DOC-20230111-WA0038.

INTRODUCTION

TO THE READER

• This manual is written for an experienced technician

to provide technical information needed to maintain

and repair this machine.

• Be sure to thoroughly read this manual for correct

product information and service procedures.

• If you have any questions or comments, at if you

found any errors regarding the contents of this

manual, please contact using “Service Manual

Revision Request Form at the end of this manual.

(Note: Do not tear off the form. Copy it for usage.):

Publications Marketing & Product Support

Hitachi Construction Machinery Co. Ltd.

TEL: 81-298-32-7173

FAX: 81-298-31-1162

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition

to this manual.

• The Operator’s Manual

• The Parts Catalog

• Operation Manual of the Engine

• Parts Catalog of the Engine

• Hitachi Training Material

MANUAL COMPOSITION

• This manual consists of three portions: the Technical

Manual (Operational Principle), the Technical

Manual (Troubleshooting) and the Workshop Manual.

• Information included in the Technical Manual

(Operational Principle):

technical information needed for redeliver and

delivery, operation and activation of all devices

and systems.

• Information included in the Technical Manual

(Troubleshooting):

technical information needed for operational performance

tests, and troubleshooting procedures.

• Information included in the Workshop Manual:

technical information needed for maintenance

and repair of the machine, tools and devices

needed for maintenance and repair, maintenance

standards, and removal/installation and assemble/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

SAFETY ALERT SYMBOL AND HEADLINE

NOTATIONS

INTRODUCTION

In this manual, the following safety alert symbol and

signal words are used to alert the reader to the

potential for personal injury of machine damage.

This is the safety alert symbol. When you see this

symbol, be alert to the potential for personal injury.

Never fail to follow the safety instructions prescribed

along with the safety alert symbol.

The safety alert symbol is also used to draw attention

to component/part weights.

To avoid injury and damage, be sure to use appropriate

lifting techniques and equipment when lifting heavy

parts.

• CAUTION:

Indicated potentially hazardous situation which

could, if not avoided, result in personal injury or

death.

• IMPORTANT:

Indicates a situation which, if not conformed to the

instructions, could result in damage to the machine.

• NOTE:

Indicates supplementary technical information or

know-how.

UNITS USED

• SI Units (International System of Units) are used in

this manual.

MKS system units and English units are also

indicated in parenthheses just behind SI units.

Example : 24.5 MPa (250 kgf/cm 2 , 3560 psi)

A table for conversion from SI units to other system

units is shown below for reference purposees.

Quantity

To Convert

From

Into Multiply By

Length mm in 0.03937

mm ft 0.003281

L US gal 0.2642

Volume L US qt 1.057

m 3 yd 3 1.308

Weight kg lb 2.205

Force N kgf 0.10197

N lbf 0.2248

Torque N⋅m kgf⋅m 1.0197

N⋅m lbf⋅ft 0.7375

Quantity

To Convert

From

Into Multiply By

Pressure MPa kgf/cm 2 10.197

MPa psi 145.0

Power kW PS 1.360

kW HP 1.341

Temperature °C °F °C×1.8+32

Velocity km/h mph 0.6214

min -1 rpm 1.0

Flow rate L/min US gpm 0.2642

mL/rev cc/rev 1.0

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

designated signal words above after the safety

alert symbol are occasionally used on this

machine.

SA-1223

• 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 machine

and all safety messages in this manual.

• Safety signs should be installed, maintained and replaced

when necessary.

• If a safety sign or this manual is damaged or missing,

order a replacement from your authorized

dealer in the same way you order other replacement

parts (be sure to state machine model and

serial number when ordering).

• Learn how to operate the machine and its controls

correctly and safely.

SA-003

• 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 machine

life.

• The safety messages in this SAFETY chapter are

intended to illustrate basic safety procedures of machines.

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 attached

on the fire extinguisher to use it properly.

• To ensure that a fire-extinguisher can be always

used when necessary, check and service the fireextinguisher

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, ambulance

service, hospital, and fire department

posted near your telephone.

SA-437

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

Respirator or filter mask.

Be sure to wear the correct equipment and clothing

for the job. Do not take any chances.

SA-438

• 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 operator’s

seat. Store them in their specified locations.

• 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 extinguish

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 machine,

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.

• Be careful of slippery conditions on platforms,

steps, and handrails when mounting and dismounting

the machine.

SA-439

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

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.

SA-237

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

machine.

SA-426

011-E01A-0426

SA-6

OPERATE ONLY FROM OPERATOR'S

SEAT

• Inappropriate engine starting procedures may cause

the machine to runaway, possibly resulting in serious

injury or death.

SAFETY

• 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.

• Before starting the engine, confirm that all control

levers are in neutral.

SA-444

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

could result in a battery explosion or a runaway

machine.

SA-032

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.

014-E01B-0379

SA-379

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 position.

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.

017-E01A-0491

SA-491

SA-8

SAFETY

DRIVE MACHINE SAFELY

• Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the direction

you wish to drive.

• Be sure to detour around any obstructions.

• Avoid traveling over obstructions. Soil, fragments

of rocks, and/or metal pieces may scatter around

the machine. Don’t allow personnel to stay around

the machine while traveling.

SA-387

• Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.

• When driving up or down a slope, keep the bucket

facing the direction of travel, approximately 200 to

300 mm (A) above the ground.

• If the machine starts to skid or becomes unstable,

immediately lower the bucket to the ground and

stop traveling.

SA-388

• 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 machine

to level ground, then, change the direction

to ensure sage operation.

SA-441

SA-589

019-E01D-0492

SA-9

AVOID INJURY FROM ROLLAWAY

ACCIDENTS

• Death or serious injury may result if you attempt to

mount or stop a moving machine.

SAFETY

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.

• Position the machine to prevent rolling.

• Park a reasonable distance from other machines.

SA-391

SA-392

020-E08A-0493

SA-10

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.

SAFETY

• 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-383

SA-384

• No machine motions shall be made unless signals

are clearly understood by both signalman and

operator.

• Learn the meanings of all flags, signs, and

markings used on the job and confirm who has

the responsibility for signaling.

• Keep windows, mirrors, and lights clean and in

good condition.

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

visibility decreases, reduce speed and use proper

lighting.

• Read and understand all operating instructions in

the operator’s manual.

S021-E01A-0494

SA-11

SAFETY

AVOID TIPPING

DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING

MACHINE---SERIOUS OR FATAL CRUSHING

INJURIES WILL RESULT

MACHINE WILL TIP OVER FASTER THAN YOU

CAN JUMP FREE

FASTEN YOUR SEAT BELT

• The danger of tipping is always present when

operating on a grade, possibly resulting in serious

injury or death.

SA-012

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.

SA-440

• Be careful when working on frozen ground.

• Temperature increases will cause the ground to

become soft and make ground travel unstable.

S025-E01B-0495

SA-12

SAFETY

AVOID POWER LINES

• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from

electric lines.

• When operating near an electric line, NEVER

move any part of the machine or load closer than

3 m (10 ft) plus twice the line insulator length.

• Check and comply with any local regulations that

may apply.

• Wet ground will expand the area that could cause

any person on it to be affected by electric shock.

Keep all bystanders or co-workers away from the

site.

SA-381

029-E01A-0381

OBJECT HANDLING

• If a lifted load should fall, any person nearby may be

struck by the falling load or may be crushed

underneath it, resulting in serious injury or death.

• When using the machine for craning operations,

be sure to comply with all local regulations.

• Do not use damaged chains or frayed cables,

sables, slings, or ropes.

• Before craning, position the upperstructure with

the travel motors at the rear.

• Move the load slowly and carefully. Never move it

suddenly.

• Keep all persons well away from the load.

• Never move a load over a person's head.

• Do not allow anyone to approach the load until it is

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.

SA-014

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.

031-E01A-0432

SA-432

PARK MACHINE SAFELY

To avoid accidents:

• Park machine on a firm, level surface.

• Lower bucket to the ground.

• Turn auto-idle / acceleration selector and H/P

mode switch off.

• Run engine at slow idle speed without load for 5

minutes.

• Turn key switch to OFF to stop engine.

• Remove the key from the key switch.

• Pull the pilot control shut-off lever to the LOCK

position.

• Close windows, roof vent, and cab door.

• Lock all access doors and compartments.

SA-390

033-E09B-0390

SA-14

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.

SAFETY

• All fuels, most lubricants, and some coolants are

flammable.

SA-018

• Store flammable fluids well away from fire

hazards.

• Do not incinerate or puncture pressurized

containers.

• Do not store oily rags; they can ignite and burn

spontaneously.

• Securely tighten the fuel and oil filler cap.

034-E01A-0496

SA-019

SA-15

SAFETY

SAFETY TRANSPORTING

• The danger of tipping is present when

loading/unloading the machine onto/from a truck or

trailer bed.

• Be sure to observe local regulations when

transporting the machine on public roads.

• Provide an appropriate truck or trailer for

transporting the machine.

Take the following precautions when loading /

unloading the machine:

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.

SA-395

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 powerdriven

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.

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

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.

SA-028

SA-527

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

case the light bulb is broken, spilled fuel, oil

antifreeze fluid, or window washer fluid may catch

fire.

SA-037

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

machine that is supported solely by a jack.

SA-527

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.

• As pieces may fly off, be sure to keep body and

face away from AIR RELEASE PLUG to avoid

injury. GEAR OIL is hot.

• Wait for GEAR OIL to cool, then gradually loosen

AIR RELEASE PLUG to release pressure.

SA-344

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.)

S522-E01A-0040

SA-040

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

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.

SA-039

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.

• Wait for the oil and components to cool before

starting any maintenance or inspection work.

SA-225

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.)

• 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.

SA-019

S506-E01A-0019

SA-20

SAFETY

AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing

serious injury, blindness or death.

• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.

• Tighten all connections before applying pressure.

• Search for leaks with a piece of cardboard; take

care to protect hands and body from highpressure

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-031

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 oilcooler

flange bolts.

• Tighten, repair or replace any missing, loose or

damaged clamps, lines, hoses, oil-cooler and oilcooler

flange bolts.

• Do not bend or strike high-pressure lines.

• Never install bent or damaged lines, pipes, or

hoses.

SA-019

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

pressurized air inside the hydraulic oil tank

is released (a hissing sound should be

heard).

• If any abnormalities are found, be sure to repair

them before operating the machine.

Check Heat Shields:

• Damaged or missing heat shields may lead to fires.

• Damaged or missing heat shields must be

repaired or replaced before operating the

machine.

S508-E02B-0019

EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the

following way:

• Stop the engine by turning the key switch to the

OFF position if there is time.

• Use a fire extinguisher if there is time.

• Exit the machine.

• 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.

SA-393

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 starting

grinding.

• After finishing welding and grinding, recheck that

there are no abnormalities such as the area surrounding

the welded area still smoldering.

SA-818

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

hoses or other materials before engaging in

welding, soldering, etc..

SA-030

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

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.

SAFETY

• Remove paint before welding or heating:

1) If you sand or grind paint, avoid breathing the

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.

SA-029

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 object

across the posts. Use a voltmeter or hydrometer.

• 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

of the battery may result.

• Loose terminals may produce sparks. Securely

tighten all terminals.

SA-032

• 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

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.

SAFETY

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

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.

SA-309

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

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.

SA-226

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 AND GROUP

CONTENTS

WORKSHOP MANUAL

All information, illustrations and specifications

in this manual are based on

the latest product information available

at the time of publication. The right is

reserved to make changes at any time

without notice.

SECTION 1 GENERAL INFORMATION

Group 1 Precautions for disassembling

and Assembling

Group 2 Tightening Torque

Group 3 Painting

SECTION 2 UPPERSTRUCTURE

Group 1 Cab

Group 2 Counterweight

Group 3 Main Frame

Group 4 Pump Device

Group 5 Control Valve

Group 6 Swing Device

Group 7 Pilot Valve

Group 8 Pilot Shut-Off Valve

Group 9 Shockless Valve

Group 10 Solenoid Valve

SECTION 3 UNDERCARRIAGE

Group 1 Swing Bearing

Group 2 Travel Device

Group 3 Center Joint

Group 4 Track Adjuster

Group 5 Front Idler

Group 6 Upper and Lower Roller

Group 7 Track

SECTION 4 FRONT ATTACHMENT

Group 1 Front Attachment

Group 2 Cylinder

SECTION 5 ENGINE

COPYRIGHT(C)2001

Hitachi Construction Machinery Co., Ltd.

Tokyo, Japan

All rights reserved

TECHNICAL MANUAL (Operational Principle)

SECTION 1 GENERAL

Group 1 Specification

Group 2 Component Layout

Group 3 Component Specifications

SECTION 2 SYSTEM

Group 1 Control System

Group 2 Hydraulic System

Group 3 Electrical System

TECHNICAL MANUAL (Troubleshooting)

SECTION 4 OPERATIONAL PER-

FORMANCE TEST

Group 1 Introduction

Group 2 Engine Test

Group 3 Excavator Test

Group 4 Component Test

Group 5 Standard

SECTION 3 COMPONENT OPERATION

Group 1 Pump Device



Group 4 Pilot Valve


Group 6 Others (Upperstructure)

Group 7 Others (Undercarriage)

SECTION 5 TROUBLESHOOTING

Group 1 Diagnosing Procedure

Group 2 Component Layout

Group 3 Troubleshooting A

Group 4 Troubleshooting B

Group 5 Troubleshooting C

Group 6 Electrical System Inspection

Group 7 ICX

SECTION 1

GENERAL INFORMATION

Group 1 Precautions for Disassembling

and Assembling

Precautions for Disassembling and

Assembling...................................... W1-1-1

Maintenance Standard Terminology... W1-1-7

CONTENTS

Group 2 Tightening Torque

Tightening Torque Specification......... W1-2-1

Torque Chart ..................................... W1-2-2

Piping Joint ....................................... W1-2-5

Periodic Replacement of Parts .......... W1-2-9

Group 3 Painting

Painting............................................. W1-3-1

1CCW-1-1

(Blank)

1CCW-1-2

GENERAL / Precautions for Disassembling and Assembling

PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING

Precautions for Disassembling and Assembling

• Clean the Machine

Thoroughly wash the machine before bringing it into

the shop. Bringing a dirty machine into the shop may

cause machine components to be contaminated

during disassembling/assembling, resulting in

damage to machine components, as well as

decreased efficiency in service work.

• Inspect the Machine

Be sure to thoroughly understand all disassembling/assembling

procedures beforehand, to help

avoid incorrect disassembling of components as well

as personal injury.

Check and record the items listed below to prevent

problems from occurring in the future.

• The machine model, machine serial number, and

hour meter reading.

• Reason for disassembly (symptoms, failed parts,

and causes).

• Clogging of filters and oil, water or air leaks, if any.

• Capacities and condition of lubricants.

• Loose or damaged parts.

• Prepare and Clean Tools and Disassembly Area

• Precautions for Disassembling

• To prevent dirt from entering, cap or plug the

removed pipes.

• Before disassembling, clean the exterior of the

components and place on a work bench.

• Before disassembling, drain gear oil from the

reduction gear.

• Be sure to provide appropriate containers for

draining fluids.

• Use matching marks for easier reassembling.

• Be sure to use the specified special tools, when

instructed.

• If a part or component cannot be removed after

removing its securing nuts and bolts, do not

attempt to remove it forcibly. Find the cause(s),

then take the appropriate measures to remove it.

• Orderly arrange disassembled parts. Mark and

tag them as necessary.

• Store common parts, such as bolts and nuts with

reference to where they are to be used and in a

manner that will prevent loss.

• Inspect the contact or sliding surfaces of

disassembled parts for abnormal wear, sticking,

or other damage.

• Measure and record the degree of wear and

clearances.

Prepare the necessary tools to be used and the area

for disassembling work.

W1-1-1


• Precautions for Assembling

• Be sure to clean all parts and inspect them for any

damage. If any damage is found, repair or replace

part.

• Dirt or debris on the contact or sliding surfaces

may shorten the service life of the machine. Take

care not to contaminate any contact or sliding

surfaces.

• Be sure to replace O-rings, backup rings, and oil

seals with new ones once they are disassembled.

Apply a film of grease before installing.

• Be sure that liquid-gasket-applied surfaces are

clean and dry.

• If an anti-corrosive agent has been used on a new

part, be sure to thoroughly clean the part to

remove the agent.

• Utilize matching marks when assembling.

• Be sure to use the designated tools to assemble

bearings, bushings and oil seals.

• Keep a record of the number of tools used for

disassembly/assembly. After assembling is

complete, count the number of tools, so as to

make sure that no forgotten tools remain in the

assembled machine.

Bleeding Air from Hydraulic System

When hydraulic oil is drained, the suction filter or the

suction lines are replaced, or the removal and installation

of the pump, swing motor, travel motor or cylinder

is done, bleed air from the hydraulic system in the

following procedures:

IMPORTANT: If the engine is started with air

trapped in the hydraulic pump housing,

damage to the pump may result.

If the hydraulic motor is operated

with air trapped in the hydraulic motor

housing, damage to the motor

may result.

If the cylinder is operated with air

trapped in the cylinder tube, damage

to the cylinder may result.

Be sure to bleed air before starting

the engine.

• Bleeding Air from Hydraulic Pump

• 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 engine

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 operation

(never fully stroke the cylinders during initial

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 hydraulic

oil level.

• Stop the engine. Recheck hydraulic oil level. Replenish

oil as necessary.

M1CC-07-002

W1-1-3


Floating Seal Precautions

1. In general, replace the floating seal with a new

one after disassembling.

If the floating seal is to be reused, follow these

procedures:

A

(1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of

cardboard to protect surfaces. Apply oil to the

sliding surface (C) on seal ring (A).

(2) Check the slide surface (C) on seal ring (A) for

scuffing, scoring, corrosion, deformation or

uneven wear.

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

or hardening.

B

W105-03-05-019

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

bores with cleaning solvent.

Use a wire brush to remove mud, rust or dirt.

After cleaning, thoroughly dry parts with

compressed air.

Correct

Incorrect

(2) Clean the floating seal and seal mounting

bores. Check the bore surface for scuffing or

scoring by touching the surface.

(3) Check that the O-ring is not twisted, and that it

is installed correctly on the seal ring.

(4) After installing the floating seal, check that seal

ring surface (C) is parallel with seal mating

face (D) by measuring the distances (C) and

(D) at point (a) and (b), as illustrated. If these

distances differ, correct the O-ring seating.

Correct

a

D

C

Incorrect

a

W105-03-05-020

a=b

b

a≠b

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

the load so that the nylon sling does not directly

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

lifted load balanced.

• When lifting a load using an eyehole, be sure to

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

slings or pushing slings with a metal object.

• When using with other types of slings (wire rope)

or accessories (shackle), protect the joint so that

the nylon sling is not damaged.

• Store the nylon slings indoors so they won’t deteriorate

with heat, sun light, or chemicals.

Correct Eyehole

Lifting Method

Incorrect Eyehole

Lifting Method

W102-04-02-016

W105-04-01-008

Bent Sling

W162-01-01-009

W1-1-5


CAUTION: If a load is lifted with a damaged

nylon sling, serious personal injury may result.

Be sure to visually check the nylon sling

for any damage before using.

Damaged Appearance

Broken Sewing Thread

2. Before using a nylon sling, visually check the nylon

sling for any damage corresponding to examples

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.

Fuzz

Scuffing

W162-01-01-002

W162-01-01-003

Broken Sewing

Thread

W162-01-01-004

Broken Sewing

Thread

W162-01-01-005

Broken Sewing

Thread

Scoring

Separation of

Belt

W162-01-01-006

Fuzz

Scuffing

Broken Warp

W162-01-01-007

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 accomplished

after exceeding this limit.

2. Repair or adjustment is impossible after exceeding

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

TIGHTENING TORQUE SPECIFICATIONS

GENERAL / Tightening

No.

Descriptions

Bolt Dia

Wrench

Torque

Q’ty

mm

Size (mm) N•m (kgf•m) (lbf•ft)

1

Engine cushion rubber mounting nut 14 4 22 140 (14.3) 103

Engine cushion rubber mounting bolt 16 4 24 270 (27.5) 200

2 Engine bracket mounting bolt and nut 10 8 17 50 (5.1) 37

3 Hydraulic oil tank mounting bolt 16 4 24 210 (21.5) 155

4 Fuel tank mounting bolt 16 4 24 270 (27.5) 200

5 ORS fittings for hydraulic hoses and piping

6 Pump mounting bolt 12 4 19 90 (9.2) 66

7 Control valve mounting bolt 14 3 22 180 (18.4) 133

8 Control valve bracket mounting bolt 14 4 22 140 (14.3) 103

9 Swing device mounting bolt 16 10 24 210 (21.5) 155

10 Battery mounting nut 10 4 17 20 (2.0) 15.0

11 Cab mounting nut 16 4 24 210 (21.5) 155

12

Swing bearing mounting bolt to upperstructure 16 22 24 270 (27.5) 200

Swing bearing mounting bolt to undercarriage 10 24 24 270 (27.5) 200

13

Travel device mounting bolt 16 20 24 300 (31) 220

Travel reduction device cover mounting bolt 14 8 22 140 (14.3) 103

14 Sprocket mounting bolt 16 24 24 270 (27.5) 200

15 Upper roller mounting bolt 14 2 22 140 (14.3) 103

16 Lower roller mounting bolt 14 40 22 245 (25) 180

17 Track shoe bolt 14 296 22 245 (25) 180

18 Cover mounting bolt

19 Coupling and T-bolt clamp of low pressure piping

6

10

12

8

5

6

-

-

-

19

22

27

32

36

41

10

17

19

13

8

11

29. 5

39

93

137

175

205

10

50

90

10.3 to 12.4

2.9

5.9

(3)

(4)

(9.5)

(14)

(18)

(21)

1

5. 1

9.2

(1.05 to 1.26)

(0. 3)

(0.6)

22

29

69

101

129

151

7. 4

37

66

(7.6 to 9.1)

(2.1)

(4.4)

20 Side-cutter mounting bolt 20 6 30 540 55 (400)

NOTE 1. Apply lubricant (e.g. white zinc B

dissolved into spindle oil) to bolts and

nuts to reduce friction coefficient of them.

2. Make sure bolt and nut threads are clean

before installing.

W1-2-1


TORQUE CHART

CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and procedures

can create safety hazards. For loosening

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

correctly when assembling the machine or components.

SA-040

Specified Tightening Torque Chart

Bolt Dia.

Wrench

Size

Hexagon

Wrench

Size

M552-07-091

M552-07-090

M157-07-225

Socket Bolt

N•m (kgf•m) (lbf•ft) N•m (kgf•m) (lbf•ft) N•m (kgf•m) (lbf•ft)

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 (14.3) (103) 55 (5.6) (41)

M16 24 14 270 (27.5) (200) 210 (21.5) (155) 80 (8.2) (59)

M18 27 14 400 (41.0) (295) 300 (30.5) (220) 120 (12.0) (89)

M20 30 17 550 (56.0) (410) 400 (41.0) (295) 170 (17.0) (125)

M22 32 17 750 (76.5) (550) 550 (56.0) (410) 220 (22.5) (162)

M24 36 19 950 (97.0) (700) 700 (71.5) (520) 280 (28.5) (205)

M27 41 19 1400 (143) (1030) 1050 (107) (770) 400 (41.0) (295)

M30 46 22 1950 (200) (1440) 1450 (148) (1070) 550 (56.0) (410)

M33 50 24 2600 (265) (1920) 1950 (200) (1440) 750 (76.5) (550)

M36 55 27 3200 (325) (2360) 2450 (250) (1810) 950 (97.0) (700)

W1-2-2

IMPORTANT: The following items are applied to

both fine and coarse pitch threads.

1. Apply lubricant (i. e. white zinc B

dissolved Into Spindle oil) to nuts

and bolts to reduce their friction

coefficients.

The plated bolts require no lubricant.

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 application.

5. Make sure that nut and bolt

threads are clean before installing.

Remove dirt or corrosion, if any.


Bolt Tightening Order

When tightening two or more bolts, tighten them alternately,

as shown, to ensure even tightening.

Equally tighten upper and lower

alternately

Tighten diagonally

Tighten from center and diagonally

1st to 4th

6

1

3

12 9 4 1 6 7

14

4

2

5

13 8 5 2 3 10 11

2nd to 3rd

W105-01-01-003

W1-2-3

Service Recommendations for Spilt Flange


IMPORTANT: 1. Be sure to clean and inspect sealing

surfaces. Scratches / roughness

cause leaks and seal wear.

Unevenness causes seal extrusion.

If defects cannot be polished

out, replace the component.

2. Be sure to use only specified O-

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

hold parts in place. Take care not

to pinch the O-ring.

4. Tighten bolts alternately and diagonally,

as shown, to ensure

even tightening.

5. Do not use air wrenches. Using

an air wrench often causes tightening

of one bolt fully before

tightening of the others, resulting

in damage to O-rings or uneven

tightening of bolts.

WRONG

RIGHT

WRONG

W105-01-01-015

W105-01-01-016

W105-01-01-008

Nut and Bolt Locking

• Lock Plate

IMPORTANT: Do not reuse lock plates. Do not try

to bend the same point twice.

Bend along edge sharply

RIGHT

RIGHT

Do not bend it round

WRONG

• Cotter Pin

IMPORTANT: Do not reuse cotter pins. Match the

holes in the bolt and nut while tightening,

not while loosening.

• Lock Wire

IMPORTANT: Apply wire to bolts in the bolttightening

direction, not in the boltloosening

direction.

Bend along edge sharply

RIGHT RIGHT

RIGHT

WRONG

Loosen WRONG

W105-01-01-009

Tighten

W105-01-01-010

W1-2-4


PIPING JOINT

1 4 3 5 2

IMPORTANT: The torques given in the chart are for

general use only.

Do not use these torques if a different

torque is given for a specific application.

Union Joint

Joint Body

M202-07-051

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°

IMPORTANT: 1. Do not over-tighten nut (3). Excessive

force will be applied to

metal sealing surfaces (4) and (5),

possibly cracking adapter (1). Be

sure to tighten nut (3) to specifications.

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.

30°

Male Union Joint

Female Union Joint

W105-01-01-017

Description

Wrench Size

mm

Wrench Size

mm

Tightening

Torque

Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)

30°male 19 19 59 (6,44)

22 22 98 (10,72)

27 27 118 (12,87)

36 36 235 (24,173)

41 41 295 (30,218)

50 50 490 (50,361)

60 60 670 (68,494)

70 70 980 (100,723)

37°female 19 17 44 (4.5,32)

22 19 59 (6,44)

27 22 118 (12,87)

36 30,32 235 (24,173)

41 36 295 (30,218)

50 46 490 (50,361)

NOTE: Tightening torque of 37°male coupling without union is similar

to tightening torque of 37°female.

W1-2-5


O-ring Seal Joint

7 6 9

O-ring (6) seats against the end face of adapter (7) to

seal pressure oil.

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

a new one when reconnecting.

2. Before tightening nut (9), confirm

that O-ring (6) is seated correctly

in O-ring groove (e). Tightening

nut (9) with O-ring (6) displaced

will damage O-ring (6), resulting

in oil leakage.

3. Take care not to damage O-ring

groove (e) or sealing surface (10).

Damage to O-ring (6) will cause

oil leakage.

4. If nut (9) is loose and oil is leaking,

do not re-tighten nut (9). Replace

O-ring (6) with a new one

and check that O-ring (6) is correctly

seated in place, tighten nut

(9).

8 10

Hose Fittings

M104-07-033

Wrench Size

mm

Wrench Size

mm

Tightening

Torque

Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)

19 17 59 (6,44)

22 19 98 (10,72)

27 22 118 (12,87)

36 30,32 235 (24,173)

41 36 295 (30,218)

50 46 490 (50,361)

W1-2-6


Screw-In Connection

Depending on types of screw and sealing, different

types of screw fittings are used.

PT

30°

PF

IMPORTANT: Be sure to confirm that the thread

pitch and thread type (tapered or

straight) are the correct type before

using any screw-in connection.

Male Tapered Thread

Male Straight Thread

W105-01-01-018

Seal Tape Application

Seal tape is used to seal clearances between male

and female threads, so as to prevent any leaks between

threads.

Be sure to apply just enough seal tape to fill up thread

clearances. Do not overwrap.

• Application Procedure

Confirm that the thread surface is clean and, free of

dirt or damage.

Apply seal tape around threads as shown. Wrap seal

tape in the same direction as the threads.

Male Tapered Thread

Wrench Size

mm

Tightening

Torque

Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)

17,19 59 (6,44)

19,22 98 (10,72)

27,22 118 (12,87)

36,32 235 (24,173)

41 295 (30,218)

50 490 (50,301)

60 670 (68,494)

70 980 (100,723)

External Thread

Internal Thread

Leave one to two pitch threads uncovered

Clearance

W105-01-01-019

Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs depending

on the type of clamp.

T-Bolt Type Band Clamp:

4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft )

Worm Gear Type Band Clamp:

5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)

T-Bolt Type

Worm Gear Type

M114-07-041

M114-07-043 M114-07-042

W1-2-7


Connecting Hose

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 machine.

WRONG

RIGHT

Do not install hoses kinked. Application of

high oil pressure, vibration, or an impact to a

kinked hose may result in oil leaks, hose rupture

or separation of fitting. Utilize Print

marks on hoses when installing to prevent

hose from being kinked.

WRONG

Rubbing Against

Each Other

RIGHT

W105-01-01-011

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

Take care that hoses do not come into contact

with moving parts or sharp objects.

WRONG

Clamp

Clamp

RIGHT

Rubbing Against

Each Other

W105-01-01-013

WRONG

RIGHT

Rubbing Against

Each Other

Clamp

W105-01-01-014

W1-2-8

PERIODIC REPLACEMENT OF PARTS


To ensure safe operation, be sure to conduct periodic

inspection of the machine. In addition, the parts listed

below, if defective, may pose serious safety/fire hazards.

It is very difficult to gauge the extent of deterioration,

fatigue, or weakening of the parts listed below

simply by visual inspection alone. For this reason, replace

these parts at the intervals shown in the table

below. However, if any of these parts are found to be

defective, replace before starting operation, regardless

of the interval.

Also, when replacing hoses, check the clamps for deformation,

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 replacement.

Hydraulic

System

Engine

Base Machine

Front

Attachment

Periodic Replacement Parts

Fuel hose (Fuel tank to filter)

Fuel hose (Fuel tank to injection pump)

Oil filter hose (Engine to oil filter)

Heater hose (Heater to engine)

Pump suction hose

Pump delivery hose

Swing hose

Boom cylinder line hose

Arm cylinder line hose

Bucket cylinder line hose

Blade cylinder line hose

Pilot hose

Replacement

Intervals

Every 2 years

Every 2 years

Every 2 years

Every 2 years

Every 2 years

Every 2 years

Every 2 years

Every 2 years

Every 2 years

Every 2 years

Every 2 years

Every 2 years

NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.

W1-2-9


(Blank)

W1-2-10

GENERAL / Painting

PAINTING

Painting Appointment

Surfaces to Be Painted

• Main surface of upperstructure

Main frame

Press cover

Counter weight

• Track(undercarriage)and blade

• Front Attachment

• Ladder rail,mirror stay,clamp

• Mirror stay of rear cab

Painting Colour

YR-01[TAXI yellow]and SC painting to covers of boom foot portion

Two-tone of YR-01[TAXI yellow]and N4.5[High-Grade Beige],and SC

painting

YR-01[TAXI yellow]and SC painting

YR-01[TAXI yellow]and SC painting

PB5-01[SP-424 Dark Grey]

YR-01[TAXI yellow]and SC painting(Except bucket and link)

N2.5[High-Grade Black]

Flat Black

Final painted colour

• Inside and outside surface of cab N4.5[High-Grade Beige]

• Seat stand TN-20[Black]

• Lever(Travel,lock,foot rest) H1-1035[Flat Black]

• Lever(Blade) TN-20[Black]

• Floor plate H4-224[Beige]

• Plastic cover(Engine,tank,front radiator) YR-01[TAXI yellow]

• Cover upper control valve (Flat Black) N2.5[High-Grade Black]

IMPORTANT: When cleaning arm, cylinder, etc.

fitted with HN bushing, take care not

to pour washing liquid directly on

them. The ambient temperature shall

be controlled under 70°C when

painting and drying.

NOTE: SC painting (self cleaning painting)

Rain water will remove dust easily due to

self-purification of water based paint.

Rail

Clamp

Cover Upper

Control Valve

Except Upperstructure

Appointment Circumference

TAXI yellow

Mirror Stay

Main Frame

Hatched

Portion

High-Grade

Beige

Press

Cover

Main Frame Except Slash

Portion TAXI yellow

W1CC-01-03-001

W1-3-1

GENERAL / Painting

Plastic Cover

Front

Attachment

Mirror Stay

Counter

weight

Main Frame

Hatched Portion

High-Grade Beige

Plastic

Cover

Track

Press

Cover

Blade

W1CC-01-03-003

536

669.3

W1CC-01-03-002

Main Frame Hatched

Portion High-Grade Beige

YR-01

(TAXI yellow)

A

Out Surface of Hinge

Swing Portion YR-01

(TAXI yellow)

B

551.2

467.3

334

W1CC-01-03-007

W1CC-01-03-006

Section A

5

Mask Garnished Portion

Section B

YR-01(TAXI Yellow)

Door

Panel Behind the

Door

10

Painting Area of the Door

YR-01 (TAXI Yellow)

W178-01-03-005

W178-01-03-004

W1-3-2

MEMO

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SECTION 2

UPPERSTRUCTURE

CONTENTS

Group 1 Cab

Remove and Install Cab .................... W2-1-1

Dimensions of the Cab Glass ............ W2-1-9

Group 2 Counterweight

Remove and Install Counterweight .....W2-2-1

Group 3 Main Frame

Remove and Install Main Frame ............ W2-3-1

Group 4 Pump Device

Remove and Install Pump Device .......... W2-4-1

Disassemble Pump Device .................... W2-4-4

Assemble Pump Device......................... W2-4-8

Disassemble and

Assemble Valve Block ........................ W2-4-12

Disassemble and

Assemble Control Piston .................... W2-4-14

Maintenance Standard ......................... W2-4-16

Disassemble and Assemble Pilot

Pump .................................................. W2-4-18


Remove and Install Control Valve 1 ....... W2-5-1

Disassemble Control Valve 1 ................. W2-5-5

Assemble Control Valve 1 .................... W2-5-15

Remove and Install Control Valve 2 ..... W2-5-24

Disassemble Control Valve 2 ............... W2-5-26

Assemble Control Valve 2 .................... W2-5-28


Remove and Install Swing Device...... W2-6-1

Disassemble Swing Device................ W2-6-4

Assemble Swing Device .................. W2-6-10

Disassemble Swing Motor .............. W2-6-18

Assemble Swing Motor .................... W2-6-22

Disassemble and Assemble

Valve Block.................................... W2-6-26

Maintenance Standard..................... W2-6-28

Group 7 Pilot Valve

Remove and Install Right Pilot Valve . W2-7-1

Remove and Install Left Pilot Valve.... W2-7-5

Remove and Install Travel

Pilot Valve........................................ W2-7-9

Remove and Install

Blade Pilot Valve............................ W2-7-13

Disassemble Right and Left

Pilot Valves.................................... W2-7-16

Assemble Right and Left

Pilot Valves.................................... W2-7-20

Disassemble Travel Pilot Valve........ W2-7-24

Assemble Travel Pilot Valve ............ W2-7-28

Disassemble Blade Pilot Valve ........ W2-7-34

Assemble Blade Pilot Valve ............. W2-7-36

Group 8 Pilot Shut-Off Valve

Remove and Install Pilot Shut-Off

Valve ............................................... W2-8-1

Disassemble Pilot Shut-Off Valve ...... W2-8-4

Assemble Pilot Shut-Off Valve ........... W2-8-6

1CCW-2-1

Group 9 Shockless Valve

Remove and Install Shockless

Valve ............................................... W2-9-1


Shockless Valve .............................. W2-9-3

Group 10 Solenoid Valve

Remove and Install Solenoid

Valve Unit ...................................... W2-10-1

Disassemble Proportional

Solenoid Valve............................... W2-10-4

Assemble Proportional

Solenoid Valve............................... W2-10-6


Pilot Relief Valve ........................... W2-10-8

1CCW-2-2

UPPERSTRUCTURE / Cab

REMOVE AND INSTALL CAB

Removal

1. Remove seat mounting bolts (2) (4 used) to remove

seat (1).

: 17 mm

1

2. Remove caps (5) (5 used) from duct cover (4)

with a screw driver. Remove screws (3) (5 used)

to remove the duct cover.

2

M1CC-01-012

3

4

5

W1SE-02-01-003

3. Remove screws (8) (2 used). Then remove duct

(7) from duct (6).

6

7

8

4. Remove bolts (11) (4 used) from the rear side of

cab. Remove cover (10) from rear cover (9).

: 13 mm

W1SE-02-01-004

9

11

10

W1SE-02-01-005

W2-1-1

5. Remove clamp (13) behind rear cover (9). Remove

air hose (14) of the air condition from air

condition hose (12).


9

12

13

14

6. Remove vinyl hose (17) and connector (15) from

washer tank (16).

16

15

W1SE-02-01-006

17

M1CC-00-003

7. Remove screws (20) (2 used). Remove duct (21)

from duct (18) and duct (19).

18

19

20

21

8. Disconnect and remove the connectors of radio

antenna feeder (22) from both right and left sides.

Remove screw (23) to remove earth wire (24).

Remove connectors (25) (6 used).

Push junction box (26) out and remove bolts (27)

(2 used) to remove earth wire (28).

: 13 mm

W1SE-02-01-008

22

23

24

25

26

28

27

W1SE-02-01-009

W2-1-2


9. Disconnect connector (30) of work light harness

(29) at right rear side from the cab. Loosen clips

(31) (2 used). Pass the work light harness at the

main frame side through to draw the harness out

by the clips.

NOTE: No need to remove the work light on the

cab, work light harness (29) of the cab side

and clips (31) (8 used).

Work Light

29

30

31

W1CC-02-01-002

10. Remove bolts (34) (6 used), spring washers (33)

(6 used), plane washers (32) (6 used). Then remove

under cover (35).

: 17 mm

35

32

33

34

W1CC-02-07-003

11. Draw out work light harness (29) at the main

frame side from the hole where under cover (35)

has been removed.

NOTE: Wind the work light harness passing

through the cab into a ball near the floor

plate hole, and secure it.

29

Floor Plate Hole

W1CC-02-01-001

W2-1-3


CAUTION: Cab weight: 270 kg (600 Ib)

12. Attach sling belts to top of the cab (at 4 places).

W1SE-02-01-011

13. Remove socket bolts (36) (4 used), bolts (38) (5

used) and nuts (37) (4 used) from the frame.

:8 mm

: 17 mm

: 24 mm

38

36

14. Hoist the cab carefully and remove from the

frame.

37

W1SE-02-01-010

W102-02-01-001

W2-1-4


Installation


1. Attach sling belts to top of the cab (at 4 places).

Hoist the cab by crane and put it on the frame.

2. Install nuts (37) (4 used), bolts (38) (5 used) and

socket bolts (36) (4 used).

: 24 mm

: 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

:8 mm

: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

38

W102-02-01-001

36

37

3. Pass work light harness (29) to the main frame

through clips (31) (2 used) to connect connector

(30). Tighten the clip to secure the harness.

W1SE-02-01-010

29

30

31

W1CC-02-01-002

W2-1-5

4. Install undercover (35) by installing plane washers

(32) (6 used), spring washers (33) (6 used) and

bolts (34) (6 used).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)


35

32

33

34

5. Connect earth wire (28) with bolts (27) (2 used).

Insert junction box (harness side) (26) to its position

and connect connectors (25) (6 used).

Connect earth wire (24) with screw (23) and insert

radio antenna feeder (22) to both right and left

side.

: 13 mm

: 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft)

W1CC-02-07-003

22

23

24

25

26

28

27

W1SE-02-01-009

6. Insert duct (21) into ducts (18) and (19). Then secure

it with screws (20) (2 used).

18

19

20

21

W1SE-02-01-008

W2-1-6


7. Install vinyl hose (17) and connector (15) to the

bottom of washer tank (16).

15

16

17

M1CC-00-003

8. Pull air condition air hose (14) upward to install air

condition hose (12).

Secure the hose at its connecting position with

clamp (13).

9

12

13

14

W1SE-02-01-006

9. Install cover (10) onto rear cover (9) with bolts (11)

(4 used).

: 13 mm

: 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft)

9

11

10

W1SE-02-01-005

W2-1-7

10. Insert duct (7) into duct (6) and install it with

screws (8) (2 used).

:3 N⋅m (0.3 kgf⋅m, 2.2 Ibf⋅ft)


6

7

8

11. Install duct cover (4) to the cab with screws (3) (5

used). Install caps (5) (5 used)

:3 N⋅m (0.3 kgf⋅m, 2.2 Ibf⋅ft)

W1SE-02-01-004

3

4

5

12. Install seat (1) with bolts (2) (4 used).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

1

W1SE-02-01-003

2

M1CC-01-012

W2-1-8

DIMENSIONS OF THE CAB GLASS


Unit: mm

Along the

Periphery

C1

Along the

Periphery

C1

75.6

1110.5

A

110

36 (Specified)

R2929

R5

R30

27.3

Section A

W178-02-01-019

36

R2929

R30

R293.5

R129

770.5

193.6

189

(5 mm)

39

(Specified)

36

R75

R5

58±5

532.5

1081.1

R20

(Fillet)

R542

52.8

R1910

1044.4

R5

39

322.1

415.1

1164.4

W1SE-02-01-013

2-R5

Chamfer along the Periphery

unless Otherwise Specified.

Chamfer

Here

R2

W1SE-02-01-012

2-φ 13.5±0.2

2-R20

2-R15

40

42.3

320±0.5

(4 mm)

34

φ 13.5±0.2

2-R105

2-R15

2-R20

4-R73

39.5

40

32.5

557

B

48±5

112±0.2

23.5

54.8±0.2

Section B

W178-02-01-019

697.5±0.5

803

Stop R Here

291±0.2

W1SE-02-01-014

W2-1-9


Unit: mm


R2852.4

R55.8

FREE R

(5 mm)

32±5

9±5

92.8

27.4

342.7

55.1

W1SE-02-01-018

W1SE-02-01-012

194.6

444.2±1

200

152.9±1

Chamfer along

the Periphery

unless Otherwise

Specified

Chamfer along the

Periphery unless

Otherwise Specified

(5 mm)

597±1

597±1

C

(5 mm)

D

R2916.2

Chamfer

Here

41.5

40

Chamfer

Here

10±5

101±5

2-φ 13 +1 0

167

50.2

4-R5

109.6

4-R5

249.7±1

W1SE-02-01-017

347.4±1

69.7

50.2

W1SE-02-01-016


596.5

537±0.5

371

2-R5

R2937

2-φ 18±0.5

(4 mm)

244±0.5

50±0.5

R114

63.5±0.5

67.5±0.5

412

372.5

Section C and D

W178-02-01-019

96

R551.5

40

637

652

490.5 40 R9

W1SE-02-01-015

W2-1-10


Method for Removing Cab Glass

Procedures for removing right-hand cab glass, rear

left-hand glass and lower glass of the door are as follows:

CAUTION: When removing broken or

cracked glass, there is a danger of severe injury

from glass shards.

Before removing, bind the broken area and

crack positions with gum tape to prevent the

danger from occurring. Fallen glass shards

must be removed.

Garnish

Right-Hand Glass

1. Remove resin panel, garnish, spacer, and etc.

around the glass.

Lower Glass

of the Door

Rear Left-Hand

Glass

Garnish

Resin Panel

W1SE-02-01-042

2. Pierce a hole in adhesive with awl (or cutter, etc).

Cab

Glass

Awl

3. Pass a piano wire or iron wire through the through

hole.

Adhesive

W1SE-02-01-033

Piano Wire

(Iron Wire)

W1SE-02-01-034

W2-1-11


4. Wind both ends of the piano wire to drivers. Saw

down the adhesive by sawing back and forth.

Remove the glass from the cab.

NOTE: Saw down from the middle of adhesive

between glass and cab.

There is a danger that piano wire may break

as it is heating in local part. Always change

the part used in sawing for cooling.

Cab

(Outside of

the Cab)

Glass

Adhesive

(Inside of the Cab)

W1SE-02-01-035

W2-1-12


Method for Installing Cab Glass

Procedures for installing right-hand cab glass, rear

left-hand glass and lower glass of the door are as

follows:

Right-Hand Glass

1. Remove the adhesive left at the cab side all

around by about 1 to 2 mm (0.04 to 0.08 in) with

cutter.

NOTE: Take care not to scratch the cab painting.

Lower Glass

of the Door

Rear Left-Hand

Glass

W1SE-02-01-042

Cab

2. Clean the adhesive surface at cab side with the

white gasoline.

Cutter

Cut the Adhesive Down

by 1 to 2 mm Deep

W1SE-02-01-036

IMPORTANT: Shake primer (24) vigorously for

about 1 minute to mix thoroughly before

loosening its cap.

It should be used quickly when

opened and sealed immediately

when applying is finished.

It should be used within 3 days after

being opened. (It can be wasted in 2

hours if left it opened.)

3. Apply coating primer (SUNRISE MSI Primer 24)

onto the adhesive cut face at cab side evenly.

Wait for 15 munutes or so to let the coating dry by

itself.

NOTE: Apply the coating evenly, neither too much,

nor too little.

Cab

Apply Primer (24)

Evenly

Adhesive Cut Face

at Cab Side

W1SE-02-01-038

W2-1-13


4. Clean the surface for installing new glass with

clean waste cloth after fully soaking it in alcohol.

IMPORTANT: Shake primer (35) vigorously for

about 1 minute to mix thoroughly before

loosening its cap.

It should be used quickly when

opened and sealed immediately

when applying is finished.

It should be used within 3 days after

being opened. (It can be wasted in 2

hours if left it opened.)

5. Apply glass primer (SUNRISE MSI Primer 35)

onto the glass where it needs to be coated with

the adhesive. Wait for 15 minutes or so to let the

coating dry itself.

(As for the position where glass primer 35 should

be applied, refer to W2-1-15)

11. Lift the glass by a suction lifter (rubber suction

plate 4355282, refer to W2-1-15) within 5 minutes

to adhere onto the cab.

NOTE: Press fit the glass onto the cab when locating

it by the spacer adhered on the glass.

The other surface where applied with adhesive,

except the mating surface, should

be cleaned with white gasoline before the

adhesive takes.

12. The glass should be secured with gum tape to

prevent it from moving until the adhesive

becomes solid.

NOTE: Time required for adhesive (SUNRISE MSI

SR Seal U90 4463876) becoming solid: 8

hours (Just for reference).

6. Peel the paper from the spacer and put on glue at

the place where the paper was instead. Then put

the adhesive tape on the glass.

(As for the position to install spacers a , b and c,

refer to W2-1-15)

7. Cut the nozzle of adhesive cut ridge (SUNRISE

MSI SR Seal U90 4463876) in V-shape. (Refer to

W2-1-15)

Right-Hand Glass

500

350

200

200

Gum Tape

500

450

8. Remove the seal from the cut ridge end to install

V cut nozzle on it.

Rear Left-Hand Glass

150 200

500

100

W1SE-02-01-039

9. Caulk the cut ridge onto hand cauking gun.

10. When applying primer, it should be applied onto

the glass evenly in V-bead-shape at the position

where adhesive should be coated.

(As for the position to apply adhesive, refer to

W2-1-15)

200

500

200

W1SE-02-01-040

Lower Glass of the Door

150

150

50

150

150

200

W1SE-02-01-041

W2-1-14


Spacer a (4458466) Spacer b (4458469) Spacer c (4458470)

20

20

20

5

8.7 0.5

Concave

1

R7

6

8.5

3.6

10.9

5

Adhesive Tape

on Both Side

Right-Hand Glass

Spacer b

B

W1SE-02-01-030

B

700

9.3

0.5

Convex

R6

10.5

Flat 7

5

3.6 Adhesive Tape

1

6

on Both Side

8.5

W1SE-02-01-031

Rear Left-Hand Glass

D

Spacer c

400

Spacer c

D

Adhesive Tape

on Both Side

Lower Glass of

the Door

225

W1SE-02-01-032

286

305

Spacer c

c

Spacer a

Lift Partially

c

110

A

52 450

85

160

650

290

30

Spacer a

445

62

Spacer b

A

W1SE-02-01-019

123

60

W1SE-02-01-021

W1SE-02-01-020

Section A-A

Section B-B

Section C-C

Section D-D

Glass

Adhesive

Install Spacer with

Its Concave Face

Facing Adhesive

Spacer a

Spacer b

Spacer c

Spacer c

Adhesive

W1SE-02-01-023

Glass Adhesive

Install Spacer with

Its Convex Face

Facing Adhesive

W1SE-02-01-024

Adhesive

18

W1SE-02-01-025

18

8 to 9 mm

W1SE-02-01-026

9.0

Coat Adhesive

Bead Here

Glass

4 to 5 mm

Spacer a or

Spacer b

Cut Nozzle End

into V-Shape

13 to 15 mm

It Should be Applied in

Even V-Bead-Shape

5.5 5.0

5.5 to 5.9

Adhesive Tape

on Both Side

W1SE-02-01-027

Glass

W1SE-02-01-043

4.9

3.6

Remove

Seal

12.0

Cab

Adhesive Bin

W1SE-02-01-022

W1SE-02-01-028

W2-1-15


13. The quantity of adhesive and primer should be used (Just for reference)

Adhesive: SUNRISE MSI SR Seal U90 Primer: SUNRISE MSI

Glass

(4463876)

Primer 24 (for coating)

320 cm 3 Cutridge

Primer 35 (for glass)

150 cm 3 in Each Bin

Right-Hand Glass (1 Piece) 1 used 1/10 used for each one

Rear Left-Hand Glass (1 Piece) 1/2 used 1/20 used for each one

Lower Glass for the Door (1 Piece) 1/3 used 1/50 used for each one

IMPORTANT: Rear left-hand glass is archedfringed

type. If this glass needs to be

replaced, contact with the nearest

HITACHI Office to preplace it as a

unit.

W2-1-16

Install upper door glass as follows


1. Before installing the glass, remove the garnish

from the outside of the sash assembly in the cab

for easier installing. Push the sash assembly out

of the cab and remove it by hand.

Sash Assembly

Glass C

2. Insert glass A and glass B into the sash slot. Insert

glass C into the mounting rubber.

Glass A

Glass B

Garnish

W1SE-02-01-044

3. Install the sash assembly with glass onto the door

from outside of the cab. Secure the sash assembly

inside of the cab with the garnish.

Mounting Rubber

Glass C

Mounting Rubber

Sash Slot

Glass A and

Glass B

W1SE-02-01-045

W2-1-17


Install rear glass as follows

1. Align rear glass (1) with the mounting position at

the rear of cab.

2. Secure the glass with screws (3) (2 used), washers

(4) (4 used) and nuts (5) (2 used) for hinges

(2) (2 used) temporarily.

3

7

3. Secure the glass with screws (7), washers (8) and

nuts (9) for catch handle (6) temporarily.

2

4. Tighten screws (3) (2 used) and screw (7) after

leveling.

1

6

5. Adjust glass positions on the cab at both right and

left with screw (10) of hinge (2).

IMPORTANT: Rear glass is arched-fringed type. If

this glass needs to be replaced, contact

with the nearest HITACHI Office

to replace it as a unit.

5

4

8

9

10 2 3

4

6 7

8

1 5 9

W1SE-02-01-046

W2-1-18

Install upper front glass as follows


1. The glass is adhered with mounting rubber. Draw

the mounting rubber and secure to the cab mounting

surface. (All around the glass)

2. Adhere seal (1) to the lower side the upper front

glass with POS seal.

Adhere both right and left ends (the part turning

thicker after bringing together) of seal (1) with adhesive

POS seal to secure them together.

Adhere the lip in the center of seal (1) with POS

seal. No visible bending or folds can be found.

Adhered with

Mounting Rubber

(All Around the

Glass)

Upper Glass

Frame

NOTE: POS seal:

TOSHIBA SILONCON POS Seal (black)

Tube adhesive in glue form

IMPORTANT: The glass and mounting rubber

should be adhered with special adhesive.

Failure to do so, may result

in the glass dropping out. Therefore,

if the glass needs to be replaced, replace

the glass and mounting rubber

as a unit.

Upper front glass is arched-fringed

type. If this glass needs to be replaced,

contact with the nearest HI-

TACHI Office to replace it as a unit.

Lower Glass

Upper Glass

1

Adhere POS

Seal

POS Seal

1 1

Lower Glass

Lower Glass

W1SE-02-01-047

W2-1-19


(Blank)

W2-1-20

UPPERSTRUCTURE / Counterweight

REMOVE AND INSTALL COUNTER-

WEIGHT

2 1

Removal

1. Loosen and remove mounting bolts (2) (4 used)

of engine cover (1) to remove engine cover (1).

: 17 mm

M1CC-00-011


of cover (3) on the top of the hydraulic oil tank to

remove cover (3).

: 17 mm

3

4

M1CC-07-001

3. Loosen and remove bolts (6) (3 used), (7) and (8)

(2 used) located on right side of cover (5), to

remove cover (5).

: 17 mm

6 5

7

8

W197-02-10-003

W2-2-1



of cover (9) at the muffler side to remove the

cover.

: 17 mm

9 10

5. Loosen and remove right side cover (11)

mounting bolts (12) (5 used) (2 for upper and 3

for lower) to remove the right side cover .

: 17 mm

12

W190-02-02-007

6. Remove hose (14) and connector (16) from window

washer tank (15).

17

11

12

W190-02-02-008

7. Loosen and remove cover (17) mounting nuts (13)

(2 used), the spring washers (2 used) and the

washers (2 used) to remove cover (17), located in

front of the radiator.

: 17 mm

16

15

13

14

M1CC-00-003

W2-2-2


8. Install eye bolts (A-27, M27, Pitch 3.0) onto

counterweight (18). Attach the wire ropes to the

eye bolts. Hold the counterweight by crane.

18

W190-02-02-012

CAUTION: Counterweight (18) weight:

1270 kg (2800 lb)


and washers (20) (3 used) for counterweight (18).

By crane, lift the counterweight slightly, then slide

it backwards to remove it.

: 41 mm

19

20

W190-02-02-013

W2-2-3


Installation

CAUTION: Counterweight(18) weight:

1270 kg (2800 lb)

1. Install eye bolts (A-27, M27, Pitch 3.0) onto

counterweight (18). Attach the wire ropes to the

eye bolts. By crane, lift and slide counterweight

(18) slightly forwards to align the mounting

holes.

18

2. Put washers (20) (3 used) to bolts (19) (3 used) .

Tighten bolts (19).

: 41 mm

: 980 N⋅m (100 kgf⋅m, 720 lbf⋅ft)

19

20

W190-02-02-012

3. Install cover (17) at the front side of the radiator.

Install the washers (2 used) and spring washers

(2 used) to the cover mounting locations. Use

nuts (13) (2 used) to secure the cover.

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

17

W190-02-02-013

4. Connect connector (16) and hose (14) to

window washer tank (15).

16

15

13

14

M1CC-00-003

W2-2-4


5. Install and secure right side cover (11) with bolts

(12) (5 used) (2 for upper and 3 for lower).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

12

11

12

W190-02-02-008

6. Install cover (9) at the muffler side to the main

body. Use bolts (10) (3 used) to secure the

cover.

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

9

10

W190-02-02-007

7. Install and secure right side cover (5) with bolts

(6) (3 used), (7) and (8) (2 used).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

6 5

7

8

W197-02-10-003

W2-2-5


8. Install the top cover (3) of the hydraulic oil tank

onto the main body. Use bolts (4) (4 used) to secure

the cover.

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

3

4

M1CC-07-001

9. Install engine cover (1) onto the main frame.

Use bolts (2) (4 used) to secure the cover.

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

2 1

M1CC-00-011

W2-2-6

REMOVE AND INSTALL MAIN FRAME

UPPERSTRUCTURE / Main Frame

CAUTION: Escaping fluid under pressure

can penetrate the skin, causing serious injury.

Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.

Hydraulic oil may be hot after operation and

may spurt, possibly causing severe burns. Be

sure to wait for oil to cool before starting any

repair work.

The hydraulic oil tank cap may fly off due to

remaining pressure if removed quickly.

Slowly loosen the cap to release any remaining

pressure completely.

Preparation

1. Park the machine on a solid, level surface. Lower

the bucket onto the ground.

2. Stop the engine. Push the air release valve on the

top of hydraulic oil tank to release any remaining

pressure.

3. Remove the hydraulic oil tank cap. Connect a

vacuum pump and operate it continuously to

maintain negative pressure in the hydraulic oil

tank. Run the vacuum pump continuously, while

working on the hydraulic system.

M1CC-07-002

W2-3-1


Removal


1. Remove the cab.

(Refer to Remove and Install Cab section)

: 13 mm, 17 mm, 24 mm

:8 mm

W102-02-01-001

CAUTION: Counterweight weight: 1270 kg

(2800 Ib)

2. Remove the counterweight.

(Refer to Remove and Install Counterweight section)

: 17 mm, 41 mm

W190-02-02-012

CAUTION: Front attachment assembly

weight: 1100 kg (2430 Ib)

3. Remove the front attachment assembly.

(Refer to Remove and Install Front Attachment

section)

: 24 mm, 27 mm

W105-02-03-002

4. Attach the identification tags to the hydraulic

hoses at the top of center joint in aid of reassembling.

Disconnect all hydraulic hoses at the top of

the center joint. Cap all disconnected hoses.

: 19 mm, 22 mm, 27 mm

5. Remove the stopper from the center joint.

: 19 mm

Front Side

W102-03-03-001

W2-3-2


CAUTION: Upperstructure weight: 2300 kg

(5070 Ib)

6. Attach wire ropes to the boom mounting hole and

the mounting bolt hole of the counterweight. Hoist

the wire rope by crane to set the rope taut.

NOTE: Use chain blocks for easy in adjusting wire

rope length and keep center gravity.

Please check translation.

W190-02-03-012

Mounting Bolt Hole

of Counterweight

W1CC-02-03-002

7. Put matching marks on the swing bearing and the

main frame.

Loosen and remove the mounting bolts (24 used)

of the swing bearing.

: 24 mm

8. Lift the main frame slightly from the undercarriage.

Level the main frame by adjusting the

chain blocks. Remove the upperstructure by

crane.

W102-02-03-004

W1CC-02-03-001

W2-3-3


Installation

CAUTION: Upperstructure weight: 2300 kg

(5070 Ib)

1. Attach wire ropes to the frame and level the frame

by chain block. Install it to the undercarriage by

crane.

NOTE: As for hoisting method, refer to Removal

section.

2. Align the matching mark on the swing bearing with

that on the upperstructure.

Install the mounting bolts (24 used) on the swing

bearing and tighten them temporarily. After

removing the wire ropes from the main frame,

tighten the bolts.

: 24 mm

: 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft)

3. Reconnect all hoses to the center joint.

: 19 mm

: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)

: 22 mm

: 39 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)

: 27 mm

: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)

W1CC-02-03-001

W102-02-03-004

4. Install the stopper onto the center joint.

: 19 mm

: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)

Front Side

W102-03-03-001

W2-3-4



5. Install cab.

(Refer to Remove and Install Cab section)

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

: 13 mm

: 10 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft)

:8 mm

: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

CAUTION: Counterweight weight: 1270 kg

(2800 Ib)

6. Install counterweight.

(Refer to Remove and Install Counterweight

section)

: 41 mm

: 980 N⋅m (100 kgf⋅m, 720 Ibf⋅ft)

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

W102-02-01-001

CAUTION: Front attachment weight: 1100 kg

(2430 Ib)

7. Install front attachment.

(Refer to Remove and Install Front Attachment

section)

: 24 mm

: 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)

[Piping]

: 27 mm

: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)

W190-02-02-012

IMPORTANT: After completing work, check for hydraulic

oil level. Start engine to

check for any oil leakage.

W105-02-03-002

W2-3-5


(Blank)

W2-3-6

REMOVE AND INSTALL PUMP DEVICE

UPPERSTRUCTURE / Pump Device



Avoid this hazard by relieving pressure

before disconnecting hydraulic lines.




repair work.



Slowly loosen the cap to release any

remaining pressure completely.

Preparation

1. Park the machine on a solid level surface.

Lower the bucket onto the ground.

2. Stop the engine. Push the air release valve on

the top of the hydraulic oil tank to release any

remaining pressure.

M1CC-07-002






W2-4-1


Removal

CAUTION: Counterweight weight:

1270 kg (2800 lb)

1. Remove the counterweight (See Remove and

Install of Counterweight in this section).

2. Loosen bolts (2) (4 used) to remove cover (1) at

the lower side of the muffler.

: 17 mm

1

W190-02-02-012

2

3. Disconnect all hoses, pipes and electric wires

from the pump device. Cap the disconnected

hoses. Attach tags to them for reassembly.

: 19, 27, 36, 41 mm

: 10 mm

W197-02-04-001

CAUTION: Pump device weight: 56 kg

(123 lb)

4. Attach a sling belt to the pump device. Lift and

hold it by crane.

Loosen and remove bolts (3) (4 used). Remove

the pump device by crane.

: 19 mm

3

W190-02-04-002

W190-02-04-003

W2-4-2


Installation

CAUTION: Pump device weight: 56 kg

(123 lb)

1. Lift the pump device by crane to install the

pump device to the pump cover.

2. Use mounting bolts (3) (4 used) to secure the

pump device.

: 19 mm

: 90 N⋅m (9.2 kgf⋅m, 67 lbf⋅ft)

Pump Cover

3

W190-02-04-003

3. Reconnect all hoses, pipes and electric wires to

the pump device.

: 19 mm

: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

: 27 mm

: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)

: 36 mm

: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)

: 41 mm

: 205 N⋅m (21 kgf⋅m,152 lbf⋅ft)

: 10 mm

: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

W190-02-04-002

IMPORTANT: Bleed air from the main pump. (See

W1-1-2) After work, check the

hydraulic oil level. Start the engine

and check all hose connections for

oil leaks.

1

4. Use bolts (2) (4 used) to secure cover (1) at the

lower side of the muffler.

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

2

CAUTION: Counterweight weight:

1270kg (2800 lb)

5. Install the counterweight (See Remove and

Install Counterweight in this section)

: 41 mm

: 980 N⋅m (100 kgf⋅m, 720 lbf⋅ft)

W197-02-04-001

W190-02-02-012

W2-4-3

DISASSEMBLE PUMP DEVICE


2

1

3

5

4

7

6

W1CC-02-04-001

1 - Cover 14 - Shim 27 - Spring 39 - O-Ring

2 - Gear Pump 15 - Spring 28 - Spring Seat 40 - Cover

3 - Socket Bolt (2 Used) 16 - Spring 29 - Cylinder Block 41 - Socket Bolt (4 Used)

4 - Body 17 - Spring Seat 30 - Pin (3 Used) 42 - Housing

5 - Socket Bolt (6 Used) 18 - Socket Bolt (2 Used) 31 - Spherical Bushing 43 - Shaft

6 - Cylinder 19 - O-Ring 32 - Retainer 44 - Retaining Ring

7 - Control Piston (2 Used) 20 - Socket Bolt (3 Used) 33 - Plunger (10 Used) 45 - Bearing

8 - Lock Nut 21 - Knock Pin (2 Used) 34 - Plate 46 - Retaining Ring

9 - Socket Bolt (2 Used) 22 - Needle Bearing 35 - Bearing 47 - O-Ring

10 - Adjusting Screw 23 - Packing 36 - Hanger 48 - Oil Seal

11 - Cover 24 - Valve Plate 37 - Bearing 49 - Cover

12 - Spring Seat 25 - Retaining Ring 38 - Distant Piece 50 - Retaining Ring

13 - O-Ring 26 - Spring Seat

W2-4-4


W2-4-5

W1CC-02-04-004

8

10

11

9

12

13

14

15

16

17

20

18

19

1

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

42

43

44

45

46

47

48

49

50

37

38

39

40

41

21


W2-4-6

W1CC-02-04-001

W1CC-02-04-004

8

10

11

9

12

13

14

15

16

17

20

18

19

1

21

22

23

25

24

2

3

26

1

4

27

5

6

28

7

29

35

36

42

30

43

31

32

33

34

37

38

39

40

21

44

45

46

47

48

49

50

41


Disassemble Pump Device

• Be sure to read “Precautions for disassembly and

Assembly” thoroughly on page W1-1-1 before

starting the disassembly work.

1. Remove socket bolts (3) (2 used) to remove

pliot pump (2) from cover (1).

:6 mm

2. Remove socket bolts (5) (6 used) to remove the

body (4) assembly from cover (1).

:8 mm

CAUTION: When removing cover (1),

temporary tighten bolts (M14, length 70 mm)

(2 used) shall be used. Prevent personal

injury. Spring (15) may fly off when not using

temporary tighten bolts.

3. Remove socket bolts (18) (2 used) and install 2

temporary assembly bolts (M14, length 70 mm)

there instead.

: 12 mm

4. Remove socket bolts (20) (3 used) and them

loosen and remove the temporary assembly bolts

(2 used) alternately.

: 12 mm

IMPORTANT: When removing the cover (1)

assembly, take care that control

pistons (7) (2 used) may come off.

As valve plate (24) is with cover (1),

take care not to drop it. Do not

remove knock pins (21) (2 used) and

needle bearing (22) unless

necessary.

5. Remove the cover (1) assembly and packing

(23) from housing (42). At this time the cover is

still with the cylinder (6) assembly on it. Remove

valve plate (24) from the cover.

IMPORTANT: The set flow rate of the pump may be

changed if lock nut (8) is screwed.

Do not disassemble adjusting screw

(10), the lock nut and cover (11).

6. Remove socket bolts (9) (2 used) and remove

the cover (11) assembly, shim (14) and spring

seat (12) from cover (1). Then remove spring

(15), spring (16) and spring seat (17) from

housing (42).

:8 mm

IMPORTANT: The cylinder block (29) assemblies

(25 to 34) can not be disassembled.

They shall be replaced in a set if

necessary.

7. Remove the cylinder block (29) assembly from

housing (42).

IMPORTANT: Do not remove oil seal (48) from

cover (49). The cover assembly shall

be replaced in a set if necessary.

8. Remove retaining ring (50) from housing (42),

and then remove the cover (49) assembly and

O-ring (47).

9. Tap at the shaft (43) assembly to make it come

to cover (49) from housing (42) with a plastic

hammer.

10. Remove retaining ring (44) from shaft (43).

Press bearing (45) to the side of housing (42)

from the shaft with a press to remove it.

IMPORTANT: Do not disassemble distant piece

(38), bearing (37) and bearing (35)

from hanger (36). The housing (42)

assembly shall be replaced in a set if

necessary.


cover (40) and O-ring (39) from housing (42).

:6 mm

W2-4-7

ASSEMBLE PUMP DEVICE


42 31 17 30 28 16 15 23 1 14

12

13 11 8 10

9

3 2

50

49

46

48

47

45

44

34

32

7

33

29

6

24

21

22

4 5

W1CC-02-04-005

35

36

20

18

43

38 37 40 41 39 27 26 25

W190-02-04-007

W2-4-8


1 - Cover 14 - Shim 27 - Spring 39 - O-Ring

2 - Gear Pump 15 - Spring 28 - Spring Seat 40 - Cover

3 - Socket Bolt (2 Used) 16 - Spring 29 - Cylinder Block 41 - Socket Bolt (4 Used)

4 - Body 17 - Spring Seat 30 - Pin (3 Used) 42 - Housing

5 - Socket Bolt (6 Used) 18 - Socket Bolt (2 Used) 31 - Spherical Bushing 43 - Shaft

6 - Cylinder 19 - * O-Ring 32 - Retainer 44 - Retaining Ring

7 - Control Piston (2 Used) 20 - Socket Bolt (3 Used) 33 - Plunger (10 Used) 45 - Bearing

8 - Lock Nut 21 - Knock Pin (2 Used) 34 - Plate 46 - Retaining Ring

9 - Socket Bolt (2 Used) 22 - Needle Bearing 35 - Bearing 47 - O-Ring

10 - Adjusting Screw 23 - Packing 36 - Hanger 48 - Oil Seal

11 - Cover 24 - Valve Plate 37 - Bearing 49 - Cover

12 - Spring Seat 25 - Retaining Ring 38 - Distant Piece 50 - Retaining Ring

13 - O-Ring 26 - Spring Seat

NOTE: For the parts marked with *, refer to page

W2-4-5.

W2-4-9


42 31 17 30 28 16 15 23 1 14

12

13 11 8 10

9

3 2

50

49

46

48

47

45

44

34

32

7

33

29

6

24

21

22

4 5

W1CC-02-04-005

35

36

20

18

43

38 37 40 41 39 27 26 25

W190-02-04-007

W2-4-10


Assemble Pump Device

• Be sure to read “Precautions for Disassembly and


starting the assembly work.

1. Install O-ring (39) and cover (40) to housing

(42) with socket bolts (41) (4 used).

:6 mm

: 8 to 35 N⋅m

(2.9 to 3.6 kgf⋅m, 21.0 to 26.0 lbf⋅ft)

2. Install retaining ring (46) to shaft (43), and then

press fit bearing (45). Install retaining ring (44)

on the shaft.

3. Press fit the shaft (43) assembly to housing (42).

Install O-ring (47), the cover (49) assembly and

retaining ring (50) to the housing.

4. Install the cylinder block (29) assembly to

housing (42).

IMPORTANT: Apply grease to the rod portion of

hanger (36).

5. Install spring seat (17) , spring (16) and spring

(15) to the rod portion of hanger (36).

6. Install O-ring (13) and shim (14) to spring seat

(12). Then install the spring seat to cover (1).

7. Install the cover (11) assembly to cover (1) with


:8 mm

: 55 to 69 N⋅m

(5.6 to 7.0 kgf⋅m, 41 to 51 lbf⋅ft)

IMPORTANT: Apply the grease to the mating

surfaces of valve plate (24) and

cover (1). Align the valve plate with

knock pins (21) (2 used) and the port

hole of the cover.

8. Install valve plate (24) to cover (1).

IMPORTANT: When installing cover(1) on housing

(42), take care not to drop control

pistons (7) (2 used) and valve plate

(24).

9. Install packing (23) and the cover (1) assembly

to housing (42) with socket bolts (18) (2 used)

and socket bolts (20) (3 used).

: 12 mm

: 150 to 180 N⋅m

(15 to 18 kgf⋅m, 108 to 130 lbf⋅ft)

10. Install the body (4) assembly to cover (1) with


:8 mm

: 55 to 69 N⋅m

(5.6 to 7.0 kgf⋅m, 41 to 51 lbf⋅ft)

11. Install O-ring (19) to cover (1) and install pilot

pump (2) with socket bolts (3) (2 used).

:6 mm

: 28 to 35 N⋅m

(2.9 to 3.6 kgf⋅m, 21.0 to 26.0 lbf⋅ft)

NOTE: Refer to page W2-4-5 for O-ring (19).

W2-4-11

DISASSEMBLE AND ASSEMBLE VALVE

BLOCK


4

12

6

3

5

11

2

9

10

1

7

8

W1CC-02-04-003

1 - O-Ring 4 - Socket Bolt (6 Used) 7 - Spring 10 - O-Ring

2 - O-Ring (2 Used) 5 - Orifice 8 - Spool 11 - Solenoid

3 - Body 6 - Plug 9 - Sleeve 12 - Socket Bolt (2 Used)

W2-4-12


Disassemble Valve Block




1. Remove socket bolts (4) (6 used) and then

remove the body (3) assembly from the pump

body.

:8 mm

2. Remove O-ring (1) and O-rings (2) (2 used)

from body (3).

3. Remove socket bolts (12) (2 used), and then

remove solenoid (11) from body (3).

:3 mm

4. Remove O-ring (10), sleeve (9), spool (8) and

spring(7) from body (3).

Assemble Valve Block




1. Install spring (7) to spool (8).

2. Install spool (8) to sleeve (9).

3. Install the sleeve (9) assembly and O-ring (10)

to body (3).

4. Install solenoid (11) to body (3) with socket bolts

(12) (2 used).

:3 mm

: 3.4 to 4.4 N⋅m

(0.35 to 0.45 kgf⋅m, 2.5 to 3.3 lbf⋅ft)

5. Install O-rings (2) (2 used) and (1) to body (3).

6. Install the body (3) assembly to the pump body

with socket bolts (4) (6 used).

:8 mm

: 55 to 69 N⋅m

(5.6 to 7.0 kgf⋅m, 41 to 51 lbf⋅ft)

W2-4-13

DISASSEMBLE AND ASSEMBLE

CONTROL PISTON


12

10

11

8

9

12

11

3

4

5

6

7

9

10

1

2

7

2

W1CC-02-04-002

1 - Control Piston 4 - Cylinder 7 - O-Ring (2 Used) 10 - Disc Spring (8 Used)

2 - Control Piston (2 Used) 5 - Orifice 8 - Cover 11 - Shim (2 Used)

3 - Socket Bolt (2 Used) 6 - O-Ring 9 - Control Piston (2 Used) 12 - Control Piston (2 Used)

W2-4-14


Disassemble Control Piston




IMPORTANT: When removing the cylinder (4)

assembly from cover (8), take care

not to drop control piston (1) and

control pistons (2) (2 used).

1. Remove socket bolts (3) (2 used). Then remove

the cylinder (4) assembly from cover (8).

:8 mm

2. Remove O-rings (6), (7) (2 used) from cylinder

(4).

IMPORTANT: Do not disassemble control piston

(1), control pistons (2) (2 used)

control pistons (12) (2 used), shims

(11) (2 used), disc springs (10) (8

used) and control pistons (9) (2

used). The cover (8) assembly shall

be replaced in a set if necessary.

Assemble Control Piston




1. Install O-rings (6), (7) (2 used) to cylinder (4).

IMPORTANT: When installing the cylinder (4)

assembly, take care not to drop

control piston (1) and control

pistons (2) (2 used).

Apply LOCTITE #270 to socket

bolts (3)(2 used).

2. Install the cylinder (4) assembly to cover (8)

with socket bolts (3) (2 used).

:8 mm

: 55 to 69 N⋅m

(5.6 to 7.0 kgf⋅m,41 to 51 lbf⋅ft)

W2-4-15

MAINTENANCE STANDARD


Main Pump

1. Clearance between plunger outer diameter and

cylinder block inner diameter.

(D-d): 0.060 mm (0.0024 in) or less.

Cylinder

Block

D

d

Plunger

W507-02-04-009

2. End play between plunger and shoe.

δ: 0.2 mm (0.0079 in) or less

δ

3. Be sure that there is no wear and score on the

oil seal mounting surface of the shaft.

Worn amount:0.025 mm (0.00098 in) or less

W107-02-06-140

4. Valve Plate

Be sure that there is no abnormal score, wear

or seizure on the valve plate.

Replace with a new one when excessive

damage is found.

Cylinder Block

Sliding Surface

W509-02-04-001

W2-4-16


(Blank)

W2-4-17


DISASSEMBLE AND ASSEMBLE PILOT

PUMP

12

11

10

9

4

8 7 6

23

14

22

5 4 3 2

4

21

20

13

19

4

18

1

3

15

16

17

25

16

24

19

18

16

26

27

29

16

28

17

21

22

23

32

31

30

33

W196-02-04-003

W2-4-18


No Parts Name Q’ty

Width Across Tightening Torque

Flats N⋅m (kgf⋅m) (lbf⋅ft)

1- Socket Bolt 4 :6 mm 29.0 (3.0) (21.5)

2- Housing 1

3- Pin 2

4- Metal 4

5- Drive Gear 1

6- Plate 1

7- Ring 1

8- Backup Ring 1

9- O-ring 1

10- Frame 1

11- Coupling 1

12- O-ring 1

13- Driven Gear 1

14- Socket Bolt 2 :6 mm 28 to 35 (2.9 to 3.6) (21 to 26)

15- Plate 1

16- Pin 4

17- Ring 2

18- Guide 2

19- O-Ring 2

20- Plate 1

21- Plate 2

22- Joint 2

23- Plate 2

24- Casing 1

Remarks

25- Drive Gear 1

26- Socket Bolt 4 :8 mm 69.0 (7.0) (51)

27- Driven Gear 1

28- O-Ring 1

29- Frame 1

30- Bushing 1

31- O-Ring 1

32- Coupling 1

33- Socket Bolt 2 :8 mm 55 to 69 (5.6 to 7.0) (41 to 51)

Clean the exterior of the gear pump before

disassembling.

Before assembling, clean each part with a cleaning

solvent and dry with compressed air .Apply a film of

hydraulic oil to inner parts. Especially, be sure to

apply hydraulic oil to sliding surfaces to prevent

seizure. Always replace O-ring and oil seals with

new ones when reassembling.

W2-4-19


(Blank)

W2-4-20

REMOVE AND INSTALLE CONTROL

VALVE 1

UPPERSTRUCTURE / Control Valve








repair work.





Preparation




top of the hydraulic oil tank to release any

remaining pressure.

CAUTION: If the overload relief valve is

loosened approx. more than 3/4 turns,

hydraulic oil may spurt. Do not loosen the

overload relief valve more than 3/4 turns.

IMPORTANT: Be sure to loosen the overload relief

valve body.

If the lock nut or adjusting screw is

loosened, set pressure will be

changed. Never loosen the lock nut

or adjusting screw.

3. Put matching marks on the overload relief valve

and the control valve. Gradually loosen the

overload relief valve to release any remaining

pressure in the circuit.

: 24 mm

: 49 to 54 N⋅m

(5 to 5.5 kgf⋅m, 36 to 40 lbf⋅ft)






Overload Relief Valve

Upper: Boom Raise


Lower: Boom Lower


Upper: Bucket Roll-Out

Lower: Bucket Roll-In

Lock nut

M1CC-07-002


Upper: Arm Roll-Out


Lower: Arm Roll-In

W1CC-02-05-002

Adjusting Screw

T152-05-04-003

W2-5-1


Removal

1. Loosen and remove bolts (2) (3 used), (3) and

(4) (2 used) of right side cover (1) to remove the

cover.

: 17 mm

IMPORTANT: Cap all disconnected hose ends and

attach tags to the hoses for

reassembly.

2. Disconnect all hoses, pipes and electrical wires

from the control valve 1.

: 19, 27, 36, 41 mm

:8 mm

2 1

4

3

CAUTION: Control valve 1 weight: 65 kg

(143 lb)

3. Remove bolts (5) (3 used) from control valve 1

and install eye bolts (M10, pitch 1.5) to bolt

holes (6). Lift and remove control valve 1 by

crane.

: 22 mm

W197-02-10-003

5

W1CC-02-05-001

6

W1CC-02-05-002

W2-5-2


Installation

CAUTION: Control valve 1 weight: 65 kg

(143 lb)

1. Lift the control valve 1 by crane. Secure the

control valve 1 with bolts (5) (3 used).

: 22 mm

: 180 N⋅m (18.4 kgf⋅m, 133 Ibf⋅ft)

2. Reconnect all hoses, pipes and electrical wire

to the control valve 1.

: 19 mm

: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)

: 27 mm

: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)

: 36 mm

: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

: 41 mm

: 205 N⋅m (21 kgf⋅m, 152 Ibf⋅ft)

:8 mm

: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

5

Travel (R)

Bucket

Boom 1

Arm 2

W1CC-02-05-001

Travel (L)

Auxiliary 1

3. Install right side cover (1) to the body. Secure

cover (1) with bolts (2) (3 used), (3) and (4) (2

used).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

IMPORTANT: After installation, check the


to check for any oil leaks.

Boom 2

Auxiliary 2

Arm 1

W1CC-02-05-008

2 1

3

4

W197-02-10-003

W2-5-3


(Blank)

W2-5-4


DISASSEMBLE CONTROL VALVE 1

21

1

20

22

2

23

24

12

23

3

18

19

3

25

20

17

16

15

4

5

6

7

8

13

14

3

3

9

12

11

10

W1CC-02-05-003

1 - Socket Bolt (3 Used) 8 - Housing 14 - O-Ring (3 Used) 20 - O-Ring (4 Used)

2 - Cover 9 - Cover 15 - Spool (Auxiliary 2) 21 - Plug (2 Used)

3 - O-Ring (18 Used) 10 - Plug (3 Used) 16 - Spool (Arm 1) 22 - Spool End (9 Used)

4 - Spool (Travel Right) 11 - O-Ring (3 Used) 17 - Spool (Boom 2) 23 - Spring Seat (18 Used)

5 - Spool (Bucket) 12 - Socket Bolt (19 Used) 18 - Spool (Auxiliary 1) 24 - Spring (9 Used)

6 - Spool (Boom 1) 13 - Plug (3 Used) 19 - Spool (Travel Left) 25 - Plug (2 Used)

7 - Spool (Arm 2)

W2-5-5


26

27

28

29

30

33

31

32

34

35

36

37

38

39

40

41

42

43

44

45

48

49

52

53

54

55 56

57

61 60 59 58

50

51

82

81

80

79

62

63

8

69

70

64

65

66

67

68

71

72

76

75

74

73

W1CC-02-05-004

26 - Plug 40 - O-Ring 55 - O-Ring 68 - Plug

27 - O-Ring 41 - Spring 56 - O-Ring 69 - O-Ring

28 - Spring 42 - Poppet 57 - Plug 70 - Plug

29 - Poppet 43 - Sleeve 58 - Plug (2 Used) 71 - O-Ring (2 Used)

30 - Sleeve 44 - Spring 59 - O-Ring (2 Used) 72 - Plug (2 Used)

31 - Spring 45 - Poppet 60 - Spring (2 Used) 73 - Plug (2 Used)

32 - Poppet 48 - Plug 61 - Poppet (2 Used) 74 - O-Ring (2 Used)

33 - Plug 49 - O-Ring 62 - O-Ring 75 - Spring(2 Used)

34 - O-Ring 50 - Spring 63 - Plug 76 - Poppet (2 Used)

35 - Spring 51 - Poppet 64 - Sleeve 79 - Poppet

36 - Poppet 52 - Plug 65 - Poppet 80 - Spring

37 - Plug 53 - O-Ring 66 - Spring 81 - O-Ring

38 - O-Ring 54 - Plug 67 - O-Ring 82 - Plug

39 - Plug

W2-5-6


95

83

84

85

86

87

88

89

90

91

92

93

94

96

97

98

99

100

101

102

103

125

126

123

124

126

8

125

108

104

109

105

106

121

122

117

118

119

112

113

114

115

116

107

110

111

120

W1CC-02-05-005

83 - Socket Bolt (4 Used) 94 - Poppet 105 - Spring 116 - Plug

84 - Cover 95 - Socket Bolt (4 Used) 106 - O-Ring 117 - Poppet

85 - O-Ring (2 Used) 96 - Anti-Drift Valve 107 - Plug 118 - Spring

86 - Backup Ring 97 - O-Ring (2 Used) 108 - Spool 119 - O-Ring

87 - O-Ring 98 - Backup Ring 109 - Spring 120 - Plug

88 - Spacer 99 - O-Ring 110 - O-Ring 121 - O-Ring

89 - O-Ring 100 - Spacer 111 - Plug 122 - Plug

90 - Plug 101 - Spring 112 - Poppet 123 - Plug

91 - Backup Ring 102 - Poppet 113 - Spring 124 - O-Ring

92 - O-Ring 103 - Main Relief valve 114 - O-Ring 125 - Overload Relief Valve (6

Used)

93 - Spring 104 - Poppet 115 - Backup Ring 126 - O-Ring (6 Used)

W2-5-7


1

22

2

23

24

12

23

3

18

19

3

17

16

4

15

5

6

7

8

3

3

9

12

W1CC-02-05-003

W2-5-8

Disassemble Control Valve 1




1. Loosen socket bolts (1) (3 used) and socket

bolts (12) (8 used) of cover (2) side to remove

the cover from housing (8). Remove O-rings (3)

(9 used) from the cover.

:5 mm

2. Remove the spool (4) to (7) and (15) to (19)

assemblies from housing (8).

3. Loosen socket bolts (12) (11 used ) of cover (9)

side to remove the cover from housing (8).

Remove O-rings (3) (9 used ) from the cover.

:5 mm

IMPORTANT: As spool end (22) screw was coated

with LOCTITE, be sure to heat the

screw to 200 to 250℃ (392 to 482 °F)

before loosening it.

4. Attaching wooden pieces to both sides of

spools (4) to (7), (15) to (19), secure each spool

in a vise. Then loosen spool end (22) to remove

spring seats (23) ( 2 used ) and spring (24) from

each spool.

:5 mm

NOTE: As spring (24) is in its free length, there is

no danger of it flying out.


W2-5-9

43

44

45


26

27

28

29

30

33

31

32

34

35

36

39

40

41

42

48

49

50

51

61 60 59 58

82

81

80

79

8

64

65

66

67

68

76

75

74

73

W1CC-02-05-004

W2-5-10

5. Remove plug (26), O-ring (27), spring (28),

poppet (29), sleeve (30), spring (31) and poppet

(32) from housing (8).

: 36 mm

6. Remove plug (33), O-ring (34), spring (35) and

poppet (36) from housing (8).

: 24 mm


poppet (42), sleeve (43), spring (44) and poppet


: 36 mm



: 24 mm



: 24 mm


poppet (65) and sleeve (64) from housing (8).

: 36 mm

11. Remove plugs (73) (2 used), O-rings (74) (2

used), springs (75) (2 used) and poppets (76) (2

used) from housing (8).

: 24 mm

12. Remove plugs (58) (2 used), O-rings (59) (2

used), springs (60) (2 used) and poppets (61) (2

used) from housing (8).

: 24 mm


W2-5-11


95

83

84

85

86

87

88

89

90

91

92

93

94

96

97

98

99

100

101

102

103

125

126

126

8

125

108

104

117

118

119

120

112

109

113

114

115

116

105

106

107

110

111

W1CC-02-05-005

W2-5-12


13. Loosen socket bolts (83) (4 used). Remove

cover (84), O-rings (85) (2 used), backup ring

(86), O-ring (87) and spacer (88) from housing

(8).

:5 mm

14. Remove O-ring (89) from housing (8).

15. Install a puller bolt (M6) to plug (90) to remove

the plug from housing (8).

21. Install a puller bolt (M6) to plug (116) to remove

the plug from housing (8).

22. Remove backup ring (115), O-ring (114), spring

(113) and poppet (112) from housing (8).

23. Remove plug (120), O-ring (119), spring (118)

and poppet (117) from housing (8).

: 19 mm

16. Remove backup ring (91), O-ring (92), spring

(93) and poppet (94) from housing (8).

17. Loosen socket bolts (95) (4 used). Remove

anti-drift valve (96), O-rings (97) (2 used),

backup ring (98), O-ring (99), spacer (100),

spring (101) and poppet (102) from housing (8).

:5 mm

18. Remove main relief valve (103) and overload

relief valves (125) (6 used) from housing (8).

Remove O-rings (126) (6 used) from the

overload relief valves.

: 32 mm (for the main relief valve)

: 24 mm (for the overload relief valve)


and poppet (104) from housing (8).

: 19 mm


and spool (108) from housing (8).

: 32 mm

W2-5-13


(Blank)

W2-5-14

ASSEMBLE CONTROL VALVE 1


1

12

95

83

T1CC-03-03-004

20, 25

20, 21 20, 25

2

22

23

24

8 3

123, 124

23

3

56, 57

58, 59

60

61

3

19 18 17 16 15 10, 11

121, 122 3 7 6 5 9 4

W1CC-02-05-009

1 - Socket Bolt (3 Used) 8 - Housing 14 - *O-Ring (3 Used) 20 - O-Ring (4 Used)

2 - Cover 9 - Cover 15 - Spool (Auxiliary 2) 21 - Plug (2 Used)

3 - O-Ring (18 Used) 10 - Plug (3 Used ) 16 - Spool (Arm 1) 22 - Spool End (9 Used)

4 - Spool (Travel Right) 11 - O-Ring (3 Used) 17 - Spool (Boom 2) 23 - Spring Seat (18 Used)

5 - Spool (Bucket) 12 - Socket Bolt (19 Used) 18 - Spool (Auxiliary 1) 24 - Spring (9 Used)

6 - Spool (Boom 1) 13 - *Plug (3 Used) 19 - Spool (Travel Left) 25 - Plug (2 Used)

7 - Spool (Arm 2)


W2-5-5.

W197-02-05-008

W2-5-15


Section A

103

Section G

Section F

Section E

Section D

54, 55

Section C

Section B

Section A

Section B

T1CC-03-03-004

Section C

T152-03-03-003

62, 63

52, 53

71, 72

30

31

26, 27

104

105

106, 107

110, 111

108

109

28

29

32

T152-03-03-004

26 - Plug 40 - O-Ring 55 - O-Ring 68 - Plug

27 - O-Ring 41 - Spring 56 - O-Ring 69 - O-Ring

28 - Spring 42 - Poppet 57 - Plug 70 - Plug

29 - Poppet 43 - Sleeve 58 - Plug (2 Used) 71 - O-Ring (2 Used)

30 - Sleeve 44 - Spring 59 - O-Ring (2 Used) 72 - Plug (2 Used)

31 - Spring 45 - Poppet 60 - Spring (2 Used) 73 - Plug (2 Used)

32 - Poppet 48 - Plug 61 - Poppet (2 Used) 74 - O-Ring (2 Used)

33 - Plug 49 - O-Ring 62 - O-Ring 75 - Spring (2 Used)

34 - O-Ring 50 - Spring 63 - Plug 76 - Poppet (2 Used)

35 - Spring 51 - Poppet 64 - Sleeve 79 - Poppet

36 - Poppet 52 - Plug 65 - Poppet 80 - Spring

37 - *Plug 53 - O-Ring 66 - Spring 81 - O-Ring

38 - *O-Ring 54 - Plug 67 - O-Ring 82 - Plug

39 - Plug


W2-5-6.

T197-03-03-004

W2-5-16


Section D

20, 25

Section E

20, 21

96

97

125, 126

76

75

73, 74

8

81, 82

98, 99

100

101

102

73, 74

54, 55

33, 34

112

113

114, 115

116

80

79

75

76

35

36

125, 126

125, 126

W1CC-02-05-006

T152-03-03-006

Section F

89

20, 21

Section G

20, 25

125, 126

85 88 83

84

123, 124

125, 126

71, 72

65

67, 68

66

64

117

118

86, 87

90

91, 92

93

94

44

39, 40

41

42

45

43

69, 70

48, 49

50

51

119, 120

125, 126

T152-03-03-008

121, 122

10, 11

W1CC-02-05-007

83 - Socket Bolt (4 Used) 94 - Poppet 105 - Spring 116 - Plug

84 - Cover 95 - Socket Bolt (4 Used) 106 - O-Ring 117 - Poppet

85 - O-Ring (2 Used) 96 - Anti-Drift Valve 107 - Plug 118 - Spring

86 - Backup Ring 97 - O-Ring (2 Used) 108 - Spool 119 - O-Ring

87 - O-Ring 98 - Backup Ring 109 - Spring 120 - Plug

88 - Spacer 99 - O-Ring 110 - O-Ring 121 - O-Ring

89 - O-Ring 100 - Spacer 111 - Plug 122 - Plug

90 - Plug 101 - Spring 112 - Poppet 123 - Plug

91 - Backup Ring 102 - Poppet 113 - Spring 124 - O-Ring

92 - O-Ring 103 - Main Relief Valve 114 - O-Ring 125 - Overload Relief Valve

(6 Used)

93 - Spring 104 - Poppet 115 - Backup Ring 126 - O-Ring (6 Used)

W2-5-17


Section D

20, 25

Section E

20, 21

96

97

125, 126

76

75

73, 74

8

81, 82

98, 99

100

101

102

73, 74

54, 55

33, 34

112

113

114, 115

116

80

79

75

76

35

36

125, 126

125, 126

W1CC-02-05-006

T152-03-03-006

Section F

89

20, 21

Section G

20, 25

125, 126

85 88 83

84

123, 124

125, 126

71, 72

65

67, 68

66

64

117

118

86, 87

90

91, 92

93

94

44

39, 40

41

42

45

43

69, 70

48, 49

50

51

119, 120

125, 126

T152-03-03-008

121, 122

10, 11

W1CC-02-05-007

W2-5-18


Assemble Control Valve 1




1. Install O-rings (126) (6 used) to overload relief

valves (125) (6 used). Install the overload relief

valves to housing (8).

: 24 mm

: 59 to 69 N⋅m (6 to 7 kgf⋅m, 43 to 51 lbf⋅ft)

2. Install O-ring (119) to plug (120). Install poppet

(117), spring (118) and the plug into housing (8).

: 19 mm

: 49 to 59 N⋅m

(5 to 6 kgf⋅m, 36 to 43 lbf⋅ft)

3. Install O-ring (49) to plug (48). Install poppet (51),

spring (50) and the plug into housing (8).

: 24 mm

: 88 to 98 N⋅m



spring (44), sleeve (43), poppet (42), spring (41)

and the plug into housing (8).

: 36 mm

: 167 to 196 N⋅m

(17 to 20 kgf⋅m, 123 to 145 lbf⋅ft)

5. Install O-ring (67) to plug (68). Install sleeve (64),

poppet (65), spring (66) and the plug into

housing (8).

: 36 mm

: 167 to 196 N⋅m

(17 to 20 kgf⋅m, 123 to 145 lbf⋅ft)

6. Install O-rings (74) (2 used) to plugs (73) (2

used). Install poppets (76) (2 used), springs (75)

(2 used) and the plugs into housing (8).

: 24 mm

: 88 to 98 N⋅m




: 24 mm

: 88 to 98 N⋅m

(9 to 10 kgf⋅m, 65 to 72 lbf ⋅ft)



: 24 mm

: 88 to 98 N⋅m

(9 to 10 kgf⋅m, 65 to 72 lbf ⋅ft)

9. Install O-ring (92) and backup ring (91) to plug

(90). Install poppet (94), spring (93), the plug

and O-ring (89) into housing (8).

10. Install O-ring (87) and backup ring (86) to spacer

(88). Install the spacer, O-rings (85) (2 used) and

cover (84) into housing (8). Secure them with


:5 mm

: 8.8 to 11 N⋅m

(0.9 to 1.1 kgf⋅m, 6.5 to 8.0 lbf⋅ft)

W2-5-19

UPPRERSTRUCTURE / Control Valve

Section A

103

95

Section G

Section F

Section E

Section D

54, 55

Section C

Section B

Section A

T1CC-03-03-004

T152-03-03-003

Section B

Section C

62, 63

30

31

52, 53

71, 72

26, 27

104

105

106, 107

110, 111

108

109

28

29

32

T152-03-03-004

Section D

Section E

96

20, 21

T197-03-03-004

125, 126

97

76

75

73, 74

8

81, 82

98, 99

100

101

102

54, 55

33, 34

112

113

114, 115

116

125, 126

80

79

73, 74

75

76

35

36

W1CC-02-05-006

125, 126

T152-03-03-006

W2-5-20


11. Install O-ring (114) and backup ring (115) to plug

(116). Install poppet (112), spring (113) and the

plug into housing (8).

12. Install O-ring (99) and backup ring (98) to spacer

(100). Install poppet (102), spring (101), the

spacer, O-rings (97) (2 used), anti-drift valve (96)

into housing (8). Secure them with socket bolts

(95) (4 used).

:5 mm

: 8.8 to 10.8 N⋅m

(0.9 to 1.1 kgf⋅m, 6.5 to 8.0 lbf⋅ft)


spring (31), sleeve (30), poppet (29), spring (28)

and the plug into housing (8).

: 36 mm

: 167 to 196 N⋅m

(17 to 20 kgf⋅m, 123 to 145 lbf⋅ft)

14. Install O-ring (106) to plug (107). Install poppet


: 24 mm

: 88 to 98 N⋅m


15. Install O-ring (110) to plug (111). Install spool


: 32 mm

: 78 to 88 N⋅m


16. Install main relief valve (103) to housing (8).

: 32 mm

: 49 to 59 N⋅m


W2-5-21


1

12

95

83

T1CC-03-03-004

20, 25

20, 21 20, 25

2

22

23

24

8 3

123, 124

23

3

56, 57

58, 59

60

61

3

19 18 17 16 15 10, 11

121, 122 3 7 6 5 9 4

W1CC-02-05-009

W197-02-05-008

W2-5-22


17. Install O-rings (59) (2 used) to plugs (58) (2 used).

Install poppets (61) (2 used), springs (60) (2 used)

and plugs (58) (2 used) into housing (8).

: 24 mm

: 88 to 98 N⋅m


IMPORTANT: Apply LOCTITE #271 to the screws

on spool ends (22).

18. Attaching wooden pieces to both sides of spools

(4) to (7) and (15) to (19), secure each spool in a

vise. Install spring seat (23), spring (24), spring

seat (23) and spool end (22) to each of the

spools.

:5 mm

: 19 to 22 N⋅m

(1.9 to 2.2 kgf⋅m, 13.5 to 16 lbf⋅ft)

NOTE: Spring (24) can be compressed by hand.

19. Install spools (4) to (7), (15) to (19) into housing

(8). Install O-rings (3) (9 used) and cover (2) to

the housing. Secure the cover with socket bolts

(1) (3 used) and (12) (8 used).

:5 mm

: 8.8 to 10.8 N⋅m

(0.9 to 1.1 kgf⋅m, 6.5 to 8.0 lbf⋅ft)

20. Install O-rings (3) (9 used) and cover (9) to

housing (8). Secure the cover with socket bolts

(12) (11 used).

:5 mm

: 8.8 to 10.8 N⋅m

(0.9 to 1.1 kgf⋅m, 6.5 to 8.0 lbf⋅ft)

NOTE: Refer to page W2-5-3 for socket bolts (12).

W2-5-23

REMOVE AND INSTALL CONTROL

VALVE 2









repair work.





Preparations





remaining pressure.

M1CC-07-002






W2-5-24


Removal


(2 used) of right side cover (1) to remove the

cover.

: 17 mm

2 1

3

IMPORTANT: Cap all disconnected hose ends and

attach tags to the hoses for

reassembly.

2. Disconnect all hoses from control valve 2 (5).

: 19, 22, 27 mm

3. Remove mounting bolts (6) of control valve 2 (5)

to remove control valve 2 (5).

: 17 mm

4

Installation

1. Install control valve 2 (5) using bolts (6).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

Blade

Swing

W197-02-10-003

Arm 3

2. Reconnect all hoses to control valve 2 (5).

: 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

: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)

5

6

3. Install right side cover (1) to the body. Secure the

cover with bolts (2) (3 used), (3) and (4) (2 used).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

W197-02-05-003

IMPORTANT: After installation, check the


to check for any oil leaks.

W2-5-25


DISASSEMBLE CONTROL VALVE 2

1

2

3

4

5

6

5

7

9

10

11

16

17

8

12

1

2

25

3

4

5

6

5

26

27

28

29

30

31

32

33

9

1

2

3

4

5

6

5

19

20

10

22

23

9

10

21

22

23

13

3

18

1

3

18

13 14 15

1

13

24

39

38

37

36

13

3

18

1

28

27

26

25

34

17 35

W197-02-05-009

1 - Socket Bolt (18 Used) 11 - Plug 21 - Bushing 31 - Backup Ring

2 - Cover ( 3 Used) 12 - O-Ring 22 - Spring ( 2 Used) 32 - O-Ring

3 - O-Ring ( 6 Used) 13 - O-Ring ( 4 Used) 23 - Check Valve ( 2 Used) 33 - O-Ring

4 - Cap Screw (3 Used) 14 - Check Valve 24 - Spool 34 - Inlet Section

5 - Spring Seat ( 6 Used) 15 - Spring 25 - Overload Relief Valve (2 Used) 35 - Bolt (3 Used)

6 - Spring ( 3 Used) 16 - Outlet Section 26 - O-Ring ( 2 Used) 36 - O-Ring

7 - Spool 17 - Nut ( 6 Used) 27 - Backup Ring ( 2 Used) 37 - Backup Ring

8 - Valve Section 18 - Cover Plate ( 3 Used) 28 - O-Ring ( 2 Used) 38 - O-Ring

9 - Plug ( 3 Used) 19 - Spool 29 - Valve Section 39 - Main Relief Valve

10 - O-Ring ( 3 Used) 20 - Valve Section 30 - Orifice

W2-5-26


Disassemble Control Valve 2




1. Loosen socket bolts (1) (18 used) to remove

covers (2) (3 used) and cover plates (18) (3

used) from each section.

:5 mm

2. Remove O-rings (3) (6 used) from covers (2) (3

used) and cover plates (18) (3 used).

3. Pull out the spool (7) assembly from valve

section (8).


section (20).


section (29).

6. Remove plugs (9) (3 used) from valve sections

(8), (20) and (29) respectively. Remove springs

(22) (2 used) and check valve (23) (2 used)

from valve sections (20) and (29) respectively.

:8 mm

7. Remove O-rings (10) (3 used) from plugs (9) (3

used).

10. Attaching wooden pieces to both sides of the

spool (24) assembly, secure the spool in a vise.

Remove cap screw (4), spring seats (5) (2

used) and spring (6) from the spool.

:5 mm

11. Remove overload relief valves (25) (2 used)

from valve section (29). Remove O-rings (26),

(28) and backup rings (27) from the overload

relief valves.

: 19 mm

12. Remove main relief valve (39) from inlet section

(34). Remove O-rings (36), (38) and backup

ring (37) from the main relief valve.

: 19 mm

13. Loosen nuts (17) (6 used) to remove bolts (35)

(3 used) from the three sections respectively.

: 19 mm

14. Remove O-rings (13) (4 used) from inlet section

(34) and valve sections (29), (20) and (8)

respectively.

15. Remove spring (15) and check valve (14) from

valve section (8).





:5 mm





:5 mm

W2-5-27

ASSEMBLE CONTROL VALVE 2


B

C

D

Section A-A

39

17

A

16

38

35

17

37

E

E

34

36

A

Section B-B

B

6 5 4 2

5

1

3

24

C

D

25

26

27

28

33

31

30

Section C-C

6

5

5 4 2

1

3

19

21

29

3

18

1

32

9

10

22

23

28

27

26

25

20

3

18

1

9

10

22

23

Section D-D

6 5

5

4 2

Section E-E

1

3

13

14

15

7

8

10

9

3

11

12

18

1

W1CC-02-05-010

W2-5-28


1 - Socket Bolt (18 Used) 11 - Plug 21 - Bushing 31 - Backup Ring

2 - Cover (3 Used) 12 - O-Ring 22 - Spring (2 Used) 32 - O-Ring

3 - O-Ring (6 Used) 13 - O-Ring (4 Used) 23 - Check Valve (2 Used) 33 - O-Ring

4 - Cap Screw (3 Used) 14 - Check Valve 24 - Spool 34 - Inlet Section

5 - Spring Seat (6 Used) 15 - Spring 25 - Overload Relief Valve 35 - Bolt (3 Used)

(2 Used)

6 - Spring (3 Used) 16 - Outlet Section 26 - O-Ring (2 Used) 36 - O-Ring

7 - Spool 17 - Nut (6 Used) 27 - Backup Ring (2 Used) 37 - Backup Ring

8 - Valve Section 18 - Cover Plate (3 Used) 28 - O-Ring (2 Used) 38 - O-Ring

9 - Plug (3 Used) 19 - Spool 29 - Valve Section 39 - Main Relief Valve

10 - O-Ring (3 Used) 20 - Valve Section 30 - Orifice

W2-5-29


B

C

D

Section A-A

39

17

A

16

38

35

17

37

E

E

34

36

A

Section B-B

B

6 5 4 2

5

1

3

24

C

D

25

26

27

28

33

31

30

Section C-C

6 5 4 2

5

1

3

19

21

Section D-D

29

3

18

6 5

5

1

4 2

32

9

10

22

23

28

27

26

25

20

3

18

Section E-E

1

9

10

22

23

1

3

13

14

15

7

8

10

9

3

11

12

18

1

W1CC-02-05-010

W2-5-30


Assemble Control Valve 2




1. Install O-rings (13) (4 used) to each sections

respectively.

2. Install check valve (14) and spring (15) to valve

section (8).

3. Arrange the each sections in order as inlet section

(34), valve sections (29), (20) and (8) and outlet

section (16).

4. Pass bolts (35) (3 used) through each sections.

Tighten nuts (17) (6 used).

: 19 mm

: 59 to 64 N⋅m

(6.0 to 6.5 kgf⋅m, 43 to 47 lbf⋅ft)

5. Attaching wooden pieces to both sides of spools

(7), (19) and (24), secure each spool in a vise.

Install spring seat (5), spring (6), spring seat (5)

and cap screw (4) into the spools in order

respectively.

:5 mm

: 9.8 to 12.8 N⋅m

(1.0 to 1.3 kgf⋅m, 7.2 to 9.4 lbf⋅ft)

IMPORTANT: Insert each assembly of spools (7),

(19) and (24) into the original

location.

6. Insert each assembly of spools (7), (19) and (24)

into valve sections (8), (20) and (29) respectively.

8. Install O-rings (3) (3 used) to cover plates (18) (3

used). Install the cover plates to each sections

respectively. Secure the cover plates with socket

bolts (1) (9 used).

:5 mm

: 9.8 to 12.8 N⋅m

(1.0 to 1.3 kgf⋅m, 7.2 to 9.4 lbf⋅ft)

9. Install check valves (23) (2 used) and springs (22)

(2 used) into valve sections (20) and (29).

10. Install O-rings (10) (2 used) to plugs (9) (2 used).

Install plugs (9) into valve sections (20) and (29).

:8 mm

: 29 to 34 N⋅m

(3.0 to 3.5 kgf⋅m, 21.5 to 25.5 lbf⋅ft)

11. Install O-rings (26) (2 used) and (28) (2 used) and

backup rings (27) (2 used) to overload relief

valves (25) (2 used). Install the overload relief

valves to valve section (29).

: 19 mm

: 34 to 39 N⋅m

(3.5 to 4.0 kgf⋅m, 25.5 to 29.0 lbf⋅ft)

12. Install O-rings (38) and (36) and backup ring (37)

to main relief valve (39). Install the main relief

valve to inlet section (34).

: 19 mm

: 34 to 39 N⋅m

(3.5 to 4.0 kgf⋅m, 25.3 to 28.9 lbf⋅ft)

7. Install O-rings (3) (3 used) to covers (2) (3 used)

and install covers (2) to each sections respectively.

Secure the covers with socket bolts (1) (9 used).

:5 mm

: 9.8 to 12.8 N⋅m

(1.0 to 1.3 kgf⋅m, 7.2 to 9.4 lbf⋅ft)

W2-5-31


(Blank)

W2-5-32

REMOVE AND INSTALLE SWING DEVICE

UPPERSTRUCTURE / Swing Device








repair work.





Preparations





remaining pressure.

M1CC-07-002






W2-6-1


Removal

1. Disconnect all hoses from the swing motor. Cap

all disconnected hose ends.

Attach tags to the hoses for reassembly.

: 19 mm, 27 mm, 36 mm

1

CAUTION: Swing device weight: 77 kg

(170 Ib)

IMPORTANT: As for the handling of the nylon

slings, refer to “Precautions for the

Handling of Nylon Slings” on page

W1-1-5.

2. Remove bolts (1) (10 used). Attach the nylon sling

to the swing device and lift to remove it by crane.

: 24 mm

M197-00-002

Installation

CAUTION: Swing device weight: 77 kg

(170 Ib)

1. Secure the swing device with bolts (1).

: 24 mm

: 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft)

2. Reconnect all hoses to the swing motor.

: 19 mm

: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)

: 27 mm

: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)

: 36 mm

: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

IMPORTANT: After installation, refill the hydraulic

oil into the swing motor. Check the

oil level. Start the engine to check

for any oil leaks.

W176-02-06-002

W2-6-2


(Blank)

W2-6-3

DISASSEMBLE SWING DEVICE


19

20

1

21

2

22

3

23

24

25

26

28

29

4

5

6

7

8

9

10

27

11

12

13

17

18

14

15

16

W152-02-06-001

1 - Socket Bolt (8 Used) 9 - First Stage Carrier 17 - Knock Pin 25 - Dust Seal

2 - Cap 10 - Second Stage Sun Gear 18 - Nut 26 - Guide

3 - Pipe 11 - Thrust Plate 19 - Ring Gear 27 - Shaft

4 - Retaining Ring (3 Used) 12 - Pin (3 Used) 20 - Bearing 28 - Drain Pipe

5 - Plate 13 - Second Stage Carrier 21 - Oil Seal 29 - Plug

6 - First Stage Sun Gear 14 - Second Stage Planetary 22 - Housing

Gear (3 Used)

7 - First Stage Planetary 15 - Plate (3 Used) 23 - Plug (2 Used)

Gear ( 3 Used)

8 - Needle Bearing (3 Used) 16 - Spring Pin (3 Used) 24 - Bearing

W2-6-4


Disassemble Swing Device




1. Remove plugs (23) (2 used) and drain pipe (28)

from housing (22). Drain the gear oil out of it.

:5 mm

2. Remove cap (2) and pipe (3) from the swing

device.

CAUTION: Swing motor weight: 21 kg

(46 lb)

3. Remove socket bolts (1) (8 used). Insert a screw

driver, etc. between the swing motor and ring gear

(19) to separate the swing motor. Sling the swing

motor by crane to remove it.

: 12 mm

5. Remove retaining rings (4) (3 used), plate (5), first

stage sun gear (6), first stage planetary gears (7)

(3 used), and needle bearings (8) (3 used) from

the first stage carrier (9) assembly.

6. Tap spring pins (16) into pins (12) in the second

stage carrier (13) assembly with a bar (length:

above 100 mm (3.9 in), diameter: 5 mm (0.2 in)).

NOTE: If spring pin (16) is tapped to the end, the

spring pin will make contact with the carrier

(13) and pin (12) can not be pulled out.

IMPORTANT: Do not remove knock pin (17) unless

necessary. In case the knock pin was

removed, replace both knock pin

(17) and second stage carrier (13)

with new ones.

7. Remove pins (12) (3 used), second stage

planetary gears (14) (3 used), plates (15) (3 used),

and thrust plate (11) from second stage carrier

(13).

8. Tap spring pins (16) (3 used) out of pins (12) (3

used).

9. With shaft (27) being held, remove nut (18) from

the shaft using special tool (ST 4129).

ST 4129

W176-02-06-002

4. Remove the first stage carrier (9) assembly,

second stage sun gear (10), the second stage

carrier (13) assembly and ring gear (19) from the

swing device.

NOTE: If ring gear (19) can not be removed from

housing (22), tap the side of it with a plastic

hammer, or insert a screw driver between

the ring gear and the housing.

W1CC-02-06-002

W2-6-5


20

22

24

26

27

W152-02-06-001

W2-6-6


CAUTION: Before pressing shaft (27),

provide a protection cover (outer diameter:

180 mm (7.1 in), inner diameter: 65 mm (2.6

in), thickness: 25 to 30 mm (1.0 to 1.2 in)).

Then, use the press to remove the shaft while

covering housing (22) and bearing (20) with

the protection cover. Failure to use the

protection cover may result in personal injury

due to metal fragments flying out if the

housing and/or bearing break. Use a press of

capacity less than 30 tons (66000 lb). Be sure

to degrease the housing inside before

heating the bearing. Failure to degrease may

cause a fire.

11. Attach the shaft (27) assembly to the bearing

removal special tool set.

Bearing Removal Special Tool Set

Shaft

Hose Clamp

22

27

20

W157-02-06-012

27

24

Protection Cover

26

W157-02-06-010

10. Remove shaft (27) from housing (22) with a press.

Guide

Shaft

W157-02-06-013

Protection Cover

press

22

W157-02-06-011

NOTE: Use the following parts as the special tool

set for removing bearing (24).

Shaft (or bolt): Length: 160 mm (6.3 in)

Diameter: 19 mm (0.7 in) 6 to 8 used.(All

should be identical in length

with no wear and deformation

on both ends).

Material: S35C

Hose Clamp: (Standard Diameter: 6-1/2

Applicable Diameter: 125 to 155 mm, 4.9

to 6.1 in) 2 used

Guide: Height: 120 mm (4.7 in )

Outer Diameter: 170 mm (6.7 in)

Inner Diameter: 150 mm (5.9 in)

W2-6-7


20

21

22

24

25

26

27

W152-02-06-001

W2-6-8


CAUTION: Work should be carried out in the

guide be sure to carry it out inside the guide.

12. Set shaft (27), with clamping apparatus on it, into

a press to remove the shaft.

27

Press

24

26

Guide

W157-02-06-014

13. Remove the inner race of bearing (24) and guide

(26) from shaft (27).

IMPORTANT: Do not remove the outer races of

bearings (20) and (24) from housing

(22). The press force on the outer

races of bearings (20) and (24) will

be reduced, shortening the service

life of the bearings. When removing

the outer races, be sure to replace

not only the outer races but also

housing (22).

14. Remove the inner race of bearing (20), oil seal

(21) and dust seal (25) from housing (22).

15. Remove all old grease from the surfaces of

housing (22), bearing (24) and guide (26).

W2-6-9

ASSEMBLE SWING DEVICE


2

3

4

7

8

12

14

19

15

16

Identification Groove

23

28

22

1

5

6

9

13

10

11

17

18

20

21

24

29

25

26

27

T152-03-02-006

1 - Socket Bolt (8 Used) 9 - First Stage Carrier 17 - Knock Pin 25 - Dust Seal

2 - Cap 10 - Second Stage Sun Gear 18 - Nut 26 - Guide

3 - Pipe 11 - Thrust Plate 19 - Ring Gear 27 - Shaft

4 - Retaining Ring (3 Used) 12 - Pin (3 Used) 20 - Bearing 28 - Drain Pipe

5 - Plate 13 - Second Stage Carrier 21 - Oil Seal 29 - Plug

6 - First Stage Sun Gear 14 - Second Stage Planetary 22 - Housing

Gear (3 Used)

7 - First Stage Planetary 15 - Plate (3 Used) 23 - Plug (2 Used)

Gear ( 3 Used)

8 - Needle Bearing (3 Used) 16 - Spring Pin (3 Used) 24 - Bearing

W2-6-10


Assemble Swing Device




IMPORTANT: Apply grease to the inner diameter of

oil seal (21), and then install it with

its lip facing up (the motor side).

1. Install oil seal (21) into housing (22).

2. In case bearings (20) and (24) were removed,

housing (22) must be replaced along with them.

Press the outer races of bearing (20) and (24)

into housing (22).

IMPORTANT: Dust seal (25) shall be installed with

its lip portion facing downward

(outside).

3. Install dust seal (25) into housing (22).

IMPORTANT: Take care not to damage oil seal (21)

with shaft (27).

Be sure plug (23) has been

removed. If it is in place, oil seal

(21) may be deformed.

7. Place housing (22) slightly on shaft (27) and

install it on while take care of the positions for

guide (26) and dust seal (25). Do not deform the

dust seal.

IMPORTANT: Nut (18) shall be installed with its

identification groove facing up (the

motor side). Apply the grease to the

thread of the nut.

8. Press the bearing (20) inner race onto shaft

(27) and temporarily tighten nut (18).

4. Press guide (26) and the inner race of roller

bearing (24) onto shaft (27).

5. Apply the grease to the outer surface of guide

(26).

CAUTION: Housing (22) weight: 19 kg (42 Ib)

6. Install eye bolts (M14, pitch 2.0) into the

mounting bolt hole on ring gear (19) of housing

(22). Lift the housing by crane.

W2-6-11


1

13

17

18

22

27

T152-03-02-006

W2-6-12


9. Adjust the bearing pre-load:

1) With shaft (27) being held, loosen nut (18).

2) Tap around the outer flange of housing (22)

three or four turns with a plastic hammer.

3) Install a socket bolt (1) to housing (22).

4) After rotating housing (22) in both clockwise

and counterclockwise directions several

times, install the spring balance to socket

bolt (1) to measure the starting torque (A)

of housing (22).

Starting Torque

IMPORTANT: When aligning holes, always

tighten the nut.

Tightening torque shall be less

than 295 N⋅m (30 kgf⋅m, 215 lbf⋅ft).

6) After installing second stage carrier (13) onto

shaft (27), check if knock pin (17) can be

installed into the nut (18) hole.

If the knock pin hole on second stage carrier

(13) is not aligned with the nut hole, tighten nut

(18) until both holes align with each other.

7) After rotating housing (22) in both clockwise and

counterclockwise directions several times,

install the spring balance to socket bolt (1) to

measure the starting torque (B) of housing (22).

8) Check that the starting torque shall be in the

following range.

If not in the range, repeat adjusting work from

step 1).

1

Torque Difference

B-A

Standard

+9.8 to +39.2 N

(+1.0 to +4.0 kgf (+7

to 29 Ibf))

22

18

Flange

27

W152-02-06-002

5) Tighten nut (18) to shaft (27) using special tool

(ST 4129).

: 152 N⋅m (15.5 kgf⋅m, 112 lbf⋅ft)

ST 4129

W1CC-02-06-002

W2-6-13


4

7

8

12

14

5

6

9

13

15

16

11

17

23

18

22

27

T152-03-02-006

W2-6-14


10. Refill grease 110 to 120g into housing (22) via

plug (23) hole.

11. Install plugs (23) (2 used) to housing (22).

:5 mm

: 9.8 N⋅m (1 kgf⋅m, 7 lbf⋅ft)

IMPORTANT: Install retaining rings (4) (3 used)

with the chamfered edge facing plate

(5).

12. Install needle bearings (8) (3 used), first stage

planetary gears (7) (3 used), first stage sun

gear (6) and plate (5) to first stage carrier (9),

and install retaining rings (4) (3 used).

13. Install thrust plate (11), plates (15) (3 used),

second stage planetary gears (14) (3 used),

and pins (12) (3 used) to second stage carrier

(13).

IMPORTANT: Tap spring pins (16) (3 used) with

slits facing upward (the motor side).

14. After aligning the holes on second stage carrier

(13) and pins (12) (3 used), tap in spring pins

(16) (3 used).

IMPORTANT: Check that the gap between the

ends of second stage planetary

gears (14) (3 used) and housing (22)

is approx. 3 mm (0.1 in).

If the gap is 12 mm (0.5 in), knock

pin (17) can be out of the hole of nut

(18).

15. Install the second stage carrier (13) assembly

onto shaft (27) so that knock pin (17) aligns with

the knock pin hole on nut (18).

Gap

14

13

22

17

18

Slits

W152-02-06-004

16

12

W152-02-06-003

W2-6-15


2

3

1

6

9

19

13

10

23

28

22

29

T152-03-02-006

W2-6-16


IMPORTANT: Install ring gear (19) with the

identification groove facing upward

(the swing motor side). (Refer to

page W2-6-4) Otherwise, socket

bolts (1) (8 used) can not be

installed.

16. Apply THREEBOND #1215 to the stepped top

face of housing (22). Install ring gear (19) onto

housing (22).

17. Install second stage sun gear (10) into second

stage carrier (13).

18. Install the first stage carrier (9) assembly onto

second stage sun gear (10).

19. Apply THREEBOND #1215 to the stepped top

face of the swing motor. Install the swing motor

onto ring gear (19) with socket bolts (1) (8

used).

: 12 mm

: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)

20. Install plug (29) to drain pipe (28). Install drain

pipe (28) and pipe (3) to the swing device.

Plug (29)

:8 mm

: 30 N⋅m (3 kgf⋅m, 21.5 bf⋅ft)

Drain Pipe (28) and Pipe (3)

: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

21. Refill gear oil (approx.1.8 L (0.5 us gal)) into the

swing device. Install cap (2) to pipe (3).

W2-6-17

DISASSEMLBE SWING MOTOR

28

27


29 30 36

31

32

33

34

35

26

25

24

23

22

21

20

19

18

38

39

37

1

2

17

16

3

4

5

15

14

6

7

8

13

12

9

11

10

1 - Spherical Bushing 11 - Block 21 - Valve Plate 31 - Poppet (2 Used)

2 - Retainer 12 - Socket Bolt (2 Used) 22 - Bushing (4 Used) 32 - Spring (2 Used)

3 - Plunger (7 Used) 13 - Rotor 23 - Teflon Ring (4 Used) 33 - O-Ring (2 Used)

4 - Swash Plate 14 - Friction Plate (2 Used) 24 - Scrowave (4 Used) 34 - Backup Ring (2 Used)

5 - Bearing 15 - Plate (2 Used) 25 - O-Ring 35 - Plug (2 Used)

6 - Spacer 16 - O-Ring 26 - Cover 36 - Socket Bolt (4 Used)

7 - Oil Seal 17 - Piston 27 - O-Ring (2 Used) 37 - Pin (2 Used)

8 - O-Ring 18 - Spring (15 Used) 28 - Plug (2 Used) 38 - Bushing (2 Used)

9 - Housing 19 - Retaining Ring 29 - O-Ring (2 Used) 39 - Teflon Ring (2 Used)

10 - O-Ring (2 Used) 20 - Needle Bearing 30 - Relief Valve (2 Used)

W1CC-02-06-001

W2-6-18


Disassemble Swing Motor




IMPORTANT: Do not disassemble relief valves (30)

(2 used).

1. Remove relief valves (30) (2 used) from cover

(26).

: 27 mm

IMPORTANT: Measure and record dimension A

between the top surfaces of piston

(17) and housing (9). This dimension

is necessary for assembly work.

8. Remove springs (18) (15 used) from housing (9).

Remove piston (17) using supports and bolts

(M6).

Spanner or so

Bolt (M6)

2. Remove plugs (35) (2 used) from cover (26).

Remove springs (32) (2 used) and poppets (31) (2

used).

: 14 mm

3. Remove socket bolts (12) (2 used). Remove block


:5 mm

IMPORTANT: Do not remove pins (37) (2 used)

from cover (26).

4. Remove socket bolts (36) (4 used). Remove

cover (26) from housing (9).

: 10 mm

Support

A

17

9

IMPORTANT: Make matching marks on valve plate

(21) and cover (26).

5. Remove retaining ring (19) from cover (26).

Remove needle bearing (20) and valve plate (21).

6. Remove bushings (38) (2 used) and teflon rings

(39) (2 used) from valve plate (21).

7. Remove O-ring (25), bushings (22) (4 used),

teflon rings (23) (4 used) and scrowaves (24) (4

used) from cover (26).

W152-02-06-006

9. Remove O-ring (16) from piston (17). Remove O-

ring (8) from housing (9).

10. Remove plates (15) (2 used) and friction plates

(14) (2 used) from housing (9).

IMPORTANT: Take care not to damage the upper

side (valve plate side) of rotor (13).

11. Remove the rotor (13) assembly from housing (9).

W2-6-19


1

2

3

4

5

6

7

13

9

W1CC-02-06-001

W2-6-20


12. Remove spacer (6) and the inner race of

bearing (5) from rotor (13) with a puller.

Puller

6

5

13

W152-02-06-007

13. Remove swash plate (4), plungers (3) (7 used),

retainer (2) and spherical bushing (1) from rotor

(13).

14. Remove the outer race of bearing (5) and oil

seal (7) from housing (9).

W2-6-21

ASSEMBLE SWING MOTOR

12

11

10


35

34

29

33

32

31

30

36

27

26

24

23

22

25

16

17

8

15

14

2

4

1

A

28

38

39

21

18

20

19

13

3

W152-02-06-005

5

6

9

7

1 - Spherical Bushing 11 - Block 21 - Valve Plate 31 - Poppet (2 Used)

2 - Retainer 12 - Socket Bolt (2 Used) 22 - Bushing (4 Used) 32 - Spring (2 Used)

3 - Plunger (7 Used) 13 - Rotor 23 - Teflon Ring (4 Used) 33 - O-Ring (2 Used)

4 - Swash Plate 14 - Friction Plate (2 Used) 24 - Scrowave (4 Used) 34 - Backup Ring (2 Used)

5 - Bearing 15 - Plate (2 Used) 25 - O-Ring 35 - Plug (2 Used)

6 - Spacer 16 - O-Ring 26 - Cover 36 - Socket Bolt (4 Used)

7 - Oil Seal 17 - Piston 27 - O-Ring (2 Used) 37 - * Pin (2 Used)

8 - O-Ring 18 - Spring (15 Used) 28 - Plug (2 Used) 38 - Bushing (2 Used)

9 - Housing 19 - Retaining Ring 29 - O-Ring (2 Used) 39 - Teflon Ring (2 Used)

10 - O-Ring (2 Used) 20 - Needle Bearing 30 - Relief Valve (2 Used)

Note: For the parts marked with*, refer to page

W3-6-18.

T152-03-02-002

W2-6-22


Assemble Swing Motor




1. Install spherical bushing (1) to rotor (13).

2. Install plungers (3) (7 used) into retainer (2). Apply

hydraulic oil to the plunger hole of rotor (13).

Install the plunger into the rotor.

3. Apply the hydraulic oil to the mating surfaces of

plungers (3) (7 used) and swash plate (4). Install

the swash plate to rotor (13).

4. Press the inner race of bearing (5) into rotor (13)

with a press.

IMPORTANT: After pressing spacer (6), wipe off

excessive LOCTITE between the

spacer and bearing (5).

5. Apply LOCTITE # 515 or # 518 to the interference

surfaces of spacer (6) of rotor (13). Press the

spacer into the rotor with a press.

6. Apply THREEBOND # 1211 to oil seal (7). Press

the oil seal into housing (9) with a press.

7. Press the outer race of bearing (5) into housing

(9) with a press.

IMPORTANT: After installing the rotor (13)

assembly into housing (9), check

that the top of the rotor is 7.5 mm

(0.3 in) below the top of housing (9).

8. Apply grease to the lip of oil seal (7). Install the

rotor (13) assembly into housing (9).

9. Apply the hydraulic oil to friction plates (14) (2

used) and plates (15) (2 used). Install the friction

plates and the plates into housing (9) alternately.

10. Apply the grease to O-ring (8). Install the O-ring to

housing (9).

11. Apply the grease to O-ring (16). Install the O-ring

to piston (17).

IMPORTANT: Press the piston into the housing

until dimension A between both tops

of piston (17) and housing (9) is

equal to the one measured when

disassembling.

12. Apply the hydraulic oil to the outer surface of

piston (17). Install the piston into housing (9) using

supports.

13. Install springs (18) (15 used) into piston (17).

14. Install teflon rings (23) (4 used) and scrowaves (24)

(4 used) to bushings (22) (4 used).

IMPORTANT: Be sure to align the matching marks

when installing valve plate (21).

15. Install bushings (22) (4 used) and valve plate (21)

to cover (26).

16. Press needle bearing (20) to cover (26). Install

retaining ring (19) to the cover.

17. Apply the grease to O-ring (25). Install the O-ring

to cover (26).

W2-6-23


12

11

10

35

34

29

33

32

31

30

36

W152-02-06-005

26

9

T152-03-02-002

W2-6-24


18. Apply THREEBOND #1211 to the mating surface

of cover (26) and housing (9). Install the cover on

the housing with socket bolts (36) (4 used).

: 10 mm

: 103 N⋅m (10.5 kgf⋅m, 76 lbf⋅ft)

19. Install O-rings (10) (2 used) to block (11). Install

the block to housing (9) with socket bolts (12) (2

used).

:5 mm

: 11.5 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)

20. Install backup rings (34) (2 used) and O-rings (33)

(2 used ) onto plugs (35) (2 used). Install poppets

(31) (2 used), springs (32) (2 used) and the plugs

onto cover (26).

: 14 mm

: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

21. Install O-rings (29) (2 used) to relief valves (30) (2

used). Install the relief valve to cover (26).

: 27 mm

: 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft)

W2-6-25


DISASSEMBLE AND ASSEMBLE

VALVE BLOCK

1

11 10

2

3

4

12

A

5

6

7

8

9

Section A

T152-03-02-003

W152-02-06-005

13

T152-03-02-002

1 - Plug 5 - Spool 8 - O-Ring 11 - Block

2 - O-Ring 6 - Spring Seat 9 - Plug 12 - O-Ring (2 Used)

3 - Spring 7 - Spring 10 - Socket Bolt (2 Used) 13 - Housing

4 - Seat

W2-6-26


Disassemble Valve Block

• Be sure to read. “Precautions for Disassembly

and Assembly” thoroughly on page W1-1-1 before


1. Remove socket bolts (10) (2 used). Remove

block (11) from housing (13).

:5 mm

2. Remove plug (1) from block (11). Remove spring

(3) and seat (4).

:5 mm

3. Remove plug (9) from block (11). Remove spring

(7), spring seat (6) and spool (5).

:5 mm

Assemble Valve Block

• Be sure to read. “Precautions for Disassembly

and Assembly” thoroughly on page W1-1-1 before


1. Install O-ring (8) to plug (9). Install spool (5),

spring seat (6), spring (7) and the plug to block

(11).

:5 mm

: 11.5 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)

2. Install O-ring (2) to plug (1). Install seat (4), spring

(3) and the plug to block (11).

:5 mm

: 11.5 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)

3. Install O-rings (12) (2 used) to block (11). Install

the block to housing (13) with socket bolts (10) (2

used).

:5 mm

: 11.5 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)

W2-6-27


Swing Motor

1. The clearance between plunger and rotor bore.


Standard clearance (D-d): 0.04 mm (0.0016 in) or

less

d

W107-02-06-138

D

D

2. The end play between plunger and shoe.

W107-02-06-139

Standard end play (δ): 0.4 mm (0.016 in) or less

δ

W107-02-06-140

W2-6-28

REMOVE AND INSTALL RIGHT PILOT

VALVE

UPPERSTRUCTURE / Pilot Valve




disconnecting hydraulic lines.




repair work.





Preparation





remaining pressure.

M1CC-07-002






W2-7-1


Removal

1. Remove bolts (3) (4 used) to remove seat (1) with

seat stand (2).

: 17 mm

2. Remove screws (18) (4 used). Move boot (5) up

to remove boot cover (17).

3. Remove caps (15) (2 used) and screws (14) (4

used) to remove cover (16).

1

2

4. Remove connector (10) and screws (13) (3 used)

to remove switch box (9).

: 13 mm

3

M1CC-01-012

5. Remove rubber cap (11) and screws (13) (3 used)

to remove cover (12).

6. Loosen nut (6) to remove lever (4) and boot (5).

: 22 mm

4

5

6

18

17

8

9

15

16

10

14

11

12

13

W1CC-02-07-001

W2-7-2


IMPORTANT: Attach identification tags on all disconnected

hoses to aid in reassembly.

7. Disconnect hoses (20 to 25), then attach a cap on

all disconnected the hose ends.

: 19 mm

8. Remove bolts (7) (4 used) to remove pilot valve

(19).

: 13 mm

24

25

20

21

22

Installation

23

1. Install pilot valve (19) to the console with bolts (7)

(4 used).

: 13 mm

: 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft)

W178-02-07-002

2. Connect hoses (20 to 25) to pilot valve (19).

: 19 mm

: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

20 - Hose T3: To pilot shut-off valve

21 - Hose B : To pilot piping coupler bracket

port B (boom lower)

22 - Hose G : To pilot piping coupler bracket

port G (bucket roll-in)

23 - Hose P2: From pilot shut-off valve

24 - Hose A : To pilot piping coupler bracket

port A (boom raise)

25 - Hose H : To pilot piping coupler bracket

port H (bucket roll-out)

NOTE: Piping location shows that of ISO pattern.

19

7

W1CC-02-07-001

W2-7-3


3. Install lever (4) and boot (5) to pilot valve (19) with

nut (6).

: 22 mm

:20±4.9 N⋅m

(2.0±0.5 kgf⋅m, 14.5±3.5 lbf⋅ft)

4

5

6

4. Install cover (12) with screws (13) (3 used).

Install rubber cap (11).

5. Install switch box (9) with screws (8) (3 used) to

connect connector (10).

19

18

17

8

9

6. Install cover (16) with screws (14) (4 used).

Install caps (15) (2 used).

15

16

10

7. Install boot (5) and boot cover (17) with screws

(18) (4 used).

8. Install seat (1) with seat stand (2) with bolts (3) (4

used).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

14

11

12

13

IMPORTANT: After installation, check the oil level,

start the engine and check for oil

leaks.

1

W1CC-02-07-001

2

3

M1CC-01-012

W2-7-4

REMOVE AND INSTALL LEFT PILOT

VALVE









repair work.





Preparation





remaining pressure.

M1CC-07-002






W2-7-5


Removal

1. Remove bolts (3) (4 used) to remove seat (1) with

seat stand (2).

: 17 mm

2. Remove screws (13) (4 used).Move boot (5) up to

remove boot cover (14).

3. Remove cap (18) and screws (20) (3 used) to remove

cover (19).

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

to remove cover (15).

1

2

5. Disconnect connector (22) of the horn harness

and remove clips (7), (23).

3

M1CC-01-012

6. Loosen nut (6) to remove lever (4) and boot (5).

: 22 mm

23

4

22

5

6

7

17 18 19 20

16

13

14

15

W178-02-07-003

W2-7-6




7. Disconnect hoses (24 to 29) and attach a cap on

each disconnected hose end.

: 19 mm

21

8. Remove bolt (9) with spring pin (8), spring washer

(11), plane washer (12) and bolts (10) (3 used) to

remove pilot valve (21).

: 13 mm

28

29

24

25

26

27

W178-02-07-004

Installation

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

to bolt (9) with spring pin (8). Install pilot valve (21)

to the console with bolts (9) and (10).

: 13 mm

: 10 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅ft)

24 - Hose T2: To pilot shut-off valve

25 - Hose F : To pilot piping coupler bracket

port F (right swing)

26 - Hose C : To pilot piping coupler bracket

port C (arm roll-out)

27 - Hose P1: From pilot shut-off valve

28 - Hose E : To pilot piping coupler bracket

port E (left swing)

29 - Hose D : To pilot piping coupler bracket

port D (arm roll-in)

NOTE: Piping location shows that of ISO pattern.


: 19 mm

: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

21

8

9

10

11

12

W178-02-07-003

W2-7-7


3. Install lever (4) and boot (5) to pilot valve (21) with

nut (6).

: 22 mm

:20±4.9 N⋅m (2±0.5 kgf⋅m, 14.5±3.5 lbf⋅ft)

23

4

IMPORTANT: If the harness is arranged to the inside

of spring pin (8), it may make

contact with the moving part of the

pilot valve damaging it. Be sure to

arrange harness to the outside of the

spring pin.

4. Align mounting clip marks of the harness to install

clips (23), (7). Arrange the harness to the outside

of spring pin (8) over bolt (9) head. Align the

marks of the harness to install clips (23), (7).

Connect connector (22).

16

15

22

21

17 18 19 20

5

6

7

8

9

13

14

5. Install cover (15) with screws (16) (4 used).Install

rubber cap (17).

6. Install cover (19) with screws (20) (3 used). Install

cap (18).

W178-02-07-003

7. Install boot (5) and boot cover (14) with screws

(13) (4 used).

1

8. Install seat (1) with seat stand (2) with bolts (3) (4

used).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

2

IMPORTANT: After installation, check the oil level.

Start the engine and check for oil

leaks.

3

M1CC-01-012

W2-7-8

REMOVE AND INSTALL TRAVEL PILOT

VALVE









repair work.





Preparation




the top of the hydraulic oil tank onto release any

remaining pressure.

M1CC-07-002






W2-7-9


Removal

1. Remove bolts (2) (4 used), spring washers (3) (4

used) and plane washers (4) (4 used) to remove

under cover (1).

: 17 mm

4

3

1

2

W1CC-02-07-003

2. Loosen bolts (5) (4 used) to remove pedal (6),

levers (17) and (18).

: 17 mm



3. Disconnect hoses (7 to 12).

: 19 mm

NOTE: Attach a cap on each disconnected hose

end.

4. Remove socket bolts (15) (2 used), spring washers

(14) (2 used) and plane washer (13) (2 used)

to remove pilot valve (16).

:8 mm

17

5

6

18

15

14

13

16

5

6

15

14

13

7

12

11

10

9

8

W1CC-02-07-004

7 - Hose P : From the pilot shut-off valve

8 - Hose T : To the pilot shut-off valve

9 - Hose 2-10 : To the control valve 1 port 10

(right travel forward)

10 - Hose 1-TR9: To control valve port 9

(right travel reverse)

11 - Hose 4-11 : To control valve port 11

(left travel reverse)

12 - Hose 3-12: (To control valve 1 port 12

(left travel forward)

W2-7-10


Installation

1. Install pilot valve (16) with socket bolts (15) (2

used), spring washers (14) (2 used) and plane

washers (13) (2 used).

:8 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

2. Connect hoses (7 to 12).

: 19 mm

: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)

17

18

5

6

3. Install pedal (6), levers (17) and (18) with bolts (5)

(4 used).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

5

6

15

14

16

15

14

13

13

7

12

11

10

9

8

W1CC-02-07-004

4. Install spring washers (3) (4 used) and plane

washers (4) (4 used) to bolts (2) (4 used).

Install under cover (1) with the bolt.

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)



9 - Hose 2-10 : To the control valve 1 port 10

(right travel forward)

10 - Hose 1-TR9: To control valve port 9

(right travel reverse)

11 - Hose 4-11 : To control valve port 11

(left travel reverse)

12 - Hose 3-12: (To control valve 1 port 12

(left travel forward)



leaks.

4

3

2

1

W1CC-02-07-003

W2-7-11


(Blank)

W2-7-12

REMOVE AND INSTALL BLADE PILOT

VALVE









repair work.





Preparation





remaining pressure.

M1CC-07-002






W2-7-13


Removal



under cover (4).

: 17 mm

4

1

2

3

W1CC-02-07-003

IMPORTANT: Do not turn rod end (15), or adjustment

is necessary.

2. Remove bolts (5) (2 used) and spring washers (6)

(2 used) to remove bracket (7) from pilot valve

(13).

: 17 mm

3. Disconnect hoses (8 to 11) from pilot valve (14).

: 19 mm

12

14

13

15

10

11 9

8

5

6

7

4. Remove bolts (14) (2 used) to remove pilot valve

(13) from bracket (12).

: 17 mm

W1CC-02-07-002



10 - Hose U : To the control valve 2 (blade raise)

11 - Hose D : To the control valve 2 (blade lower)

W2-7-14


Installation

1. Install pilot valve (13) to bracket (12) with bolts

(14) (2 used).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)


: 19 mm

: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

12

14

13

10

11 9

5

6

7

8

3. Install spring washers (6) (2 used) to bolts (5) (2

used). Install bracket (7) to pilot valve (13) with the

bolt.

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)




: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

IMPORTANT: After installing, check the hydraulic

oil level, start engine and check all

hoses for oil leaks.



10 - Hose U : To the control valve 2 (blade raise)

11 - Hose D : To the control valve 2 (blade lower)

W1CC-02-07-002

4

1

2

3

W1CC-02-07-003

W2-7-15

DISASSEMBLE RIGHT AND LEFT PILOT

VALVES


13

12

14

11

15

10

11

9

8

8

7

9

6

5

16

21

20

21

20

4

3

5

6

19

2

3

4

18

1

17

W176-02-07-001

1 - Spacer (4 Used) 7 - Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2 - Shim 8 - Push Rod A (2 Used) 13 - Screw Joint 18 - Housing

3 - Balance Spring A (2 Used) 9 - Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring

4 - Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Dowel Pin (2 Used)

5 - Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)

6 - Return Spring B (2 Used)

W2-7-16

Disassemble Right and Left Pilot Valves


IMPORTANT: Block (10) and housing (18) are

made of aluminium. Too strong a

force can deform, or damage them.

Therefore, be careful while handling

them.

IMPORTANT: As spool (17) has been selected to

match the hole of housing (18), they

must be replaced in a set. In addition,

the dimensions of balance springs A

(3), B (4) and return springs A (5), B

(6) as well as those of push rods A

(8), B (9) are different. For this reason,

be sure to indicate the port

number from which it is removed.

Port numbers are stamped on housing

(18).

IMPORTANT: Do not clamp housing (18) in a vise

to remove the screw joint because

the screw joint maybe damaged.

1. Secure screw joint (13) in a vise. Then turn cam

(12) with a spanner to remove the screw joint.

: 32 mm

2. Clamp the flat surface of housing (18) in a vise

slightly. Remove cam (12) from universal joint

(14).

: 32 mm

NOTE: The universal joint has been secured on

block (10) with LOCTITE. Do not remove it

unless necessary.

3. Remove socket bolt (11) to remove block (10). At

this time, push rods (8) and (9) are in place.

: 6 mm

IMPORTANT: Two kinds of push rods are used.

They must be handled in order of

port number after removing.

4. Pull push rods (8), (9) out from block (10).

5. With a bamboo spatula, remove oil seals (15) (4

used) from block (10).

NOTE: If a metal bar is used, the mating part of oil

seal may be damaged.

IMPORTANT: The retaining ring may come off

while disassembling. Take care not

to drop it.

6. Press springs using special tool (ST 7257) from

the top of spring guide (16). Retaining ring (7) will

appear. Remove it with a screw driver or similar

tool. (4 places)

7

ST 7257

W176-02-07-005

IMPORTANT: The number of shims has been determined

for each port during the

performance testing at the factory.

Take care not to loss them. Keep

them carefully to install them to each

former port when reassembly.

7. Remove spring guide (16), balance springs (3), (4),

return springs (5), (6), shim (2), spacer (1) from

spool (17).

16

W2-7-17


21

21

20

20

19

18

17

W176-02-07-001

W2-7-18


IMPORTANT: As the spool has been selected to

match the hole of the housing, keep

them carefully to install them to the

former port when reassembling.

8. Remove spool (17) from housing (18). Pulling it

out while turning it.

NOTE: The spool and housing must be replaced as

an assembly.

9. Remove O-rings (19), (21) from housing (18). Do

not remove dowel pin (20) unless necessary.

W2-7-19

ASSEMBLE RIGHT AND LEFT PILOT

VALVES


12

13

10

14

11

15

8, 9

7

16

3, 4

5, 6

2

19

1

17

20

21 18

W176-02-07-006

1 - Spacer (4 Used) 7 - Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2 - Shim 8 - Push Rod A (2 Used) 13 - Screw Joint 18 - Housing

3 - Balance Spring A (2 Used) 9 - Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring

4 - Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Dowel Pin (2 Used)

5 - Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)

6 - Return Spring B (2 Used)

W2-7-20

Assemble Right and Left Pilot Valves


IMPORTANT: The pilot valve is susceptible to contamination.

Keep parts clean when

assembling.

NOTE: Table below shows the relations between

each port and the components. Take care

not to confuse them when assembling.

Port

No.

Spool

(17)

Shim

(2)

Push rods

(8), (9)

1

Same to Same to

with outer

groove

2 the former

one

the former

one

without outer

groove

3 with outer

groove

4

without outer

groove

Port

No.

Return Springs

(5), (6)

1 short short

2 long long

3 short short

4 long long

Blance Springs

(3), (4)

IMPORTANT: Make sure of the port hole number

and insert the spool to the former

port.

1. Insert the thinner end of spool (17) to housing (18),

then push the spool rotating it.

NOTE: The spool has been selected to match the

hole of the housing. The spool and housing

must be replaced as an assembly.

IMPORTANT: Refer to the table above to assemble

them correctly.

2. Install the spacer (1), shim (2), balance spring (3)

or (4), return spring (5) or (6) onto spool (17) installed

in housing (18).

IMPORTANT: Install spring guide, with the protrusion

facing up.

3. Install spring guide (16) onto the return spring (3)

or (4).

4. Install retaining ring (7) onto ring holder (ST

7255).

W176-02-07-008

5. Insert the spool (17) head into the hole of spring

using special tool (ST 7257) to press the spring

from the top of spring guide (16). Install retaining

ring (7) with the ring holder (ST 7255) onto the

head of the spool.

ST 7257

7

ST 7255

W176-02-07-009

NOTE: Put approx. dia.8 mm, length 10 mm of

packing material, into the port hole not only

to make the work easy to do, but also to

prevent the spool from lowering to the bottom

when compressing the spring.

6. Assemble the remained spools (17) (3 used) into

housing (18) in the same procedures as step 2 to

5.

7. Install O-rings (19) and (21) (2 used) on to housing

(18).

17

ST 7255

Packing Material

W2-7-21


12

13

10

14

11

15

8, 9

20 18

W176-02-07-006

W2-7-22


8. Apply grease to the inner face of oil seals (15) (4

used), then install the oil seals (4 used) into block

(10) with a bamboo spatula.

NOTE: As shown bellow, inserting push rods (8),

(9) first, then installing oil seal (15). This

prevents the oil seal from entering into the

hole.

IMPORTANT: Make sure of the tighteness of cam.

13. Clamp housing (18) carefully in a vise and then

install cam (12) to universal joint (14).

Tighten the universal joint so that the clearance

between the cam and push rod (8), (9) become 0

to 2 mm.

: 32 mm

10

Oil Seal Mounting Hole

8, 9

IMPORTANT: Do not clamp housing (18) in a vise

because the screw joint maybe damaged.

14. Clamp screw joint (13) in a vise to tighten universal

joint (14). Tighten cam (12) with a spanner.

: 32 mm

: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)

W176-02-07-007

IMPORTANT: Make sure the position to install the

push rod.

9. Install push rods (8), (9) to block (10). When installing

the push rods, install the push rods with

groove to ports # 1 and # 3, the ones without

groove to ports # 2 and # 4, respectively.

10. Apply the grease to the ball at the ends of push

rods (8), (9).

11. Apply the grease to the joint part of universal joint

(14).

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

block (10) assembly to housing (18) with socket

bolts (11) (2 used).

:6mm

: 19.5 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

W2-7-23

DISASSEMBLE TRAVEL PILOT VALVE


1

31

30

35

34

33

32

2

5

4

3

26

27

28

29

11

10

9

8

7

6

25

24

23

22

21

20

19

13

12

18

17

14

15

16

W176-02-07-002

1 - Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)

2 - Cover 11 - Oil Seal (4 Used) 20 - Shim (Several) 29 - Spring Washer (4 Used)

3 - Pin (2 Used) 12 - O-Ring (4 Used) 21 - Balance Spring (4 Used) 30 - Adjust Bolt (4 Used)

4 - O-Ring (2 Used) 13 - Bushing (4 Used) 22 - Spring Guide (4 Used) 31 - Bushing (4 Used)

5 - O-Ring (2 Used) 14 - Casing 23 - Pusher (4 Used) 32 - Cam (2 Used)

6 - Damper (2 Used) 15 - O-Ring 24 - Spring Pin (2 Used) 33 - Lock Nut (4 Used)

7 - Rubber Seat (2 Used) 16 - Plug 25 - Spring Pin (2 Used) 34 - Spring Pin (2 Used)

8 - Socket Bolt (2 Used) 17 - Spool (4 Used) 26 - Bracket (2 Used) 35 - Spring Pin (2 Used)

9 - Spring Washer (2 Used) 18 - Spring (4 Used) 27 - Spring Pin (2 Used)

W2-7-24


Disassemble Travel Pilot Valve

1. Clamp casing (14) in a vise. Loosen bolt (1) to

remove cover (2) from holder (10).

: 10 mm

2. Remove socket bolts (8) (2 places), to remove

holder (10) from casing (14).

:8 mm

3. Pull out pusher (23) from casing (14) (4 places).

Bushing (13) and oil seal (11) are removed with

the pusher.

4. Pull out pusher (23) from bushing (13), with a

bamboo spatula to remove oil seal (11). (4 places)

IMPORTANT: Make mark on spools to install them

to their former position easily.

5. Pull out the spool (17) assembly from casing (14)

turning the spool.

Spring guide (22), balance spring (21), shim (20)

and spacer (19) are removed with the spool.

NOTE: The spool has been selected to match the

hole of the casing. The spool and casing

must be replaced as an assembly.

IMPORTANT: The number of the shims has been

determined during the performance

testing at the factory. They must be

kept together with their spool.

6. Compress balance spring (21). Remove spring

guide (22), balance spring (21), shim (20) and

spacer (19) from spool (17). (4 places)

7. Remove spring (18) from casing (14). (4 places)

IMPORTANT: Put a stand under bracket (26). If

holder (10) bears the reaction force,

a strong force acts on pin (3) and the

pin maybe deformed.

IMPORTANT: The inside of spring pins (24), (25)

hole in the bracket is stepped-shape.

Therefore, the spring pin can only be

pushed out in one direction.

8. Put a stand under bracket (26).

Push out spring pins (24), (25), (26) (2 used) from

bracket (26) at the same time using special tool

(ST 1237). Remove the bracket from pin (3). (2

places)

Do not remove spring pin (27) from the bracket

unless necessary.

NOTE: The outside end of the spring pin has been

caulked.

3

24,25

26

27

Caulked

Stand

W176-02-07-019


damper (6) and rubber seat (7) from pin (3). O-

ring (4) is removed with them. (2 places)

:5 mm

W2-7-25


30

31

35

34

33

32

3

5

10

14

W176-02-07-002

W2-7-26


10. Remove O-ring (5) from pin (3). (2 places)

11. Place holder (10) with the casing (14) mating surface

facing up.

IMPORTANT: The holes for spring pins (34), (35) of

cam (32) is stepped-shape. Therefore

the pins shall be removed from

the bottom of the cam.

12. Pull out spring pins (34), (35) (2 used) from cam

(32) at the same time using special tool (ST 1237).

(2 places)

NOTE: The spring pin is a double-pin.

NOTE: The spring pin is caulked in its hole, so it

may feel tight when removing.

13. Remove pin (3) with a round bar and a hammer.

At this time cam (32) is also removed. (2 places)

NOTE: Do not remove bushings (31) (4 used) left

on holder (10) unless necessary. When removal

is necessary, the bushing special

tool (ST 7256) should be used to tap it out.

14. Remove lock nuts (33) (2 used) from cam (32) to

remove adjusting bolts (30) (2 used).

: 13 mm

:4 mm

W2-7-27

ASSEMBLE TRAVEL PILOT VALVE


26 6 7

1 2 3 31 25 27 24

10

32

30

33 34, 35

8

9

13

28

29

5

4

11

12

23

22

21

18

20

19

14

17

15, 16

W176-02-07-010

1 - Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)

2 - Cover 11 - Oil Seal (4 Used) 20 - Shim (Several) 29 - Spring Washer (4 Used)

3 - Pin (2 Used) 12 - O-Ring (4 Used) 21 - Balance Spring (4 Used) 30 - Adjust Bolt (4 Used)

4 - O-Ring (2 Used) 13 - Bushing (4 Used) 22 - Spring Guide (4 Used) 31 - Bushing (4 Used)

5 - O-Ring (2 Used) 14 - Casing 23 - Pusher (4 Used) 32 - Cam (2 Used)

6 - Damper (2 Used) 15 - O-Ring 24 - Spring Pin (2 Used) 33 - Lock Nut (4 Used)

7 - Rubber Seat (2 Used) 16 - Plug 25 - Spring Pin (2 Used) 34 - Spring Pin (2 Used)

8 - Socket Bolt (2 Used) 17 - Spool (4 Used) 26 - Bracket (2 Used) 35 - Spring Pin (2 Used)

9 - Spring Washer (2 Used) 18 - Spring (4 Used) 27 - Spring Pin (2 Used)

W2-7-28

Assemble Travel Pilot Valve


IMPORTANT: Pay attention to the mounting direction

of spring guide (22).

IMPORTANT: Install the former number of shims.

1. Assemble the spool into assembly. (4 used)

• Insert spacer (19), shim (20), balance spring (21)

into the spool in order.

• Press the balance spring with hand. Install spring

guide (22) to the spool with the stepped-end facing

down.

2. Insert spring (18) to casing (14). (4 places)

IMPORTANT: Insert the spool (17) assembly into

the former port.

3. Turn and install the spool (17) assembly into casing

(14). (4 places)

4. Assemble the plunger (4 used).

• Install oil seal (11) onto bushing (13).

• Apply the grease to the inner face of the oil seal.

• Install O-ring (12) to the bushing.

• Insert pusher (23) to the bushing.

• Apply the grease to the pusher head section.

5. Insert the pusher (23) assembly to holder (10). (4

places).

6. If bushing (31) has been removed from holder

(10), it shall be installed on the holder using special

tool (ST 7256) in the following procedures.

NOTE: The bushings (4 used) are identical.

• Insert the bushing into special tool (ST 7256),

then tap on the special tool (ST 7256) to install the

bushing into the hole of the holder.

Stop tapping when the bushing end is flush with

the inside wall.

Inside Wall

10

ST 7256

W176-02-07-016

• Install the bushing on the opposite side in the

same procedure. 31

10

ST 7256

31

W176-02-07-015

• Install the bushing in near side as shown bellow.

Stop tapping when the bushing end is flush with

the outside of the holder.

31

10

ST 7256

Outside of

Holder

W176-02-07-014

• Install the bushing on opposite side as shown below.

31

10

ST 7256

W176-02-07-013

W2-7-29


3

10

32

30

33 34, 35

8

9

5

23

14

W176-02-07-010

W2-7-30


7. Place adjust bolt (30) to cam (32). Tighten the bolt

with hand, and then lightly secure it temporarily

with lock nut (33).

NOTE: Adjust the dimensions later.

8. Apply the grease on the head (mating surface for

pusher (23)) of adjust bolt (30) (2 places).

9. Install O-ring (5) to pin (3), then assemble the pin

to holder (10) with cam (32) (2 places).

IMPORTANT: Take care of the inserting direction

of the spring pin.

IMPORTANT: Tap the spring pin in until it makes

contact with the step in hole.

10. Install spring pins (34), (35) to cam (32) using

special tool (ST 1237), then secure the cam and

pin (3). The spring pins shall be displaced with

their slits at 90°.

34

35

Slit

Slit

IMPORTANT: Do not adjust adjust bolt (30) while

pressing the pusher (23) head with

the adjust bolt. The standard clearance

between the adjust bolt and

pusher must be 0 to 0.2 mm(0 to

0.008 in).

13. Adjust bolt (30) as the following procedures. (2

places)

: 13 mm

:4 mm

• Loosen lock nut (33).

• Move cam (32) to check whether there is play. If

none, turn the adjust bolt to adjust.

• Turn both the adjust bolts on the left and right alternatively

to keep the cam horizontal.

• Measure sizes A and B from both left and right

caves on the cam to holder (10). Fine adjust the

adjust bolt to get the same distance for both left

and right.

• Secure the adjust bolt with a hexagon-head

wrench. Tighten the lock nut to specified torque

first, securing the adjust bolt.

• When adjustment is finished, move cam to check

that there is a little play. If there is no play, the

pusher may be in compressed condition, and adjustment

should be carried out again.

: 9.8 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft)

30 33 32

10

W176-02-07-017

11. Caulk the hole edge of cam (32), where spring

pins (34), (35) are inserted, with a punch. (2

places)

A

B

12. Place holder (10) on the casing (14) assembly

and install it with socket bolts (8) (2 used), spring

washers (9) (2 used).

:8 mm

: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

W176-02-07-003

W2-7-31


26 7 6

1 2 3 25 27 24

10

28

29

5

4

W176-02-07-010

W2-7-32


14. Install rubber seat (7) to pin (3). (2 places)

15. Apply the grease to O-ring (5). (2 places)

IMPORTANT: Pay attention to the direction of

damper (16).

IMPORTANT: The inner bore of damper (16) is

edged-shape. If the damper is pried

upward, O-ring (5) will be damaged.

16. With the lever upward, install damper (6) to pin (3)

straight without pring. (2 places)

17. Secure damper (6) to holder (10) with socket bolts

(28) (2 used) and spring washers (29) (2 used). (2

places)

:8 mm

:7 N⋅m (0.7kgf⋅m, 5.1 Ibf⋅ft)

IMPORTANT: Place a stand under the bracket. If

holder (10) bears the reaction force,

strong force acts on the pin and the

pin maybe deformed.

IMPORTANT: The inside of the spring pin hole in

the bracket is stepped-shape. Make

sure of the direction to insert the

spring pin.

IMPORTANT: Make sure of the direction of the

spring pin.

20. Put a stand under bracket (26).

Tap spring pins (24) (25) into the bracket until the

spring pin comes to the stepped end using special

tool (ST 1237). The spring pins shall be displaced

with their slits at 90°.

18. Apply the grease to O-ring (4), then press it to the

end-most of pin (3). (2 places)

IMPORTANT: As for the direction to install the

bracket, refer to the figure in the

disassemble section. Take care not

to misassemble it.

19. Install pin (3) into bracket (26), then align the inserting

holes of spring pin (24), (25) to fix pin on

the bracket.

Caulked Here

26

Stand

Caulked Here

3

24, 25

W176-02-07-011

21. Caulk the hole edge of bracket (26), where spring

pins (24), (25) are inserted, with a punch. (2

places)

(Refer to the figure above.)

22. Install pin (3) on other bracket (26) as in step 19 to

21.

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

used).

: 10 mm

:5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)

24. Apply the grease to the spring pin (27) contact

part of damper (6). (2 places)

W2-7-33

DISASSEMBLE BLADE PILOT VALVE


22

21

20

1

2

3

4

5

6

7

1

2

3

4

5

6

7

19

19

8

8

17

18

18

17

9

10

9

16

14

14

11

12

10

11

12

15

13

W192-02-07-001

1 - Dust Seal (2 Used) 7 - Spring Seat (2 Used) 13 - Casing 18 - Lock Nut (2 Used)

2 - Bushing (2 Used) 8 - Return Spring (2 Used) 14 - Bushing (2 Used) 19 - Set Screw (2 Used)

3 - Oil Seal (2 Used) 9 - Balance Spring (2 Used) 15 - Pin 20 - Cam

4 - O- Ring (2 Used) 10 - Spacer (2 Used) 16 - Cover 21 - Set Screw

5 - Pusher (2 Used) 11 - Shim (2 Used) 17 - Socket Bolt (2 Used) 22 - Boot

6 - Washer (4 Used) 12 - Spool (2 Used)

W2-7-34

Disassemble Blade Pilot Valve




1. Remove boot (22) from cover (16).

2. Clamp the pilot valve in a vise. Loosen set screw

(21) and remove pin (15) with a bar. Remove the

cam (20) assembly from cover (16).

:3 mm

: 8 mm or less

IMPORTANT: Record the positions, related to casing

(13), of the disassembled parts.

Slowly remove socket bolts (17) and

plate (16) as pusher (15) assemblies

may fly out by the force of return

springs (8).

Do not disassemble set screws (19).

Adjustment is necessary when reassembling

them.

3. Alternately loosen and remove socket bolts (17)

(2 used). Remove cover (16) and the pusher (5)

assemblies (2 used) from casing (13).

:6 mm

4. Remove pusher (5), O-ring (4), oil seal (3) and

dust seal (1) from each bushing (2) (2 used).

IMPORTANT: In order to avoid mixing them up, be

sure to indicate the port number

from which each disassembled part

came.

5. Remove the spool (12) assemblies and return

spring (8) from each ports of casing (13).

6. Compress balance spring (9) to remove washer

(6) and spring seat (7) from spool (12).

Remove spacer (10) and shims (11) from spool

(12) (2 used).


W2-7-35

ASSEMBIE BLADE PILOT VALVE


18 19 14 21 15 20 22

5

17

2

16

6

7

12

10

1

3

4

8

9

11

13

T554-02-07-010

1 - Dust Seal (2 Used) 7 - Spring Seat (2 Used) 13 - Casing 18 - Lock Nut (2 Used)

2 - Bushing (2 Used) 8 - Return Spring (2 Used) 14 - Bushing (2 Used) 19 - Set Screw (2 Used)

3 - Oil Seal (2 Used) 9 - Balance Spring (2 Used) 15 - Pin 20 - Cam

4 - O- Ring (2 Used) 10 - Spacer (2 Used) 16 - Cover 21 - Set Screw

5 - Pusher (2 Used) 11 - Shim (2 Used) 17 - Socket Bolt (2 Used) 22 - Boot

6 - Washer (4 Used) 12 - Spool (2 Used)

W2-7-36


Assemble Blade Pilot Valve

IMPORTANT: Install washers (6) (4 used) with its

sharp edge side facing away from

balance spring (9).

Do not compress balance spring (9)

with spring guide (7) more than 4

mm (0.157 in) when installing spring

guide (7).

One face of spring guide (7) is the

spring seat. Be sure to install spring

guide (7) with the spring seat side

facing balance spring (9).

1. Install shims (11) (2 used), spacers (10) (2 used)

and balance springs (9) (2 used) on spools (12) (2

used). Compress balance springs (9) to install

spring seat (7) (2 used) and washers (6) (4 used)

to spool (12).

IMPORTANT: Be sure to confirm the port number

before inserting each the spool (12)

assembly, to be sure that the spool

assembly is inserted into its correct

port.

2. Insert return springs (8) (2 used) and spool (12)

assemblies (2 used) into casing (13).

IMPORTANT: Install oil seals (3) (2 used) and dust

seals (1) (2 used) in their correct directions.

Apply a film of grease to

the lips of the oil seal and the dust

seal, and to the inside of bushing (2).

3. Install oil seals (3) (2 used), dust seals (1) (2

used) and O-rings (4) (2 used) on bushings (2) (2

used). Insert pushers (5) (2 used) into the bushing.

4. Place the pusher (5) assemblies (2 used) and

cover (16) onto each spool (12) assemblies (2

used). Alternately tighten socket bolts (17) (2

used) to install the cover on casing (13).

:6 mm

: 29.5±2.9 N⋅m

(3.0±0.3 kgf⋅m, 21.5±2.2 lbf⋅ft)

5. Install set screws (19) (2 used) on cam (20) and

temporarily tighten lock nuts (18). Install the cam

(20) assembly on cover (16) with pin (15).

:5 mm

IMPORTANT: Apply LOCTITE #241 to set screw

(21).

6. Install set screw (21) into cam (20).

:3 mm

: 6.9±1 N⋅m (0.7±0.1 kgf⋅m, 5.0±0.7 lbf⋅ft)

7. Adjust set screws (19) (2 used).

Secure cam (20) horizontally. The clearance between

pushers (5) (2 used) and set screws (19) is

0 mm, then tighten lock nuts (18) (2 used).

: 17 mm

:5 mm

: 33.5±3.9 N⋅m

(3.4±0.4 kgf⋅m, 24.5±2.9 lbf⋅ft)

8. Tilt cam (20) and apply a film of grease to the

pushers (5) (2 used) head.

9. Install boot (22) on cover (16).

Use one of the following greases:

• Apolloil Autorex C (Idemitsu)

• Ocean 7 (Nihon Ore Louve)

• Screw Bar L60 (NOK)

W2-7-37


(Blank)

W2-7-38

UPPERSTRUCTURE / Pilot Shut-Off Valve

REMOVE AND INSTALL PILOT SHUT-OFF

VALVE








repair work.





Preparation





remaining pressure.

M1CC-07-002






W2-8-1


Removal


used) and plane washers (1) (6 used). Remove

under cover (4).

: 17 mm

4

1

2

3

IMPORTANT: Do not turn rod end (8), or

adjustment is necessary.

2. Remove socket bolt (5), plane washer (6), nut

(10) and spring washer (9).

: 10 mm

:5 mm

7

8

10

9

W1CC-02-07-003

IMPORTANT: Attach identification tags to the

hydraulic hoses for reassembly.

3. Disconnect hoses (12 to 22) from pilot shut-off

valve (7).

: 19, 22 mm

5

6

21

22

W197-02-08-001

4. Loosen socket bolts (11) (2 used). Then, remove

pilot shut-off valve (7).

:8 mm

20

11

12

19

18

17

15

14

16

11 - Socket Bolts (2 used)

12 - Hose T4 : To hydraulic oil tank

13 - Hose BT : From blade pilot valve

14 - Hose PB : From solenoid valve unit

15 - Hose T3: From right pilot valve

16 - Hose HT : To shockless valve

17 - Hose T2: From left pilot valve

18 - Hose BP : To blade pilot valve

19 - Hose P1 : To left pilot valve

20 - Hose P2: To right pilot valve

21 - Hose PT : From travel pilot valve

22 - Hose PP: To travel pilot valve

13

W1CC-02-08-003

W2-8-2

Installation


21

22

1. Install pilot shut-off valve (7) with socket bolts (11)

(2 used).

:8 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

20

11

12

19

18

2. Install plane washer (6) to socket bolt (5).

Install rod end (8) with spring washer (9), nut (10)

and the socket bolt.

: 10 mm

:5 mm

: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

17

11 - Socket Bolts (2 used)

12 - Hose T4 : To hydraulic oil tank

13 - Hose BT : From blade pilot valve

14 - Hose PB : From solenoid valve unit

15 - Hose T3: From right pilot valve

16 - Hose HT : To shockless valve

17 - Hose T2: From left pilot valve

18 - Hose BP : To blade pilot valve

19 - Hose P1 : To left pilot valve

20 - Hose P2: To right pilot valve

21 - Hose PT : From travel pilot valve

22 - Hose PP: To travel pilot valve

8

7

15

14

16

10

9

13

W1CC-02-08-003

3. Connect hoses (12 to 22) to pilot shut-off valve

(7).

: 19 mm

: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

: 22 mm

: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

5

6

W197-02-08-001




: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

4

1

2

3

W1CC-02-07-003

W2-8-3


DISASSEMBLE PILOT SHUT-OFF VALVE

1

2

3

4

14

5

6

7

8

13

12

11

9

10

W1CC-02-08-001

1 - Retaining Ring 5 - O-Ring 9 - Spring Pin 12 - Socket Bolt

2 - Washer 6 - Backup Ring 10 - Lever 13 - Steel Ball

3 - Backup Ring 7 - Washer 11 - Spool 14 - Body

4 - O-Ring 8 - Retaining Ring

W2-8-4


Disassemble Pilot Shut-Off Valve




1. Remove retaining ring (1) and washer (2) and pull

out spool (11).

IMPORTANT: Put matching marks on spool (11)

and lever (10).

2. Pull out spring pin (9) from spool (11), and remove

lever (10).

3. Remove washer (7) and retaining ring (8) from

spool (11).

4. Remove backup ring (3), (6) and O-ring (4), (5)

from body (14).

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

:6 mm

W2-8-5

ASSEMBLE PILOT SHUT-OFF VALVE


1 2 3 4

5 6 7 8 9

10

13

12

14

11

W1CC-02-08-002

1 - Retaining Ring 5 - O-Ring 9 - Spring Pin 12 - Socket Bolt

2 - Washer 6 - Backup Ring 10 - Lever 13 - Steel Ball

3 - Backup Ring 7 - Washer 11 - Spool 14 - Body

4 - O-Ring 8 - Retaining Ring

W2-8-6

Assemble Pilot Shut-Off Valve


IMPORTANT: Apply grease to O-ring (5) and

backup ring (6).

1. Install O-ring (5), backup ring (6) and washer (7)

to body (14).

IMPORTANT: Apply hydraulic oil to spool (11).

2. Install spool (11) to body (14). Install retaining ring

(8) to the spool.

2. With matching marks on spool (11) and lever (10)

aligned, tap spring pin (9) in spool (11) and lever

(10).

IMPORTANT: Apply the grease to O-ring (4) and

backup ring (3).

4. Install O-ring (4), backup ring (3), and washer (2)

to body (14). Install retaining ring (1) to spool (11).

5. Tighten socket bolts (12).

:6 mm

: 44 N⋅m (4.5 kgf⋅m, 3.3 lbf⋅ft)

W2-8-7


(Blank)

W2-8-8

REMOVE AND INSTALL SHOCKLESS

VALVE

UPPERSTRUCTURE / Shockless Valve








repair work.





Preparation





remaining pressure.

M1CC-07-002






W2-9-1


Removal



under cover (4).

: 17 mm

IMPORTANT: Attach identification tags to the hydraulic

houses for reassembly.

2. Disconnect hoses (7 to 18) from shockless valve

(6).

: 19 mm, 22 mm

3. Remove bolts (5) (2 used) to remove shockless

valve (6).

: 17 mm

Installation

4

1

2

3

1. Install shockless valve (6) with bolts (5) (2 used).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

W1CC-02-07-003

2. Connect hoses (7 to 18) to shockless valve (6).

: 19 mm

: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

: 22 mm

: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)




: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

16

15

14

18

17

13

5

6

11

12

7

10

9

8

W1CC-02-09-001

5 - Bolt (2 used)

6 - Shockless Valve

7 - Hose SD: To hydraulic oil tank

8 - Hose B5: To arm roll-out control valve (1)

9 - Hose B4: To boom lower control valve (1)

10 - Hose B3: To boom raise control valve (1)

11 - Hose B2: To left swing control valve (2)

12 - Hose B1: To right swing control valve (2)

13 - Hose HT: From pilot shut-off valve

14 - Hose A2: From pilot piping coupler bracket port ME

15 - Hose A1: From pilot piping coupler bracket port MF

16 - Hose A4: From pilot piping coupler bracket port MB

17 - Hose A3: From pilot piping coupler bracket port MA

18 - Hose A5: From pilot piping coupler bracket port MC

W2-9-2

DISASSEMBLE AND ASSEMBLE SHOCK-

LESS VALVE


1

2

5

8

2

5

5

3

4

2

6

7

9

8

2

10

11

12

1

2

3

4

4

3

2

1

25

26

2

5 22

13

5

2

5

24

2

24

23

23

22

14

15

21

17

18

14

15

16

17

18

4

3

2

1

19

19

20

20

W197-02-09-003

W2-9-3


A

B

C

D

A

B

C

D

2

1 3 4

1 3 2 26 25 19 18 20

Section A-A

Section C-C

5

4

3

1

7

2

8

3

1

2

4

2

5

14

21

15

17

E

F

G

E

F

G

4

5

3

1

7

2

8

4

1

2

3

2

5

14

4

2

5

3

1

9

2

8

3

1

2

4

2

5

14

13

2 26 25 19 18 20

Section B-B

21

15

17

24 23 22 18 20 19

Section D-D

21

15

17

4

3

1

9

2

8

3

1

2

4

2

5

2

1 3 2 5 6 10 11

2

16

15

17

5 24 23 22 18 20 19

1 3 4 2 1 3 12

Section E-E

14

Section F-F

4 3 2 1

Section G-G

W196-02-09-003

W2-9-4


key No. Parts Name Q’ty

Wrench Size

Tightening Torque

(mm) N⋅m (kgf⋅m) (lbf・ft)

Remarks

1 Plug 14 : 4 7.4 to 9.3 (0.75 to 0.95) (5 to 6.9)

2 O-Ring 23

3 Spring 14

4 Steel Ball 14

5 Plug 9 : 4 7.4 to 9.3 (0.75 to 0.95) (5 to 6.9)

6 Orifice 1 : 3 5.1 to 6.4 (0.52 to 0.65) (3.8 to 4.8) Use LOCTITE #241

7 Spring 2

8 Spool 4

9 Spring 2

10 Filter Element 1

11 Retainer 1 : 6 6.9 to 8.8 (0.70 to 0.80) (5.1 to 5.9)

12 Orifice 1 : 3 5.1 to 6.4 (0.52 to 0.65) (3.8 to 4.8) Use LOCTITE #241

13 Body 1

14 O-Ring 4

15 Sleeve 4

16 Orifice 1 : 1.5 0.31 to 0.39 (0.032 to 0.04) (0.23 to 0.29) Use LOCTITE #241

17 Spool 4

18 Spring 4

19 O-Ring 4

20 Plug 4 - Use special tool

21 Orifice 3 : 1.5 0.31 to 0.39 (0.032 to 0.04) (0.23 to 0.29) Use LOCTITE #241

22 Spring 2

23 Spool 2

24 Set Screw 2 : 1.5 0.78 to 0.98 (0.08 to 0.1) (0.6 to 0.7) Use LOCTITE #241

25 Spring 2

26 Spool 2

W2-9-5


(Blank)

W2-9-6

REMOVE AND INSTALL SOLENOID VALVE

UNIT

UPPERSTRUCTURE / Solenoid Valve








repair work.





Preparation





remaining pressure.

M1CC-07-002






W2-10-1


Removal


(2 used) from the right side cover (1). Then, remove

cover (1).

: 17 mm

2. Disconnect each harness of the solenoid valve.

1

3

IMPORTANT: Attach tags to disconnected hoses

for reassembly.

3. Disconnect hoses (5, 6, 8 and 11 to 16) from solenoid

valve unit (18). Cap all disconnected hoses.

: 19 mm, 22 mm, 27 mm

2

4. Remove bolts (17) (2 used) to remove solenoid

valve unit (18).

: 17 mm

Installation

17

18

5 6

7

4

W197-02-10-003

8

1. Install solenoid valve unit (18) with bolts (17) (2

used).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

16

9

10

11

12

2. Connect hoses (5, 6, 8 and 11 to 16) to solenoid

valve unit (18).

: 19 mm

: 29 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

: 22 mm

: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

: 27 mm

: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)

3. Connect each harness of the solenoid valve.

4. Install right side cover (1), secure the cover with

bolts (2) (3 used), (3) and (4) (2 used).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

15

14

5 - Hose DR : To hydraulic oil tank

6 - Hose PB : To pilot shut-off valve

7 - Proportional Solenoid Valve

8 - Hose PC : To control valve (1)

9 - Proportional Solenoid Valve

10 - Pilot Relief Valve

11 - Hoses SB: To control valve (2)

12 - Hose SA : To center joint

13 - Hose PE : To control valve (2)

14 - Hose PA: From pilot pump

15 - Hose TA : To hydraulic oil tank

16 - Hose PD : To regulator (pump)

17 - Bolt (2 used)

13

W1CC-02-10-001

W2-10-2


(Blank)

W2-10-3

DISASSEMBLE PROPORTIONAL SOLE-

NOID VALVE


1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

W157-02-11-016

1 - Socket Bolt (2 Used) 6 - Solenoid 11 - Washer 15 - O-Ring

2 - Lock Nut 7 - Spring 12 - Spring 16 - Sleeve

3 - O-Ring 8 - O-Ring 13 - O-Ring 17 - Plate

4 - Adjusting Screw 9 - Diaphragm 14 - O-Ring 18 - Washer

5 - Spring 10 - Spool

W2-10-4

Disassemble Proportional Solenoid Valve

• Be sure to read “Precautions for disassembly and



IMPORTANT: Take care not to lose spring (7) provided

in the groove of solenoid (6)

when removing solenoid (6).

Do not turn lock nut (2) and adjusting

screw (4).

1. Loosen socket bolts (1) (2 used) to remove solenoid

(6).

:3 mm

2. Pull out spool (10) and remove diaphragm (9),

washer (11) and spring (12).

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

(15), washer (18), and plate (17).


W2-10-5

ASSEMBLE PROPORTIONAL SOLENOID

VALVE


4 2 6 1 8 16 13 14 10 15 18

9 7 11 12

17

W157-02-11-001

1 - Socket Bolt (2 Used) 6 - Solenoid 11 - Washer 15 - O-Ring

2 - Lock Nut 7 - Spring 12 - Spring 16 - Sleeve

3 - *O-Ring 8 - O-Ring 13 - O-Ring 17 - Plate

4 - Adjusting Screw 9 - Diaphragm 14 - O-Ring 18 - Washer

5 - *Spring 10 - Spool


W2-10-4.

W2-10-6

Assemble Proportional Solenoid Valve


IMPORTANT: Apply grease to O-rings (13), (14),

(15) and apply hydraulic oil to sleeve

(16).

When inserting sleeve (16), be sure

to align the ports of the sleeve with

the ports of the housing.

1. Install washer (18), plate (17) into the housing. Install

O-rings (13), (14), (15) on sleeve (16) and insert

it into the housing.

13

14

15

16

Housing

IMPORTANT: Apply the hydraulic oil to spool(10).

Take care not to damage the edge

portion in the bore of sleeve (16)

when inserting the spool (10) assembly.

After inserting the spool, check if

spool (10) slides in and out smoothly

without any restriction about 3 to 5

mm (0.12 to 0.20 in).

2. Install diaphragm (9), washer (11), spring (12) to

spool (10) and install it in to sleeve (16).

9

10

16

W157-02-11-005

11

12

Housing

W157-02-11-009

10

IMPORTANT: Lock nut (2), adjust screw (4), spring

(5), O-ring (3), are not separated so

no need to assemble them.

Take care not to drop solenoid (6)

and spring (7).

3. Install solenoid (6) with bolt (1).

:3 mm

: 2.9 N⋅m (0.3 kgf⋅m, 2.2 Ibf⋅ft)

6

W157-02-11-010

7

1

W157-02-11-011

W2-10-7

1

2

3

DISASSEMBLE AND ASSEMBLE RELIEF

VALVE


4

5

6

7

W198-02-10-006

1 - Plug 3 - Spring 5 - poppet 7 - Gasket

2 - Shim 4 - O-Ring 6 - sleeve

W2-10-8


Disassemble Relief Valve




IMPORTANT: When removing plug (1), be sure not

to drop the shim (2) out of it.

1. Remove plug (1) from the housing.

: 22 mm

2. Remove spring (3) and O-ring (4) from the sleeve

(6) assembly.

3. Remove poppet (5) and sleeve (6) in the assembly

from the housing.

4. Remove gasket (7) from the housing.

Assemble Relief Valve




1. Install gasket (7) into the housing.

2. Install poppet (5) into sleeve (6). Install spring (3)

and O-ring (4) into the sleeve assembly. Then, insert

the sleeve assembly into the housing.

IMPORTANT: Be sure not to drop the shim (2).

3. Install shim (2) into plug (1), install the plug into

the housing. Then, secure them with the plug.

: 22 mm

: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

W2-10-9


(Blank)

W2-10-10

MEMO

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SECTION 3

UNDERCARRIAGE

CONTENTNS

Group 1 Swing Bearing

Remove and Install Swing Bearing .... W3-1-1

Disassemble Swing Bearing .............. W3-1-4

Assemble Swing Bearing....................W3-1-6


Remove and Install Travel Device ..... W3-2-1

Disassemble Travel Device ............... W3-2-4

Assemble Travel Device.................... W3-2-8

Disassemble Travel Motor ............... W3-2-12

Assemble Travel Motor.................... W3-2-16

Disassemble Travel Brake Valve ..... W3-2-20

Assemble Travel Brake Valve .......... W3-2-22

Maintenance Standard ..................... W3-2-24

Group 3 Center Joint

Remove and Install Center Joint........ W3-3-1

Disassemble Center Joint.................. W3-3-4

Assemble Center Joint ...................... W3-3-6

Maintenance Standard .......................W3-3-9

Group 5 Front Idler

Remove and Install Front Idler ........... W3-5-1

Disassemble Front Idler..................... W3-5-2

Assemble Front Idler ......................... W3-5-4

Maintenance Standard....................... W3-5-6

Group 6 Upper and Lower Roller

Remove and Install Upper Roller ....... W3-6-1


Upper Roller .................................... W3-6-4

Remove and Install Lower Roller ....... W3-6-6


Lower Roller .................................... W3-6-8

Maintenance Standard........................W3-6-10

Group 7 Track

Remove and Install Track................... W3-7-1

Maintenance Standard...........................W3-7-7

Group 4 Track Adjuster

Remove and Install Track Adjuster .... W3-4-1

Disassemble Track Adjuster.............. W3-4-2

Assemble Track Adjuster................... W3-4-8

1CCW-3-1

(Blank)

1CCW-3-2

REMOVE AND INSTALL SWING BEARING

UNDERCARRIAGE / Swing Bearing

Before removing the swing bearing, the upperstructure

must be removed first. For removal and installation of

the upperstructure, refer to “Remove and Install Main

Frame” section. In this section, the procedure starts on

the premise that the upperstructure has already been

removed.

Removal

1. Put matching marks on swing bearing (1) and

track frame (2).

Matching Mark

1 2

W105-03-01-001

2. Remove mounting bolts (3) (24 used) of the swing

bearing inner race.

: 24 mm

3

CAUTION: Swing bearing weight:93 kg

(205 lb)

3. Attach lifting tools (ST 0050) to swing bearing (4),

hoist swing bearing (4) and remove it.

W105-03-01-002

ST 0050

4

W105-03-01-003

W3-1-1


Installation

Clean the mating surfaces of the swing bearing and

the frame.

1. Apply THREEBOND #1102 to the mating surfaces

of the swing bearing and the track frame.

ST 0050

CAUTION: Swing bearing weight:93 kg

(205 lb)

IMPORTANT: Inner race soft zone (S) and the ball

filler port shall be placed on the

same position.

2. Hoist the swing bearing. Align the matching marks

on the track frame and the swing bearing.

Grease Fitting Position

Front Side

W105-03-01-003

Plug

Position

3. Install mounting bolts (3) (24 used) of the swing

bearing inner race and tighten them to

specification.

: 24 mm

: 265 N⋅m (27 kgf⋅m,195 lbf⋅ft)

15°

Grease Fitting

Position

「S」

(Soft Zone)

Marking Position

W152-03-01-001

3

W105-03-01-002

W3-1-2


(Blank)

W3-1-3


DISASSEMBLE SWING BEARING

1

2

3

4

9,10

7 6

5

W155-03-01-001

2

8

1

8

7

6

9

10

5

W105-03-01-011

1 - Outer Race 4 - Plug 7 - Inner Race 9 - Support (30 Used)

2 - Seal 5 - Seal 8 - Grease Fitting (2 Used) 10 - Support (36 Used)

3 - Pin 6 - Ball (66 Used)

W3-1-4


Disassemble Swing Bearing




1. Drive to remove pin (3) of plug (4) from the bottom

side of the swing bearing.

NOTE: The top of pin (3) was crimped. Remove

the crimped part with a grinder.

3

4

2. Remove plug (4).

NOTE: Screw bolt (M8, pitch 1.25 mm) in plug (4).

Hit the lower side of the bolt or pull the bolt

to remove plug (4).

W105-03-01-007

CAUTION: Swing bearing weight: 93 kg

(205 lb)

3. Install lifting tool (ST 0050) to swing bearing outer

race (1). Hoist the swing bearing outer race

slightly by crane. Remove seals (2) and (5).

4

4. Put inner race (7) of the swing bearing on the

wooden blocks. Hoist outer race (1) to take up a

slack of the wire rope.

5. While rotating outer race (1), remove balls (6) (66

used) and supports (9) (30 used) and (10) (36

used).

Remove the balls with bar magnet (A).

Remove supports (9) and (10) with bent wire

(B).

1

A

W105-03-01-008

2

7

6 5

W105-03-01-009

B

9,10

W105-03-01-010

W3-1-5

ASSEMBLE SWING BEARING


1

2

3

4

9,10

7 6

5

W155-03-01-001

2

8

1

8

7

6

9

10

5

W105-03-01-011

1 - Outer Race 4 - Plug 7 - Inner Race 9 - Support (30 Used)

2 - Seal 5 - Seal 8 - Grease Fitting (2 Used) 10 - Support (36 Used)

3 - Pin 6 - Ball (66 Used)

W3-1-6


Assemble Swing Bearing




2

1. Before installing the swing bearing inner and outer

races, completely remove the oil from the groove

surfaces of oil seals (2) and (5). Apply

THREEBOND #1735 to the groove surfaces, then

install seals (2) and (5).

IMPORTANT: Apply the grease to balls (6) (66

used) , supports (9) (30 used) and

(10) (36 used).

Take care to the assembling

direction of supports (9 and 10) and

balls. Supports (9 and 10) are

different figure. Support (10) is

symmetrical.

First, insert supports (9) and balls

into the swing bearing alternately.

Supports (9) should be installed with

the same direction. After installing

supports (9) completely, all of

supports (9) are in place, install

supports (10) and balls alternately.

Adjust the gap using supports (9)

and (10).

10 9

5

6

W142-03-01-005

CAUTION: Swing bearing weight: 93 kg

(205 lb)

2. Hoist the outer race using lifting tool (ST 0050).

Align the center of the outer race and the inner

race. While rotating the outer race, install ball (6)

and support (9) or (10) into the bearing races in

the order with a round wooden stick.

3. Install plug (4) into the outer race, then install pin

(3).

Crimp the top face fringe of pin (3) with a punch.

Sufficiently lubricate the swing bearing with

grease (Shell Alvania EP2 or equivalent).

3

W1CC-03-01-001

9,10

W142-03-01-006

1

4

W142-03-01-007

W3-1-7


(Blank)

W3-1-8

REMOVE AND INSTALL TRAVEL DEVICE

UNDERCARRIAGE / Travel Device








repair work.





Preparation

1. Park the machine on a solid level surface. Lower

the bucket onto the ground.


top of the hydraulic oil tank to release any

remaining pressure.

M1CC-07-002






W3-2-1


Removal

1. Remove bolt (4) and washer (3) from the track

frame to remove cover (2).

: 22 mm

2. Disconnect all hoses from the travel device. Cap

the disconnected hoses. Attach tags to them for

assembly.

: 19 mm, 22 mm, 27 mm

1

CAUTION: Travel device weight: 140 kg

(309 lb)

3. Remove the travel device mounting bolts (1).

Remove the travel device by crane.

: 24 mm

4

3

2

W152-03-02-003

W3-2-2


Installation

CAUTION: Travel device weight: 140 kg

(309 lb)

1. Install the travel device with bolt (1).

: 24 mm

: 300 N⋅m (31 kgf⋅m, 225 lbf⋅ft)

1

2. Reconnect all hoses to the travel device.

: 19 mm

: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

: 22 mm

: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

: 27 mm

: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)

3. Install washer (3) to bolt (4). Then install cover (2)

to the track frame with bolt (4).

: 22 mm

: 140 N⋅m (14.5 kgf⋅m, 103 lbf⋅ft))

4

3

2

W152-03-02-003



leaks. Be sure to conduct the breakin

operation to prevent the travel

motor seizure during the initial

operation.

Break-in operation conditions:

1. Engine control lever: Minimum speed.

2. Travel mode: slow mode

3. Operation time: 2 minutes above

W3-2-3


DISASSEMBLE TRAVEL DEVICE

6

7

2 3 4

5

8

1

12

13 14 15

21

16

22

23 24

25 26 27

9 10 11

20 19

17

18

32

33

34

28

29 30 31

1 - Travel Motor 10 - Knock Pin 19 - Spring Pin (3 Used) 27 - Shaft

2 - Floating Seal 11 - Second Stage Carrier 20 - First Stage Carrier 28 - Ring Gear

3 - Floating Seal 12 - Thrust Plate (3 Used) 21 - Thrust Plate (3 Used) 29 - Socket Bolt (16 Used)

4 - Ball Bearing 13 - Second Stage Planetary 22 - First Stage Planetary Gear 30 - Stopper Pin

Gear (3 Used)

(3 Used)

5 - Drum 14 - Needle Bearing (3 Used) 23 - Needle Bearing (3 Used) 31 - O-Ring

6 - Sprocket 15 - Thrust Plate (3 Used) 24 - Thrust Plate (3 Used) 32 - Cover

7 - Ball Bearing 16 - Pin (3 Used) 25 - Pin (3 Used) 33 - Plug (3 Used)

8 - Bolt (12 Used) 17 - Sun Gear 26 - Thrust Plate 34 - Ring

9 - Nut 18 - Spring Pin (3 Used)

W3-2-4

W1CC-03-02-001


Disassemble Travel Device




6. Remove nut (9) from travel motor (1) using

special tool (ST 4128).

CAUTION: High pressure may remain in the

travel device. After gradually loosening the

air vent plug to release any remaining

pressure thoroughly, remove the drain plug

to drain the gear oil. If the air vent plug is

quickly loosened, the plug may fly off or the

gear oil may spout out. Keep the body (parts)

and the face away from the plug.

1. Remove plug (33) (3 used) from cover (32). Drain

the gear oil from the travel device.

: 10 mm

2. Remove ring (34) from ring gear (28) with a screw

driver. Remove cover (32) from the ring gear.

3. Remove the first stage carrier (20) assembly and

shaft (27) from ring gear (28).

4. Remove sun gear (17) and the second stage

carrier (11) assembly from ring gear (28).


ring gear (28) from drum (5).

: 10 mm

ST 4128

W152-03-02-005

CAUTION: Sprocket (6) weight: 24 kg

(53 lb)

IMPORTANT: As for handling the nylon sling, refer

to “the Precautions for Handling

Nylon Sling” on page W1-1-5.

7. Remove bolts (8) (12 used) from sprocket (6).

Attach a nylon sling on the sprocket. By crane,

remove sprocket (6) from drum (5).

: 24 mm

CAUTION: Drum (5) weight: 29 kg (64 lb)

8. Install eye bolts (M12, pitch 1.75) to the socket

bolt (29) holes on drum (5). By crane, remove the

drum from travel motor (1).

1

9. Place drum (5) with ring gear (28) side facing

downward.

IMPORTANT: Do not remove bearing (4) remaining

in the travel motor unless necessary.

10. Remove the outer race of bearing (7) from drum

(5) with a bar.

W3-2-5


1

5

4

2 3

12

13 14 15

21

16

22

23 24

25

11

20 19

18

W1CC-03-02-001

W3-2-6

IMPORTANT: For handling of floating seal (2) and

(3), refer to the section “Precautions

for Floating Seal Handling” on page

W1-1-4.

11. Remove floating seal (2) from travel motor (1) and

remove floating seal (3) from drum (5).

12. Place drum (5) the place with travel motor (1) side

facing down.

13. Remove the outer race of bearing (4) from drum

(5) with a bar and a hammer.

14. Tap spring pins (19) (3 used) till they make

contact with the end of pins (25) (3 used) with a

bar.

15. Remove pins (25) (3 used), first stage planetary

gears (22) (3 used), needle bearings (23) (3 used),

thrust plates (21) (3 used) and thrust plates (24)

(3 used) from first stage carrier (20).

16. Tap spring pin (19) out of pin (25) with a bar

17. Tap spring pins (18) (3 used) till they make

contact with the end of pins (16) (3 used) with a

bar.

18. Remove pins (16) (3 used), second stage

planetary gears (13) (3 used), needle bearings

(14) (3 used), thrust plates (12) (3 used) and

thrust plates (15) (3 used) from second stage

carrier (11).

19. Tap spring pins (18) (3 used) out of pins (16) (3

used) with a bar.


W3-2-7

ASSEMBLE TRAVEL DEVICE


1 2 3 4 7 9 10 18 12 13 14 15 16 19 21

22

23

24

33

25

26

27

30

32

5

29

11

17

20

28

31

34

8

6

W197-03-02-001

1 - Travel Motor 10 - Knock Pin 19 - Spring Pin (3 Used) 27 - Shaft

2 - Floating Seal 11 - Second Stage Carrier 20 - First Stage Carrier 28 - Ring Gear

3 - Floating Seal 12 - Thrust Plate (3 Used) 21 - Thrust Plate (3 Used) 29 - Socket Bolt (16 Used)

4 - Ball Bearing 13 - Second Stage Planetary 22 - First Stage Planetary Gear 30 - Stopper Pin

Gear (3 Used)

(3 Used)

5 - Drum 14 - Needle Bearing (3 Used) 23 - Needle Bearing (3 Used) 31 - O-Ring

6 - Sprocket 15 - Thrust Plate (3 Used) 24 - Thrust Plate (3 Used) 32 - Cover

7 - Ball Bearing 16 - Pin (3 Used) 25 - Pin (3 Used) 33 - Plug (3 Used)

8 - Bolt (12 Used) 17 - Sun Gear 26 - Thrust Plate 34 - Ring

9 - Nut 18 - Spring Pin (3 Used)

W3-2-8


Assemble Travel Device




1. Install needle bearings (14) (3 used) into second

stage planetary gears (13) (3 used). With thrust

plates (12) (3 used) and thrust plates (15) (3

used) attached to both sides of the second stage

planetary gear, install the second stage planetary

gear assembly into second stage carrier (11).

IMPORTANT: Tap in spring pins (18) (3 used) with

the slit facing the travel motor.

16

18

Slit

2. Install pins (16) (3 used) into second stage carrier

(11) so that the spring pin holes align with those

on second stage carrier (11). Then, tap in spring

pins (18) ( 3 used).

3. Install thrust plate (26) on first stage carrier (20).

4. Install needle bearings (23) (3 used) into first

stage planetary gears (22) (3 used). With thrust

plates (21) (3 used) and thrust plates (24) (3

used) attached to both sides of the first stage

planetary gear, install the first stage planetary

gear assembly in first stage carrier (20).

IMPORTANT: In case the bearing (4) inner race

was removed, install the bearing

inner race onto travel motor (1) after

heating the inner race to a range of

50 to 70 °C (122 to 158 °F).

6. Install the ball bearing (4) outer race and the ball

bearing (7) outer race into drum (5) with a bar.

IMPORTANT: For handling of floating seal (2), (3),

refer to the section “Precautions for

Floating Seal Handling” on page

W1-1-4.

7. Install floating seal (2) to travel motor (1) and

install floating seal (3) to drum (5).

CAUTION: Drum (5) weight: 29 kg (64 lb)

8. Install drum (5) onto travel motor (1).

9. Heat the ball bearing (7) inner race to a range of

50 to 70 °C (122 to 158 °F). Then, install the ball

bearing (7) inner race onto travel motor (1). After

the inner race is cooled, tap in the bearing to seat

in position with a bar.

CAUTION: Sprocket (6) weight: 23 kg (51 lb)

IMPORTANT: Apply LOCTITE # 262 to the thread

portion of bolts (8) (12 used).

10. Secure sprocket (6) to drum (5) with bolts (8) (12

used).

: 24 mm

: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)

IMPORTANT: Tap in spring pins (19) (3 used) with

the slit facing the travel motor.

5. Install pins (25) (3 used) into first stage carrier

(20) so that the spring pin holes align with those

on first stage carrier (20). Then, tap in spring pins

(19) (3 used).

W3-2-9


1 9 10

22

33

27

32

5

29

11

17

20

28

31

34

6

W197-03-02-001

W3-2-10


11. Install nut (9) to travel motor (1) using special tool

(ST 4128).

: 167 N⋅m (17 kgf⋅m, 123 lbf⋅ft)

IMPORTANT: Install sun gear (17) with the

shoulder side facing first stage

carrier (20).

The Shoulder

ST 4128

1

W152-03-02-004

16. Install sun gear (17) in second stage carrier (11)

while aligning the spline teeth .

W152-03-02-005

12. Hold sprocket (6) with hands. Rotate the sprocket

both clockwise and counterclockwise 4 to 5 turns.

Reduce play on nut (9) by tapping special tool (ST

4128) with a plastic hammer.

13. After repeating step 11 and 12 twice, tighten nut

(9) using special tool (ST 4128).

: 167 N⋅m (17 kgf⋅m, 123 lbf⋅ft)

IMPORTANT: If knock pin (10) does not align with

the second stage carrier (11) hole,

align them by tightening direction

using special tool (ST 4128).

14. Align the spline teeth on second stage carrier (11)

with those of travel motor (1), and knock pin (10)

with the knock pin mounting hole on the second

stage carrier. Then, install the second stage

carrier assembly to the travel motor.

17. Install the first stage carrier (20) assembly so that

the sun gear (17) splines and the ring gear (28)

teeth mesh with those on first stage carrier (20).

18. While aligning the splines on shaft (27) with the

splines on travel motor (1) and first stage

planetary gears (22) (3 used), install shaft (27).

19. Install O-ring (31) onto cover (32).

20. Secure cover (32) to ring gear (28) with ring (34).

21. Refill gear oil 2.5 L (0.7 US gal) into the travel

device via plugs (33) (3 used) hole.

Install the plugs to cover (32).

: 10 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

IMPORTANT: Apply THREEBOND #1215 to the

interference surfaces of drum (5)

and ring gear (28).

15. Secure ring gear (28) to drum (5) with socket bolts

(29) (16 used).

: 10 mm

: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

W3-2-11

DISASSEMBLE TRAVEL MOTOR

6

5

4

3

2


1

17

12

13 14 15 16

8 9 10

11

Brake Release Circuit

7

27 32

31

18

19

20

27

28

29

Servo Piston Circuit

30

21

22

23

24

25

26

W1CC-03-02-002

1 - Socket Bolt (8 Used) 9 - Valve Plate 17 - Swash Plate 25 - Retaining Ring

2 - Brake Valve 10 - Plate (4 Used) 18 - Shaft 26 - Oil seal

3 - Disc Spring 11 - Friction Plate (3 Used) 19 - Pin ( 2 Used) 27 - O-Ring (2 Used)

4 - Piston 12 - Rotor 20 - Plate 28 - O-Ring

5 - O-Ring 13 - Disc Spring 21 - Knock Pin 29 - Plug

6 - O-Ring 14 - Spherical Bushing 22 - Servo Piston (2 Used) 30 - Housing

7 - Needle Bearing 15 - Retainer 23 - Retaining Ring 31 - O-Ring

8 - Knock Pin (2 Used) 16 - Plunger (9 Used) 24 - Bearing 32 - Plug

W3-2-12


Disassemble Travel Motor




When disassembling and assembling the travel motor,

the travel device must be disassembled and

assembled. Refer to the pages for the disassembling

or assemble travel device when disassembling and

assembling the travel device. Accordingly, description

in this section starts on the premise that the travel

motor has been dismounted.

CAUTION: Travel motor weight: 46 kg

(101 lb).

IMPORTANT: When brake valve (2) is removed,

valve plate (9) is also removed. Take

care not to allow the valve plate to

drop.

Do not remove needle bearing (7)

unless necessary.

1. Position the travel motor in vertical direction.

Loosen socket bolts (1) (8 used) to remove brake

valve (2) from housing (30).

: 12 mm

2. Remove valve plate (9) from brake valve (2).

6. Remove plates (10) (4 used) and friction plates

(11) (3 used) from housing (30).

CAUTION: Housing (30) weight: 20 kg (44 lb)

IMPORTANT: When the brake releasing circuit is

positioned upward, the thick portion

of swash plate (17) faces upward. So

take care that the swash plate may

drop off.

7. Place housing (30) horizontally. With the brake

releasing circuit in the housing downward, remove

the rotor (12) assembly from housing (30).

8. Remove plungers (16) (9 used), retainer (15),

spherical busing (14), and disc springs (13) from

rotor (12).

9. Remove swash plate (17) from housing (30).

10. Attach a bar on the inner spline of shaft (18),

tapping on it with a plastic hammer. Remove the

shaft (18) assembly from housing (30) with pins

(19) (2 used), plate (20), retaining ring (23),

bearing (24) and retaining ring (25) still on it.

11. Remove pins (19) (2 used) from plate (20).

3. Remove O-rings (27) (2 used), (28) and disc

spring (3) from housing (30).

IMPORTANT: When removing piston (4) using

compressed air, be sure to cover the

piston with cloths to prevent the

piston from flying out.

4. Supply compressed air 98 to 294 kPa (1 to 3

kgf/cm 3 , 14 to 43 psi) into the brake releasing

circuit of housing (30), so that piston (4) will float

up to be removed.

5. Remove O-rings (5) and (6) from piston (4).

W3-2-13



18

Servo Piston Circuit

30

21

22

23

24

25

26

W1CC-03-02-002

W3-2-14

12. Remove retaining rings (23) and (25) from shaft

(18). Remove bearing (24) to the brake valve side

from the shaft with a press.

IMPORTANT: When removing servo pistons (22) (2

used) using compressed air, be sure

to cover the servo pistons with

cloths to prevent the servo pistons

from flying out.

13. Supply compressed air 98 kPa (1 kgf/cm 2 , 14 psi)

into the servo piston circuit of housing (30) to

remove servo pistons (22) (2 used).

IMPORTANT: Do not remove oil seal (26) and

knock pin (21) unless necessary.


W3-2-15

ASSEMBLE TRAVEL MOTOR


27

5 4 6 10 11


18

13 17 19 20 24 26

28

3

1

8

9

21

25

32

2

31

29

16

14

15

23

22

7

27

30

12

W197-03-02-002

1 - Socket Bolt (8 Used) 9 - Valve Plate 17 - Swash Plate 25 - Retaining Ring

2 - Brake Valve 10 - Plate (4 Used) 18 - Shaft 26 - Oil seal

3 - Disc Spring 11 - Friction Plate (3 Used) 19 - Pin ( 2 Used) 27 - O-Ring (2 Used)

4 - Piston 12 - Rotor 20 - Plate 28 - O-Ring

5 - O-Ring 13 - Disc Spring 21 - Knock Pin 29 - Plug

6 - O-Ring 14 - Spherical Bushing 22 - Servo Piston (2 Used) 30 - Housing

7 - Needle Bearing 15 - Retainer 23 - Retaining Ring 31 - O-Ring

8 - Knock Pin (2 Used) 16 - Plunger (9 Used) 24 - Bearing 32 - Plug

W3-2-16


Assemble Travel Motor




CAUTION: Housing (30) weight: 20 kg

(44 lb)

IMPORTANT: Apply the inner surface of oil seal

(26) with grease and the outer

surface with THREEBOND #1104 or

#1215.

1. Place housing (30) horizontally. Install oil seal (26)

into the housing with the lip facing bearing (24)

using special tool (ST 7278).

2. Install servo pistons (22) (2 used) into housing

(30).

IMPORTANT: When installing retaining rings (25),

(23) on shaft (18), take care not to

damage shaft (18).

3. Install retaining ring (25) to shaft (18).

IMPORTANT: When installing bearing (24), be sure

with the clamp facing spline teeth on

shaft (18).

4. Press bearing (24) onto shaft (18). Then, install

retaining ring (23) on the shaft.

5. Press the shaft (18) assembly into housing (30).

7. Place housing (30) horizontally, with the brake

releasing circuit downward. Align the notch of

swash plate (17) with the hole of pins (19) (2

used), install swash plate (17) onto plate (20).

8. Install disc springs (13) and spherical bushing

(14) onto rotor(12).

9. Install plungers (16) (9 used) to retainer (15).

Install the plunger assembly to rotor (12).

10. Aligning the spline, install the rotor (12) assembly

on shaft (18).

11. Place housing (30) vertically. Install plates (10) (4

used) into housing (30) and friction plates (11) (3

used) into rotor (12) by matching their grooves

and installing them one by one alternatively.

IMPORTANT: Apply the grease to O-rings (5) and

(6).

12. Install O-rings (5 and 6) on piston (4).

IMPORTANT: Install disc spring (3) so that the

inner surface makes contact with

piston (4). Apply the grease to O-

rings (27) (2 used) and (28).

13. Install piston (4), disc spring (3), and O-rings

(27) (2 used) and (28) into housing (30).

IMPORTANT: When assembling, the slit on plate

(20) shall be aligned with bearing

(24).

6. Install pins (19) (2 used) onto plate (20). Install the

plate in housing (30) so that the hole of knock pin

(21) aligns with knock pin (21).

W3-2-17



1

8

9

2

7

30

W197-03-02-002

W3-2-18

IMPORTANT: When needle bearing (7) is removed,

it shall be replaced with a new one.

Install it with the stamped mark

facing housing (30).

Apply the grease to the brake valve

(2) contact side with valve plate (9).

14. Aligning the knock pins (8) (2 used) holes of valve

plate (9), install the valve plate to brake valve (2).

IMPORTANT: Take care not to drop valve plate (9).

15. Refill hydraulic oil 500 cm 3 into housing (30).

Secure brake valve (2) to the housing with socket

bolts (1) (8 used).

: 12 mm

: 177 N⋅m (18 kgf⋅m, 130 lbf⋅ft)


W3-2-19

DISASSEMBLE BRAKE VALVE


1

A 2 3 4 5

14

6

7

15

8

9

16

10

A

17

Section A-A

W197-03-02-003

13 12 11

1 - Valve Housing 6 - O-Ring (2 Used) 10 - O-Ring 14 - Spool

2 - Spool 7 - Poppet (2 Used) 11 - Relief Valve (2 Used) 15 - Spring

3 - Spring Seat (2 Used) 8 - Spring (2 Used) 12 - Plug 16 - O-Ring

4 - Spring (2 Used) 9 - Plug 13 - Ball 17 - Plug

5 - Plug (2 Used)

W3-2-20

Disassemble Brake Valve




1. Remove plugs (5) (2 used), springs (4) (2 used),

spring seats (3) (2 used) from valve housing (1).

: 36 mm

2. Remove O-rings (6) (2 used) from plugs (5) (2

used).

3. Remove spool (2) from valve housing (1).

IMPORTANT: Do not disassemble the relief valves

(11) assembly.

Do not move the piston on the relief

valve (11) assembly, otherwise the

O-ring will be damaged when the

piston passes the cartridge hole.

4. Remove the relief valves (11) assemblies (2 used),

springs (8) (2 used), poppets (7) (2 used) from

valve housing (1).

: 30 mm

5. Remove plug (17) from valve housing (1) to

remove O-ring (16) from the plug.

:6 mm

6. Remove spring (15), spool (14) from valve

housing (1).

7. Remove plug (9) from valve housing (1) to

remove O-ring (10) from the plug.

:6 mm

IMPORTANT: Do not remove plug (12) and ball (13)

unless necessary.

8. Remove plug (12) from valve housing (1), incline

the valve housing to take balls (13) out.

:5 mm


W3-2-21

ASSEMBLE BRAKE VALVE


1

A 2 3 4 5

14

6

7

15

8

9

16

10

13 12 11

A

17

Section A-A

W197-03-02-003

1 - Valve Housing 6 - O-Ring (2 Used) 10 - O-Ring 14 - Spool

2 - Spool 7 - Poppet (2 Used) 11 - Relief Valve (2 Used) 15 - Spring

3 - Spring Seat (2 Used) 8 - Spring (2 Used) 12 - Plug 16 - O-Ring

4 - Spring (2 Used) 9 - Plug 13 - Ball 17 - Plug

5 - Plug (2 Used)

W3-2-22

Assemble Brake Valve




IMPORTANT: Apply LOCTITE #262 on plug (12).

1. With valve housing (1) inclined, put balls (13) into

the valve housing. Install plug (12) into the valve

housing.

:5 mm

: 14.5 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

2. Install O-rings (10) to plug (9) and install the plug

to valve housing (1).

:6 mm

: 34 N⋅m (3.5 kgf⋅m, 25.5 lbf⋅ft)

3. Install spool (14), spring (15) into valve housing

(1) in that order.

4. Install O-ring (16) onto plug (17) and install the

plug to valve housing (1).

:6 mm

: 34 N⋅m (3.5 kgf⋅m, 25.5 lbf⋅ft)

5. Install springs (8) (2 used), poppets (7) (2 used) to

relief valves (11) (2 used). Install the relief valves

into valve housing (1).

: 30 mm

: 314 N⋅m (32 kgf⋅m, 230 lbf⋅ft)

6. Install spool (2) into valve housing (1) and install

spring seats (3) (2 used), springs (4) (2 used).

7. Install O-rings (6) (2 used) to plugs (5) (2 used)

and install the plugs to valve housing (1)

: 36 mm

: 441 N⋅m (45 kgf⋅m, 330 lbf⋅ft)

UNDERCARRIAGE/Travel Device

W3-2-23


Sprocket

UNDERCARRIAGE/Travel Device

D

C

B

A

E

W105-03-02-241

Unit:mm (in)

Standard Allowable Limit Remedy

A 38.0 (1.5) 28.0 (1.1)

B 477.4 (19) 467.0 (18.5) Cladding by

C PCD522.5 (20.5) - welding and

D 533.6 (21) 524.0 (20.5) finishing

E 154.0 (6.1) -

W3-2-24

REMOVE AND INSTALL CENTER JOINT

UNDERCARRIAGE / Center Joint








repair work.





Preparation





remaining pressure.

M1CC-07-002






W3-3-1


Removal

1. Remove mounting bolts (2) (4 used) on cover (1)

of the machine front side, then remove cover (1).

: 17 mm

2

1

2. Attach tags to all hoses connected to the center

joint to aid reassembly. Disconnect all hoses from

the center joint. Cap all the disconnected hose

ends.

: 19 mm, 22 mm, 27 mm

W197-03-03-001

3. Remove bolts (3) (2 used) to remove lock plate

(4) from the center joint.

: 19 mm

3

4

Front side

W102-03-03-001

5

CAUTION: Center joint weight: 31 kg (68 lb)

4. Attach a nylon sling to the flange of the center

joint, and hold it by crane. Remove bolts (5) (3

used), remove the center joint by crane.

: 17 mm

Front side

W190-03-03-001

W3-3-2


Installation

1. Secure the center joint with bolts (5) (3 used).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

5

Front side

W190-03-03-001

2. Install lock plate (4) to the center joint with bolts

(3) (2 used).

: 19 mm

: 90 N⋅m (9.2 kgf⋅m, 66.5 lbf⋅ft)

3. Reconnect all hoses to the center joint.

: 19 mm

: 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

: 22 mm

: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

: 27 mm

: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)

3

4

Front side

W102-03-03-001

4. Install cover (1) of the machine with bolts (2) (4

used).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

2

1

IMPORTANT: After installation, start the engine

and check for oil leaks.

W197-03-03-001

W3-3-3

DISASSEMBLE CENTER JOINT


1

2

7

3

4

5

6

8

9

10

11

12

W196-03-03-001

1 - Plug 4 - O-Ring 7 - Body 10 - Retaining Ring

2 - Spindle 5 - Bushing 8 - Ring 11 - Cover

3 - Dust Seal 6 - Oil Seal (8 Used) 9 - O-Ring 12 - Bolt (4 Used)

W3-3-4


Disassemble Center Joint




CAUTION: Center joint weight: 31kg (68 lb)

IMPORTANT: Take care not to damage to the end

of spindle (2) when set it onto a work

bench.

1. Remove mounting bolts (12) (2 used) from cover

(11) diagonally. Install eyebolt (M10, pitch 1.5,

length 18 mm (0.7 in) to the bolt holes (2 places).

Hoist the center joint and set it onto a work bench.

IMPORTANT: Take care not to damage the sliding

surface of the spindle (2) seal.

5. Insert ST 1020 to remove spindle (2) from body

(7).

IMPORTANT: For easy removal, two pins can be

used to pry out oil seals (6). Take

care not to damage the seal groove

with the pins.

IMPORTANT: Make a matching mark on body (7)

and spindle (2).

2. Remove bolts (12) (2 used) and eyebolts to remove

cover (11) from body (7).

: 17 mm

3. Remove O-ring (9), retaining ring (10) and ring (8)

from body (7).

4. Attach the special tool (ST 1033, ST1020) to body

(7) with bolts (12) (2 used) on cover (11).

: 17 mm

W105-03-03-015

6. Remove oil seals (6) (8 used), dust seal (3) and

O-ring (4) from body (7).

ST 1020

ST 1033

IMPORTANT: While welding, be sure to cover the

seal surface to prevent it from being

spattered.

7. When replacing bushing (5), build-up weld at 4

places in its inner diameter with welding rod,

shrink bushing (5) to pull it out.

W506-03-03-002

W3-3-5

ASSEMBLE CENTER JOINT


1

2

3

4

5

6

7

8

9

10

11

12

W196-03-03-002

1 - Plug 4 - O-Ring 7 - Body 10 - Retaining Ring

2 - Spindle 5 - Bushing 8 - Ring 11 - Cover

3 - Dust Seal 6 - Oil Seal (8 Used) 9 - O-Ring 12 - Bolt (4 Used)

W3-3-6


Assemble Center Joint

IMPORTANT: If bushing is removed, be sure to

reinstall bushing (5) first. Refer to

page W3-3-8.

1. Install O-ring (4) and dust seal (3) into body (7).

2. Install oil seals (6) (6 used) into body (7).

IMPORTANT: Just before inserting spindle, apply

molybdenum disulphide to bushing

(5) and coat the seal portion with

grease. Do not damage them when

installing.

3. Secure spindle (2) to a work bench. Mount body

(7) on spindle (2) with their matching mark aligned,

which is put before disassembling.

IMPORTANT: Be sure to install ring (8) with the

chamfered side facing spindle.

5. Install ring (8) and O-ring (9) to body (7).

6. Install retaining ring (10) to spindle (2).

7. Install cover (11) with bolts (12) (4 used).

: 17 mm

: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

IMPORTANT: Clearance between body (7) and

spindle (2) is approximately 0.1 mm

(0.004 in), so spindle (2) must be inserted

along axis straight and

slowly.

IMPORTANT: Install the ring (8) installing portion

(A) flat and even leaving no height

difference between the body, the

ring and the spindle.

A

0.1 mm

W105-03-03-024

4. Tap body (7) with a plastic hammer, install the

body to spindle (2) to make the portion A flat and

even.

W3-3-7


When replacing the body or spindle with new one, the

following procedures are required.

Replacing Body (7)

Press bushing (5) into body (7).

1. Clean body (7) and bushing (5).

ST 2770

7

5

2. Press bushing (5) into body (7), using the pressing

tool.

Pressing force: 4.9 to 14.7 kN

(0.5 to 1.5 t, 1100 to 3300 lbf)

Pressing tool: ST 2770

Replacing Spindle (2)

1

W105-03-03-029

1. Clean spindle (2).

2. Tap plugs (1) into spindle (2) using special tools

(ST 2559).

2

0.4 mm

or More

Sleeve

3. Drive the balls of plug (1) so that the top of each

ball is 0.4 mm (0.016 in) or more lower than the

respective sleeve edge, as illustrated in Detail D.

Special tool: ST 2559

Detail D

W135-03-03-001

W136-03-03-031

ST 2559

Balls

W157-03-03-004

W3-3-8



Item Allowable limit (basis for judgment) Remedy

Bushing

1. Wear more than 0.2 mm (0.008 in) Replace

2. Scored, abnormal wear Replace

3. Uneven wear (wear range is within 180°)

Wear range is within

one half

Replace

Body ⋅ spindle

Cover

Sliding surface

and sealed part

Sliding surface of

body and spindle,

except sealed

part

Sliding surface

Sliding surface

Scored or serious damage

T157-01-01-040

Replace

1) Scored or abnormal wear of more than 0.1

mm (0.004 in)

Replace

2) Scored less than 0.1 mm (0.004 in) deep Repair and finish

with oil stone

1) Wear more than 0.5 mm (0.02 in) deep

Replace

And abnormal wear

2) Wear less than 0.5 mm (0.02 in) deep Repair and finish

3) Scored or abnormal worn less than 0.5 Repair and finish

mm (0.02 in) deep and able to be repaired.

1) Wear more than 0.5 mm (0.02 in) Replace

2) Wear less than 0.5 mm (0.02 in) Repair and finish

3) Scored or abnormal worn less than 0.5

mm (0.02 in) and able to be repaired.

Repair and finish

W3-3-9


(Blank)

W3-3-10

REMOVE AND INSTALL TRACK

ADJUSTER

Before removing and adjusting the track adjuster, the

tracks and the front idler must be removed first. For

removal of the tracks and the front idler, refer to their

Removal / Installation sections.

In this section, the procedure starts on the premise that

the tracks and the front idler have already been

removed.

Removal

CAUTION: Track adjuster weight: 31 kg

(68 lb)

UNDERCARRIAGE / Track Adjuster

1. Remove track adjuster (1) from track frame (2) by

prying it out with a pry bar.

1

2

Installation

IMPORTANT: Check that the end face of track

adjuster (1) comes to contact with

the face of plate (4).

1. As illustrated, install track adjuster (1) into spring

guide (3) on track frame (2).

W157-03-04-003

2 3

3 4

W157-03-04-001

W157-03-04-002

W3-4-1

DISASSEMBLE TRACK ADJUSTER


6

7

5

2

3

4

9

8

1

10

14

11

W1CC-03-04-001

12

13

1 - Cylinder 5 - Piston Rod 9 - Socket Bolt (4 Used) 12 - Nut

2 - Retaining Ring 6 - Flange 10 - Spring 13 - Valve

3 - U-Ring 7 - Dust Seal 11 - Washer 14 - Plug

4 - Wear Ring 8 - Holder

W3-4-2

Disassemble Track Adjuster



starting any repair work.

Be sure to use special tool (ST 4920) for

assembly / disassembly of the track adjuster.


CAUTION: The spring force is extremely

large, so disassembly and assembly work

must be carried out carefully. It is necessary

to inspect the special tool for any damage

thoroughly to ensure safety.

Nut

CAUTION: Special tool weight: 225 kg

(500 lb)

1. Place an oil jack (30 ton) between the cradle and

the base of special tool (ST 4920).

Cradle

Oil Jack

CAUTION: Plate (ST 4036) weight: 34 kg

(75 lb)

2. Loosen four nuts to remove plate (ST 4036).

: 46 mm

Base

Plate (ST 4036)

W105-03-04-006


(68 lb)

3. Remove holder (8) from the track adjuster.

Connect the track adjuster to a hoist using a lifting

strap.

Put the track adjuster in special tool by crane.

W105-03-04-007

W105-03-04-009

W3-4-3


1

14

11

W1CC-03-04-001

12

W3-4-4



(75 lb)

4. Install plate (ST 4036) on to special tool (ST 4920)

so that plate (ST 4036) overlies the track adjuster.

Plate (ST 4036)

Track Adjuster

ST 4920

5. Operate the oil jack to jack up the cradle by the

specified amount 60 mm (2.4 in).

60 mm= (Free length: 327 mm) - (Set length: 267

mm)

Cradle

W105-03-04-011

Oil Jack

W105-03-04-013

6. Tighten the nuts onto plate (ST 4036) to secure

the track adjuster.

Operate the oil jack to compress the track

adjuster approximately 10 mm (0.4 in) until a

clearance is observed between washer (11) and

nut (12).

: 46 mm

Nut

Plate

(ST 4036)

W105-03-04-012

12

1

14

7. Remove plug (14) from nut (12) to remove the nut

from cylinder (1).

:5 mm

: 60 mm

W105-03-04-014

W3-4-5


6

7

5

2

3

4

9

1

10

11

W1CC-03-04-001

W3-4-6



(75 lb)

When removing the nut and plate (ST 4036),

be sure to remove it after loosening oil jack.

Not loosening the oil jack poses a danger of

washer (11) and spring (10) flying off under

the reaction of the spring.

8. Lower oil jack to release the spring force.

Loosen the nuts to remove plate (ST 4036).

Remove washer (11) from cylinder (1).

Plate (ST4036)

11

10

W105-03-04-016

CAUTION: Spring assembly weight:

28 kg (62 lb)

9. Remove the spring (10) assembly from the

special tool.

10

10. Remove spring (10) from cylinder (1).

11. Remove socket bolts (9) (4 used) from cylinder (1)

to remove flange (6) and dust seal (7).

:6 mm

12. Remove piston rod (5) from cylinder (1).

13. Remove retaining ring (2), U-ring (3) and wear

ring (4) from piston rod (5).

W105-03-04-017

W3-4-7

ASSEMBLE TRACK ADJUSTER


13

14

12

11

10

2

3 4 1 6 9 7 5 8

B

A

W152-03-04-002

1 - Cylinder 5 - Piston Rod 9 - Socket Bolt (4 Used) 12 - Nut

2 - Retaining Ring 6 - Flange 10 - Spring 13 - Valve

3 - U-Ring 7 - Dust Seal 11 - Washer 14 - Plug

4 - Wear Ring 8 - Holder

W3-4-8


Assemble Track Adjuster

IMPORTANT: Install U-ring (3) with the lip facing

retaining ring (2).

Apply hydraulic oil to wear ring (4)

and the U-ring.

1. Install wear ring (4), U-ring (3) and retaining ring

(2) onto piston rod (5).

IMPORTANT: Fill chamber (B) in cylinder (1) with

grease. Insert piston rod (5) into the

cylinder to completely bleed air

remaining in the cylinder.

Apply the hydraulic oil to the

cylinder and the piston rod.

2. Insert the piston rod (5) assembly into cylinder (1).

IMPORTANT: Fill groove A on flange (10) with

grease.

3. Install dust seal (7) into flange (6). Secure the

flange assembly to cylinder (1) with socket bolts

(9) (4 used).

:6 mm

: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

CAUTION: Spring assembly weight: 28 kg

(62 lb)

4. Install spring (10) onto cylinder (1). Install eyebolt

(M16, pitch 1.5) to the cylinder. Hoist the spring

assembly by crane. Then set them on special tool

(ST 4920).

1

ST 4920

10

W105-03-04-017

W3-4-9


14

12

11

10

1

W152-03-04-002

W3-4-10



(75 lb)

5. Install washer (11) onto cylinder (1). Install plate

(ST 4036) onto special tool (ST 4920) so that

plate (ST 4036) overlies the track adjuster.

Tighten the nuts.

: 46 mm

Plate

(ST 4036)

Nut

ST 4920

W105-03-04-012

6. Operate the oil jack to compress spring (10) until

the specified length (267 mm) (10.5 in) is

obtained.

5

Oil Jack

W105-03-04-026

12

1

14

7. Install nut (12) to cylinder (1). Install plug (14) to

the nut.

: 60 mm

:5 mm

: 14.5 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

Plate (ST 4036)

W105-03-04-014

8. Lower the oil jack to remove the nuts and plate

(ST 4036).

: 46 mm

W105-03-04-011

W3-4-11



(68 lb)

9. Attach the wire rope to the track adjuster. Hoist

the track adjuster by crane, remove them from the

special tool.

Track Adjuster

W105-03-04-027

CAUTION: Special tool weight: 64 kg (141 lb)

IMPORTANT: If only the track adjuster is to be

transported, be sure to use special

tool (ST 4930) to avoid personal

injury.

: 24 mm

Track Adjuster

Special Tool

(ST 4930)

W105-03-04-028

W3-4-12

REMOVE AND INSTALL FRONT IDLER

Before removing the front idler, the tracks must be removed

first. For removal of the tracks, refer to

“Remove and Install Tracks” section.

In this section, the procedure starts on the premise that

the tracks has already been removed.

UNDERCARRIAGE / Front Idler

Removal

CAUTION: Front idler weight: 52 kg (115 lb)

The front idler may fly out due to strong

spring force from the track adjuster spring

when removing it. Give yourself ample clearance,

staying clear of the front idler’s line.

1. Pry the front idler with a pry bar to move it out

from track frame (3).

W110-03-05-001

3

2. Attach the wire rope to the bearing (1) portion and

the yoke (2) portion as illustrated and remove the

front idler assembly from track frame (3).

3. If it is necessary to remain the front idler for a time,

be sure to place it on wooden blocks as shown to

keep it stable.

1

2

W178-03-05-001

Wooden

Block

Installation

1. Install the front idler according to the reversed

procedures of removal and pay attention to the

following precautions when installation is carried

out.

• Clean track frame (3) and the sliding surface of

bearing (1) and apply grease on them.

W178-03-05-002

3

1

W178-03-05-004

W3-5-1

DISASSEMBLE FRONT IDLER


2

3

8

7

5

4

1

7

6

3

4

5

2

1

10

9

W1CC-03-05-001

1 - Plug (2 Used) 4 - Floating Seal (2 Used) 7 - Bushing (2 Used) 9 - Socket Bolt (4 Used)

2 - Bearing (2 Used) 5 - O-Ring (2 Used) 8 - Idler 10 - Yoke

3 - Pin (2 Used) 6 - Axle

W3-5-2


Disassemble Front Idler




4. Remove pin (3) from other side bearing (2) and

press out axle (6).

1. Remove socket bolts (9) (4 used) to remove yoke

(10). Remove plug (1) to drain oil into a container.

: 12 mm

2. Remove pin (3) from bearing (2) at one side. Apply

the press on the axle end at this side to push

axle (6) out of bearing (2).

3

2

6

2 6

W105-233-05-010

5. Remove O-ring (5) (2 used) from axle (6).

W105-03-05-008

IMPORTANT: For handling of floating seal (4), refer

to the section “Precautions for

floating seal handling” on page W1-

1-4.

3. Remove floating seals (4) (2 used) from right and

left bearings (2) and idler (8).

IMPORTANT: Do not remove bushing (7) (2 used)

unless necessary.

6. Perform over laying on the inner diameter in four

places along the circumference at equal intervals.

Then, bushing (7) has shrunk enough to be removed.

90°

2

4

8

90°

4

W105-03-05-012

5

6

2

W105-03-05-009

W3-5-3

ASSEMBLE FRONT IDLER


2 3 4 6 8 7 5 1 9 10

W152-03-05-001

1 - Plug (2 Used) 4 - Floating Seal (2 Used) 7 - Bushing (2 Used) 9 - Socket Bolt (4 Used)

2 - Bearing (2 Used) 5 - O-Ring (2 Used) 8 - Idler 10 - Yoke

3 - Pin (2 Used) 6 - Axle

W3-5-4


Assemble Front Idler




1. Install bushings (7) (2 used) into idler (8) with a

press.

IMPORTANT: When installing bearing (2) onto axle

(6), take care not to damage O-ring

(5).

2. Install O-ring (5) to axle (6). Aligning the pin holes,

install bearing (2) onto axle (6). Then, tap pin (3)

into the bearing.

4. Install the other pair of floating seal (4) into idler

(8) and bearing (2). Install O-ring (5) to axle (6).

Aligning the pin holes, install bearing (2) onto axle

(6). Then tap pin (3) into the bearing.

2

4

5

8

2

3

6

6

W105-03-05-014

IMPORTANT: For handling of floating seal (4), refer


floating seal handling” on page W1-

1-4.

3. Install one pair of floating seal (4) into idler (8) and

bearing (2). Press axle (6) into idler (8) from the

side installed with the floating seal.

5

2

W157-03-05-005

5. Fill engine oil (SAE #30, API Class CD)140 cm 3

via the plug (1) hole of bearing (2). Install plug (1)

(2 used) to the bearing.

:6 mm

: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

6. Secure yoke (10) to bearings (2) with socket bolts

(9) (4 used).

: 12 mm

: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)

8 4 2

6

W157-03-05-006

W3-5-5



C

D

E

A

B

W157-03-05-001

Unit: mm (in)


A 43 (1.7) [33.4 (1.3)]

B 100 (3.9) −

C 390 (15.4) 378 (14.9)

D 434 (17.1) −

Build-up weld

and finishing

E 22 (0.9) 28.0 (1.1)

Axle and Bushing

Unit: mm (in)


Axle Outside Dia. 55 (2.2) [54.2 (2.1)]

Bushing

Inside Dia. 55 (2.2) [56.0 (2.2)]

Flange Thickness 2 (0.08) [1.2 (0.05)]

Replace

NOTE: Values in [ ] are just for reference.

W3-5-6

UNDERCARRIAGE / Upper And Lower Roller

REMOVE AND INSTALL UPPER ROLLER

Removal

CAUTION: The track adjuster is under high

pressure. Do not loosen valve (1) quickly or

loosen it too much as high pressure grease in

the adjusting cylinder may spout.

Loosen carefully, keeping body parts and

face away from the valve. Never loosen

grease fitting (2).

1. Gradually loosen valve (1) to drain grease.

NOTE: It’s enough to turn valve (1) by only one

turn.

: 24 mm

1

W105-03-06-001

2

Grease Outlet

IMPORTANT: Use a nonskid cloth between track

frame (5) and the oil jack to prevent

slipping.

2. Jack up tracks (3) high enough to permit upper

roller (4) removal. Insert wooden blocks between

the track and track frame (5).

Nonskid

Cloth

Oil Jack

Wooden Block

3

M104-07-119

4

5

3. Remove bolts (6) to remove upper roller (4) from

track frame (5).

: 22 mm

W105-03-06-003

6

4

5

M152-07-046

W3-6-1


Installation

IMPORTANT: There is a mark I (punched) on the

axle of upper roller (4). Install the

upper roller onto the track frame with

the mark facing upward.

Ι

Up

6

1. Secure upper roller (4) onto track (5) with bolts

(6).

: 22 mm

: 140 N⋅m (14.5 kgf⋅m, 105 Ibf⋅ft)

4

5

M152-07-046

Oil Jack

Wooden Block

3

4

2. Remove the wooden block and the oil jack.

5

W105-03-06-003

3. Tighten the track adjuster valve (1). Jack up

tracks (3) being adjusted for its sag. Then turn the

track slightly towards the reversed direction.

Supply the grease via grease fitting (2) to adjust

the track tension.

1

Track sag specifications (A): 210 to 245 mm

(8.3 to 9.6 in)

2

: 24 mm

: 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)

Grease Outlet

M104-07-119

W157-03-06-002

W3-6-2


(Blank)

W3-6-3


DISASSEMBLE AND ASSEMBLE UPPER

ROLLER

1 2 3 4 5 6 7 8 9

W152-03-06-001

1 - Axle 4 - Roller 6 - Washer 8 - Cover

2 - Collar 5 - Bushing 7 - Socket Bolt (2 Used) 9 - Plug

3 - Floating Seal

W3-6-4


Disassemble Upper Roller




1. Remove plug (9) from cover (8) to drain out

engine oil from the roller.

:5 mm

2. With a press, remove the axle (1) assembly and

cover (8) from roller (4). Remove collar (2) from

the roller.

Assemble Upper Roller

1. With a press, install axle (1) onto collar (2).

2

1

Press

From

Here

IMPORTANT: For handing of floating seal (3), refer


Floating Seal Handling” on page W1-

1-4.

3. Remove floating seal (3) from collar (2) and roller

(4).


washer (6) from axle (1).

:6 mm

IMPORTANT: Do not remove bushing (5) from

roller (4). In case bushing (5) must

be replaced, replace the roller

assembly.

44

W1CC-03-06-001

IMPORTANT: For handing of floating seal (3), refer


Floating Seal Handling” on page

W1-1-4.

2. Install floating seal (3) to collar (2) and roller (4).

Install axle (1) into roller (4).

3. Install washer (6) to axle (1) with socket bolts (7)

(2 used).

:6 mm

: 30 to 35 N⋅m

(3.1 to 3.6 kgf⋅m, 22.4 to 26 Ibf⋅ft)

4. Install cover (8) into roller (4) with a press.

IMPORTANT: Apply LOCTITE #503 to plug (9).

5. Refill engine oil (S-3 SAE #30) 26 to 30 cm 3 via

the plug hole on cover (8). Install plug (9) to the

cover.

:5 mm

: 14.5±1.5 N⋅m

(1.5±0.15 kgf⋅m, 11.0±1.1 Ibf⋅ft)

W3-6-5


REMOVE AND INSTALL LOWER ROLLER

Removal

CAUTION: Securely support the raised machine

with wooden blocks.

1. Loosen bolts (1). Raise one side of the track

frame high enough to remove the lower roller.

: 22 mm

90°~110°

M1CC-07-014

1



loosen it too much as valve (2) may fly off

and/or high pressure grease in the track

adjuster cylinder may spurt. Do not loosen it

over 1.5 turns. Loosen carefully, keeping

body parts and face away from valve (2).

Never loosen grease fitting (3).

M102-07-063

2. Gradually loosen the track adjuster valve (2).

Drain the grease until the clearance between the

track frame bottom face and the track link

stretches enough to remove the lower roller.

It’s enough to turn the valve by only one turn.

: 24 mm

W105-03-06-001

3. Remove bolts (1) to remove the lower roller.

2

3

M104-07-119

W3-6-6


Installation

1. Place the lower roller on the track link so that the

roller mounting bolt holes on the collar align with

those on the track frame.

Lower the track frame until the clearance between

the track frame and the lower roller is very close.

W105-03-06-012

2. Install the lower roller to the track frame with bolts

(1).

: 22 mm

: 245 N⋅m (25 kgf⋅m, 180 Ibf⋅ft)

1

3. Tighten the track adjuster valve (2). Jack up the

track being adjusted for its sag. Then turn the


Supply the grease via grease fitting (3) to adjust

the track tension.

2

M102-07-063

Track sag specifications (A): 210 to 245 mm

(8.3 to 9.6 in)

: 24 mm

: 147 N⋅m (15 kgf⋅m, 108 Ibf f⋅ft)

3

M104-07-119

W157-03-06-002

W3-6-7


DISASSEMBLE AND ASSEMBLE LOWER

ROLLER

1 2 3 4 5 6 7 8

W152-03-06-002

1 - Collar (2 Used) 3 - Roller 5 - Bushing (2 Used) 7 - Pin (2 Used)

2 - Floating Seal (2 Used) 4 - Axle 6 - O-Ring (2 Used) 8 - Plug

W3-6-8


Disassemble Lower Roller



staring any repair work.

1. Remove plug (8) from collar (1) to drain engine oil

from the roller.

:5 mm

2. Remove pin (7) from one side collar (1). Press the

axle (4) end face from the pin (7) removed side to

remove axle (4) from roller (3). Meanwhile the pin

and collar at opposite side may be removed

together.

IMPORTANT: For handling of floating seal (2),


Floating Seal Handling “ on page

W1-1-4.

3. Remove floating seal (2) from both sides of roller

(3) and collars (1) (2 used).

4. Remove pin (7) from the axle (4) assembly.

Remove the axle from collar (1) with a press.

5. Remove O-rings (6) (2 used) from axle (4).

Assemble Lower Roller

IMPORTANT: Apply grease to O-ring (6).

1. Install O-ring (6) (1 used) to axle (4). Aligning the

pin holes, install axle (4) into collar (1). Tap pin (7)

into collar (1).

IMPORTANT: For handling of floating seal (2),


Floating Seal Handling “ on page

W1-1-4.

2. Install floating seal (2) to collar (1) and roller (3).

Press axle (4) into roller (3) from the floating seal

installed side.

3. Install O-ring (6) to axle (4). Install another floating

seal (2) to roller (3) and collar (1).

Aligning the pin holes, install collar (1) onto axle

(4). Then install pin (7) into collar (1).

IMPORTANT: Apply LOCTITE #503 onto plug (8).

4. Refill engine oil (SAE #30, API class CD) through

the plug hole on collar (1). Install plug (8) to the

collar.

:5 mm

: 14.5±1.5 N⋅m

(1.5±0.15 kgf⋅m, 11.0±1.1 Ibf ⋅ft)

IMPORTANT: Do not remove bushings (5) from

roller (3). In case the bushing must

be replaced, replace the roller (3)

assembly.

W3-6-9



Upper Roller

W110-03-06-009

Unit:mm (in)


A 43 (1.7) -

B 90 (3.5) -

Replace

C 86 (3.4) 76 (3.0)

Unit:mm (in)


Axle Outer Dia. 30 (1.2) [29.2 (1.2)]

Bushing

Inner Dia. 30 (1.2) [31.0 (1.2)] Replace

Flange Thickness 2 (0.08) [1.2 (0.05)]

NOTE: Values in [

] are just for reference.

W3-6-10


Lower Roller

C

A

B

W102-03-06-006

Unit:mm (in)


A 45 (1.8) -

Cladding by welding and

B 143 (5.6) -

finishing or replace

C 110 (4.3) 92 (3.6)

Axle and Bushing

Unit:mm (in)


Axle Outer Dia. 40 (1.6) [39.2 (1.5)]

Inner Dia. 40 (1.6) [41.0 (1.6)]

Replace

Bushing Flange 2 (0.08) [1.2 (0.05)]

Thickness


W3-6-11


(Blank)

W3-6-12

REMOVE AND INSTALL TRACKS

Removal

UNDERCARRIAGE / Track



loosen too much since high pressure grease

in the adjusting cylinder may spurt. Do not

loosen it over 1.5 turns.

Loosen carefully, keeping body parts and

face away from valve (1). Never loosen

grease fitting (2).

W105-03-07-001

1. Loosen valve (1).

: 24 mm

NOTE: Turn valve (1) of the track adjuster only one

turn, grease can be drained out from the

outlet.

1

CAUTION: Secure the raised machine with

blocks or similar item.

2. Jack up the loosened side track. Turn the track in

the reversed direction.

3. Take off the track.

4. Move the tracks so that master pin (3) is

positioned over front idler (4).Put a wooden block

under track shoes (5) as shown.

2

W105-03-07-002

1

Grease Outlet

M140-07-119

5 4

3

Wooden Block

W105-03-07-006

W3-7-1


CAUTION: The front idler may jump out of

position due to strong spring force when the

tracks is disconnected.

Especially, the strong spring force is always

applied to the thread portion of the rod. If the

rod and/or the thread are damaged, metal

fragments may fly when the tracks is

disconnected. Take necessary precautions to

prevent any personal injury from occurring.

5. Remove retaining ring (6), which is used to

prevent master pin (3) from coming off.

NOTE: If retaining ring (6) interferes with master

link (7), push in master pin (3) to make a

clearance between the retaining ring and

master pin (3) before attempting to remove

the retaining ring.

W105-03-07-005

7

3

6

IMPORTANT: The removing direction is as illustrated.

Be sure to strike master pin

(3) in correctly.

6. Remove master pin (3) using special tool (ST

1970).

Direction for

Removing the

Master Pin

W105-03-07-009

Corner

Direction

for

Installing

the

Master Pin

Track Link

3

Ring

Master Link

ST 1970

W105-03-07-010

W105-03-07-008

W3-7-2


CAUTION: Secure the raised machine with

blocks or similar item.

7. Operate the boom and arm so that the angle

between them is 90 to 110°. Lower the boom with

the bucket rolled-in to jack up the machine as

illustrated.

90~110°

8. Slowly drive the machine in reverse until the

whole length of the track being removed comes

on the ground.

M1CC-07-014

W105-03-07-011

W3-7-3


Installation

1. Jack up the machine. Put the track under the

lower roller so that the sprocket teeth mesh with

the end of the track. Be sure to position the track

in correct direction as illustrated.

Idler Side

Sprocket Side

W105-03-07-013

2. Lift the track, and place it on sprocket (8).

8

W105-03-07-014

3. With the machine jacked up, operate the travel

lever for the track being wound side in forward

direction slowly. Turn travel device (9) while

installing the track.

9

W105-03-07-015

4. Turn the sprocket until the end of track (5) comes

on front idler (4). Lower the machine and place a

wooden block as illustrated.

4

5

W105-03-07-016

Wooden Block

W3-7-4


IMPORTANT: Install the master pin (3) in the

direction as illustrated below.

5. Install master pin (3) with a hammer and special

tool (ST 1970).

Remove the

Master Pin in

This Direction

Corner

Install the

Master

Pin in This

Direction

Track Link

3

Master Link

Retaining

Ring

W105-03-07-010

ST 1970

IMPORTANT: Old retaining ring (6) can not be

reused as it is easily deformed.

Replace it with a new one.

6. Install retaining ring (6).

NOTE: Retaining ring (6) has directivity. Install

retaining ring (6) into the master link (7)

groove with the flat side of the hole to insert

puller facing outward.

IMPORTANT: If any links have been removed from

the track, be sure to fill the grease

(Daphne Epones SR or equivalent)

into the clearance between the pin

and bushing when reconnecting the

links. Stand the bushing on flat plate.

Fill the bushing bore with grease.

Insert the pin into the bushing while

pushing the bushing onto the plate

so that the bushing end stays on the

plate. Wipe off excess grease.

Install the seal in the direction as

illustrated.

Bushing

W105-03-07-017

7

6

W105-03-07-009

Seal

Pin

Do not Apply

Grease

Grease

Do not Apply

Grease

Seal

W197-03-07-001

W3-7-5


7. Tighten valve (1) of the track adjuster. Jack up the

track being adjusted for its sag. Then turn the


Supply grease to the cylinder through the grease

fitting to adjust the track tension.

: 24 mm

: 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)

2

Track sag specifications: 210 to 245 mm (8.3 to

9.6 in)

1

Grease Outlet

M140-07-119

W105-03-07-018

W157-03-06-002

W3-7-6



Link

Measure the length of four links.

• The work shall be done with the tension on the

track.

• The part being measured shouldn’t include the

master pin.

B

A

W155-03-07-001


Unit: mm (in)

A 617 (24.5) 634.1 (25.0)

B 74 (2.9) 69 (2.7)

Cladding by welding

and finishing or replace

Grouser Shoe

Shoe Width

450 mm (17.72) Grouser Shoe

Unit: mm (in)

W105-03-07-024


A 165 (6.5) −

B 6 (0.24) −

C 20 (0.79) 14 (0.55)

Cladding by welding or

replace

W3-7-7


Master Bushing

Unit: mm (in)

W105-03-07-023


A 74.7 (2.9) −

B 24.5 (0.96) [27.5 (1.1)]

Replace

C 41.26 (1.6) [37.76 (1.5)]

Master Pin

W105-03-07-021

Unit: mm (in)


A 123.5 (4.9) −

B 24.2 (0.95) [21.2 (0.83)]

Replace


W3-7-8


Pin

B

A

W142-03-07-004


A 131 (5.2) −

B 24 (0.94) [21 (0.83)]

Replace

Bushing

Unit: mm (in)

W105-03-07-023


A 81 (3.2) −

B 24.35 (0.96) [25.35 (1.0)]

Replace

C 41.26 (1.6) 37.76 (1.5)


W3-7-9


(Blank)

W3-7-10

MEMO

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SECTION 4

FRONT ATTACHMENT

Group 1 Front Attachment

Remove and Install Front Attachment W4-1-1

Maintenance Standard ...................... W4-1-6

Standard Dimensions for

Arm and Bucket Connection ............ W4-1-9

Group 2 Cylinder

Remove and Install Cylinder .............. W4-2-1

Disassemble Cylinder...................... W4-2-14

Assemble Cylinder .......................... W4-2-22

Maintenance Standard ..................... W4-2-34

CONTENTS

1CCW-4-1

(Blank)

1CCW-4-2

FRONT ATTACHMENT / Front Attachment

REMOVE AND INSTALL FRONT ATTACH-

MENT








repair work.





Preparation

1. Park the machine on a solid level surface. Fully

retract the arm and bucket cylinder and lower the

front attachment onto the ground.


hydraulic oil tank to release any pressure

remaining in the hydraulic tank.

CAUTION: The overload relief valve may

spurt hydraulic oil if loosened more than 3/4

turns. Never loosen the valve further.

IMPORTANT: Be sure to loosen overload relief

valve body.


loosened, pressure setting will

change. Never attempt to loosen

them.


and the control valve. Gradually loosen the

overload relief valve to relieve any pressure

remaining in the circuit.

: 24 mm

: 49 to 54 N⋅m (5 to 5.5 kgf⋅m)

Overload Relief

Valve

Upper: Boom Raise

Overload Relief

Valve

Lower: Boom

Lower


Upper: Bucket Roll-

Out


W554-04-02-006

Overload

Relief Valve

Upper: Arm

Roll-Out

Overload

Relief Valve

Lower: Arm

Roll-In




tank.

NOTE: Run the vacuum pump continuously while


Lock Nut

W1CC-02-05-002

Adjusting

Screw

T152-05-04-003

W4-1-1


Removal

1. Remove ring (2) and stopper pin (3) on pin (1)

from the boom.

1

2, 3

W1CC-04-01-001

CAUTION: Boom cylinder weight: 92 kg (205 Ib)

Prevent personal injury. Metal

debris may fly when a hammer is

used to remove pins. Be sure to

wear necessary protection, such

as goggles, hardhat, etc.

2. Hoist the boom cylinder to take up slack of the

wire rope. Drive pin (1) out with a bar and a

hammer. Remove the boom cylinder rod side from

the boom with thrust plates (4) (2 used) coming

off together.

W102-04-01-011

3

1

2

4

W152-04-01-001

IMPORTANT: Boom cylinder rod has a grease fitting.

Lay boom cylinder on a support

so that the grease fitting does not

come in contact with the support.

3. Bind cylinder rod on cylinder tube with wire so that

cylinder rod is not extended. Lay boom cylinder on

a support by crane.

Wire

W554-02-03-007

W4-1-2


CAUTION: Front attachment weight:1110 kg

(2450 Ib)

4. Attach a wire rope to the boom to take up slack of

the wire rope.

5. Disconnect the work light connector and all hoses.

Cap the disconnected hoses. Install plug to each

pipe adapter at boom side.

: 27 mm

Plug (boom): 13/16-16UNF

Plug (boom cylinder): 13/16-16UN

W102-04-01-007

6. Loosen bolts (5) (2 used ) to remove plate (6),

then pull boom foot pin (7) out by prying with a

crowbar.

: 24 mm

NOTE: If boom foot pin (7) can not be removed,

pull them out by using special tool (ST

1953) and bolts holes (M12, pitch 1.75).

Screw Bar: M12 Pitch 1.75 Length 491mm

or more

7

(Special Tool

ST 1953)

5

6

7

Bolt Hole

W197-04-01-002

Screw Bar

W102-04-01-008

W191-04-01-004

CAUTION: Front attachment weight:

1110 kg (2450 Ib)

7. Lift the front attachment by crane to remove it

from the base machine.

Remove the thrust plates (4 used) from both sides

of the boom foot.

W102-04-01-007

W4-1-3


Installation

CAUTION: Front attachment weight: 1110 kg

(2450 Ib)

1. With the front attachment lifted by crane, align the

boom foot with the main frame mating holes.

Install thrust plates (4 used) on both sides of the

boom foot to adjust the clearances on both sides

of boom foot within 1 mm (0.04 in).

W102-04-01-007

CAUTION: Prevent personal injury. Metal

debris may fly when a hammer is used to

install pins. Be sure to wear necessary

protections, such as goggles, hard hat, etc.

2. Drive boom foot pin (7) in with a bar and a

hammer and install plate (6) with bolts (5) (2

used).

: 24 mm

: 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)

5

6

7

W191-04-01-004

3. Reconnect all hoses and the work light connector.

: 27 mm

: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)

W197-04-01-002

W4-1-4


CAUTION: Boom cylinder weight: 92 kg

(205 Ib)

4. While lifting the boom cylinder by crane, start the

engine and extend the boom cylinder rod to align

the rod connecting pin hole.

5. Install thrust plates (4) on both sides of the boom

cylinder rod ends to adjust the clearances on both

sides within 1.5 mm (0.06 in).

W102-04-01-011

3

CAUTION: Prevent personal injury. Metal

debris may fly when a hammer is used to

install pins. Be sure to wear necessary

protections, such as goggles, hard hat, etc.

IMPORTANT: Take care not to damage pin (1).

6. Drive pin (1) in with a hammer and a bar to install

boom cylinder.

1

1

2

2, 3

4

W152-04-01-001

7. Install stopper pin (3) and ring (2) to the boom.

IMPORTANT: After completing work, check hydraulic

oil level. Fully stroke each

cylinder several times to bleed any

air remaining in the circuit while

checking each hose connectors for

any oil leackage.

W1CC-04-01-001

W4-1-5



Front

• Pin and Bushing

E

F

D

G

C

T

A

F

O

H

B

I

L

M

K

J

N

Unit: mm (in)

M1CC-01-013

Parts Name Standard Allowable Limit Remedy

A

B

C

D

E

F

Pin 60 (2.4) 59.0 (2.3)

Bushing 60 (2.4) 61.5 (2.4)

Pin 55 (2.2) 54.0 (2.1)

Boss (Main Frame) 55 (2.2) 56.5 (2.2)

Bushing (Boom Cylinder) 55 (2.2) 56.5 (2.2)

Pin 55 (2.2) 54.0 (2.1)

Boss (Boom) 55 (2.2) 56.5 (2.2)

Bushing (Boom Cylinder) 55 (2.2) 56.5 (2.2)

Pin 60 (2.4) 59.0 (2.3)

Bushing (Arm) 60 (2.4) 61.5 (2.4)

Pin 55 (2.2) 54.0 (2.1)

Boss (Arm) 55 (2.2) 56.5 (2.2)

Bushing (Arm Cylinder) 55 (2.2) 56.5 (2.2)

Pin 55 (2.2) 54.0 (2.1)

Bushing (Arm Cylinder) 55 (2.2) 56.5 (2.2)

Replace

W4-1-6


Unit: mm (in)

Parts Name Standard Allowable Limit Remedy

G

Pin (Bucket Cylinder) 45 (1.8) 44.0 (1.7)

Bushing 45 (1.8) 46.5 (1.8)

Pin 55 (2.2) 54.0 (2.1)

H Bushing (Bucket Cylinder) 55 (2.2) 56.5 (2.2)

Bushing 55 (2.2) 56.5 (2.2)

I

Pin 50 (2.0) 49.0 (1.9)

Bushing 50 (2.0) 51.5 (2.0)

J

Pin 50 (2.0) 49.0 (1.9)

Bushing 50 (2.0) 51.5 (2.0)

K

Pin 50 (2.0) 49.0 (1.9)

Bushing 50 (2.0) 51.5 (2.0)

L

Pin 50 (2.0) 49.0 (1.9)

Bushing (Blade) 50 (2.0) 51.5 (2.0)

M

Pin 71 (2.8) 70.0 (2.8)

Bushing (Blade Cylinder) 71 (2.8) 72.5 (2.9)

N

Pin 71 (2.8) 70.0 (2.8)

Bushing (Blade Cylinder) 71 (2.8) 72.5 (2.9)

Replace

W4-1-7


Side Cutter

C

A

D

B

Unit: mm (in)

W505-04-01-001


A 225 (8.9) 145 (5.7)

B 250 (9.8) -

Replace

C 295 (11.6) -

D 150 (5.9) -

Point

B

C

A

D

Unit: mm (in)


A 165 (6.5) 85 (3.3)

B 57 (2.2) -

C 60 (2.4) -

Replace

D 62 (2.4) -

W554-04-01-003

W4-1-8

STANDARD DIMENSIONS FOR ARM

AND BUCKET CONNECTION


Section A

Section B

W1CC-04-01-002

Unit: mm (in)

a 255 (10.0)

b 15 (0.59)

c 417 (16.5)

d 359 (14.1)

e 310 (12.2)

f 1060 (42)

g 298 (11.7)

h 200 (7.9)

i 50 (2.0)

j 299 (11.8)

k 82 (3.2)

l 298 (11.7)

m 202 (8.0)

n 50 (2.0)

o 90°

p 90°

q 312 (12.3)

r 224 (8.8)

NOTE: Dimension h: 200 mm includes the

clearance for bucket adjuster.

W4-1-9


(Blank)

W4-1-10

REMOVE AND INSTALL CYLINDER

FRONT ATTACHMENT / Cylinder








repair work.





Preparation

1. Park the machine on a solid level surface. Fully

retract the bucket and arm cylinder and lower the

bucket onto the ground.

2. Stop the engine. Push the air release valve on top

of the hydraulic oil tank to release any pressure

remaining in the hydraulic tank.

CAUTION: The overload relief valve may

spurt hydraulic oil if loosened move than 3/4

turn. Never loosen the valve further.

IMPORTANT: Be sure to loosen overload relief

valve body.


loosened, pressure setting will

change. Never attempt to loosen

them.


and control valve. Gradually loosen the overload

relief valve to relieve any pressure remaining in

the circuit.

: 24 mm

: 49 to 54 N⋅m

(5 to 5.5 kgf⋅m, 36 to 40 Ibf⋅ft)

Overload Relief

Valve

Upper: Boom Raise

Overload Relief

Valve

Lower:

Boom Lower


Upper: Bucket Roll-Out


W554-04-02-006

Overload

Relief Valve

Upper:

Arm Roll-Out

Overload

Relief Valve

Lower:

Arm Roll-In




tank.

NOTE: Run the vacuum pump continuously while


Lock Nut

W1CC-02-05-002

Adjusting

Screw

T152-05-04-003

W4-2-1


Remove Bucket Cylinder

CAUTION: Prevent personal injury. Metal debris

may fly when a hammer is used to remove

pins. Be sure to wear necessary protections,

such as goggles, hard-hat, etc.

1

1. Lay wooden blocks under the arm (2) tip and in

the clearance between the arm (2) top surface

and bucket cylinder (1).

2

Wooden

Blocks

IMPORTANT: Before removing pin (6), secure the

links with wires to prevent the links

from falling it.

2. Remove ring (5) and stopper pin (3) to remove pin

(6).

Remove thrust plates (4) from the mating faces

between the links and the bucket cylinder (1) rod.

3

4

1

W554-04-02-006

5

6

3. Bind rod (7) of bucket cylinder (1) with wire so that

cylinder rod (7) is not extended.

7

1

W158-04-02-005

4. Disconnect hoses (11) (2 used) from the bottom

of bucket cylinder (1). Cap the disconnected hose

(11) ends.

: 27 mm

11

CAUTION: Bucket cylinder weight: 57 kg

(126 Ib)

5. Hold bucket cylinder (1) by crane using wire rope.

Remove ring (12) and stopper pin(8).

Drive pin (10) out with a bar and a hammer to remove

thrust plate (9). Hoist bucket cylinder (1)

and remove it.

1

Wire

9

8 10

W102-04-02-005

12

11

W158-04-02-007

W4-2-2


Install Bucket Cylinder

9

8 10


(126 Ib)

Prevent personal injury. Metal debris may fly

when a hammer is used to remove pins. Be

sure to wear necessary protection, such as

goggles, hard hat, etc.

1. While slinging bucket cylinder (1) by crane, align

the pin (10) holes on the bucket cylinder bottom

and the arm. Insert thrust plates (9) and drive pin

(10) in with a bar and a hammer.

2. Align the pin holes on the stopper and pin (10).

Then install stopper pin (8) to install ring (12).

1

12

Stopper

11

W158-04-02-007

3. Reconnect hoses (11) (2 used) to bucket cylinder

(1).

: 27 mm

: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)

7

1

4. Remove the wire from bucket cylinder (1) and rod

(7).

5. Start the engine. Extend bucket cylinder (1) to

align the pin (6) holes on the bucket cylinder (1)

rod and the links. Insert thrust plates (4). While

aligning the stopper pin (3) hole on the link and

pin (6), drive the pin in with a bar and a hammer.

11

IMPORTANT: After refilling the hydraulic oil to the

specified level, start the engine.

Check for any oil leaks from the

hose connections.

6. Insert stopper pin (3). Then install ring (5).

3

4

Wire

1

W102-04-02-005

IMPORTANT: After completing work, fully stroke

the bucket cylinder several times to

bleed any air remaining in the circuit.

5

6

W158-04-02-005

W4-2-3


Remove Arm Cylinder

1 2



pins. Be sure to wear necessary protections,

such as goggles, hard hat, etc.

1. Place a wooden block on the top surface of boom

(2) to support arm cylinder (1).

2. Remove ring (6) and stopper pin (3). Drive pin (5)

out with a bar and a hammer.


between the arm and the arm cylinder (1) rod.

NOTE: If it is difficult to remove pin (5), lift the

boom slightly to remove the pin.

Wooden Block

4

3 5

W102-04-02-009

3. Bind the cylinder rod with wire so that the arm cylinder

(1) rod is not extended.

6

1

W158-04-02-009

Wire

W102-04-02-013

7

4. Disconnect hoses (7) (2 used) from the bottom of

arm cylinder (1). Disconnect grease hose (8) from

the work light side of the boom and the cylinder

tube side of the arm cylinder. Cap the disconnected

hoses ends.

: 17 mm, 19 mm, 27 mm

1

8

W102-04-02-014

W4-2-4


CAUTION: Arm cylinder weight: 69 kg

(152 Ib)

5. Attach a wire rope to arm cylinder (1), hold the

arm cylinder by crane.

1

6. Remove ring (11) and stopper pin (12). Drive pin

(10) out with a bar and a hammer to remove thrust

plates (9).

Hoist arm cylinder (1) by crane and remove it.

1 12 9

10

W102-04-02-016

11

W158-04-02-011

W4-2-5


Install Arm Cylinder

CAUTION: Arm cylinder weight: 69 kg

(152 Ib)





1. While slinging arm cylinder (1) by crane, align the

pin (10) holes on the cylinder bottom and boom

(2).

Insert thrust plates (9).

While aligning the stopper pin (12) holes on the

pin and the stopper, drive the pin in with a bar and

a hammer.

2. Drive stopper pin (12) in to install ring (11).

1

2

9

1 12 10

W102-04-02-016

3. Reconnect the grease hose to the cylinder tube

side of arm cylinder (1) and to the work light side

of the boom. Reconnect hoses (7) (2 used) to the

arm cylinder.

: 17 mm

: 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft)

: 19 mm

: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)

: 27 mm

: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)

1

11

Stopper

W158-04-02-011

7

8

W102-04-02-014

W4-2-6


4. Remove the wire from the cylinder rod. Start the

engine to extend arm cylinder (1). Align the pin (5)

holes on the arm cylinder (1) rod and the arm. Insert

thrust plates (4).

While aligning the stopper pin (3) holes on the

stopper and the pin, drive the pin in with a bar and

a hammer.

NOTE: If the rod hole on arm cylinder (1) fails to

align with the arm hole, start the engine to

operate the boom to align the pin (5) hole.

4

3 5

1

5. Drive stopper pin (3) in with a bar and a hammer.

Then, install ring (6).


the arm cylinder several times to

bleed any air remaining in the circuit.

6

Stopper

W158-04-02-009

W4-2-7


Remove Boom Cylinder



pins. Be sure to wear necessary protection,


1. Remove ring (2) and stopper pin (3) from boom

pin (1).

1

2、3

CAUTION: Boom cylinder (4) weight: 92 kb

(205 Ib)

2. While holding boom cylinder (4) by crane, drive

out pin (1) with a bar and a hammer. Detach the

boom cylinder rod to remove thrust plates (5).

W1CC-04-01-001

4

W102-04-01-011

2

3

1

IMPORTANT: A grease fitting is provided on the

boom cylinder (4) rod. Lay boom cylinder

(4) on a support so that the

grease fitting does not come in contact

with the support.

3. Bind the boom cylinder (4) rod to the cylinder tube

with the wire so that the cylinder rod is not extended.

Lower boom cylinder (3) onto a support by

crane.

5

W152-04-01-001

Wire

W554-02-03-007

W4-2-8

4. Disconnect hoses (6) (2 used) from boom cylinder

(4). Cap disconnected hoses ends.

: 27 mm


4

6

5. Move the wire rope to the boom cylinder (4)’s center

of gravity and hold it.

Remove ring (7). Drive stopper pin (8) out to drive

pin (9) out with a bar and a hammer. Remove

thrust plates (10).

4

8 9

W102-04-02-023

7

W102-04-02-024

10

W152-04-01-001

CAUTION: Boom cylinder (4) weight: 92 kg

(205 Ib)

6. Lift boom cylinder (4) by crane to remove it.

4

W102-04-02-025

W4-2-9


Install Boom Cylinder

CAUTION: Boom cylinder (4) weight: 92 kg

(205 Ib)





1. While lifting boom cylinder (4) by crane, align the

pin (9) holes on the cylinder bottom and the main

frame.

Insert thrust plates (10).

2. While aligning the stopper pin (8) holes on pin (9)

and the main frame boss, drive the pin in with a

bar and a hammer.

4

W102-04-02-025

9

3. Drive stopper pin (8) in with a bar and a hammer

to install ring (7).

4

10

8

W152-04-01-001

9

7

4. Reconnect hoses (6) (2 used ) to boom cylinder

(4).

: 27 mm

: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)

4

6

W102-04-02-024

W102-04-02-023

W4-2-10

5. Hoist boom cylinder (4). Start the engine and extend

the boom cylinder to align the rod pin (1)

holes.


4

W102-04-01-011

6. Insert thrust plates (5) on both sides of the boom

cylinder (4) rod end.

2

3

1

5

W152-04-01-001

7. While aligning the stopper pin (3) holes of pin (1)

and the boom. Drive the pin in with a bar and a

hammer.

8. Install stopper pin (3) to the boom, and install ring

(2).


each cylinder several times to bleed

any air remaining in the circuit.

1

2、3

4

W1CC-04-01-001

W4-2-11


Remove Blade Cylinder



pins. Be sure to wear necessary protection,


1. Loosen bolts (1) (2 used) to remove cover (2).

: 19 mm

1

2

3

CAUTION: Blade cylinder weight: 51 kg

(112 Ib)

2. Attach a wire rope to blade cylinder (3). Hoist the

blade cylinder and hold it.

3. Disconnect hoses (2 used) from blade cylinder

(3).

Cap the disconnected hoses.

: 22 mm, 27 mm

6

5

4

4

4. Loosen bolts (6) (2 used) to remove pins (5) (2

used).


between the blade cylinder (3) tube and blade (7),

rod and track frame.

: 24 mm

5. Hoist blade cylinder (3) to remove it.

7

6

5

W197-04-02-001

W4-2-12


Install Blade Cylinder

CAUTION: Blade cylinder (3) weight: 51 kg

(112 Ib)

1. While slinging blade cylinder (3) by crane, align

the pin (5) holes on the tube and blade (7), rod

and track frame.

Insert thrust plate (4). Drive pin (5) (2 used) in with

a bar and a hammer. Secure the pins with bolts

(6) (2 used).

: 24 mm

: 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)

6

5

4

1

2

3

4

2. Reconnect hoses (2 used) to blade cylinder (3).

: 22 mm

: 39 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)

: 27 mm

: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)

3. Install cover (2) to blade cylinder (3), then secure

it with bolts (1) (2 used).

: 19 mm

: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)

7

6

5

W197-04-02-001


each cylinder several times to bleed

any air remaining in the circuit.

W4-2-13

DISASSEMBLE CYLINDER

Boom Cylinder


2

3

4

5

6

7

8

1

9

10

26

11

12

13

14

15

16

17

18

19

20

21

22

23

25

24

W152-04-02-001

1 - Piston Rod 8 - Retaining Ring 15 - Cushion Seal 21 - Slide Ring

2 - Wiper Ring 9 - O- Ring 16 - Cushion Bearing 22 - Shim

3 - Backup Ring 10 - Backup Ring 17 - Slide Ring 23 - Nut

4 - U-Ring 11 - O- Ring 18 - Piston 24 - Set Screw

5 - Buffer Ring 12 - Backup Ring 19 - Seal Ring 25 - Steel Ball

6 - Cylinder Head 13 - O- Ring 20 - O-Ring 26 - Cylinder Tube

7 - Bushing 14 - Backup Ring

W4-2-14


Disassemble Boom Cylinder




• The disassembly procedure below shall be carried

out on the premise that the hydraulic lines and the

line securing bands have been removed.

CAUTION: Boom cylinder weight: 92 kg

(205 Ib)

1. Lift and securely place the cylinder on a workbench

by crane. Drain hydraulic oil from the cylinder.

5. Remove set screw (24) to remove steel ball (25).

:8 mm

NOTE: Set screw (24) was crimped with a punch in

2 places after it was tightened. Before loosening

the set screw, cut away the crimped

portions.

6. Loosen nut (23) using special tool (ST 5908).

Remove shim (22). Remove piston (18), cushion

bearing (16) and cushion seal (15) from piston rod

(1).

Nut Turning Special Tool: 75 mm (ST 3271)

NOTE: Remove cushion seal (15) by inserting a

screw driver edge into the slit.

7. Remove cylinder head (6) from piston rod (1).

W102-04-02-027

2. Extend the detents to unlock cylinder head (6).

Using R wrench (ST 3222), loosen cylinder head

(6) 1 to 2 turns.

IMPORTANT: Be sure to pull out piston rod (1)

straight to prevent the sliding surfaces

from becoming damaged.

3. Fully extend piston rod (1). Holding the rod end by

crane, remove cylinder head (6) from cylinder

tube (26) to remove the piston rod.

IMPORTANT: When removing the seals, take care

not to damage the mating parts.

8. Remove slide rings (17), (21), seal ring (19), O-

ring (20) from piston (18).

9. Remove wiper ring (2), backup ring (3), U-ring (4),

buffer ring (5), snap ring (8) and bushing (7) from

the inside of cylinder head (6).

Bushing Special Tool: 70 mm (ST 8017)

10. Remove O-rings (9), (11) and (13), backup rings

(10), (12) and (14) from the outside of cylinder

head (6).

4. Securely place piston rod (1) on special tool (ST

5908). Put matching marks on the piston rod and

nut (23).

ST 5908

W158-04-02-022

W4-2-15


Arm Cylinder

2

3

4

5

6

7

8

10

9

11

1

24

12

13

14

15

16

17

18

20

19

21

22

23

W152-04-02-002

1 - Piston Rod 7 - Bushing 13 - Slide Ring 19 - Slide Ring

2 - Wiper Ring 8 - Snap Ring 14 - Piston 20 - Retaining Ring

3 - Backup Ring 9 - Backup Ring 15 - Steel Ball 21 - Cushion Seal

4 - U-Ring 10 - O-Ring 16 - Set Screw 22 - Cushion Bearing

5 - Buffer Ring 11 - O-Ring 17 - Seal Ring 23 - Stopper

6 - Cylinder Head 12 - Shim 18 - O-Ring 24 - Cylinder Tube

W4-2-16


Disassemble Arm Cylinder




• The disassembly procedure below starts on the

premise that the hydraulic lines and the line securing

bands have been removed.

CAUTION: Arm cylinder weight: 69 kg (152 Ib)



W102-04-02-027



(6) 1 to 2 turns.

IMPORTANT: Be sure to pull piston rod (1) straight

out to prevent the sliding surface


3. Fully extend piston rod (1) to hold the rod end by

crane. Remove cylinder head (6) from cylinder




piston (14).

ST 5908


:8 mm




portions.

6. Loosen piston (14) using special tool (ST 5908).

Remove shim (12).

Piston Turning Special Tool: 70 mm (ST 3261)

7. Remove stopper (23), cushion bearing (22), cushion

seal (21) and retaining ring (20) from piston

rod (1).

NOTE: Remove retaining ring (20) of stopper (23)

to slide cushion bearing (22). Remove the

stopper.

Remove cushion seal (21) by inserting a

screw driver edge into the slit.







buffer ring (5), snap ring (8), and bushing (7) from



11. Remove O-rings (11), (10), and backup ring (9)

from the outside of cylinder head (6).

W158-04-02-022

W4-2-17


Bucket Cylinder

12

13

14

17

18

19

15

16

1

2

20

3

4

5

6

7

8

10

9

11

W152-04-02-003

1 - Piston Rod 6 - Cylinder Head 11 - O-Ring 16 - Set Screw

2 - Wiper Ring 7 - Bushing 12 - Shim 17 - Seal Ring

3 - Backup Ring 8 - Snap Ring 13 - Slide Ring 18 - O-Ring

4 - U-Ring 9 - Backup Ring 14 - Piston 19 - Slide Ring

5 - Buffer Ring 10 - O-Ring 15 - Steel Ball 20 - Cylinder Tube

W4-2-18


Disassemble Bucket Cylinder





premise that hydraulic lines and the line securing



(123 Ib)




:8 mm




portions

6. Loosen piston (14) using special tool (ST 5908).

Remove shim (12).







W102-04-02-027



(6) 1 to 2 turns.


out to prevent the rod surface from

becoming damaged.








10. Remove O-rings (11), (10), backup ring (9) from

the outside of cylinder head (6).



piston (14).

ST 5908

W158-04-02-022

W4-2-19


Blade Cylinder

12

1

13

14

15

16

17 2

18

19

20

3

4

5

6

21

7

8

10

9

11

1 - Piston Rod 7 - Bushing 12 - Slide Ring 17 - Shim

2 - Wiper Ring 8 - Snap Ring 13 - Piston 18 - Nut

3 - Backup Ring 9 - Backup Ring 14 - Seal Ring 19 - Steel Ball

4 - U-Ring 10 - O-Ring 15 - O-Ring 20 - Set Screw

5 - Buffer Ring 11 - O-Ring 16 - Slide Ring 21 - Piston Rod

6 - Cylinder Head

W1CC-04-02-001

W4-2-20


Disassemble Blade Cylinder

• Be sure to read “Precautions for Disassembly

and Assembly” thoroughly on page W1-1-1

before starting any repair work.


premise that hydraulic lines and line securing


CAUTION: Blade cylinder weight: 51 kg

(112 Ib)




: 10 mm



the set screw (20), cut away the

crimped portions

6. Loosen nut (18) using special tool (ST 5908).

Remove shim (17).





8. Remove slide rings (12), (16), seal ring (14) and

O-ring (15) from piston (13).

W102-04-02-027



(6) 1 to 2 turns.


out to prevent the sliding surface




tube (21) to remove the piston rod .





10. Remove O-rings (11), (10), backup ring (9) from

the outside of cylinder head (6).



piston (18).

ST 5908

W158-04-02-022

W4-2-21


ASSEMBLE CYLINDER

Boom Cylinder

2

3

4

5

7

8

1

16 15 18 17 19 20 21

23

6

9

10

11

12

13

14

26

22

24

25

Be Sure That Oil Groove Face the

Correct Direction when Assembling

W190-04-02-003

With the Slit toward the Piston

1 - Piston Rod 8 - Snap Ring 15 - Cushion Seal 21 - Slide Ring

2 - Wiper Ring 9 - O-Ring 16 - Cushion Bearing 22 - Shim

3 - Backup Ring 10 - Backup Ring 17 - Slide Ring 23 - Nut

4 - U-Ring 11 - O-Ring 18 - Piston 24 - Set Screw

5 - Buffer Ring 12 - Backup Ring 19 - Seal Ring 25 - Steel Ball

6 - Cylinder Head 13 - O-Ring 20 - O-Ring 26 - Cylinder Tube

7 - Bushing 14 - Backup Ring

W4-2-22


Assemble Boom Cylinder




1. Press bushing (7) into cylinder head (6) with a

press. Install snap ring (8) into the cylinder head.


IMPORTANT: Install U-ring (4) with the lip facing

bushing (7).

Install buffer ring (5) with the protrusion

part and slits facing bushing (7).

2. Install backup ring (3), U-ring (4) and buffer ring

(5) into cylinder head (6).

3. Install wiper ring (2) into cylinder head (6) using

ST 8017.

Wiper Ring Specail Tools: ST 8017

IMPORTANT: Install backup ring (10) to the piston

rod (1) boss side of O-ring (11).

4. Install the O-rings (9, 11, 13) and backup rings (10,

12, 14) into cylinder head (6).

5. Install the cylinder head (6) assembly into piston

rod (1).

Cylinder Head Special Tool: ST 8017

IMPORTANT: After installing O-ring (20), check

there is no twisting.

6. Install O-ring (20) and seal ring (19) onto piston

(18) with a wooden spatula so that they are not

installed in the slide ring (17) groove.

IMPORTANT: While installing slide rings (17), (21),

be sure that their slit sections align

with each other.

7. Install slide rings (17), (21) onto piston (18).

IMPORTANT: Install cushion seal (15) with the slit

side facing piston (18).

Install cushion bearing (16) with the

wider split circumference side facing

cylinder head (6).

8. Install cushion seal (15) and cushion bearing (16)

into piston rod (1).

9. Install piston (18) and shim (22) into piston rod (1).

Tighten nut (23) using special tool (ST 5908) according

to the matching mark.


: 2650 N⋅m (270 kgf⋅m, 1950 Ibf⋅ft)

ST 5908

W158-04-02-022

10. Align the holes on the piston rod (1) and nut (23).

Install steel ball (25) into nut (23). Then, tighten

set screw (24). Set screw (24) should be crimped

with a punch in 2 places after it is tightened.

:8 mm

: 31.5±5.9 N⋅m

(3.2±0.6 kgf⋅m, 23±4.3 Ibf⋅ft)

W4-2-23


1

6

26

W190-04-02-003

W4-2-24


IMPORTANT: Be sure to keep piston rod (1) aligning

with center of cylinder tube (26)

when inserting in order to avoid

damaging the piston rings.

11. Securely place cylinder tube (26) on a workbench,

insert the piston rod (1) assembly into cylinder

tube (26).

12. Tighten cylinder head (6) to cylinder tube (26) using

R wrench (ST 3222). Fold the detents to lock

cylinder head (6).

: 950±215 N⋅m

(97±22 kgf⋅m, 700±159 Ibf⋅ft)

W4-2-25


Arm Cylinder

2

3

4

5

7

8

1

12

13

17

18

19 16 15 20 21

23

6

14

22

10 9

11

24

With the Slit Toward the Piston

W152-04-02-005

Be Sure that Oil Groove Face the

Correct Direction When Assembling

1 - Piston Rod 7 - Bushing 13 - Slide Ring 19 - Slide Ring

2 - Wiper Ring 8 - Snap Ring 14 - Piston 20 - Snap Ring

3 - Backup Ring 9 - Backup Ring 15 - Steel Ball 21 - Cushion Seal

4 - U-Ring 10 - O-Ring 16 - Set Screw 22 - Cushion Bearing

5 - Buffer Ring 11 - O-Ring 17 - Seal Ring 23 - Stopper

6 - Cylinder Head 12 - Shim 18 - O-Ring 24 - Cylinder Tube

W4-2-26


Assemble Arm Cylinder







IMPORTANT: Install U-ring (4) with its lip facing

bushing (7).



2. Install backup ring (3), U-ring (4) and buffer ring



ST 8012.

Wiper Ring Special Tool: ST 8012



4. Install O-rings (10), (11) and backup ring (9) onto

cylinder head (6).


rod (1).





(14) by guiding them with a wooden spatula so

that they are not installed into the slide ring (13)

groove.

IMPORTANT: Install slide rings (13), (19), be sure

that their slit sections align with

each other.


IMPORTANT: Install cushion seal (21) with the slit

side facing piston (14).

Install cushion bearing (22) with the

wider split circumference side facing

the cylinder bottom.

8. Install cushion seal (21) and cushion bearing (22)

onto piston rod (1).

9. Slide cushion bearing (22) toward piston (14) to

install stopper (23).

Slide the cushion bearing toward stopper to install

snap ring (20).


Tighten the piston using special tool (ST 5908)

according to the matching mark.


: 2450 N⋅m (250 kgf⋅m, 1810 Ibf⋅ft)

ST 5908

W158-04-02-022

W4-2-27


1

16 15

6

14

24

W152-04-02-005

W4-2-28

11. Align the holes on piston rod (1) and piston (14).

Install steel ball (15), then tighten set screw (16).

The set screw should be crimped with punch in 2

places after it is tightened.

:8 mm

: 31.5±5.9 N⋅m

(3.2±0.6 kgf⋅m, 23±4.3 lbf⋅ft)


with center of cylinder tube (24)

when inserting in order to avoid



insert the piston rod (1) assembly into the cylinder

tube .

13. Tighten cylinder head (6) to cylinder tube (24)

using R wrench (ST 3221). Fold the detents to

lock cylinder head (6).

: 570±127 N⋅m

(58±13 kgf⋅m, 420±94 lbf⋅ft)


W4-2-29


Bucket Cylinder

3 4 5 7 8

1

2 13 17 18 19 16

14

15

6

10 9

11

20

12

W190-04-02-001

1 - Piston Rod 6 - Cylinder Head 11 - O-Ring 16 - Set Screw

2 - Wiper Ring 7 - Bushing 12 - Shim 17 - Seal Ring

3 - Backup Ring 8 - Retaining Ring 13 - Slide Ring 18 - O-Ring

4 - U-Ring 9 - Backup Ring 14 - Piston 19 - Slide Ring

5 - Buffer Ring 10 - O-Ring 15 - Steel Ball 20 - Cylinder Tube

W4-2-30


Assemble Bucket Cylinder








bushing (7).



2. Install backup ring (3) and U-ring (4), buffer ring




each other.



Tighten piston using special tool (ST 5908) according

to the matching mark.


: 1470 N⋅m (150 kgf⋅m, 1080 Ibf⋅ft)

ST 5908


ST 8011.




4. Install O-rings (10), (11), backup ring (9) to cylinder

head (6).


rod (1).






that they are not installed in the slide ring (13)

groove.

W158-04-02-022

9. Align the holes on piston rod (1) and piston (14) to

install steel ball (15). Then, tighten set screw (16).

Set screw (16) should be crimped with a punch in

2 places after it is tightened.

: 8 mm

: 31.5±5.9 N⋅m

(3.2±0.6 kgf⋅m, 23±4.3 Ibf⋅ft)


with the center of cylinder tube

(20) when inserting in order to avoid




tube (20).

11. Tighten cylinder head (6) to cylinder tube (20) using

R wrench (ST 3213). Fold the detents to lock

the cylinder head .

: 490±113 N⋅m

(50±11.5 kgf⋅m, 360±83 Ibf⋅ft)

W4-2-31


Blade Cylinder

4 5 7 8 1

3

2

13

12 14 15 16

17

20

19

6

W190-04-02-002

18

10 9

11

21

1 - Piston Rod 7 - Bushing 12 - Slide Ring 17 - Shim

2 - Wiper Ring 8 - Retaining Ring 13 - Piston 18 - Nut

3 - Backup Ring 9 - Backup Ring 14 - Seal Ring 19 - Steel Ball

4 - U-Ring 10 - O-Ring 15 - O-Ring 20 - Set Screw

5 - Buffer Ring 11 - O-Ring 16 - Slide Ring 21 - Cylinder Tube

6 - Cylinder Head

W4-2-32


Assemble Blade Cylinder





press. Install retaining ring (8) into the cylinder

head.



bushing (7).


part and slits facing bushing

(7).

2. Install backup ring (3) and U-ring (4), buffer ring



ST 8017.


IMPORTANT: Install hole backup ring (9) to the

piston rod (1) boss side of O-ring

(11).

4. Install O-rings (10), (11), backup ring (9) to cylinder

head (6).


rod (1).






that they are not installed in the slide ring (12)

groove.



each other.



Tighten nut (18) using special tool (ST 5908)

according to the matching mark.


: 3330 N⋅m (340 kgf⋅m, 2460 Ibf⋅ft)

ST 5908

W158-04-02-022

9. Align the holes on the piston rod (1) and nut (18)

to install steel ball (19). Then, tighten set screw

(20). Set screw (20) should be crimped with a

punch in 2 places after it is tightened.

: 10 mm

: 56.9±10.7 N⋅m

(5.80±1.09 kgf⋅m, 42±7.8 Ibf⋅ft)


with the center of cylinder tube

(21) when inserting in order to avoid




tube (21).

11. Tighten cylinder head (6) to cylinder tube (21) by

using R wrench (ST 3223). Fold the detents to

lock cylinder head (6).

: 1340±295 N⋅m

(137±30 kgf⋅m, 990±215 lbf⋅ft)

W4-2-33


Rod


A

W105-04-02-094

Cylinder Name

Boom

Arm

Bucket

Blade

Recommended Size After

Re-Manufacturing (A)

–0.010 –0.0004

70 mm (2.8 in)

–0.023 –0.0009

–0.010 –0.0004

60 mm (2.4 in)

–0.023 –0.0009

–0.010 –0.0004

55 mm (2.0 in)

–0.023 –0.0009

–0.010 –0.0004

70 mm (2.8 in)

–0.023 –0.0009

Slide Ring and Teflon Ring

B

Slide Ring

Unit: mm (in)


B 3.91 to 3.98

(0.154 to 0.157)

3.82 (0.150) Replace

W4-2-34

MEMO

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SECTION 5

ENGINE AND ACCESSORY

SECTION 1.

General Information

General Repair Instructions.............................. 2

Notes on the Format of

This Manual.................................................... 2

Main Data and Specifications ........................... 6

Tightening Torque Specifications ...................... 7

SECTION 2.

Maintenance

Model Identification ........................................ 18

Injiction Pump Identification............................ 18

Lubricating System......................................... 18

Fuel System ................................................... 19

Cooling System .............................................. 22

Valve Clearance Adjustment........................... 23

Injection Timing.............................................. 24

Compression Pressure

Measurement ............................................... 26

Recommended Lubricants.............................. 27

Engine Repair Kit ........................................... 28

SECTION 3.

Engine Assembly 1 (Disassembly)

General Description........................................ 30

Disassembly................................................... 31

SECTION 4.

Engine Assembly 2

(Inspection and Repair)

Inspection and Repair .................................... 48

CONTENTS

SECTION 5.

Engine Assembly 3 (Reassembly)

Reassembly ................................................... 82

SECTION 6.

Lubricating System

Main Data and Specification ......................... 110

General Description.......................................111

Oil Pump ...................................................... 114

Oil Filter with Built-in Oil Cooler .................... 117

SECTION 7.

Cooling System


General Description...................................... 123

Thermostat................................................... 125

SECTION 8.

Fuel System


General Description...................................... 129

Injection Nozzle ............................................ 132

Injection Pump Calibration Data ................... 137

SECTION 9.

Engine Electricals

Starter .......................................................... 142

Alternator ..................................................... 157

1CCW-5-1

SECTION 10.

Troubleshooting

Hard Starting................................................ 171

Unstable Idling ............................................. 175

Insufficient Power......................................... 178

Excessive Fuel Consumption ....................... 182

Excessive Oil Consumption .......................... 184

Overheating ................................................. 185

Whity Exhaust Smoke .................................. 187

Darkish Exhaust Smoke ............................... 188

Oil Pressure does not Rise........................... 189

Abnormal Engine Noise................................ 191

SECTION 11.

Special Tool List

Special Tool List ........................................... 196

SECTION 12.

Repair Standards

General Ruler............................................... 199

Repair Standard Chart.................................. 200

SECTION 13.

Conversion Table

Length.......................................................... 213

Area ............................................................. 215

Volume......................................................... 215

Mass ............................................................ 217

Pressure ...................................................... 218

Torque.......................................................... 219

Temperature................................................. 220

1CCW-5-2

MEMO

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Hitachi Construction Machinery Co. Ltd

Hitachi Ref. No.

Attn: Publications, Marketing & Product Support

Fax: 81-298-31-1162

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