W17VE-00 (080616 - 7) Workshop Manual

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

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

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

signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri- • NOTE:
ate lifting techniques and equipment when lifting heavy Indicates supplementary technical information or
parts. know-how.
UNITS USED
2
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKS system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 Power kW PS 1.360
Volume L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
• This is the SAFETY ALERT SYMBOL.
• When you see this symbol on your machine or in

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

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

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

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

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

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

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

this manual.
• To avoid confusing machine protection with personal

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

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

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

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

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

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

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

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

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

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

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

appropriate to the job.
You may need:

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

flammable.
• Store flammable fluids well away from fire

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

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

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

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

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

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

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

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

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

injury.
• Before performing any work on the machine,

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

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

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

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

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

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

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

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

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

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

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

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

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

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

PERIODICALLY
• Rubber hoses that contain flammable fluids under

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

FLUID LINES
• Flammable spray can be generated by heating near

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

THE CUSTOMER
• After maintenance or repair work is complete,

confirm that:
• The machine is functioning properly, especially
the safety systems.
• Worn or damaged parts have been repaired or
replaced
S517-E01A-0435 SA-435
SA-27
SAFETY
(Blank)
SA-28
SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
WORKSHOP MANUAL Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Solenoid Valve
Group 10 Signal Control Valve
Group 11 Shockless 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
All information, illustrations and speci-
fications in this manual are based on SECTION 5 ENGINE
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 Specification 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 Standard Group 3 Troubleshooting A
Group 3 Engine Test Group 4 Troubleshooting B
Group 4 Excavator Test Group 5 Troubleshooting C
Group 5 Component Test Group 6 Electrical System Inspection
Group 6 Adjustment Group 7 ICX
SECTION 1
GENERAL INFORMATION
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling........................................... W1-1-1
Maintenance Standard Terminology....... W1-1-7
Group 2 Tightening Torque

Tightening Torque Specification......... W1-2-1
Torque Chart ..................................... W1-2-2
Piping Joint ....................................... W1-2-5
Periodic Replacement of Parts .......... W1-2-9
Group 3 Painting
Painting ............................................. W1-3-1
17VW-1-1
(Blank)
17VW-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
• Clean the Machine • Precautions for Disassembling
Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop may removed pipes.
cause machine components to be contaminated • Before disassembling, clean the exterior of the
during disassembling/assembling, resulting in components and place on a work bench.
damage to machine components, as well as • Before disassembling, drain gear oil from the
decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all disassem- instructed.
bling/assembling procedures beforehand, to help • If a part or component cannot be removed after
avoid incorrect disassembling of components as well removing its securing nuts and bolts, do not
as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if any. disassembled parts for abnormal wear, sticking,
• Capacities and condition of lubricants. or other damage.
• Loose or damaged parts. • Measure and record the degree of wear and
clearances.
• Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the area

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

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

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation M104-07-021
for approx. 5 minutes.
• Reposition the front attachment to check hydraulic
oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
W1-1-3
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of
cardboard to protect surfaces. Apply oil to the
sliding surface (C) on seal ring (A).
(2) Check the slide surface (C) on seal ring (A) for B W105-03-05-019
scuffing, scoring, corrosion, deformation or

uneven wear.
(3) Check O-ring (B) for tears, breaks, deformation

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

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

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

bores. Check the bore surface for scuffing or
scoring by touching the surface.
(3) Check that the O-ring is not twisted, and that it

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

a a
ring surface (C) is parallel with seal mating
C
face (D) by measuring the distances (C) and
(D) at point (a) and (b), as illustrated. If these
distances differ, correct the O-ring seating.
b b
a=b aҐb
W110-03-05-004
W1-1-4
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings

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

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

• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.
Bent Sling W162-01-01-009
W1-1-5
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
2. Before using a nylon sling, visually check the ny- Scuffing
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years.
W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-6
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies

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

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

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

No. Descriptions Q’ty
mm Size (mm) Nxm (kgfxm) (lbfxft)
Engine cushion Front 22 2 32 750 (76.5) (550)
1 rubber mount-
Rear Engine-cushion rubber 33 2 50 1950 (198.5) (1440)
ing bolt
2 Engine bracket mounting bolt 14 8 22 210 (21.5) (155)
3 Radiator mounting bolt 27 4 41 1050 (107.0) (770)
4 Hydraulic oil tank mounting bolt 18 8 27 300 (30.5) (220)
5 Fuel tank mounting bolt 18 5 27 300 (30.5) (220)
1 − 3 −12UNF 36 180 (18.0) (135)
16
6 ORS fittings for hydraulic hoses and piping
1 − 7 −12UNF 41 210 (21.5) (155)
16
7 Pump transmission mounting bolt 12 14 19 110 (11.2) (80)
8 Main pump mounting bolt (hexagonal wrench) 20 8 17 550 (56.0) (405)
9 Control valve mounting bolt 16 10 24 400 (41.0) (295)
10 Swing device mounting bolt 24 28 36 950 (97.0) (700)
11 Swing motor mounting bolt 20 24 30 400 (41.0) (295)
12 Battery mounting nut 12 2 19 35 (3.5) (26.0)
13 Cab mounting nut 16 6 24 210 (21.5) (155)
Swing bearing mounting bolt to upperstructure 33 36 50 2200 (224.0) (1620)
14
Swing bearing mounting bolt to undercarriage 30 40 46 1750 (178.0) (1290)
Travel device mounting bolt 27 48 41 1400 (143.0) (1030)
15 Travel motor mounting bolt 18 8 27 300 (30.5) (220)
Sprocket mounting bolt 27 48 41 1400 (143.0) (1030)
16 Upper roller mounting 20 24 30 550 (56.0) (405)
17 Lower roller mounting bolt 24 72 36 950 (97.0) (700)
18 Track shoe bolt 27 408 41 2000 (204.0) (1475)
19 Track guard mounting bolt 27 24 41 1400 (143.0) (1030)
20 Track frame mounting bolt 36 44 55 2800 (285.5) (2065)
10.5 to (1.05 to
Coupling 8 13 (7.6 to 9.1)
Coupling and clamp of low 12.5 1.26)
21
pressure piping 1/4-28
Clamp 11 9.8 (1.0) (7.2)
UNF
48 2 65 3400 (350) (2510)
22 Counterweight mounting bolt
24 4 36 700 (71.4) (516)
23 Shuttle Valve Mounting Bolt 10 4 17 50 (5.1) (37)
24 Front pin-retaining bolt (Backhoe) 20 24 30 400 (41.0) (295)
20 12 30 400 (41.0) (295)
25 Front pin retaining bolt (Loading Shovel) 16 6 24 210 (21.5) (155)
12 4 19 90 (9.2) (60)
NOTE 1.Apply lubricant (e.g. white zinc B dis-

solved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
2.Make sure bolt and nut threads are clean
before installing.
W1-2-1
TORQUE CHART
CAUTION: Use tools appropriate for the

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

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

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

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

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

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

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

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

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

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

Description mm
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
30ѯmale 17 17 24.5 (2.5,18)
19 19 29.5 (3.0,21.5)
22 22 39 (4.0,28.5)
27 27 93 (9.5,69)
32 32 137 (14.0,101)
36 36 175 (18.0,129)
41 41 205 (21.0,151)
37ѯfemale 17 14 24.5 (2.5,18)
19 17 29.5 (3.0,21.5)
22 19 39 (4.0,28.5)
27 22 93 (9.5,69)
32 27 137 (14.0,101)
36 32 175 (18.0,129)
41 36 205 (21.0,151)
NOTE: Tightening torque of 37ѯmale coupling without union is similar
to tightening torque of 37ѯfemale.
W1-2-5
O-ring Seal Joint 7 6 9
O-ring (6) seats against the end face of adapter (7) to seal
pressure oil.
IMPORTANT: 1. Be sue to replace O-ring (6) with a

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

(6), resulting in oil leakage.
3. Take care not to damage O-ring
groove (e) or sealing surface (10). Wrench Size Wrench Size Tightening Torque
Damage to O-ring (6) will cause oil mm mm
leakage. Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
4. If nut (9) is loose and oil is leaking, do 19 17 29.5 (3.0,21.5)
not re-tighten nut (9). Replace O-ring 22 19 69 (7.0,51)
(6) with a new one and check that O- 27 22 93 (9.5,69)
ring (6) is correctly seated in place, 32 27 137 (14.0,101)
tighten nut (9). 36 30,32 175 (18.0,129)
41 36 205 (21.0,151)
46 41 205 (21.0,151)
W1-2-6
Screw-In Connection
PT PF
Depending on types of screw and sealing, different types of 30ѯ
screw fittings are used.
IMPORTANT: Be sure to confirm that the thread pitch

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

Wrench Size Tightening Torque
mm N⋅m (kgf⋅m, lbf⋅ft)
Hose Fittings FC material SS material
19 14.5 (1.5,10.5) 34 (3.5,25)
22 29.5 (3.0,21.5) 49 (5.0,36)
27 49 (5.0,36) 93 (9.5,69)
36 69 (7.0,51) 157 (16,116)
41 108 (11,80) 205 (21,151)
50 157 (16,116) 320 (33,235)
60 195 (20,144)
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male and
female threads, so as to prevent any leaks between
threads.
Be sure to apply just enough seal tape to fill up thread External Thread
Clearance
clearances. Do not overwrap.
• Application Procedure W105-01-01-019
Leave one to two pitch threads uncovered

Confirm that the thread surface is clean and, free of dirt or
damage.
Apply seal tape around threads as shown. Wrap seal tape
in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs depend-

ing on the type of clamp. M114-07-041
T-Bolt Type Band Clamp:
4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft )
T-Bolt Type Worm Gear Type
Worm Gear Type Band Clamp:
5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)
M114-07-043 M114-07-042
W1-2-7
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, pos-
sibly resulting in a fire on the machine.
Do not install hoses kinked. Application of high

oil pressure, vibration, or an impact to a kinked W105-01-01-011
hose may result in oil leaks, hose rupture or sepa-
ration of fitting. Utilize Print marks on hoses
when installing to prevent hose from being WRONG RIGHT
kinked. Rubbing Against
Each Other
If hoses rub against each other, wear to the hoses
will result, leading to hose rupture. Take neces-
sary measures to protect hoses from rubbing
against each other.
W105-01-01-012
Take care so that hoses do not come into contact
WRONG RIGHT
with moving parts or sharp objects.
Clamp Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-8
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic in-
spection of the machine. In addition, the parts listed below,
if defective, may pose serious safety/fire hazards. It is very
difficult to gauge the extent of deterioration, fatigue, or
weakening of the parts listed below simply by visual inspec-
tion alone. For this reason, replace these parts at the inter-
vals shown in the table below. However, if any of these
parts are found to be defective, replace before starting op-
eration, regardless of the interval.
Also, when replacing hoses, check the clamps for deforma-
tion, cracks, or other deterioration, and replace as neces-
sary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective parts
found, as necessary.
Consult your authorized dealer for correct replacement.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years or Every 6000 hours
Engine Fuel hose (Fuel tank to injection pump) Every 2 years or Every 6000 hours
Heater hose (Heater to engine) Every 2 years or Every 6000 hours
Pump suction hose Every 2 years or Every 6000 hours
Basic Machine Pump delivery hose Every 2 years or Every 6000 hours
Swing hose Every 2 years or Every 6000 hours
Hydraulic
Travel hose Every 2 years or Every 6000 hours
System
Boom cylinder line hose Every 2 years or Every 6000 hours
Front-End Arm cylinder line hose Every 2 years or Every 6000 hours
Attachment Bucket cylinder line hose Every 2 years or Every 6000 hours
Pilot hose Every 2 years or Every 6000 hours
NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.
W1-2-9
(Blank)
W1-2-10
GENERAL / Painting
PAINTING
Painting specification
Surfaces to Be Painted Painting Colour
• Main surface of upperstructure YR-01 [TAXI yellow]
Bed cover High Grade Beige
Inner face Grey
Front left step, rear left step High Grade Black
Radiator front duct High Grade Black (Fly Screen: Grey (lacquer))
Handle of Upperstructure High Grade Black
• Front attachment YR-01 [TAXI yellow]
• Track (undercarriage) N1.0 [Black]
• A part of rear left of cab YR-01 [TAXI yellow]
Final painted colour

• Inside and outside surface of cab High Grade Beige
• Right window beam, U-Bolt [KASAI PAINT LF-113-230B
(Charcoal series black, half glossy)]
• Suspension lifter (chair bottom) [N2.0 (Black)]
• Lever (Travel, lock, foot rest) [N2.0 (Black) ]
• Floor plate Grey [Cation]
• Grid plate Deep Black
Specified masked position

• Engine plate • Angle sensor plate
• Control valve plate • Engine cover catch
• Swing motor plate • Battery cable terminal cover
• Pump plate • Air cleaner indicator
Inside and Outside

Surface of Cab
Handle Radiator Front Duct Handle Handle

Right Win-
dow Beam
W17V-01-03-002
500 910
Main Surface of
Upperstructure
Bed Cover
W1-3-1
GENERAL / Painting
YR-01
A
(TAXI Yellow) Out surface of Hinge
Swing Portion
185 YR-01 (TAXI Yellow)
W17V-01-03-003
Door Catch Cover
YR-01 (TAXI Yellow)
Front Left Step, Rear Left Step,

Mounting Bolt (High Grade Black)
720
W178-01-03-003
5
Section A Section B
Mask Garnished Portion
(Door)
YR-01 (TAXI Yellow) (Panel Behind the Door)
10
Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)
W178-01-03-004
Grid Plate Track (Undercarriage)

N1.0 (Black)
W178-01-03-008
IMPORTANT: When cleaning arm, cylinder, etc.

fitted with HN bushing, be sure not
to pour washing liquid directly on
them. The ambient temperature shall
be controlled under 70 °C (158 °F)
when painting and drying.
W17V-01-03-001
W1-3-2
MEMO
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SECTION 2
UPPERSTRUCTURE
CONTENTS ȀȀ
Group 1 Cab Disassemble Control Valve
Remove and Install Cab......................... W2-1-1 (Side Section) .....................................W2-5-28
Dimensions of the Cab Glass................. W2-1-7 Assemble Control Valve
Remove and Install Cab Glass............... W2-1-9 (Side Section) .....................................W2-5-32
Disassemble Housing...........................W2-5-34
Group 2 Counterweight Assemble Housing................................W2-5-36
Remove and Install Counterweight ........ W2-2-1 Disassemble Manifold ..........................W2-5-38
Remove and Install Counterweight Assemble Manifold ...............................W2-5-40
(with Counterweight Removal Device) . W2-2-3
Group 6 Swing Device
Group 3 Main Frame Remove and Install Swing Device ..........W2-6-1
Remove and Install Main Frame ............ W2-3-1 Disassemble Swing Device ....................W2-6-6
Assemble Swing Device .......................W2-6-12
Group 4 Pump Device Disassemble Swing Motor ...................W2-6-16
Remove and Install Pump Device .......... W2-4-1
Assemble Swing Motor .........................W2-6-20
Disassemble Pump Transmission.......... W2-4-6
Maintenance Standard..........................W2-6-25
Assemble Pump Transmission .............. W2-4-8
Disassemble Main Pump ..................... W2-4-10 Group 7 Pilot Valve
Assemble Main Pump .......................... W2-4-14 Remove and Install Pilot Valve ...............W2-7-1
Maintenance Standard ......................... W2-4-18 Disassemble Right and Left Pilot
Disassemble Regulator ........................ W2-4-20 Valves ...................................................W2-7-8
Assemble Regulator............................. W2-4-22 Assemble Right and Left Pilot Valves ...W2-7-12
Disassemble and Assemble Pilot Disassemble Travel Pilot Valve.............W2-7-16
Pump .................................................. W2-4-24 Assemble Travel Pilot Valve .................W2-7-20
Group 5 Control Valve Group 8 Pilot Shut-Off Valve

Remove and Install Control Valve .......... W2-5-1 Remove and Install Pilot Shut-Off
Disassemble Control Valve Valve .....................................................W2-8-1
(5-Spool Section).................................. W2-5-4 Disassemble and Assemble Pilot Shut-Off
Assemble Control Valve Valve .....................................................W2-8-3
(5-Spool Section)................................ W2-5-10
Disassemble Control Valve
(4-Spool Section)................................ W2-5-16
Assemble Control Valve
(4-Spool Section)................................ W2-5-22
17VW-2-1
Group 9 Solenoid Valve
Remove and Install Solenoid Valve........ W2-9-1
Disassemble and Assemble
Three-Spool Solenoid Valve ................. W2-9-4
Disassemble and Assemble Swing
Preference Circuit Shift Solenoid
Valve..................................................... W2-9-5
Group 10 Signal Control Valve

Remove and Install Signal Control
Valve................................................... W2-10-1
Group 11 Shockless Valve

Remove and Install Shockless Valve ... W2-11-1
Disassemble and Assemble
Shockless Valve ................................. W2-11-3
17VW-2-2
UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB
Removal 1
CAUTION: Seat weight: 45 kg (99 lb)
1. Remove bolts (3) (2 used) and socket bolts (2) (4
used). Put the plate on the floor plate. Move seat
(1) to remove it.
: 16 mm
: 6 mm
3
W16J-02-01-003
2. Remove bolts (5) (2 used) behind the cab to re-

move rear box (4).
: 17 mm
5
3. Raise duct (6) to remove it. 6
W178-02-01-012
4. Remove air filter (7) to remove screw (9) (12

used) and clips (8) (2 used), then remove duct
7
(10) from the cab.
8
10
W178-02-01-013
W2-1-1
5. Disconnect cable connectors (12, 13, 14 and 15)
on the right side in the cab and ground (11) on left
rear side in the cab.
11
12
13
14
15
W178-02-01-014
6. Disconnect connector (16) of the work light on the

right rear side in the cab.
16
W16J-02-01-002
7. Open the cover behind the cab to remove washer

vinyl hose (17).
17
Cover
W16J-02-01-001
18
8. Remove cap (20) (5 used) from duct cover (19)
19
with a screwdriver. Remove screw (18) (5 used)
with a screwdriver to remove the duct cover.
20
W178-02-01-016
W2-1-2
9. Remove screws (21) (2 used) and bolts (24) (2
used) to remove duct (22) and duct (23).
: 17 mm
21
Mating Surface
22
23 W178-02-01-017
24
CAUTION: Cab weight: 300 kg (670 lb)

10. Attach lifting straps (25) on the cab upper side.
25
W178-02-01-018
11. Remove socket bolts (26) (4 used), bolts (27) (4

used) and nuts (28) (6 used).
: 8 mm
: 17 mm 26
: 24 mm
28
27
W157-02-01-010
12. Carefully hoist the cab to remove it.
W157-02-01-001
W2-1-3
Installation
CAUTION: Cab weight: 300 kg (670 Ib)

1. Attach lifting straps on the cab. Hoist and install it
by crane.
W157-02-01-001
2. Install washers to socket bolts (26) (4 used), bolts
(27) (4 used) and nuts (28) (6 used). Secure cab
with them.
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
: 17 mm 26
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
28
IMPORTANT: Install the filter with the arrow mark 27

on filter (7) facing the seat side. W157-02-01-010
Rear Side Cab Arrow 7
10
Seat Side
M157-14-022
W178-02-01-013
3. Install duct (10) to the rear console of the cab with

clips (8) (2 used) and screws (9) (12 used). Install
filter (7) into the duct.
: 4.9 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft) 11
4. Connect harness connectors (12, 13, 14 and 15)

on the right side of the cab and ground connector 12
(11) on the rear side in the cab. 13
: 17 mm 14
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
15
W178-02-01-014
W2-1-4
5. Connect connector (16) of the work light on the

right rear side in the cab.
16
W16J-02-01-002
6. Connect washer vinyl hose (17) behind the cab.
17
W16J-02-01-001
7. Align the mounting hole for duct (6). While press-

ing duct downward, install it.
4
8. Install rear box (4) with bolts (5) (2 used).
: 17 mm 5
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
6
W178-02-01-012
W2-1-5
9. Install duct (23) with bolts (24) (2 used). Install

duct (22) into duct (23) and fix them with bolts (21)
(2 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
21
Mating Surface
22
23 24 W178-02-01-017
18
10. Install duct cover (19) with screws (18) (5 used).
Install caps (20) (5 used) onto the duct cover.
19
20
W178-02-01-016
CAUTION: Seat weight: 45 kg (99 lb)

11. Install seat (1) with socket bolts (2) (4 used). 1
Install the seat belt with bolts (3) (2 used).
: 6 mm
: 7.8 N⋅m (0.8 kgf⋅m, 5.8 lbf⋅ft)
: 16 mm
: 70 N⋅m (7.1 kgf⋅m, 51.5 lbf⋅ft)
3
W16J-02-01-003
W2-1-6
DIMENSIONS OF THE CAB GLASS
A
Chamfer
Unit: mm Here
R2
67 303.5 Chamfer along the
11 Periphery unless
Otherwise Specified
R98 R35
0
4-φ13 -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
W178-02-01-002
B
14
733
Along the Along the R58

Periphery Periphery R58
c1 c1
R11508
R1808
882.5 997
(4 mm)
Section B W178-02-01-019
R308 R1898
R258
100
150
943
W178-02-01-007
W2-1-7
Unit: mm
Chamfer Here
Chamfer Here
85.4
Charmfer Slightly
343.3 213 unless the periphery
Polish Chamfered
R105
R72 R10
R105
(4 mm)
Chamfer Slightly unless the
Periphery Polish Chamfered 39.5 D
733
733
C R2465 2-φ12.2 +0.5 -0
(4 mm) Section C and D 6.754°

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

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

R14
364.7 51
R2475 470.6
Chamfer along W178-02-01-009
(5 mm)
the Periphery
R115
888.58
W178-02-01-010
W2-1-8
REMOVE AND INSTALL CAB GLASS
Remove of Left-hand Cab Glass, Lower Glass of
the Door and Upper Front Glass
Mounting Rubber Section
Mounting Rubber Glass

CAUTION: When removing broken or
cracked glass there is a danger of serious in-
jury from glass shards.
Before removing, gummed tape or similar
should be used to tape the broken or cracked
glass ready to reinforce pane so as to prevent Cab
injury from occurring. Be sure to remove all Seal Rubber
glass pieces.
W178-02-01-022
1. Insert bamboo spatula into position A in mounting

rubber to pry the mounting rubber apart along all
periphery.
NOTE: It is easier to remove glass with air gap be- W178-02-01-004
tween cab and mounting rubber as per-
formed by step 1.
IMPORTANT: Be sure to perform the work by two A

persons or more.
2. Tap glass from the side in cab by palm of the hand
to remove it.
IMPORTANT: Be sure to install the cab glass and
mounting rubber using the special
bonding agent. The cab glass may
fall if the special bonding agent is
not used. The cab glass assembly
cannot be replaced individually. Be Cab
sure to change the cab glass as an Seal Rubber
assembly.
The upper front glass is arched-
fringed. If this glass needs to be re-
placed, contact with the nearest W178-02-01-022
HITACHI Office to replace it as an

assembly.
W2-1-9
Removal of Right-hand Cab Glass Mounting Rubber Section
Cab Inside
1. Insert bamboo spatula into position A in mounting
Glass
rubber to pry the mounting rubber apart along all Mounting Rubber
periphery.
A
NOTE: It is easier to remove glass with air gap be-
tween cab and mounting rubber as per-
formed by step 1. Cab
IMPORTANT: Be sure to perform the work by two

persons or more. W216-02-01-005
2. Tap glass from the side in cab by palm of the hand
to remove it.
W178-02-01-002
Mounting Rubber Section

Removal of Rear Side Cab Glass
1. Remove stopper (groove rubber) with a screw- Glass
Mounting Rubber
driver.
2. Insert a bamboo spatula into position A in Cas Inside Stopper

mounting rubber to pry the mounting rubber apart (Groove Rubber)
along all periphery.
A
A
IMPORTANT: Be sure to perform the work by two
Cab
persons or more.
3. Tap glass from the side in cab by palm of the hand W216-02-01-003
to remove it.
W178-02-01-005
W2-1-10
Left-Hand Cab Glass
Installation of Left-hand Cab Glass, Lower Glass
of the Door and Upper Front Glass
A
1. Install the seal rubber on the left-hand cab glass
and lower glass of the door. CSE Braid
Section A
Seal Rubber
Put Connect End in Center of

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

50
5
W178-02-01-023
A
CSE Braid
Seal Rubber
10 10
2. When the mounting rubber is already on the glass,

pull and fasten the mounting rubber onto the W178-02-01-020
mounting face of cab. Mounting Rubber Section
IMPORTANT: Be sure to install the cab glass and

mounting rubber using the special
bonding agent. The cab glass may
fall if the special bonding agent is
not used. The cab glass assembly
cannot be replaced individually. Be
sure to change the cab glass as an
assembly.
Cab
The upper front glass is arched-
fringed. If this glass needs to be re- Seal Rubber
placed, replaced it as an assembly.
W178-02-01-022
W178-02-01-004
W2-1-11
Installation of Right-hand Cab Glass Mounting Rubber Section
1. Install the mounting rubber into the surrounding of Glass

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

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

contact with the nearest HITACHI
Office to replace it as an assembly.
W178-02-01-005
W2-1-12
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL
COUNTERWEIGHT Handle
Removal
1. Remove handle mounting bolts (20 used) to re-

move handle from counterweight.
CAUTION: Counterweight weight:

W17V-02-02-001
12500 kg (27560 lb)
2. Attach wire ropes with shackles to the lifting
brackets on the top of the counterweight. Take out
any slack on the wire ropes by applying tension
slowly with a crane.
CAUTION: Use care to prevent hand injury

from the power wrench reaction bar. W162-02-02-001
3. Use a power wrench to remove bolt (11), nut (3),

shim (1) and washers (2 and 10). (2 places)
: 65 mm
1
3 2
4
5
4. Loosen bolts (4) (2 used) to remove spring 6
washers (5) (2 used), stopper (6) and spacer (7). 7
8 10
Remove shims (8) and (9) if equipped. (2 places) 9
11
: 36 mm
W17V-02-02-002
5. Remove the counterweight.
1
2
3
10
7, 8, 9 11
6
4, 5
W162-02-02-003
W2-2-1
Installation
12500 kg (27560 lb)
1. Attach wire ropes with shackles to the lifting
brackets on the top of the counterweight.
CAUTION: Never allow anyone under the

lifted counterweight.
2. Lift the counterweight. With the bosses on the
back face of the counterweight aligned with holes
on the frame, install the counterweight.
W162-02-02-001
CAUTION: Use care to prevent hand injury

from the power wrench reaction bar. 1
IMPORTANT: Apply a lubricant to bolts (11) before 3 2
installing. Install shim (1) with 4
flanges positioned downward. 5
3. Install bolts (11), nut (3), shim (1) and washers (2 6
and 10). Tighten bolt (11) using a power wrench. 7
8 10
(2 places) 9
11
: 65 mm
: 3400 N⋅m (350 kgf⋅m, 2530 lbf⋅ft)
W17V-02-02-002
1
2
4. Install shims (8), (9), spacer (7), stopper (6), and 3
10
spring washers (5) (2 used) and bolts (4) (2 used).
7, 8, 9 11
Detach the wire ropes and shackles. (2 places)
: 36 mm 6
: 700 N⋅m (71.5 kgf⋅m, 520 lbf⋅ft)
NOTE: Shims (8 and 9) are inserted only when any 4, 5
gap exists between spacer (7) and bracket.
5. Install handle onto counterweight with bolts (20

used).
: 19 mm W162-02-02-003
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
Handle
W17V-02-02-001
W2-2-2
REMOVE AND INSTALL COUNTER-
WEIGHT (WITH COUNTERWEIGHT RE-
MOVAL DEVICE)
Removal
NOTE: Counterweight removal procedure must be
performed with machine located on a level
surface.
1. Park the machine on a level surface with the up- M116-06-019

perstructure rotated 90°. 1
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if

the engine is not properly shut
down.
4. Run the engine at slow idle speed without load for
three minutes.
5. Stop the engine.

W17V-02-02-001
6. Pull the pilot control shut-off lever to the LOCK

position.
CAUTION: Avoid personal injury from unex- 3

2
pected counterweight movement. DO NOT go
directly under machine counterweight. To
remove or install counterweight hardware, go
under machine entering from the area on ei-
ther SIDE of the counterweight. The counter-
weight weighs approximately 11700 kg (25800
lb). Clear everyone from the area before re-
moving or installing the counterweight.
M111-06-023
7. Remove handle mounting bolts (20 used) to re-
move handles (1).
: 19 mm
8. Remove bolts (2) (6 used) to remove counter-

weight top cover plate (3).
: 17 mm
9. Open the engine hood.
10. Remove bottom covers (4 and 5). 4 5

: 19 mm
W17V-02-02-005
W2-2-3
11. Set slow return valve (6) by turning in the direction
of the arrow until opened. Then close the slow re-
turn valve 4.5 turns.
IMPORTANT: Linkage pivot areas may bind if not

properly lubricated resulting in fail-
ure of cylinder (7) to raise counter-
weight to full height.
12. Apply grease all pivot areas of counterweight lift
linkage (three fittings at the bottom and one fitting
at the top of the counterweight cylinder), the
FIRST TIME and every time the counterweight
device is operated. 6 W17V-02-02-008
8 7
13. Open stop valve (8) by turning the handle coun-

terclockwise to supply hydraulic pressure to cylin-
der (7).
14. Make sure length (A) is correct and lock nuts (10)
are not loose. M116-06-022
Length A: 110±2 mm (4.33±0.08 in)

NOTE: Tighten lock nuts (10). Then while securing 9
bolts (9), tighten lifting yokes (11).
10
: 46 mm
A
: 59 to 98 N⋅m 11
(6 to 10 kgf⋅m, 43 to 72 lbf⋅ft)
: 80 mm
: 147 to 245 N⋅m
(15 to 25 kgf⋅m, 108 to 180 lbf⋅ft)
W17V-02-02-003
W2-2-4
15. Remove both lock pins (14) from nut (13) on bolts
(12).
13 14
W17V-02-02-010
15
16
16. Open the left rear access door and pull off lever
(15) cover of counterweight pilot valve (16).
T17V-01-01-014
17. Start the engine. Run machine in “precision” work

mode (17) with the engine control dial set to the
fully counterclockwise position (slow idle).
17
M17V-01-003
W2-2-5
CAUTION: To insure good footing and visi-

bility, always stand on the machine catwalk
when operating counterweight pilot valve.
18. Slowly move the counterweight pilot valve lever
UP and DOWN several times to check the re-
sponse of cylinder control.
W17V-02-02-006
CAUTION: Keep hands (fingers) out of slots

(18) and out of movable parts of linkage dur-
ing cylinder movement. 11
19. Slide lifting yokes (11) forward to the upward posi-
tion of slot (18) away from the rear of counter-
weight and slowly raise cylinder (counterweight pi- 18
lot valve lever “UP”) to hold both the lifting yokes
in the forward position.
20. Alternately loosen each bolt (12) 2 or 3 turns.

: 65 mm
21. Loosen each bolts (19) 5 mm (0.20 in).

: 36 mm M116-06-026
12
19
W17V-02-02-007
W2-2-6
22. Slowly move the counterweight pilot valve lever
UP until counterweight bottom bosses (22) move
away from machine main frame (21) approxi-
mately 5 mm (0.20 in.) (A). This will ensure that
the weight of the counterweight is on the lift cylin-
der.
NOTE: Lifting yokes must be in the forward posi-
tion or highest point of the slot.
CAUTION: When the threads of tie bolt (12)

disengage from nut (13), the nut and nut
spacer may drop to the ground. Stay clear
from under the machine when removing the
bolts.
23. To avoid binding, loosen bolts (12) by alternately
turning each bolt one turn at-a-time.
: 65 mm
NOTE: It is not necessary to remove bolts (12)
from the counterweight/frame holes. It is A
enough nuts (13) are dropped down. The
bolts will be removed from the frame holes
when the counterweight is lowered by the
lift cylinder.
22
24. Remove bolts (19) (2 used), spring washer (20) (2
used), stopper (23), spacer (24) and shim (25)
from each counterweight boss. To avoid binding, 21
alternately loosen left hand and right hand bolts 2
W17V-02-02-009
or 3 turns at-a-time.
: 36 mm
24, 25
12 13
23
19
20
W17V-02-02-007
W2-2-7
25. Slowly lower counterweight to the ground until all
weight is removed from the linkage and the yokes
move freely in their slots.
10
IMPORTANT: Do not operate the pilot valve with
full stroke of lever. Move the cylinder
as slowly as possible.
26
26. Loosen lock nuts (10). Remove pins (26).
: 46 mm
27. Tighten lock nut (10).

: 46 mm
28. Raise lift cylinder to end of its stroke.

W17V-02-02-003
29. Store pins (25) by attaching pins to the counter-

weight lift brackets.
30. Close hydraulic stop valve by turning valve handle

clockwise.
31. Install top cover to the counterweight and two bot-

tom covers to the machine main frame.
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66.5 lbf⋅ft)
32. Install the lever cover of the counterweight pilot

valve.
33. Close left rear access door and engine hood.
W2-2-8
Installation
NOTE: Counterweight installation procedure must
be performed with machine located on a
level surface.
1. Park the machine on a level surface.
2. Rotate upperstructure 90° with front attachment

on the ground.
M116-06-029
3. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if

the engine is not properly shut
down.
4. Run the engine at slow idle speed without load for
three minutes.
5. Stop the engine.
6. Pull the counterweight pilot valve lever to the

LOCK position.
7. Open the engine hood.
8. Remove both machine main frame bottom access

covers and counterweight top cover.
9. Turn the handle of stop valve (8) (located through

8
opening under the engine) counterclockwise to
open hydraulic pressure to cylinder (7).
7
10. Start the engine. Run machine in “precision” work
mode with the engine dial set to the fully counter-
clockwise position (slow idle).
M116-06-022
W2-2-9
CAUTION: To insure good footing and visi-

bility, always stand on the machine catwalk
when operating counterweight pilot valve. 9
11. Lower the lift cylinder.
10
A
12. Install pins (26) to the counterweight pin brackets 11
(27). Slide yoke (11) forward to the top position of
the slot in the counterweight pin bracket. 26
13. When installing the counterweight for the first time,

check removal device adjustment as follows.
(When installing counterweight next times [not the 27
first time] see item 12.)
(1) Adjust bolts (9) on each yoke (11) to length (A) W17V-02-02-003
A: 110±2 mm (4.3±0.08 in)

(2) Slowly raise the counterweight until the coun-
terweight bosses are set into the main frame
holes. If alignment of the counterweight
bosses to the main frame holes is incorrect 12
(Bosses cannot be set into holes), lower the
counterweight to the ground and adjust length
(A) as required. After adjusting correct length
(A), tighten lock nut (10).
: 46 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
CAUTION:
• Length (A) cannot be made for more than
120 mm (4.7 in). Damage to bolts may oc-
cur.
• Stop cylinder when bosses are set to the M116-06-030
main frame holes. Do not raise the cylinder

when bosses are engaged with the main
frame holes.
14. Make sure length (A) is correct and lock nut (10)
are not loose.
15. Put bolts (12) into the counterweight holes.
W2-2-10
16. Slowly raise the counterweight until the counter- 12 31 13
weight bosses are set into the main frame holes.
NOTE: When raising counterweight, bolts (12) are
set into frame holes.
17. Install spacer (31) and nut (13) at the pump side.
Turn the nut into bolts (12) until the end of the bolt
face with end of nut.
: 70 mm
18. Install spacer (31) and nut (13) at the radiator side.
Turn the nut into bolts (12) until the end of the bolt
face with end of nut.
: 70 mm
M116-06-031
19. Lower the lift cylinder slightly until yoke (11) slide
backward in slots (18) to the “REST” position.
11
20. Install shims (25), spacer (24), stopper (23),
spring washers (20) (2 used) and bolts (19) (2
used) to each of the lower counterweight bosses. 18
21. Tighten bolts (12).

: 65 mm
: 2750 N⋅m (280 kgf⋅m, 2030 lbf⋅ft)
NOTE: Tighten or loosen bolts (12) (from torque) to
align lock pins.
M116-06-032
22. Tighten bolts (19).
: 36 mm
: 700 N⋅m (71.5 kgf⋅m, 520 lbf⋅ft) 12 24, 25
23
19
20
W17V-02-02-007
W2-2-11
23. Make sure the counterweight lift arms are below
the top surface of the counterweight and are not
touching the counterweight plate from inside.
Make sure yoke connected to the counterweight
pin brackets are not tight.
(If necessary, lower or raise cylinder slightly to
meet above requirements and check again
torques.)
14
24. Install lock pins (14) into the nuts from the top
side of the machine.
25. Close stop valve (8).
26. Install the both machine main frame bottom ac- W17V-02-02-010
cess covers and counterweight top cover.

: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66.5 lbf⋅ft) 8
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
M116-06-022
1
27. Install handles (1) onto counterweight with handle
mounting bolts (20 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66.5 lbf⋅ft)
W17V-02-02-001
W2-2-12
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME
CAUTION: Escaping fluid under pressure

can penetrate the skin and eyes, causing se-
rious injury. Avoid this hazard by relieving
pressure before disconnecting hydraulic
lines.
Hydraulic oil may be hot after operation and
may spurt, possibly causing severe burns. Be
sure to wait for oil to cool before starting any
repair work.
The hydraulic oil tank cap may fly off due to
remaining pressure if removed quickly.
Slowly loosen the cap to release any remain-
ing pressure completely.
Preparation
1. Park the machine on a level solid surface. Lower
the front attachment to the ground.
2. After stopping the engine, move the control levers M104-07-021
several times to release any pressure remaining

in the system. Rotate the hydraulic oil tank cap
approx. 30° counterclockwise using a hexagon Cap
wrench to release the trapped air in the hydraulic
oil tank. Refer to Bleeding Air from Hydraulic Sys-
tem on page W1-1-2.
: 4 mm
3. Remove the hydraulic oil tank cap. Connect a

vacuum pump and operate it continuously to
maintain negative pressure in the hydraulic oil
tank.
NOTE: Run the vacuum pump continuously while
working on the hydraulic system.
W183-01-01-001
W2-3-1
Removal
CAUTION: Cab Weight: 300 kg (670 Ib)
1. Remove the cab.
(Refer to Remove and Install cab on page W2-1-
1)
: 16 mm, 17 mm, 24 mm
: 6 mm, 8 mm
CAUTION: Counterweight Weight: W157-02-01-001

12500 kg (27560 lb)
Counterweight weight (for removal device):
11700 kg (25790 lb)
2. Remove the counterweight.
(Refer to Remove and Install Counterweight on
page W2-2-1)
: 36 mm, 65 mm
CAUTION: Front Attachment Assembly

Weight: 13200 kg (29100 lb)
3. Remove front attachment assembly. W162-02-02-001
(Refer to Remove and Install Front Attachment on
page W4-1-1)
: 19 mm, 30 mm
: 12 mm, 14 mm
W105-02-03-002
W2-3-2
4. Disconnect all hoses from the center joint on top

of the nipple section. Remove the stopper.
(Refer to Remove and Install Center Joint on
page W3-3-1)
: 19 mm, 22 mm, 27 mm, 41 mm
W16J-03-03-002
Rear
CAUTION: Upperstructure weight:
Shackle
19000 kg (41890 lb)
Upperstructure Weight: (with removal device) ST 0917
Bolt
19630 kg (43280 lb)
IMPORTANT: Be sure no rear slings can interfere
with engine.
5. Install special tool (ST 0917) to the bracket
(Counterweight mounting position) at the rear of
main frame with bolts (M30, pitch 3.0) and nuts.
Counterweight Mounting Surface W166-02-03-009
Install shackles (for 6.2 ton, 6200 kg, 13670 lb) to
special tool (ST 0917) to attach wire rope.
Attach wire rope to the mounting bracket of the
boom and take up slack by crane.
If chain blocks is used, the length of wire rope
ST 0917
can be adjusted and it is easy to level the frame.
: 70 mm Nut
Bolt
Counterweight
Mounting Surface
W166-02-03-010
Front
Boom Mounting
Bracket
W105-02-03-005
W2-3-3
6. Put matching marks on the outer race of swing

bearing and main frame.
Loosen and remove bolts (2) from swing bearing.
Remove knock pins (2 used).
: 50 mm
NOTE: The attitude angle for installing swing bear-
ing is determined. (Refer to Remove and
Install Swing Bearing on page W3-1-1)
2
W105-02-03-007
7. Level the main frame by adjusting chain blocks (1).

Lift and remove the main frame by crane. 1
W157-02-03-002
W2-3-4
Installation
1
19000 kg (41890 lb)
Upperstructure weight (with removal device):
19630 kg (43280 lb)
1. Attach wire ropes to the main frame. Level the
main frame by adjusting chain blocks (1) and in-
stall the main frame onto track frame by crane.
NOTE: As for lifting method, refer to Removal sec-
tion.
W157-02-03-002
2. Align the matching marks on the outer race of the

swing bearing and main frame.
Install bolts (2) on the swing bearing and tighten it
temporarily. Remove wire ropes and tighten bolts
to specification.
: 50 mm
: 1950 N⋅m (200 kgf⋅m, 1450 lbf⋅ft) 2
3. Connect all hose to the center joint.

: 19 mm W105-02-03-007
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
4. Install stopper onto center joint.

: 22 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft) W16J-03-03-002
W2-3-5
CAUTION: Cab weight: 300 kg (670 Ib)

5. Install the cab.
(Refer to Remove and Install Cab in this section.)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
: 6 mm
: 8 N⋅m (0.8 kgf⋅m, 5.8 lbf⋅ft)
: 16 mm
: 70 N⋅m (7.1 kgf⋅m, 51 lbf⋅ft)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
: 24 mm
W157-02-01-001
: 210 N⋅m (21.5 kgf⋅m, 156 lbf⋅ft)

12500 kg (27560 lb)
Counterweight weight (for removal device):
11700 kg (25790 lb)
6. Install counterweight.
(Refer to Remove and Install Counterweight in
this section.)
: 36 mm
: 700 N⋅m (71.5 kgf⋅m, 520 lbf⋅ft)
: 65 mm
: 3400 N⋅m (350 kgf⋅m, 2530 lbf⋅ft)
CAUTION: front weight: 13200 kg (29100 lb)

7. Install front attachment assembly, fill in hydraulic
oil.
(Refer to Remove and Install Front Attachment in
W162-02-02-001
this section.)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 30 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
: 12 mm
: 140 N⋅m (14 kgf⋅m, 100 lbf⋅ft)
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
W105-02-03-002
8. Start engine and place the front attachment in a
posture for checking hydraulic oil level in the tank.
M104-07-021
W2-3-6
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
CAUTION: Escaping fluid under pressure can

penetrate the skin and eyes, caus-
ing serious injury. Avoid this haz-
ard by relieving pressure before
disconnecting hydraulic lines.
Hydraulic oil may be hot after op-
eration and may spurt, possibly
causing severe burns. Be sure to
wait for oil to cool before starting
any repair work.
The hydraulic oil tank cap may fly
off due to remaining pressure if
removed quickly. Slowly loosen
the cap to release any remaining
pressure completely.
Preparation
2. After stopping the engine, move the control levers

in the system. Rotate the hydraulic oil tank cap M104-07-021
approx. 30° counterclockwise using a hexagon

oil tank. Refer to Bleeding Air from Hydraulic Sys- Cap
tem on page W1-1-2.
: 4 mm

tank.

W183-01-01-001
W2-4-1
Removal Pump Transmission
17 18 1 2 3 4 5
1. Remove bolts (4 used) to remove frame (1). 6
: 19 mm
7
IMPORTANT: Attach identification tags to discon-
nected hoses for easier reassembly. 16
A
2. Disconnect hoses (2), (6), (8 to 11), (16 to 18) and
15
electrical cables. Cap all disconnected hose ends.
Main
: 19 mm, 27 mm, 36 mm, 41 mm Pump
14
3. Remove socket bolts (5) (4 used), (13) (4 used) to
disconnect hoses (4), (12). 8
: 10 mm
13 12 11 10 9 T17V-01-01-003
(Under the
4. Remove socket bolts (14) (8 used) to remove suc- Pilot Pump)
tion pipes (15) (2 used).
: 10 mm
View A
19
CAUTION: Main pump weight: 150 kg (330 lb)
5. Attach a wire rope to eyebolt on main pump and

hold it by crane.
6. Remove socket bolts (7) (8 used) to remove the

main pumps (2 used).
: 17 mm
CAUTION: Pump transmission weight:

230 kg (510 Ib)
M17P-07-025
7. Attach a wire rope to eyebolt on the pump trans-

mission and hold it by crane.
8. Remove socket bolts (3) (14 used) and engine

rear mounting bolts (19) (2 used) to remove the
pump transmission.
: 19 mm, 50 mm
W2-4-2
Installation Pump Transmission
CAUTION: Pump transmission weight: 17 18 1 2 3 4 5

230 kg (510 Ib) 6
1. Lift pump transmission by crane and install it with 7

socket bolts (3) (14 used) and engine rear mount-
ing bolts (19) (2 used). The socket bolts should 16
get washers attached first. A
: 19 mm
15
: 110 N⋅m (11 kgf⋅m, 80 Ibf⋅ft)
Main
: 50 mm Pump
: 1950 N⋅m (200 kgf⋅m, 1450 Ibf⋅ft)
14
8
CAUTION: Main pump weight: 150 kg (330 Ib)
13 12 11 10 9 T17V-01-01-003
IMPORTANT: Apply sealant (THREEBOND #1215 (Under the

Pilot Pump)
or equivalent) to main pump mount- View A
ing surface. 19
2. Install main pumps (2 used) with socket bolts (7)

(8 used) and washers.
: 17 mm
: 400 N⋅m (41 kgf⋅m, 300 Ibf⋅ft)
3. Connect all connectors to electrical cables.
4. Install O-ring to the flange part of suction pipe (15).

Install the suction pipe onto the pump device with
socket bolts (14) (8 used).
: 10 mm
M17P-07-025
: 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
5. Connect hoses (4), (12) to the pump device with

socket bolts (5) (4 used), (13) (4 used).
: 10 mm
: 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
W2-4-3
6. Connect hoses (2), (6), (8 to 11), (16 to 18) to the
pump device. Pump Transmission
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) 17 18 2
: 27 mm 6
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
: 41 mm 16
: 205 N⋅m (21 kgf⋅m, 152 Ibf⋅ft)
7. Install frame (1) with bolts (4 used) and washers Main

(4 used). Pump
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
8
IMPORTANT: Bleed any air remaining in the pump. 10 T17V-01-01-003

11 9
(Refer to page W1-1-2) (Under the
After installation, check the oil level. Pilot Pump)
Start the engine and check each po-
sition for any oil leaks.
W2-4-4
(Blank)
W2-4-5
DISASSEMBLE PUMP TRANSMISSION
2
7 24
23
8
9 3
22
10 21
11
6
11 19
20
19
6
5
4
3
1
18
28
11
27
26 17
12
25 16
13
15
2
6
14
5
4
3
1
W17P-02-04-002
1- Cartridge (2 Used) 8- Pipe 15 - O-Ring 22 - Ball Bearing
2- Bolt (18 Used) 9- O-Ring 16 - Plug 23 - Cartridge
3- O-Ring (3 Used) 10 - Elbow 17 - O-Ring 24 - Oil Seal
4- Ball Bearing (2 Used) 11 - Plug (3 Used) 18 - Casing 25 - Socket Bolt (2 Used)
5- Gear (2 Used) 12 - Level Gauge 19 - Retaining Ring (2 Used) 26 - Spring Washer (2 Used)
6- Ball Bearing (3 Used) 13 - Pipe 20 - Coupling 27 - Plain Washer (2 Used)
7- Air Breather 14 - Bolt (4 Used) 21 - Gear 28 - Pilot Pump
W2-4-6
Disassemble Pump Transmission
• Be sure to thoroughly read all “Precautions for 8. Remove ball bearings (4), (6) from gear (5) with a
Disassembly and Assembly” on page W1-1-1 be- puller. (2 places)
fore starting the disassembly work.
CAUTION: Casing (18) + gear (21) + ball bear-

1. Loosen plug (16) to drain gear oil from the pump
ings (6), (22) + cartridge (23) +
transmission.
other weight: 145 kg (320 lb)
: 27 mm
9. Place casing (18) on the workbench with the en-
gine mounting side facing up.
CAUTION: Pump transmission weight: Ȁ
230 kg (510 lb) 10. Remove bolts (2) (10 used) from casing (18).
2. Place pump transmission with the main pump : 19 mm
mounting side facing up.
11. Place casing (18) with the engine mounting side
3. Loosen bolts (14) (4 used) to remove pipe (13) facing downward.
from pump transmission.
NOTE: At this time, set a wooden block (100 mm
: 17 mm
(4.0 in) high) so that it does not come in
contact with cartridge (23).
4. Remove elbow (10) from the pump transmission.
: 32 mm
CAUTION: Gear (21) assembly weight:
5. Remove socket bolts (25) (2 used) to remove pilot 22 kg (50 lb)
pump (28). 12. Attach an adapter bar (Dia. 50 mm (2.0 in)) to
: 8 mm coupling (20). While tapping the adapter bar, re-
move cartridge (23) and gear (21) from casing
(18).
6. Remove bolts (2) (8 used) to remove cartridges
(1) (2 used) and O-rings (3) (2 used) from casing
(18). 13. Remove O-ring (3) and oil seal (24) from cartridge
: 19 mm (23).
14. Remove retaining ring (19), coupling (20) and re-

CAUTION: Gear (5) assembly weight: taining ring (19) from gear (21).
25 kg (60 lb)
7. Remove the gear (5) assembly from casing (18).
15. Using a puller, remove ball bearings (6 and 22)
(2 places)
from gear (21).
W2-4-7
ASSEMBLE PUMP TRANSMISSION Section B-B
2
B 3
1
6
4
5
18
11
A A
16, 17
11 12
14, 15
13
1 5
6
4
2
B 3
10 8, 9 7
Section A-A 20 19
W17P-02-04-003
3 22 24 21 23 2
1- Cartridge (2 Used) 8- Pipe 15 - O-Ring 22 - Ball Bearing
2- Bolt (18 Used) 9- O-Ring 16 - Plug 23 - Cartridge
3- O-Ring (3 Used) 10 - Elbow 17 - O-Ring 24 - Oil Seal
4- Ball Bearing (2 Used) 11 - Plug (3 Used) 18 - Casing 25 - Socket Bolt (2 Used)
5- Gear (2 Used) 12 - Level Gauge 19 - Retaining Ring (2 Used) 26 - Spring Washer (2 Used)
6- Ball Bearing (3 Used) 13 - Pipe 20 - Coupling 27 - Plain Washer (2 Used)
7- Air Breather 14 - Bolt (4 Used) 21 - Gear 28 - Pilot Pump
NOTE: As for locations of pilot pump (28), socket
bolt (25), spring washer (26), plain washer
(27), refer to page W2-4-6.
W2-4-8
Assemble Pump Transmission
IMPORTANT: Remove all preservative oil from the 9. Tighten bolts (2) (10 used).
inner spline of gears (5 and 21). Do : 19 mm
not apply grease or the like to the : 90 N⋅m (9.2 kgf⋅m, 67 lbf⋅ft)
spline part at this time.
1. Press ball bearings (6 and 22) into gear (21). CAUTION: Casing (18) assembly weight:
145 kg (320 lb)
10. Place casing (18) on the workbench with the en-
2. Install retaining rings (19) (2 used) and coupling
gine mounting side facing downward.
(20) to gear (21).
11. Press ball bearings (4) (2 used), (6) (2 used) into

CAUTION: Casing (18) weight: 110 kg (240 lb) gears (5) (2 used).
3. With the main pump mounting facing downward,
place casing (18) on a workbench.
CAUTION: Gear (5) assembly weight:
25 kg (60 lb)
CAUTION: Gear (21) assembly weight: 12. Install the gear (5) assemblies (2 used) to casing
22 kg (50 lb) (18).
4. Install the gear (21) assembly into casing (18) with
an adapter bar and hammer. 13. Install O-rings (3) (2 used) onto cartridges (1) (2
used).
5. Install oil seal (24) into cartridge (23) with a pro-
tection plate. 14. Install cartridges (1) (2 used) to casing (18) with
bolts (2) (8 used).
6. Coat the inner diameter of oil seal (24) with
grease. IMPORTANT: Apply sealant (THREEBOND #1215
or equivalent) to the pilot pump
7. Install O-ring (3) to cartridge (23). mounting surface.
15. Install pilot pump (28) into casing (18) with socket
IMPORTANT: Position the casting imprint side of bolts (25) (2 used), spring washers (26) (2 used),
cartridge (23) upward (the oil filler plain washers (27) (2 used).
side) and install the cartridge on cas- : 8 mm
ing (18). : 65 N⋅m (6.6 kgf⋅m, 48 lbf⋅ft)
8. While tapping cartridge (23) evenly with a plastic
hammer, install cartridge (23) on casing (18). 16. Install elbow (10) to casing (18).
Up Side : 32 mm
Casting Imprint
17. Install pipe (13) and O-ring (15) to casing (18) with
bolts (14) (4 used).
: 17 mm
: 50 N⋅m (5.0 kgf⋅m, 36 lbf⋅ft)
Cartridge (23) W167-02-03-006
W2-4-9
DISASSEMBLE MAIN PUMP
26
25 28 29 30
1 27
Feedback Shaft
24
2
3
4
23
5я
я6 22
21
20
7 19 31
18 32
8
9 17
16
15 33
34
14 55
35
13 36 54
12 53
11 37
52
10 51
50
49
47 48
46
45
44
43
42
41 47 48
40
38 20 57 48 56
39 58
34
59
Pin
Feedback Lever
W17P-02-04-004
1- Unit 16 - Spacer 31 - O-Ring (2 Used) 46 - Needle Bearing
2- Plate Spring 17 - Retaining Ring 32 - Plug (2 Used) 47 - O-Ring (10 Used)
3- O-Ring 18 - Nut (2 Used) 33 - Pump Casing 48 - O-Ring (4 Used)
4- Angle Sensor 19 - Adjusting Screw 34 - O-Ring (2 Used) 49 - Adjusting Screw
5- Socket Bolt (2 Used) 20 - Spring Pin (2 Used) 35 - Support 50 - Nut (2 Used)
6- Washer (2 Used) 21 - Stopper 36 - Washer (4 Used) 51 - Booster
7- Socket Bolt (2 Used) 22 - Backup Ring 37 - Socket Bolt (4 Used) 52 - O-Ring
8- Screw (2 Used) 23 - O-Ring 38 - Swash Plate 53 - O-Ring
9- Plug (2 Used) 24 - Tilt Pin 39 - Shoe Plate 54 - Cover
10 - Socket Bolt (4 Used) 25 - Socket Bolt (6 Used) 40 - Plunger (9 Used) 55 - Socket Bolt (6 Used)
11 - Cover 26 - Regulator 41 - Retainer 56 - Plug (2 Used)
12 - O-Ring 27 - Servo Piston 42 - Spherical Bushing 57 - Cover
13 - Oil Seal 28 - O-Ring 43 - Spring (9 Used) 58 - Pin
14 - Drive Shaft 29 - Backup Ring 44 - Cylinder Block 59 - Shoe (9 Used)
15 - Roller Bearing 30 - Stopper 45 - Valve Plate
W2-4-10
Disassemble Main Pump
• Be sure to thoroughly read all “Precautions for 6. Take out cylinder block (44) from pump casing
Disassembly and Assembly” on page W1-1-1 be- (33). Now you can see plungers (40) (9 used),
fore starting the disassembly work. shoes (59) (9 used), spherical bushing (42) and
retainer (41) all connected together on cylinder
IMPORTANT: Put rubber plate or cloth, etc. on block (44).
workbench to prevent the parts from NOTE: Grasp cylinder (44) with two hands and
being damaged. slowly take it out while turning it to left and
right lightly.
IMPORTANT: Do not remove adjusting screws (19
and 49) and nuts (18 and 50) in sup- 7. Remove retainer (41) from the cylinder block (44)
port (35) and cover (57), the oil flow assembly. At this time, plungers (40) (9 used) and
rate setting may change as a conse- shoes (59) (9 used) are still connecting with re-
quence. tainer (41).
1. Remove plugs (32) (2 used) and O-rings (31) (2 8. Remove plungers (40) (9 used) and shoes (59) (9
used) to bleed hydraulic oil from the pump. used) from retainer (41).
: 12 mm
9. Remove spherical bushing (42) from cylinder
2. Remove socket bolts (25) (6 used) to remove block (44) to remove springs (43) (9 used).
regulator (26).
: 6 mm IMPORTANT: As for oil seal (13), do not remove it
unless necessary; replace with a
3. Remove socket bolts (55) (6 used) to remove new one when remove.
cover (54), booster (51) and O-rings (52 and 53). Oil seal (13) is installed in cover (11).
: 8 mm Be sure not to damage the lip part of
oil seal (13) when removing the
4. Place pump casing (33) with regulator (26) mount- cover.
ing surface facing downward. 10. Remove socket bolts (10) (4 used) to remove
cover (11) and O-ring (12).
IMPORTANT: Be careful as valve plate (45) may : 6 mm
come off together with cover (57) NOTE: If a bolt is inserted into the pulling hole (M8)
when removing the cover. in cover (11), it is easy to remove it.
As for bearing (46), do not remove
unless necessary; replace with a
new one when removed.
5. Remove socket bolts (37) (4 used) to remove
cover (57), O-rings (34) and (47) (10 used), (48)
(4 used), spring pins (20) (2 used), valve plate
(45) and pin (58).
: 17 mm
W2-4-11
30
1 27
24
2
3
4
5, 6
21
20
7
17
16
15 33
34
14
35
46
57
38
39
W17P-02-04-004
W2-4-12
11. Remove support (35) from pump casing (33) by IMPORTANT: Do not remove needle bearing (46)
tapping with a plastic hammer. Then, remove O- unless its service life should be con-
ring (34) and spring pins (20) (2 used). sidered.
17. Remove needle bearing (46) from cover (57).
12. Remove the angle sensor (4) assembly from
pump casing (33). 18. Remove retaining ring (17) from drive shaft to re-
At first, loosen socket bolt (5) to remove angle move spacer (16) and bearing (15).
sensor (4). Second, loosen socket bolt (7) to re-
move unit (1).
Be sure not to drop O-ring (3), plate spring (2) in-
side when removing.
: 5 mm, 6 mm
NOTE: The angle sensor (4) assembly consists of
angle sensor (4), unit (1), plate spring (2),
O-ring (3), socket bolts (5) (2 used), (7) (2
used), washers (6) (2 used).
13. Remove swash plate (38) and shoe plate (39)

from pump casing (33).
14. Remove drive shaft (14) from support (35) by tap-

ping with a plastic hammer.
15. Remove stoppers (21), (30) from pump casing

(33).
IMPORTANT: Servo piston (27) is connected to tilt

pin (24) with LOCTITE. Do not disas-
semble them unless necessary.
16. Heat tilt pin (24) with a drier. Secure servo piston
(27) with pliers and be sure not to damage servo
piston while turning tilt pin (24) to remove it. Pull
out servo piston (27) from pump casing (33).
W2-4-13
ASSEMBLE MAIN PUMP
20 21 22, 23 33 16 17 27 24 31, 32 30 28, 29 47 34 46 50 49
19 54
18
35
34
55
10
12
11 48, 56
13
1
53
14 51
15
52
37 57
36 38 39 59 41 40 42 7 5, 6 4 43 44 8, 9 20 45 58 T17V-03-01-003
1- Unit 16 - Spacer 31 - O-Ring (2 Used) 46 - Needle Bearing

2- *Plate Spring 17 - Retaining Ring 32 - Plug (2 Used) 47 - O-Ring (10 Used)
3- *O-Ring 18 - Nut (2 Used) 33 - Pump Casing 48 - *O-Ring (4 Used)
4- Angle Sensor 19 - Adjusting Screw 34 - O-Ring (2 Used) 49 - Adjusting Screw
5- Socket Bolt (2 Used) 20 - Spring Pin (2 Used) 35 - Support 50 - Nut (2 Used)
6- Washer (2 Used) 21 - Stopper 36 - Washer (4 Used) 51 - Booster
7- Socket Bolt (2 Used) 22 - Backup Ring 37 - Socket Bolt (4 Used) 52 - O-Ring
8- Screw (2 Used) 23 - O-Ring 38 - Swash Plate 53 - O-Ring
9- Plug (2 Used) 24 - Tilt Pin 39 - Shoe Plate 54 - Cover
10 - Socket Bolt (4 Used) 25 - *Socket Bolt (6 Used) 40 - Plunger (9 Used) 55 - Socket Bolt (6 Used)
11 - Cover 26 - *Regulator 41 - Retainer 56 - Plug (2 Used)
12 - O-Ring 27 - Servo Piston 42 - Spherical Bushing 57 - Cover
13 - Oil Seal 28 - O-Ring 43 - Spring (9 Used) 58 - Pin
14 - Drive Shaft 29 - Backup Ring 44 - Cylinder Block 59 - Shoe (9 Used)
15 - Roller Bearing 30 - Stopper 45 - Valve Plate
NOTE: As for positions for the items with * mark,
refer to page W2-6-10.
W2-4-14
Assemble Main Pump
IMPORTANT: Apply THREEBOND #1305N on the IMPORTANT: Apply special grease (NOK CEN-
inner face of servo piston (27) and TOPLEX2) on plate spring (2).
tilt pin (24). 8. Assemble plate spring (2) into unit (1) and install
1. Install tilt pin (24), servo piston (27) and stoppers them to pump casing (33) with socket bolts (7) (2
(21) and (30) into pump casing (33). used).
: 6 mm
2. Install bearing (15), spacer (16) and retaining ring : 29.4 N⋅m (3.0 kgf⋅m, 21 lbf⋅ft)
(17) onto shaft (14). NOTE: When installing, be sure to check that the
pin on feedback lever end of swash plate
3. Assemble spring pins (20) (2 used) and (34) onto (38) is in the groove in feedback shaft of
support (35), and install support (35) into pump unit (1).
casing (33) by tapping with a hammer lightly.
9. Install angle sensor (4), O-ring (3) to unit (1) with
4. Place pump casing (33) with regulator mounting socket bolts (5) (2 used) and washers (6) (2
surface facing downward. used).
: 5 mm
5. Align swash plate (38) which is connected with : 9.8 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft)
shoe plate (39) with tilt pin (24) and install them to 3
pump casing (33). 5, 6
NOTE: Check swash plate (38) by hand to ensure

that it moves smoothly after installing it.
IMPORTANT: Apply lubricant L101 to the outer

face of oil seal (13) and apply a film
of grease to the lip part.
6. Install oil seal (13) and O-ring (12) onto cover (11).
Feedback Lever
7. Press drive shaft (14) into support (35) and install Feedback Shaft
cover (11) with socket bolts (10) (4 used) to the
support. 4
: 6 mm Apply Grease (NOK CEN-
2
: 29 N⋅m (3.0 kgf⋅m, 21 Ibf⋅ft) 7 1 TOPLEX2) to the Plate
Spring Mounting Part
W16J-02-04-008
Detail for Angle Sensor (4) Mounting Parts
10. Install springs (43) (9 used) and spherical bushing

(42) onto cylinder block (44).
11. Assemble plungers (40) (9 used) and shoes (59)

(9 used) into retainer (41), then install them to
cylinder block (44).
12. Install cylinder block (44) assembly to drive shaft

(14).
W2-4-15
33 24 31, 32 48 34
19
54
55
53
51
14
52
57
T17V-03-01-003
37 36 45 20 58
W2-4-16
IMPORTANT: Apply grease onto valve plate (45).
Be sure not to mistake the inlet and
outlet installing direction of valve
plate.
13. Assemble spring pin (20), pin (58), O-rings (47)
(10 used), (48) (4 used) and (34) into cover (57).
Then install valve plate (45).
NOTE: Install valve plate (45) by aligning pin (58)
with the pin hole in valve plate.
14. Install cover (57) onto the pump casing (33) as-
sembly with socket bolts (37) (4 used) and wash-
ers (36) (4 used).
: 17 mm
: 490 N⋅m (50 kgf⋅m, 360 lbf⋅ft)
15. Install booster (51) to drive shaft (14) by aligning

the splines.
16. Assemble O-rings (52) and (53) to cover (54). In-

stall cover (54) onto cover (57) with socket bolts
(55) (6 used).
: 8 mm
: 57 N⋅m (5.8 kgf⋅m, 42 lbf⋅ft)
17. Align the feedback lever of regulator (26) with tilt

pin (24) and install regulator (26) with socket bolts
(25) (6 used).
: 6 mm
: 29 N⋅m (30 kgf⋅m, 215 lbf⋅ft)
NOTE: As for the position of regulator (26) and
socket bolt (25), refer to page W2-4-10.
18. Install O-rings (31) (2 used) and plugs (32) (2

used).
: 12 mm
: 170 N⋅m (17 kgf⋅m, 123 lbf⋅ft)
W2-4-17
MAINTENANCE STANDARD
1. Clearance between outer diameter (d) of plunger

(40) and bore diameter (D) of cylinder block (44)
d D
D-d Unit: mm (in)
Standard Allowable Limit
0.047 (0.002) 0.094 (0.004)
W117-02-02-009
2. Free length (L) of spring (43)
L Unit: mm (in)
49.5 (2.0) 48.0 (1.9)
3. Clearance (δ) between plunger (40) and shoe (59) W117-02-02-010

and thickness (t) of shoe (59).
δ Unit: mm (in)
0 to 0.1 (0 to 0.004) 0.35 (0.01)
t Unit: mm (in)
δ
6.5 (0.3) 6.3 (0.2) t
W117-02-02-011
4. Height from retainer (41) to spherical bushing (42)
H-h Unit: mm (in)

Stand
33.0 (1.3) 32.0 (1.3) H
h
W117-02-02-012
W2-4-18
(Blank)
W2-4-19
DISASSEMBLE REGULATOR
5 6 7
8
2
1
23
11
24
22
21
20
10
19
25
9 26
11 31 27
10 4
18
17 28
30
16
15 29
14
13
12
W17P-02-04-005
1- Spring Seat 9- Plug 17 - Pin 25 - Plug
2- Spring 10 - O-Ring (2 Used) 18 - Sleeve 26 - Pin
3- Stopper 11 - Plug (6 Used) 19 - O-Ring (2 Used) 27 - O-Ring (5 Used)
4- O-Ring (2 Used) 12 - Socket Bolt (4 Used) 20 - Seat (2 Used) 28 - O-Ring
5- Cover 13 - Valve Casing 21 - Steel Ball (2 Used) 29 - Feedback Lever
6- Socket Bolt (4 Used) 14 - Pump Control Proportional 22 - Stopper (2 Used) 30 - Pin
Solenoid Valve
7 - Screw 15 - O-Ring 23 - Socket Bolt (6 Used) 31 - Spool
8 - Nut 16 - Sleeve 24 - Casing
W2-4-20
Disassemble Regulator
• Be sure to thoroughly read all “Precautions of 8. Using forcing bolt (M4), remove stopper (3). Then,
Disassembly and Assembly” on page W1-1-1 be- remove spring (2) and spring seat (1).
9. Remove O-ring (19), seat (20), steel ball (21) and
1. Remove socket bolt (23) to remove the regulator stopper (22) from pump casing mounting surface
from pump casing. on the casing.
: 6 mm NOTE: As for the positions of O-ring (19), seat (20),
steel ball (21) and stopper (22), refer to
2. Remove pump control proportional solenoid valve page W2-4-22.
(14) from valve casing (13).
: 32 mm

valve casing (13) from casing (24).
: 5 mm
4. Remove O-ring (19), seat (20), steel ball (21) and

stopper (22) from valve casing mounting surface
on casing (24).
5. Remove O-ring (15), sleeve (16) and pin (17) from

casing (24).
6. Remove plug (25) to remove feedback lever (29),

pin (30), sleeve (18) and spool (31).
: 6 mm
NOTE: Feedback lever (29) and pin (30) will come
off at the same time.
IMPORTANT: Do not remove screw (7) and nut (8).

If removed, the pump flow rate set-
ting may change.
7. Loosen socket bolts (6) (4 used) to remove cover
(5).
: 5 mm
W2-4-21
ASSEMBLE REGULATOR
9 19 20 21 22 24 31 18 1 2 3 4 5
10 6
B
A
8
7
13
12
16 A
17
15 4 26, 27
Section A-A
23 11 30 10 25
22
Section B-B
21
13
20
19
28
29
14
W17P-02-04-007
1- Spring Seat 9- Plug 17 - Pin 25 - Plug
2- Spring 10 - O-Ring (2 Used) 18 - Sleeve 26 - Pin
3- Stopper 11 - Plug (6 Used) 19 - O-Ring (2 Used) 27 - O-Ring (5 Used)
4- O-Ring (2 Used) 12 - Socket Bolt (4 Used) 20 - Seat (2 Used) 28 - O-Ring
5- Cover 13 - Valve Casing 21 - Steel Ball (2 Used) 29 - Feedback Lever
6- Socket Bolt (4 Used) 14 - Pump Control Proportional 22 - Stopper (2 Used) 30 - Pin
Solenoid Valve
7 - Screw 15 - O-Ring 23 - Socket Bolt (6 Used) 31 - Spool
8 - Nut 16 - Sleeve 24 - Casing
W2-4-22
Assemble Regulator
7. Install pump control proportional solenoid valve
1. Install stopper (22), steel ball (21), seat (20) and (14) to valve casing (13). Install valve casing (13)
O-ring (19) into pump casing mounting surface on to casing (24) with socket bolts (12) (4 used).
casing (24). : 32 mm
: 44 N⋅m (4.5 kgf⋅m, 32.5 Ibf⋅ft)
IMPORTANT: Take care not to mistake the install- : 5 mm
ing directions of sleeve (18) and : 12 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft)
spool (31).
2. Install sleeve (18) and spool (31) into casing (24).
Then, install feedback lever (29) to sleeve (18)
with pin (30).
3. Install O-ring (10) to plug (25). Align the pin holes

both in feedback lever (29) and casing (24). Then,
install plug (25) into casing (24).
: 6 mm
: 36 N⋅m (3.7 kgf⋅m, 27.0 lbf⋅ft)
NOTE: After installing plug (25), check that feed-
back lever (29) moves smoothly.
4. Install spring seat (1), spring (2), stopper (3) and

O-ring (4) onto valve casing (13) mounting sur-
face in casing (24). Install cover (5) with socket
bolts (6) (4 used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft)
5. Install piston (17), sleeve (16) and O-ring (15) into

casing (24).
6. Install stopper (22), steel ball (21), seat (20) and

O-ring (19) into casing (24).
W2-4-23
DISASSEMBLE AND ASSEMBLE PILOT
PUMP
16
15
7
10
14
4
8
13
12
5
6
9
11
7
6
5
4
W17P-02-04-006
3
2
1
W2-4-24
Tightening Torque
Item Part Name Q’ty Wrench Size (mm) Remarks
N⋅m kgf⋅m (Ibf⋅ft)
1 Retaining Ring 1
Apply grease to oil seal lip
2 Oil Seal 1
when installing
3 Flange 1
4 O-Ring 2
when installing
5 Backup Ring 2
when installing
6 Seal 2
when installing
7 Bushing 2
8 Key 2
9 Bushing 2
when installing
10 Gear 1
11 Gear 1
12 Knock Pin 2
when installing
13 Housing 1
14 Cover 1
4 to 4.5
15 Bolt 4 : 17 39 to 44
(29 to 32.5)
16 Washer 4
W2-4-25
(Blank)
W2-4-26
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE

lines.
repair work.
Preparation

several times to release any pressure remaining M104-07-021

wrench to release the trapped air in the hydraulic Cap
tem on page W1-1-2.
: 4 mm

tank.
W183-01-01-001
W2-5-1
Removal
3
1. Remove bolts (3) (8 used) to remove covers (1)

and (2).
: 19 mm
1
2
W17V-02-05-001
Swing Arm1 Boom2 Auxiliary Left Travel Eye Bolt

Mounting
Position
IMPORTANT: Attach identification tags to hoses Eye Bolt
Mounting
for reassembly. Position
2. Disconnect all hoses and pipes, from the control
valve. Cap all disconnected hoses.
: 17 mm, 19 mm, 41 mm Front
: 12 mm
3. Remove bolts (4) (4 used).

: 30 mm
CAUTION: Control valve weight: 400 kg

(890 lb)
4. Install eye bolts (M12, pitch 1.75) (3 used) to the Eye Bolt
control valve. Hoist and remove the control valve Mounting
Position
by crane. Arm2 Boom1 Bucket Right Travel
W17V-02-05-002
T17V-01-01-013
W2-5-2
Installation
5
4
(890 lb)
1. Place the control valve on the main frame and in-
stall it with bolts (4) (4 used) and spacers (5) (4
used).
: 30 mm
: 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft)
2. Attach all the hoses and pipes to the control valve.

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm T17V-01-01-013
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

: 19 mm Swing Arm1 Boom2 Auxiliary Left Travel Eye Bolt
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) Mounting
Position
: 41 mm
: 205 N⋅m (21.0 kgf⋅m, 151 lbf⋅ft)
: 12 mm
Eye Bolt
: 180 N⋅m (18.5 kgf⋅m, 135 lbf⋅ft) Mounting
Position
Front
Eye Bolt
Mounting
Arm2 Boom1 Bucket Right Travel Position
W17V-02-05-002
3. Install the rubber and spacer to bolts (3) (4 used)

on cover (1) side. Install covers (1) and (2) with
bolts (8 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66.5 lbf⋅ft)
1
IMPORTANT: After installation, check the hydrau- 2
lic oil level. Run the engine and
check for oil leaks. W17V-02-05-001
W2-5-3
DISASSEMBLE CONTROL VALVE
(5-SPOOL SECTION)
10 11 12
Disassemble Spool and Check Valve
9
7 7 7 7 7
6 6 6 6 6
5 5 5
5 5
4 4 4 4 4
3 3 3 3 3
19
2 18
17 20
16 21 22
15
14
13
23 24 25 26 27 28
1
Check Valve
29 29 29
34
32 30
11 11
31 31
31 33
33
W17V-02-05-003
1- Housing 10 - Cover 19 - Spool (Arm 1) 27 - Chip

2- Spool (Swing) 11 - O-Ring (3 Used) 20 - Spool (Boom 2) 28 - Cap
3- Spring Guide (5 Used) 12 - Plug (2 Used) 21 - Spool (Auxiliary) 29 - O-Ring (5 Used)
4- Sleeve (5 Used) 13 - Cap 22 - Spool (Travel Left) 30 - Cover (3 Used)
5- Spring (5 Used) 14 - Backup Ring 23 - Check Valve 31 - Socket Bolt (10 Used)
6- Spring Guide (5 Used) 15 - O-Ring 24 - Spring 32 - Cover
7- Bolt (5 Used) 16 - Spacer 25 - O-Ring 33 - Plug (2 Used)
8- O-Ring (5 Used) 17 - Spring 26 - Backup Ring 34 - Cover
9- Socket Bolt (10 Used) 18 - Check Valve
W2-5-4
Disassemble Control Valve (5-Spool Section)
• Be sure to read “Precautions for Disassembly 5. Remove cap (13) of the spool (19) to remove
and Assembly Work” thoroughly on page W1-1- spacer (16), spring (17) and check valve (18).
1 before starting the disassembly work. : 8 mm
IMPORTANT: Attach tags to the spools and the NOTE: If it is difficult to remove spacer (16), spring
places where the spools are inserted (17), check valve (18), a magnet can be
in order to prevent misplacement used.
when assembling.
CAUTION: Control valve weight: 400 kg (880 Ib) covers (30) (3 used) and cover (32) and (34).
1. Place control valve on work bench. : 10 mm
Disassemble Spool 7. Remove plug (33) from cover (32).

2. Remove socket bolts (9) (10 used) to remove : 19 mm
cover (10) from housing (1).
: 10 mm Disassemble Check Valve
8. Remove cap (28) from housing (1) to remove
IMPORTANT: When pulling out each spools (2 and spring (24) and check valve (23).
19 to 22) assemblies, rotate spool : 14 mm
slowly while pulling it out straight. Do NOTE: If it is difficult to remove spring (24), check
not disassemble the spool assembly valve (23) from housing (1), a magnet can
unless necessary. be used.
3. Take out the spool (2 and 19 to 22) assemblies
(5 used) from housing (1). Remove O-rings
(8) (5 used) from the housing.
IMPORTANT: The threaded part of bolt (7) has been

applied with LOCTITE. Therefore,
when disassemble each spool as-
semblies, heat the bolts to tempera-
ture of 200 to 250 °C (392 to 482 °F)
to melt the LOCTITE and then re-
move it.
Each spool assemblies should be
degreased thoroughly before being
disassembled.
4. Clamp the spool (2 and 19 to 22) assemblies in a
vise with wooden spatulas inserted at both sides
to hold it.
Remove bolt (7) to remove spring guide (6),
spring (5), sleeve (4), spring guide (3).
: 10 mm
W2-5-5
Disassemble Valves 51
20
19
18 50
49
17
48
16
47
15
14 46
9 13 45
8 12 44
7 11 43
6 10 42
41
5 40
39
4 38
3 37
2 36
35
34
33
32
31
30
1 29
28
27
26
25
24
23
22
21
20
W17V-02-05-004
1- Housing 14 - Seat (6 Used) 27 - Backup Ring 40 - O-Ring

2- O-Ring (6 Used) 15 - Pilot Poppet (6 Used) 28 - O-Ring 41 - Sleeve
3- Backup Ring (6 Used) 16 - Spring (6 Used) 29 - Piston 42 - O-ring
4- O-Ring (6 Used) 17 - O-Ring (6 Used) 30 - Spring 43 - Backup Ring
5- Sleeve (6 Used) 18 - Adjusting Screw (6 Used) 31 - Spring 44 - Lock Nut
6- Main Poppet (6 Used) 19 - Lock Nut (6 Used) 32 - Pilot Seat 45 - O-ring
7- Piston (6 Used) 20 - Overload Relief Valve (6 Used) 33 - Backup Ring 46 - Backup Ring
8- Spring (6 Used) 21 - O-Ring 34 - O-Ring 47 - Sleeve
9- Spring (6 Used) 22 - Backup Ring 35 - Pilot Poppet 48 - Piston
10 - O-ring (6 Used) 23 - O-Ring 36 - Spring 49 - O-Ring
11 - Backup Ring (6 Used) 24 - Sleeve 37 - Spring Guide 50 - Cap
12 - Backup Ring (6 Used) 25 - Main Poppet 38 - Spring 51 - Overload Relief Valve
13 - O-Ring (6 Used) 26 - Backup Ring 39 - Poppet
W2-5-6
Disassemble Overload Relief Valve (20)
IMPORTANT: Do not disassemble the overload re-
lief valves (20) (6 used) unless nec-
essary, because its adjustment on
the test bench should be carried out.
(Refer to Troubleshooting / Opera-
tional Performance Test Section in
Technical Manual)
Keep overload relief valves (6 used)
with tag attached in order to set
them to their original position before
being removed.
9. Loosen sleeve (5) via its hexagonal part to re-
move overload relief valves (20) assembly (6
used) (3 for upper and 3 for lower) from housing
(1).
: 41 mm
10. Clamp sleeve (5) at its hexagonal part into a vise.

Loosen seat (14) via its hexagonal part to remove
seat assemblies (10 to 19). Remove springs (9
and 8), piston (7) and poppet (6) from the sleeve.
: 36 mm
11. Clamp seat (14) at its hexagonal part into a vise.

Clamp adjusting screw (18) into a wrench, remove
lock nut (19).
: 19 mm
: 6 mm
IMPORTANT: Put matching marks on adjusting

screw (18) and seat (14) and take a
note of the turning amount of the ad-
justing screw.
12. Remove adjusting screw (18) from seat (14) while
counting the turning amount of the adjusting
screw.
Remove spring (16) and pilot poppet (15) from the
seat.
W2-5-7
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
1 29
28
27
26
25
24
23
22
21
W17V-02-05-004
W2-5-8
Disassemble Overload Relief Valve (51)
IMPORTANT: Do not disassemble overload relief IMPORTANT: Put matching marks between sleeve
valve (51) unless necessary, be- (47) and sleeve (41) and lock nut (44)
cause its adjustment should be car- and take a note of turning amount of
ried out on the test bench if it is re- sleeve (47).
moved. (Refer to Troubleshooting / 17. Clamp sleeve (41) at its hexagonal part in a vise.
Operational Performance Test Sec- Loosen lock nut (44) to remove sleeve (47) and
tion in Technical Manual) the lock nut from sleeve (41)
13. Loosen sleeve (24) via its hexagonal part to re- : 36 mm, 30 mm
move overload relief valve (51) from housing (1).
: 41 mm 18. Clamp sleeve (47) at its hexagonal part in a vise.
Loosen cap (50) to remove piston (48) from the
IMPORTANT: Put matching marks on sleeves (24 sleeve.
and 41) and take a note of turning : 27 mm
amount of sleeve (41). NOTE: Take piston (48) out from the hole for pop-
14. Clamp sleeve (24) at its hexagonal part in a vise. pet (39) in sleeve (47) by pushing it with a
Loosen sleeve (41) via its hexagonal part to re- round bar (dia.: approx. 3 mm (0.12 in)).
move sleeve (41).
: 36 mm
NOTE: If sleeve (41) is loosened, overload relief
valve (51) can be removed from the vise.
Put the overload relief valve horizontally and
loosen sleeve (41) to remove it carefully.
While removing, poppet (39), spring (38)
may drop down, take care not to loose these
parts.
15. Remove spring guide (37), spring (36), pilot pop-

pet (35), pilot seat (32), spring (31), spring (30),
piston (29) and main poppet (25) from sleeve
(24).
NOTE: Take main poppet (25) out from the housing
(1) side of sleeve (24) by pushing lightly with
a round bar.
16. Remove spring (38), poppet (39) from sleeve

(41).
W2-5-9
ASSEMBLE CONTROL VALVE (5-SPOOL
SECTION)
Assemble Spool and Check Valve
Section B
1 Check Valve
B
23 27 28 26
24 25
W162-02-04-027
W17V-02-05-002
Section A
3 4 7 6 5 11
10
9 12
20
21
22
2
19
18
17 1
16
14, 15
W17V-02-05-005
13 11, 33, 34 11, 32, 33 29 30 31
1- Housing 10 - Cover 19 - Spool (Arm 1) 27 - Chip

2- Spool (Swing) 11 - O-Ring (3 Used) 20 - Spool (Boom 2) 28 - Cap
3- Spring Guide (5 Used) 12 - Plug (2 Used) 21 - Spool (Auxiliary) 29 - O-Ring (5 Used)
4- Sleeve (5 Used) 13 - Cap 22 - Spool (Travel Left) 30 - Cover (3 Used)
5- Spring (5 Used) 14 - Backup Ring 23 - Check Valve 31 - Socket Bolt (10 Used)
6- Spring Guide (5 Used) 15 - O-Ring 24 - Spring 32 - Cover
7- Bolt (5 Used) 16 - Spacer 25 - O-Ring 33 - Plug (2 Used)
8- O-Ring (5 Used) 17 - Spring 26 - Backup Ring 34 - Cover
9- Socket Bolt (10 Used) 18 - Check Valve
W2-5-10
Assemble Control Valve (5-Spool Section)

• Be sure to read “Precautions for Disassembly 6. Install cover (10) onto housing (1) with socket
and Assembly Work” thoroughly on page W1-1- bolts (9) (10 used).
1 before starting the assembly work. : 10 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
Assemble Spool Assemble Check Valve
1. Install O-rings (29) (5 used) into housing (1). In- IMPORTANT: Chip (27) prevents cap (28) from be-
stall covers (30) (3 used), (32) and (34) into the ing pulled and loosening.
housing with socket bolts (36) (10 used). The chip will be damaged when cap
: 10 mm is removed because it is made of ny-
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) lon. Be sure to replace the chip with
a new one.
2. Install O-rings (11) (2 used) into plugs (33) (2 7. Install backup ring (26), O-ring (25), chip (27) into
used). cap (28).
Install the plug into cover (37). Insert spring (24) into check valve (23).
: 19 mm Install the check valve and cap into housing (1).
: 78.5 N⋅m (8 kgf⋅m, 58 lbf⋅ft) : 14 mm
: 343 N⋅m (35 kgf⋅m, 255 lbf⋅ft)
3. Clamp spool (19) into a vise with wooden spatulas
inserted at both sides.
Install backup ring (14), O-ring (15) into cap (13).
Install check valve (18), spring (17), spacer (16)
into spool (24).
Install the cap into the spool.
: 8 mm
: 78.5 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
IMPORTANT: Apply LOCTITE to the bolt (7) hole of

each spool (2 and 19 to 22).
4. Clamp each spool (2 and 19 to 22) into a vise with
wooden spatulas inserted at both sides.
Install O-rings (8) (5 used) into housing (1).
Install spring guide (3), sleeve (4), spring (5),
spring guide (6) into spools (2 and 19 to 22). In-
stall bolts (7) to each spool.
: 10 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
IMPORTANT: Apply hydraulic oil on the surface of

spools (2 and 19 to 22).
Install each spool into the original
positions before disassembling.
5. Install spool (2 and 19 to 22) assemblies into
housing (1) while rotating them slowly.
NOTE: When unable to install the spool smoothly,

stop installing. Pull out the spool slowly and
try to install it again.
As soon as the spool (19), (20) assemblies
touches plug (33), rotate the spool to align
the spool stop pin with the plug. Press the
spool down while no reactive force coming
from the plug being felt.
W2-5-11
Assemble Valves
20 Section A
ӸOverload Relief Valve (20)
A 20
2 7 6 4 5 9 16 14 17
B
51
20
3 8 10 11 12 15 13 18 19
W16J-02-05-010
1 W162-02-04-022
Section B
21 22 23 24 32 33 34 40 45 46 41 42 43 44 47
29 25 26 27 28 31 30 35 36 37 38 39 48 49 50
W16J-02-05-013
1- Housing 14 - Seat (6 Used) 27 - Backup Ring 40 - O-Ring

2- O-Ring (6 Used) 15 - Pilot Poppet (6 Used) 28 - O-Ring 41 - Sleeve
3- Backup Ring (6 Used) 16 - Spring (6 Used) 29 - Piston 42 - O-ring
4- O-Ring (6 Used) 17 - O-Ring (6 Used) 30 - Spring 43 - Backup Ring
5- Sleeve (6 Used) 18 - Adjusting Screw (6 Used) 31 - Spring 44 - Lock Nut
6- Main Poppet (6 Used) 19 - Lock Nut (6 Used) 32 - Pilot Seat 45 - O-ring
7- Piston (6 Used) 20 - Overload Relief Valve (6 Used) 33 - Backup Ring 46 - Backup Ring
8- Spring (6 Used) 21 - O-Ring 34 - O-Ring 47 - Sleeve
9- Spring (6 Used) 22 - Backup Ring 35 - Pilot Poppet 48 - Piston
10 - O-ring (6 Used) 23 - O-Ring 36 - Spring 49 - O-Ring
11 - Backup Ring (6 Used) 24 - Sleeve 37 - Spring Guide 50 - Cap
12 - Backup Ring (6 Used) 25 - Main Poppet 38 - Spring 51 - Overload Relief Valve
13 - O-Ring (6 Used) 26 - Backup Ring 39 - Poppet
W2-5-12
Assemble Overload Relief Valve (20)
8. Install O-ring (13), backup rings (12 and 11) and IMPORTANT: Install overload relief valve (20) to its
O-ring (10) onto seat (14). Install O-ring (17) onto position where it was removed. Be
adjusting screw (18). sure to perform adjustment to the
valve on test bench.
IMPORTANT: As for adjusting screw (18), it should (Refer to Troubleshooting / Opera-
be screwed in only by the same tional Performance Test Section in
amount to removal, so that the Technical Manual)
matching marks can be aligned cor- 13. Install overload relief valves (20) (6 used) (3 for
rectly. upper and 3 for lower) into housing (1).
9. Install pilot poppet (15), spring (16), adjusting : 41 mm
screw (18), lock nut (19) onto seat (14). : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
: 6 mm NOTE: Tighten sleeve (5) at its hexagonal part.
: 19 mm
: 31.5 N⋅m (3.2 kgf⋅m, 23 lbf⋅ft)
10. Install O-ring (4), backup ring (3), O-ring (2) into
sleeve (5).
11. Install piston (7) into main poppet (6). Install the
main poppet into sleeve (5).
12. Install springs (8 and 9) into the seat (14) assem-

bly. Install the seat assembly into sleeve (5).
: 36 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
W2-5-13
B
51
1 W16J-02-05-010
Section B
21 22 23 24 32 33 34 40 45 46 41 42 43 44 47
29 25 26 27 28 31 30 35 36 37 38 39 48 49 50
W16J-02-05-013
W2-5-14
Assemble Overload Relief Valve (51)
14. Install O-ring (49) onto cap (50) and install piston IMPORTANT: Install overload relief valve (51) to its
(48) and the cap to sleeve (47). position where it was removed.
: 27 mm Be sure to perform adjustment to the
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) valve on test bench.
15. Install lock nut (44), backup ring (43) and O-ring tional Performance Test Section in
(42) to sleeve (47) in that order. Install backup ring Technical Manual)
(46), O-ring (45) and poppet (39) into sleeve (47). 24. Install overload relief valve (51) into housing (1).
: 41 mm
IMPORTANT: As for sleeve (47), it should be : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
screwed in only by the same amount
NOTE: Tighten sleeve (24) via its hexagon part.
to removal, so that the matching
marks can be aligned correctly.
16. Install the sleeve (47) assembly into sleeve (41)
and secure them with lock nut (44).
: 36 mm
: 78.5 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
17. Install O-ring (40), spring (38), spring guide (37),

spring (36) into the sleeve (41) assembly.
18. Install O-ring (23), backup ring (22), O-ring (21)

onto sleeve (24).
19. Install backup rings (26 and 27), O-ring (28) and
piston (29) onto main poppet (25).
20. Press the main poppet (25) assembly into sleeve

(24).
21. Install backup ring (33), O-ring (34) onto pilot seat
(32).
22. Install springs (31 and 30) into main poppet (25).
Install pilot seat (32) into sleeve (24). Then install
pilot poppet (35) onto the pilot seat.
23. Align the sleeve (41) assembly with the sleeve

(24) assembly and tighten it temporarily. Then
clamp sleeve (24) at its hexagonal part into a vise
to tighten sleeve (41).
: 36 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
W2-5-15
DISASSEMBLE CONTROL VALVE
(4- SPOOL SECTION)
Disassemble Spool, Check Valve and Flow Com-
bining Valve
10 11 12
9
7 7
7 7
6 6 6 6
5 5
5 5
4 4
4 4
3 3 3 3
14 15
2 13
1 16
22 17
23 18
32 19
32 24
28
25 20
11 28
11
26 21
28 27
33
29
30
31 30
W17V-02-05-006
1- Housing 10 - Cover 19 - Backup Ring 27 - Cap

2- Spool (Arm 2) 11 - O-Ring (4 Used) 20 - Chip 28 - O-Ring (4 Used)
3- Spring Guide (4 Used) 12 - Cap 21 - Cap 29 - Cover
4- Sleeve (4 Used) 13 - Spool (Boom 1) 22 - Spool 30 - Socket Bolt (8 Used)
5- Spring (4 Used) 14 - Spool (Bucket) 23 - Spacer 31 - Cover (2 Used)
6- Spring Guide (4 Used) 15 - Spool (Travel Right) 24 - Spring 32 - Plug (3 Used)
7- Bolt (4 Used) 16 - Check Valve 25 - O-Ring 33 - Cover
8- O-Ring (4 Used) 17 - Spring 26 - Chip
9- Socket Bolt (8 Used) 18 - O-Ring
W2-5-16
Disassemble Control Valve (4-Spool Section) Disassemble Check Valve

• Be sure to read “Precautions for Disassembly 6. Remove cap (21) to remove spring (17) and
and Assembly Work” thoroughly on page W1-1- check valve (16) from housing (1).
1 before starting the disassembly work. : 14 mm
IMPORTANT: Attach tags to the spools and the NOTE: If it is difficult to remove spring (17) and
places where the spools are inserted, check valve (16) from housing (1), a mag-
in order to prevent misplacement net can be used.
when assembling.
Disassemble Flow Combining Valve
Disassemble Spool 7. Remove cap (27) to remove spring (24), spacer
1. Remove socket bolts (9) (8 used) to remove cover (23) and spool (22) from housing (1).
(10) from housing (1). : 46 mm
: 10 mm
IMPORTANT: When pulling out each spool (2 and

13 to 15) assemblies, rotate spool
slowly while pulling it out straight.
Do not disassemble the spool as-
sembly unless necessary.
2. Take out the spool (2 and 13 to 15) assemblies (4
used) from housing (1). Remove O-rings (8) (4
used) from the housing.
IMPORTANT: The threaded part of bolt (7) has been

applied with LOCTITE. Therefore,
when disassemble each spool as-
semblies, heat the bolts to tempera-
ture of 200 to 250 °C (392 to 482 °F)
to melt the LOCTITE and then re-
move it.
Each spool assemblies should be
degreased thoroughly before being
disassembled.
3. Clamp the spool (2 and 13 to 15) assemblies in a
vise with wooden spatulas inserted at both sides
to hold it.
Remove bolt (7) to remove spring guide (6),
spring (5), sleeve (4) and spring guide (3).
: 10 mm

covers (29, 31 and 33) from housing (1).
: 10 mm
5. Remove plugs (32) (3 used) from covers (31) (2

used) and (33).
: 19 mm
W2-5-17
20 39
Disassemble Valves 19 38
18 37
17 36
16 35
15 34
14 33
13 32
12 31
11 48
30
10 47
29
9 46
8 28
7 27
45
6 26
5 25 44
4 24 43
3 23 42
2 22 41 Shuttle Valve
21 40
49
50
51
52
53
54
55
56
57
58
59
60
61
20
W17P-02-05-004
1- Housing 17 - O-Ring (4Used) 32 - O-Ring 47 - O-Ring
2- O-Ring (4 Used) 18 - Adjusting Screw (4 Used) 33 - O-Ring 48 - Seat
3- Backup Ring (4 Used) 19 - Lock Nut (4 Used) 34 - Sleeve 49 - O-Ring (2 Used)
4- O-Ring (4 Used) 20 - Overload relief Valve (4 Used) 35 - Piston 50 - Backup Ring (2 Used)
5- Sleeve (4 Used) 21 - Sleeve 36 - Lock Nut 51 - O-Ring (2 Used)
6- Poppet (4 Used) 22 - Main Poppet 37 - O-Ring 52 - Sleeve (2 Used)
7- Piston (4 Used) 23 - Spring 38 - Adjusting Screw 53 - Poppet (2 Used)
8- Spring (4 Used) 24 - O-Ring 39 - Main Relief Valve 54 - Backup Ring (2 Used)
9- Spring (4 Used) 25 - Backup Ring 40 - Check Valve 55 - Backup Ring (2 Used)
10 - O-Ring (4 Used) 26 - Pilot Seat 41 - Spring 56 - O-Ring (2 Used)
11 - Backup Ring (4 Used) 27 - Poppet 42 - O-Ring 57 - Spring (2 Used)
12 - Backup Ring (4 Used) 28 - Spring 43 - Backup Ring 58 - O-Ring (2 Used)
13 - O-Ring (4 Used) 29 - O-Ring 44 - O-Ring 59 - Backup Ring (2 Used)
14 - Seat (4 Used) 30 - Cap 45 - Cap 60 - Cap (2 Used)
15 - Poppet (4 Used) 31 - Lock Nut 46 - Ball 61 - Make-Up Valve (2 Used)
16 - Spring (4 Used)
W2-5-18
Disassemble Main Relief Valve (39) Disassemble Shuttle Valve
IMPORTANT: Do not disassemble main relief valve 12. Loosen cap (45) via its hexagonal part to remove
(39) unless necessary, because its shuttle valve from housing (1).
adjustment should be carried out on : 41 mm
the test bench if it is removed. (Refer
to Troubleshooting / Operational 13. Remove spring (41), check valve (40) from hous-
Performance Test Section in Techni- ing (1).
cal Manual) NOTE: If it is difficult to remove spring (41) and
check valve (40) from housing (1), a mag-
8. Loosen cap (30) via its hexagonal part to remove net can be used.
main relief valve (39) from housing (1).
: 41 mm 14. Clamp cap (45) at its hexagonal part into a vise.
Remove seat (48) to remove ball (46) from the
IMPORTANT: Do not disassemble pilot seat (26) hexagonal cap.
for being pressed under cap (30). : 27 mm
9. Pull sleeve (21) out from cap (30). Remove spring
(23) and main poppet (22) from sleeve (21).
IMPORTANT: Put matching marks on between ad-

justing screw (38) and sleeve (34) as
well as taking note of turning
amount of adjusting screw.
10. Loosen lock nut (36). Remove adjusting screw
(38) from sleeve (34) to remove piston (35),
spring (28) and poppet (27).
: 41 mm, 22 mm
IMPORTANT: Put matching marks on between

sleeve (34) and cap (30) as well as
take a note of turning amount of
sleeve.
11. Loosen lock nut (31). Remove sleeve (34) from
cap (30).
: 30 mm, 27mm
W2-5-19
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
49
50
51
52
53
54
55
56
57
58
59
60
61
20
W17P-02-05-004
W2-5-20
Disassemble Overload Relief Valve (20) Disassemble Make-up Valve (61)
IMPORTANT: Do not disassemble overload relief 19. Loosen hexagonal part of sleeve (52) to remove
valves (20) (4 used) unless neces- make-up valve (61) from housing (1).
sary, because its adjustment on the : 41 mm
test bench should be carried out.
(Refer to Troubleshooting / Opera- 20. Clamp sleeve (52) at its hexagonal part in a vise.
tional Performance Test Section in Remove cap (60) to remove spring (57) and pop-
Technical Manual) pet (53) from sleeve (52).
Keep overload relief valves (4 used) : 36 mm
with tag attached in order to set NOTE: Push poppet (53) out to the cap (60) side
them to their original position before with a pipe.
being removed.
15. Loosen sleeve (5) via its hexagonal part to re-
move overload relief valves (20) (4 used) (2 for
upper and 2 for lower) from housing (1).
: 41 mm
16. Clamp sleeve (5) at its hexagonal part into a vise.

Loosen seat (14) via its hexagonal part to remove
seat assemblies (10 to 19). Remove springs (9
and 8), piston (7) and poppet (6) from the sleeve.
: 36 mm
17. Clamp seat (14) at its hexagonal part into a vise.

Clamp adjusting screw (18) into a wrench, remove
lock nut (19).
: 19 mm
: 6 mm
IMPORTANT: Put matching marks on adjusting

screw (18) and seat (14) as well as
taking note of the turning amount of
the adjusting screw.
18. Remove adjusting screw (18) from seat (14) while
counting the turning amount of the adjusting
screw.
Remove spring (16) and pilot poppet (15) from the
seat.
W2-5-21
ASSEMBLE CONTROL VALVE (4-SPOOL
SECTION)
Assemble Spool, Check Valve and Flow Combin-
ing Valve
Check Valve
Upper Lower
Flow
Combining
Valve
W16J-02-05-019
W17V-02-05-002
Section A 11 12 Section B
3 4 7 6 5
Check Valve
10
9 14
16 17 20 18 19 21
8 15
1
22
2
23
26
13 25 W162-02-04-027
24
27
11, 32, 33
W17V-02-05-007
11, 31, 32 28 29 30
1- Housing 10 - Cover 19 - Backup Ring 27 - Cap

2- Spool (Arm 2) 11 - O-Ring (4 Used) 20 - Chip 28 - O-Ring (4 Used)
3- Spring Guide (4 Used) 12 - Cap 21 - Cap 29 - Cover
4- Sleeve (4 Used) 13 - Spool (Boom 1) 22 - Spool 30 - Socket Bolt (8 Used)
5- Spring (4 Used) 14 - Spool (Bucket) 23 - Spacer 31 - Cover (2 Used)
6- Spring Guide (4 Used) 15 - Spool (Travel Right) 24 - Spring 32 - Plug (3 Used)
7- Bolt (4 Used) 16 - Check Valve 25 - O-Ring 33 - Cover
8- O-Ring (4 Used) 17 - Spring 26 - Chip
9- Socket Bolt (8 Used) 18 - O-Ring
W2-5-22
Assemble Control Valve (4-Spool Section)
• Be sure to read “Precautions for Disassembly and 5. Install cover (10) onto housing (1) with socket
Assembly Work” thoroughly on page W1-1-1 be- bolts (9) (8 used).
fore starting the assembly work. : 10 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
Assemble Spool
1. Install O-rings (28) (4 used) into housing (1). In- Assemble Check Valve
stall covers (29), (31) (2 used) and (33) into the IMPORTANT: Chip (20) prevents cap (21) from be-
housing with socket bolts (30) (8 used). ing pulled and loosening.
: 10 mm The chip will be damaged when the
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) cap being removed because it is
made of nylon. Be sure to replace
2. Install O-rings (11) (3 used) onto plugs (32) (3 the chip with a new one.
used). Install the plug onto covers (31) (2 used) 6. Install backup ring (19), O-ring (18), chip (20) into
and (33). cap (21).
: 19 mm Insert spring (17) into check valve (16).
: 78.5 N⋅m (8 kgf⋅m, 58 lbf⋅ft) Install the check valve, cap into housing (1).
: 14 mm
IMPORTANT: Apply LOCTITE to the bolt (7) hole of : 343 N⋅m (35 kgf⋅m, 255 lbf⋅ft)
each spool (2 and 13 to 15).
3. Clamp each spool (2 and 13 to 15) into a vise with Assemble Flow Combining Valve
wooden spatulas inserted at both sides. IMPORTANT: Apply hydraulic oil to spool (22).
Install O-rings (8) (4 used) into housing (1). 7. Slowly turn spool (22) to install it into housing (1).
Install spring guide (3), sleeve (4), spring (5), Install spacer (23) onto the spool.
spring guide (6) into spools (2 and 13 to 15). In-
stall bolt (7) to the each spool. IMPORTANT: Chip (26) prevents cap (27) from be-
: 10 mm ing pulled and loosening.
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) The chip will be damaged when the
cap being removed because it is
IMPORTANT: Apply hydraulic oil to the surface of made of nylon.
spools (2 and 13 to 15). Be sure to replace the chip with a
Install each spool into the original new one.
positions before disassembling. 8. Install O-ring (25), chip (26) into cap (27).
4. Install each spool (2 and 13 to 15) assemblies into Install spring (24) and the cap into housing (1).
housing (1) while rotating them respectively. : 46 mm
NOTE: When unable to install the spool smoothly, : 176.5 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
stop installing. Pull out the spool slowly and
try to install it again. As soon as the spool
(2), (13), (14) assemblies touches plug (32),
rotate the spool to align the spool stop pin
with the plug. Press the spool down while
no reactive force coming from the plug be-
ing felt.
W2-5-23
Assemble Valves
Upper Lower
20 1
39
C
61
D
Front Front
A
1
D C B
61 20 W17V-02-05-002
Shuttle Valve
W16J-02-05-019
Section A
Main Relief Valve (39)
Section B
22 21 24 26 28 29 30 31 34 36 38
Shuttle Valve
40 43 45 46 47 48
23 25 27 32 33 35 37
W162-02-04-023
W183-02-05-007 41 42 44
NOTE: As for sections C and D in detail, refer to

W2-5-26.
1- Housing 17 - O-Ring (4 Used) 32 - O-Ring 47 - O-Ring
W2-5-24
Assemble Main Relief Valve (39)
IMPORTANT: As for sleeve (34), it should be IMPORTANT: Be sure to perform adjustment to the
screwed in only by the same amount main relief valve (39). (Refer to Trou-
to removal so that the matching bleshooting / Operational Perform-
marks can be aligned. ance Test Section in Technical Man-
9. Install lock nut (31), O-rings (33 and 32) into ual)
sleeve (34). Install the sleeve into cap (30) and 16. Install main relief valve (39) into housing (1).
tight the lock nut. : 41 mm
: 41 mm : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) NOTE: Tighten cap (30) via its hexagonal part.
10. Install poppet (27), spring (28) and piston (35) Assemble Shuttle Valve
onto cap (30). 17. Install O-ring (47) onto seat (48).
IMPORTANT: As for adjusting screw (38), it should 18. Clamp cap (45) via its hexagonal part in a vise.
be screwed in only by the same Install ball (46) and seat (48) into the cap.
amount to removal so that the : 27 mm
matching marks can be aligned cor- : 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft)
rectly.
11. Install lock nut (36), O-ring (37) into adjusting 19. Install O-ring (44), backup ring (43) and O-ring
screw (38). Install the adjusting screw into sleeve (42) into cap (45).
(34) and tighten the lock nut.
: 22 mm 20. Install spring (41) into check valve (40).
: 30 mm Install the check valve and cap (45) onto housing
: 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft) (1).
: 41 mm
12. Install backup ring (25) and O-ring (24) onto pilot : 176.5 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
seat (26).
13. Install main poppet (22), spring (23) into sleeve

(21).
14. Install the sleeve (21) assembly into cap (30).
15. Install O-ring (29) into cap (30).
W2-5-25
Assemble Valves
Upper Lower
20 1
C
61
D
Front
Front
A
1
D C B
61 20 Shuttle Valve W17V-02-05-002
W16J-02-05-019
Section C
Overload Relief Valve (20)
2 7 6 4 5 9 16 14 17 Section D
Make-up Valve (61)
49 53 54 51 57 52 58 60
3 8 10 11 12 15 13 18 19
W162-02-04-022
50 55 56 59
NOTE: As for sections A and B in detail, refer to W162-02-04-028
W2-5-24.
1- Housing 17 - O-Ring (4 Used) 32 - O-Ring 47 - O-Ring
W2-5-26
Assemble Overload Relief Valve (20) Assemble Make-up Valve (61)
21. Install O-ring (13), backup rings (12 and 11) and 27. Install backup ring (59) and O-ring (58) into cap
O-ring (10) onto seat (14). Install O-ring (17) onto (60).
adjusting screw (18).
28. Install O-ring (51), backup ring (50) and O-ring
IMPORTANT: As for adjusting screw (18), it should (49) into sleeve (52).
be screwed in only by the same
amount to removal, so that the
matching marks can be align cor- 29. Install backup rings (54 and 55) and O-ring (56)
rectly. into poppet (53).
22. Install pilot poppet (15), spring (16), adjusting
screw (18), lock nut (19) onto seat (14). 30. Install poppet (53) and spring (57) into sleeve
: 6 mm (52).
: 19 mm
: 31.5 N⋅m (3.2 kgf⋅m, 23 lbf⋅ft) 31. Clamp sleeve (52) at its hexagonal part into a
vise.
23. Install O-ring (4), backup ring (3), O-ring (2) into Install cap (60) on the sleeve.
sleeve (5). : 36 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
24. Install piston (7) into main poppet (6). Install the
main poppet into sleeve (5). 32. Install make-up valve (61) into housing (1).
: 41 mm
25. Install springs (9 and 8) into the seat (14) assem- : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
bly. Install the seat assembly into sleeve (5).
: 36 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
IMPORTANT: Install overload relief valve (20) to its

position where it was removed.
Be sure to perform adjustment to the
valve on test bench.
tional Performance Test Section in
Technical Manual)
26. Install overload relief valves (20) (4 used) (2 for
upper and 2 for lower) into housing (1).
: 41 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
NOTE: Tighten sleeve (5) via its hexagonal part.
W2-5-27
DISASSEMBLE CONTROL VALVE (SIDE
SECTION)
5-Spool Section
36
33 35
Holding Valve 34 44
32 4
37
3 43
30 38 By-Pass Cut Valve
31 42
21 41
2
22
23 20 40
24
19
25
18 39
26
27
28 17
29
Load Check Valve
13 14 15 16
11 7 7 7 7
6 6 6 6
7
5 5 5 5
6 12 12 12 12
5 10 10 10 10
10 46
9 9 9 9
9
45
4 7
6
5
W16J-02-05-005
1- Housing 8- Cap (2 Used) 15 - Cap 22 - O-Ring (2 Used)
2- O-Ring (6 Used) 9- Check Valve (6 Used) 16 - Cap 23 - O-Ring (2 Used)
3- Flange (6 Used) 10 - Spring (6 Used) 17 - Poppet (2 Used) 24 - Backup Ring (2 Used)
4- Socket Bolt (22 Used) 11 - Cap (2 Used) 18 - Spring (2 Used) 25 - Sleeve (2 Used)
5- O-Ring (10 Used) 12 - Check Valve (5 Used) 19 - O-Ring (2 Used) 26 - Poppet (2 Used)
6- Backup Ring (10 Used) 13 - Cap 20 - Backup Ring (2 Used) 27 - Spring (2 Used)
7- Chip (11 Used) 14 - Cap 21 - Backup Ring (2 Used) 28 - O-Ring (2 Used)
W2-5-28
4-Spool Section
39
By-Pass Cut Valve
40
41
42
43 2
45 44
3
46
4
45
46
5
6 29
28
7 27
8 26
5
6 25
9 24
7 17 23
10 11 18
47 22
12
10 19 21
50 5
5 20
7 6 31
6
51 38 30
7 7
2
49 48 37 Holding Valve
3
34 32
Load Check Valve 35
4 36 33
W16J-02-05-008
29 - Cap (2 Used) 35 - O-Ring (2 Used) 41 - O-Ring (2 Used) 47 - Check Valve

30 - O-Ring (2 Used) 36 - Cap (2 Used) 42 - Backup Ring (2 Used) 48 - Cap
31 - Cap (2 Used) 37 - Cover (2 Used) 43 - Chip (2 Used) 49 - Cap
32 - Washer (2 Used) 38 - O-Ring (2 Used) 44 - Cap (2 Used) 50 - O-Ring
33 - Socket Bolt (8 Used) 39 - Spring (2 Used) 45 - Washer (11 Used) 51 - Cap
34 - Piston (2 Used) 40 - Spool (2 Used) 46 - Socket Bolt (11 Used)
W2-5-29
NOTE: 5-spool section is illustrated here.
36
33 35
Holding Valve 34 44
32 4
37
3 43
30 38 By-Pass Cut Valve
31 42
21 41
2
22
23 20 40
24
19
25
18 39
26
27
28 17
29
Load Check Valve
13 14 15 16
11 7 7 7 7
6 6 6 6
7
5 5 5 5
6 12 12 12 12
5 10 10 10 10
10 46
9 9 9 9
9
45
4 7
6
5
W16J-02-05-005
W2-5-30
Disassemble Control Valve (Side Section)
Disassemble Holding Valve Disassemble Load Check Valve
1. Remove socket bolts (33) (4 used) and washers IMPORTANT: Attach tags on caps (11 and 13 to 16)
(32) (4 used) to remove the cover (37) assembly so that they can be installed to the
(holding valve) from housing (1). original position on housing (1).
: 12 mm 6. Remove caps (11 and 13 to 16) to remove check
valve (12), spring (10), check valve (9) from hous-
2. Remove spring (18) and poppet (17) from housing ing (1).
(1). : 14 mm
NOTE: If poppet (17) is difficult to remove, a mag- NOTE: Check valve (12) is not used in cap (11)
net can be used. part.
IMPORTANT: After long term operation, poppet Disassemble By-Pass Cut Valve
(26) can not be pulled out from 7. Remove cap (44) to remove spring (40) and
sleeve (25) for the seat surface being spring (39) from housing (1).
deformed, replace sleeve (25) and : 46 mm
the poppet together.
3. Remove cap (36) to remove piston (34) from
cover (37).
: 10 mm
4. Remove cap (29) to remove spring (27) and pop-

pet (26) from cover (37).
: 10 mm
5. Insert a pipe (inside dia. 10 mm (0.39 in), outside

dia. 14 mm (0.55 in)) to touch sleeve (25) from
cap (36) side. Tap the pipe with a hammer to push
the sleeve out of cover (37).
W2-5-31
ASSEMBLE CONTROL VALVE (SIDE SEC-
TION)
NOTE: 5-spool section is illustrated here.
Upper 1 Holding Valve 1 5, 6, 7, 8

Side
11
32, 33 13
A
Load Check
14 Valve
15
B
16
4
By-pass Cut Valve
2, 3
W16J-02-05-010 45, 46
Section A
17 18 19 20 38 36 35 34 26 W16J-02-05-016
Section B
37
21
22
23 44
24
25
27
30
31
29 28
43 41 42
W16J-02-05-014
40 39
13
9 10 7 12 5 6 W16J-02-05-015
1- Housing 13 - Cap 25 - Sleeve 36 - Cap

2- O-Ring (4 Used) 14 - Cap 26 - Poppet 37 - Cover
3- Flange (4 Used) 15 - Cap 27 - Spring 38 - O-Ring
4- Socket Bolt (16 Used) 16 - Cap 28 - O-Ring 39 - Spring
5- O-Ring 17 - Poppet 29 - Cap 40 - Spool
6- Backup Ring 18 - Spring 30 - O-Ring 41 - O-Ring
7- Chip 19 - O-Ring 31 - Cap 42 - Backup Ring
8- Cap 20 - Backup Ring 32 - Washer 43 - Chip
9- Check Valve 21 - Backup Ring 33 - Socket Bolt 44 - Cap
10 - Spring 22 - O-Ring 34 - Piston 45 - Washer (4 Used)
11 - Cap 23 - O-Ring 35 - O-Ring 46 - Socket Bolt (4 Used)
12 - Check Valve 24 - Backup Ring
W2-5-32
Assemble Control Valve (Side Section)
Assemble Holding Valve Assemble Load Check Valve
1. Install backup rings (24 and 21) and O-rings (23 IMPORTANT: Chips (7) prevents caps (11 and 13 to
and 22) onto sleeve (25). 16) from being pulled and loosening.
NOTE: Be sure to install O-rings (22 and 23) and The chips will be damaged when the
backup rings (21 and 24) in right direction. caps are removed because they are
made of nylon.
2. Push sleeve (25) into cover (37) with a round bar. Be sure to replace the chips with
Install poppet (26) and spring (27) into the sleeve. new ones.
7. Install backup ring (6), O-ring (5) and chip (7) onto
3. Install O-rings (28 and 35) into caps (29 and 36). caps (11 and 13 to 16).
Install piston (34) and the caps into cover (37). Install spring (10) into check valve (9).
Install check valve (9), check valve (12) into hous-
: 10 mm
ing (1).
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
Then install the caps onto the housing.
: 14 mm
IMPORTANT: Apply grease to O-ring (38).
: 343 N⋅m (35 kgf⋅m, 255 lbf⋅ft)
4. Install backup ring (20), O-rings (19 and 38) into
cover (37). NOTE: Check valve (12) is not used in cap (11)
port.
5. Install poppet (17) and spring (18) into housing
(1). Assemble By-Pass Cut Valve
IMPORTANT: Chip (43) prevents cap (44) from be-
6. Place washers (32) onto socket bolts (33) (4 ing pulled and loosening.
used) respectively. The chip will be damaged when the
Install the cover (37) assembly (holding valve) into cap is removed because it is made
housing (1) with the socket bolts (4 used). of nylon.
: 12 mm Be sure to replace the chip with a
: 176.5 N⋅m (18 kgf⋅m, 130 lbf⋅ft) new one.
8. Install backup ring (42), O-ring (41), chip (43) onto
cap (44).
9. Install spring (39), spool (40) and cap (44) into

housing (1).
: 46 mm
: 245 N⋅m (25 kgf⋅m, 180 lbf⋅ft)
W2-5-33
DISASSEMBLE HOUSING
Upper Lower
1 2 3 4 9 10
11
6
8
7
W16J-02-05-010
W16J-02-05-017
14 13 12 14
W16J-02-05-018
1- Housing (4- Spool Section) 5- Housing (5-Spool Section) 9 - Bolt Hole (M20) 12 - Socket Bolt (14 Used)
2- Socket Bolt (7 Used) 6- Bolt Hole (M12) 10 - Bolt Hole (M20) 13 - Bolt Hole (M16)
3- Bolt Hole (M12) 7- Socket Bolt (4 Used) 11 - Socket Bolt 14 - Manifold
4- Socket Bolt (6 Used) 8- Bolt Hole (M12)
W2-5-34
Disassemble Housing
• Be sure to read “Precautions for Disassembly and
CAUTION: Manifold assembly weight:
Assembly Work” thoroughly on page W1-1-1 be-
100 kg (220 Ib)
7. Install eyebolt (M16, Pitch 2.0) into the bolt (13)
• The disassembly procedure below starts on the
hole in manifold (14) and hold it by crane.
premise that all valves both on 5-spool section
and 4-spool section have been removed. NOTE: Install the eyebolts at two places diagonally.
IMPORTANT: When placing 4-spool section hous- 8. Remove socket bolts (11) and (12) (14 used).
ing (1) and 5-spool section housing : 14 mm
(5) or manifold with their mounting
surfaces touching on work bench, 9. Remove the manifold (14) assembly by crane.
lay a rag or shop cloth to prevent
scratching the mounting surface.

(880 Ib)
1. Install eyebolts (M12, Pitch 1.75) into bolt holes (3,
6 and 8). Lift and place control valve on work
bench by crane with housing (1) side of 4-spool
section facing down.
2. Remove socket bolts (7) (4 used).

: 14 mm
3. Lift and place control valve with housing (5) side

of 5-spool section facing down.
CAUTION: 4-spool section housing assem-

bly weight: 150 kg (330 Ib)
4. Install each eyebolts (M12, Pitch 1.75 and M20,
Pitch 2.5) into bolt holes (8 and 10). Attach wire
ropes to the eyebolts to hold in position by crane.
5. Remove socket bolts (4) (6 used) and (2) (7

used).
: 14 mm
6. Remove the 4-spool section housing (1) assembly

by crane.
W2-5-35
ASSEMBLE HOUSING
Upper Lower
1 2 3 4 9 10
11
6
8
W16J-02-05-017
W16J-02-05-010
14 13 12 14
W16J-02-05-018
1- Housing (4- Spool Section) 5- Housing (5-Spool Section) 9 - Bolt Hole (M20) 12 - Socket Bolt (14 Used)
2- Socket Bolt (7 Used) 6- Bolt Hole (M12) 10 - Bolt Hole (M20) 13 - Bolt Hole (M16)
3- Bolt Hole (M12) 7- Socket Bolt (4 Used) 11 - Socket Bolt 14 - Manifold
4- Socket Bolt (6 Used) 8- Bolt Hole (M12)
W2-5-36
Assemble Housing
• Be sure to read “Precautions for Disassembly and 5. Hoist 4-spool section housing (1) by crane and
Assembly Work” thoroughly on page W1-1-1 be- align it with manifold (14).
fore starting the assembly work. Install socket bolts (2) (7 used) and (4) (6 used).
: 14 mm
IMPORTANT: When placing 5-spool section hous- : 245 N⋅m (25 kgf⋅m, 180 lbf⋅ft)
ing (5) and 4-spool section housing
(1) and manifold with their mounting
surfaces touching on work bench,
(880 Ib)
lay a rag or shop cloth to prevent
6. Install eyebolts (M12, Pitch 1.75) into bolt holes (3,
scratching the mounting surface.
6 and 8). Hoist and place the control valve on
work bench by crane with the side surface of 4-
CAUTION: 5-spool section housing assem- spool section housing (1) facing down.
1. Install eyebolts (M12, Pitch 1.75 and M20, Pitch 7. Install socket bolts (7) (4 used).
2.5) into bolt holes (6 and 9). Lift and place the 5- : 14 mm
spool section housing (5) assembly on work : 245 N⋅m (25 kgf⋅m, 180 lbf⋅ft)
bench by crane with the side facing down.
CAUTION: Manifold assembly weight: 100 kg

(220 Ib)
2. Install eyebolts (M16, Pitch 2.0) onto bolt (13) hole
in manifold (14).
NOTE: Install the eyebolts at two places diagonally.
3. Hoist manifold (14) by crane and align it with 5-

spool section housing (5).
Install socket bolts (12) (14 used) and (11).
: 14 mm
: 245 N⋅m (25 kgf⋅m, 180 lbf⋅ft)

4. Install eyebolts (M12, Pitch 1.75 and M20, Pitch
2.5) into bolt holes (8) and (10).
W2-5-37
DISASSEMBLE MANIFOLD 32
31
30
29
Arm Regenerative Valve
28
27
26
25
15 24
23 39
22 38
13 21
37
20
36
19
16 35
18
34
Check Valve 2
33
17 13
14 12
15
11
12
40
11
41
10
9
8 2
44 3
6 Check Valve 1
4
5 5
6
7
1
8
11
12
11
11 42
33
42
Check Valve 2 34
36
37
38
13
43
13 15 17
W17V-02-05-008
1- Manifold 12 - Socket Bolt (7 Used) 23 - Piston 34 - Spring (2 Used)

2- Spring Guide 13 - O-Ring (8 Used) 24 - Spool 35 - Check Valve
3- Spring 14 - O-Ring 25 - Spring 36 - O-Ring (2 Used)
4- Check Valve 15 - O-Ring (14 Used) 26 - O-Ring 37 - Backup Ring (2 Used)
5- O-Ring (2 Used) 16 - O-Ring 27 - Backup Ring 38 - Chip (2 Used)
6- Backup Ring (2 Used) 17 - O-Ring (2 Used) 28 - O-Ring 39 - Cap
7- Seat 18 - Check Valve 29 - Sleeve 40 - O-Ring
8- O-Ring (2 Used) 19 - Spring 30 - Spring Guide 41 - Cap
9- O-Ring 20 - Sleeve 31 - O-Ring 42 - Socket Bolt (14 Used)
10 - Cap 21 - O-Ring 32 - Cap 43 - Cap
11 - Washer (32 Used) 22 - Backup Ring 33 - Check Valve (2 Used) 44 - Plug
W2-5-38
Disassemble Manifold
• Be sure to read “Precautions for Disassembly 6. Remove spring guide (30), spring (25), spool (24)
and Assembly Work” thoroughly on page W1-1- from manifold (1).
1 before starting the disassembly work.
7. Screw special tool (ST 1469) to sleeve (20) to pull
IMPORTANT: When placing the manifold with its it out.
housing mounting surface on work
20
bench, lay a rag or shop cloth to
prevent scratching the mounting
surface.

1. Remove the 4-spool section housing assembly. ST 1469
W183-02-05-015
(Refer to Disassemble Housing on page W2-5-
35)
8. Remove piston (23), spring (19), check valve (18)
from sleeve (20).
2. Remove O-rings (13) (4 used), (15) (6 used) and
(17) from manifold (1). NOTE: In case spring (19) and check valve (18)
are remained in manifold (1), remove them
with a magnet.
bly weight: 150 kg (330 Ib) Disassemble Check Valve 1
3. With manifold (1) facing down, remove the 5- 9. Insert a round bar (approx. dia. 15 mm (0.59 in))
spool section housing assembly. (Refer to Disas- from the side of spring guide (2) and tap on the
semble Housing on page W2-5-35) bar with a hammer to remove seat (7).
4. Remove O-rings (13) (4 used), (14), (15) (8 used), 10. Remove check valve (4), spring guide (2), spring
(16), (17) from manifold (1). (3) and O-ring (8) from manifold (1).
NOTE: In case it is difficult to remove check valve
Disassemble Regenerative Valve
(4) or similar parts, a magnet can be used.
CAUTION: When removing sleeve (29), it will
pop out due to the action force from spring Disassemble Check Valve 2
(25). 11. Remove caps (39 and 43) to remove check valve
The sleeve should be removed while press- (35), spring (34), check valve (33) from manifold
ing it. (1).
IMPORTANT: When removing sleeve (29), take : 14 mm
care not to drop spring guide (30) NOTE: Check valve (35) is not used in the port of
and spring (25). cap (43). In case it is difficult to remove
5. Loosen sleeve (29) and remove it while pressing spring (34) and check valve (33), a magnet
it. can be used.
: 46 mm
W2-5-39
ASSEMBLE MANIFOLD
4-Spool Section 11, 42 1 5-Spool Section
13 13
14
Check 11, 12
Valve1
15 9, 10
15
11, 12 A
B 15
15 Arm Regen-
erative Valve 43
C 15 15
17 40, 41
16
13 13 W16J-02-05-018
Section A
Arm Regenerative Valve
28 24 21, 22 20 19 18
31 30 29 25
32
23 27 26
W183-02-05-012
Section B Section C
39
Check Valve 1 7 6 Check Valve 2
8
36 37
35
2 34 38
33
W16J-02-05-020
3 4 5
W162-02-04-030
1- Manifold 12 - Socket Bolt (7 Used) 23 - Piston 34 - Spring (2 Used)
2- Spring Guide 13 - O-Ring (8 Used) 24 - Spool 35 - Check Valve
3- Spring 14 - O-Ring 25 - Spring 36 - O-Ring (2 Used)
4- Check Valve 15 - O-Ring (14 Used) 26 - O-Ring 37 - Backup Ring (2 Used)
5- O-Ring (2 Used) 16 - O-Ring 27 - Backup Ring 38 - Chip (2 Used)
6- Backup Ring (2 Used) 17 - O-Ring (2 Used) 28 - O-Ring 39 - Cap
7- Seat 18 - Check Valve 29 - Sleeve 40 - O-Ring
8- O-Ring (2 Used) 19 - Spring 30 - Spring Guide 41 - Cap
9- O-Ring 20 - Sleeve 31 - O-Ring 42 - Socket Bolt (14 Used)
10 - Cap 21 - O-Ring 32 - Cap 43 - Cap
11 - Washer (32 Used) 22 - Backup Ring 33 - Check Valve (2 Used) 44 - Plug
W2-5-40
Assemble Manifold
• Be sure to read “Precautions for Disassembly Assemble Arm Regenerative Valve
and Assembly Work” thoroughly on page W1-1- 5. Install O-ring (28), backup ring (27) and O-ring
1 before starting the assembly work. (26) into sleeve (29).
Assemble Check Valve 1 6. Install piston (23), backup ring (22) and O-ring
1. Install check valve (4), spring (3) and spring guide (21) into sleeve (20).
(2) into manifold (1). Install sleeve (20) into sleeve (29).
2. Install backup ring (6) and O-ring (5) onto seat (7). 7. Install spring (19) into check valve (18). Install the
check valve into sleeve (20).
IMPORTANT: Apply grease to O-ring (8). Then install the sleeve (29) assembly into mani-
3. Install seat (7) and O-ring (8) onto manifold (1). fold (1).
: 46 mm
Assemble Check Valve 2 : 176.5 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
IMPORTANT: Chips (38) prevents caps (39 and 43)
from being pulled and loosening. 8. Install spool (24), spring (25), spring guide (30)
The chips will be damaged when the into sleeve (29) from the cap (32) hole.
caps are removed because they are
made of nylon. 9. Install O-ring (31) onto cap (32). Install the cap
Be sure to replace the chips with onto sleeve (29).
new ones. : 12 mm
4. Install backup ring (37), O-ring (36) and chip (38) : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
into caps (39 and 43).
Install spring (34) into check valve (33).
Install check valve (33) and check valve (35) into
manifold (1).
Install the cap to the manifold.
: 14 mm
: 343 N⋅m (35 kgf⋅m, 255 lbf⋅ft)
NOTE: Check valve (35) is not used in the port of
cap (43).
W2-5-41
4-Spool Section 1 5-Spool Section

13 13
14
15
15
A
B 15
15
C 15 15
17
16
17
13 13 W16J-02-05-018
Section A
W183-02-05-012
Section B Section C
W16J-02-05-020 W162-02-04-030
W2-5-42
Assemble manifold
IMPORTANT: Apply grease to O-rings (13) (4 used),
(14), (15) (8 used), (16) and (17).
10. Install O-rings (13) (4 used), (14), (15) (8 used),
(16), (17) onto the 5-spool section of manifold (1).
CAUTION: Manifold assembly weight:

100 kg (220 Ib)
11. Install manifold (1) to the 5-spool section of hous-
ing.
(Refer to Assemble Housing on page W2-5-37)
IMPORTANT: Apply grease onto O-rings (13) (4 used),

(15) (6 used) and (17).
12. Install O-rings (13) (4 used), (15) (6 used) and
(17) to the 4-spool section of manifold (1).

13. Install 4-spool section housing into manifold (1).
(Refer to Assemble Housing on page W2-5-37)
W2-5-43
(Blank)
W2-5-44
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE
CAUTION: Escaping fluid under pressure can

penetrate the skin and eyes, caus-
ing serious injury. Avoid this haz-
ard by relieving pressure before
disconnecting hydraulic lines.
Hydraulic oil may be hot after op-
eration and may spurt, possibly
causing severe burns. Be sure to
wait for oil to cool before starting
any repair work.
The hydraulic oil tank cap may fly
off due to remaining pressure if
removed quickly. Slowly loosen
the cap to release any remaining
pressure completely.
Preparation

in the system. Rotate the hydraulic oil tank cap M104-07-021

oil tank. Refer to Bleeding Air from Hydraulic Sys- Cap
tem on page W1-1-2.
: 4 mm

tank.

W183-01-01-001
W2-6-1
Removal
1 2 3 4 5 6 7
IMPORTANT: Attach identification tags to the
hoses for easier reassembly.
1. Disconnect hoses (1 to 5), (8 to 11). Cap the dis-
connected hose ends.
: 17 mm, 19 mm, 22 mm, 27 mm, 41 mm
15
8
2. Remove socket bolts (14) (16 used) from split
flanges (15) (4 used) to disconnect hoses (6, 7, 12
and 13) from swing device.
: 8 mm
9
10
3. Put matching marks to main frame and the hous- 11
ing of reduction gear.
14 13 12
Remove adapters (20), (21), bolts (18) (14 used), M17V-07-046
spacers (19) (14 used) and knock pins (17) (2

1- Hose PS: To pressure sensor (Arm clowd)
used).
2- Hose 2A: To right SH port in swing device
Adapter: PT 1/2 3- Hose D7: To right DB port in swing device
: 36 mm 4- From front lower manifold side of control valve
5- From front upper manifold side of control valve
6- From swing right pipe at 5-spool side of control valve
4. Remove corks (16) (2 used) from the housing of 7- From swing left pipe at 5-spool side of control valve
reduction gear with driver. 8- Hose SH: To right SH port in swing device
9- Hose SH: To right SH port in signal control valve
10 - Hose PE: To C port in check valve
11 - Hose D6: To hydraulic oil tank
CAUTION: Swing device weight:
12 - From swing right pipe at 5-spool side of control valve
470 kg (1040 Ib) 13 - From swing left pipe at 5-spool side of control valve
5. Set pulling bolts (M24, Pitch 2.5) (2 used) to the
16 17
holes for the removed corks (16).
18
6. Turn pulling bolt to float swing device from the 18 19
main frame.
19
Attach nylon slings to the body of swing motor, lift
and remove the swing device from the main frame 20
by crane. 17
21
16
7. Remove the other swing device in same proce-
dures.
W17V-02-06-001
Nylon Slings
Motor
W155-02-06-012
W2-6-2
Installation
1. Apply fluid packing to the mounting side of reduc-

tion gear on the main frame.
CAUTION: Swing device weight:

470 kg (1040 Ib)
IMPORTANT: Align the matching marks put during 16 17
disassembling.
18
2. Align the swing device with the position for knock
18 19
pin and lower it to main frame mounting surface,
tap in knock pins (17) (2 used). 19
20
3. Install the swing device with spacers (19) (14
used), bolts (18) (14 used), insert new corks (16) 17
21
(2 used) to the pulling hole. 16
Install adapters (20), (21).
: 36 mm
: 950 N⋅m (97 kgf⋅m, 700 Ibf⋅ft)
W17V-02-06-001
Adapter: PT 1/2
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
1 2 3 4 5 6 7
4. Install the other swing device in same procedures.
5. Connect hoses (6, 7, 12, 13) to swing motor with

split flanges (15) (4 used) and tightening it with
socket bolts (14) (16 used).
15
: 8 mm
8
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
9
10
11
14 13 12
M17V-07-046

3- Hose D7: To right DB port in swing device
4- From front lower manifold side of control valve
7- From swing left pipe at 5-spool side of control valve
8- Hose SH: To right SH port in swing device
13 - From swing left pipe at 5-spool side of control valve
W2-6-3
6. Connect hoses (1 to 5, 8 to 11).
: 17 mm 1 2 3 4 5
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft) 8
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 Ibf⋅ft)
IMPORTANT: After installing, check the oil level. 9

Check for any oil leaks after starting 10
the engine. 11
M17V-07-046

3- Hose D7: To right DB port in swing device
4- From front lower manifold side of control valve
7- From swing left pipe at 5-spool side of control valve
8- Hose SH: To right SH port in swing device
13 - From swing left pipe at 5-spool side of control valve
W2-6-4
(Blank)
W2-6-5
DISASSEMBLE SWING DEVICE
20
1
19
21
21
22 2
24
23
24
3
25
4
18 5
26
13
6
15
27
17
16
28 7
29 15
30
14 5
31
32 13
8
33 11
12
11
9
10
34
W17V-02-06-002
1 - Motor 10 - Bearing 19 - Spring Washer (12 Used) 27 - Cover
2 - Ring Gear 11 - Thrust Plate (6 Used) 20 - Bolt (12 Used) 28 - Socket Bolt (10 Used)
3 - Ring Gear 12 - Second Stage Planetary 21 - Pin (3 Used) 29 - Oil Seal
Gear (3 Used)
4 - First Stage Sun Gear 13 - Spring Pin (6 Used) 22 - Housing 30 - Screw (4 Used)
5 - Thrust Plate (2 Used) 14 - Pin (3 Used) 23 - Plug 31 - Magnet (4 Used)
6 - First Stage Carrier 15 - Thrust Plate (6 Used) 24 - Cock (2 Used) 32 - Sleeve
7 - Second Stage Sun Gear 16 - Needle Bearing (3 Used) 25 - Bearing 33 - O-Ring
8 - Second Stage Carrier 17 - First Stage Planetary 26 - O-Ring 34 - Shaft
Gear (3 Used)
9 - Retaining Ring 18 - Pin (3 Used)
W2-6-6
Disassemble Swing Device
• Be sure to thoroughly read all “Precautions for
CAUTION: The second stage carrier (8) as-
Disassembly and Assembly” on page W1-1-1 be-
sembly weight: 44 kg (100 Ib)
6. Sling second stage carrier (8) with wires or belts.
Remove second stage carrier (8) by crane.
CAUTION: Motor weight: 70 kg (150 Ib)
1. Install eyebolts (M10, Pitch 1.5) to the motor. Put
CAUTION: Ring gear (3) weight: 32 kg (70 Ib)
matching marks on motor (1), ring gears (2 and 3),
7. Remove ring gear (3) from housing (22).
and housing (22). Loosen bolts (20) to lift and re-
move motor (1) by crane. NOTE: Insert a screw driver between ring gear (3)
: 30 mm and housing (22) to pry ring gear (3) up for
easy separation.
Eyebolt Mounting
Position
8. Remove retaining ring (9) from shaft (34).
CAUTION: Housing (22) + shaft (34) + other

parts weight: 265 kg (580 Ib)
9. Attach a nylon sling to the body of housing (22), lift
it by crane and place the housing with the motor
mounting side facing downward.
W162-02-05-010 10. Remove socket bolts (28) and cover (27). Re-
move O-ring (26) from housing (22).
2. Remove plug (23), turn cock (29) to drain oil. : 10 mm
Plug: PT 1/2
CAUTION: Ring gear (2) weight: 23 kg (50 Ib) CAUTION: Housing (22) + shaft (34) + other
3. Remove first stage sun gear (4) to remove ring parts weight: 260 kg (570 Ib)
gear (2) from ring gear (3). 11. Attach a nylon sling to the body of housing (22), lift
it by crane and place the housing with the motor
NOTE: Insert a screw driver between ring gears (2
mounting side facing upward.
and 3) to pry ring gear (2) up for easy sepa-
ration.
CAUTION: The first stage carrier (6) assem-

4. Remove the first stage carrier (6) assembly.
5. Remove second stage sun gear (7) from second

stage carrier (8).
W2-6-7
21
22
25
32
10
34
W17V-02-06-002
W2-6-8
13. Set special tool to the shaft (34) assembly.
CAUTION: Before pressing shaft (34), a pro-
Special Tool to Pull Bearing Out
tection cover (outer diameter: 420
mm (16.5 in), inner diameter: 130 Shaft
Hose Clamp
mm (5.1 in), thickness: 25 to
30mm (1.0 to 1.1 in)) should be
provided. Then, using a press to
remove the shaft with the protec-
tion cover.
Failure to use the protection
cover may result in personal in-
jury due to metal fragments fly
out if the housing (22) and/or
roller bearing (10) break.
W157-02-06-012
Use a press of capacity less than
30 tons (661400 Ib). Be sure to 34
degrease the housing inside be-
fore heating the bearing. Failure 25
to degrease may cause a fire. 32
34
10
22
Cover
Shaft
W157-02-06-013
Guide
W157-02-06-010
NOTE: The bearing (25) should be pulled out with
following special tool.
12. Push the shaft (34) assembly out from housing
Name Specification
(22) with a press.
Shaft Length: 305 mm (12 in)
Press (Bolt) Diameter: 19 mm(0.7 in)
Number: 8 used (Same in length and
with no wear and deformation at both
ends)
Cover
22
Material: S35C
Hose Standard dia. : 8-1/2
Clamp Tighten dimension: 235 to 350 mm
(9.3 to 13.8 in)
Number: 2 used
Guide Height: 230 mm (9.1 in)
W157-02-06-011
Outer dia.: 275 mm (10.8 in)
Inner dia.: 255 mm (10 in)
W2-6-9
22
25
18 5
13
6
15
27
17
16
29 15
30
31
32
8
33
12
10
34
W17V-02-06-002
W2-6-10
20. Drive spring pin (13) out from first stage carrier (6)
CAUTION: When pressing shaft (34) with a
using a round bar and a hammer.
press, be sure to do the work in-
Round bar (Dia: 5.0 mm (0.2 in), length: 50 mm
side of guide.
(2.0 in) or longer)
14. Set shaft (34) with special tool on the press.
Press
21. Remove pins (18) (3 used), first stage planetary
gears (17) (3 used), thrust plates (15) (6 used),
and needle bearings (16) (3 used) from first stage
34
carrier (6).
25 Ȁ
22. Remove thrust plate (5) from first stage carrier
32 (6).
23. Disassemble the second stage carrier (8) assem-

Guide
bly referring to steps 20 to 22 above.
NOTE: No needle bearings are used on second
stage planetary gear (12).
W157-02-06-014
CAUTION: shaft (34) + bearing (25) + other

15. Pull bearing (25) out from shaft (34) using a
press.
Ȁ
16. Remove sleeve (32) from shaft (34). Remove O-
ring (33), screws (30) (4 used) and magnets (31)
(4 used).
Ȁ
17. Remove oil seal (29) from cover (27).
18. Attach a nylon sling to the body of housing (22), lift

and turn the housing over by crane.
19. Remove bearing (10) from housing (22).
W2-6-11
ASSEMBLE SWING DEVICE
19 20 6 5 4 1 18 13
15
16
2
17
8 15
3 13
11
7
12
5
14
9 21
11
10
22
31 25
27
28 32 33 34 30 29 26 W17V-02-06-003
1 - Motor 10 - Bearing 19 - Spring Washer (12 Used) 27 - Cover

2 - Ring Gear 11 - Thrust Plate (6 Used) 20 - Bolt (12 Used) 28 - Socket Bolt (10 Used)
3 - Ring Gear 12 - Second Stage Planetary 21 - Pin (3 Used) 29 - Oil Seal
Gear (3 Used)
4 - First Stage Sun Gear 13 - Spring Pin (6 Used) 22 - Housing 30 - Screw (4 Used)
5 - Thrust Plate (2 Used) 14 - Pin (3 Used) 23 - Plug 31 - Magnet (4 Used)
6 - First Stage Carrier 15 - Thrust Plate (6 Used) 24 - Cock (2 Used) 32 - Sleeve
7 - Second Stage Sun Gear 16 - Needle Bearing (3 Used) 25 - Bearing 33 - O-Ring
8 - Second Stage Carrier 17 - First Stage Planetary 26 - O-Ring 34 - Shaft
Gear (3 Used)
9 - Retaining Ring 18 - Pin (3 Used)
NOTE: As for positions for cock (24) and plug (23),
refer to page W2-6-6.
W2-6-12
Assemble Swing Device
IMPORTANT: Set thrust plate (5) so that the sur- IMPORTANT: Apply grease to O-ring (33) and ap-
face with oil grooves faces upwards. ply LOCTITE #262 to screw (30).
1. Install thrust plate (5) in first stage carrier (6). 8. Install screws (30) (4 used), magnets (31) (4
used) and O-ring (33) to sleeve (32).
2. Install needle bearing (16) in first stage planetary
gear (17). IMPORTANT: Apply THREEBOND #1215 to the oil
seal mounting part on cover (27) and
IMPORTANT: Install thrust plates (15) with the apply grease to the lip part of oil
grooved side facing the planetary seal.
gear. Also, install the thrust plates 9. Install oil seal (29) on cover (27).
so that the bent tabs fit along the pe-
riphery of the carrier. 10. Install the cover (27) assembly to sleeve (32).
3. Install first stage planetary gear (17) and thrust
plates (15) (2 used) into first stage carrier (6).
11. Install the sleeve (32) assembly to shaft (34).
4. Align the hole in pin (18) with the spring pin (13) Ȁ
hole in first stage carrier (6). 12. Press bearing (25) into shaft (34) with a press.
5. Tap spring pin (13) into first stage carrier (6) and
pin (18) with a round bar and hammer. CAUTION: Housing weight: 145 kg (320 Ib)
Round bar (Dia. 5.0 mm (0.2 in), length 50 mm 13. Place housing (22) with the swing motor mounting
(2.0 in) or longer) side facing downward on a press.
NOTE: Be sure to tap spring pin (13) into the car-
rier and pin with its slit facing the end face 14. Install O-ring (26) in housing (22).
(motor side) of pin (18).
13 15. Press the shaft (34) assembly to housing (22) with
18 Motor Side a press and install socket bolts (28) (10 used).
: 10 mm
Slit : 110 N⋅m (11 kgf⋅m, 80 Ibf⋅ft)
CAUTION: Housing (22) + shaft (34) + other

W178-02-06-002
6. Assemble the left planetary gear (17) to first stage 16. Press bearing (10) onto shaft (34) in housing (22).
carrier in same procedure.
7. Assemble second stage carrier (8) referring to

steps 1 to 6 above.
NOTE: Thrust plate (11) has no tab to be bent. Also,
no needle bearings are used on second
stage planetary gear (12).
W2-6-13
6 5 4 1
22
W17V-02-06-003
W2-6-14
17. Install retaining ring (9) on shaft (34). 24. Install cocks (24) (2 used) to housing (22). To shut
off the port is just to turn the cock handle to hori-
zontal position.
sembly weight: 44 kg (100 Ib) NOTE: For the positions for cock (24), plug (23),
18. Lift and install the second stage carrier (8) as- refer to page W2-6-6.
sembly into housing (22) by crane.
25. Install plug (23) to cock (24).
Plug: PT 1/2
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
IMPORTANT: Apply THREEBOND #1215 to ring
gear (3) mounting face on housing
(22). 26. Fill with gear oil.
19. Align the matching marks put when disassembling, Gear Oil: 15 L (3.96 US gal.)
install ring gear (3) on housing (22).
CAUTION: Motor (1) weight: 70 kg (150 Ib)

20. Install second stage sun gear (7) into second 27. Install eyebolts (M10, Pitch 1.5) to motor (1). Lift
stage carrier (8). motor (1) by crane to install it on the swing re-
ducer with bolts (20) (12 used) and spring wash-
ers (19) (12 used).
CAUTION: The first stage carrier (6) assem-
: 30 mm
: 110 N⋅m (11 kgf⋅m, 80 Ibf⋅ft)
21. Lift and install the first stage carrier (6) assembly
onto second stage carrier (8).
Eyebolt Mounting Positions
IMPORTANT: Install first stage sun gear (4) with

the stepped end face facing down-
ward (thrust plate (5) side).
22. Install first stage sun gear (4) into first stage car-
rier (6).

IMPORTANT: Apply THREEBOND #1215 to ring
gear (2) mating face on ring gear (3).
23. Align the matching marks put when disassembling,
install ring gear (2) on ring gear (3). W162-02-05-010
W2-6-15
DISASSEMBLE SWING MOTOR
4 9
5 10
3 6
7 11
2 8 12
13
1
14
17
18
15 19
28 30
16 20
21
31
22
32
23
24
25
26
27
33
29 34
35
36
35
37
38
39
42
40
41
43
W142-02-06-004
1- Roller Bearing 12 - O-Ring 23 - Rotor 34 - Retaining Ring

2- O-Ring 13 - Friction Plate (2 Used) 24 - Push Rod (12 Used) 35 - Spacer (2 Used)
3- Valve Casing 14 - Relief Valve (2 Used) 25 - Spacer 36 - Roller Bearing
4- Socket Bolt (4 Used) 15 - Pin (2 Used) 26 - Holder 37 - Retaining Ring
5- Poppet (2 Used) 16 - Retaining Ring 27 - Retainer Plate 38 - O-Ring
6- Spring (2 Used) 17 - O-Ring 28 - Plunger (9 Used) 39 - Oil Seal
7- O-Ring (2 Used) 18 - Plate (3 Used) 29 - Shoe Plate 40 - Seal Cover
8- Plug (2 Used) 19 - Retaining Ring 30 - Plug 41 - Retaining Ring
9- Valve Plate 20 - Spacer (3 Used) 31 - O-Ring 42 - Swing Parking Brake Re-
lease Valve
10 - Spring (22 Used) 21 - Spring 32 - Casing 43 - Bolt
11 - Brake Piston 22 - Spacer 33 - Shaft
W2-6-16
Disassemble Swing Motor
• Be sure to thoroughly read all “Precautions for 7. Remove valve plate (9) from valve casing (3).
Disassembly and Assembly” on page W1-1-1 be-
fore starting the disassembly work. 8. Take springs (10) (22 used) out from casing (32).
CAUTION: Swing motor assembly weight:
Approx. 70 kg (150 Ib) 9. Install eyebolt into the screw hole (M8, Pitch 1.25)
1. Remove hydraulic oil from the drain port in swing in brake piston (11). Then lift and remove brake
motor casing (32). piston (11) from casing (32) by crane.
: 30 mm NOTE: When casing (32) is raised, tap the flange
part of the casing while removing it with
IMPORTANT: Do not disassemble relief valve (14). plastic hammer.
2. Remove relief valves (14) (2 used) from valve cas-
ing (3).
: 36 mm Screw Hole
3. Remove plugs (8) (2 used) from valve casing (3).

: 14 mm
4. Remove springs (6) (2 used) and poppets (5) (2

used) from valve casing (3).
Brake Piston (11)
5. Put a matching marks on the mating section of
W142-02-06-011
valve casing (3) and casing (32). Loosen and re- Parking Brake Re-
move socket bolts (4) (4 used). lease Valve (42)
: 17 mm
NOTE: Take care that valve casing (3) will be 10. Remove O-rings (12 and 17) from casing (32).
raised by spring (10) force.
6. Remove valve casing (3) from casing (32).

NOTE: Valve plate (9) may come off together with
valve casing (3). Carefully remove valve
casing (3) so that valve plate (9) does not
drop.
W2-6-17
2
13
1
18
15 19
28
16 20
21
22
32
23
24
25
26
27
33
29 34
35
36
35
37
39
42
40
41
43
W142-02-06-004
W2-6-18
11. Place casing (32) horizontally with parking brake 20. Remove retaining rings (34 and 37), spacers (35)
release valve (42) side facing upward. At this time, (2 used), inner plate of roller bearing (36) and
place wooden blocks under casing (32) to keep outer race from shaft (33).
the casing horizontal.
21. Using a press, remove the inner race of roller
12. Pull rotor (23) out from shaft (33). At this time the bearing (36) from shaft (33).
rotor is still with plunger (28), retainer plate (27), Then pull the inner race from the roller bearing (1)
and etc. in it. side.
NOTE: If it is difficult to remove rotor (23), tilt plate
(18) and friction plate (13) while pushing 22. Remove plungers (28) (9 used), retainer plate
the plate and friction plate into the most in- (27), holder (26), spacer (25) and push rods (24)
ner part with a round bar. (12 used) from rotor (23).
13. Remove plates (18) (3 used) and friction plates

(13) (2 used) from casing (32). CAUTION: When removing retaining ring
(19), be sure to hold the spacer
(20) with a press or a similar tool.
14. Remove retaining ring (41) and seal cover (40) Otherwise, the retaining ring and
from casing (32). spacer of spring (21) will fly off,
causing personal injury.
15. Remove shaft (33) from casing (32) by tapping 24. Holding spacer (20) with a press, remove retain-
the roller bearing (1) side of shaft (33) with a plas- ing ring (19).
tic hammer. At this time, the shaft is still with roller
bearing (36) on it. 24. Remove spacers (20), (22) and spring (21).
16. Remove shoe plate (29) from casing (32). 25. Loosen bolts (43) (4 used). Remove swing park-
ing brake release valve (42) from casing (32).
17. Remove oil seal (39) from seal cover (40) with a : 10 mm
screwdriver and hammer.
18. Using a puller, remove the outer race of roller

bearing (1) from valve casing (3) to remove O-ring
(2) and pins (15) (2 used).
IMPORTANT: Do not remove the inner race of

roller bearing (1) unless necessary.
19. Remove retaining ring (16) from shaft (33).
W2-6-19
ASSEMBLE SWING MOTOR 4 3 7 8 6 5 14
30
1
19 20 16 9
31 15
Section A-A
2 10 43 42
13
11
18
12
17 21
24 23
25 28
26
22
27
29
35
36 34 37 39 33 35 40 41 38 32
W142-02-06-008
1- Roller Bearing 12 - O-Ring 23 - Rotor 34 - Retaining Ring

2- O-Ring 13 - Friction Plate (2 Used) 24 - Push Rod (12 Used) 35 - Spacer (2 Used)
3- Valve casing 14 - Relief Valve (2 Used) 25 - Spacer 36 - Roller Bearing
4- Socket Bolt (4 Used) 15 - Pin (2 Used) 26 - Holder 37 - Retaining Ring
5- Poppet (2 Used) 16 - Retaining Ring 27 - Retainer Plate 38 - O-Ring
6- Spring (2 Used) 17 - O-Ring 28 - Plunger (9 Used) 39 - Oil Seal
7- O-Ring (2 Used) 18 - Plate (3 Used) 29 - Shoe Plate 40 - Seal Cover
8- Plug (2 Used) 19 - Retaining Ring 30 - Plug 41 - Retaining Ring
9- Valve Plate 20 - Spacer 31 - O-Ring 42 - Swing Parking Brake Re-
lease Valve
10 - Spring (22 Used) 21 - Spring 32 - Casing 43 - Bolt (4 Used)
11 - Brake Piston 22 - Spacer 33 - Shaft
W2-6-20
Assemble Swing Motor
1. Install spacer (35) of oil seal (39) side and retain- IMPORTANT: Apply grease onto the inner race of
ing ring (37) on shaft (33). Press the inner race of oil seal (39). Attach tape on the
roller bearing (36) onto shaft (33). spline part of shaft (33) end to pre-
vent the oil seal from being dam-
2. Install the outer race and inner plate onto the inner aged.
race of roller bearing (36) with the stamped side of 10. Install seal cover (40), retaining ring (41) into cas-
inner plate facing roller bearing (1). ing (32).
Ȁ
3. After installing another spacer (35) on shaft (33), 11. Install spacer (22), spring (21), spacer (20) to ro-
install retaining ring (34). tor (23) in that order.
4. Press the inner race of roller bearing (1) onto 12. Using a press, push spacer (20) until retaining
shaft (33). Install retaining ring (16). ring (19) is installed. Then install retaining ring
(19).
5. Using a metal bar and a hammer, install the shaft
(33) assembly into casing (32). 13. Install push rods (24) (12 used), spacer (25) and
holder (26) in rotor (23) in that order.
6. Install oil seal (39) into seal cover (40) with a pro-
14. Apply a film of hydraulic oil to the plunger holes in
tection plate or old oil seal.
rotor (23). After installing plungers (28) (9 used)
with retainer plate (27), insert plungers (28) into
7. Install O-ring (38) in casing (32).
rotor (23).
8. Place casing (32) horizontally with parking brake 15. Install the rotor (23) assembly onto shaft (33).
release valve (42) side facing upward.
IMPORTANT: There are 4 slots on the outer diame-
IMPORTANT: Apply grease to the matching sur- ter of plates (18), and there are four
face of shoe plate (29) and casing spline teeth on the inner diameter of
(32) to prevent them from coming off. friction plate (13). When installing
Install shoe plate with the big cham- plates (18) and friction plates (13), be
fer side facing the casing. sure to align these parts.
9. Install shoe plate (29) in casing (32). 16. Place casing (32) with the reducer side facing
downward on wooden blocks. Install plates (18) (3
used) and friction plates (13) (2 used) one by one
alternately.
17. Install O-rings (17), (12) onto casing (32). At this

time be sure to apply enough grease onto O-ring.
W2-6-21
14
8
7
4
9 10 43
Section A-A
1
2
42
15
12
17
11
32
W142-02-06-008
W2-6-22
IMPORTANT: Install brake piston (11) with the slits IMPORTANT: Take care not to drop valve plate (9).
in it in the illustrated position. Also, be sure to align the matching
18. Install brake piston (11) into casing (32). marks put during disassembling.
Screw Hole
22. Install valve casing (3) to casing (32) secure valve
casing (3) with bolts (4) (4 used).
: 17 mm
Slit : 630 N⋅m (64 kgf⋅m, 460 Ibf⋅ft)
23. Install swing parking brake release valve (42) to

casing (32) with bolts (43) (4 used).
Brake Piston (11)
: 10 mm
Mounting Position for
W142-02-06-011
: 12 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft)
Parking Brake Release
Valve (42)
24. Install poppets (5) (2 used) and springs (6) in
NOTE: If brake piston (11) is hard to move into cas- valve casing (3). Tighten plugs (8) (2 used) with
ing (32) because of friction between O-ring O-rings (7) (2 used).
(12 and 17), tap on the piston install bolt : 14 mm
(M8, pitch 1.25) into the brake piston uni- : 230 N⋅m (23 kgf⋅m, 166 Ibf⋅ft)
formly with a plastic hammer.
25. Install relief valves (14) (2 used) to valve casing
19. Install springs (10) (22 used) in brake piston (11).
(3).
IMPORTANT: When installing roller bearing (1), : 36 mm
tap the side face on which the bear- : 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)
ing type is marked with a plastic
hammer.
20. Drive the outer race of roller bearing (1) into valve
casing (3) with a plastic hammer.
Ȁ
IMPORTANT: Install valve plate (9) with the R part
of valve plate (9) facing the opposite
to the flange surface of valve casing
(3).
21. Install O-ring (2), pins (15) (2 used), and valve
plate (9) to valve casing (3).
Flange Surface
Valve Casing (3)
Valve Plate (9)
R Part
W17V-02-06-004
NOTE: Apply a film of grease to valve plate (9) to

prevent valve plate (9) from coming out of
valve casing (3).
W2-6-23
DISASSEMBLE AND ASSEMBLE SWING
PARKING BRAKE RELEASE VALVE
42 44 45 46 47 48
49
55
54
53
50
52
51
43
W142-02-06-010
42 - Swing Parking Brake Re- 46 - Spring 50 - Spool 53 - Spacer

lease Valve
43 - Bolt (4 Used) 47 - O-Ring 51 - Bushing 54 - Orifice
44 - O-Ring 48 - Spring 52 - Filter 55 - Poppet
45 - O-Ring 49 - Steel Ball
W2-6-24
Swing Motor
NOTE: If items 1 to 4 are out of allowable limit, re-

d
place them.
1. Clearance between plunger and rotor bore
D-d
Standard Clearance Allowable Limit
W107-02-06-138
0.032 mm (0.001 in) 0.062 mm (0.002 in)
D D
W107-02-06-139
2. Clearance between plunger top and shoe bottom

δ
δ
Standard Clearance Allowable Limit
0 mm 0.3 mm (0.012 in)
W107-02-06-140
3. Thickness of shoe
ɔ
Standard Thickness Allowable Limit
t
6.0 mm (0.24 in) 5.8 mm (0.23 in)
W107-02-06-142
W2-6-25
4. Thickness of friction plate
Standard Thickness Allowable Limit

4.0 mm (0.16 in) 3.6 mm (0.14 in)
W107-02-06-143
5. Total clearance of retainer plate (1) and holder (2)
Dimension: H−h 2
Standard Clearance Allowable Limit 1
7 mm (0.28 in) 6.5 mm (0.26 in)
If the dimension is to below 6.5 mm (0.26 in), replace

retainer plate (1) and holder (2).
hH
W107-02-06-146
W2-6-26
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL PILOT VALVE

lines.
repair work.
Preparation

tem on page W1-1-2.
: 4 mm

tank.
W183-01-01-001
W2-7-1
Removal of Right Pilot Valve
CAUTION: Seat weight : 45 kg (99 lb)

1. Remove bolts (3) (2 used) and socket bolts (2) (4
1
used). Put the panel on the floor plate. Move and
remove seat (1).
: 16mm
: 6mm
2. Remove screws (25) (4 used). Move boot (30)

upward to remove cover (24).
: 17mm
2
3. Remove caps (18) (2 used) from cover (19).
4. Remove screws (22) (4 used) and screws (17) (2

3
used). Move cover (19) upward to disconnect W16J-02-01-003
each harness connectors for key switch (21), air

conditioner controller (20), grip (4).
5. Remove cover (19). Remove screws (23, 16, and

14) to remove cover (15). 30
4
6. Disconnect the connector of switch box (13) and

remove bolts (12) (3 used) to remove the switch
box.
: 13 mm
25
12
24 13
22
21
20
23
19
18
17
14
16
15
W178-02-07-001
W2-7-2
IMPORTANT: Attach identification tags on all dis-
connected hoses for reassembly.
7. Disconnected hoses (32 to 37). Cap all discon-
nected hose ends.
: 19 mm 32
37
36 33
8. Loosen nut (5) to remove grips (6 and 28). Dis-
34
connect connector (7) to remove grip (4) (with
harness). 35
Loosen nut (29) to remove lever (31), washers
(26), (27) and boot (30).
: 22 mm, 19 mm
9. Remove bolts (10) (3 used) and (9) (with pin (8))

to remove pilot valve (11). W178-02-07-002
: 13 mm
32 - 3 port: Hose G: To signal control valve G port (bucket roll-in)
33 - 2 port: Hose B1: To shockless valve B port
34 - T port: Hose T6: To pilot shut-off valve T3 port
35 - 1 port: Hose H: To signal control valve H port (bucket roll-
Installation of Right Pilot Valve out)
36 - 4 port: Hose A: To signal control valve A port (boom raise)
1. Secure pilot valve (11) with bolts (10) (3 used) and 37 - P port: Hose P3: From pilot shut-off valve A3 port
(9) (with pin (8)).
: 13 mm NOTE: Piping location shows that of ISO pattern.
: 10 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅ft)
2. Connect hoses (32 to 37).

: 19 mm 31
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
4
30
3. Install nut (29) and washers (26 and 27) to lever 5
29
(31). Install the lever to pilot valve (11) and secure 6
28
it with nut (29).
: 22 mm 27 7
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 26 8
9
10
11
W178-02-07-001
W2-7-3
4. Install boot (30). Install nut (5) and grip (4) to lever
(31) and secure it with the nut.
: 19 mm 31
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅m)
4
30
IMPORTANT: If the harness is arranged to the in- 5
side of spring pin (8), it may make 6
28
contact with the moving part of the
pilot valve damaging it. Be sure to 7
arrange the harness to the outside of 8
9
spring pin (8).
5. Pass the harness of grip (4) through the hole on 25
the top of boot (30). Secure the harness to lever 12
24 13
(31) with grips (6 and 28).
22
Arrange the harness to the outside of spring pin
21
(8) over bolt (9) head.
20
Connect connector (7). 19
23
6. Install switch box (13) with bolts (12) (3 used),

then connect connector. 18
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅m) 17
7. Connect each harness of key switch (21) and air

conditioner controller (20).
14
8. Install cover (15) with screws (23, 16 and 14). In- 16
stall cover (19) with screws (22) (4 used), and (17)
(2 used). Install caps (18) (2 used) to the cover. 15
Install cover (24) with screw (25). W178-02-07-001
9. Install seat (1) with socket bolts (2) (4 used). In-

stall the seat belt with bolts (3) (2 used).
: 6 mm
: 8 N⋅m (0.8 kgf⋅m, 5.8 lbf⋅ft)
1
: 16 mm
: 70 N⋅m (7.1 kgf⋅m, 51 lbf⋅ft)
IMPORTANT: After installation, check the oil level,

start the engine and check for oil
leaks.
3 W16J-02-01-003
W2-7-4
Removal of Left Pilot Valve
1
1. Remove screws (13) (4 used) and cover (14) to
move boot (4) up. At this time, the console is at
the most front position. 24 2
: 17 mm
3
2. Remove cap (21) from cover (17). Remove screw
23 4
(22) (3 used) and (16) to move cover (17) up.
5
3. Disconnect the radio connector, then remove 6
cover (17). Remove screws (15, 18 and 19) to 7
remove cover (20). 8
22 9
IMPORTANT: Attach identification tags on all dis- 10
20 21 11
connected hoses for reassembly. 19 Radio 12
4. Disconnect hoses (25 to 30). Cap all discon-
nected hose ends. 13
: 19 mm 14
15
5. Loosen nut (2) to remove clips (24 and 6). Dis-
connect connector (23) to remove grip (1) (with 16
harness).
Loosen nut (5) to remove lever (3), washers (10),
(11) and boot (4).
: 22 mm, 19 mm
6. Remove bolts (9) and (8) (with pin (7)) to remove 18 17 W178-02-07-003
pilot valve (12).

: 13 mm
25
30
29 26
27
28
W178-02-07-004
25 - 3 port: Hose C: To signal control valve E port (left swing)

26 - 2 port: Hose F: To signal control valve C port (arm roll-out)
28 - 1 port: Hose D: To signal control valve F port (right swing)
29 - 4 port: Hose E: To signal control valve D port (arm roll-in)
30 - P port: Hose P2: From pilot shut-off valve A1 port
NOTE: Piping location shows that of ISO pattern.
W2-7-5
Installation of Left Pilot Valve
1
1. Install pilot valve (12) with bolts (9) (3 used) and
(8) (with pin (7)).
: 13 mm 24 2
: 10 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅ft)
3
23 4
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) 5
6
3. Install nut (5), washers (10 and 11) to lever (3). In- 7
stall the lever to pilot valve (12) and secure it with 8
the nut. Install boot (4). 22 9
: 22 mm 10
20 21 11
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 19 Radio 12
4. Install grip (1) to lever (3) with nut (2). 13
: 19 mm 14
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 15
IMPORTANT: If the harness is arranged to the in- 16

side of spring pin (7), it may make
contact with the moving part of the
pilot valve damaging it. Be sure to
arrange harness to the outside of
spring pin (7).
5. Pass the harness of grip (1) through the hole of 18 17 W178-02-07-003
the top of boot (4). Install the harness to lever (3)

with grips (24 and 6). Arrange the harness to the
outside of spring pin (7) over bolt (8) head. Con-
nect connector (23).
6. Connect the connector of the radio and install

25
cover (20) with screw (15, 18 and 19). Install 30
29 26
cover (17) with screws (22) (3 used) and (16).
Install cap (21). 27
28
7. Install boot (4) and cover (14) with screws (13) (4
used).
IMPORTANT: After installation, check the oil level.

Start the engine and check for oil
leaks.
W178-02-07-004
25 - 3 port: Hose C: To signal control valve E port (left swing)

26 - 2 port: Hose F: To signal control valve C port (arm roll-out)
28 - 1 port: Hose D: To signal control valve F port (right swing)
29 - 4 port: Hose E: To signal control valve D port (arm roll-in)
30 - P port: Hose P2: From pilot shut-off valve A1 port
NOTE: Piping location shows that of ISO pattern.
W2-7-6
Removal of Travel Pilot Valve
1. Remove floor mat (1). Remove bolts (3) (8 used)

to remove under cover (2). 1
: 17mm
2. Remove bolts (5) (4 used) to remove pedals (6) (2

used) and levers (4) (2 used).
: 17 mm
WIHH-02-07-001
3. Disconnect hoses (8 to 13). Attach a cap on each
disconnected hose end.
: 19 mm
4. Remove socket bolts (16) (2 used) to remove pilot 2

valve (7). 3
: 8 mm
W17V-02-08-001
4
Installation of Travel Pilot Valve
5
1. Install pilot valve (7) with socket bolts (16) (2
4
used), spring washers (15) (2 used) and plain 6
washers (14) (2 used).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
2. Connect hoses (8 to 13). 5

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) 6
7
3. Install pedals (6) (2 used), levers (4) (2 used) with 16
bolts (5) (4 used).
15
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 14
8
4. Install under cover (2) with bolts (3) (8 used). In-
stall floor mat (1).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 13
12
W1CC-02-07-004
11 10 9
IMPORTANT: After installation, check the oil level. 8 - T port: HoseT4: To T1 port in pilot shut-off valve
Start the engine and check for oil 9 - P port: HoseP1: From A2 port in pilot shut-off valve
leaks. 10 - 2 port: Hose K: To K port in signal control valve (right travel
forward)
11 - 1 port: Hose L: To L port in signal control valve (right travel
reverse)
12 - 4 port: Hose J: To J port in signal control valve (left travel
reverse)
13 - 3 port: Hose I: To I port in signal control valve (right travel
forward)
W2-7-7
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
1
17
W176-02-07-001
1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Knock Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)
W2-7-8
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, be careful while handling 4. Pull push rods (8), (9) out from block (10).
them.
5. With a bamboo spatula, remove oil seals (15) (4
IMPORTANT: As spool (17) has been selected to used) from block (10).
match the hole of housing (18), they NOTE: If a metal bar is used, the mating part of oil
must be replaced in a set. In addition, seal (15) may be damaged.
the dimensions of balance springs A
(3), B (4) and return springs A (5), B IMPORTANT: The retaining ring may come off
(6) as well as those of push rods A while disassembling. Take care not
(8), B (9) are different. For this rea- to drop it.
son, be sure to indicate the port 6. Press springs using special tool (ST 7257) from
number from which it is removed. the top of spring guide (16). Retaining ring (7) will
Port numbers are stamped on hous- appear. Remove it with a screw driver or similar
ing (18). tool. (4 places)
7
IMPORTANT: Do not clamp housing (18) in a vise
to remove the screw joint because
the screw joint maybe damaged.
1. Secure screw joint (13) in a vise. Then turn cam
(12) with a spanner to remove the screw joint.
: 32 mm
16
2. Clamp the flat surface of housing (18) in a vise
slightly. Remove cam (12) from universal joint ST 7257
(14).
: 32 mm
NOTE: The universal joint has been secured on
block (10) with LOCTITE. Do not remove it
unless necessary. W176-02-07-005
3. Remove socket bolts (11) (2 used) to remove IMPORTANT: The number of shims has been de-
block (10). At this time, push rods (8), (9) are in termined for each port during the
place. performance testing at the factory.
: 6 mm Take care not to loss them. Keep
them carefully to install them to each
former port when reassembly.
7. Remove spring guide (16), balance springs (3), (4),
return springs (5), (6), shim (2) and spacer (1)
from spool (17).
W2-7-9
21
20
21
20
19
18
17
W176-02-07-001
W2-7-10
IMPORTANT: As the spool has been selected to
match the hole of the housing, keep
them carefully to install them to the
former port when reassembling.
8. Remove spool (17) from housing (18). Pulling it
out while turning it.
NOTE: The spool and housing must be replaced as
an assembly.
9. Remove O-rings (19), (21) from housing (18). Do

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

2- Shim 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Knock Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)
W2-7-12
Assemble Right and Left Pilot Valves
IMPORTANT: The pilot valve is susceptible to con- IMPORTANT: Install spring guide, with the protru-
tamination. Keep parts clean when sion facing up.
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
W176-02-07-008
2 the former the former without outer
one one groove
5. Insert the spool (17) head into the hole of spring
3 with outer
using special tool (ST 7257) to press the spring
groove
from the top of spring guide (16). Install retaining
4 without outer
ring (7) with the ring holder (ST 7255) onto the
groove
head of the spool.
Port Return Springs Blance Springs ST 7255

ST 7257
No. (5), (6) (3), (4)
1 short short
2 long long 17
3 short short
4 long long
Packing Material
IMPORTANT: Apply hydraulic oil to spool (17).
Make sure of the port hole number
W176-02-07-009
and insert the spool to the former
port. NOTE: Put approx. dia.8 mm, length 10 mm of
1. Insert the thinner end of spool (17) to housing (18), packing material, into the port hole not only
then push the spool rotating it. to make the work easy to do, but also to
prevent the spool from lowering to the bot-
NOTE: The spool has been selected to match the tom when compressing the spring.
hole of the housing. The spool and housing
must be replaced as an assembly. 6. Assemble the remained spools (17) (3 used) into
housing (18) in the same procedures as step 2 to
IMPORTANT: Refer to the table above to assemble 5.
them correctly.
2. Install the spacer (1), shim (2), balance spring (3) 7. Install O-rings (19), (21) (2 used) on to housing
or (4), return spring (5) or (6) onto spool (17) in- (18).
stalled in housing (18).
W2-7-13
13 14
10
12
15
11
8, 9
W176-02-07-006
20 18
W2-7-14
8. Apply grease to the inner face of oil seals (15) (4 IMPORTANT: Make sure of the tighteness of cam
used), then install the oil seals (4 used) into block (12).
(10) with a bamboo spatula. 13. Clamp housing (18) carefully in a vise and then
NOTE: As shown bellow, inserting push rods (8), install cam (12) to universal joint (14).
(9) first, then installing oil seal (15). This Tighten the universal joint so that the clearance
prevents the oil seal from entering into the between the cam and push rod (8), (9) become 0
hole. to 2 mm.
: 32 mm
Oil Seal Mounting Hole
IMPORTANT: Do not clamp housing (18) in a vise
because the screw joint maybe dam-
10 aged.
8, 9
14. Clamp screw joint (13) in a vise to tighten univer-
sal joint (14). Tighten cam (12) with a spanner.
: 32 mm
: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)
W176-02-07-007
IMPORTANT: Make sure the position to install the

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

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

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

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

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

damper (6) and rubber seat (7) from pin (3). O-
ring (4) is removed with them. (2 places)
: 5 mm
W2-7-17
35
34
33
32
31
30
10
14
W176-02-07-002
W2-7-18
10. Remove O-ring (5) from pin (3). (2 places)
11. Place holder (10) with the casing (14) mating sur-
face facing up.
IMPORTANT: The holes for spring pins (34), (35) of

cam (32) is stepped-shape. There-
fore the pins shall be removed from
the bottom of the cam.
12. Pull out spring pins (34), (35) from cam (32) at the
same time using special tool (ST 1237). (2 places)
NOTE: The spring pin is a double-pin.
The spring pin is crimped in its hole, so it
may feel tight when removing.
13. Remove pin (3) with a bar and hammer. At this

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

remove adjusting bolts (30) (2 used). (2 places)
: 13 mm
: 4 mm
W2-7-19
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
14 17
W176-02-07-010
15, 16
1- Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)

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

the former port.
3. Turn and install the spool (17) assembly into cas- 31
ing (14). (4 places) W176-02-07-016
• Install the bushing on the opposite side in the

4. Assemble the plunger (4 used).
same procedure. 31
• Install oil seal (11) onto bushing (13).
10
• Apply the grease to the inner face of the oil seal. ST 7256
• Install O-ring (12) to the bushing.
• Insert pusher (23) to the bushing.
• Apply the grease to the pusher head section.
5. Insert the pusher (23) assembly to holder (10). (4

W176-02-07-015
places)
• Install the bushing in near side as shown bellow.
Stop tapping when the bushing end is flush with
the outside of the holder.
31
10 ST 7256
Outside of
Holder
W176-02-07-014
• Install the bushing on opposite side as shown be-

low.
31
10
ST 7256
W176-02-07-013
W2-7-21
3 10 32 30 33 34, 35 8 9
23
14
W176-02-07-010
W2-7-22
7. Install adjust bolt (30) into cam (32). Tighten the IMPORTANT: Do not adjust adjust bolt (30) while
bolt by hand, and then lightly secure it temporarily pressing the pusher (23) head with
with lock nut (33). the adjust bolt. The standard clear-
NOTE: Adjust the dimensions later. ance between the adjust bolt and
pusher must be 0 to 0.2 mm(0 to
8. Apply the grease on the head (mating surface for 0.008 in).
pusher (23)) of adjust bolt (30). (2 places) 13. Adjust bolt (30) as the following procedures. (2
places)
9. Install O-ring (5) to pin (3), then assemble the pin : 13 mm
to holder (10) with cam (32). (2 places) : 4 mm
• Loosen lock nut (33).
IMPORTANT: Take care of the inserting direction • Move cam (32) to check whether there is play. If
of the spring pin. none, turn the adjust bolt to adjust.
IMPORTANT: Tap the spring pin in until it makes • Turn both the adjust bolts on the left and right al-
contact with the step in hole. ternatively to keep the cam horizontal.
10. Install spring pins (34), (35) into cam (32) using • Measure sizes A and B from both left and right
special tool (ST 1237), then secure the cam and caves on the cam to holder (10). Fine adjust the
pin (3). The spring pins shall be displaced with adjust bolt to get the same distance for both left
their slits at 90°. and right.
• Secure the adjust bolt with a hexagon-head
34 35 Slit Slit wrench. Tighten the lock nut to specified torque
first, securing the adjust bolt.
• When adjustment is finished, move cam to check
that there is a little play. If there is no play, the
pusher may be in compressed condition, and ad-
justment should be carried out again.
: 10 N⋅m (1 kgf⋅m, 7.4 Ibf⋅ft)
30 33 32 10
W176-02-07-017
11. Crimp the hole edge of cam (32), where spring B

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

and install it with socket bolts (8) (2 used), spring
washers (9) (2 used).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
W176-02-07-003
W2-7-23
26 6 7 1 2 3 25 27 24 10
4
28
5
29
W176-02-07-010
W2-7-24
14. Install rubber seat (7) to pin (3). (2 places) IMPORTANT: Place a stand under bracket (26). If
holder (10) bears the reaction force,
15. Apply the grease to O-ring (5). (2 places) strong force acts on the pin and the
pin maybe deformed.
IMPORTANT: Pay attention to the direction of IMPORTANT: The inside of the spring pins (24),
damper (6). (25) hole in the bracket is stepped-
IMPORTANT: The inner bore of damper (6) is shape. Make sure of the direction to
edged-shape. If the damper is pried insert the spring pin.
upward, O-ring (5) will be damaged. IMPORTANT: Make sure of the direction of the
16. With the lever upward, install damper (6) to pin (3) spring pin.
straight without prying. (2 places) 20. Put a stand under bracket (26).
Ȁ Tap spring pins (24), (25) into the bracket until the
17. Secure damper (6) to holder (10) with socket bolts spring pin comes to the stepped end using special
(28) (2 used) and spring washers (29) (2 used). (2 tool (ST 1237). The spring pins shall be displaced
places) with their slits at 90°.
: 8 mm
: 7 N⋅m (0.7 kgf⋅m, 5.1 Ibf⋅ft)
18. Apply the grease to O-ring (4), then press it to the

Crimped Here Crimped Here
end-most of pin (3). (2 places)
26 3
IMPORTANT: As for the direction to install the
bracket, refer to the figure in the
disassemble section (page W2-7-16).
Take care not to misassemble it. 24, 25
Stand
19. Install pin (3) into bracket (26), then align the in-
serting holes of spring pins (24), (25) to fix pin on
the bracket.
W176-02-07-011
21. Crimp the hole edge of bracket (26), where spring

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

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

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

part of damper (6). (2 places)
W2-7-25
(Blank)
W2-7-26
UPPERSTRUCTURE / Pilot Shut-Off Valve
REMOVE AND INSTALL PILOT SHUT-OFF
VALVE

lines.
repair work.
Preparation

tem on page W1-1-2.
: 4 mm

tank.
W183-01-01-001
W2-8-1
Removal
1. Remove bolts (1) (8 used) to remove under cover

(2).
: 19 mm
2. Remove spring (5).

2 1
W17V-02-08-001
3. Disconnect hoses (8 to 17). Attach a cap on each
: 17 mm, 19 mm
4. Remove spring pin (7) to remove lever (3).
5. Remove bolts (4) (2 used) to remove pilot shut-off 3

valve (6).
: 17 mm
4
5
7
6
Installation
1. Install pilot shut-off valve (6) with bolts (4) (2

used). 4 W178-02-08-001
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
17 6
2. Install lever (3) with spring pin (7).

: 17 mm 8
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) 9
: 19 mm 16
: 29.5 N⋅m (3 kgf⋅m, 24.5 lbf⋅ft)
15 10
4. Install spring (5). 11
14 12
5. Install under cover (2) with bolts (1) (8 used).
13
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
W17P-02-08-001
8- A1 port: Hose P2: To P port in left pilot valve
9- A3 port: Hose P3: To P port in right pilot valve
10 - A2 port: Hose P1: To P port in travel pilot valve
11 - T1 port: Hose T4: From T port in travel pilot valve
12 - T2 port: Hose T5: From T port in left pilot valve
13 - T3 port: Hose T6: From T port in right pilot valve
14 - P port: Hose PD: From A port in check valve
15 - A5 port: Hose PH: To PH port in signal control valve
16 - T4 port: Hose T1: To hydraulic oil tank
17 - A4 port: Hose PI: From PI port in signal control valve
W2-8-2
DISASSEMBLE AND ASSEMBLE PILOT
SHUT-OFF VALVE
IMPORTANT: Make the matching marks on body
(4) and bracket (3) for disassembly.
1 2 3 4 5 Z
Z
Section Z-Z
W178-02-08-006
6 7 8 9 10 4 11 12 13 3
T178-03-07-002

Item No. Part Name Quantity Remarks
(mm)
Nxm (kgfxm) (lbf⋅ft)
1 Pin 1
2 Socket Bolt 3 ϖ4 3.9 (0.4) (2.9) Use LOCTITE#262
3 Bracket 1
4 Body 1
5 Socket Bolt 1 ϖ8 29.5 (3) (21.5) Use LOCTITE#262
6 Spool 1
7 Retaining Ring 1
8 Washer 1
9 Backup Ring 1
10 O-Ring 1
11 O-Ring 1
12 Backup Ring 1
13 Washer 1
W2-8-3
(Blank)
W2-8-4
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE

lines.
repair work.
Preparation

several times to release any pressure remaining M104-07-021

wrench to release the trapped air in the hydraulic Cap
tem on page W1-1-2.
: 4 mm

tank.
W183-01-01-001
W2-9-1
Removal of 3-Spool Solenoid Valve
1. Disconnect the connectors from the 3-spool sole-

noid valve. (3 places)
10
2. Disconnect hoses (5 to 11) from the 3-spool sole-
noid valve. Attach a cap on each disconnected
hose end.
: 17mm, 19 mm, 27 mm
4
3. Remove bolts (4) (2 used) to remove the 3-spool
solenoid valve. 5
: 17 mm
6
Installation of 3-Spool Solenoid Valve

W17V-02-09-001
1. Install the 3-spool solenoid valve with bolts (4) (2 9 8 7
used).
: 17 mm
5- P port: To Psv 1 port in main pump
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 6- T2 port: Hose C1: To hydraulic oil tank
7- SC port: Hose SC: To control valve 5-spool side
2. Connect hoses (5 to 11) to the 3-spool solenoid 8- SB port: Hose SB: From top of center joint
valve. 9- SA port: Hose SA: To pF2 port in control valve 4-spool side
10 - A port: To P port in check valve
: 17 mm
11 - T1 port: To hydraulic oil tank
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 24.5 lbf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
3. Connect the connectors to the 3-spool solenoid

valve.
W2-9-2
Removal of Swing Preference Circuit Shift Sole-
noid Valve

(1).
: 19 mm
2. Disconnect connector (3) from the solenoid valve.

connected hoses for reassembly. 2
W17V-02-08-001
3. Disconnect hoses (4, 6, 7 and 8) from the sole-
noid valve.
: 19 mm 3
A
4. Remove bolts (5) (2 used) to remove the solenoid
valve.
: 13 mm
T17V-01-01-008
View A
Installation of Swing Preference Circuit Shift So-
lenoid Valve
1. Install the solenoid valve with bolts (5) (2 used). 8 4

: 13 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 5
2. Connect hoses (4, 6, 7 and 8) to the solenoid 6

valve. 7
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) W17V-02-09-002
3. Connect connector (3).

: 19 mm 4- T port: Hose D2: To hydraulic oil tank
6- S port: Hose 1B: To 5 PA3 port in control valve 5-spool side
: 90 N⋅m (9.2 kgf⋅m, 66.5 lbf⋅ft)
7- P port: Hose 1A: To 4 PA3 port in control valve 4-spool side
8- P port: Hose 1: To 1 port in signal control valve
W2-9-3
DISASSEMBLE AND ASSEMBLE THREE-
SPOOL SOLENOID VALVE
IMPORTANT: One of solenoid valves (3 used) is
normal closed type and different
from others. When assembling, be
sure to install them correctly.
20 21 22 23 24
19
18
17 Pilot Relief 1
Valve
2
16
3
15
14
5
13
12
6
11
T111-02-07-002
10 9 8 8
NOTE: 1 kgfxm=7.233 lbfxft
Wrench Tightening Torque Wrench Tightening Torque
Item Item
Part Name Quantity Size Part Name Quantity Size
No. (mm) Nxm (kgfxm) (lbfxft) No. (mm) Nxm (kgfxm) (lbfxft)
1 Plug 1 22 49 (5) (36) 13 Spool 1
Assembly
2 Shim 1 14 Rod 3
3 Spring 1 15 O-Ring 3
4 O-Ring 1 16 Stopper 3
5 Valve 1 17 Plunger 3
Assembly
6 Gasket 1 18 Screw 3 32 29.5 (3) (22)
7 Casing 1 19 Coil 3
Assembly
8 Spool 2 20 Spring 3
Assembly
9 Spring 3 21 Spring Seat 3
10 O-Ring 3 22 Pipe 3
11 O-Ring 3 23 Housing 3
12 O-Ring 3 24 Spacer 3
W2-9-4
DISASSEMBLE AND ASSEMBLE SWING
PREFERENCE CIRCUIT SHIFT SOLENOID
VALVE
7
W16J-02-09-001

(mm)
1 Solenoid 1
2 Socket Bolt 2 ϖ4 4.9 to 5.9 (0.5 to 0.6) (3.6 to 4.3)
3 O-Ring 1
4 Body 1
5 Spool 1
6 Spring 1
7 O-Ring 1
8 Plug 1 ϖ5 12.5 to 17.5 (1.3 to 1.8) (9.4 to 13.0)
W2-9-5
(Blank)
W2-9-6
UPPERSTRUCTURE / Signal Control Valve
REMOVE AND INSTALL SIGNAL CON-
TROL VALVE

lines.
repair work.
Preparation

tem on page W1-1-2.
: 4 mm

tank.
W183-01-01-001
W2-10-1
Removal of Signal Control Valve

(1).
: 19 mm

2. Disconnect all the hoses from the signal control
valve. Attach a cap on all the disconnected hose
ends. 1
2
: 17 mm, 19 mm W17V-02-08-001
NOTE: When removing pipe from signal control

valve, if a snap-on tool (GAN850812B: tool
size: 19.05 mm) is used, it may be easier
to remove the pipe.
3. Disconnect connectors (2 used) from the signal

control valve.
4. Remove bolts (3) (4 used) to remove the signal

control valve.
: 17mm
3 M17V-07-053
Installation of Signal Control Valve
1. Install the signal control valve with bolts (3) (4

used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
2. Connect all the hoses and connectors (2 used) to

the signal control valve.
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 24.5 lbf⋅ft)

: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66.5 lbf⋅ft)
W2-10-2
(Blank)
W2-10-3
Pilot Valve Side

PH
C
A
E
M
D
H
B
F
SB
PI G
Pilot Valve
Side
K N
I
SH
J
DF
SA L
T178-03-06-016
W2-10-4
Pilot Valve Side(ISO PATTERN)
Port Name Connecting to Note
Port A Right Pilot Valve Boom Raise Pilot Pressure
Port B Right Pilot Valve Boom Lower Pilot Pressure
Port C Left Pilot Valve Right Swing Pilot Pressure(Label F)
Port D Left Pilot Valve Left Swing Pilot Pressure(Label E)
Port E Left Pilot Valve Arm Roll-Out Pilot Pressure(Label C)
Port F Left Pilot Valve Arm Roll-In Pilot Pressure(Label D)
Port G Right Pilot Valve Bucket Roll-In Pilot Pressure
Port H Right Pilot Valve Bucket Roll-Out Pilot Pressure
Port I Travel Pilot Valve Left Travel Forward Pilot Pressure
Port J Travel Pilot Valve Left Travel Reverse Pilot Pressure
Port K Travel Pilot Valve Right Travel Forward Pilot Pressure
Port L Travel Pilot Valve Right Travel Reverse Pilot Pressure
Port M Auxiliary Pilot Valve Auxiliary Open Pilot Pressure
Port N Auxiliary Pilot Valve Auxiliary Close Pilot Pressure
Port SA Pump Control Pressure Sensor (4-spool) Pump 1 Flow Rate Control
Port SB Pump Control Pressure Sensor (5-spool) Pump 2 Flow Rate Control
Port PI Pilot Shut-Off Valve Primary Pilot Pressure
Port PH Pilot Shut-Off Valve Primary Pilot Pressure (Heating Circuit)
Port SH Swing Parking Brake Brake Release Pressure
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Pilot Valve Side(HITACHI PATTERN)

Port A Right Pilot Valve Boom Raise Pilot Pressure
Port B Right Pilot Valve Boom Lower Pilot Pressure
Port C Left Pilot Valve Arm Roll-Out Pilot Pressure
Port D Left Pilot Valve Arm Roll-In Pilot Pressure
Port E Left Pilot Valve Left Swing Pilot Pressure
Port F Left Pilot Valve Right Swing Pilot Pressure
Port G Right Pilot Valve Bucket Roll-In Pilot Pressure
Port H Right Pilot Valve Bucket Roll-Out Pilot Pressure
Port I Travel Pilot Valve Left Travel Reverse Pilot Pressure
Port J Travel Pilot Valve Left Travel Forward Pilot Pressure
Port K Travel Pilot Valve Right Travel Forward Pilot Pressure
Port L Travel Pilot Valve Right Travel Reverse Pilot Pressure
Port M Auxiliary Pilot Valve Auxiliary Open Pilot Pressure
Port N Auxiliary Pilot Valve Auxiliary Close Pilot Pressure
Port SA Pump Control Pressure Sensor (4-spool) Pump 1 Flow Rate Control
Port SB Pump Control Pressure Sensor (5-spool) Pump 2 Flow Rate Control
Port PI Pilot Shut-Off Valve Primary Pilot Pressure
Port PH Pilot Shut-Off Valve Primary Pilot Pressure (Heating Circuit)
Port SH Swing Parking Brake Brake Release Pressure
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank
W2-10-5
Control Valve Side

SM
3
1 5
13
2 4
SK
SE
Pressure Sensor 8
(S3: Swing)
14
Control Valve 7
Side 9
6
10
SN
SL
11
Pressure Sensor (TR: Travel) 12 SP T16J-03-06-001
Control Valve Side

Port 1 Control Valve through the Solenoid Boom Raise Pilot Pressure
Valve (Swing Preference)
Port 2 Control Valve Boom Lower Pilot Pressure
Port 3 Control Valve Arm Roll-Out Pilot Pressure
Port 4 Control Valve Arm Roll-In Pilot Pressure
Port 5 Control Valve Left Swing Pilot Pressure
Port 6 Control Valve Right Swing Pilot Pressure
Port 7 Control Valve Bucket Roll-In Pilot Pressure
Port 8 Control Valve Bucket Roll-Out Pilot Pressure
Port 9 Control Valve Left Travel Forward Pilot Pressure
Port 10 Control Valve Left Travel Reverse Pilot Pressure
Port 11 Control Valve Right Travel Forward Pilot Pressure
Port 12 Control Valve Right Travel Reverse Pilot Pressure
Port 13 ȀȀȀȀȀȀ Plug
Port 14 ȀȀȀȀȀȀ Plug
Port SE ȀȀȀȀȀȀ Plug
Port SM Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port SN ȀȀȀȀȀȀ Plug
Port SP Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port SL Control Valve Flow Combiner Valve Control Pressure
Port SK ȀȀȀȀȀȀ Plug
W2-10-6
UPPERSTRUCTURE / Shockless Valve
REMOVE AND INSTALL SHOCKLESS
VALVE

lines.
repair work.
Preparation
several times to release any pressure remaining in

the system. Rotate the hydraulic oil tank cap ap-
prox. 30° counterclockwise using a hexagon Cap
tem on page W1-1-2.
: 4 mm

vacuum pump and operate it continuously to main-
tain negative pressure in the hydraulic oil tank.
W183-01-01-001
W2-11-1
Removal

(2).

2. Disconnect hoses (3 and 4). Attach a cap on each
: 19 mm
1
3. Remove bolts (5) (2 used) to remove the shock- 2
less valve.
: 13 mm
W17V-02-08-001
Front Side
3
Installation
1. Install the shockless valve with bolts (5) (2 used).

: 13 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
2. Connect hoses (3 and 4). 5

: 19 mm 4
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) W17V-02-11-001

: 19 mm 3 - A port: Hose B: To B port (boom lower) in signal control
valve
: 90 N⋅m (9.2 kgf⋅m, 67 lbf⋅ft)
4 - B port: Hose B1: From 2 port in right pilot valve
W2-11-2
DISASSEMBLE AND ASSEMBLE SHOCK-
LESS VALVE
4 5 6 7
T183-03-07-008

(mm)
1 Plug 2 ϖ8 39 (4) (29)
2 O-Ring 2
3 Body 1
4 Spring 2
5 Plunger 1
6 Ring 1
7 Orifice 1
W2-11-3
(Blank)
W2-11-4
MEMO
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SECTION 3
UNDERCARRIAGE
CONTENTNS
Group 1 Swing Bearing Group 4 Track Adjuster
Remove and Install Remove and Install Track Adjuster.........W3-4-1
Swing Bearing ........................................ W3-1-1 Disassemble Track Adjuster...................W3-4-2
Disassemble Swing Bearing .................. W3-1-4 Assemble Track Adjuster........................W3-4-8
Assemble Swing Bearing ....................... W3-1-6
Group 5 Front Idler
Group 2 Travel Device Remove and Install Front Idler................W3-5-1
Remove and Install Travel Device.......... W3-2-1 Disassemble Front Idler..........................W3-5-2
Disassemble Travel Device.................... W3-2-4 Assemble Front Idler ..............................W3-5-6
Assemble Travel Device....................... W3-2-10 Maintenance Standard..........................W3-5-10
Disassemble Travel Motor ................... W3-2-18
Assemble Travel Motor ........................ W3-2-22 Group 6 Upper and Lower Roller
Disassemble Brake Valve .................... W3-2-28 Remove and Install Upper Roller............W3-6-1
Assemble Brake Valve ......................... W3-2-30 Remove and Install Lower Roller............W3-6-4
Maintenance Standard ......................... W3-2-32 Disassemble Upper Roller ......................W3-6-8
Assemble Upper Roller.........................W3-6-10
Group 3 Center Joint Disassemble Lower Roller ....................W3-6-12
Remove and Install Center Joint ............ W3-3-1 Assemble Lower Roller.........................W3-6-14
Disassemble Center Joint ...................... W3-3-4 Maintenance Standard..........................W3-6-16
Assemble Center Joint ........................... W3-3-8
Maintenance Standard ......................... W3-3-11 Group 7 Track
Remove and Install Track .......................W3-7-1
Maintenance Standard............................W3-7-8
17VW-3-1
(Blank)
17VW-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Removal
1. Put matching marks on inner race (1) of swing
bearing and track frame (2). Matching Mark
CAUTION: Front attachment weight:

13200 kg (29100 lb)
Counterweight weight:
11700 kg (25790 lb)
Cab weight: 290 kg (640 lb) 1 2
2. Remove front attachment, counterweight and cab.
NOTE: For removal and installation of the front W142-03-01-001
attachment, counterweight and cab, refer to
“Remove and Install” sections respectively.
3
19000 kg (41890 lb)
Main frame weight:
6550 kg (14440 lb)
3. Remove the main frame mounting bolts (40 used)
to remove the main frame. Then, remove the
knock pins (2 used).
: 50 mm
4. Disconnect all grease pipes from the swing bear-

W105-03-01-002
ing.
: 17 mm
Ȁ
5. Remove inner race mounting bolts (3) (40 used)
from the track frame.
: 46 mm
ST 9051
CAUTION: Swing bearing weight:

1080 kg (2380 lb)
6. Attach lifting tool (ST 9051) to hoist and remove
swing bearing (4) by crane.
4 W105-03-01-003
W3-1-1
Installation
Clean the mating surfaces of track frame and the
swing bearing.
1. Apply THREEBOND #1102 to the mounting sur-

face of swing bearing on track frame.
1080 kg (2380 lb)
IMPORTANT: Be sure to align the matching marks.
Otherwise, the inner race soft zone
will be in wrong position.
2. Hoist swing bearing (4). Align the swing bearing
with the track frame by aligning the matching
4
marks put during disassembly. W105-03-01-003
Front
Knock Pin Mounting Positions
Soft Zone Position

(Inner Race)
Knock Pin Mounting Positions
3. Apply LOCTITE #262 to mounting bolts (3) (40 120° 120° Plug Position
used) for inner race of swing bearing and tighten Soft Zone Position
to specified torque. (Outer Race)
: 46 mm
: 1750 N⋅m (175 kgf⋅m, 1270 lbf⋅ft)
4. Connect all grease pipes to swing bearing.

: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
Greasing Hole Posi-
tions (3 Places) W111-03-01-001

19000 kg (41890 lb)
Main frame weight: 3
6550 kg (14440 lb) 5
5. Place main frame, tap the knock pins (2 used) into
the outer race and install them with mounting bolts
(5) (40 used).
: 50 mm
: 2160 N⋅m (220 kgf⋅m, 1590 lbf⋅ft)

13200 kg (29100 lb) W105-03-01-002
counterweight: weight:
11700 kg (25790 lb)
Cab weight: 290 kg (640 lb)
6. Install front attachment, counterweight and cab.
W3-1-2
(Blank)
W3-1-3
DISASSEMBLE SWING BEARING
1 2 3
10 9, 8 7 6 5 W166-03-01-001
12
11
6
7
8
10
W111-03-01-008
1 - Outer Race 4 - Plug 7 - Inner Race 10 - Rod and Turnbuckle (3 Used)

2 - Seal 5 - Seal 8 - Support (73 Used) 11 - Bolt (40 Used)
3 - Pin 6 - Ball (76 Used) 9 - Support (3 Used) 12 - Grease Fitting (3 Used)
W3-1-4
Disassemble Swing Bearing
• Be sure to read all “Precautions for Disassembly
1080 kg (2380 lb)
and Assembly” work thoroughly on page W1-1-1
3. Hoist the swing bearing outer race (1) horizontally
before starting the disassembly work.
and slightly using lifting tool (ST 9051).
Remove fastening rod and turnbuckles (10) (3
1. Remove pin (3) located in plug (4) section by tap- used) of seal (5) to remove seals (2 and 5).
ping from the bottom side of the swing bearing.
NOTE: The pin (3) head was crimped after being 4. Place inner race (7) of the swing bearing on
driven in. Grind off the crimped part. wooden blocks, then lift outer race (1) by crane.
5. While rotating outer race (1), pull out balls (6) (76
3 used) and supports (8) (73 used) and (9) (3 used)
from the plug hole.
Use round-bar magnet (A) to take out balls. Use
tip-bent wire (B) to pull out supports (8 and 9).
4 2
W105-03-01-007
A
7
2. pull out plug (4).
NOTE: Screw bolt (M10, Pitch 1.5) in the threaded
hole in plug (4). Tap the bolt head from the
bottom side or pull the bolt to remove the
plug. 5 W105-03-01-009
6
W105-03-01-008
8, 9 W105-03-01-010
W3-1-5
ASSEMBLE SWING BEARING
1 2 3
10 9, 8 7 6 5 W166-03-01-001
12
11
6
7
8
10
W111-03-01-008
1 - Outer Race 4 - Plug 7 - Inner Race 10 - Rod and Turnbuckle (3 Used)

2 - Seal 5 - Seal 8 - Support (73 Used) 11 - Bolt (40 Used)
3 - Pin 6 - Ball (76 Used) 9 - Support (3 Used) 12 - Grease Fitting (3 Used)
W3-1-6
Assemble Swing Bearing 3. Remove all oil on the groove surfaces of seal (2)
thoroughly. Then, apply THREEBOND #1735 to
the groove of seal (2) and install the seal.
1080 kg (2380 lb)
Install seal (5) in the groove of the inner race and
1. Align the ball grooves in inner race and outer race fasten seal (5) with rod and turnbuckle (10).
on swing bearing. (tighten each turnbuckle 10 to 15 turns evenly)
NOTE: When fasten the turnbuckle, use a round
IMPORTANT: Apply grease to balls (6) and bar (Dia. 2 to 2.3 mm (0.08 to 0.09 in )).
supports (8 and 9).
After installing all balls (6) and sup-
ports (8 and 9), confirm that the 4. Tap plug (4) and pin (3) into outer race (1).
clearance between the last ball and Crimp the head of the pin with a punch.
the first support is 40± ±5 mm (1.6±±0.2
3
in). If not, adjust the number of sup-
ports (8 or 9) so that the specified
clearance is obtained.
2. Install balls (6) (73 used) and supports (8) (73
1
used) into the plug hole in the order of one ball (6),
one support (8), one ball (6) again and so on. In-
stall the left balls (6) (3 used) and supports (9) (3
used) alternately.
4
W142-03-01-007
2 5. Sufficiently lubricate the swing bearing with

grease (Alvania EP2 or equivalent).
6
5
W142-03-01-005
9, 8
W142-03-01-006
40±5 mm (1.6±0.2 in)

6 8, 9
W142-03-01-004
NOTE: Dia. of support (8): 35 mm (1.4 in)

Dia. of support (9): 40 mm (1.6 in)
W3-1-7
(Blank)
W3-1-8
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE

lines.
repair work.
Preparation

wrench to release the trapped air in the hydraulic M104-07-021

tem on page W1-1-2.
: 4 mm
Cap

tank.
W183-01-01-001
W3-2-1
Removal
Before removing the travel device, the tracks must be
removed first. For removal and installation of the
tracks, refer to “Remove and Install Tracks” section on
1
page W3-7-1. Bolt
In this section, the procedure starts on the premise
that the tracks have already been removed.
1. Remove bolts from cover (2).

Install eyebolts (M16, Pitch 2.0) into the bolt
holes to hoist and hold the cover by crane.
: 24 mm
2
CAUTION: Cover (2) weight : 50 kg (110 lb)

W16J-03-02-006
2. Remove bolts (1) (7 used) and washers (7 used)
to remove cover (2) from the track frame.
: 24 mm
IMPORTANT: Attach identification tags to hoses

for re-assembly. 3 Track Frame 4
3. Disconnect hoses (3 and 4) from travel device (6)
and cap all disconnected hose ends.
: 27 mm, 22 mm
10
4. Remove socket bolts (8) (8 used) from split
5
flanges (7) (4 used) to disconnect hoses (9 and
10) from travel device (6). Cap all disconnected
hose ends.
: 10 mm
6
CAUTION: Travel Device Weight: 1085 kg
(2390 Ib) 9 8 7 W16J-03-02-005
5. Attach wire ropes on travel device (6), lift and

hold the travel device by crane.
6
6. Put matching marks on travel device (6) and the
track frame.
Remove bolts (5) (24 used). Lift and remove the
travel device by crane.
: 41 mm
7. Remove travel device (6) from the other side in

the same procedures 1 to 6.
5
W111-03-02-002
W3-2-2
Installation
5. Install bolts onto cover (2).
: 24 mm
CAUTION: Travel device weight: 1085 kg
(2390 lb) 1
IMPORTANT: Be sure to align the matching marks Blind Bolt
made during disassembling.
1. Hoist travel device (6) by crane to install the
travel device onto the track frame with bolts (5)
(24 used).
: 41 mm
: 1400 N⋅m (143 kgf⋅m, 1030 Ibf⋅ft)
2. Connect hoses (9 and 10) to the travel device (6) 2

with split flanges (7) (4 used) and tight the split
flange with socket bolts (8) (8 used). W16J-03-02-006
: 10 mm
: 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft) 6. Install travel device (6) to the other side in the
same procedures 1 to 5.
3. Connect hoses (3 and 4) onto travel device (6).
: 27 mm IMPORTANT: After installation, check the oil level.
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft) Start the engine and check for oil
: 22 mm leaks.
: 39 N⋅m (4.0 kgf⋅m, 29 Ibf⋅ft) After completing installation of the
travel device, be sure to perform
3 Track Frame 4 running-in to prevent motor seizure.
Perform break-in operation as follows:
1. Run the engine with the engine control dial in the
10 slow idle position.
2. Turn the travel speed mode switch to the slow
5 speed position.
3. Drive the machine for 2 minutes or more.
9 8 7 W16J-03-02-005
CAUTION: Cover (2) weight: 50 kg (110 lb)

4. Install cover (2) onto the track frame with bolts (1)
(7 used) and spring washers (7 used).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 156 lbf⋅ft)
W3-2-3
DISASSEMBLE TRAVEL DEVICE 12
11
10
9
8
7
6
4 28 25
27
26
25 29
3
30
24
23
22
21
2
20
1 18 19 31
17
32
32
33
34
35
36
37
38
39
40
41
37 50
14 15
16
13
49
48
47
46
45
44
43 W17V-03-02-001
42
1 - Bolt (4 Used) 14 - Lock Plate 27 - Pin (3 Used) 39 - Spring Pin (4 Used)
2 - Spring Washer (4 Used) 15 - Bolt (2Used) 28 - 1st Stage Planetary Gear 40 - Pin (4 Used)
(3 Used)
3- Motor 16 - Sprocket 29 - Spring Pin (3 Used) 41 - Needle Bearing (8 Used)
4- O-Ring 17 - Spring Washer (24 Used) 30 - Spacer 42 - Shaft
5- Housing 18 - Bolt (24 Used) 31 - 1st Stage Carrier 43 - Ring Gear
6- Floating Seal 19 - 3rd Stage Carrier 32 - Thrust Plate (8 Used) 44 - Socket Bolt (30 Used)
7- Roller Bearing 20 - Spacer 33 - 2nd Stage Planetary Gear 45 - Stopper Pin
(4 Used)
8- Bolt (12 Used) 21 - 3rd Stage Sun Gear 34 - Spring Pin (4 Used) 46 - Bearing
9- Support 22 - 2nd Stage Carrier 35 - Pin (4 Used) 47 - Cover
10 - Drum 23 - Spacer 36 - Needle Bearing (4 Used) 48 - Spring Washer (18 Used)
11 - Roller Bearing 24 - 2nd Sun Gear 37 - Thrust Plate (8 Used) 49 - Bolt (18 Used)
12 - O-Ring 25 - Thrust Plate (6 Used) 38 - 3 rd Stage Planetary Gear 50 - Plug (3 Used)
(4 Used)
13 - Bearing Nut 26 - Needle Bearing (3 Used)
W3-2-4
Disassemble Travel Device
CAUTION: Motor (3) weight: 135 kg (300 lb)
2. Put matching marks on the mounting surface of
and Assembly Work” thoroughly on page W1-1-1
motor (3) and housing (5).
Install eyebolts (M12, Pitch 1.75) (2 used) into the
motor diagonally. Remove four bolts (1), then
CAUTION: Pressure may remain in the travel hoist and remove the motor by crane. Remove O-
device. Slowly loosen the air bleed plug to ring (4) from the motor.
completely release the residual pressure. : 27 mm 5
Then, remove the drain plug and drain the
gear oil into a container. 1
If the air bleed plug is loosened quickly, the
plug may fly off and/or gear oil may spurt.
Keep your face and body away from the plug. 3
CAUTION: Travel device weight:

1085 kg (2390 lb)
1. Hoist and hold the travel device by crane. After
loosening plug (50-B) 2 to 3 turns, remove drain
plug (50-A) to drain gear oil from the travel device. Eyebolts Mount-
Lay the travel device on a workbench with motor ing Positions
(3) facing up. W16J-03-02-002
: 17 mm
CAUTION: Travel device weight:
960 kg (2120 lb)
50 -B 3. Attach a wire rope to the middle of drum (10).
Hoist the travel device by crane and place it on the
workbench with cover (47) facing up.
CAUTION: Cover (47) weight: 40 kg (90 lb)
4. Put matching marks on the mounting surface of
cover (47) and ring gear (43).
Install two eyebolts (M12, Pitch 1.75) into the plug
holes (2 places) in cover.
50 -A Remove bolts (49) (18 used), then hoist and re-
move the cover from the ring gear by crane.
W111-03-02-006 : 22 mm
NOTE: Since THREEBOND #1215 has been ap-
plied to the mating surfaces of ring gear
(43) and cover (47), a bolt of 34 mm (1.3 in)
in length or more should be screwed into
the plug hole in cover to move the cap and
remove it.
NOTE: Do not disassemble stopper pin (45) and
bearing (46) from cover (47) unless they
are damaged and worn out.
W3-2-5
12
11
10
9
8
7
6
28 25
27
26
25 29
30
24
23
22
21
20
19 31
32
32
33
34
35
36
37
38
39
40
41
37
14 15
16
13 49
44
43 W17V-03-02-001
42
W3-2-6
CAUTION: The first stage carrier (31) as- 10. Install special tool (ST 3140) onto bearing nut (13)
sembly weight: 30 kg (70 lb) to loosen and remove the bearing nut.
5. Remove shaft (42) from first stage carrier (31). At-
ST 3140
tach wire ropes on first stage carrier assemblies
(25 to 31), then hoist by crane to remove them
from second stage carriers (22). Remove second
stage sun gear (24) from the second stage carrier.

sembly weight: 50 kg (110 lb)
6. Wind a wire rope onto second stage carrier (22).
Hoist and remove the second stage carrier as-
semblies (22, 23, 32 to 36) by crane. Remove
third stage sun gear (21).
W111-03-02-018
CAUTION: Ring gear (43) weight: 130 kg IMPORTANT: The mating parts of support (9) and
(290 lb) housing (5) are sliding surface. Take
7. Put matching marks on the connecting parts of care not to damage the sliding sur-
ring gear (43) and drum (10). Remove socket face and put the removed drum (10)
bolts (44) (30 used).Install eyebolts (M14, Pitch assembly onto wooden blocks.
2.0) into the bolt (49) holes (2 places) in ring gear.
Hoist and remove the ring gear by crane. Remove CAUTION: Drum (10), sprocket (16) and
O-ring (12) from the drum. other parts weight: 350 kg (770 lb)
: 17 mm 11. Fix housing (5) to workbench securely. Install
eyebolts (M22, Pitch 2.5) into the bolt (44) holes
NOTE: Apply LOCTITE #262 to socket bolt (44).
(2 places) in the drum (10).
Hoist and remove the drum assembly from the
housing by crane.
CAUTION: The third stage carrier (19) as-
At this time, the inner race of roller bearing (7) is
also removed along with it.
8. Wind a wire rope onto third stage carrier (19).
Hoist and remove third stage carrier assemblies
(19, 20, 37 to 41) by crane. 12. Remove the inner race of roller bearing (11) from
drum (10).
Attach nylon slings (2 used) to sprocket (16) to
9. Remove bolts (15) (2 used) to remove lock plate
turn the drum assembly over.
(14).
: 19 mm
NOTE: Apply LOCTITE #262 to bolt (15). IMPORTANT: As for handling of floating seal (6),
refer to the Precautions for Floating
Seal Handling on page W1-1-4.
13. Remove the floating seal (6) from one side on
housing (5).
14. Remove the floating seal (6) from the other side
on support (9).
W3-2-7
11
10
9
8
7
29
30
23
22
20
18 19 31
34
37
38
39
40
41
37
16
W17V-03-02-001
W3-2-8
15. Put matching marks on the connecting surface of 19. Tap spring pin (39) out from pin (40) with a round
sprocket (9) and drum (10). Remove bolts (8) (12 bar [Dia: 8 mm (0.31 in)], which is installed on the
used) to remove the support from the drum. Re- third stage carrier (19) assembly.
move the inner race of roller bearing (7) from the Remove the pin to remove third stage planetary
drum. gear (38) and thrust plates (37) (2 used) from the
: 19 mm third stage carrier.
NOTE: Apply THREEBOND #1215 to the connect- Remove needle bearings (41) (2 used) from the
ing surface of support (9) and drum (10). third stage planetary gear.
20. Remove spring pins (39) (3 used), pins (40) (3

CAUTION: Sprocket (16) weight: used), third stage planetary gears (38) (3 used),
150 kg (330 lb) thrust plates (37) (6 used) and needle bearings
Drum + sprocket (41) (6 used) from third stage carrier (19) accord-
16. Attach nylon slings (2 used) on sprocket (16) and ing to the steps in procedure 19. Then remove
rotate it reverse. Put matching marks on the con- spacer (20) from the third stage carrier.
necting surface of sprocket and drum (10).
Remove the corks (2 used) from the sprocket and
21. Disassemble the first stage carrier (31) assembly
install eyebolts (M27, Pitch 3.0) into the cork holes
and the second stage carrier (22) assembly ac-
instead. Remove bolts (18) (24 used). Hoist and
cording to the steps in procedure 19.
remove the sprocket by crane.
The diameter of round bar for spring pin (29):
: 41 mm
4 mm (0.16 in)
NOTE: Apply LOTITE #262 to bolt (18). The diameter of round bar for spring pin (34):
5 mm (0.20 in)
IMPORTANT: Do not remove the outer race of
roller bearings (7) and (11) from 22. Remove spacer (30) from first stage carrier (31).
drum (10) unless necessary. Remove spacer (23) from second stage carrier
If the bearing is not pressed in suffi- (22).
ciently, the service life of the bearing
may be affected. In case the outer
race has been removed, it must be
replaced with a new one.
17. Remove the outer race of roller bearing (7) from
drum (10) with a bar and a hammer.
CAUTION: Drum (10) and other parts weight:

185 kg (410 lb)
18. Wind nylon slings at the middle part of drum (10),
then hoist the drum by crane to put it horizontally.
Install eyebolts (M12, Pitch 1.75) into the bolt (8)
holes (2 places) in drum.
Hoist and turn the drum over by crane. Remove
the outer race of roller bearing (11) from the drum
with a bar and a hammer.
W3-2-9
ASSEMBLE TRAVEL DEVICE
16
4 5 6 8 9 7 11 13 10 12 44 20 19 43 22 23
31
50
30
42
3
47
46
24
45
28
1 26
27
2
29
25
21 49
48
14 15 17 18 37 41 38 40 37 39 32 33 36 32 34 35
T17V-03-05-001
1 - Bolt (4 Used) 14 - Lock Plate 27 - Pin (3 Used) 39 - Spring Pin (4 Used)

2 - Spring Washer (4 15 - Bolt (2 Used) 28 - 1st Stage Planetary Gear (3 Used) 40 - Pin (4 Used)
Used)
3 - Motor 16 - Sprocket 29 - Spring Pin (3 Used) 41 - Needle Bearing (8 Used)
4 - O-Ring 17 - Spring Washer (24 Used) 30 - Spacer 42 - Shaft
5 - Housing 18 - Bolt (24 Used) 31 - 1st Stage Carrier 43 - Ring Gear
6 - Floating Seal 19 - 3rd Stage Carrier 32 - Thrust Plate (8 Used) 44 - Socket Bolt (30 Used)
7 - Roller Bearing 20 - Spacer 33 - 2nd Stage Planetary Gear (4 Used) 45 - Stopper Pin
8 - Bolt (12 Used) 21 - 3rd Stage Sun Gear 34 - Spring Pin (4 Used) 46 - Bearing
9 - Support 22 - 2nd Stage Carrier 35 - Pin (4 Used) 47 - Cover
10 - Drum 23 - Spacer 36 - Needle Bearing (4 Used) 48 - Spring Washer (18 Used)
11 - Roller Bearing 24 - 2nd Sun Gear 37 - Thrust Plate (8 Used) 49 - Bolt (18 Used)
12 - O-Ring 25 - Thrust Plate (6 Used) 38 - 3rd Stage Planetary Gear (4 Used) 50 - Plug (3 Used)
13 - Bearing Nut 26 - Needle Bearing (3 Used)
W3-2-10
Assemble Travel Device
CAUTION: Drum (10) and others weight:
175 kg (390 lb)
and Assembly Work” thoroughly on page W1-1-1
6. Install eyebolts (M22, Pitch 2.5) into the socket
before starting the assembly work.
bolt (44) holes (2 places) in drum (10).
Lift and place the drum with the cover (47) side
CAUTION: Housing (5) weight: facing down by crane.
140 kg (310 lb) Tap the outer race of roller bearing (11) with a bar
1. Wind a nylon sling on housing (5) body. Lift and and a hammer evenly to intall it onto the drum.
place the housing with motor (3) section facing NOTE: Tap the bearing and listen to ring to see if
down by crane. the installation of the outer race is
completed into drum (10).
IMPORTANT: For handling of the floating seal (6).
Refer to the section “Precautions for
CAUTION: Sprocket (16) weight:
Floating Seal Handling” on page
150 kg (330 lb)
W1-1-4.
7. Install eyebolt (M27, Pitch 3.0) into sprocket (16),
2. Apply enough grease to the O-ring of floating seal
then pass wire rope through. Hoist the sprocket by
(6). Install one half of the floating seal on housing
crane to lower it on the drum (10) assembly.
(5) using a bamboo spatula or similar tool to guide
the seal along the periphery.
IMPORTANT: Align the matching marks between
sprocket (16) and drum (10). Apply
3. Insert one half of floating seal (6) to support (9).
LOCTITE # 262 to bolt (18).
Install bolts (8) (12 used) to the support, then put
8. Install spring washer (17) to each bolts (18) (24
them into housing (5).
used). Tighten the bolts and install sprocket (16)
: 19 mm
onto drum (10).
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
: 41 mm
: 1370 N⋅m (140 kgf⋅m, 1010 lbf⋅ft)
4. Tap the inner race of roller bearing (7) with a bar
and hammer evenly to install it onto housing (5).
9. Apply THREEBOND #1215 to the matching sur-
NOTE: Tap the bearing and listen to ring to see if faces of support (9) and drum (10). Apply hydrau-
the installation of the inner race is lic oil to the inner race of bearing (7).
completed into housing (5).
CAUTION: Drum (10) weight: 170 kg (370 lb) CAUTION: Drum (10), sprocket (16) and oth-
5. Install eyebolts (M12, Pitch 1.75) into the bolt (8) ers weight: 330 kg (730 lb)
holes (2 places) in drum (10). IMPORTANT: Be sure the clearance all around
Lift and place the drum with the cover (47) side support (9) in housing (5) shall be
facing down by crane. equal.
Tap the outer race of roller bearing (7) with a bar 10. Hoist the drum (10) assembly by crane and put it
and a hammer evenly to install it onto the drum. onto support (9).
NOTE: Tap the bearing and listen to ring to see if
the installation of the outer race is
completed into drum (7).
W3-2-11
9 11 16 13 10 20 19
47
14
15 37 41 38 40 37 39 T17V-03-05-001
W3-2-12
IMPORTANT: Align the matching marks between IMPORTANT: After tightening bearing nut (13), be
support (9) and drum (10). sure to check bolts (8) (12 used) for
11. Install support (9) to drum (10) and secure it with looseness. If any bolts are loose,
bolts (8) (12 used). tighten it again to the specified
: 19 mm torque.
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft) 16. Perform procedures 14 and 15 twice and tighten
bearing nut (13) to the specified torque.
12. Install the inner race of roller bearing (11) into : 790 N⋅m (81 kgf⋅m, 590 lbf⋅ft)
housing (5) by tapping it with a bar and a hammer
evenly. IMPORTANT: If lock Plate (14) fails to engage the
spline of housing (5), tighten bearing
IMPORTANT: Install bearing nut (13) with the nut (13) further in the tightening di-
stepped part facing roller bearing rection to align with the spline.
(11). Apply a film of grease to the Apply LOCTITE #262 to bolt (15).
threaded part of the bearing nut. 17. Install lock plate (14) onto bearing nut (13) with
13. Install bearing nut (13) onto housing (5) and bolts (15) (2 used).
tighten it by hand. : 19 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
NOTE: Apply a film of grease to the threaded part
of bearing nut (13) so as to tighten the nut
to the specified torque. 18. Install spacer (20) onto third stage carrier (19).
14. Install special tool (ST 3140) onto bearing nut (13) IMPORTANT: There is an identification groove in
and tighten it with a wrench. the end face of third stage planetary
: 790 N⋅m (81 kgf⋅m, 590 lbf⋅ft) gear (38). Install the third stage
planetary gear with the identification
ST 3140 groove facing cover (47).
19. Install needle bearings (41) (8 used) onto third
stage planetary gears (38) (4 used). Install the
third stage planetary gear onto third stage carrier
(19) by clamping it with thrust plates (37) (8 used).
20. Apply hydraulic oil to pins (40) (4 used). Align the

spring pin (39) holes in third carrier (19) to install
the spring pin.
W111-03-02-018
15. Tap on drum (10) with a plastic hammer to secure

appropriate play. Then turn drum three times to
the right and left. Rotate the sprocket (16) both
clockwise and counterclockwise 4 to 5 turns.
W3-2-13
5 10 12 44 20 19 43 22 23
31
30
42
3
47
24
28
26
27
29
25
21 49
37 41 38 40 37 39 32 33 36 32 34 35
T17V-03-05-001
W3-2-14
IMPORTANT: When installing spring pin (39), be
CAUTION: Ring Gear (43) weight:
sure to let its slit face the end of pin
130 kg (290 lb)
(40).
IMPORTANT: Be sure to align the splines of ring
21. Install spring pins (39) (4 used) into third stage
gear (43) with the teeth of third stage
carrier (19) and pin (40) with a round bar (Dia: 8
planetary gears (38) (4 used). Be
mm (0.31 in)).
39 sure to align the matching marks
both on drum (10) and ring gear.
40 27. Apply grease to O-ring (12) and install it on drum
(10). Install eyebolts (M14, Pitch 2.0) into the bolt
(49) holes (2 places) in ring gear (43). Lift the ring
Slit
gear by crane and lower it to drum.
W178-02-06-002
22. Install spacer (30) to first stage carrier (31). 28. Apply LOCTITE #262 to socket bolts (44) (30
used). Install ring gear (43) onto drum (10) with
23. Install needle bearings (26) onto first stage plane- socket bolt.
tary gears (28). Clamp the first stage planetary : 17 mm
gear with thrust plates (25) (2 used) and install the : 740 N⋅m (76 kgf⋅m, 550 lbf·ft)
first stage planetary gear onto first stage carrier
(31). 29. Install third stage sun gear (21) onto third stage
Install the left first stage planetary gears (2 used) carrier (19) with the smaller and facing cover (47).
according to the same procedure. Upper
IMPORTANT: When installing spring pin (29), be

sure to let its slit face the end of pin
(27).
24. Apply hydraulic oil to pin (27). Install the pins (3
used) to first stage carrier (31) while aligning the W166-03-02-001
holes for spring pin (29). Install spring pins (3 21

used) into the first stage carrier and the pin with a
round bar (Dia : 4 mm (0.16 in)). CAUTION: The second stage carrier (22) as-
29 sembly weight: 50 kg (110 lb)
27 30. Wind wire rope onto second stage carrier (22) as-
semblies (22, 23 and 32 to 36). Lift the second
stage carrier assemblies by crane and lower them
Slit
onto the third stage sun gear (21).
W178-02-06-002
25. Assemble second stage carrier (22) according to 31. Install second stage sun gear (24) onto second
the procedures 22 to 24. stage carrier (22) with the smaller end facing
Round Bar Dia: 5 mm (0.20in) cover (47).
Upper
CAUTION: The third stage carrier (19) as-

26. Wind wire rope onto third stage carrier (19) as-
semblies (19, 20, 37 to 41). Lift the third stage
24 W166-03-02-002
carrier assemblies by crane and lower them onto
housing (5) carefully.
W3-2-15
16
4 5 6 9 43 22
50
31
42
3
47
46
45
28
25
49
48
T17V-03-05-001
W3-2-16
CAUTION: The first stage carrier (31) as- CAUTION: Travel device (sprocket) weight:
sembly weight: 30 kg (70 lb) 955 kg (2110 lb)
32. Hoist first stage carrier (31) assemblies (25 to 31) 40. Wind nylon sling to the matching part of housing
by crane, then install them into second stage car- (5) flange and support (9). Lift the travel device
rier (22). and turn it over by crane.
33. Install shaft (42) into the center of the carrier to 41. Fill gear oil 19 L (5.0 gal) into travel device.
engage with first stage planetary gears (28) (3
used). 42. Apply grease to O-ring (4) and install it onto motor
(3).
34. Attach a tube bar on bearing (46). Tap the tube
bar with a hammer and install the bearing onto
cover (47). CAUTION: Motor (3) weight: 135 kg (300 Ib)
Bearing inner diameter: 35 mm (1.4 in) 43. Install eyebolts (M12, Pitch 1.75) (2 used) into the
outer diameter: 80 mm (3.1 in) sling holes in motor (3). Lift the motor and install it
onto housing (5) by crane while aligning the
splines in shaft (42) with those in the motor.
35. Attach a tube bar on stopper pin (45). Tap the tube
bar with a hammer to install the stopper pin into 5
bearing (46).
Stopper pin diameter: 26 mm (1.0 in) 9
CAUTION: Cover (47) weight: 40 kg (90 lb) 3

IMPORTANT: Apply THREEBOND #1215 to the
mounting surface for cover (47) on
ring gear (43).
36. Install eyebolts (M12, Pitch 1.75) into the plug
holes (2 places) in cover (47).
Lift the cover by crane and lower it to ring gear Eyebolts Mounting
Positions
(43).
W16J-03-02-002
37. Install cover (47) onto ring gear (43) with bolts
(49) (18 used), and spring washers (48) (18 44. Install motor (3) into housing (5) with the bolts (4
used). used). Install spring washers (2) (4 used) to each
: 22 mm bolts (1) (4 used).
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) : 27 mm
: 295 N⋅m (30 kgf⋅m, 215 Ibf⋅ft)
38. Wrap the seal tape to plugs (50) (3 used) and in-
stall the plugs into cover (47).
: 17 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
39. Install new corks (2 used) to sprocket (16) and

cover (47) respectively.
W3-2-17
DISASSEMBLE TRAVEL MOTOR
4
3
2
1 17
5 16
15
6
7 14
2
13
12
11
10
9
20
8
19
18
32
21
31
30
28
29
27
26
25
24
23
22
W17P-03-02-002
1- Casing 9- Swash Plate 17 - Roller Bearing 25 - Backup Ring
2- O-Ring (4 Used) 10 - Piston (9 Used) 18 - Friction Plate 26 - Brake Piston
3- Spring (2 Used) 11 - Retainer 19 - Friction Plate (4 Used) 27 - O-Ring
4- Piston (2 Used) 12 - Holder 20 - Friction Plate 28 - Spring (10 Used)
5- Shaft 13 - Spring (9 Used) 21 - Disc Plate (5 Used) 29 - Pin (4 Used)
6- Roller Bearing 14 - Cylinder Block 22 - Backup Ring 30 - Valve Housing
7- Oil Seal 15 - Valve Plate 23 - O-Ring 31 - Socket Bolt (9 Used)
8- Steel Ball (2 Used) 16 - Collar 24 - O-Ring 32 - Pin
W3-2-18
Disassemble Travel Motor 3. Remove springs (28) (10 used), O-rings (2) (4
• Be sure to read all “Precautions for Disassembly used), pins (29) (4 used) and O-ring (27) from cas-
and Assembly Work” thoroughly on page W-1-1-1 ing (1).
IMPORTANT: Casing (1) may move away. Fix cas-
ing (1) securely.
CAUTION: Valve housing (30) weight:
4. Install eyebolts (M12, Pitch 1.75) onto pin (29)
40 kg (90 lb)
holes (2 places) in brake piston (26). Lift the brake
IMPORTANT: Loosen socket bolts (31) (9 used)
piston and remove it from casing (1) by crane.
evenly. When loosening the socket
bolts, valve housing (30) may come NOTE: In case casing (1) moved away, tap the pe-
up from casing (1) since there is a riphery of the casing with a plastic hammer.
spring force coming from springs
(13) and (28). Note down the clear- 5. Remove O-rings (23 and 24), backup rings (22)
ance between the casing and the and (25) from brake piston (26).
valve housing.
When removing the valve housing
from the casing, valve plate (15) will CAUTION: The cylinder block (14) assembly
come out with the valve housing, do weight: 20 kg (40 lb)
not let the plate come off. IMPORTANT: If cylinder block (14) needs to be re-
1. Put matching marks on the connecting part of placed, cylinder block assemblies
valve housing (30) and casing (1). Install eyebolts (10 to 15) with valve plate (15) should
(M12, Pitch 1.75) onto the valve housing. Remove be replace.
socket bolts (31) (9 sued). Lift the valve housing 6. Place casing (1) horizontally with the brake re-
and remove it from the casing by crane. At this lease circuit at lower side. Remove cylinder block
time, the valve housing is still with the outer race (14) assemblies (10 to 15) from casing (1).
of roller bearing (17) in.
: 14 mm
1 30 NOTE: Hold cylinder block (14) and turn it left and
right lightly by two hands to take it out
31 slowly.
7. Remove pistons (10) (9 used), retainer (11),

holder (12) and springs (13) (9 used) from cylinder
block (14).
IMPORTANT: Since friction plates (18, 19, 20) are

different in thickness and the order
Eyebolt Mount-
ing Position
to install them has been determined,
they should be kept in order while
W16J-03-02-002 removing.
IMPORTANT: Take care not to damage valve plate 8. Remove friction plate (20) from casing (1). Re-
(15). move disc plates (21) (5 used) and friction plates
2. Remove collar (16) and valve plate (15) from (19) (4 used) one by one alternately. Remove fric-
valve housing (30). tion plates (18).
W3-2-19
4
3
17
1
5
6
7
30
W17P-03-02-002
W3-2-20
IMPORTANT: Do not damage the friction surface 14. Remove oil seal (7) from casing (1).
of swash plate (9).
Piston (4) and steel ball (8) may IMPORTANT: Do not remove the inner race of
come out with the swash plate, be roller bearing (17) from shaft (5) and
sure to keep the piston and the steel the outer race of roller bearing from
ball from dropping. valve housing (30) unless necessary.
9. Remove swash plate (9) from casing (1). IMPORTANT: When replacing roller bearing, take
care not to damage the surfaces of
10. Remove pistons (4) (2 used), springs (3) (2 used) the shaft and valve housing.
and steel balls (8) (2 used) from casing (1). 15. Make a clearance between shaft (5) and the inner
NOTE: If it is difficult to remove steel ball (8), clean race of roller bearing (17) using a flat chisel and a
grease first with some kerosene or thinner hammer. Pull the inner race out with a gear puller.
with the steel ball set in casing (1), and then Insert a bar into the clearance between the bear-
take it out from casing (1) with a magnet. ing and housing, then pry them to pull the inner
race of roller bearing (17) out from housing (30).
IMPORTANT: Do not damage the spline part of
shaft (5) and contact part of oil seal
(7). Oil leakage will occur if they are
damaged.
11. Tap the spline hole in shaft (5) at the most end
with a bar and hammer. Remove shaft (5) from
casing (1). At this moment, the inner race of roller
bearing (6) is connecting with the shaft.
IMPORTANT: Do not remove the inner race of

roller bearing (6) from shaft (5) and
the outer race of roller bearing (6)
from casing (1) unless necessary.
12. Remove the inner race of roller bearing (6) from
shaft (5) with a press.
IMPORTANT: Keep the outer race of roller bearing

(6) properly so that it can be installed
in the same direction before disas-
sembling.
13. Remove the outer race of roller bearing (6) from
casing (1) with a bar and a hammer.
W3-2-21
ASSEMBLE TRAVEL MOTOR
3 4 5 18 20 22, 23 26 24, 25 28
31
8 32
16
30
17
1
15
29
7
27
2
6 9 12 11 13 19 21 10 14 Brake Release Circuit
W17V-03-02-002
1- Casing 9- Swash Plate 17 - Roller Bearing 25 - Backup Ring

2- O-Ring (4 Used) 10 - Piston (9 Used) 18 - Friction Plate 26 - Brake Piston
3- Spring (2 Used) 11 - Retainer 19 - Friction Plate (4 Used) 27 - O-Ring
4- Piston (2 Used) 12 - Holder 20 - Friction Plate 28 - Spring (10 Used)
5- Shaft 13 - Spring (9 Used) 21 - Disc Plate (5 Used) 29 - Pin (4 Used)
6- Roller Bearing 14 - Cylinder Block 22 - Backup Ring 30 - Valve Housing
7- Oil Seal 15 - Valve Plate 23 - O-Ring 31 - Socket Bolt (9 Used)
8- Steel Ball (2 Used) 16 - Collar 24 - O-Ring 32 - Pin
W3-2-22
Assemble Travel Motor
• Be sure to read all “Precautions for Disassembly IMPORTANT: Align the spherical hole in swash
and Assembly Work” thoroughly on page W1-1-1 plate (9) with steel ball (8), then in-
before starting the assembly work. stall the swash plate.
Apply grease to matching part of
IMPORTANT: Apply grease on inside periphery of casing (1) for the swash plate.
oil seal (7) for casing (1) at the 6. Install swash plate (9) onto casing (1) with its
pressed-in part and outside periph- thicker side facing down.
ery of the oil seal.
In addition, the oil seal should be IMPORTANT: Arrange disc plates (21) (5 used) with
pressed in straight to prevent it from their notch position facing same di-
deforming. rection. Then install them onto cas-
1. Press oil seal (7) into casing (1). ing (1).
7. Install friction plate (18) onto casing (1). Then in-
IMPORTANT: Install the outer race of roller bearing stall disc plates (21) (5 used) and friction plates
(6) with the stamp mark on the outer (19) (4 used) alternately. Install friction plate (20)
race facing the swash plate (9) side. at last.
2. Tap the outer race of roller bearing (6) evenly with NOTE: Friction plates (18), (20) and (19) are in
a bar and a hammer while instaling the outer race different thickness.
into casing (1). (18), (20): 4.8 mm (0.20 in)
NOTE: Tap the bearing and listen to ring to confirm (19) : 3 mm (0.1 in)
if installation is completed. In addition, align the friction plate with the
notch position of casing (1) first, then install
it.
IMPORTANT: Install the inner race of roller bearing
(6) with its collar facing swash plate IMPORTANT: Apply hydraulic oil on the piston (10)
(9). mounting hole of cylinder block (14).
3. Tap the inner race of roller bearing (6) evenly with Pay attention to the mounting direc-
a bar and a hammer while installing it into shaft tion of retainer (11).
(5). 8. Install springs (13) (9 used) and holder (12) into
Tap and install the shaft assembly to casing (1) cylinder block (14).
with a hammer. Install pistons (10) (9 used) onto retainer (11) and
install them into the cylinder block.
IMPORTANT: Apply hydraulic oil on outside pe-
riphery of steel ball (8) and piston (4).
Apply hydraulic oil the piston and
the steel ball mounting surface of
casing (1).
4. Install springs (3) (2 used), pistons (4) (2 used)
and steel balls (8) (2 used) into casing (1).
CAUTION: The casing (1) assembly weight:

55 kg (120 lb)
5. Install eyebolts (M18, Pitch 2.5) into the bolts (31)
holes (2 places) in casing (1). Lift the casing as-
sembly up by crane and place it with the brake re-
lease circuit facing down.
W3-2-23
5 22, 23 24, 25 28
31
32
16
30
17
1
15
29
9 12 21 10 14
W17V-03-02-002
W3-2-24
IMPORTANT: Pay attention to the mounting direc-
CAUTION: The cylinder block (14) assembly
tion for brake piston (26), so that the
weight: 20 kg (40 lb)
notch shall be square to the pin (29)
IMPORTANT: Apply hydraulic oil to the piston (10)
holes in casing (1).
sliding surface of swash plate (9)
and the spherical surface of holder 1
(12). The inner race of roller bearing
(17) is on the tip of shaft (5). Take
care not to damage them. 26
Align the shaft splines to those of
cylinder block (14) and disc plate
Notch
(21). Position
9. Install the cylinder block (14) assembly onto shaft
(5).
Ȁ
CAUTION: The casing (1) assembly weight: 29 W16J-03-02-003
55 kg (120 lb)
10. Install eyebolts (M18, Pitch 2.5) into the socket IMPORTANT: Apply grease to the outer surface of
bolts (31) holes (2 places) in casing (1). Lift the brake piston and the inner surface of
casing and place it vertically by crane. casing (1).
12. Tap brake piston (26) with a plastic hammer to in-
IMPORTANT: Apply grease to O-rings (23 and 24) stall it into casing (1).
and backup rings (22 and 25). Full at-
tention should be paid to install O- IMPORTANT: As for springs (28) (10 used), there
ring and backup ring. are twelve spring mounting holes in
11. Install backup rings (25 and 22) and O-rings (24 brake piston (26), (so pay attention
and 23) onto brake piston (26). to where the spring should be in-
NOTE: Install backup ring (22) facing the travel serted and not make mistakes).
device side. Be sure that the free holes should be
Install backup ring (25) facing the valve in diagonal position.
housing (30) side.
26
Free Hole
28
28
W16J-03-02-003
Free Hole
13. Install springs (28) (10 used) onto brake piston

(26).
W3-2-25
5 26
31
32
16
30
17
1
15
29
27
2
W17V-03-02-002
W3-2-26
IMPORTANT: Install the outer race of roller bear-
CAUTION: Valve housing (30) weight:
ing (17) with the stamp mark on the
40 kg (90 lb)
outer race facing the valve plate (15)
IMPORTANT: When installing valve housing (30)
side.
into casing (1), be sure to confirm
14. Tap the outer race of roller bearing (17) evenly
the clearance value between the cas-
with a bar and a hammer to install the outer race
ing and the valve housing is equal to
into valve housing (30).
that noted on disassembling.
Install the inner race to shaft (5).
If the value is different, disassemble
NOTE: Tap the bearing and listen to ring to confirm them and reassemble again.
if the outer race is installed to the most end IMPORTANT: Align the matching marks made
of valve housing (30). when disassembling. If the matching
marks can not be aligned with each
IMPORTANT: Apply grease to the mating surfaces other, brake piston (26) may be in-
of valve plate (15) and valve housing stalled in wrong direction.
(30). 17. Install eyebolt (M12, Pitch 1.75) into the bolt hole
15. Install collar (16) into valve housing (30). Align pin in valve housing (30).
(32) with the pin hole on valve plate (15) to install Hoist valve housing to put it onto casing (1) while
the valve plate into the valve housing. aligning the pin (29) hole in brake piston (26).
Install the valve housing onto the casing with
IMPORTANT: Apply grease to O-rings (2 and 27). socket bolts (31) (9 used).
16. Install O-rings (27) and (2) (4 used) into casing (1) : 14 mm
and install pins (29) (4 used) to valve housing : 440±22 N⋅m
(30). (45±2.2 kgf⋅m, 330±16.0 lbf⋅ft)
NOTE: Tighten socket bolts (31) (9 used) evenly.
1 30
31
Eyebolt Install-
ing Position
W16J-03-02-002
W3-2-27
DISASSEMBLE BRAKE VALVE
6
1 7
2 8
3 5
4 9
10 Plug
11
10 9
35
Orifice
12
36 13
37 14
38 16 15
39 18
40 20
21
48
17 22
19
24
26 5
47
49
46 28 23
10 30 25
9
41 32
27 33
42 34
43 29
44 31
4
45 3
Orifice 2
1
44
43
36 42
41
50
40
39
35
38
37
W183-03-02-010
1- Plug (2 Used) 14 - O-Ring 27 - Spring (2 Used) 39 - Spring (2 Used)

2- O-Ring (2 Used) 15 - Plug 28 - Spring Guide (2 Used) 40 - Spring Seat (2 Used)
3- Spring (2 Used) 16 - Poppet Seat (2 Used) 29 - O-Ring (2 Used) 41 - Plug (2 Used)
4- Check Valve (2 Used) 17 - Backup Ring (2 Used) 30 - Backup Ring (2 Used) 42 - O-Ring (2 Used)
5- Overload Relief Valve (2 18 - O-Ring (2 Used) 31 - O-Ring (2 Used) 43 - Spring (2 Used)
Used)
6- Plug 19 - Backup Ring (2 Used) 32 - Plug (2 Used) 44 - Check Valve (2 Used)
7- O-Ring 20 - Poppet (2 Used) 33 - Nut (2 Used) 45 - Spool
8- Spring 21 - Relief Housing (2 Used) 34 - Set Screw (2 Used) 46 - Valve Housing
9- Plug (6 Used) 22 - Piston (2 Used) 35 - Socket Bolt (8 Used) 47 - Pin (4 Used)
10 - O-Ring (6 Used) 23 - Backup Ring (2 Used) 36 - Cap (2 Used) 48 - Pin
11 - Orifice 24 - O-Ring (2 Used) 37 - O-Ring (2 Used) 49 - Orifice
12 - Socket Bolt (9 Used) 25 - Backup Ring (2 Used) 38 - Spring Seat (2 Used) 50 - Spool Assembly
13 - Valve Assembly 26 - Spring Seat (2 Used)
W3-2-28
Disassemble Brake Valve
CAUTION: The valve housing (46) assembly IMPORTANT: Do not disassemble overload relief
weight: 40 kg (90 lb) valves (5) (2 used). The overload re-
1. Secure the valve housing (46) assembly on a firm lief valve should be replaced as as-
workbench. sembly. Attach tags on each over-
load relief valves so that they can be
2. Remove plugs (6 and 15) and O-rings (7 and 14). installed to their original positions.
Then remove spring (8). In addition, do not rotate set screw
: 10 mm (34), or the setting pressure can
change.
IMPORTANT: Remove valve assembly (13) while 5. Loosen plug (32) to remove overload relief valve
rotating it. If a little resistance is felt (5) from valve housing (46). (2 places at right and
while removing, do not try to remove left)
it by force, return to original position : 36 mm
and retry.
In addition, do not disassemble the 6. Press cap (36) while loosening socket bolts (35)
valve assembly. In case replacement (4 used) to remove the cap from valve housing
should be carried out to any parts of (46). (2 places at right and left)
it, be sure to replace it with the valve : 10 mm
housing (46) assembly including NOTE: In case cap (36) can not be removed, a
spool assembly (50), valve assembly plastic hammer can be used to tap the cap,
(13), orifices (11 and 49) and the however, the loosened socket bolts (35)
plug. should be still on the cap while tapping.
3. Press valve assembly (13) out carefully and rotate
the valve assembly by hand to remove it from 7. Remove spring seat (38), spring (39) and spring
valve housing (46). seat (40) from valve housing (46). (2 places at
right and left)
4. Remove plug (1). Then remove O-ring (2), spring
(3) and check valve (4). (2 places at right and left) IMPORTANT: Remove spool assembly (50) while
: 14 mm rotating it. In case a little resistance
is felt while removing, do not try to
remove it by force, return to original
position and retry.
8. Press spool assembly (50) out carefully. Rotate
the spool assembly by hand to remove it from
valve housing (46).
9. Clamp spool assembly (50) in a vice with a chip of

wood inserted at both sides.
10. Remove plugs (41) (2 used), then remove springs

(43) (2 used) and check valves (44) (2 used) from
spool (45).
W3-2-29
ASSEMBLE BRAKE VALVE
Overload Relief Valve (5)
16 18 21 26 24 27 31 29 32 33
34
17, 19 20 22 23, 25 28 30
36 38
41
6
37
35 39
42
A A A
7
40
43
8
44
45
13
50
14
48 47
12
15
46
5 2 1 3 4 W17P-03-02-004
Section A-A-A
1- Plug (2 Used) 14 - O-Ring 27 - Spring (2 Used) 39 - Spring (2 Used)

2- O-Ring (2 Used) 15 - Plug 28 - Spring Guide (2 Used) 40 - Spring Seat (2 Used)
3- Spring (2 Used) 16 - Poppet Seat (2 Used) 29 - O-Ring (2 Used) 41 - Plug (2 Used)
4- Check Valve (2 Used) 17 - Backup Ring (2 Used) 30 - Backup Ring (2 Used) 42 - O-Ring (2 Used)
5- Overload Relief Valve (2 18 - O-Ring (2 Used) 31 - O-Ring (2 Used) 43 - Spring (2 Used)
Used)
6- Plug 19 - Backup Ring (2 Used) 32 - Plug (2 Used) 44 - Check Valve (2 Used)
7- O-Ring 20 - Poppet (2 Used) 33 - Nut (2 Used) 45 - Spool
8- Spring 21 - Relief Housing (2 Used) 34 - Set Screw (2 Used) 46 - Valve Housing
9- *Plug (6 Used) 22 - Piston (2 Used) 35 - Socket Bolt (8 Used) 47 - Pin (4 Used)
10 - *O-Ring (6 Used) 23 - Backup Ring (2 Used) 36 - Cap (2 Used) 48 - Pin
11 - *Orifice 24 - O-Ring (2 Used) 37 - O-Ring (2 Used) 49 - *Orifice
12 - Socket Bolt (9 Used) 25 - Backup Ring (2 Used) 38 - Spring Seat (2 Used) 50 - Spool Assembly
13 - Valve Assembly 26 - Spring Seat (2 Used)
NOTE: As for parts with *, refer to W3-2-28.
W3-2-30
Assemble Brake Valve
1. Install O-rings (7 and 14) to plugs (6 and 15) re-

spectively. Install valve assembly (13), plugs (6
and 15) into valve housing (46).
: 10 mm
: 64±4.9 N⋅m
(6.5±0.5 kgf⋅m, 47±3.6 lbf⋅ft)
2. Install O-ring (2) to plug (1) and install check valve

(4), spring (3) and the plug into valve housing (46).
(2 places at right and left)
: 14 mm
: 410±20 N⋅m
(42±2 kgf⋅m, 300±14.5 lbf⋅ft)
IMPORTANT: Install overload relief valve (5) to the

former position before disassem-
bled.
3. Install overload relief valves (5) (2 used) onto
valve housing (46).
: 36 mm
: 410±20 N⋅m
(42±2 kgf⋅m, 300±14.5 lbf⋅ft)
4. Rotate spool assembly (50) slowly to insert it into

valve housing (46).
5. Install O-ring (37) into cap (36). (2 places at right

and left)
6. Install spring seat (40), spring (39) and spring seat

(38) into valve housing (46). Then install cap (36)
with socket bolts (35) (4 used). (2 places at right
and left)
: 10 mm
: 108±4.9 N⋅m
(11±0.5 kgf⋅m, 80±3.6 lbf⋅ft)
W3-2-31
1. The clearance between the inner diameter of cyl-

Cylinder
inder block and the outer diameter of the piston Block
Ȁ (D-d): 0.06 mm (0.002 in) or less

D d
W507-02-04-009
Piston
2. The clearance between the piston and shoe when

engaging
Piston
δ: 0.4 mm (0.02 in) or less

Shoe
̗
W107-02-06-140
3. The clearance between the inner diameter and Piston

outer diameter at the matching position of casing
and piston
㈳
Ȁ (D-d): 0.03 mm (0.001 in) or less
Casing
4. The wear allowance on the sliding surfaces of cyl-

W162-03-02-005
inder block and valve plate
Check there is no abnormal scratch, wear or
score.
The wear allowance shall be within 0.02 mm
(0.0008 in) or less.
W3-2-32
Sprocket
C
D
E
A
W105-03-07-042
Unit: mm (in)
Standard Dimension Allowable Limit Remedy
A 114 (4.5) -
B 104.5 (4.1) 99.5 (3.9)
Cladding by weld-
C 139 (5.5) -
ing and finishing
D 162 (6.4) 157 (6.2)
E 260.35 (10.2) -
W3-2-33
(Blank)
W3-2-34
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT

can penetrate the skin or eyes, causing seri-
ous injury. Avoid this hazard by relieving
lines.
repair work.
Preparation

wrench to release the trapped air in the hydraulic M104-07-021

tem on page W1-1-2.
: 4 mm
Cap
tank.
W183-01-01-001
W3-3-1
Removal
Front
IMPORTANT: Attach identification tags to all

hoses of center joint for easier reas- 7 8 1
sembling. 2
IMPORTANT: Remove all hoses and adapters from 6
center joint, cap all disconnected
hose ends.
1. Disconnect hoses (1, 2, 5, 6) and adapters (4
used) from the upper side of spindle of the center
joint.
: 41 mm 5 3
W16J-03-03-002
4 Spindle
2. Disconnect hoses (3 and 4) from the spindle.
: 27 mm, 19 mm
1 - From the right travel spool in the upper side of control valve
4-spool section
3. Remove bolts (8) (2 used) and spring washers (2
2 - From the right travel spool in the lower side of control valve
used) to remove stopper (7) from the spindle. At 4-spool section
this time, the washers (2 used) between the 3 - Hose D5: To hydraulic oil tank
stopper and spindle are also removed. 4 - Hose SB: To SB port in 3-spool solenoid valve
: 22 mm 5 - From the left travel spool in the control valve 5-spool sec-
tion lower side
6 - From the left travel spool in the control valve 5-spool sec-
tion upper side
CAUTION: Center joint weight: 52 kg (110 Ib)
4. Install eyebolts (PF1) to the adapter holes (2
places) diagonally on the upper side of spindle Center Joint
16 17 9
and attach wire ropes through them. Take up 10
slack of the wire rope by crane.
5. Disconnect hoses (9 to 16) from the lower side of Track

Frame
center joint.
: 22 mm, 27 mm, 41 mm
6. Put matching marks on the track frame and the 15

center joint. 14 11
Remove bolts (17) (4 used) and spring washers (4 13 W16J-03-03-003
12
used). Raise and lower the center joint slowly by
crane to remove it.
: 24 mm
Front
9- From the right side of travel motor for right travel device
10 - To P2 port in travel motor for right travel device
12 - From the upper side of travel motor for right travel device
13 - From the upper side of travel motor for left travel device
14 - To P2 port in travel motor for left travel device
15 - To P1 port in travel motor for left travel device
16 - From the left side of travel motor for left travel device
W3-3-2
Installation
16 17 Center Joint
9
CAUTION: Center joint weight: 52 kg (110 lb) 10
IMPORTANT: Align the matching marks made dur-
ing disassembling.
1. Install spring washers onto each bolts (17). Install Track
the center joint to the track frame with bolts (4 Frame
used).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 156 lbf⋅ft) 15
14 11
2. Connect hoses (9 to 16) to the lower side of the 13 W16J-03-03-003
center joint. 12
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm Front
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 41 mm 9- From the right side of travel motor for right travel device
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) 10 - To P2 port in travel motor for right travel device
12 - From the upper side of travel motor for right travel device
3. Install spring washers onto bolts (8). Insert the 13 - From the upper side of travel motor for left travel device
washers between stopper (7) and the spindle. In- 14 - To P2 port in travel motor for left travel device
stall the stopper into the spindle with the bolts (2 15 - To P1 port in travel motor for left travel device
16 - From the left side of travel motor for left travel device
used).
: 22 mm
Front
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
7 8 1
4. Connect hoses (3 and 4) to the spindle. 2
: 27 mm
6
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
5. Install adapters (4 used) onto the upper side of

the spindle and connect hoses (1), (2), (5), (6). 3
5
: 41 mm
W16J-03-03-002
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) 4 Spindle
IMPORTANT: After installation, check the oil level.

Start the engine and check for oil
leaks. 1 - From the right travel spool in the upper side of control valve
4-spool section
2 - From the right travel spool in the lower side of control valve
4-spool section
4 - Hose SB: To SB port in 3-spool solenoid valve
tion lower side
tion upper side
W3-3-3
DISASSEMBLE CENTER JOINT
1
3
4
9
6
10
11
12
W16J-03-03-001
1 - Plug 4 - O-Ring 7 - Body 10 - O-Ring

2 - Spindle 5 - Bushing 8 - Ring 11 - Cover
3 - Dust Seal 6 - Oil Seal (6 Used) 9 - Retaining Ring 12 - Bolt (4 Used)
W3-3-4
Disassemble Center Joint
• Be sure to read all “Precautions for Disassembly 5. Install special tool (ST 1930) onto body (7) with
and Assembly” work thoroughly on page W1-1-1 bolts (12) (2 used).
before starting the disassembly work. : 19 mm
ST 1020
ST 1930 12
CAUTION: Center joint weight: 52 kg (110 lb)
1. Remove bolts (12) (2 used) in diagonal position
from cover (11). Install eyebolts (M12, Pitch 1.75)
into the bolt holes for using wire rope. 7
Lift and place the center joint on workbench by
crane.
: 19 mm
Eyebolts
W183-03-03-004
11
CAUTION: Spindle (2) weight: 22 kg (50 lb)
Body (7) weight: 29 kg (60 lb)
12
6. Tighten pressing bolt (ST 1020) of special tool (ST
1930) and press spindle (2) down out of body (7).
WorkBench When the spindle head makes contact with floor,
remove the special tool. Install eyebolt (M12, Pitch
1.75) into the bolt (12) holes (2 places) in the body
W183-03-03-003
and attach wire ropes through them. Press the
spindle while hoisting and removing the body by
crane.
2. Remove bolts (12) (2 used) and eyebolts (2 used)
to remove cover (11) from body (7).
: 19 mm IMPORTANT: It is easier to remove oil seal (6) if
two pins are used. However, take
care not to damage the seal groove
3. Remove O-ring (10), retaining ring (9) and ring (8)
with the pins.
from body (7).
7. Remove oil seals (6) (6 used) from body (7).
4. Put matching marks on body (7) and spindle (2).
Matching Marks 7
7 6
W105-03-03-015
W142-03-03-004
W3-3-5
3
4
W16J-03-03-001
W3-3-6
8. Remove dust seal (3) and O-ring (4) from body
(7).
IMPORTANT: Cover the seal to prevent its surface

from being splashed with welding
sparkle.
9. In case bushing (5) should be replaced, build up
weld at the inner diameter of the bushing in 4
places at equal distance from 90° away to shrink
the bushing enough to pull it out.
W3-3-7
ASSEMBLE CENTER JOINT
8
10
12
9
11
W183-03-08-001
1 - *Plug 4 - O-Ring 7 - Body 10 - O-Ring

2 - Spindle 5 - Bushing 8 - Ring 11 - Cover
3 - Dust Seal 6 - Oil Seal (6 Used) 9 - Retaining Ring 12 - Bolt (4 Used)
NOTE: As for the item with *, refer to W3-3-4.
W3-3-8
Assemble Center Joint
and Assembly” work thoroughly on page W1-1-1 CAUTION: Spindle (2) weight: 22 kg (50 lb)
before starting the assembly work. Body (7) weight: 29 kg (60 lb)
IMPORTANT: Apply grease to the slide surface for
dust seal (3) on spindle (2) and inner
IMPORTANT: Apply grease to the bushing (5)
surfaces of oil seal (6) and bushing
mounting portion on body (7).
(5).
1. When bushing (5) is removed, press bushing (5)
4. Place spindle (2) on a workbench with its upside
into body (7) first. (Refer to page W3-3-10)
down. Install eyebolts (M12, Pitch 1.75) into the
bolt (12) holes (2 places) in body (7). Lift and
IMPORTANT: Apply grease to the dust seal (3) place the body while aligning the matching mark
mounting portion on body (7). The with that of spindle by crane.
lip portion of dust seal must face the
body side.
2. Install O-ring (4) and dust seal (3) onto body (7).
5. Tap the circumference of body (7) evenly with a
plastic hammer while installing the body into spin-
3. Install oil seals (6) (6 used) onto body (7). dle (2).
IMPORTANT: The clearance between body (7) and IMPORTANT: Install ring (8) with the chamfered
spindle (2) is approx. 0.05 mm (0.002 edge facing the inside of body (7).
in). So that the center of the body is 6. Install ring (8) into body (7).
aligned with that of spindle (2) dur-
ing installation.
IMPORTANT: Install retaining ring (9) with its
Be sure to slowly push the spindle
chamfered edge facing ring (8).
into the body. Failure to do so may
7. Install retaining ring (9) into spindle (2).
damage seals.
No steps are allowed to form at por-
tion A (the mounting position for 8. Install O-ring (10) into body (7) and install cover
ring (8)) shown below. (11) with bolts (12) (4 used).
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
2
0.05 mm (0.002 in)
A
W105-03-03-024
W3-3-9
When replacing the body or spindle with a new one,
the following procedures are required.
IMPORTANT: When press-fitting bushing (5) into

body (7), grease and molybdenm
disulphide should be applied to the
fitting surface.
Replacing Body (7) Replacing Spindle (2)

Press bushing (5) into body (7). 1. Clean spindle (2).
1. Clean body (7) and bushing (5). 2. Insert plugs (1) into spindle (2) with special tool
2. Press bushing (5) into body (7) with a press. (ST 2559).
Pressing force: 0.5 to 1.5 ton 3. The insertion of balls into the plug (1) sleeve is il-
Pressing tool: ST 2670 lustrated in Detail D. Make sure that the ball is 0.4
mm (0.02 in) or more lower than the sleeve edge.
1
ST 2670
2
7
Sleeve
0.4 mm
(0.02 in)
or more
5
Detail D
W136-03-03-031
W135-03-03-001
W105-03-03-029
ST 2559
Ball
W157-03-03-004
W3-3-10
Item Allowable Limit (basis of judgment) Remedy

1. Wear more than 0.2 mm (0.008 in) Replace
2. Scored and abnormal wear Replace
3. Uneven wear within 180° Replace
Wear Area Within Half
Range
Bushing
T157-01-01-040
Sliding surface Heavily damaged one by seizure or foreign mat- Replace

with seals ter
1) Excessively worn one by seizure or Replace
foreign matter, or one having the score of
Sliding surface
0.1 mm (0.004 in) or more
between body and
2) One having the score of less than 0.1 mm Repair the
spindle other than
(0.004 in)
that with seals surface smooth
with oil stone
Body, Spindle
1) One that has worn 0.5 mm (0.02 in) or Replace
more, or excessively worn
2) One that has worn 0.5 mm (0.02 in) or Repair the
Sliding surface less surface smooth
with ring 3) One that has scores due to seizure or Repair the
foreign matter but the damage is less
than the allowable wear limit 0.5 mm surface smooth
(0.02 in) and is repairable
1) One that has worn 0.5 mm (0.02 in) or Replace
more
2) One that has worn less than 0.5 mm (0.02 Repair the
Sliding surface in)
Cover surface smooth
with ring 3) One that has scores due to seizure or Repair the
foreign matter but the damage is less
than the allowable wear limit 0.5 mm surface smooth
(0.02 in) and is repairable
W3-3-11
(Blank)
W3-3-12
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK AD-
JUSTER
Before removing the track adjuster, the tracks and the

front idler must be removed first. For removal and
installation of the tracks and the front idler, refer to
applicable removal and installation sections.
In this section, the procedure starts on the premise that
the tracks and the front idler have already been re-
moved.
CAUTION: When removing track adjuster (1),

the track adjuster may fly off by spring force.
Do not stand in the removal direction of the 2
track adjuster or in places where the track ad-
1
juster may fly out to cause injury.
The rod screw is loaded by spring force. Be
alert if the rod or screw section is broken, the
broken pieces may fly out by spring force,
causing personal injury and/or death.
Removal W142-03-04-002
CAUTION: Track adjuster weight:

545 kg (1200 lb)
1. Remove track adjuster (1) from track frame (2) by
prying it with a crowbar. 3
4
Installation
1. As illustrated, install track adjuster (1) into spring
guide (3) on track frame (2).
At that time, make sure that track adjuster (1) is A
inserted exactly with its end face touching the face
of plate (4).
W17V-03-04-002
2 3
Viewed from A
W17V-03-04-003
W3-4-1
DISASSEMBLE TRACK ADJUSTER
1
2
3
4
5
6
7
8
9
10
11
12
13
18
17
14
15
16
W162-03-04-001
1- Socket Bolt (6 Used) 6- Backup Ring 11 - O-Ring 15 - Bracket

2- O-Ring 7- U-Ring 12 - Cylinder 16 - Nut
3- Guide 8- Plate 13 - Spring 17 - Valve
4- Piston Rod 9- Retaining Ring 14 - Spacer 18 - Bolt
5- Wear Ring 10 - Rod
W3-4-2
Disassemble Track Adjuster
• Be sure to read all “Precautions for Disassembly IMPORTANT: Compress the spring until the clear-
and Assembly” work thoroughly on page W1-1-1 ance between bracket (15) and nut
before starting the disassembly work. (16) is approximately 10 mm (0.4 in).
Use a pump unit which has the maximum pres- 2. Loosen valve (17). Compress track adjuster
2
sure of 69 MPa (700 kgf/cm , 9950 psi) and the spring (13) using special tool (ST 4932).
flow rate of 8 to 10 liters (2.1 to 2.6 gal). Be sure : 24 mm
to set the main relief pressure to 49 MPa (500
2
kgf/cm , 7110 psi) (80 tons) or lower. 13
Clearance 10 mm (0.4 in)
IMPORTANT: Be sure to use special tool (ST 4932)

to assemble / disassemble the track
adjuster. 15
16 18
CAUTION: Carefully perform disassembly 10
and assembly work because the spring force 17
of the track adjuster is extremely large.
Thoroughly inspect the special tool for any
damage to prevent personal injury.
W17V-03-04-006
CAUTION: Track adjuster assembly weight:
545 kg (1200 lb) IMPORTANT: Put matching marks on rod (10) and
1. Position the track adjuster on the rest of special nut (16).
tool (ST 4932) by crane. 3. Remove valve (17) and bolt (18) to remove nut
(16).
: 24 mm, 19 mm, 140 mm
ST 4932
Rest
W142-03-04-019
W3-4-3
12
13
14
15 W162-03-04-001
W3-4-4
4. Slowly return the piston of special tool (ST 4932)
CAUTION: Cylinder (12) assembly weight:
until spring (13) extends to its free length.
170 kg (370 lb)
NOTE: Spring (13) free length: 1005 mm (39.6 in) 7. Remove the lifting belt attached from spring (13).
Attach a lifting belt on cylinder (12) and pass the
belt through the eyebolt. Lift and remove cylinder
(12) assembly from the spring.
540 kg (1190 lb)
5. Bind bracket (15) and spring (13) together with
Eyebolt
wire. Attach a lifting belt to spring on track ad-
juster. Lift and remove track adjuster from special
tool (ST 4932) by crane. 12
ST 4932
13
13
15
Rest
W17V-03-04-004
W142-03-04-005
CAUTION: Spring (13) weight: 305 kg (670 lb)
6. Install eyebolt (M16, Pitch 2.0) onto piston rod (4). 8. Remove the wire fastening spring (13) and
Attach a lifting belt around spring (13). Through bracket (15). Lift and remove the spring by crane.
the eyebolt then, lift and position the assembly on
the rest by crane, as illustrated.
CAUTION: Bracket (15) weight: 35 kg (80 Ib)
Eyebolt 9. Remove spacer (14) and bracket (15) out of the
rest.
4
13
Rest
W142-03-04-006
W3-4-5
1
2
3
4
5
6
7
8
9
10
11
12
W162-03-04-001
W3-4-6
CAUTION: Cylinder (12) assembly weight:

170 kg (370 lb) 14. Remove wear ring (5), retaining ring (9), plate (8) ,
10. Place cylinder assembly on the workbench with U-ring (7) and backup ring (6) from piston rod (4).
wooden blocks inserted at the flange portion of
cylinder (12). Remove socket bolts (1) (6 used) to 4
remove guide (3).
: 12 mm
5
2 6
3 7
1
9
4
12
10 8 W162-03-04-002
W142-03-04-010
CAUTION: Piston rod (4) weight: 50 kg (110 lb)

11. Pull piston rod (4) out from cylinder (12).
12. Remove O-ring (2) from guide (3).
CAUTION: Cylinder (12) weight: 65 kg (140 lb)

Rod (10) weight: 50 kg (110 lb)
13. Install eyebolt (M16, Pitch 2.0) into rod (10) at cyl-
inder (12) side. Lift and remove the rod from the
cylinder by crane. Remove O-ring (11) from inside
of the cylinder.
W3-4-7
ASSEMBLE TRACK ADJUSTER
3 1 12 8, 9 11 14 10 16 18 17
Grease Outlet
2 4 5 6, 7 B 13 15 W17V-03-04-005
1- Socket Bolt (6 Used) 6- Backup Ring 11 - O-Ring 15 - Bracket

2- O-Ring 7- U-Ring 12 - Cylinder 16 - Nut
3- Guide 8- Plate 13 - Spring 17 - Valve
4- Piston Rod 9- Retaining Ring 14 - Spacer 18 - Bolt
5- Wear Ring 10 - Rod
W3-4-8
Assemble Track Adjuster
IMPORTANT: Apply grease to wear ring (5), CAUTION: Piston rod (4) weight: 50 kg (110 Ib)
backup ring (6), U-ring (7) and plate IMPORTANT: Fill chamber (B) in cylinder (12) with
(8). Install the U-ring with the lip side grease and insert piston rod (4) to
facing rod (10). bleed air completely out from cham-
After applying hydraulic oil to the in- ber (B) and from the inside of rod
ner surface of cylinder (12), to the (10).
rod and piston rod (4), reassemble 3. Fill cylinder (12) fully with grease. Install eyebolt
them. (M16, Pitch 2.0) into piston rod (4) and lift it up by
1. After cleaning all parts, install wear ring (5), crane. Install the piston rod into cylinder (12) after
backup ring (6), U-ring (7), plate (8) and retaining being applied with grease.
ring (9) onto piston rod (4).
4 IMPORTANT: Fill V-groove in guide (3) with
5 grease.
6 4. Install O-ring (2) after being applied with grease
7 onto guide (3). Install the guide onto piston rod (4).
8 Apply LOCTITE #262 to socket bolts (1) (6 used)
9 and tighten them.
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
2
3 1
W162-03-04-002 4 Lifting Hole

CAUTION: Cylinder (12) weight: 65 kg
(140 lb)
Rod (10) weight: 50 kg (110 lb)
CAUTION: Take care not to tilt spring (12)
over.
2. Install eyebolts (M14, Pitch 2.0) to the socket bolt
(1) holes at two places diagonally in cylinder (12).
Then lift the cylinder up to set on workbench by
crane. Apply grease to O-ring (11) and install the W142-03-04-018
O-ring onto the cylinder. Install eyebolt (M16, Pitch
2.0) into rod (10). Lift and install the rod into cylin-
der by crane.
NOTE: Clearance of approx. 120 mm (4.7 in) shall
be left under cylinder (12) for lowering the
rod.
Lifting Hole
10
12
11
W17V-03-04-001
W3-4-9
12 14
Grease Outlet
4 13 15
W17V-03-04-005
W3-4-10
CAUTION: Bracket (15) weight: 35 kg (80 lb)

Spring (13) weight: 305 kg (670 lb)
Eyebolt
CAUTION: Take care not to tilt spring (13)
over. 12
5. Set wire on the rest. Lift and place the bracket
(15), spacer (14) and spring (13) on the rest by
crane. Bind the bracket and the spring together
using pieces of wire.
CAUTION: Cylinder (12) assembly weight: 14

170 kg (370 lb)
6. Install eyebolt (M16, Pitch 2.0) to piston rod (4).
Lift and install the cylinder (12) assembly while 13
aligning spacer (14) and bracket (15) by crane.
Rest
15

545 kg (1200 lb)
7. Attach a lifting belt to spring (13) and pass it W17V-03-04-004
through the eyebolt on piston rod (4). Hoist and

place it horizontally and slowly by crane. 4
13
IMPORTANT: Set rod (10) with its grease outlet

facing down.
8. Lift and position the track adjuster on special tool
(ST 4932) by crane. Remove the eyebolt and lift-
ing belt.
W142-03-04-006
ST 4932
W142-03-04-005
W3-4-11
10 13 15 18 17
Grease Outlet
16
805 mm (Free Length 1005 mm) W17V-03-04-005
31.7 in (Free Length 39.6 in)
1208.5 mm (47.6 in)
W3-4-12
IMPORTANT: Be sure to slowly compress spring
(13) while aligning the center of rod
(10) with the center of bracket (15)
using a crowbar.
Take care not to damage the threads
in rod. 13
9. Remove wire from spring (13). Compress spring
ST 4932
(13) by operating the cylinder of special tool (ST
4932) until the specified spring length is obtained.
(Specified Spring Length: 805 mm (31.7 in)) 15
IMPORTANT: Align matching marks put during Wire

disassembling. Moreover, be sure to
align the grease outlets both in rod
(10) and nut (16).
10. Install nut (16) and bolt (18) to rod (10).
: 140 mm
: 19 mm
: 59 N⋅m (6.2 kgf⋅m, 45 lbf⋅ft)
W142-03-04-015
11. Tighten valve (17). 18

: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)
10
12. Retract the cylinder of special tool (ST 4932). 16
CAUTION: Track adjuster weight: 17

545 kg (1200 lb)
13. Securely fasten a lifting belt to the track adjuster.
Lift and remove the track adjuster from the special
W17V-03-04-006
tool by crane.
CAUTION: If the spring assembly must be

transported, take care not to damage it. Use a
firm steel box for transportation of the spring
assembly and take any other precautions in
order to insure safe transportation.
W3-4-13
(Blank)
W3-4-14
UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER
Removal
Before removing the front idler, the tracks must be
removed first. For removal and installation of the
tracks, refer to “Remove and Install Tracks” section.
In this section, the procedure starts on the premise that
the tracks have already been removed.
CAUTION: When removing the front idler, the

front idler may fly off by strong spring force.
Don’t stand in the removal direction of the
front idler or in any place where the front idler W142-03-05-002
may fly out.

CAUTION: Front idler weight: 490 kg (1080 Ib)
1. Pry the front idler with a crowbar to remove it still
with the yoke attached from track frame.
2. Attach lifting belts to bearing (5) and yoke (4) Removing Direction
sections as shown. Lift and remove the front idler
assembly from track frame (2) by crane. 1
2
3. Loosen bolts (3) and remove guard (1) from yoke
(4).
4. When the front idler should be stored, place it on

wooden blocks as shown. 5
4
3
W142-03-05-003
Wooden Block
Wooden Block
Installation
CAUTION: Front idler weight: 490 kg (1080 Ib)
1. The procedures to install front idler are just the re-
verse of those for removal. However, pay attention W105-03-05-003
to following:
• Apply grease to the bearing (5) sliding surface on
track frame (2) after cleaning. Installing Direction
W142-03-05-005
W3-5-1
DISASSEMBLE FRONT IDLER
1
2
3 8
7
4
6
6 9
5
10
4
3
2 11
8 14 13 12
W162-03-05-001
1- Pin (2 Used) 5- Axle 9 - Guard 12 - Yoke

2- Bearing (2 Used) 6- Bushing (2 Used) 10 - Bolt (4 Used) 13 - Bolt (4 Used)
3- Floating Seal (2 Used) 7- Idler 11 - Spring Washer (4 Used) 14 - Spring Washer (4 Used)
4- O-Ring (2 Used) 8- Plug (2 Used)
W3-5-2
Disassemble Front Idler
and Assembly” work thoroughly on page W1-1-1 CAUTION: Bearing weight: 30 kg (70 lb)
before starting the disassembly work. Idler and other weight:
300 kg (660 lb)
Axle weight + bearing weight:
1. Remove bolts (10) (4 used) to remove guard (9),
75 kg (170 lb)
spring washers (11) (4 used) from yoke (12).
4. Set idler (7) assembly onto press. Press out axle
: 19 mm
from idler assembly with a press. At this time,
bearing (2) on other side will be removed together
CAUTION: Idler assembly weight: with the axle.
370 kg (820 lb)
Yoke weight: 80 kg (180 lb)
IMPORTANT: Keep idler (7) steady with wooden Press
blocks to prevent it from tilting over.
2 5
2. Attach a nylon sling to yoke (12) and hold idler (7)
vertically by crane. Remove bolts (13) (4 used)
1
and spring washers (14) (4 used) to remove the
yoke.
Remove plug (8) from the end of bearing (2) to 7
drain oil.
: 36 mm
: 6 mm
2
3. Put matching marks to bearing (2) and axle (5).
Tap pin (1) out from the bearing with a bar (Dia. 25 W17P-03-05-002
mm (1.0 in)) and hammer.
3
7
4
5
W105-03-05-009
5. Remove O-ring (4) from the axle.
W3-5-3
1
2
4
6
6
5
4
2
1
W162-03-05-001
W3-5-4
IMPORTANT: For handling of floating seal (3), re- IMPORTANT: Do not remove bushing (6) unless
fer to the section “Precautions for necessary.
Floating Seal Handling” on page 9. When replacing bushing (6), pull the bushing out
W1-1-4. with bushing pulling tool (ST 1914) and press.
6. Remove floating seals (3) from idler (7) and bear-
ing (2).
7. Put matching marks on bearing (2) and axle (5).

Pull out pin (1) from bearing with a bar (Dia. 25
mm (1.0 in )) and hammer.
ST 1914
CAUTION: Axle weight + bearing weight:

75 kg (170 lb)
IMPORTANT: Place wooden blocks or the like etc.
under the lower part of the bearing
to prevent bearing (2) from being
6
damaged.
8. Wind a nylon sling to the axle (5) assembly. Lift
and place axle assembly onto press by crane. Pull
out the axle from the bearing with a press. Re-
move O-ring (4) from the axle.
W105-03-05-011
Press
4
1
2
Wooden
Block
W105-03-05-010
W3-5-5
ASSEMBLE FRONT IDLER
2 3 6 4 1 9 10, 11 12 13, 14
7 5 8
W162-03-05-002
1- Pin (2 Used) 5- Axle 9 - Guard 12 - Yoke

2- Bearing (2 Used) 6- Bushing (2 Used) 10 - Bolt (4 Used) 13 - Bolt (4 Used)
3- Floating Seal (2 Used) 7- Idler 11 - Spring Washer (4 Used) 14 - Spring Washer (4 Used)
4- O-Ring (2 Used) 8- Plug (2 Used)
W3-5-6
Assemble Front Idler
CAUTION: Idler (7) weight: 290 kg (640 lb) IMPORTANT: For handling of floating seal (3), re-
1. Install bushings (6) (2 used) into both sides of fer to the section “Precautions for
idler (7) with a press. Floating Seal Handling” on page
W1-1-4.
Apply grease to O-ring on the floating
seal.
CAUTION: Axle (5) weight: 45 kg (100 Ib)
4. Install one of pair floating seal (3) (1 used) into
IMPORTANT: Support axle (5) to prevent it from
idler (7) and bearing (2).
tilting over.
2. Attach a nylon sling on axle (5). Lift and place the
axle vertically by crane. Apply enough grease onto CAUTION: Axle (5) assembly weight:
O-ring (4) and install the O-ring (1 used) onto the 75 kg (170 lb)
upper side of the axle. IMPORTANT: Support axle (7) to prevent it from
tilting over.
IMPORTANT: Align the matching marks put during 5. Attach a nylon sling to bearing (2) for the axle (5)
disassembling. assembly. Lift the axle assembly by crane and
3. Apply grease onto inner diameter of bearing (2). insert it into idler (7) from the side where floating
Insert the bearing to axle (5) at the side where O- seal (3) is installed already.
ring is installed. Tap the end face of bearing
evenly with a plastic hammer while aligning the 7
hole for pin (1). Insert the pin into bearing with a
bar and hammer. 3
2
5
5
2
W157-03-05-006
CAUTION: Idler (7) assembly weight:

300 kg (660 lb)
4 6. Attach a nylon sling to the idler (7) assembly. Lift
W105-03-05-014
and place the idler assembly with bearing (2) fac-
ing downward by crane.
Apply grease onto O-ring (4) and install O-ring (4)
onto axle (5).
W3-5-7
3 2 4 1 9 10, 11 12 13, 14
W162-03-05-002
7 5 8
W3-5-8
IMPORTANT: Apply grease to the O-ring of float- IMPORTANT: Apply LOCTITE #503 to plug (8).
ing seal (3). 12. Install plug (8) to bearing (2).
7. Install the other floating seal (3) into idler (7) and : 6 mm
bearing (2). : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
CAUTION: Bearing weight: 30 kg (70 lb) CAUTION: Yoke (12) weight: 80 kg (180 lb)
IMPORTANT: Align the matching marks put during 13. Attach a nylon sling to yoke (12). Lift and align the
disassembling. bolt (13) hole in the yoke with that in bearing (2).
8. Apply grease on inner diameter of bearing (2). Tap
the end face of bearing (2) evenly with a plastic 14. Install spring washers (14) (4 used) onto each bolt
hammer while aligning the hole for pin (1). Insert (13) (4 used). Install yoke (12) onto bearing (2)
the pin into bearing with a bar and hammer. with the bolts (4 used) on both sides.
2 : 36 mm
3 : 690 N⋅m (70 kgf⋅m, 510 lbf⋅ft)
5
4
15. Install spring washers (11) onto each bolt (10) (4
used). Install guard (9) onto yoke (12) with bolts (4
used).
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
7
W17P-03-05-003
9. Fill engine oil (API CD Class SAE30) 0.5L (0.132

gal.) via the plug (8) hole in bearing (2).
IMPORTANT: Apply LOCTITE #503 to plug (8).

10. Install plug (8) into bearing (2).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
CAUTION: Idler (7) assembly weight:

400 kg (880 lb)
11. Attach a nylon sling to idler (7) assembly, lift and
turn over the idler assembly by crane.
W3-5-9
C D
A W166-03-05-001
Unit: mm (in)
Standard Allowable Limit Remedy
A 126 (5.0) −
B 260 (10.2) −
Clad by welding and
C 800 (31.5) 780 (30.7)
finish or replace
D 845 (33.3) −
E 22.5 (0.9) 32.5 (1.3)
Axle and Bushing
Unit: mm (in)
Axle Outside Dia. 120 (4.7) [119.2 (4.7)]
Inside Dia. 120 (4.7) [121 (4.8)] Replace
Bushing
Flange Thickness 6 (0.2) [5.2 (0.2)]
NOTE: Values in [ ] are just for reference.
W3-5-10
UNDERCARRIAGE / Upper and Lower Roller
REMOVE AND INSTALL UPPER ROLLER
Removal
CAUTION: Grease pressure in the adjusting
cylinder is high. Do not loosen valve (1)
quickly or loosen it too much as the valve
may fly off or high-pressure grease in the ad-
justing cylinder may gush out.
Loosen carefully and keep body parts and
face away from the valve. Never loosen
grease fitting (2).
IMPORTANT: Clean off any mud or gravel packed W105-03-06-001
between sprockets and tracks be-
fore loosening valve (1). It is enough 2 1
to loosen the valve by 1 to 1.5
turns.
1. Loosen valve (1) on the track adjuster to drain
grease to release the tension of track link.
: 24 mm
Grease Outlet
M116-07-094
2. Insert wooden block and oil jack between track

frame (5) and tracks (4). Jack tracks (4) up high 4
enough to permit upper roller (3) to be removed.
Oil Jack
3. Insert wooden blocks under upper roller (3).
Wooden Block
5 3
W116-03-06-001
Wooden Block
W116-03-06-002
W3-6-1
4. Remove mounting bolts (6) (4 used) from upper
roller (3). 3
: 30 mm
6
W116-03-06-002
CAUTION: Upper roller weight: 60 kg (130 lb)

5. Attach a nylon sling to the roller part of upper roller
(3), lift and remove the upper roller from track
frame (5) by crane.
3 5
W116-03-06-003
4
Installation
CAUTION: Upper roller weight: 60 kg (130 lb)
1. Lift upper roller (3) and insert it between track
frame (5) and track (4) by crane.
Insert wooden blocks between upper roller and
the track frame to hold the upper roller. Align the
holes for bolt (6) and install upper roller with bolts
(4 used).
: 30 mm
: 540 N⋅m (55 kgf⋅m, 400 lbf⋅ft) 3
W116-03-06-003
5
2. Remove the wooden blocks and oil jack.
6
W116-03-06-002
W3-6-2
3. Tighten valve (1) on the track adjuster.
: 24 mm 2 1
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)
CAUTION: If track sag should be measured

with the machine raised, be sure to support
the jacked up machine firmly with wooden
blocks.
4. Jack up the track being adjusted. Supply grease
to grease fitting (2) to adjust tracks tension.
Track sag specifications (A): 460 to 510 mm
(18.1 to 20.1 in)
NOTE: Before measuring track sag, clean the track
frame and tracks and rotate the track by a M116-07-094
half turn in reverse direction.
W157-03-06-002
W3-6-3
REMOVE AND INSTALL LOWER ROLLER
Removal
CAUTION: Track guard weight: 86 kg (190 Ib)
1. Remove the track guard. 1
: 41 mm
2. Remove mounting bolts (1) (4 used) of the lower

roller.
: 36 mm
W105-03-06-008
90° to 110°
3. Jack up the machine with its front and insert

wooden blocks under the track frame (2).
2 M104-07-067
CAUTION: Grease pressure in the adjusting

cylinder is high. Do not loosen valve (3)
quickly or loosen it too much as the valve
may fly off or high-pressure grease in the ad-
justing cylinder may gush out.
Loosen carefully and keep body parts and
W105-03-06-001
face away from the valve.
Never loosen grease fitting (4).
IMPORTANT: It is enough to loosen valve (3) by 1 4 3
to 1.5 turns. Do not loosen it over
that degree.
4. Loosen valve (3) to drain enough grease to permit
the lower roller to be removed.
: 24 mm
Grease Outlet
M116-07-094
W3-6-4
CAUTION: Lower roller weight: 143 kg (320 lb)

5. Remove lower roller (5) using a fork lift.
5
W105-03-06-010
Installation
CAUTION: Lower roller weight: 143 kg (320 lb)
1. Put lower roller (5) under track frame (2) using a
fork lift.
5 W105-03-06-011
2. Lower track frame (2) so that the track frame may

keep a little clearance away from the collar of
lower roller (5).. 2
CAUTION: Track guard weight: 86 kg (190 lb)

3. Align the bolt holes and tighten bolts (1) (4 used).
Install track guard.
: 36 mm 5
: 930 N⋅m (95 kgf⋅m, 690 lbf⋅ft) W105-03-06-012
: 41 mm
: 1400 N⋅m (140 kgf⋅m, 1010 lbf⋅ft)
W105-03-06-008
W3-6-5
4. Tighten valve (3) on track adjuster.
: 24 mm 4 3
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)

the jacked up machine firmly with wooden
blocks.
5. Supply grease through grease fitting (4) to adjust
track tension.
Track sag specifications (A): 460 to 510 mm
(18.1 to 20.1 in)
frame and tracks and rotate the track by a M116-07-094
half turn in reverse direction.
W157-03-06-002
W3-6-6
(Blank)
W3-6-7
DISASSEMBLE UPPER ROLLER
11
9 10
8
7 12
6
5
4
3
2
1
W17V-03-06-001
1 - Bolt (3 Used) 4 - Cover 7 - Thrust Plate 10 - Bushing

2 - Spring Washer (3 Used) 5 - O-Ring 8 - Bushing 11 - Axle Assembly
3 - Plug 6 - Socket Bolt (3 Used) 9 - Roller 12 - Floating Seal
W3-6-8
Disassemble Upper Roller
• Be sure to read all “Precautions for Disassembly 6. When bushings (8), (10) are to be replaced, pull
and Assembly” work thoroughly on page W1-1-1 the bushing out with bushing pulling tool (ST
before starting the disassembly work. 1967) and a press .
1. Remove plug (3) to drain oil.

: 6 mm
ST 1967
2. Put matching marks to roller (9) and cover (4).
Remove bolts (1) (3 used) to remove cover (4). 8
: 17 mm
NOTE: Insert a driver between cover (4) and roller
(9). Pry the cover to remove it with the 10
driver.
3. Loosen and remove socket bolts (6) (3 used) to

remove thrust plate (7). W17V-03-06-002
: 8 mm
NOTE: If no special tool is available, build up weld
CAUTION: Axle (11) assembly weight: at the inner diameter of the bushing at 4
26 kg (60 lb) places in equal distance of 90° apart to
4. Pull roller (9) out from axle (11). shrink the bushing to pull it out.
IMPORTANT: For handling of floating seal (12),

90°
refer to the section “Precautions for
W1-1-4.
5. Remove floating seal (12) from axle (11) and roller 90°
(9).
NOTE: If floating seal (12) should be reused, it
should be kept with its seal face covered by
W105-03-05-012
cardboard.
W3-6-9
ASSEMBLE UPPER ROLLER
11 12
10 9 8 7
W142-03-06-002
1 - Bolt (3 Used) 4 - Cover 7 - Thrust Plate 10 - Bushing

2 - Spring Washer (3 Used) 5 - O-Ring 8 - Bushing 11 - Axle Assembly
3 - Plug 6 - Socket Bolt (3 Used) 9 - Roller 12 - Floating Seal
W3-6-10
Assemble Upper Roller
• Clean all parts before reassembling. 6. Align the matching marks put during disassem-
• For any part scored or with coarse surface, be bling. Install cover (4) to roller (9) and tighten it
sure to finish them with an oil stone. with bolts (1) (3 used).
• In a general way, parts, such as O-rings and seals, : 17 mm
should be replaced with new ones. : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
NOTE: If the bolt (1) hole is failure to be aligned, a
IMPORTANT: The force can be applied to press in bar can be used to move cover (4) so as to
the bushing of roller (9) when replac- align bolt holes both in roller (9) and the
ing bushings (8), (10). cover.
Force for bushing (8): 20 ton
Force for bushing (10): 2.1 to 3.7 ton 7. Fill engine oil via plug (3) hole in cover (4).
1. Press bushings (8), (10) to roller (9). Engine oil: API CD class SAE#30
Capacity: 0.2 L (0.053 gal.)
IMPORTANT: Apply grease to the O-ring part on
floating seal (12) and apply oil to the 8. Apply LOCTITE #503 or equivalent to plug (3),
steel ring. then install the plug into cover (4).
As for handling of floating seal , re- : 6 mm
fer to the section “Precautions for : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
W1-1-4.
2. Install floating seal (12) onto axle (11) and roller
(9).
NOTE: Install O-ring with grease applied to the
seal ring. Push into the O-ring with a driver
and install it to the axle and roller.
Take care not to damage O-ring when the
driver is used.
CAUTION: Roller (9) weight: 30 kg (70 lb)

3. Install roller (9) to axle (11).
4. Install thrust plate (7) to axle (11) and tighten it

with socket bolts (6) (3 used).
: 8 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
5. Apply grease to O-ring (5) and install the O-ring to

cover (4).
W3-6-11
DISASSEMBLE LOWER ROLLER
5
4
3 6
7
5
6 7
1
3
4
W166-03-06-006
1 - Floating Seal (2 Used) 3 - O-Ring (2 Used) 5 - Pin (2 Used) 7 - Bushing (2 Used)

2 - Axle 4 - Collar (2 Used) 6 - Plug (2 Used) 8 - Roller
W3-6-12
Disassemble Lower Roller
• Be sure to read all “Precautions for Disassembly 5. Remove floating seal (1) from roller (8) and collar
and Assembly” work thoroughly on page W1-1-1 (4).
4 1 8 1
IMPORTANT: Put matching marks to collar (4) and
axle (2).
1. Remove plug (6) from the end of collar (4) to drain 1
oil. (at 2 places). Pull pin (5) out from collar (4) (at
2 places) with a bar (Dia. 25 mm (1.0 in)) and 4
hammer.
: 6 mm
CAUTION: Lower roller weight: 143 kg (320 Ib)

2. Set roller (8) assembly on the press. Push axle (2)
until O-ring (3) is removed from collar (4) with a W105-03-06-026
press, remove the collar from axle. 6. Set axle (2) assembly on press and push the axle
out from collar (4).
NOTE: Collar (4) can be removed if axle (2) is
pressed down by approx. 55 mm (2.2 in) 4
with a press.
IMPORTANT: As for handling of floating seal (1),

refer to the section “Precautions for
W1-1-4. 2
3. Remove floating seal (1) from roller (8) and collar
(4).
Remove O-ring (3) from axle (2).
NOTE: Replace O-ring (3) because the O-ring is
damaged when disassembling.
W105-03-06-027
CAUTION: Axle (2) weight + collar (4) weight: 7. Remove O-ring (3) from axle (2).
48 kg (110 lb) NOTE: Replace O-ring (3) because the O-ring is
4. Push axle (2) assembly out from roller (8). damaged when disassembling.
8. In case it is necessary to replace bushing (7), pull

it out with bushing pulling tool (ST 1973) and a
press
ST 1973
W105-03-06-028
W3-6-13
ASSEMBLE LOWER ROLLER
4 5 6
8 2 7 1 3
W162-03-06-002
1 - Floating Seal (2 Used) 3 - O-Ring (2 Used) 5 - Pin (2 Used) 7 - Bushing (2 Used)

2 - Axle 4 - Collar (2 Used) 6 - Plug (2 Used) 8 - Roller
W3-6-14
Assemble Lower Roller
CAUTION: Roller (8) weight: 81 kg (180 lb) CAUTION: Axle assembly weight: 48 kg (110 Ib)
Axle (2) weight: 38 kg (80 lb) 4. Insert axle (2) into roller (8). Install O-ring (3) with
1. Install bushings (7) (2 used) onto roller (8) with a the grease applied over the axle. Install the other
press. Take care not to dent the flange surface of floating seal (1) to collar (4) in same procedures.
bushing (7). Then secure them with pin (5).
Apply a coat of grease to O-ring (3) and install the
O-ring onto axle (2). 5 1 2 8
IMPORTANT: Align the matching marks put during

disassembling.
2. Install collar (4) onto axle (2). Take care not to
damage O-ring (3). Tap pin (5) into the pin hole 3
4
and secure the collar on the axle.
5
2 W157-03-06-009
3 5. Fill engine oil (API CD class SAE30) 1.0 L (0.26

gal.) via the plug (6) hole in collar (4).
IMPORTANT: Apply LOCTITE #503 or equivalent to

plug (6).
6. Install plugs (6) (2 used) into collars (4) at both
4 W16J-03-06-001
sides.
: 6 mm
IMPORTANT: Apply grease to O-ring on floating
: 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
seal (1).
As for handling of floating seal (1),
refer to the section “Precautions for 5 8
W1-1-4.
CAUTION: Roller (8) assembly weight: 6
84 kg (190 lb)
3. Install floating seal (1) to roller (8) and to collar (4).
8 1
W105-03-06-024
1 4
W157-03-06-008
W3-6-15
Upper Roller
• Roller
B
W166-03-06-007
Unit: mm (in)
A 118 (4.6) −
Clad by welding and
B 240 (9.4) −
finish or replace
C 200 (7.9) 180 (7.1)
• Axle and Bushing
Unit: mm (in)
Standard Remedy
Axle Outside Dia. 75 (3.0)
Inside Dia. 75 (3.0) Replace
Bushing
Flange Thickness 4.5 (0.2)
W3-6-16
Lower Roller
• Roller
W157-03-06-003
Unit: mm (in)
A 274 (10.8) −
B 356 (14.0) − Clad by welding and
C 41 (1.6) − finish or replace
D 240 (9.4) 220 (8.7)
• Axle and Bushing
Unit: mm (in)
Allowable Limit Remedy
Axle Outside Dia. 110 (4.3)
Inside Dia. 110 (4.3) Replace
Bushing
Flange Thickness 6 (0.2)
W3-6-17
(Blank)
W3-6-18
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACKS
Removal
CAUTION: Grease pressure in the adjusting IMPORTANT: It is enough to loosen the valve (2)
cylinder is high. Do not loosen valve (2) by 1 to 1.5 turns. Do not loosen it
quickly or loosen it too much as high- over that degree.
pressure grease in the adjusting cylinder may 2. Loosen valve (2) for track adjuster to drain grease
gush out. out.
Loosen carefully and keep body parts and : 24 mm
face away from the valve. Never loosen
grease fitting (1).
1 2
W105-03-07-001
IMPORTANT: When gravel or mud is packed be-

tween sprockets and tracks, clean Grease Outlet
off before loosening. M116-07-094
1. Rotate the tracks so that master pin (5) is posi-

tioned over front idler (4). Put a wooden block un-
der track shoes (3).
Wooden
Block
W105-03-07-006
W3-7-1
3. Remove pin (7), which is used to secure the mas-
ter pin (5). If it is difficult to remove the pin from
master pin (6), drive in the master pin first with a
hammer to make clearance between the pin and 6
master link before attempting to pull out the pin.
5
7
W116-03-07-001
CAUTION: The front idler may jump out of

position due to strong spring force when the
track is disconnected.
Particularly, the screw part of the rod is al-
ways under the spring force. If the rod or the
rod screw is damaged, the damaged part may
fly off. Be sure to pay enough attention.
IMPORTANT: Master pin (5) has its directivity. Be

sure to remove it using tapping spe- W105-03-07-005
cial tool in from pin (7) side..
4. Remove master pin (5) using special tool (ST ST 1971
1971).
W105-03-07-008
Pin
Removing
Direction
Master
Pin
W17V-03-07-001
W3-7-2
Boom Arm
CAUTION: Support the raised machine se-
curely and steady with wooden block.
5. Raise the machine as illustrated with the angle be-
tween the boom and the arm held at 90° to 110°
and the bucket round bottom section placed on 90° to 110°
the ground. At this time, put a support under the
track frame to support the machine.
M104-07-067
Support
6. Slowly operate travel lever for the raised side in

the reverse direction to remove the tracks from
the machine.
NOTE: Track assembly weight: 4280 kg (9440 Ib).
W105-03-07-011
W3-7-3
Installation
CAUTION: Track assembly weight:

4280 kg (9440 lb)
IMPORTANT: Be sure to position the track in the
correct direction, as illustrated. Idler Side Sprocket
1. Jack up the machine and put the track under the Side
machine so that the sprocket teeth align with the
end of the track.
W105-03-07-013
2. Lift the track by crane, and place it on sprocket (8)

teeth.
W105-03-07-014
3. With the machine kept raised, slowly operate the
lever for the side being installed with track in the
forward direction. Turn travel device (9) while
winding the track around the raised track frame.
9
W105-03-07-015
4. When the joint portion of track link is wound to 4

front idler (4), lower the machine and put a
wooden block under shoe (3) to support the shoe.
3
W105-03-07-016
Wooden Block
W3-7-4
IMPORTANT: Apply a coat of grease onto the outer ST 1971
diameter of master pin (5) and inner
diameter of bushing.
Master pin (5) has its directivity. Be 5
sure to remove it by tapping special
tool in from the opposite side of the
pin.
5. Install special tool (ST 1971) of master pin to tap
master pin (5) in.
Pin
W105-03-07-017
Installing
Direction
Master Pin
W166-03-07-02
IMPORTANT: Pin (7) is easy to deform. Do not use

the old one. Be sure to replace pin
(7) with a new one.
6. Install pin (7).
W116-03-07-001
7. Tighten valve (2) on track adjuster.

: 24 mm
2
: 147 N⋅m (175 kgf⋅m, 1270 lbf⋅ft)
M116-07-094
W3-7-5

the jacked up machine securely with wooden
blocks.
8. Supply grease to the grease fitting to adjust tracks
tension.
Track Sag Specification (A): 460 to 510 mm
(18.1 to 20.1 in)
frame and tracks and rotate the track by a
half turn in reverse direction. Keep the track
with a little sag. W105-03-07-018
W157-03-06-002
W3-7-6
Assemble Link
In case link is disassembled, assemble it by follow- • Insert the pin further until it is contact with the sur-
ing procedures. face of workbench.
• Apply fully grease to the out surface of the half
IMPORTANT: Do not apply grease to the dust seal part of pin where is left to outside of bushing.
when assembling. • Place the bushing horizontally.
IMPORTANT: Install the dust seal with its flat side • Pull the pin in while rotating it until the pin comes
facing inside. to the center of the bushing.
1. Install the dust seal to the links (both right and
left).
Link
Dust Seal
3. Apply grease to both end surfaces of the bushing.
4. Apply grease to the surfaces of dust seals (both

right and left ones) which are installed on the link.
W17P-03-07-001
Install links at both right and left sides of the pin.
IMPORTANT: Fill grease (Daphne Epones SR No.2)

fully (100%) to the matched portion
between the bushing and pin.
2. Install the bushing into the pin in following proce-
dures:
• Stand the bushing on workbench.
• Fill grease into the bushing so that the grease is
up to 1/3 of the bushing height from the bottom
while taking care to let no air mix in.
• Press the bushing tight to the workbench.
• Insert pin in slowly from the top side of the bush-
ing while rotating the pin. At this time, make sure
that grease flows out between the clearance of
bushing and pin.
Pin
Insert Pin in While
Rotating It
Be Sure Grease
Bushing Flows Out Here
Grease
Press Bushing
Down to the
Work Bench Bench
W17P-03-07-002
W3-7-7
Link
Measure the length of four links.

• Do not measure the part included the master pin.
• The track is under tension.
A
W155-03-07-001
Unit: mm (in)
A 1041.4 (41.0) 1062.2 (41.8) Clad by welding and
B 152 (6.0) 144.1 (5.7) finish or replace
Master Pin
W142-03-07-003
Unit: mm (in)
Standard Remedy
A 301 (11.9)
Replace
B 56.8 (2.2)
W3-7-8
Master Bushing
W105-03-07-023
Unit: mm (in)
Standard Remedy
A 204.15 (8.0)
B 57.65 (2.3) Replace
C 85.35 (3.4)
Grouser Shoe
W105-03-07-024
Unit: mm (in)
Shoe Size 650 mm (25.6 in) Grouser Shoe
A 302 (11.9) −
B 20 (0.8) − Replace
C 50 (2.0) 24 (0.9)
W3-7-9
Bushing
W105-03-07-023
Unit: mm (in)
A 218.95 (8.6) -
B 58.15 (2.3) - Replace
C 85.35 (3.4) 78.55 (3.1)
Pin
A W142-03-07-004
Unit: mm (in)
Standard Remedy
A 319.5 (12.6)
Replace
B 57.0 (2.2)
W3-7-10
MEMO
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SECTION 4
FRONT ATTACHMENT
CONTENTS
Group 1 Front Attachment
Remove and Install Front Attachment.... W4-1-1
Remove and Install Bushing .................. W4-1-8
Maintenance Standard ......................... W4-1-10
Standard Dimensions for
Arm and Bucket Connection............... W4-1-13
Standard Dimensions for
Arm and Boom Connection ................ W4-1-14
Group 2 Cylinder
Remove and Install Cylinder .................. W4-2-1
Hydraulic Circuit Pressure
Release Procedure............................. W4-2-12
Disassemble Cylinder........................... W4-2-14
Assemble Cylinder ............................... W4-2-18
Maintenance Standard ......................... W4-2-24
17VW-4-1
(Blank)
17VW-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT
ATTACHMENT

lines.
repair work.
Preparation
1. Park the machine on a solid level surface.ӸFully
retract the arm and bucket cylinders and lower the
front attachment onto the ground.

approx. 30° counterclockwise using a hexagon W166-04-01-001

tem on page W1-1-2.
Cap
: 4 mm
W183-01-01-001
W4-1-1
Removal
(See Remove and Install Boom Cylinder section)

1. Disconnect lubrication hose (1) at the boom cylin- 1
der (2) rod. (2 places at right and left)
: 19 mm
2
W162-04-01-022
2. Remove bolts (5) (2 used), spring washers (4) (2

used) and plate (6).
: 30 mm 6 Boom
2
5
CAUTION: Boom cylinder (2) weight:
700 kg (1540 lb) 4
3. Hoist the front part of boom cylinder (2) by crane.
Flange
Insert a bar between the flange and boom to pull
the pin (3) out. Pull the pin out while rotating the 3
pin lightly right and left by its flange. Remove the
boom cylinder rods. (2 places at right and left)
W142-04-01-006
W4-1-2
4. Put a support under boom cylinder (2). Hoist the 8. Remove bolts (11) (2 used) and spring washers (2
boom cylinder and lower onto the support. At this used) from lock plate (12) of boom foot pin (13).
moment, the cylinder rod is retracted. : 30 mm
11
Support
13 12
W105-04-01-007
NOTE: Make shape mark of the boom foot on the

M162-06-027 main frame beforehand. Then it will be easy
to align the boom foot pin (13) hole when
5. Remove boom cylinder (2) from the other side ac- installing.
cording to the same procedures (2 to 4).
6. Stop the engine. Move all control levers to release

pressure remaining in the system.
Completely release the residual pressure from the Mark
hydraulic circuit. Refer to “Hydraulic Circuit Pres-
sure Release Procedure” on page W4-2-12. Main Frame
7. Remove socket bolts (7) (4 used), (8) (12 used) to M116-07-121

disconnect hoses (9 and 10).
Close all openings with plugs to keep clean.
: 12 mm
: 14 mm
8
7
8
10 9
W166-04-01-102
W4-1-3

11510 kg (25370 lb)
9. Attach the wire rope to the boom. Lift the boom by 11. Hoist the front attachment, then retract the cylin-
crane, take up slack of wire rope. der rod of boom cylinder (2) at its stroke end.
Pass wire through the cylinder rod hole to secure
the cylinder into the hole for boom foot pin. At this
moment, the boom cylinder should be held hori-
zontally.
Front Attachment
W105-04-01-008
CAUTION: Boom foot pin weight:

200 kg (440 lb) W157-04-01-004
10. Insert a bar between the flange of boom foot pin
(13) and the boss on frame to pull out a little part
of the boom foot pin. Turn the pin by hand with its
flange facing up. Then pull out the boom foot pin
while turning it lightly.
13
M162-06-028
W4-1-4
Installation
3. Connect hoses (9 and 10) with socket bolts (7)

(14 used) and (8) (12 used).
11510 kg (25370 lb)
: 12 mm
1. Align the boom foot boss with the main frame
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
boss.
: 14 mm
Insert shim to right side of the boom foot boss to
: 210 N⋅m (2.1 kgf⋅m, 15.0 lbf⋅ft)
take out clearance between the boom foot boss
and the main frame boss. Remaining clearance
should be less than 1 mm (0.04 in). 8
NOTE: Be sure to align the matching marks put 7
during disassembly. 8
10 9
W166-04-01-102
M116-07-036
CAUTION: Boom cylinder weight:

700 kg (1540 lb)
CAUTION: Prevent personal injury. Metal IMPORTANT: Fill the hydraulic oil tank with hy-
fragments may fly off when a hammer is used draulic oil to the specified level. Run
to insert pins. Be sure to wear necessary the engine at idle speed. Check hose
protection, such as goggles, hard hat, etc.. connections for any oil leaks.
2. Insert boom foot pin (13) which has been applied 4. Attach the wire rope to boom cylinder (2). Lift the
with grease. Install thrust plate (12) with bolts (11) boom cylinder by crane and align the boom cylin-
(2 used) and spring washers (2 used). der rod with the pin hole in the boom.
: 30 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
11
13 12
W105-04-01-007
W157-04-01-006
W4-1-5
8. Install boom cylinder (2) on the other side accord-
CAUTION: Prevent personal injury. Metal
ing to the same procedures (4 to 7).
fragments may fly off when a hammer is used
to insert pins. Be sure to wear necessary pro-
tection, such as goggles, hard hat, etc.. 9. Fill grease via grease fitting on boom cylinder rod
5. Drive pin (3) into the boom. Install both boom cyl- side and boom foot.
inders (2).
IMPORTANT: After completing work, check hy-
6. Install plate (6) and spring washer (4) to tighten draulic oil level. Fully stroke each
bolt (5). cylinder several times to bleed any
(See Remove and Install Boom Cylinder section.) air remaining in the circuit while
: 30 mm checking each hose connectors for
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft) any oil leaks.
6 Boom
2 Cylinder
Rod Side
5
Boom
Foot Side
4
W166-04-01-102
W142-04-01-006
7. Connect lubrication hose (1) at the boom cylinder

(2) rod.
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
2
W162-04-01-022
W4-1-6
IMPORTANT: In case the arm was separated from Thrust
Arm Thrust
Boom Plate
the boom, perform steps 10 and 11 Boss Plate
when installing the arm.
10. Install thrust plates (2 used) at both sides between
arm and boom respectively.
11. Fill grease via grease fittings on arm cylinder rod

side and boom / arm pin.
IMPORTANT: For handling of HN bushing for the

front attachment, pay attention to
the following.
• Precautions for pressing the bushing in:
If a hammer is used to drive the bushing in, the Pin
bushing may be damaged. Use a press. M162-06-036
• Precautions when reinforcing the arm:

Welding heat for arm reinforcement may cause oil
leakage from the bushing and decrease lubrica-
tion performance.
If oil leak occur, replace the bushing.
Boom/Arm Pin
Arm Cylinder
Rod Side
Boom/Arm Pin
W166-04-01-101
W4-1-7
REMOVE AND INSTALL BUSHING
d c
b
a
f
W166-04-02-005
Bucket
Link A Arm
1 Link A 2 1 2
2
Boom
1 2 1
a: Bucket and Link A

W17V-04-01-001
1 2 Link B
b: Link A
W17V-04-01-002
c: Arm
W17V-04-01-003
1 2
Link B 2 1 2
Arm
2
Boom Bucket
Main Frame
e: Arm
d: Boom and Main Frame f: Arm and Bucket
W17V-04-01-005
W17V-04-01-004 W17V-04-01-006
1 - Dust Seal 2 - Bushing
W4-1-8
Removal
1. Remove dust seal (1) and bushing (2).

NOTE: In case the bushing is difficult to be re-
moved, use a torch to remove it .
Installation
1. Cool bushing (2) in dry ice.
2. Install bushing (2) and dust seal (1).

Install bushing (2) with installing tools.
Bushing Installing Tools

a: Bucket Side .................................. ST 2873
Link A Side ................................... ST 2873
b: Link A ........................................... ST 2877
c: Arm............................................... ST 2877
Boom Side .................................... ST 2836
d: Boom Side .................................... ST 2826
Main Frame Side .......................... ST 2826
e: Arm............................................... ST 2804
f: Bucket Side .................................. ST 2873
Arm Side....................................... ST 2875
W4-1-9
Pin and Bushing
f
d
c g
h
b i
e
a
k
j
W105-04-01-018
Unit: mm (in)
Location Part Name Standard Allowable Limit
Pin Outer Dia. 130 (5.1) 129 (5.1)
a: Boom Cylinder and Main Frame Pin Hole Inner Dia. (Main Frame Side) 130 (5.1) -
Bearing Inner Dia. (Cylinder Side) 130 (5.1) 131.5 (5.2)
Pin Outer Dia. 150 (5.9) 149 (5.9)
Bushing Inner Dia. (Frame Side) 150 (5.9) 151.5 (6.0)
b: Boom and Main Frame Bushing Outer Dia. 170 (6.7) -
Bushing Inner Dia. (Boom Side) 150 (5.9) 151.5 (6.0)
Bushing Outer Dia. 175 (6.9) -
Pin Outer Dia. 130 (5.1) 129 (5.1)
c: Boom Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 130 (5.1) -
W4-1-10
Unit: mm(in)
Allowable
Location Part Name Standard
Limit
Pin Outer Dia. 130 (5.1) 129 (5.1)
d : Boom and Arm Cylinder Pin Hole Inner Dia. (Boom Side) 130 (5.1) -
Pin Outer Dia. 140 (5.5) 139 (5.5)
Bushing Inner Dia. (Boom Side) 140 (5.5) 141.5 (5.9)
e : Boom and Arm Bushing Outer Dia. 165 (6.5) -
Bushing Inner Dia. (Arm Side) 140 (5.5) 141.5 (5.9)
Pin Outer Dia. 130 (5.1) 129 (5.1)
f : Arm Cylinder and Arm Pin Hole Inner Dia. (Arm Side) 130 (5.1) -
Pin Outer Dia. 130 (5.1) 129 (5.1)
g : Arm and Bucket Cylinder Pin Hole Inner Dia. (Arm Side) 130 (5.1) -
Pin Outer Dia. 140 (5.5) 139 (5.5)
Bushing Inner Dia. (Link A Side) 140 (5.5) 141.5 (5.9)
h : Bucket Cylinder and Link
Bushing Outer Dia 160 (6.3) -
Pin Outer Dia. 130 (5.1) 129 (5.1)
Bushing Inner Dia. (Link A Side) 130 (5.1) 131.5 (5.2)
i : Link and Bucket Bushing Outer Dia. 150 (5.9) -
Bushing Inner Dia. (Bucket Side) 130 (5.1) 129 (5.1)
Pin Outer Dia. 130 (5.1) 129 (5.1)
Bushing Inner Dia. (Arm Side) 130 (5.1) 131.5 (5.2)
j : Arm and Bucket Bushing Outer Dia. 160 (6.3) -
Bushing Inner Dia. (Bucket Side) 130 (5.1) 131.5 (5.2)
Pin Outer Dia. 110 (4.3) 109 (4.3)
k : Arm and Link Bushing Inner Dia. (Arm Side) 110 (4.3) 111.5 (4.4)
NOTE: 1 mm=0.03937 in
IMPORTANT: When replacing HN bushing, press

fit it in with a press.
W4-1-11
Side Cutter
B A
W166-04-01-011
Unit: mm (in)
A 351 (13.8) 228 (9.0)
Replace
B 25 (1.0) -
Point
B C
W142-04-01-021
Unit: mm (in)
A 306 (12.0) 153 (6.0)
B 153 (6.0) −
Replace
C 164 (6.5) −
D 158 (6.2) −
W4-1-12
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION
IMPORTANT: If the front attachment of a previous
model machine is used, use the
grease intervals of the previous
model machine.
e c
b
g
h
f
i m
j n
k o
l
Section A Section B
W17V-04-01-009
Unit: mm (in)
ZAXIS800 EX750-5 EX750-3 NOTE: Dimension j: 552 (21.7 in) mm includes the
a 600 (23.6) ← ← clearance for bucket adjuster.
Dimension h: 10° means the angle of the
b 20 (0.8) ← ←
stopper.
c 890 (35.0) ← ←
d 820 (32.3) ← ←
e 2210 (87.0) 2200 (86.6) ←
f 56 (2.2) ← ←
g 674 (26.5) ← ←
h 10° ← ←
i 56 (2.2) ← ←
j 552 (21.7) ← ←
k 588 (22.0) ← ←
l 624 (24.6) ← ←
m 130 (5.1) ← ←
n 557 (21.9) ← ←
o 629 (24.8) ← ←
W4-1-13
STANDARD DIMENSIONS FOR ARM AND
BOOM CONNECTION
IMPORTANT: If the front attachment of a previous
model machine is used, use the
grease intervals of the previous
model machine.
Section C
W17V-04-01-008
Unit: mm (in)
ZAXIS800 EX750-5 EX750-3

s 140 (5.5) ← ←
t 561 (22.1) ← ←
u 738 (29.1) ← ←
W4-1-14
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER

lines.
repair work.
Preparation
1. Park the machine on a solid level surface.ӸFully
retract the arm and bucket cylinder and lower the
front attachment onto the ground.

approx. 30° counterclockwise using a hexagon W105-04-02-001
tem on page W1-1-2.
: 4 mm Cap
W183-01-01-001
W4-2-1
Remove and Install Boom Cylinder
A
B
W17V-04-02-001
A: Rod Side B: Bottom Side

7
Greasing Hose Hydraulic Hoses
2 6
W162-04-01-022
W162-04-01-019
5
6
4
8
2
3
1 9
10
W162-04-01-025
2
12 11
W142-04-01-006
1 - Pin ( 2 Used) 4 - Bolt (4 Used) 7 - Socket Bolt (16 Used) 10 - Spring Washer (4 Used)
2 - Boom Cylinder (2 Used) 5 - Spring Washer (4 Used) 8 - Plate (2 Used) 11 - Shim (2 Used)
3 - Plate (2 Used) 6 - Pin (2 Used) 9 - Bolt (2 Used) 12 - Shim (4 Used)
W4-2-2
Removal
CAUTION: When tapping the pin out with a CAUTION: Pin (6) weight: 45 kg (100 lb)
hammer, metal debris may fly out, causing 5. Remove bolts (9) (2 used), spring washers (10) (2
personal injury. Be sure to wear necessary used) and plate (8) from the cylinder bottom side
protection, such as goggles, a hard hat, etc.. to remove pin (6). Remove boom cylinder (2).
1. Disconnect the greasing hoses (2 used) from Remove shim (11) and shims (12) (2 used).
boom cylinders (2). : 30 mm
: 19 mm
6. Remove boom cylinder (2) on the other side in the
same procedures (2 to 5).
CAUTION: Boom cylinder weight:
700 kg (1540 Ib)
Pin (1) weight: 35 kg (80 lb)
2. Attach a wire rope to boom cylinder (2) to hold it
by crane.
Remove bolts (4) (2 used), spring washers (5) (2
used) and plate (3) on the cylinder rod side.
Pull pin (1) out by prying with a bar.
: 30 mm
3. Start the engine. Fully retract boom cylinder.

Secure the rod with a wire winding through the rod
hole so that boom cylinder (2) won’t extend.
CAUTION: If the air breather cap on the

hydraulic oil tank is turned quickly, the air
breather cap may fly off due to pressure
remaining inside. Slowly turn the air breather
cap to remove only after completely relieving
any remaining pressure.
4. Stop the engine. Release any remaining air from
the hydraulic lines and oil tank. (Refer to W4-2-
12) Loosen the socket bolts (7) (8 used) and dis-
connect hydraulic hoses (2 used) from the cylin-
der.
: 12 mm
W4-2-3
A
B
W17V-04-02-001
A: Rod Side B: Bottom Side

7
Greasing Hose Hydraulic Hoses
2 6
W162-04-01-022
W162-04-01-019
5
6
4
8
2
3
1 9
10
W162-04-01-025
2
12 11
W142-04-01-006
1 - Pin (2 Used) 4 - Bolt (4 Used) 7 - Socket Bolt (16 Used) 10 - Spring Washer (4 Used)
2 - Boom Cylinder (2 Used) 5 - Spring Washer (4 Used) 8 - Plate (2 Used) 11 - Shim (2 Used)
3 - Plate (2 Used) 6 - Pin (2 Used) 9 - Bolt (2 Used) 12 - Shim (4 Used)
W4-2-4
Installation
CAUTION: Boom cylinder weight: 5. Install bolts (4) (2 used), spring washers (5) (2
700 kg (1540 lb) used), Plate (3) on the pin (1).
Pin (6) weight: 45 kg (100 lb) : 30 mm
1. While hoisting boom cylinder (2) by crane, align : 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
the cylinder bottom side pin hole with the main
frame pin hole. Install shims (12) (2 used), shim 6. Connect the greasing hose.
(11) (1 used) between the main frame and boom : 19 mm
cylinder. Drive pin (6) and secure it with bolts (9) : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
(2 used), spring washers (10) (2 used) and plate
(8). Support the boom cylinder rod side with a
support. 7. Install the boom cylinder (6) at other side following
: 30 mm the same procedures (1 to 6).
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft) Ȁ
IMPORTANT: After completing work, fully stroke
2. Connect the hydraulic hoses (2 used). Remove each cylinder several times to bleed
the wire securing the cylinder rod. any air remaining in the circuit.
: 12 mm (Refer to W4-2-13)
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
3. Hoist the cylinder rod by crane and extend the rod

so that cylinder rod hole aligns with the boom pin
hole.
CAUTION: Pin (1) weight: 35 kg (80 lb)

4. Drive pin (1) into the cylinder rod side.
W4-2-5
Remove and Install Arm Cylinder
W17V-04-02-001
Hydraulic Hoses
Greasing Hose 5
Greasing Hose
W162-04-01-008
M162-06-019
4 5
W142-04-01-015
1 - Pin (2 Used) 3 - Bolt (4 Used) 4 - Spring Washer (4 Used) 5 - Arm Cylinder

2 - Plate (2 Used)
W4-2-6
Removal Installation
CAUTION: When tapping the pin out with a CAUTION: Arm cylinder weight:
hammer, metal debris may fly out, causing 1025 kg (2260 lb)
personal injury. Be sure to wear necessary 1. While hoisting arm cylinder (5) by crane, align the
protection, such as goggles, a hard hat, etc.. cylinder bottom side pin hole with the boom pin
1. Disconnect the greasing hose from the arm hole.
cylinder (5) rod.
: 19 mm
CAUTION: Pin weight: 40 kg (90 lb)
2. Hoist and insert pin (1) into the cylinder bottom
CAUTION: Arm cylinder weight: side pin hole. Install bolts (3) (2 used), spring
1025 kg (2260 lb) washers (4) (2 used) and plate (2).
Pin weight: 40 kg (90 lb) : 30 mm
2. Attach a wire rope to arm cylinder (5) to hold it by : 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
crane. Remove bolts (3) (2 used) on the cylinder
rod side to remove spring washers (4) (2 used) 3. Connect the hydraulic hoses (2 used) and greas-
and plate (2). Drive pin (1) out. ing hose on the arm cylinder bottom.
: 30 mm : 14 mm
: 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)
: 19 mm
3. Start the engine. Fully retract the arm cylinder.
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
hole so that the arm cylinder (5) won’t extend.
4. While hoisting the cylinder rod by crane, remove
the wire securing the cylinder rod.
CAUTION: If the air breather cap on the Start the engine. Extend the rod so that cylinder
hydraulic oil tank is turned quickly, the air rod hole aligns with the arm cylinder pin hole.
remaining inside. Slowly turn the air breather CAUTION: Pin weight: 40 kg (90 lb)
cap to remove only after completely relieving 5. Hoist and insert pin (1) into the cylinder rod side
any remaining pressure. pin hole. Install bolts (3) (2 used), spring washers
4. Stop the engine. Release any remaining air from (4) (2 used) and plate (2).
the hydraulic lines and oil tank (Refer to W4-2-12). : 30 mm
Disconnect the hydraulic hoses (2 used) and : 390 N⋅m (40 kgf⋅m 290 lbf⋅ft)
greasing hose from the cylinder bottom side.
: 14 mm 6. Connect the greasing hose to arm cylinder (2) rod.
: 19 mm : 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
CAUTION: Pin weight: 40 kg (90 lb)
5. Remove bolts (3) (2 Used) on the arm cylinder
each cylinder several times to bleed
bottom side, to remove spring washers (4) (2
any air remaining in the circuit.
used) and plate (2). Drive pin (1) out. Remove
(Refer to W4-2-13)
arm cylinder (5) by crane.
: 30 mm
W4-2-7
Remove and Install Bucket Cylinder
W17V-04-02-001
6 1 11
Greasing Hose
3
10
11
5 W142-04-01-009
Hydraulic Hose
W162-04-01-026
4
6 11
7
10
1я
я2
5
3
11 W142-04-01-015
W142-04-01-013
1 - Bolt (3 Used) 4 - Link B (2 Used) 7 - Plate 10 - Pin

2 - Spring Washer (3 Used) 5 - Pin 8 - Bolt (2 Used) 11 - Bucket Cylinder
3 - Stopper 6 - Link A 9 - Spring Washer (2 Used)
W4-2-8
Removal
CAUTION: When tapping the pin out with a 6. Disconnect hydraulic hoses (2 used) from the cyl-
hammer, metal debris may fly out, causing inder bottom.
personal injury. Be sure to wear necessary : 12 mm
protection, such as goggles, a hard hat, etc..
1. Disconnect the greasing hose from the bucket
cylinder (11) bottom. CAUTION: Pin (10) weight: 40 kg (90 Ib)
: 19 mm 7. Remove bolts (8) (2 Used) on the cylinder bottom
side to remove spring washers (9) (2 used) and
2. Lay a wooden block under link A (6). Then, fasten plate (7). Drive pin (10) out.
link A and link B with a wire so that links B(4) (2 : 30 mm
used) won’t fall when pin (5) is removed.
CAUTION: Bucket Cylinder weight:
CAUTION: Bucket cylinder weight: 630 kg (1390 lb)
630 kg (1390 lb) 8. Remove bucket cylinder (11) by crane.
Pin (5) weight: 85 kg (190 Ib)
3. Attach a wire rope to bucket cylinder (11) to hold it
by crane. Remove bolts (1) (3 Used) on the
cylinder rod side to remove spring washers (2) (3
used) and stopper (3). Drive pin (5) out.
: 30 mm
4. Start the engine. Fully retract bucket cylinder rod.

hole so that the bucket cylinder (11) won’t extend.
CAUTION: If the air breather cap on the

hydraulic oil tank is turned quickly, the air
remaining inside. Slowly turn the air breather
cap to remove only after completely relieving
any remaining pressure.
5. Stop the engine. Release any remaining air from
the hydraulic lines and oil tank. (Refer to W4-2-
12)
W4-2-9
W17V-04-02-001
6 1 11
Greasing Hose
3
10
11
5 W142-04-01-009
Hydraulic Hose
W162-04-01-026
4
6 11
7
10
1я
я2
5
3
11 W142-04-01-015
W142-04-01-013
1 - Bolt (3 Used) 4 - Link B (2 Used) 7 - Plate 10 - Pin

2 - Spring Washer (3 Used) 5 - Pin 8 - Bolt (2 Used) 11 - Bucket Cylinder
3 - Stopper 6 - Link A 9 - Spring Washer (2 Used)
W4-2-10
Installation
CAUTION: Bucket cylinder weight: 6. Remove the wire which fastened link A (6) with
630 kg(1390 lb) link B to prevent links B (4) (2 used) from dropping.
1. While hoisting bucket cylinder (11) by crane, align Start the engine and remove the wooden block
the cylinder bottom side pin hole with the arm pin laid under link A.
hole.
CAUTION: Pin (10) weight: 40 kg (90 lb) each cylinder several times to bleed
2. Hoist and insert pin (10) into the cylinder bottom any air remaining in the circuit.
side pin hole. Install plate (7), spring washers (9) (Refer to W4-2-13)
(2 used) and bolts (8) (2 used).
: 30 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
3. Connect the hydraulic hoses (2 used) and greas-

ing hose on the bucket cylinder (11) bottom side.
: 12 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
CAUTION: Bucket cylinder weight:

630 kg (1390 lb)
4. While hoisting the cylinder rod by crane, remove
the wire fastening the cylinder rod. Start the
engine. Extend the rod so that cylinder rod hole
aligns with link A (6) and links B (5) pin (5) holes.
CAUTION: Pin (5) weight: 85 kg (190 lb)

5. Hoist and insert pin (5) into the cylinder rod side
pin hole. Install stopper (3), spring washers (2) (3
used) and bolts (1) (3 used).
: 30 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
W4-2-11
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE
Upper
CAUTION: Be sure to slowly loosen the over-
load relief valves. The overload relief valve 1
may spurt hydraulic oil if loosened more than
3
3/4 turn. Never loosen the valve further.
IMPORTANT: Be sure to loosen overload relief
valve body. If lock nut or adjusting
screw is loosened, pressure setting
will change. Never attempt to loosen 2
them.
Also be sure to re-tighten the over-
load relief valve after releasing the
residual circuit pressure.
1. Release the residual circuit pressure by slowly W16J-02-05-010
loosening the overload relief valve(s) for the
line(s) or hose(s) to be disconnected. Front
: 41 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
Lower
W16J-02-05-017
Front
Overload Relief Valve:

1 - Arm Cylinder (Rod Side)
2 - Bucket Cylinder (Rod Side)
3 - Boom Cylinder (Rod Side)
4 - Boom Cylinder (Bottom Side)
5 - Bucket Cylinder (Bottom Side)
6 - Arm Cylinder (Bottom Side)
W4-2-12
MAIN POINTS TO BLEED AIR
NOTE: As for loader front, almost same main 1. Place front attachment in following posture.
points should be followed. 2. Start engine. (Running at low speed)
3. Remove the gum cap. Then loosen the air bleed-
CAUTION: Escaping fluid under high pres-
ing plug.
sure can penetrate the skin and eyes, causing
: 19 mm
seriously injury. Avoid this hazard by reliev-
4. Operate cylinder to extend and retract to bleed air
ing pressure before disconnecting hydraulic
out until only oil flow out from the plug hole.
lines from machine.
5. Tighten the plug and install the gum cap.
Hydraulic oil and machine parts may be hot
: 19 mm
after operation. Touching them carelessly can
: (44±2.9 N⋅m)
result in severe burns. Be sure to wait for oil
(4.5±0.3 kgf⋅m, 33.0 ± 2.2 lbf⋅ft)
to cool before starting any repair work.
Positions for Air Bleeding Plug
Air Bleeding Plug

(Arm Cylinder)
Air Bleeding Plug

(Bucket Cylinder )
W17V-04-02-001
W4-2-13
DISASSEMBLE CYLINDER
Bucket Cylinder
16
17
18
20
21 1
20
18
23 15
24 14
3
13
4
5
6
7
8
9
13
10
11
12
W17V-04-02-002
1- Cylinder Rod 7- U-Ring 13 - Air Bleeding Plug 18 - Slide Ring (2 Used)

2- Wiper Ring 8- Buffer Ring 14 - Set Screw 20 - Slide Ring (2 Used)
3- Socket Bolt (8 Used) 9- Bushing 15 - Steel Ball 21 - Seal Ring
4- Cylinder Head 10 - Retaining Ring 16 - Cushion Bearing 23 - Nut
5- Slide Ring 11 - Backup Ring 17 - Piston 24 - Cylinder Tube
6- Backup Ring 12 - O-Ring
W4-2-14
Arm Cylinder
16
17
18
20
21
1
20
15
18
22
14
23
24
13
4
5
6
7
8
9
10
13 11
12
W162-04-02-003
1- Cylinder Rod 7- U-Ring 13 - Air Bleeding Plug 20 - Slide Ring (2 Used)

2- Wiper Ring 8- Buffer Ring 14 - Set Screw 21 - Seal Ring
3- Socket Bolt (8 Used) 9- Bushing 15 - Steel Ball 22 - Shim
4- Cylinder Head 10 - Retaining Ring 16 - Cushion Bearing 23 - Nut
5- Slide Ring 11 - Backup Ring 17 - Piston 24 - Cylinder Tube
6- Backup Ring 12 - O-Ring 18 - Slide Ring (2 Used)
W4-2-15
Boom Cylinder
19
16
18
20
21
1
20
18
17
22
15
23
14
24
2
3
13
4
11
12
5
6
7
8
9
10
W162-04-02-001
1- Cylinder Rod 7- U-Ring 13 - Air Bleeding Plug 19 - Cushion Seal

2- Wiper Ring 8- Buffer Ring 14 - Set Screw 20 - Slide Ring (2 Used)
3- Socket Bolt (8 Used) 9- Bushing 15 - Steel Ball 21 - Seal Ring
4- Cylinder Head 10 - Retaining Ring 16 - Cushion Bearing 22 - Shim
5- Slide Ring 11 - Backup Ring 17 - Piston 23 - Nut
6- Backup Ring 12 - O-Ring 18 - Slide Ring (2 Used) 24 - Cylinder Tube
W4-2-16
Disassemble Cylinder
• Be sure to read all “Precautions for Disassembly 5. Loosen set screw (14) and remove steel ball (15).
and Assembly” work thoroughly on page W1-1-1 : 14 mm
before starting the disassembly procedure. NOTE: After set screw (14) was installed, two
• The disassembly procedure below starts on the places were crimped. Remove the crimped
premise that the hydraulic lines and the line secur- parts with a grinder to loosen the set screw.
ing bands have been removed.
6. Loosen nut (14) using special tool (ST 5908).
CAUTION: Boom Cylinder weight: Remove shim (22) and piston (16).
700 kg (1540 lb) NOTE: Shim (22) is not used in bucket cylinder.
Arm Cylinder: 1025 kg (2260 lb) Nut Turning Special Tools:
Bucket Cylinder: 630 kg (1390 lb) (Boom cylinder): 150 mm (5.9 in) (ST 3284)
1. Lift and securely place the cylinder on a work- (Arm cylinder) : 155 mm (6.1 in) (ST 3285)
bench by crane. Be sure to place the cylinder (Bucket cylinder) : 150 mm (5.9 in) (ST 3284)
horizontally and drain hydraulic oil from the cylin-
der.
IMPORTANT: Be sure not to reuse slide rings
(17and 18). When assembling the
cylinder, replace them with the new
ones.
7. Remove slide rings (18) (2 used), slide rings (20)
(2 used) and seal ring (21) from piston (17).
W102-04-02-027 8. Remove cushion bearing (16) and cushion seal

CAUTION: Cylinder rod weight: (19) from cylinder rod (1). Remove cylinder head
Boom Cylinder: 320 kg (710 lb) (4).
Arm Cylinder: 435 kg (960 lb) NOTE: Cushion seal (19) is not used in arm cylin-
Bucket Cylinder: 275 kg (610 lb) der and bucket cylinder.
2. Fully extend cylinder rod (1). Hold the rod end by
crane. Remove socket bolts (3) (8 Used) from cyl- IMPORTANT: Be sure not to reuse slide ring (5).
inder head (4). When assembling the cylinder, re-
: 22 mm (Boom, Bucket) place it with a new one.
: 24 mm (Arm) 9. Remove O-ring (12), backup ring (11), wiper ring
(2) and slide ring (5) from cylinder head (4). Then
IMPORTANT: Be sure to pull cylinder rod (1) remove backup ring (6), U-ring (7), backup ring
straight out so as not to damage the (8), retaining ring (10) and bushing (9).
sliding surface.
3. Pull out cylinder head (4) and cylinder rod (1) from
cylinder tube (24) by tapping with a plastic ham-
mer.
4. Secure cylinder rod (1) on special tool (ST 5908).
Put matching marks between cylinder rod (1) and
nut (23).
ST 5908
W158-04-02-022
W4-2-17
ASSEMBLE CYLINDER
Boom Cylinder
2 3 4 24 16 19 18 20 21 20 18 14
23
5 6 7 8 9 10 11, 12 1 17 22 15
Slit
W17V-04-02-003
1- Cylinder Rod 7- U-Ring 14 - Set Screw 20 - Slide Ring (2 Used)

2- Wiper Ring 8- Buffer Ring 15 - Steel Ball 21 - Seal Ring
3- Socket Bolt (8 Used) 9- Bushing 16 - Cushion Bearing 22 - Shim
4- Cylinder Head 10 - Retaining Ring 17 - Piston 23 - Nut
5- Slide Ring 11 - Backup Ring 18 - Slide Ring (2 Used) 24 - Cylinder Tube
6- Backup Ring 12 - O-Ring 19 - Cushion Seal
W4-2-18
Arm Cylinder Bucket Cylinder

2 2
5 5
1 6 1 6
8 7 8 7
9 3 9 3
10 4 10 4
11,12 24 11, 12 24
16 16
18 18
20 20
21 21
17 20 17 20
18 18
22
15 14 15 14
23 23
W162-04-02-005 W162-04-02-005

6- Backup Ring 12 - O-Ring
W4-2-19
NOTE: Boom cylinder is illustrated here.
2 3 4 24 16 19 18 20 21 20 18 14
23
5 6 7 8 9 10 11、12 1 17 22 15
Slits
W17V-04-02-003

6- Backup Ring 12 - O-Ring 19 - Cushion Seal
W4-2-20
Assemble Cylinder
1. Press bushing (9) into cylinder head (4) using 6. Install O-ring (12) and backup ring (11) around
special tool. Install retaining ring (10) in the cylinder head (4).
cylinder head.
Special tool to install bushing: ST 2507 (Boom 7. Install seal ring (21) around piston (17) using
Cylinder) special tool.
Special tools to install seal ring:
IMPORTANT: Install buffer ring (8) with the lip Boom Cylinder :ST 2189, ST 2201, ST 2225
facing bushing (9). Arm Cylinder : ST 2500
2. Install buffer ring (8) into cylinder head (4). Bucket Cylinder :ST 2200, ST 2224
IMPORTANT: Install U-ring (7) with the lip facing IMPORTANT: Install slide rings (18 and 20) with
buffer ring (8). their slits positioned 180°° each
3. After installing backup ring (6) into cylinder head facing the opposite of the other.
(4), install U-ring (7).
8. Install slide rings (18) (2 used) and (20) (2 used)
4. Install slide ring (5) in cylinder head (4). onto piston (17).
IMPORTANT: Install wiper ring (2) with the lip 9. Attach the special tool on piston (17) to retract
facing outer side of cylinder head seal ring (21) and slide rings (18 and 20).
(4). Special Tool:
5. Press wiper ring (2) into cylinder head (4). Arm Cylinder: ST 2213
Bucket Cylinder: ST 2212
CAUTION: Cylinder rod (1) weight:

Boom Cylinder : 320 kg (710 lb)
Arm Cylinder : 435 kg (960 lb)
Bucket Cylinder : 275 kg (610 lb)
10. Secure cylinder rod (1) on special tool (ST 5908).
Ȁ ST5908
W158-04-02-022
W4-2-21
3 4 24 16 19 14
23
1 17 22 15
W17V-04-02-003
W4-2-22
11. Install the cylinder head (4) assembly onto 17. Install steel ball (15) into nut (23) and secure the
cylinder rod (1) using special tool. ball with set screw (14).
: 14 mm
IMPORTANT: Install cushion seal (19) with the slit : 97±18 N⋅m (9.9±1.8 kgf⋅m, 72±13.0 lbf⋅ft)
facing the piston (17) side.
12. Install cushion seal (19) on cylinder rod (1). 18. Crimp two places around set screw (14) top fringe
NOTE: There is no cushion seal (19) in the bucket to prevent the set screw from loosening.
cylinder.
CAUTION: Cylinder tube (24) weight:
IMPORTANT: When installing cushion bearing (16), Boom Cylinder : 315 kg (700 lb)
face the cushion groove narrow side Arm Cylinder : 435 kg (960 lb)
toward piston (17). Bucket Cylinder : 265 kg (590 lb)
13. Install cushion bearing (16) onto cylinder rod (1). 19. Horizontally secure cylinder tube (24) on a work
bench.
14. Install the piston (17) assembly onto cylinder rod
(1).
CAUTION: The cylinder rod (1) assembly
weight:
15. Install shim (22) and nut (23) to cylinder rod (1).
Boom Cylinder : 385 kg (850 lb)
NOTE: There is no shim (22) in the bucket cylinder. Arm Cylinder : 590 kg (1300 lb)
Bucket Cylinder : 365 kg (800 lb)
16. Tighten nut (23) using special tool. IMPORTANT: When installing the cylinder rod (1)
Nut turning special tool: assembly into cylinder tube (24),
Boom cylinder : 150 mm (5.9 in) (ST 3284) take care to correctly align them and
: 24300 N⋅m (2480 kgf⋅m, 17940 lbf⋅ft) install the rod staight so as not to
Arm cylinder : 155 mm (6.1 in) (ST 3285) damage rings.
: 40300 N⋅m (4110 kgf⋅m, 29730 lbf⋅ft) 20. Insert cylinder rod (1) into cylinder tube (24).
Bucket cylinder : 150 mm (5.9 in) (ST 3284)
: 30200 N⋅m (3080 kgf⋅m, 22280 lbf⋅ft) 21. Install cylinder head (4) into cylinder tube (24).
Tighten socket bolts (3) (8 used).
Arm cylinder
: 24 mm
: 1910±360 N⋅m
(195±37 kgf⋅m, 1410±270 lbf⋅ft)
Boom Cylinder, Bucket Cylinder
: 22 mm
: 1590±295 N⋅m
(162±30 kgf⋅m, 1170±215 lbf⋅ft)
W4-2-23
Cylinder Rod Cylinder Rod Deflection (run out)

A
Dial Gauge
Cylinder Rod
W105-04-02-094
W166-04-02-022
Unit: mm (in) 1m
V Block
Cylinder Recommended O.D Size after
Unit: mm (in)
Recovery
+0.031 +0.001 Deflection Runout Remedy
Boom 140 -0.061 (5.5 -0.002 )
+0.031 +0.001 0.5 (0.02) 1.0 (0.04) Calibrate
Arm 150 -0.061 (5.9 -0.002 )
+0.031 +0.001 1.0 (0.04) 2.0 (0.08) Replace
Bucket 140 -0.061 (5.5 -0.002 )
W4-2-24
MEMO
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SECTION 5
ENGINE AND ACCESSORY
CONTENTS
General Information Alternator ..................................................6A-16
General Repair Instruction...........................0A-1 Oil Cooler ..................................................6A-18
Illustration Arrows........................................0A-2 Injection Pump ..........................................6A-20
Abbreviations ..............................................0A-3 Coupling Assembly....................................6A-24
Nut and Bolt Angular Tightening Method......0A-4 Cylinder Head............................................6A-27
Standard Bolt Torque Specifications ............0A-6 Rocker Arm and Shaft Assembly ...............6A-47
Recommended Thread Locking Agents .......0A-8 Camshaft...................................................6A-52
Main Data and Specifications ......................0A-9 Timing Gears.............................................6A-57
Engine External View Drawing................... 0A-11 Flywheel Housing ......................................6A-65
Service Standard.......................................0A-12 Oil Pan ......................................................6A-68
Torque Specifications ................................0A-18 Piston ........................................................6A-71
Special Tools .............................................0A-25 Crankshaft.................................................6A-86
Troubleshooting.........................................0A-27 Crank Pulley..............................................6A-97
Lubricant Application .................................0A-37 Flywheel ..................................................6A-100
Sealant Application....................................0A-37 Cylinder Body ..........................................6A-102
Service Information Engine Cooling

Identification................................................0B-1 Service Precautions.....................................6B-1
Lubrication System ......................................0B-2 General Description.....................................6B-2
Fuel System ................................................0B-2 Water Pump ................................................6B-3
Cooling System ...........................................0B-6 Thermostat ..................................................6B-8
Valve Clearance Adjustment........................0B-6
Compression Pressure Measurement..........0B-8 Engine Fuel
Recommended Lubricants ...........................0B-9 Service Precautions.................................... 6C-1
Engine Oil Viscosity Chart ...........................0B-9 General Description.................................... 6C-2
Fuel Filter ................................................... 6C-5
Engine Mechanical Injection Nozzle Holder............................... 6C-7
Service Precautions ....................................6A-2 Injection Pump ......................................... 6C-13
General Description.....................................6A-2
Fan Center ..................................................6A-4 Starting and Charging
Turbocharger...............................................6A-8 Service Precautions.................................. 6D3-1
Exhaust Manifold.......................................6A-10 Alternator ................................................. 6D3-2
Inlet Manifold............................................. 6A-11 Starter Motor ...........................................6D3-11
Water Pump ..............................................6A-14
17VW-5-1
Engine Lubrication
Service Precaution ..................................... 6G-1
General Description.................................... 6G-2
Oil Pump .................................................... 6G-4
Oil Coolor ................................................. 6G-12
Main Oil Filter ........................................... 6G-16
Partial Oil Filter ........................................ 6G-19
Engine Induction
Service Precaution ...................................... 6J-1
Turbocharger............................................... 6J-2
17VW-5-2
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
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W17VE-00 (080616 - 7) Workshop Manual

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W17VE-00 (080616 - 7) Workshop Manual

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INTRODUCTION

• Each page has a number, located on the center

Consecutive Page Number for Each Group

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

• This is the SAFETY ALERT SYMBOL.

• When you see this symbol on your machine or in

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating

• DANGER indicates an imminently hazardous

• WARNING indicates a potentially hazardous

• CAUTION indicates a potentially hazardous

• DANGER or WARNING safety signs are located

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

• CAUTION also calls attention to safety messages in

• To avoid confusing machine protection with personal

• NOTE indicates an additional explanation for an

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

• Safety signs should be installed, maintained and re-

• If a safety sign or this manual is damaged or miss-

• Learn how to operate the machine and its controls

• Allow only trained, qualified, authorized personnel to

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may

• The safety messages in this SAFETY chapter are

PREPARE FOR EMERGENCIES

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

• Keep a first aid kit and fire extinguisher on hand.

lance service, hospital, and fire department

• Wear close fitting clothing and safety equipment

You may need:

• Avoid wearing loose clothing, jewelry, or other

• Operating equipment safely requires the full

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

• Wear a suitable hearing protective device such as

• Inspect your machine carefully each day or shift by

• In the walk-around inspection be sure to cover all

• Before entering the cab, thoroughly remove all dirt

• Don’t leave parts and/or tools lying around the op-

• Avoid storing transparent bottles in the cab. Don’t

• Refrain from listening to the radio, or using music

• Keep all flammable objects and/or explosives

• After using the ashtray, always cover it to extin-

• Don’t leave cigarette lighters in the cab. When the

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

• When you mounting and dismounting the ma-

• Do not use any controls as hand-holds.

• Never jump on or off the machine. Never mount or

ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for

• The seat should be adjusted whenever changing

• If the machine should overturn, the operator may

• Prior to operating the machine, thoroughly

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

• Take extra care not to run over bystanders.

• Inappropriate engine starting procedures may cause

• Start the engine only when seated in the

• Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to

• Riders on machine are subject to injury such as

• Only the operator should be on the machine.

PROVIDE SIGNALS FOR FOBS INVOLV-