EX550-5, EX600H-5

Workshop Manual
 SECTION 1
GENERAL INFORMATION

—CONTENTS—
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling........................................... W1-1-1
Maintenance Standard
Terminology .......................................... W1-1-4

Group 2 Tightening
Tightening Torque Specification.............. W1-2-1
Torque Chart .......................................... W1-2-3
Piping Joint ............................................ W1-2-6

167W-1-1
(Blank)

167W-1-2
GENERAL INFORMATION / 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 dur-
ing disassembling/assembling, resulting in damage
to machine components, as well as decreased effi-
ciency in service work.
• Inspect the Machine
Be sure to thoroughly understand all disassem-
bling/assembling procedures beforehand, to help
avoid incorrect disassembling of components as well
as purchasing unnecessary parts.
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).
• Contamination or 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
Prepare the necessary tools to be used and the area
for disassembling work or storing disassembled
parts.
W1-1-1
• Precautions for Disassembling
• To prevent dirt contamination, cap or plug all re-
moved pipes.
• Before disassembling, clean the exterior of the
components and place on a work bench.
• Before disassembling, drain gear oil from the re-
duction 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 at-
tempt 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 disas-
sembled parts for abnormal wear, sticking, or
other damage.
• Measure and record the degree of wear and
clearances.
• Precautions for Assembling
• Be sure to clean all parts and inspect them for any
damage. If any damage is found, repair or replace
it.
• 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 slid-
ing 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 re-
move 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 dis-
assembly/assembly. After assembling is complete,
count the number of tools, so as to make sure that
no tools are missing.
GENERAL INFORMATION / Precautions for Disassembling and Assembling
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the
suction lines are replaced, or the removal and instal-
lation of the pump, swing motor, travel motor or cylin-
der is done, bleed air from the hydraulic system in the
following procedures:

• Bleeding Air from Hydraulic Pump

IMPORTANT: If the engine is started with air

trapped in the hydraulic pump hous-
ing, damage to the pump may result.
Be sure to bleed air before starting
the engine.

• Remove the air bleeding plug from the top of the

pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the pump
housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the plug.

• Bleeding Air from Travel Motor / Swing Motor

• With the drain plug (upper side) / hose on travel

motor / swing motor removed, fill the motor case
with hydraulic oil.

• Bleeding Air from Hydraulic Circuit

• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation M104-07-021
for approx. 5 minutes.
• Reposition the front attachment to check hydraulic
oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.

W1-1-2
GENERAL INFORMATION / Precautions for Disassembling and Assembling
Precautions for Handling Floating Seal
1. In general, replace the floating seal with a new A
one after disassembling.
If the floating is to be reused, follow these proce-
dures:

(1) Keep seal rings together as a matched set

with seal ring faces together. Insert a piece of
card-board to protect surfaces.

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

scuffing, scoring, corrosion, deformation or B
uneven wear. W105-03-05-019

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

tion or hardening.

2. If incorrectly assembled, oil leaks or damage will

occur. Be sure to do the following, to prevent trou-
ble.

(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 com-
pressed air. Correctly

(2) Clean the floating seal and seal mounting

bores. Check the bore surface for scuffing or Incorrectly
scoring by touching the surface with finger.

(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 surface (C) is parallel with idler face (D)
by measuring the distances (a) and (b) as il-
W105-03-05-020
lustrated. If these distances differ, correct the
O-ring seating. Correct
D Incorrect

a a
C

b b

a=b a≠b
W110-03-05-004

W1-1-3
GENERAL INFORMATION / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.

2. Dimension of components or assemblies adjusted

to specification.

Both dimensions are shown with tolerances as neces-

sary.

“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.

2. Repair or replacement is required before reaching

this limit.

Machine performance will decrease, and maintenance

and down time expense will increase as machine op-
erating hours accumulate. It is recommended that
parts are repaired or replaced before reaching the
“Allowable Limit”.

W1-1-4
 GENERAL INFORMATION / Tightening
TIGHTENING TORQUE SPECIFICATIONS

Bolt and Nut on Base Machine Standard Torques

Torque Specifications

Bolt Dia Wrench Size Torque

No. Descriptions Q’ty
mm mm N⋅m kgf⋅m lbf⋅ft
1 Engine cushion Engine cushion rubber 16 2 24 205 21 152
rubber mounting Front Cushion rubber-machine 16 2 24 205 21 152
bolt
Engine cushion rubber 22 2 32 540 55 400
Rear
Cushion rubber-machine 16 4 24 205 21 152
2 Radiator mounting bolt 16 4 24 205 21 152
3 Hydraulic oil tank mounting bolt 16 8 24 205 21 152
4 Fuel tank mounting bolt 16 8 24 205 21 152
5 ORS fittings for hydraulic hoses and piping 1-3/16-12UNF 36 175 18 130
1-7/16-12UNF 41 205 21 152
6 Pump transmission mounting bolt 7/16-14UNF 14 16 69 7 51
7 Pump device mounting bolt 20 8 30 390 40 290
8 Control valve mounting bolt 20 4 30 390 40 290
9 Swing device mounting bolt 22 26 32 740 75 540
Ring gear housing mounting bolt 18 24 14 295 30 215
(hexagonal wrench)
10 Swing motor mounting bolt (hexagonal wrench) 12 16 10 88 9 65
11 Battery mounting nut 12 2 19 34 3.5 25.5
12 Cab mounting bolt STD, LC 16 4 24 205 21 152
H, LCH 16 6 24 205 21 152
13 Swing bearing mounting bolt to upperstructure 30 36 46 1910 195 1410
Swing bearing mounting bolt to undercarriage 30 36 46 1720 175 1270
Continued on next page

W1-2-1
 GENERAL INFORMATION / Tightening

Torque Specifications (continued)

Bolt Dia Wrench Size Torque

No. Descriptions Q’ty
mm mm N⋅m kgf⋅m lbf⋅ft
14 Travel device mounting bolt 22 40 32 740 75 540
Travel motor mounting bolt 18 8 27 295 30 215
Sprocket mounting bolt 22 48 32 32 75 540
15 Upper roller mounting 20 24 30 540 55 400
16 Lower roller mounting bolt STD, H 24 64 36 930 95 690
LC, LCH 24 72 36 930 95 690
17 Track shoe bolt STD, H 24 392 32 1370 140 1010
LC, LCH 24 416 32 1370 140 1010
18 Track guard mounting bolt STD, H 24 16 36 930 95 690
LC, LCH 24 24 36 930 95 690
19 Track frame mounting bolt 33 36 50 2160 225 1590
20 Coupling and clamp of low pres- Coupling 8 13 10.5 to 10.5 to 7.6 to
sure piping 12.5 1.26 9.1
Clamp 1/4-28UNF 11 5.9 0.6 4.3
21 Counterweight mounting bolt 45 2 65 2750 280 2030
Counterweight retaining bolt 24 4 36 440 45 330
22 Front pin-retaining bolt 20 30 390 40 290
Front pin-retaining nut 20 30 390 40 290

NOTE: 1. When tightening bolts and nuts, apply a

lubricant to threads to reduce friction.
(i.e.: white zinc B dissolved into spindle
oil)
2. Remove rust, soil, and dust before
tightening.
3. Use LOCTITE to the engine cushion
rubber mounting nuts and the lower
roller mounting bolts.

W1-2-2
 GENERAL INFORMATION / Tightening
TORQUE CHART

CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and parts
create safety hazards. If an incorrect tool is
used, the tool may slip or come off or break,
resulting in personal injury.

Bolt Types
When tightening bolts and nuts, use the specified
torque. Bolts are classified according to materials and
applications. Be sure to use the correct bolts and nuts,
and tighten them to specification.
SA-040

Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt

W105-01-01-007

Specified Tightening Torque Chart

Hexagon T Bolt, Socket bolt H Bolt M Bolt

Bolt Wrench
Wrench
Dia. Size N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft
Size
M 8 13 6 29.5 3 22 19.5 2 14.5 9.8 1 7.2
M 10 17 8 64 6.5 47 49 5 36 19.5 2 14.5
M 12 19 10 108 11 80 88 9 65 34 3.5 25.5
M 14 22 12 175 18 130 137 14 101 54 5.5 40
M 16 24 14 265 27 195 205 21 152 78 8 58
M 18 27 14 390 40 290 295 30 220 118 12 87
M 20 30 17 540 55 400 390 40 290 167 17 123
M 22 32 17 740 75 540 540 55 400 215 22 159
M 24 36 19 930 95 690 690 70 505 275 28 205
M 27 41 19 1370 140 1010 1030 105 760 390 40 290
M 30 46 22 1910 195 1410 1420 145 1050 540 55 400
M 33 50 24 2550 260 1880 1910 195 1410 740 75 540
M 36 55 27 3140 320 2310 2400 245 1770 930 95 690

W1-2-3
 GENERAL INFORMATION / Tightening
IMPORTANT: (1) Apply lubricant (i.e. white zinc B
dissolved into spindle oil) to
nuts and bolts to reduce friction.
(2) Torque tolerance should be
±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.
Torque as specified.
(5) Make sure that the 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 al-
ternately, as shown, to ensure even tightening.

Equally tighten upper Tighten diagonally Tighten from center

and lower alternately and diagonally

1 12 9 4 1 6 7 14
1, 4 6 3

4 5
2 13 8 5 2 3 10 11
2, 3

W105-01-01-003

W1-2-4
 GENERAL INFORMATION / Tightening
Service Recommendations for Split Flange

IMPORTANT: (1) Be sure to clean and inspect

sealing surfaces. Scratches /
roughness cruse leaks and seal
wear. Unevenness causes seal
extrusion. If defects cannot be
polished out, replace the
component. W105-01-01-015
(2) Be sure to use only specified O- WRONG
rings. Inspect O-rings for any
damage. Take care not to file O-
ring contact surfaces. When
installing an O-ring into a groove,
use grease to hold it in place.
(3) Loosely assemble split flange
halves. Make sure that the split
is centrally located and
perpendicular to the port. Hand- W105-01-01-016

tighten the bolts to hold the

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 W105-01-01-008

tightening of one bolt fully

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

• Lock Plate RIGHT RIGHT WRONG

IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.

• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Bend along edge sharply
W105-01-01-009
holes in the bolt and nut while tight-
ening, not while loosening. RIGHT RIGHT WRONG

• Lock Wire
IMPORTANT: Apply wire to bolts in the bolt-
tightening direction, not in the bolt-
loosening direction.
RIGHT WRONG
Loosen

Tighten

W105-01-01-010

W1-2-5
 GENERAL INFORMATION / Tightening
PIPING JOINT
1 4 3 5 2
Pipe Thread Connection / Union Joint Tightening
Torque Specifications

Union Joint
Metal sealing faces (4) of adapter (1) and (5) of hose
(2) fit together to seal pressure oil. Union joints are
used to join small-diameter lines.
Joint Body M202-07-051

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

30° or 37°
cessive force is applied to metal
sealing faces (4) and (5), adaptor
(1) will be cracked. Always
30° or 37°
tighten nut (3) to specifications.

(2) Scratches or other damage to

sealing faces (4) or (5) will cause Male Joint Female Joint
oil to leak at the joint. Take care
not to damage the sealing faces W105-01-01-017

when connecting or
disconnecting the union joint.

Wrench Size (mm) Tightening Torque

Union Joint
Union Nut Joint Body N⋅m (kgf⋅m) lbf⋅ft
19 19 59 (6) 43
22 22 98 (10) 72
27 27 118 (12) 87
36 36 235 (24) 134
30° Male
41 41 295 (30) 215
50 50 490 (50) 360
60 60 670 (68) 490
70 70 980 (100) 720
19 17 44 (4.5) 32.5
22 19 59 (6) 43
27 22 118 (12) 87
37° Female
36 30, 32 235 (24) 134
41 36 295 (30) 125
50 46 490 (50) 360

NOTE: 37° male union joint tightening torque val-

ues are equal to those for 37° female union
joint.

W1-2-6
 GENERAL INFORMATION / Tightening
O-ring Seal Joint
O-ring (6) is located on the end face of adapter (7) to 7 6 9
seal pressure oil at the joint.

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

new one when reconnecting.

(2) Check that O-ring (6) is Correctly

seated in O-ring groove (8)
8 10
before tightening union nut (9). If Union Body
union nut (6) is tightened with
O-ring (6) displaced from the M104-07-033

groove, O-ring (6) will be

damaged, causing oil leaks.
Wrench Size Tightening Torque
(3) Take care not to damage O-ring Union Nut Union Body N⋅m (kgf⋅m) lbf⋅ft
groove (8) on adapter (7) and 19 17 59 (6) 43
sealing face (10) of the hose end. 22 19 98 (10) 72
Damaged O-ring (6) will cause oil 27 22 118 (12) 87
leaks. 36 30, 32 235 (24) 134
41 36 295 (30) 215
(4) If oil leaks due to looseness of 50 46 490 (50) 360
union nut (9), always replace O-
ring (6) with new one and check
that the O-ring is correctly
seated in O-ring groove (8)
before re-tightening union nut
(9).

W1-2-7
 GENERAL INFORMATION / Tightening
Screwed-In Connector PT PF

IMPORTANT: Many types of screwed-in connec-

tors are used for hose or pipe con- 30°
nections.
Be sure to confirm that the thread
pitch and thread type (tapered or
straight) correctly match before
Male Tapered Thread Male Straight Thread
connection.
W105-01-01-018

Male Tapered Thread

Wrench Tightening Torque
Joint Body N⋅m (kgf⋅m) lbf⋅ft
17, 19 59 (6) 43
19, 22 98 (10) 72
27, 22 118 (12) 87
36, 32 235 (24) 134
41 295 (30) 215
50 490 (50) 360
61 670 (68) 190
Seal Tape Application
70 980 (100) 720
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks be-
Female Thread
tween threads.
Be sure to apply just enough seal tape to fill up the
thread clearances. Wrapping too much tape has no
effect.
Male Thread Clearance

• Application Procedure W105-01-01-019

Leave one to two pitch threads uncovered

Confirm that the thread surface is clean, free of dirt
or damage.
Apply seal tape around threads as shown. Wrap
seal tape in the same direction as the threads.

M114-07-041
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs
T-Bolt Type Worm Gear Type
depending on the type of clamp.
See below for correct tightening torque of each type
of low-pressure-hose 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 kgf⋅m, 4.3 to 5.1 lbf⋅ft)

M114-07-042 M114-07-043

W1-2-8
 GENERAL INFORMATION / Tightening
Connecting Hose
WRONG RIGHT

CAUTION:
(1) 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.
(2) Do not install hoses kinked. Application W105-01-01-011

of high oil pressure, vibration, or an

impact to a kinked hose may result in
oil leakage, hose rupture or separation
of fitting. Utilize print marks on hoses
when installing hoses to check if hoses WRONG RIGHT
are installed properly.
Rubbing
(3) If hoses contact each other, wear on the Each Other
hoses will result, leading to hose
rupture. Take necessary measures to
protect hoses from contacting each
other.
Take care that hoses do not come into
contact with moving parts or sharp W105-01-01-012

objects.

WRONG RIGHT

Clamp Clamp

Rubbing

W105-01-01-013

WRONG RIGHT

Rubbing

Clamp

W105-01-01-014

W1-2-9
 GENERAL INFORMATION / Tightening
(Blank)

W1-2-10

UPPERSTRUCTURE
—CONTENTS—
Group 1 Cab
Remove and Install Cab ...................... W2-1-1
Dimensions of the Cab Glass .............. W2-1-7
Group 2 Counterweight
Remove and Install
Counterweight ................................... W2-2-1
Group 3 Pump Device
Remove and Install
Pump Device ..................................... W2-3-1
Disassemble Pump Transmission........ W2-3-4
Assemble Pump Transmission ............ W2-3-6
Remove and Install
Main Pump ........................................ W2-3-8
Disassemble Main Pump ................... W2-3-10
Assemble Main Pump........................ W2-3-16
Disassemble and Assemble
Pilot Pump ....................................... W2-3-24
Group 4 Control Valve
Remove and Install
Control Valve ..................................... W2-4-1
Disassemble
Control Valve 1 .................................. W2-4-4
Assemble
Control Valve 1 .................................. W2-4-8
167W-2-1
SECTION 2
Disassemble
Control Valve 2 ................................ W2-4-14
Assemble
Control Valve 2 ................................ W2-4-16
Disassemble
Control Valve 3 ................................ W2-4-18
Assemble
Control Valve 3 ................................ W2-4-24
Disassemble
Control Valve 4 ................................ W2-4-30
Assemble
Control Valve 4 ................................ W2-4-32
Disassemble
Control Valve 5 ................................ W2-4-34
Assemble
Control Valve 5 ................................ W2-4-36
Group 5 Swing Device
Remove and Install
Swing Device ..................................... W2-5-1
Disassemble Swing Device.................. W2-5-4
Assemble Swing Device ...................... W2-5-8
Disassemble Swing Motor ................. W2-5-12
Assemble Swing Motor ...................... W2-5-16
Maintenance Standard....................... W2-5-20
Group 6 Pilot Valve
Remove and Install Right
Pilot Valve ......................................... W2-6-1
Remove and Install Left
Pilot Valve ......................................... W2-6-4
Remove and Install
Travel Pilot Valve ............................... W2-6-7
Disassemble Front Attachment
Pilot Valve ......................................... W2-6-8
Assemble Front Attachment
Pilot Valve ....................................... W2-6-10
Disassemble Travel
Pilot Valve ....................................... W2-6-14
Assemble Travel
Pilot Valve ....................................... W2-6-16

Group 7 Pilot Shut-Off Valve

Remove and Install
Pilot Shut-off Valve ............................ W2-7-1
Disassemble Pilot Shut-off Valve ......... W2-7-4
Assemble Pilot Shut-off Valve.............. W2-7-6

Group 8 Shockless Valve

Remove and Install Front
Attachment Shockless Valve.............. W2-8-1
Disassemble and Assemble Front
Attachment Shockless Valve.............. W2-8-4
Remove and Install
Travel Shockless Valve...................... W2-8-7
Disassemble and Assemble
Travel Shockless Valve...................... W2-8-8

Group 9 Solenoid Valve

Remove and Install
Three-Spool Solenoid Valve............... W2-9-1
Disassemble and Assemble
Three-Spool Solenoid Valve............... W2-9-3

167W-2-2
 UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB
Remove Cab
1. Remove seat mounting nut (2) to remove seat (1).

: 13 mm

W157-02-01-005
2. Loosen bolt (5) in the cab rear section and bolt (6)
in rear boxes (3 and 4) to remove rear boxes (3
and 4).

: 13 mm

3. Loosen bolt (8) to remove lower cover (7) of the

rear box. 3

: 13 mm 5 6

6
5
4 8

W157-02-01-017

4. Remove filter (24) and loosen screw (9) to remove

duct (10) from the cab.

24

10 9
W158-02-01-001

W2-1-1
 UPPERSTRUCTURE / Cab
5. Disconnect harness connectors (11) located at the
rear inside the cab.

11
6. Disconnect connectors for wiper limit switch (12), W167-02-01-001

cab light (13), speaker (14), antenna (15) and

ground (17) located in the cab. 13 14
Remove washer vinyl hose (16) located behind 12
the cab.

15

17 16
W162-02-01-002

7. Remove cap (20) from duct cover (18). Loosen

screws (19) to remove duct cover (18).
18
20 19

W158-02-01-002

8. While pushing the mating face of duct (21) back- Duct Mating Face
ward, remove duct (21).

21

W157-02-01-011

W2-1-2
 UPPERSTRUCTURE / Cab
9. Attach a sling belt to the top of the cab.

CAUTION: Cab weight: 260 kg (573 lb)

W157-02-01-009

10. Remove cab mounting bolt (22) and nuts (23).

: 17 mm
: 24 mm 22
: 8 mm

23

23
W157-02-01-010
11. Slowly lift the cab with a crane to remove the cab
from the machine.

W157-02-01-001

W2-1-3
 UPPERSTRUCTURE / Cab
Install Cab
1. Attach cab to crane with sling belts and install cab
onto the machine.

CAUTION: Cab weight: 260 kg (573 lb)

W157-02-01-001

2. Tighten cab mounting bolts (22) and nuts (23).

22
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
: 24 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
: 8 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
23

23
W157-02-01-010

3. Install duct (10) into the cab and tighten screw (9).
Install filter (24).

: 4.9 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)

24
9
10
W158-02-01-001

4. Connect harness connectors (11) at the rear, in-

side the cab.

11
W167-02-01-001

W2-1-4
 UPPERSTRUCTURE / Cab
5. Connect wiper limit switch (12), cab light (13),
speaker (14), antenna (15) and ground (17) in the
13 14
cab. 12
Connect washer vinyl hose (16) behind the cab.

: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

15

17 16
W162-02-01-002

6. Install rear box lower cover (7) and tighten bolts

(8).

: 13 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

7. Install rear boxes (3 and 4) and tighten bolts (5 3

and 6). 5 6
: 13 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 6
5
4 8

W157-02-01-017

8. Push duct (21) to the cab front until the duct mat-
ing face comes in contact. Duct Mating Face

21

W157-02-01-011

W2-1-5
 UPPERSTRUCTURE / Cab
9. Install duct cover (18). Tighten screw (19) and put
cap (20) on.

18
20 19

W158-02-01-002
10. Install seat (1) and tighten nut (2).

: 13 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

W157-02-01-005

W2-1-6
 UPPERSTRUCTURE / Cab
DIMENSIONS OF THE CAB GLASS
A
R2
25.106
Unit : mm R11516
3.015
NOTE : 1 mm=0.03937 in
221.399 R70

4-φ13 +0
-1 R78 (64.74)
142.25

Section A
Chamfer R9487
both
30
fringes
580
360.78 (87.81)
R3018
(5 mm) 4°
391.8 R118
51.03 Chamfer fringe
comers.
188.5 154.81
R15

66.84
164.12 43.59
558.78

230.50
222.65
B 15
216.73

All Around All Around

c1 c1
2-R59 R11509
R2309

R4009 900.7
R9509 905
(4 mm)

R1009
Section B
R209 R509
R4009
R84
NOTE: Material: JIS- R3211,R3212
63.97
ANSI - AS2
ECE - ANNEX5 or 66.41

equivalent 87.84
947.152
35.73

756

4-R62

612 (5 mm)

W157-02-01-013

W2-1-7
 UPPERSTRUCTURE / Cab

Chamfer fringe corners.

Unit : mm
NOTE : 1 mm=0.03937 in
208 (38.5) 337.5±1.0
333.5±1.0 Chamfer fringe
comers. 22.5
113.9
R3 9.2
10.6

R30 R72.5 D

7735.4
R105
R2285.4 Chamfer 39.5 3.1
(4 mm)
both
61.8 Chamfer fringes 728.5±1.0
39.5 R3985.4
both Section C and D 40
fringes C
728.5±1.0 488.5
40 2-φ12.2 +0.5
-0
475.8
R120885.4
2-φ12.2 +0.5
-0 2-R4 290
60.1 R1985.1 (4 mm)

3-R4 398.5±1.0
Chamfer fringe
503±1.0
comers.
(38.5)
541.5

Chamfer fringe comers.

468.17

90.672
45.67

R2590
2-R5
R2477
R5175

904.13
R3877

R8075
980
753.99

740.51

19.70
8 890.03 74.95 213.97 (5 mm)

R120
227.39 R12095 165 R12.5
4-R5
276.58
R1995 R1145
370±1.0
19.29
R895 R595 516.26
R345 R295 33.60
(5 mm) 549.86

11.22 39.63
50.71
18 833±1.0
59
910

W157-02-01-014

W2-1-8
 UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTER-
WEIGHT
Removal

CAUTION: Approximate counterweight

weight: 10500 kg (23200 lb)

1. Install lifting accessories and wire ropes to sling

brackets on the top of the counterweight. Set the
wire rope taut using a crane.

CAUTION: Watch out the power-wrench re-

action bar movement. Take care not to be hit
the reaction bar.

2. Loosen bolts (10) using a power wrench to re- W166-02-02-002

move bolts (10), nuts (8), shims (7), and washers

(9).

NOTE: Shims (7) are used only when any gap be-
7 8 9
tween nuts (8) and the lock brackets exist.
When no gap exists, shims are not re- 3
2 4
quired.
1 5
6
: 65 mm
1
2
7

3. Loosen bolts (1) to remove lock washers (2), 3

washers (3), and spacers (4). If shims (5 and 6) 4
are provided, remove shims (5 and 6).
5
: 36 mm 6 9
8
9 10

W166-02-02-003

4. Remove the counterweight using a crane.

7 10

8
9
3

2,1

6,5,4
W166-02-02-001

W2-2-1
 UPPERSTRUCTURE / Counterweight
Installation

CAUTION: Approximate counterweight

weight: 10500 kg (23200 lb)

1. Install lifting accessories and wire ropes to sling

brackets on the top of the counterweight. Then, lift
the counterweight by crane.

CAUTION: Do not allow anyone under the

lifted counterweight.

2. Insert protrusions on the counterweight into holes

on the frame to install the counterweight.

W166-02-02-002
CAUTION: Watch out the power-wrench re-
action bar movement. Take care not to be hit
the reaction bar.

IMPORTANT: Apply lubricant to bolts (10) before 7 8 9

installing. Install shims (7) between 3
nuts (4) and the lock brackets with 2 4
the flange positioned in the upper
1 5
side. 6
1
3. Install bolts (10), nuts (4), shims (7), and washers 2
(9). Using a power wrench, tighten bolts (10).
7

: 65 mm
: 2750 N⋅m (280 kgf⋅m, 2030 lbf⋅ft) 3
4

5
6 9
8
9 10

W166-02-02-003

4. Install shims (5 and 6), spacers (4), washers (3)

lock washers (2), and bolts (1). Remove wire
ropes and lifting accessories.
9
: 36 mm
: 440 N⋅m (45 kgf⋅m, 330 lbf⋅ft) 10
7

8
9
3

2,1

6,5,4
W166-02-02-001

W2-2-2
 UPPERSTRUCTURE / Pump Device

REMOVE AND INSTALL PUMP DEVICE

CAUTION:
1. Escaping fluid under pressure can
penetrate the skin, causing serious
injury. Avoid this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after operation.
Hot hydraulic oil may spout, possibly
causing severe burns. Be sure to wait
for oil to cool before starting any repair
work.
3. The hydraulic oil tank cap may fly off by
remaining pressure if removed quickly.
Slowly loosen the cap to completely
release any remaining pressure.

Preparation
1. Stop the engine. Move all control levers to release
pressure remaining in the system.
Turn the hydraulic oil tank cap approx. 30° coun-
terclockwise to release any pressure remaining in
the hydraulic tank.

W2-3-1
 UPPERSTRUCTURE / Pump Device
Removal
Engine Rear
1. Disconnect all hoses and electrical cables from Mounting Bolt
the pump.
Tightening Torque
Wrench size (mm) Remark
N⋅m kgf⋅m lbf⋅ft
Wooden
: 19 29.5 3 22 Piping Block
: 22 59 6 44 Piping
: 27 93 9.5 69 Piping
: 36 175 18 130 Piping
: 10 108 11 80 Piping
: 12 175 18 130 Piping
: 14 265 27 195 Piping
: 30 390 40 290 Bolt
: 16 69 7 50 Bolt W167-02-03-005

: 32 540 55 400 Bolt

Pump Transmission
2. Lay a wooden block (300 mm long, 200 mm wide, Mounting Bolt
and 20 mm thick) under the engine oil pan.
Main Pump
CAUTION: Main pump weight: Mounting Bolt
125 kg (276 lb)

3. Remove the main pump mounting bolts to remove

the main pump.
CAUTION: Pump transmission weight:
150 kg (330 lb)
W167-02-03-003
4. Remove the pump transmission mounting bolts
and the engine rear mounting bolts to remove the
pump transmission.

Installation

NOTE: Refer to the “removal” section above for

wrench sizes and tightening torque.

1. Secure the pump device with the mounting bolts.

2. Re-connect all hoses and electrical cables to the
pump device.
3. Bleed any trapped air from the pump (refer to
page W1-1-2).

IMPORTANT: After installing the pump, be sure to

perform break-in operation to pre-
vent seizure.

Break-In Operation Process:

1. Start the engine and run at slow idle speed for
20 minutes. Check for oil leaks while running
at slow idle.
2. Increase the engine speed to the fast idle
speed. Raise and lower the boom for 20 min-
utes repeatedly. (Do not operate the control
levers quickly. Slowly move the levers to full
stroke.)

W2-3-2
 UPPERSTRUCTURE / Pump Device
(Blank)

W2-3-3
 UPPERSTRUCTURE / Pump Device
DISASSEMBLE PUMP TRANSMISSION

10

8
11
7

6
5
4
3
2
1

W167-02-03-001

1 - Casing 4 - Coupling 7 - Bearing 10 - Bolt (10 Used)

2 - Bearing 5 - Retaining Ring 8 - O-Ring 11 - Oil Seal
3 - Retaining Ring 6 - Gear 9 - Cartridge 12 - Drain Plug

W2-3-4
 UPPERSTRUCTURE / Pump Device
Disassemble Pump Transmission

• Be sure to thoroughly read all precautions for disas-

sembly/assembly work on page W1-1-1 before start-
ing any repair work.

1. Loosen drain plug (12) to drain gear oil from the

pump transmission. Remove the pilot pump from
casing (1).

: 27 mm
: 8mm

CAUTION: Pump transmission weight:

150 kg (330 lb)

2. Place casing (1) on a work bench with the main

pump mounting side facing downward.

3. Remove bolts (10).

: 19 mm

CAUTION: Pump transmission weight:

150 kg (330 lb)

4. Turn casing (1) over and place it on a work bench.

NOTE: At this time, set a wooden block (100 mm

high) so that it does not come in contact
with cartridge (9).

5. Attach a protection plate (Dia. 50 mm) to coupling

(4). While tapping the protection plate, remove
cartridge (9), bearing (2 and 7) and gear (6) from
casing (1).

6. Remove bearing (7), O-ring (8) and oil seal (11)

from cartridge (9).

7. Remove retaining ring (3), coupling (4) and retain-

ing ring (5) from gear (6).

8. Using a press or a puller, remove bearings (2 and

7) from gear (6).

W2-3-5
 UPPERSTRUCTURE / Pump Device
ASSEMBLE PUMP TRANSMISSION

10

Pilot Pump

A A

1 6 2 3 4 5

12

Section A-A
9 8 11 7

W167-02-03-002

1 - Casing 4 - Coupling 7 - Bearing 10 - Bolt (10 Used)

2 - Bearing 5 - Retaining Ring 8 - O-Ring 11 - Oil Seal
3 - Retaining Ring 6 - Gear 9 - Cartridge 12 - Drain Plug

W2-3-6
 UPPERSTRUCTURE / Pump Device
Assemble Pump Transmission
1. Press bearings (2 and 7) into gear (6).

2. Install retaining ring (5), coupling (4), and retaining

ring (3) to gear (6).

CAUTION: Casing (1) weight:

95 kg (210 lb)

3. With the main pump mounting face .downward,

place casing (1) on a work bench.

4. Press bearing (2) along with gear (6) into casing

(1).

5. Using a protection plate, press oil seal (11)into

cartridge (9).

6. Coat the inner diameter of oil seal (11) with

grease.

7. Install O-ring (8) to cartridge (9).

IMPORTANT: Position the casting imprint on car-

tridge (9) upward (the oil filler side)
and install the cartridge on casing Upward
(1). Casting Imprint

8. Install cartridge (9) on casing (1).

9. Tighten bolts (10) (10 used).

: 19 mm W167-02-03-006
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

10. Install the pilot pump on casing (1).

: 8 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

W2-3-7
 UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL MAIN PUMP

CAUTION:
1. Escaping fluid under pressure can
penetrate the skin, causing serious
injury. Avoid this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after operation.
Hot hydraulic oil may spout, possibly
causing severe burns. Be sure to wait
for oil to cool before starting any repair
work.
3. The hydraulic oil tank cap may fly off by
remaining pressure if removed quickly.
Slowly loosen the cap to completely
release any remaining pressure.

Preparation
1. Stop the engine. Move all control levers to release
pressure remaining in the system.
Turn the hydraulic oil tank cap approx. 30° coun-
terclockwise to release any pressure remaining in
the hydraulic tank.

W2-3-8
 UPPERSTRUCTURE / Pump Device
Removal
1. Disconnect all hoses and electrical cables from
the pump. Main Pump
Mounting Bolt
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 59 N⋅m (6 kgf⋅m, 44 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)
: 10 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
: 12 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
: 14 mm
: 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)

CAUTION: Main pump weight: T167-01-02-003

Approx. 125 kg (276 lb)

2. Remove the main pump mounting bolts to remove

the main pump.

: 30 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)

Installation
NOTE: Refer to the “Removal” section above for
wrench sizes and tightening torque.

1. Secure the pump device with the mounting bolts.

2. Re-connect all hoses and electrical cables to the

pump device.

3. Bleed any trapped air from the pump (refer to

page W1-1-2).

IMPORTANT: After completing installation of the

pump device, be sure to perform
break-in operation to prevent pump
seizure during initial machine opera-
tion.

Procedure:
1. Start the engine. Run at slow idle speed for 20
minutes. Check for oil leaks during this opera-
tion.
2. Increase the engine speed to the first idle
speed and raise or lower the boom for 20 min-
utes. (Do not operate the control lever quickly.
Slowly operate the lever full stroke.)

W2-3-9
 UPPERSTRUCTURE / Pump Device
DISASSEMBLE MAIN PUMP
5

6
4 7 8
3
2

1
9

10
A 9
11
12

W116-02-04-048

Pump displacement Angle Sensor (6)

13 23
22
21

14
20
19
18
17
16
15
24
25
26
27

28
W116-02-04-049
1- Retaining Ring 8- Socket Bolt 15 - Shaft 22 - Washer
2- Seal Case 9- Socket Bolt (4 Used) 16 - Spring 23 - Socket Bolt (2 Used)
3- Oil Seal 10 - Regulator 17 - Oil Seal 24 - Spring
4- O-Ring 11 - Control Plate 18 - Retainer 25 - Spring Seat
5- Housing 12 - Rotary Group 19 - Retaining Ring 26 - Arm
6- Pump Displacement Angle 13 - Socket Bolt (3 Used) 20 - O-Ring 27 - Set Screw (2 Used)
Sensor (A-Sensor)
7 - Socket Bolt (3 Used) 14 - Case 21 - Potentiometer 28 - O-Ring

W2-3-10
 UPPERSTRUCTURE / Pump Device
Regulator (10) Regulator Cover (29) Section

47
30
31 48
29
49
32
50
33 A
51

52
34

53

46 54
45 59
55
58
42
44
57 30
56
43

63
57
56 58
59

36
41
37
38 29
60
39 62
40
61

W116-02-04-050 W116-02-04-051

29 - Regulator Cover 38 - Plate 47 - Lock Nut 56 - Guide (2 Used)

30 - Socket Bolt (4 Used) 39 - Socket Bolt (4 Used) 48 - Guide 57 - Steel Ball (2 Used)
31 - Spring Seat 40 - Piston Ring (2 Used) 49 - O-Ring 58 - Plug (2 Used)
32 - Spring 41 - Piston 50 - Adjusting Screw 59 - Plug (2 Used)
33 - Spring 42 - Packing 51 - O-Ring 60 - O-Ring (6 Used)
34 - Pump Control Solenoid 43 - Rod 52 - Spring 61 - Retainer
Valve
35 - Body 44 - Knock Pin (2 Used) 53 - Distant Piece 62 - O-Ring
36 - Set Screw 45 - Bushing 54 - Spool 63 - Filter
37 - O-Ring 46 - Pin 55 - Barrel

W2-3-11
Thank you very much
for your reading.
Please Click Here
Then Get More
Information.