Undercariagge HITACHI ZX 850

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

several times to release any pressure remaining
in the system. Rotate the hydraulic oil tank cap
approx. 30° counterclockwise using a hexagon
wrench to release the trapped air in the hydraulic M104-07-021
oil tank. Refer to Bleeding Air from Hydraulic Sys-

tem on page W1-1-2.
: 4 mm
Cap
3. Remove the hydraulic oil tank cap. Connect a

vacuum pump and operate it continuously to
maintain negative pressure in the hydraulic oil
tank.
NOTE: Run the vacuum pump continuously while
working on the hydraulic system.
W183-01-01-001
W3-2-1
Removal
Before removing the travel device, the tracks must be
removed first. For removal and installation of the tracks,
refer to “Remove and Install Tracks” section on page
1
W3-7-1. Blind Bolt
In this section, the procedure starts on the premise that
the tracks have already been removed.
1. Remove blind bolts from cover (2).

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

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

for re-assembly. 3 Track Frame 4
3. Disconnect hoses (3 and 4) from travel device (6)
and cap all disconnected hose ends.
: 27 mm, 22 mm
10
4. Remove socket bolts (8) (8 used) from split 5

flanges (7) (4 used) to disconnect hoses (9 and
10) from travel device (6). Cap all disconnected
hose ends.
: 10 mm
6
CAUTION: Travel Device Weight: 1085 kg
(2390 Ib) 9 8 7 W16J-03-02-005
5. Attach wire ropes on travel device (6), lift and hold

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

several times to release any pressure remaining
in the system. Rotate the hydraulic oil tank cap
approx. 30° counterclockwise using a hexagon
wrench to release the trapped air in the hydraulic M104-07-021
oil tank. Refer to Bleeding Air from Hydraulic Sys-

tem on page W1-1-2.
: 4 mm
Cap
3. Remove the hydraulic oil tank cap. Connect a
vacuum pump and operate it continuously to
maintain negative pressure in the hydraulic oil
tank.
NOTE: Run the vacuum pump continuously while
working on the hydraulic system.
W183-01-01-001
W3-3-1
Removal
Front
IMPORTANT: Attach identification tags to all

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

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

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

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

Start the engine and check for oil
leaks. 1 - From the right travel spool in the upper side of control valve
4-spool section
2 - From the right travel spool in the lower side of control valve
4-spool section
3 - Hose D5: To hydraulic oil tank
4 - Hose SB: To SB port in 3-spool solenoid valve
tion lower side
tion upper side
W3-3-3
DISASSEMBLE CENTER JOINT
1
3
4
9
6
10
11
12
W16J-03-03-001
1 - Plug 4 - O-Ring 7 - Body 10 - O-Ring

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

• Do not measure the part included the master pin.
• The track is under tension.
A
W155-03-07-001
Unit: mm (in)
A 1041.4 (41.0) 1062.2 (41.8) Clad by welding and
B 152 (6.0) 144.1 (5.7) finish or replace
Master Pin
W142-03-07-003
Unit: mm (in)
Standard Remedy
A 301 (11.9)
Replace
B 56.8 (2.2)
W3-7-8
Master Bushing
W105-03-07-023
Unit: mm (in)
Standard Remedy
A 204.15 (8.0)
B 57.65 (2.3) Replace
C 85.35 (3.4)
Grouser Shoe
W105-03-07-024
Unit: mm (in)
Shoe Size 650 mm (25.6 in) Grouser Shoe
A 302 (11.9) −
B 20 (0.8) − Replace
C 50 (2.0) 24 (0.9)
W3-7-9
Bushing
W105-03-07-023
Unit: mm (in)
A 218.95 (8.6) -
B 58.15 (2.3) - Replace
C 85.35 (3.4) 78.55 (3.1)
Pin
A W142-03-07-004
Unit: mm (in)
Standard Remedy
A 319.5 (12.6)
Replace
B 57.0 (2.2)
W3-7-10

Undercariagge HITACHI ZX 850

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SECTION 3

CAUTION: Front attachment weight:

4. Disconnect all grease pipes from the swing bear-

CAUTION: Swing bearing weight:

1. Apply THREEBOND #1102 to the mounting sur-

Knock Pin Mounting Positions

Soft Zone Position

4. Connect all grease pipes to swing bearing.

CAUTION: Upperstructure weight:

CAUTION: Front attachment weight:

1 - Outer Race 4 - Plug 7 - Inner Race 10 - Rod and Turnbuckle (3 Used)

1 - Outer Race 4 - Plug 7 - Inner Race 10 - Rod and Turnbuckle (3 Used)

2 5. Sufficiently lubricate the swing bearing with

40±5 mm (1.6±0.2 in)

NOTE: Dia. of support (8): 35 mm (1.4 in)

CAUTION: Escaping fluid under pressure

2. After stopping the engine, move the control levers

oil tank. Refer to Bleeding Air from Hydraulic Sys-

3. Remove the hydraulic oil tank cap. Connect a

1. Remove blind bolts from cover (2).

CAUTION: Cover (2) weight : 50 kg (110 lb)

IMPORTANT: Attach identification tags to hoses

4. Remove socket bolts (8) (8 used) from split 5

5. Attach wire ropes on travel device (6), lift and hold

7. Remove travel device (6) from the other side in

2. Connect hoses (9 and 10) to the travel device (6) 2

CAUTION: Cover (2) weight: 50 kg (110 lb)

CAUTION: Travel device weight:

CAUTION: The second stage carrier (22) as-

20. Remove spring pins (39) (3 used), pins (40) (3

CAUTION: Drum (10) and other parts weight:

1 - Bolt (4 Used) 14 - Lock Plate 27 - Pin (3 Used) 39 - Spring Pin (4 Used)

20. Apply hydraulic oil to pins (40) (4 used). Align the

15. Tap on drum (10) with a plastic hammer to secure

IMPORTANT: When installing spring pin (29), be

holes for spring pin (29). Install spring pins (3 21

CAUTION: The third stage carrier (19) as-

CAUTION: Cover (47) weight: 40 kg (90 lb) 3

39. Install new corks (2 used) to sprocket (16) and

7. Remove pistons (10) (9 used), retainer (11),

IMPORTANT: Since friction plates (18, 19, 20) are

IMPORTANT: Do not remove the inner race of

IMPORTANT: Keep the outer race of roller bearing

1- Casing 9- Swash Plate 17 - Roller Bearing 25 - Backup Ring

CAUTION: The casing (1) assembly weight:

13. Install springs (28) (10 used) onto brake piston

1- Plug (2 Used) 14 - O-Ring 27 - Spring (2 Used) 39 - Spring (2 Used)

9. Clamp spool assembly (50) in a vice with a chip of

10. Remove plugs (41) (2 used), then remove springs

1- Plug (2 Used) 14 - O-Ring 27 - Spring (2 Used) 39 - Spring (2 Used)

1. Install O-rings (7 and 14) to plugs (6 and 15) re-

2. Install O-ring (2) to plug (1) and install check valve

IMPORTANT: Install overload relief valve (5) to the

4. Rotate spool assembly (50) slowly to insert it into

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

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

1. The clearance between the inner diameter of cyl-

Ȁ (D-d): 0.06 mm (0.002 in) or less

2. The clearance between the piston and shoe when

δ: 0.4 mm (0.02 in) or less

3. The clearance between the inner diameter and Piston

4. The wear allowance on the sliding surfaces of cyl-

CAUTION: Escaping fluid under pressure