DOC-20230111-WA0038.

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FRONT ATTACHMENT / CylinderDisassemble Arm Cylinder• Be sure to read “Precautions for Disassembly andAssembly” thoroughly on page W1-1-1 beforestarting any repair work.• The disassembly procedure below starts on thepremise that the hydraulic lines and the line securingbands have been removed.CAUTION: Arm cylinder weight: 69 kg (152 Ib)1. Lift and securely place the cylinder on a workbenchby crane. Drain hydraulic oil from the cylinder.W102-04-02-0272. Extend the detents to unlock cylinder head (6).Using R wrench (ST 3221), loosen cylinder head(6) 1 to 2 turns.IMPORTANT: Be sure to pull piston rod (1) straightout to prevent the sliding surfacefrom becoming damaged.3. Fully extend piston rod (1) to hold the rod end bycrane. Remove cylinder head (6) from cylindertube (24) to remove the piston rod.4. Securely place piston rod (1) on special tool (ST5908). Put matching marks on the piston rod andpiston (14).ST 59085. Remove set screw (16) to remove steel ball (15).:8 mmNOTE: Set screw (16) was crimped with a punch in2 places after it was tightened. Before looseningthe set screw, cut away the crimpedportions.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), cushionseal (21) and retaining ring (20) from pistonrod (1).NOTE: Remove retaining ring (20) of stopper (23)to slide cushion bearing (22). Remove thestopper.Remove cushion seal (21) by inserting ascrew driver edge into the slit.8. Remove cylinder head (6) from piston rod (1).IMPORTANT: When removing the seals, take carenot to damage the mating parts.9. Remove slide rings (13), (19), seal ring (17), O-ring (18) from piston (14).10. Remove wiper ring (2), backup ring (3), U-ring (4),buffer ring (5), snap ring (8), and bushing (7) fromthe inside of cylinder head (6).Bushing Special Tool: 60 mm (ST 8012)11. Remove O-rings (11), (10), and backup ring (9)from the outside of cylinder head (6).W158-04-02-022W4-2-17
FRONT ATTACHMENT / CylinderBucket Cylinder1213141718191516122034567810911W152-04-02-0031 - Piston Rod 6 - Cylinder Head 11 - O-Ring 16 - Set Screw2 - Wiper Ring 7 - Bushing 12 - Shim 17 - Seal Ring3 - Backup Ring 8 - Snap Ring 13 - Slide Ring 18 - O-Ring4 - U-Ring 9 - Backup Ring 14 - Piston 19 - Slide Ring5 - Buffer Ring 10 - O-Ring 15 - Steel Ball 20 - Cylinder TubeW4-2-18
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INTRODUCTIONTO THE READER• This m
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SAFETYRECOGNIZE SAFETY INFORMATION
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SAFETYWEAR PROTECTIVE CLOTHING• W
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SAFETYUSE HANDHOLDS AND STEPS• Fa
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OPERATE ONLY FROM OPERATOR'SSEAT•
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SAFETYDRIVE MACHINE SAFELY• Befor
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AVOID INJURY FROM BACK-OVER ANDSWIN
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SAFETYAVOID POWER LINES• Serious
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HANDLE FLUIDS SAFELY−AVOID FIRES
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SAFETYPRACTICE SAFE MAINTENANCETo a
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SAFETYPREVENT PARTS FROM FLYING•
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SAFETYAVOID HIGH-PRESSURE FLUIDS•
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SAFETYCheck Emergency Engine Stop S
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REMOVE PAINT BEFORE WELDING ORHEATI
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SAFETYDISPOSE OF WASTE PROPERLY•
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SECTION AND GROUPCONTENTSWORKSHOP M
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SECTION 1GENERAL INFORMATIONGroup 1
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GENERAL / Precautions for Disassemb
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TIGHTENING TORQUE SPECIFICATIONSGEN
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IMPORTANT: The following items are
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GENERAL / TighteningPIPING JOINT1 4
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GENERAL / TighteningScrew-In Connec
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PERIODIC REPLACEMENT OF PARTSGENERA
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GENERAL / PaintingPAINTINGPainting
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MEMO...............................
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SECTION 2UPPERSTRUCTURECONTENTSGrou
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UPPERSTRUCTURE / CabREMOVE AND INST
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UPPERSTRUCTURE / Cab9. Disconnect c
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UPPERSTRUCTURE / CabInstallationCAU
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UPPERSTRUCTURE / Cab7. Install viny
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DIMENSIONS OF THE CAB GLASSUPPERSTR
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UPPERSTRUCTURE / CabMethod for Remo
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UPPERSTRUCTURE / CabMethod for Inst
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UPPERSTRUCTURE / CabSpacer a (44584
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Install upper door glass as follows
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Install upper front glass as follow
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UPPERSTRUCTURE / CounterweightREMOV
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UPPERSTRUCTURE / Counterweight8. In
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UPPERSTRUCTURE / Counterweight5. In
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REMOVE AND INSTALL MAIN FRAMEUPPERS
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UPPERSTRUCTURE / Main FrameCAUTION:
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UPPERSTRUCTURE / Main FrameCAUTION:
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REMOVE AND INSTALL PUMP DEVICEUPPER
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UPPERSTRUCTURE / Pump DeviceInstall
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UPPERSTRUCTURE / Pump DeviceW2-4-5W
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UPPERSTRUCTURE / Pump DeviceDisasse
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UPPERSTRUCTURE / Pump Device1 - Cov
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UPPERSTRUCTURE / Pump DeviceAssembl
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UPPERSTRUCTURE / Pump Device(Blank)
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UPPERSTRUCTURE / Pump DeviceNo Part
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REMOVE AND INSTALLE CONTROLVALVE 1U
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UPPERSTRUCTURE / Control ValveInsta
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UPPERSTRUCTURE / Control ValveDISAS
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UPPERSTRUCTURE / Control Valve95838
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Disassemble Control Valve 1• Be s
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5. Remove plug (26), O-ring (27), s
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UPPERSTRUCTURE / Control Valve13. L
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ASSEMBLE CONTROL VALVE 1UPPERSTRUCT
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UPPERSTRUCTURE / Control ValveSecti
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UPPERSTRUCTURE / Control ValveAssem
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UPPRERSTRUCTURE / Control Valve11.
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UPPERSTRUCTURE / Control Valve17. I
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UPPERSTRUCTURE / Control ValveRemov
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UPPERSTRUCTURE / Control ValveDisas
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UPPERSTRUCTURE / Control Valve1 - S
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UPPERSTRUCTURE / Control ValveAssem
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REMOVE AND INSTALLE SWING DEVICEUPP
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UPPERSTRUCTURE / Swing Device(Blank
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UPPERSTRUCTURE / Swing DeviceDisass
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UPPERSTRUCTURE / Swing DeviceCAUTIO
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UPPERSTRUCTURE / Swing DeviceCAUTIO
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UPPERSTRUCTURE / Swing DeviceAssemb
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UPPERSTRUCTURE / Swing Device9. Adj
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UPPERSTRUCTURE / Swing Device10. Re
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UPPERSTRUCTURE / Swing DeviceIMPORT
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UPPERSTRUCTURE / Swing Device12. Re
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UPPERSTRUCTURE / Swing DeviceAssemb
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UPPERSTRUCTURE / Swing Device18. Ap
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REMOVE AND INSTALL RIGHT PILOTVALVE
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UPPERSTRUCTURE / Pilot ValveIMPORTA
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REMOVE AND INSTALL LEFT PILOTVALVEU
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REMOVE AND INSTALL TRAVEL PILOTVALV
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UPPERSTRUCTURE / Pilot ValveInstall
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REMOVE AND INSTALL BLADE PILOTVALVE
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UPPERSTRUCTURE / Pilot ValveInstall
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Disassemble Right and Left Pilot Va
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Assemble Right and Left Pilot Valve
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UPPERSTRUCTURE / Pilot Valve8. Appl
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UPPERSTRUCTURE / Pilot ValveDisasse
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UPPERSTRUCTURE / Pilot Valve10. Rem
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Assemble Travel Pilot ValveUPPERSTR
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UPPERSTRUCTURE / Pilot Valve7. Plac
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UPPERSTRUCTURE / Pilot Valve14. Ins
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Disassemble Blade Pilot Valve• Be
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UPPERSTRUCTURE / Pilot ValveAssembl
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UPPERSTRUCTURE / Pilot Shut-Off Val
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InstallationUPPERSTRUCTURE / Pilot
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UPPERSTRUCTURE / Pilot Shut-Off Val
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Assemble Pilot Shut-Off ValveUPPERS
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REMOVE AND INSTALL SHOCKLESSVALVEUP
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DISASSEMBLE AND ASSEMBLE SHOCK-LESS
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UPPERSTRUCTURE / Shockless Valvekey
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REMOVE AND INSTALL SOLENOID VALVEUN
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UPPERSTRUCTURE / Solenoid Valve(Bla
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Disassemble Proportional Solenoid V
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Assemble Proportional Solenoid Valv
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UPPERSTRUCTURE / Solenoid ValveDisa
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MEMO...............................
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SECTION 3UNDERCARRIAGECONTENTNSGrou
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REMOVE AND INSTALL SWING BEARINGUND
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UNDERCARRIAGE / Swing Bearing(Blank
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UNDERCARRIAGE / Swing BearingDisass
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UNDERCARRIAGE / Swing BearingAssemb
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REMOVE AND INSTALL TRAVEL DEVICEUND
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UNDERCARRIAGE / Travel DeviceInstal
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UNDERCARRIAGE / Travel DeviceDisass
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IMPORTANT: For handling of floating
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UNDERCARRIAGE / Travel DeviceAssemb
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UNDERCARRIAGE / Travel Device11. In
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UNDERCARRIAGE / Travel DeviceDisass
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12. Remove retaining rings (23) and
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UNDERCARRIAGE / Travel DeviceAssemb
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IMPORTANT: When needle bearing (7)
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Disassemble Brake Valve• Be sure
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Assemble Brake Valve• Be sure to
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REMOVE AND INSTALL CENTER JOINTUNDE
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UNDERCARRIAGE / Center JointInstall
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UNDERCARRIAGE / Center JointDisasse
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UNDERCARRIAGE / Center JointAssembl
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MAINTENANCE STANDARDUNDERCARRIAGE /
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REMOVE AND INSTALL TRACKADJUSTERBef
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Disassemble Track Adjuster• Be su
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UNDERCARRIAGE / Track AdjusterCAUTI
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UNDERCARRIAGE / Track AdjusterAssem
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REMOVE AND INSTALL FRONT IDLERBefor
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UNDERCARRIAGE / Front IdlerDisassem
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UNDERCARRIAGE / Front IdlerAssemble
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UNDERCARRIAGE / Upper And Lower Rol
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Page 310 and 311: REMOVE AND INSTALL TRACKSRemovalUND
Page 312 and 313: UNDERCARRIAGE / TrackCAUTION: Secur
Page 314 and 315: UNDERCARRIAGE / TrackIMPORTANT: Ins
Page 316 and 317: UNDERCARRIAGE / TrackMAINTENANCE ST
Page 318 and 319: UNDERCARRIAGE / TrackPinBAW142-03-0
Page 320 and 321: MEMO...............................
Page 322 and 323: SECTION 4FRONT ATTACHMENTGroup 1 Fr
Page 324 and 325: FRONT ATTACHMENT / Front Attachment
Page 332 and 333: STANDARD DIMENSIONS FOR ARMAND BUCK
Page 334 and 335: REMOVE AND INSTALL CYLINDERFRONT AT
Page 336 and 337: FRONT ATTACHMENT / CylinderInstall
Page 338 and 339: FRONT ATTACHMENT / CylinderCAUTION:
Page 340 and 341: FRONT ATTACHMENT / Cylinder4. Remov
Page 342 and 343: 4. Disconnect hoses (6) (2 used) fr
Page 344 and 345: 5. Hoist boom cylinder (4). Start t
Page 346 and 347: FRONT ATTACHMENT / CylinderInstall
Page 348 and 349: FRONT ATTACHMENT / CylinderDisassem
Page 356 and 357: FRONT ATTACHMENT / CylinderAssemble
Page 358 and 359: FRONT ATTACHMENT / CylinderIMPORTAN
Page 362 and 363: 11. Align the holes on piston rod (
Page 368 and 369: MEMO...............................
Page 370 and 371: SECTION 5ENGINE AND ACCESSORYSECTIO
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MEMO...............................
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Hitachi Construction Machinery Co.
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DOC-20230111-WA0038.

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