6

Pa4Pa5Pa3 Pa2

Pa1 A2

Pb7 Pb6Pb5

Pb4

Pb3 Pb2

A1

Pb1

Pp1

C9

D1

D7

E7

D3

D6

C9

D2

P/V(N&B)

P/V(N&B)

P/V : Pilot valveC/B : Control blockSHUT/V : Shuttle valveS/V : Solenoid valve

A7 A14

F12

A8

A15

B26

F13

B27

B28

B39

SHUT/VB

SHUT/VASHUT/V

C

F10

S/V B1

S/MPG

B27

SLEW/SWINGS/V

SLEW/SWINGS/V

A1

P/V1

P/V2

P/V3

P/V4

Pb7 Pb6

Pb2

Pa2

A2

Pa6Pa7

Pa3

Pp1

P/V2

Pa1

P/V1

9

8

Pb1

F11

S/VB2


33-17

33

(3) Removing control valve

33.1.7.3 INSTALLATION(1) Install the control valve in reverse order of the removal.(2) Attach the capscrews (4).

Tools: Socket: 17 mmTightening torque : 65.7 N-m (48 lbf-ft)

Clean the mounting surface and take care to prevent deformation of the valve.

(2) Disconnecting cableTurn the rod end (B14) to disconnect the controlvalve from the swing cable (B4).

Cable disconnection

1. Loosen four M10X50 capscrews (2) to remove thecontrol valve (10) with the bracket (1).Tools: Socket: 17 mmWeight of removed parts : Approximately 33 kg (73lbs)

2. Loosen three M10X25 capscrews (4) to remove thecontrol valve (10).Tools: Socket: 17 mmWeight: Approximately 25 kg (55 lbs)

Control valve removal

CONTROL VALVE

B14

B4

A

8 9 7 6 3 52

1

10

4


33-18

(3) Attach the capscrew (2).Tools: Socket: 17 mmTightening torque : 65.7 N-m (48 lbf-ft)

(4) Tighten the hose fittings to the following torque :

(5) Operate the attachment to check the performance.(6) Check the tank and piping for oil leakage and oil level.

Control valve

Thread size

(PF)

Spanner used(mm)

O-ring type fitting

flare type fitting

36.3 (26)73.5 (54)108 (80)162 (119)255 (188)

29.4 (22)49 (36)

78.5 (58)118 (87)

1922273641

1 / 43 / 81 / 23 / 4

1


VIEW A

2

1

10

Dozer

SlewingSupply andTravel straight

ArmService (N&B)

SwingTravel (right)

BucketBoom lock

BoomTravel (left)

Supply


33-19

33

33.1.8 SOLENOID VALVE

33.1.8.1 REMOVAL PREPARATION(1) Unlock and open the right upper cover (1).(2) Remove the right lower cover (4) [See Section 33.1.2.1-(3)].

33.1.8.2 REMOVAL

33.1.8.3 INSTALLATION(1) Install the solenoid valve in reverse order of the removal.

Tighten the fittings at the following torque:

(1) Disconnecting hosesDisconnect all the hoses connected to the solenoidvalve (B1). Then attach a plug and a tag recordingthe connecting port to each of their openings.-Item (B32) is a drain hose for the hydraulic oil tank.When disconnecting this hose, take care of oilleakage.

(2) Disconnecting connectorDisconnect two connectors connected to the mainharness.

(3) Removing solenoid valveLoosen two M8X20 capscrews (B5) to remove thesolenoid valve (B1).Tools: Spanner: 13 mm

Solenoid valve removal

TorqueN m (lbf ft)

33.3 (25)

2.94 (2.2)

Tool (mm)

13Capscrew (M8)

Clip

B5

B33

65.7 (48)17Capscrew (M10)B34

Item Name

19

22

1/4

3/8


Thread size

(PF)

Spanner used(mm)

O-ring type fitting

flare type fitting

36.3 (27)

73.5 (54)

29.4 (22)

49 (36)


33-20

33.1.9 MULTI-CONTROL VALVE

33.1.9.1 REMOVAL PREPARATION(1) Unlock and open the right upper cover (1).(2) Remove the right lower cover (4). [See Section 33.1.2.1-(3)](3) Release the residual pressure in the piping and hydraulic oil tank.

33.1.9.2 REMOVAL(1) Disconnecting hoses

Disconnect all the hoses connected to the multi-control valve. Then attach plugs and tags recording theconnecting ports to each of their openings.

Hose removal

33.1.9.3 INSTALLATION(1) Install the multi-control valve in reverse order of the removal.

Tighten the fittings at the following torque :

(2) Removing multi-control valveLoosen four M8X16 capscrews (2) to remove multi-control valve (1).Tools: Spanner: 13 mm

Multi-control valve removal

2

1Hydraulictank

TorqueN m (lbf ft)

33.3 (3.4)

Tool (mm)

13Capscrew (M8)2

Item Name

14/191/8


Thread size

(PF)

Spanner used(mm)

O-ring type fitting

flare type fitting

16.7 (1.7) 29.4 (3.0)


33-21

33

33.1.10 FUEL TANK

33.1.10.1 DISASSEMBLY PREPARATION(1) Remove the floor mats (5) and (8), the floor covers

(2) and (4), and the floor plate (1) (See Section 33.1.3.1).

(2) Remove the cover assembly (5) on the left lowerside[See Section 33.1.2.1-(4)].

(3) Remove the battery(See Section 33.1.4.2).

(4) Remove the stopper plate (6) of the battery (1) (See Fig. "Battery removal").Two M10X20 capscrews (2)Tools: Spanner: 17 mmTightening torque : 52 N-m (38lbf-ft)

Fuel drain


33-22

33.1.10.2 DISASSEMBLY(1) Open the fuel filler cap (B2) and loosen the drain plug (B11) to drain fuel.

Tank capacity : 38 liters (10 gal)(2) Disconnect the hoses (2) and (3) for the fuel inlet and outlet, the hose (B4) for the fuel supply port, and two air

bleed hoses.(3) Loosen the M10X20 sems-bolt (B10) to remove the boss (B12) together with the drain hose (B13).

Tools: Socket: 17 mm(4) Disconnect connector (A13) for the level sensor.(5) Remove two M10X20 sems-bolts (B8).

Tools: Spanner: 17 mm(6) Remove the fuel tank (A1) together with the bracket assembly (B15).

33.1.10.3 INSTALLATION

Fuel tank removal

Assemble the fuel tank in reverse order of the removaland tighten the screws to the specified torque shown inthe following table:

2

3

A1

Disconnect air bleed hose at this point

AIR BLEED HOSE

B2

A13 A1

B11

B12

B13

B10B15

B8

B4

B38

TorqueN m (lbf ft)

46.1 (34)

34 (25)

0.49 0.78

(0.36 0.58)

Capscrew (M10)

Sems-bolt (M10)

B8

B10

Item NameTool (mm)

17

17

B38 Clip


33-23

33

33.1.11 HYDRAULIC OIL TANK

33.1.11.1 DISASSEMBLY PREPARATION

Press and hold the boot until air-relieving sound stops.

(7) Remove the control valve (See Section 33.1.7.2).(8) Remove the solenoid valve (See Section 33.1.8.2).(9) In addition, remove the harness and hose clamped on the tank.

-Remove the multi-control valve (option) if it is equipped.

(1) Swing approximately 90 degrees to the right tofacilitate to remove the tank.

(2) Unlock and open the right upper cover (1).(3) Remove the right lower cover (4) [See Section

33.1.2.1-(3)].(4) Remove the floor cover (2) (See Section 33.1.3.1).(5) Remove the inspection cover (1-5) of the control

stand.Six M8X20 sems-bolts (1-8)Tools: Socket: 13 mm

Cover removal

(6) After releasing internal pressure of the hydraulic oiltank, remove the plug (B14) below the solenoidvalve to drain hydraulic oil.Tools: Socket: 22 mmTank capacity : 38 liters (10 gal)-Spread a vinyl sheet under the solenoid valve toprevent contamination around the valve due to oilleakage.-Releasing tank pressurePress the cap boot of breather assembly (A15) witha finger to release the internal pressure (See Fig."Suction hose removal").

Draining hydraulic oil

Documents

33. UPPER SLEWING STRUCTURE 33.1.5 …. UPPER SLEWING STRUCTURE 33-17 33 (3)Removing control valve 33.1.7.3 INSTALLATION (1)Install the control valve in reverse order of the removal