50 Disassembly and assembly SEN

Transcription

1 50 Disssembly nd ssembly SEN Disconnect filter (5). 8. Disconnect clmp (6). 14. Disconnect rditor lower hoses (13) (15). [*1] 9. Disconnect filter (7). Disconnect the hose clmp. 15. Disconnect ir hoses (16) nd (17). [*2] Mke mrk t the hose end of ech tube to indicte the connecting position. 10. Lift off engine hood (8). 16. Remove tube (18). 17. Disconnect ir hose (19). [*3] Mke mrk t the hose end of the tube to indicte the connecting position. 18. Disconnect reservoir tnk hose (20). 19. Disconnect rditor hoses (21) nd (22). [*4] 11. Open rditor grille (9) nd sling it temporrily. 12. Lift off rditor grille (9). 13. Remove cover (10). PC800,

2 SEN Disssembly nd ssembly 20. Remove 3 covers (23) nd cover (24). 21. Disconnect connector (25) from (B). 24. Disconnect 2 ir conditioner hoses (29). [*5] 25. Disconnect clmps (30). 22. Disconnect 3 hoses (26) nd 2 hoses (27). Prepre n oil receiver. 26. Disconnect clmps (31). 27. Disconnect 2 fuel hoses (32). 23. Lift off frme (28). AC: Air conditioner condenser, FC: Fuel cooler 12 PC800, 850-8

3 50 Disssembly nd ssembly SEN Disconnect connector (33). 29. Disconnect clmp (34). Instlltion Crry out instlltion in the reverse order to removl. [*1] Hose insertion depth: 65 mm 3 Rditor hose clmp: Nm { kgm} 30. Sling cooling ssembly (36) temporrily nd remove 4 mounting bolts (35) on the right nd left sides. [*2], [*3] MIKALOR clmp Use new MIKALOR clmp. 1) Set the hose to the originl position. (Insertion depth of ir hose: 80 mm) 2) Set the bridge (BR) under the clmp bolt nd lp it over bnd (BD) t lest (b) reches 5 mm. 3) Tightening of the clmp. Do not use n impct wrench. 2 Clmp bolt (BC): Lubricting oil (THREE- BOND PANDO 18B) When reusing the hose Instll the clmp to the clmp mrk mde on the hose. 3 Clmp bolt (BC): Min. 6 Nm {0.6 kgm}. When using new hose Tighten until dimension (BDG) is 7 10 mm. 31. Lift off cooling ssembly (36). 4 Cooling ssembly: 1,020 kg PC800,

4 SEN Disssembly nd ssembly [*4] Hose insertion depth: 70 mm 3 Rditor hose clmp: Nm { kgm} [*5] Instll ech hose so tht it will not be twisted. When instlling the ir conditioner hoses, tke cre tht dirt, dust, wter, etc. will not enter them. When tightening ech joint of the ir conditioner hose, check tht O-ring (70) is fitted to it. Apply sufficient mount of compressor oil for R134 [DENSO: ND-OIL8, ZEXEL: ZXL100PG (euivlent to PAG46) ] to ech O-ring. Refilling with compressor oil If ny ir conditioner hose ws replced, dd compressor oil for R134 (DENSO: ND-OIL8, ZEXEL: ZXL100PG (euivlent to PAG46)) to the ir conditioner compressor by the following untity. (If the compressor oil is dded too much, the cooling performnce lowers. Tke cre.) 5 Air conditioner compressor: Compressor oil for R134 [DENSO: ND-OIL8, ZEXEL: ZXL100PG (euivlent to PAG46) ] : 45 ml compressor nd condenser) : 30 ml condenser nd receiver drier) : 21 ml receiver drier nd ir conditioner unit) : 80 ml compressor nd ir conditioner unit) 3 Tightening torue for ir conditioner refrigernt piping Since the compressor oil for R134 bsorbs moisture very esily, put the cp on the oil continer to shut off ir immeditely fter supplying the oil. The compressor oil for R134 cn dissolve crylic resin nd polystyrene. Tke cre. Thred size Tightening torue Nm { kgm} Nm { kgm} Nm { kgm} Refilling with oil Add oil through the oil filler to the specified level. Run the engine to circulte the oil through the system. Then, check the oil level gin. Filling ir conditioner circuit with refrigernt (R134) Fill the ir conditioner circuit with refrigernt (R134). Quntity: 1,330 ± 50 g 5 Hydrulic tnk: 470 l Refilling with coolnt Add coolnt through the coolnt filler to the specified level. Run the engine to circulte the coolnt through the system. Then, check the coolnt level gin. 5 Coolnt: 100 l Bleed ir from the fuel system. For detils, see Testing nd djusting, Bleeding ir from fuel circuit. 14 PC800, 850-8

5 50 Disssembly nd ssembly SEN Removl nd instlltion of ftercooler ssembly 1 Removl k Lower the work euipment to the ground nd stop the engine. 1. Open rditor grille (1) nd lift it off. 4. Lift off frme (4). 5. Sling ftercooler ssembly (5) temporrily. 6. Remove the mounting bolts. While disconnecting ftercooler ssembly (5) from the rubber hose, lift it off. 4 Aftercooler ssembly: 45 kg 2. Remove 3 rditor upper covers (2). 3. Loosen clmps (3) of the rubber hose. [*1] Mke mrk t the tube of ech hose end to indicte the connecting position. (See the following figure.) PC800,

6 SEN Disssembly nd ssembly Instlltion Crry out instlltion in the reverse order to removl. [*1] MIKALOR clmp Use new MIKALOR clmp. 1) Set the hose to the originl position. (Insertion depth of ir hose: 80 mm) 2) Set the bridge (BR) under the clmp bolt nd lp it over bnd (BD) t lest (b) reches 5 mm. 3) Tightening of the clmp. Do not use n impct wrench. 2 Clmp bolt (BC): Lubricting oil (THREEBOND PANDO 18B) When reusing the hose Instll the clmp to the clmp mrk mde on the hose. 3 Clmp bolt (BC): Min. 6 Nm {0.6 kgm} When using new hose Tighten until dimension (BDG) is 7 10 mm. 16 PC800, 850-8

7 50 Disssembly nd ssembly SEN Removl nd instlltion of fuel cooler nd ir conditioner condenser ssembly 1 2. Open rditor grille (2). k Lower the work euipment to the ground nd stop the engine. k Loosen the cp of the hydrulic tnk grdully to relese the internl pressure of the hydrulic tnk. k Disconnect the cble from the negtive ( ) terminl of the bttery. k In the cse tht you do not drin the coolnt, if you disconnect the heter hose when the coolnt temperture in the rditor is high, you my be sclded. In this cse, wit until the coolnt temperture lowers nd then disconnect the heter hose. k Collect the ir conditioner refrigernt (R134) from the ir conditioner circuit in dvnce. Ask professionl trders for collecting nd filling opertion of refrigernt (R134). Never relese the refrigernt (R134) to the tmosphere. 3. Remove fuel cooler gurd (3). 4. Disconnect fuel cooler hoses (4) nd (5). 5. Remove fuel cooler (6). k If refrigernt gs (R134) gets in your eyes, you my lose your sight. Accordingly, put on protective goggles while you re collecting the refrigernt (R134) or filling the ir conditioner circuit with the refrigernt (R134). Collecting nd filling work must be conducted by ulified person. Before disconnecting ech hose, mrk it with tg etc. to indicte its position. Instll oil stopper plugs to the disconnected tubes nd hoses. 1. Close fuel tnk vlve (1). 6. Disconnect clmps (7). 7. Disconnect ir conditioner condenser hoses (8) nd (9). [*1] 8. Remove ir conditioner condenser (10). PC800,

8 SEN Disssembly nd ssembly Instlltion Crry out instlltion in the reverse order to removl. [*1] Instll ech hose so tht it will not be twisted. When instlling the ir conditioner hoses, tke cre tht dirt, dust, wter, etc. will not enter them. When tightening ech joint of the ir conditioner hose, check tht O-ring (70) is fitted to it. Apply sufficient mount of compressor oil for R134 [DENSO: ND-OIL8, ZEXEL: ZXL100PG (euivlent to PAG46) ] to ech O-ring. 3 Tightening torue for ir conditioner refrigernt piping Thred size Tightening torue Nm { kgm} Nm { kgm} Nm { kgm} Refilling with compressor oil If the ir conditioner condenser ws replced, dd compressor oil for R134 (DENSO: ND-OIL8, ZEXEL: ZXL100PG (euivlent to PAG46)) to the ir conditioner compressor by 40 ml. (If the compressor oil is dded too much, the cooling performnce lowers. Tke cre.) 5 Air conditioner compressor: Compressor oil for R134 [DENSO: ND-OIL8, ZEXEL: ZXL100PG (euivlent to PAG46), 40 ml] If ny ir conditioner hose ws replced, dd compressor oil for R134 (euivlent to PAG46) (DENSO: ND-OIL8, ZEXEL: ZXL100PG) to the ir conditioner compressor by the following untity. (If the compressor oil is dded too much, the cooling performnce lowers. Tke cre.) 5 Air conditioner compressor: Compressor oil for R134 [DENSO: ND-OIL8, ZEXEL: ZXL100PG (euivlent to PAG46) ] : 45 ml compressor nd condenser) : 30 ml condenser nd receiver drier) : 21 ml receiver drier nd ir conditioner unit) : 80 ml compressor nd ir conditioner unit) Filling ir conditioner circuit with refrigernt (R134) Fill the ir conditioner circuit with refrigernt (R134). Quntity: 1,330 ± 50 g Since the compressor oil for R134 bsorbs moisture very esily, put the cp on the oil continer to shut off ir immeditely fter supplying the oil. The compressor oil for R134 cn dissolve crylic resin nd polystyrene. Tke cre. 18 PC800, 850-8

9 50 Disssembly nd ssembly SEN Removl nd instlltion of fn motor ssembly 1 Removl k Lower the work euipment to the ground nd stop the engine. k Loosen the cp of the hydrulic tnk grdully to relese the internl pressure of the hydrulic tnk. k Disconnect the cble from the negtive ( ) terminl of the bttery. 6. Remove 3 covers (3). Remove the rer side, too. 7. Open engine hood (4). Open the rer side, too. 1. Remove the counterweight ssembly. For detils, see Removl nd instlltion of counterweight ssembly. 2. Remove undercover (1). 8. Disconnect filter (5). 9. Disconnect clmp (6). 10. Disconnect filter (7). Disconnect the hose clmp. 3. Remove undercover (2). 11. Lift off engine hood (8). 4. Remove the hydrulic tnk striner nd stop the oil with oil stopper tool S1. When not using tool S1, remove the drin plug nd drin the oil. 6 Hydrulic tnk: 470 l 5. Drin the coolnt. 6 Coolnt: 100 l PC800,