Hitashi W 1F1E 00

INTRODUCTION
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form at the end of this man-
• Be sure to thoroughly read this manual for correct ual.
product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redeliver and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
• Each page has a number, located on the center

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

Group Number
Section Number
T: Technical Manual W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:

signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri- • NOTE:
ate lifting techniques and equipment when lifting heavy Indicates supplementary technical information or
parts. know-how.
UNITS USED
2
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKS 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
L US gal 0.2642 Power kW PS 1.360
Volume 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
• This is the SAFETY ALERT SYMBOL.
• When you see this symbol on your machine or in

this manual, be alert to the potential for personal
injury.
• Follow recommended precautions and safe
operating practices.
001-E01A-0688 SA-688
UNDERSTAND SIGNAL WORDS
• On machine safety signs, signal words designating

the degree or level of hazard - DANGER, WARNING,
or CAUTION - are used with the safety alert symbol.
• DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death
or serious injury.
• WARNING indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury.
• CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in minor
or moderate injury.
• DANGER or WARNING safety signs are located

near specific hazards. General precautions are
listed on CAUTION safety signs.
• Some safety signs don’t use any of the SA-1223

designated signal words above after the safety
alert symbol are occasionally used on this
machine.
• CAUTION also calls attention to safety messages in

this manual.
• To avoid confusing machine protection with personal

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

element of information.
002-E01C-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the ma-

chine and all safety messages in this manual.
• Safety signs should be installed, maintained and re-

placed when necessary.
• If a safety sign or this manual is damaged or miss-

ing, order a replacement from your authorized
dealer in the same way you order other replace-
ment parts (be sure to state machine model and
serial number when ordering).
SA-003
• Learn how to operate the machine and its controls

correctly and safely.
• Allow only trained, qualified, authorized personnel to

operate the machine.
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may

impair its function and/or safety and affect ma-
chine life.
• The safety messages in this SAFETY chapter are

intended to illustrate basic safety procedures of ma-
chines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your
authorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.

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

posted near your telephone.
004-E01A-0437
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
• Wear close fitting clothing and safety equipment

appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other

items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full

attention of the operator. Do not wear radio or music
headphones while operating the machine.
005-E01A-0438
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.
006-E01A-0434 SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by

walking around it before you start it to avoid personal
injury.
• In the walk-around inspection be sure to cover all

points described in the “PRE-START
INSPECTION” chapter in the operator’s manual.
S007-E01A-0435
SA-435
SA-3
SAFETY
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all dirt

and/or oil from the soles of your work boots. If any
controls such as a pedal is operated while with dirt
and/or oil on the soles of the operator’s work
boots the operator’s foot may slip off the pedal,
possibly resulting in a personal accident.
• Don’t leave parts and/or tools lying around the op-

erator’s seat. Store them in their specified loca-
tions.
• Avoid storing transparent bottles in the cab. Don’t

attach any transparent type window decorations
on the windowpanes as they may focus sunlight,
possibly starting a fire.
• Refrain from listening to the radio, or using music

headphones or mobile telephones in the cab while
operating the machine.
• Keep all flammable objects and/or explosives

away from the machine.
• After using the ashtray, always cover it to extin-

guish the match and/or tobacco.
• Don’t leave cigarette lighters in the cab. When the

temperature in the cab increases, the lighter may
explode.
524-E01A-0000
SA-4
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
• When you mounting and dismounting the ma-

chine, always face the machine and maintain a
three-point contact with the steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount or

dismount a moving machine.
SA-439
• Be careful of slippery conditions on platforms,
steps, and handrails when mounting and dis-
mounting the machine.
008-E01B-0439
ADJUST THE OPERATOR'S SEAT
• A poorly adjusted seat for either the operator or for

the work at hand may quickly fatigue the operator
leading to misoperations.
• The seat should be adjusted whenever changing

the operator for the machine.
• The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
• If not, move the seat forward or backward, and
check again. SA-378
009-E01A-0378
SA-5
SAFETY
FASTEN YOUR SEAT BELT
• If the machine should overturn, the operator may

become injured and/or thrown from the cab.
Additionally the operator may be crushed by the
overturning machine, resulting in serious injury or
death.
• Prior to operating the machine, thoroughly

examine webbing, buckle and attaching hardware.
If any item is damaged or worn, replace the seat
belt or component before operating the machine.
• Be sure to remain seated with the seat belt SA-237
securely fastened at all times when the machine is
in operation to minimize the chance of injury from
an accident.
• We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY
• Bystanders can be run over.
• Take extra care not to run over bystanders.

Confirm the location of bystanders before moving,
swinging, or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the SA-426
machine.
011-E01A-0426
SA-6
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may cause

the machine to runaway, possibly resulting in serious
injury or death.
• Start the engine only when seated in the

operator's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals. SA-444
• Before starting the engine, confirm that all control
levers are in neutral.
012-E01B-0444
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to

follow the instructions shown in the “OPERATING
THE ENGINE” chapter in the operator’s manual.
• The operator must be in the operator’s seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person
operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures SA-032
could result in a battery explosion or a runaway
machine.
S013-E01A-0032
SA-7
SAFETY
KEEP RIDERS OFF MACHINE
• Riders on machine are subject to injury such as

being struck by foreign objects and being thrown off
the machine.
• Only the operator should be on the machine.

Keep riders off.
• Riders also obstruct the operator’s view, resulting
in the machine being operated in an unsafe
manner.
SA-379
014-E01B-0379
PROVIDE SIGNALS FOR FOBS INVOLV-

ING MULTIPLE NUMBERS OF MACHINES
• For jobs involving multiple numbers of machines,

provide signals commonly known by all personnel
involved. Also, appoint a signal person to coordinate
the job site. Make sure that all personnel obey the
signal person’s directions.
018-E01A-0481
SA-481
CONFIRM DIRECTION OF MACHINE TO

BE DRIVEN
• Incorrect travel pedal/lever operation may result in

serious injury death.
• Before driving the machine, confirm the position of

the undercarriage in relation to the operator’s po-
sition. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.
SA-491
017-E01A-0491
SA-8
SAFETY
DRIVE MACHINE SAFELY
• Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the di-
rection you wish to drive.
• Be sure to detour around any obstructions.

• Avoid traveling over obstructions. Soil, fragments
of rocks, and/or metal pieces may scatter around
the machine. Don’t allow personnel to stay around
the machine while traveling.
SA-387
• Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.
• When driving up or down a slope, keep the bucket

facing the direction of travel, approximately 200 to
300 mm (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop traveling.
SA-388
SA-441
• Driving across the face of a slope or steering on a

slope may cause the machine to skid or turnover.
If the direction must be changed, move the ma-
chine to level ground, then, change the direction
to ensure sage operation.
019-E01D-0492
SA-589
SA-9
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
• Death or serious injury may result if you attempt to

mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the SA-391
H/P mode switch off.
• Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK
position.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
SA-392
020-E08A-0493
SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when

backing or swinging the upperstructure, the machine
may hit or run over that person, resulting in serious
injury or death.
To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
SA-383
• Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP

IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person. SA-384
• No machine motions shall be made unless signals

are clearly understood by both signalman and
operator.
• Learn the meanings of all flags, signs, and

markings used on the job and confirm who has
the responsibility for signaling.
• Keep windows, mirrors, and lights clean and in

good condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As

visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in

the operator’s manual.
S021-E01A-0494
SA-11
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING

MACHINE---SERIOUS OR FATAL CRUSHING
INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU

CAN JUMP FREE
FASTEN YOUR SEAT BELT
• The danger of tipping is always present when

operating on a grade, possibly resulting in serious SA-012
injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or
slipping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper SA-440
than 15 degrees if crossing the grade is

unavoidable.
• Reduce swing speed as necessary when swinging
loads.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to

become soft and make ground travel unstable.
S025-E01B-0495
SA-12
SAFETY
AVOID POWER LINES
• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines.
• When operating near an electric line, NEVER

move any part of the machine or load closer than
3 m (10 ft) plus twice the line insulator length.
• Check and comply with any local regulations that
may apply.
• Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site. SA-381
029-E01A-0381
OBJECT HANDLING
• If a lifted load should fall, any person nearby may be

struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.
• When using the machine for craning operations,

be sure to comply with all local regulations.
• Do not use damaged chains or frayed cables,
sables, slings, or ropes.
• Before craning, position the upperstructure with
the travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it is
SA-014
safely and securely situated on supporting blocks
or on the ground.
• Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.
032-E01A-0014
SA-13
SAFETY
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body,

serious injury may result.
• Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.
• Keep bystanders away from the working area
before striking any object.
SA-432
031-E01A-0432
PARK MACHINE SAFELY
To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle / acceleration selector and H/P
mode switch off.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK
position. SA-390
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
033-E09B-0390
SA-14
SAFETY
HANDLE FLUIDS SAFELYҥ
ҥAVOID FIRES
• Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.
• Do not refuel the machine while smoking or when

near open flame or sparks.
• Always stop the engine before refueling the
machine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are SA-018

flammable.
• Store flammable fluids well away from fire

hazards.
• Do not incinerate or puncture pressurized
containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-15
SAFETY
SAFETY TRANSPORTING
• The danger of tipping is present when

loading/unloading the machine onto/from a truck or
trailer bed.
• Be sure to observe local regulations when

transporting the machine on public roads.
• Provide an appropriate truck or trailer for
transporting the machine.
Take the following precautions when loading /

unloading the machine: SA-395
1) Select firm level ground.
2) Be sure to use a loading dock or ramp.
3) Be sure to have a signal person when
loading/unloading the machine.
4) Always turn the auto-idle / acceleration selector
and the H/P mode switch OFF when loading or
unloading the machine, to avoid unexpected
speed increase due to unintentional operation of
a control lever.
5) Always select the slow speed mode with the
travel mode switches. In the high speed mode,
travel speed may automatically increase.
6) Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify traveling direction, and begin to
drive again.
7) Do not operate any levers besides the travel
levers when driving up or down the ramp.
8) The top end of the ramp where it meets the
flatbed is a sudden bump. Take care when
traveling over it.
9) Prevent possible injury from machine tipping
while the upperstructure is rotating.
10) Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11) Securely fasten chain or cables to the machine
frame. Refer to "transporting" chapter in the
operator's manual for details.
S035-E08A-0395
SA-16
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before doing

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

1) Park the machine on a level surface.
2) Lower the bucket to the ground.
3) Turn the auto-idle / acceleration selecltor off.
4) Run the engine at slow idle speed without load
for 5 minutes. SA-028
5) Turn the key switch to OFF to stop engine.
6) Relieve the pressure in the hydraulic system by
moving the control levers several times.
7) Remove the key from the switch.
8) Attach a “Do Not Operate” tag on the control
lever.
9) Pull the pilot control shut-off lever to the LOCK
position.
10) Allow the engine to cool.
• If a maintenance procedure must be performed

with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or SA-527
replace as necessary. Refer to the section

discussing that part in the “MAINTENANCE”
chapter in the operator’s manual.
• Keep all parts in good condition and properly
installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
• When cleaning parts, always use nonflammable
detergent oil. Never use highly frammable oil such
as fuel oil and gasoline to clean parts or surfaces.
• Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
• Illuminate your work area adequately but safely.
S500-E02B-0497
SA-17
SAFETY
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or
inside the machine.
• Always use a work light protected with a guard. In SA-037
case the light bulb is broken, spilled fuel, oil

antifreeze fluid, or window washer fluid may catch
fire.
S500-E02B-0497
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause serious

injury.
• Before performing any work on the machine,

attach a “Do Not Operate” tag on the control lever.
S501-E01A-0287
SA-287
SUPPORT MACHINE PROPERLY
• Never attempt to work on the machine without

securing the machine first.
• Always lower the attachment to the ground before

you work on the machine.
• If you must work on a lifted machine or
attachment, securely support the machine or
attachment. Do not support the machine on cinder
blocks, hollow tires, or props that may crumble
under continuous load. Do not work under a
SA-527
machine that is supported solely by a jack.
519-E01A-0527
STAY CLEAR OF MOVING PARTS
• Entanglement in moving parts can cause serious

injury.
• To prevent accidents, care should be taken to

ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working around
rotating parts.
502-E01A-0026
SA-026
SA-18
SAFETY
PREVENT PARTS FROM FLYING
• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in
serious injury, blindness, or death.
• Do not attempt to remove GREASE FITTING or

VALVE ASSEMBLY.
• As pieces may fly off, be sure to keep body and
face away from valve.
• Travel reduction gears are under pressure.

SA-344
• As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen
AIR RELEASE PLUG to release pressure.
503-E01B-0344
STORE ATTACHMENTS SAFELY
• Stored attachments such as buckets, hydraulic

hammers, and blades can fall and cause serious
injury or death.
• Securely store attachments and implements to

prevent falling. Keep children and bystanders
away from storage areas.
SA-034
504-E01A-0034
USE TOOLS PROPERLY
• Use tools appropriate for the work to be done.

• Makeshift tools, parts, and procedures can create
safety hazards.
• For loosening and tightening hardware, use the
correct size tools to avoid injury caused by
slipping wrenches.
• Use only recommended replacement parts.
(See the parts catalog.)
SA-040
S522-E01A-0040
SA-19
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water.

DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the SA-039
stop. Allow all pressure to be released before
removing the cap.
• The hydraulic oil tank is pressurized. Again, be
sure to release all pressure before removing the
cap.
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot
as well.
SA-225
• Wait for the oil and components to cool before

starting any maintenance or inspection work.
505-E01B-0498
REPLACE RUBBER HOSES

PERIODICALLY
• Rubber hoses that contain flammable fluids under

pressure may break due to aging, fatigue, and
abrasion. It is very difficult to gauge the extent of
deterioration due to aging, fatigue, and abrasion of
rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the

page of “Periodic replacement of parts” in the
operator’s manual.)
SA-019
• Failure to periodically replace rubber hoses may
cause a fire, fluid injection into skin, or the front
attachment to fall on a person nearby, which may
result in severe burns, gangrene, or otherwise
serious injury or death.
S506-E01A-0019
SA-20
SAFETY
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take
care to protect hands and body from high- SA-031
pressure fluids. Wear a face shield or goggles for

eye protection.
• If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
SA-292
507-E03A-0499
SA-044
SA-21
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to

fires.
• Check for oil leaks due to missing or loose clamps,

kinked hoses, lines or hoses that rub against each
other, damage to the oil-cooler, and loose oil-
cooler flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oil- SA-019
cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or
hoses.
Check for Shorts:
• Short circuits can cause fires.
• Clean and tighten all electrical connections.

• Check before starting work for loose, kinked,
hardened or frayed electrical cables and wires.
• Check before starting work for missing or
damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris,

accumulated coal dust, and other flammables may
cause fires.
• Prevent fires by inspecting and cleaning the

machine daily and by removing spilled or
accumulated flammables immediately.
Check Key Switch:
• If a fire breaks out, failure to stop the engine will

escalate the fire, hampering fire fighting.
• Always check key switch function before

operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to
confirm that the engine stops.
• If any abnormalities are found, be sure to repair

them before operating the machine.
S508-E02B-0019
SA-22
SAFETY
Check Emergency Engine Stop Switch:
• If a fire breaks out, failure to release pressurized air
inside the hydraulic tank will escalate fire, hampering
fire fighting.
• Check the emergency engine stop switch function
every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to the
EMERG. STOP position.
3) Confirm that both engines stop and that pres-
surized air inside the hydraulic oil tank is re-
leased (a hissing sound should be heard).
• If any abnormalities are found, be sure to repair
them before operating the machine.
Check Heat Shields:

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
S508-E02B-0019
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the machine in the

following way:
• Stop the engine by turning the key switch to the

OFF position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
SA-393
• In an emergency, if the cab door and/or the front
window cannot be opened, break the front or rear
window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on “EMERGENCY
EXIT” in Operator’s Manual.
518-E02B-0393
SS-1510
SA-23
SAFETY
BEWARE OF EXHAUST FUMES
• Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.
• If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.
509-E01A-0016
SA-016
PRECAUTIONS FOR WELDING AND

GRINDING
• Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe
place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before start-
ing grinding.
• After finishing welding and grinding, recheck that SA-818
there are no abnormalities such as the area sur-

rounding the welded area still smoldering.
523-E01A-0818
AVOID HEATING NEAR PRESSURIZED

FLUID LINES
• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
• Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable
materials.
• Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area.
Install temporary fire-resistant guards to protect
SA-030
hoses or other materials before engaging in
welding, soldering, etc..
AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that

contain flammable fluids.
• Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
510-E01B-0030
SA-24
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
• Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.
• Remove paint before welding or heating:

1) If you sand or grind paint, avoid breathing the SA-029
dust.
Wear an approved respirator.
2) If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers and
other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
511-E01A-0029
PREVENT BATTERY EXPLOSIONS
• Battery gas can explode.
• Keep sparks, lighted matches, and flame away

from the top of battery.
• Never check battery charge by placing a metal ob-
ject across the posts. Use a voltmeter or hy-
drometer.
• Do not charge a frozen battery; it may explode.
Warm the battery to 16 °C ( 60 °F ) first.
• Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion SA-032
of the battery may result.
• Loose terminals may produce sparks. Securely
tighten all terminals.
• Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into
eyes, possibly resulting in blindness.
• Be sure to wear eye protection when checking

electrolyte specific gravity.
512-E01C-0032
SA-25
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold

contact burn.
• Refer to the freon container for proper use when

servicing the air conditioning system.
• Use a recovery and recycling system to avoid
venting freon into the atmosphere.
• Never let the freon stream make contact with the
skin.
SA-405
513-E01A-0405
HANDLE CHEMICAL PRODUCTS SAFELY
• Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used
with your machine include such items as lubricants,
coolants, paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
• Check the MSDS before you start any job using a SA-309
hazardous chemical. That way you will know
exactly what the risks are and how to do the job
safely. Then follow procedures and use
recommended equipment.
S515-E01A-0309
SA-26
SAFETY
DISPOSE OF WASTE PROPERLY
• Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do

not use food or beverage containers that may
mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain,
or into any water source.
• Air conditioning refrigerants escaping into the air SA-226
can damage the Earth’s atmosphere.
Government regulations may require a certified air
conditioning service center to recover and recycle
used air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.
S516-E01A-0226
BEFORE RETURNING THE MACHINE TO

THE CUSTOMER
• After maintenance or repair work is complete,

confirm that:
• The machine is functioning properly, especially
the safety systems.
• Worn or damaged parts have been repaired or
replaced
S517-E01A-0435 SA-435
SA-27
SAFETY
(Blank)
SA-28
SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
WORKSHOP MANUAL Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Signal Control Valve
Group 10 Solenoid Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
SECTION 5 ENGINE
All information, illustrations and speci-
fications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
COPYRIGHT(C)2001
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specification Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Control System Group 5 Travel Device
Group 2 Hydraulic System Group 6 Signal Control Valve
Group 3 Electrical System Group 7 Others (Upperstructure)
Group 8 Others (Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 General
Group 1 Introduction Group 2 Component Layout
Group 2 Engine Test Group 3 Troubleshooting A
Group 3 Excavator Test Group 4 Troubleshooting B
Group 4 Component Test Group 5 Troubleshooting C
Group 5 Standard Group 6 Electrical System Inspection
Group 7 ICX
SECTION 1
GENERAL INFORMATION
 CONTENTS 
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling........................................... W1-1-1
Maintenance Standard Terminology........ W1-1-7
Group 2 Tightening Torque

Tightening Torque Specification.............. W1-2-1
Torque Chart .......................................... W1-2-3
Piping Joint ............................................ W1-2-6
Periodic Replacement of Parts ............. W1-2-10
Group 3 Painting
Painting .................................................. W1-3-1
1F1W-1-1
(Blank)
1F1W-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
• Clean the Machine • Precautions for Disassembling
Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop may removed pipes.
cause machine components to be contaminated • Before disassembling, clean the exterior of the
during disassembling/assembling, resulting in components and place on a work bench.
damage to machine components, as well as • Before disassembling, drain gear oil from the
decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all disassem- instructed.
bling/assembling procedures beforehand, to help • If a part or component cannot be removed after
avoid incorrect disassembling of components as well removing its securing nuts and bolts, do not
as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if any. disassembled parts for abnormal wear, sticking,
• Capacities and condition of lubricants. or other damage.
• Loose or damaged parts. • Measure and record the degree of wear and
clearances.
• Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the area

for disassembling work.
W1-1-1
• Precautions for Assembling Bleeding Air from Hydraulic System
• Be sure to clean all parts and inspect them for any When hydraulic oil is drained, the suction filter or the
damage. If any damage is found, repair or replace suction lines are replaced, or the removal and instal-
part. lation of the pump, swing motor, travel motor or cylin-
• Dirt or debris on the contact or sliding surfaces der is done, bleed air from the hydraulic system in the
may shorten the service life of the machine. Take following procedures:
care not to contaminate any contact or sliding
surfaces. IMPORTANT: If the engine is started with air
• Be sure to replace O-rings, backup rings, and oil trapped in the hydraulic pump hous-
seals with new ones once they are disassembled. ing, damage to the pump may result.
Apply a film of grease before installing. If the hydraulic motor is operated
• Be sure that liquid-gasket-applied surfaces are
with air trapped in the hydraulic mo-
clean and dry.
tor housing, damage to the motor
• If an anti-corrosive agent has been used on a new
may result.
part, be sure to thoroughly clean the part to
remove the agent. If the cylinder is operated with air
• Utilize matching marks when assembling. trapped in the cylinder tube, damage
• Be sure to use the designated tools to assemble to the cylinder may result.
bearings, bushings and oil seals. Be sure to bleed air before starting
• Keep a record of the number of tools used for the engine.
disassembly/assembly. After assembling is
complete, count the number of tools, so as to • Bleeding Air from Hydraulic Pump
make sure that no forgotten tools remain in the
assembled machine. • Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the pump
housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the plug.
• Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic
oil.
W1-1-2
• Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes. M104-07-021
• Reposition the front attachment to check hydraulic

oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
W1-1-3
Floating Seal Precautions A
1. In general, replace the floating seal with a new

one after disassembling.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of
cardboard to protect surfaces.
B W105-03-05-019
(2) Check the slide surface on seal ring (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

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

bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.
(3) Check that the O-ring is not twisted, and that it W105-03-05-020
is installed correctly on the seal ring. Correct

D Incorrect
a a
(4) After installing the floating seal, check that seal
ring surface (A) is parallel with seal mating face C
(C) by measuring the distances (A) and (C) at
point (a) and (b), as illustrated. If these
distances differ, correct the O-ring seating.
b b
a=b aҐb
W110-03-05-004
W1-1-4
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 being damaged and the lifted load from
slipping.
• Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load
with a temperature of 100 °C (212 °F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
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 object.
• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.
Bent Sling W162-01-01-009
W1-1-5
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
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-6
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies

adjusted to specification.
“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
2. Repair or adjustment is impossible after exceed-

ing this limit.
3. Therefore, in consideration of operation efficiency

and maintenance expense, proper maintenance
shall be carried out before reaching the “Allowable
Limit”.
W1-1-7
(Blank)
W1-1-8
GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATIONS
Bolt Dia Wrench Torque

No. Descriptions Q’ty
mm Size (mm) Nxm (kgfxm) (lbfxft)
Engine cushion rubber mounting nut 14 4 22 140 (14.3) (103)
1
Engine cushion rubber mounting bolt 16 2 24 235 (24) (175)
Engine bracket mounting bolt 10 7 17 50 (5.1) (37)
2
Engine bracket mounting nut 10 1 17 50 (5.1) (37)
3 Hydraulic oil tank mounting bolt 16 4 24 210 (21.5) (155)
4 Fuel tank mounting bolt 16 4 24 210 (21.5) (155)
5 19 29.5 (3) (22)
1-3/16-12UNF 22 39 (4) (29)
27 93 (9.5) (69)
ORS fittings for hydraulic hoses and piping
32 137 (14) (101)
1-7/16-12UNF 36 175 (18) (129)
41 205 (21) (151)
6 Pump mounting bolt 10 8 17 50 (5.1) (37)
7 Control valve mounting bolt 14 6 22 140 (14.3) (103)
8 Control valve bracket mounting bolt 16 4 24 210 (21.5) (155)
9 Swing device mounting bolt 20 12 30 500 (51) (370)
10 Battery mounting nut 10 2 17 20 (2.0) (14.5)
11 Cab mounting nut 16 4 24 210 (21.5) (155)
Swing bearing mounting bolt to upperstructure 20 31 30 510 (52) (380)
12
Swing bearing mounting bolt to undercarriage 20 36 30 490 (50) (360)
Travel device mounting bolt 16 32 24 305 (31) (225)
13
Travel reduction device cover mounting bolt 14 8 22 140 (14.3) (103)
14 Sprocket mounting bolt 20 32 30 460 (47) (340)
15 Upper roller mounting bolt 16 16 24 265 (27) (195)
16 Lower roller mounting bolt 18 56 27 460 (47) (340)
17 Track shoe bolt 18 344 27 560 (57) (410)
6 - 10 10 (1) (7.4)
18 Cover mounting bolt 10 - 17 50 (5.1) (37)
12 - 19 90 (9.2) (66)
8 - 13 10.3 to 12.4 (1.05 to 1.26) (7.6 to 9.2)
19 Coupling and T-bolt clamp of low pressure piping
4 11 5.90 (0.6) (4.4)
W1-2-1
NOTE 1. Apply lubricant (e.g. white zinc B

dissolved into spindle oil) to bolts and
nuts to reduce friction coefficient of them.
2. Make sure bolt and nut threads are clean
before installing.
W1-2-2
TORQUE CHART
CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and proce-
dures can create safety hazards. For loosen-
ing and tightening nuts and bolts, use correct
size tools. Otherwise, tightening tools may
slip, potentially causing personal injury.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.

Four different types and grades of bolt are employed.
Make sure to employ correct bolts and tighten them SA-040
correctly when assembling the machine or compo-

nents.
Specified Tightening Torque Chart
Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M157-07-225
Socket Bolt
Nxm (kgfxm) (lbfxft) Nxm (kgfxm) (lbfxft) Nxm (kgfxm) (lbfxft)
M6 10 5 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3.1)
M8 13 6 30 (3.1) (22) 20 (2.0) (15.0) 10 (1.0) (7.4)
M10 17 8 65 (6.6) (48) 50 (5.1) (37) 20 (2.0) (15.0)
M12 19 10 110 (11.0) (81) 90 (9.2) (66) 35 (3.6) (26.0)
M14 22 12 180 (18.5) (135) 140 (14.0) (103) 55 (5.6) (41)
M16 24 14 270 (27.5) (200) 210 (21.5) (155) 80 (8.2) (59)
M18 27 14 400 (41.0) (295) 300 (30.5) (220) 120 (12.0) (89)
M20 30 17 550 (56.0) (410) 400 (41.0) (295) 170 (17.0) (125)
M22 32 17 750 (76.5) (550) 550 (56.0) (410) 220 (22.5) (162)
M24 36 19 950 (97.0) (700) 700 (71.5) (520) 280 (28.5) (205)
M27 41 19 1400 (143) (1030) 1050 (107) (770) 400 (41.0) (295)
M30 46 22 1950 (200) (1440) 1450 (148) (1070) 550 (56.0) (410)
M33 50 24 2600 (265) (1920) 1950 (200) (1440) 750 (76.5) (550)
M36 55 27 3200 (325) (2360) 2450 (250) (1810) 950 (97.0) (700)
W1-2-3
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to nuts
and bolts to reduce their friction
coefficients.
The plated bolts require no lubri-
cant.
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 suf-
ficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them alter-

nately, as shown, to ensure even tightening.
Equally tighten upper and lower Tighten from center and diagonally
alternately Tighten diagonally
1 12 9 4 1 6 7 14
6 3
1st to 4th
4 5
2 13 8 5 2 3 10 11
2nd to 3rd
W105-01-01-003
W1-2-4
Service Recommendations for Spilt Flange
IMPORTANT: 1. Be sure to clean and Inspect seal-

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

tightening of the others, resulting
in damage to O-rings or uneven
tightening of bolts.
Bend along edge sharply Do not bend it round
Nut and Bolt Locking

RIGHT RIGHT WRONG
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while tight- Bend along edge sharply
W105-01-01-009
ening, not while loosening.
RIGHT RIGHT WRONG
• Lock Wire
IMPORTANT: Apply wire to bolts in the bolt-
tightening direction, not in the bolt-
loosening direction.
Loosen WRONG
RIGHT
Tighten
W105-01-01-010
W1-2-5
PIPING JOINT 1 4 3 5 2
IMPORTANT: The torques given in the chart are for

general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
M202-07-051
Joint Body
Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and

hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines. 37ѯ
30ѯ
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
cations. W105-01-01-017
2. Scratches or other damage to

sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them
when connecting/disconnecting.
Wrench Size Wrench Size Tightening Torque

Description mm mm
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
30ѯmale 17 17 24.5 (2.5,18)
19 19 29.5 (3.0,22)
22 22 39 (4.0,28.5)
27 27 93 (9.5,69)
32 32 137 (14,101)
36 36 175 (18,129)
41 41 205 (21,151)
37ѯfemale 17 14 24.5 (2.5,18)
19 17 29.5 (3.0,22)
22 19 39 (4.0,28.5)
27 22 93 (9.5,69)
32 27 137 (14,101)
36 32 175 (18,129)
41 36 205 (21,151)
NOTE: Tightening torque of 37ѯmale coupling without union is similar
to tightening torque of 37ѯfemale.
W1-2-6
O-ring Seal Joint 7 6 9
O-ring (6) seats against the end face of adapter (7) to

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

a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly Hose Fittings
8 10
in O-ring groove (e). Tightening M104-07-033
nut (9) with O-ring (6) displaced

will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring Wrench Size Wrench Size Tightening Torque
groove (8) or sealing surface (10). mm mm
Damage to O-ring (6) will cause Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
oil leakage. 19 17 29.5 (3.0,22)
4. If nut (9) is loose and oil is leak- 22 19 69 (7.0,51)
ing, do not re-tighten nut (9). Re- 27 22 93 (9.5,69)
place O-ring (6) with a new one 32 27 137 (14,101)
and check that O-ring (6) is cor- 36 30,32 175 (18,129)
rectly seated in place, tighten nut 41 36 205 (21,151)
(9). 46 41 205 (21,151)
W1-2-7
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30ѯ
types of screw fittings are used.
IMPORTANT: Be sure to confirm that the thread

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

Wrench Size Tightening Torque
mm N⋅m (kgf⋅m, lbf⋅ft)
Hose Fittings FC material SS material
19 14.5 (1.5,10.5) 34 (3.5,25)
22 29.5 (3.0,21.5) 49 (5.0,36)
27 49 (5.0,36) 93 (9.5,69)
36 69 (7.0,51) 157 (16,116)
41 108 (11,80) 205 (21,151)
50 157 (16,116) 320 (33,235)
60 195 (20,144)
Seal Tape Application
Seal tape is used to seal clearances between male Internal Thread

and female threads, so as to prevent any leaks be-
tween threads.
Be sure to apply just enough seal tape to fill up thread
clearances. Do not overwrap. External Thread
Clearance
• Application Procedure
W105-01-01-019
Confirm that the thread surface is clean and, free of Leave one to two pitch threads uncovered
dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs de-

pending on the type of clamp.
T-Bolt Type Band Clamp: M114-07-041
4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft )
Worm Gear Type Band Clamp:
T-Bolt Type Worm Gear Type
5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)
M114-07-043 M114-07-042
W1-2-8
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation of
fitting, possibly resulting in a fire on the ma-
chine.
Do not install hoses kinked. Application of W105-01-01-011

high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose rup-
ture or separation of fitting. Utilize Print WRONG RIGHT
marks on hoses when installing to prevent Rubbing Against
hose from being kinked. Each Other
If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other. W105-01-01-012
WRONG RIGHT
Take care so that hoses do not come into
contact with moving parts or sharp objects. Clamp Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-9
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic
inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deteriora-
tion, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regardless
of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace if
necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, if necessary.
Ȁ
Consult your authorized dealer for correct replace-
ment.
Ȁ
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years or Every 6000 hours
Fuel hose (Fuel tank to injection pump) Every 2 years or Every 6000 hours
Engine
Oil filter hose (Engine to oil filter) Every 2 years or Every 6000 hours
Heater hose (Heater to engine) Every 2 years or Every 6000 hours
Pump suction hose Every 2 years or Every 6000 hours
Basic Machine Pump delivery hose Every 2 years or Every 6000 hours
Swing hose Every 2 years or Every 6000 hours
Hydraulic
Travel hose Every 2 years or Every 6000 hours
System
Boom cylinder line hose Every 2 years or Every 6000 hours
Front-End Arm cylinder line hose Every 2 years or Every 6000 hours
Attachment Bucket cylinder line hose Every 2 years or Every 6000 hours
Pilot hose Every 2 years or Every 6000 hours
NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.
W1-2-10
GENERAL / Painting
PAINTING
Surfaces to Be Painted Painting Colour

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

• Inside and outside surface of cab High-grade beige
[KASAI PAINT LF-113-230B
• Right window beam, U bolt
(Charcoal series black, semi glossy)]
• Suspension lifter (chair bottom) [N2.0 (Black) ]
• Lever (Travel, lock, foot rest) [N2.0 (Black) ]
• Engine cover High-grade beige
• Ladder rail on right side of upperstructure High-grade beige
• Mirror stay High-grade beige
• Antislip cover KASAI PAINT Amilack 1400 Deep Black.
Inside and Outside Surface of Cab
Engine Cover Right Window Engine Cover

Beam
Right Ladder
Rail
Mirror Stay
900 720
350
Bed Cover W178-01-03-001
Main Surface of Tool Box Cover Main Surface of
Upperstructure Upperstructure
W178-01-03-002
W1-3-1
GENERAL / Painting
A
YR-01
(TAXI Yellow) Out Surface of Hinge Swing
Portion YR-01 (TAXI Yellow)
185
Door Catch Cover YR-01

(TAXI Yellow)
720
W178-01-03-003
5
Section A Section B
Mask Garnished Portion
Door
YR-01(TAXI Yellow) Panel Behind the
Door
10
Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)
Antislip Cover
W178-01-03-004
KASAI PAINT
Amilack 1400
Deep Black
Front Attachment YR-
01 (TAXI Yellow)
W178-01-03-007 Upper Side

of Frame
W178-01-03-006
IMPORTANT: When cleaning arm, cylinder, etc.

fitted with HN bushing, take care not Track (Undercarriage)
to pour washing liquid directly on N1.0 (Black)
them. The ambient temperature
should not exceed 70 °C when paint-
ing and drying.
W178-01-03-008
W1-3-2
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
SECTION 2
UPPERSTRUCTURE
 CONTENTS 
Group 1 Cab Group 6 Swing Device
Remove and Install Cab .............................. W2-1-1 Remove and Install Swing Device................W2-6-1
Dimensions of the Cab Glass ...................... W2-1-7 Disassemble Swing Reduction Gear............W2-6-4
Assemble Swing Reduction Gear ..............W2-6-10
Group 2 Counterweight Disassemble Swing Motor .........................W2-6-18
Remove and Install Counterweight.............. W2-2-1 Assemble Swing Motor ..............................W2-6-22
Maintenance Standard ...............................W2-6-26
Group 3 Main Frame
Remove and Install Main Frame.................. W2-3-1 Group 7 Pilot Valve
Remove and Install Right Pilot Valve ...........W2-7-1
Group 4 Pump Device Remove and Install Left Pilot Valve..............W2-7-5
Remove and Install Pump Device ............... W2-4-1 Remove and Install Travel
Disassemble Pump Device.......................... W2-4-4 Pilot Valve...................................................W2-7-9
Assemble Pump Device ............................ W2-4-10 Disassembe Right and Left
Disassemble Regulator Cover ................... W2-4-18 Pilot Valves ...............................................W2-7-12
Assemble Regulator Cover........................ W2-4-22 Assemble Right and Left
Disassemble and Assemble Pilot Valves ...............................................W2-7-16
Control Housing ....................................... W2-4-24 Disassemble Travel Pilot Valve ..................W2-7-20
Disassemble and Assemble Cover............ W2-4-26 Assemble Travel Pilot Valve.......................W2-7-24
Disassemble and Assemble Gear Pump... W2-4-28
Group 8 Pilot Shut-Off Valve
Group 5 Control Valve Remove and Install Pilot Shut-Off
Remove and Install Control Valve................ W2-5-1 Valve...........................................................W2-8-1
Disassemble 4-Spool Control Valve ............ W2-5-4 Disassemble Pilot Shut-Off Valve ................W2-8-4
Disassemble 5-Spool Control Valve .......... W2-5-10 Assemble Pilot Shut-Off Valve .....................W2-8-6
Separate and Combine
4-Spool and 5-Spool Control Valve .......... W2-5-16
Assemble 4-Spool Control Valve ............... W2-5-18
Assemble 5-Spool Control Valve ............... W2-5-24
1F1W-2-1
Group 9 Signal Control Valve
Remove and Install Signal
Control Valve.............................................. W2-9-1
Group 10 Solenoid Valve

Remove and Install Solenoid
Valve Unit ................................................. W2-10-1
Disassemble Proportional
Solenoid Valve ......................................... W2-10-4
Assemble Proportional
Solenoid Valve ......................................... W2-10-6
1F1W-2-2
UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB
Removal
1. Remove seat mounting nuts (2) (4 used) to re-
move seat (1).
: 17 mm
W178-02-01-001
2. Remove bolt (4) behind the cab to remove rear

box (3).
: 17 mm
4
5
3. Raise duct (5) to remove it.
4. Remove air filter (6), remove screw (7) with a W178-02-01-012
screwdriver, then remove duct (8) from the cab.

6
W178-02-01-013
W2-1-1
5. Disconnect cable connectors (10, 11, 12 and 13)
on the right side in the cab and ground (9) at the
rear side in the cab.
10
11
12
13
6. Remove washer vinyl hose (14) at the rear side in

the cab. W178-02-01-014
14
W178-02-01-015
16
7. Remove cap (15) from duct cover (17) with a
screwdriver. Remove screw (16) with a screw- 17
driver to remove duct cover (17).
15
W178-02-01-016
8. Remove screw (18) and bolt (21) to remove duct

(19) and duct (20).
: 17 mm 18
Mating Surface
19
W178-02-01-017
20 21
W2-1-2
CAUTION: Cab weight: 290 kg (640 Ib)
9. Attach lifting straps (22) on the cab upper side.
22
W178-02-01-018
10. Remove cab mounting bolts (23) and nut (24)

from the frame.
: 17 mm 23
: 24 mm
: 8 mm
24
W157-02-01-010
11. Hoist the cab carefully and remove from the

frame.
W157-02-01-001
W2-1-3
Installation
CAUTION: Cab weight: 290 kg (640 Ib)
1. Attach the cab with lifting straps to hoist it by

crane.
W157-02-01-001
2. Install cab mounting bolts (23) and nuts (24). 23

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 24 mm
: 205 N⋅m (21 kgf⋅m, 152 Ibf⋅ft)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
24
W157-02-01-010
3. Install duct (8) to the rear console of the cab with 7

screws (7). Install filter (6) into duct (8).
: 4.9 N]m (0.5 kgf]m, 3.6 Ibf⋅ft)

8
W178-02-01-013
4. Connect harness connectors (10, 11, 12 and 13)

at the right side in the cab. Connect ground con-
nector (9) at rear side in the cab.
: 17 mm 9
: 50 N]m (5.1 kgf]m, 37 Ibf⋅ft)
10
11
12
13
W178-02-01-014
W2-1-4
5. Connect washer vinyl hose (14) at the rear of the
cab inside.
14
W178-02-01-015
6. Aligning the mounting hole for duct (5), while
pressing it to install the hose into the hole.
4
5
7. Install rear box (3) with bolt (4).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
W178-02-01-012
8. Install duct (20) with bolt (21). Install duct (19) into
duct (20) and fix them with bolt (18).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
18
Mating Surface
19
W178-02-01-017
20 21
W2-1-5
9. Install duct cover (17) with screws (16). Install
caps (15) onto duct cover (17). 16
17
15
W178-02-01-016
10. Install seat (1) with nuts (2).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
W178-02-01-001
W2-1-6
DIMENSIONS OF THE CAB GLASS
Chamfer
A
Unit: mm Here
R2
67 303.5 Chamfer along the
11 Periphery unless
Otherwise Specified
R98 R35
4-φ13 0 -1
R3018
Section A W178-02-01-019
405 30 Chamfer Both
Sides
375
238 51 612
R118
(5 mm)
343.5 148.5
196
100
50
R70
370.5
W178-02-01-006
B
Along the Along the W178-02-01-002
Periphery Periphery
c1 c1
14
733
R58
R58
R11508
Section B W178-02-01-019
R1808
882.5 997
(4 mm)
R308 R1898
R258
100
150
943
W178-02-01-007
W2-1-7
Unit: mm
Chamfer Here
Chamfer Here
85.4
Chamfer Slightly
343.3 213 unless the periphery
Polish Chamfered
R105
R72 R10
R105
(4 mm)
Chamfer Slightly unless the
Periphery Polish Chamfered 39.5 D
733
733
C R2465 2-φ12.2 +0.5 -0
(4 mm) Section C and D 6.754°

40
W178-02-01-019
Polish Chamfer
Both Sides
289.5
3-R4 50
2-R4
86.9 50 50
556.3
W178-02-01-011 50
423
W178-02-01-008
366.1 104.5
R12 R95
(5 mm) Chamfer along

982.7 the Periphery
W178-02-01-004
R2002
872
R123
R5 for 3 Places 38.2

R14
364.7 51
R2475 470.6
Chamfer along W178-02-01-009
(5 mm)
the Periphery
R115
888.58
W178-02-01-010
W2-1-8
Left-Hand Cab Glass
Installation of Left-hand Cab Glass, Lower Glass
of the Door and Upper Front Glass
A
1. Install the seal rubber on the left-hand cab glass
and lower glass of the door. CSE Braid
Section A
Seal Rubber
Put Connect End in Center

of Glass Edge and Then
Stick It Down.
W178-02-01-021
Lower Glass of Door

50
5
W178-02-01-023
A
CSE Braid
Seal Rubber
10 10
IMPORTANT: Be sure to install the cab glass and

mounting rubber using the special W178-02-01-020
bonding agent. The cab glass may Mounting Rubber Section

fall if the special bonding agent is
not used. The cab glass assembly
cannot be replaced individually. Be
Mounting Rubber Glass
sure to change the cab glass as an
assembly.
The upper front glass is arched-
fringed. If this glass needs to be re-
placed, replaced it as an assembly.
2. When the mounting rubber is already on the glass,
Cab
pull and fasten the mounting rubber onto the
mounting face of cab. Seal Rubber
W178-02-01-022
W178-02-01-004
W2-1-9
Installation of Right-hand Cab Glass Mounting Rubber Section
1. Install the mounting rubber into the surrounding of Glass

Mounting Rubber
cab glass. Bond the connectors of mounting rub-
ber with the bonding agent (Cemedine 366 Stan-
dard or equivalent).
NOTE: Rubber aging will cause the contraction of
Cab
rubber, be sure to leave a little extra, install
by pressing with hands.
2. Put and fasten the mounting rubber on the mount- W216-02-01-005
ing face of cab after installing rubber.
W178-02-01-002
Installation of Rear Cab Glass
1. Insert mounting rubber around the cab glass. In- Mounting Rubber Section
stall the connectors or mounting rubber with the
bonding agent (Cemedine 366 Standard or Glass
Mounting
equivalent). Rubber
NOTE: Rubber aging will cause the contraction of
rubber, be sure to leave a little extra, install Stopper
by pressing with hands.
2. After installing the glass assembly on the cab, in-

sert the stopper into rubber. Cab
IMPORTANT: The rear side glass is arched-fringed. W216-02-01-003
If this glass needs to be replaced,

contact with the nearest HITACHI
Office to replace it as an assembly.
W178-02-01-005
W2-1-10
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTER-
WEIGHT
1
Removal
CAUTION: Counterweight weight:
3000 kg (6610 lb)
1. Remove caps (1) from upper counterweight. In-

stall sling bolts to the counterweight.
NOTE: Sling bolt specification:
(B-36: M36, Pitch 4.0)
W178-02-02-001
2. Attach wire ropes to sling bolts. Hoist and take out Wire Rope
the slack of wire ropes by crane.
Sling Bolt
3. Remove mounting bolt (2) from the counterweight.

Hoist and remove the counterweight by crane.
W178-02-02-002
: 41 mm
W178-02-02-003
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation
3000 kg (6610 lb)
1. Lift counterweight (3) and install it onto the frame

by crane.
Install washer (4) and tighten mounting bolts (2) to
counterweight temporarily. 3
: 41 mm 2
4
2. Remove wire ropes. Tighten the counterweight W178-02-02-003

mounting bolts with a power wrench and torque
wrench.
: 41 mm
: 1150 N⋅m (117 kgf⋅m, 850 Ibf⋅ft)
3. Remove the sling bolts. Install caps (1) to the

counterweight.
Torque Wrench
Power Wrench W178-02-02-004
W178-02-02-001
W2-2-2
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME
CAUTION: Escaping fluid under pressure

can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before
Hydraulic oil may be hot just after operation,
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
work.
The hydraulic oil tank cap may fly off if re-
moved without releasing internal pressure
first. Push the air release valve on top of the
hydraulic oil tank to release any remaining
pressure.
Preparation
1. Place the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on top

of the hydraulic oil tank to release any remaining
pressure.
Ȁ
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau-
lic oil tank.
Be sure to run the vacuum pump continuously
while working. M104-07-021
W2-3-1
Removal
CAUTION: Cab weight:
290 kg (640 Ib)
1. Remove the cab (Refer to “Remove Cab” in this

section).
: 24mm, 17 mm, 13 mm
: 8 mm
W157-02-01-001
3000 kg (6610 lb)
2. Remove the counterweight.

(Refer to “Remove Counterweight” in this section.)
: 41 mm
W178-02-02-002
W2-3-2
CAUTION: Front attachment assembly

weight: 2700 kg (5950 lb)
3. Remove the front attachment assembly.

(Refer to “Remove Front Attachment” in this sec-
tion.)
: 17 mm, 24 mm, 27 mm, 36 mm
4. Remove all hoses from upper side of center joint.

Then remove the stopper. W105-02-03-002
: 17 mm, 19 mm , 22 mm, 27 mm, 36 mm
CAUTION: Upperstructure weight:

3300 kg (7280 lb)
5. Attach wire ropes to the rear (counterweight W173-03-03-001
bracket) of frame and boom bracket. Pull wire

ropes taut.
If chain block (1) is used, it is not only easy to ad-
just the length of wire rope, but also easy to level
the frame.
IMPORTANT: Be sure not to damage the engine by Rear

the attached wire ropes at rear side
of frame. W105-02-03-004
Front
W105-02-03-005
W157-02-03-001
W2-3-3
6. Put matching marks on the upperstructure and outer
race of the swing bearing.
Loosen and remove mounting bolt (2) of the swing
bearing.
: 30 mm
NOTE: The mounting angle of swing bearing is

specified. (Refer to W3-1)
W105-02-03-007
7. Chain block (1) shall be used to adjust and level

the frame, then lift it slightly to remove it from the
1
undercarriage by crane.
W157-02-03-002
W2-3-4
Installation
CAUTION: Upperstructure weight:
3300 kg (7280 lb)
1
1. Attach wire ropes to the main frame. Level the
main frame by chain block (1).
Lift it by crane to install it to the undercarriage.
As for lifting method, refer to “Removal” section.
2. Align the matching mark on the swing bearing with

that on the upperstructure.
Install mounting bolts (2) to the swing bearing and
tighten them temporarily. Remove wire ropes and
tighten the mounting bolts to the swing bearing to
specification. W157-02-03-002
: 30 mm
: Swing device section:
510 N⋅m (52 kgf⋅m, 380 Ibf⋅ft)
Track section:
490 N⋅m (50 kgf⋅m, 360 Ibf⋅ft)
3. Install all hoses to the center joint.

: 17 mm
: 25 N⋅m (2.6 kgf⋅m, 18.5 Ibf⋅ft)
: 19 mm
: 30 N⋅m (3 kgf⋅m, 22 Ibf⋅ft) 2
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)
: 36 mm W105-02-03-007
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft) 3

4
4. Install stopper (4) to the center joint with bolt (3).
: 22 mm
: 140 N⋅m (14 kgf⋅m, 103 Ibf⋅ft)
W173-03-03-001
W2-3-5
CAUTION: Cab weight:

290 kg (640 Ib)
5. Install cab (5).

(Refer to “Remove and Install Cab” in this sec- 5
tion.)
: 24 mm
: 205 N⋅m (21 kgf⋅m, 151 Ibf⋅ft)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
W157-02-01-001

3000 kg (6610 lb)
6. Install counterweight (6).

(Refer to “Counterweight” in this section.)
: 41 mm
: 1150 N⋅m (117 kgf⋅m, 850 Ibf⋅ft)
W178-02-02-002
CAUTION: Front attachment assembly

7. Install front attachment assembly (7) and fill hy-
draulic oil.
(Refer to “Remove and Install Front Attachment”
in this section.)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft)
: 27 mm 7
: 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) W105-02-03-002
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft)
8. Start the engine and set the front attachment in

posture for checking hydraulic oil level in its tank.
Inspect the hydraulic oil level and check if for any
oil leaks.
M104-07-021
W2-3-6
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE

Avoid the hazard by relieving pressure before
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
work.
pressure.
Preparation

pressure.
Ȁ
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau-
lic oil tank.
M104-07-021
NOTE: Be sure to run the vacuum pump continu-

ously while working.
W2-4-1
Removal
1. Remove bolts (1) (4 used) to remove cover (2).
: 17 mm
2. Remove bolts (3) (4 used) to remove cover (10).

Remove bolts (4) (4 used) to remove bracket (9).
Remove bolts (5) (6 used) to remove cover (6).
Remove bolts (8) (4 used)to remove cover (7).
: 17 mm 2
3. Disconnect the connectors from the pump device.

1
4. Disconnect all hoses (11 to 16, 18 and 19) and
pipe (17) from the pump device, then cap the re-
moved hoses. Attach identification tags to the W1F1-02-04-001
hoses to aid in reassembly. 3
: 19 mm, 27 mm
: 8 mm, 14 mm
4
10
CAUTION: Pump device weight:
82 kg (180 lb) 9
5. Install eyebolt (M12, pitch 1.25, length 21 mm) 5
(ST 0024) to the pump device. Lift and hold it by 8
crane. 6
7
6. Remove bolts (20) (8 used) to lift and remove the
pump device by crane.
: 17 mm 11 12 13
W1F1-02-04-002
14
15
16
19
18
M1F1-00-001
17
20
Eyebolt
Mounting
Position
W1F1-02-04-003
W2-4-2
Installation
20
CAUTION: Pump device weight:
82 kg (180 lb) Eyebolt
1. Lift the pump device by crane. Insert the drive Mounting
shaft of the pump device into the coupling at the Position
engine side, then install them onto the engine fly-
wheel housing with bolts (20) (8 used). Coupling
: 17 mm
: 50 N⋅m(5.1 kgf⋅m, 37 lbf⋅ft)
W1F1-02-04-003
2. Connect all hoses, pipes and connectors onto the 11 12 13
pump device.
14
: 19 mm (Hose 12, 13 and 14)
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 27 mm (Hose 11)
: 93 N⋅m(9.5 kgf⋅m, 69 lbf⋅ft) 15
: 8 mm (Hose 15, 16, 18 and 19)
: 50 N⋅m(5.1 kgf⋅m, 37 lbf⋅ft)
: 14 mm (Pipe 17) 16
: 210 N⋅m(21.5 kgf⋅m, 155 lbf⋅ft)
19
IMPORTANT: Bleed air from the pump. (Refer to
W1-1-2) 18
When the installation is completed,
check the oil level. Start the engine
M1F1-00-001
and check for any oil leaks. 17
3. Install top covers (6) and (7) of the pump device
with bolts (5) (6 used) and (8) (4 used). 3
Install bracket (9) with bolts (4) (4 used). Install
cover (10) with bolts (3) (4 used). 4
: 17 mm 10
: 50 N⋅m(5.1kgf⋅m, 37 lbf⋅ft)
9
4. Install top cover (2) of the engine with bolts (1) (4 5

used). 8
6
: 17 mm
: 50 N⋅m(5.1kgf⋅m, 37 lbf⋅ft) 7
W1F1-02-04-002
W1F1-02-04-001
W2-4-3
DISASSEMBLE PUMP DEVICE
1
2
3
17
4
6
7
8
15я
я 16 9
11
14
13
W1F1-02-04-011
12
1 - Socket Bolt (6 Used) 5 - Socket bolt (6 Used) 9 - Pump Housing 14 - Socket Bolt (4 Used)
2 - Eyebolt Mounting Position 6 - Socket Bolt 11 - Socket Bolt (12 Used) 15 - Cover
(M12)
3 - Cover 7 - Control Housing 12 - Regulator Cover 16 - O-Ring
4 - N Sensor 8 - Air Bleeding valve 13 - Drain Plug 17 - Plug
W2-4-4
18 19 20 21 22
23
9
24
39я
я 40
25
38 26я
я 27
37
36
35
34
33
28я
я 29
32 31 30
W1F1-02-04-012
9- Pump Housing 23 - Shaft 29 - Valve Plate 35 - Rotary Group (Drive Side)

18 - O-Ring 24 - Lock Bolt 30 - Cup Spring (2 Used) 36 - Shim
19 - Roller Bearing 25 - Piston (7 Used) 31 - Spring Collar (14 Used) 37 - Retaining Ring
20 - Gear 26 - Cylinder Block 32 - Center Pin 38 - Oil Seal
21 - Key 27 - Cylinder Block 33 - Rotary Group (Idle Side) 39 - Gear Pump
22 - Roller Bearing 28 - Valve Plate 34 - Plug 40 - Socket Bolt (2 Used)
W2-4-5
1
2
17 3
6
7
8
15я
я 16
9
11
14
13
W1F1-02-04-011
12
26я
я 27
28я
я 29
W1F1-02-04-013
W2-4-6
Disassemble Pump Device
• Be sure to thoroughly read “Precautions for Dis-
assembling and Assembling” on page W1-1-1 be-
fore starting the disassembly work.
CAUTION: Pump Device weight:

82 kg (180 lb)
1. Remove plug (13) from pump housing (9) to drain
gear oil.
2. Put the pump device on a wooden blocks (50×500

mm square) with the drive shaft side facing
downward.
NOTE: Workbench: ST 5092
Plate: ST 5083
3. Remove socket bolts (1) (6 used) to remove cover

(3) from control housing (7).
: 5 mm
CAUTION: When removing control housing

(7) from regulator cover (12), take care as the
spring and spring collar may fly out.
4. Remove socket bolts (5) (6 used) to remove con-
trol housing (7) from regulator cover (12).
: 5 mm
CAUTION: When removing regulator cover

(12) from pump housing (9), take care not to
drop valve plates (28) and (29).
5. Remove socket bolts (11) (12 used) to remove
regulator cover (12) from pump housing (9).
: 8 mm
IMPORTANT: As the right and left sides of valve

plate are different, put the mating
marks on them to aid in reassembly.
6. Remove valve plates (28) and (29) from cylinder
blocks (26) and (27).
7. Remove socket bolt (6) to remove N sensor (4).

: 5 mm

cover (15) and O-ring (16) from pump housing (9).
: 10 mm
9. Remove plug (17) from pump housing (9).

: 6 mm
W2-4-7
18 19 20 21 22
23
9
24
39я
я 40
25
38 26я
я 27
37
36
35
34
33
28я
я 29
32 31 30
W1F1-02-04-012
W2-4-8
IMPORTANT: ]As the right and left sides of cylin- 18. Remove roller bearing (19), key (21) and shaft
der blocks (26) and (27) are differ- (23) from pump housing (9) with special tools.
ent, put the mating marks on them
to aid in reassembly. ST7303
]When removing cylinder blocks
(26) and (27) from pump housing (9),
take care not to drop cup springs
(30) (2 used) and spring collars (31)
(14 used). ST7302
10. Remove cylinder blocks (26) and (27) from pump
housing (9).
11. Remove lock bolt (24) from pump housing (9). ST7301
: 6 mm
12. Place pump housing (9) horizontally. Remove re-

taining ring (37) and shim (36) from pump housing
(9).
13. Drive rotary group (35) shaft end to remove it from

pump housing (9)with a bar and plastic hammer.
14. Remove plug (34) from pump housing (9). Insert a W1F1-02-04-004
bar (8×200 mm) into the plug hole. Tap rotary
group (33) to remove it from pump housing (9) 19. Remove gear (20) and roller bearing (22) from
with a plastic hammer. pump housing (9).
: 6 mm NOTE: When removing gear (20), put the mating
marks to aid in reassembly.
15. Remove oil seal (38) from pump housing (9).
CAUTION: Pump housing weight:

27 kg (60 lb)
16. Place pump housing (9) with the regulator cover
side facing down.

gear pump (39) from pump housing (9).
: 8 mm
W2-4-9
ASSEMBLE PUMP DEVICE
1
2
17 3
6
7
8
15я
я 16
9
11
14
13
W1F1-02-04-011
12
1 - Socket Bolt (6 Used) 5 - Socket bolt (6 Used) 9 - Pump Housing 14 - Socket Bolt (4 Used)
2 - Eyebolt Mounting Position 6 - Socket Bolt 11 - Socket Bolt (12 Used) 15 - Cover
(M12)
3 - Cover 7 - Control Housing 12 - Regulator Cover 16 - O-Ring
4 - N Sensor 8 - Air Bleeding Balve 13 - Drain Plug 17 - Plug
W2-4-10
18 19 20 21 22
23
9
24
39я
я 40
25
38 26я
я 27
37
36
35
34
33
28я
я 29
32 31 30
W1F1-02-04-012
9- Pump Housing 23 - Shaft 29 - Valve Plate 35 - Rotary Group (Drive Side)

18 - O-Ring 24 - Lock Bolt 30 - Cup Spring (2 Used) 36 - Shim
19 - Roller Bearing 25 - Piston (7 Used) 31 - Spring Collar (14 Used) 37 - Retaining Ring
20 - Gear 26 - Cylinder Block 32 - Center Pin 38 - Oil Seal
21 - Key 27 - Cylinder Block 33 - Rotary Group (Idle Side) 39 - Gear Pump
22 - Roller Bearing 28 - Valve Plate 34 - Plug 40 - Socket Bolt (2 Used)
W2-4-11
18 19 20 21 22
23
9
24
39я
я 40
25
38 26я
я 27
37
36
35
34
33
28я
я 29
32 31 30
W1F1-02-04-012
W2-4-12
Assemble Pump Device IMPORTANT: When installing the rotary group, be
sure to align the matching marks on
the top of gears.
CAUTION: Pump housing (10) weight: Matching Mark
25 kg (55 lb)
1. Place pump housing (9) with the regulator cover
facing downward.
35
2. Install roller bearing (22) into pump housing (9).
33
3. Install key (21) into shaft (23).
4. Install gear (20) and shaft (23) into pump housing

(9).
5. Install roller bearing (19) into pump housing (9).

W1F1-02-04-005
6. Install O-ring (18) into gear pump (39). Install it
into pump housing (9) with socket bolts (40) (2 10. Insert rotary group (idle side) (33) into pump hous-
used). ing (9).
: 8 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 11. Align rotary group (33) gear with rotary group (35)
gear by aligning the matching marks put during
7. Place pump housing (9) on a wooden block disassembly.
(50×500 mm square) with the drive shaft facing
dounward. 12. Insert rotary group (35) into pump housing (9) with
NOTE: Workbench: ST 5092 their matching marks aligned.
Plate: ST 5083
8. Heat rotary groups (33) and (35) mounting posi- CAUTION: Pump housing (9) assembly
tion on pump housing (9) to 80 to 85°C. weight: 51 kg (112 lb)
13. Place the pump housing (9) assembly horizon-
9. Apply a film of hydraulic oil to rotary groups (33) tally. Install oil seal (38), shim (36) and retaining
and (35). Confirm the location of matching marks ring (37) into the rotary group (35) in pump hous-
on the rotary groups (33) and (35). ing (9).
14. Install plug (34) into pump housing (9).

: 6 mm
: 41 N⋅m (4.2 kgf⋅m, 30 lbf⋅ft))
W2-4-13
1
2
17 3
4
5
6
7
8
15я
я 16
9я
я 10
11
14
13
W1F1-02-04-011
12
18 19 20 21 22
23
9
24
39я
я 40
25
38
37 26я
я 27
36
35
34
33
28я
я 29
32 31 30
W1F1-02-04-012
W2-4-14
15. Place pump housing (9) on wooden blocks
(50×500 mm square) with the drive shaft facing
down.
NOTE: Workbench: ST 5092
Plate: ST 5083
16. Install O-ring (16) into cover (15).
17. Install cover (15) onto pump housing (9) with

socket bolts (14) (4 used).
: 10 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
18. Install plug (17) into pump housing (9).

: 6 mm
: 25 N⋅m (2.6 kgf⋅m, 18.5 lbf⋅ft)
19. Install N sensor (4) into pump housing (9) with

socket bolts (6).
: 5 mm
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
20. Install lock bolt (24) into pump housing (9).

: 6 mm
: 25 N⋅m (2.6 kgf⋅m, 18.5 lbf⋅ft)
IMPORTANT: The right and left of cylinder block

are different. Install them into the
former positions respectively.
21. Install cup springs (30) (2 used) and spring collars
(31) (14 used) into cylinder blocks (26) and (27).
22. Install piston (25) and center pin (32) into the cyl-
inder block (26) and (27) assemblies.
IMPORTANT: The right and left of valve plate are

different. Install them into the former
positions respectively.
23. Install valve plates (28) and (29) into the cylinder
block (26) and (27) assemblies respectively.
W2-4-15
1
2
6
7
11
Pressure Sensor
Mounting Hole
13
W1F1-02-04-011
12
W2-4-16
CAUTION: Pump housing (9) assembly

24. Install the regulator cover (12) assembly onto
pump housing (9) with socket bolts (11) (12 used).
: 8 mm
: 69 N⋅m (7 kgf⋅m, 51 lbf⋅ft)
25. Place the pump housing (9) assembly with the

drain plug (13) facing down. Secure it with a block
so as not tilt over.
26. Install the control housing (7) assembly onto regu-

lator cover (12)with socket bolts (5) (6 used).
: 5 mm
: 17.5 N⋅m (1.8 kgf⋅m, 13 lbf⋅ft)
27. Install cover (3) onto control housing (7) with

: 5 mm
: 17.5 N⋅m (1.8 kgf⋅m, 13 lbf⋅ft)
W2-4-17
DISASSEMBLE REGULATOR COVER
1
2
3
4
5
6
7
8
9
10
11
12
21 13
20
14
15
16
17 T1F1-03-01-001
18
19
1- Spring Collar (2 Used) 7- Spring Collar (2 Used) 12 - Piston 17 - Seal Lock Nut (2 Used)
2- Pressure Spring (2 Used) 8- Control Piston (2 Used) 13 - Square Ring (4 Used) 18 - Set Screw (2 Used)
3- O-Ring (2 Used) 9- Regulator Cover 14 - Hexagon Screw (2 Used) 19 - Cover (2 Used)
4- O-Ring (2 Used) 10 - Swivel Pin 15 - O-Ring (2 Used) 20 - Gasket
5- Pressure Spring (2 Used) 11 - Set Screw 16 - Lock Nut (2 Used) 21 - Knock Pin (2 Used)
6- Spring Collar (2 Used)
W2-4-18
Disassemble regulator Cover
CAUTION: Take care not to burn yourself
when heating swivel pin (10) and around it
• The procedure below shows the disassembly on ro- with a burner.
tary group (idle side). Disassemble the rotary group 10. Heat swivel pin (10) mounting position with a
(drive side) in the same procedure. burner.
NOTE: The adhesive is applied to swivel pin (10)
1. Remove gasket (20) from regulator cover (9). and set screw (11). When heating them, set
Remove knock pins (21) (2 used). the burner temperature (around 120°C) to
soften the adhesive.
2. remove O-rings (3) and (4) from regulator cover
(9).
3. Remove spring collar (1) and pressure spring (2)

from regulator cover (9).
4. Remove pressure spring (5), spring collars (6)

and (7) from regulator cover (9).
NOTE: Spring collar (6) is removed with pressure
spring (5). Do not remove spring collar (6)
from pressure spring (5).
W1F1-02-04-007
5. Remove cover (19) from regulator cover (9).
IMPORTANT: Do not loosen set screw (18) and

seal lock nut (17). If loosened, the
set values will be changed.
6. Remove lock nut (16) assembly (O-ring (15), seal
lock nut (17) and set screw (18)) from regulator
cover (9).
: 24 mm
7. Remove hexagon screw (14) from control piston

(8).
: 17 mm
8. Pull out piston (12) from control piston (8).
9. Remove square rings (13) (2 used) from piston

(12).
W2-4-19
8
9
10
11
T1F1-03-01-001
W2-4-20
11. Pull out set screw (11) from control piston (8).
: 4 mm
W1F1-02-04-008
12. Remove swivel pin (10) from control piston (8)

while turning it with a wrench.
: 12 mm
W1F1-02-04-009
13. Pull out control piston (8) from regulator cover (9)
with it facing pressure spring (2) side.
W2-4-21
ASSEMBLE REGULATOR COVER
1
2
3
4
5
6
7
8
9
10
11
12
21 13
20
14
15
16
17 T1F1-03-01-001
18
19
1- Spring Collar (2 Used) 7- Spring Collar (2 Used) 12 - Piston 17 - Seal Lock Nut (2 Used)
2- Pressure Spring (2 Used) 8- Control Piston (2 Used) 13 - Square Ring (4 Used) 18 - Set Screw (2 Used)
3- O-Ring (2 Used) 9- Regulator Cover 14 - Hexagon Screw (2 Used) 19 - Cover (2 Used)
4- O-Ring (2 Used) 10 - Swivel Pin 15 - O-Ring (2 Used) 20 - Gasket
5- Pressure Spring (2 Used) 11 - Set Screw 16 - Lock Nut (2 Used) 21 - Knock Pin (2 Used)
6- Spring Collar (2 Used)
W2-4-22
Assemble Regulator Cover
• The procedure below shows the assembly on ro-
tary group (idle side). Assemble the rotary group
(drive side) in the same procedure.
1. Install knock pins (21) (2 used) into regulator

cover (9). Apply THREEBOND#1212 between
regulator cover (9) and gasket (20).
2. Apply hydraulic oil onto inner side of regulator

cover (9) to insert control piston (8).
IMPORTANT: Check if control piston (8) slides in

and out smoothly without any re-
striction before installing swivel pin
(10).
IMPORTANT: Align the taper hole on swivel pin
(10) outer surface with set screw (11)
side.
3. Apply LOCTITE #241 onto swivel pin (10) to insert

it into control piston (8).
4. Apply LOCTITE #241 onto set screw (11) to insert

it into control piston (8) and secure swivel pin (10).
: 4 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)
5. Install square rings (13) (2 used) into piston (12).
6. Install piston (12) into regulator cover (9) with

hexagon screw (14).
: 17 mm
: 87 N⋅m (8.9 kgf⋅m, 64 lbf⋅ft)
7. Install the lock nut (16) assemblies (15 to 18) into

regulator cover (9).
: 24 mm
: 180 N⋅m (18 kgf⋅m, 133 lbf⋅ft)
8. Install cover (19) onto set screw (18).
9. Install spring collar (7) onto control piston (8).
10. Install the pressure spring (5) assembly onto

spring collar (7).
11. Install pressure spring (2) and spring collar (1)

onto the pressure spring (5) assembly.
W2-4-23
DISASSEMBLE AND ASSEMBLE CON-
TROL HOUSING
A-A
3
4
5
6
7
8
9
W1F1-02-04-010
1 - O-Ring (2 Used) 4 - Cover (2 Used) 6 - Seal Lock Nut (2 Used) 8 - Plug

2 - Pressure Spring (2 Used) 5 - Set Screw (2 Used) 7 - Control Piston (2 Used) 9 - Control Housing
3 - Spring Bushing (2 Used)
W2-4-24
Disassemble and Assemble Control Housing
• The control housing is symmetrical. The procedure

below shows on one side.
IMPORTANT: Do not loosen set screw (5) and seal

lock nut (6). If loosened, the set val-
ues will be changed.
Disassemble
1. Remove O-ring (1) from control housing (9).
2. Pull out control piston (7), pressure spring (2) and

spring bushing (3) from control housing (9).
3. Remove plug (8) from control housing (9).

: 5 mm
Assemble
1. Install plug (8) into control housing (9).
: 5 mm
: 10 N⋅m (1 kgf⋅m, 7.4 lbf⋅ft)
2. Install spring bushing (3), pressure spring (2) and

control piston (7) into control housing (9).
3. Install O-ring (1) into control housing (9).
W2-4-25
DISASSEMBLE AND ASSEMBLE COVER
1
2
3
4
5
6
7
8
9
10
11 T1F1-03-01-002
12 13
1- Cap (2 Used) 5 - Spring Collar (2 Used) 8 - Cover 11 - Control Piston (2 Used)

2- Set Screw (2 Used) 6 - Pressure Spring (2 Used) 9 - spring Collar (2 Used) 12 - Pin (2 Used)
3- Seal Lock Nut (2 Used) 7 - O-Ring (2 Used) 10 - Control Bushing (2 Used) 13 - Knock Pin (2 Used)
4- Lock Bolt (2 Used)
W2-4-26
Disassemble and Assemble Cover
• The cover is symmetrical. The procedure below

shows on one side.
IMPORTANT: Do not loosen set screw (2) and seal

lock nut (3). If loosened, the set val-
ues will be changed.
Disassemble
1. Remove knock pins (13) (2 used) from cover (8).
2. Remove control piston (11) and pin (12) form con-

trol bushing (10).
3. Remove lock bolt (4) assembly (cap (1), set screw

(2), seal lock nut (3) and O-ring (7) form cover (8).
: 30 mm
4. Remove spring collar (5), pressure spring (6) and

spring collar (9) from cover (8).
5. Pull out control bushing (10) from cover (8).
Assemble
1. Install control bushing (10) into cover (8).
NOTE: Check if control bushing (10) slides in and
out smoothly without any restriction after
installing control bushing (10).
2. Install spring collar (9), pressure spring (6) and

spring collar (5) into cover (8).
3. Install lock bolt (4) assemblies (1 to 3, 7) into

cover (8).
: 30 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
4. Install knock pins (13) (2 used) into cover (8).
W2-4-27
DISASSEMBLE AND ASSEMBLE GEAR
PUMP
1
16
15
5
14
10
11
1
2 2
13
12 3
7
8
9
10
11
3
W165-02-04-004
1- O-Ring (2 Used) 5- Metal (2 Used) 9- Plate 13 - Case

2- O-Ring (2 Used) 6- Gear 10 - O-Ring (2 Used) 14 - Gear
3- O-Ring (2 Used) 7- Plate 11 - Guide (2 Used) 15 - Socket Bolt
4- Pin (2 Used) 8- Ring 12 - Socket Bolt (4 Used) 16 - Frame
W2-4-28
Disassemble and Assemble Gear Pump
Disassemble Assemble
1. Remove O-rings (1 to 3) from frame (16). 1. Install O-rings (10) (2 used) into guides (11) (2
used) and then insert guides (11) (2 used) into
2. Loosen and remove socket bolts (12) (4 used) case (13).
from case (13).
: 8 mm 2. Insert guide (11) into plate (9) hose, then install
plate (9) into case (13).
3. Remove frame (16) from case (13).
3. Install ring (8) into plate (7) and then install plate
4. Remove gears (6 and 14) from case (13). (7) into case (13).
5. Remove O-rings (1 to 3) from case (13). 4. Install O-rings (1 to 3) onto case (13).
6. Remove plates (7 and 9) and ring (8) from case 5. Install gears (6 and 14) into case (13) and then in-
(13). stall frame (16) onto case (13).
7. Remove O-rings (10) (2 used) and guides (11) (2 6. Install O-rings (1 to 3) onto frame (16).
used) from case (13).
7. Install frame (16) onto case (13) with socket bolts
(12) (4 used).
: 8 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
W2-4-29
(Blank)
W2-4-30
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE
CAUTION: Escaping fluid under pressure may

penetrate the skin, causing serious
injury. Avoid this hazard by relieving
pressure before disconnecting
hydraulic or other lines.
Hydraulic oil may be hot just after
operation and may spurt, possibly
causing severe burns. Be sure to
wait for oil to cool before starting
any repair work.
The hydraulic oil tank cap may fly off
if removed without releasing
accumulated pressure first. Push the
air release valve on top of the
hydraulic oil tank to release any
remaining pressure.
Preparation
2. Stop the engine. Push the air release valve on top of

the hydraulic oil tank to release any remaining pres-
sure. Refer to "bleed pressure from hydraulic circuit"
on page W4-2-13.
3. Remove hydraulic oil tank cap. Connect a vacuum M104-07-021
pump to maintain negative pressure in the hydraulic

oil tank.
NOTE: Be sure to run the vacuum pump continuously
while working on the hydraulic system.
W2-5-1
Removal
1. Open engine cover (1) and lock.

Remove bolts (3) (6 used) to remove cover (2) on 1 2
the top of control valve from the main frame. 3
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
IMPORTANT: Cap the ends of all disconnected

hoses and pipes, and attach labels or
tags, to aid when reassembling. W1F1-02-05-001
2. Disconnect all hoses and pipes from signal control
4
valve (4) (Refer to W2-9-1)
: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
3. Remove bolts (6) (3 used) to remove signal control 5

valve (4) with bracket (5) from control valve (7).
: 22 mm
: 140 N⋅m (14.3 kgf⋅m, 103 Ibf⋅ft)
7
6
IMPORTANT: Cap the ends of all disconnected
hoses and pipes, and attach labels or
tags, to aid when reassembling.
4. Disconnect all hoses, pipes and connectors from the
control valve.
: 17 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
: 36 mm W1F1-02-05-002
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft) Swing

: 6 mm Arm 1
Boom 2
: 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
Auxiliary
: 8 mm Arm 2
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) Boom 1
Bucket
Right Travel
Left Travel
Machine Forward
T176-03-03-038
W2-5-2
CAUTION: Control valve weight: 132 kg (291 lb)

7
5. Remove control valve mounting bolts (8) (4 used).
Install eyebolts (M14, pitch 2) (2 used) into bolt hole
(9) on the top of the control valve. Hoist and remove
it by crane.
: 22 mm
: 140 N⋅m (14.3 kgf⋅m, 103 Ibf⋅ft)
Installation
NOTE: Refer to "removal" section above for wrench
sizes and tightening torques.
CAUTION: Control valve weight: 132 kg (291 lb)
1. Hoist control valve (7) by crane.
Install it with bolts (8) (4 used). W187-02-05-003
8
2. Connect all hoses, pipes and connectors to the con- 9
trol valve.
3. Install signal control valve (4) with bracket (5) to con-

trol valve (7) with bolts (6) (3 used).
4. Connect all hoses and pipes to the signal control

valve. (Refer to W2-9-1)
5. Install cover (2) to the main frame with bolts (3) (6

used).
Unlock engine cover (1) and shut the engine cover.
IMPORTANT: After completing installation, check

hydraulic oil level. Add oil as neces-
sary. Run the engine. Check the com-
ponent for any oil leaks.
W1F1-02-05-003
W2-5-3
DISASSEMBLE 4-SPOOL CONTROL VALVE

41
X 1
2
42
3 29
23 43 47
4
5 30
44 48
6 24
7 31
8 45
25 49
9 Arm Re-
generative 32
10 Valve 26 50
Boom (Switch 46
Valve) 36 33
Anti-
Drift 11 19 27 51
Valve
12 20 34
13 21 28 53
14 37 52 54 Check Valve
15 35 55 (Main Relief
22 38 Circuit)
16 56
17 57
39
18
40
W
69
60 62
61 63
64
65 70
71 W
68
58
66
59
67
72
X W1F1-02-05-004
1- O-Ring 19 - Spring 37 - Poppet 55 - O-Ring
2- Screw 20 - Washer 38 - Spring 56 - Spring
3- Backup Ring 21 - O-Ring 39 - O-Ring 57 - Poppet
4- O-Ring 22 - Spool 40 - Plug 58 - Cap
5- O-Ring 23 - O-Ring 41 - O-Ring 59 - Nut
6- O-Ring 24 - Bolt 42 - Bolt 60 - Plug
7- Backup Ring 25 - Spring Seat 43 - Spring Seat 61 - O-Ring
8- Backup Ring 26 - Spring 44 - Spring 62 - Cap
9- O-Ring 27 - Spring Seat 45 - Spring Seat 63 - Retaining Ring
10 - Sleeve 28 - Main Spool 46 - Main Spool 64 - Shim
11 - Spool 29 - O-Ring 47 - O-Ring 65 - Nut
12 - Washer 30 - Screw 48 - Bolt 66 - Pilot housing
13 - Spring 31 - O-Ring 49 - Spring Seat 67 - Socket bolt
14 - Backup Ring 32 - Bolt 50 - Spring 68 - Overload Relief Valve
15 - O-Ring 33 - Spring Seat 51 - Spring Seat 69 - Overload Relief Valve
16 - Plug 34 - Spring 52 - Main Spool 70 - Backup Ring
17 - Spring 35 - Spring Seat 53 - Plug 71 - O-Ring
18 - Poppet 36 - Main Spool 54 - Backup Ring 72 - Housing
W2-5-4
Disassemble 4-Spool Control Valve Upper
Section
• Be sure to thoroughly read precautions for disas- IMPORTANT: Make alignment marks on main
sembly and assembly on page W1-1-1 before spools (28, 36, 46 and 52) and hous-
starting the disassembly work. ing (72) in order to avoid confusion
• Attach identification tags to the spool and mount- during reassembling.
ing positions in the housing in order to avoid mis- 8. Clamp main spools (28, 36, 46 and 52) in a vise
assembling. with padded wooden pieces, then remove bolts
(24, 32, 42 and 48), spring seats (25, 33, 43 and
1. Remove socket bolts (67) (11 used) from housing 49), springs (26, 34, 44 and 50) and spring seats
(72), and then remove pilot housing (66). (27, 35, 45 and 51).
: 8 mm : 17 mm
2. Remove boom anti-drift valve assembly (5 to 16), 9. Remove plug (40), O-ring (39), spring (38) and
O-ring (4) and backup ring (3) from pilot housing poppet (37) from spool (36).
(66). : 17 mm
NOTE: Pry the boom anti-drift valve assembly by
hand and remove it from pilot housing (66). 10. Remove spring (17) and poppet (18) from housing
(72).
3. Remove plug (16), O-ring (15), backup ring (14),
spring (13), washer (12) and spool (11) from 11. Remove spring (19), washer (20), O-ring (21) and
sleeve (10). spool (22) from housing (72).
4. Remove O-rings (5, 6, 9) and backup rings (7, 8) 12. Remove plug (53), backup ring (54), O-ring (55),
from sleeve (10). spring (56) and poppet (57) from housing (72).
: 14 mm
5. Remove cap (62), retaining ring (63), shim (64)
and nut (65) from pilot housing (66). IMPORTANT: Never turn the lock nut. If turned, the
Remove screw (30) from the pilot housing, then set pressure may be changed.
O-ring (29) from screw (30). 13. Turn the cartridges of overload relief valves (68,
: 17 mm 69). Remove overload relief valves (68, 69) from
: 4 mm housing (72).
: 27 mm
6. Remove cap (58) and nut (59) from pilot housing
(66).
Lock Nut
Remove screw (2) from pilot housing (66), then
O-ring (1) from screw (2). Cartridge
: 17 mm
: 4 mm
IMPORTANT: Remove main spool assemblies (28,

36, 46 and 52) while carefully moving W176-02-06-017
them. If they stick, even a little, try it 14. Remove backup ring (70) and O-ring (71) from
again instead of pulling roughly. housing (72).
7. Remove main spool assemblies (28, 36, 46 and
52) and O-rings (23, 31, 41 and 47) from housing
(72).
W2-5-5
72
Bypass Shut-Out Valve
79
78
77 83
76 82
81
Check Valve 80
75 87
Orifice (Arm 1 86
74 Parallel
Load Check 85
73 Circuit) 84
(Arm 2 98
Tandem 97
Circuit) 96
95
94
93 Bucket Flow
92 Rate Control
91 Valve (Poppet
90 Valve)
89
88 108
99 109
107
Bucket Flow Rate

Control Valve
(Switch Valve)
102
100 103
104
101 105
W176-02-05-012
106
72 - Housing 82 - Poppet 92 - O-Ring 101 -Socket Bolt

73 - Plug 83 - Bushing 93 - Spring 102 -Spool
74 - O-Ring 84 - O-Ring 94 - Plug 103 -Washer
75 - Plug 85 - Backup Ring 95 - O-Ring 104 -Spring
76 - O-Ring 86 - Spring 96 - Spring 105 -O-Ring
77 - Spring 87 - Poppet 97 - Poppet 106 -Plug
78 - Seat 88 - O-Ring 98 - Valve Seat 107 -O-Ring
79 - Spool 89 - Backup Ring 99 - Pilot Plate 108 -O-Ring
80 - Plug 90 - Bushing 100 -Socket Bolt 109 -Backup Ring
81 - Spring 91 - Backup Ring
W2-5-6
Disassemble 4-Spool Control Valve Side Section
15. Remove plug (106), then spring (104), washer
(103), spool (102) and O-ring (105).
: 36 mm
16. Loosen socket bolts (100) (7 used) and (101) (3

used). Remove pilot plate (99), O-ring (107, 108)
and backup ring (109).
17. Remove bushing (90) from pilot plate (99), then

O-rings (88, 92) backup ring (89, 91) and spring
(93) from bushing (90).
18. Remove plug (94) from housing (72).

Clamp the step portion of plug (94) with wooden
pieces and secure it in a vise. Then remove valve
seat (98), poppet (97), spring (96) and O-ring (95)
from plug (94).
19. Remove O-ring (84), backup ring (85), spring (86)

and poppet (87) from housing (72). (2 places).
20. Remove plug (80), spring (81), poppet (82) and

bushing (83) from housing (72).
21. Remove plug (75), O-ring (76), spring (77), seat

(78) and spool (79) from housing (72).
W2-5-7
72
115
110 119
116
111 117
112 118
113 Check Valve
(Flow 120
Combiner
114 Circuit)
Auxiliary
Flow Rate
Control
Valve
121
122
W1F1-02-05-005
72- Housing 113 -Backup Ring 117 -O-Ring 120 -O-Ring

110 -Poppet 114 -Plug 118 -Plug 121 -Pilot Housing
111 -Spring 115 -Poppet 119 -Overload Relief Valve 122 -Socket Bolt
112 -O-Ring 116 -Spring
W2-5-8
Disassemble 4-Spool Control Valve Lower
Section
IMPORTANT: Never turn the lock nut.
If turned, the set pressure may be
changed.
22. Turn the cartridge of overload relief valve (119)
and remove it from housing (72).
: 27 mm
Lock Nut
Cartridge
W176-02-06-017
23. Remove socket bolts (122) (5 used) from housing

(72), then remove pilot housing (121) and O-ring
(120).
: 8 mm
Ȁ
24. Remove plug (118), O-ring (117), spring (116) and
poppet (115) from housing (72).
: 14 mm
25. Remove plug (114), backup ring (113), O-ring

(112), spring (111) and poppet (110) from housing
(72).
: 14 mm
W2-5-9
DISASSEMBLE 5-SPOOL CONTROL
VALVE 184
183
123 185
124
155
125
156
126 149
127 186
128 157
129 150
130 158
131 165
151
144 159
132 171
152
134 145 166
Arm Anti-Drift
135 133 146 177
Valve 153 160
136 167 172
137 147
143
141 173
138 168 178
148 154
139
169 174 179
140
161
142 175
162 180
163 170
181
164 176
182
187
W176-02-05-011
123 -Back Up Ring 140 -Poppet 157 -Spring Seat 174 -Spring
124 -O-Ring 141 -Backup Ring 158 -Spring 175 -Spring Seat
125 -Plug 142 -O-Ring 159 -Spring Seat 176 -Main Spool
126 -O-Ring 143 -Overload Relief Valve 160 -Main Spool 177 -O-Ring
127 -O-Ring 144 -Plug 161 -Poppet 178 -Bolt
128 -O-Ring 145 -O-Ring 162 -Spring 179 -Spring Seat
129 -Backup Ring 146 -Backup Ring 163 -O-Ring 180 -Spring
130 -Backup Ring 147 -O-Ring 164 -Plug 181 -Spring Seat
131 -O-Ring 148 -Main Relief Valve 165 -O-Ring 182 -Main Spool
132 -Sleeve 149 -O-Ring 166 -Bolt 183 -Socket Bolt
133 -Spool 150 -Bolt 167 -Spring Seat 184 -Plug
134 -Washer 151 -Spring Seat 168 -Spring 185 -O-Ring
135 -Spring 152 -Spring 169 -Spring Seat 186 -Pilot Housing
136 -Backup Ring 153 -Spring Seat 170 -Main Spool 187 -Housing
137 -O-Ring 154 -Main Spool 171 -O-Ring
138 -Plug 155 -O-Ring 172 -Bolt
139 -Spring 156 -Bolt 173 -Spring Seat
W2-5-10
Disassemble 5-Spool Control Valve Upper Sec-
tion
1. Remove socket bolts (183) (10 used) from hous-
ing (187) to remove pilot housing (186).
: 8 mm
2. Remove arm anti-drift valve assembly (125 to

138) and O-ring (124), backup ring (123) from pi-
lot housing (186).
NOTE: Pry out the arm anti-drift valve assembly by
hand while removing pilot housing (186).
3. Remove plug (138), O-ring (137), backup ring

(136), spring (135), washer (134) and spool (133)
from sleeve (132).
4. Remove plug (125), O-rings (126, 127, 128, 131)

and backup rings (129, 130) from sleeve (132).
5. Remove main spool assemblies (154, 160, 170,

176, 182) and O-rings (149, 155, 165, 171, 177)
from housing (187).
IMPORTANT: Make alignment marks on main

spools (154, 160, 170, 176, 182) and
housing (187) in order to avoid con-
fusion during reassembling.
6. Clamp main spools (154, 160, 170, 176, 182) in a

vise, then remove bolts (150, 156, 166, 172, 178),
spring seats (151, 157, 167, 173, 179), springs
(152, 158, 168, 174, 180), and spring seats (153,
159, 169, 175, 181).
: 17 mm
7. Remove plug (164), O-ring (163), spring (162)

and poppet (161) from main spool (160).
: 17 mm
8. Remove spring (139), poppet (140), backup ring

(141), and O-ring (142) from housing (187).
IMPORTANT: Never turn the lock nut. If turned, the

set pressure may be changed.
9. Turn the cartridges of overload relief valve (143)
and main relief valve (148) to remove them from
housing (187).
: 27 mm Lock Nut
Cartridge
W176-02-06-017
W2-5-11
Load Check
Load Check
Valve (Arm 1 213 Valve (Arm 2
Aux. Flow Rate 197 Parallel Circuit)
214 Parallel Circuit)
Control Valve
198 215
(Poppet Valve)
199 208
209 216
200
201 210
Load Check 202 211
191 Valve (Travel 203 212
Parallel Circuit) 193 204
192 194 205
195 206
196 207
188
189
190
187
223
224
222
225
Aux. Flow Rate 226
Control Valve
(Switch Valve) 221
220
219
218
W176-02-05-013
217
187 -Housing 197 -O-Ring 207 -Valve Seat 217 -Plug

188 -Socket Bolt 198 -Backup Ring 208 -O-Ring 218 -O-Ring
189 -Cover 199 -Bushing 209 -Backup Ring 219 -Spring
190 -O-Ring 200 -Backup Ring 210 -Plug 220 -Washer
191 -Socket Bolt 201 -O-Ring 211 -Spring 221 -Spool
192 -Pilot Plate 202 -Spring 212 -Poppet 222 -Socket Bolt
193 -O-Ring 203 -Plug 213 -O-Ring 223 -Socket Bolt
194 -Backup Ring 204 -O-Ring 214 -Backup Ring 224 -Pilot Plate
195 -Spring 205 -Spring 215 -Spring 225 -O-Ring
196 -Poppet 206 -Poppet 216 -Poppet 226 -O-Ring
W2-5-12
Disassemble 5-Spool Control Valve Side Section
10. Remove plug (217), then remove O-ring (218),
spring (219), washer (220) and spool (221).
: 36 mm
Ȁ
11. Remove socket bolts (222, 223), then remove pi-
lot plate (224), O-rings (225, 226).
: 6 mm, 8 mm
12. Remove bushing (199) from pilot plate (224), then

remove O-rings (197, 201), backup rings (198,
200) and spring (202) From bushing (199).
13. Remove plug (203) from pilot plate (224) mount-

ing surface of housing (187).
Clamp the stepped portion of plug (203) with
wood pieces in a vise, then remove valve seat
(207), poppet (206), spring (205) and O-ring
(204).
14. Remove O-ring (193), backup ring (194), spring

(195) and poppet (196) from the pilot plate (224)
mounting surface of housing (187).
Ȁ
mounting surface of housing (187). (3 places)

(187), then remove pilot plate (192).
: 6 mm
17. Remove O-ring (208), backup ring (209), plug

(210), spring (211) and poppet (212) from the pilot
plate (192) mounting surface of housing (187). (2
places)

mounting surface of housing (187).
W2-5-13
187
244
235 243 245
227 236 246
228 237
229 247
238
230
248
239
231 240
232 254
241
233
242
Flow
234 Combiner
Valve
Auxiliary Flow
Combiner 252
249
Valve
250 253
251
W1F1-02-05-006
187 -Housing 234 -Bolt 241 -Spring 248 -O-Ring

227 -Plug 235 -Plug 242 -Bolt 249 -Socket Bolt
228 -Spring 236 -Spring 243 -Overload Relief Valve 250 -O-Ring
229 -Poppet 237 -Poppet 244 -O-Ring 251 -Plug
230 -Spool 238 -Spool 245 -Backup Ring 252 -O-Ring
231 -O-Ring 239 -O-Ring 246 -O-Ring 253 -Plug
232 -Washer 240 -Washer 247 -Plug 254 -Pilot Housing
233 -Spring
W2-5-14
Disassemble 5-Spool Control Valve Lower
Section
IMPORTANT: Never turn the lock nut. If turned, the
set pressure may be changed.
19. Turn the cartridge of overload relief valve (243) to
remove it from housing (187).
: 27 mm
Lock Nut
Cartridge
W176-02-06-017

(187), then remove pilot housing (254) and O-ring
(248) (5 used).
: 8 mm
21. Remove O-rings (231, 239), flow combiner valve

assembly (235 to 242), and auxiliary flow com-
biner valve assembly (227 to 234) from housing
(187).
IMPORTANT: Do not remove plug (227), spring

(228), poppet (229) from spool (230).
When replacing these parts, replace
them as an assembly.
22. Clamp spool (230) with wood pieces in a vise,

then remove bolt (234), spring (233) and washer
(232).
: 17 mm
IMPORTANT: Do not remove plug (235), spring

(236), and poppet (237) from spool
(238). When replacing these parts,
replace them as an assembly.

then remove bolt (242), spring (241) and washer
(240).
: 17 mm
W2-5-15
SEPARATE AND COMBINE 4-SPOOL AND
5-SPOOL CONTROL VALVES
187
262
261
256
257
259
258
72 260
263
264
265
255 266 267
268
269
270
271
272
273 277
274 275 276
W176-02-05-015
72 - Housing 260 -O-Ring 266 -O-Ring 272 -O-Ring

187 -Housing 261 -O-Ring 267 -Backup Ring 273 -Backup Ring
256 -O-Ring 263 -O-Ring 269 -O-Ring 275 -Backup Ring
257 -O-Ring 264 -Backup Ring 270 -O-Ring 276 -O-Ring
258 -O-Ring 265 -O-Ring 271 -O-Ring 277 -Backup Ring
259 -Backup Ring
W2-5-16
Separate Combine
1. Install O-rings (256 to 258, 260, 261, 263, 265,
CAUTION: Housing (72) weight: 45 kg (99 Ib)
266, 268 to 272, 274, 276) and backup rings (259,
Housing (187) weight: 49 kg (108 Ib)
262, 264, 267, 273, 275, 277) into housing (187).
1. Remove socket bolts (255) (9 used), then sepa-
rate housing (72) and housing (187). CAUTION: Housing (72) weight: 45 kg (99 Ib)
: 12 mm Housing (187) weight: 49 kg (108 Ib)
2. Remove O-rings (256 to 258, 260, 261, 263, 265, 2. Connect housing (72) and housing (187) with
266, 268 to 272, 274, 276) and backup rings (259, socket bolt (255).
262, 264, 267, 273, 275, 277) from housing (187). : 12 mm
: 108 + 9.8 N⋅m (11+1 kgf⋅m, 80 + 7 lbf⋅ft)
W2-5-17
ASSEMBLE 4-SPOOL CONTROL VALVE Main Spool Main Spool
A (28, 46, 52) (36)
61 60 31 41 47 43, 25,49 33
23
19 44, 26, 50
34
20 42, 24, 48 32
21
45, 27, 51 35
53
22
54, 55
56
57
72
46, 28, 52 36
37
38
W176-02-05-020 39
Section A Boom 1
40
63, 64
62 Boom Anti-Drift Valve W176-02-05-024
65 5
66
29 10
6
30 11
58
59 7
1 8
2 14 9
12
Boom Anti- 13
Drift Valve 15
16
17
18
3 4 W176-02-05-022 W176-02-05-025
1- O-Ring 19 - Spring 37 - Poppet 55 - O-Ring

2- Screw 20 - Washer 38 - Spring 56 - Spring
3- Backup Ring 21 - O-Ring 39 - O-Ring 57 - Poppet
4- O-Ring 22 - Spool 40 - Plug 58 - Cap
5- O-Ring 23 - O-Ring 41 - O-Ring 59 - Nut
6- O-Ring 24 - Bolt 42 - Bolt 60 - Plug
7- Backup Ring 25 - Spring Seat 43 - Spring Seat 61 - O-Ring
8- Backup Ring 26 - Spring 44 - Spring 62 - Cap
9- O-Ring 27 - Spring Seat 45 - Spring Seat 63 - Retaining Ring
10 - Sleeve 28 - Main Spool 46 - Main Spool 64 - Shim
11 - Spool 29 - O-Ring 47 - O-Ring 65 - Nut
12 - Washer 30 - Screw 48 - Bolt 66 - Pilot Housing
13 - Spring 31 - O-Ring 49 - Spring Seat 67 - *Socket Bolt
14 - Backup Ring 32 - Bolt 50 - Spring 68 - *Overload Relief Valve
15 - O-Ring 33 - Spring Seat 51 - Spring Seat 69 - *Overload Relief Valve
16 - Plug 34 - Spring 52 - Main Spool 70 - *Backup Ring
17 - Spring 35 - Spring Seat 53 - Plug 71 - *O-Ring
18 - Poppet 36 - Main Spool 54 - Backup Ring 72 - Housing
NOTE: As for mark *, refer to W2-5-4.
W2-5-18
Assemble 4-Spool Control Valve Upper Section
1. Clamp main spool (36) with wood pieces in a vise, IMPORTANT: When replacing sleeve (10) or spool
then install poppet (37), spring (38), O-ring (39) (11), replace them together.
and plug (40). 6. Assemble O-ring (15), backup ring (14), spring
: 17 mm (13), washer (12), and spool (11) onto plug (16),
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) then install them onto sleeve (10).
NOTE: When assembling washer (12), the cham-
2. Install spring seats (27, 35, 45, 51), springs (26, fer side shall be facing to the spring side.
34, 44, 50), spring seats (25, 33, 43, 49) and bolts
(24, 32, 42, 48) onto spools (28, 36, 46, 52) re- 7. Install boom anti-drift valve assembly (5 to 16)
spectively. onto pilot housing (66).
: 17 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft) IMPORTANT: When replacing housing (72) or
poppet (18), tap poppet (18) with a
3. Install screw (30) and O-ring (29) onto pilot hous- steel bar.
ing (66), then install nut (65), shim (64), retaining 8. Install poppet (18) and spring (17) into housing
ring (63) and cap (62) into screw (30). (72).
: 4 mm
: 17 mm 9. Install spool (22), O-ring (21), washer (20) and
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) spring (19) into housing (72).
NOTE: When assembling washer (20), the cham-
4. Install screw (2) and O-ring (1) onto pilot housing
fer side shall be facing to the spring side.
(66), then install nut (59) and cap (58) onto screw
(2).
10. Install poppet (57), spring (56), O-ring (55),
: 4 mm
backup ring (54) and plug (53) into housing (72).
: 17 mm
: 14 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
: 120+20 N⋅m (12+2 kgf⋅m, 87+14.5 lbf⋅ft)
5. Install backup rings (7, 8) and O-rings (5, 6, 9)
11. Install main spool assemblies (28, 36, 46, 52), O-
onto sleeve (10).
rings (4, 23, 31, 41, 47, 71) and backup rings (3,
NOTE: Pay attention to the assembling location of 70) into housing (72) respectively.
backup rings (7, 8) and O-rings (6, 9).
9 8 7 6
W176-02-05-023
W2-5-19
A
B
66 C
Section B Arm 2 Arm 1
72 69
69 Load Check Valve

68 (Arm 2 Tandem Cir-
cuit) 86 87
99
D
67
101 72
100
T176-03-03-038
Section D 106 105 104 103 102
Bucket Flow Rate 80 81 82 83
Control Valve Check Valve Orifice
(Switch Valve) (Arm 1 Parallel Cir-
cuit)
T176-03-03-006
94
88
93
89 Section C Boom 1
90 95
Boom 2
91 96
92
97
98 Bucket Flow Rate
Control Valve
(Poppet Valve)
W176-02-05-026
Section A Swing
84, 85
86
75
87
74 Load Check Valve
73 (Boom 1 Parallel
Circuit)
T176-03-03-005
76 77 78 79
Bypass Shut-Out Valve T176-03-03-007
66 - Pilot Housing 79 - Spool 90 - Bushing 100 -Socket Bolt
67 - Socket Bolt 80 - Plug 91 - Backup Ring 101 -Socket Bolt
68 - Overload Relief Valve 81 - Spring 92 - O-Ring 102 -Spool
69 - Overload Relief Valve 82 - Poppet 93 - Spring 103 -Washer
72 - Housing 83 - Bushing 94 - Plug 104 -Spring
73 - Plug 84 - O-Ring 95 - O-Ring 105 -O-Ring
74 - O-Ring 85 - Backup Ring 96 - Spring 106 -Plug
75 - Plug 86 - Spring 97 - Poppet 107 -*O-Ring
76 - O-Ring 87 - Poppet 98 - Valve Seat 108 -*O-Ring
77 - Spring 88 - O-Ring 99 - Pilot Plate 109 -*Backup Ring
78 - Seat 89 - Backup Ring
W2-5-20
IMPORTANT: Never turn the lock nut of relief valve. 17. Install poppet (87), spring (86), O-ring (84) and
If turned, the set pressure may be backup ring (85) into housing (72). (2 places)
changed.
12. Install pilot housing (66) onto housing (72) with 18. Install bushing (83), poppet (82), spring (81) and
socket bolts (67) (11 used). Turn the cartridges of plug (80) into housing (72).
overload relief valves (68, 69) to install them into
housing (72). 19. Install O-rings (107, 108) and backup ring (109)
: 8 mm into housing (72). Install pilot plate (99) with
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) socket bolts (100) (7 used) and (101) (3 used).
: 27 mm : 6 mm
: 78+3 N⋅m (8+0.3 kgf⋅m, 58+2.2 Ibf⋅ft) : 25 N⋅m (2.5 kgf]m, 18 Ibf⋅ft)
: 8 mm
Lock Nut
: 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
Cartridge Ȁ
20. Tighten plug (106) which has been temporarily
tightend in step 13.
: 36 mm
: 200 N⋅m (20 kgf⋅m, 145 Ibf⋅ft)
W176-02-06-017
NOTE: Apply grease onto O-rings of overload relief 21. Install spool (79), seat (78), spring (77), O-ring
valves (68, 69). (In order to protect O-rings (76) and plug (75) into housing (72).
from breakage). : 27 mm
: 180+3 N⋅m (18+0.3 kgf⋅m, 130.2+2.2 Ibf⋅ft)
Assemble 4-Spool Valve Side Section NOTE: Install seat (78) with the chamfered side
13. Install spool (102), washer (103), spring (104) and facing the spring.
O-ring (105) onto pilot plate (99), then install plug
(106) (Temporarily tighten it).
: 36 mm
NOTE: Tighten plug (106), after installation of pilot
plate (99) to housing(72). Pay attention to
the plugs identification because plug (106)
and plug (217) have different length of
screw thread.
14. Install poppet (97), spring (96), O-ring (95) and

plug (94) onto valve seat (98).
15. Install O-rings (88, 92) and backup rings (89, 91)
onto bushing (90).
16. Install valve seat (98) assembly, spring (93) and

bushing (90) into housing (72).
W2-5-21
Section A
72
121
122
B 119 T176-03-03-036
W176-02-05-020
120 120 120 120
Section B
110
111
112ĉĉ113
115
Check
Valve 116
(Flow 117
Combiner
Circuit)
118 114
Aux. Flow Rate T176-03-03-002
Control Valve
72 - Housing 113 -Backup Ring 117 -O-Ring 120 -O-Ring
110 -Poppet 114 -Plug 118 -Plug 121 -Pilot Housing
111 -Spring 115 -Poppet 119 -Overload Relief Valve 122 -Socket Bolt
112 -O-Ring 116 -Spring
W2-5-22
Assemble 4-Spool Control Valve Lower Section
22. Install O-ring (120) onto housing (72), then install
pilot housing (121) with socket bolts (122) (5
used).
: 8 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
23. Install poppet (115), spring (116), O-ring (117) and

plug (118) into housing (72).
: 14 mm
: 120+20 N⋅m (12+2 kgf⋅m, 87+14.5 lbf⋅ft)

backup ring (113) and plug (114) into housing
(72).
: 14 mm
: 120+20 N⋅m (12+2 kgf⋅m, 87+14.5 lbf⋅ft)
IMPORTANT: Never turn the lock nut of relief valve.

changed.
install it into housing (72).
: 27 mm
: 78+3 N⋅m (8+0.3 kgf⋅m, 57.9+2.2 lbf⋅ft)
Lock Nut
Cartridge
W176-02-06-017
NOTE: Apply grease to O-ring of the overload relief

valve. (In order to protect O-ring from
breakage.)
W2-5-23
ASSEMBLE 5-SPOOL CONTROL VALVE Main Spool Main Spool
(154, 170, 176, 182) (160)
177 171 165 155 149
Section A 151, 167,
157
173, 179
158
152, 168,
174, 180
156
150, 166,
172, 178
159
153, 169,
175, 181
160
154, 170,
176, 182
161
162
Arm Anti-Drift Valve
163
W176-02-05-021
B 184 185
A 164
143 W176-02-05-024
Arm Anti-Drift Valve
Section B 132 125
127
186 126
128
183 129
133
148
130
187
131
136
134
137
135
138
139
140
T176-03-03-038 W176-02-05-027
123 -*Backup Ring 140 -Poppet 157 -Spring Seat 174 -Spring
124 -*O-Ring 141 -*Backup Ring 158 -Spring 175 -Spring Seat
125 -Plug 142 -*O-Ring 159 -Spring Seat 176 -Main Spool
126 -O-Ring 143 -Overload Relief Valve 160 -Main Spool 177 -O-Ring
127 -O-Ring 144 -*Plug 161 -Poppet 178 -Bolt
128 -O-Ring 145 -*O-Ring 162 -Spring 179 -Spring Seat
129 -Backup Ring 146 -*Backup Ring 163 -O-Ring 180 -Spring
130 -Backup Ring 147 -*O-Ring 164 -Plug 181 -Spring Seat
131 -O-Ring 148 -Main Relief Valve 165 -O-Ring 182 -Main Spool
132 -Sleeve 149 -O-Ring 166 -Bolt 183 -Socket Bolt
133 -Spool 150 -Bolt 167 -Spring Seat 184 -Plug
134 -Washer 151 -Spring Seat 168 -Spring 185 -O-Ring
135 -Spring 152 -Spring 169 -Spring Seat 186 -Pilot Housing
136 -Backup Ring 153 -Spring Seat 170 -Main Spool 187 -Housing
137 -O-Ring 154 -Main Spool 171 -O-Ring
138 -Plug 155 -O-Ring 172 -Bolt
139 -Spring 156 -Bolt 173 -Spring Seat
NOTE: As for mark *, refer to W2-5-10
W2-5-24
Assemble 5-Spool Control Valve Upper Section
1. Clamp main spool (160) with wood pieces in a 5. Install arm anti-drift valve assembly (125 to 138)
vise. Install poppet (161), spring (162), O-ring onto pilot housing (186).
(163) and plug (164).
: 17 mm IMPORTANT: Tap poppet (140) with a steel bar
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) when replacing housing (187) or
poppet (140).
2. Install spring seats (153, 159, 169, 175, 181),
springs (152, 158, 168, 174, 180), spring seats 6. Install poppet (140) and spring (139), O-ring (142)
(151, 157, 167, 173, 179), and bolts (150, 156, and backup ring (141) onto housing (187).
166, 172, 178) onto main spools (154, 160, 170,
176, 182) respectively. 7. Install main spool assemblies (154, 160, 170, 176,
: 17 mm 182), O-rings (124, 149, 155, 165, 171, 177) and
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft) backup ring (123) into housing (187).
3. Install backup rings (129, 130) and O-rings (126, IMPORTANT: Never turn the lock nut of relief valve.
127, 128, 131) and plug (125) onto sleeve (132). If turned, the set pressure may be
NOTE: Pay attention to the mounting location of changed.
backup rings (129, 130) and O-rings (128, 8. Install pilot housing (186) onto housing (187) with
131). socket bolts (183) (10 used). Turn the cartridges
of overload relief valve (143) and main relief valve
131 130 129 128 (148) to install them into housing (187).
: 8 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 27 mm
: 78+3 N⋅m (8+0.3 kgf⋅m, 58+2.2 lbf⋅ft)
Lock Nut
W176-02-05-023 Cartridge
IMPORTANT: When replacing sleeve (132) or

spool (133), replace them together.
4. Install O-ring (137), backup ring (136), spring
W176-02-06-017
(135), washer (134) and spool (133) into plug
(138), then install them on sleeve (132).
NOTE: Assemble washer (134) with the chamfered
side facing the spring.
W2-5-25
191 Section B Travel (Left) Boom 2 Section C
192 187
223
222
224
Load Check Valve
(Travel Tandem
Circuit)
F
E
D 216
C 215 216
Aux. Flow B 215
Rate A 213, 214
Control Load
Valve 193, Check
194 Valve
T176-03-03-036
217 218 219 220 221 (Boom 2
Section ɮ Parallel
Aux. Flow Rate 195 Circuit) 2
Control Valve
(Switch Valve) 196
Load
Check
203 Valve
197 (travel parallel
202 circuit) W176-02-05-029
198 Section D Arm 1 Swing Section E
199 204
200 205
201
206
207 Aux. Flow Rate
Control Valve
Load Check Load Check
(Poppet Valve)
Valve (Arm 1 Valve
W176-02-05-026
Parallel Circuit) (Swing Cir-
Section A
cuit)
216 216
216
215 215
215 208,
213,
209
213, 214 214
210
Check Valve
(Main Circuit)
210
208,
209
211
212
Load Check
Valve (Arm 1
Tandem Cir-
cuit)
W176-02-05-030
W176-02-05-028
187 -Housing 197 -O-Ring 207 -Valve seat 217 -Plug
189 -Cover 199 -Bushing 209 -Backup Ring 219 -Spring
190 -O-Ring 200 -Backup Ring 210 -Plug 220 -Washer
191 -Socket Bolt 201 -O-Ring 211 -Spring 221 -Spool
192 -Pilot Plate 202 -Spring 212 -Poppet 222 -Socket Bolt
193 -O-Ring 203 -Plug 213 -O-Ring 223 -Socket Bolt
194 -Backup Ring 204 -O-Ring 214 -Backup Ring 224 -Pilot Plate
195 -Spring 205 -Spring 215 -Spring 225 -*O-Ring
196 -Poppet 206 -Poppet 216 -Poppet 226 -*O-Ring
W2-5-26
Assemble 5-Spool Control Valve Side Sec-
tion
9. Install spool (221), washer (220), spring (219) and
O-ring (218) into pilot plate (224), then install plug
(217) (temporarily).
: 36 mm
NOTE: Tighten plug (217) after installing pilot plate
(224) on housing (187). Pay attention to the
length of the threaded portion because the
thread length of plug (217) and plug (106) is
different.
10. Install poppet (206), spring (205), O-ring (204)

and plug (203) onto valve seat (207).
11. Install O-rings (197, 201) and backup rings (198,

200) onto bushing (199).
12. Install valve seat (207) assembly, spring (202) and

bushing (199) into housing (187).

and backup ring (214) into housing (187). (3
places)
14. Install poppet (196), spring (195), backup ring

(194), and O-ring (193) into housing (187).
15. Install O-rings (225, 226) onto housing (187). In-

stall pilot plate (224) into housing (187) with
socket bolts (222, 223).
: 6 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 8 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
16. Tighten plug (217) which is temporarily tightened

in step 9.
: 36 mm
: 200 N⋅m (20 kgf⋅m, 144.7 lbf⋅ft)
17. Install poppet (212), spring (211), plug (210),

backup ring (209) and O-ring (208) into housing
(187) (2 places).
18. Install poppet (216), spring (215), backup ring

(214) and O-ring (213) into housing (187).
19. Install pilot plate (192) onto housing (187) with

: 6 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
W2-5-27
Section B
187
247
249
254
A
243
T176-03-03-036 W176-02-05-021
248 248 248 248 248
Section A
227
235
Flow 236
Combiner 228
Valve 237
229 Aux. Flow
Combiner
238
230 Valve
239, 240
231, 232
241
233
242
234
W176-02-05-028
187 -Housing 234 -Bolt 241 -Spring 248 -O-Ring

227 -Plug 235 -Plug 242 -Bolt 249 -Socket Bolt
228 -Spring 236 -Spring 243 -Overload Relief Valve 250 -*O-Ring
229 -Poppet 237 -Poppet 244 -*O-Ring 251 -*Plug
230 -Spool 238 -Spool 245 -*Backup Ring 252 -*O-Ring
231 -O-Ring 239 -O-Ring 246 -*O-Ring 253 -*Plug
232 -Washer 240 -Washer 247 -*Plug 254 -Pilot Housing
233 -Spring
W2-5-28
Assemble 5-Spool Control Valve Lower from breakage.)
Section
IMPORTANT: Overall dimensions of spool (230)
have been determined. When disas-
sembling or replacing poppet (229),
spring (228), plug (227), replace
then install washer (232), spring (233) and bolt
(234).
: 17 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
Ȁ
IMPORTANT: Overall dimensions of spool (238)
have been determined. When disas-
sembling or replacing poppet (237),
spring (236), plug (235), replace
then install washer (240), spring (241) and bolt
(242).
: 17 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
22. Install O-rings (231, 239), flow combiner valve as-

sembly (235 to 242) and auxiliary flow combiner
valve assembly (227 to 234) onto housing (187).
Ȁ
23. Install O-rings (248) (5 used) onto housing (187).
Then install pilot housing (254) with socket bolts
(249) (9 used).
: 8 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
IMPORTANT: Never turn the lock nut of relief

valve.
changed.
install it into housing (187).
: 27 mm
: 78+3 N⋅m (8+0.3 kgf⋅m, 57.9+2.2 lbf⋅ft)
Lock Nut
Cartridge
W176-02-06-017
NOTE: Apply grease on the O-ring of over-
load relief valve (243). (In order to protect the O-ring
W2-5-29
(Blank)
W2-5-30
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE

may penetrate the skin, causing serious in-
jury. Avoid this hazard by relieving pressure
before disconnecting hydraulic or other
lines.
Hydraulic oil may be hot just after operation
and may spurt, possibly causing severe
burns. Be sure to wait for oil to cool before
starting any repair work.
moved without releasing accumulated pres-
sure first. Push the air release valve on top of
the hydraulic oil tank to release any remain-
ing pressure.
Preparation

pressure.
3. Remove the hydraulic oil tank cap. Connect a

vacuum pump to maintain negative pressure in
the hydraulic oil tank.
NOTE: Be sure to run the vacuum pump continu-

ously while working on the hydraulic sys- M104-07-021
tem.
W2-6-1
Removal
1. Open engine cover (1) and lock it.
1
Remove bolts (3) (6 used) to remove cover (2) on
the top of the swing device from the main frame. 2
: 17 mm 3
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
2. Disconnect hoses (4 to 7 , 11) and cable (10).

: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
: 17 mm
W1F1-02-05-001
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm 10 11 4 5 6 7
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
NOTE: Attach caps to the disconnected hoses and

pipes.
IMPORTANT: As for the handling of the nylon

slings, refer to “Precautions for the
Handling of Nylon Slings” on page
W1-1-5.
3. Attach a nylon sling to swing motor (9) so as to
hoist it by crane.
Nylon sling (eye-type at both ends): 2 pieces
CAUTION: Swing device weight: 9 8 M178-07-014
220 kg (485 Ib) Front
Nylon Sling
4. Remove bolts (8) (12 used) to hoist and remove

the swing device by crane.
: 30 mm
: 500 N·m (50 kgf·m, 360 Ibf⋅ft)
NOTE: When lifting the swing device, the machine

may float together with it. Therefore,
remove plugs (12) (2 places) to hoist the
swing device out from the main frame with 9
pulling bolt (M30, Pitch 2.5).
NOTE: When hoisting the swing device, one part of

it will contact with the main frame. Be sure
to press cab side while hoisting it slowly. 12
12
W176-02-06-002
W2-6-2
Installation
Nylon Sling
NOTE: Refer to “Removal” section above for
wrench sizes and tightening torques.
IMPORTANT: Apply liquid packing to both

mounting surfaces on the swing
device and frame.
1. Install the swing device assembly with bolts (8)
(12 used).
2. Connect hoses (4 to 7, 11) and cable (10). 9
IMPORTANT: Be sure to fill the swing motor with

hydraulic oil through the drain port
of swing motor after completing
installation. Run the engine and
check the component for any oil
leaks.
3. Fill the swing motor with the hydraulic oil.
4. Install cover (2) onto the main frame with bolts (3)
W176-02-06-002
(6 used). Unlock engine cover (1) and shut the
engine cover.
10 11 4 5 6 7
9 8 M178-07-014
Front
1
2
3
W1F1-02-05-001
W2-6-3
DISASSEMBLE SWING REDUCTION
GEAR
22
23 1
24
32 21
25 4
31 5
20 6
26 7
19
8
27
18 9
28 10
17
11
29
16
12
30 15 13
14
W178-02-06-004
1- Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing

2- 1st Stage Sun Gear 10 - Spring Pin (3 Used) 18 - 2nd Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (6 Used) 20 - 2nd Stage Sun Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - 1st Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - Bolt (8 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe
W2-6-4
Disassemble Swing Reduction Gear
4. Remove pipe (32) from housing (25).
CAUTION: Swing device weight:
: 18 mm
216 kg (480 Ib)
CAUTION: When hoisting the swing device, 5. Put alignment marks at the jointed portion
don’t string the rope suddenly. between motor (1) and ring gear (24), between
1. Secure the swing device body with nylon slings, ring gear (24) and housing (25).
then hoist it by crane.
CAUTION: Swing motor weight:
Nylon Sling 47 kg (104 Ib)
6. Remove bolts (22) (8 used). Remove motor (1)
from ring gear (24).
: 10 mm
NOTE: THREEBOND has been applied on the joint
faces. Insert a screw driver into the gap be-
tween the swing motor and the ring gear,
then pry it up for easy removing.
7. Remove 1st stage sun gear (2) from 1st stage

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

gear (24).
9. Remove the ring gear (24) mounting bolt (23) (12

used).
W176-02-06-002
CAUTION: Ring gear weight: 23 kg (51 lb)
10. Install eyebolts (M12) (2 used) to the hole for the
motor (1) mounting bolt on ring gear (24). Hoist
2. Install the swing device on the bracket (ST 5097). and remove the ring gear from housing (25) by
Secure it with bolts (M20) (2 used). Insert the crane.
stopper located at the bottom of the bracket into
the middle of two teeth of the pinion gear. Secure
the bracket on a working bench. NOTE: THREEBOND has been applied on the joint
: 30 mm surfaces. Insert a screwdriver into the gap
Swing Device between the ring gear and housing, then
pry it up for easy removing.
11. Remove 2nd stage sun gear (20) from 2nd carrier
ST 5097 (18).
Stopper
12. Remove 2nd stage carrier (18) assembly from

shaft (30).
W178-02-06-012
3. Remove drain plug (31), then drain the oil.

: 8 mm
W2-6-5
23
25 21
4
18
10
17
11
16
12
30 15
14
W178-02-06-004
W2-6-6
IMPORTANT: The hole for the spring pin located
CAUTION:Housing assembly
on the 1st stage carrier does not
weight:
continue through. Pay attention to
110 kg (240 Ib)
the drive-in distance when driving
21. Install eyebolt (M16) into the bolt (23) hole in
spring pin in.
housing (25). Hoist it by crane. Remove bracket
13. Drive spring pin (5) in the 1st stage carrier (21)
(ST 5097) which has been installed at the pinion
assembly into pin (4) with special tool (ST 1462).
gear side.
Don’t drive spring pin (5) to the end.
: 30 mm
14. Remove pin (4), planetary gear (7), needle
bearing (6) and thrust plate (8) from 1st stage CAUTION: Before pressing shaft (30), pro-
carrier (21). vide a protection cover (outer diameter: 380
mm (15”), inner diameter: 110 mm (4.3”),
15. Remove remaining two sets of pin (4), planetary thickness: 25 to 30 mm (0.98” to 1.18”)). Then,
gear (7), needle bearing (6) and thrust plate (8) use the press to remove the shaft while cov-
from 1st stage carrier (21) according to the ering housing (25) and bearing (14) with the
removal procedure in step 13 and step 14. protection cover may result in personal injury
due to metal fragments flying off if the hous-
16. Remove thrust plate (3) from 1st stage carrier ing and/or bearing is broken. Use a press of
(21). capacity less than 30 tons (66000 lb). Be sure
to degrease the housing inside before heat-
IMPORTANT: The surface of the pin except for ing the bearing. Failure to degrease may
both ends is a rotating surface for cause a fire.
the needle bearing. 22. Install the protection cover on housing (25). Push
Pay attention not to damage it. the upper end of shaft (30) with a press and re-
17. Clamp the pin (4) with a vise. Push spring pin (5) move it from housing (25). The inner race of roller
out using special removing tool (ST 1462). (3 bearing (26) and sleeve (28) are removed with the
places) shaft.
Shaft(30)
18. Disassemble the 2nd stage carrier (18) assembly Bearing(14)
Housing(25)
according to the removing procedure for the 1st
stage carrier (21) assembly. However 6 needle
bearings (12) and 6 thrust plates (11) are used on Protection
the 2nd stage carrier (18) assembly. Cover
Moreover, use ST 1463 as the extractor for spring
pin (10).
19. Remove bolt (17) (2 used) to remove lock plate

(16).
: 17 mm W157-02-06-010
20. Remove bearing nut (15) from shaft (30) using

Press
special removing tool for nut (ST 2926).
ST 2926
15
Protection
Cover
W178-02-06-008
W157-02-06-011
W2-6-7
25
26
27
28
29
30
14
W178-02-06-004
W2-6-8
23. Attach the shaft (30) assembly to the special tool
CAUTION: Shaft weight: 40 kg (88 lb)
bearing removal set.
NOTE: Use the following parts as the special tool CAUTION: Be sure to use the guide when
set for removing bearing (26). pushing shaft (30) with a press.
Part Size Remarks
Press
Shaft Length: 200 mm 8 used. All should be
or Bolt (8 in) identical in length with no
Diameter: 19 mm wear and deformation on
(3/4 in) both ends.
Material: S35C (JIS), Bearing (26) Shaft (30)
1035 (AISI) Inner Race
Hose Standard Diame- 2 used.
Sleeve (28)
Clamp ter: 8-1/2”
(Applicable Di-
ameter: 185 to
215 mm)
Guide Height: 160 mm Guide
(6.3 in)
Outer Diameter:
260 mm (10.24 in)
Inner Diameter:
240 mm (9.45 in) W157-02-06-014
24. Push the spline side of shaft (30) with a press.

Bearing Removal Tool
The inner race of roller bearing (26) and sleeve
Shaft (28) are removed from the shaft.
Hose Clamp
25. Remove O-ring (29) from sleeve (28).
26. Insert a round bar into the oil passage in housing

(25). Tap the outer race of roller bearing (26) out.
Oil Passage
Outer Race
W157-02-06-012
Shaft (30)
Bearing (26)
Inner Race
W178-02-06-001
Sleeve (28)
CAUTION: Housing (25) weight:

60 kg (132 Ib)
27. Secure housing (25) body with nylon sling, hoist it
by crane. Turn the up side of the housing down.
28. Insert a screwdriver into the notch on housing (25)

Shaft where oil seal (27) is mounted. Remove the oil
W157-02-06-013 seal.
Guide
NOTE: THREEBOND has been applied on the
periphery of oil seal. Thus, it can’t be re-
IMPORTANT: Push the shaft of the special tool used.
into the gully side of the pinion. Se-
cure the shaft with the hose clamp in 29. Insert a bar at the back side of the outer race of
order not to loosen and separate. roller bearing (14). Remove the outer race from
housing (25) while tapping with a bar and
hammer.
W2-6-9
ASSEMBLE SWING REDUCTION GEAR
1
2 4
3 5
22
21 6
20
7
18
24
8
19 10
11
23
13
12
11
17
9
16
32
15
14
26
29 25 31
27
28
30
W178-02-06-003
1- Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing

2- 1st Stage Sun Gear 10 - Spring Pin (3 Used) 18 - 2nd Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (6 Used) 20 - 2nd Stage Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - 1st Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - Bolt (8 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe
W2-6-10
Assemble Swing Reduction Gear
1. Install O-ring (29) onto sleeve (28). 5. Apply THREEBOND #1215 on the outer surface
of oil seal (27). Put the oil seal flat on housing (25)
and push it, by hand, in gently. Then place seal
CAUTION: Shaft + Sleeve + Outer race
mounting tool (ST 2925) on the oil seal and tap it
in with a hammer directly.
2. Install sleeve (28), and the inner race of roller
bearing (26) into shaft (30). Press the sleeve and
inner race using bearing mounting tool (ST 2923).
NOTE: Press-in distance of the bearing inner race
can be assured by using the bearing mount- ST 2925
ing tool. 27
25
Press
ST 2923 W178-02-06-007
26
6. Apply grease at the inner face of oil seal (27) all
28 around. Apply grease at the outer surface of
sleeve (28) on shaft (30).
30
NOTE: Apply grease carefully when installing the
shaft to prevent accidental curling of the
seal lip from the shaft.
W178-02-06-013
CAUTION: Housing +outer race weight:
63 kg (139 Ib)
7. Secure housing (25) body with nylon sling and
CAUTION: Housing (25) weight: hoist it by crane. Place it with the ring gear (24)
60 kg (132 Ib) side up.
3. Secure the housing (25) body with nylon sling,
then hoist it by crane. Place it with the sleeve (28) 8. Tap outer race of roller bearing (14) evenly with a
mounting side up. bar and hammer. When installing the outer race
into housing (25), tap the bearing and listen to ring
4. Tap the outer race of roller bearing (26) evenly to check that installation is completed.
with a bar and hammer while installing the outer
race into housing (25). Tap the bearing and listen
to ring to check that installation is completed.
W2-6-11
24
23
15
14
25
27
30
W178-02-06-003
W2-6-12
14. Place mounting tool (ST 2924) onto the inner race
CAUTION: Housing + outer races (2 used)
of roller bearing (14). Push the inner race down
weight: 65 kg (140 Ib)
using a press.
NOTE: Press-in distance of the inner race can be

9. Install eyebolt (M16) into the ring gear mounting assured by using the mounting tool.
bolt (23) hole in housing (25). Then hoist and
place it on shaft (30) by crane slowly. Check and
align carefully to protect oil seal (27) lip from ST 2924
curling while mounting it.
14
10. Tap the inner race of roller bearing (14) into shaft
(30) with a bar and hammer. Tap the inner race
until two threads of shaft bearing nut (15) appear.
NOTE: The fitting between the inner race and shaft

is tight.
W178-02-06-011
11. Screw-in bearing nut (15) to shaft (30). Tighten as

much as possible by hand.
15. Hoist the housing (25) assembly and place it on
NOTE: Prevent shaft (30) from falling down when bracket (ST 5097) by crane. Secure it with 2 bolts
lifting housing (25). (M20) while the stopper at the bottom of bracket is
located at the middle of two teeth of the pinion
gear. Secure the bracket on a work bench.
CAUTION: Housing + shaft + bearing weight: : 30 mm
110 kg (240 Ib)
25
12. Lift housing (25) of ring gear (24) by crane and
eyebolt (M16) .
Place it on a press. ST 5097
Stopper
13. Remove bearing nut (15) from shaft (30).

Ȁ
W178-02-06-012
W2-6-13
3 5
22
21 6
7
18
19 10
11
13
12
11
17
9
16
15
14
30
W178-02-06-003
W2-6-14
IMPORTANT: Pay attention to the mounting direc- y Tap spring pin (10) into 2nd stage carrier (18)
tion of the bearing nut. using the special tool (ST 1463). At this time,
16. Apply a little amount of grease on the thread the slit of the spring pin should face the end of
surface of bearing nut (15), then install it on shaft pin (19).
(30) with the stepped side of the bearing nut
10
facing roller bearing (14). Tighten the bearing nut
using mounting tool (ST 2926). 9
: 353 N⋅m (36 kgf⋅m, 260 lbf⋅ft)
Slit
NOTE: Grease must be applied for assuring
correct tightening torque. W178-02-06-002
y Install thrust plate (19) into 2nd stage carrier

ST 2926 (18), while the oil groove of thrust plate (19) is
15 facing upward.
y Install needle bearings (12) (4 used), thrust
plates (11) (4 used), pins (9) (2 used) and
spring pins (10) (2 used) into two remaining
holes of the 2nd stage carrier according to the
same procedure mentioned above.
IMPORTANT: Pay attention to the mounting loca-

W178-02-06-008 tion of thrust plate (8).
17. Install lock plate (16) onto bearing nut (15) with 19. Assemble the following parts to form the 1st stage
bolt (17). In case the spline of lock plate and that carrier (21) assembly. According to the procedure
of shaft (30) are not aligned, tighten the bearing mentioned for the 2nd stage carrier assembly, in-
nut in tightening direction until both splines are stall planetary gears (7) (3 used), needle bearings
aligned. (6) (3 used), thrust plates (8) (3 used), pins (4) (3
: 17 mm used), spring pins (5) (3 used) and thrust plate (3)
: 49 N⋅m (5 kgf⋅m, 36.2 lbf⋅ft) together. Thrust plate (8) is installed under needle
bearing (6). Use special tool (ST 1462).
IMPORTANT: Pay attention to the mounting direc-
tion of spring pin (10) and thrust
plate (19).
18. Assemble 2nd stage carrier (18) according to
following steps.
y Install needle bearing (12) (2 used) into plane-
tary gear (13). Clamp planetary gear (13) with
two pieces of thrust plate (11), then install them
together into 2nd stage carrier (18).
y When mounting needle bearings (12) (2 used),
the spring pin hole (in mounting pin (9)) should
be facing out. Align the spring pin hole in 2nd
stage carrier (18) with that of pin (9).
W2-6-15
22
21
20
18
24
23
16
32
25 31
30
W178-02-06-003
W2-6-16
IMPORTANT: Pay attention to the mounting IMPORTANT: Pay attention to the mounting
direction of the 2nd stage carrier. direction of the sun gear.
20. Install the 2nd stage carrier (18) assembly onto 25. Install 1st stage sun gear (2) into the 1st stage
the spline of shaft (30), while the concave part of carrier (21) assembly with the stepped side of the
the boss in bottom side of the carrier comes in sun gear facing down.
contact with lock plate (16).
26. Install pipe (32) into housing (25) with seal tape
Concave Part 18 wound on the threaded part of the pipe.
16 : 18 mm
30
27. Wind seal tape on drain plug (31), then install it

into pipe (32).
: 8 mm
: 30 N⋅m (3 kgf⋅m, 22 Ibf⋅ft)
W178-02-06-014
28. Fill gear oil into ring gear (24) until the middle part
21. Install 2nd stage sun gear (20) into the 2nd stage of the 1st stage sun gear (2) is submerged.
carrier (18) assembly with the small diameter part (Approx. 6.2 L, 1.6 Us gal)
of the 2nd stage sun gear facing up.
29. Clean off the old THREEBOND, then apply new

22. Clean off old THREEBOND and apply new THREEBOND #1215 onto the motor (1) mounting
THREEBOND #1215 onto the mounting surface surface of ring gear (24).
of ring gear (24) inside of housing (25).
CAUTION: Ring gear weight: 23 kg (51 lb) CAUTION: Motor weight: 47 kg (100 Ib)
23. Install eyebolt (M12) (2 used) to the motor 30. Install eyebolt (M10) to motor (1), and hoist it up
mounting threaded hole on ring gear (24). Hoist by crane. Align the mating marks, then fasten the
the ring gear up by crane and install it on housing swing motor and ring gear (24) with bolts (22) (8
(25) with socket bolts (23) (12 used) while aligning used).
the matching marks made when disassembling. : 10 mm
: 14 mm : 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
: 205 N⋅m (21 kgf⋅m, 151 Ibf⋅ft)
Eyebolt Mounting
24. Install the 1st stage carrier (21) assembly onto the Position
spline of 2nd stage sun gear (20).
W178-02-06-005
W2-6-17
DISASSEMBLE SWING MOTOR
10
8
7
6
5
4 11
3
2
24
25 29
26 30
1 27 31
28
23 27
26
25
24
12
13
14 22
15 21 32
16 20
W178-02-06-015
19
18
17
1- Casing 9- Rotor 17 - O-Ring 25 - O-Ring (2 Used)

2- Oil Seal 10 - Plate (4 Used) 18 - O-Ring 26 - Spring (2 Used)
3- Bearing 11 - Friction Plate (3 Used) 19 - Brake Piston 27 - Poppet (2 Used)
4- Shaft 12 - O-Ring 20 - Spring (24 Used) 28 - Valve Casing
5- Shoe Plate 13 - Piston 21 - Valve Plate 29 - Socket Bolt (4 Used)
6- Plunger (9 Used) 14 - Spring 22 - Bearing 30 - O-Ring (2 Used)
7- Plate 15 - Ball 23 - O-Ring 31 - Plug (2 Used)
8- Retainer 16 - Plug (2 Used) 24 - Plug (2 Used) 32 - Relief Valve (2 Used)
W2-6-18
Disassemble Swing Motor
• Be sure to thoroughly read “Precautions for IMPORTANT: Be sure not to damage the mating
Disassembly and Assembly Work” on page surface when separating valve plate
W1-1-1 before starting the disassembly work. (21) from valve casing (28) or rotor
(9) with a screwdriver. (Be sure not
to mismatch the surfaces of the
CAUTION: Swing motor assembly weight: valve plate when installing.)
55 kg (120 Ib)
6. If valve plate (21) is still on rotor (9) in step 5,
Relief valve
remove the valve plate from the rotor. Remove
IMPORTANT: Don’t disassemble relief valve (32).
springs (20) (24 used).
1. Remove relief valves (32) (2 used) from valve

casing (28). CAUTION: Another method is to float the
: 41 mm brake piston by blowing air from port B.
However, piston (13) may fly off when
2. Remove plugs (24) (2 used) from valve casing blowing air. Don’t use this method.
(28).
: 14 mm 7. Install tool (ST 1468) into notch A of brake piston
(19), then pull it out from casing (1).
3. Remove springs (26) (2 used) and poppets (27)
(2 used) from valve casing (28).
4. Make matching marks at the joint surface

between valve casing (28) and casing (1). Then
loosen socket bolts (29) (4 used). At this moment, Notch A
there is a clearance between valve casing (28)
and casing (1). Take this clearance down.
: 17 mm
5. Remove valve casing (28) from casing (1).
NOTE: At this moment, valve casing (28) may be Port B

with valve plate (21) attached. Pay attention
not to drop valve plate (21).
T178-03-02-003
8. Remove O-rings (17, 18) from casing (1).
W2-6-19
10
8
7
6
5
4 11
3
2
12
13
14
15
W178-02-06-015
W2-6-20
IMPORTANT: Take care not to damage the slide IMPORTANT: Filter and orifice are mounted inside
surface of rotor (9) and plunger (6). of piston (13). Do not disassemble
them unless they are clogged or
9. Place casing (1) horizontally. Remove rotor (9), deformed. Disassemble them only
retainer (8), plate (7) and plungers (6) (9 used) when absolutely needed.
from shaft (4). If the inner parts need to be replaced,
replace them as an assembly.
10. Remove plates (10) (4 used) and friction plates
(11) (3 used) from casing (1). 16. Remove piston (13) from casing (1) with pliers.
IMPORTANT: Take care not to damage the slide

surface of shoe plate (5). 17. Remove spring (14) and ball (15) from casing (1).
11. Remove shoe plate (5) from casing (1).
12. Tap shaft (4) with a plastic hammer lightly to

remove it from casing (1).
13. Push out oil seal (2) from casing (1).
14. Remove the outer race of bearing (3) from casing

(1) with a guide bar.
15. Remove the inner race of bearing (3) from shaft

(4) with a press.
W2-6-21
ASSEMBLE SWING MOTOR
27 26 25 24
12
13
14
15
16
29
T178-03-02-004
T178-03-02-003
31
30
28 32
22 21
20
23
19
18
10
17
6
11
9 8
7 3
5
1
4 T178-03-02-002
1- Casing 9- Rotor 17 - O-Ring 25 - O-Ring (2 Used)

2- Oil Seal 10 - Plate (4 Used) 18 - O-Ring 26 - Spring (2 Used)
3- Bearing 11 - Friction Plate (3 Used) 19 - Brake Piston 27 - Poppet (2 Used)
4- Shaft 12 - O-Ring 20 - Spring (24 Used) 28 - Valve Casing
5- Shoe Plate 13 - Piston 21 - Valve Plate 29 - Socket Bolt (4 Used)
6- Plunger (9 Used) 14 - Spring 22 - Bearing 30 - O-Ring (2 Used)
7- Plate 15 - Ball 23 - O-Ring 31 - Plug (2 Used)
8- Retainer 16 - Plug (2 Used) 24 - Plug (2 Used) 32 - Relief Valve (2 Used)
W2-6-22
Assemble Swing Motor
IMPORTANT: Be sure to install the inner race of 8. Place casing (1) horizontally. Install the rotor (9)
bearing (3) with the flange facing the assembly onto shaft (4).
stepped side of shaft (4).
IMPORTANT: 4 notches are on the outer side of
1. Push the inner races of bearings (3), (22) into plate (10). And 4 notches are on the
shaft (4) with a press. spline teeth side of friction plate (11).
Be sure to align each notch at the
IMPORTANT: Push oil seal (2) in, with its lip facing same place when installing.
up.
9. Place casing (1) vertically. Alternately install plates
2. Push oil seal (2) into casing (1) with a guide plate. (10) (4 used), friction plates (11) (3 used) into
casing (1).
3. Install the outer race of bearing (3) into casing (1)
with a guide bar. 10. Install O-rings (17) and (18) onto casing (1).
11. Install brake piston (19) into casing (1) while

IMPORTANT: Wind the tape on the spline at the aligning the mating marks.
end of shaft (4) to prevent damaging
oil seal (2) from being damaged.
NOTE: If it is not easy to install O-rings (17), (18)
4. Place casing (1) horizontally. Install shaft (4) into into brake piston (19) due to the resistant
casing (1). force from the O-rings, tap them evenly with
a plastic hammer to force them in.
5. Place casing (1) vertically with the valve casing
(28) mounting surface up. Then install shoe plate 12. Install springs (20) (24 used) onto brake piston
(5) with its chamfered inner side facing inside. (19).
IMPORTANT: When installing retainer (8) into

plunger (6), be sure to place the
notch side of the retainer facing
shoe plate (5).
6. Assemble plate (7) and retainer (8) aligning the

notches. Then install plungers (6) (9 used).
IMPORTANT: Apply hydraulic oil into the plunger

hole in rotor (9), then install plunger
(6).
7. Insert the plunger (6) assembly into rotor (9).
W2-6-23
27 26 25 24
Drain Port
12
13
14
15
29
T178-03-02-004
T178-03-02-003
28 32
22 21
23
T178-03-02-002
W2-6-24
IMPORTANT: If the inner parts of piston (13) need 18. Install valve casing (28) onto casing (1) with
to be replaced, replace the piston as socket bolts (29) (4 used).
an assembly. : 17 mm
Be sure to align the end face of the : 430 N]m (44 kgf]m, 320 Ibf⋅ft)
piston with that of casing (1).
19. Install poppets (27) (2 used) and springs (26) ( 2
13. Install ball (15), spring (14) and piston (13) into used) into valve casing (28). Tighten plug (24)
casing (1). with O-ring (25) attached.
: 14 mm
IMPORTANT: Tap the bearing type indicated : 330 N]m (34 kgf]m, 245 Ibf⋅ft)
surface with a plastic hammer while
installing roller bearing (22). 20. Install relief valves (32) (2 used) into valve casing
(28).
14. Tap the outer race of bearing (22) with a plastic : 41 mm
hammer while installing it into valve casing (28). : 175 N]m (18 kgf]m, 130 Ibf⋅ft)
21. Fill hydraulic oil through the drain port.

IMPORTANT: Pay attention to the surfaces of NOTE: Amount of Hydraulic oil: 0.8 L (0.211 US
valve plate (21). gal)
(Install the valve plate with the notch
in the port facing rotor (9).)
15. Install O-ring (23) onto valve casing (28). Then

install valve plate (21).
NOTE: Apply grease onto valve plate (21) to avoid

it coming off from valve casing (28).
16. Apply grease to the roller part on bearing (22).
NOTE: It is easy to install shaft (4) into bearing (22)

by pushing the roller with grease.
17. Align the matching marks in valve casing (28) and

casing (1), while placing the valve casing onto
casing (1). Be sure to confirm that the clearance
between valve casing (28) and casing (1) is same
to that before disassembling. If the clearance is
larger than that before disassembling, reinstallation
shall be carried out from step 5.
W2-6-25
MAINTENANCE STANDARD
Swing Motor
1. Clearance between the outer diameter of plunger d

and the inner bore of cylinder
D-d Unit: mm (in)

Standard Allowable Limit
0.027 (0.0011) 0.052 (0.0020) W107-02-06-138
D D
W107-02-06-139
2. Clearance between plunger and shoe at the

caulked position
δ
Unit: mm (in)
0 (0) 0.3 mm (0.0118 in)
W1F1-02-06-001
W2-6-26
3. Thickness of shoe
Unit: mm (in)
5.5 (0.22) 5.3 (0.21)
W107-02-06-142
4. Thickness of friction plate
Unit: mm (in)
2.0 (0.08) 1.8 (0.07)
W107-02-06-143
W2-6-27
(Blank)
W2-6-28
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL RIGHT PILOT
VALVE

jury. Avoid the hazard by relieving pressure
before disconnecting hydraulic or other lines.
pressure.
Preparation

pressure.
M104-07-021
Removal
1. Remove seat mounting bolts (2) (4 used) to re-
move seat (1) (with seat stand).
: 17 mm
W178-02-01-001
W2-7-1
2. Remove screws (27) (4 used), cover (26) to move
boot (6) upward.
3
3. Remove screws (24) (4 used), caps (20) (2 used)
and screws (19) (2 used) to move cover (21) up- 4
ward. Disconnect each harness connectors for 5
key switch (23) and air conditioner controller (22),
6
then remove cover (21). Remove screw (25), (15)
(16), (18) and rubber (13) to remove cover (17).
7
27
4. Remove connector (12) and bolts (10) (3 used) of 26 8
switch box (11) to remove switch box (11). 25 10
: 13 mm 9 11
24
23
IMPORTANT: Attach identification tags on all dis- 22
connected hoses to aid in reassem- 21 12
bly. 20
5. Disconnect hoses (28 to 33).
: 19 mm
NOTE: Attach a cap on all disconnected hose
ends.
19
13
6. Loosen nut (4) to remove grip (3)
Loosen nut (7) to remove lever (5), and boot (6). 14
: 22 mm
15
: 19 mm
18 16
7. Remove bolts (8) (4 used) to remove valve (9).
: 13 mm 17
W1CC-02-07-001
Installation
1. Install valve (9) with bolts (8) (4 used).
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf·ft)
28
33
32 29
30
31
W178-02-07-002
28 - Hose T6: (To the pilot shut-off valve)

29 - Hose H: (To the signal control valve port H (bucket roll-out))
30 - Hose A: (To the signal control valve port A (boom raise))
31 - Hose P3: (From the pilot shut-off valve)
32 - Hose G: (To the signal control valve port G (bucket roll-in))
33 - Hose B: (To the signal control valve port B (boom lower))
NOTE: Piping location shows that of ISO pattern.
W2-7-2
2. Connect hoses (28 to 33).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
3. Temporarily tighten nut (7) to lever (5), then install 28

lever (5) onto valve (9) with nut (7). Install boot 33
32 29
(6).
Temporarily tighten nut (4) to lever (5), then install 30
grip (3) with nut (4). 31
: 22 mm
: 26 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft)
: 19 mm
: 26 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft)
4. Install switch box (11) with bolt (10), then connect W178-02-07-002
connector (12).
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅ft) 3
5. Connect each harness of key switch (23) and air 4

conditioner controller (22). 5
6
6. Install cover (17) with screws (25), (15) and (18).
Install rubber (13).
7
Install cover (21) with screws (24) (4 used) and 27
(19) (2 used). Install caps (20) (2 used). 26 8
25 10
7. Install cover (26) with screws (27) (4 used). 24 9 11
23
22
21 12
20
19
13
14
15
18 16
17
W1CC-02-07-001
W2-7-3
8. Install seat (1) (with the seat stand) with nut (2).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
IMPORTANT: After installation, check the oil level,
start the engine and check for oil
leaks.
2
Ȁ
W178-02-01-001
W2-7-4
REMOVE AND INSTALL LEFT PILOT
VALVE

ing pressure.
Preparation
1. Park the machine on a solid level surface. Lower
the bucket to the ground.
2. Stop the engine. Push the air release valve on the

hydraulic oil tank to release any pressure remain-
ing in the hydraulic tank.
Removal
M104-07-021
1. Remove screw (2) and cover (3) to move boot (1)
upward. At this time, the console is at the most
front position.
: 17 mm
2. Remove screws (7) and (8) to remove cover (9).

Remove screws (4) and (5) to move cover (6) up-
ward. Disconnect the radio connector, then re-
move cover (6).
2
9 Radio
3
8
4
7
6
5
W178-02-07-003
W2-7-5
IMPORTANT: Attach identification tags on all dis-
connected hoses for reassembly.
3. Disconnected hoses (10 to 15).
: 19 mm
NOTE: Attach a cap on each disconnected hose
end. 10
15
14 11
4. Remove clips (28) and (20) and disconnect con-
12
nector (27). Loosen nut (17) to remove grip (16)
(with harness). 13
Ȁ Loosen nut (19) to remove lever (18), washers
(24) and (25) and boot (1).
: 22 mm
: 19 mm
5. Remove bolts (23) and (22) (with pin (21)) to re-

move valve (26).
: 13 mm W178-02-07-004
10 - Hose T5: (To the pilot shut-off valve)
11 - Hose D: (To the signal control valve port D (arm roll-in))
Installation 12 - Hose E: (To the signal control valve port E (left swing))
1. Install valve (26) with bolts (23) and (22) (with pin 13 - Hose P2: (From the pilot shut-off valve)
14 - Hose C: (To the signal control valve port C (arm roll-out))
(21)). 15 - Hose F: (To the signal control valve port F (right swing))
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅ft)
NOTE: Piping location shows that of ISO pattern.
2. Connect hoses (10 to 15). 16
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
28
17
18
27
1
19
20
21
22
23
24
25
26
W178-02-07-003
W2-7-6
IMPORTANT: If the harness is arranged to the in-
side of spring pin (21), it may make
contact with the moving part of the
pilot valve damaging it. Be sure to 16
arrange harness to the outside of
spring pin (21).
3. Temporarily tighten nut (19) to lever (18), then in- 28
stall washers (24) and (25).
17
4. Install lever (18) onto valve (26) with nut (19).
5. Install boot (1). 18
27
Temporarily tighten nut (17) to lever (18), then se-
1
cure grip (16) with nut (17). 19
6. Pass the harness of grip (16) through the upper 20
hole of boot (1), then connect it to lever (18) with 21
clips (28) and (20). 22
7. Arrange the harness to the outside of spring pin
(21) over bolt (22) head to connect connector 24
(27). 25
: 22 mm 26
: 26 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft) 9 Radio 2
: 19 mm 8 3
: 26 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft) 4
8. Connect the radio connector and install cover (6)

with screws (4) and (5).
Ȁ Install cover (9) with screws (7) and (8).
7
6
9. Install cover (3) with screw (2). 5
IMPORTANT: After installation, check the oil level.
Start the engine and check for oil W178-02-07-003
leaks.
W2-7-7
(Blank)
W2-7-8
REMOVE AND INSTALL TRAVEL PILOT
VALVE

ing pressure.
Preparation
1. Park the machine on a solid level surface. Lower
the bucket to the ground.

hydraulic oil tank to release any pressure remain-
ing in the hydraulic tank.
M104-07-021
W2-7-9
Removal
1. Loosen bolts (1) (5 used) to remove under cover
(2).
: 17 mm
2. Loosen bolt (3) to remove pedal (4), levers (15)
and (16).
: 17 mm
IMPORTANT: Attach identification tags on all dis- 2

connected hoses for reassembly.
3. Disconnect pipes (5 and 6) and hoses (7 to 10).
: 19 mm
NOTE: Attach a cap on each disconnected hose
end.
1
4. Remove socket bolt (13), spring washer (12) and
plain washer (11) to remove pilot valve (14). W1F1-02-07-001
: 8 mm
3
16
15
4
4
14
13
13
12
12
11
11 5
6
10
9
8
7
W178-02-07-005
5 - Pipe: (To the pilot shut-off valve)
6 - Pipe: (From the pilot shut-off valve)
7 - Hose K: (To the signal control valve port K (right travel
forward))
8 - Hose L: (To the signal control valve port L (right travel
reverse))
9 - Hose J: (To the signal control valve port J (left travel
reverse))
10 - Hose I: (To the signal control valve port I (left travel
forward))
W2-7-10
Installation
1. Install pilot valve (14) with socket bolt (13), spring
washer (12) and plain washer (11).
: 8 mm
: 49 N⋅m (5.0 kgf⋅m, 36 lbf⋅ft)
3
16
2. Connect pipes (5, 6) and hoses (7) to (10). 15
: 19 mm 4
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
3. Install pedal (4), lever (15) and (16) with bolt (3).
3
: 17 mm
: 49 N⋅m (5.0 kgf⋅m, 36 lbf⋅ft)
4. Install under cover (2) with bolts (1) (5 used). 4
: 17 mm 14
13
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 13
12
12
IMPORTANT: After installation, check the oil level. 11
Start the engine and check for oil 11 5
leaks. 6
10
9
8
7
W178-02-07-005
5 - Pipe: (To the pilot shut-off valve)
6 - Pipe: (From the pilot shut-off valve)
7 - Hose K: (To the signal control valve port K (right travel
forward))
8 - Hose L: (To the signal control valve port L (right travel
reverse))
9 - Hose J: (To the signal control valve port J (left travel
reverse))
10 - Hose I: (To the signal control valve port I (left travel
forward))
W1F1-02-07-001
W2-7-11
DISASSEMBLE RIGHT AND LEFT PILOT
VALVES
13
12
14
11
15
11
10
8
8
7
9
21
6
16 20
21
5
20
4 5
19
3 6
3 18
2
4
17
W176-02-07-001
1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim (Several) 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Knock Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)
W2-7-12
Disassemble Right and Left Pilot Valves
IMPORTANT: Block (10) and housing (18) are IMPORTANT: Two kinds of push rods are used.
made of aluminium. Too strong a They must be handled in order of
force can deform, or damage them. port number after removing.
Therefore, handle with care.
4. Pull push rods (8) and (9) out of block (10).
IMPORTANT: As spool (17) has been selected to
match the hole of housing (18), they 5. Remove oil seals (15) (4 used) from block (10)
must be replaced as a set. In addi- with a bamboo spatula.
tion, the dimensions of balance NOTE: If a metal bar is used, the mating part of oil
springs A (3), B (4) and return seal may be damaged.
springs A (5), B (6) as well as those
of push rods A (8), B (9) are different. IMPORTANT: The retaining ring may come off
For this reason, be sure to indicate while disassembling. Take care not
the port number from which each is to drop it.
removed. Port numbers are stamped 6. Press springs with special tool (ST 7257) from the
on housing (18). top of spring guide (16). Retaining ring (7) will ap-
pear. Remove it with a screwdriver or similar tool.
IMPORTANT: Do not clamp housing (18) in a vise (4 places)
to remove the screw joint because
the strong torque may act on the 7
screw joint (13).
1. Clamp screw joint (13) in a vise. Then turn cam
(12) with a spanner to remove the screw joint.
: 32 mm
2. Clamp the flat surface of housing (18) in a vise

slightly. Remove cam (12) from universal joint 16
(14).
: 32 mm ST 7257
NOTE: The universal joint has been secured on

block (10) with LOCTITE. Don’t remove it
unless necessary.
3. Remove socket bolt (11) to remove block (10). At W176-02-07-005
this time, push rods (8) and (9) are still on the
block side. IMPORTANT: The number of shims has been de-
: 6 mm termined for each port during the
performance testing at the factory.
Take care not to lose them. Keep
them carefully so as to install them
to each former port when reassem-
bly.
7. Remove spring guide (16), balance springs (3)
and (4), return springs (5) and (6), shim (2) and
spacer (1) from spool (17).
W2-7-13
21
20
21
20
19
18
17
W176-02-07-001
W2-7-14
IMPORTANT: As the spool has been selected to
match the hole of the housing, keep
them carefully so as to install them
to the former port when reassem-
bling.
8. Remove spool (17) from housing (18). Pulling it
out while turning it slowly.
NOTE: The spool and the housing must be re-
placed as an assembly.
9. Remove O-rings (19) and (21) from housing (18).

Don’t remove knock pin (20) unless necessary.
W2-7-15
ASSEMBLE RIGHT AND LEFT PILOT
VALVES
13 14
10
12
15
11
8, 9
7
16
3, 4
5, 6
19
17
W176-02-07-006
21 20 18
1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim (Several) 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Knock Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)
W2-7-16
Assemble Right and Left Pilot Valves
IMPORTANT: The pilot valve is susceptible to con- IMPORTANT: Install the spring guide, with the pro-
tamination. Keep parts clean when trusion facing upward.
assembling. 3. Install spring guide (16) onto return spring (3) or
(4).
NOTE: Table below shows the relations between
each port and the components. Take care 4. Install retaining ring (7) onto ring holder (ST
not to confuse them when assembling. 7255).
ST 7255
Port Spool Shim Push rods 7
No. (17) (2) (8), (9)
1 with outer
Same to Same to groove
2 the former the former without outer W176-02-07-008
one one groove

3 with outer 5. Insert the spool (17) head into the hole of spring
groove special tool (ST 7257) to press the spring from the
4 without outer top of spring guide (16). Install retaining ring (7)
groove with the ring holder (ST 7255) onto the head of the
spool.
Port Return Springs Blance Springs
No. (5), (6) (3), (4) ST 7257 ST 7255
1 short short
2 long long 17
3 short short
4 long long
Packing Material
IMPORTANT: Make sure of the port hole number
and insert the spool to the former
port. W176-02-07-009
1. Insert the thinner end of spool (17) to housing (18), NOTE: Put approx. dia.8 mm, length 10 mm of
then push the spool in rotating it. packing material into the port hole so as to
NOTE: The spool has been selected to match the not only make the work easy to do, but also
hole of the housing. The spool and housing prevent the spool from lowering to the bot-
must be replaced as an assembly. tom when compressing the spring.
IMPORTANT: Refer to the table above to assemble 6. Assemble remained spools (17) (3 used) into
them correctly. housing (18) in the same procedures as step 2 to
2. Install the spacer (1), shim (2), balance spring (3) 5.
or (4), return spring (5) or (6) onto spool (17) in-
stalled in housing (18). 7. Install O-rings (19) and (21) (2 used) onto housing
(18).
W2-7-17
13 14
10
12
15
11
8, 9
W176-02-07-006
20 18
W2-7-18
8. Apply grease to the inner faces of oil seals (15) (4 IMPORTANT: Make sure of the tighteness of cam.
used), then install the oil seals (4 used) into block 13. Clamp housing (18) carefully in a vise and then
(10) with a bamboo spatula. install cam (12) to universal joint (14).
NOTE: As shown bellow, insert push rods (8) and Tighten the universal joint so that the clearance
(9) first, then install oil seal (15). This pre- between the cam and push rod (8) and (9)
vents the oil seal from entering into the becomes 0 to 0.2 mm.
hole. : 32 mm
Oil Seal IMPORTANT: Do not clamp housing (18) in a vise

Mounting Hole
because the strong torque may act
on the screw joint.
10 14. Clamp screw joint (13) in a vise to tighten univer-
8, 9
sal joint (14). Tighten cam (12) with a spanner.
: 32 mm
: 88.2 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
W176-02-07-007
IMPORTANT: Make sure of the position to install

the push rod.
9. Install push rods (8) and (9) to block (10). When
installing the push rods, install the push rods with
groove to ports # 1 and # 3, the ones without
groove to ports # 2 and # 4, respectively.
10. Apply grease to the ball at the ends of push rods

(8) and (9).
11. Apply grease to the joint part of universal joint

(14).
12. Align the position of knock pin (20), install the

block (10) assembly to housing (18) with socket
bolts (11) (2 used).
: 6mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
W2-7-19
DISASSEMBLE TRAVEL PILOT VALVE
35 2
34
33
32
31
30
3
4
5
6
29
28 7
27
8
9
10
26
11
12
25 13
24 23
22
21
20
19
18
14
17
15
16
W176-02-07-002
1- Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)

2- Cover 11 - Oil Seal (4 Used) 20 - Shim (Several) 29 - Spring Washer (4 Used)
3- Pin (2 Used) 12 - O-Ring (4 Used) 21 - Balance Spring (4 Used) 30 - Adjust Bolt (4 Used)
4- O-Ring (2 Used) 13 - Bushing (4 Used) 22 - Spring Guide (4 Used) 31 - Bushing (4 Used)
5- O-Ring (2 Used) 14 - Casing 23 - Pusher (4 Used) 32 - Cam (2 Used)
6- Damper (2 Used) 15 - O-Ring 24 - Spring Pin (2 Used) 33 - Lock Nut (4 Used)
7- Rubber Seat (2 Used) 16 - Plug 25 - Spring Pin (2 Used) 34 - Spring Pin (2 Used)
8- Socket Bolt (2 Used) 17 - Spool (4 Used) 26 - Bracket (2 Used) 35 - Spring Pin (2 Used)
9- Spring Washer (2 Used) 18 - Spring (4 Used) 27 - Spring Pin (2 Used)
W2-7-20
Disassemble Travel Pilot Valve
1. Clamp casing (14) in a vise. Loosen bolt (1) to 7. Remove spring (18) from casing (14). (4 places)
remove cover (2) from holder (10).
: 10 mm IMPORTANT: Put a stand under bracket (26). If
holder (10) bears the reaction force,
2. Remove socket bolts (8) (2 places) to remove a strong force acts on pin (3) and the
holder (10) from casing (14). pin may deform.
: 8 mm
IMPORTANT: The inside of the spring pins (24)
3. Pull out pusher (23) from casing (14) (4 places). and (25) hole in the bracket is
Bushing (13) and oil seal (11) are removed with stepped-shape. Therefore, the
the pusher. spring pin can only be pulled out in
one direction.
4. Pull out pusher (23) from bushing (13) with a 8. Put a stand under bracket (26).
bamboo spatula to remove oil seal (11). (4 places) Ȁ Push out spring pins (24) and (25) from bracket
(26) at the same time with special tool (ST 1237).
IMPORTANT: Make marks on spools so as to eas- Remove the bracket from pin (3). (2 places)
ily install them to their former posi- Ȁ Don’t remove spring pin (27) from the bracket un-
tion. less necessary.
5. Pull out the spool (17) assembly from casing (14)
NOTE: The outside end of the spring pin has been
turning the spool.(4 places)
caulked.
Ȁ Spring guide (22), balance spring (21), shim (20)
and spacer (19) are removed with the spool.
NOTE: The spool has been selected to match the 24,25
hole of the casing. The spool and casing
must be replaced as an assembly. 26
3 27
IMPORTANT: The number of shims has been de- Caulked
termined during the performance Position
testing at the factory. They must be
Stand
kept together with their spool.
6. Compress balance spring (21). Remove spring
guide (22), balance spring (21), shim (20) and
spacer (19) from spool (17). (4 places)
W176-02-07-019

damper (6) and rubber seat (7) from pin (3). O-
ring (4) is removed with them. (2 places)
: 5 mm
W2-7-21
35
34
33
32
31
30
10
14
W176-02-07-002
W2-7-22
10. Remove O-ring (5) from pin (3). (2 places)
11. Place holder (10) with the casing (14) mating sur-
face facing upward.
IMPORTANT: The holes for spring pins (34) and

(35) of cam (32) are stepped-shape.
Therefore the pins shall be removed
from the bottom of the cam.
12. Pull out spring pins (34) and (35) from cam (32) at
the same time with special puller (ST 1237). (2
places)
NOTE: The spring pin is a double-pin.
NOTE: The spring pin is caulked in its hole, so it

may feel tight when removing.
13. Remove pin (3) with a bar and hammer. At this

time cam (32) is also removed. (2 places)
NOTE: Don’t remove bushings (31) (4 used) left on
holder (10) unless necessary. When re-
moval is necessary, the bushing special
tool (ST 7256) should be used to tap it out.
14. Remove lock nuts (33) (2 used) from cam (32) to

remove adjusting bolts (30) (2 used).(2 places)
: 13 mm
: 4 mm
W2-7-23
ASSEMBLE TRAVEL PILOT VALVE
26 6 7 1 2 3 31 25 27 24 10 32 30 33 34, 35 8 9
13
22
4
28
5 11 21
29 12 18
23
20
19
17
14
W176-02-07-010
15, 16
1- Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)

2- Cover 11 - Oil Seal (4 Used) 20 - Shim (Several) 29 - Spring Washer (4 Used)
3- Pin (2 Used) 12 - O-Ring (4 Used) 21 - Balance Spring (4 Used) 30 - Adjust Bolt (4 Used)
4- O-Ring (2 Used) 13 - Bushing (4 Used) 22 - Spring Guide (4 Used) 31 - Bushing (4 Used)
5- O-Ring (2 Used) 14 - Casing 23 - Pusher (4 Used) 32 - Cam (2 Used)
6- Damper (2 Used) 15 - O-Ring 24 - Spring Pin (2 Used) 33 - Lock Nut (4 Used)
7- Rubber Seat (2 Used) 16 - Plug 25 - Spring Pin (2 Used) 34 - Spring Pin (2 Used)
8- Socket Bolt (2 Used) 17 - Spool (4 Used) 26 - Bracket (2 Used) 35 - Spring Pin (2 Used)
9- Spring Washer (2 Used) 18 - Spring (4 Used) 27 - Spring Pin (2 Used)
W2-7-24
Assemble Travel Pilot Valve
IMPORTANT: Pay attention to the mounting direc- 6. If bushing (31) removes from holder (10), install it
tion of spring guide (22). on the holder using special tool (ST 7256) in the
following procedures.
IMPORTANT: Install the former number of shims. NOTE: The bushings (4 used) are identical.
1. Assemble spool (17) into an assembly. (4 used)
• Insert spacer (19), shim (20) and balance spring • Insert the bushing into special tool (ST 7256),
(21) into the spool in order. then tap on the special tool (ST 7256) to install the
• Press the balance spring by hand. Install spring bushing into the hole of holder.
guide (22) to the spool with the stepped-end fac- Ȁ Stop tapping when the bushing end is flush with
ing downward. the inside wall.
Inside Wall
2. Insert spring (18) to casing (14). (4 places)
10 ST 7256
IMPORTANT: Insert the spool (17) assembly into

the former port.
3. Turn and install the spool (17) assembly into cas-
ing (14). (4 places)
31
W176-02-07-016
4. Assemble pusher (23) into an assembly (4 used).
• Install oil seal (11) onto bushing (13).
• Install the bushing on the opposite side in the
• Apply grease to the inner face of the oil seal.
same procedure. 31
• Install O-ring (12) to the bushing.
10
• Insert pusher (23) to the bushing. ST 7256
• Apply grease to the pusher head section.
5. Insert the pusher (23) assembly to holder (10). (4

places).
W176-02-07-015
• Install the bushing in near side as shown bellow.

Stop tapping when the bushing end is flush with
the outside of holder.
31
10 ST 7256
Outside of
Holder
W176-02-07-014
• Install the bushing on opposite side as shown be-

low. 31
10
ST 7256
W176-02-07-013
W2-7-25
3 10 32 30 33 34, 35 8 9
23
14
W176-02-07-010
W2-7-26
7. Insert adjust bolt (30) to cam (32). Tighten the bolt IMPORTANT: Do not adjust the adjust bolt (30)
by hand, and then lightly secure it temporarily with while pressing the pusher (23) head
lock nut (33). (2 places) with the adjust bolt. The standard
clearance between the adjust bolt
NOTE: Adjust the dimensions later. and pusher must be 0 to 0.2 mm(0 to
0.008 in).
8. Apply grease on the head (mating surface for 13. Adjust adjust bolt (30) as the following procedures.
pusher (23)) of adjust bolt (30) (2 places). (2 places)
: 13 mm
9. Install O-ring (5) to pin (3), then assemble the pin : 4 mm
to holder (10) with cam (32) (2 places). • Loosen lock nut (33).
• Move cam (32) to check if there is any play. If
IMPORTANT: Take care of the inserting direction none, turn the adjust bolt to adjust.
of the spring pin. • Turn both adjust bolts on the left and right alterna-
tively to keep the cam horizontal.
IMPORTANT: Tap the spring pin in until it makes • Measure dimensions A and B from both left and
contact with the stepped-shape in right caves on the cam to holder (10). Fine adjust
hole. the adjust bolt to get same distance for both left
10. Install spring pins (34), (35) to cam (32) using and right.
special tool (ST 1237), then secure the cam and • Secure the adjust bolt with a hexagon-head
pin (3). The spring pins shall be displaced with wrench. Tighten the lock nut to specified torque
their slits at 90° (2 places). first, securing the adjust bolt.
• When adjustment is finished, move the cam to
34 35 Slit Slit check that is a little play. If there is no play, the
pusher may be in compressed condition, and ad-
justment should be carried out again.
: 9.8 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft)
30 33 32 10
A B
W176-02-07-017
11. Caulk the hole edge of cam (32), where spring

pins (34) and (35) are inserted, with a punch. (2
places)
12. Place holder (10) on the casing (14) assembly

and install it with socket bolts (8) (2 used) and
spring washers (9) (2 used). W176-02-07-003
: 8 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
W2-7-27
26 6 7 1 2 3 25 27 24 10
4
28
5
29
W176-02-07-010
W2-7-28
14. Install rubber seat (7) to pin (3). (2 places) IMPORTANT: Place a stand under the bracket. If
holder (10) bears the reaction force,
15. Apply grease to O-ring (5). (2 places) strong force acts on the pin and the
pin may deform.
IMPORTANT: Pay attention to the direction of
damper (6). IMPORTANT: The inside of the spring pin hole in
the bracket is stepped-shape. Make
IMPORTANT: The inner bore of damper (6) is sure of the direction to insert the
edged-shape. If the damper is pried spring pin.
upward, O-ring (5) will be damaged.
16. With the lever upward, install damper (6) to pin (3) IMPORTANT: Make sure of the direction of the
straight without prying. (2 places) spring pin.
20. Put a stand under bracket (26).
17. Secure damper (6) to holder (10) with socket bolts Ȁ Tap spring pins (24) and (25) into the bracket until
(28) (2 used) and spring washers (29) (2 used). (2 the spring pin comes to the stepped end using
places) special tool (ST 1237). The spring pins shall be
: 8 mm displaced with their slits at 90°.
: 7 N⋅m (0.7kgf⋅m, 5.1 Ibf⋅ft)
18. Apply grease to O-ring (4), then press it to the ab-

solute most end of pin (3). (2 places)
Caulked Here Caulked Here
IMPORTANT: As for the direction to install the

26 3
bracket, refer to the figure in the
disassemble section. Take care not
to misassemble it.
19. Install pin (3) into bracket (26), then align the in- 24, 25
Stand
serting holes of spring pins (24) and (25) to fix pin
on the bracket.
W176-02-07-011
21. Caulk the hole edge of bracket (26), where spring

pins (24) and (25) are inserted, with a punch. (2
places)
(Refer to the figure above.)
22. Install pin (3) on other bracket (26) as in step 19 to

21.
23. Install cover (2) to holder (10) with bolts (1) (2

used).
: 10 mm
: 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
24. Apply grease to the spring pin (27) contact part of

damper (6). (2 places)
W2-7-29
(Blank)
W2-7-30
UPPERSTRUCTURE / Pilot Shut-Off Valve
REMOVE AND INSTALL PILOT SHUT-OFF
VALVE

ing pressure.
Preparation
1. Park the machine on a firm, level surface.

top of the hydraulic oil tank to release any remain-
ing pressure.

NOTE: Be sure to run the vacuum pump con-

tinuously while working on the hydraulic M104-07-021
system.
W2-8-1
Removal
1. Remove bolts (1) (5 used) to remove under cover

(2).
: 17 mm
2. Remove spring (5). 2
IMPORTANT: Attach tags to hoses for assembly.
3. Disconnect hoses (8 to 15) and pipes (16 and 17).

: 19 mm
1
4. Remove spring pin (7) to remove lever (3).
W1F1-02-07-001
5. Remove bolt (4) to remove pilot shut-off valve (6).
: 17 mm
4
5
7
6
W178-02-08-001
15 16 4
14 17
13
12
10
11 W178-02-08-002
8- Hose DP: (To the oil tank)
9- Hose PI: (To the signal control valve)
10 - Hose PH: (To the signal control valve)
11 - Hose PF: (To the solenoid valve unit)
12 - Hose T6: (To the right pilot valve)
13 - Hose P2: (To the left pilot valve)
14 - Hose P3: (To the right pilot valve)
15 - Hose T5: (To the left pilot valve)
16 - Hose P1: (To the travel pilot valve)
17 - Hose T4: (To the travel pilot valve)
W2-8-2
Installation
1. Install pilot shut-off valve (6) with bolt (4).
15 16 4
14 17
2. Install lever (3) with spring pin (7).
13
3. 3. Connect hoses (8 to 15) and pipes (16 and 17). 6
4. Install spring (5).

8
5. Install under cover (2) with bolts (1) (5 used).
Tightening Torqne 12
Wrench Size (mm) Remark
N]m (kgf]m) (lbf]ft)
: 17 50 (5.1) (37) Bolt
: 19 29.5 (3) (21.5) Hose, pilot
10
11 W178-02-08-002
8- Hose DP: (To the oil tank)
9- Hose PI: (To the signal control valve)
10 - Hose PH: (To the signal control valve)
11 - Hose PF: (To the solenoid valve unit)
12 - Hose T6: (To the right pilot valve)
13 - Hose P2: (To the left pilot valve)
14 - Hose P3: (To the right pilot valve)
15 - Hose T5: (To the left pilot valve)
16 - Hose P1: (To the travel pilot valve)
17 - Hose T4: (To the travel pilot valve)
4
5
7
6
W178-02-08-001
W1F1-02-07-001
W2-8-3
DISASSEMBLE PILOT SHUT-OFF VALVE
3
6
2
7
1
8
9
13 10
11
12
W178-02-08-005
1- Washer 5- Socket Bolt 9- O-Ring 13 - Socket Bolt

2- Backup Ring 6- Retaining Ring 10 - Spool
3- O-Ring 7- Washer 11 - Bracket
4- Body 8- Backup Ring 12 - Pin
W2-8-4
Disassemble Pilot Shut-Off Valve
• Be sure to thoroughly read all Precautions for

Disassembly / Assembly work on page W1-1-1
before starting any work.
1. Make the matching marks on body (4) and

bracket (11). Remove retaining ring (6), washer
(7), backup ring (8) and O-ring (9) from body (4) to
remove the spool (10) assembly.
2. Remove washer (1), backup ring (2) and O-ring

(3) from body (4).
3. Clamp spool (10) with a wooden pieces in a vise.

Remove socket bolt (13) and bracket (11).
: 4 mm
NOTE: Don’t remove pin (12) unless necessary.
4. Remove socket bolt (5) from body (4).

: 8 mm
W2-8-5
ASSEMBLE PILOT SHUT-OFF VALVE
12 13 11 4 5 Z
፽⹥ ZҥZ W178-02-08-006
10 6 7 8 9 4 3 2 1 11
13
T178-03-07-002
1- Washer 5- Socket Bolt 9- O-Ring 13 - Socket Bolt

2- Backup Ring 6- Retaining Ring 10 - Spool
3- O-Ring 7- Washer 11 - Bracket
4- Body 8- Backup Ring 12 - Pin
W2-8-6
Assemble Pilot Shut-Off Valve
1. Apply LOCTITE # 262 on socket bolt (5) and in-

stall it to body (4).
: 8 mm
: 29.4 N⋅m (3.0 kgf⋅m, 21.7 Ibf⋅ft)
2. Clamp spool (10) with a wooden pieces in a vise.

Apply LOCTITE #262 on socket bolt (13), then in-
stall bracket (11) onto spool (10).
: 4 mm
: 3.9 N⋅m (0.4 kgf⋅m, 2.9 lbf⋅ft)
3. Install O-ring (3), backup ring (2) and washer (1)

to body (4).
4. Apply hydraulic oil to spool (10) and install it to

body (4).
5. Install O-ring (9), backup ring (8) and washer (7)

to body (4), and install retaining ring (6) to spool
(10).
W2-8-7
(Blank)
W2-8-8
UPPERSTRUCTURE / Signal Control Valve
REMOVE AND INSTALL SIGNAL CON-
TROL VALVE

ing pressure.
Preparation

ing pressure.

NOTE: Be sure to run the vacuum pump con- M104-07-021
tinuously while working on the hydraulic

system.
W2-9-1
Removal Signal Control Valve
IMPORTANT: Attach tags to the disconnected
hoses and pipes to aid in assembly.
NOTE: When removing pipe of signal control valve,

if a SNAP-ON TOOL (GAN850812B: tool Control Valve
size: 19.05 mm) is used, it may be easier to
remove the pipe.
1. Disconnect all hoses and pipes from each port.
2. Remove the pressure sensors (swing, travel).
3. Remove bolt (20) to remove the signal control

valve.
: 8 mm
Installation T176-04-04-001
1. Apply LOCTITE to bolt (20) and install the signal Pilot Valve Side
PH
control valve. A
C M
2. Connect all hoses and pipes to each port.
E B
3. Install the pressure sensors (swing, travel). D SB
H G
Wrench size Tightening Torque F
Remark N
(mm) N⋅m (kgf⋅m) (Ibf⋅ft)
PI
: 17 25 (2.5) (18) Hose, pipe
: 19 29.5 (3) (21.5) Hose Pilot Valve
I
: 24 16 (1.6) (11.5) Pressure sensor Side
K J
:8 50 (5.1) (37) Bolt
DF
SH
SA L 20
T178-03-06-016
Control Valve Side
SM
3
1 5
13
2 4
SK SE
7 8
14
6
Pressure Sensor
(Swing)
9
Control Valve SN
Side
10 11
SL
Pressure
Sensor (Travel) 20 12 SP T178-03-06-015
W2-9-2
Pilot Valve Side

Port Name Connected To Remark
Port A Right pilot valve Boom raise pilot pressure
Port B Right pilot valve Boom lower pilot pressure
Port C Left pilot valve Arm roll-out pilot pressure
Port D Left pilot valve Arm roll-in pilot pressure
Port E Left pilot valve Left swing pilot pressure
Port F Left pilot valve Right swing pilot pressure
Port G Right pilot valve Bucket roll-in pilot pressure
Port H Right pilot valve Bucket roll-out pilot pressure
Port I Travel pilot valve Left travel forward pilot pressure
Port J Travel pilot valve Left travel reverse pilot pressure
Port K Travel pilot valve Right travel forward pilot pressure
Port L Travel pilot valve Right travel reverse pilot pressure
Port M Auxiliary pilot valve Auxiliary open pilot pressure
Port N Auxiliary pilot valve Auxiliary close pilot pressure
Port SA Pump 1 regulator Pump 1 control pressure
Port SB Pump 2 regulator Pump 2 control pressure
Port PI Pilot shut-off valve Primary pilot pressure
Port PH Pilot shut-off valve Primary pilot pressure (Heat Circuit)
Port SH Swing parking brake Brake release pressure
Port DF Hydraulic oil tank Return to hydraulic oil tank
Control Valve Side

Port Name Connected To Remark
Port 1 Control valve Boom raise pilot pressure
Port 2 Control valve Boom lower pilot pressure
Port 3 Control valve Arm roll-out pilot pressure
Port 4 Control valve Arm roll-in pilot pressure
Port 5 Control valve Left swing pilot pressure
Port 6 Control valve Right swing pilot pressure
Port 7 Control valve Bucket roll-in pilot pressure
Port 8 Control valve Bucket roll-out pilot pressure
Port 9 Control valve Left travel forward pilot pressure
Port 10 Control valve Left travel reverse pilot pressure
Port 11 Control valve Right travel forward pilot pressure
Port 12 Control valve Right travel reverse pilot pressure
Port 13 Control valve Auxiliary open pilot pressure
Port 14 Control valve Auxiliary close pilot pressure
Port SE – Plug
Port SM Hydraulic oil tank Return to hydraulic oil tank
Port SN – Plug
Port SP Solenoid Valve Unit Return to hydraulic oil tank
Port SL Control valve Flow combiner valve control pressure
Port SK Control valve Bucket flow rate control valve control pressure
W2-9-3
(Blank)
W2-9-4
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE
UNIT
CAUTION: Escaping fluid under pressure may

penetrate the skin, causing serious injury.
Avoid this hazard by relieving pressure be-
fore disconnecting hydraulic or other lines.
ing pressure.
Preparation

ing pressure.

NOTE: Be sure to run the vacuum pump con- M104-07-021
tinuously while working on the hydraulic

system.
W2-10-1
Removal Solenoid Valve Unit
1. Disconnect each harness of solenoid valves (8
and 9) from the connector.
2. Disconnect pilot pipes (1 to 6, 10 and 11).
3. Remove bolts (7) (2 used) to remove the solenoid

valve unit. 9
: 17, 19 mm
: 8 mm 8
Installation
1. Install the solenoid valve unit with bolts (7) (2
Connector
used).
W1F1-02-10-003
2. Connect pilot pipes (1 to 6, 10 and 11) 11 1
2
3. Connect each harness of solenoid valves (8 and
9) to the connector.
Tightening Torque
Wrench Size (mm) Remark 10
N⋅m (kgf⋅m) (Ibf⋅ft)
: 17 25 (2.5) (18) Pipe, Hose

: 19 30 (3) (21.5) Hose
Solenoid Valve Unit
: 8 50 (5.1) (37) Bolt 9
8
7
4
5
W187-02-10-001
1- Hose (DK): To control valve (4-spool section)

2- Hose : To signal control valve port SP
3- Hose : To hydrarulic oil tank
4- Hose (SI) : To center joint
5- Pipe : To control valve (4-spool section)
6- Hose : To control valve (5-spool section)
7- Socket Bolt
8- Proportional solenoid valve (SI)
9- Proportional solenoid valve (SC)
10 - Hose (PF): From pilot shut-off valve
11 - Hose (PD): From pilot filter
W2-10-2
Removal Solenoid
1. Disconnect each harness of solenoid valves (19, Valve Unit
20) from the connector.
2. Disconnect pilot pipes (13 to 18).
3. Remove bolts (12) (4 used) to remove the sole-

19
noid valve unit.
: 17, 19, 27 mm 20
: 6 mm
Connector
Installation
1. Install the solenoid valve unit with bolts (12) (4
used).
Pilot Filter
2. Connect pilot pipes (13 to 18)
3. Connect each harness of solenoid valves (19, 20)

to the connector. W1F1-02-10-001
12
Tightening Torque
Wrench Size (mm) Remark 13
N⋅m (kgf⋅m) (Ibf⋅ft)
: 17 25 (2.5) (18) Pipe, Hose Solenoid Valve Unit

: 19 30 (3) (21.5) Hose
: 27 93 (9.5) (69) Hose 14
: 6 20 (2.0) (15) Bolt
19
15
20
17 16
18
W1F1-02-10-002
12 - Socket bolt
13 - Hose (ST) : From pump
14 - Hose (DI) : To hydraulic oil tank
15 - Hose (SB) : To signal control valve port SB
16 - Hose (SB2) : From pump
17 - Hose (PD) : To solenoid valve port PD
18 - Hose (TA) : To hydraulic oil tank
19 - Proportional solenoid valve (SB)
20 - Proportional solenoid valve (ST)
W2-10-3
DISASSEMBLE PROPORTIONAL SOLENOIDVALVE
1
3
2
4
5
7
8
9
10
13
11
12 14
15
16
17
18
W157-02-11-016
1- Socket Bolt (2 Used) 6- Solenoid 11 - Washer 15 - O-Ring

2- Lock Nut 7- Spring 12 - Spring 16 - Sleeve
3- O-Ring 8- O-Ring 13 - O-Ring 17 - Plate
4- Adjusting Screw 9- Diaphragm 14 - O-Ring 18 - Washer
5- Spring 10 - Spool
W2-10-4
Disassemble Proportional Solenoid Valve
• Be sure to read “Precautions for disassembly and
Assembly” thoroughly on page W1-1-1 before
starting the disassembly work.
IMPORTANT: Take care not to lose spring (7) pro-

vided in the hole of solenoid (6)
when removing solenoid (6).
Do not turn lock nut (2) and adjust-
ing screw (4).
1. Loosen socket bolts (1) (2 used) to remove sole-
noid (6).
: 3 mm
2. Pull out spool (10) and remove diaphragm (9),

washer (11) and spring (12).
3. Pull sleeve (16) out and remove O-rings (13), (14)

and (15). Remove washer (18) and plate (17).
W2-10-5
ASSEMBLE PROPORTIONAL SOLENOID
VALVE
4 2 6 1 8 16 13 14 10 15 18
9 7 11 12 17
W157-02-11-001
1- Socket Bolt (2 Used) 6- Solenoid 11 - Washer 15 - O-Ring

2- Lock Nut 7- Spring 12 - Spring 16 - Sleeve
3- *O-Ring 8- O-Ring 13 - O-Ring 17 - Plate
4- Adjusting Screw 9- Diaphragm 14 - O-Ring 18 - Washer
5- *Spring 10 - Spool
NOTE: As for the parts marked with *, refer to page
W2-10-4.
W2-10-6
Assemble Proportional Solenoid Valve
IMPORTANT: Lock nut (2), adjusting screw (4),
IMPORTANT: Apply grease to O-rings (13), (14) spring (5) and O-ring (3) are not
and (15). Apply hydraulic oil to separated, so no need to assemble
sleeve (16). them.
1. Install washer (18) and plate (17) into the housing. Take care not to drop spring (7)
Install O-rings (13), (14) and (15) onto sleeve (16) when installing solenoid (6).
and insert it into the housing. 3. Install solenoid (6) with socket bolts (1) (2 used).
: 3 mm
16
: 2.9 N⋅m (0.3 kgf⋅m, 2.1 Ibf⋅ft)
15
14
13
6
Housing
7
W157-02-11-005
IMPORTANT: Apply hydraulic oil to spool(10). Take
care not to damage the edge portion
in the bore of sleeve (16) when in-
1
serting the spool (10) assembly.
After inserting the spool, check if W157-02-11-011
spool (10) slides in and out smoothly
without any restriction about 3 to 5
mm (0.12 to 0.20 in).
2. Install diaphragm (9), washer (11) and spring (12)
to spool (10) and insert it into sleeve (16).
10
16
12 Housing
11
W157-02-11-009
10
W157-02-11-010
W2-10-7
(Blank)
W2-10-8
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
SECTION 3
UNDERCARRIAGE
 CONTENTS 
Group 1 Swing Bearing Group 5 Front Idler
Remove and Install Swing Bearing.............. W3-1-1 Remove and Install Front Idler .....................W3-5-1
Disassemble Swing Bearing ........................ W3-1-4 Disassemble Front Idler ...............................W3-5-2
Assemble Swing Bearing............................. W3-1-6 Assemble Front Idler ....................................W3-5-6
Maintenance Standard .................................W3-5-8
Group 2 Travel Device
Remove and Install Travel Device ............... W3-2-1 Group 6 Upper and Lower Roller
Disassemble Travel Motor ........................... W3-2-4 Remove and Install Upper Roller .................W3-6-1
Assemble Travel Motor................................ W3-2-8 Remove and Install Lower Roller .................W3-6-5
Disassemble Travel Device ....................... W3-2-12 Disassemble Lower Roller ...........................W3-6-8
Assemble Travel Device ............................ W3-2-16 Assemble Lower Roller ..............................W3-6-10
Disassemble Base Plate............................ W3-2-20 Maintenance Standard ...............................W3-6-12
Assemble Base Plate................................. W3-2-22
Maintenance Standard............................... W3-2-24 Group 7 Track
Remove and Install Tracks...........................W3-7-1
Group 3 Center Joint Maintenance Standard .................................W3-7-8
Remove and Install Center Joint.................. W3-3-1
Disassemble Center Joint............................ W3-3-4
Assemble Center Joint ................................ W3-3-6
Maintenance Standard................................. W3-3-9
Group 4 Track Adjuster

Remove and Install Track Adjuster.............. W3-4-1
Disassemble Track Adjuster........................ W3-4-2
Assemble Track Adjuster........................... W3-4-10
1F1W-3-1
(Blank)
1F1W-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Before removing the swing bearing, the upperstructure

must be removed first. For removal and installation of
the upperstructure, refer to “Remove and Install Main
Frame” section.
In this section, the procedure starts on the premise that
the upperstructure has already been removed.
Removal
1. Put alignment marks on inner race of swing bear-
ing (1) and track frame (2).
Mark
1 2
W105-03-01-001
2. Remove all bolts (3) (36 used) from inner race of

swing bearing.
: 30 mm
W158-03-01-001
CAUTION: Swing bearing weight: 220 kg

(490 Ib)
3. Attach lifting tools (ST 0050), hoist swing bearing

(4) and remove it.
ST 0050
4 W110-03-01-004
W3-1-1
Installation
Clean the matching surfaces of the frame and swing
bearing.
1. Apply THREEBOND # 1102 to the matching sur-

faces of the track frame and swing bearing.
CAUTION: Swing bearing weight:

220 kg (490 Ib)
W110-03-01-004
IMPORTANT: Failure to align the marks may result Front Side Position for Grease Fitting
in misalignment of the inner race
soft zone. ″S″ (Soft Zone)
Marking Position
2. Hoist the swing bearing by crane. Align the align- 8°
Position of Plug
ment marks both on the track frame and swing
bearing.
10°
19°
Position for Grease

Fitting
W178-03-01-001
3. Install mounting bolts (3) (36 used) to the inner

race of the swing bearing and tighten to specifica-
tion.
: 30 mm
: 490 N]m (50 kgf]m, 360 Ibf⋅ft)
W158-03-01-001
W3-1-2
4. After installing the swing bearing, fill the grease
bath with grease (Shell Alvania EP2 or equivalent) Swing Bearing Grease Level Pinion
until the pinion of the swing bearing is covered
5 mm in grease.
5 mm
W175-03-01-002
Grease Bath
W3-1-3
DISASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W157-03-01-003
9
7
6
W157-03-01-002
1 - Outer Race 4 - Plug 6 - Ball (121 Used) 8 - Grease Fitting (2 Used)

2 - Seal 5 - Seal 7 - Inner Race 9 - Support (121 Used)
3 - Pin
W3-1-4
Disassemble Swing Bearing
• Be sure to read “Precautions for Disassembly and
Assembly” thoroughly on page W1-1-1 before CAUTION: Swing bearing outer race (1)
starting the disassembly work. weight: 90 kg (200 lb)
3. Install lifting tool (ST 0050) to swing bearing outer
1. Drive to remove pin (3) of plug (4) from the bottom race (1). Hoist the swing bearing outer race
side of the swing bearing. slightly by crane. Remove seals (2) and (5).
NOTE: The top of pin (3) was crimped. Shave the
crimped part with a grinder. 4. Put inner race (7) of the swing bearing on the
wooden blocks. Hoist outer race (1) to take up a
3 slack of the wire rope by crane.
5. While rotating outer race (1), remove balls (6)

(121 used) and supports (9) (121 used).
Remove the balls with bar magnet (A).
Remove supports (9) with bent wire (B).
1
4 2
W105-03-01-007
A
Ȁ
2. Remove plug (4). 7
NOTE: Screw bolt (M10, pitch 1.5 mm) in plug (4).
Take out the bolt together with the plug (4)
by tapping the bolt head back or by with-
drawing the bolt.
6 5 W105-03-01-009
4
B
W105-03-01-008
9 W105-03-01-010
W3-1-5
ASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W157-03-01-003
9
7
6
W157-03-01-002
1 - Outer Race 4 - Plug 6 - Ball (121 Used) 8 - Grease Fitting (2 Used)

2 - Seal 5 - Seal 7 - Inner Race 9 - Support (121 Used)
3 - Pin
W3-1-6
Assemble Swing Bearing

• Be sure to read “Precautions for Disassembly and 3. Drive the plug (4) into outer race (1), then drive
Assembly” thoroughly on page W1-1-1 before pin (3) into the pin hole.
starting the assembly work. Caulk pin (3) top with a punch.
Fill grease 0.5 L (0.132 US gal, Alvania EP2 or
1. Before installing the swing bearing inner and outer equivalent) into a grease fitting (8) at the swing
races, completely remove the oil from the groove bearing.
surfaces of oil seals (2) and (5). Apply THREE- 3
BOND #1735 to the groove surfaces (seal (5)),
#1745 to the groove surface (seal (2)), then install
1
seals (2) and (5).
IMPORTANT: Apply the grease to balls (6) (121

used) , supports (9) (121 used).
CAUTION: Swing bearing outer race weight: 4

90 kg (200 lb)
2. Hoist the outer race using lifting tool (ST 0050) by
W142-03-01-007
crane. Align the center of the outer race and the
inner race. While rotating the outer race, install
ball (6) and support (9) into the bearing races in
the order with a round wooden stick.
5
W142-03-01-005
W142-03-01-006
W3-1-7
(Blank)
W3-1-8
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE

Avoid this hazard by relieving pressure
Hydraulic oil may be hot just after operation.
Hot hydraulic oil may spout, possibly causing
severe burns. Be sure to wait for oil to cool
before starting work.
The hydraulic oil tank cap may fly off if
removed without releasing internal pressure
pressure.
Preparations
1. Park the machine on a film and level surface.

Then, lower the front attachment to the ground.
2. Stop the engine. Operate all control levers several

times to release remaining pressure in the
hydraulic circuits. Push the air release valve on
the top of the hydraulic oil tank to release any
remaining pressure.
3. Remove the cap from the hydraulic oil tank and M104-07-021
install a vacuum pump. Operate the vacuum

pump to maintain negative pressure in the
hydraulic oil tank.
NOTE: Keep the vacuum pump running while

working.
W3-2-1
Removal
The removal procedure below starts on the premise
that track has been removed. As for the removal of
track, refer to W3-7-1.
1. Remove bolt (7) (6 used) and cover (6) to discon-

nect hoses (2 to 5).
: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18.5 lbf⋅ft)
: 22 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
: 27 mm
: 95 N⋅m (9.7 kgf⋅m, 70 lbf⋅ft)
: 36 mm
: 180 N⋅m (18.5 kgf⋅m, 133 lbf⋅ft)
NOTE: Cap the ends of disconnected hoses and

pipes.
2. Make preparation to hoist the travel device with 5
wire rope. 4
CAUTION: Travel device weight:

230 kg (510 Ib)
1
3. Remove bolt (1) (16 used) to hoist and remove the
travel device by crane.
: 22 mm
: 140 N⋅m (14.3 kgf⋅m, 103 Ibf⋅ft)
3
Installation
2
NOTE: Refer to the “Removal” section for wrench
sizes and tightening torque.
1. Install the travel device to the track frame with

bolts (1) (16 used).
2. Reconnect hoses (2 to 5) to the travel device.
3. Install cover (6) to the track frame with bolt (7) (6 6
used).
IMPORTANT: After completing travel motor instal-

lation, be sure to fill the travel motor 7 W157-03-02-006
with hydraulic oil 0.5 L (0.13 US gal).
After completing installation of the
travel motor or the travel device, be
sure to perform break-in operation
to prevent motor seizure. Test drive
as follows:
Break-in operation condition:
1. Engine control dial: Slow idle
2. Travel mode switch: Slow speed mode
3. Operation duration: Above two minutes
W3-2-2
(Blank)
W3-2-3
DISASSEMBLE TRAVEL MOTOR
9 10
8
7
5 6
4 22
3 21
20
19
39
18
2 17
16
1 15
14
13
12
36
11
35
33 34
32
31
30
29
27 28
26
24
25
24
37
23
38
W1F1-03-02-002
1- Bolt (16 Used) 11 - Shaft 21 - Collar 31 - Pin (4 Used)

2- Spring Washer (16 Used) 12 - Steel Ball (2 Used) 22 - Retaining ring 32 - O-Ring
3- Sprocket 13 - Thrust Plate 23 - Valve Plate 33 - Backup Ring
4- Plug (3 Used) 14 - Plunger (9 Used) 24 - Disc Plate (2 Used) 34 - Ball Bearing
5- Housing 15 - Retainer Plate 25 - Friction Plate 35 - Pin
6- Spring (2 Used) 16 - Holder 26 - O-Ring 36 - Base Plate
7- Piston (2 Used) 17 - Pin (3 Used) 27 - Collar 37 - Socket Bolt (9 Used)
8- O-Ring 18 - Rotor 28 - Backup Ring 38 - Spring (8 Used)
9- Oil Seal 19 - Collar 29 - O-Ring 39 - O-Ring (9 Used)
10 - Ball Bearing 20 - Spring 30 - Piston
W3-2-4
Disassemble Travel Motor

assembly and Assembly” on page W1-1-1 before
starting the disassembly work.
CAUTION: Travel devise weight: 280 kg

(620 Ib)
1. Lift the travel device by crane, and rest it on a

workbench, with the base plate (36) facing upward.
Then secure it in stable position.
CAUTION: Base plate weight: 22kg (49 Ib)
IMPORTANT: When removing base plate (36),

valve plate (23) may come off.
Slowly remove the base plate from
housing (5).
2. Springs (38) (8 used) are pushing base plate (36)

upward.
Loosen socket bolts (37) (9 used) uniformly to
remove the base plate from housing (5).
: 12 mm
3. Remove O-rings (39) (4 used), (8) and springs

(38) (8 used) from housing (5). Remove valve
plate (23), Pins (31) (4 used), (35) from base plate
(36).
CAUTION: When removing piston (30) using

compressed air, be sure to cover the piston
with cloths to prevent the piston from flying
out.
4. Supply compressed air less than 0.3 MPa (3.1

3
kgf/cm , 44 psi) into the brake release oil passage
so that piston (30) will float up to be removed.
5. Remove collar (27), disc plate (24), friction plate

(25) and disc plate (24) from housing (5).
6. Remove O-rings (29 and 32) and backup rings

(28 and 33) from piston (30). Remove O-ring (26)
from collar (27).
7. Remove rotor (18) assembly from housing (5).
8. Put matching marks on plungers (14) and rotor

(18) so that they can be reassembled in the same
position each other. Remove plungers (14) and re-
tainer plate (15).
W3-2-5
10
7
5 6
4 22
3 21
20
19
18
2 17
16
1
13
12
36
11
34
W1F1-03-02-002
W3-2-6
9. Remove holder (16) and pins (17) (3 used) from
rotor (18).
10. Using a press, compress collar (21) and spring

(20). While holding the press in that position, re-
move retaining ring (22).
Remove collar (21), spring (20) and collar (19)
from rotor (18) in order while retracting the press.
IMPORTANT: When removing thrust plate (13),

pistons (7) (2 used) and steel balls
(12) (2 used) may come out together
with thrust plate (13). Take care not
to drop pistons or steel balls.
11. Remove thrust plate (13) from housing (5).
12. Remove pistons (7) (2 used) and springs (6) (2

used). If steel balls (12) (2 used) are hard to be
removed, clean the balls and their vicinities with
white kerosene or thinner. Then, use a magnet to
draw steel balls (2 used) out of housing (5).
13. Remove shaft (11) from housing (5). Remove ball

bearing (10) from shaft using a press.
14. Remove ball bearing (34) from base plate (36).
CAUTION: Housing (5) assembly weight:

120 kg (265 Ib)
15. Install eye-bolts (M16) into screw holes on hous-

ing (5). Lift housing (5) by crane.
While lifting the housing by crane, loosen plugs
(4) (2 used) to drain oil.
: 12 mm
CAUTION: Housing (5) assembly weight:

120 kg (265 Ib)
16. Turn over housing (5) assembly by crane.
CAUTION: Sprocket weight: 50 kg (110 Ib)
17. Remove bolts (1) (16 used) and spring washers

(2) (16 used). Remove sprocket (3) from housing
(5) by crane.
: 30 mm
W3-2-7
ASSEMBLE TRAVEL MOTOR
26 24
28
32 27 25 24 14 17
33 5
8
37
29
31
18
35
23
36 Drive Gear
34
21
22
4
20
38
19
31
30
39 15
16 11 9
13 12 10
W1F1-03-02-003
1- *Bolt (16 Used) 11 - Shaft 21 - Collar 31 - Pin (4 Used)

2- *Spring Washer (16 Used) 12 - Steel Ball (2 Used) 22 - Retaining ring 32 - O-Ring
3- *Sprocket 13 - Thrust Plate 23 - Valve Plate 33 - Backup Ring
4- Plug (3 Used) 14 - Plunger (9 Used) 24 - Disc Plate (2 Used) 34 - Ball Bearing
5- Housing 15 - Retainer Plate 25 - Friction Plate 35 - Pin
6- *Spring (2 Used) 16 - Holder 26 - O-Ring 36 - Base Plate
7- *Piston (2 Used) 17 - Pin (3 Used) 27 - Collar 37 - Socket Bolt (9 Used)
8- O-Ring 18 - Rotor 28 - Backup Ring 38 - Spring (8 Used)
9- Oil Seal 19 - Collar 29 - O-Ring 39 - O-Ring (9 Used)
10 - Ball Bearing 20 - Spring 30 - Piston
NOTE: As for mark *, refer to W3-2-4
W3-2-8
Assemble Travel Motor
7. Apply grease to steel balls (12) (2 used), then in-

CAUTION: Sprocket weight: 50 kg (110 Ib)
sert them into housing (5).
IMPORTANT: Check that the chamfered sprocket
8. Align the holes on thrust plate (13) with the loca-
(3) surface faces toward the mating
tions of steel balls (12) (2 used). Then, install
surface on housing (5)
thrust plate into housing (5).
1. Install sprocket (3) onto housing (5) by crane.
9. Install collar (19), spring (20) and collar (21) into
Tighten sprocket (3) to housing (5) with bolts (1)
rotor (18) in order. While pushing collar (21) with a
(16 used) and spring washer (2) (16 used).
press, install retaining ring (22) into rotor (18).
: 30 mm
10.Install pins (17) (3 used) and holder (16) into rotor
: 460 N⋅m (47 kgf⋅m, 340 Ibf⋅ft)
(18).
CAUTION: Housing (5) assembly weight: 11.Align matching marks put on when disassembling
170 kg (370 Ib) plungers (14) and rotor (18). Install plungers (14)
(9 used) and retainer plate (15) into rotor (18).
2. Turn over housing (5) assembly by crane.
3. Install ball bearing (34) into base plate (36). At-

tach a metal bar to ball bearing (34) and tap the
end of the metal bar to completely install the bear-
ing in position.
4. Install ball bearing (10) on to shaft (11) with a

press.
5. Align spline teeth on both shaft (11) and the drive

gear (the drive gear (5) is shown on page W3-2-
12). While tapping the end of shaft (11) with a
plastic hammer, Install shaft (11) with ball bearing
(10) into the drive gear.
6. Apply grease to pistons (7) (2 used). Then, install

spring (6) into each piston. Install piston with
spring into housing (5).
6
7 W1F1-03-02-004
W3-2-9
28 26 24
32 27 25 24
33 5
8
37
29
31
18
35
23
36
38
30
39
11
W1F1-03-02-003
W3-2-10
12. Engage rotor assembly (18) with spline on shaft
(11) in housing (5).
13. Engage disc plate (24) with spline of the rotor (18)
in housing (5). Then, install friction plate (25) and
disc plate (24).
14. Attach O-ring (26) to collar (27), and install them

in housing (5).
15. Attach O-rings (29 and 32) and backup rings (28
and 33) to piston (30). Then, install the piston into
housing (5) while tapping with a plastic hammer.
16. Attach O-rings (39) (4 used) and O-rings (8) to

housing (5). Install springs (38) (8 used) into pis-
ton (30).
CAUTION: Base plate weight: 22 kg (49 Ib)
17. Install pins (31) (4 used) and pin (35) into base
plate (36). Apply a film of grease to valve plate
(23) and install it onto base plate (36), aligning the
pin hole with pin (35).
18. Slowly overturn base plate (36) so that valve plate

(23) does not come off. Install base plate (36)
onto piston (30), aligning the pin (31) (4 used)
holes with pins (31) (4 used).
Equally tighten socket bolts (37) (9 used).
: 12 mm
: 205 N⋅m (21 kgf⋅m, 151 Ibf⋅ft)
W3-2-11
DISASSEMBLE TRAVEL DEVICE
8
7
6
5
4
3
2 9
1 10
11
12
13
14
20
15
16
19
18
17
24
23
22
21
25
26
27
28
29
31 30
W1F1-03-02-005
1- Socket Bolt (16 Used) 9- Thrust Washer (3 Used) 17 - Bearing Nut 25 - Thrust Washer (4 Used)
2- Cover 10 - Inner Race (3 Used) 18 - Bearing 26 - Needle Bearing (4 Used)
3- Thrust Plate 11 - Needle Bearing (3 Used) 19 - Housing 27 - Inner Race (4 Used)
4- Thrust Plate 12 - First Stage Planetary Gear 20 - Bearing 28 - Second Sage Planetary
(3 Used) Gear (4 Used)
5- Drive Gear 13 - Thrust Washer (3 Used) 21 - Floating Seal 29 - Thrust Plate (4 Used)
6- First Stage Holder 14 - Screw (3 Used) 22 - Plug (4 Used) 30 - Spring Pin (4 Used)
7- Retaining Ring 15 - O-Ring (3 Used) 23 - Second Stage Holder 31 - Screw (4 Used)
8- Sun Gear 16 - Plug (3 Used) 24 - Oil Seal
W3-2-12
Disassemble Travel Device
CAUTION: Travel Device Weight:

120 kg (265 Ib)
1. Install eye blots (M16) (2 used) to the screw holes

on second stage holder (23). Using the eye bolts,
Lift the travel device by crane. Loosen two plugs
(16) to drain oil.
: 12 mm
2. Loosen and remove socket bolts (1) (16 used). Af-

ter tapping the fringe of cover (2) with a plastic
hammer, insert a screwdriver into the mating gap
between housing (19) and cover to remove cover.
: 8 mm
IMPORTANT: Remove thrust plate (3), and meas-

ure and record a step distance be-
tween face of housing (19) and that
of thrust plate (4) protruded from
housing (19).
3. Remove thrust plate (3), screw (14) (3 used) and

thrust plate (4) from first stage holder (6).
4. Remove thrust washer (13) (3 used), Planetary

gear (12) (3 used), needle bearing (11) (3 used),
inner race (10) (3 used) and thrust washer (9) (3
used) from first stage holder (6).
5. Remove first stage holder (6) from sun gear (8).
6. Remove sun gear (8) from second stage holder

(23).
7. Loosen and remove screws (31) (4 used). Re-

move second stage planetary gear (28) (4 used)
and thrust plate (29) (4 used) from second stage
holder (23).
: 8 mm
8. Remove needle bearing (26) (4 used), inner race

(27) (4 used) and thrust washer (25) (4 used) from
second stage planetary gears (28) (4 used).
W3-2-13
20
19
18
17
24
23
22
21
30
W1F1-03-02-005
W3-2-14
NOTE: Do not remove spring pins (25) unless re- 15. Tap outer races out of bearings (18) and (20) in
quired. housing (19), using a bar and plastic hammer.
9. Remove plugs (22) (4 used) from second stage

holder (23). Remove bearing nut (17) from hous-
ing (19) with special tool (ST 3154).
: 8 mm, 22 mm
Socket Wrench 22 mm ST 3154
Rotation Handle
W1F1-03-02-006
17 22
W1F1-03-02-007
CAUTION: Second stage holder weight:

50 kg (110 Ib)
10. Remove second stage holder (23) from housing

(19) with a press.
11. Remove the inner race of bearing (18) from hous-

ing (19).
12. Remove one side of floating seal (21) from hous-

ing (19).
13. Remove the other side of floating seal (21) from

second stage holder (23).
NOTE: Do not remove the inner race of bearing

(20) remaining on second stage holder (23)
unless replacement is required.
14. Remove oil seal (24) from second stage holder

(23).
W3-2-15
ASSEMBLE TRAVEL DEVICE
25 26 27 28 29
9 10 11 12 13
4
6
14
3
7
8
5
31
30
16
24
23 21 15
20 18 17 22 19 W1F1-03-02-008
1- Socket Bolt (16 Used) 9- Thrust Washer (3 Used) 17 - Bearing Nut 25 - Thrust Washer (4 Used)
2- Cover 10 - Inner Race (3 Used) 18 - Bearing 26 - Needle Bearing (4 Used)
3- Thrust Plate 11 - Needle Bearing (3 Used) 19 - Housing 27 - Inner Race (4 Used)
4- Thrust Plate 12 - First Stage Planetary Gear 20 - Bearing 28 - Second Sage Planetary
(3 Used) Gear (4 Used)
5- Drive Gear 13 - Thrust Washer (3 Used) 21 - Floating Seal 29 - Thrust Plate (4 Used)
6- First Stage Holder 14 - Screw (3 Used) 22 - Plug (4 Used) 30 - Spring Pin (4 Used)
7- Retaining Ring 15 - O-Ring (3 Used) 23 - Second Stage Holder 31 - Screw (4 Used)
8- Sun Gear 16 - Plug (3 Used) 24 - Oil Seal
W3-2-16
Assemble Travel Device
17 23 22
CAUTION: Housing weight: 45 kg (100 Ib)
1. Tap outer races for bearings (18) and (20) into

housing (19), with a bar and hammer.
2. Install oil seal (24) into second stage holder (23).
3. Heat inner race for the bearing (20) up to 50° to W1F1-03-02-007

70°C (122° to 158°F) with a heater, then set it in IMPORTANT: Re-tap screw holes for plugs (22).
second-stage holder (23). After bearing is cooled
down, drove it into position, using a bar and 8. After tightening plugs (22) (4 used) to second
hammer. stage holder (23), crimp plugs (22) (4 used) two
places with a punch.
4. Install one side of floating seal (21) into housing
(19) and the other side of it into second stage : 8 mm
holder (23). : 39±4.9 N⋅m
(4±0.5 kgf⋅m, 29±3.6 Ibf⋅ft)
CAUTION: Second stage holder weight:
50 kg (110 Ib) 9. Install inner race (27) and needle bearing (26) in
Housing weight: 45 kg (100 Ib) second-stage planetary gear (28). Then, install
thrust washer (25) and planetary gear (28) on
5. Hoist and install housing (19) onto second stage second-stage holder (23) in this order.
holder (23) by crane.
IMPORTANT: Drive spring pin (30) with a slit di-
6. Heat inner race for the bearing (18) up to 50° to rected toward the outer circumfer-
70°C (122° to 158°F) with a heater, then set it in ence.
second-stage holder (23). After bearing is cooled
down, drive it into position, using a bar and ham- 10. Install thrust plate (29) on second stage holder
mer. (23) and drive in spring pins (30). Then tighten
screws (31). Follow the same procedures to install
IMPORTANT: Do not reuse bearing nut (17). Be the other three second stage planetary gears (28).
sure to replace it with new one.
: 8 mm
7. Tighten bearing nut (17) to second stage holder : 59±4.9 N⋅m
(23) with special tool (ST 3154). (6±0.5 kgf⋅m, 43±3.6 Ibf⋅ft)
: 22 mm
: 1245±137 N⋅m
(127±14 kgf⋅m, 920±100 Ibf⋅ft)
Socket Wrench 22 mm ST 3154
Rotation Handle
W1F1-03-02-006
W3-2-17
28
9 10 11 12 13
4
6
14
3
7
8
5
16
19 W1F1-03-02-008
W3-2-18
11. Install retaining ring (7) in sun gear (8). 19. Supply gear oil 3.5 L (0.9 US gal) into a hole of oil
Then, install sun gear (8) aligning the gear teeth supply plug (16) (until oil comes out). Then, install
on second stage planetary gears (28). oil supply plug (16) and oil level check plug (16) to
cover (2).
12. Install inner race (10) and needle bearing (11) into
first stage planetary gear (12). : 12 mm
: 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
13. Install thrust washer (9), first stage planetary gear
(12) and thrust washer (13) in order onto first
stage holder (6). Oil Supply Plug
14. Follow the same procedures to install the other Oil Level
two first stage planetary gears (12) onto first stage Check Plug
holder (6).
15. Install first stage holder (6) into housing (19).

Install drive gear (5) aligning gear teeth on first
W1F1-03-02-009
stage planetary gears (12).
16. Install thrust plate (4) onto first stage holder (6)
with screw (14) (3 used).
IMPORTANT: Before installing thrust plate (3),

measure a step distance between
face of housing (19) and that of
thrust plate (4) protruded from hous-
ing (19). Install thrust plate (3) ac-
cording to the table below.
(mm)
Measure Step Thrust Plate (3) to be
Distance Used
2.88 to 2.22 2.3
2.21 to 1.84 2.8
1.83 to 1.64 3.0
1.63 to 1.36 3.2
1.35 to 1.12 3.6
17. Measure a step distance between face of housing

(19) and that of thrust plate (4) protruded from
housing (19). Then select thrust plate (3) from the
table above, and install it on first-stage holder (6).
18. Apply a film of THREEBOND #1211 to the mount-

ing face on housing (19). Install cover (2) with
: 8 mm
: 73±3.6 N⋅m
(7.4±0.4 kgf⋅m, 54±2.7 Ibf⋅ft)
W3-2-19
DISASSEMBLE BASE PLATE
1
A
B
CD
E
5 7 F 2
5 G
4 A 3
6 B
CD
E D
F
8 GH A
I 9
14 J K 8
15 13 L 10
11
3 13
2
12 13 B
33
16
17 A
B
16
19 34
18 20
13
35
25 21
22
26 23
27 A
28 B
C 24
D
E
D
C 19
B 18
A
23
22
21
20
25
26
28
27
W1F1-03-02-010
1- Spool Assembly 8- Relief Valve (2 Used) 9- O-Ring 23 - Spring Seat (2 Used)
A- Spool A- Poppet 10 - Plug (3 Used) 24 - Plunger Assembly
B- Backup Ring B- Housing 11 - O-Ring (3 used) A- Plug (2 Used)
C- O-Ring C- Piston 12 - Spring B- O-Ring (2 used)
D- O-Ring D- Backup Ring 13 - Plug (9 Used) C- Spring (2 Used)
E- Backup Ring E- O-Ring 14 - Orifice (2 Used) D- Check Valve (2 Used)
F- Filter F- Spring Seat 15 - Orifice (2 Used) E- Plunger
G- Retaining Ring G- Spring 16 - Orifice (2 Used) 25 - Steel Ball (2 Used)
2- O-Ring (2 used) H- Spring Guide 17 - Pin 26 - Spring (2 Used)
3- Plug (2 Used) I- O-Ring 18 - Socket Bolt (8 Used) 27 - O-Ring (2 used)
4- Plug J- Plug 19 - Cap (2 Used) 28 - Plug (2 Used)
5- Backup Ring (2 Used) K- Nut 20 - O-Ring (2 used) 33 - Socket Bolt (9 Used)
6- O-Ring L- Set Screw 21 - Spring Seat (2 Used) 34 - Base Plate
7- Seat 22 - Spring (2 Used) 35 - Pin (2 Used)
W3-2-20
Disassemble base Plate
• Replace each spool assembly (1), relief valve (8) 7. Remove two plus (3) (2 used) to remove spring
and plunger assembly (24) as an assembly unit. (12) from base plate (34).
• Spool assembly (1) and plunger assembly (24)
are installed in base plate (34) with selective fit. : 10 mm
Avoid disassembling them unless required.
When unavoidably disassembled, take care not to 8. Remove O-rings (2) (2 used) from two plugs (3) (2
damage them. used).
1. Remove socket bolts (18) (8 used) to remove IMPORTANT: Spool assembly (1) is installed in
caps (19) (2 used) from base plate (34). base plate (34) with selective fit.
When removing spool assembly (1)
: 8 mm from base plate (34), if spool assem-
bly (1) does not come out smoothly,
2. Remove plugs (28)(2 used) from caps (19) (2 do not try to forcibly remove it.
used). Remove O-ring (27) (2 used) spring (26) (2 Softly tap it with a plastic hammer to
used) and steel ball (25) (2 used) from cap (19) (2 push it back slightly first. Then, after
used). checking that spool assembly (1)
moves smoothly, remove it while
: 14 mm slowly turning it.
3. Remove spring seat (21) (2 used), spring (22) (2 9. Softly tap the end face of spool assembly (1) to
used) and spring seat (23) (2 used) from base push out the other end of spool assembly (1) from
plate (34). base plate (34). Hold the protruded end of spool
assembly (1) by hand and pull it out of base plate
IMPORTANT: Plunger assembly (24) is installed in (34) while turning the spool assembly.
base plate (34) with selective fit.
When removing plunger assembly NOTE: Do not remove plugs (13) (9 used) unless
(24) from base plate (34), if plunger required.
assembly (24) does not come out Do not remove orifices (14 (2 used), 15 (2
smoothly, do not try forcibly remove used) and 16 (2 used)) as they are crimped
it. Softly tap it with a plastic hammer with base plate (1).
to push it back slightly first. Then,
after checking that plunger assem-
bly (24) moves smoothly, remove it
while slowly turning it.
4. Softly tap the end face of plunger assembly (24) to

push out the other end of plunger assembly (24)
from base plate (34). Hold the protruded end of
plunger assembly (24) by hand and pull it out of
base plate (34) while turning the plunger.
5. After removing relief valve (8), remove seat (7)

from base plate (34).
6. Remove backup rings (5) (2 used) and O-ring (6)

from seat (7). Remove O-ring (9) from relief valve
(8).
: 27 mm
W3-2-21
ASSEMBLE BASE PLATE
6, 5
2 7 13 14, 15 1 12 2 3 8
4 33 17
9 10, 11
18
21
19
22
16 34 13 24 23 20 35
18
19
27
25
26
28
W1F1-03-02-011
1- Spool Assembly 8- Relief Valve (2 Used) 16 - Orifice (2 Used) 24 - Plunger Assembly

2- O-Ring (2 used) 9- O-Ring 17 - Pin 25 - Steel Ball (2 Used)
3- Plug (2 Used) 10 - Plug (3 Used) 18 - Socket Bolt (8 Used) 26 - Spring (2 Used)
4- Plug 11 - O-Ring (3 used) 19 - Cap (2 Used) 27 - O-Ring (2 used)
5- Backup Ring (2 Used) 12 - Spring 20 - O-Ring (2 used) 28 - Plug (2 Used)
6- O-Ring 13 - Plug (9 Used) 21 - Spring Seat (2 Used) 33 - Socket Bolt (9 Used)
7- Seat 14 - Orifice (2 Used) 22 - Spring (2 Used) 34 - Base Plate
J- Plug 15 - Orifice (2 Used) 23 - Spring Seat (2 Used) 35 - Pin (2 Used)
W3-2-22
Assemble Base Plate
IMPORTANT: Spool assembly (1) and plunger as- 8. Attach O-rings(27) (2 used) to plugs (28) (2used).
sembly (24) are installed in base Then install plugs (28) (2 used) into caps (19) (2
plate (34) with selective fit. used).
Avoid disassembling them unless
required. When disassembly is un- : 14 mm
avoidable, take care not to damage : 21±1 N⋅m
them. (2.1±0.1 kgf⋅m, 15.5±0.7 Ibf⋅ft)
9. Install spring seats (23), springs (22) and spring

CAUTION: Base plate weight: 22 kg (49 Ib)
seats (21) in order on the both ends of plunger
assembly (24) in base plate (34).
1. After applying a film of hydraulic oil to spool as-
sembly (1), install it into base plate (34) while turn-
10. Attach O-rings (20) (2 used) to caps (19) (2 used).
ing spool (1). After installing spool (1) assembly,
Then, install caps (19) (2 used) into base plate
check that spool assembly (1) smoothly moves.
(34) with socket bolts (18) (8 used).
2. Install spring (12) into spool assembly (1). Attach
: 8 mm
O-ring (2) (2 used) to plug (3) (2 used). Then, in-
: 59±5 N⋅m
stall plugs (3) (2 used) into base plate (34).
(6±0.5 kgf⋅m, 44±3.6 Ibf⋅ft)
: 10 mm
: 118±6 N⋅m
(12±0.6 kgf⋅m, 87±4.4 Ibf⋅ft)
3. Attach backup ring (5), O-ring (6) and backup ring

(5) to seat (7).
4. Attach O-ring (9) to plug (J) of relief valve (8).

Then, install seat (7) into relief valve (8).
5. Install relief valves (8) (2 used) to base plate (34).
: 27 mm
: 370±20 N⋅m
(38±2 kgf⋅m, 275±15 Ibf⋅ft)
6. After applying a film of hydraulic oil to plunger as-

sembly (24), install it into base plate (34) while
turning plunger (24). After installing plunger as-
sembly (24), check that plunger assembly (24)
smoothly moves.
7. Install steel balls (25) (2 used) and springs (26) (2

used) into caps (19) (2 used).
W3-2-23
Sprocket
B
C
D
A W105-03-07-040
W1SE-03-02-001
Unit: mm (in)
A 70.00 (2.76) [60.00 (2.36)]

B 110.3 (4.34) 105.3 (4.15) Build up and
C 149.7 (5.89) 144.7 (5.70) finishing
C’ PCD142.8 (5.62) -
D 190.0 (7.48) -
NOTE: Value in [Ӹ] is just for reference.
W3-2-24
Parking Brake
W165-03-02-008
Unit: mm (in)
Allowable Limit
Part Name Standard Remedy
(Thickness)
A Spring Free Length :36.2 - Replace the deformed or damaged
(1.425) spring.
B Piston Thickness :45.7 45.68 Replace if scratch depth is 0.02 mm or
(1.799) (1.798) more, or surface is capped.
C Friction Plate Thickness :3.2 - Replace if slide surface is deeply
(0.126) scratched or friction or friction material
is separated.
W3-2-25
(Blank)
W3-2-26
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT
CAUTION: Hydraulic flue under pressure can

penetrate the skin or eyes, causing serious
injury. Avoid this hazard by releasing pres-
sure before disconnecting hydraulic or other
lines.
Hydraulic oil may be hot just after operation
and may spurt, causing severe burns. Be
sure to wait for oil to cool before starting
work.
moved without first releasing internal pres-
sure. Push the air release valve on top of
ing pressure.
Preparation
1. Park the machine on a firm, level surface. Lower
the front attachment onto the ground.

pressure.
3. Remove hydraulic oil tank cap, connect a vacuum

pump and put it into operation to keep negative
pressure in the hydraulic oil tank. M104-07-021
Be sure to run the vacuum pump continuously
while working.
W3-3-1
Removal
1. Attach tags to hoses and adapters of the center

joint to aid in assembly.
Ȁ Disconnect all hoses and adapters from the cen-
ter joint. Plug all disconnected ends.
: 17 mm
: 25 N⋅m (2.6 kgf⋅m, 18.5 lbf⋅ft)
: 19 mm
: 30 N⋅m (3.1 kgf⋅m, 22 lbf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
2. Remove bolt (1) (2 used) from the center joint to

remove stopper plate (2). 1 2
: 22 mm
: 140 N⋅m (14.5 kgf⋅m, 103 lbf⋅ft)
CAUTION: Center joint weight: 26.5 kg (58 lb)
3. Remove bolt (3) (2 used) from the center joint. Lift

the center joint and remove it by crane.
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
W157-03-03-003
Installation
NOTE: Refer to “Removal” section above for
wrench sizes and tightening torque. 3
1. Install the center joint with bolts (3) (4 used).
2. Install stopper plate (2) to the center joint with

bolts (1) (2 used).
3. Connect all hoses to center joint.
IMPORTANT: After installation, start engine and

check the component for any oil
leaks.
W105-03-03-003
W3-3-2
(Blank)
W3-3-3
DISASSEMBLE CENTER JOINT
3
4
10
9
11
12
W157-03-03-002
1 - Plug (With Ball) 4 - O-Ring 7 - Body 10 - Retaining Ring

2 - Spindle 5 - Bushing 8 - Ring 11 - Cover
3 - Dust Seal 6 - Oil Seal (6 Used) 9 - O-Ring 12 - Bolt (4 Used)
W3-3-4
Disassemble Center Joint IMPORTANT: For easy removal, two pins can be
• Be sure to thoroughly read “Precautions for Dis- used to pry out oil seals (6). Take
assembly and Assembly Work” on page W1-1-1 care not to damage the seal groove
before starting the disassembly work. with the pins.
6. Remove oil seals (6) (6 used) and O-ring (4) from

CAUTION: Center joint weight: 26.5 kg (58 lb)
body (7).
1. Remove bolt (12) (2 used) from cover (11) di- ȗȎȀ
agonally. Using eyebolts M10 (pitch 1.5, length 18
mm) (2 used), lift the center joint by crane, then
secure it on a workbench.
IMPORTANT: Put matching marks on body (7) and

spindle (2).
2. Remove bolts (12) (2 used) and eyebolts (2 used)

to remove cover (11) from body (7).
: 17 mm
3. Remove O-ring (9), retaining ring (10) and ring (8)

from body (7).
W105-03-03-015
4. Attach the special tool (ST 1033, ST 1020) to
body (7) with bolts (12) (2 used) on cover (11).
IMPORTANT: While welding, be sure to cover the
: 17 mm
seal surface to prevent it from being
ST 1020 spattered.
ST 1033 12 7. When replacing bushing (5), build-up weld at 4

places in its inner diameter with welding rod,
shrink bushing (5) to pull it out.
W506-03-03-002
IMPORTANT: Take care not to damage the sliding

surface of the spindle (2) with seal
(6).
5. Screw ST 1020 to remove spindle (2) from body

(7).
Remove dust seal (3) from spindle (2).
W3-3-5
ASSEMBLE CENTER JOINT
3
4
6
7
8
10
9
11
12
W178-03-03-001
1 - Plug (With Ball) 4 - O-Ring 7 - Body 10 - Retaining Ring

2 - Spindle 5 - Bushing 8 - Ring 11 - Cover
3 - Dust Seal 6 - Oil Seal (6 Used) 9 - O-Ring 12 - Bolt (4 Used)
W3-3-6
Assemble Center Joint
IMPORTANT: If bushing is removed, be sure to

reinstall bushing (5) first. (Refer to IMPORTANT: Clearance between body (7) and
page W3-3-8.) spindle (2) is approximately 0.1 mm
(0.004 in), so the spindle must be in-
IMPORTANT: Install dust seal (3) with its lip side serted along axis straight and
facing body (7). slowly.
1. Install dust seal (3) to spindle (2). 4. Tap body (7) with a plastic hammer until its sur-
face A is flush with that of spindle (2).
Surface A 2
0.1 mm
Dust Seal (3)
7
Out Side
Lip
Body (7)
W105-03-03-024
W178-03-03-002
IMPORTANT: Be sure to install ring (8) with the

2. Install oil seals (6) (6 used) and o-ring (4) into
chamfered side facing spindle.
body (7).
Ȁ
5. Install ring (8) and O-ring (9) to body (7).
3. Secure spindle (2) to a workbench. Install body (7)
on spindle (2) with their matching marks aligned.
6. Install retaining ring (10) to spindle (2).
Ȁ
7. Install cover (11) to body (7) with bolts (12) (4
used).
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
Ȁ
Ȁ
W3-3-7
When replacing the body or spindle with new one, the
following procedures are required.
IMPORTANT: When pressing bushing (5) into

body (7), grease or molybdenum di-
sulfide shall be applied to the fitting
surface.
Replacing Body (7)
Press bushing (5) into body (7). Replacing Spindle (2)
1. Clean body (7) and bushing (5). 1. Clean spindle (2).
2. Press bushing (5) into body (7), using the press- 2. Tap plugs (1) into spindle (2) using special tools
ing tool. (ST 2559).
Pressing force: 0.5 to 1.5 t (1100 to 3300 lb)
Pressing tool: ST 2558 3. Tap the balls of plug (1) so that the top of each
ball is 0.4 mm (0.016 in) or more lower than the
respective sleeve edge as illustrated in detail D.
1
ST 2558
2 Sleeve
7
0.4 mm
or More
Detail D
W135-03-03-001
W136-03-03-031
W105-03-03-029
ST 2559
Ball
W157-03-03-004
W3-3-8
Item Allowable limit (basis for judgment) Remedy

1. Wear more than 0.2 mm (0.008 in) Replace
2. Scored, abnormal wear Replace
3. Uneven wear (wear range is within 180°) Replace
Wear range is within
one half
Bushing
T157-01-01-040
Sliding surface Scored or serious damage Replace

in contact with
sealed part
Sliding surface in 1) Scored or abnormal wear of more than Replace
contact with 0.1 mm (0.004 in)
everywhere except 2) Scored less than 0.1 mm (0.004 in) deep Repair and finish
Body ⋅ spindle sealed part with oil stone
1) Wear more than 0.5 mm (0.02 in) deep Replace
And abnormal wear
Sliding surface in 2) Wear less than 0.5 mm (0.02 in) deep Repair and finish
contact with ring
3) Scored or abnormal worn less than 0.5 mm Repair and finish
(0.02 in) deep and able to be repaired.
1) Wear more than 0.5 mm (0.02 in) Replace
Sliding surface in 2) Wear less than 0.5 mm (0.02 in) Repair and finish
Cover contact with ring 3) Scored or abnormal wear less than 0.5 mm Repair and finish
(0.02 in) and able to be repaired.
W3-3-9
(Blank)
W3-3-10
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK AD-
JUSTER
Before removing and adjusting the track adjuster, the

tracks and the front idler must be removed first. For
removal of the tracks and front idler, refer to their Re-
moval / Installation sections.
In this section, the procedure starts on the premise that
the tracks and front idler have already been removed.
Removal
CAUTION: Track adjuster weight:
102 kg (225 Ib)
CAUTION: Track adjuster (1) may jump out of
position due to strong spring force when
track adjuster (1) is removed. Especially, a
strong spring force is always applied to the
threaded part of rod. If the rod and/or the
threads are damaged, metal fragments may
fly off when track adjuster (1) is removed.
Take necessary precautions to prevent any
personal injury from occurring.
2
1. After removing the front idler with yoke, remove
track adjuster (1) from track frame (2) by prying it
1
out with a pry bar.
Installation
1. As illustrated, install track adjuster (1) into spring
guide (3) on track frame (2).
Ȁ Check that the end face of track adjuster (1) W157-03-04-003
comes into contact with the face of plate (4).
2 3
A 3 4
W157-03-04-001
View A
W157-03-04-002
W3-4-1
DISASSEMBLE TRACK ADJUSTER
1
2
4
5
6
7
8
9
3
10
11
12
13
14
15
18
17
W178-03-04-001
16
1- Holder 6- Piston Rod 11 - Cylinder 15 - Valve

2- Dust Seal 7- Wear Ring 12 - O-Ring 16 - Nut
3- Socket Bolt (3 Used) 8- U-Ring 13 - Spacer 17 - Washer
4- Flange 9- Retaining Ring 14 - Plug 18 - Spring
5- Wear Ring 10 - Rod
W3-4-2
Disassemble Track Adjuster
• Be sure to thoroughly read “Precautions for
Disassembly and Assembly Work” on page CAUTION: Track adjuster weight:
W1-1-1 before starting the disassembly work. 102 kg (225 lb)
Be sure to use special tool (ST 4920) for assembly / 3. Remove holder (1) from the track adjuster.
disassembly of the track adjuster. Attach the wire rope to the track adjuster. Hoist
The spring force is extremely large, so disassembly the track adjuster by crane and put the track ad-
and assembly work must be carried out carefully. In juster on cradle of special tool.
addition, it is necessary to inspect the special tool for
Track Adjuster
any damage thoroughly to ensure safety.
CAUTION: Special tool weight:

225 kg (500 lb)
1. Place an oil jack (30 t) between the cradle and the

Cradle of
base of special tool (ST 4920). Special tool
ȒȎȀ
Nut
W105-03-04-009
Cradle
Oil Jack
Base
W105-03-04-006
2. Loosen the nuts (4 used) to remove plate (ST

4036).
: 46 mm
Plate (ST 4036)
W105-03-04-007
W3-4-3
10
14
15
17
W178-03-04-001
16
W3-4-4
4. Install plate (ST 4036) onto the track adjuster and 7. Operate the oil jack to compress the track ad-
secure them together. juster approximately 10 mm (0.4 in ) until a clear-
ance is observed between washer (17) and nut
(16).
Plate (ST 4036) 8. Remove plug (14) from nut (16). Remove nut (16)
and valve (15) from rod (10).
: 5 mm
: 75 mm
: 24 mm
16 10 14
W105-03-04-011
5. Operate the oil jack to jack up with nut (16) facing

the top surface of the plate (till spanner can be
used).
Cradle
Oil Jack
W105-03-04-014
W105-03-04-013
6. Tighten the nuts of the special tool to secure the

track adjuster.
: 46 mm
Nut
Plate
(ST 4036)
W105-03-04-012
W3-4-5
3
10
11
13
18
17
W178-03-04-001
W3-4-6
9. Lower the oil jack slowly.
CAUTION: Spring weight:
49 kg (108 Ib)
Nut
12. After removing the eyebolt, remove spring (18)
from rod (10).
13. Remove spacer (13) from rod (10).
14. Remove socket bolts (3) (3 used) and then move

flange (4) in the direction of holder (1).
: 8 mm
W105-03-04-015
15. Pull out the piston rod (6) assembly from cylinder
10. Remove the nuts of the special tool to remove (11).
plate (ST 4036) and washer (17).
16. Pull out holder (1) from the piston rod (6) assem-
bly with a press.
Plate (ST 4036)
: 30 mm
17
W105-03-04-016
CAUTION: Spring assembly weight:

94 kg (210 Ib)
11. Install eyebolt (M16, pitch 1.5) to rod (10) and

hoist the track adjuster by crane to remove it from
the special tool.
Eyebolt
W105-03-04-017
W3-4-7
2
4
5
6
7
8
9
10
11
12
W178-03-04-001
W3-4-8
17. Remove flange (4) from piston rod (6). Remove
dust seal (2) and wear ring (5) from flange (4).
Ȁ
18. Remove rod (10) and O-ring (12) from cylinder
(11).
19. Remove, retaining ring (9), U-ring (8) and wear

ring (7) from piston rod (6).
8
9
W105-03-04-025
W3-4-9
ASSEMBLE TRACK ADJUSTER
15 14 17 10 13 12 11 9 7 6 A 3 4 1
W178-03-04-002
16 18 B 8 5 2
C 424 mm(Free Length 521 mm)
D 611 mm
1- Holder 6- Piston Rod 11 - Cylinder 15 - Valve

2- Dust Seal 7- Wear Ring 12 - O-Ring 16 - Nut
3- Socket Bolt (3 Used) 8- U-Ring 13 - Spacer 17 - Washer
4- Flange 9- Retaining Ring 14 - Plug 18 - Spring
5- Wear Ring 10 - Rod
W3-4-10
Assemble Track Adjuster
6. Apply grease to U-ring (8), wear ring (7), cylindr
1. Clean all parts. Then install dust seal (2) and wear (11) and piston rod (6). Install the piston rod (6)
ring (5) to flange (4) after applying grease on assembly into cylinder (11).
them.
11
IMPORTANT: Fill (A) portion of flange (4) with full
of grease. 8
7
2. Install flange (4) to piston rod (6).
6
3. Apply grease into holder (1), and press it into pis-
ton rod (6) using a press and special tool (ST
7229).
4. Install wear ring (7), U-ring (8), retaining ring (9)

onto piston rod (6).
W105-03-04-021
6
7. Tighten flange (4) with socket bolts (3) (3 used).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
8 8. Install spacer (13) onto rod (10).

9
CAUTION: Spring weight:

7
49 kg (108 Ib)
W105-03-04-025 9. Install spring (18) onto rod (10).
5. Apply grease to O-ring (12), and install it on cylin- CAUTION: Spring assembly weight:
der (11). Install rod (10) into cylinder (11). 94 kg (210 Ib)
10. Install eyebolt (M16, pitch 1.5) to rod (10). Lift the
IMPORTANT: Fill (B) portion of cylinder (11) with spring assembly by crane and put it on the special
grease. Push the piston rod (6) as- tool.
sembly into the cylinder to com-
pletely bleed air from portion (B) and
Eyebolt
rod (10). 10
W105-03-04-017
W3-4-11
14 17 10
W178-03-04-002
16 18
D 611 mm
W3-4-12
11. Remove the eyebolt from rod (10). Put washer 14. Install nut (16) to rod (10), and then install plug
(17) on spring (18) and install plate (ST 4036). (14) to nut.
: 75 mm
: 5 mm
: 14.5 N⋅m (1.5 kgf⋅m, 11.0 Ibf⋅ft)
Plate (ST 4036)
16 10 14
17
18
W105-03-04-016
12. Tighten the nuts of the special tool to secure the
spring assembly.
: 46 mm
W105-03-04-014 l
Nut
W105-03-04-012
13. Compress spring (18) to the specified length with

oil jack.
18
W105-03-04-026
W3-4-13
15 10
W178-03-04-002
D 611 mm
W3-4-14
15. Install valve (15) to rod (10).
CAUTION: Track adjuster weight:
: 24 mm
102 kg (225 Ib)
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
16. Lower the oil jack. 18. Attack the wire rope to the track adjuster. Hoist
the track adjuster by crane and remove them from
the special tool.
Oil Jack
Track Adjuster
W105-03-04-013
Cradle of
Special tool
17. Remove the nuts of the special tool and plate
(ST 4036)
: 46 mm
W105-03-04-009
Plate (ST 4036)

CAUTION: Special tool (ST 4930) weight
: 64 kg (141 lb)
IMPORTANT: If only the track adjuster is to be
transported, be sure to use special
tool (ST 4930) to avoid personal in-
jury.
: 24 mm
Track Adjuster
W105-03-04-011
W105-03-04-028
Special Tool
(ST 4930)
W3-4-15
(Blank)
W3-4-16
UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER
Removal
Before removing the front idler, the tracks must be
removed first. For removal of the tracks, refer to
“Remove and Install Tracks” section.
In this section, the procedure starts on the premise
that the tracks has already been removed.
CAUTION: Front idler weight:

116 kg (255 Ib)
W110-03-05-001
CAUTION: Front idler (1) may fly out due to
the strong spring force from the track ad-
juster spring when removing it. Give yourself
ample clearance, staying clear of the front
idler’s line.
3
1. Pry front idler (1) with yoke (2) using a pry bar to
move it out of track frame (3).
2. Attach the wire rope to the bearing (1) portion and

the yoke (2) portion as illustrated and remove the 1
front idler assembly from track frame (3).
2
3. If it is necessary to retain the front idler for a time,
W178-03-05-001
be sure to place it on wooden blocks as shown to
keep it stable.
Installation
1. Install the front idler according to the reversed
procedures of removal and pay attention to the
following precautions when installation is carried
out.
• Clean the sliding surface (a) of yoke (2) and slid-
ing surface (b) of track frame (3), then apply
grease on them.
W178-03-05-002
(b)
3
(a)
2
W178-03-05-004
W3-5-1
DISASSEMBLE FRONT IDLER
2
1
3
4
6
7
8
6
4
3
2
1
10
W178-03-05-003
1 - Bearing (2 Used) 4 - Floating Seal (2 Used) 7 - Idler 9 - Yoke

2 - Pin (2 Used) 5 - Axle 8 - Plug (2 Used) 10 - Bolt (4 Used)
3 - O-Ring (2 Used) 6 - Bushing (2 Used)
W3-5-2
Disassemble Front Idler
• Be sure to thoroughly read “Precautions for 4. Remove floating seals (4) (2 used) from bearings
Disassembly and Assembly Work” on page (1) (2 used) and idler (7).
W1-1-1 before starting the disassembly work.
1
1. Remove bolt (10) to remove yoke (9). Remove 4
plug (8) from bearing (1) to drain oil into a con- 7
tainer.
: 24 mm
4
: 6 mm
3
2. Withdraw pin (2) from one of bearings (1). 5
: 16 mm
1
W105-03-05-009
CAUTION: Idler, etc. weight:

97 kg (215 Ib)
3. Push axle (5) out of bearing (1) with a press. Bear-

ing (1) in opposite side shall be pushed out of idler
(7) with its axle (5). Remove O-ring (3) from axle
(5).
1 5
W105-03-05-008
IMPORTANT: For handling of floating seal (4), re-
fer to the section “Floating Seal Pre-
cautions” on page W1-1-4.
W3-5-3
W178-03-05-003
W3-5-4
5. Withdraw pin (2) from the other bearing (1), and
remove axle (5) with a press.
Then remove O-rings (3) from axle (5).
3
2
W105-03-05-010
6. When replacing bush (6) with a new one, remove

bush (6), using special tool (ST 1425) and press.
ST 1425
W105-03-05-011
W3-5-5
ASSEMBLE FRONT IDLER
1 2 4 5 6
10
8 9
3
7
W157-03-05-003
1 - Bearing (2 Used) 4 - Floating Seal (2 Used) 7 - Idler 9 - Yoke

2 - Pin (2 Used) 5 - Axle 8 - Plug (2 Used) 10 - Bolt (4 Used)
3 - O-Ring (2 Used) 6 - Bushing (2 Used)
W3-5-6
Assemble Front Idler
1. Install bushing (6) (2 used) into idler (7) from both 5. Install the other pair of floating seal (4) into idler
ends with a press. (7) and bearing (1).
2. Apply a film of grease onto O-ring (3). Install O- 7

ring (3) onto axle (5). Aligning the pin holes, install
1 4 3
axle (5) into bearing (1) at one side and secure it 1
with pin (2). While doing this, take care not to
damage O-ring (3).
2
5
1
5
W157-03-05-005
6. Aligning the pin holes, install bearing (1) onto axle

(5). Then tap pin (2) into the bearing.
3 W105-03-05-014
7. Fill engine oil via the plug (8) hole of bearing (1).
MPORTANT: For handling of floating seal (4), refer Apply sealant (LOCTITE # 503 or equivalent) to
to the section “Floating Seal plug (8). Install plugs (8) (2 used) to the bearings
Precautions” on page W1-1-4. (2 used).
3. Install one pair of floating seal (4) into idler (7) and : 6 mm
bearing (1). : 20 N⋅m (2 kgf⋅m, 14.5 lb f⋅ft)
Engine oil: API CD Class SAE 30
Quantity: 265 mL (0.07 US gal)
4. Insert axle (5) into idler (7) from the side installed
8. Install yoke (9) to bearings (1) (2 used) with bolts
with floating seal. Apply a film of grease onto O-
(10) (4 used).
ring (3). Install O-ring (3) onto axle (5).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
7
4 1
W157-03-05-006
W3-5-7
C D
A
B
W157-03-05-001
Unit: mm (in)
Standard Allowable Limit Remedy
A 84 (3.31) [66 (2.60)]
B 159 (6.26) −
Build-up weld and

C 500 (19.69) 482 (18.98)
finishing
D 538 (21.18) −
E 19 (0.75) 25 (0.98)
Axle and Bushing Unit: mm (in)
Axle Outside Dia. 75.0 (2.95) [74.2 (2.92)]
Inside Dia. 75.0 (2.95) [76 (2.992)] Replace

Bushing
Flange Thickness 2 (0.08) [1.2 (0.05)]
NOTE: Values in [ ] are just for reference.
W3-5-8
UNDERCARRIAGE / Upper And Lower Roller
REMOVE AND INSTALL UPPER ROLLER
NOTE: In case of replacing the upper roller,

replace it as an asembly.
Removal
CAUTION: Do not loosen valve (1) quickly or
loosen it too much as high-pressure grease
in the adjusting cylinder may spurt out.
Loosen carefully, keeping body parts and
face away from valve (1). Never loosen
grease fitting (2).
W105-03-06-001
IMPORTANT: Clean off gravel or mud packed

between the sprockets and tracks
before loosening valve (1).
It’s enough to turn valve (1) by only
one turn. Do not loosen it over one 2
turn. Grease Outlet
W178-03-06-001
1. Loosen valve (1) of the track adjuster to loosen
the track tension.
3
: 24 mm
CAUTION: Use a non-skid cloth between

track frame (5) and an oil jack to prevent
slipping. 4
5
2. Insert an oil jack between track frame (5) and W105-03-06-002
tracks (3). Jack up tracks (3) high enough to

3
permit upper roller (4) removal.
3. Insert wooden blocks between tracks (3) and

track frame (5). W105-03-06-003
W3-6-1
4. Loosen mounting bolts (6) of upper roller (4).
: 24 mm
W157-03-06-001
CAUTION: Upper roller weight:

18 kg (40 lb)
5. Remove upper roller (4) from track frame (5).
4
Installation
1. Install upper roller (4) onto track frame (5) with 5
bolts (6). W105-03-06-005
: 24 mm
: 270 N]m (28 kgf]m, 200 lbf]ft)
6
2. Remove the wooden blocks and oil jack. 5
W157-03-06-001
W105-03-06-002
W3-6-2
3. Install valve (1) of the track adjuster.
: 24 mm
: 88 N⋅m (9 kgf⋅m,65 lbf]ft)
1
CAUTION: Securely support the raised ma-

chine with wooden blocks.
4. Jack up the track at the side being adjusted and
rotate slightly in reverse direction.
Ȁ 2
5. Supply grease via grease fitting (2) to adjust the Grease Outlet
track tension. W178-03-06-001
Track sag specifications (A):

285 to 320 mm (11.22 to 12.6 in)
6. Add lubrication oil via the hole of plug (8) on cover

(7), then tighten plug (8).
Apply LOCTITE # 503 or equivalent to the plug.
: 6 mm
: 20 N⋅m (2 kgf⋅m 14.5 lbf]ft)
Lubrication oil: Engine oil API CD Class SAE30

Quantity: 70 mL(0.018 US gal) W157-03-06-002
W158-03-06-001
W3-6-3
(Blank)
W3-6-4
REMOVE AND INSTALL LOWER ROLLER
Removal
1. Remove mounting bolts (1) of lower roller (5) after 5
removing the track guard.
: 27 mm
1
2. Operate the boom and arm so shat the angle

between them is 90° to 110°, Lower the boom with
the bucket rolled-in to jack up the machine. Then W105-03-06-008
place a block under track frame (2) to support the

machine.
90°ϡ110°

loosen it too much as high-pressure grease
in the adjusting cylinder may spurt out. 2 M104-07-067
face away from valve (3).
Never loosen grease fitting (4).
IMPORTANT: It’s enough to turn valve (1) by only

1.5 turns. Do not loosen it over 1.5
turns.
3. Loosen valve (3) of the track adjuster to maintain
the track in such tension that lower roller (5) can
be removed.
: 24 mm
W105-03-06-001
4
Grease Outlet
W178-03-06-001
W3-6-5
CAUTION: Lower roller weight:

35 kg (77 lb)
4. Remove lower roller (5) using a fork lift, etc.
W105-03-06-010
Installation
1. Place lower rollers (5) under the tracks (2) as
illustrated using a fork lift, etc.
5
W105-03-06-011
2
2. Lower track frame (2) enough to gain a little
clearance between collar (6) and track frame (2).
3. Align the bolt holes and tighten bolt (1).

: 27 mm
: 460 N]m (47 kgf]m, 340 lbf]ft) 6 W105-03-06-012
W105-03-06-008
W3-6-6
4. Install valve (3) of the track adjuster.
: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf]ft) 3
CAUTION: Securely support the raised ma-

chine with wooden blocks.
5. Jack up the track at the side being adjusted and 4

rotate slightly in reverse direction. Grease Outlet
Ȁ W178-03-06-001
6. Supply grease via grease fitting (4) to adjust the
track tension.
Track sag specification (A):

285 to 320 mm (11.22 to 12.6 in)
W157-03-06-002
W3-6-7
DISASSEMBLE LOWER ROLLER
3
2
4 1
5
6
5
4
3
2
1
W157-03-06-004
1 - Plug (2 Used) 3 - Pin (2 Used) 5 - Floating Seal (2 Used) 7 - Roller

2 - Collar (2 Used) 4 - O-Ring (2 Used) 6 - Bushing (2 Used) 8 - Axle
W3-6-8
Disassemble Lower Roller
• Be sure to thoroughly read “Precautions for 5. Remove O-rings (4) (2 used) from axle (8).
Disassembly and Assembly Work” on page
NOTE: When disassembling, O-ring may be
W1-1-1 before starting the disassembly work.
damaged. Replace it with the new one.
1. Remove plug (1) from collars (2) and drain oil.

6. In case of replacing bushing (6), push out bushing
:6 mm
(6) with a press and special tools.
2. Remove pin (3) from collar (2) at one side only.
Remove axle (8) from roller (7) by the side where
pin (3) was removed with a press. At this moment,
the pin and collar at opposite side are also ST 1955
removed together.
: 14 mm
2 5 7 5
W105-03-06-028
5
2
Pulling Tool: ST-1955
W105-03-06-026
3. Remove floating seal (5) from both sides of roller
(7) and collars (2) (2 used).
4. Remove pin (3) from axle (8) assembly to push

out the axle from collar (2) with a press.
4 2
W105-03-06-027
W3-6-9
ASSEMBLE LOWER ROLLER
2 7 6 5 4 3 1
W105-03-06-023
1 - Plug (2 Used) 3 - Pin (2 Used) 5 - Floating Seal (2 Used) 7 - Roller

2 - Collar (2 Used) 4 - O-Ring (2 Used) 6 - Bushing (2 Used) 8 - Axle
W3-6-10
Assemble Lower Roller
1. Install bushings (6) (2 used) onto roller (7) with a 4. Insert axle (8) into roller (7).
press. Take care not to dent the flange surface of Apply a film of grease to O-ring (4) and install it
bushing (6). onto the axle.
Apply a film of grease to O-ring (4) and install it The other collar (2) and floating seal (5) shall be
onto axle (8). assembled in the same way.
Secure them with pin (3).
2. Install collar (2) of one side onto axle (8), aligning
the pin holes. Secure them with pin (3). Take care 5 8 7
not to damage O-ring (4). 2
3
4
W157-03-06-009
5. Add engine oil via plug (1) hole on collar (2).

2 4 Tighten plug (1).
W105-03-06-031
Apply LOCTITE # 503 or equivalent to the plug.
: 6 mm
IMPORTANT: Coat grease on O-ring of floating
: 20 N]m (2 kgf]m, 14.5 lbf]ft)
seal and then install it.
Engine oil: API CD class, SAE30
When installing O-ring, take care not
Quantity: 260 mL (0.069 US gal)
to twist it and install it at the correct
angle.
The floating seals are in pairs. So
don’t use them randomly with other
seals.
3. Install floating seal (5) to roller (7) and collar (2).
7 5
5 2
W157-03-06-008
W3-6-11
Upper Roller
W105-03-06-032
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 84(3.31) ҥ
B 150(5.91) ҥ Replace
C 120(4.72) [110(4.33)]
W3-6-12
Lower Roller
W157-03-06-003
Roller
Unit: mm (in)

A 169.0(6.65) [193.5(7.62)]
Build-up weld
B 218.0(8.58) ҥ
and finishing
C 24.5(0.97) [12.3(0.48)]
or replace
D 150.0(5.90) 132(5.20)
Axle and Bushing

Unit: mm (in)

Axle Outside Dia. 65(2.56) [64.2(2.53)]
Inside Dia. 65(2.56) [66.0(2.60)]
Replace
Bushing Flange
2(0.079) [1.2(0.047)]
Thickness
W3-6-13
(Blank)
W3-6-14
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACKS
Removal
loosen too much since high-pressure grease
in the adjusting cylinder may spurt out.
face away from valve (1). Never loosen
grease fitting (2).
1. Rotate the track so that master pin (3) is

positioned on front idler (4) side. Put a wooden
block under track shoes (5).
W105-03-07-001
IMPORTANT: Rotate valve (1) one turn to let

grease discharge from the grease 5
outlet. 4
Avoid excessive turning.
2. Loosen valve (1) at the track adjuster to loosen 3

track tension.
: 24 mm
W105-03-07-006
W105-03-07-002
1
2
Grease Outlet
W1F1-03-07-001
W3-7-1
3. Remove retaining ring (6), which is used to
7
prevent the master pin from coming off.
3
NOTE: If retaining ring (6) interferes with master
link (7), drive master pin (3) in to make
clearance between retaining ring (6) and
master pin (3) before attempting to remove
retaining ring (6). 6
CAUTION: The front idler may jump out of

position due to strong spring force when the
tracks is disconnected. W105-03-07-009
Particularly, a strong spring force is always

applied to the thread portion of the rod. If the
rod and/or the thread are damaged, metal
fragments may fly out when the tracks is
disconnected. Take necessary precautions to
prevent any personal injury from occurring.
IMPORTANT: Master pin (3) is directional. Be sure

to strike the pin in or pull it out in
correct direction.
4. Remove master pin (3) using special tool (ST

W105-03-07-005
1970).
Corner
Direction for Direction for
Removing the Installing the
Master Pin. Master Pin.
Retaining Ring
Track Link
3
Master Link
W105-03-07-010
ST 1970
W105-03-07-008
W3-7-2
CAUTION: Securely support the raised

machine with wooden blocks.
5. Operate the boom and arm so that the angle
between them is 90° to 110° . Lower the boom
with the bucket rolled-in to jack up the machine so 90°ϡ110°
as to pull the track out.
Wooden Blocks M104-07-067
6. Slowly operate the travel lever for the side of the

track being removed in reverse direction until the
whole length of the track being removed comes
on the ground.
NOTE: Track assembly weight: 1030 kg (2270 lb)
W105-03-07-011
W3-7-3
Installation
CAUTION: Truck assembly weight:

1030 kg (2270 lb)
Sprocket
IMPORTANT: Be sure to position the track in Idler Side Side
correct direction as illustrated.
1. Jack up the machine and put the track under the
lower roller so that the sprocket teeth mesh with
the end of the track.
W105-03-07-013
2. Hoist the trucks and place it on sprocket (8) by

crane.
3. With the machine being jacked up, operate the

8
travel lever for the side of the track being installed
in forward direction. Wind the track while rotating
travel device (9).
W105-03-07-014
4. When wind the connecting part of track link onto

front idler (4), lower the machine and place a
wooden block under shoe (5) to support shoe (5).
W105-03-07-015
W105-03-07-016
W3-7-4
IMPORTANT: Master pin (3) is directional. Be sure
to install it in the correct direction. Corner
Direction for
Removing the Direction for
Master Pin Installing the
5. Install master pin (3) using special tool (ST 1970). Master Pin
Retainin Ring
Track Llink
3
Master Link
W105-03-07-010
ST 1970
IMPORTANT: Old retaining ring (6) can’t be reused

as it deforms easily. Replace it with a
new one. W105-03-07-017
7
6. Install retaining ring (6). Retaining ring (6) is
directional. Install retaining ring (6) into master
link (7) groove with the flat side of retaining ring
hole facing outward.
W105-03-07-009
W3-7-5
7. Tighten adjuster valve (1).
: 24 mm 1
2
: 88 N]m (9 kgf]m, 65 Ibf⋅ft)
Grease Outlet
W1F1-03-07-001
CAUTION: In case of jacking up the machine

to measure track sag, place a block under the
track frame to support the machine securely.
8. Apply the grease to grease fitting (2) at track
adjuster to adjust track tension.
Track sag specification (A):
285 to 320 mm (11.2 to 12.5 in)
NOTE: Before measuring track sag, slowly drive
the track in reverse by half turn to provide
sag the lower part of track.
W105-03-07-018
W157-03-06-002
W3-7-6
Assemble Link • Slowly insert the pin into the bushing until the pin
comes in contact with the plate.
If any links have been removed from the track, • Apply grease to the pin’s surface out of the
reconnect in accordance with the following bushing.
procedure. • Lay the bushing with pin on the workbench.
• Slowly insert the pin further into the bushing, while
IMPORTANT: Do not apply grease onto dust seal turning the pin, until the bushing is centered on
at this stage (step 1) the pin.
IMPORTANT: Be sure install the dust seal into the
link groove with the flat side of dust 3. Apply grease onto both side of the bushing ends.
seal facing inward.
1. Install the dust seal into the link groove. 4. Apply grease onto surface of dust seal in the link
(right link and left link) groove.
Link (right link and left link)
Dust Seal Install right link and left link onto right and left
sides of pin respectively.
W17P-03-07-001
IMPORTANT: Fully fill grease (Daphne Epones SR

No.2) into a clearance between pin
and bushing.
2. Insert the pin into the bushing in accordance with
the following procedure.
• Stand the bushing on flat plate.
• Fill grease into the bushing up to about 1/3 of
bushing height. At this time, avoid that air is mixed
into grease.
• Push the bushing onto the plate so that the
bushing end stays on the plate.
• Slowly insert the pin into the bushing from above
while turning the pin left and right.
• Confirm that grease comes out from a clearance
between pin and bushing.
Slowly insert the pin into Pin

the bushing while turning
the pin left and right.
Confirm that grease comes
Bushing out from a clearance between
pin and bushing.
Grease
Push the bushing on to

Plate the plate.
W17P-03-07-002
W3-7-7
Link
Measure the length of four links.
• Master pin is not included in measurement part.
• Measurement shall be carried out with the track in
tension.
W155-03-07-001
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 761.8(29.99) 785.8(30.94) Build-up weld and finishing or
B 104(4.09) 97(3.82) replace
Grouser shoe
W105-03-07-024
Unit: mm (in)
Shoe Size 500 mm Grouser
Allowable
Standard Remedy
Limit
A 219 (8.62) ҥ Build-up weld
B 8.5 (0.34) ҥ and finishing
C 26 (1.02) 18.2 (0.72) or replace
W3-7-8
Master Bushing
W105-03-07-023
Unit: mm (in)
Allowable
Standard Remedy
Limit
129.2
A ҥ
(5.09)
Replace
B 38.7 (1.52) [41.7 (1.64)]
C 59 (2.32) [54 (2.13)]
Master Pin
W105-03-07-021
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 203 (7.99) ҥ
38.4 Replace
B [35.4 (1.39)]
(1.51)
W3-7-9
Pin
A
W142-03-07-004
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 212(8.35) ҥ
Replace
B 38(1.496) [35(1.38)]
Bushing
W105-03-07-023
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 137.5(5.41) ҥ
B 38.7(1.52) [39.7(1.56)] Replace
C 59(2.32) [54(2.13)]
W3-7-10
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
SECTION 4
FRONT ATTACHMENT
 CONTENTS 
Group 1 FrontȀ
ȀAttachment
Remove and Install Front Attachment........ W4-1-1
Maintenance Standard................................. W4-1-8
Standard Dimensions for
Arm and Bucket Connection .................... W4-1-11
Group 2 Cylinder
Remove and Install Cylinder ................... W4-2-1
Hydraulic Circuit Pressure Release
Procedure........................................... W4-2-15
Disassemble Cylinder ........................... W4-2-16
Assemble Cylinder ............................... W4-2-24
Maintenance Standard ......................... W4-2-32
1F1W-4-1
(Blank)
1F1W-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FROM ATTACH-
MENT

ing pressure.
Preparation
1. Park the machine on a solid level surface. Fully
retract the bucket and arm cylinders and lower the
bucket to the ground.

pressure.
3. Release pressure from hydraulic oil circuit accord-

ing to the introduction at page W4-2-15.
W105-04-02-001
W4-1-1
Removal
1. Remove grease hose (1) from the adapter at the
boom cylinder rod side boss (2 places on both left 1
and right)
: 17 mm
Adapter
2. Remove nuts (4) and bolts (6) from boom cylinder Boom Cylinder
rod front pin (3). Then remove stopper (5). (2
places on both left and right)
: 24 mm
W105-04-01-002
CAUTION: Boom cylinder weight:
153 kg (337 lb) 3 2
Prevent personal injury.
Metal fragments may fly off when a hammer
is used to remove pins.
Be sure to wear necessary protection, such
as goggles, hard hat, etc. 6 Boom Cylinder
3. Hoist the boom cylinder by crane. With a bar and

hammer drive pin (3) into the position where thrust
plate (2) can be removed. Remove thrust plate
(2).
5
NOTE: When pin (3) is impossible to pull out. Start 4
the engine, slightly operate the boom lever
W178-04-01-004
and align the boom cylinder rod pin hole.
W4-1-2
4. Place the boom cylinder on a bench of 1 m height.
Start engine, operate the boom lever to retract the
boom cylinder, use a wire to secure the boom
cylinder rod as illustrated.
Stop the engine.
Boom Cylinder
5. Remove boom cylinder.
Refer to “Remove Boom Cylinder” (W4-2-10).
Metal Wire
6. Remove other boom cylinder in the same proce-
dures as steps 3, 4, 5.
CAUTION: The pin sometimes releases sud-

denly. Be sure no one stands in the way. W554-02-03-007
7. Drive pin (3) out with a bar and hammer. Remove

thrust plate (2).
8. After stopping the engine, push the air release Air Bleeding Valve
valve on the top of hydraulic oil tank to release
any remaining pressure. Then remove the cap.
Completely release the residual pressure from the
hydraulic circuit by performing the “Hydraulic Cir-
cuit Pressure Release Procedure”
Refer to page W4-2-15.
9. Remove hoses (7), (8) for bucket cylinder and

arm cylinder, close all openings with cap.
: 36 mm
M157-07-173
10. Remove mounting bolts (8 used) to remove the
tool box and cover.
: 17 mm
㈓ 8
W157-04-01-001
Cover
Tool Box W178-04-01-002
W4-1-3
11. Remove bolt (12), spring washer (13), plate (11)
and block (10) from the plate of boom foot pin (9). 9
: 27 mm
10
11
CAUTION: Front attachment weight: 12
2700 kg (5950 lb)
13
12. Attach a wire rope to the front attachment. W178-04-01-001
Slightly hoist to take up any wire rope slack by

crane.
13. Insert a bar between the plate of boom foot pin (9)
and bracket, slightly pull the plate out.
14. Turn the plate upward by hand and turn it left and
W105-04-01-008
right to pull boom foot pin (9) out. (Adjust the posi-
tion of the boom foot pin hole, hoisting/lowering
9
the front attachment.)
15. After hoisting the front attachment, move the ma-

chine backward.
16. Place the front attachment on wooden blocks.

Plate
Insert Bar
Bracket
W1F1-04-01-002
W178-04-01-005
W4-1-4
Install Attachment
CAUTION: Front attachment weight:
2700 kg (5950 lb)
1. Hoist the front attachment by crane.
Move the machine forward, aligning the boom foot
pin holes.
Insert the thrust plates into boom left and right
sides and adjust the clearance between the plate
and frame within 1 mm.
(Adjust the boom foot pin hole, hoisting / lowering
the front attachment.) W178-04-01-005
9
CAUTION: Prevent personal injury. Metal

fragments may fly off when a hammer is used
to remove pins. Be sure to wear necessary
protection, such as goggles, hard hats, etc.
10
2. Drive in boom foot pin (9). Install stopper bolt (12), 11
washer (13), plate (11) and block (10).
: 27 mm 12
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft) 13
3. Install the tool box and cover with bolts (8 used). W178-04-01-001
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
4. Remove caps from hoses and pipings. Install

bucket cylinder hoses and arm cylinder hoses (7),
(8).
: 36 mm
Cover
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
Tool Box
W178-04-01-002

153 kg (337 lb)
5. Install boom cylinder. ㈓ 8

Refer to “Install Boom Cylinder” (W4-2-12).
W157-04-01-001
Boom Cylinder
W105-04-02-040
W4-1-5

fragments may fly off when a hammer is used.
as goggles, hard hats, etc. 3 2
6. Hoist boom cylinder by crane. Insert thrust plates

(2) (2 used), then drive in pin (3), to install boom 6 Boom Cylinder
cylinders to both sides.
7. Install stopper (5) and secure it with bolt (6) and 5

nuts (4) (2 used). (2 places on both left and right)
4
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft) W178-04-01-004
1
8. Install grease hose (1) onto the boom cylinder rod
side boss. (2 places on both left and right)
: 17 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
W105-04-01-002
9. Apply grease to the boom cylinder rod side, bot-
tom side and boom foot side.
Boom Cylinder
Rod Side
Boom Foot
Side
M157-07-155
IMPORTANT: After filling hydraulic oil to specified
level, start the engine, check the
connections for any oil leakage.
IMPORTANT: After all work is completed, run each

cylinder several times to stroke end
to bleed air from the circuit.
Boom Cylinder M157-07-156

Bottom Side
W4-1-6
IMPORTANT: When the arm has been removed
from the boom, perform the follow-
ing steps when installing the arm.
10. Install thrust plates (14) into arm left and right
sides. Adjust total clearance of left and right within 14 14
1.5 mm or less.
11. After arm is installed, apply grease to grease fit-

ting (15) on the boom connecting boss of the arm.
IMPORTANT: For handling of HN bushing for the

front attachment, pay attention to 15 15
the following.
Precautions for pressing the bushing in:

If a hammer is used to drive the bushing in, the
bushing may be damaged. Use a press.
M157-07-157
Precautions when reinforcing the arm:
Welding heat for arm reinforcement may cause oil
leakage from the bushing and decrease lubrication
performance.
If oil leak occurs, replace the bushing.
Use tool (ST 1454) to pull the bushing out or press it in.
W4-1-7
Pin and Bushing
F E
G
C
H
D J
A
ȩ K
B
W105-04-01-018
Unit: mm (in)
Part Name Standard Allowable Limit Remedy
Pin 80 (3.15) 79.0 (3.11)
A
Bushing 80 (3.15) 81.5 (3.21)
Pin 80 (3.15) 79.0 (3.11)
B Boss (Main Frame) 80 (3.15) 81.5 (3.21)
Bushing (Boom Cylinder) 80 (3.15) 81.5 (3.21)
Pin 80 (3.15) 79.0 (3.11)
C Bushing (Boom Cylinder) 80 (3.15) 81.5 (3.21)
Boss (Boom) 80 (3.15) 81.5 (3.21)
Replace
Pin 80 (3.15) 79.0 (3.11)
D
Bushing 80 (3.15) 81.5 (3.21)
Pin 71 (2.80) 70.0 (2.76)
E Boss (Arm) 71 (2.80) 72.5 (2.85)
Bushing (Arm Cylinder) 71 (2.80) 72.5 (2.85)
Pin 71 (2.80) 70.0 (2.76)
F Boss (Boom) 71 (2.80) 72.5 (2.85)
Bushing (Arm Cylinder) 71 (2.80) 72.5 (2.85)
W4-1-8
Unit: mm (in)
Part Name Standard Allowable Limit Remedy
Pin 65 (2.56) 64.0 (2.52)
G Boss (Arm) 65 (2.56) 66.5 (2.62)
Bushing (Bucket Cylinder) 65 (2.56) 66.5 (2.62)
Pin 71 (2.80) 70.0 (2.76)
H Bushing 71 (2.80) 72.5 (2.85)
Bushing (Bucket Cylinder) 71 (2.80) 72.5 (2.85)
Replace
Pin 71 (2.80) 70.0 (2.76)
I
Bushing 71 (2.80) 72.5 (2.85)
Pin 80 (3.15) 79.0 (3.11)
J
Bushing 80 (3.15) 81.5 (3.21)
Pin 80 (3.15) 79.0 (3.11)
K
Bushing 80 (3.15) 81.5 (3.21)
IMPORTANT: When replacing HN bushing, press
fit it in with a press.
W4-1-9
Side Cutter
C
D
W155-04-01-002
Unit: mm (in)
A 229 (9.0) 149(5.9)
B 245 (9.6) -
Replace
C 330 (13.0) -
D 135 (5.3) -
Point
B C
W105-04-01-020
Unit: mm (in)
A 178.5 (7.0) 90 (3.5)
B 79 (3.1) -
Replace
C 95 (3.7) -
D 81 (3.2) -
W4-1-10
STANDARD DIMENSIONS FOR ARM
AND BUCKET CONNECTION
Section A Section B
W1F1-04-01-001
Unit: mm (in)
a 370 mm (14.6)
b 0 mm (0) NOTE: Dimension h: 305 mm includes the clear-
c 540 mm (21.3) ance for bucket adjuster.
d 520 mm (20.5)
e 401 mm (15.8)
f 1430 mm (56.3)
g 449 mm (17.7)
h 305 mm (12.0)
i 80 mm (3.15)
j 400 mm (15.7)
k 31 mm (1.22)
l 433 mm (17.0)
m 307 mm (12.1)
n 80 mm (3.15)
o 0°
p 0°
q 455 mm (18.0)
r 326 mm (12.8)
W4-1-11
(Blank)
W4-1-12
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER

ing pressure.
Preparation
1. Park the machine on a solid level surface. Fully
retract the bucket and arm cylinders and lower the
bucket to the ground.

pressure.
Ȁ
3. Release pressure from hydraulic oil circuit accor-
ding to the introduction at page W4-2-15.
W105-04-02-001
W4-2-1
Remove Bucket Cylinder
1. Lay wooden blocks (3) under the arm (2) tip and in
the clearance between the arm (2) top surface 1
and bucket cylinder (1).
2. After stopping the engine, push the air release

valve to release any remaining pressure from the 3
hydraulic oil tank, then remove the cap.
Release bucket circuit pressure. 2
Refer to “Release Hydraulic Circuit Pressure”. 3
(W4-2-15)
W554-04-02-006
Ȁ
CAUTION: Use a wire to secure the link to
prevent it from falling down before pushing
pin (7) out.

protection, such as goggles, a hard hat, etc. 4 5
3. Remove nut (6) and bolt (4) and drive pin (7) out
with a bar and hammer. Remove thrust plate (5).
: 30 mm
6
4. To prevent bucket cylinder (1) rod (8) from extend-
ing, pass wire (9) through the cylinder rod hole
and secure it to the bucket cylinder (1) pipe.
7
1 W158-04-02-006
8
9
W102-04-02-005
W4-2-2
5. Disconnect bucket cylinder hoses (12) (2 used)
from the bottom of bucket cylinder (1). Close all
openings with cap.
: 36 mm
10
CAUTION: Bucket cylinder weight:

125 kg (275 Ib)
15
to remove pins. Be sure to wear necessary 11
protection, such as goggles, a hard hat, etc. 13
6. Hoist bucket cylinder (1) by crane, remove nut

(13) and bolt (15). Drive pin (11) out with a bar and
hammer to remove thrust plates (10).
: 24 mm 1
7. Remove bucket cylinder (1).
12
W187-04-02-004
W4-2-3
Install Bucket Cylinder
IMPORTANT: When pressing the bushing in, if a

hammer is used, the bushing may be
damaged. Use a press.
CAUTION: Bucket cylinder weight:

125 kg (275 Ib)
10
to install pin (11). Be sure to wear necessary
protection, such as goggles, a hard hat, etc.
15
1. While hoisting bucket cylinder (1) by crane, align
the cylinder bottom side pin hole with the bucket 14
cylinder mounting hole on arm. Insert thrust plates 11
(10) and drive pin (11) in with a bar and hammer. 13
2. Insert bolt (15) into arm stopper (14) and pin (11)
to install nuts (13) (2 used).
: 24 mm 1
: 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft)
IMPORTANT: After installing hoses, fill hydraulic

oil to specified level, start the engine
and check the connections for any 12
W187-04-02-004
oil leaks.
3. Reconnect bucket cylinder hoses (12) (2 used) to

bucket cylinder (1).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft)
4. Remove wire (9) from bucket cylinder (1) rod (8).
1
8
9 W102-04-02-005
W4-2-4

16 4 17 5
5. Start the engine, operate the bucket lever, align

the cylinder rod side pin hole with those of links
(16) and (18). Insert thrust plate (5). Drive pin (7)
in with a bar and hammer.
6. Insert bolt (4) into stopper (17) and pin (7) to in-
stall nuts (6) (2 used).
: 30 mm
: 550 N⋅m (56.0 kgf⋅m, 405 Ibf⋅ft) 7 18 6
W158-04-02-006
IMPORTANT: In case link (18) has been removed
from the arm, don’t forget to re-
insert thrust plate (19).
19 19
IMPORTANT: When all work is completed, run the
bucket cylinder for several times to
stroke end to bleed air from the cir-
cuit.
W157-04-01-015
18 18
W4-2-5
Remove Arm Cylinder
1
1. Place a wooden block (3) on the top surface of
boom (2) to support arm cylinder (1).
2. After stopping the engine, push the air release 2

valve to release any remaining pressure from the
hydraulic oil tank, then remove the cap.
Release arm circuit pressure.
3
Refer to “Hydraulic Circuit Pressure Release”
(W4-2-15)
W187-04-02-005
3. Remove nut (6) and bolt (7) from pin (5) at the 4
7 5
arm cylinder (1) rod side.
: 30 mm
1

4. Start the engine, slightly operating the boom and

the arm and push pin (5) out.
Remove thrust plate (4). After that lower the boom 6
gently. W187-04-02-006
8 1
5. To prevent arm cylinder (1) rod (8) from extending,

pass wire (9) through the cylinder rod hole and
secure it to the arm cylinder (1) tube.
6. Disconnect hoses (10) (2 used) from arm cylinder

9
(1), and close all openings with cap.
: 36 mm
W187-04-02-010
10
1
7. Disconnect grease hose (11) from arm cylinder
(1).
: 17 mm
11
W102-04-02-014
W4-2-6
CAUTION: Arm cylinder weight:

210 kg (460 Ib)
1
8. Attach a sling at the center of gravity of arm cylin-
der (1). Slightly hoist it by crane.

to remove pin (13). Be sure to wear necessary W102-04-02-016

12
15
9. Remove nuts (14) and bolt (15) from the arm cyl-
1 13
inder (1) bottom side. Push out pin (13) to remove
thrust plates (12). Remove arm cylinder (1).
: 30 mm
14
W187-04-02-007
W4-2-7
Install Arm Cylinder

CAUTION: Arm cylinder weight:

210 kg (460 Ib)
1. Attach a sling at the center of gravity of arm cylin-

der (1). Hoist the arm cylinder by crane. Align the
cylinder bottom side hole with the arm cylinder
mounting hole on boom.
12
CAUTION: Prevent personal injury. Metal 15
fragments may fly when a hammer is used to 1 13
install pin (13). Be sure to wear necessary
2. Insert thrust plate (12), then install pin (13). Install

bolt (15) to pin (13) and stopper (16) and put nut
(14) on the bolt. 16
: 30 mm 14
: 550 N⋅m (56 kgf⋅m, 405 Ibf⋅ft)
W187-04-02-007
3. Connect grease hose (11) and arm cylinder hoses
(10) (2 used).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) 10
: 36 mm 1
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft)
IMPORTANT: After filling hydraulic oil to specified

level, start the engine and check the
connections for any oil leaks.
11
W102-04-02-014
W4-2-8
4. Remove wire (9) from arm cylinder (1) rod (8).
Hoist arm cylinder (1) by crane. Start the engine, 8 1
operate the arm lever, align the arm cylinder rod
side pin hole with the arm cylinder mounting hole
on arm (17).
17
9
fragments may fly off when a hammer is used W187-04-02-010

4
5. Insert thrust plates (4), then install pin (5). 7 5
Ȁ Insert bolt (7) into pin (5) and stopper (18), then
put nut (6) on the bolt. 18
: 30 mm
: 550 N⋅m (56 kgf⋅m, 405 Ibf⋅ft)
IMPORTANT: When all work is completed, run the 17

arm cylinder several times to stroke
end to bleed air from the circuit.
6
W187-04-02-006
W4-2-9
Remove Boom Cylinder 1
1. Disconnect grease hoses (1) from boom cylinder.
: 17 mm

153 kg (337 Ib)
2. Attach a wire rope to boom cylinder (2) and hoist it

by crane.

W105-04-02-032
as goggles, hard hats, etc.
3. Remove nut (5), bolt (7) and stopper (6) from the
boom cylinder (2) rod, and drive out pin (4) with a 7
bar and hammer.
Remove thrust plate (3).
: 24 mm
NOTE: When it is impossible to drive out pin (4),

start the engine and operate the boom lever 6
to align the boom cylinder rod pin hole.
5 3 4 3 2
W178-04-01-004
4. To prevent the boom cylinder (2) rod from stretch-
ing, pass the wire through the cylinder rod hole
and secure it to the cylinder tube. Hoist boom cyl-
inder (2) by crane and place it on the stand. Place
the other boom cylinder by the same method.
5. After stopping the engine, push the air release

valve to release any remaining pressure from the
hydraulic tank. Then remove the cap.
Release circuit pressure.
Refer to “Release Hydraulic Circuit Pressure”.
(W4-2-15).
2
W105-04-02-035
Wire
2
W105-04-02-036
W4-2-10
6. Disconnect hoses (12) (4 used) from boom cylin-
der (2) at the boom cylinder bottom. Close all
openings of the hoses with plug (4174549) and of
the boom cylinder with cap.
: 36 mm

2
fragments may fly off when a hammer is used. 11
Be sure to wear necessary protection, such 8
7. Loosen nut (10) at the boom cylinder bottom side

of the main frame, and remove bolt (8).
Pull out pin (9). 9
Remove thrust plate (11).
: 24 mm 9 10
10
12
W178-04-02-009

153 kg (337 Ib)
CAUTION: When attaching a wire rope, be
sure that it may not come in contact with the
boom cylinder pipings.
8. Attach a wire rope at the center of gravity of boom
cylinder (2). Hoist it by crane to remove.
Remove the other side boom cylinder by the same 2
method.
W105-04-02-040
W4-2-11
Install Boom Cylinder
153 kg (337 lb)
CAUTION: When attaching a wire rope, be

sure that it may not come in contact with the
boom cylinder pipings.
1. Attach a wire rope at the center of gravity of boom
cylinder (2) to hoist it by crane. Align the boom cyl-
inder bottom side pin hole with the boom cylinder
2
mounting hole on the main frame.
W105-04-02-040

2. Insert thrust plate (11) and pin (9). Install bolt (8),
then tighten with nut (10). 2
: 24 mm 11
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft) 8
3. Install the other side boom cylinder by the same

method.
4. Install hoses (12) (4 used) on boom cylinders (2) 9

(2 used).
: 36 mm 9 10
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
10
12
IMPORTANT: After filling hydraulic oil to specified W178-04-02-009
level, start the engine, and check the

connections for any oil leaks.
W4-2-12
5. Hoist boom cylinder (2) by crane. Operate the
boom lever to align the cylinder rod side pin hole
with the boom cylinder mounting hole of the
boom.

Be sure to wear necessary protection, such 7
as goggle, hard hats, etc.
6. Install thrust plate (3), drive in pin (4) to connect

boom cylinder (2) to the boom.
7. Install stopper (6), bolt (7) and nut (5).

: 24 mm 6
: 270 N⋅m (27.5 kgf⋅m, 199 lbf⋅ft)
5
3 4 3 2
8. Connect grease hoses (1). W178-04-01-004
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
9. Install the other side boom cylinder by the same

method.
1
IMPORTANT: When all work is completed, run the
boom cylinder for several times to
stroke end to bleed air from the cir-
cuit.
W105-04-02-032
W4-2-13
(Blank)
W4-2-14
HYDRAULIC CIRCUIT PRESSURE
1
RELEASE PROCEDURE
CAUTION: Be sure to slowly loosen the

overload relief valves. Quick loosening of the
overload relief valves may cause pressurized
oil to spurt, possibly resulting in severe
burns and/or oil penetration of skin.
IMPORTANT: Be sure to loosen the valve body,
not the adjusting screw. Also be 4
sure to re-tighten the overload relief
valve after releasing the residual 6
circuit pressure.
Release the residual circuit pressure by slowly
loosening the overload relief valve(s) for the line(s) or
hose(s) to be disconnected. Machine
Front
: 27 mm
+20
: 177 0 N⋅m
+3 +22
(18 0 kgf⋅m, 130 lbf⋅ft) T176-03-03-038
Overload Relief Valve:

1- Boom Cylinder (Bottom Side)
2- Boom Cylinder (Rod Side)
3- Arm Cylinder (Bottom Side)
4- Arm Cylinder (Rod Side)
5- Bucket Cylinder (Bottom Side)
6- Bucket Cylinder (Rod Side)
Machine
Front
2
T176-03-03-036
5
W4-2-15
DISASSEMBLE CYLINDER
Boom Cylinder
11 1 2 3 4 7 5 6 9 10
8
14 13 19 16 20 21 22 12
20 16 15 17 18 19 24 23
W158-04-02-016
Bucket Cylinder
11 1 2 3 4 7 5 6 9 10
13 20 19 20 21 22 12
16 15 17 18 16 19 24 23
W158-04-02-018
1- Wiper Ring 7- Cylinder Head 13 - Cushion Bearing 19 - Slide Ring (2 Used)

2- Backup Ring 8- Socket Bolt (12 Used) 14 - Cushion Seal 20 - Slide Ring (2 Used)
3- U-Ring 9- Backup Ring 15 - Piston 21 - Shim
4- Buffer Ring 10 - O-Ring 16 - Backup Ring (2 Used) 22 - Set Screw
5- Bushing 11 - Piston Rod 17 - Seal Ring 23 - Steel Ball
6- Retaining Ring 12 - Cylinder Tube 18 - O-Ring 24 - Nut
W4-2-16
Disassemble Boom and Bucket Cylinder
starting any disassembling work.
• The disassembly procedure below starts on the

premise that the hydraulic line and the line secur-
ing bands have been removed.
CAUTION: Cylinder weight:

Boom cylinder: 153 kg (337 lb)
Bucket cylinder:125 kg (276 lb)
1. Hoist and securely place the cylinder on a work-

bench by crane. Be sure that the cylinder is
placed horizontally. Drain hydraulic oil from the
cylinder.
W102-04-02-027
2. Fully extend piston rod (11). Secure the rod end

by crane. Remove socket bolts (8) from cylinder
head (7).
: 12 mm
3. Pull out cylinder head (7) from cylinder tube (12)

by tapping with a plastic hammer.
IMPORTANT: Be sure to pull piston rod (11)

straight so as not to damage the
sliding surfaces.
4. Secure piston rod (11) on special tool (ST 5908).

Put matching marks between the piston rod and
nut (24).
ST 5908
W158-04-02-022
W4-2-17
Boom Cylinder
11 1 2 3 4 7 5 6 9 10
14 13 19 16 20 21 22
20 16 15 17 18 19 24 23
W158-04-02-016
Bucket Cylinder
11 1 2 3 4 7 5 6 9 10
13 20 19 20 21 22
16 15 17 18 16 19 24 23
W158-04-02-018
W4-2-18
5. Remove set screw (22) and steel ball (23).
NOTE: Set screw (22) was crimped with a punch in

2 places after it was tightened. Before loos-
ing the set screw, cut away the crimped
portions.
: 6 mm
6. Loosen nut (24) using special tool (ST 5908).

Remove piston (15), shim (21) and cushion bear-
ing (13). (In Boom cylinder only, remove cushion
seal (14).)
Ȁ Tool for turning nut:
Boom 85 mm (ST 3304)
Bucket 80 mm (ST 3262)
ST 5908
W158-04-02-022
7. Remove seal ring (17), slide rings (19) (2 used),

slide rings (20) (2 used), O-ring (18) and backup
rings (16) (2 used) from piston (15).
8. Remove cylinder head (7) from piston rod (11).
9. Remove O-ring (10) and backup rings (9), (2)

from cylinder head (7). Then remove wiper ring
(1), U-ring (3), buffer ring (4), retaining ring (6)
and bushing (5).
Ȁ Tool for removing bushing:
Boom 80 mm (ST 8019/ST 1286)
Ȁ Bucket 75 mm (ST 8018/ST 1285)
Ȁ
W4-2-19
ARM CYLINDER
11 1 2 3 4 7 5 6 9 10
14 13 15 16 25 26 28 22 12
20 19 16 17 18 19 20 27 21 24 23
W158-04-02-017
1- Wiper Ring 8- Socket Bolt(12 Used) 15 - Piston 22 - Set Screw

2- Backup Ring 9- Backup Ring 16 - Backup Ring (2 Used) 23 - Steel Ball
3- U-Ring 10 - O-Ring 17 - Seal Ring 24 - Nut
4- Buffer Ring 11 - Piston Rod 18 - O-Ring 25 - Retaining Ring
5- Bushing 12 - Cylinder Tube 19 - Slide Ring (2 Used) 26 - Cushion Seal
6- Retaining Ring 13 - Cushion Bearing 20 - Slide Ring (2 Used) 27 - Cushion Bearing
7- Cylinder Head 14 - Cushion Seal 21 - Shim 28 - Stopper (2 used)
W4-2-20
Disassemble Arm Cylinder
starting the disassembling work.
• The disassembly procedure below starts on the

premise that the hydraulic line and the line secur-
ing bands have been removed.
CAUTION: Cylinder weight:

Arm cylinder: 210 kg (460 lb )
1. Place the cylinder horizontally on a workbench by

crane and secure it.
Drain hydraulic oil from the cylinder.
W102-04-02-027
2. Fully extend piston rod (11). Secure the rod end

by crane. Remove socket bolts (8) from cylinder
head (7).
: 14 mm
IMPORTANT: Be sure to pull piston rod (11)

straight so as not to damage the
sliding surfaces.
3. Pull out cylinder head (7) with piston rod (11) from
cylinder tube (12) by tapping with a plastic ham-
mer.
4. Secure piston rod (11) on special tool (ST 5908).

Put matching marks between the piston rod and
nut (24).
ST 5908
W158-04-02-022
W4-2-21
Arm Cylinder
11 1 2 3 4 7 5 6 9 10
14 13 15 16 25 26 28 22
20 19 16 17 18 19 20 27 21 24 23
W158-04-02-017
W4-2-22
5. Remove set screw (22) and steel ball (23).
NOTE: Set screw (22) was crimped with a punch in

2 places after it was tightened. Before loos-
ing the set screw, cut away the crimped
portions.
: 6 mm
6. Loosen nut (24) using special tool (ST 5908) to

remove piston (15), shim (21), cushion bearing
(13) and cushion seal (14).
Tool for turning nut: 90 mm (ST 3263)
ST 5908
W158-04-02-022
7. Remove seal ring (17), slide rings (19) (2 used),

(20) (2 used), O-ring (18) and backup rings (16) (2
used) from piston (15).
8. Remove cylinder head (7) from pistion rod (11).
9. Remove O-ring (10), backup rings (9), (2) from

cylinder head (7). Then remove wiper ring (1), U-
ring (3), buffer ring (4), retaining ring (6) and bush-
ing (5).
Special tool for bushing removal:
90 mm (ST 8024/ST 1991)
10. Remove retaining ring (25) from piston rod (11)

with a screw driver. Remove cushion bearing (27)
and cushion seal (26) after cushion bearing (27)
moves to the retaining ring to remove stopper
(28).
W4-2-23
ASSEMBLE CYLINDER
Boom Cylinder
Hole (1 Place)
Face the slit toward the piston.
1 7 8
2 3 4 5 6 9, 10 14
11 12 13 15 16 17, 18 19 20
21
22, 23
24
Be sure that oil groove faces the W1F1-04-02-001

correct direction when assembling.
Bucket Cylinder
Hole (1 Place)
4 5 6 7 8 9, 10
1 11 12
3 17, 18 19 20 21
2 13 15 16
22, 23
24
Be sure that oil groove faces the

correct direction when assembling. W1F1-04-02-002
1 - Wiper Ring 7 - Cylinder Head 13 - Cushion Bearing 19 - Slide Ring (2 Used)

2 - Backup Ring 8 - Socket Bolt 14 - Cushion Seal 20 - Slide Ring (2 Used)
(12 Used)
3- U-Ring 9 - Backup Ring 15 - Piston 21 - Shim
4- Buffer Ring 10 - O-Ring 16 - Backup Ring (2 Used) 22 - Set Screw
5- Bushing 11 - Piston Rod 17 - Seal Ring 23 - Steel Ball
6- Retaining Ring 12 - Cylinder Tube 18 - O-Ring 24 - Nut
W4-2-24
Assemble Boom and Bucket Cylinder
1. Install bushing (5) to cylinder head (7) with a
press.
Tools for bushing installation:
Boom 80 mm (ST 8019/ST 1286)
Bucket 75 mm (ST 8018/ST 1285)
Ȁ
IMPORTANT: Be sure that the rings are installed
correctly.
Ȁ
2. Install U-ring (3), backup ring (2), buffer ring (4)
and retaining ring (6) onto cylinder head (7).
3. Install wiper ring (1) to cylinder head (7) with a

plastic hammer.
Tools for wiper ring installation:
Boom (ST 8019/ST 1297)
Bucket (ST 8018/ST 1296)
4. Install O-ring (10) and backup ring (9) to cylinder

head (7).
IMPORTANT: Be sure to install so that the division

parts of slide rings (19) and (20) do
not align.
5. Install O-ring (18), backup rings (16) (2 used),
seal ring (17) and slide rings (19) (2 used), (20) (2
used) to piston (15).
6. Install cylinder head (7) to piston rod (11).

Ȁ Tool for installing cylinder head:
Boom (ST 8019/ST 2345)
Bucket (ST 8018/ST 2344)
Ȁ
IMPORTANT: Be sure that the cushion seal (14)
slit the faces toward the piston and
that cushion bearing (13) oil groove
faces the correct direction.
7. Install cushion bearing (13) to piston rod (11). In-

stall the piston (15) assembly to piston rod (11).
(For boom cylinder only: install cushion seal (14).)
13
Oil Groove
Head Side Nut Side
W18B-04-02-011
W4-2-25
Boom Cylinder
7 8
11 12 21, 23
21
24
W1F1-04-02-001
Bucket Cylinder
7 8
11 12
21 21, 23
24
W1F1-04-02-002
W4-2-26
8. Install shim (21) to piston rod (11). Tighten nut
(24) using special tool (ST 5908). Be sure to align
the matching mark on the rod with that on the nut.
Ȁ Tool for tightening nut:
Boom 85 mm (ST 3304)
Bucket 80 mm (ST 3262)
: Boom cylinder
3800 N⋅m (390 kgf⋅m, 2800 lbf⋅ft)
Bucket cylinder
4780 N⋅m (490 kgf⋅m, 3530 lbf⋅ft)
ST 5908
W158-04-02-022
IMPORTANT: Mushroom the head of set screw

(22) at two places with a punch and
hammer.
9. Align the holes on piston rod (11) and nut (24). In-
sert steel ball (23) into the hole, and tighten set
screw (22) into the hole.
: 6 mm (Boom, bucket)
: 56.9±10.7 N⋅m
(5.8±1.09 kgf⋅m, 42.0±7.9 lbf⋅ft)
(Boom, Bucket)
CAUTION: Be sure to align piston rod (11)

assembly with the center of cylinder tube (12)
when inserting, in order to avoid damaging
the rings.
10. Secure cylinder tube (12) horizontally on a work

bench. Insert piston rod (11) assembly into cylin-
der tube (12).
11. Install cylinder head (7) to cylinder tube (12).

Tighten them with socket bolts (8) (12 used).
: 12 mm (Boom, bucket)
: 171 N⋅m (17.5 kgf⋅m, 126 lbf⋅ft)
W4-2-27
Arm Cylinder
Hole (1 Place)
1 2 3 4 5 6 7 8 9, 10
11 12 13 14 15 16 17, 18 19 20 21
22, 23
24
25
26
27
28
W1F1-04-02-003

correct direction when asembling.
1- Wiper Ring 8- Socket Bolt(12 Used) 15 - Piston 22 - Set Screw

2- Backup Ring 9- Backup Ring 16 - Backup Ring (2 Used) 23 - Steel Ball
3- U-Ring 10 - O-Ring 17 - Seal Ring 24 - Nut
4- Buffer Ring 11 - Piston Rod 18 - O-Ring 25 - Retaining Ring
5- Bushing 12 - Cylinder Tube 19 - Slide Ring (2 Used) 26 - Cushion Seal
6- Retaining Ring 13 - Cushion Bearing 20 - Slide Ring (2 Used) 27 - Cushion Bearing
7- Cylinder Head 14 - Cushion Seal 21 - Shim 28 - Stopper (2 Used)
W4-2-28
Assemble arm cylinder
1. Install bushing (5) to cylinder head (7) with a
press.
Tool for pressing bushing:
90 mm (ST 8024/ST 1991)
IMPORTANT: Be sure that the rings are installed

correctly.
2. Install U-ring (3), backup ring (2), buffer ring (4)

and retaining ring (6) to cylinder head (7).
3. Install wiper ring (1) to cylinder head (7) with a

plastic hammer.
Tool for pressing wiper ring: (ST 8024/ST 1368)
4. Install O-ring (10) and backup ring (9) to cylinder

head (7).
Ȁ
IMPORTANT: Be sure to install so that the division
parts of slide rings (19) and (20) do
not align.
5. Install seal ring (17), O-ring (18), slide rings (19)
(2 used), (20) (2 used) and backup ring (16) (2
used) to piston (15).
Ȁ
6. Install cylinder head (7) assembly to piston rod
(11).
Tool for installing cylinder head: (ST 8024/ST
2510)
Ȁ
slit faces toward the piston and that
the cushion bearing (13) oil groove
7. Install cushion seal (14) to piston rod (11). Install

cushion bearing (13) and piston (15) assembly to
piston rod (11). 13
Oil Groove
Head Side Nut Side
W18B-04-02-011

slit faces toward the piston and that
the cushion bearing (27) oil groove
8. Install cushion seal (26) to piston rod (11) to install
cushion bearing (27) and stopper (28). Move
cushion bearing (27) to the stopper to install re-
taining ring (25).
W4-2-29
Arm Cylinder
7 8
11 12 22, 23 24
25
26
27
28
W1F1-04-02-004
correct direction when assembling.
W4-2-30
9. Install shim (21) to piston rod (11). Tighten nut
(24) with special tool (ST 5908).
Be sure to align the matching mark on the rod with
that on the nut.
Tool for tightening nut: 90 mm (ST 3263)
: 7230 N⋅m (740 kgf⋅m, 5330 lbf⋅ft)
ST 5908
W158-04-02-022
IMPORTANT: Mushroom the head of set screw

(22) at two places with a punch and
hammer.
10. Align the holes on piston rod (11) and nut (24).
Insert steel ball (23) into the hole, and tighten set
screw (22) into the hole. If it is impossible to align
the holes, tighten nut (24).
: 6 mm
: 56.9±10.7 N⋅m
(5.8±1.09 kgf⋅m, 42.0±7.9 lbf⋅ft)
CAUTION: Be sure to align piston rod (11)

assembly with the center of cylinder tube (12)
when inserting, in order to avoid damaging
the rings.
11. Secure cylinder tube (12) horizontally on a work

bench. Insert piston rod (11) assembly into cylin-
der tube (12).
12. Install cylinder head (7) to cylinder tube (12).

Tighten socket bolts (8) (12 used).
: 14 mm
: 267 N⋅m (27 kgf⋅m, 195 lbf⋅ft)
W4-2-31
Rod Rod Bend and Run Out

A
Dial Gauge
Cylinder Rod
W105-04-02-094
W166-04-02-022
unit: mm (in) 1m
Recommended Size After V Block
Cylinder Name
Re-manufacturing (A) unit: mm (in)
+0.023 +0.00091 Bend Run out Remedy
Boom 80 (3.15 )
-0.053 −0.0021 Allowable limit 0.5 (0.020) 1.0 (0.039) Repair
+0.027 +0.0011 Allowable limit 1.0 (0.039) 2.0 (0.079) Replace
Arm 90 (3.54 )
-0.057 −0.0022
+0.023 +0.0009
Bucket 75 (2.95 )
-0.053 −0.0021
Wear to The Inner Diameter of Rod Bushing

unit: mm (in)
Cylinder Allowable
Standard inner Diameter (C) Remedy
Name Limit
-0.06 −0.002 +0.3 C
Boom 80 (3.15 ) Replace
-0.19 −0.007 (0.012)
-0.06 −0.002 +0.3
Arm 90 (3.54 ) Replace
-0.19 −0.007 (0.012)
-0.06 −0.002 +0.3
Bucket 75 (2.95 ) Replace
-0.19 −0.007 (0.012)
W4-2-32
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
SECTION 5
ENGINE AND ACCESSORY
 CONTENTS 
General Information Engine Assembly 2
General Repair Instructions ........................... 1-2 (Inspection and Repair)
Notes on the Format of This Manual.............. 1-2 Cylinder Head................................................ 4-2
Main Data and Specifications ........................ 1-6 Valve Guide ................................................... 4-3
Performance Curve ....................................... 1-8 Valve Spring .................................................. 4-6
External View .............................................. 1-11 Tappet ........................................................... 4-7
Tightening Torque Specifications ................. 1-14 Push Rod ...................................................... 4-8
Angular Nut and Bolt Tightening Method...... 1-16 Rocker Arm Shaft and Rocker Arm................ 4-8
Major Parts Fixing Nuts and Bolts................ 1-18 Idler Gear and Idler Gear Shaft ..................... 4-9
Identifications .............................................. 1-26 Camshaft..................................................... 4-10
Cylinder Body and Liner............................... 4-11
Maintenance Piston and Piston Ring ................................ 4-17
Lubricating System ........................................ 2-2 Piston Pin .................................................... 4-18
Fuel System .................................................. 2-3 Connecting Rod........................................... 4-19
Cooling System ............................................. 2-6 Crankshaft................................................... 4-21
Valve Clearance Adjustment.......................... 2-6 Flywheel ...................................................... 4-28
Injection Timing ............................................. 2-8 Timing Gear Case Cover ............................. 4-28
Compression Pressure Measurement.......... 2-12
Turbocharger Inspection.............................. 2-13 Engine Assembly 3 (Reassembly)
Engine Repair Kit ........................................ 2-14 Piston and Connecting Rod
Recommended Lubricants ........................... 2-15 Reassembly Steps ....................................... 5-2
Engine Oil Viscosity Chart ........................... 2-15 Cylinder Head Reassembly Steps.................. 5-4
Rocker Arm and Rocker Arm Shaft
Engine Assembly 1 (Disassembly) Reassembly Steps ....................................... 5-7
External Parts Disassembly Steps ................. 3-2 Major Component Reassembly Steps 1 ......... 5-8
Major Components ........................................ 3-6 Major Component Reassembly Steps 2 ....... 5-13
Rocker Arm and Rocker Arm Shaft External Parts Reassembly Steps
Disassembly Steps .................................... 3-10 (Left-Hand Side) ........................................ 5-18
Cylinder Head Disassembly Steps ............... 3-11 External Parts Reassembly Steps
Piston and Connecting Rod (Right-Hand Side) ...................................... 5-21
Disassembly Steps .................................... 3-12 Engine Tuning Operation ............................. 5-25
1F1W-5-1
Lubricating System Troubleshooting
General Description....................................... 6-2 Hard Starting ............................................... 11-2
Oil Pump ....................................................... 6-3 1) Starter Inoperative................................. 11-2
Oil Cooler ...................................................... 6-5 2) Starter Operates but
Engine does not Turn Over.................... 11-3
Cooling System 3) Engine Turns Over but does not Start
General Description....................................... 7-2 Fuel is Being Delivered to the
Thermostat.................................................... 7-3 Injection Pump ...................................... 11-4
4) Engine Turns Over but does not Start.... 11-5
Fuel System Unstable Low Idling ..................................... 11-6
General Description....................................... 8-2 Insufficient Power ........................................ 11-8
Injection Nozzle ............................................. 8-3 Excessive Fuel Consumption..................... 11-11
Injection Pump Calibration Data .................... 8-8 Excessive Oil Consumption ....................... 11-13
Overheating............................................... 11-14
Turbocharger Whity Exhaust Smoke ............................... 11-16
General Description....................................... 9-2 Dark Exhaust Smoke................................. 11-17
Turbocharger Identification ............................ 9-3 Oil Pressure does not Rise ........................ 11-18
Troubleshooting............................................. 9-5 Abnormal Engine Noise ............................. 11-20
Inspection and Repair ................................... 9-7
Special Tool List
Engine Electricals Special Tool List .......................................... 12-2
Starter Identification .................................... 10-2
Starter Main Data and Specifications........... 10-3 Repair Standards
Starter Sectional View ................................. 10-4 Repair Standards ........................................ 13-1
Performance ............................................... 10-4
Disassembly................................................ 10-5 Conversion Table
Inspection and Repair ................................. 10-8 Length ......................................................... 14-1
Reassembly .............................................. 10-12 Area ............................................................ 14-3
Adjustment ................................................ 10-13 Volume ........................................................ 14-3
Performance Test ...................................... 10-14 Mass ........................................................... 14-5
Alternator Identification.............................. 10-15 Pressure...................................................... 14-6
Main Data and Specifications .................... 10-16 Torque ......................................................... 14-7
Alternator Sectional View........................... 10-17 Temperature ................................................ 14-8
Charging Circuit ........................................ 10-17
Structure ................................................... 10-18
Disassembly.............................................. 10-19
Inspections................................................ 10-22
Reassembly .............................................. 10-24
Bench Test ................................................ 10-25
Current Output Test ................................... 10-26
Fault Finding ............................................. 10-27
Specifications ............................................ 10-27
1F1W-5-2
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
SERVICE MANUAL REVISION REQUEST FORM
NAME OF COMPANY: MODEL:

PUBLECATION NO.:
YOUR NAME: (Located at the left bottom corner in the cover page)
PAGE NO.:
DATE: (Located at the bottom center in the page. If two or more
revisions are requested, use the comment column)
FAX:
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch is required.
If your need more space, please use another sheet.
REPLY:
(Copy this form for usage)

Hitashi W 1F1E 00

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Hitashi W 1F1E 00

Uploaded by

Copyright:

Available Formats

INTRODUCTION

• Each page has a number, located on the center

Consecutive Page Number for Each Group

In this manual, the following safety alert symbol and • CAUTION:

• This is the SAFETY ALERT SYMBOL.

• When you see this symbol on your machine or in

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating

• DANGER indicates an imminently hazardous

• WARNING indicates a potentially hazardous

• CAUTION indicates a potentially hazardous

• DANGER or WARNING safety signs are located

• Some safety signs don’t use any of the SA-1223

• CAUTION also calls attention to safety messages in

• To avoid confusing machine protection with personal

• NOTE indicates an additional explanation for an

• Carefully read and follow all safety signs on the ma-

• Safety signs should be installed, maintained and re-

• If a safety sign or this manual is damaged or miss-

• Learn how to operate the machine and its controls

• Allow only trained, qualified, authorized personnel to

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may

• The safety messages in this SAFETY chapter are

PREPARE FOR EMERGENCIES

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

• Keep a first aid kit and fire extinguisher on hand.

lance service, hospital, and fire department

• Wear close fitting clothing and safety equipment

You may need:

• Avoid wearing loose clothing, jewelry, or other

• Operating equipment safely requires the full

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

• Wear a suitable hearing protective device such as

• Inspect your machine carefully each day or shift by

• In the walk-around inspection be sure to cover all

• Before entering the cab, thoroughly remove all dirt

• Don’t leave parts and/or tools lying around the op-

• Avoid storing transparent bottles in the cab. Don’t

• Refrain from listening to the radio, or using music

• Keep all flammable objects and/or explosives

• After using the ashtray, always cover it to extin-

• Don’t leave cigarette lighters in the cab. When the

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

• When you mounting and dismounting the ma-

• Do not use any controls as hand-holds.

• Never jump on or off the machine. Never mount or

ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for

• The seat should be adjusted whenever changing

• If the machine should overturn, the operator may

• Prior to operating the machine, thoroughly

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

• Take extra care not to run over bystanders.

• Inappropriate engine starting procedures may cause

• Start the engine only when seated in the

• Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to

• Riders on machine are subject to injury such as

• Only the operator should be on the machine.

PROVIDE SIGNALS FOR FOBS INVOLV-

• For jobs involving multiple numbers of machines,