Hitachi ZX40U, ZX50U Service Manual (Technical Manual+ Workshop Manual + Diagramas) PRIME A+ 657 Páginas

Technical Manual
Vol No.: T1LDE-00

INTRODUCTION
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
This manual consists of two portions:

the Technical Manual and the Workshop Manual.
Use the manuals according to purpose.
• Information included in the Technical Manual: • Information included in the Workshop Manual:
technical information needed for redelivery and technical information needed for maintenance and
delivery, operation and activation of all devices repair of the machine, tools and devices needed
and systems, operational performance tests, and for maintenance and repair, maintenance stan-
troubleshooting procedures. dards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
Each page has a number, located on the center

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

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

signal words are used to alert the reader to the Indicated potentially hazardous situation which could,
potential for personal injury of machine damage. if not avoided, result in personal injury or death.
This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury. Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights. NOTE:
To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or
ate lifting techniques and equipment when lifting heavy know-how.
parts.
UNITS USED
SI Units (International System of Units) are used in 2

Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
°C °F °C×1.8+32
3 3
m yd 1.308 Temperature
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgf m 1.0197 mL/rev cc/rev 1.0
Nm lbf ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
 This is the SAFETY ALERT SYMBOL.
• When you see this symbol on your machine or in

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

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

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

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

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

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

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

this manual.
 To avoid confusing machine protection with personal

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

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

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

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

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

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

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

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

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

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

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

appropriate to the job.
You may need:

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

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

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

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

earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.
006-E01A-0434 SA-434
INSPECT MACHINE
 Inspect your machine carefully each day or shift by
walking around it before you start it to avoid personal
injury.
• In the walk-around inspection be sure to cover all

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Confirm the location of bystanders before moving,
swinging, or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the SA-659
machine.
011-E01A-0426
SA-6
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
 Inappropriate engine starting procedures may cause

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

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

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

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

Keep riders off.
• Riders also obstruct the operator’s view, resulting
in the machine being operated in an unsafe
manner.
SA-660
014-E01B-0379
PROVIDE SIGNALS FOR FOBS INVOLV-

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

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

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

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

the undercarriage in relation to the operator’s po-
sition. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.
SA-662
017-E01A-0491
SA-8
SAFETY
DRIVE MACHINE SAFELY
 Before driving the machine, always confirm that the

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

• Avoid traveling over obstructions. Soil, fragments
of rocks, and/or metal pieces may scatter around
the machine. Don’t allow personnel to stay around
the machine while traveling.
SA-663
 Driving on a slope may cause the machine to slip or

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

facing the direction of travel, approximately 200 to
300 mm (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop traveling.
SA-664
• Driving across the face of a slope or steering on a

slope may cause the machine to skid or turnover.
If the direction must be changed, move the ma-
chine to level ground, then, change the direction
SA-441
to ensure sage operation.
019-E01D-0492
SA-589
SA-9
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
 Death or serious injury may result if you attempt to

mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the
H/P mode switch off.
• Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK
position.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade. SA-666
• Position the machine to prevent rolling.

• Park a reasonable distance from other machines.
020-E08A-0493
SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
 If any person is present near the machine when

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

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

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

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

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

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

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

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

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

CAN JUMP FREE
 The danger of tipping is always present when

operating on a grade, possibly resulting in serious
injury or death.
To avoid tipping: SA-670

 Be extra careful before operating on a grade.
• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or
slipping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is
unavoidable.
• Reduce swing speed as necessary when swinging
loads.
 Be careful when working on frozen ground.
• Temperature increases will cause the ground to

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

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

move any part of the machine or load closer than
3 m (10 ft) plus twice the line insulator length.
• Check and comply with any local regulations that
may apply.
• Wet ground will expand the area that could cause
SA-674
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site.
029-E01A-0381
OBJECT HANDLING
 If a lifted load should fall, any person nearby may be

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

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

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

debris; wear goggles or safety glasses.
• Keep bystanders away from the working area
before striking any object.
SA-432
031-E01A-0432
PARK MACHINE SAFELY
To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle / acceleration selector and H/P
mode switch off.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK
SA-675
position.
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
033-E09B-0390
SA-14
SAFETY
HANDLE FLUIDS SAFELY AVOID FIRES
 Handle fuel with care; it is highly flammable. If fuel

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

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

flammable.
• Store flammable fluids well away from fire

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

loading/unloading the machine onto/from a truck or
trailer bed.
SA-676
• Be sure to observe local regulations when
transporting the machine on public roads.
• Provide an appropriate truck or trailer for
transporting the machine.
Take the following precautions when loading /

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

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

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

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

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

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

injury.
• Before performing any work on the machine,

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

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

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

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

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

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

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

SA-344
face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen
AIR RELEASE PLUG to release pressure.
503-E01B-0344
STORE ATTACHMENTS SAFELY
 Stored attachments such as buckets, hydraulic

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

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

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

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

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

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

PERIODICALLY
 Rubber hoses that contain flammable fluids under

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

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

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

disconnecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take
SA-031
care to protect hands and body from high-
pressure fluids. Wear a face shield or goggles for
eye protection.
• If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
SA-292
507-E03A-0499
SA-044
SA-21
SAFETY
PREVENT FIRES
Check for Oil Leaks:
 Fuel, hydraulic oil and lubricant leaks can lead to

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

FLUID LINES
 Flammable spray can be generated by heating near

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

THE CUSTOMER
 After maintenance or repair work is complete,

confirm that:
• The machine is functioning properly, especially
the safety systems.
• Worn or damaged parts have been repaired or
replaced
S517-E01A-0435 SA-435
SA-27
SAFETY
(Blank)
SA-28
SECTION 1
GENERAL
CONTENTS
Group 1 Specification
Specifications ............................................ T1-1-1
Working Ranges and Machine
Dimensions for Transportation.................. T1-1-4
Group 2 Component Layout

Main Component ...................................... T1-2-1
Electrical System ...................................... T1-2-2
Relays ...................................................... T1-2-3
Monitor and Switches ............................... T1-2-4
Solenoid Valve Unit .................................. T1-2-4
Group 3 Component Specifications

Engine ...................................................... T1-3-1
Engine Accessories .................................. T1-3-4
Hydraulic Component ............................... T1-3-5
Filter ......................................................... T1-3-7
Electrical Component ............................... T1-3-8
1LDT-1-1
(Blank)
1LDT-1-2
GENERAL / Specifications
SPECIFICATIONS
40U
A
C
E
D
J I
G
H
M1LD-12-003
40U
Type
Canopy Cab
Type of Front-End Attachment Boom Swing Type
3 3
Bucket Capacity (Heaped) m (yd ) 0.14 (0.18)
Operating Weightkg kg (lb) 4040 (8910) 4100 (9040)
Basic Machine Weight kg (lb) 3040 (6700) 3100 (6830)
Isuzu CC-4LE2
-1
Engine kW/min 30.5/2200
(PS/rpm) (41.5/2200)
A: Overall Width mm (ft in) 1870 (6 2 )
B: Overall Height mm (ft in) 2610 (8 7 ) 2660 (8 9 )
C: Rear-End Swing Radius mm (ft in) 975 (3 2 )
D: Minimum Ground Clearance mm (ft in) 335 (1 1 )
E: Counterweight Clearance mm (ft in) 650 (2 2 )
F: Engine Cover Height mm (ft in) 1580 (5 2 )
G: Undercarriage Length mm (ft in) 2450 (8 0 )
H: Undercarriage Width mm (ft in) 1950 (6 5 )
I: Sprocket Center to Idler Center mm (ft in) 1960 (6 5 )
400 (1 4 )
J: Track Shoe Width mm (ft in)
(Rubber Crawler)
kPa 23.0 24.0
Ground Pressure
(kgf/cm2, psi) (0.24, 3.3) (0.25, 3.5)
Swing Speed min1 (rpm) 9.0 (9.0)
Travel Speed (fast/slow) km/h (mph) 4.4/2.5 (2.7/1.6)
Gradeability (tan ) 30 (58%)
NOTE: The dimensions do not include the height of the shoe lug.
T1-1-1
50U
A
C
E
D
J I
G
H
M1LD-12-003
50U
Type
Canopy Cab
Type of Front-End Attachment Boom Swing Type
Bucket Capacity (Heaped) m3 (yd3) 0.16 (0.21)
Operating Weightkg kg (lb) 4510 (9940) 4570 (10080)
Basic Machine Weight kg (lb) 3500 (7720) 3560 ( 7850)
Isuzu CC-4LE2
Engine kW/min-1 30.5/2200
(PS/rpm) (41.5/2200)
A: Overall Width mm (ft in) 1870 (6 2 )
B: Overall Height mm (ft in) 2610 (8 7 ) 2660 (8 9 )
C: Rear-End Swing Radius mm (ft in) 1000 (3 3 )
D: Minimum Ground Clearance mm (ft in) 335 (1 1 )
E: Counterweight Clearance mm (ft in) 600 (1 12 )
F: Engine Cover Height mm (ft in) 1580 (5 2 )
G: Undercarriage Length mm (ft in) 2450 (8 0 )
H: Undercarriage Width mm (ft in) 2000 (6 7 )
I: Sprocket Center to Idler Center mm (ft in) 1960 (6 5 )
400 (1 4 )
J: Track Shoe Width mm (ft in)
(Rubber Crawler)
kPa 26.0
Ground Pressure 2
(kgf/cm , psi) (0.27, 3.8)
1
Swing Speed min (rpm) 9.0 (9.0)
Travel Speed (fast/slow) km/h (mph) 4.4/2.5 (2.7/1.6)
Gradeability (tan ) 30 (58%)
T1-1-2
WORKING RANGES
40U G
L (Left) L (Right)
I
J
F
A
B
M571-11-002
M1LD-12-004
40U
Canopy Cab
A: Maximum Digging Reach mm (ft in) 5690 (18 8 )
B: Maximum Digging Depth mm (ft in) 3400 (11 2 )
C: Maximum Cutting Height mm (ft in) 5650 (18 6 )
D: Maximum Dumping Height mm (ft in) 4000 (13 1 )
E: Transport Height
2610 (8 7 ) 2660 (8 9 )
(Rubber Crawler) mm (ft in)
F: Overall Transport Length mm (ft in) 5300 (17 5 )
G: Minimum Swing Radius mm (ft in) 2030 (6 10 ) 2340 (7 8 )
I: Blade Bottom Highest Position
400 (1 4 )
(above ground level) mm (ft in)
J: Blade Bottom Lowest Position
365 (1 2 )
K: Maximum Boom-Swing Angle L60 /R80
L950 (L 3 1 )
L: Offset Distance mm (ft in)
R650 (R 2 2 )
T1-1-3
50U G
L (Left) L (Right)
I
J
F
A
B
M571-11-002
M1LD-12-004
50U
Canopy Cab
A: Maximum Digging Reach mm (ft in) 5800 (19 0 )
B: Maximum Digging Depth mm (ft in) 3600 (11 10 )
C: Maximum Cutting Height mm (ft in) 5640 (18 6 )
D: Maximum Dumping Height mm (ft in) 3950 (12 12 )
E: Transport Height
2610 (8 7 ) 2660 (8 9 )
(Rubber Crawler) mm (ft in)
F: Overall Transport Length mm (ft in) 5330 (17 6 )
G: Minimum Swing Radius mm (ft in) 2100 (6 11 ) 2650 (8 8 )
I: Blade Bottom Highest Position
400 (1 4 )
J: Blade Bottom Lowest Position
365 (1 2 )
K: Maximum Boom-Swing Angle L60 /R80
L950 (L 3 1 )
L: Offset Distance mm (ft in)
R650 (R 2 2 )
T1-1-4
GENERAL / Component Layout
MAIN COMPONENTS
3 4
5
6
7
8
9
22 10
21 11
20 12
13
19
18
17 14
15
16
T1LD-01-02-001
1- Bucket Cylinder 7- Revolution Sensing Valve 13 - Engine 18 - Swing Device

2- Arm Cylinder 8- Solenoid Valve Unit 14 - Center Joint 19 - Boom Swing Cylinder
3- Boom Cylinder 9- Hydraulic Oil Tank 15 - Pump Device 20 - Blade Cylinder
4- Front Attachment / Swing 10 - Pilot Filter 16 - Travel Device 21 - Travel Pilot Valve
Pilot Valve
5 - Blade Pilot Valve 11 - Oil Cooler 17 - Fuel Tank 22 - Boom Swing Pilot Valve
6 - Control Valve 12 - Radiator
T1-2-1
ELECTRICAL SYSTEM
2
3
6
19
7
18
9
10
17
16
15 11
14 12
13
T1LD-01-02-002
1 - Work Light (Boom) 6 - Overheat Switch 11 - Engine Stop Solenoid 16 - Fusible Link
2 - Horn Switch 7 - Coolant Temperature Sensor 12 - Starter 17 - Horn
(for Glow Timer)
3 - Pilot Shut-Off Switch 8 - Coolant Temperature Sensor 13 - Fuel Pump 18 - Work Light (Base Machine)
(for Coolant Temperature Gauge)
4 - Solenoid Valve Unit 9 - Glow Plug 14 - Fast Speed Travel 19 - Battery
Pedal
5 - Alternator 10 - Engine Oil Pressure Switch 15 - Fuel Sensor
T1-2-2
RELAYS
Seat
View A (Relay Box)
Relay Box
7
2 3
6
4
A
1 5
T1LA-01-02-003
M1LA-01-005
1 - Fuse Box 3 - Horn Relay 5 - Glow Timer 7 - Glow Relay

2 - Work Light Relay 4 - Starter Relay 1 6 - Starter Relay 2
T1-2-3
MONITOR AND SWITCHES
1 2 3
4
M573-01-025
8 7 6
1 - Preheat Indicator 3 - Alternator Indicator 5 - Coolant Temperature 7 - Work Light Switch

Gauge (Indicator)
2 - Engine Oil Pressure 4 - Fuel Gauge (Indicator) 6 - Hour Meter 8 - Auto-Idle Switch (Optional)
Indicator
SOLENOID VALVE UNIT
Hydraulic Oil Tank
Solenoid Valve Unit

9 10 11
Revolution
Sensing Valve
Pilot Filter
W574-02-07-001
T1LD-04-05-001
9 - Pilot Shut-Off Valve 10 - Pilot Relief Valve 11 - Travel Speed Changeover

Solenoid Valve Solenoid Valve
T1-2-4
GENERAL / Component Specifications
ENGINE
Manufacturer ISUZU
Model 4LE2
Type Diesel, 4-Cycle, Water-cooled, Inline, Direct Injection
Cyl. No.-Bore Stroke 4-85 mm 96 mm 3.35 in 9.30 in)
Piston Displacement 2179 cm3 (85.8 in3)
2.2 +0 -1 +3 +0 -1
Rated Output 30.5 -0 kW / 2200 -25 min (41 -0 PS / 2200 -25 min )
Compression Ratio 18.8
Dry Weight 168 kg (370 lb)
Firing Order 1-3-4-2
Rotation Direction Clockwise (View from fan side)
COOLING SYSTEM
Cooling Fan Dia. 430 mm, 8 Blades (F-Type Blade), Draw-In Type
Fan Pulley Ratio Engine rpm 0.97
Thermostat (Atmospheric Pressure) : Full open temp. 82 C (180 F)
: Cracking temp. 95 C (230 F)
Water Pump Centrifugal Belt Driven Type
LUBRICATION SYSTEM
Lubrication Pump Type Trochoid Pump
Oil Filter Full-Flow Paper Element Type
STARTING SYSYTEM
Motor Magnetic Pinion Shift Type
Voltage / Output 12 V / 2.0 kW
PREHEAT SYSMTEM
Preheating Method Glow Plug
ENGINE STOP SYSYTEM

Stop Method Fuel Shut-Off
ALTERNATOR
Type Regulator Integrated AC type
Voltage / Output 12 V / 35 A
FUEL SYSTEM
Type BOSCH A Type
Governor Centrifugal All Speed Control
Injection Nozzle Multi-Injection Hole Type
T1-3-1
PERFORMANCE
Lubricant Consumption Less than 15 mL/hr at Rated Output
Fuel Consumption Ratio Less than 240 g/kW h (177 g/PS h) at Rated Output
Injection Timing 11.5 before T. D. C
-1
Maximum Output Torque More than 145 6 N m at 1600 min
(14.8 0.6 kgm / Approx. 1600 min-1)
2
Injection Pressure 17.7 MPa (180 kgf/cm )
Compression Pressure 3.04 MPa (31 kgf/cm2) at 250 min-1
Valve Clearance (Inlet/Exhaust) 0.4/0.4 mm (when cool)
No Load Speed Slow:1100 25 min-1 Fast:2375 25 min-1
T1-3-2
Engine Performance Curve (4LE2)
Test Condition: 1. In conformity with JIS D1005 (Performance Test Method for Diesel Engine Used for
Construction Machinery) under standard atmospheric pressure.
2. Equipped with the fan and alternator.
-1
30.5 kW/2200 min
145 N m / Approx. 1600 min-1
(45 PS/2200 rpm) Torque
(14.8 kgf m / Approx. 1600 rpm)
Output 150
kW 10
PS
45
140 9
40 30
130
8
35 25
30
20 0 0
Nm kgf m
25
Fuel Consumption
Ratio
20
15
600
15
10
10 500
5
5
400
g/kW h
0
1200 1400 1600 1800 2000 2200 2400 T1LD-01-03-001
Engine Speed min-1(rpm)
T1-3-3
ENGINE ACCESSORIES
RADIATOR ASSEMBLY
Type ...............................................................Radiator/Oil Cooler Tandem Type Assembly
Weight ............................................................8.05 kg (17.7 lb)
Radiator Oil Cooler

Capacity ......................................................... Approx. 1.6 L Approx. 0.6 L
Cap Opening Pressure .................................. 90 kPa (0.9 kgf/cm2, 13 psi)
BATTERY
Capacity ......................................................... 52 Ah (5-Hour Rate), 65 Ah (20-Hour Rate)
Voltage ........................................................... 12 V
Weight ............................................................ 18 kg (39.7 lb)
T1-3-4
HYDRAULIC COMPONENT
PUMP DEVICE
MAIN PUMP
Model ............................................................. PVK-2B
Type ............................................................... Variable Displacement Swash Plate Pump
Maximum Flow (Theoretical Value) ............... 110 L/min (29.0 US gpm)
PILOT PUMP
Type ............................................................... Trochoid Pump
Maximum Flow (Theoretical Value) ............... 11.0 L/min (2.9 US gpm)
CONTROL VALVE
Model ............................................................. DPK-T04-6P3G-AC-7804B
Type ............................................................... All Pilot Pressure Operated Type
27U
Main Relief Set-Pressure............................... 24.5 MPa (250 kgf/cm2, 3560 psi)
Overload Relief Set-Pressure ........................ 26.5 MPa (270 kgf/cm2, 3840 psi)
(Boom, Arm, Bucket)
11.8 MPa (120 kgf/cm2, 1710 psi) (Blade: Rod Side)
SWING DEVICE
Type ............................................................... Two-Stage Reduction Planetary Gear
Reduction Gear Ratio .................................... 20.615
SWING MOTOR
Model ............................................................. HT32
Type ............................................................... Swash-Plate Type, Fixed Displacement Axial Plunger Motor
SWING VALVE UNIT

Type ............................................................... Non Counterbalance Valve Type
Relief Set-Pressure........................................ 19.6 0.5 MPa (200 5 kgf/cm2, 2840 71 psi) at 32 L/min
SWING PARKING BRAKE

Type ............................................................... Single-Disc-Wet Negative Type
Release Pressure (Full Stroke)...................... 2.9 MPa or less (29.6 kgf/cm2 or less, 421 psi or less)
T1-3-5
TRAVEL DEVICE
Model .............................................................PHV-390-53
Type ...............................................................Two-Stage Reduction Planetary Gear
Reduction Gear Ratio ....................................52.73
TRAVEL MOTOR
Type ............................................................... Varivble Displacement Swash-Plate Piston Motor
TRAVEL BRAKE VALVE

Type ............................................................... Counter Balance Valve Type
CYLINDER
40U Boom Arm Bucket
Rod Diameter................................................. 55mm 50 mm 40 mm
Cylinder Bore ................................................. 90 mm 80 mm 70 mm
Stroke............................................................. 670 mm 702 mm 551 mm
Fully Retracted Length................................... 1070 mm 1041 mm 840 mm
Plating Thickness........................................... 30 m or more
Swing Blade
Rod Diameter................................................. 50 mm 55 mm
Cylinder Bore ................................................. 100 mm 100 mm
Stroke............................................................. 575 mm 150 mm
Fully Retracted Length................................... 905 mm 490 mm
50U Boom Arm Bucket

Rod Diameter................................................. 55 mm 50 mm 45 mm
Cylinder Bore ................................................. 95 mm 80 mm 75 mm
Stroke............................................................. 670 mm 738 mm 551 mm
Fully Retracted Length................................... 1070 mm 1081 mm 840 mm
Swing Blade
Rod Diameter................................................. 50 mm 55 mm
Cylinder Bore ................................................. 100 mm 100 mm
Stroke............................................................. 575 mm 150 mm
Fully Retracted Length................................... 905 mm 490 mm
T1-3-6
FRONT ATTACHMENT PILOT VALVE

Model ............................................................. HVP06C-040-101
TRAVEL PILOT VALVE

Model ............................................................. PVD6PC4018
SWING PILOT VALVE

Model ............................................................. PV6P1029
BLADE PILOT VALVE

Model ............................................................. PV6P1026A
SOLENOID VALVE UNIT (2-Spool Solenoid Valve with Pilot Relief Valve)
Relief Set Pressure ........................................ 3.9 MPa (40 kgf/cm2, 570 psi)
Solenoid Valve ............................................... A Port Side : Solenoid Valve for Pilot Shut-Off Valve
B Port Side : Travel Mode Switch Solenoid Valve
OIL COOLER BYPASS CHECK VALVE

Set Pressure .................................................. 0.4 MPa (4.0 kgf/cm2, 57 psi)
T1-3-7
FILTER
Filtration
Fuel Filter ISUZU
8971788181
Air Filter (with mechanical indicator)
(Indicator Operation Pressure : -6.23 kPa 5%)
Full Flow Filter (Paper Type)
Suction Filter (80 Mesh)
Pilot Filter 10 m
ELECTRICAL COMPONENT
ENGINE OIL PRESSURE SWITCH

Model ............................................................. ISUZU 182410-0082
Operating Pressure........................................ 30 to 50 kPa (0.3 to 0.5 kgf/cm2)
OVERHEAT SWITCH
Model ............................................................. ISUZU 894132-3310
Operating Temperature .................................. 110 C (230 F)
COOLANT TEMPERATURE SENSOR

Glow Timer..................................................... ISUZU 897063-3010
Coolant Temperature Gauge ......................... ISUZU 897142-4110
FUEL SENSOR
Resistance Value Empty : 90 Full : 10
HORN
Voltage / Current DC 12 V 3 A
Sound Pressure 110 dB (A)
IllUMINATION
Output Work Light : Halogen 12V·55 W
T1-3-8
SECTION 2
SYSTEM
CONTENTS
Group 1 Hydraulic System
Outline ...................................................... T2-1-1
Pilot Circuit................................................ T2-1-2
Main Circuit ............................................... T2-1-6
Group 2 Electrical System

Outline ...................................................... T2-2-1
Power Circuit
(key Switch : OFF) ........................ T2-2-2
Indicator Light Check Circuit/Accessory Circuit
(Key Switch : ON).......................... T2-2-4
Preheat Circuit (Key Switch : ON) ............ T2-2-6
Starting Circuit (Key Switch : START)....... T2-2-8
Charging Circuit (Key Switch : ON) ........ T2-2-10
Engine Stop Circuit (Key Switch : OFF) ...T2-2-11
1LDT-2-1
(Blank)
1LDT-2-2
SYSTEM / Hydraulic System
OUTLINE
The hydraulic system consists of the main circuit and

the pilot circuit along with their related items.
Pilot Circuit
Supplies the pressure oil which is delivered from
the pilot pump to the machine operation control
circuit, the pump control circuit, the travel mode
control circuit, and the swing parking brake re-
lease circuit.
Main Circuit
Controls the pressure oil which is delivered from
the main pump to the control valve which in turn
drive the cylinders and the hydraulic motors.
T2-1-1
PILOT CIRCUIT
The pressure oil which is delivered from the pilot pump

is supplied to each circuit as is described below.
Machine Operation Control Circuit Swing Parking Brake Release Circuit

Controls the control valve operation. The major Releases the swing parking brake. This circuit
components in this circuit are the pilot valves. In consists of the pilot shut-off switch, and the pilot
response to the control lever stroke, the pilot shut-off solenoid valve (dual-stop solenoid valve).
valve regulates the pressure oil supplied to the In response to the pilot shut-off switch position
spool end in the control valve which in turn control (ON OFF), the pilot shut-off solenoid valve
the control valve operation. (dual-stop solenoid valve) is shifted so that the
swing parking release oil pressure is supplied to
Pump Control Circuit (Flow Rate Control Circuit) the swing motor. (Refer to COMPONENT OP-
Controls the main pump swash angle. This circuit ERATION/Swing Device group.)
consists of the main pump, the revolution sensing
valve, and the control valve differential reducing
valve. Oil pressure (PGR) from the revolution
sensing valve and oil pressure (PLS) from the
control valve differential reducing valve are sup-
plied to both spool ends of the main pump PS
valve respectively. The PS valve controls the
main pump swash angle in response to the pres-
sure difference between PGR and PLS pressures
to regulate the main pump flow rate. (Refer to
COMPONENT OPERATIN / Pump Device group.)
Travel Mode Control Circuit

Controls the travel mode. This circuit consists of
the travel mode switch, the travel speed
changeover solenoid valve, and the travel mode
control valve. In response to travel mode switch
position (ON OFF), the travel speed changeo-
ver solenoid valve is shifted so that the travel
speed control oil pressure is supplied to the travel
motor. (Refer to COMPONENT OPERA-
TION/Travel Device group.)
T2-1-2
Differential Reducing Valve
Pilot Valve (Left)
Pilot Valve (Right)
Travel Motor
Travel
Mode
Control
Valve
Travel Speed Solenoid
Changeover Valve
Solenoid Valve Unit
Pilot Shut-Off
Solenoid Valve Travel Pilot Valve
Swing Parking
Brake Valve
Swing Pilot Valve
Revolution
Sensing Valve
Pressure Blade Pilot Valve

PGR
Pressure
PLS
PS Valve
Main Pilot Pump

Pump
T1LD-02-01-001
Control Valve
T2-1-3
Machine Operation Control Circuit
NOTE: The boom raise operation is explained

here as an example.
1. The pressure oil from the pilot pump is delivered

to both right and left pilot valves.
2. When the control lever is moved in the boom
raise position, the pressure oil from the pilot pump
is routed to the right pilot valve via the solenoid
valve unit. Then, after being reduced at the pilot
valve to the pressure corresponding to the control
lever stroke, the pressure oil is supplied to the
boom spool end so that the spool is moved in re-
sponse to the control lever stroke.
3. The pressure oil from main pump (P1) is routed to
the boom anti-drift valve via the boom spool.
(Refer to COMPONENT OPERATION / Control
Valve group.)
4. After passing through the anti-drift valve, the
pressure oil is routed to the boom cylinder bottom,
extending the boom cylinder so that the boom is
raised.
T2-1-4
Boom Anti-Drift Valve P1

Pilot Valve (Left)
Swing Motor
Boom Cylinder
Swing
Pilot Valve (Right)

Boom
Arm Cylinder
Arm
Bucket Cylinder
Travel Pilot Valve
Bucket
Boom Swing
Boom Swing Cylinder
Boom Swing Pilot Valve
Auxiliary
Blade Pilot Valve
Travel (Right)
Travel Motor
Travel (Left) Solenoid Valve Unit
Blade Cylinder
Blade
Control Valve T1LD-02-01-002
T2-1-5
MAIN CIRCUIT
Neutral Circuit (When the control lever is in neu-

tral)
1. Main pump (P1) draws hydraulic oil from the hy-

draulic oil tank and delivers it to the control valve.
2. When the control lever is in neutral, the delivered
oil is blocked by the control valve spool. When the
pilot control shut-off lever is in the LOCK position,
the pressure compensator blocks the oil flow.
(Refer to COMPONENT OPERATION / Control
Valve group.) Accordingly, oil pressure in the cir-
cuit up to the control valve increases.
3. When the oil pressure increases more than the
set pressure of the unload valve, the unload valve
is unseated. (Refer to COMPONENT OPERA-
TION / Control Valve group.)
NOTE: When the control lever is in neutral, the
unload valve set pressure is kept at low
pressure.
4. The delivered oil from the main pump is returned

to the hydraulic oil tank via the unload valve and
the oil cooler.
5. When the oil temperature is low (high viscosity),
the oil flow resistance to pass through the oil
cooler increases. Therefore, the bypass check
valve is opened so that the hydraulic oil is re-
turned directly to the hydraulic oil tank without
flowing through the oil cooler, allowing the oil
temperature to quickly increase.
T2-1-6
Unload Valve
Swing Motor
Main Pump
(P1) Boom Cylinder
Blade Cylinder
Bypass Check
Valve
Swing
Oil Cooler
Hydraulic Oil Boom

Tank
Travel Motor
Arm
Pressure Compensator
Bucket
Bucket Cylinder
Boom Swing
Boom Swing Cylinder
Arm
Cylinder
Auxiliary
Travel (Right)
Travel (Left)
Blade
Control Valve T1LD-02-01-003
T2-1-7
Single Operation Circuit (When a control lever is
operated)
NOTE: The main circuits to drive the cylinders and

motors are all identical except when the
boom is raised, the boom anti-drift valve is
employed. Only the boom raise operation
is explained here.

the swing, boom, arm, bucket, boom swing, travel
(right), travel (left), and blade spools in the control
valve.
2. When the boom spool is moved, the pressure oil
from main pump (P1) is routed to the boom anti-
drift valve via the boom spool. (Refer to COM-
PONENT OPERATION / Control Valve group.)
3. After passing through the boom anti-drift valve,
the pressure oil is routed to the boom cylinder
bottom, causing the boom to raise.
T2-1-8
Swing Motor
Differential
Reducing Valve
Boom Cylinder
Swing
Boom Anti-Drift
Valve
Boom
Pressure
Compensator
Main Pump
(P1)
T1LD-02-01-004
To the arm, boom swing, travel

(right), travel (left), and blade
spools
T2-1-9
Combined Operation Circuit (Swing and Boom
Combined Operation)
NOTE: The swing and boom combined operation

is explained here as an example.

the swing and boom spools via the pressure
compensator in the control valve. The pressure
oil from pilot pump (P2) is routed to the differential
reducing valve in the control valve.
2. When the swing and boom control levers are op-
erated, the pressure oil from the pilot valves
moves the swing and boom spools.
3. The pressure oil from main pump (P1) flows to
the swing motor and the boom cylinder via the
swing spool and the boom spool. Thereby, the
swing function and the boom function are oper-
ated.
Pump Operation
4. The differential reducing valve converts the differ-
ential pressure in the circuit between, before and
after the control valve spool into the PLS pressure.
The PLS pressure, accordingly, varies depending
on the load pressure change in the control valve.
The PLS pressure delivered from the differential
reducing valve is routed to the main pump and
the pressure compensators to control their opera-
tion. (Refer to COMPONENT OPERATION / Con-
trol Valve group.)
5. The main pump flow rate is controlled so that the
PLS pressure (the differential pressure in the cir-
cuit between before and after the control valve
spool) supplied from the differential reducing
valve and signal pressure (PGR) delivered from
the revolution sensing valve become balance.
(Refer to COMPONENT OPERATION / Pump
Device group.)
NOTE: Signal pressure (PGR) is used to control
the actuator speeds.
6. As mentioned above, the differential reducing
valve converts the differential pressure in the cir-
cuit between before and after the control valve
spool into the PLS pressure and supplies it to
control the main pump so that the main pump de-
livers oil flow meeting the volume the control
valve requires (equivalent to the load pressure in
the control valve).
T2-1-10
Swing
Motor
Boom Cylinder
Pressure PLS
Swing
Spool
Pressure Boom
Compensator Spool
PGR Pressure
Revolution Main Pump (P1) Pilot Pump (P2) T1LD-02-01-005

Sensing Valve
T2-1-11
Differential Reducing Valve Operation Pressure Compensator Operation
7. The load pressure from the boom cylinder and the 11. As the swing motor load decreases, pressure
swing motor acts on the shuttle valve. (PL) after the spool is reduced, causing differen-
8. When load pressure (PL) from the boom cylinder tial pressure (PLS) between, before and after the
is higher than load pressure (PL) from the swing spool to increase.
motor, load pressure (PL) from the boom cylinder 12. As the boom cylinder load increases, pressure
passes the shuttle valve. That is, maximum load (PL) after the spool is raised, causing differential
pressure (PLMAX) from among the spools is pressure (PLS) between, before and after the
routed to the differential reducing valve. Delivery spool to decrease.
pressures (P1 and P2) from main pump (P1) and 13. Both spool before pressure (PIN) and after pres-
pilot pump (P2) are also routed to the differential sure (PL) are always routed to the pressure com-
reducing valve. pensator. In addition, pressure PLS from the dif-
9. According to maximum load pressure (PLMAX) ferential reducing valve is acting on the differen-
from the actuators, the differential reducing valve tial reducing valve as the target differential pres-
control the PLS pressure and supplies the con- sure. The pressure compensaor operates so as
trolled PLS pressure to the main pump and the to satisfy the relationship between pressures (PIN,
pressure compensator. (Refer to COMPONENT PL, and PLS) as shown in the following formula:
OPERATION / Control Valve group.) The pres- Pressure PIN = Pressure PL + Pressure PLS
sure relationship between PLS, Pump Delivery (Refer to COMPONENT OPERATION / Control
Pressure (P1) and PLMAX acting on the differen- Valve group.)
tial reducing valve is described in the following 14. When the swing motor load is light, high hydraulic
formula: oil pressure to drive the swing motor is not re-
Pressure PLS = Pressure P Pressure PLMAX quired. When the boom cylinder load is heavy,
The differential reducing valve outputs pressure high hydraulic oil pressure is required to drive the
PLS equivalent to the differential pressure be- boom cylinder. Under this condition, each pres-
tween pump delivery pressure (P) and maximum sure compensator operates as described below,
actuator load pressure (PLMAX). allowing the main pump to supply more hydraulic
10. Depending on change in pressure PLS from the oil to the actuator which requires more hydraulic
differential reducing valve, the pump control op- oil.
eration is performed. As differential pressure (PLS) between before
spool pressure (PIN) and after spool pressure
(PL) in the swing circuit is large, the pressure
compensator is pushed by before spool pressure
(PIN), causing the pressure compensator to move
to the left. Thereby, the pressure compensator
closes the opening port area, restricting the main
hydraulic oil flow to the swing spool via the pres-
sure compensator.
As differential pressure (PLS) between before
spool pressure (PIN) and after spool pressure
(PL) in the boom circuit is small, the pressure
compensator is pushed by after spool pressure
(PL + PLS), causing the pressure compensator to
move to the right. Thereby, the pressure compen-
sator open the opening port area wider, allowing
the main hydraulic oil to flow more to the boom
spool via the pressure compensator.
T2-1-12
Swing
Motor
(Load:
Light)
Shuttle Valve Boom Cylinder

(Load: Heavy)
Pressure
Compensator
Pressure
Pressure PL PIN
Pressure PLS
Pressure PL Pressure PIN
Pressure PLS Pressure Compensator
Main Pump (P1) Pilot Pump (P2) T1LD-02-01-006
T2-1-13
(Blank)
T2-1-14
SYSTEM / Electrical System
OUTLINE
The electrical system is roughly classified into the The main functions and construction of the main circuit
main circuit and the monitor circuit. are outlined here:
Main Circuit Power Circuit: Supplies electrical power to all

Operates the engine and accessory circuits. electrical systems on the machine.
(including key switch, battery, fuse box and fusible
Monitor Circuit links)
Consists of the monitors, sensors, and switches to
display machine operating conditions. Indicator Light Check Circuit: Checks for burned
monitor indicators.
(including key switch, fuse box and controller)
Accessory Circuit: Works with the key switch ON.

(including key switch and fuse box)
Preheating Circuit: Helps start the engine in cold

weather.
(including key switch, QOS sensor, glow timer, glow
relay and glow plugs)
Engine Starting Circuit: Starts the engine.

(including key switch, starter and starter relay 1)
Charging Circuit: Supplies all electric power to

onboard systems and recharges the batteries.
(including alternator and battery)
Engine Stop Circuit: Stops the engine with the stop

solenoid.
(including stop solenoid and alternator)
T2-2-1
POWER CIRCUIT (KEY SWITCH: OFF)
The battery negative terminal is grounded to the

vehicle frame. When the key is in the OFF position,
electrical power from the positive battery terminal is
supplied as follows:
Fusible Link a Alternator Terminal B

Glow Relay (Power Source)
Battery Monitor Panel and Switch Panel

Key Switch Terminal B
Fusible Link b Terminal #7
Fuse Box Terminal #11
Radio (Optional) (Backup Power
Source for Clock and Memory)
Starter Terminal B
Monitor Panel and Switch Panel
Fuse Box
Key Switch
Radio
Fusible Link
Battery
From Starter
Relay 1
Starter
Glow Relay
Alternator
T1LA-02-02-001
T2-2-2
(Blank)
T2-2-3
INDICATOR LIGHT CHECK CIRCUIT·ACC-
ESSORY CIRCUIT (KEY SWITCH : ON)
1. When the key switch is turned to the ON position,

terminal B is connected to terminals BR, R2 and
the ACC terminal in the key switch.
2. Current from key switch terminal BR flows to the
alternator, engine stop solenoid and fuse box.
3. Current to the fuse box flows to operate the fuel
feed pump, warning system (optional), monitor
panel, switch panel, auto-idle system (optional),
and radio (optional).
4. Current from the fuse box also flows to the
monitor panel and switch panel terminal #8 to
check for any burned preheat indicator, alternator
indicator, and engine oil pressure indicator.
5. Current from key switch terminal ACC flows via
the fuse box to operate the pilot shut-off valve
solenoid valve, work light, horn and travel speed
changeover solenoid valve, starter relay 2, glow
timer, glow relay and to supply auxiliary power.
6. Current from key switch terminal R2 flows via the
fuse box to operate the heater and air conditioner
(optional), wiper motor (optional), and blower
motor (optional).
T2-2-4
Key Switch
To Alternator and
Engine Stop Solenoid
Fuse Box
Radio (Optional)
Preheat
Indicator
Auto-Idle System (Optional) Alternator
Indicator
8
Warning System (Optional) etc.

Buzzer
Fuel Feed Pump
Blower Motor (Optional) Engine Oil

Pressure
Heater / Air Conditioner and Wiper (Optional) Indicator
Starter Relay 2, Glow Timer and Glow Relay
Backup Power Source
Horn and Travel Speed Change Solenoid Valve
Work Light
Pilot Shut-Off Valve Solenoid Valve
T1LA-02-02-002
T2-2-5
PREHEATING CIRCUIT (KEY SWITCH:ON)
1. When the key switch is turned to the ON position,

terminal B is connected to terminals BR, R2 and
terminal ACC inside the key switch.
2. Current from terminal ACC flows via the fuse box
to the glow timer terminal #3 and glow relay
terminal #3.
3. The QOS sensor is connected to terminal #4 of
glow timer to detect the engine coolant
temperature. When the engine coolant
temperature is below the set temperature, the
glow timer is activated. When the glow timer is
activated, the current from terminal #5 in the
monitor panel and switch panel to terminal #2 in
the glow timer is grounded, lighting the grow
signal.
4. At the same time, the glow timer grounds the
current from terminal #4 in the glow relay to
terminal #5 in the glow timer. Then, the glow relay
is magnetized, allowing the current from terminal
#1 in the glow relay to flow into the glow plug via
terminal #2.
5. The actuation time of the glow timer is determined
depending on the resistance value of the QOS
sensor. When preheating is complete, the glow
timer stops and indicates preheating has been
completed (the preheat indicator goes OFF).
Simultaneously, the glow relay is turned OFF,
stopping the current to the glow plugs.
NOTE: When the key switch is turned to the

START position after preheating, the
current flows from terminal #1 in the key
switch to terminal #1 in the glow timer.
Receiving this signal, the glow timer
activates glow relay again. Therefore, the
starter rotates while the current is flowing
to the glow plugs, causing the engine to
start more easily.
T2-2-6
Key Switch
Fuse Box
Preheat Indicator
Battery
QOS Sensor
Glow Relay
Glow Timer
Monitor Panel and
Switch Panel
Glow Plug
T1LA-02-02-003
T2-2-7
STARTING CIRCUIT (KEY SWITCH :
START POSITION)
1. When the key switch is turned to the START 11. The current to terminal #3 in starter relay 2 flows
position, terminal B is connected to terminals into the base part in transistor.
BR,R1,C,and ACC in the key switch. 12. Consequently, the current from terminal #1 in
2. The current from terminal BR in the key switch starter relay 1 to terminal #4 in starter relay 2 is
flows to two directions. One current flows to the grounded through the transistor and terminal #2
fuel feed pump via the fuse box and activates the to magnetize starter relay 1
fuel feed pump. 13. Therefore, the contact between terminals #3 and
3. The current from terminal C in the key switch #6 is turned OFF. Then, the current from terminal
flows to the engine start side of the stop solenoid. R1 in the key switch does not flow into terminal
The stop solenoid moves to the engine start side ST in the starter via starter relay 1, stopping the
to release the fuel cut off lever. (The engine can starter.
rotate under this condition.)
4. Terminal L in the alternator is connected to the
ground inside the alternator. The terminal #1 in
starter relay 2 and terminal #3 in the monitor
panel and switch panel are grounded in the
alternator.
5. Therefore, the alternator indicator comes ON.
6. The current from terminal ACC in the key switch
is grounded in the alternator via the fuse box and
terminals #3 to #1 in starter relay 2.
7. As no base current flows to the transistor (base
part) in starter relay 2 , the current from terminal
#1 in the starter relay 1 to terminal #4 in starter
relay 2 is not grounded.
8. The current from terminal R1 in the key switch
flows to terminal ST in the starter via the contact
between terminals #3 and #6 in starter relay 1.
Therefore, the contact in the starter is closed to
rotate the starter.
9. After the engine is started, the alternator starts
generating the electrical power, increasing the
voltage at terminal L in the alternator. Then, the
current from the alternator indicator and terminal
#3 in the monitor panel and switch panel is not
grounded in the alternator, turning the alternator
indicator OFF.
10.At the same time, the current from terminal ACC
in the key switch to terminal L in the alternator via
the fuse box and terminals #3 to #1 in starter
relay 2 is not also grounded.
T2-2-8
Key Switch
Battery
Starter
ST
Alternator

Engine Start Side
Stop Solenoid
Fuel Feed Pump
Starter Starter T1LA-02-02-004

Relay 2 Relay 1
T2-2-9
CHARGING CIRCUIT (KEY SWITCH : ON)
1. The key switch is automatically returned to the 4. After the alternator begins to generate electrical
ON position upon releasing it after the engine current, the voltage at terminal L in the alternator
starts. With the key switch ON, terminal B is increases. The current flowing to alternator
connected to terminals BR, R2 and ACC in the terminal L via the alternator indicator and the
key switch. monitor panel and switch panel terminal #3 is not
grounded, turning the charge lamp OFF.
2. Current from the key switch terminal BR flows to
alternator terminal #2, exciting the field coil in side 5. Current from key switch terminal BR flows to the
the alternator. holding side of the stop solenoid, holding the fuel
cut lever in the release position so that the engine
3. As the engine runs, the alternator rotates,
is ready to start.
generating electrical current. Electrical current
flows from alternator terminal B to the battery via
the fusible link, recharging the battery. The
electrical current is maintained constant by a
built-in regulator.
Key Switch
Fuse Box Alternator

Indicator
8
Battery
Alternator
Stop Solenoid
Holding Side Monitor Panel and T1LA-02-02-005
Switch Panel
T2-2-10
ENGINE STOP CIRCUIT
(KEY SWITCH: OFF)
1. When the key switch is turned from the ON NOTE: Surge voltage to be developed when
position to the OFF position, key switch terminal stopping the engine doesnt arise because
B is disconnected from terminals BR, R2 and the alternator generation circuit is directly
ACC in the key switch. connected to the battery. (The batteries
2. Current to the accessories from key switch function as a condenser.)
terminal R2 and ACC is stopped.
3. Current to the holding side of the stop solenoid
from key switch terminal BR is stopped,
deactivating the stop solenoid. Then, the fuel cut
lever is moved by spring force to the fuel cut
position. Therefore, the fuel isnt supplied,
causing the engine to stop.
Key Switch
Fuse Box
To Each Accessory
Battery
Alternator
Stop Solenoid
T1LA-02-02-006
Holding Side
T2-2-11
(Blank)
T2-2-12
SECTION 3
COMPONENT OPERATION
CONTENTS
Group 1 Pump Device Group 5 Pilot Valve
Outline ...................................................... T3-1-1 Outline........................................................... T3-5-1
Main Pump P1........................................... T3-1-4 Operation ...................................................... T3-5-4
Power Control........................................... T3-1-5
Flow Rate Control...................................... T3-1-6 Group 6 Travel Device
PS Valve ................................................... T3-1-7 Outline........................................................... T3-6-1
Travel Motor .................................................. T3-6-2
Group 2 Revolution Sensing Valve Travel Brake Valve ........................................T3-6-3
Outline ...................................................... T3-2-1 Travel Reduction Gear ..................................T3-6-8
Operation .................................................. T3-2-4

Group 7 Others (Upperstructure)
Solenoid Valve Unit .......................................T3-7-1
Group 3 Swing Device
Pilot Relief Valve ...........................................T3-7-2
Outline ...................................................... T3-3-1
Swing Motor .............................................. T3-3-2 Group 8 Others (Undercarriage)
Parking Brake............................................ T3-3-3 Swing Bearing ............................................... T3-8-1
Valve Unit...................................................... T3-3-4 Center Joint................................................... T3-8-2
Swing Reduction Gear ................................. T3-3-6 Track Adjuster ............................................... T3-8-4
Group 4 Control Valve

Outline ...................................................... T3-4-1
Hydraulic Circuit ........................................... T3-4-6
Main Relief Valve.......................................... T3-4-8
Overload Relief Valve ................................... T3-4-9
Make-Up Valve ........................................... T3-4-10
Main Shut-Off Valve.................................... T3-4-12
Boom Anti-Drift Valve ................................. T3-4-14
Unload Valve .............................................. T3-4-16
Differential Reducing Valve ........................ T3-4-18
Pressure Compensator .............................. T3-4-20
Variable Relief Valve................................... T3-4-22
1LDT-3-1
(Blank)
1LDT-3-2
COMPONENT OPERATION / Pump Device
OUTLINE
The pump device consists of main pump P1 and pilot

pump P2 and is directly driven by the engine. Main
pump (P1) is a swash plate type variable displacement
axial plunger pump and supplies high pressure oil to
operate the actuators via the control valve.
Pilot pump (P2) is a gear pump and supplies pressure
oil to the pilot circuit.
Main Pump P1
Pilot Pump P2
T1LD-03-01-002
T3-1-1
Hydraulic Diagram
1 2 3 4 5 6
12 11 10 9 8 7
T1LD-03-01-007
1 - Port PLS 4 - Port PGR 7 - Swash Plate 10 - Plunger

(from control valve differ- (from revolution sensing valve)
ential reducing Valve)
2 - Port PA 5 - Port P1 8 - Port S1 11 - Control Piston
(to control valve) (from hydraulic oil
tank )
3 - Valve PS 6 - Port P2 9 - Spring 12 - Orifice
(to pilot filter)
T3-1-2
A B
C T1LD-03-01-003
D
View A
View B
6
2
4
D
T1LD-03-01-002
Cross Section C-C

9 8 T1LD-03-01-004
Cross Section D-D
T1LD-03-01-005
7 10 11 12
T1LD-03-01-006
T3-1-3
MAIN PUMP P1
Supplies pressure oil to the main circuit.
The cylinder block is splined to the shaft. The plungers

are inserted in the cylinder block. When the engine
rotates, the shaft is driven so that the cylinder block is
rotated together with plungers. The plunger slides
along the shoe plate while oscillating in the cylinder
block due to tilt of the swash plate, drawing and deliv-
ering oil.
Plunger Cylinder
Block
Shoe Plate
Shaft
T1LD-03-01-005
Swash Plate
T3-1-4
POWER CONTROL
Purpose:
Controls the oil flow rate from main pump P1 so that
the total power to drive main pump P1 and pilot pump
P2 doesnt exceed the engine power.
Operation:
1. When the main pump P1 delivery oil pressure in-
creases more than the load pressure, the in-
creased pressure acts on the plunger.
2. The pressure force on the plunger pushes the
swash plate around the oscillation pin until the
pressure force increases to balance with the
spring force.
3. Then, main pump (P1) decreases the delivery oil
flow rate.
4. Accordingly, depending on the own delivery oil
pressure, the delivery oil flow rate from main
pump (P1) is controlled so that the total power to
drive main pump P1 and pilot pump P2 is main-
tained lower than the engine power.
Spring
Spring Force
Oscillation Pin
T1LD-03-01-005
Swash Plate Plunger
T3-1-5
FLOW RATE CONTROL
Purpose:
Controls the pump delivery flow rate in response to Operation:
change in loads to the cylinders and the motors. 1. The pressure oil from the PS valve is routed to
the control piston via the orifice, causing the con-
trol piston to push the swash plate.
NOTE: Both pressure PGR (varies in response to
2. The swash plate is moved to tilt until the control
change in the engine speed) from the revo-
piston force becomes to balance with the plunger
lution sensing valve and pressure PLS
swash plate pushing force. (Refer to POWER
(varies depending on the load pressure in
CONTROL on page T3-1-5.)
the control valve) from the control valve dif-
3. The delivery flow rate from main pump P1 varies.
ferential reducing valve act on the PS valve.
4. As the delivery flow rate from main pump P1 var-
Until pressure PGR becomes equal with
ies, the pressure oil supplied to the control valve
pressure PLS, the PS valve operates to
varies.
regulate the pump delivery flow rate.
5. As pressure oil supplied to the control valve var-
ies, pressure PLS from the differential reducing
valve varies.
6. When pressure PLS and PGR, both are routed to
the PS valve on the main pump, become equal,
the main pump swash plate stops tilting.
Plunger
Spring Force
Orifice
PS Valve
Swash Plate Control Piston

T1LD-03-01-005
T3-1-6
PS VALVE
Construction / Function Operation:

The PS valve consists of the springs, the spool, and 1. Signal pressures (PGR and PLS) are routed on
the sleeve. The PS valve controls the main pump de- both ends of the spool in the PS valve, moving
livery flow rate in response to the oil pressure signals the spool to either the right or the left.
in the following. 2. Then, the oil ports on the PS valve are shifted.
Pressure PGR (varies in proportion to the engine 3. In response to shifting of the oil ports, the oil
speed) from the revolution sensing valve. (Refer pressure routed from the PS valve to the control
to the revolution sensing valve group in this sec- piston in the main pump varies.
tion.) 4. Then, the swash plate tilt angle is changed so
Pressure PLS (varies in response to the pressure that the delivery flow rate from main pump P1 is
change from the actuators) from the control valve controlled.
differential reducing valve. Pressure PGR Pressure PLS ( Actuator loads
The PS valve controls the main pump delivery flow have increased):
rate in response to change in pressure difference be- The delivery flow rate from main pump P1 is in-
tween pressures PGR and PLS. creased.
Pressure PGR Pressure PLS ( Actuator loads
have decreased):
The delivery flow rate from main pump P1 is re-
duced.
5. When the actuator load increases, more oil flow is
required to drive the actuator so that the PS valve
increases the pump delivery flow rate. When the
actual load decreases, the pump delivery flow
rate is reduced.
A
Cross Section A-A
Spring
PS Valve
T1LD-03-01-002
Spring Spool Sleeve
T1LD-03-01-006
T3-1-7
Main Pump Delivery Flow Rate Increase (When a
control lever is operated:)
1. Pressure PGR from the revolution sensing valve 7. The oil in chamber C (9) of control piston (10) is
and pressure PLS from the control valve differen- routed to the pump suction port via orifice (8).
tial reducing valve are routed to chamber A (6) Since swash plate (11) is moved by spring (1)
and B (4) in the PS valve respectively. force, the tilting angle increases, causing the
2. When the actuator load increases, pressure PLS main pump delivery flow rate to increase.
becomes lower than pressure PGR (Pressure
PLS Pressure PGR). Therefore, the pressure NOTE: Orifice (8) is provided to prevent swash
force in chamber A (6) overcomes spring B (3) in plate (11) from being suddenly moved.
chamber B (4) so that spool (5) is moved toward Therefore, swash plate (11) is smoothly
chamber B (4). moved.
3. Then, the oil port on control piston (10) is con-
nected to the pump suction port via PS valve
spool (5) and sleeve (2), releasing the oil pres-
sure behind control piston (10) to the pump suc-
tion port. The pilot pump delivery pressure port is
blocked by PS valve spool (5).
4. The pilot oil pressure from pilot pump (P2) is
routed to port PA.
5. The oil port to control piston (10) is connected to
the pump suction port via PS valve spool (5) and
sleeve (2). Accordingly, the oil pressure behind
the control piston (10) is released to the pump
suction port.
6. Although the oil pressure in the pump suction port
acts on control piston (10), as it is a suction oil
pressure, its pressure force cannot overcome
spring (1) force in the main pump. Accordingly,
control piston (10) is moved toward chamber C
(9).
T3-1-8
Oil pressure form 2

1
pilot pump (PA)
PS Valve
Pressure Pump
11 10 9 8 PGR Suction
7 6 5 Port 4 3
T1LD-03-01-005
T1LD-03-01-006
P1 Pressure PGR PA Pressure PLS
5
3
PS
Valve
4
8
9
Increase 10
Decrease
T1LD-03-01-008
11 6 1
1 - Spring 4 - Chamber B 7 - Spring A 10 - Control Piston

2 - Sleeve 5 - Spool 8 - Orifice 11 - Swash Plate
3 - Spring B 6 - Chamber A 9 - Chamber C
T3-1-9
Main Pump Delivery Flow Rate Decrease (When a
control lever is operated:)
1. Pressure PGR from the revolution sensing valve

and pressure PLS from the control valve differen-
tial reducing valve are routed to chamber A (6)
and B (4) in the PS valve respectively.
2. When the actuator load decreases, pressure PLS
becomes higher than pressure PGR (Pressure
PLS Pressure PGR). Therefore, the pressure
force in chamber B (4) overcomes spring A (7) in
chamber A (6) so that spool (5) is moved toward
chamber A (6).
3. Then, the oil port to control piston (10) is con-
nected to pump delivery pressure port (PA) via
PS valve spool (5) and sleeve (2). The pump suc-
tion port is blocked by PS valve spool (5).
4. The pilot oil pressure from pilot pump (P2) is
routed to port PA.
5. When pilot pump delivery pressure delivered into
chamber C (9) in control piston (10) overcomes
spring (1) force, swash plate (11) is moved
against spring (1) so that the main pump flow rate
is reduced.
NOTE: Orifice (8) is provided to prevent swash

plate (11) from being suddenly moved.
Therefore, swash plate (11) is smoothly
moved.
T3-1-10
Oil pressure from 2

1
pilot Pump (PA)
PS Valve
Pressure PGR Pump

11 10 9 8 Suction
7 6 5 Port 4 3
T1LD-03-01-005
T1LD-03-01-006

7
5
3
PS
Valve 4
8
Increase 10
Decrease
T1LD-03-01-009
11 6 1

T3-1-11
Main Pump Flow Rate Minimization (When con-
trol levers are in neutral:)
4. Pressure PLS from the differential reducing valve

1. When all control valve spools are in neutral (all and pressure PGR from the revolution sensing
control levers are in neutral), the system oil pres- valve are routed to the main pump PS valve.
sure after the control valve spools is zero. There- Since pressure PLS is higher than pressure PGR,
fore, pressure PLMAX (zero) from the main circuit spool (5) is moved to the left, causing the main
after the spools is routed to the differential reduc- pump to reduce the delivery flow rate. (Refer to
ing valve at this time. this group in this section.)
2. When the control valve spools are in neutral, the 5. Pilot pump delivery pressure (PA) is supplied to
unload valve is unseated if the main pump deliv- the PS valve.
ery pressure increases more than the total com- 6. Pilot pump delivery pressure (PA) is routed into
bined pressure force of pressure PGR and spring chamber C (9) in control piston (10) and over-
force. Accordingly, the main pump oil pressure comes spring (1) force. Accordingly, control pis-
routed to the differential reducing valve is equal to ton (10) is moved toward swash plate (11)so that
the unload valve operation pressure (pressure swash plate (11) is held in the minimum flow rate
PGR + spring force). position. Thereby, the main pump maintains the
3. As the unload valve operation pressure is higher minimum flow rate.
than pressure PLMAX (zero), the differential re-
ducing valve is moved to the left. Then, after re-
ducing the pilot pressure to the unload valve op-
eration pressure, the differential reducing valve
delivers it as pressure PLS.
Pilot Pressure Pressure PGR
Differential Unload Valve

Reducing
Valve
Spring
Main Pump
(Unload Valve Delivery Pressure
Operation Pressure)
Pressure PLMAX Pressure PLS
(Zero) T566-03-01-011
T3-1-12
1 Oil pressure from

pilot pump (PA)
Valve PS
Pressure PLS
Pressure PGR Pump
11 10 9 Suction
5 Port
T1LD-03-01-005
T1LD-03-01-006
PS
Valve
Increase 10
Decrease
T1LD-03-01-010
11 1

T3-1-13
(Blank)
T3-1-14
COMPONENT OPERATION / Revolution Sensing Valve
OUTLINE
The revolution sensing valve converts change in the

pilot pump delivery flow rate to signal pressure (PGR)
to be used for controlling the pump flow rate. (The pilot
pump is a fixed displacement pump so that the deliv-
ery flow rate changes directly in proportion to the en-
gine speed.)
The revolution sensing valve is located in the pilot cir-

cuit between the pilot pump and the solenoid valve. In
response to change in the engine speed, the pressure
PGR is routed to the main pump swash angle control
system from port PGR to regulate the pump tilt angle.
The revolution sensing valve consists of the variable
metering valve and the differential reducing valve.
Revolution Sensing Valve

Port PPLO Port PPHI
Variable Metering
Valve
Differential Reducing
Valve
T566-03-02-001
Port DR
A
View A
T566-03-02-003
Port PGR
T3-2-1
Hydraulic Circuit Diagram
3
2
T566-03-02-013
7 6
1 - Port PPLO 3 - Differential Reducing Valve 5 - Port PPHI 7 - Orifive

(to solenoid valve unit, main (from pilot filter)
pump, and control valve)
2 - Port PGR 4 - Port DR 6 - Variable Metering Valve
(to main pump. Control (to hydraulic tank)
valve)
T3-2-2
1 5
T566-03-02-001
A
2
View A
B B
T566-03-02-003
Cross Section B-B
3
T566-03-02-002
T3-2-3
OPERATION
Spool (3), piston (7), and spool (8) are illustrated in the
position when the engine is stopped. Spool (3) is
pushed by spring (2) to the right. Both spring (6) force
and spring (9) force are identical to so that piston (7)
and spool (8) are held in the position illustrated.
1 2 3 4 Port PPHI
Variable Metering
Valve
Port PPLO
Valve
Port PGR T566-03-02-002
11 10 9 8 7 6 5
Port DR
1 - Sleeve 4 - Orifice 7 - Piston 10 - Spring Seat

2 - Spring 5 - Guide 8 - Spool 11 - Sleeve
3 - Spool 6 - Spring 9 - Spring
T3-2-4
(Blank)
T3-2-5
While the Engine is Running (Output Diagram:
between A and B)
6. The differential pressure between ports PPHI and

1. When the engine speed increases, the differential PPLO decides whether spool (8) is moved to the
pressure between the front and the rear of orifice left or to the right. Accordingly, the differential re-
(4) changes in proportion to the engine speed. ducing valve operation regulates pressure PGR
2. Spool (8) and piston (7) in the differential reduc- at port PGR corresponding to the pressure differ-
ing valve are moved so that the pressure force ences between points A and B on the output dia-
balance satisfies the formula of Pressure PGR gram.
Area S3 + Pressure PPLO Area S2 = Pressure
PPHI Area S1. Thereby, pressure PGR be-
comes equal to the differential pressure between
the front and the rear of orifice (4) (Pressure PPHI
Pressure PPLO)
For example:
(1) When pressure PGR Area S3 + Pressure
PPLO Area S2 Pressure PPHI Area S1,
spool (8) is moved to the right, pressure
PGR is drained through notch D, reducing
pressure PGR.
(2) When pressure PGR Area S3 + Pressure
PPLO Area S2 Pressure PPHI Area S1,
piston (7) and spool (8) are moved to the left
so that port PPLO is opened at notch C, al-
lowing pressure PGR to increase.
Repetition of operations (1 and 2) maintains
the pressure balance Pressure PGR Area
S3 = Pressure PPHI Area S1 - Pressure
PPLO Area S2. Since S1= S2 = S3, the re-
lation of Pressure PGR = Pressure PPHI
Pressure PPLO is maintained.
3. The opening area of notch C varies depending on
the engine speed. Therefore pressure PGR at Pressure PGR
port PGR varies depending on the engine speed. (Pressure at
This process corresponds to the points between Output Port)
A and B on the output diagram.
4. While the engine is running, the pressure oil from
the pilot pump routed into port PPHI flows into ori- B
fice (4) and onto variable metering valve spool
(3).
5. In proportion to the engine speed, pressure PPHI A
and pressure PPLO vary due to orifice (4) to-
gether with the pilot pump (fixed displacement)
delivery flow rate. When the engine speed is be- Engine Speed
tween points A and B, spool (3) receive pressure Slow Idle Fast Idle
PPLO and spring (2) force. When pressure PPLO
Output Diagram
is still high, the spring force and pressure PPLO is
larger than pressure force PPHI so that spool (3)
remains closed.
T3-2-6
Port PPLO Port PPHI

(Pressure (Pressure
PPLO) PPHI)
2 3 4
Variable Metering
Valve
Section C
Section D
Chamber (b)
Chamber (a)
11
Port PGR
9 8 (Pressure 7
PGR)
Hydraulic Oil
Tank
T566-03-02-008
S3 S2 S1
Port PPLO Port PPHI
(Pressure PPLO) (Pressure PPHI)
Section D
Section C
Valve
Port PGR T566-03-02-009

(Pressure PGR)
11 8
2 - Spring 4 - Orifice 9 - Spring 11 - Sleeve

3 - Spool 8 - Spool
T3-2-7
While the Engine is Running (Output Diagram:
between B and C)
1. While the engine is running, the pressure oil from

the pilot pump is routed into port PPHI flows into
orifice (4) and onto variable metering valve spool
(3).
Pressure PGR
2. When the differential pressure between pressure (Pressure at
PPHI and Pressure PPLO increases more than Output Port)
the specified valve, the oil pressure at port PPHI
overcomes spring (2) force, moving spool (3) to
the left. C
B
3. When spool (3) is moved to the left, some pres-
sure oil from port PPHI is bypassed through notch
(d) on variable metering valve spool (3) and
sleeve (1) so that the differential pressure be-
tween ports PPHI and PPLO doesnt increase
more than required. Pressure PGR created by the
variable metering valve operation corresponds to Engine Speed
the pressure between points B and C on the out-
Slow Idle Fast Idle
put diagram.
Output Diagram
T3-2-8
1 2 Port PPLO Section (d) 3 4
Port PPHI
Variable Metering
Valve
Section (C)
Port PGR T566-03-02-011

(Pressure PGR)
11 8
1 - Sleeve 3 - Spool 8 - Spool 11 - Sleeve

2 - Spring 4 - Orifice
T3-2-9
(Blank)
T3-2-10
COMPONENT OPERATION / Swing Device
OUTLINE
The swing device consists of the valve unit swing mo-

tor and swing reduction gear.
The valve unit prevents cavitation and overload in the
swing circuit.
The swing motor is a swash-plate-type axial plunger
motor incorporating a parking brake. The swing motor,
driven by pressure oil from the pump, transmits the
rotation force to the swing reduction gear. The swing
reduction gear converts the swing motor rotation
power to a slow but large torque which rotates the up-
perstructure.
Valve Unit
Swing Motor
Swing Reduction
Gear
T575-03-02-001
T3-3-1
SWING MOTOR
The inner rotor is splined to the shaft, and the plunger

is inserted in the rotor.
When the pump supplies pressure oil to the swing mo-
tor, plungers are pushed down with pressure oil while
sliding along the swash plate, developing turning force.
As the shaft is splined to the rotor and sun gear in the
swing reduction gear, the rotor torque is transmitted to
the swing reduction gear unit.
Valve Plate
Shaft
Rotor
Plunger
Shoe
Swash
Plate
Retainer
Sun Gear
T575-03-02-001
T3-3-2
PARKING BRAKE
The parking brake is a wet-negative-type single disc

brake which is released only when the brake release Brake Piston
pressure oil is routed into the brake piston chamber. Motor Housing Chamber
When releasing the brake:

When the pilot control shut-off lever is in the UN- Brake Piston
LOCKED position, the pilot shut-off switch is ON. By
this action, the pilot shut-off valve solenoid valve is
ON, so that the brake release pressure (pilot pres-
sure) is guided to the brake piston chamber
Through the inner passage in motor housing to push
Disc Plate
the brake piston upward, allowing the brake piston
and the disc plate contact to free, so that the rotor
can be rotated.
When the brake is applied:

When the pilot control shut-off lever is in the Inner Passage
LOCKED position, the pilot shut-off switch is OFF.
Rotor
By this action, the pilot shut-off valve solenoid valve
is OFF, so that the brake release pressure (pilot Pilot Shut-Off
pressure) is not guided to the brake piston chamber. Valve Solenoid
Valve
The brake release pressure oil in brake piston
chamber flows back to the hydraulic oil tank via the
pilot shut-off valve solenoid valve. T565-03-02-005
Pilot Pump
Accordingly, by the spring, the disc plate splined to
the rotor is pushed onto the motor housing . There-
fore the rotor is secured.
Motor Housing Brake Piston Chamber
Spring
Disc Plate
Rotor
Pilot Shut-Off
Valve Solenoid
Valve
T565-03-02-006
Pilot Pump
T3-3-3
VALVE UNIT
The valve unit consists of the make-up valves and re-

lief valves.
The make-up valve prevents the occurrence of cavita-
tion in the circuit. The relief valve also protects the
circuit from surge pressure and overloading.
Make-Up Valve
When stopping swing operation, the swing spool is in
neutral by returning the swing lever and the flow rate
to swing motor stops flowing.
But the swing motor rotates by inertia, so cavitation
occurs in the circuit.
To prevent cavitation, when the oil pressure in the
circuit is lower than the pressure at port M (hydraulic
oil tank pressure), the poppet opens to draw hydrau-
lic oil into the circuit so that the pump oil flow rate is
replenished.
Relief Valve
Made-Up
Valve
T565-03-02-002
From Control Port M To Control Poppet

Vavle Valve
T3-3-4
Relief Valve
The relief valve functions to reduce shocks devel-
oped when starting or stopping swing movement
(shockless) and to protect the circuit from overload-
ing (relief).
Shockless Operation
When the pressure in the circuit increases, the
pressure oil enters in the piston chamber via the ori-
fice of poppet and housing, to move the piston to the
left.
Piston
The pressure in the spring chamber is kept low dur- Chamber
Poppet Orifice Spring
ing the movement of piston. Therefore, the pressure
at port HP opposes the spring set force only, and
the poppet opens to relieve the hydraulic oil under LP
low pressure whenever the pressure at port HP is
low.
HP
Therefore, the pressure stops temporally increasing
and shocks are retuced when starting or stopping
the swing operation. When the piston moves to the
stroke end, the pressure in the spring chamber be-
S1 S2 Housing Spring
comes equal to the pressure at port HP. As a result, Chamber
T561-02-03-001
the relief set force becomes to the normal pressure,

so the poppet closes.
Relief Operation
When the pressure in the circuit increases, the force
which acting on poppet (Pressurized Area (S1-
S2) Pressure at Port HP) exceeds the spring force,
so the poppet opens to allow the hydraulic oil to be
relieved. Poppet
Quick Return Operation of Piston LP

This operation is to return the piston to the original
position. The shockless operation is performed as
the piston moves from right to left. Therefore, when HP
stopping the swing operation, move the piston to
right. When returning the swing lever to the neutral
position, the back pressure arises in the return cir-
cuit due to the swing inertial force. The piston is re- S1 S2
turned to the original position quickly by the back T566-03-03-039
pressure.
Piston
LP
HP
T566-03-03-039
T3-3-5
SWING REDUCTION GEAR
First stage ring gear (8) and second stage ring gear
The swing reduction gear is a two-stage planetary- (9) are attached and secured onto the housing.
gear reduction type. The output shaft of swing motor rotates first stage sun
The swing motor rotation force is transmitted to the gear (1). The rotation force is transmitted to second
sun gear. stage sun gear(3) via first stage planetary gear (9) and
The rotation of sun gear is reduced by the planetary first stage carrier(2).
gear and ring gear. This in turn rotates the shaft via the The rotation force of second stage sun gear (3) rotates
carrier. shaft (5) (output shaft) via second stage planetary
gear (7) and second stage carrier (4).
Shaft (5) meshes with the internal gear on swing bear-
ing secured onto the undercarriage to rotate the up-
perstructure.
3
9
8
4
7
5 6
T575-03-02-001
1 - First Stage Sun Gear 4 - Second Stage Carrier 6 - Second Stage Ring Gear 8 - First Stage Ring Gear
2 - First Stage Carrier 5 - Shaft (Output Shaft) 7 - Second Stage Planetary 9 - First Stage Planetary Gear
Gear
3 - Second Stage Sun Gear
T3-3-6
COMPONENT OPERATION / Control Valve
OUTLINE
The control valve controls the oil pressure along with

the flow rate and direction in the hydraulic circuit. The
major components in the hydraulic circuit are the main
relief valve, overload relief valve, make-up valve, un-
load valve, differential reducing valve, and pressure
compensators. All spools are fully operated by the pilot
pressure oil.
Unload Valve Variable Relief Valve
Main Relief Valve
Differential Reducing Main Relief Valve

Valve
Swing Overload Relief Valve
Boom
Arm
Overload Relief Valve
Bucket
Boom Swing Make-Up Valve
Auxiliary
Travel (Right)
Travel (Left)
Blade Overload Relief Valve
T1LD-03-04-001
T3-4-1
Hydraulic Circuit Diagram
40 2
3 1 - Variable Relief Valve 21 - Shuttle Valve (Travel
Left)
2 - Main Relief Valve 22 - Pressure Compensator
4 (Travel Right)
3 - Unload Valve 23 - Shuttle Valve (Travel
39 Right)
4 - Main Shut-Off Valve 24 - Pressure Compensator
(Auxiliary)
38 5 5 - Load Check Valve 25 - Shuttle Valve (Auxiliary)
(swing)
37
6 - Overload Relief Valve 26 - Pressure Compensator
36 (Boom) (Boom Swing)
6 7 - Load Check Valve 27 - Shuttle Valve (Boom
35 (Boom) Swing)
8 - Overload Relief Valve 28 - Pressure Compensator
34 7
(Arm) (Bucket)
9 - Load Check Valve (Arm) 29 - Shuttle Valve (Bucket)
33 10 - Overload Relief Valve 30 - Overload Relief Valve
32 8 (Bucket) (Bucket)
11 - Load Check Valve 31 - Pressure Compensator
9 (Bucket) (Arm)
31 12 - Make-Up Valve (Boom 32 - Shuttle Valve (Arm)
30 Swing)
13 - Load Check Valve (Boom 33 - Overload Relief Valve
10 Swing) (Arm)
29 11 (Auxiliary) (Boom)
15 - Load Check Valve 35 - Shuttle Valve (Boom)
12 (Travel Right)
28 16 - Load Check Valve 36 - Boom Anti-Drift Valve
13 (Travel Left)
27
17 - Overload Relief Valve 37 - Overload Relief Valve
(Blade) (Boom)
26 18 - Load Check Valve 38 - Pressure Compensator
14 (Blade) (Swing)
25
19 - Pressure Compensator 39 - Shuttle Valve (Swing)
(Blade)
20 - Pressure Compensator 40 - Differential Reducing
24 15 (Travel Left) Valve
23
22 16
21
17
20
T1LD-03-04-004
19 18
T3-4-2
A A
B B
D D
E E
F F
F F
G G
H H
I I
I I
J J
T1LD-03-04-001
1
Cross Section A-A Cross Section B-B
2
40
C C
T566-03-03-005
3
T566-03-03-006
Cross Section C-C Cross Section D-D

K 39
4
T566-03-03-007
T566-03-03-008
38 K
T3-4-3
40 2 1 - Variable Relief Valve 21 - Shuttle Valve (Travel

Left)
3 2 - Main Relief Valve 22 - Pressure Compensator
(Travel Right)
3 - Unload Valve 23 - Shuttle Valve (Travel
4 Right)
4 - Main Shut-Off Valve 24 - Pressure Compensator
39 (Auxiliary)
5 - Load Check Valve 25 - Shuttle Valve (Auxiliary)
(swing)
38 5 6 - Overload Relief Valve 26 - Pressure Compensator
(Boom) (Boom Swing)
37
7 - Load Check Valve 27 - Shuttle Valve (Boom
36 (Boom) Swing)
6 8 - Overload Relief Valve 28 - Pressure Compensator
35 (Arm) (Bucket)
9 - Load Check Valve (Arm) 29 - Shuttle Valve (Bucket)
34 7
10 - Overload Relief Valve 30 - Overload Relief Valve
(Bucket) (Bucket)
33 11 - Load Check Valve 31 - Pressure Compensator
32 8 (Bucket) (Arm)
12 - Make-Up Valve (Boom 32 - Shuttle Valve (Arm)
9 Swing)
31 13 - Load Check Valve (Boom 33 - Overload Relief Valve
30 Swing) (Arm)
10 (Auxiliary) (Boom)
15 - Load Check Valve 35 - Shuttle Valve (Boom)
29 11 (Travel Right)
16 - Load Check Valve 36 - Boom Anti-Drift Valve
12 (Travel Left)
28 17 - Overload Relief Valve 37 - Overload Relief Valve
13 (Blade) (Boom)
27
(Blade) (Swing)
26 19 - Pressure Compensator 39 - Shuttle Valve (Swing)
14 (Blade)
25
20 - Pressure Compensator 40 - Differential Reducing
(Travel Left) Valve
24 15
23
22 16
21
17
20
T1LD-03-04-004
19 18
T3-4-4
Cross Section E-E Cross Section F-F
37 36 35 6
30, 33 K
29, 32 8, 10
K
T566-03-03-011
T566-03-03-010 28, 31 K
34 K
Cross Section H-H 25

Cross Section G-G 27 12 K
K
T566-03-03-013
T566-03-03-012 24 K
26 K
Cross Section J-J
Cross Section I-I K 17
K
21, 23
T1LD-03-04-003
T1LD-03-04-002 19 K
20, 22 K
Cross Section K-K
5, 7, 9, 11, 13,
14, 15, 16, 18
T566-03-03-009
T3-4-5
HYDRAULIC CIRCUIT
Main pump P1 supplies pressure oil to the control

valve. When the spools in the control valve are in neu-
tral (when the control levers, travel levers, and the
blade control lever are in neutral), the pressure oil
from main pump P1 flows back to the hydraulic oil tank
via the unload valve. When the spools in the control
valve are operated (when the control levers, the travel
levers, and/or blade control lever is operated), the
pressure oil from main pump P1 flows to the cylinders
and/or the motors after passing through the pressure
compensator and the operated spools.
A pressure compensator is provided in each spool

section of the control valve. When the spools in the
control valve are operated (when the control levers,
the travel levers, and/or blade control lever is oper-
ated), the oil flow rate passing through the spool is
maintained constant by the pressure compensator.
Therefore, the main pump can supply the optimum oil
flow to the cylinders and/or motors. Beside the pres-
sure compensators, the main shut-off valve, boom
anti-drift valve, unload valve, differential reducing
valve, and variable relief valve are provided in the con-
trol valve.
T3-4-6
Variable Relief
Valve Main Relief Valve
Swing Motor
Control Valve
Main Pump Unload Valve

(P1)
Main Shut-Off Valve
Swing Spool
Differential Reducing Valve Boom Cylinder
Boom Anti-Drift Valve

Blade Cylinder
Swing
Overload
Relief Valve
Boom Spool
Hydraulic
Oil Tank
Travel Motor
Arm Spool
Pressure
Compensator
Bucket
Spool
Made-Up Valve
Bucket Cylinder
Boom Swing
Boom Cylinder
Arm
Swing
Cylinder
Spool
Auxiliary Spool
Pressure
Compensator Travel (Right) Spool
Travel (Left) Spool
Blade Spool
T1LD-02-01-003
T3-4-7
MAIN RELIEF VALVE
1. The main relief valve is provided in the primary

circuit (before spools) to prevent the oil pressure
in the main circuit from increasing more than the In Neutral
set pressure.
2. The oil pressure in port P acts on pilot poppet (10) Port T
via orifices (2 and 5) in poppet (1) and seat (6).
3. When the oil pressure in the main circuit in-
creases more than the set pressure of spring (8), Port P
pilot poppet (10) moves to the right.
4. Then, a small quantity of the pressure oil flows to
pot T via passage (7) in holder (9) and around Port T
sleeve (11). Thereby, a differential pressure T566-03-03-016
arises between port P and spring chamber (4)

due to orifice (2). When this differential pressure
In Operation
increases more than spring (3) force, poppet (1)
is moved to the right so that the pressure oil in 1 2 3 4 5 6 7 8
port P flows directly to port T.
5. When the oil pressure is reduced, pilot poppet
(10) is closed by spring (8), causing the oil pres-
sure in spring chamber (4) to increase. The in-
creased pressure oil in spring chamber (4) and Port P
spring (3) cause poppet (1) to close again.
Port T
T566-03-03-017
11 10 9
1- Poppet 7- Passage
2- Orifice 8- Spring
3- Spring 9- Holder
4- Spring Chamber 10 - Pilot Poppet
5- Orifice 11 - Sleeve
6- Seat
T3-4-8
OVERLOAD RELIEF VALVE
1. The overload relief valve is provided in the sec-

ondary (after spool) circuit of the cylinder so that
even if the cylinder is moved by external loads, In Neutral
the overload relief valve regulates the oil pressure
in the secondary circuit so as to avoid abnormal
pressure increase.
2. The oil pressure on the cylinder side acts on pilot Cylinder
poppet (5) via passage (2) in piston (1). Side
3. If the oil pressure in the circuit increases more
than the set pressure of spring (6), pilot poppet
(5) is moved to the right.
Port T
4. A small quantity of the pressure oil flows to port T T566-03-03-018
through passage (8) in holder (7) and passage

(10) in sleeve (9).
5. When pilot poppet (5) is moved to the right, the oil In Operation
pressure in chamber (11) decreases, causing a
pressure difference to arise between the cylinder 1 2 3 4 5 6
side port and chamber (11).When this differential
pressure overcomes spring (4) force, poppet (3)
is moved to the right, allowing the pressure oil in
the cylinder side port to directly flow to port T. Cylinder
When the oil pressure in the cylinder side de- Side
creases lower than the oil pressure in port T, this
overload relief valve draws oil from port T
(hydraulic oil tank side), preventing cavitation
Port T
from occurring (make-up function). 11 10 9 8 7
T566-03-03-019
1- Piston 7- Holder
2- Passage 8- Passage
3- Poppet 9- Sleeve
4- Spring 10 - Passage
5- Pilot Pump 11 - Chamber
6- Spring
T3-4-9
MAKE-UP VALVE
1. The make-up valve prevents cavitation from oc-

curring in the boom swing cylinder. In Neutral
NOTE: Other cylinder circuits have one overload
relief valve each, by which make-up func-
tion the occurrence of cavitation in the cir-
cuit is prevented.
2. The oil pressure in the cylinder side is routed into Cylinder
Side
spring chamber (4) through passage (2) in poppet
(1) so that the oil pressure in the spring chamber
increases to the same pressure in the cylinder
side. Accordingly, when the oil pressure in the cyl-
inder side is high, the poppet (1) closing force
Port T
[pressure in spring chamber (4) pressure receiv- T566-03-03-020
ing area (S2)] overcomes the poppet (1) opening In Operation

force [pressure in cylinder side pressure receiv-
ing area (S1)], causing poppet (1) to close. S1 1 2 S2 3 4
3. When the oil pressure in the cylinder side be-
comes lower than the pressure in port T, poppet
(1) is closed by spring (3) force only. Therefore,
when poppet (1) opening force [pressure in port T
pressure receiving area (S2-S1)] overcomes Cylinder
Side
poppet (1) closing force [spring (3) force], poppet
(1) is unseated, allowing the hydraulic oil to sup-
ply to the cylinder side so that occurrence of cavi-
tation in the cylinder side is prevented.
Port T 6 5 T566-03-03-021
1 - Poppet 4 - Spring Chamber

2 - Passage 5 - Sleeve
3 - Spring 6 - Passage
T3-4-10
(Blank)
T3-4-11
MAIN SHUT-OFF VALVE
The pressure oil from the main pump flows to the con- When the main shut-off valve is closed:
trol valve spool via the pressure compensator. The 1. When the pilot shut-off valve solenoid valve
main shut-off valve is activated by the pilot shut-off (dual-stop solenoid) is deactivated (when the pilot
valve solenoid valve. When the main shut-off valve is control shut-off lever is in the LOCK position),
deactivated, the pressure oil from the main pump is pressure PP2 is not routed to the main shut-off
routed to the pressure compensator via the main shut- valve from the pilot shut-off valve solenoid valve
off valve, forcibly closing the pressure compensator (dual-stop solenoid).
main circuit. Therefore, the pressure oil from the main 2. Then, the spool in the pilot shut-off valve solenoid
pump cannot flow to the spool through the pressure valve is held toward the right.
compensator so that even if the control lever is oper- 3. Therefore, notch A is closed and notch B is
ated, the actuator doesnt operate. opened. Consequently, the pressure oil from the
main pump is supplied to the pressure compensa-
tor via the holes in the retainer and notch B, caus-
ing the pressure compensator to close the main
circuit. Thereby, even if the control valve spool is
moved, the main pressure oil is not supplied.
When the main shut-off valve is opened:

1. When the pilot shut-off valve solenoid valve
(dual-stop solenoid) is activated (when the pilot
control shut-off lever is in the UNLOCK position),
pressure PP2 is routed to the main shut-off valve
from the pilot shut-off valve solenoid valve (dual-
stop solenoid).
2. Then, the spool in the pilot shut-off valve solenoid
valve is moved toward the left.
3. Therefore, notch A is opened and notch B is
closed. Consequently, the pressure oil flow from
the main pump is blocked by the main shut-off
valve spool so that the pressure oil flow from the
main pump is not supplied to the pressure com-
pensator. Port DR1 on the main shut-off valve is
connected to notch A on the pressure compensa-
tor at this time.
4. The oil from the pressure compensator is re-
turned to port DR1 (hydraulic oil tank) via holes in
the retainer, and notch A, freeing spool (9) to
move. Thereby, the main pressure oil can flow to
the control valve spool.
T3-4-12
Main Shut-Off Valve Port Pressure PP2 from the pilot

(when closed:) DR1 shut-off valve solenoid valve
From the main pump
T566-02-02-013
Spool Pressure Compensator
When Closed:
To the pressure
compensator From the main pump
Spring Spool
Notch A Notch B
Pressure PP2
Port DR1
T566-03-03-022
Retainer
When Opened: From the

pressure
compensator From the main pump
Spring Spool
Notch A Notch B
Pressure PP2
Port DR1 Retainer T566-03-03-023
T3-4-13
BOOM ANTI-DRIFT VALVE
Boom Cylinder
The boom anti-drift valve is provided in the boom cyl- When Neutral:
inder bottom circuit to reduce the boom cylinder drift. From the control valve
When the boom spool is in neutral: Spring Chamber Poppet Orifice

1. When the engine is stopped with the boom raised,
the oil pressure in the boom cylinder bottom in-
creases due to the front attachment weight.
2. The increased oil pressure is routed into the Ball
spring chamber via the poppet orifice and acts on
S1
the ball and pressure receiving area S1.
3. Therefore, when the ball is pushed the sleeve by
the increased oil pressure, the pressure force (oil
pressure in the spring chamber pressure receiv-
ing area S1) closes the poppet. Then, the poppet
blocks the pressure oil in the bottom circuit, not
allowing the pressure oil to leak to the spool side
so that the cylinder drift is reduced.
When raising the boom:

When the boom raise operation is made, the spool is
moved to the left, allowing the pressure oil from the
spool to open the poppet and to flow further to the
boom cylinder bottom. Thereby, the boom is raised. Sleeve Spool
T566-03-03-024
When Raising: Boom cylinder
To the control valve
Poppet
Spool
T566-03-03-027
T3-4-14
When lowering the boom:
1. When the boom lower operation is made, the
Piston Section A Sleeve Ball
boom lower pilot oil pressure is routed to the
spool end and the piston, causing the spool and
the piston to move to the right.
2. When the piston is moved to the right, the right tip
of the piston pushes the ball so that the ball be-
comes unseated from the sleeve.
3. Then, the pressure oil in the boom cylinder bot-
tom circuit is returned to the hydraulic oil tank via
the orifice in the poppet, section A, and the pas-
sage around the piston, reducing the oil pressure
in the spring chamber.
4. When the oil pressure in the spring chamber is
reduced, the poppet is closed by spring force only.
Accordingly, when poppet opening force [oil pres-
sure at port A2 pressure receiving area (S1-S2)]
overcomes poppet closing force (spring), the
poppet is opened.
5. Therefore, the pressure oil in the boom cylinder
Boom Lower
bottom circuit is returned to the hydraulic oil tank Pilot Oil
via the poppet and the spool, allowing the boom Pressure
cylinder to move downwards. Spool Circuit T Circuit T2 T566-03-03-025
Boom Cylinder
From the control valve
Piston Section A Poppet

Port A2
S2 S1
T566-03-03-026
Spring Spring Spool
Chamber
T3-4-15
UNLOAD VALVE
The unload valve operates in response to pump deliv- 7. Then, notch D is opened, oil pressure P1 is
ery pressure (P1) and maximum load pressure routed to port T via the spool. The opening area
(PLMAX) to control the differential pressure between at notch D varies in proportion to the spool stroke
before and after the spool in the control valve. (depending on variations in the spool pushing
force balance).
NOTE: The differential reducing valve outputs 8. As pressure areas S1, S2, and S3 are all identical,
pressure PLS (Pressure PLS Pressure pressure P1 is maintained so as to match the
P1 Pressure PLMAX). Therefore, pres- formula Pressure P1 = Pressure PLMAX + Pres-
sure P1 must be higher than pressure sure PGR .
PLMAX to output pressure PLS. The un-
load valve controls the differential pressure
between before and after the spool in the
control valve so that pressure P1
( Pressure P1 = Pressure PLMAX + Pres-
sure PGR) is higher than pressure PLMAX. T
Unload Valve
Then, the differential reducing valve out-
puts pressure PLS (Pressure PLS Pres- Pressure
PGR
sure P1 Pressure PLMAX), by which the
pump delivery flow rate is controlled. Pressure
PLMAX
Pressure P1 T1LD-03-04-005
1. The pressure oil flow diverges from port P into
two routes, to the differential reducing valve and Pressure P1 : Oil Pressure in the circuit before
to chamber C through the spool. the spool
2. As pressure P1 routed into chamber C increases, Pressure PLMAX : Maximum oil pressure in all cir-
the spool is pushed to the left by pressure P1 cuits after the spool
force (pressure P1 pressure receiving area S3). Pressure PLS : Reduced pilot oil pressure at the
3. Pressure PGR from port PGR is routed into differential reducing valve
chamber A, increasing the pressure in chamber A Pressure PGR : Oil pressure sent from the revolu-
so that the spool is pushed to the right by pres- tion sending valve
sure force (pressure PGR pressure receiving
area S1).
4. Pressure PLMAX from port PLMAX is routed into
chamber B, increasing the pressure in chamber B
so that the spool is pushed to the right by pres-
sure force (pressure PLMAX pressure receiving
area S2).
5. The pressure forces pushing the spool from both
ends is expressed as below:
Pressure PGR Pressure Receiving Area S1 +
Pressure PLMAX Pressure Receiving Area S2
= Pressure P1 Pressure Receiving Area S3
6. When pressure P1 increases until spool left push-
ing force (Pressure P1 Pressure Receiving
Area S3) overcomes spool right pushing force
(Pressure PGR Pressure Receiving Area S1 +
Pressure PLMAX Pressure Receiving Area S2),
the spool is moved to the left.
T3-4-16
Chamber A Chamber B S2 Port P (Pressure P1)
Differential
Reducing Valve
Unload Valve
Port PGR Port PLMAX T566-03-03-028

(Pressure PGR) (PLMAX Spool Chamber C S3
Pressure )
S1
Pressure P1
T566-03-03-029
Port T Section D
Spool
T3-4-17
DIFFERENTIAL REDUCING VALVE
The differential reducing valve supplies pressure PLS When the right pushing force is stronger:
to main pump valve PS to regulate the pump flow rate. ( Pressure P1 S3 pressure PLS S1) + pres-
sure PLMAX S2)
1. Oil pressure P1 from the main pump is routed into
chamber C so that it acts on the piston, creating 8. The spool is moved to the right.
pressure force (pressure P1 pressure receiving 9. As section D is closed, pressure PP1 from the pi-
area S3) to move the spool to the left. lot pump cannot go through notch D. Section E is
2. Oil pressure PLS from port PLS is routed into opened, the oil pressure in chamber A and from
chamber A via the hole in the sleeve and the pas- port PLS is routed into port DR1 via notch E.
sage in the spool, creating pressure force 10. As described in step 4, the spool is moved so as
(pressure PLS pressure receiving area S1) to to keep the force balance, pressure PLS to con-
move the spool to the right. trol the pump is returned to the hydraulic oil tank
3. Oil pressure PLMAX from port PLMAX is routed that pressure PLS decreases.
into chamber B, creating pressure force (pressure 11. According to the repeated operation as described
PLMAX pressure receiving area S2) to move in step 5 to 7 and 8 to10, pressure PLS is main-
the spool to the right. tained so as to match the pressure balance (PLS
4. Accordingly, the spool moves so as to match the = P1 PLMAX) as described in step 4 since S1,
force balance as expressed in the formula below: S2, and S3 are all identical.
Spool left pushing force (pressure P1 pressure
receiving area S3) = Spool right pushing force
[(pressure PLS pressure receiving area S1) + Pressure
(pressure PLMAX pressure receiving area S2)] PP1 DR1
Differential
When the left pushing force is stronger: Reducing
( Pressure P1 S3 pressure PLS S1) + pres- Valve
sure PLMAX S2)
Pressure
5. The spool is moved to the left. PLMAX
6. As section D is opened, pressure PP1 from the Pressure P1
pilot pump is routed to chamber A and port PLS
Pressure
via notch D. Section E is closed, blocking port PLS T1LD-03-04-006
DR1 (return port to the hydraulic oil tank).
7. As described in step 4, the spool is moved so as
to keep the force balance, pressure PP1 is routed Pressure P1: : Oil Pressure in the circuit before
to port PLS to control the pump so that pressure the spool
PLS increases. Pressure PLS : Reduced pilot oil pressure at the
differential reducing valve
Pressure PLMAX : Maximum oil pressure in all cir-
cuits after the spool
Pressure PP1 : Primary Pilot Oil Pressure
T3-4-18
S1 S2 Piston S3
Chamber
Chamber A B Sleeve Spool Chamber C
Main Pump Delivery

Pressure (P1)
Port PLMAX Port PLS T566-03-03-030

(Pressure (Pressure
PLMAX) PLS)
When the left pushing force is stronger:

Chamber A Chamber D Chamber E
Port PLMAX Port PLS T566-03-03-031

(Pressure PLMAX ) (Pressure
PLS)
Port DR1
Port PP1
(Pressure DR1)
(Pressure PP1)
When the right pushing force is stronger:

Chamber A Chamber D Chamber E
Port PLS T566-03-03-032

(Pressure
PLS)
Port PP1 Port DR1
(Pressure (Pressure
PP1) DR1)
T3-4-19
PRESSURE COMPENSATOR
The pressure compensator is located in the circuit be- When the differential pressure between pressure
fore control valve spool (2). The pressure compensa- (PIN) and pressure (PL) is lower than pressure
tor regulates the oil flow rate passing through spool (2) PLS:
so that the differential pressure in the circuit between 8. When the differential pressure between pressure
before and rear spool (2) is kept constant. (PIN) and pressure (PL) is lower than pressure
1. Oil Pressure (PIN) in circuit (1) before spool (2) is PLS, right pushing force becomes stronger than
routed into chamber C (5) via passage (6) in left pushing force so that spool (7) is moved to the
spool (2), creating force [pressure PIN pressure right.
receiving area S3 (4)] that moves spool (7) to the 9. Then, notch (13) becomes gradually wider, in-
left against piston (3). creasing the hydraulic oil passing through notch
2. Oil pressure (PLS) from the differential reducing (13) so that the pressure oil routed into circuit (1)
valve is routed into chamber B (9), creating force before the spool increases. Therefore, pressure
[pressure PLS pressure receiving area S2 (8)] PIN increases, causing the differential pressure
that moves spool (7) to the right. between circuits (1 and 12) to increase.
3. Oil Pressure (PL) in circuit (12) after spool (2) is 10. When spool pushing forces on both sides be-
routed into chamber A (11), creating force comes equal, spool (7) stops moving. Spool (7)
[pressure PL pressure receiving area S1 (10)] keeps moving right and left while repeating opera-
that moves spool (7) to the right. tion in steps 5 to 7 and 8 to 9. Thereby, the differ-
4. Spool (7) is moved so that pressures PIN, PLS, ential pressure between pressure PIN in before
and PL maintain the force balance as described spool side circuit (1) and pressure PL after spool
in the formula below: side (2) is kept equal to pressure PLS so that the
Right pushing force [pressure PLS pressure re- hydraulic oil flow rate passing through spool (2) is
ceiving area S2) + (pressure PL pressure re- maintained constant
ceiving area S1)] = Left pushing force (pressure
PIN pressure receiving area S3)
When the differential pressure between pressure

Pressure
(PIN) and pressure (PL) is higher than pressure Compensator To the control valve
PLS: main spool
5. When the differential pressure between pressure
Pressure
(PIN) and pressure (PL) is higher than pressure PL
PLS, left pushing force becomes stronger than
right pushing force so that spool (7) is moved to
the left. Pressure
PLS
6. Then, notch (13) becomes gradually narrower, Pressure PIN
reducing the hydraulic oil passing through notch T1LD-03-04-007
(13) so that the pressure oil routed into circuit (1)

before the spool is reduced. Therefore, pressure Pressure Pin: : Oil Pressure in the circuit before
PIN decreases, causing the differential pressure the spool
between circuits (1 and 12) to reduce. Pressure PLS : Reduced pilot oil pressure at the
7. When spool pushing force on both sides be- differential reducing valve
comes equal, spool (7) stops moving. Pressure PL : Oil pressure in the corresponding
circuit after the spool
T3-4-20
1 2
12
T566-03-03-033
11 10 9 8 7 6 5 4 3
From the differential
When the differential pressure is high: reducing valve
1 2 13
12
7 T566-03-03-035
When the differential pressure is low:

1 2 13
12
T566-03-03-008
7
1- Circuit before spool 5 - Chamber C 8 - Pressure receiving area S2 11 - Chamber A
2- Spool 6 - Passage 9 - Chamber B 12 - Circuit after spool
3- Piston 7 - Spool 10 - Pressure receiving area S1 13 - Notch
4- Pressure receiving area S3
T3-4-21
VARIABLE RELIEF VALVE
The differential reducing valve outputs pressure PLS NOTE: The variable relief valve system operates
to be used to control the pump flow rate. as follows:
NOTE: Pump delivery pressure (P1) and maxi- Control signal pressure (PLS) from the dif-
mum load pressure (PLMAX) are routed to ferential reducing valve is routed to each
the differential reducing valve. Pressure pressure compensator. Pressure PLS is a
PLS is output so as to match the relation signal pressure reduced at the differential
Pressure PLS Pressure P1 Pressure reducing valve from the pilot pressure
PLMAX. The variable relief valve operates (pressure PLS pressure P1 Pressure
to relieve pressure PLMAX (maximum load PLMAX). Pressure P1 is the pump delivery
pressure in the circuit after the spool) so pressure. Pressure PLMAX is the maxi-
that pressure PLMAX doesnt exceed mum load pressure adjusted by the vari-
pump delivery pressure P1. able relief valve.
1. Pressure (PGR) from the revolution sensing valve When the circuit pressure is relieved, the
and load maximum pressure (PLMAX) from the main circuit pressure is equal to the main
spool act on the poppet, creating poppet pushing relief valve set pressure so that both pres-
force [(pressure PGR pressure receiving area sure P1 and pressure PLMAX are equal to
S1) + (pressure PLMAX pressure receiving area the main relief valve relief pressure. There-
S2)] to the right. fore, if the variable relief valve doesnt op-
NOTE: The spring set force of the variable relief erate, pressure PLS may become equal to
valve is equal to that of the main relief zero (0) (pressure P1 - pressure PLMAX).
valve. In case more than one actuator is operated
and the oil pressure to one of them
2. As long as the engine is running, both pressure reaches the relief pressure, signal pressure
PGR and PLMAX act on the poppet so that the (PLS) to the pressure compensator be-
poppet is moved before pressure PLMAX in- comes zero (0) if the variable relief valve
creases to the main relief valve set pressure. doesnt operate. Therefore, all pressure
3. When poppet pushing force [(pressure PGR compensators are closed so that other ac-
pressure receiving area S1) + (pressure PLMAX tuators are stopped.
pressure receiving area S2)] to the right over-
comes the spring force, the poppet is moved, al- As pressure PLS is maintained higher than
lowing pressure PLMAX to return to the hydraulic the pressure difference (pressure P1
oil tank port. Pressure PLMAX) by means of the vari-
able relief valve operation, even though
combine operation including the relieving
actuator is made, other actuators are oper-
able.
Variable Relief
Valve
Pressure
PLMAX
Pressure
PGR T1LD-03-04-008
Pressure PLS : Reduced pilot oil pressure at the

differential reducing valve
Pressure P1: : Oil Pressure in the circuit before
the spool
Pressure PLMAX : Maximum oil pressure in all cir-
cuits after the spool
Pressure PGR : Oil pressure from the revolution
sensing valve
T3-4-22
S1 S2 Poppet Spring
From the revolution

sensing valve
(Pressure PGR)
Load pressure Hydraulic oil T566-03-03-036

(PLMAX) from tank port
the main spool
Pressure Hydraulic oil T566-03-03-037

PLMAX tank port
T3-4-23
(Blank)
T3-4-24
COMPONENT OPERATION / Pilot Valve
OUTLINE
The pilot valve controls the pilot pressure to move the

control valve spools.
The 4-port pilot valve is used for front attachment,
swing, and travel operation. The 2-port pilot valve is
used for blade and offset operation.
The blade, and boom swing pilot valves is the same in
construction except for the cam which pushes the
pusher.
Front and Swing Pilot Valve

Port No. HITACHI ISO Standard
Standard
1 Bucket Roll-Out
2 Boom Lower
Right
3 Bucket Roll-In
4 Boom Raise
P
1 Arm Roll-In Left Swing
2 Left Swing Arm Roll-Out
Left 3 Arm Roll-Out Right Swing
4 Right Swing Arm Roll-In View A
A
4 1
Hydraulic Symbol
T
3 PT 1 2 4 4 PT 2 1 3 3 2 T567-03-04-001
T566-03-05-002
Tarvel Pilot Valve

Port No.
1 Left Travel Reverse
2 Left Travel Forward
3 Right Travel Reverse
4 Right Travel Forward T
P
P
View A 2 1
A
1 2 3 4
T573-03-04-003
4 3 T585-03-04-005
T3-5-1
Boom Swing Pilot Valve

Port No.
1 Right Boom Swing
2 Left Boom Swing
T
Blade Pilot Valve
T
Port No.
P
1 Blade Lower
P
2 Blade Raise
1 2
P T
T190-02-06-005
1 2
1 2
T554-02-07-009
T3-5-2
(Blank)
T3-5-3
OPERATION
Front Attachment and Swing Pilot Valve

Spool (6) head comes in contact with the upper face
of spring guide (3) which is kept raised by return
spring (5).
Pilot Presure
Control Lever-In Neutral (Output Diagram: A to B)
1. When neutral, spool (6) totally blocks pressure oil
port P (from the pilot pump).The output port is
opened to port T (hydraulic oil tank) through the D
passage in spool (6). Therefore, oil pressure in
the output port (to the control valve) is equal to
that in port T.
2. When the control lever is slightly tilted, cam (1) is C
tilted, moving pusher (2) downward. Then, pusher
(2) compress return spring (5) along with spring A B
guide (3). At this time, as oil pressure in the Lever Stroke
output port is equal to that in port T, spool (6) T567-03-04-002
moves downward while keeping the under face of

the spool head in contact with spring guide (3).
3. This status continues until hole (7) on spool (6) is
opened to port P.
T3-5-4
1 1
2 2
6
3 3 Port T
4 4
7
5 5 Port P
6 Output Port
6
Port T Port T
7 Port P 7 Port P
Output Port T183-03-04-002

1 - Cam 3 - Spring Guide 5 - Return Spring 7 - Hole

2 - Pusher 4 - Balance Spring 6 - Spool
T3-5-5
During Metering or Decompressing (Output
Diagram: C to D)
1. When the control lever is further tilted to move
pusher (2) downward more, hole (7) on spool (6)
is opened to port P, allowing pressure oil in port P
to flow into the output port.
2. Oil pressure in the output port acts on the bottom
Pilot Presure
face of spool (6) so that spool (6) is pushed
upward.
3. However, until upward force acting on the bottom
face of spool (6) overcomes balance spring (4) D
force, balance spring (4) is not compressed. Then,
spool (6) is not raised, allowing oil pressure in the
output port to increase.
4. As oil pressure in the output port increases, force C
to push spool (6) upward increases. When, this
force overcomes balance spring (4) force, A B
balance spring (4) is compressed so that spool Lever Stroke
(6) is moved upward. T567-03-04-002
5. As spool (6) is moved upward, hole (7) is closed

so that pressure oil from port P stops flowing into
the output port, stopping pressure oil in the output
port to increase.
6. As spool (6) is moved downward, balance spring
(4) is compressed, increasing the spring force.
Therefore, oil pressure in the output port
becomes equal to the oil pressure acting on the
bottom face of spool (6) being balanced in
position with the spring force.
T3-5-6
1 1
2 2
3 3
4 4
5 5
6 6
Port T Port T
7 Port P 7 Port P

1 - Cam 3 - Spring Guide 5 - Return Spring 7 - Hole

2 - Pusher 4 - Balance Spring 6 - Spool
T3-5-7
Travel Pilot Valve
Control Lever-In Neutral (Pusher Stroke: A to B) Control Lever-Full Stroke (Pusher Stroke: E to F)
When the control lever is in neutral, spool (8) blocks When the control lever is moved to full stroke, pusher
the pressure oil in port P completely. The output port (2) compresses spring (4) and return spring (7) more
is connected to port T through hole (9), so the and pusher (2) is moved down.
pressure at output port becomes equal to the Thereby, spool (8) is pressed directly by the bottom
hydraulic oil tank pressure. of pusher (2). As a result, the lower notch of spool (8)
When the control lever is moved slightly, pusher (2) does not close even if the pressure at output port
and spring guides (3), (5) move downward together, rises.
compressing spring (4), and return spring (7). At this As a result, the pressure at output port becomes
time, as the pressure under spool (8) (output port) is equal to the pressure at port P.
equal to the hydraulic oil tank pressure, spool (8)
moves downward by balance spring (6), while the top
of spool is kept with spring guide (5). This state is
maintained until clearance (A) of spool (8) becomes
zero.
Control Lever-Operated (Pusher Stroke: C to D

Delivery Port E F
Metering) Pressure
When the control lever is moved further, hole (9) of (Pilot Pressure)
spool (8) reaches port P. The pressure oil in port P D
flows into the output port via the passage in spool (8),
so the pressure at output port increases. C
The pressure at output port acts on the bottom of
spool (8), to push spool (8) upward. A B
If the acting force on spool (8) is smaller than the
Pusher Stroke
spring force of balance spring (6), balance spring (6)
will not be pressed. As a result, spool (8) will not be OUTPUT DIAGRAM
pushed up, and the pressure at output port increases
continuously.
If the pressure at output port increases further, the
force to push up spool (8) increases. When this force
becomes larger than the spring force of balance
spring (6), spool (8) pushes balance spring (6) and
moves upward.
When spool (8) moves upward, hole (9) closes, so
the pressure oil does not flow into the output port
from port P. Thereby, the pressure at output port
stops raising.
Accordingly, the amount the balance spring (6) is
compressed is equal to the amount spool (8) is
pressed down, so the balanced pressure between
the spring force and the force acting on spool (8)
becomes the pressure at output port.
T3-5-8
Pusher Stroke: A to B
5
6
7
Port T
8 9
(A) (A)
Port P
T585-03-04-001 T585-03-04-002
Output Port
Pusher Stroke: C to D Pusher Stroke: E to F
6
Port T Port T
8
Port P Port P
T585-03-04-003 T585-03-04-004
Output Port Output Port
1 - Cam 4 - Spring 6 - Balance Spring 8 - Spool

2 - Pusher 5 - Spring Guide 7 - Return Spring 9 - Hole
3 - Spring Guide
T3-5-9
Boom Swing and Blade Pilot Valves
Control Pedal-In Neutral (Pusher Stroke: A to B) Control Pedal-Full Stroke (Pusher Stroke: E to F)
When the control pedal is in neutral, spool (7) blocks When the control pedal is moved to full stroke,
the pressure oil in port P completely. The output port pusher (2) is moved down until it comes into contact
is connected to port T through the passage in spool with the top of plate (3).
(7), so the pressure at output port becomes equal to Thereby, spool (7) is pressed directly by the bottom
the hydraulic oil tank pressure. of pusher (2). As a result, notch (B) of spool (7) does
When the control pedal is moved slightly, cam (1) not close even if the pressure at output port rises.
moves and pusher (2) and spring guide (4) move As a result, the pressure at output port becomes
downward together, compressing return spring (6). At equal to the pressure at port P.
this time, balance spring (5) pushes spool (7) and
spool (7) moves downward until clearance (A)
becomes ZERO.
While spool (7) moves downward, the output port is
connected to port T and the pressure oil does not
flow into the output port.
NOTE: The pedal stroke moved until clearance (A)

E F
becomes zero, corresponds to the pedal
play in the neutral position. Pilot Pressure
D
Control Pedal-Operated (Pusher Stroke: C to D
Metering)
When the control pedal is moved further, the hole on
spool (7) is connected to notch (B). The pressure oil
C
in port P flows into the output port via the hole in
spool (7) from notch (B), so the pressure at output
port increases.
The pressure at output port acts on the bottom of A B Pusher Stroke
spool (7), to push spool (7) upward. T505-02-07-006
If the acting force on spool (7) is smaller than the

spring force of balance spring (5), balance spring (5)
will not be pressed. As a result, as port P is
connected to the output port, the pressure at output
port increases continuously.
If the pressure at output port increases further, the
force to push up spool (7) increases. When this force
becomes larger than the spring force of balance
spring (5), spool (7) pushes balance spring (5), and
moves upward.
When spool (7) moves upward, notch (B) closes, so
the pressure oil does not flow into the output port
from port P. Thereby, the pressure at port P stops
raising.
Accordingly, the amount balance spring (5) is
compressed is equal to the amount spool (7) is
pressed down, so the balanced pressure between
the spring force and the force acting on spool (7)
becomes the pressure at output port.
T3-5-10
Pusher Stroke: A to B
3
4
5
Port T
6
(A)
Clearance (A): 0
Port P
Hole
7
Passage
T1LA-03-04-002
T1LA-03-04-003
Output Port
Pusher Stroke: C to D Pusher Stroke: E to F
2
3
Port T Port T
Notch (B) Notch (B)
Port P Port P
Hole
7 7
Output Port T1LA-03-04-004

Output Port T1LA-03-04-005
1 - Cam 3 - Plate 5 - Balance Spring 7 - Spool

2 - Pusher 4 - Spring Guide 6 - Return Spring
T3-5-11
(Blank)
T3-5-12
COMPONENT OPERATION / Travel Device
OUTLINE
The travel device consists of travel motor, travel

reduction gear and travel brake valve.
The travel motor is a variable displacement axial
plunger swash plate type. This motor is operated by
pressure oil from the pump, and transmits the rotation
to the travel reduction gear.
The travel reduction gear is a two-stage planetary-
gear reduction type, reducing travel motor speed,
increasing travel motor torque, and allowing the
sprocket and track to rotate.
The travel brake valve functions to protect the travel
circuit.
Travel Reduction Gear Travel Brake Valve
Travel Motor
T571-03-05-001
T3-6-1
TRAVEL MOTOR
The travel motor consists of valve plate, rotor,

plungers, shoes, swash plate and shaft. The rotor is
connected to the shaft by a spline joint, and the
plungers are inserted in the rotor.
When the pressure oil is supplied from the pump, the
plungers are pushed. The swash plate is installed at
an angle toward the plungers, the shoe slides on the
swash plate, so the rotor rotates. This rotation is
transmitted to the travel reduction gear via the shaft.
Swash Plate Rotor Valve Plate
Shaft
T571-03-05-002
Shoe Plunger
T3-6-2
TRAVEL BRAKE VALVE
The travel brake valve consists of counterbalance

valve, relief valves and travel speed changeover
valve.
The counterbalance valve has two functions; one is to
start and stop the travel smoothly, and the other is to
prevent the machine from running away while
descending slopes.
The relief valve prevents the pressure in travel circuit
from exceeding the set pressure.
The travel speed changeover valve is switched by
pressure oil from the travel speed changeover
solenoid valve. It switches the travel speed by the
control piston.
Counterbalance Valve
Travel Speed Changeover Valve
Relief Valve
T571-03-05-003
T3-6-3
Counterbalance Valve
Travel Operation Descending Operation

When pressure oil from control valve is supplied When the machine travels down a slope, the
to port P1, the pressure oil flows to motor port AM travel motors are forcibly driven by the machine
through the inside of the spool and opens the weight, so that the motor draws oil like a pump.
check valve. On the other hand, the return oil The pressure oil in port P1 is drawn into the travel
from motor port BM is blocked by the check valve motor, so the pressure on port P1 decreases.
and spool. Thereby, the spool returns to the left, and
Thereby, the pressure on port P1 side increases returning oil from port BM to port P2 is restricted,
gradually, so the pressure on port P1 enters into so the oil pressure brake is activated.
the spring chamber from the orifice, and moves When the returning oil from port BM is restricted,
the spool to the right by the pressure at the end the pressure on port P1 increases again, and
surface of the spool. moves spool to the right, so the motor rotates.
As a result, spool notch opens so port BM and
port P2 connect, so the travel motor rotates.
Control Valve
Spool
Orifice Orifice
P1 P2
Spring Chamber Spring Chamber

AM BM
Check Valve Check Valve T571-03-05-006
T3-6-4
Relief Valve
By the following two staged relief operation, relief

valve functions to reduce shocks developed when the
travel motor is started on stopped, and prevent
overload in the travel circuit.
NOTE: The force equal to [Pressure on Port HP

Pressurized Area of Poppet S1] is applied
on the poppet to the opening direction, and
force equal to [Pressure in Spring Chamber
Pressurized Area of Poppet S2 Spring
Force] is applied to the closing direction.
The pressurized area of poppet S2 is Poppet Piston Seat
smaller than S1. Orifice Spring
LP
Shockless Operation
When the pressure in the circuit the increases,
the pressure oil enters into the piston chamber
through the orifices of the poppet and seat, to
move the piston. HP
While the piston moves, the pressure in the
spring chamber is kept low. For this reason, the
force applied in the closing direction of poppet
becomes almost the spring force only.
Accordingly, when the force acting in the opening
direction of poppet [Pressure on Port HP S1 S2 Spring Chamber
Pressurized Area of Poppet S1] becomes larger T571-03-05-007
than the set force of spring, the poppet opens to Piston Chamber Orifice
relieve the hydraulic oil.
Relief Operation
When the piston moves to the stroke end, the
pressure in the spring chamber becomes equal to
the pressure on port HP. (The relief set force
becomes as the normal setting pressure, so
poppet closes.).
For this reason, the force equal to [Pressure on
Port HP Pressurized Area of Poppet S1] acts on
the opening direction, and the force equal to
[(Pressure in Spring Chamber Pressurized Area
of Poppet S2) Spring Force] acts on the closing
direction.
Accordingly, when the force acting on the opening
direction of the poppet [Pressure on Port HP
Pressurized Area of Poppet S1] becomes larger
than [(Pressure on Spring Chamber
Pressurized Area of Poppet S2) Spring Force],
the poppet opens to relieve the hydraulic oil.
T3-6-5
Travel Speed Changeover Valve
There are two surfaces on the swash plate; surface (a)

and surface (b). Surface (a) makes contact with the
housing at slow speed, and surface (b) makes contact
with the housing at fast speed.
Two balls are located off the center line on the swash
plate, so they can roll freely.
Slow Speed Operation

When the travel is in slow speed, the pressure oil
from the travel speed changeover solenoid valve
is not supplied to the travel speed changeover
valve. Thereby, surface (a) of the swash plate
makes contact with the housing by the oil
pressure acting on the plunger, and the spring
force in the rotor.
As a result, the angle of swash plate increases
which makes the stoke of plunger longer. As a
consequence, the motor capacity becomes larger,
so the travel motor rotates in slow speed.
Fast Speed Operation

When the travel is in fast speed, the pressure oil
from the travel speed changeover solenoid valve
is supplied to the travel speed changeover valve.
Thereby, the travel speed changeover valve
switches to supply the pressure oil to the control
piston. The swash plate is pushed by the control
piston, which makes surface (b) contact with the
housing.
As a result, the angle of swash plate decreases
which makes the stroke of plunger shorter. As a
consequence, the motor capacity becomes
smaller, so the travel motor rotates in fast speed.
When Engine Stops

When engine stops, pressure oil applied to the
control piston returns to the hydraulic oil tank
through the travel speed changeover valve. As a
consequence, surface (a) of the swash plate
makes contact with the housing by the spring
force in the rotor.
As a result, the travel motor always rotates in
slow speed whenever the engine is started.
T3-6-6
From Travel Speed

Changeover Solenoid Valve
To Control Piston Travel Speed Changeover Valve T571-03-05-006
Swash Swash
At Slow Speed: Plate Rotor Plunger At Fast Speed: Plate Rotor Plunger
Surface (b) Surface (b)
Spring From
Travel
Speed
Change-
Surface (a) over
Valve
Surface (a)
Control
T571-03-05-005
T571-03-05-004
Piston
T3-6-7
TRAVEL REDUCTION GEAR
The travel motor rotates the shaft, and the rotation is

transmitted to the first stage sun gear. The rotation of
the first stage sun gear is reduced by the first stage
planetary gear and the first stage carrier, and is
transmitted to the second stage sun gear. The rotation
of the second stage sun gear is reduced by the
second stage planetary gear and the second stage
carrier (united with the travel motor housing).
As second stage carrier and travel motor housing is
united into one part, the rotation of the second stage
planetary gear is transmitted to sprocket via the ring
gear.
First Stage Second Stage Second Stage

Planetary Gear Planetary Gear Carrier
First Stage Sun

Gear
First Stage
Carrier
Ring Gear Second Stage Sun Gear
T571-03-05-001
T3-6-8
COMPONENT OPERATION / Others (Upperstructure)
SOLENOID VALVE UNIT
Pilot Relief
There are two kinds of solenoid valves; one is the pilot Valve
shut-off valve solenoid valve, the other is the travel Pilot Shut-Off Travel Speed
speed changeover solenoid valve. Valve Changeover
Solenoid Valve Solenoid Valve
The solenoid valve is switched ON/OFF by the posi-
tion of pilot control shut-off lever to control the pilot
pressure to pilot valve.
When the pilot control shut-off lever is in the LOCK
position, the pilot shut-off switch is OFF. By this ac-
tion, the solenoid valve is OFF, so that pilot pressure
is blocked by the solenoid valve spool. As a conse-
quence, the pressure oil is not delivered to the pilot
valve.
When the pilot control shut-off lever is in the UN-
LOCK position, the pilot shut-off switch is ON. By this
action, the solenoid valve is ON, so the pilot pressure
is supplied to the pilot valve through the solenoid
valve spool.
Travel Speed Changeover Solenoid Valve T574-03-06-001

The travel speed is controlled by the fast speed travel To Pilot Valve To Travel Motor
pedal.
When the fast speed travel pedal is in the slow speed
position (released position), the travel speed
changeover switch is OFF. By this action, the sole- Pilot Control
noid valve is OFF, so that pilot pressure is blocked by Shut-Off Lever
the solenoid valve spool. As a consequence, the
travel speed changeover pressure is not delivered to
the travel motor.
When the fast speed travel pedal is in the fast speed
position (step-on position), the travel speed change-
over switch is ON. By this action, the solenoid valve
is ON, so that pilot pressure is delivered to the travel
motor as the travel speed changeover pressure
through the solenoid valve spool.
T532-02-06-002
Pilot Shut-Off Switch
Fast Speed Travel Pedal
T532-02-06-005
T3-7-1
COMPONENT OPERATION / Others (Upperstructure)
PILOT RELIEF VALVE
The pilot circuit of solenoid valve unit has a pilot relief

valve, preventing the circuit pressure from rising more
than the set pressure. The pressure oil from pilot
pump always acts on the plunger. When this pressure
increases more than the set pressure ( by spring Spring
force), the plunger is moved, allowing the pressure oil
to be relieved through the passage in the plunger.
From To
Pilot Pump Hydraulic
Oil Tank
Plunger T574-03-06-002
T3-7-2
COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
The swing bearing supports the upperstructure on the Outer race (1) is bolted to the upperstructure.
undercarriage and allows the upperstructure to rotate Inner race (2) is bolted to the undercarriage.
smoothly. The internal gear meshes with the pinion of the swing
The swing bearing is a single-row ball-type. device.
The major parts of swing bearing are outer race (1),
inner race (2) with internal gear, ball (5), support (4)
and seal (3).
3 5
T507-03-02-001
1 - Outer Race 3 - Seal 4 - Support 5 - Ball

2 - Inner Race
T3-8-1
CENTER JOINT
The center joint is a 360 rotating joint. It allows oil to Body (5) rotates together with the upperstructure
flow to and from travel motors (12) and blade cylinder around spindle (10) during swing operation.
(13) without twisting hoses when the upperstructure is Oil flows into and through the passages in body (5) to
rotated. spindle (10) and then out of spindle (10) to travel mo-
Spindle (10) is fastened to the undercarriage with bolts tor (12) and blade cylinder (13).
(4 used) and body (5) is fastened to the upperstructure Oil seal (11) prevents oil leaks from the clearance be-
with lock pins. tween spindle (10) and body (5).
DR
A
B
C
D
E
F
G
4 D
13 8 G C
F B
9 E A
1 6 DR
7 Hydraulic Circuit
1 6
3
2
2
9
7
8
4 3
12
T554-03-03-001
T3-8-2
5
A
B
9
6
1
C
D
E
7
F 2
G
11
3
Mounting face to the track

frame
4 10
3
9
2 1
T554-03-03-002
1 - Port E (Blade Lower) / 5 - Body 8 - Port B (Right Travel For- 11 - Seal
Pressure Oil from Port E ward) / Pressure Oil from
Port B
2 - Port F (Blade Raise) / 6 - Port A (Right Travel Re- 9 - Port D (Left Travel For- 12 - Travel Motor
Pressure Oil from Port F verse) / Pressure Oil from ward) / Pressure Oil from
Port A Port D
3 - Port G (for Travel Speed 7 - Port C (Left Travel Re- 10 - Spindle 13 - Blade Cylinder
Changeover) / Pressure Oil verse) / Pressure Oil from
from Port G Port C
4 - Port DR (Drain) / Pressure
Oil from Port DR
T3-8-3
TRACK ADJUSTER
The track adjuster located on the side frame is com-

posed of spring (4) and adjuster cylinder (5). Spring
(4) absorbs loads applied to the front idler. Adjuster
cylinder (5) adjusts track sag.
Grease is applied through the grease fitting into

chamber (A) of adjuster cylinder (5) as illustrated be-
low. The pressure of the grease pushes piston rod
(6) out and decreases track sag.
To increase track sag, loosen valve (1) 1 to 1.5 turns
counterclockwise to release grease from the track 1
adjuster cylinder through the grease discharge out-
let. Grease Fitting
Grease Discharge Outlet
M104-07-119
Track Adjuster (Rubber Crawler)

1 2 3
4 A 5 6
Grease Discharge Track Adjuster (Iron Crawler)

Outlet 8 7
T507-03-05-001
1 - Valve 4 - Spring 6 - Piston Rod 8 - Plug

2 - Nut 5 - Adjuster Cylinder 7 - Flange 9 - Rod
3 - Washer
T3-8-4
SECTION 4
OPERATIONAL PERFORMANCE TEST
CONTENTS
Group 1 Introduction Group 5 Component Test
Operational Performance Test.................... T4-1-1 Primary Pilot Pressure ..................................T4-5-1
Preparation for Performance Tests ............. T4-1-2 Secondary Pilot Pressure .............................T4-5-2
Main Relief Valve Set Pressure ....................T4-5-4
Group 2 Standard Overload Relief Valve Set Pressure ............. T4-5-8
Operational Performance Standard ............. T4-2-1 Swing Motor Drainage ................................T4-5-10
Travel Motor Drainage ................................T4-5-12
Group 3 Engine Test Revolution Sensing Valve Output Pressure T4-5-14
Engine Speed ............................................... T4-3-1 Pump Delivery Pressure .............................T4-5-16
Engine Compression Pressure..................... T4-3-2 Pump Driving Torque ..................................T4-5-18
Valve Clearance ........................................... T4-3-3
Nozzle Check ............................................... T4-3-4
Injection Timing............................................. T4-3-6
Group 4 Excavator Test

Travel Speed ................................................ T4-4-1
Track Revolution Speed ............................... T4-4-2
Mistrack Check ............................................. T4-4-3
Travel Motor Leakage................................... T4-4-4
Swing Speed ................................................ T4-4-5
Swing Function Drift Check .......................... T4-4-6
Swing Motor Leakage................................... T4-4-7
Maximum Swingable Slant Angle................. T4-4-8
Swing Bearing Play ...................................... T4-4-9
Hydraulic Cylinder Cycle Time ................... T4-4-10
Dig Function Drift........................................ T4-4-12
Control Lever Operating Force................... T4-4-13
Control Lever Stroke................................... T4-4-15
1LDT-4-1
(Blank)
1LDT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TEST
Use operational performance test procedure to quanti-

tatively check all system and functions on the ma-
chine.
Purpose of Performance Tests

1. To comprehensively evaluate each operational
function by comparing the performance test data
with the standard values.
2. According to the evaluation results, repair, adjust,
or replace parts or components as necessary to
restore the machines performance to the desired
standard.
3. To economically operate the machine under opti-
mal conditions.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
Performance Standard is shown in tables to evalu-
ate the performance test data.
Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
The machine performance does not always deterio-

rate as the working hours increase. However, the ma-
chine performance is normally considered to reduce in
proportion to the increase of the operation hours. Ac-
cordingly, restoring the machine performance by repair,
adjustment, or replacement shall consider the number
of the machines working hours.
Definition of Performance Standard

1. Operation speed values and dimensions of the
new machine.
2. Operational performance of new components ad-
justed to specifications. Allowable errors will be
indicated as necessary.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out

performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 20 m (65 ft 7 in), and to make a
full swing with the front attachment extended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to communi- T105-06-01-003
cate with each other using these signals, and to

follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.
MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use T505-06-01-003
mean values of measurements if necessary.
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE
STANDARD
This Operational Performance Standard values are The value in ( ) is shown for reference only.
listed below. * The standard measurement condition is as follows;
Refer to the correspondence section in T4-3 and after Engine Speed Control Lever: Full Stroke
for the details of measurement method. Hydraulic Oil Temperature: 50 5 C
Item 40U 50U Remarks

ENGINE SPEED min
-1
Slow Idle Speed 1075 50

Fast Idle Speed 2330 50
Fast Idle Speed (Bucket Relief Opera-
2250 50
tion)
Fast Idle Speed (Boom Relief Operation) 2250 50
ENGINE COMPRESSION
3.04(31.0) After engine warm-up
PRESSURE MPa (kgf/cm2)
VALVE CLEARANCE (IN, EX) mm 0.4 0.05 With engine cold
NOZZLE INJECTION
17.7(180)
PRESSURE 2
MPa (kgf/cm )
INJECTION TIMING
11.5 1
(Before Top Dead Center) deg.
TRAVEL SPEED sec/20 m

Fast Speed Mode 16.5 1.5/ 15.7 1.5/
(Rubber Crawler/Steel Crawler) 17.7 1.5 16.9 1.5
Slow Speed Mode 29.3 1.5/ 28.0 1.5/
TRACK REVOLUTION SPEED sec/3 rev.
Fast Speed Mode 12.9 1.5/ 12.5 1.5/
Slow Speed Mode 22.3 1.5/ 21.9 1.5/
MISTRACK
200 or less
(Fast Speed Slow Speed) mm/20 m
TRAVEL MOTOR LEAKAGE mm/3 min 60 or less
SWING SPEED sec/3 rev. 20.0 1.5
SWING FUNCTION DRIFT mm/90 150 or less
SWING MOTOR LEAKAGE mm/5 min 0 Bucket loaded
MAXIMUM SWINGABLE
21 or more Bucket loaded
SLANT ANGLE deg.
SWING BEARING PLAY mm 0.4 or less
T4-2-1

HYDRAULIC CYLINDER
CYCLE TIME sec
Boom Raise 2.1 0.3
Boom Lower 2.6 0.3 2.8 0.3
Arm Roll-In 2.9 0.3 3.1 0.3
Arm Roll-Out 2.7 0.3
Bucket Roll-In 3.1 0.3 3.4 0.3
Bucket Roll-Out 2.1 0.3 2.3 0.3
Right Boom Swing 8.0 0.5
Left Boom Swing 6.0 0.5
Blade Raise 2.6 0.5
Blade Lower 3.1 0.5
DIG FUNCTION DRIFT mm/5 min Bucket loaded
Boom Cylinder 5 or less
Arm Cylinder 8 or less
Bucket Cylinder 5 or less
Bucket Bottom 70 or less
Blade Cylinder 3 or less
Blade Cylinder (When jacked up) 8 or less 10 or less
Boom Swing Cylinder 2 or less
CONTROL LEVER/PEDAL HITACHI Lever
OPERATING FORCE N (kgf) Pattern
15.0 or less
Boom Lever
(1.5 or less)
15.0 or less
Arm Lever (ISO Lever Pattern: Swing)
(1.5 or less)
15.0 or less
Bucket Lever
(1.5 or less)
15.0 or less
Swing Lever (ISO Lever Pattern: Arm)
(1.5 or less)
19.0 or less
Travel Lever
(1.9 or less)
21.0 or less
Blade Lever
(2.1 or less)
54.0 or less
Boom Swing Pedal
(5.5 or less)
60.0 or less
Fuel Lever
(6.1 or less)
T4-2-2

HITACHI Lever
CONTROL LEVER/PEDAL STROKE mm
Pattern
Boom Lever 100 10
Arm Lever (ISO Lever Pattern: Swing) 90 10
Bucket Lever 90 10
Swing Lever (ISO Lever Pattern: Arm) 100 10
Travel Lever 135 10
Blade Lever 100 10
Fuel Lever 190 10
Boom Swing Pedal 18 5
BOOM RAISE/SWING (Bucket Empty)
Height mm 2800 or more 2700 or more
Time sec 2.1 0.3 2.1 0.3
PRIMARY PILOT
5.9 0.5(60 5)
SECONDARY PILOT
4.4 0.5(45 5)
MAIN RELIEF VALVE, RELIEF
Measure at Machine
25.1 1.0
Main Pumps P1
(255 10)
21.6 1.0
Swing
(220 10)
25.1 1.0
Travel
(255 10)
OVERLOAD RELIEF VALVE, RELIEF
Measure at Bench
PRESSURE 2
MPa (kgf/cm )
+1.0
26.5 -0
Boom, Arm, Bucket +10
(270 -0)
Blade (Rod Side) 11.8+1.0-0
19.6 0.5
Swing
(200 5)
+1.0
24.5 -0
Travel +10
(250 -0)
SWING MOTOR DRAINAGE L/min
at constant speed (0.5) or less
TRAVEL MOTOR DRAINAGE L/min
at constant speed (0.7 or less/ Refer to Drain Pres-
(Fast/Slow) 0.7or less) sure (5.9 to 8.3 Mpa)
T4-2-3

REVOLUTION SENSING VALVE OUTPUT
PRESSURE (Pressure PGR ) Measure at bench
2
MPa (kgf/cm )
Fast Idle 1.49 (15.2) 1.48 (15.1) Reference
Slow Idle 0.47 (4.8) 0.49 (5.0) Reference
PUMP DELIVERY PRESSURE
(Lever in Neutral) 2
MPa (kgf/cm )
Fast Idle 2.7 (27.5) 2.8 (28.6) Reference
Slow Idle 1.1 (11.2) 1.1 (11.2) Reference
T4-2-4
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. Be sure to check the engine speed before per-
forming all other tests, since it always affects test
results.
Preparation:
1. Warm up the machine, until the engine coolant
Stopper
temperature reaches 50 C (122 F) or more, and
hydraulic oil temperature is 50 5 C (122 9 F).
2. Move the engine speed control lever from slow
idle to fast idle. Confirm that the fuel injection
pump governor lever comes into contact with the
slow-idle and fast-idle stoppers.
3. Connect an engine tachometer to the fuel injec-
tion line.
Measurement:
1. Slow idle.
Start the engine. Place the engine speed control
lever in the slow idle position and measure the
speed of the engine.
2. Fast idle.
Start the engine. Place the engine speed control
lever in the fast idle position and measure the
speed of the engine.
3. Repeat measurement three times and calculate T1LD-04-03-001
the mean value.
Evaluation:
Refer to T4-2 Operational Performance Standard.
Governor
Lever
T573-04-03-007
Stopper
T4-3-1
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders
to check for a reduction in engine power.
2. Check exhaust gas color. Keep track of engine oil
consumption.
3. Check for abnormalities in the intake system, in-
cluding the air cleaner.
Preparation:
1. Warm up the engine.
2. Disconnect the negative terminal at the battery,
then remove all glow plugs and engine stop sole-
noid connectors.
Reconnect the negative terminal to battery.
3. Install the pressure gauge to the glow plug bore
with an adapter (Isuzu: 5-8840-2656-0). (Be sure
to tighten them sufficiently to prevent air leakage.)
4. Confirm that the batteries are charged.
IMPORTANT: Use the fully charged battery to keep

the engine speed over 250 min 1.
Measurement:
1. Turn the starter to crank the engine. Record the
compression pressure of each cylinder. T571-04-02-001
2. Repeat measurement three times and calculate

the mean value.
Evaluation:
T4-3-2
VALVE CLEARANCE
Summary:
1. Perform the measurement when the engine is
cold.
2. Before removing the head cover, clean the area
around the head cover to prevent the entry of Mark Groove
dust into the engine.
Preparation:
1. Remove the head cover.
2. Locate the top dead center (TDC) in the com-
pression stroke. Align "Mark Groove" on crank
pulley with "TDC Mark" on timing gear case
cover. Crank Pulley
In this position, cylinder No.1 is at the top dead TDC Mark
center in the compression stroke.
NOTE: The flywheel can be easily turned after the

glow plugs are removed. T533-06-02-001
Measurement:
1. Measure the valve clearance between the rocker
arm and valve.
2. When the measurement is started from cylinder
No.1, measure the clearances of valves marked Valve
( ) in the table below. Clearance
Cylinder No. 1 2 3 4
Valve I E I E I E I E
Cylinder No.1 at top dead center
Cylinder No.1 at overlap
3. Turn flywheel 360 , then measure the valve

clearances marked ( ) in the above table.
T532-06-02-001
Evaluation:
Adjustment:
If the measured value is not within specification,
loosen the lock nut and adjust valve clearance by
turning the adjusting bolt, then tighten lock nut.
T4-3-3
NOZZLE CHECK
Summary:
1. Check the injection pressure and the spray pat-
tern with a nozzle tester.
2. Before starting work, clean the nozzle holder

mounting area to avoid contamination in the en-
gine.
Preparation:
1. Remove all nozzle holders and fuel injection pip-
ings from the engine.
2. Attach a nozzle holder to nozzle tester.
Measurement:
CAUTION: Never touch spray directly. The
fuel spray from the nozzle may penetrate the
skin, resulting in serious injury. If fuel pene- T107-06-02-006
trates into the blood stream, it may cause

blood toxication.
1. Injection pressure
After attaching the nozzle holder to nozzle tester,
strongly make several strokes of the tester to in-
ject fuel. Then, while operating the tester at ap-
prox. 60 time strokes a minute, measure the fuel
injection pressure.
Use shims in the nozzle holder to adjust the pres-
sure.
2. Spray pattern
For this test, turn the pressure tester knob to by-
pass the pressure gauge. Attach the nozzle
holder to the nozzle tester. Strongly make several Nozzle Holder
strokes of the tester and check the fuel spray pat-
tern.
NOTE: Use clean diesel oil.

Shim
3. Oil tight condition
Keep the pressure slightly below the injection
pressure. Check for fuel leak from around the
nozzle tip.
T1LA-04-02-002
T4-3-4
Evaluation:
Normal Abnormal
1. Standard Injection Pressure:
2. Spray pattern standards

(1) No visibly coarse distribution.
(2) No stray sideways sprays.
(3) Fine spray size and intermittent injection dur-
ing initial injection stage.
(4) No post-injection dripping.
(5) Correct injection angles.
3. Oil Tight Condition

No fuel leaks.
T523-06-02-001
T4-3-5
INJECTION TIMING
Preparation
1. Rotate the crank pulley until No.1 cylinder is at Mark Groove
TDC of the compression stroke.
Align "Mark Groove" on the crank pulley with
"TDC Mark" on the timing gear case cover.
2. Rotate the crank pulley approx. 100 counter-
clockwise.
3. Remove No. 1 injection pipe (1).
4. Remove No. 1 delivery valve holder (2) on injec- Crank Pulley
tion pump (5) to pull out delivery valve (4) and
spring (3). Reinstall delivery valve holder (2) to in- TDC Mark
jection pump (5).
Tightening Torque: 39 to 44 N m (4 to 4.5 kgf m, T533-06-02-001
29 to 33 lbf ft)
5. Turn the key switch to "ON". While supplying fuel 1
from fuel pump, rotate the crank pulley clockwise
slowly until the fuel leak stops at the tip of the de-
livery valve holder. At this moment, the "Mark
Groove" on the crank pulley should be aligned
with "TDC Mark" on the timing gear case cover. If
not, adjust the injection timing.
(11.5 BTDC [Before Top Dead Center] of the
compression stroke)
Adjustment:
1. Remove bolt (7) and nut (6) from injection pump T533-06-02-004
(5).
2. Adjust timing position by increasing or decreasing 2 5
the number of shims (8) between injection pump
(5) and body (9).
3. When delaying timing, increase the number of
shims (8). When advancing timing, decrease the 3
number of shims (8).
4
NOTE: The crank angle will vary 1 per shim 0.1
mm.
T533-06-02-003
7
5
6
8 9
T533-06-02-002
T4-3-6
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
To check overall performance of travel drive system
(between main pump and travel motor), measure the
time required for the excavator to travel a test track.
Preparation:
1. Adjust the track sag of both tracks to be equal.
2. Prepare a level and solid test track 20 m (65.5 ft)
in length, with an extra length of 3 to 5 m (9.8 to
16 ft) on both ends for machine acceleration and
deceleration.
3. Hold the bucket 0.3 to 0.5 m (1.0 to 1.6 ft) above
the ground with the arm and bucket extended.
4. Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
End
Arm roll-in, Bucket roll-in
Start
Raise bucket 0.3 to 0.5 m

(1.0 to 1.6 ft) above the
ground.
3 to 5 m (9.8 to 16 ft)
extra length for accelera-
20 m (65.5 ft) tion/deceleration
3 to 5 m (9.8 to 16 ft)
extra length for accelera- T570-06-03-001
tion/deceleration
Measurement:
1. The test should be performed with each mode
(slow and fast travel speeds) in the fast-idle
speed.
2. Start traveling the machine in the acceleration
zone with the travel levers at full stroke.
3. Measure the time required to travel 20 m (65 ft 7
in).
4. After measuring the forward travel speed, turn the
upperstructure 180 and measure the reverse
travel speed.
5. Repeat steps (2) and (4) three times in each di-
rection and calculate the mean values.
Evaluation:
Remedy:
Refer to T5-2 "Troubleshooting A".
T4-4-1
TRACK REVOLUTION SPEED
Summary:
With the track raised off ground, measure the track
revolution cycle time to check the total track drive
system (between main pump and travel motor).
Preparation:
1. Adjust the track sag of both side tracks equally.
2. On the track to be measured, mark one shoe with
chalk.
CAUTION: Support the lifted track securely
with wooden blocks.
3. Swing the upperstructure 90 and lower the

bucket to raise the track off ground. Keep the 90 to 110
boom-arm angle between 90 to 110 as shown.
Mark
Measurement:
(slow and fast travel speeds) in the fast idle T570-06-03-009
speed.
2. Operate the travel control lever of the raised track
in the full forward or reverse stroke.
3. Measure the time required for 3 revolutions of
shoe in both directions.
4. Raise the other track and repeat the procedures.
5. Repeat steps (2) and (4) three times for each
track and calculate the mean values.
Evaluation:
NOTE: The measured values may vary widely. The

evaluation based on the results obtained
from the 20 m (65.5 ft) travel speed check
is more recommendable.
Remedy:
T4-4-2
MISTRACK CHECK
Summary:
1. Allow the machine to travel 20 m (65.5 ft). Meas-
ure the maximum tread deviation from the tread
chord line drawn between the travel start and end
points to check the performance equilibrium be-
tween both sides of the travel device systems
(between main pump and travel motor).
2. If measured on a concrete surface, the tread de-
viation has a trend to decrease.
Preparation:
1. Adjust the track sag of both tracks to be equal.
2. Provide a flat, solid test yard 20 m (65.5 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft)
on both ends for machine acceleration and de-
celeration.
3. Hold the bucket 0.3 to 0.5 m (1.0 to 1.6 ft) above
the ground with the arm and bucket extended.
(122 9 F).
Max Distance
20 m T570-06-03-002
Measurement:
(slow and fast travel speeds) in the fast idle
speed.
2. Start traveling the machine in the acceleration
zone with the travel levers at full stroke.
3. Measure the distance between a straight 20 m
(65.5 ft) line and the tread made by the machine.
4. After measuring the tracking in forward travel,
swing the upperstructure 180 and measure that
in reverse travel.
5. Repeat steps (3) and (4) three times in each di-
rection and calculate the mean values.
Evaluation:
Refer to T 4-2 Operational Performance Standard.
Remedy:
T4-4-3
TRAVEL MOTOR LEAKAGE
Summary:
Measure the amount of travel motor slippage on a
slope, which is due to travel motor inner oil leak.
Preparation:
1. The surface of the test slope must be even, with a
gradient of 20 (11.31 ).
2. Raise the bucket 0.2 to 0.3 m above the ground
with the arm and bucket cylinders fully extended
(rolled in)
(122 9 F).
Measurement:
1. Measure the slip amount of travel motor at park-
ing. T570-06-03-010
1-1. Climb the slope and place the travel levers in

neutral.
1-2. Stop the engine.
1-3. After parking the machine, makes aligning
marks on the side frame and a track link or
shoe.
1-4. After 3 minutes, measure discrepancy be-
tween the marks.
Amount of slippage after 3 minutes
Evaluation:
T505-06-03-005
T4-4-4
SWING SPEED
Summary:
Measure the time required to swing three complete
turns to check the total swing drive system (between
the main pump and swing motor).
Preparation:
1. Check the lubrication of swing gear and swing
bearing.
2. Place the machine on level, solid ground with
ample space for swinging. Do not conduct this
test on slopes.
3. With the arm rolled out and bucket rolled in, hold Even with
the Boom
the bucket so that the height of arm top pin is Foot Pin.
even with the boom foot pin. The bucket must be
empty. T570-06-03-003

(122 9 F)
CAUTION: Before starting the measurement,

make sure that there are no person or obsta-
cles within the swing area.
Measurement:
1. Run engine at fast idle speed. Operate swing con-
trol lever fully.
2. Measure the time required to swing 3 turns in one
direction.
3. Operate swing control lever fully in the opposite
direction and measure the time required for 3
turns.
4. Repeat steps (2) and (3) three times each and
calculate the average values.
Evaluation
Remedy:
T4-4-5
SWING FUNCTION DRIFT CHECK
Summary:
To check the valve unit performance, measure the
swing drift on the bearing outer circumference when
stopping after a 90 full speed swing.
Mechanical brake for swing parking is installed on
swing motor.
Preparation:
bearing. Make aligning marks on the
2. Place the machine on level, solid ground with swing bearing outer circum-
ference and track frame.
ample space for swinging. Do not conduct this
test on slopes. T570-06-03-004
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of bucket pin is even
with the boom foot pin. The bucket must be
empty.
4. Make the marks on the swing bearing and track
frame.
5. Swing the upperstructure 90 .
(122 9 F).
CAUTION: Before starting the measurement,

make sure that there are no person or obsta- Swing the upperstructure 90
to the test start position.
cles within the swing area.
T570-06-03-005
Measurement:
1. Start and run engine at fast idle speed. Operate
the swing control lever fully to swing the upper-
structure. When the marks on the swing bearing
and track frame meet, return the swing lever to Measure the arc length along the
the neutral position. circumference of swing bearing.
2. After the swing movement stops, measure the arc
length between two aligning marks along the cir-
cumference of the swing bearing.
3. Align the marks again, swing 90 then test in the
opposite direction.
4. Repeat steps (1) and (2) three times each and Mark on the track frame
calculate the mean values.
Mark on the swing bearing
Evaluation:
T105-06-03-010
Remedy:
T4-4-6
SWING MOTOR LEAKAGE
Summary:
To check swing parking brake performance, meas-
ure the upperstructure drift after parking the machine
on a slope with the upperstructure positioned 90 to
the slope.
(Mechanical brake for swing parking is installed on
swing device.)
Preparation:
bearing.
2. Load the bucket with either soil or a weight
equivalent to the weight standard.
Weight: 40U: 210 kg (463 lb)
50U: 240 kg (529 lb)
the bucket so that the height of bucket pin is even
with the boom foot pin.
4. Park the machine on a flat slope with a gradient of
15 1 .
5. Climb the slope, then swing the upperstructure
90 toward the slope. Make aligning marks on
the swing bearing circumference and track frame.
(122 9 F).
T570-06-03-006
Measurement:
1. Start the engine and maintain engine speed at
idle speed. After 5 minutes, measure the differ-
ence between the marks on the swing bearing
circumference and the track frame.
2. Perform the measurement under the following
two conditions: Measure the arc length along the swing
bearing circumference.
When the brake is applied(with the pilot control
shut-off lever in the LOCK position).
When the brake is released(with the pilot control
shut-off lever in the UNLOCK position).
3. Perform the measurement on both right and left
swing directions.
Mark on the track frame
4. Perform the measurement three times in each di-
rection and calculate the average values.
Mark on the swing bearing
Evaluation: T105-06-03-010
Remedy:
T4-4-7
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
To measure the maximum slope angle on which the
upperstructure can swing, park the machine on a
slope with the upperstructure positioned 90 to the
slope.
Preparation:
bearing.
Weight: 40U: 210 kg (463 lb)
50U: 240 kg (529 lb)
3. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the bucket so
that the height of bucket pin is even with the
boom foot pin. T570-06-03-006
4. Climb the slope, then set the upperstructure 90

to the slope.
(122 9 F).
Measurement:
1. Run engine at fast idle speed. Operate the swing
control lever fully to swing the upperstructure to
the uphill side of slope.
2. If swing is possible, measure the slant angle on
the cab floor.
3. Increase the slope angle. Measure on both right
and left swing directions.
4. Perform the measurement three times.
Evaluation:
Remedy:
T4-4-8
SWING BEARING PLAY
Summary:
Measure the swing play with a dial gauge to check
the wear of bearing races and balls.
Preparation:
1. Check the swing bearing mounting bolt for loose-
ness.
2. Check the lubrication of swing bearing. Confirm
that bearing rotation is smooth and noiseless.
T105-06-03-014
3. Install a dial gauge with a magnetic base on the Magnetic Base Dial Gauge
track frame as shown.
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the travel
motors.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race as shown. Round Frame Trunk
6. Bucket should be empty.
NOTE: The measured value may differ depending

on where the dial gauge magnetic base is
located. Mount the magnetic base directly T105-06-03-015
onto the round frame trunk or as close to

the round frame trunk as possible. Measurement: [h1]
Measurement:
the bucket so that the height of the bucket pin is
even with the boom foot pin. Record the dial
gauge reading (h1).
2. Lower the bucket to the ground and use it to raise Even with the
the front idler 0.5 m (20 in). Record the dial gauge Boom Foot Pin.
reading (h2).
3. Calculate bearing play (H) from this data (h1 and T570-06-03-003
h2) as follows:
H = h2 h1
Measurement: [h2]
Evaluation:
T570-06-03-007
T4-4-9
HYDRAULIC CYLINDER CYCLE TIME
Boom Cylinder
Summary:
1. To totally check the front attachment function per-
formance (between the main pump and each cyl-
inder) by measuring each cylinder cycle time.
2. Bucket should be empty.
Preparation:
1. Take the following machine position:
T570-06-03-011
1-1. When measuring the boom cylinder: Arm Cylinder

With the arm cylinder fully retracted and the
bucket cylinder fully extended, lower the
bucket to the ground.
1-2. When measuring the arm cylinder:

With the bucket cylinder fully extended, adjust
the boom and arm cylinder strokes so that
when the arm is moved half the full stroke, the 0.5 m
arm longitudinal center line perpendicularly
points to the ground and the bucket bottom
T570-06-03-012
clearance above the ground is approx. 0.5 m
(20 in). Bucket Cylinder
1-3. When measuring the bucket cylinder:

Adjust the boom and arm cylinder strokes so
that when the bucket is moved half the full
stroke, the bucket edge points to the ground
perpendicularly.
1-4. When measuring the boom swing cylinder:

Set the boom swing cylinder in either the right
or left swing stroke end position.
T105-06-03-020
1-5. When measuring the blade cylinder:
Boom Swing Cylinder
Lower the bucket to the ground to raise the
machine front off the ground and secure the
height space to allow the blade to move up-
and-down full stroke.
2. Maintain hydraulic oil temperature at 50 5 C

(122 9 F).
T523-06-03-006
Blade Cylinder
T570-06-03-007
T4-4-10
Measurement:
1. Run engine at fast idle speed.
Operate each cylinder as follows:

(The cylinder stroke excludes the cushion range.)
1-1. Measure the boom cylinder.

Measure the time required to raise or lower the
boom while operating the boom control lever
full stroke.
1-2. Measuring the arm cylinder.

Measure the time required to roll in or out the
arm while operating the arm control lever full
stroke.
1-3. Measuring the bucket cylinder.

Measure the time required to roll in or out the
bucket while operating the bucket control lever
full stroke.
1-4. Measuring the boom swing cylinder

Measure the time required to swing the front
attachment from right to left or vice versa while
operating the boom swing pedal full stroke.
1-5. Measuring the blade cylinder

Measure the time required to raise or lower the
blade while operating the blade control lever
full stroke.
2. Repeat each measurement three times and calcu-

late the average values.
Evaluation:
Refer to T 4-2 Operational Performance Standard.
Remedy:
T4-4-11
DIG FUNCTION DRIFT
Summary: Retraction
Extension
1. With the bucket loaded, measure dig function drift,
which can be caused by oil leakage in the control Retraction
valve and / or boom, arm, bucket, blade and
boom swing cylinders.
2. When testing the dig function drift just after cylin-

der replacement, slowly operate each cylinder to Arm Top Pin is
even with Boom Front Drift
its stroke end to purge trapped air prior to testing. Foot Pin.
Preparation: Extension T570-06-03-008

Weight: 40U: 210 kg (463 lb)
50U: 240 kg (529 lb)
2. With the arm cylinder fully retracted and bucket
cylinder fully extended, had the bucket pin height
even with the boom foot pin.
When measuring the boom swing cylinder, climb
the slope with a gradient of 15 1 and set the
upperstructure 90 to the slope.
3. Retract arm cylinder and bucket cylinder approx.
50 mm to away from the cushion range. T570-06-03-006

Boom, Bucket and blade Cylinder Retraction
(122 9 F).
Mark Mark
Measurement:
1. Stop the engine.
2. After five minutes, measure the boom, bucket and
blade cylinder retraction, arm cylinder extension,
and amount of the bucket drift.
3. Repeat step 2. three times and calculate the
mean values.
T110-06-03-002
Evaluation:
Refer to T4-2 Operational Performance Standard. Arm Cylinder Extension
Remedy:
Mark
T110-06-03-001
Boom Swing Cylinder Extension
T506-06-03-001
T4-4-12
CONTROL LEVER OPERATING FORCE
Summary:
Use a spring scale to measure the maximum force
needed to move each control lever and pedal.
Measure the operating force at the center of each
lever grip.
Preparation:
(122 9 F).
CAUTION: Before the measurement, make

sure there are no personnel or obstacles
within the swing area.
Measurement:
1. Start the engine.
2. Measure the maximum operating force with each T107-06-03-003
boom raise, arm, bucket, swing lever, full stroke.

3. Measure the maximum operating force with the
boom lower lever full stroke until the fully raised
boom comes in contact with the ground.
4. Operate swing lever and measure the maximum
operating force with swing relieved after securing
the front attachment to prevent swinging.
5. Lower the bucket to the ground to raise one track
off the ground. Operate the travel lever to full
stroke and measure the maximum operating
force.
When finished, lower the track and then jack up
the other track.
6. Repeat each measurement three times and calcu- T107-06-03-004
late the mean values.
Evaluation:
T4-4-13
(Blank)
T4-4-14
CONTROL LEVER STROKE
Summary:
1. Measure each lever stroke at the lever top using
a ruler.
2. Measure the lever stroke at the grip center of
each control lever.
As for the boom swing pedal, measure the stroke
from the center position to stopper.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.
Preparation:
Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
T107-06-03-005
Measurement:
1. Stop the engine.
2. Measure the boom, arm, bucket, swing, travel
and blade control lever strokes at the grip top
center from the neutral position to the stroke end.
On the swing pedal, measure the straight dis-
tance between the center and fully depressed po-
sitions at tip of the pedal.
On the engine speed control lever, measure the
distance between the slow and fast idle positions
at center of the top on the grip.
3. Take the measurements by the straight stroke dis-
tances.
4. Conduct the measurement three times.
Calculate the average values.
Evaluation:
T4-4-15
Engine Speed Control Lever Adjustment
IMPORTANT: Never adjust the idle adjusting

screws (slow idle and fast idle) on
the governor lever.
1. Loosen the stopper bolt of engine speed control

lever.
2. Adjust the length (G) of the stopper bolt tip (lower)
on the slow idle side to standard.
3. Move the engine speed control lever until it con-
tacts against the stopper on the slow idle side.
Make sure that the governor lever contacts with
the slow idle adjusting screw. If it does not contact
with the stopper, adjust the length of the cable.
4. Move the engine speed control lever until the
governor lever contacts with the fast idle adjust-
ing screw.
Adjust the length (F) of the stopper bolt tip (upper)
on the fast idle side so that the clearance be-
tween the engine speed control lever and stopper
bolt is 1 to 2 mm (0.04 to 0.08 in), then secure it
with the nuts.
T1LD-04-03-001
Stopper
Bolt
Fast Idle Side

Stopper
Engine Control
Cable
G
Slow Idle Side
Stopper
T574-04-03-006
Stopper Bolt
40U,50U
Standard Length (F) 25 mm (0.98 in)
Standard Length (G) 30 mm (1.18 in)
T4-4-16
Governor Lever:
T1LD-04-04-001
Fast Idle Slow Idle

Adjusting Adjusting
Screw Screw
Nut Governor Lever

T573-04-03-007
T4-4-17
(Blank)
T4-4-18
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Stop the engine.
2. Turn the filling cap on hydraulic oil tank to bleed
air.
3. Disconnect the hose (PF 3/8) at the pilot filter. In-
stall pressure gauge assembly (ST 6932) with tee
(ST 6639) and adapter (ST 6069) to the pilot filter.
Pilot Filter
: 22 mm
4. Start the engine and check for oil leakage from

the gauge connection.
(122 9 F).
Measurement:
Hose
1. Run engine at fast idle speed. (PF3/8)
2. Measure the pressure without load.
3. Perform the measurement three times and calcu-
late the average value.
Evaluation:
Adjustment: T1LD-04-05-001
Adjustment the relief valve on 2-unit solenoid valve

if necessary.
Adjusting Screw
1. Loosen the lock nut. Lock Nut
2. Turn the adjusting screw to adjust the pressure.
: 5 mm
3. Tighten the lock nut.

: 17 mm
: 20 to 29 N m (2 to 3 kgf m, 14 to 22 lbf ft)
4. After completing the adjustment, recheck the set

pressure.
NOTE: Standard change in pressure.
Screw Turns 1/4 1/2 3/4 1

T574-03-06-002
Change in kPa 147 294 441 588

Relief (kgf/cm )
2
(1.5) (3) (4.5) (6)
Pressure
(psi) (21) (43) (64) (85)
T4-5-1
SECONDARY PILOT PRESSURE
Preparation: Pilot Hose

1. Properly shut down the engine.
air.
3. Install pressure gauge (ST 6932), adapter (ST
6069) and tee (ST 6640) to the end of pilot hose
(PF 1/4) at the respective control valve spool end,
as illustrated.
: 19 mm
4. Start the engine and check for oil leakage at the

pressure gauge connection.
(122 9 F).
Measurement: T157-05-04-011
CAUTION: Before measuring, check that

there are no obstacles or personnel within
the swing radius. When measuring the boom
lower pilot pressure, raise the machine off
the ground while paying attention not to al-
low the base machine (counterweight) to
contact with the ground. Be careful not to
tip-over due to a loss of balance.
1. Operate the lever to be measured. Measure the

pilot pressure at its full stroke with the pressure
gauge.
late the average valve.
Evaluation:
T4-5-2
(Blank)
T4-5-3
MAIN RELIEF VALVE SET PRESSURE
Summary: Delivery Port in

Measure the main relief valve setting pressure at the Main Pump (P1)
main delivery port.
Preparation:
1. Stop the engine.
air.
3. Disconnect the hose (PF 3/4) onto the delivery
port in main pump (P1). Install tee (ST 6639),
adapter (ST 6069), and pressure gauge assembly
(ST 6933).
: 36 mm
4. Start the engine and check for oil leakage at the

(122 9 F).
Measurement: T1LD-03-01-002
1. Run the engine at fast idle speed.

2. Slowly operate each control lever or pedal to fully
extend or retract each cylinder to relieve the
pressure. Measure the relief pressure at this
time.
3. Repeat the measurement three times and calcu-
late the average values.
Evaluation:
T4-5-4
Main Relief Valve Adjustment Procedure
A A
Adjustment:
Adjust the main relief valves if necessary. The main
relief valves are installed on the position as illus-
trated.
NOTE: Before loosening the lock nut, make the

alignment marks on the adjusting screw,
lock nut and valve. Using these alignment
marks, the number of turns of the adjusting
screw can be checked easily.
1. Loosen the lock nut on main relief valve.

: 17 mm
IMPORTANT: Adjust the pressure so that it does

not exceed the upper limit of stan-
dard.

: 6 mm
T1LD-03-04-001
Adjusting
: 17 mm Screw Lock Nut
Cross Section A-A
: 34 to 39 N m
(3.5 to 4 kgf m, 25 to 29 lbf ft)
4. After completing the adjustment, recheck the set

pressure.

Change in MPa 2.2 4.4 6.7 (8.9)
Relief (kgf/cm2) (22.4) (44.9) (69.4) (90.9)
Pressure (psi) (319) (638) (986) (1290)
T566-03-03-005
Main Relief Valve
IMPORTANT: In case adjusting the main relief
valve, be sure to adjust the variable
Adjusting
relief valve. (Refer to T4-2-4.) Lock Nut Screw
Pressure
Pressure Decrease
Increase
W107-02-05-129
T4-5-5
Variable Relief Valve Adjustment Procedure Port PLS
After adjusting the main relief valve, be sure to check

the pressure at port PLS (pressure PLS) and adjust A A
the variable relief valve as necessary while relieving
the main relief valve. Port PLS and the variable relief
valve are located in the position as illustrated to the
right.

lock nut, and valve. Using these alignment
1. Disconnect the hose (PF 1/4) of port PLS at the

connect part on control valve. Install tee (ST
6640), adapter (ST 6069), pressure gauge as-
sembly (ST 6632).
: 19 mm
2. Start the engine. Check for oil leakage at the
3. Install the engine tachometer to the injection pipe
in the engine. Set the engine speed at fast idle T1LD-03-04-001
speed (2330 min-1) While checking the tachome- Adjusting

Screw Lock Nut
ter. Cross Section A-A
4. Loosen the lock nut of variable relief valve.
: 17 mm
5. Relieve one of the boom, arm, or bucket circuits.
While relieving the main relief valve, adjust the
pressure by turning the adjusting screw so that
the pressure at port PLS matches the value be-
low.
Pressure PLS: 1.3 MPa (13.3 lgf/cm2, 189 psi)
: 6 mm
: 17 mm T566-03-03-005
: 34 N m (3.5 to 4 kgf m, lbf ft) Variable Relief Valve
After the adjustment, recheck the set pressure.
Adjusting
Lock Nut Screw
Pressure
Pressure
Increase
Decrease
W107-02-05-129
T4-5-6
Swing Relief Pressure Adjustment Procedure
Adjustment: Swing Relief Valve

Adjust the pressure of swing relief valve with the ad-
justing screw after loosening the lock nut.
1. Loosen the lock nut.

: 17 mm
2. Turn the adjusting screw to adjust the pressure

referring to the table below.
: 4mm
3. Retighten the lock nut.

: 17 mm
: 15.7 0.1 N m
(16 1 kgf m, 116 7 lbf ft)
4. Recheck the set pressure.
NOTE: Standard change in pressure. T523-02-03-003
Screw Turns 1/4 1/2 3/4 1 Lock Nut Adjusting

Screw
Change MPa 2.45 4.9 7.4 9.8
in Relief (kgf/cm )
2
(25) (50) (75) (100)
Pressure
(psi) (360) (710) (1070) (1420)
Lock Nut Adjusting Screw
T561-02-03-001
Pressure Increase Pressure Decrease
W107-02-05-129
T4-5-7
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary:
1. With the return circuit from the control valve
blocked, the circuit pressure must be increased
by applying an external load. This checking
method is hazardous and the results obtained
with this method are unreliable.
2. Pressure setting of the overload relief valve must
be made at a specified oil flow rate normally far
smaller than the delivery flow rate of main relief
valve. Accordingly, even if the main relief valve
set pressure can be reset higher than the set
pressure of overload relief valve, the main pump
supplies too much oil to correctly measure the set
pressure of overload relief valve.
The main relief valve has pre-leaking function.
In this case, the set pressure of main relief valve
at pre-leaking function need to be set higher than
that of overload relief valve.
Accordingly, the main relief valve pressure setting
may not be reset higher than the set pressure of
overload relief valve plus the pressure at pre-
leaking.
Therefore, when the set pressure of overload re-
lief valve must be checked correctly, remove the
overload relief valve assembly from the machine
and check the overload relief valve unit perform-
ance using the test stand and test block prepared
for this purpose.
If the poppet of overload relief valve seats to the
body of control valve, the test block requires pre-
cise machining.
Use other control valve unit for the measurement
instead of the test block.
3. As an easier method, however, measure the relief
pressure of each cylinders in the same method as
of main relief pressure setting in previous section.
Then, when each relief pressure meets its re-
spective specifications, judge that the set pres-
sure of overload relief valve is correct.
T4-5-8
Overload Relief Valve Adjustment Procedure
Adjustment: Lock Nut
NOTE: Pressure of overload relief valve shall be

adjusted with test device in principle.
1. Loosen the lock nut on overload relief valve.
: 17 mm
2. Turn adjusting screw to adjust the set pressure.

: 6 mm
Adjusting Screw
: 17 mm T566-03-03-018
: 34 to 39 N m
(3.5 to 4 kgf m, 25 to 29 lbf ft)
4. After the adjustment, check the set pressure.
Overload Relief Valves (Boom, Arm and Bucket): Adjusting

Lock Nut Screw
NOTE: Standard Change in Pressure.

Screw Turns 1/4 1/2 3/4 1 Pressure
Pressure Decrease
Change in MPa 2.7 5.5 8.3 (11.0)
2
Increase
Relief (kgf/cm ) (72.5) (56.1) (84.7) (112)
Pressure (psi) (392) (798) (1200) (1600)
W107-02-05-129
T4-5-9
SWING MOTOR DRAINAGE
Summary:
1. To check the performance of swing motor, meas-
ure the amount of oil draining from the swing mo-
tor while swinging the upperstructure.
2. Always secure the test personnels safe during
the measurement. Before the measurement,
make sure there are no person or obstacles
within the test track. Make-Up Line
3. The amount of drain oil will change depending on Drain Hose (PF 3/8)
hydraulic oil temperature. Maintain hydraulic oil
temperature at 50 5 C (122 9 F).
Preparation:
1. Warm the hydraulic oil temperature to 50 5 C
(122 9 F). Rotate the swing motor to warm up
the inside of motor.
2. Stop the engine. Turn the filling cap to bleed air
from the hydraulic oil tank.
3. Disconnect the drain hose at swing motor. In-
stall a plug (PF 3/8) to the disconnected hose end.
Connect hose (ST 6961) onto the drain port of
swing motor.
T1LD-04-05-002
: 22 mm
: 39 N m (4 kgf m, 29 lbf ft)
CAUTION: Before the measurement, make

sure there are no person or obstacles within
the swing area.
Make sure not to fall off from machine during
the measurement.
4. Disconnect the make-up line at swing motor. In-

stall plugs on the disconnected line end and mo-
tor port.
Measurement Condition:
1. Before the measurement, set the fuel lever to the
fast idle position, then measure it.
T4-5-10
Measurement:
1. Drain Oil Volume at Swing Operation
(1) With the arm rolled out and bucket rolled in,
hold the bucket so that the height of arm top
pin is even with the boom foot pin. The bucket
must be empty.
(2) Start the engine. Operate the swing lever to
the full stroke. After swing speed reaches a Even with the
constant maximum speed, collect the hydraulic Boom Foot
Pin.
oil from drain hose. Measure the time also.
(3) Repeat the measurement more than 3 times in
T570-06-03-003
both clockwise and counterclockwise direc-
tions, and calculate the average value.
(4) The measurement should be at least 45 sec-
onds.
2. Drain Oil Volume at Swing Lock Operation

(1) Seize the ground with bucket so that the ma-
chine does not move.
(2) Start the engine. Operate the swing lever to
the full stroke. Collect the hydraulic oil from
drain hose. Measure the time also.
both clockwise and counterclockwise direc-
tions, and calculate the average value.
onds.
Evaluation:
* Conversion of Measured Value into the Per-
Minute Value
Measure the amount of drain oil using a cali-
brated container. Then, convert the measured
drain oil into the per-minute value using the fol-
lowing formula;
Q = 60 q/t
Q : Per-Minute Drain Volume (L/min)

t : Time Measured (sec)
q : Measured Drain Oil Volume (L)
T4-5-11
TRAVEL MOTOR DRAINAGE
Summary:
1. To check the performance of travel motor, meas-
ure the amount of oil draining from the travel mo-
tor, while rotating the travel motor with the meas-
uring side track jacked up.
2. Always secure the test personnels safe during
the measurement. Before the measurement,
make sure there are no personnel or obstacles
within the test track.
3. Evaluate the overall performance of the travel mo-
tor taking the test results such as travel speed
and mistrack amount into consideration together
with this test results.
4. The amount of drain oil will change depending on
hydraulic oil temperature. Maintain the hydraulic
oil temperature at 50 5 C (122 9 F).
Preparation:
1. Warm the hydraulic oil results temperature to
50 5 C (122 9 F). Rotate the travel motor to
warm up the inside of motor.
2. Stop the engine. Turn the filling cap to bleed air
from the hydraulic oil tank. Drain Hose
3. Disconnect the drain hose at the travel motor. In-
stall a plug (PF 3/8) to the disconnected hose end.
Connect hose (ST 6961) onto the drain port of
travel motor.
: 22 mm
: 39 N m (4 kgf m, 29 lbf ft)
Measurement Condition:
1. Set the fuel lever to the fast idle position and
measure at slow travel speed.
T566-04-04-004
T4-5-12
Measurement:
CAUTION: When approaching to the rotation

parts, take care that hands, legs or clothes
are not entangled.
Support the lifted machine securely with
wooden block.
(1) Start the engine. Jack-up the measuring side 90 to 110

track.
(2) Rotate the raised track. Collect the hydraulic
oil from drain hose. Measure the time also.
both forward and reverse directions, and calcu- T570-06-03-009

onds.
Evaluation:
* Conversion of Measured Value into the Per-
Minute Value
Measure the amount of drain oil using a cali-
brated container. Then, convert the measured
drain oil into the per-minute value using the fol-
lowing formula;
Q = 60 q/t
Q : Per-Minute Drain Volume (L/min)

t : Time Measured (sec)
q : Measured Drain Oil Volume (L)
T157-05-04-019
T4-5-13
REVOLUTION SENSING VALVE OUTPUT
PRESSURE(PRESSURE PGR) Revolution
Sensing Valve
Summary :
Measure pressure PGR at the output port of the revo-
lution sensing valve while running the engine at the
slow and fast idle speeds.
Preparation :
1. Stop the engine.
2. Disconnect the hose (PF 1/4) at revolution sens- Hose
ing valve connection. Install tee (ST 6640),
adapter (ST 6069), and pressure gauge assem-
bly(ST 6932).
: 19 mm
(122 9 F).
Measurement :
1. Set the engine speed at slow idle speed and fast
idle speed.
2. Measure the pressure PGR without load at slow
and fast idle speed.
T1LD-04-05-001
Evaluation :
T4-5-14
Revolution Sensing Valve Adjustment Procedure Adjusting
Revolution Sensing Valve
Lock Nut Screw
lock nut and valve. Using these alignment
screw can be checked easily. Variable
Metering
Valve
1. Loosen the variable metering valve lock nut on
the revolution sensing valve.
2. Slightly tighten the variable metering valve adjust-
ing screw so that the variable metering valve Differential
doesnt operate. Tighten the adjusting screw until Reducing
Valve
the adjusting screw end face is retracted from the
lock nut by approximately 1 mm.
: 6 mm
3. Run the engine at the minimum speed (1 075
-1 T566-03-02-002
min ). Loosen the differential reducing valve lock Lock Nut Adjusting Screw
nut. Turn the differential reducing valve adjusting
screw so the pressure PRG matches the value
below. (Variable Metering Valve)
2
Pressure PGR: 0.5 MPa (5 kgf/cm , 71 psi)
: 17 mm Lock Nut
Adjusting
Screw
: 6 mm
4. Increase the engine speed to the maximum
-1
speed (2 330 min ). Loosen the variable metering
Pressure
valve lock nut. Turn the variable metering valve Pressure
Decrease
adjusting screw so the pressure PRG matches Increase
the value below.
2
Pressure PGR: 1.47 MPa (15 kgf/cm , 213 psi)
: 17 mm
: 6 mm W107-02-05-129
5. Tighten both the variable metering valve and dif-

ferential reducing valve lock nuts. (Differential Reducing Valve)
: 17 mm
: 34 to 39 N m (3.5 to 4 kgf m, 25 to 29 Adjusting
Lock Nut Screw
lbf ft)
6. After completing adjustment, recheck the set
pressure. Pressure
Pressure Decrease
Increase
W107-02-05-129
T4-5-15
PUMP DELIVERY PRESSURE
Summary :
Measure the pump delivery pressure at the main pump
delivery port when all the control levers are in neutral.
Preparation :
1. Stop the engine. Delivery Port in
2. Turn the filling cap on hydraulic oil tank to bleed Main Pump (P1)
air.
3. Disconnect the hose (PF 3/8) onto the delivery
port in main pump (P1). Install tee (ST 6639),
adapter (ST 6069), and pressure gauge assembly
(ST 6933).
: 36 mm
(122 9 F).
Measurement :
1. Set the engine speed at slow idle speed or fast
idle speed.
2. Turn all the control levers into neutral. Measure
the pump delivery pressure.
late the average value. T1LD-03-01-002
Evaluation :
T4-5-16
Unload Valve Adjustment Procedure

lock nut , and valve. Using these alignment
A A
1. Loosen the lock nut on unload valve.

: 17 mm
: 6 mm
: 17 mm
: 34 to 39 N m (3.5 to 4 kgf m, 25 to 29
lbf ft)
4. After the adjustment, recheck the set pressure.

MPa 0.025 0.05 0.075 0.1
Change in
Pressure (kgf/cm2) (0.26) (0.5) (0.76) (1) T1LD-03-04-001
(psi) (3.6) (7.3) (10.9) (14.5)

Crosse Section A-A
Adjusting
Lock Nut Screw
Unload
Pressure Valve
Pressure
Decrease
Increase
Lock Nut Adjusting Screw

W107-02-05-129 T566-03-03-005
T4-5-17
PUMP DRIVING TORQUE
Summary:
The adjustment of pump driving torque is not recom-
Adjusting
mended. If the adjustment of pump driving torque is Screw
necessary, perform the following procedures.
Adjustment:
1. Loosen the lock nut.
2. Turn the adjusting screw to adjust. (Turn clock-

wise to increase the driving torque. Turn counter-
clockwise to decrease the driving torque)
: 4 mm
NOTE: Replace the lock nut washer after every

adjustment. Failure to do so may cause oil
leaks.
T1LD-03-01-003
: 13 mm
: 10 to 14 N m
(1 to 1.4 kgf m, 7.2 to 10 lbf ft)
Lock Nut Adjusting

Screw
NOTE: Standard change in pressure

Change in kPa 113 225 338 441
Pressure 2 Torque
(kgf/cm ) (1.15) (2.3) (3.45) (4.5) Torque
(difference Increase Decrease
from point A) (psi) (16) (33) (49) (64)
W107-02-05-129
Point A
Flow
Rate (Q)
Torque Torque
Decrease Increase
Pressure (P)
T4-5-18
SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure Group 4 Electrical System Inspection
Introduction ............................................... T5-1-1 Precautions for Inspection and
Diagnosing Procedure ............................... T5-1-2 Maintenance................................................T5-4-1
Fuse Continuity Test ..................................... T5-4-3
Group 2 Troubleshooting A Battery Voltage Check ..................................T5-4-4
Troubleshooting A Procedure....................... T5-2-1 Voltage Check ...............................................T5-4-5
Engine System Troubleshooting .................. T5-2-2 Continuity Check ...........................................T5-4-6
Actuator Operating System
Troubleshooting .......................................... T5-2-6
Front Attachment System
Troubleshooting .........................................T5-2-11
Swing System Troubleshooting .................. T5-2-18
Travel System Troubleshooting.................. T5-2-20
Blade System Troubleshooting................... T5-2-24
Boom Swing System Troubleshooting ....... T5-2-26
Group 3 Troubleshooting B
Troubleshooting B Procedure....................... T5-3-1
Malfunction of Coolant
Temperature Gauge.................................... T5-3-2
Malfunction of Fuel Gauge ........................... T5-3-4
Malfunction of Alternator Indicator................ T5-3-6
Malfunction of Engine Oil Pressure
Indicator ...................................................... T5-3-7
Malfunction of Overheat Indicator ................ T5-3-8
Malfunction of Fuel Level Indicator............... T5-3-9
Malfunction of Buzzer ................................. T5-3-10
Malfunction of Hour Meter ...........................T5-3-11
1LDT-5-1
(Blank)
1LDT-5-2
TROUBLESHOOTING / Diagnosing Procedure
INTRODUCTION
Troubleshooting charts shown in this section indicate

the orderly procedures for inspecting and finding out
the cause(s) of problems in the machine.
This section is comprised of three groups:

Troubleshooting A (diagnosis of machine by symptom),
Troubleshooting B (diagnosis of monitor) and Electric
System Check.
Troubleshooting A (diagnosis of machine by

symptom)
This procedure is used when operating the
diagnosis by the symptom.
Example: Starter does not rotate.
Troubleshooting B (diagnosis of monitor)

This procedure is used when there are
malfunction on components regarding monitor,
such as gauges or indicators.
Example: Fuel gauge does not operate.
Electric System Check

This procedure is used when the information on
precaution for electric system inspection or
inspection method is needed.
Example: Fuse inspection.
T5-1-1
DIAGNOSING PROCEDURE
Follow the five basic steps shown below for efficient

troubleshooting.
1. Know the system

Study the appropriate technical manuals. Know
what the system is composed of and how it works,
as well as the construction, functions and
specifications of the system components.
2. Ask the operator

T107-07-01-001
Before inspecting, get the full story of
malfunctions from a witness --- the operator.
(a) How the machine has been used and properly
operated?
(b) When was the trouble noticed, and what work
was the machine doing at that time?
(c) What is the character of the trouble? Did the
trouble slowly get worse, or did it appear
suddenly for the first time?
(d) Did the machine have any trouble previously?
If so, which parts were repaired or replaced
before?
3. Inspect the machine
Before starting troubleshooting, check the
machine's daily maintenance points, as shown in
the operator's manual.
Check the electrical system, including batteries.

Trouble in the electrical system such as low T107-07-01-002
battery voltage, loose connections and blown
fuses will result in malfunction of the controllers,
causing total operational failure of the machine.
Note that if the troubleshooting is performed

without noticing that the fuse is blown, it may lead
to the incorrect diagnosis results which causes
significant loss of time. Make sure to check the
fuse before performing the troubleshooting.
Fuse failure is often caused by a fine crack in the
fuse, and such fine cracks are very hard to detect
by visual inspection.
T107-07-01-003
T5-1-2
4. Inspect the actual trouble on the machine
Reproduce the trouble on the machine and make
sure the actual phenomenon.
In case some trouble cannot be actually
confirmed, obtain the details of the malfunction
from the operator.
Also check for any incomplete connections of the
wire harnesses.
5. Check by Each System

CAUTION: Always stop the engine before
disconnecting the harnesses or lines. If they T107-07-01-004
are disconnected while the engine running, it

may cause improper operation of the
machine, or the pressurized oil may spout.
Use "Troubleshooting A, B" in this chapter to

confirm the operation condition for each
equipment.
6. Trace causes
Before reaching a conclusion, check the most
suspectable causes again. Try to trace what the
real cause of the trouble is.
Make a plan of appropriate repairing procedure,
T107-07-01-005
to avoid consequential malfunctions.
T107-07-01-006
T107-07-01-007
T5-1-3
(Blank)
T5-1-4
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
(DIAGNOSIS OF MACHINE BY SYMPTOM)
This procedure is used when operating the diagnosis

by the symptom.
How to Read the Troubleshooting Flow Charts
YES (OK)
(2)
(1) After checking or measuring item (1), select either YES (OK) or NO
(NOT OK) and proceed to item (2) or (3) next.
(3)
NO (NOT OK)
As shown to the left, measuring methods or items to be referred to are indicated in the
spaces under the box. Take care to measure or check correctly. Incorrect measuring or
Key switch: ON
checking methods may result in making troubleshooting impossible, and may damage
components.
The thick-line box indicates the causes. Scanning through thick-line boxes, possible
causes can be focused.
NOTE: The connector drawings show the harness

end connectors seen from the open end
side.
Wire Harness Side
Open End Harness End Connector

Side
T158-05-03-001
T5-2-1
ENGINE SYSTEM TROUBLESHOOTING
Starter does not rotate

YES
Be sure to inspect connection prior to trouble
shooting.
No voltage or less
than 12 V at termi-
nal B.
With key switch
positioned as
shown in the table
YES below, check if
each terminal volt-
age on starter is
normal.
Unit: V
Key Switch
OFF ON START
Terminal
B (M8) 12 12 12
#50 (S) 0 0 12 NO
Check if battery No voltage or less

voltage and elec- than 12 V at termi-
trolyte density are nal #50 (S) with
normal. key switch at
· Voltage: 12 volts START position.
or more · Key switch START
· Density: 1.25 to
1.28
NO (When key switch is turned to the START position, if voltage at

terminal B is lower than 9 volts, battery may be faulty.)
Starter voltage check

Starter
1. Turn key switch to the ON or START position.

2. Contact minus ( ) probe of a circuit tester to the
machine (ground to unpainted area like bolt head)
and plus (+) probe terminals to the starter termi-
nal respectively, and check voltages.
#50(S)
(Measure with the harness connected.)
B T523-07-02-001
T5-2-2
Faulty starter.
Faulty harness between bat-

tery and starter, or incorrect
connection.
YES Faulty harness between

starter relay and fusible link or
faulty key switch.
Voltage at terminal
#3: 0 V
#6: 0 V Check if fusible link b (65 A) (Red
wire) is normal (not blown).
· Visual Inspection
Faulty fusible link b.
NO
Measure voltage at terminals

#3 and #6 on starter relay.
Faulty starter relay.
· Key switch START Voltage at terminal
#3: 12 V
#6: 0 V
Faulty harness between ter-

minal #6 on starter relay and
Voltage at terminal terminal #50 on starter.
#3: 12 V
#6: 12 V
Faulty battery.
Starter Relay
Connector (View A)
#1
#2
#5 No Harness
#3
#6
View A
T573-05-02-001 T573-05-02-002
T5-2-3
Starter rotates but engine does not start.
The faulty engine and the faulty electrical circuit

are suspected. This page describes the trouble-
shooting of electrical circuit (fuel pump, engine
stop solenoid).
In case of faulty engine, refer to "Engine Shop
Manual".
Be sure to inspect connection prior to trouble
shooting.
YES
Engine Stop
Solenoid
Disconnect fuel line

that goes to engine at
fuel pump. Check if T573-05-02-005
fuel is delivered when Pin
key switch is turned
ON.
YES
Check if fuel filter is YES

NO clogged.
Disconnect fuel pump

connector. Check if
terminal #2 on har-
NO ness end connector
is 12V.
· Key switch: ON
NO
T5-2-4
Connector
Engine Stop Fuel Pump

Solenoid
Remove engine stop YES Faulty engine.
solenoid from engine.
Remove lead wire
YES from starter motor.
Check if pin on sole-
Disconnect engine noid top moves when
stop solenoid con- key switch is turned Faulty engine stop
to START. solenoid.
YES nector. Check if there NO
is continuity between
terminal #1 on har-
Disconnect engine ness end connector
stop solenoid connec- and vehicle. Broken harness be-
tor. Check if terminal tween engine stop
#2 on harness end NO solenoid and ground.
connector is 12V.
· Key switch: START
Broken harness be-
tween engine stop
NO solenoid and key
switch.
Faulty fuel filter.
YES Faulty fuel pump.

Check if there is
continuity between
terminal #1 on har-
ness end connector
of fuel pump and Broken harness be-
vehicle. tween fuel pump and
NO
ground.
Broken harness be-

YES tween fuse box and
fuel pump.
Check if fuse #8 (5A)
on fuse box is 12V. Faulty key switch, or
· Key switch: ON broken harness be-
NO tween key switch and
fuse box.
T5-2-5
ACTUATOR OPERATING SYSTEM TROU-
BLESHOOTING
All actuators do not work or do slowly.
As all the control circuits are pilot systems, the pi-

lot system may be faulty.
Be sure to inspect connection prior to trouble-
shooting. Check if there is conti-
YES nuity between terminal
#1 on harness end
connector and vehicle.
Disconnect pilot shut-

off valve solenoid valve
connector. Measure
voltage at terminal #2
YES on harness end con-
nector. Check if volt-
age is 12V.
· Key switch : ON
· Pilot shut-off lever : RE-
LEASE position
YES Check if main relief

pressure is normal.
· Refer to OPERATIONAL Measure voltage at fuse
PERFORMANCE TEST. #1 in fuse box. Check if
NO voltage is 12V.
Check if primary pilot

pressure is normal. Faulty main relief valve
in control valve.
· Refer to OPERATIONAL NO
PERFORMANCE TEST.
YES End(Faulty pilot relief

Disassemble , clean , valve).
and adjust pilot relief
valve. Check if symp-
NO tom disappears.
Faulty pilot pump.
NO
Connector
Pilot Shut-Off Switch

T5-2-6
YES Faulty pilot shut-off

valve solenoid
valve.(Spool is stuck.)
Disassemble pilot
YES shut-off valve sole-
noid valve. Check YES Faulty main shut-off
if it is abnormal. valve in control
valve.(Spool is stuck.)
Disassemble main
shut-off valve in
control valve.
Check if it is ab- YES Faulty revolution
NO
normal. Disassemble revolu- sensing valve.
tion sensing valve or
variable metering
NO valve. Check if it is
abnormal.
(A)
NO
Faulty right or left pilot

shut-off switch, or bro-
ken ground circuit be-
NO tween pilot shut-off
valve solenoid valve
and vehicle.
Broken harness be-

YES tween fuse box terminal
#1 and pilot shut-off
valve solenoid valve.
Faulty key switch, or

broken harness be-
tween key switch and
NO
fuse box.
YES Faulty unload valve in

control valve.
Disassemble unload
valve in control valve.
Check if it is abnor- YES Faulty variable relief
(A)
mal. valve in control valve.
Disassemble variable
relief valve in control
valve. Check if it is
NO abnormal. YES Faulty differential reduc-
Disassemble differen- ing valve in control
tial reducing valve in valve. (Spool is stuck.)
NO control valve. Check
if it is abnormal.
Faulty main pump.
NO
T5-2-7
All actuators work fast.
YES
Normal.
Check if hydraulic cylin-
der operating time is
normal.
· Refer to OPERATIONAL Faulty revolution sensing
PERFORMANCE TEST. valve.
NO
T5-2-8
Actuators work when control lever is in neutral.
Refer to T5-2-10 in case the Actuator doesnt stop

even if control lever is returned to neutral.
YES Stuck pilot valve spool.

Turn the pilot shut-off
lever into LOCKED
position. Check if symp-
tom disappears.
Find out cause of trouble
by tracing other trouble
NO symptoms.
T5-2-9
Actuators never stop even if control lever is re-
turned to neutral.
Replace overload relief

valve corresponding to YES Faulty overload relief valve
actuators (except blade) or faulty make-up valve in
and make-up front attachment system.
valve(boom swing) with
overload relief valve with
Boom,
normal actuator(except
Arm,
blade) and make-up
Bucket, Stuck spool in control valve
valve(boom swing).
Boom Swing, NO in front attachment system.
Check if symptom dis-
or Blade
appears.
Check which actuators YES Stuck swing spool in con-

are abnormal. trol valve.
Adjust swing relief valve.
Swing Check if trouble ap-
pears.
Faulty relief valve or faulty
· Refer to OPERATIONAL make-up valve in swing
PERFORMANCE TEST. NO device.
Faulty counterbalance
YES
valve or faulty relief valve in
travel device.
Disassemble counter-
Travel balance valve and relief
valve in travel device.
Check if they are ab-
normal. Stuck spool in right or left
travel in control valve.
NO
T5-2-10
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
All front attachment functions are weak.
Not only the front attachment but also other func-

tions will have the problem. If the travel function is
also abnormal, refer to All actuators do not work
or do slowly (T5-2-6). In case only the front at-
tachment is abnormal, check the pilot valve.
T5-2-11
Only Specific cylinder(s) does not work, or it

(they) does slow and weakly.
In case the cylinder speeds are slow, the pump

flow rate may be reduced. If the pump flow rate is
reduced due to some problems, only actuators
requiring more oil flow rate than the reduced
pump flow rate look to be slow.
In case the cylinder works weakly, the relief valve
set pressure may be lower than specific one. Be
careful not to mix the problem of slow with that of
weak because these symptoms are different from
each other.
YES Faulty overload relief

valve corresponding
to cylinder.
Replace overload
relief valve corre-
sponding to cylinder
Faulty make-up valve
with normal one. YES
corresponding to
Check if symptom
cylinder.
disappears.
Replace make-up
valve corresponding
to cylinder with the
NO new one. Check if Faulty pressure com-
YES
symptom disappears. pensator correspond-
ing to cylinder.
Disassemble pres-
sure compensator in
control valve corre-
NO sponding to cylinder.
Check if it is abnor- Disassemble shuttle
mal. valve in control valve
corresponding to
NO
cylinder. Check if it is
abnormal.
T5-2-12
Faulty shuttle valve in

YES control valve corre-
sponding to cylinder.
Stuck control valve

YES spool corresponding
to cylinder.
Disassemble control
valve spool corre-
sponding to cylinder.
NO Check if it is abnor-
mal.
Faulty main pump.
NO
T5-2-13
Only specific cylinder works fast.
Even if the pump flow rate increases due to some

problems in the pump, the oil flow rate is con-
trolled so that the optimum oil flow can be sup-
plied to the actuators by the flow Pressure Com-
pensator in the control valve. Accordingly, any
problems in the pump will not cause the actuator
speed to increase. However, in case the flow
Pressure Compensator is stuck in the open posi-
tion, the flow Pressure Compensator will be un-
able to control the optimum oil flow to the actua-
tors (excessive oil more than required will be
supplied to the actuators). Therefore, stuck flow
Pressure Compensator in the control valve may
be the most possible cause in this case.
Only boom does not work, or it does slow.

YES Stuck boom anti-drift
YES Disassemble boom

anti-drift valve in
control valve. Check
if it is abnormal.
Check if pilot secon- Faulty overload relief
dary pressure is valve in control valve.
NO
normal.
· Refer to OPERATIONAL
PERFORMANCE TEST.
Faulty pilot valve.
NO
T5-2-14
Front attachment cylinders leaking (drift) is large.
YES Normal.
YES Faulty seal in cylinder.

Check if each front
attachment cylinder
drift is within stan-
dards. NO Check if oil leaks
inside cylinder. Faulty boom anti-drift
· Refer to OPERATIONAL valve, faulty overload
PERFORMANCE TEST. relief valve, scored
Check if symptom control valve spool,
disappears when pilot NO damaged spring, or
NO shut-off lever is loosed spool end.
turned into LOCK
position.
Faulty pilot valve.
YES
Boom cylinder inner leak check
1. With the bucket cylinder fully retracted and the

arm cylinder slightly extended from the fully re-
tracted position, lower the bucket tooth tip to the
ground.
2. Disconnect the hydraulic hose at the rod side of
boom cylinder, and drain oil in the cylinder and
hose. (Install a plug on disconnected hose end
from vehicle.)
3. Retract the rod of the arm cylinder to raise the
bucket from the ground.
If oil comes out from disconnected and opened
pipe on boom cylinder and the rod of that is re- T571-05-02-001
tracted, oil is leaking in the boom cylinder.
If oil does not come out from disconnected pipe
on boom cylinder and the rod of that is retracted,
oil is leaking in the control valve.
T5-2-15
When control levers are operated (boom raise,
arm roll-out), front attachment drops briefly, then
begins to work.
YES Internal leakage in cylinder.
Check if load check

valve in control valve is
normal.
· Visually check after
disassembling. Faulty load check valve.
NO
NOTE: 1. During the initial stage of operation, the

oil pressure and flow rate from the
pump are low. If the load check valve is
failed, oil in the bottom side of cylinder (B)
flows back into the circuit through the
load check valve, causing the boom cyl-
inder to temporarily retract because of At failure in load
check valve (A)
the load on boom cylinder.
2. If oil is leaking from bottom side (A) to

rod side (B) due to the failed piston or
tube of the boom cylinder, the boom cyl-
inder temporarily retracts as oil pres-
sure and flow rate from the pump is low
during the initial stage of operation.
Then, the cylinder cannot support the
load, reducing cylinder force and in- T105-07-04-012
creasing the cylinder drift in this case.
T5-2-16
(Blank)
T5-2-17
SWING SYSTEM TROUBLESHOOTING
Upperstructure does not swing, its speed is slow,

or its swing power is weak.
Check if problem
YES disappears after
control valve spool
is disassembled
and cleaned.
Check if swing motor
YES oil drain amount is
normal
· Refer to
"OPERATIONAL
PERFORMANCE
Faulty swing motor.
TEST". NO
Check if swing
YES motor relief pres-
sure is normal.
· Refer to
"OPERATIONAL
Check if swing PERFORMANCE
pilot secondary TEST".
pressure is nor- Faulty swing motor
mal. NO relief valve.
· Refer to
"OPERATIONAL
PERFORMANCE Faulty pilot valve.
TEST". NO
T5-2-18
YES Faulty control valve

spool(stuck).
YES Faulty pressure com-

pensator in control
valve.
Disassemble pres-
NO sure compensator
in control valve. YES Faulty make-up valve
Check if it in control in swing device.
valve is abnormal. Check if make-up
valve in swing device
NO is abnormal.
Disassemble shuttle Faulty swing parking
valve in control brake, or faulty swing
valve. Check if it is NO reduction gear.
NO abnormal.
Faulty shuttle valve in

control valve.
YES
T5-2-19
TRAVEL SYSTEM TROUBLESHOOTING
Machine does not travel, or does slowly, or

travel weakly.
Both right and left travel motors seldom become

faulty at same time. Although the trouble shooting
hare is for the vehicle that both right and left travel
motors become faulty. When only one side is
faulty, refer to The excavator mistracks.
T5-2-20
Travel speed does not change to the fast speed.
Be sure to inspect wiring connection prior to trou-

ble shooting.
In case the problem cannot be solved due to the

flowchart below, the travel speed changeover
valve in travel device may be faulty. Faulty fast speed
YES travel pedal, or bro-
ken harness in
ground circuit.
Check if travel speed

changes to fast
YES speed when terminal
#1 on travel speed
changeover solenoid
valve connector is
connected to vehicle.
Check if terminal #2 · Ground the connec-
Faulty travel speed
on harness end tor to the vehicle with
changeover solenoid
connector of travel a clip without discon- NO valve.
speed changeover necting.
solenoid valve is
12V.
· Measure voltage
with a clip without Broken harness be-
disconnecting. tween travel speed
changeover solenoid
NO valve and fuse box.
Travel speed does not change to the slow speed.

ble shooting.

flowchart below, the travel speed changeover
valve in travel device may be faulty.
YES Fault fast speed

travel pedal.
Check if problem
disappears after
disconnecting travel
speed changeover
solenoid valve con-
nector.
Faulty travel speed
NO changeover solenoid
valve (stuck).
T5-2-21
One side track doesnt rotate or rotates slow. Ma-
chine mistracks.
Check that both side track sags are equally ad-

justed.

flowchart below, the shuttle valve in control valve
may be faulty.
Check if travel relief

NO pressure in slow speed
side is normal.
Check if symptom is
reversed when right · Measurement: Refer
NO to OPERATIONAL
and left travel line
hoses are switched PERFORMANCE
each other at the top of TEST.
Disassemble pressure center joint.
YES Stuck control valve
compensator in control
valve travel spool sec- YES spool.
Check if secondary tion. Check if it is ab-
travel pilot pressure normal. Faulty pressure com-
is normal. pensator in control
YES
valve.
Refer to
OPERATIONAL
PERFORMANCE Faulty pilot valve.
TEST. NO
Relationship between Faulty Seal

Location and Mistrack Direction 1
Seal When traveling When pivot turn 2
No. straight: is performed: 3
Right Travel
Left Travel forward
4
Reverse
Left Travel 5
Forward
Right Travel
Reverse
T555-05-03-001
T563-05-03-002
T5-2-22
NO Faulty travel motor.
YES Faulty travel reduction

Check if travel motor
YES drain oil amount is nor- gear.
YES Disassemble and clean
mal. travel motor servo pis-
Refer to ton. Check if same
Disassemble and symptom occurs. Faulty travel motor
OPERATIONAL
clean travel motor NO servo piston.
PERFORMANCE
counterbalance valve.
TEST. YES Check if same symp-
tom occurs. Faulty counterbalance
NO valve.
Switch forward travel NO Faulty center joint.

relief valve with reverse
one, or right travel relief
NO valve with left one. Faulty travel relief
Check if symptom is
YES valve.
reversed.
T5-2-23
BLADE SYSTEM TROUBLESHOOTING
Blade does not move, or its speed is slow.
YES Faulty seal in cylin-

der.
Remove the blade cyl-

inder, and fully retract it. YES Faulty overload relief
YES Connect only the line to valve.
the rod side. Check for
oil leaks from other Replace overload
opened pipe on cylinder relief valve with
when blade is raised. normal overload
NO relief valve. Check
if symptom disap-
Check if pilot valve pears. Disassemble pres-
secondary pressure is sure compensator
normal. in control valve.
NO
Check if it is ab-
normal.
Faulty blade pilot

valve.
NO
T5-2-24
Faulty pressure
YES compensator in
control valve.
NO Faulty center joint.
Disassemble shuttle
NO Check if it is abnormal.
Faulty shuttle valve
in control valve.
YES
T5-2-25
BOOM SWING SYSTEM TROUBLESHOOT-
ING
Boom swing does not work or does slowly.

flowchart below, the shuttle valve in control valve
may be faulty.
In case one side only cannot be operated or
moves slowly, the make-up valve may be faulty.
YES Faulty seal in cylin-

der.
Operate boom swing to
the right and fully retract
cylinder. Faulty pressure
YES Disconnect the line on YES compensator in
rod side. control valve.
Check if oil leaks occur Disassemble pres-
during operation of right sure compensator
boom swing. in control valve.
NO Check if it is ab-
normal.
Check if pilot valve
secondary pressure is
normal. Faulty center joint.
NO
Faulty boom swing

pilot valve.
NO
T5-2-26
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
(DIAGNOSIS OF MONITOR)
This procedure is used when there are malfunction on

components regarding monitor, such as gauge or indi-
cators.
How to Read the Troubleshooting Flow Charts
YES (OK)
(2)
(1) After checking or measuring item (1), select either Yes (OK) or No
(NOT OK) and proceed to item (2) or (3) next.
(3)
NO (NOT OK)
As shown to the left, measuring methods or items to be referred to are indicated in the
spaces under the box. Take care to measure or check correctly. Incorrect measuring or
checking methods may result in making troubleshooting impossible, and may damage
· Key switch: ON components.
The thick-line box indicates the causes. Scanning through thick-line boxes, possible
causes can be focused.
NOTE: The connector drawings show the harness

end connectors, seen from the open end
side.
Wire Harness Side
Open End Harness End Connector

Side
T158-05-03-001
T5-3-1
MALFUNCTION OF COOLANT TEMPERA-
TURE GAUGE
NOTE: The troubleshooting here only covers the

malfunction of coolant temperature gauge.
For the malfunction of overheat indicator,
refer to T5-3-8.

ble shooting. YES
Coolant temperature Disconnect coolant temperature

gauge monitor light sensor terminal, and connect har-
does not proceed from ness end terminal to the vehicle
segment no. 1. ground. Check if all segments
light. With coolant temperature sensor
terminal disconnected, remove
· Key switch: ON 12P connector from monitor panel.
NO Check if there is continuity be-
tween terminal #12 and sensor
harness end terminal.
YES
When coolant tempera-

ture sensor terminal is
All the segments on
disconnected, check if
coolant temperature YES
only one coolant tem-
gauge monitor light up.
perature monitor seg-
ment lights up.
With coolant temperature sen-
· Key switch: ON sor terminal disconnected, dis-
NO connect 12P connector from
monitor panel. Check if there is
continuity between harness end
terminal #12 and vehicle.
NO
YES
Disconnect coolant temperature
Coolant temperature sensor terminal, and connect
gauge monitor seg- harness end terminal to vehicle.
ment light moves its Check if all coolant temperature
position unsuitably. monitor segments light up.
· Key switch: ON NO
T5-3-2
Coolant Temperature Gauge

50 C 108 C
(122 F) (226 F) 115 C(239 F) or over
1 2 3 4 5 6 7 8 9 10
Faulty coolant tempera- Segment Number T573-05-02-004
ture sensor.
YES Faulty coolant tempera-

ture gauge or faulty moni-
tor controller.
Coolant
Segment
Temperature Resistance ( )
Broken harness between Number
C ( F)
coolant temperature 50
NO gauge and coolant tem- C 1 174 10
perature sensor. (122 F)
65
2 97 6
(149 F)
Faulty coolant tempera- 80
ture sensor. 3 58 4
(176 F)
90
4 42 4
(194 F)
Short-circuited harness 95
between monitor panel 5 35 3
and coolant temperature
(203 F)
sensor. 100
6 30 3
(212 F)
104
7 26 3
(219 F)
108
Faulty coolant tempera- 8 23 3
ture gauge or faulty moni-
(226 F)
tor controller. 115
9 20.5 3
(239 F)
115 C
H 10 (239 F)
or over
Faulty coolant tempera-
ture sensor.
Connector
Faulty coolant tempera-

ture gauge or faulty moni- Monitor Panel
tor controller.
6 5 4 3 2 1
12 11 10 9 8 7
T5-3-3
MULFUNCTION OF FUEL GAUGE
NOTE: The troubleshooting here only covers the

malfunction of fuel level gauge. For the
malfunction of fuel level indicator, refer to
T5-3-9.

ble shooting.
YES
Disconnect fuel level sensor con-

Fuel gauge monitor nector, and connect harness end
light does not proceed terminals #1 to #2. Check if all
from segment no. 1. segments on fuel gauge monitor With fuel level sensor connector
light up. disconnected, remove 12P con-
· Buzzer does not
sound. nector from monitor panel. Check
· Key switch: ON
if there is continuity between har-
· Use a clip to connect terminals. NO ness end connector #11 on moni-
tor panel and harness end con-
nector terminal #2 on sensor.
YES
When fuel level sensor

All segments on fuel connector is discon-
gauge monitor light up. nected, check if only
one fuel gauge monitor YES
segment lights up. With fuel level sensor connector
· Key switch: ON disconnected, disconnect 12P
connector from monitor panel.
NO Check if there is continuity be-
tween terminal #11 on harness
end connector and vehicle.
NO
YES
Disconnect fuel level sensor con-
Fuel gauge monitor nector, and connect harness end
segment light moves connector terminals #1 to #2.
its position unsuitably. Check if all fuel gauge monitor
segments light up stably.
· Key switch: ON
· Use a clip to connect terminals. NO
T5-3-4
Fuel Gauge
Lower Upper
Limit Limit
Faulty fuel level sensor.
YES Faulty fuel gauge or faulty

monitor controller. 1 2 3 4 5 6 7 8 9 10
Segment Number T573-05-02-003
Broken harness between

fuel gauge and fuel level
NO sensor.

Segment Number Resistance ( )
F 10 13 2
9 20 2
8 27 2
7 34 2
6 40 2
Short-circuited harness 5 48 2
between fuel gauge and 4 56 2
fuel level sensor.
3 67 2
2 79 2
E 1
Faulty fuel gauge or faulty
monitor controller.
Connector
Fuel Level Sensor

3 2 1
Faulty fuel gauge or faulty Monitor Panel

monitor controller.
6 5 4 3 2 1
12 11 10 9 8 7
T5-3-5
MALFUNCTION OF ALTERNATOR INDI-
CATOR

ble shooting.
NO Broken harness between
Check if there is conti- alternator and monitor.
nuity between harness
NO end terminal #3 on
connector on alternator
and monitor panel ter-
minal #3.
Disconnect connector on Burnt indicator bulb.
When key switch is alternator, and connect YES Or broken harness in
turned ON, alternator in- harness end terminal #3 monitor.
dicator does not light. to vehicle. Check if alter-
· Engine: Stop nator indicator lights.
· Key switch: ON
Faulty alternator
· Engine: Stop
YES (regulator).
YES Faulty alternator

(regulator).
Even if engine rotates, When alternator is dis-

indicator does not go out. connected, check if al-
ternator indicator goes
out.
· Key switch: ON
· Engine: Stop Short-circuited harness
between alternator and
NO indicator.
Connector
Monitor Panel
Altenator
6 5 4 3 2 1
12 11 10 9 8 7 3 2 1
T5-3-6
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR
NOTE: The indicator comes on when engine oil

pressure is below 0.5 0.1 kgf/cm2.
NOTE: 1 kgf/cm2=98.07 kPa
ble shooting.
YES Faulty engine oil pressure

switch.
When oil pressure switch
is disconnected, and
When key switch is harness end terminal is
turned ON, indicator connected to vehicle,
does not light. check if indicator comes NO Burnt indicator bulb.
· Engine: Stop on. Reconnect the discon-
· The indicator may not nected terminal.
· Key switch: ON When terminal #4 on
light up for 1 to 2 min-
utes just after the en- NO monitor panel is con-
gine stops. nected to vehicle, check
if indicator comes on. Broken harness between
engine oil pressure switch
· Key switch: ON YES and indicator.
· Ground the connector to
the vehicle with a clip
without disconnecting.
YES Faulty engine oil pressure

switch.
After engine is started, When oil pressure switch

indicator does not go out. is disconnected, check if
indicator goes out.
· Check if oil filter is · Key switch: ON
clogged or not. · Engine: Stop Short-circuited harness
between engine oil pres-
sure switch and indicator.
NO
Connector
Monitor Panel
6 5 4 3 2 1
12 11 10 9 8 7
T5-3-7
MALFUNCTION OF OVERHEAT INDICA-
TOR
NOTE: The indicator comes on when coolant tem-

perature is above 110 2 C(230 3.6 F)
and keeps its temperature more than 2
seconds.

ble shooting.
YES Faulty overheat switch.
When overheat switch

Even though all seg- terminal is discon-
ments of coolant tem- nected, and harness
perature gauge moni- end terminal is con- Broken harness between
nected to vehicle, YES overheat switch and
tor light up, they do not
check if segments blink Reconnect the discon- monitor.
blink for warning.
for warning. nected terminal. When
· Engine: Running terminal #2 on monitor
· Key switch: ON
· Buzzer does not NO panel is connected to
sound. vehicle, check if indica-
tor blink. Faulty coolant tempera-
· Key switch: ON NO ture gauge or faulty
· Ground the connector to monitor controller.
YES Faulty overheat switch.
Segments on coolant When overheat switch

temperature gauge terminal is discon-
monitor do not stop nected, check if indica- Short-circuited harness
tor stop blinking. YES
blinking. With overheat switch between overheat switch
terminal disconnected, and monitor.
· Key switch: ON · Key switch: ON remove 12P connector
from monitor panel.
NO Check if there is conti-
nuity between terminal
#2 on harness end con- Faulty coolant tempera-
nector and vehicle. NO ture gauge or faulty
monitor controller.
Connector · Key switch: ON
Monitor Panel
6 5 4 3 2 1
12 11 10 9 8 7
T5-3-8
MALFUNCTION OF FUEL LEVEL INDICA-
TOR
NOTE: The indicator comes on when amount of

fuel is below 5.5L.

ble shooting.
YES Faulty fuel level sensor.
When fuel level sensor

connector is discon-
nected, and terminal
Even if fuel is empty, #3 on harness end
lowest segment does connector is connected
not blink for warning. YES Broken harness between
to vehicle, check if in-
Reconnect the discon- fuel level sensor and
· Key switch: ON dicator blinks for warn-
nected terminal. When monitor.
ing.
terminal #1 on monitor
· Key switch: ON
NO panel is connected to
vehicle, check if indica-
tor blinks. Faulty fuel gauge or
· Key switch: ON NO faulty monitor controller.
· Ground the connector to
YES Faulty fuel level sensor.
Even if sufficient fuel is When fuel level sensor With fuel level sensor
in fuel tank, segment is disconnected, check if connector disconnect,
blinks for warning. segment stops blinking. YES Short-circuited harness
disconnect 12P connec- between fuel level sensor
· Key switch: ON tor from monitor panel. and monitor.
· Key switch: ON
Check if there is conti-
nuity between terminal
NO #1 on harness end con-
nector and vehicle.
Faulty fuel gauge or
· Key switch: ON faulty monitor controller.
NO
Connector
Fuel Level Sensor Monitor Panel
3 2 1
6 5 4 3 2 1
12 11 10 9 8 7
T5-3-9
MALFUNCTION OF BUZZER
Buzzer sounds continuously when engine oil
pressure indicator and overheat indicator light up.
Buzzer sounds 5 times when fuel level indicator
lights up.
ble shooting.
Faulty engine oil lubrica-

YES tion system or faulty en-
gine oil pressure indica-
tor system.
After engine is started, Check if engine oil

buzzer continues to pressure indicator Engine is overheated, or
sound. stays ON. YES
faulty overheat indicator
· Engine: Running system.
Check if all segments of
coolant temperature
NO gauge monitor blink.
Faulty monitor controller,
· Key switch: ON faulty buzzer, or faulty
NO buzzer circuit.
YES Not enough fuel, or faulty

fuel level indicator sys-
tem.
Check if the lowest
YES segment of fuel gauge
monitor blinks.
· Engine: Running Faulty monitor controller,
faulty buzzer, or faulty
After engine is started, Check if buzzer stops NO buzzer circuit.
buzzer continues to after sounding 5 times.
sound.
· Engine: Running
Faulty monitor controller,
faulty buzzer, or faulty
NO buzzer circuit.
Even if engine oil pres-

sure indicator, over- Faulty monitor controller,
heat indicator or fuel faulty buzzer, or faulty
level indicator lights up buzzer circuit.
or blinks, buzzer does
not sound.
· Engine: Running
T5-3-10
MALFUNCTION OF HOUR METER

ble shooting.
Faulty alternator or faulty

YES alternator indicator sys-
tem.
While engine is run- Check if alternator in-

ning, hour meter does dicator stays ON.
not operate.
· Engine: Running
Faulty hour meter or faulty

NO monitor controller.
YES Faulty hour meter or faulty

monitor controller.
Disconnect connector
on alternator. Check if
Hour meter operates there is continuity be-
with key switch turned tween harness end
ON. terminal #3 on con-
nector and terminal #3
on monitor panel.
Broken harness between
monitor panel and alterna-
NO tor.
Connector
Alternator
3 2 1
T5-3-11
(Blank)
T5-3-12
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.

Be sure to remove the negative terminals from
the batteries first when taking wire harnesses and
connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuiting. Code Color Code Color
2. Color coding of wire harnesses. R Red W White
The color codes of the wire harnesses in the L Blue G Green
electrical system are shown below. Or Orange Lg Light Green
In cases on the design sheet where two colors Y Yellow B Black
are indicated for one wire, the left initial stands for Br Brown P Pink
Gr Gray V Violet
the base color, while the right initial stands for the
marking color.
NOTE: 1) Code BW indicates a black base wire

with white fine-line marking.
2) Initials O and Or both stand for the
color orange.
3) Wires with longitudinal stripes printed
on them are not color coded. Be sure
not to confuse them with color coded
wires.
Right Wrong
3. Precautions for connecting and disconnecting
terminal connectors.
(1) When disconnecting harnesses, grasp them
by their connectors. Do not pull on the wire
itself. T107-07-06-001
Be sure to release the lock first before

attempting to separate connectors, if a lock is
provided.
(2) Water-resistant connectors keep water out so
Right
that if water enters them, water will not easily
Rust
drain from them. When checking water
resistant connectors, take extra care not to Wrong
allow water to enter the connectors. In case (Deformation)
water should enter the connectors, reconnect
Wrong (Coming off, Separation)
only after the connectors are thoroughly dried.
(3) Before connecting terminal connectors, check T107-07-06-002
that no terminals are bent or coming off. In

addition, as, most connectors are made of
brass, check that no terminals are rusting.
(4) When connecting terminal connectors
provided with a lock, be sure to insert them
together until the lock "clicks."
T5-4-1
4. Precaution for using a circuit tester.
Wind a piece of wire Tester Probe
(1) Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object to
be measured, voltage range and current
polarity.
Sharpen the end of wire
(2) Before starting the connector test, always T107-07-06-003
check the connector terminal numbers,
referring to the circuit diagram.
When the connector size is very small, and the
standard probe size is too large to be used for
testing, wind a fine piece of sharpened wire or
a pin around the probe to make the test easier.
(3) When performing the connector test with the
circuit tester, be sure to insert the tester probe
from the connector harness side in order not to
damage the terminals in the connector.
T5-4-2
FUSE CONTINUITY TEST
Fuse failure is often caused by a fine crack in the fuse,

and such fine cracks are very hard to detect by visual
inspection. 11 1
Checking fuse continuity with a tester is far superior to
sight inspection. 12 2
1. Turn the key switch ON 13 3

When key switch is turned ON, the power is
supplied to all circuit from key switch R2 and Acc 4
Terminal (Refer to Circuit Diagram).
2. Remove the fuse box cover and set the correct 5
voltage measurement range of the tester.
(Measurement range: 0 to 14.5 V) 6
3. Connect the negative probe to the vehicle ground,
and touch the outside terminal of each fuse with 7
the positive probe of the tester.
When normal continuity of a fuse is intact, the 8
tester will indicate 12 volts.
9
10
M1LA-07-011
Number Capacity Connected to

1 5A Pilot Shut-Off Valve Solenoid Valve
2 20 A Light
3 5A Horn, Traval Speed Change over Solenoid Valve
4 10 A Auxiliary
5 10 A ENG. Electrical Component
6 15 A Air Conditioner Wiper
7 20A Air Conditioner Heater
8 5A Fuel Feed Pump
9 20A Travel Alarm
10 5A Monitor
11 5A Radio Backup
12 5A Auto-Idle
13 5A Radio
T5-4-3
BATTERY VOLTAGE CHECK
1. Turn key switch OFF.

2. Measure between battery plus terminal and the
ground (vehicle) with a voltmeter.
Correct Voltage Reading: 12 V
NOTE: If voltage is abnormal, re-charge or replace

the battery.
3. Start the engine. V

4. Measure the battery voltage again.
Correct Voltage Reading: 14.5 V
NOTE: If voltage is abnormal, check the charging

system.
T505-07-01-002
T5-4-4
VOLTAGE CHECK
Turn switches ON so that the specified voltage is

supplied to the check point. Measure voltage.
Diagnose the circuit between power source and the
checking point by checking that specified voltage is
supplied or not.
Evaluation
12 volt circuit Measured voltage must equal 12 V (battery voltage).
(example: the horn circuit) If the measured voltage is less than the battery
Check the circuit in either the upstream (from the voltage by 0.5 V or more, some incorrect contacts
power source) or downstream (from the accessory) may exist at connectors.
order to locate the failed section in the circuit.
Set the following check conditions:
Key switch position:
ON (When checking points (4) to (8)
Relay position:
ON (When checking points (9) or (10)
Tester black terminal (negative):
Connected to the vehicle (ground)
Tester red terminal (positive):
Connected to the checking point
Power source:
Batteries (12 volts)
Key Switch
B BR R1 R2 C ACC
PREHEAT
OFF
ON
START
1
2
4
Battery 3
5
6
Relay
8 7 9
10
An example of the checking order (Horn Circuit)

1 2 3 4 5 6 7 8 9 10
T5-4-5
CONTINUITY CHECK Harness
A
Single-line continuity check
Disconnect both end connectors of the harness and
check continuity between ends:
If the ohm-meter reading is: 0 = Continuity
= Discontinuity
NOTE: When the one end connector is far apart Connect to the
vehicle frame. A
from the other, connect one end of
connector (A) or the vehicle frame using a
clip. Then, check continuity of the harness
through the vehicle frame as illustrated.
Connect to the
vehicle frame.
If the ohm-meter reading is: 0 = Continuity
= Discontinuity
A a
Single-line short-circuit check
Disconnect both end connectors of the harness and Short circuit
check continuity between one end connector of the between the
harness and
harness and the vehicle frame: the vehicle
If the ohm-meter reading is: frame.
0 = Short circuit is present.
= No short circuit is present.
T107-07-05-003
Multi-line continuity check First Connected
Disconnect both end connectors of the harness, and
connect two terminals (A) and (B), using a jumper
wire at one end of the connector, as illustrated. Then,
check continuity between terminals (a) and (b) at the
other connector. If the ohm-meter reading is ,
either line (A)-(a), or (B)-(b) is in discontinuity. To find
out which line is discontinued, conduct the single line Second Connected
continuity check on both lines individually, or after
changing the connected terminals from (A)-(B) to
(A)-(C). Check continuity once more between
terminals (a) and (c).
NOTE: By Conducting the multi-line continuity T107-07-05-004
check twice, it is possible to find out which

line is discontinued. With terminals (A) and Short circuit between harnesses.
(C) shortcircuited, check continuity
A
between terminals (a) and (c). B
C
If the ohm-meter reading is:
0 = Line (B)-(b) has discontinuity.
= Line (A)-(a) has discontinuity.
Multi-lines short circuit check

Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or
(C).
If the ohm-metor reading is: T107-07-05-005
0 = Short circuit exists between the lines.

= No Short circuit exists between the lines.
T5-4-6
5V System Circuit Signal or Ground
Power Source
Voltage between Terminal No. 1 and the vehicle
Turn OFF the key switch, and disconnect the
Two-Polarities
connector. Measure the voltage between terminal
No. 1 (5 V power supply) on the machine harness
end connector and the vehicle (ground) under the
following conditions.
Key Switch: ON V
Black (Negative) Terminal of Tester: Vehicle
(Ground)
Red (Positive) Terminal of Tester: Terminal No. 1
Power T107-07-05-006
Standard Voltage: If 5 0.5 V, the circuit is normal Source Signal Ground
up to terminal No. 1.
Three-Polarities
Voltage between Terminal No.1 and Ground

Terminal
Turn OFF the key switch, and disconnect the T107-07-05-007
sensor connector. Measure the voltage between

terminal No. 1 (5 V power supply) on the machine
harness end connector and the ground terminal Two-Polarities
(terminal No. 2 for two-polarities or terminal No. 3
for three-polarities connector) under the following
conditions. V
Key Switch: ON
Black (Negative) Terminal of Tester: Connected to
the ground Terminal (Terminal No. 2 or No. 3)
Red (Positive) Terminal of Tester: Connect to
Terminal No. 1 T107-07-05-008
Standard Voltage: If 5 0.5 V, the circuit is normal

up to terminal No. 1 or ground terminal (terminal Three-Polarities
No. 2 or No. 3).
T107-07-05-009
T5-4-7
(Blank)
T5-4-8
Many thanks for your purchase.
Happy every day.
QIWEN YE
file:///C|/Users/yeqiwen/Documents/QIWEN-YE-END.txt[2015/1/2 21:22:16]
Workshop Manual
Vol No.: W1LDE-00

INTRODUCTION
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
This manual consists of two portions:

the Technical Manual and the Workshop Manual.
Use the manuals according to purpose.
• Information included in the Technical Manual: • Information included in the Workshop Manual:
technical information needed for redelivery and technical information needed for maintenance and
delivery, operation and activation of all devices repair of the machine, tools and devices needed
and systems, operational performance tests, and for maintenance and repair, maintenance stan-
troubleshooting procedures. dards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
Each page has a number, located on the center

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

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

signal words are used to alert the reader to the Indicated potentially hazardous situation which could,
potential for personal injury of machine damage. if not avoided, result in personal injury or death.
This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury. Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights. NOTE:
To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or
ate lifting techniques and equipment when lifting heavy know-how.
parts.
UNITS USED
SI Units (International System of Units) are used in 2

Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
°C °F °C×1.8+32
3 3
m yd 1.308 Temperature
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgf m 1.0197 mL/rev cc/rev 1.0
Nm lbf ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
 This is the SAFETY ALERT SYMBOL.
• When you see this symbol on your machine or in

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

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

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

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

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

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

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

this manual.
 To avoid confusing machine protection with personal

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

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

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

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

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

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

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

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

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

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

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

appropriate to the job.
You may need:

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

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

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

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

earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.
006-E01A-0434 SA-434
INSPECT MACHINE
 Inspect your machine carefully each day or shift by
walking around it before you start it to avoid personal
injury.
• In the walk-around inspection be sure to cover all

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Confirm the location of bystanders before moving,
swinging, or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the SA-366
machine.
011-E01A-0426
SA-6
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
 Inappropriate engine starting procedures may cause

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

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

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

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

Keep riders off.
• Riders also obstruct the operator’s view, resulting
in the machine being operated in an unsafe
manner. SA-370
014-E01B-0379
PROVIDE SIGNALS FOR FOBS INVOLV-

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

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

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

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

the undercarriage in relation to the operator’s po-
sition. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.
SA-500
017-E01A-0491
SA-8
SAFETY
DRIVE MACHINE SAFELY
 Before driving the machine, always confirm that the

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

• Avoid traveling over obstructions. Soil, fragments
of rocks, and/or metal pieces may scatter around
the machine. Don’t allow personnel to stay around
the machine while traveling.
SA-367
 Driving on a slope may cause the machine to slip or

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

facing the direction of travel, approximately 200 to
300 mm (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop traveling.
SA-368
• Driving across the face of a slope or steering on a

slope may cause the machine to skid or turnover.
If the direction must be changed, move the ma-
chine to level ground, then, change the direction
SA-441
to ensure sage operation.
019-E01D-0492
SA-589
SA-9
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
 Death or serious injury may result if you attempt to

mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the
H/P mode switch off.
• Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK
position.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade. SA-364
• Position the machine to prevent rolling.

• Park a reasonable distance from other machines.
020-E08A-0493
SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
 If any person is present near the machine when

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

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

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

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

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

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

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

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

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

CAN JUMP FREE
 The danger of tipping is always present when

operating on a grade, possibly resulting in serious
injury or death. SA-373
To avoid tipping:
 Be extra careful before operating on a grade.
• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or
slipping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is
unavoidable.
• Reduce swing speed as necessary when swinging
loads.
 Be careful when working on frozen ground.
• Temperature increases will cause the ground to

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

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

move any part of the machine or load closer than
3 m (10 ft) plus twice the line insulator length.
• Check and comply with any local regulations that
may apply.
• Wet ground will expand the area that could cause
SA-374
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site.
029-E01A-0381
OBJECT HANDLING
 If a lifted load should fall, any person nearby may be

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

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

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

debris; wear goggles or safety glasses.
• Keep bystanders away from the working area
before striking any object.
SA-432
031-E01A-0432
PARK MACHINE SAFELY
To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle / acceleration selector and H/P
mode switch off.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK SA-375
position.
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
033-E09B-0390
SA-14
SAFETY
HANDLE FLUIDS SAFELY AVOID FIRES
 Handle fuel with care; it is highly flammable. If fuel

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

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

flammable.
• Store flammable fluids well away from fire

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

loading/unloading the machine onto/from a truck or
trailer bed.
SA-376
• Be sure to observe local regulations when
transporting the machine on public roads.
• Provide an appropriate truck or trailer for
transporting the machine.
Take the following precautions when loading /

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

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

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

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

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

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

injury.
• Before performing any work on the machine,

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

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

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

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

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

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

VALVE ASSEMBLY.
face away from valve.
 Travel reduction gears are under pressure.

SA-344
face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen
AIR RELEASE PLUG to release pressure.
503-E01B-0344
STORE ATTACHMENTS SAFELY
 Stored attachments such as buckets, hydraulic

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

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

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

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

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

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

PERIODICALLY
 Rubber hoses that contain flammable fluids under

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

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

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

• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take
SA-031
care to protect hands and body from high-
pressure fluids. Wear a face shield or goggles for
eye protection.
• If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
SA-292
507-E03A-0499
SA-044
SA-21
SAFETY
PREVENT FIRES
Check for Oil Leaks:
 Fuel, hydraulic oil and lubricant leaks can lead to

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

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

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

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

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

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

operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to
confirm that the engine stops.

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

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

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

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

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

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

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

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

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

FLUID LINES
 Flammable spray can be generated by heating near

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

THE CUSTOMER
 After maintenance or repair work is complete,

confirm that:
• The machine is functioning properly, especially
the safety systems.
• Worn or damaged parts have been repaired or
replaced
S517-E01A-0435 SA-435
SA-27
SAFETY
(Blank)
SA-28
SECTION 1
GENERAL INFORMATION
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ............................................ W1-1-1
Group 2 Tightening
Tightening Torque Specification............... W1-2-1
Torque Chart............................................ W1-2-3
Piping Joint.............................................. W1-2-6
Periodic Replacement of parts............... W1-2-10
Group 3 Bleeding Air

Bleed Air from Hydraulic Oil Tank ............ W1-3-1
Group 4 Painting
Painting ................................................... W1-4-1
1LDW-1-1
Blank
1LDW-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
Clean the Machine Precautions for Disassembling
Thoroughly wash the machine before bringing it into To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as Before disassembling, drain gear oil from the
well as decreased efficiency in service work. reduction gear.
Be sure to provide appropriate containers for
draining fluids.
Inspect the Machine Use matching marks for easier reassembling.
Be sure to use the specified special tools, when
Be sure to thoroughly understand all disassem- instructed.
bling/assembling procedures beforehand, to help If a part or component cannot be removed after
avoid incorrect disassembling of components as removing its securing nuts and bolts, do not
well as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. Orderly arrange disassembled parts. Mark and
tag them as necessary.
The machine model, machine serial number, and Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). Inspect the contact or sliding surfaces of
Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
Capacities and condition of lubricants. Measure and record the degree of wear and
Loose or damaged parts. clearances.
Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the

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

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

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes.
Reposition the front attachment to check hydrau-
lic oil level.
Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary. T570-06-03-011
W1-1-3
Floating Seal Precautions A
1. In general, replace the floating seal with a new

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

seal ring faces together. Insert a piece of
cardboard to protect surfaces.
B W105-03-05-019
(2) Check the slide surface on seal ring (A) for
scuffing, scoring, corrosion, deformation or
uneven wear.
(3) Check O-ring (B) for tears, breaks,

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

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

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

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

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

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

When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
Avoid using twisted, bound, connected, or hitched
slings.
Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
Avoid dragging slings on the ground, throwing W105-04-01-008
slings or pushing slings with a metal object.
When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
Store the nylon slings indoors so they wont dete-
riorate with heat, sun light, or chemicals.
Bent Sling W162-01-01-009
W1-1-5
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-6
MAINTENANCE STANDARD TERMINOL-
OGY
Standard
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies

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

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

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

No. Descriptions Qty
mm Size (mm) Nm (kgf m) (lbf ft)
Engine cushion rubber mounting nut 14 4 22 137 (14) (101)
1
Engine cushion rubber mounting bolt 12 2 19 88 (9) (65)
Engine bracket mounting bolt (Front) 10 8 17 49 (5) (36)
2
Engine bracket mounting bolt (Rear) 10 8 17 49 (5) (36)
3 Hydraulic oil tank mounting bolt 12 4 19 88 (9) (65)
4 Fuel tank mounting bolt 10 2 17 20 (2) (15)
5 PF 1/8 19 29.5 (3) (22)
ORS fittings for hydraulic hoses and piping PF 3/8 22 39 (4) (29)
PF 1/2 27 64 (6.5) (47)
6 Pump mounting bolt 12 2 10 108 (11) (80)
7 Pump cover mounting bolt 10 6 17 49 (5) (36)
Control valve mounting bolt 10 4 17 49 (5) (36)
8
Control valve base mounting bolt 10 4 17 49 (5) (36)
9 Swing device mounting bolt 16 4 24 205 (21) (152)
Battery mounting nut 6 2 10 5 (0.5) (3.5)
10
Battery mounting bolt 10 2 17 49 (5) (36)
11 Canopy mounting bolt 16 4 24 205 (21) (152)
12 Cab mounting bolt 16 4 24 205 (21) (152)
Swing bearing mounting bolt to upperstructure 14 22 22 175 (18) (130)
13
Swing bearing mounting bolt to undercarriage 12 20 19 108 (11) (80)
14 Travel device mounting bolt 12 26 19 128 (13) (94)
15 Sprocket mounting bolt 12 24 19 128 (13) (94)
16 Upper roller mounting bolt 14 2 22 137 (14) (101)
17 Lower roller mounting bolt 18 8 27 451 (46) (332)
18 Cover mounting bolt 6 10 5 (0.5) (3.5)
8 13 10 (1) (7)
10 17 49 (5) (36)
19 Counterweight mounting bolt 20 3 30 390 (40) (290)
W1-2-1
NOTE 1. Apply lubricant (e.g. white zinc B

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

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

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

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

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

ing surfaces. Scratches / rough-
ness cause leaks and seal wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
nent.
W105-01-01-015
2. Be sure to use only specified O-
WRONG
rings. Inspect O-rings for any
damage. Take care not to file O-
ring surfaces. When installing an
O-ring into a groove, use grease
to hold it in place.
3. While lightly tightening split
flange halves, check that split is
centered and perpendicular to
the port. Hand-tighten bolts to W105-01-01-016
hold parts in place. Take care not

to pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using
an air wrench often causes tight- W105-01-01-008
ening of one bolt fully before RIGHT WRONG

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

RIGHT RIGHT WRONG
Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while tight- Bend along edge sharply
ening, not while loosening. W105-01-01-009
RIGHT RIGHT WRONG

Lock Wire
IMPORTANT: Apply wire to bolts in the bolt-
tightening direction, not in the bolt-
loosening direction.
Loosen WRONG
RIGHT
Tighten
W 105-01-01-010
W1-2-5
PIPING JOINT 1 4 3 5 2
IMPORTANT: The torques given in the chart are

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

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

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

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

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

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

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

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

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

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

depending on the type of clamp.
T-Bolt Type Band Clamp: M114-07-041
4.4 N m ( 0.45 kgf m, 3.25 lbf ft )

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

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

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other. W105-01-01-012
WRONG RIGHT
Take care so that hoses do not come into
contact with moving parts or sharp objects. Clamp Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-9
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic

inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deteriora-
tion, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regard-
less of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace if
necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, if necessary.
Consult your authorized dealer for correct replace-
ment.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years or Every 6000 hours
Engine Fuel hose (Fuel tank to injection pump) Every 2 years or Every 6000 hours
Heater hose (Heater to engine) Every 2 years or Every 6000 hours
Pump suction hose Every 2 years or Every 6000 hours
Basic Machine
Pump delivery hose Every 2 years or Every 6000 hours
Hydraulic Swing hose Every 2 years or Every 6000 hours
System Boom cylinder line hose Every 2 years or Every 6000 hours
Front-End Arm cylinder line hose Every 2 years or Every 6000 hours
Attachment Bucket cylinder line hose Every 2 years or Every 6000 hours
Pilot hose Every 2 years or Every 6000 hours
NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.
W1-2-10
GENERAL / Bleeding Air
BLEED AIR FROM HYDRAULIC OIL TANK
CAUTION: Escaping fluid under pressure

can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before
Hydraulic oil may be hot just after operation,
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
work.
The hydraulic oil tank cap may fly off if re-
moved without releasing internal pressure
first. Loosen the hydraulic oil tank cap to re-
lease any remaining pressure.
Preparation M570-07-005
1. Place the machine on a firm, level surface and

lower the bucket to the ground.
2. Stop the engine. Loosen the hydraulic oil tank (2) 1

cap (1) to release any remaining pressure.
3. Remove hydraulic oil tank (2) cap (1). 2
4. Connect a vacuum pump with the hole removed

cap (1) to maintain negative pressure in the hy-
draulic oil tank.
NOTE: Be sure to run the vacuum pump continu-
ously while working.
W1LD-01-03-001
Vacuum Pump
Hose
Adapter
W1LD-01-03-002
W1-3-1
GENERAL / Bleeding Air
(Blank)
W1-3-2
GENERAL / Painting
PAINTING
Section Surfaces to Be Painted Painting Color
Upperstructure Outer cover (Right, Left, Rear, Top) YR1-01[TAXI yellow]
Skirt (Front, Right, Left) SP-424[Dark gray]
Main frame SP-424[Dark gray]
Inner face (Oil tank, Fuel tank) SP-424[Dark gray]
Canopy (Pole) SP-424[Dark gray]
Stay (Front, Right, Left) SP-424[Dark gray]
Lever (Travel, Blade, Fuel, Lock) SP-424[Dark gray]
Pedal (Travel, Boom swing) SP-424[Dark gray]
Floor plate, Seat base SP-424[Dark gray]
Console (Right, Left) SP-424[Dark gray]
Counterweight SP-424[Dark gray]
Undercarriage Track frame (Including idler, upper roller and SP-424[Dark gray]
lower roller)
Swing bearing SP-424[Dark gray]
Blade (Including cylinder) SP-424[Dark gray]
Front attachment Boom, Arm, Bucket and Link (Including cyl- YR1-01[TAXI yellow]
inder)
Swing post (Including cylinder) SP-424[Dark gray]
Front Attachment Outer Cover
Canopy (Pole)
Lever
Stay (Front) Skirt (Left)
Swing Skirt (Right)

Post
Swing Bearing
Blade
Counterweight W1LD-01-04-001
Track Frame
W1-4-1
GENERAL / Painting
(Blank)
W1-4-2
SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Canopy Group 6 Pilot Valve
Remove and Install Canopy ............... W2-1-1 Remove and Install Front Pilot Valve ....W2-6-1
Remove and Install Travel Pilot Valve...W2-6-3
Group 2 Counterweight Remove and Install Blade Pilot Valve ...W2-6-5
Remove and Install Remove and Install Boom Swing
Counterweight .................................. W2-2-1 Pilot Valve ...........................................W2-6-7
Disassemble Front Pilot Valve ............W2-6-10
Group 3 Pump Device Assemble Front Pilot Valve .................W2-6-14
Remove and Install Disassemble Travel Pilot Valve ...........W2-6-18
Pump Device .................................... W2-3-1 Assemble Travel Pilot Valve................W2-6-22
Disassemble Pump Device................. W2-3-4 Disassemble Blade and Boom Swing
Assemble Pump Device ..................... W2-3-6 Pilot Valve .........................................W2-6-26
Maintenance Standard ..................... W2-3-10 Assemble Blade and Boom Swing
Pilot Valve .........................................W2-6-28
Group 4 Control Valve
Remove and Install Group 7 Solenoid Valve
Control Valve .................................... W2-4-1 Disassemble and Assemble
Disassemble And Assemble Solenoid Valve ....................................... W2-7-1
Control Valve .................................... W2-4-6
Group 5 Swing Device Group 8 Revolution Sensing Valve

Remove and Install Remove and Install Revolution
Swing Device.................................... W2-5-1 Sensing Valve ........................................ W2-8-1
Disassemble Swing Disassemble Revolution Sensing Valve ... W2-8-6
Reduction Gear ................................ W2-5-4 Assemble Revolution Sensing Valve ........ W2-8-8
Assemble Swing
Reduction Gear ................................ W2-5-6
Disassemble Swing Motor ................ W2-5-12
Assemble Swing Motor ..................... W2-5-14
Maintenance Standards.................... W2-5-18
1LDW-2-1
Blank
1LDW-2-2
UPPERSTRUCTURE / Canopy
REMOVE AND INSTALL CANOPY
Removal 2
1
1. Attach sling belt (2) to canopy (1) and hold it.
2. Remove screws (3) (4 used) to remove cover (4).
W1LD-02-01-001
CAUTION: Canopy weight : 32 kg (71 lb)

3. Remove bolts (5) (4 used) from the frame. Lift
canopy (1) by crane to remove it from the frame.
: 24 mm
3 W1LD-02-01-002
W1LD-02-01-003
W2-1-1
UPPERSTRUCTURE / Canopy
Installation
CAUTION: Canopy weight : 32 kg (71 lb)
2
1. Attach sling belt (2) to canopy (1). Lift the canopy 1
(1) by crane and put it on the frame.
2. Install canopy (1) to the frame with bolts (5) (4 W1LD-02-01-001
used) . 1
: 24 mm
: 205 N m (21 kgf m, 151 lbf ft)
W1LD-02-01-003
3. Install cover (4) to canopy (1) with screw (3) (4
used).
3 W1LD-02-01-002
W2-1-2
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTERWEIGHT
Removal
CAUTION: Counterweight weight:

370 kg (820 lb) (ZX40U)
600 kg (1320 lb) (ZX50U)
1
1. Remove the canopy from the frame.
NOTE: Refer to "REMOVE AND INSTALL
CANOPY".
2. Loosen bolts (1) (4 used) and remove engine

cover (2). 2
: 13 mm
SS-2304
4
3. Open tank cover (3) until lock (4) is locked.
3
: 13 mm
M1LD-07-014
4. Install eyebolts (M16, Pitch 2.0) (2 used) onto

counterweight (5).
Attach the wire ropes to the eyebolts.
Hold the counterweight by crane.
W571-02-02-003
W2-2-1
5. Remove counterweight (5) mounting bolts (6) (3

used).
6
: 30 mm (ZX40U, ZX50U)
W571-02-02-004
6. Lift counterweight (5) and slide it backward to

remove it from the frame by crane.
W571-02-02-003
W2-2-2
Installation
CAUTION: Counterweight weight:

370 kg (820 lb) (ZX40U)
600 kg (1320 lb) (ZX50U)
1. Install eyebolts (M16, pitch 2.0) (2 used) to

counterweight (5).
Attach the wire ropes to the eyebolts. 5
Lift and move counterweight (5) forward to install
it onto the frame by crane.
W571-02-02-003
2. Tighten bolts (6) (3 used) to hold counter weight

(5) in position. 6
: 30 mm (ZX40U, ZX50U)
5
: 392 N m (40 kgf m, 290 lbf ft)
W571-02-02-004
3. Unlock lock (4). Shut tank cover (3). 4

3
M1LD-07-014
1
4. Install engine cover (2) with bolts (1) (4 used).
: 13 mm
: 9.8 N m (1 kgf m , 7.2 lbf ft)
5. Install the canopy onto the frame.

NOTE: Refer to "REMOVE AND INSTALL
CANOPY".
SS-2304
W2-2-3
Blank
W2-2-4
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
Removal 1
IMPORTANT: Bleed air from the hydraulic oil tank 5
before any work. (Refer to W1-3-1.)
2
1. Remove canopy (1), engine cover (2), and

counterweight (3) from the frame.
3
NOTE: As for removal of the canopy, engine cover ,
and counterweight, refer to the section of
canopy and counterweight.
2. Remove bolts (6) (6 used) and (7) (4 used) to

remove covers (4 and 5) from the frame.
: 13 mm
4 M1LD-05-001
3. Disconnect all the hoses from pump device (9).

Cap the removed hoses.
: 19 mm , 22 mm , 36 mm
: 8 mm
W571-02-03-001
CAUTION: Pump device weight : 19 kg (42

lb)
4.Remove bolts (8) (2 used) to lift and remove pump

device (9) by crane.
: 10 mm
W566-02-03-003
W2-3-1
Installation
CAUTION: Pump device weight : 19 kg (42

lb)
1. Install pump device (9) onto the engine flywheel

housing with blots (8) (2 used).
: 10 mm
: 108 N m (11 kgf m)
2. Connect all the hoses onto pump device (9).

: 19 mm
: 29.5 N m (3 kgf m, 22 lbf ft)
: 22 mm
8
: 39 N m (4 kgf m, 29 lbf ft)
: 36 mm
: 235 N m (24 kgf m, 175 lbf ft)
: 8 mm
: 65 N m (6.6 kgf m, 48 lbf ft) 9
3. Install covers (4 and 5) onto the frame with W566-02-03-003
bolts(6) (6 used) and (7) (4 used). 7

: 13 mm
: 10 N m (1 kgf m, 7.4 lbf ft)
6
4. Install counterweight(3), engine cover(2), and

canopy(1) onto the frame.
NOTE: As for installation of the counterweight,

engine cover , and canopy, refer to the
section of counterweight and canopy.
IMPORTANT: Bleed air from the pump. (Refer to

W1-1-2)
When the installation is completed, W571-02-03-001
check the oil level. Start the engine

and check for any oil leaks. 1
5
4 M1LD-05-001
W2-3-2
Blank)
W2-3-3
DISASSEMBLE PUMP DEVICE
28
7
27 6
26
25
24 5
23
22
21
20
19 4 3
18
17 2
1
16
15
14
13
11
12
10
8
9
49
48 47
46
45
40
39
38
37
31
43
42 30
41 29
44
35
34
36 33
32
W1LD-02-03-001
1- Retaining Ring 14 - Stopper Pin 26 - Retaining Ring 38 - Seal Washer
2- O-Ring 15 - Ceramic Ball (2 Used) 27 - Valve Plate 39 - Bolt
3- Seal Holder 16 - Swash Plate 28 - Needle Bearing 40 - Nut
4- Oil Seal 17 - Plunger (11 Used) 29 - Spring Holder 41 - Choke
5- Shaft 18 - Retainer 30 - Spring 42 - O-Ring
6- Ball Bearing 19 - Holder 31 - Spring Guide 43 - Plug
7- Retaining Ring 20 - Retainer 32 - Control Piston 44 - Socket Bolt (7 Used)
8- Plug 21 - Needle (3 Used) 33 - Sleeve 45 - Coupling
9- O-Ring 22 - Cylinder Block 34 - O-Ring 46 - Collar (2 Used)
10 - Body S 23 - Retainer 35 - Spring Pin 47 - Gear Pump
11 - Gasket 24 - Spring 36 - LS Valve 48 - Washer (4 Used)
12 - Pin (2 Used) 25 - Retainer 37 - Body H 49 - Socket Bolt 4 Used)
13 - Spring
W2-3-4
Disassemble Pump Device
10. Remove spring guide (31) from body H (37).
Be sure to thoroughly read Precautions for Remove spring (30), spring holder (29), and
Disassembling and Assembling on page W1-1-1 cylinder block (22) assembly from body S (10).
before starting the disassembly work.
11. Remove plungers(17) (11 used), retainer (18),
1. Remove socket bolts (49) (4 used) to remove holder (19), retainer (20), and needles (21) (3
gear pump (47) from body H (37). used) from cylinder block (22).
: 6 mm
CAUTION: When removing retaining ring
2. Remove collars (46) (2 used) from gear pump (26), push spring (24) with a press. By failing
(47) and coupling (45) from body H (37). to use a press, the spring tends to fly off.
12. Remove retaining ring (26) from cylinder block

IMPORTANT: Never loosen the lock nut (40) and
(22) to remove retainer (25), spring (24), retainer
bolt (39). If loosened, the set values
(23).
will be changed.
3. Remove valve (36) from body H (37).
13. Remove swash plate (16) from body S (10) to
: 24 mm
remove ceramic balls (15) (2 used). Remove
stopper pin (14) and spring (13) from body S (10).
CAUTION: To remove body H (37) from body
S (10), 2 temporary bolts (M10, length 60 mm IIMPORTANT: Do not remove ball bearing (6)
(2.4 in)) can be used. By failing to use the unless replacing it.
temporary bolts, spring (30) tends to fly off.
Take care not to let spring (30) fly off.
4. Remove socket bolts (44) (2 used) on spring (30) 14. Remove retaining ring (1) from body S (10). Tap
side. Install temporary bolts (M10, length 60 mm) the body H (37) side on shaft assembly (5) with a
in the holes instead. plastic hammer lightly to remove it. Remove seal
: 8 mm holder (3), retaining ring (7), and ball bearing (6)
from the shaft assembly. Remove oil seal (4) and
5. Remove other socket bolts (44) (5 used). O-ring (2) from seal holder (3).
: 8 mm
6. Loosen and remove temporary bolts (2 used)

from body H (37) alternately.
IMPORTANT: When removing body H (37) from

body S (10), take care not to drop
valve plate (27) and spring pin (35).
Do not remove needle bearing (28)
unless replacing it.
7. Remove body H (37) from body S (10) to remove
gasket (11), pins (12) (2 used), and valve plate
(27) in this order.
8. Remove control piston (32) and sleeve (33) from

body H (37).
: 35 mm
9. Remove plug (43) and choke (41) from body H

(37).
: 5 mm, 4 mm
W2-3-5
ASSEMBLE PUMP DEVICE
2 3 6 7 29 30 19 20 23 24 25 11 26 27 28 31 38 40 39
1
45
5 46
47
48
49
10
43
13 14 15 16 21 18 17 22 32 33 34 35 37 41 42
W1LD-02-03-002
44
48 49
36
W1LD-02-03-003
1- Retaining Ring 14 - Stopper Pin 26 - Retaining Ring 38 - Seal Washer
2- O-Ring 15 - Ceramic Ball (2 Used) 27 - Valve Plate 39 - Bolt
3- Seal Holder 16 - Swash Plate 28 - Needle Bearing 40 - Nut
4- Oil Seal 17 - Plunger (11 Used) 29 - Spring Holder 41 - Choke
5- Shaft 18 - Retainer 30 - Spring 42 - O-Ring
6- Ball Bearing 19 - Holder 31 - Spring Guide 43 - Plug
7- Retaining Ring 20 - Retainer 32 - Control Piston 44 - Socket Bolt (7 Used)
8- *Plug 21 - Needle (3 Used) 33 - Sleeve 45 - Coupling
9- *O-Ring 22 - Cylinder Block 34 - O-Ring 46 - Collar (2 Used)
10 - Body S 23 - Retainer 35 - Spring Pin 47 - Gear Pump
11 - Gasket 24 - Spring 36 - LS Valve 48 - Washer (4 Used)
12 - *Pin (2 Used) 25 - Retainer 37 - Body H 49 - Socket Bolt 4 Used)
13 - Spring
NOTE: As for items with , refer to W2-3-4.
W2-3-6
Assemble Pump Device
11. Install cylinder block (22) assembly to body S (10).
Be sure to thoroughly read Precautions for Install coupling (45) onto the end of shaft (5).
Disassembly and Assembly Work on page W1-
1-1 before starting the assembly work. 12. Install O-ring (42) onto plug (43). Install choke
(41) and plug (43) into body H (37).
IMPORTANT: When replacing ball bearing (6), : 4 mm (choke)
press the ball bearing down onto : 6 to 9 N m (0.6 to 0.9 kgf m, 4.4 to 6.6
shaft (5) first and install retaining lbf ft)
ring (7) onto the shaft. : 5 mm(plug)
1. Press ball bearing (6) onto shaft (5) to install : 15 to 20 N m (1.5 to 2 kgf m, 11 to 14.5
retaining ring (7). Insert the shaft assembly into lbf ft)
body S (10).
13. Install O-ring (34) onto sleeve (33). Install the
IMPORTANT: Apply grease onto O-ring(2) on the sleeve into body H (37). Install control piston (32)
outer diameter on seal holder(3) and into the sleeve.
oil seal(4) lip part. : 35 mm(sleeve)
2. Install oil seal (4) and O-ring (2) onto seal holder : 50 to 60 N m (5.1 to 6.1 kgf m, 37 to 44
(3). Install seal holder (3) onto shaft (5) using lbf ft)
special tool (ST 7274) to install retaining ring (1).
14. Install spring pin (35) for valve plate (27), valve
3. Install O-ring (9) onto plug (8). Install plug (8) into plate (27), spring guide (31), pins (12) (2 used),
body S (10). and gasket(11) into body h(37).
: 6 mm NOTE: Refer to W2-3-4 as for pin (12).
NOTE: Refer to W2-3-4 as for plug (8) and O-ring
(9).
4. Install spring (13) and stopper pin (14) to body S

(10).
IMPORTANT: Apply grease onto ceramic balls (15)

(2 used) and swash plate (16) slide
surface.
5. Install ceramic balls (15) (2 used) into body S (10)
to install swash plate (16).
6. Install retainer (23), spring (24), and retainer (25)

to cylinder block (22) in this order.
7. Push retainer (25) and spring (24) with a press to

install retaining ring (26).
8. Turn cylinder block (22) upside down to install

needles (21) (3 used), retainer (20), and holder
(19).
9. Install plungers (17) (11 used) and retainer (18)

into cylinder block (22).
10. Align the hole in swash plate (16) on body S (10)

with the spherical part of spring holder (29), then
install the spring holder and spring (30).
W2-3-7
30
46
48
49
47
10
37 W1LD-02-03-002
44
48 49
36
W1LD-02-03-003
W2-3-8
15. Cover body S (10) with body H (37) aligning pins
(12) (2 used) position. Install and tighten
temporary bolts (M10, length 60 mm) (2 used)
into the socket bolt (44) holes on spring (30) side.
: 8 mm
16. Tighten socket bolts (44) (5 used) into other

socket bolt (44) holes in body H (37) slightly.
: 8 mm
17. Remove one of temporary bolts (M10, length 60

mm) to install socket bolt (44). Remove the other
temporary bolt to install socket bolt (44). Tighten
socket bolts slightly.
: 8 mm
18. Tighten socket bolts (44) (7 used).

: 8 mm
: 51 to 65 N m (5.2 to 6.6 kgf m, 38 to 48
lbf ft)
19. Install LS valve (36) into body H (37).

: 24 mm
: 59 to 69 N m (6 to 7 kgf m, 44 to 51 lbf ft)
20. Install collars (46) (2 used) into gear pump (47).

Install the gear pump to body H (37) with socket
bolts (49) (4 used) and washers (48) (4 used).
: 6 mm
: 24.5 to 27.5 N m (2.5 to 2.8 kgf m, 18 to
20 lbf ft)
W2-3-9
MAINTENANCE STANDARDS
1. Clearance between the cylinder block bore and

plunger
Cylinder
Block
(D-d): 0.05 mm (0.002 in) or less.
D d
W507-02-04-009
Plunger
2. Clearance between the plunger tip and shoe

bottom
: 0.2 mm (0.008 in) or less.
W107-02-06-140
3. Oil Seal Lip Surface Wear: 0.025 mm (0.001 in) or

less
Make sure that there is no damage.
W2-3-10
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE 1
Removal
IMPORTANT: Bleed air from the hydraulic oil tank

1. Remove covers (1 ,2, and 3) from the main frame.

: 13 mm
IMPORTANT: Cap all disconnected hose ends and

attach tags to the hoses to aid in re-
assembly. 2
2. Disconnect all the hoses and pipes from the con-
trol valve.
: 19 mm, 22 mm, 27 mm, 36 mm, 41 mm
M1LD-05-007
Control Valve
CAUTION: Plate weight: 8 kg 3
Control valve weight: 60 kg
3. Remove bolts (4) (4 used) to remove plate (5)
from main frame (6).
: 17 mm
W1LD-02-04-002
8 7 6
W2-4-1
4. Attach the nylon slings to the caps of control
Nylon 4
valve. Lift control valve (8) with plate (5) and re- Sling
move from the main frame by crane.
Nylon
Sling
Nylon
Sling
5
Nylon 8
Sling
W1LD-02-04-001
5. Remove bolts (7) (4 used) to remove control

valve (8) from plate (5).
: 17 mm 5
W1LD-02-04-002
8 7
W2-4-2
Installation 4
CAUTION: Control valve weight: 60 kg

Plate weight: 8 kg 5
1. Install plate (5) to control valve (8) with bolts (7) (4
used).
: 17 mm W1LD-02-04-002
: 49 N m (5 kgf m) 8 7
Nylon
Sling
4
2. Attach the nylon slings to the caps of control
valve. Lift control valve (8) with plate (5) by crane.
Install the control valve onto the main frame with Nylon
bolts (4) (4 used). Sling
: 17 mm
: 49 N m (5 kgf m)
3. Connect all the hoses onto control valve (8).

: 19 mm
: 29.5 N m (3 kgf m)
Nylon
: 22 mm Sling
: 39 N m (4 kgf m)
: 27 mm
: 93 N m (9.5 kgf m)
: 36 mm
: 175 N m (18 kgf m) 5
Nylon
: 41 mm Sling 8
: 205 N m (21 kgf m) W1LD-02-04-001
W2-4-3
4. Install covers (3, 2, and 1) onto the main frame. 1
: 13 mm
: 10 N m (1.0 kgf m)
IMPORTANT: After connecting the hoses, check

the hydraulic oil level. Start the en-
gine and check the hoses for any oil
leaks.
M1LD-05-007
Control Valve
3
W2-4-4
(Blank)
W2-4-5
DISASSEMBLE AND ASSEMBLE CONTROL VALVE
21
14
20 13 22
18
18
19 23
18
14 13 24
17 25
16 26
27
15 28
29
30
12
11 29
10 33
35
9 31 34
29 32
2
3 1-a
4 29
5
6
7 9 30
8
31
21
30
47 20 1-b 29
48
55
49 54
50 53
51
52
56
57
58 47
59 77
39 48
49 55
40 60 50 54
41 61
42 51 53
43
44 52
1-c 77 56
45 57
46 36 58 47 77
37 76 59 48
75 55
38 74 49
73 54
72 50
71 51 53
70
69
68 52
67 39
66 1-d 77 56
57
65 37 58
40 38 59
41
42
43
44
62
9 1-e
63
64 39
40 37
38
41
42
43
44
45 W1LD-02-04-003
46
W2-4-6
1a - Body (Unload) 14 - Plug (2 Used) 36 - Spring (4 Used) 58 - Piston (9 Used)

1b - Body (Piping Port) 15 - Plug 37 - O-Ring (9 Used) 59 - Spool (9 Used)
1c - Body (Swing) 16 - Spring 38 - Plug (9 Used) 60 - Check Valve (7 Used)
1d - Body (Boom) 17 - Strainer 39 - Spool (9 Used) 61 - Spring (7 Used)
1e - Body (Arm) 18 - Choke (3 Used) 40 - Retainer (9 Used) 62 - Cover
1f - Body (Bucket) 19 - Stocking Plug 41 - Spring (9 Used) 63 - Choke
1g - Body (Offset) 20 - O-Ring (2 Used) 42 - Retainer (9 Used) 64 - Socket Bolt (2 Used)
1h - Body (Auxiliary) 21 - Plug (2 Used) 43 - Bolt (9 Used) 65 - Socket Bolt (2 Used)
1i - Body (Travel Right) 22 - Relief Cut Valve 44 - O-Ring (9 Used) 66 - Plug
1j - Body (Travel Left) 23 - Main Relief Valve 45 - Socket Bolt (16 Used) 67 - O-Ring
1k - Body (Blade) 24 - Plug 46 - Cover (8 Used) 68 - Piston
2- Steel Ball 25 - O-Ring 47 - Plug (9 Used) 69 - O-Ring
3- Spring Seat 26 - Piston 48 - O-Ring (9 Used) 70 - Sleeve
4- Spring 27 - Spring 49 - Seat (8 Used) 71 - Backup Ring
5- O-Ring 28 - Spool 50 - Backup Ring (8 Used) 72 - O-Ring
6- Retainer 29 - O-Ring (55 Used) 51 - O-Ring (8 Used) 73 - Steel Ball
7- O-Ring 30 - O-Ring (21 Used) 52 - Steel Ball (8 Used) 74 - Stopper
8- Adjuster 31 - O-Ring (11 Used) 53 - O-Ring (9 Used) 75 - Spring
9- Metal Plug (24 Used) 32 - O-Ring (10 Used) 54 - Cover (9 Used) 76 - Poppet
10 - Differential Pressure 33 - Plug 55 - Socket Bolt (18 Used) 77 - Overload Relief Valve (7 Used)
Reducing Valve
11 - Stocking Plug 34 - O-Ring 56 - Plug (9 Used) 78 - Make-Up Valve
12 - Choke 35 - Safety Lock Valve 57 - O-Ring (9 Used) 79 - Plug (2 Used)
13 - O-Ring (2 Used)
W2-4-7
47 77
55
48 54
49 53
50
51 56
77
52 57
58 47 78
59 48 55
49 54
50 53
51
52
56
39 57
40 1-f 58
41 59
37
42 38 39
43 40
44 41 37
46 42
45 43 38 1-g 79
45 44
47 55
46 48 54
49 53
50
51 56
52 57
79 58 47
59 48 55
49 54
50 53
51
52
56
1-h 57
39 58
40 37 59
41 38 39
42
40
43 41
44 42 36
46 37 1-i
43 38
45 44
47 55
48 54
49 53
50
46 51
45 52 56 77
57
58
39 59 55
40 47 54
41
42 48 53
43 36
44 37 1-j 56
38
57
58
39 59
40
41
42
43
46
44 1-k
45
37
38
46 W1LD-02-04-004
45
W2-4-8
1a - Body (Unload) 14 - Plug (2 Used) 36 - Spring (4 Used) 58 - Piston (9 Used)

1b - Body (Piping Port) 15 - Plug 37 - O-Ring (9 Used) 59 - Spool (9 Used)
1c - Body (Swing) 16 - Spring 38 - Plug (9 Used) 60 - Check Valve (7 Used)
1d - Body (Boom) 17 - Strainer 39 - Spool (9 Used) 61 - Spring (7 Used)
1e - Body (Arm) 18 - Choke (3 Used) 40 - Retainer (9 Used) 62 - Cover
1f - Body (Bucket) 19 - Stocking Plug 41 - Spring (9 Used) 63 - Choke
1g - Body (Offset) 20 - O-Ring (2 Used) 42 - Retainer (9 Used) 64 - Socket Bolt (2 Used)
1h - Body (Auxiliary) 21 - Plug (2 Used) 43 - Bolt (9 Used) 65 - Socket Bolt (2 Used)
1i - Body (Travel Right) 22 - Relief Cut Valve 44 - O-Ring (9 Used) 66 - Plug
1j - Body (Travel Left) 23 - Main Relief Valve 45 - Socket Bolt (16 Used) 67 - O-Ring
1k - Body (Blade) 24 - Plug 46 - Cover (8 Used) 68 - Piston
2- Steel Ball 25 - O-Ring 47 - Plug (9 Used) 69 - O-Ring
3- Spring Seat 26 - Piston 48 - O-Ring (9 Used) 70 - Sleeve
4- Spring 27 - Spring 49 - Seat (8 Used) 71 - Backup Ring
5- O-Ring 28 - Spool 50 - Backup Ring (8 Used) 72 - O-Ring
6- Retainer 29 - O-Ring (55 Used) 51 - O-Ring (8 Used) 73 - Steel Ball
7- O-Ring 30 - O-Ring (21 Used) 52 - Steel Ball (8 Used) 74 - Stopper
8- Adjuster 31 - O-Ring (11 Used) 53 - O-Ring (9 Used) 75 - Spring
9- Metal Plug (24 Used) 32 - O-Ring (10 Used) 54 - Cover (9 Used) 76 - Poppet
10 - Differential Pressure 33 - Plug 55 - Socket Bolt (18 Used) 77 - Overload Relief Valve (7 Used)
Reducing Valve
11 - Stocking Plug 34 - O-Ring 56 - Plug (9 Used) 78 - Make-Up Valve
12 - Choke 35 - Safety Lock Valve 57 - O-Ring (9 Used) 79 - Plug (2 Used)
13 - O-Ring (2 Used)
W2-4-9
Remove and Install Relief Valve and Make-up Valve
22
23
10 35
77
77
78
79
79
77
T1LD-03-04-001
10 - Differential Pressure 23 - Main Relief Valve 77 - Overload Relief Valve (7 Used) 79 - Plug (2 Used)
Reducing Valve
22 - Relief Cut Valve 35 - Safety Lock Valve 78 - Make-Up Valve
W2-4-10
Removal Installation
Read PRECAUTIONS FOR DISASSEMBLING Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before AND ASSEMBLING (W1-1-1) carefully before in-
Removing. stalling.
1. Remove differential pressure reducing valve (10). 1. Install plugs (79) (2 used).
: 24 mm : 21 mm
: 64 to 68 N m (6.5 to 6.9 kgf m, 47 to 50
2. Remove relief cut valve (22). lbf ft)
: 27 mm
2. Install make-up valve (78).
3. Remove main relief valve (23). : 26 mm
: 26 mm : 59 to 63 N m (6.0 to 6.4 kgf m, 44 to 46
lbf ft)
4. Remove safety lock valve (35).
: 24 mm 3. Install overload relief valves (77) (7 used).
: 26 mm
5. Remove overload relief valves (77) (7 used). : 59 to 63 N m (6.0 to 6.4 kgf m, 44 to 46
: 26 mm lbf ft)
6. Remove make-up valve (78). 4. Install safety lock valve (35).

: 26 mm : 24 mm
: 54 to 59 N m (5.5 to 6.0 kgf m, 40 to 44
7. Remove plugs (79) (2 used). lbf ft)
: 21 mm
5. Install main relief valve (23).
: 26 mm
: 69 to 78 N m (7.0 to 8.0 kgf m, 51 to 58
lbf ft)
6. Install relief cut valve (22).

: 27 mm
: 69 to 78 N m (7.0 to 8.0 kgf m, 51 to 58
lbf ft)
7. Install differential pressure reducing valve (10).

: 24 mm
: 79 to 83 N m (8.1 to 8.5 kgf m, 58 to 61
lbf ft)
W2-4-11
DISASSEMBLE AND ASSEMBLE BODY
Tie Rod Nut
Unload Section
Washer
Piping Port Section
B B
1 mm
Function
Section
T1LD-03-04-001
NOTE: The illustration shows the swing section.

W1LD-02-04-006
29
A
60
61
32
1 A
Cross Section A-A
T566-03-03-009 Cross Section B-B
W566-02-04-005
1 - Body 30 - *O-Ring 32 - O-Ring 61 - Spring

29 - O-Ring 31 - *O-Ring 60 - Check Valve
NOTE: As for items with *, refer to W2-4-6 to 8.
W2-4-12
Disassemble Assemble

AND ASSEMBLING (W1-1-1) carefully before AND ASSEMBLING (W1-1-1) carefully before as-
disassembling. sembling.
IMPORTANT: Take care not to drop off O-rings 1. Install check valve (60), O-rings (29,30,31,and
(29,30,31, and 32). 32) into each section. Install spring (61) into the
bore of check valve (60).
NOTE: As for O-rings (30 and 31), refer to W2-4-6
1. Remove the nuts (4 used). Remove the washers
to 8.
(4 used) and tie rods (4 used) to divide the control
valve into each section.
: 17 mm IMPORTANT: Pay attention to the direction of tie
rod. Install the tie rod with its longer
2. Remove O-rings (29,30,31,and 32) from each thread side facing unload section.
section. Remove spring (61) and check valve (60) IMPORTANT: When installing the function sec-
from each section with a magnet. tions, install them 1mm away from
NOTE: As for O-rings (30 and 31), refer to W2-4-6 the unload section and piping port
to 8. section. Assemble it putting a metal
plate( thickness : 1mm) beneath the
function sections.
Metal Plate: thickness: 1 mm W1LD-02-04-005
2. Put a metal plate(thickness: 1 mm) beneath the

function sections(9 used). Put bodies (1) in each
section as before disassembling. Attach the tie
rods and tighten them with washers (4 used) and
nuts (4 used).
: 17 mm
: 54 to 58 N m (5.5 to 5.9 kgf m, 40 to 43
lbf ft)
W2-4-13
DISASSEMBLE UNLOAD SECTION
B C C B
9 18 19 12 22
11
A 10
23
8
24
7 6 5 4 3 2 1 28 27 26 25
16 17 13 14 20 21
15 18 18
Cross Section A-A Cross Section B-B Cross Section C-C

W566-02-04-001
1 - Body 8 - Adjuster 15 - Plug 22 - Relief Cut Valve

2 - Steel Ball 9 - Metal Plug (15 Used) 16 - Spring 23 - Main Relief Valve
3 - spring Seat 10 - Differential Pressure Re- 17 - Strainer 24 - Plug
ducing Valve
4- Spring 11 - Stocking Plug 18 - Choke (3 Used) 25 - O-Ring
5- O-Ring 12 - Choke 19 - Stocking Plug 26 - Piston
6- retainer 13 - O-Ring (2 Used) 20 - O-Ring 27 - Spring
7- O-Ring 14 - Plug (2 Used) 21 - Plug 28 - Spool
W2-4-14
Disassemble Unload Section IMPORTANT: Never loosen the lock nut of relief
cut valve (22). If loosened, the set
Read PRECAUTIONS FOR DISASSEMBLING pressure may be changed.
AND ASSEMBLING (W1-1-1) carefully before 4. Remove relief cut valve (22) from body (1).
disassembling. : 27 mm
IMPORTANT: Never turn the lock nut of relief valve. IMPORTANT: Never loosen the lock nut of differ-
If turned, the set pressure may be ential pressure reducing valve (10).
changed. If loosened, the set pressure may be
1. Remove main relief valve (23) from body (1). changed.
: 26 mm 5. Remove differential pressure reducing valve (10)
from body (1). Remove the piston and spring from
IMPORTANT: Do not remove steel ball (2) from body (1) with a magnet.
spring seat (3). When replacing : 24 mm
these parts, replace them as an as-
sembly. When removing retainer (6) Guide Spring
from body (1), spring (4) and spring
seat (3) tend to come off together
with retainer (6). When removing re- 10
tainer (6), take care not to drop
spring (4) and spring seat (3).
IMPORTANT: Never loosen adjuster (8) and the
nut of retainer (6). If loosened, the
set pressure may be changed.
2. Remove retainer (6) from body (1). Remove
spring (4) and spring seat (3) from body (1) with a
magnet.
: 24 mm
Piston 1 T566-03-03-005
IMPORTANT: When removing piston (26) from
body (1), spring (27) is removed to-
gether with the piston. When remov- 6. Install the bolt (M8, pitch 1.25) into the guide hole
ing piston (26), take care not to drop to pull the guide out of body (1).
off spring (27).
3. Remove plug (24) from body (1). Remove piston 7. Remove plug (15) from body (1). Remove spring
(26) and spring (27) from body (1) with a magnet. (16) and strainer (17) from body (1).
: 8 mm : 8 mm
IMPORTANT: Metal plug (9) and choke (18) cannot

be removed.
W2-4-15
ASSEMBLE UNLOAD SECTION
B C C B
9 18 19 12 22
11
A 10
23
8
24
7 6 5 4 3 2 1 28 27 26 25
16 17 13 14 20 21
15 18 18
Cross Section A-A Cross Section B-B Cross Section C-C

W566-02-04-001
1 - Body 8 - Adjuster 15 - Plug 22 - Relief Cut Valve

2 - Steel Ball 9 - Metal Plug (15 Used) 16 - Spring 23 - Main Relief Valve
3 - spring Seat 10 - Differential Pressure Re- 17 - Strainer 24 - Plug
ducing Valve
4- Spring 11 - Stocking Plug 18 - Choke (3 Used) 25 - O-Ring
5- O-Ring 12 - Choke 19 - Stocking Plug 26 - Piston
6- retainer 13 - O-Ring (2 Used) 20 - O-Ring 27 - Spring
7- O-Ring 14 - Plug (2 Used) 21 - Plug 28 - Spool
W2-4-16
Assemble Unload Section 5. Install plug (24) into body (1).
: 8 mm
Read PRECAUTIONS FOR DISASSEMBLING : 59 to 69 N m (6 to 7 kgf m, 44 to 51 lbf ft)
AND ASSEMBLING (W1-1-1) carefully before as-
sembling. 6. Insert spring (4) into retainer (6) until spring (4)
comes in contact with adjuster (8) to install spring
Apply grease onto the seals. seat (3) to spring (4).
1. Install strainer (17) , spring (16) , and plug (15) 7. Install the retainer (6) assembly to body (1) while
wound with a seal tape to body(1). taking care not to drop off spring seat (3) and
: 8 mm spring (4).
: 54 to 58 N m (5.5 to 5.9 kgf m, 40 to 43 : 24 mm
lbf ft) : 54 to 59 N m (5.5 to 6.0 kgf m, 40 to 44
lbf ft)
2. Install the guide, piston, and spring to differential 8. 8.Install main relief valve (23) into body (1).
pressure reducing valve (10). Install differential : 26 mm
pressure reducing valve (10) to body (1) while tak- : 69 to 78 N m (7.0 to 8.0 kgf m, 51 to 58
ing care not to drop off the guide, piston, and lbf ft)
spring.
: 24 mm
: 79 to 83 N m (8.1 to 8.5 kgf m, 58 to 61
lbf ft)
Guide Spring
10
Piston 1 T566-03-03-005
3. install relief cut valve (22) to body (1).

: 27 mm
: 69 to 78 N m (7.0 to 8.0 kgf m, 51 to 58
lbf ft)
4. Install spring (27) into piston (26) in the unload

valve. Install the piston (26) assembly into spool
(28) while taking care not to drop off the spring.
W2-4-17
DISASSEMBLE AND ASSEMBLE SPOOL
39
46 45 41 40
53 54
55
43 42 44
1
W566-02-04-005
1 - Body 41 - Spring 44 - O-Ring 53 - O-Ring

39 - Spool 42 - Retainer 45 - Socket Bolt (2 Used) 54 - Cover
40 - Retainer 43 - Bolt 46 - Cover 55 - Socket Bolt (2 Used)
W2-4-18

1. Remove socket bolts (45) (2 used) from body (1). 1. Install the spool (39) assembly into body (1).
Remove cover (46) and O-ring( 44) from body (1).
: 5 mm 2. 2.Install O-ring (53) onto cover (54). Install the
cover onto body (1) with socket bolts (55) (2
2. Pull spool (39) as am assembly out of body (1). used).
NOTE: The spool (39) assembly consists of spool : 5 mm
(39), bolt (43), retainer (42),spring (41), : 10 to 12 N m (1.0 to 1.2 kgf m, 7.4 to 8.9
and retainer (40). lbf ft)
NOTE: Do not remove bolt (43), retainer (42),
spring (41) and retainer (40) from spool 3. Install O-ring (44) onto cover (46). Install the
(39). cover onto body (1) with socket bolts (45) (2
When replacing these parts, replace them used).
as an assembly. : 5 mm
: 10 to 12 N m (1.0 to 1.2 kgf m, 7.4 to 8.9
3. Remove socket bolts (55) (2 used) from body (1) lbf ft)
to remove cover (54) and O-ring (53).
: 5 mm
W2-4-19
DISASSEMBLE AND ASSEMBLE BOOM SECTION
66 67 70 69 71 72
65
68
63 62 73 74 75 76
1
T566-03-03-010
1- Body 65 - Socket Bolt (2 Used) 69 - O-Ring 73 - Steel Ball

62 - Cover 66 - Plug 70 - Sleeve 74 - Set Screw
63 - Choke 67 - O-Ring 71 - Backup Ring 75 - spring
64 - *Socket Bolt (2 Used) 68 - Piston 72 - O-Ring 76 - Poppet
NOTE: As for items with *, refer to W2-4-6.
W2-4-20

IMPORTANT: Do not remove choke (63), plug (66), 1. Install poppet (76) into body (1). Install spring (75)
and set screw (74). into the poppet (76) hole.
IMPORTANT: When removing cover (62) from
body (1), piston (68) tends to come IMPORTANT: Apply grease onto O-rings (69 and
off together with cover (62). Take 72). Install sleeve (70) so that spring
care not to drop piston (68). (75) can be aligned with the spring
1. Remove socket bolts (64) (2 used) and (65) (2 mounting position in sleeve (70).
used) from body (1) to remove cover (62) and pis- 2. Install O-rings (69,72) and backup ring (71) onto
ton (68). sleeve (70). Install the sleeve (70) assembly into
: 5 mm body (1).
3. Install piston (68) and O-ring (67) into cover (62).
2. Install the bolt (M12, pitch 1.75) into the sleeve
(70) hole to pull the sleeve (70)assembly out of 4. Install the cover (62) assembly to body (1) with
body (1). socket bolts (65) (2 used) and (64) (2 used) while
taking care not to drop off piston (68).
NOTE: The sleeve (70)assembly consists of
: 5 mm
sleeve (70), steel ball (73), and set screw
: 10 to 12 N m
(74).
(1.0 to 1.2 kgf m, 7.4 to 8.9 lbf ft)
IMPORTANT: Check if spring (75) stays in body
(1).
3. Remove spring (75) and poppet (76) from body
(1) with a magnet.
W2-4-21
DISASSEMBLE AND ASSEMBLE SHUT-
TLE VALVE AND PRESSURE COMPEN-
SATION VALVE
52 48 47 49 50 51
38 37 36 59 58 57 56
W566-02-04-005
1- Body 47 - Plug 51 - O-Ring 57 - O-Ring

36 - Spring 48 - O-Ring 52 - Steel Ball 58 - Piston
37 - O-Ring 49 - Seat 56 - Plug 59 - Spool
38 - Plug 50 - Backup Ring
W2-4-22

AND ASSEMBLING (W1-1-1) carefully before
disassembling. AND ASSEMBLING (W1-1-1) carefully before as-
sembling.
1. Remove plug (47) from body (1).
: 6 mm 1. Install piston (58) into spool (59). Insert spring
(36) into the spring hole in spool (59) completely.
IMPORTANT: When removing seat (49) from body NOTE: Spring (36) is provided for the swing, boom,
(1), steel ball (52) tends to come off right travel, and left travel.
together with seat (49). Take care
not to drop steel ball (52). 2. Install the spool (59) assembly into body (1). At
2. Remove seat (49) and steel ball (52) from body this time take care not to drop off piston (58).
(1) with a pliers.
3. Install O-ring (57) to plug (56) and O-ring (37) to
3. Remove O-Ring (51) and backup ring (50) from plug (38). Install plugs (56 and 38) to body (1) in
seat (49). this order.
: 8 mm
4. Remove plug (38) from body (1) to remove spring : 59 to 69 N m (6 to 7 kgf m, 44 to 51 lbf ft)
(36) with a magnet.
: 8 mm IMPORTANT: Apply grease onto O-ring (51).
NOTE: Spring (36) is provided for the swing, boom, 4. Install backup ring (50), O-ring (51),and steel ball
right travel, and left travel. (52) onto seat (49).
IMPORTANT: When removing the spool (59) as- 5. Install the seat(49) assembly into body (1).
sembly, take care not to drop piston
(58). 6. Install plug (47) into body (1).
5. Remove plug (56). Push the spool (59) assembly : 6 mm
with piston (58) out from plug (38) side by finger : 30 to 34 N m (3.1 to 3.5 kgf m, 22 to 25
and remove the spool (59) assembly with piston lbf ft)
(58) from body (1).
6. Remove piston (58) from spool (59).
W2-4-23
(Blank)
W2-4-24
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE
Removal

before any work. (Refer to W1-3-1)
1. Remove the canopy.

1
NOTE: Refer to REMOVE AND INSTALL
CANOPY.
2. Remove covers (1, 2) from the frame.

: 13 mm
3. Disconnect all the pilot hoses at the quick coupler 2

part. Disconnect all the connectors.
M1LD-01-001
CAUTION: Floor plate with seat and pilot

valve weight: 105 kg 12 3 4
11
4. Remove bolts (3 to 11). Install eyebolts (M8, pitch
1.25) (4 used). Lift floor plate (12) with the seat
and pilot valve to remove from the frame by crane.
: 13 mm, 17 mm, 24 mm 5
5. Disconnect all the hoses from swing device (13). 6

Cap the removed hoses.
: 19 mm, 22 mm
Eyebolt
7
Eyebolt
W1LD-02-05-002
10 9 8
CAUTION: Swing device weight: 50 kg 13

6. Remove bolts (14) (8 used) to lift and remove
swing device (13) from the frame by crane.
: 24 mm
W1LD-02-05-003
14
W2-5-1
Installation
13
CAUTION: Swing device weight: 50 kg
1. Install swing device (13) to the frame with bolts
(14) (8 used).
: 24 mm
: 205 N m (21 kgf m, 151 lbf ft)
2. Connect all the hoses to swing device (13).

: 19 mm
W1LD-02-05-003
: 29.5 N m (3 kgf m, 22 lbf ft) 14
: 22 mm
: 39 N m (4 kgf m, 29 lbf ft) 12 3
11 4
CAUTION: Floor plate with seat and pilot

valve weight: 105 kg 5
3. Install eyebolts (M8, pitch 1.25) (4 used) to floor
plate (12) with the seat and valve plate. 6
Lift and install it onto the frame with bolts (3 to 11)
by crane.
: 13 mm
: 10 N m (1 kgf m, 7.4 lbf ft)
Eyebolt
: 17 mm 7
: 49 N m (5 kgf m, 36 lbf ft) Eyebolt
: 24 mm
: 205 N m (21 kgf m, 151 lbf ft)
4. Connect all the pilot hoses at the quick coupler

part. Connect all the connectors.
W1LD-02-05-002
10 9 8
5. Install covers (1, 2) to the frame with the bolts (17

used).
: 13 mm
: 10 N m (1 kgf m, 7.4 lbf ft)
6. Install the canopy.

NOTE: Refer to REMOVE AND INSTALL
CANOPY. 1
IMPORTANT: When the installation is completed,

check the oil level. Start the engine
and check for any oil leaks.
M1LD-01-001
W2-5-2
(Blank)
W2-5-3
DISASSEMBLE SWING REDUCTION
GEAR
20
21
1 Swing Motor
22
23 2
4
29
24 5
25 6
7
26
8
9
27
10
11
28 12
13
14
15
19
16
17
18
W571-02-05-005
1- Socket Bolt (4 Used) 9- Retaining Ring 17 - Socket Bolt (9 Used) 25 - Spring Plate
2- O-Ring 10 - Second Stage Sun Gear 18 - Ring Gear 26 - Thrust Plate
3- Retaining Ring (3 Used) 11 - Thrust Plate 19 - Spring Pin (4 Used) 27 - Plate
4- Plate 12 - Pin (4 Used) 20 - Nut 28 - Shaft
5- First Stage Sun Gear 13 - Second Stage Carrier 21 - Roller Bearing 29 - Plug
6- First Stage Planetary Gear 14 - Second Stage Planetary 22 - Oil Seal
(3 Used) Gear (4 Used)
7 - Needle Bearing (3 Used) 15 - Needle Bearing (4 Used) 23 - Housing
8 - First Stage Carrier 16 - Thrust Plate (4 Used) 24 - Roller Bearing
W2-5-4
Disassemble Swing Reduction Gear 9. Remove shaft (28) from housing (23) with a
press.
Read PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING (W1-1-1) carefully before 10. Remove the inner race of roller bearing (24),
disassembling. spring plate (25), thrust plate (26) and plate (27)
from shaft (28) with a press.
CAUTION: Swing motor weight: 13 kg IMPORTANT: Do not remove the outer races of
roller bearings (21) and (24) from
1. Remove socket bolts (1) (4 used) from the swing housing (23). Failure to follow these
motor, then remove the swing motor. instructions will shorten service life
: 6 mm of the bearings as press-fit force of
roller bearing (21 and 24) outer
2. Remove socket bolts (17) (9 used) from ring gear races is reduced. Always replace
(18). housing (23) with a new one if the
: 8 mm bearings are removed.
11. Remove oil seal (22) from housing (23).
3. Remove ring gear (18), first stage carrier (8)
assembly, second stage sun gear (10) and
second stage carrier (13) assembly from housing
(23).
Remove retaining ring (9) from second stage sun
gear (10).
4. Remove retaining rings (3) (3 used), plate (4), first

stage sun gear (5), first stage planetary gears (6)
(3 used) and needle bearings (7) (3 used) from
first stage carrier (8) asembly.
5. Drive spring pins (19) (4 used) at second stage

carrier (13) assembly into pin (12) with a round
bar (length: 100 mm or more, diameter: 5 mm).
6. Remove pins (12) (4 used), second stage

planetary gears (14) (4 used), needle bearings
(15) (4 used), thrust plates (16) (4 used) and plate
(11) from second stage carrier (13) assembly.
7. Securely hold shaft (28). Remove nut (20) from

shaft (28) using a special tool (ST 7313).
(ST 7313)
W1LD-02-05-001
8. Remove plug (29) from housing (23).

: 5 mm
W2-5-5
ASSEMBLE SWING REDUCTION GEAR
30
2
3
17
6
4
7
5
8
18
15
9
14
10
12 11
16 13
19 20
23 21
22 29
25 24
26
27
28
W571-02-05-004
1- Socket Bolt (4 Used) 9- Retaining Ring 17 - Socket Bolt (9 Used) 25 - Spring Plate
2- O-Ring 10 - Second Stage Sun Gear 18 - Ring Gear 26 - Thrust Plate
3- Retaining Ring (3 Used) 11 - Thrust Plate 19 - Spring Pin (4 Used) 27 - Plate
4- Plate 12 - Pin (4 Used) 20 - Nut 28 - Shaft
5- First Stage Sun Gear 13 - Second Stage Carrier 21 - Roller Bearing 29 - Plug
6- First Stage Planetary Gear 14 - Second Stage Planetary 22 - Oil Seal 30 - Swing Motor
(3 Used) Gear (4 Used)
7 - Needle Bearing (3 Used) 15 - Needle Bearing (4 Used) 23 - Housing
8 - First Stage Carrier 16 - Thrust Plate (4 Used) 24 - Roller Bearing
W2-5-6
Assemble Swing Reduction Gear

assembling.
IMPORTANT: Install oil seal (22) with the lip of the

oil seal facing upward (motor side).
1. Install oil seal (22) into housing (23).
2. If roller bearings (21 and 24) are replaced with

new ones together with housing (23), press the
outer race of roller bearings (21) and (24) into
housing (23).
3. Press plate (27), thrust plate (26), spring plate

(25) and the inner race of roller bearing (24) onto
shaft (28).
IMPORTANT: Be careful not to damage oil seal

(22) by shaft (28) during installation.
Also, make sure that plug (29) has
been removed. If plug (29) is not
removed, distortion of oil seal (22)
may result.
4. Install shaft (28) assembly into housing (23).
IMPORTANT: Install nut (20) with the grooved face

upward (motor side).
5. Install the inner race of roller bearing (21) into

shaft (28), and temporarily tighten nut (20).
6. Install plug (29).
: 5 mm
: 9.8 N m (1 kgf m, 7.2 lbf ft)
W2-5-7
3
17
6
4
7
5
8
18
15
14 10
12
11
16
13
20
23
28
W571-02-05-004
W2-5-8
7. Adjust the roller bearing pre-load. 5) Tighten nut (20) onto shaft (28) using a special
tool (ST 7313).
Starting Torque
: 152 N m (15.5 kgf m, 112 lbf ft)
(ST7313)
17 W1LD-02-05-001
6) After turning housing (23) in both directions

several times, measure rotation starting torque
20 (B) of housing (23) at socket bolt (17).
23
7) Confirm that the measured torque value is within

standards.
(If not, repeat procedure from 1).
Torpue difference Standard value

B-A +1.0 to +3.3 kgf
IMPORTANT: Install retaining ring (3) with the

chamfered corner facing toward
plate (4).
28
8. Install needle bearings (7) (3 used), first stage
W571-02-05-008
planetary gears (6) (3 used), first stage sun gear
1) Securely hold shaft (28), then loosen nut (20).
(5), plate (4) and retaining ring (3) onto first stage
carrier (8).
2) Tap the outer diameter of housing (23) (shown
with * to the illustration) 3 to 4 turns with a plastic
9. Install thrust plates (11), (16) (4 used), needle
hammer.
bearings (15) (4 used), second stage planetary
gears (14) (4 used) and pins (12) (4 used) onto
3) Install one socket bolt (17) into housing (23).
second stage carrier (13).
4) After turning housing (23) to both directions
several times, measure rotation starting torque
(A) of housing (23) at socket bolt (17).
W2-5-9
30
2
17
8
18
12 10
13
19 20
23
28
W571-02-05-004
W2-5-10
IMPORTANT: Drive in spring pins (19) (4 used) IMPORTANT: Install retaining ring (9) with its
with its slit facing upward (motor chamfered corner facing upwards.
side).
12. Install retaining ring (9) onto second stage sun
10. Align pin holes on second stage carrier (13) and gear (10). Install second stage sun gear (10) into
pins (12) (4 used), then drive spring pins (19) (4 second stage carrier (13).
used) into the carrier.
13. Install first stage carrier (8) assembly into second
stage carrier (13) assembly.
14. Apply THREEBOND #1215 to the counter bore

on the housing (23). Install ring gear (18) into
12 housing (23), and tighten it with socket bolts (17)
(9 used).
19 : 8 mm
W571-02-05-007
: 69 N m (7 kgf m, 51 lbf ft)
IMPORTANT: Install second stage carrier (13)
aligning splines so that the pin on 15. Add approx. 0.7 litter (0.185 US gal) of hydraulic
second stage carrier (13) is inserted oil into the swing reduction gear.
into the hole of nut (20). Confirm
dimension A shown in the 16. Install O-ring (2) onto swing motor (30). Install the
illustration is approx. 18.5 mm. If swing motor onto ring gear (18). Tighten socket
dimension A is approx. 27.5 mm, it bolts (1) (4 used).
indicates that pin is not inserted into
the hole on nut (20) properly. : 6 mm
: 29 N m (3 kgf m, 21 lbf ft)
13
Pin
20
W571-02-05-006
11. Install second stage carrier (13) assembly onto

shaft (28) aligning the holes on nut (20) with the
pin.
W2-5-11
DISASSEMBLE SWING MOTOR 8
6
5
4
13
14
15
16
17
18
19
20
21
22
11
10
9
30
29
28
27
26
25
24
23 W1LD-02-05-005
1- Friction Plate (2 Used) 9- Collar 17 - Rotor 24 - Cover
2- Disc Plate (2 Used) 10 - O-Ring 18 - Collar 25 - Pin
3- Swash Plate 11 - O-Ring 19 - Spring 26 - Bearing
4- Shaft 13 - Plunger (9 Used) 20 - Washer 27 - Valve Plate
5- Bearing 14 - Retainer 21 - Retaining Ring 28 - Spring (22 Used)
6- O-Ring 15 - Holder 22 - Pin 29 - Brake Piston
7- Case 16 - Pin (3 Used) 23 - Socket Bolt (3 Used) 30 - O-Ring
8- O-Ring
W2-5-12
Disassemble Swing Motor
CAUTION: Always use a special tool on
Read PRECAUTIONS FOR DISASSEMBLING washer (20) to press spring (19) when
AND ASSEMBLING (W1-1-1) carefully before removing retaining ring (21). If retaining ring
disassembling. (21) is removed without pressing, washer
(20) and spring (19) may fly out, possibly
IMPORTANT: Be careful not to allow valve plate causing serious injury.
(27) to fall when removing cover
(24). 7. Press washer (20) and spring (19) using a special
tool (ST 7314). Remove retaining ring (21) to
1. Put matching marks on cover (24) and case (7). remove washer (20), spring (19) and collar (18)
Loosen socket bolts (23) (3 used). Remove cover from rotor (17).
(24) and valve plate (27) in this order.
: 12 mm
(ST7314)
2. Remove springs (28) (22 used) and O-ring (6)
from case (7).
21
CAUTION: When removing brake piston (29)
using compressed air, be sure to cover the
brake piston with rags to prevent the piston 20
from flying out. 19
3. Remove brake piston (29) and O-ring (30) from
18
case (7) by applying compressed air into the pilot
port on case (7).
4. Remove collar (9), and O-rings (10),(11).

W1LD-02-05-004
5. Remove rotor (17) assemblies (13 to 21), swash 8. Remove shaft (4) from case (7) by tapping shaft
plate (3), friction plates (1) (2 used) and disc (4) with a plastic hammer.
plates (2) (2 used) .
9. Remove O-ring (8) from case (7).
NOTE: Take care not to damage the sliding
surface of swash plate (3).
6. Remove plungers (13) (9 used), retainer (14),

holder (15) and pins (16) (3 used) from rotor
assemblies (13 to 21).
W2-5-13
ASSEMBLE SWING MOTOR
22 23 28 27 21 20 26 24
25
30
29
17
10
11
19 9
18
1
16
2
7
13
8
W555-02-05-003
15 5 4 3 14
1- Friction Plate (2 Used) 9- Collar 17 - Rotor 24 - Cover

2- Disc Plate (2 Used) 10 - O-Ring 18 - Collar 25 - Pin
3- Swash Plate 11 - O-Ring 19 - Spring 26 - Bearing
4- Shaft 13 - Plunger (9 Used) 20 - Washer 27 - Valve Plate
5- Bearing 14 - Retainer 21 - Retaining Ring 28 - Spring (22 Used)
6- O-Ring 15 - Holder 22 - Pin 29 - Brake Piston
7- Case 16 - Pin (3 Used) 23 - Socket Bolt (3 Used) 30 - O-Ring
8- O-Ring
W2-5-14
Assemble Swing Motor
8. Install friction plates (1) (2 used) and disc plates
Read PRECAUTIONS FOR DISASSEMBLING (2) (2 used) to rotor (17) one by one alternately in
AND ASSEMBLING (W1-1-1) carefully before place.
assembling.
IMPORTANT: Do not tap collar (9) with a plastic
IMPORTANT: If ball bearing (5) has been removed, hammer or similar instrument to
press bearing (5) onto shaft (4) install collar (9). Collar (9) and / or
beforehand. case (7) may be damaged. Use a
Press ball bearing (5) until the end of press to install collar (9) into case
ball bearing (5) is flush with the end (7).
surface of case (7).
9. Install O-rings (10) and (11) onto collar (9), and
1. Press shaft (4) and ball bearing (5) assembly into press them into case (7).
case (7).
2. Install collar (18), spring (19) and washer (20) into

rotor (17).
3. While depressing washer (20) and spring (19)

using a special tool (ST 7314), install retaining
ring (21) into rotor (17).
(ST7314)
21
20
19
17
W1LD-02-05-004
4. Install pins (16) (3 used) into rotor (17). Put holder

(15) onto pins (16).
5. Install plungers (13) (9 used) and retainer (14)

into rotor (17).
6. Install swash plate (3) into case (7).
7. Install rotor (17) assemblies (13 to 21) into case

(7).
W2-5-15
23 28 27 24
30
29
W555-02-05-003
W2-5-16
IMPORTANT: Do not tap brake piston (29) with a
plastic hammer or similar
instrument to install brake piston 29
(29). Brake piston (29) and / or case
(7) may be damaged. Use a press to
install brake piston (29) into case (7)
as the illustration.
10. Install O-ring (30) onto brake piston (29). Press

brake piston (29) into case (7).
11. Install springs (28) (22 used) and O-ring (6) into
case (7).
12. Attach valve plate (27) to cover (24). Install cover

M6 Threaded Hole
(24) on case (7) while aligning the matching
marks on cover (24) and case (7). Tighten socket
W527-02-05-003
bolts (23) (3 used).
: 12 mm
: 177 10 N m (18 1 kgf m, 131 7.4 lbf ft)
NOTE: Apply grease to valve plate (27) before

attaching it to cover (24) in order to prevent
it from falling.
W2-5-17
1. The clearance between the plunger diameter and

the rotor bore diameter
Rotor
(D-d): 0.40 mm or less.
D d
W507-02-04-009
2. The clearance between the plunger and the shoe

: 0.4 mm or less.
W107-02-06-140
3. The wear amount of the oil seal mounting

surfaces no damage and / or wear is allowed. D0 D1
(D0 - D1): 0.25 mm or less.
W509-02-04-010
W2-5-18
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL FRONT PILOT 4
VALVE
Removal

1. Remove screws(1) (6 used) from the lever stand
to remove covers (2, 3).
2. Remove clip band (10) and plug (11) from pilot

valve (13) on the left stand only.
3. Raise boots (4) (2 used) to remove screws (16) (8

used) and plates (15) (4 used). 2 1 3
Fast Speed Travel Pedal M1LA-01-006
4. Raise boot (4) on the left lever to remove clip
band (9).
5
5. Raise boots (4) (2 used) and loosen lock nuts (8)
(2 used) to remove levers (7) (2 used) with grip 6
(5) together.
: 22 mm 7
Pilot Shut-off
Lever 8
6. Remove boot (4) (2 used). 9
10
11
IMPORTANT: Attach identification tags on the 16
disconnected hoses to aid in 15
reassembly.
7. Remove hoses (12) (12 used) from pilot valves
(13) (2 used).
: 19 mm 14
IMPORTANT: Put the mating marks on pilot valve 13

(13) and the lever stand to aid in Left Stand Pilot
Shut-off Switch 12 T532-02-06-002
reassembly.
8. Remove bolts (14) (8 used) to remove pilot valves
(13) ( 2used) from the lever stand.
: 13 mm
W2-6-1
Installation
5
1. Insert pilot valves (13) (2 used) into the lever
stand and align the matching marks made when
6
disassembling.
7
2. Install pilot valves (13) (2 used) to the lever stand Pilot Shut-off
with bolts (14) (8 used). Lever 8
: 13 mm 9
10
: 10 N m (1 kgf m, 7.4 Ibf ft)
11
16
3. Connect hoses (12) (12 used) to pilot valves (13) 15
(2 used).
: 19 mm
: 29.5 N m (3 kgf m, 22 Ibf ft)
14
4. Insert levers (7) (2 used) (with grip (5)) into boots
13
(4) (2 used). Install levers (7) (2 used) into pilot
Left Stand Pilot
valves (13) (2 used). When installing, lever (7) 12 T532-02-06-002
Shut-off Switch
with horn button should be installed on left side.
5. Secure levers (7) (2 used) to pilot valves (13) (2

used) with lock nuts (8) (2 used).
4
: 22 mm
: 140 N m (14 kgf m, 103 Ibf ft)
6. Raise boot (4) to install clip band (9).
7. Install clip band (10) and plug (11) to pilot valve

(13) on the left lever stand only.
8. Install boot (4) (2 used) with plates (15) (4 used)

and screws (16) (8 used).
9. Install covers (2 and 3) with screws (1) (6 used)

on the stands. 2 1 3
Fast Speed Travel Pedal M1LA-01-006
IMPORTANT: After the complete work, check the
oil level. Start the engine and check
the connection for oil leaks.
W2-6-2
REMOVE AND INASTALL TRAVEL PILOT
VALVE
Removal
IMPORTANT: Bleed air from the hydraulic oil tank 1

1. Remove bolts (2) (4 used) and wing bolt (3) to
remove cover (1) from the main frame.
: 13 mm
2. Remove bolts (6) (4 used) from pilot valve (10) to

remove pedals (5) (2 used) and levers (4) (2 2
used).
: 6 mm
3 W1LA-02-05-006
IMPORTANT: Attach identification tags onto the

disconnected hoses to aid in
reassembly. 4
3. Disconnect pilot hoses (9) (6 used) from pilot
valve (10). Attach a cap onto the open ends. 5
6
4. Loosen bolts (7) (4 used) for pilot valve (10).

: 13 mm
11
5. Remove bolts (11) (4 used) to remove the cover
(8) assembly from the floor. 7
: 13 mm 8
6. Remove bolts (7) (4 used) to remove pilot valve

(10) from cover (8). W1LA-02-06-004
: 13 mm 10 9
W2-6-3
Installation
1. Install pilot valve (10) to cover (8) with bolts (7) (4

used) temporarily.
: 13 mm
4
2. Install the cover (8) assembly to the floor with
bolts (11) (4 used). 5
: 13 mm 6
: 10 N m (1 kgf m, 7.4 lbf ft)
3. Connect hoses (9) (6 used) onto pilot valve (10).

11
: 19 mm
: 29.5 N m (3 kgf m, 22 lbf ft)
7
8
4. Tighten bolts (7) (4 used) for pilot valve (10).
: 13 mm
: 10 N m (1 kgf m, 7.4 lbf ft)
W1LA-02-06-004
5. Install levers (4) (2 used) and pedals (5) (2 used) 10 9

to pilot valve (10) with socket bolts (6) (4 used).
: 6 mm
: 30 N m (3.1 kgf m, 22 lbf ft)
6. Install cover (1) to the floor in the main frame with 1

bolts (2) (4 used) and wing bolt (3).
: 13 mm
: 10 N m (1 kgf m, 7.4 lbf ft)
IMPORTANT: After connecting the hoses and

connectors, check the hydraulic oil
level. Start the engine and check the
2
connections for oil leaks.
W1LA-02-05-006
W2-6-4
REMOVE AND INSTALL BLADE PILOT
VALVE
Removal 4

1. Remove bolts (2) (4 used) to remove cover (1).
: 13 mm
2. Remove bolts (3) (2 used) to remove lever (4)

from pilot valve (6).
: 13 mm
1 2 M1LA-05-004
3. Loosen bolts (5) (2 used). 4

3
: 13 mm
4. Remove bolts (8) (2 used) to remove the bracket 5

(9) assembly from the floor. 9
6
: 17 mm
IMPORTANT: Attach identification tags onto the

disconnected hoses to aid in
ressembly.
5. Disconnect hoses (7) (4 used) from pilot valve (6).
Attach a cap onto the open ends. W1LA-02-06-005
: 19 mm
7
NOTE: Hold hoses (7) (4 used) with a wire to
prevent them from falling down.
6. Remove bolts (5) (2 used) to remove pilot valve

(6).
: 13 mm
W2-6-5
Installation
3 4
1. Install pilot valve (6) to bracket (9) with bolts (5) (2
used). 5
: 13 mm 9
: 10 N m(1 kgf m, 7.4 lbf ft) 6

: 19 mm
: 29.5 N m(3 kgf m, 22 lbf ft)
8
3. Install the bracket (9) assembly to the floor with
bolts (8) (2 used).
: 17 mm
: 50 N m(5.1 kgf m, 37 lbf ft)
W1LA-02-06-005
7
4. Install lever (4) with bolts (3) (2 used).
: 13 mm
: 10 N m(1 kgf m, 7.4 lbf ft)
4
5. Install cover (1) with bolts (2) (4 used).

: 13 mm
: 10 N m(1 kgf m, 7.4 lbf ft)

connectors, check the hydraulic oil 1 2 M1LA-05-004

W2-6-6
REMOVE AND INSTALL BOOM SWING
PILOT VALVE
Removal
1
Floor
1. Remove bolts (2) (4 used) and wing bolt (3) to
remove cover (1) from the main frame.
: 13 mm
2. Open cover (5). 2
W1LA-02-05-006
3
3. Remove socket bolts (13) (2 used) to remove
pedal (6) from pilot valve (7).
: 6 mm
4
4. Remove bolts (12) (2 used) from pilot valve (7).
: 13 mm
13
5
5. Remove bolts (11) (2 used) in plate (9).
: 13 mm
6
IMPORTANT: Attach identification tags onto the 12
disconnected hoses to aid in 11
reassembly.
6. Disconnect hoses (10) (4 used) from pilot valve 7
(7). Attach a cap onto the open ends.
: 19 mm 8
7. Remove pilot valve (7) from plate (9).

9
10
10
W1LD-02-06-001
W2-6-7
Installation
1. Install pilot valve (7) to bracket (8) with bolts (12)

(2 used). 4
: 13 mm
: 10 N m(1 kgf m, 7.4 lbf ft) 13
5
: 19 mm
: 29.5 N m(3 kgf m, 22 lbf ft) 6
12
11
3. Install pilot valve (7) assembly to the floor with
bolts (11) (2 used). 7
: 13 mm
: 10 N m(1 kgf m, 7.4 lbf ft)
8
4. Install pedal (6) to pilot valve (7) with socket bolts

(13) (2 used).
: 6 mm 9
: 20 N m(2 kgf m, 15 lbf ft)
5. Shut cover (5). 10

10
6. Install cover (1) onto the floor in the main frame

with bolts (2) (4 used) and wing bolt (3).
: 13 mm W1LD-02-06-001
: 10 N m(1 kgf m, 7.4 lbf ft)
connectors, check the hydraulic oil
connections for oil leaks. 1
Floor
W1LA-02-05-006
3
W2-6-8
(Blank)
W2-6-9
DISASSEMBLE FRONT PILOT VALVE
13
12
14
11
15
11
10
8
8
7
9
21
6
20
16 21
5
20
4 5
19
3 6
3 18
2
4
1
17
W567-02-06-002
1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

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

slightly. Remove cam (12) from universal joint
(14). 16
: 32 mm
ST 7257
NOTE: Universal joint (14) has been secured on
block (10) with LOCTITE. Dont remove it
unless necessary.
3. Remove socket bolts (11) (2 used) to remove

block (10). At this time, push rods (8) (2 used) W176-02-07-005
and (9) (2 used) are still on the block side.

: 6 mm IMPORTANT: The number of shims (2) has been
determined for each port during the
performance testing at the factory.
Take care not to lose them. Keep
them carefully so as to install them
to each former port when
reassembly.
7. Remove spring guide (16) (4 used), balance
springs (3) (2 used) and (4) (2 used), return
springs (5) (2 used) and (6) (2 used), shim (2)
and spacer (1) (4 used) from spool (17) (4 used).
W2-6-11
21
20
21
20
19
18
17
W567-02-06-002
W2-6-12
IMPORTANT: As the spool (17) has been selected
to match the hole of the housing (18),
keep them carefully so as to install
them to the former port when
reassembling.
8. Remove spool (17) from housing (18). Pulling it
out while turning it slowly.
NOTE: The spool and the housing must be
replaced as an assembly.
9. Remove O-rings (19) and (21) (2 used) from

housing (18). Dont remove dowel pin (20) (2
used) unless necessary.
W2-6-13
ASSEMBLE FRONT PILOT VALVE
13
14
12
10
11 15 8, 9
16
3, 4
21 5, 6
2
19
20 1
17
W567-02-06-001
18
1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

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

3 with outer 5. Insert the spool (17) head into the hole of spring
groove special tool (ST 7257) to press the spring from
4 without outer the top of spring guide (16). Install retaining ring
groove (7) with the ring holder (ST 7255) onto the head of
the spool.
Port Return Springs Blance Springs 7
No. (5), (6) (3), (4) ST 7257 ST 7255
1 short short
2 long long 17
3 short short
4 long long
Packing Material
IMPORTANT: Make sure of the port hole number 16
and insert the spool (17) to the
former port. W176-02-07-009
1. Insert the thinner end of spools (17) (4 used) to NOTE: Put approx. dia.8 mm, length 10 mm of
housing (18), then push the spool in rotating it. packing material into the port hole so as to
NOTE: The spool has been selected to match the not only make the work easy to do, but also
hole of the housing. The spool and housing prevent the spool from lowering to the
must be replaced as an assembly. bottom when compressing the spring.
IMPORTANT: Refer to the table above to assemble 6. Assemble remained spools (17) (3 used) into
them correctly. housing (18) in the same procedures as step 2 to
2. Install the spacers (1) (4 used), shim (2), balance 5.
springs (3) (2 used) or (4) (2 used), return springs
(5) (2 used) or (6) (2 used) onto spool (17) 7. Install O-rings (19) and (21) (2 used) onto
installed in housing (18). housing (18).
W2-6-15
13
14
12
10
11 15 8, 9
20
W567-02-06-001
18
W2-6-16
8. Apply grease to the inner faces of oil seals (15) (4 IMPORTANT: Make sure of the tighteness of cam.
used), then install the oil seals (4 used) into block 13. Clamp housing (18) carefully in a vise and then
(10) with a bamboo spatula. install cam (12) to universal joint (14).
NOTE: As shown bellow, insert push rods (8) and Tighten the universal joint so that the clearance
(9) first, then install oil seal (15). This between the cam and push rods (8) (2 used) and
prevents the oil seal from entering into the (9) (2 used) becomes 0 to 0.2 mm.
hole. : 32 mm
Oil Seal IMPORTANT: Do not clamp housing (18) in a vise

Mounting Hole
because screw joint (13) may be
damaged.
10 14. Clamp screw joint (13) in a vise to tighten
8, 9
universal joint (14). Tighten cam (12) with a
spanner.
: 32 mm
: 90 N m (9.2 kgf m, 66 Ibf ft)
W176-02-07-007
IMPORTANT: Make sure of the position to install

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

(8) (2 used) and (9) (2 used).
11. Apply grease to the joint part of universal joint

(14).
12. Align the position of dowel pins (20) (2 used),

install the block (10) assembly to housing (18)
with socket bolts (11) (2 used).
: 6mm
: 20 N m (2 kgf m, 15 Ibf ft)
W2-6-17
DISASSEMBLE TRAVEL PILOT VALVE
18 19
20
19
21
7 8 17 20 22
9 21
10 22 23
11 18
16
5 23
17
6 15 24
7
14
16 24 25
5 35
15
12 25
4
14
3 34
4 13
2 3
2 33
1 32
1
26
27
28
29
30
31
W585-02-06-006
1- O-Ring (4 Used) 10 - Cam (2 Used) 19 - Spring Guide (4 Used) 28 - Steel Ball (2 Used)
2- Bushing (4Used) 11 - Pin (2 Used) 20 - Spring (4 Used) 29 - Seat (2 Used)
3- Packing (4 Used) 12 - Cover (2 Used) 21 - Shim (4 Used) 30 - O-Ring (2 Used)
4- Grease Cup (4 Used) 13 - Casing 22 - Washer (4 Used) 31 - Plug (2 Used)
5- Bushing (4 Used) 14 - Steel Ball (12 Used) 23 - Spool (4 Used) 32 - Plug (3 Used)
6- Steel Ball (4 Used) 15 - Spring Seat (4 Used) 24 - Spring (4 Used) 33 - O-Ring (3 Used)
7- Socket Bolt (4 Used) 16 - Spring (4 Used) 25 - O-Ring (4 Used) 34 - Casing
8- Boot (2 Used) 17 - Piston (4 Used) 26 - Seat (2 Used) 35 - O-Ring (2 Used)
9- Set Screw (2 Used) 18 - Push Rod (4 Used) 27 - Bushing (2 Used)
W2-6-18
Disassemble Travel Pilot Valve
IMPORTANT: As the spool (23) assemblies (4
Thoroughly read PRECAUTIONS FOR used) are adjusted by the pressure
DISASEMBLING AND ASSEMBLING (W1-1-1) of shim (21), they should not be
prior to disassembling. disassembled. If disassembling the
Spool (23) has been selected to match the hole of spool (23) assemblies, record the
casing (34). number and thickness of shim (21).
The spool and casing must be replaced as an 7. Remove spool (23) assemblies (2 used), O-rings
assembly. (25) (4 used) and (35) (2 used), and springs (24)
Put identification tags on the disassembled parts (4 used) from casing (34).
by port to aid when re-assembling.
8. Remove spring guides (19) (4 used), springs (20)
(4 used), shims (21) (4 used), and washers (22)
IMPORTANT: Put the mating marks onto cam (10), (4 used) from spool (23) assemblies (4 used).
pin (11) and cover (12), casings (13,
34) before disassembling.
1. Clamp the pilot valve in a vise to remove boot (8)
from cover (12).
2. Remove set screw( 9) from cam (10). Pull pin (11)

out to remove cam (10) from cover (12).
: 2 mm
NOTE: LOCTITE is applied onto the set screw.
Steel ball (6) can not be removed from
cam (10).
3. Loosen and remove socket bolts (7) (2 used)

alternately. Remove covers (12) (2 used) and
casing (13) assembly from casing (34).
: 6 mm
IMPORTANT: Put identification tags on the

disassembled parts by port.
4. Remove grease cups (4) (4 used), push rods (18)
(4 used), and bushing (2) assemblies (4 used)
from casing (13) assembly.
5. Remove pistons (17) (4 used), springs (16) (4

used), spring seats (15) (4 used), and steel balls
(14) (12 used) from casing (13).
6. Remove packings (3) (4 used) and O-rings (1) (4

used) from bushing (2) assemblies (4 used).
W2-6-19
5
12
34
26
27
28
29
30
31
W585-02-06-006
W2-6-20
9. 9.Remove plugs (31) (2 used) and O-rings (30) (2
used) from casing (34).
: 6 mm
10. Remove seats (29) (2 used), steel balls (28) (2

used), bushings (27) (2 used) and seats (26) (2
used) from casing (34) with a magnet.
IMPORTANT: Be sure not to remove busing (5)

from cover (12) unless bushing (5) is
damaged.
11. Pull bushings (5) (4 used) out of covers (12) (2
used).
W2-6-21
ASSEMBLE TRAVEL PILOT VALVE
9
8 11 5
6 10
18 4
3
2
7
12
1
17
16
35
15 13
19
14
31
25
30
20
21
24
22
32
33
23 C C
34
27
29 28 W585-02-06-008
26
Cross SectionC-C
W585-02-06-007
1- O-Ring (4 Used) 10 - Cam (2 Used) 19 - Spring Guide (4 Used) 28 - Steel Ball (2 Used)
2- Bushing (4Used) 11 - Pin (2 Used) 20 - Spring (4 Used) 29 - Seat (2 Used)
3- Packing (4 Used) 12 - Cover (2 Used) 21 - Shim (4 Used) 30 - O-Ring (2 Used)
4- Grease Cup (4 Used) 13 - Casing 22 - Washer (4 Used) 31 - Plug (2 Used)
5- Bushing (4 Used) 14 - Steel Ball (12 Used) 23 - Spool (4 Used) 32 - Plug (3 Used)
6- Steel Ball (4 Used) 15 - Spring Seat (4 Used) 24 - Spring (4 Used) 33 - O-Ring (3 Used)
7- Socket Bolt (4 Used) 16 - Spring (4 Used) 25 - O-Ring (4 Used) 34 - Casing
8- Boot (2 Used) 17 - Piston (4 Used) 26 - Seat (2 Used) 35 - O-Ring (2 Used)
9- Set Screw (2 Used) 18 - Push Rod (4 Used) 27 - Bushing (2 Used)
W2-6-22
Assemble Travel Pilot Valve
7. Install push rods (18) (4 used) and bushing (2)
Thoroughly read PRECAUTIONS FOR assemblies (4 used) to casing (13).
DISASEMBLING AND ASSEMBLING (W1-1-1)
prior to assembling. 8. Install bushings (5)(4 used) to covers (12) (2
Clean the parts and put them by port for used).
assembling.
9. Clamp casing (34) in a vise. Install casing (13)

1. Install seats (26) (2 used), bushings (27) (2 used), assembly and cover (12) to casing (34) with
steel balls (28) (2 used) and seats (29) (2 used) socket bolts (7) (4 used).
to casing (34). : 6 mm
: 23.5 N m (2.4 kgf m, 17.5 lbf ft)
2. Install O-rings (30) (2 used) to plugs (31) (2 used).
Install them to casing (34).
IMPORTANT: Be sure to install shim (21) to the

original condition.
3. Install washers (22) (4 used), shims (21) (4 used),
springs (20) (4 used), and spring guides (19) (4
used) to spools (23) (4 used) in this order.
IMPORTANT: Be sure to install spool (23)

assembly into the original hole when
dissembling.
4. Install springs (24) (4 used), spool (23)
assemblies (4 used), and O-rings (25) (4
used)and (35) (2 used) to casing (34).
5. Install steel balls (14) (12 used), spring seats (15)

(4 used), springs (16) (4 used) and pistons (17) (4
used) to casing (13).
6. Install O-rings (1) (4 used) and packings (3) (4

used) to bushings (2) (4 used).
3
W585-02-06-005
Lip Part
W2-6-23
9
11
8 10
18 4
12
C C
W585-02-06-008
Cross Section C-C
W585-02-06-007
W2-6-24
10. Install grease cups (4) (4 used) to push rods (18)
(4 used).
11. Install cams (10) (2 used) to cover (12) with pins

(11) (2 used).
12. Apply LOCTITE #241 onto set screws (9) (2

used). Secure cams (10) (2 used) and pin (11) (2
used) with set screws (9) (2 used).
: 2 mm
: 5 N m (0.5 kgf m, 3.7 lbf ft)
13. Install boots (8) (2 used) to covers (12) (2 used).
W2-6-25
DISASSEMBLE BLADE AND BOOM
SWING PILOT VALVE
20
7 20
8 19
6
9 19
18
4 18 17
10
5 16
17
16
6 15
15
4
11 14
14
3
3 12
13
2
2
21
1
1
W1LA-02-06-001
1 - O-Ring (2 Used) 7- Boot 12 - Plug 17 - Shim (2 Used)

2 - Bushing (2 Used) 8- Set Screw 13 - O-Ring 18 - Spring (2 Used)
3 - Packing (2 Used) 9- Cam 14 - Spring (2 Used) 19 - Spring Guide (2 Used)
4 - Bushing (2 Used) 10 - Pin 15 - Spool (2 Used) 20 - Pusher (2 Used)
5 - Steel Ball (2 Used) 11 - Cover 16 - Washer (2 Used) 21 - Casing
6 - Socket Bolt (2 Used)
W2-6-26
Disassemble Blade and Boom Swing Pilot Valve
7. Remove spring guides (19) (2 used), springs (18)
Read PRECAUTIONS FOR DISASEMBLING (2 used), washers (16) (2 used), and shims (17)
AND ASSEMBLING (W1-1-1) carefully before (2 used) from spool (15) assemblies (2 used).
disassembling.
Spool (15) has been selected to match the hole of IMPORTANT: As the spool (15) assemblies (2
casing (21). used) are adjusted by the pressure
The spool and casing must be replaced as an of shim (17), they should not be
assembly. disassembled. If disassembling the
Discriminate between the disassembled parts by spool (15) assemblies, record the
port No. where the parts are located in order to quantity and thickness of shim (17).
avoid confusion. IMPORTANT: Do not remove bushing (4) from
cover (11) unless bushing (4) is
IMPORTANT: Put the mating marks onto cam (9), damaged.
pin (10), cover (11), and casing (21) 8. Pull bushings (4) (2 used) out of cover (11).
before disassembling.
1. Clamp the pilot valve in a vise to remove boot (7)
from cover (11).
2. Remove set screw (8) from cam (9). Pull pin (10)
out to remove cam (9) from cover (11).
: 2 mm
NOTE: LOCTITE is applied onto the set screw.
NOTE: Steel ball (5) cannot be disassembled from
cam (9).
3. Loosen and remove socket bolts (6) (2 used)

alternately. Remove cover (11) from casing (21).
: 6 mm
4. Remove pusher (20) assemblies (2 used) from

casing (21).
5. Remove bushings (2) (2 used) from pusher (20)

assembly. Remove O-rings (1) (2 used) and
packings (3) (2 used) from bushings (2) (2 used).
IMPORTANT: Put identification tags on the

disassembled parts by port in order
to avoid confusion.
6. Remove spool (15) assemblies (2 used) and
springs (14) (2 used) from casing (21).
W2-6-27
ASSEMBLE BLADE AND BOOM SWING
PILOT VALVE
8 10
7
9
5
20
3
6
2
11
19
18
14
17
16
12
13
15 W1LA-02-06-002
21
1 - O-Ring (2 Used) 7- Boot 12 - Plug 17 - Shim (2 Used)

2 - Bushing (2 Used) 8- Set Screw 13 - O-Ring 18 - Spring (2 Used)
3 - Packing (2 Used) 9- Cam 14 - Spring (2 Used) 19 - Spring Guide (2 Used)
4 - *Bushing (2 Used) 10 - Pin 15 - Spool (2 Used) 20 - Pusher (2 Used)
5 - Steel Ball (2 Used) 11 - Cover 16 - Washer (2 Used) 21 - Casing
6 - Socket Bolt (2 Used)
NOTE: As for the items with a mark *, refer to

W2-6-26.
W2-6-28
Assemble Blade and Boom Swing Pilot Valve
8. Apply LOCTITE #241 onto set screw (8). Secure
Read PRECAUTIONS FOR DISASEMBLING cam (9) and pin (10) with set screws (8).
AND ASSEMBLING (W1-1-1) carefully before : 2 mm
assembling. : 5 N m (0.5 kgf m, 3.7 lbf ft)
Clean the parts and put them by port for
assembling. 9. Install boot (7) to cover (11).
1. Install bushings (4) (2 used) to cover (11).
IMPORTANT: Be sure to install shim (17) to the

original condition.
2. Install washers (16) (2 used), shims (17) (2 used),
springs (18) (2 used), and spring guides(19) (2
used) to spools (15) (2 used) in this order.
IMPORTANT: Be sure to install spool (15)

assembly into the original hole when
disassembling.
3. Install springs (14) (2 used) and spool(15)
assemblies (2 used) to casing (21).
4. Install O-rings (1) (2 used) and packings (3) (2

used) to bushings (2) (2 used).
3
W585-02-06-005
Lip Part
5. Install pushers (20) (2 used) to bushing (2)

assemblies (2 used). Install them to casing (21).
6. Clamp casing (21) in a vise. Install cover (11) to

casing (21) with socket bolts (6) (2 used).
: 6 mm
: 23.5 N m (2.4 kgf m, 17.5 lbf ft)
7. Install cam (9) to cover (11) with pin (10).
W2-6-29
(Blank)
W2-6-30
UPPERSTRUCTURE / Solenoid Valve
DISASSEMBLE AND ASSEMBLE SOLENOID VALVE
1 3 2
W574-02-07-001
1 - ON-OFF Solenoid Valve 2 - ON-OFF Solenoid Valve 3 - Relief Valve 4 - Housing

(Pilot Control (Travel Speed Selector)
Shut-Off Lever )
W2-7-1
7
1
8
3
6
9
10
11
12
13
W574-02-07-002
1 - Guide 5 - Washer 8 - Solenoid 11 - Spool

2 - O-Ring 6 - Spool 9 - Tube 12 - Spring
3 - Washer 7 - Nut 10 - O-Ring 13 - Housing
4 - Spring
W2-7-2
Disassemble Solenoid Valve Assemble Solenoid Valve

AND ASSEMBLING (W1-1-1) carefully before AND ASSEMBLING (W1-1-1) carefully before
disassembling. assembling.
1. Loosen nut (7), then remove solenoid (8). 1. Install spool (6), washer (5), spring (4) and
washer (3) into housing (13).
: 19 mm
2. Install guide (1) with O-ring (2) into housing (13).

2. Remove tube (9), O-ring (10), spool (11) and
spring (12) from housing (13). : 24 mm
: 74 to 88 N m
: 21 mm (7.5 to 9.0 kgf m, 55 to 65 lbf ft)
3. Remove guide (1) from housing (13). 3. Install spring (12) and spool (11) into housing
(13).
: 24 mm
4. Install tube (9) with O-ring (10) into housing (13).

4. Remove washer (3), spring (4), washer (5) and
spool (6) from housing (13). : 21 mm
: 47 to 74 N m
(4.8 to 7.5 kgf m, 35 to 55 lbf ft)
5. Install solenoid (8) and nut (7) onto tube (9).
: 19 mm
: 4.9 N m (0.5 kgf m, 3.6 lbf ft)
W2-7-3
Blank
W2-7-4
UPPERSTRUCTURE / Revolution Sensing Valve
REMOVE AND INSTALL REVOLUTION 1 2
SENSING VALVE
Removal
3
1. Open engine cover (1). Insert rod (3) into hole (2)
for the lock to lock engine cove (1).
2. Push latch (4) on tank cover (5) upward to unlock.
4 SS-2304
M1LD-07-017
3. Open tank cover (5) until lock (6) is locked. 5
M1LD-07-013
M1LD-07-014
W2-8-1
4. Disconnect all hoses from revolution sensing 7
valve (8). Cap all the disconnected hoses. Attach 8
tags onto them to aid reassembly.
: 19 mm, 22 mm
5. Remove bolts (7) (2 used) to remove revolution

sensing valve (8).
: 13 mm
M1LD-07-007
W2-8-2
Installation 7
8
1. Install revolution sensing valve (8) with bolts (7)
(2 used).
: 13 mm
: 19.5 N m (2 kgf m, 14.5 lbf ft)
2. Connect all the hoses onto revolution sensing

valve (8).
: 19 mm
: 29.5 N m (3 kgf m, 22 lbf ft)
: 22 mm
: 39 N m (4 kgf m, 29 lbf ft)
3. Push lock (6) upward by right hand to unlock.
M1LD-07-007
6
4. Shut tank cover (5).
M1LD-07-015
M1LD-07-013
W2-8-3
5. Align the mating mark on tank cover (5) with that 5
on cover (9).
9 M1LD-07-010
6. Push tank cover (5) downward until tank cover (5)
is locked.
7. Remove rod (3) from hole (2) for the lock. Shut
engine cover (1).
M1LD-07-012
3 2
SS-2304
W2-8-4
(Blank)
W2-8-5
DISASSEMBLE REVOLUTION SENSING
VALVE
5
4
4
4 6
2
W566-02-08-001
3 11 12 13 4 14 4
15
2 10 1 9 8 18 17 7 16
W566-02-08-002
1- Body 6- Choke 11 - O-Ring 15 - Spring

2- Differential Reducing Vlave 7- Plug 12 - Spring 16 - O-Ring
3- Variable Orifice Valve 8- O-Ring 13 - Spool 17 - Guide
4- Plug (3 Used) 9- O-Ring 14 - O-Ring 18 - Piston
5- Plug 10 - O-Ring
W2-8-6
Disassemble Revolution Sensing Valve

disassembling.
IMPORTANT: Do not remove plugs (5 and 7).
IMPORTANT: Never turn the lock nuts of differen-

tial reducing valve(2) and variable
orifice valve(3). If turned, the set
pressure may be changed.
Lock Nut
Cartridge
W176-02-06-017
1. Remove differential reducing valve (2) from body

(1). Remove piston (18) and spring (15) from
body (1) with a magnet.
: 24 mm
2. Install the bolt (M8) into the hole on guide (17) to

remove guide (17) from body (1).
IMPORTANT: When removing variable orifice

valve (3) from body (1), spool (13)
and spring (12) may be left inside
the body. In this case, remove spool
(13) and spring (12) with a magnet.
3. Remove variable orifice valve (3), spring (12),
and spool (13) from body (1).
: 24 mm
4. Remove plugs (4) (3 used) and choke (6) from

body (1).
: 6 mm, 5 mm
W2-8-7
ASSEMBLE REVOLUTION SENSING
VALVE
5
4
4
4 6
2
W566-02-08-001
3 11 12 13 4 14 4
15
2 10 1 9 8 18 17 7 16
W566-02-08-002
1- Body 6- Choke 11 - O-Ring 15 - Spring

2- Differential Reducing Vlave 7- Plug 12 - Spring 16 - O-Ring
3- Variable Orifice Valve 8- O-Ring 13 - Spool 17 - Guide
4- Plug (3 Used) 9- O-Ring 14 - O-Ring 18 - Piston
5- Plug 10 - O-Ring
W2-8-8
Assemble Revolution Sensing Valve IMPORTANT: Install differential reducing valve (2)
into body (1) with guide (17) assem-
Read PRECAUTIONS FOR DISASSEMBLING bly facing upward. In case differen-
AND ASSEMBLING (W1-1-1) carefully before as- tial reducing valve (2) cannot be in-
sembling. stalled to body (1) by hand, guide
(17) assembly may be off. At this
time check if the sliding surfaces of
1.Install choke (6) and plugs (4) (3 used) to body (1). piston (18) and guide (17) are dam-
: 5 mm aged after pulling differential reduc-
: 9.8 to 11.0 N m ing valve (2) out of body (1).
(1.0 to 1.2 kgf m, 7.2 to 8.1 lbf ft)
: 6 mm
: 30.5 to 34.0 N m
(3.1 to 3.5 kgf m, 22.5 to 25 lbf ft) 5. Install differential reducing valve (2) to body (1)
turning it I to 2 times by hand. Tighten it.
: 24 mm
IMPORTANT: Apply grease onto O-Rings (14, 11). : 79 to 83 N m
2. Install spring (12), spool (13), and O-rings (11, 14) (8.1 to 8.5 kgf m, 58 to 61 lbf ft)
to variable orifice valve (3).
IMPORTANT: Install variable orifice valve (3) into

body (1) with O-ring (14) facing up-
ward. In case variable orifice valve
(3) cannot be installed to body (1) by
hand, spool (13) may be off. At this
time check if the spool (13) sliding
surface is damaged after pulling
variable orifice valve (3) out of body
(1).
3. Install variable orifice valve (3) to body (1) turning
it 1 to 2 times by hand. Tighten it.
: 24 mm
: 54 to 59 N m
(5.5 to 6.0 kgf m, 40 to 44 lbf ft)
IMPORTANT: Apply grease onto O-rings (10, 9, 8,

16) and spring (15).
4. Install piston (18), spring (15) and O-ring (16) to
guide (17). Install O-rings (10, 9, 8) and guide
(17) assembly to differential reducing valve (2).
W2-8-9
(Blank)
W2-8-10
SECTION 3
UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing Group 6 Upper and Lower Roller
Remove and Install Swing Bearing .......... W3-1-1 Remove and Install Upper Roller ............. W3-6-1
Remove and Install Lower Roller ............. W3-6-3
Group 2 Travel Device Disassemble and Assemble
Remove and Install Travel Device ........... W3-2-1 Lower Roller........................................... W3-6-6
Disassemble Travel Device ..................... W3-2-2 Maintenance Standards ........................... W3-6-8
Assemble Travel Device .......................... W3-2-6
Maintenance Standards......................... W3-2-16 Group 7 Track
Remove and Install Rubber Crawler ........ W3-7-1
Group 3 Center Joint Maintenance Standards ........................... W3-7-3
Remove and Install Center Joint.............. W3-3-1
Disassemble Center Joint........................ W3-3-4
Assemble Center Joint ............................ W3-3-6
Group 4 Track Adjuster

Remove and Install Track Adjuster .......... W3-4-1
Disassemble Track Adjuster .................... W3-4-2
Assemble Track Adjuster ......................... W3-4-8
Group 5 Front Idler

Remove and Install Front Idler................. W3-5-1
Disassemble and Assemble Front Idler ... W3-5-2
Maintenance Standards........................... W3-5-4
1LDW-3-1
Blank
1LDW-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
The procedures described below starts after removing

the upper structure.
Removal
1. Put matching marks on inner race (1) of the swing
bearing and track frame (2). Matching Mark
2. Remove mounting bolts (3) (20 used) of the swing

bearing inner race. 1 2 W105-03-01-001
: 19 mm
W507-02-03-002
CAUTION: Swing bearing weight: 55 kg
(121 lb)
3. Attach lifting tools (ST 0052) to swing bearing (4)
outer race, lift swing bearing (4) by crane and
remove it.
ST 0052
W507-03-01-001
W3-1-1
UNDERCARRIAGE / Swing Bearing
Installation
Clean the mating surfaces of the track frame and
swing bearing.
1. Apply THREEBOND #1102 to the mating

surfaces of the swing bearing and the track
frame.
Front Side
CAUTION: Swing bearing weight: 55 kg Position for
(121 lb) "S" (Soft Zone) Grease Fitting
Marking Position
IMPORTANT: Failure to align the marks may result
in misalignment of the inner race
soft zone. 25
2. Lift the swing bearing by crane. Align the

alignment marks both on the track frame and
swing bearing.
9
16
Position for
Grease Fitting
W1LD-03-01-001
3
3. Install mounting bolts (3) (20 used) to the inner
race of the swing bearing and tighten to
specification.
: 19 mm
: 108 N m (11 kgf m 80 lbf ft)
W507-02-03-002
W3-1-2
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
Removal
1. Remove bolts (1) (3 used) to remove cover (2).

: 8 mm
: 49 N m (5 kgf m, 36 lbf ft)
2
2. Disconnect all hoses from the travel device.
Cap all disconnected hose ends and put tags on
all disconnected hoses to aid in ressambly.
: 19 mm 1
W507-03-02-001
: 29.5 N m (3 kgf m, 22 lbf ft)
: 22 mm
: 39 N m (4 kgf m, 29 lbf ft)
: 27 mm
: 64 N m (6.5 kgf m, 47 lbf ft)
CAUTION: Travel device weight: 65 kg

(143 lb)
3. Remove travel device mounting bolts (3) (13

used). Lift and remove the travel device by crane.
: 19 mm
: 128 N m (13 kgf m, 94 lbf ft)
Installation 3
W554-03-02-005
NOTE: Refer to "Removal" section for wrench size
and tightening torque.
1. Lift the travel device by crane. Install the travel

device to the track frame with mounting bolts (3)
(13 used).
2. Connect all hoses to the travel device.
3. Install the travel motor cover (2) onto the track
frame with bolts (1) (3 used).
IMPORTANT: After connecting the hoses, check

the hydraulic oil level. Start the en-
gine and check the hoses for oil
leaks.
To prevent the travel motor from
seizing, be sure to perform break-in
operation after installation.
Break-in operation conditions

1.Engine speed: Slow idle speed
2.Travel pedal : Slow speed range
3.Operation duration: 2 minutes or
more
W3-2-1
1 2
DISASSEMBLE TRAVEL DEVICE 3
29 4
30 5
30
29 6
27 7
28 8
27 9
15 10
18 11
17
26 16
15
25 14
24
23
22
21 13
12
20
19
37 36
W571-03-02-004
55 35
54
53 58 52
51 50 34
49 33
48 32
47 31
46
45
43
44
71 43
42
70 41
40
59 39
57
60 38
61 56
62
63
66 64
67 65
68
50
49 69
52
51 W571-03-02-005
1 - Sun Gear 19 - Retaining Ring (4 Used) 37 - Swash Plate 55 - Socket Bolt (4 Used)
2 - Thrust Collar 20 - Thrust Washer (4 Used) 38 - Plunger (9 Used) 56 - O-Ring
3 - First Stage Carrier 21 - Second Stage Planetary Gear 39 - Holder 57 - Choke
(4 Used)
4- Retaining Ring 22 - Needle Bearing (4 Used) 40 - Barrel Holder 58 - Body
5- Drive Gear 23 - Ring (4 Used) 41 - Pin (3 Used) 59 - Ball (2 Used)
6- Slide Ring 24 - Thrust Washer (4 Used) 42 - Rotor 60 - Spring (2 Used)
7- O-Ring 25 - Retaining Ring 43 - Retainer (2 Used) 61 - Spring Guide (2 Used)
8- Cover 26 - Ring Gear 44 - Spring 62 - O-Ring (2 Used)
9- Stopper Ring 27 - Bearing (2 Used) 45 - Retaining Ring 63 - Plug (2 Used)
10 - O-Ring (2 Used) 28 - Retaining Ring 46 - Valve Plate 64 - Spring
11 - Plug (2 Used) 29 - O-Ring (2 Used) 47 - O-Ring 65 - Spool
12 - Plug 30 - Seal Ring (2 Used) 48 - Bearing 66 - Spacer
13 - O-Ring 31 - Body 49 - Plug (2 Used) 67 - O-Ring (2 Used)
14 - Retaining Ring (3 Used) 32 - Control Piston 50 - O-Ring (2 Used) 68 - Plug (2 Used)
15 - Thrust Washer (6 Used) 33 - Oil Seal 51 - Spring (2 Used) 69 - Spool
16 - Pin (3 Used) 34 - Bearing 52 - Ring (2 Used) 70 - O-Ring (2 Used)
17 - Needle Bearing (3 Used) 35 - Shaft 53 - Socket Bolt (7 Used) 71 - O-Ring
18 - First Stage Planetary Gear 36 - Ball (2 Used) 54 - Relief Valve Assembly
(3 Used)
W3-2-2
Disassemble Travel Device
Read PRECAUTIONS FOR DISASSEMBLING 9. Remove plungers (38) (9 used), holder (39), bar-
AND ASSEMBLING (W1-1-1) carefully before rel holder (40) and pins (41) (3 used) from rotor
disassembling. (42).
1. Remove plugs (63) (2 used), spring guides (61)
(2 used), springs (60) (2 used) and balls (59) (2 CAUTION: Always hold retainer (43) and
used) from body (58). Remove O-rings (62) (2 spring (44) with a press when removing re-
used) from plugs (63) (2 used). taining ring (45). If retaining ring (45) is re-
moved without holding retainer (43) and
2. Remove plugs (49) (2 used), springs (51) (2 spring (44), retainer (43) and spring (44) may
used), Rings (52) (2 used) and spool (69) from fly out potentially causing serious injury.
body (58). Remove O-rings (50) (2 used) from
plugs (49) (2 used). 10. Remove retaining ring (45) from rotor (42), then
remove retainer (43), spring (44) and retainer
3. Remove plugs (68) (2 used), spacer (66), spool (43).
(65) and spring (64) from body (58). Remove O-
rings (67) (2 used) from plugs (68) (2 used). 11. Remove plug (12), O-ring (13), plugs (11) (2
used) and O-rings (10) (2 used) from cover (8).
4. Remove socket bolts (55) (4 used), relief valve : 5 mm, 8 mm
assembly (54), O-rings (70) (2 used) and (71)
from body (58).
: 6 mm 12. Remove stopper ring (9) from cover (8) using a
screwdriver, then remove cover (8) from ring gear
(26).
CAUTION: Valve plate (46) may stick to body
(58). Take care not to drop valve plate (46)
when removing body (58).
5. Removes socket bolts (53) (7 used) to remove

body (58) and valve plate (46) from body (31).
: 10 mm
6. Remove O-ring (56), bearing (48) and choke (57)

from body (58).
7. Remove O-ring (47) from body (31).
8. Remove rotor (42) assembly, swash plate (37),

balls (36) (2 used), and control piston (32) from
body (31).
W3-2-3
1
2
3
4
29
30 5
30
29 6
7
27
28 8
27
15
18
17
26 16
15
25
24 14
23
22
21
20
19
W571-03-02-004
35
34
33
32
31
W571-03-02-005
W3-2-4
13. Remove O-ring (7) and slide ring (6) from cover
(8).
14. Remove drive gear (5), first stage carrier (3) as-
sembly, retaining ring (4) and sun gear (1) from
ring gear (26).
15. Remove retaining rings (14) (3 used), thrust

washers (15) (3 used), first stage planetary gears
(18) (3 used), needle bearings (17) (3 used),
thrust washers (15) (3 used) and pins (16) (3
used) from first stage carrier (3).
16. Remove thrust collar (2), retaining rings (19) (4

used), thrust washers (20) (4 used), second stage
(22) (4 used), rings (23) (4 used) and thrust
washers (24) (4 used) from body (31).
CAUTION: Attach a bar to shaft (35) assem-

bly. While tapping the end of the bar with a
hammer, remove shaft (35) assembly from
body (31). Do not remove bearing (34) unless
replacement is necessary.
17. Remove shaft (35) from body (31).
18. Remove retaining ring (25) from body (31).
19. Remove body (31) from ring gear (26).
IMPORTANT: Attach a bar to bearing (27). While

tapping the end of the bar with a
hammer, remove bearing (27) from
ring gear (26). Replace bearing (27)
with a new one if removed.
20. Remove seal ring (30), O-ring (29), bearing (27),

retaining ring (28) and bearing (27) from ring gear
(26).
21. Remove O-ring (29) and seal ring (30) from body
(31).
22. Remove oil seal (33) from body (31).
W3-2-5
ASSEMBLE TRAVEL DEVICE
18 17 15 19 20 21 22 24 25 33 28 34 29 37 36 40 41 47 53 44 48
58
15
16
23
14
55
13 54
12
6
8
10
11
9 7 4 3 2 1 5 26 32 27 39 30 38 42 43 31 56 35 57 45 46
T571-03-05-001
1 - Sun Gear 19 - Retaining Ring (4 Used) 37 - Swash Plate 55 - Socket Bolt (4 Used)
2 - Thrust Collar 20 - Thrust Washer (4 Used) 38 - Plunger (9 Used) 56 - O-Ring
3 - First Stage Carrier 21 - Second Stage Planetary 39 - Holder 57 - Choke
Gear (4 Used)
4- Retaining Ring 22 - Needle Bearing (4 Used) 40 - Barrel Holder 58 - Body
5- Drive Gear 23 - Ring (4 Used) 41 - Pin (3 Used) 59 - Ball (2 Used)
6- Slide Ring 24 - Thrust Washer (4 Used) 42 - Rotor 60 - Spring (2 Used)
7- O-Ring 25 - Retaining Ring 43 - Retainer (2 Used) 61 - Spring Guide (2 Used)
8- Cover 26 - Ring Gear 44 - Spring 62 - O-Ring (2 Used)
9- Stopper Ring 27 - Bearing (2 Used) 45 - Retaining Ring 63 - Plug (2 Used)
10 - O-Ring (2 Used) 28 - Retaining Ring 46 - Valve Plate 64 - Spring
11 - Plug (2 Used) 29 - O-Ring (2 Used) 47 - O-Ring 65 - Spool
12 - Plug 30 - Seal Ring (2 Used) 48 - Bearing 66 - Spacer
13 - O-Ring 31 - Body 49 - Plug (2 Used) 67 - O-Ring (2 Used)
14 - Retaining Ring (3 Used) 32 - Control Piston 50 - O-Ring (2 Used) 68 - Plug (2 Used)
15 - Thrust Washer (6 Used) 33 - Oil Seal 51 - Spring (2 Used) 69 - Spool
16 - Pin (3 Used) 34 - Bearing 52 - Ring (2 Used) 70 - O-Ring (2 Used)
17 - Needle Bearing (3 Used) 35 - Shaft 53 - Socket Bolt (7 Used) 71 - O-Ring
18 - First Stage Planetary Gear 36 - Ball (2 Used) 54 - Relief Valve Assembly
(3 Used)
W3-2-6
69 69
52
49
51
50 68
59
60
61
64 62 63 65 66 67
W571-03-02-001
W3-2-7
19 20 21 22 24 25 33 28 29 30
23
2 26 27 31
T571-03-05-001
W3-2-8
Assemble Travel Device
Read PRECAUTIONS FOR DISASSEMBLING 5. Install rings (23) (4 used), thrust washers (24) (4
AND ASSEMBLING (W1-1-1) carefully before as- used), second stage planetary gears (21) (4
sembling. used), needle bearings (22) (4 used) and thrust
washers (20) (4 used) onto body (31) in this order.
1. Install oil seal (33) into body (31). Secure them with retaining rings (19) (4 used),
then install thrust collar (2).
2. Install O-ring (29) onto seal ring (30), then install
them into the body (31).
3. Install bearing (27), retaining ring (28), bearing

(27) and the assembly of seal ring (30) and O-ring
(29) into ring gear (26) in this order.
NOTE: Apply grease to O-ring (29) for easy as-

sembling. Degrease the seating surface of
seal ring (30).
4. Install ring gear (26) into body (31), tapping

around the circumference of ring gear (26) evenly
with a plastic hammer. Install retaining ring (25)
while depressing clearance between the flanges
of body (31) and ring gear (26) using screw
clamps.
26
Screw Clamp
31
W571-03-02-006
W3-2-9
18 17 15
15
16
14
13
12
6
8
10
11
9 7 4 3 1 5 26
T571-03-05-001
W3-2-10
6. Install pins (16) (3 used) onto first stage carrier
(3). Install sun gear (1) and secure it with retain-
ing ring (4).
7. Install thrust washers (15) (3 used), first stage

(17) (3 used) and thrust washers (15) (3 used)
onto first stage carrier (3) in this order, then install
retaining rings (14) (3 used).
8. Install first stage carrier (3) assembly onto ring

gear (26), then install drive gear (5) into first stage
carrier (3) assembly.
9. Install O-ring (7) onto ring gear (26). Add 0.6 litter
(0.159 US gal) of lubrication oil into ring gear (26).
CAUTION: Apply grease to cover (8) and

slide ring (6) to hold them. Apply grease to
O-ring (7), then install it horizontally with
care to avoid damage. Install cover (8) so that
its plug hole aligns with the notch on ring
gear (26).
10. Install the assembly of cover (8) and slide ring (6)
onto ring gear (26), then secure them using stop-
per ring (9).
11. Install plug (11), O-ring (10), plug (12) and O-ring
(13) onto cover (8).
: 5 mm
: 12 to 13 N m
(1.2 to 1.3 kgf m, 8.9 to 9.6 lbf ft)
: 8 mm
: 46 to 51 N m
(4.7 to 5.2 kgf m, 34 to 38 lbf ft)
W3-2-11
34 37 36 40 41 47 53 44 43 48
58
71
55
54
70
32 39 38 43 42 31 56 35 57 45 46
T571-03-05-001
W3-2-12
IMPORTANT: Do not remove bearing (34) on shaft
(35) assembly unless replacing it.
12. Install control piston (32), shaft (35) assembly,

balls (36) (2 used) and swash plate (37) into body
(31) in this order.
13. Install retainer (43), spring (44) and retainer (43)

into rotor (42) in this order.
14. Depress retainer (43) and spring (44) downward

with a press, and install retaining ring (45).
15. Install pins (41) (3 used) and barrel holder (40)

into rotor (42).
16. Install plungers (38) (9 used) and holder (39) onto

rotor (42).
17. Install rotor (42) assembly into body (31). Add 0.2
litter (0.053 US gal) of hydraulic oil into body (31).
18. Install bearing (48), O-ring (47) and valve plate

(46) onto body (58) in this order. Install choke (57)
and O-ring (56).
19. Install body (58) onto body (31), and tighten using
socket bolts (53) (7 used).
: 10 mm
: 51 to 65 N m
(5.2 to 6.6 kgf m, 38 to 48 lbf ft)
20. Install O-ring (70), O-ring (71), relief valve (54)

and socket bolt (55) onto body (58).
: 6 mm
: 25 to 32 N m
(2.6 to 3.3 kgf m, 18.5 to 24 lbf ft)
W3-2-13
69 58 69
52
49
51
50 68
59
60
61
64 63 62 65 66 67
W571-03-02-001
W3-2-14
21. Install O-rings (67) (2 used) onto plugs (68) (2
used). Install spring (64), spool (65) and spacer
(66) into body (58), then install plugs (68) (2
used).
: 8 mm
: 46 to 51 N m
(4.7 to 5.2 kgf m, 34 to 38 lbf ft)

used). Install spool (69), rings (52) (2 used),
springs (51) (2 used) into body (58), then install
plugs (49) (2 used).
: 36 mm
: 196 to 245 N m
(20 to 25 kgf m, 145 to 180 lbf ft)

used). Install balls (59) (2 used), springs (60) (2
used), spring guides (61) (2 used), plugs (63) (2
used) into body (58) in this order.
: 6 mm
: 5.9 N m (0.6 kgf m, 4.4 lbf ft)
W3-2-15
Sprocket
C B
D
A
W1SE-03-02-001 W105-03-07-040
Unit: mm
Dimension Standard Allowable Limit Remedy
A 47.6 (42.6)
B 73.1 70.6
Cladding by
C 96.05 93.55 welding and
finishing
C PCD92.35 -
D 135.0 -
NOTE: The value in the parenthesis is the refer-
ence value.
W3-2-16
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT
Removal

1. Remove floor plate.

1
NOTE: Refer to "REMOVE AND INSTALL SWING
DEVICE" for removing floor plate.
2. Attach tags to all hoses connected to center joint

(1), to identify for reassembling in the same posi-
tions.
W507-03-03-001
Remove all body side hoses from center joint (1). 1
Cap all disconnected hose ends. 2
: 19 mm, 22 mm, 27 mm
3
3. Remove bolts (3) (2 used) to remove lock plate

(2) from the frame.
: 19 mm
W1LD-03-03-001
4
4. Remove bolts (4) (3 used) to remove undercover

(5) from the frame. 5
: 19 mm
W554-03-03-002
5. Disconnect all spindle side hoses from center

joint (1). Cap all disconnected hose ends.
: 19 mm, 22 mm, 27 mm
6. Install eye bolt to the center joint to lift the center

joint with a wire rope.
CAUTION: Center joint weight: 19 kg (42 lb)
7. Remove center joint mounting bolts (6) (4 used). 1
Then, remove the center joint (1) while holding W507-03-03-004
the center joint by a crane.

: 17 mm 1
6
W571-03-03-001
W3-3-1
Installation
1
6
CAUTION: Center joint weight: 19 kg (42 lb)
1. Install center joint (1) onto the frame with bolts (6)
(4 used).
: 17 mm
: 49 N m (5 kgf m, 36 lbf ft)
W571-03-03-001
2. Connect all spindle side hoses to center joint (1).

: 19 mm
: 29.5 N m (3 kgf m, 22 lbf ft)
: 22 mm
: 39 N m (4 kgf m, 29 lbf ft)
: 27 mm
: 64 N m (6.5 kgf m, 47 lbf ft)
1
W507-03-03-004
4
3. Install undercover (5) onto the frame with bolts (4)
(3 used).
: 19 mm 5
: 88 N m (9 kgf m, 65 lbf ft)
4. Install lock plate (2) onto the frame with bolts (3)
(2 used).
: 19 mm W554-03-03-002
1
: 88 N m (9 kgf m, 65 lbf ft)
2
3
5. Connect all body side hoses to center joint (1).
: 19 mm
: 29.5 N m (3 kgf m, 22 lbf ft)
: 22 mm
: 39 N m (4 kgf m, 29 lbf ft) W1LD-03-03-001
: 27 mm
: 64 N m (6.5 kgf m, 47 lbf ft)
6. Install the floor plate.

NOTE: Refer to "REMOVE AND INSTALL SWING
DEVICE" for installing the floor plate. 1
IMPORTANT: After connecting the hoses, fill the

hydraulic oil tank to the correct level.
Start the engine and check the hose
W507-03-03-001
W3-3-2
(Blank)
W3-3-3
DISASSEMBLE CENTER JOINT
11
10
12 13
W555-03-03-001
1- Bolt (4 Used) 5 - Thrust Washer 8 - O-Ring 11 - Spindle
2- Cover 6 - Body 9 - Backup Ring 12 - Plug (4 Used)
3- Retaining Ring 7 - Oil Seal (7 Used) 10 - Dust Seal 13 - Plug (3 Used)
4- O-ring
W3-3-4
Disassemble Center Joint IMPORTANT: For easy removal, two pins can be
Read PRECAUTIONS FOR DISASSEMBLING used to pry out oil seals (7). Take
AND ASSEMBLING (W1-1-1) carefully before care not to damage the seal groove
disassembling. with the pins.
1. Clamp the center joint horizontally in a vise.
2. Remove bolt (1) (4 used), to remove cover (2)

from body (6). Pin
: 13 mm
3. Remove O-ring (4), retaining ring (3) and thrust

washer (5) from body (6).
7
4. Attach the special tool (ST 1995) to body (6) with
bolts (1) (2 used).
: 13 mm
W105-03-03-015
ST 1995
6. Remove oil seals (7) (7 used) from body (6).
1
7. Remove dust seal (10), backup ring (9) and O-
ring (8) from body (6).
6
W506-03-03-002
IMPORTANT: Take care not to damage the seal

sliding surface of spindle (11), when
removing spindle (8). When laying
spindle (8) horizontally on the
ground, take extra care not to dam-
age or contaminate the spindle sur-
faces with rough materials such as
sand. Put alignment marks on body
(6) and spindle (11).
5. Screw ST 1995 to remove spindle (11) from body
(6).
: 13
W3-3-5
ASSEMBLE CENTER JOINT
5 2
4
6
8
9
10
11
W555-03-03-002
12 13
1- Bolt (4 Used) 5 - Thrust Washer 8 - O-Ring 11 - Spindle

2- Cover 6 - Body 9 - Backup Ring 12 - Plug (4 Used)
3- Retaining Ring 7 - Oil Seal (7 Used) 10 - Dust Seal 13 - Plug (3 Used)
4- O-ring
W3-3-6
Assemble Center Joint
AND ASSEMBLING (W1-1-1) carefully before as-
sembling.
IMPORTANT: Before installing various seals into

the seating grooves, coat the seals
with grease or hydraulic oil. After
installing O-ring (8), dust seal (10),
and oil seals (7), coat the lips of
them with grease.
1. Install O-ring (8), backup ring (9), dust seal (10)

and oil seals (7) (7 used) onto body (6).
IMPORTANT: Align the alignment marks when in-

stalling body (6). If body (6) is rap-
idly pushed downward, the seal may
be damaged. Install body (6) onto
spindle (11) while pushing and turn-
ing body (6) slowly.
2. Place spindle (11) on a work bench, then install

body (6) onto spindle (11).
3. Install body (6) until body (6) comes into contact

with spindle (11) flange while tapping the outside
of body (6) with a plastic hammer.
4. Install thrust washer (5) and O-ring (4) onto body

(6).
IMPORTANT: Install retaining ring (3) with the

chamfered side facing cover (2).
Confirm that retaining ring (3) is cor-
rectly seated.
5. Install retaining ring (3) onto spindle (11).
6. Secure cover (2) to body (6) with bolts (1) (4

used).
: 13 mm
: 10.8 N m (1.1 kgf m, 8.0 lbf ft)
W3-3-7
Blank
W3-3-8
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK ADJUSTER
Before removing or installing the track adjuster, the

rubber crawler and front idler must be removed or
installed beforehand. Refer to the corresponding
sections for the removal and installation of the rubber
crawler and front idler
The procedures described below start after the rubber
crawler and front idler are removed.
Removal
CAUTION: Truck adjuster weight:

14 kg (30 lb)
1. After removing the front idler assembly, remove

track adjuster (1) from the track frame.
2
Installation W507-03-04-001
IMPORTANT: Make sure that the track adjuster (1)

is not hung on spring guide (3) on
track frame (2) and correctly seated
on the plate (4).
1. Insert track adjuster (1) into track frame (2) as

illustrated.
W507-03-04-001
3 3
W507-03-04-003
W507-03-04-002
W3-4-1
DISASSEMBLE TRACK ADJUSTER
1 2
3
5
6
7
10
16
15 13
12
11
14
W1LD-03-04-001
1- Socket Bolt (3 Used) 5- Wear Ring 9- Cylinder 13 - Plug

2- Dust Seal 6- U-Ring 10 - O-Ring 14 - Washer
3- Flange 7- Retaining Ring 11 - Valve 15 - Spring
4- Piston Rod 8- Rod 12 - Nut 16 - Spacer
W3-4-2
Disassemble Track Adjuster
Be sure to read Precautions for Disassembly and CAUTION: Track adjuster weight:
Assembly thoroughly on page W1-1-1 before 14 kg (31 lb)
starting any repair work. 3. Attach the wire rope to the track adjuster. Lift the
track adjuster by crane and put the track adjuster
on cradle of special tool.
CAUTION: Special tool weight: 161 kg
(350 lb)
Track Adjuster
CAUTION: Be sure to use special tool (ST

4943) for assembly / disassembly of the track
adjuster.
The spring force is extremely large, so
disassembly and assembly work must be
carried out carefully. It is necessary to
Cradle of
inspect the special tool for any damage Special tool
thoroughly to ensure safety.
1. Place an oil jack (30 ton) between the cradle and
the base of special tool (ST 4943).
W 105-03-04-009
Nut
CAUTION: Plate (ST 4140) weight: 36 kg
(79 lb)
4. Install plate (ST 4140) onto special tool (ST 4943)
so that plate (ST 4140) overlies the track adjuster.
Cradle
Remove valve (11) from rod (8).
Oil Jack
Plate
(ST 4140)
Base
W 105-03-04-006
Track
Adjuster

(79 lb) (ST 4943)
2. Loosen the nuts (4 used) to remove plate (ST
4140).
: 46 mm W105-03-04-011
5. Operate the oil jack to jack up the cradle by the

specified amount 82.1 mm (3.2 in)
Plate (ST 4140)
NOTE: 82.1 mm=(Free length: 305.1 mm)-(Set
length 223 mm)
Cradle
Oil Jack
W 105-03-04-007
W 105-03-04-013
W3-4-3
15 13
12
11
14
W1LD-03-04-001
W3-4-4
6. Tighten the nuts onto plate (ST 4140) to secure
the track adjuster. CAUTION: Plate (ST 4140) weight:
Operate the oil jack to compress the track 36 kg (79 lb)
adjuster approximately 10 mm (0.4 in) until a When removing the nut and plate (ST 4140),
clearance is observed between washer (14) and be sure to remove it after loosening the oil
nut (12). jack. Not loosening the oil jack poses a
: 46 mm danger of washer (14) and spring (15) flying
off under the reaction of the spring.
8. Lower the oil jack to release the spring force.
Loosen the nuts to remove plate (ST 4140).
Remove washer (14) from rod (8).
Nut
Plate (ST4140)
Plate
(ST 4140)
14
W 105-03-04-012
15
7. Remove plug (13) from nut (12). Remove the nut

(12) from rod (8).
: 5 mm
: 46 mm W 105-03-04-016
CAUTION: Spring assembly weight:

13 kg (28.5 lb)
12 8 13 9. Install eyebolt (M14, pitch 1.5) to the rod (8). Lift

and remove the spring (15) assembly from the
special tool by crane.
Eyebolt
15
W 105-03-04-014
W 105-03-04-017
CAUTION: Spring weight: 7 kg (15.5 lb)

10. Remove spring (15) from rod (8) after removing
the eyebolt.
W3-4-5
1 2
3
5
6
7
10
16
W1LD-03-04-001
W3-4-6
11. Remove spacer (16) from rod (8).
12. Remove socket bolts (1) (3 used) from cylinder

(9) to remove flange (3) and dust seal (2).
: 6 mm
13. Remove piston rod (4) from cylinder (9).
14. Remove retaining ring (7), U-ring (6) and wear

ring (5) from piston rod (4).
15. Remove rod (8) and O-ring (10) from cylinder (9).
W3-4-7
ASSEMBLE TRACK ADJUSTER
4 5 6 7 9 10 14
1 3
12 13 8 11
W1LD-03-04-002
A 15 B 16
1- Socket Bolt (3 Used) 5- Wear Ring 9- Cylinder 13 - Plug

2- Dust Seal 6- U-Ring 10 - O-Ring 14 - Washer
3- Flange 7- Retaining Ring 11 - Valve 15 - Spring
4- Piston Rod 8- Rod 12 - Nut 16 - Spacer
W3-4-8
Assemble Track Adjuster
CAUTION: Spring assembly weight:
13 kg (28.5 lb)
Be sure to read Precautions for Disassembly and 6. Install spring (15) onto cylinder (9). Install eyebolt
Assembly thoroughly on page W1-1-1 before (M14, pitch 1.5) to the cylinder. Lift the spring
starting any repair work. assembly by crane. Then set them on special tool
(ST 4943).
1. Install O-ring (10) and rod (8) into cylinder (9). Eyebolt
9
IMPORTANT: Install U-ring (6) with the lip facing
retaining ring (7).
Apply the hydraulic oil to wear ring
(5) and the U-ring (6).
2. Install wear ring (5), U-ring (6) and retaining ring
(7) onto piston rod (4). ST 4943
IMPORTANT: Fill chamber (B) in cylinder (9) with

grease. Insert piston rod (4) into the
cylinder to completely bleed air 15
remaining in the cylinder.
3. Apply grease onto piston rod (4) assembly, and
insert it into cylinder (9).
IMPORTANT: Fill groove (A) on flange (3) with W105-03-04-017
7. Install washer (14) onto rod (8).

grease.
4. Install dust seal (2) into flange (3). Secure the
flange assembly to cylinder (9) with socket bolts
(1) (3 used).
(79 lb)
: 6 mm
8. Lift and Install plate (ST 4140) onto the spring.
: 29.5 N m (3 kgf m, 21.5 lbf ft)
Tighten the nuts of the special tool to secure the
spring assembly.
5. Install spacer (16) onto rod (8). : 46 mm
Plate
(ST 4140)
Nut
ST 4943
W 105-03-04-012
W3-4-9
12 13 8 11
W1LD-03-04-002
15
W3-4-10
9. Operate the oil jack to compress spring (15) until
the specified length (223 mm) (8.8 in) is obtained. CAUTION: Track adjuster weight:
14 kg (30 lb)
12. Attach the wire rope to the track adjuster. Lift the
track adjuster by crane and remove them from the
special tool.
15
Track Adjuster
Oil Jack
Special Tool
W 105-03-04-026
10. Install nut (12) and valve (11) to rod (8). Install
plug (13) to the nut. W105-03-04-009
: 46 mm
: 5 mm
: 14.5 N m (1.5 kgf m, 10.5 lbf ft) CAUTION: Special tool (ST 4944) weight:
: 19 mm 64 kg (141 lb)
: 88 N m (9 kgf m, 65 lbf ft) IMPORTANT: If only the track adjuster is to be
transported, be sure to use special
12 8 13 tool (ST 4944) to avoid personal
injury.
: 30 mm
Track Adjuster
W 105-03-04-014
CAUTION: Plate (ST 4140) weight:

36 kg (79 lb)
11. Lower the oil jack to remove the nuts and plate Special Tool
W 105-03-04-028
(ST 4140). (ST 4944)

: 46 mm
Plate (ST 4140)
W105-03-04-011
W3-4-11
(Blank)
W3-4-12
UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER
Before removing or installing the front idler, the rubber

crawler must be removed or installed beforehand.
Refer to "REMOVE AND INSTALL RUBBER
CRAWLER".
The procedures described below start after the rubber
crawler is removed.
Removal
CAUTION: Front idler weight: 41 kg (90 lb)

The front idler may fly out due to the strong
spring force from the track adjuster spring
when removing it. Give yourself ample clear-
ance, staying clear of the front idlers line. W507-03-05-001
1. Remove the idler assembly from the track frame. Idler Assembly
Remove the front idler and yoke assembly from Track Frame
the track frame using a crowbar.
CAUTION: When storing the front idler, lay

the front idler on wooden blocks to keep bal-
ance.
W562-03-05-001
Installation
1. To install the front idler, simply perform the re-

moval procedures in reverse. Take care on follow-
ing points:
Apply grease to the sliding surfaces of the track

frame and bearing after cleaning them.
Sliding
Surfaces
Track
Frame
W507-03-04-003
W3-5-1
DISASSEMBLE AND ASSEMBLE FRONT
IDLER
4 5
6 7
2
8
1
9 W1LD-03-05-001
1 - Axle 4 - Bushing (2 Used) 6 - Yoke (2 Used) 8 - Bolt (4 Used)

2 - Floating Seal (2 Used) 5 - O-Ring (2 Used) 7 - Plate 9 - Spring Pin (2 Used)
3 - Idler
W3-5-2
Disassemble Front Idler Assemble Front Idler
Be sure to read Precautions for Disassembly and Be sure to read Precautions for Disassembly and
Assembly thoroughly on page W1-1-1 before Assembly thoroughly on page W1-1-1 before
starting any repair work. starting any repair work.
1. Remove bolts (8) (4 used) to remove plate (7) 1. Install bushings (4) (2 used) into idler (3) with a
from yoke (6) (2 used). press.
: 19 mm
2. Install axle (1) into idler (3).
2. Remove spring pin (9) (2 used) from yoke (6) (2
used). 3. Install O-ring (5) (2 used) onto axle (1).
8 mm
IMPORTANT: For handling of floating seal (2), re-
IMPORTANT: For handling of floating seal (2), refer to the section Floating Seal Pre-
fer to the section Floating Seal Pre- cautions on page W1-1-4.
cautions on page W1-1-4. 4. Install floating seal (2) (2 used) and yoke (6) (2
3. Remove yoke (6) (2 used) and floating seals (2) used) into idler (3).
(2 used) from idler (3).
5. Tap spring pin (9) (2 used) into yoke (6) (2 used).
4. Remove O-ring (5) (2 used) from axle (1).
6. Secure plate (7) to yoke (6) (2 used) with bolts (8)
5. Remove axle (1) from idler (3). (4 used).
: 19 mm
IMPORTANT: Do not remove bushings (4) (2 used) : 88 N m (9 kgf m, 65 lbf ft)
unless necessary.
6. When replacing bushing (4) (2 used), build-up
weld at 4 places in its inner diameter with welding
rod, shrink bushing (4) to pull it out.
90
90
W105-03-05-012
W3-5-3
MAINTENANCE STANDARD
C D F
A
B
W503-03-05-001
Unit: mm (in)
Standard Allowable Limit Remedy
A 53 (2.1)
B 92 (3.6)
C 44 (1.7) Build-up weld
D 300 (11.8) and finishing
E 10 (0.4)
F 344 (13.5)
Axle and Bushing Unit: mm (in)
Axle Outside Dia. 40 (1.6)
Inside Dia. 40 (1.6) Replace

Bushing
Flange Thickness 2 (0.08)
NOTE: Lubrication Oil

Engine Oil Grade: API Class CD, SAE30
3
Oil Capacity: 60 cm (0.063 US qt)
W3-5-4
UNDERCARRIAGE / Upper and Lower Roller
REMOVE AND INSTALL UPPER ROLLER
Removal
1
CAUTION: Grease pressure in the track ad-

juster is high. Do not loosen valve (1) quickly
or loosen it too much. Valve (1) may fly out or
high pressure grease in the track adjuster
may spout out. Loosen carefully, keeping
body parts and face away from valve (1).
Never loosen grease fitting (2). W105-03-07-002
1 2
IMPORTANT: Clean off gravel or mud packed
between the sprockets and tracks
before loosening valve (1).
Its enough to turn valve (1) by only
one turn. Do not loosen it over one
turn.
Grease Outlet
W1F1-03-07-001
1. Slowly loosen track adjuster valve (1) to loosen

the track tension.
: 19 mm
IMPORTANT: Place pads between track frame (3)

and oil jack (4) when jacking up to
prevent the jack from slipping.
2. Jack up track (6) until the clearance between

track (6) and upper roller (5) is wide enough to
remove upper roller (5). Then place wooden
blocks on track frame (3) to support track (6).
W507-03-06-001
6 Wooden Blocks 5 7
3. Loosen bolt (7) and remove upper roller (5). 3
: 22 mm
W507-03-06-003
W3-6-1
Installation
1. Install upper roller (5) onto track frame (3) with
6 Wooden Blocks 5 7
bolt (7). 3
: 22 mm
: 137 N m (14 kgf m, 101 lbf ft)
2. Remove wooden blocks.
4
3. Lower oil jack (4) to lower the track (6).
Remove oil jack (4).
W507-03-06-003
4. Tighten track adjuster valve (1).

: 19 mm
: 88 N m (9 kgf m, 65 lbf ft)
2
CAUTION: Securely support the raised ma-

chine with wooden blocks.
5. Jack up the track at the side being adjusted and
rotate slightly in reverse direction.
6. Supply grease via grease fitting (2) to adjust the

track tension.
Track sag specifications (A):

10 to 15 mm (0.4 to 0.6 in) (Rubber Cralwer)
Roller W507-03-06-005
Rubber Cralwer
M503-05-050 90 110º
7. Jack up the one side track using the front attach-

ment and remove wooden blocks.
M570-07-001
W3-6-2
REMOVE AND INSTALL LOWER ROLLER
Removal
CAUTION: Support the raised track securely

using wooden blocks.
1. Raise the one side track off the ground using the
90 110º
front attachment. Then place a block under track
frame to support the machine.
M570-07-001
CAUTION: Grease pressure in the track ad-

juster is high. Do not loosen valve (1) quickly 1
or loosen it too much. Valve (1) may fly out or
high pressure grease in the track adjuster
may spout. Loosen carefully, keeping body
parts and face well away from valve (1).
Never loosen grease fitting (2).
IMPORTANT: Clean off gravel or mud packed W105-03-07-002

before loosening valve (1). 1 2
turn.
2. Loosen track adjuster valve (1) slowly to let
grease flow out until the clearance between the
track frame and crawler is wide enough to remove
lower roller (3). Grease Outlet
: 19 mm
W1F1-03-07-001
3. Loosen bolt (4) and remove lower roller (3).
: 27 mm
1
3
4
W507-03-06-005
W3-6-3
Installation
1 2
CAUTION: Securely support the raised ma-
chine with wooden blocks.
1. Install lower roller (3) to the underside of the track 3
frame, aligning the bolt holes. 4
2. Apply LOCTITE #262 to bolt (4) threads and

tighten to specifications.
: 27 mm
: 450 N m (46 kgf m, 330 lbf ft)
W507-03-06-005
3. Tighten track adjuster valve (1). 1

: 19 mm
: 88 N m (9 kgf m, 65 lbf ft)
4. Rotate slightly in reverse direction the track at the

side being adjusted.
5. Supply grease via grease fitting (2) to adjust the

track tension.
W105-03-07-002
Track sag specifications (A):

10 to 15 mm (0.4 to 0.6 in ) (Rubber Cralwer) 1 2
Roller
A Grease Outlet
W1F1-03-07-001
Rubber Crawler
M503-05-050
6. Jack up the one side track using the front attach-

ment and remove wooden blocks.
90 110º
M570-07-001
W3-6-4
(Blank)
W3-6-5
DISASSENBLE AND ASEMBLE LOWER
ROLLER
1 2 3 4 5 6 7
10
W577-03-06-001
1 - Floating Seal 4 - Axle 7 - O-Ring 9 - Stopper Ring

2 - Roller 5 - Floating Seal 8 - Plug 10 - Collar
3 - Busing (2 Used) 6 - Collar
W3-6-6
Disassemble Lower Roller Assemble Lower Roller
Be sure to read Precautions for Disassembly and Be sure to read Precautions for Disassembly and
Assembly thoroughly on page W1-1-1 before Assembly thoroughly on page W1-1-1 before
starting any repair work. starting any repair work.
1. Remove plug (8) from collar (6) to drain engine oil IMPORTANT: For handling of floating seal (1) and
from the roller. (5), refer to the section Precautions
: 4 mm for Floating Seal Handling on page
W1-1-4.
IMPORTANT: Axle (4) and collar (10) unable to be 1. Install floating seal (1) to roller (2) and collar (10).
disassembled. In case the axle must Press axle (4) with collar (10) into roller (2).
be replaced, replace axle (4) assem-
bly. 2. Install floating seal (5) to roller (2) and collar (6).
2. Remove stopper ring (9) from collar (6). Push out NOTE: When disassembling, O-ring (7) may be
axle (4) assembly from the collar (6) side in roller damaged. Replace it with the new one.
(2) with a press.
3. Install O-ring (7) to axle (4).
IMPORTANT: For handling of floating seal (1) and Aligning the grooves on axle (4) and collar (6) for
(5), refer to the section Precautions stopper ring (9), install collar (6) and stopper ring
for Floating Seal Handling on page (9) onto axle (4).
W1-1-4.
IMPORTANT: Apply LOCTITE #503 onto plug (8).
3. Remove collar (6) from roller (2). Remove floating 4. Refill engine oil (SAE #30, API class CD) (45 cm3
seal (1) and (5) from both sides of roller (2). (0.047 US qt)) through the plug hole on collar (6).
Install plug (8) to the collar.
4. Remove O-ring (7) from axle (4). : 4 mm
: 9.8 N m (1 kgf m, 7.2 lbf ft)
IMPORTANT: Do not remove bushings (3) (2 used)
from roller (2). In case the bushing
must be replaced, replace the roller
(2) assembly.
W3-6-7
Upper Roller
W566-03-06-001
Unit: mm

A 110 (4.33) -
Replace
B 80 (3.15) -
IMPORTANT: Do not disassemble the upper roller.

Replace it as an assembly.
Lubrication oil: Engine oil API CD Class SAE30
Quantity: 60 mL (0.016 US gal)
W3-6-8
Lower Roller
C D E
B
W577-03-06-001
Unit: mm (in)
A 53 (2.09) -
B 142 (5.59) -
Build-up weld
C 39 (1.54) - and finishing or
D 95 (3.74) - replace
E 122 (4.80) -
Unit: mm (in)
Axle and Bushing

Outside
Axle 35 (1.39) -
Dia
Inside
35 (1.39) - Replace
Dia
Bushing
Flange
2 (0.08) -
Thickness
Lubrication Oil
Engine Oil Grade: API Class CD, SAE30
3
Oil Capacity: 45 cm (0.048 US qt)
W3-6-9
(Blank)
W3-6-10
UNDERCARRIAGE / Track
REMOVE AND INSTALL RUBBER CRAWLER
Removal
1 2
CAUTION: Grease pressure in the track

adjuster is high. Do not loosen valve (1)
quickly or loosen it too much. Valve (1) may
fly out or high pressure grease in the track
adjuster may spout. Loosen carefully,
keeping body parts and face well away from
Grease Outlet
valve (1). Never loosen grease fitting (2).
If the rod and/or the threads are damaged,
metal fragments may fly off when track
W1F1-03-07-001
adjuster is removed. Take necessary

precautions to prevent any personal injury
from occurring.
1. Operate the boom and arm so shat the angle
between them is 90° to 110°, Lower the boom
with the bucket rolled-in to jack up the machine.
Then place a block under track frame to support
the machine. 90 110º
M570-07-001
IMPORTANT: Clean off gravel or mud packed

before loosening valve (1).
turn.
1
2. Slowly loosen track adjuster valve (1) to allow
grease to escape.
: 19 mm
W 190-03-06-001
Rotate Direction
3. Insert steel pipes into the gaps between the

rubber crawler and track frame.
Then, rotate the sprocket in reverse direction.
After the rubber crawler is raised off the front idler
with the steel pipes, slide the rubber track away Steel pipe
from the track frame and remove it. M503-07-062
W3-7-1
Installation
CAUTION: Support the raised track securely

using wooden blocks.
1. Using the front attachment, raise the one side

track of the machine off the ground, and place
wooden blocks under the track frame to securely
90 110º
support the machine.
2. Reinstall the rubber crawler on the sprocket and

hang the other end of the rubber track over the
front idler.
M570-07-001
Rotate the sprocket in the reverse direction to
sufficiently remesh the rubber crawler back onto
the sprocket.
Rotate Direction
IMPORTANT: Check that the rubber crawler is
securely engaged onto both the
sprocket and front idler.
3. After inserting a steel pipe into the gap between

the rubber crawler and track frame, rotate the Steel pipe
sprocket again. Then, completely install the M503-07-063
2
rubber track onto the front idler.
4. Tighten the track adjuster valve (1). Add grease

into the adjuster cylinder via the grease fitting to
adjust track sag.
Track Sag Specification (A)

Rubber Crawler: 10 to 15 mm (0.4 to 0.6 in)
NOTE: With the joint section of the rubber track W 507-03-06-005

placed just under the lower roller, measure
track sag at the lower center roller as
illustrated.
Roller
Joint
Track (Rubber Crawler)

M503-05-050
Joint M102-07-070
M102-07-075
W3-7-2
Outside of Rubber Crawler

1. If there is a crack on lug base (1) with depth of 6
mm (0.2 in) or more, repair crawler. 1
4
If there is a crack between lugs (2) with depth of 6
mm (0.2 in) or more, repair crawler. 5
2
If there is a crack on rugs (3) or between lugs (2)
that reaches to steel code (5) or steel core (4)
with length of 30 mm (1.2 in) or more,
immediately repair crawler. 3
2. Inside of Rubber Crawler (Roller Side)

If there is a crack that reaches to steel code (5) or
steel core (4), immediately repair crawler.
W190-03-07-001
5 W190-03-07-002
Lower Roller
Lug Wear
1. If the lug height (A) is less than 5 mm, replace the Rubber Track
rubber crawler as an assembly.
Lug W190-03-07-003
2. If any portion of steel code (5) appeared on

crawler, replace worn rubber crawler as an
assembly.
5
W190-03-07-004
W3-7-3
Rubber Crawler and Steel Cord Cutting
1. When either of the two rows of the steel cord (5)
has cut, replace rubber crawler as an assembly.
5
W190-03-07-005
Steel Core Separation

1. When any steel core (4) has separated, replace
rubber crawler as an assembly.
W190-03-07-006
W3-7-4
SECTION 4
FRONT ATTACHMENT
CONTENTS
Group 1 Front Attachment
Remove and Install Front Attachment...... W4-1-1
Maintenance Standards........................... W4-1-6
Group 2 Cylinder
Remove and Install Cylinders .................. W4-2-1
Disassemble Boom Cylinder.................... W4-2-8
Assemble Boom Cylinder ...................... W4-2-12
Disassemble Arm Cylinder .................... W4-2-16
Assemble Arm Cylinder ......................... W4-2-20
Disassemble Bucket Cylinder ................ W4-2-26
Assemble Bucket Cylinder..................... W4-2-30
Disassemble Boom Swing Cylinder
and Blade Cylinder .............................. W4-2-34
Assemble Boom Swing Cylinder
and Blade Cylinder .............................. W4-2-38
Maintenance Standards......................... W4-2-44
1LDW-4-1
Blank
1LDW-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT ATTACH-
MENT
Removal
1. Park the machine on a solid level surface. Fully
retract the bucket and arm cylinder and lower the
bucket onto the ground. Lay wooden block under
the arm tip.
2. Loosen bolt (5) to remove cover (3). W1LD-04-01-003
: 19 mm
CAUTION: Boom cylinder weight:

1
51 kg (112 lb) (ZX40U)
55 kg (121 lb) (ZX50U)
2
IMPORTANT: As for the handling of the nylon

slings, refer to Precautions for the
Handling of Nylon Slings on page
W1-1-5.
3. Connect boom cylinder (2) to a crane with sling
belts. Remove bolt (1) and pin (4) while slightly
lifting the boom cylinder.
: 22 mm
5 4 3
W1LD-04-01-002
4. Start the engine, slightly operate the boom lever

to retract boom cylinder (2).
5. Place the boom cylinder (2) on a bench. Use a

wire to secure the boom cylinder rod as illus-
trated.
Stop the engine.
2
NOTE: Bench Height: 700 mm (28 in) or more.
6. Remove boom cylinder.

Refer to Remove Boom Cylinder (W4-2-5). Wire
W554-02-03-007
W4-1-1
7. Loosen bolt (7) (2 used) to remove cover (6).
: 13 mm
8. Disconnect all hoses. Cap each disconnected

hose end. 6
: 22 mm, 27 mm
W1LD-04-01-001
9. Loosen nut (10) (2 used) for stopper bolt (8) on

boom foot pin (9), then remove stopper bolt (8).
: 22 mm
CAUTION: Front attachment weight:

490 kg (1080 lb) (ZX40U)
W527-04-01-004
513 kg (1130 lb) (ZX50U) 10 9
10. Attach a wire rope around the boom at the boom
foot side as in illustration. Take up slack of the
wire rope.
W1LD-04-01-004
W4-1-2
11. Remove boom foot pin (9).
9 W527-04-01-004
12. After hoisting the front attachment, move the ma-

chine backward. Place the front attachment on
wooden blocks.
W1LD-04-01-005
W4-1-3
Installation
CAUTION: Front attachment weight:

490 kg (1080 lb) (ZX40U)
513 kg (1130 lb) (ZX50U)
1. Attach a wire rope around the boom.
Lift the boom to the boom foot pin pinhole position
by crane. Move the machine forward.
W1LD-04-01-005
2. Drive in boom foot pin (9) while aligning the boom

foot with the pin holes on the frame bracket.
IMPORTANT: Apply LOCKTITE #262 to nuts (10 (2

used), and adjust the clearance be-
tween the frame and nut within 2 to
3 mm, when tightening the nuts. 8
3. Install stopper bolt (8) into boom foot pin (9).
Tighten stopper bolt (8) with nut (10) (2 used).
: 22 mm
: 137 N m (14 kgf m, 101 lbt ft)
4. Uncap the ends of hoses routed on the machine. 10 9 W527-04-01-004

Connect all hoses.
: 22 mm
: 39 N m (4 kgf m, 29 lbt ft)
: 27 mm
: 64 N m (6.5 kgf m, 47, lbt ft)
5. Install cover (6) with bolts (7) (2 used).

6
: 13 mm
: 19.5 N m (2 kgf m, 14.5 lbt ft)
W1LD-04-01-001
W4-1-4

51 kg (112 lb) (ZX40U)
55 kg (121 lb) (ZX50U)
6. Install boom cylinder.
Refer to Install Boom Cylinder (W4-2-6).
IMPORTANT: After filling hydraulic oil to specified

level, start the engine, check the
connections for any oil leakage.
IMPORTANT: After all work is completed, run each

cylinder several times to stroke end
to bleed air from the circuit.
W4-1-5
Pin Bushing
M N
H A
C
B
E D P
I K Q
J
O
G
H
W571-04-01-004
W533-04-01-002
Unit: mm (in)
Key Letter Part Name Standard Allowable Limit Remedy

Pin 50 (1.97) 49.0 (1.93)
A
Bushing (Boom) 50 (1.97) 51.5 (2.03)
Pin 50 (1.97) 49.0 (1.93)
B
Bushing (Boom Cylinder) 50 (1.97) 51.5 (2.03)
Pin 50 (1.97) 49.0 (1.93)
C
Bushing (Boom Cylinder) 50 (1.97) 51.5 (2.03)
Pin 50 (1.97) 49.0 (1.93)
D Replace
Bushing (Arm) 50 (1.97) 51.5 (2.03)
Pin 45 (1.77) 44.0 (1.73)
E
Bushing (Arm Cylinder) 45 (1.77) 46.5 (1.83)
Pin 45 (1.77) 44.0 (1.73)
F
Bushing (Arm Cylinder) 45 (1.77) 46.5 (1.83)
Pin 45 (1.77) 44.0 (1.73)
G
Bushing (Bucket Cylinder) 45 (1.77) 46.5 (1.83)
W4-1-6
Unit: mm (in)
Key Letter Part Name Standard Allowable Limit Remedy

Pin 45 (1.77) 44.0 (1.73)
Bushing (Bucket Cylinder) 45 (1.77) 46.5 (1.83)
H
Bushing (Link A) 45 (1.77) 46.5 (1.83)
Bushing (Link B) 45 (1.77) 46.5 (1.83)
Pin 45 (1.77) 44.0 (1.73)
I Bushing (Arm) 45 (1.77) 46.5 (1.83)
Link B 45 (1.77) 46.5 (1.83)
Pin 45 (1.77) 44.0 (1.73)
J
Bushing (Link A) 45 (1.77) 46.5 (1.83)
Pin 45 (1.77) 44.0 (1.73)
K
Bushing (Arm) 45 (1.77) 46.5 (1.83)
Pin 90 (3.54) 89.0 (3.50)
L
Bushing (Main Frame) 90 (3.54) 91.5 (3.60) Replace
Pin 50 (1.97) 49.0 (1.93)
M Bushing
50 (1.97) 51.5 (2.03)
(Boom Swing Cylinder)
Pin 50 (1.97) 49.0 (1.93)
N Bushing
50 (1.97) 51.5 (2.03)
(Boom Swing Cylinder)
Pin 45 (1.77) 44.0 (1.73)
O
Bushing (Blade) 45 (1.77) 46.5 (1.83)
Pin 55 (2.17) 54.0 (2.13)
P
Bushing (Blade Cylinder) 55 (2.17) 56.5 (2.22)
Pin 55 (2.17) 54.0 (2.13)
Q
Bushing (Blade Cylinder) 55 (2.17) 56.5 (2.22)
W4-1-7
Side Cutter
D
A
W505-04-01-001
Unit: mm (in)

A 127 (5.00) 85 (3.35)
B 163 (6.42) -
Replace
C 223 (8.78) -
D 130 (5.12) -
Point
B C
W554-04-01-003
Unit: mm (in)

A 128 (5.04) 65 (2.56)
B 56 (2.21) -
Replace
C 62 (2.44) -
D 51 (2.01) -
W4-1-8
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER
Remove Bucket Cylinder

1
1. Lay wooden blocks (3) under the arm (2) tip and
in the clearance between the arm (2) top surface 3
and bucket cylinder (1).
2
3
IMPORTANT: Secure the link using a wire to W554-04-02-006
prevent the link from falling before

4 5
removing pin (7).
2. Remove ring (4) and stopper pin (6) from the link,
then remove pin (7).
3. Secure cylinder rod (5) using a wire to prevent 6

rod (5) from extending.
Link
Link W527-04-02-002
CAUTION: Bucket cylinder weight:

28 kg (62 lb) (ZX40U)
33 kg (73 lb) (ZX50U) 1
4. Attach bucket cylinder (1) to crane using sling belt
and hold it.
5. Remove bolt (9). Remove pin (8) to remove

cylinder (1).
: 22 mm
W571-04-02-002
6. Disconnect hoses (10) (2 used) from bucket

cylinder (1) at the cylinder bottom. Close all 9
8
openings with cap. 1
: 22 mm
7. Lift and remove bucket cylinder (1) by crane.
10
W571-04-02-003
W4-2-1
Install Bucket Cylinder
CAUTION: Bucket cylinder weight: 9

28 kg (62 lb) (ZX40U) 1 8
33 kg (73 lb) (ZX50U)
1. Lift bucket cylinder (1) by crane. Connect hoses
(10) (2 used) to bucket cylinder (1).
: 22 mm
: 39 N m (4 kgf m, 29 lbf ft)
2. Align the pin holes on cylinder (1) tube and arm.

Insert pin (8), and secure it with bolt (9).
: 22 mm
: 137 N m (14 kgf m, 101 lbf ft) 10
W571-04-02-003
3. Start the engine, and extend bucket cylinder rod
(5). Align the rod hole of bucket cylinder rod (5)
7
with the link hole, then insert pin (7).
5
4. Insert stopper pin (6) into link and pin (7) to install
ring (4). W507-04-02-004
4
IMPORTANT: After installation, bleed air from the
hydraulic system by moving the
bucket cylinder full stroke several
times.
Link
W527-04-02-002
Link
W4-2-2
Remove Arm Cylinder
4 5 1
1. Insert a wooden block (3) between arm cylinder
(1) and boom (2).
2. Remove bolt (4), then remove pin (5).

: 22 mm
3. Secure the cylinder rod with a wire to prevent the

rod from extending.
4. Disconnect cylinder hoses (6) (2 used) from arm 3 2

W571-04-02-004
cylinder (1), and close all openings with cap.
: 27 mm
1
CAUTION: Arm cylinder weight:

41 kg (90 lb) (ZX40U)
42 kg (93 lb) (ZX50U)
5. Attach a sling belt onto arm cylinder (1), and hold
it by crane. 6
W527-04-02-006
W571-04-02-006
6. Remove bolt (7), then remove pin (8).

: 22 mm 1
7. Lift and remove arm cylinder (1) by crane.
8 7 W527-04-02-008
W4-2-3
Install Arm Cylinder
CAUTION: Arm cylinder weight: 1

41 kg (90 lb) (ZX40U)
42 kg (93 lb) (ZX50U)
1. Lift arm cylinder (1) by crane. Align the pin holes
on the cylinder tube side and arm.
2. Insert pin (8) and secure it with bolt (7).

: 22 mm
: 137 N m (14 kgf m, 101 lbf ft) 7
8
3. Connect hoses (6) (2 used) to arm cylinder (1). W527-04-02-008
: 27 mm
: 64 N m (6.5 kgf m, 47 lbf ft) 1
6
W527-04-02-006
4. Start the engine and extend arm cylinder (1) so

that the rod hole on arm cylinder (1) is aligned 1
with the hole on the arm. 4 5

: 22 mm
: 137 N m (14 kgf m, 101 lbf ft)
IMPORTANT: After installation, bleed air from the

bucket cylinder full stroke several
times.
3 2
W571-04-02-004
W4-2-4
Remove Boom Cylinder
1. Loosen bolt (5) to remove cover (3). 1

: 19 mm
2
2. Attach a sling belt to boom cylinder (2). While

holding boom cylinder (2) by crane, remove bolt
(1) and pin (4).
: 22 mm
CAUTION: Boom cylinder weight: 5 4

3
51 kg (112 lb) (ZX40U) W1LD-04-01-002
55 kg (121 lb) (ZX50U)
3. Place a support under the end of boom cylinder
(2) tube. Operate the boom control lever to fully
retract the rod. Thread a piece of wire through the
rod hole, and tie it to the boom cylinder (2) tube to
2
prevent the cylinder rod from extending.
Wire
4. Disconnect hose (6) (2 used) from boom cylinder W554-02-03-007
(2). Close all openings with cap.

: 27 mm 6
5. Loosen nut (8) (2 used), and remove bolt (7). W1LD-04-02-001
Pull out pin (9). 2

: 22 mm
6. Lift and remove boom cylinder (2) by crane.
7
9
8 W1LD-04-02-002
W4-2-5
Install Boom Cylinder

51 kg (112 lb) (ZX40U)
55 kg (121 lb) (ZX50U)
1. Lift boom cylinder (2) by crane. Align the pin 2
holes on the cylinder tube side and swing post.
IMPORTANT: Apply LOCKTITE #262 to nuts (10) (2

used), and adjust the clearance
between the frame and nut within 2
to 3 mm, when tightening the nuts.
2. Insert pin (9) and secure it with bolt (7) and nut (8)
7
(2 used).
9
: 22 mm 8 W1LD-04-02-002
: 137 N m (14 kgf m, 101 lbf ft)
6
3. Connect hoses (6) (2 used) to boom cylinder (2).

: 27 mm 2
: 64 N m (6.5 kgf m, 47 lbf ft)
W1LD-04-02-001
4. Lift boom cylinder (2) by crane. Start engine and

1
extend boom cylinder (2) until mounting holes are
aligned.
2
: 22 mm
: 137 N m (14 kgf m, 101 lbf ft)
6. Install cover (3) onto boom cylinder with bolt (5).

: 19 mm
: 88 N m (9 kgf m, 65 lbf ft)
IMPORTANT: After installation, bleed air from the 5 4

3
boom cylinder full stroke several W1LD-04-01-002
times.
W4-2-6
(Blank)
W4-2-7
DISASSEMBLE BOOM CYLINDER
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
27 Clevis Part
W1LD-04-02-003
1- Piston Rod 8- Backup Ring 15 - Cushion Ring 22 - Steel Ball
2- Wiper Ring 9- U-Ring 16 - Spacer 23 - Set Screw
3- Cylinder Head 10 - Connector 17 - Stopper 24 - Seal Ring
4- O-Ring 11 - Stopper 18 - Cushion Bearing 25 - O-Ring
5- Backup Ring 12 - Retainer 19 - Shim 26 - Slide Ring
6- O-Ring 13 - Backup Ring 20 - Slide Ring 27 - Cylinder Tube
7- Bushing 14 - O-Ring 21 - Piston
W4-2-8
Disassemble Boom Cylinder 3. Loosen cylinder head (3) with a hook wrench and
pull piston rod (1) (with protective cover on it) out
Read PRECAUTIONS FOR DISASSEMBLING of cylinder tube (27).
AND ASSEMBLING (W1-1-1) carefully before Cylinder head (3) diameter: 105 mm (4.13 in)
disassembling.
Start the following procedures after disconnecting
Hook Wrench
the lines.

51 kg (112 lb) (ZX40U)
55 kg (121 lb) (ZX50U) 27
IMPORTANT: When draining off hydraulic oil from

the cylinder, piston rod (1) shall be
moved slowly in order to prevent the 3
oil from splashing.
1. Clamp the pin mounting part (clevis part) of
cylinder tube (27) and hold it horizontally in a vise Protective Cover
1
to drain hydraulic oil from the cylinder. W506-04-02-004
IMPORTANT: As set screw (23) head is

IMPORTANT: Be careful not to damage cylinder
mushroomed after being installed,
tube (27) when locking or unlocking
cut the mushroomed part with a
cylinder head.
hand drill before loosening set
2. Pull out piston rod (1) approximately 200 mm (7.9
screw (23).
in). Place a protective cover onto the piston rod,
4. Secure piston rod (1) horizontally. Remove set
extend the detent.
screw (23) and steel ball (22) from piston (21).
: 4 mm
Detent 5. Remove piston (21), shim (19) and cushion

bearing (18) from piston rod (1).
: 65 mm
6. Wrap piston rod (1) screw thread with protective

tape to protect wiper ring (2) of cylinder head (3)
and then remove cylinder head (3) from piston
rod (1).
1 3
IMPORTANT: Do not reuse slide rings (20) and (26).
W506-04-02-003
When disassembling boom cylinder,
replace them with new ones.
7. Clamp piston (21) and hold it horizontally in a vice
to remove slide ring (20) and (26) from piston
(21).
W4-2-9
25
24
21
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
W1LD-04-02-003
W4-2-10
IMPORTANT: Take care not to damage piston (21 IMPORTANT: Do not reuse bushing (7).
when removing seals. Replace it with new one when
8. Insert a screwdriver into the clearance between disassembling the cylinder.
piston (21) and seal ring (24). Raise seal ring (24) 14. Remove bushing (7) from the inside of cylinder
with screwdriver. Cut off seal ring (24) with cutting head (3) with a special tool.
pliers to remove seal ring (24) from piston (21). NOTE: As bushing (7) is installed into cylinder
Remove O-ring (25) in the same procedure. head (3) with a press, it can not be
removed with a hammer. After cutting off
the inner surface of bushing (7) with a lathe,
scrape off thinned bushing (7) from
21 cylinder head (3) with a special tool
24, 25 (copper spatula).
W506-04-02-007
9. Remove stopper (11), connector (10) and retainer

(12) from cylinder head (3).
10. Remove backup ring (13) and O-ring (14) from

the outside of retainer (12).
11. Remove stopper (17), spacer (16) and cushion

bearing (15) from the inside of retainer (12).
12. Remove wiper ring (2), U-ring (9) and backup ring
(8) from the inside of cylinder head (3).
13. Remove O-ring (4), backup ring (5) and O-ring (6)
from the outside of cylinder head (3).
W4-2-11
ASSEMBLE BOOM CYLINDER
3 4 7 5 6 13 14 27 18 19 21 20 26 23 22
W571-04-02-009
2 8 9 10 11 12 15 16 17 1 25 24
1- Piston Rod 8- Backup Ring 15 - Cushion Ring 22 - Steel Ball

2- Wiper Ring 9- U-Ring 16 - Spacer 23 - Set Screw
3- Cylinder Head 10 - Connector 17 - Stopper 24 - Seal Ring
4- O-Ring 11 - Stopper 18 - Cushion Bearing 25 - O-Ring
5- Backup Ring 12 - Retainer 19 - Shim 26 - Slide Ring
6- O-Ring 13 - Backup Ring 20 - Slide Ring 27 - Cylinder Tube
7- Bushing 14 - O-Ring 21 - Piston
W4-2-12
Assemble Boom Cylinder IMPORTANT: Take care of the mounting direction
Read PRECAUTIONS FOR DISASSEMBLING of U-ring (9).
AND ASSEMBLING (W1-1-1) carefully before 2. Install backup ring (8) and U-ring (9) to cylinder
assembling. head (3).
3

51 kg (112 lb) (ZX40U)
9
55 kg (121 lb) (ZX50U)
IMPORTANT: Apply hydraulic oil to the inner side
of cylinder head (3).
Press bushing (7) until the end of
bushing (7) is flush with the end
surface of cylinder head (3). If not
flushing, backup ring (8) will be
damaged when installing backup
ring (8). W1LD-04-02-004
3. Install wiper ring (2) to cylinder head (3) with

special tool (ST 8048).
7
3
ST 8048
Flush the
surface
3
W577-04-02-007
2
W506-04-02-012
1. Press bushing (7) into cylinder head (3) with 4. Install O-ring (4), backup ring (5) and O-ring (6) to
special tool (ST 7275). the outside of cylinder head (3).
5. Install cushion ring (15), spacer (16) and stopper

(17) to the inside of retainer (12).
ST 7275 Install O-ring (14) and backup ring (13) to the
outside of retainer (12).
7
3 6. Install retainer (12) assembly, connector (10) and
stopper (11) to cylinder head (3).
W506-04-02-010
W4-2-13
3 27 18 19 21 20 26 23 22
W571-04-02-009
1 25 24
W4-2-14
IMPORTANT: Make sure that o-ring (25) is not IMPORTANT: When the work of installing set
twisted after installing it. screw (23) is finished, crimp it at two
7. Install o-ring (25) to piston (21), and then install places with a punch in order to
seal ring (24) with special tool (ST 2594, ST2335) prevent it from loosening.
and (ST 2590, ST 2334). 12. Install steel ball (22) into piston (21) and then
install set screw (23) on it.
ST 2594(ZX40U)
ST 2335(ZX50U) : 4 mm
: 16.5 N m (1.7 kgf m, 12 lbf ft)
24
ST 2590(ZX40U) IMPORTANT: Take care not to let slide rings (20)
ST 2334(ZX50U) and (26) drop from piston (21) when
25 inserting the piston rod (1) assembly.
In addition, care should be taken not
to damage the piston rod assembly
21
and insert the piston rod assembly
straightly. Apply the hydraulic oil to
the packing parts.
W566-04-02-010 13. Lay cylinder tube (27) horizontally in a vise, and
insert the piston rod (1) assembly into the cylinder
IMPORTANT: Adjust seal ring (24). If not adjusting, tube.
piston (21) can not be installed to
cylinder tube (27). IMPORTANT: Apply the hydraulic oil to the
8. Adjust seal ring (24) with special tool (ST 2598, packing parts.
ST 2336). 14. Tighten cylinder head (3) to cylinder tube (27)
with a hook wrench. Bend the detent to prevent it
from loosening.
Cylinder head (3) diameter: 105 mm
: 360 N m (37 kgf m, 265 lbf ft)
24
Hook Wrench
ST 2598(ZX40U)
ST 2336(ZX50U)
W566-04-02-011
IMPORTANT: When installing slide ring (20) and

(26), do not align their split portion.
27
9. Install slide rings (20) and (26) to piston (21).
W506-04-02-019
10.Wrap the piston rod (1) screw thread with

protective tape and then install the cylinder head
(3) assembly to the piston rod while rotating the
former one.
IMPORTANT: Take care not to install cushion

bearing (18) in wrong direction.
11. Install cushion bearing (18), shim (19) and the
piston (21) assembly to piston rod (1).
: 65 mm
: 1740 N m (175 kgf m, 1280 lbf ft)
W4-2-15
DISASSEMBLE ARM CYLINDER
1 30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
Clevis Part
31
W1LD-04-02-006
1- Piston Rod 9- U-Ring 17 - Stopper 25 - O-Ring
2- Wiper Ring 10 - Connector 18 - Cushion Bearing 26 - Slide Ring
3- Cylinder Head 11 - Stopper 19 - Backup Ring 27 - Cushion Seal
4- O-Ring 12 - Retainer 20 - Slide Ring 28 - Retaining Ring
5- Backup Ring 13 - Backup Ring 21 - Piston 29 - Cushion Bearing
6- O-Ring 14 - O-Ring 22 - Steel Ball 30 - Stopper
7- Bushing 15 - Cushion Ring 23 - Set Screw 31 - Cylinder Tube
8- Backup Ring 16 - Spacer 24 - Seal Ring
W4-2-16
Disassemble Arm Cylinder
Read PRECAUTIONS FOR DISASEMBLING IMPORTANT: Set screw (23) was crimped with a
AND ASEMBLING (W1-1-1) carefully before punch in two places after it was
disassembling. tightened. Before loosening set
Start the following procedures after disconnecting screw, cut away the crimped
the lines. portions.
4. Secure piston rod (1) horizontally and remove set
screw (23) and steel ball (22) from piston (21).
CAUTION: Arm cylinder weight: : 4 mm
41 kg (90 lb) (ZX40U)
42 kg (93 lb) (ZX50U) 5. Remove piston (21), backup ring (19) and cushin
IMPORTANT: When draining off hydraulic oil from bearing (18) from piston rod (1).
the cylinder, piston rod (1) shall be : 60 mm
moved slowly in order to prevent the
oil from splashing.
6. Remove retaining ring (28) from piston rod (1).
1. Clamp the cylinder tube (31) pin at its mounting
portion (clevis part) in a vise and secure it
horizontally to drain off hydraulic oil from the 7. Slide cushion bearing (29) toward piston rod (1)
cylinder. screw thread to remove stoppers (30).
IMPORTANT: The detent is provided on cylinder 8. Remove cushion bearing (29) and cushion seal
tube (29) to form an integral part. (27) from piston rod (1).
Take care not to damage the cylinder
tube and cylinder head (30) when 9. Wrap piston rod (1) screw thread with protective
bending and extending the detent. tape to protect wiper ring (2) of cylinder head (3)
2. Pull piston rod (1) approx. 200 mm (7.9 in) out to and then remove cylinder head (3) from piston
install a protective cover on the piston rod and rod (1).
then extend the detent at cylinder head (3).
Detent
When disassembling boom cylinder,
replace them with new ones.
10. Clamp piston (21) and hold it horizontally in a vice
(21).
1 3
W506-04-02-003
3. Loosen cylinder head (3) with a hook wrench and

of cylinder tube (31).
Arm cylinder head diameter: 95 mm (3.7 in)
Hook Wrench
31
1
W506-04-02-004
W4-2-17
25
24
21
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
W1LD-04-02-006
W4-2-18
IMPORTANT: Take care not to damage piston (21) IMPORTANT: Do not reuse bushing (7).
when removing seals. Replace it with new one when
11. Insert a screwdriver into the clearance between disassembling the cylinder.
piston (21) and seal ring (24). Raise seal ring (24) 17. Remove bushing (7) from the inside of cylinder
with screwdriver. Cut off seal ring (24) with cutting head (3) with a special tool.
pliers to remove seal ring (24) from piston (21). NOTE: As bushing (7) is installed into cylinder
Remove o-ring (25) in the same procedure. head (3) with a press, it can not be
21 cylinder head (3) with a special tool
24 25 (copper spatula).
W506-04-02-007
12. Remove stopper (11), connector (10) and retainer

(12) from cylinder head (3).
13. Remove backup ring (13) and O-ring (14) from

the outside of retainer (12).
14. Remove stopper (17), spacer (16) and cushion

bearing (15) from the inside of retainer (12).
(8) from the inside of cylinder head (3).
from the outside of cylinder head (3).
W4-2-19
ASSEMBLE ARM CYLINDER
3 4 5 6 15 16 17 31 18 19 20 26 23 22
28 27
2 7 8 9 10 11 12 13 14 1 21 25 24 29 30 W1LD-04-02-007
1- Piston Rod 9- U-Ring 17 - Stopper 25 - O-Ring

2- Wiper Ring 10 - Connector 18 - Cushion Bearing 26 - Slide Ring
3- Cylinder Head 11 - Stopper 19 - Backup Ring 27 - Cushion Seal
4- O-Ring 12 - Retainer 20 - Slide Ring 28 - Retaining Ring
5- Backup Ring 13 - Backup Ring 21 - Piston 29 - Cushion Bearing
6- O-Ring 14 - O-Ring 22 - Steel Ball 30 - Stopper
7- Bushing 15 - Cushion Ring 23 - Set Screw 31 - Cylinder Tube
8- Backup Ring 16 - Spacer 24 - Seal Ring
W4-2-20
Assemble Arm Cylinder IMPORTANT: Take care of the mounting direction
Read PRECAUTIONS FOR DISASSEMBLING of U-ring (9).
AND ASSEMBLING (W1-1-1) carefully before 2. Install backup ring (8) and U-ring (9) to cylinder
assembling. head (3).
3
CAUTION: Arm cylinder weight:
41 kg (90 lb) (ZX40U) 9
42 kg (93 lb) (ZX50U)
of cylinder head (3).
Press bushing (7) until the end of
bushing (7) is flush with the end
surface of cylinder head (3).
If not flushing, backup ring (8) will
be damaged when installing backup
ring (8). W1LD-04-02-004

special tool (ST 8047).
7
3
ST 8047
Flush the
surface
3
W577-04-02-007
2
W506-04-02-012
1. Press bushing (7) into cylinder head (3) with 4. Install O-ring (4), backup ring (5) and O-ring (6) to
special tool (ST 7325). the outside of cylinder head (3).
5. Install cushion ring (15), spacer (16) and stopper

(17) to the inside of retainer (12).
ST 7325 Install O-ring (14) and backup ring (13) to the
outside of retainer (12).
7
3 6. Install retainer (12) assembly, connector (10) and
stopper (11) to cylinder head (3).
W506-04-02-010
W4-2-21
3 31 18 19 20 26 23 22
28 27
1 21 25 24 29 30 W1LD-04-02-007
W4-2-22
IMPORTANT: Make sure that O-ring (25) is not IMPORTANT: Take care not to install cushion
twisted after installing it. bearing (18) in wrong direction.
7. Install O-ring (25) to piston (21), and then install 13. Install cushion bearing (18), backup ring (19) and
seal ring (24) with special tool (ST 2625) and (ST piston (21) assembly to piston rod (1).
2623). : 60 mm
: 1270 N m (130 kgf m, 940 lbf ft)
ST 2625
IMPORTANT: When the work of installing set

24 screw (23) is finished, crimp it at two
ST 2623 places with a punch in order to
prevent it from loosening.
25 14. Install steel ball (22) into piston (21) and then
: 4 mm
21
: 16.5 N m (1.7 kgf m, 12 lbf ft)
IMPORTANT: Take care not to let slide rings (20)

W566-04-02-010 and (26) drop from piston (21) when
inserting the piston rod (1) assembly.
IMPORTANT: Adjust seal ring (24). If not adjusting, In addition, care should be taken not
piston (21) can not be installed to to damage the piston rod assembly
cylinder tube (21). and insert the piston rod assembly
8. Adjust seal ring (24) with special tool (ST 2627). straightly. Apply the hydraulic oil to
the packing parts.
15. Lay cylinder tube (31) horizontally in a vise, and
tube.
24
ST 2627
W566-04-02-011

10. Wrap the piston rod (1) screw thread with

former one.
11. Install cushion seal (27) and cushion bearing (29)

to piston rod (1).
12. Install stopper (30) and retaining ring (28) to

piston rod (1).
W4-2-23
3 31
W1LD-04-02-007
W4-2-24
IMPORTANT: Apply the hydraulic oil to the
packing parts.
16. Tighten cylinder head (3) to cylinder tube (31)
from loosening.
: 330 N m (34 kgf m, 245 lbf ft)
Hool Wrench
31
W506-04-02-019
W4-2-25
DISASEMBLE BUCKET CYLINDER
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
Clevis Part
17
W1LD-04-02-005
1- Piston Rod 6- O-Ring 10 - Slide Ring 14 - Seal Ring

2- Wiper Ring 7- Backup Ring 11 - Piston 15 - O-Ring
3- Cylinder Head 8- U-Ring 12 - Steel Ball 16 - Slide Ring
4- O-Ring 9- Bushing 13 - Set Screw 17 - Cylinder Tube
5- Backup Ring
W4-2-26
Disassemble Bucket Cylinder 3. Loosen cylinder head (3) with a hook wrench and
Read PRECAUTIONS FOR DISASSEMBLING of cylinder tube (17).
AND ASSEMBLING (W1-1-1) carefully before Cylinder head (3) diameter: 85 mm (3.35 in)
disassembling. Hook Wrench
the lines.
CAUTION: Bucket cylinder weight: 17

28 kg (62 lb) (ZX40U)
33kg (73 lb) (ZX50U)
IMPORTANT: When draining off hydraulic oil from 3

oil from splashing. Protective Cover
1
1. Clamp the pin mounting part (clevis part) of W506-04-02-004
cylinder tube (17) and hold it horizontally in a vise

to drain hydraulic oil from the cylinder. IMPORTANT: As set screw (13) head is
IMPORTANT: The detent in cylinder head (3) is cut the mushroomed part with a
provided on cylinder tube (17) to hand drill before loosening set
form an integral part. Take care not screw (13).
to damage the cylinder tube and 4. Secure piston rod (1) horizontally.
cylinder head (3) when bending and Remove set screw (13) and steel ball (12) from
extending the detent. piston (11).
2. Pull out piston rod (1) approximately 200 mm (7.9 : 3 mm
extend the detent. 5. Remove piston (11) from piston rod (1).
: 50 mm (ZX40U)
Detent 55 mm (ZX50U)

rod (1).

When dissembling bucket cylinder,
1 3 replace them with new ones.
W506-04-02-003 7. Clamp piston (11) and hold it horizontally in a vice
(11).
W4-2-27
15
14
11
9
8
7
6
5
4
3
2
W1LD-04-02-005
W4-2-28
IMPORTANT: Take care not to damage piston (11)
when removing seals.
8. Insert a screwdriver into the clearance between
piston (11) and seal ring (14). Raise seal ring (14)
with screwdriver. Cut off seal ring (14) with cutting
pliers to remove seal ring (14) from piston (11).
Remove O-ring (15) in the same procedure.
11
14, 15
W506-04-02-007

(7) from the inner side of cylinder head (3).
from the outer side of cylinder head (3).
IMPORTANT: Do not reuse bushing (9).

Replace it with new one when
disassembling the cylinder.
11. Remove bushing (9) from the inner side of
cylinder head (3) with a special tool.
NOTE: As bushing (9) is installed into cylinder
head (3) with a press, it can not be
cylinder head (3) with a special tool
(copper spatula).
W4-2-29
ASSEMBLE BUCKET CYLINDER
3 4 5 6 17 10 16 13 12
W571-04-02-011
2 7 8 9 1 11 14 15
1- Piston Rod 6- O-Ring 10 - Slide Ring 14 - Seal Ring

2- Wiper Ring 7- Backup Ring 11 - Piston 15 - O-Ring
3- Cylinder Head 8- U-Ring 12 - Steel Ball 16 - Slide Ring
4- O-Ring 9- Bushing 13 - Set Screw 17 - Cylinder Tube
5- Backup Ring
W4-2-30
Assemble Bucket Cylinder 3. Install wiper ring (2) to cylinder head (3) with
Read PRECAUTIONS FOR DISASSEMBLING special tool (ST 8045, ST 8046).
assembling.
ST 8045 (ZX40U)
CAUTION: Bucket cylinder weight: ST 8046 (ZX50U)
28 kg (62 lb) (ZX40U)

3
33kg (73 lb) (ZX50U)
1. Press bushing (9) into cylinder head (3) with
special tool (ST 7277, ST 7276).
ST 7277 (ZX40U)
ST 7276 (ZX50U)
2
9
W506-04-02-012
3
4. Install O-ring (4), backup ring (5) and O-ring (6) to
the outside of cylinder head (3).
IMPORTANT: Make sure that O-ring (15) is not

twisted after installing it.
5. Install O-ring (15) to piston (11), and then install
W506-04-02-010
seal ring (14) with special tool (ST 2624, ST
2596) and (ST 2622, ST2592).
IMPORTANT: Take care of the mounting direction ST 2624 (ZX40U)
of U-ring (8). ST 2596 (ZX50U)
2. Install backup ring (7) and U-ring (8) to cylinder 14
head (3). ST 2622 (ZX40U)
3 ST 2592 (ZX50U)
15
8
11
W566-04-02-010
W1LD-04-02-004
W4-2-31
3 17 10 16 13 12
W571-04-02-011
1 11 14
W4-2-32
IMPORTANT: Adjust seal ring (14). If not adjusted, IMPORTANT: Take care not to let slide rings (10)
piston (11) can not be installed to and (16) drop from piston (11) when
cylinder tube (17). inserting the piston rod (1) assembly.
6. Adjust seal ring (14) with special tool (ST 2626, In addition, care should be taken not
ST 2600). to damage the piston rod assembly
the packing parts.
14 tube.
ST 2626 (ZX40U)
ST 2600 (ZX50U) IMPORTANT: Apply the hydraulic oil to the
packing parts.
from loosening.
Cylinder head (3) diameter: 85 mm (ZX40U)
W566-04-02-011
90 mm (ZX50U)
: 320 N m (32.5 kgf m, 235 lbf ft)
IMPORTANT: When installing slide ring (10) and (ZX40U ZX50U)
7. Install slide rings (10) and (16) to piston (11). Hook Wrench
8. Wrap the piston rod (1) screw thread with

former one.
9. Install piston (11) assembly to piston rod (1).

: 50 mm (ZX40U)
: 830 N m (85 kgf m, 610 lbf ft)
: 55 mm (ZX50U) 17
: 1030 N m (105 kgf m, 760 lbf ft)
W506-04-02-019
IMPORTANT: When the work of installing set

screw (13) is finished, crimp it at two
places with a punch in order to
10. Install steel ball (12) into piston (11) and then
: 3 mm (ZX40U)
: 6.8 N m (0.7 kgf m, 5 lbf ft)
: 4 mm (ZX50U)
: 16.5 N m (1.7 kgf m, 12 lbf ft)
W4-2-33
DISASSEMBLE BOOM SWING CYLINDER
AND BLADE CYLINDER
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
Clevis Part
17
W1LD-04-02-008
1- Piston Rod 6- U-Ring 10 - Slide Ring 14 - Seal Ring
2- Wiper Ring 7- O-Ring 11 - Piston 15 - O-Ring
3- Cylinder Head 8- Backup Ring 12 - Steel Ball 16 - Slide Ring
4- Bushing 9- O-Ring 13 - Set Screw 17 - Cylinder Tube
5- Backup Ring
W4-2-34
Disassemble Boom Swing Cylinder and Blade 3. Loosen cylinder head (3) with a hook wrench and
Cylinder pull piston rod (1) (with protective cover on it) out
of cylinder tube (17).
Read PRECAUTIONS FOR DISASSEMBLING Cylinder head (3) diameter: 115 mm (4.53 in)
AND ASSEMBLING (W1-1-1) carefully before (Boom swing cylinder, Blade cylinder)
disassembling. Hook Wrench
the lines.
CAUTION: Cylinder weight: 17

Boom swing cylinder: 48 kg (106 lb)
Blade cylinder: 30 kg (66 lb)
IMPORTANT: When draining off hydraulic oil from 3

oil from splashing. Protective Cover
1
1. Clamp the pin mounting part (clevis part) of W506-04-02-004
cylinder tube (17) and hold it horizontally in a vise

to drain hydraulic oil from the cylinder. IMPORTANT: As set screw (13) head is
IMPORTANT: The detent in cylinder head (3) is cut the mushroomed part with a
provided on cylinder tube (17) to hand drill before loosening set
form an integral part. Take care not screw (13).
to damage the cylinder tube and 4. Secure piston rod (1) horizontally.
cylinder head (3) when bending and Remove set screw (13) and steel ball (12) from
extending the detent. piston (11).
2. Pull out piston rod (1) approximately 200 mm (7.9 : 4 mm
extend the detent. 5. Remove piston (11) from piston rod (1).
: 60 mm
Detent (Boom swing cylinder, Blade cylinder)

rod (1).

When dissembling the cylinder,
1 3 replace them with new ones.
W506-04-02-003 7. Clamp piston (11) and hold it horizontally in a vise
(11).
W4-2-35
15
14
11
9
8
7
6
5
4
3
2
W1LD-04-02-008
W4-2-36
IMPORTANT: Take care not to damage piston (11)
when removing seals.
8. Insert a screwdriver into the clearance between
piston (11) and seal ring (14). Raise seal ring (14)
with screwdriver. Cut off seal ring (14) with cutting
pliers to remove seal ring (14) from piston (11).
Remove O-ring (15) in the same procedure.
11
14, 15
W506-04-02-007

(5) from the inner side of cylinder head (3).
from the outer side of cylinder head (3).
IMPORTANT: Do not reuse bushing (4).

Replace it with new one when
disassembling the cylinder.
11. Remove bushing (4) from the inner side of
cylinder head (3) with a special tool.
NOTE: As bushing (4) is installed into cylinder
head (3) with a press, it can not be
cylinder head (3) with a special tool
(copper spatula).
W4-2-37
ASSEMBLE BOOM SWING CYLINDER
AND BLADE CYLINDER
NOTE: The cross section of boom swing cylinder

and the cross section of blade cylinder are
the same.
3 7 8 9 17 11 10 16 13 12
W1LD-04-02-009
2 7 5 6 1 14 15
1- Piston Rod 6- U-Ring 10 - Slide Ring 14 - Seal Ring

2- Wiper Ring 7- O-Ring 11 - Piston 15 - O-Ring
3- Cylinder Head 8- Backup Ring 12 - Steel Ball 16 - Slide Ring
4- Bushing 9- O-Ring 13 - Set Screw 17 - Cylinder Tube
5- Backup Ring
W4-2-38
Assemble Boom Swing Cylinder and Blade IMPORTANT: Take care of the mounting direction
Cylinder of U-ring (6).
Read PRECAUTIONS FOR DISASSEMBLING 2. Install backup ring (5) and U-ring (6) to cylinder
AND ASSEMBLING (W1-1-1) carefully before head (3).
assembling. 3
CAUTION: Cylinder weight:

Boom swing cylinder: 48 kg (106 lb) 6
Blade cylinder: 30 kg (66 lb)
of cylinder head (3). Press bushing
(4) until the end of bushing (4) is
flush with the end surface of
cylinder head (3). If not flush,
backup ring (5) will be damaged
when installing backup ring (5.) W1LD-04-02-004

4 special tool.
3 Boom swing cylinder: ST 8047
Blade cylinder: ST 8048
Flush the
surface
ST 8047
ST 8048
3
W577-04-02-007
1. Press bushing (4) into cylinder head (3) with

special tool.
Boom swing cylinder: ST 7325 2
Blade cylinder: ST 7275 W506-04-02-012
4. Install O-ring (7), backup ring (8) and O-ring (9) to

ST 7325
the outer side of cylinder head (3).
ST 7275
4
3
W506-04-02-010
W4-2-39
3 17 11 10 16 13 12
W1LD-04-02-009
1 14 15
W4-2-40
IMPORTANT: Make sure that O-ring (15) is not 8. Wrap the piston rod (1) screw thread with
twisted after installing it. protective tape and then install the cylinder head
5. Install O-ring (15) to piston (11), and then install (3) assembly to the piston rod while rotating the
seal ring (14) with special tool. former one.
Boom swing cylinder and blade cylinder:
ST 2597, ST 2593 9. Install piston (11) assembly to piston rod (1).
: 60 mm
ST 2597
: 1960 N m (200 kgf m, 1450 lbf ft)
14 IMPORTANT: When the work of installing set

screw (13) is finished, crimp it at two
ST 2593
places with a punch in order to
15 10. Install steel ball (12) into piston (11) and then
11 : 4 mm
: 16.5 N m (1.7 kgf m, 12 lbf ft)
W566-04-02-010
IMPORTANT: Take care not to let slide rings (10)
and (16) drop from piston (11) when
inserting the piston rod (1) assembly.
IMPORTANT: Adjust seal ring (14). If not adjusted,
In addition, care should be taken not
piston (11) can not be installed to
to damage the piston rod assembly
cylinder tube (17).
and insert the piston rod assembly
6. Adjust seal ring (14) with special tool.
Boom swing cylinder and blade cylinder: ST 2601
the packing parts.
tube.
14
ST 2601
W566-04-02-011

W4-2-41
3 17
W1LD-04-02-009
W4-2-42
IMPORTANT: Apply the hydraulic oil to the
packing parts.
from loosening.
: 390 N m (40 kgf m, 290 lbf ft)
Hook Wrench
17
W506-04-02-019
W4-2-43
Rod Rod Bend and Run Out
A Dial Gauge
Cylinder Rod
W105-04-02-094 W166-04-02-022
ZX40U unit: mm (in)
1m
Recommended Size After
Cylinder Name V Block
Re-manufacturing (A)
+0.023 (2.1 0.0009 unit: mm (in)
Boom 55 ) Bend Run out Remedy
-0.043 7 0.0017
+0.023 (1.9 0.0009 Allowable limit 0.5 (0.020) 1.0 (0.039) Repair
Arm 50 ) Allowable limit 1.0 (0.039) 2.0 (0.079) Replace
-0.043 7 0.0017
+0.023 (1.5 0.0009
Bucket 40 )
-0.043 8 0.0017
+0.023 (1.9 0.0009
Boom Swing 50 )
-0.043 7 0.0017
+0.023 (2.1 0.0009
Blade 55 )
-0.043 7 0.0017
ZX50 unit: mm (in)

Recommended Size After
Cylinder Name
Re-manufacturing (A)
+0.023 (2.1 0.0009
Boom 55 )
-0.043 7 0.0017
+0.023 (1.9 0.0009
Arm 50 )
-0.043 7 0.0017
+0.023 (1.7 0.0009
Bucket 45 )
-0.043 7 0.0017
+0.023 (1.9 0.0009
Boom Swing 50 )
-0.043 7 0.0017
+0.023 (2.1 0.0009
Blade 55 )
-0.043 7 0.0017
Wear to The Inner Diameter of Rod Bushing

ZX40U,ZX50U unit: mm (in)
Cylinder Remedy
Standard inner Diameter (C) Allowable Limit
Name
-0.21 0.008
) +0.3
Boom 50 (1.97 Replace
-0.16 0.006 (0.012)
-0.16 0.006
) +0.3
Arm 45 (1.77 Replace C
-0.11 0.004 (0.012)
-0.16 0.006
) +0.3
Bucket 45 (1.77 Replace
-0.11 0.004 (0.012)
-0.21 0.008
) +0.3
Boom Swing 50 (1.97 Replace
-0.16 0.006 (0.012)
-0.21 0.008 ) +0.3
Blade 55 (2.17 Replace
-0.16 0.006 (0.012)
W4-2-44
SECTION 5
ENGINE
CONTENTS
SECTION 1 General Information SECTION 5 Fuel System
GENERAL REPAIR INSTRUCTION................... 2 FUEL CIRCULATION SYSTEM DIAGRAM ......88
NOTES ON THE FORMAT GOVERNOR ....................................................89
OF THIS MANUAL ........................................... 2 NOZZLE HOLDER ASSEMBLY .......................97
APPEARANCE .................................................. 5
MAIN DATA AND SPECIFICATIONS ................. 6 SECTION 6 Troubleshooting
TIGHTENING TORQUE SPECIFICATIONS....... 7
ANGULAR NUT AND BOLT SECTION 7 Special Tool
TIGHTENING METHOD .................................. 9
TIGHTENING TORQUE ON SECTION 8 Service Standard
MAJOR COMPONENTS ................................ 11
GASKET LOCATION ....................................... 17 SECTION 9 Conversion Table
MAINTENANCE............................................... 20 LENGTH ........................................................109
RECOMENDED LUBRICATION OIL................ 25 AREA ............................................................. 111
VOLUME........................................................ 111
SECTION 2 Engine MASS ............................................................ 113
DISASSEMBLY................................................ 28 PRESSURE ................................................... 114
INSPECTION AND REPAIR ............................ 41 TORQUE ....................................................... 115
REASSEMBLY................................................. 55 TEMPERATURE ............................................ 116
SECTION 3 Lubrication System

LUBRICATION OIL CIRCULATION
SYSTEM DIAGRAM....................................... 78
OIL PUMP ....................................................... 79
SECTION 4 Cooling System

COOLING WATER CIRCULATION
SYSTEM DIAGRAM....................................... 82
WATER PUMP................................................. 83
THERMOSTAT ................................................ 86
1LDW-5-1
Blank
1LDW-5-2
Many thanks for your purchase.
Happy every day.
QIWEN YE
file:///C|/Users/yeqiwen/Documents/QIWEN-YE-END.txt[2015/1/2 21:20:52]
Attach to Vol. No. : T1LDE-00
ZAXIS 40U,50U ELECTRICAL CIRCUIT DIAGRAM

CAUTION: Parts numbers on the drawing are provided only for reference purpose.
ZAXIS 40U,50U ENGINE HARNESS To order parts on the drawing, be sure to consult the Parts Catalog.
CONNECTOR TERMINAL LOCATION

(Drawing are shown in face view of the connector) Engine 2
MITSUBISHI
A
Connector
Engine 1
Main YAZAKI
YAZAKI
Starter
YAZAKI
Alternator B Eng. Oil press. SW.

Stop Sol.
YAZAKI
Fuel Pump
YAZAKI
Eng. Oil Press. SW. Shermo Sensor

Alternator B
Shermo SW.
Shermo Sensor
QOS Sensor
QOS Sensor YAZAKI
Glow Glow Plug Alternator
Starter YAZAKI
Shermo SW.
Shermo SW.
ZAXIS 40U,50U FLOOR HARNESS
Fuse Box
To order parts on the drawing, be sure to consult the Parts Catalog.
CONNECTOR TERMINAL LOCATION

(Drawing are shown in face Glow Relay YAZAKI
View of the connector)
Relay a Relay b
YAZAKI Light Horn
A
Connector
Starter Relay1 Starter Relay2
YAZAKI Glow Timer
YAZAKI YAZAKI
YAZAKI
Install a Puller
Key SW.
SUMITOMO Harness
Auxiliary
Satellite Terminal
YAZAKI
AUX
Gauge Panel
Power
Heater
YAZAKI
Relay a
Relay a Power
Alarm Power
MITSUBISHI
Bypass a Relay b
Bypass a Relay b Horn SW
Bypass a
Bypass a
Relay a
Relay a Gauge Panel
Lock SW. (R)
Relay b
Relay b
Auxilialy Bypass b
Bypass b
Bypass b
Horn SW
Water Proof
Horn SW.
Water Proof
Lock SW. (L)
Alarm Alarm
Main1
Auxilialy
Power YAZAKI
Open Engine2 Engine1 Main2
MITSUBISHI SUMITOMO
Fuse Box Open YAZAKI
SUMITOMO
Open Open
Open
Open
CAUTION: Refer to the performance standard table in the Technical
ZAXIS 40U,50U HYDRAULIC CIRCUIT DIAGRAM Manual for the set pressure of each relief valve.
Swing Device Travel Device
Blade Cylinder
Backet Cylinder
Arm Cylinder
Swing Cylinder
Boom Cylinder
Center Joint
Pilot Valve (Left)

(HITACHI Lever Pattern)
Arm Swing
Roll-Out Roll-In Left Right
Pilot Valve (Right)

Boom Bucket
Raise Lower Roll-Out Roll-In
Swing Boom Arm Bucket Boom Swing Auxiliary Travel(R) Travel(L) Blade
Cont rol Valve
Pilot Valve (Travel)
Engine Pilot Valve

ISUZU (Boom Swing)
Pilot Filter
Mesh 2-Unit Solenoid Valve
Revolution Sensing Valve Pump
Hydraulic Oli Tank 4-Way Rotary Valve

Pilot Valve
Oil Cooler (Blade)
ZAXIS 40U,50U MAIN HARNESS To order parts on the drawing, be sure to consult the Parts Catalog.
Pilot Shut-Off
CONNECTOR TERMINAL LOCATION Sol. Valve Travel Mode SW.
(Drawing are shown in face view of the connector)
Water Proof Water Proof
A Float
Connector
Floor 1 Travel
Changeover
YAZAKI Sol. Valve
Groud
Work Light Battery

Work Light
Horn
Travel Mode SW. Work Light (Boom)

Bypass C Floor 2 Water Proof
Bypass C SUMITOMO
Horn
Ground Bypass C Engine YAZAKI
Horn YAZAKI
Travel Mode SW. Work Light
Ground Water Proof
Ground

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Hitachi ZX40U, ZX50U Service Manual (Technical Manual+ Workshop Manual + Diagramas) PRIME A+ 657 Páginas

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Technical Manual

Vol No.: T1LDE-00

 This manual consists of two portions:

 Each page has a number, located on the center

Consecutive Page Number for Each Group

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

 SI Units (International System of Units) are used in 2

 This is the SAFETY ALERT SYMBOL.

• When you see this symbol on your machine or in

UNDERSTAND SIGNAL WORDS

 On machine safety signs, signal words designating

• DANGER indicates an imminently hazardous

• WARNING indicates a potentially hazardous

• CAUTION indicates a potentially hazardous

• DANGER or WARNING safety signs are located

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

 CAUTION also calls attention to safety messages in

 To avoid confusing machine protection with personal

 NOTE indicates an additional explanation for an

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

 Safety signs should be installed, maintained and re-

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

 Learn how to operate the machine and its controls

 Allow only trained, qualified, authorized personnel to

 Keep your machine in proper working condition.

• Unauthorized modifications of the machine may

 The safety messages in this SAFETY chapter are

PREPARE FOR EMERGENCIES

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

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

lance service, hospital, and fire department

 Wear close fitting clothing and safety equipment

You may need:

• Avoid wearing loose clothing, jewelry, or other

 Operating equipment safely requires the full

PROTECT AGAINST NOISE

 Prolonged exposure to loud noise can cause

• Wear a suitable hearing protective device such as

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

• Before entering the cab, thoroughly remove all dirt

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

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

• Refrain from listening to the radio, or using music

• Keep all flammable objects and/or explosives

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

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

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

• When you mounting and dismounting the ma-

• Do not use any controls as hand-holds.

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

ADJUST THE OPERATOR'S SEAT

 A poorly adjusted seat for either the operator or for

• The seat should be adjusted whenever changing

 If the machine should overturn, the operator may

• Prior to operating the machine, thoroughly

MOVE AND OPERATE MACHINE SAFELY

 Bystanders can be run over.

• Take extra care not to run over bystanders.

 Inappropriate engine starting procedures may cause

• Start the engine only when seated in the

 Battery gas can explode, resulting in serious injury.

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

 Riders on machine are subject to injury such as

This manual consists of two portions:

Each page has a number, located on the center

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

SI Units (International System of Units) are used in 2