1-2 Work Shop Manual SCX550E WRHAE0-EN-00

WRHAE0-EN-00
SCX550E
CRAWLER CRANE
Workshop Manual
WORKSHOP MANUAL
SCX550E
Crawler Crane
HITACHI SUMITOMO HEAVY INDUSTRIES

CONSTRUCTION CRANE Co., Ltd.
PRINTED IN JAPAN (KW) 2013.01

INTRODUCTION
TO THE READER
 This manual is written for an experienced technician

to provide technical information needed to maintain
and repair this machine.
• Be sure to thoroughly read this manual for correct

product information and service procedures.
ADDITIONAL REFERENCES
 Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
PAGE NUMBER
 Each page has a number, located on the center

lower part of the page, and each number contains
the following information:
Example : W 1-3-5
Consecutive Page Number for Each Group

Group Number
Section Number
W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and  CAUTION:
signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.  IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
 NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.
UNITS USED
 SI Units (International System of Units) are used in 2

Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature C F C1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgfm 1.0197 mL/rev cc/rev 1.0
Nm lbfft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
 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 don’t 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 messages in this SA-1223
manual.
 To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indicates a
situation which, if not avoided, could result in damage to
the machine.
 NOTE indicates an additional explanation for an

element of information.
SA-1
SAFETY
1 BASIC PRECAUTIONS
1.1 Follow Safety Instructions

Read this manual and the safety labels carefully to fully
understand the instructions and handle the machine
safely.
 Sections that include CAUTION describe basic

safety instructions. However, even for situations not
covered by this manual, always pay careful attention to
SA-003
safety.
1.2 Wear Safe Clothes and Protective Gear

Loose clothes may catch on the control levers or
machine protrusions, resulting in personal injury or death.
Wear clothes that are appropriate for the work.
Wear protective gear that is appropriate for the work.
Check that the protective gear functions properly before
using it.
SA-438
1.3 Protect Against Noise

Loud ambient noise may lead to hearing loss or
deafness.
 If prolonged exposure to loud noise is unavoidable,
such as during engine maintenance, wear ear
covers or earplugs.
SA-434
1.4 Coordinate with the Personnel Concerned

If work coordination is omitted or inadequate, it may
result in an accident.
Before starting work, hold a meeting with the personnel
concerned to coordinate the following work procedures.
1.5 Always Signal Properly

Failure to signal properly may result in personal injury or
death.
SA-481
SA-2
SAFETY
1.6 Prepare for Emergencies
Decide in advance who to contact and what action to
take in the event of an accident or fire. Learn in advance
where the fire extinguishers and first-aid kits are stored
and how to use them.
SA-437
1.7 Keep Personnel Away from the Working Area

Set up barriers around the working area to prevent entry.
Make it a rule for the operator to check that no personnel
or obstructions are present around the machine before
starting work.
SA-432
Protect Against Flying Objects

If flying or falling pieces of gravel, rock or metal hit a
person in the eye or body, serious injury may result.
M25N-02-003
1.8 Operate the Machine in the Correct Position

If the machine is operated in an incorrect position or is
modified, the machine may be damaged or tip over,
resulting in personal injury or death.
Operate the machine in a work position that is
appropriate for the machine specifications. Never
attempt to modify the machine. If you require any
modifications, first contact HITACHI SUMITOMO.
M25N-02-004
1.9 Setting the Machine

If the machine is slanted, it may tip over and result in
personal injury or death.
Set the machine in a level position. Check the strength
of the ground and reinforce any soft ground by laying
down sufficiently strong steel plates.
MRHAE0-02-003
SA-3
SAFETY
1.10 Do Not Remove the Safety Devices
Removal or incorrect use of safety devices may result in
Never remove the safety devices. Maintain the safety
devices so that they function normally and learn the
correct way to use them. Check that all guards and
covers are correctly installed, and that there are no
missing parts or damage. Perform maintenance if there
are any abnormalities.
1.11 Mounting and Dismounting the Machine

Always use the handrails and steps when mounting and
dismounting the machine. Jumping on or off the machine
may lead to a fall or other accident.
When mounting and dismounting, face the machine, use
the steps and handrails, and always maintain contact
with the machine in at least three locations.
SA-439
1.12 Operate the Machine Only from the Operator's

Seat
Starting the engine or operating the machine from a
position other than the operator's seat may result in a
mistaken operation and an accident.
Always sit in the operator's seat when starting the engine
and operating the machine.
SA-444
1.13 Fasten the Seat Belt (If Equipped)

If the machine tips over, the operator may be smashed
against the side of the cab, thrown from the cab, or
thrown under the machine. This may result in serious
injury or death.
SA-237
1.14 Keep Riders off the Machine

Riders on the machine may obstruct the operator's view
and impede operations. Further, the rider may fall off the
machine or be trapped against an obstruction, resulting
in a serious accident.
M25N-02-006
SA-4
SAFETY
1.15 Do Not Lift a Person
If you lift a person with the crane, the person may fall,
resulting in a serious accident.
Do not lift people.
SA-333
1.16 Prevent Tipping-Over Accidents

If the slanting, weight or vibration of the machine causes
ground subsidence, sagging or collapse, the machine
may tip or roll over and cause personal injury or death.
Operate and travel the machine only on solid, level
ground. Before setting the machine, inspect the landform
and geological conditions, and check for bridges or other
structures.
If the ground is soft, slanted or has underground
structures, reinforce the ground and make it level using
steel plates of the required size and strength.
MRHAE0-02-005
1.17 Avoid Power Lines

If the machine or lifted load makes contact with or goes
too close to power lines, it may result in an electrical
shock.
Prevent Electrical Shocks
When working near power lines, take the following
measures to prevent electrical shocks.
 Contact the electric utility in advance to discuss safety
Number of
before starting work.
 Keep bystanders away from the machine and the lifted Safety Insulators
Voltage
load. Distance (Reference
 Appoint a signal person and obey this person's signals. only)
 Keep a safe distance between the power lines and the
Low
machine and lifted load. Up to 6600 V 2m 1 to 2
 Confirm the voltage of the power lines with the electric voltage
utility. The number of insulators is approximate. Use it as 22000 V 3m 2 to 4
a guideline only.
 Personnel involved in the job must wear rubber or Specially 66000 V 4m 5 to 9
leather soled shoes. high 154000 V 5m 10 to 20
 If operation near power lines is unavoidable, be sure to voltage
use the proper electrical shock protective equipment. 275000 V 7m 16 to 30
• Ask the electric utility to perform the installation and 500000 V 11 m More than 31
removal of the electrical shock protective equipment.
SA-5
SAFETY
Measures in the Event of an Electrification Accident
Take the following measures if an electrification accident
occurs.
 Immediately contact the electric utility or management

company to shut down the power supply and obtain
instructions from them for emergency measures.
 Operate the machine to move it away from the cause of
electrification.
 Evacuate workers from the area and keep other people
away from the electrified machine and lifted load to
prevent secondary accidents.
 If people have been electrified, try to get them to escape
from the electricity source by themselves.
• Make sure that the machine is no longer electrified
before trying to help anyone who has suffered an
electrical shock.
 The operator should stay in the operator's cab until the
machine has been separated from the source of the
electrification. If the operator must get off the machine,
he or she should use a wooden ladder or jump as far as
possible off the machine.
• If a metal ladder must be used, lay a wooden board
under the ladder. The operator must climb down the
ladder and step on the board, and release his or her
hands from the ladder before stepping from the board
onto the ground.
• If the operator decides to jump from the machine,
place cushioning materials such as mats in the target
position. The operator must make sure that no part of SA-468
his or her body will touch the machine when landing

on the ground.
Inspection after an Accident
Inspect all machine parts before restarting operation. If
any abnormalities are found, contact your nearest
HITACHI SUMITOMO distributor for maintenance.
1.18 Beware of Charging by Strong Radio Waves

When the machine is operated near a radio or television
transmitting station, the wire ropes or hook may become
charged. This may result in injury when slinging or
damage to safety devices.
Before slinging, ground the hook to
discharge the electricity.
SA-402
SA-6
SAFETY
1.19 Stop Operation When Lightning Is Expected
If the machine is struck by lightning, it may result in the
injury or death of the operator or people around the
machine. It may also damage machine parts.
In the event of an electrical storm, immediately stop
operation and lower the lifted load to the ground. Lay the
boom on the ground and stop the engine.
Go to a safe location away from the machine.
After the storm has passed, inspect all machine parts
before restarting operation. If any abnormalities are
found, contact your nearest HITACHI SUMITOMO
distributor for maintenance.
SA-336
1.20 Wind Precautions

Effects of Wind
If work is performed during strong wind, the machine
may tip over.
If the wind speed exceeds 10 m/s, stop operation. Take
action as described in "Wind Countermeasures" in
accordance with the wind velocity.
 The longer the boom or jib, the higher the lifted load
position, and the larger the lifted load area that is
exposed to the wind, then the greater the effect of the
wind and the greater the risk of the machine being tipped
over or damaged.
 If a strong wind blows from the front while the boom
angle is at its maximum and no load is suspended, the
boom or jib may whip up and cause the machine to tip
over backward.
 Wind strength varies greatly depending on the landform
and the height above the ground. Be very careful while
working.
M25N-02-015
SA-7
SAFETY
Estimation of Wind Velocity
The wind velocity described in this section is the
instantaneous wind velocity at the tip of the boom.
If the machine is not equipped with an anemometer, Anemometer
estimate the instantaneous wind velocity by multiplying
the mean wind velocity in the "Wind Velocity Conversion
Table" on the this page by 1.5 to 1.7.
 Use the "Wind Velocity Conversion Table" to convert the

value derived from the mean velocity of the anemometer
at the job site office into the mean velocity at the tip of
the boom. Then, multiply this number by 1.5 to 1.7 to
obtain the instantaneous wind velocity.
 When using the mean wind velocity in weather reports,
which is based on values measured at 10 meters above
ground for 10 minutes, use "Weather Report Mean Wind
Velocity" in the "Wind Velocity Conversion Table" to
convert the value into the mean velocity at the tip of the M25N-02-018
boom. Then, multiply this number by 1.5 to 1.7 to obtain

the instantaneous wind velocity.
Average Wind Velocity at the Tip of the Boom

Unit: m/s
Height
Above Sea Above Level Ground Above Rural Area Above Urban Area
(m)
10 10.0 10.0 10.0 10.0
15 10.5 10.7 11.1 11.5
20 10.9 11.2 11.9 12.6
25 11.2 11.7 12.6 13.6
30 11.5 12.0 13.2 14.4
40 11.9 12.6 14.1 15.9
50 12.2 13.1 15.0 17.1
75 12.9 14.0 16.5 19.6
100 13.3 14.7 17.8 22.2
125 13.7 15.2 18.8 23.2
150 14.0 15.7 19.7 24.7
200 14.5 16.5 21.1 27.1
NOTE: 1. The wind velocity value available from meteorological agencies is the average value measured at 10
m above the ground.
2. Obtain the approximate instantaneous wind velocity of 1.5 to 1.7 times the value shown in the above
chart.
SA-8
SAFETY
Wind Velocity Reference Guide
The information described on this page is a guideline for machines operated in Japan and shown for
your reference only.
Table 1 Expected Wind Speed Changes in Various Surfaces in Relation to Height Change
(Expected wind speeds at various heights, assuming the wind blows 10 m/s at a height
of 10 m)
Wind Speed (m/s)
Surface Height above the ground (m)
10 20 30 40 50
Surface of Sea 10 10.7 11.2 11.5 11.8
Flat surface, such as a pastureland 10 11.4 12.1 12.7 13.1
Forests, residential areas, capes or uneven
10 11.9 13.2 14.1 15.0
coast lines
Large downtown areas (High-rise building
10 14.1 17.3 20.0 22.4
districts)
Table 2 Standard Wind Speed, Wind Scale and Phenomena Observed

Wind Speed
Name Scale No. Description
(m/s)
0 to 0.5 Calm 0 No wind; smoke rises vertically.
0.6 to 1.7 Light air 1 Direction air movement shown by smoke.
1.8 to 3.3 Light breeze 2 Wind felt on face; leaves rustle.
3.4 to 5.2 Gentle breeze 3 Leaves and small twigs in constant motion, flags wave.
5.3 to 7.4 Moderate breeze 4 Raises dust and loose paper.
7.5 to 9.8 Fresh breeze 5 Small trees begin to sway; small waves form on inland waters.
Large branches in motion; telegraph wires whistle; umbrellas
9.9 to 12.4 Strong breeze 6
used with difficulty.
12.5 to 15.2 Moderate gale 7 Whole trees in motion; difficulty in walking against wind.
15.3 to 18.2 * Fresh gale 8 Breaks twigs off trees; generally impedes progress.
18.3 to 21.5 * Strong gale 9 Slight structural damage occurs; roof tiles blow off.
21.6 to 25.1 * Storm 10 Trees uprooted; considerable structural damage occurs.
25.2 to 29 * Violent storm 11 Widespread damage occurs.
29.1 or more Typhoon/Hurricane 12 Widespread devastation occurs.
NOTE: If winds marked with an asterisk (*) are generated by a tropical cyclone, they may commonly be referred
to as “typhoon winds”.
SA-9
SAFETY
Wind Countermeasures
Crane Attachments
When the wind velocity is lower than 10 m/s:
Refer to the previous section "Effects of Wind" for
the appropriate work position and lifted load
handling, and stop work if required.
Wind
When the wind velocity is 10 to 15 m/s:
Stop work and take the following measures.
1. Position the counterweight on the windward

side.
2. Set the boom angle to 60 degrees.
3. Hoist the hook to the position just before the 60゜
hoist limiting device is activated.
4. Engage the swing lock and apply the swing
brake.
5. Place all control levers in the neutral position.
6. Push the gate lock lever forward. (LOCK M25N-02-024
position)
7. Engage the drum lock and turn the other
switches to OFF or neutral.
8. Stop the engine.
When the wind velocity is 15 to 30 m/s:

Stop work and take the following measures.
If the boom can be lowered to the ground:

1. Lower the hook to the ground.
2. Lower the boom to the ground.
brake.
M25N-02-025
5. Push the gate lock lever forward. (LOCK
position)
7. Stop the engine.
SA-10
SAFETY
If the boom cannot be lowered to the ground
(emergency measure):
1. Position the counterweight on the windward
side.
2. Set the boom angle to 60 degrees.
Wind
3. Sling the anchor weight and tense the hoist
rope.
• Refer to Anchor Weight Table on page SA-12
and prepare the proper anchor weight in
advance.
• Do not lift the anchor weight from the ground
Anchor
when tensing the hoist rope. 60゜ Weight
4. Engage the swing gate lock and apply the
swing brake.
6. Push the lock lever forward. (LOCK position)
M25N-02-026
8. Stop the engine.
When the wind velocity exceeds 30 m/s (in

storms):
When a wind velocity exceeding 30 m/s is expected
due to a storm or typhoon, take the following
measures in advance.
1. Lower the hook to the ground.

2. Lower the boom to the ground.
brake.
5. Push the gate lock lever forward. (LOCK M25N-02-025
position)
7. Stop the engine.
SA-11
SAFETY
Anchor Weight Table
Model Anchor Weight
35 t Class 1 t or more
Measures to be taken after the wind calms

Check all parts of the machine for any abnormalities before restarting operation. Repair the machine if any
abnormalities are found.
SA-12
SAFETY
1.21 Earthquake Precautions
The information described on this page is usually used in Japan as a guideline. Past experience shows that the
crane can usually withstand earthquakes up to intensity 4 on the Japanese scale (a moderate earthquake).
However, no one can predict the time or size of an earthquake. However, no one can predict the time and size of
an earthquake. It is important to always be mentally prepared for an earthquake. Take the following safety
countermeasures.
 Inspect the geological conditions of the job site in advance and study whether there are any problems. If there
are, take countermeasures.
 Take special care after heavy rain, because it becomes easy for the ground to collapse.
 Prepare the ground where you will position the machine to make it level. Select ground that can withstand the
machine weight.
Lay steel plates in the movement area of the machine to make the ground even safer.
 If an earthquake warning or alarm sounds, take safety measures such as laying down the boom.
Get into the habit of laying down the boom at the end of each work session.
 For details on the Japanese shindo earthquake scale, refer to the "Earthquake Intensity Scale" table.
Earthquake Intensity Scale

Intensity Scale Acceleration
Description
Scale Designation (cm/s2)
1 Slight 0.8 to 2.5 Felt by people who are still or very sensitive.
2 Weak 2.5 to 8 Many people can feel. Partitions may slightly rattle.
Houses shake, partitions may rattle.
3 Rather Strong 8 to 25
Also, water in a washbasin ripples.
Houses shake violently. Unstable furniture falls. Also, people who are
4 Strong 25 to 80
walking can feel.
5 Very Strong 80 to 250 Wall cracks. Tall structures may fall.
Many houses (less than 30% of all houses) collapse. Landslides and
6 Disastrous 250 to 400
cracks in the ground. Many people cannot stand.
Higher than Many houses (more than 30 % of all houses) collapse. Landslides and
7 Ruinous
400 cracks in the ground, and dislocations.
SA-13
SAFETY
1.22 Precautions for Stopping Machine Operation
Failure to stop the machine safely after finishing work
may result in an accident.
Before leaving the machine after finishing work, take the
following measures.
 Stop the machine on solid, level ground.

 Set the boom angle to 60 degrees. Wind
 Hoist the hook to the position just before the hoist
limiting device is activated.
 Push the gate lock lever forward. (LOCK position)
 Apply all the brakes and locks, and place the levers in
the neutral position.
 Remove the engine key.
 Lock all the doors and covers.
60゜
If strong wind is expected while the machine is stopped,
take the advance measures described in "Wind
Countermeasures" in "1.20 Wind Precautions".
M25N-02-024
SA-14
SAFETY
2 PREPARATIONS FOR SAFETY
OPERATIONS
2.1 Ensure a Safe Job Site

If safety is not ensured, it may result in personal injury or
death.
Work with the optimum methods for ensuring safety.
Check conditions such as the job site size, the landform
and geological features, the work positions, aisles,
whether there are obstructions, the weight of the load to
be handled, and the crane performance. When working
on a public road, set up barriers and appoint guidance
workers to ensure the safety of passing motorists and MRHAE0-02-003
pedestrians.
SA-15
SAFETY
2.2 Inspection Before Starting Operations
Keep the Safety Signs Clean
Machine Parts Inspection
If the safety signs that are attached to the various
Failure to perform this inspection before starting a day's
machine parts cannot be read, the operator and
work may result in an accident.
workers will not understand the required
Inspect the machine parts and perform maintenance for
precautions, which could result in an accident.
any abnormalities.
Keep the safety signs clean. If any signs are
missing or damaged, attach new ones in the same
Keep Hand Areas, Foot Areas and Aisles Clean and
positions.
Tidy
Do not leave parts or tools lying around, and do not let Precautions in the operator's room
substances such as oil, mud, water or snow attach to
• When entering the operator's room, remove the
areas such as handrails, steps, levers, pedals, floors and
mud, oils and fats, gravels and stones from the
aisles. Otherwise, a slipping or falling accident may
shoe sole.
result.
Wipe off foreign substances such as oil, and do not • Do not leave any parts, tools, gravels, stones,
leave parts or tools in foot areas or aisles. things that are likely to fall, roll or crumble,
empty cans or lunch boxes around the
Clean the Engine Area operator's seat. If something is get caught in the
winch brake pedal, accelerator pedal, lock lever
Dry leaves, pieces of paper or oil grime may cause a fire.
or operation lever, the lever or pedal cannot be
Remove such substances before operation.
operated, which may lead to an unexpected
accident.
Secure Visibility
• Put down a floor mat dedicated to this machine
If visibility is poor, safe work is not possible and an
properly. Otherwise the floor mat will become
accident may occur.
misaligned and interfere with the winch brake
Clean the window glass, lights and mirrors. To ensure
pedal or accelerator pedal and hinder pedal
good visibility, adjust the mirror positions and check that
operation, which may result in an unexpected
the working light and operation light are working normally.
accident.
If there are any abnormalities or damage, perform
maintenance.
SA-435
SA-028
SA-16
SAFETY
2.3 Adjust the Operator's Seat Position
If the operator's seat is not correctly adjusted, it may
result in a mistaken operation and an accident.
Adjust the seat to a position where you can correctly
operate the pedals and levers.
M25N-02-002
2.4 Check Safety Before Starting the Engine

Starting the engine without checking the position of the
operating device or the surrounding safety may cause
Before starting the engine, check the following points,
and sound the horn to alert the personnel around the
machine.
2.5 Warm Up the Machine

Failure to perform a warm up operation may cause
insufficient output during operation, a reduced machine
service life or poor operation, which may result in an
accident.
Perform the warm up operation until the engine and
hydraulic oil is sufficiently warm.
2.6 Perform an Inspection After Starting the

Moment Limiter Display Panel
Engine
Failure to perform an inspection after starting the
engine may cause a delay in finding an instrument,
component or device abnormality, which may result
in an accident. Monitor Panel
After starting the engine, inspect the displays and
components of instruments such as the engine
monitoring lamps. After performing the warm up
operation, check the surrounding safety and then
perform an operation without a load to inspect the
operating condition of parts such as the operating
devices and safety devices. If you find any
abnormalities, repair them immediately.
MRHAE0-02-013
SA-17
SAFETY
2.7 Do Not Deactivate the Safety Devices
Working after deactivating a safety device may result in
Before starting work, make sure that all the safety
devices, such as the moment limiter and hoist limiting
devices, are operating correctly.
If a safety device is abnormal, perform maintenance.
SA-18
SAFETY
3 PRECAUTIONS FOR OPERATION
3.1 Check the Job Site Conditions

Failure to check the surrounding conditions before
operating the machine may result in an accident.
Before starting work, check the surrounding conditions,
such as the work positions, aisles, whether there are
obstructions and the setup positions of other devices. In
addition, always check for changes in the surrounding MRHAE0-02-003
conditions while performing work.
3.2 Avoid Abrupt Operations

Abrupt operations may make the machine or load
unstable, resulting in an accident.
Do not operate the machine abruptly with sudden
operations such as sudden start offs, sudden
acceleration or sudden stops.
3.3 Do Not Operate Inattentively

Inattentive operation may result in an accident.
Concentrate while working, never looking away from the
signal person or the load.
3.4 Do Not Leave the Operator's Seat

Leaving the operator's seat while a load is lifted or the
engine is running may result in an accident.
Before leaving the operator's seat, take the following
measures.
1. Lower the load to the ground.
2. Place the control levers in the neutral position.
3. Apply all brakes and locks.
4. Push the gate lock lever forward. (LOCK position)
5. Engage the drum lock and turn the other switches
to OFF or neutral.
M25N-02-045
6. Stop the engine and remove the key.
7. Lock the operator cab door.
SA-19
SAFETY
3.5 Operate the Machine within the Working Range
Shown in the Gross Rated Load Table
If an incorrect boom length and working radius
combination is used, and if the machine is operated
outside the performance range, the machine may tip Gross
Rated
over or be damaged, resulting in personal injury or Load
death. Performance
Check items such as the boom length, working radius Range
and load in the Gross Rated Load Table. Always operate
within the performance range that is described.
Working
Radius M25N-02-047
3.6 Prevent the Load from Contacting the Boom and

Jib
If the load makes contact with the boom or jib, the load
may fall or the boom or jib may be damaged, resulting in
an accident.
Do not let the load make contact with the boom or jib.
If the load does make contact and causes damage,
immediately stop work, lower the boom to the ground
and contact your nearest HITACHI SUMITOMO
distributor for maintenance.
 When lowering the damaged boom, use the auxiliary
crane.
SA-406
3.7 Precautions When the Engine Stalls

If the engine stalls during work, the load may fall and
cause personal injury or death.
If the engine stalls, immediately apply the brake and
return the drum lever to neutral.
3.8 Keep Away from Obstructions

If the machine or load makes contact with an obstruction,
the machine or obstruction may be damaged, or the load
may fall and cause personal injury or death.
Look out for any obstructions around or above the
machine.
If the machine does make contact with an obstruction
and a wire rope or the load becomes entangled in the
obstruction, remove the entanglement without trying to
forcibly hoist the load.
W25T-SA-003
SA-20
SAFETY
3.9 Beware of Machine Abnormalities
Continuing to work while the machine is in an abnormal
condition may result in an accident.
If abnormalities such as abnormal noise, vibration, heat,
odors, faulty instrument indicators or displays, or fuel, oil
or coolant leaks are found, immediately stop working,
stop the machine in a safe place, find the cause, and
repair.
3.10 Keep Good Visibility

Working while visibility is poor will make it more difficult
to see your footings and people or obstructions in the
surrounding area, and may result in an accident.
In dark locations, turn on the working light and operation
light. If required, set up other lighting equipment to
brighten the area and make it easy to clearly see the
machine and the entire working area.
If visibility is poor because of rain, snow or mist, stop
working and wait for better visibility.
W25T-SA-004
3.11 Cold Weather Precautions take action such as removing snow, melting ice, or
drying parts.
When the weather is cold, poor mechanical
 When starting work, operate the machine slowly with
operation may cause accidents such as falling loads
a light load until the machine is fully lubricated
or collisions during travel. To prevent such accidents,
inside.
warm up the machine sufficiently and strictly
 After finishing work, take measures to ensure that
observe the following points.
the crawler and load do not freeze to the ground,
 Check that the operation of parts such as the safety
and that mud around the machine underbody does
devices, winches and brakes are normal. If required,
not freeze.
3.12 Perform Combined Operations Carefully

When performing combined operations, load swaying or
mistaken operations caused by sudden speed changes
Perform combined operations smoothly without any
sudden speed changes. Do not attempt combined
operations while you are still new to the machine. Wait
until you have mastered the operations.
 Combined operations may result in a slower work speed
than using separate operations. Changing from
combined operations to separate operations may
increase the work speed in some cases.
SA-21
SAFETY
3.13 Do Not Use the Boom to Push or Pull Objects
Pushing or pulling objects with the boom may damage
the boom and cause an accident.
Move objects by lifting them with a crane or specialist
equipment such as a forklift. Do not use the crane for
anything other than its intended application.
M25N-02-057
3.14 Do Not Over-Rely on the Safety Devices

This machine is equipped with safety devices such as a
moment limiter, boom hoist limiting device, and anti-two
block. However, these devices cannot detect improper
machine assembly or adjustment, predict collapsing
ground under the machine, or stop the effects of wind.
There is a limit to the capabilities of the safety devices.

To prevent accidents, read the Operator's Manual
carefully and make sure that you fully understand it
before you operate the machine.
M25N-02-058
3.15 Precautions for Travel Operations

Ensure Surrounding Safety
Before performing travel operations, ensure that the
surrounding area is safe.
Check the Direction of the Lower Structure

If you perform travel operations without checking the
direction of the lower structure, the machine may move SA-337
in the opposite way to what you intended, resulting in an

accident.
Check the direction of the lower structure before
performing travel operations.
Boom Angle and Hook Position

If the boom angle is too small or too large, or if a travel
operation is performed while the hook is in a low position, M25N-02-059
a travel collision could cause boom damage, tilting or
hook swaying, resulting in an accident.
Before performing a travel operation, be sure to raise the
boom to about 60 degrees and hoist the hook to a
position close to the hoist limiting device.
M25N-02-060
SA-22
SAFETY
Pay Attention to Ground Conditions
If a travel operation is performed without paying
sufficient attention to the ground, the machine may tip,
fall, or hit or trap someone, resulting in personal injury or
death.
When performing a travel operation, always pay
attention to the ground conditions and strictly observe
the following points.
Take Care When Crossing Rivers

If possible, do not cross rivers. If the machine is
submerged or tipped over, it may result in personal injury
or death.
If you must unavoidably cross a river in the machine, first
check the river bed condition, the flow strength and the
water depth, and proceed very carefully. M25H-02-059
 When crossing a river, the maximum water level should
be roughly the underside of the car body.
Precautions for Traveling on Slopes

 When traveling on slopes is unavoidable, be sure to
check the ground strength, and operate the machine at
angles less than those shown in the tables in the Travel
Operation section of the Operator’s Manual.
3.16 Do Not Travel with a Load  While performing the travel operation, never
operate other controls such as hoisting, swing, or
If you perform a travel operation while a load is lifted, the
winching.
load may sway or collide with something, tipping over or
 Make sure that the weight of the load is lower than
damaging the machine and resulting in personal injury or
the overload value.
death.
 Use a boom that is shorter than half the length of
Do not perform travel operations while a load is lifted.
the longest boom specified for the machine.
Move the load using another, safe method.
 Never lift a load exceeding a third of the gross
If a travel operation with a lifted load is unavoidable,
rated load during a travel operation.
strictly observe the following points and consult HITACHI
 Make sure that the lifting direction is the forward
SUMITOMO if anything is unclear.
lifting configuration (crawler forward direction).
 Appoint a signal person in advance and obey this
 Engage the swing lock and apply the swing brake.
person's instructions.
 When passing under power lines, be sure to leave
 Perform in a location with a level road surface.
enough space.
Avoid soft ground and bumpy locations.
 Lower the load to the ground before changing the
 Lift the load to a low position and support the load so that
machine direction. Perform after letting out just
it does not sway.
enough hoist rope for the direction change,
• Position the load lower than 300 mm above ground
loosening the hoist rope, and removing the
(as low as possible).
machine load.
• Perform the travel operation so that the hoist wire rope
does not sway more than 3 degrees if the load sways.
 Perform the travel operation at a low speed to avoid
vibration.
 Perform the travel operation in the crawler forward
direction.
SA-23
SAFETY
3.17 Be Careful When Swing and Reversing
During swing and reversing operations, visibility is poor
and there is a risk of an accident, such as trapping
someone, that could result in personal injury or death.
Strictly observe the following points.
 Appoint a signal person and operate the machine while

obeying this person's signals. SA-383
 Make sure that nobody is in the surrounding area.

 Sound an alarm such as a horn to keep people out of the
area surrounding the machine.
SA-384
3.18 Precautions for Swing

Beware of Swaying Loads
If you slew or stop suddenly, or perform swing at high
speed, it may cause the load to sway, the machine to be
damaged or tipped over, or the load to fall. This may
result in personal injury or death.
Perform swing operations (starting, operating, stopping)
slowly so that the load does not sway.
Do Not Drag or Raise a Load

Do not drag or raise a load with a swing operation
because the machine may tip over or be damaged, SA-384
Beware of Unexpected Swing

When the machine is on a slant or during high winds,
swing may occur unexpectedly, resulting in an accident.
When not performing swing operations, apply the swing
brake.
3.19 Never Move the Load Over a Person

If the load should fall while over someone's head, it
could result in personal injury or death.
Do not let a load pass over a person's head. Do not let
anyone go under the load.
SA-118
SA-24
SAFETY
3.20 Beware of the Swaying of the Unused Hook
During swing or boom hoisting operations using a jib, the
hook that is not being used may sway and hit the boom
or obstructions in the surrounding area, resulting in an
accident.
Hoist the unused hook up to a point close to the height
where the hoist limiting device is activated.
3.21 Precautions for Hoisting

Strictly Observe the Conditions for Boom Erecting
and Lowering
There is a risk of machine damage or tipping over that
could result in personal injury or death.
When erecting the boom or lowering it to the ground, be
sure to strictly observe conditions such as the direction
of the boom relative to the machine, and whether or not
plates are required. M25N-02-072
Do Not Drag, Raise or Lift a Load from the Ground

Overloading or load swaying may cause machine
damage or tipping over, resulting in personal injury or
death.
Do not use boom hoisting to drag or raise a load, or lift it
from the ground.
M25N-02-073
Do Not Perform Sudden Hoisting Operations

Sudden hoisting operations may make the machine or
load unstable, resulting in an accident.
Do not perform sudden hoisting operations.
M25N-02-075
Be Careful When Working Near the Boom Upper
Limit Angle
If the boom is carelessly raised to a position near the
upper limit angle, the boom may tilt or the load may
contact the boom, causing machine damage or tipping
over, and resulting in personal injury or death.
When the boom approaches the upper limit angle,
reduce the hoisting speed so that it does not exceed the
upper limit angle.
When lowering the lifted load, always select the
auto-brake mode to lower the load using engine power.
M25N-02-078
SA-25
SAFETY
3.22 Do Not Make the Boom or Jib Longer Than
Necessary
Working with a boom or jib that is longer than necessary
may make the load unstable and cause an accident.
Work with the boom or jib as short as is reasonable for
efficient work.
3.23 Do Not Use Both the Front and Rear Winches at

the Same Time
If two separate loads are lifted, or one load is lifted with
the front drum and rear drum at the same time, the
moment limiter will not operate correctly. This may cause
machine damage or tipping over, resulting in personal
injury or death.
During crane work, operate either the front winch or the
rear winch, never both together.
3.24 Do Not Lift More Than One Load

If more than one load is lifted at the same time, it is
difficult for the operator to pay equal attention to all
the loads. The lifting tool may come into contact with
another load and cause an accident.
Do not lift more than one load in one operation.
M25N-02-082
SA-26
SAFETY
3.25 Do Not Laterally Pull or Drag a Load with the
Hook
Laterally pulling or dragging a load with the hook may
cause machine damage or tipping over, resulting in
Move the load near the machine and then lift it vertically.
M25N-02-084
3.26 Do Not Lift One Load with Two or More

Machines
Lifting a load with more than one machine may cause
machine damage or tipping over, or the load may fall,
Avoid using two or more machines to lift one load.
If working with more than one machine is unavoidable,
strictly observe the following.
 Set the machines on solid, level ground.

 Use cranes of the same model that have sufficient lifting
capacity.
 Set up the same configurations for work, such as the
boom length and working radius.
 Operate by following the direct commands of the job site
manager.
• Before starting work, the manager must hold a
meeting with both operators regarding the work
contents.
 Operate both machines in conjunction. M25N-02-086
• Operate the machines slowly.
• Perform crane operations with separate operations.
However, do not perform travel operations.
• Lift the load vertically.
• Make sure that the load does not tilt to one side.
• Always keep the load level.
SA-27
SAFETY
3.27 Know the Load Weight in Advance
If you try lifting a load whose weight you do not know,
overloading may damage or tip over the machine or the
load may fall, resulting in personal injury or death.
Check the weight of the load.
W25T-SA-006
3.28 Do Not Overload the Machine

 When a load is in water it feels lighter because of
Overloading may damage or tip over the machine,
buoyancy. But when the load breaks the water
surface, the buoyancy effect is lost, and the load
Do not attach loads that exceed the gross rated load.
also becomes heavier with any water that it
When lifting a load out of water, do not break the water
contains. Lift the load slowly until it is out of the
surface suddenly, and do not drag the load laterally in an
water.
attempt to reduce the negative pressure of the load
bottom.
3.29 Do Not Use the Machine to Lift Difficult Loads

Lifting a load that is buried or knocked into the ground, or
lifting a load while a wire rope or load is tied or caught on
something may damage or tip over the machine, or the
load may fall. This may result in personal injury or death.
Do not lift objects that are knocked into the ground or are
buried in mud or sand.
If a wire rope or load is caught in a tree, steel frame or
some other obstruction, do not try to forcibly lift the load.
Eliminate the obstruction or untangle the load before
starting the lift operation. M25N-02-122
3.30 Do Not Allow the Load to Free Fall

Free fall of a heavy load by operating the brake pedal
may cause a mistaken operation, resulting in personal
injury or death due to the load falling.
Use the free fall operation mode only when lowering a
hook with no load.
When lowering the lifted load, always select the
auto-brake mode to lower the load using engine power.
M25S-02-001
SA-28
SAFETY
3.31 Be Ready for Braking
Delayed braking operation may cause the hook to fall,
possibly resulting in personal injury or death.
To ensure you can apply the brake quickly whenever
needed, do not remove your foot from the brake pedal
during free fall operation.
3.32 Precautions for Lifting the Load Off the Ground

Lifting the load off the ground without first checking the
safety may cause the load to fall or the machine to tip
over, resulting in personal injury or death.
After lifting the load off the ground by a few centimeters,
stop lifting the load. Check the brake function, slinging
condition, and machine stability for any abnormalities.
Restart
Winching
Stop
Check Safety
Start
Winching
M25N-02-090
3.33 Prevent Hook Overhoisting

If overhoisting occurs, the hook or load will make contact
with the boom or jib, which may damage the boom or jib,
or cause the load to fall, resulting in personal injury or
death.
Always pay attention the position of the load and do not
allow hook overhoisting.
 Sometimes, even if you do not wind up the wire rope, the

hook may move up when you lower the boom, resulting
in overhoisting.
 Depending on the boom angle and the size of the load,
the load may be overhoisted to where it makes contact
with the boom or jib before the hoist limiting device is
M25N-02-092
activated.
SA-29
SAFETY
3.34 Lifting Long Objects
When lifting long objects, the load may become unstable
and cause an accident.
Attach tag-lines to both ends of the load to maintain the
load stability.
 Make sure that the personnel are not shaken by the lifted
load.
M25T-SA-007
3.35 Precautions When the Working Radius Extends

When a load is lifted, the working radius is extended.
Depending on the situation, overloading may occur. This
may cause the machine to tip over, resulting in personal
injury or death.
Before starting work, consider the extensions in the
working radius that will be caused by the load. Set a
working radius with a sufficient margin, or set the gross
rated load to a low level.
 When lifting a load, the working radius increases due to M25N-02-094
the stretching of the hoist and pendant ropes. This

tendency increases the heavier the load.
3.36 Select the Correct Hook Size and Number of

Sling Wire Ropes
Selecting an incorrect hook size or number of sling wire
ropes may cause the wire rope to snap, resulting in
Select a hook size and number of sling wire ropes that is
appropriate for the load weight and the boom or jib
length.
M25N-02-176
3.37 Do Not Go Under a Lifted Load

Holding the load with just the brake may cause the load
to fall, resulting in personal injury or death.
When holding the load, do not go under the lifted load.
M25N-02-045
SA-30
SAFETY
3.38 Do Not Let Out the Wire Rope Excessively
Letting out the wire rope by too much may make the
rope separate from the drum or snap. The load or hook
could fall, resulting in personal injury or death.
When letting out the wire rope during a lowering
operation, leave at least three turns of the rope around
the drum. (At least three dead turns of the rope.)
M25N-02-097
3.39 Rectify Irregular Winding or Twisting of the Wire

Rope
If you leave the wire rope in an irregularly wound or
twisted condition, the wire rope may snap and cause the
load to fall, the hook may rotate, or the wire rope could
separate from the sheave, resulting in personal injury or
death.
If there is irregular winding, wind the wire rope around
the drum again correctly. If there is twisting, rectify the
lay of the wire rope.
M25N-02-098
3.40 Action if Overloading Occurs

Should an overload occur during work, sudden operation
of the jib may make the situation worse by causing the
load to sway. This could cause the machine to tip over,
Lower the load to the ground with a hook lowering
operation.
W25T-SA-008
3.41 Precautions for Slinging

Do Not Use Inappropriate Sling Tools
If you use an inappropriate sling tool, the sling tool may
break or be damaged, causing the load to fall and
Use wire ropes, lift chains and shackles that are meant
for sling use. Make sure that they are an appropriate
size and strength, and that they are not damaged.
M25N-02-100
SA-31
SAFETY
Keep a Small Lifting Angle between the Sling Ropes
If the lifting angle is large, the rope may snap due to
excessive force, or the rope may slip to the side. The
load may fall and cause personal injury or death.
Set the lifting angle between the sling wire ropes to 60
degrees or less.
Position the Hook Directly Above the Load's Center

of Gravity
If the hook is not properly set at the center of gravity, the
load may fall or turn over when lifted, resulting in M25N-02-101
Sling the load with the hook positioned directly above the
center of gravity of the load.
Use Protectors
Slinging the ropes in angular or slippery positions may
make the sling ropes snap or separate from the load,
causing the load to fall and resulting in personal injury or
death.
Use protectors in angular and slippery areas.
M25N-02-102
Do Not Lift a Load with Only One Sling Rope

Lifting a load with only one sling rope may make the load
rotate and cause an accident.
Do not lift a load with only one sling rope.
M25N-02-103
Do Not Allow Anyone Under the Load

If the load falls while someone is underneath, it may
result in personal injury or death.
Do not go under a lifted load. Also, do not let anyone
else go under a lifted load.
M25N-02-104
SA-32
SAFETY
Use a Safety Latch
If you do not use a safety latch or the safety latch does
not function correctly, the sling ropes may separate from
the hook, causing the load to fall and resulting in
Be sure to use a hook safety latch when performing sling
operations.
Check that the latch is functioning normally.
M25N-02-105
Assign a Signal Person
If there is no signal person when you perform slinging or
if you do not follow the instructions of the signal person,
it may result in an accident.
When slinging, appoint a signal person and work in
accordance with this person's signals.
M25T-SA-009
3.42 Precautions for Operating a Clamshell Bucket

Check the Locations of Underground Gas, Water and
Power Lines in Advance
Accidentally severing underground gas lines, water lines,
or power lines may result in personal injury or death.
Accurately locate all underground utilities such as gas,
water, power lines and telephone lines before digging.
M25N-02-107

If the bucket is difficult to see from the operator's seat,
the bucket may come in contact with sheetings, resulting
in an accident.
Appoint a signal person and obey this person's signals.
M25N-02-108
Do Not Hit the Ground with the Bucket
The bucket may rebound and cause an accident.
Do not use the bucket as a hammer to loosen the
ground.
M25N-02-109
SA-33
SAFETY
Do Not Apply Excessive Tension to the Bucket
Pendant Rope
If excessive tension is applied to the bucket pendant
rope when lifting the bucket, the bucket may open,
causing the bucket load to fall. This may lead to personal
injury or death.
Before lifting the bucket, be sure to close the bucket by
winding up the bucket open/close wire rope.
Do Not Allow the Bucket to Sway M25N-02-110
If the bucket sways due to sudden swing, sudden

stopping or swing at high speed, the machine may tip
over or be damaged, or the bucket load may fall,
Perform swing operations (starting, operating, stopping)
slowly so that the bucket does not sway.
 Attach a tagline to prevent the bucket from swaying or
rotating. M25N-02-111
Never Move the Bucket Over a Person

If the bucket load falls, personal injury or death may
result.
Never move the bucket over the truck operator's cab or a
person's head.
M25N-02-112
Avoid Irregular Winding of Wire Rope

Irregular winding may break the wire rope, resulting in
personal injury or death if the bucket or load falls.
Do not excessively loosen the wire rope during
excavation work.
M25N-02-113
Lower the Bucket onto the Ground after Operation

If the bucket is kept lifted above the ground or is lowered
onto the ground with the teeth closed, the bucket may
fall or overturn and cause personal injury or death.
After finishing the work, lower the bucket onto the
ground with the teeth opened.
M25N-02-115
SA-34
SAFETY
3.43 Precautions for Lifting Magnet Operation
If the electric power supply is cut off during lifting magnet
operation, the lifted load may fall and result in personal
injury or death.
Be sure to follow the instructions below during lifting
magnet operation.
 Start and stop the generator using the correct

procedures.
 Before operating the lifting magnet, check that no one is
around the machine. Do not allow anyone to go under
the lifted load, and do not pass the lifted load over a
person.
 Operate the magnet accurately when attracting and
releasing the loads. Lower the lifted loads to the M25N-02-116
specified position.
 Before leaving the operator's seat, lower the magnet to
the storage position and turn off the electric power.
 Correctly perform inspections and maintenance of the
electric system to prevent electrification, which is more
likely on rainy days.
3.44 Precautions for Vibration Hammer Operation  Rest the vibration hammer weight on the pile head
before stopping the hammer operation.
Be Prepared for Vibration and Impacts
 Check for boom and hook damage and any
Vibration hammer operation will constantly create fastener looseness before and after operation. If
vibration and impacts which affect the machine as a you find any problems, immediately repair or
whole. Toppling of piles, falling of the hook or vibration replace.
hammer, or damage to the machine may cause personal
injury or death.
 Be sure to chuck the pile properly. Support the pile with
an auxiliary rope.
• Remove any mud or rust adhered to the vibration
hammer and the pile chucking areas. Always keep
these areas clean. If the pile head becomes
excessively deformed, cut off the deformed area
before chucking.
 When suspending a vibration hammer, use a hook
equipped with a latch and connect the vibration hammer
to the hook with wire rope.
• Use a hook and wire rope which matches the vibratory M25N-02-117
force.
 Keep the gross lifting load of the vibration hammer
operation to less than the gross crane rated load at the
working radius.
 Gross rated load ≧ Hook weight + Sling rope weight +
Vibration hammer weight + Pile weight +
Vibration hammer vibratory force × 1/4
 Set the boom length as short as possible.
 Slightly reduce the hoist rope tension before starting to
operate the vibration hammer.
 Do not allow the absorption spring to become tightly
compressed during vibration hammer operation.
SA-35
SAFETY
Precautions for Handling Cab Tire Cable
Damaged or broken cab tire cable may cause electrical
shocks or short circuits, resulting in personal injury or
death.
Before starting machine operation, check the cab tire
cable for any damage. If you find any damage, repair or
replace the cab tire cable. Be careful not to catch the cab
tire cable during operation.
Turn Off the Power Switch after Operation

Failure to turn off the switch after completing machine M25N-02-118
operation may, in the worst case scenario, result in an

accident such as fire.
After completing machine operation, turn off all electrical
switches such as the power switch and the earth
leakage breaker.
 When turning off the switches, turn off the switch located
at the end of the circuit first, and turn off the main switch
last.
M25N-02-119
3.45 Precautions for Lifting from an Underground

Level
Pay Attention to the Wire Rope Length
If the wire rope is not long enough, the rope may
separate from the drum or snap. The load or hook could
fall, resulting in personal injury or death.
Select a machine model that is equipped with a wire
M25N-02-097
rope of sufficient length. When the hook is lowered to the
lowest position, a minimum of three turns of wire rope
must remain around the drum.

If work conditions such as the sling positions cannot be
seen from the operator's seat, an accident may result.
Appoint a signal person and obey this person's signals.
M25N-02-108
3.46 Precautions for Pulling Out Buried Objects,

Such as a Pile
If a buried object such as a pile is forcibly pulled out,
overturning or damage to the machine may result,
When pulling out a buried object such as a pile, avoid
pulling it out abruptly. If pulling is difficult, use other
equipment such as a vibration hammer to assist the
work.
M25N-02-122
SA-36
SAFETY
4 PRECAUTIONS FOR PREPARATION OF
OPERATION AND TRANSPORTATION
4.1 Setting the Machine

If the machine is slanted it may tip over, resulting in
Set the machine in a level position. Check the strength
of the ground and reinforce any soft ground by laying
down sufficiently strong steel plates.
M25N-02-125
4.2 Keep Away from the Machine When Giving

Signals
If a person enters the installation or removal area during
assembly or disassembly, trapping could result in
Give signals in a position away from the machine.
M25N-02-126
4.3 Never Jump On or Off the Machine

Jumping on or off the machine may result in a fall and
Use the handrails, steps or ladder when getting on or
off the machine. Do not jump.
SA-439
4.4 Use the Correct Assembly and Disassembly

Procedures
Using incorrect assembly or disassembly procedures for
machine parts may result in personal injury or death.
Use the correct procedures for assembly and
disassembly, and for removal and installation.
SA-111
4.5 Precautions When Aligning Pin Holes

Inserting your fingers or hands into the holes when
aligning the pin holes may result in personal injury.
When aligning pin holes, do so visually or use a tool
such as a screwdriver. Do not put your fingers or
hands into the holes.
M25N-02-128
SA-37
SAFETY
4.6 Precautions for Working in High Locations
Falling when working in a high location may result in
Be sure to wear a safety belt when working.
SA-439
4.7 Precautions When Changing the Gantry Height

When changing the gantry height, there is a risk of
personal injury or death due to the gantry falling or a
person being trapped.
4.8 Precautions for Counterweight Removal and

Installation
If the machine tips over or the counterweight falls when
removing or installing the counterweight, it may result in
M25N-02-131
4.9 Do Not Go Inside the Boom or Jib

If a person goes inside or under the boom or jib while
assembly, disassembly or replacement is being
performed, and the boom or jib falls, it may result in
Do not go inside or under the boom or jib.
SA-111
4.10 Ensure Your Footing Is Secure

Falling from the boom or jib may result in personal injury
or death.
Ensure that your footing is secure when working on the
boom or jib.
SA-38
SAFETY
4.11 Limit the Boom Length When Raising the Boom
Supported by a Upper Spreader Do not Exceed
the Allowable
The boom length that can be raised is limited when a Boom Length.
upper spreader is installed on the base section tip. If a
boom longer than the limit is raised, the boom may fall
and result in personal injury or death.
Never attempt to raise a boom longer than the limit.
M25N-02-130
4.12 Precautions for Lowering the Boom
If the wire rope snaps when the boom tip makes contact
with the ground, it may result in an accident. Make sure
that the winch wire rope is not pinched.
M25N-02-134
4.13 Prevent the Pendant Rope from Falling

If the boom pendant rope separates from the upper
spreader of the boom and the pendant rope falls, it may
cause an accident.
Take measures to prevent the pendant rope from falling,
such as fixing it with wires.
M25N-02-135
SA-39
SAFETY
4.14 Precautions for Removing the Connect Pins
If the connect pins are removed when replacing or
disassembling the boom or jib and the boom or jib is
insufficiently supported, the boom or jib may fall and
cause personal injury or death.
Before removing the connect pins, fully support the
boom or jib with the auxiliary crane or a stand of
sufficient strength.
SA-111
4.15 Beware of Pins Flying Out

When driving out the connect pins from the boom or jib,
the pins may fly out with great force and cause an
accident.
Do not stand in front of the connecting area and be
careful of the pin movement.
M25N-02-136
4.16 Wire Rope Unwinding Precautions

If the wire rope is unwound incorrectly, it may result in
shape loss, kinks, twisting and lay return. This may
significantly shorten the service life of the rope and
cause an accident.
When unwinding the wire rope, use a wooden frame or
unwind by rotating the coil.
M25N-02-137
4.17 Wire Rope Winding Precautions

When winding wire rope around the drum, never
allow the wire rope to become twisted or loosely
wound. Failure to do so may cause premature
damage or kinking of the wire rope, resulting in an
accident.
Do not Twist
M25N-02-139
SA-40
SAFETY
4.18 Precautions When Installing the End of the Wire d: Rope Diameter
Rope
Wedge 5d Rope
If the end of the wire rope is incorrectly installed, the wire
rope may come off and cause an accident.
Pay attention to the following points and install correctly. d
 Are the sizes of the rope socket, wedge and wire clip
appropriate for the wire rope diameter? Wire Clip
Rope Socket
 Is the direction of the wire rope assembly on the drum
and rope socket correct?
 Is the installation direction of the wire clip correct?
 Is the installation distance of the wire clip correct?
MRHAE0-02-053
4.19 Check the Boom Before Erecting It

If a tool or part is left on the boom and the boom is raised,
it may fall and cause personal injury or death.
After completing the installation of the boom onto the
upper structure, make sure that you have not forgotten a
tool, part or anything else on the boom before erecting it.
4.20 Perform Repeat Checks

Failure to perform repeat safety checks before using the
machine may result in an accident.
Be sure to perform repeat checks.
SA-41
SAFETY
4.21 Loading and Unloading Precautions
If you use an incorrect method for loading or unloading
the machine or if the machine is not sufficiently secured,
the trailer may roll over, or the machine may tip over, fall
or collide with another object, resulting in personal injury
or death.
4.22 Do Not Overload the Trailer

Overloading may cause the truck to roll over or collide
with something, resulting in personal injury or death.
Before transporting the machine, disassemble it to the
standard transportation weight and dimensions, and
select an appropriate trailer and truck.
4.23 Obey Applicable Regulations

Failure to obey the applicable regulations when
transporting the machine on a public road, such as using
guidance vehicles and the correct transportation
conditions, may cause the trailer to roll over or collide
with something, resulting in personal injury or death.
Inspect the road conditions as far as the destination in
advance and transport the machine in compliance with
the applicable regulations. M25N-02-147
 If special permission is required, send an application in

advance to the related authority to receive permission for
traveling on the road.
4.24 Research the Local Traffic Regulations

Some parts of the road may have restrictions for width,
height or weight. Ignoring these restrictions may result in
an accident.
Before transporting the vehicle on a public road,
research the traffic regulations and select a safe route.
M25N-02-148
4.25 Beware of Obstructions

If you misjudge the width or height of an obstruction and
contact or collide with it while transporting the machine,
it may result in personal injury or death.
Check the height and width before going under train
tracks, overpasses or railroad bridges, and before
passing through tunnels, and make sure there is enough
space around the truck.
M25N-02-149
SA-42
SAFETY
4.26 Be Careful in Narrow Locations and Poor
Visibility
If you proceed without first checking safety, you may
contact or collide with a person or building, resulting in
Send a signal person into narrow locations or locations
with poor visibility, and proceed by following this
person's signals and after checking safety.
M25N-02-150
4.27 Road Surface Precautions

If the road conditions are poor, the vehicle may slip or
the steering wheel may veer to one side, resulting in an
accident.
When transporting the machine on surfaces such as
snow, ice, uneven roads or slope drive slowly and safely.
Check the road surface conditions before starting and
attach tire chains to the truck if necessary.
M25N-02-151
4.28 Parking Precautions

Leaving the machine in an area exposed to rock falls,
mudslides or flash-flooding, or parking unnecessarily on
slopes or roads may result in an accident.
Park the machine in a level and safe location.
If parking on a slope or road is unavoidable, take the
following safety measures.
 When parking on a slope, park with the machine parallel
to the slope and block the crawlers so that the machine
does not move.
 When parking on a road, do not obstruct the passage of
other vehicles or pedestrians. Take measures so that
people can clearly see the machine, such as using flags,
barriers, flashing lights or other indicators.
M25S-02-002
SA-43
SAFETY
5 PRECAUTIONS FOR MAINTENANCE impair safety and functionality, resulting in an
accident. Use HITACHI SUMITOMO genuine parts.
5.1 Use Genuine HITACHI SUMITOMO Parts
Failure to use genuine HITACHI SUMITOMO parts
when replacing parts during maintenance may
5.2 Replace Important Parts at Regular Intervals

To help ensure safety, important parts that require
regular replacement are specified. Failure to perform
these replacements will cause part deterioration and
wear, which may result in an accident.
Replace the parts at the specified intervals.
5.3 Perform Monthly Inspections

If inspections and maintenance are not performed, it
Be sure to perform the monthly inspections. If you find
an abnormality in the inspection, immediately take action
such as maintenance, adjustment or replacement.
5.4 Perform Yearly Inspections

If inspections and maintenance are not performed, it
Be sure to perform the yearly inspections, starting from
when the machine is set up. If you find an abnormality in
the inspection, immediately take action such as
maintenance, adjustment or replacement.
5.5 Coordinate with the Personnel Concerned

If maintenance is performed using incorrect procedures,
it may result in personal injury or death.
Hold a meeting with all workers before performing
maintenance to confirm the work contents and
procedures. SA-435
5.6 Perform Maintenance on a Level Surface

If maintenance is performed on a slope, the
machine may tip over or move and trap someone,
Perform machine maintenance in a solid and level
location where there is no danger.
M25N-02-125
SA-44
SAFETY
5.7 Ensure Proper Ventilation
If ventilation is poor, poisoning may be caused by
exhaust gas, fuel, washing oil or paint, resulting in
When performing maintenance indoors, ensure that the
ventilation is good. For example, extend the ventilation
pipes to the outside or open the windows to ensure that
sufficient air enters from outside.
If necessary, set up extractor fans.
5.8 Precautions for Working in High Locations

Falling when performing maintenance in a high location
may result in personal injury or death.
 Keep footings tidy and clean.
• Clear away unnecessary tools and any other objects
that may get in the way, and wipe off any spilt
lubricant.
 Be careful not to slip or trip while walking.
 Use ladders and handrails when climbing up to or down
from high locations, and support your body properly with
both your hands and feet.
 Wear a safety belt. SA-439
5.9 Tidy and Clean the Machine and Surrounding

Area
If you do not tidy or clean the area before performing
maintenance, you may overlook defective areas, allow
dirt to enter, allow dust or mud to get into your eyes, you
could slip and tumble or fall, or flammable objects could
ignite a fire, resulting in personal injury or death.
Tidy and clean the machine and the working area
around the machine.
 Clear away objects that may obstruct work, remove dirt
such as grease, oil, paint and splinters, and clean the M25N-02-118
machine to ensure that maintenance can be safely

performed.
5.10 Attach a "DO NOT OPERATE" Tag

If an unauthorized person unexpectedly starts the
engine during maintenance and the machine operates, it
may result in personal injury or death.
Before performing maintenance such as inspections,
adjustments and replacements, attach a "DO NOT
OPERATE" tag to a highly visible location such as the
door or the control levers. If necessary, also display it in
the area surrounding the machine. If you see a "DO NOT
OPERATE" tag, do not operate the machine.
MRHAE0-02-056
SA-45
SAFETY
5.11 Keep Unauthorized Personnel Out of the
Working Area
If an unauthorized person enters the working area, it
When performing maintenance, keep unauthorized
persons out of the area surrounding the machine.
M25N-02-162
5.12 Use Protective Gear

Performing work in a vulnerable area, such as in a high
location or somewhere exposed to flying dust, gravel or
metal pieces, may result in personal injury or death.
Wear protective gear that is appropriate for the work.
Check that the protective gear functions properly before
using it.
SA-432
5.13 Protect Against Flying Parts

 When the hydraulic cylinder type of shoe tension
adjuster (optional) is used, the pressure inside the
cylinder reaches a high level. If the following precautions
are not observed, it may result in serious injury or death.
• Do not remove the coupler assembly.
• Do not position your face or body near to the coupler
because of the risk of flying parts. SA-344
 Pressure is applied to the travel reduction gear.

• Do not position your face or body near to the air bleed
plug because of the risk of flying parts.
• The gear oil is very hot.
Wait until the gear oil cools down. Loosen the air bleed
plug gradually to release the pressure.
5.14 Appoint a Job Site Manager for Joint Work

If joint work with more than one person is performed and
people misunderstand each other, it may result in an
accident.
Before starting work, appoint a job manager and follow
this person's instructions.
SA-48
5.15 Immediately Repair Any Abnormalities

• If you leave an abnormality unrepaired, it may result in
• If you discover any abnormalities, perform
maintenance immediately.
SA-46
SAFETY
5.16 Stop the Engine Before Performing Maintenance
If you accidentally touch a moving part during
maintenance, you may be trapped or pulled into the
machine. This may result in personal injury or death.
Perform maintenance while the engine is stopped.
If you must unavoidably perform maintenance while the
engine is running or the machine is operating, perform
maintenance with at least 2 people and strictly observe
the rules to ensure each others' safety.
5.17 Brake Maintenance

If brake maintenance is not performed properly, it may
result in an accident.
Perform this maintenance correctly.
 Lower the boom to the ground.
 Engage the drum lock and slew lock.
5.18 Battery Handling Precautions

The battery uses diluted sulfuric acid. It also generates
flammable hydrogen gas. Incorrect handling of the
battery may cause an explosion or burns, resulting in
Strictly observe the rules when handling the battery. SA-032
5.19 Stay Clear of Moving Parts

When the machine operates, space may change, such
as the space between the boom and the upper structure,
the space between the cylinder and the bracket, and the
various link mechanisms. This may cause trapping or
crushing, resulting in personal injury or death.
Do not go near moving machine parts or insert any of
your limbs into them. SA-026
5.20 Beware of High-Pressure Oil

If high-pressure fuel or hydraulic oil or the caps or plugs
from these oil lines fly into your body, it may result in
Release the hydraulic pressure before performing SA-031
maintenance.
When inspecting for high-pressure oil leaks, do not
touch parts directly with your bare hands or body. Wear
protective goggles and heavy gloves and use thick
paper or boards.
Should you be touched by high-pressure oil, seek SA-292
immediate medical attention from a specialist.
SA-47
SAFETY
5.21 Beware of Hose and Pipe Leaks
Fuel or oil leaks may result in a fire and personal injury
or death.
Retighten loose hoses and pipes, and replace damaged
ones.
SA-037
SA-028
5.22 Maintenance Under the Machine

If the machine falls or tips over while maintenance is
being performed underneath, it may result in personal
injury or death.
Strictly observe the following points before starting work.
 Lower the boom to the ground.
• If the boom cannot be lowered as far as the ground,
support it with a stand.
 Block the crawlers.
 Insert a sufficiently strong support or stand under the
lower structure so that the machine is properly M25N-02-125
supported.
5.23 Fuel and Oil Refilling Precautions

If a fire ignites or a person slips and falls over when
refilling the fuel or oil, it may result in personal injury or
death.
SA-018
 Perform refilling in a location with good ventilation.

 Stop the engine.
 Keep away flames.
 Firmly tighten the fuel and oil caps.
 If fuel or oil spills, wipe it up immediately.
SA-019
5.24 Coolant Refilling Precautions

Refilling coolant while it is hot may cause burns,
Perform after the engine and radiator have cooled down.
SA-039
SA-48
SAFETY
5.25 Always Use Proper Work Lights
Using a light from a flame such as a cigarette lighter
when inspecting the fuel, oil or battery may cause a fire
or explosion, resulting in personal injury or death.
Use explosion-proof lights.
SA-037
5.26 Precautions for Electric System Maintenance

Performing maintenance of the electric system without
disconnecting the battery cable may cause a fire,
Before performing maintenance of the electric system,
disconnect the battery cable on the negative terminal
side (-) of the battery.
SA-019
5.27 Lock Any Open Doors or Covers

If a sudden wind slams shut a door or cover during
maintenance, it may result in an accident such as
trapping.
If any doors or covers are open, lock them not to shut.
Do not try to open them during strong wind.
5.28 Do Not Hang Out of the Cab Window on the

Boom Side
If you hang your body out of the operator's seat window
on the boom side, the boom hoisting operation may trap
you against the operator's cab. This may result in
Do not hang your body out of the window.
5.29 Do Not Drop Tools or Parts

If you drop a tool or part, it may hit a person, or the
resulting machine damage or operational defect may
cause an accident.
Do not drop tools, parts or any other objects.
If you drop an object into the machine, remove it.
SA-49
SAFETY
5.30 Watch Your Step and Head
If you are not paying attention and put your foot in a bad
footing, you may hit your head against the hook and
boom above, or you may slip and fall.
When performing maintenance, watch your step and
your head.
5.31 Machine Cleaning Precautions

When you clean the machine with high-pressure steam,
flying dirt may enter your eyes.
Also, if water enters the electric system, operational
defects or mistaken operations may result in an
accident.
When cleaning the machine, use protective goggles and
do not expose electrical parts to water.
5.32 Precautions When Welding Painted Surfaces

When welding painted surfaces, strictly observe the
following points.
 If the ventilation is poor, harmful smoke that is generated
when the paint is heated may result in an accident.
Perform the work outdoors or in a location with good
ventilation.
 When removing the paint with a tool such as a grinder,
an accident may result if you breathe in paint particles or SA-029
dust, or if these substances get into your eyes.
Use protective goggles and an anti-dust mask.
 If you weld after removing paint with a solvent, a fire may
ignite, resulting in personal injury or death.
Before welding, wash away the solvent with soapy water
and clean water.
Keep flames away from the solvent.
5.33 Do Not Heat Hydraulic Components or Lines

If hydraulic components, lines or nearby areas are
heated, it may ignite a fire, resulting in personal injury or
death.
Do not expose these areas to heat through welding or
gas cutting.
SA-030
SA-50
SAFETY
5.34 Do Not Modify Electric Parts or Hydraulic
Components
Improper adjustments or modifications may impair safety,
resulting in an accident.
Do not reconfigure the electric parts, hydraulic
components or wiring.
SA-019
5.35 Repair the Boom and Jib on the Ground

If you repair the boom or jib while they are supported in
the air, they may fall, resulting in personal injury or
death.
Before repairing them, lower these parts to the ground or
place them on a stand.
5.36 Do Not Use Damaged Booms or Jibs

Damage to the boom or jib is dangerous, even if the
damage is only slight localized bending. If you continue
using damaged parts, they may fall, resulting in personal
injury or death.
If the boom or jib is damaged, replace it.
 Advanced technology is required for repairing the boom
and jib. Contact your nearest HITACHI SUMITOMO
distributor.
5.37 Never Weld Another Object to the Boom or Jib

Welding another object to the boom or jib may weaken
the boom or jib, and the resulting damage may cause
Do not weld other objects to the boom or jib.
SA-030
SA-51
SAFETY
5.38 Wire Rope Handling
Incorrect handling of the wire ropes may cause injury or
reduce the service life of the ropes.
Strictly observe the following points when handling wire
ropes.
 Wear leather gloves when handling the wire ropes. Be
especially careful when handling ropes with broken wire
strands or kinks.
 When unwinding new wire rope from a wooden reel, set
the reel so that it can be rotated in the same direction as
the wire rope is unwound, to prevent the wire rope from
being twisted, kinked or unraveled.
M25N-02-137
5.39 Wire Rope Maintenance

If the wire rope inspection is performed incorrectly, the
rope may snap and cause an accident.
When performing maintenance, refer to “6 Wire Rope
Handling” in Chapter 5 of the Operator’s Manual.
5.40 Install the Rope Socket Correctly

If you assemble the rope socket incorrectly, the wire
rope may separate from the socket and cause an
accident.
When performing installation, refer to “3.5 Install Hook
and Reeve Wire Rope” in Chapter 5 of the Operator’s
Manual.
5.41 Use Appropriate Tools

Using damaged or deteriorated tools or tools that were
designed for another purpose may result in an accident.
Use tools that are appropriate for the work.
SA-040
5.42 Contact HITACHI SUMITOMO for Hydraulic

Component Adjustments
The hydraulic components were very precisely adjusted
before shipment. Incorrect adjustment of the hydraulic
components may impair safety and functionality,
If adjustments are required, contact your nearest
HITACHI SUMITOMO distributor.
SA-52
SAFETY
5.43 Precautions When Using Booster Cables
When starting the engine with booster cables, incorrect
operation may cause the battery to explode, resulting in
When using booster cables to start the engine, strictly
observe the rules.
SA-032
5.44 Prevent Fires

During maintenance, many flammable substances are
used, such as fuel and lubricants. Failure to pay
attention may result in a fire, causing personal injury or
death.
Put out any flames and keep them away from flammable
objects. Strictly observe the rules.
SA-018
5.45 Beware of Burns

The machine parts, coolant, lubrication oil and operation
oil are very hot during and immediately after operation. If
you perform maintenance while parts are hot, you risk
being burned.
Wait for parts to fully cool before performing SA-225
maintenance.
 Because the radiator is pressurized, boiling water will
spray out if you remove the cap. When removing the cap,
first wait for the coolant temperature to drop, and then
slowly loosen it to release the pressure.
SA-039
5.46 Handling Hazardous Chemicals

 Contact your nearest HITACHI SUMITOMO
Directly touching hazardous chemicals will cause a
distributor for the MSDS on hazardous chemicals.
serious injury.
The hazardous chemicals that are used in the
machine include the lubrication oil, electrolyte,
coolant, paint and adhesives.
 The Material Safety Data Sheet (MSDS) provides
the following details about the chemicals:
• Hazardous material types, descriptions and
strength
SA-309
• Precautions for storing and handling
• Emergency action in case of accidents
 Always check the MSDS before handling hazardous
chemicals. Handle them correctly.
SA-53
SAFETY
5.47 Waste Disposal Precautions
Improper disposal of waste may pollute or destroy the
environment, and result in an accident.
When disposing of the machine's waste oil or waste
materials such as used filters, strictly observe the
following points.
 When removing waste liquids from the machine, drain
them into a container. SA-226
 Do not dispose of substances by pouring them into the
ground or into rivers or swamps.
 When disposing of oil, fuel, coolant, brake fluid, solvent,
filters, batteries and other harmful substances, be sure to
follow the appropriate laws and regulations.
5.48 Air Conditioner Maintenance

If air conditioner refrigerant gets into your eyes or makes
contact with your skin, it may cause blindness or cold
injuries.
 Refer to the precautions on the container for details on
handling the refrigerant.
 To prevent refrigerant from being discharged into the air,
use a recovery and recycling system.
 Never touch the refrigerant.
SA-405
5.49 Be Sure to Recover Freon

Freon (R134a equivalent to type HFC) is used as the
refrigerant for the air conditioner in this machine. If the
refrigerant is discharged into the atmosphere, it will
contribute to global warming and the destruction of the
ozone layer.
To protect the environment, do not discharge the
refrigerant into the atmosphere. When disposing of the
air conditioner, first recover the refrigerant inside.
5.50 Post-Maintenance Precautions

The maintenance has not finished until you have
Failure to check the machine operations after
checked that all the machine operations are normal.
finishing maintenance may cause a delay in
discovering a fuel leak or operational defect,
After finishing maintenance, check the operation of
each device, check for oil leaks, and check whether
you have forgotten to tighten any bolts.
When checking the operation, run the engine at a
low speed and operate slowly. If you do not notice
any abnormalities, raise the engine speed and
check again.
SA-54
SAFETY
5.51 Attachment Storage Precautions
If you leave removed hooks or buckets lying around,
they may fall and cause personal injury or death.
When storing attachments such as hooks and
buckets, store them in a stable position and do not
let people enter the storage location.
SA-034
5.52 Use Diesel and Correct Lubricants (Engine Oil)

Always use diesel and the correct lubricants (engine oil).
Never use a fuel other than diesel, because it may cause
a serious malfunction such as the seizure or wearing of
the fuel injection system. A malfunction caused by using
fuel other than diesel is not covered by the warranty. The
M25U-02-001
engine oil greatly affects the engine performance,
startability and service life. A malfunction or accident
caused by using inappropriate engine oil is not covered
by the warranty.
5.53 Beware of Asbestos, Silicon Dust and Other

Pollutants
 Take care not to inhale the dust that is generated during
work. The inhalation of asbestos fibers may cause lung
cancer.
 The inhalation of silicon dust or other pollutants may
cause illness.
• The inhalation of asbestos fibers may be a danger at
some job sites. Spray water to help prevent asbestos
from floating in the air. Do not use compressed air.
• When operating the machine at a job site where the
presence of asbestos is suspected, be sure to operate SA-029
the machine from the windward side and wear an
anti-dust mask that prevents the inhalation of
asbestos.
• Keep unauthorized persons away from the job site
while operating the machine.
• It is possible that asbestos is used in non-genuine
parts.Use HITACHI SUMITOMO genuine parts.
SA-55
SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening Torque
SECTION 2 UPPER STRUCTURE
Group 1 Cab
Group 2 Counterweight
WORKSHOP MANUAL Group 3 Swing Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Winch
Group 8 Boom Hoist
Group 9 Remote Control Valve
Group 10 Lock Valve
Group 11 Shuttle Valve
Group 12 Solenoid Valves
Group 13 Winch Brake Valve
Group 14 Swing Valve
Group 15 Negative/Positive Selection,
Positive Hoisting Up/Down,
Free Motor Multiple Plate
Negative Release Valve
All information, illustrations and speci- SECTION 3 LOWER STRUCTURE
fications in this manual are based on
the latest product information available Group 1 Travel Device
at the time of publication. The right is
reserved to make changes at any time Group 2 Center Joint
without notice.
Group 3 Idler
Group 4 Upper/Lower Rollers
Group 5 Shoe
COPYRIGHT(C)2007
Hitachi Sumitomo Heavy Industries
Group 6 Cylinder
Construction Crane Co., Ltd. Group 7 Extend/Retract / Travel Selection
Tokyo, Japan
All rights reserved Valve
SECTION 1
GENERAL INFORMATION
 CONTENTS 
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling............................................W1-1-1
Group 2 Tightening Torque

Tightening Torque Specifications .............W1-2-1
Standard Torque Specifications................W1-2-2
Piping Joint .............................................W1-2-5
Periodic Replacement of Parts ................W1-2-9
RHAE0W-1-1
(Blank)
RHAE0W-1-2
GENERAL INFORMATION / Precautions for Disassembling and Assembling
Precautions for Disassembling and
Assembling
Precautions for Disassembling and Assembling • Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
 Clean the Machine manner that will prevent loss.
Thoroughly wash the machine before bringing it into • Inspect the contact or sliding surfaces of
the shop. Bringing a dirty machine into the shop disassembled parts for abnormal wear, sticking,
may cause machine components to be or other damage.
contaminated during disassembling/assembling, • Measure and record the degree of wear and
resulting in damage to machine components, as clearances.
well as decreased efficiency in service work.
 Precautions for Assembling
 Inspect the Machine • Be sure to clean all parts and inspect them for
Be sure to thoroughly read and understand all dis- any damage. If any damage is found, repair or
assembling/assembling procedures before starting replace it.
any repair work. Understanding these procedures • Dirt or debris on the contact or sliding surfaces
will help avoid incorrect disassembling of compo- may shorten the service life of the machine. Take
nents as well as the purchasing of unnecessary ser- care not to contaminate any contact or sliding
vice parts. surfaces.
• Before assembling, coat all inner parts with clean
• The machine model, machine serial number, and hydraulic oil or gear oil. Especially coat the slid-
hour meter reading. ing surfaces with clean hydraulic oil or gear oil.
• Be sure to replace O-rings, backup rings, and oil
• Reason for disassembly (symptoms, failed parts,
seals with new ones once they are disassembled.
and causes).
Apply a film of grease before installing.
• Clogging of filters and oil, water or air leaks, if • Be sure that liquid-gasket-applied surfaces are
any. clean and dry.
• Capacities and condition of lubricants. • If an anti-corrosive agent has been used on a
• Loose or damaged parts. new part, be sure to thoroughly clean the part to
remove the agent.
 Prepare and Clean Tools and Disassembly Area • Utilize matching marks when assembling.
Prepare the necessary tools to be used and the • Be sure to use the designated tools to assemble
area for disassembling work. bearings, bushings and oil seals.
• Keep a record of the number of tools used for
 Precautions for Disassembling disassembly/assembly. After assembling is com-
• To prevent dirt from entering, cap or plug the plete, count the number of tools, so as to make
removed pipes. sure that no tools are missing.
• Before disassembling, clean the exterior of the
components and place it on a work bench.
• Before disassembling, drain gear oil from the
reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
instructed.
• If a part or component cannot be removed after
removing its securing nuts and bolts, do not
attempt to remove it forcibly. Find the cause(s),
then take the appropriate measures to remove it.
• Orderly arrange disassembled parts. Mark and
tag them as necessary.
W1-1-1
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the

suction lines are replaced, or the removal and install
ation of the pump, swing motor, travel motor or cyl-
inder is done, bleed air from the hydraulic system in
the following procedures:
IMPORTANT: If the engine is started with air

trapped in the hydraulic pump
housing, damage to the pump may
result.
If the hydraulic motor is operated
with air trapped in the hydraulic
motor housing, damage to the motor
may result.
If the cylinder is operated with air
trapped in the cylinder tube,
damage to the cylinder may result.
Be sure to bleed air before starting
the engine.
 Bleeding Air from Hydraulic Pump
• Remove the air bleeding plug from the top of the

pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the
engine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the
plug.
 Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic
oil.
 Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each
operation (never fully stroke the cylinders during
initial operation stage). As the pilot oil circuit has
an air bleed device, air trapped in the pilot oil
circuit will be bled while performing the above
operation for approx. 5 minutes.
• Reposition the front attachment to check WRHAE0-01-01-001
hydraulic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
W1-1-2
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one.
If the floating is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set

with seal ring faces together. Insert a piece of
cardboard to protect surfaces.
B W105-03-05-019
(2) Check the seal ring face (A) for scuffing,
scoring, corrosion, deformation or uneven
wear.
(3) Check O-ring (B) for tears, breaks,

deformation or hardening.
2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.
(1) Clean the floating seal and seal mounting

bores with cleaning solvent. Correct
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air.
(2) Clean the floating seal and seal mounting Incorrect

bores, as dust on them tends to enter the
floating seal when installing it.
(3) Check that the O-ring is not twisted, and that it

is installed correctly on the seal ring.
D W105-03-05-020
(4) After installing the floating seal, check that

seal surface (C) is parallel with the seal
Correct C Incorrect
a a
mounting bore end face (D) and O-ring (B) as
illustrated. B
b b
a=b a≠b
W110-03-05-004
W1-1-3
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings

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

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

• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.
Bent Sling W162-01-01-009
W1-1-4
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon
sling for any damage before using.
W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Scoring Separation of W162-01-01-006

Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-5
Maintenance Standard Terminology
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of components or assemblies ad-
justed to specification. Tolerances are indicated
as necessary.
“Allowable Limit”
1. Machine cannot operate normally with the parts
exceeding this dimension installed.
2. Repair or adjustment is impossible if this dimen-
sion is exceeded.
3. To maintain high machine availability and to save
the repair expense, the machine parts should be
repaired or replaced before reaching the “Allow-
able Limit.”
W1-1-6
GENERAL INFORMATION / Tightening Torque
Tightening Torque Specifications
Bolts and Nuts of Machine: Standard Tightening Torque Chart
Bolt Wrenc Torque

No. Descriptions Dia. Q’ty h Size
mm Nm kgfm
mm
Front 12 8 19 110 11.2
1. Engine Mounting Bolt
Rear 10 8 17 65 6.6
2. Counterweight Mounting Bolt 30 4 46 550 56.0
3. Cab Bed Mounting Bolt 16 12 24 210 21.4
4. Cab Mounting Bolt 16 4 24 205 21
5. Valve Bed Mounting Bolt 16 12 24 210 21.4
12 4 19 60 to 64 6.1 to 6.6
6. Gantry Stay Mounting Bolt
16 4 24 148 to 160 15.0 to 16.3
7. Upper Roller Mounting Bolt 20 16 30 670 68.3
8. Lower Roller Mounting Bolt 20 80 30 670 68.3
9. Travel Device Mounting Bolt (Right/Left) 22 48 32 740 75.0
10. Travel Motor Mounting Bolt (Right/Left) 18 8 27 294 30.0
11. Hoist Device Mounting Bolt (Front/Rear Winch) 36 8 55 1570 160
Hoist Device Break Cover Mounting Bolt
12. 12 8 19 88 9.0
(Front/Rear Winch)
13. Hoist Motor Mounting Bolt (Front/Rear Winch) 20 8 30 540 55.0
14. Boom Hoist Device Mounting Bolt 30 4 46 1177 120
15. Boom Hoist Device Cover Mounting Bolt 10 4 17 50 5.1
16. Boom Hoist Motor Mounting Bolt 16 16 24 265 27.0
17. Swing Device Mounting Bolt 16 36 24 210 21.5
18. Swing Motor Mounting Bolt 10 4 17 430 44.0
19. Pump Transmission Mounting Bolt 10 12 17 41 to 45 4.2 to 4.6
20. Main Pump Mounting Bolt 20 4 Hex.17 430 41.0
21. 2-Unit Gear Pump Mounting Bolt 12 4 19 30.3 to 38.3 3.1 to 3.9
22. Hydraulic Oil Tank Mounting Bolt 20 4 30 350 to 399 35.7 to 38.7
23. Radiator Mounting Bolt 12 4 19 60 to 64 6.1 to 6.6
24. Radiator Stay Mounting Bolt 16 4 24 148 to 160 15.0 to 16.3
25. Swing Bearing Mounting Bolt 27 62 41 1200 122
NOTE: (1) Apply lubricant (i.e. white zinc B dissolved into spindle oil) to reduce their friction coefficients.
(2) Remove rust, dirt, and dust before installing fasteners.
(3) Use LOCTITE on the bolts for mounting the pump device onto the engine flywheel housing.
W1-2-1
Standard Torque Specifications
CAUTION: 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
the correct tools. Avoid bodily injury caused
by slipping wrenches.
Bolt Types
Tighten nuts or bolts correctly to torque

specifications. Four kinds of bolts, hexagon bolts T, H, SA-040
M and socket bolts, each made of different material,
are used. Make sure to employ the correct bolts and
tighten them to specification when assembling the
machine or components.
Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt
W157-01-01-001
Specified Tightening Torque Chart

T Bolt H Bolt M Bolt Socket Bolt Hexagon
Wrench
Bolt Dia. Wrench
Nm kgfm Nm kgfm Nm kgfm Size Nm kgfm
Size
M 8 30 3.1 20 2.0 10 1.0 13 30 3.1 6
M 10 65 6.6 50 5.1 20 2.0 17 65 6.6 8
M 12 110 11.0 90 9.2 35 3.6 19 110 11.0 10
M 14 180 18.5 140 14.0 55 5.6 22 180 18.5 12
M 16 270 27.5 210 21.5 80 8.2 24 270 27.5 14
M 18 400 41.0 300 30.5 120 12.0 27 400 41.0 14
M 20 550 56.0 400 41.0 170 17.0 30 550 56.0 17
M 22 750 76.5 550 56.0 220 22.5 32 750 76.5 17
M 24 950 97.0 700 71.5 280 28.5 36 950 97.0 19
M 27 1400 143 1050 107 400 41.0 41 1400 143 19
M 30 1950 200 1450 148 550 56.0 46 1950 200 22
M 33 2600 265 1950 200 750 76.5 50
M 36 3200 325 2450 250 950 97.0 55
W1-2-2
IMPORTANT: (1) Apply lubricant (i. e. white zinc B
dissolved into spindle oil) to nuts
and bolts to stabilize their
friction coefficients.
(2) Torque tolerance is 10 %.
(3) Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
(4) The torques given in the chart
are for general use only.
Do not use these torques if a
different torque is given for a
specific application.
(5) Make sure that the nut and bolt
threads are clean before
installing. Remove dirt or
corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them

alternately, as shown, to ensure even tightening.
Equally tighten upper Tighten diagonally Tighten from center

and lower alternately and diagonally
1,4 1 12 9 4 1 6 7 14
6 3
4 5
2 13 8 5 2 3 10 11
2,3
W105-01-01-003
W1-2-3
Service Recommendations for Split Flange
IMPORTANT: (1) Be sure to clean and inspect

sealing surfaces. Scratches /
roughness cause leaks and seal
wear. Unevenness causes seal
extrusion. If defects cannot be
removed, replace the
component.
(2) Be sure to use only specified W105-01-01-015
O-rings. Inspect O-rings for any WRONG

damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
(3) Loosely assemble split flange
halves. Make sure that the split
is centrally located and
perpendicular to the port. W105-01-01-016
Hand-tighten the bolts to hold

the parts in place. Take care not
to pinch the O-ring.
(4) Tighten bolts alternately and
diagonally, as shown, to ensure
even tightening.
(5) Do not use air wrenches. Using
an air wrench often causes
tightening of one bolt fully before W105-01-01-008
tighten the others, resulting in RIGHT WRONG

damage to O-rings or uneven
tightening of bolts.
Bend along edge sharply Do not bend it round

Nut and Bolt Lockings
 Lock Plate RIGHT RIGHT WRONG

IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
Bend along edge sharply

W105-01-01-009
RIGHT RIGHT WRONG

 Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while
tightening, not while loosening.
RIGHT Loosen WRONG

 Lock Wire
Tighten
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
W105-01-01-010
W1-2-4
Piping Joint
Pipe Thread Connection / Union Joint Tightening

Torque Specifications 1 4 3 5 2
Union Joint
Metal sealing faces (4) and (5) of adaptor (1) and

hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
Joint Body
M202-07-051
IMPORTANT: (1) Do not over-tighten union nut (3).
Excessive force will be applied
to metal sealing surfaces (4) and
(5), possibly cracking adaptor (1). 37
Be sure to tighten union nut (3) 30
to specifications.
(2) Scratches or other damage to

Male Union Joint Female Union Joint
sealing surfaces (4) or (5) will
cause oil leakage at the joint. W105-01-01-017
Take care not to damage them

when connecting /disconnecting.
Wrench Size Tightening Torque

Type
Union Nut Joint Body Nm kgfm
17 17 24.5 2.5
19 19 29.5 3.0
22 22 39 4.0
30 Male Union Joint 27 27 93 9.5
32 32 137 14.0
36 36 175 18.0
41 41 205 21.0
17 14 24.5 2.5
19 17 29.5 3.0
22 19 39 4.0
37 Female Union Joint 27 22 93 9.5
32 27 137 14.0
36 32 175 18.0
41 36 205 21.0
W1-2-5
O-Ring Seal Joint
7 6 9
O-ring (6) seats against the end face of adaptor (7)
to seal pressure oil.
IMPORTANT: (1) Be sure to replace O-ring (6) with

a new one when reconnecting.
(2) Before tightening union nut (9), Joint Body

confirm that O-ring (6) is seated 8 10
correctly in O-ring groove (8). M104-07-033
Tightening union nut (9) with

O-ring (6) displaced will damage Wrench Size Tightening Torque
O-ring (6), resulting in oil Union Nut Joint Body Nm kgfm
leakage. 19 17 29.5 3.0
22 19 69 7.0
(3) Take care not to damage O-ring
groove (8) or sealing face (10). 27 22 93 9.5
Damage to O-ring (6) will cause 32 27 137 14.0
oil leakage. 36 30, 32 175 18.0
41 36 205 21.0
(4) If union nut (9) is found to be 46 41 205 21.0
loose, causing oil leakage, do not
tighten it to stop the leak. Instead,
replace O-ring (6) with a new one,
then tighten union nut (9) after
confirming that O-ring (6) is
securely seated in place.
W1-2-6
Screwed-In Connection
PT PF
IMPORTANT: Many types of screwed-in

30
connec-tions are used for hose
connections.
Be sure to confirm that the thread
pitch and thread type (tapered or
straight) are the correct type before
using any screw-in connection.
Male Tapered Thread Male Straight Thread
W105-01-01-018
Male Tapered Thread

Wrench Tightening Torque
Joint Body Nm kgfm
17, 19 59 6
19, 22 98 10
27, 22 118 12
36, 32 235 24
41 295 30
50 490 50
60 670 68
70 980 100
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male

and female threads, so as to prevent any leakage
between threads.
Be sure to apply just enough seal tape to fill up External Thread Clearance
thread clearances. Do not overwrap.
W105-01-01-019
Leave one to two pitch threads uncovered

 Application Procedure
Confirm that the thread surface is clean, free of dirt

or damage.
Apply seal tape around threads as shown. Wrap
seal tape in the same direction as the threads.
M114-07-041
Low-Pressure-Hose Clamp Tightening Torque

T-Bolt Type Worm Gear Type
Low-pressure-hose clamp tightening torque differs
depending on the type of clamp.
See below for correct tightening torque of each type
of low-pressure-hose clamp.
T-Bolt Type Band Clamp:

4.4 Nm (0.45 kgfm)
Worm Gear Type Band Clamp:
5.9 to 6.9 Nm (0.6 to 0.7 kgfm)
M114-07-042 M114-07-043
W1-2-7
Connecting Hose
WRONG RIGHT
CAUTION:
(1) When replacing hoses, be sure to use
only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses
may cause oil leakage, hose rupture or
separation of fitting, possibly resulting in
a fire on the machine.
(2) Do not install hoses kinked. Application
of high oil pressure, vibration, or an
impact to a kinked hose may result in oil W105-01-01-011
leakage, hose rupture or separation of

fitting. Utilize print marks on hoses when WRONG RIGHT
installing hoses to prevent hose from
Rubbing Against
being installed kinked. Each Other
(3) If hoses rub against each other, wear to
the hoses will result, leading to hose
rupture. Take necessary measures to
protect hoses from rubbing against each
other.
Take care that hoses do not come into
contact with moving parts or sharp W105-01-01-012
objects.
WRONG RIGHT
Clamp Clamp
Rubbing
W105-01-01-013
WRONG RIGHT
Rubbing
Clamp
W105-01-01-014
W1-2-8
Periodic Replacement of Parts
The parts listed below deteriorate as the machine ages and are worn out or fatigued by repeated loads, resulting
in possible severe personal injury and/or machine trouble. The service life of these parts can not be detected
through machine operation or visual inspection.
Therefore, these parts should be replaced at regular intervals even if no abnormalities are noticed. In case any
abnormalities are found on a part at any time regardless of its specified replacement interval, immediately re-
place the part.
Part Location Part to be Replaced Interval (Hours or Period)

Crane operation :Every 4 years or 4000
hours whichever
comes first.
Front Pendant Rope Heavy duty operation
(Bucket, Lifting magnet, etc.) :Every 2 years or 2000
hours whichever
comes first.
Hydraulic hoses for Hydraulic hoses connecting to
2 years
brake and clutch the brake cylinder
Other high pressre,
suction and return Hydraulic hoses 4 years
hoses
Fuel hoses (fuel tank to engine) Every 2 years or 2000 hours whichever comes first.
Engine
Fuel hoses (gauge hose) Every 2 years or 2000 hours whichever comes first.
Electrical cables (front harness,
6 years
Safety devices etc.), micro switch
Load sensor/angle sensor 6 years (Replace or overhaul)
IMPORTANT: Each hose has an individual service life. If any abnormalities are found during the regular
interval check and/or maintenance service, be sure to replace with a new one.
W1-2-9
(Blank)
W1-2-10
SECTION 2
UPPER STRUCTURE
— CONTENTS —
Group1 Cab Group 6 Swing Device
Remove and Install Cab ..........................W2-1-1 Remove and Install Swing Device............W2-6-1
Cab Glass Dimensions ............................W2-1-8 Disassemble Swing Device......................W2-6-4
Assemble Swing Device ........................W2-6-10
Group 2 Couterweight Disassemble Swing Motor .....................W2-6-16
Remove and Install Counterweight ............W2-2-1 Assemble Swing Motor ..........................W2-6-20
Maintenance Standards .........................W2-6-24
Group 3 Swing Frame
Remove and Install Swing Frame ............W2-3-1 Group 7 Winch
Remove and Install Winch .......................W2-7-1
Group 4 Pump Device Disassemble Winch ...............................W2-7-10
Remove and Install Main Pump ...............W2-4-1 Assemble Winch....................................W2-7-18
Disassemble Main Pump .........................W2-4-4 Disassemble Winch Motor .....................W2-7-30
Assemble Main Pump............................W2-4-10 Assemble Winch Motor ..........................W2-7-34
Maintenance Standards .........................W2-4-16 Maintenance Standards .........................W2-7-38
Disassemble Regulator .........................W2-4-18
Assemble Regulator ..............................W2-4-24 Group 8 Boom Hoist
Remove and Install 2-Unit Gear Pump...W2-4-28 Remove and Install Boom Hoist ...............W2-8-1
Disassemble 2-Unit Gear Pump.............W2-4-30 Disassemble Boom Hoist.........................W2-8-4
Assemble 2-Unit Gear Pump .................W2-4-32 Assemble Boom Hoist .............................W2-8-8
Disassemble Boom Hoist Motor .............W2-8-14
Group 5 Control Valve Assemble Boom Hoist Motor..................W2-8-18
Remove and Install 4-Unit Control Valve Disassemble Brake Valve ......................W2-8-24
(for Front Winch, Rear Winch, Travel, Assemble Brake Valve ...........................W2-8-26
Boom Hoist).........................................W2-5-1 Parking Brake Maintenance
Disassemble 4-Unit Control Valve............W2-5-4 Standards ..........................................W2-8-28
Assemble 4-Unit Control Valve ..............W2-5-10 Disassemble Relief Valve ......................W2-8-30
Remove and Install 3-Unit Control Valve Assemble Relief Valve ...........................W2-8-32
(for Front Winch, Rear Winch, Travel) W2-5-17
Disassemble 3-Unit Control Valve..........W2-5-20
Assemble 3-Unit Control Valve ..............W2-5-26
RHAE0W-2-1
Group 9 Remote Control Valve Group 14 Swing Valve
Remove and Install Remote Control Remove and Install Swing Valve ............W2-14-1
Valve for Swing Device, Winch, Disassemble Swing Valve ......................W2-14-4
Boom Hoist ..........................................W2-9-1 Assemble Swing Valve ..........................W2-14-8
Disassemble Remote Control Valve for
Swing Device, Winch, Boom Hoist .......W2-9-4 Group 15 Negative / Positive Selection,
Assemble Remote Control Valve for Positive Hoisting Up / Down, Free Motor
Swing Device, Winch, Boom Hoist .......W2-9-8 Multiple Plate Negative Release Valve
Remove and Install Travel Remote Remove and Install Negative / Positive
Control Valve .....................................W2-9-13 Selection, Positive Hoisting Up / Down,
Disassemble Travel Remote Control Free Motor Multiple Plate Negative
Valve .................................................W2-9-16 Release Valve....................................W2-15-1
Assemble Travel Remote Control Disassemble Negative / Positive
Valve .................................................W2-9-20 Selection, Positive Hoisting Up / Down,
Free Motor Multiple Plate Negative
Group 10 Lock Valve Release Valve....................................W2-15-4
Remove and Install Lock Valve ..............W2-10-1 Assemble Negative / Positive
Disassemble Lock Valve ........................W2-10-4 Selection, Positive Hoisting Up / Down,
Assemble Lock Valve ............................W2-10-6 Free Motor Multiple Plate Negative
Release Valve....................................W2-15-6
Group 11 Shuttle Valve
Remove and Install Shuttle Valve .......... W2-11-1
Disassemble and Assemble Shuttle
Valve ................................................. W2-11-2
Remove and Install Remote Control
Valve Delivery Valve .......................... W2-11-3
Disassemble and Assemble Remote
Control Valve Delivery Valve .............. W2-11-4
Group 12 Solenoid Valves

Remove and Install Solenoid Valve
Block .................................................W2-12-1
Disassemble Solenoid Valve..................W2-12-2
Assemble Solenoid Valve ......................W2-12-4
Group 13 Winch Brake Valve

Remove and Install Winch Brake
Valve .................................................W2-13-1
Disassemble Winch Brake Valve ...........W2-13-2
Assemble Winch Brake Valve ................W2-13-6
RHAE0W-2-2
UPPER STRUCTURE / Cab
Remove and Install Cab
Removal
2
1. Remove the seat mounting socket bolts (2), (4
used), and then remove the seat (1).
: 6 mm
2
WRHAE0-02-01-001
4
2. Remove the bolts (4) (3 used), (27) (2 used), and
then remove the rear box (3).
: 13 mm,17 mm
3
3. Remove the duct (5) in the upward direction.
27
WRHAE0-02-01-002
4. Remove the air filter (6), remove the clips (7) (2

used) with the pliers, and then remove the duct
(8) from the cab body.
6
WRHAE0-02-01-003
W2-1-1
5. Remove the cable connectors (10) to (13) located
to the right inside the cab, and the ground
connector (9) located to the rear inside the cab.
: 13 mm
9
10
11
12
13
W178-02-01-004
6. Remove the vinyl hose (14) for the washer

located to the rear inside the cab.
14
WRHAE0-02-01-005
16
7. Remove the caps (15) (5 used) from the duct
cover (17) with a slotted screwdriver, remove the
screws (16) (5 used) with a Phillips screwdriver, 17
and then remove the duct cover (17).
15
WRHAE0-02-01-006
8. Remove the bolts (18) , (21), and then remove the

ducts (19), (20).
: 10 mm,17 mm
18
Duct Mating Surface
19
20 21
WRHAE0-02-01-007
W2-1-2
9. Remove the cab mounting nuts (26) (4 used).
: 24 mm
26
CAUTION: Cab (22) weight: 280 kg 23 WRHAE0-02-01-009
24 23
10. Remove the bolts for preventing screw hole 24
rusting (23) (4 used) from the top of the cab (22),
and then install the eyebolts (24) (4 used).
24
24
23
23
22
WRHAE0-02-01-008
11. Attach wire ropes (25) to the eyebolts (24) (4

places) and hold them with the crane.
25
12. Lift the cab (22) carefully to avoid touching the
rear stand, left stand, right stand and other 24
components on the floor plate.
22
WRHAE0-02-01-010
W2-1-3
Installation
CAUTION: Cab (22) weight: 279 kg 25
1. Attach wire ropes (25) to the eyebolts (24) (4 24

places) on the top of the cab (22) and lift them
with the crane.
22
2. Lower the cab (22) carefully to avoid touching the
rear stand, left stand, right stand and other
components on the floor plate.
WRHAE0-02-01-010
3. Remove the wire ropes (25) and eyebolts (24), 23

and install the bolts for preventing screw hole 24 23
rusting (23) (4 used) onto the top of the cab (22). 24
24
24
23
23
22
WRHAE0-02-01-008
4. Install the cab mounting nuts (26) (4 used).

: 24 mm
: 205 Nm (21 kgfm)
26
WRHAE0-02-01-009
W2-1-4
5. Install the duct (8) with the clips (7) (2 used) so
that it sandwiches the plates at the rear of the cab.
Insert the filter (6) so that the arrow imprinted on
the filter (6) faces the seat side. 6
W1F3-02-01-002
6. Install the cable connectors (10) to (13), located

to the right inside the cab, and install the ground
connector (9) located to the rear inside the cab.
: 13 mm
: 8 Nm (0.8 kgfm)
9
10
11
12
13
WRHAE0-02-01-004
7. Install the vinyl hose (14) for the washer located

to the rear inside the cab.
14 WRHAE0-02-01-005
W2-1-5
8. Align the insertion opening of the duct (5), and
install the duct (5) by pushing it downward.
4
9. Install the rear box (3) with the bolts (4) (3 used),
(27) (2 used).
: 13 mm
: 6 Nm (0.6 kgfm)
: 17 mm
: 12 Nm (1.2 kgfm) 3
27
WRHAE0-02-01-002
IMPORTANT: After installation, check that each

duct is fitted securely.
10. Install the duct (20) with the bolt (21) (2 used).
Insert the duct (19) into the duct (20), and fasten it
with the bolts (18) (2 used).
: 10 mm
: 3 Nm (0.3 kgfm) 18
: 17 mm Duct Mating Surface
: 12 Nm (1.2 kgfm) 19
20
21
WRHAE0-02-01-007
W2-1-6
11. Install the duct cover (17) with the screws (16) (5
used), and then install the caps (15) (5 used).
16
17
15
WRHAE0-02-01-006
12. Install the seat (1) with the bolts (2) (4 used).
: 6 mm
: 8 Nm (0.8 kgfm)
2
WRHAE0-02-01-001
W2-1-7
Cab Glass Dimensions
Polish chamfering
A
between here
Unit: mm R2
All around light
67 303.5 chamfering except for
11 locations where other
instruction is specified
R98 R35
4-13 0 -1
R3018
Cross Section A W178-02-01-019
405 30 Light
chamfering on
both sides 375
238 51 612
R118
(5 mm)
343.5 148.5
196
100
50
R70
370.5
W178-02-01-006
B
All around All around W178-02-01-002
c1 c1
14
733
R58
R58
R11508
Cross Section B W178-02-01-019
R1808
882.5 997
(4 mm)
R308 R1898
R258
100
150
943
W178-02-01-007
W2-1-8
Unit: mm Polish chamfering between here
All around light
Polish chamfering between chamfering except
85.4
for locations where
343.3 213 polish chamfering
is specified
R105
R72 R10
R105
(4 mm)
All around light chamfering 39.5 D

except for locations where
polish chamfering is Cross Sections 733
733
C specified R2465 C and D +0.5
2-12.2 -0
W178-02-01-019
(4 mm)
40 6.754
Light
chamfering on
289.5 both sides
3-R4 50
2-R4
86.9 50 50
556.3
W178-02-01-011 50
423
W178-02-01-008
366.1 104.5
R12 R95
(5 mm) All around light

982.7 chamfering
R2002
W178-02-01-004
R123
872
38.2
R14
51
470.6
R5 (3 places) W178-02-01-009
364.7
R2475
All around light
(5 mm)
chamfering
R115
888.58
W178-02-01-010
W2-1-9
Cab Glass Removal
Mounting Rubber Cross Section
CAUTION: Removing shattered or cracked
glass is dangerous because sharp glass
shards can cause a serious injury.
Take protective measures before starting the Mounting Glass
removal work; for example, use packing tape Rubber
to thoroughly reinforce or cover the shattered
or cracked locations. Be sure to clean up any
glass shards that fall.
IMPORTANT: The glass and mounting rubber are Cab

attached to each other using a Seal Rubber
special adhesive. If this special
adhesive is not used, the glass may
fall out. When replacing the glass,
replace the glass and mounting W178-02-01-022
rubber together as an assembly.
Curved glass is used for the front
upper glass. When replacing the
glass, contact your nearest Hitachi
branch or dealer and replace it as an
assembly.
W178-02-01-004
Procedure for removing the left side glass, door

A
lower glass and front upper glass
1. Insert a spatula into section A of the mounting

rubber, and slightly raise the mounting rubber all Mounting Glass
Rubber
around. Air will enter the contact surface between
the cab and rubber and make removal easier.
2. Remove the glass by patting it with the palm of

your hand from inside the cab. Be sure to perform
this work with two persons. Cab
Seal Rubber
W178-02-01-022
W2-1-10
Procedure for removing the right side glass
Mounting Rubber Cross
1. Insert a spatula into section A of the mounting Inside the Cab
rubber, and slightly raise the mounting rubber all Glass
Mounting
around. Air will enter the contact surface between Rubber
the cab and rubber and make removal easier. A
2. Remove the glass by patting it with the palm of

Cab
this work with two persons.
W216-02-01-005
W178-02-01-002
Procedure for removing the rear side glass Mounting Rubber Cross Section
1. Use a slotted screwdriver to remove the stopper

Glass
(groove rubber). Mounting
Rubber
2. Insert a spatula into section A of the mounting

rubber, and slightly raise the mounting rubber all Inside the Cab Stopper
around. Air will enter the contact surface between (Groove
Rubber)
the cab and rubber and make removal easier. A
A
3. Remove the glass by patting it with the palm of Cab
this work with two persons. W216-02-01-003
W178-02-01-005
W2-1-11
(Blank)
W2-1-12
UPPER STRUCTURE / Counterweight
Remove and Install Counterweight
CAUTION: Do not stand under a lifted

counterweight.
Do not lift counterweights “A” (1) and “B” (2)
at the same time.
Do not let the wire ropes used for slinging
interfere with the rope stopper bar of the
hanger.
Removal
1. Lower the boom, remove the hook, and remove

the wire ropes from the front and rear winch.
Remove the pendant rope, boom insert and
boom top. (For details on removing the pendant
rope, boom insert and boom top, refer to the
Operator’s Manual.)
3
2. Fully extend the crawler side frame. (For details
on extending the crawler side frame, refer to the
4
CAUTION: Counterweight “B” (2) 4
Weight: Approx. 8400 kg 5
3. Attach the sling ropes onto counterweight “B” (2)

and support it with the auxiliary crane. 5
NOTE: • Lift using the lifting lugs of counterweight
“B” (2).
• Tense the sling ropes until there is no 1
slackness in them. 2 WRHAE0-02-02-001
4. Remove the bolts (3) (2 used), spring washers

(4) (2 used) and washers (5) (2 used) from the
upper surface of counterweight “B” (2).
: 46 mm
5. Lift counterweight “B” (2) and lower it from

counterweight “A” (1).
W2-2-1
CAUTION: Counterweight “A” (1)

Weight: Approx. 8600 kg
6. Attach the sling ropes onto counterweight “A” (1)

and support it with the auxiliary crane.
NOTE: • Lift using the lifting lugs of counterweight
“A” (1).
• Tense the sling ropes until there is no
8
slackness in them. 7
7. Remove the mounting bolts (6) (2 used), spring

washers (7) (2 used) and washers (8) (2 used) 8 1
from the rear surface of counterweight “A” (1). 7
6
: 46 mm WRHAE0-02-02-002
8. Lift counterweight “A” (1) and lower it from the

hook area at the rear of the upper structure.
W2-2-2
Installation
CAUTION: Counterweight “A” (1)

Weight: Approx. 8600 kg
1. Attach the sling ropes onto counterweight “A” (1)

and lift it with the auxiliary crane.
8
2. Install counterweight “A” (1) onto the rear of the 7
upper structure with the mounting bolts (6) (2
used), spring washers (7) (2 used) and washers
(8) (2 used). 1
: 46 mm 8
: 550 Nm (56 kgfm) 7
6 WRHAE0-02-02-002
NOTE: • Check that the hole positions for the

mounting bolts (6) are aligned.
• Apply grease onto the threads of the
mounting bolts (6).
CAUTION: Counterweight “B” (2)

Weight: Approx. 8400 kg 3
3. Attach the sling ropes onto counterweight “B” (2)

and lift it with the auxiliary crane.
4
4
4. Install counterweight “B” (2) onto counterweight
“A” (1) with the mounting bolts (3) (2 used), 5
spring washers (4) (2 used) and washers (5) (2
used).
: 46 mm 5
: 550 Nm (56 kgfm)
NOTE: • Check that the hole positions for the 1
mounting bolts (3) are aligned.
• Apply grease onto the threads of the 2 WRHAE0-02-02-001
mounting bolts (3).
5. Install the hook, front and rear winch wire ropes,

boom insert, boom top and pendant rope. (For
details on installing the hook, front and rear winch
wire ropes, boom insert, boom top and pendant
rope, refer to the Operator’s Manual.)
W2-2-3
(Blank)
W2-2-4
UPPER STRUCTURE / Swing Frame
Remove and Install Swing Frame
CAUTION: If pressurized hydraulic oil makes

contact with the skin or eyes, it may cause
serious injury. Release the pressure before
removing the hydraulic lines.
Hot hydraulic oil just after operation may
spout and cause severe burns. Wait for the oil
to cool before starting any work.
Preparation
1. Stop the engine, and then operate the control

levers several times to release the remaining
pressure from the circuit.
Removal

the wire ropes from the front and rear winches.
Remove the pendant rope, boom insert and boom
top. (For details on removing the pendant rope,
boom insert and boom top, refer to the Operator’s
Manual.)
2. Remove the counterweights. (For details on

removing the counterweights, refer to W2-2 in this
section.)
3. Retract the gantry, install the upper spreader on

the boom base, and remove the boom hoist wire
ropes. (For details on retracting the gantry,
installing the upper spreader on the boom base
and removing the boom hoist wire ropes, refer to
the Operator’s Manual.)
4. Remove the boom backstop. (For details on

removing the boom backstop, refer to the
5. Remove the boom base. (For details on removing

the boom base, refer to the Operator’s Manual.)
W2-3-1
CAUTION: Gantry weight: Approx. 905 t 3

4
1
6. Attach the sling ropes onto the gantry and support
2
it with the auxiliary crane.
7. Remove the bolts (1) (4 used) (5) (4 used),

washers (2) (4 used) (6) (4 used), lock plates (3)
(2 used) (7) (2 used) and pins (4) (2 used) (8) (2
used), and then remove the gantry.
8
8. Remove the center joint stopper and hose from
the upper structure side only. (For details on
removing the center joint, refer to W3-2 in the next 5
section.) 6
7
WRHAE0-02-03-001
9. Attach the shackles (9) to the installation holes at
the rear of the gantry on the swing frame, and
attach the wire ropes.
9
WRHAE0-02-03-002
IMPORTANT: Take care not to damage the

bushing.
10. Attach the shackles (9) to the boom foot of the
swing frame, and attach the wire ropes. 9
11. Using wire ropes and chain blocks, balance the

center of gravity and support with the crane.
9
WRHAE0-02-03-003
W2-3-2
12. Loosen the bolts (10) (26 used) on the outer race
of the swing bearing by approx. 10 mm.
: 41 mm
13. Lift the upper structure with the crane by approx. 10

10 mm to balance it.
14. Remove the bolts starting from the bolts closest to

the bosses (2 places) on the outer race, and then
remove the outer race. WRHAE0-02-03-005
NOTE: Lift using the lifting lugs of counterweight

“B” (2).
CAUTION: Upper structure weight:

Approx. 15 t
15. Attach the special lifting tool to the upper structure

and lift it with the crane to remove it from the lower
structure.
NOTE: Use the special lifting tool.
Use an auxiliary crane.
WRHAE0-02-03-004
W2-3-3
Installation
1. Insert the bolts (10) into the holes on the outer

race, and place blocks under the bolt (10) heads.
NOTE: 3 different bolt types are used. Insert the
bolts into their correct positions.
2. Attach the special lifting tool onto the upper

structure.
NOTE: Use the special lifting tool.
Use an auxiliary crane.
10
WRHAE0-02-03-006
CAUTION: Upper structure weight:
Approx. 15 t
3. Lift the upper structure and rotate the outer race to

align it with the car body.
4. Align the bolt hole positions and slowly lower the

upper structure.
WRHAE0-02-03-004
12
11 13
5. Install the spacers (11) and nuts (12), and
provisionally tighten the nuts (12). 12
6. Fully tighten the nuts (12) and fix them with the
lock plate (13).
: 41 mm 11
: 1200 Nm (122 kgfm)
7. Remove all the lifting tools from the upper

structure.
8. Install all the hoses and stoppers onto the center

joint. (Refer to W3-2 in the next section.)
WRHAE0-02-03-007
W2-3-4
9. Support the gantry with the auxiliary crane.
10. Fix the gantry with the pins (4), (8), and install it 3
with the lock plates (3), (7), washers (2), (6) and 1
4
bolts (1), (5).
2
11. Install the boom base. (For details on installing the
boom base, refer to the Operator’s Manual.)
12. Install the boom backstop. (For details on

installing the boom backstop, refer to the
8
13. Extend the gantry.

5
14. Install the counterweights. (For details on installing 6
the counterweights, refer to W2-2 in this section.) 7
WRHAE0-02-03-001
15. Install the boom top. (For details on installing the
boom top, refer to the Operator’s Manual.)
16. Install the boom insert. (For details on installing

the boom insert, refer to the Operator’s Manual.)
17. Install the pendant rope. (For details on installing

the pendant rope, refer to the Operator’s Manual.)
18. Wind up the boom hoist wire ropes. (For details on

winding up the boom hoist wire ropes, refer to the
W2-3-5
(Blank)
W2-3-6
UPPER STRUCTURE / Pump Device
Remove and Install Main Pump
CAUTION: If pressurized hydraulic oil

makes contact with the skin or eyes, it may
cause serious injury. Release the pressure
before removing the hydraulic lines.
Before draining the hydraulic oil, lower the
boom to the ground and apply all the brakes
and drum locks.
Preparations

2. Remove the drain plug (1) and drain the hydraulic
oil into a container (approx. 300 L). Install the
drain plug (1).
: 17 mm
Removal
1. Remove all hoses, pipes and electric cables from 1 WRHAE0-02-04-001
the pump mechanism. Cap the removed hoses.

: 22 mm, 27 mm, 36 mm 2
: 8 mm, 10 mm
2. Attach the wire ropes onto the main pump and

support it with the crane.
CAUTION: Main pump weight:

Approx. 160 kg
3. Remove the main pump mounting socket bolts (2)

(4 used), and lift and remove the main pump with
the crane.
: 17 mm
WRHAE0-02-04-002
W2-4-1
CAUTION: 2-unit gear pump weight:

Approx. 18.0 kg
4. Remove the 2-unit gear pump mounting bolts (3)

(4 used), and lift and remove the 2-unit gear pump
(4) with the crane. 2
: 19 mm
Installation 3

4
Approx. 18.0 kg
1. Install the 2-unit gear pump (4) onto the main

pump with the 2-unit gear pump mounting bolts (3)
(4 used).
: 19 mm
: 30.3 to 38.3 Nm (3.1 to 3.9 kgfm)

Approx. 160 kg
WRHAE0-02-04-002
2. Lift the main pump with the crane and install it

onto the coupling and bracket.
3. Apply LOCTITE onto the main pump mounting

socket bolts (2) (4 used), and then install the bolts.
: 17 mm
: 430 Nm (41.0 kgfm)
4. Install all hoses, pipes and electric cables onto the

main pump.
: 22 mm
: 36 Nm (3.7 kgfm)
: 27 mm
: 93 Nm (9.5 kgfm)
: 36 mm
: 175 Nm (18.0 kgfm)
: 8 mm
: 57 Nm (5.8 kgfm)
: 10 mm
: 98 Nm (10.0 kgfm)
W2-4-2
5. Remove the filler port cover of the hydraulic oil
tank, and fill hydraulic oil to the appropriate level
on the level gauge.
6. Remove the air bleed plug (5) from the top of the
main pump, and fill the pump with hydraulic oil. 5
Install the air bleed plug (5), start the engine, and
run it at low idle speed.
: 36 mm
: 170 Nm (17.3 kgfm)
7. Loosen the air bleed plug (5) to release the

pressure from inside the pump.
: 36 mm
8. After releasing the pressure, tighten the air bleed

plug (5). Perform various operations at low idle
speed, and check the hydraulic oil level and for oil
leaks.
: 36 mm
: 170 Nm (17.3 kgfm)
WRHAE0-02-04-002
W2-4-3
Disassemble Main Pump
68
65 66 67 67 65 66
69
2 3 4 5 6 7 8 9 11 12 13 10 14 15 16 17 18 19 20 21 22 23 24
1
57
17
56
55
54
53
52
51
50
49
48 47 46 45 44 41 42, 43 40 39 38 37 35, 36 34 33 30, 31 32 29 28 27 26 25
58
59
60
61
36,62
63
64
WRHAE0-02-04-003
W2-4-4
1- Setscrew (2 Used) 19 - Shoe (18 Used) 37 - Valve Block 55 - Seal Cover

2- Nut (2 Used) 20 - Shoe Plate (2 Used) 38 - Spline Connector 56 - Socket Bolt (4 Used)
3- Stopper (2 Used) 21 - Shaft 39 - Bearing (2 Used) 57 - Spring Pin (4 Used)
4- Backup Ring (2 Used) 22 - Screw Block (4 Used) 40 - Valve Plate 58 - Stopper (2 Used)
5- O-Ring (2 Used) 23 - Socket Bolt (4 Used) 41 - Cylinder Spring (18 Used) 59 - Stopper (2 Used)
6- Servo Piston (2 Used) 24 - Rear Cover 42 - Plug (4 Used) 60 - Steel Ball (4 Used)
7- Tilt Bushing (2 Used) 25 - Locking Ring 43 - O-Ring (4 Used) 61 - Seat (4 Used)
8- Feedback Pin (2 Used) 26 - Spline Connector 44 - Bushing (2 Used) 62 - O-Ring
9- Tilt Pin (2 Used) 27 - O-Ring 45 - Plate (2 Used) 63 - Assist Casing
10 - O-Ring (16Used) 28 - Socket Bolt (8 Used) 46 - Plug (21 Used) 64 - Socket Bolt (3 Used)
11 - O-Ring (2 Used) 29 - Pump Casing (2 Used) 47 - Plate (2 Used) 65 - Regulator (2 Used)
12 - Backup Ring (2 Used) 30 - Nameplate 48 - Support (2 Used) 66 - Socket Bolt (4 Used)
13 - Stopper (2 Used) 31 - Pin (2 Used) 49 - O-Ring 67 - Socket Bolt (4 Used)
14 - Nut (2 Used) 32 - Cylinder Block (2 Used) 50 - Bearing (2 Used) 68 - O-Ring (2 Used)
15 - Eyebolt (2 Used) 33 - Valve Plate 51 - Stop Ring (2 Used) 69 - O-Ring (2 Used)
16 - Setscrew (2 Used) 34 - Valve Plate Pin (2 Used) 52 - Bearing Spacer (4 Used)
17 - O-Ring (4 Used) 35 - Plug (2 Used) 53 - Shaft
18 - Piston (18 Used) 36 - O-Ring (7 Used) 54 - Oil Seal
W2-4-5
68
65 66 67 67 65 66
69
18 19 20
56
55
54
53
49
48 47 46 45 44 41 42 38 37 32 29 28
WRHAE0-02-04-003
W2-4-6
Disassemble Main Pump
• Thoroughly read “PRECAUTIONS FOR 8. Separate the valve block (37) from the pump
DISASSEMBLING AND ASSEMBLING” (W1-1-1) casing (29).
before disassembling. NOTE: When separating the valve block (37) from
the pump casing (29), remove the spline
IMPORTANT: Place a rubber plate or cloth on the connector (38) at the same time.
workbench to prevent damage to the
parts. IMPORTANT: Do not damage sliding surfaces,
1. Select the disassembly location. such as those of the cylinder block
NOTE: Select a clean location. (32), bushing (44), shoe (19) or plate
(47).
2. Remove any dust or rust from the pump surface 9. Remove the cylinder block (32) from inside the
using washing oil. pump casing (29), keeping it straight relative to
the shaft (53). At the same time, remove the
3. Remove the plugs (42) (4 used) and drain the oil piston (18), shoes (19) (9 used), shoe plate (20),
from inside the pump casing (29). plate (45), bushing (44) and cylinder springs (41)
: 36 mm (9 used).
NOTE: Drain the oil from the plugs on both the
front pump and rear pump. IMPORTANT: The oil seal (54) is mounted on the
seal cover (55), so be careful not to
4. Remove the socket bolts (66) (4 used) (67) (4 damage the oil seal (54) when
used), and then remove the regulator (65) (2 removing the seal cover (55).
used). 10. Remove the socket bolts (56) (4 used), and then
: 6 mm remove the seal cover (55).
: 6 mm
NOTE: For details on disassembling the regulator
(65), refer to the Disassemble Regulator NOTE: The seal cover (55) is easy to remove if
section. you insert a bolt into the hole (M8 tapped)
on the seal cover (55) and then pull it out.
5. Remove the O-rings (68) (2 used) (69) (2 used) 11. Remove the O-ring (49) from the seal cover (55).
from the regulators (65) (2 used).
12. Remove the oil seal (54) from the seal cover (55).

Approx. 130 kg
IMPORTANT: Before placing the pump on the

workbench with the regulator
mounting surface facing downward,
be sure to place a rubber plate etc.
on the workbench to prevent
damage to the mounting surface.
6. Place the pump level on the workbench with the
regulator mounting surface facing downward.
7. Remove the front support (48), pump casing (29),

and socket bolts (28) (4 used) that fasten the
valve block (37).
: 17 mm
W2-4-7
2 3 6 9 13 14 18 19 21 22 23 24
53
48 47 45 44 41 40 39 37 33 32 29 28 27 26
WRHAE0-02-04-003
W2-4-8
13. Remove the socket bolts (23) (4 used) and screw 22. Remove the valve plates (33), (40) from the valve
blocks (22) (4 used), and then remove the rear block (37).
cover (24). NOTE: The valve plates may come off in step 8 or
: 10 mm 17.
14. Remove the O-ring (27) from the rear cover (24). IMPORTANT: When removing the tilt pin (9), use
the special tool to prevent damage
15. Remove the spline connector (26) from the shaft to the head of the tilt pin (9).
(21). Be careful not to damage the servo
piston (6), because LOCTITE has
16. Remove the rear support (48), pump casing (29), been applied to the contacting part
and socket bolts (28) (4 used) that fasten the between the tilt pin (9) and servo
valve block (37). piston (6).
: 17 mm Do not remove the bearing (39)
unless necessary, such as when you
17. Separate the valve block (37) from the pump think it has reached the end of its
casing (29). service life.
Do not loosen the lock nuts (2) (14)
IMPORTANT: Do not damage sliding surfaces, of the valve block (37) and support
such as those of the cylinder block (48). The flow rate setting will
(32), bushing (44), shoe (19) or plate change.
(47). 23. If necessary, remove the stoppers (13), (3), servo
18. Remove the cylinder block (32) from inside the piston (6) and tilt pin (9) from the pump casing
pump casing (29), keeping it straight relative to (29), and remove the bearing (39) from the valve
the shaft (53). At the same time, remove the block (37).
piston (18), plate (45), bushing (44) and spring
(41).
19. Lightly tap the mounting flange part of the support

(48) from the pump casing (29) side to separate
the support (48) from the pump casing (29).
20. Remove the plates (45), (47) from the pump

casing (29).
21. Lightly tap the ends of the shafts (21), (53) with a
plastic hammer to remove the shafts (21) (53)
from the support (48).
W2-4-9
Assemble Main Pump
68
65 66 67 67 65 66
69
2 3 4 5 6 7 8 9 11 12 13 10 14 15 16 17 18 19 20 21 22 23 24
1
57
17
56
55
54
53
52
51
50
49
48 47 46 45 44 41 42, 43 40 39 38 37 35, 36 34 33 30, 31 32 29 28 27 26 25
58
59
60
61
36,62
63
64
WRHAE0-02-04-003
W2-4-10
1- Setscrew (2 Used) 19 - Shoe (18 Used) 37 - Valve Block 55 - Seal Cover
2- Nut (2 Used) 20 - Shoe Plate (2 Used) 38 - Spline Connector 56 - Socket Bolt (4 Used)
3- Stopper (2 Used) 21 - Shaft 39 - Bearing (2 Used) 57 - Spring Pin (4 Used)
4- Backup Ring (2 Used) 22 - Screw Block (4 Used) 40 - Valve Plate 58 - Stopper (2 Used)
5- O-Ring (2 Used) 23 - Socket Bolt (4 Used) 41 - Cylinder Spring (18 Used) 59 - Stopper (2 Used)
6- Servo Piston (2 Used) 24 - Rear Cover 42 - Plug (4 Used) 60 - Steel Ball (4 Used)
7- Tilt Bushing (2 Used) 25 - Locking Ring 43 - O-Ring (4 Used) 61 - Seat (4 Used)
8- Feedback Pin (2 Used) 26 - Spline Connector 44 - Bushing (2 Used) 62 - O-Ring
9- Tilt Pin (2 Used) 27 - O-Ring 45 - Plate (2 Used) 63 - Assist Casing
10 - O-Ring (16 Used) 28 - Socket Bolt (8 Used) 46 - Plug (21 Used) 64 - Socket Bolt (3 Used)
11 - O-Ring (2 Used) 29 - Pump Casing (2 Used) 47 - Plate (2 Used) 65 - Regulator (2 Used)
12 - Backup Ring (2 Used) 30 - Nameplate 48 - Support (2 Used) 66 - Socket Bolt (4 Used)
13 - Stopper (2 Used) 31 - Pin (2 Used) 49 - O-Ring 67 - Socket Bolt (4 Used)
14 - Nut (2 Used) 32 - Cylinder Block (2 Used) 50 - Bearing (2 Used) 68 - O-Ring (2 Used)
15 - Eyebolt (2 Used) 33 - Valve Plate 51 - Stop Ring (2 Used) 69 - O-Ring (2 Used)
16 - Setscrew (2 Used) 34 - Valve Plate Pin (2 Used) 52 - Bearing Spacer (4 Used)
17 - O-Ring (4 Used) 35 - Plug (2 Used) 53 - Shaft
18 - Piston (18 Used) 36 - O-Ring (7 Used) 54 - Oil Seal
W2-4-11
65 65
3 6 7 8 9 13 17 18 19 20 21 22 23 24
52
51
50
48 47 44 41 39 38 37 34 33 32 29 28 27 26 25
WRHAE0-02-04-003
W2-4-12
Assemble Main Pump
IMPORTANT: When tightening the servo piston (6) IMPORTANT: Make sure that the suction and
and tilt pin (9), use the special tool to delivery directions of the valve plate
prevent damage to the head of the (33) are correct.
tilt pin (9) and the feedback pin (8). 5. Align the valve plate (33) with the valve plate pin
Apply Three Bond #1305N onto the (34), and install it onto the valve block (37).
thread area. NOTE: After removing the bearing (39), install it
1. Install the O-ring (17) onto the rear support (48), onto the valve block (37) in preparation for
and install the support (48) onto the rear pump assembly.
casing (29) while lightly tapping it with the
hammer. IMPORTANT: Make sure that the direction of the
NOTE: After removing the servo piston (6), tilt pin valve block (37) is correct.
(9) and stoppers (13), (3), install them onto (Assemble the valve block (37) with
the pump casing (29) in preparation for the regulator (65) facing up and the
assembly. suction flange facing right as seen
from the front.)
2. Position the pump casing (29) with the regulator 6. Install the O-ring (17) onto the valve block (37),
mounting surface facing downward. Correctly and then install the valve block (37) onto the
install the plate (47) onto the support (48) by pump casing (29) with the socket bolts (28) (4
inserting the tilt bushing (7) of the plate (47) into used).
the tilt pin (9). : 17 mm
NOTE: Check whether you can smoothly move the : 430 Nm (44.0 kgfm)
plate (47) with your fingertips, using both
hands. 7. Install the spline connector (26) onto the shaft
If you apply grease onto the sliding (21).
surfaces of the plate (47) and support (48), NOTE: After removing the locking ring (25), install
the shaft (21) can be installed easily. the locking ring (25) in preparation for
assembly.
IMPORTANT: Do not tap the shaft (21) with a
hammer. 8. Install the O-ring (27) onto the rear cover (24),
3. The bearing (50), spacer (52) and stop ring (51) and then install the rear cover (24) onto the
have been set on the shaft (21). Install this shaft support (48) with the socket bolts (23) (4 used)
onto the support (48). and screw blocks (22) (4 used).
NOTE: Install by lightly tapping the outer ring of the
bearing (50) with a plastic hammer, and 9. Install the spline connector (38) onto the shaft
then fully insert by using a steel bar. (21) inside the valve block (37).
4. Assemble the piston cylinder assembly (cylinder 10. Install the O-ring (17) onto the front support (48),
block (32), piston (18), shoes (19) (9 used), shoe and install the support (48) onto the front pump
plate (20), plate (45), bushing (44) and cylinder casing (29) by lightly tapping it with the hammer.
springs (41) (9 used)), and then install the NOTE: After removing the servo piston (6), tilt pin
assembly inside the pump casing (29), matching (9) and stoppers (13), (3), install them onto
the phases of the bushing (44) and cylinder block the pump casing (29) in preparation for
(32) splines. assembly.
W2-4-13
68
65 66 67 67 65 66
69
7 8 9 17 18 19 20
56
55
54
53
52
51
50
49
48 47 45 44 41 42, 43 40 38 37 34 32 29 28
WRHAE0-02-04-003
W2-4-14
11. Position the pump casing (29) with the regulator IMPORTANT: Make sure that the suction and
mounting surface facing downward. Correctly delivery directions of the valve plate
install the plate (47) onto the support (48) by (40) are correct.
inserting the tilt bushing (7) of the plate (47) into 17. Align the valve plate (40) with the valve plate pin
the tilt pin (9). (34), and install it onto the valve block (37).
NOTE: Check whether you can smoothly move the
plate (47) with your fingertips, using both 18. Install the O-ring (17) onto the valve block (37).
hands.
Applying grease onto the plate (47), 19. Install the pump casing (29) onto the valve block
support (48) and moving parts makes it (37), and then install the socket bolts (28) (4
easier to install the shafts (53). used).
: 17 mm
IMPORTANT: Do not tap the shaft (53) with a : 430 Nm (44.0 kgfm)
hammer etc. NOTE: The work is easier if you assemble the rear
12. The bearing (50), spacer (52) and stop ring (51) pump first.
have been set on the shaft (53). Install this shaft Install the spline connector (38) inside the
onto the support (48). valve block (37) in advance, and then mesh
NOTE: Install by lightly tapping the outer ring of the it with the connection splines of the drive
bearing (50) with a plastic hammer, and shaft of the shafts (21), (53).
then fully insert by using a steel bar etc.
20. Install the O-rings (68), (69) onto the regulators
13. Install the oil seal (54) onto the seal cover (55). (65) (2 used).
14. Install the O-ring (49) onto the seal cover (55). IMPORTANT: Check the regulators (65) (2 used) to
make sure that the front and rear
IMPORTANT: Do not damage the oil seal (54) ones are positioned correctly.
during installation. 21. Insert the feedback pin (8) of the tilt pin (9) into the
15. Install the seal cover (55) onto the pump casing feedback lever of the regulator (65). Install the
(29) with the socket bolt (56). regulators (65) (2 used), and then install the
: 6 mm socket bolts (66) (4 used), (67) (4 used).
: 29 Nm (3.0 kgfm) : 6 mm
: 29 Nm (3.0 kgfm)
NOTE: Apply a thin film of grease onto the oil seal
(54) inside the seal cover (55).
22. Install the plug (42) (4 used).
: 36 mm
16. Assemble the piston cylinder assembly (cylinder
: 170 Nm (17.0 kgfm)
block (32), piston (18), shoes (19) (9 used), shoe
plate (20), plate (45), bushing (44) and cylinder
springs (41) (9 used)), and then install the
assembly inside the pump casing (29), matching
the phases of the bushing (44) and cylinder block
(32) splines.
W2-4-15
Maintenance Standards
1. Clearance between piston outer diameter and
cylinder inner bore
D-d Unit: mm
Standard Allowable Limit
d D
0.035 0.062
W25N-02-04-005
2. Clearance between piston and caulking part of

shoe
δ Unit: mm
0 to 0.1 0.3
δ
3. Shoe thickness
t Unit: mm W25N-02-04-006

4.9 4.7
4. Free length of cylinder spring

L Unit: mm
39.5 38.7
W25N-02-04-007
5. Height of plate and spherical bushing

H-h Unit: mm
Standard Allowable Limit H
h
23.0 22.0
W25N-02-04-008
W2-4-16
(Blank)
W2-4-17
Disassemble Regulator
3
11
10
9
8
21
7
6 20 12
16 19
5 17 13
4
3 14
2 22
1 15
23
24 16
25
26 18
29
30 44
27
28 43 41
42 45
40
36 37 39
38
31
32
30
46
47
33 48
35 49
34
30
50
54
56
55 54 53 52 51
58 57 49 50
WRHAE0-02-04-004
W2-4-18
1- Pin 16 - Pin (2 Used) 31 - Cover 46 - Casing

2- Sleeve 17 - Lever 32 - O-Ring 47 - Pin (2 Used)
3- O-Ring 18 - Pin 33 - O-Ring (3 Used) 48 - Plug
4- O-Ring 19 - Pin 34 - O-Ring 49 - O-Ring (2 Used)
5- Case 20 - Feedback Lever 35 - Plug (5 Used) 50 - Retaining Ring (2 Used)
6- Piston 21 - Lever 36 - Socket Bolt (2 Used) 51 - Plug
7- Rod 22 - Spool 37 - Socket Bolt (2 Used) 52 - Pin
8- Spring Seat 23 - Sleeve 38 - O-Ring 53 - O-Ring
9- Spring 24 - Retaining Ring 39 - Adjusting Screw 54 - O-Ring (9 Used)
10 - Spring 25 - Set Spring 40 - Nut 55 - O-Ring
11 - Adjusting Rod 26 - Return Spring 41 - Nut 56 - O-Ring
12 - O-Ring 27 - Spring Seat 42 - O-Ring 57 - Cover
13 - Adjusting Rod 28 - Retaining Ring 43 - Cover 58 - Socket Bolt (2 Used)
14 - Spring 29 - Piston 44 - Lock Nut 59 - O-Ring
15 - Spring Seat 30 - Socket Bolt (10 Used) 45 - Setscrew
W2-4-19
11
10
9
8
13
14
15
23
24
25
26
30 44
27
28 43 41
45
40
36 37 39
48
30
50
54 51
58 57 50
WRHAE0-02-04-004
W2-4-20
Disassemble Regulator
6. Remove the socket bolts (58) (2 used), (30) (2
• Thoroughly read “PRECAUTIONS FOR used), and then remove the cover (57).
DISASSEMBLING AND ASSEMBLING” (W1-1-1) After removing the cover (57), remove the set
before disassembling. spring (25) from the pilot part.
: 5 mm
IMPORTANT: Place a rubber plate or cloth on the
workbench to prevent damage to the IMPORTANT: When removing the retaining ring
parts. (28), the return spring (26) flies out.
The parts are small. Be careful not to Be careful not to lose it.
lose them. 7. Remove the retaining ring (28), and then remove
1. Select the disassembly location. the spring seat (27), return spring (26) and sleeve
NOTE: Select a clean location. (23).
NOTE: The retaining ring (24) is assembled on the
sleeve (23).
2. Remove any dust or rust from the regulator
surface using washing oil. 8. Remove the retaining rings (50) (2 used), and
then pull out the plugs (48), (51).
IMPORTANT: Do not lose the O-ring (54). NOTE: The plugs (48), (51) are easy to remove if
3. Remove the socket bolts (36) (2 used), (37) (2 you use an M6 bolt.
used), and then remove the regulator from the
pump.
: 6 mm
IMPORTANT: An adjusting screw (39), adjusting

rod (11), lock nut (44), nuts (40) (41)
and setscrew (45) are assembled on
the cover (43). Do not loosen these
screws and nuts. If you loosen them,
the adjusted pressure and flow rate
setting will change.
4. Remove the socket bolts (30) (4 used), and then
remove the cover (43).
: 5 mm
5. After removing the cover (43) assembly, pull out

the springs (9), (10) and spring seat (8) from the
compensating part. Also, remove the adjusting
rod (13), spring (14) and spring seat (15) from the
pilot part.
NOTE: The adjusting rod (13) is easy to remove if
you use an M4 bolt.
W2-4-21
21
7
6 20
16 19
5 17
22
16
29
31
30
30
WRHAE0-02-04-004
W2-4-22
IMPORTANT: Do not remove the pin (16).
9. Remove the lever (17).
NOTE: Removal is easier if you use tweezers.
10. Remove the pin (19), and then remove the

feedback lever (20).
NOTE: Push out the pin (19) (pin diameter: Φ4)
from above using a thin steel bar, making
sure that it does not make contact with the
lever (21).
IMPORTANT: Do not remove the pin (16).

11. Remove the lever (21).
12. Remove the piston (29) and spool (22).
13. Remove the case (5), piston (6) and rod (7).
NOTE: Push out the rod (7) from the opposite side
of the case (5), and then remove the case
(5).

remove the cover (31).
: 5 mm
W2-4-23
Assemble Regulator
30 32 36 30 14 30
31
41
33 35 54 56 29 53 15 13 12 45
55 58
25 34 27 26 24 23 22 46 8 43 44
37 21 18 47 19 49 50
57 39
48 28
40
51 3
1 11
17
59
16 2 3
3 38
4 42
20
52
5 6 7 9 10
WRHAE0-02-04-005
1- Pin 16 - Pin (2 Used) 31 - Cover 46 - Casing

2- Sleeve 17 - Lever 32 - O-Ring 47 - Pin (2 Used)
3- O-Ring 18 - Pin 33 - O-Ring (3 Used) 48 - Plug
4- O-Ring 19 - Pin 34 - O-Ring 49 - O-Ring (2 Used)
5- Case 20 - Feedback Lever 35 - Plug (5 Used) 50 - Retaining Ring (2 Used)
6- Piston 21 - Lever 36 - Socket Bolt (2 Used) 51 - Plug
7- Rod 22 - Spool 37 - Socket Bolt (2 Used) 52 - Pin
8- Spring Seat 23 - Sleeve 38 - O-Ring 53 - O-Ring
9- Spring 24 - Retaining Ring 39 - Adjusting Screw 54 - O-Ring (9 Used)
10 - Spring 25 - Set Spring 40 - Nut 55 - O-Ring
11 - Adjusting Rod 26 - Return Spring 41 - Nut 56 - O-Ring
12 - O-Ring 27 - Spring Seat 42 - O-Ring 57 - Cover
13 - Adjusting Rod 28 - Retaining Ring 43 - Cover 58 - Socket Bolt (2 Used)
14 - Spring 29 - Piston 44 - Lock Nut 59 - O-Ring
15 - Spring Seat 30 - Socket Bolt (10 Used) 45 - Setscrew
W2-4-24
Assemble Regulator
1. Insert the rod (7) into the compensating hole on 5. Insert the piston (29) into the hole for negative
the casing (46). control on the casing (46).
NOTE: Make sure that the piston (29) moves
2. Insert the pin (16) that is press fitted to the lever smoothly without catching.
(21) into the groove on the rod (7), and install the
pin (47) that is press fitted to the casing (46) onto 6. Insert the pin (16) that is press fitted to the lever
the lever (21). (17) into the groove on the piston (29), and install
the lever (17).
IMPORTANT: Make sure that the spool (22) and
sleeve (23) can move smoothly in IMPORTANT: Make sure that the insertion holes of
the casing (46), without catching. the plugs (48), (51) are correct.
Make sure that the direction of the 7. Install the plug (48) so that the pin (47) that is
spool (22) is correct. press fitted to the plug (48) is inserted into the pin
hole on the lever (17), and then install the
retaining ring (50).
8. Install the plug (51), and then install the retaining

ring (50).
NOTE: At this time, move the feedback lever (20)
22 20
to make sure that the play is not too large
W25N-02-04-011
and that the lever does not catch.
3. Install the spool (22) and sleeve (23) into the 9. Insert the return spring (26) and spring seat (27)
spool hole on the casing (46). into the spool hole, and then install the retaining
ring (28).
IMPORTANT: Make sure that the direction of the
feedback lever (20) is correct.
Lever (17) Side

Lever (21) Side
(Plugs (48), (51) Side)
W25N-02-04-012
4. Install the feedback lever (20), and then install the

pin (19) by aligning it with the pin hole on the
feedback lever (20).
NOTE: If you first slightly insert the pin (19) into the
feedback lever (20), the pin can be
installed easily.
W2-4-25
30 30 14 30
31
41
15 13 45
58
25 8 43 44
57 39
40
11
5 6 9 10
WRHAE0-02-04-005
W2-4-26
10. Insert the set spring (25) into the spool hole, insert
the piston (6) and case (5) into the compensating
hole, install the cover (57), and then install the
socket bolts (58) (2 used), (30) (2 used).
: 5 mm
: 12 Nm (1.2 kgfm)
IMPORTANT: Make sure that the direction of the

spring seat (15) is correct.
11. Insert the spring seat (15), spring (14) and
adjusting rod (13) into the pilot hole, and then
insert the spring seat (8) and springs (10), (9) into
the compensating hole.
12. Install the cover on which the adjusting screw (39),

adjusting rod (11), lock nut (44), nuts (40), (41)
and setscrew (45) are assembled, and then install
the socket bolts (30) (4 used).
: 5 mm
: 12 Nm (1.2 kgfm)
13. Install the cover (31), and then install the socket
bolts (30) (4 used).
: 5 mm
: 12 Nm (1.2 kgfm)
W2-4-27
Remove and Install 2-Unit Gear Pump
CAUTION: If pressurized hydraulic oil

makes contact with the skin or eyes, it may
cause serious injury. Release the pressure
before removing the hydraulic lines.
Before draining the hydraulic oil, lower the
boom to the ground and apply all the brakes
and drum locks.
Preparations

2. Remove the drain plug (1) and drain the hydraulic

oil into a container (approx. 300 L). Install the
drain plug (1).
: 17 mm
Removal
1. Remove all hoses and pipes from the 2-unit gear

pump. Cap the removed hoses.
: 22 mm, 27 mm 1 WRHAE0-02-04-001
: 8 mm, 10 mm
2. Support the 2-unit gear pump.

Approx. 18.0 kg
3. Remove the 2-unit gear pump mounting bolts (2)

(4 used), and then remove the 2-unit gear pump.
: 19 mm
2
WRHAE0-02-04-002
W2-4-28
Installation
7. After releasing the pressure, tighten the air bleed

plug (3). Perform various operations at low idle
Approx. 18.0 kg speed, and check the hydraulic oil level and for oil
leaks.
1. Install the 2-unit gear pump onto the reduction : 36 mm
gear of the main pump. : 170 Nm (17.3 kgfm)
2. Apply LOCTITE onto the 2-unit gear pump
mounting bolts (2) (4 used), and then install the 3
bolts.
: 19 mm
: 30.3 to 38.3 Nm (3.1 to 3.9 kgfm)
3. Install all hoses and pipes onto the 2-unit gear

pump. At this time, fill the 2-unit gear pump with
hydraulic oil.
: 8 mm
: 57 Nm (5.8 kgf m)
: 10 mm
: 98 Nm (10.0 kgf m)
: 22 mm
: 36 Nm (3.7 kgfm)
: 27 mm
: 93 Nm (9.5 kgfm) 2
WRHAE0-02-04-002
4. Remove the filler port cover of the hydraulic oil

tank, and fill hydraulic oil to the appropriate level
on the level gauge.
5. Remove the air bleed plug (3) from the top of the
main pump, and fill the pump with hydraulic oil.
Install the air bleed plug (3), start the engine, and
run it at low idle speed.
: 36 mm
: 170 Nm (17.3 kgfm)
6. Loosen the air bleed plug (3) to release the

pressure from inside the pump.
: 36 mm
W2-4-29
Disassemble 2-Unit Gear Pump
1 2 3 25 4 5 6 7 8 9 10 11 12 13
24 23 22 21 20 19 18 17 16 15 14
WRHAE0-02-04-009
1- Retaining Ring 8- Adapter Plate 15 - Gasket (2 Used) 22 - O-Ring (2 Used)

2- Oil Seal 9- Bearing (2 Used) 16 - Side Plate (2 Used) 23 - Washer (16 Used)
3- Front Cover 10 - Body 17 - Driven Gear 24 - Socket Bolt (8 Used)
4- Bearing (2 Used) 11 - Drive Gear 18 - Socket Bolt (8 Used) 25 - O-Ring (5 Used)
5- Drive Gear 12 - Rear Cover 19 - Driven Gear
6- Body 13 - Bolt (4 Used) 20 - Socket Bolt (8 Used)
7- Side Plate (2 Used) 14 - Backup Strip (2 Used) 21 - Backup Strip (2 Used)
W2-4-30
Disassemble 2-Unit Gear Pump
• Thoroughly read “PRECAUTIONS FOR 10. Remove the socket bolts (18) (8 used).
DISASSEMBLING AND ASSEMBLING” (W1-1-1) : 8 mm
before disassembling.
11. Remove the adapter plate (8).
NOTE: Although the gaskets (15), (20) and side
plates (7), (16) are the same parts, their 12. Remove the O-ring (22).
assembly directions are different. If you
attach a tag to identify the location of use 13. Remove the backup strip (21), gasket (20),
on each block after disassembly, it will bearing (4) and side plate (7).
make reassembly easier.
The driven gears (17), (19) are symmetrical 14. Remove the socket bolts (24) (8 used).
from the front to rear. After disassembly, : 8 mm
attach a tag to the shafts to identify the
front and rear. 15. Remove the body (6).
1. Remove any dust or rust from the pump surface 16. Remove the drive gear (5) and driven gear (19).
using washing oil.
17. Remove the backup strip (21), gasket (20),
2. Position the rear cover (12) side upward, and fix bearing (4) and side plate (7).
the installation area of the front cover (3) in a vise.
18. Remove the O-ring (22), (25).
3. Put matching marks at the joining locations on the
drive side of the front cover (3), body (6), adapter 19. Remove the front cover (3) from the vise.
plate (8), body (10) and rear cover (12).
20. Remove the retaining ring (1).
4. Remove the bolts (13) (4 used).
21. Remove the oil seal (2).
5. Remove the rear cover (12).
6. Remove the gasket (15), backup strip (14),

2
bearing (9) and side plate (16).
7. Remove the drive gear (11) and driven gear (17).
8. Remove the body (10).
9. Remove the gasket (15), backup strip (14),

bearing (9) and side plate (16). 3
WRHAE0-02-04-006
W2-4-31
Assemble 2-Unit Gear Pump
1 2 3 25 4 5 6 7 8 9 10 11 12 13
24 23 22 21 20 19 18 17 16 15 14
WRHAE0-02-04-009
1- Retaining Ring 8- Adapter Plate 15 - Gasket (2 Used) 22 - O-Ring (2 Used)

2- Oil Seal 9- Bearing (2 Used) 16 - Side Plate (2 Used) 23 - Washer (16 Used)
3- Front Cover 10 - Body 17 - Driven Gear 24 - Socket Bolt (8 Used)
4- Bearing (2 Used) 11 - Drive Gear 18 - Socket Bolt (8 Used) 25 - O-Ring (5 Used)
5- Drive Gear 12 - Rear Cover 19 - Driven Gear
6- Body 13 - Bolt (4 Used) 20 - Gasket (2 Used)
7- Side Plate (2 Used) 14 - Backup Strip t (2 Used) 21 - Backup Strip (2 Used)
W2-4-32
Assemble 2-Unit Gear Pump
• Replace all oil seals and gaskets with new ones.

Before assembling, clean each part using clean
washing oil, and let them dry.
Apply clean hydraulic oil onto the inner parts
before assembly. In particular, be sure to apply
hydraulic oil onto sliding parts to prevent seizure.
NOTE: Fix the gasket (20), backup strips (14), (21),

side plates (7), (16) into the groove with
grease, installing them without any twisting
or catching.
When installing the front cover (3), body (6),
adapter plate (8), body (10) and rear cover
(12), align the matching marks at the
joining locations on the drive side of each
part that you marked during disassembly.
Install the driven gears (17), (19) according
to the direction of the tags that you
attached during disassembly to identify the
front and rear of the shafts.
1. Fix the front cover (3) in a vise with the body (6)
mounting surface facing upward.
2. Install the O-ring (22), (25) onto the front cover

(3).
3. Install the body (6) onto the front cover (3).
4. Install the socket bolts (24) (8 used).

: 8 mm
: 50 Nm (5.1 kgfm)
5. Install the bearing (4) onto the body (6).
6. Install the gasket (20), backup strip (21) and side

plate (7) onto the body (6).
W2-4-33
3 4 5 6 7 8 9 10 11 12 13
22 21 20 19 18 17 16 15 14
WRHAE0-02-04-009
W2-4-34
7. Install the drive gear (5) and driven gear (19) onto 22. Install the bolt (13) (4 used).
the body (6).
23. Turn over the assembled pump so that the oil seal
8. Install the gasket (20), backup strip (21) and side (2) mounting side faces upward, and fix it in the
plate (7) onto the body (6). vise.
9. Install the bearing (4) onto the body (6). 24. Fill grease between the main lip and dust lip of the
oil seal (2).
10. Install the O-ring (22) onto the adapter plate (8).
11. Install the adapter plate (8) onto the body (6).
12. Install the socket bolts (18) (8 used).

2
: 8 mm
: 50 Nm (5.1 kgfm) Dust Lip
13. Install the gasket (15) and backup strip (14) onto
Fill grease.
the adapter plate (8).
14. Install the body (10) onto the adapter plate (8). Main Lip
15. Install the bearing (9) onto the body (10). W25N-02-04-021
16. Install the side plate (16) onto the body (10).
17. Install the drive gear (11) and driven gear (17)
onto the body (10).
18. Install the side plate (16) onto the body (10).
19. Install the bearing (9) onto the body (10).
20. Install the gasket (15) and backup strip (14) onto
the rear cover (12).
21. Install the rear cover (12) onto the body (10).
W2-4-35
IMPORTANT: Do not damage the oil seal (2) during
installation.
25. Install the oil seal (2) onto the front cover (3) using Pipe
a guide and pipe.
Guide
WRHAE0-02-04-007
26. Install the retaining ring (1).
WRHAE0-02-04-008
W2-4-36
UPPER STRUCTURE / Control Valve
Remove and Install 4-Unit Control Valve
(for Front Winch, Rear Winch, Travel,
Boom Hoist)

spout and cause severe burns. Wait for the
oil to cool before starting any work.
Preparation

Removal
1. Remove all hoses and pipes from the control

valve (1).
: 19 mm, 22 mm
: 8 mm, 10 mm
NOTE: Cap the open ends of the removed hoses
and pipes, and then tag them to enable
identification during assembly.
2. Remove the control valve mounting bolts (2) (4

used).
: 19 mm
CAUTION: Control valve (1) weight:

Approx. 75 kg
3. Lift and remove the control valve (1) with the

crane. 1
WRHAE0-02-05-001
2
W2-5-1
Installation

Approx. 75 kg
1. Install the control valve (1) with the bolts (2) (4

used).
：19 mm
2. Install all hoses and pipes onto the control valve

(1).
：19 mm
：29.5 Nm (3.0 kgfm)
：22 mm
：39 Nm (4.0 kgfm)
：8 mm
：50 Nm (5.1 kgfm) 1
WRHAE0-02-05-001
：10 mm 2
：90 Nm (9.2 kgfm)
IMPORTANT: After completing the work, check the

hydraulic oil level and for any oil
leaks.
W2-5-2
(Blank)
W2-5-3
Disassemble 4-Unit Control Valve
38 42 21 29 41 40 45 30 43 38 44 39
C D
32
E
17 B
2
52
26
1 19
24
10 28
A
16 20
18 A 11
12
53
34
31
54
55 B 7
D E 25
3
C
4 36 46 21 6 23 37 33 22 37 5 35 27 28
C-C
47
51 57
51
50 58
7 50
12
13 49
8 56 48
14
A-A 15
9
B-B E-E D-D
WRHAE0-02-05-002
W2-5-4
1- Inlet Section 16 - O-Ring (5 Used) 31 - O-Ring (12 Used) 46 - Plug (4 Used)

2- Outlet Section 17 - O-Ring (10 Used) 32 - Socket Bolt (20 Used) 47 - Valve
3- Valve Section 18 - O-Ring (5 Used) 33 - Socket Bolt (12 Used) 48 - Poppet
4- Valve Section 19 - O-Ring 34 - Solenoid Valve (3 Used) 49 - Spring
5- Valve Section 20 - O-Ring (12 Used) 35 - Spool 50 - Cap (4 Used)
6- Valve Section 21 - End Cover (2 Used) 36 - Spool 51 - O-Ring (4 Used)
7- Plug (2 Used) 22 - End Cover (3 Used) 37 - Spool (2 Used) 52 - Relief Valve
8- Plug 23 - End Cover (3 Used) 38 - Spring (4 Used) 53 - Bolt (4 Used)
9- Plug 24 - Air Bleed Valve Seat (8 Used) 39 - Spring (2 Used) 54 - Nut (8 Used)
10 - Plug 25 - Plug (3 Used) 40 - Spring (2 Used) 55 - Spring Washer (8 Used)
11 - Plug (7 Used) 26 - Air Bleed Valve (8 Used) 41 - Spring (2 Used) 56 - Cover
12 - O-Ring (2 Used) 27 - Plug (12 Used) 42 - Spring Seat (2 Used) 57 - O-Ring
13 - O-Ring 28 - O-Ring (11 Used) 43 - Spring Seat (2 Used) 58 - Socket Bolt (4 Used)
14 - O-Ring 29 - O-Ring (2 Used) 44 - Spring Seat (2 Used)
W2-5-5
38 42 29 41 40 45 30 43 38 44 39
C D
32
E
B
26
24
28
A
34
31
B
D E 25
4
3
C
36 46 21 6 23 37 33 22 37 5 35 27 28
C-C
A-A
B-B E-E D-D
WRHAE0-02-05-002
W2-5-6
• Thoroughly read “PRECAUTIONS FOR 7. Remove the socket bolts (32), (33) (12 used), and
DISASSEMBLING AND ASSEMBLING” (W1-1-1) then remove the end covers (21) to (23) from the
before disassembling. valve sections (3) to (6).
: 5 mm
• This section describes the disassembly and
assembly of the 4-unit control valve for travel (left), 8. Remove the spring seats (43), (45) (2 used),
boom hoist, rear winch (low speed) and front springs (38), (40) (2 used), (41) (2 used) and
winch (high speed). Also refer to this section O-rings (30) (3 used), (31) (6 used) from the end
when disassembling and assembling other 4-unit covers (23) (3 used).
control valves, because their structures are
almost the same. 9. Remove the plugs (25) (3 used) and O-rings (28)
(3 used) from the end covers (23) (3 used).
: 6 mm
CAUTION: Control valve weight:
Approx. 75 kg 10. Remove the plugs (27) (12 used) from the end
covers (23) (3 used).
1. Place the control valve assembly on a clean : 4 mm
workbench.
IMPORTANT: Do not touch the adjusting screw of

the solenoid valve (34). CAUTION: Do not damage the holes on the
2. Remove the solenoid valves (34) (3 used) from spools and valve sections.
the end covers (23) (3 used).
: 32 mm 11. Remove the spools (35) to (37) (2 used) from
each valve section.
3. Remove the air bleed valves (26) (8 used), air NOTE: Do not remove the plugs (46) (4 used) from
bleed valve seats (24) (8 used) and O-rings (28) the spools (36), (37) (2 used) unless
(8 used) from the end covers (21) (2 used), (22) necessary.
(3 used), (23) (3 used). : 5 mm
: 17 mm, 19 mm

used), and then remove the end covers (21) (2
used) (22) (3 used) from each valve section.
: 5 mm
5. Remove the spring seats (42) (2 used), springs

(38) (2 used) and O-rings (29) (2 used) from the
end covers (21) (2 used).
6. Remove the spring seats (43), (44) (2 used),

springs (38), (39) (2 used) and O-rings (30) (3
used), (31) (6 used) from the end covers (22) (3
used).
W2-5-7
C D
E
17 B
2
52
1 19
10
A
16 20
18 A 11
12
53
54
55 B 7
D E
3
C
4 6 5
C-C
47
51 57
51
50 58
7 50
12
13 49
8 56 48
14
A-A 15
9
B-B E-E D-D
WRHAE0-02-05-002
W2-5-8
IMPORTANT: Do not disassemble the relief valve
(52).
12. Remove the relief valve (52) from the inlet section 24. Remove the O-rings (16), (17) (2 used) (18) from
(1), and then remove the O-ring. each section.
: 41 mm
25. Remove the O-rings (20) (12 used) from the valve
13. Remove the plugs (7), (8) and O-rings (12), (13) sections (3), (5) and the outlet section (2).
from the inlet section (1).
: 41 mm 26. Remove the socket bolts (58) (4 used), O-ring
: 6 mm (57) and cover (56) from the valve section (3).
: 10 mm
14. Remove the plugs (7), (10), (11) (7 used) and
O-rings (12), (19) from the outlet section (2).
15. Remove the valve (47) from the valve section (5),
and then remove the O-ring.
: 36 mm
16. Remove the plug (9) from the valve section (5).
: 36 mm
17. Remove the O-rings (14), (15) from the plug (9).
18. Turn over the control valve and remove the caps
(50) (4 used) from each valve section.
: 50 mm
19. Remove the poppet (48) and spring (49) from the
valve section (3).
20. Remove the O-rings (51) (4 used) from the caps

(50) (4 used).
21. Turn over the control valve.
22. Remove the nuts (54) (4 used) and spring

washers (55) (4 used), of the one side and then
remove the bolts (53) (4 used), nuts (54) (4 used),
spring washers (55) (4 used) from the other side.
: 24 mm
23. Divide each section into an inlet section (1), valve

sections (3) to (6) and outlet section (2).
W2-5-9
Assemble 4-Unit Control Valve
38 42 21 29 41 40 45 30 43 38 44 39
C D
32
E
17 B
2
52
26
1 19
24
10 28
A
16 20
18 A 11
12
53
34
31
54
55 B 7
D E 25
3
C
4 36 46 21 6 23 37 33 22 37 5 35 27 28
C-C
47
51 57
51
50 58
7 50
12
13 49
8 56 48
14
A-A 15
9
B-B E-E D-D
WRHAE0-02-05-002
W2-5-10
1- Inlet Section 16 - O-Ring (5 Used) 31 - O-Ring (12 Used) 46 - Plug (4 Used)

2- Outlet Section 17 - O-Ring (10 Used) 32 - Socket Bolt (20 Used) 47 - Valve
3- Valve Section 18 - O-Ring (5 Used) 33 - Socket Bolt (12 Used) 48 - Poppet
4- Valve Section 19 - O-Ring 34 - Solenoid Valve (3 Used) 49 - Spring
5- Valve Section 20 - O-Ring (12 Used) 35 - Spool 50 - Cap (4 Used)
6- Valve Section 21 - End Cover (2 Used) 36 - Spool 51 - O-Ring (4 Used)
7- Plug (2 Used) 22 - End Cover (3 Used) 37 - Spool (2 Used) 52 - Relief Valve
8- Plug 23 - End Cover (3 Used) 38 - Spring (4 Used) 53 - Bolt (4 Used)
9- Plug 24 - Air Bleed Valve Seat (8 Used) 39 - Spring (2 Used) 54 - Nut (8 Used)
10 - Plug 25 - Plug (3 Used) 40 - Spring (2 Used) 55 - Spring Washer (8 Used)
11 - Plug (7 Used) 26 - Air Bleed Valve (8 Used) 41 - Spring (2 Used) 56 - Cover
12 - O-Ring (2 Used) 27 - Plug (12 Used) 42 - Spring Seat (2 Used) 57 - O-Ring
13 - O-Ring 28 - O-Ring (11 Used) 43 - Spring Seat (2 Used) 58 - Socket Bolt (4 Used)
W2-5-11
38
38 42 21 29
C D
32
E
17 B
2
1 19
A 10
16 20
18 A 11
12
53
54
55 B 7
D E
3
C
4 36 21 6 37 5 35
C-C
57 51
58
7 50
12
13 49
8 56 48
14
A-A 15
9
B-B E-E D-D
WRHAE0-02-05-002
W2-5-12
1. Install the socket bolts (58) (4 used), O-ring (57) 10. Install the plug (9) onto the valve section (5).
and cover (56) onto the valve section (3). : 36 mm
: 10 mm : 100 to 120 Nm (10.0 to 12.0 kgfm)
: 85 to 115 Nm (8.7 to 11.7 kgfm)
11. Install the plugs (7), (10), (11) (7 used) and
2. Install the O-rings (16), (17) (2 used), (18) onto O-rings (12), (19) onto the outlet section (2).
each section.
12. Install the plugs (7), (8) and O-rings (12), (13) onto
3. Install the O-rings (20) (12 used) onto the valve the inlet section (1).
sections (3), (5) and the outlet section (2). : 41 mm
: 6 mm
4. Arrange each section in the order of inlet section
(1), valve sections (4), (6), (5), (3) and outlet
section (2). CAUTION: Do not damage the holes on the
spools and valve sections.
5. Insert the bolts (53) (4 used) into each section,
and install the spring washers (55) (8 used) with IMPORTANT: Make sure that the insertion
the nuts (54) (8 used). positions of the spools (35), (36),
: 24 mm (37) are correct.
: 100 to 120 Nm (10.0 to 12.0 kgfm) 13. Install the spool (37) onto the valve sections (5),
(6), install the spool (36) onto the valve section (4),
6. Turn over the control valve, and install the poppet and install the spool (35) onto the valve section
(48) and spring (49) onto the valve section (3). (3).
: 5 mm
7. Install the O-rings (51) (4 used) onto the caps (50)
(4 used), and then install the caps (50) onto the 14. Install the O-rings (29) (2 used), springs (38) (2
valve sections (3) to (6). used) and spring seats (42) (2 used) onto the end
: 50 mm covers (21) (2 used).
: 190 to 210 Nm (19.0 to 21.0 kgfm)
15. Install the end cover (21) assemblies (2 used)
8. Turn over the control valve. onto the valve section (4) with the socket bolts
(32) (8 used).
9. Install the O-rings (14), (15) onto the plug (9). : 5 mm
: 11 to 13 Nm (1.1 to 1.3 kgfm)
W2-5-13
21 41 40 45 30 43 38 44 39
C D
32
E
B
52
1 26
24
28
A
34
31
B
D E 25
3
C
21 6 23 33 22 5 27 28
C-C
47
A-A
B-B E-E D-D
WRHAE0-02-05-002
W2-5-14
16. Install the plugs (27) (12 used) onto the end 25. Install the assembled end cover (22) assemblies
covers (23) (3 used). (2 used) onto the valve section (3) with the socket
: 4 mm bolts (32) (8 used).
: 5 mm
17. Install the O-rings (28) (3 used) and plugs (25) (3 : 11 to 13 Nm (1.1 to 1.3 kgfm)
used) onto the end covers (23) (3 used).
: 6 mm 26. Install the O-ring onto the relief valve (52), and
then install the relief valve (52) onto the inlet
18. Install the O-rings (30) (2 used), (31) (4 used), section (1).
springs (40) (2 used), (41) (2 used), and spring : 41 mm
seats (45) (2 used), onto the end covers (23) (2 : 69 to 79 Nm (7.0 to 8.1 kgfm)
used).
27. Install the O-ring onto the valve (47), and then
19. Install the assembled end cover (23) assemblies install the valve (47) onto the valve section (5).
(2 used) onto the valve section (6) with the socket : 36 mm
bolts (33) (8 used). : 100 to 120 Nm (10.0 to 12.0 kgfm)
: 5 mm
: 15 to 17 Nm (1.5 to 1.7 kgfm) 28. Install the air bleed valves (26) (8 used), air bleed
valve seats (24) (8 used) and O-rings (28) (8
20. Install the O-rings (30), (31) (2 used), spring (38) used) onto the end covers (21) to (23).
and spring seat (43) onto the remaining end cover : 17 mm
(23). : 15 to 17 Nm (1.5 to 1.7 kgfm)
: 19 mm
21. Install the assembled end cover (23) assembly : 34 to 38 Nm (3.5 to 3.9 kgfm)
onto the valve section (5) with the socket bolts
(33) (4 used). 29. Install the solenoid valves (34) (3 used) onto the
: 5 mm end covers (23) (3 used).
: 15 to 17 Nm (1.5 to 1.7 kgfm) : 32 mm
: 39 to 49 Nm (4.0 to 5.0 kgfm)
22. Install the O-rings (30), (31) (2 used), spring (38)
and spring seat (43) onto the end cover (22).
23. Install the assembled end cover (22) assembly

(32) (4 used).
: 5 mm
: 11 to 13 Nm (1.1 to 1.3 kgfm)
24. Install the O-rings (30) (2 used), (31) (4 used),

springs (39) (2 used) and spring seats (44) (2
used) onto the remaining end covers (22) (2
used).
W2-5-15
(Blank)
W2-5-16
Remove and Install 3-Unit Control Valve
(for Front Winch, Rear Winch, Travel)

spout and cause severe burns. Wait for the
oil to cool before starting any work.
Removal

2. Remove all hoses and pipes from the control

valve (1).
: 22 mm
: 8 mm, 10 mm
NOTE: Cap the open ends of the removed hoses
and pipes, and then tag them to enable
identification during assembly.
3. Remove the control valve mounting bolts (2) (4

used).
: 19 mm
CAUTION: Control valve (1) weight: 1

Approx. 65 kg 2
WRHAE0-02-05-004
4. Lift and remove the control valve (1) with the

crane.
W2-5-17
Installation

Approx. 65 kg
1. Install the control valve (1) with the bolts (2) (4

used).
: 19 mm
2. Install all hoses and pipes onto the control

valve (1).
: 22 mm
: 8 mm, 10 mm
IMPORTANT: After completing the work, check the 1

hydraulic oil level and for any oil 2
WRHAE0-02-05-004
leaks.
W2-5-18
(Blank)
W2-5-19
39 19 28 38 20 41 29 21
37 25 23 27
40
31
C D 37
B 2
48
47 46 43
15
1
14 17
8
16 54
A 53
18
A 52
51 9 12
49 13
50
10
7
30
5 33
4 B
C 24
B-B
D
34 42 19 4 35 32 22 36 3 26 27
D-D
47
46
5
10
11 45
44
6 A-A
C-C
WRHAE0-02-05-003
W2-5-20
1- Inlet Section 15 - O-Ring (8 Used) 29 - O-Ring (4 Used) 43 - Valve

2- Outlet Section 16 - O-Ring (4 Used) 30 - O-Ring (4 Used) 44 - Poppet
3- Valve Section 17 - O-Ring 31 - Socket Bolt (20 Used) 45 - Spring
4- Valve Section 18 - O-Ring (4 Used) 32 - Socket Bolt (4 Used) 46 - Cap (3 Used)
5- Plug (2 Used) 19 - End Cover (2 Used) 33 - Solenoid Valve 47 - O-Ring (3 Used)
6- Plug 20 - End Cover (2 Used) 34 - Spool 48 - Relief Valve
7- Plug 21 - End Cover 35 - Spool 49 - Bolt (4 Used)
8- Plug 22 - End Cover 36 - Spool 50 - Nut (8 Used)
9- Plug (7 Used) 23 - Air Bleed Valve Seat (6 Used) 37 - Spring (4 Used) 51 - Spring Washer (8 Used)
10 - O-Ring (2 Used) 24 - Plug 38 - Spring (2 Used) 52 - Cover
11 - O-Ring 25 - Air Bleed Valve (6 Used) 39 - Spring Seat (2 Used) 53 - O-Ring
12 - O-Ring 26 - Plug (4 Used) 40 - Spring Seat (2 Used) 54 - Socket Bolt (4 Used)
14 - O-Ring (4 Used) 28 - O-Ring (2 Used) 42 - Plug (2 Used)
W2-5-21
39 19 28 38 20 41 29 21
37 25 23 27
40
31
C D 37
B
48
A
A
30
33
4 B
C 24
B-B
D
34 42 19 4 35 32 22 36 3 26 27
D-D
A-A
C-C
WRHAE0-02-05-003
W2-5-22
• Thoroughly read “PRECAUTIONS FOR 8. Remove the spring seat (40), spring (37) and
DISASSEMBLING AND ASSEMBLING” (W1-1-1) O-ring (29) from the end cover (22).
before disassembling.
9. Remove the plug (24) and O-ring (27) from the
• This section describes the disassembly and end cover (22).
assembly of the 3-unit control valve for travel (left), : 6 mm
rear winch (high speed) and front winch (low
speed). Also refer to this section when 10. Remove the plugs (26) (4 used) from the end
disassembling and assembling other 3-unit cover (22).
control valves, because their structures are : 4 mm
almost the same.
CAUTION: Do not damage the holes on the
CAUTION: Control valve weight: spools and valve sections.
Approx. 65 kg
11. Remove the spools (34) to (36), from each valve
1. Place the control valve assembly on a clean section.
workbench. NOTE: Do not remove the plug (42) from the spool
(34) unless necessary.
IMPORTANT: Do not touch the adjusting screw of
the solenoid valve (33). IMPORTANT: Do not disassemble the relief valve
2. Remove the solenoid valve (33) from the end (48).
cover (22). 12. Remove the relief valve (48) from the inlet section
: 32 mm (1), and then remove the O-rings (2 used).
: 41 mm
3. Remove the air bleed valves (25) (6 used), air
bleed valve seats (23) (6 used) and O-rings (27)
(6 used) from the end covers (19) (2 used), (20)
(2used), (21), (22).
: 17 mm, 19 mm

used), and then remove the end covers (19) (2
used), (20) (2 used), (21), (22) from each valve
section.
: 5 mm
5. Remove the spring seats (39) (2 used), springs

6. Remove the spring seat (41) (2 used), springs

7. Remove the spring seat (40), spring (37) and

O-rings (29) (2 used) from the end cover (21).
W2-5-23
C D
B 2
47 46 43
15
1
14 17
8
16 54
A 53
18
A 52
51 9 12
49 13
50 10
7
5
4 B
C
B-B
D
4 3
D-D
47
46
5
10
11 45
44
6 A-A
C-C
WRHAE0-02-05-003
W2-5-24
13. Remove the plugs (5), (6) and O-rings (10), (11) 23. Divide each section into an inlet section (1), valve
from the inlet section (1). sections (3), (4) (2 used) and outlet section (2).
: 41 mm
: 6 mm 24. Remove the O-rings (14), (15) (2 used), (16) from
each section.
14. Remove the plugs (5), (8), (9) (7 used) and
O-rings (10), (17) from the outlet section (2). 25. Remove the O-rings (18) (4 used) from the valve
sections (3), (4) and the outlet section (2).
15. Remove the valve (43) from the valve section (3),
and then remove the O-ring. 26. Remove the socket bolts (54) (4 used), O-ring
: 36 mm (53) and cover (52) from the valve section (3).
: 10 mm
16. Remove the plug (7) from the valve section (3).
: 36 mm
17. Remove the O-rings (12), (13) from the plug (7).
18. Turn over the control valve and remove the caps
(46) (3 used) from each valve section.
: 50 mm
19. Remove the poppet (44) and spring (45) from the
valve section (4).
20. Remove the O-rings (47) (3 used) from the caps

(46) (3 used).
21. Turn over the control valve.
22. Remove the nuts (50) (4 used) and spring

washers (51) (4 used) from one side, and then
remove the bolts (49) (4 used), nuts (50) (4 used)
and spring washers (51) (4 used) from the
opposite side.
: 24 mm
W2-5-25
37 25 23 27
40
31
C D 37
B 2
48
47 46 43
15
1
14 17
8
16 54
A 53
18
A 52
51 9 12
49 13
50 10
7
30
5 33
4 B
C 24
B-B
D
34 42 19 4 35 32 22 36 3 26 27
D-D
47
46
5
10
11 45
44
6 A-A
C-C
WRHAE0-02-05-003
W2-5-26
1- Inlet Section 15 - O-Ring (8 Used) 29 - O-Ring (4 Used) 43 - Valve

2- Outlet Section 16 - O-Ring (4 Used) 30 - O-Ring (4 Used) 44 - Poppet
3- Valve Section 17 - O-Ring 31 - Socket Bolt (20 Used) 45 - Spring
4- Valve Section 18 - O-Ring (4 Used) 32 - Socket Bolt (4 Used) 46 - Cap (3 Used)
5- Plug (2 Used) 19 - End Cover (2 Used) 33 - Solenoid Valve 47 - O-Ring (3 Used)
6- Plug 20 - End Cover (2 Used) 34 - Spool 48 - Relief Valve
7- Plug 21 - End Cove 35 - Spool 49 - Bolt (4 Used)
8- Plug 22 - End Cover 36 - Spool 50 - Nut (8 Used)
9- Plug (7 Used) 23 - Air Bleed Valve Seat (6 Used) 37 - Spring (4 Used) 51 - Spring Washer (8 Used)
10 - O-Ring (2 Used) 24 - Plug 38 - Spring (2 Used) 52 - Cover
11 - O-Ring 25 - Air Bleed Valve (6 Used) 39 - Spring Seat (2 Used) 53 - O-Ring
12 - O-Ring 26 - Plug (4 Used) 40 - Spring Seat (2 Used) 54 - Socket Bolt (4 Used)
14 - O-Ring (4 Used) 28 - O-Ring (2 Used) 42 - Plug (2 Used)
W2-5-27
39 19 28
37
31
C D
B 2
15
1
14 17
8
16 54
A
18 53
A 52
51 9 12
49 13
50
10
7
5
4 B
C
B-B
D
34 19 4 35 22 36 3
D-D
47
46
5
10
11 45
44
6 A-A
C-C
WRHAE0-02-05-003
W2-5-28
1. Install the socket bolts (54) (4 used), O-ring (53) 10. Install the plug (7) onto the valve section (3).
and cover (52) onto the valve section (3). : 36 mm
: 10 mm : 100 to 120 Nm (10.0 to 12.0 kgfm)
: 85 to 115 Nm (87 to 11.7 kgfm)
11. Install the plugs (5), (8), (9) (7 used) and O-rings
2. Install the O-rings (14), (15) (2 used) (16) onto (10), (17) onto the outlet section (2).
each section.
12. Install the plugs (5), (6) and O-rings (10), (11) onto
3. Install the O-rings (18) (4 used) onto the valve the inlet section (1).
sections (3), (4) and the outlet section (2). : 41 mm
: 6 mm
4. Arrange each section in the order of inlet section
(1), valve sections (4) (2 used), (3), and outlet CAUTION: Do not damage the holes on the
section (2). spools and valve sections.
5. Insert the bolts (49) (4 used) into each section, IMPORTANT: Make sure that the insertion
and install the spring washers (51) (8 used) with positions of the spools (34) to (36)
the nuts (50) (8 used). are correct.
: 24 mm 13. Install the spools (34), (35) onto the valve sections
: 100 to 120 Nm (10.0 to 12.0 kgfm) (4) (2 used), and install the spool (36) onto the
valve section (3).
6. Turn over the control valve, and install the poppet
(44) and spring (45) onto the valve section (4). 14. Install the O-rings (28) (2 used), springs (37) (2
used) and spring seats (39) (2 used) onto the end
7. Install the O-rings (47) (3 used) onto the caps (46) covers (19) (2 used).
(3 used), and then install the caps (46) (3 used)
onto the valve sections (3), (4) (2 used). 15. Install the end cover (19) assemblies (2 used)
: 50 mm
(31) (8 used).
: 190 to 210 Nm (19.0 to 21.0 kgfm)
: 5 mm
8. Turn over the control valve. : 11 to 13 Nm (1.1 to 1.3 kgfm)
9. Install the O-rings (12), (13) onto the plug (7).
W2-5-29
19 38 20 41 29 21
25 23 27
40
31
C D 37
B 5
48
43
1
A
A
33
4 B
C 24
B-B
D
19 4 32 22 3 26 27
D-D
A-A
C-C
WRHAE0-02-05-003
W2-5-30
16. Install the O-rings (29) (2 used), springs (38) (2 25. Install the O-ring onto the valve (43), and then
used) and spring seats (41) (2 used) onto the end install the valve (43) onto the valve section (3).
covers (20) (2used). : 36 mm
: 100 to 120 Nm (10.0 to 12.0 kgfm)
onto the valve section (4) with the socket bolts 26. Install the air bleed valves (25) (6 used), air bleed
(31) (8 used). valve seats (23) (6 used) and O-rings (27) (6
: 5 mm used) onto the end covers (19) to (22).
: 15 to 17 Nm (1.5 to 1.7 kgfm) : 17 mm
: 15 to 17 Nm (1.5 to 1.7 kgfm)
18. Install the O-ring (29), spring (37) and spring seat : 19 mm
(40) onto the end cover (21). : 34 to 38 Nm (3.5 to 3.9 kgfm)
19. Install the assembled end cover (21) assembly 27. Install the solenoid valve (33) onto the end cover
onto the valve section (3) with the socket bolts (22).
(31) (4 used). : 32 mm
: 5 mm : 39 to 49 Nm (4.0 to 5.0 kgfm)
: 15 to 17 Nm (1.5 to 1.7 kgfm)
20. Install the plugs (26) (4 used) onto the end cover
(22).
: 4 mm
21. Install the O-ring (27) and plugs (24) (3 used) onto
the end cover (22).
: 6 mm
22. Install the O-ring (29), spring (37) and spring seat
(40) onto the end cover (22).

(32) (4 used).
: 5 mm
: 11 to 13 Nm (1.1 to 1.3 kgfm)
24. Install the O-ring onto the relief valve (48), and
then install the relief valve (48) onto the inlet
section (1).
: 41 mm
: 69 to 79 Nm (7.0 to 8.1 kgfm)
W2-5-31
(Blank)
W2-5-32
UPPER STRUCTURE / Swing Device
Remove and Install Swing Device

Preparation

Removal
1. Remove the hoses (1) to (7) from the swing 2 3

device. Cap the removed hose.
：22 mm, 32 mm, 36 mm, 41 mm
2. Remove the bolts (8) (18 used).

1
：24 mm
CAUTION: Swing device weight:

Approx. 355 kg 4
3. Lift and remove the swing device with the crane. 5
7 6
WRHAE0-02-06-001
W2-6-1
Installation
CAUTION: Swing device weight:

Approx. 355 kg
2 3
1. Lift the swing device with the crane and install it
onto the swing frame.
2. Install the bolts (8) (18 used).

1
：24 mm
：210 Nm (21.5 kgf･m)
3. Install the hoses (1) to (7) onto the swing device.

：22 mm 4
：39 Nm (4.0 kgf･m)
：32 mm 5
：137 Nm (14.0 kgf･m)
：36 mm 8
：175 Nm (18.0 kgf･m)
：41 mm
：205 Nm (21.0 kgf･m)
7 6
WRHAE0-02-06-001
W2-6-2
(Blank)
W2-6-3
Disassemble Swing Device
39 40 27 7
41
42
8 9 10 11 12 13 14 15 16 17 18 19
7
6
View A
5 A
3
2
20
21
22
23
24
25
26
38 37 36 35 34 33 32 31 30 29 28 27
44 43 WRHAE0-02-06-003
W2-6-4
1. Shaft 12 - Socket Bolt (2 Used) 23 - Bearing 34 - Bearing

2. Seal Ring 13 - Bearing (2 Used) 24 - Cover 35 - Spacer
3. O-Ring 14 - Pinion 25 - Retaining Ring 36 - Bearing
4. Casing 15 - Pin 26 - O-Ring 37 - Shim
5. Pin (3 Used) 16 - Stop Ring (2 Used) 27 - Socket Bolt (4 Used) 38 - Oil Seal
6. Thrust Washer (6 Used) 17 - O-Ring 28 - Casing 39 - Plug
7. Plug (2 Used) 18 - Bolt (4 Used) 29 - Carrier 40 - Socket Bolt (14 Used)
8. Planetary Gear (3 Used) 19 - Motor 30 - Casing 41 - Plate
9. Needle Cage (6 Used) 20 - Level Gauge 31 - Bearing 42 - Pin (2 Used)
10. Set Bolt (3 Used) 21 - Pipe 32 - Sun Gear 43 - Knock Pin (2 Used)
11. Washer (3 Used) 22 - Shim 33 - Ring Gear 44 - Bolt (6 Used)
W2-6-5
40 27 7
12 13 14 15 16 17 18 19
7
View A
A
20
21
22
23
24
25
26
33 32 31 30 29 28 27
44 WRHAE0-02-06-003
W2-6-6
Disassemble Swing Device
• Thoroughly read "PRECAUTIONS FOR 9. Remove the bearing (13) from the casing (28).
DISASSEMBLING AND ASSEMBLING" (W1-1-1)
before disassembling. 10. Remove the bearing (23) and shim (22) from the
casing (28).
CAUTION: Swing device assembly weight: 11. Remove the pin (15) from the casing (30).
Approx. 300 kg
12. Remove the stop ring (16) from the sun gear (32).
1. Remove the plugs (7) (2 used) and drain the gear
oil. Amount of gear oil: Approx. 8 L 13. Remove the carrier (29) assembly from the casing
：10 mm (30).
NOTE: Drain the gear oil into a clean container and NOTE: Install the eyebolts (M10) onto the thread
check it for foreign matter such as worn areas (2 places) on the carrier (29), and
particles. then slowly lift and remove the carrier (29)
by hand or with the crane.
2. Put matching mark onto the casings (4), (28), (30),
ring gear (33) and motor (19). 14. Remove the pinion (14) from the casing (30).
3. Remove the bolts (18) (4 used) from the motor 15. Remove the bearing (13) from the casing (30).
(19).
：24 mm 16. Remove the sun gear (32) from the shaft (1).
CAUTION: Motor weight: Approx. 56 kg 17. Remove the stop ring (16) from the sun gear (32).
4. Remove the motor (19) from the swing device. 18. Remove the socket bolts (12) (2 used) and bolts
(44) (6 used) from the casing (30), and then
NOTE: Lift the motor (19) slightly with the crane,
remove the casing (30).
and tap the swing device lightly with a
：24 mm
plastic hammer to remove the motor (19).
：14 mm
5. Remove the level gauge (20) from the pipe (21),
19. Remove the bearing (31) from the shaft (1).
and then remove the pipe (21) from the casing
(28).
6. Remove the O-ring (17) from the casing (28).

used) from the casing (28), and then remove the
casing (28).
：10 mm
8. Remove the retaining ring (25), cover (24) and

O-ring (26) from the casing (28).
W2-6-7
8 9 10 11
6
View A
5 A
3
2
38 37 36 35 34 33
43 WRHAE0-02-06-003
W2-6-8
20. Remove the shaft (1) assembly from the casing
(4).
21. Remove the ring gear (33) from the casing (4).
22. Remove the knock pins (43) (2 used) from the

casing (4).
23. Remove the set bolts (10) (3 used) and washers

(11) (3 used) from the shaft (1).
：17 mm
24. Remove the pins (5) (3 used) from the planetary

gears (8) (3 used).
25. Remove the planetary gears (8) (3 used), thrust

washers (6) (6 used) and needle cages (9) (6
used) from the shaft (1).
26. Remove the bearing (34) and spacer (35) from the
shaft (1).
27. Remove the seal ring (2) from the casing (4).
28. Remove the O-ring (3) from the seal ring (2).
29. Remove the bearing (36) and shim (37) from the
casing (4).
30. Remove the oil seal (38) from the casing (4).
W2-6-9
Assemble Swing Device
39 40 27 7
41
42
8 9 10 11 12 13 14 15 16 17 18 19
7
6
View A
5 A
3
2
20
21
22
23
24
25
26
38 37 36 35 34 33 32 31 30 29 28 27
44 43 WRHAE0-02-06-003
W2-6-10
1- Shaft 12 - Socket Bolt (2 Used) 23 - Bearing 34 - Bearing

2- Seal Ring 13 - Bearing (2 Used) 24 - Cover 35 - Spacer
3- O-Ring 14 - Pinion 25 - Retaining Ring 36 - Bearing
4- Casing 15 - Pin 26 - O-Ring 37 - Shim
5- Pin (3 Used) 16 - Stop Ring (2 Used) 27 - Socket Bolt (4 Used) 38 - Oil Seal
6- Thrust Washer (6 Used) 17 - O-Ring 28 - Casing 39 - Plug
7- Plug (2 Used) 18 - Bolt (4 Used) 29 - Carrier 40 - Socket Bolt (14 Used)
8- Planetary Gear (3 Used) 19 - Motor 30 - Casing 41 - Plate
9- Needle Cage (6 Used) 20 - Level Gauge 31 - Bearing 42 - Pin (2 Used)
10 - Set Bolt (3 Used) 21 - Pipe 32 - Sun Gear 43 - Knock Pin (2 Used)
11 - Washer (3 Used) 22 - Shim 33 - Ring Gear 44 - Bolt (6 Used)
W2-6-11
8 9 10 11 12
6
View A
5 A
38 37 36 35 34 33 31 30
44 43 WRHAE0-02-06-003
W2-6-12
Assemble Swing Device
1. Install the oil seal (38) onto the casing (4).
2. Install the shim (37) and bearing (36) onto the

casing (4).
3. Install the spacer (35) and bearing (34) onto the

shaft (1).
4. Install the thrust washers (6) (6 used), needle

cages (9) (6 used) and planetary gears (8) (3
used) onto the shaft (1) with the pins (5) (3 used),
and then install the washers (11) (3 used) and set
bolts (10) (3 used).
：17 mm
：50 Nm (5.1 kgfm)
5. Install the knock pins (43) (2 used) onto the

casing (4).
6. Install the ring gear (33) onto the casing (4).

NOTE: • Install by aligning the matching marks on
the casing (4) and ring gear (33)
• Apply Three Bond #1217 onto the mating
surfaces of the casing (4) and ring gear
(33)
7. Install the shaft (1) assembly onto the casing (4).
8. Install the bearing (31) onto the shaft (1).
9. Install the casing (30) onto the ring gear (33) with
the socket bolts (12) (2 used) and bolts (44) (6
used).
：24 mm
：235 Nm (24.0 kgf･m)
：14 mm
：235 Nm (24.0 kgfm)
NOTE: • Align the matching marks of the ring gear
(33) and casing (30).
• Apply Three Bond #1217 onto the mating
surfaces of the ring gear (33) and casing
(30)
W2-6-13
40
13 14 15 16 17 18 19
7
View A
A
3
2
20
21
22
23
24
25
26
32 30 29 28 27
WRHAE0-02-06-003
W2-6-14
10. Install the bearing (13) onto the casing (30). 21. Install the O-ring (17) onto the casing (28).
11. Install the sun gear (32) onto the shaft (1).
CAUTION: Motor weight: Approx. 56 kg
12. Install the stop ring (16) onto the sun gear (32).
22. Lift the motor (19) vertically and install it onto the
13. Install the carrier (29) onto the sun gear (32). pinion (14) of the swing device with the bolts (18)
(4 used).
14. Install the stop ring (16) onto the sun gear (32). ：24 mm
：235 Nm (24.0 kgfm)
15. Install the pinion (14) onto the casing (30). NOTE: Install by aligning the matching marks on
the casing (28) and motor (19).
16. Install the pin (15) onto the casing (30).
23. Install the O-ring (3) onto the seal ring (2).
17. Install the O-ring (26), cover (24) and retaining
ring (25) onto the casing (28). 24. Install the seal ring (2) onto the casing (4).
18. Install the shim (22) and bearing (23) onto the 25. Install the plugs (7) (2 used) onto the casing (4).
casing (28). ：10 mm
：65 Nm (6.6 kgfm)
19. Install the bearing (13) onto the casing (28). NOTE: Wind the seal tape around the plugs (7).
20. Install the casing (28) onto the casing (30) with 26. Add gear oil from the filler port.
the socket bolts (27) (4 used), (40) (14 used). Amount of gear oil: Approx. 8.0 L
：10 mm NOTE: • Temporarily mount the pipe (21) and level
：98 Nm (10.0 kgfm) gauge (20) and check the gear oil level.
NOTE: • Install by aligning the matching marks on • After installing the swing device onto the
the casing (30) and casing (28) machine, mount the pipe (21) and level
• Apply Three Bond #1217 onto the mating gauge (20). At this time, completely
surfaces of the casing (30) and casing remove the seal tape from the thread
(28). areas and clean off the grease, and then
apply new seal tape before mounting.
W2-6-15
Disassemble Swing Motor
11
15
10
26 25 1 2 3 4 5 6 7 8 9 10
B Cross Section 30
29 11 B-B
28
27
12
26 13
25
14
24 15
23
22
21
B
5
20 19 18 17 16
Brake Spring Cross

Section
WRHAE0-02-06-002
1- Shoe Plate 9- Valve Plate 17 - Friction Plate (3 Used) 25 - Snap Ring (2 Used)
2- Shoe (9 Used) 10 - Bearing 18 - Cylinder 26 - Spacer (2 Used)
3- Piston (9 Used) 11 - Valve Casing 19 - Spring 27 - Front Cover
4- O-Ring 12 - Pin (2 Used) 20 - Retainer 28 - O-Ring
5- Brake Piston 13 - Nameplate 21 - Casing 29 - Bearing
6- O-Ring 14 - Snap Ring 22 - Snap Ring 30 - Socket Bolt (4 Used)
7- Spring (12 Used) 15 - Pin (2 Used) 23 - Oil Seal
8- O-Ring 16 - Separator Plate (4 Used) 24 - Shaft
W2-6-16
Disassemble Swing Motor
• Thoroughly read “PRECAUTIONS FOR 7. Remove the brake piston (5) from the casing (21).
DISASSEMBLING AND ASSEMBLING” (W1-1-1) NOTE: Fit the cylinder ends of the special tool into
before disassembling. the groove on the brake piston (5) and pull
it up straight.
CAUTION: Swing motor weight:
Approx. 56 kg ・Special Tool
Special Tool
1. Put matching marks onto the valve casing (11)
and casing (21).
5
2. Drain the gear oil from the valve casing (11).
3. Fix the shaft (24) with its end facing downward in 21

a workbench that will facilitate disassembly.
NOTE: Place a rubber plate or cloth or the like on
the disassembly workbench to prevent
damage to the parts.
IMPORTANT: Work carefully, making sure that the

valve plate (9) does not fall from the
valve casing (11). (The valve plate (9)
may be installed to the cylinder (18) W25N-02-06-009
side.)
Do not damage the mating surfaces
when prying the valve casing (11)
from the casing (21) with a
screwdriver or other tool.
remove the valve casing (11) from the casing (21).
：17 mm
NOTE: When the socket bolts (30) are loosened,
the valve casing (11) rises because of the
spring (7).
5. Remove the O-ring (8), valve plate (9) and pins

(15) (2 used) from the valve casing (11).
6. Remove the springs (7) (12 used) from the brake

piston (5).
W2-6-17
26 25 2 3 4 6 10
B Cross Section
B-B
29
28
27
26
25
14
24
23
22
21
20 19 18 17 16
Brake Spring Cross

Section
WRHAE0-02-06-002
W2-6-18
8. Remove the O-rings (6), (4) from the casing (21). • If necessary, perform the following work. Do not
reuse the removed bearings (10), (29).
9. Reposition the motor horizontally.
18. Remove the shaft (24) from the casing (21).
10. Remove the snap ring (14) from the shaft (24). NOTE: Remove the shaft (24) by tapping it with a
plastic hammer.
11. Remove the bearing (10) from the shaft (24).
19. Remove the snap rings (25) (2 used) from the
IMPORTANT: Do not damage sliding surfaces, shaft (24).
such as those of the cylinder (18) or
shoe (2). 20. Remove the spacers (26) (2 used) from the shaft
12. Remove the cylinder (18), pistons (3) (9 used), (24).
spring (19), retainer (20) and shoes (2) (9 used)
from the shaft (24). 21. Remove the bearing (29) from the shaft (24).
13. Remove the separator plates (16) (4 used) and

friction plates (17) (3 used) from the casing (21).
14. Remove the snap ring (22) from the casing (21).
15. Remove the front cover (27) and oil seal (23) from
the casing (21).
NOTE: Because the oil seal (23) may be damaged
by the splines when removing the front
cover (27), wind vinyl tape or the like onto
the spline area of the shaft (24) assembly.
16. Remove the oil seal (23) from the front cover (27).
17. Remove the O-ring (28) from the casing (21).
W2-6-19
Assemble Swing Motor
11
15
10
26 25 1 2 3 4 5 6 7 8 9 10
B Cross Section 30
11 B-B
29
28
27
12
26 13
25
14
24 15
23
22
21
B
5
20 19 18 17 16
Brake Spring Cross

Section
WRHAE0-02-06-002
1- Shoe Plate 9- Valve Plate 17 - Friction Plate (3 Used) 25 - Snap Ring (2 Used)
2- Shoe (9 Used) 10 - Bearing 18 - Cylinder 26 - Spacer (2 Used)
3- Piston (9 Used) 11 - Valve Casing 19 - Spring 27 - Front Cover
4- O-Ring 12 - Pin (2 Used) 20 - Retainer 28 - O-Ring
5- Brake Piston 13 - Nameplate 21 - Casing 29 - Bearing
6- O-Ring 14 - Snap Ring 22 - Snap Ring 30 - Socket Bolt (4 Used)
7- Spring (12 Used) 15 - Pin (2 Used) 23 - Oil Seal
8- O-Ring 16 - Separator Plate (4 Used) 24 - Shaft
W2-6-20
Assemble Swing Motor
1. Place the casing (21) on a suitable workbench 11. Install the snap ring (22) onto the casing (21).
with the valve casing (11) side facing downward.
12. Reposition the casing (21) horizontally.
2. Install the snap ring (25) onto the shaft (24).
13. Install the shoe plate (1) onto the casing (21).
3. Install the spacer (26) onto the shaft (24). NOTE: Position the larger-chamfered side of shoe
plate (1) facing the inside of the casing (21).
IMPORTANT: Make sure that the direction of the Apply a thin film of grease onto the mating
flange on the inner ring of the surface to prevent disengagement.
bearing (26) is correct.
4. Install the bearing (29) onto the shaft (24). 14. Set the retainer (20) and spring (19), and then set
NOTE: Shrink-fit the inner ring. the pistons (3) (9 used) with the attached shoe
(2).
5. Install the spacer (26) onto the shaft (24).
15. Install the piston (3) with the attached shoe (2)
6. Install the snap ring (25) onto the shaft (24). that was set on the retainer (20) onto the cylinder
(18).
IMPORTANT: Make sure that the installation
direction of the oil seal (23) is 16. Install the cylinder (18) assembly onto the shaft
correct, and be sure to tap it evenly (24) by aligning the splines of the cylinder (18)
and not damage its outer surface. and shaft (24).
7. Install the oil seal (23) onto the front cover (27).
NOTE: Apply a thin film of grease onto the lip area 17. Reposition the casing (21) with the front cover
of the oil seal (23). (27) side facing downward.
Use the special tool.
18. Install the separator plates (16) and friction plates
8. Install the shaft (23) assembly onto the casing (17) onto the casing (21) in this order and
(21). alternately.
NOTE: Install 4 separator plates (16) and 3 friction
9. Install the O-ring (28) onto the casing (21). plates (17).
NOTE: Apply a thin film of grease onto the O-ring
(28). 19. Install the O-rings (4), (6) onto the casing (21).
NOTE: Apply a thin film of grease onto the O-rings
IMPORTANT: To prevent damage to the lip of the (4), (6).
oil seal (23), protect the spline area
of the shaft (24) assembly by 20. Install the brake piston (5) onto the casing (21).
winding vinyl tape or the like around
it.
10. Install the front cover (27) onto the casing (21).
W2-6-21
5 7 8 9 10
B Cross Section 30
11 B-B
21
Brake Spring Cross

Section
WRHAE0-02-06-002
W2-6-22
21. Install the spring (7) onto the brake piston (5).
22. Lightly tap the outer ring of the bearing (10) with a
steel bar and hammer to install it onto the valve
casing (11).
NOTE: Evenly tap around the outer ring of the
bearing (10) until the outer ring stops at the
step part in the valve casing (11).
23. Apply grease onto the valve casing (11) mounting

surface of the valve plate (9), and then install it
onto the valve casing (11).
IMPORTANT: Make sure that the installation

direction of the valve casing (11) is
correct.
Do not let the valve plate (9)
disengage.
Do not let the spring (7) fall off.
24. Install the O-ring (8) onto the valve casing (11),
install the valve casing (11) onto the casing (21),
and then install the socket bolts (30) (4 used).
：17 mm
：430 Nm (44.0 kgfm)
W2-6-23
Maintenance Standards
Swing Device
• Replacement Standard for Gears
Replace the gear when pitting of 1 mm or more per pit

or 5% or more of the area occurs in the teeth of the
sun gear (32), planetary gear (8) or ring gear (33).
Also replace if significant damage is visible on the
exterior, even if there is no pitting.
Swing Motor
1. Clearance between piston outer diameter and

cylinder inner bore
D-d Unit: mm
d D
0.028 0.058
W25N-02-04-005
2. Clearance between piston and shoe caulking part

δ Unit: mm
0 0.3
δ
3. Shoe thickness
t Unit: mm
t
5.5 5.3 W25N-02-04-006
4. Friction plate thickness

t Unit: mm
Standard Allowable Limit t
4.0 3.6
W107-02-06-143
W2-6-24
UPPER STRUCTURE / Winch
Remove and Install Winch

Preparation

Removal

the wire ropes from the front and rear drums.
Remove the pendant rope, boom insert and boom
top. (For details on removing the pendant rope,
boom insert and boom top, refer to the Operator's
Manual.)
WRHAE0-02-07-001
2. Remove the counterweights. (For details on

removing the counterweights, refer to W2-2 in this
section.)
3. Retract the gantry. (For details on retracting the

gantry, refer to the Operator's Manual.)
4. Remove the boom hoist wire rope from the upper

spreader and lower spreader, and then wind it
around the boom hoist. (For details on removing
the boom hoist wire rope, refer to the Operator's
Manual.)
5. Remove the boom backstop. (For details on

removing the boom backstop, refer to W2-3 in this
section.)
W2-7-1
6. Remove the bolt (2) located at the front of the
brake cover, and then remove the cover (1). 3
：13 mm
7. Remove the cover (3) located at the rear of the

brake cover.
WRHAE0-02-07-002
8. Remove the nuts of the lift springs (4), (5) on the

brake band, and then remove the washer, spring 4
seat, spring and hook.
5
WRHAE0-02-07-006
CAUTION: Brake cover weight: Brake Cover

Approx. 55 kg Mounting Bolt
9. Remove the brake cover mounting bolt, and then Mounting Bolt
remove the brake cover.
NOTE: Use the same procedure to remove the
other brake cover.
Front Winch Side Rear Winch Side
WRHAE0-02-07-003
W2-7-2
10. Start the engine, and while stepping on the brake 8 9
pedal (6), (7), move the free-fall interlocking
switch (8), (9) to the free position, and then
release the brake pedal (6), (7).
WRHAE0-02-07-004
6 7
WRHAE0-02-07-005
11. Loosen the lock nut (11) and nut (12) of the brake
12
band (10).
11
: 46 mm
12. Loosen the bolt (13), remove the plate (14),

10
remove the pin (15), and then remove the brake
band (10).
: 19 mm 13
14
15
WRHAE0-02-07-017
W2-7-3
13. Remove the electric cables and all the hoses from
the winch motor (16). Attach plugs to the removed
hoses.
: 10 mm
: 36 mm
CAUTION: Winch motor weight:

Approx. 1210 kg
IMPORTANT：When lifting the winch with a crane,

do not attach the wire ropes to the
motor area.
14. Attach a wire rope to the drum of the winch, and
slightly tense the wire rope.
16
IMPORTANT: The swing frame and bearing are 17
fixed with knock pins. When
removing the bearing from the swing WRHAE0-02-07-007
frame, using a plastic hammer or bar

makes removal easier. When prying
them apart with a bar, applying oil
between the bearing and swing
frame makes removal easier. Be sure
not to pry out the motor.
15. Remove the bolt (17), and then lift and remove the
winch with the crane.
: 55 mm
W2-7-4
Installation
1. Drive the knock pins (4 used) into the swing

frame.
CAUTION: Winch motor weight:

Approx. 1210 kg
2. Lift the winch with the crane, align it with the

positions of the bearing and knock pins, and then
lower the winch and fasten it with the bolt (17).
: 55 mm
: 1570 N･m (160 kgf･m)
3. Install all the hoses and electric cables onto the

16
winch motor (16). 17
: 10 mm
: 69 N･m (7.0 kgf･m) WRHAE0-02-07-007
: 36 mm
: 175 N･m (18.0 kgf･m)
4. Align the hole on the lever (18) with the hole on

the brake band (10), insert the pin (15), install the 10
plate (14) onto the pin (15), and fasten with the
bolt (13). 13
: 19 mm 18 14
: 88 N･m (9.0 kgf･m) 15
WRHAE0-02-07-017
W2-7-5
5. Start the engine, move the control lever to neutral
and step on the pedal (6), (7). Move the free-fall 8 9
interlocking switch (8), (9) to the auto brake
position.
6 7 WRHAE0-02-07-004
WRHAE0-02-07-005
6. Pass the bolt (19) through the brake band (10), 10

fasten it with the nut (12) as far as specified A
dimension A, and lock it with the lock nut (11).
Before adjusting, tighten the nuts (20) and bolt 12
11
(21).
A = 154 mm 20
: 36 mm, 46 mm 21
20
19
W324-02-07-010
W2-7-6
CAUTION: Brake cover (22) weight:

Approx. 55 kg
7. Place the brake cover (22) on the frame and

fasten it with the bolt (23). 22
: 19 mm
: 88 N･m (9.0 kgf･m)
23
WRHAE0-02-07-010
8. Install the hook, spring seat, spring, washer and 4

nut onto the brake band, and then adjust the 5
height of the lift springs (4), (5) to 46 mm.
46 mm
46 mm
9. Wind the wire rope onto the lower spreader and

upper spreader. (For details on winding the wire
rope, refer to the Operator’s Manual.)
10. Extend the gantry. (For details on extending the

gantry, refer to the Operator’s Manual.)
11. Install the boom backstop. (For details on

installing the boom backstop, refer to the
Operator’s Manual.) WRHAE0-02-07-006
12. Install the counterweights. (For details on

installing the counterweights, refer to W2-2 in this
section.)
13. Wind the wire rope onto the winch drum.
14. Check the performance of the winch drum brake

and for oil leaks from the winch motor.
W2-7-7
Adjust Brake Band
CAUTION： Before adjustment, lower 8 9

equipment such as the lifting tools to the
ground to ensure safety.
IMPORTANT：• Be sure to adjust both bolts (19),

(21) at the same time.
• If the bolt (19) tightening is
insufficient, the hunting
phenomenon may occur during
free fall. WRHAE0-02-07-004
If the tightening is excessive, the 6 7

brake performance may be
reduced.
1. While fully stepping on the brake pedals (6), (7),
set the free-fall interlocking switches (8), (9) to the
free-brake mode.
2. Loosen the nut (20) of the brake band, and then

loosen the bolt (21).
：36 mm
3. Loosen the lock of the nut (11) of the brake band WRHAE0-02-07-005
adjusting bolt (19). 21

20
：46 mm 19 12
4. Check the clearance of the dead brake band. Live Brake Band 11
Adjust the clearance (a) (clearance between the
drum and lining) to 0.5 mm by tightening the bolt
(24). Dead Brake
Band
5. Tighten the nut (12) gradually. 24
(a)
6. Fully step on the brake pedals (6), (7). Check the

indicator (25) in this condition.
7. Repeat steps 5 and 6 to adjust the pin (26) until it

is positioned in the center of the blue area of the
indicator (25).
8. Lock the nut (11).
25
White
Red
Yellow Blue
WRHAE0-02-07-008
26
W2-7-8
9. While fully stepping on the brake pedals (6), (7), 6 7
rotate the bolts (21) by hand until the bolt heads
make contact with each other, then tighten the
bolts further by approximately 1/6 of a rotation and
lock them with the nut (20).
：36 mm
WRHAE0-02-07-005
10. Unlock the drum lock (optional) and return the 21

20
brake pedal, and check that free fall occurs. If free
fall does not occur, adjust the lift springs (4) (5).
(Clearance (a) between the lining and drum is
approximately 0.8 mm (all around, excluding the 4
5
dead area).)
：13 mm
(a)
WRHAE0-02-07-009
11. Install the cover (1) onto the brake cover with the
bolt (2). 3
：13 mm
：20 Nm (2.0 kgfm)
12. Install the cover (3) onto the brake cover.
2
WRHAE0-02-07-002
W2-7-9
Disassemble Winch
1 2 3 4 5 6 7 8 9 10 11 12 13 14 16, 17 19 20 21 24
55 18
15
56
54
24
53
52
28
29
51
30
31 22
50
32
33 23
34
49 48 46 47 45 44 42, 43 41 40 39 38 37 36 35 28 27 24 25 26
62 63
57 58 58 61
59 60 57
WRHAE0-02-07-012
W2-7-10
1- Plug (2 Used) 17 - Bolt (36 Used) 33 - Cork (4 Used) 49 - Brake Drum

2- Sleeve 18 - Drum Cover 34 - Ring Gear 50 - Bolt (8 Used)
3- Plate 19 - Pedestal 35 - Needle Bearing (6 Used) 51 - Sleeve
4- Sleeve 20 - Plug 36 - Pin (3 Used) 52 - Cover
5- Shaft 21 - Level Gauge 37 - Spring Pin (4 Used) 53 - Grease Fitting
6- Bearing 22 - Motor 38 - Spacer (4 Used) 54 - Retainer
7- Thrust Plate (8 Used) 23 - Bolt (4 Used) 39 - Planetary Gear (4 Used) 55 - Pedestal
8- Spacer 24 - Bolt (18 Used) 40 - Pin (4 Used) 56 - Bolt (6 Used)
9- Needle Bearing (8 Used) 25 - Retainer 41 - Carrier 57 - Oil Seal (2 Used)
10 - Sun Gear 26 - Plug 42 - Bolt (20 Used) 58 - O-Ring (4 Used)
11 - Carrier 27 - Retainer 43 - Washer (20 Used) 59 - Grease Fitting
12 - Spacer 28 - Bearing (2 Used) 44 - Gear Coupling 60 - Oil Seal
13 - Planetary Gear (3 Used) 29 - Sleeve 45 - Drum 61 - O-Ring
14 - Spring Pin (3 Used) 30 - Plug (2 Used) 46 - Bearing 62 - Cork (2 Used)
15 - Propeller Shaft 31 - Knock Pin (2 Used) 47 - Drum 63 - Air Breather
16 - Washer (40 Used) 32 - Thrust Plate (6 Used) 48 - Retainer
W2-7-11
16, 17 19 20
55 18
15
53
52
29
30
22
23
49 47 28 27 24 25 26
61
57
WRHAE0-02-07-012
W2-7-12
Disassemble Winch
• Thoroughly read “PRECAUTIONS FOR

CAUTION: Pedestal (19) weight:
DISASSEMBLING AND ASSEMBLING” (W1-1-1)
before disassembling. Approx. 47 kg
7. Install the eyebolt onto the pedestal (19), and then

CAUTION: Winch weight: Approx. 1210 kg lift and remove it with the crane.
NOTE: If the pedestal (19) is stuck and cannot be
1. Lift the winch with the crane and place it onto a removed, lightly tap it with a plastic
workbench. hammer.
2. Remove the plugs (20), (26) from the pedestal 8. Turn the pedestal (19) upside down, and use a
(19) and remove the plugs (30) (2 used) from the pusher to remove the bearing (28) from the
drum cover (18) to drain the gear oil. pedestal (19).
Amount of gear oil: Approx. 12.5 L
：10 mm, 14 mm 9. Remove the oil seal (57) from the pedestal (19).
： 7 mm
NOTE: Drain the gear oil into a clean container and 10. Remove the sleeve (29) from the drum cover
check it for foreign matter such as worn (18).
particles.
11. Remove the O-ring (61) from the sleeve (29).
3. Install the eyebolt onto the motor (22) and support
it with the crane. 12. Remove the drum cover mounting bolt (17) and
washer (16) from the drum cover (18) outer
circumference.
CAUTION: Motor (22) weight: Approx. 155 kg
：30 mm
4. Remove the bolts (23) (4 used) and washers (16)
(4 used), and then remove the motor (22) from the CAUTION: Winch drum weight:
pedestal (19). Approx. 1010 kg
IMPORTANT: Perform slinging on the drum (47) NOTE: Do not remove the ring gear mounting bolt
and brake drum (49). Do not perform (17) or washer (16) from the drum cover
slinging on the pedestals (19) (55). (18) inner circumference.
Also, do not apply excessive force
to the pedestal (19). IMPORTANT: When rotating the winch drum, take
5. Lift the winch with the crane and place it on a care not to hit the propeller shaft
workbench with the brake drum (49) side facing (15) against the ground.
downward. 13. Attach the wire ropes onto the winch drum, lift it
NOTE: Place a wooden block (200 mm square) or with the crane, turn it over, and place it on a
the like under the brake drum (49) to workbench with the brake drum side facing
stabilize the winch. upward.
NOTE: Place a wooden block (300 mm square) or
6. Remove the bolts (24) (14 used), and then the like under the drum cover (18) to
remove the retainers (25), (27). stabilize the winch.
：19 mm
14. Remove the plug (1) and grease fitting (53) from
the cover (52).
W2-7-13
1 2 3 4 5 6 8 10 11
55 18
56
54
24
52
28
51
50
34
49 48 46 47 45 44 42, 43 41
57 58 58
59 60
WRHAE0-02-07-012
W2-7-14
15. Remove the bolts (56) (6 used), and then remove
CAUTION: Shaft (5) weight: Approx. 90 kg
the cover (52).
：13 mm
27. Install the eyebolt onto the shaft (5) and lift it with
the crane to remove it from the drum (47).
CAUTION: Pedestal (55) weight: NOTE: If it needs to be replaced, remove the
Approx. 29 kg bearing (46) from the shaft (5).

the retainer (54) and pedestal (55). CAUTION: Drum (47) weight: Approx. 315 kg
：19 mm
28. Lift the drum (47) with the crane and remove it
17. Remove the bearing (28) and oil seal (57) from from the drum (45).
the pedestal (55). NOTE: Put matching marks onto the drum (47),
drum (45) and drum cover (18).
18. Remove the sleeve (51) from the shaft (5).
29. Remove the bolts (42) (20 used) and washers
19. Remove the plug (1) from the sleeve (51). (43) (20 used) from the drum (45).
：22 mm
20. Remove the O-ring (58) from the brake drum
(49).
CAUTION: Drum (45) weight: Approx. 61 kg
CAUTION: Brake drum (49) weight: 30. Install the eyebolt onto the drum (45) and lift it
Approx. 235 kg with the crane to remove it from the ring gear
(34).
21. Attach the wire ropes onto the brake drum (49)
and lift it with the crane to remove it from the shaft
(5). CAUTION: Gear coupling (44) weight:
Approx. 24 kg
22. Remove the grease fitting (59) from the sleeve
(2). 31. Remove the gear coupling (44) from the second
stage carrier (41).
23. Remove the sleeve (2) and plate (3) from the NOTE: If it needs to be replaced, remove the
shaft (5). bearing (6) from the gear coupling (44).
24. Remove the O-rings (58) (2 used) from the

CAUTION: Second stage carrier (41)
sleeve (2).
assembly weight: Approx. 61 kg
32. Remove the second stage carrier (41) assembly
the retainer (48), oil seal (60) and sleeve (4).
from the ring gear (34).
：19 mm
33. Remove the spacer (8) and second stage sun
26. Remove the O-ring (58) from the sleeve (4).
gear (10) from the first stage carrier (11).
W2-7-15
7 9 11 12 13 14 16, 17
18
15
31
32
34
41 40 39 38 37 36 35
WRHAE0-02-07-012
W2-7-16
CAUTION: First stage carrier (11) assembly

weight: Approx. 32 kg
34. Remove the first stage carrier (11) assembly from

the ring gear (34).
35. Remove the propeller shaft (15) from the ring

gear (34).
36. Turn the ring gear (34) upside down.
CAUTION: Drum cover (18) weight:

Approx. 41 kg
37. Remove the ring gear (34) mounting bolt (17),

washer (16) and knock pins (31) (2 used), and
then remove the drum cover (18) from the ring
gear (34).
：30 mm
NOTE: Put matching marks onto the ring gear (34)
and drum cover (18).
• Disassemble first stage carrier
38. Remove the spring pins (14) (3 used) and pins

(36) (3 used) from the first stage carrier (11).
39. Remove the first stage planetary gears (13) (3

used) and thrust plates (32) (6 used) from the first
stage carrier (11).
40. Remove the needle bearings (35) (6 used) from

the first stage planetary gears (13) (3 used).
41. Remove the spacer (12) from the first stage

carrier (11).
• Disassemble second stage carrier
42. Remove the spring pins (37) (4 used) and pins

(40) (4 used) from the second stage carrier (41).
43. Remove the second stage planetary gears (39) (4

used) from the second stage carrier (41).
44. Remove the thrust plates (7) (4 used), needle

bearings (9) (4 used), spacers (38) (4 used),
needle bearings (9) (4 used) and thrust plates (7)
(4 used) in this order from the second stage
planetary gears (39) (4 used).
W2-7-17
Assemble Winch
1 2 3 4 5 6 7 8 9 10 11 12 13 14 16, 17 19 20 21 24
55 18
15
56
54
24
53
52
28
29
51
30
31 22
50
32
33 23
34
49 48 46 47 45 44 42, 43 41 40 39 38 37 36 35 28 27 24 25 26
62 63
57 58 58 61
59 60 57
WRHAE0-02-07-012
W2-7-18
1- Plug (2 Used) 17 - Bolt (36 Used) 33 - Cork (4 Used) 49 - Brake Drum

2- Sleeve 18 - Drum Cover 34 - Ring Gear 50 - Bolt (8 Used)
3- Plate 19 - Pedestal 35 - Needle Bearing (6 Used) 51 - Sleeve
4- Sleeve 20 - Plug 36 - Pin (3 Used) 52 - Cover
5- Shaft 21 - Level Gauge 37 - Spring Pin (4 Used) 53 - Grease Fitting
6- Bearing 22 - Motor 38 - Spacer (4 Used) 54 - Retainer
7- Thrust Plate (8 Used) 23 - Bolt (4 Used) 39 - Planetary Gear (4 Used) 55 - Pedestal
8- Spacer 24 - Bolt (18 Used) 40 - Pin (4 Used) 56 - Bolt (6 Used)
9- Needle Bearing (8 Used) 25 - Retainer 41 - Carrier 57 - Oil Seal (2 Used)
10 - Sun Gear 26 - Plug 42 - Bolt (20 Used) 58 - O-Ring (4 Used)
11 - Carrier 27 - Retainer 43 - Washer (20 Used) 59 - Grease Fitting
12 - Spacer 28 - Bearing (2 Used) 44 - Gear Coupling 60 - Oil Seal
13 - Planetary Gear (3 Used) 29 - Sleeve 45 - Drum 61 - O-Ring
14 - Spring Pin (3 Used) 30 - Plug (2 Used) 46 - Bearing 62 - Cork (2 Used)
15 - Propeller Shaft 31 - Knock Pin (2 Used) 47 - Drum 63 - Air Breather
16 - Washer (40 Used) 32 - Thrust Plate (6 Used) 48 - Retainer
W2-7-19
7 8 9 10 11 12 13 14 16, 17
18
15
31
32
34
41 40 39 38 37 36 35
WRHAE0-02-07-012
W2-7-20
Assemble Winch
11. Repeat steps 7 to 10 above to install the other 3
• Assemble first stage carrier second stage planetary gears (39) onto the
second stage carrier (41).
1. Install the spacer (12) onto the first stage carrier
(11). • Assemble winch drum
2. Install the needle bearings (35) (2 used) onto the

CAUTION: Drum cover (18) weight:
first stage planetary gear (13).
Approx. 41 kg
3. Install a thrust plate (32) at the top and the bottom
of the first stage planetary gear (13). 12. Apply Three Bond #1389 onto the end surface of
the ring gear (34), and then install the drum cover
4. Insert the pin (36) into the first stage carrier (11), (18) and install the knock pin (31).
and then align the positions of the holes for NOTE: Align the matching marks of the ring gear
inserting the spring pin (14). (34) and drum cover (18).
5. Position the slit area of the spring pin (14) facing 13. Install the washer (16) and bolt (17) onto the
the end surface of the pin (36), and then insert the drum cover (18), and fix the drum cover onto the
spring pin (14) into the first stage carrier (11) and ring gear (34).
pin (36). ：30 mm
：540 Nm (55 kgfm)
6. Repeat steps 1 to 5 above to install the other 2
first stage planetary gears (13) onto the first stage
CAUTION: Ring gear (34) + drum cover (18)
carrier (11).
weight: Approx. 125 kg
• Assemble second stage carrier 14. Turn the ring gear (34) upside down and place it
on a workbench with the drum cover (18) side
7. Install the thrust plate (7), needle bearing (9),
facing downward.
spacer (38), needle bearing (9) and thrust plate
(7) in this order onto the second stage planetary NOTE: Place a wooden block (300 mm square) or
gear (39). the like under the drum cover (18) to
stabilize the ring gear (34).
8. Assemble the second stage planetary gear (39)
onto the second stage carrier (41), and then align 15. Install the propeller shaft (15) onto the drum
the positions of the holes for inserting the pin (40). cover (18).
9. Insert the pin (40) into the second stage carrier CAUTION: First stage carrier (11) assembly
(41), and then align the positions of the holes for weight: Approx. 32 kg
inserting the spring pin (37).
16. Install the first stage carrier (11) assembly onto
10. Position the slit area of the spring pin (37) facing the ring gear (34).
the end surface of the pin (40), and then insert
the spring pin (37) into the second stage carrier 17. Install the spacer (8) and second stage sun gear
(41) and pin (40). (10) onto the first stage carrier (11).
W2-7-21
2 3 4 5 6 16, 17
18
15
50
34
48 46 47 45 44 42, 43 41
58
59 60
WRHAE0-02-07-012
W2-7-22

1-2 Work Shop Manual SCX550E WRHAE0-EN-00

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WRHAE0-EN-00

HITACHI SUMITOMO HEAVY INDUSTRIES

PRINTED IN JAPAN (KW) 2013.01

 This manual is written for an experienced technician

• Be sure to thoroughly read this manual for correct

 Each page has a number, located on the center

Consecutive Page Number for Each Group

 SI Units (International System of Units) are used in 2

 These are the SAFETY ALERT SYMBOLS.

• When you see these symbols on your machine or in

UNDERSTAND SIGNAL WORDS

 On machine safety signs, signal words designating the

• DANGER indicates an imminently hazardous situation

 To avoid confusing machine protection with personal

 NOTE indicates an additional explanation for an

1.1 Follow Safety Instructions

 Sections that include CAUTION describe basic

1.2 Wear Safe Clothes and Protective Gear

1.3 Protect Against Noise

1.4 Coordinate with the Personnel Concerned

1.5 Always Signal Properly

1.7 Keep Personnel Away from the Working Area

Protect Against Flying Objects

1.8 Operate the Machine in the Correct Position

1.9 Setting the Machine

1.11 Mounting and Dismounting the Machine

1.12 Operate the Machine Only from the Operator's

1.13 Fasten the Seat Belt (If Equipped)

1.14 Keep Riders off the Machine

1.16 Prevent Tipping-Over Accidents

1.17 Avoid Power Lines

 Immediately contact the electric utility or management

his or her body will touch the machine when landing

1.18 Beware of Charging by Strong Radio Waves

1.20 Wind Precautions

 Use the "Wind Velocity Conversion Table" to convert the

boom. Then, multiply this number by 1.5 to 1.7 to obtain

Average Wind Velocity at the Tip of the Boom

Table 2 Standard Wind Speed, Wind Scale and Phenomena Observed

1. Position the counterweight on the windward

When the wind velocity is 15 to 30 m/s:

If the boom can be lowered to the ground:

When the wind velocity exceeds 30 m/s (in

1. Lower the hook to the ground.

Measures to be taken after the wind calms

Earthquake Intensity Scale

 Stop the machine on solid, level ground.

2.1 Ensure a Safe Job Site

2.4 Check Safety Before Starting the Engine

2.5 Warm Up the Machine

2.6 Perform an Inspection After Starting the

3.1 Check the Job Site Conditions

conditions while performing work.

3.2 Avoid Abrupt Operations

3.3 Do Not Operate Inattentively

3.4 Do Not Leave the Operator's Seat

3.6 Prevent the Load from Contacting the Boom and

3.7 Precautions When the Engine Stalls

3.8 Keep Away from Obstructions

3.10 Keep Good Visibility

3.12 Perform Combined Operations Carefully

3.14 Do Not Over-Rely on the Safety Devices

There is a limit to the capabilities of the safety devices.

3.15 Precautions for Travel Operations