W1cde 00

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

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

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

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

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

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

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

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

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

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

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

this manual.
• To avoid confusing machine protection with personal

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

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

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

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

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

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

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

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

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

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

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

appropriate to the job.
You may need:

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

flammable.
• Store flammable fluids well away from fire

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

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

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

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

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

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

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

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

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

injury.
• Before performing any work on the machine,

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

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

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

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

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

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

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

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

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

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

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

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

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

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

PERIODICALLY
• Rubber hoses that contain flammable fluids under

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

FLUID LINES
• Flammable spray can be generated by heating near

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

THE CUSTOMER
• After maintenance or repair work is complete,

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

SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 General
Group 1 Introduction Group 2 Component Layout
Group 2 Engine Test Group 3 Troubleshooting A
Group 3 Excavator Test Group 4 Troubleshooting B
Group 4 Component Test Group 5 Troubleshooting C
Group 5 Standard Group 6 Electrical System Inspection
Group 7 ICX
SECTION 1
GENERAL INFORMATION
— CONTENTS —
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling...................................... W1-1-1
Maintenance Standard Terminology... W1-1-7
Group 2 Tightening Torque

Tightening Torque Specification......... W1-2-1
Torque Chart ..................................... W1-2-2
Piping Joint ....................................... W1-2-5
Periodic Replacement of Parts .......... W1-2-9
Group 3 Painting
Painting ............................................. W1-3-1
1CDW-1-1
(Blank)
1CDW-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 M1CC-07-002
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
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-6
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies

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

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

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

No. Descriptions Q’ty
mm Size (mm) Nxm (kgfxm) (lbfxft)
1 Engine cushion rubber mounting bolt (Front, Rear) 16 4 24 270 (27.5) (200)
2 Engine bracket mounting bolt 14 8 22 140 (14) (103)
3 Hydraulic oil tank mounting bolt 16 4 24 210 (21.5) (155)
4 Fuel tank mounting bolt 16 4 24 210 (21.5) (155)
5 ORS fittings for hydraulic hoses and piping 17 24.5 (2.5) (18)
19 29.5 (3) (22)
22 39 (4) (29)
27 93 (9.5) (69)
32 137 (14) (101)
36 175 (18) (129)
41 205 (21) (151)
6 Pump mounting bolt 12 4 19 90 (9.2) (66)
7 Pump cover mounting bolt 10 7 17 50 (5.1) (37)
8 Control valve mounting bolt 14 3 22 180 (18.5) (133)
9 Control valve bracket mounting bolt 12 4 19 90 (9.2) (66)
10 Swing device mounting bolt 16 10 24 210 (21.5) (155)
11 Battery mounting nut 10 4 17 20 (2.0) (14.5)
12 Cab mounting nut 16 4 24 210 (21.5) (155)
Swing bearing mounting bolt to upperstructure 16 24 24 270 (27.5) (200)
13
Swing bearing mounting bolt to undercarriage 16 24 24 270 (27.5) (200)
Travel device mounting bolt 16 20 24 300 (30.5) (220)
14
Travel reduction device cover mounting bolt 14 8 22 140 (14) (103)
15 Sprocket mounting bolt 16 24 24 270 (27.5) (200)
16 Upper roller mounting bolt 14 2 22 140 (14) (103)
17 Lower roller mounting bolt 14 40 22 245 (25) (180)
18 Track shoe bolt 14 296 22 245 (25) (180)
6 10 10 (1) (7.4)
19 Cover mounting bolt 10 17 50 (5.1) (37)
12 19 90 (9.2) (66)
8 ҥ 13 10.3 to 12.4 (1.1 to 1.3) (7.6 to 9.2)
Coupling and T-bolt clamp (suction hose, return
20 ҥ 11 6.0 (0.6) (4.4)
pipe) of low pressure piping
ҥ 9.5 4.4 (0.4) (3.2)
21 Side-cutter mounting bolt 20 6 30 540 55 (400)
NOTE 1. Apply lubricant (e.g. white zinc B

dissolved into spindle oil) to bolts and
nuts to reduce friction coefficient of them.
2. Make sure bolt and nut threads are clean
before installing.
W1-2-1
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.
Equally tighten upper and lower Tighten from center and diagonally
alternately Tighten diagonally
1 12 9 4 1 6 7 14
6 3
1st to 4th
4 5
2 13 8 5 2 3 10 11
2nd to 3rd
W105-01-01-003
W1-2-3
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 Tightening Torque

Description mm mm
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
30ѯmale 17 17 24.5 (2.5,18)
19 19 29.5 (3.0,22)
22 22 39 (4.0,28.5)
27 27 93 (9.5,69)
32 32 137 (14,101)
36 36 175 (18,129)
41 41 205 (21,151)
37ѯfemale 17 14 24.5 (2.5,18)
19 17 29.5 (3.0,22)
22 19 39 (4.0,28.5)
27 22 93 (9.5,69)
32 27 137 (14,101)
36 32 175 (18,129)
41 36 205 (21,151)
NOTE: Tightening torque of 37ѯmale coupling without union is similar
to tightening torque of 37ѯfemale.
W1-2-5
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 Hose Fittings
8 10
in O-ring groove (e). Tightening M104-07-033
nut (9) with O-ring (6) displaced

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

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

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

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

pending on the type of clamp.
T-Bolt Type Band Clamp: M114-07-041
4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft )
Worm Gear Type Band Clamp:
T-Bolt Type Worm Gear Type
5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)
M114-07-043 M114-07-042
W1-2-7
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, possibly resulting in a fire on the ma-
chine.
Do not install hoses kinked. Application of W105-01-01-011

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

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other. W105-01-01-012
WRONG RIGHT
Take care that hoses do not come into con-
tact 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
inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deteriora-
tion, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regardless
of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace if
necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, if necessary.
Consult your authorized dealer for correct replace-
ment.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Engine Fuel hose (Fuel tank to injection pump) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years
Base Machine Pump delivery hose Every 2 years
Swing hose Every 2 years
Hydraulic
Travel hose Every 2 years
System
Boom cylinder line hose Every 2 years
Front Arm cylinder line hose Every 2 years
Attachment Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years
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 Appointment
Surfaces to Be Painted Painting Colour
• Main surface of upperstructure YR-01[TAXI yellow]and SC painting to outside surface of
upperstructure
Two-tone of YR-01[TAXI yellow]and N4.5[High-Grade Beige],and SC
Main frame
painting to outside surface of upperstructure
Fuel Tank Front N2.5[High-Grade Black]
Cover
Counter weight YR-01[TAXI yellow]and SC painting
• Track(undercarriage) PB5-01[SP-424 Dark Grey]
• Front Attachment YR-01[TAXI yellow]and SC painting(Except bucket and link)
• Ladder rail,mirror stay,clamp • N2.5[High-Grade Black]
Final painted colour

• Inside and outside surface of cab YR-01[TAXI yellow]and N4.5[High-Grade Beige]
• Seat stand TN-20[Black]
• Lever(Travel,lock,foot rest) H1-1035[Flat Black]
• Lever(Blade) TN-20[Black]
• Floor plate H4-224[Beige]
• Left mirror of cab Chromate plating Black
Except Upperstructure
Appointment Circumference
IMPORTANT: When cleaning arm, cylinder, etc. TAXI yellow Mirror Stay
fitted with HN bushing, take care not
to pour washing liquid directly on Fuel Tank
Front
them. The ambient temperature shall Cover
be controlled under 70°°C when
painting and drying. Main Frame
Hatched
Portion
High-Grade
NOTE: SC painting (self cleaning painting) Beige
Rain water will remove dust easily due to
self-purification of water based paint. Clamp
W1CD-01-03-001
Track
W1-3-1
GENERAL / Painting
Cab Inside and Outside
Front Attachment Right

Ladder
Rail
Mirror 600
Stay Main Surface of
Main Surface of
Upperstructure
Upperstructure
Left Mirror of 672
Fuel Tank Cab W1CD-01-03-002
ÙïіÌ Front Cover
(672) (672)
M1CD-01-010
(380) (380)
W1CD-01-03-003
Upper Surface of Frame Lower Surface of Frame
A Out Surface of Hinge

YR-01 Swing Portion YR-01
(TAXI Yellow) (TAXI Yellow)
190
5
Section A
Mask Garnished Portion
YR-01(TAXI Yellow)
W1CC-01-03-006
Section B
(Door)
Panel Behind the Door
W178-01-03-004
10
Painting Area of the W178-01-03-005
Door
YR-01(TAXI Yellow)
W1-3-2
MEMO
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SECTION 2
UPPERSTRUCTURE
— CONTENTS —
Group 1 Cab Group 6 Swing Device
Remove and Install Cab .................... W2-1-1 Remove and Install Swing Device...... W2-6-1
Dimensions of the Cab Glass ............ W2-1-9 Disassemble Swing Reduction Gear .. W2-6-4
Assemble Swing Reduction Gear .... W2-6-10
Group 2 Counterweight Disassemble Swing Motor .............. W2-6-18
Remove and Install Counterweight .....W2-2-1 Assemble Swing Motor .................... W2-6-22
Disassemble and Assemble
Group 3 Main Frame Valve Block .................................... W2-6-26
Remove and Install Main Frame ............ W2-3-1 Maintenance Standard..................... W2-6-28
Group 4 Pump Device Group 7 Pilot Valve

Remove and Install Pump Device .......... W2-4-1 Remove and Install Right Pilot Valve . W2-7-1
Disassemble Main Pumps 1 and 2......... W2-4-4 Remove and Install Left Pilot Valve.... W2-7-5
Assemble Main Pumps 1 and 2 ........... W2-4-10 Remove and Install Travel
Disassemble Main Pump 3 .................. W2-4-18 Pilot Valve........................................ W2-7-9
Assemble Main Pump 3 ....................... W2-4-22 Remove and Install
Maintenance Standards ....................... W2-4-28 Blade Pilot Valve............................ W2-7-13
Disassemble and Assemble Pilot Disassemble Right and Left
Pump .................................................. W2-4-30 Pilot Valves .................................... W2-7-16
Assemble Right and Left
Group 5 Control Valve Pilot Valves .................................... W2-7-20
Remove and Install Control Valve .......... W2-5-1
Disassemble Travel Pilot Valve........ W2-7-24
Disassemble Control Valve .................... W2-5-4
Assemble Travel Pilot Valve ............ W2-7-28
Assemble Control Valve ....................... W2-5-15
Disassemble Blade Pilot Valve ........ W2-7-34
Assemble Blade Pilot Valve ............. W2-7-36
Group 8 Pilot Shut-Off Valve

Remove and Install Pilot Shut-Off
Valve ............................................... W2-8-1
Disassemble Pilot Shut-Off Valve ...... W2-8-4
Assemble Pilot Shut-Off Valve ........... W2-8-6
1CDW-2-1
Group 9 Shockless Valve
Remove and Install Shockless
Valve ............................................... W2-9-1
Disassemble and Assemble
Shockless Valve .............................. W2-9-3
Group 10 Solenoid Valve

Remove and Install Solenoid
Valve Unit ...................................... W2-10-1
Disassemble Proportional
Solenoid Valve............................... W2-10-4
Assemble Proportional
Solenoid Valve............................... W2-10-6
1CDW-2-2
UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB
1
Removal
1. Remove seat mounting bolts (2) (04 used) to re-
move seat (1).
: 17 mm
2
2. Remove caps (5) (5 used) from duct cover (4) M1CC-01-012
with a screw driver. Remove screws (3) (5 used)

to remove the duct cover.
3
W1SE-02-01-003
3. Remove screws (8) (2 used).Push duct (7) into
the duct (6) side once, and remove the bottom of
duct (7) from the air conditioner unit. Remove duct
(7) from duct (6). 6
Air-
8 conditioner
Unit
4. Remove bolts (11)(4 used) from the rear side of W1SE-02-01-004
cab. Remove cover (10) from rear cover (9).
: 13 mm 9
11
10
W1SE-02-01-005
W2-1-1
5. Remove clamp (13) behind rear cover (9). Re-
move air hose (14) of the air conditioner from air
conditioner hose (12).
9
12
13
14
W1SE-02-01-006
15
6. Remove vinyl hose (17) and connector (15) from 17
washer tank (16). 16
M1CD-07-028
7. Remove screws (20)(2 used). Remove duct (21)

from duct (18) and duct (19). Remove screws (22) 18
(4 used). Remove duct (23) from duct (18). 19
20
21
22
23
W1CD-02-01-001
8. Disconnect and remove the connectors of radio 24

antenna feeder (24) from both right and left sides.
Remove screw (25) to remove earth wire (26). 25
Remove connectors (27) (6 used).
Push junction box (28) out and remove bolts (29) 26
(2 used) to remove earth wire (30).
: 13 mm 27
28
30
W1SE-02-01-009
29
W2-1-2
9. Disconnect connector (31) of work light harness Work 31
Light
(32) at upper side from the cab. Loosen all the 32
clips (33).
NOTE: No need to remove the work light on the
cab.
33
10. Remove bolts (34) (4 used). Then remove under

cover (35).
W1CC-02-01-002
: 17 mm
34
35
W1CD-02-01-002
11. Draw out work light harness (32) from the hole
where under cover (35) has been removed.
NOTE: Wind the work light harness passing
through the cab and secure it near the floor
plate hole.
32
Floor Plate Hole
W1CC-02-01-001
W2-1-3
CAUTION: Cab weight: 270 kg (600 Ib)

12. Attach sling belts to brackets on top of the cab (at
4 places).
W1SE-02-01-011
13. Remove socket bolts (36) (4 used), bolts (38) (5

used) and nuts (37) (4 used) from the frame.
: 8 mm
: 17 mm
: 24 mm
36
38
14. Hoist the cab carefully and remove from the 37

frame.
W1SE-02-01-010
W102-02-01-001
W2-1-4
Installation

1. Attach sling belts to brackets on top of the cab (at
4 places). Hoist the cab by crane and put it on the
frame carefully.
2. Install nuts (37) (4 used), bolts (38) (5 used) and

socket bolts (36) (4 used). W102-02-01-001
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
36
38
37
3. Put harness (32) on top of the cab. Connect con-
W1SE-02-01-010
nector (31) of the work light. Tighten all the clips
(33) to secure the harness.
31
NOTE: The work light on top of the cab is optional 32
parts.
33
W1CC-02-01-002
W2-1-5
4. Install under cover (35) by bolts (34) (4 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 34
35
W1CD-02-01-002
24
25
5. Connect earth wire (30) with bolts (29) (2 used).
Insert junction box (harness side) (28) to its posi-
tion and connect connectors (27) (6 used). 26
Connect earth wire (26) with screw (25) and insert
27
radio antenna feeder (24) to both right and left
side.
: 13 mm 28
: 10 N⋅m (1.0 kgf⋅m, 7.4 Ibf⋅ft)
30 29 W1SE-02-01-009
6. Insert duct (21) into ducts (18) and (19). Then se- 19
cure it with screws (20) (2 used). 18
Install duct (23) onto duct (18) with screws (22) (4
used).
20
: 3 N·m (0.3 kgf⋅m, 2.2 Ibf⋅ft)
21
22
7. Install vinyl hose (17) and connector (15) to the
23
bottom of washer tank (16).
W1CD-02-01-001
15
16
17
M1CD-07-028
W2-1-6
8. Pull air conditioner hose (14) upward to install air
conditioner hose (12).
Secure the hose at its connecting position with
clamp (13). 9
12
13
14
W1SE-02-01-006
9. Install cover (10) onto rear cover (9) with bolts (11)
(4 used).
: 13 mm 9
: 10 N⋅m (1.0 kgf⋅m, 7.4 Ibf⋅ft)
11
10
W1SE-02-01-005
10. Insert duct (7) to the end of duct (6). After duct (7) 6
comes back downward a little, and insert it into
the air conditioner unit. Install duct (7) with screws
(8) (2 used).
: 3 N⋅m (0.3 kgf⋅m)
Air-
8 conditioner
Unit
W1SE-02-01-004
W2-1-7
11. Install duct cover (4) to the cab with screws (3) (5
used). Install caps (5) (5 used)
: 3 N⋅m (0.3 kgf⋅m, 2.2 Ibf⋅ft)
3
W1SE-02-01-003
12. Install seat (1) with bolts (2) (4 used).

: 17 mm 1
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
2 M1CC-01-012
W2-1-8
DIMENSIONS OF THE CAB GLASS
Unit: mm
Along the Along the A

Periphery Periphery
75.6
C1 C1 1110.5
R5
27.3
110 36(Specified) R2929 R30

R293.5
R129
36
532.5
(5 mm) R75
770.5
36
1081.1
R2929 193.6 R5
189 39 58±5
Section A W178-02-01-019 R30 (Specified)
R20 R542
(Fillet) 52.8
1044.4
R1910
R5
39 415.1
322.1 1164.4
W1SE-02-01-013
Chamfer
Here
Chamfer along the Periphery
2-R5 unless Otherwise Specified.
2-R20
2-R15 34 2-R105 32.5
4-R73
40
42.3 39.5
W1SE-02-01-012 ̨ 13.5±0.2 557
(4 mm) 40
320±0.5
2-R15
R2 2-R20
B
2-̨ 13.5±0.2
48±5
112±0.2 23.5
54.8±0.2
697.5±0.5 291±0.2
Stop R Here
803
W1SE-02-01-014
Section B W178-02-01-019
W2-1-9
Unit: mm
R2852.4 R55.8
FREE R 9±5
32±5
(5 mm) 92.8
27.4
342.7
55.1
W1SE-02-01-018
W1SE-02-01-012
444.2±1
200 152.9±1
194.6
Chamfer along the

Periphery unless
Chamfer along
Otherwise Speci-
the Periphery
fied
unless Other-
wise Specified
597±1
(5 mm)
C
(5 mm)
D
597±1
R2916.2
41.5
Chamfer
Here
40
Chamfer
Here
101±5 2-̨ 13 +1 0
10±5 167
50.2
4-R5 4-R5
109.6
249.7±1 347.4±1 50.2

W1SE-02-01-017 69.7
W1SE-02-01-016

596.5
537±0.5 2-R5
371
R2937 2-̨ 18±0.5
(4 mm)
412
50±0.5
63.5±0.5
244±0.5
R114 Section C and D W178-02-01-019
67.5±0.5
372.5
R551.5
96 40
490.5 40 R9
637
652
W1SE-02-01-015
W2-1-10
Method for Removing Cab Glass
Procedures for removing right-hand cab glass, rear

left-hand glass and lower glass of the door are as fol-
lows:
Right-Hand Glass
CAUTION: When removing broken or
cracked glass, there is a danger of severe in-
jury from glass shards.
Before removing, bind the broken area and
crack positions with gum tape to prevent the
danger from occurring. Fallen glass shards
must be removed.
Garnish
Garnish
1. Remove resin panel, garnish, spacer, and etc.

around the glass. Resin Panel
Rear Left-Hand
Lower Glass Glass
of the Door W1SE-02-01-042
2. Pierce a hole in adhesive with awl (or cutter, etc).

Cab
Glass
Awl
Adhesive W1SE-02-01-033
3. Pass a piano wire or iron wire through the through

hole.
Piano Wire
(Iron Wire)
W1SE-02-01-034
W2-1-11
4. Wind both ends of the piano wire to drivers. Saw
down the adhesive by sawing back and forth.
Remove the glass from the cab. (Outside of
Cab the Cab)
NOTE: Saw down from the middle of adhesive
between glass and cab. Glass
There is a danger that piano wire may break
as it is heating in local part. Always change
the part used in sawing for cooling.
Adhesive
(Inside of the Cab)
W1SE-02-01-035
W2-1-12
Method for Installing Cab Glass
Procedures for installing right-hand cab glass, rear Right-Hand Glass

left-hand glass and lower glass of the door are as
follows:
1. Remove the adhesive left at the cab side all

around by about 1 to 2 mm (0.04 to 0.08 in) with
cutter.
NOTE: Take care not to scratch the cab paint.
Lower Glass Rear Left-Hand

of the Door Glass
W1SE-02-01-042
Cab
2. Clean the adhesive surface at cab side with the

white gasoline. Cutter
Cut the Adhesive Down

by 1 to 2 mm Deep
W1SE-02-01-036
IMPORTANT: Shake primer 24 vigorously for

about 1 minute to mix thoroughly be-
fore loosening its cap.
It should be used quickly when
opened and sealed immediately Cab
Apply Primer 24
when applying is finished. Evenly
It should be used within 3 days after
Adhesive Cut Face
being opened. (It can be wasted in 2 at Cab Side
hours if left it opened.)
3. Apply coating primer (SUNRISE MSI Primer 24)
onto the adhesive cut face at cab side evenly. W1SE-02-01-038
Wait for 15 munutes or so to let the coating dry by
itself.
NOTE: Apply the coating evenly, neither too much,
nor too little.
W2-1-13
4. Clean the surface for installing new glass with 11. Lift the glass by a suction lifter (rubber suction
clean waste cloth after fully soaking it in alcohol. plate 4355282, refer to W2-1-15) within 5 minutes
to adhere onto the cab.
IMPORTANT: Shake primer 35 vigorously for
about 1 minute to mix thoroughly be- NOTE: Press fit the glass onto the cab when locat-
fore loosening its cap. ing it by the spacer adhered on the glass.
It should be used quickly when The other surface where applied with ad-
opened and sealed immediately hesive, except the mating surface, should
when applying is finished. be cleaned with white gasoline before the
It should be used within 3 days after adhesive takes.
being opened. (It can be wasted in 2
hours if left it opened.) 12. The glass should be secured with gum tape to
5. Apply glass primer (SUNRISE MSI Primer 35) prevent it from moving until the adhesive
onto the glass where it needs to be coated with becomes solid.
the adhesive. Wait for 15 minutes or so to let the
coating dry itself.
NOTE: Time required for adhesive (SUNRISE MSI
(As for the position where glass primer 35 should
SR Seal U90 4463876) becoming solid: 8
be applied, refer to W2-1-15)
hours (Just for reference).
6. Peel the paper from the spacer and put on glue at
the place where the paper was instead. Then put
the adhesive tape on the glass.
Right-Hand Glass
(As for the position to install spacers a , b and c, 500
Gum Tape
refer to W2-1-15) 350
7. Cut the nozzle of adhesive cut ridge (SUNRISE 500

MSI SR Seal U90 4463876) in V-shape. (Refer to
450
W2-1-15)
200
8. Remove the seal from the cut ridge end to install 200
V cut nozzle on it.
100
500
9. Caulk the cut ridge onto hand cauking gun. W1SE-02-01-039
200
Rear Left-Hand Glass 150
10. When applying primer, it should be applied onto
the glass evenly in V-bead-shape at the position
where adhesive should be coated.
(As for the position to apply adhesive, refer to
200
W2-1-15)
500
200
W1SE-02-01-040
150
Lower Glass of the Door
150
50
150
200
150
W1SE-02-01-041
W2-1-14
Spacer a (4458466) Spacer b (4458469) Spacer c (4458470)

20 20
20 5
R7
10.9 R6
8.7 0.5 10.5 Flat 7
5 9.3
5
0.5
1 3.6 Adhesive Tape
3.6 Adhesive Tape Adhesive Tape W1SE-02-01-032
Concave 6 on Both Side 1 on Both Side on Both Side
Convex 6
8.5
8.5 W1SE-02-01-031
W1SE-02-01-030
Lower Glass of
Right-Hand Glass Rear Left-Hand Glass D
the Door
B D
286
B
400 Spacer c
Spacer c 225
700
Spacer b
Spacer c
30
650
Lift Par- 160 62
305 c Spacer a tially
Spacer a
c
Spacer b
A 445
110 85 290
52 450
60
A 123 W1SE-02-01-020
W1SE-02-01-019
W1SE-02-01-021
Section A-A Section B-B Section C-C Section D-D

Glass
Adhesive
Install Spacer with

Spacer b
Its Concave Face
Facing Adhesive Adhesive
Spacer c
Spacer a Spacer c
Glass Adhesive Install Spacer with Adhesive

Its Convex Face
Facing Adhesive
W1SE-02-01-023 18
W1SE-02-01-024
W1SE-02-01-025 18
W1SE-02-01-026
8 to 9 mm
Coat Adhesive Glass

4 to 5 mm
Bead Here It Should be Applied in
13 to 15 mm Even V-Bead-Shape
Cut Nozzle End
into V-Shape
Spacer a or
Spacer b
9.0
Adhesive Tape
on Both Side
5.5 5.0 W1SE-02-01-027
Glass
5.5 to 5.9
Remove W1SE-02-01-043
Seal
4.9 3.6
Cab
12.0
Adhesive
Cartridge
W1SE-02-01-022
W1SE-02-01-028
W2-1-15
13. The quantity of adhesive and primer should be used (Just for reference)
Adhesive: SUNRISE MSI SR Seal U90 Primer: SUNRISE MSI

(4463876) Primer 24 (for coating)
Glass 3
320 cm Cutridge Primer 35 (for glass)
3
150 cm in Each Bottle
Right-Hand Glass (1 Piece) 1 used 1/10 used for each one
Rear Left-Hand Glass (1 Piece) 1/2 used 1/20 used for each one
Lower Glass for the Door (1 Piece) 1/3 used 1/50 used for each one
IMPORTANT: Rear left-hand glass is arched-

fringed type. If this glass needs to be
replaced, contact with the nearest
HITACHI Office to preplace it as a
unit.
W2-1-16
Install upper door glass as follows
1. Before installing the glass, remove the garnish

from the outside of the sash assembly in the cab
for easier installing. Push the sash assembly out
of the cab and remove it by hand.
Sash Assembly Glass C
Garnish
2. Insert glass A and glass B into the sash slot. In-
sert glass C into the mounting rubber.
Glass A Glass B
W1SE-02-01-044
Glass C
3. Install the sash assembly with glass onto the door
from outside of the cab. Secure the sash assem- Mounting Rubber
bly inside of the cab with the garnish. Mounting Rubber
Sash Slot
Glass A and
Glass B
W1SE-02-01-045
W2-1-17
Install rear glass as follows
1. Align rear glass (1) with the mounting position at

the rear of cab.
2. Secure the glass with screws (3) (2 used), wash-

ers (4) (4 used) and nuts (5) (2 used) for hinges
3 7
(2) (2 used) temporarily.
3. Secure the glass with screws (7), washers (8) and 2

nuts (9) for catch handle (6) temporarily.
1
4. Tighten screws (3) (2 used) and screw (7) after 6
leveling.
5. Adjust glass positions on the cab at both right and

left with screw (10) of hinge (2).
5
IMPORTANT: Rear glass is arched-fringed type. If 8
this glass needs to be replaced, con- 4
9
tact with the nearest HITACHI Office 10 2 3 6 7
to replace it as a unit.
4 8
1 5 9 W1SE-02-01-046
W2-1-18
Install upper front glass as follows
1. The glass is adhered with mounting rubber. Draw Adhered with

the mounting rubber and secure to the cab mount- Mounting Rubber
(All Around the
ing surface. (All around the glass) Glass) Frame
2. Adhere seal (1) to the lower side the upper front

glass with POS seal.
Adhere both right and left ends (the part turning
thicker after bringing together) of seal (1) with ad-
hesive POS seal to secure them together.
Adhere the lip in the center of seal (1) with POS
Upper Glass
seal. No visible bending or folds can be found.
NOTE: POS seal:

TOSHIBA SILONCON POS Seal (black)
Tube adhesive in glue form
IMPORTANT: The glass and mounting rubber

should be adhered with special ad- 1
hesive. Failure to do so, may result
in the glass dropping out. Therefore, Lower Glass
if the glass needs to be replaced, re-
place the glass and mounting rubber
as a unit.
Upper front glass is arched-fringed
type. If this glass needs to be re- Upper Glass
placed, contact with the nearest HI-
TACHI Office to replace it as a unit.
Adhere POS
POS Seal
Seal
1 1
Lower Glass
Lower Glass
W1SE-02-01-047
W2-1-19
(Blank)
W2-1-20
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTER-
WEIGHT 1 2
Removal
1. Loosen and remove mounting bolts (1) (4 used)

of engine cover (2) to remove engine cover (2).
: 17 mm
M1CD-01-008
3 4 5 6
2. Push reserve tank (6) upward to remove it from

the bracket (A) on bracket (4).
Remove bolts (5) (2 used) . Remove bracket (4)
from radiator (3).
: 17 mm
Bracket (A)
W1CD-02-02-002
3. Install eye bolts (B-27, M27, Pitch 3.0) onto coun-

terweight (7). Attach the wire ropes to the eye
bolts. Hold the counterweight by crane.
CAUTION: Counterweight (7) weight:
700 kg (1540 lb)
4. Loosen and remove mounting bolts (9) (4 used)
and washers (8) (4 used) for counterweight (7). By
crane, lift the counterweight slightly, then slide it
backwards to remove it.
: 30 mm
7
8
W1CD-02-02-003
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation
CAUTION: Counterweight(7) weight:

700 kg (1540 lb)
1. Install eye bolts (B-27, M27, Pitch 3.0) onto
counterweight (7). Attach the wire ropes to the
eye bolts. By crane, lift and slide counterweight
(7) slightly forwards to align the mounting holes.
Ȁ
Ȁ
Ȁ
Ȁ
Ȁ 7
Ȁ
8
2. Put washers (8) (4 used) to bolts (9) (4 used) .
Tighten bolts (9).
: 30 mm 9
: 550 N⋅m (56 kgf⋅m, 410 lbf⋅ft)
W1CD-02-02-003
3 4 5 6
3. Install bracket (4) to radiator (3) with bolts (5) (2

used).
: 17mm
: 50 N·m(5.1kgf·m, 37 lbf·ft)
4. Insert to install reserve tank (6) to the bracket (A)

on bracket (4).
5. Install engine cover (2) onto the main frame.

Use bolts (1) (4 used) to secure the cover.
: 17 mm
Bracket (A)
: 50 N·m(5.1kgf·m, 37 lbf·ft)
W1CD-02-02-002
1 2
M1CD-01-008
W2-2-2
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME
CAUTION: Escaping fluid under pressure

can penetrate the skin, causing serious injury.
Avoid this hazard by relieving pressure be-
fore disconnecting hydraulic or other 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 solid, level surface. Lower
the bucket onto the ground.
2. Stop the engine. Push the air release valve on the

top of hydraulic oil tank to release any remaining
pressure.
Ȁ
3. Remove the hydraulic oil tank cap. Connect a
vacuum pump and operate it continuously to M1CC-07-002
maintain negative pressure in the hydraulic oil
tank. Run the vacuum pump continuously, while
working on the hydraulic system.
W2-3-1
Removal
1. Remove the cab.
(Refer to Remove and Install Cab section)
: 13 mm, 17 mm, 24 mm
: 8 mm
W102-02-01-001
CAUTION: Counterweight weight: 700 kg

(1540 Ib)
2. Remove the counterweight.
(Refer to Remove and Install Counterweight sec-
tion)
: 17 mm, 30 mm
W1CD-02-02-003
CAUTION: Front attachment assembly
weight: 1000 kg (2200 Ib)
3. Remove the front attachment assembly.
(Refer to Remove and Install Front Attachment
section)
: 24 mm, 27 mm
4. Attach the identification tags to the hydraulic W105-02-03-002

hoses at the top of center joint in aid of reassem-
bling. Disconnect all hydraulic hoses at the top of
the center joint. Cap all disconnected hoses.
: 17 mm, 19 mm, 27 mm
CenterJoint
5. Loosen and remove the mounting bolts (2) (2
used) of the stopper (1). Remove the stopper
from the center joint.
: 19 mm
2 Front ㈨㈸㈳㈴
1
W102-03-03-001
W2-3-2
CAUTION: Upperstructure weight: 2100 kg

(4630 Ib)
6. Attach wire ropes to the rear (counterweight
bracket) of frame and boom bracket. Pull wire
ropes taut then.
If chain block (3) is used, it is not only easy to ad-
just the length of wire rope, but also easy to level
the frame.
Rear Side
IMPORTANT: Make sure rear wire ropes do not
touch engine.
W105-02-03-004
Front Side
W105-02-03-005
7. Put matching marks on the upperstructure and
3
outer race of the swing bearing. Loosen and
remove mounting bolts (4) (24 used) of the swing
bearing.
: 24 mm
NOTE: The mounting angle of swing bearing is

specified. (Refer to W3-1)
W157-02-03-001
8. Chain block (3) shall be used to adjust and level

the frame, then lift it slightly to remove it from the
undercarriage.
4
W102-02-03-004
W157-02-03-002
W2-3-3
Installation
CAUTION: Upperstructure weight: 2100 kg 3
(4630 Ib)
1. Attach wire ropes to the frame and level the frame
by chain block (3). Install it to the undercarriage by
crane.
NOTE: As for hoisting method, refer to Removal
section.
W157-02-03-002
2. Align the matching mark on the swing bearing with

that on the upperstructure.
Install the mounting bolts (4) (24 used) on the
swing bearing and tighten them temporarily. After
removing the wire ropes from the main frame,
tighten the bolts.
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft)
4
3. Reconnect all hoses to the center joint. W102-02-03-004
: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 Ibf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft) Center Joint
4. Install stopper (1) to the center joint with bolt (2)(2

used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft) 2 Front Side
1
W102-03-03-001
W2-3-4

5. Install the cab.
(Refer to Remove and Install Cab section)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 13 mm
: 10 N⋅m (1 kgf⋅m, 7.4 Ibf⋅ft)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
W102-02-01-001
CAUTION: Counterweight weight: 700 kg

(1540 Ib)
6. Install the counterweight.
(Refer to Remove and Install Counterweight
section)
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 Ibf⋅ft)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
CAUTION: Front attachment weight: 1000 kg

(2200 Ib)
7. Install the front attachment.
(Refer to Remove and Install Front Attachment
section)
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
[Piping] W1CD-02-02-003
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)
IMPORTANT: After completing work, check for hy-

draulic oil level. Start engine to
check for any oil leakage.
W105-02-03-002
W2-3-5
(Blank)
W2-3-6
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
CAUTION: Escaping fluid under pressure can

penetrate the skin, causing serious
injury.
Avoid this hazard by relieving
pressure before disconnecting hy-
draulic 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
out by remaining pressure if
removed quickly. Slowly loosen the
cap to completely release any
remaining pressure.
Preparation
1. Park the machine on a solid level surface. Lower
the bucket to the ground.
M1CC-07-002
2. Stop the engine. Push the air release valve on

top of the hydraulic oil tank to release any
remaining pressure.

vacuum pump and operate it continuously to
tank. Run the vacuum pump continuously while
W2-4-1
Removal
CAUTION: Counterweight weight:

700 kg (1540 Ib)
1. Remove the counterweight:

(Refer to the section on “Remove and Install
Counterweight”)
W1CD-02-02-003
1 5
4
2. Remove bolts (1) (4 used) to remove top cover (2) 2 3
of air cleaner. Remove nuts (5) (4 used), spring 6
washers (4) (4 used) and washers (3) (4 used) to
8
remove right door (6) at rear. Remove bolts (8)
(7 used) to remove top cover (7) of the pump
device.
ϖ 17 mm
7
3. Disconnect all hoses and pipes from the pump
device, then cap the removed hoses. Attach W1CD-02-04-015
identification tags to the hoses to aid in

reassembly.
ϖ 27 mm
ϖ 10 mm, 8 mm
CAUTION: Pump device weight:

75 kg (165 Ib) T1CD-01-02-004
9
4. Attach s sling belt onto pump device and hoist it
by crane.
Remove bolts (9) (7 used) to lift and remove the
pump device by crane.
ϖ 17 mm
W190-02-04-003
W2-4-2
Installation
9
CAUTION: Pump device weight:
75 kg (165 Ib)
1. Lift the pump device by crane. Insert the drive

shaft of the pump device into the coupling at the
engine side, then install them onto the engine
flywheel housing with bolts (9) (7 used).
ϖ 17 mm
ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) W190-02-04-003
2. Connect all hoses and pipes onto the pump

device.
ϖ 27 mm
ϖ 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)
ϖ 8 mm
ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
ϖ 10 mm
ϖ 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)
IMPORTANT: Bleed air from the pump. (Refer to

W1-1-2)
When the installation is completed, 1 5
T1CD-01-02-004
check the oil level. Start the engine 4

and check for any oil leakage. 2 3
6
3. Install top cover (7) of the pump device with bolts 8
(8) (7 used). Install right door (6) at rear side with
washers (3) (4 used), spring washers (4) (4 used)
and nuts (5) (4 used). Install top cover (2) of the
air cleaner with bolts (1) (4 used).
ϖ 17 mm
ϖ 50 N⋅m(5.1 kgf⋅m, 37 Ibf⋅ft)
7
CAUTION: Counterweight weight: W1CD-02-04-015
700 kg (1540 Ib)
4. Install the counterweight.

(Refer to the section on “Remove and Install
Counterweight”)
ϖ 30 mm
ϖ 550 N⋅m(56 kgf⋅m, 410 Ibf⋅ft)
W1CD-02-02-003
W2-4-3
DISASSEMBLE MAIN PUMPS 1 AND 2
1
Main Pumps 1 and 2
4 W1CD-02-04-006
5
Rear Pump
(Main Pump 3 and Pilot Pump)
1- Cover 18 - Socket Bolt 35 - Knock Pin (2 Used) 52 - Pin

2- Rear Pump 19 - Cover 36 - Square Ring (2 Used) 53 - Guide
3- Socket Bolt (2 Used) 20 - O-Ring 37 - Packing 54 - Guide
4- O-Ring 21 - Retainer 38 - Needle Bearing 55 - Backup Ring
5- Coupling 22 - O-Ring 39 - Valve Plate 56 - O-Ring
6- Nut 23 - Sleeve 40 - Retaining Ring 57 - Orifice
7- Socket Bolt (2 Used) 24 - Piston 41 - Spring Seat 58 - Square Ring
8- Adjusting Screw 25 - Disc Spring (4 Used) 42 - Spring 59 - Air Bleeding Valve
9- Cover 26 - Shim 43 - Spring Seat 60 - Housing
10 - O-Ring 27 - Piston 44 - Cylinder Block 61 - Shaft
11 - Spring Seat 28 - Backup Ring 45 - Pin (3 Used) 62 - Retaining Ring
12 - Shim 29 - O-Ring 46 - Spherical Bushing 63 - Bearing
13 - Spring 30 - Cylinder 47 - Retainer 64 - Retaining Ring
14 - Spring 31 - Piston 48 - Plunger (10 Used) 65 - Oil Seal
15 - Guide 32 - Socket Bolt 49 - Bushing 66 - O-Ring
16 - Spring Seat 33 - Socket Bolt (4 Used) 50 - Hanger 67 - Cover
17 - Socket Bolt (2 Used) 34 - O-Ring 51 - Plug (2 Used) 68 - Retaining Ring
W2-4-4
6
8
9
10 7
11
12
13
14
15
16 19 17
20
21
22 18
23
24
25
26
27
28
29
30 1
31 34
33
32
35
36
37
38
39
36 41 40
35 42
43
44
45 51 50 49
46
47
48 52
53
51
54
61 55
58
57 56
62
63
64 60 59
65
66
67
68
W1CD-02-04-007
W2-4-5
Main Pumps 1 and 2

2
5 4
W1CD-02-04-006
8 6
9
10 7
12 11
13
15 14 20 19
16 17
21
22
23 18
24
25
26
27
30 28 1 34
29 33
31 32
35
36
37
38
39 41 40
36 42
35 43 50 49
45
46 52
47
48 44
61
62 58
63
64
66 65
60
67
68
W1CD-02-04-007
W2-4-6
Disassemble Main Pumps 1 and 2
• Be sure to thoroughly read “Precautions for 5. Remove cover (1) assembly, square rings (58) (2
Disassembly and Assembly Work” on page used) and packing (37) from housing (60). At this
W1-1-1 before starting the disassembly work. time some parts (6 to 12) of control spring and
control piston assembly (parts 17 to 31) are also
1. Remove socket bolts (3) (2 used) to remove rear removed with the cover. Remove square rings
pump assembly (2) from cover (1). (36) (2 used) and valve plate (39) from the cover.
ϖ 10 mm
IMPORTANT: If lock nut (6) is turned, the setting
delivery rate of pump may change.
2. Remove coupling (5) and O-ring (4) from cover
Don’t disassemble the lock nut,
(1).
adjusting screw (8) and cover (9).
IMPORTANT: To remove cover (1), 2 guide studs
(M14, length 100 mm (3.9 in), Pitch 2 6. Remove control springs (13 and 14), guide (15)
mm (0.08 in)) can be used. By failing and spring seat (16) from housing (60).
to use the guide studs, cover (1) can
tilt and be pushed out by the force IMPORTANT: Don’t disassemble cylinder block (44)
from spring (13) and cylinder (30) assembly (parts 40 to 48). If any part
can be damaged. needs to be replaced, it should be
replaced as assembly.
3. Remove socket bolts (33) (4 used) and install 2
guide studs (M14, length 100 mm (3.9 in), Pitch 2 IMPORTANT: When removing the cylinder block
mm (0.08 in)) in the holes diagonally instead. (44) assembly, make sure that pins
(45) (3 used) are left in housing (60).
ϖ 12 mm
Tilt retainer (47) and pull it out to
prevent plunger (48) from coming
4. Remove socket bolt (32) (1 used). Then, loosen
out.
and remove the guide studs (2 used) alternately.
ϖ 12 mm
7. Place housing (60) horizontally while picking
retainer (47) by two fingers to prevent plungers
NOTE: If cover (1) can’t be pressed out, a plastic (48) (10 used) being inserted into the retainer
hammer can be used to tap spring (13) of from being removed. Remove the cylinder block
cover (1) from opposite side. (44) assembly from shaft (61).
IMPORTANT: When removing cover (1) assembly IMPORTANT: Don’t remove oil seal (65) from cover
from housing (60), take care not to (67). The cover assembly parts shall
drop control piston (31). Pay be replaced as assembly.
attention to valve plate (39) when
removing the cover (1) as it tends to 8. Remove retaining ring (68) from housing (60) to
fall down. remove the cover (67) assembly and O-ring (66).
Do not remove knock pins (35) (2
used) and needle bearing (38) unless
necessary.
W2-4-7
W1CD-02-04-006
20 19
17
21
22
23 18
24
25
26
27
30 28 1
29
31
50
53 52
61
63 62 54
64
60
67
W1CD-02-04-007
W2-4-8
9. Remove the shaft (61) assembly from housing 17. Since shim (26) and disc spring (25) are installed
(60) and drive it out to cover (67) side with plastic onto piston (27), shim (26) and the piston can be
hammer. removed from cover (1) as long as disc spring
(25) is removed by fingers.
10. Remove retaining rings (62 and 64) from shaft
(61) and press bearing (63) to housing (60) side 18. Hold control piston (31) at the opposite side of
with press to remove it from the shaft. cover (19) by hand to remove it from cylinder (30).
IMPORTANT: Pin (52) is pressed into hanger (50). 19. Remove control cylinder (30) from cover (1).
Don’t remove the pin from the hanger ϖ 24 mm
unless abnormity (wear and
deformation) is found. 20. Remove O-ring (29) and backup ring (28) from
control cylinder (30).
11. Remove hanger (50) from housing (60) by hand.
12. Remove guide (53) at suction side and guide (54)

at delivery side from housing (60).
IMPORTANT: Do not remove socket bolt (18) from

cover (19).
13. Remove socket bolts (17) (2 used) to remove

cover (19) from cover (1).
ϖ 6 mm
14. Push the tip of control piston (31) out from the
opposite side of cover (19) by finger and remove
the cover assembly (parts 18 to 21) from cover
(1).
15. Remove O-ring (20) from retainer (21).
IMPORTANT: Sleeve (23) is pressed to fit together

with O-ring (22) and cover (1). Don’t
disassemble the cover (1) assembly.
When replacement is necessary, do it
as assembly.
16. Pick piston (24) from cover (1) with fingers.
W2-4-9
ASSEMBLE MAIN PUMPS 1 AND 2
11
60 9
37 1 10
58 12 3
16 13 4 6 7
5 8
3
44 15 14
47 49
50
46
48 2
45 68
61 39
64 38
Section A
36 29
62
65 28
67
63
66
43 52 31 42 40 27
30 17
25,26 18 34
W1CD-02-04-008
41 23 19 17
35
24
22
20 21
59
54 51 50
Section A 55
32
56
33
57
53
51 W1CD-02-04-009
W2-4-10
1- Cover 18 - Socket Bolt 35 - Knock Pin (2 Used) 52 - Pin

2- Rear Pump 19 - Cover 36 - Square Ring (2 Used) 53 - Guide
3- Socket Bolt (2 Used) 20 - O-Ring 37 - Packing 54 - Guide
4- O-Ring 21 - Retainer 38 - Needle Bearing 55 - Backup Ring
5- Coupling 22 - O-Ring 39 - Valve Plate 56 - O-Ring
6- Nut 23 - Sleeve 40 - Retaining Ring 57 - Orifice
7- Socket Bolt (2 Used) 24 - Piston 41 - Spring Seat 58 - Square Ring
8- Adjusting Screw 25 - Disc Spring (4 Used) 42 - Spring 59 - Air Bleeding Valve
9- Cover 26 - Shim 43 - Spring Seat 60 - Housing
10 - O-Ring 27 - Piston 44 - Cylinder Block 61 - Shaft
11 - Spring Seat 28 - Backup Ring 45 - Pin (3 Used) 62 - Retaining Ring
12 - Shim 29 - O-Ring 46 - Spherical Bushing 63 - Bearing
13 - Spring 30 - Cylinder 47 - Retainer 64 - Retaining Ring
14 - Spring 31 - Piston 48 - Plunger (10 Used) 65 - Oil Seal
15 - Guide 32 - Socket Bolt 49 - Bushing 66 - O-Ring
16 - Spring Seat 33 - Socket Bolt (4 Used) 50 - Hanger 67 - Cover
17 - Socket Bolt (2 Used) 34 - O-Ring 51 - Plug (2 Used) 68 - Retaining Ring
W2-4-11
11
60 9
1 10
12
16 13 6 7
8
44 15 14
49
50
45 68
61
64
Section A
62
65
67
63
66
W1CD-02-04-008
60
54 50
Section A 55
56
57
53
W1CD-02-04-009
W2-4-12
Assemble Main Pumps 1 and 2
• Be sure to thoroughly read “Precautions for 6. Install cylinder block (44) assembly (parts 40 to
Disassembly and Assembly Work” on page 48) onto shaft (61) in housing (60) to prevent pin
W1-1-1 before starting the assembly work. (45) from dropping off.
IMPORTANT: Install guides (53) and (54) into IMPORTANT: Apply grease on the spherical tip
housing (60) and apply grease to the surface of spring seat (16).
guide axle part to prevent it from
coming off. 7. Install spring seat (16), guide (15), spring (14) and
Be sure that the O-ring (56) and spring (13) onto hanger (50) from bushing (49)
backup ring (55) of guide (54) at side.
delivery side are set in correct
positions as shown below. IMPORTANT: Apply grease on shim (12) to prevent
When installing guide (53) and (54) it from dropping.
into housing (60), be sure that those
are set in correct positions as
8. Install O-ring (10) and shim (12) onto spring seat
shown below.
(11) and install the spring seat into cover (1).
Pay attention the slot directions for
guide (53) and (54).
9. Install cover (9) assembly (parts 6, 8, 9) into cover
Apply grease around all spherical
(1) with socket bolts (7) (2 used).
surfase.
ϖ 8 mm
Apply Grease to Spherical Surface
ϖ 55 to 69 N⋅m
(5.6 to 7.0 kgf⋅m, 41 to 51Ibf⋅ft)
Slot
Hanger
Backup Ring (55) Guide (53) at Suction Side

O-Ring (56)
W1CD-02-04-001
Guide (54) Apply Grease to Axle Part

at Delivery Side
1. Install guides (53 and 54) into housing (60).

Ȁ
2. Install hanger (50) onto guides (53 and 54).
3. Install retaining ring (64) onto shaft (61) to press

bearing (63) down. Install retaining ring (62) onto
shaft.
4. Support the hanger (50) with hands and press

shaft (61) assembly into housing (60). Install O-
ring (66), cover (67) assembly and retaining ring
(68) into the housing.
5. Apply enough grease on pins (45) (3 used) and

install the pins into the spline groove of cylinder
block (44). (Refer to Illustration W1CD-02-04-007
on page W2-4-5.)
W2-4-13
60
37 1
58
39
36 29
28
31 30 27
W1CD-02-04-008
25,26
35
24
W2-4-14
IMPORTANT: Take care to the position where 14. With the center hole of piston (31) facing up,
THREEBOND is applied and install the piston into cover (1).
mounting position for O-ring and
backup ring. IMPORTANT: Pay attention to the mounting
direction for shim (26) and disc
Apply THREEBOND #1305 Here springs (25) (4 used).
Control Cylinder (30) No THREEBOND Applied Here
0.3 to 0.4 mm
Disc
Spring (25)
Width Across Flat 24 mm O-Ring (29)

Shim (26)
Backup Ring (28)
W1CD-02-04-002
Piston (27)
10. Install O-ring (29) and backup ring (28) onto W1CD-02-04-004
control cylinder (30). Apply THREEBOND #1305
to the screw section of control cylinder and install 15. Install shim (26) and disc springs (25) (4 used)
it on cover (1). onto piston (27). Then insert the piston into cover
ϖ 24 mm (1) with the disc spring end facing up.
ϖ 118 to 142 N⋅m
(12 to 14.5 kgf⋅m, 87 to 105 Ibf⋅ft) 16. Insert piston (24) into cover (1) with its open end
facing down.
IMPORTANT: Apply grease on mating surfaces of
cover (1) and valve plate (39). Align
the port hole in cover with knock
pins (35) (2 used), then install the
valve plate.
11. Install valve plate (39) and square rings (36) (2

used) into cover (1).
12. Install packing (37) and square rings (58) (2 used)

into housing (60).
IMPORTANT: When installing the cover (1) onto

housing (60), the two guide studs
(M14, length 100 mm (3.9 in), Pitch 2
mm (0.08 in)) shall be used. Take
care not to drop valve plate (39).
13. Install guide stud bolts (2 used) onto housing (60)

diagonally. Hold both sides of cover (1) and put it
over housing (60) to install it.
W2-4-15
60
1
3
4
5 3
Section A
17
18 34
W1CD-02-04-008
19 17
20 21
Section A
32
33
W1CD-02-04-009
W2-4-16
IMPORTANT: Pay attention to the mounting NOTE: In case cover (19) and retainer (21) have
position on cover (19). been removed, THREEBOND #1305 shall
be applied to socket bolt (18). Install cover
Socket Bolt (18) (19) and retainer (21) with the socket bolt.
ϖ 4 mm
ϖ 6.9 to 8.3 N⋅m
Cover (19) (0.7 to 0.8 kgf⋅m, 5.0 to 6.1 Ibf⋅ft)
18. Remove guide bolts (M14, length 100 mm (3.9 in),

Pitch 2 mm (0.08 in)) (2 used) from housing (60).
Install cover (1) onto the housing with socket bolts
(33) (4 used) and socket bolt (32).
ϖ 12 mm
Socket Bolt (17)
ϖ 150 to 180 N⋅m
(15.3 to 18.35 kgf⋅m, 111 to 133 Ibf⋅ft)
W1CD-02-04-005
19. Install O-rings (34 and 4), coupling (5) and rear
17. Install O-ring (20) onto retainer (21) of cover (19) pump (2) onto cover (1) with socket bolts (3) (2 used).
assembly (parts 18 to 21), then install the cover ϖ 10 mm
assembly onto cover (1) with socket bolts (17) (2 ϖ 98 to 123 N⋅m
used). (10 to 12.5 kgf⋅m, 72 to 91 Ibf⋅ft)
ϖ 6 mm
ϖ 28 to 35 N⋅m
(2.9 to 3.6 kgf⋅m, 21 to 26 Ibf⋅ft)
W2-4-17
DISASSEMBLE MAIN PUMP 3
2 1
3
4
5
6
7
8
4
9
10 14 13
3
11 4
15
17
12 18
19
20
21
22 16
23
24
25 29
31 30
32
26 33
27 35 34
36
28
38 37
39
40
41
44 42
43
45
46
47
48
49 55
50
51 60 59
56
52 58 61
53 57
54 62
64
67
65 63
68 66
75 71
69
72
62
74
W1CD-02-04-011
73 70
W2-4-18
1- Socket Bolt (4 Used) 20 - Valve Plate 39 - Retaining Ring 58 - Orifice

2- Housing 21 - Retaining Ring 40 - Plate 59 - Shaft
3- Knock Pin 22 - Spring 41 - Adjusting Disc 60 - Ball Stopper
4- Metal (4 Used) 23 - Plate 42 - Piston Rod 61 - Swash Plate
5- Drive Gear 24 - Pin (3 Used) 43 - Piston 62 - Cradle Shell
6- Plate 25 - Cylinder Block 44 - Socket Bolt (4 Used) 63 - Bearing
7- Square Ring 26 - Spherical Bushing 45 - Reducing Valve Body 64 - Spring
8- Backup Ring 27 - Retainer 46 - Socket Bolt 65 - Plug
9- O-Ring 28 - Plunger (9 Used) 47 - Spool 66 - Square Ring
10 - Coupling 29 - Cover 48 - Spring Seat 67 - Plug
11 - Retaining Ring 30 - O-Ring 49 - Spring 68 - Plug
12 - Driven Gear 31 - Nut 50 - Spring Seat 69 - Plug
13 - Socket Bolt (4 Used) 32 - Nut 51 - O-Ring 70 - Housing
14 - Plug 33 - Spring 52 - Guide 71 - Plug
15 - Knock Pin 34 - Spring Collar 53 - Adjusting Screw 72 - Flange
16 - Cover 35 - Valve Piston 54 - Nut 73 - O-Ring
17 - O-Ring 36 - Orifice 55 - Plug 74 - Socket Bolt (2 Used)
18 - Bearing 37 - Piston Guide 56 - O-Ring (3 Used) 75 - Socket Bolt (2 Used)
19 - Shim 38 - O-Ring 57 - Plug
W2-4-19
2 1
3
4
5
6
7
8
4
9
10 13
3
11 4
17
12 18
19
20
21
22 16
23
24
25 29
31 30
32
26 33
27 35 34
36
28
38 37
39
40
41
44 42
43
45
46
47
48
49 55
50
51 60 59
56
52 58 61
53 57
54 62
64
63
66
75
72
62
74
W1CD-02-04-011
73 70
W2-4-20
Disassemble Main Pump 3
• Be sure to thoroughly read “Precautions for 7. Remove valve plate (20) and O-ring (17) from
Disassembly and Assembly Work” on page cover (16).
W1-1-1 before starting the disassembly work.
8. Remove coupling (10), bearing (18) and shim (19)
1. Remove socket bolts (74) (2 used) and (75) (2 from shaft (59) in housing (70) to remove retaining
used) to remove flange (72) and O-ring (73) from ring (11) from inside of the coupling.
housing (70).
IMPORTANT: Do not disassemble the cylinder
ϖ 8 mm
block assembly (parts 21 to 28). The
cylinder block assembly shall be
IMPORTANT: Do not disassemble LR regulator
replaced as assembly.
assembly (parts 29 to 43), LR
regulator assembly shall be replaced
as assembly. 9. Remove cylinder block assembly (parts 21 to 28)
from shaft (59) in housing (70).
2. Remove LR regulator assembly (parts 29 to 43)
10. Remove shaft (59), ball stopper (60), swash plate
from housing (70).
(61) and spring (64) from housing (70) to remove
ϖ 32 mm the inner race of bearing (63) from shaft (59) with
press.
IMPORTANT: Do not disassemble the reducing
valve assembly (parts 45 to 55, 57 11. Remove the outer race of bearing (63) from
and 58). The reducing valve housing (70) with press.
assembly shall be replaced as
assembly. 12. Remove cradle shells (62) (2 used) from housing
(70).
3. Remove socket bolts (44) (4 used) to remove the Ȁ
reducing valve assembly (parts 45 to 55, 57 and
58) and O-rings (56) (3 used) from housing (70).
ϖ 5 mm
4. Remove socket bolts (1) (4 used) to remove the

pilot pump assembly (parts 2 to 8 and 12) from
cover (16).
O-ring (9) will remain on cover (16), coupling (10)
and its retaining ring (11) will remain on shaft (59).
ϖ 6 mm
5. Remove O-ring (9) from cover (16). Remove

socket bolts (13) (4 used) to remove cover (16)
from housing (70).
ϖ 8 mm
6. Remove square ring (66) from housing (70).
W2-4-21
ASSEMBLE MAIN PUMP 3
17
29
37 34 30 33
70 35 38 16
60 36 31
64 61 41 39
40 42 32
43
62
15
8
2
7
63
3 6
5
1
59
4
View from A
12
26 9
28 11
27
24 10 W1CD-02-04-012
23 25 22 21 19 20 18 4
13
View A
1
W1CD-02-04-013
W2-4-22
1- Socket Bolt (4 Used) 20 - Valve Plate 39 - Retaining Ring 58 - *Orifice

2- Housing 21 - Retaining Ring 40 - Plate 59 - Shaft
3- Knock Pin 22 - Spring 41 - Adjusting Disc 60 - Ball Stopper
4- Metal 23 - Plate 42 - Piston Rod 61 - Swash Plate
5- Drive Gear 24 - Pin (3 Used) 43 - Piston 62 - Cradle Shell
6- Plate 25 - Cylinder Block 44 - *Socket Bolt (4 Used) 63 - Bearing
7- Square Ring 26 - Spherical Bushing 45 - *Reducing Valve Body 64 - Spring
8- Backup Ring 27 - Retainer 46 - *Socket Bolt 65 - *Plug
9- O-Ring 28 - Plunger (9 Used) 47 - *Spool 66 - *Square Ring
10 - Coupling 29 - Cover 48 - *Spring Seat 67 - *Plug
11 - Retaining Ring 30 - O-Ring 49 - *Spring 68 - *Plug
12 - Driven Gear 31 - Nut 50 - *Spring Seat 69 - *Plug
13 - Socket Bolt (4 Used) 32 - Nut 51 - *O-Ring 70 - Housing
14 - *Plug 33 - Spring 52 - *Guide 71 - *Plug
15 - Knock Pin 34 - Spring Collar 53 - *Adjusting Screw 72 - *Flange
16 - Cover 35 - Valve Piston 54 - *Nut 73 - *O-Ring
17 - O-Ring 36 - Orifice 55 - *Plug 74 - *Socket Bolt (2 Used)
18 - Bearing 37 - Piston Guide 56 - *O-Ring (3 Used) 75 - *Socket Bolt (2 Used)
19 - Shim 38 - O-Ring 57 - *Plug
NOTE: As for parts with * mark, refer to the

illustration on page W2-4-18.
W2-4-23
17
70 60 16
64 61
62
15
8
2
7
63
3 6
5
1
59
4
View from A
12
26 9
28 11
27
24 10 W1CD-02-04-012
23 25 22 21 19 20 18 4
13
View A
1
W1CD-02-04-013
W2-4-24
Assemble Main Pump 3
• Be sure to thoroughly read “Precautions for IMPORTANT: Apply grease onto the mating
Disassembly and Assembly Work” on page surfaces of cover (16) and valve
W1-1-1 before starting the assembly work. plate (20). Align the port hole in the
cover with knock pin (15), and
1. Install the outer race of bearing (63) into housing install the valve plate.
(70) with press.
9. Install valve plate (20) and O-ring (17) onto cover
2. Install the inner race of bearing (63) into shaft (59) (16).
with press.
10. Install square ring (66) (Refer to page W2-4-18)
3. Install cradle shells (62) (2 used) and spring (64) and cover (16) onto housing (70) with socket bolts
into housing (70). (13) (4 used).
ϖ 8 mm
4. Insert ball stopper (60) and shaft (59) onto swash
ϖ 58 N⋅m (5.9 kgf⋅m, 43 Ibf⋅ft)
plate (61) on which the inner race of bearing (63)
is already attached.
IMPORTANT: When installing pilot pump assembly
(parts 2 to 8 and 12), take care not to
IMPORTANT: When installing swash plate (61),
drop plate assembly (parts 6 to 8).
take care not to drop spring (64).
11. Install O-ring (9) and pilot pump assembly (parts 2

5. Install swash plate (61) with shaft (59) attached
to 8 and 12) onto cover (16) with socket bolts
onto housing (70).
(1) (4 used).
IMPORTANT: When installing the cylinder block ϖ 6 mm
assembly (parts 21 to 28), take care ϖ 29 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
not to drop pins (24) (3 used).
12. Install O-rings (56) (3 used) (Refer to page W2-4-18)
and the reducing valve assembly (parts 45 to 55,
6. Install cylinder block assembly (parts 21 to 28)
57 and 58) (Refer to page W2-4-18) onto housing
onto shaft (59) in housing (70).
(70) with socket bolts (44) (4 used) (Refer to page
W2-4-18).
7. Install retaining ring (11) to the inside of coupling
(10). ϖ 5 mm
ϖ 12 to 15 N⋅m
8. Install shim (19), bearing (18) and coupling (10) (1.2 to 1.5 kgf⋅m, 8.9 to 11.0 Ibf⋅ft)
onto shaft (59) in housing (70).
W2-4-25
29
37 34 30 33
70 35 38 32
60 36
41 39
42 31
40
43
W1CD-02-04-012
W2-4-26
IMPORTANT: When installing LR regulator
assembly (parts 29 to 43), be sure
that ball stopper (60) fits into the
mounting hole with its flat surface
facing up.
13. Install LR regulator assembly (parts 29 to 43) onto

housing (70).
ϖ 32 mm
ϖ 150 N⋅m (15 kgf⋅m, 111 Ibf⋅ft)
14. (As for the illustration, refer to page W2-4-18.)

Install flange (72) onto housing (70) with socket
bolts (75) (2 used) and (74) (2 used) to install O-
ring (73).
ϖ 8 mm
ϖ 55 to 69 N⋅m
(5.6 to 7.0 kgf⋅m, 41 to 51 Ibf⋅ft)
W2-4-27
MAINTENANCE STANDARDS
Main Pumps 1, 2 and 3 Cylinder

Block
1. Clearance between the outer diameter of plunger

and the inner bore of cylinder block
D d
(D-d) : 0.060 mm (0.0024 in) or less
Plunger W507-02-04-009
2. Clearance from the plunger end to the shoe

surface when they are engaged
δ : 0.2 mm (0.0079 in) or less
3. Be sure to check the mounting surface for oil seal W107-02-06-140
on the shaft and no abnormality, damage and

wear can be found.
Allowable wear limit: 0.025 mm (0.00098 in) or

less
4. Valve plate
Be sure no abnormal wear, score and seizure can

be found. Cylinder Block
Sliding Surface
In case heavy damage is found on the valve plate,
replace it with a new one.
W509-02-04-001
W2-4-28
(Blank)
W2-4-29
DISASSEMBLE AND ASSEMBLE PILOT PUMP
2 1
3
4
6
7
8
4
9
10
11 3
4
12
4
W1CD-02-04-014
W2-4-30
No. Parts Name Q’ty Width Across Tightening Torque Note

Flats N⋅m (kgf⋅m, Ibf⋅ft)
1- Socket Bolt 4 ϖ 6 mm 29.0 (3.0, 21.5)
2- Housing 1
3- Pin 2
4- Metal 4
5- Drive Gear 1
6- Plate 1
7- Square Ring 1
8- Backup Ring 1
9- O-Ring 1
10- Coupling 1
11- Retaining Ring 1
12- Driven Gear 1
Clean the exterior of the pilot pump before disassembly.
Before assembly, clean each part with cleaning solvent and dry with compressed air. Apply a film of hydraulic oil to
the inner parts. Especially, be sure to apply hydraulic oil to the sliding surfaces to prevent them from being seized.
Always replace O-rings and rings with new ones when reassembling.
W2-4-31
(Blank)
W2-4-32
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE
CAUTION: Escaping fluid under pressure can

penetrate the skin, causing serious
injury. Avoid this hazard by reliev-
ing pressure before disconnecting
hydraulic lines.
Hydraulic oil may be hot after
operation and may spurt, possibly
causing severe burns. Be sure to M1CC-07-002
Front View
wait for oil to cool before starting Overload Relief
any repair work. Valve for Blade
The hydraulic oil tank cap may fly Rod
off by remaining pressure if
removed quickly. Slowly loosen the
cap to completely release any Overload Overload Relief
remaining pressure. Relief Valve Valve for Boom
for Arm Rod Bottom
Preparation
the bucket to the ground.
2. Push the air release valve on the hydraulic oil Overload Relief
tank cap to release any pressure remaining in Valve for Bucket
the hydraulic oil tank. Bottom
Ȁ CAUTION: If the overload relief valve is W1CD-02-05-004

loosened approx. more than 3/4 Back View
turns, hydraulic oil may spurt.
Do not loosen the overload
relief valve more than 3/4 turns.
Overload Relief
IMPORTANT: Be sure to loosen the overload relief Valve for Blade
Overload Relief
valve body. If the lock nut or Bottom Valve for Arm
adjusting screw is loosened, set Bottom
Overload Relief
pressure will change. Never loosen Valve for Boom
the lock nut or adjusting screw. Rod
3. Put matching marks on the overload relief valve Overload Relief

and the control valve. Gradually loosen the Valve for Bucket
overload relief valve to release any remaining Rod
pressure in the circuit.
ϖ 24 mm
ϖ 49 to 54 N⋅m W1CD-02-05-005
(5 to 5.5 kgf⋅m, 36 to 40 Ibf⋅ft) Lock Nut
4. Remove the hydraulic oil tank cap. Connect a Adjusting

vacuum pump and operate it continuously to Screw
tank.
NOTE: Run the vacuum pump continuously while

T152-05-04-003
W2-5-1
Removal
1 2
1. Loosen and remove bolt (2) for pipe (1), bolts (3) 3
(2 used) for coupling (4) and bolt (5) for plate (6)
to remove pipe (1) from coupling (4) by moving
the coupling to the oil tank side.
Remove plate (6) and collar (7) from control valve
(8).
ϖ 13, 17, 19 mm
5 4
IMPORTANT: Cap all disconnected hose ends and 6

attach tags to the hoses to aid in 7 Oil
reassembly. Tank
2. Disconnect all hoses and pipes and electrical

8
cables from control valve (8).
9
ϖ 17, 19, 22, 27 mm
10
ϖ 8 mm
CAUTION: Control valve (8) weight:

76 kg (168 Ib)
3. Remove bolts (10) (3 used) of control valve (8) Holes in

from the holes (3 used) in the frame floor using a Frame Floor
socket wrench with extension bar. Remove spring
washers (9) (3 used) from bolt (10) and install an
eyebolt (M10, Pitch 1.5) into bolt hole (11) in the
control valve. Press the pipe forward or backward
to keep pipe (1) away from control valve (8), then W1CD-02-05-027
hoist the control valve and remove it by crane.

ϖ 22 mm
Top View
11
W1CD-02-05-003
W2-5-2
Installation
1 2
CAUTION: Control valve (8) weight: 3
76 kg (168 Ib)
1. Install spring washers (9) (3 used) onto bolts (10)

(3 used).
Lift the control valve (8) by crane. In order to keep
pipe (1) away, press pipe (1) forward or backward
and lay the control valve down. Install bolts (10)
(3 used) from the holes (3 used) in the frame floor
using a socket wrench with extension bar. 5 4
ϖ 22 mm 6
ϖ 180 N⋅m (18.5 kgf⋅m, 133 Ibf⋅ft)
7 Oil
Tank
2. Connect all hoses and pipes as well as electrical

8
cables onto control valve (8).
9
ϖ 17 mm
ϖ 25.0 N⋅m (2.6 kgf⋅m, 18.5 Ibf⋅ft) 10
ϖ 19 mm
ϖ 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
ϖ 22 mm
ϖ 39.0 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)
ϖ 27 mm
ϖ 93.0 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)
ϖ 8 mm Holes in
Frame Floor
ϖ 64 N⋅m (6.5 kgf⋅m, 47 Ibf⋅ft)
W1CD-02-05-027
3. Install collar (7) and plate (6) to the control valve
(8) with bolt (5).
Insert coupling (4) into pipe (1) and install it with
bolts (3) (2 used). Install pipe (1) onto plate (6)
with bolt (2).
ϖ 13 mm (Bolt (3) for coupling) Offset Blade
ϖ 10.3 to 12.4 N⋅m
(1.05 to 1.26 kgf⋅m, 7.6 to 9.1 Ibf⋅ft) Auxiliary
Swing
ϖ 17 mm (Bolt 5)
ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) Arm 1 Auxiliary
Boom 2 Merged Circuit
ϖ 19 mm (Bolt 2) Arm 2
ϖ 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft) Travel Right
Boom 1
Flow combiner
IMPORTANT: When installation is finished, the oil Valve
Bucket
level shall be checked. Start the
engine to check for any oil leakage.
Travel Left
T1CD-03-03-017
W2-5-3
DISASSEMBLE CONTROL VALVE
1
2
3
4 Upper Section
5
6
3 7
4 8
5 7
6 10
3 7
4 8
5 7
1 6 11 1
2 7 2
8 3
3 4 Lower Section
4 7
24 5 5
25 6 12 6
7 7
26 8
8
7 7
5
6 18
7 13
8
3 7
5
14
3
1
26 2
5 3
6 4
1 5
2 7
8 6
3 7 7
4 5 8
15
7
5
6 6
7 19
3 7
8 8
4 7
7
5 16 20
6
7 6
8 7
7 8
3 7
17 4
5 21
6
7
8
7
3
4 22
5
6
7
9
7
23
W1CD-02-05-025
W2-5-4
27
5 5
5 28
2
1
3
5
2 2
28 28 1
28
5 3
5 1 3
28
28 3 5
5 2 5 3 3
1
5 3
5
28
5 3
5 29
3
28 28 25
24
3 29 3
W1CD-02-05-026
1- Plug (9 Used) 9- Spring 16 - Spool (Bucket) 23 - Spool (Flow Combiner Valve)

2- O-Ring (9 Used) 10 - Spool (Blade) 17 - Spool (Travel Left) 24 - Plug (2 Used)
3- Socket Bolt (54 Used) 11 - Spool (Swing) 18 - Spool (Offset) 25 - O-Ring (2 Used)
4- Single Long Cover (10 Used) 12 - Spool (Arm 3) 19 - Spool (Auxiliary) 26 - Double Long Cover (2 Used)
5- O-Ring (27 Used) 13 - Spool (Auxiliary 20 - Spool (Arm 1) 27 - Housing
Merged Circuit)
6 - Spool End (14 Used) 14 - Spool (Arm 2) 21 - Spool (Boom 2) 28 - Single Short Cover (9 Used)
7 - Spring Seat (28 Used) 15 - Spool (Boom 1) 22 - Spool (Travel Right) 29 - Double Short Cover (2 Used)
8 - Spring (13 Used)
W2-5-5
31
32
52
53
50 51 33
31
32 34
35
39
39 36
40 40
31
32 48
49
46
47
27
45
34
43 33
44
38
37
40
39
32
31
32
40 31
39
32
42
31
41
W1CD-02-05-023
31 - Overload Relief Valve (6 Used) 37 - Plug 43 - Main Relief Valve 49 - O-Ring

32 - O-Ring (6 Used) 38 - O-Ring 44 - O-Ring 50 - Plug
33 - Overload Relief Valve (2 Used) 39 - Shut-Off Valve (4 Used) 45 - Plug 51 - O-Ring
34 - O-Ring (2 Used) 40 - O-Ring (4 Used) 46 - Signal Plug 52 - Main Relief Valve
35 - Plug 41 - Plug 47 - O-Ring 53 - O-Ring
36 - O-Ring 42 - O-Ring 48 - Plug
W2-5-6
60
55 61
62 65
54
63 66
67
64 68
56
57
58
59
65
66
67
68 27
89
88
87
86
68
67
66
65
73
72
80
71
79
85 70
78 69
84
83 77
82 76
81 75
74
W1CD-02-05-019
54 - Anti-Drift Valve 63 - Poppet 72 - Spring 81 - Socket Bolt (2 Used)
55 - Socket Bolt 64 - Sleeve 73 - Poppet 82 - Cover
56 - O-Ring 65 - Plug (13 Used) 74 - Plug 83 - O-Ring
57 - O-Ring 66 - O-Ring (13 Used) 75 - O-Ring 84 - Spring
58 - Spring 67 - Spring (13 Used) 76 - Spring 85 - Spool
59 - Poppet 68 - Poppet (13 Used) 77 - Poppet 86 - Plug
60 - Plug 69 - Socket Bolt 78 - Sleeve 87 - O-Ring
61 - O-Ring 70 - Cover 79 - Spring 88 - Spring
62 - Spring 71 - O-Ring 80 - Poppet 89 - Poppet
W2-5-7
1
3
4 Upper Section
5
3 6
4 7
5 8
7
3 6 10
4 7
8
5 7
1 6 1
3 7 11 3
8 4
4 7 Lower Section
24 5
6 12 5
26 7 6
8 7
5 7 8
6 7
7 13
3 18
8
7
5 14
1
26
3
5 4
1 6
7 5
4 8 6
5 7 7
15 8
5 7
6 6 19
4 7 7
8 8
5 7 7
6 16 20
7 6
8 3 7
7 4 8
17 7
5 21
6
7
8
3 7
4 22
27 5
6
7
9
7
23
28 28 28
5
28
1
3
5 1
3
5
1
5 28
1
3
5 28
28
3 29 3 28 5 28 3 29 24 W1CD-02-05-024
W2-5-8
Disassemble Control Valve
• Be sure to thoroughly read “Precautions for IMPORTANT: The LOCTITE has been applied to the
Disassembly and Assembly Work” on page screw part of spool end (6). Heat its
W1-1-1 before starting the disassembly work. screw part to temperature of 200 to
250 °C (for 1 to 5 minutes with dryer
IMPORTANT: Do not remove top plugs (1 and 24) of 1KW) first, and then remove it.
from covers (4, 26, 28 and 29). In
case the top plugs have been 4. Clamp the spools (10 to 23) in a vise with chips of
removed, take care not to damage wood inserted at both sides to hold it. Loosen
the threaded part when installing spool ends (6) (14 used) from each spool to
them as they are made of aluminium. remove spring seats (7) (28 used) and springs (8)
(13 used) and (9) (1 used).
1. Loosen socket bolts (3) (28 used) to remove ϖ 5 mm
single long covers (4) (10 used) and double long
covers (26) (2 used) from housing (27). Remove
O-rings (5) (14 used) from housing (27). NOTE: Springs (8) (13 used) and (9) (1 used) are in
ϖ 5 mm their free length, so there is no danger of the
spring flying out.
IMPORTANT: When it is difficult to pull the spool
out for sticking, rotate the spool
clockwise and counterclockwise with
a hexagon wrench (5 mm) inserting
into the spool end to pull it out.
2. Remove spools (10 to 23) assemblies (14 used)

from housing (27).
NOTE: Attach tags to the spool to aid in

reassembly.
3. Loosen socket bolts (3) (26 used) on single short

covers (28) (9 used) and double short covers (29)
(2 used) to remove both single and double short
covers and O-rings (5) (13 used) from housing
(27).
ϖ 5 mm
W2-5-9
31
32
52
53
50 51 33
31
32 34
39 35
39 36
40 40
31
32 48
49
46
47
27
45
34
43 33
44
38
37
40
39
32
31
32
40 31
39
32
42
31
41
W1CD-02-05-023
W2-5-10
5. Remove main relief valves (43 and 52) and
overload relief valves (31) (6 used), (33) (2 used)
from housing (27).
Remove O-rings (44, 53) from main relief valves
(43, 52) and remove O-rings (32) (6 used) and
(34) (2 used) from overload relief valves (31) (6
used) and (33) (2 used).
ϖ 32 mm (Main relief valve 43)
ϖ 24 mm(Main relief valve 52, overload
relief vavles 31, 33)
6. Loosen the lock nut and adjusting screw on shut-

off valves (39) (4 used) to remove the plug and
O-ring (40) from the body of shut-off valve in
housing (27). Remove the poppet.
(Refer to the illustration below)
ϖ 14 mm (Lock nut)
ϖ 5 mm (Adjusting screw)
ϖ 17 mm (Plug for shut-off valve body)
Shut-Off Valve (39)

Adjusting Screw
5 mm
Lock Nut
14 mm
Plug
17 mm
Housing (27)
Poppet O-Ring
W1CD-02-05-001
7. Remove signal plug (46) and O-ring (47) from

housing (27).
ϖ 22 mm
W2-5-11
60
55 61
62 65
54
63 66
67
64 68
56
57
58
59
65
66
67
68 27
89
88
87
86
68
67
66
65
73
72
80
71
79
85 70
78 69
84
83 77
82 76
81 75
74
W1CD-02-05-019
W2-5-12
8. Loosen socket bolts (55) (4 used) to remove anti- 13. Remove plug (74), O-ring (75), spring (76),
drift valve (54), O-rings (56, 57), spring (58) and poppet (77), sleeve (78), spring (79) and poppet
poppet (59) from housing (27). (80) for the load check valve of travel from
ϖ 5 mm housing (27).
ϖ 27 mm
9. Remove plug (60), O-ring (61), spring (62),
poppet (63) and sleeve (64) for the load check 14. Remove plug (86), O-ring (87), spring (88) and
valve of arm 2 from housing (27). poppet (89) (no identification groove) for the
ϖ 27 mm merged check valve of bucket from housing (27).
ϖ 8 mm
IMPORTANT: When removing plug (65), take care
as spring (67) may fly out.
10. Remove plug (65) (13 used), O-ring (66) (13

used), springs (67) (13 used) and poppets (68)
(13 used) for load check valve A, B, C from
housing (27).
ϖ 24 mm
11. Loosen socket bolts (69) (4 used) to remove

cover (70), O-ring (71), spring (72) and poppet
(73) (with identification groove) for the merged
check valve of boom 2 from housing (27).
ϖ 5 mm
IMPORTANT: When removing cover (82), take care

as spring (84) may fly out.
12. Loosen socket bolt (81) to remove cover (82),

O-ring (83), spring (84) and spool (85) for the
parking brake selector valve of swing from
housing (27).
ϖ 5 mm
W2-5-13
(Blank)
W2-5-14
ASSEMBLE CONTROL VALVE

Back View
A B
W1CD-02-05-005
A B
Section A-A Section B-B

5 5 7 8 6 4 7
7 4 6 8 7 5 27 5 28
18
10 1,2
1,2 1,2
1,2
11
12
13 19
14
26 20
29
26 15 21
29 24,25
16 22
17
9
W1CD-02-05-009 23 W1CD-02-05-008
1- Plug (9 Used) 9- Spring 17 - Spool (Travel Left) 24 - Plug (2 Used)

2- O-Ring (9 Used) 10 - Spool (Blade) 18 - Spool (Offset) 25 - O-Ring (2 Used)
3- Socket Bolt (54 Used) 11 - Spool (Swing) 19 - Spool (Auxiliary) 26 - Double Long Cover (2 Used)
4- Single Long Cover (10 Used) 12 - Spool (Arm 3) 20 - Spool (Arm 1) 27 - Housing
5- O-Ring (27 Used) 13 - Spool (Auxiliary 21 - Spool (Boom 2) 28 - Single Short Cover (9 Used)
Merged Circuit)
6 - Spool End (14 Used) 14 - Spool (Arm 2) 22 - Spool (Travel Right) 29 - Double Short Cover (2 Used)
7 - Spring Seat (28 Used) 15 - Spool (Boom 1) 23 - Spool (Flow Combiner Valve)
8 - Spring (13 Used) 16 - Spool (Bucket)
W2-5-15
Viewed from Right Side 27

Section D
33 34 66 65 67 68 27 34 33
Section D
Section E
Section F
Section G
Section H
Section I
Section J
39 40
Section K 66 65 67 68 40 39
Section L
W1CD-02-05-002 W1CD-02-05-010
66 65 67 68 27 27 66 65 67 68
Section E Section F
W1CD-02-05-011 W1CD-02-05-012
52 53
31 - Overload Relief Valve (6 Used) 37 - Plug 43 - Main Relief Valve 49 - O-Ring

32 - O-Ring (6 Used) 38 - O-Ring 44 - O-Ring 50 - Plug
33 - Overload Relief Valve (2 Used) 39 - Shut-Off Valve (4 Used) 45 - Plug 51 - O-Ring
34 - O-Ring (2 Used) 40 - O-Ring (4 Used) 46 - Signal Plug 52 - Main Relief Valve
35 - Plug 41 - Plug 47 - O-Ring 53 - O-Ring
36 - O-Ring 42 - O-Ring 48 - Plug
W2-5-16
66 65 67 68 27
Section G Section H 31 32 61 60 62 63 64 27
39 40 66 65 67 68 40 39 31 32 66 65 67 68 32 31
W1CD-02-05-013 W1CD-02-05-014
Section I 54
Section J
57 66 65 67 68 27 32
31 31 32 66 65 67 68 27 32 31
56
58
59
73
72
70
Poppet (73) for 78
Merged Check Valve 71
80
of Boom Has an
Identification Groove 79
75 74 76 77
66 65 67 68
W1CD-02-05-016
W1CD-02-05-015
54 - Anti-Drift Valve 63 - Poppet 72 - Spring 81 - Socket Bolt (2 Used)

55 - Socket Bolt 64 - Sleeve 73 - Poppet 82 - Cover
56 - O-Ring 65 - Plug (13 Used) 74 - Plug 83 - O-Ring
57 - O-Ring 66 - O-Ring (13 Used) 75 - O-Ring 84 - Spring
58 - Spring 67 - Spring (13 Used) 76 - Spring 85 - Spool
59 - Poppet 68 - Poppet (13 Used) 77 - Poppet 86 - Plug
60 - Plug 69 - Socket Bolt 78 - Sleeve 87 - O-Ring
61 - O-Ring 70 - Cover 79 - Spring 88 - Spring
62 - Spring 71 - O-Ring 80 - Poppet 89 - Poppet
W2-5-17
46 47 27 67 68 27 85 83 82 84
Section K Section L
65
66
68
68
67
67
W1CD-02-05-018
43 44
W1CD-02-05-017
66 65 66 65
Front View 3 27 86 27
Bottom View
C C
Section C-C 86
87
88
89
W1CD-02-05-006
W1CD-02-05-004
W2-5-18
(Blank)
W2-5-19
Viewed from Right Side 27

33 34 66 65 67 68 27 34 33
Section D
Section D
Section E
Section F
Section G
Section H
Section I
39 40
Section J
66 65 67 68 40 39
Section K Poppet 68 Install Spring (67) with Its Bigger
Diameter End Facing Poppet (68).
W1CD-02-05-010
Section L
W1CD-02-05-002
66 65 67 68 27 27 66 65 67 68
Section E Section F
W1CD-02-05-011 W1CD-02-05-012
52 53
66 65 67 68 27 31 32 61 60 62 63 64 27
Section G Section H
39 40 66 65 67 68 40 39 31 32 66 65 67 68 32 31
W1CD-02-05-013 W1CD-02-05-014
W2-5-20
Assemble Control Valve
• Be sure to thoroughly read “Precautions for IMPORTANT: As for spring (67) diameter, one end
Disassembly and Assembly Work” on page is small while the other end is big.
W1-1-1 before starting the assembly work. Install the spring with its bigger end
to poppet (68).
1. Install O-rings (34) (2 used) to overload relief
valves (33) (2 used) and install the overload relief 3. Install O-rings (66) (7 used) onto plugs (65) (7
valve into housing (27). used) for load check valve. Install poppets (68)
ϖ 24 mm (7 used), springs (67) (7 used) and plug into
ϖ 59 to 69 N⋅m housing (27).
(6 to 7 kgf⋅m, 44 to 51 Ibf⋅ft) ϖ 24 mm
ϖ 88 to 98 N⋅m
2. Install O-rings (40) (4 used) onto shut-off valves (9 to 10 kgf⋅m, 65 to 72 Ibf⋅ft)
(39) (4 used). Install the poppet into housing (27).
Install the plug assembly of valve into housing 4. Install O-ring (53) to main relief valve (52) of
(27) with the adjusting screw and lock nut pump 3 and install the main relief valve into
loosened. housing (27).
Tighten the adjusting screw and lock nut.
ϖ 24 mm
ϖ 17 mm (Plug) ϖ 49 to 54 N⋅m
ϖ 5 mm (Adjusting screw) (5 to 5.5 kgf⋅m, 36 to 40 Ibf⋅ft)
ϖ 14 mm (Lock nut)
ϖ 59 to 69 N⋅m 5. Install O-rings (32) (3 used) onto overload relief
(6 to 7 kgf⋅m, 44 to 51 Ibf⋅ft) (Plug) valves (31) (3 used) and install the overload relief
ϖ 19 to 22 N⋅m valve into housing (27).
(1.9 to 2.2 kgf⋅m, 14.0 to 16.0 Ibf⋅ft)
(Adjusting screw, lock nut) ϖ 24 mm
ϖ 59 to 69 N⋅m
(6 to 7 kgf⋅m, 44 to 51 Ibf⋅ft)
Shut-Off Valve (39)
Adjusting Screw 6. Install O-ring (61) to the plug (60) for load check
5 mm valve of arm 2.
Install sleeve (64), poppet (63), spring (62) and
Lock Nut plug into housing (27).
14 mm
ϖ 27 mm
Plug ϖ 167 to 196 N⋅m
17 mm
(17 to 20 kgf⋅m, 123 to 145 Ibf⋅ft)
Housing (27)
Poppet O-Ring
W1CD-02-05-001
W2-5-21
27
Viewed from Right Side 27 Back View
Section D
Section E
55 Section F
Section G
Section H
Section I
Section J
81
Section K
82
Section L
W1CD-02-05-002 W1CD-02-05-005
Section I 54
Section J
57 66 65 67 68 27 32
31 31 32 66 65 67 68 27 32 31
56
58
59
80
78
79
75 74 76 77
66 65 67 68
W1CD-02-05-016
W1CD-02-05-015
67 68 27 85 83 82 84
46 47 27 Section L
Section K
65
66
68
68
67
67
W1CD-02-05-018
43 44
W1CD-02-05-017
66 65 66 65
W2-5-22
7. Install poppet (59), spring (58), O-rings (56, 57) IMPORTANT: There is a filter fitted by a rivet inside
and anti-drift valve (54) into housing (27). Tight of signal plug (46). The filter can’t be
them with socket bolts (55) (4 used). disassembled.
ϖ 5 mm In case the filter is clogged, or the
ϖ 8.8 to 11 N⋅m foreign matter can’t be removed even
(0.9 to 1.1 kgf⋅m, 6.5 to 8.1 Ibf⋅ft) by washing and cleaning as well as
being damaged, signal plug (46) must
IMPORTANT: As for spring (67) diameter, one end be replaced as assembly.
is small while the other end is big.
Install the spring with its bigger end 11. Install O-ring (47) to signal plug (46). Then install
to poppet (68). the signal plug into housing (27).
ϖ 22 mm
8. Install O-rings (66) (6 used) to plugs (65) (6 used) ϖ 49 to 59 N⋅m
for load check valve. (5 to 6 kgf⋅m, 36 to 44 Ibf⋅ft)
Install poppets (68) (6 used), springs (67) (6 used)
and the plug into housing (27). 12. Install O-ring (44) onto main relief valve (43) for
ϖ 24 mm pump 1 and 2. Then install the main relief valve
ϖ 88 to 98 N⋅m into housing (27).
(9 to 10 kgf⋅m, 65 to 72 Ibf⋅ft) ϖ 32 mm
ϖ 49 to 59 N⋅m
9. Install O-rings (32) (3 used) to overload relief (5 to 6 kgf⋅m, 36 to 44 Ibf⋅ft)
valves (31) (3 used) and install the overload relief
valve into housing (27). 13. Install spool (85), spring (84), O-ring (83) and
ϖ 24 mm cover (82) to the parking brake selector valve of
ϖ 59 to 69 N⋅m swing into housing (27), tight them with socket
(6 to 7 kgf⋅m, 44 to 51 Ibf⋅ft) bolts (81) (2 used).
ϖ 4 mm
10. Install O-ring (75) to plug (74) for load check valve ϖ 7.3 to 10 N⋅m
of travel. (0.7 to 1 kgf⋅m, 5.4 to 7.4 Ibf⋅ft)
Install poppet (80), spring (79), sleeve (78),
poppet (77), spring (76) and plug (74) into housing
(27).
ϖ 27 mm
ϖ 167 to 196 N⋅m
(17 to 20 kgf⋅m, 123 to 145 Ibf⋅ft)
W2-5-23
27
Viewed from Right Side 27 Back View
Section D
Section E
Section F
Section G 69
Section H
Section I
Section J
Section K
Section L
W1CD-02-05-002 W1CD-02-05-005
Section I Viewed from Bottom 86 27

27
C C
73
72
70 Section C-C 86
Poppet (73) for
Merged Check Valve 71 87
of Boom Has an
Identification Groove 88 Merged
89 Check Valve
of Bucket
W1CD-02-05-015
W1CD-02-05-006
W2-5-24
IMPORTANT: The shape of poppet (73) for the
merged check valve of boom 2 is
similar to that of poppet (89) for the
merged check valve of bucket.
But on the tip of poppet (73), there is
an identification groove.
14. Install poppet (73), spring (72), O-ring (71) and

cover (70) of the merged check valve for boom 2
into housing (27). Then tight them with socket
bolts (69) (4 used).
ϖ 5 mm
ϖ 8.8 to 11 N⋅m
(0.9 to 1.1 kgf⋅m, 6.5 to 8.1 Ibf⋅ft)
15. Install O-ring (87) to the plug (86) of the merged

check valve for bucket.
Install poppet (89) (no identification groove),
spring (88) and plug into housing (27).
ϖ 8 mm
ϖ 61.8 to 82.4 N⋅m
(6.3 to 8.4 kgf⋅m, 46 to 61Ibf⋅ft)
W2-5-25
Back View Front View 3

A B
W1CD-02-05-005 W1CD-02-05-004
A B
Section A-A Section B-B

5 27 5 7 8 6 4 7
7 4 6 8 7 5 27 5 28
18
10
11
12
13 19
14
26 20
29
26 15 21
29
16 22
17
9
W1CD-02-05-009 23 W1CD-02-05-008
W2-5-26
16. Remove the LOCTITE from the thread parts of
spools (10 to 23) (14 used in all) and spool ends
(6) (14 used) with a die (8 mm, Pitch 1.25) and a
tap (8 mm, Pitch 1.25).
17. Clamp spools (10 to 23) (14 used in all) vertically

with chips of wood inserted into a vise. Apply
LOCTITE (#271) to one pitch in the spool thread
hole. Install spring seat (7), springs (8 and 9),
spring seat (7) and spool end (6) respectively.
ϖ 5 mm
ϖ 19 to 22 N⋅m
(1.9 to 2.2 kgf⋅m, 14.0 to 16.0 Ibf⋅ft)
IMPORTANT: As for the short covers, there are

single type ones and double type
ones. Be sure to confirm their
mounting positions.
18. Install O-rings (5) (13 used), single short covers

(28) (9 used) and double short covers (29) (2
used) onto housing (27). Then tighten them with
socket bolts (3) (26 used).
ϖ 5 mm
ϖ 8.8 to 11 N⋅m
(0.9 to 1.1 kgf⋅m, 6.5 to 8.1 Ibf⋅ft)
19. Insert spool assemblies (10 to 23) into housing

(27).
Install O-rings (5) (14 used), single long covers (4)
(10 used) and double long covers (26) (2 used)
into the housing. Then tighten them with socket
bolt (3) (28 used).
ϖ 5 mm
ϖ 8.8 to 11 N⋅m
(0.9 to 1.1 kgf⋅m, 6.5 to 8.1 Ibf⋅ft)
W2-5-27
(Blank)
W2-5-28
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE

Avoid this hazard by relieving pressure
before disconnecting hydraulic lines.
repair work.
Slowly loosen the cap to release any
remaining pressure completely.
Preparations

remaining pressure.

working on the hydraulic system. M1CC-07-002
W2-6-1
Removal
1. Disconnect all hoses from the swing motor. Cap

all disconnected hose ends. 1
Attach tags to the hoses for reassembly.
: 19 mm, 27 mm, 36 mm
CAUTION: Swing device weight:

73 kg (161 Ib)
IMPORTANT: As for the handling of the nylon
slings, refer to “Precautions for the
Handling of Nylon Slings” on page
W1-1-5.
2. Remove bolts (1) (10 used). Attach the nylon sling
to the swing device and lift to remove it by crane. M1CD-07-004
: 24 mm
Installation
CAUTION: Swing device weight:

73 kg (161 Ib)
1. Secure the swing device with bolts (1).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft)
2. Reconnect all hoses to the swing motor.

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 Ibf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft)
IMPORTANT: After installation, refill the hydraulic

oil into the swing device. Check the
oil level. Start the engine to check
for any oil leaks. W1CD-02-06-017
W2-6-2
(Blank)
W2-6-3
DISASSEMBLE SWING REDUCTION
GEAR
19
20
Swing Motor
21
2
22 3
23
6
24
25
8
9
26
10
11
27
12
13
18
14
17
12
16 15
W1CD-02-06-007
1 -
Socket Bolt (8 Used) 8- Second Stage Sun Gear 15 - Spring Pin (3 Used) 22 - Housing
2 -
Retaining Ring (3 Used) 9- Thrust Plate 16 - Spring Pin (3 Used) 23 - Cork
3 -
Plate 10 - Pin (3 Used) 17 - Bearing Nut 24 - Bearing
4 -
First Stage Sun Gear 11 - Second Stage Carrier 18 - Knock Pin 25 - Thrust Plate
5 -
First Stage Planetary 12 - Plate (6 Used) 19 - Ring Gear 26 - Spacer
Gear ( 3 Used)
6 - Needle Bearing (3 Used) 13 - Needle Bearing (3 Used) 20 - Bearing 27 - Shaft
7 - First Stage Carrier 14 - Second Stage Planetary 21 - Oil Seal
Gear (3 Used)
W2-6-4
Disassemble Swing Reduction Gear
• Be sure to read “Precautions for Disassembly and 4. Remove retaining rings (2) (3 used), plate (3), first
Assembly” thoroughly on page W1-1-1 before stage sun gear (4), first stage planetary gears (5)
starting the disassembly work. (3 used), and needle bearings (6) (3 used) from
the first stage carrier (7) assembly.
1. Drain the hydraulic oil (for the motor and the
reduction gear) from the drain port tipping the 5. Tap spring pins (15), (16) into pins (10) in the
swing device. second stage carrier (11) assembly with a bar
(length: above 100 mm (3.9 in), diameter: 5 mm
Drain Port (0.2 in)).
NOTE: If spring pin (15), (16) are tapped to the end,
the spring pin will make contact with the
carrier (11) and pin (10) can not be pulled
out.
IMPORTANT: The knock pin (18) is pressed into

second stage carrier (11). Do not
remove knock pin (18) unless
necessary. In case the knock pin was
removed, replace both knock pin
T1CD-03-02-001 (18) and second stage carrier (11)
with new ones.
CAUTION: Swing motor weight:
6. Remove pins (10) (3 used), second stage
20 kg (44 lb)
planetary gears (14) (3 used), needle bearing (13)
2. Remove socket bolts (1) (8 used). Insert a screw
(3 used) plates (12) (6 used) and thrust plate (9)
driver, etc. between the swing motor and ring gear
from second stage carrier (11).
(19) to separate the swing motor. Sling the swing
motor by crane to remove it.
7. Tap spring pins (15) (3 used) and (16) (3 used)
: 12 mm
out of pins (10) (3 used).
8. With shaft (27) being held, remove nut (17) from

the shaft using special tool (ST 4129).
Swing Motor
Ȁ
ST 4129
Swing Device
W1CD-02-06-017
3. Remove the first stage carrier (7) assembly,

second stage sun gear (8), the second stage
carrier (11) assembly and ring gear (19) from the W1CC-02-06-002
swing device.
NOTE: If ring gear (19) can not be removed from
housing (22), tap the side of it with a plastic
hammer, or insert a screw driver between
the ring gear and the housing.
W2-6-5
20
21
22
24
25
26
27
W1CD-02-06-007
W2-6-6
10. Attach the shaft (27) assembly to the bearing
CAUTION: Before pressing shaft (27) from
removal special tool set.
housing (22), provide a protection cover
(outer diameter: 190 mm (7.5 in), inner
diameter: 65 mm (2.6 in), thickness: 25 to 30
Bearing Removal Special Tool Set
mm (1.0 to 1.2 in)). Then, use the press to
remove the shaft while covering housing (22) Shaft
Hose Clamp
and bearing (20) with the protection cover.
Failure to use the protection cover may result
in personal injury due to metal fragments
flying out if the housing and/or bearing break.
Use a press of capacity less than 30 tons
(66000 lb). Be sure to degrease the housing
inside before heating the bearing. Failure to
degrease may cause a fire.
27 W157-02-06-012
20
27
22
24
26
Protection Cover
W157-02-06-010
Shaft
9. Remove shaft (27) from housing (22) with a press. W157-02-06-013
Guide
press
NOTE: Use the following parts as the special tool
set for removing bearing (24).
Shaft (or bolt):
Length: 160 mm (6.3 in)
Protection Cover
Diameter: 19 mm (0.7 in) 6 to 8 used.
22
(All should be identical in length with no
wear and deformation on both ends).
Material: S35C
Hose Clamp:
(Standard Diameter: 6-1/2 Applicable
Diameter: 125 to 155 mm, 4.9 to 6.1 in)
2 used
W157-02-06-011
Guide:
Height: 120 mm (4.7 in )
Outer Diameter: 170 mm (6.7 in)
Inner Diameter: 150 mm (5.9 in)
W2-6-7
20
21
22
24
25
26
27
W1CD-02-06-007
W2-6-8
CAUTION: Work should be carried out in the

guide be sure to carry it out inside the guide.
11. Set shaft (27), with clamping apparatus on it, into
a press.
Press
27
24 25
26
Guide
W157-02-06-014
12. Remove the inner race for bearing (24), thrust

plate (25) and spacer (26) from shaft (27).
IMPORTANT: Do not remove the outer races of

bearings (20) and (24) from housing
(22). The press force on the outer
races of bearings (20) and (24) will
be reduced, shortening the service
life of the bearings. When removing
the outer races, be sure to replace
not only the outer races but also
housing (22).
13. Remove the inner race of bearing (20) and oil seal
(21) from housing (22).
Ȁ
14. Remove all old grease from the surfaces of
housing (22), bearing (24) and spacer (26).
W2-6-9
ASSEMBLE SWING REDUCTION GEAR
1
2
5 3
6
19
4
12
14 7
8
13 9
12
11
15, 16
18
10
23 17
22 20
21
24
25
26
27 T1CD-03-02-001
1 -
Socket Bolt (8 Used) 8- Second Stage Sun Gear 15 - Spring Pin (3 Used) 22 - Housing
2 -
Retaining Ring (3 Used) 9- Thrust Plate 16 - Spring Pin (3 Used) 23 - Cork
3 -
Plate 10 - Pin (3 Used) 17 - Bearing Nut 24 - Bearing
4 -
First Stage Sun Gear 11 - Second Stage Carrier 18 - Knock Pin 25 - Thrust Plate
5 -
First Stage Planetary 12 - Plate (6 Used) 19 - Ring Gear 26 - Spacer
Gear ( 3 Used)
6 - Needle Bearing (3 Used) 13 - Needle Bearing (3 Used) 20 - Bearing 27 - Shaft
7 - First Stage Carrier 14 - Second Stage Planetary 21 - Oil Seal
Gear (3 Used)
W2-6-10
Assemble Swing Reduction Gear
• Be sure to read “Precautions for Disassembly and IMPORTANT: Take care not to damage oil seal (21)
Assembly” thoroughly on page W1-1-1 before with shaft (27).
starting the assembly work. 5. Place housing (22) slightly on shaft (27) and install
it while taking care of the positions for the top of
IMPORTANT: Apply grease to the inner the shaft and the threads. Do not deform the oil
circumference of oil seal (21), and seal (21).
then install it with its lip facing up
(the motor side). IMPORTANT: Bearing Nut (17) shall be installed
1. Install oil seal (21) into housing (22). with its identification groove facing
up (the motor side). Apply the grease
2. In case bearings (20) and (24) were removed, to the thread of the nut.
housing (22) must be replaced along with them. 6. Press the bearing (20) inner race onto shaft (27)
Press the outer races of bearing (20) and (24) into and tighten bearing nut (17) temporarily.
housing (22).
3. Install spacer (26) and thrust plate (25) onto shaft

(27).
Press the inner race of roller bearing (24) onto
shaft (27).
CAUTION: Housing (22) weight: 19 kg (42 Ib)

4. Install eye bolts (M14, pitch 2.0) into the mounting
bolt hole on ring gear (19) of housing (22). Lift the
housing by crane.
W2-6-11
11
18
17
22
27 T1CD-03-02-001
W2-6-12
7. Adjust the bearing pre-load: IMPORTANT: When aligning holes, always tighten
the nut.
1) With shaft (27) being held, loosen bearing nut Tightening torque shall be less than
(17). 295 N⋅⋅m (30 kgf⋅⋅m, 215 lbf⋅⋅ft).
6) After installing second stage carrier (11) onto
2) Tap around the outer flange of housing (22) three shaft (27), check if knock pin (18) can be installed
or four turns with a plastic hammer. into nut (17) hole.
If the knock pin hole on second stage carrier (11)
3) Install a socket bolt (1) to housing (22). is not aligned with the nut hole, tighten nut (17)
until both holes align with each other.
4) After rotating housing (22) in both clockwise and
counterclockwise directions several times, install 7) After rotating housing (22) in both clockwise
the spring balance to socket bolt (1) to measure and counterclockwise directions several times,
the starting torque (A) of housing (22). install the spring balance to socket bolt (1) to
measure the starting torque (B) of housing (22).
Starting Torque
8) Check that the starting torque shall be in the
following range.
If not in the range, repeat adjusting work from
step 1).
Torque Difference Standard

B-A +10 to +40 N
(+1.0 to +4.1 kgf, +2.2
to 9.0 Ibf)
㈍
17
22
Flange
27
W1CD-02-06-010
5) Tighten bearing nut (17) to shaft (27) using

special tool (ST 4129).
: 152 N⋅m (15.5 kgf⋅m, 112 lbf⋅ft)
ST 4129
W1CC-02-06-002
W2-6-13
2
5 3
6
4
12
14 7
13 9
12
11
15, 16
18
10
17
22
27 T1CD-03-02-001
W2-6-14
IMPORTANT: Install retaining rings (2) (3 used) IMPORTANT: Check that the gap between the
with the chamfered edge facing plate ends of second stage planetary
(3). gears (14) (3 used) and housing (22)
8. Install needle bearings (6) (3 used), first stage is approx. 2 mm (0.08 in).
planetary gears (5) (3 used), first stage sun gear If the gap is 11 mm (0.43 in), knock
(4) and plate (3) to first stage carrier (7), and pin (18) can be out of the hole of
install retaining rings (2) (3 used). bearing nut (17).
11. Install the second stage carrier (11) assembly
9. Install needle bearing (13) (3 used) into second onto shaft (27) so that knock pin (18) aligns with
stage planetary gears (14) (3 used). Install thrust the knock pin hole on bearing nut (17).
plate (9), plates (12) (6 used), second stage
planetary gears (14) (3 used), and pins (10) (3
11
used) to second stage carrier (11). 14
Gap
IMPORTANT: Be sure to replace new ones as for 18
spring pins (15) (3 used) and (16) (3
used).
First insert spring pins (16) (3 used)
(outer diameter : 3.5 mm) into spring
pins (15) (3 used) (outer diameter : 6 22 17
mm) with the slits of them facing the
contrary side (an angle of 180°°).
Tap spring pins (15) (3 used)
including spring pins (16) into with
the slit of spring pin (15) upward and 27
the slit of spring pin (16) downward.
10. After aligning the holes on second stage carrier
(11) and pins (10) (3 used), tap in spring pins (15)
(3 used). W1CD-02-06-012
Slit of 15
15
16
10
11
Slit of 16 W1CD-02-06-011
W2-6-15
19
11
23
22
T1CD-03-02-001
W2-6-16
IMPORTANT: Install ring gear (19) with the IMPORTANT: Be sure to release the drain hole
identification groove facing upward when installing the motor so as to
(the swing motor side). (Refer to protect the oil seal.
page W2-6-4) Otherwise, socket 15. Apply THREEBOND #1215 to the stepped top
bolts (1) (8 used) can not be face of the swing motor. Install the swing motor
installed. onto ring gear (19) with socket bolts (1) (8 used).
: 12 mm
7 First Stage Carrier 19 Identification : 177 N⋅m (18 kgf⋅m, 131 lbf⋅ft)
Assembly
Groove
Swing Motor
Drain Hole
Coat
Adhesive
THREEBOND
1
Here
22
23
W1CD-02-06-014
Swing Motor
W1CD-02-06-013
W1CD-02-06-015
THREE BOND1215
12. Apply THREEBOND #1215 to the stepped top
face of housing (22). Install ring gear (19) onto
housing (22). 16. Refill hydraulic oil (approx. 2.5 L (0.7 US gal)) into
THREEBOND 1215
the drain hole swing device. Install cap (2) to pipe
(3).
22
17. Insert cork (23) into housing (22).
W1CD-02-06-016
13. Install second stage sun gear (8) into second

stage carrier (11).
14. Install the first stage carrier (7) assembly onto

second stage sun gear (8).
W2-6-17
DISASSEMLBE SWING MOTOR
27
28 4
26
29
5
30
25
31 24
23 6
32
33 7
34 8
35 9 10 11
38
36
37
39
40
12
13
41
21 14
15
22 16
17
18
20
19
W1CD-02-06-006
1 - O-Ring 12 - O-Ring (2 Used) 22 - Relief Valve (2 Used) 32 - Teflon Ring (2 Used)
2 - Needle Bearing 13 - Housing 23 - Friction Plate (2 Used) 33 - Piston (2 Used)
(Outer Race)
3 - Rotor 14 - Poppet (2 Used) 24 - Plate (2 Used) 34 - Bushing (2 Used)
4 - Spherical Bushing 15 - Spring (2 Used) 25 - Piston 35 - Teflon Ring (4 Used)
5 - Retainer 16 - O-Ring (2 Used) 26 - Spring (14 Used) 36 - Scrowave (4 Used)
6 - Plunger (7 Used) 17 - Backup Ring (2 Used) 27 - O-Ring 37 - Pin (2 Used)
7 - Swash plate 18 - Plug (2 Used) 28 - O-Ring 38 - O-Ring (2 Used)
8 - Bearing (Inner Race) 19 - Plug (2 Used) 29 - Retaining Ring 39 - Cover
9 - Bearing (Outer Race) 20 - O-Ring (2 Used) 30 - Needle Bearing 40 - Orifice
(Inner Race)
10 - Block 21 - O-Ring (2 Used) 31 - Valve Plate 41 - Socket Bolt (5 Used)
11 - Socket Bolt (2 Used)
W2-6-18
Disassemble Swing Motor
• Be sure to read “Precautions for Disassembly and IMPORTANT: Measure and record dimension A
Assembly” thoroughly on page W1-1-1 before between the top surfaces of piston
starting the disassembly work. (25) and housing (13). This dimension
is necessary for assembly work.
IMPORTANT: Do not disassemble relief valves (22) 8. Remove springs (26) (14 used) from housing (13).
(2 used). Screw bolts (M6, pitch 1.0) (2 used) into the tap
1. Remove relief valves (22) (2 used) from housing hole on piston (25). Remove piston (25) using
(13). supports and bolts (M6, pitch 1.0).
: 32 mm
Spanner Bolt (M6, pitch 1.0)
2. Remove plugs (18) (2 used) from housing (13).
Remove springs (15) (2 used) and poppets (14) (2
used).
: 36 mm
3. Remove socket bolts (11) (2 used). Remove block Support A

(10) from housing (13).
: 5 mm
IMPORTANT: Do not remove pins (37) (2 used) 25

from cover (39).
4. Remove socket bolts (41) (5 used). Remove 13
cover (39) from housing (13).
: 10 mm
IMPORTANT: Put matching marks on valve plate

(31) and cover (39). W152-02-06-006
5. Remove retaining ring (29) from cover (39).
Remove needle bearing (30) and valve plate (31). 9. Remove O-ring (27) from piston (25). Remove O-
ring (1) from housing (13).
6. Remove pistons (33) (2 used) and teflon rings
(32) (2 used) from valve plate (31). 10. Remove plates (24) (2 used) and friction plates
(23) (2 used) from housing (13).
7. Remove O-ring (28) and (38), bushings (34) (4
used), teflon rings (35) (4 used) and scrowaves IMPORTANT: Take care not to damage the upper
(36) (4 used) from cover (39). side (valve plate side) of rotor (3).
11. Remove the rotor (3) assembly from housing (13).
12. Remove the outer race (9) of bearing from

housing (13).
W2-6-19
W1CD-02-06-006
W2-6-20
13. Remove inner race (8) of bearing from rotor (3) Ȁ
with a puller.
Puller
W152-02-06-007
14. Remove swash plate (7), plungers (6) (7 used),

retainer (5) and spherical bushing (4) from rotor
(3).
Ȁ
Ȁ
Ȁ
Ȁ
W2-6-21
ASSEMBLE SWING MOTOR
40
37
41
11
10
24 38 25 31 32 33 2 30 39 36 35 34
29
23 26
28 14 15 16 17 18
27
A 12
1
B
22 21
B 3
6 B-B
4
5
7
13
9 W1CD-02-06-002
19,20 8
1 - O-Ring 12 - O-Ring (2 Used) 22 - Relief Valve (2 Used) 32 - Teflon Ring (2 Used)

2 - Needle Bearing 13 - Housing 23 - Friction Plate (2 Used) 33 - Piston (2 Used)
(Outer Race)
3 - Rotor 14 - Poppet (2 Used) 24 - Plate (2 Used) 34 - Bushing (4 Used)
4 - Spherical Bushing 15 - Spring (2 Used) 25 - Piston 35 - Teflon Ring (4 Used)
5 - Retainer 16 - O-Ring (2 Used) 26 - Spring (14 Used) 36 - Scrowave (4 Used)
6 - Plunger (7 Used) 17 - Backup Ring (2 Used) 27 - O-Ring 37 - Pin (2 Used)
7 - Swash Plate 18 - Plug (2 Used) 28 - O-Ring 38 - O-Ring (2 Used)
8 - Bearing (Inner Race) 19 - Plug (2 Used) 29 - Retaining Ring 39 - Cover
9 - Bearing (Outer Race) 20 - O-Ring (2 Used) 30 - Needle Bearing 40 - Orifice
(Inner Race)
10 - Block 21 - O-Ring (2 Used) 31 - Valve Plate 41 - Socket Bolt (5 Used)
11 - Socket Bolt (2 Used)
W2-6-22
Assemble Swing Motor
• Be sure to read “Precautions for Disassembly and IMPORTANT: Press the piston into the housing
Assembly” thoroughly on page W1-1-1 before until dimension A between both tops
starting the assembly work. of piston (25) and housing (13) is
Ȁ equal to the one measured when
1. Install spherical bushing (4) to rotor (3). disassembling.
Ȁ 10. Apply the hydraulic oil to the outer surface of
2. Install plungers (6) (7 used) into retainer (5). Apply piston (25). Install the piston into housing (13)
hydraulic oil to the plunger hole of rotor (3). Install using supports.
the plunger into the rotor.
Ȁ 11. Install springs (26) (14 used) into piston (25).
3. Apply the hydraulic oil to the mating surfaces of Ȁ
plungers (6) (7 used) and swash plate (7). Install 12. Install teflon rings (35) (4 used) to bushings (34) (4
the swash plate to rotor (3). used).
Ȁ
4. Press inner race (8) of bearing into rotor (3) with a 13. Install teflon rings (32) (2 used) to piston (33) (2
press. used).
Install piston (33) (2 used) to valve plate (31).
5. Press outer race (9) of bearing into housing (13)
with a press. IMPORTANT: Be sure to align the matching marks
when installing valve plate (31).
IMPORTANT: After installing the rotor (3) 14. Install bushings (34) (with teflon rings) (4 used)
assembly into housing (13), check and scrowaves (36) (4 used) to cover (39). Install
that the top of the rotor is 7.5 mm valve plate (31) (with pistons and teflon rings) to
(0.3 in) below the top of housing cover (39).
(13). Ȁ
6. Install rotor (3) assembly into housing (13). 15. Press inner race (30) of needle bearing to cover
(39). Install retaining ring (29) to the cover.
7. Apply the hydraulic oil to friction plates (23) (2
used) and plates (24) (2 used). Install the friction 16. Apply the grease to O-rings (28) and (38) (2 used).
plates and the plates into housing (13) alternately. Install O-rings to cover (39).
8. Apply the grease to O-ring (1). Install the O-ring to

housing (13).
9. Apply the grease to O-ring (27). Install the O-ring

to piston (25).
W2-6-23
41
11
10
39
14 15 16 17 18
A 12
B
22 21
B
B-B
13
W1CD-02-06-002
W2-6-24
17. Apply THREEBOND #1211 to the mating surface
of cover (39) and housing (13). Install the cover
on the housing with socket bolts (41) (5 used).
: 8 mm
: 65 N⋅m (6.6 kgf⋅m, 48 lbf⋅ft)
18. Install O-rings (12) (2 used) to block (10). Install

the block to housing (13) with socket bolts (11) (2
used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)
19. Install backup rings (17) (2 used) and O-rings (16)

(2 used ) onto plugs (18) (2 used). Install poppets
(14) (2 used), springs (15) (2 used) and the plugs
onto housing (13).
: 36 mm
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
20. Install O-rings (21) (2 used) to relief valves (22) (2

used). Install the relief valve to housing (13).
: 32 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
W2-6-25
DISASSEMBLE AND ASSEMBLE VALVE
BLOCK
Valve block
9 1
10 2
8
7
3
4
5
6
12
W1CD-02-06-008
7 8
12
C
9
1
10
2
C
3
11
4
Section C-C 6 5 W1CD-02-06-009
1- Plug 4- O-Ring 7- Spring 10- Socket Bolt (2 Used)

2- O-Ring 5- Spring 8- Spool 11- Housing
3- Plug 6- Spool 9- Block 12- O-Ring (2 Used)
W2-6-26
Disassemble Valve Block Assemble Valve Block
• Be sure to read. “Precautions for Disassembly • Be sure to read. “Precautions for Disassembly
and Assembly” thoroughly on page W1-1-1 before and Assembly” thoroughly on page W1-1-1 before
starting the disassembly work. starting the assembly work.
Ȁ Ȁ
1. Remove socket bolts (10) (2 used). Remove block 1. Install O-ring (4) to plug (3). Install spool (6),
(9) from housing (11). spring (5) and the plug to block (9).
: 5 mm : 5 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
2. Remove plug (1) from block (9). Remove spool
(8) and spring (7). 2. Install O-ring (2) to plug (1). Install spring (7),
: 5 mm spool (8) and the plug to block (9).
: 5 mm
3. Remove plug (3) from block (9). Remove spring : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
(5) and spool (6).
: 5 mm 3. Install O-rings (12) (2 used) to block (9). Install the
block to housing (11) with socket bolts (10) (2
used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)
W2-6-27
MAINTENANCE STANDARD
Swing Motor
1. The clearance between plunger and rotor bore.

d
Standard clearance (D-d): 0.04 mm (0.0016 in) or
less
W107-02-06-138
D D
W107-02-06-139
2. The end play between plunger and shoe.
Standard end play (δ): 0.4 mm (0.016 in) or less
W107-02-06-140
W2-6-28
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL RIGHT PILOT
VALVE

fore disconnecting hydraulic lines.
repair work.
Preparation
1. Park the machine on a solid level surface.
Lower the bucket onto the ground.
Ȁ
the top of the hydraulic oil tank to release any
remaining pressure.
Ȁ
tank. Run the vacuum pump continuously, while M1CC-07-002
W2-7-1
Removal
1
1. Remove bolts (3) (4 used) to remove seat (1) with
seat stand (2).
: 17 mm
2
2. Remove screws (18) (4 used). Move boot (5) up
to remove cover (17).
3. Remove caps (15) (2 used) and screws (14) (4

used) to remove cover (16).
4. Remove connector (10) and screws (8) (3 used)

to remove switch box (9).
3 M1CC-01-012
5. Remove rubber cap (11) and screws (13) (3 used)
4
6. Loosen nut (6) to remove lever (4) and boot (5).
: 22 mm 5
18 8
17 9
16
10
15
14
11
12
13
W1CC-02-07-001
W2-7-2
7. Disconnect hoses (20 to 25) on to pilot valve (19),
then attach a cap on all disconnected the hose
ends.
Attach identification tags on all disconnected 19
hoses to aid in reassembly.
: 19 mm
20
8. Remove bolts (7) (4 used) to remove pilot valve 21
(19). 22
: 13 mm 23
25
24
W1CD-02-07-001
20 - Hose B: To port A4(boom lower) in shockless valve

21 - Hose T6 : To port T3 in pilot shut-off valve
22 - Hose H : To port H(bucket roll-out) at the top of coupler
bracket
23 - Hose A: To port A3(boom raise) in shockless valve
24 - Hose P3 : From port A3 in pilot shut-off valve
25 - Hose G : To port G(bucket roll-in) at the second port from
top of coupler bracket
NOTE: Piping location shows that of ISO pattern.
Installation
1. Install pilot valve (19) to the console with bolts (7)

(4 used). 7
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.4 Ibf⋅ft) 19
2. Connect hoses (20 to 25) to pilot valve (19).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
W1CC-02-07-001
W2-7-3
3. Install lever (4) and boot (5) to pilot valve (19) with
nut (6). 4
: 22 mm
5
: 20±4.9 N⋅m
(2.0±0.5 kgf⋅m, 14.5±3.6 lbf⋅ft) 6
4. Install cover (12) with screws (13) (3 used).

19
Install rubber cap (11).
18 8
5. Install switch box (9) with screws (8) (3 used) to 17 9
connect connector (10).
16
6. Install cover (16) with screws (14) (4 used). 10
Install caps (15) (2 used). 15
7. Install boot (5) and boot cover (17) with screws 14

(18) (4 used). 11
12
13
W1CC-02-07-001
1
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
IMPORTANT: After installation, check the oil level,

start the engine and check for oil
leaks.
3 M1CC-01-012
W2-7-4
REMOVE AND INSTALL LEFT PILOT
VALVE

repair work.
Preparation
Ȁ
remaining pressure.
Ȁ
M1CC-07-002
W2-7-5
Removal
1
1. Remove bolts (3) (4 used) to remove seat (1) with
seat stand (2).
: 17 mm
2
2. Remove screws (13) (4 used). Move boot (5) up
to remove boot cover (14).
3. Remove cap (18) and screws (20) (3 used) to re-

move cover (19).
4. Remove rubber cap (17) and screws (16) (4 used)

3 M1CC-01-012
5. Disconnect connector (22) of the horn harness
and remove clips (7), (23).
6. Loosen nut (6) to remove lever (4) and boot (5). 23

: 22 mm 4
5
22 6
7
17 18 19 20
13
16 14
15
W178-02-07-003
W2-7-6
7. Disconnect hoses (24 to 29) onto pilot valve (21)
and attach a cap on each disconnected hose end.
Attach identification tags on all disconnected
: 19 mm 21
8. Remove bolt (9) with spring pin (8), spring washer

(11), plane washer (12) and bolts (10) (3 used) to 24 25
26
remove pilot valve (21).
: 13 mm 27
29
28
W1CD-02-07-001
24 - Hose F: To port A5(arm roll-out) in shockless valve

25 - Hose T5: To port T2 in pilot shut-off valve
26- Hose O: To port F(right swing) at the third port from top in
coupler bracket
27 - Hose E: To port A2(arm roll-in) in shockless valve
28- Hose P2: To port A1 in pilot shut-off valve
29- Hose C: To port E(left swing) at the fourth port from top in
coupler bracket
NOTE: Piping location shows that of ISO pattern.

Installation
1. Install spring washer (11) and plane washer (12)

to bolt (9) with spring pin (8). Install pilot valve (21)
to the console with bolts (9) and (10) (3 used).
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.4 lbf⋅ft)
8
2. Connect hoses (24 to 29) to pilot valve (21). 9
21 10
: 19 mm
11
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
12
W178-02-07-003
W2-7-7
3. Install lever (4) and boot (5) to pilot valve (21) with
nut (6).
: 22 mm
: 20±4.9 N⋅m (2±0.5 kgf⋅m, 14.5±3.6 lbf⋅ft) 23
4
IMPORTANT: If the harness is arranged to the in- 5
side of spring pin (8), it may make 22 6
contact with the moving part of the 7
pilot valve damaging it. Be sure to 8
arrange harness to the outside of the 9
spring pin. Align mounting clip 21
marks of the harness to install clips 17 18 19 20
(23) and (7).
4. Arrange the harness to the outside of spring pin 13
(8) on bolt (9) head. Align the marks of the har- 16 14
ness to install clips (23) and (7). Connect connec-
tor (22). 15
5. Install cover (15) with screws (16) (4 used). Install

rubber cap (17).
6. Install cover (19) with screws (20) (3 used). Install W178-02-07-003
cap (18).
7. Install boot (5) and boot cover (14) with screws 1

(13) (4 used).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
IMPORTANT: After installation, check the oil level.

Start the engine and check for oil
leaks.
3 M1CC-01-012
W2-7-8
REMOVE AND INSTALL TRAVEL PILOT
VALVE

repair work.
Preparation
Ȁ
the top of the hydraulic oil tank onto release any
remaining pressure.
Ȁ
M1CC-07-002
W2-7-9
Removal
1. Remove bolts (2) (6 used) to remove under cover

(1). 1
: 17 mm
W1CD-02-07-002
2. Loosen bolts (3) (4 used) to remove pedal (4), 3

16
levers (15) and (16).
15
: 17 mm
4
3. Disconnect hoses (5 to 10). Attach a cap on each

disconnected hose end.
Attach identification tags on all disconnected 3
: 19 mm
4
4. Remove socket bolts (13) (2 used), spring wash- 14 13
ers (12) (2 used) and plane washer (11) (2 used) 13
to remove pilot valve (14). 12
12
: 8 mm
11
11
5
10
9
W1CC-02-07-004
8
7 6
5- Hose PT: To pilot shut-off valve

6- Hose PP: From pilot shut-off valve
7- Hose L: To control valve port Pb8(right travel reverse)
8- Hose J: To control valve port Pb1(left travel reverse)
9- Hose K: To control valve port Pa8(right travel forward)
10 - Hose I: To control valve port Pa1(left travel forward)
W2-7-10
Installation
1. Install pilot valve (14) with socket bolts (13) (2

used), spring washers (12) (2 used) and plane
washers (11) (2 used).
: 8 mm
16 3
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
15
2. Connect hoses (5 to 10). 4
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
3
3. Install pedal (4), levers (15) and (16) with bolts (3)
(4 used).
: 17 mm 4
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
14 13
13
12
12
11
11
5
10
9
W1CC-02-07-004
8
7 6
5- Hose PT: To pilot shut-off valve

6- Hose PP: From pilot shut-off valve
7- Hose L: To control valve port Pb8(right travel reverse)
8- Hose J: To control valve port Pb1(left travel reverse)
9- Hose K: To control valve port Pa8(right travel forward)
10 - Hose I: To control valve port Pa1(left travel forward)
4. Install under cover (1) with bolts (2) (6 used). 1

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
IMPORTANT: After installation, check the oil level. 2

leaks.
W1CD-02-07-002
W2-7-11
(Blank)
W2-7-12
REMOVE AND INSTALL BLADE PILOT
VALVE

repair work.
Preparation
Ȁ
remaining pressure.
Ȁ
tank. Run the vacuum pump continuously, while M1CC-07-002
W2-7-13
Removal

(1).
: 17 mm 1
W1CD-02-07-002
3
12
IMPORTANT: Do not turn the rod end, or adjust- 11 4
ment is necessary.
5
2. Remove bolts (3) (2 used) and spring washers (4)
(2 used) to remove bracket (5) from pilot valve 10
(11). 6
: 17 mm 8
9 7
3. Disconnect hoses (6 to 9) from pilot valve (11).
: 19 mm
4. Remove bolts (12) (2 used) to remove pilot valve W1CC-02-07-002
(11) from bracket (10).

: 17 mm
8- Hose BT : To pilot shut-off valve
9- Hose BP : From pilot shut-off valve
10 - Hose BU : To control valve (blade raise)
11 - Hose BD : To control valve (blade lower)
W2-7-14
Installation
3
12
1. Install pilot valve (11) to bracket (10) with bolts 11 4
(12) (2 used).
5
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 10
6
8
2. Connect hoses (6 to 9) to pilot valve (11).
: 19 mm 9 7
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
3. Install spring washers (4) (2 used) to bolts (3) (2

W1CC-02-07-002
used). Install bracket (5) to pilot valve (11) with the
bolt.
: 17 mm 8- Hose BT : To pilot shut-off valve
9- Hose BP : From pilot shut-off valve
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 10 - Hose BU : To control valve (blade raise)
11 - Hose BD : To control valve (blade lower)
4. Install under cover (1) with the bolts (2) (6 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
IMPORTANT: After installing, check the hydraulic 1

oil level, start the engine and check
all hoses for oil leaks.
W1CD-02-07-002
W2-7-15
DISASSEMBLE RIGHT AND LEFT PILOT
VALVES
13
12
14
11
15
11
10
8
8
7
9
21
6
16 20
21
5
20
4 5
19
3 6
3 18
2
4
17
W176-02-07-001
1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim (Several) 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Dowel Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)
W2-7-16
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) and (9) out of 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 may be damaged.
the dimensions of balance springs A
(3), B (4) and return springs A (5), B IMPORTANT: Retaining ring (7) 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).
ȗȎȀ
IMPORTANT: Do not clamp housing (18) in a vise
7
to remove the screw joint (13) be-
cause the screw joint may be dam-
aged.
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 bolt (11) to remove block (10). At

IMPORTANT: The number of shims (2) has been
this time, push rods (8) and (9) are in place.
determined for each port during the
: 6 mm
performance testing at the factory.
Take care not to lose them. Keep
them carefully to install them to each
former port when reassembly.
7. Remove spring guide (16), balance springs (3)
and (4), return springs (5) and (6), shim (2) and
spacer (1) from spool (17).
W2-7-17
21
20
21
20
19
18
17
W176-02-07-001
W2-7-18
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) and (21) from housing (18).

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

2- Shim (Several) 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Dowel 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)
W2-7-20
Assemble Right and Left Pilot Valves
IMPORTANT: The pilot valve is susceptible to con- IMPORTANT: Install spring guide (16), with the
tamination. Keep parts clean when protrusion facing up.
assembling. 3. Install spring guide (16) onto the 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).
ȕȎȀ
Port Spool Shim Push rods ST 7255
No. (17) (2) (8), (9) 7
1 with outer
Same to Same to groove
2 the former the former without outer
one one groove W176-02-07-008
3 with outer
groove 5. Insert the spool (17) head into the hole of spring
4 without outer using special tool (ST 7257) to press the spring
groove from the top of spring guide (16). Install retaining
ring (7) with the ring holder (ST 7255) onto the
Port Return Springs Blance Springs head of the spool.
No. (5), (6) (3), (4) 7
1 short short ST 7257 ST 7255
2 long long
3 short short
17
4 long long 16
IMPORTANT: Make sure of the port hole number

and insert spool (17) to the former Packing Material
port.
1. Insert the thinner end of spool (17) to housing (18), W176-02-07-009
then push the spool rotating it. NOTE: Put approx. dia.8 mm, length 10 mm of
NOTE: The spool has been selected to match the packing material, into the port hole not only
hole of the housing. The spool and housing to make the work easy to do, but also to
must be replaced as an assembly. prevent the spool from lowering to the bot-
tom when compressing the spring.
IMPORTANT: Refer to the table above to assemble
them correctly. 6. Assemble the remained spools (17) (3 used) into
2. Install spacer (1), shim (2), balance spring (3) or housing (18) in the same procedures as step 2 to
(4), return spring (5) or (6) onto spool (17) in- 5.
stalled in housing (18).
7. Install O-rings (19) and (21) (2 used) on to hous-
ing (18).
W2-7-21
13 14
10
12
15
11
8, 9
W176-02-07-006
20 18
W2-7-22
8. Apply the grease to the inner face of oil seals (15) IMPORTANT: Make sure of the tighteness of cam.
(4 used), then install the oil seals (4 used) into 13. Clamp housing (18) carefully in a vise and then
block (10) with a bamboo spatula. install cam (12) to universal joint (14).
NOTE: As shown bellow, inserting push rods (8) Tighten the universal joint so that the clearance
and (9) first, then installing oil seal (15). between the cam and push rod (8) and (9)
This prevents the oil seal from entering into become 0 to 2 mm.
the hole. : 32 mm
Oil Seal Mounting Hole IMPORTANT: Do not clamp housing (18) in a vise
because screw joint (13) may be
damaged.
10 14. Clamp screw joint (13) in a vise to tighten univer-
8,9 sal joint (14). Tighten cam (12) with a spanner.
: 32 mm
: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)
W176-02-07-007
IMPORTANT: Make sure of the position to install

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

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

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

block (10) assembly to housing (18) with socket
bolts (11) (2 used).
: 6mm
: 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
W2-7-23
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)
W2-7-24
Disassemble Travel Pilot Valve
1. Clamp casing (14) in a vise. Loosen bolt (1) to 7. Remove spring (18) from casing (14) (4 places).
remove cover (2) from holder (10).
: 10 mm IMPORTANT: Put a stand under bracket (26). If
holder (10) bears the reaction force,
2. Remove socket bolts (8) (2 places), to remove a strong force acts on pin (3) and the
holder (10) from casing (14). pin may be deformed.
: 8 mm
IMPORTANT: The inside of spring pins (24) and
3. Pull out pusher (23) from casing (14) (4 places). (25) hole in the bracket is stepped-
Bushing (13) and oil seal (11) are removed with shape. Therefore, the spring pin can
the pusher. only be pushed out in one direction.
8. Put a stand under bracket (26).
4. Pull out pusher (23) from bushing (13), with a Ȁ Push out spring pins (24) and (25) from bracket
bamboo spatula to remove oil seal (11) (4 places). (26) at the same time using special tool (ST 1237).
Remove the bracket from pin (3). (2 places)
IMPORTANT: Put mark on spools to install them to Ȁ Do not remove spring pin (27) from the bracket
their former position easily. unless necessary.
5. Pull out the spool (17) assembly from casing (14)
NOTE: The outside end of the spring pin has been
turning the spool (4 places).
caulked.
Ȁ Spring guide (22), balance spring (21), shim (20)
and spacer (19) are removed with the spool.
NOTE: The spool has been selected to match the
hole of the casing. The spool and casing
24,25
must be replaced as an assembly.
26
IMPORTANT: The number of the shims has been 3 27
determined during the performance
testing at the factory. They must be Caulked
kept together with their spool.
6. Compress balance spring (21). Remove spring Stand
guide (22), balance spring (21), shim (20) and
spacer (19) from spool (17) (4 places).
W176-02-07-019
9. Remove socket bolts (28) (2 used) to remove

damper (6) and rubber seat (7) from pin (3). O-
ring (4) is removed with them (2 places).
: 5 mm
W2-7-25
35
34
33
32
31
30
10
14
W176-02-07-002
W2-7-26
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) and

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

may feel tight when removing.
13. Remove pin (3) with a round bar and a 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
W2-7-27
ASSEMBLE TRAVEL PILOT VALVE
26 6 7 1 2 3 31 25 27 24 10 32 30 33 34, 35 8 9
13
22
4
28
5 11 21
29 12 18
23
20
19
17
14
W176-02-07-010
15, 16
1- Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)

2- Cover 11 - Oil Seal (4 Used) 20 - Shim (Several) 29 - Spring Washer (4 Used)
3- Pin (2 Used) 12 - O-Ring (4 Used) 21 - Balance Spring (4 Used) 30 - Adjust Bolt (4 Used)
4- O-Ring (2 Used) 13 - Bushing (4 Used) 22 - Spring Guide (4 Used) 31 - Bushing (4 Used)
5- O-Ring (2 Used) 14 - Casing 23 - Pusher (4 Used) 32 - Cam (2 Used)
6- Damper (2 Used) 15 - O-Ring 24 - Spring Pin (2 Used) 33 - Lock Nut (4 Used)
7- Rubber Seat (2 Used) 16 - Plug 25 - Spring Pin (2 Used) 34 - Spring Pin (2 Used)
8- Socket Bolt (2 Used) 17 - Spool (4 Used) 26 - Bracket (2 Used) 35 - Spring Pin (2 Used)
9- Spring Washer (2 Used) 18 - Spring (4 Used) 27 - Spring Pin (2 Used)
W2-7-28
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.
(20).
1. Assemble spool (17) 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 with 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-
ing (14) (4 places). 31
W176-02-07-016
4. Assemble plunger (23) into assembly (4 used).

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

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

low. 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 in the left side as shown below.
31
10
ST 7256
W176-02-07-013
W2-7-29
3 10 32 30 33 34, 35 8 9
23
14
W176-02-07-010
W2-7-30
7. Place adjust bolt (30) to cam (32). Tighten the bolt IMPORTANT: Do not adjust adjust bolt (30) while
with hand, and then lightly secure it temporarily pressing the pusher (23) head with
with lock nut (33) (2 places). the adjust bolt. The standard clear-
ance between the adjust bolt and
NOTE: Adjust the dimensions later. pusher must be 0 to 0.2 mm(0 to
0.008 in).
8. Apply the grease on the head (mating surface for 13. Adjust adjust bolt (30) as the following procedures
pusher (23)) of adjust bolt (30) (2 places). (2 places).
: 13 mm
9. Install O-ring (5) to pin (3), then assemble the pin : 4 mm
to holder (10) with cam (32) (2 places). • Loosen lock nut (33).
• Move cam (32) to check whether there is play. If
IMPORTANT: Take care of the inserting direction none, turn the adjust bolt to adjust.
of spring pins (34) and (35). • Turn both the adjust bolts on the left and right al-
ternatively to keep the cam horizontal with a
IMPORTANT: Tap the spring pin in until it makes hexagon-head wrench.
contact with the step in hole. • Measure sizes A and B from both left and right
10. Install spring pins (34) and (35) to cam (32) using caves on the cam to holder (10). Fine adjust the
special tool (ST 1237), then secure the cam and adjust bolt to get the same distance for both left
pin (3). The spring pins shall be displaced with and right.
their slits at 90° (2 places). • Secure the adjust bolt with a hexagon-head
ȑȑȎȀ wrench. Tighten the lock nut to specified torque
first, securing the adjust bolt.
34 35 Slit Slit • When adjustment is finished, move the cam to
check that there is a little play. If there is no play,
the pusher may be in compressed condition, and
adjustment should be carried out again.
: 10 N⋅m (1 kgf⋅m, 7.4 Ibf⋅ft)
30 33 32 10
W176-02-07-017
A B
11. Caulk the hole edge of cam (32), where spring
pins (34) and (35) are inserted, with a punch (2
places).
12. Place holder (10) on the casing (14) assembly

and install it with socket bolts (8) (2 used) and
spring washers (9) (2 used).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) W176-02-07-003
W2-7-31
26 6 7 1 2 3 25 27 24 10
4
28
5
29
W176-02-07-010
W2-7-32
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 may be deformed.
IMPORTANT: Pay attention to the direction of
damper (6). IMPORTANT: The inside of spring pins (24) and
(25) holes in the bracket are
IMPORTANT: The inner bore of damper (6) is stepped-shape. Make sure of the di-
edged-shape. If the damper is pried rection to insert the spring pin.
upward, O-ring (5) will be damaged.
16. With the lever upward, install damper (6) to pin (3) IMPORTANT: Make sure of the direction of the
straight without pring (2 places). spring pin.
20. Put a stand under bracket (26).
17. Secure damper (6) to holder (10) with socket bolts Ȁ Tap spring pins (24) and (25) into the bracket until
(28) (2 used) and spring washers (29) (2 used) (2 the spring pin comes to the stepped end using
places). special tool (ST 1237). The spring pins shall be
: 8 mm displaced with their slits at 90°.
: 7 N⋅m (0.7kgf⋅m, 5.2 Ibf⋅ft) ȒȑȎȀ
18. Apply the grease to O-ring (4), then press it to the

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

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

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

used).
: 10 mm
: 5 N⋅m (0.5 kgf⋅m, 3.7 lbf⋅ft)
24. Apply the grease to the spring pin (27) contact

part of damper (6) (2 places).
W2-7-33
DISASSEMBLE BLADE PILOT VALVE
1
2 1
22
3 2
4 3
21 5 4
5
6
20 6
7
7
8
19 19 8
18 18
17 9
17 9
10
11 10
14
12 11
16
12
14
15
13
W192-02-07-001
1- Dust Seal (2 Used) 7- Spring Seat (2 Used) 13 - Casing 18 - Lock Nut (2 Used)
2- Bushing (2 Used) 8- Return Spring (2 Used) 14 - Bushing (2 Used) 19 - Adjusting Screw (2 Used)
3- Oil Seal (2 Used) 9- Balance Spring (2 Used) 15 - Pin 20 - Cam
4- O- Ring (2 Used) 10 - Spacer (2 Used) 16 - Cover 21 - Set Screw
5- Pusher (2 Used) 11 - Shim (2 Used) 17 - Socket Bolt (2 Used) 22 - Boot
6- Washer (4 Used) 12 - Spool (2 Used)
W2-7-34
Disassemble Blade Pilot Valve
• Be sure to read “Precautions for Disassembly and
Assembly” thoroughly on page W1-1-1 before
starting the disassembly work.
1. Remove boot (22) from cover (16).
2. Clamp the pilot valve in a vise. Loosen set screw

(21) and remove pin (15) with a bar. Remove the
cam (20) assembly from cover (16).
: 3 mm
: 8 mm or less
IMPORTANT: Record the positions, related to cas-

ing (13), of the disassembled parts.
Slowly remove socket bolts (17) and
plate (16) as pusher (5) assemblies
may fly out by the force of return
springs (8).
Do not disassemble lock nut (18)
and adjusting screws (19). Adjust-
ment is necessary when reassem-
bling them.
3. Alternately loosen and remove socket bolts (17)
(2 used). Remove cover (16) and the pusher (5)
assemblies (2 used) from casing (13).
: 6 mm
4. Remove pusher (5), O-ring (4), oil seal (3) and

dust seal (1) from each bushing (2) (2 used).
IMPORTANT: In order to avoid mixing them up, be

sure to indicate the port number
from which each disassembled part
came.
5. Remove the spool (12) assemblies and return
spring (8) from each port of casing (13).
6. Compress balance spring (9) to remove washer

(6) and spring seat (7) from spool (12).
Remove spacer (10) and shims (11) from spool
(12) (2 places).
W2-7-35
ASSEMBIE BLADE PILOT VALVE
18 19 14 21 15 20 22
5 17
16
6 1
3
7
4
12
8
10 9
11
13
T554-02-07-010
1- Dust Seal (2 Used) 7- Spring Seat (2 Used) 13 - Casing 18 - Lock Nut (2 Used)
2- Bushing (2 Used) 8- Return Spring (2 Used) 14 - Bushing (2 Used) 19 - Adjusting Screw (2 Used)
3- Oil Seal (2 Used) 9- Balance Spring (2 Used) 15 - Pin 20 - Cam
4- O- Ring (2 Used) 10 - Spacer (2 Used) 16 - Cover 21 - Set Screw
5- Pusher (2 Used) 11 - Shim (2 Used) 17 - Socket Bolt (2 Used) 22 - Boot
6- Washer (4 Used) 12 - Spool (2 Used)
W2-7-36
Assemble Blade Pilot Valve
Assembly” thoroughly on page W1-1-1 before 4. Place the pusher (5) assemblies (2 used) and
starting the disassembly work. cover (16) onto each spool (12) assembly (2
used). Alternately tighten socket bolts (17) (2
IMPORTANT: Install washers (6) (4 used) with its used) to install the cover on casing (13).
sharp edge side facing upward. : 6 mm
Install spring seat (7) in its correct : 29.5±2.9 N⋅m
direction. (3.0±0.3 kgf⋅m, 21.5±2.1 lbf⋅ft)
Do not compress balance spring (9)
with spring seat (7) more than 4 mm 5. Install adjusting screws (19) (2 used) on cam (20)
(0.157 in) when installing spring seat and temporarily tighten lock nuts (18). Install the
(7). cam (20) assembly on cover (16) with pin (15).
1. Install shims (11) (2 used), spacers (10) (2 used) : 5 mm
and balance springs (9) (2 used) on spools (12) (2
used). Compress balance springs (9) to install IMPORTANT: Apply LOCTITE #241 to set screw
spring seat (7) (2 used) and washers (6) (4 used) (21).
to spool (12). 6. Install set screw (21) into cam (20).
: 3 mm
IMPORTANT: Be sure to confirm the port number : 6.9±1 N⋅m (0.7±0.1 kgf⋅m, 5.0±0.7 lbf⋅ft)
before inserting each spool (12) as-
sembly, to be sure that the spool as- 7. Adjust adjusting screws (19) (2 used).
sembly is inserted into its correct Secure cam (20) horizontally. The clearance be-
port. tween pushers (5) (2 used) and adjusting screws
2. Insert return springs (8) (2 used) and spool (12) (19) is 0 mm, then tighten lock nuts (18) (2 used).
assemblies (2 used) into casing (13). : 5 mm
: 17 mm
IMPORTANT: Install oil seals (3) (2 used) and dust : 33.3±3.4 N⋅m
seals (1) (2 used) in their correct di- (3.4±0.3 kgf⋅m, 24.5±2.5 lbf⋅ft)
rections. Apply a film of grease to
the lips of the oil seal and the dust 8. Tilt cam (20) and apply a film of grease to the
seal, and to the inside of bushing (2). pushers (5) (2 used) heads.
3. Install oil seals (3) (2 used), dust seals (1) (2
used) and O-rings (4) (2 used) on bushings (2) (2 9. Install boot (22) on cover (16).
used). Insert pushers (5) (2 used) into the bush-
ing.
Use one of the following greases:

• Apolloil Autorex C (Idemitsu)
• Ocean 7 (Nihon Ore Louve)
• Screw Bar L60 (NOK)
W2-7-37
(Blank)
W2-7-38
UPPERSTRUCTURE / Pilot Shut-Off Valve
REMOVE AND INSTALL PILOT SHUT-OFF
VALVE

repair work.
Preparation
Ȁ
remaining pressure.
Ȁ
3. Remove the hydraulic oil tank cap. Connect a M1CC-07-002
W2-8-1
Removal
1. Remove bolts (2) (6 used). Remove under cover

(1). 1
: 17 mm
W1CD-02-07-002
3
4
5
IMPORTANT: Do not turn rod end (5), or adjust-

ment is necessary.
2. Remove socket bolt (8), plane washer (7), nut (3) 6
and spring washer (4).
: 10 mm
: 5 mm
7
8 W1SE-02-08-004
3. Disconnect hoses (10 to 18) from pilot shut-off 18
valve (6). Attach a cap to all the disconnected 17
6
hoses. Attach identification tags to the hydraulic 16
hoses for reassembly. 9
: 19, 22 mm
4. Loosen socket bolts (9) (2 used). Then, remove

pilot shut-off valve (6). 10
: 8 mm
11
12
13
15 14 W1CD-02-08-001
9- Socket Bolts (2 used)

10 - Hose T : To shockless valve
11 - Hose PT : From travel pilot valve
12 - Hose P : From pilot filter
13 - Hose T5: From left pilot valve
14 - Hose T6 : From right pilot valve
15 - Hose HT: From shockless valve
16 - Hose P2 : To left pilot valve
17 - Hose PP : To travel pilot valve
18 - Hose P3 : To right pilot valve
W2-8-2
Installation
18
1. Install pilot shut-off valve (6) with socket bolts (9) 17
6
(2 used). 16
: 8 mm 9
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
10
11
12
13
15 14 W1CD-02-08-001
9- Socket Bolts (2 used)

10 - Hose T : To shockless valve
11 - Hose PT : From travel pilot valve
12 - Hose P : From pilot filter
13 - Hose T5: From left pilot valve
14 - Hose T6 : From right pilot valve
15 - Hose HT: From shockless valve
2. Install plane washer (7) to socket bolt (8). 16 - Hose P2 : To left pilot valve
17 - Hose PP : To travel pilot valve
Install rod end (5) with spring washer (4), nut (3) 18 - Hose P3 : To right pilot valve
and the socket bolt.
: 10 mm 3
: 5 mm 4
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
5
3. Connect hoses (10 to 18) to pilot shut-off valve
(6).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 28.5 lbf⋅ft) 6
4. Install under cover (1) with the bolt (2) (6 used).

: 17 mm 7
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 8 W1SE-02-08-004
W1CD-02-07-002
W2-8-3
DISASSEMBLE PILOT SHUT-OFF VALVE
1
2
3
4
5
6
7
14
8
13
12
11 9
W1CC-02-08-001
10
1- Retaining Ring 5- O-Ring 9 - Spring Pin 12 - Socket Bolt

2- Washer 6- Backup Ring 10 - Lever 13 - Steel Ball
3- Backup Ring 7- Washer 11 - Spool 14 - Body
4- O-Ring 8- Retaining Ring
W2-8-4
Disassemble Pilot Shut-Off Valve
1. Remove retaining ring (1) and washer (2) and pull

out spool (11).
IMPORTANT: Put matching marks on spool (11)

and lever (10).
2. Pull out spring pin (9) from spool (11), and remove
lever (10).
3. Remove retaining ring (8) and washer (7) from

spool (11).
4. Remove backup ring (3) and (6), and O-ring (4)

and (5) from body (14).
5. Remove socket bolt (12) from body (14).

: 6 mm
W2-8-5
ASSEMBLE PILOT SHUT-OFF VALVE
1 2 3 4 5 6 7 8 9
13
10
12
14 11
W1CC-02-08-002
1- Retaining Ring 5- O-Ring 9 - Spring Pin 12 - Socket Bolt

2- Washer 6- Backup Ring 10 - Lever 13 - Steel Ball
3- Backup Ring 7- Washer 11 - Spool 14 - Body
4- O-Ring 8- Retaining Ring
W2-8-6
Assemble Pilot Shut-Off Valve
IMPORTANT: Apply grease to O-ring (5) and

backup ring (6).
1. Install O-ring (5), backup ring (6) and washer (7)
to body (14).
IMPORTANT: Apply the hydraulic oil to spool (11).

2. Install spool (11) to body (14). Install retaining ring
(8) to the spool.
3. With matching marks on spool (11) and lever (10)

aligned, tap spring pin (9) into spool (11) and lever
(10).
IMPORTANT: Apply grease to O-ring (4) and

backup ring (3).
4. Install O-ring (4), backup ring (3), and washer (2)
to body (14). Install retaining ring (1) to spool (11).
5. Tighten socket bolts (12).

: 6 mm
: 44 N⋅m (4.5 kgf⋅m, 32.5 lbf⋅ft)
W2-8-7
(Blank)
W2-8-8
UPPERSTRUCTURE / Shockless Valve
REMOVE AND INSTALL SHOCKLESS
VALVE

repair work.
Preparation
Ȁ
remaining pressure.
Ȁ
M1CC-07-002
W2-9-1
Removal

(1).
: 17 mm
IMPORTANT: Attach identification tags to the hy-

draulic houses for reassembly.
2. Disconnect hoses (5 to 17) from shockless valve
(4). Attach a cap to all the disconnected hoses.
: 17 mm, 19 mm 1
3. Remove bolts (3) (2 used) to remove shockless

valve (4). 2
: 17 mm
Installation
1. Install shockless valve (4) with bolts (3) (2 used).

W1CD-02-09-004
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
2. Connect hoses (5 to 17) to shockless valve (4). 3

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm 4
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
5
3. Install cover (1) with the bolt (2) (4 used). 6
: 17 mm 7
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
8
9
17 10
16
15 11
14 12
13
W1CD-02-09-001
3- Bolt (2 used)
4- Shockless Valve
5- Hose B2: To arm roll-in control valve
6- Hose 1: To boom raise side control valve
7- Hose 2: To boom lower side control valve
8- Hose 3: To arm roll-out side control valve
9- Hose HT: From pilot shut-off valve
10 - Hose T: To pilot shut-off valve
11 - Hose DR3: To swing parking brake selector valve side
control valve
12 - Hose TS1: To hydraulic oil tank
13 - Hose TS2: Connection of port D and port P2 in shockless
Valve
14 - Hose F: From arm roll-out side left pilot valve
15 - Hose B: From boom lower side right pilot valve
16 - Hose A: From boom raise side right pilot valve
17 - Hose E: From arm roll-in side left pilot valve
W2-9-2
DISASSEMBLE AND ASSEMBLE SHOCK-
LESS VALVE
27
28
1 5
5
2 2
2
5
8 5
3
2 7 2
4 8
6
9
11
10
12
4 1
3
2 2
1 3
4
25
28
27
26 13
2 22
5 23
14
14
24
2 22 4
5
23 15 15 3
24 21 16
2 2
5 17
17
1
18 18
19
19
20
20
W1CD-02-09-002
W2-9-3
3 4 5 7 8 5
2
2
2
2
1
5
A A
14
B B 5
21
15
C C 1 17
2 3 2 26 25 19 20 18
D D Section A-A Section C-C
E
2 1 7 8 4 1 2 1 9 8 3 1
E
3 2 3 2
4 3 4 4
F F 2
2 2 2
5 5
G G
5 5
14
21 14
15 21
13
27 27 15
28 17
28 26 25 19 18 20 17 24 23 22 19 20 18
Section B-B Section D-D
3 2 5 6 10 11
5 9 8 5
2
2 2
2 1
5 3
2 14
16
15 1
5
17 2
24 23 22 19 20 18 3 4 2 1 12
Section E-E Section F-F
4 3 1
2
Section G-G
W1CD-02-09-003
W2-9-4
Wrench Size Tightening Torque

key No. Parts Name Q’ty Remarks
(mm) N⋅m (kgf⋅m) (lbf]ft)
1 Plug 10 :4 7.4 to 9.3 (0.75 to 0.95) (5.5 to 6.9)
2 O-Ring 23
3 Spring 10
4 Steel Ball 10
5 Plug 13 :4 7.4 to 9.3 (0.75 to 0.95) (5.5 to 6.9)
6 Orifice 1 :3 5.1 to 6.4 (0.52 to 0.65) (3.8 to 4.7) Use LOCTITE #241
7 Spring 2
8 Spool 4
9 Spring 2
10 Filter Element 1
11 Retainer 1 :6 6.9 to 8.8 (0.70 to 0.90) (5.1 to 6.5)
12 Orifice 1 :3 5.1 to 6.4 (0.52 to 0.65) (3.8 to 4.7) Use LOCTITE #241
13 Body 1
14 O-Ring 4
15 Sleeve 4
16 Orifice 1 : 1.5 0.31 to 0.39 (0.032 to 0.04) (0.23 to 0.29) Use LOCTITE #241
17 Spool 4
18 Spring 4
19 O-Ring 4
20 Plug 4 - Use special tool
21 Orifice 3 : 1.5 0.31 to 0.39 (0.032 to 0.04) (0.23 to 0.29) Use LOCTITE #241
22 Spring 2
23 Spool 2
24 Set Screw 2 : 1.5 0.78 to 0.98 (0.08 to 0.1) (0.6 to 0.7) Use LOCTITE #241
25 Spring 2
26 Spool 2
27 Plug 2 :6 10 (1.0) (7.4)
28 O-Ring 2
W2-9-5
(Blank)
W2-9-6
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE
UNIT

repair work.
Preparation
Ȁ
remaining pressure.
Ȁ
vacuum pump and operate it continuously to M1CC-07-002

W2-10-1
Removal
1
1. Open rear cover (1) of the machine right side. Set
lock (2) to secure cover (1).
2. Disconnect each harness of the solenoid valve

(4).
3. Disconnect hoses (3, 6 and 7) from solenoid valve

unit (4). Cap all disconnected hoses. Attach tags 4
to disconnected hoses for reassembly.
: 17 mm
4. Remove bolts (5) (2 used) to remove solenoid

valve unit (4).
: 13 mm
2
Installation
W1CD-02-10-001
1. Install solenoid valve unit (4) with bolts (5) (2
used).
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.4 lbf⋅ft)
3
2. Connect hoses (3, 6 and 7) to solenoid valve unit
(4). 8
: 17 mm
4
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
3. Connect each harness of the solenoid valve.

5
4. Unlock lock (2) on rear cover (1) of the machine
right side to close cover (1).
7
6
T1CD-03-06-001
3- Hose PI: To center joint

4- Solenoid Valve Unit
5- Bolt (2 used)
6- Hose PF: From pilot filter
7- Hose ST: To hydraulic tank
8- Proportional Solenoid Valve
W2-10-2
(Blank)
W2-10-3
DISASSEMBLE PROPORTIONAL SOLE-
NOID VALVE
1
3
2
4
5
7
8
9
10
13
11
12 14
15
16
17
18
W157-02-11-016
1- Socket Bolt (2 Used) 6- Solenoid 11 - Washer 15 - O-Ring

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

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

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

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

2- Lock Nut 7- Spring 12 - Spring 16 - Sleeve
3- *O-Ring 8- O-Ring 13 - O-Ring 17 - Plate
4- Adjusting Screw 9- Diaphragm 14 - O-Ring 18 - Washer
5- *Spring 10 - Spool
NOTE: For the parts marked with *, refer to page
W2-10-4.
W2-10-6
Assemble Proportional Solenoid Valve
IMPORTANT: Lock nut (2), adjusting screw (4),
IMPORTANT: Apply grease to O-rings (13), (14) spring (5) and O-ring (3) are not
and (15). Apply hydraulic oil to separated, so no need to assemble
sleeve (16). them.
1. Install washer (18) and plate (17) into the housing. Take care not to drop spring (7)
Install O-rings (13), (14) and (15) on sleeve (16) when installing solenoid (6).
and insert it into the housing. 3. Install solenoid (6) with socket bolt (1) (2 used).
: 3 mm
16
: 2.9 N⋅m (0.3 kgf⋅m, 2.1 Ibf⋅ft)
15
14
13
6
Housing
7
W157-02-11-005
IMPORTANT: Apply hydraulic oil to spool(10). Take
care not to damage the edge portion
in the bore of sleeve (16) when in-
1
serting the spool (10) assembly.
After inserting the spool, check if W157-02-11-011
spool (10) slides in and out smoothly
without any restriction about 3 to 5
mm (0.12 to 0.20 in).
2. Install diaphragm (9), washer (11) and spring (12)
to spool (10) and insert it into sleeve (16).
10
16
12 Housing
11
W157-02-11-009
10
W157-02-11-010
W2-10-7
(Blank)
W2-10-8
MEMO
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SECTION 3
UNDERCARRIAGE
— CONTENTNS —
Group 1 Swing Bearing Group 5 Front Idler
Remove and Install Swing Bearing .... W3-1-1 Remove and Install Front Idler ........... W3-5-1
Disassemble Swing Bearing .............. W3-1-4 Disassemble Front Idler..................... W3-5-2
Assemble Swing Bearing.................... W3-1-6 Assemble Front Idler ......................... W3-5-4
Maintenance Standard....................... W3-5-6
Group 2 Travel Device
Remove and Install Travel Device ..... W3-2-1 Group 6 Upper and Lower Roller
Disassemble Travel Reduction Gear . W3-2-4 Remove and Install Upper Roller ....... W3-6-1
Assemble Travel Reduction Gear ...... W3-2-8 Remove and Install Lower Roller ....... W3-6-4
Disassemble Travel Motor ............... W3-2-12 Disassemble and Assemble
Assemble Travel Motor.................... W3-2-16 Lower Roller .................................... W3-6-6
Disassemble Brake Valve ................ W3-2-24 Maintenance Standard ..........................W3-6-8
Assemble Brake Valve..................... W3-2-28
Maintenance Standard ..................... W3-2-32 Group 7 Track
Remove and Install Track................... W3-7-1
Group 3 Center Joint Maintenance Standard...........................W3-7-7
Remove and Install Center Joint ........ W3-3-1
Disassemble Center Joint.................. W3-3-4
Assemble Center Joint ...................... W3-3-6
Maintenance Standard .......................W3-3-9
Group 4 Track Adjuster

Remove and Install Track Adjuster .... W3-4-1
Disassemble Track Adjuster .............. W3-4-2
Assemble Track Adjuster................... W3-4-8
1CDW-3-1
(Blank)
1CDW-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Before removing the swing bearing, the upperstructure

must be removed first. For removal and installation of
the upperstructure, refer to “Remove and Install Main
Frame” section. In this section, the procedure starts on
the premise that the upperstructure has already been
removed.
Removal
1. Put matching marks on swing bearing (1) and

track frame (2).
Matching Mark
2. Remove mounting bolts (3) (24 used) of the swing

bearing inner race.
: 24 mm 1 2 W105-03-01-001
CAUTION: Swing bearing weightϖ ϖ 91 kg

(200 lb)
3. Attach lifting tools (ST 0050) to swing bearing (4),
hoist swing bearing (4) by crane and remove it.
W105-03-01-002
ST 0050
4
W105-03-01-003
W3-1-1
Installation
Clean the mating surfaces of the swing bearing and

the track frame.
1. Apply THREEBOND #1102 to the mating surfaces

of the swing bearing and the track frame.
ST 0050
CAUTION: Swing bearing weightϖ ϖ 91 kg
(200 lb)
IMPORTANT: Inner race soft zone (S) and the ball
filler port shall be placed on the
same position.
2. Hoist the swing bearing by crane. Align the W105-03-01-003
matching marks on the track frame and the swing Grease Fitting
bearing. Position
Front Side
Plug Position
27ѯ
S
3. Install mounting bolts (3) (24 used) of the swing

bearing inner race and tighten them to
specification. ѧSѨ
ЁSoft ZoneЂ
: 24 mm Marking Position
: 270 N⋅m (27.5 kgf⋅m,200 lbf⋅ft)
15ѯ Grease Fiting Position
W1CD-03-01-001
W105-03-01-002
W3-1-2
(Blank)
W3-1-3
DISASSEMBLE SWING BEARING
1 2 3
9,10 7 6 5 W155-03-01-001
6
9
10
W105-03-01-011
1 - Outer Race 4 - Plug 7 - Inner Race 9 - Support (74 Used)

2 - Seal 5 - Seal 8 - Grease Fitting (2 Used) 10 - Support (4 Used)
3 - Pin 6 - Ball (78 Used)
W3-1-4
Disassemble Swing Bearing
starting the disassembly work. CAUTION: Swing bearing weight: 91 kg
(200 lb)
1. Drive to remove pin (3) of plug (4) from the bottom 3. Install lifting tool (ST 0050) to swing bearing outer
side of the swing bearing. race (1). Hoist the swing bearing outer race
NOTE: The top of pin (3) was crimped. Remove slightly by crane. Remove seals (2) and (5).
the crimped part with a grinder.
4. Put inner race (7) of the swing bearing on the
wooden blocks. Hoist outer race (1) to take up a
3 slack of the wire rope by crane.
5. While rotating outer race (1), remove balls (6) (78

used), supports (9) (74 used) and (10) (4 used).
Remove the balls with bar magnet (A).
4 Remove supports (9) and (10) with bent wire
(B).
1
W105-03-01-007
2
A
7
2. Remove plug (4).
NOTE: Screw bolt (M8, pitch 1.25 mm) in plug (4).
Hit the lower side of the bolt or pull the bolt
to remove plug (4).
6 5 W105-03-01-009
W105-03-01-008
9,10 W105-03-01-010
W3-1-5
ASSEMBLE SWING BEARING
1 2 3
9,10 7 6 5 W155-03-01-001
6
9
10
W105-03-01-011
1 - Outer Race 4 - Plug 7 - Inner Race 9 - Support (74 Used)

2 - Seal 5 - Seal 8 - Grease Fitting (2 Used) 10 - Support (4 Used)
3 - Pin 6 - Ball (78 Used)
W3-1-6
Assemble Swing Bearing
Assembly” thoroughly on page W1-1-1 before CAUTION: Swing bearing weight: 91 kg
starting the assembly work. (200 lb)
2. Hoist the outer race using lifting tool (ST 0050) by
1. Before installing the swing bearing inner and outer crane. Align the center of the outer race and the
races, completely remove the oil from the groove inner race. While rotating the outer race, install
surfaces of oil seals (2) and (5). Apply ball (6) and support (9) or (10) into the bearing
THREEBOND #1735 to the groove surfaces, then races in the order with a round wooden stick.
install seals (2) and (5).
2
IMPORTANT: Apply the grease to balls (6) (78
used) , supports (9) (74 used) and
(10) (4 used).
Pay attention to the assembling
direction of supports (9 and 10) and
balls. Supports (9 and 10) are
different figure. Supports (9) (74
used) are thick, supports (10) (4 6
used) are thin as shown below.
First, insert support (9) and balls
5
into the swing bearing alternately.
After installing support (9) W142-03-01-005
completely, all of support (9) are in

place, install support (10) and balls
alternately.
Adjust the gap using supports (9)
and (10).
Finally the gap is less than 20 mm to
adjust.
9 10 9,10
W142-03-01-006
3. Install plug (4) into outer race (1), then install pin
(3).
Crimp the top face fringe of pin (3) with a punch.
Sufficiently lubricate the swing bearing with
grease (Shell Alvania EP2 or equivalent).
W1CD-03-01-002
W142-03-01-007
W3-1-7
(Blank)
W3-1-8
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE

repair work.
Preparation
Ȁ
remaining pressure.

M1CC-07-002
W3-2-1
Removal
1. Remove bolt (4) and washer (3) from the track

frame to remove cover (2).
: 22 mm
1
2. Disconnect all hoses from the travel device. Cap
the disconnected hoses. Attach tags to them for
assembly.
: 19 mm, 22 mm, 27 mm
CAUTION: Travel device weight: 130 kg

(285 lb)
3. Remove travel device mounting bolt (1).
Hoist and remove the travel device by crane.
: 24 mm
2
3 W152-03-02-003
W3-2-2
Installation
CAUTION: Travel device weight: 130 kg

(285 lb)
1. Install the travel device with bolt (1). 1
: 24 mm
: 300 N⋅m (31 kgf⋅m, 220 lbf⋅ft)
2. Reconnect all the hoses to the travel device.

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
3. Install washer (3) to bolt (4). Then install cover (2) 2

to the track frame with bolt (4).
: 22 mm 3 W152-03-02-003
: 140 N⋅m (14 kgf⋅m, 103 lbf⋅ft)) 4
IMPORTANT: After installation, check the oil level.

leaks. Be sure to conduct the break-
in operation to prevent the travel
motor seizure during the initial
operation.
Break-in operation conditions:

1. Engine control lever: Slow Idle.
2. Travel mode: Slow mode
3. Operation time: 2 minutes above
W3-2-3
DISASSEMBLE TRAVEL REDUCTION
GEAR 7
6
3
2
8
27
26
11 25
19
10 17
24
9 20 22
16 23
21
18 15
13
14
12
34
33
32
31
30
29
28 W1CD-03-02-002
1- Travel Motor 10 - Knock Pin 19 - Spring Pin (3 Used) 27 - Shaft
2- Floating Seal 11 - Second Stage Carrier 20 - First Stage Carrier 28 - Ring Gear
3- Floating Seal 12 - Thrust Plate (3 Used) 21 - Thrust Plate (3 Used) 29 - Socket Bolt (12 Used)
4- Ball Bearing 13 - Second Stage Planetary 22 - First Stage Planetary Gear 30 - Stopper Pin
Gear (3 Used) (3 Used)
5- Drum 14 - Needle Bearing (3 Used) 23 - Needle Bearing (3 Used) 31 - O-Ring
6- Sprocket 15 - Thrust Plate (3 Used) 24 - Thrust Plate (3 Used) 32 - Cover
7- Ball Bearing 16 - Pin (3 Used) 25 - Pin (3 Used) 33 - Plug (3 Used)
8- Bolt (12 Used) 17 - Sun Gear 26 - Thrust Plate 34 - Ring
9- Bearing Nut 18 - Spring Pin (3 Used)
W3-2-4
Disassemble Travel Reduction Gear
• Be sure to read “Precautions for Disassembly and 6. Remove bearing nut (9) from travel motor (1)
Assembly” thoroughly on page W1-1-1 before using special tool (ST 4128).
CAUTION: High pressure may remain in the

travel device. After gradually loosening the
air vent plug to release any remaining ST 4128
pressure thoroughly, remove the drain plug
to drain the gear oil. If the air vent plug is
9
quickly loosened, the plug may fly off or the
gear oil may spout out. Keep the body (parts)
and the face away from the plug.
1. Remove plug (33) (3 used) from cover (32). Drain

the gear oil from the travel reduction gear.
: 10 mm
W152-03-02-005
2. Remove ring (34) from ring gear (28) with a screw

driver. Remove cover (32) from the ring gear.
CAUTION: Sprocket (6) weight: 20 kg
3. Remove the first stage carrier (20) assembly and (44 lb)
shaft (27) from ring gear (28). IMPORTANT: As for handling the nylon sling, refer
to “the Precautions for Handling
4. Remove sun gear (17) and the second stage Nylon Sling” on page W1-1-5.
carrier (11) assembly from ring gear (28). 7. Remove bolts (8) (12 used) from sprocket (6).
Attach a nylon sling on the sprocket. By crane,
5. Remove socket bolts (29) (12 used) to remove hoist and remove sprocket (6) from drum (5).
ring gear (28) from drum (5). : 24 mm
: 12 mm
CAUTION: Drum (5) weight: 29 kg (64 lb)
IMPORTANT: Be sure not to remove knock pin (10) 8. Install eye bolts (M14, pitch 2.0) to the socket bolt
in bearing nut (9). (29) holes on drum (5). By crane, hoist and
remove the drum from travel motor (1).
9. Place drum (5) with ring gear (28) side facing

downward.
IMPORTANT: Do not remove bearing (4) remaining

in the travel motor unless necessary.
10. Remove the outer race of bearing (7) from drum
(5) with a bar.
W3-2-5
3
2
11 25
19
24
20 22
16 23
21
18 15
13
14
12
W1CD-03-02-002
W3-2-6
IMPORTANT: For handling of floating seal (2) and
(3), refer to the section “Precautions
for Floating Seal Handling” on page
W1-1-4.
11. Remove floating seal (2) from travel motor (1) and
remove floating seal (3) from drum (5).
12. Place drum (5) on the wooden block with travel

motor (1) side facing down.
13. Remove the outer race of bearing (4) from drum

(5) with a bar and a hammer.
IMPORTANT: If spring pins (19) are completely

tapped into the end of pins (25), pins
(25) are unable to be pulled out.
14. Tap spring pins (19) (3 used) till they make
contact with the end of pins (25) (3 used) with a
bar.
15. Remove pins (25) (3 used), first stage planetary

gears (22) (3 used), needle bearings (23) (3 used),
thrust plates (21) (3 used) and thrust plates (24)
(3 used) from first stage carrier (20).
Ȁ
16. Tap spring pins (19) out of pins (25) with a bar.
Ȁ
IMPORTANT: If spring pins (18) are completely
tapped into the end of pins (16), pins
(16) are unable to be pulled out.
17. Tap spring pins (18) (3 used) till they make
contact with the end of pins (16) (3 used) with a
bar.
18. Remove pins (16) (3 used), second stage

planetary gears (13) (3 used), needle bearings
(14) (3 used), thrust plates (12) (3 used) and
thrust plates (15) (3 used) from second stage
carrier (11).
Ȁ
19. Tap spring pins (18) (3 used) out of pins (16) (3
used) with a bar.
W3-2-7
ASSEMBLE TRAVEL REDUCTION GEAR
1 2 3 4 7 9 10 18 12 13 14 15 16 19 21
22
23
24
33
25
26
27
30
32
5 29 11 17 20 28 31 34
T1CD-03-05-003
1- Travel Motor 10 - Knock Pin 19 - Spring Pin (3 Used) 27 - Shaft

2- Floating Seal 11 - Second Stage Carrier 20 - First Stage Carrier 28 - Ring Gear
3- Floating Seal 12 - Thrust Plate (3 Used) 21 - Thrust Plate (3 Used) 29 - Socket Bolt (12 Used)
4- Ball Bearing 13 - Second Stage Planetary 22 - First Stage Planetary Gear 30 - Stopper Pin
Gear (3 Used) (3 Used)
5- Drum 14 - Needle Bearing (3 Used) 23 - Needle Bearing (3 Used) 31 - O-Ring
6- Sprocket 15 - Thrust Plate (3 Used) 24 - Thrust Plate (3 Used) 32 - Cover
7- Ball Bearing 16 - Pin (3 Used) 25 - Pin (3 Used) 33 - Plug (3 Used)
8- Bolt (12 Used) 17 - Sun Gear 26 - Thrust Plate 34 - Ring
9- Bearing Nut 18 - Spring Pin (3 Used)
W3-2-8
Assemble Travel Reduction Gear
• Be sure to read “Precautions for Disassembly and IMPORTANT: In case the bearing (4) inner race
Assembly” thoroughly on page W1-1-1 before was removed, install the bearing
starting the assembly work. inner race onto travel motor (1) after
heating the inner race to a range of
1. Install needle bearings (14) (3 used) into second 50 to 70 °C (122 to 158 °F).
stage planetary gears (13) (3 used). With thrust 6. Install the ball bearing (4) outer race and the ball
plates (12) (3 used) and thrust plates (15) (3 bearing (7) outer race into drum (5) with a bar.
used) attached to both sides of the second stage
planetary gear, install the second stage planetary IMPORTANT: For handling of floating seal (2) and
gear assembly into second stage carrier (11). (3), refer to the section “Precautions
for Floating Seal Handling” on page
IMPORTANT: Tap in spring pins (18) (3 used) with W1-1-4.
the slit facing the shaft edge. 7. Install floating seal (2) to travel motor (1) and
install floating seal (3) to drum (5).
16
CAUTION: Drum (5) weight: 29 kg (64 lb)
8. Install drum (5) onto travel motor (1).
Slit
18
9. Heat the ball bearing (7) inner race to a range of
50 to 70 °C (122 to 158 °F). Then, install the ball
bearing (7) inner race onto travel motor (1). After
2. Install pins (16) (3 used) into second stage carrier the inner race is cooled, tap in the bearing to seat
(11) so that the spring pin holes align with those in position with a bar.
on second stage carrier (11). Then, tap in spring
pins (18) ( 3 used).
3. Install thrust plate (26) on first stage carrier (20). CAUTION: Sprocket (6) weight: 20 kg (44 lb)
IMPORTANT: Apply LOCTITE # 262 to the thread
4. Install needle bearings (23) (3 used) into first portion of bolts (8) (12 used).
stage planetary gears (22) (3 used). With thrust 10. Secure sprocket (6) to drum (5) with bolts (8) (12
plates (21) (3 used) and thrust plates (24) (3 used).
used) attached to both sides of the first stage : 24 mm
planetary gear, install the first stage planetary : 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
gear assembly in first stage carrier (20).
IMPORTANT: Tap in spring pins (19) (3 used) with

the slit facing the shaft edge.
5. Install pins (25) (3 used) into first stage carrier
(20) so that the spring pin holes align with those
on first stage carrier (20). Then, tap in spring pins
(19) (3 used).
W3-2-9
1 9 10
22
33
27
32
5 29 11 17 20 28 31 34
T1CD-03-05-003
W3-2-10
11. Install bearing nut (9) to travel motor (1) using IMPORTANT: Install sun gear (17) with the
special tool (ST 4128). shoulder side facing first stage
: 167 N⋅m (17 kgf⋅m, 123 lbf⋅ft) carrier (20).
The Shoulder
ST 4128
1
W152-03-02-004
16. Install sun gear (17) into second stage carrier (11)
while aligning the spline teeth .
17. Install the first stage carrier (20) assembly so that

the sun gear (17) splines and the ring gear (28)
W152-03-02-005 teeth mesh with those on first stage carrier (20).
12. Hold sprocket (6) with hands. Rotate the sprocket
both clockwise and counterclockwise 4 to 5 turns. 18. While aligning the splines on shaft (27) with the
Reduce play on nut (9) by tapping special tool (ST splines on travel motor (1) and first stage
4128) with a plastic hammer. planetary gears (22) (3 used), install shaft (27).
13. After repeating steps 11 and 12 twice, tighten 19. Install O-ring (31) onto cover (32).
bearing nut (9) using special tool (ST 4128).
: 167 N⋅m (17 kgf⋅m, 123 lbf⋅ft) 20. Secure cover (32) to ring gear (28) with ring (34).
IMPORTANT: If knock pin (10) does not align with 21. Refill the gear oil 2.5 L (0.7 US gal) into the travel
the second stage carrier (11) hole, device via plugs (33) (3 used) hole.
align them by tightening direction of Install the plugs to cover (32).
bearing nut (9) using special tool (ST : 10 mm
4128). : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
14. Align the spline teeth on second stage carrier (11)
with those of travel motor (1), and knock pin (10)
with the knock pin mounting hole on the second
stage carrier. Then, install the second stage
carrier assembly to the travel motor.
IMPORTANT: Apply THREEBOND #1215 to the

interference surfaces of drum (5)
and ring gear (28).
15. Secure ring gear (28) to drum (5) with socket bolts
(29) (12 used).
: 12 mm
: 177 N⋅m (18 kgf⋅m, 131 lbf⋅ft)
W3-2-11
DISASSEMBLE TRAVEL MOTOR
Parking Brake Release Oil Passage
1 2 3 4 5 6 7 8 9 10
11
12
13
14
15
16
17
26 25 24 23 22 21 20 19 18 W172-03-02-012
1- Spring Pin 8- Rotor 15 - Oil Seal 21 - O-ring

2- Bolt (6 Used) 9- Retainer 16 - Ball Bearing 22 - O-ring
3- Valve Plate 10 - Swash Plate 17 - Piston 23 - O-ring
4- O-ring 11 - Bushing 18 - Spring (6 Used) 24 - O-ring
5- Disc Spring 12 - Housing 19 - Friction Plate (3 Used) 25 - Roller Bearing
6- Brake Piston 13 - Ball (2 Used) 20 - Plate (4 Used) 26 - Brake Valve Assembly
7- Plunger Assembly (9 Used) 14 - Shaft
W3-2-12
Disassemble Travel Motor
5. Remove plates (20) (4 used) and friction plates
IMPORTANT: When removing brake valve (19) (3 used) from housing (12).
assembly (26) from the motor, valve
plate (3) and the outer race of roller 6. Remove swash plate (10) from housing (12).
bearing (25) may be removed with
the brake valve. Be sure not to allow 7. Remove balls (13) (2 used) and piston (17) with a
valve plate (3) and the outer race of magnet from housing (12).
roller bearing (25) to drop.
IMPORTANT: The open part of brake valve

assembly (26) is the surface to
prevent from the oil leaks when
releasing the parking brake. When
placing brake valve assembly (26)
with the open part downward, be
sure not to damage the surface.
26
W172-03-02-006
Surface
CAUTION: Travel motor weight: 40 kg

(88 lb).
1. Place the travel motor with brake valve assembly
(26) upward. Remove bolts (2) (6 used) to remove
the brake valve assembly from housing (12).
: 12 mm
2. Remove valve plate (3) from brake valve

assembly (26).
3. Remove disc spring (5), rotor (8), springs (18) (6

used), bushing (11), retainer (9), and plunger
assemblies (7) (9 used) from housing (12)
respectively.
IMPORTANT: When removing piston (6) using

compressed air, be sure to cover the
piston with cloths to prevent the
piston from flying out.
4. Supply compressed air 98 to 294 kPa (1 to 3
3
kgf/cm , 14 to 43 psi) into the parking brake
release oil passage so that brake piston (6) will
float up to be removed.
W3-2-13
12
14
15
16
25 W172-03-02-012
W3-2-14
CAUTION: Housing (12) weight: 21 kg (46 lb) CAUTION: When shaft (14) is removed from
8. Place housing (12) horizontally. Pull out shaft (14) the ball bearing (16), be sure to avoid
with bearing (16), tapping the inner circumference dropping it.
of spline side of shaft (14) attaching a bar with a
plastic hammer. IMPORTANT: If the shaft (14) drops off, the surface
9. Push oil seal (15) out of the hole on shaft (14) in of shaft (14) may be damaged.
the housing (12) with a flat-headed screwdriver. 11. Remove ball bearing (16) remained on shaft (14).
Balance the inner race of ball bearing on a vice.
NOTE: Since the outer circumference of the oil Using a bar and plastic hammer, tap the shaft
seal has been covered with adhesive, it slightly, to remove the roller bearing from the
can’t be used again. shaft.
CAUTION: When shaft (14) is removed from

the inner race of roller bearing (25), be sure to Bar
avoid dropping it.
16
IMPORTANT: If the shaft (14) drops off, the surface
of shaft (14) may be damaged. 14
IMPORTANT: Be sure not to damage the inner race

of roller bearing (25).
10. Remove the inner race of roller bearing (25)
remained on shaft (14). Balance the flange of the
inner race on a vice. Using a bar and plastic
hammer, tap the shaft slightly, to remove the inner W172-03-02-003
race from the shaft.
Bar
14
Inner Race
W172-03-02-002
W3-2-15
ASSEMBLE TRAVEL MOTOR
1 2 3 4 5 6 7 8 9 10
11
12
13
14
15
16
17
26 25 24 23 22 21 20 19 18 W172-03-02-012
1- Spring Pin 8- Rotor 15 - Oil Seal 21 - O-Ring

2- Bolt (6 Used) 9- Retainer 16 - Ball Bearing 22 - O-Ring
3- Valve Plate 10 - Swash Plate 17 - Piston 23 - O-Ring
4- O-Ring 11 - Bushing 18 - Spring (6 Used) 24 - O-Ring
5- Disc Spring 12 - Housing 19 - Friction Plate (3 Used) 25 - Roller Bearing
6- Brake Piston 13 - Ball (2 Used) 20 - Plate (4 Used) 26 - Brake Valve Assembly
7- Plunger Assembly (9 Used) 14 - Shaft
W3-2-16
Assemble Travel Motor
IMPORTANT: The lip mounting surface of oil seal
CAUTION: Housing (12) weight: 21 kg (15) is located on the mounting side
(46 lb) of ball bearing (16) in shaft (14). Be
sure not to damage it.
1. Place housing (12) with the brake valve assembly 3. Install ball bearing (16) to the inner spline side of
(26) mating surface facing upward. shaft (14).
IMPORTANT: Apply THREEBOND #1104 or #1215 NOTE: Attach the pipe fitting the outer diameter of
to the outer circumference of the oil the shaft onto the inner race of the bearing,
seal (15). tap them evenly.
IMPORTANT: Be sure to use the special tools to
avoid damaging oil seal (15). IMPORTANT: Be sure to use the special tool for
ST No. : 2891,2892 the inner race of roller bearing (25).
Ȁ ST No. : 2890
2. Clean the mounting parts of oil seal (15) in IMPORTANT: Install the inner race of roller bearing
housing (12), and apply the adhesive to the outer (25) with the flange downward.
circumference of the oil seal. Install the oil seal to
the housing with the special tools. 4. Install the inner race of roller bearing (25) into
After installing, apply the grease to the inner shaft (14) with the special tool.
circumference of the oil seal.
NOTE: Be sure to use OCEAN #7 as the grease.
2892 2890
Inner Race
2891
14
W172-03-02-005
12
W172-03-02-004
15
W3-2-17
7 8 9 10
11
12
13
14
17
26 25 18 W172-03-02-012
W3-2-18
IMPORTANT: Be sure to face the taper side on the
CAUTION: Housing weight: 21 kg (46 lb)
outer circumference of retainer (9)
onto the bushing.
5. Place housing (12) with the brake valve assembly
(26) mounting surface facing upward.
10. Install springs (18) (6 used), bushing (11), retainer
(9) and plunger assemblies (7) (9 used) into rotor
6. Install shaft (14)into housing (12)tapping shaft
(8) respectively.
(14) with a plastic hammer slightly. At this time, be
sure not to tap the inner race of roller bearing (25). 9
IMPORTANT: Insert piston (17) into the piston hole

with the shoulder side facing
downward.
7. Install piston (17) and balls (13) (2 used) into
housing (12). 11 W172-03-02-001
NOTE: At first apply the grease to ball (13) to
prevent it dropping down.
IMPORTANT: When installing rotor (8), take care
not to let spring (18) fall.
8. Install swash plate (10) into housing (12) aligning
the hollows (2 places) on the back side of the
11. Install the rotor installed at step 10 into shaft (14).
swash plate with ball (13).
9. Place housing (12) horizontally with the parking

brake release oil passage facing downward. Be
sure to align with the center of swash plate (10).
NOTE: If placing housing (12) with the parking

brake release oil passage facing upward, it
may not align with the center because the
thick part of swash plate (10) faces upward.
W3-2-19
4 5 6 8
12
17
26 25 24 23 22 21 20 19 W172-03-02-012
W3-2-20
IMPORTANT: Install disc spring (5) so that the
outer circumference of disc spring
(5) comes into contact with brake
12. Place housing (12) with the brake valve assembly
piston (6).
(26) mounting surface facing upward.
15. Install disc spring (5) into housing (12).
IMPORTANT: Install plates (20) (4 used) and
friction plates (19) (3 used)
16. Install o-rings (4) and (24) into housing (12).
alternately. Be sure to Install plate
(20) first.
17. Refill the hydraulic oil 0.5 L into housing (12).
13. Install plates (20) (4 used) into the groove of
18. Install o-ring (23) into brake valve assembly (26).
housing (12) and friction plates (19) (3 used) into
the groove of rotor (8) alternately.
IMPORTANT: Install the outer race of roller
bearing (25) with the stamped mark
IMPORTANT: Install brake piston (6) with the
facing upward.
notch (1 place) on brake piston (6)
facing the piston (17) operation oil
19. Install the outer race of roller bearing (25) into
passage side.
brake valve assembly (26).
IMPORTANT: Brake piston (6) keeps floating
because of the o-ring of the outer
circumference. Evenly push brake
piston (6) into housing (12) by hands.
Be sure never tap brake piston (6)
with a hammer forcedly.
14. Install o-ring (21) and (22) into brake piston (6).
Install it (6) into housing (12).
Piston Operation Oil Passage

6
Notch
17
W172-03-02-013
W3-2-21
1 2 3 6
12
26 W172-03-02-012
W3-2-22
IMPORTANT: Install valve plate (3) with the thrust
side in the brass facing upward.
IMPORTANT: Apply the grease to the back of valve

plate (3) to prevent it from dropping
down.
20. Install valve plate (3) onto brake valve assembly

(26), aligning spring pin (1) of brake valve
assembly (26) with the hole of valve plate (3).
IMPORTANT: Take care not to drop and damage

valve plate (3) when installing.
21. Install brake valve assembly (26) into housing (12)

aligning the hole for bolt (2).
As brake piston (6) is not completely pushed into
housing (12) , the clearance between the brake
valve assembly and the housing is approx. 10
mm. Install the brake valve assembly, pushing
brake piston (6) into, tightening bolts (2) (6 used)
evenly.
: 12 mm
: 140 N·m (14 kgf·m, 103 lbf⋅ft)
W3-2-23
DESASSEMBLE BRAKE VALVE
1 2 3 4 5 6 7 8 9 10
25 24 23 22 21 20 19 18 17 16 15 14 13 12 11
W172-03-02-014
1- Valve Casing 8- O-ring 15 - Plug 22 - O-ring ( 2 Used)

2- Spool 9- Adapter 16 - O-ring 23 - Piston (2 Used)
3- Stopper (2 Used) 10 - Spool 17 - Spring 24 - Spring (2 Used)
4- Spring (2 Used) 11 - Poppet 18 - Plug 25 - Seat Plug
5- O-ring (2 Used) 12 - Spring 19 - O-ring
6- Plug (2 Used) 13 - Plug 20 - Poppet (2 Used)
7- Spindle 14 - O-ring 21 - Relief valve cartridge (2
Used)
W3-2-24
Disassemble Brake Valve
IMPORTANT: If placing the brake valve with the

travel motor mounting surface
facing downward , be sure not to
damage the seat surface.
W172-03-02-006
Seat Surface
IMPORTANT: Do not disassemble relief valve

cartridge (21).
IMPORTANT: Do not pull out piston (23) on relief
valve cartridge (21), otherwise the
O-ring in the piston will be damaged
when the piston passes the
cartridge hole.
1. Remove relief valve cartridge (21) from valve

casing (1). Pull spring (24) and poppet (20) out of
the valve casing with a magnet.(2 places)
: 10 mm
IMPORTANT: After removing plug (18) , seat plug

(25) remains in the hole. Do not
remove seat plug (25) unless
necessary. The seat plug is fixed
with LOCTITE.
2. Remove plug (18) from valve casing (1).
: 6 mm
3. Remove plugs (6) (2 used) from valve casing (1).

Pull spring (4) (2 used) and stopper (3) (2 used)
out of the valve casing respectively.
: 30 mm
4. Pull spool (2) out of the hole removed at step 3.
5. Remove plug (13) from valve casing (1) to pull

spring (12) and poppet (11) out of the valve casing
respectively.
: 6 mm
W3-2-25
1 7 9 10
17 15
W172-03-02-014
W3-2-26
6. Remove plug (15) from valve casing (1) to pull
spring (17) and spindle (7) out of the valve casing
with a magnet respectively.
: 6 mm
NOTE: it is impossible to pull spool (10) in spindle

(7) to the direction of plug (15) . Remove
spool (10) at step 7.
7. Remove adapter (9) from valve casing (1) to pull

spool (10) out of the valve casing.
: 19 mm
W3-2-27
ASSEMBLE BRAKE VALVE
1 2 3 4 5 6 7 8 9 10
25 24 23 22 21 20 19 18 17 16 15 14 13 12 11
W172-03-02-014
1- Valve Casing 8- O-ring 15 - Plug 22 - O-ring ( 2 Used)

2- Spool 9- Adapter 16 - O-ring 23 - Piston (2 Used)
3- Stopper (2 Used) 10 - Spool 17 - Spring 24 - Spring (2 Used)
4- Spring (2 Used) 11 - Poppet 18 - Plug 25 - Seat Plug
5- O-ring (2 Used) 12 - Spring 19 - O-ring
6- Plug (2 Used) 13 - Plug 20 - Poppet (2 Used)
7- Spindle 14 - O-ring 21 - Relief valve cartridge (2
Used)
W3-2-28
Assemble Brake Valve
IMPORTANT: If placing the brake valve with the

travel motor mounting surface
facing downward , be sure not to
damage the seat surface.
W172-03-02-006
Seat Surface
IMPORTANT: Do not insert spool (10) from the

direction of plug (15).
IMPORTANT: Insert the smaller part of spool (10)
into valve casing (1) first.
1. Install spindle (7) into the end of spool (10) to

insert them into the adapter (9) side in valve
casing (1). Install o-ring (8) into the adapter to
install them into the valve casing.
: 19 mm
: 30 N·m(3.1 kgf·m, 22 lbf·ft)
2. Install o-ring (16) and spring (17) into plug (15) to

install them into valve casing (1).
: 6 mm
: 35 N·m(3.6 kgf·m, 26 lbf·ft)
3. Install o-ring(14) into plug (13). Install poppet (11) ,

spring(12) , and plug (13) into valve casing (1).
: 6 mm
: 35 N·m(3.6 kgf·m, 26 lbf·ft)
4. Insert spool(2) nearby the center of valve casing

(1)
5. Install o-ring (5) (2 used), spring (4) (2 used), and

stopper (3) (2 used) into plug (6) (2 used) to install
the plug into valve casing (1).
: 30 mm
: 270 N·m(27.5 kgf·m, 200 lbf·ft)
6. Install o-ring (19) into plug (18) to install them into

valve casing (1).
: 6 mm
: 35 N·m(3.6 kgf·m, 26 lbf·ft)
W3-2-29
24 22 21 20
W172-03-02-014
W3-2-30
7. Install o-ring (22) into relief valve cartridge (21).
Install spring (24) into poppet (20).
Insert the poppet into the relief valve cartridge (21)
and mounting hole on valve casing (1) (2 places).
: 10 mm
: 120 N·m(12 kgf·m, 89 lbf·ft)
NOTE: When inserting the poppet with relief valve

cartridge (21), on the way spring (24) may
come off.
W3-2-31
Sprocket
C B
D
A
W1SE-03-02-001 W105-03-07-040
Unit: mm (in)
Standard Allowable Limit Remedy
A 38.00(1.50) (28.00)(1.10)
B 92.70(3.65) 87.70(3.45)
Cladding by
C 120.80(4.76) 115.80(4.56) welding and
finishing
C’ PCD115.25(4.54) -
D 154.0(6.06) -
NOTE: The value in the parenthesis is the
reference valve.
W3-2-32
Shoe
Travel Motor
1. End play between plunger and shoe.

Standard Allowable Limit
0 0.2 mm (0.0079 in)
̘
̘≤0.2 mm (0.0079 in) Plunger
W105-02-06-130
2. The clearance between plunger and rotor bore.
Standad Allowable Limit
0 0.04 mm (0.0016 in) D
Dҥd≤0.04 mm (0.0016 in) Rotor
W105-02-06-134
Plunger Assembly
d Rotor
W105-02-06-135
3. Shoe thickness
Standard Allowable Limit
Shoe
4.5 mm (0.18 in) 4.3 mm (0.17 in)
Plunger
W105-02-06-130
W3-2-33
Parking Brake
C W1CD-03-02-001
Part Name Overall height Allowable Limit Remedy

A Plate Thickness 1.4(0.0551) 1.35(0.053)
B Disc spring ϑOverall heightϒ 5.2(0.205) 5.1(0.201)
C Brake piston Thickness 36(1.42) −
D Friction plate Thickness 2.4(0.0945) 2.35(0.0925)
No wearing on the brake piston because it does not slide.
Remarks
NOTE: The brake piston thickness is shown as the

distance from the contact point of the disc
spring to the contact point of the plate.
W3-2-34
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT

repair work.
Preparation
Ȁ
M1CC-07-002
remaining pressure.
Ȁ
W3-3-1
Removal
1. Attach tags to all hoses connected to the center

joint to aid reassembly. Disconnect all hoses from
the center joint. Cap all the disconnected hose
ends.
: 17 mm
: 25 N⋅m (2.6 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 30 N⋅m (3.1 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
2. Remove bolts (1) (2 used) to remove lock plate

(2) from the center joint
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
CAUTION: Center joint weight: 19 kg (42 lb)

3. Remove bolts (3) (3 used) to hoist and remove the 1
center joint by crane.
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 2
Installation Machine Front
NOTE: As for wrench size and tightening torque,

refer to the above removal W102-03-03-001
. 3
1. Secure the center joint with bolts (3) (3 used).
2. Install lock plate (2) to the center joint with bolts

(1) (2 used).
3. Reconnect all hoses to the center joint
IMPORTANT: After installation, start the engine

and check for oil leaks
Machine Front W190-03-03-001
W3-3-2
(Blank)
W3-3-3
DISASSEMBLE CENTER JOINT
1
7
3
10
11
12
W196-03-03-001
1 - Plug 4 - O-Ring 7 - Body 10 - Retaining Ring

2 - Spindle 5 - Bushing 8 - Ring 11 - Cover
3 - Dust Seal 6 - Oil Seal (8 Used) 9 - O-Ring 12 - Bolt (4 Used)
W3-3-4
Disassemble Center Joint
• Be sure to read “Precautions for Disassembly and IMPORTANT: Take care not to damage the sliding
Assembly” thoroughly on page W1-1-1 before surface of the spindle (2) seal.
starting the disassembly work. 5. Screw ST 1020 to remove spindle (2) from body
(7).
CAUTION: Center joint weight: 19kg (42 lb)
IMPORTANT: For easy removal, two pins can be
used to pry out oil seals (6). Take
IMPORTANT: Take care not to damage the end of
care not to damage the seal groove
spindle (2) when setting it onto a
with the pins.
work bench.
1. Remove mounting bolts (12) (2 used) from cover
(11) diagonally. Install eyebolt (M10, pitch 1.5,
length 18 mm (0.7 in) to the bolt holes (2 places).
Hoist the center joint and set it onto a work bench.
: 17 mm
IMPORTANT: Put a matching mark on body (7) and

spindle (2).
2. Remove bolts (12) (2 used) and eyebolts to re-
move cover (11) from body (7).
: 17 mm
3. Remove O-ring (9), retaining ring (10) and ring (8)

W105-03-03-015
from body (7).
6. Remove oil seals (6) (8 used), dust seal (3) and
4. Attach the special tools (ST 1033, ST1020) to
O-ring (4) from body (7).
body (7) with mounting bolts (12) (2 used) on
cover (11).
: 17 mm
IMPORTANT: While welding, be sure to cover the
ST 1020 seal surface to prevent it from being
spattered.
ST 1033 7. When replacing bushing (5), build-up weld at 4
places in its inner diameter with welding rod,
12 shrink bushing (5) to pull it out.
W506-03-03-002
W3-3-5
ASSEMBLE CENTER JOINT
8
10
9
11
12
W196-03-03-002
1 - Plug 4 - O-Ring 7 - Body 10 - Retaining Ring

2 - Spindle 5 - Bushing 8 - Ring 11 - Cover
3 - Dust Seal 6 - Oil Seal (8 Used) 9 - O-Ring 12 - Bolt (4 Used)
W3-3-6
Assemble Center Joint
IMPORTANT: If bushing is removed, be sure to IMPORTANT: Be sure to install ring (8) with the
reinstall bushing (5) first. Refer to chamfered side facing the spindle.
page W3-3-8. 5. Install ring (8) and O-ring (9) to body (7).
1. Install O-ring (4) and dust seal (3) into body (7). 6. Install retaining ring (10) to spindle (2).
2. Install oil seals (6) (8 used) into body (7). 7. Install cover (11) to body (7) with bolts (12) (4
used).
IMPORTANT: Just before inserting spindle, apply : 17 mm
molybdenum disulfide to bushing (5) : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
and coat the seal portion with grease.
Do not damage them when install-
ing.
3. Secure spindle (2) to a work bench. Mount body
(7) on spindle (2) with their matching mark aligned,
which is put before disassembling.
IMPORTANT: Clearance between body (7) and

spindle (2) is approximately 0.1 mm
(0.004 in), so spindle (2) must be in-
serted along axis straight and
slowly.
IMPORTANT: Install the ring (8) installing portion
(A) flat and even leaving no height
difference between the body, the
ring and the spindle.
0.1 mm
A
W105-03-03-024
4. Tap body (7) with a plastic hammer to install the

body to spindle (2) to make the portion A flat and
even.
W3-3-7
When replacing the body or spindle with new one, the
following procedures are required.
ST 2770
Replacing Body (7)

7
Press bushing (5) into body (7).
1. Clean body (7) and bushing (5). 5
2. Press bushing (5) into body (7), using the press-

ing tool.
Ȁ Pressing force: 4.9 to 14.7 kN
(0.5 to 1.5 t, 1100 to 3300 lbf)
Ȁ Pressing tool: ST 2770
1 W105-03-03-029
Replacing Spindle (2)
1. Clean spindle (2). 2

Sleeve
0.4 mm
2. Tap plugs (1) into spindle (2) using special tools or More
(ST 2559).
3. Drive the balls of plug (1) so that the top of each

ball is 0.4 mm (0.016 in) or more lower than the
respective sleeve edge, as illustrated in Detail D.
Ȁ Special tool: ST 2559
Detail D
W135-03-03-001
W136-03-03-031
ST 2559
Ball
W157-03-03-004
W3-3-8
Item Allowable limit (basis for judgment) Remedy

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

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

tracks and the front idler must be removed first. For
removal of the tracks and the front idler, refer to their
Removal / Installation sections.
In this section, the procedure starts on the premise that
the tracks and the front idler have already been re-
moved.
Removal
CAUTION: Track adjuster weight: 31 kg
(68 lb) 2
1
CAUTION: Track adjuster (1) may jump out of

position due to strong spring
force when track adjuster (1) is
removed. Especially, a strong
spring force is always applied to
the threaded part of rod. If the rod
W157-03-04-003
and/or the threads are damaged,
metal fragments may fly off when
track adjuster (1) is removed. Take
necessary precautions to prevent
any personal injury from occur-
ring.
1. Remove track adjuster (1) from track frame (2) by

prying it out with a pry bar.
Installation
IMPORTANT: Check that the end face of track ad-

juster (1) comes into contact with
the face of plate (4).
1. As illustrated, install track adjuster (1) into spring
guide (3) on track frame (2). A
2 3
3 4
W157-03-04-001
View A W157-03-04-002
W3-4-1
DISASSEMBLE TRACK ADJUSTER
7
6
4 8
3
2 9
10
14
11
W1CC-03-04-001
12
13
1- Cylinder 5- Piston Rod 9 - Socket Bolt (4 Used) 12 - Nut

2- Retaining Ring 6- Flange 10 - Spring 13 - Valve
3- U-Ring 7- Dust Seal 11 - Washer 14 - Plug
4- Wear Ring 8- Holder
W3-4-2
Disassemble Track Adjuster
(68 lb)
starting any repair work.
3. Remove holder (8) from the track adjuster.
Attach the wire rope to the track adjuster. Hoist
Be sure to use special tool (ST 4920) for assem-
the track adjuster by crane and put the track ad-
bly / disassembly of the track adjuster.
juster on special tool.
CAUTION: The spring force is extremely

large, so disassembly and assembly work
must be carried out carefully. It is necessary Track Adjuster
to inspect the special tool for any damage
thoroughly to ensure safety.
CAUTION: Special tool weight: 225 kg

(500 lb)
1. Place an oil jack (30 ton) between the cradle and
the base of special tool (ST 4920). Special tool
Nut
W105-03-04-009
Cradle
Oil Jack
Base
W105-03-04-006
CAUTION: Plate (ST 4036) weight: 34 kg

(75 lb)
2. Loosen nuts (4 used) to remove plate (ST 4036).
: 46 mm
Plate (ST 4036)
W105-03-04-007
W3-4-3
14
11
W1CC-03-04-001
12
13
W3-4-4
CAUTION: Plate (ST 4036) weight: 34 kg

(75 lb)
4. Install plate (ST 4036) onto special tool (ST 4920) 6. Tighten the nuts onto plate (ST 4036) to secure
so that plate (ST 4036) overlies the track adjuster. the track adjuster.
Operate the oil jack to compress the track ad-
juster approximately 10 mm (0.4 in) until a clear-
ance is observed between washer (11) and nut
Plate (ST 4036)
(12).
: 46 mm
Track Adjuster Nut
Plate
ST 4920
(ST 4036)
W105-03-04-01
5. Operate the oil jack to jack up the cradle by the

specified amount 60 mm (2.4 in).
W105-03-04-012
60 mm= (Free length: 327 mm) - (Set length: 267

mm) 7. Remove plug (14) from nut (12) to remove the nut
and valve (13) from cylinder (1).
Cradle : 5 mm
: 60 mm
Oil Jack
12 1 14
W105-03-04-013
W105-03-04-014
W3-4-5
7
6
4
3
2 9
10
11
W1CC-03-04-001
W3-4-6
CAUTION: Plate (ST 4036) weight: 34 kg 10. Remove spring (10) from cylinder (1).
(75 lb)
When removing the nut and plate (ST 4036), 11. Remove socket bolts (9) (4 used) from cylinder (1)
be sure to remove it after loosening the oil to remove flange (6) and dust seal (7).
jack. Not loosening the oil jack poses a dan- : 6 mm
ger of washer (11) and spring (10) flying off
under the reaction of the spring. 12. Remove piston rod (5) from cylinder (1).
8. Lower the oil jack to release the spring force.
Loosen the nuts to remove plate (ST 4036). 13. Remove retaining ring (2), U-ring (3) and wear
Remove washer (11) from cylinder (1). ring (4) from piston rod (5).
Plate (ST4036)
11
10
W105-03-04-016
CAUTION: Spring assembly weight:

28 kg (62 lb)
9. Remove the spring (10) assembly from the spe-

cial tool.
10
W105-03-04-017
W3-4-7
ASSEMBLE TRACK ADJUSTER
13 14 12 11 10 2 3 4 1 6 9 7 5 8
B A W152-03-04-002
1- Cylinder 5- Piston Rod 9 - Socket Bolt (4 Used) 12 - Nut

2- Retaining Ring 6- Flange 10 - Spring 13 - Valve
3- U-Ring 7- Dust Seal 11 - Washer 14 - Plug
4- Wear Ring 8- Holder
W3-4-8
Assemble Track Adjuster
IMPORTANT: Install U-ring (3) with the lip facing

retaining ring (2).
Apply the hydraulic oil to wear ring
(4) and the U-ring.
1. Install wear ring (4), U-ring (3) and retaining ring
(2) onto piston rod (5).
IMPORTANT: Fill chamber (B) in cylinder (1) with

grease. Insert piston rod (5) into the
cylinder to completely bleed air re-
maining in the cylinder.
Smear hydraulic oil to the cylinder
and the piston rod.
2. Insert the piston rod (5) assembly into cylinder (1).
IMPORTANT: Fill groove (A) on flange (6) with the

grease.
3. Install dust seal (7) into flange (6). Secure the
flange assembly to cylinder (1) with socket bolts
(9) (4 used).
: 6 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
CAUTION: Spring assembly weight: 28 kg

(62 lb)
4. Install spring (10) onto cylinder (1). Install eyebolt
(M16, pitch 1.5) to the cylinder. Hoist the spring
assembly by crane. Then set them on special tool
(ST 4920).
ST 4920
10
W105-03-04-017
W3-4-9
Ȁ
13 14 12 11 10 1
W152-03-04-002
W3-4-10
CAUTION: Plate (ST 4036) weight: 34 kg CAUTION: Plate (ST 4036) weight
(75 lb) : 34 kg (75 lb)
5. Install washer (11) onto cylinder (1). Install plate
(ST 4036) onto the spring. 8. Lower the oil jack to remove the nuts and plate
: 46 mm (ST 4036).
: 46 mm
Plate
(ST 4036)
Plate (ST 4036)
Nut
ST 4920
W105-03-04-012
6. Operate the oil jack to compress spring (10) until

the specified length (267 mm) (10.5 in) is ob-
tained.
W105-03-04-011
10
Oil Jack
W105-03-04-026
7. Install nut (12) and valve (13) to cylinder (1). In-

stall plug (14) to the nut.
: 60 mm
: 5 mm
: 14.5 N⋅m (1.5 kgf⋅m, 10.5 lbf⋅ft)
12 1 14
W105-03-04-014
W3-4-11

(68 lb)
9. Attach the wire rope to the track adjuster. Hoist
the track adjuster by crane and remove them from
the special tool.
Track Adjuster
Special Tool
W105-03-04-027
CAUTION: Special tool (ST 4930) weight

: 64 kg (141 lb)
IMPORTANT: If only the track adjuster is to be
transported, be sure to use special
tool (ST 4930) to avoid personal in-
jury.
: 24 mm
Track Adjuster
W105-03-04-028
Special Tool
(ST 4930)
W3-4-12
UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER
Before removing the front idler, the tracks must be re-

moved first. For removal of the tracks, refer to
“Remove and Install Tracks” section.
In this section, the procedure starts on the premise that
the tracks has already been removed.
Removal
CAUTION: Front idler weight: 52 kg (115 lb) W110-03-05-001

The front idler may fly out due to the strong
spring force from the track adjuster spring
when removing it. Give yourself ample clear-
ance, staying clear of the front idler’s line.
3
1. Pry the front idler with a pry bar to move it out of
track frame (3).
2. Attach the wire rope to the bearing (1) portion and

the yoke (2) portion as illustrated and remove the
front idler assembly from track frame (3).
1 2
3. If it is necessary to retain the front idler for a time,
be sure to place it on wooden blocks as shown to W110-03-05-002
keep it stable.
Wooden
Block
Installation
1. Install the front idler according to the reversed

procedures of removal and pay attention to the
following precautions when installation is carried
out.
W105-03-05-003
• Clean track frame (3) and the sliding surface of
bearing (1) and apply the grease to them.
W157-03-05-002
W3-5-1
DISASSEMBLE FRONT IDLER
3
2
4
5
8 7
5
4
3
2
10
9
W1CC-03-05-001
1 - Plug (2 Used) 4 - Floating Seal (2 Used) 7 - Bushing (2 Used) 9 - Socket Bolt (4 Used)
2 - Bearing (2 Used) 5 - O-Ring (2 Used) 8 - Idler 10 - Yoke
3 - Pin (2 Used) 6 - Axle
W3-5-2
Disassemble Front Idler
• Be sure to read “Precautions for Disassembly and 5. Remove pin (3) from other side bearing (2) and
Assembly” thoroughly on page W1-1-1 before remove axle (6) with a press.
1. Remove socket bolts (9) (4 used) to remove yoke

3 2
(10). Remove plugs (1) (2 used) to drain engine
oil in bearing (2).
: 12 mm
2. Remove pin (3) from bearing (2) at one side.
3. Push axle (6)out of bearing (2) with a press. 6
2 6
W105-233-05-010
6. Remove O-rings (5) (2 used) from axle (6).
IMPORTANT: Do not remove bushings (7) (2 used)

W105-03-05-008 unless necessary.
7. When replacing bushing (7), build-up weld at 4
IMPORTANT: For handling of floating seal (4), re- places in its inner diameter with welding rod,
fer to the section “Floating Seal Pre- shrink bushing (7) to pull it out.
cautions” on page W1-1-4.
4. Remove floating seals (4) (2 used) from right and
90°
left bearings (2) and idler (8).
2
90°
4
8
W105-03-05-012
5
6
W105-03-05-009
W3-5-3
ASSEMBLE FRONT IDLER
2 3 4 6 8 7 5 1 9 10
W152-03-05-001
1 - Plug (2 Used) 4 - Floating Seal (2 Used) 7 - Bushing (2 Used) 9 - Socket Bolt (4 Used)
2 - Bearing (2 Used) 5 - O-Ring (2 Used) 8 - Idler 10 - Yoke
3 - Pin (2 Used) 6 - Axle
W3-5-4
Assemble Front Idler
• Be sure to read “Precautions for Disassembly and 4. Install the other pair of floating seal (4) into idler
Assembly” thoroughly on page W1-1-1 before (8) and bearing (2). Install O-ring (5) to axle (6).
starting any repair work. Aligning the pin holes, install bearing (2) onto axle
(6). Then tap pin (3) into the bearing.
1. Install bushings (7) (2 used) into idler (8) with a
press.
8
IMPORTANT: When installing bearing (2) onto axle 2 4 5
(6), take care not to damage O-ring 2
(5).
2. Install O-ring (5) to axle (6). Aligning the pin holes,
install bearing (2) onto axle (6). Then, tap pin (3)
into the bearing.
6
3
W157-03-05-005
6 2
5. Fill engine oil (SAE #30, API Class CD)140 mL via

the plug (1) hole of bearing (2). Install plugs (1) (2
used) to the bearing.
: 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
5 W105-03-05-014
6. Secure yoke (10) to bearings (2) (2 used) with

IMPORTANT: For handling of floating seal (4), re- socket bolts (9) (4 used).
fer to the section “Floating Seal Pre- : 12 mm
cautions” on page W1-1-4. : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
3. Install one pair of floating seal (4) into idler (8) and
bearing (2). Press axle (6) into idler (8) from the
side installing with the floating seal.
8 4 2
W157-03-05-006
W3-5-5
C D
A
B
W157-03-05-001
Unit: mm (in)
A 43 (1.7) [33.4 (1.3)]
B 100 (3.9) −
Build-up weld
C 390 (15.4) 378 (14.9)
and finishing
D 434 (17.1) −
E 22 (0.9) 28.0 (1.1)
Axle and Bushing Unit: mm (in)
Axle Outside Dia. 55 (2.2) [54.2 (2.1)]
Inside Dia. 55 (2.2) [56.0 (2.2)] Replace

Bushing
Flange Thickness 2 (0.08) [1.2 (0.05)]
NOTE: Values in [ ] are just for reference.
W3-5-6
UNDERCARRIAGE / Upper And Lower Roller
REMOVE AND INSTALL UPPER ROLLER
Removal
CAUTION: The track adjuster is under high

pressure. Do not loosen valve (1) quickly or
loosen it too much as high pressure grease in
the adjusting cylinder may spurt. Do not
loosen it over 1.5 turns.
Loosen carefully, keeping body parts and
face away from the valve. Never loosen
grease fitting (2).
W105-03-06-001
1. Gradually loosen valve (1) to drain the grease. 1
NOTE: It’s enough to turn valve (1) by only one
turn.
: 24 mm
Grease Outlet
IMPORTANT: Use a nonskid cloth between track W1CD-03-06-002

frame (5) and the oil jack to prevent
slipping.
Oil Jack Wooden Block 3
2. Jack up tracks (3) high enough to permit upper
roller (4) removal. Insert wooden blocks between
the track and track frame (5). 4
Nonskid
Cloth
5
3. Remove bolts (6) to remove upper roller (4) from
track frame (5). W105-03-06-003
: 22 mm
4 M152-07-046
5
W3-6-1
Installation
IMPORTANT: There is a mark I (punched) on the

axle of upper roller (4). Install the
upper roller onto the track frame with
the mark facing upward.
Ι
Up 6
1. Secure upper roller (4) onto track (5) with bolts

(6). 4 M152-07-046
: 22 mm 5
: 140 N⋅m (14 kgf⋅m, 103 Ibf⋅ft)
Oil Jack Wooden Block 3
2. Remove the wooden block and the oil jack.
W105-03-06-003
3. Tighten track adjuster valve (1). Jack up tracks (3)

being adjusted for its sag. Then turn the track
slightly towards the reversed direction. Supply the
grease via grease fitting (2) to adjust the track
tension.
Track sag specifications (A): 210 to 235 mm 2

(8.3 to 9.3 in)
Grease Outlet
: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft) W1CD-03-06-002
W157-03-06-002
W3-6-2
4. Add engine oil via plug (8) hole on cover (7).

Tighten plug (8).
Engine oil: API CD class, SAE 30
Quantity: 35 ml 7
: 5 mm
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
Apply LOCTITE # 503 or equivalent to plug. 8
NOTE: Do not disassemble the upper roller. Re-

place it as an assembly.
W158-03-06-001
W3-6-3
REMOVE AND INSTALL LOWER ROLLER
Removal
90°ϡ110°
CAUTION: Securely support the raised ma-
chine with wooden blocks.
1. Loosen bolts (1). Raise one side of the track
frame high enough to remove the lower roller.
: 22 mm
M1CC-07-014

loosen it too much as valve (2) may fly off M102-07-063
and/or high pressure grease in the track ad-
juster cylinder may spurt. Do not loosen it
over 1.5 turns. Loosen carefully, keeping
body parts and face away from valve (2).
Never loosen grease fitting (3).
2. Gradually loosen track adjuster valve (2). Drain

the grease until the clearance between the track
frame bottom face and the track link stretches
enough to remove the lower roller.
It’s enough to turn the valve by only one turn.
W105-03-06-001
: 24 mm
3. Remove bolts (1) to remove the lower roller.

2
: 22 mm
W1CD-03-06-002
W3-6-4
Installation
1. Place the lower roller on the track link so that the

roller mounting bolt holes on the collar align with
those on the track frame.
Lower the track frame until the clearance between
the track frame and the lower roller is very close.
W105-03-06-012
2. Install the lower roller to the track frame with bolts

(1). 1
: 22 mm
: 245 N⋅m (25 kgf⋅m, 180 Ibf⋅ft)
M102-07-063
3. Tighten track adjuster valve (2). Jack up the track

being adjusted for its sag. Then turn the track
slightly towards the reversed direction. Supply the 2
grease via grease fitting (3) to adjust the track
tension.
Track sag specifications (A): 210 to 235 mm

(8.3 to 9.3 in)
: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf f⋅ft)
3
W1CD-03-06-002
W157-03-06-002
W3-6-5
DISASSEMBLE AND ASSEMBLE LOWER
ROLLER
1 2 3 4 5 6 7 8 9
W1CD-03-06-001
1 - Collar 4 - Axle 6 - O-Ring 8 - Collar

2 - Floating Seal (2 Used) 5 - Bushing (2 Used) 7 - Pin 9 - Plug
3 - Roller
W3-6-6
Disassemble Lower Roller Assemble Lower Roller
• Be sure to read “Precautions for Disassembly and IMPORTANT: Apply the grease to O-ring (6).
Assembly” thoroughly on page W1-1-1 before 1. Install O-ring (6) (1 used) to axle (4).
staring any repair work.
IMPORTANT: For handling of floating seal (2), re-
1. Remove plug (9) from collar (8) to drain engine oil fer to the section “Precautions for
from the roller. Floating Seal Handling “ on page
: 5 mm W1-1-4.
2. Install floating seal (2) to collar (1), (8), and both
2. Remove pin (7) from collar (8). Pull axle (4) out of sides of roller (3). Press axle (4) with collar (1) into
the collar (8) side in roller (3) with a press. At this roller (3).
time collar (1) at the opposite side is removed with
axle (4). NOTE: When disassembling, O-ring may be dam-
aged. Replace it with the new one.
NOTE: Axle (4) and collar (1) are unable to be dis-
assembled. 3. Install O-ring (6) to axle (4).
Aligning the pin holes, install collar (8) onto axle
IMPORTANT: For handling of floating seal (2), re- (4). Then install pin (7) into collar (8).
fer to the section “Precautions for
Floating Seal Handling “ on page IMPORTANT: Apply LOCTITE #503 onto plug (9).
W1-1-4. 4. Refill engine oil (SAE #30, API class CD) through
the plug hole on collar (8). Install plug (9) to the
3. Remove floating seal (2) from both sides of roller collar.
(3), collars (1) and (8). : 5 mm
: 14.5±1.5 N⋅m
4. Remove O-ring (6) from axle (4). (1.5±0.15 kgf⋅m, 10.5±1.1 lbf⋅ft)
IMPORTANT: Do not remove bushings (5) from

roller (3). In case the bushing must
be replaced, replace the roller (3) as-
sembly.
W3-6-7
Upper Roller
W110-03-06-009
Unitϖmm (in)
A 43 (1.7) -
B 90 (3.5) - Replace
C 86 (3.4) 76 (3.0)
W3-6-8
Lower Roller
W102-03-06-006
Unitϖmm (in)

A 45 (1.8) -
Cladding by welding and
B 143 (5.6) -
finishing or replace
C 110 (4.3) 92 (3.6)
Axle and Bushing Unitϖmm (in)

Axle Outer Dia. 40 (1.6) [39.2 (1.5)]
Inner Dia. 40 (1.6) [41.0 (1.6)]
Replace
Bushing Flange 2 (0.08) [1.2 (0.05)]
Thickness
W3-6-9
(Blank)
W3-6-10
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACKS
Removal

loosen too much since high pressure grease
in the adjusting cylinder may spurt. Do not
loosen it over 1.5 turns.
Loosen carefully, keeping body parts and
face away from valve (1). Never loosen
grease fitting (2).
W105-03-07-001
1. Gradually loosen valve (1) in the track adjuster to

1
drain the grease.
: 24 mm
NOTE: It’ s enough to turn valve (1) by only one
turn.
CAUTION: Secure the raised machine with

blocks or similar item.
2. Jack up the loosened side track. Rotate the track
W105-03-07-002
in the forward direction so that master pin (3) is
positioned over front idler (4). 1
3. Lower the track.
4. Put a wooden block under track shoes (5) as

shown.
Grease Outlet
W1CD-03-06-002
5 4
W105-03-07-006
Wooden Block
W3-7-1
CAUTION: The front idler may jump out of

position due to strong spring force when the
tracks is disconnected.
Especially, the strong spring force is always
applied to the thread portion of the rod. If the
rod and/or the thread are damaged, metal
fragments may fly off when the tracks is dis-
connected. Take necessary precautions to
prevent any personal injury from occurring.
5. Remove retaining ring (6), which is used to pre-

vent master pin (3) from coming off.
NOTE: If retaining ring (6) interferes with master W105-03-07-005
link (7), push in master pin (3) to make a 7

clearance between the retaining ring and
master pin (3) before attempting to remove
the retaining ring. 3
W105-03-07-009
Corner
Direction
IMPORTANT: The removing direction is as illu- Direction for for Install-
Removing the ing the
strated. Be sure to strike master pin Master Pin Master Pin
(3) in correctly.
6. Remove master pin (3) using special tool (ST
1970).
Retaining Ring
Track Link 3
Master Link
W105-03-07-010
ST 1970
W105-03-07-008
W3-7-2
CAUTION: Secure the raised machine with

blocks or similar item.
7. Rotate the upperstructure 90° degrees toward the
side of the track to be removed, perpendicular to
90ϡ110ѯ
the tracks. Operate the boom and arm so that the
angle between them is 90 to 110°. Lower the
boom with the bucket rolled-in to jack up the
machine as illustrated.
M1CC-07-014
8. Slowly drive the machine in reverse until the
whole length of the track being removed comes
on the ground.
W105-03-07-011
W3-7-3
Installation
1. Jack up the machine. Put the track under the

lower roller so that the sprocket teeth mesh with
the end of the track. Be sure to position the track Idler Side Sprocket Side
in correct direction as illustrated.
W105-03-07-013
2. Hoist the track by crane and place it on sprocket

(8).
8
W105-03-07-014
9
3. With the machine jacked up, operate the travel
lever for the track being wound in forward direc-
tion slowly. Turn travel device (9) while installing
the track.
W105-03-07-015
4. Turn the sprocket until the end of track (5) comes

on front idler (4). Lower the machine and place a
wooden block as illustrated.
W105-03-07-016
Wooden Block
W3-7-4
IMPORTANT: Install master pin (3) in the correct Corner
direction as illustrated below. Install the
5. Install master pin (3) using a hammer and special Remove the Master
Pin in This
tool (ST 1970). Master Pin in
Direction
This Direction
Retaining
Track Link 3 Master Link Ring
W105-03-07-010
ST 1970
W105-03-07-017
IMPORTANT: Old retaining ring (6) can not be re-
used as it is easily deformed. Re-
7
place it with a new one.
6. Install retaining ring (6).
NOTE: Retaining ring (6) has directivity. Install re-
taining ring (6) into the master link (7) 6
groove with the flat side of the hole to insert
puller facing outward.
IMPORTANT: If any links have been removed from

the track, be sure to fill the grease W105-03-07-009
(Daphne Epones SR or equivalent)
into the clearance between the pin Bushing Seal
and bushing when reconnecting the
links. Stand the bushing on flat plate. Pin
Fill the bushing bore with the grease.
Insert the pin into the bushing while
pushing the bushing onto the plate
so that the bushing end stays on the
plate. Wipe off excess grease.
Install the seal in the correct direc-
tion as illustrated.
Apply
Do not Apply Grease Do not Apply
Grease. Grease.
Seal W197-03-07-001
W3-7-5
7. Tighten valve (1) of the track adjuster. Jack up the
track being adjusted for its sag. Then turn the
track slightly towards the reversed direction. Apply 1
the grease to the cylinder through grease fitting
(2) to adjust the track tension.
: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
Track sag specifications: 210 to 235 mm (8.3 to

9.3 in)
2
Grease Outlet
W1CD-03-06-002
W105-03-07-018
W157-03-06-002
W3-7-6
Link
Measure the length of four links.
• The work shall be done with the tension on the
track.
• The part being measured shouldn’t include the
master pin.
A
W155-03-07-001
Unit: mm (in)
A 617 (24.5) 634.1 (25.0) Cladding by welding

B 74 (2.9) 69 (2.7) and finishing or replace
Grouser Shoe
W105-03-07-024
Unit: mm (in)
Shoe Width 450 mm (17.72) Grouser Shoe
A 165 (6.5) −
Cladding by welding or
B 6 (0.24) −
replace
C 20 (0.79) 14 (0.55)
W3-7-7
Master Bushing
W105-03-07-023
Unit: mm (in)
A 74.7 (2.9) −
B 24.5 (0.96) [27.5 (1.1)] Replace
C 41.26 (1.6) [37.76 (1.5)]
Master Pin
W105-03-07-021
Unit: mm (in)
A 123.5 (4.9) −
Replace
B 24.2 (0.95) [21.2 (0.83)]
W3-7-8
Pin
W142-03-07-004
Unit: mm (in)
A 131 (5.2) −
Replace
B 24 (0.94) [21 (0.83)]
Bushing
W105-03-07-023
Unit: mm (in)
A 81 (3.2) −
B 24.5 (0.97) [25.5 (1.0)] Replace
C 41.26 (1.6) 37.76 (1.5)
W3-7-9
(Blank)
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
Maintenance Standard ...................... W4-1-6
Standard Dimensions for
Arm and Bucket Connection ............ W4-1-9
Group 2 Cylinder
Remove and Install Cylinder .............. W4-2-1
Disassemble Cylinder...................... W4-2-16
Assemble Cylinder .......................... W4-2-24
Maintenance Standard ..................... W4-2-36
1CDW-4-1
(Blank)
1CDW-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT ATTACH-
MENT

sure to wait for oil to cool before starting any W554-04-02-006
repair work. Front

The hydraulic oil tank cap may fly off due to Overload Relief
remaining pressure if removed quickly. Valve Blade
Rod
Preparation Overload
Overload Relief
Relief Valve
1. Park the machine on a solid level surface.ӸFully Arm Rod
Valve Boom
Bottom
retract the arm and bucket cylinder and lower the
front attachment onto the ground.

hydraulic oil tank to release any pressure
remaining in the hydraulic oil tank.
Overload Relief
CAUTION: The overload relief valve may Valve Bucket
spurt the hydraulic oil if loosened more than Bottm
3/4 turns. Never loosen the valve further. W1CD-02-05-004
IMPORTANT: Be sure to loosen overload relief
valve body. Back
If the lock nut or adjusting screw is
loosened, pressure setting will
change. Never attempt to loosen Overload Relief
Valve Blade
them. Bottom
3. Put matching marks on the overload relief valve
Overload Relief
and the control valve. Gradually loosen the Valve Arm
overload relief valve to relieve any pressure Overload Relief
Bottom
Valve Boom
remaining in the circuit. Rod
: 24 mm
: 49 to 54 N⋅m
(5 to 5.5 kgf⋅m, 36 to 40 Ibf⋅ft) Overload Relief
Valve Bucket
4. Remove the hydraulic oil tank cap. Connect a Rod
tank. W1CD-02-05-005
NOTE: Run the vacuum pump continuously while

Lock Nut
Adjusting
Screw
T152-05-04-003
W4-1-1
Removal
1. Remove nuts (3) (2 used) and bolt (5) from

stopper (4) in boom cylinder rod end pin (1).
: 24mm 1
4
3
CAUTION: Boom cylinder weight: 90 kg (200 Ib)

Prevent personal injury. Metal W1CD-04-01-001
debris may fly off when a hammer

is used to remove pins. Be sure to
wear necessary protection, such
as goggles, a hard hat, etc.
2. Hoist the boom cylinder tube end by crane. Drive
pin (1) out with a bar and a hammer until thrust
plates (2) is removed. Remove thrust plates (2).
W102-04-01-011
3я
я5
NOTE: When pin (1) can not be removed, start the

engine and operate the boom lever to
adjust the hole position of the boom 1
cylinder piston rod end.
4 2 W152-04-01-001
IMPORTANT: Boom cylinder rod has a grease fit-
ting. Lay the boom cylinder on a
support so that the grease fitting
does not come in contact with the
support.
3. Secure the cylinder rod on the cylinder tube with a
wire so that the cylinder rod is not extended. Lay
the boom cylinder on a support by crane.
Wire
W554-02-03-007
W4-1-2
CAUTION: Front attachment weight:1000 kg

(2200 Ib)
4. Attach a wire rope to the boom to take up slack of
the wire rope.
5. Disconnect the work light connector and all hoses.

Cap the disconnected hoses. Install plug to each
pipe adapter at the boom side.
: 27 mm
W102-04-01-007
Plug (boom): 13/16-16UNF
Plug (boom cylinder): 13/16-16UN
6. Loosen bolts (6) (2 used ) to remove plate (7),

then pull boom foot pin (8) out by prying with a
crowbar.
: 24 mm
NOTE: If boom foot pin (8) can not be removed,
pull them out by using special tool (ST
1953) and bolts holes (M12, pitch 1.75).
Screw Bar: M12 Pitch 1.75 Length 492 mm
or more
W197-04-01-002
7 8
7
(Special Tool 6 Bolt Hole
ST 1953)
Screw Bar
W102-04-01-008
W191-04-01-004
CAUTION: Front attachment weight:

1000 kg (2200 Ib)
7. Hoist the front attachment by crane to remove it
from the base machine.
Remove the thrust plates (3 used) from both sides
of the boom foot.
W102-04-01-007
W4-1-3
Installation
CAUTION: Front attachment weight: 1000 kg

(2200 Ib)
1. With the front attachment lifted by crane, align the
boom foot with the main frame mating holes.
Install thrust plates (3 used) on both sides of the
boom foot to adjust the clearances on both sides
of boom foot within 1 mm (0.04 in).
W102-04-01-007
CAUTION: Prevent personal injury. Metal 8

debris may fly off when a hammer is used to 7
install pins. Be sure to wear necessary 6
protections, such as goggles, a hard hat, etc.
2. Drive boom foot pin (8) in with a bar and a
hammer and install plate (7) with bolts (6) (2
used).
: 24 mm
: 210 N⋅m (21 kgf⋅m, 155 Ibf⋅ft)
W191-04-01-004
3. Reconnect all hoses and the work light connector.

: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)
W197-04-01-002
W4-1-4
CAUTION: Boom cylinder weight: 90 kg

(200 Ib)
4. While lifting the boom cylinder by crane, start the
engine and extend the boom cylinder rod to align
the rod with connecting pin hole.
5. Install thrust plates (2) on both sides of the boom W102-04-01-011

cylinder rod end to adjust the clearances on both
sides within 1.5 mm (0.06 in).
3я
я5

debris may fly off when a hammer is used to
install pins. Be sure to wear necessary 4 W152-04-01-001
protections, such as goggles, a hard hat, etc. 2
IMPORTANT: Take care not to damage pin (1).
6. Drive pin (1) in with a hammer and a bar to install
the boom cylinder.
1
7. Install bolt (5) into stopper (4) and pin (1) in the
boom to install nuts (3) (2 used).
: 24mm 5
: 270 N·m (27.5 kgf·m, 200 lbf·ft) 4
3
IMPORTANT: After completing work, check the hy-
draulic oil level. Fully stroke each
cylinder several times to bleed any
air remaining in the circuit while 2
checking each hose connectors for
any oil leakage.
W1CD-04-01-001
W4-1-5
Front E
• Pin and Bushing F
D C
B
I
M
K
H
L
J
N
M1CD-01-010
Unit: mm (in)
Parts Name Standard Allowable Limit Remedy

Pin 60 (2.4) 59.0 (2.3)
A
Bushing (Boom) 60 (2.4) 61.5 (2.4)
Pin 55 (2.2) 54.0 (2.1)
B Boss (Main Frame) 55 (2.2) 56.5 (2.2)
Bushing (Boom Cylinder) 55 (2.2) 56.5 (2.2)
Pin 55 (2.2) 54.0 (2.1)
C Boss (Boom) 55 (2.2) 56.5 (2.2)
Bushing (Boom Cylinder) 55 (2.2) 56.5 (2.2) Replace
Pin 60 (2.4) 59.0 (2.3)
D
Bushing (Arm) 60 (2.4) 61.5 (2.4)
Pin 55 (2.2) 54.0 (2.1)
E Boss (Arm) 55 (2.2) 56.5 (2.2)
Bushing (Arm Cylinder) 55 (2.2) 56.5 (2.2)
Pin 55 (2.2) 54.0 (2.1)
F
Bushing (Arm Cylinder) 55 (2.2) 56.5 (2.2)
W4-1-6
Unit: mm (in)
Parts Name Standard Allowable Limit Remedy

Pin 45 (1.8) 44.0 (1.7)
G
Bushing (Bucket Cylinder) 45 (1.8) 46.5 (1.8)
Pin 55 (2.2) 54.0 (2.1)
H Bushing (Bucket Cylinder) 55 (2.2) 56.5 (2.2)
Bushing (Link A) 55 (2.2) 56.5 (2.2)
Pin 50 (2.0) 49.0 (1.9)
I
Bushing (Arm) 50 (2.0) 51.5 (2.0)
Pin 50 (2.0) 49.0 (1.9)
J
Bushing(Link A) 50 (2.0) 51.5 (2.0) Replace
Pin 50 (2.0) 49.0 (1.9)
K
Bushing (Arm) 50 (2.0) 51.5 (2.0)
Pin 50 (2.0) 49.0 (1.9)
L
Bushing (Blade) 50 (2.0) 51.5 (2.0)
Pin 71 (2.8) 70.0 (2.8)
M
Bushing (Blade Cylinder) 71 (2.8) 72.5 (2.9)
Pin 71 (2.8) 70.0 (2.8)
N
Bushing (Blade Cylinder) 71 (2.8) 72.5 (2.9)
W4-1-7
Side Cutter
D
A
W505-04-01-001
Unit: mm (in)

A 225 (8.9) 145 (5.7)
B 250 (9.8) -
Replace
C 295 (11.6) -
D 150 (5.9) -
Point
B C
W554-04-01-003
Unit: mm (in)
A 165 (6.5) 85 (3.3)
B 57 (2.2) -
Replace
C 60 (2.4) -
D 62 (2.4) -
W4-1-8
STANDARD DIMENSIONS FOR ARM
AND BUCKET CONNECTION
Section A Section B
W1CD-04-01-002
Unit: mm (in)
a 255 (10.0)
b 15 (0.59) NOTE: Dimension h: 200 mm includes the
c 417 (16.5) clearance for bucket adjuster.
d 359 (14.1)
e 310 (12.2)
f 1060 (42)
g 298 (11.7)
h 200 (7.9)
i 50 (2.0)
j 299 (11.8)
k 82 (3.2)
l 298 (11.7)
m 202 (8.0)
n 50 (2.0)
o 90°
p 90°
q 312 (12.3)
r 224 (8.8)
W4-1-9
(Blank)
W4-1-10
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER

repair work.
remaining pressure if removed quickly. W554-04-02-006
Slowly loosen the cap to release any remain- Front

Overload
ing pressure completely. Relief valve
Blade Rod
Preparation
1. Park the machine on a solid level surface. Fully
Overload Overload
retract the bucket and arm cylinder and lower the Relief Valve Relief Valve
bucket onto the ground. Arm Rod Boom Bottom

top of the hydraulic oil tank to release any pres-
sure remaining in the hydraulic oil tank.
CAUTION: The overload relief valve may Overload
spurt the hydraulic oil if loosened more than Relief Valve
Bucket Bottom
3/4 turn. Never loosen the valve further.
IMPORTANT: Be sure to loosen the overload relief
valve body. W1CD-02-05-004
Back
If the lock nut or adjusting screw is
loosened, pressure setting will
change. Never attempt to loosen
them.
Overload
3. Put matching marks on the overload relief valve Relief Valve Overload
and control valve. Gradually loosen the overload Blade Bottom Relief Valve
relief valve to relieve any pressure remaining in Arm Bottom
the circuit.
: 24 mm Overload
Relief Valve
: 49 to 54 N⋅m Boom Rod
(5 to 5.5 kgf⋅m, 36 to 40 Ibf⋅ft)
4. Remove the hydraulic oil tank cap. Connect a Overload

Relief Valve
vacuum pump and operate it continuously to Bucket Rod
tank. W1CD-02-05-005
NOTE: Run the vacuum pump continuously while Lock Nut

Adjusting
Screw
T152-05-04-003
W4-2-1
Remove Bucket Cylinder
1. Lay wooden blocks (3) under the arm (2) tip and in
the clearance between the arm (2) top surface 1
and bucket cylinder (1).
2. After stopping the engine, push the air release

valve to release any remaining pressure from the 3
hydraulic oil tank, then remove the cap.
Release bucket circuit pressure. 2
Refer to “Release Hydraulic Circuit Pressure”. 3
(W4-2-1)
W554-04-02-006
Ȁ
CAUTION: Use a wire to secure the link to
prevent it from falling before pushing pin (7)
out.
CAUTION: Prevent personal injury. Metal

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

56 kg (123 Ib)
15
to remove pins. Be sure to wear necessary 11
protection, such as goggles, a hard hat, etc. 13
6. Hoist bucket cylinder (1) by crane, remove nut

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

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

56 kg (123 Ib)
10
to install pin (11). Be sure to wear necessary
protection, such as goggles, a hard hat, etc.
15
1. While hoisting bucket cylinder (1) by crane, align
the cylinder bottom side pin hole with the bucket 14
cylinder mounting hole on arm. Insert thrust plates 11
(10) and drive pin (11) in with a bar and hammer. 13
2. Insert bolt (15) into arm stopper (14) and pin (11),
install nuts (13) (2 used).
: 24 mm 1
: 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft)
IMPORTANT: After installing hoses, fill hydraulic

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

bucket cylinder (1).
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)
4. Remove wire (9) from bucket cylinder (1) rod (8).
1
8
9 W102-04-02-005
W4-2-4

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

the cylinder rod side pin hole with those of links
(16) and (18). Insert thrust plate (5). Drive pin (7)
in with a bar and hammer.
6. Insert bolt (4) into stopper (17) and pin (7), install
nuts (6) (2 used).
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft) 7 18 6
W158-04-02-006
IMPORTANT: In case link (18) has been removed
from the arm, don’t forget to re-
insert thrust plate (19).
19 19
IMPORTANT: After completing work, fully stroke
the bucket cylinder several times to
bleed any air remaining in the cir-
cuit.
W157-04-01-015
18 18
W4-2-5
Remove Arm Cylinder
1
1. Place a wooden block (3) on the top surface of
boom (2) to support arm cylinder (1).
2. After stopping the engine, push the air release 2

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

4. Start the engine. Operating the boom and the arm

slightly, align the arm cylinder (1) rod side pin hole
with the arm cylinder mounting hole on arm. 6
W187-04-02-006
8 1
5. To prevent arm cylinder (1) rod (8) from extending,

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

(1), and close all openings with cap.
9
: 27 mm
W187-04-02-010
10
7. Remove grease hose (11) from arm cylinder (1). 1

: 17 mm
11
W102-04-02-014
W4-2-6
CAUTION: Arm cylinder weight:

70 kg (154 Ib)
1
8. Attach a sling at the center of gravity of arm cylin-
der (1). Slightly hoist by crane.

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

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

CAUTION: Arm cylinder weight:

70 kg (154 Ib)
1. Attach a sling at the center of gravity of arm cylin-

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

bolt (15) to the pin and stopper (16) and put nut
(14) on the bolt. 16
: 24 mm 14
: 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft)
W187-04-02-007
3. Install grease hose (11) and arm cylinder hoses
(10) (2 used).
: 17 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) 10
: 27 mm 1
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)
IMPORTANT: After filling hydraulic oil to specified

level, start the engine and check the
connections for any oil leakage.
11
W102-04-02-014
W4-2-8
4. Remove wire (9) from arm cylinder (1) rod (8).
Start the engine, operate the arm lever, align the 8 1
arm cylinder rod side pin hole with the arm cylin-
der mounting hole on arm (17).
17

to install pin (5). Be sure to wear necessary W187-04-02-010
5. Insert thrust plates (4), then install pin (5).

4
Ȁ Insert bolt (7) into pin (5) and stopper (18), then 7 5
put nut (6) on the bolt.
: 24 mm 18
: 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft)

the arm cylinder several times to 17
cuit.
6
W187-04-02-006
W4-2-9
Remove Boom Cylinder
CAUTION: Boom cylinder weight:

90 kg (200 Ib)
1. Remove nut (3) and bolt (5) from stopper (4) in 1
boom cylinder rod end pin (1).
5
: 24 mm
4
3
90 kg (200 lb)
Prevent personal injury. Metal fragments may
fly off when a hammer is used to remove pins. 2
Be sure to wear necessary protection, such
as goggles, a hard hat, etc. W1CD-04-01-001
2. Hoist the boom cylinder tube end by crane. Drive
pin (1) out with a bar and hammer until thrust
plates (2) is removed. Remove thrust plates (2).
NOTE: When pin (1) can not be removed, start the
engine and operate the boom lever to ad-
just the hole position of the boom cylinder
piston rod end.
IMPORTANT: Boom cylinder rod has a grease fit-

ting. Lay the boom cylinder on a
support so that the grease fitting
does not come in contact with the
W102-04-01-011
support.
3. Secure the cylinder rod on the cylinder tube with a
wire so that the cylinder rod is not extended. Lay
the boom cylinder on a support by crane.
3я
я5
4. After stopping the engine, push the air release
valve to release any remaining pressure from the
Release boom circuit pressure. 1
Refer to “Hydraulic Circuit Pressure Release”
(W4-2-1) 4
W152-04-01-001
2
Wire
6
W187-04-02-008
W4-2-10
5. Remove hoses (10) (2 used) from boom cylinder
(6) at the cylinder bottom. Close all openings with
plug (13/16-16 UN). 11 6
: 27 mm
7
fragments may fly off when a hammer is used 8
to remove pin (8). Be sure to wear necessary
9
6. Loosen nut (9) at the boom cylinder bottom side of
the main frame, remove bolt (7).
Ȁ Pull out pin (8).
Ȁ Remove thrust plate (11). 10 W1CD-04-02-001
: 24mm

90 kg (200 Ib)
CAUTION: Attach a wire rope to the boom

cylinder so that the rope does not damage
the boom cylinder tube while hoisting the cyl-
inder.
7. Attach a wire rope at the center of gravity of

boom cylinder (6), hoist it by crane.
W187-04-01-001
W4-2-11
Install Boom Cylinder

90 kg (200 Ib)
CAUTION: Attach a wire rope to the boom

cylinder so that the rope does not damage
the boom cylinder tube while hoisting the cyl-
inder.
1. Attach a wire rope at the center of gravity of boom

cylinder (6), hoist it by crane. Align the boom cyl-
inder bottom side pin hole with the boom cylinder 6
mounting hole on the main frame.
W187-04-01-001

to install pin (8). Be sure to wear necessary 11 6
2. Insert thrust plate (11) and pin (8). Install bolt (7), 7
tighten with nuts (9) (2 used).
: 24 mm 8
: 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft)
3. Install hoses (10) (2 used) on boom cylinders (6). 9

: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)
W1CD-04-02-001
IMPORTANT: After filling hydraulic oil to specified 10
level, start the engine and check the
connections for any oil leakage.
W4-2-12
4. Hoist boom cylinder (6) with a crane. Operate the
boom lever, align the cylinder rod side pin hole
with the boom cylinder mounting hole on the
boom.

5. Install thrust plates (2) (2 used), drive in pin (1),

connect boom cylinder (6) to the boom.
6. Insert bolt (5) into stopper (4) and pin (1), tighten it
with nuts (3) (2 used).
: 24 mm 6
: 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft) W102-04-01-011

the boom cylinder several times to
cuit.
5
4
3
W1CD-04-01-001
W4-2-13
Remove Blade Cylinder

1. Loosen bolts (1) (2 used) to remove cover (2).
: 19 mm 1 2 3
CAUTION: Blade cylinder weight: 51 kg 4

(112 Ib)
2. Attach a wire rope to blade cylinder (3). Hoist the 4
blade cylinder and hold it by crane.
6 5
Ȁ
3. Disconnect hoses (2 used) from blade cylinder
(3).
Cap the disconnected hoses.
: 22 mm, 27 mm
4. Loosen bolts (6) (2 used) to remove pins (5) (2

used). Hose
Remove thrust plates (4) from the mating faces
between blade cylinder (3) tube and blade (7), cyl-
inder rod and track frame.
: 24 mm
5
5. Hoist blade cylinder (3) to remove it. 7 6
W197-04-02-001
W4-2-14
Install Blade Cylinder
1 2 3
CAUTION: Blade cylinder weight: 51 kg
(112 Ib)
1. While hoisting blade cylinder (3) by crane, align
4
pin (5) holes on the tube and blade (7), cylinder
rod and track frame.
4
Insert thrust plate (4). Drive pin (5) (2 used) in with
a bar and hammer. Secure the pins with bolts (6) 6 5
(2 used).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
2. Reconnect hoses (2 used) to blade cylinder (3).

: 22 mm
: 39 N⋅m (4 kgf⋅m, 28.5 Ibf⋅ft)
Hose
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)
3. Install cover (2) to blade cylinder (3), then secure

it with bolts (1) (2 used). 5
: 19 mm
7 6
: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft) W197-04-02-001

blade cylinder several times to bleed
any air remaining in the circuit.
W4-2-15
DISASSEMBLE CYLINDER
Boom Cylinder
2
3
4
7
8
1
9
10
11
Detent
12
13
14
15
16
27 17
18
19
20
21
22
23
24
25
26
W1CD-04-02-002
1- Piston Rod 8- O- Ring 15 - Backup Ring 22 - O- Ring

2- Wiper Ring 9- Backup Ring 16 - O- Ring 23 - Slide Ring
3- U-Ring 10 - O- Ring 17 - Backup Ring 24 - Nut
4- Buffer Ring 11 - Collar 18 - Cushion Bearing 25 - Steel Ball
5- Cylinder Head 12 - Cushion Seal 19 - Slide Ring 26 - Set Screw
6- Bushing 13 - Cushion Seal 20 - Piston 27 - Cylinder Tube
7- Retaining Ring 14 - Holder 21 - Seal Ring
W4-2-16
Disassemble Boom Cylinder
• Be sure to read “Precautions for Disassembly and 5. Remove set screw (26) to remove steel ball (25).
Assembly” thoroughly on page W1-1-1 before : 8 mm
NOTE: Set screw (26) was crimped with a punch in
• The disassembly procedure below shall be carried
2 places after it was tightened. Before loos-
out on the premise that the hydraulic lines and the
ening the set screw, cut away the crimped
line securing bands have been removed.
portions.
CAUTION: Boom cylinder weight: 90 kg 6. Loosen and remove nut (24) using special tool
(200 Ib) (ST 5908). Remove piston (20) and cushion bear-
1. Hoist and securely place the cylinder on a working (18) from piston rod (1).
bench by crane. Drain the hydraulic oil from the Nut Turning Special Tool: 80 mm (ST 3262)
cylinder.
7. Remove holder (14) and cylinder head (5) from
piston rod (1).
IMPORTANT: When removing the seals, take care

not to damage the mating parts.
IMPORTANT: As slide rings (19) and (23) cannot
be reused, be sure to replace them
with the new ones when disassem-
W102-04-02-027 bling the cylinder.
2. Extend the detents in the groove of cylinder head 8. Remove slide rings (19), (23), seal ring (21) and
(5). (Refer to W4-2-26.) Using R wrench (ST O-ring (22) from piston (20).
3219), loosen cylinder head (5) 1 to 2 turns.
9. Remove wiper ring (2), U-ring (3), buffer ring (4),
IMPORTANT: Be sure to pull out piston rod (1) retaining ring (7) and bushing (6) from the inside
straight to prevent the sliding sur- of cylinder head (5).
faces from becoming damaged. Bushing Special Tool: 65 mm (ST 8015)
3. Fully extend piston rod (1). Holding the rod end by
crane, remove cylinder head (5) from cylinder 10. Remove O-rings (8), (10) and backup ring (9)
tube (27) to remove the piston rod. from the outside of cylinder head (5).
4. Securely place piston rod (1) on special tool (ST

11. Remove cushion seals (13), (12), and collar (11)
5908). Put matching marks on the piston rod and
from the inside of holder (14).
nut (24).
ST 5908 12. Remove backup rings (17), (15), and O-ring (16)
from the outside of holder (14).
W158-04-02-022
W4-2-17
Arm Cylinder
2
3
4
5 1
6
Detent
7
8
9
10
11
12
22
13
14
15
16
17
18
19
20
21
Slit
W1CD-04-02-003
1- Piston Rod 7- Retaining Ring 13 - Steel Ball 19 - Cushion Seal

2- Wiper Ring 8- O-Ring 14 - Set Screw 20 - Cushion Bearing
3- U-Ring 9- Backup Ring 15 - Seal Ring 21 - Stopper (Slit) (2 Used)
4- Buffer Ring 10 - O-Ring 16 - O-Ring 22 - Cylinder Tube
5- Cylinder Head 11 - Slide Ring 17 - Slide Ring
6- Bushing 12 - Piston 18 - Retaining Ring
W4-2-18
Disassemble Arm Cylinder
• The disassembly procedure below starts on the
premise that the hydraulic lines and the line secur-
ing bands have been removed.
portions.
CAUTION: Arm cylinder weight: 70 kg (154 Ib) 6. Loosen and remove piston (12) using special tool
1. Hoist and securely place the cylinder on a work- (ST 5908).
bench by crane. Drain the hydraulic oil from the Piston Turning Special Tool: 70 mm (ST 3261)
cylinder. Ȁ
7. Remove stoppers (21) (slit) (2 used), cushion
bearing (20), cushion seal (19) and retaining ring
(18) from piston rod (1).
NOTE: Remove retaining ring (18) of stopper (21)
(slit) to slide cushion bearing (20). Remove
the stopper.
Remove cushion seal (19) by inserting a
screw driver edge into the slit.
W102-04-02-027
2. Extend the detents in the groove of cylinder head
8. Remove cylinder head (5) from piston rod (1).
(5). (Refer to W4-2-30.) Using R wrench (ST
3220), loosen cylinder head (5) 1 to 2 turns.
IMPORTANT: Be sure to pull piston rod (1) straight
IMPORTANT: As slide rings (11) and (17) cannot be
out to prevent the sliding surface
reused, be sure to replace them with
from becoming damaged.
the new ones when disassembling
3. Fully extend piston rod (1) to hold the rod end by
the cylinder.
crane. Remove cylinder head (5) from cylinder
9. Remove slide rings (11), (17), seal ring (15) and
tube (22) to remove the piston rod.
O-ring (16) from piston (12).
10. Remove wiper ring (2), U-ring (3), buffer ring (4),
retaining ring (7), and bushing (6) from the inside
piston (12).
of cylinder head (5).
ST 5908 Bushing Special Tool: 60 mm (ST 8012)
11. Remove O-rings (8), (10), and backup ring (9)

from the outside of cylinder head (5).
W158-04-02-022
W4-2-19
Bucket Cylinder
11
12
13
15 14
16 1
17
Detent
18
2
3
4
6
7
8
10
W1CD-04-02-004
1- Piston Rod 6- Bushing 11 - Slide Ring 16 - O-Ring

2- Wiper Ring 7- Retaining ring 12 - Piston 17 - Slide Ring
3- U-Ring 8- O-Ring 13 - Steel Ball 18 - Cylinder Tube
4- Buffer Ring 9- Backup Ring 14 - Set Screw
5- Cylinder Head 10 - O-Ring 15 - Seal Ring
W4-2-20
Disassemble Bucket Cylinder
premise that hydraulic lines and the line securing
bands have been removed.
portions
CAUTION: Bucket cylinder weight: 56 kg 6. Loosen and remove piston (12) using special tool
(123 Ib) (ST 5908).
1. Hoist and securely place the cylinder on a work- Piston Turning Special Tool: 65 mm (ST 3270)
bench by crane. Drain the hydraulic oil from the
cylinder. 7. Remove cylinder head (5) from piston rod (1).

the cylinder.
8. Remove slide rings (11), (17), seal ring (15) and
W102-04-02-027
O-ring (16) from piston (12).
2. Extend the detents in the groove of cylinder head
(5). (Refer to W4-2-32.) Using R wrench (ST 9. Remove wiper ring (2), U-ring (3), buffer ring (4),
3213), loosen cylinder head (5) 1 to 2 turns. retaining ring (7) and bushing (6) from the inside
of cylinder head (5).
IMPORTANT: Be sure to pull piston rod (1) straight Bushing Special Tool: 55 mm (ST 8011)
out to prevent the rod surface from
becoming damaged. 10. Remove O-rings (8), (10) and backup ring (9)
3. Fully extend piston rod (1) to hold the rod end by from the outside of cylinder head (5).
crane. Remove cylinder head (5) from cylinder
tube (18) to remove the piston rod.

piston (12).
ST 5908
W158-04-02-022
W4-2-21
Blade Cylinder
11
1
12
13
14
15
16
3
17
4
Detent 18
6
19
10
W1CD-04-02-010
1- Piston Rod 6- Bushing 11 - Slide Ring 16 - Nut

2- Wiper Ring 7- Retaining Ring 12 - Piston 17 - Steel Ball
3- U-Ring 8- O-Ring 13 - Seal Ring 18 - Set Screw
4- Buffer Ring 9- Backup Ring 14 - O-Ring 19 - Cylinder Tube
5- Cylinder Head 10 - O-Ring 15 - Slide Ring
W4-2-22
Disassemble Blade Cylinder
• Be sure to read “Precautions for Disassembly 5. Remove set screw (18) to remove steel ball (17).
and Assembly” thoroughly on page W1-1-1 : 6 mm
before starting any repair work.
premise that hydraulic lines and line securing
ening the set screw (20), cut away the
bands have been removed.
crimped portions
CAUTION: Blade cylinder weight: 51 kg 6. Loosen and remove nut (16) using special tool
(112 Ib) (ST 5908). Remove piston (12) from piston rod
1. Hoist and securely place the cylinder on a work- (1).
bench by crane. Drain the hydraulic oil from the Nut Turning Special Tool: 85 mm (ST 3304)
cylinder.
7. Remove cylinder head (5) from piston rod (1).

the cylinder.
W102-04-02-027 8. Remove slide rings (11), (15), seal ring (13) and
2. Extend the detents in the groove of cylinder head O-ring (14) from piston (12).
(5). (Refer to W4-2-34.) Using R wrench (ST
3223), loosen cylinder head (5) 1 to 2 turns. 9. Remove wiper ring (2), U-ring (3), buffer ring (4),
retaining ring (7) and bushing (6) from the inside
IMPORTANT: Be sure to pull piston rod (1) straight of cylinder head (5).
out to prevent the sliding surface Bushing Special Tool: 70 mm (ST 8017)
from becoming damaged.
3. Fully extend piston rod (1) to hold the rod end by 10. Remove O-rings (8), (10), backup ring (9) from
crane. Remove cylinder head (5) from cylinder the outside of cylinder head (5).
tube (19) to remove the piston rod .

nut (18).
ST 5908
W158-04-02-022
W4-2-23
ASSEMBLE CYLINDER
Boom Cylinder
15 16 17
14 11 12
8 13
2 3 4 5 6 7 9 10 1 27 18 20 19 21 22 23 24 26 25
With Hole Details at S Part
W1CD-04-02-005
1- Piston Rod 8- O-Ring 15 - Backup Ring 22 - O-Ring

2- Wiper Ring 9- Backup Ring 16 - O-Ring 23 - Slide Ring
3- U-Ring 10 - O-Ring 17 - Backup Ring 24 - Nut
4- Buffer Ring 11 - Collar 18 - Cushion Bearing 25 - Steel Ball
5- Cylinder Head 12 - Cushion Seal 19 - Slide Ring 26 - Set Screw
6- Bushing 13 - Cushion Seal 20 - Piston 27 - Cylinder Tube
7- Retaining ring 14 - Holder 21 - Seal Ring
W4-2-24
Assemble Boom Cylinder
• Be sure to read “Precautions for Disassembly and IMPORTANT: While installing slide rings (19) and
Assembly” thoroughly on page W1-1-1 before (23), be sure that their slit sections
starting any repair work. do not align with each other.
8. Install slide rings (19) and (23) onto piston (20).
1. Press bushing (6) into cylinder head (5) with a Ȁ
press. Install retaining ring (7) into the cylinder IMPORTANT: Install cushion bearing (18) with the
head. wider split circumference side facing
Bushing Special Tool: 65 mm (ST 8015) cylinder head (5).
9. Install cushion bearing (18) into piston rod (1).
IMPORTANT: Install U-ring (3) with the lip facing
bushing (6). 10. Install piston (20) into piston rod (1). Tighten nut
Install buffer ring (4) with the protru- (24) using special tool (ST 5908) according to the
sion part and slits facing bushing (6). matching mark.
2. Install U-ring (3) and buffer ring (4) into cylinder Nut Turning Special Tool: 80 mm (ST 3262)
head (5). : 2900 N⋅m (295 kgf⋅m, 2140 Ibf⋅ft)
Ȁ
ST 5908
3. Install wiper ring (2) into cylinder head (5) using a
plastic hammer.
Wiper Ring Specail Tools: ST 8015
IMPORTANT: Install backup ring (9) to the piston

rod eye side. (Refer to page W4-2-24)
4. Install O-rings (8), (10) and backup ring (9) into
cylinder head (5). W158-04-02-022
5. Install cushion seals (13), (12), collar (11), backup 10. Align the holes on the piston rod (1) and nut (24).
ring (17), O-ring (16), and backup ring (15) into Install steel ball (25) into nut (24). Then, tighten
holder (14). set screw (26). Set screw (26) should be crimped
with a punch in 2 places after it is tightened.
6. Install cylinder head (5) assembly and holder (14) : 6 mm
assembly into piston rod (1). : 56.9±10.7 N⋅m
Cylinder Head Special Tool: ST 8015 (5.8±1.1 kgf⋅m, 42±7.9 Ibf⋅ft)
IMPORTANT: After installing O-ring (22), check

there is no twisting.
7. Install O-ring (22) and seal ring (21) onto piston
(20) with a wooden spatula so that they are not in-
stalled in the slide ring (19) groove.
W4-2-25
5 1 27
Detent
With Hole
W1CD-04-02-005
W4-2-26
IMPORTANT: Be sure to keep piston rod (1) align-
ing with the center of cylinder tube
(27) when inserting in order to avoid
damaging the piston rings.
12. Securely place cylinder tube (27) on a work-bench,
insert the piston rod (1) assembly into cylinder
tube (27).
13. Tighten cylinder head (5) to cylinder tube (27) us-

ing R wrench (ST 3219). Fold the detents to lock
cylinder head (5).
: 950±216 N⋅m
(97±22 kgf⋅m, 700±159 Ibf⋅ft)
W4-2-27
Arm Cylinder
4 5 8 6 7 9 10
2 3 1
22 12 11 15 17 14
13
16
18
19
20
With Hole 21
W1CD-04-02-006
With the Slit Facing the Piston

W1CD-04-02-009
1- Piston Rod 7- Retaining ring 13 - Steel Ball 19 - Cushion Seal

2- Wiper Ring 8- O-Ring 14 - Set Screw 20 - Cushion Bearing
3- U-Ring 9- Backup Ring 15 - Seal Ring 21 - Stopper (Slit ) (2 Used)
4- Buffer Ring 10 - O-Ring 16 - O-Ring 22 - Cylinder Tube
5- Cylinder Head 11 - Slide Ring 17 - Slide Ring
6- Bushing 12 - Piston 18 - Retaining ring
W4-2-28
Assemble Arm Cylinder
• Be sure to read “Precautions for Disassembly and IMPORTANT: Install slide rings (11), (17), be sure
Assembly” thoroughly on page W1-1-1 before that their slit sections do not align
starting any repair work. with each other.
7. Install slide rings (11), (17) onto piston (12).
1. Press bushing (6) into cylinder head (5) with a
press. Install retaining ring (7) into the cylinder IMPORTANT: Install cushion seal (19) with the slit
head. side facing piston (12).
Bushing Special Tool: 60 mm (ST 8012) Install cushion bearing (20) with the
wider split circumference side facing
IMPORTANT: Install U-ring (3) with its lip facing the cylinder bottom.
bushing (6). 8. Install cushion seal (19) and cushion bearing (20)
Install buffer ring (4) with the protru- onto piston rod (1).
sion part and slits facing bushing (6).
2. Install U-ring (3) and buffer ring (4) into cylinder 9. Slide cushion bearing (20) toward piston (12) to
head (5). install stoppers (21) (slit) (2used).
Ȁ Slide the cushion bearing toward the stopper to
3. Install wiper ring (2) into cylinder head (5) using a install retaining ring (18).
plastic hammer.
Wiper Ring Special Tool: ST 8012 10. Install piston (12) into piston rod (1). Tighten the
piston using special tool (ST 5908) according to
IMPORTANT: Install backup ring (9) to the piston the matching mark.
rod eye side. (Refer to page W4-2-28) Piston Turning Special Tool: 70 mm (ST 3261)
4. Install O-rings (8), (10) and backup ring (9) onto : 2470 N⋅m (250 kgf⋅m, 1820 Ibf⋅ft)
cylinder head (5).
ST 5908
5. Install the cylinder head (5) assembly into piston

rod (1).
Cylinder Head Special Tool: ST 8012
IMPORTANT: After installing O-ring (16), check

there is no twisting.
6. Install O-ring (16) and seal ring (15) onto piston W158-04-02-022
(12) with a wooden spatula so that they are not
installed into the slide ring (11) groove.
W4-2-29
5 1 22 12
Detent 14 13
W1CD-04-02-006
W4-2-30
11. Align the holes on piston rod (1) and piston (12).
Install steel ball (13), then tighten set screw (14).
The set screw should be crimped with punch in 2
places after it is tightened.
: 5 mm
: 31.5±5.9 N⋅m
(3.2±0.6 kgf⋅m, 23±4.3 lbf⋅ft)

ing with the center of cylinder tube
(22) when inserting in order to avoid
damaging the piston rings.
12. Securely place cylinder tube (22) on a work-bench,
insert the piston rod (1) assembly into the cylinder
tube .
Ȁ
13. Tighten cylinder head (5) to cylinder tube (22)
using R wrench (ST 3220). Fold the detents to
lock cylinder head (5).
: 570 N⋅m
(58 kgf⋅m, 420 lbf⋅ft)
W4-2-31
Bucket Cylinder
Detent
8 6 7 9 10
3 4 5
1 18 12 11 15 16 17
2
14
13
With Hole
W1CD-04-02-007
1- Piston Rod 6- Bushing 11 - Slide Ring 15 - Seal Ring

2- Wiper Ring 7- Retaining Ring 12 - Piston 16 - O-Ring
3- U-Ring 8- O-Ring 13 - Steel Ball 17 - Slide Ring
4- Buffer Ring 9- Backup Ring 14 - Set Screw 18 - Cylinder Tube
5- Cylinder Head 10 - O-Ring
W4-2-32
Assemble Bucket Cylinder
press. Install retaining ring (7) into the cylinder 8. Install piston (12) into piston rod (1). Tighten the
head. piston using special tool (ST 5908) according to
Bushing Special Tool: 55 mm (ST 8011) the matching mark.
Nut Turning Special Tool: 65 mm (ST 3270)
IMPORTANT: Install U-ring (3) with its lip facing : 1480 N⋅m (151 kgf⋅m, 1090 Ibf⋅ft)
bushing (6).
ST 5908
Install buffer ring (4) with the protru-
sion part and slits facing bushing (6).
2. Install U-ring (3) and buffer ring (4) into cylinder
head (5).
Ȁ
plastic hammer.
Wiper Ring Special Tool: ST 8011 W158-04-02-022
IMPORTANT: Install backup ring (9) to the piston 9. Align the holes on piston rod (1) and piston (12) to
rod eye side. (Refer to page W4-2-32) install steel ball (13). Then, tighten set screw (14).
4. Install O-rings (8), (10) and backup ring (9) to cyl- Set screw (14) should be crimped with a punch in
inder head (5). 2 places after it is tightened.
ϖ 5 mm
5. Install the cylinder head (5) assembly into piston ϖ 31.5±5.9 N⋅m
rod (1). (3.2±0.6 kgf⋅m, 23±4.3 Ibf⋅ft)
IMPORTANT: After installing O-ring (16), check ing with the center of cylinder tube
there is no twisting. (18) when inserting in order to avoid
6. Install O-ring (16) and seal ring (15) onto piston damaging the piston rings.
(12) with a wooden spatula so that they are not in- 10. Securely place cylinder tube (18) on a work-bench,
stalled in the slide ring (11) groove. insert the piston rod (1) assembly into cylinder
tube (18).
11. Tighten cylinder head (5) to cylinder tube (18) us-

ing R wrench (ST 3213). Fold the detents to lock
the cylinder head .
: 450 N⋅m (46 kgf⋅m, 330 Ibf⋅ft)
W4-2-33
Ȁ
Ȁ
Blade Cylinder
Detent
7
6 9 1
3 4 5 10 11
8 19 12 13 14 15 16
2 18
17
With Hole
W1CD-04-02-008
1- Piston Rod 6- Bushing 11 - Slide Ring 16 - Nut

2- Wiper Ring 7- Retaining Ring 12 - Piston 17 - Steel Ball
3- U-Ring 8- O-Ring 13 - Seal Ring 18 - Set Screw
4- Buffer Ring 9- Backup Ring 14 - O-Ring 19 - Cylinder Tube
5- Cylinder Head 10 - O-Ring 15 - Slide Ring
W4-2-34
Assemble Blade Cylinder
press. Install retaining ring (7) into the cylinder 8. Install piston (12) into piston rod (1). Tighten nut
head. (16) using special tool (ST 5908) according to the
Bushing Special Tool: 70 mm (ST 8017) matching mark.
Nut Turning Special Tool: 85 mm (ST 3304)
IMPORTANT: Install U-ring (3) with its lip facing : 3310 N⋅m (340 kgf⋅m, 2440 Ibf⋅ft)
bushing (6).
Install buffer ring (4) with the protru- ST 5908
sion part and slits facing bushing
(6).
2. Install U-ring (3) and buffer ring (4) into cylinder
head (5).

plastic hammer.
Wiper Ring Special Tool: ST 8017 W158-04-02-022
IMPORTANT: Install backup ring (9) to the piston 9. Align the holes on the piston rod (1) and nut (16)
rod eye side. (Refer to page W4-2-34) to install steel ball (17). Then, tighten set screw
4. Install O-rings (8), (10) and backup ring (9) to cyl- (18). Set screw (18) should be crimped with a
inder head (5). punch in 2 places after it is tightened.
: 6 mm
5. Install the cylinder head (5) assembly into piston : 56.9±10.7 N⋅m
rod (1). (5.80±1.1 kgf⋅m, 42±7.9 Ibf⋅ft)
IMPORTANT: After installing O-ring (14), check ing with the center of cylinder tube
there is no twisting. (19) when inserting in order to avoid
6. Install O-ring (14) and seal ring (13) onto piston damaging the piston rings.
(12) with a wooden spatula so that they are not 10. Securely place cylinder tube (19) on a work-
installed in the slide ring (11) groove. bench, insert the piston rod (1) assembly into cyl-
inder tube (19).
11. Tighten cylinder head (5) to cylinder tube (19) by

using R wrench (ST 3223). Fold the detents to
lock cylinder head (5).
: 1060 N⋅m (108 kgf⋅m, 780 lbf⋅ft)
W4-2-35
Bend (Run out)
Rod
Dial Gauge
Rod
A
W166-04-02-022
W105-04-02-094 1m
V shaped Block
Unit: mm (in)
Cylinder Name Recommended Size After Unit: mm (in)
Re-Manufacturing (A) Bend Run out Remedy
Boom +0.023 (+0.0009) Allowable limit 0.5 (0.020) 1.0 (0.039) Repair
65 (2.6)
-0.053 (-0.0020) Allowable limit 1.0 (0.039) 2.0 (0.079) Replace
Arm 60 +0.023 (+0.0009)
(2.4)
-0.043 (-0.0017)
Bucket 55 +0.023 (+0.0009)
(2.2)
-0.043 (-0.0017)
Blade 70 +0.023 (+0.0009)
(2.8)
-0.053 (-0.0020)
Rod Bushing
Unit: mm (in)
Cylinder Allowable Limit Remedy
Standard (C)
Name
Boom 65 +0.023 (+0.0009)
(2.6) +0.3 (0.012) Replace
-0.053 (-0.0020) C
Arm 60 +0.023 (+0.0009)
(2.4) +0.3(0.012) Replace
-0.043 (-0.0017)
Bucket 55 +0.023 (+0.0009)
(2.2) +0.3(0.012) Replace
-0.043 (-0.0017)
Blade 70 +0.023 (+0.0009)
(2.8) +0.3 (0.012) Replace
-0.053 (-0.0020)
W4-2-36
MEMO
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SECTION 5
ENGINE AND ACCESSORY
— CONTENTS —
SECTION 1. SECTION 5.
General Information Engine Assembly 3 (Reassembly)
General Repair Instructions .............................. 2 Reassembly ................................................... 84
Notes on the Format of

This Manual.................................................... 2 SECTION 6.
Main Data and Specifications ........................... 6 Lubricating System
Tightening Torque Specifications .................... 11 Main Data and Specification ......................... 112
General Description...................................... 113
SECTION 2. Oil Pump ...................................................... 116
Maintenance
Model Identification ........................................ 22 SECTION 7.
Injiction Pump Identification............................ 22 Cooling System
Lubricating System ......................................... 22 Main Data and Specification ......................... 122
Fuel System ................................................... 23 General Description...................................... 123
Cooling System .............................................. 25 Thermostat ................................................... 125
Valve Clearance Adjustment........................... 26
Injection Timing .............................................. 28 SECTION 8.
Compression Pressure Fuel System
Measurement ............................................... 29 Main Data and Specification ......................... 128
Recommended Lubricants .............................. 30 General Description...................................... 129
Engine Repair Kit ........................................... 31 Injection Nozzle ............................................ 132
Injection Pump Calibration Data ................... 138
SECTION 3.
Engine Assembly 1 (Disassembly) SECTION 9.
General Description........................................ 34 Engine Electricals
Disassembly................................................... 35 Starter .......................................................... 144
Alternator ..................................................... 159
SECTION 4.
Engine Assembly 2
(Inspection and Repair)
Inspection and Repair .................................... 52
1CDW-5-1
SECTION 10.
Troubleshooting
Hard Starting ................................................ 174
Unstable Idling ............................................. 178
Insufficient Power ......................................... 181
Excessive Fuel Consumption ....................... 185
Excessive Oil Consumption .......................... 187
Overheating ................................................. 188
White Exhaust Smoke .................................. 190
Dark Exhaust Smoke.................................... 191
Oil Pressure does not Rise ........................... 192
Abnormal Engine Noise ................................ 194
SECTION 11.
Special Tool List
Special Tool List ........................................... 198
SECTION 12.
Repair Standards
General Rules .............................................. 201
Repair Standards Chart ................................ 202
SECTION 13.
Conversion Table
Length .......................................................... 215
Area ............................................................. 217
Volume ......................................................... 217
Mass ............................................................ 219
Pressure ...................................................... 220
Torque.......................................................... 221
Temperature................................................. 222
1CDW-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
SERVICE MANUAL REVISION REQUEST FORM
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revisions are requested, use the comment column)
FAX:
YOUR COMMENTS / SUGGESTIONS:

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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