Professional Documents
Culture Documents
To The Reader
To The Reader
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
Example : T 1-3-5
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
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
001-E01A-0688 SA-688
002-E01C-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
004-E01A-0437
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
005-E01A-0438
006-E01A-0434 SA-434
INSPECT MACHINE
S007-E01A-0435
SA-435
SA-3
SAFETY
GENERAL PRECAUTIONS FOR CAB
524-E01A-0000
SA-4
SAFETY
USE HANDHOLDS AND STEPS
008-E01B-0439
009-E01A-0378
SA-5
SAFETY
FASTEN YOUR SEAT BELT
010-E01A-0237
011-E01A-0426
SA-6
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
012-E01B-0444
JUMP STARTING
S013-E01A-0032
SA-7
SAFETY
KEEP RIDERS OFF MACHINE
SA-379
014-E01B-0379
018-E01A-0481
SA-481
SA-8
SAFETY
DRIVE MACHINE SAFELY
SA-387
SA-441
019-E01D-0492
SA-589
SA-9
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
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
S021-E01A-0494
SA-11
SAFETY
AVOID TIPPING
To avoid tipping:
• Be extra careful before operating on a grade.
S025-E01B-0495
SA-12
SAFETY
AVOID POWER LINES
029-E01A-0381
OBJECT HANDLING
032-E01A-0014
SA-13
SAFETY
PROTECT AGAINST FLYING DEBRIS
SA-432
031-E01A-0432
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
034-E01A-0496
SA-019
SA-15
SAFETY
SAFETY TRANSPORTING
S035-E08A-0395
SA-16
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
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
S501-E01A-0287
SA-287
502-E01A-0026
SA-026
SA-18
SAFETY
PREVENT PARTS FROM FLYING
503-E01B-0344
SA-034
504-E01A-0034
SA-040
S522-E01A-0040
SA-19
SAFETY
PREVENT BURNS
• 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
505-E01B-0498
S506-E01A-0019
SA-20
SAFETY
AVOID HIGH-PRESSURE FLUIDS
SA-292
507-E03A-0499
SA-044
SA-21
SAFETY
PREVENT FIRES
Clean up Flammables:
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.
S508-E02B-0019
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
509-E01A-0016
SA-016
SA-24
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
511-E01A-0029
512-E01C-0032
SA-25
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
513-E01A-0405
• 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
S516-E01A-0226
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 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
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
W1-1-1
GENERAL / Precautions for Disassembling and Assembling
• Precautions for Assembling Bleeding Air from Hydraulic System
• Be sure to clean all parts and inspect them for 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.
W1-1-2
GENERAL / Precautions for Disassembling and Assembling
• Bleeding Air from Hydraulic Circuit
W1-1-3
GENERAL / Precautions for Disassembling and Assembling
Floating Seal Precautions A
(3) Check that the O-ring is not twisted, and that it W105-03-05-020
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
GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling
W1-1-5
GENERAL / Precautions for Disassembling and Assembling
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
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
GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.
“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
W1-1-7
GENERAL / Precautions for Disassembling and Assembling
(Blank)
W1-1-8
GENERAL / Tightening
W1-2-1
GENERAL / Tightening
W1-2-2
GENERAL / Tightening
TORQUE CHART
Bolt Types
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
GENERAL / Tightening
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to nuts
and bolts to reduce their friction
coefficients.
The plated bolts require no 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.
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
GENERAL / Tightening
Service Recommendations for Spilt Flange
• 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
GENERAL / Tightening
PIPING JOINT 1 4 3 5 2
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
W1-2-6
GENERAL / Tightening
O-ring Seal Joint 7 6 9
W1-2-7
GENERAL / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30ѯ
types of screw fittings are used.
• 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.
M114-07-043 M114-07-042
W1-2-8
GENERAL / Tightening
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation of
fitting, possibly resulting in a fire on the ma-
chine.
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
GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic
inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of 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
W1-2-10
GENERAL / Painting
PAINTING
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
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)
W178-01-03-006
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
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
4
5
3. Raise duct (5) to remove it.
W178-02-01-013
W2-1-1
UPPERSTRUCTURE / Cab
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
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
19
W178-02-01-017
20 21
W2-1-2
UPPERSTRUCTURE / Cab
22
W178-02-01-018
24
W157-02-01-010
W157-02-01-001
W2-1-3
UPPERSTRUCTURE / Cab
Installation
W157-02-01-001
W157-02-01-010
W178-02-01-013
10
11
12
13
W178-02-01-014
W2-1-4
UPPERSTRUCTURE / Cab
5. Connect washer vinyl hose (14) at the rear of the
cab inside.
14
W178-02-01-015
6. Aligning the mounting hole for duct (5), while
pressing it to install the hose into the hole.
4
5
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
UPPERSTRUCTURE / Cab
9. Install duct cover (17) with screws (16). Install
caps (15) onto duct cover (17). 16
17
15
W178-02-01-016
W178-02-01-001
W2-1-6
UPPERSTRUCTURE / Cab
DIMENSIONS OF THE CAB GLASS
Chamfer
A
Unit: mm Here
R2
67 303.5 Chamfer along the
11 Periphery unless
Otherwise Specified
R98 R35
4-φ13 0 -1
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
UPPERSTRUCTURE / Cab
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
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
R2002
872
R123
R115
888.58
W178-02-01-010
W2-1-8
UPPERSTRUCTURE / Cab
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
A
CSE Braid
Seal Rubber
10 10
W178-02-01-022
W178-02-01-004
W2-1-9
UPPERSTRUCTURE / Cab
Installation of Right-hand Cab Glass Mounting Rubber Section
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.
W178-02-01-005
W2-1-10
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTER-
WEIGHT
1
Removal
CAUTION: Counterweight weight:
3000 kg (6610 lb)
2. Attach wire ropes to sling bolts. Hoist and take out Wire Rope
the slack of wire ropes by crane.
Sling Bolt
W178-02-02-003
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation
CAUTION: Counterweight weight:
3000 kg (6610 lb)
Torque Wrench
Power Wrench W178-02-02-004
W178-02-02-001
W2-2-2
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME
Preparation
1. Place the machine on a firm, level surface.
W2-3-1
UPPERSTRUCTURE / Main Frame
Removal
CAUTION: Cab weight:
290 kg (640 Ib)
: 24mm, 17 mm, 13 mm
: 8 mm
W157-02-01-001
CAUTION: Counterweight weight:
3000 kg (6610 lb)
W178-02-02-002
W2-3-2
UPPERSTRUCTURE / Main Frame
Front
W105-02-03-005
W157-02-03-001
W2-3-3
UPPERSTRUCTURE / Main Frame
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
W105-02-03-007
W157-02-03-002
W2-3-4
UPPERSTRUCTURE / Main Frame
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.
: 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)
W173-03-03-001
W2-3-5
UPPERSTRUCTURE / Main Frame
: 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
W178-02-02-002
W2-3-6
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
Preparation
1. Place the machine on a firm, level surface.
W2-4-1
UPPERSTRUCTURE / Pump Device
Removal
1. Remove bolts (1) (4 used) to remove cover (2).
: 17 mm
14
15
16
19
18
M1F1-00-001
17
20
Eyebolt
Mounting
Position
W1F1-02-04-003
W2-4-2
UPPERSTRUCTURE / Pump Device
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
W1F1-02-04-002
W1F1-02-04-001
W2-4-3
UPPERSTRUCTURE / Pump Device
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
UPPERSTRUCTURE / Pump Device
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
W2-4-5
UPPERSTRUCTURE / Pump Device
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
UPPERSTRUCTURE / Pump Device
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.
W2-4-7
UPPERSTRUCTURE / Pump Device
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
UPPERSTRUCTURE / Pump Device
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
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).
W2-4-9
UPPERSTRUCTURE / Pump Device
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
UPPERSTRUCTURE / Pump Device
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
W2-4-11
UPPERSTRUCTURE / Pump Device
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
UPPERSTRUCTURE / Pump Device
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).
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).
W2-4-13
UPPERSTRUCTURE / Pump Device
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
UPPERSTRUCTURE / Pump Device
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
22. Install piston (25) and center pin (32) into the cyl-
inder block (26) and (27) assemblies.
W2-4-15
UPPERSTRUCTURE / Pump Device
1
2
6
7
11
Pressure Sensor
Mounting Hole
13
W1F1-02-04-011
12
W2-4-16
UPPERSTRUCTURE / Pump Device
W2-4-17
UPPERSTRUCTURE / Pump Device
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
UPPERSTRUCTURE / Pump Device
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).
W2-4-19
UPPERSTRUCTURE / Pump Device
8
9
10
11
T1F1-03-01-001
W2-4-20
UPPERSTRUCTURE / Pump Device
11. Pull out set screw (11) from control piston (8).
: 4 mm
W1F1-02-04-008
W1F1-02-04-009
13. Pull out control piston (8) from regulator cover (9)
with it facing pressure spring (2) side.
W2-4-21
UPPERSTRUCTURE / Pump Device
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
UPPERSTRUCTURE / Pump Device
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.
W2-4-23
UPPERSTRUCTURE / Pump Device
DISASSEMBLE AND ASSEMBLE CON-
TROL HOUSING
A-A
3
4
5
6
7
8
9
W1F1-02-04-010
W2-4-24
UPPERSTRUCTURE / Pump Device
Disassemble and Assemble Control Housing
Disassemble
1. Remove O-ring (1) from control housing (9).
Assemble
1. Install plug (8) into control housing (9).
: 5 mm
: 10 N⋅m (1 kgf⋅m, 7.4 lbf⋅ft)
W2-4-25
UPPERSTRUCTURE / Pump Device
DISASSEMBLE AND ASSEMBLE COVER
1
2
3
4
5
6
7
8
9
10
11 T1F1-03-01-002
12 13
W2-4-26
UPPERSTRUCTURE / Pump Device
Disassemble and Assemble Cover
Disassemble
1. Remove knock pins (13) (2 used) 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).
W2-4-27
UPPERSTRUCTURE / Pump Device
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
W2-4-28
UPPERSTRUCTURE / Pump Device
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
UPPERSTRUCTURE / Pump Device
(Blank)
W2-4-30
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE
Preparation
1. Place the machine on a firm, level surface.
W2-5-1
UPPERSTRUCTURE / Control Valve
Removal
Machine Forward
T176-03-03-038
W2-5-2
UPPERSTRUCTURE / Control Valve
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.
W2-5-3
UPPERSTRUCTURE / Control Valve
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
UPPERSTRUCTURE / Control Valve
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
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
UPPERSTRUCTURE / Control Valve
72
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
102
100 103
104
101 105
W176-02-05-012
106
W2-5-6
UPPERSTRUCTURE / Control Valve
Disassemble 4-Spool Control Valve Side Section
15. Remove plug (106), then spring (104), washer
(103), spool (102) and O-ring (105).
: 36 mm
W2-5-7
UPPERSTRUCTURE / Control Valve
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
W2-5-8
UPPERSTRUCTURE / Control Valve
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
W2-5-9
UPPERSTRUCTURE / Control Valve
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
UPPERSTRUCTURE / Control Valve
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
W176-02-06-017
W2-5-11
UPPERSTRUCTURE / Control Valve
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
W2-5-12
UPPERSTRUCTURE / Control Valve
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
W2-5-13
UPPERSTRUCTURE / Control Valve
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
W2-5-14
UPPERSTRUCTURE / Control Valve
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
W2-5-15
UPPERSTRUCTURE / Control Valve
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
W2-5-16
UPPERSTRUCTURE / Control Valve
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
UPPERSTRUCTURE / Control Valve
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
W2-5-18
UPPERSTRUCTURE / Control Valve
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
UPPERSTRUCTURE / Control Valve
A
B
66 C
Section B Arm 2 Arm 1
72 69
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
NOTE: As for mark *, refer to W2-5-6.
W2-5-20
UPPERSTRUCTURE / Control Valve
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.
15. Install O-rings (88, 92) and backup rings (89, 91)
onto bushing (90).
W2-5-21
UPPERSTRUCTURE / Control Valve
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
UPPERSTRUCTURE / Control Valve
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)
W176-02-06-017
W2-5-23
UPPERSTRUCTURE / Control Valve
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
UPPERSTRUCTURE / Control Valve
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
W2-5-25
UPPERSTRUCTURE / Control Valve
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
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
NOTE: As for mark *, refer to W2-5-12.
W2-5-26
UPPERSTRUCTURE / Control Valve
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.
W2-5-27
UPPERSTRUCTURE / Control Valve
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
W2-5-28
UPPERSTRUCTURE / Control Valve
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
them as an assembly.
20. Clamp spool (230) with wood pieces in a vise,
then install washer (232), spring (233) and bolt
(234).
: 17 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
NOTE: Assemble washer (232) with the chamfered
side facing the spring.
Ȁ
IMPORTANT: Overall dimensions of spool (238)
have been determined. When disas-
sembling or replacing poppet (237),
spring (236), plug (235), replace
them as an assembly.
21. Clamp spool (238) with wood pieces in a vise,
then install washer (240), spring (241) and bolt
(242).
: 17 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
NOTE: Assemble washer (240) with the chamfered
side facing the spring.
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
UPPERSTRUCTURE / Control Valve
(Blank)
W2-5-30
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE
Preparation
1. Place the machine on a firm, level surface.
W2-6-1
UPPERSTRUCTURE / Swing Device
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)
Nylon Sling
W176-02-06-002
W2-6-2
UPPERSTRUCTURE / Swing Device
Installation
Nylon Sling
NOTE: Refer to “Removal” section above for
wrench sizes and tightening torques.
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
UPPERSTRUCTURE / Swing Device
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
W2-6-4
UPPERSTRUCTURE / Swing Device
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.
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
W178-02-06-012
W2-6-5
UPPERSTRUCTURE / Swing Device
23
25 21
4
18
10
17
11
16
12
30 15
14
W178-02-06-004
W2-6-6
UPPERSTRUCTURE / Swing Device
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).
ST 2926
15
Protection
Cover
W178-02-06-008
W157-02-06-011
W2-6-7
UPPERSTRUCTURE / Swing Device
25
26
27
28
29
30
14
W178-02-06-004
W2-6-8
UPPERSTRUCTURE / Swing Device
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
Oil Passage
Outer Race
W157-02-06-012
Shaft (30)
Bearing (26)
Inner Race
W178-02-06-001
Sleeve (28)
W2-6-9
UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING REDUCTION GEAR
1
2 4
3 5
22
21 6
20
7
18
24
8
19 10
11
23
13
12
11
17
9
16
32
15
14
26
29 25 31
27
28
30
W178-02-06-003
W2-6-10
UPPERSTRUCTURE / Swing Device
Assemble Swing Reduction Gear
1. Install O-ring (29) onto sleeve (28). 5. Apply THREEBOND #1215 on the outer surface
of oil seal (27). Put 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
weight: 36 kg (79 lb)
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
UPPERSTRUCTURE / Swing Device
24
23
15
14
25
27
30
W178-02-06-003
W2-6-12
UPPERSTRUCTURE / Swing Device
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.
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.
W2-6-13
UPPERSTRUCTURE / Swing Device
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
UPPERSTRUCTURE / Swing Device
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
W2-6-15
UPPERSTRUCTURE / Swing Device
22
21
20
18
24
23
16
32
25 31
30
W178-02-06-003
W2-6-16
UPPERSTRUCTURE / Swing Device
IMPORTANT: 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
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.
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
UPPERSTRUCTURE / Swing Device
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
W2-6-18
UPPERSTRUCTURE / Swing Device
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).
T178-03-02-003
W2-6-19
UPPERSTRUCTURE / Swing Device
10
8
7
6
5
4 11
3
2
12
13
14
15
W178-02-06-015
W2-6-20
UPPERSTRUCTURE / Swing Device
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.
W2-6-21
UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING MOTOR
27 26 25 24
12
13
14
15
16
29
T178-03-02-004
T178-03-02-003
31
30
28 32
22 21
20
23
19
18
10
17
6
11
9 8
7 3
5
1
4 T178-03-02-002
W2-6-22
UPPERSTRUCTURE / Swing Device
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).
W2-6-23
UPPERSTRUCTURE / Swing Device
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
UPPERSTRUCTURE / Swing Device
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)
W2-6-25
UPPERSTRUCTURE / Swing Device
MAINTENANCE STANDARD
Swing Motor
D D
W107-02-06-139
W1F1-02-06-001
W2-6-26
UPPERSTRUCTURE / Swing Device
3. Thickness of shoe
Unit: mm (in)
Standard Allowable Limit
5.5 (0.22) 5.3 (0.21)
W107-02-06-142
4. Thickness of friction plate
Unit: mm (in)
Standard Allowable Limit
2.0 (0.08) 1.8 (0.07)
W107-02-06-143
W2-6-27
UPPERSTRUCTURE / Swing Device
(Blank)
W2-6-28
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL RIGHT PILOT
VALVE
Preparation
1. Place the machine on a firm, level surface.
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
UPPERSTRUCTURE / Pilot Valve
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
W2-7-2
UPPERSTRUCTURE / Pilot Valve
2. Connect hoses (28 to 33).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 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
19
13
14
15
18 16
17
W1CC-02-07-001
W2-7-3
UPPERSTRUCTURE / Pilot Valve
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
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL LEFT PILOT
VALVE
Preparation
1. Park the machine on a solid level surface. Lower
the bucket to the ground.
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
9 Radio
3
8
4
7
6
5
W178-02-07-003
W2-7-5
UPPERSTRUCTURE / Pilot Valve
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
W178-02-07-003
W2-7-6
UPPERSTRUCTURE / Pilot Valve
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
leaks.
W2-7-7
UPPERSTRUCTURE / Pilot Valve
(Blank)
W2-7-8
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL TRAVEL PILOT
VALVE
Preparation
1. Park the machine on a solid level surface. Lower
the bucket to the ground.
M104-07-021
W2-7-9
UPPERSTRUCTURE / Pilot Valve
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
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
UPPERSTRUCTURE / Pilot Valve
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
UPPERSTRUCTURE / Pilot Valve
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
W2-7-12
UPPERSTRUCTURE / Pilot Valve
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
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
UPPERSTRUCTURE / Pilot Valve
21
20
21
20
19
18
17
W176-02-07-001
W2-7-14
UPPERSTRUCTURE / Pilot Valve
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.
W2-7-15
UPPERSTRUCTURE / Pilot Valve
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
W2-7-16
UPPERSTRUCTURE / Pilot Valve
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
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
UPPERSTRUCTURE / Pilot Valve
13 14
10
12
15
11
8, 9
W176-02-07-006
20 18
W2-7-18
UPPERSTRUCTURE / Pilot Valve
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
W176-02-07-007
W2-7-19
UPPERSTRUCTURE / Pilot Valve
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
W2-7-20
UPPERSTRUCTURE / Pilot Valve
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
W2-7-21
UPPERSTRUCTURE / Pilot Valve
35
34
33
32
31
30
10
14
W176-02-07-002
W2-7-22
UPPERSTRUCTURE / Pilot Valve
10. Remove O-ring (5) from pin (3). (2 places)
11. Place holder (10) with the casing (14) mating sur-
face facing upward.
W2-7-23
UPPERSTRUCTURE / Pilot Valve
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
W2-7-24
UPPERSTRUCTURE / Pilot Valve
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
Outside of
Holder
W176-02-07-014
W176-02-07-013
W2-7-25
UPPERSTRUCTURE / Pilot Valve
3 10 32 30 33 34, 35 8 9
23
14
W176-02-07-010
W2-7-26
UPPERSTRUCTURE / Pilot Valve
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
W2-7-27
UPPERSTRUCTURE / Pilot Valve
26 6 7 1 2 3 25 27 24 10
4
28
5
29
W176-02-07-010
W2-7-28
UPPERSTRUCTURE / Pilot Valve
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)
W2-7-29
UPPERSTRUCTURE / Pilot Valve
(Blank)
W2-7-30
UPPERSTRUCTURE / Pilot Shut-Off Valve
REMOVE AND INSTALL PILOT SHUT-OFF
VALVE
Preparation
1. Park the machine on a firm, level surface.
W2-8-1
UPPERSTRUCTURE / Pilot Shut-Off Valve
Removal
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
UPPERSTRUCTURE / Pilot Shut-Off Valve
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
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
UPPERSTRUCTURE / Pilot Shut-Off Valve
DISASSEMBLE PILOT SHUT-OFF VALVE
3
6
2
7
1
8
9
13 10
11
12
W178-02-08-005
W2-8-4
UPPERSTRUCTURE / Pilot Shut-Off Valve
Disassemble Pilot Shut-Off Valve
W2-8-5
UPPERSTRUCTURE / Pilot Shut-Off Valve
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
W2-8-6
UPPERSTRUCTURE / Pilot Shut-Off Valve
Assemble Pilot Shut-Off Valve
W2-8-7
UPPERSTRUCTURE / Pilot Shut-Off Valve
(Blank)
W2-8-8
UPPERSTRUCTURE / Signal Control Valve
REMOVE AND INSTALL SIGNAL CON-
TROL VALVE
Preparation
1. Park the machine on a firm, level surface.
W2-9-1
UPPERSTRUCTURE / Signal Control Valve
Removal Signal Control Valve
IMPORTANT: Attach tags to the disconnected
hoses and pipes to aid in assembly.
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
UPPERSTRUCTURE / Signal Control Valve
W2-9-3
UPPERSTRUCTURE / Signal Control Valve
(Blank)
W2-9-4
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE
UNIT
Preparation
1. Park the machine on a firm, level surface.
W2-10-1
UPPERSTRUCTURE / Solenoid Valve
Removal Solenoid Valve Unit
1. Disconnect each harness of solenoid valves (8
and 9) from the connector.
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)
8
7
4
5
W187-02-10-001
W2-10-2
UPPERSTRUCTURE / Solenoid Valve
Removal Solenoid
1. Disconnect each harness of solenoid valves (19, Valve Unit
20) from the connector.
12
Tightening Torque
Wrench Size (mm) Remark 13
N⋅m (kgf⋅m) (Ibf⋅ft)
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
UPPERSTRUCTURE / Solenoid Valve
1
3
2
4
5
7
8
9
10
13
11
12 14
15
16
17
18
W157-02-11-016
W2-10-4
UPPERSTRUCTURE / Solenoid Valve
Disassemble Proportional Solenoid Valve
• Be sure to read “Precautions for disassembly and
Assembly” thoroughly on page W1-1-1 before
starting the disassembly work.
W2-10-5
UPPERSTRUCTURE / Solenoid Valve
ASSEMBLE PROPORTIONAL SOLENOID
VALVE
4 2 6 1 8 16 13 14 10 15 18
9 7 11 12 17
W157-02-11-001
W2-10-6
UPPERSTRUCTURE / Solenoid Valve
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
UPPERSTRUCTURE / Solenoid Valve
(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
1F1W-3-1
(Blank)
1F1W-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Removal
1. Put alignment marks on inner race of swing bear-
ing (1) and track frame (2).
Mark
1 2
W105-03-01-001
W158-03-01-001
ST 0050
4 W110-03-01-004
W3-1-1
UNDERCARRIAGE / Swing Bearing
Installation
Clean the matching surfaces of the frame and swing
bearing.
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°
W158-03-01-001
W3-1-2
UNDERCARRIAGE / Swing Bearing
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
UNDERCARRIAGE / Swing Bearing
DISASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W157-03-01-003
9
7
6
W157-03-01-002
W3-1-4
UNDERCARRIAGE / Swing Bearing
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.
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
UNDERCARRIAGE / Swing Bearing
ASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W157-03-01-003
9
7
6
W157-03-01-002
W3-1-6
UNDERCARRIAGE / Swing Bearing
5
W142-03-01-005
W142-03-01-006
W3-1-7
UNDERCARRIAGE / Swing Bearing
(Blank)
W3-1-8
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
Preparations
3. Remove the cap from the hydraulic oil tank and M104-07-021
W3-2-1
UNDERCARRIAGE / Travel Device
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.
: 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)
W3-2-2
UNDERCARRIAGE / Travel Device
(Blank)
W3-2-3
UNDERCARRIAGE / Travel Device
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
W3-2-4
UNDERCARRIAGE / Travel Device
Disassemble Travel Motor
: 12 mm
W3-2-5
UNDERCARRIAGE / Travel Device
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
UNDERCARRIAGE / Travel Device
9. Remove holder (16) and pins (17) (3 used) from
rotor (18).
: 12 mm
: 30 mm
W3-2-7
UNDERCARRIAGE / Travel Device
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
W3-2-8
UNDERCARRIAGE / Travel Device
Assemble Travel Motor
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.
7 W1F1-03-02-004
W3-2-9
UNDERCARRIAGE / Travel Device
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
UNDERCARRIAGE / Travel Device
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).
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.
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).
: 12 mm
: 205 N⋅m (21 kgf⋅m, 151 Ibf⋅ft)
W3-2-11
UNDERCARRIAGE / Travel Device
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
UNDERCARRIAGE / Travel Device
Disassemble Travel Device
: 12 mm
: 8 mm
: 8 mm
W3-2-13
UNDERCARRIAGE / Travel Device
20
19
18
17
24
23
22
21
30
W1F1-03-02-005
W3-2-14
UNDERCARRIAGE / Travel Device
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.
: 8 mm, 22 mm
Rotation Handle
W1F1-03-02-006
17 22
W1F1-03-02-007
W3-2-15
UNDERCARRIAGE / Travel Device
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
UNDERCARRIAGE / Travel Device
Assemble Travel Device
17 23 22
: 22 mm
: 1245±137 N⋅m
(127±14 kgf⋅m, 920±100 Ibf⋅ft)
Rotation Handle
W1F1-03-02-006
W3-2-17
UNDERCARRIAGE / Travel Device
28
9 10 11 12 13
4
6
14
3
7
8
5
16
19 W1F1-03-02-008
W3-2-18
UNDERCARRIAGE / Travel Device
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).
16. Install thrust plate (4) onto first stage holder (6)
with screw (14) (3 used).
(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
: 8 mm
: 73±3.6 N⋅m
(7.4±0.4 kgf⋅m, 54±2.7 Ibf⋅ft)
W3-2-19
UNDERCARRIAGE / Travel Device
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
UNDERCARRIAGE / Travel Device
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.
: 27 mm
W3-2-21
UNDERCARRIAGE / Travel Device
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
W3-2-22
UNDERCARRIAGE / Travel Device
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)
: 27 mm
: 370±20 N⋅m
(38±2 kgf⋅m, 275±15 Ibf⋅ft)
W3-2-23
UNDERCARRIAGE / Travel Device
MAINTENANCE STANDARD
Sprocket
B
C
D
A W105-03-07-040
W1SE-03-02-001
Unit: mm (in)
W3-2-24
UNDERCARRIAGE / Travel Device
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
UNDERCARRIAGE / Travel Device
(Blank)
W3-2-26
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT
Preparation
1. Park the machine on a firm, level surface. Lower
the front attachment onto the ground.
W3-3-1
UNDERCARRIAGE / Center Joint
Removal
W157-03-03-003
Installation
NOTE: Refer to “Removal” section above for
wrench sizes and tightening torque. 3
W105-03-03-003
W3-3-2
UNDERCARRIAGE / Center Joint
(Blank)
W3-3-3
UNDERCARRIAGE / Center Joint
DISASSEMBLE CENTER JOINT
3
4
10
9
11
12
W157-03-03-002
W3-3-4
UNDERCARRIAGE / Center Joint
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.
W506-03-03-002
W3-3-5
UNDERCARRIAGE / Center Joint
ASSEMBLE CENTER JOINT
3
4
6
7
8
10
9
11
12
W178-03-03-001
W3-3-6
UNDERCARRIAGE / Center Joint
Assemble Center Joint
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
W3-3-7
UNDERCARRIAGE / Center Joint
When replacing the body or spindle with new one, the
following procedures are required.
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
UNDERCARRIAGE / Center Joint
MAINTENANCE STANDARD
Bushing
T157-01-01-040
W3-3-9
UNDERCARRIAGE / Center Joint
(Blank)
W3-3-10
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK AD-
JUSTER
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
UNDERCARRIAGE / Track Adjuster
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
W3-4-2
UNDERCARRIAGE / Track Adjuster
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.
Nut
W105-03-04-009
Cradle
Oil Jack
Base
W105-03-04-006
W105-03-04-007
W3-4-3
UNDERCARRIAGE / Track Adjuster
10
14
15
17
W178-03-04-001
16
W3-4-4
UNDERCARRIAGE / Track Adjuster
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
Oil Jack
W105-03-04-014
W105-03-04-013
: 46 mm
Nut
Plate
(ST 4036)
W105-03-04-012
W3-4-5
UNDERCARRIAGE / Track Adjuster
3
10
11
13
18
17
W178-03-04-001
W3-4-6
UNDERCARRIAGE / Track Adjuster
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).
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
Eyebolt
W105-03-04-017
W3-4-7
UNDERCARRIAGE / Track Adjuster
2
4
5
6
7
8
9
10
11
12
W178-03-04-001
W3-4-8
UNDERCARRIAGE / Track Adjuster
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).
8
9
W105-03-04-025
W3-4-9
UNDERCARRIAGE / Track Adjuster
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
D 611 mm
W3-4-10
UNDERCARRIAGE / Track Adjuster
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).
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
UNDERCARRIAGE / Track Adjuster
14 17 10
W178-03-04-002
16 18
D 611 mm
W3-4-12
UNDERCARRIAGE / Track Adjuster
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
18
W105-03-04-026
W3-4-13
UNDERCARRIAGE / Track Adjuster
15 10
W178-03-04-002
D 611 mm
W3-4-14
UNDERCARRIAGE / Track Adjuster
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
Track Adjuster
W105-03-04-011
W105-03-04-028
Special Tool
(ST 4930)
W3-4-15
UNDERCARRIAGE / Track Adjuster
(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.
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).
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
UNDERCARRIAGE / Front Idler
DISASSEMBLE FRONT IDLER
2
1
3
4
6
7
8
6
4
3
2
1
10
W178-03-05-003
W3-5-2
UNDERCARRIAGE / Front Idler
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
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
UNDERCARRIAGE / Front Idler
W178-03-05-003
W3-5-4
UNDERCARRIAGE / Front Idler
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
ST 1425
W105-03-05-011
W3-5-5
UNDERCARRIAGE / Front Idler
ASSEMBLE FRONT IDLER
1 2 4 5 6
10
8 9
3
7
W157-03-05-003
W3-5-6
UNDERCARRIAGE / Front Idler
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
5
1
5
W157-03-05-005
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
UNDERCARRIAGE / Front Idler
MAINTENANCE STANDARD
C D
A
B
W157-03-05-001
Unit: mm (in)
B 159 (6.26) −
D 538 (21.18) −
E 19 (0.75) 25 (0.98)
W3-5-8
UNDERCARRIAGE / Upper And Lower Roller
REMOVE AND INSTALL UPPER ROLLER
W3-6-1
UNDERCARRIAGE / Upper And Lower Roller
4. Loosen mounting bolts (6) of upper roller (4).
: 24 mm
W157-03-06-001
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
UNDERCARRIAGE / Upper And Lower Roller
3. Install valve (1) of the track adjuster.
: 24 mm
: 88 N⋅m (9 kgf⋅m,65 lbf]ft)
1
W158-03-06-001
W3-6-3
UNDERCARRIAGE / Upper And Lower Roller
(Blank)
W3-6-4
UNDERCARRIAGE / Upper And Lower Roller
REMOVE AND INSTALL LOWER ROLLER
Removal
1. Remove mounting bolts (1) of lower roller (5) after 5
removing the track guard.
: 27 mm
1
90°ϡ110°
4
Grease Outlet
W178-03-06-001
W3-6-5
UNDERCARRIAGE / Upper And Lower Roller
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).
W105-03-06-008
W3-6-6
UNDERCARRIAGE / Upper And Lower Roller
4. Install valve (3) of the track adjuster.
: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf]ft) 3
W157-03-06-002
W3-6-7
UNDERCARRIAGE / Upper And Lower Roller
DISASSEMBLE LOWER ROLLER
3
2
4 1
5
6
5
4
3
2
1
W157-03-06-004
W3-6-8
UNDERCARRIAGE / Upper And Lower Roller
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.
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).
W105-03-06-027
W3-6-9
UNDERCARRIAGE / Upper And Lower Roller
ASSEMBLE LOWER ROLLER
2 7 6 5 4 3 1
W105-03-06-023
W3-6-10
UNDERCARRIAGE / Upper And Lower Roller
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
7 5
5 2
W157-03-06-008
W3-6-11
UNDERCARRIAGE / Upper And Lower Roller
MAINTENANCE STANDARD
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
UNDERCARRIAGE / Upper And Lower Roller
Lower Roller
W157-03-06-003
Roller
Unit: mm (in)
W3-6-13
UNDERCARRIAGE / Upper And Lower Roller
(Blank)
W3-6-14
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACKS
Removal
CAUTION: Do not loosen valve (1) quickly or
loosen too much since 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).
W105-03-07-006
W105-03-07-002
1
2
Grease Outlet
W1F1-03-07-001
W3-7-1
UNDERCARRIAGE / Track
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
Retaining Ring
Track Link
3
Master Link
W105-03-07-010
ST 1970
W105-03-07-008
W3-7-2
UNDERCARRIAGE / Track
W105-03-07-011
W3-7-3
UNDERCARRIAGE / Track
Installation
W105-03-07-014
W105-03-07-015
W105-03-07-016
W3-7-4
UNDERCARRIAGE / Track
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
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
UNDERCARRIAGE / Track
7. Tighten adjuster valve (1).
: 24 mm 1
2
: 88 N]m (9 kgf]m, 65 Ibf⋅ft)
Grease Outlet
W1F1-03-07-001
W105-03-07-018
W157-03-06-002
W3-7-6
UNDERCARRIAGE / Track
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
W17P-03-07-002
W3-7-7
UNDERCARRIAGE / Track
MAINTENANCE STANDARD
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
UNDERCARRIAGE / Track
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
UNDERCARRIAGE / Track
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
Preparation
1. Park the machine on a solid level surface. Fully
retract the bucket and arm cylinders and lower the
bucket to the ground.
W105-04-02-001
W4-1-1
FRONT ATTACHMENT / Front Attachment
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
W4-1-2
FRONT ATTACHMENT / Front Attachment
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.
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.
㈓ 8
W157-04-01-001
Cover
W4-1-3
FRONT ATTACHMENT / Front Attachment
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
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.)
Bracket
W1F1-04-01-002
W178-04-01-005
W4-1-4
FRONT ATTACHMENT / Front Attachment
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
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)
W157-04-01-001
Boom Cylinder
W105-04-02-040
W4-1-5
FRONT ATTACHMENT / Front Attachment
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.
W4-1-6
FRONT ATTACHMENT / Front Attachment
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.
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
FRONT ATTACHMENT / Front Attachment
MAINTENANCE STANDARD
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
FRONT ATTACHMENT / Front Attachment
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
FRONT ATTACHMENT / Front Attachment
Side Cutter
C
D
W155-04-01-002
Unit: mm (in)
Standard Allowable Limit Remedy
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)
Standard Allowable Limit Remedy
A 178.5 (7.0) 90 (3.5)
B 79 (3.1) -
Replace
C 95 (3.7) -
D 81 (3.2) -
W4-1-10
FRONT ATTACHMENT / Front Attachment
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
FRONT ATTACHMENT / Front Attachment
(Blank)
W4-1-12
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER
Preparation
1. Park the machine on a solid level surface. Fully
retract the bucket and arm cylinders and lower the
bucket to the ground.
W105-04-02-001
W4-2-1
FRONT ATTACHMENT / Cylinder
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).
Ȁ
CAUTION: Use a wire to secure the link to
prevent it from falling down before pushing
pin (7) out.
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
FRONT ATTACHMENT / Cylinder
5. Disconnect bucket cylinder hoses (12) (2 used)
from the bottom of bucket cylinder (1). Close all
openings with cap.
: 36 mm
10
12
W187-04-02-004
W4-2-3
FRONT ATTACHMENT / Cylinder
Install Bucket Cylinder
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)
1
8
9 W102-04-02-005
W4-2-4
FRONT ATTACHMENT / Cylinder
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
FRONT ATTACHMENT / Cylinder
Remove Arm Cylinder
1
1. Place a wooden block (3) on the top surface of
boom (2) to support arm cylinder (1).
3. Remove nut (6) and bolt (7) from pin (5) at the 4
7 5
arm cylinder (1) rod side.
: 30 mm
1
8 1
10
1
7. Disconnect grease hose (11) from arm cylinder
(1).
: 17 mm
11
W102-04-02-014
W4-2-6
FRONT ATTACHMENT / Cylinder
14
W187-04-02-007
W4-2-7
FRONT ATTACHMENT / Cylinder
Install Arm Cylinder
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
protection, such as goggles, a hard hat, etc.
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)
W102-04-02-014
W4-2-8
FRONT ATTACHMENT / Cylinder
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
CAUTION: Prevent personal injury. Metal
fragments may fly off when a hammer is used W187-04-02-010
6
W187-04-02-006
W4-2-9
FRONT ATTACHMENT / Cylinder
Remove Boom Cylinder 1
1. Disconnect grease hoses (1) from boom cylinder.
: 17 mm
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
W105-04-02-035
Wire
2
W105-04-02-036
W4-2-10
FRONT ATTACHMENT / Cylinder
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
10
12
W178-04-02-009
W4-2-11
FRONT ATTACHMENT / Cylinder
Install Boom Cylinder
IMPORTANT: When pressing the bushing in, if a
hammer is used, the bushing may be
damaged. Use a press.
CAUTION: Boom cylinder weight:
153 kg (337 lb)
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
W4-2-12
FRONT ATTACHMENT / Cylinder
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.
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
W105-04-02-032
W4-2-13
FRONT ATTACHMENT / Cylinder
(Blank)
W4-2-14
FRONT ATTACHMENT / Cylinder
HYDRAULIC CIRCUIT PRESSURE
1
RELEASE PROCEDURE
Machine
Front
2
T176-03-03-036
5
W4-2-15
FRONT ATTACHMENT / Cylinder
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
W4-2-16
FRONT ATTACHMENT / Cylinder
Disassemble Boom and Bucket Cylinder
• Be sure to thoroughly read “Precautions for Dis-
assembly and Assembly” on page W1-1-1 before
starting any disassembling work.
W102-04-02-027
W158-04-02-022
W4-2-17
FRONT ATTACHMENT / Cylinder
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
FRONT ATTACHMENT / Cylinder
5. Remove set screw (22) and steel ball (23).
ST 5908
W158-04-02-022
W4-2-19
FRONT ATTACHMENT / Cylinder
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
W4-2-20
FRONT ATTACHMENT / Cylinder
Disassemble Arm Cylinder
• Be sure to thoroughly read “Precautions for Dis-
assembly and Assembly” on page W1-1-1 before
starting the disassembling work.
W102-04-02-027
3. Pull out cylinder head (7) with piston rod (11) from
cylinder tube (12) by tapping with a plastic ham-
mer.
ST 5908
W158-04-02-022
W4-2-21
FRONT ATTACHMENT / Cylinder
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
FRONT ATTACHMENT / Cylinder
5. Remove set screw (22) and steel ball (23).
ST 5908
W158-04-02-022
W4-2-23
FRONT ATTACHMENT / Cylinder
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
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
W4-2-24
FRONT ATTACHMENT / Cylinder
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).
Oil Groove
W18B-04-02-011
W4-2-25
FRONT ATTACHMENT / Cylinder
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
FRONT ATTACHMENT / Cylinder
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
W4-2-27
FRONT ATTACHMENT / Cylinder
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
W4-2-28
FRONT ATTACHMENT / Cylinder
Assemble arm cylinder
1. Install bushing (5) to cylinder head (7) with a
press.
Tool for pressing bushing:
90 mm (ST 8024/ST 1991)
W18B-04-02-011
W4-2-29
FRONT ATTACHMENT / Cylinder
Arm Cylinder
7 8
11 12 22, 23 24
25
26
27
28
W1F1-04-02-004
Be sure that oil groove faces the
correct direction when assembling.
W4-2-30
FRONT ATTACHMENT / Cylinder
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
W4-2-31
FRONT ATTACHMENT / Cylinder
MAINTENANCE STANDARD
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
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
PAGE NO.:
DATE: (Located at the bottom center in the page. If two or more
revisions are requested, use the comment column)
FAX:
REPLY: