INTRODUCTION

TO THE READER

• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog

MANUAL COMPOSITION

• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.

• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.

PAGE NUMBER

• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual

IN-01
 INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:
signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
• NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.

UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.

To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375

IN-02
 SAFETY
RECOGNIZE SAFETY INFORMATION

• This is the SAFETY ALERT SYMBOL.

• When you see this symbol on your machine or in
this manual, be alert to the potential for personal
injury.
• Follow recommended precautions and safe
operating practices.

001-E01A-0688

SA-688

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating
the degree or level of hazard - DANGER,
WARNING, or CAUTION - are used with the safety
alert symbol.
• DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
• WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
• CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
DANGER or WARNING safety signs are
located near specific hazards. General
precautions are listed on CAUTION safety
signs.
• Some safety signs don’t use any of the
designated signal words above after the safety
alert symbol are occasionally used on this
machine. SA-1223

• CAUTION also calls attention to safety messages in

this manual.
• To avoid confusing machine protection with
personal safety messages, a signal word
IMPORTANT indicates a situation which, if not
avoided, could result in damage to the machine.

• NOTE indicates an additional explanation for an

element of information.
002-E01C-1223

SA-1
 SAFETY
FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the

machine and all safety messages in this manual.
• Safety signs should be installed, maintained and
replaced when necessary.
• If a safety sign or this manual is damaged or
missing, order a replacement from your author-
ized dealer in the same way you order other re-
placement parts (be sure to state machine model
and serial number when ordering).
• Learn how to operate the machine and its controls
correctly and safely.
• Allow only trained, qualified, authorized personnel SA-003

to operate the machine.

• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may
impair its function and/or safety and affect ma-
chine life.
• The safety messages in this SAFETY chapter are
intended to illustrate basic safety procedures of
machines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your au-
thorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003

SA-2
 SAFETY
PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.
• Thoroughly read and understand the label at-
tached on the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always
used when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
• Establish emergency procedure guidelines to
cope with fires and accidents.
• Keep emergency numbers for doctors, ambu-
lance service, hospital, and fire department SA-437

posted near your telephone.

004-E01A-0437

WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask. SA-438

Be sure to wear the correct equipment and clothing

for the job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other
items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full
attention of the operator. Do not wear radio or
music headphones while operating the machine.

005-E01A-0438

SA-3
 SAFETY
PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
• Wear a suitable hearing protective device such
as earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.

006-E01A-0434

SA-434

INSPECT MACHINE
• Inspect your machine carefully each day or shift by
walking around it before you start it to avoid
personal injury.
• In the walk-around inspection be sure to cover all
points described in the “PRE-START
INSPECTION” chapter in the operator’s manual.

S007-E01A-0435

SA-435

SA-4
 SAFETY
GENERAL PRECAUTIONS FOR CAB

• Before entering the cab, thoroughly remove all

dirt and/or oil from the soles of your work boots. If
any controls such as a pedal is operated while
with dirt and/or oil on the soles of the operator’s
work boots the operator’s foot may slip off the
pedal, possibly resulting in a personal accident.
• Don’t leave parts and/or tools lying around the
operator’s seat. Store them in their specified lo-
cations.
• Avoid storing transparent bottles in the cab. Don’t
attach any transparent type window decorations
on the windowpanes as they may focus sunlight,
possibly starting a fire.
• Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab
while operating the machine.
• Keep all flammable objects and/or explosives
away from the machine.
• After using the ashtray, always cover it to extin-
guish the match and/or tobacco.
• Don’t leave cigarette lighters in the cab. When
the temperature in the cab increases, the lighter
may explode.
524-E01A-0000

SA-5
 SAFETY
USE HANDHOLDS AND STEPS

• Falling is one of the major causes of personal injury.

• When you mounting and dismounting the ma-
chine, always face the machine and maintain a
three-point contact with the steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount
or dismount a moving machine.
• Be careful of slippery conditions on platforms,
steps, and handrails when mounting and dis-
mounting the machine.
SA-439

008-E01B-0439

ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for
the work at hand may quickly fatigue the operator
leading to misoperations.
• The seat should be adjusted whenever changing
the operator for the machine.
• The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
• If not, move the seat forward or backward, and
check again.
SA-378

009-E01A-0378

SA-6
 SAFETY
FASTEN YOUR SEAT BELT

• If the machine should overturn, the operator may

become injured and/or thrown from the cab.
Additionally the operator may be crushed by the
overturning machine, resulting in serious injury or
death.
• Prior to operating the machine, thoroughly
examine webbing, buckle and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
• Be sure to remain seated with the seat belt SA-237

securely fastened at all times when the machine

is in operation to minimize the chance of injury
from an accident.
• We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.

010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.
• Take extra care not to run over bystanders.
Confirm the location of bystanders before moving,
swinging, or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the
machine. SA-083

011-E01A-0426

SA-7
 SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may
cause the machine to runaway, possibly resulting in
serious injury or death.
• Start the engine only when seated in the
operator's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals.
• Before starting the engine, confirm that all control
levers are in neutral.
SA-084

012-E01B-0444

JUMP STARTING

• Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to
follow the instructions shown in the “OPERATING
THE ENGINE” chapter in the operator’s manual.
• The operator must be in the operator’s seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person
operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway SA-032

machine.

S013-E01A-0032

SA-8
 SAFETY
KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as

being struck by foreign objects and being thrown off
the machine.
• Only the operator should be on the machine.
Keep riders off.
• Riders also obstruct the operator’s view, resulting
in the machine being operated in an unsafe
manner.

014-E01B-0379

SA-091

PROVIDE SIGNALS FOR FOBS INVOLV-

ING MULTIPLE NUMBERS OF MACHINES

• For jobs involving multiple numbers of machines,

provide signals commonly known by all personnel
involved. Also, appoint a signal person to coordi-
nate the job site. Make sure that all personnel obey
the signal person’s directions.

018-E01A-0481
SA-481

CONFIRM DIRECTION OF MACHINE TO

BE DRIVEN

• Incorrect steering wheel shift lever operation may

result in serious injury death.
• Before driving the machine, confirm the position
of the undercarriage in relation to the operator’s
position. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.

017-E01A-0491

SA-092

SA-9
 SAFETY
DRIVE MACHINE SAFELY (WORK SITE)

• Before driving the machine, always confirm that the

steering wheel/shift lever direction corresponds to
the direction you wish to drive.
• Be sure to detour around any obstructions.

• Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or SA-090
death.
• When driving up or down a slope, keep the
bucket facing the direction of travel, approxi-
mately 0.5 to 1.0 m (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop.

SA-288

• Driving across the face of a slope or steering on

a slope may cause the machine to skid or over-
turn. If the direction must be changed, move the
machine to level ground, then, change the direc-
tion to ensure sage operation.

019-E05B-0090

SA-10
 SAFETY
AVOID INJURY FROM ROLLAWAY
ACCI-DENTS
• Death or serious injury may result if you attempt to
mount or stop a moving machine.

To avoid rollaways:
• Select level ground when possible to park ma-
chine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Place the shift lever in neutral, and put the brake
switch in the P (parking brake) position.
• Turn the auto-idle switch and the H/P mode
switch off.
• Run the engine at slow idle speed without load
for 5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK posi-
SA-278
tion.
• Block both tires and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
020-E01A-0270

SA-11
 SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.

To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if SA-383

equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a
signal person.
• No machine motions shall be made unless
signals are clearly understood by both signalman SA-384

and operator.
• Learn the meanings of all flags, signs, and
markings used on the job and confirm who has
the responsibility for signaling.
• Keep windows, mirrors, and lights clean and in
good condition.
• Dust, heavy rain, fog, etc., can reduce visibility.
As visibility decreases, reduce speed and use
proper lighting.
• Read and understand all operating instructions in
the operator’s manual.

S021-E01A-0494

SA-12
 SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINE---SERIOUS OR FATAL
CRUSHING INJURIES WILL RESULT

MACHINE WILL TIP OVER FASTER THAN YOU

CAN JUMP FREE

FASTEN YOUR SEAT BELT

• The danger of tipping is always present when

operating on a grade, possibly resulting in serious
injury or death. SA-012

To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.
• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or
slipping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper
than 5 degrees if crossing the grade is
unavoidable. SA-562

• Reduce swing speed as necessary when

swinging loads.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to
become soft and make ground travel unstable.

S025-E01B-0495

SA-13
 SAFETY
AVOID POWER LINES

• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines.
• When operating near an electric line, NEVER
move any part of the machine or load closer than
3 m (10 ft) plus twice the line insulator length.
• Check and comply with any local regulations that
may apply.
• Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
SA-089
site.

029-E01A-0381

OBJECT HANDLING

• If a lifted load should fall, any person nearby may

be struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.
• When using the machine for craning operations,
be sure to comply with all local regulations.
• Do not use damaged chains or frayed cables,
sables, slings, or ropes.
• Before craning, position the upperstructure with
the travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it
is safely and securely situated on supporting
SA-014
blocks or on the ground.
• Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.

032-E01A-0014

SA-14
 SAFETY
PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body,

serious injury may result.
• Guard against injury from flying pieces of metal
or debris; wear goggles or safety glasses.
• Keep bystanders away from the working area
before striking any object.

031-E01A-0432
SA-432

PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Place the shift lever in neutral, and put the brake
switch in the P (parking brake) position.
• Turn auto-idle switch and auto-acceleration
switch off.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull up the pilot shut-off lever further to release
SA-093

the catch, so that the left console can be moved

upward (“CONSOLE UP” position).
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.

033-E07B-0093

SA-15
 SAFETY
HANDLE FLUIDS SAFELY－AVOID FIRES

• Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.
• Do not refuel the machine while smoking or when
near open flame or sparks.
• Always stop the engine before refueling the
machine.
• Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are

flammable. SA-018

• Store flammable fluids well away from fire

hazards.
• Do not incinerate or puncture pressurized
containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten the fuel and oil filler cap.

034-E01A-0496

SA-019

SA-16
 SAFETY
SAFETY TRANSPORTING

• The danger of tipping is present when

loading/unloading the machine onto/from a truck or
trailer bed.
• Be sure to observe local regulations when
transporting the machine on public roads.
• Provide an appropriate truck or trailer for
transporting the machine.

Take the following precautions when load-

Less than 15°
ing/unloading the machine:
1. Select firm level ground.
SA-094
2. Be sure to use a loading dock or ramp.
3. Be sure to have a signal person when load-
ing/unloading the machine.
4. Always turn the auto-idle switch,
auto-acceleration switch and the H/P mode
switch OFF when loading or unloading the ma-
chine, to avoid unexpected speed increase due
to unintentional operation of a control lever.
5. Always select the slow travel with the fast/slow
travel switches.
6. Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is un-
avoidable, first move back to the ground or flat-
bed, modify traveling direction, and begin to
drive again.
7. Do not operate any levers besides the travel lev-
ers when driving up or down the ramp.
8. The top end of the ramp where it meets the flat-
bed is a sudden bump. Take care when traveling
over it.
9. Prevent possible injury from machine tipping
while the upperstructure is rotating.
10.Keep the arm tucked under and rotate the up- Less than 15°
perstructure slowly for best stability.
11.Turn the brake switch to the parking (P) position. SA-095

Place blocks in front of and behind the tires to

secure the machine.
12.Securely fasten chain or cables to the machine
frame. Refer to "transporting" chapter in the op-
erator’s manual for details.

035-E06A-0395

SA-17
 SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:

• Understand service procedures before doing

work.
• Keep work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is
moving.
• Keep hands, feet and clothing away from
power-driven parts.

• Before servicing the machine:

1) Park the machine on a level surface.
2) Lower the bucket to the ground.
3) Turn the auto-idle / acceleration selecltor off.
4) Run the engine at slow idle speed without load
for 5 minutes.
5) Turn the key switch to OFF to stop engine.
6) Relieve the pressure in the hydraulic system by
moving the control levers several times.
7) Remove the key from the switch.
8) Attach a “Do Not Operate” tag on the control
lever.
9) Pull the pilot control shut-off lever to the LOCK
position.
10) Allow the engine to cool.

SA-18
 SAFETY
• If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or
replace as necessary. Refer to the section
discussing that part in the “MAINTENANCE”
chapter in the operator’s manual.
• Keep all parts in good condition and properly
installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
• When cleaning parts, always use nonflammable
SA-028
detergent oil. Never use highly frammable oil
such as fuel oil and gasoline to clean parts or
surfaces.
• Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
• Illuminate your work area adequately but safely.
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or SA-527

inside the machine.

• Always use a work light protected with a guard.
In case the light bulb is broken, spilled fuel, oil
antifreeze fluid, or window washer fluid may
catch fire.

S500-E02B-0497

SA-037

SA-19
 SAFETY
WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious

injury.
• Before performing any work on the machine, at-
tach a “Do Not Operate” tag on the control lever.
This tag is available from your authorized dealer.

SS2045102

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without
securing the machine first.
• Always lower the attachment to the ground
before you work on the machine.
• If you must work on a lifted machine or
attachment, securely support the machine or
attachment. Do not support the machine on
cinder blocks, hollow tires, or props that may
crumble under continuous load. Do not work
under a machine that is supported solely by a
SA-527
jack.
519-E01A-0527

STAY CLEAR OF MOVING PARTS

• Entanglement in moving parts can cause serious
injury.
• To prevent accidents, care should be taken to
ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working around
rotating parts.

502-E01A-0026

SA-026

SA-20
 SAFETY
PREVENT PARTS FROM FLYING

• Travel reduction gears are under pressure.

• As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen
AIR RELEASE PLUG to release pressure.

503-E03A-0344

SA-344

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic
hammers, and blades can fall and cause serious
injury or death.
• Securely store attachments and implements to
prevent falling. Keep children and bystanders
away from storage areas.

SA-034
504-E01A-0034

SUPPORT MAINTENANCE PROPERLY

• Explosive separation of a tire and rim parts can
cause serious injury or death.
• Do not attempt to mount a tire unless you have
the proper equipment and experience to perform
the job. Have it done by your authorized dealer or
a qualified repair service.
• Always maintain the correct tire pressure. DO
NOT inflate tire above the recommended pres-
sure.
• When inflating tires, use a chip-on chuck and
extension hose long enough to allow you to stand
to one side and not in front of or over the tire as-
sembly. Use a safety cage it available.
• Inspect tires and wheels daily. Do not operate
with low pressure, cuts bubbles, damaged rims,
or missing lug bolts and nuts. SA-249

• Never cut or weld on an inflated tire or rim as-

sembly. Heat from welding could cause an in-
crease in pressure and may result in tire explo-
sion.

521-E02A-0249

SA-21
 SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under
pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap. SA-039

• The hydraulic oil tank is pressurized. Again, be

sure to release all pressure before removing the
cap.

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become
hot during operation.
The engine, hoses, lines and other parts become
hot as well.
• Wait for the oil and components to cool before
starting any maintenance or inspection work.

505-E01B-0498 SA-225

REPLACE RUBBER HOSES

PERIODICALLY
• Rubber hoses that contain flammable fluids under
pressure may break due to aging, fatigue, and
abrasion. It is very difficult to gauge the extent of
deterioration due to aging, fatigue, and abrasion of
rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the
page of “Periodic replacement of parts” in the
operator’s manual.)
• Failure to periodically replace rubber hoses may
cause a fire, fluid injection into skin, or the front SA-019

attachment to fall on a person nearby, which may

result in severe burns, gangrene, or otherwise
serious injury or death.

S506-E01A-0019

SA-22
 SAFETY
AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
• Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take
care to protect hands and body from
high-pressure fluids. Wear a face shield or SA-031

goggles for eye protection.

• If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.

SA-292

507-E03A-0499

SA-044

SA-23
 SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to
fires.
• Check for oil leaks due to missing or loose
clamps, kinked hoses, lines or hoses that rub
against each other, damage to the oil-cooler, and
loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or SA-019

hoses.

Check for Shorts:

• Short circuits can cause fires.
• Clean and tighten all electrical connections.
• Check before starting work for loose, kinked,
hardened or frayed electrical cables and wires.
• Check before starting work for missing or
damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..

Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.
• Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.

SA-24
 SAFETY
Check Key Switch:
• If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
• Always check key switch function before
operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to
confirm that the engine stops.
• If any abnormalities are found, be sure to repair
them before operating the machine.

Check Heat Shields:

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be
repaired or replaced before operating the
machine.

S508-E02B-0019

SA-25
 SAFETY
EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the

following way:
• Stop the engine by turning the key switch to the
OFF position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.

• In an emergency, if the cab door and/or the front SA-393

window cannot be opened, break the front or rear

window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on “EMERGENCY
EXIT” in Operator’s Manual.

518-E02B-0393

SS-1510

BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.
• If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.

509-E01A-0016

SA-016

SA-26
 SAFETY
PRECAUTIONS FOR WELDING AND
GRINDING
• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated
and prepared area. Store flammable objects in a
safe place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before
starting grinding.
• After finishing welding and grinding, recheck that SA-818

there are no abnormalities such as the area sur-

rounding the welded area still smoldering.
523-E01A-0818

AVOID HEATING NEAR PRESSURIZED

FLUID LINES

• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
• Do not heat by welding, soldering, or using a
torch near pressurized fluid lines or other
flammable materials.
• Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area.
Install temporary fire-resistant guards to protect
hoses or other materials before engaging in
welding, soldering, etc..
SA-030

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that
contain flammable fluids.
• Clean them thoroughly with nonflammable
solvent before welding or flame cutting them.
510-E01B-0030

SA-27
 SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
• Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.

• Remove paint before welding or heating:

1) If you sand or grind paint, avoid breathing the
dust. SA-029

Wear an approved respirator.

2) If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.

511-E01A-0029

PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.
• Keep sparks, lighted matches, and flame away
from the top of battery.
• Never check battery charge by placing a metal
object across the posts. Use a voltmeter or hy-
drometer.
• Do not charge a frozen battery; it may explode.
Warm the battery to 16 °C ( 60 °F ) first.
• Do not continue to use or charge the battery
when electrolyte level is lower than specified. Ex-
plosion of the battery may result. SA-032

• Loose terminals may produce sparks. Securely

tighten all terminals.
• Battery electrolyte is poisonous. If the battery
should explode battery electrolyte may be splashed
into eyes, possibly resulting in blindness.
• Be sure to wear eye protection when checking
electrolyte specific gravity.

512-E01C-0032

SA-28
 SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold
contact burn.
• Refer to the freon container for proper use when
servicing the air conditioning system.
• Use a recovery and recycling system to avoid
venting freon into the atmosphere.
• Never let the freon stream make contact with the
skin.

SA-405
513-E01A-0405

HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals
used with your machine include such items as
lubricants, coolants, paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides
specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
• Check the MSDS before you start any job using a
hazardous chemical. That way you will know
exactly what the risks are and how to do the job SA-309

safely. Then follow procedures and use

recommended equipment.

S515-E01A-0309

SA-29
 SAFETY
DISPOSE OF WASTE PROPERLY

• Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids.
Do not use food or beverage containers that may
mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain,
or into any water source.
• Air conditioning refrigerants escaping into the air
can damage the Earth’s atmosphere. SA-226

Government regulations may require a certified

air conditioning service center to recover and
recycle used air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.

S516-E01A-0226

BEFORE RETURNING THE MACHINE TO

THE CUSTOMER
• After maintenance or repair work is complete,
confirm that:
• The machine is functioning properly, especially
the safety systems.
• Worn or damaged parts have been repaired or
replaced

S517-E01A-0435 SA-435

SA-30
 SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling and
Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil Tank
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
WORKSHOP MANUAL Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Signal Control Valve
Group 10 Travel Shockless Valve
Group 11 Solenoid Valve
Group 12 Pilot Relief Valve
Group 13 Steering Valve
Group 14 Brake Valve
Group 15 Accumulator Charging Valve
Group 16 Transmission Control Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Motor
All information, illustrations and speci- Group 3 Center Joint
fications in this manual are based on
the latest product information available Group 4 Transmission
at the time of publication. The right is
reserved to make changes at any time
Group 5 Axle
without notice. Group 6 Axle Lock Cylinder
Group 7 Operate-Check Valve
Group 8 Propeller Shaft
SECTION 4 FRONT ATTACHMENT
COPYRIGHT(C)2003 Group 1 Front Attachment
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan Group 2 Cylinder
All rights reserved
Group 3 Hose-Rupture Safety Valve
Group 4 Operate-Check Valve
SECTION 5 ENGINE
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Control System Group 5 Travel Device
Group 2 Hydraulic System Group 6 Signal Control Valve
Group 3 Electrical System Group 7 Steering Valve
Group 8 Brake Valve
Group 9 Transmission Control Valve
Group 10 Others (Upperstructure)
Group 11 Others (Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 General
Group 1 Introduction Group 2 Component Layout
Group 2 Standard Group 3 Troubleshooting A
Group 3 Engine Test Group 4 Troubleshooting B
Group 4 Excavator Test Group 5 Troubleshooting C
Group 5 Component Test Group 6 Electrical System Inspection
Group 6 Adjustment Group 7 ICX
 SECTION 1
GENERAL

— CONTENTS —
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling.................................................W1-1-1
Maintenance Standard Terminology.......... W1-1-7

Group 2 Tightening Torque

Tightening Torque Specification ..................W1-2-1
Torque Chart ................................................W1-2-2
Piping Joint ..................................................W1-2-5
Periodic Replacement of Parts .................. W1-2-9

Group 3 Painting
Painting.................................................... W1-3-1

Group 4 Bleeding Air from Hydraulic Oil

Tank
Bleeding Air from Hydraulic Oil tank .......... W1-4-1

CDBW-1-1
(Blank)

CDBW-1-2
 GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling

• Clean the Machine • Precautions for Disassembling

Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be • Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as • Before disassembling, drain gear oil from the
well as decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all instructed.
disassem-bling/assembling procedures beforehand, • If a part or component cannot be removed after
to help avoid incorrect disassembling of removing its securing nuts and bolts, do not
components as well as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
• Capacities and condition of lubricants. • Measure and record the degree of wear and
• Loose or damaged parts. clearances.

• Prepare and Clean Tools and Disassembly Area

Prepare the necessary tools to be used and the

area for disassembling work.

W1-1-1
 GENERAL / Precautions for Disassembling and Assembling
• Precautions for Assembling Bleeding Air from Hydraulic System

• Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the
any damage. If any damage is found, repair or suction lines are replaced, or the removal and in-
replace part. stallation of the pump, swing motor, travel motor or
• Dirt or debris on the contact or sliding surfaces cylinder is done, bleed air from the hydraulic system
may shorten the service life of the machine. Take in the following procedures:
care not to contaminate any contact or sliding
surfaces. IMPORTANT: If the engine is started with air
• Be sure to replace O-rings, backup rings, and oil trapped in the hydraulic pump hous-
seals with new ones once they are disassembled. ing, damage to the pump may result.
Apply a film of grease before installing. If the hydraulic motor is operated
• Be sure that liquid-gasket-applied surfaces are
with air trapped in the hydraulic mo-
clean and dry.
tor housing, damage to the motor
• If an anti-corrosive agent has been used on a
may result.
new part, be sure to thoroughly clean the part to
remove the agent. If the cylinder is operated with air
• Utilize matching marks when assembling. trapped in the cylinder tube, dam-
• Be sure to use the designated tools to assemble age to the cylinder may result.
bearings, bushings and oil seals. Be sure to bleed air before starting
• Keep a record of the number of tools used for the engine.
disassembly/assembly. After assembling is
complete, count the number of tools, so as to • Bleeding Air from Hydraulic Pump
make sure that no forgotten tools remain in the
assembled machine. • Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the
plug.

• Bleeding Air from Travel Motor / Swing Motor

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

motor removed, fill the motor case with hydraulic
oil.

W1-1-2
 GENERAL / Precautions for Disassembling and Assembling
• Bleeding Air from Hydraulic Circuit

• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level. W1F3-01-04-001

• Stop the engine. Recheck hydraulic oil level. Re-

plenish oil as necessary.

W1-1-3
 GENERAL / Precautions for Disassembling and Assembling
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:

(1) Keep seal rings together as a matched set

with seal ring faces together. Insert a piece of
cardboard to protect surfaces.

(2) Check the slide surface on seal ring (A) for

scuffing, scoring, corrosion, deformation or B W105-03-05-019

uneven wear.

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

deformation or hardening.

2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.

(1) Clean the floating seal and seal mounting

bores with cleaning solvent. Correct
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air. Incorrect

(2) Clean the floating seal and seal mounting

bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.

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

is installed correctly on the seal ring.
W105-03-05-020
Correct C Incorrect
(4) After installing the floating seal, check that
seal ring surface (A) is parallel with seal a a
mating face (C) by measuring the distances
A
(A) and (C) at point (a) and (b), as illustrated.
If these distances differ, correct the O-ring
seating. B

b b

a=b a≠b
W110-03-05-004

W1-1-4
 GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings

safely. Correct Eyehole
• Attach protectors (soft material) on the corners of Lifting Method
the load so that the nylon sling does not directly
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
• Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load
with a temperature of 100 °C (212 °F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use W102-04-02-016

slings with the same width and length to keep the Incorrect Eyehole
lifted load balanced. Lifting Method
• When lifting a load using an eyehole, be sure to
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or
hitched slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions. W105-04-01-008

• Avoid dragging slings on the ground, throwing

slings or pushing slings with a metal object.
• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.

Bent Sling W162-01-01-009

W1-1-5
 GENERAL / Precautions for Disassembling and Assembling

Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.

W162-01-01-002
2. Before using a nylon sling, visually check the ny- Scuffing
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years.
W162-01-01-003

Fuzz

Broken Sewing
Thread

W162-01-01-004

Broken Sewing
Thread

W162-01-01-005
Broken Sewing
Thread

Separation of W162-01-01-006
Scoring
Belt

W162-01-01-007
Fuzz Scuffing
Broken Warp

W162-01-01-008

W1-1-6
 GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.

2. Dimension of new components or assemblies

adjusted to specification.

“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.

2. Repair or adjustment is impossible after exceed-

ing this limit.

3. Therefore, in consideration of operation efficiency

and maintenance expense, proper maintenance
shall be carried out before reaching the “Allow-
able Limit”.

W1-1-7
 GENERAL / Precautions for Disassembling and Assembling
(Blank)

W1-1-8
 GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATION

Bolt Dia Wrench Torque

No. Descriptions Q’ty
mm Size (mm) Nxm (kgfxm) (lbfxft)
(Pump Upper) 18 2 27 360 (37) (265)
Engine cushion rubber mounting bolt
1 (Pump Lower) 16 4 24 210 (21.5) (155)
Engine cushion rubber mounting nut (Fan Side) 14 4 22 140 (14.0) (103)
2 Engine bracket mounting bolt and nut 10 8 17 50 (5.1) (37)
3 Hydraulic oil tank mounting bolt 16 4 24 210 (21.5) (155)
4 Fuel tank mounting bolt 16 4 24 210 (21.5) (155)
17 24.5 (2.5) (18)
19 30 (3.1) (22)
22 40 (4.1) (30)
ORS and metal face seal fittings for hydraulic hoses
5 27 95 (9.7) (70)
and piping 32 140 (14.3) (105)
36 175 (17.8) (130)
41 210 (21.5) (155)
6 Pump mounting bolt 10 8 17 50 (5.1) (37)
7 Control valve mounting bolt 16 4 24 210 (21.5) (155)
8 Control valve bracket mounting bolt 16 4 24 210 (21.5) (155)
9 Swing device mounting bolt 20 12 30 500 (51) (370)
12
10 Swing motor mounting bolt (Hex. 8 10 90 (9.2) (66)
Wrench)
11 Battery mounting nut 10 2 17 50 (5.1) (37)
12 Cab mounting nut 16 4 24 210 (21.5) (155)
Swing bearing mounting bolt to upperstructure 20 32 30 510 (52) (380)
13
Swing bearing mounting bolt to chassis 20 36 30 490 (50) (360)
14 Center joint lock mounting bolts ※ 16 5 24 270 (27.5) (200)
15 － － － － － －
16
16 * Travel motor mounting bolts (Hex. 4 14 270 (27.5) (200)
Wrench)
17 * Propel shaft mounting nuts 10 16 14 76 (8) (60)
18 Center Bearing mounting bolt 10 2 17 50 (5.1) (37)
19 * Rear axle mounting bolts 24 8 36 950 (97.0) (700)
20 Wheel pin nuts 22 40 30 600 (61) (440)
6 － 10 10 (1) (7.4)
21 Cover mounting bolt 10 － 17 50 (5.1) (37)
12 － 19 90 (9.2) (66)
22 Flexible master coupling of piping 8 4 pairs 13 10.3 to 12.4 (1.05 to 1.26) (7.59 to 9.11)
Jubilee Clamp of low pressure piping － － 7 5.9 (0.6) (4.3)
23
T-bolt clamp of low pressure piping － － 11 5.9 (0.6) (4.3)
* : Apply LOCTITE to the threads.

NOTE: 1. Apply lubricant (e.g. white zinc B dis-

solved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
2. Make sure bolt and nut threads are
clean before installing.

W1-2-1
 GENERAL / Tightening
TORQUE CHART

CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and proce-
dures can create safety hazards. For loos-
ening and tightening nuts and bolts, use cor-
rect size tools. Otherwise, tightening tools
may slip, potentially causing personal injury.

Bolt Types

Tighten nuts or bolts correctly to torque specifications.

Four different types and grades of bolt are employed. SA-040

Make sure to employ correct bolts and tighten them

correctly when assembling the machine or compo-
nents.
Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt

W162-01-01-001

Specified Tightening Torque Chart

Bolt Wrench Hexagon T Bolt H Bolt, Socket bolt M Bolt
Dia. Size Wrench
Size N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft)
M8 13 6 30 (3.1) (22) 20 (2.0) (15.0) 10 (1.0) (7.4)
M10 17 8 65 (6.6) (48) 50 (5.1) (37) 20 (2.0) (15.0)
M12 19 10 110 (11.0) (81) 90 (9.2) (66) 35 (3.6) (26.0)
M14 22 12 180 (18.5) (135) 140 (14.0) (103) 55 (5.6) (41)
M16 24 14 270 (27.5) (200) 210 (21.5) (155) 80 (8.2) (59)
M18 27 14 400 (41.0) (295) 300 (30.5) (220) 120 (12.0) (89)
M20 30 17 550 (56.0) (410) 400 (41.0) (295) 170 (17.0) (125)
M22 32 17 750 (76.5) (550) 550 (56.0) (410) 220 (22.5) (162)
M24 36 19 950 (97.0) (700) 700 (71.5) (520) 280 (28.5) (205)
M27 41 19 1400 (143) (1030) 1050 (107) (770) 400 (41.0) (295)
M30 46 22 1950 (200) (1440) 1450 (148) (1070) 550 (56.0) (410)
M33 50 24 2600 (265) (1920) 1950 (200) (1440) 750 (76.5) (550)
M36 55 27 3200 (325) (2360) 2450 (250) (1810) 950 (97.0) (700)

W1-2-2
 GENERAL / Tightening
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lu-
bricant.
2. Torque tolerance is ±10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.

Bolt Tightening Order

When tightening two or more bolts, tighten them al-

ternately, as shown, to ensure even tightening.
Tighten from center and diago-
Equally tighten upper and lower alter- Tighten diagonally

1 12 9 4 1 6 7 14
6 3
1st to 4th

4 5
2 13 8 5 2 3 10 11

2nd to 3rd
W105-01-01-003

W1-2-3
 GENERAL / Tightening
Service Recommendations for Split Flange

IMPORTANT: 1. Be sure to clean and Inspect

sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
W105-01-01-015
nent.
WRONG
2. Be sure to use only specified
O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
W105-01-01-016
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using W105-01-01-008

an air wrench often causes RIGHT WRONG

tightening of one bolt fully before
tightening of the others, result-
ing in damage to O-rings or un-
even tightening of bolts. Do not bend it round
Bend along edge sharply

Nut and Bolt Locking RIGHT RIGHT WRONG

• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.

• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Bend along edge sharply
holes in the bolt and nut while tight- W105-01-01-009

RIGHT RIGHT WRONG

ening, not while loosening.

• Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
Loosen WRONG
RIGHT

Tighten

W105-01-01-010

W1-2-4
 GENERAL / Tightening
PIPING JOINT
IMPORTANT: The torques given in the chart are 1 4 3 5 2
for general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.

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

IMPORTANT: 1. Do not over-tighten nut (3). Ex- 37°

cessive force will be applied to
30°
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be
sure to tighten nut (3) to specifi-
cations. Male Union Joint Female Union Joint
2. Scratches or other damage to
sealing surfaces (4) or (5) will W105-01-01-017

cause oil leakage at the joint.

Take care not to damage them
when connecting/disconnecting.

Wrench Size Wrench Size mm Tightening

Description mm Torque
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
30°male 17 17 24.5 (2.5,18)
19 19 29.5 (3.0, 21.5)
22 22 39 (4.0, 28.5)
27 27 78 (8.0, 58)
32 32 137 (14.0,101)
36 36 175 (18.0,129)
41 41 205 (21.0,151)
37°female 17 14 24.5 (2.5,18)
19 17 29.5 (3.0, 21.5)
22 19 39 (4.0, 28.5)
27 22 78 (8.0, 58)
32 27 137 (14.0,101)
36 32 175 (18.0,129)
41 36 205 (21.0,151)
NOTE: Tightening torque of 37°male coupling without union is similar
to tightening torque of 37°female.

W1-2-5
 GENERAL / Tightening
O-ring Seal Joint 9
7 6

O-ring (6) seats against the end face of adapter (7) to

seal pressure oil.

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

a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly Hose Fittings
8 1
in O-ring groove (e). Tightening M104-07-033

nut (9) with O-ring (6) displaced

will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring Wrench Size Wrench Size Tightening Torque
groove (e) or sealing surface mm mm
(10). Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
Damage to O-ring (6) will cause 19 17 29.5 (3.0, 21.5)
oil leakage. 22 19 69 (7.0, 51)
4. If nut (9) is loose and oil is leak- 27 22 93 (9.5, 69)
ing, do not re-tighten nut (9). Re- 32 27 137 (14.0,101)
place O-ring (6) with a new one 36 30,32 175 (18.0,129)
and check that O-ring (6) is cor- 41 36 205 (21.0,151)
rectly seated in place, tighten nut 46 41 205 (21.0,151)
(9).

W1-2-6
 GENERAL / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30°
types of screw fittings are used.

IMPORTANT: Be sure to confirm that the thread

pitch and thread type (tapered or
straight) are the correct type before Male Tapered Thread Male Straight Thread
using any screw-in connection.
W105-01-01-018

Male Tapered Thread

Wrench Size Tightening Torque
mm N⋅m (kgf⋅m, lbf⋅ft)
Hose Fittings FC material SS material
19 14.5 (1.5,10.5) 34 (3.5, 25)
22 29.5 (3.0, 21.5) 49 (5.0, 36)
27 49 (5.0, 36) 93 (9.5, 69)
36 69 (7.0, 51) 157 (16,116)
41 108 (11, 80) 205 (21,151)
50 157 (16,116) 320 (33, 235)
60 195 (20,144)
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks be-
tween threads.
Be sure to apply just enough seal tape to fill up thread External Thread
Clearance
clearances. Do not overwrap.

• Application Procedure W105-01-01-019

Leave one to two pitch threads uncovered

Confirm that the thread surface is clean and, free of
dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.

Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs

depending on the type of clamp. M114-07-041
T-Bolt Type Band Clamp:
4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft )
T-Bolt Type Worm Gear Type
Worm Gear Type Band Clamp:
5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)

M114-07-043 M114-07-042

W1-2-7
 GENERAL / Tightening
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation
of fitting, possibly resulting in a fire on the
machine.

Do not install hoses kinked. Application of W105-01-01-011

high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose
rupture or separation of fitting. Utilize Print WRONG RIGHT
marks on hoses when installing to prevent Rubbing Against
hose from being kinked. Each Other

If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other. W105-01-01-012

WRONG RIGHT
Take care so that hoses do not come into
contact with moving parts or sharp objects. Clamp Clamp

Rubbing Against
Each Other

W105-01-01-013

WRONG RIGHT

Rubbing Against
Each Other Clamp
W105-01-01-014

W1-2-8
 GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic
inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deterio-
ration, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regard-
less of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace
as necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, as necessary.
Consult your authorized dealer for correct replace-
ment.

Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Fuel hose (Fuel tank to injection pump) Every 2 years
Engine
Oil filter hose (Engine to oil filter) Every 2 years
Heater hose (Heater to engine) Every 2 years
Brake valve seals (Rubber parts) Every 2 years
Upperstructure Brake hose Every 2 years
Brakes Stop light switch Every 2 years
Center joint seals (Rubber parts) Every 2 years
Undercarriage
Brake hose Every 1 years
Steering hose Every 2 years
Steering Mechanism Steering cylinder seals (Rubber parts) Every 2 years
Steering valve seals (Rubber parts) Every 2 years
Pump suction hose Every 2 years
Base Machine Pump delivery hose Every 2 years
Swing hose Every 2 years
Hydraulic
Boom cylinder line hose Every 2 years
System
Arm cylinder line hose Every 2 years
Front Attachment
Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years

NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.

W1-2-9
 GENERAL / Tightening
(Blank)

W1-2-10
 GENERAL / Painting
PAINTING

Surfaces to Be Painted Painting Colour

• Main surface of upperstructure YR-01 [TAXI yellow]
Bed cover High-grade beige
Engine cover High-grade black
Front-right cover High-grade black
Front-right step High-grade black
Inner face Grey
• Front attachment YR01 [TAXI yellow]
• Chassis (undercarriage) N1.0 [Black]
• Floor plate M/F cation colour
• A part of rear left of cab YR-01 [TAXI yellow]

Final painted colour

• Inside and outside surface of cab High-grade beige
[KASAI PAINT LF-113-230B
• Right window beam, U bolt
(Charcoal series black, semi glossy)]
• Suspension lifter (chair bottom) [N2.0 (Black) ]
• Lever (lock, foot rest) [N2.0 (Black) ]
• Torsion bar [N4.0 (Grey) ]
• Ladder rail on right side of upperstructure High-grade black
• Mirror stay (cab side and right side stay) High-grade black
• Head light bracket [N1.0 (Black) ]
• Antislip cover KASAI PAINT Amilack 1400 Deep Black.

Front Right Front Right

Step Cover

W1GL-01-03-002

350 900
Bed Cover

W1-3-1
 GENERAL / Painting

A
YR-01
(TAXI Yellow) Out Surface of Hinge Swing
Portion YR-01 (TAXI Yellow)
185

Door Catch Cover YR-01

(TAXI Yellow)

720
W178-01-03-003

5
Section A Section B
Mask Garnished Portion

Door
YR-01(TAXI Yellow) Panel Behind the
Door

10
Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)

W178-01-03-004

Antislip Cover
KASAI PAINT
Front Attachment Amilack 1400
YR-01 (TAXI Yellow) Deep Black

W178-01-03-007 Upper Side

of Frame

IMPORTANT: When cleaning arm, cylinder, etc.

fitted with HN bushing, take care not
to pour washing liquid directly on W1GL-01-03-001

them. The ambient temperature

should not exceed 70 °C when
painting and drying.

W1-3-2
 GENERAL / Bleeding Air from Hydraulic Oil Tank
BLEEDING AIR FROM HYDRAULIC OIL
TANK

CAUTION: Escaping fluid under pressure

can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation,
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
work.
The hydraulic oil tank cap may fly off if
removed without releasing internal pressure
first. Loosen the hydraulic oil tank cap to
release any remaining pressure.

Preparation
1. Place the machine on a firm, level surface and
lower the bucket to the ground.

W1F3-01-04-001

2. Stop the engine. Push pressure release button (1)

1
on the air breather to release any remaining
pressure from hydraulic oil tank (3).

3. Remove cap (2) of hydraulic oil tank (3).

: 5 mm 2

W1F3-01-04-002
Vacuum Pump

Hose
4. Connect a vacuum pump with the hole removed
cap (2) to maintain negative pressure in the
hydraulic oil tank (3). Adapter
NOTE: Be sure to run the vacuum pump
continuously while working.

W562-02-03-008

W1-4-1
 GENERAL / Bleeding Air from Hydraulic Oil Tank
(Blank)

W1-4-2
 MEMO

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 SECTION 2
UPPERSTRUCTURE

— CONTENTS —
Group 1 Cab Group 5 Control Valve
Remove and Install Cab .........................W2-1-1 Remove and Install Control Valve.......... W2-5-1
Dimensions of the Cab Glass.................W2-1-7 Disassemble Control Valve
(4-Spool Section) ................................. W2-5-2
Group 2 Counterweight Disassemble Control Valve
Remove and Install Counterweight ........W2-2-1
(5-Spool Section) ................................. W2-5-8
Group 3 Main Frame Disassemble and Assemble
Remove and Install Main Frame ............W2-3-1 4-Spool and 5-Spool Sections............ W2-5-14
Assemble Control Valve
Group 4 Pump Device (4-Spool Section) ............................... W2-5-16
Remove and Install Pump Device ..........W2-4-1 Assemble Control Valve
Disassemble Pump Device ....................W2-4-4 (5-Spool Section) ............................... W2-5-24
Assemble Pump Device .......................W2-4-12 Remove and Install
Disassemble Regulator ........................W2-4-24 Auxiliary Control Valve ....................... W2-5-33
Assemble Regulator .............................W2-4-26 Disassemble Auxiliary Control Valve ... W2-5-34
Disassemble Solenoid Valve ................W2-4-28 Assemble Auxiliary Control Valve ........ W2-5-36
Assemble Solenoid Valve.....................W2-4-30
Disassemble and Assemble Group 6 Swing Device
Pilot Pump ..........................................W2-4-32 Remove and Install Swing Device ......... W2-6-1
Maintenance Standard .........................W2-4-34 Disassemble Swing Reduction Gear ..... W2-6-4
Assemble Swing Reduction Gear ........ W2-6-10
Disassemble Swing Motor ................. W2-6-18
Assemble Swing Motor ........................ W2-6-22
Maintenance Standard ......................... W2-6-26

CDBW-2-1
Group 7 Pilot Valve Group 12 Pilot Relief Valve
Remove and Install Pilot Valve...............W2-7-1 Remove and Install Pilot Relief Valve .. W2-12-1
Disassemble Front/Swing Pilot Valve.....W2-7-6 Construction of Pilot Relief Valve......... W2-12-2
Assemble Front/Swing Pilot Valve........W2-7-10
Disassemble Travel,
Group 13 Steering Valve
Remove and Install Steering Valve ...... W2-13-1
Positioning/Auxiliary
Disassemble Steering Valve ................ W2-13-2
Blade/Stabilizer Pilot Valve .................W2-7-14
Assemble Steering Valve ..................... W2-13-6
Assemble Travel,
Positioning/Auxiliary Group 14 Brake Valve
Blade/Stabilizer Pilot Valve .................W2-7-16 Remove and Install Brake Valve .......... W2-14-1
Disassemble Brake Valve .................... W2-14-2
Group 8 Pilot Shut-Off Valve
Assemble Brake Valve ......................... W2-14-6
Remove and Install
Pilot Shut-Off Valve...............................W2-8-1 Group 15 Accumulator Charging Valve
Disassemble Pilot Shut-Off Valve...........W2-8-2 Remove and Install
Assemble Pilot Shut-Off Valve ...............W2-8-4 Accumulator Charging Valve.............. W2-15-1
Construction of
Group 9 Signal Control Valve
Accumulator Charging Valve.............. W2-15-2
Remove and Install Signal
Control Valve ........................................W2-9-1 Group 16 Transmission Control Valve
Remove and Install
Group 10 Travel Shockless Valve
Transmission Control Valve ............. W2-16-1
Remove and Install
Construction of
Travel Shockless Valve.......................W2-10-1
Transmission Control Valve ............. W2-16-2
Construction of
Travel Shockless Valve.......................W2-10-2

Group 11 Solenoid Valve

Remove and Install 4-Unit
Solenoid Valve Unit ............................ W2-11-1
Disassemble Proportional
Solenoid Valve .................................... W2-11-2
Assemble Proportional
Solenoid Valve .................................... W2-11-4
Remove and Install 2-Unit Solenoid
Valve (for Pump Control) .................... W2-11-6
Construction of 2-Unit Solenoid
Valve (for Pump Control) .................... W2-11-7
Remove and Install 2-Unit Solenoid
Valve (for Blade/Stabilizer) ................. W2-11-8
Construction of 2-Unit Solenoid
Valve (for Blade/Stabilizer) ................. W2-11-9

CDBW-2-2
 UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB

Removal
1. Remove seat mounting nuts (2) (4 used) to re-
move seat (1).
: 17 mm

2
1

W1F3-02-01-001

2. Remove bolts (4) (2 used) behind the cab to re-

move rear deck (3).
: 17 mm

4
3. Raise duct (5) to remove it. 5

4. Remove air filter (6). Remove clips (7) (2 used) W178-02-01-012

with a plier, then remove duct (8) from the cab.

W1F3-02-01-002

W2-1-1
 UPPERSTRUCTURE / Cab
5. Disconnect cable connectors (10, 11, 12, 13) on
the right side in the cab and ground (9) at rear
side in the cab.
: 13 mm

10
11
12

13

6. Remove washer vinyl hose (14) at rear side in the

cab. W178-02-01-014

14

W178-02-01-015

16
7. Remove cap (15) from duct cover (17) with a
screwdriver. Remove screw (16) with a screw- 17
driver then remove duct cover (17).

15

W178-02-01-016

8. Remove screw (18) and bolt (21) then remove

duct (19, 20).
: 17 mm 18
Mating Surface
19

W178-02-01-017
20 21

W2-1-2
 UPPERSTRUCTURE / Cab

CAUTION: Cab weight: 290 kg (640 lb)

9. Remove cab mounting bolts (23) and nut (24).

: 17 mm
: 24 mm 22
: 8 mm

W178-02-01-018

23

24

W157-02-01-010

10. Lift the cab off.

W157-02-01-001

W2-1-3
 UPPERSTRUCTURE / Cab
Installation

CAUTION: Cab weight: 290 kg (640 lb)

1. Lift the cab.

W157-02-01-001

2. Install cab mounting bolts (23) and nuts (24). 23

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 24 mm
: 205 N⋅m (21 kgf⋅m, 152 Ibf⋅ft)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 24

W157-02-01-010

6
3. Install duct (8) to the rear console of the cab with
clips (7) (2 used). Install filter (6) into duct (8).

7
: 4.9 N⋅m (0.5 kgf⋅m, 3.6 Ibf⋅ft)

W1F3-02-01-002

4. Install harness connectors (10, 11, 12, 13) at the

right side of the cab and install ground connector
(9) at rear side in the cab.
: 13 mm 9
: 20 N⋅m (2.0 kgf⋅m, 15 Ibf⋅ft)

10
11
12

13

W178-02-01-014

W2-1-4
 UPPERSTRUCTURE / Cab
5. Connect washer vinyl hose (14) at the rear of the
cab inside.

14

6. While aligning the mounting hole for duct (5), W178-02-01-015

press it to install the hose into the hole.

4
5

7. Install rear beck (3) with bolt (4).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

W178-02-01-012

8. Install duct (20) with bolt (21). Install duct (19) into
duct (20) and secure them with bolts (18).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
18
Mating Surface

19

W178-02-01-017
20 21

W2-1-5
 UPPERSTRUCTURE / Cab
9. Install duct cover (17) with screws (16). Install
caps (15) onto duct cover (17).
16

17

15

W178-02-01-016

10. Install seat (1) with nuts (2).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

2
1

W1F3-02-01-001

W2-1-6
 UPPERSTRUCTURE / Cab
DIMENSIONS OF THE CAB GLASS
Chamfer
A
Unit: mm Here
R2
67 303.5 Chamfer along the
11 Periphery unless
Otherwise Specified

R98 R35

4-φ13 0 -1

Section A R3018
W178-02-01-019
405 30 Chamfer Both
Sides
375
238 51 612

R118
(5 mm)

343.5 148.5
196
100

50
R70
370.5

W178-02-01-006

B
Along the Along the W178-02-01-002

Periphery Periphery
c1 c1
14
733

R58
R58

R11508

Section B W178-02-01-019

R1808
882.5 997

(4 mm)

R308 R1898
R258

100

150
943
W178-02-01-007

W2-1-7
 UPPERSTRUCTURE / Cab
Unit: mm
Chamfer Here
Chamfer Here
85.4
Charmfer Slightly
343.3 213 unless the periphery
Polish Chamfered

R105
R72 R10

R105

(4 mm)
Chamfer Slightly unless the
Periphery Polish Chamfered 39.5 D
733
733
C R2465
2-φ12.2 +0.5-0

(4 mm) Section C and D 6.754°

40

W178-02-01-019

Polish Chamfer
Both Sides
289.5
3-R4 50

2-R4
86.9 50 50
556.3

W178-02-01-011 50
423

W178-02-01-008

366.1 104.5

R12 R95

(5 mm) Chamfer along

982.7 the Periphery
W178-02-01-004

R2002

872
R123

R5 for 3 Places 38.2

R14
364.7 51
R2475 470.6
Chamfer along W178-02-01-009
(5 mm)
the Periphery

R115

888.58

W178-02-01-010

W2-1-8
 UPPERSTRUCTURE / Cab
Remove Cab Glass
Procedures to remove left-hand cab glass, lower
glass of the door and upper front glass
Mounting Rubber Section

Mounting Rubber Glass

CAUTION: When removing broken or
cracked glass beware of the danger of glass
shards that may cause serious injury.
Before removing, gummed tape or something
like should be used to paste the broken or
cracked glass ready to reinforce them so as Cab
to prevent hurt from occurring. Be sure to Seal Rubber
remove glass pieces away.
Take protective measures before removing.
Reinforce broken or cracked glass with
gummed tape to assist in safe removal. W178-02-01-022

W178-02-01-004

1. Insert bamboo spatula into position A in mounting

rubber to pry the mounting rubber apart along all A
periphery. It is easier to remove glass when air is
entered between cab and mounting rubber.
Mounting Rubber Glass
2. Tap glass from the side in cab by palm of the hand
to take the glass off. Two men are required to do
the work.

IMPORTANT: Be sure to install the cab glass and

mounting rubber using the special Cab
bonding agent. The cab glass may
Seal Rubber
fall if the special bonding agent is
not used. The cab glass assembly
cannot be replaced individually. Be
sure to change the cab glass as an
W178-02-01-022
assembly.
The upper front glass is
arched-fringed. If this glass needs to
be replaced, contact with the
nearest HITACHI dealers to replace
it as an assembly.

W2-1-9
 UPPERSTRUCTURE / Cab
Procedure to Remove Right-Hand Cab Glass Mounting Rubber Section
Cab Inside
1. Insert a bamboo spatula into position A in Glass
Mounting Rubber
mounting rubber to pry the mounting rubber apart
along all periphery. It is easier to remove the glass
A
when air is entered between cab and mounting
rubber.
Cab

2. Tap glass from the side in cab by palm of the hand

W216-02-01-005
to take the glass off. Two men are required to do
the work.

W178-02-01-002

Mounting Rubber Section

Glass
Mounting Rubber

Procedure to Remove Rear Side Cab Glass

Cab Inside Stopper
1. Remove stopper (groove rubber) with a screw-
(Groove Rubber)
driver.
A
A
2. Insert a bamboo spatula into position A in Cab
mounting rubber to pry the mounting rubber apart
along all periphery. W216-02-01-003

3. Tap glass from the side in cab by palm of the hand

to take the glass off. Two men are required to do
the work.

W178-02-01-005

W2-1-10
 UPPERSTRUCTURE / Cab
Left-Hand Cab Glass
Cab Glass Installation Procedure
Procedure for installing left-hand cab glass, lower
glass of the door and upper front glass
A

1. Install the seal rubber on the left-hand cab glass CSE Braid
and lower glass of the door.

Section A
Seal Rubber

Put Connect End in Center

of Glass Edge and Then
adhere It
W178-02-01-021

Lower Glass Of Door

50

5
W178-02-01-023 A
CSE Braid
Seal Rubber

10 10

2. When the mounting rubber is already on the glass, W178-02-01-020

pull and fasten the mounting rubber onto the Mounting Rubber Section
mounting face of cab.

IMPORTANT: Be sure to install the cab glass and

Mounting Rubber Glass
mounting rubber using the special
bonding agent. The cab glass may
fall if the special bonding agent is
not used. The cab glass assembly
cannot be replaced individually. Be
sure to change the cab glass as an
Cab
assembly.
The upper front glass is arched- Seal Rubber
fringed. If this glass needs to be re-
placed, replaced it as an assembly.

W178-02-01-022

W178-02-01-004

W2-1-11
 UPPERSTRUCTURE / Cab
Procedure for Installing Right-Hand Cab Glass Mounting Rubber Section

1. Install the mounting rubber into the surrounding of Glass

Mounting Rubber
cab glass. Bond the connectors of mounting
rubber with the bonding agent (Cemedine 366
Standard or equivalent).
Cab
NOTE: Rubber aging will cause the contraction of
rubber, be sure to leave a little extra, install
by pressing with hands.
W216-02-01-005

2. Put and fasten the mounting rubber on the

mounting face of cab after installing rubber.

W178-02-01-002

Procedure for Installing Rear Cab Glass

Mounting Rubber Section
1. Insert mounting rubber around the cab glass. In-
stall the connectors or mounting rubber with the Glass
Mounting
bonding agent (Cemedine 366 Standard or Rubber
equivalent).
Stopper
NOTE: Rubber aging will cause the contraction of
rubber, be sure to leave a little extra, install
by pressing with hands.
Cab
2. After installing the glass assembly on the cab,
insert the stopper into rubber. W216-02-01-003

IMPORTANT: The rear side glass is arched-fringed.

If this glass needs to be replaced,
contact with the nearest HITACHI
dealers to replace it as an assembly.

W178-02-01-005

W2-1-12
 UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTER-
FLENO LINKBOLT 1
WEIGHT Mounting Holes
2
Removal
CAUTION: Counterweight Weight:
4050 kg (8930 lb)

1. Remove caps (1) from upper counterweight (2).

Install FLENO LINKBOLTs to the counterweight.
NOTE: FLENO LINKBOLTs specification 3
(B-42: M42, Pitch 4.5)
4

2. Attach wire rope to FLENO LINKBOLTs. Take

out slack of wire rope by applying tension slowly
by crane.
W1F3-02-02-002

3. Remove counterweight mounting bolts (4) (4

used).
: 60 mm

IMPORTANT: The wire of combination lamp has

been connected to back of coun-
terweight. Before remove counter-
weight, disconnect the wire. 2

CAUTION: When disconnecting wire take

care not to get hands caught between the
counterweight and frame. 3

4. Hoist the counterweight (2) slowly and dislocate it

to backward approx. 200mm. Remove connec- 4
tors of both side combination lights.
W178-02-02-003

5. Lift counterweight (2) and remove it from the

frame.

W2-2-1
 UPPERSTRUCTURE / Counterweight
Installation
CAUTION: Counterweight Weight:
4050 kg (8930 lb)

1. Lift counterweight (2) by crane then place it on

the frame leaving 200 mm between frame back
side and counterweight.

2. Connect connectors of both side of the combina-

tion lamp.
2
4
3. Lift counterweight (2) and place it on mounting 3
position by crane.
W178-02-02-003

4. Temporarily tighten counterweight (2) onto the

frame with washers (3) (4 used) and bolts (4) (4
used).

5. Remove wire rope to tighten counterweight

mounting bolt with a power wrench and toque
wrench.
: 60 mm
: 3530 N⋅m (360 kgf⋅m, 2600 Ibf⋅ft)

6. Remove FLENO LINKBOLTs then install caps

(1).

Toque Wrench
Power Wrench W178-02-02-004

W178-02-02-001

W2-2-2
 UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME

CAUTION: Be sure to bleed air from

hydraulic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)

Removal

CAUTION: Counterweight weight: 4050 kg Counterweight

(8930 Ib)

1. Remove the counterweight.

(Refer to “Remove and Install Counterweight”
group.)
: 60 mm

CAUTION: Front attachment assembly W178-02-02-003

weight:
Monoblock boom: 3330 kg (7350 Ib) Monoblock Boom
2-Piece boom: 4270 kg (9420 Ib)

2. Remove the front attachment assembly.

(Refer to “Remove and Install Front Attachment”
group on page W4-1-2.)
: 27 mm, 30 mm, 36 mm

W1GL-04-01-002

2-Piece Boom

W1GL-04-01-001

W2-3-1
 UPPERSTRUCTURE / Main Frame

CAUTION: Center joint weight: 93 kg Stopper

(210 Ib)

3. Remove the stopper and hoses.

(Refer to “Remove and Install Center Joint” Center Joint
group.)
: 24 mm, 36 mm

W1F3-03-03-003

CAUTION: Upperstructure weight: 4980 kg

(10980 Ib)

IMPORTANT: Make sure rear wire ropes not to

touch engine.
4. Attach wire ropes to the rear (counterweight
bracket) of the frame and boom bracket.
NOTE: It is easy to adjust the wire ropes length Rear
and level the frame if a chain block is
W105-02-03-004
used.

Front
5. Put mating marks on the upperstructure and the W105-02-03-005
outer race of the swing bearing.
Loosen the mounting bolt of the swing bearing
and remove it.
: 27 mm
NOTE: Chain block shall be used to adjust and
level the frame, then lift it slightly off the
undercarriage.

W1F3-03-01-002

Bolt

W2-3-2
 UPPERSTRUCTURE / Main Frame
Installation

CAUTION: Upperstructure weight: 4980 kg

(10980 Ib)

1. Fasten wire ropes to the main frame. Level the

main frame by adjusting the chain block. Lift and
install the main frame to the undercarriage.
NOTE: As for lifting method, refer to Removal
section.

2. Align the mating mark on the outer race of the

upperstructure and the swing bearing.
Install the mounting bolt to the swing bearing and
tighten it temporarily. Remove wire ropes and
tighten the mounting bolts to the swing bearing to
specification.
Upperstructure Side:
: 27 mm W1F3-03-01-002
: 390 N⋅m (40 kgf⋅m, 285 Ibf⋅ft)
Undercarriage Side: Bolt
: 30 mm Bolt
: 490 N⋅m (50 kgf⋅m, 360 Ibf⋅ft)
Stopper

3. Connect the hoses (15 used) to the center joint.

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
Center Joint
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 Ibf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft)

4. Apply LOCTITE#262 to the bolts (5 used). Install

W1F3-03-03-003
the stopper with them.
: 24 mm
: 265 N⋅m (27 kgf⋅m, 195 Ibf⋅ft)

CAUTION: Counterweight weight: 4050 kg Counterweight

(8930 Ib)

5. Install counterweight (6).

(Refer to “Remove and Install Counterweight”
group.)
: 60 mm
: 3530 N⋅m (360 kgf⋅m, 2600 Ibf⋅ft)

W178-02-02-003

W2-3-3
 UPPERSTRUCTURE / Main Frame

CAUTION: Front attachment assembly Monoblock Boom

weight:
Monoblock boom: 3330 kg (7350 Ib)
2-Piece boom: 4270 kg (9420 Ib)

6. Install front attachment assembly. Then, fill with

hydraulic oil.
(Refer to “Remove and Install Front Attachment”
group on page W4-1-2.)
: 27 mm
W1GL-04-01-002
: 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)
: 30 mm 2-Piece Boom
: 540 N⋅m (55 kgf⋅m, 400 Ibf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft)

7. Start the engine and set the front attachment in

posture for checking hydraulic oil level in its tank.
Inspect the hydraulic oil level and check if there
is any oil leakage.

W1GL-04-01-001

W2-3-4
 UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE

CAUTION: Be sure to bleed air from hydrau-

lic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)

Removal
4
1. Remove bolts (2) (3 used) to remove bracket (1)
and engine cover (3).

2. Disconnect connectors (7 places). 3 2

2
CAUTION: Pump device weight: 170 kg
(375 Ib)
5
IMPORTANT: Attach the identification tag onto the 1
disconnected hoses for re-assem-
bling.
3. Disconnect main hoses (8) (2 used) and hoses (7)
(2 used) from pump device (5). Cap open ends.
: 8 mm, 10 mm
10
4. Disconnect suction pipe (6) from pump device (5). W1GL-02-04-003
: 10 mm
6
9 8 7
5. Disconnect suction hoses (9) (2 used) and pilot
hoses (10) (6 used) from pump device (5).
: 17 mm, 19 mm Eyebolt Mounting
: 10 mm Position N Sensor

6. Disconnect the hoses (2 used) below the gear

pumps.
: 27 mm

7. Remove plate (4) between the engine room and

pump device (5) room.
: 17 mm, 19 mm

IMPORTANT: Do not install the eyebolt to the

regulator, which is with solenoid
valves (pump 2 side).
8. Attach eyebolts (M12, Pitch 1.75 mm) (ST 0002)
to pump device (5). Lift and hold pump device (5).

9. Remove the pump device (5) mounting bolts (8

used) then lift pump device (5) off.
W1GL-02-04-005
: 17 mm

W2-4-1
 UPPERSTRUCTURE / Pump Device

Installation Eyebolt Mounting

Position N Sensor

IMPORTANT: Do not install the eyebolt to the

regulator, which is with solenoid
valves (pump 2 side).
1. Install eyebolt (M12, Pitch 1.75 mm) (ST 0002) on
pump device (5) and lift pump device (5).

2. Insert the drive shaft of pump device (5) into the

pump mission, and install pump device (5) with
the pump device (5) mounting bolts (8 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

3. Install plate (4) between the engine room and

pump device (5) room with the bolts (9 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 19 mm
W1GL-02-04-005
: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)
4
4. Connect pilot hoses (10) (6 used) and suction
hoses (9) (2 used).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft) 2
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 10 mm 5
: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)

5. Connect main hoses (8) and hoses (7) (2 used

each).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 10
: 10 mm
: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft) W1GL-02-04-003

6
9 8 7

W2-4-2
 UPPERSTRUCTURE / Pump Device

6. Install suction pipe (6).

: 10 mm
: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)
3
2
7. Connect the hoses (2 used) below the gear
pumps. 2
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)

8. Install bracket (1) and the engine cover (3) as- 1

sembly with bolts (2) (3 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)

9. Connect connectors (7 places). W1GL-02-04-003

6
IMPORTANT: Bleed the air from the pump. (Refer
to W1-1-2).
Be sure to check hydraulic oil level
and that no oil leaks after assem-
bling.
: 27 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

W2-4-3
 UPPERSTRUCTURE / Pump Device
DISASSEMBLE PUMP DEVICE
4
3 5
1 2
17
16
15
14
18
13
6
12
11
10
9
56
7

55
8 17
54 16
14
53 15
52 19

12
51
20
11
49 10
9

21
22
50 23
49 21 24
48 22
28

27
26
25
47

37 36

33 38
35
29
46 26
45 34

32
31 30 39

40
41
42
43
44 W1GL-02-04-001
42

W2-4-4
 UPPERSTRUCTURE / Pump Device
68
69
70
67
67
66
71

65
64
63

60 61 72
58 62 61 74
58 73

58 61
59
78 77 61 75
60
57 76
60
58 68
59
58 78
58
79

57
58

79 W178-02-04-005

1- Socket Bolt (4 Used) 21 - O-Ring (2 Used) 41 - Retaining Ring 61 - Pin (4 Used)

2- Right Regulator 22 - Plug (2 Used) 42 - Ball Bearing (2 Used) 62 - Right Valve Plate
3- Socket Bolt (2 Used) 23 - O-Ring 43 - Gear 63 - Backup Ring
4- Socket Bolt (2 Used) 24 - Stopper 44 - Gear Shaft 64 - O-Ring
5- Socket Bolt (2 Used) 25 - Plug 45 - Retaining Ring 65 - Spring Pin (2 Used)
6- Left Regulator 26 - Retaining Ring (2 Used) 46 - Oil Seal 66 - Selector Head
7- O-Ring (4 Used) 27 - Gear 47 - Gear Casing 67 - O-Ring (4 Used)
8- O-Ring (6 Used) 28 - Gasket 48 - Spring Pin (2 Used) 68 - Socket Bolt (16 Used)
9- Bearing Nut (2 Used) 29 - Gear 49 - Oil Seal (2 Used) 69 - Stopper S (2 Used)
10 - Bearing (2 Used) 30 - Plug 50 - Retaining Ring (2 Used) 70 - O-Ring (2 Used)
11 - Ring (2 Used) 31 - O-Ring 51 - Pump Casing 71 - Socket Bolt (12 Used)
12 - Bearing (2 Used) 32 - Gasket 52 - Spring Washer (6 Used) 72 - Set Screw (2 Used)
13 - Shaft 33 - Socket Bolt (2 Used) 53 - Bolt (6 Used) 73 - Servo Piston (2 Used)
14 - Pin (2 Used) 34 - Pipe 54 - Spring Pin (2 Used) 74 - Pin (2 Used)
15 - Center Shaft (2 Used) 35 - Level Gauge 55 - O-Ring (2 Used) 75 - O-Ring (2 Used)
16 - Spring (2 Used) 36 - Socket Bolt (2 Used) 56 - O-Ring (2 Used) 76 - Stopper L (2 Used)
17 - Plunger (14 Used) 37 - Spring Washer (2 Used) 57 - Pin (2 Used) 77 - Left Valve Plate
18 - Rotor (2 Used) 38 - Washer (2 Used) 58 - Retaining Ring (12 Used) 78 - Pin (4 Used)
19 - Shaft 39 - Pilot Pump 59 - Pin (2 Used) 79 - Link (2 Used)
20 - Slide Ring 40 - Retaining Ring 60 - Lever (4 Used)

W2-4-5
 UPPERSTRUCTURE / Pump Device

4
3 5
1 2

68
6 69

66
71

51

76

68

25
47

33 35

36
34

32
30 39

W1GL-02-04-002

W2-4-6
 UPPERSTRUCTURE / Pump Device
1. Remove plug (25) from gear casing (47). 8. Remove socket bolts (71) (12 used) from selector
: 17 mm head (66).
: 10 mm
2. Remove plug (30) from gear casing (47) to drain NOTE: When loosening the socket bolts, the se-
gear oil. (Approx. 1.0 L (0.26 US gal.)) lector head will jump out due to the force of
: 22 mm spring (16). Be sure to record the clearance
between pump casing (51) and the selector
3. Remove socket bolts (1) (4 used) to remove right head to ensure the internal parts of pump
regulator (2) from pump casing (51). casing is in correct position when re-as-
: 8 mm sembling.
NOTE: Pry up the right regulator to the selector
head (66) side for easy removal.
CAUTION: Selector head weight:
4. Remove socket bolts (3) and (5) (2 used each), 28 kg (60 lb)
remove left regulator (6) from pump casing (51).
Socket bolts (4) are used to install the solenoid 9. Install eyebolt (M12, pitch 1.75 mm) to the bolt
valve, do not remove socket bolt (4). hole on the top of selector head (66), lift the se-
: 8 mm lector head off pump casing (51). At this time, the
O-ring is removed with the lower surface of the
NOTE: Pry up the left regulator to selector head selector head. Remove the O-ring before setting
(66) side for easy removal. down.

CAUTION: Pump device weight: 10. Remove socket bolts (68) (16 used) from selector
160 kg (350 lb) head (66), remove stopper S (69) and stopper L
(76). (2 places)
CAUTION: When lifting, do not take pump : 6 mm
casing (51) off the ground. Turn it to the gear
casing (47) side. NOTE: O-rings (70, 75) are attached on stopper S
(69) and stopper L (76). If they are assem-
5. Install eyebolt (M10, Pitch 1.5 mm) to the bled too tightly to remove, tap the outer pe-
threaded hole for socket bolts (1, 3) of pump riphery of the stopper to the position where
casing (51), lift pump casing (51), position the about half of the hole for the mounting bolt
pump device with gear casing (47) facing down. can be seen. Turn the stopper, insert a
At this time, place 80 mm square wooden blocks screwdriver into the mounting bolt hole to
under the gear casing. pry the stopper for easy removing.
6. Remove socket bolts (33) (2 used) from gear cas-
ing (47), remove level gauge (35), pipe (34) and
gasket (32). Stopper
: 6 mm

7. Remove socket bolt (36) from gear casing (47),

remove pilot pump (39).
: 8 mm
NOTE: THREEBOND has been applied to the
mounting surface of pilot pump (39), tap
the flange of pilot pump (39) along the pe-
riphery with a plastic hammer lightly and
then remove pilot pump (39).
W178-02-04-055

W2-4-7
 UPPERSTRUCTURE / Pump Device
18
17
16
15
13

17
53 15
19
51

28

27
26

66 71
47

29 64
26 63

60 72
61
58 62
61 73
74
58
61
77
78 61

60

78
79 58
60

79 W178-02-04-011

W2-4-8
 UPPERSTRUCTURE / Pump Device
11. Remove set screw (72) out of servo piston (73), 17. Remove bolts (53) (6 used) from gear casing (47).
and then remove pins (74). (2 places) : 24 mm
: 6 mm
NOTE: LOCTITE has been applied to the set CAUTION: Pump casing weight:
screw. Heat it with a drier etc. for easy re- 105 kg (230 lb)
moval.
18. Install eyebolt (M12, Pitch 1.75 mm) to the
12. Pull out servo piston (73) from selector head (66). threaded hole for socket bolt (71) of pump casing
(2 places) (51), lift the pump casing off gear casing (47). At
this time, shafts (13, 19), gears (27, 29) and etc.
13. Remove backup ring (63) and O-ring (64) from are removed with the pump casing.
pump casing (51). Place the pump casing with the mounting surface
of the regulator facing up.
IMPORTANT: Both right valve plates (62), left (77)
are very similar. Their installation 19. Remove gasket (28) from gear casing (47).
direction is determined. Record their
position and direction before dis- IMPORTANT: The position where the gears en-
assemble. gaging are determined. Make align-
ing marks on the gears for easy
14. Remove retaining rings (58) (8 used) from pins re-assembling.
(61, 78) (4 used each). Then, remove levers (60) 20. Make aligning marks on meshed position of
(4 used) and right valve plate (62) and left valve splines on shafts (13, 19) and gears (27, 29). And
plate (77) from links (79) (2 used). make aligning marks on meshed position of gears
NOTE: Pin (61) has been attached on valve plates (27, 29).
(62, 77) with LOCTITE. Do not remove it
unless necessary. 29
27
15. Remove rotor (18), spring (16), center shaft (15)
and plunger (17) from pump casing (51) in order.
(Both right and left)
NOTE: When remove the plunger, turn over the
plunger inside and pull it out.
13 19
IMPORTANT: If link (79) is distorted, the pump W137-02-04-007
performance will be changed. Do not
apply excess loads.
21. Remove retaining rings (26) from shafts (13, 19),
16. Remove the two link (79) assemblies from pump
and then remove gears (27, 29).
casing (51). Do not disassemble the link
assembly unless necessary.
NOTE: If it is difficult to remove, tap the two roots CAUTION: Pump casing weight: 70 kg (154 lb)
of the link lightly with a plastic hammer.
22. Lift pump casing (51), and position selector head
(66) with the mounting side facing down.

W2-4-9
 UPPERSTRUCTURE / Pump Device

13

12
11
10
9

19

12
51 20
11
49 10
9

50 24
49

47

46
45

40
41
42
43
44
W1GL-02-04-001
42

W2-4-10
 UPPERSTRUCTURE / Pump Device
23. Remove stopper (24) from pump casing (51). 28. Remove bearings (10, 12) as well as ring (11)
from shafts (13, 19) with a press.
CAUTION: Pump casing weight: 70 kg (154 lb)
CAUTION: Pump casing weight: 42 kg (93 lb)
24. Lift pump device (51) and place the pump casing
on the wooden blocks with mission side facing 29. Lift pump casing (51), and position the regulator
down. Wooden block size: 100 mm or more in with the mounting surface facing up.
width and height.
30. Remove retaining rings (50) (2 used), oil seals
25. Remove shafts (13, 19) from pump casing (51) (49) (2 used) from pump casing (51).
using special tool (ST 1470) (ST 1471). At this
time, bearings (10, 12) are removed with the 31. Remove retaining ring (40) from gear casing (47)
shafts. and remove retaining ring (41) from gear shaft
(44).
Special Tool
ST 1470
32. Pull out upper ball bearing (42) and gear shaft
Special Tool
ST 1471 (44) from gear casing (47) using special tool (ST
1393).
13

19
44

51
42

W178-02-04-054

26. Remove slide ring (20) from shaft (19).

W178-02-04-009

27. Remove bearing nut (9) from shafts (13, 19) using
special tool (ST 3058). 33. Remove gear (43) and ball bearing (42) from gear
casing (47).
ST 3058
34. Install a shackle to the bolt hole on the periphery
9 of gear casing (47), lift and turn gear casing (47)
over.

35. Remove retaining ring (45), oil seal (46) from gear
casing (47).

W137-02-04-023

W2-4-11
 UPPERSTRUCTURE / Pump Device
ASSEMBLE PUMP DEVICE
77 64 63 18 16 15 17 12 20 11 10 9 49 29

26

19

50

13
26

27

62 58, 61 60 18 78 16 15 17 12 11 9 49
10
68 69 67 70 8 7 54 55 59 58
57 56 51

66

73

72

74

76
W178-02-04-003

68 65 22 21 79 14 24 23
75

W2-4-12
 UPPERSTRUCTURE / Pump Device

32, 33, 34
30, 31 39 36, 37, 38 25 6 5 4 35 3 41 40 43 42

44

45

46

48

47
W1GL-02-04-004

71 2 1 53 52 28

1- Socket Bolt (4 Used) 21 - O-Ring (2 Used) 41 - Retaining Ring 61 - Pin (4 Used)

2- Right Regulator 22 - Plug (2 Used) 42 - Ball Bearing (2 Used) 62 - Right Valve Plate
3- Socket Bolt (2 Used) 23 - O-Ring 43 - Gear 63 - Backup Ring
4- Socket Bolt (2 Used) 24 - Stopper 44 - Gear Shaft 64 - O-Ring
5- Socket Bolt (2 Used) 25 - Plug 45 - Retaining Ring 65 - Spring Pin (2 Used)
6- Left Regulator 26 - Retaining Ring (2 Used) 46 - Oil Seal 66 - Select Head
7- O-Ring (4 Used) 27 - Gear 47 - Gear Casing 67 - O-Ring (4 Used)
8- O-Ring (6 Used) 28 - Gasket 48 - Spring Pin (2 Used) 68 - Socket Bolt (16 Used)
9- Bearing Nut (2 Used) 29 - Gear 49 - Oil Seal (2 Used) 69 - Stopper S (2 Used)
10 - Bearing (2 Used) 30 - Plug 50 - Retaining Ring (2 Used) 70 - O-Ring (2 Used)
11 - Ring (2 Used) 31 - O-Ring 51 - Pump Casing 71 - Socket Bolt (12 Used)
12 - Bearing (2 Used) 32 - Gasket 52 - Spring Washer (6 Used) 72 - Set Screw (2 Used)
13 - Shaft 33 - Socket Bolt (2 Used) 53 - Bolt (6 Used) 73 - Servo Piston (2 Used)
14 - Pin (2 Used) 34 - Pipe 54 - Spring Pin (2 Used) 74 - Pin (2 Used)
15 - Center Shaft (2 Used) 35 - Level Gauge 55 - O-Ring (10 Used) 75 - O-Ring (2 Used)
16 - Spring (2 Used) 36 - Socket Bolt (2 Used) 56 - O-Ring (2 Used) 76 - Stopper L (2 Used)
17 - Plunger (14 Used) 37 - Spring Washer (2 Used) 57 - Pin (2 Used) 77 - Left Valve Plate
18 - Rotor (2 Used) 38 - Washer (2 Used) 58 - Retaining Ring (12 Used) 78 - Pin (4 Used)
19 - Shaft 39 - Pilot Pump 59 - Pin (2 Used) 79 - Link (2 Used)
20 - Slide Ring 40 - Retaining Ring 60 - Lever (4 Used)

W2-4-13
 UPPERSTRUCTURE / Pump Device

30, 31 25 41 40 42 43 42

44

47
W1GL-02-04-004

51 12 20 11 10

19

13

12 11 10 9 W178-02-04-013

W2-4-14
 UPPERSTRUCTURE / Pump Device
1. With a guide bar and hammer, tap the inside ball 10. Set the pre-loads of bearings (10, 12) installed on
bearing (42) into gear casing (47), with the stamp shaft (13) according to the following procedures.
mark facing inside. • Apply a film of hydraulic oil to bearing nut (9)
NOTE: Tap the bearing and listen to ring to confirm threads. Tighten bearing nut (9) until it comes in
installation is completed. contact with bearing (10) using special tool (ST
3058).
2. Put gear (43) to ball bearing (42), insert gear shaft ST 3058
(44) while aligning the spline.
9
3. With a guide bar and hammer, tap the outside ball 10
bearing (42) into gear casing (44), with the stamp
mark facing outward.
NOTE: Tap the bearing and listen to ring to confirm
installation is completed.
W137-02-04-023

4. Install retaining ring (40) onto gear casing (47), • Attach special tool (ST 3070) on bearing (10),
and install retaining ring (41) onto gear shaft (44). rotate bearing (10) 2 to 3 turns and measure the
starting torque.
5. Install O-ring (31) onto plug (30) and install plug
(30) to gear casing (47). ST 3070
: 22 mm
: 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft) 10

6. Heat bearings (10, 12) (2 used each) to 50 to 80 °C

(122 to 176 °F).

CAUTION: Take care that bearing (12) is hot. W107-02-04-052

7. Apply a film of hydraulic oil to the inside of bear- • Adjust the starting torque repeatedly, until it
ings (12) (2 used), and install them onto shafts reaches specification.
(13, 19) with a press. Torque: 2.16±0.49 N⋅m
(0.22±0.05 kgf⋅m, 1.59±0.36 Ibf⋅ft)
8. Install ring (11) onto shafts (13, 19).
NOTE: If the starting torque is higher than the limit
of specified torque, loosen the bearing nut,
CAUTION: Take care that bearing (10) is hot. tap the shaft end to release the bearing’s
load, and repeat the procedure.
9. Apply a film of hydraulic oil to the inside of bear-
ings (10) (2 used), and install them onto shafts 11. Set the pre-loads for bearing (10, 12) installed on
(13, 19) with a press. shaft (19) by the same procedure as step 10
above mentioned.

12. Install slide ring (20) to the shaft (19) at inserting

side to pump casing (51).

W2-4-15
UPPERSTRUCTURE / Pump Device

12 20 10 49

19

50

13

49

Regulator Mounting Surface

51

24 23 W178-02-04-003

W2-4-16
 UPPERSTRUCTURE / Pump Device
13. Heat pump casing (51) to 50 to 80 °C (122 to 176 19. Install special tools (ST 2649, ST 2650) over the
°F). spline parts of shafts (13, 19).
NOTE: If the special tools are not available, wind
CAUTION: Use special tool to insert the shaft vinyl tape and etc. over spline part of the
(19) assembly, because pump casing (51) has shaft to protect the oil seal (49) from being
been heated. damaged.

14. Apply a film of hydraulic oil to the outside of bear-

ings (10, 12) installed on shaft (19), install shaft
(19) to pump casing (51) using special tool.
ST 2650
If it is difficult to insert, tap in shaft (19) with a
guide bar, etc.
49
Special Tool

M8, Pitch 1.25 mm

51

19 W157-02-04-022
ST 2649

IMPORTANT: Apply a film of grease to the inner

diameter of oil seals (49) (2 used).
Wooden Wooden
Block 20. Evenly tap oil seals (49) (2 used) onto shafts (13,
Block
19).
W178-02-04-012

21. Remove special tool (ST 2649, ST 2650) from

15. Install shaft (13) into pump casing (51), using the shafts (13, 19).
same procedure as above step 14.
22. Install retaining rings (50) (2 used) to pump casing
16. Wait for pump casing (51) cooling down to the (51).
temperature lower than 40 °C (104 °F).

17. Install O-rings (23) (2 used) to stoppers (24) (2

used), and install stoppers (24) to pump casing
(51).
: 19 mm
: 34.5 N⋅m (3.5 kgf⋅m, 25.3 Ibf⋅ft)

CAUTION: Pump casing weight: 65 kg (143 lb)

18. Lift pump casing (51) and position the regulator

with the mounting surface facing up.

W2-4-17
 UPPERSTRUCTURE / Pump Device

39 36, 37, 38 25 32, 33, 34 41 40 42 42

44

47

48

W1GL-02-04-004

71 53 52 28

66 60 58,78 79 15 14 17 51 29

26

19

13

26

60 58, 78 79 15 14 17 27 W178-02-04-013

W2-4-18
 UPPERSTRUCTURE / Pump Device
23. Install gears (27, 29) onto shafts (13, 19), aligning 26. Apply THREEBOND #1215 to the mounting sur-
the mating marks made when disassembling, face of pilot pump (39), install the pilot pump to
and install retaining rings (26) (2 used). gear casing (47) with socket bolts (36), spring
When replacing the shafts and gears, install the washers (37) and washers (38) (2 used each).
gear according to the following procedure. : 8 mm
• Secure the special tool (ST 7934) to the mounting : 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
surface of shafts (13, 19) for plunger (17).
27. Install gasket (32), pipe (34) to gear casing (47).
19 Tighten them with socket bolts (33) (2 used).
: 6 mm
ST 7934 13 : 19.5 N⋅m (2 kgf⋅m, 14 Ibf⋅ft)

28. Install levers (60), pins (78) and retaining rings

(58) (4 for each) to links (79) (2 used).

IMPORTANT: If link (79) is distorted, the pump

M8, Pitch 1.25 mm W137-02-04-029 performance will be changed. Do not
apply unreasonable loads.
• Turn shafts (13, 19) clockwise, viewed from the
mounting side of gears (27, 29), until it comes into 29. Install the link (79) assemblies (2 used), aligning
contact using special tool. (To remove the play in the groove for pin (57) in pump casing (51). At this
periphery direction) time, lever (60) faces selector head (66).
• Install gear (27) and retaining ring (26) to the
spline of shaft (13). NOTE: Both surfaces of pin (57) are parallel to
• Install gear (29) onto the spline of shaft (19), with each other. Insert the pin aligning the par-
engaging to gear (27). If it does not engage, turn allel face with the groove.
shaft (19) in the play range of special tool to find
57
the engaging position. 79
• Install retaining ring (26) to the spline of shaft 51
(19).
• Remove the special tool.

24. Tap spring pins (48) (2 used) into gear casing (47),
and install gasket (28). Parallel Face Parallel Face W176-02-04-016

CAUTION: Pump casing weight: 70 kg (154 lb) 30. Apply hydraulic oil to the plunger (17) mounting
surface of shafts (13, 19).
25. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the threaded hole for socket bolt (71) in pump 31. Insert plungers (17) (7 used each) into shafts (13,
casing (51), lift pump casing (51). 19).
Engaging gear (43) and gear (29), install the
gears into gear casing (47). Install the gear casing 32. Apply a film of grease to pins (14) (2 used), and
to the pump casing with bolts (53), spring wash- then install them to center shafts (15) (2 used).
ers (52) (6 used each).
: 24 mm 33. Apply a film of grease to the spherical surface of
: 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft) center shafts (15) (2 used), and then install them
to shafts (13, 19).

W2-4-19
 UPPERSTRUCTURE / Pump Device

58 60 16 79 18 15 14 17 51

61

77

W178-02-04-013
62 58, 61 60 18 58, 78 79 16 15 14 17

8 7 54 55 59 56

5 6 3

66

72

74
73
2 1
64 63 W178-02-04-018

W2-4-20
 UPPERSTRUCTURE / Pump Device
34. Install springs (16) (2 used) to center shafts (15) 41. Install right regulator (2) into pump casing (51),
(2 used). according to the following procedure.
• Adjust the sleeve position so that the grooves in
35. Insert center shafts (15) (2 used) and plungers both sleeves on the right regulator are in a line.
(17) (14 used) into rotors (18) (2 used). • Put the right regulator on the pump casing, install
pin (59) for link (79) into the both grooves in the
36. Insert a file’s shank etc. into the center hole of sleeve.
center shaft (15), rotate the center shaft to install • Move the right regulator, so that spring pin (54)
pin (14) into the groove of rotor (18). (Both right extended from the pump casing can enter into the
and left pump) right regulator.
NOTE: If the pin does not enter into the groove of • Install the right regulator into the pump casing
the rotor, selector head (66) cannot be with socket bolts (1) (4 used).
assembled to pump casing (51). : 8 mm
: 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
37. Apply a film of LOCTITE LI829 to the threads of 59
pins (61) (4 used), and then install the pins to 2 Sleeve
valve plates (62, right) and (77, left).
: 7 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft)

IMPORTANT: Take care to the mounting direction

of right regulator (62).
38. Insert pins (61) (2 used) for right valve plate (62) 51 54 W178-02-04-015
79
into the hole of levers (60) (2 used) for right regu-
lator (2), and install retaining rings (58) (2 used). 42. Install left regulator (6) onto pump casing (51) in
the same procedure as step 41, and secure the
77 62 left regulator with socket bolts (3, 5) (2 used
Upper
each).
: 8 mm
: 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)

43. Install backup ring (63), O-ring (64) and O-rings

(8) (6 used) into pump casing (51).

44. Insert servo pistons (73) (2 used) into selector

W178-02-04-014
head (66).

IMPORTANT: Take care to the mounting direction 45. Install pin (74) into servo piston (73), fix the servo
of left regulator (77). piston with set screw (72). (Both right and left
39. Insert pins (61) (2 used) for left valve plate (77) servo pistons)
into the hole of levers (60) (2 used) for left regu- Beforehand, apply a film of LOCTITE LI829 to the
lator (6), and install retaining rings (58) (2 used). threads of the set screw.
: 6 mm
40. Install O-rings (56) (2 used), (55) (10 used), (7) (4 : 34.3 N⋅m (3.5 kgf⋅m, 25 Ibf⋅ft)
used) and spring pins (54) (2 used) into pump
casing (51).

W2-4-21
 UPPERSTRUCTURE / Pump Device

25 35 34

45

46

47
W1GL-02-04-004

71

68 67 69 70 18 51

19

66

74

Mounting Surface
for Suction Pipe
W178-02-04-016

75 68 62 76 65 14

W2-4-22
 UPPERSTRUCTURE / Pump Device
46. Install spring pins (65) (2 used) into selector head
CAUTION: Pump device weight:
(66).
160 kg (350 lb)

CAUTION: Selector head weight: 29 kg (64 lb) 52. Install eyebolts (M12, Pitch 1.75 mm) (4 used) to
the threaded hole for suction pipe in selector head
47. Install eyebolts (M12, Pitch 1.75 mm) (2 used) (66). Lift the selector head and position it with the
into the threaded hole for suction pipe in selector regulator mounting side upward.
head (66), lift selector head (66).
Install the selector head on pump casing (51), 53. Insert special tool (ST 2650) on shaft (19). Apply a
while aligning the selector head with spring pin film of grease to oil seal (46) and install the oil
(65). seal to shaft (19).
Pull out the special tool, tap oil seal (46) into the
NOTE: Measure the clearance between the se- gear casing.
lector head and pump casing. Compare it NOTE: If special tool (ST 2650) is not available,
with the clearance, which was recorded wind vinyl tape etc. over the spline parts of
during disassembling. If it is larger, pin (14) shaft (19) to protect the oil seal from being
cannot be inserted into the groove in rotor damaged, and then install the oil seal.
(18), or pin (14) cannot be inserted into the ST 2650
holes in valve plates (62, 77). Please con-
firm it.
46
48. Tighten selector head (66) to pump casing (51)
with socket bolts (71) (12 used).
: 10 mm
: 108 N⋅m (11 kgf⋅m, 80 Ibf⋅ft)

49. Install O-rings (67) (4 used) to selector head (66).

50. Install O-ring (70) to stopper S (69). Install the W157-02-04-023

stopper S to selector head (66) with socket bolts
(68) (4 used). (2 places)
54. Install retaining ring (45) to gear casing (47).
: 6 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
55. Supply engine oil 1.0 L (0.26 US gal.) into gear
casing (47) through the hole for plug (25).
51. Install O-ring (75) to stopper L (76). Install the
stopper L to selector head (66) with socket bolts IMPORTANT: The breather hole for plug (25) lo-
(68) (4 used). (2 places) cates at left side, seen from the front
: 6 mm of gear casing (47).
: 19.5 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft) 56. Wind plug (25) with seal tape and install plug (25)
to gear casing (47).
: 17 mm
: 39.5 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)

57. Insert level gauge (35) into pipe (34).

W2-4-23
 UPPERSTRUCTURE / Pump Device
DISASSEMBLE REGULATOR

1 2 3

Right Regulator Left Regulator

6 7 8 9 10 11 12 13 14 15

5 16

4 17

18
19
33
W176-02-04-001

32
31 30 29 28 27 26 25 24 23 22 21 20

1- Pipe 10 - Spool 18 - Lock Nut 26 - Spool

2- Socket Bolt (2 Used) 11 - Sleeve 19 - Lock Nut 27 - Piston
3- Solenoid Valve 12 - Piston 20 - Socket Bolt (4 Used) 28 - Cylinder
4- Lock Nut 13 - Cylinder 21 - Stopper Assembly 29 - O-Ring
5- Lock Nut 14 - O-Ring 22 - O-Ring 30 - Backup Ring
6- Stopper Assembly 15 - Cover 23 - Spring 31 - O-Ring
7- O-Ring 16 - Set Bolt 24 - Spring 32 - Socket Bolt (4 Used)
8- Spring 17 - Lock Nut 25 - Sleeve 33 - Cover
9- Casing

W2-4-24
 UPPERSTRUCTURE / Pump Device
Disassemble Regulator

• Regulators are used for right pump and left pump. 9. Insert a round bar into the hole of casing (9).
The regulator’s inner structure is fully identical, Pushing the spool (10) end, push out cylinder (13),
and the difference is only in its accessories. Here sleeve (11) and the spool. At this time, piston (12)
is the description of left regulator. is removed with the cylinder.

IMPORTANT: If adjusting screws (4, 5, 16, 17, 18, 10. Pull out piston (12) from cylinder (13).
19) are disassembled, their set val-
ues will change. So, do not disas-
semble them.
When these adjusting screws must
be disassembled, carry out adjust-
ment according to the procedure of
performance test after assembling.

1. Clamp casing (9) in a vise, then remove pipe (1)

from the casing.
: 17 mm

2. Remove socket bolts (2) (2 used) and remove

solenoid valve (3) from the casing (9).

IMPORTANT: Do not loosen set bolt (16), lock nuts

(17, 18 and 19). Otherwise, the set
values will change.
3. Remove socket bolts (20) (4 used), and then re-
move cover (15) from casing (9). At this time, set
bolt (16) and stopper assembly (21) are removed
with the cover.
: 6 mm

IMPORTANT: Do not loosen lock nuts (4, 5). Oth-

erwise, set values will change.
4. Remove socket bolts (32) (4 used), and then re-
move cover (33) from casing (9). At this time,
stopper assembly (6) is removed with the cover.
: 6 mm

5. Pull out springs (23, 24) from casing (9).

6. Insert a round bar into the hole of casing (9). Push-

ing the spool (26) end, push out cylinder (28),
sleeve (25) and the spool from the casing. At this
time, piston (27) is removed with the cylinder.

7. Pull out piston (27) from cylinder (28).

8. Remove spring (8) from casing (9).

W2-4-25
 UPPERSTRUCTURE / Pump Device
ASSEMBLE REGULATOR

1 2 3

Right Pump Regulator Left Pump Regulator

6 7 8 9 10 11 12 13 14 15

5 16

4 17

18
19
33
W176-02-04-001

32
31 30 29 28 27 26 25 24 23 22 21 20

1- Pipe 10 - Spool 18 - Lock Nut 26 - Spool

2- Socket Bolt (2 Used) 11 - Sleeve 19 - Lock Nut 27 - Piston
3- Solenoid Valve 12 - Piston 20 - Socket Bolt (4 Used) 28 - Cylinder
4- Lock Nut 13 - Cylinder 21 - Stopper Assembly 29 - O-Ring
5- Lock Nut 14 - O-Ring 22 - O-Ring 30 - Backup Ring
6- Stopper Assembly 15 - Cover 23 - Spring 31 - O-Ring
7- O-Ring 16 - Set Bolt 24 - Spring 32 - Socket Bolt (4 Used)
8- Spring 17 - Lock Nut 25 - Sleeve 33 - Cover
9- Casing

W2-4-26
 UPPERSTRUCTURE / Pump Device
Assemble Regulator

IMPORTANT: Two holes for sleeve in casing (9) 9. Install O-ring (22) and springs (23, 24) to stopper
are with identical bores, and the assembly (21) on cover (15). Install the cover on
shapes of various parts are very casing (9) with socket bolts (20) (4 used).
similar. Take care not to misassem- : 6 mm
ble them. Perform assembling as il- : 19.6 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
lustrated.
10. With socket bolts (2) (2 used), install solenoid
1. Clean all parts neatly and apply hydraulic oil. valve (3) onto casing (9).
: 8 mm
IMPORTANT: Take care to the direction for sleeve : 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
(11), spool (10) and piston (12) when
assembling. 11. Apply a film of grease to the threaded part of pipe
2. Insert spool (10) into sleeve (11). With a round bar, (1). Install pipe (1) to casing (9).
assemble it at the position closed to the center of : 17 mm
casing (9). : 34 N⋅m (3.5 kgf⋅m, 25.3 Ibf⋅ft)

3. Install O-ring (14) onto cylinder (13).

4. Insert piston (12) into cylinder (13), then assem-

ble on casing (9).

IMPORTANT: Take care to the direction for sleeve

(25) and spool (26) when assem-
bling.
5. Insert spool (26) into sleeve (25), with a round bar
to assemble it at the position closed to the center
of casing (9).

6. Install O-rings (29, 31) and backup ring (30) onto

cylinder (28).

7. Insert piston (27) into cylinder (28), then install the

cylinder into casing (9).

8. Install O-ring (7) and spring (8) to stopper as-

sembly (6) on cover (33). Install the cover on
casing (9) with socket bolts (32) (4 used).
: 6 mm
: 19.6 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

W2-4-27
 UPPERSTRUCTURE / Pump Device
DISASSEMBLE SOLENOID VALVE

1
2
3
4
5
6
7
8
9
10
11
12

13
14
15

16

17
18
19
20
21

W178-02-04-050

1- Socket Bolt (4 Used) 7- Spring (2 Used) 13 - Orifice (2 Used) 19 - O-Ring

2- Solenoid (2 Used) 8- O-Ring (2 Used) 14 - Plate (2 Used) 20 - Filter
3- Spring (2 Used) 9- O-Ring (2 Used) 15 - Wave Washer (2 Used) 21 - O-Ring
4- O-Ring (2 Used) 10 - O-Ring (2 Used) 16 - Filter (2 Used)
5- Diaphragm (2 Used) 11 - Sleeve (2 Used) 17 - Body
6- Retaining Ring (2 Used) 12 - Spool (2 Used) 18 - O-Ring

W2-4-28
 UPPERSTRUCTURE / Pump Device
Disassemble Solenoid Valve
• Be sure not to damage the mating surface for the IMPORTANT: Do not remove orifice (13) from
regulator. spool (12).
• When replacing inner parts, replace solenoid
valve as an assembly. 4. Remove retaining ring (6), then remove spring (7)
• Take care not to hit the solenoid part. and spool (12).
• When removing the connector, do not pry, but pull NOTE: Spool (7) and spool (12) should be pulled
out straight. out from the opposite direction.

1. Remove socket bolt (1), then remove solenoid (2) 5. Remove filters (16, 20) from body (17).
and O-ring (4). : 6 mm
: 4 mm
NOTE: When cleaning filter (16), first blow the filter
with air from both surfaces, and finally blow
NOTE: When solenoid (2) is removed, O-ring (4) the filter with air from outer side (threaded
and spring (3) may come off occasionally. side).

2. Using special tool (ST 2953), pull out the sleeve

(11) assembly from body (17).

NOTE: When pulling out sleeve (11), built-in plate

(14) and wave washer (15) may come off
occasionally.
ST 2953

W178-02-04-052

3. Remove plate (14) and wave washer (15) from

body (17).

W2-4-29
 UPPERSTRUCTURE / Pump Device
ASSEMBLE SOLENOID VALVE

2 1 5 6 7 11 12 13 14 15 17 16

3 4 8 9 10
21 20

19

18

W178-02-04-051

1- Socket Bolt (4 Used) 7- Spring (2 Used) 13 - Orifice (2 Used) 19 - O-Ring

2- Solenoid (2 Used) 8- O-Ring (2 Used) 14 - Plate (2 Used) 20 - Filter
3- Spring (2 Used) 9- O-Ring (2 Used) 15 - Wave Washer (2 Used) 21 - O-Ring
4- O-Ring (2 Used) 10 - O-Ring (2 Used) 16 - Filter (2 Used)
5- Diaphragm (2 Used) 11 - Sleeve (2 Used) 17 - Body
6- Retaining Ring (2 Used) 12 - Spool (2 Used) 18 - O-Ring

W2-4-30
 UPPERSTRUCTURE / Pump Device
Assemble Solenoid Valve
1. Install filters (16, 20) onto body (17).
: 6 mm
: 10+3-0 N⋅m (1+0.3-0 kgf⋅m, 7.2+2.2-0 Ibf⋅ft)

2. Install wave washer (15) and plate (14) on body

(17).
NOTE: When body (17) is horizontally inserted,
apply a film of grease to wave washer (15)
and plate (14) to prevent them from coming
off.
After assembling, check for straight posi-
tion of plate (14).

3. Install O-rings (8, 9, 10) to sleeve (11).

4. Insert spool (12) into sleeve (11), then install

spring (7), retaining ring (6) and diaphragm (5) on
spool (12).
NOTE: Install and let diaphragm (5) crimp towards
out.
After installing, check that spool (12) moves
smoothly.

IMPORTANT: When installing sleeve (11), keep the

sleeve end and body (17) end in the
same position.
In addition, when installing the
sleeve, be sure not to pry and cause
damage to O-ring.
5. Using special tool (ST 2953), install sleeve (11)
assembly to body (17).
NOTE: When there is no special tool (ST 2953)
available, tighten solenoid (2) alternately
with socket bolts (1) (2 used). Then sleeve
(11) end and body (17) end should be
placed in the same position. Install the so-
lenoid.
ST 2953

W178-02-04-052

6. Install solenoid (2) to body (17) with socket bolt

(1) (2 used).
: 4 mm
: 5+2-0 N⋅m (0.5+0.2-0 kgf⋅m, 3.6+1.4-0 lbf⋅ft)

W2-4-31
 UPPERSTRUCTURE / Pump Device
DISASSEMBLE AND ASSEMBLE PILOT
PUMP

1
3
2
4
5
2

6
7
8
9
13
1
10
11
5

12

14 3
15 11
16 10

6 1
3
4
5

21 2

20
6
1
10 6
11
5
19

3
11
10

18 W216-02-04-002

17

W2-4-32
 UPPERSTRUCTURE / Pump Device

Tightening Torque
Wrench Size
Item No. Part Name Q’ty N⋅m Remarks
(mm) (lbf⋅ft)
(kgf⋅m)
1 Pin 6
2 Key 4
Apply grease to bushing when
3 Bushing 4
installing.
4 Gear 2
Apply grease to bushing when
5 Bushing 4
installing.
Apply grease to O-ring when
6 O-ring 4
installing.
7 Flange 1
Apply grease to oil seal when
8 Oil Seal 1
installing.
9 Retaining Ring 1
Apply grease to back up ring
10 Backup Ring 4
when installing.
Apply grease to seal when
11 Seal 4
installing.
12 Gear 2
13 Housing 1
39 to 44 Apply a film of hydraulic oil to nut
14 Nut 4 : 17 (4 to 4.5)
(29 to 33)
when installing.
Apply a film of hydraulic oil to
15 Washer 4
washer when installing.
16 Bolt 4
17 Coupling 1
18 Flange 1
19 Gear 1
20 Housing 1

W2-4-33
 UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD
Pump Device
Unit: mm (in)
Standard Allowable Limit Remedy
Gear Backlash 0.68 (0.027) 1.5 (0.059) Replace

Main Pump
1. Drive Disc: Spline tooth thickness.
Unit: mm (in)
1
Standard Allowable Limit
5.4 (0.213) 3.8 (0.150) 3 2

2. Drive Disc: Oil seal outer diameter.

Unit: mm (in)
Standard Allowable Limit
1 45 (1.77) 44.8 (1.76)
2 55 (2.17) 54.8 (2.16) W157-02-04-015

3 55 (2.17) 54.8 (2.16)

3. Spherical joint: The clearance between plunger

and drive disc.
Unit: mm (in)
Standard Allowable Limit
0.058 (0.0023) 0.4 (0.0157)

4. Rotor: Clearance between plunger outer diameter

and rotor bore.
D–a
Unit: mm (in)
W157-02-04-016
Standard Allowable Limit
0.043 (0.0017) 0.08 (0.0031)

W157-02-04-017

W2-4-34
 UPPERSTRUCTURE / Pump Device
5. Plunger clearance between connecting rod and
plunger
Unit: mm (in)
Standard Allowable Limit Plunger

0.15 (0.0059) 0.4 (0.0157)

Conneting Rod

W157-02-04-033

6. Clearance between small chamber I.D. and servo a Small Diameter

piston O.D. End
D-a
Unit: mm (in)
Standard Allowable Limit
0.083 (0.0033) 0.2 (0.0079)

7. Clearance between large chamber I.D. and servo

piston O.D.
D-a
Unit: mm (in)
Standard Allowable Limit
0.079 (0.0031) 0.2 (0.0079)

a Large Diameter
End
D W157-02-04-018

8. Clearance between servo pin and valve plate

D-a
Unit: mm (in)
Standard Allowable Limit
D a
0.051 (0.0020) 0.3 (0.0118)

W157-02-04-019

W2-4-35
 UPPERSTRUCTURE / Pump Device
(Blank)

W2-4-36
 UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE
Swing
Lifting Tool Mounting Arm 2 Arm 1
Part (M10, Pitch 1.5) Boom 2
CAUTION: Be sure to bleed air from hydrau-
Auxiliary
lic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)
Positioning

Removal Travel
IMPORTANT: Attach identification tags discon-
nected hoses to aid re-assembling.
1. Disconnect all hoses, pipes and connectors from Boom 1
the control valve. Cap open ends. Bucket
: 17 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft)
: 19 mm Lifting Tool Mounting
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) Part (M10, Pitch 1.5) Front
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft) W1GL-02-05-001
: 8 mm
Arm 1 Swing
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 10 mm
: 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)

2. Remove control valve mounting bolts (1) (4 used).

: 24 mm
: 210 N⋅m (21 kgf⋅m, 152 Ibf⋅ft)
Swing
Arm 1
CAUTION: Control valve weight: 183 kg (400 lb)
Boom 2
Auxiliary
3. Install eyebolts (M10, Pitch 1.5 mm) (2 used) onto
the control valve, lift the control valve off bracket Arm 2
(2).
Positioning Boom 1

Installation Travel Bucket W1GL-02-05-002

NOTE: Refer to "Removal" section above for

wrench sizes and tightening torques. Front

CAUTION: Control valve weight: 183 kg (400 lb)

1. Install the control valve with bolts (1) (4 used).

2
2. Connect all hoses, pipes and connectors to the
control valve.

IMPORTANT: After completing installation, check

hydraulic oil level. Add oil as nec-
essary. Run the engine to check the
component for any oil leaks.

W1GL-02-05-003
1

W2-5-1
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE CONTROL VALVE
4-SPOOL SECTION
Bucket

Travel
Boom 1
3 4

2 Arm 2
5 8
Boom Anti-Drift
6 Valve (Switch
7 13
Valve)
14
12 15
1 16

17
9 18
19
20
55 10 19 21
22
54
29 23
53 24
35
52 30 11 25
47 36 26
37 31 27
51 46 39
45 38 32 28
50 44 Check
43 Valve (Arm 33
42 Regenerative
49 41 Arm Regenerative Valve
Circuit)
40
48 34
Flow Combiner Valve W178-02-05-013

1- Housing 15 - Piston 29 - Spring 43 - Cap

2- Overload Relief Valve 16 - Spring 30 - Spacer 44 - Socket Bolt
3- O-Ring 17 - Body 31 - O-Ring 45 - Cap
4- Pilot Housing 18 - O-Ring 32 - Backup Ring 46 - Socket Bolt
5- Socket Bolt 19 - O-Ring 33 - Spool 47 - Cap
6- O-Ring 20 - Sleeve 34 - Overload Relief Valve 48 - Socket Bolt
7- Overload Relief Valve 21 - Backup Ring 35 - Poppet 49 - Cap
8- Spool (Travel) 22 - O-Ring 36 - Spring 50 - O-Ring
9- Spool (Bucket) 23 - O-Ring 37 - O-Ring 51 - Bolt
10 - Spool (Boom 1) 24 - Backup Ring 38 - Plug 52 - Spring Seat
11 - Spool (Arm 2) 25 - Spool 39 - O-Ring 53 - Spring
12 - Socket Bolt 26 - Poppet 40 - Socket Bolt 54 - Spring Seat
13 - Plug 27 - Spring Washer 41 - Cap 55 - Spool
14 - O-Ring 28 - Spring 42 - Socket Bolt

W2-5-2
 UPPERSTRUCTURE / Control Valve
• Be sure to read “Precautions for Disassembly 7. Remove overload relief valves (2, 7) from housing
and Assembly” thoroughly on page W1-1-1 be- (1).
fore starting the disassembly work. : 32 mm
• Attach identification tags to the spool and mount-
ing positions in the housing in order to avoid mis- 8. Remove socket bolts (40, 42, 44, 46) from hous-
assembling. ing (1) to remove caps (41, 43, 45, 47) and O-ring
(39).
1. Remove socket bolt (5) from housing (1), and : 8 mm
remove pilot housing (4) and O-rings (3, 6).
: 8 mm 9. Remove plug (38), O-ring (37), spring (36), and
poppet (35) from housing (1).
IMPORTANT: Remove spools (8, 9, 10, 11) while : 6 mm
carefully moving them. If they stick,
even a little, try it again instead of 10. Remove socket bolt (48) from housing (1) to
pulling roughly. remove cap (49), O-ring (50) and the spool (55)
Make mating marks on spools (8, 9, assembly.
10, 11) and housing (1) in order to : 4 mm
avoid confusion during re-assem-
bling. 11. Clamp spool (55) with wooden pieces in a vise.
2. Remove spool assemblies (8, 9, 10, 11), spring Remove bolt (51), spring seat (52), spring (53)
(29) and the spool (33) assembly from housing and spring seat (54).
(1). : 8 mm
NOTE: Do not disassemble the spool (33) assem-
bly unless necessary. 12. Remove overload relief valve (34) from housing
(1).
3. Loosen plug (13) from body (17). : 32 mm
: 38 mm

4. Remove socket bolt (12) from housing (1).

Remove the body (17) assembly and O-rings (18,
19).
: 8 mm

5. Remove plug (13), O-ring (14), piston (15) and

spring (16) from body (17).

6. Remove sleeve (20), spool (25), poppet (26),

spring washer (27) and spring (28) from housing
(1).
Remove backup rings (21, 24), O-rings (22, 23)
from sleeve (20).

W2-5-3
 UPPERSTRUCTURE / Control Valve

Travel Bucket Boom 1 Arm 2

56 60 75 87

57 61 76 88
89
58 62 77
90
59 63 78
64 79
91
65 80
66 81
8
67
92
68
93
69
10

9
11
82
83
84
70
71 85
72 86
73
74

W178-02-05-016

8- Spool (Travel) 63 - Spring Seat 74 - Plug 85 - Backup Ring

9- Spool (Bucket) 64 - Plug 75 - Bolt 86 - Plug
10 - Spool (Boom 1) 65 - Backup Ring 76 - Spring Seat 87 - Bolt
11 - Spool (Arm 2) 66 - O-Ring 77 - Spring 88 - Spring Seat
56 - Bolt 67 - Sleeve 78 - Spring Seat 89 - Spring Seat
57 - Spring Seat 68 - Spring 79 - Plug 90 - Spring
58 - Spring 69 - Poppet 80 - Backup Ring 91 - Spring
59 - Spring Seat 70 - Poppet 81 - O-Ring 92 - Spring Seat
60 - Bolt 71 - Spring 82 - Poppet 93 - Spring Seat
61 - Spring Seat 72 - O-Ring 83 - Spring
62 - Spring 73 - Backup Ring 84 - O-Ring

W2-5-4
 UPPERSTRUCTURE / Control Valve
• Disassemble travel spool • Disassemble boom 1 spool
13. Clamp spool (8) with wooden pieces in a vise. 19. Clamp spool (10) with wooden pieces in a vise.
Remove bolt (56), spring seat (57), spring (58), Remove bolt (75), spring seat (76), spring (77)
and spring seat (59). and spring seat (78).
: 8 mm : 8 mm

• Disassemble bucket spool 20. Heat the plug (79) part of spool (10) with a drier to
14. Clamp spool (9) with wooden pieces in a vise. melt LOCTITE. Remove plug (79) using special
Remove bolt (60), spring seat (61), spring (62) tool (ST 5909).
and spring seat (63).
ST 5909
: 8 mm

15. Heat the plug (64) part of spool (9) with a drier to
melt LOCTITE. Remove plug (64) using special
tool (ST 5909). W157-02-05-049

ST 5909
21. Turn over spool (10) and clamp it in a vice. Heat
the plug (86) part of spool (10) with a drier to melt
LOCTITE. Remove plug (86) using special tool
(ST 5909).
W157-02-05-049
ST 5909

16. Remove sleeve (67), spring (68) and poppet (69)

from spool (9).

17. Turn over spool (9) and clamp it in a vice. Heat W157-02-05-049

the plug (74) part of spool (9) with a drier to melt

LOCTITE. Remove plug (74) using special tool 22. Remove spring (83) and poppet (82) from spool
(ST 5909). (10).
ST 5909
• Disassemble arm 2 spool
23. Clamp spool (11) with wooden pieces in a vise.
Remove bolt (87), spring seats (88, 89), springs
(90, 91), and spring seats (92, 93).
W157-02-05-049 : 8 mm

18. Remove spring (71) and poppet (70) from spool

(9).

W2-5-5
 UPPERSTRUCTURE / Control Valve

Bucket Flow Control

Valve (Switch Valve)
102
103
104
105
106

Bucket Flow Control 107

100 108
Valve (Poppet Valve)
99
98
97 121 129
96 109 Emergency Load Check Valve
95 120 Valve 128 (Boom 1 Parallel
110 119 Circuit)
94 127
118 126
117 125
116
115
101 114
113
112
111
122 Load Check Valve
(Arm 2 Tandem
123 Circuit)
124
Boom Anti-Drift
Valve (Poppet 134
1 Valve) 133
132
131
130 139
138
137
136
Bypass Shut-Out
135
Valve

142
141
140

W178-02-05-011

1 - Housing 106 -Spool 119 -O-Ring 132 -O-Ring

94 - Poppet 107 -Body 120 -Nut 133 -Flange
95 - Poppet 108 -Socket Bolt 121 -Nut 134 -Socket Bolt
96 - Spring 109 -O-Ring 122 -Socket Bolt 135 -Spool
97 - Plug 110 -Plug 123 -O-Ring 136 -Spring
98 - Spring 111 -Poppet 124 -Plug 137 -O-Ring
99 - Sleeve 112 -Spring 125 -Poppet 138 -Flange
100 -O-Ring 113 -O-Ring 126 -Spring 139 -Socket Bolt
101 -O-Ring 114 -O-Ring 127 -O-Ring 140 -O-Ring
102 -Plug 115 -O-Ring 128 -Flange 141 -Flange
103 -O-Ring 116 -Body 129 -Socket Bolt 142 -Socket Bolt
104 -Spring Seat 117 -O-Ring 130 -Poppet
105 -Spring 118 -Screw 131 -Spring

W2-5-6
 UPPERSTRUCTURE / Control Valve
24. Loosen plug (102) from body (107).
: 36 mm

25. Remove socket bolt (108), from housing (1) to

remove body (107) and O-rings (100, 101).
: 8 mm

26. Remove plug (102), O-ring (103), spring seat

(104), spring (105) and spool (106) from body
(107).

27. Remove sleeve (99), spring (98), plug (97), spring

(96) and poppets (95, 94) from housing (1).

28. Remove socket bolt (122) from housing (1) to

remove the body (116) assembly, O-rings (113,
114, 115).
: 8 mm
NOTE: Do not remove nuts (120, 121) and screw
(118) from body (116) unless necessary.

29. Remove spring (112) and poppet (111) from

housing (1).

30. Remove socket bolt (129) from housing (1).

Remove flange (128), O-ring (127), spring (126)
and poppet (125) from housing (1).
: 8 mm

31. Remove socket bolt (134) from housing (1).

Remove flange (133), O-ring (132), spring (131)
and poppet (130) from housing (1).
: 8 mm

32. Remove socket bolt (139) from housing (1).

Remove flange (138), O-ring (137), spring (136)
and spool (135) from housing (1).
: 8 mm

W2-5-7
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE CONTROL VALVE
5-SPOOL SECTION
Positioning

Auxiliary
150
149
Boom 2
148

151 Arm 1

Swing
147

146 Arm Anti-Drift Valve

(Switch Valve)
157
158
145 156
152 159
160
153 161
154 162
163
155 164
192 182 178 165
163
166
179 167
191 173 168
198
190 174 169
175 170
197 189
188 176 171
196 187 177 172
195 186 Check Valve (Orifice)
185 180 (Parallel Circuit in
184 4-Spool Section)
194 Auxiliary Flow 183 181
Combiner Valve

193
W178-02-05-012

145 -Housing 159 -Piston 173 -Plug 187 -Cap

146 -O-Ring 160 -Spring 174 -Backup Ring 188 -Socket Bolt
147 -Main Relief Valve 161 -Body 175 -O-Ring 189 -Cap
148 -Socket Bolt 162 -O-Ring 176 -Spring 190 -Socket Bolt
149 -O-Ring 163 -O-Ring 177 -Poppet 191 -Cap
150 -Pilot Housing 164 -Sleeve 178 -Overload Relief Valve 192 -Socket Bolt
151 -Spool (Positioning) 165 -Backup Ring 179 -O-Ring 193 -Socket Bolt
152 -Spool (Auxiliary) 166 -O-Ring 180 -O-Ring 194 -Cap
153 -Spool (Boom 2) 167 -O-Ring 181 -Overload Relief Valve 195 -O-Ring
154 -Spool (Arm 1) 168 -Backup Ring 182 -O-Ring 196 -Spring Washer
155 -Spool (Swing) 169 -Spool 183 -Cap 197 -Spring
156 -Socket Bolt 170 -Poppet 184 -Socket Bolt 198 -Spool
157 -Plug 171 -Spring Washer 185 -Cap
158 -O-Ring 172 -Spring 186 -Socket Bolt

W2-5-8
 UPPERSTRUCTURE / Control Valve
• Be sure to read “Precautions for Disassembly and 7. Remove plug (173), spring (176) and poppet
Assembly” thoroughly on page W1-1-1 before (177) from housing (145).
starting the disassembly work.
• Attach identification tags to the spool and mount- 8. Remove overload relief valve (178) and main re-
ing positions in the housing in order to avoid lief valve (147) from housing (145).
misassembling. : 32 mm

1. Remove socket bolt (148) from housing (145). 9. Remove socket bolts (184, 186, 188, 190, 192)
Remove pilot housing (150) and O-ring (149). from housing (145). Remove caps (183, 185, 187,
: 8 mm 189, 191) and O-ring (182) from housing (145).
: 8 mm
IMPORTANT: Remove spools (151, 152, 153, 154,
155) while carefully moving them. If 10. Remove socket bolt (193) from housing (145).
they stick, even a little, try it again Remove cap (194), O-ring (195), spring washer
instead of pulling roughly. (196), spring (197) and spool (198) from housing
Make mating marks on spools (151, (145).
152, 153, 154, 155) and housing (1) in : 4 mm
order to avoid confusion during re-
assembling. 11. Remove overload relief valve (181) from housing
2. Remove the spool (151, 152, 153, 154, 155) as- (145).
semblies from housing (145). : 32 mm

3. Loosen plug (157) from body (161).

: 38 mm

4. Remove socket bolt (156) from housing (145).

Remove the body (161) assembly and O-ring
(162).
: 8 mm

5. Remove plug (157), O-ring (158), piston (159)

and spring (160) from body (161).

6. Remove sleeve (164), spool (169), poppet (170)

spring washer (171) and spring (172) from hous-
ing (145).
Remove backup rings (165, 168) and O-rings
(166, 167) from sleeve (164).

W2-5-9
 UPPERSTRUCTURE / Control Valve

Positioning Auxiliary Boom 2 Arm 1 Swing

199 203 207 211 215

200 204 208 212 216

201 205 209 213 217

202 206 210 214 218

151 152 153 154 155

W178-02-05-015

151 -Spool (Positioning) 201 -Spring 208 -Spring Seat 215 -Bolt
152 -Spool (Auxiliary) 202 -Spring Seat 209 -Spring 216 -Spring Seat
153 -Spool (Boom 2) 203 -Bolt 210 -Spring Seat 217 -Spring
154 -Spool (Arm 1) 204 -Spring Seat 211 -Bolt 218 -Spring Seat
155 -Spool (Swing) 205 -Spring 212 -Spring Seat
199 -Bolt 206 -Spring Seat 213 -Spring
200 -Spring Seat 207 -Bolt 214 -Spring Seat

W2-5-10
 UPPERSTRUCTURE / Control Valve
• Disassemble positioning spool
12. Clamp spool (151) with wooden pieces in a vise.
Remove bolt (199), spring seat (200), spring (201)
and spring seat (202).
: 8 mm

• Disassemble auxiliary spool

13. Clamp spool (152) with wooden pieces in a vise.
Remove bolt (203), spring seat (204), spring (205)
and spring seat (206).
: 8 mm

• Disassemble boom 2 spool

14. Clamp spool (153) with wooden pieces in a vise.
Remove bolt (207), spring seat (208), spring (209)
and spring seat (210).
: 8 mm

• Disassemble arm 1 spool

15. Clamp spool (154) with wooden pieces in a vise.
Remove bolt (211), spring seat (212), spring (213)
and spring seat (214).
: 8 mm

• Disassemble swing spool

16. Clamp spool (155) with wooden pieces in a vise.
Remove bolt (215), spring seat (216), spring (217)
and spring seat (218).
: 8 mm

W2-5-11
 UPPERSTRUCTURE / Control Valve
226
225 Arm Anti-Drift Valve
224 (Poppet Valve)
223
222
221
220
219
227
145
228
Check Valve (Auxiliary
Flow Combining Circuit) 233
232
231
230 Load Check Valve
229 (Travel Parallel Circuit)
Auxiliary Flow Control Valve 253
252
234 251
235 250
243
236 244
237
238 249 284
239 248 285
240 247
246
245
277
241 276
259
242 275
258
257 268
260 269 282
256 261
255 281
Load Check Valve 262 280
254
(Boom 2 Parallel 263 274 279
Circuit) 264 273 278 Load Check Valve
272 (Swing)
265 271
270
266
267

Arm Flow Control Valve W178-02-05-010

145 -Housing 235 -O-Ring 252 -Spring 269 -Sleeve

219 -Socket Bolt 236 -Spring Seat 253 -Poppet 270 -Spring
220 -Cover 237 -Spring 254 -Socket Bolt 271 -Plug
221 -O-Ring 238 -Spool 255 -Flange 272 -Spring
222 -Socket Bolt 239 -Body 256 -O-Ring 273 -Poppet
223 -Flange 240 -Socket Bolt 257 -Spring 274 -Poppet
224 -O-Ring 241 -O-Ring 258 -Poppet 275 -Socket Bolt
225 -Spring 242 -Plug 259 -Plug 276 -Cover
226 -Poppet 243 -O-Ring 260 -O-Ring 277 -O-Ring
227 -O-Ring 244 -Sleeve 261 -Spring Seat 278 -Socket Bolt
228 -Plug 245 -Spring 262 -Spring 279 -Flange
229 -Socket Bolt 246 -Plug 263 -Spool 280 -O-Ring
230 -Flange 247 -Spring 264 -Body 281 -Spring
231 -O-Ring 248 -Poppet 265 -Socket Bolt 282 -Poppet
232 -Spring 249 -Poppet 266 -O-Ring
233 -Poppet 250 -Plug 267 -Plug
234 -Plug 251 -O-Ring 268 -O-Ring

W2-5-12
 UPPERSTRUCTURE / Control Valve
17. Remove socket bolt (229) from housing (145) to 25. Remove sleeve (244), spring (245), plug (246),
remove flange (230), O-ring (231), spring (232) spring (247) and poppets (248, 249) from housing
and poppet (233). (145).
: 8 mm
26. Loosen plug (259) of body (264).
18. Remove plug (250), O-ring (251), spring (252) : 36 mm
and poppet (253) from housing (145).
: 6 mm 27. Remove socket bolt (265) from housing (145) to
remove the body (264) assembly and O-ring
19. Remove socket bolt (222) from housing (145) to (268).
remove flange (223), O-ring (224), spring (225) : 8 mm
and poppet (226).
: 8 mm 28. Remove plug (259), O-ring (260), spring seat
(261), spring (262), and spool (263) from body
20. Remove socket bolt (254) from housing (145) to (264).
remove flange (255), O-ring (256), spring (257)
and poppet (258). 29. Remove sleeve (269), spring (270), plug (271),
: 8 mm spring (272) and poppets (273, 274) from housing
(145).
21. Remove socket bolt (278) from housing (145) to
remove flange (279), O-ring (280), spring (281)
and poppet (282).
: 8 mm

22. Loosen plug (234) of body (239).

: 36 mm

23. Remove socket bolt (240) from housing (145) to

remove the body (239) assembly and O-ring
(243).
: 8 mm

24. Remove plug (234), O-ring (235), spring seat

(236), spring (237) and spool (238) from body
(239).

W2-5-13
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE
4-SPOOL AND 5-SPOOL SECTIONS 302
301
Check Valve 300
(Main Relief Circuit) 299
292
293 298
294 297
295 303
296
304
Check Valve (Orifice) 305
(Boom Circuit) 306
288 1
Check Valve 289 291
(Flow Combiner Valve Circuit) 290

283
284
285
286
287

307
308
Check Valve 309
(Main Relief Valve) 310
311
312
318 313
321
322 314 317
323 319 315
316
324
320
325

326
327
328
329
Load Check Valve 330
(Travel Tandem Circuit)

145

W178-02-05-014
331

1 - Housing 294 -O-Ring 307 -O-Ring 320 -O-Ring

145 -Housing 295 -Spring 308 -O-Ring 321 -Socket Bolt
283 -Socket Bolt 296 -Poppet 309 -O-Ring 322 -Flange
284 -Flange 297 -O-Ring 310 -O-Ring 323 -O-Ring
285 -O-Ring 298 -O-Ring 311 -O-Ring 324 -Flange
286 -Spring 299 -O-Ring 312 -O-Ring 325 -Poppet
287 -Poppet 300 -O-Ring 313 -O-Ring 326 -Socket Bolt
288 -Plug 301 -O-Ring 314 -O-Ring 327 -Flange
289 -O-Ring 302 -O-Ring 315 -O-Ring 328 -O-Ring
290 -Spring 303 -O-Ring 316 -O-Ring 329 -Flange
291 -Poppet 304 -O-Ring 317 -O-Ring 330 -Poppet
292 -Socket Bolt 305 -O-Ring 318 -O-Ring 331 -Socket Bolt
293 -Flange 306 -O-Ring 319 -O-Ring

W2-5-14
 UPPERSTRUCTURE / Control Valve
• Be sure to read “Precautions for Disassembly and
Assembly” thoroughly on page W1-1-1 before
starting the disassembly work.

Disassemble Assemble
1. Remove socket bolts (283, 292) from housing (1) 1. Install O-rings (297 to 320) onto the mounting sur-
to remove flanges (284, 293), O-rings (285, 294), face of the housing.
springs (286, 295) and poppet (287, 296).
: 8 mm
CAUTION: Housing (1) weight: 75 kg (165 lb)
2. Remove plug (288), O-ring (289), spring (290) Housing (145) weight: 74 kg (163 lb)
and poppet (291) from housing (1).
: 6 mm 2. Connect housing (1) and housing (145) with
socket bolt (331).
3. Remove socket bolts (321, 326) from housing : 14 mm
(145) to remove flanges (322, 327), O-rings (323, : 167 to 177 N⋅m
328), springs (324, 329) and poppets (325, 330). (17 to 18 kgf⋅m, 123 to 130 Ibf⋅ft)
: 8 mm
3. Install poppets (325, 330), springs (324, 329),
O-rings (323, 328), flanges (322, 327) and socket
CAUTION: Housing (1) weight: 75 kg (165 lb) bolts (321, 326) into housing (145).
Housing (145) weight: 74 kg (163 lb) : 8 mm
: 61±3 N⋅m
4. Remove socket bolt (331), and separate housing (6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)
(1) and housing (145).
: 14 mm 4. Install poppet (291), spring (290), O-ring (289)
and plug (288) into housing (1).
5. Remove O-rings (297 to 320) from the mounting : 6 mm
surface of the housing. : 76±3 N⋅m
(7.8±0.3 kgf⋅m, 56.4±2.2 Ibf⋅ft)

5. Install poppets (287, 296), springs (286, 295),

O-rings (285, 294), flanges (284, 293) and socket
bolts (283, 292) into housing (1).
: 8 mm
: 61±3 N⋅m
(6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)

W2-5-15
 UPPERSTRUCTURE / Control Valve
ASSEMBLE CONTROL VALVE 4-SPOOL 115
SECTION 120
114
121

118
B
A
C 117 119
139
116
123
122
111 112 113 124
W178-02-05-022

135 136 137 138

Section A

108

1
W178-02-05-017

Section B Section C

T178-03-03-009
Section D
99 98 97 96 95 94

130 102

131
103
132 105
104
128 106

129 109
127
133 126
134 110 107 101 100 T178-03-03-013
125

W178-02-05-020
1 - Housing 106 -Spool 119 -O-Ring 132 -O-Ring
94 - Poppet 107 -Body 120 -Nut 133 -Flange
95 - Poppet 108 -Socket Bolt 121 -Nut 134 -Socket Bolt
96 - Spring 109 -O-Ring 122 -Socket Bolt 135 -Spool
97 - Plug 110 -Plug 123 -O-Ring 136 -Spring
98 - Spring 111 -Poppet 124 -Plug 137 -O-Ring
99 - Sleeve 112 -Spring 125 -Poppet 138 -Flange
100 -O-Ring 113 -O-Ring 126 -Spring 139 -Socket Bolt
101 -O-Ring 114 -O-Ring 127 -O-Ring
102 -Plug 115 -O-Ring 128 -Flange
103 -O-Ring 116 -Body 129 -Socket Bolt
104 -Spring Seat 117 -O-Ring 130 -Poppet
105 -Spring 118 -Screw 131 -Spring

W2-5-16
 UPPERSTRUCTURE / Control Valve
• Be sure to read “Precautions for Disassembly and 5. Install poppet (95), spring (96), plug (97), spring
Assembly” thoroughly on page W1-1-1 before (98) and sleeve (99) into poppet (94).
starting the assembly work.
6. Install spool (106), spring (105) and spring seat
1. Install spool (135), spring (136), O-ring (137), (104) onto body (107). Tighten plug (102) tem-
flange (138) and socket bolt (139) into housing porarily.
(1). : 36 mm
: 8 mm
: 61±3 N⋅m 7. Install the poppet (94) assembly into housing (1).
(6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft) Install body (107) onto the housing with socket
bolt (108).
2. Install poppet (130), spring (131), O-ring (132), : 8 mm
flange (133) and socket bolt (134) into housing : 61±3 N⋅m
(1). (6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)
: 8 mm
: 61±3 N⋅m 8. Completely tighten plug (102), which was tem-
(6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft) porarily tightened in step 6.
: 36 mm
3. Install poppet (125), spring (126), O-ring (127), : 98 N⋅m (10 kgf⋅m, 72.3 Ibf⋅ft)
flange (128) and socket bolt (129) into housing
(1).
: 8 mm
: 61±3 N⋅m
(6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)

IMPORTANT: When the emergency valve has been

disassembled, tighten nut (120),
screw (118) and nut (121) securely.
By failing to do so, boom drifting
amount will be increased (increasing
oil leakage amount).
: 13 mm
: 13 N⋅m (1.3 kgf⋅m, 9.4 Ibf⋅ft)
: 4 mm
: 6.9 N⋅m (0.7 kgf⋅m, 5.1 Ibf⋅ft)

4. Install poppet (111) and spring (112) into housing

(1). Install the body (116) assembly onto the
housing with socket bolt (122).
: 8 mm
: 61±3 N⋅m
(6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)

W2-5-17
 UPPERSTRUCTURE / Control Valve

W178-02-05-017
Section E
Arm 2 Boom 1 Bucket Travel
87 75 60 56
88 76 61 57

89
91 77 62 58
90
92
93 78 63 59
79 64
80 65
81 66 68
67
69

11 10 9 8

82 70

83 71

84 72

85 73
86 74
W178-02-05-023
1- Housing 62 - Spring 73 - Backup Ring 84 - O-Ring
8- Spool (Travel) 63 - Spring Seat 74 - Plug 85 - Backup Ring
9- Spool (Bucket) 64 - Plug 75 - Bolt 86 - Plug
10 - Spool (Boom 1) 65 - Backup Ring 76 - Spring Seat 87 - Bolt
11 - Spool (Arm 2) 66 - O-Ring 77 - Spring 88 - Spring Seat
56 - Bolt 67 - Sleeve 78 - Spring Seat 89 - Spring Seat
57 - Spring Seat 68 - Spring 79 - Plug 90 - Spring
58 - Spring 69 - Poppet 80 - Backup Ring 91 - Spring
59 - Spring Seat 70 - Poppet 81 - O-Ring 92 - Spring Seat
60 - Bolt 71 - Spring 82 - Poppet 93 - Spring Seat
61 - Spring Seat 72 - O-Ring 83 - Spring

W2-5-18
 UPPERSTRUCTURE / Control Valve
• Assemble travel spool • Assemble boom 1 spool
9. Clamp spool (8) with wooden pieces in a vise. In- 17. Clamp spool (10) with wooden pieces in a vise,
stall spring seat (59), spring (58), spring seat (57) with the plug (86) side facing up.
and bolt (56). Install poppet (82), and spring (83) into spool (10).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft) 18. Install O-ring (84) and backup ring (85) into plug
(86). Apply LOCTITE #271 on the threaded part of
• Assemble bucket spool the plug.
10. Clamp spool (9) with wooden pieces in a vise,
with the plug (74) side facing up. 19. Install plug (86) into spool (10) using special tool
Install poppet (70) and spring (71) into spool (9). (ST 5909).
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)
11. Install O-ring (72) and backup ring (73) onto plug
(74). Apply LOCTITE #271 on thread part of plug. 20. Turn spool (10) over, then clamp it in a vise. Install
O-ring (81) and backup ring (80) into plug (79).
12. Install plug (74) onto spool (9) using special tool Apply LOCTITE #271 on the threaded part of the
(ST 5909). plug.
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)
21. Install plug (79) into spool (10) using special tool
13. Turn over spool (9), then clamp spool (9) in a vise. (ST 5909).
Install poppet (69), spring (68) and sleeve (67). : 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)

14. Install O-ring (66) and backup ring (65) onto plug 22. Install spring seat (78), spring (77), spring seat
(64). Apply LOCTITE #271 on the threaded part of (76) and bolt (75) into spool (10).
the plug. : 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)
15. Install plug (64) onto spool (9) using special tool
(ST 5909). • Assemble arm 2 spool
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft) 23. Clamp spool (11) with wooden pieces in a vise.
Install spring seats (93, 92), springs (91, 90),
16. Install spring seat (63), spring (62), spring seat spring seats (89, 88) and bolt (87).
(61) and bolt (60) onto spool (9). : 8 mm
: 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)

W2-5-19
 UPPERSTRUCTURE / Control Valve

Section G
12

H
55

54
53
50
48 52

1
49 51

W178-02-05-025

Section H
W178-02-05-017
13

14
15 17
25
16
18 20
19 26
21
22
23
24
27
28

W178-02-05-021

1- Housing 19 - O-Ring 27 - Spring Washer 49 - Cap

12 - Socket Bolt 20 - Sleeve 28 - Spring 50 - O-Ring
13 - Plug 21 - Backup Ring 35 - Poppet 51 - Bolt
14 - O-Ring 22 - O-Ring 36 - Spring 52 - Spring Seat
15 - Piston 23 - O-Ring 37 - O-Ring 53 - Spring
16 - Spring 24 - Backup Ring 38 - Plug 54 - Spring Seat
17 - Body 25 - Spool 48 - Socket Bolt 55 - Spool
18 - O-Ring 26 - Poppet

W2-5-20
 UPPERSTRUCTURE / Control Valve
24. Clamp spool (55) with wooden pieces in a vise.
Install spring seat (54), spring (53), spring seat
(52) and bolt (51).
: 4 mm
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)

25. Install the spool (55) assembly, O-ring (50), cap

(49) and socket bolt (48) into housing (1).
: 4 mm
: 10±1 N⋅m (1±0.1 kgf⋅m, 7.2±0.72 Ibf⋅ft)

26. Install poppet (35), spring (36), O-ring (37) and

plug (38) into housing (1).
: 6 mm
: 76±3 N⋅m (7.7±0.3 kgf⋅m, 55.7±2.2 Ibf⋅ft)

27. Install backup rings (21, 24) and O-rings (22, 23)
onto sleeve (20).

IMPORTANT: Be sure to place spool (25) with the

hole side facing poppet (26) when
installing the spool.
28. Install spool (25), poppet (26), spring washer (27)
and spring (28) into sleeve (20). Install the sleeve
(20) assembly into housing (1).
NOTE: Apply more grease on spring washer (27)
and spring (28) to prevent them from
coming off.

29. Install spring (16) and piston (15) onto body (17).
Install plug (13) with O-ring (14) onto the body
temporarily.
: 38 mm

30. Install O-rings (18, 19), the body (17) assembly

and socket bolt (12) into housing (1).
: 8 mm
: 61±3 N⋅m (6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)

31. Completely tighten plug (13), which was tempo-

rarily tightened onto body (17).
: 38 mm
: 93 to 108 N⋅m
(9.5 to 11 kgf⋅m, 69 to 80 Ibf⋅ft)

W2-5-21
 UPPERSTRUCTURE / Control Valve

E
7
F
5

2 1
4

1
34

W178-02-05-018
W178-02-05-017

Section E Section Ｆ

6 3 11 3 10 3 9 3 8 29
6

33

T178-03-03-018

T178-03-03-042

1- Housing 5- Socket Bolt 9 - Spool (Bucket) 29 - Spring

2- Overload Relief Valve 6- O-Ring 10 - Spool (Boom 1) 33 - Spool
3- O-Ring 7- Overload Relief Valve 11 - Spool (Arm 2) 34 - Overload Relief Valve
4- Pilot Housing 8- Spool (Travel)

W2-5-22
 UPPERSTRUCTURE / Control Valve
IMPORTANT: After installing spool (8, 9, 10, 11)
assemblies into housing (1), push
them by hand to confirm smooth-
ness.
32. Install the spool (8, 9, 10, 11) assemblies, spool
(33) and spring (29) into housing (1).

33. Install O-rings (3, 6), pilot housing (4) and socket
bolt (5) into housing (1).
: 8 mm
: 42±2 N⋅m (4.3±0.2 kgf⋅m, 31.1±1.4 Ibf⋅ft)

34. Install overload relief valves (2, 7, 34) into hous-

ing (1).
: 32 mm
: 83±5 N⋅m (8.5±0.5 kgf⋅m, 61.5±3.6 Ibf⋅ft)

W2-5-23
 UPPERSTRUCTURE / Control Valve
ASSEMBLE CONTROL VALVE 5-SPOOL Section A Section B
SECTION

145 226
222 225
265
240 224
223

247, 272 W178-02-05-027

W178-02-05-018
246, 271 248, 273
245, 270 249, 274
244, 269
234, 259

235, 260
237, 262
236, 261
238, 263
241, 266

242, 267 239, 264 243, 268 T178-03-03-013

283, 284

145 -Housing 238 -Spool 248 -Poppet 266 -O-Ring

222 -Socket Bolt 239 -Body 249 -Poppet 267 -Plug
223 -Flange 240 -Socket Bolt 259 -Plug 268 -O-Ring
224 -O-Ring 241 -O-Ring 260 -O-Ring 269 -Sleeve
225 -Spring 242 -Plug 261 -Spring Seat 270 -Spring
226 -Poppet 243 -O-Ring 262 -Spring 271 -Plug
234 -Plug 244 -Sleeve 263 -Spool 272 -Spring
235 -O-Ring 245 -Spring 264 -Body 273 -Poppet
236 -Spring Seat 246 -Plug 265 -Socket Bolt 274 -Poppet
237 -Spring 247 -Spring

W2-5-24
 UPPERSTRUCTURE / Control Valve
• Be sure to read “Precautions for Disassembly and
Assembly” thoroughly on page W1-1-1 before
starting the assembly work.

1. Install poppet (273), spring (272), plug (271),

spring (270) and sleeve (269) into poppet (274).

2. Install spool (263), spring (262) and spring seat

(261) onto body (264). Temporarily tighten plug
(259).
: 36 mm

3. Install the poppet (274) assembly into housing

(145). Install body (264) with socket bolt (265).
: 8 mm
: 61±3 N⋅m (6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)

4. Completely tighten plug (259), which was tem-

porarily tightened in step 2.
: 36 mm
: 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

5. Install poppet (248), spring (247), plug (246),

spring (245) and sleeve (244) into poppet (249).

6. Install spool (238), spring (237) and spring seat

(236) into body (239), then temporarily tighten
plug (234).
: 36 mm

7. Install the poppet (249) assembly into housing

(145). Install body (239) with socket bolt (240).
: 8 mm
: 61±3 N⋅m (6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)

8. Completely plug (234) which was temporarily

tightened in step 6.
: 36 mm
: 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

9. Install poppet (226), spring (225), O-ring (224),

flange (223) and socket bolt (222) into housing
(145).
: 8 mm
: 61±3 N⋅m (6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)

W2-5-25
 UPPERSTRUCTURE / Control Valve

145 Section C
278
254

282
229 281
C
280
D
E

278
279

W178-02-05-018
Section E Section D W178-02-05-028
253
252 Section F

251

250
258
257
233 256 T178-03-03-044

232
231
254
255

230

W178-02-05-026

145 -Housing 233 -Poppet 254 -Socket Bolt 278 -Socket Bolt
229 -Socket Bolt 234 -Plug 255 -Flange 279 -Flange
230 -Flange 235 -O-Ring 256 -O-ring 280 -O-Ring
231 -O-Ring 252 -Spring 257 -Spring 281 -Spring
232 -Spring 253 -Poppet 258 -Poppet 282 -Poppet

W2-5-26
 UPPERSTRUCTURE / Control Valve
10. Install poppet (282), spring (281), O-ring (280),
flange (279) and socket bolt (278) into housing
(145).
: 8 mm
: 61±3 N⋅m (6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)

11. Install poppet (258), spring (257), O-ring (256),

flange (255) and socket bolt (254) into housing
(145).
: 8 mm
: 61±3 N⋅m (6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)

12. Install poppet (253), spring (252), O-ring (251)

and plug (250) into housing (145).
: 6 mm
: 76±3 N⋅m (7.8±0.3 kgf⋅m, 56.4±2.2 Ibf⋅ft)

13. Install poppet (233), spring (232), O-ring (231),

flange (230) and socket bolt (229) into housing
(145).
: 8 mm
: 61±3 N⋅m (6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)

W2-5-27
 UPPERSTRUCTURE / Control Valve

Section E

145

193

198
195
197
W178-02-05-018
196 194
Section G
Positioning Auxiliary Boom 2 Arm 1 Swing
199 203 207 211 215 W178-02-05-026
200 204 208 212 216

201 205 209 213 217

202 206 210 214 218

151 152 153 154 155

W178-02-05-024
151 -Spool (Positioning) 196 -Spring Washer 204 -Spring Seat 212 -Spring Seat
152 -Spool (Auxiliary) 197 -Spring 205 -Spring 213 -Spring
153 -Spool (Boom 2) 198 -Spool 206 -Spring Seat 214 -Spring Seat
154 -Spool (Arm 1) 199 -Bolt 207 -Bolt 215 -Bolt
155 -Spool (Swing) 200 -Spring Seat 208 -Spring Seat 216 -Spring Seat
193 -Socket Bolt 201 -Spring 209 -Spring 217 -Spring
194 -Cap 202 -Spring Seat 210 -Spring Seat 218 -Spring Seat
195 -O-Ring 203 -Bolt 211 -Bolt

W2-5-28
 UPPERSTRUCTURE / Control Valve
• Assemble positioning spool
14. Clamp spool (151) with wooden pieces in a vise.
Install spring seat (202), spring (201), spring seat
(200) and bolt (199).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)

• Assemble auxiliary spool

15. Clamp spool (152) with wooden pieces in a vise.
Install spring seat (206), spring (205), spring seat
(204) and bolt (203).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)

• Assemble boom 2 spool

16. Clamp spool (153) with wooden pieces in a vise,
install spring seat (210), spring (209), spring seat
(208) and bolt (207).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)

• Assemble arm 1 spool

17. Clamp spool (154) with wooden pieces in a vise.
Install spring seat (214), spring (213), spring seat
(212) and bolt (211).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)

• Assemble swing spool

18. Clamp spool (155) with wooden pieces in a vise.
Install spring seat (218), spring (217), spring seat
(216) and bolt (215).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)

19. Install spool (198), spring (197), spring seat (196),

O-ring (195), cap (194) and socket bolt (193) into
housing (145).
: 4 mm
: 10±1 N⋅m (1±0.1 kgf⋅m, 7.2±0.72 Ibf⋅ft)

W2-5-29
 UPPERSTRUCTURE / Control Valve

147

178

150
148 184
181
156 186
H
188
190
192

183
145 G 185
187
M178-05-003 189
Section G 191
149 151 149 152 149 153 149 154 155 149 W178-02-05-018
Section H
157

158
161 159
169
160
164
174, 175 162
170
173 163
176 165
177 166
167
168
171
172

T178-03-03-041

182 182 182 182 182 W178-02-05-029

145 -Housing 159 -Piston 172 -Spring 187 -Cap

146 -Main Relief Valve 160 -Spring 173 -Plug 188 -Socket Bolt
147 -Socket Bolt 161 -Body 174 -Backup Ring 189 -Cap
148 -O-Ring 162 -O-Ring 175 -O-Ring 190 -Socket Bolt
149 -Pilot Housing 163 -O-Ring 176 -Spring 191 -Cap
150 -Spool (Positioning) 164 -Sleeve 177 -Poppet 192 -Socket Bolt
151 -Spool (Auxiliary) 165 -Backup Ring 178 -Overload Relief Valve
152 -Spool (Boom 2) 166 -O-Ring 181 -Overload Relief Valve
153 -Spool (Arm 1) 167 -O-Ring 182 -O-Ring
154 -Spool (Swing) 168 -Backup Ring 183 -Cap
155 -Socket Bolt 169 -Spool 184 -Socket Bolt
156 -Plug 170 -Poppet 185 -Cap
157 -O-Ring 171 -Spring Washer 186 -Socket Bolt

W2-5-30
 UPPERSTRUCTURE / Control Valve
20. Install O-ring (182), caps (183, 185, 187, 189, 28. Install O-ring (149), pilot housing (150) and socket
191) and socket bolts (184, 186, 188, 190, 192) bolt (148) into housing (145).
into housing (145). : 8 mm
: 8 mm : 42±2 N⋅m (4.4±0.2 kgf⋅m, 31.8±1.4 Ibf⋅ft)
: 42±2 N⋅m
(4.4±0.2 kgf⋅m, 31.8±1.4 Ibf⋅ft) 29. Install main relief valve (147) and overload relief
valves (178, 181) into housing (145).
21. Install backup rings (165, 168), and O-rings (166, : 32 mm
167) onto sleeve (164). : 83±5 N⋅m (8.5±0.5 kgf⋅m, 61.5±3.6 Ibf⋅ft)

IMPORTANT: Be sure to place spool (169) with the

hole side facing poppet (170) when
installing the spool.
22. Install spool (169), poppet (170), spring washer
(171) and spring (172) into sleeve (164). Then in-
stall the sleeve assembly into housing (145).
NOTE: Apply more grease on spring washer (171)
and spring (172) to prevent them from
coming off.

23. Install spring (160) and piston (159) into body

(161). Temporarily tighten plug (157) with O-ring
(158) onto the body.
: 38 mm

24. Install O-rings (162, 163), the body (161) assem-

bly and socket bolt (156) into housing (145).
: 8 mm
: 61±3 N⋅m
(6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)

25. Completely tighten plug (157), which was tem-

porarily tightened, onto body (161).
: 38 mm
: 93 to 108 N⋅m
(9.5 to 11 kgf⋅m, 68.7 to 79.6 Ibf⋅ft)

26. Install poppet (177), spring (176) and plug (173)

onto housing (145).

IMPORTANT: After installing spools (151, 152, 153,

154, 155) into housing (145), push
them by hand to confirm smooth-
ness.
27. Install the spools (151, 152, 153, 154, 155) as-
sembly into housing (145).

W2-5-31
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-5-32
 UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL AUXILIARY
CONTROL VALVE

CAUTION: Be sure to bleed air from hydrau-

lic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil 1
Tank” on page W1-4-1.)

Removal 2

1. Open cover (2). Remove bolts (3) (4 used) then

remove cover (1).
: 17 mm

IMPORTANT: Attach identification tags to dis-

connected hoses for re-assembly.
2. Disconnect hoses (4) (6 used) from valve (6). Cap
the disconnected hose ends.
: 19 mm, 27 mm

3. Remove bolts (5) (3 used) then remove valve (6) W1GL-02-05-005

from bracket (7).
: 17 mm
4 3

5
Installation

1. Install valve (6) to bracket (7) with bolts (5) (3 6

used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
7
2. Connect hoses (4) (6 used) to valve (6).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)
4
3. Install cover (1) with bolts (3) (4 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

4. Close cover (2).

W1GL-02-05-004

IMPORTANT: After installation, check the hydrau-

lic oil level. Run the engine and
check for oil leaks.

W2-5-33
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE AUXILIARY CONTROL VALVE 19
20
10 21
9 22
8 23
7
6 24
25
5 26
4 27
3 28
2
1

37

38 29
30
39 31
18 32
17 33
40 34
16
15 41 35
14 36
13 42
12 43
11
44

56 45
55
54
53 46
52 47
51
48 62
61
60

50
49
59
58
57
W198-02-05-001

1- Nut 17 - Sleeve 33 - Backup Ring 48 - Socket Bolt

2- Bolt 18 - O-Ring 34 - Valve 49 - Socket Bolt
3- O-Ring 19 - Nut 35 - Sleeve 50 - Cover
4- Spring 20 - Bolt 36 - O-Ring 51 - End Spool
5- Valve 21 - O-Ring 37 - Seat 52 - Seat
6- Sleeve 22 - Spring 38 - O-Ring 53 - Spring
7- Backup Ring 23 - Valve 39 - Valve 54 - Spring
8- O-Ring 24 - Sleeve 40 - Spring 55 - Seat
9- O-Ring 25 - Backup Ring 41 - Sleeve 56 - O-Ring
10 - Spring 26 - O-Ring 42 - O-Ring 57 - Spool
11 - Spring 27 - O-Ring 43 - Spring 58 - O-Ring
12 - Pin 28 - Spring 44 - Poppet 59 - Plug
13 - Valve 29 - Spring 45 - Socket Bolt (2 Used) 60 - Drive Screw
14 - O-Ring 30 - Pin 46 - Cover 61 - Plate
15 - Backup Ring 31 - Valve 47 - O-Ring 62 - Housing
16 - Valve 32 - O-Ring

W2-5-34
 UPPERSTRUCTURE / Control Valve
Disassemble Auxiliary Control Valve
• Be sure to read “Precautions for Disassembly and
Assembly” thoroughly on page W1-1-1 before
starting any repair work.

1. Loosen socket bolts (45) (2 used), (48), and (49)

to remove covers (46, 50) and O-rings (47, 56).
: 6 mm

IMPORTANT: Remove the spool (57) assembly (51

to 59) while carefully moving them. If
they stick, even a little, try it again
instead of pulling roughly.

2. Remove spool (57) assembly (51 to 59) from

housing (62).

3. Secure spool (57) with wooden pieces in a vice.

Remove end spool (51), seat (52), springs (53,
54) and seat (55).
: 8 mm

IMPORTANT: As the set pressure may be changed,

be sure not to disassemble overload
relief valve assemblies (1 to 18) and
(19 to 36).
4. Remove overload relief valve assembly (1 to 18)
and (19 to 36) from housing (62).
: 32 mm
NOTE: As each set pressure is different, be sure to
install overload relief valve assemblies (1 to
18) and (19 to 36) correctly.

5. Remove sleeve (41) assembly (37 to 42) from

housing (62).
: 36 mm

6. Pull out spring (43) and poppet (44) from housing

(62).

7. Secure seat (37) in a vice. Remove sleeve (41),

spring (40), valve (39), and O-rings (38, 42).
: 36 mm
NOTE: As plate (61) is installed with drive screw
(60), be sure not to disassemble the plate.

W2-5-35
 UPPERSTRUCTURE / Control Valve
ASSEMBLE AUXILIARY CONTROL VALVE
Cross Section
X-X 37 39 40 38
41

43
62
42
44
1 to 18 A1 B1 19 to 36

A1 B1
X X

W198-02-05-002
W198-02-05-003

57

Cross Section
W-W

52 54 53 55 56 62 47
48 45
50 51

W W

W198-02-05-004
49

57 59 58 46
W198-02-05-005

1- Nut 17 - Sleeve 33 - Backup Ring 48 - Socket Bolt

2- Bolt 18 - O-Ring 34 - Valve 49 - Socket Bolt
3- O-Ring 19 - Nut 35 - Sleeve 50 - Cover
4- Spring 20 - Bolt 36 - O-Ring 51 - End Spool
5- Valve 21 - O-Ring 37 - Seat 52 - Seat
6- Sleeve 22 - Spring 38 - O-Ring 53 - Spring
7- Backup Ring 23 - Valve 39 - Valve 54 - Spring
8- O-Ring 24 - Sleeve 40 - Spring 55 - Seat
9- O-Ring 25 - Backup Ring 41 - Sleeve 56 - O-Ring
10 - Spring 26 - O-Ring 42 - O-Ring 57 - Spool
11 - Spring 27 - O-Ring 43 - Spring 58 - O-Ring
12 - Pin 28 - Spring 44 - Poppet 59 - Plug
13 - Valve 29 - Spring 45 - Socket Bolt (2 Used) 60 - Drive Screw
14 - O-Ring 30 - Pin 46 - Poppet 61 - Plate
15 - Backup Ring 31 - Valve 47 - O-Ring 62 - Housing
16 - Valve 32 - O-Ring

W2-5-36
 UPPERSTRUCTURE / Control Valve
Assemble Auxiliary Control Valve

1. Secure seat (37) in a vice. Install O-ring (38),

valve (39), spring (40), sleeve (41) and O-ring
(42).
: 36 mm
: 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft)

2. Install poppet (44) and spring (43) into housing

(62).

3. Install sleeve (41) assembly (37 to 42) to housing

(62).
: 36 mm
: 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft)

IMPORTANT: As each set pressure is different, be

sure to install overload relief valve
assemblies (1 to 18) and (19 to 36)
correctly.
4. Install overload relief valve assembly (1 to 18)
and (19 to 36) to housing (62).
: 32 mm
: 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft)

5. Secure spool (57) with wooden pieces in a vice.

Install O-ring (58) to plug (59). Install plug (59) to
spool (57). Install seat (55), springs (53, 54), seat
(52), and end spool (51) to spool (57).
: 5 mm
: 9.8 N⋅m (1 kgf⋅m, 7.4 lbf⋅ft)
: 8 mm
: 18.6 N⋅m (1.9 kgf⋅m, 13.7 lbf⋅ft)

IMPORTANT: After installing spool (57) assembly

(51 to 59) into housing (62), push
them by hand to confirm smooth-
ness.
6. Insert spool (57) assembly (51 to 59) to housing
(62) through port A1 side.
NOTE: When installing the spool assembly, be
sure to install it straight to prevent it from
damaging spool (57) inside housing (62).

7. Install O-ring (56) to cover (50) and O-ring (47) to

cover (46). Install them to housing (62) with
socket bolts (45) (2 used), (48), and (49).
: 6 mm
: 25.5 N⋅m (2.6 kgf⋅m, 18.8 lbf⋅ft)

W2-5-37
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-5-38
 UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE

CAUTION: Be sure to bleed air from hydrau-

lic oil tank before starting the work. 1 2 3 4 5 6
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)

Removal

IMPORTANT: Attach identification tags to discon-

nected hoses for re-assembly.
1. Disconnect the harness (1) connector and hoses
(2 to 6). Cap the disconnected hose ends.
• Main hose: 2 used
• Makeup hose: 1 used
• Drain hose: 1 used
• Pilot hose: 1 used
: 17 mm, 19 mm, 36 mm
: 8 mm

IMPORTANT: As for the handling of floating seal, M178-07-014

refer to the “Handling of Floating 8 7
Seal” on page W1-1-4. Front
2. Lift swing motor (8) off.
Nylon sling (eye-type at both ends): 2 pieces
Nylon Sling

CAUTION: Swing device weight:

220 kg (485 lb)
3. Remove bolts (7) (12 used). Lift the swing device
off the main frame.
: 30 mm

NOTE: When lifting the swing device, the machine 8

may float together with it. Therefore,
remove plugs (9) (2 places) to lift the swing
device off the main frame with pulling bolt
(M20, Pitch 2.5 mm).

NOTE: The number of hoses around the swing 9

9
device is different according to the specifi-
cation of front attachment.
Be sure not to damage the hoses when
removing and installing the swing device.

W176-02-06-002

W2-6-1
 UPPERSTRUCTURE / Swing Device
Installation

CAUTION: Swing device weight:

220 kg (485 lb) 1 2 3 4 5 6
1. Install the swing device with bolts (7) (12 used).
: 30 mm
: 500 N·m (50 kgf·m, 360 Ibf⋅ft)

IMPORTANT: Apply liquid packing to both

mounting surfaces on the swing
device and frame.
2. Connect hoses (2 to 6) and the harness (1)
connector.
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) M178-07-014
8 7
IMPORTANT: Be sure to fill the swing motor with Front
hydraulic oil after installing it. After
completing installation, check
hydraulic oil level. Add oil as
necessary. Run the engine and
check the component for any oil
leaks.

W2-6-2
 UPPERSTRUCTURE / Swing Device
(Blank)

W2-6-3
 UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING REDUCTION
GEAR

22
23 1

24

2
3

32 21
25 4

31 5

20 6

26 7
19
8

27
18 9

28 10
17
11
29
16
12

30 15 13

14

W178-02-06-004

1- Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing

2- 1st Stage Sun Gear 10 - Spring Pin (3 Used) 18 - 2nd Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (6 Used) 20 - 2nd Stage Sun Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - 1st Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - Socket Bolt (8 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Socket Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe

W2-6-4
 UPPERSTRUCTURE / Swing Device
Disassemble Swing Reduction Gear

CAUTION: Swing device weight: CAUTION: Motor weight: 47 kg (100 Ib)

220 kg (485 lb)
6. Remove motor (1) from ring gear (24).
CAUTION: When hoisting the swing device,
: 10 mm
do not string the rope suddenly.
NOTE: THREEBOND has been applied on the
1. Install eyebolts (M10) (2 used) to the swing device, joint surface. Insert a screwdriver into the
and then lift the swing device off. gap between the swing motor and ring gear.
Then pry it up for easy removing.
Eyebolt
Mounting 7. Remove 1st stage sun gear (2) from 1st stage
Position
carrier (21).

8. Remove the 1st stage carrier (21) assembly from

ring gear (24).

9. Remove the ring gear (24) mounting bolt (23).

: 14 mm

W178-02-06-005
CAUTION: Ring gear weight: 23 kg (50 lb)
2. Put the swing device on bracket (ST 5097). Se-
cure it with 2 bolts (M20). Insert the stopper lo- 10. Install eyebolts (M12) (2 used) to the hole for the
cated at the bottom of bracket into the middle of motor (1) mounting bolt on ring gear (24). Lift the
two teeth of pinion gear. Secure the bracket on a ring gear off housing (25).
workbench. NOTE: THREEBOND has been applied on the
: 30 mm joint surface. Insert a screwdriver into the
Swing Device gap between the ring gear and housing.
Then pry it up for easy removing.

11. Remove 2nd stage sun gear (20) from 2nd carrier
ST 5097 (18).
Stopper

12. Remove the 2nd stage carrier (18) assembly from

shaft (30).

W178-02-06-012

3. Remove drain plug (31), then drain off oil.

: 8 mm

4. Remove pipe (32) from housing (25).

: 18 mm

5. Put alignment marks at the jointed portion be-

tween motor (1) and ring gear (24), between ring
gear (24) and housing (25).

W2-6-5
UPPERSTRUCTURE / Swing Device

23

25 21
4

7
8

18

10
17
11
16
12

30 15

W178-02-06-004

W2-6-6
 UPPERSTRUCTURE / Swing Device
IMPORTANT: The hole for the spring pin located 20. Remove bearing nut (15) from shaft (30) using
on the 1st stage carrier is not a special nut removing tool (ST 2926).
through one. Take care to the tap-
ping-in distance when tapping the ST 2926
spring pin in. 15
13. Tap spring pin (5) on the 1st stage carrier (21)
assembly into pin (4) using special tool (ST 1462).
Stop tapping when the spring pin is driven to the
middle of the pin hole. Do not try to tap spring pin
(5) to the end.

14. Remove pin (4), planetary gear (7), needle bear-

ing (6), thrust plate (8) from 1st stage carrier (21).

15. Remove remaining two sets of pin (4), planetary

gear (7), needle bearing (6), thrust plate (8) from W178-02-06-008

1st stage carrier (21) according to the removing

procedure in step 13 and step 14. CAUTION: Housing (25) assembly weight:
110 kg (240 lb)
16. Remove thrust plate (3) from 1st stage carrier
(21). 21. Install eyebolt (M16) into bolt (23) hole in housing
(25). Lift housing (25). Remove bracket (ST 5097),
IMPORTANT: The surface of the pin except for which has been installed at the pinion gear side.
both ends is a rotating surface for : 30 mm
the needle bearing.
Take care not to damage it. 22. After removing bracket (ST 5097), install bracket
17. Clamp the pin (4) with a vise. Push the spring pin (ST 1464). Install the housing (25) assembly on a
out using special removing tool (ST 1462). (3 press.
places) : 30 mm
Press
18. Disassemble the 2nd stage carrier (18) assembly
according to the removing procedure for the 1st
stage carrier (21) assembly. However 6 needle
bearings (12) and 6 thrust plates (11) are used on
the 2nd stage carrier (18) assembly.
Moreover, use ST 1463 as the extractor for spring 25
pin (10) .

19. Remove bolt (17) to remove lock plate (16).

ST 1464
: 17 mm

W178-02-06-006

W2-6-7
UPPERSTRUCTURE / Swing Device

25

26

27

28

29

30

14

W178-02-06-004

W2-6-8
 UPPERSTRUCTURE / Swing Device
23. Push the upper end of shaft (30) with a press and 28. Insert a round bar into the oil passage in housing
remove the outer race of roller bearing (26) from (25), tap the outer race of roller bearing (26) out.
housing (25). The inner race of roller bearing (26)
and sleeve (28) are removed with the shaft.

24. Place pulling tool B (ST 1460) of roller bearing

Insert Round
(26) onto the stepped part of pulling tool A (ST Bar Here
Outer Race
1461) for roller bearing (26).
ST 1460

W178-02-06-001
ST 1461

CAUTION: Housing weight: 60 kg (130 lb)

29. Secure housing (25) body with a nylon sling, lift

housing (25). Turn the up side of the housing
W178-02-06-010
down.

CAUTION: Shaft weight: 40 kg (90 lb) 30. Insert a screwdriver into the gap on housing (25)
where oil seal (27) is mounted. Remove the oil
25. Insert the pinion gear of shaft (30) into the seal.
tooth-hole of pulling tool B (ST 1460) for roller
bearing (26). Set them onto press. NOTE: THREEBOND has been applied on the
periphery of oil seal. Thus, it cannot be re-
Press used.

31. Insert a bar at the backside of the outer race of

roller bearing (14). Remove the outer race from
housing (25) by tapping with a bar and hammer.
30

26

ST 1460 28
ST 1461

W178-02-06-009

26. Push spline side on shaft (30) with press and

remove inner race of roller bearing (26) and
sleeve (28).

27. Remove O-ring (29) from sleeve (28).

W2-6-9
 UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING REDUCTION GEAR

1
2 4
3 5

22
21 6
20
7
18

24
8
19 10
11
23
13
12
11
17
9
16
32
15

14

26

29 25 31

27
28
30
W178-02-06-003

1- Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing

2- 1st Stage Sun Gear 10 - Spring Pin (3 Used) 18 - 2nd Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (6 Used) 20 - 2nd Stage Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - 1st Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - Socket Bolt (8 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Socket Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe

W2-6-10
 UPPERSTRUCTURE / Swing Device
Assemble Swing Reduction Gear

1. Install O-ring (29) onto sleeve (28). 5. Apply THREEBOND #1215 on the outer surface
of oil seal (27). Put oil seal (27) flat on housing
(25) and push oil seal (27) in gently. Then place
CAUTION: Shaft + sleeve + outer race
seal mounting tool (ST 2925) on oil seal (27) and
weight: 36 kg (80 lb) tap the seal mounting tool in by hammering di-
rectly.
2. Install sleeve (28) and the inner race of roller
bearing (26) into shaft (30). Press sleeve and in- NOTE: If special tool (ST 2925) is used to replace
ner race using bearing mounting tool (ST 2923). the seal, no need to remove the sleeve.
NOTE: Press-in distance of the bearing inner race
can be assured by using the bearing
ST 2925
mounting tool. 27

25
Press

ST 2923
W178-02-06-007

26
6. Apply grease to the inner surface of oil seal (27)
28 all around. Apply grease to the outer surface of
sleeve (28) on shaft (30).
30
NOTE: Apply grease carefully when installing the
shaft to avoid accidental curling of the seal
lip from the shaft.
W178-02-06-013

CAUTION: Housing + outer race weight:

63 kg (140 lb)
CAUTION: Housing weight: 60 kg (130 lb)
7. Secure housing (25) body with a nylon sling and
3. Secure housing (25) body with a nylon sling, and
lift housing (25) off. Place ring gear (24) with the
then lift housing (25). Place sleeve (28) with the
mounting side up.
mounting side up.
8. Tap the outer race of roller bearing (14) evenly
4. Tap the outer race of roller bearing (26) evenly by
using a bar and hammer while installing the outer
using a bar and hammer while installing the outer
race into housing (25). Tap the bearing and listen
race into housing (25). Tap the bearing and listen
to ring to confirm if installation is completed.
to ring to confirm if installation is completed.

W2-6-11
 UPPERSTRUCTURE / Swing Device

24

23

15

14

25

27

30
W178-02-06-003

W2-6-12
 UPPERSTRUCTURE / Swing Device
15. Lift and place the housing (25) assembly on
CAUTION: Housing + outer races (2 used)
bracket (ST 5097). Secure the housing (25) as-
weight: 65 kg (140 lb) sembly with 2 bolts (M20) while the stopper at the
bottom of bracket is located at the middle of two
9. Install eyebolt (M16) into the ring gear mounting teeth of the pinion gear. Secure the bracket on a
bolt (23) hole in housing (25). Then lift and place workbench.
housing (25) on shaft (30). Check and align : 30 mm
carefully to protect the oil seal (27) lip from curl-
25
ing.

10. Tap the inner race of roller bearing (14) into shaft
(30) with a bar and hammer. Tap the inner race
ST 5097
until two threads of shaft bearing nut (15) appear. Stopper
NOTE: The fitting between the inner race and shaft
is tight.

11. Screw-in bearing nut (15) to shaft (30). Tighten as

much as possible by hand. W178-02-06-012

NOTE: Prevent shaft (30) from falling down when

lifting housing (25).

CAUTION: Housing + shaft + bearing weight:

110 kg (240 lb)

12. Install eyebolt (M16) into the ring gear mounting

bolt (23) hole in housing (25).
Lift and place housing (25) on a press.

13. Remove bearing nut (15) from shaft (30).

14. Place mounting tool (ST 2924) onto the inner race
of roller bearing (14). Push the inner race down
using a press.
NOTE: Press-in distance of the inner race can be
assured by using the mounting tool.

ST 2924

14

W178-02-06-011

W2-6-13
 UPPERSTRUCTURE / Swing Device

4
3 5

22
21 6

7
18

8
10
11
13
12
11
17
9
16

15

30
W178-02-06-003

W2-6-14
 UPPERSTRUCTURE / Swing Device
IMPORTANT: Take care to the direction of the IMPORTANT: Take care to the direction of the
bearing nut. spring pin.
16. Apply a film of grease on the threaded surface of 20. Tap spring pin (10) into 2nd stage carrier (18)
bearing nut (15), then install bearing nut (15) on using tool (ST 1463). At this time, the slit of the
shaft (30) with the stepped side of bearing nut spring pin should face to the end of pin (9).
facing roller bearing (14). Tighten the bearing nut
using mounting tool (ST 2926). 10
: 490 N⋅m (50 kgf⋅m, 360 Ibf⋅ft)
9
NOTE: Grease must be applied for keeping correct
tightening torque.
Slit

ST 2926 W178-02-06-002
15
IMPORTANT: Take care to the direction of the
thrust plate.
21. Install thrust plate (19) into 2nd stage carrier (18),
while the oil groove of thrust plate (19) is facing
upward.

22. Install planetary gears (13) (2 used), needle

W178-02-06-008
bearings (12) (4 used), thrust plates (11) (4 used),
pins (9) (2 used) and spring pins (10) (2 used) into
17. Install lock plate (16) onto bearing nut (15) with the two remaining holes in the 2nd stage carrier
bolt (17). In case the spline of lock plate and that (18) according to the same procedures 18 to 20
of shaft (30) are not aligned, tighten the bearing mentioned above.
nut in tightening direction until both splines are
aligned. IMPORTANT: Take care to the mounting location
: 17 mm of thrust plate (8).
23. Assemble the following parts to form the 1st stage
18. Clamp planetary gear (13), needle bearings (12) carrier (21) assembly according to the same
(2 used) with thrust plates (11) (2 used), and then procedures 18 to 22 for 2nd stage carrier assem-
install them together into 2nd stage carrier (18). bly: planetary gears (7) (3 used), needle bearings
(6) (3 used), thrust plates (8) (3 used), pins (4) (3
19. When planetary gear (13) has been installed onto used), spring pins (5) (3 used) and thrust plate (3).
second stage carrier (18), install pin (9) with the Thrust plate (8) is installed under needle bearing
spring pin hole facing front. At this time, the spring (6). Special tool (ST 1462) should be used as the
pin holes both in second stage carrier (18) and pin extractor for the spring pin.
(9) should be in one line.

W2-6-15
 UPPERSTRUCTURE / Swing Device

22

21

20

18

24

23

16

32

25 31

30

W178-02-06-003

W2-6-16
 UPPERSTRUCTURE / Swing Device
IMPORTANT: Take care to the mounting direction 32. Fill gear oil into ring gear (24) until the middle part
of the 2nd stage carrier. of the 1st stage sun gear (2) is submerged.
24. Install the 2nd stage carrier (18) assembly onto (Approx. 6.5 L (1.72 US gal.))
the spline of shaft (30), while the concave part of
the boss in bottom side of the carrier comes in 33. Clean off the old THREEBOND, then apply new
contact with lock plate (16). THREEBOND #1212 onto the motor (1) mounting
surface of ring gear (24).
Concave Part 18
16 CAUTION: Motor weight: 47 kg (100 lb)
30
34. Install eyebolt (M10) to motor (1) and lift motor (1)
off. Align the mating marks, and then fasten the
swing motor and ring gear (24) with bolts (22) (8
used).
: 10 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
W178-02-06-014

Eyebolt Mounting
25. Install 2nd stage sun gear (20) into the 2nd stage Position
carrier (18) assembly with the small diameter part
of the 2nd stage sun gear facing up.

26. Clean off old THREEBOND and apply new

THREEBOND #1215 onto the mounting surface
of ring gear (24) inside of housing (25).

27. Install eyebolt (M12) to the motor mounting

W178-02-06-005
threaded hole on ring gear (24). Lift the ring gear
off, install the ring gear on housing (25) with
socket bolts (23) (12 used) while aligning the
mating marks.
: 10 mm

28. Install the 1st stage carrier (21) assembly onto the
spline of 2nd stage sun gear (20).

IMPORTANT: Take care to the mounting direction

of the sun gear.
29. Install 1st stage sun gear (2) into the 1st stage
carrier (21) assembly with the stepped side of the
sun gear facing down.

30. Install pipe (32) into housing (25) with seal tape
wound on the threaded part of the pipe.
: 18 mm

31. Wind seal tape on drain plug (31), then install

drain plug (31) into pipe (32).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)

W2-6-17
 UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING MOTOR

11

8
7
6
5

4 10

3
2
24
25 29
26 30
1 27 31
28

23 27
26
25
24

12
13
14 22
15 21 32
16 20
W178-02-06-015
19
18
17

1- Casing 9- Rotor 17 - O-Ring 25 - O-Ring (2 Used)

2- Oil Seal 10 - Plate (4 Used) 18 - O-Ring 26 - Spring (2 Used)
3- Bearing 11 - Friction Plate (3 Used) 19 - Brake Piston 27 - Poppet (2 Used)
4- Shaft 12 - O-Ring 20 - Spring (24 Used) 28 - Valve Casing
5- Shoe Plate 13 - Piston 21 - Valve Plate 29 - Socket Bolt (4 Used)
6- Plunger (9 Used) 14 - Spring 22 - Bearing 30 - O-Ring (2 Used)
7- Plate 15 - Ball 23 - O-Ring 31 - Plug (2 Used)
8- Retainer 16 - Plug (2 Used) 24 - Plug (2 Used) 32 - Relief Valve (2 Used)

W2-6-18
 UPPERSTRUCTURE / Swing Device
Disassemble Swing Motor
• Be sure to read “Precautions for Disassembly
CAUTION: Another method is to float fload
and Assembly” thoroughly on page W1-1-1
before starting the disassembly work. brake piston (19) by blowing air from port B.
However, piston (13) may fly out when
blowing air. Do not use this method.
CAUTION: Swing motor assembly weight:
55 kg (120 Ib) 7. Install tool (ST 1468) into notch A of brake piston
(19), then pull brake piston (19) out from casing
IMPORTANT: Do not disassemble relief valve (32). (1).
1. Remove relief valves (32) (2 used) from valve
casing (28).
: 41 mm
Notch A
2. Remove plugs (24) (2 used) from valve casing 13
(28).
1
: 14 mm 19

3. Remove springs (26) (2 used) and poppets (27)

(2 used) from valve casing (28).
Port B
4. Make mating marks at the joint surface between
valve casing (28) and casing (1). Then loosen
socket bolts (29) (4 used). At this moment, there
is a clearance between valve casing (28) and
casing (1). Take this clearance down.
: 17 mm

5. Remove valve casing (28) from casing (1). T178-03-02-003

NOTE: At this moment, valve casing (28) may be

with valve plate (21) attached. Take care do 8. Remove O-rings (17, 18) from casing (1).
not drop valve plate (21).

IMPORTANT: Be sure not to damage the mating

surface when separating valve plate
(21) from valve casing (28) or rotor
(9) with a screwdriver. (Be sure not
to mismatch the surfaces of the
valve plate when installing.)
6. If valve plate (21) is still on rotor (9) in step 5,
remove the valve plate from the rotor. Remove
springs (20) (24 used).

W2-6-19
 UPPERSTRUCTURE / Swing Device

10

8
7
6
5

4 11

3
2

13
14
15
W178-02-06-015

W2-6-20
 UPPERSTRUCTURE / Swing Device
IMPORTANT: Take care not to damage the slide
surface of rotor (9) and plunger (6).
9. Place casing (1) horizontally. Remove rotor (9),
retainer (8), plate (7) and plungers (6) (9 used)
from shaft (4).

10. Remove plates (10) (4 used), friction plates (11)

(3 used) from housing (1).

IMPORTANT: Take care not to damage the slide

surface of shoe plate (5).
11. Remove shoe plate (5) from casing (1).

12. Tap shaft (4) with a plastic hammer lightly and

remove shaft (4) from casing (1).

13. Push out oil seal (2) from casing (1).

14. Remove the outer race of bearing (3) from casing

(1) with a guide bar.

15. Remove the inner race of roller bearing (3) from

shaft (4) with a press.

IMPORTANT: Filter and orifice are mounted inside

of piston (13). Do not disassemble
them unless they are clogged or
deformed. Disassemble them only
when absolutely needed.
If the inner parts need to be replaced,
replace them as an assembly.
16. Remove piston (13) from casing (1) with pliers.

17. Remove spring (14) and ball (15) from casing (1).

W2-6-21
 UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING MOTOR
27 26 25 24

12

13
14

15

16

29

T178-03-02-004 T178-03-02-003

31
30
28 32

22 21
20
23
19
18
10

17
6
11
9 8
7 3
5
1

4 T178-03-02-002

1- Casing 9- Rotor 17 - O-Ring 25 - O-Ring (2 Used)

2- Oil Seal 10 - Plate (4 Used) 18 - O-Ring 26 - Spring (2 Used)
3- Bearing 11 - Friction Plate (3 Used) 19 - Brake Piston 27 - Poppet (2 Used)
4- Shaft 12 - O-Ring 20 - Spring (24 Used) 28 - Valve Casing
5- Shoe Plate 13 - Piston 21 - Valve Plate 29 - Socket Bolt (4 Used)
6- Plunger (9 Used) 14 - Spring 22 - Bearing 30 - O-Ring (2 Used)
7- Plate 15 - Ball 23 - O-Ring 31 - Plug (2 Used)
8- Retainer 16 - Plug (2 Used) 24 - Plug (2 Used) 32 - Relief Valve (2 Used)

W2-6-22
 UPPERSTRUCTURE / Swing Device
Assemble Swing Motor
IMPORTANT: Be sure to install the inner race of 11. Install brake piston (19) into casing (1) while
bearing (3) with the flange facing the aligning the mating mark.
stepped side of shaft (4). NOTE: If it is not easy to install O-rings (17, 18)
into brake piston (19) due to the resistant
1. Push the inner races of bearings (3, 22) into shaft force from the O-rings, tap them evenly
(4) with a press. with a plastic hammer to force them in.

IMPORTANT: Push oil seal (2) in, with its lip facing 12. Install springs (20) (24 used) onto brake piston
up. (19).
2. Push oil seal (2) into casing (1) with a guide plate.

3. Install the outer race of bearing (3) into casing (1)

with a guide bar.

IMPORTANT: Wind tape on the spline at the end of

shaft (4) to prevent damaging oil
seal (2) from being damaged.
4. Place casing (1) horizontally. Install shaft (4) into
casing (1).

5. Place casing (1) vertically with the valve casing

(28) mounting surface up. Then install shoe plate
(5) with its chamfered inner side facing inside.

IMPORTANT: When installing retainer (8) into

plunger (6), be sure to place the
notch side of the retainer facing
shoe plate (5).
6. Assemble plate (7) and retainer (8) with the notch
matched. Then install plungers (6) (9 used).

IMPORTANT: Apply hydraulic oil into the plunger

hole in rotor (9), then install plunger
(6).
7. Insert the plunger (6) assembly into rotor (9).

8. Place casing (1) horizontally. Install the rotor (9)

assembly onto shaft (4).

IMPORTANT: 4 notchs are on the outer side of

plate (10). And 4 notchs are on the
spline teeth side of friction plate (11).
Be sure to align each notch at the
same place when installing.
9. Place casing (1) vertically. Alternately install
plates (10) (4 used), friction plates (11) (3 used)
into casing (1).

10. Install O-ring (17) and (18) onto casing (1).

W2-6-23
 UPPERSTRUCTURE / Swing Device

27 26 25 24

13
14

15

29

T178-03-02-004 T178-03-02-003

28 32

22 21

23

4 T178-03-02-002

W2-6-24
 UPPERSTRUCTURE / Swing Device
IMPORTANT: If the inner parts of piston (13) need
to be replaced, replace the piston as
an assembly.
Be sure to align the end face of the
piston with that of casing (1).
13. Install ball (15), spring (14) and piston (13) into
housing (1).

IMPORTANT: Tap the bearing type indicated

surface with a plastic hammer while
installing roller bearing (22).
14. Tap the outer race of bearing (22) with a plastic
hammer while installing it into valve casing (28).

IMPORTANT: Take care to the surfaces of valve

plate (21).
(Install the valve plate with the notch
in the port facing rotor (9).)
15. Install O-ring (23) onto valve casing (28). Then
install valve plate (21).
NOTE: Apply grease onto valve plate (21) to avoid
valve plate (21) coming off from valve
casing (28).

16. Apply grease to the needle part on bearing (22).

NOTE: It is easy to install shaft (4) into bearing (22)

by pushing the needle with grease.

17. Align the mating marks in valve casing (28) and

casing (1), while placing valve casing (28) onto
casing (1). Be sure to confirm that the clearance
between valve casing (28) and casing (1) is same
to that before disassembling. If the clearance is
larger than that before disassembling, reinstallation
shall be carried out from step 5.

18. Install valve casing (28) onto casing (1) with

socket bolts (29) (4 used).
: 17 mm
: 430 N⋅m (44 kgf⋅m, 320 Ibf⋅ft)

19. Install poppets (27) (2 used) and springs (26) ( 2

used) into valve casing (28). Tighten plug (24)
with O-ring (25) attached.
: 14 mm
: 330 N⋅m (34 kgf⋅m, 245 Ibf⋅ft)

20. Install relief valves (32) (2 used) into valve casing

(28).
: 41 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

W2-6-25
 UPPERSTRUCTURE / Swing Device
MAINTENANCE STANDARD

Swing Motor

1. Clearance between the out diameter of plunger

d
and the inner bore of cylinder

D-d Unit: mm (in)

Standard Allowable Limit
0.027 (0.0011) 0.052 (0.0020)
W107-02-06-138

D D

W107-02-06-139

2. Clearance between plunger and shoe at the

crimped position
Unit: mm (in)
Standard Allowable Limit
0 (0) 0.3 mm (0.0118 in)
δ

W107-02-06-140

W2-6-26
 UPPERSTRUCTURE / Swing Device

3. Thickness of shoe
Unit: mm (in)
Standard Allowable Limit
5.5 (0.22) 5.3 (0.21)

W107-02-06-142

4. Thickness of friction plate

Unit: mm (in)
Standard Allowable Limit
2.0 (0.08) 1.8 (0.07)

W107-02-06-143

W2-6-27
 UPPERSTRUCTURE / Swing Device
(Blank)

W2-6-28
 UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL PILOT VALVE

The following is explained on the lever stand in the left.

As for that in the right, perform the same procedure.

CAUTION: Be sure to bleed air from

hydraulic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)

Removal of Front/Swing Pilot Valve

1. Remove screws (3) (5 used) from the lever stand 1, 2

then remove covers (1, 2).
3
2. Remove the clip band and disconnect the plug
receptacle.

3. Lower boots (8). Loosen lock nut (7) then remove

lever (5) and grip (6).
: 22 mm
3 W1F3-02-07-003

4. Raise boots (8). Remove screws (9) (4 used) then

remove cover (10) and boots (8).
6
IMPORTANT: Attach identification tags to 7
disconnected hoses for re-assembly. 8
5 9
5. Disconnect hoses (12) (6 used) from pilot valve 10
(11). Cap all open ends. 11
: 19 mm 4

IMPORTANT: Put mating marks on pilot valve (11)

and lever stand to aid in reassembly.
6. Remove bolts (4) (4 used) then remove pilot valve
(11) from the lever stand.
: 13 mm

12

W1F3-02-07-004

W2-7-1
 UPPERSTRUCTURE / Pilot Valve

Installation of Front/Swing Pilot Valve

1. Insert pilot valve (11) into the lever stand and align 6
the mating marks made when disassembling. 7
8
2. Install pilot valve (11) to the lever stand with bolts 5 9
(4) (4 used). 10
11
: 13 mm 4
: 20 N⋅m (2.1 kgf⋅m, 15 lbf⋅ft)

3. Connect hoses (12) (6 used) to pilot valve (11).

: 19 mm
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)

4. Insert lever (5) (with grip (6)) into boots (8). Install
lever (5) into pilot valve (11). 12

5. Secure lever (5) to pilot valve (11) with lock nut

(7).
: 22 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
W1F3-02-07-004

6. Connect the plug receptacle and Install the clip

band.

7. Install boots (8) with cover (10) and screws (9) (4

used).

9. Install covers (1, 2) on the lever stand with screws 1, 2

(3) (5 used).
3
IMPORTANT: After installation, check the
hydraulic oil level. Run the engine
and check for oil leaks.

3 W1F3-02-07-003

W2-7-2
 UPPERSTRUCTURE / Pilot Valve

CAUTION: Be sure to bleed air from

hydraulic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.) 1, 2, 3

Removal of Travel Pilot Valve

1. Remove rubber (1) from forward/reverse travel

pedal (2).

2. Remove socket bolts (3) (2 used) from pilot valve

(6) then remove forward/reverse travel pedal (2).
Brake Pedal
: 6 mm

IMPORTANT: Attach identification tags to

disconnected hoses for re-assembly.
3. Disconnect hoses (5) (4 used) from pilot valve (6). Attachment Pedal
Cap all open ends.
: 19 mm W1F3-02-14-002

4. Remove bolts (4) (2 used) then remove pilot valve 4

(6).
: 17 mm

Installation of Travel Pilot Valve

1. Install pilot valve (6) with bolts (4) (2 used).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

2. Connect hoses (5) (4 used) to pilot valve (6).

: 19 mm 6 W1F3-02-14-001
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) 5

3. Install forward/reverse travel pedal (2) on pilot

valve (6) with socket bolts (3) (2 used).
: 6 mm
: 20 N⋅m (2.1 kgf⋅m, 15 lbf⋅ft)

4. Install rubber (1) on forward/reverse travel pedal

(2).

IMPORTANT: After installation, check the

hydraulic oil level. Run the engine
and check for oil leaks.

W2-7-3
 UPPERSTRUCTURE / Pilot Valve

CAUTION: Be sure to bleed air from

hydraulic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)
3 4
Removal of Blade/Stabilizer Pilot Valve
2
1. Remove the under cover.
1
: 17 mm

2. Remove socket bolts (2) (2 used) and remove the

bracket (1) assembly from pilot valve (4).
: 6 mm

IMPORTANT: Attach identification tags to

disconnected hoses for re-assembly.
3. Disconnect hoses (5) (4 used) from pilot valve (4).
Cap all open ends.
: 19 mm, 22 mm
W1F3-02-07-006
4. Remove bolts (6) (2 used) and remove pilot valve
(4) from bracket (3). 5
: 17 mm 3

5
Installation of Blade/Stabilizer Pilot Valve

1. Install pilot valve (4) on bracket (3) with bolts (6) (2

used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
W1F3-02-07-005
6 4
2. Connect hoses (5) (4 used) to pilot valve (4).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft)

3. Install the bracket (1) assembly to pilot valve (4)

with socket bolts (2) (2 used).
: 6 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)

IMPORTANT: After installation, check the

hydraulic oil level. Run the engine
and check for oil leaks.

W2-7-4
 UPPERSTRUCTURE / Pilot Valve
(Blank)

W2-7-5
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE FRONT/SWING PILOT
VALVE

10

10
11
1

11 12

12
2 13

13

14

5
5

6 15
6

16
7
7
17

8
8

18

9
9

19

19

20

20

W1F3-02-07-001
1- Screw Joint 6- Bushing (4 Used) 11 - Spring (4 Used) 16 - Bushing
2- Cam 7- O-Ring (4 Used) 12 - Washer (4 Used) 17 - Spring Pin
3- Universal Joint 8- Pusher (4 Used) 13 - Spool (4 Used) 18 - Port Plate
4- Plate 9- Spring Seat (4 Used) 14 - Casing 19 - Seal Washer (2 Used)
5- Oil Seal (4 Used) 10 - Spring (4 Used) 15 - O-Ring 20 - Socket Bolt (2 Used)

W2-7-6
 UPPERSTRUCTURE / Pilot Valve
Disassemble Front/Swing Pilot Valve
• Be sure to read “Precautions for Disassembly and IMPORTANT: Put on the mating mark to install the
Assembly” thoroughly on page W1-1-1 before plate (4) in the right direction.
starting any repair work. 4. Remove plate (4) from casing (14).
• The spool (13) diameter and the casing (14) bore
are selectively fitted. Do not replace individually. IMPORTANT: When bushings (6) (4 used) are still
• Discriminate between the disassembled parts by in casing (14), pry the bushing while
port No. where the parts are located in order to moving pusher (8) left and right.
avoid confusion. The port Nos. are indicated on Meanwhile take care not to damage
the periphery of casing (14) by embossed letters. the pusher.
IMPORTANT: Put port Nos. on the spool (13)
1. Clamp the pilot valve to vise with port plate (8) assembly and springs (10) (4 used)
facing downward and secure it. so as to avoid confusing each port.
Take care not to damage spool (13).
2. Put a wrench on cam (2) and secure it. Then 5. Remove the pusher (8) assembly, the spool (13)
remove screw joint (1) and the cam from universal assembly and springs (10) (4 used) from casing
joint (3). (14).
: 22 mm, 32 mm
6. Remove pushers (8) (4 used), O-rings (7) (4
used) and oil seals (5) (4 used) from bushings (6)
CAUTION: As soon as loosening universal
(4 used).
joint (3), the plate (4), bushings (6) (4 used)
and pushers (8) (4 used) may come up same
time for springs (10) (4 used) being
compressed. Take care not to let these parts
fly out.

3. Install special tool (ST 7260) on universal joint (3).

Rotate special tool (ST 7260) to left and remove
universal joint (3).
: 24 mm

Section A-A

ST 7260

A A

W577-02-06-003

W2-7-7
 UPPERSTRUCTURE / Pilot Valve

11

11 12

12
13

13

14

15

16

18

9
9

20

W1F3-02-07-001

W2-7-8
 UPPERSTRUCTURE / Pilot Valve
IMPORTANT: Do not remove the spool (13)
assembly unless necessary.
IMPORTANT: When removing spool (13) from
spring seats (9) (4 used), push the
spool in the spring seat, then direct
it towards the bigger hole while
remove it. However, do not push the
spring seat in more than 6 mm (0.24
in).

13

11

9
W577-02-06-004

7. Remove spring seats (9) (4 used), springs (11) (4

used) and washers (12) (4 used) from spool (13).

8. Clamp the pilot valve on a vise and secure the

pilot valve with the port plate (18) facing upward.

9. Remove socket bolts (20) (2 used) from casing

(14).
: 6 mm

10. Remove port plate (18), O-ring (15) and bushing

(16) from casing (14).

W2-7-9
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLE FRONT/SWING PILOT VALVE

1
3

8
5

4
6

11

10
12
13

14

16
15

17
18

19

20 W1F3-02-07-002

1- Screw Joint 6- Bushing (4 Used) 11 - Spring (4 Used) 16 - Bushing

2- Cam 7- O-Ring (4 Used) 12 - Washer (4 Used) 17 - Spring Pin
3- Universal Joint 8- Pusher (4 Used) 13 - Spool (4 Used) 18 - Port Plate
4- Plate 9- Spring Seat (4 Used) 14 - Casing 19 - Seal Washer (2 Used)
5- Oil Seal (4 Used) 10 - Spring (4 Used) 15 - O-Ring 20 - Socket Bolt (2 Used)

W2-7-10
 UPPERSTRUCTURE / Pilot Valve
Assemble Front/Swing Pilot Valve
• Be sure to read “Precautions for Disassembly and IMPORTANT: Install spring (10) in the same
Assembly” thoroughly on page W1-1-1 before position of when disassembling.
starting the assembly work. 5. Install springs (10) (4 used) to casing (14).
• The seal parts shall be replaced with new ones
when assembling. IMPORTANT: Install the spool (13) assemblies (4
used) in the same position of when
1. Install bushing (16) and O-ring (15) to casing (14). disassembling.
6. Install the spool (13) assemblies (4 used) to
2. Install spring pin (17) to port plate (18) and seal casing (14).
washers (19) (2 used) to socket bolts (20) (2
used) respectively. 7. Install O-rings (7) (4 used) and oil seals (5) (4
used) to bushings (6) (4 used).
IMPORTANT: Tighten socket bolts (20) (2 used) in
turn slowly. IMPORTANT: Apply a film of hydraulic oil to the
3. Install the port plate (18) assembly to casing (14) circumference of pushers (8) (4
with socket bolts (20) (2 used). used).
: 6 mm 8. Install pushers (8) (4 used) to bushings (6) (4
: 20.5±2 N⋅m used).
(2.1±0.2 kgf⋅m, 15±1.4 lbf⋅ft)
IMPORTANT: When it is difficult to install plate (4)
IMPORTANT: When installing spool (13) to spring because of the strong force from
seats (9) (4 used), insert the spool springs (10) (4 used), put the
through bigger one of the two holes bushing (6) assemblies (4 used) on
on the spring seat and move the the four holes of casing (14) and
spool to the smaller hole. However, then add plate (4). Simultaneously
do not insert the spool more than 6 press the bushing assemblies (4
mm (0.24 in). used) and tighten the universal joint
(3) temporarily.
9. Align the mating mark put when disassembling to
install the bushing (6) assemblies (4 used) and
plate (4) to casing (14).

13

9
W577-02-06-004

4. Install washers (12) (4 used), springs (11) (4

used), spring seats (9) (4 used) to spools (13) (4
used) in order.

W2-7-11
UPPERSTRUCTURE / Pilot Valve

1
3

14

W1F3-02-07-002

W2-7-12
 UPPERSTRUCTURE / Pilot Valve
10. Install universal joint (3) to casing (14) using
special tool (ST 7260).
: 24 mm
: 47±2.9 N⋅m
(4.8±0.3 kgf⋅m, 35±2.2 lbf⋅ft)

11. Screw universal joint (3) until pushers (8) (4 used)

contact with cam (2) evenly.

IMPORTANT: When tightening screw joint (1), do

not move the location of cam (2).
12. Secure cam (2) with the spanner. Then install
screw joint (1) to universal joint (3).
: 32 mm
: 22 mm
: 69±4.9 N⋅m
(7.0±0.5 kgf⋅m, 51±3.6 Ibf⋅ft)

13. Apply grease to the rotation portion of universal

joint (3) and the top face of pusher (8).

W2-7-13
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE TRAVEL, POSITIONING /
AUXILIARY, BLADE / STABILIZER PILOT
VALVE

20

7 20

8 19
6
9 19
18
4 18 17
10
5 16
17
16
6 15

15
4
11 14

14
3

3 12
13
2
2

21
1
1

W1LA-02-06-001

1- O-Ring (2 Used) 7- Boot 13 - Plug 19 - Shim (2 Used)

2- Bushing (2 Used) 8- Set Screw 14 - O-Ring 20 - Spring (2 Used)
3- Packing (2 Used) 9- Cam 15 - Spring (2 Used) 21 - Spring Guide (2 Used)
4- Bushing (2 Used) 10 - Pin 16 - Spool (2 Used) 22 - Pusher (2 Used)
5- Steel Ball (2 Used) 11 - Cover 17 - Washer (2 Used) 23 - Casing
6- Socket Bolt (2 Used)

W2-7-14
 UPPERSTRUCTURE / Pilot Valve
Disassemble Travel, Positioning/Auxiliary and
Blade/Stabilizer Pilot Valve
• Be sure to read “Precautions for Disassembly and IMPORTANT: Shim (17) adjusts the pressure of the
Assembly” thoroughly on page W1-1-1 before spool (15) assemblies (2 used), they
starting any repair work. had better not be disassembled. If
• As casing (21) and spool (15) cannot be disassembling the spool (15)
disassembled, they cannot be replaced with new assemblies, record the number and
ones one by one. thickness of shim (17).
• Put identification tags on the disassembled parts
by port to aid when re-assembling. IMPORTANT: Be sure not to remove bushing (4)
from cover (11) unless bushing (4) is
IMPORTANT: Put the mating marks onto cam (9), damaged.
pin (10), cover (11), and casing (21) 8. Pull bushings (4) (2 used) out of cover (11).
before disassembling.
1. Clamp the pilot valve in a vise to remove boot (7)
from cover (11).

2. Remove set screw (8) from cam (9). Pull pin (10)
out to remove cam (9) from cover (11).
: 2 mm

NOTE: LOCTITE is applied onto the set screw.

Steel ball (5) cannot be disassembled from
cam (9).

3. Loosen and remove socket bolts (6) (2 used)

alternately. Remove cover (11) from casing (21).
: 6 mm

4. Remove pusher (20) assemblies (2 used) from

casing (21).

5. Remove bushings (2) (2 used) from pusher (20)

assembly. Remove O-rings (1) (2 used) and
packings (3) (2 used) from bushings (2) (2 used).

IMPORTANT: Put identification tags on the

disassembled parts by port.
6. Remove spool (15) assemblies (2 used) and
springs (14) (2 used) from casing (21).

7. Remove spring guides (19) (2 used), springs (18)

(2 used), washers (16) (2 used), and shims (17)
(2 used) from spool (15) assemblies (2 used).

W2-7-15
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLE TRAVEL, POSITIONING /
AUXILIARY, BLADE / STABILIZER PILOT
VALVE

8 10
7
9
5

20

3
6
2

11

19

18

14

17

16

12

13

15 W1LA-02-06-002

21

1- O-Ring (2 Used) 7- Boot 12 - Plug 17 - Shim (2 Used)

2- Bushing (2 Used) 8- Set Screw 13 - O-Ring 18 - Spring (2 Used)
3- Packing (2 Used) 9- Cam 14 - Spring (2 Used) 19 - Spring Guide (2 Used)
4- *Bushing (2 Used) 10 - Pin 15 - Spool (2 Used) 20 - Pusher (2 Used)
5- Steel Ball (2 Used) 11 - Cover 16 - Washer (2 Used) 21 - Casing
6- Socket Bolt (2 Used)

NOTE: As for the item with mark “ * ”, refer to

W2-7-14.

W2-7-16
 UPPERSTRUCTURE / Pilot Valve
Assemble Travel, Positioning/Auxiliary and
Blade/Stabilizer Pilot Valve
• Be sure to read “Precautions for Disassembly and
Assembly” thoroughly on page W1-1-1 before
starting the assembly work.
• Clean the parts and put them by port for
assembling.

1. Install bushings (4) (2 used) to cover (11).

IMPORTANT: Be sure to install shim (17) to the

original condition.
2. Install washers (16) (2 used), shims (17) (2 used),
springs (18) (2 used), and spring guides (19) (2
used) to spools (15) (2 used) in this order.

IMPORTANT: Be sure to install the spool (15)

assembly into the original hole when
disassembling.
3. Install springs (14) (2 used) and spool (15)
assemblies (2 used) to casing (21).

4. Install O-rings (1) (2 used) and packings (3) (2

used) to bushings (2) (2 used).
3

W585-02-06-005
Lip Part

5. Install pushers (20) (2 used) to bushing (2)

assemblies (2 used). Install the bushing (2)
assemblies to casing (21).

6. Clamp casing (21) in a vise. Tighten cover (11)

with socket bolts (6) (2 used).
: 6 mm
: 23.5 N⋅m (2.4 kgf⋅m, 17 lbf⋅ft)

7. Install cam (9) to cover (11) with pin (10).

8. Apply LOCTITE #241 onto set screw (8). Install

set screw (8) to cam (9) with pin (10).
: 2 mm
: 5 N⋅m (0.5 kgf⋅m, 4 lbf⋅ft)

9. Install boot (7) to cover (11).

W2-7-17
 UPPERSTRUCTURE / Pilot Valve
(Blank)

W2-7-18
 UPPERSTRUCTURE / Pilot Shut-Off Valve
REMOVE AND INSTALL PILOT SHUT-OFF
VALVE

CAUTION: Be sure to bleed air from hydrau-

lic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)

Removal
1. Remove spring (3).
1
IMPORTANT: Attach identification tags to dis-
connected hoses for re-assembly.
2. Disconnect hoses (6 to 13) and pipes (14, 15). 2
: 17 mm, 19 mm, 22 mm 3

3. Remove spring pin (5) then remove lever (1). 5

4
4. Remove bolts (2) (2 used) and remove pilot
shut-off valve (4).
: 17 mm W178-02-08-001

13 14 2
12 15
11
Installation
4
1. Install pilot shut-off valve (4) with bolts (2) (2
used).
: 17 mm 6
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
10
2. Install lever (1) with spring pin (5).

3. Connect hoses (6 to 13) and pipes (14, 15).

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) 7
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) 8
: 22 mm 9 W178-02-08-002
: 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft)

4. Install spring (5).

W2-8-1
 UPPERSTRUCTURE / Pilot Shut-Off Valve
DISASSEMBLE PILOT SHUT-OFF VALVE

3
6
2
7
1
8
9

13 10

11

12

W178-02-08-005

1- Washer 5- Socket Bolt 9- O-Ring 13 - Socket Bolt (3 Used)

2- Backup Ring 6- Retaining Ring 10 - Spool
3- O-Ring 7- Washer 11 - Bracket
4- Body 8- Backup Ring 12 - Pin

W2-8-2
 UPPERSTRUCTURE / Pilot Shut-Off Valve
Disassemble Pilot Shut-Off Valve
• Be sure to read “Precautions for Disassembly
and Assembly” thoroughly on page W1-1-1 be-
fore starting the repair work.

1. Put the mating marks on body (4) and bracket

(11). Remove retaining ring (6), washer (7),
backup ring (8) and O-ring (9) from body (4) to
remove the spool (10) assembly.

2. Remove washer (1), backup ring (2) and O-ring

(3) from body (4).

3. Clamp spool (10) with a wooden pieces in a vise.

Remove socket bolts (13) (3 used) and bracket
(11).
: 4 mm
NOTE: Do not remove pin (12) unless necessary.

4. Remove socket bolt (5) from body (4).

: 8 mm

W2-8-3
 UPPERSTRUCTURE / Pilot Shut-Off Valve
ASSEMBLE PILOT SHUT-OFF VALVE

12 13 11 4 5 Z

W178-02-08-006

Section Z－Z

10 6 7 8 9 4 3 2 1 11

13

T178-03-07-002

1- Washer 5- Socket Bolt 9- O-Ring 13 - Socket Bolt (3 Used)

2- Backup Ring 6- Retaining Ring 10 - Spool
3- O-Ring 7- Washer 11 - Bracket
4- Body 8- Backup Ring 12 - Pin

W2-8-4
 UPPERSTRUCTURE / Pilot Shut-Off Valve
Assemble Pilot Shut-Off Valve

1. Apply LOCTITE#262 on socket bolt (5) and install

socket bolt (5) to body (4).
: 8 mm
: 29.4 N⋅m (3.0 kgf⋅m, 21.7 Ibf⋅ft)

2. Clamp spool (10) with a wooden pieces in a vise.

Apply LOCTITE#262 on socket bolts (13) (3
used), then install bracket (11) onto spool (10).
: 4 mm
: 3.9 N⋅m (0.4 kgf⋅m, 2.9 lbf⋅ft)

3. Install O-ring (3), backup ring (2) and washer (1)

to body (4).

4. Apply hydraulic oil to spool (10) and install spool

(10) to body (4).

5. Install O-ring (9), backup ring (8) and washer (7)

to body (4), and install retaining ring (6) to spool
(10).

W2-8-5
 UPPERSTRUCTURE / Pilot Shut-Off Valve
(Blank)

W2-8-6
 UPPERSTRUCTURE / Signal Control Valve
REMOVE AND INSTALL SIGNAL CON-
TROL VALVE

CAUTION: Be sure to bleed air from hydrau-

lic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)

Removal
1. Remove the mounting bolts (14 used) of the
swing device upper side covers (2 used) and the
cab rear cover. Then, remove the covers (3
used).
: 17 mm

IMPORTANT: Attach identification tags to dis-

connected hoses for re-assembly. Signal Control Valve
2. Disconnect all hoses and pipes from each port.
: 17 mm, 19 mm, 22 mm
NOTE: When removing pipe from signal control
valve, if a snap-on tool (GAN850812B: tool
size: 19.05 mm) is used, it may be easier
to remove the pipe.
Control Valve
3. Disconnect the pressure sensor connectors
(swing, auxiliary).

4. Remove socket bolts (20) (4 used) and remove

the signal control valve. 20
: 8 mm

Installation
1. Apply LOCTITE to socket bolts (20) (4 used). In-
stall the signal control valve with them. T176-04-04-001
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

2. Connect all hoses and pipes to each port.

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft)

3. Connect the pressure sensor connectors (swing,

auxiliary).

W2-9-1
 UPPERSTRUCTURE / Signal Control Valve

Pilot Valve Side

PH
C
A

E
M
D
H
B
F
SB
PI G

Pilot Valve Side

K N

I
SH
J

DF

SA L
T178-03-06-016

Pilot Valve Side

Port Name Connecting to Note
Port A Right Pilot Valve Boom Raise Pilot Pressure
Port B Right Pilot Valve Boom Lower Pilot Pressure
Port C Left Pilot Valve Arm Roll-Out Pilot Pressure
Port D Left Pilot Valve Arm Roll-In Pilot Pressure
Port E Left Pilot Valve Left Swing Pilot Pressure
Port F Left Pilot Valve Right Swing Pilot Pressure
Port G Right Pilot Valve Bucket Roll-In Pilot Pressure
Port H Right Pilot Valve Bucket Roll-Out Pilot Pressure
Port I Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port J  Plug
Port K Travel Shockless Valve Travel Reverse Pilot Pressure
(Travel Pilot Valve)
Port L Travel Shockless Valve Travel Forward Pilot Pressure
(Travel Pilot Valve)
Port M Positioning/Auxiliary Pilot Valve Positioning Raise/Auxiliary Open Pilot Pressure
Port N Positioning/Auxiliary Pilot Valve Positioning Lower/Auxiliary Close Pilot Pressure
Port SA Pump 1 Regulator Pump 1 Control Pressure
Port SB Pump 2 Regulator Pump 2 Control Pressure
Port PI Pilot Relief Valve Primary Pilot Pressure
Port PH Pilot Shut-Off Valve Primary Pilot Pressure (Heating Circuit)
Port SH Shuttle Valve Brake Release Pressure
(Swing Parking Brake)
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank

W2-9-2
 UPPERSTRUCTURE / Signal Control Valve

Control Valve Side

3
1
Pressure Sensor 5
(Auxiliary)

13
2 4
SK SE
Pressure Sensor 8
(Swing)

14
Control 7
Valve Side
9
6
10

SN
SL
11

T1F3-03-06-003
12 SP
Control Valve Side
Port Name Connecting to Note
Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 Control Valve Boom Lower Pilot Pressure
Port 3 Control Valve Arm Roll-Out Pilot Pressure
Port 4 Control Valve Arm Roll-In Pilot Pressure
Port 5 Control Valve Left Swing Pilot Pressure
Port 6 Control Valve Right Swing Pilot Pressure
Port 7 Control Valve Bucket Roll-In Pilot Pressure
Port 8 Control Valve Bucket Roll-Out Pilot Pressure
Port 9 Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port 10  Plug
Port 11 Control Valve Travel Reverse Pilot Pressure
Port 12 Control Valve Travel Forward Pilot Pressure
Port 13 Pilot Pressure Shift Valve Positioning Raise/Auxiliary Open Pilot Pressure
Port 14 Pilot Pressure Shift Valve Positioning Lower/Auxiliary Close Pilot Pressure
Port SE Control Valve Arm Flow Rate Control Valve Control Pressure
Port SN  Plug
Port SP Shuttle Valve Pump 1 Flow Rate Control Valve Control Pressure
Port SL Control Valve Flow Combiner Valve Control Pressure
Port SK Control Valve Bucket Flow Rate Control Valve Control Pressure

W2-9-3
 UPPERSTRUCTURE / Signal Control Valve

NOTE: Machines Equipped with Optional Auxiliary

Flow Combining System

Control Valve Side

SM

Control
Valve Side

SN

T1F3-03-06-004

Control Valve Side

Port Name Connecting to Note
Port SM Auxiliary Flow Combiner Solenoid Valve Auxiliary Flow Combiner Valve Shift Pressure
Port SN Auxiliary Flow Combiner Reducing Valve Auxiliary Flow Combiner Valve Shift Pressure

NOTE: The reducing valve and the auxiliary flow

combiner solenoid valve are installed only
on the machines equipped with the op-
tional auxiliary flow combining system.

W2-9-4
 UPPERSTRUCTURE / Travel Shockless Valve
REMOVE AND INSTALL TRAVEL
SHOCKLESS VALVE

CAUTION: Be sure to bleed air from

hydraulic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)
Accumulator
Removal Charging Valve
3

1. Remove the protection cover above the

accumulator charging valve and travel shockless 1, 2
valve (1).

IMPORTANT: Attach identification tags to

disconnected hoses for re-assembly.
2. Disconnect connectors (4) (2 used) and hoses (3)
(5 used). Cap open ends.
: 19 mm

3. Remove bolts (2) (2 used) and remove travel

shockless valve (1).
: 17 mm
W1GL-02-10-001
4 3

Installation

1. Install travel shockless valve (1) with bolts (2) (2

used).
: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)

2. Connect hoses (3) (5 used) and connectors (4) (2

used).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)

3. Install the removed covers.

W2-10-1
 UPPERSTRUCTURE / Travel Shockless Valve
CONSTRUCTION OF TRAVEL
SHOCKLESS VALVE

13

1
14

4
4

T1F3-03-08-005 T1F3-03-08-004

5
Section A

7
T1F3-03-08-006

8 9 10 11 12

Section B

W2-10-2
 UPPERSTRUCTURE / Travel Shockless Valve

Item Wrench Size Tightening Torque

Part Name Q’ty Remark
No. (mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Solenoid 2
2 O-Ring 2 1B P14
3 Spool 2
4 Body 1
5 Spring 2
6 Plug 6
7 Orifice 2 1.6 to 2.0 (0.16 to 0.2) (1.2 to 1.5)
8 Plug 2 13.2 to 17.6 (1.3 to 1.8) (9.7 to 13.0)
9 Steel Ball 2 9/32
10 Spring 2
11 O-Ring 4 1B P8
12 Plug 2 13.2 to 17.6 (1.3 to 1.8) (9.7 to 13.0)
13 Nut 2 ： 19 4.9 (0.5) (3.6)
14 Tube 2 30 to 37 (3.1 to 3.8) (22 to 27)

W2-10-3
 UPPERSTRUCTURE / Travel Shockless Valve
(Blank)

W2-10-4
 UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL 4-UNIT SOLE-
NOID VALVE UNIT

CAUTION: Be sure to bleed air from hydrau-

lic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)

Removal
3, 4
1. Disconnect the harness connector of each
proportional solenoid valve (13 to 16). 5, 6

IMPORTANT: Attach identification tags to dis-

connected hoses for re-assembly. 2
2. Disconnect pilot hoses and pipes (1 to 9, 11, 12, 18
17, 18). Cap open ends.
: 17 mm, 19 mm 1
Solenoid Valve Unit
3. Remove bolts (10) (2 used) and remove the so-
lenoid valve unit.
: 8 mm
17
16
7
15
Installation 14
13
1. Install the solenoid valve unit with bolts (10) (2
used). 12
: 8 mm 11
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
10 8
9
2. Connect pilot hoses and pipes (1 to 9, 11, 12, 17,
18). W1GL-02-11-001

: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)

3. Connect the harness connector of each

proportional solenoid valve (13 to 16).

W2-11-1
 UPPERSTRUCTURE / Solenoid Valve
DISASSEMBLE PROPORTIONAL SOLE-
NOID VALVE

1
3
2

4
5

7
8
9
10
13
11
12 14
15

16
17

18

W157-02-11-016

1- Socket Bolt (2 Used) 6- Solenoid 11 - Washer 15 - O-Ring

2- Lock Nut 7- Spring 12 - Spring 16 - Sleeve
3- O-Ring 8- O-Ring 13 - O-Ring 17 - Plate
4- Adjusting Screw 9- Diaphragm 14 - O-Ring 18 - Washer
5- Spring 10 - Spool

W2-11-2
 UPPERSTRUCTURE / Solenoid Valve
Disassemble Proportional Solenoid Valve

IMPORTANT: Take care not to lose spring (7) pro-

vided in the groove of solenoid (6)
when removing solenoid (6).
Do not disassemble lock nut (2) and
adjusting screw (4).
1. Remove socket bolts (1) (2 used) and remove
solenoid (6).
: 3 mm

2. Pull out spool (10) and remove diaphragm (9),

washer (11) and spring (12).

3. Pull sleeve (16) out and remove O-rings (13, 14,

15), washer (18) and plate (17).

W2-11-3
 UPPERSTRUCTURE / Solenoid Valve
ASSEMBLE PROPORTIONAL SOLENOID
VALVE

4 2 6 1 8 16 13 14 10 15 18

3, 5
9 7 11 12 17

W157-02-11-001

1- Socket Bolt (2 Used) 6- Solenoid 11 - Washer 15 - O-Ring

2- Lock Nut 7- Spring 12 - Spring 16 - Sleeve
3- O-Ring 8- O-Ring 13 - O-Ring 17 - Plate
4- Adjusting Screw 9- Diaphragm 14 - O-Ring 18 - Washer
5- Spring 10 - Spool

W2-11-4
 UPPERSTRUCTURE / Solenoid Valve
Assemble Proportional Solenoid Valve

IMPORTANT: Apply grease to O-rings (13, 14, 15) IMPORTANT: Lock nut (2), adjusting screw (4),
and apply a film of hydraulic oil to spring (5) and O-ring (3) are not
sleeve (16). separated, so no need to assemble
When inserting the sleeve, be sure them.
to align the ports of the sleeve with When assembling solenoid (6), take
the ports in the housing. care not to drop spring (7).
Install sleeve so that the end faces 3. Install solenoid (6) with socket bolts (1) (2 used).
of sleeve and body come to the : 3 mm
same point. : 2.9 N⋅m (0.3 kgf⋅m, 2.2 lbf⋅ft)
1. Install washer (18), plate (17) into the housing.
Install O-rings (13, 14, 15) on sleeve (16), and 6
then insert the sleeve (16) assembly into the
housing.

16
15 7
14
13

1
W157-02-11-011

Housing

W157-02-11-005

IMPORTANT: Take care not to damage the edge

portion in the bore of sleeve (16)
when inserting the spool (10) as-
sembly.
After inserting spool in, check that
the spool slides in and out smoothly
without any restriction about 3 to 5
mm (0.12 to 0.20 in).
Apply hydraulic oil to the spool.
2. Install diaphragm (9), washer (11) and spring (12)
to spool (10). Then, install the spool (10) assem-
bly into sleeve (16).

10 Housing

16

12
11
W157-02-11-009

W2-11-5
 UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL 2-UNIT SOLE-
NOID VALVE (FOR PUMP CONTROL)

NOTE: As for disassemble and assemble solenoid

valve, refer to “Disassemble and Assemble
Proportional Solenoid Valve” on page
W2-11-2.

CAUTION: Be sure to bleed air from hydrau-

lic oil tank before starting the work. 1 2
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)

Removal
1. Open cover (2) of the machine right side and se-
cure it with stopper (1).

2. Remove the bolts (4 used) and remove the cover

of the pump device upper side.
: 17 mm

3. Disconnect connectors (6) from solenoid valves

(3).
MCBB-07-004
IMPORTANT: Attach identification tags to dis-
connected hoses for re-assembly.
4. Disconnect hoses (5) (5 used) from solenoid 4 5
3
valve unit (7). Cap open ends.
: 17 mm, 19 mm

5. Remove bolts (4) (2 used) and remove solenoid

valve unit (7).
: 13 mm

Installation
1. Install solenoid valve unit (7) with bolts (4) (2
used).
: 13 mm 6
: 20 N·m (2.0 kgf·m, 15 Ibf⋅ft)

2. Connect hoses (5) (5 used) to solenoid valve unit

(7). Connect connectors (6) (2 used) to solenoid
valve (3).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) W1GL-02-11-002
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft) 4 5

3. Install the cover of the pump device upper side

with the bolts (4 used).
: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)

4. Remove stopper (1) and close cover (2).

W2-11-6
 UPPERSTRUCTURE / Solenoid Valve
CONSTRUCTION OF 2-UNIT SOLENOID
VALVE (FOR PUMP CONTROL)

3
3

4
5
6
6

7 7

9
8
10
9 11

10 12

11 13
15 T1GL-03-10-001

12 13 14 16

Item Wrench Size Tightening Torque

Part Name Q’ty Remark
No. (mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Adjust Screw 1
2 Lock Nut 1 : 10 5+2−0 0.5+0.2−0 3.7+1.5−0
3 Solenoid 1
4 Socket Bolt 2 : 4 5+2−0 0.5+0.2−0 3.7+1.5−0
5 Spring 1
6 O-Ring 1
7 Diaphragm 1
8 Washer 1
9 O-Ring 1
10 Spring 1
11 O-Ring 1
12 Spool 1
13 O-Ring 1
14 Plate 1
15 Sleeve 1
16 Washer 1

W2-11-7
 UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL 2-UNIT SOLE-
NOID VALVE (FOR BLADE/STABILIZER)

CAUTION: Be sure to bleed air from hydrau-

lic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.) Solenoid Valve Solenoid Valve
for Blade for Stabilizer

Removal
IMPORTANT: The one side of solenoid valve unit
cannot be removed. Be sure to re-
move the solenoid valve unit as the
plate (7) assembly.

IMPORTANT: Attach identification tags to dis-

connected hoses for re-assembly.
1. Disconnect hoses (3, 5, 6) (4 used) and (9) (2
used). Cap open ends.
: 22 mm, 19 mm

2. Disconnect connectors (2) (2 used) and (4) (2

used). W1F3-04-04-004

3. Remove bolts (1) (5 used) and remove the plate

(7) assembly. 1 2 3 1 4 5
: 17 mm

4. Remove bolts (8) (4 used) and remove the sole-

noid valve units (2 used) from plate (7).
: 17 mm

Installation
1. Install the solenoid valve units (2 used) on plate
(7) with bolts (8) (4 used).
: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)

2. Install the plate (7) assembly with bolts (1) (5

9 7, 8 6 1
used).
: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft) Solenoid Valve Solenoid Valve
for Blade for Stabilizer
W1F3-02-11-002
3. Connect connectors (2) (2 used) and (4) (2
used).

4. Connect hoses (3, 5, 6) (4 used) and (9) (2

used).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 Ibf⋅ft)

W2-11-8
 UPPERSTRUCTURE / Solenoid Valve
CONSTRUCTION OF 2-UNIT SOLENOID
VALVE (FOR BLADE/STABILIZER)

T1F3-03-08-001
6

Item Wrench Size Tightening Torque

Part Name Q’ty Remark
No. (mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Solenoid 2
2 Piston 2
3 O-Ring 2 1B P14
4 Body 1
5 Spool 2
6 Spring 2

W2-11-9
 UPPERSTRUCTURE / Solenoid Valve
(Blank)

W2-11-10
 UPPERSTRUCTURE / Pilot Relief Valve
REMOVE AND INSTALL PILOT RELIEF
VALVE

CAUTION: Be sure to bleed air from

hydraulic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)

Removal

1. Remove the bolts (7 used) then remove the upper 1 2 Accumulator 3

covers (2 used).
: 17 mm

IMPORTANT: Attach identification tags to

disconnected hoses for
re-assembly. 4
2. Disconnect hoses (1) (6 used). Cap open ends.
: 17 mm, 19 mm, 27 mm

3. Remove socket bolts (2) (2 used) and remove

pilot relief valve (4) from hydraulic oil tank (3).
: 17 mm

Installation W1GL-02-12-001

1. Install pilot relief valve (4) on hydraulic oil tank (3)

with bolts (2) (2 used).
: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)

2. Connect hoses (1) (6 used).

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)

3. Install the upper covers with the bolts (7 used).

: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)

W2-12-1
 UPPERSTRUCTURE / Pilot Relief Valve
CONSTRUCTION OF PILOT RELIEF 1 2 3, 4 5 6
VALVE

W1GL-02-12-002

T1F3-03-08-002
10 9 Section A
8 7

11

12

B
13

Section B 14 T1F3-03-08-003

T1F3-03-08-008

Item Wrench Size Tightening Torque

Part Name Q’ty Remark
No. (mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Body 1
2 Plug 1 59±5.9 (6.0±0.6) (44±4.4)
3 Shim 1 0.5 mm
4 Shim 1 0.2 mm
5 Spring 1
6 O-Ring 1 1B P24
7 O-Ring 3 1B P11
8 Plug 3 26.5±3.0 (2.7±0.3) (19.5±2.2)
9 Plug 1 39±4.0 (4.0±0.4) (28.5±3.0)
10 O-Ring 1 1B P14
11 Check Valve 1
12 Spring 1
13 O-Ring 1 1B
14 Plug 1 49±4.9 (5.0±0.5) (36±3.6)

W2-12-2
 UPPERSTRUCTURE / Steering Valve
REMOVE AND INSTALL STEERING VALVE

CAUTION: Be sure to bleed air from hydrau-

lic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Travel Pilot Valve
Tank” on page W1-4-1.)
1
Removal
IMPORTANT: Attach identification tags to hoses
to aid re-assembly.
1. Disconnect hoses (3) (4 used) from steering
valve (4). Cap the open ends.

2. Remove bolts (2) (4 used) from stand (1) to re- Brake Valve
move steering valve (4).
Stand Mount-
ing Bolt

Installation
2
1. Install steering valve (4) to stand (1) with bolts (2)
(4 used).
: 17 mm Attachment Pedal W1F3-02-14-002

: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

2. Connect hoses (3) (4 used) to steering valve (4).

1
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 Ibf⋅ft)
: 27 mm 2 Floor Plate
: 78 N⋅m (8 kgf⋅m, 58 Ibf⋅ft)
3

4
W216-02-12-005

W2-13-1
 UPPERSTRUCTURE / Steering Valve
DISASSEMBLE STEERING VALVE

14
19
17
18

16
39
5
38
37 15
36
35
6

5
4 33
2 3 12
1 13 20
12 21
11 32
10 31
9 6
5 24
8 4
7 3 30 34
2 28
1 27
26
25

24
29
23 28
22 27
26

T1F3-03-07-004

1- O-Ring (2 Used) 11 - Seal 21 - Ball 31 - Spacer

2- Plug (2 Used) 12 - Bearing Race (2 Used) 22 - O-Ring 32 - Cap
3- Spring (2 Used) 13 - Thrust Needle 23 - Plate 33 - Screw (6 Used)
4- Holder (2 Used) 14 - Housing Assembly 24 - O-Ring (2 Used) 34 - Screw
5- Ball (2 Used) 15 - Housing 25 - Drive 35 - Plug
6- Seat (2 Used) 16 - Sleeve 26 - Ball (2 Used) 36 - O-Ring
7- Dust Seal 17 - Center Spring (6 Used) 27 - Plug (2 Used) 37 - Spring
8- Retaining Ring 18 - Pin 28 - Spring (2 Used) 38 - Poppet
9- Bushing 19 - Spool 29 - Star 39 - Valve Seat
10 - O-Ring 20 - Screw 30 - Rotor

W2-13-2
 UPPERSTRUCTURE / Steering Valve
Disassemble steering valve
IMPORTANT: The O-ring (1), plug (2), spring (3), 4. Remove drive (25) and plate (23) to remove
holder (4), ball (5) and seat (6) are O-ring (22) from housing assembly (14). Remove
adjustment parts. Do not disassem- screw (20) from housing (15) with a screwdriver.
ble them. If disassemble them, the
setting may change, malfunction of 5. Dismount the steering valve from the vise. Turn
the base machine may result. the housing (15) over. Remove ball (21), springs
IMPORTANT: Cover the open ends of vice with (28) (2 used), plugs (27) (2 used), and balls (26)
cloth. Lightly secure the valve. (2 used) from housing (15). Place the steering
1. Secure the steering valve in a vice with cap (32) valve on a clean cloth with care not to damage
upward. the machined surfaces. Remove retaining ring (8)
from housing (15) with a screwdriver.
32
Vice

15

W202-02-14-002
W202-02-14-006

6. Turn spool (19) and sleeve (16) so that pin (18) is

horizontal. From the cap (32) side, push spool
2. Remove screws (33) (6 used) and (34) to remove (19) and sleeve (16) to remove bushing (9) from
cap (32). Remove O-ring (24) from cap (32). the steering valve.
Tool: 5/16 inch-12 Point Flange Head Socket

3. Remove rotor (30) to remove O-ring (24) and

spacer (31) from rotor (30).
NOTE: Take care not to allow star (29) to drop out
of rotor (30) when removing rotor (30).

W2-13-3
 UPPERSTRUCTURE / Steering Valve

19
17
18

39
5 16
38
37 15
36
35

5
4
2 3 12
1 13
12 21
11
10
9
5
4
7 3
2
1
26

26

T1F3-03-07-004

W2-13-4
 UPPERSTRUCTURE / Steering Valve
7. Remove seal (11) and dust seal (7) from bushing
(9).
NOTE: Take care not to damage bushing (9) when
removing seal (11).

8. Remove bearing races (12) (2 used) and thrust

needle (13) from spool (19).

9. Remove spool (19) and the sleeve (16) assembly

from housing (15).
NOTE: Remove the sleeve (16) assembly from
housing (15) while slowly turning the
sleeve (16) assembly so that sleeve (16)
doesn’t score housing (15).

10. Remove pin (18) from the sleeve (16) assembly.

11. Push spool (19) of sleeve (16) inside into forward

slightly then remove center springs (17) (6 used)
from spool (19).

12. Turn spool (19) lightly while removing it from

sleeve (16).

13. Remove O-ring (10) from housing (15)

14. Remove plug (35) from housing (15).

15. Remove spring (37), poppet (38) and valve seat

(39) from housing (15) with a magnet.

W2-13-5
 UPPERSTRUCTURE / Steering Valve
ASSEMBLE STEERING VALVE
16 15 21 20 22 30 31

32

12 34
11

A B

25

33
7
24
8
T1F3-03-07-002
9 10 13 17 18 19 23 24 29

View A C View B

D
E
D
E
D
E

D E

T487-03-02-005
W1F3-02-13-001

Section C-C

Section E-E

36 35 37 38 39
T1F3-03-07-003

Section D-D
T487-03-02-006
26 27 28

6 5 4 3 2 1 T487-03-02-007

W2-13-6
 UPPERSTRUCTURE / Steering Valve

1- O-Ring (2 Used) 11 - Seal 21 - Ball 31 - Spacer

2- Plug (2 Used) 12 - Bearing Race (2 Used) 22 - O-Ring 32 - Cap
3- Spring (2 Used) 13 - Thrust Needle 23 - Plate 33 - Screw (6 Used)
4- Holder (2 Used) 14 - Housing Assembly 24 - O-Ring (2 Used) 34 - Screw
5- Ball (2 Used) 15 - Housing 25 - Drive 35 - Plug
6- Seat (2 Used) 16 - Sleeve 26 - Ball (2 Used) 36 - O-Ring
7- Dust Seal 17 - Center Spring (6 Used) 27 - Plug (2 Used) 37 - Spring
8- Retaining Ring 18 - Pin 28 - Spring (2 Used) 38 - Poppet
9- Bushing 19 - Spool 29 - Star 39 - Valve Seat
10 - O-Ring 20 - Screw 30 - Rotor

W2-13-7
 UPPERSTRUCTURE / Steering Valve

16 15

32

A B

25

T1F3-03-07-002
17 18 19

View A C View B

D
E
D
E
D
E

D E

T487-03-02-005
W1F3-02-13-001

Section C-C

Section E-E

36 35 37 38 39
T1F3-03-07-003

Section D-D
T487-03-02-006
26 27 28

6 5 4 3 2 1 T487-03-02-007

W2-13-8
 UPPERSTRUCTURE / Steering Valve
Assemble Steering Valve

Precautions for before assemble 3. Install pin (18) into spool (19) and sleeve (16).
• Check all parts for scores or coarse surfaces. Level the ends of pin (18) with the outer diameter
If any, grind to a smooth finish using an oil stone. of sleeve (16).

IMPORTANT: Align the spring grooves on spool

(19) and sleeve (16). Pin (18)
1. Install spool (19) into sleeve (16) while turning
spool (19).
Spring Groove

W202-02-14-021

4. Install sleeve (16) assembly into housing (15)

from the cap (32) mounting side.
NOTE: Take care not to install the sleeve (16) as-
sembly with excessive force into housing
Spool (19) (15). While keeping pin (18) in the hori-
zontal position and slightly turning the
Sleeve (16) W202-02-14-019
sleeve (16) assembly right and left, install
the sleeve (16) assembly into housing (15)
until the rear ends of both the sleeve (16)
2. Place spool (19) and sleeve (16) on a flat plate
assembly and housing (15) level off.
so that the spring grooves on them align. Install
center springs (17) into special tool (ST 2497)
with the back of 2-sets of three center springs
(17) contacted each other. Install center springs
(17) into spool (19) and sleeve (16) using special
tool (ST 2497).

Spool (19)
ST 2497
Center Spring (17)

Sleeve (16)
W202-02-14-020

W2-13-9
 UPPERSTRUCTURE / Steering Valve

15 21 20 22

12
11

A B

8
T1F3-03-07-002
9 10 13 19 23

View A C View B

D
E
D
E
D
E

D E

T487-03-02-005
W1F3-02-13-001

Section C-C

Section E-E

T1F3-03-07-003

Section D-D
T487-03-02-006
26 27 28

T487-03-02-007

W2-13-10
 UPPERSTRUCTURE / Steering Valve
5. Install O-ring (10), bearing races (12) (2 used) 9. Lightly hold housing (15) with a vise.
and thrust needle (13) to housing (15).
10. Install O-ring (22) in housing (15). Install ball (21)
and screw (20) in housing (15) as illustrated be-
13 low. Install balls (26) (2 used), plugs (27) (2 used),
12 and springs (28) (2 used) in housing (15) as illus-
trated below. Put plate (23) on housing (15). Align
10 the bolt holes with tapped holes on housing (15).
15

Screw (20)

Ball (21)
W202-02-14-023
Housing (15)

6. Install dust seal (7) and seal (11) to bushing (9).

7. Install bushing (9) to spool (19) while tapping

bushing (9) with a plastic hammer.
NOTE: Check that bushing (9) comes in contact
with bearing race (12) flat.
W487-03-08-004
Driver

8
Spring (28)
7
15

Plug (27)
11 10
12
Ball (26)
9

Housing (15)

W212-02-14-002

8. Install retaining ring (8) to housing (15).

NOTE: After installing retaining ring (8) into hous-
ing (15), make sure that retaining ring (8)
is correctly seated in the groove on hous-
ing (15) by expanding the inner diameter of W487-03-08-005

retaining ring (8) with a screwdriver.

W2-13-11
 UPPERSTRUCTURE / Steering Valve

16 15 30 31

32

12 34
11

A B

25

33

24

T1F3-03-07-002
13 18 19 23 24 29

View A C View B

D
E
D
E
D
E

D E

T487-03-02-005
W1F3-02-13-001

Section C-C

Section E-E

36 35 37 38 39
T1F3-03-07-003

Section D-D
T487-03-02-006

T487-03-02-007

W2-13-12
 UPPERSTRUCTURE / Steering Valve
IMPORTANT: Steps 11 to 13 described above are 14. Install spacer (31) into rotor (30). Install O-ring
important procedure to determine (24) on cap (32). Install cap (32) on rotor (30).
the valve timing. Carefully follow the
procedures in these steps. 15. Install screws (33) (6 used) and screw (34) onto
11. Turn spool (19) and the sleeve (16) assembly so cap (32), tighten them with the specified torque.
that pin (18) is parallel to the port face on housing Tool: 5/16 inch-12 Point Flange Head Socket
(15). Draw line (B) on the end face of the spline : 28.5 N⋅m (2.9 kgf⋅m, 21 Ibf⋅ft)
on drive (25) so that line (B) is parallel to line (C)
at the yoke of drive (25). Insert drive (25) to install
the yoke of drive (25) onto pin (18). (Line (B) on 16. Install valve seat (39), poppet (38) and spring
the end face of the spline on drive (25) is parallel (37) into housing (15) then secure them with plug
to the port face on housing (15).) (35).

B
Rotor (30)
C A
Draw Line (a)

Star (29)
Drive (25)
B

Bolt Hole
Yoke
Drive (25) C
W487-03-08-006
D

12. Install O-ring (24) to rotor (30). Plate (23)

13. Face the O-ring (24) mounting side of rotor (30)

toward plate (23). Draw line (a) on star (29) so
that two tooth bottoms at the opposite sides are
on line (A). Install star (29) onto drive (25) while
aligning the spline pitch so that line (A) is parallel
to line (B).
Recheck that lines (A, B, C, and D) are all parallel
to each other. Align the bolt holes of rotor (30)
with those of housing (15) without disengaging
the splines on drive (25) and star (29).
Pin (18)
Port Face
W202-02-14-031
Port Face

Drive (25)
Make surface of pin
(18) paralleled with
port face

Pin (18)
Yoke
Housing (15) W487-03-08-007

W2-13-13
 UPPERSTRUCTURE / Steering Valve
(Blank)

W2-13-14
 UPPERSTRUCTURE / Brake Valve
REMOVE AND INSTALL BRAKE VALVE
1 2
CAUTION: Be sure to bleed air from hydrau-
lic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)

Removal

IMPORTANT: Attach tags to the disconnected

hoses to aid re-assembling. 1
1. Disconnect hoses (1) (6 used) from brake valve
(2). Cap the disconnected hose ends.
: 17, 22, 27 mm

2. Remove bolts (4) (4 used) from frame (3) to re- W1F3-02-14-001

move brake valve (2).

: 17 mm

Installation

1. Install brake valve (2) to frame (3) with bolts (4)

(4 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
4
2. Connect all hoses (1) (6 used) to brake valve (2).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 29 Ibf⋅ft)
W1F3-02-14-002
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)

W2-14-1
 UPPERSTRUCTURE / Brake Valve
DISASSEMBLE BRAKE VALVE
1

5 11
28
27 8

4 7
26
10
6
7
12
9

13

15
14

16
25
9
29 24 3
17
23
30
42 31
32 22
21 16
33
34 20
35 18
36 19
41 20
40
37

39

28

43 38
44
45
46
47

43
44
45
46 48 47
W1F3-02-14-003

W2-14-2
 UPPERSTRUCTURE / Brake Valve

1- Rubber 13 - Spring Pin 25 - Bracket 37 - Push Rod

2- Brake Pedal 14 - Bushing 26 - Oil Seal 38 - P Cylinder
3- Cotter Pin (4 Used) 15 - Yoke 27 - T Flange 39 - S Cylinder
4- Stopper Bolt 16 - Pin (2 Used) 28 - O-Ring (2 Used) (1B, G45) 40 - O-Ring (1B, P32)
5- Bushing 17 - Link 29 - Rod 41 - Plug
6- Lock Nut 18 - Roller 30 - Return Spring 42 - Socket Bolt (4 Used)
7- Bushing (2 Used) 19 - Bushing 31 - Holder 43 - Spring (2 Used)
8- Pin 20 - Washer (2 Used) 32 - Spring 44 - Retaining Ring (2 Used)
9- Bushing (2 Used) 21 - Seat 33 - Balance Spring 45 - Retainer (2 Used)
10 - Pin 22 - Stopper 34 - Retainer 46 - Plunder (2 Used)
11 - Boots 23 - Boots 35 - Retainer 47 - Spool (2 Used)
12 - Pin 24 - Socket Bolt (4 Used) 36 - Pilot Piston 48 - Spring

W2-14-3
 UPPERSTRUCTURE / Brake Valve

5 11
28
27 8

4 7
26
10
6
7
12
9

13

15
14

16
25
9
29 24 3
17
23
30
42 31
32 22
21 16
33
34 20
35 18
36 19
41 20
40
37

39

28

43 38
44
45
46
47

43
44
45
46 48 47 W1F3-02-14-003

W2-14-4
 UPPERSTRUCTURE / Brake Valve
Disassemble Brake Valve
• Be sure to read “Precautions for Disassembly IMPORTANT: As the action force from springs is
and Assembly” thoroughly on page W1-1-1 be- applied to socket bolt (42), slowly
fore starting the disassembly work. remove socket bolt (42) while push
S cylinder (39) on top.
IMPORTANT: Before disassembling, put matching 9. Remove socket bolts (42) (4 used) from S cylin-
marks on bracket (25), T flange (27), der (39).
P cylinder (38), S cylinder (39).
1. Secure S cylinder (39) on a vice with the S cylin- 10. Remove S cylinder (39) and the P cylinder (38)
der (39) facing lower side. Except the roller (18) assembly from T flange (27).
parts, remove cotter pins (3) (3 used) then re-
move pins (8), (10), (16).
11. Pulling out the spool (47) assembly from P cylin-
der (38).
2. Remove spring pin (13) from yoke (15) to remove
pin (12).
12. Remove plunger (46), spring (48) and retaining
ring (44), retainer (45) from the spool (47) as-
3. Remove cotter pin (3) from link (17) then remove sembly.
pin (16), washers (20) (2 used) and roller (18).

13. Remove return spring (30), holder (31), rod (29),

4. Remove seat (21), stopper (22) and boots (23) balance spring (33), spring (32), retainers (34),
from T flange (27). (35) and pilot piston (36), push rod (37) from T
flange (27).
5. Remove socket bolts (24) (4 used) to remove
bracket (25) from T flange (27).

6. Secure the T flange (27) position on a vice with

the push rod (37) side facing down.

IMPORTANT: The spool (47) assembly also is

used in P cylinder (38). Be sure
store the parts correctly without
mixing.
7. Pulling out plug (41), spring (43) and the spool
(47) assembly from S cylinder (39).

8. Remove plunger (46) and retaining ring (44), re-

tainer (45) from the spool (47) assembly.

W2-14-5
 UPPERSTRUCTURE / Brake Valve
ASSEMBLE BRAKE VALVE 2
1
12
11
8

15

14
25 27 38 42 39 41

16

10
16
18 21 24
23 W1F3-02-14-004

34 30 28 46 44 28 47 43 40

41

46

45

37 22 26 36 35 32 29 33 31 47 48 45 43 T1F3-03-09-002

View A 13 5
12
7
15
8
9
3
24
25
17
10

3 16

18 19 20 W1F3-02-14-005

W2-14-6
 UPPERSTRUCTURE / Brake Valve

1- Rubber 13 - Spring Pin 25 - Bracket 37 - Push Rod

2- Brake Pedal 14 - Bushing 26 - Oil Seal 38 - P Cylinder
3- Cotter Pin (4 Used) 15 - Yoke 27 - T Flange 39 - S Cylinder
4- *Stopper Bolt 16 - Pin (2 Used) 28 - O-Ring (2 Used) (1B, G45) 40 - O-Ring (1B, P32)
5- Bushing 17 - Link 29 - Rod 41 - Plug
6- *Lock Nut 18 - Roller 30 - Return Spring 42 - Socket Bolt (4 Used)
7- Bushing (2 Used) 19 - Bushing 31 - Holder 43 - Spring (2 Used)
8- Pin 20 - Washer (2 Used) 32 - Spring 44 - Retaining Ring (2 Used)
9- Bushing (2 Used) 21 - Seat 33 - Balance Spring 45 - Retainer (2 Used)
10 - Pin 22 - Stopper 34 - Retainer 46 - Plunder (2 Used)
11 - Boots 23 - Boots 35 - Retainer 47 - Spool (2 Used)
12 - Pin 24 - Socket Bolt (4 Used) 36 - Pilot Piston 48 - Spring

NOTE: As for parts with * mark, refer to W2-14-2.

W2-14-7
 UPPERSTRUCTURE / Brake Valve

2
1
12
11
8

15

14
25 27 38 42 39 41

16
17
10
16
18 21 24
23 W1F3-02-14-004

34 30 28 46 44 28 47 43 40

41

46

45

37 22 26 36 35 32 29 33 31 47 48 45 43 T1F3-03-09-002

View A 13 5
12
7
15
8
9
3
24
25
17
10

3 16

18 19 20 W1F3-02-14-005

W2-14-8
 UPPERSTRUCTURE / Brake Valve
Assemble Brake Valve
• Be sure to read “Precautions for Disassembly 10. Install spring (48), plunger (46) and spring (43)
and Assembly” thoroughly on page W1-1-1 be- into P cylinder (38).
fore starting the assembly work.
11. Align the matching marks while placing S cylinder
1. Install oil seal (26) into T flange (27). (39) onto P cylinder (38).

2. Secure T flange (27) in a vice with oil seal (26) 12. Install retainer (45) and retaining ring (44) to
facing down. spool (47).

3. Install O-ring (28) to T flange (27). 13. Install the spool (47) assembly to S cylinder (39).

4. Apply hydraulic oil onto all parts of rod (29), pilot 14. Install plunger (46), spring (43) and plug (41) to S
piston (36), push rod (37), plunger (46), spool cylinder (39).
(47). : 130 to 180 N⋅m
(13.0 to18.0 kgf⋅m, 94 to 130 Ibf⋅ft)
5. Install push rod (37), pilot piston (36) and retainer
(35), retainer (34), return spring (30), balance 15. Joint T flange (27), P cylinder (38), S cylinder (39)
spring (33), spring (32), holder (31), rod (29) into with socket bolts (42) (4 used).
T flange (27) in that order. : 60 to 75 N⋅m
(6.0 to 7.5 kgf⋅m, 43 to 54 Ibf⋅ft)
6. Install O-ring (28) to P cylinder (38).

7. Align the matching marks while placing P cylinder

(38) on the T flange (27) assembly.

8. Install retainer (45) and retaining ring (44) to

spool (47).

9. Install the spool (47) assembly to P cylinder (38).

W2-14-9
 UPPERSTRUCTURE / Brake Valve

2
1
12

11
8

15

14 25 27 39

16
17
10
16
18
21 23 24 W1F3-02-14-004

22 T1F3-03-09-002

View A 13
12

15

3
24
25
17

10
16
3

3
W1F3-02-14-005
18 20

W2-14-10
 UPPERSTRUCTURE / Brake Valve
16. Secure the cylinder assembly in a vice with the S 26. Secure link (17) with lock nut (6).
cylinder (39) side facing down. : 6.0 to 10 N⋅m
(0.6 to 1.0 kgf⋅m, 4.3 to 7.2 Ibf⋅ft)
17. Install bracket (25) to T flange (27) with socket
bolts (24) (4 used). 27. Install rubber (1) onto brake pedal (2).
: 60 to 75 N⋅m
(6.0 to 7.5 kgf⋅m, 43 to 54 Ibf⋅ft)

18. Install boots (23), stopper (22) and seat (21) to T

flange (27).

19. Apply grease onto all pin hole of brake pedal (2),
bracket (25), yoke (15) and link (17).

20. Install yoke (15) into brake pedal (2) with pin (12)
and spring pin (13).

21. Install roller (18), washers (20) (2 used) onto link

(17) with pin (16). Lock them with cotter pin (3).

22. Install the link (17) assembly with pin (10) and
bracket (25). Lock them with cotter pin (3).

23. Install boots (11) to the brake pedal (2) assembly,

then install it to bracket (25) with pin (8). Lock
them with cotter pin (3).

24. Install yoke (15) to link (17) with pin (16), lock
them with cotter pin (3).

25. Adjust the play of link (17) with stopper bolt (4) to
0 mm.

W2-14-11
 UPPERSTRUCTURE / Brake Valve
(Blank)

W2-14-12
 UPPERSTRUCTURE / Accumulator Charging Valve
REMOVE AND INSTALL ACCUMULATOR
CHARGING VALVE

CAUTION: Be sure to bleed air from

hydraulic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)
Travel Shockless
Removal
1 2 3, 4 Valve
IMPORTANT: Attach identification tags to
disconnected hoses for
re-assembly.
1. Disconnect connector (1) and hoses (2) (4 used).
Cap open ends.
: 17 mm, 22 mm, 27 mm

2. Remove socket bolts (4) (2 used) and remove

accumulator charging valve (3).
: 5 mm

Installation 2 W1GL-02-10-001

1. Install accumulator charging valve (3) with socket

bolts (4) (2 used).
: 5 mm
: 12 N·m (1.2 kgf·m, 8.9 Ibf⋅ft)

2. Connect connector (1) and hoses (2) (4 used).

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 Ibf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)

W2-15-1
 UPPERSTRUCTURE / Accumulator Charging Valve
CONSTRUCTION OF ACCUMULATOR
CHARGING VALVE

5
2

4
7

10

11
12

13

14
24
23 15
21
16
17
22
18
19
20

W1F3-02-15-001

W2-15-2
 UPPERSTRUCTURE / Accumulator Charging Valve

Item Wrench Size Tightening Torque

Part Name Q’ty Remark
No. (mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Lock Nut 1
2 Adjusting Screw 1
3 Nut 1 45 (4.6) (33)
4 O-Ring 1
5 Spring Seat 2
6 Spring 1
7 Spool 1
8 Plug 1 18 (1.8) (13)
9 Body 1
10 Plug 1 40 (4.1) (29.5)
11 Piston 1
12 O-Ring 1
13 Spring 1
14 Spring Seat 1
15 Spring 1
16 O-Ring 1
17 O-Ring 1
18 Backup Ring 1
19 Check Valve 1
20 Sleeve 1 10 (1.0) (7.4)
21 Plug 3 7 (0.7) (5.2)
22 Compensator Plunger 1
23 Spring 1
24 O-Ring 3

W2-15-3
 UPPERSTRUCTURE / Accumulator Charging Valve
(Blank)

W2-15-4
 UPPERSTRUCTURE / Transmission Control Valve
REMOVE AND INSTALL TRANSMISSION
CONTROL VALVE

CAUTION: Be sure to bleed air from

hydraulic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)

Removal

1. Open the front right side cover of the machine.

1 2
IMPORTANT: Attach identification tags to
disconnected hoses for
re-assembly.
2. Disconnect connectors (1) (2 used) and hoses (2)
(6 used). Cap open ends.
: 19 mm

3. Remove bolts (3) (2 used) and remove

transmission control valve (4).
: 17 mm

W1GL-02-16-001

Installation 2 4 3

1. Install transmission control valve (4) with bolts (3)

(2 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

2. Connect connectors (1) (2 used) and hoses (2) (6

used).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)

W2-16-1
 UPPERSTRUCTURE / Transmission Control Valve
CONSTRUCTION OF TRANSMISSION
CONTROL VALVE

28 29 30 31
1 2
B C

27

18 13
A

W1GL-02-16-002 12
17 16 15 14 W1F3-02-16-001

Section B
19
1 *2 5 6 7
20
21

22

23

*1 8

24
25
9

12 11 10 W1GL-02-16-003

T1F3-03-03-006
Section C
Section A
26

W2-16-2
 UPPERSTRUCTURE / Transmission Control Valve

Item Wrench Size Tightening Torque

Part Name Q’ty Remark
No. (mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Solenoid 1
2 Body 1
3 Orifice 1 5.1 to 6.4 (0.5 to 0.7) (3.8 to 4.7)
4 Orifice 1 7.8 to 9.8 (0.8 to 1.0) (5.8 to7.2)
5 O-Ring 2 1B P14
6 Spool 1
7 Plug 3
8 Spring 2
9 Spool 1
10 Plug 2 31 to 37 (3.2 to 3.8) (23 to 27)
11 O-Ring 3 1B P11
12 Solenoid 1 4.9 (0.5) (3.6)
13 Plug 1 : 22 74 to 88 (7.5 to 9.0) (55 to 65)
14 Spring 1
15 O-Ring 2 1B P20
16 Spring 1
17 Plug 1 19 to 23 (1.9 to 2.3) (14 to 17)
18 Plunger 1
19 Adjusting Screw 1 : 5
20 Seal Lock Nut 1 : 17 20 to 29 (2.0 to 3.0) (14.5 to 21.5)
21 Spring Guide 1
22 Spring 1
23 Guide 1 74 to 88 (7.5 to 9.0) (55 to 65)
24 Spring Guide 1
25 Spool 1
26 Plug 3
27 Plug 1 13.0 to 17.5 (1.3 to 1.8) (9.6 to 13.0)
28 O-Ring 1 1B P8
29 Orifice 1 5.1 to 6.4 (0.5 to 0.7) (3.8 to 4.7)
30 Spool 1
31 Spring Guide 1
*1 Nut 2 : 19 4.9 (0.5) (3.6)
*2 Tube 2 30 to 37 (3.1 to 3.8) (22 to 27)

W2-16-3
 UPPERSTRUCTURE / Transmission Control Valve
(Blank)

W2-16-4
 MEMO

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 SECTION 3
UNDERCARRIAGE

―CONTENTS―
Group 1 Swing Bearing Group 5 Axle
Remove and Install Swing Bearing ......... W3-1-1 Remove and Install Axle ......................... W3-5-1
Disassemble Swing Bearing ................... W3-1-4 Disassemble Front Axle.......................... W3-5-6
Assemble Swing Bearing........................ W3-1-6 Assemble Front Axle ............................ W3-5-12
Disassemble Rear Axle ........................ W3-5-22
Group 2 Travel Motor Assemble Rear Axle ............................ W3-5-28
Remove and Install Travel Motor ............ W3-2-1
Disassemble Differential....................... W3-5-36
Disassemble Travel Motor...................... W3-2-4
Assemble Differential ........................... W3-5-38
Assemble Travel Motor ........................ W3-2-12
Disassemble Steering Cylinder ............. W3-5-42
Disassemble Brake Valve .................... W3-2-18
Assemble Steering Cylinder ................. W3-5-44
Assemble Brake Valve ......................... W3-2-20
Group 6 Axle Lock Cylinder
Group 3 Center Joint Remove and Install
Remove and Install Center Joint ........... W3-3-1
Axle Lock Cylinder .............................. W3-6-1
Disassemble Center Joint....................... W3-3-4
Disassemble and Assemble
Assemble Center Joint ......................... W3-3-6
Axle Lock Cylinder .............................. W3-6-4
Maintenance Standard ........................... W3-3-9
Group 7 Operate-Check Valve
Group 4 Transmission Remove and Install Operate-Check
Remove and Install Transmission............ W3-4-1
Valve (for Axle Lock Cylinder) ................ W3-7-1
Disassemble Transmission ..................... W3-4-6
Construction of Operate-Check
Disassemble Final Drive and
Valve (for Axle Lock Cylinder)................ W3-7-2
Differential.......................................... W3-4-16
Assemble Final Drive and Differential.... W3-4-20 Group 8 Propeller Shaft
Assemble Transmission........................ W3-4-26 Remove and Install Propeller Shaft.......... W3-8-1
Adjusting Gear Clearance..................... W3-4-36

CDBW-3-1
(Blank)

CDBW-3-2
 UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Before removing the swing bearing, the upperstruc-
ture must be removed first. For removal and installa-
tion of the upperstructure, refer to “Remove and Install
Main Frame” section.
In this section, the procedure starts on the premise
that the upperstructure has already been removed.

Mark

Removal
1. Put mating marks on inner race (1) of swing
bearing (4) and chassis (2).

1 2

W105-03-01-001

2. Remove bolts (3) (36 used) from inner race (1) of

swing bearing (4).
: 30 mm

W158-03-01-001

CAUTION: Swing bearing weight:

220 kg (490 Ib)

3. Attach lifting tools (ST 0050), lift swing bearing

(4) off.

ST 0050

W110-03-01-004
4

W3-1-1
 UNDERCARRIAGE / Swing Bearing

Installation
Clean the matching surfaces of the chassis and
swing bearing.

1. Apply THREEBOND#1102 to the matching sur-

faces of the chassis and swing bearing.

CAUTION: Swing bearing weight:

220 kg (490 Ib)

IMPORTANT: Failure to align the mating marks W110-03-01-004

may result in misalignment of the

inner race soft zone. Front Side Position for Grease Fitting
2. Lift the swing bearing. Align the mating marks “S” (Soft Zone)
both on the chassis and swing bearing. Marking Position
8°
Position of Plug

10°

19°

Position for Grease

Fitting
W178-03-01-001

3. Install bolts (3) (36 used) to the inner race of the

swing bearing and tighten to specification.
: 30 mm
: 490 N⋅m (50 kgf⋅m, 360 Ibf⋅ft)

W158-03-01-001

W3-1-2
 UNDERCARRIAGE / Swing Bearing
4. After installing the swing bearing, fill the grease
Grease Level
bath with grease (Shell Alvania EP2 or equiva- Swing Bearing Pinion
lent) until the pinion of the swing bearing is
covered A in grease.
A: 5 mm (0.2 in)

W175-03-01-002
Grease Bath

W3-1-3
 UNDERCARRIAGE / Swing Bearing
DISASSEMBLE SWING BEARING
1 2 3

9 7 6 5 W157-03-01-003

9
7
6

W157-03-01-002

1 - Outer Race 4 - Plug 6 - Ball (121 Used) 8 - Grease Fitting (2 Used)

2 - Seal 5 - Seal 7 - Inner Race 9 - Support (121 Used)
3 - Pin

W3-1-4
 UNDERCARRIAGE / Swing Bearing
Disassemble Swing Bearing
• Be sure to read “Precautions for Disassembly
and Assembly” thoroughly on page W1-1-1 be- CAUTION: Swing bearing weight:
fore starting any repair work. 220 kg (490 Ib)

1. Tap stopper pin (3) of plug (4) up from the bottom 3. Unseat outer race (1) of swing bearing horizon-
side. tally and slightly by crane using lifting tools (ST
0050). Remove seals (2, 5).
NOTE: Since pin (3) was crimped after being in-
stalled, grind the crimped part with a 4. Place the inner race (7) of swing bearing onto
grounder. wooden blocks while holding outer race (1) by
crane.
3
5. Remove balls (6) (121 used) and supports (9)
(121 used) out from the plug hole, while rotating
the outer race (1).
Magnet rod (A) can be used to remove the balls
4 out, and a hooked wire (B) can be used to re-
move supports (9).

1
2

A
W105-03-01-007

7
2. Pull plug (4) out.
NOTE: Insert a bolt into the hole (M10, Pitch 1.5
mm) from it plug (4) was pull out. Then tap
or pull the bolt from inside.

6 5 W105-03-01-009

4
B

W105-03-01-008
9, 10 W105-03-01-010

6. Remove seal (2) from outer race (1) and remove

seal (5) from inner race (7) with scrapper.

W3-1-5
 UNDERCARRIAGE / Swing Bearing
ASSEMBLE SWING BEARING
1 2 3

9 7 6 5 W157-03-01-003

9
7
6

W157-03-01-002

1 - Outer Race 4 - Plug 6 - Ball (121 Used) 8 - Grease Fitting (2 Used)

2 - Seal 5 - Seal 7 - Inner Race 9 - Support (121 Used)
3 - Pin

W3-1-6
 UNDERCARRIAGE / Swing Bearing
Assemble Swing Bearing

IMPORTANT: Be sure to apply grease to balls (6) 2. Tap plug (4) into outer race (1) and then, drive
and to supports (9). pin (3) into the pin hole.
Crimp the head of pin (3) with a punch.
CAUTION: Swing bearing weight:
220 kg (490 Ib) 3

1. Lift the outer race horizontally and match it with 1

the inner race coaxially.
Rotating the outer race, insert balls (6), support
(9) into the plug hole one by one with a round
bar.

2 4

W142-03-01-007

3. Install lifting tools (ST 0050) onto outer race (4)

and lift outer race (4). Thoroughly degrease the
slots for seals (2, 5). Apply THREEBOND # 1745
(to seal (2)) and # 1735 (to seal (5)). Then as-
6 semble seals (2, 5) into the slots.

5 4. Fill grease 0.5 L (0.132 US gal) (Alvania EP2

W142-03-01-005
grease or equivalent) through the grease fitting
(8). Rotate the outer race while filling.

NOTE: Fill grease from two places (0.30 L).

W142-03-01-006

W3-1-7
 UNDERCARRIAGE / Swing Bearing
(Blank)

W3-1-8
 UNDERCARRIAGE / Travel Motor
REMOVE AND INSTALL TRAVEL MOTOR

CAUTION: Be sure to bleed air from hydrau-

lic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)

When removing and installing travel motor (7), pro-

peller shaft has to be removed. As for procedures to
remove and install propeller shaft, refer to “Remove
and Install Propeller Shaft”.
The work below starts on the premise that propeller
shaft were removed already.
Front Side
2 3 4
Removal 5

IMPORTANT: Attach identification tags to dis-

connected hoses to aid
re-assembly.
1. Disconnect drain hoses (4) (2 used) and pilot
hose (8). Cap all disconnected hose ends.
: 19 mm, 22 mm, 27 mm

2. Remove socket bolts (2) (8 used) and split 1

flanges (3) (4 used) from travel motor (7) to dis- 7 6 W1GL-03-02-002

connect main hoses (1) (2 used), then cap all

disconnected hose ends.
Front Side
: 12 mm
7

CAUTION: Travel Motor Weight:

85 kg (190 lb)
3. Loosen mounting socket bolts (6) (4 used) from 8
travel motor (7), then support the lower side of
travel motor (7) by forklift to remove socket bolts
(6) (4 used).
: 14 mm

4. Remove travel motor (7) from transmission (5).

5 6
W1GL-03-02-001

W3-2-1
 UNDERCARRIAGE / Travel Motor
Installation
Front Side

CAUTION: Travel Motor Weight:

7
85 kg (190 lb)
1. Install travel motor (7) onto mission (5) with
socket bolts (6) (4 used).
: 14 mm 8
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)

2. Connect main hoses (1) (2 used) with socket

bolts (2) (8 used) and split flanges (3) (4 used).
: 12 mm
: 140 N⋅m (14 kgf⋅m, 103 lbf⋅ft)

3. Connect drain hoses (4) (2 used) and pilot hose

(8).
: 19 mm 5 6
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) W1GL-03-02-001

: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft)
: 27 mm Front Side
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)
2 3 4 5

1
7 6 W1GL-03-02-002

W3-2-2
 UNDERCARRIAGE / Travel Motor
(Blank)

W3-2-3
 UNDERCARRIAGE / Travel Motor
DISASSEMBLE TRAVEL MOTOR
52 53 1 2 3 4 5 6 7 8

50 51 9 10
49
48
11
45, 46, 47
12
44
13
14
43 15
16, 17
18

42 41 20
40 21
39 19
23 22
38 24
37 25
26
36
27
28
35 29
30
34 31
33 32

59 2 W1GL-03-02-007

45, 46, 47

16, 17
57
57
56
56
54

W1F3-03-02-002
58 55
36
55 36 W1F3-03-02-003

W3-2-4
 UNDERCARRIAGE / Travel Motor

1- Head Cover 16 - O-Ring (3 Used) 31 - Oil Seal 46 - O-Ring

2- Brake Valve 17 - Cover 32 - Shim 47 - Cover
3- O-Ring (2 Used) 18 - Adjusting Screw 33 - Key 48 - Valve Plate
4- Pin 19 - Lock Nut 34 - Retaining Ring 49 - Socket Bolt
5- Spring 20 - Pin 35 - Retaining Ring 50 - Piston
6- Spring 21 - Adjusting Screw 36 - Housing 51 - Ring (2 Used)
7- Collar 22 - Lock Nut 37 - Drive Shaft 52 - Servo Piston
8- Spring Collar 23 - Rotor 38 - Retainer Plate 53 - Lock Pin
9- Bushing 24 - Adjusting Plate 39 - Center Joint 54 - Socket Bolt (4 Used)
10 - O-Ring 25 - Spring 40 - Plunger (7 Used) 55 - Socket Bolt (8 Used)
11 - Spring 26 - Screw Bolt (7 Used) 41 - Lock Nut 56 - Plug (2 Used)
12 - Retaining Ring 27 - Bearing 42 - Adjusting Screw 57 - Relief Valve (2 Used)
13 - Control Piston 28 - Ring 43 - O-Ring 58 - Socket Bolt (4 Used)
14 - Sleeve 29 - Bearing 44 - Pin (2 Used) 59 - Socket Bolt (2 Used)
15 - Retaining Ring 30 - Adjusting Shim 45 - O-Ring

W3-2-5
 UNDERCARRIAGE / Travel Motor

52 53 1 2 3 4 5 6 7 8

50 51 9 10
49
48
11
45, 46, 47
12
44
13
14
43 15
16, 17
18

42 41 20
40 21
39 19
23 22
38 24
37 25
26
36
27
28
35 29
30
34 31
33 32

59 2 W1GL-03-02-007

45, 46, 47

16, 17
57
57
56
56
54

W1F3-03-02-002
58 55
36
55 36 W1F3-03-02-003

W3-2-6
 UNDERCARRIAGE / Travel Motor
Disassemble Travel Motor
• Be sure to read “Precautions for Disassembly
and Assembly” thoroughly on page W1-1-1 be- CAUTION: Take care when removing cover
fore starting any repair work. (17) as the spring inside may fly out.

5. Remove socket bolts (54) (4 used) to remove

CAUTION: Travel Motor Weight: O-ring (16) and cover (17).
85 kg (190 lb) : 6 mm
1. Set the travel motor onto wooden block (100×500
mm (3.9×19.7 in)) with drive shaft (37) facing 6. Remove bushing (9), spring (6), collar (7) and
down. spring (5) from head cover (1) in order.
NOTE: When the work bench is used
Work bench: ST 5092 7. Remove spring collar (8) and spring (11) from
Upper Plate: ST 7333 cover (17).

2. Remove socket bolts (59) (2 used) to remove 8. Remove O-rings (10), (16) (3 used), adjusting
brake valve (2) and O-rings (3) (2 used). screw (18), lock nut (19) and pin (20) from cover
: 5 mm (17).

IMPORTANT: Do not to disassemble relief valves 9. Remove retaining ring (12) from the inside of
(57) (2 used). cover (17) to remove the sleeve (14) assembly.
3. Remove relief valves (57) (2 used) and plugs
(56) (2 used) from head cover (1). 10. Pull control piston (13) out from sleeve (14) then
: 27 mm, 32 mm remove retaining ring (15) from control piston
(13).
4. Record the measurement of A part before re-
moving cover (17). 11. Remove socket bolts (58) (4 used) from head
cover (1) to remove cover (47) and O-rings (45),
17 (46).
17 18 19 : 10 mm

W1GL-03-02-006

W3-2-7
 UNDERCARRIAGE / Travel Motor

42 41
21
39
23 22

37

36

34 31
33 32

W1GL-03-02-007

W1F3-03-02-002
55
36
55 36 W1F3-03-02-003

W3-2-8
 UNDERCARRIAGE / Travel Motor
12. Record measurements of B, C parts before re- 16. Secure rotor (23) with screw bar (M8, Pitch 1.25
moving lock nuts (22), (41) and adjusting screws mm (0.05 in), Length 120 mm (4.7 in)) to prevent
(21), (42). rotor (23) removing, then remove adjusting screw
(42).
B Screw Bar

Lock Nut

C Washer

42 41

22 21

W1GL-03-02-003
W1GL-03-02-005

13. Loosen lock nuts (22), (41) to remove adjusting 17. Place housing (36) horizontally. Remove key (33)
screws (21), (42). from drive shaft (37).
: 19 mm
: 6 mm 18. Remove retaining ring (34) from housing (36) to
remove shim (32).
14. Install adjusting screw (42) (M12, Pitch 1.75 mm
(0.1 in), Length 100 mm (3.9 in)) into the location 19. Place housing (36) assembly on press stand with
where adjusting screw (21) is inserted, the angle rotor (23) side facing down. Pull drive shaft (37)
of center shaft (39) should be zero. assembly out.

20. Pull oil seal (31) out from housing (36).

Temporarily
Mounting Adjusting
Screw (42)

W1GL-03-02-004
39

15. Put matching marks onto the contact surface of

head cover (1) and housing (36). Remove socket
bolts (55) (8 used) to remove head cover (1) from
housing (36).
: 14 mm

W3-2-9
 UNDERCARRIAGE / Travel Motor

52 53 1 4

50 51

49

W1GL-03-02-007

W1F3-03-02-002

W1F3-03-02-003

W3-2-10
 UNDERCARRIAGE / Travel Motor
21. Secure head cover (1) on the vice with valve
plate (48) facing up.

22. Remove socket bolt (49) and piston (50) from

servo piston (52).
: 12 mm

23. Remove rings (51) (2 used) from piston (50).

CAUTION: Heat lock pin (53). Take care not

to burn yourself.

24. Heat the mounting portion of lock pin (53) using a

torch.
NOTE: LOCTITE is used for lock pin (53). Heat it
with slow fire.

25. Remove pin (4) from servo piston (52).

26. Pull servo piston (52) out from head cover (1).

W3-2-11
 UNDERCARRIAGE / Travel Motor
ASSEMBLE TRAVEL MOTOR
52 53 1 2 3 4 5 6 7 8

50 51 9 10
49
48
11
45, 46, 47
12
44
13
14
43 15
16, 17
18

42 41 20
40 21
39 19
23 22
38 24
37 25
26
36
27
28
35 29
30
34 31
33 32

59 2 W1GL-03-02-007

45, 46, 47

16, 17
57
57
56
56
54

W1F3-03-02-002
58 55
36
55 36 W1F3-03-02-003

W3-2-12
 UNDERCARRIAGE / Travel Motor

1- Head Cover 16 - O-Ring (3 Used) 31 - Oil Seal 46 - O-Ring

2- Brake Valve 17 - Cover 32 - Shim 47 - Cover
3- O-Ring (2 Used) 18 - Adjusting Screw 33 - Key 48 - Valve Plate
4- Pin 19 - Lock Nut 34 - Retaining Ring 49 - Socket Bolt
5- Spring 20 - Pin 35 - Retaining Ring 50 - Piston
6- Spring 21 - Adjusting Screw 36 - Housing 51 - Ring (2 Used)
7- Collar 22 - Lock Nut 37 - Drive Shaft 52 - Servo Piston
8- Spring Collar 23 - Rotor 38 - Retainer Plate 53 - Lock Pin
9- Bushing 24 - Adjusting Plate 39 - Center Joint 54 - Socket Bolt (4 Used)
10 - O-Ring 25 - Spring 40 - Plunger (7 Used) 55 - Socket Bolt (8 Used)
11 - Spring 26 - Screw Bolt (7 Used) 41 - Lock Nut 56 - Plug (2 Used)
12 - Retaining Ring 27 - Bearing 42 - Adjusting Screw 57 - Relief Valve (2 Used)
13 - Control Piston 28 - Ring 43 - O-Ring 58 - Socket Bolt (4 Used)
14 - Sleeve 29 - Bearing 44 - Pin (2 Used) 59 - Socket Bolt (2 Used)
15 - Retaining Ring 30 - Adjusting Shim 45 - O-Ring

W3-2-13
 UNDERCARRIAGE / Travel Motor

52 53 1 2 3 4 5 6 7 8

50 51 9 10
49
48
11
45, 46, 47
12
44
13
14
43 15
16, 17
18

42 41 20
40 21
39 19
23 22
38 24
37 25
26
36
27
28
35 29
30
34 31
33 32

59 2 W1GL-03-02-007

45, 46, 47

16, 17
57
57
56
56
54

W1F3-03-02-002
58 55
36
55 36 W1F3-03-02-003

W3-2-14
 UNDERCARRIAGE / Travel Motor
Assemble Travel Motor
• Be sure to read “Precautions for Disassembly 7. Install retaining rings (15), (12) to control piston
and Assembly” thoroughly on page W1-1-1 be- (13) and sleeve (14).
fore starting any repair work.
8. Apply hydraulic oil to cover (17), control piston
1. Secure head cover (1) to a vice with valve plate (13) and sleeve (14).
(48) facing up.
9. Install O-ring (10) to cover (17).
2. Apply hydraulic oil on servo piston (52), then in-
sert it into head cover (1) and install pin (4). 10. Install control piston (13) to sleeve (14), then in-
sert the sleeve (14) assembly and pin (20) into
3. Apply LOCTITE #241 on lock pin (53) and insert cover (17).
it into servo piston (52) to secure pin (4).
11. Install spring collar (8) and spring (11) into the
4. Install rings (51) (2 used) to piston (50). Install cover (17) assembly.
piston (50) to servo piston (52) with socket bolt
(49). 12. Install O-rings (16) (3 used) onto head cover (1)
: 12 mm and the cover (17) mounting surface.
: 190 N⋅m (19.5 kgf⋅m, 140 lbf⋅ft)
13. Install spring (5), collar (7), spring (6) and bush-
5. Install O-ring (45) to head cover (1), install O-ring ing (9) into the large chamber of head cover (1).
(46) to cover (47). Install cover (47) to head cover
(1) with socket bolts (58) (4 used). 14. Install the cover (17) assembly to head cover (1)
: 10 mm with socket bolts (54) (4 used).
: 120 N⋅m (12 kgf⋅m, 89 lbf⋅ft) : 6 mm
: 96 N⋅m (9.8 kgf⋅m, 71 lbf⋅ft)
6. Install adjusting screw (18) and lock nut (19) into
cover (17) with the measurement of A part as re-
corded before disassembling.

18 19

W1GL-03-02-006

W3-2-15
 UNDERCARRIAGE / Travel Motor

42 41
21
39
23 22

37

36

34 31
33 32

W1GL-03-02-007

57
57
56
56

W1F3-03-02-002
55
36
55 36 W1F3-03-02-003

W3-2-16
 UNDERCARRIAGE / Travel Motor
20. Install adjusting screw (42) (M12, Pitch 1.75 mm
CAUTION: After heating housing (36), start (0.1 in), Length 100 mm (3.9 in)) into the location
installation work. where adjusting screw (21) is inserted, the angle
of center shaft (39) should be zero.
15. Heat housing (36) to 50 to 80°C, then install the
drive shaft (37) assembly into housing (36). If it
cannot be installed, use a bar to insert it.

16. Install oil seal (31) and shim (32) into housing
(36) with the rotor (23) side facing down, then in-
stall retaining ring (34).

17. Install key (33) into drive shaft (37). Temporarily

Mounting Adjusting
Screw (42)
18. Place the travel motor on wooden block (100×
500 mm (3.9×20 in)) with the drive shaft (37)
facing down. W1GL-03-02-008

NOTE: When using work stand:

Work Bench: ST 5092 21. Align the matching marks and install head cover
Upper Plate: ST 7333 (1) to housing (36) with socket bolts (55) (8
used).
19. Remove screw bar, lock nut and washer from ro- : 14 mm
tor (23). : 295 N⋅m (30 kgf⋅m, 215 lbf⋅ft)

Screw Bar 22. Remove temporarily tightened adjusting screw

Lock Nut (42).
Washer
23. Install adjusting screw (42), lock nut (41), adjust-
ing screw (21) and lock nut (22) into housing (36)
with the measurements of B and C as recorded
before disassembling.

W1GL-03-02-003

42 41

22 21

W1GL-03-02-005

24. Install relief valves (57) (2 used) and plug (56) to

head cover (1).
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)
: 32 mm
: 83±5 N⋅m (8.5±0.5 kgf⋅m, 62±3.6 lbf⋅ft)

W3-2-17
 UNDERCARRIAGE / Travel Motor
DISASSEMBLE BRAKE VALVE B
8

16, 17

W1F3-03-02-002

1 2 3
13 14 15

12

Section A

7 6

11 10 9

8
Section B

T1F3-03-05-034

1- O-Ring (2 Used) 6- Check Valve (2 Used) 11 - Check Valve Assembly (2 Used) 16 - Plug
2- Cover 7- O-Ring (2 Used) 12 - Cover 17 - Orifice
3- Socket Bolt (4 Used) 8- Plug 13 - Socket Bolt (4 Used)
4- Plug (2 Used) 9- O-Ring 14 - Valve Casing
5- Spring (2 Used) 10 - Shuttle Valve 15 - Counterbalance Valve

W3-2-18
 UNDERCARRIAGE / Travel Motor
Disassemble Brake Valve

1. Remove socket bolts (13) (4 used) to remove

cover (12) from valve casing (14).
: 10 mm

2. Remove socket bolts (3) (4 used) to remove

cover (2) from valve casing (14).
: 10 mm

IMPORTANT: Be sure to turn counterbalance

valve when pulling it out. It may be
stuck otherwise.
3. Turn counterbalance valve (15) while pulling it
out from valve casing (14) slowly.

CAUTION: When removing plug (4), spring

(5) will fly out due to spring force.

4. Remove plugs (4) (2 used), springs (5) (2 used)

and check valve (6).
: 36 mm

5. Pull check valve assembly (11) out from valve

casing (14) with a socket wrench.

6. Remove plug (8) from valve casing (14).

7. Pull shuttle valve (10) out from valve casing (14)

with a socket wrench.
: 4 mm

8. Remove plug (16) from valve casing (14).

9. Remove orifice (17) from valve casing (14).

: 3 mm

W3-2-19
 UNDERCARRIAGE / Travel Motor
ASSEMBLE BRAKE VALVE B
8

16, 17

W1F3-03-02-002

1 2 3
13 14 15

12

Section A

7 6

11 10 9

8
Section B

T1F3-03-05-034

1- O-Ring (2 Used) 6- Check Valve (2 Used) 11 - Check Valve Assembly (2 Used) 16 - Plug
2- Cover 7- O-Ring (2 Used) 12 - Cover 17 - Orifice
3- Socket Bolt (4 Used) 8- Plug 13 - Socket Bolt (4 Used)
4- Plug (2 Used) 9- O-Ring 14 - Valve Casing
5- Spring (2 Used) 10 - Shuttle Valve 15 - Counterbalance Valve

W3-2-20
 UNDERCARRIAGE / Travel Motor
Assemble Brake Valve

1. Install orifice (17) and plug (16) to valve casing

(14).

2. Install shuttle valve (10) and plug (8) into valve

casing (14).

3. Install check valve assemblies (11) (2 used) to

valve casing (14).

4. Install check valves (6) (2 used) to check valve

assembly (11).

5. Install spring (5) to plug (4), then install the plug

(4) assembly to valve casing (14).
: 36 mm
: 167 N⋅m (17 kgf⋅m, 123 lbf⋅ft)

IMPORTANT: Turn counterbalance valve (15)

slowly while inserting it to valve
casing (14) and check that it can
move smoothly.

6. Insert counterbalance valve (15) into valve cas-

ing (14).

7. Install cover (12) to valve casing (14) with socket

bolts (13) (4 used).
: 10 mm
: 120 N⋅m (12 kgf⋅m, 89 lbf⋅ft)

8. Install cover (2) to valve casing (14) with socket

bolts (3) (4 used).
: 10 mm
: 120 N⋅m (12 kgf⋅m, 89 lbf⋅ft)

W3-2-21
 UNDERCARRIAGE / Travel Motor
(Blank)

W3-2-22
 UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT

CAUTION: Be sure to bleed air from

hydraulic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)

NOTE: When removing and installing the center

joint, remove the main hoses (5 used) on
the back of boom and remove the center
joint easily. 1 2 3 4

Removal
1. Remove the swing device upper side cover
mounting bolts (2 used) and remove the cover.
: 17 mm
Center Joint
2. Disconnect connectors (6) (2 places upper and
lower).

3. Remove bolts (5) (2 places upper and lower).

: 17 mm

4. Remove bolts (4) (3 used) and pull out the slip ring
(3) assembly from center joint. (Length: approx.
670 mm (26.4 in))

5. Remove bolts (2) (5 used) and remove stopper

(1).
: 24 mm

IMPORTANT: Attach identification tags to

disconnected hoses for re-assembly.
6. Disconnect hoses (37 used) from the center joint.
Plug all disconnected hose ends and the ports on
the center joint.
: 17 mm, 19 mm, 22 mm, 27 mm, 36 mm 6 5
NOTE: Upperstructure side: 15 used T1F3-03-10-014
Undercarriage side: 22 used
Refer to COMPONENT OPERATION /
Others (Undercarriage) group in the T/M on
page T3-11-2.

W3-3-1
 UNDERCARRIAGE / Center Joint

7. Install eyebolts (M16, Pitch 2.0 mm) (2 used) into

the bolt (2) holes. 1 2 3 4

CAUTION: Center joint assembly weight:

93 kg (210 lb).
Center Joint
IMPORTANT: The propeller shaft and transmission
are under the center joint. When
lifting the center joint while
disassembling, be careful not to
damage the propeller shaft and
transmission.
8. Remove bolts (7) (4 used), and then lift the center
joint assembly.
: 22 mm

Installation

CAUTION: Center joint assembly weight:

93 kg (210 lb).

IMPORTANT: The propeller shaft and transmission

6 5
are under the installation position of
center joint. When lifting the center T1F3-03-10-014
joint, take care not to damage the
propeller shaft and transmission.
Chassis Frame
1. Apply LOCTITE to bolts (7) (4 used). Lift the
center joint, then install the center joint on the 7
chassis frame with bolts (7) (4 used).
: 22 mm
: 180 N⋅m (18.5 kgf⋅m, 130 lbf⋅ft)

2. Connect hoses (37 used) to the center joint.

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
W1F3-03-03-002
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

W3-3-2
 UNDERCARRIAGE / Center Joint

3. Apply LOCTITE#577 to bolts (2) (5 used). Install

stopper (3) with bolts (2) (5 used). 1 2 3 4
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)

4. Insert slip ring (3) into the center joint.

Center Joint
5. Install slip ring (3) with bolts (4) (3 used).

6. Connect connector (6) (2 places upper and lower).

7. Secure connector (6) with bolt (5) (2 places upper

and lower).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

6 5

T1F3-03-10-014

W3-3-3
 UNDERCARRIAGE / Center Joint
DISASSEMBLE CENTER JOINT

2
3

12 3
11

6
10 T1F3-03-10-001

9
8 7

1 - Spindle 4- Body 7- O-Ring 10 - Cover

2 - O-Ring 5- Oil Seal (15 Used) 8- Bolt (4 Used) 11 - Plate
3 - Bushing (2 Used) 6- Bolt (6 Used) 9- O-Ring 12 - O-Ring

W3-3-4
 UNDERCARRIAGE / Center Joint
Disassemble Center Joint

CAUTION: Center joint weight: 93kg (210 lb) IMPORTANT: Use two picks for easy removal.
Take care not to damage the seal
1. Remove mounting bolt (6) of cover (10) diagonally, groove with the picks.
and install eyebolts (M10, Pitch 1.5 mm, length 18 5. Remove oil seals (5) (15 used) from body (4).
mm: ST 0001). Then, secure center joint on
workbench (ST 5103).

IMPORTANT: Be sure to make the mating marks

on body (4) and spindle (1).
2. Remove bolts (6) (6 used) and remove cover (10)
and O-rings (11, 12).
: 17 mm

3. Remove bolt (8) and remove plate (11). 3

: 17 mm
4, 5
IMPORTANT: Take care not to scratch the seal
slide face of spindle (1).
4. Install puller onto the center joint, pull out spindle
(1). W105-03-03-015
Puller

6. Remove bushings (3) (2 used) and O-rings (2, 12)

from body (4).

W202-03-03-011

NOTE: There is a hole for the harness at the

center of spindle (1). Make a plate to cover
the hole. Place the plate cap between the
puller and spindle (1) to pull out spindle.

W3-3-5
 UNDERCARRIAGE / Center Joint
ASSEMBLE CENTER JOINT

2
3

12 3
11

6
10 T1F3-03-10-001

9
8 7

1 - Spindle 4- Body 7- O-Ring 10 - Cover

2 - O-Ring 5- Oil Seal (15 Used) 8- Bolt (4 Used) 11 - Plate
3 - Bushing (2 Used) 6- Bolt (6 Used) 9- O-Ring 12 - O-Ring

W3-3-6
 UNDERCARRIAGE / Center Joint
Assemble Center Joint

CAUTION: Body (4) weight: 40 kg (89 lb)

1. Install O-rings (2, 12) into body (4).

NOTE: If bushing (3) is removed, be sure to

reinstall bushing (3) before reassembling.

2. Install oil seals (5) (15 used) into body (4).

IMPORTANT: After installing the seals, apply

grease to the inner wall of body (4),
and the seals.

3. Put spindle (1) on workbench, install spindle (1)

into body (4), align the mating marks made during
disassembly.

IMPORTANT: Slowly and straightly insert spindle

(1) along with the center of body (4),
because the clearance between
body (4) and spindle (1) is
approximately 0.1 mm. 0.1 mm

4. Tap body (4) lightly with a plastic hammer, insert

body (4) until it touches spindle (1).

5. Install plate (11) onto spindle (1) with bolts (8) (4

used).
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

6. Install O-ring (7) to body (4) and install O-ring (9)

to spindle (1).

7. Install cover (10) with bolts (6) (6 used). W105-03-03-024

: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

W3-3-7
 UNDERCARRIAGE / Center Joint
When replacing the body or spindle with a new one,
the following procedures are required:

Press bushing (3) into body. 1

1. Clean body (4) and bushing (3).
2. Press bushing (3) into body (4) using pressing
4
tool.

Pressing force: 0.5 to 1.5 tons

Pressing tool (1): ST 7331 3

W105-03-03-029

W3-3-8
 UNDERCARRIAGE / Center Joint
MAINTENANCE STANDARD

Parts Name Allowable Limit (basis of judgement) Remedy

1. Wear more than 0.2 mm (0.008 in) Replace
2. Scored, abnormal wear Replace
3. Uneven wear (wear range is less Replace
than 180°)
uneven wear
Bushing

T157-01-01-040

Sliding surface of Scored or something hurt it. Replace

sealed part
Sliding surface of 1) Scored more than 0.1 mm (0.004 in). Replace
body and spindle 2) Scored less than 0.1 mm (0.004 in) Repair with oil stone
except sealed deep.
part
Body, Spindle 1) Wear more than 0.5 mm (0.02 in) Replace
deep.
Abnormal wear.
Sliding surface of
2) Wear less than 0.5 mm (0.02 in) Repair to smooth
plate
deep.
3) Scored less than 0.5 mm (0.02 in) Repair to smooth
deep and able to repair.
1) Wear less than 0.5 mm (0.02 in). Replace
Sliding surface of 2) Wear less than 0.5 mm (0.02 in). Repair to smooth
Cover plate 3) Scored less than 0.5 mm (0.02 in) Repair to smooth
and able to repair.

W3-3-9
 UNDERCARRIAGE / Center Joint
(Blank)

W3-3-10
 UNDERCARRIAGE / Transmission
REMOVE AND INSTALL TRANSMISSION

CAUTION: Be sure to bleed air from hydrau-

lic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)

When removing and installing the transmission, the

propeller shaft, the pipe of travel motor and a part of
the rear axle must be removed. Refer to the pages for
the “Remove and Install Propeller Shaft”, “Remove and
Install Travel Motor”, “Remove and Install Rear Axle”.

IMPORTANT: Be sure to bleed air from hydraulic

and brake circuits when removing
and installing transmission.
Refer to TROUBLESHOOTING /
Troubleshooting B group in the T/M.

Removal

IMPORTANT: In order to keep the balance of

weight, remove the travel motor
when removing the transmission.
90° to 110°
1. Loosen the wheel nut to jack the machine up then
put block under chassis.
: 30 mm

2. Remove tires (4 used) and tire links (2 used). Block W1GL-03-08-003

3. Remove plugs (4, 5) to drain oil. 1

: 8 mm, 22 mm

4. Remove plugs (3) (2 used) to remove planetary 2

carrier (2) from axle housing (1).
: 8 mm 3
3

W1GL-03-05-006

W3-4-1
 UNDERCARRIAGE / Transmission
5. Remove the gear (6) assembly from axle housing
(1).

W1GL-03-05-007
6. Pull axle shaft (8) from axle housing (1).
7

7. Remove retaining ring (7) from axle housing (1) to

remove plate (9).

8
8. Remove plugs (16, 17) to drain oil.
: 12 mm
9 W1GL-03-05-008

9. Remove propeller shaft (18). 10 11 12

: 14 mm

10. Disconnect hoses (10) (2 used), (11) (2 used) and

hose (22) from travel motor (19).
: 19 mm, 22 mm, 27 mm 13
: 12 mm
14
IMPORTANT: Attach identification tags to hoses to
aid re-assembly.
11. Disconnect hoses (12) (2 used) and cap the hose 15
ends.
: 22 mm 19 18 17 16
W1GL-03-02-002

12. Remove nut (24) and bolt (23) to remove cover 26 20 21

(25).

13. Disconnect connectors (20, 26) from transmission

(15).
: 13 mm
15
14. Disconnect hose (21) from transmission (15) and
cap the hose end.
: 22 mm

25 23, 24 18 22 W1GL-03-02-001

W3-4-2
 UNDERCARRIAGE / Transmission

CAUTION: Travel motor weight:

85 kg (190 lb)
Transmission weight: 140 kg (310 lb)

13
15. Loosen mounting bolts (14) (12 used) from the
transmission (15) assembly.
: 19 mm

16. Support the travel motor (19) by forklift to remove

bolts (14) (12 used) then remove the transmission
W1GL-03-02-002
(15) assembly from rear axle (13). 19 15 14
: 19 mm

W3-4-3
 UNDERCARRIAGE / Transmission
Installation
10 11 12

CAUTION: Travel motor weight:

85 kg (190 lb)
Transmission weight: 140 kg (310 lb)
13

1. Install plug (17) to transmission (15) then tempo- 14

rarily install plug (16).
: 12 mm
: 79 N･m (8 kgf･m, 58 lbf･ft) 15

2. Install the transmission (15) assembly to rear axle 18

W1GL-03-02-002
19 17 16
(13) with bolts (14) (12 used).
: 19 mm
26 20 21
: 230 N･m (23 kgf･m, 166 lbf･ft)

3. Connect connector (20, 26) to transmission (15).

4. Connect hoses (12) (2 used) and hose (21) to

transmission (15). 15
: 22 mm
: 39 N･m (4.0 kgf･m, 29 lbf･ft)

5. Install cover (25) to transmission (15) with bolt

(23) and nut (24).
: 13 mm
: 20 N･m (2.0 kgf･m, 14.5 lbf･ft)

6. Connect hoses (10) (2 used), (11) (2 used) and 25 23, 24 17 19 18 22

W1GL-03-02-001

hose (22) to transmission (15).

: 19 mm
: 29.5 N･m (3.0 kgf･m, 21.5 lbf･ft)
: 22 mm
: 39 N･m (4.0 kgf･m, 29 lbf･ft)
: 27 mm
: 93 N･m (9.5 kgf･m, 69 lbf･ft)
: 12 mm
: 140 N･m (14.0 kgf･m, 101 lbf･ft)

7. Install propeller shaft (18) to transmission (15).

: 14 mm
: 108 N･m (11.0 kgf･m, 80 lbf･ft)

8. Remove plug (16) which was temporarily installed,

supply gear oil into transmission (15).
Install plug (16) after supplying the oil.
Gear Oil: 2.9 L (0.8 US gal.)
: 12 mm
: 79 N･m (8.0 kgf･m, 58 lbf･ft)

W3-4-4
 UNDERCARRIAGE / Transmission

9. Install plate (9) to axle housing (1) then install re-

7
taining ring (7).

10. Install axle shaft (7) to axle housing (1).

11. Install the gear (6) assembly to axle housing (1).

9 W1GL-03-05-008

1
12. Install planetary carrier (2) to axle housing (1) with
plugs (3) (2 used).
: 8 mm
: 55 N･m (6.0 kgf･m, 43 lbf･ft)
W1GL-03-05-007

13. Install plug (5) to planetary carrier (2).

: 8 mm
: 69 N･m (7.0 kgf･m, 50 lbf･ft) 1

14. Supply gear oil to planetary carrier (2) from plug

(4). Install plug (4) after supplying gear oil. 2
: 22 mm
3
: 79 N･m (8.0 kgf･m, 58 lbf･ft) 3
Gear Oil: 2.1 L (0.6 US gal.)
4

W1GL-03-05-006

W3-4-5
 UNDERCARRIAGE / Transmission
DISASSEMBLE TRANSMISSION

54 55 48 6

A Part

W1GL-03-04-002

47

T1GL-03-05-001

8 9 10 11 13 14 15 16 17, 18 19 20 21 22 23 24 25 26 27

28, 29, 30, 31

6

32
5

4 33
A Part
34
3
35
12 36
2 37

53 38
50, 51 39

40
1

129 52 130 49 48 47 46 45 44 43 42 41 W1F3-03-04-002

W3-4-6
 UNDERCARRIAGE / Transmission

1- Flange 15 - O-Ring 29 - Friction Plate (11 Used) 43 - Shim

2- Relief Valve 16 - O-Ring 30 - Plate (10 Used) 44 - Friction Plate (6 Used)
3- Shaft 17 - Seal Ring 31 - Spacer 45 - Piston
4- Retaining Ring 18 - Backup Ring (2 Used) 32 - Retaining Ring 46 - Disc Spring (3 Used)
5- O-Ring 19 - Piston 33 - Shim 47 - Gear Case
6- Drive Case 20 - Retaining Ring 34 - Retaining Ring 48 - Socket Bolt (9 Used)
7- Plug 21 - O-Ring 35 - U-Ring 49 - Disc Spring (2 Used)
8- O-Ring 22 - Gasket 36 - O-Ring 50 - Seal
9- Spring 23 - O-Ring 37 - Bearing 51 - Ring
10 - Bearing 24 - Seal Ring 38 - Sun Gear 52 - O-Ring (2 Used)
11 - Retaining Ring 25 - Plate 39 - Cover 53 - Retaining Ring
12 - Piston Ring (2 Used) 26 - Retaining Ring 40 - Retaining Ring 54 - Pipe
13 - Piston 27 - Ring Gear 41 - Disc Carrier 55 - Hose (2 Used)
14 - Seal Ring 28 - Plate 42 - Plate (6 Used) 129 - Retaining Ring
130 - Plate

W3-4-7
 UNDERCARRIAGE / Transmission

B Part 107 64, 108

W1GL-03-04-003
111 110 109

T1GL-03-05-001

26 56 57 58 59 60 61 62, 63 64 65 66 67 68 69 70 73 74 75

B Part

25
76, 77
27
39
34

37
78
32 79
81
40
80
38
82
33
105
104
83
106
103, 102
101
100
99
98
97
96

W1GL-03-04-004

95 94 93 47 92 91 90 89 88 87 86 85 84

W3-4-8
 UNDERCARRIAGE / Transmission

1- Flange 15 - O-Ring 29 - Friction Plate (11 Used) 43 - Shim

2- Relief Valve 16 - O-Ring 30 - Plate (10 Used) 44 - Friction Plate (6 Used)
3- Shaft 17 - Seal Ring 31 - Spacer 45 - Piston
4- Retaining Ring 18 - Backup Ring (2 Used) 32 - Retaining Ring 46 - Disc Spring (3 Used)
5- O-Ring 19 - Piston 33 - Shim 47 - Gear Case
6- Drive Case 20 - Retaining Ring 34 - Retaining Ring 48 - Socket Bolt (9 Used)
7- Plug 21 - O-Ring 35 - Ring 49 - Disc Spring (2 used)
8- O-Ring 22 - Gasket 36 - O-Ring 50 - Seal
9- Spring 23 - O-Ring 37 - Bearing 51 - Ring
10 - Bearing 24 - Seal Ring 38 - Sun Gear 52 - O-Ring (2 Used)
11 - Retaining Ring 25 - Plate 39 - Cover 53 - Retaining
12 - Piston Ring (2 Used) 26 - Retaining Ring 40 - Retaining Ring 54 - Piping
13 - Piston 27 - Ring Gear 41 - Disc Carrier 55 - Hose (2 Used)
14 - Seal Ring 28 - Plate 42 - Plate (6 Used) 129 - Retaining Ring
130 - Plate

56 - Retaining Ring (3 Used) 70 - Bearing 84 - Drive Pinion 98 - Plate

57 - Plate (3 Used) 73 - Bearing 85 - Bushing 99 - Lock Plate
58 - Needle bearing (3 Used) 74 - Shaft 86 - Bolt (12 Used) 100 - Bolt (2 Used)
59 - Planetary Gear (3 Used) 75 - Bearing 87 - O-Ring 101 - Clutch
60 - Needle bearing 76 - Shift Interlock Controller 88 - O-Ring 102 - Shim
61 - Carrier 77 - Socket Bolt (3 Used) 89 - Gear 103 - Retaining Ring
62 - Shift fork 78 - Gear 90 - Seal 104 - Bearing
63 - Shoe (2 Used) 79 - Cover 91 - Cover 105 - Retaining Ring
64 - Plug 80 - Bearing 92 - Bearing 106 - Retaining Ring
65 - Pin 81 - Cover 93 - Seal 107 - Socket Bolt
66 - Retaining Ring 82 - Bolt (4 Used) 94 - Plate 108 - Spring Pin
67 - Retaining Ring 83 - Cap 95 - Flange 109 - Bolt
68 - Gear 96 - Bolt (8 Used) 110 - Lever
69 - Plug 97 - O-Ring 111 - Pin
129 - Retaining Ring
130 - Plate

W3-4-9
 UNDERCARRIAGE / Transmission

54 55 48 6

A Part

W1GL-03-04-002

47
T1GL-03-05-001

8 9 10 11 13 14 15 16 17, 18 19 20 21 22 23 24 25 26 27

28, 29, 30, 31

6

32
5

4 33
A Part
34
3
35
12 36
2 37

53 38
50, 51 39

40
1

129 52 130 49 48 47 46 45 44 43 42 41 W1F3-03-04-002

W3-4-10
 UNDERCARRIAGE / Transmission
Disassemble Transmission

1. Disconnect hoses (55) (2 used) and pipe (54) 8. Remove screw and breather from gear case (47).
from gear case (47). : 5 mm
: 19 mm, 27 mm : 12 mm
Breather

2. Loosen plug (7).

: 24 mm

3. Remove socket bolts (48) (9 used) and retaining

ring (11) to remove drive case (6) from gear case
(47).
: 12 mm

4. Remove plug (7), O-ring (8), spring (9) and the

piston (3) assembly from drive case (6).
: 24 mm

5. Remove seal ring (14) from piston (13).

Screw W1GL-03-04-009

6. Remove disc springs (49) (2 used) from piston

(19). 9. Remove O-ring (15), seal ring (17) and backup
rings (18) (2 used) from gear case (47).
7. Pull piston (19) out from gear case (47) with a
compressor. 10. Remove retaining ring (20) from gear case (47).

NOTE: Plug port A then supply air with pressure to 11. Remove gasket (22) from gear case (47) by an
pull piston (19) out. offset driver.

A 12. Remove O-ring (23) from gasket (22).

13. Remove O-ring (21) from gear case (47).

14. Remove plates (42) (6 used) and friction plates

(44) (6 used) from gear case (47).

15. Remove plate (25) from gear case (47).

B

W1GL-03-04-009

W3-4-11
 UNDERCARRIAGE / Transmission

10 24 26 27

28, 29, 30, 31

32

4 33

34
3

12

2 37

53 38
50, 51 39

40
1

129 52 130 47 46 45 43 41 W1F3-03-04-002

W3-4-12
 UNDERCARRIAGE / Transmission
16. Remove retaining ring (26) from gear case (47),
and then pull the shaft (3) assembly out from gear
case (47).

17. Secure the shaft (3) assembly on a vice with relief

valve (2) facing down.

18. Remove retaining ring (34) and shim (33) from

shaft (3) to remove sun gear (38).

19. Remove retaining ring (40) from ring gear (27) to

remove ring gear (27) from piston (45).

20. Remove the cover (39) assembly from shaft (3).

21. Remove retaining ring (32) from cover (39) to

remove bearing (37) from cover (39).

22. Remove spacer (31), plates (30) (10 used) and

friction plates (29) (11 used) and plate (28) from
shaft (3).

23. Remove disc carrier (41) and shim (43) from shaft
(3).

24. Remove seal ring (24) from disc carrier (41).

25. Remove piston (45), disc springs (46) (3 used)

and plate (130) from shaft (3).

26. Remove retaining ring (53) from shaft (3).

27. Remove shaft (3) from a vice.

28. Remove retaining rings (4, 129) from shaft (3) to

remove shaft (3) from flange (1).

29. Remove bearing (10) and relief valve (2) from

shaft (3).

30. Remove piston ring (12) from shaft (3).

31. Remove ring (51) and seal (50) from flange (1).

32. Remove O-rings (52) (2 used) from flange (1).

W3-4-13
 UNDERCARRIAGE / Transmission

B Part 107 64,108

W1GL-03-04-003
111 110 109

T1GL-03-05-001

26 56 57 58 59 60 61 62, 63 64 65 66 67 68 69 70 73 74 75

B Part

25
76, 77
27
39
34

37
78
32 79
81
40
80
38
82
33
105
104
83
106
103, 102
101
100
99
98
97
96

W1GL-03-04-004

95 94 93 47 92 91 90 89 88 87 86 85 84

W3-4-14
 UNDERCARRIAGE / Transmission
33. Remove retaining ring (105) from gear (68) to
remove the carrier (61) assembly from gear case
(47).

34. Remove retaining rings (56) (3 used) and plates

(57) (3 used) from carrier (61).

35. Remove planetary gears (59) (3 used) and needle

bearings (60) (3 used) from carrier (61).

36. Remove retaining ring (106) and bearing (104)

from carrier (61).

37. Remove bolt (109) from lever (110) to remove

clutch (101) and shoes (63) (2 used) from shift
fork (62).
: 17 mm

38. Remove plug (64) from gear case (47), tap and
remove spring pin (108) to gear case (47) inside
from shift fork (62).
: 10 mm

39. Pull the lever (110) assembly out from gear case
(47) then remove shift fork (62) from inside.

40. Remove socket bolts (77) (3 used) to remove shift

interlock controller (76) from gear case (47).
: 6 mm

41. Pull shaft (74) out from gear (68).

42. Remove retaining ring (66) from gear case (47) to

remove the gear (68) assembly from gear case
(47).

43. Remove retaining ring (103) and shim (102) from

gear (68) to remove gear (78) from gear (68).

44. Remove the cover (79) assembly from gear (68).

45. Remove retaining ring (67) and bearing (70) from

cover (79).

46. Remove bearing (73) from gear (68).

47. Remove bolts (72) (2 used) from gear case (47) to

remove oil cover (71).

W3-4-15
 UNDERCARRIAGE / Transmission
DISASSEMBLE FINAL DRIVE AND DIF-
FERENTIAL
112 47 80 81

82

83
100

99
98
97 Differential
96
95

94
W1GL-03-04-005

93 47 92 91 90 89 88 87 86 85 84

81 86

83 113 114

115

85
112
80

115 114
84

116

W1GL-03-04-006
123
116
120
122
121
120 119 118
119 124
118
117

127 125
126
121 120
120 W1GL-03-04-007

W3-4-16
 UNDERCARRIAGE / Transmission

47 - Gear Case 89 - Gear 99 - Lock Plate 120 - Thrust Washer (4 Used)

80 - Bearing 90 - Seal 100 - Bolt (2 Used) 121 - Pinion Gear (4 Used)
81 - Cover 91 - Cover 112 - Plate 122 - Differential Case
82 - Bolt (4 Used) 92 - Bearing 113 - Roll Pin (2 Used) 123 - Socket Bolt (8 Used)
83 - Cap 93 - Seal 114 - Bearing (2 Used) 124 - Socket Bolt (4 Used)
84 - Drive Pinion 94 - Plate 115 - Nut (2 Used) 125 - Spring Pin (4 Used)
85 - Bushing 95 - Flange 116 - Bevel Gear 126 - Spring Pin (4 Used)
86 - Bolt (12 Used) 96 - Bolt (8 Used) 117 - Differential Case 127 - Spider
87 - O-Ring 97 - O-Ring 118 - Thrust Washer (2 Used)
88 - O-Ring 98 - Plate 119 - Side Gear (2 Used)

W3-4-17
 UNDERCARRIAGE / Transmission

112 47 80 81

82

83
100

99
98
97 Differential
96
95

94
W1GL-03-04-005

93 47 92 91 90 89 88 87 86 85 84

81 86

83 113 114

115

85
112
80

115 114
84

116

W1GL-03-04-006
123
116
120
122
121
120 119 118
119 124
118
117

127 125
126
121 120
120 W1GL-03-04-007

W3-4-18
 UNDERCARRIAGE / Transmission
Disassemble Final Drive and Differential

1. Remove lock plate (99) from plate (98). CAUTION: Be sure to put mating marks on
cap (83) and the differential before removing
2. Remove bolts (100) (2 used) to remove plate (98) them.
and O-ring (97).
: 17 mm 12. Remove the differential assembly from cover (81).

3. Remove the flange (95) assembly from drive 13. Remove O-ring (88), bushing (85) and the inner
pinion (84). race of bearing (80) from drive pinion (84).

4. Remove seal (93) from gear case (47). 14. Remove the outer race of bearing (80) and seal
(90) from cover (81).
5. Remove bolts (86) (12 used) from cover (81) then
pull cover (81) out using removed bolts (86) (3 15. Remove socket bolts (123) (8 used) and (124) (4
used). used) from bevel gear (116).
: 19 mm
16. Pull the spring pin (126) assembly (4 used) out
6. Remove gear (89) from drive pinion (84). from differential cases (117, 122).

7. Remove cover (91) from gear case (47). 17. Remove differential case (117) from differential
case (122).
8. Remove the outer race of bearing (92) from gear
case (47). 18. Remove side gear (119), pinion gear (121) (4
used), thrust washers (120) (4 used), (118) (2
9. Tap roll pins (113) (2 used) while removing it from used) and spider (127) from differential case
cap (83). (122).

10. Remove nuts (115) (2 used) from cap (83). 19. Remove differential case (122) from bevel gear
(116).
11. Remove bolts (82) (4 used) to remove caps (83)
(2 used) from cover (81). 20. Pull spring pins (125) (4 used) out from spring
pins (126) (4 used).

W3-4-19
 UNDERCARRIAGE / Transmission
ASSEMBLE FINAL DRIVE AND DIFFERENTIAL
112 47 80 81

82

83
100

99
98
97 Differential
96
95

94 Preload
1.0 to 4.0 N･m W1GL-03-04-005

93 47 92 91 90 89 88 87 86 85 84

81 86

83 113 114

115

85
112
80

115 114
84

116

W1GL-03-04-006
123
116
120
122
121
120 119 118
119 124
118
117

127 126 125

121 120
120 W1GL-03-04-007

W3-4-20
 UNDERCARRIAGE / Transmission

47 - Gear Case 89 - Gear 99 - Lock Plate 120 - Thrust Washer (4 Used)

80 - Bearing 90 - Seal 100 - Bolt (2 Used) 121 - Pinion Gear (4 Used)
81 - Cover 91 - Cover 112 - Plate 122 - Differential Case
82 - Bolt (4 Used) 92 - Bearing 113 - Roll Pin (2 Used) 123 - Socket Bolt (8 Used)
83 - Cap 93 - Seal 114 - Bearing (2 Used) 124 - Socket Bolt (4 Used)
84 - Drive Pinion 94 - Plate 115 - Nut (2 Used) 125 - Spring Pin (4 Used)
85 - Bushing 95 - Flange 116 - Bevel Gear 126 - Spring Pin (4 Used)
86 - Bolt (12 Used) 96 - Bolt (8 Used) 117 - Differential Case 127 - Spider
87 - O-Ring 97 - O-Ring 118 - Thrust Washer (2 Used)
88 - O-Ring 98 - Plate 119 - Side Gear (2 Used)

W3-4-21
 UNDERCARRIAGE / Transmission

112 47 80 81

82

83
100

99
98
97 Differential
96
95

94
W1GL-03-04-005

93 47 92 91 90 89 88 87 86 85 84

81 86

83 113 114

115

85
112
80

115 114
84

116

W1GL-03-04-006
123
116
120
122
121
120 119 118
119 124
118
117

127 125
126
121 120
120 W1GL-03-04-007

W3-4-22
 UNDERCARRIAGE / Transmission
Assemble Final Drive and Differential

1. Align the mounting hole and install differential 9. Align the mating mark on the differential case
case (122) to bevel gear (116). (117) assembly then install them to the differential
case (122) assembly.
2. Place bevel gear (116) on a workbench with it
facing lower side. 10. Tap spring pin (125) into spring pins (126) (4
used) then tap approx. 10 mm (0.4 in) further.
3. Apply grease on the thrust surface of side gears
(119) (2 used). Install thrust washers (118) (2 11. Install the differential assembly to bevel gear (116)
used) to side gears (119) (2 used). with socket bolts (123) (8 used) and (124) (4
used).
4. Apply grease on pinion gears (121) (4 used) and : 145 N･m (14.8 kgf･m, 107 lbf･ft)
thrust washers (120) (4 used). Install them to
spider (127).

5. Tap spring pins (126) (4 used) onto differential

case (117) until mating with surface of differential
case (122).

IMPORTANT: When installing thrust plate (118), be

sure to align the flange with the
groove of the differential case. When
installing thrust plate (120), be sure
to make its protrusion at right angles
with differential case (117).

6. Install the side gear (119) assembly to differential

case (122).

7. Install the spider (127) assembly to differential

case (122).

8. Apply grease on the side gear (119) assembly

then install it to differential case (122).

W3-4-23
 UNDERCARRIAGE / Transmission

112 47 80 81

82

83
100

99
98
97 Differential
96
95

94
W1GL-03-04-005

93 47 92 91 90 89 88 87 86 85 84

81 86

83 113 114

115

85
112
80

115 114
84

116

W1GL-03-04-006

W3-4-24
 UNDERCARRIAGE / Transmission
12. Install the inner race of bearing (80) and bushing 20. Install bolts (96) (8 used) and plate (94) to flange
(85) to drive pinion (84). Then, install O-ring (88) (95).
on the groove of drive pinion (84).
21. After applying grease on the seal (93) mating
13. Install plate (112), the inner race of bearing (80) to surface of flange (95), install it to drive pinion (84)
cover (81) then install seal (90) to other side. and install O-ring (97).

14. Install the drive pinion (84) assembly to the cover 22. Install bolts (100) (2 used) to lock plate (99).
(81) assembly. Install gear (89) and install O-ring Install plate (98) to drive pinion (84) with bolts
(87). (100) (2 used).
: 17 mm
15. Install cover (91) to gear case (47). : 46 N⋅m (5.0 kgf⋅m, 36 lbf⋅ft)

16. Install the outer race of bearing (92) to gear case 23. Install the inner races of bearing (114) (2 used) to
(47). the differential.

17. Install the cover (81) assembly to gear case (47) 24. Install roll pins (113) (2 used) to caps (83) (2
with bolts (86) (12 used). used).
: 19 mm
: 79 N⋅m (8 kgf⋅m, 58 lbf⋅ft) 25. Install the outer race of bearings (114) (2 used) to
the differential.
18. Install the inner race of bearing (92) and spacer
(128) to drive pinion (84). 26. Insert the differential assembly to cover (81),
install nuts (115) (2 used).
19. Be sure to install seal (93) to gear case (47) within
certain depth. 27. Install the differential assembly with caps (83) (2
used) and bolts (82) (4 used).
47 : 195 N⋅m (20 kgf⋅m, 145 lbf⋅ft)

28. After adjusting the backlash and preload of bevel

95 92 gear (116) and drive pinion (84), secure nut (115)
with roll pins (113) (2 used).
84
• The backlash is stamped on the side surface of
bevel gear (116) and the end of drive pinion (84).
93 • Preload of drive pinion (84)
1.0 to 1.4 N･m (0.1 to 0.14 kgf･m, 0.7 to 1.0 lbf･ft)

94
W1GL-03-04-008

+1.0
2.0 -0 mm
+0.04
(0.08 -0 in)

W3-4-25
 UNDERCARRIAGE / Transmission
ASSEMBLE TRANSMISSION

54 55 48 6

A Part

W1GL-03-04-002

47
T1GL-03-05-001

8 9 10 11 13 14 15 16 17, 18 19 20 21 22 23 24 25 26 27

28, 29, 30, 31

6

32
5

4 33
A Part
34
3
35
12 36
2 37

53 38
50, 51 39

40
1

129 52 130 49 48 47 46 45 44 43 42 41 W1F3-03-04-002

W3-4-26
 UNDERCARRIAGE / Transmission

1- Flange 15 - O-Ring 29 - Friction Plate (11 Used) 43 - Shim

2- Relief Valve 16 - O-Ring 30 - Plate (10 Used) 44 - Friction Plate (6 Used)
3- Shaft 17 - Seal Ring 31 - Spacer 45 - Piston
4- Retaining Ring 18 - Backup Ring (2 Used) 32 - Retaining Ring 46 - Disc Spring (3 Used)
5- O-Ring 19 - Piston 33 - Shim 47 - Gear Case
6- Drive Case 20 - Retaining Ring 34 - Retaining Ring 48 - Socket Bolt (9 Used)
7- Plug 21 - O-Ring 35 - U-Ring 49 - Disc Spring (2 Used)
8- O-Ring 22 - Gasket 36 - O-Ring 50 - Seal
9- Spring 23 - O-Ring 37 - Bearing 51 - Ring
10 - Bearing 24 - Seal Ring 38 - Sun Gear 52 - O-Ring (2 Used)
11 - Retaining Ring 25 - Plate 39 - Cover 53 - Retaining Ring
12 - Piston Ring (2 Used) 26 - Retaining Ring 40 - Retaining Ring 54 - Pipe
13 - Piston 27 - Ring Gear 41 - Disc Carrier 55 - Hose (2 Used)
14 - Seal Ring 28 - Plate 42 - Plate (6 Used) 129 - Retaining Ring
130 - Plate

W3-4-27
 UNDERCARRIAGE / Transmission

B Part 107 64, 108

W1GL-03-04-003
111 110 109

T1GL-03-05-001

26 56 57 58 59 60 61 62, 63 64 65 66 67 68 69 70 73 74 75

B Part

25
76, 77
27
39
34

37
78
32 79
81
40
80
38
82
33
105
104
83
106
103, 102
101
100
99
98
97
96

W1GL-03-04-004

95 94 93 47 92 91 90 89 88 87 86 85 84

W3-4-28
 UNDERCARRIAGE / Transmission

1- Flange 15 - O-Ring 29 - Friction Plate (11 Used) 43 - Shim

2- Relief Valve 16 - O-Ring 30 - Plate (10 Used) 44 - Friction Plate (6 Used)
3- Shaft 17 - Seal Ring 31 - Spacer 45 - Piston
4- Retaining Ring 18 - Backup Ring (2 Used) 32 - Retaining Ring 46 - Disc Spring (3 Used)
5- O-Ring 19 - Piston 33 - Shim 47 - Gear Case
6- Drive Case 20 - Retaining Ring 34 - Retaining Ring 48 - Socket Bolt (9 Used)
7- Plug 21 - O-Ring 35 - Ring 49 - Disc Spring (2 used)
8- O-Ring 22 - Gasket 36 - O-Ring 50 - Seal
9- Spring 23 - O-Ring 37 - Bearing 51 - Ring
10 - Bearing 24 - Seal Ring 38 - Sun Gear 52 - O-Ring (2 Used)
11 - Retaining Ring 25 - Plate 39 - Cover 53 - Retaining
12 - Piston Ring (2 Used) 26 - Retaining Ring 40 - Retaining Ring 54 - Piping
13 - Piston 27 - Ring Gear 41 - Disc Carrier 55 - Hose (2 Used)
14 - Seal Ring 28 - Plate 42 - Plate (6 Used) 129 - Retaining Ring
130 - Plate

56 - Retaining Ring (3 Used) 70 - Bearing 84 - Drive Pinion 98 - Plate

57 - Plate (3 Used) 73 - Bearing 85 - Bushing 99 - Lock Plate
58 - Needle bearing (3 Used) 74 - Shaft 86 - Bolt (12 Used) 100 - Bolt (2 Used)
59 - Planetary Gear (3 Used) 75 - Bearing 87 - O-Ring 101 - Clutch
60 - Needle bearing 76 - Shift Interlock Controller 88 - O-Ring 102 - Shim
61 - Carrier 77 - Socket Bolt (3 Used) 89 - Gear 103 - Retaining Ring
62 - Shift fork 78 - Gear 90 - Seal 104 - Bearing
63 - Shoe (2 Used) 79 - Cover 91 - Cover 105 - Retaining Ring
64 - Plug 80 - Bearing 92 - Bearing 106 - Retaining Ring
65 - Pin 81 - Cover 93 - Seal 107 - Socket Bolt
66 - Retaining Ring 82 - Bolt (4 Used) 94 - Plate 108 - Spring Pin
67 - Retaining Ring 83 - Cap 95 - Flange 109 - Bolt
68 - Gear 96 - Bolt (8 Used) 110 - Lever
69 - Plug 97 - O-Ring 111 - Pin

W3-4-29
 UNDERCARRIAGE / Transmission

107 64, 108

W1GL-03-04-003
111 110 109

T1GL-03-05-001

26 56 57 58 59 60 61 62,63 64 65 66 67 68 69 70 73 74 75

B Part

25
76, 77
27
39
34

37
78
32 79
81
40
80
38
82
33
105
104
83
106
103, 102
101
100
99
98
97
96

W1GL-03-04-004

95 94 93 47 92 91 90 89 88 87 86 85 84

W3-4-30
 UNDERCARRIAGE / Transmission
Assemble Transmission

1. Install bearing (73) and needle bearing (60) to

gear (68).

2. Install bearing (70) to cover (79) and secure it with

retaining ring (67).

3. Install gear (68) to the cover (79) assembly.

4. Install the cover (79) assembly to gear case (47)

and secure them with retaining ring (66).

5. Install gear (78) and shim (102) to gear (68),

secure them with retaining ring (103).

6. Install shoes (63) (2 used) to shift fork (62), install

the shift fork (62) assembly to cluch (10).

7. Install the shift fork (62) assembly into gear case

(47). Pass pin (111) through lever (110) and the
shift fork (62) assembly. Align the spring pin (108)
hole of pin (111) to secure them with spring pin
(108).

8. Install lever (110) to gear case (47) with bolt

(109).
: 17 mm
: 65 N⋅m (6.6 kgf⋅m, 48 lbf⋅ft)

9. Install plug (64) to gear case (47).

: 10 mm
: 95 N⋅m (10 kgf⋅m, 72 lbf⋅ft)

10. Install bearing (104) to carrier (61) and secure it

with retaining ring (106).

11. Install needle bearings (58) (3 used), planetary

gears (59) (3 used), plates (57) (3 used) and
retaining rings (56) (3 used) to carrier (61) in
order.

12. Install the carrier (61) assembly to gear (68) and

secure them with retaining ring (105).

W3-4-31
 UNDERCARRIAGE / Transmission

54 55 48 6

A Part

W1GL-03-04-002

47

T1GL-03-05-001

8 9 10 11 13 14 15 16 17, 18 19 20 21 22 23 24 25 26 27

28, 29, 30, 31

6

32
5

4 33
A Part
34
3
35
12 36
2 37

53 38
50, 51 39

40
1

129 52 130 49 48 47 46 45 44 43 42 41 W1F3-03-04-002

W3-4-32
 UNDERCARRIAGE / Transmission
13. Install bearing (10) into shaft (3) and secure them 18. Install plate (130) and the piston (45) assembly to
with retaining ring (4). the shaft (3) assembly, and then install shim (43)
into inside.
14. Install piston rings (12) (2 used) to shaft (3).
19. Install seal ring (24) to disc carrier (41), install the
15. Install shaft (3) to flange (1) and secure it with disc carrier (41) assembly to the shaft (3)
retaining ring (129). assembly.
Install seal (50) into the flange (1) inside, secure it
with ring (51). 20. Install plate (28) friction plates (29) (11 used) and
plates (30) (10 used), spacer (31) to the shaft (3)
16. Install retaining ring (53), U-ring (35) and O-ring assembly (disc carrier) in order.
(36) to shaft (3) in order.
21. Install bearing (37) to cover (39), secure it with
retaining ring (32).
CAUTION: When install U-ring (35), be sure
to put the groove of U-ring (35) facing the 22. Install ring gear (27) to the shaft (3) assembly
disc carrier (41) side. (plate part).

17. Install disc springs (46) (3 used) to piston (45).

23. Install the cover (39) assembly to the ring gear
(27) assembly, secure them with retaining ring
(40).

24. Install sun gear (38), shim (33) and retaining ring
(34) to the shaft (3) assembly.

25. Install gear case (47) to the shaft (3) assembly,

secure it with retaining ring (26).
46

CAUTION: Install plate (25) with the

machined part facing retaining ring (26).

26. Install plate (25), friction plates (44) (6 used) and

45
plates (42) (6 used) to the ring gear (27) out race
part alternatively.
W1GL-03-04-010

W3-4-33
 UNDERCARRIAGE / Transmission

74
54 55 48 6

76, 77

A Part

W1GL-03-04-002

47

T1GL-03-05-001

8 9 10 11 13 14 15 16 17, 18 19 20 21 22 23 24 25 26 27

28, 29, 30, 31

6

32
5

4 33
A Part
34
3
35
12 36
2 37

53 38
50, 51 39

40
1

129 52 130 49 48 47 46 45 44 43 42 41 W1F3-03-04-002

W3-4-34
 UNDERCARRIAGE / Transmission
27 Install O-ring (23) to gasket (22). 36. Install piston (13), spring (9) and plug (7) to drive
case (6) in order.
28. Install O-ring (21) to the gear case (47) inside, : mm
install gasket (22) and secure them with retaining : 140 N･m (14 kgf･m, 101 lbf･ft)
ring (20).
37. Install O-ring (5) to drive case (6).
29. Install seal ring (17) and backup rings (18) (2
used) to the gear case (47) inside. Install O-ring 38. Install shaft (74) to shaft (3), install shift interlock
(15). controller (76) to gear case (47) with socket bolts
(77) (3 used).
30. Install piston (19) to gear case (47). : 6 mm
: 23 N･m (2.5 kgf･m, 18.1 lbf･ft)
31. Align disc springs (49) (2 used) on piston (19)
surface. 39. Connect hoses (55) (2 used) and pipe (54) to gear
case (47).

49

19

W1GL-03-04-010

32. Install O-ring (16) to the flange of piston (19) side

on drive case (6).

33. Install drive case (6) to gear case (47) with socket
bolts (48) (9 used) and retaining ring (11).
: 10 mm
: 79 N･m (8 kgf･m, 58 lbf･ft)

34. Install seal ring (14) to piston (13).

35. Install O-ring (8) to plug (7).

W3-4-35
 UNDERCARRIAGE / Transmission
ADJUSTING GEAR CLEARANCE

When assembling the drive pinion, error in adjusting

shim may occur due to the big gear clearance.

A) Correct clearance between gear and pinion.

Meshing Surface (Concave Part) Meshing Surface (Convex Part)

W1GL-03-05-021

W1GL-03-05-019 W1GL-03-05-020

B) Increasing clearance of pinion is necessary.

Meshing Surface (Concave Part) Meshing Surface (Convex Part)

Clearance of pinion

W1GL-03-05-027

Reducing Thickness of Shim for Pinion

W1GL-03-05-022 W1GL-03-05-023

C) Decreasing clearance of pinion is necessary.

Meshing Surface (Concave Part) Meshing Surface (Convex Part)

Clearance of pinion

W1GL-03-05-027

Increasing Thickness of Shim for Pinion

W1GL-03-05-025
W1GL-03-05-026

W3-4-36
 UNDERCARRIAGE / Axle
REMOVE AND INSTALL AXLE
3 2 3 3 2 3 4
CAUTION: Be sure to bleed air from
hydraulic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)

Removal of Front Axle

1. Loosen mounting nuts (1) (20 used) from tires (3)
(4 used) and tire rings (2) (2 used). 1
: 30 mm

W1GL-03-05-003

2. Jack up frame (4) with tire (3) floated then put the
blocks under the machine.

90 to 110°
CAUTION: Tire (3) weight: 98 kg (220 lb)
Tire ring (2) weight: 17 kg (38 lb)

3. Remove nuts (1) (20 used) to remove tires (3) (4

used) and tire rings (2) (2 used).
: 30 mm Block SA-096

4. Disconnect brake hoses (5) (2 used) and grease

hose (10).
: 17 mm, 22 mm 7 8 9 5
6

5. Disconnect steering hoses (2 used). 5

: 22 mm
10
11
CAUTION: Propeller shaft weight:
20 kg (44 lb) 12

6. Remove nuts (12) (8 used) to remove propeller Steering

shaft (11). Box
: 14 mm 1
W1GL-03-05-001

7. Remove nuts (6) (2 used) to remove bolt (8).

: 24 mm

CAUTION: Front axle (9) weight:

590 kg (1300 lb)
CAUTION: Pin (7) weight: 18 kg (40 lb) (Outer
Diameter 70 mm (2.8 in))

8. Lift front axle (9) off to remove pin (7), then

remove front axle (9).

W3-5-1
 UNDERCARRIAGE / Axle

Installation of Front Axle

CAUTION: Front axle (9) weight:
590 kg (1300 lb)
CAUTION: Pin (7) weight: 18 kg (40 lb) (Outer 7 8 9 5
6
Diameter 70 mm (2.8 in))

1. Lift front axle (9) off, then install front axle (9) with 5
pin (7). 10
11
2. Lock pin (7) with bolt (8) and nuts (6) (2 used).
: 24 mm 12
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
Steering
3. Connect steering hoses (2 used). Box
: 22 mm 1
: 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft) W1GL-03-05-001

4. Connect brake hoses (5) (2 used) and grease

hose (10).
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft)
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

CAUTION: Propeller shaft (11) weight:

20 kg (44 lb)

5. Install propeller shaft (11) with bolts and nuts (12)

(8 used). 3 2 3 3 2 3 4
: 14 mm
: 108 N⋅m (11.0 kgf⋅m, 80 lbf⋅ft)

CAUTION: Tire (3) weight: 98 kg (220 lb)

Tire ring (2) weight: 17 kg (38 lb)

6. Install tire (3), tire ring (2) and tire (3) to front axle
(9) in order, then temporarily tighten them with 1
nuts (1) (10 used). (The installing order for both
sides are the same.)
: 30 mm
W1GL-03-05-003

7. Remove the block from frame (4).

8. Tight tires (3) (4 used) and tire rings (2) (2 used)

with nuts (1) (20 used).
: 30 mm 90 to 110°
: 600 N⋅m (61 kgf⋅m, 440 lbf⋅ft)

Block SA-096

W3-5-2
 UNDERCARRIAGE / Axle

CAUTION: Be sure to bleed air from

hydraulic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)
4
3
Removal of Rear Axle
1. Loosen mounting nuts (1) (20 used) from tires (3)
(4 used) and tire rings (2) (2 used).
: 30 mm

1 3 W1GL-03-05-003

2. Jack up frame (4) with tire (3) floated, then put the
blocks under the machine.
90 to 110°

CAUTION: Tire (3) weight: 98 kg (220 lb)

Tire ring (2) weight: 17 kg (38 lb)

3. Remove nuts (1) (20 used) to remove tires (3) (4 Block W1GL-03-08-003

used) and tire rings (2) (2 used).

: 30 mm

CAUTION: Propeller shaft (8) weight:

30 kg (66 lb)

4. Remove nuts (7) (8 used) to remove propeller 5

shaft (8).
: 14 mm

CAUTION: The transmission (6) assembly

weight: 225 kg (500 lb) 8 7 6 12

W1GL-03-02-002
5. Support the lower side of the transmission (6)
assembly by a fork lift after remove bolts (5) (12
used) to remove the transmission (6) assembly
from axle (12).
: 19 mm

When removing and installing the travel motor, refer to

“Remove and Install Travel Motor”, and when removing
and installing the transmission, refer to “Remove and
Install Transmission”.

W3-5-3
 UNDERCARRIAGE / Axle

6. Disconnect brake pipes (9) (2 used). 9

: 19 mm 10

CAUTION: Rear axle (12) weight:

440 kg (970 lb)

7. Lift rear axle (12) off. Remove nuts (10) (8 used) 11

to remove bolts (11) (8 used) and axle (12) from
frame (4). 12
: 36 mm
10
11

W1GL-03-05-002

W1GL-03-05-003

W3-5-4
 UNDERCARRIAGE / Axle

Installation of Rear Axle 10

CAUTION: Rear axle (12) weight:
440 kg (970 lb) 9

1. Lift rear axle (12) off, then install rear axle (12) to
frame (4) with bolts (11) (8 used) and nuts (10) (8 11
used).
: 36 mm 12
: 960 N⋅m (98.0 kgf⋅m, 710 lbf⋅ft)
10
2. Connect brake pipes (9) (2 used). 11
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) 1 W1GL-03-05-002

CAUTION: The transmission (6) assembly

weight: 225 kg (500 lb)

3. Support the transmission (6) assembly by a fork

lift while aligning it to rear axle (12), then install the
transmission (6) assembly to rear axle (12) with
bolts (5) (12 used). 5
: 19 mm
: 250 N⋅m (25.5 kgf⋅m, 180 lbf⋅ft)

CAUTION: Propeller shaft (8) weight:

30 kg (66 lb) 8 7 6 12

W1GL-03-02-002
4. Install propeller shaft (8) to trans mission (6) with
nuts (7) (8 used).
: 14 mm
: 108 N⋅m (11.0 kgf⋅m, 80 lbf⋅ft) 4
3

CAUTION: Tire (3) weight: 98 kg (220 lb)

Tire ring (2) weight: 17 kg (38 lb)

5. Install tire (3), tire ring (2) and tire (3) into axle (12)
in order then temporarily tighten them with nuts (1)
(10 used). (The installing order for both sides are 2
the same.)
: 30 mm 1 3 W1GL-03-05-003

6. Remove the block from frame (4).

7. Tighten tires (3) (4 used) and tire rings (2) (2

used) with nuts (1) (20 used).
90 to 110°
: 30 mm
: 600 N⋅m (61 kgf⋅m, 440 lbf⋅ft)

Block W1GL-03-08-003

W3-5-5
 UNDERCARRIAGE / Axle
DISASSEMBLE FRONT AXLE
3
4
5
1 2 6

8
9
6
5
10 4
11 3
12
13

20
24 25 26

19
21 22 23
18

17

14 15 16

27

44
28 46
40 45
39 43
38
29 41 42
30, 70
36 37
35
34
33
32 61
31 47
48 60
57 58 59
55 56 62
54
52 53
51
50
50
49

63

69 64
66 65
68 67 W1GL-03-05-015

W3-5-6
 UNDERCARRIAGE / Axle

1- Plug 19 - Bearing Pin 37 - Lock Washer 55 - Sun Gear Shaft

2- Body 20 - Bolt (4 Used) 38 - Bolt (8 Used) 56 - Socket Bolt
3- O-Ring (2 Used) 21 - Gasket Ring 39 - Spring Guide (8 Used) 57 - Plain Washer
4- Seal Ring (2 Used) 22 - Bearing 40 - Spring (8 Used) 58 - Retaining Ring
5- Bearing (2 Used) 23 - Bushing 41 - Plate 59 - Retaining Ring
6- Seal Ring (2 Used) 24 - Hub Carrier 42 - Retaining Ring 60 - Washer
7- Shaft Seal 25 - O-Ring 43 - Piston 61 - Bolt (2 Used)
8- Bushing 26 - Bearing 44 - Nut (8 Used) 62 - Plug
9- Plug 27 - Wheel Stud (10 Used) 45 - U-Ring 63 - Planetary Carrier
10 - Bolt (2 Used) 28 - Stopper Bolt 46 - Ring 64 - Thrust Plate (3 Used)
11 - Nut (3 Used) 29 - Bolt (4 Used) 47 - U-Ring 65 - Planetary Gear (3 Used)
12 - Stud Bolt (3 Used) 30 - Bearing Pin 48 - Ring 66 - Needle Bearing (3 Used)
13 - Bolt (7 Used) 31 - Backup Ring 49 - Ring Gear 67 - Thrust Plate (3 Used)
14 - Double Joint Shaft 32 - O-Ring (2 Used) 50 - Plate (4 Used) 68 - Retaining Ring (3 Used)
15 - Shaft Seal 33 - Backup Ring 51 - Plate 69 - Friction Plate (3 Used)
16 - Bushing 34 - Retaining Ring (3 Used) 52 - Retaining Ring 70 - *O-Ring (2 Used)
17 - Joint Housing 35 - Ring Gear 53 - Thrust Washer 71 - Plug
18 - Shim 36 - Bearing Nut 54 - Gear

NOTE: As for marked “ * ”, refer to page W3-5-12.

W3-5-7
 UNDERCARRIAGE / Axle

3
4
5
1 2 6

8
9
6
5
10 4
11 3
12
13

20
24 25 26

19
21 22 23
18

17

14 15 16

27

44
28 46
40 45
38 39 43
29 41 42
30, 70
36 37
35
34
33 61
32
31 47
48 60
57 58 59
55 56 62
54
52 53
51
50
50
49

63

69 64
66 65
68 67 W1GL-03-05-015

W3-5-8
 UNDERCARRIAGE / Axle
Disassemble Front Axle

1. Remove plugs (1, 9, 62 and 71) to drain oil. 8. Remove bearing nut (36) from joint housing (17).
: 8 mm, 22 mm
9. Remove the ring gear (35) assembly from joint
2. Remove bolts (61) (2 used) to remove planetary housing (17).
carrier (63) from hub carrier (24).
: 8 mm
10. Remove retaining rings (34) (3 used) to remove
ring gear (49) from the ring gear (35) assembly.
24 34 49

61

61 35
63

W1GL-03-05-013
71
62 W1GL-03-05-006
11. Remove nuts (44) (8 used) from the ring gear (35)
assembly to remove bolts (38) (8 used), spring
3. Remove retaining rings (68) (3 used) to remove guides (39) (8 used) and springs (40) (8 used).
thrust plates (67) (3 used), planetary gears (65) (3 : 10 mm
used), needle bearings (66) (3 used) and thrust
plates (64) (3 used) from planetary carrier (63).
12. Remove piston (43) from ring gear (35).

4. Remove retaining ring (58), plain washer (57) and

13. Remove U-rings (45, 47) and rings (46, 48) from
socket bolt (56) from sun gear shaft (55).
piston (43).
: 10 mm

5. Pull sun gear shaft (55) out from gear (54),

remove gear (54) from double joint shaft (14).

6. Remove lock washer (37) and thrust washer (53)

from bearing nut (36).

7. Remove retaining ring (52) from ring gear (49) to

remove plate (51), plates (50) (4 used) and
friction plates (69) (3 used).

W3-5-9
 UNDERCARRIAGE / Axle

3
4
5
2 6

6
5
10 4
11 3
13

20
24 25 26

19
21 22 23
18

17

14 15 16

29 41 42
30, 70

35

33
32
31

W1GL-03-05-015

W3-5-10
 UNDERCARRIAGE / Axle
14. Remove retaining ring (42) and plate (41) from
ring gear (35).

15. Remove backup ring (33) and O-ring (32) from

ring gear (35).

16. Remove O-ring (25) from hub carrier (24).

17. Remove backup ring (31) and O-ring (32) from

joint housing (17).

18. Remove the hub carrier (24) assembly from joint

housing (17).

19. Remove outer races of bearings (22, 26), bushing

(23) and gasket ring (21) from hub gear (24).

IMPORTANT: When removing bearing pins (19, 30),

the inner race of bearing (5) should
be removed together. Take care not
to damage it.
20. Remove bolts (29) (4 used) to remove bearing pin
(30) and O-rings (3, 70) (2 used) from body (2).
: 24 mm

21. Remove bolts (20) (4 used) to remove bearing pin

(19), shim (18) and O-ring (3) from body (2).
: 24 mm

22. Remove joint housing (17) from body (2).

23. Pull double joint shaft (14) out from body (2).

24. Remove seal rings (4) (2 used), O-rings (3) (2

used) and bearing inner races (2 used) from
bearing pins (19, 30).

25. Remove shaft seals (7, 15) from joint housing (17)
and body (2).

26. Remove outer races (2 used) of bearing (5) and

seal rings (6) (2 used) from body (2). The other
side should be removed in the same way.

NOTE: Remove bushings (8, 16) from body (2)

and joint housing (17) if necessary.

27. Remove bolts (10) (2 used), bolts (13) (7 used)

and nuts (11) (3 used) to remove the differential
assembly from body (2).
: 19 mm

W3-5-11
 UNDERCARRIAGE / Axle
ASSEMBLE FRONT AXLE

20 19 6 3 8 21 22 23 26 61 38 39 35 40 41 42 43 44 36 50

18

4
5
52

51
15 62
37
16 53

54
14 60
59
58
57

56
55

64
2
66
17

30 7 29 70 27 25 24 63 31 32 33 48 47 45 46 49 69 68 67 65

W1GL-03-05-029

W3-5-12
 UNDERCARRIAGE / Axle

1- Plug 19 - Bearing Pin 37 - Lock Washer 55 - Sun Gear Shaft

2- Body 20 - Bolt (4 Used) 38 - Bolt (8 Used) 56 - Socket Bolt
3- O-Ring (2 Used) 21 - Gasket Ring 39 - Spring Guide (8 Used) 57 - Plain Washer
4- Seal Ring (2 Used) 22 - Bearing 40 - Spring (8 Used) 58 - Retaining Ring
5- Bearing (2 Used) 23 - Bushing 41 - Plate 59 - Retaining Ring
6- Seal Ring (2 Used) 24 - Hub Carrier 42 - Retaining Ring 60 - Washer
7- Shaft Seal 25 - O-Ring 43 - Piston 61 - Bolt (2 Used)
8- Bushing 26 - Bearing 44 - Nut (8 Used) 62 - Plug
9- Plug 27 - Wheel Stud (10 Used) 45 - U-Ring 63 - Planetary Carrier
10 - Bolt (2 Used) 28 - Stopper Bolt 46 - Ring 64 - Thrust Plate (3 Used)
11 - Nut (3 Used) 29 - Bolt (4 Used) 47 - U-Ring 65 - Planetary Gear (3 Used)
12 - Stud Bolt (3 Used) 30 - Bearing Pin 48 - Ring 66 - Needle Bearing (3 Used)
13 - Bolt (7 Used) 31 - Backup Ring 49 - Ring Gear 67 - Thrust Plate (3 Used)
14 - Double Joint Shaft 32 - O-Ring (2 Used) 50 - Plate (4 Used) 68 - Retaining Ring (3 Used)
15 - Shaft Seal 33 - Backup Ring 51 - Plate 69 - Friction Plate (3 Used)
16 - Bushing 34 - Retaining Ring (3 Used) 52 - Retaining Ring 70 - O-Ring (2 Used)
17 - Joint Housing 35 - Ring Gear 53 - Thrust Washer 71 - Plug
18 - Shim 36 - Bearing Nut 54 - Gear

NOTE: As for marked “ * ”, refer to page W3-5-6.

W3-5-13
 UNDERCARRIAGE / Axle

20 19 6 3 8 21 22 23 26 61 38 39 35 40 41 42 43 44 36 50

18

4
5
52

51
15 62
37
16 53

54
14 60
59
58
57

56
55

64
2
66
17

30 7 29 70 27 25 24 63 31 32 33 48 47 45 46 49 69 68 67 65

W1GL-03-05-029

W3-5-14
 UNDERCARRIAGE / Axle
Assemble Front Axle

1. Install the differential assembly to body (2) with 7. Apply grease on shim (18) then install it to the
bolts (10) (2 used), (13) (7 used) and nuts (11) (3 bearing pin (19) assembly.
used).
: 19 mm
: 250 N⋅m (25.5 kgf⋅m, 180 lbf⋅ft) 8. Install inner race of bearing (22) to joint housing
(17).
2

9. Install joint housing (17) to body (2) with the

bearing pins (19) and (30) assembly and secure
Differential them with bolts (20) (4 used) and bolts (29) (4
used).
: 24 mm
: 410 N⋅m (42 kgf⋅m, 300 lbf⋅ft)

10. Install gasket ring (21) and the outer races of

10
12 bearings (22, 26) to hub carrier (24).
11
13 11. Install the hub carrier (24) assembly to joint
W1GL-03-05-018

housing (17), install bushing (23) and the inner

2. Install shaft seals (7, 15) to body (2) and joint race of bearing (26).
housing (17).

3. Install seal rings (6) (2 used) and outer races (2

used) of bearing (5) to body (2).

4. Insert double joint shaft (14) into body (2).

IMPORTANT: Be sure to check double joint shaft

(14) and differential are connected.

5. Apply grease onto O-rings (70) (2 used) then

install O-rings to joint housing (17).

6. Apply grease onto O-rings (3) (2 used) then install

O-rings (3) (2 used), seal rings (4) (2 used) and
inner races (2 used) of bearing (5) to bearing pins
(19, 30).

W3-5-15
 UNDERCARRIAGE / Axle

38 39 35 40 41 42 43 44 36

24 32 33 48 47 45 46 49

W1GL-03-05-029

NOTE: There is no item no. 34 in the illustration.

W3-5-16
 UNDERCARRIAGE / Axle
12. Install ring gear (35) to hub carrier (24) and 18. Install bolt so that the dimension A should be 0.5
temporary tighten them with bearing nut (36). to 1.0 mm (0.02 to 0.04 in)
: 1200 to 1400 N⋅m : 10 mm
(112 to 143 kgf⋅m, 810 to 1030 lbf⋅ft) : 10 N⋅m (1.1 kgf⋅m, 8 lbf⋅ft)
44
13. Measure the preload of hub carrier (24).
Preload: 13 to 18 N⋅m
(1.3 to 1.8 kgf⋅m, 9.4 to 13 lbf⋅ft)

14. If the preload torque is within specified value,

38
remove bearing nut (36) and ring gear (35) again.

39
15. Install plate (41) and retaining ring (42) to ring
gear (35). A
43
W1GL-03-05-012
16. Install rings (46), (48) and U-rings (45, 47) to
piston (43).
19. After adjusting, secure nuts (44) (8 used) with
Apply grease after installing them.
LOCTITE # 242.
46 45 47 48

20. Install the ring gear (35) assembly to ring gear

(49) with retaining rings (34) (3 used).

49
34

43
W1GL-03-05-011
35

17. Install piston (43) to ring gear (35) and secure it

with bolts (38) (8 used), spring guides (39) (8 W1GL-03-05-013

used), springs (40) (8 used) and nuts (44) (8

used). 21. Install backup ring (33) and O-ring (32) to ring
gear (35).
Apply grease after installing them.

W1GL-03-05-032

33 32

W3-5-17
 UNDERCARRIAGE / Axle

35 36 50

52
51

37
53

54
14 60
59
58
57

56
55

64

66
17

25 24 63 31 32 49 69 68 67 65

W1GL-03-05-029

W3-5-18
 UNDERCARRIAGE / Axle
22. Apply grease on the both sides of O-ring (32) and 27. Install plate (50), friction plate (69) into the inside
backup ring (31) then install them into the groove of ring gear (49) in order, then install plate (51)
of joint housing (17). and secure them with retaining ring (52).

IMPORTANT: When installing the ring gear (35) 28. Insert sun gear shaft (55) into gear (54) and
assembly to joint housing (17), secure it with bolt (56).
tighten bearing nut (36) while : 10 mm
rotating the ring gear (35) assembly : 120 N⋅m (12.2 kgf⋅m, 88 lbf⋅ft)
in the direction of clockwise and
counterclockwise several times. 29. Install plain washer (57) to the top mounted with
socket bolt (56), lock them with retaining ring (58).
23. Install the ring gear (35) assembly to joint housing
(17) with bearing nut (36). 30. Install O-ring (25) into the groove on the outer
: 1200 to 1400 N⋅m race of hub carrier (24).
(122 to 143 kgf⋅m, 880 to 1030 lbf⋅ft)
31. Install thrust plate (64), needle bearing (66),
24. Lock bearing nut (36) with lock washer (37). planetary gear (65) and thrust plate (67) to
planetary carrier (63) in order and lock them with
25. Apply grease on thrust washer (53) and adhere it retaining ring (68). (3 places)
to bearing nut (36).
IMPORTANT: Install thrust plates (64, 67) with the
IMPORTANT: Readjust lock washer (37), if thrust wide side of L-link facing bearing
washer (53) cannot be adhered. side.

26. Insert gear (54) into double joint shaft (14). NOTE: When disassembling, washer (60) should
not be removed normally. When replace
planetary carrier (63), it should be replaced
together with washer (60).

W3-5-19
 UNDERCARRIAGE / Axle

61

62

24 63

W1GL-03-05-029

W3-5-20
 UNDERCARRIAGE / Axle
32. Install the planetary carrier (63) assembly to the
hub carrier (24) assembly and secure them with
bolts (61) (2 used).
: 8 mm
: 86 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

33. Install plug (1) into body (2) and install plug (62)
into planetary carrier (63).
Supply oil into the differential and the wheel hub,
then install plugs (9, 71).
: 8 mm
: 69 N⋅m (7.0 kgf⋅m, 50 lbf⋅ft)
: 22 mm
: 79 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)
Differential
Front: 11.0 L (2.9 US gal.)
Rear: 13.0 L (3.4 US gal.)
Wheel Hub Front, Rear:
Each 2.0 L (0.5 US gal.) ×2

34. After assembling the front axle, install straight

edge to adjust toe-in.

Straight Edge
A1

A2

Straight Edge Tie Rod End Tie Rod End

W1GL-03-05-017

Measure the dimension A1 between the notch marked

on straight edge, and measure the dimension A2 after
rotating both sides of wheel hub to 180°. Then adjust
with tie rod end so that dimension of A1 and A2 is the
same.

W3-5-21
 UNDERCARRIAGE / Axle
DISASSEMBLE REAR AXLE

1 2
W1GL-03-05-009

3 4

16
15
14

2
13
12
11
10
5 8
7 9

17
6 18
25 21
26 20 19
27 22
30 24 23

32 31 29 28

33
34
35 37
36 49

47 48

39 50

45 46
44 51
42 43

41
40
57 53 52
55 54
56
38 W1GL-03-05-010

W3-5-22
 UNDERCARRIAGE / Axle

1- Brake Pipe (2 Used) 16 - Bearing 31 - Ring Gear 45 - O-Ring

2- Bolt (12 Used) 17 - Wheel Stud (10 Used) 32 - Retaining Ring (3 Used) 46 - Sun Gear Shaft
3- Plug 18 - Bolt (16 Used) 33 - Backup Ring 47 - Retaining Ring
4- Body 19 - Ring 34 - O-Ring (2 Used) 48 - Washer
5- Plug 20 - U-Ring 35 - Backup Ring 49 - Bolt (2 Used)
6- Axle Shaft 21 - Nut (8 Used) 36 - Ring 50 - Plug
7- Valve Assembly 22 - Piston 37 - U-Ring 51 - Planetary Carrier
8- Plug (4 Used) 23 - Retaining Ring 38 - Ring Gear 52 - Thrust Plate (3 Used)
9- Knuckle 24 - Plate 39 - Plate (3 Used) 53 - Planetary Gear (3 Used)
10 - Screen Sheet 25 - Spring (8 Used) 40 - Plate 54 - Needle Bearing (3 Used)
11 - Gasket Ring 26 - Spring Guide (8 Used) 41 - Retaining Ring 55 - Thrust Plate (3 Used)
12 - Bearing 27 - Bolt (8 Used) 42 - Seal 56 - Retaining Ring (3 Used)
13 - Bushing 28 - Lock Washer 43 - Thrust Washer 57 - Friction Plate (2 Used)
14 - Hub Carrier 29 - Bearing Nut 44 - Gear 58 - Plug
15 - O-Ring 30 - Plug

W3-5-23
 UNDERCARRIAGE / Axle

1 2
W1GL-03-05-009

3 4

16
15
14

2
13
12
11
10
5 8
7 9

17
6 18
25 21
26 20 19
27 22
30 24 23

32 31 29 28

33
34
35 37
36 49

47 48

39 50

45 46
44 51
42 43

41
40
57 53 52
55 54
56
38 W1GL-03-05-010

W3-5-24
 UNDERCARRIAGE / Axle
Disassemble Rear Axle

1. Disconnect brake pipes (1) (2 used).

: 19 mm 8. Remove the ring gear (31) assembly from hub
carrier (14).
2. Remove plugs (3, 5) and (50, 58) to drain oil.
: 8 mm、22 mm 9. Remove retaining rings (32) (3 used) to remove
the ring gear (31) assembly from ring gear (38).
3. Remove bolts (49) (2 used) to remove planetary
carrier (51) from hub carrier (14).
: 8 mm 32 38

14

38

49

49 W1GL-03-05-013
51 10. Remove nuts (21) (8 used) from the ring gear (31)
assembly to remove bolts (27) (8 used), spring
guides (26) (8 used) and springs (25) (8 used).
58
: 10 mm
50 W1GL-03-05-006

11. Remove piston (22) from ring gear (31).

4. Remove retaining rings (56) (3 used) to remove
thrust plates (55) (3 used), planetary gears (53) (3
12. Remove ring (19), U-ring (20), ring (36) and
used), needle bearings (54) (3 used) and thrust
U-ring (37) from piston (22).
plates (52) (3 used) from planetary carrier (51).

13. Remove retaining ring (23) and plate (24) from

NOTE: When disassembling, the washer (48)
ring gear (31).
should not be removed normally. When
replace planetary carrier (51), it should be
replaced together with washer (60). 14. Remove backup ring (33) and O-ring (34) from
ring gear (31).
5. Remove the sun gear (44) assembly and gear
(44) assembly from axle shaft (6). 15. Remove O-ring (15) from hub carrier (14).

6. Remove retaining ring (41) from ring gear (38) to

remove plate (40), plates (39) (3 used) and
friction plates (57) (2 used).

7. Remove thrust plate (43) and lock washer (28)

from bearing nut (29).

W3-5-25
 UNDERCARRIAGE / Axle

W1GL-03-05-009

16
14

12
11
10

6 18

34
35

W1GL-03-05-010

W3-5-26
 UNDERCARRIAGE / Axle
16. Remove O-ring (34) and backup ring (35) from
knuckle (9).

17. Remove the hub carrier (14) assembly from

knuckle (9).

18. Remove the outer races of bearings (12, 16) and

bushing (13) from hub carrier (14).

19. Pull axle shaft (6) out from body (4).

20. Remove the inner race of bearing (12), gasket

ring (11) and screen sheet (10) from knuckle (9).

IMPORTANT: Put mating marks on body (4) and

knuckle (9).

21. Remove bolts (18) (16 used) to remove knuckle

(9) from body (4).
: 27 mm

W3-5-27
 UNDERCARRIAGE / Axle
ASSEMBLE REAR AXLE

1 2
W1GL-03-05-009

4 9 18 10 11 12 13 14 49 15 16 36 37 24 20 19 29 57 39 40 41 38

50

44
28
51
6

42
45
47
48
33
46
34
52

35 54

43

56
53

55

W1GL-03-05-031

7 17 27 26 25 31 22 23 21

W3-5-28
 UNDERCARRIAGE / Axle

1- Brake Pipe (2 Used) 16 - Bearing 31 - Ring Gear 45 - O-Ring

2- Bolt (12 Used) 17 - Wheel Stud (10 Used) 32 - *Retaining Ring (3 Used) 46 - Sun Gear Shaft
3- *Plug 18 - Bolt (16 Used) 33 - Backup Ring 47 - Retaining Ring
4- Body 19 - Ring 34 - O-Ring (2 Used) 48 - Washer
5- *Plug 20 - U-Ring 35 - Backup Ring 49 - Bolt (2 Used)
6- Axle Shaft 21 - Nut (8 Used) 36 - Ring 50 - Plug
7- Valve Assembly 22 - Piston 37 - U-Ring 51 - Planetary Carrier
8- *Plug (4 Used) 23 - Retaining Ring 38 - Ring Gear 52 - Thrust Plate (3 Used)
9- Knuckle 24 - Plate 39 - Plate (3 Used) 53 - Planetary Gear (3 Used)
10 - Screen Sheet 25 - Spring (8 Used) 40 - Plate 54 - Needle Bearing (3 Used)
11 - Gasket Ring 26 - Spring Guide (8 Used) 41 - Retaining Ring 55 - Thrust Plate (3 Used)
12 - Bearing 27 - Bolt (8 Used) 42 - Seal 56 - Retaining Ring (3 Used)
13 - Bushing 28 - Lock Washer 43 - Thrust Washer 57 - Friction Plate (2 Used)
14 - Hub Carrier 29 - Bearing Nut 44 - Gear 58 - Plug
15 - O-Ring 30 - *Plug

NOTE: As for marked “ * ”, refer to page W3-5-22.

W3-5-29
 UNDERCARRIAGE / Axle

1 2
W1GL-03-05-009

4 9 18 10 11 12 13 14 49 15 16 36 37 24 20 19 29 57 39 40 41 38

50

44
28
51
6

42
45
47
48
33
46
34
52

35 54

43

56
53

55

W1GL-03-05-031

7 17 27 26 25 31 22 23 21

W3-5-30
 UNDERCARRIAGE / Axle
Assemble Rear Axle

1. Apply THREEBOND on the mating surface on 9. Install plate (24) and retaining ring (23) to ring
knuckle (9) and body (4). gear (31).

2. Align the mating marks, install knuckle (9) onto 10. Install rings (19, 36) and U-rings (20, 37) to piston
body (4) with bolts (18) (16 used). (22).
: 27 mm Apply grease after installing them.
: 390 N⋅m (40 kgf⋅m, 209 lbf⋅ft)

22 19 20 37 36
3. Install screen sheet (10) and seal (42) to knuckle
(9).

4. Install the outer race of bearing (12), bushing (13)

and the outer race of bearing (16) to hub carrier
(14) in order, then install gasket ring (11) together.

5. Install the inner race of bearing (12) to knuckle

(9).
W1GL-03-05-011
6. Install ring gear (31) to hub carrier (14), then
temporarily tighten it with bearing nut (29). 11. Install piston (22) to the ring gear (31) assembly
: 1200 to 1400 N⋅m and secure it with bolts (27) (8 used), spring
(122 to 143 kgf⋅m, 880 to 1030 lbf⋅ft) guides (26) (8 used), springs (25) (8 used) and
nuts (21) (8 used).
7. Measure the preload of hub carrier (14). : 10 mm
Preload: 13 to 18 N⋅m
(1.3 to 1.8 kgf⋅m, 9.4 to 13 lbf⋅ft) 12. Install bolt so that the dimension A should be 0.5
to 1.0 mm (0.02 to 0.04 in).
8. If the preload is within specified value, remove : 10 mm
bearing nut (29) and ring gear (31). : 10 N⋅m (1.1 kgf⋅m, 8 lbf⋅ft)

A
22 37 36
W1GL-03-05-012

13. After adjusting, secure nuts (21) (8 used) with

LOCTITE #242.

W3-5-31
 UNDERCARRIAGE / Axle

W1GL-03-05-009

4 14 29 57 39 40 41 38

44
28

45

33
46
34

35

43

W1GL-03-05-031

31

W3-5-32
 UNDERCARRIAGE / Axle
14. Secure the ring gear (31) assembly to ring gear 18. Lock bearing nut (29) with lock washer (28).
(38) with retaining rings (32) (3 used).
19. Apply grease on thrust washer (43) and adheres
to knuckle (9).
38
32
CAUTION: Readjust lock washer (28) if
31 thrust washer (43) is not adhered on knuckle
(9).

20. Install O-ring (45) to sun gear shaft (46), then

install sun gear (46) to gear (44).
W1GL-03-05-013
21. Install plate (39) and friction plate (57) into the
inside of ring gear (38) in order, install plate (40)
secure it with retaining ring (41).
15. Install backup ring (33) and O-ring (34) to ring
gear (31).
22. Insert axle shaft (6) into body (4) inside.
Apply grease after installing them.

IMPORTANT: Be sure to check that axle shaft (6)

and differential are connected.

W1GL-03-05-032

35 34

16. Apply grease on both surfaces of backup ring (35)

and O-ring (34), then install them to the groove of
knuckle (9).

IMPORTANT: When installing the ring gear (31)

assembly to knuckle (9), tighten
bearing nut (36) while rotating the
ring gear (31) assembly in the
direction of clockwise and
counterclockwise several times.

17. Install the ring gear (31) assembly to knuckle (9)

with bearing nut (29).
: 1200 to 1400 N⋅m
(122 to 143 kgf⋅m, 880 to 1030 lbf⋅ft)

W3-5-33
 UNDERCARRIAGE / Axle

1
W1GL-03-05-009

4 14 49 15

44

51

47
48

52
54

56
53

55

W1GL-03-05-031

W3-5-34
 UNDERCARRIAGE / Axle
23. Install thrust plate (52), needle bearing (54),
planetary gear (53) and thrust plate (55) to
planetary carrier (51) in order and lock them with
retaining ring (56). (3 places)

IMPORTANT: Install thrust plates (52, 55) with the

wide side of L-link facing bearing
side.

24. Install the gear (44) assembly to the ring gear (38)
inside.

25. Install O-ring (15) to the groove of outrace on hub

carrier (14), then secure the planetary carrier (51)
assembly with mounting bolts (49) (2 used).
: 8 mm
: 86 N⋅m (8.8 kgf⋅m, 64 lbf⋅ft)

26. Connect brake pipes (1) (2 used) to body (4).

: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5lbf⋅ft)

27. Install plug (3) to body (4) and install plug (50) to
planetary carrier (63). Supply oil to differential and
wheel hub inside.
Differential
Front: 11.0 L (2.9 US gal.)
Rear: 13.0 L (3.4 US gal.)
Wheel Hub Front, Rear:
Each 2.0 L (0.5 US gal.) × 2

W3-5-35
 UNDERCARRIAGE / Axle
DISASSEMBLE DIFFERENTIAL

1
2
3
4
5
6 8
7
9
10
11
12

13
16
14

15

12 11
17

20

18
18 19
19 21

27
24
25 16
22
26 26 23
18
19
25
28 19 18
T1GL-03-05-007

1 - Nut 8- Housing 15 - Drive Pinion 22 - Spring Pin (4 Used)

2 - Washer 9- Bolt (4 Used) 16 - Bevel Gear 23 - Spring Pin (4 Used)
3 - Flange 10 - Cap (2 Used) 17 - Roll Pin (2 Used) 24 - Differential Case
4 - Guard 11 - Bearing (2 Used) 18 - Thrust Washer (4 Used) 25 - Thrust Washer (2 Used)
5 - Seal 12 - Nut (2 Used) 19 - Pinion Gear (4 Used) 26 - Side Gear (2 Used)
6 - Bearing 13 - Shim 20 - Socket Bolt (8 Used) 27 - Spider
7 - Ring 14 - Bearing 21 - Socket Bolt (4 Used) 28 - Differential Case

W3-5-36
 UNDERCARRIAGE / Axle
Disassemble Differential

1. Remove nut (1) and washer (2) from drive pinion 8. Remove ring (7) and the inner race of bearing
(15). (14) from drive pinion (15).
: 46 mm
9. Remove the outer race of bearing (6) and seal (5)
2. Remove flange (3) from drive pinion (15). from housing (8).

3. Tap and remove roll pins (17) (2 used) from cap 10. Remove socket bolts (20) (8 used) and (21) (4
(10). used) from bevel gear (16).
: 10 mm, 14 mm
4. Remove nuts (12) (2 used) from caps (10) (2 : 19 mm, 24 mm
used).
11. Pull the spring pin (23) assembly (4 used) out
IMPORTANT: Be sure to put mating marks before from differential cases (28, 24).
removing cap (10) and differential.
5. Remove bolts (9) (4 used) to remove caps (10) (2 12. Remove differential case (28) from differential
used) from housing (8). case (24).
: 22 mm
13. Remove side gear (26), pinion gears (19) (4 used),
6. Remove the differential assembly from housing thrust washers (18) (4 used), (25) (2 used) and
(8). spider (27) from differential case (24).

7. Pull drive pinion (15) out from housing (8) and 14. Remove differential case (24) from bevel gear
remove the inner race of bearing (6) together. (16).

15. Pull spring pins (22) (4 used) out from spring pins
(23) (4 used).

W3-5-37
 UNDERCARRIAGE / Axle
ASSEMBLE DIFFERENTIAL

15 1 2 3

4
5

7
8

13

18 14

19 16
20, 21

24

27

17

W1GL-03-05-034
12 10 11 25 26 23 22

1 - Nut 8- Housing 15 - Drive Pinion 22 - Spring Pin (4 Used)

2 - Washer 9- *Bolt (4 Used) 16 - Bevel Gear 23 - Spring Pin (4 Used)
3 - Flange 10 - Cap (2 Used) 17 - Roll Pin (2 Used) 24 - Differential Case
4 - Guard 11 - Bearing (2 Used) 18 - Thrust Washer (4 Used) 25 - Thrust Washer (2 Used)
5 - Seal 12 - Nut (2 Used) 19 - Pinion Gear (4 Used) 26 - Side Gear (2 Used)
6 - Bearing 13 - Shim 20 - Socket Bolt (8 Used) 27 - Spider
7 - Ring 14 - Bearing 21 - Socket Bolt (4 Used) 28 - Differential Case

NOTE: As for marked “ * ”, refer to page W3-5-36.

W3-5-38
 UNDERCARRIAGE / Axle
Assemble Differential

1. Install differential case (24) to bevel gear (16) with 9. Align the matching marks to install the differential
aligning the mounting holes. case (28) assembly and install it to the differential
case (24) assembly.
2. Place bevel gear (16) on a workbench with facing
lower side. 10. Drive spring pin (22) into spring pins (23) (4 used)
until spring pin (22) touch differential case (28).
IMPORTANT: When installing thrust washer (25),
be sure to align the edge with the 11. Install the differential assembly to bevel gear (16)
groove on the differential case. with socket bolts (20) (8 used) and (21) (4 used).
When installing thrust washer (18), : 10 mm, : 19 mm
be sure to make its protrusion at : 25 N⋅m (12.7 kgf⋅m, 92 lbf⋅ft)
right angles with differential case : 14 mm, ： 24 mm
(28). : 315 N⋅m (32.0 kgf⋅m, 230 lbf⋅ft)

3. Apply grease on the thrust surface, then install 12. Install the outer race of bearings (6, 14) and shim
thrust washers (25) (4 used) to side gears (26) (2 (13) to housing (8).
used).
13. Install the inner race of bearing (14) to drive pinion
4. Install pinion gears (19) (4 used) and thrust (15).
washers (18) (4 used) to spider (27) applied
grease.
14. Install the drive pinion (15) assembly to housing
(8), then install ring (7) and the inner race of
5. Drive spring pins (23) (4 used) to differential case bearing (6).
(28) until it touch the mating surface of differential
case (24).
15. Install seal (5) and flange (3) to the housing (8)
assembly.

6. Install the side gear (26) assembly to differential 16. Install flange (3) to drive pinion (15) with washer
case (24). (2) and nut (1).
: 46 mm
7. Install the spider (27) assembly to differential : 600 N⋅m (60 kgf⋅m, 430 lbf⋅ft)
case (24).

8. Apply grease on the side gear (26) assembly,

then install it to differential case (28).

W3-5-39
 UNDERCARRIAGE / Axle

15

16

17

W1GL-03-05-034
12 10 11

W3-5-40
 UNDERCARRIAGE / Axle
17. Install the inner race of bearings (11) (2 used) to
the differential.

18. Install roll pins (17) (2 used) to caps (10) (2 used).

19. Install the outer races (2 used) of bearing (11) to

the differential.

20. Insert the differential assembly into housing (8)

and install nuts (12) (2 used) together.

21. Install the differential assembly with caps (10) (2

used) and bolts (9) (4 used).
: 22 mm
: 195 N⋅m (20 kgf⋅m, 145 lbf⋅ft)

22. After adjusting the backlash and preload of bevel

gear (16) and drive pinion (15), secure nut (12)
with roll pins (17) (2 used).
• The backlash is stamped on side surface of bevel
gear (16) and the end of drive pinion (15).
• Preload of drive pinion (15)
1.0 to 1.4 N⋅m (0.1 to 0.14 kgf⋅m, 0.7 to 1.0 lbf⋅ft)

W3-5-41
 UNDERCARRIAGE / Axle
DISASSEMBLE STEERING CYLINDER

2 4 2

T1GL-03-05-020

1 3, 24 23 3, 24 1

18 19
12 17
15 16
14
12 13
10
11
10
9
8

6
7
5

23

20

22
21 T1GL-03-05-008

1 - Tie Rod (2 Used) 7- U-Ring (2 Used) 13 - Seal Ring 19 - Guide Ring

2 - Lock Nut (2 Used) 8- Bolt (4 Used) 14 - O-Ring 20 - Shim
3 - Joint Parts (2 Used) 9- Cover 15 - Piston 21 - Cover
4 - Differential Housing 10 - O-Ring (2 Used) 16 - O-Ring 22 - Bolt (4 Used)
5 - Ring (4 Used) 11 - Cylinder 17 - Plate 23 - Piston Rod
6 - Scraper Ring (2 Used) 12 - Half Ring (2 Used) 18 - Retaining Ring 24 - Plug (2 Used)

W3-5-42
 UNDERCARRIAGE / Axle
Disassemble Steering Cylinder

1. Loosen lock nuts (2) (2 used) to remove plugs

(24) (2 used) from joint parts (3), then remove tie
rods (1) (2 used) from piston rods (23) (2 used).
: 19 mm, 41 mm, 74 mm
: 4 mm

2. Remove bolts (8) (4 used) and bolts (22) (4 used)

to remove covers (9, 21) from differential housing
(4).
: 24 mm

3. Pull the piston rod (23) assembly out from

differential housing (4).

4. Remove cylinder (11) and O-rings (10) (2 used)

from differential housing (4).

5. Secure the piston rod (23) assembly on a vice

with retaining ring (18) facing up.

6. Remove seal ring (13), O-ring (14) and guide ring

(19) from piston (15).

7. Remove retaining ring (18) from piston (15) to

remove plate (17) and half ring (12).

8. Pull piston (15) out to retaining ring (18) side from

piston rod (23).

9. Remove half ring (12) from piston rod (23).

10. Remove O-ring (16) from piston (15).

11. Remove rings (5) (4 used) from cover (9) and

cover (16).

12. Remove scraper rings (6) (2 used) and U-rings (7)

(2 used) from covers (9, 21).

W3-5-43
 UNDERCARRIAGE / Axle
ASSEMBLE STEERING CYLINDER

2 4 2

T1GL-03-05-020

1 3, 24 23 3, 24 1

23 15 19 13 14 4 11 18 10 20 9, 21, 8, 22

12 16 12 17 5 7 6

W1GL-03-05-014

1 - Tie Rod (2 Used) 7- U-Ring (2 Used) 13 - Seal Ring 19 - Guide Ring

2 - Lock Nut (2 Used) 8- Bolt (4 Used) 14 - O-Ring 20 - Shim
3 - Joint Parts (2 Used) 9- Cover 15 - Piston 21 - Cover
4 - Differential Housing 10 - O-Ring (2 Used) 16 - O-Ring 22 - Bolt (4 Used)
5 - Ring (4 Used) 11 - Cylinder 17 - Plate 23 - Piston Rod
6 - Scraper Ring (2 Used) 12 - Half Ring (2 Used) 18 - Retaining Ring 24 - Plug (2 Used)

W3-5-44
 UNDERCARRIAGE / Axle
Assemble Steering Cylinder

1. Install O-ring (14), guide ring (19) to the outer 11. Insert shim (20) to cover (21) in accordance with
diameter of piston (15) and install O-ring (16) into the amount of clearance.
the inner diameter of piston (15).
12. Remove cover (9) installed temporarily from
2. Heat seal ring (13) with an oil bath (Approx. 90°), differential housing (4), then install the piston rod
then install it onto piston (15) (on the upper side of (23) assembly.
O-ring (14)).
13. Install cover (9) and cover (21) to both sides of
3. Secure piston rod (23) on a vice with the retaining differential housing (4) then secure them with the
ring (18) side facing up. mounting bolts (8) (4 used) and (22) (4 used).
: 24 mm
4. Install half ring (12) to the groove of piston rod : 300 N⋅m (30.5 kgf⋅m, 220 lbf⋅ft)
(23) lower side.
14. Connect tie rods (1) (2 used) to piston rod (23).
5. Apply grease on the inner diameter of piston (15), : 4 mm
install the piston (15) assembly to piston rod (23). : 18 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft)
: 74 mm
6. Install half ring (12) and plate (17) into the inside : 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
of piston (15), then mount them to retaining ring
(18). IMPORTANT: Be sure to install piston rod (23) so
that the dimensions of part A on
7. Install rings (5) (4 used) to covers (9, 21). both sides are the same.

8. Install U-rings (7) (2 used) and scraper rings (6) (2

used) to covers (9, 21).

IMPORTANT: Be sure to install U-ring (7) with the

U section side facing the ring (5)
side.

9. Install O-rings (10) (2 used) to cylinder (11), then

A A
install the cylinder to differential housing (4).
W1GL-03-05-016

10. Temporarily install cover (9) to differential housing

(4), then install cover (21) and check the 15. After adjusting, mount them with lock nut (2).
clearance between the mounting surfaces of : 19 mm
differential housing (4). : 70 to 80 N⋅m
(7.0 to 8.0 kgf⋅m, 50 to 58 lbf⋅ft)

W3-5-45
 UNDERCARRIAGE / Axle
(Blank)

W3-5-46
 UNDERCARRIAGE / Axle Lock Cylinder
REMOVE AND INSTALL AXLE LOCK
CYLINDER

CAUTION: Be sure to bleed air from hydrau-

lic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)

In this section, the procedure starts on the premise that 1

the front axle has already been removed. 2

Removal
3
1. Disconnect pipes (1) (2 used) from check valve (2).
Cap the open ends.

IMPORTANT: Do not remove check valve (2). The 4

rod (6) will drop when cap is re-
moved because the air supplying.
5
2. Remove socket bolts (7) (2 used), then install
eyebolts (M8, Pitch 1.25 mm) to the removed bolt 6
holes.
: 6 mm W1F3-03-06-003

CAUTION: Axle lock cylinder weight:

61 kg (135 lb)
7
3. Attach a wire rope on eyebolt to hold it by crane.

4. Remove bolts (5) (4 used) from chassis (4).

: 24 mm
2
5. Lower axle lock cylinder (3) while lifing it off chas-
sis (4), by crane.

W1F3-03-06-002

W3-6-1
 UNDERCARRIAGE / Axle Lock Cylinder

Installation
1. Remove socket bolts (7) (2 used), then install
eyebolts (M8, Pitch 1.25 mm) to the removed bolt
holes. 7

CAUTION: Axle lock cylinder weight:

61 kg (135 lb)
2
2. Hoist axle lock cylinder (3) and place it on chassis
(4) by crane. Install them with bolts (5) (4 used).
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)

3. Remove eyebolt, then install socket bolts (7) (2 3

used).
: 6 mm
: 20 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft) W1F3-03-06-002

1
4. Connect pipes (1) (2 used). 2
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
3

W1F3-03-06-003

W3-6-2
 UNDERCARRIAGE / Axle Lock Cylinder
(Blank)

W3-6-3
 UNDERCARRIAGE / Axle Lock Cylinder
DISASSEMBLE AND ASSEMBLE AXLE
LOCK CYLINDER

2
A

1
3

W1F3-03-06-002
7 View A

5 4
W1F3-03-06-001

1 - Socket Bolt (4 Used) 3 - Housing 5 - Retaining Ring 7 - Seal

2 - Check Valve 4 - Rod 6 - Dust Seal

W3-6-4
 UNDERCARRIAGE / Axle Lock Cylinder
Disassemble Axle Lock Cylinder Assemble Axle Lock Cylinder
• Be sure to read “Precautions for Disassembly and • Be sure to read “Precautions for Disassembly and
Assembly” thoroughly on page W1-1-1 before Assembly” thoroughly on page W1-1-1 before
starting any repair work. starting any repair work.

CAUTION: Axle lock cylinder weight: CAUTION: Housing (3) weight: 35 kg (78 lb)
61 kg (135 lb) Rod (4) weight: 23.5 kg (52 lb)

1. Place the axle lock cylinder on a workbench 1. Install seal (7), dust seal (6) and retaining ring (5)
horizontally. to housing (3).

2. Remove socket bolts (1) (4 used) to remove check IMPORTANT: Apply hydraulic oil to the inner sur-
valve (2). face of housing (3) and seals (6, 7).

2. Install rod (4) to housing (3).

CAUTION: Housing (3) weight: 35 kg (78 lb)
Rod (4) weight: 23.5 kg (52 lb)
CAUTION: Axle lock cylinder weight:
3. Supply air to the hole of the housing (3) port to 61 kg (135 lb)
push rod (4) out.
3. Temporarily install check valve (2) to the housing
4. Remove retaining ring (5) from housing (3) to re- (3) assembly with socket bolts (1) (2 used).
move dust seal (6, 7).

W3-6-5
 UNDERCARRIAGE / Axle Lock Cylinder
(Blank)

W3-6-6
 UNDERCARRIAGE / Operate-Check Valve
REMOVE AND INSTALL OPERATE-CHECK
VALVE (FOR AXLE LOCK CYLINDER)

CAUTION: Be sure to bleed air from hydrau-

lic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil 2
Tank” on page W1-4-1.) 1

Removal
Axle Lock Cylinder
1. Disconnect pipes (2) (2 used) from operate-check
valve (1). Cap the open ends.
: 19 mm

2. Remove socket bolts (3) (4 used) to remove op-

erate-check valve (1) from the axle lock cylinder.
Cap the open ends of the axle lock cylinder.
: 6 mm

W1F3-03-06-003
Installation
1. Install operate-check valve (1) to the axle lock
cylinder with socket bolts (3) (4 used).
: 6 mm
: 20 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft) 3

2. Connect pipes (2) (2 used).

: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
1

W1F3-03-06-002

Axle Lock Cylinder

W3-7-1
 UNDERCARRIAGE / Operate-Check Valve
CONSTRUCTION OF OPERATE-CHECK
VALVE (FOR AXLE LOCK CYLINDER)

1 2 3 4 5 6 7 8

T1F3-03-10-002

Wrench Size Tighten Torque

Item Parts Name Q’ty Remarks
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 1 ：27 120±12 (12±0.12) (89±8.9)
2 O-Ring 1 1B P18
3 Piston 1
4 Body 1
5 Sleeve 1
6 Poppet 1
7 O-Ring 1 1B P26
8 Spring 1
9 Plug 1 ：36 360±36 (36±3.6) (265±26.5)

W3-7-2
 UNDERCARRIAGE / Propeller Shaft
REMOVE AND INSTALL PROPELLER
SHAFT
Preparation
1. Park the machine on a solid level surface. Lower
the bucket to the ground.

2. Lower the blade and outrigger to the ground to-

gether.

3. Put the blocks under the front and rear wheels to

secure the machine.

M202-04-002

W3-8-1
 UNDERCARRIAGE / Propeller Shaft
Remove and Install Propeller Shaft

Front Axle

Travel Motor Rear Axle

1
2

4
5

W1GL-03-08-001

View A
3 6
7 2 1
5
C

10

W1GL-03-05-005

8 Part B 9
4

Section C 15
13 12 11 2
16 14

17
T1GL-03-05-003

T202-03-03-002

W3-8-2
 UNDERCARRIAGE / Propeller Shaft

5 18
19
Detail of Part B

20

W1GL-03-08-002

1 - Nut (8 Used) 6- Bearing Strap 11 - Spline Seal 16 - Retaining Ring

2 - Propeller Shaft 7- Flange 12 - Grease Fitting 17 - Spider
3 - Bolt (2 Used) 8- Nut (8 Used) 13 - Fork 18 - Bearing Assembly
4 - Bracket 9- Bolt (4 Used) 14 - Spider 19 - Yoke
5 - Propeller Shaft 10 - Flange 15 - Needle Bearing (12 Used) 20 - Nut

W3-8-3
 UNDERCARRIAGE / Propeller Shaft

Front Axle

Travel Motor Rear Axle

1
2

4
5

W1GL-03-08-001

View A
3 6
7 2 1
5
C

10

W1GL-03-05-005

8 Part B 9
4

Section C 15
13 12 11 2
16 14

17
T1GL-03-05-003

T202-03-03-002

W3-8-4
 UNDERCARRIAGE / Propeller Shaft
Removal

IMPORTANT: Be sure to remove grease fitting (12) 5. Remove nuts (8) (8 used) from flange (7).
with the grease in inside drained. : 14 mm
1. Remove grease fitting (12).

IMPORTANT: Take care not to remove propeller CAUTION: The propeller shaft (5) assembly
shaft (2) individually. If it is to be weight: 30 kg (66 lb)
removed individually, the spline seal
(11) should be damaged. Be sure to 6. Remove bolts (3) (2 used) from the bearing as-
remove propeller shaft (2) and fork sembly (18), then lower it on bracket (4).
(13) together as assembly. : 17 mm
2. Remove nuts (1) (8 used) from flange (10).
: 14 mm 7. Move propeller shaft (5) to bracket (4) side, then
pull it out.

CAUTION: The propeller shaft (2) assembly IMPORTANT: Do not remove bearing assembly
weight: 20 kg (44 lb) (18). If removal is necessary, be sure
to follow procedures are provided.
3. Insert bar into the clearance between propeller Discard the removed bearing as-
shaft (2) and flange (10) then pry it to fork (13) sembly (18).
side and lower propeller shaft (2) on the ground.
8. Remove nut (20) from propeller shaft (5) to re-
IMPORTANT: When removing the propeller shaft move yoke (19).
assembly, take care not to remove : 32 mm
needle bearings (15) (2 used).
4. Remove bolts (9) (4 used) to remove bearing 9. Remove bearing assembly (18) from propeller
strap (6) and propeller shaft (2). shaft (5).
: 9 mm
5 18 19

20

Detail of Part B W1GL-03-08-002

W3-8-5
 UNDERCARRIAGE / Propeller Shaft

Front Axle

Travel Motor Rear Axle

1
2

4
5

W1GL-03-08-001

View A
3 6
7 2 1
5
C

10

W1GL-03-05-005

8 Part B 9
4

Section C 15
13 12 11 2
16 14

17
T1GL-03-05-003

T202-03-03-002

W3-8-6
 UNDERCARRIAGE / Propeller Shaft
Installation

1. Install bearing assembly (18) to propeller shaft

(5). CAUTION: The propeller shaft (2) assembly
weight: 20 kg (44 lb)

5 18 19
6. Install the propeller shaft (2) assembly to yoke
(19) with bolts (9) (4 used) and bearing strap (6).
20 : 11 mm
: 61 to 81 N⋅m
(6.3 to 8.2 kgf⋅m, 46 to 59 lbf⋅ft)

7. Install the flange (10) side to the transmission

with nuts (1) (8 used).
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
Detail of Part B W1GL-03-08-002

8. Install grease fitting (12) to fork (13) then supply

2. Install yoke (19) to propeller shaft (5) then tighten grease.
it with nut (20).
: 32 mm
: 370 to 440 N⋅m
(38 to 45 kgf⋅m, 275 to 325 lbf⋅ft)

CAUTION: The propeller shaft (5) assembly

weight: 30 kg (66 lb)

3. Insert the yoke (19) mounting side of propeller

shaft (5) into bracket (4) then install the flange (7)
side to the transmission with nuts (8) (8 used).
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

4. Install the propeller shaft (5) assembly to bracket

(4) with bolts (3) (2 used).
: 17 mm
: 65 N⋅m (6.6 kgf⋅m, 48 lbf⋅ft)

IMPORTANT: Check that inside of needle bearings

(15) (2 used) has no contaminant.
Take care not to contaminate the
needle bearing because it maybe
shorten the service life of the needle
bearing.
5. Apply grease on needle bearings (15) (2 used)
and install them to spider (14).

W3-8-7
 UNDERCARRIAGE / Propeller Shaft
(Blank)

W3-8-8
 MEMO

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 SECTION 4
FRONT ATTACHMENT

— CONTENTS —
Group 1 Front Attachment Group 3 Hose-Rupture Safety Valve
Hydraulic Circuit Pressure Remove and Install
Release Procedure...............................W4-1-1 Hose-Rupture Safety Valve.................. W4-3-1
Remove and Install Monoblock Boom Construction of
Front Attachment ..................................W4-1-2 Hose-Rupture Safety Valve.................. W4-3-4
Remove and Install 2-Piece Boom
Front Attachment ................................W4-1-10
Group 4 Operate-Check Valve
Remove and Install Operate-Check
Maintenance Standard .........................W4-1-18
Valve (for Blade/Stabilizer) ................... W4-4-1
Standard Dimensions for
Construction of Operate-Check
Arm and Bucket Connection...............W4-1-21
Valve (for Blade/Stabilizer) ................... W4-4-2
Standard Dimensions for
Arm and Boom Connection ................W4-1-22

Group 2 Cylinder
Remove and Install Cylinder
(Monoblock Boom, 2-Piece Boom).......W4-2-1
Disassemble Cylinder
(Boom (Monoblock/2-Piece),
Positioning, Bucket)............................W4-2-20
Assemble Cylinder
(Boom (Monoblock/2-Piece),
Positioning, Bucket)............................W4-2-22
Disassemble Cylinder (Arm) ................W4-2-24
Assemble Cylinder (Arm) .....................W4-2-26
Disassemble Cylinder
(Stabilizer, Blade)................................W4-2-28
Assemble Cylinder
(Stabilizer, Blade)................................W4-2-30
Maintenance Standard .........................W4-2-32

CDBW-4-1
(Blank)

CDBW-4-2
 FRONT ATTACHMENT / Front Attachment
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE

NOTE: Do not start the engine. Operate pilot

pump with the power from battery to de-
liver pilot pressure to the spool of control
valve. 6 1
5
1. Push pilot control shut-off lever (1) forward
(UNLOCK position).

2. Pull engine stop knob (2) fully out and secure it

using special tool (ST 7334).

IMPORTANT: Battery will deplete. Be sure to op-

erate key switch for short period.
3. Turn the key switch to START position and oper-
4
ate the lever for releasing pressure from hydrau-
lic circuit 4 to 5 times.

Releasing Circuit Operating Lever

Boom/Bucket Right Control Lever (5)
Arm Left Control Lever (4) MCBB-01-016

*Positioning/
Attachment Pedal (3) 3 2
Auxiliary
*Stabilizer/Blade Stabilizer/Blade Lever (6)
NOTE: *: Optional

4. Push engine stop knob (2) in.

W4-1-1
 FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL MONOBLOCK 1
BOOM FRONT ATTACHMENT
Removal

CAUTION: Prevent person from injury. Metal

fragments may fly when a hammer is used to
remove the pins. Be sure to wear necessary
protection, such as goggles, hardhat and etc.

1. Remove grease hose (1) from the adapter on the

boss at the boom cylinder rod side. (2 places
Boom Cylinder
both left and right)
: 17 mm

2. Remove nuts (4) and bolts (6) from boom cylin- W1GL-04-01-005

der rod pin (3). Then remove stopper (5). (2

places both left and right) 2, 3 1 5
: 30 mm

CAUTION: Boom cylinder weight:

171 kg (377 lb)

3. Hoist and hold the boom cylinder by a crane.

With a bar and hammer, drive pin (3) into the
position where thrust plate (2) can be removed. 4, 6
NOTE: When pin (3) cannot be removed, start the Boom Cylinder
engine and operate the boom lever to ad-
just the hole position of the boom cylinder
piston rod end.

W1GL-04-01-006

W4-1-2
 FRONT ATTACHMENT / Front Attachment
4. Place the boom cylinder on a bench of 1 m height.
Start the engine. Operate the boom lever to re-
Bench
tract the boom cylinder. Secure the boom cylin-
der rod as illustrated with a wire.
Stop the engine.
Boom Cylinder
5. Remove the boom cylinder.
Refer to “Remove Boom Cylinder” on page
W4-2-10. Wire

6. Remove other boom cylinder in the same proce-

dures as steps 3 to 5.

W554-02-03-007
CAUTION: The pin sometimes releases
suddenly. Be sure no one stands in the way.

7. Tap pin (3) out with a bar and hammer. Remove

thrust plate (2).
Pressure
8. After stopping the engine, push the pressure re- Release
Button
lease button on the air breather to release any
remaining pressure from the hydraulic oil tank. Cap
Remove the cap to release the residual pressure
from the hydraulic circuit.
Hydraulic
Refer to “Hydraulic Circuit Pressure Release Oil Tank
Procedure” on page W4-1-1.

W1F3-01-04-002

9. Disconnect hoses (7), (8) for bucket cylinder and

arm cylinder. Attach a cap onto all the open ends
of disassembled hoses.
: 36 mm, 41 mm

W1F3-04-01-010

7 8

W4-1-3
 FRONT ATTACHMENT / Front Attachment
10. Open cover (9). Remove bolts (10) (4 used) to
remove cover (11). 9
: 17 mm

W1GL-02-05-005

11 10

W4-1-4
 FRONT ATTACHMENT / Front Attachment

CAUTION: Boom foot pin (12) weight:

12
45 kg (100 lb)

11. Remove bolt (15), spring washer (16), plate (14)

and block (13) from the plate of boom foot pin
(12).
: 27 mm 13
14
15
16
W178-04-01-001

Boom and Arm Cylinder

Center of Gravity
CAUTION: Front attachment weight: Boom Assembly A
3330 kg (7350 lb) Center of Gravity

12. Attach a wire rope onto the boom. Slightly hoist to

take up any slack of wire rope.

D
C

B
W1GL-04-01-002

13. Insert a bar between the plate of boom foot pin Unit: mm (in)
(12) and the bracket. Slightly pull the plate out. A 3492 (137.5)
B 3813 (150)
14. Pull boom foot pin (12) out while rotating the plate C 1422 (56)
slowly by hand. D 2064 (81.3)

NOTE: When boom foot pin (12) cannot be re-

moved, adjust the position of the boom
12
foot pin (12) hole by hoisting and lowering
the front attachment.

15. After hoisting the front attachment, move the

machine backward.

16. Place the front attachment on wooden blocks. Plate

Insert a bar.

Bracket

W178-04-01-001

W4-1-5
 FRONT ATTACHMENT / Front Attachment
Installation
Boom and Arm Cylinder
Center of Gravity
A
CAUTION: Prevent person from injury. Metal Boom Assembly
fragments may fly when a hammer is used to Center of Gravity
install the pins. Be sure to wear necessary
protection, such as goggles, hardhat and etc.

CAUTION: Front attachment weight: D

3330 kg (7350 lb) C

1. Hoist the front attachment by a crane. Move the

machine forward, aligning the boom foot pin (12) B
holes. W1GL-04-01-002

Insert the thrust plates into boom left and right

sides and adjust the clearance between the plate Unit: mm (in)
and frame within 1 mm. A 3492 (137.5)
(Adjust the position of the boom foot pin hole by B 3813 (150)
hoisting and lowering the front attachment.) C 1422 (56)
D 2064 (81.3)

12

2. Drive in boom foot pin (12). Install stopper bolt 13

(15), washer (16), plate (14) and block (13). 14
: 27 mm
15
: 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)
16
W178-04-01-001

3. Install cover (11) with bolts (10) (4 used).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

4. Close cover (9).

W1GL-02-05-005

11 10

W4-1-6
 FRONT ATTACHMENT / Front Attachment
5. Remove the caps from hoses and pipings. Install
the bucket cylinder hoses (7) and the arm cylin-
der hoses (8).
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 Ibf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft)

W1F3-04-01-010

7 8

CAUTION: Boom cylinder weight:

171 kg (377 lb)

6. Install the boom cylinder.

Refer to “Install Boom Cylinder” on page
W4-2-12.
Boom Cylinder W105-04-02-040

3 2

7. Hoist the boom cylinder by a crane. Insert thrust

plates (2) (2 used), and then drive in pin (3) to in- 6 Boom Cylinder
stall boom cylinders to both sides.

8. Install stopper (5) and secure it with bolt (6) and

nuts (4) (2 used). (2 places both left and right)
: 30 mm
: 550 N⋅m (56 kgf⋅m, 405 Ibf⋅ft)
5
4
W178-04-01-004

W4-1-7
 FRONT ATTACHMENT / Front Attachment
9. Connect grease pipe (1) onto the boss at boom
cylinder rod side. (2 places both left and right)
1
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)

W105-04-01-002

10. Add grease to the boom cylinder rod side, bottom

Right Boom
side and boom foot side. Cylinder Rod
Side
Arm Cylinder
Bottom Side

Left Boom
Cylinder Rod
Side
Boom Foot
Side

W1F3-04-01-010

W4-1-8
 FRONT ATTACHMENT / Front Attachment
11. Install thrust plates (17) into arm left and right
sides. Adjust total clearance of left and right
within 1.5 mm or less. Arm and Bucket
Center of Gravity

12. After installing arm, add grease to grease fitting

(18) on the boom-connecting boss of the arm.

IMPORTANT: For handling of HN bushing for the

front attachment, pay attention to
following requirements.
Precautions for pressing the bushing in: F
If a hammer is used to drive the bushing in, the bush-
ing may be damaged. Use a press. E
W1GL-04-01-002
Precautions when reinforcing the arm:
Welding heat for arm reinforcement may cause oil to Unit: mm (in)
leak from the bushing and decrease lubrication per- E 4343 (163)
formance. F 765 (30.1)
If oil leak occurs because of heated bushing after
welding, replace the bushing.

Special tools should be used to pull the bushing out or

press it in.
Special Tool: ST 1454
17 17

18 18

M157-07-157

W4-1-9
 FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL 2-PIECE BOOM
1
FRONT ATTACHMENT
Removal

CAUTION: Prevent person from injury. Metal

fragments may fly when a hammer is used to
remove the pins. Be sure to wear necessary
protection, such as goggles, hardhat and etc.

1. Remove grease hose (1) from the adapter on the

boss at the boom cylinder rod side. (2 places
both left and right)

2. Remove nuts (4) and bolts (6) from boom cylin-

der rod front pin (3). Then remove stopper (5). (2
places both left and right)
: 30 mm W1GL-04-01-007

1
CAUTION: Boom cylinder weight: 2, 3
173 kg (382 lb)
5
3. Hoist and hold the boom cylinder by a crane.
With a bar and hammer drive pin (3) into the po-
sition where thrust plate (2) can be removed.
NOTE: When pin (3) cannot be removed, start the
engine and operate the boom lever to ad- 4, 6
just the hole position of the boom cylinder Boom Cylinder
piston rod end.

W1GL-04-01-008

W4-1-10
 FRONT ATTACHMENT / Front Attachment
4. Place the boom cylinder on a bench of 1 m height.
Start the engine. Operate the boom lever to re-
tract the boom cylinder. Secure the boom cylin-
Bench
der rod as illustrated with a wire.
Stop the engine.
Boom Cylinder
5. Remove the boom cylinder.
Refer to “Remove Boom Cylinder” on page
W4-2-10. Wire

6. Remove other boom cylinder in the same proce-

dures as steps 3 to 5.

W554-02-03-007
CAUTION: The pin sometimes comes out
suddenly. Be sure no one stands in the way.

7. Tap pin (3) out with a bar and hammer. Remove

thrust plate (2).

8. After stopping the engine, push the pressure re- Pressure

lease button on the air breather to release any Release
Button
remaining pressure from the hydraulic oil tank.
Remove the cap to release the residual pressure Cap
from the hydraulic circuit.
Refer to “Hydraulic Circuit Pressure Release
Hydraulic
Procedure” on page W4-1-1. Oil Tank

W1F3-01-04-002

9. Disconnect hoses (7, 8) for bucket cylinder and

arm cylinder. Attach a cap onto all the open ends
of disassembled hoses.
: 36 mm, 41 mm

W1GL-04-01-009

7 8

W4-1-11
 FRONT ATTACHMENT / Front Attachment
10. Open cover (9). Remove bolts (10) (4 used) to
remove cover (11). 9
: 17 mm

W1GL-02-05-005

11 10

W4-1-12
 FRONT ATTACHMENT / Front Attachment

CAUTION: Boom foot pin (12) weight:

12
45 kg (100 lb)

11. Remove bolt (15), spring washer (16), plate (14)

and block (13) from the plate of boom foot pin
(12).
: 27 mm 13
14
15
16
W178-04-01-001
Boom and Arm Cylinder
Center of Gravity
A

B
Front Attachment Assembly
Center of Gravity
CAUTION: Front attachment weight:
4270 kg (9420 lb)

12. Attach a wire rope onto the boom. Slightly hoist to

take up any slack of wire rope. F
E
D

C
W1GL-04-01-001

Unit: mm (in)
A 3436 (135)
B 2920 (115)
C 4321 (170)
D 1037 (41)
E 1907 (75)
F 2414 (95)

13. Insert a bar between the plate of boom foot pin

(12) and the bracket. Slightly pull the plate out. 12

14. Pull boom foot pin (12) out while rotating the plate
slowly by hand.
NOTE: When boom foot pin (12) cannot be re-
moved, adjust the position of the boom
foot pin hole by hoisting and lowering the Plate
Insert a bar.
front attachment.
Bracket
15. After hoisting the front attachment, move the
machine backward.
W178-04-01-001

16. Place the front attachment on wooden blocks.

W4-1-13
 FRONT ATTACHMENT / Front Attachment
Front Attachment Assembly
Installation Center of Gravity

A
CAUTION: Prevent person from injury. Metal B
Boom and Arm Cylinder
fragments may fly when a hammer is used to Center of Gravity
install the pins. Be sure to wear necessary
protection, such as goggles, hardhat and etc.

CAUTION: Front attachment weight:

4270 kg (9420 lb) F
E
1. Hoist the front attachment by a crane. Move the D
machine forward, aligning the boom foot pin
holes.
Insert the thrust plates into boom left and right C
sides and adjust the clearance between the plate W1GL-04-01-001
and frame within 1 mm.
(Adjust the position of the boom foot pin hole by Unit: mm (in)
hoisting and lowering the front attachment.) A 3436 (135)
B 2920 (115)
C 4321 (170)
D 1037 (41)
E 1907 (75)
F 2414 (95)

12

2. Drive in boom foot pin (12). Install stopper bolt

(15), washer (16), plate (14) and block (13).
: 27 mm
: 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)
13
14
15
16

3. Install cover (11) with bolts (10) (4 used). W178-04-01-001

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
9

4. Close cover (9).

W1GL-02-05-005

11 10

W4-1-14
 FRONT ATTACHMENT / Front Attachment
5. Remove the caps from hoses and pipings. Install
bucket cylinder hoses (7) and arm cylinder hoses
(8).
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 Ibf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

W1GL-04-01-009

7 8

CAUTION: Boom cylinder weight:

172 kg (380 lb)

6. Install the boom cylinder.

Refer to “Install Boom Cylinder” on page
W4-2-12.
Boom Cylinder W105-04-02-040

2, 3 1

5
7. Hoist the boom cylinder by a crane. Insert thrust
plates (2) (2 used), and then drive in pin (3) to in-
stall boom cylinders to both sides.

8. Install stopper (5) and secure it with bolt (6) and 4, 6

nuts (4) (2 used). (2 places both left and right)
: 30 mm
: 550 N⋅m (56 kgf⋅m, 405 Ibf⋅ft)

W1GL-04-01-008

W4-1-15
 FRONT ATTACHMENT / Front Attachment
9. Connect grease pipe (1) onto the boss at boom
1
cylinder rod side. (2 places both left and right)
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)

W1GL-04-01-007

Right Boom
Cylinder Rod Side
Arm Cylin-
der Bottom
10. Add grease to the boom cylinder rod side, bottom Side
side and boom foot side. Lift Boom
Cylinder
Rod Side

Left Boom
Foot Side

Right Boom
Foot Side

W1GL-04-01-009

W4-1-16
 FRONT ATTACHMENT / Front Attachment
11. Install thrust plates (17) into arm left and right
sides. Adjust total clearance of left and right
within 1.5 mm or less. Arm and Bucket
Center of Gravity

12. After installing arm, add grease to grease fitting

(18) on the boom-connecting boss of the arm.

IMPORTANT: For handling of HN bushing for the

front attachment, pay attention to
following requirements.
Precautions for pressing the bushing in: D
If a hammer is used to drive the bushing in, the bush-
ing may be damaged. Use a press.
C
Precautions when reinforcing the arm: W1GL-04-01-001
Welding heat for arm reinforcement may cause oil to
leak from the bushing and decrease lubrication per- Unit: mm (in)
formance. C 4321 (170)
If oil leak occurs because of heated bushing after D 1037 (41)
welding, replace the bushing.

Special tools should be used to pull the bushing out or 352+

0.5
−0 mm
press it in. (14 + 0.02
−0 in)
Special Tool: ST 1454

17 17

W1GL-04-01-012

18

W1GL-04-01-011

W4-1-17
 FRONT ATTACHMENT / Front Attachment
MAINTENANCE STANDARD
Pin and Bushing

N
F

C
A L
M
E B

D
K
I J
G
H

W1GL-04-01-002

W1GL-04-01-001

Unit: mm (in)

Item Standard Allowable Limit Remedy

Pin 90 (3.54) 89.0 (3.50)
A
Bushing 90 (3.54) 91.5 (3.60)
Pin 80 (3.15) 79.0 (3.11)
B Boss (Main Frame) 80 (3.15) 81.5 (3.21)
Bushing (Boom Cylinder) 80 (3.15) 81.5 (3.21)
Pin 90 (3.54) 89.0 (3.50)
C Bushing (Boom Cylinder) 90 (3.54) 91.5 (3.60)
Boss (Boom) 90 (3.54) 91.5 (3.60)
Replace
Pin 90 (3.54) 89.0 (3.50)
D
Bushing 90 (3.54) 91.5 (3.60)
Pin 80 (3.15) 79.0 (3.11)
E Boss (Arm) 80 (3.15) 81.5 (3.21)
Bushing (Arm Cylinder) 80 (3.15) 81.5 (3.21)
Pin 80 (3.15) 79.0 (3.11)
F Boss (Boom) 80 (3.15) 81.5 (3.21)
Bushing (Arm Cylinder) 80 (3.15) 81.5 (3.21)

W4-1-18
 FRONT ATTACHMENT / Front Attachment

Unit: mm (in)

Item Standard Allowable Limit Remedy

Pin 71 (2.80) 70.0 (2.76)
G Boss (Arm) 71 (2.80) 72.5 (2.85)
Bushing (Bucket Cylinder) 71 (2.80) 72.5 (2.85)
Pin 80 (3.15) 79.0 (3.11)
H Bushing 80 (3.15) 81.5 (3.21)
Bushing (Bucket Cylinder) 80 (3.15) 81.5 (3.21)
Pin 71 (2.80) 70.0 (2.76)
I
Bushing 71 (2.80) 72.5 (2.85)
Pin 80 (3.15) 79.0 (3.11)
J Replace
Bushing 80 (3.15) 81.5 (3.21)
Pin 80 (3.15) 79.0 (3.11)
K
Bushing 80 (3.15) 81.5 (3.21)
Pin 100 (3.94) 99.0 (3.90)
L
Bushing 100 (3.94) 101.5 (4.0)
Pin 100 (3.94) 99.0 (3.90)
M
Bushing 100 (3.94) 101.5 (4.0)
Pin 90 (3.54) 89.0 (3.50)
N
Bushing 90 (3.54) 91.5 (3.60)

IMPORTANT: When replacing HN bushing, press

fit it in with a press.

W4-1-19
 FRONT ATTACHMENT / Front Attachment
Point

B C

W105-04-01-020
Unit: mm (in)

Standard Allowable Limit Remedy

A 215 (8.47) 107.5 (4.23)

B 95 (3.74) －
Replace
C 108 (4.25) －

D 95 (3.74) －

Side Cutter

C
D

W155-04-01-002

Unit: mm (in)

Standard Allowable Limit Remedy

A 278 (10.9) 181 (7.13)

B 295 (11.6) －
Replace
C 433 (17.0) －

D 135 (5.31) －

W4-1-20
 FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION

W1CF-04-01-007

Section A Section B

Unit: mm (in)
a 450 (17.7)
b 0
c 604 (23.8)
d 580 (22.8)
e －
f 1471 (57.9)
g 433 (17.0)
h 305.5 (12.0)
i 80 (3.15)
j 475 (18.7)
k 31 (1.22)
l 433 (17.0)
m 307 (12.1)
n 80 (3.15)
o 3.7°
p 3.7°
q 449 (17.7)

W4-1-21
 FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND
BOOM CONNECTION

W1GL-04-01-004

W1GL-04-01-003

Section C

W1GL-04-01-010

Unit: mm (in)
s 90 (3.54)
t 352 (13.9)
u 490 (19.3)

W4-1-22
 FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER
(MONOBLOCK BOOM, 2-PIECE BOOM)
Remove Bucket Cylinder 1

CAUTION: Prevent person from injury. Metal

fragments may fly when a hammer is used to 3
remove the pins. Be sure to wear necessary
protection, such as goggles, hardhat and etc. 2
3
1. Insert wooden block (3) between bucket cylinder
(1) and arm (2). W554-04-02-006

4 5
2. After stopping the engine, push the pressure
release button on the air breather to release any
remaining pressure from the hydraulic oil tank.
Then remove the cap.
Release the bucket circuit pressure. (Refer to
“Hydraulic Circuit Pressure Release Procedure” 6
on page W4-1-1.)

CAUTION: Secure the link with a wire to

prevent it from falling before pushing pin (7) 7
out. 1 W158-04-02-006
8
3. Remove nut (6) and bolt (4). Push out pin (7).
Remove thrust plate (5).
: 30 mm

4. To prevent rod (8) of bucket cylinder (1) from

extending, pass wire (9) through the cylinder rod
hole and secure wire (9) to the bucket cylinder
(1) tube.
9
W102-04-02-005

W4-2-1
 FRONT ATTACHMENT / Cylinder
5. Disconnect bucket cylinder hoses (12) (2 used)
at the bucket cylinder (1) bottom. Attach a cap 10
onto the open ends.
: 36 mm

CAUTION: Bucket cylinder weight:

15
145 kg (320 lb)

6. Lift bucket cylinder (1) off. Remove nut (13) and 11

bolt (15). Push pin (11) out. 13
Remove thrust plate (10).

7. Remove bucket cylinder (1).

1

12 W187-04-02-004

W4-2-2
 FRONT ATTACHMENT / Cylinder
Install Bucket Cylinder

IMPORTANT: When pressing the bushing in, if a

hammer is used, the bushing may 10
be damaged. Use a press.

CAUTION: Prevent person from injury. Metal

fragments may fly when a hammer is used to
15
install the pins. Be sure to wear necessary
protection, such as goggles, hardhats and
etc. 14 11
13
CAUTION: Bucket cylinder weight:
145 kg (320 lb)

1. Lift bucket cylinder (1). Align cylinder tube side 1

pin hole with the bucket cylinder mounting hole
on arm. Install thrust plate (10) and pin (11).

2. Insert bolt (15) into arm stopper (14) and pin (11).
Install nut (13). 12 W187-04-02-004

: 180 N⋅m (18.5 kgf⋅m, 133 Ibf⋅ft)

3. Connect the bucket cylinder hoses (12) (2 used). 1

8
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

4. Remove wire (9) from rod (8) of bucket cylinder

(1).

9 W102-04-02-005

W4-2-3
 FRONT ATTACHMENT / Cylinder
5. Start the engine and operate the bucket lever to
align the cylinder rod side pin hole with those of 16 4 17 5
links (16, 18). Insert thrust plate (5) and pin (7).

6. Insert bolt (4) into stopper (17) and pin (7). Install
nut (6).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 Ibf⋅ft)

IMPORTANT: In case link (18) has been removed

from the arm, never forget to
reinsert thrust plate (19). 7 18 6
W158-04-02-006
IMPORTANT: Fill the hydraulic oil to the specified
level after installation. Start the
19 19
engine. Fully stroke each cylinder
several times to bleed any air
remaining in the circuit. Check for
any oil leakage.

W157-04-01-015
18 18

W4-2-4
 FRONT ATTACHMENT / Cylinder
Remove Arm Cylinder
1
CAUTION: Prevent person from injury. Metal
fragments may fly when a hammer is used to
remove the pins. Be sure to wear necessary
2
protection, such as goggles, hardhat and etc.

1. Insert wooden block (3) between arm cylinder (1)

and boom (2). 3

2. After stopping the engine, push the pressure W187-04-02-005

release button on the air breather to release any
remaining pressure from the hydraulic oil tank. 4
10 5
Then remove the cap.
Release the arm circuit pressure. (Refer to
1
“Hydraulic Circuit Pressure Release Procedure”
on page W4-1-1.)

3. Remove nut (8) and bolt (10) from pin (5) at the
arm cylinder (1) rod side.
: 30 mm

4. Push pin (5) out. Remove thrust plate (4).

8
W187-04-02-006

6 1

5. To prevent arm cylinder (1) rod (6) from

extending, pass wire (7) through the cylinder rod
hole and secure wire (7) to the arm cylinder (1)
tube.

W187-04-02-010

W4-2-5
 FRONT ATTACHMENT / Cylinder
6. Disconnect hoses (11) (2 used) from the bottom Monoblock Boom
of arm cylinder (1). Attach a cap onto the open
ends. In case the hose-rupture safety valve is 1
equipped, refer to the “Remove and Install
Hose-Rupture Safety Valve”.
: 36 mm

7. Disconnect grease hose (12) from arm cylinder

(1).
: 19 mm

11 12

W1GL-04-01-005

2-Piece Boom

1 11

11 12

W1GL-04-01-007

CAUTION: Arm cylinder weight: 1

260 kg (575 lb)

8. Attach a sling at the arm cylinder (1) center of

gravity. Lift arm cylinder (1) off.

W102-04-02-016
13
17
9. Remove nuts (15) and bolt (17) from the tube 1 14
side of arm cylinder (1). Push out pin (14).
Remove thrust plates (13) and remove arm
cylinder (1).
: 30 mm

15

W187-04-02-007

W4-2-6
 FRONT ATTACHMENT / Cylinder
Install Arm Cylinder
13
17
IMPORTANT: When pressing the bushing in, if a 14
1
hammer is used, the bushing may
be damaged. Use a press.

CAUTION: Prevent person from injury. Metal

fragments may fly when a hammer is used to 16
install the pins. Be sure to wear necessary 15
protection, such as goggles, hardhat and etc.

CAUTION: Arm cylinder weight: W187-04-02-007

260 kg (575 lb) Monoblock Boom

1. Attach a sling at arm cylinder (1) where can make 1

the cylinder level. Lift arm cylinder (1). Align the
cylinder tube side hole with the arm cylinder
mounting hole on boom.

2. Install thrust plate (13) and pin (14). Install bolt

(17) to pin (14) and stopper (16). Then install nut
(15).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 Ibf⋅ft) 11 12

3. Connect grease hose (12) and the arm cylinder

hoses (11) (2 used). W1GL-04-01-005

: 19 mm 2-Piece Boom
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
: 36 mm 1 11
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 Ibf⋅ft)

IMPORTANT: Fill hydraulic oil to the specified

level. Start the engine. Check the
connections for any oil leakage.

11 12

W1GL-04-01-007

W4-2-7
 FRONT ATTACHMENT / Cylinder
4. Remove wire (7) from arm cylinder (1) rod (6). Lift 6 1
arm cylinder (1) off. Start the engine. Operate the
arm lever and align the arm cylinder rod side pin
hole with the arm cylinder mounting hole on arm
(18).
18
5. Install thrust plate (3) and pin (5).
Install bolt (10) to pin (5) and stopper (9), and put 7
nut (8) on bolt (10).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 Ibf⋅ft) W187-04-02-010

IMPORTANT: After installation, operate the 10 4

9 5
cylinder several times to stroke end
to bleed air from the circuit.

18

8
W187-04-02-006

W4-2-8
 FRONT ATTACHMENT / Cylinder
Remove Boom Cylinder Monoblock Boom

CAUTION: Prevent person from injury. Metal

fragments may fly when a hammer is used to
remove the pins. Be sure to wear necessary
protection, such as goggles, hardhat and etc.

1. Remove grease hoses (1) from boom cylinder.

: 19 mm

CAUTION: Boom cylinder weight: 1

173 kg (385 lb)
W1GL-04-01-005

2. Attach a wire rope to boom cylinder (2) and lift 2-Piece Boom
boom cylinder (2) off.

4 1 2

W1GL-04-01-008
3. Remove nut (5), bolt (7) and stopper (6) from the
boom cylinder (2) rod to push pin (4) out.
Remove thrust plate (3).
: 30 mm
7
4. Place boom cylinder (2) on a bracket. Remove
boom cylinder at other side by the same method.

5. Operate the boom lever to retract the boom. To

prevent the boom cylinder (2) rod from stretching,
pass the wire through the cylinder rod hole and
secure the wire to the cylinder tube. 6
5 3 4 3 2
6. After stopping the engine, push the pressure W158-04-02-013
release button on the air breather to release any
remaining pressure from the hydraulic oil tank.
Then remove the cap.
Release the boom circuit pressure. (Refer to
“Hydraulic Circuit Pressure Release Procedure”
on page W4-1-1.)

Bench
2

W105-04-02-035

W4-2-9
 FRONT ATTACHMENT / Cylinder
7. Remove hoses (12) (4 used) from boom cylinder
(2) at the boom cylinder bottom. Cover all
openings with plug to hoses and with cap to
boom cylinder. In case the hose-rupture safety
valve is equipped, refer to the “Remove and
Install Hose-Rupture Safety Valve”.
Plug: 13/16-12UNF
: 36 mm

W105-04-02-036
2
8. Loosen nut (10) at the boom cylinder bottom side 11
of the main frame and remove bolt (8). 8
Remove pin (9) completely.
Remove thrust plate (11).
: 24 mm
9

9 10

10
12
W178-04-02-009

CAUTION: Boom cylinder weight:

173 kg (385 lb)

9. Attach a wire rope at boom cylinder (2) where

can make the cylinder level. Lift boom cylinder (2)
off.
Remove boom cylinder at other side by the same
method.

W105-04-02-040

W4-2-10
 FRONT ATTACHMENT / Cylinder
Install Boom Cylinder

IMPORTANT: When pressing the bushing in, if a

hammer is used, the bushing may
be damaged. Use a press.

CAUTION: Prevent person from injury. Metal

fragments may fly when a hammer is used to
install the pins. Be sure to wear necessary
protection, such as goggles, hardhat and etc.

CAUTION: Boom cylinder weight:

173 kg (385 lb)

1. Attach a sling at boom cylinder (2) where can

make the cylinder level. Lift boom cylinder (2).
Align the cylinder tube side hole with the boom
cylinder mounting hole on boom. 2

W105-04-02-040
2. Insert thrust plate (11) and pin (9). Install bolt (8),
then tighten with nut (10).
: 24 mm 2
: 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft) 11
8
3. Install the boom cylinder at other side by same
method.

4. Connect hoses (12) (4 used) on boom cylinders

9
(2) (2 used).
: 36 mm
9 10
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

IMPORTANT: Fill hydraulic oil to the specified 10

12
W178-04-02-009
level. Start the engine. Check the
connections for any oil leakage.

W4-2-11
 FRONT ATTACHMENT / Cylinder
5. Lift boom cylinder (2). Operate the boom lever.
Align the pin hole at cylinder rod side with the
mounting hole of the boom cylinder.

6. Install thrust plate (3) and pin (4). 7

7. Install bolt (7) to pin (4) and stopper (6). Then

install nut (5).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 Ibf⋅ft)
6
5
3 4 3 2
W158-04-02-013

Monoblock Boom

8. Connect grease hoses (1).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)

9. Install the boom cylinder at other side by same

method.

IMPORTANT: After installation, operate the

cylinder several times to stroke end 1
to bleed air from the circuit.
W1GL-04-01-005

2-Piece Boom

4 1 2

W1GL-04-01-008

W4-2-12
 FRONT ATTACHMENT / Cylinder
Remove Positioning Cylinder
(2-Piece Boom Only)

CAUTION: Prevent person from injury. Metal

fragments may fly when a hammer is used to
remove the pins. Be sure to wear necessary
protection, such as goggles, hardhat and etc. 1 2

CAUTION: Positioning cylinder weight:

167 kg (370 lb)

1. Attach a nylon sling to positioning cylinder (3). Lift

and hold positioning cylinder (3).

2. After stopping the engine, push the pressure

5 3
release button on the air breather to release any 4
remaining pressure from the hydraulic oil tank.
Then remove the cap.
Release the positioning circuit pressure. (Refer to
“Hydraulic Circuit Pressure Release Procedure”
on page W4-1-1.)

3. Remove nuts (5) (2 used) and bolt (1) from

stopper (4) of the second boom. W1GL-04-01-008

4. Drive pin (2) into the second boom at approx. 6 7

160 mm (6.3 in)

5. Disconnect hoses (6) (2 used) and hoses (7) (3

used) from positioning cylinder (3). Attach a cap
onto the open ends.

6. Remove nuts (10) (2 used) and bolt (11) from

stopper (8) of the first boom.
Drive pin (9) in with a bar and hammer.
8
CAUTION: Positioning cylinder weight:
167 kg (370 lb) 7
W1GL-04-03-004

3
11 10 9
7. Lift positioning cylinder (3) off.

W4-2-13
 FRONT ATTACHMENT / Cylinder
Install Positioning Cylinder

CAUTION: Prevent person from injury. Metal

fragments may fly when a hammer is used to
install the pins. Be sure to wear necessary 6 7
protection, such as goggles, hardhat and etc.
12
CAUTION: Positioning cylinder weight:
167 kg (370 lb)

1. Lift positioning cylinder (3). Align the pin holes on

both cylinder bottom side and first boom.
Install thrust plate (12) and drive pin (9).
8
2. Align the pin holes of stopper (8) and pin (9).
W1GL-04-03-004
Install bolt (11) and nuts (10) (2 used). 7
3
11 10 9
IMPORTANT: Fill hydraulic oil to the specified
level. Start the engine. Check the
connections for any oil leakage. 2, 13
1
3. Connect hoses (7) (2 used) and (6) (2 used) to
positioning cylinder (3).

4. Start the engine, extend positioning cylinder (3).

Align the pin holes of the positioning cylinder (3)
rod and the second boom. Install thrust plate (13)
and drive pin (2).

5. Align the pin holes of stopper (4) and pin (2). 5 3

4
Install bolt (1) and nuts (5) (2 used).

IMPORTANT: After installation, operate the

cylinder several times to stroke end
to bleed air from the circuit.

W1GL-04-01-008

W4-2-14
 FRONT ATTACHMENT / Cylinder
Remove Blade Cylinder

IMPORTANT: Before working, lower the blade

onto the ground. 1

CAUTION: Prevent person from injury. Metal

2
fragments may fly when a hammer is used to
remove the pins. Be sure to wear necessary
protection, such as goggles, hardhat and etc.

1. Remove bolts (2) (4 used) to remove protection

cover (1).

2. After stopping the engine, push the pressure

release button on the air breather to release any
remaining pressure from the hydraulic oil tank.
Then remove the cap.
Release the blade circuit pressure. (Refer to
“Hydraulic Circuit Pressure Release Procedure”
on page W4-1-1.) W1GL-04-01-013

3. Disconnect hoses (10) (4 used) from blade 3, 4 5 6 7

cylinder (8). Cap the disconnected hose ends.
: 27 mm

CAUTION: Blade cylinder (8) weight:

70 kg (155 lb)

4. Attach a nylon sling to blade cylinder (8). Lift and

hold blade cylinder (8). 8

5. Remove nuts (6) (8 used) and bolts (5) (2 used).

Pull out pins (3) (2 used).
Remove thrust plate (4) from the both blade
cylinder (8) bottom and rod sides. W1GL-04-02-004
10
3, 4, 5, 6 9
6. Lift blade cylinder (8) off.

W4-2-15
 FRONT ATTACHMENT / Cylinder
Install Blade Cylinder
3, 4 5 6 7

CAUTION: Prevent person from injury. Metal

fragments may fly when a hammer is used to
install the pins. Be sure to wear necessary
protection, such as goggles, hardhat and etc.

CAUTION: Blade cylinder (8) weight:

70 kg (155 lb)
8
1. Lift and hold blade cylinder (8). Align the pin (3)
holes of the blade cylinder (8) bottom side and
bracket (7) and the rod side and blade (9).
Install thrust plate (4) and drive pins (3) (2 used).
Install bolts (5) (2 used) and nuts (6) (4 used). 10 W1GL-04-02-004

: 24 mm 3, 4, 5, 6 9
: 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)

2. Connect hoses (10) (4 used) to blade cylinder 1

(8).
: 19 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18.0 lbf⋅ft) 2
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)

3. Install protection cover (1) to blade cylinder (8)

with bolts (2) (4 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)

IMPORTANT: After installation, operate the

cylinder several times to stroke end
to bleed air from the circuit.

W1GL-04-01-013

W4-2-16
 FRONT ATTACHMENT / Cylinder
Remove Stabilizer Cylinder

In this section, the procedure starts on the premise 1, 2, 3, 4 6 7 8

5
that the stabilizer operate-check valve has already
been removed. For removal and installation of the
operate-check valve, refer to “Remove and Install
Operate-Check Valve” section.
9
CAUTION: Prevent person from injury. Metal
fragments may fly when a hammer is used to 10, 11
remove the pins. Be sure to wear necessary 12
protection, such as goggles, hardhat and etc.

1. Remove bolts (9) (3 used) to remove cover (7).

: 17 mm
Operate-Check Valve
2. After stopping the engine, push the pressure
W1F3-04-01-011
release button on the air breather to release any
remaining pressure from the hydraulic oil tank. 13
Then remove the cap. 9
Release the stabilizer circuit pressure. (Refer to 7
“Hydraulic Circuit Pressure Release Procedure”
on page W4-1-1.)

3. Disconnect hoses (13) (2 used) from stabilizer

cylinder (6). Attach a cap onto the open ends.
： 27 mm

4. Attach a nylon sling to the rod side of the

stabilizer cylinder (6) tube. Lift stabilizer cylinder Operate-Check
Valve Hose
(6) off. W1F3-04-01-012

5
5. Remove bolts (12) (3 used), pin (10) and thrust
plate (11) from stabilizer (8).
7

CAUTION: Stabilizer cylinder weight: 9

88 kg (195 lb)
10, 11
6. Lift stabilizer cylinder (6) off. Insert the sleeper
under the stabilizer cylinder (6) tube. 6 12
7. Remove ring (2) and lock pin (3) of the stabilizer Sleeper
cylinder (6) bottom side. Pull out pin (1).
8
8. Pull out stabilizer cylinder (6) from stabilizer
beam (5).
W1GL-04-02-006

W4-2-17
 FRONT ATTACHMENT / Cylinder
Install Stabilizer Cylinder

5
CAUTION: Prevent person from injury. Metal
fragments may fly when a hammer is used to
7
install the pins. Be sure to wear necessary
protection, such as goggles, hardhat and etc.
9

CAUTION: Stabilizer cylinder weight: 10, 11

88 kg (195 lb)
6 12
1. Lift stabilizer cylinder (6). Align the pin (1) holes
of the stabilizer cylinder (6) bottom side and Sleeper
stabilizer beam (5).
Install thrust plate (4) and drive pin (1). 8

2. Install lock pin (3) and ring (2) to pin (1).

W1GL-04-02-006

3. Connect hoses (13) (2 used) onto stabilizer 13

cylinder (6). 9
: 19 mm 7
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)

4. Start the engine and extend stabilizer cylinder (6)

to align the rod with connecting pin hole.

5. Install thrust plate (11), pin (10) and bolts (12) (3

used) to stabilizer (8). Operate-Check
: 17 mm Valve Hose W1F3-04-01-012

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

6. Install cover (7) with bolts (6) (3 used). 1, 2, 3, 4 6 7 8

5
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

IMPORTANT: After installation, operate the

cylinder several times to stroke end
9
to bleed air from the circuit.
10, 11
12

W1F3-04-01-011

W4-2-18
 FRONT ATTACHMENT / Cylinder
(Blank)

W4-2-19
 FRONT ATTACHMENT / Cylinder
DISASSEMBLE CYLINDER
(BOOM (MONOBLOCK/2-PIECE), POSI-
TIONING, BUCKET)

Boom Cylinder (Monoblock/2-Piece Boom)

Positioning Cylinder

11 1 2 3 4 7 5 6 9 10

8
14 13 19 16 20 21 22 12

20 16 15 17 18 19 24 23

W158-04-02-016

Bucket Cylinder
11 1 2 3 4 7 5 6 9 10

13 20 19 20 21 22 12

16 15 17 18 16 19 24 23
W158-04-02-018

1- Wiper Ring 7- Cylinder Head 13 - Cushion Bearing 19 - Slide Ring (2 Used)

2- Backup Ring 8- Socket Bolt (12 Used) 14 - Cushion Seal 20 - Slide Ring (2 Used)
3- U-Ring 9- Backup Ring 15 - Piston 21 - Shim
4- Buffer Ring 10 - O-Ring 16 - Backup Ring (2 Used) 22 - Set Screw
5- Bushing 11 - Piston Rod 17 - Seal Ring 23 - Steel Ball
6- Snap Ring 12 - Cylinder Tube 18 - O-Ring 24 - Nut

W4-2-20
 FRONT ATTACHMENT / Cylinder
Disassemble Boom (Monoblock/2-Piece), Posi-
tioning and Bucket Cylinders
• Be sure to read “Precautions for Disassembly 5. Remove set screw (22) and steel ball (23).
and Assembly” thoroughly on page W1-1-1 be- NOTE: Set screw (22) was crimped with a punch
fore starting the repair work. in two places after it was tightened. Before
loosening set screw (22), cut away the
The disassembly procedure below starts on the prem- crimped portions.
ise that the hydraulic lines and the line securing bands
have been removed. 6. Loosen nut (24) using special tool (ST 5908).
Remove piston (15), shim (21) and cushion bear-
CAUTION: Cylinder weight: ing (13).
Boom cylinder (Monoblock): 171 kg (377 lb) In case of the boom and positioning cylinders,
Boom cylinder (2-Piece): 175 kg (386 lb) remove cushion seal (14).
Positioning cylinder: 188 kg (415 lb) Tools for turning nut:
Bucket cylinder: 145 kg (320 lb) Boom (Monoblock)/Bucket : 90 mm (ST 3263)
Boom (2-Piece) : 95 mm (ST 3075)
1. Lift and horizontally secure the cylinder on a Positioning : 100 mm (ST 3264)
workbench. Then, drain the hydraulic oil from the
ST 5908
cylinder.

W158-04-02-022

W102-04-02-027
7. Remove seal ring (17), slide rings (19 and 20) (2
used for each), O-ring (18) and backup rings (16)
2. Fully extend cylinder rod (11). Hold the rod end (2 used) from piston (15).
by crane. Remove socket bolts (8) from cylinder
head (7). 8. Remove cylinder head (7) from cylinder rod (11).

3. Pull out cylinder head (7) from cylinder tube (12) 9. Remove O-ring (10) and backup rings (9, 2) from
by tapping with a plastic hammer. cylinder head (7). Then remove wiper ring (1),
U-ring (3), backup ring (4), snap ring (6) and
IMPORTANT: Be sure to pull out piston rod (11) bushing (5).
straight to prevent the sliding sur- Tools for removing bushing:
faces from being damaged. Boom : 85 mm (ST 8020)
4. Secure cylinder rod (11) on special tool (ST Positioning : 95 mm (ST 8021)
5908). Put mating marks between cylinder rod Bucket : 80 mm (ST 8019)
(11) and nut (24).
ST 5908

W158-04-02-022

W4-2-21
 FRONT ATTACHMENT / Cylinder
ASSEMBLE CYLINDER
(BOOM (MONOBLOCK/2-PIECE), POSI-
TIONING, BUCKET)
Boom Cylinder (Monoblock/2-Piece Boom)
Positioning Cylinder

Hole (1 Place)
Be sure with the slit facing piston (15).
1 2 3 4 5 6 7 8 9, 10
11 12 13 14 15 16 17, 18 19 20
21
22, 23
24

Be sure with oil groove facing

correct direction when assembling. W178-04-02-003

Bucket Cylinder

Hole (1 Place)

1 2 3 4 5 6 7 8 9, 10
11 12 13 15 16 17, 18 19 20
21
22, 23
24

Be sure with oil groove facing

correct direction when assembling.
W178-04-02-004

1- Wiper Ring 7- Cylinder Head 13 - Cushion Bearing 19 - Slide Ring (2 Used)

2- Backup Ring 8- Socket Bolt (12 Used) 14 - Cushion Seal 20 - Slide Ring (2 Used)
3- U-Ring 9- Backup Ring 15 - Piston 21 - Shim
4- Buffer Ring 10 - O-Ring 16 - Backup Ring (2 Used) 22 - Set Screw
5- Bushing 11 - Piston Rod 17 - Seal Ring 23 - Steel Ball
6- Snap Ring 12 - Cylinder Tube 18 - O-Ring 24 - Nut

W4-2-22
 FRONT ATTACHMENT / Cylinder
Assemble Boom (Monoblock/2-Piece), Position-
ing and Bucket Cylinders

1. Press bushing (5) into cylinder head (7). 8. Install shim (21) to cylinder rod (11). Tighten nut
Tools for installing bushing: (24) using special tool (ST 5908) while aligning
Boom (Monoblock)/Bucket : 80 mm (ST 8019) the mating mark on the rod with that on nut (24).
Boom (2-Piece) : 85 mm (ST 8020)
ST 5908
Positioning : 95 mm (ST 8021)

IMPORTANT: Be sure to install rings in correct

direction.
2. Install U-ring (3), backup ring (2), buffer ring (4),
and snap ring (6) to cylinder head (7).

3. Install wiper ring (1) to cylinder head (7) with a W158-04-02-022

plastic hammer.
Tools for installing wiper ring : Tools for tightening nut:
Boom (Monoblock)/Bucket : ST 8019/1297 Boom (Monoblock)/Bucket : 90 mm (ST 3263)
Boom (2-Piece) : ST 8020/1298 Boom (2-Piece) : 95 mm (ST 3075)
Positioning : ST 8021/1299 Positioning : 100 mm (ST 3264)
Boom cylinder (Monoblock)
4. Install O-ring (10) and backup ring (9) to cylinder : 4780 N⋅m (490 kgf⋅m, 3530 lbf⋅ft)
head (7). Boom cylinder (2-Piece)
: 5470 N⋅m (560 kgf⋅m, 4030 lbf⋅ft)
5. Install O-ring (18), backup rings (16) (2 used), Positioning cylinder
seal ring (17), and slide rings (19, 20) (2 used for : 6850 N⋅m (700 kgf⋅m, 5050 lbf⋅ft)
each) to piston (15). Bucket cylinder
: 6570 N⋅m (670 kgf⋅m, 4850 lbf⋅ft)
6. Install the cylinder head (7) assembly into piston
rod (11). 9. Align the holes of piston rod (11) and nut (24),
Tools for installing cylinder head: then install steel ball (23).
Boom (Monoblock)/Bucket : ST 8019/2345
Boom (2-Piece) : ST 8020/2362 10. Crimp the head of set screw (22) at two places
Positioning : ST 8021/2363 with a punch.
: 57±10.5 N⋅m
IMPORTANT: Be sure that the slit in cushion seal (5.8±1.1 kgf⋅m, 42±7.7 lbf⋅ft)
(14) is facing piston and that the oil
groove in cushion bearing (13) is IMPORTANT: Take care not to damage rings. In-
facing correct direction. stall the piston rod (11) assembly
7. Install cushion bearing (13) to piston rod (11). In- into cylinder tube (12) while aligning
stall the piston (15) assembly to the piston rod it with the center of cylinder tube
(11). (16).
In case of the boom and positioning cylinders, in- 11. Horizontally secure cylinder tube (12) on a work-
stall cushion seal (14). bench. Insert the piston rod (11) assembly into
cylinder tube (12).

12. Install cylinder head (7) into cylinder tube (12)

with socket bolts (8) (12 used).
Boom/Bucket cylinder
: 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)
Positioning cylinder
: 370 N⋅m (38 kgf⋅m, 270 lbf⋅ft)

W4-2-23
 FRONT ATTACHMENT / Cylinder
DISASSEMBLE CYLINDER (ARM)
Arm Cylinder

11 1 2 3 4 7 5 6 9 10

14 13 15 16 25 26 28 22 12

20 19 16 17 18 19 20 27 21 24 23

W158-04-02-017

1- Wiper Ring 8- Socket Bolt (12 Used) 15 - Piston 22 - Set Screw

2- Backup Ring 9- Backup Ring 16 - Backup Ring (2 Used) 23 - Steel Ball
3- U-Ring 10 - O-Ring 17 - Seal Ring 24 - Nut
4- Buffer Ring 11 - Piston Rod 18 - O-Ring 25 - Snap Ring
5- Bushing 12 - Cylinder Tube 19 - Slide Ring (2 Used) 26 - Cushion Seal
6- Snap Ring 13 - Cushion Bearing 20 - Slide Ring (2 Used) 27 - Cushion Bearing
7- Cylinder Head 14 - Cushion Seal 21 - Shim 28 - Stopper (2 Used)

W4-2-24
 FRONT ATTACHMENT / Cylinder
Disassemble Arm Cylinder
• Be sure to read “Precautions for Disassembly 5. Remove set screw (22) and steel ball (23).
and Assembly” thoroughly on page W1-1-1 be- NOTE: Set screw (19) was crimped with a punch
fore starting the repair work. in two places after it was tightened. Before
loosening set screw (19), cut away the
The disassembly procedure below starts on the prem- crimped portions.
ise that the hydraulic lines and the line securing bands
have been removed. 6. Loosen nut (24) using special tool (ST 5908).
Remove piston (15), shim (21), cushion bearing
CAUTION: Arm cylinder weight: (13) and cushion seal (14).
260 kg (574 lb) Tool for tightening nut: 100 mm (ST 3264)

ST 5908
1. Lift and horizontally secure the cylinder on a
workbench by crane. Then, drain the hydraulic oil
from the cylinder.

W158-04-02-022

7. Remove seal ring (17), slide rings (19, 20) (2

used for each), O-ring (18), backup rings (16) (2
W102-04-02-027
used) from piston (15).

2. Fully extend cylinder rod (11). Lift and hold the 8. Remove cylinder head (7) from cylinder rod (11).
rod. Remove socket bolts (8) from cylinder head
(7). 9. Remove O-ring (10) and backup rings (9, 2) from
cylinder head (7). Then remove wiper ring (1),
IMPORTANT: Be sure to pull out piston rod (11) U-ring (3), backup ring (4), snap ring (6) and
straight to prevent the sliding sur- bushing (5).
faces from being damaged. Tool for removing bushing: 95 mm (ST 8021)
3. Pull out cylinder head (7) with piston rod still at-
tached from cylinder tube (12) by tapping with a 10. Remove stopper (28) from piston rod (11) with a
plastic hammer. screwdriver. Remove cushion bearing (27), cush-
ion seal (26) and snap ring (25).
4. Secure cylinder rod (11) on special tool (ST
5908). Put mating marks between cylinder rod
(11) and nut (24).
ST 5908

W158-04-02-022

W4-2-25
 FRONT ATTACHMENT / Cylinder
ASSEMBLE CYLINDER (ARM)
Arm Cylinder

Be sure with the slit facing piston (15).

Hole (1 Place)

1 2 3 4 5 6 7 8 9, 10
11 12 13 14 15 16 17, 18 19 20 21
22, 23
24
25
26

27

28

W178-04-02-005
Be sure with oil groove facing correct
direction when assembling.

1- Wiper Ring 8- Socket Bolt (12 Used) 15 - Piston 22 - Set Screw

2- Backup Ring 9- Backup Ring 16 - Backup Ring (2 Used) 23 - Steel Ball
3- U-Ring 10 - O-Ring 17 - Seal Ring 24 - Nut
4- Buffer Ring 11 - Piston Rod 18 - O-Ring 25 - Snap Ring
5- Bushing 12 - Cylinder Tube 19 - Slide Ring (2 Used) 26 - Cushion Seal
6- Snap Ring 13 - Cushion Bearing 20 - Slide Ring (2 Used) 27 - Cushion Bearing
7- Cylinder Head 14 - Cushion Seal 21 - Shim 28 - Stopper (2 Used)

W4-2-26
 FRONT ATTACHMENT / Cylinder
Assemble Arm Cylinder

1. Press bushing (5) into cylinder head (7). 9. Align the hole of piston rod (11) and nut (24),
Tools for pressing bushing: ST 8021/ST 1288 then install steel ball (23).

IMPORTANT: Be sure to install rings in correct 10. After tightening set screw (22), crimp the head of
direction. set screw (22) at two places with a punch.
2. Install U-ring (3), backup ring (2), buffer ring (4), : 10 mm
and snap ring (6) to cylinder head (7). : 57±10.5 N⋅m
(5.8±1.1 kgf⋅m, 42±7.7 lbf⋅ft)
3. Install wiper ring (1) to cylinder head (7) with a
plastic hammer. IMPORTANT: Be sure that cushion seal (26) slit is
Tool for pressing wiper ring: ST 8021/ST 1299 facing piston and that the oil groove
in cushion bearing (27) is facing
4. Install O-ring (10) and backup ring (9) to cylinder correct direction.
head (7). 11. Install snap ring (25) and cushion seal (26) to
cylinder rod (11). Install cushion bearing (27) and
5. Install seal ring (17), O-ring (18), and slide rings stopper (28) to the cylinder rod.
(19, 20) (2 used for each) to piston (15).

6. Install the cylinder head (7) assembly into piston CAUTION: Be sure to keep cylinder rod (11)
rod (11). aligning with the center of cylinder tube (12)
Tools for installing cylinder head: when inserting in order to avoid damaging
ST 8021/ST 2363 rings.

IMPORTANT: Be sure that the slit in cushion seal 12. Horizontally secure cylinder tube (12) on a
(14) is facing piston and that the oil workbench. Insert the piston rod (11) assembly
groove in cushion bearing (13) is into cylinder tube (12).
facing correct direction.
7. Install cushion seal (14) to cylinder rod (11). 13. Install cylinder head (7) into cylinder tube (12)
Install cushion bearing (13) and the piston (15) with socket bolts (8) (12 used).
assembly to cylinder rod (11). : 14 mm
: 370 N⋅m (38 kgf⋅m, 270 Ibf⋅ft)
8. Install shim (21) to cylinder rod (11). Tighten nut
(24) using special tool (ST 5908) while aligning
the mating mark on the rod with that on the nut.
Tool for tightening nut: 100 mm (ST 3264)
: 10200 N⋅m (1040 kgf⋅m, 7520 Ibf⋅ft)

ST 5908

W158-04-02-022

W4-2-27
 FRONT ATTACHMENT / Cylinder
DISASSEMBLE CYLINDER
(STABILIZER, BLADE)

Stabilizer Cylinder

W1GL-04-02-001

Blade Cylinder

W1GL-04-02-002
Section A

1 Lock Washer 10 11 12 13 15 15
4 14 16 14 13
3 18
Slit 19
Hole (1 Place) Black
Green 20
2

5 6 7 8 9
17 W1GL-04-02-003

1- Wiper Ring 6- Bushing 11 - Cylinder Tube 16 - Seal Ring

2- Cylinder Head 7- Retaining Ring 12 - Piston 17 - O-Ring
3- O-Ring 8- Backup Ring 13 - Slide Ring (2 Used) 18 - Nut
4- Buffer Ring 9- O-Ring 14 - Slide Ring (2 Used) 19 - Set Screw
5- U-Ring 10 - Piston Rod 15 - Backup Ring (2 Used) 20 - Steel Ball

W4-2-28
 FRONT ATTACHMENT / Cylinder
Disassemble Stabilizer and Blade Cylinders
• Be sure to read “Precautions for Disassembly 4. Secure piston rod (10) on special tool (ST 5908).
and Assembly” thoroughly on page W1-1-1 Put mating marks between piston rod (10) and
before starting the repair work. nut (18).
• The disassembly procedure below starts on the
ST 5908
premise that the hydraulic lines and the line
securing bands have been removed.

CAUTION:
Stabilizer cylinder weight: 88 kg (195 lb)
Blade cylinder weight: 70 kg (155 lb)
W158-04-02-022
1. Lift and horizontally secure the cylinder on a
workbench. Then, drain the hydraulic oil from the 5. Remove set screw (19) and steel ball (20).
cylinder.
NOTE: Set screw (19) was crimped with a punch
in two places after it was tightened. Before
loosening set screw (19), cut away the
crimped portions.

6. Loosen and remove nut (18) using special tool

(ST 5908).
Remove piston (12) from piston rod (10).
Tools for turning nut:
W102-04-02-027
Stabilizer/Blade cylinder: 85 mm (ST 3304)

2. Let the lock washer in cylinder tube (11) bend. 7. Remove cylinder head (2) from cylinder rod (10).
Using a hook spanner wrench, loosen cylinder
head (2) by 1 to 2 turns. IMPORTANT: When removing the seal parts, take
Hook spanner wrench: care not to damage them.
Stabilizer cylinder: ST 3223 IMPORTANT: Do not reuse slide rings (13) and
Blade cylinder: ST 3219 (14). When dissembling cylinder,
replace them with new ones.
NOTE: The lock washer in cylinder head (2) is
8. Remove slide rings (13, 14) (2 used for each),
provided on cylinder tube (11) to from an
backup rings (15) (2 used), seal ring (16) and
integral part.
O-ring (17) from piston (15).
IMPORTANT: Be sure to pull out piston rod (1)
9. Remove wiper ring (1), U-ring (5), buffer ring (5),
straight to prevent the sliding
retaining ring (7) and bushing (6) from the
surfaces from being damaged.
cylinder head (1) inside.
3. Fully extend piston rod (10). Hold the rod end by
Tools for removing bushing:
crane. Remove cylinder head (2). Pull out the
Stabilizer cylinder: 70 mm (ST 8017)
piston rod (10) assembly from cylinder tube (11).
Blade cylinder: 60 mm (ST 8017)

10. Remove O-rings (3, 9) and backup ring (8) from

the cylinder head (2) outside.

W4-2-29
 FRONT ATTACHMENT / Cylinder
ASSEMBLE CYLINDER
(STABILIZER, BLADE)

Stabilizer Cylinder

W1GL-04-02-001

Blade Cylinder

W1GL-04-02-002
Section A

1 Lock Washer 10 11 12 13 15 15
4 14 16 14 13
3 18
Slit 19
Hole (1 Place) Black
Green 20
2

5 6 7 8 9
17 W1GL-04-02-003

1- Wiper Ring 6- Bushing 11 - Cylinder Tube 16 - Seal Ring

2- Cylinder Head 7- Retaining Ring 12 - Piston 17 - O-Ring
3- O-Ring 8- Backup Ring 13 - Slide Ring (2 Used) 18 - Nut
4- Buffer Ring 9- O-Ring 14 - Slide Ring (2 Used) 19 - Set Screw
5- U-Ring 10 - Piston Rod 15 - Backup Ring (2 Used) 20 - Steel Ball

W4-2-30
 FRONT ATTACHMENT/ Cylinder
Assemble Stabilizer and Blade Cylinders
• Be sure to read “Precautions for Disassembly 8. Install piston (12) to piston rod (10). Tighten nut
and Assembly” thoroughly on page W1-1-1 (18) using special tool (ST 5908) while aligning
before starting the repair work. the mating mark on the rod with that on nut (18).
Tools for turning nut:
1. Press bushing (6) into cylinder head (2) using the Stabilizer/Blade cylinder: 85 mm (ST 3304)
special tool. Install retaining ring (7) in cylinder : 3560 N⋅m (360 kgf⋅m, 2630 Ibf⋅ft)
head (4).
Tools for pressing bushing: ST 5908
Stabilizer cylinder: 70 mm (ST 8017)
Blade cylinder: 60 mm (ST 8017)

IMPORTANT: Install U-ring (5) with the lip facing

the bushing (6) side.
Install buffer ring (4) with the
protrusion part and slit facing the W158-04-02-022

bushing (6) side.

2. Install U-ring (5) and buffer ring (4) to cylinder 9. Align the hole on cylinder rod (10) with that on
head (2). nut (18). Insert steel ball (20) into the hole and
tighten set screw (19).
3. Install wiper ring (1) to cylinder head (2) with a After tightening set screw (19), crimp the head of
plastic hammer. set screw (19) at two places with a punch.
Tools for pressing wiper ring: Stabilizer/Blade cylinder:
Stabilizer/Blade cylinder: ST 8051 : 10 mm
: 57±10.5 N⋅m
IMPORTANT: Install backup ring (8) to the piston (5.8±1.1 kgf⋅m, 42±7.7 lbf⋅ft)
rod (10) side of O-ring (9).
4. Install O-ring (3), (9) and backup ring (8) to IMPORTANT: Be sure to keep piston rod (10)
cylinder head (2). aligning with the center of cylinder
tube (11) when inserting in order to
5. Install the cylinder head (2) assembly into piston avoid damaging the piston rings.
rod (10). IMPORTANT: Apply THREEBOND #1901 onto the
Tools for installing cylinder head: thread of cylinder head (2).
Stabilizer/Blade cylinder: ST 8017 10. Securely place cylinder tube (11) on a workbench,
insert the piston rod (10) assembly into cylinder
IMPORTANT: Make sure that O-ring (17) is not tube (11).
twisted after installing it.
6. Install backup rings (15) (2 used), and O-ring (17) 11. Tighten cylinder head (2) to cylinder tube (11)
and seal ring (16) onto sleeve (12) with a wooden using R wrench. Bend the lock washer to prevent
spatula so that they are not installed in the slide cylinder head (2) from loosening.
ring (13) groove. R wrench:
Stabilizer cylinder: ST 3223
IMPORTANT: When installing slide rings (13), (14) : 1060 N⋅m (108 kgf⋅m, 780 Ibf⋅ft)
do not align their split portion. Blade cylinder: ST 3219
7. Install slide rings (13), (14) to piston (12). : 735 N⋅m (75 kgf⋅m, 540 Ibf⋅ft)

W4-2-31
 FRONT ATTACHMENT/ Cylinder
MAITENANCE STANDARD
Piston Rod Rod Bend and Run Out
Dial Gauge
Piston Rod
A

W166-04-02-022

1 m (3.9 in)
W105-04-02-094 V Block

Unit: mm (in)
Cylinder Recommended Size After Unit: mm (in)
Name Re-manufacturing (A) Bend Run out Remedy
-0.012 (-0.0005) 0.5 (0.020) 1.0 (0.039) Repair
Boom 85 (3.35) 1.0 (0.039) 2.0 (0.079) Replace
-0.027 (-0.0010)
-0.012 (-0.0005)
Positioning 95 (3.74)
-0.027 (-0.0010)
-0.012 (-0.0005)
Arm 95 (3.74)
-0.027 (-0.0010)
-0.010 (-0.0003)
Bucket 80 (3.15)
-0.023 (-0.0009)

W4-2-32
 FRONT ATTACHMENT / Hose-Rupture Safety Valve
REMOVE AND INSTALL HOSE-RUPTURE
SAFETY VALVE
Removal of Hose-Rupture Safety Valve for Arm
Cylinder 1 2 3, 4

1. After stopping the engine, push the pressure

release button on the air breather to release any
remaining pressure from the hydraulic oil tank.
Then remove the cap.
Release the arm circuit pressure. (Refer to
“Hydraulic Circuit Pressure Release Procedure”
on page W4-1-1.)

IMPORTANT: Attach identification tags to the

hydraulic hoses and pipes for
re-assembly.
2. Disconnect hoses (2) and (5) (2 used) from 5
hose-rupture safety valve (6).
Attach a cap onto the open ends. W1GL-04-03-005
: 17 mm, 19 mm, 27 mm
6
3. Remove socket bolts (4) (4 used) then remove
pipe (3) from hose-rupture safety valve (6).
: 10 mm

4. Remove socket bolts (1) (4 used) then remove

hose-rupture safety valve (6) from the arm
cylinder.
: 10 mm

Installation of Hose-Rupture Safety Valve for Arm

Cylinder

1. Install hose-rupture safety valve (6) onto the arm

cylinder with socket bolts (1) (4 used).
: 10 mm
: 93±2 N⋅m (9.5±0.2 kgf⋅m, 69±1.5 lbf⋅ft)

2. Install pipe (3) onto hose-rupture safety valve (6)

with socket bolts (4) (4 used).
: 10 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

3. Connect hoses (2) and (5) (2 used).

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m,18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

IMPORTANT: Fill hydraulic oil to the specified

level. Start the engine. Check the
connections for any oil leakage.

W4-3-1
 FRONT ATTACHMENT / Hose-Rupture Safety Valve

Removal of Hose-Rupture Safety Valve for

Positioning Cylinder

1. After stopping the engine, push the pressure

release button on the air breather to release any
remaining pressure from the hydraulic oil tank.
Then remove the cap. 1 2 3 4
Release the arm circuit pressure. (Refer to
“Hydraulic Circuit Pressure Release Procedure”
on page W4-1-1.)

IMPORTANT: Attach identification tags to the

hydraulic hoses and pipes for
re-assembly.
2. Disconnect hoses (1, 2, 3) and (7) from
hose-rupture safety valve (5).
Attach a cap onto the open ends.
: 19 mm, 36 mm
W1GL-04-03-004

3. Remove the pipe (6) securing bolt (8) and the 8 7 6 5

pipe clamp.
: 22 mm

4. Remove socket bolts (4) (4 used) then remove

pipe (6) and hose-rupture safety valve (5) from
the positioning cylinder.
: 10 mm

Installation of Hose-Rupture Safety Valve for

Positioning Cylinder

1. Install hose-rupture safety valve (5) and pipe (6)

onto the positioning cylinder with socket bolts (4)
(4 used).
: 10 mm
: 93±2 N⋅m (9.5±0.2 kgf⋅m, 69±1.5 lbf⋅ft)

2. Connect hoses (1), (2), (3) and (7).

: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

3. Secure the pipe clamp with bolt (8).

: 22 mm
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

IMPORTANT: Fill hydraulic oil to the specified

level. Start the engine. Check the
connections for any oil leakage.

W4-3-2
 FRONT ATTACHMENT / Hose-Rupture Safety Valve

Removal of Hose-Rupture Safety Valve for Boom

Cylinder

1. After stopping the engine, push the pressure

release button on the air breather to release any
remaining pressure from the hydraulic oil tank. 1 2 3
Then remove the cap.
Release the arm circuit pressure. (Refer to
“Hydraulic Circuit Pressure Release Procedure”
on page W4-1-1.)

IMPORTANT: Attach identification tags to the

hydraulic hoses and pipes for
re-assembly.
2. Disconnect hoses (3) (4 used) and (5) (2 used)
from hose-rupture safety valve (6).
Attach a cap onto the open ends.
: 19 mm, 36 mm

3. Remove the pipe (7) securing bolts (1, 2) and the

pipe clamp.
: 17 mm, 22 mm

4. Remove socket bolts (4) (4 used) then remove 4

W1GL-04-03-003
7 6 5
pipe (7) and hose-rupture safety valve (6) from
the boom cylinder.
: 10 mm

Installation of Hose-Rupture Safety Valve for

Boom Cylinder

1. Install hose-rupture safety valve (6) and pipe (7)

onto the boom cylinder with socket bolts (4) (4
used).
: 10 mm
: 93±2 N⋅m (9.5±0.2 kgf⋅m, 69±1.5 lbf⋅ft)

2. Connect hoses (3) (4 used) and (5) (2 used).

: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

3. Secure the pipe clamp with bolts (1, 2).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
: 22 mm
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

IMPORTANT: Fill hydraulic oil to the specified

level. Start the engine. Check the
connections for any oil leakage.

W4-3-3
 FRONT ATTACHMENT / Hose-Rupture Safety Valve
CONSTRUCTION OF HOSE-RUPTURE
SAFETY VALVE

For Arm Cylinder

1 2

20 21
19
3

18 4

17 5

7
16 15 14 13
8
9

10

11

12

W1GL-04-03-002

W4-3-4
 FRONT ATTACHMENT / Hose-Rupture Safety Valve

Tightening Torque
Item No. Part Name Quantity Wrench Size Remark
N⋅m (kgf⋅m) (lbf⋅ft)
1 Casing 1
2 Plug 3
3 O-Ring 3
4 Spool 1
5 O-Ring 1
6 Plug 1
7 Spring Seat 1
8 Backup Ring 1
9 O-Ring 1
10 Spring 1
11 Poppet 1
12 Body 1
13 O-Ring 2
14 Seat 1
15 O-Ring 1
16 Stopper 1
17 Set Screw 1
18 Lock Nut 1
19 O-Ring 1
20 Cover 1
21 Spring 1

W4-3-5
 FRONT ATTACHMENT / Hose-Rupture Safety Valve

For Boom/Positioning Cylinder

3 4 5 6 7 8
2

1
29 30 31
28 9
27
10

26
11
25
12

13

14

15

16

17
24 23 22 21 18

19

20

W1GL-04-03-001

W4-3-6
 FRONT ATTACHMENT / Hose-Rupture Safety Valve

Item Tightening Torque

Part Name Quantity Wrench Size Remark
No. N⋅m (kgf⋅m) (lbf⋅ft)
1 Pilot Poppet 1
2 Adapter 1 : 24 mm
3 Plain Washer 1
4 Lock Nut 1 : 17 mm
5 Set Screw 1 : 5 mm
6 O-Ring 1
7 Spring 1
8 O-Ring 1
9 Casing 1
10 Backup Ring 1
11 O-Ring 1
12 O-Ring 1
13 Spool 1
14 Plug 1 : 32 mm
15 Plug 1
16 Backup Ring 1
17 O-Ring 1
18 Spring 1
19 Poppet 1
20 Body 1
21 O-Ring 2
22 Seat 1
23 O-Ring 1
24 Stopper 1
25 Set Screw 1 : 3 mm
26 Lock Nut 1 : 10 mm
27 O-Ring 1
28 Cover 1 : 32 mm
29 Spring 1
30 Plug 3 : 3 mm
31 O-Ring 3

W4-3-7
 FRONT ATTACHMENT / Hose-Rupture Safety Valve
(Blank)

W4-3-8
 FRONT ATTACHMENT / Operate-Check Valve
REMOVE AND INSTALL OPERATE-CHECK
VALVE (FOR BLADE/STABILIZER)
1
Removal
2
IMPORTANT: Before working, lower the blade onto
the ground.
IMPORTANT: Before working, be sure to secure
the stabilizer beam and stabilizer
with the lock pin.
1. Remove bolts (2) (4 used) then remove protection
cover (1).
: 19 mm

2. Disconnect hoses (5) (4 used) from operate-check

valve (4). Attach a cap onto the open ends. W1GL-04-01-013
: 17 mm, 19 mm, 22 mm, 27 mm
3 4
3. Remove socket bolts (6) (2 used) then remove
bracket (7).

4. Remove plug (3) then remove operate-check

valve (4).
Attach a cap onto the open ends.

6, 7

Installation

1. Install operate-check valve (4) on the blade

cylinder with plug (3).
: 36 mm
: 128±6.4 N⋅m (13±0.7 kgf⋅m, 94±4.7 lbf⋅ft) W1GL-04-02-004

2. Install bracket (7) on the blade cylinder with 5

socket bolts (6) (2 used).
: 6 mm Float
: 26.5 N⋅m (2.7 kgf⋅m, 19.5 Ibf⋅ft) Stabilizer Beam Lock Pin

3. Connect hoses (5) (4 used) to operate-check

valve (4).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) 4 Stabilizer
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 Ibf⋅ft)

4. Install protection cover (1) with bolts (2) (4 used).

5
: 19 mm W1F3-04-01-011
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)

W4-4-1
 FRONT ATTACHMENT / Operate-Check Valve
CONSTRUCTION OF OPERATE-CHECK
VALVE (FOR BLADE/STABILIZER)

4
5

11 10 9 8 7
T1F3-03-10-003

Item Tightening Torque

Part Name Q’ty Wrench Size Remark
No. N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 1 : 5 mm
2 O-Ring 1 1B P11
3 Casing 1
4 O-Ring 1 1B P26
5 Plug 1 : 36 mm 360±36 (37±3.7) (265±26.5)
φ
6 Spring 1 1.0×φ8.5×31.0 mm
7 Poppet 1
8 Check Valve 1
9 Piston 1
10 O-Ring 1 1B P24
11 Plug 1 : 36 mm 240±24 (24±2.4) (175±17.5)

W4-4-2
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 SECTION 5
ENGINE AND ACCESSORY
 CONTENTS 
General Information Engine Assembly 2
General Repair Instructions ........................... 1-2 (Inspection and Repair)
Notes on the Format of This Manual .............. 1-2 Cylinder Head ................................................ 4-2

Main Data and Specifications......................... 1-6 Valve Guide.................................................... 4-3

Performance Curve........................................ 1-7 Valve Spring ................................................... 4-6

External View ................................................. 1-9 Tappet ............................................................ 4-7

Tightening Torque Specifications ..................1-11 Push Rod ....................................................... 4-8

Angular Nut and Bolt Tightening Method...... 1-13 Rocker Arm Shaft and Rocker Arm................. 4-8

Major Parts Fixing Nuts and Bolts ................ 1-15 Idler Gear and Idler Gear Shaft ...................... 4-9

Identifications............................................... 1-26 Camshaft...................................................... 4-10

Cylinder Body and Liner ............................... 4-11
Maintenance Piston and Piston Ring ................................. 4-17
Lubricating System ........................................ 2-2 Piston Pin..................................................... 4-19
Fuel System................................................... 2-3 Connecting Rod ........................................... 4-20
Cooling System.............................................. 2-7 Crankshaft.................................................... 4-22
Valve Clearance Adjustment .......................... 2-7 Flywheel....................................................... 4-29
Injection Timing.............................................. 2-9 Timing Gear Case Cover.............................. 4-29
Compression Pressure Measurement .......... 2-14
Turbocharger Inspection .............................. 2-15 Engine Assembly 3 (Reassembly)
Engine Repair Kit ......................................... 2-16 Piston and Connecting Rod
Recommended Lubricants ........................... 2-17 Reassembly Steps........................................ 5-2
Engine Oil Viscosity Chart ........................... 2-17 Cylinder Head Reassembly Steps .................. 5-4
Rocker Arm and Rocker Arm Shaft
Engine Assembly 1 (Disassembly) Reassembly Steps........................................ 5-7
External Parts Disassembly Steps ................. 3-2 Major Component Reassembly Steps 1.......... 5-8
Major Components......................................... 3-6 Major Component Reassembly Steps 2........ 5-13
Rocker Arm and Rocker Arm Shaft External Parts Reassembly Steps
Disassembly Steps......................................3-11 (Left-Hand Side) ......................................... 5-18
Cylinder Head Disassembly Steps ............... 3-12 External Parts Reassembly Steps
Piston and Connecting Rod (Right-Hand Side)....................................... 5-21
Disassembly Steps..................................... 3-13 Engine Tuning Operation.............................. 5-25

CDBW-5-1
Lubricating System Troubleshooting
General Description ....................................... 6-2 Hard Starting ................................................ 11-2
Oil Pump ........................................................ 6-3 1) Starter Inoperative ................................. 11-2
Oil Cooler....................................................... 6-5 2) Starter Operates but
Engine does not Turn Over .................... 11-3
Cooling System
3) Engine Turns Over but does not Start
General Description ....................................... 7-2
Fuel is Being Delivered to the
Thermostat..................................................... 7-3
Injection Pump ....................................... 11-4
Fuel System 4) Engine Turns Over but does not Start .... 11-5
General Description ....................................... 8-2 Unstable Low Idling ...................................... 11-6
Injection Nozzle ............................................. 8-3 Insufficient Power......................................... 11-8
Injection Pump Calibration Data..................... 8-8 Excessive Fuel Consumption ......................11-11
Excessive Oil Consumption........................ 11-13
Turbocharger
Overheating ............................................... 11-14
General Description ....................................... 9-2
Whity Exhaust Smoke ................................ 11-16
Turbocharger Identification ............................ 9-3
Dark Exhaust Smoke.................................. 11-17
Troubleshooting ............................................. 9-5
Oil Pressure does not Rise......................... 11-18
Inspection and Repair .................................... 9-7
Abnormal Engine Noise.............................. 11-20
Engine Electricals
Special Tool List
Starter Identification ..................................... 10-2
Special Tool List ........................................... 12-2
Starter Main Data and Specifications ........... 10-3
Starter Sectional View.................................. 10-4 Repair Standards
Performance ................................................ 10-4 Repair Standards ......................................... 13-1
Disassembly ................................................ 10-5
Conversion Table
Inspection and Repair .................................. 10-8
Length .......................................................... 14-2
Reassembly ............................................... 10-12
Area ............................................................. 14-3
Adjustment................................................. 10-13
Volume ......................................................... 14-3
Performance Test....................................... 10-14
Mass ............................................................ 14-5
Alternator Identification .............................. 10-15
Pressure....................................................... 14-6
Main Data and Specifications..................... 10-16
Torque .......................................................... 14-7
Alternator Sectional View ........................... 10-17
Temperature ................................................. 14-8
Charging Circuit ......................................... 10-17
Structure .................................................... 10-18
Disassembly .............................................. 10-19
Inspections ................................................ 10-22
Reassembly ............................................... 10-24
Bench Test ................................................. 10-25
Current Output Test.................................... 10-26
Fault Finding .............................................. 10-27
Specifications............................................. 10-27

CDBW-5-2
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162

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