PART NO.

WDEE-EN-00

ZX85USB-5A
HYDRAULIC EXCAVATOR
Workshop Manual

ZX85USB-5A

WORKSHOP MANUAL
Hydraulic Excavator

URL:[Link]

Service Manual consists of the following separate Part No.

WDEE-EN-00

Technical Manual (Operational Principle) : Vol. [Link]-EN

Technical Manual (Troubleshooting) : Vol. [Link]-EN
Workshop Manual : Vol. [Link]-EN
PRINTED IN JAPAN (K) 2014, 04 Engine Manual : Vol. [Link]-EN, EWADB-EN
 INTRODUCTION
To The Reader
This manual is written for an experienced technician to  If you have any questions or comments, at if you found
provide technical information needed to maintain and any errors regarding the contents of this manual,
repair this machine. please contact using “Service Manual Revision Request
The machine specification and description according to Form” at the end of this manual. (Note: Do not tear off
destination may be explained on this manual. the form. Copy it for usage.):
 Technical Information Center Hitachi Construction
 Be sure to thoroughly read this manual for correct Machinery Co., Ltd.
product information and service procedures.  TEL: 81-29-832-7084
 FAX: 81-29-831-1162
 E-mail: HCM-TIC-GES@[Link]

Additional References
Please refer to the other materials (operator’s manual,
parts catalog, engine technical material and Hitachi
training material etc.) in addition to this manual.

Manual Composition
This manual consists the Technical Manual, the Workshop  Information included in the Workshop Manual:
Manual and the Engine Manual. Technical information needed for maintenance and
repair of the machine, tools and devices needed for
 Information included in the Technical Manual: maintenance and repair, maintenance standards, and
Technical information needed for redelivery and delivery, removal / installation and assemble / disassemble
operation and activation of all devices and systems, procedures.
operational performance tests, and troubleshooting
procedures.  Information included in the Engine Manual:
Technical information needed for redelivery and delivery
and maintenance and repair of the machine, operation
and activation of all devices and systems, troubleshooting
and assemble / 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:
 Technical Manual: T 1-3-5  Workshop Manual: W 1-3-2-5
T Technical Manual W Workshop Manual
1 Section Number 1 Section Number
3 Group Number 3 Group Number
5 Consecutive Page Number for Each Group 2 Sub Group Number
5 Consecutive Page Number for Each Group

IN-01
 INTRODUCTION
Safety Alert Symbol and Headline Notations
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the potential dCAUTION:
for personal injury of machine damage. Indicates potentially hazardous situation which could, if
not avoided, result in personal injury or death.
d This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury.
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.
To avoid injury and damage, be sure to use appropriate
fNOTE:
Indicates supplementary technical information or know-
lifting techniques and equipment when lifting heavy
how.
parts.

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

Quantity To Convert From Into Multiply By

Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m3 yd3 1.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N·m kgf·m 0.10197
Pressure MPa kgf/cm 2
10.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C×1.8+32
Velocity km/h mph 0.6214
min -1
rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0

fNOTE: The numerical value in this manual might be

different from the above-mentioned table.

IN-02
 SYMBOL AND ABBREVIATION

Symbol / Name Explanation

Abbreviation
TO Technical manual (Operational principle)Technical manual (Operational Principle).
TT Technical manual (Troubleshooting) Technical manual (Troubleshooting).
T/M Technical manual Technical manual.
W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly
and Assembly).
MC Main Controller Main controller. MC controls the engine, pump, and valve
according to the machine operating condition.
ECU Engine Control Module Engine controller. ECU controls fuel injection amount
according to the machine operating condition.
GSM Global System for Mobile communications Communication controller. GSM is a type of wireless
controller communication system, is used in more than on 100
countries around Europe and Asia, and becomes the factual
global standards of the mobile telephone.
GPS Global Positioning System Global positioning system.
CAN Controller Area Network CAN communication. CAN is a serial communications
protocol internationally-standardized by ISO (International
Organization for Standardization).
A/C Air Conditioner Air conditioner.
OP, OPT Option Optional component.
MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and
adjustment.
A/I Auto-Idle Auto-idle.
WU Warming-Up Warming-up.
Li Low (Slow) Idle Slow idle engine speed.
ATT Attachment Attachment. Attachment is optional parts such as breaker,
crusher, and pulverizer in this manual.
HI, Hi High Travel fast position.
LO, Lo Low Travel slow position.
EGR Exhaust Gas Recirculation The EGR control re-circulates a part of exhaust gas in the
intake manifold and combines it with intake-air. Therefore,
combustion temperature is lowered and generation of oxide
of nitrogen (NOx) is controlled.
CSD Cold Start Device Engine start device at low temperature. It increasingly
advances the fuel injection timing and increases the fuel
injection amount a little when coolant temperature is less
than 5 °C. Therefore, the engine starting is improved.

SY-1
 SYMBOL AND ABBREVIATION
(Blank)

SY-2
 SAFETY

Recognize Safety Information

 These are the SAFETY ALERT SYMBOLS.
 When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
 Follow recommended precautions and safe operating
practices.

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 do not use any of the designated signal
words above after the safety alert symbol are occasionally
used on this machine.

 CAUTION also calls attention to safety message in this

manual.
SA-1223
 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.

SA-1
 SAFETY

Follow Safety Instructions

 Carefully read and follow all safety signs on the machine
and all safety messages in operator's manual.
 Safety signs should be installed, maintained and replaced
when necessary.
 If a safety sign or operator's manual is damaged or
missing, order a replacement from your authorized dealer
in the same way you order other replacement 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 to
operate the machine. SA-003
 Keep your machine in proper working condition.
 Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
 Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, function,
and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
 Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do so
may deteriorate the safety, function, and/or service life
of the machine. In addition, personal accident, machine
trouble, and/or damage to material caused by using
unauthorized attachments and/or optional parts or
equipment will void Hitachi Warranty Policy.
 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 authorized dealer before operating or performing
maintenance work on the machine.

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 attached 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, ambulance
service, hospital, and fire department posted near your
telephone. SA-437

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 SA-438
Wet weather gear
Respirator or filter mask.
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.

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.

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 "Inspect Machine Daily Before Starting"
section in the operator’s manual.

SA-435

SA-4
 SAFETY
General Precautions for Cab
 Before entering the cab, thoroughly remove all dirt and/or
oil such as mud, grease, soil or stones that may mess up
the cab 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.
 Do not mess up around the operator’s seat with parts,
tools, soil, stones, obstacles that may fold up or turn
over, cans or lunch box. The levers or pedals become
inoperable if obstacle jams in operation stroke of the
travel levers/pedals, pilot control shut-off lever or control
levers, which may result in serious injury or death.
 Avoid storing transparent bottles in the cab. Do not
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 extinguish the
match and/or tobacco.
 Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
 Use proper floor mat dedicated to the machine. If another
floor mat is used, it may be displaced and contact with
the travel pedals during operation, resulting in serious
injury or death.

SA-5
 SAFETY

Use Handholds and Steps

 Falling is one of the major causes of personal injury.
 When you get on and off the machine, 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 leaving the machine.
 Never get on and off the machine with tools in your
hands.
SA-439

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.
 Adjust the rear view mirror position so that the best rear
visibility is obtained from the operator’s seat. If the mirror SA-378
is broken, immediately replace it with a new one.

SA-6
 SAFETY
Ensure Safety Before Rising from or Leaving
Operator’s Seat
 Before rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with
a control lever and/or pedal, possibly resulting in serious
personal injury or death.
 Before leaving the machine, be sure to first lower the front
attachment to the ground and then move the pilot control
shut-off lever to the LOCK position. Turn the key switch OFF
to stop the engine.
 Before leaving the machine, close all windows, doors, and
access covers and lock them up.

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 securely
fastened at all times when the machine is in operation to SA-237
minimize the chance of injury from an accident.
 We recommend that the seat belt be replaced every three
years regardless of its apparent condition.

SA-7
 SAFETY

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.
 Use appropriate illumination. Check that all lights are SA-426
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
 Ensure the cab door, windows, doors and covers are
securely locked.
 Check the mirrors and the monitor in the CAB for
problems.
If there is, replace the problem part(s) or clean the mirror,
camera and the monitor.
Refer to Rear View Monitor section on the cleaning of the
camera and the monitor.

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.
 Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders. SA-444

SA-8
 SAFETY

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 machine.
SA-032

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.

SA-379

SA-9
 SAFETY

Precautions for Operations

 Investigate the work site before starting operations.
 Be sure to wear close fitting clothing and safety
equipment appropriate for the job, such as a hard hat,
etc. when operating the machine.
 Clear all persons and obstacles from area of operation and
machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by obstacles,
take care not to hit the upperstructure against obstacles.
 When loading onto trucks, bring the bucket over the truck
beds from the rear side. Take care not to swing the bucket
over the cab or over any person.

M178-05-007

SA-10
 SAFETY

Investigate Job Site Beforehand

 When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death.
 Investigate the configuration and ground conditions of
the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles or banks
from collapsing.
 Make a work plan. Use machines appropriate to the work
and job site.
 Reinforce ground, edges and road shoulders as
necessary. Keep the machine well back from the edges of
excavations and road shoulders.
 When working on an incline or on a road shoulder, SA-380
employ a signal person as required.
 Confirm that your machine is equipped with a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
 When the footing is weak, reinforce the ground before
starting work.
 When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
 Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.

SA-11
 SAFETY
 Make sure the worksite has sufficient strength to firmly
support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks positioned
perpendicular to the cliff face with travel motors at the rear,
so that the machine can more easily evacuate if the cliff face
collapses.
 If working on the bottom of a cliff or a high bank is required,
be sure to investigate the area first and confirm that no
danger of the cliff or bank collapsing exists. If any possibility
of cliff or bank collapsing exists, do not work on the area.
 Soft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm
enough to easily support the machine.
 Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent M104-05-016
machine tipping over from occurring. When operating on
rough terrain or on slopes:
 Reduce the engine speed.
 Select slow travel speed mode.
 Operate the machine slowly and be cautious with
machine movements.

Install OPG Guard

In case the machine is operated in areas where the possibilities
of falling stones or debris exist, equip Hitachi OPG guard.
Consult your authorized dealer for installing the OPG guard.
The guard can be compliant with ROPS standards depending
on the machine specifications.
In order not to impair operator protective structure:
Replace damaged ROPS or OPG guard. Never attempt to repair
or modify the guard.

ROPS: Roll Over Protective Structure

OPG: Operator Protective Guard

SA-490

SA-12
 SAFETY

Provide Signals for Jobs Involving Multiple

Machines
 For jobs involving multiple machines, provide signals
commonly known by all personnel involved. Also, appoint
a signal person to coordinate the job site. Make sure that all
personnel obey the signal person’s directions.

SA-481

Confirm Direction of Machine to Be Driven

 Incorrect travel pedal/lever operation may result in serious
injury or 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.

SA-491

SA-13
 SAFETY

Drive Machine Safely

 Before driving the machine, always confirm that the travel
levers/pedals direction corresponds to the direction you
wish to drive.
 Be sure to detour around any obstructions.
 Avoid traveling over obstructions. Soil, fragments of rocks,
and/or metal pieces may scatter around the machine. Do A
not allow personnel to stay around the machine while
traveling.

 Driving on a slope may cause the machine to slip or SA-657

overturn, possibly resulting in serious injury or death.
 Never attempt to ascend or descend 35 degrees or
steeper slopes.
 Be sure to fasten the seat belt.
 When driving up or down a slope, keep the bucket facing
the direction of travel, approximately 0.2 to 0.3 m (A)
above the ground.
 If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.
 Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If A SA-658
the direction must be changed, move the machine to
level ground, then, change the direction to ensure safe
operation.

SA-441

WRONG

SA-590

SA-14
 SAFETY
 Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
 If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to neutral.
Then, restart the engine.
 Be sure to thoroughly warm up the machine before
ascending steep slopes. If hydraulic oil has not warmed
up sufficiently, sufficient performance may not be Travel Motor
obtained.
 Use a signal person when moving, swinging or operating M104-05-008
the machine in congested areas. Coordinate hand signals
before starting the machine.
 Before moving machine, determine which way to move
travel pedals/levers for the direction you want to go.
When the travel motors are in the rear, pushing down
on the front of the travel pedals or pushing the levers
forward moves the machine forward, towards the idlers.
An arrow-mark seal is stuck on the inside surface of the
side frame to indicate the machine front direction.
 Select a travel route that is as flat as possible. Steer the
Arrow -mark
machine as straight as possible, making small gradual
changes in direction. M178-03-001
 Before traveling on them, check the strengths of bridges
and road shoulders, and reinforce if necessary.
 Use wood plates in order not to damage the road surface.
Be careful of steering when operating on asphalt roads in
summer.
 When crossing train tracks, use wood plates in order not
to damage them.
 Do not make contact with electric wires or bridges.
 When crossing a river, measure the depth of the river
using the bucket, and cross slowly. Do not cross the river
when the depth of the river is deeper than the upper
edge of the upper roller.
SA-011
 When traveling on rough terrain, reduce engine speed.
Select slow travel speed. Slower speed will reduce
possible damage to the machine.
 Avoid operations that may damage the track and
undercarriage components.
 During freezing weather, always clean snow and ice from
track shoes before loading and unloading machine, to
prevent the machine from slipping.

SA-15
 SAFETY

Avoid Injury from Rollaway Accidents

 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 the machine.
 Do not park the machine on a grade.
 Lower the bucket and/or other work tools to the ground.
 Turn the auto-idle 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 position.
SA-391
 Block both tracks 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 at a reasonable distance from other machines.

SA-2273

SA-16
 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 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. SA-383
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 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 SA-384
operator’s manual.

SA-17
 SAFETY

Keep Person Clear from Working Area

 A person may be hit severely by the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or death.
 Keep all persons clear from the area of operation and
machine movement.
 Before operating the machine, set up barriers to the
sides and rear area of the bucket swing radius to prevent
anyone from entering the work area.

SA-386

Never Position Bucket Over Anyone

 Never lift, move, or swing bucket above anyone or a truck
cab.
Serious injury or machine damage may result due to bucket
load spill or due to collision with the bucket.

SA-487

SA-18
 SAFETY
Avoid Undercutting
 In order to retreat from the edge of an excavation if the
footing should collapse, always position the undercarriage
perpendicular to the edge of the excavation with the travel
motors at the rear.
 If the footing starts to collapse and if retreat is not
possible, do not panic. Often, the machine can be secured
by lowering the front attachment, in such cases.

SA-488

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.
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 SA-012
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 15
degrees if crossing the grade is unavoidable.
 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.

SA-440

SA-19
 SAFETY

Never Undercut a High Bank

 The edges could collapse or a land slide could occur causing
serious injury or death.

SA-489

Dig with Caution

 Accidental severing of underground cables or gas lines may
cause an explosion and/or fire, possibly resulting in serious
injury or death.
 Before digging check the location of cables, gas lines, and
water lines.
 Keep the minimum distance required, by law, from cables,
gas lines, and water lines.
 If a fiber optic cable should be accidentally severed, do
not look into the end. Doing so may result in serious eye
injury.
 Contact your local “diggers hot line” if available in your
area , and/or the utility companies directly.
SA-382
Have them mark all underground utilities.

Operate with Caution

 If the front attachment or any other part of the machine hits
against an overhead obstacle, such as a bridge, both the
machine and the overhead obstacle will be damaged, and
personal injury may result as well.
 Take care to avoid hitting overhead obstacles with the
boom or arm.

SA-389

SA-20
 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 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 site.

SA-381

Precautions for Lightning

 The machine is vulnerable to lightning strikes.
 In the event of an electrical storm, immediately stop
operation, and lower the bucket to the ground. Evacuate
to a safe place far away from the machine.
 After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed
safety devices are found, operate the machine only after
repairing them.

SA-1088

SA-21
 SAFETY

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 blocks or on the
ground.
 Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.

SA-014

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.
 Always close the front windows, doors, door windows and
the overhead window when operating the machine.

SA-432

SA-22
 SAFETY

Park Machine Safely

To avoid accidents:
 Park machine on a firm, level surface.
 Lower bucket to the ground.
 Turn auto-idle 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 the pilot control shut-off lever to the LOCK position.
 Close windows, roof vent, and cab door.
 Lock all access doors and compartments.

SA-390

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.

 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 SA-018
spontaneously.
 Securely tighten the fuel and oil filler cap.

SA-019

SA-23
 SAFETY

Transport Safely
 Take care the machine may turn over when loading or
unloading the machine onto or off of a truck or trailer.
 Observe the related regulations and rules for safe
transportation.
 Select an appropriate truck or trailer for the machine to
be transported.
 Be sure to use a signal person.
 Always follow the following precautions for loading or
unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the
machine weight. SA-395

3. Turn auto-idle switch OFF.

4. Always select the slow speed mode with the travel mode
switch.
5. Never load or unload the machine onto or off a truck
or trailer using the front attachment functions when
driving up or down the ramp.
6. Never steer the machine while on the ramp. If the
traveling direction must be changed while the ramp,
unload the machine from the ramp, reposition the
machine on the ground, then try loading again.
7. The top end of the ramp where it meets the flatbed is a
sudden bump. Take care when traveling over it.
8. Place blocks in front of and behind the tires. Securely
hold the machine to the truck or trailer deck with wire
ropes.

Be sure to further follow the details described in the

TRANSPORTING section.

SA-24
 SAFETY

Practice Safe Maintenance

To avoid accidents:
 Understand service procedures before starting work.
 Keep the 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 switch 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. SA-028

7. Remove the key from the key 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.

 If a maintenance procedure must be performed with the

engine running, do not leave the 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.
 Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the
“MAINTENANCE” chapter of operator's manual. SA-527
 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
detergent oil. Never use highly flammable oil such as fuel
oil and gasoline to clean parts or surfaces.
 Disconnect battery ground cable (−) before making
adjustments to electrical systems or before performing
welding on the machine.

SA-25
 SAFETY
 Sufficiently illuminate the work site. Use a maintenance
work light when working under or 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.

SA-037

Warn Others of Service Work

 Unexpected machine movement can cause serious injury.
 Before performing any work on the machine, attach 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 jack.
SA-527

SA-26
 SAFETY

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.

SA-026

SA-2294

Prevent Parts from Flying

 Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result in serious
injury, blindness, or death.
 Do not attempt to remove GREASE FITTING or VALVE
ASSEMBLY.
 Do not attempt to remove grease fitting securing cover.
 As pieces may fly off, be sure to keep body and face away
from valve.
 Never attempt to disassemble the track adjuster.
Inadvertent disassembling of the track adjuster may
cause the parts such as a spring to fly off, possibly SA-344
resulting in severe personal injury or death.

 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.

SA-27
 SAFETY

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

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.
 The hydraulic oil tank is pressurized. Again, be sure to SA-039
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.

SA-225

SA-28
 SAFETY

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 attachment to fall on a
SA-019
person nearby, which may result in severe burns, gangrene,
or otherwise serious injury or death.

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 goggles for eye protection.
 If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the SA-031
skin must be surgically removed within a few hours or
gangrene may result.

SA-292

SA-044

SA-29
 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 hoses.
 Replace fuel hoses and hydraulic hoses periodically even
if there is no abnormality in their external appearance.
SA-019
Check for Shorts:
 Short circuits can cause fires.
 Clean and tighten all electrical connections.
 Check before each shift or after eight (8) to ten (10) hours
operation for loose, kinked, hardened or frayed electrical
cables and wires.
 Check before each shift or after eight (8) to ten (10) hours
operation for missing or damaged terminal caps.
 DO NOT OPERATE MACHINE if cable or wires are loose,
kinked, etc.
 Never attempt to modify electric wirings.

SA-30
 SAFETY
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 adhered oil or accumulated
flammables immediately. Check and clean high
temperature parts such as the exhaust outlet and
mufflers earlier than the normal interval.
 Do not wrap high temperature parts such as a muffler or
exhaust pipe with oil absorbents.
 Do not store oily cloths as they are vulnerable to catching
fire.
 Keep flammables away from open flames.
 Do not ignite or crush a pressurized or sealed container.
 Wire screens may be provided on openings on the engine
compartment covers to prevent flammables such as
dead leaves from entering. However, flammables which
have passed through the wire screen may cause fires.
Check and clean the machine every day and immediately
remove accumulated flammables.

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.
 If hydraulic hoses are broken while the engine cover is
open, splattered oil on the high temperature parts such
as mufflers may cause fire. Always close the engine cover
while operating the machine.

SA-31
 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 or front window can not
be opened, break the front or rear window panes with
the emergency evacuation hammer to escape from the
cab. Refer to the explanation pages on the Emergency SA-393
Evacuation Method.

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.

SA-016

SA-32
 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 there are
no abnormalities such as the area surrounding the welded
area still smoldering. SA-818

SA-33
 SAFETY

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.

Precautions for Handling Accumulator and Gas

Damper
High-pressure nitrogen gas is sealed in the accumulator and
the gas damper. Inappropriate handling may cause explosion,
possibly resulting in serious injury or death.

Strictly comply with the following items: Do not disassemble

the unit.
 Keep the units away from open flames and fire.
 Do not bore a hole, do not cut by torch.
 Avoid giving shocks by hitting or rolling the unit.
 Before disposing the unit, sealed gas must be released.
Consult your nearest Hitachi dealer.

SA-34
 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.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with SA-029
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.

Beware of Asbestos and Silicon Dust and Other

Contamination
 Take care not to inhale dust produced in the work site.
Inhalation of asbestos fibers may be the cause of lung
cancer. Inhalation of silicon dust or other contamination
may cause sickness.
 Depending on the work site conditions, the risk
of inhaling asbestos fiber, silicon dust or other
contamination may exist. Spray water to prevent asbestos
fibers, silicon dust or other contamination from becoming
airborne. Do not use compressed air.
 When operating the machine in a work site where
asbestos fibers, silicon dust or other contamination SA-029
might be present, be sure to operate the machine
from the upwind side and wear a mask rated to
prevent the inhalation of asbestos, silicon dust or other
contamination.
 Keep bystanders out of the work site during operation.
 Asbestos fibers might be present in imitation parts. Use
only genuine Hitachi Parts.

SA-35
 SAFETY

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 hydrometer.
 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. Explosion of the
battery may result.
 Loose terminals may produce sparks. Securely tighten all
terminals. SA-032
 Connect terminals to the correct electrical poles. Failure
to do so may cause damage to the electrical parts or fire.

 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.

Service Air Conditioning System Safely

 If spilled onto skin, refrigerant may cause a cold contact
burn.
 Refer to the instructions described on the container for
proper use when handling the refrigerant.
 Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
 Never touch the refrigerant.

SA-405

SA-36
 SAFETY

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 safely. Then follow
procedures and use recommended equipment. SA-309
 See your authorized dealer for MSDS’s (available only in
English) on chemical products used with your machine.

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. Government regulations SA-226
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, or from
your authorized dealer.

SA-37
 SAFETY

Never Ride Attachment

Never allow anyone to ride attachments or load. This is an
extremely dangerous practice.

Precautions for Communication Terminal

Electrical wave transmitted from the communication terminal
may cause malfunction of other electronic devices.
Inquire the device manufacturer for electrical wave
disturbance upon using an electronic device near the
communication terminal.

SA-38
 SAFETY
Precaution for Communication Terminal
Equipment
This machine has a communication terminal equipment
emitting electrical waves installed inside a rear tray which is
situated at the back of the driver's seat. There is a possibility
that a medical device, including an implantable device
such as a cardiac pacemaker, would be affected and would
malfunction by the electrical waves emitted from the
communication terminal equipment.

Any person affixed with a medical device such as the above

should not use this machine, unless the medical device and
SA-2346
the rear tray are at least 22 centimeters (8.662 inches) apart at
all times. If such condition cannot be met, please contact our
company's nearest dealer and have the person in charge stop
the communication terminal equipment from functioning
completely and confirm that it is not emitting electrical waves.

Specific Absorption Rate ("SAR") (measured by 10 g per unit) of

communication terminal equipments:
E-GSM900 0.573 W/Kg (914.80 MHz)
DCS-1800 0.130 W/Kg (1710.20 MHz)
WCDMA Band I 0.271 W/Kg (1950.00 MHz)

*This data was measured by having each type of

communication terminal equipment, such as the
communication terminal equipment used with this machine,
and a human body set apart by 3 cm (1.18 inches).
* SAR is a measure of the amount of radio frequency energy
absorbed by the body when using a wireless application such
as a mobile phone.

In Japan: *Under the Japanese Radio Act and other relevant

Japanese regulations, the maximum SAR value is 2 W/kg (as of
March 2010).

In EU Member nation: *Under the "Council Recommendation

1999/519/EC 12 July 1999'; the maximum SAR value is 2 W/kg
(as of March 2010).

SA-39
 SAFETY
 Do not attempt to disassemble, repair, modification and
displacement of the communication terminal, antenna
and cables. Failure to do so may cause damage or fire on
the machine and the communication terminal. (Before
removing or installing the communication terminal, consult
your authorized Hitachi dealer.)

 Do not pinch or forcibly pull cables, cords and connectors.

Failure to do so may cause damage or fire on the machine
and the communication terminal due to short/broken
circuit.

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.

SA-435

SA-40
 SECTION AND GROUP SECTION 1 GENERAL INFORMATION
CONTENTS Group 1 Precautions for Disassembling and
Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air
Group 5 Pressure Release Procedure
WORKSHOP MANUAL Group 6 Preparation
SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure
Group 2 Undercarriage
Group 3 Front Attachment
SECTION 3 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
Group 4 Engine
Group 5 Pump Device
Group 6 Control Valve
Group 7 Swing Device
Group 8 Pilot Valve
Group 9 Solenoid Valve
Group 10 Shockless Valve
SECTION 4 UNDERCARRIAGE
All information, illustrations and Group 1 Swing Bearing
specifications in this manual are based on
the latest product information available Group 2 Travel Device
at the time of publication. The right is
reserved to make changes at any time Group 3 Center Joint
without notice. Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Rollers
Group 7 Track
Group 8 Blade Cylinder
SECTION 5 FRONT ATTACHMENT
COPYRIGHT(C)2014
Hitachi Construction Machinery Co., Ltd. Group 1 Front Attachment
Tokyo, Japan
All rights reserved Group 2 Cylinder
TECHNICAL MANUAL (Operational Principle) TECHNICAL MANUAL (Troubleshooting)
SECTION 1 GENERAL SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Specifications Group 1 Introduction
Group 2 Component Layout Group 2 Standard
Group 3 Component Specifications Group 3 Engine Test
SECTION 2 SYSTEM Group 4 Excavator Test
Group 1 Controller Group 5 Component Test
Group 2 Control System SECTION 5 TROUBLESHOOTING
Group 3 Hydraulic System Group 1 Diagnosing Procedure
Group 4 Electrical System Group 2 Monitor
SECTION 3 COMPONENT OPERATION Group 3 e-Service
Group 1 Pump Device Group 4 Component Layout
Group 2 Swing Device Group 5 Troubleshooting A
Group 3 Control Valve Group 6 Troubleshooting B
Group 4 Pilot Valve Group 7 Air Conditioner
Group 5 Travel Device
Group 6 Others (Upperstructure)
Group 7 Others (Undercarriage)
SECTION 1

GENERAL
CONTENTS
Group 1 Precautions for Disassembling and
Assembling
Precautions for Disassembling and
Assembling..................................................................W1-1-1-1
Group 2 Tightening
Tightening Bolts and Nuts...........................................W1-2-1-1
Piping Joint.......................................................................W1-2-1-4
Group 3 Painting
Painting..............................................................................W1-3-1-1
Group 4 Bleeding Air
Bleeding Air from Hydraulic Oil Tank.......................W1-4-1-1
Bleeding Air from Hydraulic System........................W1-4-1-2
Bleeding Air from Fuel System...................................W1-4-1-3
Bleeding Air from Radiator..........................................W1-4-1-4
Group 5 Releasing Pressure
Releasing Pressure in Hydraulic Circuit...................W1-5-1-1
Group 6 Preparation
Preparation before Inspection and
Maintenance...............................................................W1-6-1-1

DEEW-1-1
(Blank)

DEEW-1-2
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

Precautions for Disassembling and  If a part or component cannot be removed after

Assembling removing its securing nuts and bolts, do not attempt
to remove it forcibly. Find the cause (s), then take the
Precautions for Disassembling appropriate measures to remove it.
 Orderly arrange disassembled parts. Mark and tag
 Clean the Machine
them if necessary.
Thoroughly wash the machine before bringing it
 Store common parts, such as bolts and nuts with
into the shop. Bringing a dirty machine into the shop
reference to where they are to be used and in a
may cause machine components to be contaminated
manner that will prevent loss.
during disassembling / assembling, resulting in
 Inspect the contact or sliding surfaces of
damage to machine components, as well as decreased
disassembled parts for abnormal wear, sticking, or
efficiency in service work.
other damage.
 Measure and record the degree of wear and
 Inspect the Machine
clearances.
Be sure to thoroughly understand all disassembling
/ assembling procedures beforehand to help avoid
 Precautions for Assembling
incorrect disassembling of components as well as
 Be sure to clean all parts and inspect them for any
personal injury.
damage. If any damage is found, repair or replace
Check and record the items listed below to prevent
part.
problems from occurring in the future.
 Dirt or debris on the contact or sliding surfaces may
 The machine model, machine serial number, and
shorten the service life of the machine. Take care not
hour meter reading.
to contaminate any contact or sliding surfaces.
 Reason for disassembly (symptoms, failed parts, and
 Apply appropriate lubricant oil onto parts in order to
causes).
prevent them from seizing.
 Clogging of filters and oil, water or air leaks, if any.
 Be sure to replace O-rings, backup rings, oil seals, and
Capacities and condition of lubricants.
floating seals with new ones once they have been
 Loose or damaged parts.
disassembled. Apply grease before installing
 Be sure that liquid-gasket-applied surfaces are clean
 Prepare and Clean Tools and Disassembly Area
and dry.
Prepare the necessary tools to be used and the area for
 If an anti-corrosive agent has been used on a new
disassembling work.
part, be sure to thoroughly clean the part to remove
the agent.
Precautions for Disassembling and Assembling
 Fit the matching marks made when disassembling
 Precautions for Disassembling and assemble them.
 Cap the open ends in case the hoses and pipes  Be sure to use the designated tools to assemble
have been disconnected. In addition, attach an bearings, bushings, and oil seals.
identification tag onto the connectors, hoses, and  Keep a record of the number of tools used for
pipes for assembling. disassembly / assembly. After assembling is
 Before disassembling, clean the exterior of the completed, count the number of tools so as to make
components and place on a workbench. sure that no forgotten tools remain in the assembled
 Drain hydraulic oil and gear oil from the hydraulic machine.
components and reduction gear.
 Be sure to provide appropriate containers for
draining fluids.
 Use matching marks for easier reassembling if
necessary.
 Be sure to use the specified special tools when
instructed.

W1-1-1-1
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

Precautions for Using Floating Seal 1

1. In general, replace the floating seal with a new one

after disassembling.
If the floating seal is required to be reused, follow
these procedures:
 Keep seal rings together as a matched set with seal
ring (1) surfaces together. Apply oil onto sliding
surface (e) of seal ring (1). W178-02-11-001
2
 Check sliding surface (e) of seal ring (1) for scuffing,
scoring, corrosion, deformation, or uneven wear.
Check the step part of seal ring (1).
 Check O-ring (2) 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.
 Clean the floating seal and seal mounting bores with
cleaning solvent. a
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air. c
 Clean seal ring (1) and O-ring (2) mounting bores. b
Check the bore surface for scuffing or scoring by
d
touching the surface with finger.
 After installing the floating seal, check that O-ring (2)
W178-02-11-002
is not twisted, and that it is installed correctly on seal
ring (1). a- Correct c- Twist of O-Ring
 After installing the floating seal, check that O-ring b- Incorrect d- Bend of O-Ring
(2) and seal ring sliding surface (e) is parallel with
seal mating surface (f ) by measuring the distances f
(e) and (f ) at point (A) and (B), as illustrated. If these
distances differ, correct O-ring (2) seating. a A b A

B B

A=B A≠B

W178-02-11-003

a- Correct e- Sliding Surface

b- Incorrect f- Seal Mating Surface

W1-1-1-2
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings a
safely.
 Attach protectors (soft material) on the corners of
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. W102-04-02-016
 Take care not to allow the sling to become wet. The
a- Correct Eyehole Lifting
load may slip.
Method
 When required to use more than one sling, use slings
with the same width and length to keep the lifted b
load balanced.
 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 W105-04-01-008
with protrusions.
 Avoid dragging slings on the ground, throwing b- Incorrect Eyehole Lifting
Method
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 that they won’t
deteriorate with heat, sun light, or chemicals.

c W162-01-01-009

c- Bent of Sling

W1-1-1-3
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

dCAUTION: If a load is lifted with a damaged

nylon sling, serious personal injury may result.
Be sure to visually check the nylon sling for any
damage before using.

2. Before using a nylon sling, visually check the nylon

sling for any damage corresponding to examples
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.

Damaged Appearance a
a

W162-01-01-002 W162-01-01-006
e
a- Broken Sewing Thread a- Broken Sewing Thread e- Separation of Belt

b f

W162-01-01-003 W162-01-01-007
b
b- Scuffing b- Scuffing f- Scoring

c
c g

W162-01-01-004
W162-01-01-008
c- Fuzz d- Broken Sewing Thread
c- Fuzz g- Broken Warp

W162-01-01-005

a- Broken Sewing Thread

W1-1-1-4
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

Maintenance Standard Terminology

“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies
adjusted to specification. Allowable errors will be
indicated if necessary.

“Allowable Limit”
1. Normal machine performance cannot be
accomplished after exceeding this limit.
2. Repair or adjustment is difficult after exceeding this
limit.
3. Repair or adjustment is impossible after exceeding
this limit.
Therefore, in consideration of operation efficiency
and maintenance expense, proper maintenance
shall be carried out before reaching the “Allowable
Limit”.

W1-1-1-5
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

(Blank)

W1-1-1-6
 SECTION 1 GENERAL
Group 2 Tightening

Tightening Bolts and Nuts

dCAUTION: Use tools appropriate for the work

to be done. Makeshift tools and procedures
can create safety hazards. For loosening and
tightening nuts and bolts, use correct size tools.
Otherwise, tightening tools may slip, potentially
causing personal injure.
IMPORTANT:
 Apply lubricant to the bolts and nuts in order
to reduce friction coefficient of them. (For
example, spindle oil with white zinc B dissolved
in it) WDAA-01-02-001
 Clean the bolt and nut threads and remove dirt
or corrosion before installing.

Bolt Types
Tighten the nuts or bolts correctly to the torque
specifications.
As the different types and grades of bolt are used,
use and tighten the correct bolts correctly when
assembling the machine or components.

Specified Tightening Torque Chart

2013/09
Bolt Hexagon Head Bolt Socket Bolt
Dia. Wrench Socket Bolt Wrench
mm Size mm Size mm

WDAA-01-02-002 WDAA-01-02-003 WDAA-01-02-004

N·m (lbf·ft) N·m (lbf·ft) N·m (lbf·ft) N·m (lbf·ft)
6 3 to 4 (2.2 to 3) 10 5
8 30 (22) 20 (15) 10 (7.4) 13 20 (15) 6
10 65 (48) 50 (37) 20 (15) 17 50 (37) 8
12 110 (81) 90 (66) 35 (26) 19 90 (66) 10
14 180 (133) 140 (103) 55 (41) 22 140 (103) 12
16 270 (200) 210 (155) 80 (59) 24 210 (155) 14
18 400 (300) 300 (220) 120 (89) 27 300 (220) 14
20 550 (410) 400 (300) 170 (125) 30 400 (300) 17
22 750 (550) 550 (410) 220 (162) 32
24 950 (700) 700 (520) 280 (205) 36
27 1400 (1030) 1050 (770) 400 (300) 41
30 1950 (1440) 1450 (1070) 550 (410) 46
33 2600 (1920) 1950 (1440) 750 (550) 50
36 3200 (2360) 2450 (1810) 950 (700) 55

W1-2-1-1
 SECTION 1 GENERAL
Group 2 Tightening

IMPORTANT: The following items are applied to both

fine and coarse pitch threads.
 Apply lubricant to the bolts and nuts in order
to reduce friction coefficient of them. (For
example, spindle oil with white zinc B dissolved
in it)
 Torque tolerance is ±10 %.
 Use the bolts of correct length. The bolts that
are too long cannot be tightened as the bolt tip
comes into contact with the bottom of bolt hole.
Also the bolts that are too short cannot develop
sufficient tightening force.
 The torque given in the chart on the previous
page are for general use only, however,
a different torque is given for a specific
application. Use the specified torque.
 Clean the nut and bolt threads and remove dirt
or corrosion before installing.

Tightening Order
When tightening two or more bolts, tighten them
alternately, as shown, to ensure even tightening.

a b c

1 12 9 4 1 6 7 14
1.4 6 3

4 5
2 13 8 5 2 3 10 11
2.3

W105-01-01-003

a- Equally tighten upper and b- Tighten diagonally c- Tighten from center

lower alternately diagonally

W1-2-1-2
 SECTION 1 GENERAL
Group 2 Tightening

Precautions for Spilt Flange

IMPORTANT:
 Clean the sealing surfaces. Check if there are
any scratches and roughness on the surface of
the seal that cause oil leaks and damage to the
WDAA-01-02-005
O-ring.
 Use only specified O-rings. Inspect O-rings for
any damage. Do not file the O-ring surfaces. Incorrect
When installing O-ring into a groove, use grease
in order to hold O-ring in place.
 While tightening the bolt by hand, check that
flange is installed to the port correctly. Do not
pinch the O-ring.
 Tighten the bolts up and down, left and right
alternately, in order to ensure even tightening
WDAA-01-02-006
to the specified torque.
 Do not use air wrenches. Using an impact
wrench often causes tightening of one bolt fully
before tighten the others, resulting in damage
to O-rings or uneven tightening of bolts.

Nut and Bolt Locking

 Lock Plate
W105-01-01-008
IMPORTANT: Do not reuse the lock plates. Do not try
to bend the same point twice.
Correct Incorrect
 Split Pin
IMPORTANT: Do not turn in the loosening direction
in order to align the grooves and holes on the nut.
a b
Always turn in the tightening direction. Do not
reuse the split pins.
Correct Correct Incorrect

 Wire
IMPORTANT: Attach wire to bolts in the bolt-
tightening direction. Do not reuse the wire.

a
WDAA-01-02-007

a- Bend along edge sharply b- Do not bend it round

Correct Correct
Incorrect

Correct d Incorrect
c

WDAA-01-02-008

c- Tighten d- Loosen

W1-2-1-3
 SECTION 1 GENERAL
Group 2 Tightening

Piping Joint
IMPORTANT:
 The torque given in table below are for general
use only, however, a different torque is given for
a specific application. Use the specified torque.
 Apply lubricant, such as the Grease Spray to
the bolts and nuts in order to reduce friction
coefficient of them.
 Torque tolerance is ±10 %.
 Slightly apply lubricant onto the threads first by
using the Grease Spray.

W1-2-1-4
 SECTION 1 GENERAL
Group 2 Tightening

Union Joint
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 4 3 5 2
 Do not over-tighten union nut (3). Excessive
force will be applied to metal sealing surfaces (4)
and (5), possibly cracking the adapter. Tighten
union nut (3) to the specifications.
 Scratches or other damage to sealing surfaces
(4) or (5) will cause oil leakage at the joint. Take
care not to damage them when connecting / a- Joint Body WDAA-01-02-009
a
disconnecting.

37 °
2013/09
Description Wrench Size mm Tightening Torque 30 °
Union Nut N·m (lbf·ft)
30 ° male 17 25 (18.5) b c
19 30 (22)
22 40 (29.5) b- Male Union Joint c- Female Union Joint
27 80 (59) WDAA-01-02-010
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)
55 380 (280)
60 380 (280)
37 ° female 17 25 (18.5)
19 30 (22)
22 40 (29.5)
27 80 (59)
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)

fNOTE: Tightening torque of 37 ° male coupling without

union is similar to tightening torque of 37° female.

W1-2-1-5
 SECTION 1 GENERAL
Group 2 Tightening

Pipe Joint
Pipe connection (metal joint)
(Union Nut Wrench Size: 17, 19, 22, 27)

Metal (3) of adapter (1) and pipe (2) seals pressure oil.

 Precautions for use

Do not damage sealing surfaces (4) and (5) when
disassembling and assembling. 1 4 5 3 2

Tightening Torque
Use the specified tightening torque in the table below.
2013/09
Wrench Size (mm) 17 19 22 27
Tightening N·m 25 30 40 80 M1M7-07-005
Torque (lbf·ft) (18.5) (22) (29.5) (59)

O-ring Seal Joint

O-ring (6) is installed against the end surface of adapter
(7) and seals pressure oil.
IMPORTANT:
 Replace O-ring (6) with a new one when 7 6 9
reinstalling.
 Before tightening union nut (9), confirm that
O-ring (6) is seated correctly in O-ring groove
(8). Tightening union nut (9) with O-ring (6)
displaced will damage O-ring (6), resulting in oil
leakage.
 Do not damage O-ring groove (8) of adapter (7)
or sealing surface (10) on the hose side. Damage 8 10 a
WDAA-01-02-011
to O-ring (6) may cause oil leakage. a- Joint Body
 If union nut (9) is found to be loose, causing
oil leakage, do not tighten it to stop the leak.
Instead, replace O-ring (6) with a new one, then 2013/09
tighten union nut (9) after confirming that Wrench Size mm Tightening Torque
O-ring (6) is securely seated in O-ring groove (8). Union Nut N·m (lbf·ft)
19 30 (22)
22 70 (52)
27 95 (70)
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)

W1-2-1-6
 SECTION 1 GENERAL
Group 2 Tightening

Quick Coupling
3 1
1. Coupling procedure
 Push socket ring (1) into plug (3) by rotating it fully
counterclockwise and then pulling it toward you.
 Release socket ring (1). Check that socket ring (1)
is returned by the spring force and the coupling is
locked completely by ball (2). At this time, check if
socket ring (1) is returned to the original position (to
M1M7-07-006
the rightmost direction). 2
2. Separating procedure
 Remove the hose by rotating socket ring (1) fully
counterclockwise and then pulling it. Because no
check function is attached inside, be careful that oil
flows out.
 Cap the removed hoses using special plug.
dCAUTION:
 When disconnecting, do not damage joint
surface.
 When disconnecting, clean the joint part and
thoroughly wipe off the cleaning solution to
prevent any foreign material from entering.
 Complete the joint disconnecting / connecting
procedure. Check enough if oil leaks especially
after installation.
 After installation, check if socket ring (1)
is returned to the original position (to the
rightmost direction).

W1-2-1-7
 SECTION 1 GENERAL
Group 2 Tightening

Screw-In Connection R G
30 °
Depending on types of screw and sealing, different
types of screw-in connection are used.

IMPORTANT: Check that the thread pitch and thread

type (tapered or straight) are the correct type
before using any screw-in connection. (In general, a b
the screw-in connection of male tapered thread (a) a- Male Tapered Thread b- Male Straight Thread
is used except for measurement purpose.) W105-01-01-018

2013/09
Wrench Size mm Tightening Torque
Joint Body Cast iron Structural rolled
steel
19 15 (11) 35 (26)
22 30 (22) 50 (37)
Seal Tape Application 27 50 (37) 95 (70)
Seal tape is used in order to seal clearances between 36 70 (52) 160 (118)
male (d) and female (c) threads so that any leaks 41 110 (81) 200 (148)
between threads may be prevented. Therefore, apply 50 160 (118) 330 (245)
just enough seal tape to fill up thread clearances (e). Do 60 200 (148)
not overwrap.

 Application Procedure
fNOTE: Unit: N·m (lbf·ft)

Check that the thread surface is clean and, free of dirt c

or damage. Apply the seal tape around threads in order
to leave one to two pitch threads uncovered. Wrap the
seal tape in the same direction as the threads.
d e
W105-01-01-019
c- Internal Thread e- Clearance
d- External Thread
Low-Pressure-Hose Clamp Tightening f
Low-pressure-hose clamp tightening torque differs
depending on the type of clamp.

T-Bolt Type Band Clamp (g):

4.5 N·m (3.3 lbf·ft)

Worm Gear Type Band Clamp (h):

6 to 7 N·m (4.4 to 5.2 lbf·ft)

f- Leave one to two pitch

M114-07-041
threads uncovered
g h

WDAA-01-02-012 M114-07-043
g- T-Bolt Type Band Clamp h- Worm Gear Type Band Clamp

W1-2-1-8
 SECTION 1 GENERAL
Group 2 Tightening

Connecting Hose

dCAUTION: When replacing the hoses, use only

genuine Hitachi service parts. Using hoses other
Incorrect Correct

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 high oil pressure,
vibration, or an impact to a kinked hose may
result in oil leaks, hose rupture or separation of
fitting. Utilize the print marks on hoses when W105-01-01-011
installing in order to prevent hose from being
kinked. Take necessary measures to protect hoses
from rubbing against each other. If the hoses rub Incorrect a Correct
against each other, wear to the hoses may result
and lead to hose rupture. Take care so that the
hoses do not come into contact with the moving
parts or sharp objects.
W105-01-01-012

a- Rubbing Against Each Other

Incorrect Correct
b b

W105-01-01-013
a- Rubbing Against Each Other b- Clamp

Incorrect Correct

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

W1-2-1-9
 SECTION 1 GENERAL
Group 2 Tightening

(Blank)

W1-2-1-10
 SECTION 1 GENERAL
Group 3 Painting

Painting
Painting specification
Surfaces to Be Painted Painting Color
Main surface of (except cab) YR-01 [TAXI yellow]
upperstructure
Main frame P1-01 [High Grade Black]
Contorl valve cover P1-01 [High Grade Black]
Inner P1-01 [High Grade Black]
Swing post P1-01 [High Grade Black]
Front YR-01 [TAXI yellow]
Track PB5-01 [SP-424 Dark Grey]
Floor plate P1-01 [High Grade Black]

Final painted color

Inside and outside surface of cab P1-01 [High Grade Black]
Shaded part of cab Shining Silver
Right window beam P1-01 [High Grade Black]
Seat stand N-10 [Black]
Lever (Travel, pilot shut-off ) N-10 [Black]
Engine cover YR-01 [TAXI yellow]
Mirror stay P1-01 [High Grade Black]
Under cover P1-01 [High Grade Black]
Fuel tank lower cover P1-01 [High Grade Black]
Handrail on upperstructure right side P1-01 [High Grade Black]
Boom foot pin brim P1-01 [High Grade Black]
Grease check plate P1-01 [High Grade Black]

a- Shaded Part (Shining Silver) WDEE-01-03-001

W1-3-1-1
 SECTION 1 GENERAL
Group 3 Painting

(Blank)

W1-3-1-2
 SECTION 1 GENERAL
Group 4 Bleeding Air

Bleeding Air from Hydraulic Oil Tank

dCAUTION: Escaping fluid under pressure may

penetrate the skin and eyes, and cause serious
injury. Release the pressure before disconnecting
the hydraulic pipings or removing other
equipment. Hot hydraulic oil just after operation
may spout out and cause severe burns. Wait until
oil cools before starting any work. Do not turn cap
(2) of hydraulic oil tank (3) quickly. Cap (2) may fly
off by internal pressure. Release any remaining
pressure before removing cap (2).

Preparation
1. Park the machine on a solid and level surface.
Set the front attachment in position for checking
hydraulic oil level.
2. Stop the engine. Slowly loosen cap (2) of hydraulic 3 2
oil tank (3) and bleed air from hydraulic oil tank (3).
3. Remove cap (2) of hydraulic oil tank (3).

W1M9-01-04-001

4. Install vacuum pump (a) to the position where cap a

(2) has been removed. Operate vacuum pump (a)
and maintain negative pressure in hydraulic oil tank
(3). b

fNOTE: Operate vacuum pump (a) continuously while c

working.

W1R7-01-04-002

a- Vacuum Pump
b- Hose
c- Adapter

W1-4-1-1
 SECTION 1 GENERAL
Group 4 Bleeding Air

Bleeding Air from Hydraulic System

Bleed air from the hydraulic system as follows when
hydraulic oil has been drawn, the suction filter and
suction pipe have been replaced, or the pump device,
swing motor, travel motor, cylinders have been removed/
installed.
IMPORTANT: If air is accumulated inside of the pump IMPORTANT: If air is accumulated inside of the
and if the engine starts in lacking of hydraulic oil, cylinder and if the cylinder is operated suddenly
the pump may be damaged. in lacking of hydraulic oil, the seal may be
 Bleeding Air from Pump damaged or the cylinder may seize.
 Remove the air bleed plug on top of the pump. Add  Bleeding Air from Hydraulic Circuit
hydraulic oil to the pump.  After refilling hydraulic oil, start the engine. While
 After the pump is filled with hydraulic oil, temporarily operating each cylinder, swing motor, and travel
tighten the plug. Then, start the engine and run it at motor evenly, operate the machine under light loads
slow idle speed. for 10 to 15 minutes. Slowly start each operation
 Slightly loosen the plug and bleed air from the pump (never fully stroke the cylinders during initial
until hydraulic oil comes out from the gap. operation stage).
 After bleeding all air, securely tighten the plug.  As the pilot circuit has an air bleed device, air in the
IMPORTANT: If air is accumulated inside of the motor pilot circuit will be bled while performing the above
and if the engine starts in lacking of hydraulic oil, operation for approx. 5 minutes.
the motor may be damaged.  Reset the front attachment in position for checking
 Bleeding Air from Travel Motor, Swing Motor hydraulic oil level.
 Remove the air bleed plug (top) from the travel  Stop the engine. Check hydraulic oil level. Replenish
motor and swing motor. Fill the motor case with hydraulic oil if necessary.
hydraulic oil.

W1-4-1-2
 SECTION 1 GENERAL
Group 4 Bleeding Air

Bleeding Air from Fuel System

Air in the fuel system may make the engine hard to
start or make it run irregularly. After draining water and
sediment from the fuel filter, replacing the fuel filter, or
running the fuel tank dry, be sure to bleed the air from
the fuel system.

Air Bleeding Procedures

Automatic bleeding deveice is provided on this
machine.
1. Confirm that the fuel level is more than one-half of
the fuel tank capacity. If the fuel is lower, add fuel.
2. Set the key switch to the ON position and hold it for
10 to 15 seconds.
3. Start the engine and check the fuel system for fuel
leaks.

W1-4-1-3
 SECTION 1 GENERAL
Group 4 Bleeding Air

Bleeding Air from Radiator

dCAUTION: Do not loosen the radiator cap until

the system has cooled. Hot steam may spout out
and cause severe burns. Wait until coolant cools
and loosen the cap slowly. Release all pressure
and remove the cap.

Preparation
1. Park the machine on a solid and level surface.
Set the front attachment in position for checking
hydraulic oil level.
2. Stop the engine. Remove the radiator cap.

W1-4-1-4
 SECTION 1 GENERAL
Group 5 Releasing Pressure

Releasing Pressure in Hydraulic Circuit

Release any remaining pressure in the following
procedures when removing and installing the front
attachment. A
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.) 7

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)

dCAUTION: Each attachment may move rapidly in

case the overload relief valve is loosened rapidly.
1

Check that the machine has set in the position for

inspection and maintenance and loosen it slowly.
Do not loosen it more than 3/4 turns as hydraulic
oil may spout.
3

T1CD-03-03-018

View A

4
6

W1CD-02-05-004

1- Overload Relief Valve (Arm 5- Overload Relief Valve (Bucket

Roll-In) Roll-In)
2- Overload Relief Valve (Bucket 6- Overload Relief Valve (Arm
Roll-Out) Roll-Out)
3- Overload Relief Valve (Boom 7- Overload Relief Valve (Boom
Lower) Swing Left)
4- Overload Relief Valve (Boom 8- Overload Relief Valve (Boom
Raise) Swing Right)

W1-5-1-1
 SECTION 1 GENERAL
Group 5 Releasing Pressure

IMPORTANT: Do not turn lock nut (11) and adjusting

screw (10). If turning, the setting changes. 9 10

2. Slowly loosen body (9) of the overload relief valve in

which any remaining pressure will be released.

j : 24 mm

m : 60 to 70 N·m (6 to 7 kgf·m, 44 to 52 lbf·ft)

11

T152-03-03-015

9- Body 11- Lock Nut

10- Adjusting Screw

W1-5-1-2
 SECTION 1 GENERAL
Group 6 Preparation

Preparation before Inspection and

Maintenance

dCAUTION: Components, hydraulic oil, lubricant,

and coolant just after operation are too hot. Wait
until they cool. Then, start the work.
Before performing the maintenance procedures given in
the following chapters, park the machine as described
below, unless otherwise specified.

1. Park the machine on a solid and level surface. M1M7-05-024

2. Lower the bucket and the blade onto the ground.
3. Set the engine control lever to the slow idle position
and run the engine for 5 minutes in order to cool
the engine. 1

4. Set the key switch to the OFF position and stop the
engine. Remove the key.
5. Set pilot shut-off lever (1) to the LOCK position.
6. Before performing any work on the machine, attach
the tag on the door or control lever.

MADB-07-001

W1-6-1-1
 SECTION 1 GENERAL
Group 6 Preparation

dCAUTION: Never attempt to maintain the

machine when the engine is running in order to
prevent the accident. If maintenance work while
engine running is unavoidable, strictly comply
with the following items.
 One person should take the operator's seat
to be ready to stop the engine any time while
communicating with other workers.
 When working around the moving parts is
unavoidable, pay special attention to ensure
that hands, feet, and clothing and do not SA-2294
become entangled.
 If parts or tools are dropped or inserted into
the fan or the belt, they may fly off or be cut off.
Do not drop or insert parts and tools into the
moving parts.
 Set pilot control shut-off lever (1) to the LOCK
position so that the front attachment will not
move.
 Never touch the control levers and pedals.
If operating the control levers or pedals is
unavoidable, signal co-workers to evacuate to
the safer place.

SA-026

W1-6-1-2
MEMO
MEMO
SECTION 2

MAINTENANCE STANDARD
CONTENTS
Group 1 Upperstructure
Main Pumps 1, 2..............................................................W2-1-1-1
Main Pump 3.....................................................................W2-1-1-3
Swing Motor.....................................................................W2-1-2-1
Group 2 Undercarriage
Travel Motor......................................................................W2-2-1-1
Parking Brake....................................................................W2-2-1-3
Sprocket.............................................................................W2-2-1-4
Front Idler..........................................................................W2-2-2-1
Upper Roller......................................................................W2-2-3-1
Lower Roller......................................................................W2-2-3-2
Track.....................................................................................W2-2-4-1
Group 3 Front Attachment
Pin and Bushing...............................................................W2-3-1-1
Side Cutter (3053595, 3053596)................................W2-3-1-3
Point (4135496)...............................................................W2-3-1-4
Standard Dimensions for Arm and Bucket
Connection..................................................................W2-3-1-5
Cylinder..............................................................................W2-3-2-1

DEEW-2-1
(Blank)

DEEW-2-2
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

Main Pumps 1, 2

1 2

WDEA-03-08-007
5 4 3

1- Piston (9 Used) 3- Spring (6 Used) 5- Retainer

2- Cylinder Block 4- Spherical Bushing

W2-1-1-1
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

Main Pumps 1, 2
1. Clearance (D-d) between piston (1) and cylinder 1 2
block (2)
Unit: mm (in)
Standard Allowable Limit
0.032 (0.001) 0.056 (0.002) d D

W1P1-02-04-063
2. Piston (1): Clearance (δ) of the crimped part of the
shoe bottom
Unit: mm (in) 1
Standard Allowable Limit
0 to 0.1 (0 to 0.004) 0.3 (0.012)

t δ

3. Piston (1): Shoe thickness (t)

Unit: mm (in)
Standard Allowable Limit
W1P1-02-04-064
3.9 (0.154) 3.7 (0.146)

4. Spring (3) free length (L)

Unit: mm (in)
3
Standard Allowable Limit
41.1 (1.62) 40.3 (1.59)

5. Combined height (H-h) between retainer (5) and W1P1-02-04-065

spherical bushing (4)
Unit: mm (in)
5 4
Standard Allowable Limit
17.2 (0.677) 15.6 (0.614)

H
h

W1P1-02-04-066

W2-1-1-2
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

Main Pump 3

1 2

WDEA-03-08-007
5 4 3

1- Piston (9 Used) 3- Spring (6 Used) 5- Retainer

2- Cylinder Block 4- Spherical Bushing

W2-1-1-3
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

Main Pump 3
1 2
1. Clearance (D-d) between piston (1) and cylinder
block (2)
Unit: mm (in)
Standard Allowable Limit
d D
0.024 (0.001) 0.044 (0.002)

W1P1-02-04-063

2. Piston (1): Clearance (δ) of the crimped part of the

shoe bottom
Unit: mm (in) 1

Standard Allowable Limit

0 to 0.1 (0 to 0.004) 0.22 (0.009)

t δ

3. Piston (1): Shoe thickness (t)

Unit: mm (in)
Standard Allowable Limit W1P1-02-04-064
2.9 (0.11) 2.75 (0.108)

4. Spring (3) free length (L)

3
Unit: mm (in)
Standard Allowable Limit
31.3 (1.23) 30.6 (1.21)

W1P1-02-04-065
5. Combined height (H-h) between retainer (5) and
spherical bushing (4)
Unit: mm (in) 5 4
Standard Allowable Limit
12.6 (0.496) 11.3 (0.445)
H
h

W1P1-02-04-066

W2-1-1-4
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

Swing Motor

2 1 WDEB-02-01-001

1- Cylinder 2- Piston (9 Used)

W2-1-2-1
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

1. Clearance between outer diameter (d) of piston (2)

and inner diameter (D) of cylinder (1)
Unit: mm (in)
Standard Allowable Limit 2

D-d - 0.04 (0.002)

d

W107-02-06-138

D D
1

2. Clearance (δ) between piston (2) and shoe (a)

bottom
Unit: mm (in)
W107-02-06-139
Standard Allowable Limit
- 0.4 (0.016)

W107-02-06-140
a- Shoe

W2-1-2-2
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Travel Motor

1 2

6 5 4 3

WBAT-06-01-080

1- Rotor 3- Friction Plate (3 Used) 5- Brake Piston

2- Plunger Assembly (9 Used) 4- Plate (4 Used) 6- Disc Spring

W2-2-1-1
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

1. Clearance (ε) between shoe (a) and plunger (2)

bottom a

Unit: mm (in)
Standard Allowable Limit
0 (0) 0.2 (0.008)
ε≤0.2 mm (0.008 in) ε
2
a- Shoe

W1V1-03-02-005

2. Clearance between outer diameter (d) of plunger (2)

and inner diameter (D) of rotor (1) D

Unit: mm (in)
Standard Allowable Limit
0 (0) 0.04 (0.002)
D-d≤0.04 mm (0.002 in)

W105-02-06-134

3. Thickness (t) of shoe (a)

Unit: mm (in) W105-02-06-135

Standard Allowable Limit a

4.5 (0.177) 4.3 (0.169)

t
2
a- Shoe

W1V1-03-02-005

W2-2-1-2
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Parking Brake

A B

6 4

D C W1CD-03-02-001
5 3

Unit: mm (in)
Part Name Standard Allowable Limit
3 Friction Plate C 2.4 (0.094) 2.35 (0.093)
4 Plate B 1.4 (0.055) 1.35 (0.053)
5 Brake Piston A 36 (1.42) -
6 Disc Spring D 5.2 (0.210) 5.1 (0.201)

W2-2-1-3
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Sprocket

C'

B
C

D
A
W178-02-11-235 W178-02-11-236

Unit: mm (in)
Standard Allowable Limit
A 38 (1.5) [28 (1.1)] Replace
B 113.7 (4.5) 104 (4.1)
C 141.8 (5.6) 132 (5.2)
C' 522.5 (20.6) -
D 154 (6.1) -

fNOTE: Values in [ ] are just for reference.

W2-2-1-4
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Front Idler

C D

WDCA-02-01-002
E
A

Unit: mm (in)
Standard Allowable Remedy
Limit
A 43 (1.69) [33.7 (1.33)] Replace
B 100 (3.94) -
C 390 (15.4) [376 (14.8)]
D 434 (17.1) -
E 22 (0.87) -

fNOTE: Values in [ ] are just for reference.

Axle and Bushing

Unit: mm (in)
Standard Allowable Remedy
Limit
Axle Outer 55.0 (2.17) [54.2 (2.13)] Replace
Diameter
Bushing Inner 55.0 (2.17) [56.0 (2.21)]
Diameter
Flange 2 (0.08) [1.2 (0.05)]
Thickness

fNOTE: Values in [ ] are just for reference.

W2-2-2-1
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

(Blank)

W2-2-2-2
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Upper Roller

A
WDEA-02-02-001
B

Unit: mm (in)
Standard Allowable Remedy
Limit
A 43 (1.7) - Replace
B 90 (3.5) -
C 86 (3.4) 76 (3.0)

W2-2-3-1
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Lower Roller

W102-03-06-006

Roller

Unit: mm (in)
Standard Allowable Remedy
Limit
A 44 (1.7) - Build up
welding and
B 143 (5.6) -
hand finishing
C 110 (4.3) 102 (4.0) or replace

fNOTE: Values in [ ] are just for reference.

Axle and Bushing

Unit: mm (in)
Standard Allowable Remedy
Limit
Axle Outer 40 (1.6) [39.2 (1.5)] Replace
Diameter
Bushing Inner 40 (1.6) [41.0 (1.6)]
Diameter
Flange 2 (0.08) [1.2 (0.05)]
Thickness

fNOTE: Values in [ ] are just for reference.

W2-2-3-2
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Track
Link
Measure the length of four links.
 Do not measure the part included the master pin.
 Measure the length with tension on the track.

Unit: mm (in) W155-03-07-001

Standard Allowable Limit Remedy
A 616 (24.3) 634.1 (25.0) Build up
B 74 (2.9) 69 (2.7) welding and
hand finishing
or replace

Grouser Shoe

W105-03-07-024

Unit: mm (in)
Shoe Size 450 mm Grouser
Standard Allowable Limit Remedy
A 165 (6.5) - Build up
B 6 (0.24) - welding or
C 20 (0.79) 14 (0.55) replace

W2-2-4-1
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Master Bushing

W105-03-07-023
Unit: mm (in)
Standard Allowable Limit Remedy
A 74.7 (2.94) - Replace
B 24.5 (0.97) [27.5 (1.08)]
C 41.26 (1.62) [37.76 (1.49)]

fNOTE: The value in [ ] is just for reference.

Master Pin

W105-03-07-021
Unit: mm (in)
Standard Allowable Limit Remedy
A 123.5 (4.86) - Replace
B 24.2 (0.95) [21.2 (0.84)]

fNOTE: The value in [ ] is just for reference.

W2-2-4-2
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Pin

W142-03-07-004
A
Unit: mm (in)
Standard Allowable Limit Remedy
A 131 (5.16) - Replace
B 24 (0.95) 21 (0.83)

Bushing

W105-03-07-023

Unit: mm (in)
Standard Allowable Limit Remedy
A 81 (3.12) - Replace
B 24.5 (0.97) [25.5 (1.00)]
C 41.26 (1.62) [37.76 (1.49)]

fNOTE: The value in [ ] is just for reference.

W2-2-4-3
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

(Blank)

W2-2-4-4
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Pin and Bushing

N M L

O
P

B Q

A
W1M9-04-01-002 W1CF-04-01-006

F
C A

E D
K
I J
G
H
WBAT-06-01-076

Unit: mm (in)
Part Name Standard Allowable Limit Remedy
A Pin 60 (2.36) 59.0 (2.32) Replace
Boss (Main Frame) 60 (2.36) 61.5 (2.42)
Bushing (Boom) 60 (2.36) 61.5 (2.42)
B Pin 55 (2.17) 54.0 (2.13)
Boss (Swing Post) 55 (2.17) 56.5 (2.22)
Bushing (Boom Cylinder) 55 (2.17) 56.5 (2.22)
C Pin 55 (2.17) 54.0 (2.13)
Boss (Boom) 55 (2.17) 56.5 (2.22)
Bushing (Boom Cylinder) 55 (2.17) 56.5 (2.22)
D Pin 60 (2.36) 59.0 (2.32)
Boss (Boom) 60 (2.36) 61.5 (2.42)
Bushing (Arm) 60 (2.36) 61.5 (2.42)
E Pin 55 (2.17) 54.0 (2.13)
Boss (Arm) 55 (2.17) 56.5 (2.22)
Bushing (Arm Cylinder) 55 (2.17) 56.5 (2.22)
F Pin 55 (2.17) 54.0 (2.13)
Boss (Boom) 55 (2.17) 56.5 (2.22)
Bushing (Arm Cylinder) 55 (2.17) 56.5 (2.22)

W2-3-1-1
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Unit: mm (in)
Part Name Standard Allowable Limit Remedy
G Pin 45 (1.77) 44.0 (1.73) Replace
Boss (Arm) 45 (1.77) 46.5 (1.83)
Bushing (Bucket Cylinder) 45 (1.77) 46.5 (1.83)
H Pin 55 (2.17) 54.0 (2.13)
Boss (Link B) 55 (2.17) 56.5 (2.22)
Bushing (Link A) 55 (2.17) 56.5 (2.22)
Bushing (Bucket Cylinder) 55 (2.17) 56.5 (2.22)
I Pin 50 (1.97) 49.0 (1.93)
Boss (Link B) 50 (1.97) 51.5 (2.03)
Bushing (Arm) 50 (1.97) 51.5 (2.03)
J Pin 50 (1.97) 49.0 (1.93)
Boss (Bucket) 50 (1.97) 51.5 (2.03)
Bushing (Link A) 50 (1.97) 51.5 (2.03)
K Pin 50 (1.97) 49.0 (1.93)
Boss (Bucket) 50 (1.97) 51.5 (2.03)
Bushing (Arm) 50 (1.97) 51.5 (2.03)
L Pin 50 (1.97) 49.0 (1.93)
Boss (Track Frame) 50 (1.97) 51.5 (2.03)
Bushing (Blade) 50 (1.97) 51.5 (2.03)
M Pin 71 (2.80) 70.0 (2.76)
Boss (Track Frame) 71 (2.80) 72.5 (2.85)
Bushing (Blade Cylinder) 71 (2.80) 72.5 (2.85)
N Pin 71 (2.80) 70.0 (2.76)
Boss (Blade) 71 (2.80) 72.5 (2.85)
Bushing (Blade Cylinder) 71 (2.80) 72.5 (2.85)
O Pin 60 (2.36) 59 (2.32)
Boss (Swing Post) 60 (2.36) 61.5 (2.42)
Bushing (Boom Swing Cylinder) 60 (2.36) 61.5 (2.42)
P Pin 60 (2.36) 59 (2.32)
Boss (Main Frame) 60 (2.36) 61.5 (2.42)
Bushing (Boom Swing Cylinder) 60 (2.36) 61.5 (2.42)
Q Pin 110 (4.33) 109 (4.29)
Bushing (Main Frame) 110 (4.33) 111.5 (4.39)
Bushing (Swing Post) 110 (4.33) 111.5 (4.39)
IMPORTANT: When replacing HN bushing for the
front attachment, install it by using a press.

W2-3-1-2
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Side Cutter (3053595, 3053596)

D
A

W505-04-01-001

Unit: mm (in)
Standard Allowable Limit Remedy
A 213 (8.39) 138 (5.43) Replace
B 250 (9.84) -
C 295 (11.6) -
D 150 (5.91) -

W2-3-1-3
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Point (4135496)

B C

W105-04-01-020

Unit: mm (in)
Standard Allowable Limit Remedy
A 165 (6.5) 85 (3.4) Replace
B 57 (2.2) -
C 60 (2.4) -
D 62 (2.4) -

W2-3-1-4
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Standard Dimensions for Arm and Bucket

Connection
IMPORTANT: If the front attachment of a previous
model machine is used, use the grease intervals
for previous model machine.

WDCD-02-03-005

Section A Section B

WDCA-02-03-002

Unit: mm (in)
ZX85USB-5A Class ZX85USB-3 Class
a 255 (10.0) 
b 15 (0.59) 
c 417 (16.4) 
d 359 (14.1) 
e 310 (12.2) 
f 1060 (41.7) 
g 298 (11.7) 
h 200 (7.87) 
i 50 (2.0) 
j 299 (11.8) 
k 82 (3.23) 
l 298 (11.7) 
m 202 (7.95) 
n 50 (2.0) 
o 90° 
p 90° 
q 312 (12.3) 

W2-3-1-5
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

(Blank)

W2-3-1-6
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Cylinder

Rod Rod Bend and Run Out

b
a
A

W166-04-02-022
c d
W105-04-02-094 a- Cylinder Rod c- V Block
b- Dial Gauge d- 1m

Unit: mm (in) Unit: mm (in)

Bend Run Out Remedy
Cylinder Name Recommended Size After Re- 0.5 (0.020) 1.0 (0.039) Repair
Manufacturing (A) 1.0 (0.039) 2.0 (0.079) Replace
Boom 65+0.023-0.053 (2.56+0.0009-0.002)
Arm 60+0.023-0.053 (2.36+0.0009-0.002)
Bucket 55+0.023-0.043 (2.17+0.0009-0.002)
Boom Swing 60+0.023-0.053 (2.36+0.0009-0.002)
Blade 70+0.023-0.053 (2.76+0.0009-0.002)

W2-3-2-1
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

(Blank)

W2-3-2-2
MEMO
MEMO
SECTION 3

UPPERSTRUCTURE
CONTENTS
Group 1 Cab Assembly of Blade Pilot Valves...................................W3-8-8-4
Removal and Installation of Cab...............................W3-1-1-1 Disassembly of Pilot Valves for Boom Swing,
Dimensions of Cab Glass..............................................W3-1-2-1 Positioning, Auxiliary (Optional)..........................W3-8-9-1
Procedure to Install Cab Glass....................................W3-1-2-6 Assembly of Pilot Valves for Boom Swing,
Positioning, Auxiliary (Optional) .........................W3-8-9-4
Group 2 Counterweight
Removal and Installation of Counterweight.........W3-2-1-1 Group 9 Solenoid Valve
Removal and Installation of 2-Spool Solenoid
Group 3 Main Frame Valve Unit.....................................................................W3-9-1-1
Removal and Installation of Main Frame................W3-3-1-1 Structure of 2-Spool Solenoid Valve Unit...............W3-9-2-1
Group 4 Engine Removal and Installation of Pilot Shut-Off
Removal and Installation of Engine.........................W3-4-1-1 Solenoid Valve............................................................W3-9-3-1
Structure of Pilot Shut-Off Solenoid Valve.............W3-9-4-1
Group 5 Pump Device
Removal and Installation of Pump Device.............W3-5-1-1 Group 10 Shockless Valve
Disassembly of Main Pump 3.....................................W3-5-3-1 Removal and Installation of Shockless Valve..... W3-10-1-1
Assembly of Main Pump 3...........................................W3-5-3-5 Structure of Shockless Valve.................................... W3-10-2-1
Disassembly of Main Pumps 1, 2...............................W3-5-4-1 Removal and Installation of Swing
Assembly of Main Pumps 1, 2.....................................W3-5-4-7 Shockless Valve....................................................... W3-10-3-1
Structure of Gear Pump Assembly...........................W3-5-5-1 Structure of Swing Shockless Valve....................... W3-10-4-1

Group 6 Control Valve

Removal and Installation of Control Valve.............W3-6-1-1
Disassembly of Control Valve.....................................W3-6-2-1
Assembly of Control Valve........................................ W3-6-2-10
Group 7 Swing Device
Removal and Installation of Swing Device............W3-7-1-1
Disassembly of Swing Device.....................................W3-7-2-1
Assembly of Swing Device..........................................W3-7-2-5
Disassembly of Swing Motor......................................W3-7-3-1
Assembly of Swing Motor............................................W3-7-3-4
Disassembly of Valve Block.........................................W3-7-4-1
Assembly of Valve Block...............................................W3-7-4-3
Group 8 Pilot Valve
Removal and Installation of Pilot Valve (Left).......W3-8-1-1
Removal and Installation of Pilot Valve (Right)....W3-8-2-1
Removal and Installation of Travel Pilot Valve......W3-8-3-1
Removal and Installation of Blade Pilot Valve......W3-8-4-1
Removal and Installation of Positioning Pilot
Valve...............................................................................W3-8-5-1
Disassembly of Pilot Valves (Right and Left).........W3-8-6-1
Assembly of Pilot Valves (Right and Left)...............W3-8-6-4
Disassembly of Travel Pilot Valve...............................W3-8-7-1
Assembly of Travel Pilot Valve....................................W3-8-7-5
Disassembly of Blade Pilot Valves.............................W3-8-8-1

DEEW-3-1
(Blank)

DEEW-3-2
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Removal and Installation of Cab

7
10
8

WDEE-03-08-004
1 2
9

WDAE-03-01-029

IMPORTANT Cap the open ends in case the hoses

and pipes have been disconnected. In addition, dCAUTION: Seat (3) weight: 45 kg (100 lb)
attach an identification tag onto the connectors, 5. Remove socket bolts (5) (4 used) and washers (6) (4
hoses, and pipes for assembling. Connect the used). Remove seat (3).
hoses and install the clips in case the clips which
secure the hoses have been removed. l : 6 mm
6. Remove floor mat (1).
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Open door (2).
3. Disconnect connectors (4) (2 used).
4. Remove bolt (7), spring washer (8), and washers (9)
(2 used). Remove seat belt (10).

j : 16 mm

W3-1-1-1
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

6
3

WDEE-03-01-001 4 WDEE-03-01-002

2
7. Remove screws (2) (6 used). Remove cover (3).
8. Remove screws (4) (3 used). Remove buzzer (6) and
duct (5).

W3-1-1-2
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

WDEE-03-01-003

9. Disconnect connectors (1) (6 used).

10. Remove bolt, washer (2). Remove duct (3).

j : 13 mm

W3-1-1-3
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Detail A
4 3

A
3

1
7

5 WDEE-03-01-004
2 WDEE-03-01-005

11. Disconnect connectors (6) (4 used).

12. Remove bolt, washer (1). Disconnect ground (2).

j : 17 mm
13. Remove bolts, washers (5) (4 used). Remove cover
(4).

j : 13 mm
14. Remove bolt, washer (7). Remove duct (3).

j : 13 mm

W3-1-1-4
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

2, 3 1 WDEE-03-01-006

15. Disconnect connectors (1) (3 used).

16. Remove bolt, washer (2). Disconnect ground (3).

j : 17 mm

W3-1-1-5
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

WDEE-03-01-003 8 WDEE-03-01-004
2

17. Loosen socket bolts (2) (2 used). Move the right

console (1) assembly inward.

l : 8 mm
18. Loosen socket bolts (8) (2 used). Move the left
console (5) assembly inward.

l : 8 mm

W3-1-1-6
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

MDEC-07-002

3 WDEB-03-01-001

19. Open door (1). 20. Remove screws (2) (4 used). Remove the filter (3)
assembly.

j : 10 mm

W3-1-1-7
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

WDEB-03-02-001

21. Disconnect hose (5).

W3-1-1-8
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

a
5, 6

3, 4

3, 4
2

3, 4

11
3, 4 10
2
9
WDEE-03-01-007 WDEE-03-01-008

a- Lifting Bracket

25. Remove socket bolts (5) (2 used) and washers (6) (2

dCAUTION:
(510 lb)
The cab (1) assembly weight: 230 kg used).

22. Attach the nylon slings onto lifting brackets (a) l : 8 mm

(4 places) of cab (1). Hoist and hold the cab (1) 26. Remove bolts, washers (2) (6 used). Remove the cab
assembly. (1) assembly.
23. Remove bolt (9), washer (10), and spacer (11).
j : 17 mm
j : 32 mm
24. Remove nuts (3) (4 used) and washers (4) (4 used).

j : 24 mm

W3-1-1-9
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Detail A
1
A

2 4
4

WDEE-03-01-009 WDEE-03-01-010

27. Remove screws (1) (6 used). Remove cover (2).

28. Remove bolts, washers (4) (3 used). Remove bracket
(3).

j : 13 mm
29. Disconnect connector (5).
30. Disconnect cable (6) and cables (7) (2 used).

WDEE-03-01-011
7

W3-1-1-10
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

4 5 4 6

2 9 4 5 8 4
WDEE-03-01-013

WDEE-03-01-012
3

31. Remove screws (1) (4 used) and screws (3) (2 used). 36. Remove bolts, washers (4) (5 used). Remove the
Remove cover (2). bracket (7) assembly.
32. Disconnect connectors (6) (2 used). j : 13 mm
33. Disconnect connectors (8) (3 used).
34. Disconnect connector (9).
35. Remove clamps (5) (3 used).

W3-1-1-11
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

4 5 4 6

2
9 4 5 8 4

WDEE-03-01-013

WDEE-03-01-012
3

Installation
1. Install the bracket (7) assembly with bolts, washers 5. Install clamps (5) (3 used).
(4) (5 used).
6. Install cover (2) with screws (3) (2 used) and screws
j : 13 mm (1) (4 used).

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

2. Connect connector (9).
3. Connect connectors (8) (3 used).
4. Connect connectors (6) (2 used).

W3-1-1-12
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Detail A
1
A

2 4
4

WDEE-03-01-009 WDEE-03-01-010

7. Connect cables (7) (2 used) and cable (6).

8. Connect connector (5).
9. Install bracket (3) with bolts, washers (4) (3 used).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

10. Install cover (2) with screws (1) (6 used).

WDEE-03-01-011
7

W3-1-1-13
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

a
5, 6

3, 4

3, 4
2

3, 4

11
3, 4 10
2
9
WDEE-03-01-007 WDEE-03-01-008

a- Lifting Bracket

14. Install bolts, washers (2) (6 used).

dCAUTION:
(510 lb)
The cab (1) assembly weight: 230 kg
j : 17 mm
11. Attach the nylon slings onto lifting brackets (a) (4
m : 50 N·m (5 kgf·m, 37 lbf·ft)
places) of cab (1). Hoist the cab (1) assembly.
15. Install washers (6) (2 used) and socket bolts (5) (2
12. Install the cab (1) assembly with washers (4) (4 used)
used).
and nuts (3) (4 used).
l : 8 mm
j : 24 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 210 N·m (21 kgf·m, 155 lbf·ft)
13. Install spacer (11), washer (10), and bolt (9).

j : 24 mm

m : 210 N·m (21 kgf·m, 155 lbf·ft)

W3-1-1-14
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

WDEB-03-02-001

16. Connect hose (5).

W3-1-1-15
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

MDEC-07-002
3 WDEB-03-01-001

17. Install the filter (3) assembly with screws (2) (4 used). 18. Close door (1).

W3-1-1-16
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

8 WDEE-03-01-004 WDEE-03-01-003
2

19. Fully move the left console (5) assembly outward.

Tighten socket bolts (8) (2 used).

l : 8 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

20. Fully move the right console (1) assembly outward.
Tighten socket bolts (2) (2 used).

l : 8 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-17
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

2, 3 1 WDEE-03-01-006

21. Connect ground (3) with bolt, washer (2).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

22. Connect connectors (1) (3 used).

W3-1-1-18
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Detail A
4

A
3

1
7

5 WDEE-03-01-004
2 WDEE-03-01-005

23. Install duct (3) with bolt, washer (7). 26. Connect connectors (6) (4 used).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

24. Install cover (4) with bolts, washers (5) (4 used).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

25. Connect ground (2) with bolt, washer (1).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-19
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

WDEE-03-01-003

27. Install duct (3) with bolt, washer (2).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

28. Connect connectors (1) (6 used).

W3-1-1-20
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

6
3

4 WDEE-03-01-002 WDEE-03-01-001

29. Install buzzer (6) and duct (5) with screws (4) (3
used).
30. Install cover (3) with screws (2) (6 used).

W3-1-1-21
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

7
10
8
WDEE-03-08-004
1 2

WDAE-03-01-029
31. Install floor mat (1).

dCAUTION: Seat (3) weight: 45 kg (100 lb)

32. Install seat (3) with washers (6) (4 used) and socket
bolts (5) (4 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

33. Install seat belt (10) with bolt (7), spring washer (8),
and washers (9) (2 used).

j : 16 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

34. Connect connectors (4) (2 used).
35. Close door (2).

W3-1-1-22
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Dimensions of Cab Glass

a A 4-R32
4-R10
Unit: mm

36
Section A C0.5 to 1.0 C0.5 to 1.0
33
33 (4 mm)

559
c
70

5(b)
W178-02-01-019

33

63
795

WDEE-03-01-014
a- Black Ceramic Painted Range
b- Shaded Paint Range
c- Glass Mark

A
39.2 65.3
12.6 124.4 489.5

50 45

4-R169 R45
4-φ20
483.2
(5 mm)
11.5 557.6

(38.3)
358.9 40
2-φ20
971.7 1150
26 594
φ42 2-φ27 1562
50
WBAT-06-01-007 303.5
362.5 156.6

φ57
643.6 613

357.4 2-φ20
R45 c
191.5
61.5
40 581 Ｒ45

731 WBAT-06-01-092

c- Glass Mark

W3-1-2-1
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

4-Ｒ10 A
2-Ｃ46
Unit: mm
Ｒ65 19
R65

Section A C0.5 to 1.0 C0.5 to 1.0 23

23
(4 mm)
976

R43
a
W178-02-01-019
53
255 R76
φ28

4-R5 165 23
118 175
22

22
2-R3
748 C

a- Black Ceramic Painted Range WBAT-06-01-096

c- Glass Mark
Chamfer along the Periphery
754

R3
Ｒ3

(4 mm)
453.1

4-R5
2-C55
C WBAT-06-01-098
c- Glass Mark
WBAT-06-01-099

A 64.2
122.6 29.5
984.2
32

3-R10

32 2-R52 3-R137
32
484.5

3-R169
616.8

(5 mm) 32
1121
359.1
)
5(b

c
R32.8 40 32
504.2

R15
30

2-R30 R25
277.3
.2)

R20
(27

235
155.8
35

R135 140.9
42

R80 188.3 WDEE-03-01-015

a
206.1
939.6 281.6
628
a- Black Ceramic Painted Range
b- Shaded Paint Range 1221.3
c- Glass Mark

W3-1-2-2
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm A a

2-R30 2-R60

38
2-R100
38
2-R35

(8 mm)
536 612
572.8

2-R10
b
35

38 2-R60
35
38
36 533 36
117.5
605
WBAT-06-01-094
a- Silk-Screen Painted Range
b- Glass Mark

WBAT-06-01-099

Section A C1±0.5 C1±0.5

W178-02-01-019

W3-1-2-3
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Procedure to Remove Cab Glass

Procedures to Remove Right-Hand Glass (2), Left-Hand 1
Sash, and Rear Glass
dCAUTION: When removing the broken or cracked
glass, the glass shards may cause serious injury.
Before removing, use the duct tape or equivalent 2
in order to paste the broken or cracked glass and
reinforce them. Remove the glass pieces away.
1. Remove the resin panel, garnish (1), and the spacer
around the glass.

WBAT-06-01-099

2. Prick a hole in adhesive (b) by using awl (a) (or a

knife).

WBAT-06-01-109

7 8
a
3. Pass piano wire (c) (or a metal wire) through the
hole.

b W1SE-02-01-033

7- Cab a- Awl
8- Glass b- Adhesive

W1SE-02-01-034
c- Piano Wire

W3-1-2-4
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

IMPORTANT: The piano wire is easily broken if a part

of the piano wire turns hot. Change the position a
7
and cut the adhesive. 8
4. Wind the both ends of the piano wire onto the
screwdriver. Draw the wire back and forth in order
to cut adhesive (b) between cab (7) and glass (8).
Remove glass (8) from cab (7).

fNOTE: Cut off the middle of adhesive between glass (8)

and cab (7). b
c

a- Cab Outside
b- Adhesive
c- Cab Inside

W3-1-2-5
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Procedure to Install Cab Glass

1. Left-Hand Glass

A 1

WBAT-06-01-104

1- Sash Assembly
a- Apply Primer for paint
(SUNSTAR #435-95) onto the
adhesive part.

3
c
d

b
WBAT-06-01-105

2- Spacer (120 mm) c

b- 320 mm
4
d
Section A-A
fNOTE: Apply dam, primer, and adhesive onto all WBAT-06-01-106
circumference in order to prevent water leakage.
3- Dam c- Primer for Paint (SUNSTAR
4- Spacer #435-95)
d- Adhesive (SUNSTAR #580)

W3-1-2-6
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

2. Right-Hand Glass and Rear Glass

a A a

A
1

WBAT-06-01-107

1- Right-Hand Glass a- Apply Primer for paint

2- Rear Glass (SUNSTAR #435-40) onto the
adhesive part.

c
b

Section A-A
WBAT-06-01-108

3- Dam c- Adhesive (SUNSTAR #580)

b- Primer for Paint (SUNSTAR
#435-95)

fNOTE: Apply dam, primer, and adhesive onto all

circumference in order to prevent water leakage.

W3-1-2-7
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

3. Upper Polycarbonate

WBAT-06-01-111
a- Mark Position
b- Apply Primer for glass onto
the adhesive part. (As the
adhesive surface is hard-
coated, apply SUNSTAR #435-
41 for glass.)

1 c

Section A-A
d
WBAT-06-01-112

1- Dam d- Primer for Paint (SUNSTAR

c- Adhesive (SUNSTAR #580) #435-95)

fNOTE: Apply dam, primer, and adhesive onto all

circumference in order to prevent water leakage.

W3-1-2-8
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Procedure to Install Cab Glass

1
Procedures to Install Right-Hand Glass (1), Rear Glass
(2), and Rear Left-Hand Sash
1. Cut off the residual adhesive from the cab (7) side
by 1 to 2 mm deep all around by using a knife or
similar.
In addition, remove the dam rubber completely.

fNOTE: Do not damage the cab (7) paint.

WBAT-06-01-099

2. Clean the cutting edge of adhesive at cab (7) side by

using white spirit.
WBAT-06-01-007

b
IMPORTANT: Primer should be shaken for about 1 W1SE-02-01-036
minute and mix thoroughly before opening the
cap. After opening Primer, apply Primer as quickly a- Knife b- Cut off adhesive by 1 to 2
as possible and close the cap immediately after mm deep.
using. After opening Primer, all the contents
should be used within 180 days (or 2 hours with
7
the cap off).
3. Apply Primer for paint (SUNSTAR #435-95) to the c
cutting edge of adhesive at cab (7) side by using a
brush. Wait for about 15 minutes in order to let it d
dry by itself.

W1SE-02-01-038

c- Apply Primer by using a d- Cutting edge of adhesive at

brush. cab (7) side

W3-1-2-9
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

4. Clean the mating edge of the new glass by using 11. Raise the glass by using the suction lifter (rubber
clean rag and ethyl alcohol. sucker 4355282), and adhere it to the cab within 5
minutes.
IMPORTANT: Primer (SUNSTAR #435-40) should be
shaken for about 1 minute and mix thoroughly
before opening the cap. After opening Primer,
fNOTE: Install the glass while fitting the spacer position
on the glass. Remove all adhesive except the mounting
apply Primer as quickly as possible and close surface before solidifying by using white spirit.
the cap immediately after using. After opening
12. Secure the glass by using the duct tape until the
Primer, all the contents should be used within 180
adhesive becomes solid in order to prevent them
days (or 2 hours with the cap off).
from being mispositioned or coming off.
5. Apply Primer for glass (SUNSTAR Primer #435-40) to
the cutting edge of adhesive at cab side by using fNOTE: Time for adhesive (SUNSTAR #580) to become
a brush. Wait for about 15 minutes in order to let it solid: 8 hours (just for reference)
dry by itself.
(As for the position to apply Primer for glass, refer to
W3-1-2-10.)

fNOTE: Overhead Window

Polycarbonate: SUNSTAR #435-41
Sash: SUNSTAR #435-95
6. Put the dam rubber onto the cab side. In case of the
left-hand glass, put the dam rubber onto the sash
side.
7. Cut off the nozzle of adhesive cartridge (SUNSTAR
#580) into V-shaped by using a knife. (As for the
cutting procedure of nozzle, refer to W3-1-2-14.)
8. Remove the seal of the cartridge end. Install the
V-shaped nozzle.
9. Install the cartridge to the manual coking gun.
10. Apply adhesive onto the adhesive position at cab
side so that the bead triangle may be even. (As for
the position to apply adhesive, refer to W3-1-2-14.)
In case of the left-hand glass, apply adhesive onto
the sash side.

W3-1-2-10
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

Rear Glass Right-Hand Glass

250 300
350 500

100

200 200 200

500

200 200 200

250 300

W1JB-02-01-029

200
200
100
100
W1JB-02-01-030

W3-1-2-11
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

Spacer A Spacer B Spacer C

20 6 20 6 20 6
2
4 4 4 R0.5
R8
R0.5 R5 75SDgr
6 6 R0.5 8
84SDgr 3 78SDgr
R10
12
3
a a a
10.5
10.5

W1JB-02-01-022 W1JB-02-01-023 W1JB-02-01-024

a- Two-Side Adhesive Tape a- Two-Side Adhesive Tape a- Two-Side Adhesive Tape

Dam Rubber
30 6.4

W1JB-02-01-025

Right-Hand Glass
Rear Glass

a
c

b
a
e
c

a- Dam Rubber W1JB-02-01-026 e- Spacer C

W1JB-02-01-042
b- Spacer A
c- Spacer B

W3-1-2-12
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

8~9 mm

a
13~15 mm
e
b

12 W1SE-02-01-027
b- Cut nozzle end into V-shaped. f W1SE-02-01-043
W1JB-02-01-031
a- Apply adhesive (bead) here. e- Apply bead so that bead triangle may be even.
f- Panel

W1SE-02-01-028
c- Remove the seal.
d- Adhesive Cartridge

13. The required amount (just for reference) of adhesive and primer

Painted Surface or
Glass Surface Polycarbonate Surface
Adhesive Surface
Adhesive Primer Primer
SUNSTAR #580 SUNSTAR #435-95 SUNSTAR #435-40 SUNSTAR #435-41
(Sika Tack-Drive)
310 ml Cartridge 250 ml Can 30 ml Bottle
Upper Front Glass 120 ml 3 ml 4 ml
Right-Hand Glass 280 ml 5 ml 16 ml
Rear Glass 240 ml 5 ml 16 ml
Upper Polycarbonate 240 ml 4 ml 4 ml
Left-Hand Sash 240 ml 6 ml -
(Cab Side/Sash Side)

W3-1-2-13
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Procedures to Install Upper Front Glass

1. Stick seal (1) to the lower side of the upper front Adhere the glass in the same way as right-hand glass.
glass by using Cemedine Super X.
Stick and secure both right and left ends (the thicker
part) of seal (1) to the glass by using Cemedine
Super X.
Stick the mating surface of seal (1) and the glass
by using Cemedine Super X so that no visible
undulation or boss can be found.

fNOTE: Cemedine Super X Black No. 8008

Glue-state adhesive, tubed

W1JB-02-01-034

b 2
2
a

1 1

3 3

W1JB-02-01-032 W1JB-02-01-033

2- Upper Glass b- Cemedine Super X

3- Lower Glass
a- Cemedine Super X Seal here.

W3-1-2-14
 SECTION 3 UPPERSTRUCTURE
Group 2 Counterweight

Removal and Installation of Counterweight 6 2

1
2 1
4, 5

WBAT-06-01-020
3

7, 8
WDEE-03-02-002
9

WDEB-03-04-013

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
dCAUTION: Engine cover (2) weight: 21kg (47 lb)
3. Attach the nylon slings onto engine cover (2). Hoist
2. Open doors (1) (2 used). and hold engine cover (2).
4. Remove lock pin (4) and washer (5). Remove stay (6).
5. Remove lock pin (7) and washer (8). Remove stay (9).
6. Remove bolts, washers (3) (4 used). Remove engine
cover (2).

j : 17 mm

W3-2-1-1
 SECTION 3 UPPERSTRUCTURE
Group 2 Counterweight

7
8

WDEE-03-02-001

7. Remove bolts, washers (5) (2 used). Remove cover

(6).

j : 13 mm
8. Remove bolts, washers (8) (2 used). Remove the
catch (7) assembly.

j : 17 mm

W3-2-1-2
 SECTION 3 UPPERSTRUCTURE
Group 2 Counterweight

3
5

1 WDEB-03-02-001 7 4 6 WDEB-03-02-002

9. Disconnect connector (3). 11. Remove coolant reservoir (7) and window washer
fluid tank (5). Replace them horizontally. Remove
10. Remove bolts, washers (2) (2 used). Remove cover
bolts, washers (4) (2 used). Remove the cover (6)
(1).
assembly.
j : 17 mm
j : 17 mm

W3-2-1-3
 SECTION 3 UPPERSTRUCTURE
Group 2 Counterweight

5
6
1

WDEB-03-05-007 WDEB-03-02-003
2

12. Remove bolts, washers (2) (4 used). Remove cover

(1). dCAUTION:
(3180 lb)
Counterweight (4) weight: 1440 kg

j : 17 mm 13. Remove caps (3) (2 used). Install the Freno-Linkbolt

(A-24, M24, Pitch 3.0 mm) to the cap (3) mounting
holes (2 places). Attach the wire ropes onto the
Freno-Linkbolts. Hoist and hold counterweight (4).
14. Remove bolts (6) (3 used) and washers (5) (3 used).
Remove counterweight (4).

j : 41 mm

W3-2-1-4
 SECTION 3 UPPERSTRUCTURE
Group 2 Counterweight

5
6

WDEB-03-02-003 WDEB-03-05-007
2

Installation

dCAUTION:
(3180 lb)
Counterweight (4) weight: 1440 kg 4. Install cover (1) with bolts, washers (2) (4 used).

j : 17 mm
1. Install the Freno-Linkbolt (A-24, M20, Pitch 3.0 mm)
to the cap (3) mounting holes (2 places). Attach m : 50 N·m (5 kgf·m, 37 lbf·ft)
the wire ropes onto the Freno-Linkbolts. Hoist
counterweight (4).
2. Install counterweight (4) with washers (5) (3 used)
and bolts (6) (3 used).

j : 41 mm

m : 1300 N·m (130 kgf·m, 960 lbf·ft)

3. Remove the Freno-Linkbolts from the cap (3)
mounting holes (2 places). Install caps (3) (2 used).

W3-2-1-5
 SECTION 3 UPPERSTRUCTURE
Group 2 Counterweight

5
2

WDEB-03-02-002 1 WDEB-03-02-001
7 4 6

5. Install the cover (6) assembly with bolts, washers (4) 6. Install cover (1) with bolts, washers (2) (2 used).
(2 used). Install window washer fluid tank (5) and
coolant reservoir (7). j : 17 mm

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

7. Connect connector (3).
m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-2-1-6
 SECTION 3 UPPERSTRUCTURE
Group 2 Counterweight

7
8

WDEE-03-02-001

8. Install the catch (7) assembly with bolts, washers (8)

(2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

9. Install cover (6) with bolts, washers (5) (2 used).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

W3-2-1-7
 SECTION 3 UPPERSTRUCTURE
Group 2 Counterweight

6 2
1
2 1

4, 5

WBAT-06-01-020
3

2
WDEE-03-02-002

7, 8

WDEB-03-04-013

14. Close doors (1) (2 used).

dCAUTION: Engine cover (2) weight: 21kg (47 lb)
10. Attach the nylon slings onto engine cover (2). Hoist
engine cover (2).
11. Install engine cover (2) with bolts, washers (3) (4
used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

12. Install stay (6) with washer (5) and lock pin (4).
13. Install stay (9) with washer (8) and lock pin (7).

W3-2-1-8
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

Removal and Installation of Main Frame

5 1

WDEE-04-03-001
3

IMPORTANT: The hose and pipe contain hydraulic 4. Remove the counterweight. (Refer to W3-2-1.)
oil. When removing the hose and pipe, receive oils
5. Remove the boom cylinder. (Refer to W5-2-1.)
with a container in order to avoid spilling oils.
IMPORTANT: Cap the open ends in case the hoses 6. Remove the front attachment. (Refer to W5-1-1.)
and pipes have been disconnected. In addition, 7. Remove the cab. (Refer to W3-1-1.)
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the 8. Remove the engine. (Refer to W3-4-1.)
hoses and install the clips in case the clips which 9. Remove the swing device. (Refer to W3-7-1.)
secure the hoses have been removed.

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Remove bolts, washers (1) (2 used) and bolts,
washers (4) (2 used). Remove cover (5).

j : 17 mm
3. Remove bolts, washers (3) (2 used). Remove cover
(2).

j : 17 mm

W3-3-1-1
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

2, 17 2, 17, 18

2, 17, 18

2, 19

1, 13

3, 14
15, 16

6, 8
4
5

WDEB-04-03-002
6 15, 16 6

10. Disconnect hoses (2) (4 used). 16. Disconnect hose (1).

j : 27 mm j : 17 mm
11. Remove elbows (17) (3 used), elbow (19), and 17. Remove elbow (13).
sockets (18) (2 used).
j : 19 mm
j : 27 mm
18. Remove bolts, washers (5) (2 used). Remove stopper
12. Disconnect hose (3). (8) and washers (6) (2 used).

j : 22 mm j : 19 mm
13. Remove adapter (14). 19. Remove boot cover (4).

j : 22 mm
14. Disconnect hoses (15) (2 used).

j : 27 mm
15. Remove adapters (16) (2 used).

j : 22 mm

W3-3-1-2
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

b
1

WBAT-06-01-091
3, 4
a

WDEE-03-03-001
e

a- Counterweight Mounting Part

b- Boom Mounting Bracket Hole
c

dCAUTION:
lb)
Main frame (1) weight: 2300 kg (5080

20. Attach the wire ropes onto the rear side

(counterweight mounting parts (a) (2 places)) of g f
main frame (1) and boom mounting bracket holes d
(b) (2 places).
21. Reduce slack of the wire ropes by using a chain
block. Put the matching marks onto main frame (1)
and outer race (2) of the swing bearing. WBAT-04-01-004

22. Remove bolts (3) (24 used) and washers (4) (24
c- Boom Foot Pin f- Center of Rope
used). d- Swing Post g- Center
e- Approx 37 mm (1.5 in)
j : 24 mm
23. Adjust the chain blocks in order to level main frame
(1). Hoist and remove main frame (1).

W3-3-1-3
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

Detail A
A
1
2
3

WDCF-03-03-004
1 b- THREEBOND Applying Surface
WDEA-04-01-001

a- Front Side

Installation
IMPORTANT: Apply THREEBOND #1102 when
installing the main frame so that it does not
overflow the main frame mounting surface.
1. Apply THREEBOND #1102 onto THREEBOND
applying surface (b) of the main frame mounting
surface of swing bearing (1). At this time, apply
THREEBOND #1102 until the hole center of bolt (3)
in outer race (1).

fNOTE: Install knock pin (2) after applying THREEBOND

#1102.

W3-3-1-4
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

b
1

WBAT-06-01-091
3, 4

WDEE-03-03-001 e

a- Counterweight Mounting Part

b- Boom Mounting Bracket Hole
c

dCAUTION:
lb)
Main frame (1) weight: 2300 kg (5080

2. Attach the wire ropes onto the rear side

(counterweight mounting parts (a) (2 places)) of g f
main frame (1) and boom mounting bracket holes d
(b) (2 places).
3. Adjust the chain blocks in order to level main frame
(1).
4. Fit the matching marks made when disassembling WBAT-04-01-004
and the position of the knock pins. Install main
frame (1) to outer race (2) of the swing bearing. c- Boom Foot Pin f- Center of Rope
d- Swing Post g- Center
Temporarily tighten washers (4) (24 used) and bolts
e- Approx 37 mm (1.5 in)
(3) (24 used).

j : 24 mm
5. Tighten bolts (3) (24 used).

j : 24 mm

m : 270 N·m (27 kgf·m, 200 lbf·ft)

W3-3-1-5
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

2, 17 2, 17, 18

2, 17, 18

2, 19

1, 13

3, 14
15, 16

6, 8
4
5

WDEB-04-03-002
6 15, 16 6

6. Install boot cover (4). 13. Connect hose (3).

7. Install stopper (8) and washers (6) (2 used) with j : 22 mm
bolts, washers (5) (2 used).
m : 40 N·m (4 kgf·m, 29.5 lbf·ft)
j : 19 mm
14. Install elbows (17) (3 used), elbow (19), and sockets
m : 90 N·m (9 kgf·m, 66 lbf·ft) (18) (2 used).
8. Install elbow (13). j : 27 mm
j : 19 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft)
m : 30 N·m (3 kgf·m, 22 lbf·ft) 15. Connect hoses (2) (4 used).
9. Connect hose (1). j : 27 mm
j : 17 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft)
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 16. Install the swing device. (Refer to W3-7-1.)
10. Install adapters (16) (2 used).

j : 22 mm

m : 70 N·m (7 kgf·m, 52 lbf·ft)

11. Connect hoses (15) (2 used).

j : 27 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

12. Install adapter (14).

j : 22 mm

m : 70 N·m (7 kgf·m, 52 lbf·ft)

W3-3-1-6
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

5 1

3 WDEE-04-03-001

17. Install the engine (Refer to W3-4-1.) 23. Install cover (2) with bolts, washers (3) (2 used).
18. Install the cab. (Refer to W3-1-1.) j : 17 mm
19. Install the front attachment. (Refer to W5-1-1.)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
20. Install the boom cylinder. (Refer to W5-2-1.)
24. Install cover (5) with bolt, washers (1) (2 used) and
21. Bleed air from the hydraulic system. (Refer to W1-4- bolts, washers (4) (2 used).
1.)
j : 17 mm
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks. m : 50 N·m (5 kgf·m, 37 lbf·ft)
22. Install the counterweight. (Refer to W3-2-1.)

W3-3-1-7
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

(Blank)

W3-3-1-8
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

Removal and Installation of Engine

1

4, 5

6
2

WDEB-03-05-005 WDEB-03-05-006

Removal
d CAUTION: Escaping fluid under pressure may
penetrate the skin and eyes, and cause serious 1. Set the machine position for inspection and
injury. Release the pressure before disconnecting maintenance. (Refer to W1-6-1.)
the hydraulic pipings or removing other
equipment. Hot hydraulic oil just after operation dCAUTION: Bleed air from hydraulic oil tank (6).
(Refer to W1-4-1.)
may spout out and cause severe burns. Wait for oil
in order to cool before starting any work. Do not 2. Remove bolts, washers (1) (8 used). Remove cover
turn the cap of hydraulic oil tank (6) quickly. The (2).
cap may fly off by internal pressure. Release any j : 17 mm
remaining pressure and remove the cap.
IMPORTANT: The hose and pipe contain hydraulic 3. Remove bolts, washers (3) (6 used). Remove the
oil. When removing the hose and pipe, receive oils cover (4) assembly and O-ring (5).
with a container in order to avoid spilling oils. j : 17 mm
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition, 4. Place a container. Drain off hydraulic oil by using an
attach an identification tag onto the connectors, oil feed pump.
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
fNOTE: Total oil amount of hydraulic oil tank (6): 91 L
(24 US gal)
secure the hoses have been removed.

W3-4-1-1
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

7 8

10, 11
1

9
WBAT-06-01-020

2, 3, 4 5, 6 8
WDEB-03-04-001

12, 13

5. Open door (1).

6. Remove nut (2) and washer (3). Disconnect ground 14
(4).

j : 17 mm
7. Bleed air from the radiator. (Refer to W1-4-1.)
8. Place a container under hose (5). Loosen cock (6).
Drain off coolant. Close cock (6). WDEB-03-04-013

fNOTE: Amount of coolant: 7 L (1.85 US gal) 11. Remove lock pin (12) and washer (13). Remove stay
(14).
dCAUTION: Engine cover (8) weight: 21 kg (47 lb)
12. Remove bolts, washers (9) (4 used). Remove engine
9. Attach the nylon slings onto engine cover (8). Hoist
and hold engine cover (1). cover (8).
10. Remove lock pin (10) and washer (11). Remove stay j : 17 mm
(7).

W3-4-1-2
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

1 2 3
8 7

4 7 9, 10

WDEB-03-05-007
6
WDEB-03-04-002

13. Remove bolts, washers (6) (4 used). Remove cover 16. Remove bolts, washers (7) (5 used). Remove plate
(5). (9), rubber plate (10), and cover (8).

j : 17 mm j : 17 mm
14. Remove bolts, washers (1) (2 used). Remove cover
(2).

j : 17 mm
15. Remove bolts, washers (4) (3 used). Remove cover
(3).

j : 17 mm

W3-4-1-3
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

1 3 2
8

6, 7

3 MDEC-07-008

WDEB-03-04-003

17. Disconnect connector (2). Remove bolts, washers (6) 19. Open door (8).
(3 used) and washers (7) (3 used). Remove controller
(1).

j : 13 mm
18. Remove bolts, washers (3) (3 used). Remove covers
(4, 5).

j : 17 mm

W3-4-1-4
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

1 2

4 3

WDEB-03-05-008

20. Remove bolts, washers (2) (3 used). Remove stay (3).

j : 17 mm
21. Remove bolts, washers (1) (2 used). Remove the oil
filter (4) assembly. Place it horizontally.

j : 13 mm

W3-4-1-5
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

WDEE-04-03-001 WDEE-03-04-001
3 4

22. Remove bolts, washers (1) (2 used). 24. Remove bolts, washers (4) (5 used). Remove cover
(5) and support (6).
j : 17 mm
j : 17 mm
23. Remove bolts, washers (3) (2 used). Remove cover
(2).

j : 17 mm

W3-4-1-6
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

1
2
5

3
4

8, 9

3
6
7
WDEB-03-05-009
WDEB-03-05-010

25. Remove bolts, washers (1) (2 used) and bolts,

washers (3) (4 used). Remove the cover (2) assembly.

j : 17 mm
26. Remove nuts (8) (4 used) and spring washers (9) (4
used).

j : 13 mm
27. Remove nuts (7) (4 used), nuts (6) (4 used), and
U-bolts (5) (2 used). Remove muffler (4).

j : 17 mm

W3-4-1-7
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

1 2 3
10 12

10 4

6 5
WDEB-03-02-001 12 13
WDEB-03-02-002

28. Remove bolts, washers (3) (2 used) and bolt, washer 32. Remove wind washer tank (13). Place it horizontally.
(5). Remove cover (4). Remove bolts, washers (12) (2 used). Remove the
cover (10) assembly.
j : 17 mm
j : 17 mm
29. Remove bolts, washers (1) (2 used). Remove cover
(2).

j : 17 mm
30. Remove bolts, washers (7) (2 used). Remove cover
(6).

j : 17 mm
31. Disconnect connector (9) and hose (8).

W3-4-1-8
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

6 2

4
WDEB-03-04-005
WDEB-03-04-006

33. Remove clamp (3). Disconnect the engine side of 37. Disconnect connectors (16) (3 used). Remove caps
hose (5). (7) (3 used). Remove nut (8) and washer (9). Remove
screw (10). Remove clamps (15) (4 used). Remove
34. Remove clamp (1). Disconnect the air cleaner side of
harness (18).
hose (6). Remove the resonator (2) assembly.
35. Remove counterweight (4). (Refer to W3-2-1.) j : 13 mm

36. Remove the pump device. (Refer to W3-5-1.) 38. Remove nut (11) and washer (12). Disconnect
terminal (17).

j : 13 mm
39. Remove bolts, washers (13) (2 used). Remove
bracket (14).

j : 17 mm

W3-4-1-9
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

4, 5

2 1
WDEB-03-04-016

40. Remove cap (4) and nut (5).

j : 10 mm
41. Disconnect connectors (1) (6 used).
42. Remove clamps (2) (2 used). Remove harness (3).

W3-4-1-10
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

1
7, 8, 9

c
14 10
b

7, 8
11

2
4 WDEB-03-04-007
3

a- 9 to 12 mm, 98 N (10 kgf )

13, 15 12
b- Compressor Pulley
c- Crank Pulley WDEB-03-04-008

43. Loosen bolt (2) of tension pulley (4). 45. Remove bolt, washer (15). Remove clamp (13).

j : 22 mm j : 17 mm
44. Release the belt (1) tension by moving tension 46. Remove bolts (7) (4 used), washers (8) (4 used), and
pulley (4) by using adjusting bolt (3). bracket (9). Remove and place compressor (14)
outside of the work area.
j : 13 mm
j : 13 mm

fNOTE: LOCTITE #262 has been applied on bolt (7).

47. Remove clamp (12). Remove bolt, washer (10).
Disconnect ground (11).

j : 17 mm

W3-4-1-11
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

5 6 7

3
2

WDEB-03-04-014 WDEB-03-04-015
1

48. Remove bolts, washers (2) (2 used) and bolts, 49. Remove wing bolts (6) (2 used). Remove cover (7).
washers (3) (2 used). Remove cover (1).
50. Remove bolts, washers (4) (4 used). Remove cover
j : 17 mm (5).

j : 17 mm

W3-4-1-12
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

1 2 3 4

WDEB-03-04-010
6 WDEB-03-04-009

51. Remove clamp (3) and clamp (5). Disconnect hose 53. Remove clamps (7) (2 used). Disconnect hoses (8) (2
(4). used).
52. Remove clamp (6) and clamp (2). Disconnect hose
(1).

W3-4-1-13
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

a 1
a 9
10
11
12
13
16 10 10
7, 8
11 11
2 15 12
14 13 12
13 13
12 13
12 13
12
10
11
3 12
13
17 13
12

6, 7 4, 5
WDEB-03-04-012
WDEB-03-04-011

a- Lifting Bracket

58. Remove bolts, washers (2) (7 used). Remove cover

dCAUTION: Engine (9) weight: 260 kg (575 lb) (1).
54. Install the shackles to lifting bracket (a) (2 places) of
engine (9). Attach the nylon slings onto the shackles j : 17 mm
(2 used). Hoist and hold engine (9). 59. Remove bolt (8), bolts (6) (3 used) and washers (7) (4
55. Remove spacer (3). Remove socket bolts (4) (3 used). used). Remove bracket (17).
Remove coupling (5).
j : 17 mm
l : 12 mm
fNOTE: LOCTITE #262 has been applied on bolts (8, 6).
56. Remove bolts (10) (4 used), plates (11) (4 used), 60. Remove bolts (16) (4 used) and washers (15) (4
stoppers (12) (8 used), and rubber cushions (13) (8 used). Remove bracket (14).
used).
j : 17 mm
j : 24 mm
57. Move engine (9) to the pump device mounting side. fNOTE: LOCTITE #262 has been applied on bolt (16).
Remove it. 61. Remove the adapter with engine (9) attached if
necessary.

W3-4-1-14
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

a 1
a 9
10
11
12
13
16 10 10 7, 8
11 11
15 12 2
14 13 12
13 13
12 13
12 13
12
10
11
12 3
13
13 17
12

6, 7 4, 5
WDEB-03-04-012
WDEB-03-04-011

a- Lifting Bracket

Installation
1. Install all removed adapters to engine (9).
dCAUTION: Engine (9) weight: 260 kg (575 lb)
2. Install cover (1) with bolts, washers (2) (7 used). 5. Install the shackles to lifting bracket (a) (2 places) of
engine (9). Attach the nylon slings onto the shackles
j : 17 mm (2 used). Hoist engine (9).
m : 50 N·m (5 kgf·m, 37 lbf·ft) 6. Install engine (9) with rubber cushions (13) (8 used),
stoppers (12) (8 used), plates (11) (4 used), and bolts
3. Apply LOCTITE #262 onto bolts (6, 8). Install bracket
(10) (4 used).
(17) with washers (7) (4 used), bolts (6) (3 used), and
bolt (8). j : 24 mm
j : 17 mm m : 270 N·m (27 kgf·m, 200 lbf·ft)
m : 65 N·m (6.5 kgf·m, 48 lbf·ft) 7. Install coupling (5) with socket bolts (4) (3 used).
Install spacer (3).
4. Apply LOCTITE #262 onto bolt (16). Install bracket
(14) with washers (15) (4 used) and bolts (16) (4 l : 12 mm
used).
m : 140 N·m (14 kgf·m, 103 lbf·ft)
j : 17 mm

m : 65 N·m (6.5 kgf·m, 48 lbf·ft)

W3-4-1-15
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

1 2 3 4

WDEB-03-04-010
6 WDEB-03-04-009

8. Connect hoses (8) (2 used) with clamps (7) (2 used). 9. Connect hose (1) with clamp (2) and clamp (6).

m : 6 N·m (0.6 kgf·m, 4.4 lbf·ft) m : 6 N·m (0.6 kgf·m, 4.4 lbf·ft)
10. Connect hose (4) with clamp (3) and clamp (5).

m : 6 N·m (0.6 kgf·m, 4.4 lbf·ft)

m : 8 N·m (0.8 kgf·m, 5.9 lbf·ft)

W3-4-1-16
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

5 6 7

3
2

WDEB-03-04-015 WDEB-03-04-014
1

11. Install cover (5) with bolts, washers (4) (4 used). 13. Install cover (1) with bolts, washers (3) (2 used) and
bolts, washers (2) (2 used).
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
12. Install cover (7) with wing bolts (6) (2 used).

W3-4-1-17
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

6 7, 8, 9

14 10

c
7, 8
11 b

13, 15 12 2
4 WDEB-03-04-007
WDEB-03-04-008 3
a- 9 to 12 mm, 98 N (10 kgf )
b- Compressor Pulley
c- Crank Pulley

14. Install ground (11) with bolt, washer (10). Install 17. Loosen bolt (2) of tension pulley (4).
clamp (12).
j : 22 mm
j : 17 mm
18. Adjust the belt (1) tension correctly by moving
m : 78.5 to 98.3 N·m (7.85 to 9.83 kgf·m, 58 to tension pulley (4) by using adjusting bolt (3).
73 lbf·ft)
j : 13 mm
15. Apply LOCTITE #262 onto bolt (7). Install
19. Tighten bolt (2) of tension pulley (4).
compressor (14) with bracket (9), washers (8) (4
used), and bolts (7) (4 used). j : 22 mm
j : 13 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 20 N·m (2 kgf·m, 15 lbf·ft) IMPORTANT: The belt does not fit when replacing
with a new one. Therefore, adjust the belt tension
16. Install hoses (6) (2 used) with clamp (13) and bolt,
again after running the engine at slow idle for 3 to
washer (15).
5 minutes.
j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-4-1-18
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

4, 5

2 1
WDEB-03-04-016

20. Install harness (3) with clamps (2) (2 used).

21. Connect connectors (1) (6 used).
22. Install nut (5) and cap (4).

j : 10 mm

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)

W3-4-1-19
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

6 2

4
WDEB-03-04-006 WDEB-03-04-005

23. Install bracket (14) with bolts, washers (13) (2 used). 26. Connect engine side of hose (5) of the resonator (2)
assembly with clamp (3).
j : 17 mm
m : 6 N·m (0.6 kgf·m, 4.4 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
27. Connect the air cleaner side of hose (6) with clamp
24. Connect terminal (17) with washer (12) and nut (11). (1).
j : 13 mm m : 6 N·m (0.6 kgf·m, 4.4 lbf·ft)
m : 20 N·m (2 kgf·m, 15 lbf·ft) 28. Install the pump device. (Refer to W3-5-1.)
25. Install harness (18) with clamps (15) (4 used). Install 29. Install counterweight (4). (Refer to W3-2-1.)
screw (10), washer (9), and nut (8). Install caps (7) (3
used). Connect connectors (16) (3 used).

j : 13 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-4-1-20
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

5, 6

3
4
WDEB-03-05-010

30. Install muffler (1) with U-bolts (2) (2 used) and nuts
(3) (4 used).

j : 17 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

31. Install nuts (4) (4 used).

j : 17 mm

m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

32. Install spring washers (6) (4 used) and nuts (5) (4
used).

j : 13 mm

m : 26±3 N·m (2.6±0.3 kgf·m, 19±2.2 lbf·ft)

W3-4-1-21
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

10 12 1 2 3

10 4

9
8

12 13 6 5
WDEB-03-02-002 WDEB-03-02-001

33. Install the cover (10) assembly with bolts, washers 34. Connect connector (9) and hose (8).
(12) (2 used). Install window washer tank (13).
35. Install cover (6) with bolts, washers (7) (2 used).
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
36. Install cover (2) with bolts, washers (1) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

37. Install cover (4) with bolts, washers (3) (2 used) and
bolt, washer (5).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-4-1-22
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

5 1 2
6

4 3

WDEB-03-05-009 WDEB-03-05-008

38. Install the cover (6) assembly with bolts, washers (5) 39. Install the oil filter (4) assembly with bolts, washers
(2 used) and bolts, washers (7) (4 used). (1) (2 used).

j : 17 mm j : 13 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft) m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

40. Install stay (3) with bolts, washers (2) (3 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-4-1-23
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

WDEE-03-04-001 WDEE-04-03-001
4 3

41. Install support (6) and cover (5) with bolts, washers 42. Install cover (2) with bolts, washers (1) (2 used) and
(4) (5 used). bolts, washers (3) (2 used).

j : 17 mm j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft) m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-4-1-24
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

1 3 2

6, 7

WDEB-03-04-003

43. Install covers (4, 5) with bolts, washers (3) (3 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

44. Install controller (1) with washers (7) (3 used) and
bolts, washers (6) (3 used). Connect connector (2).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

W3-4-1-25
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

8 7 1 2 3

7 9, 10
4

WDEB-03-05-007
WDEB-03-04-002 6

45. Install cover (8), rubber plate (10), and plate (9) with 46. Install cover (3) with bolts, washers (4) (3 used).
bolts, washers (7) (5 used).
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
47. Install cover (2) with bolts, washers (1) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

48. Install cover (5) with bolts, washers (6) (4 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-4-1-26
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

7 8

10, 11

9
WBAT-06-01-020

8 2, 3, 4
WDEB-03-04-001

12, 13

14

WDEB-03-04-013

53. Add coolant to the radiator.

dCAUTION: Engine cover (8) weight: 21 kg (47 lb)
fNOTE: Amount of coolant: 7 L (1.85 US gal)
49. Attach the nylon slings onto engine cover (8). Hoist
engine cover (8). 54. Connect ground (4) with washer (3) and nut (2).
50. Install engine cover (8) with bolts, washers (9) (4 j : 17 mm
used).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 17 mm
55. Bleed air from the fuel system. (Refer to W1-4-1.)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
56. Bleed air from the radiator. (Refer to W1-4-1.)
51. Install stay (7) with washer (11) and lock pin (10).
57. Close door (1).
52. Install stay (14) with washer (13) and lock pin (12).

W3-4-1-27
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

4, 5

6
2

WDEB-03-05-006 WDEB-03-05-005

58. Fill hydraulic oil to hydraulic oil tank (6). 60. Install cover (2) with bolts, washers (1) (8 used).

fNOTE: Total oil amount of hydraulic oil tank (6): 91 L j : 17 mm

(24 US gal)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
59. Install O-ring (5). Install the cover (4) assembly with
bolts, washers (3) (6 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-4-1-28
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

MDEC-07-008

61. Bleed air from the hydraulic system. (Refer to W1-4-

1.)
 Pump Air Bleed Plug
j : 27 mm

m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
62. Close door (1).

W3-4-1-29
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

(Blank)

W3-4-1-30
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

Removal and Installation of Pump Device

1

4, 5

6
2

WDEB-03-05-005 WDEB-03-05-006

Removal
d CAUTION: Escaping fluid under pressure may
penetrate the skin and eyes, and cause serious 1. Set the machine position for inspection and
injury. Release the pressure before disconnecting maintenance. (Refer to W1-6-1.)
the hydraulic pipings or removing other
equipment. Hot hydraulic oil just after operation dCAUTION: Bleed air from hydraulic oil tank (6).
(Refer to W1-4-1.)
may spout out and cause severe burns. Wait for oil
in order to cool before starting any work. Do not 2. Remove bolts, washers (1) (8 used). Remove cover
turn the cap of hydraulic oil tank (6) quickly. The (2).
cap may fly off by internal pressure. Release any j : 17 mm
remaining pressure and remove the cap.
IMPORTANT: The hose and pipe contain hydraulic 3. Remove bolts, washers (3) (6 used). Remove the
oil. When removing the hose and pipe, receive oils cover (4) assembly and O-ring (5).
with a container in order to avoid spilling oils. j : 17 mm
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition, 4. Place a container. Drain off hydraulic oil by using an
attach an identification tag onto the connectors, oil feed pump.
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
fNOTE: Total oil amount of hydraulic oil tank (6): 91 L
(24 US gal)
secure the hoses have been removed.

W3-5-1-1
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

6 7

1 2 8

9
4, 5

WBAT-06-01-020
3

10
WDEB-03-05-007
11

8. Remove bolts, washers (11) (4 used). Remove cover

dCAUTION: Engine cover (2) weight: 21 kg (47 lb) (10).
5. Attach nylon slings onto engine cover (2). Hoist and
hold engine cover (2). j : 17 mm

6. Remove lock pin (4) and plane washer (5). Remove 9. Remove bolts, washers (6) (2 used). Remove cover
stay (1). (7).

7. Remove bolts, washers (3) (4 used). Remove engine j : 17 mm

cover (2).
10. Remove bolts, washers (9) (3 used). Remove cover
j : 17 mm (8).

j : 17 mm

W3-5-1-2
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

2 3

MDEC-07-008

WDEB-03-05-008

11. Open door (1).

12. Remove bolts, washers (3) (3 used). Remove stay (4).

j : 17 mm
13. Remove bolts, washers (2) (2 used). Remove the oil
filter (5) assembly. Place it horizontally.

j : 13 mm

W3-5-1-3
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

1
2

7, 8 a

6
9
WDEB-03-05-009 WDEB-03-05-010

14. Remove bolts, washers (1) (2 used) and bolts,

washers (3) (4 used). Remove the cover (2) assembly.

j : 17 mm
15. Remove nuts (7) (4 used) and spring washers (8) (4
used).

j : 13 mm
16. Remove nuts (9) (4 used), nuts (6) (4 used), and
U-bolts (5) (2 used). Remove muffler (4).

j : 17 mm

W3-5-1-4
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

1 2 3

WDEB-03-05-011 4 WDEB-03-05-014

17. Remove bolts, washers (1) (3 used). Remove bracket

(2). dCAUTION: Remove cover (4) while holding it. Do
not drop cover (4).
j : 17 mm 18. Remove bolts, washers (3) (6 used). Remove cover
(4).

j : 17 mm

W3-5-1-5
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

WDEB-03-05-015 WDEB-03-05-016

19. Disconnect all hoses (1).

j : 17 mm, 27 mm, 36 mm
dCAUTION: Pump device (8) weight: 72 kg (160 lb)
21. Attach nylon slings onto pump device (8). Hoist and
20. Place containers under the disconnecting part of hold pump device (8).
suction pipes (4, 5). Remove socket bolts (2, 6) (4 22. Remove bolts (9) (2 used) and spring washers (10) (2
used for each). Remove suction pipes (4, 5). Remove used). Remove pump device (8).
O-rings (3, 7).
j : 27 mm
l : 8 mm, 10 mm
fNOTE: LOCTITE #262 has been applied on bolt (9).
23. Remove the adapters with pump device (8)
attached if necessary.

W3-5-1-6
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

WDEB-03-05-016
a- Nylon Sling Mounting Part

Installation
1. Install all removed adapters to pump device (8).

dCAUTION: Pump device (8) weight: 72 kg (160 lb)

2. Attach nylon slings onto pump device (8). Hoist
pump device (8).
3. Apply LOCTITE #262 onto bolt (9). Install pump
device (9) with spring washers (10) (2 used) and
bolts (9) (2 used).

j : 27 mm

m : 300 N·m (30 kgf·m, 220 lbf·ft)

W3-5-1-7
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

8 9

WDEB-03-05-011

WDEB-03-05-015

4. Install O-rings (3, 7). Install suction pipes (4, 5) with 5. Connect all hoses (1).
socket bolts (2, 6) (4 used for each).
j : 17 mm
l : 8 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
m : 30 N·m (3 kgf·m, 22 lbf·ft)
j : 27 mm
l : 10 mm
m : 80 N·m (8 kgf·m, 59 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

6. Install bracket (9) with bolts, washers (8) (3 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-5-1-8
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

1
2
5

3
4

7, 8 a

6
9
WDEB-03-05-010 WDEB-03-05-009

7. Install muffler (4) with U-bolts (5) (2 used) and nuts 10. Install the cover (2) assembly with bolts, washers (1)
(6) (4 used). (2 used) and bolts, washers (3) (4 used).

j : 17 mm j : 17 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft) m : 50 N·m (5 kgf·m, 37 lbf·ft)

8. Install nuts (9) (4 used).

j : 17 mm

m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

9. Install spring washers (8) (4 used) and nuts (7) (4
used).

j : 13 mm

m : 26 ± 3 N·m (2.6 ± 0.3 kgf·m, 19 ± 2.2 lbf·ft)

W3-5-1-9
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

2 3

WDEB-03-05-008

11. Install the oil filter (5) assembly with bolts, washers
(2) (2 used).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

12. Install stay (4) with bolts, washers (3) (3 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-5-1-10
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

6 7
8

1 2

4, 5

WBAT-06-01-020
3

10
WDEB-03-05-007
11

13. Install cover (8) with bolts, washers (9) (3 used).

j : 17 mm
dCAUTION: Engine cover (2) weight: 21 kg (47 lb)
16. Attach nylon slings onto engine cover (2). Hoist
engine cover (2).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
17. Install engine cover (2) with bolts, washers (3) (4
14. Install cover (7) with bolts, washers (6) (2 used).
used).
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
15. Install cover (10) with bolts, washers (11) (4 used).
18. Install stay (1) with plane washer (5) and lock pin (4).
j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-5-1-11
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

3 2

4, 5

6
2

WDEB-03-05-006 WDEB-03-05-005

19. Fill hydraulic oil to hydraulic oil tank (6). 21. Install cover (2) with bolts, washers (1) (8 used).

fNOTE: Total oil amount of hydraulic oil tank (6): 91 L j : 17 mm

(24 US gal)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
20. Install O-ring (5). Install the cover (4) assembly with
bolts, washers (3) (6 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-5-1-12
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

1 3

MDEC-07-008

4 WDEB-03-05-014

22. Bleed air from the hydraulic system. (Refer to W1- 24. Install cover (4) with bolts, washers (3) (6 used).
4-1.)
j : 17 mm
 Pump Air Bleed Plug
j : 27 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
23. Close door (1).

W3-5-1-13
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

(Blank)

W3-5-1-14
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

Disassembly of Main Pump 3

4
3
1 2

Main Pumps 1, 2
50

19 23, 24, 25
44
20 22
42
44

26
17
42
16
43 21
15
14
13
12 42
11
8 10

9
7
35
31
32
33
34
47
37
41 48 WDEB-03-05-003
36
49

W3-5-3-1
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

1- Gasket 11- Retainer 22 - Socket Bolt 36 - Spring Seat

2- Retaining Ring 12- Spherical Bushing 23 - O-Ring 37 - Spring
3- Spacer 13- Spring (6 Used) 24 - Gear Pump Assembly 41 - Tilt Piston
4- Bearing 14- Cylinder Block 25 - Socket Bolt (4 Used) 42 - Spring Pin (3 Used)
5- Shaft 15- Valve Plate 26 - Casing 43 - Needle Bearing
6- Support Plate 16- Pin 31 - Lock Nut 44 - O-Ring (2 Used)
7- Swash Plate 17- Piston Case 32 - Cover 47 - Spring Seat
8- Pin 19 - Plug 33 - O-Ring 48 - Spring
9- Retaining Ring 20 - O-Ring 34 - O-Ring 49 - Plug (2 Used)
10- Piston (9 Used) 21 - Socket Bolt (6 Used) 35 - Adjusting Screw 50 - Pin

W3-5-3-2
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

Disassembly of Main Pump 3

6. Remove socket bolts (25) (4 used). Remove gear
d CAUTION: The pump assembly weight: 72 kg
(160 lb)
pump assembly (24) and O-ring (23) from casing
(26).
1. Remove plug (19) and O-ring (20) from casing (26).
Drain off oil. l : 6 mm
IMPORTANT: Do not drop and damage valve plate
l : 10 mm
(15) while removing casing (26).
IMPORTANT: As the setting changes, do not 7. Remove socket bolt (22). Loosen socket bolts (21) (6
disassemble lock nut (31) and adjusting screw used). Record the clearance between main pumps 1,
(35). 2 and casing (26). Remove socket bolts (21) (6 used).
2. Remove the cover (32) assembly from casing (26). Remove casing (26), gasket (1), and spring pins (42)
(2 used) from main pumps 1, 2.
j : 36 mm
l : 10 mm
3. Remove O-ring (33) and spring seat (47) from the
cover (32) assembly. 8. Remove O-rings (44) (2 used) from casing (26).
4. Remove O-ring (34) from spring seat (47).
fNOTE: When loosening socket bolts (21) (6 used),
5. Remove springs (37, 48) and spring seat (36) from casing (26) will be pushed out due to the force of spring
casing (26). (13).
9. Remove pin (16) from piston case (17).
10. Remove piston case (17) from casing (26).

j : 24 mm

fNOTE: THREEBOND #1305N has been applied on piston

case (17).

W3-5-3-3
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

IMPORTANT: Do not damage the sliding surface and IMPORTANT: When replacing component parts (7, 8,
the mounting surface of valve plate (15). 41) of the swash plate (7) assembly, replace them
11. Remove valve plate (15) from casing (26). as an assembly.
15. Remove the swash plate (7) assembly from support
IMPORTANT: Do not remove needle bearing (43)
plate (6).
unless necessary.
12. Remove needle bearing (43) from casing (26). 16. Remove the shaft (5) assembly from main pumps 1,
2.
IMPORTANT: Do not damage the sliding surfaces of
cylinder block (14), piston (10), spherical bushing 17. Remove support plate (6) from shaft (5).
(12), and swash plate (7). 18. Remove pin (50) from support plate (6).
13. Remove the cylinder block (14) assembly from shaft
19. Remove retaining ring (2), spacer (3), and bearing
(5).
(4) from shaft (5).
14. Remove pistons (10) (9 used), retainer (11), spherical
bushing (12), and springs (13) (6 used) from cylinder
block (14).

W3-5-3-4
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

Assembly of Main Pump 3

42 21 22 19, 20

WDEB-03-05-004
44 42

8, 9 1 7, 49 16 17 14 15 26 25
11

12

50

4
3

2
5

23
6
25
10

WDEA-03-08-003
41 37 48 13 36 42 47 34 33 32 31 35 43

W3-5-3-5
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

1- Gasket 11- Retainer 22 - Socket Bolt 36 - Spring Seat

2- Retaining Ring 12- Spherical Bushing 23 - O-Ring 37 - Spring
3- Spacer 13- Spring (6 Used) 24 - Gear Pump Assembly 41 - Tilt Piston
4- Bearing 14- Cylinder Block 25 - Socket Bolt (4 Used) 42 - Spring Pin (3 Used)
5- Shaft 15- Valve Plate 26 - Casing 43 - Needle Bearing
6- Support Plate 16- Pin 31 - Lock Nut 44 - O-Ring (2 Used)
7- Swash Plate 17- Piston Case 32 - Cover 47 - Spring Seat
8- Pin 19 - Plug 33 - O-Ring 48 - Spring
9- Retaining Ring 20 - O-Ring 34 - O-Ring 49 - Plug (2 Used)
10- Piston (9 Used) 21 - Socket Bolt (6 Used) 35 - Adjusting Screw 50 - Pin

W3-5-3-6
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

Assembly of Main Pump 3

1. Install bearing (4), spacer (3), and retaining ring (2) IMPORTANT: Install valve plate (15) as illustrated
to shaft (5). below.
2. Install support plate (6) to shaft (5). IMPORTANT: When replacing valve plate (15),
replace it with cylinder block (14) together as an
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
assembly.
8. Apply grease onto the casing (26) mounting surface
such as goggles, helmets, etc in order to prevent of valve plate (15). Fit groove (a) of valve plate (15)
personal injury. to spring pin (42) of casing (26) and install valve
3. Evenly tap the outer race of bearing (4) by using a plate (15).
plastic hammer and install the shaft (5) assembly to
main pumps1, 2. Tap the outer race of bearing (4) by 26
using a bar and a hammer and listen to ring in order
to check if the installation is completed.
IMPORTANT: When replacing component parts (7, 8,
41) of the swash plate (7) assembly, replace them 15
as an assembly.
4. Apply grease onto the sliding surfaces of support
plate (6) and the swash plate (7) assembly. Install
the swash plate (7) assembly to support plate (6).
5. Install springs (13) (6 used), spherical bushing (12),
retainer (11), and pistons (10) (9 used) to cylinder
block (14). a 42 W1P1-02-04-054

6. Install the cylinder block (14) assembly to shaft (5).

7. Install needle bearing (43) to casing (26). 9. Apply THREEBOND #1305N onto the thread part of
piston case (17). Install piston case (17) to casing
(26).

j : 24 mm

m : 110 N·m (11.0 kgf·m, 81 lbf·ft)

10. Install pin (16) to piston case (17).

W3-5-3-7
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

11. Install O-rings (44) (2 used) to casing (26). 14. Install spring seat (36) and springs (37, 48) to casing
(26).
12. Install spring pins (42) (2 used), O-rings (44) (2 used),
gasket (1), and casing (26) to main pumps 1, 2 with 15. Install O-ring (33) to cover (32).
socket bolts (21) (6 used). Install socket bolt (22).
16. Install O-ring (34) to spring seat (47). Install spring
l : 10 mm seat (47) to cover (32).
17. Install the cover (32) assembly to casing (26).
m : 98 N·m (9.8 kgf·m, 72 lbf·ft)
j : 36 mm
fNOTE: Check the clearance between main pumps 1, 2
and casing (26). If the clearance is larger, the component m : 310 N·m (31.0 kgf·m, 230 lbf·ft)
parts may not be installed correctly; such as the groove
of valve plate (15) may not be inserted into spring pin 18. Install O-ring (20) to plug (19). Install plug (19) to
(42). casing (26).
13. Install O-ring (23) to gear pump assembly (24). l : 10 mm
Install gear pump assembly (24) to casing (26) with
socket bolts (25) (4 used). m : 110 N·m (11.0 kgf·m, 81 lbf·ft)

l : 6 mm

m : 17 N·m (1.7 kgf·m, 12.5 lbf·ft)

W3-5-3-8
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

Disassembly of Main Pumps 1, 2

15 15 9

14 13

10

58 16

33
32
72
31
12 17
11 21
20
19
18

7
6 25
5
73
3 24
2
1 70
69
23
59
60

22
61
62
63
64
65
66
67
68

WDEB-03-05-001

W3-5-4-1
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

41
40
39
38
37
36 46
42
43
44
45
34 50
35

52
72
71
27 48
28
29
30
29 51
28
27

53
50
54

56

57

26
55

WDEA-03-08-005

W3-5-4-2
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

1- Plug 20- Backup Ring 38- O-Ring 58- O-Ring (3 Used)

2- O-Ring 21- Stopper 39- Cover 59- Retaining Ring
3- Pf Piston Case 22- Casing 40- Lock Nut 60- Spacer
5- Pf Piston 23- Swash Plate 41- Lock Nut 61- Shaft
6- Piston Case 24- Piston (10 Used) 42- O-Ring 62- Bearing
7- Compensating Piston 25- Retainer 43- Adjusting Screw 63- Spacer
8- Socket Bolt (8 Used) 26- Gasket 44- Outer Spring 64- Retaining Ring
9- Cover 27- Check Valve (2 Used) 45- Inner Spring 65- Oil Seal
10- Gasket 28- O-Ring (2 Used) 46- Socket Bolt (2 Used) 66- O-Ring
11- Plug 29- Backup Ring (2 Used) 48- Reducing Valve 67- Cover
12- O-Ring 30- Seal Pipe 50- Socket Bolt (3 Used) 68- Socket Bolt (4 Used)
13- Pin 31- Sleeve 51- Spring Pin 69- Plug
14- O-Ring (2 Used) 32- Spool 52- O-Ring 70- O-Ring
15- O-Ring (5 Used) 33- Spring Seat 53- Needle Bearing 71- Spacer
16- Feedback Lever 34- Eyebolt (2 Used) 54- Valve Plate 72- O-Ring (2 Used)
17- Tilt Pin 35- Valve Block 55- Cylinder Block 73- O-Ring
18- Servo Piston 36- Adjusting Screw 56- Spring (10 Used)
19- O-Ring 37- O-Ring 57- Spherical Bushing

a- View X

W3-5-4-3
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

Disassembly of Main Pumps 1, 2

1. Remove plug (11) and O-ring (12) from casing (22). 6. Remove plug (1), O-ring (2), Pf piston case (3), O-ring
Drain off oil. (73), Pf piston (5), piston case (6), and compensating
piston (7) from casing (22).
l : 10 mm
l : 10 mm
IMPORTANT: Do not remove pin (13). Replace it and
cover (9) together as an assembly. IMPORTANT: Do not disassemble reducing valve
2. Remove socket bolts (8) (8 used). Remove cover (9), (48).
gasket (10), O-rings (14) (2 used), and O-rings (15) (5 7. Remove reducing valve (48) from valve block (35).
used) from casing (22).
j : 19 mm
l : 6 mm
IMPORTANT: Do not drop and damage valve plate
3. Remove feedback lever (16) from casing (22). (54) while removing valve block (35).
IMPORTANT: As the setting changes, do not 8. Loosen socket bolts (50) (3 used). Record the
disassemble lock nuts (40, 41) and adjusting clearance between casing (22) and valve block (35).
screws (36, 43). Remove socket bolts (50) (3 used). Remove valve
block (35), gasket (26), O-rings (58) (3 used), and
IMPORTANT: When replacing component parts (36
O-ring (72) from casing (22).
to 43) of the cover (39) assembly, replace them as
an assembly. l : 10 mm
IMPORTANT: Slowly remove socket bolts (46) (2
used) alternately as the spring force is applied to fNOTE: When loosening socket bolts (50) (3 used), valve
the cover (39) assembly. block (35) will be pushed out due to the force of spring
(56).
4. Remove socket bolts (46) (2 used). Remove the
cover (39) assembly, outer spring (44), inner spring
(45), and spring seat (33) from valve block (35).

l : 5 mm
IMPORTANT: Replace sleeve (31) and spool (32) as an
assembly.
5. Remove the sleeve (31) assembly from casing (22).

W3-5-4-4
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

9. Remove spacer (71) from casing (22). 15. Remove socket bolts (68) (4 used). Install bolts (M6)
(2 used) to thread parts (b) (2 places) of cover (67).
10. Remove O-rings (52, 72) and the seal pipe (30)
Tighten the bolts evenly. Remove the cover (67)
assembly from valve block (35). Remove O-rings (28)
assembly from casing (22).
(2 used) and backup rings (29) (2 used) from seal
pipe (30). l : 5 mm
IMPORTANT: Do not damage the sliding surface and
the mounting surface of valve plate (54).
IMPORTANT: When replacing valve plate (54),
replace it with cylinder block (55) together as an b
assembly.
11. Remove valve plate (54) from valve block (35).
IMPORTANT: Do not remove needle bearing (53)
unless necessary.
12. Remove needle bearing (53) from valve block (35). 67
IMPORTANT: Do not damage the sliding surfaces of
cylinder block (55), piston (24), spherical bushing W1P1-02-04-056
(57), and swash plate (23).
13. Remove the cylinder block (55) assembly from shaft 16. Remove oil seal (65) and O-ring (66) from cover (67).
(61).
17. Tap the rear end of shaft (61) by using a plastic
IMPORTANT: When replacing cylinder block (55), hammer. Remove the shaft (61) assembly from
replace it with valve plate (54) together as an casing (22).
assembly.
18. Remove retaining ring (64), spacer (63), bearing (62),
14. Remove pistons (24) (10 used), retainer (25),
spacer (60), and retaining ring (59) from shaft (61).
spherical bushing (57), and springs (56) (10 used)
from cylinder block (55).

W3-5-4-5
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

IMPORTANT: Do not damage the sliding surfaces of

tilt pin (17) and swash plate (23).
19. Remove swash plate (23) from tilt pin (17).
20. Install the bolt to the screw hole of stopper (21).
Remove the stopper (21) assembly from casing
(22). Remove backup ring (20) and O-ring (19) from
stopper (21).
IMPORTANT: Do not disassemble servo piston (18)
and tilt pin (17) unless necessary.
21. Warm up tilt pin (17) and servo piston (18) by using
a drier. Remove servo piston (18) from tilt pin (17).
Remove servo piston (18) from casing (22).

l : 12 mm
Special Tool for Tilt Pin (17): Wrench Size 38 mm

fNOTE: THREEBOND #1305N has been applied on servo

piston (18).
22. Remove check valves (27) (2 used) from casing (22).

W3-5-4-6
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

Assembly of Main Pumps 1, 2

5 6 7 31 58 32 33 44 45 38 46 43 37 34 40 42 36
73

3 41

39

1, 2
50

48

WDEB-03-05-002

17 15 10 8 9 16 13 18 21 26 19 20 51 35

69
70
25

57
68
67 Y
Y
62
64 X
X

61
59

65

63

66 60 23 22 24 56 11, 12 55 54 53
WDEA-03-08-007

W3-5-4-7
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

27 30 27 71

28 72

29
WDEA-03-08-008 WDEA-03-08-009
Section X Section Y

1- Plug 20- Backup Ring 38- O-Ring 58- O-Ring (3 Used)

2- O-Ring 21- Stopper 39- Cover 59- Retaining Ring
3- Pf Piston Case 22- Casing 40- Lock Nut 60- Spacer
5- Pf Piston 23- Swash Plate 41- Lock Nut 61- Shaft
6- Piston Case 24- Piston (10 Used) 42- O-Ring 62- Bearing
7- Compensating Piston 25- Retainer 43- Adjusting Screw 63- Spacer
8- Socket Bolt (8 Used) 26- Gasket 44- Outer Spring 64- Retaining Ring
9- Cover 27- Check Valve (2 Used) 45- Inner Spring 65- Oil Seal
10- Gasket 28- O-Ring (2 Used) 46- Socket Bolt (2 Used) 66- O-Ring
11- Plug 29- Backup Ring (2 Used) 48- Reducing Valve 67- Cover
12- O-Ring 30- Seal Pipe 50- Socket Bolt (3 Used) 68- Socket Bolt (4 Used)
13- Pin 31- Sleeve 51- Spring Pin 69- Plug
14- *O-Ring (2 Used) 32- Spool 52- *O-Ring 70- O-Ring
15- O-Ring (5 Used) 33- Spring Seat 53- Needle Bearing 71- Spacer
16- Feedback Lever 34- Eyebolt (2 Used) 54- Valve Plate 72- O-Ring (2 Used)
17- Tilt Pin 35- Valve Block 55- Cylinder Block 73- O-Ring
18- Servo Piston 36- Adjusting Screw 56- Spring (10 Used)
19- O-Ring 37- O-Ring 57- Spherical Bushing

fNOTE: As for the item with mark *, refer to W3-8-4-1.

W3-5-4-8
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

Assembly of Main Pumps 1, 2

1. Install check valves (27) (2 used) to casing (22). 6. Install the shaft (61) assembly to casing (22).
IMPORTANT: After installing tilt pin (17) and servo 7. Install O-ring (66) and oil seal (65) to cover (67).
piston (18), check if servo piston (18) moves
IMPORTANT: When installing the cover (67) assembly
smoothly.
to casing (22), do not damage oil seal (65).
2. Install tilt pin (17) to casing (22). Apply THREEBOND
8. Install the cover (67) assembly to casing (22) with
#1305N onto the thread part of servo piston (18).
socket bolts (68) (4 used).
Install it to tilt pin (17).
l : 5 mm
l : 12 mm
Special Tool for Tilt Pin (17): Wrench Size 38 mm m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft)
IMPORTANT: When replacing cylinder block (55),
m : 240 N·m (24.5 kgf·m, 175 lbf·ft)
replace it with valve plate (54) together as an
3. Install O-ring (19) and backup ring (20) to stopper assembly.
(21). Install the stopper (21) assembly to casing (22). 9. Install springs (56) (10 used), spherical bushing (57),
4. Apply grease onto the sliding surfaces of casing (22) retainer (25), and pistons (24) (10 used) to cylinder
and swash plate (23). Install swash plate (23) to tilt block (55).
pin (17). 10. Install the cylinder block (55) assembly to shaft (61).
5. Install retaining ring (59), spacer (60), bearing (62), 11. Install needle bearing (53) to valve block (35).
spacer (63), and retaining ring (64) to shaft (61).

W3-5-4-9
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

IMPORTANT: Install valve plate (54) as illustrated 14. Install spacer (71) and O-rings (52, 72) to valve block
below. (35).
IMPORTANT: When replacing valve plate (54), 15. Install O-rings (58) (3 used), gasket (26), and valve
replace it with cylinder block (55) together as an block (35) to casing (22) with socket bolts (50) (3
assembly. used).
12. Apply grease onto the valve block (35) mounting
surface of valve plate (54). Fit groove (c) of valve l : 10 mm
plate (54) to spring pin (51) of valve block (35) and
m : 98 N·m (10 kgf·m, 72 lbf·ft)
install valve plate (54).

51
fNOTE: Check the clearance between valve block (35)
and casing (22). If the clearance is larger, the component
parts may not be installed correctly; such as the groove
of valve plate (54) may not be inserted into spring pin
(51).
16. Install reducing valve (48) to valve block (35).

c j : 19 mm

m : 38 N·m (3.9 kgf·m, 28.0 lbf·ft)

17. Install compensating piston (7), piston case (6), Pf
piston (5), Pf piston case (3), O-ring (73), O-ring (2),
and plug (1) to casing (22).
54 35
W1P1-02-04-059 l : 10 mm

m : 110 N·m (11 kgf·m, 81 lbf·ft)

13. Install backup rings (29) (2 used) and O-rings (28)
(2 used) to seal pipe (30). Install the seal pipe (30)
assembly to valve block (35).

W3-5-4-10
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

IMPORTANT: Replace sleeve (31) and spool (32) as an IMPORTANT: Pin (e) in feedback lever (16) should be
assembly. inserted into hole (f) of the sleeve (31) assembly
18. Install the sleeve (31) assembly to casing (22) with and pin (g) in tilt pin (17) should be inserted into
hole (d) up. groove (h) of feedback lever (16) when installing.
20. Install feedback lever (16) to casing (22).
d

31 e
22
16

f 31

22
17

g
W1P1-02-04-060

IMPORTANT: When replacing component parts (36 W1P1-02-04-061

to 43) of the cover (39) assembly, replace them as
an assembly.
19. Install spring seat (33), inner spring (45), outer 21. Install O-rings (15) (5 used), O-rings (14) (2 used),
spring (44), and the cover (39) assembly to valve gasket (10), and cover (9) to casing (22) with socket
block (35) with socket bolts (46) (2 used). bolts (8) (8 used).

l : 5 mm l : 6 mm

m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft) m : 29 N·m (3 kgf·m, 21.5 lbf·ft)

22. Install O-ring (12) to plug (11). Install plug (11) to
casing (22).

l : 10 mm

m : 110 N·m (11 kgf·m, 81 lbf·ft)

W3-5-4-11
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

(Blank)

W3-5-4-12
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

Structure of Gear Pump Assembly

9
8

7 10
6
5
4
3
2

6
12
11

W1P1-02-04-062

No. Part Name Q’ty Wrench Size Tightening Torque Remark

(mm) N·m (kgf·m) (lbf·ft)
1 Flange 1
2 Drive gear 1
3 Driven gear 1
4 Seal 1
5 Knock pin 2
6 Plug 2 j : 19 16 (1.6) (12.0)
7 O-Ring 1 Apply grease when
assembling.
8 Gear case 1
9 Socket bolt 2 l:6 17 (1.7) (12.5)
10 Socket bolt 2 l:6 17 (1.7) (12.5)
11 Plug 1 j : 36 74 (7.4) (55)
12 O-Ring 1 Apply grease when
assembling.

W3-5-5-1
 SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device

(Blank)

W3-5-5-2
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

Removal and Installation of Control Valve

MDEC-07-007

WDEB-03-05-005

IMPORTANT: The hose and pipe contain hydraulic 3. Remove bolts, washers (1) (8 used). Remove cover
oil. When removing the hose and pipe, receive oils (2).
with a container in order to avoid spilling oils.
j : 17 mm
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W4-4-1.)
2. Open cover (3).

W3-6-1-1
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

1 2

View A

WDEE-03-06-008 4 WDEB-03-06-007

4. Remove bolts, washers (2) (2 used). Remove mirror 5. Disconnect connectors (4) (2 used) and connector
(1). (3).

j : 13 mm

W3-6-1-2
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

1
View A

4 3

A 2

WDEE-03-06-009 WDEB-03-06-007
2

6. Remove bolts, washers (3), bolts, washers (1) (2

used) and bolts, washers (2) (2 used). Remove cover
(4).

j : 17 mm

W3-6-1-3
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

6 7
1 2

WDEE-04-03-001 7 WDEE-03-06-010
4 3

7. Remove bolts, washers (2) (2 used) and bolts,

washers (3) (2 used). Remove cover (1).

j : 17 mm
8. Remove bolts, washers (4) (2 used). Remove cover
(5).

j : 17 mm
9. Remove bolts, washers (7) (3 used). Remove cover
(6).

j : 17 mm

W3-6-1-4
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

1
10

8 9 11

2
13
12

3
14
15

4 WDEB-03-06-009 WDEB-03-06-010

10. Remove bolts, washers (1) (2 used). Remove the oil 12. Remove coupling (11).
filter (2) assembly. Place it horizontally.
j : 13 mm
j : 17 mm
13. Remove socket bolts (12) (2 used). Disconnect pipe
11. Remove bolt, washer (4). Remove support (3). (10). Remove O-ring (8) and valve (9).

j : 17 mm l : 8 mm
14. Remove socket bolts (14) (4 used). Disconnect pipe
(15). Remove O-ring (13).

l : 8 mm

W3-6-1-5
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

1 2

5
6

9
2 5
6

WDEB-03-06-011 7
3
8
7
8

WDEB-03-06-012

15. Disconnect connectors (3) (2 used).

16. Disconnect all hoses (2) and pipe (1).
dCAUTION: The control valve (4) assembly weight:
90 kg (200 lb)
j : 17 mm, 19 mm , 27 mm, 36 mm 17. Attach nylon slings onto control valve (4). Hoist and
hold control valve (4).
18. Remove bolts (8) (4 used) and washers (7) (4 used).
Remove the control valve (4) assembly.

j : 22 mm

dCAUTION: Control valve (4) weight: 76 kg (170 lb)

19. Hoist and hold control valve (4).
20. Remove bolts (6) (3 used) and washers (5) (3 used).
Remove control valve (4) from bracket (9).

j : 22 mm
21. Remove the adapters with control valve (4) attached
if necessary.

W3-6-1-6
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

1 2

5
6

9
5
6
2

7
8
WDEB-03-06-011
7 3
8

WDEB-03-06-012

Installation

dCAUTION: Control valve (4) weight: 76 kg (170 lb) 4. Connect all hoses (2) and pipes (1).
1. Install all removed adapters to control valve (4). j : 17 mm
2. Install control valve (4) to bracket (9) with washers
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
(5) (3 used) and bolts (6) (3 used).
j : 19 mm
j : 22 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
m : 180 N·m (18 kgf·m, 133 lbf·ft)
j : 27 mm
dCAUTION: The control valve (4) assembly weight:
90 kg (200 lb) m : 95 N·m (9.5 kgf·m, 70 lbf·ft)
3. Install the control valve (4) assembly with washers
(7) (4 used) and bolts (8) (4 used). j : 36 mm

j : 22 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)

5. Connect connectors (3) (2 used).
m : 140 N·m (14 kgf·m, 103 lbf·ft)

W3-6-1-7
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

1
10

8 9 11

2
13
12

3
14
15

WDEB-03-06-010 4 WDEB-03-06-009

6. Install O-ring (13). Install pipe (15) with socket bolts 10. Install support (3) with bolt, washer (4).
(14) (4 used).
j : 17 mm
l : 8 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
11. Install oil filter (2) with bolts, washers (1) (2 used).
7. Install valve (9) and O-ring (8). Temporarily install
pipe (10), coupling (11), and socket bolts (12) (2 j : 17 mm
used).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 13 mm

l : 8 mm
8. Tighten socket bolts (12) (2 used).

l : 8 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

9. Tighten coupling (11).

j : 13 mm

m : 10 to 13 N·m (1.0 to 1.3 kgf·m, 7.4 to 9.6

lbf·ft)

W3-6-1-8
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

6 7
1 2

7 WDEE-03-06-010 WDEE-04-03-001
4 3

12. Install cover (6) with bolts, washers (7) (3 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

13. Install cover (5) with bolts, washers (4) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

14. Install cover (1) with bolts, washers (3) (2 used) and
bolts, washers (2) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-6-1-9
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

1
View A

4 3

A 2

WDEE-03-06-009 WDEB-03-06-007
2

15. Install cover (4) with bolts, washers (3), bolts,

washers (2) (2 used) and bolts, washers (1) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-6-1-10
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

1 2

View A

WDEE-03-06-008 4 WDEB-03-06-007

16. Install mirror (1) with bolts, washers (2) (2 used). 17. Connect connector (3) and connectors (4) (2 used).

j : 13 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-6-1-11
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

MDEC-07-007

WDEB-03-05-005

18. Install cover (2) with bolts, washers (1) (8 used). 20. Close cover (3).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

19. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.

W3-6-1-12
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

Disassembly of Control Valve

3
4
c
5 a
6
3
d 4 7
8
5 7
6
3 7 10
e 4
8
5 7
1 6
2 7 11
f 3 8
4 3
7 4
k b
5
24 6 12 5
g 25 6
7
26 7
8
5 7 8
7
6
7 13 18
8
3 7
5 14

3
26 1
h 2
5 l 3
6 4
1 7 5
2
8 6
3 7 7
i 4 5 15 8
7
5
6 6 19
3 7 m 7
j 8 8
4 7 7
5
6 16 20
7 6
8 7
7 n
3 8
17 7
o 4
5 21
6
7
8
7
3 22
p 4
5
6
7
9
7
23

WDEE-03-06-004

W3-6-2-1
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

27

5
28

3
5
5 5
28 28
5
28
3 3
28 2 1 3 5
5
3 28
2 5 3
5 1
5 5
3
28
3
29
5 5
3 25
28 28 24
29
3 3 WDEE-03-06-005

W3-6-2-2
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

31

ab 32

52
aa
53

33
50
31 51 ac
34
z 32
31 35
39, 90, 91, 92, 93 ad
32 36
31 y 40
x 32
48
49

46
an
47
27

45
94
34
43
33
w
44
q
38
37

32
31
32
r
31 s
32

31 t
40
u
32 39, 90, 91, 92, 93
42
41 v
31 WDEE-03-06-001

W3-6-2-3
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

am
60

al 61
55 65
62
54 63 66
67
64 68

56
57
ak 58
59

65
66
67
68
27
ao

af
ae

ap
aq

ar

89
87 88
86

as
68
aj au 67
av 66
at
65
aw

73
80 72
79 71 ag
85 ah
78
84 70 69
77
83 ax 76
82
ai 75
81
74
WDEE-03-06-002

W3-6-2-4
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

1- Plug (5 Used) 25- O-Ring (2 Used) 50- Plug 74- Plug

2- O-Ring (5 Used) 26- Cover (2 Used) 51- O-Ring 75- O-Ring
3- Socket Bolt (54 Used) 27- Housing 52- Main Relief Valve 76- Spring
4- Cover (10 Used) 28- Cover (9 Used) 53- O-Ring 77- Poppet
5- O-Ring (27 Used) 29- Cover (2 Used) 54- Anti-Drift Valve 78- Sleeve
6- Spool End (14 Used) 31- Overload Relief Valve (8 Used) 55- Socket Bolt (4 Used) 79- Spring
7- Spring Seat (28 Used) 32- O-Ring (8 Used) 56- O-Ring 80- Poppet
8- Spring (13 Used) 33- Overload Relief Valve (2 Used) 57- O-Ring 81- Socket Bolt (2 Used)
9- Spring 34- O-Ring (2 Used) 58- Spring 82- Cover
10- Spool 35- Plug 59- Poppet 83- O-Ring
11- Spool 36- O-Ring 60- Plug 84- Spring
12- Spool 37- Plug 61- O-Ring 85- Spool
13- Spool 38- O-Ring 62- Spring 86- Plug
14- Spool 39- Screw (2 Used) 63- Poppet 87- O-Ring
15- Spool 40- O-Ring (2 Used) 64- Sleeve 88- Spring
16- Spool 41- Plug 65- Plug (13 Used) 89- Poppet
17- Spool 42- O-Ring 66- O-Ring (13 Used) 90- Lock Nut (2 Used)
18- Spool 43- Main Relief Valve 67- Spring (13 Used) 91- Plug (2 Used)
19- Spool 44- O-Ring 68- Poppet (13 Used) 92- Poppet (2 Used)
20- Spool 45- Plug 69- Socket Bolt 93- O-Ring (2 Used)
21- Spool 46- Signal Plug 70- Cover 94- O-Ring
22- Spool 47- O-Ring 71- O-Ring
23- Spool 48- Plug 72- Spring
24- Plug (2 Used) 49- O-Ring 73- Poppet

a- Upper Section s- Overload Relief Valve (Boom: ae- Load Check Valve (Blade) ar- Check Valve (Arm Roll-In Flow
b- Lower Section Rod Side) af- Load Check Valve (Swing) Combiner Circuit)
c- Blade t- Overload Relief Valve (Bucket: ag- Flow Combiner Check Valve as- Load Check Valve (Boom
d- Swing Rod Side) (Boom: Raise) Swing)
e- Arm 3 u- Shut-Off Valve (Port A5) ah- Flow Combiner Check Valve at- Load Check Valve (Auxiliary)
f- Auxiliary Flow Combiner v- Overload Relief Valve (Arm: (Travel) au- Load Check Valve (Arm 1)
g- Arm 2 Bottom Side) ai- Swing Parking Brake Selection av- Load Check Valve (Boom 2)
h- Boom 1 w- Main Relief Valves (P1, P2) Valve aw- Check Valve (Main Relief
i- Bucket x- Overload Relief Valve (Arm: aj- Flow Combiner Check Valve Circuit)
j- Travel (Left) Rod Side) (Bucket) ax- Load Check Valve (Travel:
k- Boom Swing y- Shut-Off Valve (Port B5) ak- Check Valve (Flow Combiner Right)
l- Auxiliary z- Overload Relief Valve (Bucket: Valve Circuit)
m- Arm 1 Bottom Side) al- Anti-Drift Valve (Boom)
n- Boom 2 aa- Main Relief Valve (P3) am- Load Check Valve (Arm 2)
o- Travel (Right) ab- Overload Relief Valve (Boom: an- Signal Plug
p- Flow Combiner Valve Bottom Side) ao- Check Valve (Auxiliary Flow
q- Overload Relief Valve (Blade: ac- Overload Relief Valve (Blade: Combiner Circuit)
Raise) Lower) ap- Load Check Valve (Boom 1)
r- Overload Relief Valve (Boom ad- Overload Relief Valve (Boom aq- Load Check Valve (Bucket)
Swing) Swing)

W3-6-2-5
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

Disassembly of Control Valve

IMPORTANT: Do not remove plugs (1, 24) at the IMPORTANT: LOCTITE has been applied onto the
top of covers (4, 26, 28, 29). The cover is made of thread part of spool end (6). Warm the thread part
aluminum. Do not damage the thread part when to 200 to 250 °C (392 to 482 °F) (for one to five
installing the cover. minutes by using a drier (capacity: 1 kW)) before
removing.
Disassembly of Spool: 4. Secure spools (10 to 23) by using wooden pieces in
1. Remove socket bolts (3) (28 used) from covers (4) a vise. Remove spool ends (6) (14 used) from each
(10 used) and covers (26) (2 used). Remove covers spool. Remove spring seats (7) (28 used), springs (8)
(4) (10 used) and covers (26) (2 used) from housing (13 used), and spring (9) from spools (10 to 23).
(27). Remove O-rings (5) (14 used) from housing
(27). l : 5 mm

l : 5 mm fNOTE: As springs (8) (13 used) and spring (9) are in their
free length, there is no danger that they fly out.
2. Remove the spool (10 to 23) assemblies (14 used)
from housing (27).

fNOTE: Attach an identification tag onto the spools for

assembling.
3. Remove socket bolts (3) (26 used) from covers (28)
(9 used) and covers (29) (2 used). Remove covers
(28) (9 used), covers (29) (2 used), and O-rings (5) (13
used) from housing (27).

l : 5 mm

W3-6-2-6
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

Disassembly of Main Relief Valves (w, z): Disassembly of Overload Relief Valves (q, r, s, t, v, x, z, ab,
IMPORTANT: Do not disassemble the main relief ac, ad):
valve. If it has been disassembled, pressure IMPORTANT: Do not disassemble the overload
should be adjusted. (Refer to T4-5 in the separated relief valve. If it has been disassembled, pressure
volume, T/M.) should be adjusted. (Refer to T4-5 in the separated
5. Remove main relief valve (43) from housing (27). volume, T/M.)
9. Remove overload relief valves (31) (8 used) and
j : 32 mm overload relief valves (33) (2 used) from housing
6. Remove O-ring (44) from main relief valve (43). (27).
7. Remove main relief valve (52) from housing (27). j : 24 mm
j : 24 mm 10. Remove O-rings (32) (8 used) and O-rings (34) (2
used) from overload relief valves (31) (8 used) and
8. Remove O-ring (53) from main relief valve (52). overload relief valves (33) (2 used).

W3-6-2-7
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

Disassembly of Signal Plug (an):

11. Remove signal plug (46) and O-ring (47) from
housing (27).

j : 22 mm

Disassembly of Anti-Drift Valve (al):

12. Remove socket bolts (55) (4 used) from anti-drift
valve (54). Remove anti-drift valve (54), O-rings (56,
57), spring (58), and poppet (59) from housing (27).

l : 5 mm

Disassembly of Load Check Valve (am):

13. Remove plug (60), O-ring (61), spring (62), poppet
(63), and sleeve (64) from housing (27).

j : 27 mm

Disassembly of Load Check Valves (ae, af, ap, aq, as, at, au,
av) and Check Valves (ak, ar, aw, ao):
14. Remove plugs (65) (13 used), O-rings (66) (13 used),
springs (67) (13 used), and poppets (68) (13 used)
from housing (27).

j : 24 mm

W3-6-2-8
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

Disassembly of Flow Combiner Check Valve (ag): Disassembly of Shut-Off Valve (u, y):
15. Remove socket bolts (69) (4 used) from cover (70). 19. Remove the plug (91) assemblies (4 used) from
Remove cover (70), O-ring (71), spring (72), and housing (27). Secure the plug (91) assemblies (4
poppet (73) (with an identification groove) from used) in a vise. Remove lock nuts (90) (4 used),
housing (27). screws (39) (4 used), and poppets (92) (4 used) from
the plug (91) assemblies (4 used).
l : 5 mm
(Screw (39))
Disassembly of Swing Parking Brake Selection Valve (ai): l : 5 mm
16. Remove socket bolts (81) (2 used) from cover (82).
Remove cover (82), O-ring (83), spring (84), and (Lock Nut (90))
spool (85) from housing (27).
j : 14 mm
l : 5 mm
(Plug (91))
Disassembly of Flow Combiner Check Valve (ah) and Load j : 17 mm
Check Valve (ax): 93
17. Remove plug (74), O-ring (75), spring (76), poppet
(77), sleeve (78), spring (79), and poppet (80) from
39
housing (27).

j : 27 mm 90

Disassembly of Flow Combiner Check Valve (aj): 91

18. Remove plug (86), O-ring (87), spring (88), and 27
poppet (89) (without an identification groove) from 92 40 W1CD-02-05-001
housing (27).

l : 8 mm 20. Remove O-rings (93) (4 used) from poppets (92) (4

used).

W3-6-2-9
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

Assembly of Control Valve

A B
3

W1CD-02-05-005
A B

Rear View

7 4 6 8 7 5 27 5 28 5 5 7 8 6 4 7
18
10

c 11 k

d 12
1, 2 13 19
e 1, 2
1, 2 1, 2
f 14 l
26 20
29 21
g m
26 15 24, 25
h n
29 22
i o
16
j p

17 9

23
Section A-A Section B-B
WDEE-03-06-006 WDEE-03-06-007

W3-6-2-10
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

27
33 34 66 65 67 68 27 34 33

ae
Section D
ac q
Section E 92, 93

Section F

Section G

Section H
ad r
Section I

Section J 31 32 as
66 65 67 68 32 31
Section K

68
Section L
WDEE-03-06-003

WDEA-03-09-012
Right-Side View Section D

66 65 67 68 27 27 66 65 67 68
af ar

aa

52 53 WDEA-03-09-004 WDEA-03-09-005
Section E Section F

W3-6-2-11
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

66 65 67 68 27 31 32 61 60 62 63 64 27
ao am

ab
92, 93

92, 93

90
y u x v

39 39
as at
90 91 40 66 65 67 68 40 91 31 32 66 65 67 68 32 31

WDEA-03-09-006 WDEA-03-09-007
Section G Section H

54 57 66 65 67 68 27 32 31 31 32 66 65 67 68 27 32 31

al aq

ap
z s
56
t
58

59
73
72 78
70
80

av 79
71
ag 75 74 76 77
au
66 65 67 68
WDEB-03-06-003 WDEA-03-09-009
Section I Section J

W3-6-2-12
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

46 47 27
45 94 27 85 83 82 84

an
ai
65

ak
68
66
68
W
67
67
av
aw
43 44
66 65 66 65 WDEB-03-06-004
WDEA-03-09-010
Section K Section L

3 27 3 27

C C

Bottom View
86
aj
87
88
89
WDEA-03-09-013
Section C-C

W1CD-02-05-004
Front View

W3-6-2-13
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

1- Plug (5 Used) 25- O-Ring (2 Used) 50- Plug 74- Plug

2- O-Ring (5 Used) 26- Cover (2 Used) 51- O-Ring 75- O-Ring
3- Socket Bolt (54 Used) 27- Housing 52- Main Relief Valve 76- Spring
4- Cover (10 Used) 28- Cover (9 Used) 53- O-Ring 77- Poppet
5- O-Ring (27 Used) 29- Cover (2 Used) 54- Anti-Drift Valve 78- Sleeve
6- Spool End (14 Used) 31- Overload Relief Valve (8 Used) 55- Socket Bolt (4 Used) 79- Spring
7- Spring Seat (28 Used) 32- O-Ring (8 Used) 56- O-Ring 80- Poppet
8- Spring (13 Used) 33- Overload Relief Valve (2 Used) 57- O-Ring 81- Socket Bolt (2 Used)
9- Spring 34- O-Ring (2 Used) 58- Spring 82- Cover
10- Spool 35- Plug 59- Poppet 83- O-Ring
11- Spool 36- O-Ring 60- Plug 84- Spring
12- Spool 37- Plug 61- O-Ring 85- Spool
13- Spool 38- O-Ring 62- Spring 86- Plug
14- Spool 39- Screw (2 Used) 63- Poppet 87- O-Ring
15- Spool 40- O-Ring (2 Used) 64- Sleeve 88- Spring
16- Spool 41- Plug 65- Plug (13 Used) 89- Poppet
17- Spool 42- O-Ring 66- O-Ring (13 Used) 90- Lock Nut (2 Used)
18- Spool 43- Main Relief Valve 67- Spring (13 Used) 91- Plug (2 Used)
19- Spool 44- O-Ring 68- Poppet (13 Used) 92- Poppet (2 Used)
20- Spool 45- Plug 69- Socket Bolt 93- O-Ring (2 Used)
21- Spool 46- Signal Plug 70- Cover 94- O-Ring
22- Spool 47- O-Ring 71- O-Ring
23- Spool 48- Plug 72- Spring
24- Plug (2 Used) 49- O-Ring 73- Poppet

a- Upper Section s- Overload Relief Valve (Boom: ae- Load Check Valve (Blade) ar- Check Valve (Arm Roll-In Flow
b- Lower Section Rod Side) af- Load Check Valve (Swing) Combiner Circuit)
c- Blade t- Overload Relief Valve (Bucket: ag- Flow Combiner Check Valve as- Load Check Valve (Boom
d- Swing Rod Side) (Boom: Raise) Swing)
e- Arm 3 u- Shut-Off Valve (Port A5) ah- Flow Combiner Check Valve at- Load Check Valve (Auxiliary)
f- Auxiliary Flow Combiner v- Overload Relief Valve (Arm: (Travel) au- Load Check Valve (Arm 1)
g- Arm 2 Bottom Side) ai- Swing Parking Brake Selection av- Load Check Valve (Boom 2)
h- Boom 1 w- Main Relief Valves (P1, P2) Valve aw- Check Valve (Main Relief
i- Bucket x- Overload Relief Valve (Arm: aj- Flow Combiner Check Valve Circuit)
j- Travel (Left) Rod Side) (Bucket) ax- Load Check Valve (Travel:
k- Boom Swing y- Shut-Off Valve (Port B5) ak- Check Valve (Flow Combiner Right)
l- Auxiliary z- Overload Relief Valve (Bucket: Valve Circuit)
m- Arm 1 Bottom Side) al- Anti-Drift Valve (Boom)
n- Boom 2 aa- Main Relief Valve (P3) am- Load Check Valve (Arm 2)
o- Travel (Right) ab- Overload Relief Valve (Boom: an- Signal Plug
p- Flow Combiner Valve Bottom Side) ao- Check Valve (Auxiliary Flow
q- Overload Relief Valve (Blade: ac- Overload Relief Valve (Blade: Combiner Circuit)
Raise) Lower) ap- Load Check Valve (Boom 1)
r- Overload Relief Valve (Boom ad- Overload Relief Valve (Boom aq- Load Check Valve (Bucket)
Swing) Swing)

W3-6-2-14
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

Assembly of Control Valve

IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.

Assembly of Overload Relief Valves (q, ac):

1. Apply grease onto O-rings (34) (2 used). Install
O-rings (34) (2 used) to overload relief valves (33) (2
used). Install overload relief valves (33) (2 used) to
housing (27).

j : 24 mm

m : 59 to 69 N·m (5.9 to 6.9 kgf·m, 44 to 51

lbf·ft)

W3-6-2-15
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

Assembly of Load Check Valves (ae, af, ap, aq) and Check
Valves (ak, ao, ar):
IMPORTANT: As for the spring (67) diameter, one is
smaller and the other is bigger. Install spring (67)
with its bigger side facing to the poppet (68) side.
2. Apply grease onto O-rings (66) (7 used). Install
O-rings (66) (7 used) to plugs (65) (7 used). Install
poppets (68) (7 used), springs (67) (7 used), and
plugs (65) (7 used) to housing (27).

j : 24 mm

m : 88 to 98 N·m (8.8 to 9.8 kgf·m, 65 to 72

lbf·ft)

Assembly of Main Relief Valve (P3) (aa):

3. Apply grease onto O-ring (53). Install O-ring (53) to
main relief valve (52). Install main relief valve (52) to
housing (27).

j : 24 mm

m : 49 to 54 N·m (4.9 to 5.4 kgf·m, 36 to 40

lbf·ft)

Assembly of Overload Relief Valves (r, ad, v, x, ab):

4. Apply grease onto O-rings (32) (5 used). Install
O-rings (32) (5 used) to overload relief valves (31) (3
used). Install overload relief valves (31) (5 used) to
housing (27).

j : 24 mm

m : 59 to 69 N·m (5.9 to 6.9 kgf·m, 44 to 51

lbf·ft)

Assembly of Load Check Valve (Arm 2) (am):

5. Apply grease onto O-ring (61). Install O-ring (61) to
plug (60). Install sleeve (64), poppet (63), spring (62),
and plug (60) to housing (27).

j : 27 mm

m : 165 to 195 N·m (16.5 to 19.5 kgf·m, 122 to

144 lbf·ft)

W3-6-2-16
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

Assembly of Anti-Drift Valve (Boom) (al): Assembly of Overload Relief Valves (t, z, s):
6. Install poppet (59), spring (58), O-rings (56, 57), and 8. Apply grease onto O-rings (32) (3 used). Install
anti-drift valve (54) to housing (27) with socket bolts O-rings (32) (3 used) to overload relief valves (31) (3
(55) (4 used). used). Install overload relief valves (31) (3 used) to
housing (27).
l : 5 mm
j : 24 mm
m : 9 to 11 N·m (0.9 to 1.1 kgf·m, 6.6 to 8.1 lbf·ft)
m : 59 to 69 N·m (5.9 to 6.9 kgf·m, 44 to 51
lbf·ft)
Assembly of Load Check Valves (as, at, au, av) and Check
Valve (aw):
IMPORTANT: As for the spring (67) diameter, one is Assembly of Flow Combiner Check Valve (Travel) (ah) and
smaller and the other is bigger. Install spring (67) Load Check Valve (ax):
with its bigger side facing to the poppet (68) side. 9. Apply grease onto O-ring (75). Install O-ring (75) to
7. Apply grease onto O-rings (66) (6 used). Install plug (74). Install poppet (80), spring (79), sleeve (78),
O-rings (66) (6 used) to plugs (65) (6 used). Install poppet (77), spring (76), and plug (74) to housing
poppets (68) (6 used), springs (67) (6 used), and (27).
plugs (65) (6 used) to housing (27).
j : 27 mm
j : 24 mm
m : 165 to 195 N·m (16.5 to 19.5 kgf·m, 122 to
m : 88 to 98 N·m (8.8 to 9.8 kgf·m, 65 to 72 144 lbf·ft)
lbf·ft)

W3-6-2-17
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

Assembly of Signal Plug (an):

IMPORTANT: As the filter has been crimped in signal
plug (46), it cannot be disassembled. In case the
filter is clogged, or the foreign matter cannot be
removed even by washing and cleaning as well
as being damaged, signal plug (46) should be
replaced as an assembly.
10. Apply grease onto O-ring (47). Install O-ring (47) to
signal plug (46). Install signal plug (46) to housing
(27).

j : 22 mm

m : 59 to 69 N·m (5.9 to 6.9 kgf·m, 44 to 51

lbf·ft)

Assembly of Main Relief Valve (P1, P2) (w):

11. Apply grease onto O-ring (44). Install O-ring (44) to
main relief valve (43). Install main relief valve (43) to
housing (27).

j : 32 mm

m : 49 to 59 N·m (4.9 to 5.9 kgf·m, 36 to 44

lbf·ft)

Assembly of Swing Parking Brake Selection Valve (ai):

12. Install spool (85), spring (84), O-ring (83), and cover
(82) to housing (27) with socket bolts (81) (2 used).

l : 4 mm

m : 7 to 10 N·m (0.7 to 1.0 kgf·m, 5.2 to 7.4 lbf·ft)

W3-6-2-18
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

IMPORTANT: The shape of poppet (73) is similar

to that of poppet (89). There is an identification
groove on the end of poppet (73),

Assembly of Flow Combiner Check Valve (Boom: Raise)

(ag):
13. Apply grease onto O-ring (71). Install poppet (73),
spring (72), O-ring (71), and cover (70) to housing
(27) with socket bolts (69) (4 used).

l : 5 mm

m : 9 to 11 N·m (0.9 to 1.1 kgf·m, 6.6 to 8.1 lbf·ft)

Assembly of Flow Combiner Check Valve (Bucket) (aj):

14. Apply grease onto O-ring (87). Install O-ring
(87) to plug (86). Install poppet (89) (without an
identification groove), spring (88), and plug (86) to
housing (27).

l : 8 mm

m : 62 to 82 N·m (6.2 to 8.2 kgf·m, 46 to 60

lbf·ft)

W3-6-2-19
 SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve

Assembly of Spool: Assembly of Shut-Off Valve (u, y):

15. Remove LOCTITE from the thread parts of spools 19. Install O-rings (93) (4 used) to poppets (92) (4 used).
(10 to 23) (14 used) and spool ends (6) (14 used) by
20. Apply grease onto O-rings (40) (4 used). Install
using a dies (8 mm, Pitch 1.25 mm) and a tap (8 mm,
poppets (92) (4 used), screws (39) (4 used), and lock
Pitch 1.25 mm).
nuts (90) (4 used) to plugs (91) (4 used). Install the
16. Secure spools (10 to 23) (14 used) by using wooden plug (91) assemblies (4 used) to housing (27). Install
pieces in a vise. Apply LOCTITE #271 onto one screws (39) (4 used) and lock nuts (90) (4 used).
pitch in the thread hole of spools (10 to 23) (14
used). Install spring seats (7) (14 used), springs (8) (Lock Nut (90))
(13 used), spring (9), spring seats (7) (14 used), and
j : 14 mm
spool ends (6) (14 used) respectively.
m : 19 to 22 N·m (1.9 to 2.2 kgf·m, 14.0 to 16.0
l : 5 mm
lbf·ft)
m : 19 to 22 N·m (1.9 to 2.2 kgf·m, 14.0 to 16.0
(Plug (91))
lbf·ft)
17. Apply grease onto O-rings (5) (13 used). Install j : 17 mm
O-rings (5) (13 used), covers (28) (9 used), and
m : 59 to 69 N·m (5.9 to 6.9 kgf·m, 44 to 51
covers (29) (2 used) to housing (27) with socket
lbf·ft)
bolts (3) (26 used).
(Screw (39))
l : 5 mm
l : 5 mm
m : 9 to 11 N·m (0.9 to 1.1 kgf·m, 6.6 to 8.1 lbf·ft)
18. Insert the spool (10 to 23) assemblies (14 used) into m : 19 to 22 N·m (1.9 to 2.2 kgf·m, 14.0 to 16.0
housing (27). Install O-rings (5) (14 used), covers (4) lbf·ft)
(10 used), and covers (26) (2 used) to housing (27) 93
with socket bolts (3) (28 used).

l : 5 mm
39
m : 9 to 11 N·m (0.9 to 1.1 kgf·m, 14.0 to 16.0
lbf·ft) 90

91
27
92 40 W1CD-02-05-001

W3-6-2-20
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

Removal and Installation of Swing Device

5 1

WDEE-04-03-001 WDEE-03-07-001
4 3

IMPORTANT: The hose and pipe contain hydraulic 5. Disconnect hose (8).
oil. When removing the hose and pipe, receive oils
with a container in order to avoid spilling oils. j : 36 mm
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Remove bolts, washers (1) (2 used).

j : 17 mm
3. Remove bolts, washers (3) (2 used). Remove cover
(2).

j : 17 mm
4. Remove bolts, washers (4) (2 used). Remove cover
(5).

j : 17 mm

W3-7-1-1
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

1 4

5
6

3 WDEB-03-07-007
WDEB-03-07-008

6. Disconnect hoses (1) (2 used). IMPORTANT: Cork (9) cannot be reused.

11. Remove cork (9) from housing (7) by using a
j : 17 mm
screwdriver.
7. Disconnect hose (2).
12. Install the bolts (M16, Pitch 2 mm) to the holes
j : 19 mm where cork (9) has been removed. Turn the bolts
and raise swing device (4) from the main frame.
8. Disconnect hoses (3) (2 used). Hoist and remove swing device (4) from the main
j : 27 mm frame.

dCAUTION: Swing device (4) weight: 71 kg (160 lb) fNOTE: THREEBOND #1102 has been applied on the
main frame mounting surface of swing device (4).
9. Attach the nylon slings onto the body of swing
motor. Hoist and hold swing device (4). 13. Remove knock pin (8).

10. Put the matching marks onto housing (7) of swing 14. Remove the adapters with swing device (4)
device (4) and the main frame. Remove bolts (5) (10 attached if necessary.
used) and washers (6) (10 used).

j : 24 mm

fNOTE: LOCTITE #262 has been applied on bolt (5).

W3-7-1-2
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

4 1

5
6

WDEB-03-07-008 3 WDEB-03-07-007

Installation
1. Install all removed adapters to swing device (4). 7. Connect hoses (3) (2 used).

dCAUTION: Swing device (4) weight: 71 kg (160 lb) j : 27 mm

2. Apply THREEBOND #1102 onto the main frame
m : 95 N·m (9.5 kgf·m, 70 lbf·ft)
mounting surface of swing device (4). Attach the
nylon slings onto the body of swing motor. Hoist 8. Connect hose (2).
swing device (4).
j : 19 mm
3. Fit the matching marks and the position of knock
pin (8). Install swing device (4) to the main frame. m : 30 N·m (3 kgf·m, 22 lbf·ft)
4. Apply THREEBOND #1102 onto knock pin (8). Install 9. Connect hoses (1) (2 used).
knock pin (8) to the main frame.
j : 17 mm
5. Apply LOCTITE #262 onto bolt (5).Install swing
device (4) with washers (6) (10 used) and bolts (5) m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
(10 used).

j : 24 mm

m : 210 N·m (21 kgf·m, 155 lbf·ft)

6. Install cork (9) to the bolt mounting hole.

W3-7-1-3
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

5 1

WDEE-03-07-001 WDEE-04-03-001
4 3

10. Connect hose (8). 11. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
j : 36 mm
IMPORTANT: Check the hydraulic oil level. Start the
m : 180 N·m (18 kgf·m, 133 lbf·ft) engine and check for any oil leaks.
12. Install cover (5) with bolts, washers (4) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

13. Install cover (2) with bolts, washers (1) (2 used) and
bolts, washers (3) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-7-1-4
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

Disassembly of Swing Device

1 3

13
4

28 23

27
6
21
5
29 14
2

26
20

24
7 15

25
19

22 11, 12

8 16
9
10 18
8

17

WDEB-03-07-001

1- Swing Motor 8- Plate (6 Used) 15- Seal 23- Ring Gear

2- First Stage Carrier 9- Needle Bearing (3 Used) 16- Plate 24- Thrust Plate
3- Socket Bolt (8 Used) 10- Second Stage Planetary Gear 17- Shaft 25- Second Stage Carrier
4- Retaining Ring (3 Used) (3 Used) 18- Spacer 26- Second Stage Sun Gear
5- Needle Bearing (3 Used) 11- Spring Pin (3 Used) 19- Roller Bearing 27- First Stage Sun Gear
6- First Stage Planetary Gear (3 12- Spring Pin (3 Used) 20- Housing 28- Plate
Used) 13- Socket Bolt (13 Used) 21- Roller Bearing 29- Inner Ring (3 Used)
7- Pin (3 Used) 14- Oil Seal 22- Adjusting Washer

W3-7-2-1
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

Disassembly of Swing Device

1. Tilt the swing device. Drain off hydraulic oil from 6. Remove pins (7) (3 used), second stage planetary
drain port (a). gears (10) (3 used), needle bearings (9) (3 used),
plates (8) (6 used), and thrust plate (24) from second
fNOTE: Amount of oil: 2 L stage carrier (25).
a 7. Remove spring pins (11, 12) (3 used for each) from
pins (7) (3 used).
8. Remove socket bolts (13) (13 used) from ring gear
(23). Remove ring gear (23) from housing (20).

l : 12 mm

fNOTE: THREEBOND #1102 has been applied on the ring

gear (23) mounting surface.
9. Place the shaft (17) assembly on a press. Remove
WBAT-06-01-003
adjusting washer (22) from shaft (17) by using the
a- Drain Port
special tool (ST 2725).

dCAUTION: Swing motor (1) weight: 20 kg (44 lb)

2. Put the matching marks on the mating surfaces of b
swing motor (1) and ring gear (23), ring gear (23)
and housing (20). Remove socket bolts (3) (8 used) ST 2725
from swing motor (1). Insert a screwdriver into the
clearance between swing motor (1) and ring gear 17
(23). Raise swing motor (1). Remove swing motor (1)
from ring gear (23). 22
l : 12 mm 21
3. Remove the first stage carrier (2) assembly, second
stage sun gear (26), and the second stage carrier
(25) assembly from ring gear (23). WBAT-06-01-083

4. Remove retaining rings (4) (3 used) from first stage b- Pushing Force
carrier (2). Remove plate (28), first stage sun gear
(27), first stage planetary gears (6) (3 used), needle
bearings (5) (3 used), and inner rings (29) (3 used)
from first stage carrier (2).
5. Tap and install spring pins (11, 12) of the second
stage carrier (25) assembly to the end of pin (7) by
using a round bar (length 100 mm (3.9 in) or more,
dia. 7 mm).

fNOTE: If spring pins (11, 12) are tapped to the end, they
make contact with second stage carrier (25) and pin (7)
cannot be removed.

W3-7-2-2
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

11. Set the special tool to the shaft (17) assembly.

d CAUTION: If pushing out the shaft (17) assembly
from the hosing (20) assmelby by using a press, a
b
provide a protection cover (outer diameter:
190 mm (7.5 in), inner diameter: 65 mm (2.6 in),
thickness: 25 to 30 mm (1.0 to 1.2 in)). Push it with
the protection cover attached by using a press.
When housing (20) and/or roller bearing (21) are
broken and flown off without the protection cover,
the metal fragments may result in personal injury.
Be sure to degrease the housing (20) inside before
heating roller bearing (21). Failure to degrease
may cause a fire. W157-02-06-012
10. Place the hosing (20) assmelby on a press. Remove
the shaft (17) assembly and the inner race of roller 17
bearing (21) from the housing (20) assembly.
19

16
18

c W157-02-06-013

a- Shaft c- Guide
b- Hose Clamp

fNOTE: Use the following parts as the special tool

forroller bearing (19).
Shaft (a) or Bolt: Length: 160 mm (6.3 in), Diameter: 19
mm (0.7 in), 6 to 8 used (All should be identical in length
with no wear and deformation on both ends.)
Material: S35C
Hose Clamp (b): (Standard Diameter: 6-1/2”, Applicable
Diameter: 125 to 155 mm (4.9 to 6.1 in)), 2 used
Guide (c): Height: 120 mm, Outer Diameter: 170 mm (6.7
in), Inner Diameter: 150 mm (5.9 in)

W3-7-2-3
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

dCAUTION: When pushing shaft (17) by using a

press, set shaft (27) into guide (b).
12. Place the shaft (17) assembly with the special tool
attached on a press.
b

17

19

16
18

W157-02-06-014

a- Guide
b- Press

13. Remove the inner race of roller bearing (19), plate

(16), and spacer (18) from shaft (17).
IMPORTANT: Do not remove the outer races of roller
bearings (21, 19) from housing (20). Failure to
follow these instructions will shorten service life
of the bearing as press-fit force of roller bearings
(21, 19) outer races is reduced. When they have
been removed, replace housing (20) with the new
one.
14. Remove oil seal (14) and seal (15) from housing (20).
15. Thoroughly degrease housing (20), roller bearing
(19), and spacer (18).

W3-7-2-4
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

Assembly of Swing Device

3
28 4
29
27 5
6

7
26 8
25 9
24 10
8
23
11, 12
22 13

21 14

20 15

19 16

18
17

WDEB-03-07-004

1- Swing Motor 8- Plate (6 Used) 15- Seal 23- Ring Gear

2- First Stage Carrier 9- Needle Bearing (3 Used) 16- Plate 24- Thrust Plate
3- Socket Bolt (8 Used) 10- Second Stage Planetary Gear 17- Shaft 25- Second Stage Carrier
4- Retaining Ring (3 Used) (3 Used) 18- Spacer 26- Second Stage Sun Gear
5- Needle Bearing (3 Used) 11- Spring Pin (3 Used) 19- Roller Bearing 27- First Stage Sun Gear
6- First Stage Planetary Gear (3 12- Spring Pin (3 Used) 20- Housing 28- Plate
Used) 13- Socket Bolt (13 Used) 21- Roller Bearing 29- Inner Ring (3 Used)
7- Pin (3 Used) 14- Oil Seal 22- Adjusting Washer

fNOTE: The adjusting washer (22) thickness is as follows;

7.9 mm, 8.05 mm, 8.2 mm, 8.35 mm, 8.5 mm, and 8.65
mm.

W3-7-2-5
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

Assembly of Swing Device

IMPORTANT: Before assembling, apply hydraulic oil 7. Adjust the preload of roller bearings (19, 21).
onto parts in order to prevent them from seizing.
 Install roller bearing (21) by using the special tool
IMPORTANT: Apply grease onto the inside of oil seal (ST 2725). Keep the pushing force 3500 N (350 kgf ).
(14) and seal (15). Install oil seal (14) with the lip Rotate housing (20) and adjust roller bearings (19,
part up (the motor side). 21).
1. Install oil seal (14) and seal (15) to housing (20).  Insert adjusting washers (22) in sequence from the
thinnest one into clearance (a). Check the thickness
2. When roller bearings (19, 21) have been removed
of adjusting washer (22) which cannot be inserted.
and they including housing (20) are replaced
with the new ones, install the outer races of roller
bearings (19, 21) to housing (20) by using a press. Adjusting Washer Dimension (mm)
(22)
3. Install spacer (18) and plate (16) to shaft (17). Install A 7.9
the inner race of roller bearing (19) to shaft (17) by B 8.05
using a press. C 8.2
D 8.35
4. Install eyebolts (M14, Pitch 2.0 mm) (2 used) to the E 8.5
ring gear (23) mounting holes of housing (20). Hoist F 8.65
housing (20).
IMPORTANT: Do not damage oil seal (14) with shaft  Insert the thinnest adjusting washer (22) which
(17). cannot be inserted into shaft (17) with the pushing
5. Place and install housing (22) to the top of shaft force 16500 N (1650 kgf, 3650 lbf ).
(27). At this time, check the positions of the shaft
(17) end, the screw part, and the stepped part in b
order not to curl oil seal (14).
6. Install the inner race of roller bearing (21) to shaft ST 2725
(17).

21

WBAT-06-01-004

a- Clearance b- Pushing Force

8. Apply THREEBOND #1215 onto the ring gear (23)

mounting surface of housing (20).

W3-7-2-6
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

9. Fit the matching marks made when disassembling 13. Install the second stage carrier (25) assembly to
and install ring gear (23) to housing (20) with socket shaft (17).
bolts (13) (13 used).
14. Install second stage sun gear (26) to second stage
l : 12 mm carrier (25).
15. Install the first stage carrier (2) assembly to second
m : 180 N·m (18 kgf·m, 133 lbf·ft)
stage carrier (26).
IMPORTANT: Install retaining rings (4) (3 used) with
16. Add hydraulic oil through drain hole (e) of the swing
the chamfered par (a) side facing to the plate (28)
reduction gear.
side.

28 4 2
fNOTE: Amount of oil: 2 L
IMPORTANT: When installing the motor, release
drain hole (e) in order to protect the oil seal.
17. Apply THREEBOND #1215 (f ) onto the stepped part
at the swing motor (1) side. Fit the matching marks
made when disassembling and install swing motor
(1) to ring gear (23) with socket bolts (3) (8 used).

l : 12 mm
a WBAT-06-01-006
m : 180 N·m (18 kgf·m, 133 lbf·ft)
a- Chamfered Part

e 1
10. Install inner rings (29) (3 used), needle bearings
(5) (3 used), first stage planetary gears (6) (3 used),
first stage sun gear (27), and plate (28) to first stage
carrier (2). Install plate (28) with retaining rings (4) (3
used).
11. Install needle bearings (9) (3 used) to second stage
planetary gears (10) (3 used). Install thrust plate
(24), plates (8) (6 used), second stage planetary
gears (10) (3 used), and pins (7) (3 used) to second
stage carrier (25).
IMPORTANT: Replace spring pins (11, 12) (3 used for
each) with the new ones. When installing, set slit
(b) of spring pin (11) and slit (c) of spring pin (12) WBAT-06-01-002
oppositely (180°). When installing, face slit (b)
of spring pin (11) and slit (c) of spring pin (12) to 1
swing motor side (d) and machine mounting side
(g).
f W1CD-02-06-015
12. Fit the holes of second stage carrier (25) and pin (7)
(3 used). Install spring pins (11, 12) (3 used for each). e- Drain Hole f- THREEBOND #1215

12 c 11 18. Install a cap to drain hole (e) of the swing device.

d

WDEB-03-07-005
25 b
b- Slit of Spring Pin (11) d- Swing Motor Side
c- Slit of Spring Pin (12) g- Machine Mounting Side

W3-7-2-7
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

(Blank)

W3-7-2-8
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

Disassembly of Swing Motor

27

28
26 4
29
30 5
25
31

6
32
24
33
34 23
7
35 8
38
9 10 11
36
37

39

12
40 13

41 14 15 16
21 17 18
22

20
19

W1CD-02-06-006

1- O-Ring 12- O-Ring (2 Used) 23- Friction Plate (2 Used) 34- Bushing (4 Used)
2- Needle Bearing (Outer Race) 13- Housing 24- Plate (2 Used) 35- Ring (4 Used)
3- Rotor 14- Poppet (2 Used) 25- Piston 36- Scrowave (4 Used)
4- Spherical Bushing 15- Spring (2 Used) 26- Spring (14 Used) 37- Pin (2 Used)
5- Retainer 16- O-Ring (2 Used) 27- O-Ring 38- O-Ring (2 Used)
6- Plunger (7 Used) 17- Backup Ring (2 Used) 28- O-Ring 39- Cover
7- Swash Plate 18- Plug (2 Used) 29- Retaining Ring 40- Orifice
8- Bearing (Inner Race) 19- Plug (2 Used) 30- Needle Bearing (Inner Race) 41- Socket Bolt (5 Used)
9- Bearing (Outer Race) 20- O-Ring (2 Used) 31- Valve Plate
10- Block 21- O-Ring (2 Used) 32- Ring (2 Used)
11- Socket Bolt (2 Used) 22- Relief Valve (2 Used) 33- Piston (2 Used)

W3-7-3-1
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

Disassembly of Swing Motor

IMPORTANT: Do not disassemble relief valves (22) (2 IMPORTANT: Measure dimension (a) between the
used). upper surface of piston (25) and the upper surface
1. Remove relief valves (22) (2 used) from housing (13). of housing (13). This dimension (a) is necessary for
assembly work.
j : 32 mm 8. Remove springs (26) (14 used) from piston (25).
2. Remove plugs (18) (2 used), springs (15) (2 used), Install bolts (M6, Pitch 1.0 mm) (d) into tap hole (e)
and poppets (14) (2 used) from housing (13). of piston (25). Remove piston (25) with plate (b) and
Remove backup rings (17) (2 used) and O-rings (16) spanner (c).
(2 used) from plugs (18) (2 used).

j : 36 mm c d

3. Remove socket bolts (11) (2 used) from block (10).

Remove block (10) and O-rings (12) (2 used) from
housing (13). e

l : 5 mm b
a
IMPORTANT: Do not remove pins (37) (2 used) from
cover (39). 13
4. Remove socket bolts (41) (5 used) from cover (39). 25
Remove the cover (39) assembly from housing (13).

l : 10 mm
IMPORTANT: Put the matching marks on valve plate
(31) and cover (39).
5. Remove retaining ring (29), needle bearing (inner
race) (30), and the valve plate (31) assembly from
cover (39). W152-02-06-006

6. Remove pistons (33) (2 used) and rings (32) (2 used) a- Dimension d- Bolt (M6, Pitch 1.0 mm)
from valve plate (31). b- Plate e- Tap Hole
c- Spanner
7. Remove O-ring (28), O-rings (38) (2 used), bushings
(34) (4 used), rings (35) (4 used), and scrowaves (36) 9. Remove O-ring (27) from piston (25). Remove O-ring
(4 used) from cover (39). (1) from housing (13).
10. Remove plates (24) (2 used) and friction plates (23)
(2 used) from housing (13).
IMPORTANT: Do not damage the upper surface
(valve plate side) of rotor (3).
11. Remove the rotor (3) assembly from housing (13).
12. Remove bearing (outer race) (9) from housing (13).

W3-7-3-2
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

13. Remove bearing (inner race) (8) from rotor (3) by

using puller (a).

W152-02-06-007

a- Puller

14. Remove swash plate (7), plungers (6) (7 used),

retainer (5), and spherical bushing (4) from rotor (3).

W3-7-3-3
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

Assembly of Swing Motor

40
37
41

11

10

24 38 25 31 32 33 2 30 39 36 35

34
29
26
23 14 15 16 17 18
28
27
A 12
1
B
22 21

B 3
6 B-B
4
5
7
13
9
W1CD-02-06-002

19,20 8

1- O-Ring 12- O-Ring (2 Used) 23- Friction Plate (2 Used) 34- Bushing (4 Used)
2- Needle Bearing (Outer Race) 13- Housing 24- Plate (2 Used) 35- Ring (4 Used)
3- Rotor 14- Poppet (2 Used) 25- Piston 36- Scrowave (4 Used)
4- Spherical Bushing 15- Spring (2 Used) 26- Spring (14 Used) 37- Pin (2 Used)
5- Retainer 16- O-Ring (2 Used) 27- O-Ring 38- O-Ring (2 Used)
6- Plunger (7 Used) 17- Backup Ring (2 Used) 28- O-Ring 39- Cover
7- Swash Plate 18- Plug (2 Used) 29- Retaining Ring 40- Orifice
8- Bearing (Inner Race) 19- Plug (2 Used) 30- Needle Bearing (Inner Race) 41- Socket Bolt (5 Used)
9- Bearing (Outer Race) 20- O-Ring (2 Used) 31- Valve Plate
10- Block 21- O-Ring (2 Used) 32- Ring (2 Used)
11- Socket Bolt (2 Used) 22- Relief Valve (2 Used) 33- Piston (2 Used)

W3-7-3-4
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

Assembly of Swing Motor

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Push piston (25) to housing (13) until
onto parts in order to prevent them from seizing. dimension A between the upper surface of piston
1. Install spherical bushing (4) to rotor (3). (25) and the upper surface of housing (13) is same
to dimension A measured when disassembling.
2. Install plungers (6) (7 used) to retainer (5). Install the
10. Install piston (25) to housing (13) by using a plate.
plunger (6) assembly to rotor (3).
11. Install springs (26) (14 used) to piston (25).
3. Install swash plate (7) to rotor (3).
12. Install rings (35) (4 used) to bushings (34) (4 used).
4. Install bearing (inner race) (8) to rotor (3) by using a
press. 13. Install rings (32) (2 used) to pistons (33) (2 used).
Install pistons (33) (2 used) to valve plate (31).
5. Install bearing (outer race) (9) to housing (13) by
using a press. IMPORTANT: Fit the matching marks and install
valve plate (31).
IMPORTANT: After installing the rotor (3) assembly,
check that the upper surface of rotor (3) is 14. Install the busing (34) assemblies (4 used) and
positioned 7.5 mm (0.3 in) lower than the end scrowaves (36) (4 used) to cover (39). Install the
surface of housing (13). valve plate (31) assembly to cover (39).
6. Install the rotor (3) assembly to housing (13). 15. Install needle bearing (inner race) (30) to cover (39).
Install retaining ring (29) to cover (39).
7. Install friction plates (23) (2 used) and plates (24) (2
used) to housing (13) alternately. 16. Apply grease onto O-ring (28) and O-rings (38) (2
used). Install O-ring (28) and O-rings (38) (2 used) to
8. Apply grease onto O-ring (1). Install O-ring (1) to
cover (39).
housing (13).
9. Apply grease onto O-ring (27). Install O-ring (27) to
piston (25).

W3-7-3-5
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

17. Apply THREEBOND #1211 onto the cover (39)

mounting surface of housing (13). Install the cover
(39) assembly to housing (13) with socket bolts (41)
(5 used).

l : 8 mm

m : 65 N·m (6.5 kgf·m, 48 lbf·ft)

18. Install O-rings (12) (2 used) to block (10). Install
block (10) to housing (13) with socket bolts (11) (2
used).

l : 5 mm

m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft)

19. Install backup rings (17) (2 used) and O-rings (16) (2
used) to plugs (18) (2 used). Install poppets (14) (2
used), springs (15) (2 used), and plugs (18) (2 used)
to housing (13).

l : 36 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft)

20. Install relief valves (22) (2 used) to housing (13).

j : 32 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

W3-7-3-6
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

Disassembly of Valve Block

1
10 9 2
8
7

3
4
5
6

11 12
W1CD-02-06-008

WDEB-03-07-002

1- Plug 4- O-Ring 7- Spring 10- Socket Bolt (2 Used)

2- O-Ring 5- Spring 8- Spool 11- Housing
3- Plug 6- Spool 9- Block 12- O-Ring (2 Used)

W3-7-4-1
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

Disassembly of Valve Block

1. Remove socket bolts (10) (2 used) from block (9).
Remove block (9) and O-rings (12) (2 used) from
housing (11).

l : 5 mm
2. Remove plug (1) from block (9). Remove spool (8)
and spring (7) from block (9).

l : 5 mm
3. Remove plug (3) from block (9). Remove spring (5)
and spool (6) from block (9).

l : 5 mm
4. Remove O-rings (2, 4) from plugs (1, 3).

W3-7-4-2
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

Assembly of Valve Block

7 8

12

C
9
10 1

C 3

11 4

Section C-C
WDEB-03-07-003
6 5

1- Plug 4- O-Ring 7- Spring 10- Socket Bolt (2 Used)

2- O-Ring 5- Spring 8- Spool 11- Housing
3- Plug 6- Spool 9- Block 12- O-Ring (2 Used)

W3-7-4-3
 SECTION 3 UPPERSTRUCTURE
Group 7 Swing Device

Assembly of Valve Block

IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.
1. Install O-ring (4) to plug (3). Install spool (6), spring
(5), and plug (3) to block (9).

l : 5 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

2. Install O-ring (2) to plug (1). Install spring (7), spool
(8), and plug (1) to block (9).

l : 5 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

3. Install O-rings (12) (2 used) to block (9). Install block
(9) to housing (11) with socket bolts (10) (2 used).

l : 5 mm

m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft)

W3-7-4-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Removal and Installation of Pilot Valve (Left)

9 6
7

8
WDEE-03-08-004
1

WDAE-03-01-029

IMPORTANT: The hose and pipe contain hydraulic 4. Remove bolt (6), spring washer (7), and washers (8)
oil. When removing the hose and pipe, receive oils (2 used). Remove seat belt (9).
with a container in order to avoid spilling oils.
j : 16 mm
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
dCAUTION: Seat (2) weight: 45 kg (100 lb)
5. Remove socket bolts (4) (4 used) and washers (5) (4
hoses, and pipes for assembling. Connect the
used). Remove seat (2).
hoses and install the clips in case the clips which
secure the hoses have been removed. l : 6 mm
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open door (1).
3. Disconnect connectors (3) (2 used).

W3-8-1-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

3 7
6

4
8

5
14
2, 16
9

13 10
12

17
1
15
WDEE-03-08-010 18

WDEE-03-08-009

6. Remove bolts (7) (3 used), bolt (14), and washers (6) 9. Raise boot (4). Loosen lock nut (13). Remove the
(4 used). Remove cover (8). lever (3) assembly and boot (4) from pilot valve (9).

j : 10 mm j : 19 mm
7. Remove bolts, washers (15) (3 used). Remove cover 10. Disconnect hoses (12) (6 used) from pilot valve (9).
(1).
j : 17 mm
j : 10 mm
11. Put the matching marks on frame (5) and pilot valve
8. Disconnect connector (10). (9). Remove socket bolts (2) (4 used) and washers
(16) (4 used) from frame (5). Remove pilot valve (9),
plate (17), and boot (18) from frame (5).

l : 6 mm
12. Remove the adapters with pilot valve (9) attached if
necessary.

W3-8-1-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

3 7
6
4

8
5
2, 16 14

9
13 10

12
17
1
18 15
WDEE-03-08-010

WDEE-03-08-009

Installation 4. Install the lever (3) assembly and boot (4) to pilot
valve (9). Secure the lever (3) assembly to pilot valve
1. Install all removed adapters to pilot valve (9).
(9) with lock nut (13).
2. Fit the matching marks on frame (5) and pilot valve
(9). Install boot (18), plate (17), and pilot valve (9) j : 19 mm
to frame (5) with washers (16) (4 used) and socket
m : 90 N·m (9 kgf·m, 66 lbf·ft)
bolts (2) (4 used).
5. Connect connector (10).
l : 6 mm
6. Install cover (1) with bolts, washers (15) (3 used).
m : 20 N·m (2 kgf·m, 15 lbf·ft)
j : 10 mm
3. Connect hoses (12) (6 used) to pilot valve (9).
m : 5 N·m (0.5 kgf·m, 3.7 lbf·ft)
j : 17 mm
7. Install cover (8) with bolts (7) (3 used), bolt (14), and
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) washers (6) (4 used).
IMPORTANT: Check the hydraulic oil level. Start the j : 10 mm
engine and check for any oil leaks.
m : 5 N·m (0.5 kgf·m, , 3.7 lbf·ft)

W3-8-1-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

9 6
7

1
WDAE-03-01-029 WDEE-03-08-004

dCAUTION: Seat (2) weight: 45 kg (100 lb)

8. Install seat (2) with washers (5) (4 used) and socket
bolts (4) (4 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

9. Install seat belt (9) with washers (8) (2 used), spring
washer (7), and bolt (6).

j : 16 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

10. Connect connectors (3) (2 used).
11. Close door (1).

W3-8-1-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Removal and Installation of Pilot Valve

(Right)
2

9 6
7

1 WDEE-03-08-004

WDAE-03-01-029

IMPORTANT: The hose and pipe contain hydraulic 4. Remove bolt (6), spring washer (7), and washers (8)
oil. When removing the hose and pipe, receive oils (2 used). Remove seat belt (9).
with a container in order to avoid spilling oils.
j : 16 mm
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
dCAUTION: Seat (2) weight: 45 kg (100 lb)
5. Remove socket bolts (4) (4 used) and washers (5) (4
hoses, and pipes for assembling. Connect the
used). Remove seat (2).
hoses and install the clips in case the clips which
secure the hoses have been removed. l : 6 mm
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open door (1).
3. Disconnect connectors (3) (2 used).

W3-8-2-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

1 2
3 5

WDEE-03-08-001 WDEE-03-08-002

7 6

6. Remove socket bolts (7) (2 used) and washers (6) (2

used). Remove armrest (5).

l : 6 mm
7. Remove tray (3). Remove screws (2) (3 used).
Remove cover (4).
8. Raise boot (1). Remove screws (9) (2 used). Remove
cover (8).

W3-8-2-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

1 2 2

7
6

8
6

9
WDEE-03-08-003 WDEE-03-08-001
5

9. Loosen lock nut (1). Remove the lever (2) assembly.

j : 19 mm
10. Remove bolts, washers (5) (3 used). Tilt the bracket
(9) assembly with the cover (7) side up.

j : 17 mm
11. Remove screws (6) (3 used) and washer (8). Remove
cover (7).

W3-8-2-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

A Detail A
2, 3

WDAA-03-12-008
1

5 1 WDAA-03-12-020

12. Disconnect hoses (1) (6 used).

j : 17 mm
13. Remove socket bolts (2) (4 used) and washers (3) (4
used). Remove pilot valve (5) and boot (4).

l : 6 mm
14. Remove the adapters with pilot valve (5) attached if
necessary.

W3-8-2-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

A Detail A
2, 3

WDAA-03-12-008
1

5 1 WDAA-03-12-020

Installation
1. Install all removed adapters to pilot valve (5).
2. Install pilot valve (5) and boot (4) with washers (3) (4
used) and socket bolts (2) (4 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

3. Connect hoses (1) (6 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

W3-8-2-5
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

2 1 2

7
6

8
6

9
WDEE-03-08-001 WDEE-03-08-003
5

4. Install cover (7) with washer (8) and screws (6) (3

used).
5. Install the bracket (9) assembly with bolts, washers
(5) (3 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

6. Install the lever (2) assembly and tighten lock nut
(1).

j : 19 mm

m : 40±5 N·m (4±0.5 kgf·m, 29.5±3.7 lbf·ft)

W3-8-2-6
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

1 2
3 5

WDEE-03-08-001 WDEE-03-08-002

7 6

7. Install cover (8) with screws (9) (2 used).

8. Install cover (4) with screws (2) (3 used).
9. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
10. Install boot (1).
11. Install tray (3).
12. Install armrest (5) with washers (6) (2 used) and
socket bolts (7) (2 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-8-2-7
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

9 6
7

WDAE-03-01-029 1 WDEE-03-08-004

dCAUTION: Seat (2) weight: 45 kg (100 lb)

13. Install seat (2) with washers (5) (4 used) and socket
bolts (4) (4 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

14. Install seat belt (9) with washers (8) (2 used), spring
washer (7), and bolt (6).

j : 16 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

15. Connect connectors (3) (2 used).
16. Close door (1).

W3-8-2-8
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Removal and Installation of Travel Pilot Valve

4 1

2, 3 WDEE-03-08-005
WDEE-03-08-006

IMPORTANT: The hose and pipe contain hydraulic

oil. When removing the hose and pipe, receive oils dCAUTION: Remove cover (4) while holding it. Do
not drop cover (4).
with a container in order to avoid spilling oils.
IMPORTANT: Cap the open ends in case the hoses 4. Remove bolts (2) (4 used), and washers (3) (4 used).
and pipes have been disconnected. In addition, Remove cover (4).
attach an identification tag onto the connectors,
j : 17 mm
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which 5. Disconnect hoses (6) (6 used).
secure the hoses have been removed.
j : 17 mm
Removal
1. Swing the upperstructure by 90 degrees and set the
machine for inspection and maintenance. (Refer to
W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open door (1).
3. Remove the floor mat.

W3-8-3-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

1 5, 6 4 5, 6

3 WBAT-06-01-038
WAEBJ0-03-08-004

6. Remove bolts, washers (3) (4 used). Remove levers

(1) (2 used) and pedals (2) (2 used).

j : 17 mm
7. Remove socket bolts (5) (2 used) and washers (6) (2
used). Remove pilot valve (4).

l : 8 mm
8. Remove the adapters with pilot valve (4) attached if
necessary.

W3-8-3-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

5, 6 4 5, 6 1

3 WBAT-06-01-038
WAEBJ0-03-08-004

Installation
1. Install all removed adapters to pilot valve (4).
2. Install pilot valve (4) with washers (6) (2 used) and
socket bolts (5) (2 used).

l : 8 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Install pedals (2) (2 used) and levers (1) (2 used) with
bolts, washers (3) (4 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-8-3-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

4 1

WDEE-03-08-006 2, 3 WDEE-03-08-005

4. Connect hoses (6) (6 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

5. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
6. Install cover (4) with washers (3) (4 used), and bolts
(2) (4 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

7. Install the floor mat.
8. Close door (1).

W3-8-3-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Removal and Installation of Blade Pilot Valve

9 6
7

1
WDEE-03-08-004
WDAE-03-01-029

IMPORTANT: The hose and pipe contain hydraulic 4. Remove bolt (6), spring washer (7), and washers (8)
oil. When removing the hose and pipe, receive oils (2 used). Remove seat belt (9).
with a container in order to avoid spilling oils.
j : 16 mm
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
dCAUTION: Seat (2) weight: 45 kg (100 lb)
5. Remove socket bolts (4) (4 used) and washers (5) (4
hoses, and pipes for assembling. Connect the
used). Remove seat (2).
hoses and install the clips in case the clips which
secure the hoses have been removed. l : 6 mm
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open door (1).
3. Disconnect connectors (3) (2 used).

W3-8-4-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

1 2 3
5
4

WDEE-03-08-001 WDEE-03-08-002
7 6

6. Remove socket bolts (7) (2 used) and washers (6) (2

used). Remove armrest (5).

l : 6 mm
7. Remove tray (3). Remove screws (2) (3 used).
Remove cover (4).
8. Raise boot (1). Remove screws (9) (2 used). Remove
cover (8).

W3-8-4-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

2
4
2

5
WDEE-03-08-003 WDEE-03-08-001
1

9. Remove bolts, washers (1) (3 used). Tilt the bracket

(5) assembly with the cover (3) side up. 6 7 8
j : 17 mm
10. Remove socket bolts (7) (2 used) and washers (8) (2
used). Remove lever (6).

l : 6 mm
11. Remove screws (2) (3 used) and washer (4). Remove
cover (3).

7 8

WDEB-03-08-006

W3-8-4-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

11 7 8 4

11

10
5

10

WDEB-03-08-005
6 WDAD-03-11-006

12. Remove clip bands (9) (2 used). Disconnect 14. Disconnect hoses (6) (4 used).
connectors (10) (6 used).
j : 17 mm
13. Remove screws (11) (2 used). Remove switch panels
(7, 8). 15. Remove bolts, washers (5) (2 used). Remove pilot
valve (4).

j : 17 mm
16. Remove the adapters with pilot valve (4) attached if
necessary.

W3-8-4-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

4
11 7 8

11

5 10

10

WDEB-03-08-005
6 WDAD-03-11-006

Installation
1. Install all removed adapters to pilot valve (4). 4. Install switch panels (7, 8) with screws (11) (2 used).
2. Install pilot valve (4) with bolts, washers (5) (2 used). 5. Connect connectors (10) (6 used). Install clip bands
(9) (2 used).
j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Connect hoses (6) (4 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

W3-8-4-5
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

6 7 8

3
2

7 8
5 4 2
WDEB-03-08-006
WDEB-03-08-002

6. Install cover (3) with washer (4) and screws (2) (3

used).
7. Install lever (6) with washers (8) (2 used) and socket
bolts (7) (2 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

8. Install the bracket (5) assembly with bolts, washers
(1) (3 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

WDEE-03-08-003
1

W3-8-4-6
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

1 2 3
5
4

WDEE-03-08-002 WDEE-03-08-001
7 6

9. Install cover (8) with screws (9) (2 used).

10. Install cover (4) with screws (2) (3 used).
11. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
12. Install boot (1).
13. Install tray (3).
14. Install armrest (5) with washers (6) (2 used) and
socket bolts (7) (2 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-8-4-7
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

9 6
7

1
WDEE-03-08-004
WDAE-03-01-029

dCAUTION: Seat (2) weight: 45 kg (100 lb)

15. Install seat (2) with washers (5) (4 used) and socket
bolts (4) (4 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

16. Install seat belt (9) with washers (8) (2 used), spring
washer (7), and bolt (6).

j : 16 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

17. Connect connectors (3) (2 used).
18. Close door (1).

W3-8-4-8
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Removal and Installation of Positioning Pilot

Valve
1

2, 3 WDEE-03-08-005
5 4 WDEE-03-08-007

IMPORTANT: The hose and pipe contain hydraulic

oil. When removing the hose and pipe, receive oils dCAUTION: Remove cover (1) while holding it. Do
not drop cover (1).
with a container in order to avoid spilling oils.
IMPORTANT: Cap the open ends in case the hoses 2. Remove bolts (2) (4 used) and washers (3) (4 used).
and pipes have been disconnected. In addition, Remove cover (1).
attach an identification tag onto the connectors,
j : 17 mm
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which 3. Disconnect hoses (4) (4 used).
secure the hoses have been removed.
j : 17 mm
Removal
4. Remove the adapters with pilot valve (5) attached if
1. Set the machine position for inspection and necessary.
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)

W3-8-5-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

3
9

8 5
4 6

1 2 WDEE-03-08-004
WDEE-03-08-008

5. Open door (2). 7. Remove bolts, washers (6) (2 used). Remove pedal
(3).
6. Remove floor mat (1).
j : 13 mm
8. Remove bolts, washers (4) (2 used). Remove bracket
(5).

j : 13 mm
9. Remove bolts, washers (8) (2 used). Remove cover
(9) and pilot valve (7).

W3-8-5-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

3
9

8 5
4 6

WDEE-03-08-008

Installation
1. Install pilot valve (7) and cover (9) with bolts,
washers (8) (2 used).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

2. Install bracket (5) with bolts, washers (4) (2 used).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

3. Install pedal (3) with bolts, washers (6) (2 used).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

W3-8-5-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

2, 3 WDEE-03-08-005
5 4 WDEE-03-08-007

6. Install all removed adapters to pilot valve (5).

7. Connect hoses (4) (4 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18.51 lbf·ft)

8. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.

6 7 WDEE-03-08-004

9. Install cover (1) with washers (3) (4 used) and bolts

(2) (4 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

10. Install floor mat (6).
11. Close door (7).

W3-8-5-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Disassembly of Pilot Valves (Right and Left)

17

16

15

14

13

12

11

10
18
9

7
6 19
23
5 20
4 21
22
3

WDAA-03-12-021

1- Spacer (4 Used) 7- Spring Guide (4 Used) 13- O-Ring (4 Used) 19- Spool (4 Used)
2- Shim (Several) 8- Retaining Ring (4 Used) 14- Plate 20- O-Ring
3- Balance Spring (2 Used) 9- Pusher (2 Used) 15- Universal Joint 21- Plug
4- Balance Spring (2 Used) 10- Pusher (2 Used) 16- Cam 22- Retaining Ring
5- Return Spring (2 Used) 11- Oil Seal (4 Used) 17- Screw Joint 23- Filter
6- Return Spring (2 Used) 12- Sleeve (4 Used) 18- Casing

W3-8-6-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Disassembly of Pilot Valves (Right and Left)

IMPORTANT: Casing (18) is made of aluminium. 3. Attach a spanner onto the upper part of universal
Strong force deforms it. Handle it with care. joint (15). Remove universal joint (15).
IMPORTANT: Spool (19) has been selected to match
j : 17 mm
the hole on casing (18). The dimensions of balance
springs (3, 4) and return springs (5, 6) as well as
those of pushers (9, 10) are different. Arrange
fNOTE: Universal joint (15) has been secured on casing
(18) by using LOCTITE #262.
the disassembled parts together with the port in
4. Remove plate (14).
order not to confuse. The port number is stamped
on the outer surface of casing (18). IMPORTANT: Do not damage sleeve (12). Insert a soft
IMPORTANT: Do not remove screw joint (17) while rubber between sleeve (12) and a tool. Oil seal
securing casing (18) in a vise. The strong torque (11) cannot be removed from sleeve (12). Sleeve
may act on screw joint (17). (12) and oil seal (11) should be replaced as an
assembly.
1. Secure screw joint (17) in a vise. Turn cam (16) by
using a spanner. Remove screw joint (17). 5. Remove sleeves (12) (4 used) upward by using a pair
of pliers. Remove O-rings (19) (4 used) from sleeves
j : 19 mm, 32 mm (12) (4 used).
2. Secure the flat surface of casing (18) in a vise. IMPORTANT: The dimensions of pushers (9, 10) for
Remove cam (16) from universal joint (15). ports (1, 3) and for ports (2, 4) are different. Keep
the disassembled parts together by the port
j : 32 mm number in order not to confuse.
6. Remove pushers (9, 10) (2 used for each) from
casing (18).

W3-8-6-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

7. When compressing the spring, do not lower spool IMPORTANT: The quantity of shims (2) has been
(19). Install the special tool (ST 4145) to the port determined for each port during the performance
hole on casing (18) as illustrated. testing. Do not lose shim (2). Keep shim (2)
carefully in order to install shim (2) to the original
l : 6 mm port when assembling.
9. Remove the special tool (ST4146). Remove spring
guides (7) (4 used), return springs (5, 6) (2 used for
each), and balance springs (3, 4) (2 used for each)
from spools (19) (4 used).
18 10. Remove shim (2) and spacers (1) (4 used) from
spools (19) (4 used).
IMPORTANT: Spool (19) has been selected to match
the hole on casing (18). Spool (19) and casing (18)
should be replaced as an assembly.
11. Remove the special tool (ST 4145) from casing (18).
Slowly turn and remove spool (19) from casing (18).
W178-02-07-048
ST 4145 IMPORTANT: Retaining ring (22) may come off while
disassembling. Do not drop retaining ring (22)
8. Install the special tool (ST 4146) to the pusher hole inside casing (18). If retaining ring (22) falls inside
on casing (18). Push the special tool (ST 4146) and casing (18), remove retaining ring (22) completely.
compress the spring. Tighten the special tool (ST Retaining ring (22) cannot be reused.
4146) by using the socket bolt (M14, Pitch 2.0 mm). 12. Remove retaining ring (22) from casing (18) by
Remove retaining rings (8) (4 used) from spools (19) using a screwdriver. Install a bolt (M8, Pitch 1.25
(4 used) by using a screwdriver. mm) to plug (21). Remove plug (21) from casing
(18). Remove O-ring (20) from plug (21).
l : 12 mm
j : 13 mm

ST 4146
13. Remove filter (23) from casing (18).

j : 10 mm

18

W178-02-07-048

W3-8-6-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Assembly of Pilot Valves (Right and Left)

17

15
16

11
14 9, 10
13
12
8
7
3, 4
5, 6
2

1
21
20

23 18 19

22

WDAA-03-12-022

1- Spacer (4 Used) 7- Spring Guide (4 Used) 13- O-Ring (4 Used) 19- Spool (4 Used)
2- Shim (Several) 8- Retaining Ring (4 Used) 14- Plate 20- O-Ring
3- Balance Spring (2 Used) 9- Pusher (2 Used) 15- Universal Joint 21- Plug
4- Balance Spring (2 Used) 10- Pusher (2 Used) 16- Cam 22- Retaining Ring
5- Return Spring (2 Used) 11- Oil Seal (4 Used) 17- Screw Joint 23- Filter
6- Return Spring (2 Used) 12- Sleeve (4 Used) 18- Casing

W3-8-6-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Assembly of Pilot Valves (Right and Left)

IMPORTANT: Refer to the table in the left in order to
IMPORTANT: Before assembling, apply hydraulic oil
assemble the parts correctly.
onto parts in order to prevent them from seizing.
3. Install spacer (1), shim (2), and balance spring (3) to
IMPORTANT: The pilot valve is the susceptible
spool (19). Install return spring (5) to casing (18).
hydraulic component to contamination. Keep the
parts clean when assembling. 4. Install spring guide (7) to return spring (5) with the
protrusion up.
fNOTE: The table below shows the relations between
each port and the parts. Do not confuse them when 5. Install other spools (19) (3 used) in the same way as
assembling. step 1 to step 4.
Port No. Spool Shim Pushers (9, 10) 6. Install the special tool (ST 4146) to the pusher (9, 10)
(19) (2) holes on casing (18). Push the special tool (ST 4146)
1 Same to the Same to the One outer groove and compress the spring. Tighten the special tool
2 former one former one Two outer (ST 4146) by using a bolt (M14, Pitch 2.0 mm).
grooves
l : 12 mm
3 One outer groove
4 Two outer ST 4146
grooves

Port No. Return Springs Balance Springs ST 4144

(5, 6) (3, 4)
1 Short Short
2 Long Long
3 Short Short
4 Long Long

1. Check the port hole number and insert same spool

(19) before disassembling. Install the thinner end
of spool (19) into the port hole on casing (18) by
turning slowly. W178-02-07-049
ST 4145

fNOTE: Spool (19) has been selected to match the port

7. Install retaining ring (8) to the ring holder (ST 4144).
hole. Spool (19) and casing (18) should be replaced as an
assembly.
2. Install the special tool (ST 4145) to the port hole on
casing (18) in order not to lower spool (19) when
the spring is compressed.

j : 6 mm

W3-8-6-5
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

8. Install retaining ring (8) to the groove on the head IMPORTANT: Fit the bolt hole on plate (14) to the
of spool (21) extending from the special tool (ST screw hole on casing (18).
4146). 16. Apply LOCTITE #262 onto the screw part of
IMPORTANT: Check the position to install pusher (9). universal joint (15). Place plate (14) on casing (18).
Install universal joint (15).
9. Install pusher (9).
After pushing pusher (9) several times by hand, j : 17 mm
remove it. Check if retaining ring (8) comes off or
balance spring (3) is located correctly. m : 25 N·m (2.5 kgf·m, 19 lbf·ft)
Install pusher (9) to casing (18) after checking.
IMPORTANT: Check the tightness of cam (16).
10. Install other pushers (9, 10) in the same way as step 17. Install cam (16) to universal joint (15). The clearance
8 to step 9. between cam (16) and pushers (9, 10) (2 used for
11. Apply grease onto the ball part at the ends of each) should be 0 to 0.2 mm.
pushers (9, 10) (2 used for each). 18. Secure cam (16) by using a spanner. Tighten screw
12. Apply grease onto the joint part of universal joint joint (17) by using a spanner.
(15).
j : 19 mm, 32 mm
13. Apply grease onto the inner surface of oil seals (11)
(4 used). m : 70 N·m (7 kgf·m, 51 lbf·ft)
19. Install plug (23) to casing (18).
fNOTE: Sleeve (12) and oil seal (11) should be replaced
as an assembly. l : 10 mm
14. Install oil seals (11) (4 used) to sleeves (12) (4 used).
Push the sleeve (12) assemblies (4 used) by hand m : 20 N·m (2 kgf·m, 15 lbf·ft)
until O-ring (13) is inserted into the hole on sleeves
(12) (4 used).
15. Secure casing (18) in a vise lightly.

W3-8-6-6
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Disassembly of Travel Pilot Valve

3
4

7 35
34
33
32
8 31
9
30
10 29
11

28

14
27
12
15 26
13

25
16

17 24

18

19 23

20
21 22
WDAA-03-12-024

1- Bolt, Washer (2 Used) 10- Spring Pin (2 Used) 19- O-Ring (2 Used) 28- Oil Seal (4 Used)
2- Cover 11- Bracket (2 Used) 20- Plug (2 Used) 29- Spring Washer (2 Used)
3- Spring Pin (2 Used) 12- Spring Pin (2 Used) 21- Plug (2 Used) 30- Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13- Spring Pin (2 Used) 22- O-Ring (2 Used) 31- Rubber Seat (2 Used)
5- Cam (2 Used) 14- O-Ring (4 Used) 23- Casing 32- Damper (2 Used)
6- Bushing (4 Used) 15- Bushing (4 Used) 24- Spool 33- O-Ring (2 Used)
7- Holder 16- Pusher (4 Used) 25- Spring (4 Used) 34- O-Ring (2 Used)
8- Spring Washer (4 Used) 17- Spring Guide (4 Used) 26- Spacer (4 Used) 35- Pin (2 Used)
9- Socket Bolt (4 Used) 18- Balance Spring (4 Used) 27- Shim (12 Used)

W3-8-7-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Disassembly of Travel Pilot Valve

IMPORTANT: Spool (24) has been selected to match
IMPORTANT: Casing (23) is made of aluminium.
the hole of casing (23). Spool (24) and casing (23)
Strong force deforms it. Handle it with care.
should be replaced as an assembly.
IMPORTANT: Spool (24) has been selected to match
IMPORTANT: Put the mark on spools (24) (4 used)
the hole on casing (23).
when keeping in order to easily install spools (24)
Arrange the disassembled parts together with (4 used) to the original hole.
each port in order not to confuse.
5. Remove the spool (24) assembly from casing (23) by
The port number is stamped on the outer surface rotating.
of casing (23). Spring guide (17), balance spring (18), shims (27) (3
1. Secure casing (23) in a vise. Remove bolts, washers used), and spacer (26) are removed with spool (24)
(1) (2 used). Remove cover (2) from holder (7). together.
j : 10 mm IMPORTANT: The quantity of shims (27) have been
determined during the performance testing at the
2. Remove socket bolts (30) (2 used) and spring factory. When keeping, pair shim (27) with each
washers (29) (2 used). Remove the holder (7) spool.
assembly from casing (23).
6. Compress balance spring (18). Remove spring guide
l : 8 mm (17), balance spring (18), shims (27) (3 used), and
spacer (26) from spool (24).
3. Remove the pusher (16) assemblies (4 used) from
casing (23). 7. Remove spring (25) from casing (23).
4. Remove pushers (16) (4 used) from bushings (15) 8. Remove other spools (24) in the same way as step 5
(4 used). Remove oil seals (28) (4 used) and O-rings to step 7.
(14) (4 used) from bushings (15) (4 used) by using a
bamboo spatula.

W3-8-7-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

11. Remove O-ring (33) from pin (35).

d CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, 12. Remove other bracket (11) in the same way as step
such as goggles, helmets, etc in order to prevent 9 to step 11.
personal injury. 13. Place holder (7) with the casing (23) mounting
IMPORTANT: Place a stand under bracket (11) and surface up.
receive a reaction force. If holder (7) bears the
reaction force, strong force acts on pin (35). dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
Therefore, pin (35) may be deformed.
such as goggles, helmets, etc in order to prevent
9. Place a stand under bracket (11). The inner surfaces
personal injury.
of the spring pins (12, 13) holes on bracket (11) are
stepped-shape. The spring pin can only be removed 14. The holes of spring pins (3, 4) (2 used for each) in
in one direction. Tap and remove spring pins (12, cam (5) are stepped-shape. Tap the bottom of cam
13) from bracket (11) at the same time by using the (5) and remove spring pins (3, 4) (2 used for each)
special tool (ST 1237). Remove bracket (11) from pin from cams (5) (2 used) at the same time by using the
(35). Do not remove spring pin (10) with bracket (11) special tool (ST 1237).
attached unless necessary. The hole end of spring As the holes of spring pins (3, 4) (2 used for each)
pin (10) has been crimped. are crimped, spring pins (3, 4) may feel tight when
removing.

12, 13
11
35
10

W176-02-07-019
a- Crimped Position
b- Stand

10. Remove socket bolts (9) (2 used) and spring washers

(8) (2 used). Remove damper (32) and rubber seat
(31) from pin (35). O-ring (34) is removed together.

l : 5 mm

W3-8-7-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
15. Remove pin (35) by using a bar and a hammer. At
the same time, cams (5) (2 used) are removed.
Do not remove bushings (6) (4 used) with holder
(7) attached unless necessary. If removing, remove
bushings (6) (4 used) by tapping by using the
special tool (ST 7256).
16. Remove plugs (20) (2 used) from casing (23).
Remove O-rings (19) (2 used) from plugs (20) (2
used).

l : 5 mm

W3-8-7-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Assembly of Travel Pilot Valve

11 32 31 1 2 35 6 12 10 13 7 5 3, 4 30

29
34 15
9
33
8 17
28
18
14
25
27
16
26

24
23

WDAA-03-12-025

1- Bolt, Washer (2 Used) 10- Spring Pin (2 Used) 19- *O-Ring (2 Used) 28- Oil Seal (4 Used)
2- Cover 11- Bracket (2 Used) 20- *Plug (2 Used) 29- Spring Washer (2 Used)
3- Spring Pin (2 Used) 12- Spring Pin (2 Used) 21- *Plug (2 Used) 30- Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13- Spring Pin (2 Used) 22- *O-Ring (2 Used) 31- Rubber Seat (2 Used)
5- Cam (2 Used) 14- O-Ring 23- Casing 32- Damper (2 Used)
6- Bushing (4 Used) 15- Bushing (4 Used) 24- Spool (4 Used) 33- O-Ring (2 Used)
7- Holder 16- Pusher (4 Used) 25- Spring (4 Used) 34- O-Ring (2 Used)
8- Spring Washer (4 Used) 17- Spring Guide (4 Used) 26- Spacer (4 Used) 35- Pin (2 Used)
9- Socket Bolt (4 Used) 18- Balance Spring (4 Used) 27- Shim (12 Used)

fNOTE: As for the parts with mark *, refer to W3-8-6-1.

W3-8-7-5
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Assembly of Travel Pilot Valve

IMPORTANT: Before assembling, apply hydraulic oil dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
onto parts in order to prevent them from seizing.
such as goggles, helmets, etc in order to prevent
IMPORTANT: The pilot valve is the susceptible
personal injury.
hydraulic component to contamination. Keep the
parts clean when assembling. fNOTE: Bushings (6) (4 used) are identical.
1. Insert spacer (26), shims (27) (3 used), and balance  Insert bushings (6) (4 used) into the special tool
spring (18) into spool (24) in sequence. Install shim (ST 7256). Tap the special tool (ST 7256) by using a
(27) as the same condition before disassembling. hammer and install bushing (6) to the end of hole on
holder (7). Stop tapping when the bushing (6) end is
IMPORTANT: Check the direction to install spring
flush with the hole end.
guide (17).
2. Compress balance spring (18) by hand. Install spring
guide (17) to spool (24) with the stepped part down. 7 ST 7256

IMPORTANT: Before inserting the parts into holder

(7) and casing (23), apply hydraulic oil.
3. Insert spring (25) into casing (23).
6
4. Insert the spool (24) assembly into the original port W178-02-11-310
before disassembling. Insert the spool (24) assembly
into casing (23) by rotating.
5. Install oil seal (28) to bushing (15).
6. Apply grease onto the inner surface of oil seal (28).
7. Install O-ring (14) and pusher (16) to bushing (15).
8. Apply grease onto the head of pusher (16).
9. Insert the pusher (16) assembly into casing (23).
10. Install other spools (24) in the same way as step 1 to
step 9.
11. When bushing (6) has been removed from holder
(7), install bushings (6) (4 used) to holder (7) by
using the special tool (ST 7256) in the following
procedures.

W3-8-7-6
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

 Install bushing (6) on the opposite side in the same 12. Install O-rings (33) (2 used) to pin (35). Apply grease
way. onto O-rings (33) (2 used). Install pin (35) and cams
6 (5) (2 used) to holder (7).
ST 7256 7
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: Check the direction to install spring
pins (3, 4).
W178-02-11-311
13. Install spring pins (3, 4) to cam (5) by using the
special tool (ST 1237). Secure cam (5) and pin (35).
 Install bushing (6) in the near side as illustrated. Stop At this time, the slits (a) of spring pins (3, 4) should
tapping when the bushing (6) end is flush with the be positioned 90° away each other. Tap and install
outside of holder (7). spring pins (3, 4) until spring pins (3, 4) come in
contact with the stepped part in the hole.
6
7 ST 7256 3 a a

a
4 W178-02-07-050
W178-02-11-312
a- Slit
a- Outside of Holder

14. Crimp the hole end of cam (5) where spring pins (3,
 Install bushing (6) in the near and opposite side as 4) are inserted by using a punch.
illustrated.
15. Install other cam (5) in the same way as step 13 to
6 step 14.
ST 7256 7

W178-02-11-313

W3-8-7-7
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

16. Place holder (7) on the casing (23) assembly. Install 21. As for the direction to install bracket (11), refer to
holder (7) to casing (23) with socket bolts (30) (2 the figure in Disassembly of Travel Pilot Valve on
used) and spring washers (29) (2 used). W3-8-6-1. Install bracket (11) to pin (35). Fit the
Check the mark direction and install holder (7). holes to insert spring pins (12, 13).

l : 8 mm IMPORTANT: Place a stand under bracket (11) and

receive a reaction force. If holder (7) bears the
m : 50 N·m (5 kgf·m, 37 lbf·ft) reaction force, strong force acts on pin (35).
Therefore, pin (35) may be deformed.
17. Install rubber seats (31) (2 used) to pin (35).
22. Place a stand (b) under bracket (11). Install spring
IMPORTANT: Check the direction of damper (32). pins (12, 13) to bracket (11) until they come in
The inner surface of damper (32) is edged-shape. contact with the stepped part by using the special
If damper (32) is pried when installing, O-ring (33) tool (ST 1237). The slits of spring pins (2 used)
may be damaged. should be positioned 90° away each other.
18. Install dampers (32) (2 used) to pin (35) with the
lever up. a a
19. Secure damper (32) and rubber seat (31) to holder
(7) with socket bolts (9) (4 used) and spring washers 11 35
(8) (4 used).

l : 5 mm

m : 7 N·m (0.7 kgf·m, 5 lbf·ft) b

12, 13

20. Apply grease onto O-ring (34). Push O-rings (34) (2

used) to the end of pin (35).
W176-02-07-011
a- Crimped Position
b- Stand

W3-8-7-8
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

23. Crimp the hole edge of bracket (11) where spring

pins (12, 13) are inserted by using a punch.
24. Install other bracket (11) in the same way as step 22
to step 23.
25. Install cover (2) to holder (7) with bolts, washers (1)
(2 used).

j : 10 mm

m : 5 N·m (0.5 kgf·m, 3.5 lbf·ft)

26. Apply grease onto the spring pin (10) contact part
of dampers (32) (2 used).
27. Install O-rings (19) (2 used) to plugs (20) (2 used).
Install plugs (20) (2 used) to casing (23).

j : 5 mm

m : 10 N·m (1 kgf·m, 7.5 lbf·ft)

28. Install O-rings (22) (2 used) to plugs (21) (2 used).
Install plugs (21) (2 used) to casing (23).

j : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-8-7-9
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

(Blank)

W3-8-7-10
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Disassembly of Blade Pilot Valves

WDAD-03-11-001

00- Spacer (2 Used) 04C- O-Ring (2 Used) 09- Set Screw 15A- Casing
01- Shim (6 Used) 04D- Pusher (2 Used) 10- Socket Bolt (2 Used) 15B- Spool (2 Used)
02- Balance Spring (2 Used) 05- Cam 11- Boot 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 06- Holder 12- O-Ring
04A- Bushing (2 Used) 07- Bushing (2 Used) 13- Plug
04B- Oil Seal (2 Used) 08- Pin 14- Filter

W3-8-8-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Disassembly of Pilot Valve

IMPORTANT: Casing (15A) is made of aluminium. IMPORTANT: The pusher (04D) assembly may fly out
Strong force deforms it. Handle it with care. when removing holder (06).
IMPORTANT: Spool (15B) has been selected to 5. Put the matching marks on casing (15A) and holder
match the hole of casing (15A). Arrange the (06). Loosen and remove socket bolts (10) (2 used)
disassembled parts together with each port in alternately. Remove holder (06) from casing (15A).
order not to confuse. The port number is stamped
on the outer surface of casing (15A). l : 5 mm
1. Secure the pilot valve in a vise. Remove boot (11) 6. Remove the pusher (04D) assemblies (2 used) from
from holder (06). casing (15A).
2. Remove set screw (09) from cam (05). IMPORTANT: Do not damage bushing (04A).
7. Remove pushers (04D) (2 used), O-rings (04C) (2
l : 2.5 mm
used), and oil seals (04B) (2 used) from bushings
fNOTE: LOCTITE #262 has been applied on set screw (04A) (2 used).
(09).
3. Remove pin (08). Remove cam (05) from holder (06).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: Do not remove bushing (07) unless
necessary.
IMPORTANT: Bushing (07) cannot be reused.
4. Remove bushings (07) (2 used) from holder (06) by
using a hammer and the special tool (ST 7690).

W3-8-8-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

IMPORTANT: Spool (15B) has been selected to match

the hole of casing (15A). Spool (15B) and casing
(15A) should be replaced as an assembly.
IMPORTANT: Put the mark on spools (15B) (2 used)
when keeping in order to easily install spools
(15B) (2 used) to the original hole.
8. Remove the spool (15B) assembly from casing (15A)
by rotating.
IMPORTANT: The quantity of shims (01) has been
determined during the performance testing at the
factory. When keeping, pair shim (01) with each
spool.
9. Compress balance spring (02). Remove spring guide
(03), balance spring (02), shims (01) (3 used), and
spacer (00) from spool (15B).
10. Remove return spring (16) from casing (15A).
11. Remove other spools (15B) in the same way as step
8 to step 10.
12. Remove plug (13) from casing (15A). Remove O-ring
(12) from plug (13).

l : 6 mm
IMPORTANT: Do not disassemble filter (14).
13. Remove filter (14) from casing (15A).

l : 10 mm

W3-8-8-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Assembly of Blade Pilot Valves

07 08 09

05

11
04D

04B 10

06
03
04C
02

16
04A

01

00
15A
13

14 12

15B

WDAD-03-11-002

00- Spacer (2 Used) 04C- O-Ring (2 Used) 09- Set Screw 15A- Casing
01- Shim (6 Used) 04D- Pusher (2 Used) 10- Socket Bolt (2 Used) 15B- Spool (2 Used)
02- Balance Spring (2 Used) 05- Cam 11- Boot 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 06- Holder 12- O-Ring
04A- Bushing (2 Used) 07- Bushing (2 Used) 13- Plug
04B- Oil Seal (2 Used) 08- Pin 14- Filter

W3-8-8-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Assembly of Pilot Valve

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Do not deform and damage the sliding
onto parts in order to prevent them from seizing. surface when installing oil seal (04B).
IMPORTANT: The pilot valve is the susceptible IMPORTANT: Check the direction to install oil seal
hydraulic component to contamination. Keep the (04B).
parts clean when assembling. 5. Apply grease (NOK KLUBER #L60) onto oil seal (04B).
IMPORTANT: Install shims (01) as the same condition Install oil seal (04B) to bushing (04A).
before disassembling.
1. Insert spacer (00), shims (01) (3 used), and balance
spring (02) to spool (15B) in sequence. 04B

IMPORTANT: Install spring guide (03) with the

stepped part down.
2. Compress balance spring (02) by hand. Install spring 04A
guide (03) to spool (15B).
IMPORTANT: Before installing the parts to holder WDAD-03-11-003
(06) and casing (15A), apply hydraulic oil.
3. Secure casing (15A) in a vise. Install return spring 6. Apply grease (NOK KLUBER #L60) onto the sliding
(16) to casing (15A). surface of bushing (04A) and O-ring (04C). Install
O-ring (04C) and pusher (04D) to bushing (04A).
IMPORTANT: Install the spool (15B) assembly to the
original port before disassembling. 7. Install the pusher (04D) assembly to casing (15A).
4. Install the spool (15B) assembly to casing (15A) by 8. Install other spools (15B) and pushers (04D) in the
rotating. same way as step 1 to step 7.

W3-8-8-5
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

13. Install filter (14) to casing (15A).

d CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, l : 10 mm
such as goggles, helmets, etc in order to prevent
personal injury. m : 19.6 N·m (1.96 kgf·m, 14.5 lbf·ft)
IMPORTANT: Bushing (07) should be replaced with 14. Install O-ring (12) to plug (13). Install plug (13) to
the new one. casing (15A).
9. Install bushings (07) (2 used) to holder (06) by using l : 6 mm
a hammer and the special tool (ST 7690).
10. Fit the matching marks made when disassembling m : 19.6 N·m (1.96 kgf·m, 14.5 lbf·ft)
and install holder (06) to casing (15A) by tightening 15. Install boot (11) to holder (06).
socket bolts (10) (2 used) alternately.

l : 5 mm

m : 6.9 N·m (0.69 kgf·m, 5.1 lbf·ft)

11. Apply grease (Apolloil Autorex C) onto portion A
of pushers (04D) (2 used). Install cam (05) to holder
(06) with pin (08).

04D

WDAD-03-11-004

12. Apply LOCTITE #262 onto set screw (09). Install set
screw (09) to cam (05).

l : 2.5 mm

m : 6.9 N·m (0.69 kgf·m, 5.1 lbf·ft)

W3-8-8-6
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Disassembly of Pilot Valves for Boom Swing,

Positioning, Auxiliary (Optional)
11

09

05

10

10 07
06

08
07

B
B
A
A 04
04 C
C
D
D 03
03
02
02
01
01 00
00
16
16

15

B WADB-03-08-001

00- Spacer (2 Used) 04B- Oil Seal (2 Used) 07- Bushing (2 Used) 15A- Casing
01- Shim (6 Used) 04C- O-Ring (2 Used) 08- Pin 15B- Spool (2 Used)
02- Balance Spring (2 Used) 04D- Pusher (2 Used) 09- Set Screw 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 05- Cam 10- Socket Bolt (2 Used)
04A- Bushing (2 Used) 06- Holder 11- Boot

W3-8-9-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Disassembly of Pilot Valve

IMPORTANT: Casing (15A) is made of aluminium. IMPORTANT: When removing holder (06), the pusher
Strong force deforms it. Handle it with care. (04D) assembly may fly out.
IMPORTANT: Spool (15B) has been selected to 5. Put the matching marks on casing (15A) and holder
match the hole on casing (15A). Arrange the (06). Loosen and remove socket bolts (10) (2 used)
disassembled parts together with each port in alternately. Remove holder (06) from casing (15A).
order not to confuse. The port number is stamped
on the outer surface of casing (15A). l : 5 mm
1. Secure the pilot valve in a vise. Remove boot (11) 6. Remove the pusher (04D) assemblies (2 used) from
from holder (06). casing (15A).
2. Remove set screw (09) from cam (05). IMPORTANT: Do not damage bushing (04A).
7. Remove pushers (04D) (2 used), O-rings (04C) (2
l : 2.5 mm
used), and oil seals (04B) (2 used) from bushings
fNOTE: LOCTITE #262 has been applied on set screw (04A) (2 used).
(09).
3. Remove pin (08). Remove cam (05) from holder (06).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: Do not remove bushing (07) unless
necessary.
IMPORTANT: Bushing (07) cannot be reused.
4. Remove bushings (07) (2 used) from holder (06) by
using a hammer and the special tool (ST7690).

W3-8-9-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

IMPORTANT: Casing (15A) has been selected to

match the hole of spool (15B). Replace spool (15B)
and casing (15A) as an assembly.
IMPORTANT: Put the mars on spools (15B) (2 used)
when keeping in order to easily install spools
(15B) (2 used) to the original hole.
8. Remove the spool (15B) assembly from casing (15A)
by rotating.
IMPORTANT: The quantity of shims (01) has been
determined during the performance testing at the
factory. When keeping, pair shim (01) with each
spool.
9. Compress balance spring (02). Remove spring guide
(03), balance spring (02), shims (01) (3 used), and
spacer (00) from spool (15B).
10. Remove return spring (16) from casing (15A).
11. Remove other spools (15B) in the same way as step
8 to step 11.

W3-8-9-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Assembly of Pilot Valves for Boom Swing,

Positioning, Auxiliary (Optional)

07 08 09

05

11
04D

04B 10

06

03

04C
16

04A
E

15B

02
01
00

15A

Detail E WADB-03-08-006

00- Spacer (2 Used) 04B- Oil Seal (2 Used) 07- Bushing (2 Used) 15A- Casing
01- Shim (6 Used) 04C- O-Ring (2 Used) 08- Pin 15B- Spool (2 Used)
02- Balance Spring (2 Used) 04D- Pusher (2 Used) 09- Set Screw 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 05- Cam 10- Socket Bolt (2 Used)
04A- Bushing (2 Used) 06- Holder 11- Boot

W3-8-9-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

Assembly of Pilot Valve

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Do not deform and damage the sliding
onto parts in order to prevent them from seizing. surface when installing oil seal (04B).
IMPORTANT: The pilot valve is the susceptible IMPORTANT: Check the direction to install oil seal
hydraulic component to contamination. Keep the (04B).
parts clean when assembling. 5. Apply grease onto oil seal (04B). Install oil seal (04B)
IMPORTANT: Install shim (01) as the same quantity to bushing (04A).
before disassembling.
1. Install spacer (00), shims (01) (3 used), and balance 04B
spring (02) to spool (15B) in sequnce.
IMPORTANT: Install spring guide (03) with the
stepped part down.
04A
2. Compress balance spring (02) by hand. Install spring
guide (03) to spool (15B).
WDAD-03-11-003
IMPORTANT: When installing the parts to holder (06)
and casing (15A), apply hydraulic oil.
3. Secure casing (15A) in a vise. Install return spring 6. Apply grease onto the bushing (04A) sliding surface
(16) to casing (15A). and O-ring (04C). Install O-ring (04C) and pusher
(04D) to bushing (04A).
IMPORTANT: Install the spool (15B) assembly to the
original port before disassembling. 7. Install the pusher (04D) assembly to cashing (15A).
4. Install the spool (15B) assembly to casing (15A) by 8. Install other spool (15B) and pusher (04D) in the
rotating. same way as step 1 to step 7.

W3-8-9-5
 SECTION 3 UPPERSTRUCTURE
Group 8 Pilot Valve

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
9. Install bushings (07) (2 used) to holder (06) by using
a hammer and the special tool (ST7690).
10. Fit the matching marks made when disassembling
and install holder (06) to casing (15A) by tightening
socket bolts (10) (2 used) alternately.

l : 5 mm

m : 7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)

11. Apply grease onto A part of pushers (04D) (2 used).
Install cam (05) to holder (06) with pin (08).

04D

WDAD-03-11-004

12. Apply LOCTITE #262 onto set screw (09). Install set
screw (09) to cam (05).

l : 2.5 mm

m : 7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)

13. Install boot (11) to holder (06).

W3-8-9-6
 SECTION 3 UPPERSTRUCTURE
Group 9 Solenoid Valve

Removal and Installation of 2-Spool Solenoid

Valve Unit
2

1 3

MDEC-07-007

WDEB-03-09-001

IMPORTANT: The hose and pipe contain hydraulic 3. Disconnect connectors (4) (2 used).
oil. When removing the hose and pipe, receive oils
4. Disconnect hoses (2) (4 used).
with a container in order to avoid spilling oils.
IMPORTANT: Cap the open ends in case the hoses j : 17 mm
and pipes have been disconnected. In addition,
5. Remove bolts, washers (5) (2 used). Remove 2-spool
attach an identification tag onto the connectors,
solenoid valve unit (3).
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which j : 17 mm
secure the hoses have been removed.
6. Remove the adapters with 2-spool solenoid valve
Removal unit (3) attached if necessary.
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open cover (1).

W3-9-1-1
 SECTION 3 UPPERSTRUCTURE
Group 9 Solenoid Valve

3 1

MDEC-07-007

WDEB-03-09-001

Installation
1. Install all removed adapters to 2-spool solenoid 5. Bleed air from the hydraulic system. (Refer to W1-
valve unit (3). 4-1.)
2. Install 2-spool solenoid valve unit (3) with bolts, IMPORTANT: Check the hydraulic oil level. Start the
washers (5) (2 used). engine and check for any oil leaks.
6. Close cover (1).
j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Connect hoses (2) (4 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

4. Connect connectors (4) (2 used).

W3-9-1-2
 SECTION 3 UPPERSTRUCTURE
Group 9 Solenoid Valve

Structure of 2-Spool Solenoid Valve Unit

W8HT-02-03-008
A

1
2
3
4
5
8 6
9
10 7

Cross Section A-A W8HT-02-03-009

No. Part Name Q’ty Wrench Size Tightening Torque Remark

(mm) N·m (kgf·m) (lbf·ft)
1 Solenoid 2
2 O-ring 2
3 Plug 1
4 Filter 1
5 Sleeve 2
6 Spool 2
7 Body 1
8 Orifice 2
9 Plate 2
10 Wave spring 2

W3-9-2-1
 SECTION 3 UPPERSTRUCTURE
Group 9 Solenoid Valve

(Blank)

W3-9-2-2
 SECTION 3 UPPERSTRUCTURE
Group 9 Solenoid Valve

Removal and Installation of Pilot Shut-Off

Solenoid Valve

5, 6 7 8
1, 2 3 4

8
WDEB-03-01-002 WDEB-03-09-004

IMPORTANT: The hose and pipe contain hydraulic 3. Disconnect connector (9).
oil. When removing the hose and pipe, receive oils
4. Disconnect hoses (8) (8 used) from pilot shut-off
with a container in order to avoid spilling oils.
solenoid valve (7).
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition, j : 17 mm, 19 mm
attach an identification tag onto the connectors,
5. Remove bolts, washers (5) (2 used). Remove pilot
hoses, and pipes for assembling. Connect the
shut-off solenoid valve (7) and bracket (6).
hoses and install the clips in case the clips which
secure the hoses have been removed. j : 17 mm
Removal
1. Swing the upperstructure by 90 degrees and set the
machine position for inspection and maintenance.
(Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)

dCAUTION: Remove cover (3) while holding it. Do

not drop cover (3).
2. Remove bolts (1) (2 used), washers (2) (2 used), and
bolts, washers (4) (4 used). Remove cover (3).

j : 17 mm

W3-9-3-1
 SECTION 3 UPPERSTRUCTURE
Group 9 Solenoid Valve

3 WDEB-03-09-003

6. Remove bolts, washers (1) (2 used). Remove bracket

(2).

j : 17 mm
7. Remove the adapter with pilot shut-off solenoid
valve (3) attached if necessary.

W3-9-3-2
 SECTION 3 UPPERSTRUCTURE
Group 9 Solenoid Valve

3 WDEB-03-09-003

Installation
1. Install all removed adapters to pilot shut-off
solenoid valve (3).
2. Install bracket (2) with bolts, washers (1) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-9-3-3
 SECTION 3 UPPERSTRUCTURE
Group 9 Solenoid Valve

5, 6 7 8

1, 2 3 4

8
WDEB-03-09-004 WDEB-03-01-002

3. Install pilot shut-off solenoid valve (7) and bracket 5. Connect connector (9).
(6) with bolts, washers (5) (2 used).
6. Bleed air from the hydraulic system. (Refer to W1-
j : 17 mm 4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
m : 50 N·m (5 kgf·m, 37 lbf·ft)
engine and check for any oil leaks.
4. Connect hoses (8) (12 used) to pilot shut-off 7. Install cover (3) with bolts, washers (4) (4 used),
solenoid valve (7). washers (2) (2 used), and bolts (1) (2 used).
j : 17 mm j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-9-3-4
 SECTION 3 UPPERSTRUCTURE
Group 9 Solenoid Valve

Structure of Pilot Shut-Off Solenoid Valve

W1JB-02-08-001

3 4 5 6 7 8

9
W1JB-02-08-002

No. Part Name Q’ty Wrench Size Tightening Torque Remark

(mm) N·m (kgf·m) (lbf·ft)
1 Plug 1 l:6 26.5 (2.7) (20)
2 O-ring 1 (1B P11)
3 Spring 1
4 Spool 1
5 Filter 1
6 Body 1
7 O-ring 1 (1A P16)
8 Solenoid 1
9 Socket blot 2 l:4 3.92 (0.4) (3)

W3-9-4-1
 SECTION 3 UPPERSTRUCTURE
Group 9 Solenoid Valve

(Black)

W3-9-4-2
 SECTION 3 UPPERSTRUCTURE
Group 10 Shockless Valve

Removal and Installation of Shockless Valve

5

1, 2

3 WDEE-03-08-005 WDEE-03-08-007

IMPORTANT: The hose and pipe contain hydraulic 3. Disconnect hoses (6) (11 used) from shockless valve
oil. When removing the hose and pipe, receive oils (7).
with a container in order to avoid spilling oils.
j : 17 mm, 19 mm
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition, 4. Remove bolts, washers (5) (4 used). Remove
attach an identification tag onto the connectors, shockless valve (7).
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which j : 17 mm
secure the hoses have been removed.

Removal
1. Swing the upperstructure by 90 degrees and set the
machine position for inspection and maintenance.
(Refer to W1-6-1.)

dCAUTION: Bleed air from hydraulic oil tank.

(Refer to W1-4-1.)

dCAUTION: Remove cover (3) while holding it. Do

not drop cover (3).
2. Remove bolts (1) (5 used), and washers (2) (5 used).
Remove cover (3).

j : 17 mm

W3-10-1-1
 SECTION 3 UPPERSTRUCTURE
Group 10 Shockless Valve

3
WDEE-03-10-001

5. Remove bolts, washers (1) (2 used). Remove bracket

(2).

j : 17 mm
6. Remove the adapters with shockless valve (3)
attached if necessary.

W3-10-1-2
 SECTION 3 UPPERSTRUCTURE
Group 10 Shockless Valve

3
WDEE-03-10-001

Installation
1. Install all removed adapters to shockless valve (3).
2. Install bracket (2) with bolts, washers (1) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-10-1-3
 SECTION 3 UPPERSTRUCTURE
Group 10 Shockless Valve

1, 2

WDEE-03-08-007 3 WDEE-03-08-005

3. Install shockless valve (7) with bolts, washers (5) (4 5. Bleed air from the hydraulic system. (Refer to W1-
used). 4-1.)

j : 17 mm IMPORTANT: Check the hydraulic oil level. Start the

engine and check for any oil leaks.
m : 50 N·m (5 kgf·m, 37 lbf·ft) 6. Install cover (3) with washers (2) (5 used), and bolts
4. Connect hoses (6) (11 used) to shockless valve (7). (1) (5 used).

j : 17 mm j : 17 mm

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-10-1-4
 SECTION 3 UPPERSTRUCTURE
Group 10 Shockless Valve

Structure of Shockless Valve

1 3 4 5
A

C
B B

2
17

17

A
C

6 7 8 9 10 11 12

13
Section B-B View A-A

14 15 16

Section D-D (5 places)

Detail C
WBAT-06-01-084

W3-10-2-1
 SECTION 3 UPPERSTRUCTURE
Group 10 Shockless Valve

No. Part Name Q’ty Wrench Size Tightening Torque Remark

(mm) N·m (kgf·m) (lbf·ft)
1 Flange Bolt 4 j : 14 49±0.2 (5±0.02) (3.6±0.1)
2 Socket Bolt 2 l:5 6.9±0.3 (0.7±0.03) (5.1±0.2)
3 Body 1
4 Packing 1
5 Body 1
6 Cover 1
7 Stopper 1
8 O-Ring 1
9 Spring 1
10 Spring Seat 1
11 Spool 1
12 Spring 1
13 Filter 1
14 Shuttle 5
15 Spring 5
16 Steel Ball 6
17 Socket Bolt 2 l:5 6.9±0.3 (0.7±0.03) (5.1±0.2)

W3-10-2-2
 SECTION 3 UPPERSTRUCTURE
Group 10 Shockless Valve

Removal and Installation of Swing Shockless

Valve

1, 2

3 WDEE-03-08-005 WDEE-03-08-006
5 6

IMPORTANT: The hose and pipe contain hydraulic 3. Disconnect hoses (6) (4 used) from swing shockless
oil. When removing the hose and pipe, receive oils valve (7).
with a container in order to avoid spilling oils.
j : 17 mm
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition, 4. Remove bolts, washers (5) (3 used). Remove swing
attach an identification tag onto the connectors, shockless valve (7).
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which j : 17 mm
secure the hoses have been removed.

Removal
1. Swing the upperstructure by 90 degrees and set the
machine position for inspection and maintenance.
(Refer to W1-6-1.)

dCAUTION: Bleed air from hydraulic oil tank.

(Refer to W1-4-1.)

dCAUTION: Remove cover (3) while holding it. Do

not drop cover (3).
2. Remove bolts (1) (4 used), and washers (2) (4 used).
Remove cover (3).

j : 17 mm

W3-10-3-1
 SECTION 3 UPPERSTRUCTURE
Group 10 Shockless Valve

WDEE-03-10-002

5. Remove bolts, washers (1) (2 used). Remove bracket

(2).

j : 17 mm
6. Remove the adapters with swing shockless valve (3)
attached if necessary.

W3-10-3-2
 SECTION 3 UPPERSTRUCTURE
Group 10 Shockless Valve

WDEE-03-10-002

Installation
1. Install all removed adapters to swing shockless
valve (3).
2. Install bracket (2) with bolts, washers (1) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-10-3-3
 SECTION 3 UPPERSTRUCTURE
Group 10 Shockless Valve

1, 2

WDEE-03-08-006
3 WDEE-03-08-005
5 6

3. Install swing shockless valve (7) with bolts, washers 5. Bleed air from the hydraulic system. (Refer to W1-
(5) (3 used). 4-1.)

j : 17 mm IMPORTANT: Check the hydraulic oil level. Start the

engine and check for any oil leaks.
m : 50 N·m (5 kgf·m, 37 lbf·ft) 6. Install cover (3) with washers (2) (4 used), and bolts
4. Connect hoses (6) (4 used) to swing shockless valve (1) (4 used).
(7).
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

W3-10-3-4
 SECTION 3 UPPERSTRUCTURE
Group 10 Shockless Valve

Structure of Swing Shockless Valve

Section D
1 2

B D
Section B

18
A
17
3
16
15
Orifice
4

14 5
C C
13 6
7
12 8
Section C
11 9

10

Section A
Orifice WCEB-02-10-001

W3-10-4-1
 SECTION 3 UPPERSTRUCTURE
Group 10 Shockless Valve

No. Part Name Q’ty Wrench Size Tightening Torque Remark

(mm) N·m (kgf·m) (lbf·ft)
1 Check Valve 1
2 Retaining Ring 1
3 Body 1
4 Steel ball 2
5 O-ring 2
6 Plug 2
7 Spring 2
8 O-ring 2
9 Plug 2 9.8 (1) (7)
10 Plug 2 8.8 (0.9) (6)
11 Plug 2 48.5 (4.9) (36)
12 O-ring 2
13 Spring 2
14 Plunger 2
15 Ring 2
16 Spring 2
17 O-ring 2
18 Plug 2 48.5 (4.9) (36)

W3-10-4-2
SECTION 4

UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing
Removal and Installation of Swing Bearing..........W4-1-1-1
Disassembly of Swing Bearing...................................W4-1-2-1
Assembly of Swing Bearing.........................................W4-1-2-4
Group 2 Travel Device
Removal and Installation of Travel Device.............W4-2-1-1
Disassembly of Travel Reduction Gear....................W4-2-2-1
Assembly of Travel Reduction Gear..........................W4-2-2-4
Disassembly of Travel Motor.......................................W4-2-3-1
Assembly of Travel Motor............................................W4-2-3-4
Disassembly of Brake Valve.........................................W4-2-4-1
Assembly of Brake Valve...............................................W4-2-4-4
Precautions for Using Floating Seal.........................W4-2-5-1
Group 3 Center Joint
Removal and Installation of Center Joint...............W4-3-1-1
Disassembly of Center Joint........................................W4-3-2-1
Assembly of Center Joint.............................................W4-3-2-3
Replacement of Body....................................................W4-3-2-6
Group 4 Track Adjuster
Removal and Installation of Track Adjuster...........W4-4-1-1
Disassembly of Track Adjuster....................................W4-4-2-1
Assembly of Track Adjuster.........................................W4-4-2-5
Group 5 Front Idler
Removal and Installation of Front Idler...................W4-5-1-1
Disassembly of Front Idler...........................................W4-5-2-1
Assembly of Front Idler.................................................W4-5-2-4
Precautions for Using Floating Seal.........................W4-5-3-1
Group 6 Upper and Lower Rollers
Removal and Installation of Upper Roller..............W4-6-1-1
Removal and Installation of Lower Roller..............W4-6-2-1
Disassembly of Lower Roller.......................................W4-6-3-1
Assembly of Lower Roller.............................................W4-6-3-3
Precautions for Using Floating Seal.........................W4-6-4-1
Group 7 Track
Removal and Installation of Track.............................W4-7-1-1
Group 8 Blade Cylinder
Removal and Installation of Blade Cylinder..........W4-8-1-1
Disassembly of Blade Cylinder...................................W4-8-2-1
Assembly of Blade Cylinder.........................................W4-8-2-4

DEEW-4-1
(Blank)

DEEW-4-2
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

Removal and Installation of Swing Bearing

1 2 3

a 4
a- Matching Mark

WDAD-04-01-002 W105-03-01-002

Before removing and installing the swing bearing, the

upperstructure must be removed first. (Refer to W3-3-1.)
Therefore, the procedure starts on the premise that the
upperstructure has already been removed here.

Removal
1. Put matching marks (a) on inner race (3) of swing
bearing (1) and track frame (4).
2. Remove knock pin (2).
3. Remove bolts (5) (24 used).

j : 24 mm

W4-1-1-1
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

ST 0050

1
W110-03-01-004

dCAUTION:
lb)
Swing bearing (1) weight: 91 kg (205

4. Install the special tools (ST 0050) (3 used) to swing

bearing (1). Attach the wire ropes onto the special
tools (ST 0050) (3 used). Hoist swing bearing (1).
Remove swing bearing (1).

fNOTE: THREEBOHD #1102 has been applied on the

mating surface.

W4-1-1-2
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

WDEA-04-01-002

Detail A
2
WDAD-04-01-002

Installation
a
1. Clean the mounting surfaces of track frame (2) and
swing bearing (1).
2. Apply THREEBOND #1102 onto the swing bearing
(1) mounting surface of track frame (2).
WDEA-04-01-003

a- THREEBOND Applying
Surface

W4-1-1-3
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

1 2

ST 0050

1 W110-03-01-004

b e

a 3 d
a- Matching Mark

WDAD-04-01-002

10 º
c
9º
dCAUTION:
lb)
Swing bearing (1) weight: 91 kg (205

3. Install the special tools (ST 0050) (3 used) to swing

bearing (1). Attach the wire rope onto the special b
tools (ST 0050) (3 used). Hoist swing bearing (1). WDEA-04-01-001
IMPORTANT: If matching marks (a) do not fit, the soft
zone position of inner race will be dislocated.
4. Fit matching marks (a) on track frame (3) and inner
race (2) of swing bearing (1). b- Position for Grease Fitting
c- Soft Zone Marking Position
d- Position for Plug
e- Front Side

W4-1-1-4
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

1 3

1
2

WDAD-04-01-002

a d

W105-03-01-002

5. Install swing bearing (1) with bolts (2) (24 used).

e
j : 24 mm 11.8 º

10 º
m : 270 N·m (27 kgf·m, 200 lbf·ft)
b
IMPORTANT: Check the position to install knock pin 9º
(3).
IMPORTANT: Check the direction to install knock pin
(3).
a
6. Apply THREEBOND #1102 onto knock pin (3). Install
knock pin (3) by using a plastic hammer with taper WDEA-04-01-001
part (f ) up.

f a- Position for Grease Fitting

b- Soft Zone Marking Position
c- Position for Plug
d- Front Side
g e- Knock Pin Mounting Position

WDEA-03-10-018

f- Taper Part
g- Up

W4-1-1-5
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

a b 1

5 mm

W175-03-01-002

a- Swing Bearing b- Grease Level

7. After installing swing bearing (a), add grease

(Alvania EP2 or equivalent) to the gear part of swing
bearing (a). Add grease (Alvania EP2 or equivalent)
to grease bath (2) until pinion (1) of the swing
device is 5 mm (0.2 in) under grease.

fNOTE: Grease amount: 4.4+10 L (1.2+0.30 US gal)

W4-1-1-6
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

Disassembly of Swing Bearing

1 2 3

8 7 6 5

W178-02-11-193

7 8

W178-02-11-194

1- Outer Race 4- Plug 7- Inner Race

2- Seal 5- Seal 8- Support (79 Used)
3- Pin 6- Ball (79 Used) 9- Grease Fitting (2 Used)

W4-1-2-1
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

Disassembly of Swing Bearing 3. Install bolt (10) to the screw hole (M8, Pitch 1.25
mm) of plug (4). Tap or pull bolt (10) and remove
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
plug (4) from outer race (1).

such as goggles, helmets, etc in order to prevent

personal injury.
1. Grind off the crimped part of pin (3) by using a
1
grinder. Tap the bottom side of pin (3) of plug (4) by
using a bar and a hammer. Remove pin (3) of plug
(4).
3
4

4
7

W178-02-11-196
10

dCAUTION: Swing bearing weight: 91 kg (205 lb)

W178-02-11-195 4. Place inner race (7) of the swing bearing on a
wooden block by using the special tool (ST 0050).
Hoist outer race (1) horizontally. Hold outer race (1).
2. Thread hole (a) of plug (4) by using a tap (M8, Pitch
1.25 mm).

WJAA-04-01-002

a- Hole

W4-1-2-2
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

5. Remove balls (6) (79 used) and supports (8) (79

used) from the plug (4) hole while rotating outer
race (1).

1
2

11 7

6 5
W178-02-11-197

12

8
W178-02-11-198

fNOTE: Remove ball (6) by using magnet (11). Use wire

(12) and remove support (8).
6. Remove seals (2, 5) from outer race (1) and inner
race (7) by using a scrapper.

W4-1-2-3
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

Assembly of Swing Bearing

1 2 3

8 7 6 5

W178-02-11-193

7 8

W178-02-11-194

1- Outer Race 4- Plug 7- Inner Race

2- Seal 5- Seal 8- Support (79 Used)
3- Pin 6- Ball (79 Used) 9- Grease Fitting (2 Used)

W4-1-2-4
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

Assembly of Swing Bearing

dCAUTION: Swing bearing weight: 91 kg (205 lb) dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
1. Install special tools (ST 0050) (3 used) to outer race
(1). Attach wire ropes onto special tools (ST 0050) such as goggles, helmets, etc in order to prevent
(3 used). Hoist the swing bearing horizontally. Align personal injury.
outer race (1) and inner race (7) coaxially. 2. Install plug (4) to outer race (1) by using a hammer.
Secure plug (4) to outer race (1) with pin (3).
Apply grease onto balls (6) (79 used) and supports
(8) (79 used). Crimp the head of pin (3) by using a punch.
Install balls (6) (79 used) and supports (8) (79 used)
from the plug (4) hole by using a round bar while
turning outer race (1). Install the balls and the
supports alternately. 3

1
2

4
7
1

6 W178-02-11-201

3. Degrease the groove part for seals (2, 5) completely.

5 Apply THREEBOND #1530 onto outer race (1) and
W178-02-11-199 inner race (7). Install seals (2, 5) to outer race (1) and
inner race (7).
4. Add grease (Alvania EP2 or equivalent) to the swing
bearing through grease fittings (9) (2 used). At this
time, add grease while turning outer race (1).

fNOTE: Grease amount: 0.2 L (0.21 US qt)

W178-02-11-200

W4-1-2-5
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

(Blank)

W4-1-2-6
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Removal and Installation of Travel Device

7, 8 6
1 4, 5

W1P1-03-02-001 W1P1-03-02-002
2 9

Removal 4. Disconnect hoses (1) (2 used).

IMPORTANT: The hose and pipe contain hydraulic j : 36 mm
oil. When removing the hose and pipe, receive oils
with a container in order to avoid spilling oils. 5. Disconnect hose (9).
IMPORTANT: Cap the open ends in case the hoses j : 17 mm
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors, 6. Disconnect hose (2).
hoses, and pipes for assembling. Connect the j : 19 mm
hoses and install the clips in case the clips which
secure the hoses have been removed. dCAUTION:
lb)
Travel device (3) weight: 110 kg (245

Removal 7. Attach nylon slings onto travel device (3). Hoist and
1. Set the machine position for inspection and hold travel device (3). Remove bolts (4) (12 used)
maintenance. (Refer to W1-6-1.) and washers (5) (12 used). Hoist and remove travel
device (3).
dCAUTION: Bleed air from the hydraulic oil tank.
(Refer to W1-4-1.) j : 24 mm
2. Disconnect the track. (Refer to W4-7-1.) fNOTE: LOCTITE #262 has been applied on bolt (4).
3. Remove bolts (8) (5 used) and washers (7) (5 used). 8. Remove the adapters with travel device (3) attached
Remove cover (6). if necessary.

j : 22 mm 9. Remove other travel device in the same way as step

2 to step 8.

W4-2-1-1
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

7, 8 6
1 4, 5

W1P1-03-02-001 W1P1-03-02-002
2 9

Installation 6. Connect the track. (Refer to W4-7-1.)

1. Install all removed adapters to travel device (3). 7. Install other travel device in the same way as step 1
to step 6.
dCAUTION:
lb)
Travel device (3) weight: 110 kg (245
8. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
2. Attach nylon slings onto travel device (3). Hoist
travel device (3). Apply LOCTITE #262 onto bolt (4). IMPORTANT: Check the hydraulic oil level. Start the
Install travel device (3) with washers (5) (12 used) engine and check for any oil leaks. In order to
and bolts (4) (12 used). prevent the travel motor from seizing, perform
the break-in operation after installing.
j : 24 mm
Condition: 1. Engine speed: Slow idle speed
m : 310 N·m (31 kgf·m, 230 lbf·ft) 2. Travel mode switch: Slow speed
3. Connect hose (2). 3. Forward and reverse round-trip operation (0.5
to 1 m, 0.5 to 1 yd) more than five times
j : 19 mm 9. Install cover (6) with washers (7) (5 used) and bolts
m : 30 N·m (3 kgf·m, 22 lbf·ft) (8) (5 used).

4. Connect hose (9). j : 22 mm

j : 17 mm m : 140 N·m (14 kgf·m, 103 lbf·ft)

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 10. Install other cover in the same way as step 9.

5. Connect hoses (1) (2 used).

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

W4-2-1-2
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Travel Reduction Gear

33
6

12

4
32
2, 3

20
9 22
11
10
8
23
18 30 27
19 28
24
29
17
31 16

7 15

14

25
21
13 WDEB-04-02-003
26
1- Travel Motor 10- Ring (4 Used) 19- Sun Gear 28- Needle Bearing (3 Used)
2- Floating Seal 11- Needle Bearing (4 Used) 20- Shaft 29- Thrust Plate (3 Used)
3- Floating Seal 12- Ring Gear 21- Stopper Pin 30- Carrier
4- Ball Bearing 13- O-Ring 22- Thrust Plate 31- Lock Plate
5- Ring 14- Ring 23- Retaining Ring (3 Used) 32- Bolt (16 Used)
6- Ball Bearing 15- Plug (3 Used) 24- Ring (3 Used) 33- Sprocket
7- Bearing Nut 16- Thrust Plate 25- Cover
8- Thrust Plate (2 Used) 17- Flash Bolt (4 Used) 26- Thrust Plate
9- Planetary Gear (4 Used) 18- Retaining Ring 27- Planetary Gear (3 Used)

W4-2-2-1
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Travel Reduction Gear

dCAUTION: There may be pressure accumulated

inside of the travel device. Loosen the air bleed
7. Remove flash bolts (17) (4 used) from thrust plate
(16). Remove thrust plate (16) from travel motor (1).
plug slowly. Release any remaining pressure. 8. Remove planetary gears (9) (4 used), needle
Remove the drain plug and drain gear oil. If the air bearings (11) (4 used), rings (10) (4 used), and thrust
bleed plug is loosened suddenly, the plug may be plates (8) (2 used) from travel motor (1).
fly out and gear oil may gush out. Keep body and
face away from the plug. 9. Remove lock plate (31) from bearing nut (7).
Remove bearing nut (7) from travel motor (1).
1. Place travel motor (1) with the brake valve side
down.
dCAUTION: Ring gear (12) weight: 20 kg (45 lb)
2. Remove plugs (15) (3 used) from cover (25). Drain 10. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
gear oil from the travel reduction gear. the sprocket (33) mounting holes of ring gear (12).
Attach nylon slings onto the eyebolts. Hoist and
l : 10 mm hold ring gear (12).
Amount of oil: 1.2 L (1.27 USqt) 11. Remove ring gear (12) from travel motor (1) by
3. Remove ring (14) from ring gear (12) by using a using a plastic hammer.
screwdriver. Remove cover (25) from ring gear (12). IMPORTANT: Handle floating seal (3) with care.
Remove O-ring (13) from cover (25). (Refer to W4-2-5.)
4. Remove shaft (20) and the carrier (30) assembly 12. Remove floating seal (3) from ring gear (12).
from ring gear (12).
13. Remove ball bearings (4, 6) from ring gear (12) by
5. Remove sun gear (19) from travel motor (1). Remove using a bar and a plastic hammer. Remove ring (5)
retaining ring (18) from sun gear (19). from ring gear (12).
IMPORTANT: Handle floating seal (2) with care.
dCAUTION: Sprocket (33) weight: 24 kg (53 lb)
(Refer to W4-2-5.)
6. Remove bolts (32) (16 used) from sprocket (33).
Attach nylon slings onto sprocket (33). Hoist and 14. Remove floating seal (2) from travel motor (1).
remove sprocket (33) from ring gear (12).

j : 24 mm

fNOTE: LOCTITE #262 has been applied on bolt (32).

W4-2-2-2
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

IMPORTANT: Do not remove rings (24) (3 used) in

carrier (30) unless necessary.
15. Remove retaining rings (23) (3 used) and thrust
plate (26) from carrier (30).
16. Remove planetary gears (27) (3 used), needle
bearings (28) (3 used), thrust plates (29) (3 used),
and thrust plate (22) from carrier (30).

W4-2-2-3
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Travel Reduction Gear

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

31 30 29 28 27

32

33
WBAT-06-01-079

1- Travel Motor 10- Ring (4 Used) 19- Sun Gear 28- Needle Bearing (3 Used)
2- Floating Seal 11- Needle Bearing (4 Used) 20- Shaft 29- Thrust Plate (3 Used)
3- Floating Seal 12- Ring Gear 21- Stopper Pin 30- Carrier
4- Ball Bearing 13- O-Ring 22- Thrust Plate 31- Lock Plate
5- Ring 14- Ring 23- Retaining Ring (3 Used) 32- Bolt (16 Used)
6- Ball Bearing 15- Plug (3 Used) 24- Ring (3 Used) 33- Sprocket
7- Bearing Nut 16- Thrust Plate 25- Cover
8- Thrust Plate (2 Used) 17- Flash Bolt (4 Used) 26- Thrust Plate
9- Planetary Gear (4 Used) 18- Retaining Ring 27- Planetary Gear (3 Used)

W4-2-2-4
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Travel Reduction Gear

IMPORTANT: Before assembling, apply gear oil onto
dCAUTION: Sprocket (33) weight: 24 kg (53 lb)
7. Apply LOCTITE #262 onto bolts (32) (16 used).
parts in order to prevent them from seizing.
8. Install sprocket (33) to ring gear (12) with bolts (32)
dCAUTION: Ring gear (12) weight: 20 kg (45 lb)
(16 used).
1. Install ring (5) to ring gear (12). Install ball bearings
(4, 6) to ring gear (12) by using a bar and a plastic j : 24 mm
hammer.
m : 270 N·m (27 kgf·m, 200lbf·ft)
IMPORTANT: Handle floating seal (3) with care.
(Refer to W4-2-5.) 9. Install bearing nut (7) to travel motor (1).
2. Install floating seal (3) to ring gear (12).  After tightening bearing nut (7) with the force (170
N·m (17 kgf·m, 125 lbf·ft)), rotate sprocket (33) both
dCAUTION: Travel motor (1) weight: 41 kg (91 lb) clockwise and counterclockwise by 4 to 5 turns. Tap
3. Place travel motor (1) with the brake valve side bearing nut (7) by using a hammer and tighten it
down. with the force (170 N·m (17 kgf·m, 125 lbf·ft)) again.
Repeat these works two times.
IMPORTANT: Handle floating seal (2) with care.
 Check the positions where the claws of lock plate
(Refer to W4-2-5.)
(31) mesh with the outer surface of bearing nut (7).
4. Install floating seal (2) to travel motor (1). Install lock plate (31).
5. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to  If the claws of lock plate (31) do not mesh correctly,
the sprocket (33) mounting holes of ring gear (12). tighten bearing nut (7) again.
Attach nylon slings onto the eyebolts. Hoist and fit  Install thrust plates (8) (2 used) to other two places.
ring gear (12) to travel motor (1). 10. Install rings (10) (4 used), needle bearings (11) (4
used), and planetary gears (9) (4 used) to travel
6. Install the ring gear (12) assembly to travel motor (1) motor (1).
by using a bar and a plastic hammer.
11. Install thrust plate (16) to travel motor (1) with flash
bolts (17) (4 used).

m : 21 N·m (2.1 kgf·m, 15.5 lbf·ft)

W4-2-2-5
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

12. Install retaining ring (18) to sun gear (19). Install sun
gear (19) to travel motor (1).
13. Install thrust plate (22) to carrier (30).
14. Install thrust plates (29) (3 used), needle bearings
(28) (3 used), planetary gears (27) (3 used), and
thrust plate (26) to carrier (30).
15. Secure thrust plate (26) to carrier (30) with retaining
rings (23) (3 used).
16. Install the carrier (30) assembly to sun gear (19).
17. Fit the spline of planetary gears (27) (3 used) to
travel motor (1). Install shaft (20).
18. Apply grease onto O-ring (13). Install O-ring (13) to
cover (25).
19. Install cover (25) to ring gear (12) with ring (14).
20. Add gear oil to the travel reduction gear through
the holes of plugs (15) (3 used).
Amount of gear oil: 1.2 L (1.27 USqt)
21. Install plugs (15) (3 used) to cover (25).

l : 10 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-2-2-6
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Travel Motor

4 12

17

16

13
14

15 24 18

10
7
9
11

3
25

19
20
19
20
19
20
21

6
22
2
5
23
26
WDEB-04-02-004

1- *Spring Pin 9- Retainer 17- Piston 25- Roller Bearing

2- Socket Bolt (6 Used) 10- Swash Plate 18- Spring (6 Used) 26- Brake Valve Assembly
3- Valve Plate 11- Bushing 19- Friction Plate (3 Used)
4- O-Ring 12- Housing 20- Plate (3 Used)
5- Disc Spring 13- Ball (2 Used) 21- O-Ring
6- Brake Piston 14- Shaft 22- O-Ring
7- Plunger Assembly (9 Used) 15- Oil Seal 23- O-Ring
8- Rotor 16- Ball Bearing 24- O-Ring

fNOTE: As for the item with mark *, refer to W4-2-3-4.

W4-2-3-1
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Travel Motor

IMPORTANT: When removing brake valve assembly
(26) from the motor, valve plate (3) and the outer
race of roller bearing (25) may be removed with
the brake valve side. Do not to drop valve plate (3)
and the outer race of roller bearing (25).
IMPORTANT: The open end of brake valve assembly
(26) is the seat surface for pressure oil when
releasing the parking brake. When placing brake
valve assembly (26) with the open part down, do 26
not to damage the seat surface.

dCAUTION:
(91 lb)
Travel motor weight: Approx. 41 kg

1. Place the travel motor with brake valve assembly

(26) up. Remove bolts (2) (6 used). Remove brake
valve assembly (26) from housing (12). Remove
O-rings (4, 24) from housing (12).
a
l : 12 mm a- Seat Surface
2. Remove valve plate (3), the outer race of roller WDEA-04-02-007
bearing (25), and O-ring (23) from brake valve
assembly (26).
3. Remove disc spring (5), rotor (8), springs (18) (6
used), bushing (11), retainer (9), and plunger
assemblies (7) (9 used) from housing (12) in
sequence.

dCAUTION: When removing brake piston (6) by

using air, hold brake piston (6) with a cloth in
order not to fly out.
4. Apply air 98 to 294 kPa (1 to 3 kgf/cm2, 14 to 43 psi)
or less to the parking brake releasing oil passage.
Raise and remove brake piston (6). Remove O-rings
(21, 22) from brake piston (6).
5. Remove plates (20) (3 used) and friction plates (19)
(3 used).
6. Remove swash plate (10).
7. Remove balls (13) (2 used) and piston (17) by using
a magnet.

W4-2-3-2
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

dCAUTION:
(49 lb)
Housing (12) weight: Approx. 22 kg dCAUTION: When shaft (14) is removed from ball
bearing (16), be sure to avoid dropping it.
8. Place housing (12) horizontally. Remove shaft (14) IMPORTANT: If the shaft (14) drops off, the seal
and bearing (16) while tap the inner surface of contact surface of shaft (14) may be damaged.
spline side of shaft (14) by using a bar and a plastic 11. Remove ball bearing (16) remained in shaft (14).
hammer. Place the inner race of ball bearing (16) on a vise.
9. Remove oil seal (15) from the shaft (14) mounting Tap and remove shaft (14) from ball bearing (16) by
hole side of housing (12) by using a screwdriver. using a plastic hammer.

fNOTE: THREEBOND #1104 or #1215 has been applied a

on the outer surface of oil seal (15). Oil seal (15) can not
be reused when it has been removed.
16
dCAUTION: When shaft (14) is removed from the
inner race of roller bearing (25), be sure to avoid
dropping it. 14
IMPORTANT: If shaft (14) drops off, the seal contact
surface of shaft (14) may be damaged.
IMPORTANT: Take care not to damage the inner race
of roller bearing (25).
10. Remove the inner race of roller bearing (25)
remained in shaft (14). Place the flange of the inner
race on a vise. Tap and remove shaft (14) from the
a- Bar
inner race by using a bar and a plastic hammer.
WDEA-04-02-009

14

a- Bar b- Inner Race

WDEA-04-02-008

W4-2-3-3
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Travel Motor

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

13

14

15

16

17

26 25 24 23 22 21 20 19 18
WBAT-06-01-080

a- Parking Brake Releasing Oil

Passage

1- Spring Pin 9- Retainer 17- Piston 25- Roller Bearing

2- Socket Bolt (6 Used) 10- Swash Plate 18- Spring (6 Used) 26- Brake Valve Assembly
3- Valve Plate 11- Bushing 19- Friction Plate (3 Used)
4- O-Ring 12- Housing 20- Plate (3 Used)
5- Disc Spring 13- Ball (2 Used) 21- O-Ring
6- Brake Piston 14- Shaft 22- O-Ring
7- Plunger Assembly (9 Used) 15- Oil Seal 23- O-Ring
8- Rotor 16- Ball Bearing 24- O-Ring

W4-2-3-4
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Travel Motor

IMPORTANT: The lip mounting surface of oil seal (15)
dCAUTION:
(49 lb)
Housing (12) weight: Approx. 22 kg
is located on the mounting side of ball bearing
(16) in shaft (14). Be sure not to damage it.
1. Place housing (12) with the brake valve assembly
(26) mounting surface up. 3. Install ball bearing (16) to the inner spline side of
shaft (14).
IMPORTANT: Apply THREEBOND #1104 or #1215
onto the outer surface of oil seal (15). fNOTE: Attach the pipe fitting the outer diameter of
IMPORTANT: Install the special tools in order not to shaft (14) onto the inner race of the bearing. Tap them
damage oil seal (15). ST 2891, ST 2892 evenly.
2. Clean the mounting parts of oil seal (15) in housing
(12). Apply THREEBOND #1104 or #1215 onto the
outer surface of oil seal (15). Install oil seal (15)
to housing (12) by using the special tools. After
installing, apply grease onto the inner surface of oil
seal (15).

fNOTE: Use OCEAN #7 for the grease.

12

15
a- ST 2891 b- ST 2892
WDEA-04-02-010

W4-2-3-5
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

IMPORTANT: Be sure to use the special tool for the

inner race of roller bearing (25). ST 7599
IMPORTANT: Install the inner race of roller bearing
(25) with the flange down.
4. Install the inner race of roller bearing (25) to shaft
(14) by using the special tool.

14
c- ST 7599 d- Inner Race
WDEA-04-02-011

W4-2-3-6
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

IMPORTANT: Fit the taper side on the outer surface

d CAUTION: Housing (12) weight: Approx. 22 kg
(49 lb)
of retainer (9) to bushing (11).
9. Install springs (18) (6 used), bushing (11), retainer
5. Install shaft (14) to housing (12) while tapping shaft (9), and plunger assemblies (7) (9 used) to rotor (8)
(14) by using a plastic hammer. At this time, be sure in sequence.
not to tap the inner race of roller bearing (25).
IMPORTANT: Insert piston (17) into the piston hole
with the shoulder side down. 9

6. Install piston (17) and balls (13) (2 used) to housing

(12).

fNOTE: At first, apply grease onto ball (13) in order to

prevent it from down. 11
7. Install swash plate (10) to housing (12). Fit the WDEA-04-02-012
hollows (2 places) on the back side of swash plate
(10) to ball (13). IMPORTANT: When installing rotor (8), take care not
to drop spring (18).
dCAUTION: Housing (12) weight: 24 kg (53 lb)
10. Install rotor (8) which has been installed at step 9 to
8. Place housing (12) horizontally with the parking shaft (14).
brake release oil passage down. At this time, check if
swash plate (10) is located correctly.

fNOTE: If housing (12) is placed with the parking brake

releasing oil passage topside, the thick part of swash
plate (10) becomes topside and swash plate (10) may be
located off the center.

W4-2-3-7
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

IMPORTANT: Install disc spring (5) so that the outer

d CAUTION: Housing (12) weight: Approx. 28 kg
(62 lb)
surface of disc spring (5) can come into contact
with brake piston (6).
11. Place housing (12) with the brake valve assembly 14. Install disc spring (5) to housing (12).
(26) mounting surface up.
15. Install O-rings (4, 24) to housing (12).
IMPORTANT: Install plates (20) (3 used) and friction
plates (19) (3 used) alternately. Be sure to install 16. Add hydraulic oil to housing (12).
friction plate (19) first.
12. Install friction plates (19) to the groove of rotor
fNOTE: Amount of hydraulic oil: 0.5 L (0.53 USqt)
Install O-ring (23) to brake valve assembly (26).
(8) and plates (20) to the groove of housing (12)
alternately. (Plate : 3 used, Friction Plate : 3 used) IMPORTANT: Install the outer race of roller bearing
(25) with the stamped mark up.
IMPORTANT: Install brake piston (6) with the notch
(1 place) on brake piston (6) facing to the piston 18. Install the outer race of roller bearing (25) to brake
(17) operation oil passage side. valve assembly (26).
IMPORTANT: Brake piston (6) keeps floating due to
O-rings in the outer surface. Evenly push brake
piston (6) by hands. Do not push brake piston (6)
by using a hammer excessively.
13. Install O-rings (21, 22) to brake piston (6). Install
brake piston (6) to housing (12).

a 6 b

17

WDEB-04-02-006
a- Piston Operation Oil Passage b- Notch

W4-2-3-8
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

IMPORTANT: Install valve plate (3) with the thrust

side of the brass up.
IMPORTANT: Apply grease onto the back side of
valve plate (3) in order not to prevent it from
dropping down.
19. Fit spring pin (1) of brake valve assembly (26) to
valve plate (3). Install valve plate (3) to brake valve
assembly (26).
IMPORTANT: Take care not to drop and damage
valve plate (3) when installing.
20. Fit the holes for bolt (2). Install brake valve assembly
(26) to housing (12). At this time, as brake piston
(6) is not completely pushed in housing (12), the
clearance between brake valve assembly (26) and
housing (12) is approx. 10 mm (0.39 in). Install brake
valve assembly (26) while pushing brake piston (6)
into and tightening socket bolts (2) (6 used) evenly.

l : 12 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft)

W4-2-3-9
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

(Blank)

W4-2-3-10
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Brake Valve

8
6
5
10
4

3
7

3
4
5
6

20
25
24
19
17 11 18
21 16 12
14
23
15 13

22

WDEB-04-02-005

1- Valve Casing 9- Adapter 17- Spring 25- Seat Plug

2- Spool 10- Spool 18- Plug
3- Stopper (2 Used) 11- Poppet 19- O-Ring
4- Spring (2 Used) 12- Spring 20- Poppet (2 Used)
5- O-Ring (2 Used) 13- Plug 21- Relief Valve Cartridge (2 Used)
6- Plug (2 Used) 14- O-Ring 22- O-Ring (2 Used)
7- Needle 15- Plug 23- Piston (2 Used)
8- O-Ring 16- O-Ring 24- Spring (2 Used)

W4-2-4-1
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Brake Valve

IMPORTANT: If placing the brake valve with the
travel motor mounting surface down, be sure not
to damage the seat surface.

a- Seat Surface a
WDEA-04-02-007

IMPORTANT: Do not disassemble relief valve

cartridge (21).
IMPORTANT: Do not pull out piston (23) on relief
valve cartridge (21). Otherwise, the O-ring in
piston (23) will be damaged when piston (23)
passes the cartridge (21) hole.
1. Remove the relief valve cartridge (21) assemblies (2
used) from valve casing (1). Remove springs (24) (2
used) and poppets (20) (2 used) from valve casing
(1) by using a magnet. Remove O-rings (22) (2 used)
from the relief valve cartridge (21) assemblies (2
used).

l : 12 mm
IMPORTANT: After removing plug (18), seat plug
(25) remains in the hole. Do not remove seat plug
(25) unless necessary. Seat plug (25) is fixed with
LOCTITE.
2. Remove plug (18) from valve casing (1). Remove
O-ring (19) from plug (18).

l : 6 mm
3. Remove plugs (6) (2 used) from valve casing (1).
Remove springs (4) (2 used) and stoppers (3) (2
used) from valve casing (1) in sequence. Remove
O-rings (5) (2 used) from plugs (6) (2 used).

j : 30 mm
4. Remove spool (2) through the holes where they
have been at step 3.
5. Remove plug (13) from valve casing (1). Remove
spring (12) and poppet (11) from valve casing (1) in
sequence. Remove O-ring (14) from plug (13).

l : 6 mm

W4-2-4-2
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

6. Remove plug (15) from valve casing (1). Remove

spring (17) and needle (7) from valve casing (1) in
sequence by using a magnet. Remove O-ring (16)
from plug (15).

fNOTE: It is impossible to remove spool (10) in needle (7)

to the direction of plug (15). Remove it at step 7.
l : 6 mm
7. Remove adapter (9) from valve casing (1). Remove
spool (10) from valve casing (1). Remove O-ring (8)
from adapter (9).

j : 19 mm

W4-2-4-3
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Brake Valve

1 2 3 4 5 6 7 8 9 10

25 24 23 22 21 20 19 18 17 16 15 14 13 12 11

WDEA-04-02-013

1- Valve Casing 9- Adapter 17- Spring 25- Seat Plug

2- Spool 10- Spool 18- Plug
3- Stopper (2 Used) 11- Poppet 19- O-Ring
4- Spring (2 Used) 12- Spring 20- Poppet (2 Used)
5- O-Ring (2 Used) 13- Plug 21- Relief Valve Cartridge (2 Used)
6- Plug (2 Used) 14- O-Ring 22- O-Ring (2 Used)
7- Needle 15- Plug 23- Piston (2 Used)
8- O-Ring 16- O-Ring 24- Spring (2 Used)

W4-2-4-4
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Brake Valve

IMPORTANT: If placing the brake valve with the 5. Install O-rings (5) (2 used), springs (4) (2 used), and
travel motor mounting surface down, be sure not stoppers (3) (2 used) to plugs (6) (2 used). Install
to damage the seat surface. plugs (6) (2 used) to valve casing (1).

j : 30 mm

m : 270 N·m (27 kgf·m, 200 lbf·ft)

6. Install O-ring (19) to plug (18). Install them to valve
casing (1).

l : 6 mm
a
a- Seat Surface m : 35 N·m (3.5 kgf·m, 26 lbf·ft)
WDEA-04-02-007

IMPORTANT: Do not insert spool (10) from the

direction of plug (15).
IMPORTANT: Insert the smaller part of spool (10) into
valve casing (1) first.
1. Install neelde (7) to the end of spool (10). Insert
spool (10) from the adapter (9) side in valve casing
(1). Install O-ring (8) to adapter (9). Install them to
valve casing (1).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

2. Install O-ring (16) and spring (17) to plug (15). Install
them to valve casing (1).

l : 6 mm

m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

3. Install O-ring(14) to plug (13). Install poppet (11),
spring (12), and plug (13) to valve casing (1).

l : 6 mm

m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

4. Insert spool (2) nearby the center of valve casing (1).

W4-2-4-5
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

7. Install springs (24) (2 used) to poppets (20) (2 used).

Insert poppets (20) (2 used) into the relief valve
cartridge (21) mounting holes on valve casing (1)
until poppets (20) (2 used) are hidden.

fNOTE: If inserting poppet (20) to the end, on the way

spring (24) may come off. Insert it with relief valve
cartridge (21) together at step 8.
8. Install O-rings (22) (2 used) to the relief valve
cartridge (21) assemblies (2 used). Install relief valve
cartridges (21) (2 used), poppets (20) (2 used), and
springs (24) (2 used), which have been installed at
step 7, to valve casing (1).

l : 12 mm

m : 240 N·m (24 kgf·m, 175 lbf·ft)

W4-2-4-6
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Precautions for Using Floating Seal 1

1. In general, replace the floating seal with a new one

after disassembling.
If the floating seal is required to be reused, follow
these procedures:
 Keep seal rings together as a matched set with seal
ring (1) surfaces together. Apply oil onto sliding W178-02-11-001
surface (e) of seal ring (1). 2
 Check sliding surface (e) of seal ring (1) for scuffing,
scoring, corrosion, deformation, or uneven wear.
Check the step part of seal ring (1).
 Check O-ring (2) 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.
 Clean the floating seal and seal mounting bores with a
cleaning solvent.
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air. c
 Clean seal ring (1) and O-ring (2) mounting bores. b
Check the bore surface for scuffing or scoring by d
touching the surface with finger.
 After installing the floating seal, check that O-ring (2) W178-02-11-002
is not twisted, and that it is installed correctly on seal
a- Correct c- Twist of O-Ring
ring (1).
b- Incorrect d- Bend of O-Ring
 After installing the floating seal, check that O-ring
(2) and seal ring sliding surface (e) is parallel with
f
seal mating surface (f ) by measuring the distances
(e) and (f ) at point (A) and (B), as illustrated. If these a b
A A
distances differ, correct O-ring (2) seating.

B B

A=B A≠B

W178-02-11-003

a- Correct e- Sliding Surface

b- Incorrect f- Seal Mating Surface

W4-2-5-1
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

(Blank)

W4-2-5-2
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Removal and Installation of Center Joint

2 3

WDEE-04-03-001
5 1

IMPORTANT: The hose and pipe contain hydraulic

oil. When removing the hose and pipe, receive oils
with a container in order to avoid spilling oils.
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Remove bolts, washers (1) (2 used).

j : 17 mm
3. Remove bolts, washers (3) (2 used). Remove cover
(2).

j : 17 mm
4. Remove bolts, washers (5) (2 used). Remove cover
(4).

j : 17 mm

W4-3-1-1
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

2, 17 2, 17, 18

2, 17, 18

1, 13

2, 19
15, 16

3, 14

5
WDEE-04-03-002
4 6 15, 16

5. Disconnect hoses (2) (4 used). 11. Disconnect hose (1).

j : 36 mm j : 17 mm
6. Remove elbows (17) (3 used), elbow (19), and 12. Remove elbow (13).
sockets (18) (2 used).
j : 19 mm
j : 27 mm
13. Remove bolts, washers (5) (2 used). Remove stopper
7. Disconnect hose (3). (8) and washers (6) (2 used).

j : 19 mm j : 19 mm
8. Remove adapter (14). 14. Remove boot cover (4).

j : 22 mm
9. Disconnect hoses (15) (2 used).

j : 27 mm
10. Remove adapters (16) (2 used).

j : 22 mm

W4-3-1-2
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

8 3 5 3 9

7
6
2
2

1 1 WDEB-04-03-004 WDEB-04-03-001

15. Disconnect hoses (1) (2 used). 21. Remove bolts, washers (5) (3 used). Remove center
joint (4).
j : 22 mm
16. Disconnect hoses (2) (4 used). fNOTE: LOCTITE #262 has been applied onto bolts (5) (3
used).
j : 32 mm j : 17 mm
17. Disconnect hose (8). 22. Remove the adapters with center joint (4) attached
if necessary.
j : 27 mm
18. Disconnect hose (9).

j : 22 mm
19. Disconnect hoses (3) (2 used).

j : 17 mm

dCAUTION: Center joint (4) weight: 32 kg (71 lb)

20. Install the adapters (A853144) (2 used) to the holes
of elbow (6) and socket (7) of center joint (4). Install
the special tool (ST 0243) to the adapters (A853144)
(2 used). Attach the nylon slings onto the special
tools (ST 0243) (2 used). Hoist and hold center joint
(4).

j : 27 mm

W4-3-1-3
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

8 3 5 3 9

7
6
2
2

1 1 WDEB-04-03-004 WDEB-04-03-001

Installation
1. Install all removed adapters to center joint (4) after 6. Connect hose (8).
removing center joint (4).
j : 27 mm
dCAUTION: Center joint (4) weight: 32 kg (71 lb)
m : 80 N·m (8 kgf·m, 59 lbf·ft)
2. Diagonally install the adapters (A853144) (2 used)
to the mounting holes (2 places) for elbow (6) and 7. Connect hoses (2) (4 used).
socket (7) on upper side of the center joint (4).
Install the special tool (ST 0243) to the adapters j : 32 mm
(A853144) (2 used). Attach the nylon slings onto the m : 140 N·m (14 kgf·m, 103 lbf·ft)
special tools (ST 0243) (2 used). Hoist center joint
(4). 8. Connect hoses (1) (2 used).

j : 27 mm j : 22 mm
3. Apply LOCTITE #262 onto bolts (5) (3 used). Install m : 40 N·m (4 kgf·m, 29.5 lbf·ft)
center joint (4) with bolts, washers (5) (3 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

4. Connect hoses (3) (2 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

5. Connect hose (9).

j : 22 mm

m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

W4-3-1-4
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

2, 17 2, 17, 18

2, 17, 18

1, 13

2, 19
15, 16

3, 14

5
WDEE-04-03-002
4 6 15, 16

9. Install boot cover (4). 16. Connect hose (3).

10. Install stopper (8) and washers (6) (2 used) with j : 19 mm
bolts, washers (5) (2 used).
m : 30 N·m (3 kgf·m, 22 lbf·ft)
j : 19 mm
17. Install elbows (17) (3 used), elbow (19), and sockets
m : 90 N·m (9 kgf·m, 66 lbf·ft) (18) (2 used).
11. Install elbow (13). j : 27 mm
j : 19 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft)
m : 30 N·m (3 kgf·m, 22 lbf·ft) 18. Connect hoses (2) (4 used).
12. Connect hose (1). j : 36 mm
j : 17 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 19. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
13. Install adapters (16) (2 used).
IMPORTANT: Check the hydraulic oil level. Start the
j : 22 mm engine and check for any oil leaks.
m : 40 N·m (4 kgf·m, 29.5 lbf·ft)
14. Connect hoses (15) (2 used).

j : 27 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

15. Install adapter (14).

j : 22 mm

m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

W4-3-1-5
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

2 3

WDEE-04-03-001
5 1

20. Install cover (4) with bolts, washers (5) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

21. Install cover (2) with bolts, washers (3) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

22. Install bolts, washers (1) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-3-1-6
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Disassembly of Center Joint

WDAD-04-03-007

1- Spindle 4- Bushing 7- Ring 10- Cover

2- Dust Seal 5- Oil Seal (8 Used) 8- O-Ring 11- Bolt, Washer (4 Used)
3- O-Ring 6- Body 9- Retaining Ring

W4-3-2-1
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Disassembly of Center Joint

IMPORTANT: For easy removal of oil seal (5), use the
d CAUTION: Center joint weight: 31 kg (69 lb) pins (2 used). Do not damage the seal groove.
1. Remove bolts and washers (11) (2 used) diagonally. 6. Remove oil seals (5) (8 used), O-ring (3), and dust
Install eyebolts (M10, Pitch 1.5 mm) (2 used) to the seal (2) from body (6).
bolts and washers (11) holes (2 places) of body (6).
Attach the nylon slings onto the eyebolts (2 used).
Hoist the center joint. Secure the center joint on a
workbench.

j : 17 mm
2. Put the matching marks at the mating part between
body (6) and spindle (1). Remove other bolts,
washers (11) (2 used). Remove cover (10) from body
(6).

j : 17 mm
3. Remove O-ring (8), retaining ring (9), and ring (7)
from body (6).
W178-02-11-240
4. Install the special tools (ST1033 and ST1020) to
body (6) with bolts, washers (11) (2 used).
IMPORTANT: Do not damage the seal surface.
j : 17 mm
7. When replacing bushing (4), weld four places on the
bushing (4) bore by using a welding bar. Shrink and
remove bushing (4).
ST 1020
11

ST 1033

W506-03-03-002

IMPORTANT: Do not damage the seal sliding surface

of spindle (1).
5. Remove spindle (1) from body (6).

W4-3-2-2
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Assembly of Center Joint

8
9
10
11

WDAD-04-03-008

1- Spindle 4- Bushing 7- Ring 10- Cover

2- Dust Seal 5- Oil Seal (8 Used) 8- O-Ring 11- Bolt, Washer (4 Used)
3- O-Ring 6- Body 9- Retaining Ring

W4-3-2-3
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Assembly of Center Joint

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Do not damage bushing (4).
onto parts in order to prevent them from seizing. IMPORTANT: The clearance between body (6) and
IMPORTANT: When assembling the seals, apply spindle (1) is approximately 0.1 mm. Insert body
grease (Apolloil Autolex C) onto the seals. Install (6) along axis straight and slowly. Do not damage
the seals to the grooves. the seal.
IMPORTANT: If bushing (4) has been removed, install IMPORTANT: Do not make a step on ring (7)
bushing (4) first. (Refer to W4-3-3-6.) mounting part (a).
IMPORTANT: Check the direction to install dust seal 3. Apply molybdenum disulfide on the sliding surface
(2). of bushing (4). Apply grease (Apolloil Autolex C)
1. Install dust seal (2) to body (6). onto the seal part. Place spindle (1) on a workbench.
Fit the matching marks made when disassembling
2 and install body (6) to spindle (1).

6 1
6
a

WDAD-04-03-004
a- Ring (7) Mounting Part

WDAD-04-03-003

2. Install O-ring (3) and oil seals (5) (8 used) to body (6).

W4-3-2-4
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

IMPORTANT: Install ring (7) with the chamfered

surface facing to the spindle (1) side.
4. Install ring (7) and retaining ring (9) to body (6).
1
9
7 6

WDAD-04-03-005

5. Install O-ring (8) to spindle (1).

6. Apply hydraulic oil onto sliding surface (a) of ring
(7). Install cover (10) to body (6) with bolts, washers
(11) (4 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

1
8 6

a WDAD-04-03-006

a- Ring (7) Sliding Part

W4-3-2-5
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Replacement of Body
ST 2770
IMPORTANT: When replacing body (6) with the new
one, the following procedures are required.
IMPORTANT: Before assembling, apply hydraulic oil 6
onto parts in order to prevent them from seizing.
IMPORTANT: Do not damage the inner surface of
bushing (4).
1. Clean body (6) and bushing (4). 4

2. Install bushing (4) to body (6) by using the special

tool (ST 2770) and a press.

fNOTE: Pushing force: 0.5 to 1.5 t (1110 to 3310 lb)

W178-02-11-242

W4-3-2-6
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Removal and Installation of Track Adjuster

b
a

W157-03-04-003 c d W1R7-03-04-001

a- Nut c- Thread Part

b- Spring d- Rod

Before removing and installing the track adjuster, the

tracks and front idler must be removed first. (Refer to W4-
5-1 and W4-7-1.) Therefore, the procedure starts on the
premise that the tracks and front idler have already been
removed here.

Removal

dCAUTION: Track adjuster (1) weight: 34 kg (75 lb)

dCAUTION: Track adjuster (1) may fly out due to
the spring force when removing track adjuster (1).
Do not stand in the same direction to remove track
adjuster (1) or where it may fly out. Particularly,
the spring force is always applied to the thread
part of the rod. If the rod and/or the threads are
damaged, metal fragments may fly out due to the
spring force .
1. Attach the nylon slings onto track adjuster (1). Hoist
and hold track adjuster (1). Pry and remove track
adjuster (1) from track frame (2) by using a pry bar.

W4-4-1-1
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

3
2
2
1

W157-03-04-003 WDEA-04-04-002

Installation

dCAUTION: Track adjuster (1) weight: 34 kg (75 lb)

1. Attach the nylon slings onto track adjuster (1). Hoist
track adjuster (1). Install track adjuster (1) to spring
guide (3) in track frame (2). At this time, check that
track adjuster (1) comes in contact with the surface
of plate (4).
2. Install the front idler. (Refer to W4-5-1).
3. Connect the track. (Refer to W4-7-1).

W4-4-1-2
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Disassembly of Track Adjuster

7
3
1

14
10

13

11
12

12
b

WDEB-04-04-001

a- Rubber Crawler b- Steel Crawler

1- Cylinder 7- Dust Seal 11- Washer 14- Plug

3 U-Ring 8- Holder 12- Nut
5- Cylinder Rod 10- Spring 13- Valve

W4-4-2-1
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Disassembly of Track Adjuster

IMPORTANT: Use the special tool (ST 4920) when
dCAUTION: Track adjuster weight: 34 kg (75 lb)
3. Attach the wire ropes onto the track adjuster. Install
assembling and disassembling the track adjuster.
the track adjuster to the holder of the special tool
dCAUTION: As the spring force is too strong, carry
out the disassembly and assembly work carefully.
(ST 4920).
Wire Rope
In addition, inspect the special tool (ST 4920) for
any damage thoroughly in order to perform the
work safely.

dCAUTION:
(355 lb)
Special tool (ST 4920) weight: 159 kg Track Adjuster

1. Place an oil jack (30 tons) between the holder and

the base of the special tool (ST 4920).

Nut

Holder

Holder

Oil Jack

W105-03-04-009

Base
W105-03-04-006

dCAUTION: Plate (ST 4036) weight: 34 kg (75 lb)

2. Remove nuts (4 used) from the special tool (ST
4920). Attach the nylon slings onto the eyebolts (2
used) of the special tool (ST 4036). Hoist the special
tool (ST 4036). Remove the special tool (ST 4036)
from the special tool (ST 4920).

j : 46 mm

ST 4036

W105-03-04-007

W4-4-2-2
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

6. Tighten the nuts of the special tool (ST 4920) and

dCAUTION: Plate (ST 4036) weight: 34 kg (75 lb) secure the track adjuster. Operate the oil jack.
4. Install the special tool (ST 4036) to the special tool Compress the track adjuster until a clearance
(ST 4920) in order to cover the track adjuster. is observed between washer (11) and nut (12).
(Approx. 10 mm (0.39 in))

j : 46 mm
ST 4036

Nut

Track Adjuster

W105-03-04-012

W105-03-04-011
7. Remove plug (14) from nut (12). Remove nut (12)
and valve (13) from cylinder (1).

l : 5 mm
5. Operate the oil jack. Raise the holder.
j : 60 mm
Holder Oil Jack
j : 24 mm

12 1 14

W105-03-04-013

W105-03-04-014

W4-4-2-3
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

10. Remove spring (10) from cylinder (1).

d CAUTION: Plate (ST 4036) weight: 34 kg (75 lb)
11. Remove cylinder rod (5) from cylinder (1).
dCAUTION: Remove the nuts and the plate (ST
4036) after lowering the oil jack. Prevent washer 12. Remove U-ring (3) and dust seal (7) from cylinder
(11) and spring (10) from flying out due to the (1).
spring (10) force.
8. Remove the nuts and the plate (ST 4036) after
lowering the oil jack. Remove washer (11) from
cylinder (1).
ST 4036

11

10

W105-03-04-016

dCAUTION:
kg (69 lb)
The spring (10) assembly weight: 31

9. Install eyebolts (M16, Pitch 1.5 mm) to cylinder (1).

Remove the spring (10) assembly from the special
tool (ST 4920).
1
a
10

W105-03-04-017

a- Eyebolt

W4-4-2-4
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Assembly of Track Adjuster

Steel Crawler
11 10 1 3 7 5 8
13 14 12

267 mm (10.5 in) (Free Length 316.9 mm (12.5 in))

412 mm (16.2 in)

WDEB-04-04-002

Rubber Crawler

11 10 1 3 7 5 8
13 12 14

242 mm (9.5 in) (Free Length 316.9 mm (12.5 in))

446 mm (17.6 in)

WDEB-04-04-003

1 - Cylinder 7- Dust Seal 11 - Washer 14 - Plug

3- U-Ring 8 - Holder 12 - Nut
5- Cylinder Rod 10 - Spring 13 - Valve

W4-4-2-5
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Assembly of Track Adjuster

IMPORTANT: Install U-ring (3) with its lip part facing
dCAUTION:
kg (69 lb)
The spring (10) assembly weight: 31

to the inside of cylinder (1). Apply grease onto

3. Install spring (10) to cylinder (1). Install eyebolts
dust seal (7) and U-ring (3) after assembling.
(M16, Pitch 1.5 mm) to cylinder (1). Place the spring
1. Install U-ring (3) and dust seal (7) to cylinder (1). (10) assembly on the special tool (ST 4920).
IMPORTANT: Fill grease in chamber B of cylinder
(1). Push cylinder rod (5) into cylinder (1) and
completely bleed air from cylinder (1). In addition,
apply grease onto cylinder (1) and cylinder rod (5). 1
2. Install cylinder rod (5) to cylinder (1).

10

ST 4920

W105-03-04-017

W4-4-2-6
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

6. Install nut (12) and valve (13) to cylinder (1). Install

dCAUTION: Plate (ST 4036) weight: 34 kg (75 lb) plug (14) to nut (12).
4. Install washer (11) to cylinder (1). Install the plate
Nut (12)
(ST 4036) to washer (11).
j : 60 mm
j : 46 mm
Plug (14)

l : 5 mm
ST 4036
m : 14.8 N·m (1.5 kgf·m, 11 lbf·ft)
Valve (13)

j : 24 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

12 1 14

W105-03-04-012

5. Operate the oil jack. Compress spring (10) to the

specified length.
Specified length:
Steel Crawler: 267 mm (10.5 in)
Rubber Crawler: 242 mm (9.5 in)

W105-03-04-014

10
dCAUTION: Plate (ST 4036) weight: 34 kg (75 lb)
7. Loosen the oil jack. Remove the nuts. Remove the
plate (ST 4036).

j : 46 mm

ST 4036
Oil Jack

W105-03-04-026

W105-03-04-011

W4-4-2-7
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

dCAUTION: Track adjuster weight: 34 kg (75 lb)

8. Attach the wire ropes onto the track adjuster.
Remove the track adjuster from the special tool (ST
4920).

Track Adjuster

Holder

W105-03-04-009

dCAUTION:
(105 lb)
Special tool (ST 4930) weight: 47 kg

IMPORTANT: If only the track adjuster is transported,

use the special tool (ST 4930) in order to transport
the track adjuster safely.
j : 24 mm

Track Adjuster

W105-03-04-028
ST 4930

W4-4-2-8
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

Removal and Installation of Front Idler

2
W178-03-05-001 a- Wooden Block W178-03-05-002

Removal
Before removing the front idler, the tracks should be
removed first. (Refer to 4-7-1.) Therefore, the procedure
dCAUTION: Front idler (1) weight: 52 kg (115 lb)
2. Attach the nylon slings onto the bearing part and
starts on the premise that the tracks have already been
the yoke (2) part of front idler (1). Hoist and remove
removed here.
front idler (1) from track frame (3).
d CAUTION: Front idler (1) may fly out due to the
spring force when removing front idler (1). Do not 3. When keeping front idler (1) temporarily, place front
stand in the same direction to remove front idler idler (1) on wooden blocks (a) as illustrated.
(1) or where front idler (1) may fly out.
1. Remove front idler (1) with yoke (2) together from
track frame (3) by using a pry bar.

W4-5-1-1
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

2
W178-03-05-004
a- Sliding Part b- Sliding Part

Installation

dCAUTION: Front idler (1) weight: 52 kg (115 lb)

IMPORTANT: Clean sliding part (a) of yoke (2) and
sliding part (b) of track frame (3). Apply grease.
1. Install front idler (1) in the reverse way of removal.

W4-5-1-2
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

Disassembly of Front Idler

04

06
03A 05
02
03B

00
03B

01

02
05
04

06
08

07
00
W1CC-03-05-001

00- Bearing (2 Used) 03A- Idler 05- Floating Seal (2 Used) 08- Yoke
01- Axle 03B- Bushing (2 Used) 06- Plug (2 Used)
02- O-Ring (2 Used) 04- Pin (2 Used) 07- Socket Bolt (4 Used)

W4-5-2-1
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

Disassembly of Front Idler

IMPORTANT: Handle floating seals with care. (Refer
dCAUTION:
kg (115 lb)
The idler (03A) assembly weight: 52
to W4-5-3.)
1. Remove socket bolts (07) (4 used). Remove yoke 5. Remove the upper side of bearing (00) from idler
(08) from bearings (00) (2 used). (03A). Remove floating seals (05) (2 used) from idler
(03A) and bearing (00).
l : 12 mm

dCAUTION:
kg (93 lb)
The idler (03A) assembly weight: 42

2. Place the idler (03A) assembly horizontally. Remove

plug (06) on the lower side. Drain off engine oil from
the idler (03A) assembly. 00

l : 6 mm 05

fNOTE: Oil amount: 0.14 L (0.15 US qt)

03A
d CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent 05
personal injury.
3. Remove pin (04) from bearing (00) on the upper 02
side by using a round bar and a hammer.

fNOTE: Diameter of round bar: 10 to 11 mm (0.39 to 0.43 01

in)
00
4. Put the matching marks on bearing (00) and axle
(01). Remove the axle (01) assembly from the idler
(03A) assembly.

00 01 W105-03-05-009

03A

W105-03-05-008

W4-5-2-2
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

IMPORTANT: Place wooden blocks under bearing

(00) in order not to damage bearing (00). dCAUTION: Idler (03A) weight: 29 kg (64 lb)
6. Attach nylon slings onto the axle (01) assembly. IMPORTANT: Do not remove bushing (03B) unless
Hoist the axle (01) assembly. Place the bearing (00) necessary.
part of the axle (01) assembly onto wooden blocks. 10. When replacing bushing (03B), weld four places
on the bushing (03B) bore by using a welding bar.
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
Shrink and remove bushing (03B).

such as goggles, helmets, etc in order to prevent

personal injury.
7. Remove pin (04) by using a bar and a hammer. 90°

fNOTE: Diameter of round bar: 10 to 11 mm (0.39 to 0.43

in) 90°
8. Put the matching marks on bearing (00) and axle
(01). Remove axle (01) from bearing (00).
9. Remove O-rings (02) (2 used) from axle (01). W105-03-05-012

04 02

00
a

01

02

W105-03-05-010

a- Wooden Block

W4-5-2-3
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

Assembly of Front Idler

03B 03A

06
04 00 07

01 05 02 08

W152-03-05-001

00- Bearing (2 Used) 03A- Idler 05- Floating Seal (2 Used) 08- Yoke
01- Axle 03B- Bushing (2 Used) 06- Plug (2 Used)
02- O-Ring (2 Used) 04- Pin (2 Used) 07- Socket Bolt (4 Used)

W4-5-2-4
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

Assembly of Front Idler

IMPORTANT: Handle floating seal (05) with care.
dCAUTION: Idler (03A) weight: 29 kg (64 lb)
(Refer to W4-5-3.)
1. Install bushings (03B) (2 used) to idler (03A).
5. Apply engine oil onto the O-ring of floating seal
2. Place axle (01) vertically. Install O-ring (02) to the (05). Install floating seal (05) to idler (03A) and
upper side of axle (01). bearing (00).
3. Fit the matching marks on axle (01) and bearing 6. Attach nylon slings onto bearing (00) of the axle (01)
(00). Evenly tap and install bearing (00) to axle (01) assembly. Hoist the axle (01) assembly. Install the
by using a plastic hammer. axle (01) assembly to idler (03A) on the side where
floating seal (05) has already been installed.
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury. 05 00
4. Install pin (04) by using a bar and a hammer.

04
01 01

00

03A
W157-03-05-006

02 7. Apply THREEBOND #2353 onto plug (06). Install

plug (06) to bearing (00).
W105-03-05-014 l : 6 mm

m : 20 N·m (2.0 kgf·m, 15.0 lbf·ft)

W4-5-2-5
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

dCAUTION:
kg (84 lb)
The idler (03A) assembly weight: 38 dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
8. Attach nylon slings onto the idler (03A) assembly. such as goggles, helmets, etc in order to prevent
Hoist the idler (03A) assembly. Turn over the idler personal injury.
(03A) assembly. 12. Install pin (04) by using a bar and a hammer.
9. Install O-ring (02) to axle (01). 13. Add engine oil (API CD class, SAE #30) through the
plug (06) hole of bearing (00).
IMPORTANT: Handle floating seal (05) with care.
(Refer to W4-5-3.) fNOTE: Oil amount: 0.14 L (0.15 US qt)
10. Apply engine oil onto the O-ring of floating seal 14. Apply THREEBOND #2353 onto plug (06). Install
(05). Install floating seal (05) to idler (03A) and plug (06) to bearing (00).
bearing (00).
l : 6 mm

00 05 02 03A m : 20 N·m (2.0 kgf·m, 15.0 lbf·ft)

00 15. Install yoke (08) to bearings (00) (2 used) with socket

bolts (07) (4 used).

l : 12 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft)

01

W157-03-05-005

11. Fit the matching marks on axle (01) and bearing

(00). Evenly tap and install bearing (00) to axle (01)
by using a plastic hammer.

W4-5-2-6
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

Precautions for Using Floating Seal 1

1. In general, replace the floating seal with a new one

after disassembling.
If the floating seal is required to be reused, follow
these procedures:
 Keep seal rings together as a matched set with seal
ring (1) surfaces together. Apply oil onto sliding W178-02-11-001
surface (e) of seal ring (1). 2
 Check sliding surface (e) of seal ring (1) for scuffing,
scoring, corrosion, deformation, or uneven wear.
Check the step part of seal ring (1).
 Check O-ring (2) 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.
 Clean the floating seal and seal mounting bores with a
cleaning solvent.
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air. c
 Clean seal ring (1) and O-ring (2) mounting bores. b
Check the bore surface for scuffing or scoring by d
touching the surface with finger.
 After installing the floating seal, check that O-ring (2) W178-02-11-002
is not twisted, and that it is installed correctly on seal
a- Correct c- Twist of O-Ring
ring (1).
b- Incorrect d- Bend of O-Ring
 After installing the floating seal, check that O-ring
(2) and seal ring sliding surface (e) is parallel with
f
seal mating surface (f ) by measuring the distances
(e) and (f ) at point (A) and (B), as illustrated. If these a b
A A
distances differ, correct O-ring (2) seating.

B B

A=B A≠B

W178-02-11-003

a- Correct e- Sliding Surface

b- Incorrect f- Seal Mating Surface

W4-5-3-1
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

(Blank)

W4-5-3-2
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

Removal and Installation of Upper Roller

1
W105-03-06-001 a- Grease Outlet W1V7-03-04-006

dCAUTION: The pressure inside the track adjuster

(1) cylinder is high. As valve (3) may fly out and
the high-pressure grease may spout out, do not
loosen valve (3) quickly and/or excessively. Keep
body parts and face away from valve (3) and
loosen it carefully. Do not loosen grease fitting (2).
IMPORTANT: When gravel or mud is packed between
sprockets and track links, remove them before
loosening.
IMPORTANT: Loosening valve (3) by 1 to 1.5 turns is
enough. Do not it over those turns.

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Loosen valve (3) in track adjuster (1). Drain grease
from the cylinder.

j : 24 mm

W4-6-1-1
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

b a 1
4, 5

3 c 2
2

W105-03-06-003 M152-07-046

a- Oil Jack
b- Nonskid Cloth
c- Wooden Block

dCAUTION: Use nonskid cloth (b) between track

frame (3) and oil jack (a) in order not to slip.
3. Raise track (1) in order to get clearance between
upper roller (2) and track (1).
4. Place wooden blocks (c) between track (1) and track
frame (3).
5. Remove bolt (4) and washer (5). Remove upper
roller (2).

j : 22 mm

fNOTE: LOCTITE #262 has been applied onto bolt (4).

W4-6-1-2
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

View A
4, 8
a

7
b

A WDEA-06-01-001 6

a- I-Shaped Mark
b- Up
c- Axle End
2 3
5
M152-07-046
W1V7-03-04-006

e d 1

3 f 2
W105-03-06-003

d- Oil Jack Wxxx-03-07-001

e- Nonskid Cloth
f- Wooden Block g- Track Sag Specification

Installation
IMPORTANT: I-shaped mark (a) (punching) is 3. Tighten valve (7) of track adjuster (5).
stamped on axle end (c) of upper roller (2). Install
upper roller (2) to track frame (3) with I-shaped j : 24 mm
mark (a) up.
m : 90 N·m (9 kgf·m, 66 lbf·ft)
1. Apply LOCTITE #262 onto bolt (4). Install upper
roller (2) with washer (8) and bolt (4). dCAUTION: Securely support the raised machine
by using the blocks.
j : 22 mm
4. Raise the track to be adjusted. Rotate the track in
m : 140 N·m (14 kgf·m, 103 lbf·ft) the reverse direction a little.

2. Remove wooden blocks (f ), oil jack (d), and nonskid 5. Apply grease through grease fitting (6) and adjust
cloth (e) between track (1) and track frame (3). the track tension.

fNOTE: Track sag specification (g): 210 to 245 mm (8.3 to

9.6 in)

W4-6-1-3
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

W158-03-06-001

6. Lower the track.

IMPORTANT: Upper roller (1) cannot be
disassembled. Replace it as an assembly.
7. Remove plug (2).

l : 5 mm
8. Add engine oil (API CD class, SAE #30) through the
plug (2) hole.

fNOTE: Amount of oil: 26 to 30 mL (0.027 to 0.032 USqt)

9. Apply LOCTITE #503 onto plug (2). Install plug (2).

l : 5 mm

m : 15±1.5 N·m (1.5±0.15 kgf·m, 11±1.1 lbf·ft)

W4-6-1-4
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

Removal and Installation of Lower Roller

1
90º to 110º

M102-07-063
a M104-07-067

a- Stand

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Remove bolts (1) (4 used).

j : 22 mm
3. Swing the upperstructure to position it 90°. Operate
the boom and the arm so that the angle between
them is 90° to 110°. Lower the boom with the round
bottom of bucket contacting with the ground. Raise
the track frame. At this time, place stand (a) under
the track frame and support the machine.

W4-6-2-1
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

1
a- Grease Outlet W1V7-03-04-006

4 W105-03-06-001

5. Remove lower roller (4).

dCAUTION: The pressure inside the track adjuster
(1) cylinder is high. Do not loosen valve (3) quickly
or too much as valve (3) may fly out or high-
pressure grease in the adjuster cylinder may gush
out. Keep body parts and face away from valve
(3) and loosen valve (3) carefully. Do not loosen
grease fitting (2).
IMPORTANT: Loosening valve (3) by 1 to 1.5 turns is
enough. Do not loosen valve (3) over those turns.
IMPORTANT: When gravel or mud is packed between
sprockets and track links, remove them before
loosening.
4. Loosen valve (3) of track adjuster (1). Drain grease
until the clearance is enough to remove lower roller
(4).

j : 24 mm

W4-6-2-2
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

4 1

3 2
M102-07-063

Installation
1. Place lower roller (1) onto track link (2).
2. Lower the machine so that the position to install
lower roller (1) can be adjusted.
3. Clean bolts (3) (4 used). Fit the bolt (3) holes of track
frame (4) and lower roller (1). Install lower roller (1)
with bolts (3) (4 used).

j : 22 mm

m : 250 N·m (25 kgf·m, 185 lbf·ft)

W4-6-2-3
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

a
1

W1V7-03-04-006 WXXX-03-07-001

a- Track Sag Specification

4. Tighten valve (2).

j : 24 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

dCAUTION: Securely support the raised machine

by using the blocks.
5. Raise the track to be adjusted. Rotate the track in
the reverse direction a little.
6. Apply grease through grease fitting (1) and adjust
the track tension.

fNOTE: Track sag specification (a): 210 to 245 mm (8.3 to

9.6 in)

W4-6-2-4
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

Disassembly of Lower Roller

3
2
1
5
4
6

WDEA-04-05-001

1- Plug 4- O-Ring 6- Bushing (2 Used) 8- Axle

2- Collar 5- Floating Seal (2 Used) 7- Roller 9- Collar
3- Pin

W4-6-3-1
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

Disassembly of Lower Roller

1. Remove plug (1) from the end of collar (2). Drain off IMPORTANT: Handle floating seal (5) with care.
oil from roller (7). (Refer to W4-6-4.)
3. Remove floating seals (5) (2 used) from both sides of
l : 5 mm
roller (7) and collars (2, 9).
fNOTE: Oil amount : 0.12 L (0.127 USqt) 4. Remove O-rings (4) from axle (8).
d CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
IMPORTANT: Do not remove bushing (6) unless
necessary.
such as goggles, helmets, etc in order to prevent
5. Remove bushing (6) by using the special tool (ST
personal injury.
7780) and a press.

IMPORTANT: Do not remove collar (9) from axle (8).

Replace them as the axle (8) assembly.

2. Put the matching marks on collar (2) and axle (8).

Remove pin (3) from collar (2) by using a round bar ST 7780
and a hammer. Place the axle (8) assembly with
collar (9) mounting side down, and remove axle (8)
from roller (7) by using a press. At this time, collar
(9) on the opposite side is removed with axle (8) 6
together.
7
fNOTE: Diameter of round bar: 6 mm (0.236 in)

2 5 7 5
WDEA-04-05-004

5
9

8
WDEA-04-05-003

W4-6-3-2
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

Assembly of Lower Roller

9 5 6 8 7 6 5 4 3 2 1

WDEA-04-05-002

1- Plug 4- O-Ring 6- Bushing (2 Used) 8- Axle

2- Collar 5- Floating Seal (2 Used) 7- Roller 9- Collar
3- Pin

W4-6-3-3
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

Assembly of Lower Roller

3. Install the axle (8) assembly to roller (7).
IMPORTANT: Do not dent the flange surface of
bushing (6). 4. Apply grease onto O-ring (4). Install O-ring (4) to the
1. Install bushings (6) (2 used) to roller (7) by using a axle (8) assembly.
press. IMPORTANT: Handle floating seal (5) with care.
(Refer to W4-6-4.)
IMPORTANT: Handle floating seal (5) with care. 5. Install floating seal (5) to roller (7) and collar (2).
(Refer to W4-6-4.)
IMPORTANT: Do not damage O-ring (4).
2. Install floating seal (5) to roller (7) and collar (9).
6. Fit the matching marks on collar (2) and axle (8). Fit
the pin (3) hole and install collar (2) to axle (8) with
pin (3).
7. Apply LOCTITE #503 onto plug (1). Add engine oil
7 5 (API CD class, SAE #30) through the plug (1) hole of
collar (2). Tighten plug (1).

l : 5 mm

m : 15±1.5 N·m (1.5±0.15 kgf·m, 11±1.1 lbf·ft)

5
9 fNOTE: Oil amount: 0.12 L (0.127 USqt)

WDEA-04-05-003

W4-6-3-4
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Roller

Precautions for Using Floating Seal 1

1. In general, replace the floating seal with a new one

after disassembling.
If the floating seal is required to be reused, follow
these procedures:
 Keep seal rings together as a matched set with seal
ring (1) surfaces together. Apply oil onto sliding W178-02-11-001
surface (e) of seal ring (1). 2
 Check sliding surface (e) of seal ring (1) for scuffing,
scoring, corrosion, deformation, or uneven wear.
Check the step part of seal ring (1).
 Check O-ring (2) 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.
 Clean the floating seal and seal mounting bores with a
cleaning solvent.
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air. c
 Clean seal ring (1) and O-ring (2) mounting bores. b
Check the bore surface for scuffing or scoring by d
touching the surface with finger.
 After installing the floating seal, check that O-ring (2) W178-02-11-002
is not twisted, and that it is installed correctly on seal
a- Correct c- Twist of O-Ring
ring (1).
b- Incorrect d- Bend of O-Ring
 After installing the floating seal, check that O-ring
(2) and seal ring sliding surface (e) is parallel with
f
seal mating surface (f ) by measuring the distances
(e) and (f ) at point (A) and (B), as illustrated. If these a b
A A
distances differ, correct O-ring (2) seating.

B B

A=B A≠B

W178-02-11-003

a- Correct e- Sliding Surface

b- Incorrect f- Seal Mating Surface

W4-6-4-1
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Roller

(Blank)

W4-6-4-2
 SECTION 4 UNDERCARRIAGE
Group 7 Track

Removal and Installation of Track

5
3
b

4
a b- Grease Outlet
W105-03-07-006 W1V7-03-04-006

a- Wooden Block

Removal
1. Set the machine for inspection and maintenance.
(Refer to W1-6-1.)
2. Rotate the track so that master pin (3) is positioned
over the front idler (2) side of track adjuster (4).
Place wooden blocks (a) under shoe (1) and support
shoe (1).

dCAUTION: The pressure inside cylinder of track

adjuster (4) is high. As valve (6) may fly out and
the high-pressure grease may spout out, do not
loosen valve (6) quickly and/or excessively. Keep
body parts and face away from valve (6) and
loosen valve (6) carefully. Do not loosen grease
fitting (5).
IMPORTANT: Loosening valve (6) 1 to 1.5 turns is
enough. Do not loosen valve (6) over those turns.
IMPORTANT: When gravel or mud is packed between
sprockets and track links, remove them before
loosening.
3. Loosen valve (6). Drain grease and loosen the tracks.

j : 24 mm

W4-7-1-1
 SECTION 4 UNDERCARRIAGE
Group 7 Track

1
3
2 2 1
a- Direction to Remove
W105-03-07-010

3
ST 1653

W105-03-07-009

W1V1-03-07-001

4. Remove snap ring (3) from master pin (2).

fNOTE: If snap ring (3) interferes with master link (1),

dCAUTION: The front idler part may fly out due to
the spring force when removing the track. Do not
push master pin (2) to the installing direction in order to stand in the same direction to remove the front
make clearance between snap ring (3) and master pin idler or where it may fly out. Particularly, strong
(2). Then, remove master pin (2). force is always applied to the thread part of the
rod of the track adjuster. If the rod and/or the
threads are damaged, metal fragments may fly
out due to the spring force.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: Master pin (2) can be removed to only
one direction. Check direction (a) to remove
master pin (2).
5. Remove master pin (2) by using the special tool (ST
1653) and a hammer.

W4-7-1-2
 SECTION 4 UNDERCARRIAGE
Group 7 Track

90° to 110°

a
a- Stand

M104-07-067 W105-03-07-011

6. Set the angle between boom and arm to 90° to

110°. Lower the boom with the round bottom of the
bucket contacting with the ground. Raise the track
frame and pull out the track. Place stand (a) under
the track frame and support the machine at this
time.

dCAUTION:
(950 lb)
The track assembly weight: 430kg

7. Slowly operate the travel control lever for the track

to be removed to the reverse position and extend
the track.

W4-7-1-3
 SECTION 4 UNDERCARRIAGE
Group 7 Track

a b

W105-03-07-014

W105-03-07-013

a- Front Idler Side

b- Sprocket (1) Side

W105-03-07-015

Installation
1. Raise the machine. Set the track under the machine 3. Slowly operate the travel control lever on the side
so that sprocket (1) meshes with the track end. to install the track in the forward position with the
Check the direction of the track at this time. machine raised off the ground. Wind the track while
rotating travel device (2).
dCAUTION:
(950 lb)
The track assembly weight: 430kg

2. Hoist and mesh the track with the claws of sprocket

(1).

W4-7-1-4
 SECTION 4 UNDERCARRIAGE
Group 7 Track

5
3 4
b- Direction to Install
W105-03-07-010

4
2

a
5
W105-03-07-016

a- Wooden Block

W105-03-07-009

4. Wind the track link until the connection part of the

track link reaches the front idler (1) side. Lower the
machine. Place wooden blocks (a) under shoe (2)
and support shoe (2).
IMPORTANT: Master pin (3) can be installed to only
one direction. Check direction (b) to install master
pin (3).
5. Install master pin (3) to the track.
IMPORTANT: Replace snap ring (5) with the new one.
6. Install snap ring (5). Snap ring (5) has the direction
to install. Install snap ring (5) to the groove of
master link (4) with the flat surface of a pair of pliers
hole facing the near side.

W4-7-1-5
 SECTION 4 UNDERCARRIAGE
Group 7 Track

7
1

8
3

4
5 W1V7-03-04-006

c b c

W197-03-07-001
8
b- Apply grease.
c- Do not apply grease.

Wxxx-03-07-001

a- Track Sag Specification

IMPORTANT: If link (4) has been disassembled, fill 10. Install pin (3) to link (4) and bushing (1) while
grease (Daphne Eponex SR Grade No.2) into the holding them in order not to move due to grease.
clearance between bushing (1) and pin (3).
11. Wipe off excess grease after installing pin (3).
IMPORTANT: If link (4) has been disassembled,
perform step 7 to step 11. 12. Tighten valve (7) of track adjuster (5). Apply grease
through grease fitting (6) and adjust the track
IMPORTANT: Check the direction to install seal (8).
tension.
7. Install seal (8) to link (4).
j : 24 mm
8. Apply grease onto the bushing (1) end. Fit the pin
(3) holes on link (4) and bushing (1). Stand them on m : 90 N·m (9 kgf·m, 66 lbf·ft)
a flat plate.
fNOTE: Track sag specification (a): 210 to 245 mm (8.3 to
dCAUTION: Take care not to come off link (4). 9.6 in)
9. Fill the bushing (1) inside with grease.

W4-7-1-6
 SECTION 4 UNDERCARRIAGE
Group 8 Blade Cylinder

Removal and Installation of Blade Cylinder 1 2 3

IMPORTANT: The hose and pipe contain hydraulic
oil. When removing the hose and pipe, receive oils
with a container in order to avoid spilling oils.
IMPORTANT: Cap the open ends in case the hoses
8
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors, 10
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.
9
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1) 9

dCAUTION:
lb)
Blade cylinder (3) weight: 48 kg (110 4

8
2. Remove bolts, washers (1) (2 used). Remove cover 6 W197-04-02-001
(2) from blade cylinder (3). 7

j : 19 mm
3. Remove grease fittings (9) (2 used) from pins (8) (2
used).

j : 10 mm
4. Attach the nylon slings onto blade cylinder (3). Hoist
and hold blade cylinder (3).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
5. Remove bolt (7) and bushing (6) from pin (8).
Remove pin (8) from track frame (4) by using a bar
and a hammer. Remove shim (10).

j : 24 mm
6. Start the engine. Operate the blade control lever
and retract the cylinder rod to the stroke end. In
order not to extend the cylinder rod, pass wires
through the boss of cylinder rod and secure it. Stop
the engine.

W4-8-1-1
 SECTION 4 UNDERCARRIAGE
Group 8 Blade Cylinder

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
1 10

7. Disconnect hoses (4, 11) from blade cylinder (1).

Hose (4) 10

j : 22 mm 5
8
Hose (11) 7 4

j : 27 mm

dCAUTION:
lb)
Blade cylinder (1) weight: 48 kg (110

11
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
8. Remove bolt (7) and bushing (8) from pin (5). 9
Remove pin (5) from blade (9) by using a bar and a W197-04-02-001
hammer. Remove shim (10) between blade (9) and
blade cylinder (1). Hoist and remove blade cylinder
(1).

j : 24 mm

W4-8-1-2
 SECTION 4 UNDERCARRIAGE
Group 8 Blade Cylinder

Installation
1 10
d CAUTION: Blade cylinder (1) weight: 48 kg (110
lb)
1. Apply grease onto the bushing inside and the lip
part of the dust seal (both bottom and rod sides) for 10
blade cylinder (1) .
5
2. Apply grease onto pin (5). Attach the nylon slings 8
7 4
onto blade cylinder (1). Hoist blade cylinder (1).
Fit the pin (5) holes of blade cylinder (1) and blade
(9). Install shim (10) between blade (9) and blade
cylinder (1).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
11

such as goggles, helmets, etc in order to prevent

personal injury.
3. Install blade cylinder (1) to blade (9) with pin (5) by
using a hammer. Install bolt (7) and bushing (8). 9
W197-04-02-001
j : 24 mm

m : 210 N·m (21 kgf·m, 155 lbf·ft)

4. Connect hoses (4, 11) to blade cylinder (1).
Hose (4)

j : 22 mm

m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

Hose (11)

j : 27 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

W4-8-1-3
 SECTION 4 UNDERCARRIAGE
Group 8 Blade Cylinder

5. Remove the wires from the blade cylinder (3) rod

side. 1 2 3

IMPORTANT: Check the hydraulic oil level. Start the

10
engine and check for any oil leaks.
6. Start the engine. Operate the blade control lever
and slowly extend the cylinder rod. Fit the pin 8
(8) holes of blade cylinder (3) and track frame (4).
Install shim (10) between track frame (4) and blade
cylinder (3).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection, 9
such as goggles, helmets, etc in order to prevent
personal injury.
7. Apply grease onto pin (8). Install blade cylinder (3) 9
to track frame (4) with pin (8) by using a hammer. 4
8. Secure pin (8) to track frame (4) with bolt (7) and 8
bushing (6). 6 W197-04-02-001
7
j : 24 mm

m : 210 N·m (21 kgf·m, 155 lbf·ft)

9. Install grease fittings (9) (2 used) to pins (8) (2 used).
Apply grease.

j : 10 mm

m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

10. Install cover (2) to blade cylinder (3) with bolts,
washers (1) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

IMPORTANT: After completing the work, operate the
blade cylinder to the stroke end several times and
bleed air from the circuit.

W4-8-1-4
 SECTION 4 UNDERCARRIAGE
Group 8 Blade Cylinder

Disassembly of Blade Cylinder

9
8
7
6
5

4
3
2

14

13
12
11

10

W1N0-04-02-005

1- Piston Rod 5- Bushing 9- O-Ring 13- Nut

2- Snap Ring 6- U-Ring 10- Piston Ring 14- Cylinder Tube
3- Wiper Ring 7- O-Ring 11- Piston
4- Cylinder Head 8- Backup Ring 12- Seal Ring

W4-8-2-1
 SECTION 4 UNDERCARRIAGE
Group 8 Blade Cylinder

Disassembly of Blade Cylinder

 The procedure starts on the premise that the piping 3. Loosen cylinder head (4) by using a hook wrench
and the bands securing the piping have been (b). Remove the piston rod (1) assembly from
removed. cylinder tube (14).
d CAUTION: Blade cylinder weight: 46 kg (105 lb) Diameter of cylinder head (4): 140 mm (5.51 in)
1. Secure the pin mounting part (clevis part) of
cylinder tube (14) in a vise horizontally. Drain b
hydraulic oil from the cylinder.
IMPORTANT: The lock washer in cylinder head
(4) is provided on cylinder tube (14) and forms
an integral part. Do not damage cylinder tube
(14) and cylinder head (4) when bending and
extending the lock washer.
2. Pull out piston rod (1) about 200 mm (7.87 in) from
cylinder tube (14). Install a protective cover on
piston rod (1). Extend the lock washer (a) in cylinder
head (4) by using a chisel and a hammer.

1 4 W506-04-02-004
b- Hook Wrench

4. Secure piston rod (1) horizontally. Remove nut (13)

from piston rod (1).
a
j : 75 mm
5. Remove piston (11) from piston rod (1).
6. Install a protection tape onto the thread part of
piston rod (1). Remove cylinder head (4) from piston
rod (1).
7. Secure piston (11) in a vise. Remove piston ring (10)
1 4 from piston (11).

a- Lock Washer W506-04-02-003

W4-8-2-2
 SECTION 4 UNDERCARRIAGE
Group 8 Blade Cylinder

IMPORTANT: When removing the seals, do not IMPORTANT: Bushing (5) cannot be reused. If
damage piston (11). bushing (5) has been removed, replace with a new
8. Cut and remove seal ring (12) from piston (11) by one when assembling.
using a screwdriver. 10. Remove bushing (5) from cylinder head (4) by using
the special tool (ST 8016).

11

12

ST 8016

4
W506-04-02-007
5
9. Remove U-ring (6), snap ring (2), backup ring (8),
and O-rings (7, 9) from cylinder head (4). Remove
wiper ring (3) from cylinder head (4).

W1MP-04-02-016

W4-8-2-3
 SECTION 4 UNDERCARRIAGE
Group 8 Blade Cylinder

Assembly of Blade Cylinder

2 3 4 7 6 14 1 11 13

W1N0-04-02-004
5 8, 9 10 12

1- Piston Rod 5- Bushing 9- O-Ring 13- Nut

2- Snap Ring 6- U-Ring 10- Piston Ring 14- Cylinder Tube
3- Wiper Ring 7- O-Ring 11- Piston
4- Cylinder Head 8- Backup Ring 12- Seal Ring

W4-8-2-4
 SECTION 4 UNDERCARRIAGE
Group 8 Blade Cylinder

Assembly of Blade Cylinder

IMPORTANT: Check that bushing (5) is not out from IMPORTANT: Check the direction to install rod
the U-ring (6) mounting part in cylinder head (4) in packing (6).
order not to damage rod packing (6). 2. Install U-ring (6) to cylinder head (4).

4
4 5

a.

a- Check that bushing (5) is not out. WDEA-05-02-011 W1LD-04-02-004

3. Install wiper ring (3) and snap ring (2) to cylinder

1. Apply hydraulic oil onto the inside of cylinder head
head (4) by using the special tool (ST 8016).
(4). Install bushing (5) to cylinder head (4) by using
the special tool (ST 8016).

ST 8016 ST 8016

4
5
4

W506-04-02-012
W506-04-02-010
4. Install O-rings (7, 9) and backup ring (8) to cylinder
head (4).

W4-8-2-5
 SECTION 4 UNDERCARRIAGE
Group 8 Blade Cylinder

5. Install piston ring (10) and seal ring (12) to piston 7. Install a protection tape onto the thread part of
(11) by using the special tool (ST 2935). piston rod (1). Rotate and install the cylinder head
(4) assembly to piston rod (1).
8. Install the piston (11) assembly and nut (13) to
piston rod (1).
ST 2935
j : 75 mm
12
m : 3140±310 N·m (315±31 kgf·m, 2320±230
ST 2935 lbf·ft)
10 IMPORTANT: When installing the piston rod (1)
11 assembly, do not drop piston ring (10) and seal
ring (12) from piston (11).
W1LD-04-02-014 9. Apply hydraulic oil onto the packing parts. Secure
cylinder tube (14) in a vise horizontally. Install the
piston rod (1) assembly to cylinder tube (14).
IMPORTANT: If not adjusting piston ring (10) and
seal ring (12), piston (11) cannot be installed to
cylinder tube (14).
6. Pass piston (11) through the special tool (ST 2935)
and adjust piston ring (10) and seal ring (12).

10
12

ST 2935

W1LD-04-02-015

W4-8-2-6
 SECTION 4 UNDERCARRIAGE
Group 8 Blade Cylinder

10. Tighten cylinder head (4) to cylinder tube (14) by

using a hook wrench (a). Bend the lock washer in
order not to loosen.
Diameter of cylinder head (4): 140 mm (5.51 in)

m : 981±98 N·m (98±9.8 kgf·m, 725±72 lbf·ft)

14

a- Hook Wrench W506-04-02-019

W4-8-2-7
 SECTION 4 UNDERCARRIAGE
Group 8 Blade Cylinder

(Blank)

W4-8-2-8
MEMO
MEMO
SECTION 5

FRONT ATTACHMENT
CONTENTS
Group 1 Front Attachment
Removal and Installation of Front Attachment....W5-1-1-1
Group 2 Cylinder
Removal and Installation of Boom Cylinder..........W5-2-1-1
Removal and Installation of Arm Cylinder.............W5-2-2-1
Removal and Installation of Bucket Cylinder........W5-2-3-1
Removal and Installation of Boom Swing
Cylinder.........................................................................W5-2-4-1
Disassembly of Boom, Arm, and Bucket
Cylinders.......................................................................W5-2-5-1
Assembly of Boom, Arm, and Bucket
Cylinders.......................................................................W5-2-5-6
Disassembly of Boom Swing Cylinder.....................W5-2-6-1
Assembly of Boom Swing Cylinder..........................W5-2-6-4

DEEW-5-1
(Blank)

DEEW-5-2
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

Removal and Installation of Front

Attachment
4
IMPORTANT: The hose and pipe contain hydraulic
oil. When removing the hose and pipe, receive oils
with a container in order to avoid spilling oils.
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition, 8
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which 7
secure the hoses have been removed.
Removal
1. Park the machine on a solid and level surface. Fully
13 5
retract the arm cylinders and the bucket cylinders
WDEB-05-02-008
and lower the boom. Place the arm end on the
ground.

dCAUTION:
lb)
Boom cylinder (5) weight: 88 kg (195
12

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
2. Attach the nylon slings onto boom cylinder (5).
Hoist and hold boom cylinder (5). Remove bolt (7)
a 5
and nuts (8) (2 used) from the boom. Remove pin
(4) from the boom by using a bar and a hammer.
Remove shim (13) between the boom and boom
cylinder (5).

j : 24 mm

fNOTE: LOCTITE # 262 has been applied on bolt (7).

a- Wire W554-02-03-007
3. Start the engine. Operate the boom control lever
and retract cylinder rod (12). Pass the wires (a)
through the cylinder rod (12) hole and secure
cylinder rod (12) in order not to extend.
4. Place the cylinder rod (12) side of boom cylinder (5)
onto the stand.

W5-1-1-1
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)

dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.)
5. Disconnect connector (2).

dCAUTION:
(2210 lb)
Front attachment weight: 1000 kg
2
6. Attach the nylon slings onto the boom. Reduce
slack of the nylon slings. Hoist and hold the boom at
the center of gravity.
7. Disconnect hoses (9, 10) (2 used each).

j : 27 mm, 36 mm WBAT-06-01-074

8. Remove nuts (6) (2 used). Remove bolt (4) from the

swing post.

j : 24 mm

fNOTE: LOCTITE #262 has been applied on bolt (4)

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
9 10

such as goggles, helmets, etc in order to prevent

personal injury.
9. Remove boom foot pin (5) from the swing post by
using a bar and a hammer. WDEE-05-01-002

fNOTE: Put the matching marks on the swing post boss

and boom foot pin (5) for assembling. 4

dCAUTION:
(2210).
Front attachment weight: 1000 kg
5
10. Hoist and remove the front attachment. Remove
the thrust plates (8) from left and right sides of the 8 6
boom foot pin (5) part.

WBAT-06-01-075

W5-1-1-2
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

Installation

dCAUTION:
(2210 lb)
Front attachment weight: 1000 kg 4

1. Hoist the front attachment. Fit the boom foot part 5

to the mounting hole of the swing post. Insert the
thrust plates (8) to both right and left of the boom
foot parts and adjust the right and left clearances 8 6
within 1 mm (0.039 in).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
7
such as goggles, helmets, etc in order to prevent
personal injury. WBAT-06-01-075
2. Install boom foot pin (5) by using a hammer.
IMPORTANT: Install nut (6) so that the clearance
between nut (6) and the swing post boss should
be 2 to 3 mm.
3. Apply LOCTITE #262 onto bolt (4). Install bolt (4) and
nuts (6) (2 used).
9 10
j : 24 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

4. Connect hoses (9, 10) (2 used each).
WDEE-05-01-002
j : 27 mm

m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

dCAUTION:
lb)
Boom cylinder (7) weight: 88 kg (195

5. Attach nylon slings onto boom cylinder (7). Hoist

and hold boom cylinder (7).

W5-1-1-3
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

6. Remove the wires (a) from the boom cylinder (5) rod
side.
7. Start the engine with the cylinder rod of boom
cylinder (5) retracted to the stroke end. Extend
boom cylinder (5) slowly. Fit the pin (4) holes of the
boom cylinder (5) cylinder rod side and the boom.
Insert the thrust plates (13) to both right and left of
the cylinder rod parts and adjust the right and left
clearances within 1 mm (0.039 in).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
a 5

such as goggles, helmets, etc in order to prevent

personal injury.
8. Apply LOCTITE # 262 onto bolt (7). Install pin (4) by
using a hammer. Secure pin (4) to the boom with
bolt (7) and nuts (8) (2 used).
W554-02-03-007
j : 24 mm
a- Wires
m : 80 N·m (8 kgf·m, 59 lbf·ft)
9. Connect connector (2). 4

IMPORTANT: After completing the work, add

hydraulic oil to the specified level. Operate each
cylinder to the stroke end several times and bleed
air in the circuit. Check for any oil leak of each
hose connection. 8

13 5
WDEB-05-02-008

WBAT-06-01-074

W5-1-1-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Removal and Installation of Boom Cylinder 4

IMPORTANT: The hose and pipe contain hydraulic

oil. When removing the hose and pipe, receive oils
with a container in order to avoid spilling oils.
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition, 2
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which 1
secure the hoses have been removed.
Removal
1. Park the machine on a solid and level surface. Fully
retract the arm cylinders and the bucket cylinders
and lower the boom. Place the arm end on the 12 5 WDEB-05-02-008
ground.

dCAUTION:
lb)
Boom cylinder (5) weight: 90 kg (200

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
10

such as goggles, helmets, etc in order to prevent

personal injury.
2. Attach the nylon slings onto boom cylinder (5).
Hoist and hold boom cylinder (5). Remove bolt (1)
and nuts (2) (2 used). Remove pin (4) by using a bar 5
and a hammer.

j : 24 mm

fNOTE: LOCTITE#262 has been applied on bolt (1).

3. Remove thrust plates (12) from both sides of the
cylinder rod (10) boss. Start the engine. Retract
W554-02-03-007
cylinder rod (10) to the stroke end. In order not to
extend cylinder rod (10), pass the wires through the
boss of cylinder rod (10) and secure it.
4. Place boom cylinder (5) on the stands.

W5-2-1-1
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)

dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.)
5. Disconnect hoses (6) (2 used) from boom cylinder
(4).

j : 36 mm

dCAUTION:
lb)
Boom cylinder (4) weight: 90 kg (200

6. Remove nuts (5) (2 used) and bolt (2) from pin (1).
4
j : 24 mm 6

fNOTE: LOCTITE #262 has been applied on bolt (2).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent WDEE-05-02-003
personal injury.
7. Remove pin (1) by using a bar and a hammer.
7
Remove thrust plates (7) from both sides of the
cylinder tube boss.

fNOTE: Put the matching marks on the swing post (3)

boss and pin (1) for assembling.
8. Hoist and remove boom cylinder (4).

5, 2 1 3 WDEE-05-02-001

W5-2-1-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Installation
7
dCAUTION:
lb)
Boom cylinder (4) weight: 90 kg (200

IMPORTANT: Insert at least one thrust plates to both

left and right sides of all pins respectively. When
thrust plates should be used in order to adjust the
clearance, thrust plates should be inserted at both
sides respectively. (Clearance: 1.0 mm (0.039 in) or
less)
1. Apply grease onto the lip part of the dust seal for
boom cylinder (4), the boss side, and the bushing
inside (both bottom and rod sides).
2. Attach the nylon slings onto boom cylinder (4).
Hoist boom cylinder (4). Fit the pin (1) holes of 5, 2 1 3 WDEE-05-02-001
boom cylinder (4) and the swing post (3). Insert
thrust plates (7) to both sides of the cylinder tube
boss.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: Install nut (5) so that the clearance
between nut (5) and the swing post (3) boss
should be 2 to 3 mm (0.079 to 0.118 in).
3. Apply grease onto pin (1). Install pin (1) by using a
hammer. Apply LOCTITE #262 onto bolt (2). Install
bolt (2) to pin (1) with nuts (5) (2 used). 4
6
j : 24 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

4. Connect hoses (6) (2 used) to boom cylinder (4).

j : 36 mm WDEE-05-02-003

m : 180 N·m (18 kgf·m, 133 lbf·ft)

W5-2-1-3
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

5. Remove the wires from the rod side of boom 4

cylinder (5).
6. Hoist boom cylinder (5). Start the engine with the
cylinder rod retracted to the stroke end. Slowly
extend the cylinder rod. Fit the pin (4) holes of
boom cylinder (5) and the boom.

fNOTE: When the work in step 6 is finished, air in the 2

cylinder has been released.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
1

such as goggles, helmets, etc in order to prevent

personal injury.
7. Insert thrust plates (12) to both sides of the cylinder
rod boss and adjust the right and left clearances
12 5 WDEB-05-02-008
within 1 mm (0.039 in). Install pin (4) by using a
hammer. Apply LOCTITE # 262 onto bolt (1). Secure
pin (4) to the boom with nuts (2) (2 used) and bolt
(1).

j : 24 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

IMPORTANT: After completing the work, operate the
boom cylinder to the stroke end several times and
bleed air from the circuit.

W5-2-1-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Removal and Installation of Arm Cylinder

IMPORTANT: The hose and pipe contain hydraulic
oil. When removing the hose and pipe, receive oils
with a container in order to avoid spilling oils.
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which 1
secure the hoses have been removed.
Removal
1. Park the machine on a solid and level surface. Fully
retract the arm cylinder and bucket cylinder and 2
lower the arm top onto the ground.
2. Place wooden block (3) between arm cylinder (1)
and boom (2). Stop the engine. 3

3. Remove nuts (6) (2 used) and bolt (8) from stopper W187-04-02-005
(7) and pin (5) at the rod side.

j : 24 mm
4
8
fNOTE: LOCTITE # 262 has been applied on bolt (8). 5
1
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
7
4. Remove pin (5) by using a bar and a hammer.
Remove thrust plates (4).

6
W187-04-02-006

W5-2-2-1
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

5. Start the engine. Operate the arm control lever and 1 2

retract arm cylinder (2). In order not to extend rod
(1), pass wires (3) through the rod hole and secure
rod (1) to the arm cylinder (2) tube.
6. Stop the engine.

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.) 3

dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.) W187-04-02-010

7. Disconnect hoses (4) (2 used) and hose (5) from arm

cylinder (2). 2 4 5

j : 19 mm, 36 mm

W102-04-02-014

d CAUTION: Arm cylinder (2) weight: 75 kg (170 lb)

8. Attach the nylon sling onto arm cylinder (2). Hoist
and hold arm cylinder (2). 2

W102-04-02-016

W5-2-2-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

9. Remove nuts (5) (2 used) and bolt (2) from stopper

(6) and pin (4) at the bottom side.

j : 24 mm 1 6 3

fNOTE: LOCTITE # 262 has been applied on bolt (2).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
10. Remove pin (4) by using a bar and a hammer.
Remove thrust plates (3).
11. Hoist and remove arm cylinder (1).
4 2, 5 WDEB-05-02-002

W5-2-2-3
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Installation

dCAUTION: Arm cylinder (1) weight: 75 kg (170 lb)

1
1. Attach the nylon slings onto arm cylinder (1).
Hoist arm cylinder (1). Fit the holes on the cylinder
bottom side to the cylinder mounting holes on
boom.
IMPORTANT: Use one or more thrust plates (3)
respectively at the left and right sides.
2. Fit the holes of thrust plates (3) and the left and
right sides at cylinder bottom side. Adjust the
clearance between cylinder bottom side and
cylinder mounting hole of boom within 1 mm W102-04-02-016
(0.039 in).

fNOTE: Thrust plate (3) thickness: 1 mm (0.039 in), 2 mm

(0.079 in)

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
1 6 3

such as goggles, helmets, etc in order to prevent

personal injury.
3. Install pin (4) by using a hammer.
4. Apply LOCTITE # 262 onto bolt (2). Install bolt (2) to
pin (4) and stopper (6) with nuts (5) (2 used).

j : 24 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

4 2, 5 WDEB-05-02-002

W5-2-2-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

5. Connect hose (3) to arm cylinder (1). Apply grease. 1 2 3

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

6. Connect hoses (2) (2 used) to arm cylinder (1).

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
7. Remove wires (5) from rod (4) of arm cylinder (1). W102-04-02-014
Start the engine. Operate the arm control lever and
fit the hole at cylinder rod side to the mounting
hole on arm (6). 4 1
IMPORTANT: Use one or more thrust plates (7)
respectively at the right and left sides.
8. Fit the holes of thrust plates (7) and the left and 6
right sides at cylinder rod side. Adjust the clearance
between cylinder rod side and cylinder mounting
hole of arm (6) within 1 mm (0.039 in). 5

fNOTE: Thrust plate (7) thickness: 1 mm (0.039 in), 2 mm

(0.079 in) W187-04-02-010

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
9. Install pin (8) by using a hammer.
10. Apply LOCTITE # 262 onto bolt (12). Install bolt (12)
7
to pin (8) and stopper (11) with nuts (9) (2 used). 12 8
11
j : 24 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

IMPORTANT: After completing the work, operate the
arm cylinder several times to the stroke end and 6
bleed air from the circuit.

W187-04-02-006

W5-2-2-5
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

(Blank)

W5-2-2-6
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Removal and Installation of Bucket Cylinder

IMPORTANT: The hose and pipe contain hydraulic
oil. When removing the hose and pipe, receive oils
with a container in order to avoid spilling oils.
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed. 1
Removal
1. Park the machine on a solid and level surface. Fully
retract the arm cylinders and the bucket cylinders
and lower the boom. Place the arm end on the 3
ground.
2
2. Insert wooden blocks (3) (2 used) under the arm (2) 3
top and between bucket cylinder (1) and arm (2).
Stop the engine. W178-02-11-287

dCAUTION: Before removing pin (7), secure the

link by using wires in order not to fall off.
4 5
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
3. Remove nuts (6) (2 used) and bolt (4). Remove pin
(7) by using a bar and a hammer. Remove thrust
plates (5).

j : 24 mm

fNOTE: LOCTITE # 262 has been applied on bolt (4).

7 6
WDEB-05-02-010

W5-2-3-1
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

4. Start the engine. Operate the bucket control lever 1 2

and retract bucket cylinder (2). In order not to
extend rod (1), pass wire (3) through the rod hole
and secure rod (1) to the bucket cylinder (2) tube.
5. Stop the engine.

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)

dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.)
3 W102-04-02-005
6. Disconnect hoses (6) (2 used) from bucket cylinder
(2).

j : 27 mm
2 6 4 8 7
dCAUTION:
lb)
Bucket cylinder (2) weight: 50 kg (115

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
7. Attach the nylon slings onto bucket cylinder (2).
Hoist and hold bucket cylinder (2). Remove nuts (7)
(2 used) and bolt (4). Remove pin (5) by using a bar
and a hammer. Remove thrust plate (8).

j : 24 mm 6 5 WDEB-05-02-003

fNOTE: LOCTITE # 262 has been applied on bolt (4).

8. Hoist and remove bucket cylinder (2).

W5-2-3-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Installation

dCAUTION:
lb)
Bucket cylinder (4) weight: 50 kg (115
4 3 1 7 6

1. Attach the nylon slings onto bucket cylinder (4).

Hoist bucket cylinder (4). Fit the hole at the cylinder
bottom side to the cylinder mounting hole on the
arm.
IMPORTANT: Use one or more thrust plates (7)
respectively at the right and left sides.
2. Fit the holes of thrust plates (7) and the left and
right sides at cylinder bottom side. Adjust the total
clearance of left and right within 1 mm (0.039 in).

fNOTE: Thrust plate (7) thickness: 1 mm (0.039 in), 2 3 2 5

mm (0.079 in) WDEB-05-02-003

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
3. Install pin (2) by using a hammer.
4. Apply LOCTITE # 262 onto bolt (1). Install bolt (1) to
stopper (6) and pin (2) of the arm with nuts (5) (2
used).

j : 24 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

5. Connect hoses (3) (2 used) to bucket cylinder (4).

j : 27 mm

m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

W5-2-3-3
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

IMPORTANT: Check the hydraulic oil level. Start the 1 2

engine and check for any oil leaks.
6. Remove wires (3) from rod (1) of bucket cylinder (2).
Start the engine. Operate the bucket control lever.
Fit the hole at cylinder rod side with the holes of link
A (4) and link B (9). Fit thrust plates (7) (2 used) with
the holes of link A (4) and link B (9).
MPORTANT: Use one or more thrust plates (7)
respectively at the right and left sides.
7. Fit the holes of thrust plates (7) and the left and
3 W102-04-02-005
right sides at cylinder rod side. Adjust the clearance
between cylinder rod side and cylinder mounting
hole of link A (4) within 1 mm (0.039 in).
4 5 7
fNOTE: Thrust plate (7) thickness: 1 mm (0.039 in)

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
8. Install pin (10) by using a hammer.
9. Apply LOCTITE # 262 onto bolt (5). Install bolt (5) to
stopper (6) and pin (10) with nuts (8) (2 used).

j : 24 mm WDEB-05-02-010
10 9 8 6
m : 80 N·m (8 kgf·m, 59 lbf·ft)
IMPORTANT: In case link B (9) has been removed 11 11
from the arm, insert thrust plates (11) (2 used)
when installing.
IMPORTANT: After completing the work, operate the
bucket cylinder to the stroke end several times
and bleed air from the circuit.
W178-02-11-289
9 9

W5-2-3-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Removal and Installation of Boom Swing 1

Cylinder
IMPORTANT: The hose and pipe contain hydraulic
oil. When removing the hose and pipe, receive oils
with a container in order to avoid spilling oils.
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.
M1P1-07-044

Removal
The procedure starts on the premise that the front
attachment has swung to the left.
1. Park the machine on a solid and level surface. Fully
retract the arm cylinder and the bucket cylinder and
lower the boom. Place the arm end on the ground.
2 3
2. Open cover (1).
3. Attach the nylon slings onto boom swing cylinder 4
(7). Hoist and hold boom swing cylinder (7).
4. Remove nuts (2) (2 used) from bolt (5). Remove bolt 5
(5) from swing post (3).
6
j : 24 mm
7
fNOTE: LOCTITE #262 has been applied on bolt (5).
5. Remove pin (4), thrust plates (6), and boom swing
cylinder (7) from swing post (3).
WBAT-06-01-045
6. Start the engine. Retract the cylinder rod to the
stroke end. In order not to extend the cylinder rod,
pass wires through the boss of cylinder rod and
secure it.

W5-2-4-1
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)

dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.)
8

7. Disconnect hoses (8) (2 used) from boom swing

cylinder (7).

j : 22 mm

dCAUTION: Remove cover (11) while holding it.

Do not drop cover (11).
8. Remove bolts, washers (9) (6 used). Remove cover
(11) from frame (10).

j : 17 mm
7 WDEE-05-02-002

9 10 11 9

dCAUTION:
(155 lb)
Boom swing cylinder (7) weight: 70 kg

9. Remove bolt (14) and washer (12) from pin (13). WBAT-06-01-047
Remove pin (13) from frame (10). A

j : 24 mm Detail A
10. Remove boom swing cylinder (7) and thrust plates 12 10
(15) from frame (10).
7

15

13

14 WBAT-06-01-048

W5-2-4-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Installation 9 10 11 9

dCAUTION:
(155 lb)
Boom swing cylinder (7) weight: 70 kg

1. Attach the nylon slings onto boom swing cylinder

(7). Hoist boom swing cylinder (7). Fit the holes on
the cylinder bottom side to the cylinder mounting
holes on frame (10).
IMPORTANT: Use one or more thrust plates (15) WBAT-06-01-047
respectively at the upper and lower sides. A
2. Fit the holes of thrust plates (15) and the upper
and lower sides at cylinder bottom side. Adjust Detail A
the clearance between cylinder bottom side and 12 10
cylinder mounting hole of frame (10) within 1 mm
(0.039 in). 7

fNOTE: Thrust plates (15) thickness: 1 mm (0.039 in) 15

3. Secure boom swing cylinder (7) to frame (10) with
pin (13), washer (12), and bolt (14). 13
j : 24 mm

m : 210 N·m (21 kgf·m, 155 lbf·ft) 14 WBAT-06-01-048

4. Install cover (11) to frame (10) with bolts, washers

(9) (6 used).

j : 17 mm
8
m : 50 N·m (5 kgf·m, 37 lbf·ft)
5. Connect hoses (8) (2 used) to boom swing cylinder
(7).

j : 22 mm

m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

6. Remove the wires from the rod side of boom swing
cylinder (7).
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
7 WDEE-05-02-002

W5-2-4-3
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

7. Start the engine with the cylinder rod retracted to

2 3
the stroke end. Slowly extend the cylinder rod. Fit
the pin (4) holes on boom swing cylinder (7) and
4
swing post (3).

fNOTE: When the work in step 7 is finished, air in the 5

cylinder has been released.
IMPORTANT: Use one or more thrust plates (6) 6
respectively at the upper and lower sides.
8. Fit the holes of thrust plates (6) and the upper and 7
lower sides at cylinder rod side. Adjust the clearance
between cylinder rod side and cylinder mounting
hole of swing post (3) within 1 mm (0.039 in). WBAT-06-01-045

fNOTE: Thrust plates (6) thickness: 1 mm (0.039 in)

IMPORTANT: Install nut (2) so that the clearance
between the boss of swing post (3) and nut (2)
should be 2 to 3 mm (0.079 to 0.118 in). 1
9. Apply LOCTITE #262 onto bolt (5). Secure boom
swing cylinder (7) to swing post (3) with pin (4), bolt
(5), and nuts (2) (2 used).

j : 24 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

10. Close cover (1).
IMPORTANT: After completing the work, operate
boom swing cylinder (7) to the stroke end several
times and bleed air from the circuit. M1P1-07-044

W5-2-4-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Disassembly of Boom, Arm, and Bucket Cylinders

Boom Cylinder

WDEB-05-02-001

W5-2-5-1
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Arm Cylinder

WDEA-05-02-002

W5-2-5-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Bucket Cylinder

WDEB-05-02-014

1- Cylinder Tube 10- Backup Ring 15- Cushion Ring (only Boom 20- O-Ring
3- Cylinder Rod 11- Dust Seal Cylinder) 21- Backup Ring (2 Used)
5- Cylinder Head 12- O-Ring (Boom Cylinder: 2 16- Piston 22- Nut
6- Bushing Used) 17- Seal Ring 23- Set Screw
7- Retaining Ring 13- Backup Ring (Boom Cylinder: 18- Wear Ring (2 Used) (Bucket 25- Ring (only Arm Cylinder)
8- Seal 3 Used) Cylinder: 1 Used) 26- Plunger (only Arm Cylinder)
9- U-Ring 14- O-Ring 19- Dust Seal (2 Used)
a- Detent

W5-2-5-3
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Disassembly of Boom, Arm, and Bucket Cylinders

 The procedure starts on the premise that the IMPORTANT: Pull out cylinder rod (3) straight in
pipes and the bands securing the pipes have been order not to damage the sliding surface.
removed. 3. Pull out cylinder rod (3) from cylinder tube (1) fully.
dCAUTION: Boom cylinder weight: 88 kg (195 lb) Attach the nylon slings onto cylinder rod (3). Hoist
and hold cylinder rod (3). Remove cylinder head (5)
Arm cylinder weight: 71 kg (160 lb)
from cylinder tube (1). Remove the cylinder rod (3)
Bucket cylinder weight: 47 kg (105 lb) assembly from cylinder tube (1).
1. Hoist the cylinder. Secure the cylinder horizontally 4. Secure cylinder rod (3) on the special tool (ST 5908).
on a workbench. Drain hydraulic oil from the Put the matching marks on the ends of cylinder rod
cylinder. (3) and nut (22).

W102-04-02-027

2. Raise a part of detent (a) in the groove of cylinder

head (5). Loosen cylinder head (5) one to two turns
by using a hook wrench. Special Tool for Cylinder: ST 5908
Hook Wrench: W158-04-02-022

ST 3162: 148 mm (Boom Cylinder)

ST 3162: 127 mm (Arm Cylinder, Bucket Cylinder)

W5-2-5-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

5. Cut away the crimped part by using a hand drill. 8. Remove wear rings (18) (2 used) (bucket cylinder: 1
Remove set screw (23). used), seal ring (17), dust seals (19) (2 used), buckup
rings (21) (2 used), and O-rings (20) from piston (16).
l : 4 mm
9. Remove cylinder head (5) from cylinder rod (3).
fNOTE: Set screw (23) has been crimped by using a
10. Remove dust seal (11), buckup ring (10), U-ring (9),
punch at two places after installing.
seal (8), O-ring (12) (boom cylinder: 2 used), buckup
fNOTE: LOCTITE #242 has been applied on set screw ring (13) (boom cylinder: 3 used), and O-ring (14)
(23). from cylinder head (5).
6. Remove nut (22) by using the special tool (ST 5908) IMPORTANT: Do not remove bushing (6) unless
and the special tool for nut. damage and wear are found.
Special Tool for Nut: ST 3261: 70 mm 11. Remove retaining ring (7). Remove bushing (6).

fNOTE: Bushing (6) cannot be tapped and removed from

cylinder head (5). Shape it on a lathe. Insert a screwdriver
and remove it.
IMPORTANT: Ring (25) and plunger (26) can not be
disassembled. (Ring (25) and plunger (26) is not
equipped for the boom and bucket cylinders.)
Special Tool for Cylinder: ST 5908
W158-04-02-022

7. Remove piston (16) by using the special tool for

piston. Remove cushion ring (15) from cylinder rod
(3). (Cushion ring (15) is not equipped for the arm
and bucket cylinders.)
Special Tool for Piston:
ST 3371: 85 mm (Boom Cylinder)
ST 3431: 70 mm (Arm Cylinder)
ST 3430: 64 mm (Bucket Cylinder)

W5-2-5-5
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Assembly of Boom, Arm, and Bucket Cylinders

Boom Cylinder

3 1, a 15 22 23

A B

WDEA-05-02-004

Detail A Detail B
14 5 13 12 13 12 13 16 19 18 17 18 19

21
20
21

WDEA-05-02-007 WDEA-05-02-008

11 9 10 8 6 7

W5-2-5-6
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Arm Cylinder

1, a 23 22 25, 26

A B

WDEA-05-02-005

Detail A Detail B
5 14 13 12 16 19 18 17 18 19

21
20
21

WDEA-05-02-009 WDEA-05-02-008

11 9 10 8 6 7

W5-2-5-7
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Bucket Cylinder

1, a 22 23

A B

WDEA-05-02-006

Detail A 5 14 13 12 Detail B
19 17 18 19

21
16 20
21

WDEA-05-02-009 WDEA-05-02-010

11 9 10 8 6 7

1- Cylinder Tube 10- Backup Ring 15- Cushion Ring (only Boom 20- O-Ring
3- Cylinder Rod 11- Dust Seal Cylinder) 21- Backup Ring (2 Used)
5- Cylinder Head 12- O-Ring (Boom Cylinder: 2 16- Piston 22- Nut
6- Bushing Used) 17- Seal Ring 23- Set Screw
7- Retaining Ring 13- Backup Ring (Boom Cylinder: 18- Wear Ring (2 Used) (Bucket 25- Ring (only Arm Cylinder)
8- Seal 3 Used) Cylinder: 1 Used) 26- Plunger (only Arm Cylinder)
9- U-Ring 14- O-Ring 19- Dust Seal (2 Used)
a- Detent

W5-2-5-8
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Assembly of Boom, Arm, and Bucket Cylinders

5. Install seal ring (17) to piston (16) by using the
1. Install bushing (6) to cylinder head (5).
special tool. After installing seal ring (17), adjust seal
Special Tool for Bushing (Rod Outer Diameter): ring (17) by using the special tool.
ST 8015: 65 mm (Boom Cylinder) Special Tool for Seal Ring (Tube Inner Diameter):
ST 8012: 60 mm (Arm Cylinder) ST 2963: 115 mm (Boom Cylinder)
ST 8011: 55 mm (Bucket Cylinder) ST 2976: 95 mm (Arm Cylinder)
IMPORTANT: Check the direction to install U-ring (9) ST 2938: 85 mm (Bucket Cylinder)
and seal (8).
6. Install wear rings (18) (2 used) (bucket cylinder:
2. Install U-ring (9), backup ring (10), and seal (8) to 1 used), dust seals (19) (2 used), O-ring (20), and
cylinder head (5). backup rings (21) (2 used) to piston (16).
3. Install dust seal (11) to cylinder head (5) by using a 7. Install the cylinder head (5) assembly to cylinder rod
plastic hammer. (3).
Special Tool for Dust Seal (Rod Outer Diameter): Special Tool for Cylinder Head (Rod Outer Diameter):
ST 8015: 65 mm (Boom Cylinder) ST 8015: 65 mm (Boom Cylinder)
ST 8012: 60 mm (Arm Cylinder) ST 8012: 60 mm (Arm Cylinder)
ST 8011: 55 mm (Bucket Cylinder) ST 8011: 55 mm (Bucket Cylinder)
4. Install O-ring (12) (boom cylinder: 2 used), O-ring
(14), and backup ring (13) (boom cylinder: 3 used)
to cylinder head (5).

W5-2-5-9
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

IMPORTANT: Check the direction of the oil groove in IMPORTANT: In case cushion ring (15) is stuck,
cushion ring (15). repeat the procedures in step 8 to step 9. (Cushion
8. Install cushion ring (15) and the piston (16) ring (15) is not equipped for the arm and bucket
assembly to cylinder rod (3) by using the special cylinders.)
tool (ST 5908) and the special tool for piston. 10. Check that cushion ring (15) is not stuck.
(Cushion ring (15) is not equipped for the arm and
11. Apply LOCTITE #242 onto set screw (23). Tighten set
bucket cylinders.)
screw (23) to nut (22). Crimp set screw (23) by using
Special Tool for Piston: a punch (2 places).
ST 3371: 85 mm (Boom Cylinder) l : 4 mm
ST 3431: 70 mm (Arm Cylinder)
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
ST 3430: 64 mm (Bucket Cylinder)

m : 491±49 N·m (49±4.9 kgf·m, 360±36 lbf·ft)

dCAUTION: Fit the cylinder rod (3) assembly to the
center of cylinder tube (1) and install it in order
not to damage the rings.
12. Secure cylinder tube (1) on a workbench
horizontally. Insert the cylinder rod (3) assembly
into cylinder tube (1).
Special Tool for Piston:
ST 7752: 115 mm (Boom Cylinder)

Special Tool for Cylinder: ST 5908 ST 7753: 95 mm (Arm Cylinder)

W158-04-02-022 ST 7754: 85 mm (Bucket Cylinder)

13. Tighten cylinder head (5) to cylinder tube (1) by
9. Fit the matching marks before disassembling and using the hook wrench (ST 3162). Bend detent (a)
tighten nut (22) by using the special tool (ST 5908) and secure cylinder head (5).
and the special tool for nut.
(Boom Cylinder, Bucket Cylinder)
Special Tool for Nut: ST 3261: 70 mm
m : 736±74 N·m (74±7.4 kgf·m, 540±55 lbf·ft)
m : 736±74 N·m (74±7.4 kgf·m, 540±55 lbf·ft)
(Arm Cylinder)

m : 882±88 N·m (88±8.8 kgf·m, 650±65 lbf·ft)

W5-2-5-10
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Disassembly of Boom Swing Cylinder

2
3
4
5

6
7
8
9
10
1
11
12
13
14
15
16
17

18

19
31
20

21
22
23
24
25
26
27
28
30
29
WBAT-04-02-004

1- Cylinder Rod 9- O-Ring 17- Backup Ring 25- Cushion Seal

2- Wiper Ring 10- O-Ring 18- Cushion Bearing 26- Cushion Bearing
3- U-Ring 11- Collar 19- Slide Ring 27- Halved Stopper (2 Used)
4- Buffer Ring 12- Cushion Seal 20- Piston 28- Nut
5- Cylinder Head 13- Cushion Seal 21- Seal Ring 29- Steel Ball
6- Bushing 14- Holder 22- O-Ring 30- Set Screw
7- Retaining Ring 15- Backup Ring 23- Slide Ring 31- Cylinder Tube
8- Backup Ring 16- O-Ring 24- Retaining Ring

W5-2-6-1
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Disassembly of Boom Swing Cylinder

The procedure starts on the premise that the pipes and 5. Cut away the crimped part by using a hand drill.
the bands securing the pipes have been removed. Remove set screw (30). Remove steel ball (29) from
d CAUTION: Boom swing cylinder weight: 70 kg
(155 lb)
nut (28).

l : 5 mm
IMPORTANT: The seals cannot be reused. Replace
them with the new ones. fNOTE: Set screw (30) has been crimped by using a
1. Hoist the cylinder and secure it on a workbench punch (2 places) after installing.
horizontally. Drain off hydraulic oil from the 6. Remove nut (28) from cylinder rod (1) by using the
cylinder. special tool (ST 5908) and the special tool (ST 3271).
Remove piston (20) and cushion bearing (18) from
cylinder rod (1).
Special tool: 75 mm (ST 3271)
7. Remove halved stoppers (27) (2 used), cushion
bearing (26), cushion seal (25), and retaining ring
(24) from cylinder rod (1).

W102-04-02-027 fNOTE: Halved stopper (27) can be removed after

removing retaining ring (24) and sliding cushion bearing
2. Extend detent (a) (a part of cylinder tube (31), Refer (26).
to W5-2-6-4.). Loosen cylinder head (5) one to two Insert a screwdriver into the notch and remove cushion
turns by using the special tool (ST 3162). seal (25).
Special tool: 138 mm (ST 3162) 8. Remove holder (14) and cylinder head (5) from
cylinder rod (1).
IMPORTANT: Remove cylinder rod (1) straight in
order not to damage the rod surface.
3. Pull out cylinder rod (1) from cylinder tube (31) fully.
Attach the nylon slings onto cylinder rod (1). Hold
cylinder rod (1). Remove cylinder head (5) from
cylinder tube (31). Remove cylinder rod (1) from
cylinder tube (31).
4. Secure cylinder rod (1) on the special tool (ST 5908).
Put the matching marks on the ends of cylinder rod
(1) and piston (20).

ST 5908

W158-04-02-022

W5-2-6-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

IMPORTANT: When removing the seals, do not

damage the parts.
IMPORTANT: Slide rings (19, 23) cannot be reused.
When disassembling the cylinder, replace them
with the new ones.
9. Remove slide rings (19, 23), seal ring (21), and
O-ring (22) from piston (20).
IMPORTANT: Bushing (6) cannot be reused. When
bushing (6) has been removed, replace it with the
new one when assembling.
10. Remove wiper ring (2), U-ring (3), buffer ring (4),
retaining ring (7), and bushing (6) from the inside of
cylinder head (5) by using the special tool (ST 8012).
Special tool: 60 mm (ST 8012)
11. Remove backup ring (8) and O-rings (9, 10) from the
outside of cylinder head (5).
12. Remove cushion seals (13, 12) and collar (11) from
the inside of holder (14).
13. Remove backup rings (17, 15) and O-ring (16) from
the outside of holder (14).

W5-2-6-3
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Assembly of Boom Swing Cylinder

2 5 3 10 a 4 6 8, 9 1 31 18 20 19 22 21 23 28 30 29

24

26
b

27

25
W1CF-04-02-005

Detail of Position S
14 11 15 16 17 12 13

W1CF-04-02-013 c W1CD-04-02-009

a- Detent c- Face the slit to the piston side.

b- Hole

1- Cylinder Rod 9- O-Ring 17- Backup Ring 25- Cushion Seal

2- Wiper Ring 10- O-Ring 18- Cushion Bearing 26- Cushion Bearing
3- U-Ring 11- Collar 19- Slide Ring 27- Halved Stopper (2 Used)
4- Buffer Ring 12- Cushion Seal 20- Piston 28- Nut
5- Cylinder Head 13- Cushion Seal 21- Seal Ring 29- Steel Ball
6- Bushing 14- Holder 22- O-Ring 30- Set Screw
7- Retaining Ring 15- Backup Ring 23- Slide Ring 31- Cylinder Tube
8- Backup Ring 16- O-Ring 24- Retaining Ring

W5-2-6-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Assembly of Boom Swing Cylinder

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Install slide rings (19, 23) in order not
onto parts in order to prevent them from seizing. to align their split positions at the same place.
IMPORTANT: The seals cannot be reused. Replace 7. Install slide rings (19, 23) to piston (20).
them with the new ones.
IMPORTANT: Install cushion bearing (18) with the
1. Install bushing (6) to cylinder head (5) by using the larger split part facing to the cylinder head (5)
special tool (ST 8012). Install retaining ring (7) to side.
cylinder head (5).
8. Install cushion bearing (18) to cylinder rod (1).
Special tool: 60 mm (ST 8012)
IMPORTANT: Install U-ring (3) with its lip part facing
to the bushing (6) side.
Install buffer ring (4) with its projection part and
slit part facing to the bushing (6) side.
2. Install U-ring (3), buffer ring (4), backup ring (8), and
O-rings (9, 10) to cylinder head (5).
3. Install wiper ring (2) to cylinder head (5) by using
the special tool (ST 8012) and a plastic hammer.
Special tool: ST 8012
IMPORTANT: Install collar (11) with its slit part facing
to the cushion seal (12) side.
4. Install cushion seals (13, 12), collar (11), backup ring
(17), O-ring (16), and backup ring (15) to holder (14).
5. Install the cylinder head (5) assembly and the holder
(14) assembly to cylinder rod (1) by using the special
tool (ST 8012).
Special tool: ST 8012
IMPORTANT: Check that O-ring (22) is not twisted.
6. Install O-ring (22) and seal ring (21) to piston (20). At
this time, do not push them in the groove on slide
ring (19) or slide ring (23) by using a spatula.

W5-2-6-5
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

IMPORTANT: Install cushion seal (25) with its slit part 14. Tighten cylinder head (5) to cylinder tube (31) by
facing to the piston (20) side. using the special tool (ST 3162). Bend detent (a) and
Install cushion bearing (26) with the larger split secure cylinder head (5).
part facing to the cylinder bottom side. Special tool: 138 mm (ST 3162)
9. Install cushion seal (25) and cushion bearing (26) to
cylinder rod (1). m : 834 N·m (83 kgf·m, 620 lbf·ft)

10. Slide cushion bearing (26) to the piston (20) side

and install halved stoppers (27) (2 used).
Slide cushion bearing (26) to the halved stopper
(27) side and install retaining ring (24).
11. Install piston (20) to cylinder rod (1). Fit the
matching marks and tighten nut (28) by using the
special tool (ST 5908) and the special tool (ST 3271).
Special tool: 75 mm (ST 3271)

m : 2470 N·m (245 kgf·m, 1820 lbf·ft)

ST 5908

W158-04-02-022

12. Fit the holes on cylinder rod (1) and nut (28). Install
steel ball (29). Tighten steel ball (29) to nut (28)
with set screw (30). Crimp set screw (30) by using a
punch (2 places) after tightening set screw (30).

l : 5 mm

m : 31.5±5.88 N·m (3.2±0.6 kgf·m, 23±4.3 lbf·ft)

IMPORTANT: When inserting cylinder rod (1), do
not damage the rings. Align the cylinder rod (1)
assembly with the center of cylinder tube (31) and
insert it straight.
13. Apply THREEBOND #1901 onto the thread part of
cylinder head (5). Secure cylinder tube (31) on a
workbench horizontally. Insert the cylinder rod (1)
assembly into cylinder tube (31).

W5-2-6-6
MEMO
MEMO
Hitachi Construction Machinery Co., Ltd. Hitachi Ref. No.
Attn: Technical Information Center
Tel: 81-29-982-7084
Fax: 81-29-831-1162
E-mail: HCM-TIC-GES@[Link]

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